Chrysler Voyager 2001

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2001 RS/RG Technical Publications
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Service Manual
Gas Powertrain Diesel Powertrain Body Chassis Transmission

SERVICE MANUAL
2001
VOYAGER
NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC,
MECHANICAL, PHOTOCOPYING, RECORD-
ING, OR OTHERWISE, WITHOUT THE
PRIOR WRITTEN PERMISSION OF
DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right

to make changes in design or to make additions
to or improvements in its products without
imposing any obligations upon itself to install
them on its products previously manufactured.
Copyright © DaimlerChrysler Corporation
81-726-1042CD
FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician 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 compo-
nents. To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
first page of the group has a contents section that lists major topics within the group.
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.
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM . . . . . . . .2

3.1.1 DRIVER AIRBAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.2 CLOCKSPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1.3 PASSENGER AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1.4 SEAT BELT TENSIONER (SBT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.5 SEAT BELT SWITCHES (SBS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.6 SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) . . . . . . . . . . . .5
3.1.7 SEAT AIRBAGS (SAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.8 ORC/SIACM DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . .6
3.1.9 ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1.10 STORED CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2.1 REMOTE RADIO CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.2.2 CD CHANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.3 BODY CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.4 CHIME WARNING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.4.1 CHIME PRIORITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.4.2 CHIME ON CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.4.3 WARNING LAMP ANNOUNCEMENT . . . . . . . . . . . . . . . . . . . . . . . . .10
3.4.4 OTHER CHIME ON CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.5 COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.6 DOOR AJAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7 EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.1 HEADLAMP POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.2 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.3 PARK LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.4 FOG LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.5 FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7.6 EXTERIOR LIGHTING BATTERY SAVER . . . . . . . . . . . . . . . . . . . . . .13
3.7.7 AUTO HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.8 FRONT CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.8.1 CONTROLLED POWER FEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.8.2 RELAY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.8.3 ELECTRICAL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.9 HEATING & A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1 AUTOMATIC TEMPERATURE CONTROL (ATC) . . . . . . . . . . . . . . . .16
3.9.1.1 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.2 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.3 BLOWER MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.4 INFRARED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.5 REAR ATC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.6 COOLDOWN TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.9.1.7 ACTIVE AND STORED TROUBLE CODES . . . . . . . . . . . . . . . . . . . .17
3.9.2 MANUAL TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . .17
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TABLE OF CONTENTS - Continued
3.9.2.1 SYSTEM AVAILABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.2 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.3 ZONE CONTROL – SINGLE-ZONE . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.4 ZONE CONTROL – DUAL-ZONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.5 AIR DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.6 DOOR ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.7 DOOR ACTUATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.9.2.8 HVAC SYSTEM RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.9.2.9 EVAPORATOR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . .18
3.9.2.10 A/C – HEATER CONTROL MODULE, SWITCH OPERATION . . . . . .18
3.9.2.11 HVAC DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.10.1 GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.10.2 COMPONENT DESCRIPTION AND OPERATION . . . . . . . . . . . . . . .19
3.10.2.1 DCHA ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.10.2.2 COMBUSTION AIR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.10.2.3 BURNER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.2.4 BURNER INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.2.5 CONTROL UNIT/HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.2.6 DOSING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.3.1 ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.10.3.2 HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.10.3.3 DEACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.10.4 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.11 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.11.1 INSTRUMENT CLUSTER SELF TEST . . . . . . . . . . . . . . . . . . . . . . . .22
3.11.2 MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.12 INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.12.1 COURTESY LAMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.12.2 ILLUMINATED ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.12.3 INTERIOR LIGHTING BATTERY SAVER . . . . . . . . . . . . . . . . . . . . . .22
3.13 MEMORY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.13.1 POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.13.2 MEMORY MIRRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.14 OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.14.1 COMPASS/MINI-TRIP COMPUTER (CMTC). . . . . . . . . . . . . . . . . . . .23
3.14.2 ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) . . . . . . . .23
3.14.3 SETTING THE COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.14.4 SETTING THE VARIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.15 POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.15.1 SLIDING DOOR MEMORY LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.15.2 DOOR LOCK INHIBIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.15.3 AUTOMATIC DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.15.4 REMOTE KEYLESS ENTRY (RKE) . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.16 POWER FOLDING MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.17 POWER LIFTGATE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.17.1 POWER LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.17.2 DIAGNOSTIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.17.3 SYSTEM INHIBITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.18 POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.18.1 POWER SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.18.2 DIAGNOSTIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ii
3.18.3 SYSTEM INHIBITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.19 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE . . . . . . . .26
3.20 VEHICLE THEFT SECURITY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.20.1 BASE ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.20.2 THATCHAM ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21 WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.1 FRONT WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.2 SPEED SENSITIVE INTERMITTENT WIPE MODE . . . . . . . . . . . . . .27
3.21.3 PULSE WIPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.4 PARK AFTER IGNITION OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.5 WIPE AFTER WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.6 REAR WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.21.7 SPEED SENSITIVE INTERMITTENT WIPE MODE . . . . . . . . . . . . . .27
3.21.8 WIPE AFTER WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.22 USING THE DRBIIIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.22.1 DRBIIIT ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.22.2 DRBIIIT DOES NOT POWER UP (BLANK SCREEN). . . . . . . . . . . . .28
3.22.3 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .28
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . .29
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.2.4 DRBIIIT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3.2 ROAD TESTING A COMPLAINT VEHICLE. . . . . . . . . . . . . . . . . . . . .29
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .31
AIRBAG
FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
FCM, ORC RUN ONLY DRIVER OVER CURRENT - ACTIVE. . . . . . . . . . . . . . . . . . . .32
FCM, ORC RUN ONLY DRIVER OVER TEMP - ACTIVE . . . . . . . . . . . . . . . . . . . . . . .32
FCM, ORC RUN ONLY DRIVER OVER VOLT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . .32
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . .32
ORC, LOSS OF IGNITION RUN ONLY - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
FCM, ORC RUN ONLY DRIVER OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN ONLY DRIVER OVER CURRENT - STORED . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN ONLY DRIVER OVER TEMP - STORED . . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN ONLY DRIVER OVER VOLT - STORED . . . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - STORED . . . . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER OVER CURRENT - STORED . . . . . . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER OVER TEMP - STORED . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER OVER VOLT - STORED . . . . . . . . . . . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER SHORT TO GROUND - STORED . . . . . . . . . . . . . .37
iii
FCM, SIACM RUN-START DRIVER OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . .37
FCM, SIACM RUN-START DRIVER OVER CURRENT - STORED . . . . . . . . . . . . . . . .37
FCM, SIACM RUN-START DRIVER OVER TEMP - STORED. . . . . . . . . . . . . . . . . . . .37
FCM, SIACM RUN-START DRIVER OVER VOLT - STORED . . . . . . . . . . . . . . . . . . . .37
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - STORED . . . . . . . . . . . .37
FCM, ORC RUN-START DRIVER OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
FCM, ORC RUN-START DRIVER OVER CURRENT - ACTIVE. . . . . . . . . . . . . . . . . . .41
FCM, ORC RUN-START DRIVER OVER TEMP - ACTIVE . . . . . . . . . . . . . . . . . . . . . .41
FCM, ORC RUN-START DRIVER OVER VOLT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . .41
FCM, ORC RUN-START DRIVER SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . .41
ORC, LOSS OF IGNITION RUN-START - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
FCM, SIACM RUN-START DRIVER OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .46
FCM, SIACM RUN-START DRIVER OVER CURRENT - ACTIVE . . . . . . . . . . . . . . . . .46
FCM, SIACM RUN-START DRIVER OVER TEMP - ACTIVE . . . . . . . . . . . . . . . . . . . . .46
FCM, SIACM RUN-START DRIVER OVER VOLT - ACTIVE . . . . . . . . . . . . . . . . . . . . .46
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - ACTIVE . . . . . . . . . . . . .46
LEFT SIACM ACCELEROMETER 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM ACCELEROMETER 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM ACCELEROMETER 2 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM ACCELEROMETER 2 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM INTERNAL 1 - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM INTERNAL 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM OUTPUT DRIVER 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM OUTPUT DRIVER 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM, LOSS OF IGNITION RUN-START - ACTIVE . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM, NO PCI TRANSMISSION - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
LEFT SIACM, NO PCI TRANSMISSION - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . .55
LEFT SIACM, NO PCM MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . .55
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED. . . . . . . . . . . . . . . . . . . . . . .55
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED. . . . . . . . . . . . . . . . . . .55
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . . . .55
ORC, INTERROGATE LEFT SIACM - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
ORC, NO LEFT SIACM MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
LEFT SIACM, NO PCM MESSAGE - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . .59
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . .62
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . .64
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . .67
ORC ACCELEROMETER - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC ACCELEROMETER - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC INTERNAL 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC INTERNAL 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC INTERNAL 2 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC INTERNAL 2 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC OUTPUT DRIVER 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC OUTPUT DRIVER 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC OUTPUT DRIVER 2 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC OUTPUT DRIVER 2 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC STORED ENERGY FIRING - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC STORED ENERGY FIRING - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC, NO PCI TRANSMISSION - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ORC, CALIBRATION MISMATCH - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
iv
ORC, CALIBRATION MISMATCH - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, CLUSTER MESSAGE MISMATCH - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBS OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBS SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBS SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBT CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBT CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBT SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SBT SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - STORED. . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 1 SHORT TO GROUND - STORED. . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 2 CIRCUIT OPEN - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 2 CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 2 SHORT TO BATTERY - STORED. . . . . . . . . . . . . . . . . . . . . .75
ORC, DRIVER SQUIB 2 SHORT TO GROUND - STORED. . . . . . . . . . . . . . . . . . . . . .75
ORC, LOSS OF IGNITION RUN ONLY - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, LOSS OF IGNITION RUN-START - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, NO CLUSTER MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, NO ODOMETER MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBS OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBS SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBS SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBT CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBT CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBT SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SBT SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 2 CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 2 SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . . .75
ORC, PASSENGER SQUIB 2 SHORT TO GROUND - STORED . . . . . . . . . . . . . . . . .75
ORC, VEHICLE BODY STYLE UNKNOWN - STORED . . . . . . . . . . . . . . . . . . . . . . . . .75
ORC, WARNING INDICATOR CIRCUIT OPEN - STORED . . . . . . . . . . . . . . . . . . . . . .75
ORC, WARNING INDICATOR CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . . .75
ORC, CLUSTER MESSAGE MISMATCH - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
ORC, DRIVER SBS OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
ORC, DRIVER SBS SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .86
ORC, DRIVER SBS SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .88
ORC, DRIVER SBT CIRCUIT OPEN - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
ORC, DRIVER SBT CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
ORC, DRIVER SBT SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .94
ORC, DRIVER SBT SHORT TO GROUND - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . .96
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . .101
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - ACTIVE. . . . . . . . . . . . . . . . . . . . . .104
ORC, DRIVER SQUIB 1 SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . . . .107
ORC, DRIVER SQUIB 2 CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . .110
ORC, DRIVER SQUIB 2 CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .113
v
ORC, DRIVER SQUIB 2 SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . . . .116
ORC, DRIVER SQUIB 2 SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . . . .119
ORC, INTERROGATE LEFT SIACM - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
ORC, INTERROGATE RIGHT SIACM - ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
ORC, INTERROGATE RIGHT SIACM - STORED. . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
ORC, NO RIGHT SIACM MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
RIGHT SIACM, NO PCI TRANSMISSION - STORED . . . . . . . . . . . . . . . . . . . . . . . . .124
RIGHT SIACM, NO PCM MESSAGE - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED. . . . . . . . . . . . . . . . . . . . . .124
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED . . . . . . . . . . . . . . . . . . . .124
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED . . . . . . . . . . . . . . . .124
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - STORED. . . . . . . . . . . . . . . . .124
ORC, NO CLUSTER MESSAGE - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
ORC, NO LEFT SIACM MESSAGE - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
ORC, NO ODOMETER MESSAGE - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
ORC, NO PCI TRANSMISSION - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
ORC, NO RIGHT SIACM MESSAGE - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
ORC, NOT CONFIGURED FOR SAB - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
ORC, NOT CONFIGURED FOR SAB - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
ORC, PASSENGER SBS OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
ORC, PASSENGER SBS SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . . .137
ORC, PASSENGER SBS SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . . .139
ORC, PASSENGER SBT CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .141
ORC, PASSENGER SBT CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . .143
ORC, PASSENGER SBT SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . . . . . .145
ORC, PASSENGER SBT SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . . . . . .147
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . .149
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . .152
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . .154
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . .157
ORC, PASSENGER SQUIB 2 CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . .159
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . .162
ORC, PASSENGER SQUIB 2 SHORT TO BATTERY - ACTIVE . . . . . . . . . . . . . . . . .164
ORC, PASSENGER SQUIB 2 SHORT TO GROUND - ACTIVE . . . . . . . . . . . . . . . . .167
ORC, VEHICLE BODY STYLE UNKNOWN - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . .169
ORC, WARNING INDICATOR CIRCUIT OPEN - ACTIVE . . . . . . . . . . . . . . . . . . . . . .171
ORC, WARNING INDICATOR CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . .171
RIGHT SIACM ACCELEROMETER 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM ACCELEROMETER 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM ACCELEROMETER 2 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM ACCELEROMETER 2 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM INTERNAL 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM INTERNAL 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM OUTPUT DRIVER 1 - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM OUTPUT DRIVER 1 - STORED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM, LOSS OF IGNITION RUN-START - ACTIVE. . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM, NO PCI TRANSMISSION - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . .173
RIGHT SIACM, NO PCM MESSAGE - ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE. . . . . . . . . . . . . . . . . . . . . . .177
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE . . . . . . . . . . . . . . . . . . . . .180
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE. . . . . . . . . . . . . . . . . .182
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE. . . . . . . . . . . . . . . . . .185
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES . . . . . . . . . . . . . . .188
vi
AUDIO
ALL OUTPUTS SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
AM SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASS ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASSETTE COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASSETTE EJECT FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASSETTE LOADING FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASSETTE TAPE TENSION HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CASSETTE TAPE TENSION LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CD ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CD MECHANICAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
FM SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
MICRO OUTPUT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
RADIO ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*AM/FM SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*ANY STATION PRESET SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*BALANCE INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*CD EJECT SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*EQUALIZER INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*FADER INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*FF/RW SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*HOUR/MINUTE SWITCHES INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*PAUSE/PLAY SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*PWR SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*SCAN SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*SEEK SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*SET SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*TAPE EJECT SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*TIME SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
*TUNE SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
CD CHANGER MECHANICAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
CD CHANGER PLAY FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
CD CHANGER READ FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
IMPROPER DISK IN CD CHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
CD CHANGER POWER SUPPLY TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
CD CHANGER TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
CD CHANGER TEMPERATURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
CD PLAY FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
CD READ FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
IMPROPER DISK IN CD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
CD TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
CD TEMPERATURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
FRONT OUTPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
LEFT OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
NBS OUTPUT 1 OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
NBS OUTPUT 2 OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
NBS OUTPUT 1 SHORT TO BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
NBS OUTPUT 2 SHORT TO BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
NO ANTENNA CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
NO VIN RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
POWER SUPPLY TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
REAR OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
vii
REMOTE RADIO SWITCH OPEN OR *REMOTE RADIO CONTROLS
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
REMOTE RADIO SWITCH STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
RIGHT OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
AUTOMATIC TEMPERATURE CONTROL

AC PRESSURE TOO HIGH (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
AC PRESSURE TOO LOW (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
AC PRESSURE TOO HIGH (STORED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
AC PRESSURE TOO LOW (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
DRIVER BLEND DOOR NOT RESPONDING (STORED) . . . . . . . . . . . . . . . . . . . . . .226
DRIVER BLEND DOOR RANGE TOO LARGE (STORED) . . . . . . . . . . . . . . . . . . . . .226
DRIVER BLEND DOOR TRAVEL TOO SMALL (STORED) . . . . . . . . . . . . . . . . . . . . .226
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (STORED). . . . . . . . . . . . .226
FRONT IR SENSOR CHANGE TOO LARGE (STORED). . . . . . . . . . . . . . . . . . . . . . .226
FRONT IR SENSOR HIGH (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
FRONT IR SENSOR LOW (STORED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
FRONT IR SENSOR NOT CALIBRATED (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . .226
FRONT KEYBOARD COMMUNICATION FAULT (STORED) . . . . . . . . . . . . . . . . . . . .226
FRONT KEYBOARD FAULT (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
FRONT MODE DOOR NOT RESPONDING (STORED). . . . . . . . . . . . . . . . . . . . . . . .226
FRONT MODE DOOR TRAVEL TOO LARGE (STORED) . . . . . . . . . . . . . . . . . . . . . .226
FRONT MODE DOOR TRAVEL TOO SMALL (STORED) . . . . . . . . . . . . . . . . . . . . . .226
PASS BLEND DOOR NOT RESPONDING (STORED). . . . . . . . . . . . . . . . . . . . . . . . .226
PASS BLEND DOOR TRAVEL TOO LARGE (STORED) . . . . . . . . . . . . . . . . . . . . . . .226
PASS BLEND DOOR TRAVEL TOO SMALL (STORED) . . . . . . . . . . . . . . . . . . . . . . .226
PCI BUS SHORTED HIGH (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
PCI BUS SHORTED LOW (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR BLEND DOOR NOT RESPONDING (STORED) . . . . . . . . . . . . . . . . . . . . . . . .226
REAR BLEND DOOR RANGE TOO LARGE (STORED) . . . . . . . . . . . . . . . . . . . . . . .226
REAR BLEND DOOR TRAVEL TOO SMALL (STORED) . . . . . . . . . . . . . . . . . . . . . . .226
REAR FAN POT OPEN (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR FAN POT SHORTED (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR IR SENSOR HIGH (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR IR SENSOR LOW (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR IR SENSOR NOT CALIBRATED (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR KEYBOARD FAULT (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR MODE DOOR NOT RESPONDING (STORED) . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR MODE DOOR TRAVEL TOO LARGE (STORED) . . . . . . . . . . . . . . . . . . . . . . .226
REAR MODE DOOR TRAVEL TOO SMALL (STORED). . . . . . . . . . . . . . . . . . . . . . . .226
REAR MODE POT OPEN (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
REAR MODE POT SHORTED (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
RECIRC DOOR NOT RESPONDING (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
RECIRC DOOR TRAVEL TOO LARGE (STORED). . . . . . . . . . . . . . . . . . . . . . . . . . . .226
RECIRC DOOR TRAVEL TOO SMALL (STORED) . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
COOLDOWN TEST FAILED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
DRIVER BLEND DOOR NOT RESPONDING (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . .234
DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE) . . . . . . . . . . . . . . . . . . . . . .236
DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE) . . . . . . . . . . . . . . . . . . . . . .238
EEPROM CHECKSUM ERROR (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
EVAP TEMP SENSOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
EVAP TEMP SENSOR SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (ACTIVE). . . . . . . . . . . . . .245
viii
FRONT IR SENSOR CHANGE TOO LARGE (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . .245
FRONT IR SENSOR HIGH (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
FRONT IR SENSOR LOW (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
FRONT IR SENSOR NOT CALIBRATED (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . .246
FRONT KEYBOARD FAULT (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
FRONT KEYBOARD COMMUNICATION FAULT (ACTIVE) . . . . . . . . . . . . . . . . . . . . .251
FRONT MODE DOOR NOT RESPONDING (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . .252
FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . .254
FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . .256
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERATURE TOO
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
PASS BLEND DOOR NOT RESPONDING (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . . .261
PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . .263
PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . .265
PCI BUS SHORTED HIGH (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
PCI BUS SHORTED LOW (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
REAR BLEND DOOR NOT RESPONDING (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . .268
REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . .270
REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . .272
REAR FAN POT OPEN (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR FAN POT SHORTED (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR IR SENSOR HIGH (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR IR SENSOR LOW (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR MODE POT OPEN (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR MODE POT SHORTED (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
REAR IR SENSOR NOT CALIBRATED (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
REAR KEYBOARD FAULT (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
REAR MODE DOOR NOT RESPONDING (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . .284
REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . .286
REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . .288
RECIRC DOOR NOT RESPONDING (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
RECIRC DOOR TRAVEL TOO LARGE (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
RECIRC DOOR TRAVEL TOO SMALL (ACTIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
CABIN HEATER
CABIN HEATER PRE-TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
CABIN HEATER CONTROL CIRCUIT OPEN (STORED). . . . . . . . . . . . . . . . . . . . . . .296
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (STORED). . . . . . . . . .296
B1000 CONTROL UNIT ERRONEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
B1800 NO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
B1801 FLAME OUT: DURING HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
B1801 FLAME OUT: UNSTABLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD. . . . . . . .304
B1802 POWER SUPPLY OUT OF RANGE: VOLTAGE ABOVE 15.5 VOLTS . . . . . . .307
B1803 FLAME DETECTED PRIOR TO COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . .308
B1811 HEATER OVERHEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
B1813 HEATER IN LOCKOUT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY . . . . . . . . . . . . .315
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .318
B1821 COMBUSTION AIR FAN CIRCUIT: OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
B1821 COMBUSTION AIR FAN CIRCUIT: SHORT TO GROUND . . . . . . . . . . . . . . . .321
B1822 GLOW PIN/FLAME SENSOR: OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
B1822 GLOW PIN/FLAME SENSOR: SHORT TO GROUND . . . . . . . . . . . . . . . . . . .322
ix
B1823 WATER PUMP CIRCUIT: OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
B1823 WATER PUMP CIRCUIT: SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . .323
B1824 FAN SWITCH LINE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE). . . . . . . . . . . . . . . . . . . . . . . .325
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE). . . . . . . . . . .329
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE . . . . . . . . . . . . . . .332
CHIME
*CHIME INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
*KEY IN IGNITION AND DRIVER’S DOOR OPEN CHIME NOT OPERATING
PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
*PROBLEM WITH THE HIGH VEHICLE SPEED WARNING CHIME . . . . . . . . . . . . .337
COMMUNICATION
ATC MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
AUDIO MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
BCM, PCI BUS SHORTED TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
BCM, PCI BUS SHORTED TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
FCM, PCI BUS SHORTED TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
FCM, PCI BUS SHORTED TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
COUNTRY CODE NOT PROGRAMMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
FCM MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
FCM, BCM COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
FCM, HVAC COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345
FCM, PCI INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346
FCM, PCM COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
FCM, RADIO COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
FCM, TCM COMMUNICATION FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
IGNITION MUX SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
IGNITION MUX SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
IGNITION RUN OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
INTERNAL BCM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
LEFT PSD MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
LIFTGATE MODULE MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . .359
MIC MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360
MSM MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
NO PCI MESSAGES FROM CD CHANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362
ORC MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
OTIS MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
PCI INTERNAL HARDWARE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
PCM MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
RADIO MEM MSG NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
RIGHT PSD MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
RUN/START HARDWIRE INPUT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
SKIM MESSAGES NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
TCM MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372
*BUS +/- SIGNALS OPEN FROM AUTOMATIC TEMPERATURE CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
*BUS +/- SIGNALS OPEN FROM MEMORY SEAT/MIRROR MODULE . . . . . . . . . . .375
*BUS +/- SIGNALS OPEN FROM SENTRY KEY IMMOBILIZER MODULE . . . . . . . .377
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM BODY CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM HVAC . . . . . . . . . . . . . . . . . .381
x
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM INSTRUMENT CLUSTER . .383
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM LEFT SLIDING DOOR
CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM POWER LIFTGATE
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM RIGHT SLIDING DOOR
CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM THATCHAM ALARM
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395
*NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY . . . . . . . . . . . . . .397
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . .399
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . .401
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . .402
*NO RESPONSE FROM FRONT CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . .404
*NO RESPONSE FROM LEFT SIACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
*NO RESPONSE FROM ORC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
*NO RESPONSE FROM OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
*NO RESPONSE FROM PCM (PCI BUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
*NO RESPONSE FROM PCM (SCI ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
*NO RESPONSE FROM RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416
*NO RESPONSE FROM RIGHT SIACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE . . . . . . . . . . . . . . . .420
*PCI BUS COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
DOOR AJAR
*HOOD AJAR CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426
*HOOD AJAR CIRCUIT SHORTED TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . .427
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN . . . . . . . . . . . . . . . . .428
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND. .429
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN . . . . . . . . . . . . . . . .430
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO
GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .432
*LIFTGATE AJAR CIRCUIT OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
*LIFTGATE AJAR CIRCUIT SHORTED TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .434
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN . . . . . . . . . . . . . . . .435
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO
GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436
*RIGHT SLIDING DOOR AJAR CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437
*RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND . . . . . . . . . . . . . .439
ELECTRICALLY HEATED SYSTEMS

EBL RUN ONLY RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
EBL RUN ONLY RELAY SHORTED TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . .442
EXTERIOR LIGHTING
BACKUP LAMP OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443
BACKUP LAMP OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445
FRONT FOG LAMP RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
FRONT FOG LAMP SHORTED TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448
HEADLAMP SWITCH MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449
HEADLAMP SWITCH OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
HEADLAMP SWITCH SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452
HIGH BEAM SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
xi
HIGH BEAM SWITCH INPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456
LEFT FRONT TURN SIGNAL OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
LEFT FRONT TURN SIGNAL OUTPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
LEFT HIGH BEAM HEADLAMP CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND . . . . . . . . . . . . .464
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE . . . . . . . . . . . . .466
LEFT LOW BEAM HEADLAMP CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND . . . . . . . . . . . . . .470
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE. . . . . . . . . . . . . .472
LEFT REAR TURN SIGNAL OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
LEFT REAR TURN SIGNAL OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
LEFT SIDE PARK LAMP OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
PARK LAMP OUTPUT 1 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480
PARK LAMP OUTPUT 1 SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482
PARK LAMP OUTPUT 2 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483
PARK LAMP OUTPUT 2 SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
RIGHT FRONT TURN SIGNAL OUTPUT OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486
RIGHT FRONT TURN SIGNAL OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .488
RIGHT HIGH BEAM HEADLAMP CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . .490
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND . . . . . . . . . . . .492
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE . . . . . . . . . . . .494
RIGHT LOW BEAM HEADLAMP CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . .496
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND. . . . . . . . . . . . .498
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE . . . . . . . . . . . .500
RIGHT REAR TURN SIGNAL OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
RIGHT REAR TURN SIGNAL OUTPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504
RIGHT SIDE PARK LAMP OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506
TURN SIGNAL SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508
TURN SIGNAL SWITCH INPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .510
HEATING & A/C

A/C FAULT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
CHECKSUM FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
POWER FAULT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
REAR DEFOG FAILURE (ACTIVE) - MAN A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
RECIRCULATION FAULT (ACTIVE) - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . . . . . . .512
UNKNOWN FAULT DETECTED (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . .512
A/C FAULT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
BACKLIGHT DIMMING RX FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . .514
BLEND OVERCURRENT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .514
CHECKSUM FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (STORED) - MANUAL
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (STORED) - MANUAL
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
LOOPBACK FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
LOOPBACK TEST FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . .514
MODE OVERCURRENT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .514
NO BCM MESSAGE RECEIVED (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . .514
NO PCM MESSAGE RECEIVED (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . .514
PCM COMMUNICATION FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . .514
POWER FAULT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
REAR BLEND OVERCURRENT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . .514
xii
REAR BLEND POT CIRCUIT OPEN (STORED) - MANUAL A/C. . . . . . . . . . . . . . . . .514
REAR BLEND POT CIRCUIT SHORT (STORED) - MANUAL A/C . . . . . . . . . . . . . . .514
REAR DEFOG FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .514
REAR MODE OVERCURRENT (STORED) - MANUAL A/C. . . . . . . . . . . . . . . . . . . . .514
RECIRC OVERCURRENT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . .514
RECIRCULATION FAULT (STORED) - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . . . . . .514
TX FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
UNKNOWN FAULT DETECTED (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . .514
VEHICLE ODOMETER FAILURE (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . .514
ZONE OVERCURRENT (STORED) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . .514
BACKLIGHT DIMMING RX FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . .519
NO BCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . .519
BLEND CALIBRATION FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
MODE CALIBRATION FAULT - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
RECIRCULATION CALIBRATION FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . .521
ZONE CALIBRATION FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . . . . . . .526
MODE OVERCURRENT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . .526
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . .526
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . .526
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .526
ZONE OVERCURRENT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . .526
COOLDOWN TEST EXCESSIVE FAULT - MANUAL A/C. . . . . . . . . . . . . . . . . . . . . . .532
COOLDOWN TEST SENSOR FAILURE - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . .532
COOLDOWN TEST SET UP FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .534
COOLDOWN TEST TOO COLD TO START - MANUAL A/C . . . . . . . . . . . . . . . . . . . .535
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE) - MANUAL
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .538
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (ACTIVE) - MANUAL
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540
FRONT AND REAR BLOWER OUTPUT 1 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . .542
FRONT AND REAR BLOWER OUTPUT 2 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . .542
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT . . . . . . . . . . . . . . . . . . .544
FRONT AND REAR BLOWER OUTPUT 2 SHORT TO BATT . . . . . . . . . . . . . . . . . . .544
LOOPBACK FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
LOOPBACK TEST FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . .546
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . .547
PCM COMMUNICATION FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . .547
VEHICLE ODOMETER FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . .547
REAR BLEND CALIBRATION FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . .549
REAR MODE CALIBRATION FAULT - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . .549
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C. . . . . . . . . . . . . . . . . .553
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . .556
TX FAILURE (ACTIVE) - MANUAL A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559
INSTRUMENT CLUSTER
ABS LAMP CKT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
ABS LAMP OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562
AIRBAG LAMP CKT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
AIRBAG LAMP OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .564
EL PANEL SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .565
FRONT FOG LAMP INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567
FRONT FOG LAMP INDICATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .569
xiii
FUEL GAUGE CHECKSUM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .571
FUEL LEVEL SENDING UNIT INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572
FUEL LEVEL SENDING UNIT INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .574
IOD WAKEUP CLUSTER OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576
IOD WAKEUP CLUSTER OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE) . . . . . . . . . . . . . . . . . . . . . . . . .580
LEFT TURN SIGNAL INDICATOR OPEN (LOWLINE) . . . . . . . . . . . . . . . . . . . . . . . . .582
LEFT TURN SIGNAL INDICATOR SHORT (HIGHLINE). . . . . . . . . . . . . . . . . . . . . . . .584
LEFT TURN SIGNAL INDICATOR SHORT (LOWLINE) . . . . . . . . . . . . . . . . . . . . . . . .586
LOOPBACK FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
NO ABS BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
NO BCM BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590
NO FCM BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591
NO ORC BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592
NO PCM BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
NO TCM BUS MESSAGES RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
PANEL DIMMING OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .595
REAR FOG INDICATOR OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600
REAR FOG INDICATOR OUTPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
RIGHT TURN SIGNAL INDICATOR OPEN (HIGHLINE). . . . . . . . . . . . . . . . . . . . . . . .604
RIGHT TURN SIGNAL INDICATOR OPEN (LOWLINE) . . . . . . . . . . . . . . . . . . . . . . . .606
RIGHT TURN SIGNAL INDICATOR SHORT (HIGHLINE) . . . . . . . . . . . . . . . . . . . . . .608
RIGHT TURN SIGNAL INDICATOR SHORT (LOWLINE) . . . . . . . . . . . . . . . . . . . . . . .610
SPEEDOMETER CHECKSUM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
TACHOMETER CHECKSUM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .613
TCM MESSAGE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
TEMPERATURE GAUGE CHECKSUM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .615
*ANY PCI BUS INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616
INTELLIGENT POWER MODULE

ACCESSORY POWER OUTPUT #1 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617
ACCESSORY POWER OUTPUT #1 SHORTED TO BATTERY. . . . . . . . . . . . . . . . . .619
ACCESSORY POWER OUTPUT #2 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .621
ACCESSORY POWER OUTPUT #2 SHORTED TO BATTERY. . . . . . . . . . . . . . . . . .623
CPA NOT ENGAGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625
IGN RUN/START INPUT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627
IGNITION START INPUT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629
INTERNAL DRIVER FAULT #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631
INTERIOR LIGHTING
DOME LAMP OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .634
DOME SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635
DOME SWITCH INPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636
FRONT COURTESY LAMPS OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638
HALO/DOOR/LIFTGATE LAMP OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .640
READING LAMP OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641
MEMORY SEAT
BCM MESSAGE NOT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
CHARGING VOLTAGE HIGH MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643
CHARGING VOLTAGE LOW MESSAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .644
xiv
EEPROM REFRESH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645
FRONT RISER DOWN POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .646
FRONT RISER SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . .648
FRONT RISER SENSOR OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . .651
FRONT RISER UP POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .654
HORIZONTAL FORWARD POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .656
HORIZONTAL REARWARD POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .658
HORIZONTAL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660
HORIZONTAL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .663
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . .666
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . .668
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . .670
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . .672
MEMORY POSITION SWITCH STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674
MEMORY SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676
MEMORY SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678
REAR RISER DOWN POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680
REAR RISER SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .682
REAR RISER SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685
REAR RISER UP POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688
RECLINER DOWN POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
RECLINER SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .692
RECLINER SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695
RECLINER UP POSITION STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .698
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . .700
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . .702
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . .704
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . .706
OVERHEAD CONSOLE
BUS MESSAGES MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708
COMPASS TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710
DEMAGNETIZE COMPASS AS PER SERVICE MANUAL . . . . . . . . . . . . . . . . . . . . . .711
EC MIRROR DAY/NIGHT LINE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .712
EVIC INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
OTIS MODULE MESSAGE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .715
OTIS MODULE MESSAGE MISMATCH (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
*REPAIRING CMTC DISPLAYS DOUBLE DASH ( - - ) IN TEMP DISPLAY . . . . . . . .719
POWER DOOR LOCKS/RKE

DRIVER DOOR LOCK SWITCH INPUT OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
DRIVER DOOR LOCK SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724
DRIVER DOOR LOCK SWITCH INPUT STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726
LEFT CYLINDER LOCK SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728
LEFT CYLINDER LOCK SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .730
LEFT CYLINDER LOCK SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
LEFT UNLOCK OUTPUT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734
LIFTGATE CYLINDER SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736
LIFTGATE CYLINDER SWITCH INPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .738
LIFTGATE CYLINDER SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740
LIFTGATE UNLOCK POWER OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742
LOCK OUTPUT FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744
PASSENGER DOOR LOCK SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . .747
xv
PASSENGER DOOR LOCK SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . .749
PASSENGER DOOR LOCK SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . .751
RIGHT CYLINDER LOCK SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
RIGHT CYLINDER LOCK SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . .755
RIGHT CYLINDER LOCK SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . .757
RIGHT UNLOCK OUTPUT FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759
RKE PROGRAM LINE OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .761
RKE PROGRAM LINE OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .763
POWER DOORS - LIFTGATE

AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . .764
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND . . . . . . . . . . .766
CONTROL MODULE FAILURE - INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . .768
INCOMPLETE LATCH CINCH - NO CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .769
INCOMPLETE LATCH CINCH - NO PAWL TRANSITION . . . . . . . . . . . . . . . . . . . . . .771
INCOMPLETE LATCH CINCH - OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .773
INCOMPLETE LATCH CINCH - PAWL SWITCH FAILURE . . . . . . . . . . . . . . . . . . . . .776
INCOMPLETE LATCH CINCH - RATCHET SWITCH FAILURE . . . . . . . . . . . . . . . . . .779
INCOMPLETE LATCH RELEASE - NO CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . .782
INCOMPLETE LATCH RELEASE - RATCHET SWITCH FAILURE . . . . . . . . . . . . . . .785
INCOMPLETE LATCH RELEASE- OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . .787
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE . . . . . . . . . . . . . . . . . . .788
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE . . . . . . . . . .790
INCOMPLETE POWER CLOSE - FULL OPEN SWITCH FAILURE. . . . . . . . . . . . . . .791
INCOMPLETE POWER CLOSE - MISSING HALL SIGNAL. . . . . . . . . . . . . . . . . . . . .793
INCOMPLETE POWER CLOSE - OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . .796
INCOMPLETE POWER CLOSE - TIME OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799
INCOMPLETE POWER OPEN - FULL OPEN SWITCH FAILURE. . . . . . . . . . . . . . . .800
INCOMPLETE POWER OPEN - LATCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .802
INCOMPLETE POWER OPEN - MISSING HALL SIGNAL. . . . . . . . . . . . . . . . . . . . . .808
INCOMPLETE POWER OPEN - OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .811
INCOMPLETE POWER OPEN - TIME OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .814
IOD WAKE UP OPEN - PLG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .815
LOOPBACK TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .817
LOSS OF BCM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .818
LOSS OF EATX MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .819
LOSS OF FCM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .820
LOSS OF SBEC MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .821
OUTSIDE LIFTGATE HANDLE INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .822
OUTSIDE LIFTGATE HANDLE INPUT STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .823
OVERHEAD LIFTGATE SWITCH INPUT STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . .824
OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN . . . . . . . . . . . . . . . . . . . . . . . .825
OVERHEAD LIFTGATE/LOCKOUT SWITCHES SHORT . . . . . . . . . . . . . . . . . . . . . . .827
PINCH SENSOR CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .828
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . .831
*POWER LIFTGATE INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .833
POWER DOORS - SLIDING

AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . .834
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND . . . . . . . . . . .835
CONTROL MODULE FAILURE - INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . .836
INCOMPLETE LATCH CINCH - NO CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837
INCOMPLETE LATCH CINCH - NO PAWL TRANSITION . . . . . . . . . . . . . . . . . . . . . .839
xvi
INCOMPLETE LATCH CINCH - OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .841
INCOMPLETE LATCH CINCH - PAWL SWITCH FAILURE . . . . . . . . . . . . . . . . . . . . .843
INCOMPLETE LATCH CINCH - RATCHET SWITCH FAILURE . . . . . . . . . . . . . . . . . .845
INCOMPLETE LATCH RELEASE - FULL OPEN SWITCH FAILURE . . . . . . . . . . . . .848
INCOMPLETE LATCH RELEASE - NO CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . .851
INCOMPLETE LATCH RELEASE - RATCHET SWITCH FAILURE . . . . . . . . . . . . . . .853
INCOMPLETE LATCH RELEASE- NO REVERSE TO UNLOAD CLUTCH . . . . . . . . .855
INCOMPLETE LATCH RELEASE- OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . .856
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE . . . . . . . . . . . . . . . . . . .857
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE . . . . . . . . . .859
INCOMPLETE POWER CLOSE - FULL OPEN SWITCH FAILURE. . . . . . . . . . . . . . .860
INCOMPLETE POWER CLOSE - LATCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . .862
INCOMPLETE POWER CLOSE - MISSING HALL SIGNAL. . . . . . . . . . . . . . . . . . . . .868
INCOMPLETE POWER CLOSE - OVERCURRENT. . . . . . . . . . . . . . . . . . . . . . . . . . .871
INCOMPLETE POWER CLOSE - TIME OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
INCOMPLETE POWER OPEN - FULL OPEN SWITCH FAILURE. . . . . . . . . . . . . . . .874
INCOMPLETE POWER OPEN - LATCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .876
INCOMPLETE POWER OPEN - MISSING HALL SIGNAL. . . . . . . . . . . . . . . . . . . . . .881
INCOMPLETE POWER OPEN - OVERCURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .884
INCOMPLETE POWER OPEN - TIME OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .886
IOD WAKE UP OPEN - PSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887
IOD WAKE UP PSD & PLG SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889
LEFT B-PILLAR SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891
LEFT B-PILLAR SWITCH INPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893
LEFT B-PILLAR SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894
LOOPBACK TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .895
LOSS OF BCM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .896
LOSS OF EATX MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
LOSS OF FCM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898
LOSS OF SBEC MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899
OVERHEAD LEFT SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
OVERHEAD RIGHT SWITCH INPUT STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .901
OVERHEAD RIGHT/LEFT SWITCHES SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
RIGHT B-PILLAR SWITCH INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .903
RIGHT B-PILLAR SWITCH INPUT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .905
RIGHT B-PILLAR SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .906
*POWER SLIDING DOOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .907
POWER MIRROR – FOLDING

FOLD MIRROR OUTPUT FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .908
PASSENGER MIRROR RELAY OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .910
PASSENGER MIRROR RELAY OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . .912
UNFOLD MIRROR OUTPUT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913
*BOTH MIRRORS DO NOT UNFOLD EXCEPT WITH EITHER FRONT DOOR . . . .916
*BOTH POWER FOLDING MIRRORS DO NOT FOLD . . . . . . . . . . . . . . . . . . . . . . . .917
*DRIVER FOLDING MIRROR DOES NOT FOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
*PASSENGER FOLDING MIRROR DOES NOT FOLD . . . . . . . . . . . . . . . . . . . . . . . .920
VEHICLE THEFT/SECURITY
BCM MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922
HORN INPUT STUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923
HORN RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924
HORN RELAY SHORTED TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925
xvii
INTERNAL EEPROM WRITE ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .927
INTERNAL TRANSMIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .928
INTERNAL ULTRASONIC FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929
LOOPBACK ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .935
NO VALID MESSAGES RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .936
PCI BUS SHORTED TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .937
PCI BUS SHORTED TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .938
PCM MESSAGES NOT RECEIVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .939
VEHICLE THEFT ALARM INDICATOR OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . .940
VEHICLE THEFT ALARM INDICATOR OUTPUT SHORT . . . . . . . . . . . . . . . . . . . . . .941
*ALARM TRIPS ON ITS OWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .942
*HOOD DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .943
*LEFT FRONT DOOR DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .944
*LEFT SLIDING DOOR DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .945
*LIFTGATE DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .946
*REPEATER LAMPS INOPERATIVE WITH ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . .947
*RIGHT FRONT DOOR DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .948
*RIGHT SLIDING DOOR DOES NOT TRIP VTSS . . . . . . . . . . . . . . . . . . . . . . . . . . . .949
*VTSS INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .950
*VTSS INDICATOR LAMP INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .951
*VTSS SIREN INOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .952
*VTSS WILL NOT ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955
WINDSHIELD WIPER & WASHER

FR WIPER HI-LO RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .956
FR WIPER HI-LO RELAY SHORT TO BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .958
FRONT WASH SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959
FRONT WASHER OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .961
FRONT WIPER NOT PARKED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .963
FRONT WIPER ON RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .965
FRONT WIPER ON RELAY SHORT TO BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .966
FRONT WIPER PARK SWITCH SHORT TO GND . . . . . . . . . . . . . . . . . . . . . . . . . . . .967
FRONT WIPER SWITCH MUX INPUT OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .969
FRONT WIPER SWITCH MUX INPUT SHORT TO GROUND. . . . . . . . . . . . . . . . . . .971
HEADLAMP WASHER RELAY OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .973
HEADLAMP WASHER RELAY SHORT TO BATT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .975
REAR WASH SWITCH INPUT STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .976
REAR WASHER OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .978
REAR WIPER OUTPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .980
REAR WIPER OUTPUT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .982
REAR WIPER SWITCH MUX INPUT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .984
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . .986
VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .988
8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995
8.1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995

8.2 BODY CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .996
8.3 ENGINE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .996
8.4 HEATING & A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .996
8.4.1 ACTUATORS – FRONT LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .996
xviii
8.4.2 ACTUATOR – FRONT RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .997
8.4.3 ACTUATOR – FRONT LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .997
8.4.4 ACTUATOR – FRONT RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .998
8.4.5 EVAPORATOR TEMPERATURE SENSOR LHD. . . . . . . . . . . . . . . .998
8.4.6 EVAPORATOR TEMPERATURE SENSOR RHD . . . . . . . . . . . . . . .999
8.4.7 C202 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .999
8.4.8 ACTUATORS – REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000
8.4.9 REAR A/C HEATER UNIT CONNECTOR . . . . . . . . . . . . . . . . . . . .1000
8.5 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
8.5.1 DIESEL CABIN HEATER ASSIST (CABIN HEATER) ASSEMBLY .1001
8.5.2 C331 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
8.5.3 C330 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
8.7 MEMORY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
8.7.1 MEMORY SEAT MIRROR MEDULE/SEAT MOTORS . . . . . . . . . .1002
8.7.2 MEMORY SEAT MIRROR MODULE CIRCUIT BREAKER. . . . . . .1003
8.8 OVERHEAD SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
8.9 POWER FOLDING MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
8.10 POWER LIFTGATE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004
8.10.1 MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004
8.10.2 PINCH SENSORS (TAPE SWITCH) . . . . . . . . . . . . . . . . . . . . . . . .1004
8.10.3 LATCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1005
8.11 POWER DOOR LOCK/RKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1005
8.11.1 DOOR LOCK MOTOR/AJAR SWITCH . . . . . . . . . . . . . . . . . . . . . .1005
8.11.1 CYLINDER LOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1005
8.11.3 REMOTE KEYLESS ENTRY MODULE . . . . . . . . . . . . . . . . . . . . . .1006
8.12 POWER SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006
8.12.1 MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006
8.12.2 LOWER DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006
8.12.3 LATCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007
8.13 VEHICLE THEFT SECURITY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007
8.13.1 RKE/THATCHAM ALARM MODULE . . . . . . . . . . . . . . . . . . . . . . . .1007
8.13.2 RKE/THATCHAM ALARM MODULE CONNECTORS . . . . . . . . . . .1007
8.13.3 VTSS LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1008
8.13.4 VTSS SIREN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1008
8.13.5 FRONT INTRUSION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1009
8.13.6 REAR INTRUSION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1009
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1011
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . . .1011

A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY . . . . . . . . . . . . . . . . . .1011
AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAY . . . . . . . . . . . . . . . . .1011
ATC REMOTE SENSOR (ATC) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1012
AUTO TEMP CONTROL C1 - WHITE 13 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1012
AUTO TEMP CONTROL C2 - BLACK 13 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1012
AUTO TEMP CONTROL C3 - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1012
BLOWER MOTOR RESISTOR C1 (MTC) - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . .1013
BLOWER MOTOR RESISTOR C2 (MTC) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . .1013
BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . .1013
BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY . . . . . . . . . . . . . . . . . . . .1014
BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY . . . . . . . . . . . . . . . . . . . .1015
BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY . . . . . . . . . . . . . . . . . . . . .1016
BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY . . . . . . . . . . . . . . . . . . . .1017
xix
C200 - GRAY (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1018
C200 - GRAY (INSTRUMENT PANEL SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1020
C201 - YELLOW (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1021
C201 - YELLOW (INSTRUMENT PANEL SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1022
C202 - GRAY (COMPONENT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1022
C202 - GRAY (INSTRUMENT PANEL SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1023
C304 - YELLOW (SEAT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1023
C305 - GRAY (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1024
C307 - GRAY (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1024
C307 - GRAY (SEAT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1025
C311 - GRAY (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1025
C311 - GRAY (REAR A/C JUMPER SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1026
C314 (HIGH LINE) - BLACK (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1026
C314 (HIGH LINE) - BLACK (LIFTGATE SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1027
C315 (HIGH LINE) - BLACK (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1027
C315 (HIGH LINE) - BLACK (LIFTGATE SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1027
C316 (POWER SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY
SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1028
C316 (POWER SLIDING DOOR) - BLACK (LEFT SLIDING DOOR SIDE). . . . . . . .1028
C317 (POWER SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY
SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1028
C317 (POWER SLIDING DOOR) - BLACK (RIGHT SLIDING DOOR SIDE) . . . . . .1028
C322 (MEMORY) - BLACK (BODY SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1029
C322 (MEMORY) - BLACK (POWER SEAT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . .1029
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY
SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1029
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT MANUAL SLIDING DOOR
SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1030
C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY
SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1030
C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT MANUAL SLIDING DOOR
SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1030
C326 - YELLOW (SAFETY SEAT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1030
C327 - YELLOW (SAFETY SEAT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1031
C330 (DIESEL) - GRAY (CABIN HEATER JUMPER SIDE) . . . . . . . . . . . . . . . . . . . .1031
C330 (DIESEL) - LT. GRAY (BODY SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1031
C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE) . . . . . . . . . . . . . . . . . . .1031
C331 (DIESEL) - GRAY (CABIN HEATED COMPONENT SIDE). . . . . . . . . . . . . . . .1032
CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .1032
CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .1032
CD CHANGER - 8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1033
CENTER DOME LAMP (BASE/HIGH LINE) - GRAY 3 WAY . . . . . . . . . . . . . . . . . . .1033
CLOCKSPRING C1 - WHITE 6 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1033
CLOCKSPRING C2 - YELLOW 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1034
CLOCKSPRING C4 - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1034
CLOCKSPRING C5 - YELLOW 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1034
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY . . . . . . . . . . . . . . . . . . . . . . . .1035
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1035
xx
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .1036
DOSING PUMP - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1036
DRIVER AIRBAG C1 - BROWN 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1036
DRIVER AIRBAG C2 - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1036
DRIVER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . .1037
DRIVER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . .1037
DRIVER DOOR LOCK SWITCH - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1037
DRIVER SEAT BELT SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1037
DRIVER SEAT BELT TENSIONER - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1038
ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1038
ELECTRIC WIPER DE-ICER C2 - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1038
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY. . . . . . . . . . . . . . . . .1039
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY. . . . . . . . . . . . . . . . .1041
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . .1041
FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . .1042
FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .1042
FRONT READING LAMPS/SWITCH - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . .1042
GLOVE BOX LAMP - BLUE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1042
HALO LAMP - BLUE 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1042
HEADLAMP SWITCH - BLACK 13 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1043
HEADLAMP WASHER PUMP MOTOR (BUILT-UP-EXPORT) - BLACK 2 WAY . . . .1043
IGNITION SWITCH - BLACK 5 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1043
INSTRUMENT CLUSTER - BLACK 13 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1044
INTELLIGENT POWER MODULE C1 - LT. GREEN/RED 20 WAY . . . . . . . . . . . . . .1044
INTELLIGENT POWER MODULE C2 - GREEN/BLUE 10 WAY . . . . . . . . . . . . . . . .1045
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY . . . . . . . .1045
INTELLIGENT POWER MODULE C3 (GAS) - NATURAL/RED 20 WAY. . . . . . . . . .1046
INTELLIGENT POWER MODULE C4 - BLUE 10 WAY . . . . . . . . . . . . . . . . . . . . . . .1046
INTELLIGENT POWER MODULE C5 - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . .1046
INTELLIGENT POWER MODULE C6 - NATURAL 10 WAY . . . . . . . . . . . . . . . . . . . .1047
INTELLIGENT POWER MODULE C7 - BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . .1047
INTELLIGENT POWER MODULE C8 - ORANGE 10 WAY . . . . . . . . . . . . . . . . . . . .1048
INTELLIGENT POWER MODULE C9 - BLACK 10 WAY . . . . . . . . . . . . . . . . . . . . . .1048
LEFT B-PILLAR SWITCH - GRAY 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1048
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY . . . . .1048
LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .1049
LEFT DOOR SPEAKER - BLACK/RED 6 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1049
LEFT FOG LAMP - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1049
LEFT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY. . . . . . . . . . . . . . . . .1049
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) -
BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1050
LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) -
BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1050
LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY . . . . . . . .1050
LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY . . . . . . . . . . . . .1050
LEFT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . .1051
LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .1051
LEFT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . .1051
LEFT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . .1051
LEFT POWER MIRROR - BLACK 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1052
LEFT REAR PILLAR SPEAKER - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . .1052
LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY . . . . . . . . . . . . . . . . . . . . .1052
LEFT REAR SPEAKER - BLACK/RED 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1052
xxi
LEFT REMOTE RADIO SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1053
LEFT SEAT AIRBAG - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1053
LEFT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY . . . . . .1053
LEFT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) -
BLACK 8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1053
LEFT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) -
BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1054
LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) -
BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1054
LEFT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4
WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1054
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL
SLIDING DOOR) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1055
LEFT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY . . . . .1055
LEFT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY . . . . . . . . . .1055
LEFT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY . . . . . . . . . . . .1055
LICENSE LAMP (POWER LIFTGATE) - DK. GRAY 8 WAY . . . . . . . . . . . . . . . . . . . .1056
LICENSE LAMP (POWER RELEASE) - DK. GRAY 4 WAY . . . . . . . . . . . . . . . . . . . .1056
LIFTGATE AJAR SWITCH (MANUAL RELEASE) - BLACK 2 WAY . . . . . . . . . . . . . .1056
LIFTGATE AJAR SWITCH (POWER RELEASE) - BLACK 4 WAY . . . . . . . . . . . . . .1056
LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) - BLUE 7 WAY . . . . . .1057
LIFTGATE CYLINDER LOCK SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .1057
LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY. . . . . . . .1057
LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY . . . . . .1057
MEMORY POWER SEAT SWITCH - GREEN 10 WAY. . . . . . . . . . . . . . . . . . . . . . . .1058
MEMORY SEAT FRONT VERTICAL MOTOR - RED 2 WAY . . . . . . . . . . . . . . . . . . .1058
MEMORY SEAT FRONT VERTICAL POSITION SENSOR - BLACK 3 WAY . . . . . .1058
MEMORY SEAT HORIZONTAL MOTOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .1058
MEMORY SEAT HORIZONTAL POSITION SENSOR - BLACK 3 WAY. . . . . . . . . . .1058
MEMORY SEAT REAR VERTICAL MOTOR - RED 2 WAY . . . . . . . . . . . . . . . . . . . .1059
MEMORY SEAT REAR VERTICAL POSITION SENSOR - BLACK 3 WAY. . . . . . . .1059
MEMORY SEAT RECLINER MOTOR - GREEN 2 WAY. . . . . . . . . . . . . . . . . . . . . . .1059
MEMORY SEAT RECLINER POSITION SENSOR - BLACK 3 WAY . . . . . . . . . . . . .1059
MEMORY SEAT SWITCH - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1059
MEMORY SEAT/MIRROR MODULE C1 - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . .1060
MEMORY SEAT/MIRROR MODULE C2 - GRAY 26 WAY . . . . . . . . . . . . . . . . . . . . .1060
MEMORY SEAT/MIRROR MODULE C3 - GRAY 16 WAY . . . . . . . . . . . . . . . . . . . . .1060
MEMORY SEAT/MIRROR MODULE C4 - WHITE 12 WAY . . . . . . . . . . . . . . . . . . . .1061
MODE DOOR ACTUATOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1061
MODE DOOR ACTUATOR (MTC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .1061
MULTI-FUNCTION SWITCH - BLACK 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1061
OCCUPANT RESTRAINT CONTROLLER - YELLOW/RED 23 WAY. . . . . . . . . . . . .1062
OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY . . . . . . . . . . . . . . . . . .1062
PASSENGER AIRBAG - YELLOW 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1063
PASSENGER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . .1063
PASSENGER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY. . . . . . . . . . . . . . .1063
PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . .1063
PASSENGER FOLDING MIRROR RELAY (BUILT-UP-EXPORT) - BLUE 9 WAY . .1064
PASSENGER SEAT BELT SWITCH - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1064
PASSENGER SEAT BELT TENSIONER - 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . .1064
FUSES (IPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066
ACCESSORY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066
xxii
FRONT BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066
FRONT CONTROL MODULE - BLACK 49 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1067
FRONT FOG LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
HEADLAMP WASHER RELAY (BUILT-UP-EXPORT) . . . . . . . . . . . . . . . . . . . . . . . . .1068
NAME BRAND SPEAKER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
PARK LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
POSITIVE TEMPERATURE COEFFICIENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
REAR BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
POWER FOLDING MIRROR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY . . . .1069
POWER LIFTGATE MODULE C1 - BLACK 8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .1069
POWER LIFTGATE MODULE C2 - BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . . . . .1069
POWER LIFTGATE MOTOR - BLACK 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1070
POWER SEAT CIRCUIT BREAKER (30A) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . .1070
POWERTRAIN CONTROL MODULE C1 (2.4L/3.3L/3.8L) - GRAY/BLACK
40-WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1071
POWERTRAIN CONTROL MODULE C2 (2.4L/3.3L/3.8L) - GRAY/GRAY 40 WAY .1072
RADIO C1 - GRAY 7 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1073
RADIO C2 - BLACK 7 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1073
RADIO C3 - WHITE/RED 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1073
RADIO C4 - 8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1074
RADIO CHOKE - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1074
REAR A/C-HEATER UNIT (3 ZONE HVAC) - LT. GREEN 10 WAY . . . . . . . . . . . . . .1074
REAR AUTO TEMP CONTROL SWITCH (ATC) - BLACK 13 WAY . . . . . . . . . . . . . .1075
REAR BLOWER MOTOR POWER MODULE C1 (ATC) - RED/BLACK 4 WAY . . . .1075
REAR BLOWER MOTOR POWER MODULE C2 (ATC) - BLACK 2 WAY. . . . . . . . .1075
REAR DOME LAMP (EXCEPT LUXURY) - GRAY 3 WAY . . . . . . . . . . . . . . . . . . . . .1075
REAR MODE MOTOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1076
REAR TEMPERATURE MOTOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . .1076
RECIRCULATION DOOR ACTUATOR (ATC) - GRAY 2 WAY . . . . . . . . . . . . . . . . . .1076
RECIRCULATION DOOR ACTUATOR (MTC) - GRAY 2 WAY. . . . . . . . . . . . . . . . . .1076
REMOTE KEYLESS ENTRY ANTENNA (JAPAN) - BLACK 2 WAY. . . . . . . . . . . . . .1077
REMOTE KEYLESS ENTRY MODULE - BLACK/RED 6 WAY . . . . . . . . . . . . . . . . .1077
RIGHT B-PILLAR SWITCH - GRAY 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1077
RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY. . . .1077
RIGHT CYLINDER LOCK SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .1078
RIGHT DOOR SPEAKER - BLACK/RED 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1078
RIGHT FOG LAMP - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1078
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) -
BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1078
RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) -
BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1079
RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY . . . . . . .1079
RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY. . . . . . . . . . . .1079
RIGHT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY. . . . . . . . . . . . . .1079
RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . .1080
RIGHT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . .1080
RIGHT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . .1080
RIGHT POWER MIRROR - BLACK 12 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1080
RIGHT REAR PILLAR SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .1081
RIGHT REAR SPEAKER - BLACK/RED 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1081
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .1081
RIGHT SEAT AIRBAG - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1081
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY. . . . .1081
xxiii
RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK
8 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1082
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) -
BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1082
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) -
BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1082
RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4
WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1083
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) -
BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1083
RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY . . . .1083
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . .1083
SIREN (UNITED KINGDOM) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1083
THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY. . . . . . .1084
THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAY. . . . . . . .1084
TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY . . . . . . . . . . . . . .1085
TXV SOLENOID (ATC) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1086
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1087
10.1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1087

10.2 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1088
10.2.1 PREMIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1088
10.2.2 BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1089
10.2.3 CD CHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1090
10.2.4 REMOTE RADIO CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1091
10.3 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1092
10.4 AUTOMATIC TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . .1093
10.4.1 FRONT ATC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1093
10.4.2 REAR ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1094
10.5 COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1095
10.5.1 PCM COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1096
10.5.2 ECM & CABIN HEATER ASSIST COMMUNICATION - DIESEL
ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1096
10.6 DOOR AJAR WITH POWER SLIDING DOORS . . . . . . . . . . . . . . . . . . . . . . . .1097
10.7 DOOR AJAR WITHOUT POWER SLIDING DOORS . . . . . . . . . . . . . . . . . . . .1098
10.8 EXTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1099
10.9 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100
10.10 INSTRUMENT CLUSTER — BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1101
10.11 INSTRUMENT CLUSTER & MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . . .1102
10.12 INTELLIGENT POWER MODULE/BODY CONTROL MODULE POWER AND
GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1103
10.13 INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1104
10.14 MANUAL TEMPERATURE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1105
10.14.1 BASE MANUAL TEMPERATURE CONTROL SYSTEM LHD . . . . .1105
10.14.2 BASE MANUAL TEMPERATURE CONTROL SYSTEM RHD . . . .1106
10.14.3 DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM
LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1107
10.14.4 DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1108
10.14.5 BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1109
10.15 MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1110
10.16 OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1111
xxiv
10.17 POWER FOLDING MIRROR LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1112
10.18 POWER FOLDING MIRROR RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1113
10.19 POWER DOOR LOCKS/RKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1114
10.20 POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1115
10.21 POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1116
10.22 REAR DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE . . . . . . . . . . . . . . .1117
10.23 SLIDING DOOR AND LIFTGATE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . .1118
10.24 VEHICLE THEFT SECURITY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1119
10.24.1 BASE ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1119
10.24.2 THATCHAM ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1120
10.25 WIPERS - FRONT AND REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1121
11.0 CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1122
11.1 KDB LAB SCOPE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1123

11.2 PCI BUS LAB SCOPE PATTERN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1124
xxv
NOTES
xxvi
GENERAL INFORMATION
1.0 INTRODUCTION 1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
The procedures contained in this manual include
all the specifications, instructions and graphics Diagnosis of the body system is done in six basic
needed to diagnose 2001 body system problems. The steps:
diagnostics in this manual are based on the failure
• verification of complaint
condition or symptom being present at the time of
diagnosis. • verification of any related symptoms
Please follow the recommendations below when • symptom analysis
choosing your diagnostic path. • problem isolation
1. First make sure the DRBIIIt is communicating • repair of isolated problem
with the appropriate modules; i.e., if the
• verification of proper operation
DRBIIIt displays a “No Response” or a “Bus 6
Signals Open” condition, you must diagnose that
first. 2.0 IDENTIFICATION OF
2. Read DTC’s (diagnostic trouble codes) with the SYSTEM
DRBIIIt.
3. If no DTC’s are present, identify the customer The vehicle systems that are part of the “body”
complaint. system are:
4. Once the DTC or customer complaint is identi- • Airbag
fied, locate the matching test in the Table of • Audio
Contents and begin to diagnose the symptom. • Cabin Heater
All component location views are in Section 8.0. All
• Chime
connector pinouts are in Section 9.0. All schematics
are in Section 10.0. All Charts and Graphs are in • Communication
Section 11.0. • Door Ajar System
An * placed before the symptom description indi- • Electrically heated system
cated a customer complaint.
• Exterior lighting
When repairs are required, refer to the appropri-
ate service information for the proper removal and • Heating and A/C
repair procedure. • Instrument Cluster
Diagnostic procedures change every year. New • Interior Lighting
diagnostic systems may be added: carryover systems
• Manual Temperature Control
may be enhanced. READ THIS MANUAL BEFORE
TRYING TO DIAGNOSE A VEHICLE DIAGNOS- • Memory Seat
TIC TROUBLE CODE. It is recommended that you • Overhead Console
review the entire manual to become familiar with all • Power Door Lock/RKE
the new and changed diagnostic procedures.
• Power Folding Mirrors
This book reflects many suggested changes from
readers of past issues. After using this book, if you • Power Sliding Doors
have any comments or suggestions, please fill out • Power Liftgate
the form in the back of this book and mail it back to • Power windows
us.
• Vehicle Theft Security System (VTSS)
1.1 SYSTEM COVERAGE • Windshield Wiper and Washer
This diagnostic procedures manual covers all

2001 Chrysler Voyager and Caravan vehicles. This 3.0 SYSTEM DESCRIPTION AND
diagnostic procedures manual also covers both left FUNCTIONAL OPERATION
hand drive (LHD) and right hand drive (RHD)
vehicles. There may be some slight differences in The body system on the 2001 RG consists of a
the location views of components. If the location combination of modules that communicate over the
views shown are on a LHD vehicle, a RHD vehicle PCI bus (Programmable Communication Interface
will be symmetrically opposite. multiplex system). Through the PCI bus, informa-
tion about the operation of vehicle components and
circuits is relayed quickly to the appropriate mod-
ule(s). All modules receive all the information trans-
1
GENERAL INFORMATION
mitted on the bus even though a module may not vides verification of the direction and severity of an
require all information to perform its function. It impact. A pre-programmed decision algorithm in
will only respond to messages “addressed” to it the ORC microprocessor determines when the de-
through binary coding process. This method of data celeration rate is severe enough to require airbag
transmission significantly reduces the complexity system protection. The Occupant Restraint Control-
of the wiring in the vehicle and the size of wiring ler (ORC) also uses the driver and front passenger
harnesses. All of the information about the func- seat belt switch status (buckled or unbuckled) as
tioning of all the systems is organized, controlled, inputs to determine the level of airbag deployment,
and communicated by the PCI bus, which is de- low, medium, or high as well as whether or not the
scribed in the Communication Section of this gen- seat belt tensioners should deploy. The ORC also
eral information. uses the crash severity to determine the level of
driver and front passenger deployment, low me-
3.1 AIRBAG SYSTEM/OCCUPANT dium or high. When the programmed conditions are
RESTRAINT CONTROLLER SYSTEM met, the ORC sends an electrical signal to deploy
the appropriate airbag system components.
The 2001 Minivan Airbag System contain the
following components: Occupant Restraint Control- WARNING: THE AIRBAG SYSTEM IS A
ler (ORC), Airbag Warning Indicator, Clockspring, SENSITIVE, COMPLEX ELECTRO-
Driver and Passenger Airbags, Seat belt Tensioners MECHANICAL UNIT. BEFORE ATTEMPTING
(SBT), Hall-effect Seat Belt Switches (SBS), Left TO DIAGNOSE OR SERVICE ANY AIRBAG
and Right Side Airbag Control Module (SIACM), SYSTEM OR RELATED STEERING WHEEL,
and Seat (mounted side) Airbags. STEERING COLUMN, OR INSTRUMENT
The Occupant Restraint Controller (ORC) is a PANEL COMPONENTS YOU MUST FIRST
new type of Airbag Control Module (ACM) that DISCONNECT AND ISOLATE THE BATTERY
supports staged airbag deployment. Staged deploy- NEGATIVE (GROUND) CABLE. WAIT TWO
ment is the ability to trigger airbag system squib MINUTES FOR THE SYSTEM CAPACITOR TO
inflators all at once or individually as needed to
DISCHARGE BEFORE FURTHER SYSTEM
provide the appropriate restraint for the severity of
the impact. The ORC has four major functions: PCI
SERVICE. THIS IS THE ONLY SURE WAY TO
Bus communications, onboard diagnostics, impact DISABLE THE AIRBAG SYSTEM. FAILURE
sensing, and component deployment. The ORC also TO DO THIS COULD RESULT IS ACCIDENTAL
contains an energy-storage capacitor. This capaci- AIRBAG DEPLOYMENT AND POSSIBLE
tor stores enough electrical energy to deploy the PERSONAL INJURY. NEVER STRIKE OR
front airbag components for two seconds following a KICK THE AIRBAG CONTROL MODULE, AS
battery disconnect or failure during an impact. The IT CAN DAMAGE THE IMPACT SENSOR OR
ORC is secured to the floor panel transmission AFFECT ITS CALIBRATION. IF AN AIRBAG
tunnel below the instrument panel inside the vehi- CONTROL MODULE IS ACCIDENTALLY
cle. The ORC cannot be repaired or adjusted and DROPPED DURING SERVICE, THE MODULE
must be replaced. MUST BE SCRAPPED AND REPLACED WITH
The ORC sends and/or receives PCI Bus mes-
A NEW UNIT.
sages with the Instrument Cluster (MIC), Body
The airbag warning lamp is the only point at
Control Module (BCM), and Powertrain Control
which the customer can observe symptoms of a
Module (PCM). Diagnostic trouble codes will be set
system malfunction. Whenever the ignition key is
if the communication with these modules is lost or
turned to the run or start position, the MIC per-
contains invalid information.
forms a lamp check by turning the airbag warning
The microprocessor in the ORC monitors the
indicator on for 6-8 seconds. After the lamp check, if
impact sensor signal and the airbag system electri-
the indicator turns on, it means that the ORC has
cal circuits to determine the system readiness. The
checked the system and found it to be free of
ORC also monitors bus messages from both SIACM.
discernible malfunctions. If the lamp remains on,
If the ORC detects a monitored system fault or
there could be an active fault in the system or the
SIACM fault, it sends a message to the instrument
MIC lamp circuit may be internally shorted to
cluster via PCI bus to turn on the airbag warning
ground. If the lamp comes on and stays on for a
indicator. The ORC can set both active and stored
period longer than 6-8 seconds then goes off, there
diagnostic trouble codes to aid in the diagnosing
is usually an intermittent problem in the system.
system problems. See ORC/SIACM DIAGNOSTIC
TROUBLE CODES in this section.
The ORC has an internal accelerometer that
senses the rate of vehicle deceleration, which pro-
2
GENERAL INFORMATION
3.1.1 DRIVER AIRBAG WARNING: THE DRIVER AIRBAG MODULE
The airbag protective trim cover is the most CONTAINS ARGON GAS PRESSURIZED TO
visible part of the driver side airbag system. The OVER 17236.89 Kpa (2500 PSI). DO NOT
protective trim cover is fitted to the front of the ATTEMPT TO DISMANTLE AN AIRBAG
airbag module and forms a decorative cover in the MODULE OR TAMPER WITH ITS INFLATOR.
center of the steering wheel. The module is DO NOT PUNCTURE, INCINERATE, OR
mounted directly to the steering wheel. Located BRING INTO CONTACT WITH ELECTRICITY.
under the trim cover are the horn switch, the airbag DO NOT STORE AT TEMPERATURE
cushion, and the airbag cushion supporting compo- EXCEEDING 93°C (200°F). REPLACE AIRBAG
nents. The airbag module includes a housing to SYSTEM COMPONENTS ONLY BUT
which the cushion and hybrid inflator are attached INTERNAL DIFFERENCES MAY RESULT IN
and sealed. The 2001 Minivan is equipped with
INFERIOR OCCUPANT PROTECTION. THE
driver airbag with dual stage inflators that include
a small canister of highly compressed argon gas.
FASTENERS, SCREWS, AND BOLTS
The Occupant Restraint Controller (ORC) uses ve- ORIGINALLY USED FOR THE AIRBAG
hicle crash severity, driver seat belt switch status SYSTEM COMPONENTS HAVE SPECIAL
(buckled or unbuckled) as inputs to determine the COATINGS AND ARE SPECIFICALLY
level of airbag deployment. When supplied with the DESIGNED FOR THE AIRBAG SYSTEM. THEY
proper electrical signal, the hybrid inflator or infla- MUST NEVER BE REPLACED WITH ANY
tors discharge the compressed gas it contains di- SUBSTITUTES. ANY TIME A NEW FASTENER
rectly into the cushion. The airbag module cannot IS NEEDED, REPLACE IT WITH THE
be repaired, and must be replaced if deployed or in CORRECT FASTENERS PROVIDED IN THE
any way damaged. SERVICE PACKAGE OR SPECIFIED IN THE
MOPAR PARTS CATALOG.
CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the
air bag inflator. Do not dispose of 2001 Model Year Driver and Passenger Airbags unless you
are sure of complete deployment. Please refer to the Hazardous Substance Control System for
Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial,
local, and federal regulations. Use the following table to identify the status of the Airbag Squib.
AIRBAG SQUIB STATUS
(1) Using a DRBIIIt read Airbag DTC’s If the following active codes are present:
ACTIVE DTC CONDITIONS SQUIB STATUS

Driver Squib 1 open Check the stored DTC’s AND IF the stored min- Both Driver Squib 1
Driver Squib 2 open utes for both are within 15 minutes of each other. and 2 were used.
Driver Squib 1 open Check the stored DTC’s AND IF the stored min- Driver Squib 1 was
Driver Squib 2 open utes for Driver Squib 2 open is GREATER than used;
the stored minutes for Driver Squib 1 by 15 min- Driver Squib 2 is live.
utes or more.
Driver Squib 1 open Check the stored DTC’s AND IF the stored min- Driver Squib 1 is live;
Driver Squib 2 open utes for Driver Squib 1 open is GREATER than Driver Squib 2 was
the stored minutes for Driver Squib 2 by 15 min- used.
utes or more.
If Driver Squib 1 open AND IF Driver Squib 2 opens is NOT an active Driver Squib 1 was
code. used;
Driver Squib 2 is live.
If Driver Squib 2 open AND IF Driver Squib 1 open is NOT an active Driver Squib 1 is live;
code. Driver Squib 2 was
used.
3
GENERAL INFORMATION
If neither of the following codes is an active code: WARNING: THE PASSENGER AIRBAG
ACTIVE DTC SQUIB STATUS MODULE CONTAINS ARGON GAS
PRESSURIZED TO 17236.89 Kpa (2500 PSI).
Driver squib 1 open Status of Airbag is
DO NOT ATTEMPT TO DISMANTLE AN
Driver Squib 2 open Unknown. AIRBAG MODULE OR TAMPER WITH ITS
INFLATOR. DO NOT PUNCTURE,
3.1.2 CLOCKSPRING INCINERATE, OR BRING INTO CONTACT
The clockspring is mounted on the steering col- WITH ELECTRICITY. DO NOT STORE AT
umn behind the steering wheel. This assembly TEMPERATURE EXCEEDING 93°C (200°F).
consist of a plastic housing which contains a flat, REPLACE AIRBAG SYSTEM COMPONENTS
ribbon-like, electrically conductive tape that winds ONLY WITH PARTS SPECIFIED IN THE
and unwinds with the steering wheel rotation. The MOPAR PARTS CATALOG. SUBSTITUTE
clockspring is used to maintain a continuous elec- PARTS MAY APPEAR INTERCHANGEABLE,
trical circuit between the instrument panel wiring
BUT INTERNAL DIFFERENCES MAY RESULT
and the driver airbag, the horn, and the vehicle
IN INFERIOR OCCUPANT PROTECTION. THE
speed control switches if equipped. The clockspring
must be properly centered when it is reinstalled on FASTENERS, SCREWS, AND BOLTS
the steering column following any service proce- ORIGINALLY USED FOR THE AIRBAG
dure, or it could be damaged. The clockspring can- SYSTEM COMPONENTS HAVE SPECIAL
not be repaired and it must be replaced. COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE AIRBAG SYSTEM. THEY
3.1.3 PASSENGER AIRBAG MUST NEVER BE REPLACED WITH ANY
The airbag door in the instrument panel top cover SUBSTITUTES. ANY TIME A NEW FASTENER
the glove box is the most visible part of the passen- IS NEEDED, REPLACE IT WITH THE
ger side airbag system. The airbag door has a living CORRECT FASTENERS PROVIDED IN THE
hinge at the top, which is secured to the instrument SERVICE PACKAGE OR SPECIFIED IN THE
panel top cover. Located under the airbag door is MOPAR PARTS CATALOG.
the airbag cushion and its supporting components.
The airbag module includes a housing to which the
cushion and hybrid inflators are attached and
sealed. The 2001 Minivan is equipped with front
passenger airbag with dual stage inflators that
include a small canister of highly compressed argon
gas. The ORC uses vehicle crash severity, front
passenger seat belt switch status (buckled or un-
buckled) inputs to determine the level of airbag
deployment. When supplied with the proper electri-
cal signal, the hybrid inflator or inflators discharge
the compressed gas it contains directly into the
cushion. The airbag module cannot be repaired, and
must be replaced if deployed or in any way dam-
aged.
4
GENERAL INFORMATION
CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the
air bag inflator. Do not dispose of 2001 Mopar Year Driver and Passenger Airbags unless you
are sure of complete deployment. Please refer to the Hazardous Substance Control System for
Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial,
local, and federal regulations. Use the following table to identify the status of the Airbag Squib.
AIRBAG SQUIB STATUS

(1) Using a DRBIIIt read Airbag DTC’s If the following active codes are present:
ACTIVE DTC CONDITIONS SQUIB STATUS

Passenger Squib 1 open Check the stored DTC’s AND IF the stored min- Both Passenger Squib 1
Passenger Squib 2 open utes for both are within 15 minutes of each other. and 2 were used.
Passenger Squib 1 open Check the stored DTC’s AND IF the stored min- Passenger Squib 1 was
Passenger Squib 2 open utes for Passenger Squib 2 open is GREATER used; Passenger Squib
than the stored minutes for Passenger Squib 1 by 2 is live.
15 minutes or more.
Passenger Squib 1 open Check the stored DTC’s AND IF the stored min- Passenger Squib 1 is
Passenger Squib 2 open utes for Passenger Squib 1 open is GREATER live; Driver Squib 2
than the stored minutes for Driver Squib 2 by 15 was used.
minutes or more.
If Passenger Squib 1 AND IF Passenger Squib 2 open is NOT an ac- Passenger Squib 1 was
open tive code. used; Passenger Squib
2 is live.
If Passenger Squib 2 AND IF Passenger Squib 1 open is NOT an ac- Passenger Squib 1 is
open tive code. live; Passenger Squib 2
was used.
If neither of the following codes is an active code: or unbuckled, via hardwired inputs to the ORC. The
ACTIVE DTC SQUIB STATUS ORC uses seat belt switch inputs to determine the
appropriate level of airbag deployment. If the seat
Passenger squib 1 open Status of Airbag is belt switches are damaged or defective the seat belt
Passenger squib 2 open Unknown. tensioner must be replaced. The ORC continuously
monitors the seat belt switch circuits for an open or
3.1.4 SEAT BELT TENSIONER (SBT) shorted conditions.
The driver and passenger seat belt (buckle) ten- 3.1.6 SIDE IMPACT AIRBAG CONTROL
sioners are mounted to the inboard side of the front
seats. The seat belt buckle and seat belt switch are MODULE (SIACM)
connected directly to the seat belt tensioner cable. Supplemental driver and front passenger seat
At the onset of an impact event the ORC uses the airbags provide side impact protection for the front
seat belt tensioner to rapidly retract the seat belt seat occupants. Each side airbag has it own side
buckles. With the slack removed, the occupant’s impact airbag control module (SIACM) to provide
forward motion in an impact will be reduced as will independent impact sensing and deployment. SI-
the likelihood of contacting interior components. ACM are located on the left and right B post just
The seat belt tensioner cannot be removed, the above the seat belt retractor. One, same part num-
occupant’s forward motion in an impact will be ber, side impact airbag control module (SIACM) is
reduced as will the likelihood of contacting reused on both side of the vehicle. However, for proper
paired, if damaged or defective it must be replaced. PCI bus operation each SIACM must have a unique
The ORC continuously monitors the resistance of module identification. To provide the unique mod-
the seat belt tensioner circuits an open or shorted ule identification for both, left and right, the
conditions. SIACM software looks for a ground on cavity 5 of
the SIACM connector. If cavity 5 is grounded the
3.1.5 SEAT BELT SWITCHES (SBS) SIACM communicates as a left SIACM otherwise it
The hall-effect driver and front passenger seat communicates as a right SIACM. The SIACM per-
belt switches provide the seat belt status, buckled forms self diagnostics and circuit tests to determine
5
GENERAL INFORMATION
if the system is functioning properly. If the test 3.1.7 SEAT AIRBAGS (SAB)
finds a problem the SIACM will set both active and
The left and right seat airbag modules are located
stored diagnostic trouble codes. If a DTC is active
in the outboard end of the front seat backs. The
the SIACM will request that the airbag warning
airbag module contains a bag, an inflator (a small
lamp be turned on. The results of the system test
canister of highly compressed argon gas) and a
are transmitted on the PCI Bus to the ORC once
mounting bracket. The seat airbag module cannot
each second or on change in lamp state. If the
be repaired and must be replaced if deployed or in
warning lamp status message from the either SI-
any way damaged. When supplied with the proper
ACM contains a lamp on request, the ORC will set
electrical signal the inflator seals the hole in the
an active DTC. At the same time as the DTC is set
airbag cushion so it can discharge the compressed
the ORC sends a PCI Bus message to the mechan-
gas it contains directly into the cushion. Upon
ical instrument cluster (MIC) requesting the airbag
deployment, the seat back trim cover will tear open
warning lamp be turned on. Observe all ORC warn-
and allow the seat airbag to fully deploy between
ing and caution statements when servicing or han-
the seat and the door.
dling the SIACM. SIACM are not repairable and
must be replaced if they are dropped. WARNING: SEAT AIRBAG CONTAINS ARGON
WARNING: THE AIRBAG SYSTEM IS A GAS PRESSURIZED TO OVER 17236.89 Kpa
SENSITIVE, COMPLEX ELECTRO- (2500 PSI). DO NOT ATTEMPT TO
MECHANICAL UNIT. BEFORE ATTEMPTING DISMANTLE AN AIRBAG MODULE OR
TO DIAGNOSE OR SERVICE ANY AIRBAG TAMPER WITH ITS INFLATOR. DO NOT
SYSTEM OR RELATED STEERING WHEEL, PUNCTURE, INCINERATE, OR BRING INTO
STEERING COLUMN, OR INSTRUMENT CONTACT WITH ELECTRICITY. DO NOT
PANEL COMPONENTS YOU MUST FIRST STORE AT TEMPERATURE EXCEEDING 93°C
DISCONNECT AND ISOLATE THE BATTERY (200°F). REPLACE AIRBAG SYSTEM
NEGATIVE (GROUND) CABLE. WAIT TWO COMPONENTS ONLY WITH PARTS
MINUTES FOR THE SYSTEM CAPACITOR TO SPECIFIED IN THE CHRYSLER MOPAR
DISCHARGE BEFORE FURTHER SYSTEM PARTS CATALOG. SUBSTITUTE PARTS MAY
SERVICE. THIS IS THE ONLY SURE WAY TO APPEAR INTERCHANGEABLE, BUT
DISABLE THE AIRBAG SYSTEM. FAILURE INTERNAL DIFFERENCES MAY RESULT IN
TO DO THIS COULD RESULT IN ACCIDENTAL INFERIOR OCCUPANT PROTECTION. THE
AIRBAG DEPLOYMENT AND POSSIBLE FASTENERS, SCREWS, AND BOLTS
PERSONAL INJURY. NEVER STRIKE OR ORIGINALLY USED FOR THE AIRBAG
KICK THE AIRBAG CONTROL MODULE, AS SYSTEM COMPONENTS HAVE SPECIAL
IT CAN DAMAGE THE IMPACT SENSOR OR COATINGS AND ARE SPECIFICALLY
AFFECT ITS CALIBRATION. IF AN AIRBAG DESIGNED FOR THE AIRBAG SYSTEM. THEY
CONTROL MODULE IS ACCIDENTALLY MUST NEVER BE REPLACED WITH ANY
DROPPED DURING SERVICE, THE MODULE SUBSTITUTES. ANY TIME A NEW FASTENER
MUST BE SCRAPPED AND REPLACED WITH IS NEEDED, REPLACE IT WITH THE
A NEW UNIT. CORRECT FASTENERS PROVIDED IN THE
The airbag warning lamp is the only point at SERVICE PACKAGE OR SPECIFIED IN THE
which the customer can observe symptoms of a MOPAR PARTS CATALOG.
system malfunction. Whenever the ignition key is
turned to the run or start position, the MIC per- 3.1.8 ORC/SIACM DIAGNOSTIC TROUBLE
forms a lamp check by turning the airbag warning CODES
indicator on for 6-8 seconds. After the lamp check, if
the indicator turns on, it means that the ORC has Airbag diagnostic trouble codes consist of active
checked the system and found it to be free of and stored codes. If more than one code exists,
discernible malfuctions. If the lamp remains on, diagnostic priority should be given to the active
there could be an active fault in the system or the codes. Each diagnostic trouble code is diagnosed by
MIC lamp circuit may be internally shorted to following a specific testing procedure. The diagnos-
ground. If the lamp comes on and stays on for a tic test procedures contain step-by-step instructions
period longer than 6-8 seconds then goes off, there for determining the cause of the trouble codes. It is
is usually an intermittent problem in the system. not necessary to perform all of the tests in this book
to diagnose an individual code. Always begin by
reading the diagnostic trouble codes using the DRB.
Always begin diagnostic with the Table of Contents
6
GENERAL INFORMATION
section 7.0. This will direct you to the specific test(s) the source of the problem. In this case, the stored
that must be performed. Active diagnostic trouble code can indicate an area to inspect. If no obvious
codes for the airbag system are not permanent and problems are found, erase stored codes, and with
will change the moment the reason for the code is the ignition on wiggle the wire harness and connec-
corrected. In certain test procedures within this tors, rotate the steering wheel from stop to stop.
manual, diagnostic trouble codes are used as a Recheck for codes periodically as you work through
diagnostic tool. the system. This procedure may uncover a malfunc-
tion that is difficult to locate.
3.1.9 ACTIVE CODES
The code becomes active as soon as the malfunc- 3.2 AUDIO SYSTEM
tion is detected or key-on, whichever occurs first. An
The following radios are all on the PCI Bus
active trouble code indicates an on-going malfunc-
system - RBB, RBK, RAZ, RAD, RBT, and RBY. The
tion. This means that the defect is currently there
remaining radio also available, the RAS, is NOT on
every time the airbag control module checks that
the PCI Bus. The PCI Bus inputs into the radio are
circuit or component. It is impossible to erase an
used for VF dimming, remote steering wheel con-
active code. Active codes automatically erase by
trols and cabin EQ preference. PCI Bus outputs
themselves when the reason for the code has been
from the radio are used for the Name Brand
corrected. With the exception of the warning lamp
Speaker (NBS) relay activation, as well as cabin EQ
trouble codes or malfunctions, when a malfunction
preference.
is detected, the airbag lamp remains lit for a mini-
The RBB and RBK radios have the capability of
mum of 12 seconds or as long as the malfunction is
containing multiple vehicle unique equalization
present.
curves (cabin EQ preferences) within the radio.
These curves will reside in the radio’s flash memory.
3.1.10 STORED CODES
The radio is capable of storing up to 20 unique
Airbag codes are automatically stored in the equalization curves. The latent curves can be se-
ORC’s memory as soon as the malfunction is de- lected via the Front Control Module transmitting a
tected. The exception is the Loss of Ignition Run PCI Bus message to the radio in response to a radio
Only code which is an active code only. A stored code request for equalization message. Upon receipt of a
indicates there was an active code present at some valid equalization select message response, the ra-
time. However, the code currently may not be dio will switch to output the corresponding equal-
present as an active code, although another code ization curve.
could be active. When a trouble code occurs, the All the radios, except the RAS, are capable of
airbag warning indicator illuminates for 12 seconds displaying faults and allowing certain actuation
minimum (even if the problem existed for less than tests through the use of the DRBIIIt. When at-
12 seconds). The code is stored, along with the time tempting to perform PCI Bus diagnostics, the first
in minutes it was active, and the number of times step is to identify the radio in use in the vehicle.
the ignition has been cycled since the problem was When trouble shooting output shorts or “output”
last detected. The minimum time shown for any error messages, the following applies:
code will be one minute, even if the code was On radios without an external amplifier, the term
actually present for less than one minute. Thus, the output refers to the path between the radio and the
time shown for a code will be one minute, even if the speaker. This type of circuit can be monitored all
code was actually present for less than one minute. the way through the speaker connections by the
Thus, the time shown for a code that was present radio assembly. When the radio displays a shorted
for two minutes 13 seconds, for example, would be output DTC with this type of system, the speaker,
three minutes. If a malfunction is detected a diag- radio, or wiring could be at fault. The output DTC
nostic trouble code is stored and will remain stored. could refer to the front or rear output or a left or
When and if the malfunction ceases to exist, an right output. The reason for the difference is the
ignition cycle count will be initiated for that code. If pairing of the output sections of the radio. Some are
the ignition cycle count reaches 100 without a paired left and right, others are paired front and
reoccurrence of the same malfunction, the diagnos- rear.
tic trouble code is erased and that ignition cycle On radios with an external amplifier, the term
counter is reset to zero. If the malfunction reoccurs “output” refers to the circuit between the radio
before the count reaches 100, then the ignition cycle connector and the amplifier. The radio is capable of
counter will be reset and diagnostic trouble code monitoring only this portion and can tell nothing
will continue to be a stored code. If a malfunction is about the circuit between the amplifier and the
not active while performing a diagnostic test proce- speakers. Consequently, a shorted output DTC on
dure, the active code diagnostic test will not locate
7
GENERAL INFORMATION
this type of system would only refer to this circuit. currently empty, actuating the Load/Eject button
A faulty speaker could not cause this DTC. will position that chamber to receive and load a new
disc in that chamber.
3.2.1 REMOTE RADIO CONTROLS
These radios can be controlled via remote radio 3.3 BODY CONTROL MODULE
switches (optional). These switches are located on
The body control module (BCM) supplies vehicle
the back side of the steering wheel. They control
occupants with visual and audible information and
mode, preset, seek up, seek down, volume up and
controls various vehicle functions. To provide and
volume down functions.
receive information, the module is interfaced to the
These functions are inputs to the Body Control
vehicle’s serial bus communications network (PCI).
Module and can be read with the DRBIIIt under
This network consists of the powertrain control
“body computer”. The switches are a multiplexed
module (PCM), the engine control module (ECM) -
signal to the BCM. The radio control MUX circuit is
diesel only, the transmission control module (TCM),
a 5 volt line that is pulled to ground through
the mechanical instrument cluster (MIC), the front
different value resistors built into the switches.
control module (FCM), the occupant restraint con-
This causes a voltage drop to be seen by the BCM
troller (ORC), the compass/mini-trip (CMTC), the
and it sends a specific message to the radio on the
electronic vehicle information center (EVIC), the
PCI Bus circuit. The radio then responses to the
controller antilock brake (CAB), the HVAC control
message.
module (ATC & MTC), the power sliding door (Left
This circuit is fairly simple to troubleshoot. The
& Right) modules (PSD), the power liftgate module
circuit must be complete from the switches in the
(PLG), the Audio system, the side impact airbag
steering wheel to the BCM. The ground must be
control (left & right) modules (SIACM), the memory
complete so that the switches can cause the voltage
seat/mirror module (MSMM), the RKE/thatcham
drop for the BCM to see. The circuit passes through
alarm module and the sentry key immobilizer mod-
the clockspring so continuity through this devise
ule (SKIM). The BCM is operational when battery
must be verified.
power is supplied to the module.
The body control module provides the following
3.2.2 CD CHANGER
features:
The new in-dash CD Changer is designed to fit
• Power Door Locks
into the existing cubby bin in the center stack. This
new cartridge-less CD Changer is controlled by • Automatic Door Lock
your radio, and allows you to individually load up to • Door Lock Inhibit
four discs at a time. However, due to its compact • Central Locking (with VTSS Only)
design, the CD Changer can only carry out one
• Battery Protection
operation at a time. For example, you can not load
a new disc while playing another at the same time. • The BCM will automatically turn off all exterior
Each operation happens sequentially. lamps after 3 minutes and all interior lamps after
The radio unit installed with your system pro- 15 minutes after the ignition is turned off, if they
vides control over all features of the CD Changer are not turned off by the driver.
with the exception of the CD load and eject func- • Chime
tions, which are controlled by buttons located on the • Compass/Minitrip Support
front of the CD Changer. The radio also supplies the
• Interior Lighting (Courtesy/Reading Lamps)
power, ground, PCI Bus, left and right speaker
output thru a single DIN cable. All features you • BCM Diagnostic Reporting
would expect, such as Disc Up/Down, Track Up/ • Electronic Liftgate Release (with Power Door
Down, Random and Scan are controlled by the Locks)
radio, which also displays all relevant CD Changer • Exterior Lighting
information on the radio display.
• Power Folding Mirrors
The CD Changer contains a Load/Eject button
and an indicator light for each of the four disc • Remote Radio Controls
positions. The individual light indicates whether a • Headlamp Time Delay (with/without Autohead-
CD is currently loaded in that particular chamber of lamps)
the CD Changer. Pressing the individual Load/Eject • Automatic Headlamps (with electrochromatic
button for a particular chamber will eject a disc mirror)
currently present in that chamber. If the chamber is
• Illuminated Entry
• Fade to Off
8
GENERAL INFORMATION
This feature dims the interior lighting (courtesy • Seat belt
lamps) gradually if the BCM does not receive any • Exterior lights on
new inputs that would cause the interior lamps to
• Key-in Ignition
remain on.
• Key-in Accessory
• PWM Instrument Panel Dimming
• Engine temperature critical
• Door Lock Inhibit
This feature disables the door lock functions if the • Low washer fluid
key is in the ignition and either front door is ajar. • Turn signals on
Pressing the RKE lock/unlock button under these • Dome light on
conditions, result in normal lock/unlock activation.
• Low oil pressure
• Power Sliding Door Switch Inputs
• Any warning lamp announcement
The BCM has 4 switch inputs for the power
sliding door feature: Located in the overhead con- • High-speed warning Gulf Coast Countries (GCC)
sole are the Left and Right side sliding door only
switches to activate either or both sliding doors The output sound intensity of the chime is ap-
under the proper conditions. Also are B-Pillar proximately 72 decibels.
switches located on the Left and Right B-pillar
posts. 3.4.1 CHIME PRIORITY
• Power Liftgate Switch Input The following list indicates the priority of the
The BCM has 1 Liftgate switch input located in chime when more than one chime is active at the
the overhead console same time:
• Power Lockout Switch Input • Seat belt warning
The BCM has 1 Lockout switch that when en- • High-speed warning Gulf Coast Countries (GCC)
abled will disable the B-Pillar sliding door switches only
from activating either sliding door when depressed. • Turn signal on
When replacing a body control module there are 2
• Chime request
modules available, a Base and a Midline. The
Midline controller is used on vehicles that have • Warning lamp announcement
Power Door Locks. If a vehicle is equipped with the The cluster is responsible to set priority on all
Vehicle Theft Security System, the midline control- warning lamp announcement chimes.
ler becomes a premium when the theft feature is
enabled. 3.4.2 CHIME ON CONDITIONS
The following is a list of the chime warnings and
NOTE: DO NOT SWAP THE BODY CONTROL when they will sound.
MODULE BETWEEN VEHICLES OR BODY Driver’s Seat Sounds for approximately 662
CONTROL MODULES OFF THE SHELF. belt Unbuckled: seconds when the igntion is turned
Engineering does not recommend that service, on and driver’s seat belt is not
dealers or the plant swap Body Control Modules buckled, as a reminder to the
(BCM) between vehicles or off the shelf. The BCM driver to buckle the seat belt.
has internal diagnostic capability that assists in Exterior Lights Ignition is in the lock position,
diagnosing the system. When an “Open” or a On: the driver door is ajar, and the
“Short” circuit exists, the diagnostic tool can be headlight switch is left in any
used to read the BCM codes. The codes are very position, other than auto or off.
descriptive in identifying the appropriate feature The chime will sound as a warn-
that has faulted. ing to the driver until one of the
above conditions is removed or
3.4 CHIME WARNING SYSTEM until the battery protection time
of 3 minutes has expired.
The BCM monitors the door/liftgate ajar
switches, multifunction switches, headlight switch, Key-In Ignition: Ignition is in the lock position,
ignition switch, PCI bus, and the diagnostic tool to driver door is ajar and the key is
perform various chime operations. The BCM uses a in the ignition. The chime will
low-side driver to control the chime located in the sound until one of the above con-
cluster. ditions is removed or until the
The chime system provides the Driver with warn- battery protection time of 15 min-
ing chimes for: utes has expired.
9
GENERAL INFORMATION
Turn Signal On: When the BCM detects a turn 3.4.3 WARNING LAMP ANNOUNCEMENT
signal input continuously for
Low Fuel Lamp: The cluster will request a single
1.0mile/0.6km and the vehicle
chime after the indicator is illu-
speed is greater than 15 mph/
minated.
24kph, the chime will sound until
the specific turn signal is can- Volt Lamp: The cluster will request a single
celled. chime after the indicator is illu-
minated.
Dome Lights On: Ignition is in the lock position,
driver door ajar, and the dome Oil Pressure The cluster will request a single
light switch is left in the on Lamp: chime after illuminating the in-
position. The chime will sound dicator above 450rpm vehicle op-
until one of the above conditions eration.
is removed or until the battery Headlight Out The cluster will request a single
protection time of 15 minutes has Lamp: chime after the indicator is illu-
expired. minated.
Low Oil Pres- The chime will sound when the Liftgate Ajar The BCM determines when to
sure: engine is operating and the oil Lamp: chime for liftgate ajar.
pressure drops below 4psi/27.5kPa. Fasten Seat Belt The BCM will request five chimes
Engine The chime will sound when the Lamp: from the MIC when the ignition
Temperature engine is operating and the cool- is turned to the unlock/run/start
Critical: ant temperature exceeds 252°F/ positions if the driver seat belt is
122C or 234°/112C(diesel). The not buckled.
chime is continuous at 257°F/ Check Engine The cluster will request a single
125C and will chime for 4 min- Lamp: chime after the indicator is illu-
utes and stop if the temperature minated.
drops below 255°F/123C. Low Washer The cluster will request a single
Low Washer The chime will sound when the Fluid Lamp: chime after the indicator is illu-
Fluid washer fluid drops below a spe- minated.
cific level. Engine Tempera- The cluster will request a single
Warning Lamp A chime will sound to alert the ture Lamp: chime when the indicator is first
Announcement: driver to scan the instrument illuminated at 252°F/122C.
panel to see which warning lamp
is illuminated. The door/liftgate 3.4.4 OTHER CHIME ON CONDITIONS
ajar warning lamp will appear Bulb Check: The chime will sound three times
without a chime if the vehicle is during bulb check.
running and a door or the liftgate Programming of Adouble cluster chime will sound,
is opened. A chime will sound if an Additional which signals that the program
the door or liftgate is still open Key Fob: mode has been initiated.
and the vehicle speed is greater
Programming for When the programming has been
than 4mph/6kph.
Rolling Door completed, a single tone from the
High-speed The chime will sound, acting as a Locks: chime system, will occur.
warning Gulf warning to the driver that the
Coast Countries vehicle speed has exceed
(GCC) only 75mph62/120kph63.
10
GENERAL INFORMATION
3.5 COMMUNICATION a conventional voltmeter. The preferred method is
to use the DRBIIIt lab scope. The 12v square wave
The Programmable Communication Interface or selection on the 20-volt scale provides a good view of
PCI Bus is a single wire multiplexed network capa- the bus activity. Voltage on the bus should pulse
ble of supporting binary encoded messages shared between zero and about seven and a half volts.
between multiple modules. The PCI bus circuit is Refer to the following figure for some typical dis-
identified as D25 and is white with a violet tracer. plays.
Additional tracer colors may be added to the violet The PCI Bus failure modes are broken down into
in order to distinguish between different module two categories. Complete PCI Bus Communication
connections. The modules are wired in parallel. Failure and individual module no response. Causes
Connections are made in the harness using splices. of complete PCI Bus Communication Failure in-
One splice called the Diagnostic Junction Port, clude a short to ground or battery on the PCI
serves as the “Hub” of the bus. The Diagnostic circuit. Individual module no response can be
Junction Port provides an access point to isolate caused by an open circuit at either the Diagnostic
most of the modules on the bus in order to assist in Junction Port or the module, or an open battery or
diagnosing the circuit. The following modules are ground circuit to the affected module.
used on the RG: Symptoms of a complete PCI Bus Communication
• Body Control Module
Failure would include but are not limited to:
• All gauges on the MIC stay at zero
• Front Control Module
• All telltales on MIC illuminate
• Occupant Restraint Controller
• Left Side Impact Airbag Control Module • MIC backlighting at full intensity
• Right Side Impact Airbag Control Module • Dashed lines in the overhead console ambient
temperature display
• Controller Antilock Brake
• No response received from any module on the PCI
• Powertrain Control Module bus (except the PCM)
• Engine Control Module - Diesel Only • No start (if equipped with Sentry Key Immobi-
• Radio lizer)
• CD Changer Symptoms of Individual module failure could
• Transmission Control Module include any one or more of the above. The difference
would be that at least one or more modules would
• Automatic Temperature Control Module
respond to the DRBIIIt.
• A/C Heater Control Module (MTC) Diagnosis starts with symptom identification. If a
• Sentry Key Immobilizer Module complete PCI Bus Communication Failure is sus-
• RKE/Thatcham Alarm Module pected, begin by identifying which modules the
vehicle is equipped with and then attempt to get a
• Memory Seat/Mirror Module
response from the modules with the DRBIIIt. If any
• Overhead Console modules are responding, the failure is not related to
• Mechanical Instrument Cluster the total bus, but can be caused by one or more
• Left Sliding Door Control Module modules PCI circuit or power supply and ground
circuits. The DRBIIIt may display “BUS +/- SIG-
• Right Sliding Door Control Module
NAL OPEN” or “NO RESPONSE” to indicate a
• Power Liftgate Module communication problem. These same messages will
Each module provides its own bias and termina- be displayed if the vehicle is not equipped with that
tion in order to transmit and receive messages. The particular module. The CCD error message is a
bus voltage is at zero volts when no modules are default message used by the DRBIIIt and in no way
transmitting and is pulled up to about seven and a indicates whether or not the PCI bus is operational.
half volts when modules are transmitting. The message is only an indication that a module is
The bus messages are transmitted at a rate either not responding or the vehicle is not equipped.
averaging 10800 bits per second. Since there is only
voltage present when the modules transmit and the
message length is only about 500 milliseconds, it is
ineffective to try and measure the bus activity with
11
GENERAL INFORMATION
3.7 EXTERIOR LIGHTING SYSTEM
3.7.1 HEADLAMP POWER

The headlamp switch is a direct input to the
BCM. The BCM sends a BUS message to the FCM
informing it of a headlamp switch status change.
The FCM then turns on power to the headlamps
through four “fuseless” circuits. These circuits are
electronically controlled and continuously moni-
tored for malfunctions. Power is supplied to each
filament in a separate circuit. For vehicles equipped
with daytime running Lamps (DRL), the FCM elec-
tronically steps down the headlamp voltage to pro-
vide the desired illumination.
3.7.2 HEADLAMP SWITCH

The Headlamp Switch uses a multiplexed (MUX)
circuit to the Body Control Module (BCM). The
Headlamp Switch controls the Fog lamp relay, Park
lamps and the Low and High headlamps. The BCM
then sends a signal through the PCI Bus line to the
FCM as to what state the switch has selected. The
FCM energizes the high side output drivers to turn
ON the desired lamps.
3.7.3 PARK LAMP RELAY

The park lamp switch is a direct input to the
BCM. The BCM sends a BUS message to the FCM
informing it to turn on the park lamp relay. The
park lamp relay is then powered through low side
control of the FCM. This circuit is electronically
controlled and continuously monitored for malfunc-
tions.
3.7.4 FOG LAMP RELAY

The fog lamp switch is a direct input to the BCM.
The BCM sends a BUS message to the FCM inform-
3.6 DOOR AJAR SYSTEM ing it to turn on the fog lamp relay. The fog lamp
relay is then powered through low side control of
The door ajar and liftgate ajar states are used as the FCM. This circuit is electronically controlled
inputs for the Body Control Module (BCM). The and continuously monitored for malfunctions. Fog
BCM uses these inputs to determine exactly what lamp functionality is not equipped on all vehicles.
position the doors and liftgate are in. The DRBIIIt The FCM “learns” that the vehicle is equipped with
will display the state of the door ajar and the fog lamps by reading the BCM BUS message.
liftgate ajar switches in Inputs/Outputs. It’s impor-
tant to note, that when any door, or the liftgate is 3.7.5 FOG LAMPS
closed, the switch state on the DRBIIIt will show
The BCM controls the operation of the fog lamp
OPEN. When any door, or the liftgate is open the
relay that turns the fog lamps ON and OFF. The
switch state on the DRBIIIt will show CLOSED.
Fog lamps can only be ON when the park and low
During diagnosis, if a door or the liftgate is closed
beams are ON. If the high beams are switched ON
and the DRBIIIt displays the switch state as
then the Fog lamps will be automatically turned
CLOSED, it indicates a shorted ajar circuit. If the
OFF.
door or the liftgate is open and the DRBIIIt dis-
plays the switch state as OPEN, it indicates an
open ajar circuit.
12
GENERAL INFORMATION
3.7.6 EXTERIOR LIGHTING BATTERY Electrical inputs:
• Headlamp battery supplies 1 & 2
SAVER
• Module battery supply
The BCM monitors the status of, and controls, the
Park Lamps, Headlamps and Fog Lamp relays. If • Power ground
any exterior lamps are left ON after the ignition is • Ignition switch RUN or START position status
turned OFF, the BCM will turn them OFF after 3 • Ignition switch START only status
minutes.
• PCI Bus
3.7.7 AUTO HEADLAMPS • Stop lamp switch
This feature is available on vehicles equipped • Horn switch
with both the Electrocromatic Mirror (ECM) and • Back-up switch
the Compass/Mini-Trip Computer (CMTC). When • Wiper park switch
the BCM detects a day/night signal from the CMTC,
• Washer fluid level switch
an ECM is present and Auto Headlamp mode is
• Brake fluid level switch
selected.
• Ambient temperature sensor
3.8 FRONT CONTROL MODULE • Right park lamp outage
• Left park lamp outage
The Front Control Module (FCM) is an electrical
control and interface center located in the engine • Battery IOD
compartment. When it is mated to the Power Dis- • Battery (+) connection detection
tribution Center (PDC), it is referred to as the • Flash reprogramming voltage
Intelligent Power Module (IPM). The IPM, with its
fuses and relays provides power and signal distri- 3.8.1 CONTROLLED POWER FEEDS
bution throughout most of the vehicle. The FCM
Front airbag system
receives both hard wire and digital electronic inputs
The FCM provides power to the Occupant Re-
from the vehicle electrical system through the PDC.
straint Control (ORC) system through two “fuse-
Based on these inputs and the ignition switch
less” circuits (ORC RUN/START, and ORC RUN
position, it provides direct power feeds and relay
only). These circuits are electronically controlled
control to some of the vehicles’ most critical electri-
and continuously monitored for malfunctions.
cal systems.
Power is supplied while the ignition switch is in the
The Front Control Module provides the following
RUN and START positions on pin 48 of the FCM
features:
connector, and in the RUN only position on pin 29.
Controlled power feeds:
Side airbag system
• Front airbag system The FCM provides power to the Side Impact
• Side airbag system Airbag Control Module (SIACM) system through
• Headlamp power one “fuseless” circuit. This circuit is electronically
• EATX module power (4 speed only) controlled and continuously monitored for malfunc-
tions. Power is supplied in the ignition RUN and
• Front washer motor START positions on pin 28 of the FCM connector.
• Rear washer motor Headlamp power
•Brake shift interlock system The headlamp switch is a direct input to the
Relay controls: BCM. The BCM sends a PCI Bus message to the
• Fog lamp relay (when equipped) FCM informing it of a headlamp switch status
change. The FCM then turns on power to the
• Park lamp relay headlamps through four “fuseless” circuits. These
• Front wiper on relay circuits are electronically controlled and continu-
• Front wiper high/low relay ously monitored for malfunctions. Power is supplied
• Accessory relay to each filament in a separate circuit (RH low on pin
6, RH high on pin 4, LH low on pin 3 and LH high
• Horn relay on pin 5). For vehicles equipped with Daytime
• Front & rear blower relay Running Lamps (DRL), the FCM electronically
• Name brand speakers (NBS) relay steps down the headlamp voltage to provide the
• Electronic back light (EBL) run only relay desired illumination.
• Cabin heater relay
13
GENERAL INFORMATION
EATX power side control on pin 13 of the FCM. This circuit is
The electronic automatic 4 speed transmission electronically controlled and continuously moni-
module is powered when the ignition switch is in tored for malfunctions.
the UNLOCK, RUN or START positions. This cir- Front wiper on relay
cuit is electronically controlled and continuously The front wiper switch is a direct input to the
monitored for malfunctions. Power is supplied BCM. The BCM sends a PCI Bus message to the
through pin 27 of the FCM connector. FCM informing it to turn on the front wiper on
Front washer motor relay. The front wiper on relay is then powered
The front washer switch is a direct input to the through low side control on pin 14 of the FCM. This
BCM. The BCM sends a PCI Bus message to the circuit is electronically controlled and continuously
FCM informing it of a request to wash. The front monitored for malfunctions.
washer motor is then powered through low side Front wiper high/low relay
control inside the FCM. This circuit is electronically The front wiper switch is a direct input to the
controlled and continuously monitored for malfunc- BCM. The BCM sends a PCI Bus message to the
tions. In addition, the FCM electronically protects FCM informing it to turn on the front wiper high/
the washer motor from system voltages higher than low relay. The relay switches power between the low
16 volts by automatically switching off the low side speed and high speed windings of the wiper motor.
circuit. The low side circuit is connected to pin 45 in The front wiper high/low relay is powered through
the FCM connector. low side control on pin 34 of the FCM. This circuit is
Rear washer motor electronically controlled and continuously moni-
The rear washer switch is a direct input to the tored for malfunctions.
BCM. The BCM sends a PCI Bus message to the Accessory relay
FCM informing it of a request to wash. The rear The accessory relay works in conjunction with the
washer motor is then powered through low side FCM’s power accessory delay feature to control the
control inside the FCM. This circuit is electronically operation of the radio, power windows, washer
controlled and continuously monitored for malfunc- motors, wiper motors and power outlet. The acces-
tions. In addition, the FCM electronically protects sory relay is turned on through low side control on
the washer motor from system voltages higher than pin 35 of the FCM. This circuit is electronically
16 volts by automatically switching off the low side controlled and continuously monitored for malfunc-
circuit. The low side circuit is connected to pin 46 in tions. Depending on the ignition switch position,
the FCM connector. the accessory relay will remain on or will time-out
Brake shift interlock system and turn off. The accessory relay remains on in the
The brake shift interlock solenoid receives power RUN and ACCY positions of the ignition switch. In
from both high side and low side controls inside the the UNLK and OFF positions, the relay will remain
FCM. The high side control is on the same circuit as energized for 45 seconds then turn off. During this
the EATX module power, and the low side control time-out period, if the driver or passenger doors are
comes through pin 47 of the FCM connector. The opened, the relay will turn off immediately. While
solenoid is controlled by the low side driver when the ignition switch is in the START position, the
the brake pedal is pressed. Both circuits are contin- relay will also drop-out, then resume operation.
uously monitored for malfunctions. Accessory relay operation is most noticeable by
observing the operation of the radio or blower
3.8.2 RELAY CONTROLS functions.
Fog lamp relay Horn relay
The fog lamp switch is a direct input to the BCM. The horn relay operates through a direct wire
The BCM sends a PCI Bus message to the FCM input to the FCM from the horn switch (FCM pin
informing it to turn on the fog lamp relay. The fog 17) , or a PCI Bus message from the BCM. The relay
lamp relay is then powered through low side control responds to the horn switch, remote door lock and
on pin 33 of the FCM. This circuit is electronically VTA alarm functions. The horn relay is powered
controlled and continuously monitored for malfunc- through low side control on pin 10 of the FCM.
tions. Fog lamp functionality is not equipped on all Under normal operating conditions, if the horn is
vehicles. The FCM “learns” that the vehicle is pressed for longer than 30 seconds, the FCM will
equipped with fog lamps by reading the BCM PCI automatically deactivate the horn to prevent dam-
Bus message. age to it. The FCM will re-activate control of the
Park lamp relay relay after a 25 second cool-down period. This
The park lamp switch is a direct input to the circuit is electronically controlled and continuously
BCM. The BCM sends a PCI Bus message to the monitored for malfunctions.
FCM informing it to turn on the park lamp relay.
The park lamp relay is then powered through low
14
GENERAL INFORMATION
Front and rear blower relay 3.8.3 ELECTRICAL INPUTS
The blower control switch is part of the Automatic
Headlamp battery supplies 1 & 2 — 12 volt
Temperature Control (ATC) or A/C-Heater Control
input on pins 1 and 2. Battery supply voltage for
Module, (Manual Temp). When the blower switch is
switching headlamp circuits only.
turned on, the ATC or A/C-Heater Control Module
Module battery supply — 12 volt input on pin 9.
sends a PCI Bus message to the FCM. The front and
Battery supply voltage for all other FCM opera-
rear blower relay is then powered through low side
tions.
control on pin 30 of the FCM. The relay provides the
Power ground — Ground source on pin 8 for all
high side to the blower motor, and the blower speed
FCM operations.
is governed through low side control in the ATC or
Ignition switch RUN or START position status
A/C-Heater Control Module. This circuit is electron-
— 12 volt input on pin 37. Allows the FCM to
ically controlled and continuously monitored for
determine the ignition switch status for related
malfunctions.
FCM operations.
Name Brand Speakers (NBS) relay
Ignition switch START only status — 12 volt
The NBS relay operates through the vehicle bus
input on pin 19. Allows the FCM to discriminate
interface between the radio and the FCM. When the
between RUN/START input and START for related
radio is turned on, the radio sends a PCI Bus
FCM operations.
message to the FCM. The NBS relay is then pow-
PCI Bus — Approximately 7.5 volt input on pin 22.
ered on through low side control on pin 11 of the
Allows the FCM to communicate with other mod-
FCM. The relay supplies power to the amplified
ules on the vehicle bus.
speaker, and ground is supplied through the radio.
Stop lamp Switch status — 12 volt input on pin
This circuit is electronically controlled and contin-
44. Provides for brake shift interlock function.
uously monitored for malfunctions.
Horn Switch — Ground input on pin 17. Primary
Electronic Back Light (EBL) relay
means for engaging the horn.
The rear defrost switch is part of the Automatic
Back-up switch — Ground input on pin 39. Input
Temperature Control or A/C-Heater Control Module
is converted to a PCI Bus status message for use by
(Manual Temp). When the ignition switch is in the
other modules.
RUN position and the rear defrost switch is turned
Wiper park switch — Ground input on pin 16.
on, the ATC or A/C-Heater Control Module sends a
Used to determine park placement of wipers. Also
PCI Bus message to the FCM. The EBL run only
used as feedback to FCM to determine correct
relay is then powered through low side control on
operating mode of wipers.
pin 31 of the FCM. The relay provides the high side
Washer fluid level switch — Ground input to
to the rear window defrost grid, and ground is
pull-up on pin 18. Ground is switched into the
attached to the vehicle body. The FCM will only
circuit when washer bottle fluid level is low.
allow the rear defrost to operate in the RUN posi-
Brake fluid level switch — Ground input to
tion. This circuit is electronically controlled and
pull-up on pin 36. Ground is switched into the
continuously monitored for malfunctions.
circuit when brake fluid level is low.
Cabin Heater Relay
Ambient temperature sensor — Resistive input
When the ignition is in Run, the FCM monitors
to pull-up on pin 25. Corresponding voltage level is
the PCI bus for the Cabin Heater Activation re-
converted to a PCI Bus message for use by other
quest. The A/C – Heater Control Module initiates
modules on the bus.
this request only when all conditions for Cabin
Right park lamp outage — 12 volt input on pin
Heater activation are favorable. The request carries
21. Used to determine if right park lamp circuit is
the status bit that the FCM requires to activate its
operating properly.
Cabin Heater Assist Control output. This output is
Left park lamp outage — 12 volt input on pin 41.
a low side driver (coming from FCM pin 15) which
Used to determine if left park lamp circuit is
supplies a ground signal to the Cabin Heater (pin
operating properly.
5). When the Cabin Heater receives this ground
Battery IOD — 12 volt input on pin 20. The FCM
signal input, it interprets this as an activation
enters a low power consumption mode when the
signal. The FCM low side driver is also capable of
ignition is turned OFF. This low current draw
diagnostic sensing. The driver will sense an open
battery supply keeps the microprocessor function-
circuit when the driver is off, and will sense a short
ing in the low power mode.
to voltage when the driver is on. The FCM will set
Battery (+) connection detection — 12 volt
DTCs for both of these types of faults. For addi-
input on pin 38. The battery connection on the PDC
tional information, refer to Cabin Heater under
incorporates the use of an internal switch to deter-
General Information and Diagnostic Procedures in
mine if the connector is properly mated and the
the manual.
Connector Positive Assurance (CPA) is engaged. If
15
GENERAL INFORMATION
the CPA is not properly engaged, a voltage on pin 38 3.9.1.3 BLOWER MOTOR OPERATION
will be interpreted as an unseated connector and a
The Automatic Temperature Control (ATC) front
fault will set.
and rear blower control provides continuously vari-
Flash programming voltage — 20 volt input on
able control of air flow rate to meet occupant
pin 42. When a DRBIIIt is connected and the
comfort requirements. Pulse width modulation of
proper flash reprogramming sequence is selected,
the blower motor power allows the front and rear
the 20 volt signal will be applied through pin 42.
blower to operate at any speed from off to full speed.
When front or rear blower operation is required, the
3.9 HEATING & A/C ATC sends a PCI Bus message to the Front Control
Module (FCM) requesting blower relay ON. The
FCM provides a ground for the front and rear
3.9.1 AUTOMATIC TEMPERATURE
blower motor relay coils, activating both relays. The
CONTROL (ATC) front and rear blower relays provide 12 volts to
their respective blower motor power modules. Each
3.9.1.1 CABIN HEATER module provides a 12 volt blower motor control
signal to the ATC. The ATC provides a pulse width
For vehicles equipped with a diesel engine, a
modulated (duty-cycle) ground signal to this circuit
Cabin Heater is used in conjunction with the HVAC
based on climate requirements. The higher voltage
system. The Cabin Heater is designed to supply the
on the signal circuit (less duty-cycle ground) the
vehicle’s occupants with heat prior to the engine
lower the blower speed request. The lower voltage
reaching operating temperature. For additional in-
on the signal circuit (more duty-cycle ground) the
formation on this system, refer to Cabin Heater
higher the blower speed request.
under General Information and Diagnostic Proce-
dures in this manual.
3.9.1.4 INFRARED SENSORS
3.9.1.2 SYSTEM OPERATION The ATC system uses infrared (I/R) sensors to
monitor and control oocupant comfort levels. This
The Automatic Temperature Control (ATC) sys-
sensing system replaces interior air temperature
tem provides fully adjustable three zone climate
and solar sensors which required complex control
control; Driver front zone, Passenger Front zone
programs to maintain occupant comfort levels. The
and Rear zone. The following is a list of ATC
front I/R sensor is located in the instrument panel
controls and features:
center bezel outlet. The rear I/R sensor is located in
– a POWER button which allows the operator to the rear overhead mounted ATC switch.
turn the system completely off.
– AUTO HIGH/LOW switch allows the operator 3.9.1.5 REAR ATC SWITCH
to select what rate (fan speed) the system will The rear ATC switch is mounted in the headliner.
provide the selected comfort level. The switch contains a rotary adjustment for fan
– DRIVER, REAR and PASSENGER rocker speed, a rotary adjustment for mode selection, a
switches to select desired temperature for each push button switch for temperature selection and a
zone. digital display of the selected temperature.
– Recirculation button allows cooling air to be
recirculated which maximizes cooling ability. 3.9.1.6 COOLDOWN TESTING
– A/C select button allows the operator to turn The ATC provides a feature referred to as a
the A/C compressor off. Cooldown Test. This test is initiated using the
DRBIIIt and is designed to check the performance
– Defroster button allows the operator to turn on
of the air conditioning system. The ATC will not
the defroster independently during automatic
perform this test if the ambient air temperature is
control.
below 12°C (53°F). During the test, the ATC com-
– Fan control rotary switch for selecting fan pares the ambient air temperature to the evapora-
speed. tor temperature sensor. To pass the cooldown test,
– Mode rotary switch for selecting heating/ the evap temperature sensor must drop -6°C (20°F)
cooling direction. below ambient temperature within 2 minutes of
– REAR SYSTEM rotary switch for activating start of test. At the completion of the cooldown test
the Rear ATC Switch allowing intermediate the DRBIIIt will display one of the following mes-
passenger control over rear climate control. sages indicating test outcome:
– Cooldown Test Passed
– Cooldown Test Failed
16
GENERAL INFORMATION
– Evap Temp Sensor Shorted Module. In addition, this system provides com-
– Evap Temp Sensor Open pletely independent side-to-side control of incoming
air temperature. The full range of temperature that
– A/C Pressure Too Low
the system can produce in any mode is available on
– A/C Pressure Too High either side of the vehicle by positioning the inde-
– Invalid Conditions for Cooldown Test, Evap pendent driver and passenger blend controls to the
Temperature Too Low desired range.
If a message other than Cooldown Test Passed
occurs, refer to the appropriate symptom for diag- 3.9.2.5 AIR DISTRIBUTION
nosis. The HVAC unit has five fully adjustable instru-
ment panel outlets. Side-window demister outlets
3.9.1.7 ACTIVE AND STORED TROUBLE in the instrument panel eliminate door ducts and
CODES door-to-instrument panel seals. A single, central
mounted outlet delivers air for defrosting the wind-
The Automatic Temperature Control (ATC) is
shield. Air exhausters allow air entering at the
capable of storing Active and Stored trouble codes.
front of the vehicle to flow out the back to the rear
Active codes indicate a current fault in the system.
occupants. Mid-cabin comfort control directs only
Stored codes indicate that a problem has occurred
cooling air flow to the intermediate seat occupants
in the system, however is not currently present.
through outlets at the rear of each front door trim
Active codes cannot be erased until the problem
panel. Air is supplied to these outlets from the
causing the code has been repaired. At this time the
instrument panel through ducts in the doors that
Active code is converted to a Stored code, which can
use molded seals at the instrument panel to prevent
be erased using the DRBIIIt.
air leakage. Wide outlets under the front seats with
directional dividers distribute heated air across the
3.9.2 MANUAL TEMPERATURE CONTROL floor to the intermediate seat occupants. Ducts in
the center of the vehicle under the carpet deliver air
3.9.2.1 SYSTEM AVAILABILITY from the HVAC unit to these outlets. Models
Depending on the model, either a Single-Zone Air equipped with Dual-Zone A/C systems also include
Conditioning System or a Dual-Zone Air Condition- a dust and odor air filter installed in the HAVC
ing System is currently available in these vehicles. housing.
3.9.2.2 CABIN HEATER 3.9.2.6 DOOR ACTUATORS

For Vehicles equipped with a diesel engine, a The electric door actuators are a two-wire design.
Cabin Heater is used in conjunction with the HVAC Each door actuator uses a similar connector wired
system. The Cabin Heater is designed to supply the directly to the A/C – Heater Control Module. Single-
vehicle’s occupants with heat prior to the engine Zone systems have one blend door actuator, one
reaching operating temperature. For additional in- mode door actuator, and one recirculation door
formation on this system, refer to Cabin Heater actuator. Dual-Zone systems have two blend door
under General Information and Diagnostic Proce- actuators, one mode door actuator, and one recircu-
dures in this manual. lation door actuator. All of the door actuators are
accessible from the vehicle’s interior.
3.9.2.3 ZONE CONTROL – SINGLE-ZONE
The Single-Zone Air Conditioning System main-
3.9.2.7 DOOR ACTUATOR CONTROL
tains incoming air temperature, airflow, fan speed, The A/C – Heater Control Module knows the
and fresh air intake for the entire vehicle from the number of operating actuator revolutions required
instrument panel mounted A/C – Heater Control for full door travel as well as the number of actuator
Module. The full range of temperature that the commutator pulses per revolution. Using these pa-
system can produce in any mode for the entire rameters, the A/C – Heater Control Module runs
vehicle is available by positioning the blend control the actuator for the number of commutator pulses
to the desired range. that correspond to the desired door position. To
maintain accuracy, the system recalibrates itself
3.9.2.4 ZONE CONTROL – DUAL-ZONE periodically at known zero and full travel condi-
tions.
The Dual-Zone Air Conditioning System main-
tains incoming air temperature, airflow, fan speed,
and fresh air intake for the entire vehicle from the
instrument panel mounted A/C – Heater Control
17
GENERAL INFORMATION
3.9.2.8 HVAC SYSTEM RELAYS or Engine Control Module (ECM – diesel) to provide
A/C compressor clutch activation or deactivation
The Integrated Power Module (IPM) houses and
respectively. The A/C – Heater Control Module will
provides power to the A/C Clutch Relay and Front
only provide this request if EVAP function is found
Blower Motor Relay.
acceptable. The Power Switch must be on to make
the A/C switch active. The switch LED illuminates
3.9.2.9 EVAPORATOR TEMPERATURE when the switch is on. The A/C Switch setting is
SENSOR remembered during power down.
An evaporator temperature sensor, located on the
Blower Switch
A/C expansion valve under the hood, replaces the
The rotary Blower Switch has five positions, Low,
previously used fin sensor.
M1, M2, M3, and High. The Power Switch must be
on to make the Blower Switch active. Toggling the
3.9.2.10 A/C – HEATER CONTROL Power Switch results in the A/C – Heater Control
MODULE, SWITCH OPERATION Module sending a request to the FCM to provide
blower motor activation or deactivation respec-
Power Switch tively.
The Power Switch is a momentary contact switch.
The switch LED illuminates when the switch is on. Blend Switch – Single Zone
The Power Switch setting is remembered during The single rotary Blend Switch has multiple
power down. detents to control the full range of temperature that
the system can produce in any mode. Rotating the
Rear Window Defogger Switch switch results in the A/C – Heater Control Module
The Rear Window Defogger Switch is a momen- signaling the actuator to move the blend door. All
tary contact switch. Toggling the switch results in door positions are determined relative to the num-
the A/C – Heater Control Module sending a change ber of commutator pulses required to provide full
of state message to the FCM to provide rear window travel of the door. On command, the A/C – Heater
defogger activation or deactivation respectively. Control Module runs the actuator for the number of
The switch LED illuminates when the switch is on. pulses corresponding to the desired door position.
Recirculation Switch Blend Switch – Dual Zone

The Recirculation Switch is a momentary contact The dual sliding Blend Switches have multiple
switch. Toggling the switch on results in the A/C – detents to control the full range of temperature that
Heater Control Module signaling the actuator to the system can produce an any mode. The upper
close the fresh-air door. Toggling the switch off slide pot controls the driver-side blend door, while
results in the A/C – Heater Control Module signal- the lower slide pot controls the passenger-side
ing the actuator to open the fresh-air door. The blend door. Sliding the switch results in the A/C –
switch LED illuminates when the switch is on. Heater Control Module signaling the actuator to
When the Power Switch is off, the A/C – Heater move the blend door. All door positions are deter-
Control Module closes the fresh-air door to prevent mined relative to the number of commutator pulses
outside air from entering the passenger compart- required to provide full travel of the door. On
ment. The recirculation mode will cancel whenever command, the A/C – Heater Control Module runs
defrost is requested. Pressing the Recirculation the actuator for the number of pulses corresponding
Switch while in defrost mode will illuminate the to the desired door position.
Recirculation Switch LED, but only while the but-
ton is pressed. Under this circumstance, the recir- Mode Switch
culation request will be denied and the fresh-air The single rotary Mode Switch has 13 detents to
door will remain in the fresh position. All door either direct airflow to the panel outlets, a mix of
positions are determined relative to the number of floor and panel outlets, floor outlets, a mix of floor
commutator pulses required to provide full travel of and defrost outlets, or defrost outlets. Rotating the
the door. On command, the A/C – Heater Control switch results in the A/C – Heater Control Module
Module runs the actuator for the number of pulses signaling the actuator to move the mode door. All
corresponding to the desired door position. door positions are determined relative to the num-
ber of commutator pulses required to provide full
A/C Switch travel of the door. On command, the A/C – Heater
The A/C Switch is a momentary contact switch. Control Module runs the actuator for the number of
Toggling the switch results in the A/C – Heater pulses corresponding to the desired door position.
Control Module sending a change of state message
to the Powertrain Control Module (PCM – gasoline)
18
GENERAL INFORMATION
3.9.2.11 HVAC DIAGNOSTICS WARNING: NEVER ATTEMPT TO REPAIR THE
The A/C – Heater Control Module is fully addres- DCHA HEATER MODULE OR ANY OF ITS
sable with the DRBIIIt. Two of the Control Mod- INTERNAL COMPONENTS. ALWAYS PER-
ule’s diagnostic capabilities that the DRBIIIt will FORM DCHA COMPONENT REPLACEMENT
actuate include the A/C Cooldown Test to test A/C IN ACCORDANCE WITH THE SERVICE
system performance and the HVAC Door Recalibra- INFORMATION. FAILURE TO FOLLOW
tion Test to determine actuator travel span. After THESE INSTRUCTIONS MAY RESULT IN
performing either test, the Control Module will PERSONAL INJURY OR DEATH.
display one or more messages on the DRBIIIt
screen. The message will indicate either that the CAUTION: Do not actuate the DCHA Field
HVAC system passed the test or that there is a fault Mode Test with the engine off. Failure to
currently active in the HVAC system. The DRBIIIt follow these instructions may result in
can also extract active and stored Diagnostic Trou- internal damage to the DCHA Heater Module.
ble Codes (DTCs) from the control module. Active
DTCs are faults that currently exit in the HVAC CAUTION: Always Perform The Cabin Heater
system. Active DTCs cannot be erased until the Pre-Test Prior To Performing Any Other Cabin
condition causing the code is repaired. Stored DTCs Heater Test For The Test Result To Be Valid.
are faults that occurred in the HVAC system since
the control module received the last “clear diagnos- NOTE: Do not disconnect the vehicle’s
tic info” message. battery or the DCHA’s main power-supply
while the DCHA is in operation or in
3.10 CABIN HEATER run-down mode. Failure to follow these
instructions may result in excess emissions
NOTE: The Cabin Heater, also known as the from the DCHA Heater Module.
Diesel Cabin Heater Assist (DCHA), will be
NOTE: Failure to prime the Dosing Pump
referred to as the DCHA throughout most of
after draining the DCHA fuel line will prevent
the General Information and the Diagnostic
DCHA heater activation during the first
Procedures in this manual.
attempt to start the heater. This will also set a
Diagnostic Trouble Code (DTC) in the DCHA
3.10.1 GENERAL SAFETY INFORMATION
Control’s memory. Do not perform the Dosing
WARNING: DO NOT OPERATE THE DCHA IN Pump Priming Procedure if an attempt was
AN ENCLOSED AREA SUCH AS A GARAGE made to start the DCHA without priming the
THAT DOES NOT HAVE EXHAUST Dosing Pump first. This will put excess fuel
VENTILATION FACILITIES. ALWAYS VENT in the DCHA Heater Module and cause smoke
THE DCHA’s EXHAUST WHEN OPERATING to emit from the DCHA exhaust pipe when
THE DCHA. FAILURE TO FOLLOW THESE heater activation occurs.
INSTRUCTIONS MAY RESULT IN PERSONAL NOTE: Waxed fuel can obstruct the fuel line
INJURY OR DEATH. and reduce flow. Check for the appropriate
WARNING: ALLOW THE DCHA ASSEMBLY winter grade fuel and replace as necessary.
TO COOL BEFORE PERFORMING A COM-
3.10.2 COMPONENT DESCRIPTION AND
PONENT INSPECTION/REPAIR/REPLACE-
MENT. FAILURE TO FOLLOW THESE OPERATION
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY. 3.10.2.1 DCHA ASSEMBLY
The DCHA is a supplemental heater designed to
WARNING: ALWAYS DISCONNECT THE
pre-heat the engine’s coolant in order to supply the
VEHICLE’S BATTERY PRIOR TO PER- vehicle’s occupants with heat prior to the engine
FORMING ANY TYPE OF WORK ON THE reaching operating temperature. The DCHA assem-
DCHA. FAILURE TO FOLLOW THESE bly mounts underneath the vehicle on the left side
INSTRUCTIONS MAY RESULT IN PERSONAL floor pan near the front door opening. The DCHA
INJURY OR DEATH. assembly connects to the vehicle’s heater hoses and
has a fuel supply line that connects to the vehicle’s
fuel tank.
19
GENERAL INFORMATION
The DCHA assembly consists of a: means of a ventilation hose routed from the com-
• combustion air fan assembly bustion air collector compartment of the burner.
The heat exchanger transfers the heat generated by
• burner housing
combustion to the coolant circuit. The control unit/
• burner insert heat exchanger and the burner housing are an
• control unit/heat exchanger assembly and must not be disassembled.
• combustion chamber The temperature sensor senses the coolant tem-
perature in the heat exchanger as an electrical
• dosing pump
resistance. This signal is sent to the control unit for
processing.
3.10.2.2 COMBUSTION AIR FAN The overheat protection, controlled by the tem-
The combustion air fan assembly includes the: perature resistor, protects the heater against undue
• combustion air fan operating temperatures. The overheat protection
• combustion air fan inlet
will switch the heater off if the water temperature
exceeds 105°C (221°F).
• fuel supply inlet
The combustion air fan delivers the air required
3.10.2.6 DOSING PUMP
for combustion from the combustion air inlet to the
burner insert. The dosing pump is a combined delivery, dosing,
and shut-off system for the fuel supply of the heater.
3.10.2.3 BURNER HOUSING The dosing pump receives its supply of fuel from the
vehicle’s fuel tank.
The burner housing includes the:
• coolant inlet 3.10.3 OPERATION
• coolant outlet
• exhaust outlet 3.10.3.1 ACTIVATION
The burner housing accommodates the burner When the ignition is in Run, the FCM monitors
insert and is combined with the control unit/heat the PCI bus for the Cabin Heater Activation re-
exchanger as an assembly. quest. The A/C – Heater Control Module initiates
this request only when all conditions for Cabin
3.10.2.4 BURNER INSERT Heater activation are favorable (see below). The
The burner insert includes the: request carries the status bit that the FCM requires
• combustion pipe fuel cross section to activate its Cabin Heater Assist Control Output.
This output is a low side driver (coming from FCM
• glow plug/flame sensor
pin 15) which supplies a ground signal to the Cabin
Inside the burner insert fuel is distributed across
Heater (pin 5). When the Cabin Heater receives this
the combustion pipe fuel cross section. Combustion
ground signal input, it interprets this as an activa-
of the fuel/air mixture takes place within the com-
tion signal. The FCM low side driver is also capable
bustion pipe to heat the exchanger. The glow plug/
of diagnostic sensing. The driver will sense an open
flame sensor located in the burner insert ignites the
circuit when the driver is off, and will sense a short
fuel/air mixture during heater start up. After heater
to voltage when the driver is on. The FCM will set
start up, the glow plug/flame sensor operates in the
DTCs for both of these types of faults.
flame sensor function. The glow plug/flame sensor
The DCHA will activate only when the:
designed as an electrical resistor is located in the
burner insert opposite the flame side. • engine is running.
• coolant temperature is below 66°C (151°F).
3.10.2.5 CONTROL UNIT/HEAT • fuel tank has greater than 1/8 of a tank of fuel.
EXCHANGER • Power switch on the A/C – Heater Control Module
The control unit/heat exchanger includes the: is on.
• control unit • Blend Control on the A/C – Heater Control Mod-
ule is set above 95% reheat.
• temperature sensor
• Front Control Module (FCM) sees the Cabin
• overheat protection
Heater Activation request that is bussed from the
• heat exchanger A/C – Heater Control Module.
• connector terminal When the DCHA starting sequence begins, the
The control unit controls and monitors combus- glow plug and the combustion air fan are activated.
tion operation. The control unit is ventilated by After 30 seconds, the fuel dosing pump begins oper-
20
GENERAL INFORMATION
ating and the combustion air fan operation is sus- combustion air fan speed depend on the heater
pended for 3 seconds. Subsequently, the combustion operating condition at the time of deactivation.
air fan speed is increased in two ramps within 56 Run-down time is approximately 175 seconds when
seconds to nearly full load operation. After a stabi- deactivated in full load operation and approxi-
lization phase of 15 seconds, the combustion air fan mately 100 seconds when deactivated in part load
speed is again increased in a ramp within 50 operation.
seconds to nearly full load. After reaching full load
fuel delivery, the glow plug is deactivated and the 3.10.4 DIAGNOSTICS
combustion air fan operation is increased to full The DCHA is fully addressable with the DRBIIIt.
load. During the subsequent 45 seconds, as well as System tests include a Field Mode Test to activate
in normal operation, the glow plug functions as a the DCHA for diagnostic testing purposes. The
flame sensor to monitor the flame condition. After DCHA Control will store up to three DTCs in its
all these events, the automatically controlled heat- memory. If the Controller detects a new fault in the
ing operation starts. DCHA system, one that is not already stored in its
In case of a no flame or a flame out condition, a memory, it will clear the oldest of the three stored
restart is automatically initiated. If the no flame DTCs, and it will store the new fault’s DTC. If the
condition persists, fuel delivery is stopped and the Controller detects a reoccurrence of a stored fault, it
heater enters an error lockout mode with a run- will overwrite that fault’s DTC with the most recent
down of the combustion air fan. This will set one or occurrence.
more DTCs in the DCHA Control’s memory. If six
continuous attempts to start the heater fail due to 3.11 INSTRUMENT CLUSTER
one or more faults in the DCHA system, the heater
enters a heater lockout mode. This will set DTC The Instrument Cluster receives and sends mes-
B1813 along with any other fault(s) that the DCHA sages to other modules via the PCI bus circuit. The
Control identified. indicator lamps will illuminate briefly for a bulb
check when the ignition is turned from off to run.
3.10.3.2 HEATING All of the gauges receive their information via the
During the automatically controlled heating op- PCI bus from the powertrain control module and
eration, when the coolant temperature reaches body control module.
72°C (162°F), the heater will switch to a part load The gauges and the LEDs are not individually
operation. When the coolant temperature reaches replaceable thereby requiring complete replace-
75°C (167°F) or if the heater runs for longer than 76 ment of the Instrument Cluster if a repair is neces-
minutes the heater will switch to a control idle sary. In the event that the Instrument Cluster loses
period. If the coolant temperature drops to 71°C communication with other modules on the PCI bus,
(160°F) during a control idle period, the heater will the cluster will display “no bus” in the VF display.
perform a regular starting sequence into full load The Trip/Reset button is used to switch the dis-
operation. A drop in coolant temperature to 65°C play from trip to total mileage. Holding the button
(149°F) during part load operation will cause the when the display is in the trip mode will reset the
heater to switch to a full load operation. trip mileage. This button is also used to put the
cluster in self-diagnostic mode. The odometer dis-
3.10.3.3 DEACTIVATION play uses blue-green vacuum fluorescent digital
The DCHA will deactivate if the: characters.
On base vehicles, the Instrument Cluster has
• engine is turned off. three gauges: Speedometer, Fuel and Engine Cool-
• coolant temperature reaches 75°C (167°F). ant Temperature. A red dot moves transversely
• heater runs longer than 76 minutes. through openings in the Instrument Cluster face
• fuel tank has less than 1/8 of a tank of fuel. (P-R-N-D-2-1) to indicate the gear selected.
With all other models, the Instrument Cluster
• Power switch on the A/C – Heater Control Module also includes a Tachometer and uses a vacuum-
is off. fluorescent shift indicator.
• Blend Control on the A/C – Heater Control Mod- The odometer display and door/liftgate ajar indi-
ule is set below 75% reheat. cators turn on when a door is opened to assist both
When the heater is deactivated, the combustion the customer and service technician to view the
stops and a run-down sequence begins. During the odometer without turning the ignition on.
run-down sequence, the combustion air fan contin-
ues operation to cool down the heater. The fan is
automatically switched off after the run-down se-
quence is complete. The run-down time and the
21
GENERAL INFORMATION
On vehicles equipped with AutoStick, the display vehicle, if the lock button is pressed with a door
includes an O/D OFF indicator that is illuminated open, illuminated entry will cancel when the door
when the driver presses the Overdrive Off button closes. If the doors are closed and the ignition
on the transaxle shifter. switch is turned on, the illuminated entry also
cancels. The illuminated entry feature will not
3.11.1 INSTRUMENT CLUSTER SELF TEST operate if the courtesy lamp switch is in the dome
off position.
1. Depress and hold the Odometer Reset button.
2. Turn the ignition switch to the RUN/START 3.12.3 INTERIOR LIGHTING BATTERY
position.
SAVER
3. Release the Odometer reset button.
The Instrument Cluster will illuminate all indi- If any of the interior lamps are left on after the
cators and step the gauges through several calibra- ignition is turned off, the BCM will turn them off
tion points. Also, the odometer will display any after 8 minutes. To return to normal operation, the
stored codes that may have set. courtesy lamps will operate after the dome lamp
switch or door ajar switch changes state. The glove
3.11.2 MESSAGE CENTER box and switched reading lamps require that the
ignition be turned to the on/acc position.
The Message Center is located above the brow of
the Instrument Cluster. It houses the following
3.13 MEMORY SYSTEM
warning indicators: Check Engine/Service Engine
Soon, high beam, left and right turn signals, Secu- The memory system consists of power driver’s
rity Alarm Set, and low oil pressure. On base seat, power mirrors and radio presets. The Memory
models equipped with the three-speed transaxle, Seat/Mirror Module (MSMM) is located under the
these indicators appear in the face of the cluster. driver’s seat. It receives input from the following:
The Security Alarm set indicator is a red circle. driver’s manual 8-way seat switch, driver’s seat
Activation of Instrument Cluster indicators is position sensors, PCI bus circuits, and the power
coordinated with indicators in the message center mirror sensors. The module uses these inputs to
and EVIC to avoid redundancy. A revised safety perform the following functions: position the driv-
standard now requires that the seat belt warning er’s memory seat, both exterior mirrors (during
lamp in the Instrument Cluster remain lit if the recalls), and send/receive the memory system infor-
driver seat belt is not buckled. A headlamp out ISO mation over the PCI bus.
indicator has been added to the Instrument Cluster The Memory Set Switch is wired to the Body
to alert the driver when a headlamp is not function- Control Module (BCM). When a button (either #1 or
ing. #2) is pressed on the set switch causes the to BCM
send a message to the MSMM which in turn sends
3.12 INTERIOR LIGHTING a motion status messages to the BCM. If the BCM
receives no motion from the MSMM it will send a
recall message to the MSMM and radio (once igni-
3.12.1 COURTESY LAMP CONTROL tion is in run or accessory). The MSMM will in turn
The body controller has direct control over all of position the drivers seat, both mirrors along with
the vehicle’s courtesy lamps. The body computer recalling the radio presets. If the drivers seat or
will illuminate the courtesy lamps under any of the either exterior mirror is inoperative from its own
following conditions: respective switches, use the service information
1. Any door ajar and courtesy lamp switch on the and schematic to diagnose the problem. This man-
headlamp switch is not in the dome off position. ual addresses the memory problems only and it is
2. The courtesy lamp switch on the headlamp assumed there is not a basic component failure.
switch is in the dome on position.
3.13.1 POWER SEAT
3. A Remote Keyless Entry unlock message is re-
ceived. The memory power seat provides the driver with
2 position settings for the driver’s seat. Each power
4. Driver door unlocked with key (with VTSS only). seat motor is connected to the MSMM with two
motor drive circuits. Each circuit is switched be-
3.12.2 ILLUMINATED ENTRY tween battery and ground. By being able to bi-
Illuminated entry will be initiated when the cus- directionally drive the circuits, the MSMM controls
tomer enters the vehicle by unlocking the doors the movement of the motors based on input from
with the key fob, or with the key if the vehicle is the power seat switch or from the position sensors
equipped with vehicle theft alarm. Upon exiting the when performing a memory recall. Each motor
22
GENERAL INFORMATION
contains a potentiometer to monitor the seat posi- and trip odometer (ODO). The information needed
tion. To monitor the position of the motor, the for the CMTC functions is received over the PCI bus
MSMM sends out a 5-volt reference on the sensor from other modules.
supply circuit. The sensor is grounded back to the
module on a common ground circuit. Based on the 3.14.2 ELECTRONIC VEHICLE
position of the sensor, the MSMM monitors the
voltage change through the sensor on a separate
INFORMATION CENTER (EVIC)
signal circuit. The Electronic Vehicle Information Center
The MSMM stores the input value of each of the (EVIC) includes all the same functions and is lo-
four seat potentiometers in memory when the sys- cated in the same area as the Compass/Mini-Trip
tem requests a set. The driver can initiate a mem- Computer, but it adds a number of warning mes-
ory recall, using either the door mounted memory sages. Also, the EVIC messages are spelled out on
switch or the RKE transmitter (if the remote linked the screen, for example, DISTANCE TO EMPTY,
to memory feature is enabled via the EVIC). When where the Mini-Trip Computer displays only shows
initiated, the MSMM adjusts the four seat sensors DTE.
(by using the motors) to match the memorized seat If the compass/mini-trip computer or EVIC has
position data. been replaced, it may be necessary to reset the
For safety, the memory seat recall is disabled by calibration.
the MSMM when the vehicle is out of park position
or if the speed is not zero. Any obstruction to seat 3.14.3 SETTING THE COMPASS
movement over a 2-second delay will cause the seat The compass/mini-trip computer and EVIC are
to stop moving in which case a stalled motor would self-calibrated and requires no adjustment. The
be detected by the MSMM and the corresponding word CAL will be displayed to indicate that the
seat output would be deactivated. However, if the compass is in the fast calibrating mode. CAL will
object obstructing the seat is removed, the seat will turn off after the vehicle has gone in three complete
function normally again. circles without stopping, in an area free of magnetic
disturbance.
3.13.2 MEMORY MIRRORS If the module displays the temperature while the
Each outside mirror contains vertical and hori- compass is blank or shows a false reading, the
zontal bi-directional drive positioning motors and vehicle must be demagnetized. See the service man-
position sensors. The MSMM provides a 5-volt ual for the proper procedure.
reference on the signal circuit to each position If the compass still goes blank after the vehicle is
sensor. The sensors share a common ground circuit. demagnetized, the compass/mini-trip/EVIC module
The MSMM monitors the position of the mirror must be replaced.
motors by measuring the voltage on each signal
circuit. When a memory position is set, the MSMM 3.14.4 SETTING THE VARIANCE
monitors and stores the position of the outside Variance is the difference between magnetic
mirrors. The MSMM adjusts the mirrors to the north and geographic north. To determine the vari-
appropriate positions when a memory recall mes- ance for the area you are in, refer to the following
sage is received from the RKE or is requested from zone map provided. The number shown for your
the memory set switch. area is the variance number for your area.
The power mirror switch during non-memory
operation operates both mirrors independently of
the MSMM.
3.14 OVERHEAD CONSOLE
3.14.1 COMPASS/MINI-TRIP COMPUTER

(CMTC)
The compass/mini-trip computer is located in the
overhead console. It displays to the driver the
direction the vehicle is traveling and the current 1. Set the compass/mini-trip computer (CMTC) to
outside temperature, as well as the following trav- compass/temperature mode.
eler navigational information: average fuel econ- 2. Press and hold down the RESET button for 5
omy (AVG ECO), distance to empty (DTE), instan- seconds. NOTE: If the button is held for 10
taneous fuel economy (ECO), elapsed time (ET),
23
GENERAL INFORMATION
seconds instead of 5, the CMTC will set the door locks will operate again once all doors are
variance to 8 and enter the fast calibration closed and the speed is above 15 MPH (24 KMH).
mode.
3. The VAR light will come on and the last variance 3.15.4 REMOTE KEYLESS ENTRY (RKE)
setting will be displayed. The body control module interfaces with the RKE
4. Press the STEP button to set the zone number. module via a one-way serial bus interface. The RKE
module is not on the PCI bus. The RKE module
5. Press the US/M button and resume normal op-
sends a 0-5 volt pulse width signal to the BCM
eration.
depending on which button on the transmitter was
NOTE: Do not attach any magnetic device pressed. The BCM controls the door lock/unlock
such as a magnetic CB antenna to the functions and the arming/disarming of the Vehicle
vehicle. This can cause the compass to give Theft Security System (if equipped) and the activa-
tion of illuminated entry. The BCM will also send
false readings.
the appropriate messages to the Power Sliding
Doors and Power Liftgate modules. The Intelligent
3.15 POWER DOOR LOCK SYSTEM Power Module (IPM) activates the park lamps,
When the BCM receives input for a lock request headlamps, and horn for horn chirp when sent the
from a door lock switch, RKE or cylinder lock switch appropriate message from the BCM as received
(only with VTSS), it will turn the lock driver on for from the RKE transmitter. When a one-button
a specified time of 375 msec. If the request is there press is made for unlock, both driver side doors will
beyond 375 msec, the BCM considers the door lock unlock and the front and rear turn signal will flash.
signal stuck. Once a door lock or unlock signal is When a second press is initiated (within 5 seconds
stuck for longer than 10 seconds, the BCM will set of the first) both passenger doors will unlock and all
a trouble code and the signal input is ignored until four turn signals will flash.
the stuck condition disappears. The door lock The RKE module is capable of retaining up to 4
switches provide a variable amount of resistance individual access codes (4 transmitters). If the
thereby dropping the voltage of the multiplexed PRNDL is in any position except park, the BCM will
(MUX) circuit and the BCM will respond to that ground the interface thereby disabling the RKE.
command. The 2 button transmitter will have 2-CR2016
batteries in series. The 5 button transmitter will
have 1-CR2016 battery. The minimum battery life
3.15.1 SLIDING DOOR MEMORY LOCK
should be approximately 4.7 years based on 20
When the BCM receives an input for a lock transmissions a day at 84°F (25°C). Using the
request and a sliding door is open, the BCM will DRBIIIt and selecting RKE FOB Test can test the
turn on the lock driver as described above, and will transmitter.
turn it on again when all sliding doors are closed. The RKE module can be programmed via the
NOTE: If the BCM receives an unlock input before DRBIIIt or the customer programming method.
a sliding door is closed, this will cancel the memory The BCM will only allow programming mode to be
lock. entered when the ignition is in the on position, the
PRNDL is in park position, and the VTSS (if
3.15.2 DOOR LOCK INHIBIT equipped) is in the disarmed mode.
When the key is in the ignition and in any
position and either front door is open, the door lock 3.16 POWER FOLDING MIRRORS
switches LOCK functions are disabled. The UN-
LOCK functions are still functional. This protects The power folding mirrors are powered to two
against locking the vehicle with the keys still in the positions: folded and unfolded. The driver may
ignition. The RKE key fob will still lock the doors as choose fold or unfold with a switch that is located on
usual. This allows the driver to lock the vehicle with the right side of the steering column. The folding
the engine running for warm up. mirror switch grounds a sense wire that comes from
the Body Control Module when it is placed in the
3.15.3 AUTOMATIC DOOR LOCKS fold position. The mirrors will move to the position
designated by the switch whether the ignition
This feature can be enabled or disabled by using
switch is the On or Off position and both front doors
either the DRBIIIt or the customer programming
are closed. When the Power Folding Mirror switch
method. When enabled all the doors will lock when
is left in the fold position during a vehicle exit the
the vehicle reaches a speed of 18 MPH (29 KMH)
mirrors will automatically unfold then refold after
and all the doors are closed. If a door is opened and
both front doors are closed. This is to prevent mirror
the vehicle slows to below 18 MPH (29 KMH), the
contact with either front door when opened. When
24
GENERAL INFORMATION
opening either front door, the Body Control Module read all inputs, actuate all outputs, read module
will unfold the mirrors in the following manner information, and read diagnostic trouble codes. As a
depending on which front door is opened. If the reminder, some DTC’s can be set during normal
driver door is opened, only the driver side mirror PLG operation.
will unfold. If the passenger door is opened, both
mirrors will unfold. The passenger mirror is pre- 3.17.3 SYSTEM INHIBITORS
vented from unfolding when the driver’s door is
1. Battery voltage too high or too low (above 16V,
opened by the Passenger Folding Mirror Relay,
below 9.5V)
which opens the driver circuit to the passenger side
mirror. 2. Vehicle in gear
3. Vehicle speed > 0 mph/km/h
3.17 POWER LIFTGATE SYSTEM 4. Outside temperature too high, above 143°F
(62°C) or too low, below -12°F (-24°C).
3.17.1 POWER LIFTGATE 5. O/H console lockout will inhibit the B pillar
switches only.
The power liftgate (PLG) system is activated
through the use of the following: remote keyless 6. Liftgate locked will inhibit all interior switches
entry (RKE), overhead console switches, outside from opening (overhead console). A locked lift-
liftgate handle switch or the DRBIIIt. These inputs gate can be power closed.
are hardwired to the body control module (BCM) 7. Pinch Sensor switch stuck shall inhibit the
and can be monitored with a diagnostic tool. The power close feature.
BCM will send the message via PCI bus to the
power liftgate module (PLGM). The liftgate must be 3.18 POWER SLIDING DOOR SYSTEM
in the full open or full closed position to operate.
Once the BCM sends a button activation message to
the PLGM, the module shall read all inputs, out- 3.18.1 POWER SLIDING DOOR
puts and vehicle conditions to determine whether it The Power Sliding Door (PSD) system is acti-
shall open, close or inhibit the PLG operation. Once vated through the use of the following: Remote
the PLGM determines the vehicle conditions are Keyless Entry (RKE), overhead console switches, B
safe for operation, the PLGM will initiate a chime pillar switches or the DRBIIIt. These inputs are
for 2 seconds prior to the liftgate activation and 2 hardwired to the body control module (BCM) and
seconds during the open or close cycle. can be monitored with a diagnostic tool. The BCM
During an opening or closing cycle, the PLGM can will send the message via PCI bus to the power
detect an obstacle present should it meet sufficient sliding door module (PSDM). The sliding door must
resistance by the hall effect sensors (integrated in be in the full open or full closed position to operate.
the gear motor assembly GMA). Once the BCM sends a button activation message to
During an open cycle, multiple liftgate activa- the PSDM, the module shall read all inputs, out-
tions (RKE, overhead console, B pillar) are ignored puts and vehicle conditions to determine whether it
until the liftgate reaches the full open position. shall open, close or inhibit the PSD operation.
However, during a close cycle, a 2nd liftgate activa- During an opening or closing cycle, the PSDM can
tion (RKE, overhead console, B pillar) will reverse detect an obstacle present should it meet sufficient
the liftgate to the full open position. resistance by the hall effect sensors (integrated in
If the engine is cranked during a power open/close the drive motor).
the PLG will pause then resume after engine crank- During an open cycle, multiple door activations
ing. In addition, if the vehicle is placed in gear (RKE, overhead console, B pillar) are ignored until
during an open cycle, the PLG shall reverse direc- the door reaches the full open position. However,
tion and begin closing. If the vehicle is placed in during a close cycle, a 2nd door activation (RKE,
gear during a closing cycle, the PLG shall continue overhead console, B pillar) will reverse the door to
closing until fully closed. If the outside handle is the full open position.
activated during an open cycle, the PLG will become If the engine is cranked during a power open/close
a full manual liftgate. If the outside handle is the PSD will pause then resume after engine crank-
activated during a close cycle, the PLG shall reverse ing. In addition, if the vehicle is placed in gear
direction of travel to the full open position. during an open cycle, the PSD shall reverse direc-
tion and begin closing. If the vehicle is placed in
3.17.2 DIAGNOSTIC FEATURES gear during a closing cycle, the PSD shall continue
The PLG can be flashed on vehicle via PCI bus closing until fully closed.
with a DRBIIIt diagnostic tool. The DRBIIIt can If the inside or outside handle is activated during
an open or close cycle, the PSD will become a full
25
GENERAL INFORMATION
manual sliding door. When the child lock out switch ignition for unauthorized operation. The alarm ac-
is on, the B pillar switches are disabled. tivates by sounding the horn, flashing the head-
There is only one part number for the power lamps and the VTSS indicator lamp. The VTSS does
sliding door module (PSDM). The driver sliding not prevent engine operation, this is done with the
door harness has an additional ground circuit which Sentry Key Immobilizer Module (SKIM). Passive
will identify it as the driver side. This eliminates arming occurs in one of two ways. Upon normal
the need for a left and a right side module. vehicle exit by removing the ignition key, opening
the driver door, locking the doors with the power
3.18.2 DIAGNOSTIC FEATURES lock, and closing the driver door, or by removing the
The PSDM can be flashed on vehicle via PCI bus ignition key, opening the driver door, closing the
with a DRBIIIt diagnostic tool. The DRBIIIt can driver door, and locking the doors with the Remote
read all inputs, actuate all outputs, read module Keyless Entry (RKE) transmitter. The VTSS indi-
information, and read diagnostic trouble codes. As a cator lamp will flash for approximately 15 seconds
reminder, some DTC’s can be set during normal during the arming process. If there is no interrup-
PSD operation. tion during the arming process, upon completion
the VTSS indicator lamp will flash at a slower rate.
3.18.3 SYSTEM INHIBITORS When the BCM receives an input to trigger the
alarm, the BCM will control the outputs of the
1. Battery voltage too high or too low (above 16V, headlamps, horn, and VTSS lamp for approxi-
below 9.5V) mately 18 minutes.
2. Vehicle in gear Arming (Active and Passive)
Active arming occurs when the RKE transmitter
3. Vehicle speed > 0 mph/km/h
is used to lock the vehicle doors, whether the doors
4. Child locks enabled inhibit the B pillar switch are open or closed. The arming process is complete
operation only after all doors are closed.
5. O/H console lockout will inhibit the B pillar Passive arming occurs when the ignition key is
switches removed, the driver door is opened, and the doors
6. Doors locked will inhibit all interior switches are locked with the power door lock switch, and the
from opening (Overhead Console, B Pillar). A door is closed.
locked sliding door can be power closed. Disarming (Active and Passive)
Active disarming occurs when the RKE transmit-
3.19 REAR WINDOW DEFOG/HEATED ter is used to unlock the vehicle doors. This disarm-
ing will also halt the alarm once it has been acti-
MIRROR/FRONT WIPER DE-ICE
vated.
The defroster button located on the HVAC control Passive disarming occurs upon normal vehicle
controls the rear window defogger, heated side view entry (unlocking driver door with the key). This
mirrors and front wiper de-icer grid. In addition the disarming will also halt the alarm once it has been
front wiper de-ice function is turned on when front activated.
defog/defrost mode is selected. Tamper Alert
When the defroster button is pushed, the HVAC The VTSS tamper alert will sound the horn three
control sends a bus message over the PCI bus to the times upon disarming to indicate a tamper condi-
Front Control Module (FCM) which controls the tion has occurred.
Rear Window Defogger relay. The defroster LED Manual Override
will illuminate when the defroster function is on. The system will not arm if the doors are locked
The defroster will function for 10 minutes or can be using the manual lock control or if the locks are
cycled off sooner by pressing the defroster button actuated by an inside occupant after the doors are
again. The front wiper de-icer grid receives its 12 closed.
volts from the accessory relay through fuse 11 and Diagnosis
the HVAC control module supplies the grid ground. For complaints about the Vehicle Theft Alarm
triggering on its own, use the DRBIIIt and read the
3.20 VEHICLE THEFT SECURITY SYSTEM Last VTSS Cause status.
3.20.1 BASE ALARM SYSTEM

The Vehicle Theft Security System (VTSS) is part
of the Body Control Module (BCM). The BCM
monitors the vehicle doors, liftgate, hood, and the
26
GENERAL INFORMATION
NOTE: A POWERTRAIN CONTROL MODULE OFF relay, the HIGH/LOW relay and the front and
FROM A VEHICLE EQUIPPED WITH A rear washer pump motors.
VEHICLE THEFT SECURITY SYSTEM The Wiper system utilizes the BCM to control the
CANNOT BE USED IN A VEHICLE THAT IS on/off and hi/low relays for the low and hi speed
NOT EQUIPPED WITH A VEHICLE THEFT wiper functions, intermittent wiper delay as the
switch position changes, pulse wipe, wipe after
SECURITY SYSTEM IF THE VTSS INDICATOR
wash mode and wiper motor functions. The BCM
LAMP COMES ON AFTER IGNITION ON AND uses the vehicle speed input to double the usual
STAYS ON, THE PCI BUS COMMUNICATION delay time below 10 MPH (6 KPH).
WITH THE POWERTRAIN CONTROL
MODULE HAS POSSIBLY BEEN LOST. 3.21.2 SPEED SENSITIVE INTERMITTENT
3.20.2 THATCHAM ALARM SYSTEM WIPE MODE
The Thatcham Alarm Module monitors the vehi- There are 5 individual delay time settings with a
cle doors, liftgate, hood and the interior of the minimum delay of 1.7 seconds to a maximum of 18.4
vehicle for unauthorized operation. The vehicle seconds. When the vehicle speed is under 10 MPH
doors, liftgate, and hood use ajar switches as inputs (6 KPM), the delay time is doubled, providing a
to the BCM to indicate their current status. The delay range of 3.4 seconds to 36.8 seconds.
interior of the vehicle is secured by the use of
Intrusion Sensors. The Intrusion Sensors are used 3.21.3 PULSE WIPE
as inputs to the RKE/Thatcham Alarm Module to When the wiper is in the off position and the
report any motion in the interior of the vehicle. The driver presses the wash button for more than .062
alarm activates by sounding the siren, flashing the seconds, but less than .5 seconds, 2 wipe cycles in
hazard lamps, and the VTSS Indicator Lamp. low speed mode will be provided.
Arming
Before arming, all doors, liftgate, and the hood 3.21.4 PARK AFTER IGNITION OFF
must be completely closed. The system can then be Because the wiper relays are powered from the
armed by following a normal exit sequence, of battery, the BCM can run the wipers to park after
opening the door and then locking the doors with the ignition is turned off.
the door lock switch and then closing the door. The
system can also be armed by opening the door, 3.21.5 WIPE AFTER WASH
closing the door and then locking the doors with the
RKE transmitter. When the driver presses the wash button for over
Disarming .5 seconds and releases it, the wiper will continue to
To disarm the alarm system, the RKE transmit- run for 2 additional wipe cycles.
ter is used. The RKE transmitter will unlock the
vehicle doors and disarm the alarm system. The 3.21.6 REAR WIPER
RKE transmitter can also be used to halt the alarm The rear wiper/washer system consists of the
once it has been activated. following features: mist wipers, intermittent wipers
and wipe after wash. The rear wiper system is only
3.21 WIPER SYSTEM active when the ignition switch is in the RUN/ACC
position. The vehicle operator selects the rear wiper
function using one of the three buttons on the dash
3.21.1 FRONT WIPER mounted rear wiper switch. The rear wiper switch
The front wiper/washer system consists of the is hardwired to the Body Control Module (BCM).
following features: lo-hi-speed, mist wipers, inter- Upon receiving a wiper switch signal, the BCM
mittent wipers and wipe after wash. The front provides 12 volts to the rear wiper motor. Rear
wiper system is only active when the ignition switch washer occurs when the BCM receives a rear
is in the RUN/ACC position. The vehicle operator washer switch ON input. The BCM sends a PCI Bus
selects the front wiper function using the front message to the FCM requesting rear washer on.
wiper switch (a resistive multiplexed stalk switch) The FCM activates the rear washer by providing a
which is integral to the Multi-Function Switch. The ground for the rear washer motor.
front wiper switch is hardwired to the Body Control
Module (BCM). Upon receiving a wiper switch sig- 3.21.7 SPEED SENSITIVE INTERMITTENT
nal, the BCM sends a PCI Bus message to the Front WIPE MODE
Control Module (FCM). The FCM controls the ON/
The delay setting of the rear wiper system is
based solely on the vehicle speed. The delay time is
27
GENERAL INFORMATION
defined as the amount of time from the start of a 3.22.3 DISPLAY IS NOT VISIBLE
wipe to the beginning of the next wipe. The rear
wiper system delay time is based on the following: Low temperatures will affect the visibility of the
7.75 - (MPH x .05) = Seconds delay display. Adjust the contrast to compensate for this
Examples: condition.
At zero (0) MPH the delay is 7.75 seconds.
At 100 MPH the delay is 2.75 seconds.
3.21.8 WIPE AFTER WASH

When the driver presses the wash button for over
1.5 seconds and releases it, the wiper will continue
to run for 2 additional wipe cycles.
3.22 USING THE DRBIIIT

Refer to the DRBIIIt user guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIIt functions.
3.22.1 DRBIIIT ERROR MESSAGES

Under normal operation, the DRBIIIt will dis-
play one of only two error messages: user-requested
WARM Boot or User-Requested COLD Boot. If the 4.0 DISCLAIMERS, SAFETY,
DRBIIIt should display any other error message, WARNINGS
record the entire display and call the STAR Center.
This is a sample of such an error message display:
ver:2.14 4.1 DISCLAIMERS
date: 26 Jul93
file: key_iff.cc All information, illustrations, and specifications
date: Jul26 1993 contained in this manual are based on the latest
line: 548 information available at the time of publication.
err: 0xi The right is reserved to make changes at any time
User-Requested COLD Boot without notice.
Press MORE to switch between this display 4.2 SAFETY

and the application screen.
Press F4 when done noting information.
4.2.1 TECHNICIAN SAFETY INFORMATION
3.22.2 DRBIIIT DOES NOT POWER UP
(BLANK SCREEN) WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
If the LED’s do not light or no sound is emitted at SLOWER REACTION TIME, AND CAN LEAD
start up, check for loose cable connections or a bad TO SERIOUS INJURY. WHEN THE ENGINE IS
cable. Check the vehicle battery voltage (data link OPERATING, KEEP SERVICE AREAS WELL
connector cavity 16). A minimum of 11 volts is
VENTILATED OR ATTACH THE VEHICLE
required to adequately power the DRBIIIt. Check
EXHAUST SYSTEM TO THE SHOP EXHAUST
for proper grounds at DLC cavities 4 and 5.
If all connections are proper between the REMOVAL SYSTEM.
DRBIIIt and the vehicle or other devices, and the Set the parking brake and block the wheel before
vehicle battery is fully charged, an inoperative testing or repairing the vehicle. It is especially
DRBIIIt may be the result or a faulty cable or important to block the wheels on front-wheel drive
vehicle wiring. vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
rings, watchbands or bracelets that might make an
inadvertent electrical contact.
28
GENERAL INFORMATION
When diagnosing a chassis system problem, it is * Ohms cannot be measured if voltage is present.
important to follow approved procedures where Ohms can be measured only in a non-powered
applicable. These procedures can be found in this circuit.
General Information Section or in the service man- • Voltage between any terminal and ground must
ual procedures. Following these procedures is very not exceed 500v DC or 500v peak AC.
important to safety of individuals performing diag-
• Use caution when measuring voltage above 25v
nostic tests.
DC or 25v AC.
4.2.2 VEHICLE PREPARATION FOR • Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
TESTING circuits exceeding 10A.
Make sure the vehicle being tested has a fully • When testing for the presence of voltage or cur-
charged battery. If it does not, false diagnostic codes rent, make sure the meter is functioning cor-
or error messages may occur. rectly. Take a reading of a known voltage or
current before accepting a zero reading.
4.2.3 SERVICING SUB-ASSEMBLIES • When measuring current, connect the meter in
Some components of the chassis system are in- series with the load.
tended to be serviced as an assembly only. Attempt- • Disconnect the live test lead before disconnecting
ing to remove or repair certain system sub- the common test lead.
components may result in personal injury and/or
• When using the meter function, keep the
improper system operation. Only those components
DRBIIIt away from spark plug or coil wires to
with approved repair and installation procedures in
avoid measuring error from outside interference.
the service manual should be serviced.
4.2.4 DRBIIIT SAFETY INFORMATION 4.3 WARNINGS
WARNING: EXCEEDING THE LIMITS OF THE 4.3.1 VEHICLE DAMAGE WARNINGS

DRBIIIT MULTIMETER IS DANGEROUS. IT
Before disconnecting any control module, make
CAN EXPOSE YOU TO SERIOUS OR
sure the ignition is “off”. Failure to do so could
POSSIBLY FATAL INJURY. CAREFULLY damage the module.
READ AND UNDERSTAND THE CAUTIONS When testing voltage or continuity at any control
AND THE SPECIFICATION LIMITS. module, use the terminal side (not the wire end) of
• Follow the vehicle manufacturer’s service speci- the connector. Do not probe a wire through the
fications at all times. insulation; this will damage it and eventually cause
• Do not use the DRBIIIt if it has been damaged. it to fail because of corrosion. Be careful when
performing electrical tests so as to prevent acciden-
• Do not use the test leads if the insulation is
tal shorting of terminals. Such mistakes can dam-
damaged or if metal is exposed.
age fuses or components. Also, a second code could
• To avoid electrical shock, do not touch the test be set, making diagnosis of the original problem
leads, tips, or the circuit being tested. more difficult.
• Choose the proper range and functions for the
measurement. Do not try voltage or current mea- 4.3.2 ROAD TESTING A COMPLAINT
surement that may exceed the rated capacity.
VEHICLE
• Do not exceed the limits shown in the table below:
Some complaints will require a test drive as part
FUNCTION INPUT LIMIT of the repair verification procedure. The purpose of
Volts 0 - 500 peak volts AC the test drive is to try to duplicate the diagnostic
0 - 500 volts DC code or symptom condition.
Ohms (resistance)* 0 -1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated
Temperature -58 - 1100°F
-50 - 600°C
29
GENERAL INFORMATION
WARNING: BEFORE ROAD TESTING A ECM Engine control module
VEHICLE, BE SURE THAT ALL EVIC electronic vehicle information center
COMPONENTS ARE REASSEMBLED.
FCM front control module
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIIT SCREEN WHILE IN GCC Gulf Coast Countries
MOTION. DO NOT HANG THE DRBIIIT FROM HVAC heater ventilation, air conditioning
THE REAR VIEW MIRROR OR OPERATE IT IPM intelligent power module
YOURSELF. HAVE AN ASSISTANT
LDU lower drive unit
AVAILABLE TO OPERATE THE DRBIIIT.
LHD Left Hand Drive
MIC mechanical instrument cluster
5.0 REQUIRED TOOLS AND MTC manual temperature control
EQUIPMENT MSMM memory seat/mirror module
OBD on board diagnostics
DRBIIIt (diagnostic read-out box)
Jumper wires ODO odometer
Ohmmeter ORC occupant restraint controller
Voltmeter PAB passenger airbag
Sentry Key Tester
Test Light PASS passenger
8310 Airbag System Load Tool PCI Programmable Communication In-
8443 SRS Airbag System Load Tool terface (vehicle communication bus)
Diagnostic Junction Port Tester 8339 PCM powertrain control module
PDC power distribution center
6.0 GLOSSARY OF TERMS PLG power liftgate
PLGM power liftgate module
ABS antilock brake system
PSD power sliding door
ACM airbag control module
PSDM power sliding door module
AECM airbag electronic control module
(ACM) PWM pulse width modulated
ASDM airbag system diagnostic module RHD Right Hand Drive
(ACM) RKE remote keyless entry
ATC automatic temperature control SAB seat airbag
BCM body control module SBT seat belt tensioner
CAB controller antilock brake SIACM side impact airbag control module
CMTC compass/mini-trip computer SKIM sentry key immobilizer module
CPA connector positive assurance SKIS sentry key immobilizer system
DAB driver airbag SQUIB also called initiator (located inside
DCHA diesel cabin heater assist airbag)
(cabin heater) SRS supplemental restraint system
DLC data link connector TCM transmission control module
DTC diagnostic trouble code VFD vacuum fluorescent display
DR driver VTSS vehicle theft security system
EBL electric back lite (rear window de-
fogger)
30
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
31
AIRBAG
Symptom List:
FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE
FCM, ORC RUN ONLY DRIVER OVER CURRENT - ACTIVE
FCM, ORC RUN ONLY DRIVER OVER TEMP - ACTIVE
FCM, ORC RUN ONLY DRIVER OVER VOLT - ACTIVE
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - ACTIVE
ORC, LOSS OF IGNITION RUN ONLY - ACTIVE
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be FCM, ORC RUN ONLY DRIVER
OPEN - ACTIVE.
When Monitored and Set Condition:
FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE

When Monitored: When the ignition is turned OFF, the microprocessor controlled
transistor (high side driver) places a diagnostic voltage on the ORC Run-Start circuit for
60 seconds. An open high side driver (HSD) circuit voltage is between 2.4 and 5.0 volts.
Set Condition: This code will set within 10 second, if the microprocessor senses 2.4 to 5.0
volts on the HSD. Note: the diagnostic voltage will only last for 60 seconds after the
ignition is turned off.
FCM, ORC RUN ONLY DRIVER OVER CURRENT - ACTIVE

When Monitored: The FCM uses a microprocessor controlled transistor (high side driver)
to supply power to the ORC. The microprocessor monitors the high side driver (HSD)
internal temperature when the ignition is in the Run Only position.
Set Condition: The code will set within 1 second, if the microprocessor senses HSD
internal temperature. The high temperature is caused by over current.
FCM, ORC RUN ONLY DRIVER OVER TEMP - ACTIVE

internal temperature when the ignition is in the Run position.
Set Condition: The code will set within 2.5 second, if the microprocessor senses high HSD
FCM, ORC RUN ONLY DRIVER OVER VOLT - ACTIVE

battery voltage when the ignition is in the run position.
Set Condition: The code will set if the microprocessor senses HSD battery voltage is over
30 volts.
32
AIRBAG
FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE — Continued
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - ACTIVE

ORC, LOSS OF IGNITION RUN ONLY - ACTIVE

When Monitored: With the ignition in the run only position the ORC monitors the ORC
Run Only Driver circuit for proper system voltage.
Set Condition: If the voltage on the ORC Run Only Driver circuit drops below 4.5 volts,
the code will set.
POSSIBLE CAUSES
VERIFYING ORC RUN ONLY DRIVER CODES
CHECK BATTERY VOLTAGE
FCM, RUN ONLY DRIVER OVER VOLTAGE
ORC, RUN ONLY OPEN TEST
FCM, RUN ONLY OPEN TEST
IPM, RUN ONLY OPEN TEST
ORC RUN ONLY DRIVER CIRCUIT OPEN
FCM, RUN ONLY SHORT TEST
IPM, RUN ONLY SHORT TEST
ORC RUN ONLY DRIVER CIRCUIT SHORT
33
AIRBAG
TEST ACTION APPLICABILITY

1 Ensure that the battery is fully charged. All
WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED
AT ANY TIME, IT MUST BE REPLACED.
Disconnect the Occupant Restraint Controller Connector.
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TURN IGNITION ON, THEN RECONNECT THE BATTERY.
With the DRBIIIt, read the active FCM DTCs.
Turn the ignition off.
NOTE: The ORC RUN ONLY DRIVER OPEN code may not set until the
ignition key is turned off.
Select the active FCM DTC that was displayed on the DRB.
1. ORC RUN ONLY DRIVER OPEN
Go To 2
2. ORC RUN ONLY DRIVER OVER VOLTAGE

Go To 5
3. ORC RUN ONLY SHORT TO GROUND
Go To 6
4. ORC RUN ONLY DRIVER OVER CURRENT

Go To 6
5. ORC RUN ONLY DRIVER OVER TEMP

Go To 6
6. None of the above.
Replace the Front Control Module.
Perform BODY VERIFICATION TEST - VER 1.
NOTE: When reconnecting airbag system components the Ignition must be
turned off and the Battery must be disconnected.
2 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND All
Disconnect the Occupant Restraint Controller.
TURN THE IGNITION ON, THEN RECONNECT THE BATTERY.
Connect a test light to ground and the ORC Run Only Driver circuit at the Occupant
Restraint Controller connector.
Cycle the ignition switch from ON to OFF.
Does the DRB show an active ORC RUN ONLY DRIVER OPEN code?
Yes → Go To 3
No → Replace the Occupant Restraint Controller in accordance with

Service Instructions. WARNING: make sure the battery is discon-
nected and wait 2 minutes before proceeding.
Perform AIRBAG VERIFICATION TEST - VER 1.

34
AIRBAG

3 Disconnect the Front Control Module. All
Measure the resistance of the ORC Run Only Driver circuit between the Front
Control Module connector and the Occupant Restraint Controller connector.
Is the resistance below 1.0 ohms ?
Yes → Replace the Front Control Module.
No → Go To 4
4 Gain access to the connectors on the bottom of the IPM. All

Disconnect the IPM C7 connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance of the ORC Run Only Driver circuit between the IPM C7
connector and the Occupant Restraint Controller connector.
Yes → Replace the IPM.

No → Repair the open ORC Run Only Driver circuit.
5 Measure the battery voltage. All

Is the voltage above 30.0 volts?
Yes → Refer to Charging Category for the P1594 Charging System Too
High symptom.
No → Replace the Front Control Module.
6 WARNING: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT All
TWO MINUTES BEFORE PROCEEDING.
Disconnect Occupant Restraints Controller.
Control Module connector and ground.
Is the resistance below 500.0 Kohms?
Yes → Go To 7


35
AIRBAG

connector and ground.
Yes → Repair the ORC Run Only Driver circuit shorted to ground.
No → Replace the IPM.

36
AIRBAG
Symptom List:
FCM, ORC RUN ONLY DRIVER OPEN - STORED
FCM, ORC RUN ONLY DRIVER OVER CURRENT - STORED
FCM, ORC RUN ONLY DRIVER OVER TEMP - STORED
FCM, ORC RUN ONLY DRIVER OVER VOLT - STORED
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - STORED
FCM, ORC RUN-START DRIVER OPEN - STORED
FCM, ORC RUN-START DRIVER OVER CURRENT - STORED
FCM, ORC RUN-START DRIVER OVER TEMP - STORED
FCM, ORC RUN-START DRIVER OVER VOLT - STORED
FCM, ORC RUN-START DRIVER SHORT TO GROUND - STORED
FCM, SIACM RUN-START DRIVER OPEN - STORED
FCM, SIACM RUN-START DRIVER OVER CURRENT - STORED
FCM, SIACM RUN-START DRIVER OVER TEMP - STORED
FCM, SIACM RUN-START DRIVER OVER VOLT - STORED
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - STORED
The title for the tests will be FCM, ORC RUN ONLY DRIVER
OPEN - STORED.
FCM, ORC RUN ONLY DRIVER OPEN - STORED

FCM, ORC RUN ONLY DRIVER OVER CURRENT - STORED

Set Condition: The code will set within 1 second, if the microprocessor senses HSD
FCM, ORC RUN ONLY DRIVER OVER TEMP - STORED

internal temperature when the ignition is in the Run position.
37
AIRBAG
FCM, ORC RUN ONLY DRIVER OPEN - STORED — Continued
FCM, ORC RUN ONLY DRIVER OVER VOLT - STORED

battery voltage when the ignition is in the run position.
30 volts.
FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - STORED

Set Condition: The code will set within 1 second, if the microprocessor senses high HSD
internal temperature. The high temperature is caused by a short to ground.
FCM, ORC RUN-START DRIVER OPEN - STORED

transistor (high side driver) places a diagnostic voltage on the ORC Run Only circuit for 60
seconds. An open high side driver (HSD) circuit voltage is between 2.4 and 5.0 volts.
FCM, ORC RUN-START DRIVER OVER CURRENT - STORED

internal temperature when the ignition is in the Run or Start position.
FCM, ORC RUN-START DRIVER OVER TEMP - STORED

FCM, ORC RUN-START DRIVER OVER VOLT - STORED

battery voltage when the ignition is in the Run or Start position.
30 volts.
38
AIRBAG
FCM, ORC RUN-START DRIVER SHORT TO GROUND - STORED

circuit for short to ground when the ignition is in the Run or Start position.
internal temperature. The high temperature is caused by short to ground.
FCM, SIACM RUN-START DRIVER OPEN - STORED

transistor (high side driver) places a diagnostic voltage on the SIACM Run-Start circuit for
FCM, SIACM RUN-START DRIVER OVER CURRENT - STORED

to supply power to the SIACM. The microprocessor monitors the high side driver (HSD)
FCM, SIACM RUN-START DRIVER OVER TEMP - STORED

to supply power to the SIACM. The microprocessor monitors high side driver (HSD)
FCM, SIACM RUN-START DRIVER OVER VOLT - STORED

Set Condition: The code will set if the microprocessor senses the HSD battery voltage is
over 30 volts.
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - STORED

39
AIRBAG
POSSIBLE CAUSES
CHECKING FOR ACTIVE FRONT CONTROL MODULE DTCS
STORED CODE PRESENT

1 Turn ignition on. All
NOTE: Ensure the battery is fully charged.
Active codes must be resolved before diagnosing stored codes.
With the DRBIIIt, record and erase all DTCs from all modules.
With the DRB III monitor active codes as you work through the system.
Wiggle the wiring harness and connectors of the Airbag and FCM modules.
The following additional checks may assist you in identifying a possible intermittent
problem:
- Visually inspect related wire harness connectors. Look for broken, bent, pushed out,
spread, corroded, or contaminated terminals.
- Visually inspect related harnesses. Look for chafed, pierced, pinched or partially
broken wire.
- Refer to Wiring Diagrams and Technical Service Bulletins that may apply.
Did the DTC become active ?
Yes → Select appropriate symptom from Symptom List and continue
with diagnosis.
No → No problem found at this time.
40
AIRBAG
Symptom List:
FCM, ORC RUN-START DRIVER OPEN - ACTIVE
FCM, ORC RUN-START DRIVER OVER CURRENT - ACTIVE
FCM, ORC RUN-START DRIVER OVER TEMP - ACTIVE
FCM, ORC RUN-START DRIVER OVER VOLT - ACTIVE
FCM, ORC RUN-START DRIVER SHORT TO GROUND - ACTIVE
ORC, LOSS OF IGNITION RUN-START - ACTIVE
The title for the tests will be FCM, ORC RUN-START DRIVER
OPEN - ACTIVE.
FCM, ORC RUN-START DRIVER OPEN - ACTIVE

transistor (high side driver) places a diagnostic voltage on the ORC Run Only circuit for 60
seconds. An open high side driver (HSD) circuit voltage is between 2.4 and 5.0 volts.
FCM, ORC RUN-START DRIVER OVER CURRENT - ACTIVE

FCM, ORC RUN-START DRIVER OVER TEMP - ACTIVE

FCM, ORC RUN-START DRIVER OVER VOLT - ACTIVE

30 volts.
41
AIRBAG
FCM, ORC RUN-START DRIVER OPEN - ACTIVE — Continued
FCM, ORC RUN-START DRIVER SHORT TO GROUND - ACTIVE

circuit for short to ground when the ignition is in the Run or Start position.
internal temperature. The high temperature is caused by short to ground.
ORC, LOSS OF IGNITION RUN-START - ACTIVE

When Monitored: With the ignition in the Run-Start position the ORC monitors the ORC
Run-Start Driver circuit for proper system voltage.
Set Condition: If the voltage on the ORC Run-Start Driver circuit drops below 4.5 volts,
the code will set.
POSSIBLE CAUSES
VERIFYING ORC RUN-START DRIVER CODES
FCM, RUN-START DRIVER OVER VOLTAGE
ORC, RUN-START TEST
FCM, RUN ONLY OPEN TEST
IPM, RUN ONLY OPEN TEST
ORC RUN ONLY DRIVER CIRCUIT OPEN
FCM, RUN-START SHORT TEST
IPM, RUN-START SHORT TEST
ORC RUN-START DRIVER CIRCUIT SHORT
42
AIRBAG

NOTE: The ORC RUN-START DRIVER OPEN code may not set until the
Select the active FCM DTC displayed on the DRB.
1. ORC RUN-START DRIVER OPEN
Go To 2
2. ORC RUN-START DRIVER OVER VOLTAGE

Go To 5
3. ORC RUN-START SHORT TO GROUND
Go To 6
4. ORC RUN-START DRIVER OVER CURRENT

Go To 6
5. ORC RUN-START DRIVER OVER TEMP

Go To 6
6. None of the above.
TURN THE IGNITION ON, THEN RECONNECT THE BATTERY.
Connect a test light to ground and the ORC Run-Start Driver circuit at the ORC
connector.
Does the DRB show an active ORC RUN-START DRIVER OPEN code?
Yes → Go To 3
No → Replace the Occupant Restraint Controller in accordance with


43
AIRBAG

Control Module connector and the Occupant Restraint Controller connector.
No → Go To 4

connector and the Occupant Restraint Controller connector.

No → Repair the open ORC Run Only Driver circuit.

High symptom.
6 NOTE: Check connectors - Clean and repair as necessary. All

Disconnect the Front Control Module.
Disconnect the Occupant Restraint Controller
Check connectors - Clean/repair as necessary.
Measure the resistance of the ORC Run-Start Driver circuit between the Front
Yes → Go To 7


44
AIRBAG

Measure the resistance of the ORC Run-Start Driver circuit between the IPM C7
Yes → Repair the ORC Run-Start Driver circuit shorted to ground.


45
AIRBAG
Symptom List:
FCM, SIACM RUN-START DRIVER OPEN - ACTIVE
FCM, SIACM RUN-START DRIVER OVER CURRENT - ACTIVE
FCM, SIACM RUN-START DRIVER OVER TEMP - ACTIVE
FCM, SIACM RUN-START DRIVER OVER VOLT - ACTIVE
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - ACTIVE
The title for the tests will be FCM, SIACM RUN-START
DRIVER OPEN - ACTIVE.
FCM, SIACM RUN-START DRIVER OPEN - ACTIVE

transistor (high side driver) places a diagnostic voltage on the SIACM Run-Start circuit for
FCM, SIACM RUN-START DRIVER OVER CURRENT - ACTIVE

FCM, SIACM RUN-START DRIVER OVER TEMP - ACTIVE

FCM, SIACM RUN-START DRIVER OVER VOLT - ACTIVE

to supply power to the SIACM circuit. The microprocessor monitors the battery voltage
when the ignition is in the run or start position.
Set Condition: The code will set if the microprocessor senses the battery voltage is over
30 volts.
46
AIRBAG
FCM, SIACM RUN-START DRIVER OPEN - ACTIVE — Continued
FCM, SIACM RUN-START DRIVER SHORT TO GROUND - ACTIVE

POSSIBLE CAUSES
FCM, SIACM RUN-START DR OVER VOLTAGE
FCM, SIACM RUN-START OPEN TEST
FCM, SIACM RUN-START OPEN TEST
FCM, SIACM RUN-START SHORT TEST
IPM, SIACM RUN-START OPEN TEST
RSIACM, RUN-START OPEN TEST
RUN-START OPEN TEST
SIACM RUN-START DRIVER CIRCUIT OPEN
IPM, SIACM RUN-START SHORT TEST
LSIACM, SIACM RUN-START SHORT TEST
RIGHT SIACM RUN-START DRIVER CIRCUIT OPEN
SIACM RUN-START DRIVER CIRCUIT SHORT
RIGHT SIACM, SIACM RUN-START SHORT TEST
47
AIRBAG

Turn the ignition on.
NOTE: The SIACM RUN-START DRIVER OPEN code may not set until the
With the DRBIIIt, read the active SIACM FCM Diagnostic Trouble Codes.
Select the active SIACM FCM code displayed on the DRB.
1. SIACM RUN-START DRIVER OPEN

Go To 2
2. SIACM RUN-START DRIVER OVER VOLTAGE
Go To 7
3. SIACM RUN-START SHORT TO GROUND

Go To 8
4. SIACM RUN-START DRIVER OVER CURRENT
Go To 8
5. SIACM RUN-START DRIVER OVER TEMP
Go To 8

WARNING: IF THE SIDE IMPACT AIRBAG CONTROL MODULE IS
DROPPED AT ANY TIME, IT MUST BE REPLACED.
Disconnect the Left Side Impact Airbag Control Module.
NOTE: When the ignition key is turned off, the FCM will supply a diagnostic
voltage to the SIACM Run-Start Driver circuit for approximately 60 sec-
onds.
Measure the voltage of the SIACM Run-Start Driver circuit between the Left Side
Impact Airbag Control Module connector and ground.
Turn the ignition switch ON and observe the diagnostic voltage on the SIACM
Run-Start circuit.
Select the results from the list below?
Is the voltage between 1.0 and 2.2 volts
Is the voltage between 2.4 and 5.0 volts

Go To 3
No Voltage present?
Go To 4

48
AIRBAG

3 Disconnect the Right Side Impact Airbag Control Module. All
Measure the voltage of the SIACM Run-Start Driver circuit at the Right Side Impact
Airbag Control Module connector.
Is there any voltage present?
Yes → Replace the Left and Right Side Impact airbag Control Modules.
No → Replace the Left Side Impact Airbag Control Module and repair
the open SIACM Run-Start Driver circuit between the splice and
the Right Side Impact Airbag control Module connector.

4 Disconnect the Right Side Airbag Control Module. All

Measure the voltage of the SIACM Run-Start Driver circuit between the Right Side
Yes → Replace the Right Side Impact Airbag Control Module and repair
the open SIACM Run-Start Driver circuit between the splice and
the Left Side Impact Airbag Control Module connector.
No → Go To 5


Disconnect the Right Side Impact Airbag Control Module.
Measure the resistance of the SIACM Run-Start Driver circuit between the Front
Control Module connector and the Right SIACM connector.

No → Go To 6
49
AIRBAG

Measure the resistance of both SIACM Run-Start Driver circuits between the IPM
C7 connector and the Right connector.

No → Repair the open SIACM Run-Start Driver circuit.


High symptom.
8 Disconnect the Right Side Impact Airbag Control Module. All

Measure the resistance of the SIACM Run-Start Driver circuit between the Front
Yes → Go To 9



Measure the resistance of the SIACM Run-Start Driver circuit between the IPM C7
Yes → Go To 10


50
AIRBAG

10 The SIACM Run-Start Driver circuit must be SHORTED for the result of this test to All
be valid
Yes → Go To 11
No → Replace the Left Side Impact Airbag Control Module..


Disconnect the Right Side Impact Airbag Control Module.
Yes → Repair the SIACM Run-Start Driver circuit shorted to ground.
No → Replace the Right Side Impact Airbag Control Module.
51
AIRBAG
Symptom List:
LEFT SIACM ACCELEROMETER 1 - ACTIVE
LEFT SIACM ACCELEROMETER 1 - STORED
LEFT SIACM INTERNAL 1 - ACTIVE
LEFT SIACM INTERNAL 1 - STORED
LEFT SIACM OUTPUT DRIVER 1 - ACTIVE
LEFT SIACM OUTPUT DRIVER 1 - STORED
LEFT SIACM, LOSS OF IGNITION RUN-START - ACTIVE
LEFT SIACM, NO PCI TRANSMISSION - ACTIVE
The title for the tests will be LEFT SIACM ACCELEROMETER
1 - ACTIVE.

When Monitored: When the ignition on, the Left SIACM on board diagnostics continu-
ously performs internal circuit tests.
Set Condition: This DTC will set if the Left SIACM identifies an out of range internal
circuit

circuit.

circuit.

circuit.
52
AIRBAG
LEFT SIACM ACCELEROMETER 1 - ACTIVE — Continued
LEFT SIACM INTERNAL 1 - ACTIVE

circuit.
LEFT SIACM INTERNAL 1 - STORED

circuit.
LEFT SIACM OUTPUT DRIVER 1 - ACTIVE

circuit.
LEFT SIACM OUTPUT DRIVER 1 - STORED

circuit.
LEFT SIACM, LOSS OF IGNITION RUN-START - ACTIVE

When Monitored: With the ignition in the run or start position the Left SIACM monitors
the SIACM Run-Start Driver circuit for proper system voltage. This is an active trouble
code only.
Set Condition: If the voltage on the SIACM Run-Start Driver circuit is below 4.0 volts,
the code will set.
LEFT SIACM, NO PCI TRANSMISSION - ACTIVE

When Monitored: With the ignition in the On position and the Left SIACM transmitting
information on the PCI BUS.
Set Condition: The code will set, if the Left SIACM cannot detect the Left SIACM
transmitting information on the PCI BUS for 4 consecutive seconds. NOTE: Any PCI Bus
Failure will cause this code to set.
53
AIRBAG
LEFT SIACM ACCELEROMETER 1 - ACTIVE — Continued
POSSIBLE CAUSES
LEFT SIDE IMPACT AIRBAG CONTROL MODULE, ACTIVE OR STORED CODE

If there are no possible causes remaining, view repair.
Repair
Replace the Left Side Impact Airbag Control Module in accordance
with Service Instructions. WARNING: Make sure the battery is
disconnected and wait 2 minutes before proceeding. Erase DTCs
in all Modules.
NOTE: When reconnecting Airbag system components, the ignition must be

turned off and the battery must be disconnected.
54
AIRBAG
Symptom List:
LEFT SIACM, NO PCI TRANSMISSION - STORED
LEFT SIACM, NO PCM MESSAGE - STORED
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - STORED
ORC, INTERROGATE LEFT SIACM - STORED
ORC, NO LEFT SIACM MESSAGE - STORED
The title for the tests will be LEFT SIACM, NO PCI TRANS-
MISSION - STORED.
LEFT SIACM, NO PCI TRANSMISSION - STORED

When Monitored: With the ignition in the On position and the Left SIACM transmitting
Set Condition: The code will set if, the Left SIACM cannot detect the Left SIACM
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED

When Monitored: When the ignition is ON, the Left SIACM monitors the Left Seat Squib
circuits for high resistance.
Set Condition: The Left SIACM has detected an open circuit or high resistance on the
Left Seat Squib circuits.
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED

When Monitored: When the ignition is on, the Left SIACM monitors the resistance of the
Set Condition: The Left SIACM has detected low resistance in the Left Seat Squib
circuits.
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED

When Monitored: When the ignition is on, the Left SIACM monitors the voltage of the
Set Condition: The Left SIACM has detected high voltage on the Left Seat Squib circuits.
55
AIRBAG
LEFT SIACM, NO PCI TRANSMISSION - STORED — Continued
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - STORED

left Seat Squib circuits for low resistance.
Set Condition: The Left SIACM has detected a short to ground in the left Seat Squib
circuits.
ORC, INTERROGATE LEFT SIACM - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for a Left SIACM
status message containing the airbag warning lamp 9On or OFF9 request. The status
message is sent to the ORC once each second or upon any change in the active DTCs.
Set Condition: The Code will set, if the ORC receives an 9Lamp On9 status message from
the Left SIACM. NOTE: This indicates that there was an active diagnostic trouble code in
the Left SIACM.
ORC, NO LEFT SIACM MESSAGE - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Left SIACM
status message. The Left SIACM transmits the status message to the ORC at 1 - second
intervals.
Set Condition: If the ORC fails to see the Left SIACM status message on the PCI Bus for
10 seconds the code will set.
56
AIRBAG
LEFT SIACM, NO PCI TRANSMISSION - STORED — Continued
POSSIBLE CAUSES
CHECKING FOR ACTIVE LEFT SIACM DTCS
STORED CODE PRESENT

Wiggle the wiring harness and connectors of the Airbag System.
problem:
broken wire.
with diagnosis.
No → No problem found at this time. NOTE: interrogate the ORC and

Right SIACM for DTCs. Erase all codes in all airbag modules
before returning vehicle to customer.
57
AIRBAG
Symptom:
LEFT SIACM, NO PCM MESSAGE - ACTIVE
POSSIBLE CAUSES
PCM, PCI COMMUNICATION FAILURE
LSIACM, NO PCI MESSAGE

1 Turn the ignition on. All
With the DRBIIIt, select BODY, BODY COMPUTER, and PCM MONITOR.
With the DRBIIIt, read the PCM MONITOR.
Does the DRB show PCM ACTIVE ON THE BUS?
Yes → Go To 2
No → Refer to category 9 COMMUNICATION CATEGORY9 and select
the related symptom.
WARNING: IF THE LEFT SIDE IMPACT AIRBAG CONTROL MODULE IS
Repair
with Service Instructions. WARNING: make sure the battery is
disconnected and wait 2 minutes before proceeding.
58
AIRBAG
Symptom:
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE

When Monitored: When the ignition is On, the Left SIACM monitors the Left Seat Squib
circuits for high resistance.
Set Condition: The Left SIACM has detected an open circuit or high resistance on the left
Seat Squib circuits.
POSSIBLE CAUSES
LEFT SEAT AIRBAG MODULE CIRCUIT OPEN
LEFT SEAT SQUIB LINE 1 CIRCUIT OPEN
LEFT SEAT SQUIB LINE 2 CIRCUIT OPEN
LSIACM, LEFT SEAT SQUIB CIRCUIT OPEN

1 NOTE: Ensure that the battery is fully charged. All
WARNING: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT
CAUTION: DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD-
DED SIDE DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL
INTO THE AIR IF ACCIDENTALLY DEPLOYED, AND COULD RESULT IN
SERIOUS OR FATAL INJURY.
Disconnect the Left Seat Airbag inline connector located between the seat back and
seat cushion.
Connect the SRS Load Tool 8443 Passenger cable to the Left Seat Airbag inline
connector.
With the DRBIIIt, read the Left SIACM active DTC’s.
Does the DRB show LEFT SEAT SQUIB CIRCUIT OPEN?
Yes → Go To 2
No → Replace Left Seat Airbag.

59
AIRBAG
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE — Continued

seat cushion.
Do not disconnect the airbag connectors at the base of the seat.
Disconnect the Left Side Impact Airbag Control Module Connector.
Connect the SRS Load Tool 8443 SIACM Adaptor to the Left SIACM connector.
Measure the resistance of the Left Seat Squib Line 1 circuit between the Left SIACM
connector and the Left Seat Airbag connector.
Yes → Go To 3
No → Repair open or high resistance in the Left Seat Squib Line 1

circuit.
seat cushion.
Disconnect the Left Side Impact Airbag Control Module connector.
Connect the SRS Load Tool 8443 SIACM Adaptor to the Left SIACM connector.
connector and the Left Seat Airbag connector.
Is the resistance below 1.0 ohms?
Yes → Go To 4
No → Repair open or high resistance in the Left Seat Squib Line 2

circuit.

60
AIRBAG
LEFT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE — Continued

Repair
with the Service information. WARNING: Make sure the battery
is disconnected and wait 2 minutes before proceeding.
61
AIRBAG
Symptom:
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE

Set Condition: The Left SIACM has detected low resistance in the Left Seat Squib
circuits.
POSSIBLE CAUSES
LEFT SEAT AIRBAG CIRCUIT SHORT
LEFT SEAT SQUIB LINE 1 SHORT TO LINE 2
LSIACM, LEFT SEAT SQUIB CIRCUIT SHORT

seat cushion.
NOTE: Check connectors - Clean repair as necessary.
Connect the SRS Load Tool 8443 SIACM Adaptor to the LSIACM connector.
Turn Ignition On and then reconnect the Battery.
With the DRB, read the active codes.
Does the DRB show LEFT SEAT SQUIB CIRCUIT SHORT?
Yes → Go To 2

62
AIRBAG
LEFT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE — Continued

2 WARNING: Turn Ignition OFF. Disconnect the Battery and wait 2 minutes All
before proceeding.
seat cushion.
Disconnect the Left Side Impact Airbag Control Module connector
Connect the SRS Load Tool 8443 SIACM Adaptor to the Left Seat Airbag connector.
Measure the resistance between the Left Seat Squib Line 1 and line 2 at the Left Side
Impact Airbag Control Module connector.
Is the resistance below 5.0 Ohms?
Yes → Repair Left Seat Squib Line 1 short to the Left Seat Squib Line 2
circuit.
No → Go To 3
Repair
63
AIRBAG
Symptom:
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE

When Monitored: When the ignition is on, the Left SIACM monitors the voltage of the left
Seat Squib circuits.
Set Condition: The Left SIACM has detected high voltage on the Left Seat Squib circuits.
POSSIBLE CAUSES
LEFT SEAT AIRBAG CIRCUIT SHORT TO BATTERY
LEFT SEAT SQUIB LINE 1 SHORT TO BATTERY
LEFT SEAT SQUIB LINE 2 SHORT TO BATTERY
LSIACM, LEFT SEAT SQUIB CIRCUIT SHORT TO BATTERY

WARNING: DO NOT PLACE AN INTACT UNDEPLOYED SEAT BACK PAD-
seat cushion.
Connect the SRS Load Tool 8443 Passenger cable to he Left Seat Airbag inline
connector.
Turn Ignition On, then reconnect the Battery.
With the DRBIIIt, read active Side Airbag DTC’s.
Does the DRBIIIt display LEFT SEAT SQUIB SHORT TO BATTERY?
Yes → Go To 2

64
AIRBAG
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE — Continued

WARNING: DO NOT PLACE AN INTACT UNDEPLOYED SIDE AIRBAG
FACE DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL INTO
THE AIR IF ACCIDENTALLY DEPLOYED, AND COULD RESULT IN SERI-
OUS OR FATAL INJURY.
seat cushion.
Connect the SRS Load Tool 8443 SIACM adaptor to the Left Side Impact Airbag
Control Module connector.
Measure the voltage of the Left Seat Squib Line 2 circuit in the Left Side Impact
Yes → Repair Left Seat Squib Line 2 short to battery.

No → Go To 3

seat cushion.
Measure the voltage of the Left Seat Squib Line 1 circuit in the Left Side Impact
Airbag Control Module connector.
Yes → Repair Left Seat Squib Line 1 short to battery.
No → Go To 4
65
AIRBAG
LEFT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE — Continued

Repair
66
AIRBAG
Symptom:
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE

left Seat Squib circuits for low resistance.
Set Condition: The Left SIACM has detected a short to ground in the left Seat Squib
circuits.
POSSIBLE CAUSES
LEFT SEAT AIRBAG CIRCUIT SHORT TO GROUND
LEFT SEAT SQUIB LINE 1 SHORT TO GROUND
LEFT SEAT SQUIB LINE 2 SHORT TO GROUND
LSIACM, LEFT SEAT SQUIB CIRCUIT SHORT TO GROUND

seat cushion.
Connect the Airbag System Load Tool 8443 Passenger cable and jumper harness to
the Left Seat Airbag inline connector.
Turn ignition on, then reconnect the battery.
With the DRBIIIt, read active Side Airbag DTC’s.
Does the DRBIIIt display 9LEFT SEAT SQUIB SHORTED TO GROUND9?
Yes → Go To 2
No → Replace the Left Seat Airbag.

67
AIRBAG
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE — Continued

seat cushion.
Disconnect the Left Side Impact Airbag Control Module connector
Measure the resistance of the Left Seat Squib Line 2 circuit between the Left Side
Is the resistance below 5.0 Ohms on the Left Seat Squib Line 2 circuit?
Yes → Repair Left Seat Squib Line 2 short to ground.

No → Go To 3
seat cushion.
Is the resistance below 5.0 Ohms on the Left Seat Squib Line 1 circuit?

No → Go To 4

68
AIRBAG
LEFT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE — Continued

Repair
69
AIRBAG
Symptom List:
ORC ACCELEROMETER - ACTIVE
ORC ACCELEROMETER - STORED
ORC INTERNAL 1 - ACTIVE
ORC INTERNAL 1 - STORED
ORC OUTPUT DRIVER 1 - ACTIVE
ORC OUTPUT DRIVER 1 - STORED
ORC STORED ENERGY FIRING - ACTIVE
ORC STORED ENERGY FIRING - STORED
ORC, NO PCI TRANSMISSION - ACTIVE
The title for the tests will be ORC ACCELEROMETER -
ACTIVE.
ORC ACCELEROMETER - ACTIVE

When Monitored: When the ignition is on, the ORC on board diagnostics continuously
performs internal circuit tests.
Set Condition: This DTC will set if the ORC identifies an out of range internal circuit.
ORC ACCELEROMETER - STORED

When Monitored: When the ignition on, the ORC on board diagnostics continuously


70
AIRBAG
ORC ACCELEROMETER - ACTIVE — Continued






ORC STORED ENERGY FIRING - ACTIVE

When Monitored: Continuously with ignition on.
ORC STORED ENERGY FIRING - STORED

When Monitored: Continuously with ignition on.
71
AIRBAG
ORC ACCELEROMETER - ACTIVE — Continued
ORC, NO PCI TRANSMISSION - ACTIVE

When Monitored: With the ignition in the On position and the ORC transmitting
Set Condition: The code will set if the ORC cannot detect the ORC transmitting
information on the PCI BUS for 5 consecutive seconds. NOTE: Any PCI Bus Failure will
cause this code to set.
POSSIBLE CAUSES
ORC, ACTIVE OR STORED CODE

WARNING: IF THE AIRBAG MODULE IS DROPPED AT ANY TIME, IT MUST
BE REPLACED.
Repair
Replace the Occupant Restraint Controller in accordance with
72
AIRBAG
Symptom:
ORC, CALIBRATION MISMATCH - ACTIVE
ORC, CALIBRATION MISMATCH - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for the VIN message
containing the body style. The PCM transmits the complete VIN message every 14 seconds.
Note: The VIN message should match the vehicle VIN plate.
Set Condition: If the Body style stored in ORC does not exactly match the vehicle body
style indicated by the PCM, then the fault shall be set.
POSSIBLE CAUSES
COMPARE VEHICLE IDENTIFICATION NUMBERS
ORC, ORC CALIBRATION MISMATCH

Connect the DRB to the data link connector and select PASSIVE RESTRAINTS,
AIRBAG, SYSTEM TEST.
With the DRBIIIt, read the system test.
Does the DRB show PCM Active on the Bus:?
Yes → Go To 2
No → Refer to category COMMUNICATION CATEGORY and select the
related symptom.
2 With the DRB select ENGINE MISCELLANEOUS, select MISC FUNCTION, and All
then CHECK VIN to read the Vehicle Identification Number in the Powertrain
Control Module.
Compare the VIN displayed on the DRB screen and the Vehicle VIN plate.
Does the VIN plate and the PCM VIN match?
Yes → Go To 3
No → Replace the Powertrain Control Module and program with the
correct vehicle identification number.
73
AIRBAG
ORC, CALIBRATION MISMATCH - ACTIVE — Continued

Repair
74
AIRBAG
Symptom List:
ORC, CALIBRATION MISMATCH - STORED
ORC, CLUSTER MESSAGE MISMATCH - STORED
ORC, DRIVER SBS OPEN - STORED
ORC, DRIVER SBS SHORT TO BATTERY - STORED
ORC, DRIVER SBS SHORT TO GROUND - STORED
ORC, DRIVER SBT CIRCUIT OPEN - STORED
ORC, DRIVER SBT CIRCUIT SHORT - STORED
ORC, DRIVER SBT SHORT TO BATTERY - STORED
ORC, DRIVER SBT SHORT TO GROUND - STORED
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - STORED
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - STORED
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - STORED
ORC, DRIVER SQUIB 1 SHORT TO GROUND - STORED
ORC, LOSS OF IGNITION RUN ONLY - STORED
ORC, LOSS OF IGNITION RUN-START - STORED
ORC, NO CLUSTER MESSAGE - STORED
ORC, NO ODOMETER MESSAGE - STORED
ORC, PASSENGER SBS OPEN - STORED
ORC, PASSENGER SBS SHORT TO BATTERY - STORED
ORC, PASSENGER SBS SHORT TO GROUND - STORED
ORC, PASSENGER SBT CIRCUIT OPEN - STORED
ORC, PASSENGER SBT CIRCUIT SHORT - STORED
ORC, PASSENGER SBT SHORT TO BATTERY - STORED
ORC, PASSENGER SBT SHORT TO GROUND - STORED
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - STORED
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - STORED
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - STORED
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - STORED
ORC, VEHICLE BODY STYLE UNKNOWN - STORED
ORC, WARNING INDICATOR CIRCUIT OPEN - STORED
ORC, WARNING INDICATOR CIRCUIT SHORT - STORED
The title for the tests will be ORC, CALIBRATION MISMATCH
- STORED.
75
AIRBAG
ORC, CALIBRATION MISMATCH - STORED — Continued
ORC, CALIBRATION MISMATCH - STORED

containing the body style. The PCM transmits the 17- character VIN message every 14
seconds. Note: The VIN message should match the vehicle VIN plate.
Set Condition: If the Body style stored in ORC does not exactly match the vehicle body
style indicated by the PCM, then the fault shall be set.
ORC, CLUSTER MESSAGE MISMATCH - STORED

When Monitored: After the MIC bulb test is completed, the ORC compares the Lamp
Request by ORC (On or Off) and the Lamp on by MIC (On or Off) PCI Bus messages. Each
message is transmitted one time per second or when a change in the lamp state occur.
Set Condition: If the Lamp Request by ORC (On or Off) and the Lamp on by MIC (On or
Off) messages do not match, the code will set.
ORC, DRIVER SBS OPEN - STORED

When Monitored: The ORC monitors the Seat Belt Switch circuit for an open condition.
Set Condition: The code will set if the ORC does not detect the correct circuit voltage.
ORC, DRIVER SBS SHORT TO BATTERY - STORED

When Monitored: The ORC monitors the Seat Belt Switch circuit for an short to battery.
Set Condition: The code will set if the ORC detects high circuit voltage.
ORC, DRIVER SBS SHORT TO GROUND - STORED

When Monitored: The ORC monitors the Seat Belt Switch circuit for a shorted together
or shorted to ground condition.
Set Condition: The code will set if the ORC detects low circuit voltage.
ORC, DRIVER SBT CIRCUIT OPEN - STORED

When Monitored: When the ignition is On, the ORC monitors the resistance of the Driver
Seat Belt Tensioner circuits.
Set Condition: The ORC has detected an open circuit or high resistance on the Driver
ORC, DRIVER SBT CIRCUIT SHORT - STORED

When Monitored: When the ignition is on, the ORC monitors the resistance of the Driver
Set Condition: The ORC has detected low resistance in the Driver Seat Belt Tensioner
circuits.
76
AIRBAG
ORC, DRIVER SBT SHORT TO BATTERY - STORED

When Monitored: When the ignition is on, the ORC monitors the voltage of the Driver
Set Condition: When the ignition is on, the ORC monitors the voltage of the Driver Seat
Belt Tensioner circuits.
ORC, DRIVER SBT SHORT TO GROUND - STORED

Seat Belt Tensioner circuits for low resistance.
Set Condition: The ORC has detected a short to ground in the Driver Seat Belt Tensioner
circuits.

Squib 1 circuits.
Set Condition: The ORC has detected an open circuit or high resistance in the Driver
Squib 1 circuits.

Squib 1 circuits.
Set Condition: The ORC has detected low resistance on the Driver Squib 1 circuits.

Squib 1 circuits.
Set Condition: The ORC has detected high voltage on the Driver Squib 1 circuits.

Squib 1 circuits.
Set Condition: The ORC has detected a short to ground in the Driver Squib 1 circuits.

Squib 2 circuits.
Squib 2 circuits.

Squib 2 circuits.
77
AIRBAG

Squib 2 circuits.

Squib 2 circuits.
ORC, LOSS OF IGNITION RUN ONLY - STORED

When Monitored: With the ignition in the run position the ORC monitors the ORC Run
Only Driver circuit for proper system voltage.
Set Condition: If the voltage on the ORC Run Only Driver circuit drops below 4.5 volts,
the code will set.
ORC, LOSS OF IGNITION RUN-START - STORED

When Monitored: With the ignition in the run or start position the ORC monitors the
ORC Run-Start Driver circuit for proper system voltage.
Set Condition: If the voltage on the ORC Run-Start Driver circuit drops below 4.5 volts,
the code will set.
ORC, NO CLUSTER MESSAGE - STORED

When Monitored: With the ignition in the ON position, the ORC monitors the PCI Bus for
a message from the MIC containing the airbag warning lamp status. The MIC transmits
the message one time at ignition on, lamp state change, or in response to the ORC lamp
message.
Set Condition: If the MIC message is not received for 10 consecutive seconds, the code
will set.
ORC, NO ODOMETER MESSAGE - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Odometer
message from the Body Control Module. The BCM transmits the odometer message at 1
second intervals.
Set Condition: The code will set, if the ORC does not see the odometer message for 10
seconds.
ORC, PASSENGER SBS OPEN - STORED

78
AIRBAG
ORC, PASSENGER SBS SHORT TO BATTERY - STORED

ORC, PASSENGER SBS SHORT TO GROUND - STORED

ORC, PASSENGER SBT CIRCUIT OPEN - STORED

When Monitored: When the ignition is on, the ORC monitors the resistance of the
Passenger Seat Belt Tensioner circuits.
Set Condition: The ORC has detected an open circuit or high resistance or open circuit in
the Passenger Seat Belt Tensioner circuits.
ORC, PASSENGER SBT CIRCUIT SHORT - STORED

Set Condition: The ORC has detected low resistance in the Passenger Seat Belt Tensioner
circuits.
ORC, PASSENGER SBT SHORT TO BATTERY - STORED

When Monitored: When the ignition is on, the ORC monitors the voltage of the Passenger
Set Condition: The ORC has detected high voltage on the Passenger Seat Belt Tensioner
circuits.
ORC, PASSENGER SBT SHORT TO GROUND - STORED

Passenger Seat Belt Tensioner circuits for low resistance.
Set Condition: The ORC has detected a short to ground in the Passenger Seat Belt
Tensioner circuits.

When Monitored: With the ignition is On, the ORC monitors the resistance of the
Passenger Squib 1 circuits.
Squib 1 circuits.

Set Condition: The ORC has detected low resistance in the Passenger Squib 1 circuits.
79
AIRBAG

Squib 1 circuits.
Set Condition: The ORC has detected high voltage on the Passenger Squib 1 circuits.

Passenger Squib 1 circuits for low resistance.
Set Condition: The ORC has detected a short to ground in the Passenger Squib 1 circuits.

When Monitored: With the ignition is On, the ORC monitors the resistance of the
Set Condition: The ORC has detected an open circuit or high resistance on the Passenger
Squib 2 circuits.


Squib 2 circuits.

ORC, VEHICLE BODY STYLE UNKNOWN - STORED

containing the vehicle body style from the Powertrain Control Module. The PCM transmits
the VIN message every 14 seconds.
Set Condition: With ignition on, If the ORC does not receive the 2 consecutive matching
(vehicle Body Style) VIN messages on the bus the code will set.
80
AIRBAG
ORC, WARNING INDICATOR CIRCUIT OPEN - STORED

When Monitored: When the ignition is On, the ORC monitors the PCI Bus for a message
from the MIC containing the airbag warning lamp status Ok or Open. The MIC transmits
the message one time at ignition on, upon lamp state change, or in response to the ORC
lamp message.
Set Condition: The code is set if the lamp state is open for 2 consecutive messages or 2
seconds.
ORC, WARNING INDICATOR CIRCUIT SHORT - STORED

from the MIC containing the airbag warning lamp status Ok or Shorted. The MIC
transmits the message one time at ignition on and upon lamp state change.
Set Condition: If the lamp state is Shorted for 2 consecutive messages the code will be set.
POSSIBLE CAUSES
CHECKING FOR ACTIVE ORC DTC’S
STORED CODE PRESENT

Wiggle the wiring harness and connectors of the Airbag System and rotate the
steering wheel from stop to stop.
You have just attempted to simulate the condition that initially set the trouble code
message.
problem:
broken wire.

with diagnosis.
No → No problem found at this time. Erase codes in all modules before

returning vehicle to customer.
81
AIRBAG
Symptom:
ORC, CLUSTER MESSAGE MISMATCH - ACTIVE
ORC, CLUSTER MESSAGE MISMATCH - ACTIVE

When Monitored: After the MIC bulb test is completed, the ORC compares the Lamp
Request by ORC, On or Off, and the Lamp on by MIC, On or Off, PCI Bus messages. Each
message is transmitted one time per second or when a change in the lamp state occur.
Set Condition: If the Lamp Request by ORC, On or Off, and the Lamp on by MIC, On or
Off, messages do not match, the code will set.
POSSIBLE CAUSES
MIC, COMMUNICATION FAILURE
MIC, CLUSTER MESSAGE MISMATCH
ORC, CLUSTER MESSAGE MISMATCH

With the DRBIIIt, ensure PCI Bus communications with the Instrument Cluster.
Is the Instrument Cluster communicating on the PCI Bus?
Yes → Go To 2

related symptom INSTRUMENT CLUSTER BUS +/- SIGNAL
OPEN.
2 With the DRB select PASSIVE RESTRAINTS, AIRBAG, MONITOR DISPLAY and All
WARNING LAMP STATUS.
Cycle the ignition key and observe the LAMP ON BY MIC and LAMP REQ BY ORC
monitors after the 6 to 8 second indicator test.
Does the LAMP ON BY MIC and LAMP REQ BY ORC monitors match?
YES
Go To 3
NO
Replace Mechanical Instrument Cluster.
82
AIRBAG
ORC, CLUSTER MESSAGE MISMATCH - ACTIVE — Continued

Repair
83
AIRBAG
Symptom:
ORC, DRIVER SBS OPEN - ACTIVE
ORC, DRIVER SBS OPEN - ACTIVE

POSSIBLE CAUSES
DRIVER SBS OPEN
DRIVER SEAT BELT SWITCH CIRCUITS OPEN
ORC, DRIVER SEAT BELT SWITCH CIRCUIT OPEN

Disconnect the Driver Seat Belt Switch.
Measure the voltage between Driver Seat Belt Switch Line 1 and Line 2 circuits and
ground.
Is there voltage present on both circuits?
Yes → Replace the Driver Seat Belt Tensioner.

No → Go To 2

Disconnect the Driver Seat Belt Switch connector.
Disconnect the Occupant Restraint Controller connector
Measure the resistance of the Driver SBS Line 1 and line 2 circuits between the
Driver SBS harness connector and ORC connector.
Is the resistance of both circuits below 5.0 ohms?
Yes → Go To 3
No → Repair the open Driver Seat Belt Switch Line 1 or Line 2.
84
AIRBAG
ORC, DRIVER SBS OPEN - ACTIVE — Continued

3 WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER IS DROPPED All
Repair
Replace the Occupant Restraint Controller (ORC) in accordance
85
AIRBAG
Symptom:
ORC, DRIVER SBS SHORT TO BATTERY - ACTIVE
ORC, DRIVER SBS SHORT TO BATTERY - ACTIVE

POSSIBLE CAUSES
DRIVER SBS SHORT TO BATTERY
DRIVER SEAT BELT SWITCH CIRCUITS SHORTED TO BATTERY
ORC, DRIVER SEAT BELT SWITCH SHORT TO BATTERY

Disconnect the Driver Seat Belt Switch.
With the DRBIIIt, read the active Airbag DTCs.
Does the DRB show DRIVER SBS CIRCUIT OPEN?
No → Go To 2

WARNING: TURN THE IGNITION OFF, THEN RECONNECT THE BATTERY.
Measure the voltage on the Driver SBS Line 1 and line 2 circuits at the Driver SBS
connector.
Is the voltage above 4.0 volts on either circuit?
Yes → Repair the Driver Seat Belt Switch line 1 or line 2 shorted to
battery.
No → Go To 3
86
AIRBAG
ORC, DRIVER SBS SHORT TO BATTERY - ACTIVE — Continued

Repair
87
AIRBAG
Symptom:
ORC, DRIVER SBS SHORT TO GROUND - ACTIVE
ORC, DRIVER SBS SHORT TO GROUND - ACTIVE

POSSIBLE CAUSES
DRIVER SEAT BELT SWITCH SHORT TOGETHER OR TO GROUND
DRIVER SEAT BELT SWITCH CIRCUITS SHORTED TOGETHER
DRIVER SEAT BELT SWITCH CIRCUITS SHORTED TO GROUND
ORC, DRIVER SEAT BELT SWITCH SHORT TO GROUND

Turn Ignition On.
Does the DRB show DRIVER SBS CIRCUIT OPEN?
No → Go To 2

Measure the resistance between the Driver SBS Line 1 and line 2 circuits at the
Driver SBS connector.
Yes → Repair the Driver Seat Belt Switch Line 1 and Line 2 shorted
together.
No → Go To 3
88
AIRBAG
ORC, DRIVER SBS SHORT TO GROUND - ACTIVE — Continued

Driver SBS connector and ground.
Is the resistance below 5.0 ohms on either circuit?
Yes → Repair the Driver Seat Belt Switch line 1 or line 2 shorted to
ground.
No → Go To 4


Repair
89
AIRBAG
Symptom:
ORC, DRIVER SBT CIRCUIT OPEN - ACTIVE
ORC, DRIVER SBT CIRCUIT OPEN - ACTIVE

When Monitored: When the ignition is On, the ORC monitors the resistance of the Driver
POSSIBLE CAUSES
DRIVER SBT CIRCUITS OPEN
DRIVER SBT LINE 1 CIRCUIT OPEN
DRIVER SBT LINE 2 CIRCUIT OPEN
ORC, DRIVER SBT CIRCUITS OPEN

1 NOTE: Ensure the battery is fully charged. All
Disconnect the Driver SBT.
Connect the SRS Load Tool 8443 Passenger cable and jumper to the Driver SBT
connector.
With the DRBIIIt, read the active DTC’s.
Does the DRBIIIt display DRIVER SBT CIRCUIT OPEN?
Yes → Go To 2
No → Replace Driver Seat Belt Tensioner.

90
AIRBAG
ORC, DRIVER SBT CIRCUIT OPEN - ACTIVE — Continued

Connect the SRS Load Tool 8443 ORC adaptor to the Occupant Restraint Controller
connector.
Measure the resistance of the Driver SBT Line 1 circuit between the SRS Load Tool
ORC Adaptor and the Diver SBT connector.
Yes → Go To 3
No → Repair open or high resistance in Driver Seat Belt Tensioner Line

1 circuit.
Disconnect the Occupant Restraint Controller connector.
connector.
Measure the resistance of the Driver SBT Line 2 circuit between the SRS Load Tool
ORC Adaptor connector and Driver SBT connector.
Yes → Go To 4
No → Repair the open or high resistance in Driver Seat Belt Tensioner
Line 2 circuit.

Repair
91
AIRBAG
Symptom:
ORC, DRIVER SBT CIRCUIT SHORT - ACTIVE
ORC, DRIVER SBT CIRCUIT SHORT - ACTIVE

Seat Belt Tensioner circuits
Set Condition: The ORC has detected low resistance in the Driver Seat Belt Tensioner
circuits.
POSSIBLE CAUSES
DRIVER SBT CIRCUITS SHORT
DRIVER SBT LINE 1 SHORT TO LINE 2
ORC, DRIVER SBT CIRCUIT SHORT

Disconnect the Driver SBT connector.
connector.
Does the DRBIIIt display DRIVER SBT CIRCUIT SHORT?
Yes → Go To 2


92
AIRBAG
ORC, DRIVER SBT CIRCUIT SHORT - ACTIVE — Continued

connector.
Measure the resistance of the Driver SBT Line 1 and line 2 circuit at the Driver SBT
connector.
Yes → Repair Driver Seat Belt Tensioner Line 1 circuit shorted to Driver
Seat Belt Tensioner Line 2 circuit.
No → Go To 3
Repair
93
AIRBAG
Symptom:
ORC, DRIVER SBT SHORT TO BATTERY - ACTIVE
ORC, DRIVER SBT SHORT TO BATTERY - ACTIVE

Set Condition: The ORC has detected high voltage on the Driver Seat Belt Tensioner
circuits.
POSSIBLE CAUSES
DRIVER SBT CIRCUITS SHORT TO BATTERY
DRIVER SBT LINE 1 SHORT TO BATTERY
DRIVER SBT LINE 2 SHORT TO BATTERY
ORC, DRIVER SBT CIRCUITS SHORT TO BATTERY

connector.
Does the DRBIIIt display DRIVER SBT SHORT TO BATTERY?
Yes → Go To 2


94
AIRBAG
ORC, DRIVER SBT SHORT TO BATTERY - ACTIVE — Continued

connector.
Measure the voltage of the Driver SBT Line 1 between the Driver SBT connector and
ground.
Yes → Repair Driver Seat Belt Tensioner Line 1 circuit shorted to

battery.
No → Go To 3

Measure the voltage of the Driver SBT Line 2 circuit between the Driver SBT

battery.
No → Go To 4

Repair
95
AIRBAG
Symptom:
ORC, DRIVER SBT SHORT TO GROUND - ACTIVE
ORC, DRIVER SBT SHORT TO GROUND - ACTIVE

Set Condition: The ORC has detected a short to ground in the Driver Seat Belt Tensioner
circuits.
POSSIBLE CAUSES
DRIVER SBT CIRCUITS SHORT TO GROUND
DRIVER SBT LINE 1 SHORT TO GROUND
DRIVER SBT LINE 2 SHORT TO GROUND
ORC, DRIVER SBT CIRCUITS SHORT TO GROUND

connector.
Does the DRBIIIt display DRIVER SBT SHORT TO GROUND?
Yes → Go To 2
No → Replace the Driver Seat Belt Tensioner.


96
AIRBAG
ORC, DRIVER SBT SHORT TO GROUND - ACTIVE — Continued

Disconnect the Occupant Restraint Controller Connector
connector.
Measure the resistance of the Driver SBT Line 1 circuit between the Driver SBT
ground.
No → Go To 3
connector.
Measure the resistance of the Driver SBT Line 2 circuit between the Driver SBT
Yes → Repair Driver Seat Belt Tensioner Line 2 circuit for a short to
ground.
No → Go To 4

Repair
97
AIRBAG
Symptom:
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - ACTIVE

Squib 1 circuits.
Squib 1 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT OPEN
CLOCKSPRING, DRIVER SQUIB 1 CIRCUIT OPEN
DRIVER SQUIB 1 LINE 1 CIRCUIT OPEN
ORC, DRIVER SQUIB 1 CIRCUIT OPEN

WARNING: DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE
DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR
IF ACCIDENTALLY DEPLOYED, AND COULD RESULT IN SERIOUS OR
FATAL INJURY.
Disconnect the Driver Airbag.
Connect the SRS Load Tool 8443 Driver cable and jumpers to the Driver Airbag
connectors.
Does the DRB show DRIVER SQUIB 1 CIRCUIT OPEN?
Yes → Go To 2
No → Replace the Driver Airbag.

98
AIRBAG
ORC, DRIVER SQUIB 1 CIRCUIT OPEN - ACTIVE — Continued

FATAL INJURY.
Disconnect the Clockspring connector.
Connect the SRS Load Tool 8443 Clockspring cable and jumper to the Clockspring
connector.
With the DRB, read the active Airbag codes.
Yes → Go To 3
No → Replace the Clockspring.


WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
Disconnect the ORC connector.
connector.
Measure the resistance of the Driver Squib 1 Line 1 circuit between the ORC adaptor
and the Clockspring harness connector.
Yes → Go To 4
No → Repair the open or high resistance in the Driver Squib 1 Line 1

circuit.
99
AIRBAG

connector.
and the Clockspring connector.
Yes → Go To 5
No → Repair open or high resistance in the Driver Squib 1 Line 2

Circuit.
Repair
Replace the Occupant Restraint Controller ORC in accordance
with the Service information. WARNING: make sure the battery
100
AIRBAG
Symptom:
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - ACTIVE

Squib 1 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT SHORT
CLOCKSPRING, DRIVER SQUIB 1 CIRCUIT SHORT
DRIVER SQUIB 1 LINE 1 SHORT TO LINE 2
ORC, DRIVER SQUIB 1 CIRCUIT SHORT

Connect the SRS Load Tool 8443 Driver cable and jumpers to the Diver Airbag
connectors.
FATAL INJURY.
Does the DRB show DRIVER SQUIB 1 CIRCUIT SHORT?
Yes → Go To 2
No → Replace Driver Airbag.

101
AIRBAG
ORC, DRIVER SQUIB 1 CIRCUIT SHORT - ACTIVE — Continued

FATAL INJURY.
connector.
Yes → Go To 3
No → Replace Clockspring.

connector.
Measure the resistance between the Driver Squib 1 Line 1 and Line 2 at the
Clockspring connector.
Yes → Repair the Driver Squib 1 Line 1 circuit shorted to Driver Squib
1 Line 2 circuit.
No → Go To 4
102
AIRBAG

Repair
Replace the Airbag Control Module in accordance with Service
Instructions. WARNING: make sure the battery is disconnected
and wait 2 minutes before proceeding.

103
AIRBAG
Symptom:
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - ACTIVE

Squib 1 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT SHORT TO BATTERY
CLOCKSPRING, DRIVER SQUIB 1 CIRCUIT SHORT TO BATTERY
DRIVER SQUIB 1 LINE 1 SHORT TO BATTERY
ORC, DRIVER SQUIB 1 CIRCUIT SHORT TO BATTERY

FATAL INJURY.
Connect the SRS Load Tool 8443 Driver cable and jumper to the Driver Airbag
connectors.
With the DRBIIIt, read the active Airbag DTCS.
Does the DRB show DRIVER SQUIB 1 SHORT TO BATTERY?
Yes → Go To 2

104
AIRBAG
ORC, DRIVER SQUIB 1 SHORT TO BATTERY - ACTIVE — Continued

FATAL INJURY.
connector.
Does the DRB show DRIVER SQUIB 1 SHORT TO BATTERY ?
Yes → Go To 3


connector.
Measure the voltage on the Driver Squib 1 Line 1 circuit between the Clockspring
Yes → Repair the Driver Squib 1 Line 1 circuit short to battery.
No → Go To 4
105
AIRBAG

connector.
Measure the voltage on the Driver Squib 1 Line 2 circuit between the Clockspring
Is the voltage above 0.5 volts
Yes → Repair Driver Squib 1 Line 2 circuit short to battery voltage.
No → Go To 5
Repair
106
AIRBAG
Symptom:
ORC, DRIVER SQUIB 1 SHORT TO GROUND - ACTIVE

Squib 1 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT SHORT TO GROUND
CLOCKSPRING, DRIVER SQUIB 1 CIRCUIT SHORT TO GROUND
DRIVER SQUIB 1 LINE 1 SHORT TO GROUND
ORC, DRIVER SQUIB 1 CIRCUIT SHORT TO GROUND

Disconnect the Driver Airbag Module.
connectors.
Does the DRB show DRIVER SQUIB 1 SHORT TO GROUND?
Yes → Go To 2


107
AIRBAG
ORC, DRIVER SQUIB 1 SHORT TO GROUND - ACTIVE — Continued

FATAL INJURY.
connector.
Yes → Go To 3


connector.
Measure the resistance of the Driver Squib 1 Line 1 circuit between Clockspring
Yes → Repair Driver Squib 1 Line 1 circuit short to ground.
No → Go To 4

108
AIRBAG

connector.
Measure the resistance of the Driver Squib 1 Line 2 circuit between the Clockspring
No → Go To 5

turned off and the Battery must be disconnected..
FATAL INJURY.
Repair

109
AIRBAG
Symptom:

Squib 2 circuits.
Squib 2 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT OPEN
CLOCKSPRING, DRIVER SQUIB 2 CIRCUIT OPEN
ORC, DRIVER SQUIB 2 CIRCUIT OPEN

FATAL INJURY.
connectors.
Does the DRBIIIt show DRIVER SQUIB 2 CIRCUIT OPEN?
Yes → Go To 2

110
AIRBAG

FATAL INJURY.
connector.
With the DRB, read the active Airbag codes.
Yes → Go To 3


connector.
Yes → Go To 4
No → Repair the open or high resistance in the Driver Squib 2 Line 1

circuit.
111
AIRBAG

connector.
Yes → Go To 5
No → Repair open or high resistance in the Driver Squib 2 Line 2

Circuit.
Repair
Replace the Occupant Restraint Controller ORC in accordance
with the Service information. WARNING: make sure the battery
112
AIRBAG
Symptom:

Squib 2 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT SHORT
CLOCKSPRING, DRIVER SQUIB 2 CIRCUIT SHORT
DRIVER SQUIB 2 LINE 1 SHORT TO LINE 2
ORC, DRIVER SQUIB 2 CIRCUIT SHORT

FATAL INJURY.
Connect the SRS Load Tool 8443 Driver cable and jumper to the Driver Airbag
connectors.
Yes → Go To 2
No → Replace Driver Airbag.

113
AIRBAG

FATAL INJURY.
connector.
Yes → Go To 3
No → Replace Clockspring.

connector.
Measure the resistance between the Driver Squib 2 Line 1 and Line 2 at the
Clockspring connector.
Yes → Repair the Driver Squib 2 Line 1 circuit shorted to Driver Squib
2 Line 2 circuit.
No → Go To 4
114
AIRBAG

Repair

115
AIRBAG
Symptom:

Squib 2 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG CIRCUIT SHORT TO BATTERY
CLOCKSPRING, DRIVER SQUIB 2 CIRCUIT SHORT TO BATTERY
DRIVER SQUIB 2 LINE 2 SHORTED TO BATTERY
ORC, DRIVER SQUIB 2 CIRCUIT SHORT TO BATTERY

FATAL INJURY.
connector.
Does the DRB show DRIVER SQUIB 2 SHORT TO BATTERY ?
Yes → Go To 2

116
AIRBAG

connector.
Measure the voltage on the Driver Squib 2 Line 1 at the Clockspring connector.
Yes → Repair the Driver Squib 2 Line 1 circuit short to battery.
No → Go To 3


connector.
Measure the voltage on the Driver Squib 2 Line 2 at the Clockspring connector.
Is the voltage above 0.5 volts
Yes → Repair Driver Squib 2 Line 2 circuit shorted to battery voltage.
No → Go To 4

117
AIRBAG

FATAL INJURY.
connectors.
With the DRBIIIt, read the active Airbag DTC’s.
Does the DRB show DRIVER SQUIB 2 SHORT TO BATTERY?
Yes → Go To 5
Repair
118
AIRBAG
Symptom:

Squib 2 circuits.
POSSIBLE CAUSES
DRIVER AIRBAG, CIRCUIT SHORT TO GROUND
CLOCKSPRING, DRIVER SQUIB 2 CIRCUIT SHORT TO GROUND
ORC, DRIVER SQUIB 2 CIRCUIT SHORT TO GROUND

FATAL INJURY.
connectors.
Yes → Go To 2

119
AIRBAG

FATAL INJURY.
connector.
Yes → Go To 3


Connect the Airbag SRS Tool 8443 ORC adaptor to the Occupant Restraint Controller
connector.
Measure the resistance of the Driver Squib 2 Line 1 circuit between Clockspring
No → Go To 4

120
AIRBAG

Connect the Airbag SRS Tool 8443 ORC adaptor to the Occupant Restraint Controller
connector.
Measure the resistance of the Driver Squib 2 Line 2 circuit between the Clockspring
No → Go To 5

turned off and the Battery must be disconnected..
Repair

121
AIRBAG
Symptom:
ORC, INTERROGATE LEFT SIACM - ACTIVE
ORC, INTERROGATE LEFT SIACM - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for a Left SIACM
status message containing the airbag warning lamp 9On or OFF9 request. The status
the Left SIACM. NOTE: This indicates that there was an active diagnostic trouble code in
the Left SIACM.
POSSIBLE CAUSES
INTERROGATE LEFT SIACM
ORC, INTERROGATE LEFT SIACM

With the DRB select SIDE AIRBAG then LEFT SIACM.
Does the DRB show any active diagnostic trouble codes in the Left SIACM?
Yes → Refer to PASSIVE RESTRAINTS category and select the symp-
tom from the LEFT SIACM symptom list.
No → Go To 2
WARNING: IF THE LEFT SIDE AIRBAG CONTROL MODULE IS DROPPED
Repair
122
AIRBAG
Symptom:
ORC, INTERROGATE RIGHT SIACM - ACTIVE
ORC, INTERROGATE RIGHT SIACM - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for a Right SIACM
status message containing the airbag warning lamp 9Lamp On/ OFF9 request. The status
the Right SIACM. NOTE: This indicates that there is an active diagnostic trouble code in
the Right SIACM.
POSSIBLE CAUSES
INTERROGATE RIGHT SIACM
ORC, INTERROGATE RIGHT SIACM

With the DRB select SIDE AIRBAG then RIGHT SIACM.
Does the DRB show any active diagnostic trouble codes in the Right SIACM?
Yes → Refer to PASSIVE RESTRAINTS category and select the symp-
tom from the RIGHT SIACM symptom list.
No → Go To 2
WARNING: IF THE RIGHT SIDE IMPACT AIRBAG CONTROL MODULE IS
Repair
123
AIRBAG
Symptom List:
ORC, INTERROGATE RIGHT SIACM - STORED
ORC, NO RIGHT SIACM MESSAGE - STORED
RIGHT SIACM, NO PCI TRANSMISSION - STORED
RIGHT SIACM, NO PCM MESSAGE - STORED
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - STORED
The title for the tests will be ORC, INTERROGATE RIGHT
SIACM - STORED.
ORC, INTERROGATE RIGHT SIACM - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for a Right SIACM
status message containing the airbag warning lamp 9Lamp On/ OFF9 request. The status
the Right SIACM. NOTE: This indicates that there was an active diagnostic trouble code
in the Right SIACM.
ORC, NO RIGHT SIACM MESSAGE - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Right Side
Impact Airbag Control Module status message. The Right SIACM transmits the status
message to the ORC at 1 - second intervals.
Set Condition: If the ORC fails to see the Right SIACM status message on the PCI Bus
for 10 seconds the code will set.
RIGHT SIACM, NO PCI TRANSMISSION - STORED

When Monitored: With the ignition in the On position and the Right SIACM transmitting
Set Condition: The code will set if the Right SIACM cannot detect the Right SIACM
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - STORED

When Monitored: With the ignition is On, the Right SIACM monitors the resistance of
the Right Seat Squib circuits.
Set Condition: The Right SIACM has detected an open circuit or high resistance on the
Right Seat Squib circuits.
124
AIRBAG
ORC, INTERROGATE RIGHT SIACM - STORED — Continued
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - STORED

When Monitored: When the ignition is on, the Right SIACM monitors the resistance of
Set Condition: The Right SIACM has detected that the Right Seat Squib circuits are
shorted together.
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - STORED

When Monitored: When the ignition is on, the Right SIACM monitors the voltage of the
Set Condition: The Right SIACM has detected high voltage on the Right Seat Squib
circuits.
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - STORED

Set Condition: The Right SIACM has detected a short to ground in the Right Seat Squib
circuits.
POSSIBLE CAUSES
CHECKING FOR ACTIVE RIGHT SIACM DTCS
STORED CODE PRESENT

Wiggle the wiring harness and connectors of the Airbag System.
problem:
broken wire.

with diagnosis.
No → No problem found at this time. NOTE: interrogate the ORC and

Left SIACM for DTCs. Erase all codes in all airbag modules before
returning vehicle to customer.
125
AIRBAG
Symptom:
ORC, NO CLUSTER MESSAGE - ACTIVE
ORC, NO CLUSTER MESSAGE - ACTIVE

When Monitored: With the ignition in the On position, the ORC monitors the PCI Bus for
a message from the MIC containing the airbag warning lamp status. The MIC transmits
the message one time at ignition on, lamp state change, or in response to the ORC lamp
message.
Set Condition: If the MIC message is not received for 10 consecutive seconds, the code
will set.
POSSIBLE CAUSES
NO CLUSTER MESSAGES
ORC, NO CLUSTER MESSAGES

Yes → Go To 2

OPEN.
2 With the DRB select PASSIVE RESTRAINTS, AIRBAG, MONITOR DISPLAY and All
WARNING LAMP STATUS.
Cycle the ignition key and observe the LAMP ON BY MIC monitor after the 6 to 8
seconds bulb check.
Does the DRB show LAMP ON BY MIC: ON or OFF?
YES
Go To 3
NO
Replace Instrument Cluster circuit board.
126
AIRBAG
ORC, NO CLUSTER MESSAGE - ACTIVE — Continued

Repair
127
AIRBAG
Symptom:
ORC, NO LEFT SIACM MESSAGE - ACTIVE
ORC, NO LEFT SIACM MESSAGE - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Left SIACM
status message. The Left SIACM transmits the status message to the ORC at 1 - second
intervals.
Set Condition: If the ORC fails to see the Left SIACM status message on the PCI Bus for
10 seconds the code will set.
POSSIBLE CAUSES
NO LEFT SIACM MESSAGE
ORC, NO LEFT SIACM MESSAGE

1 With the DRB select SIDE AIRBAG then LEFT SIDE AIRBAG from the DRB menu. All
Does the DRB show NO RESPONSE or BUS +/- SIGNAL OPEN?
Yes → Refer to the Communication category for the related symptom.
No → Go To 2
Repair
128
AIRBAG
Symptom:
ORC, NO ODOMETER MESSAGE - ACTIVE
ORC, NO ODOMETER MESSAGE - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Odometer
message from the Body Control Module. The BCM transmits the odometer message at 1
second intervals.
Set Condition: The code will set, if the ORC does not see the odometer message for 10
seconds.
POSSIBLE CAUSES
BODY CONTROL MODULE COMMUNICATION
ORC, NO ODOMETER MESSAGE

With the DRB, attempt to communicate with the BCM.
Was the DRB able to I/D or communicate with the BCM?
Yes → Go To 2
No → Refer to the Communication category for the related symptom.

Repair
129
AIRBAG
Symptom:
ORC, NO PCI TRANSMISSION - STORED
ORC, NO PCI TRANSMISSION - STORED

When Monitored: With the ignition in the On position and the ORC transmitting
Set Condition: The code will set if the ORC cannot detect the ORC transmitting
information on the PCI BUS for 5 consecutive seconds. NOTE: Any PCI Bus Failure will
cause this code to set.
POSSIBLE CAUSES
ACTIVE OR STORED CODE PRESENT
STORED CODE OR INTERMITTENT CONDITION

Wiggle the wiring harness and connectors of the Airbag System and rotate the
steering wheel from stop to stop.
NOTE: Check connectors - Clean / repair as necessary.
You have just attempted to simulate the condition that initially set the trouble code
message.
problem:
- Visually inspect the related harnesses. Look for chafed, pierced, pinched or partially
broken wire.
Yes → Select appropriate active symptom from Symptom List.
No → No problem found at this time. Erase all codes before returning

vehicle to customer.
130
AIRBAG
Symptom:
ORC, NO RIGHT SIACM MESSAGE - ACTIVE
ORC, NO RIGHT SIACM MESSAGE - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for the Right Side
Impact Airbag Control Module status message. The Right SIACM transmits the status
message to the ORC at 1 - second intervals.
Set Condition: If the ORC fails to see the Right SIACM status message on the PCI Bus
for 10 seconds the code will set.
POSSIBLE CAUSES
NO RIGHT SIACM MESSAGE
ORC, NO RIGHT SIACM MESSAGE

1 With the DRB select SIDE AIRBAG and the RIGHT SIDE AIRBAG from the DRB All
menu.
Does the DRB show NO RESPONSE or BUS +/- SIGNAL OPEN?
Yes → Refer to the COMMUNICATION category for the related symp-
tom.
No → Go To 2

Repair

131
AIRBAG
Symptom:
ORC, NOT CONFIGURED FOR SAB - ACTIVE
ORC, NOT CONFIGURED FOR SAB - ACTIVE

When Monitored: With ignition on, the ORC monitors the PCI Bus for a message
containing an 9A9 in the 4 th position of the VIN. This character identifies the type of safety
equipment and should match the VIN. The PCM transmits the VIN every 13.76 seconds.
Set Condition: The code will set, if the ORC detects a Side Impact Airbag Module active
on the PCI Bus and the 4 th character of the VIN message is not an 9A9.
POSSIBLE CAUSES
CHECK PCM VIN
ORC, ORC NOT CONFIGURED FOR SIDE AIRBAGS

Connect the DRB to the data link connector and select PASSIVE RESTRAINTS,
AIRBAG, SYSTEM TEST
With the DRBIIIt, read the PCM Active on the Bus
Does the DRB show PCM Active on the Bus:?
Yes → Go To 2
No → Refer to category COMMUNICATION and select the related
symptom.
2 With the DRB read the Vehicle Identification Number in the Powertrain Control All
Module.
Yes → Go To 3
132
AIRBAG
ORC, NOT CONFIGURED FOR SAB - ACTIVE — Continued

Repair
133
AIRBAG
Symptom:
ORC, NOT CONFIGURED FOR SAB - STORED
ORC, NOT CONFIGURED FOR SAB - STORED

When Monitored: With ignition on, the ORC monitors the PCI Bus for a message
containing an 9A9 in the 4 th position of the VIN. This character identifies the type of safety
equipment and should match the VIN. The PCM transmits the VIN every 13.76 seconds
Set Condition: The code will set, if the ORC detects a Side Impact Airbag Module active
on the PCI Bus and the 4 th character of the VIN message is not an 9A9.
POSSIBLE CAUSES
INTERMITTENT PCI BUS TEST

1 Note: Ensure the battery is fully charged. All
Turn ignition on.
Read both active and stored codes, and record them.
With the DRB III monitor stored codes as you work through the system.
NOTE: Check for partially seated connectors and spread terminals - Clean
/ repair as necessary.
Wiggle the wiring harness of each module on the PCI Bus.
While monitoring the DRB road test the vehicle.
Is a connector, wiring or loss of communication problem?
Yes → Repair the PCI Bus wiring, connectors or terminals as necessary.
No → Test Complete.
134
AIRBAG
Symptom:
ORC, PASSENGER SBS OPEN - ACTIVE
ORC, PASSENGER SBS OPEN - ACTIVE

POSSIBLE CAUSES
PASSENGER SBS OPEN
PASSENGER SEAT BELT SWITCH CIRCUITS OPEN
ORC, PASSENGER SEAT BELT SWITCH CIRCUIT OPEN

Disconnect the Passenger Seat Belt Switch.
Measure the voltage between Passenger Seat Belt Switch Line 1 and Line 2 circuits
and ground.
Is there voltage present on both circuits?
Yes → Replace the Passenger Seat Belt Tensioner.

No → Go To 2

Disconnect the Passenger Seat Belt Switch connector.
Passenger SBS harness connector and ORC connector.
Is the resistance of both circuits below 5.0 ohms?
Yes → Go To 3
No → Repair the open Passenger Seat Belt Switch Line 1 or Line 2.
135
AIRBAG
ORC, PASSENGER SBS OPEN - ACTIVE — Continued

Repair
136
AIRBAG
Symptom:
ORC, PASSENGER SBS SHORT TO BATTERY - ACTIVE
ORC, PASSENGER SBS SHORT TO BATTERY - ACTIVE

POSSIBLE CAUSES
PASSENGER SBS SHORT TO BATTERY
PASSENGER SEAT BELT SWITCH CIRCUITS SHORTED TO BATTERY
ORC, PASSENGER SEAT BELT SWITCH SHORT TO BATTERY

Disconnect the Passenger Seat Belt Switch.
Does the DRB show PASSENGER SBS CIRCUIT OPEN?
Yes → Replace the Passenger Seat Belt Tensioner.
No → Go To 2

WARNING: TURN THE IGNITION OFF, THEN RECONNECT THE BATTERY.
Measure the voltage on the Passenger SBS Line 1 and line 2 circuits at the Passenger
SBS connector.
Is the voltage above 4.0 volts on either circuit?
Yes → Repair the Passenger Seat Belt Switch line 1 or line 2 shorted to
battery.
No → Go To 3
137
AIRBAG
ORC, PASSENGER SBS SHORT TO BATTERY - ACTIVE — Continued

Repair
138
AIRBAG
Symptom:
ORC, PASSENGER SBS SHORT TO GROUND - ACTIVE
ORC, PASSENGER SBS SHORT TO GROUND - ACTIVE

POSSIBLE CAUSES
PASSENGER SEAT BELT SWITCH SHORT TOGETHER OR TO GROUND
PASSENGER SEAT BELT SWITCH CIRCUITS SHORTED TOGETHER
PASSENGER SEAT BELT SWITCH CIRCUITS SHORTED TO GROUND
ORC, PASSENGER SEAT BELT SWITCH SHORT TO GROUND

Turn Ignition On.
Does the DRB show PASSENGER SBS CIRCUIT OPEN?
Yes → Replace the Passenger Seat Belt Switch.
No → Go To 2

Measure the resistance between the Driver SBS Line 1 and line 2 circuit at the
Passenger SBS connector.
Yes → Go To 3
No → Repair the Passenger Seat Belt Switch Line 1 and Line 2 shorted
together.
139
AIRBAG
ORC, PASSENGER SBS SHORT TO GROUND - ACTIVE — Continued

Measure the resistance of the Driver SBS Line 1 and line 2 circuit between the
Passenger SBS connector and ground.
Is the resistance below 5.0 ohms on either circuit?
Yes → Repair the Passenger Seat Belt Switch line 1 or line 2 shorted to
ground.
No → Go To 4


Repair
140
AIRBAG
Symptom:
ORC, PASSENGER SBT CIRCUIT OPEN - ACTIVE
ORC, PASSENGER SBT CIRCUIT OPEN - ACTIVE

When Monitored: When the ignition is On, the ORC monitors the resistance of the
Set Condition: The ORC has detected an open circuit or high resistance or open circuit in
the Passenger Seat Belt Tensioner circuits.
POSSIBLE CAUSES
PASSENGER SBT CIRCUITS OPEN
PASSENGER SBT LINE 1 CIRCUIT OPEN
PASSENGER SBT LINE 2 CIRCUIT OPEN
ORC, PASSENGER SBT CIRCUITS OPEN

Disconnect the Passenger SBT connector.
Connect the SRS Load Tool 8443 Passenger cable and jumper to the Passenger SBT
connector.
Does the DRBIIIt display PASSENGER SBT CIRCUIT OPEN?
Yes → Go To 2
No → Replace the Passenger Seat Belt Tensioner in accordance with the
Service Information.

141
AIRBAG
ORC, PASSENGER SBT CIRCUIT OPEN - ACTIVE — Continued

Disconnect the Passenger SBT.
Connect the SRS load tool 8443 ORC adaptor to the Occupant Restraint Controller
connector.
Measure the resistance of the Right Seat Belt Tensioner Line 1 circuit between the
SRS Load Tool ORC Adaptor connector and the Passenger SBT connector.
Yes → Go To 3
No → Repair open or high resistance in Passenger Seat Belt Tensioner

Line 1 circuit.
connector.
Measure the resistance of the Passenger SBT Line 2 circuit between the SRS Load
Tool ORC Adaptor and the Passenger SBT connector.
Yes → Go To 4
No → Repair open or high resistance in Passenger Seat Belt Tensioner
Line 2 circuit.

Repair
142
AIRBAG
Symptom:
ORC, PASSENGER SBT CIRCUIT SHORT - ACTIVE
ORC, PASSENGER SBT CIRCUIT SHORT - ACTIVE

Set Condition: The ORC has detected low resistance in the Passenger Seat Belt Tensioner
circuits.
POSSIBLE CAUSES
PASSENGER SBT CIRCUITS SHORT
PASSENGER SBT LINE 1 SHORT TO LINE 2
ORC, PASSENGER SBT CIRCUITS SHORT

Disconnect the Right Seat Belt Tensioner connector.
connector.
Does the DRB show PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT?
Yes → Go To 2
No → Replace the Passenger Seat Belt Tensioner in accordance with the


143
AIRBAG
ORC, PASSENGER SBT CIRCUIT SHORT - ACTIVE — Continued

connector.
Measure the resistance between the Passenger SBT Line 1 and line 2 circuit at the
Passenger SBT connector.
Yes → Repair the Passenger SBT Line 1 circuit for a short to the
Passenger SBT Line 2 circuit.
No → Go To 3
Repair
144
AIRBAG
Symptom:
ORC, PASSENGER SBT SHORT TO BATTERY - ACTIVE
ORC, PASSENGER SBT SHORT TO BATTERY - ACTIVE

Set Condition: The ORC has detected high voltage on the Passenger Seat Belt Tensioner
circuits.
POSSIBLE CAUSES
PASSENGER SBT CIRCUITS SHORT TO BATTERY
PASSENGER SBT LINE 1 SHORT TO BATTERY
PASSENGER SBT LINE 2 SHORT TO BATTERY
ORC, PASSENGER SBT CIRCUITS SHORT TO BATTERY

connector.
Does the DRBIIIt display PASSENGER SBT SHORT TO BATTERY?
Yes → Go To 2
No → Replace the Passenger Seat Belt Tensioner, SBT, in accordance

with the Service Information.

145
AIRBAG
ORC, PASSENGER SBT SHORT TO BATTERY - ACTIVE — Continued

Connect the SRS load tool 8443 ORC adaptor to the Occupant Restraint Controller
connector.
Measure the voltage of the Passenger SBT Line 1 circuit between the Passenger SBT
Yes → Repair the Passenger Seat Belt Tensioner Line 1 Short To

Battery.
No → Go To 3

Measure the voltage between Passenger SBT Line 2 circuit between the Passenger
SBT connector and ground.
Yes → Repair the Passenger Seat Belt Tensioner Line 2 circuit for a
short to battery.
No → Go To 4


Repair
146
AIRBAG
Symptom:
ORC, PASSENGER SBT SHORT TO GROUND - ACTIVE
ORC, PASSENGER SBT SHORT TO GROUND - ACTIVE

Passenger Seat Belt Tensioner circuits for low resistance.
Set Condition: The ORC has detected a short to ground in the Passenger Seat Belt
Tensioner circuits.
POSSIBLE CAUSES
PAS SBT CIRCUITS SHORT TO GROUND
PASSENGER SBT LINE 1 SHORT TO GROUND
PAS SBT LINE 2 SHORT TO GROUND
ORC, PASSENGER SBT CIRCUITS SHORTED TO GROUND

NOTE: Check connectors - Clean and repair as necessary. .
connector.
Does the DRBIIIt display PASSENGER SBT SHORT TO GROUND?
Yes → Go To 2
No → Replace the Passenger SBT in accordance with the Service

Information.

147
AIRBAG
ORC, PASSENGER SBT SHORT TO GROUND - ACTIVE — Continued

Disconnect the Occupant Restraint Controller Connector
connector.
Measure the resistance of the Passenger SBT Line 1 circuit between the Passenger
Yes → Repair the Passenger SBT Line 1 shorted to ground.
No → Go To 3
connector.
Measure the resistance of the Passenger SBT Line 2 circuit between the Passenger
Yes → Repair the Passenger SBT Line 2 circuit for a short to ground.
No → Go To 4
Repair

148
AIRBAG
Symptom:
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - ACTIVE

Squib 1 circuits.
POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT OPEN
PASSENGER SQUIB 1 LINE 1 CIRCUIT OPEN
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN

FATAL INJURY.
Disconnect the Passenger Airbag.
Connect the SRS Load Tool 8443 Passenger cable to the Passenger Airbag connector.
Does the DRB show PASSENGER SQUIB 1 CIRCUIT OPEN?
Yes → Go To 2
No → Replace Passenger Airbag.

149
AIRBAG
ORC, PASSENGER SQUIB 1 CIRCUIT OPEN - ACTIVE — Continued

FATAL INJURY.
connector.
Measure the resistance of the Passenger Squib 1 Line 1 circuit between the ORC
Adaptor and the Passenger Airbag connector.
Yes → Go To 3
No → Repair open or high resistance in Passenger Squib 1 Line 1
circuit.
FATAL INJURY.
connector.
Yes → Go To 4
circuit.

150
AIRBAG

Repair
151
AIRBAG
Symptom:
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - ACTIVE

POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT
PASSENGER SQUIB 1 LINE 1 SHORT TO LINE 2
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT

FATAL INJURY.
With the DRBIIIt, read the active DTCs.
Does the DRB show PASSENGER SQUIB 1 CIRCUIT SHORT?
Yes → Go To 2


152
AIRBAG
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT - ACTIVE — Continued

FATAL INJURY.
connector.
Measure the resistance between Passenger Squib 1 Line 1 and Squib 1 Line 2 circuit
at the Passenger Airbag connector.
Yes → Repair Passenger Squib 1 Line 1 circuit short to Passenger Squib
1 Line 2 circuit.
No → Go To 3
Repair

153
AIRBAG
Symptom:
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - ACTIVE

Squib 1 circuits.
POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT TO BATTERY
PASSENGER SQUIB 1 LINE 1 SHORT TO BATTERY
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT TO BATTERY

FATAL INJURY.
Connect the SRS Load Tool 8443 Passenger cable the Passenger Airbag connector.
Does the DRB show PASSENGER SQUIB 1 CIRCUIT SHORT TO BATTERY?
Yes → Go To 2


154
AIRBAG
ORC, PASSENGER SQUIB 1 SHORT TO BATTERY - ACTIVE — Continued

FATAL INJURY.
connector.
Measure the voltage on the Passenger Squib 1 Line 1 at the Passenger Airbag
connector.
Yes → Repair Passenger Squib 1 Line 1 circuit short to battery.

No → Go To 3
FATAL INJURY.
connector.
Measure the voltage on the Passenger Squib 1 Line 2 at the Passenger Airbag
connector.

No → Go To 4

155
AIRBAG

Repair
156
AIRBAG
Symptom:
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - ACTIVE

POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT TO GROUND
PASSENGER SQUIB 1 LINE 1 SHORT TO GROUND
ORC, PASSENGER SQUIB 1 CIRCUIT SHORT TO GROUND

FATAL INJURY.
Disconnect the Passenger Airbag connector.
Does the DRB show PASSENGER SQUIB 1 CIRCUIT SHORT TO GROUND?
Yes → Go To 2
No → Replace the Passenger Airbag.


157
AIRBAG
ORC, PASSENGER SQUIB 1 SHORT TO GROUND - ACTIVE — Continued

FATAL INJURY.
connector.
Measure the resistance of the Passenger Squib 1 Line 1 circuit between the
Passenger Airbag Module Connector and ground.
Yes → Repair Passenger Squib 1 Line 1 circuit for a shorted to ground.
No → Go To 3
FATAL INJURY.
connector.
Passenger Airbag connector to ground.
Yes → Repair Passenger Squib 1 Line 2 circuit for a short to ground.
No → Go To 4

Repair

158
AIRBAG
Symptom:

Squib 2 circuits.
POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT OPEN
ORC, PASSENGER SQUIB 2 CIRCUIT OPEN

FATAL INJURY.
Connect the SRS Load Tool 8443 Passenger cable to the Passenger Airbag inline
connector.
Does the DRB show PASSENGER SQUIB 2 CIRCUIT OPEN?
Yes → Go To 2


159
AIRBAG

FATAL INJURY.
connector.
Yes → Go To 3
circuit.
FATAL INJURY.
connector.
Yes → Go To 4
circuit.

160
AIRBAG

Repair
161
AIRBAG
Symptom:

POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT
PASSENGER SQUIB 1 LINE 1 SHORT TO LINE 2
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT

FATAL INJURY.
Does the DRB show PASSENGER SQUIB 2 CIRCUIT SHORT?
Yes → Go To 2


162
AIRBAG
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT - ACTIVE — Continued

FATAL INJURY.
connector.
Measure the resistance of the Passenger Squib 2 Line 1 and line 2 at the Passenger
Airbag connector.
Yes → Repair Passenger Squib 2 Line 1 circuit short to Passenger Squib
2 Line 2 circuit.
No → Go To 3
Repair

163
AIRBAG
Symptom:

Squib 2 circuits.
POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT TO BATTERY
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT TO BATTERY

FATAL INJURY.
Does the DRB show PASSENGER SQUIB 2 CIRCUIT SHORT TO BATTERY?
Yes → Go To 2


164
AIRBAG

FATAL INJURY.
connector.
Measure the voltage on the Passenger Squib 2 Line 1 circuit between the Passenger
Airbag connector and ground.

No → Go To 3
FATAL INJURY.
connector.
Measure the voltage on the Passenger Squib 2 Line 2 circuit between the Passenger
Airbag connector and ground.

No → Go To 4

165
AIRBAG

Repair
166
AIRBAG
Symptom:

POSSIBLE CAUSES
PASSENGER AIRBAG CIRCUIT SHORT TO GROUND
ORC, PASSENGER SQUIB 2 CIRCUIT SHORT TO GROUND

FATAL INJURY.
Disconnect the Passenger Airbag connector.
Does the DRB show PASSENGER SQUIB 2 CIRCUIT SHORT TO GROUND?
Yes → Go To 2
No → Replace the Passenger Airbag.


167
AIRBAG
ORC, PASSENGER SQUIB 2 SHORT TO GROUND - ACTIVE — Continued

FATAL INJURY.
connector.
Passenger Airbag Module connector and ground.
Yes → Repair Passenger Squib 2 Line 1 circuit for a shorted to ground.
No → Go To 3
FATAL INJURY.
connector.
Passenger Airbag connector to ground and ground.
Yes → Repair Passenger Squib 2 Line 2 circuit for a short to ground.
No → Go To 4


Repair

168
AIRBAG
Symptom:
ORC, VEHICLE BODY STYLE UNKNOWN - ACTIVE
ORC, VEHICLE BODY STYLE UNKNOWN - ACTIVE

containing the vehicle body style from the Powertrain Control Module. The PCM transmits
the VIN message every 14 seconds.
Set Condition: With ignition on, If the ORC does not receive the 2 consecutive matching
(vehicle Body Style) VIN messages on the bus the code will set.
POSSIBLE CAUSES
VEHICLE BODY STYLE UNKNOWN
ORC, VEHICLE BODY STYLE UNKNOWN

Connect the DRBIIIt to the data link connector and select PASSIVE RESTRAINTS,
AIRBAG, SYSTEM TEST.
With the DRBIIIt, read the PCM Active on the Bus:.
Does the DRB show PCM ACTIVE ON THE BUS:?
Yes → Go To 2
related symptom.
2 With the DRB select ENGINE, MISCELLANEOUS, SELECT MISC FUNCTION, All
and then CHECK VIN to read the Vehicle Identification Number in the Powertrain
Control Module.
Yes → Go To 3
169
AIRBAG
ORC, VEHICLE BODY STYLE UNKNOWN - ACTIVE — Continued

Repair
170
AIRBAG
Symptom List:
ORC, WARNING INDICATOR CIRCUIT OPEN - ACTIVE
ORC, WARNING INDICATOR CIRCUIT SHORT - ACTIVE
The title for the tests will be ORC, WARNING INDICATOR
CIRCUIT OPEN - ACTIVE.
ORC, WARNING INDICATOR CIRCUIT OPEN - ACTIVE

from the MIC containing the airbag warning lamp status Ok or Open. The MIC transmit
the message one time at ignition on, upon lamp state change,or in response to the ORC
lamp message.
Set Condition: The code is set if the lamp state is open for 2 consecutive messages or 2
seconds.
ORC, WARNING INDICATOR CIRCUIT SHORT - ACTIVE

from the MIC containing the airbag warning lamp status Ok or Shorted. The MIC transmit
the message one time at ignition on and upon lamp state change.
Set Condition: If the lamp state is Shorted for 2 consecutive messages the code will be set.
POSSIBLE CAUSES
WARNING INDICATOR
ORC, WARNING INDICATOR

Yes → Go To 2
OPEN.
171
AIRBAG
ORC, WARNING INDICATOR CIRCUIT OPEN - ACTIVE — Continued

2 With the DRB select PASSIVE RESTRAINTS, AIRBAG and MONITOR DISPLAY. All
Using the DRB, read the WARNING LAMP MONITOR screen.
Select the LAMP STATUS displayed on the DRB monitors screen.
Does the DRB show the LAMP STATUS: OK?
YES
Go To 3
NO
Replace Instrument Cluster circuit board.
Repair
172
AIRBAG
Symptom List:
RIGHT SIACM ACCELEROMETER 1 - ACTIVE
RIGHT SIACM ACCELEROMETER 1 - STORED
RIGHT SIACM INTERNAL 1 - ACTIVE
RIGHT SIACM INTERNAL 1 - STORED
RIGHT SIACM OUTPUT DRIVER 1 - ACTIVE
RIGHT SIACM OUTPUT DRIVER 1 - STORED
RIGHT SIACM, LOSS OF IGNITION RUN-START - ACTIVE
RIGHT SIACM, NO PCI TRANSMISSION - ACTIVE
The title for the tests will be RIGHT SIACM ACCELEROME-
TER 1 - ACTIVE.

When Monitored: When the ignition on, the Right SIACM on board diagnostics contin-
uously performs internal circuit tests.
Set Condition: This DTC will set if the Right SIACM identifies an out of range internal
circuit

circuit

circuit.

circuit.
173
AIRBAG
RIGHT SIACM ACCELEROMETER 1 - ACTIVE — Continued
RIGHT SIACM INTERNAL 1 - ACTIVE

circuit.
RIGHT SIACM INTERNAL 1 - STORED

circuit.
RIGHT SIACM OUTPUT DRIVER 1 - ACTIVE

circuit.
RIGHT SIACM OUTPUT DRIVER 1 - STORED

circuit.
RIGHT SIACM, LOSS OF IGNITION RUN-START - ACTIVE

When Monitored: With the ignition in the run or start position the Right SIACM
monitors the SIACM Run-Start Driver circuit for proper system voltage. This is an active
trouble code only.
Set Condition: If the voltage on the SIACM Run-Start Driver circuit is below 4.0 volts,
the code will set.
RIGHT SIACM, NO PCI TRANSMISSION - ACTIVE

When Monitored: With the ignition in the On position and the Right SIACM transmitting
Set Condition: The code will set if the Right SIACM cannot detect the Right SIACM
174
AIRBAG
RIGHT SIACM ACCELEROMETER 1 - ACTIVE — Continued
POSSIBLE CAUSES
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE, ACTIVE/STORED CODE

Repair
Replace the Right Side Impact Airbag Control Module in accor-
dance with Service information. WARNING: Make sure the bat-
tery is disconnected and wait 2 minutes before proceeding. Erase
DTCs in all modules.

175
AIRBAG
Symptom:
RIGHT SIACM, NO PCM MESSAGE - ACTIVE
POSSIBLE CAUSES
RSIACM, NO PCM MESSAGE

With the DRBIIIt, select BODY, BODY COMPUTER, and PCM MONITOR.
With the DRBIIIt, read the PCM MONITOR.
Does the DRB show PCM ACTIVE ON THE BUS?
Yes → Go To 2
No → Refer to category 9 COMMUNICATION CATEGORY9 and select
the related symptom.
Repair
dance with Service Instructions. WARNING: make sure the bat-
tery is disconnected and wait 2 minutes before proceeding.
176
AIRBAG
Symptom:
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE

When Monitored: With the ignition is On, the Right SIACM monitors the resistance of
Set Condition: The Right SIACM has detected an open circuit or high resistance on the
POSSIBLE CAUSES
RIGHT SEAT AIRBAG CIRCUIT OPEN
RIGHT SEAT SQUIB LINE 1 CIRCUIT OPEN
RIGHT SEAT SQUIB LINE 2 CIRCUIT OPEN
RISACM, RIGHT SEAT SQUIB CIRCUIT OPEN

WARNING: DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG
FACE DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL INTO
THE AIR IF ACCIDENTALLY DEPLOYED, AND COULD RESULT IN SERI-
OUS OR FATAL INJURY.
Remove the seat back cover and partially remove the material to gain access to the
Seat Airbag connector.
Disconnect the Right Seat Airbag connector located inside the right seat.
Connect the SRS Load Tool 8443 Passenger cable, and appropriate jumper to the
Right Seat Airbag connector.
With the DRBIIIt, read the active Right SIACM DTC’s.
Does the DRBIIIt display RIGHT SEAT SQUIB CIRCUIT OPEN?
Yes → Go To 2
No → Replace Right Seat Airbag.

177
AIRBAG
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE — Continued

Disconnect the Right Seat Airbag Module Squib connector located inside the right
seat.
Disconnect the Right Side Impact Airbag Control Module connector.
Connect the SRS Load Tool 8443 SIACM adaptor to the Right Side Impact Airbag
Measure the resistance of the Right Seat Squib Line 1 circuit between the Right Seat
Airbag connector and 8443 SIACM adaptor.
Yes → Go To 3
No → Repair open or high resistance in the Right Seat Squib Line 1
circuit.

3 WARNING: Turn Ignition Off, Disconnect the Battery and wait 2 minutes All
before proceeding.
Disconnect the Right Seat Airbag Module Squib connector located inside the right
seat.
Disconnect the Right Side Impact Airbag Control Module Connector.
Connector.
Measure the resistance of the Right Seat Squib Line 2 circuit between the Right
SIACM connector and the Right Seat Squib connector.
Yes → Repair open or high resistance in Right Seat Squib Line 2 circuit.
No → Go To 4

178
AIRBAG
RIGHT SIACM, SEAT SQUIB CIRCUIT OPEN - ACTIVE — Continued

Repair
179
AIRBAG
Symptom:
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE

Set Condition: The Right SIACM has detected that the Right Seat Squib circuits are
shorted together.
POSSIBLE CAUSES
RIGHT SEAT AIRBAG CIRCUIT SHORT
RIGHT SEAT SQUIB LINE 1 SHORT TO LINE 2
RSIACM, RIGHT SEAT SQUIB CIRCUITS SHORTED

Disconnect the Right Seat Airbag inline connector located between the seat back and
seat cushion.
Connect the SRS Load Tool 8443 Passenger cable and jumper harness to the Right
Seat Airbag inline connector.
Does the DRB show RIGHT SEAT SQUIB CIRCUIT SHORTED?
Yes → Go To 2


180
AIRBAG
RIGHT SIACM, SEAT SQUIB CIRCUIT SHORT - ACTIVE — Continued

2 WARNING: MAKE SURE THE BATTERY IS DISCONNECTED, THEN WAIT All
seat cushion.
Disconnect the Right Side Impact Airbag Control Module connector
Measure the resistance of the Right Seat Squib Line 1 and line 2 circuit at the Right
Side Impact Airbag Control Module connector.
Yes → Repair Right Seat Squib Line 1 short to Right Seat Squib Line 2.
No → Go To 3
Repair
Replace the Right Side Impact Airbag Control Module RSIACM in
accordance with the Service information. WARNING: Make sure
the battery is disconnected and wait 2 minutes before proceeding.
181
AIRBAG
Symptom:
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE

When Monitored: When the ignition is on, the Right SIACM monitors the voltage of the
Set Condition: The Right SIACM has detected high voltage on the Right Seat Squib Line
circuits.
POSSIBLE CAUSES
RIGHT SEAT AIRBAG CIRCUIT SHORT TO BATTERY
RIGHT SEAT SQUIB LINE 1 SHORT TO BATTERY
RIGHT SEAT SQUIB LINE 2 SHORT TO BATTERY
RSIACM, RIGHT SEAT SQUIB CIRCUIT SHORT TO BATTERY

seat cushion.
Connect the SRS Load Tool 8443 Passenger cable and jumper harness to the Right
With the DRBIIIt, read the active Side Airbag DTCs.
Does the DRB show RIGHT SEAT SQUIB SHORT TO BATTERY?
Yes → Go To 2

182
AIRBAG
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE — Continued

seat cushion.
Measure the voltage on the Right Seat Squib Line 1 at the Right Side Impact Airbag
Yes → Repair Right Seat Squib Line 1 short to battery.

No → Go To 3

seat cushion.
Measure the voltage on the Right Seat Squib Line 2 circuit at the Right Side Impact
Yes → Repair Right Seat Squib Line 2 short to battery.
No → Go To 4
183
AIRBAG
RIGHT SIACM, SEAT SQUIB SHORT TO BATTERY - ACTIVE — Continued

Repair
184
AIRBAG
Symptom:
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE

Set Condition: The Right SIACM has detected a short to ground in the Right Seat Squib
circuits.
POSSIBLE CAUSES
RIGHT SEAT AIRBAG CIRCUIT SHORT TO GROUND
RIGHT SEAT SQUIB LINE 1 SHORT TO GROUND
RIGHT SEAT SQUIB LINE 2 SHORT TO GROUND
RSIACM, RIGHT SEAT SQUIB CIRCUIT SHORT TO GROUND

seat cushion.
NOTE: Check connectors - Clean / repair as necessary. .
Connect the Airbag System Load Tool 8443 Passenger cable and jumper harness to
the Right Seat Airbag connector.
With the DRBIIIt, read the active Right Side Airbag DTCs.
Does the DRB show RIGHT SEAT SQUIB SHORT TO GROUND?
Yes → Go To 2
No → Replace the Right Seat Airbag.

185
AIRBAG
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE — Continued

seat cushion.
Measure the resistance of the Right Seat Squib Line 1 circuit between the Right
SIACM connector and ground.
Is the resistance below 5.0 Ohms on the Right Seat Squib Line 1 circuit ?
Yes → Repair Right Seat Squib Line 1 for a short to ground.

No → Go To 3
seat cushion.
Disconnect the Right Side Impact Airbag Control Module connector
Measure the resistance of the Right Seat Squib Line 2 circuit between the Right Side
Impact Airbag Control Module and ground.
Is the resistance below 5.0 Ohms on Right Seat Squib Line 2 circuit ?

No → Go To 4

186
AIRBAG
RIGHT SIACM, SEAT SQUIB SHORT TO GROUND - ACTIVE — Continued

Repair
187
AIRBAG
Symptom:
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES
POSSIBLE CAUSES
AIRBAG INDICATOR ON WITHOUT TROUBLE CODES
INSTRUMENT CLUSTER PROBLEMS

Make sure that all active DTCS have been repaired before pre forming this
procedure.
With the DRBIII select PASSIVE RESTRAINTS, AIRBAG, MONITOR DISPLAY,
WARNING LAMP STATUS and read the WARNING LAMP STATUS.
Does the DRB show LAMP REQ BY ACM: ON?
Yes → Replace the Occupant Restraint Controller in accordance with
Service Instructions. WARNING: make sure the battery is dis-
connected and wait 2 minutes before proceeding.
No → Refer to INSTRUMENT CLUSTER CATEGORY symptom list for
problems related to Instrument Cluster.
188
AUDIO
Symptom:
ALL OUTPUTS SHORTED
ALL OUTPUTS SHORTED

When Monitored: Ignition in RUN and IOD fuse installed.
Set Condition: The radio has sensed a short on the output for more than 10 seconds.
POSSIBLE CAUSES
DETERMINE FAULT
FRONT SHORTED SPEAKER
REAR SHORTED SPEAKER
(+) CIRCUIT SHORTED TO GROUND
(-) CIRCUIT SHORTED TO GROUND
SPEAKER (+) & (-) CIRCUITS SHORTED TOGETHER
SPEAKER SECTION OF RADIO

Turn the Radio on.
With the DRBIIIt, erase the audio DTC’s.
Cycle the ignition switch from off to on and wait 10 seconds.
With the DRBIIIt, read the audio DTC’s.
Does the DRBIIIt display ALL OUTPUTS SHORTED?
Yes → Go To 2
No → Refer to the wiring diagrams located in the service information to
help isolate a possible intermittent short.
189
AUDIO
ALL OUTPUTS SHORTED — Continued

2 Turn the ignition off. All
NOTE: Perform this procedure after disconnecting each front speaker
connector.
Disconnect each front speaker harness connector one at a time.
Turn the radio on.
With the DRBIIIt, erase the audio DTCs.
With the DRBIIIt, read DTC’s.
Does the DRBIIIt display ALL OUTPUTS SHORTED with all the front speakers
disconnected?
Yes → Go To 3
No → Replace the Speaker that when disconnected the DTC did not
reset. Note: On the premium system, check the I/P speaker
circuits between the front door speaker and the I/P speaker for a
short to ground or shorted together condition before replacing
speaker.

NOTE: Perform this procedure after disconnecting each rear speaker
connector.
Disconnect each rear speaker harness connector one at a time.
Turn the radio on.
Does the DRBIIIt display ALL OUTPUTS SHORTED with all the rear speakers
disconnected?
Yes → Go To 4
No → Replace Speaker that when disconnected the DTC did not reset.
Note: On the premium system, check the rear speaker ckts
between the rear door speaker and the rear pillar speaker for a
short to ground or shorted together condition before replacing
speaker.

Disconnect each front and rear speaker harness connector.
Disconnect the Radio C1 and C2 harness connectors.
Measure the resistance between ground and each speaker (+) circuit.
Is the resistance below 1000.0 (1K) ohms?
Yes → Repair the speaker (+) circuit for a short to ground.

No → Go To 5
190
AUDIO
ALL OUTPUTS SHORTED — Continued

Measure the resistance between ground and each speaker (-) circuit.
Yes → Repair the speaker (-) circuit for a short to ground.
No → Go To 6

Measure the resistance between each speaker (+) circuit and each speaker (-) circuit.
Is the resistance below 1000.0 (1K) ohms for any of the measurements?
Yes → Repair the speaker circuits shorted together.

No → Go To 7
7 If there are no possible causes remaining, view repair. All

Repair
Replace the Radio.
191
AUDIO
Symptom List:
AM SECTION
CASS ERROR
CASSETTE COMMUNICATION FAULT
CASSETTE EJECT FAILURE
CASSETTE LOADING FAILURE
CASSETTE TAPE TENSION HIGH
CASSETTE TAPE TENSION LOW
CD ERROR
CD MECHANICAL FAILURE
FM SECTION
MICRO OUTPUT FAILURE
RADIO ERROR
*AM/FM SWITCH INOPERATIVE
*ANY STATION PRESET SWITCH INOPERATIVE
*BALANCE INOPERATIVE
*CD EJECT SWITCH INOPERATIVE
*EQUALIZER INOPERATIVE
*FADER INOPERATIVE
*FF/RW SWITCH INOPERATIVE
*HOUR/MINUTE SWITCHES INOPERATIVE
*PAUSE/PLAY SWITCH INOPERATIVE
*PWR SWITCH INOPERATIVE
*SCAN SWITCH INOPERATIVE
*SEEK SWITCH INOPERATIVE
*SET SWITCH INOPERATIVE
*TAPE EJECT SWITCH INOPERATIVE
*TIME SWITCH INOPERATIVE
*TUNE SWITCH INOPERATIVE
The title for the tests will be AM SECTION.
AM SECTION
When Monitored: Continuously with the ignition and radio turned on.
Set Condition: The code will set if the radio detects a AM Section failure.
CASS ERROR
Set Condition: The code will set if the radio detects a internal cassette failure.
192
AUDIO
AM SECTION — Continued
CASSETTE COMMUNICATION FAULT

Set Condition: The code will set if the radio detects a cassette com failure.
CASSETTE EJECT FAILURE

Set Condition: The code will set if the radio detects a cassette eject failure.
CASSETTE LOADING FAILURE

Set Condition: The code will set if the radio detects a cassette loading failure.
CASSETTE TAPE TENSION HIGH

CASSETTE TAPE TENSION LOW

CD ERROR
Set Condition: The code will set if the radio detects a internal CD failure.
CD MECHANICAL FAILURE
When Monitored: Continuously with the ignition and CD player turned on.
Set Condition: The code will set if the radio detects a CD mechanical failure.
FM SECTION
Set Condition: The code will set if the radio detects a FM Section failure.
RADIO ERROR
Set Condition: The code will set if the radio detects a internal radio failure.
193
AUDIO
AM SECTION — Continued
POSSIBLE CAUSES
INTERNAL FAILURE

1 NOTE: If a DTC is set, erase the DTC and attempt to reset the DTC. If DTC All
resets, follow this test.
This is an internal radio failure.
View repair
Repair
Replace the Radio.
194
AUDIO
Symptom:
CD CHANGER MECHANICAL FAILURE
CD CHANGER MECHANICAL FAILURE

When Monitored: Continuously with the ignition and CD Changer turned on.
Set Condition: The code will set if the CD Changer detects a mechanical failure.
POSSIBLE CAUSES
INTERNAL FAILURE

1 This is an internal CD Changer failure. All
View repair
Repair
Replace the CD Changer.
195
AUDIO
Symptom List:
CD CHANGER PLAY FAILURE
CD CHANGER READ FAILURE
IMPROPER DISK IN CD CHANGER
The title for the tests will be CD CHANGER PLAY FAILURE.
CD CHANGER PLAY FAILURE

Set Condition: If the CD is scratched, dirty, so that the head cannot play the disk, the
code will set.
CD CHANGER READ FAILURE

Set Condition: The code will set if a CD that is not formatted as a music CD is installed
in the CD Changer.
IMPROPER DISK IN CD CHANGER

in the CD Changer.
POSSIBLE CAUSES
CD CHANGER PLAY OR READ FAILURE

1 Replace the problem CD with a good, clean, unscratched, music CD. All
Turn the radio on and select the good CD.
Does the DRBIIIt display CD CHANGER PLAY FAILURE, READ FAILURE, or
IMPROPER DISK IN CD CHANGER?
Yes → Replace the CD Changer.

196
AUDIO
Symptom:
CD CHANGER POWER SUPPLY TOO HIGH

Set Condition: The code will set if the radio detects voltage above 16.0 volts for 5 seconds.
POSSIBLE CAUSES
POWER SUPPLY OF CD CHANGER

Disconnect the CD Changer harness connector.
Start the engine.
Measure the voltage of the Ignition Switch Output circuit.
Yes → Repair the charging system as necessary.
No → Replace the CD Changer.

197
AUDIO
Symptom List:
CD CHANGER TEMPERATURE HIGH
CD CHANGER TEMPERATURE LOW
The title for the tests will be CD CHANGER TEMPERATURE
HIGH.
CD CHANGER TEMPERATURE HIGH

Set Condition: The code will set if the temperature inside the CD Changer is above +65°
C (+145° F).
CD CHANGER TEMPERATURE LOW

Set Condition: The code will set if the temperature inside the CD Changer is below -23°
C (-10° F).
POSSIBLE CAUSES
LOW OR HIGH TEMPERATURE FAILURE

1 With the DRBIIIt, erase the audio DTC’s. All
Start the engine and allow the engine to reach normal operating temperature.
If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors
and open the doors to allow the inside temperature to stabilize.
The CD Changer will operate between -23° C and 65° C (-10° F and +145° F).
Does the DRBIIIt display CD CHANGER TEMPERATURE LOW or CD CHANGER
TEMPERATURE HIGH?
Yes → Replace the CD Changer.

198
AUDIO
Symptom List:
CD PLAY FAILURE
CD READ FAILURE
IMPROPER DISK IN CD
The title for the tests will be CD PLAY FAILURE.
CD PLAY FAILURE
When Monitored: Continuously with the ignition and the radio CD player turned on.
Set Condition: If the CD is scratched, dirty, so that the head cannot play the disk, the
code will set.
CD READ FAILURE
in the radio CD player.
IMPROPER DISK IN CD
in the radio CD player.
POSSIBLE CAUSES
CD PLAY, READ OR IMPROPER DISK FAILURE

1 Replace the problem CD with a good, clean, unscratched, music CD. All
Turn the radio CD player on.
Does the DRBIIIt display CD PLAY FAILURE, CD READ FAILURE, or IMPROPER
DISK IN CD?
Yes → Replace the Radio.

199
AUDIO
Symptom List:
CD TEMPERATURE HIGH
CD TEMPERATURE LOW
The title for the tests will be CD TEMPERATURE HIGH.
CD TEMPERATURE HIGH
Set Condition: The code will set if the temperature inside the radio CD player is above
+65° C (+145° F).
CD TEMPERATURE LOW
Set Condition: The code will set if the temperature inside the radio CD player is below
-23° C (-10° F).
POSSIBLE CAUSES
LOW OR HIGH TEMPERATURE FAILURE

1 With the DRBIIIt, erase the audio DTC’s. All
Start the engine and allow the engine to reach normal operating temperature.
If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors
and open the doors to allow the inside temperature to stabilize.
The radio CD player will operate between -23° C and 65° C (-10° F and +145° F).
Does the DRBIIIt display CD TEMPERATURE LOW or CD TEMPERATURE
HIGH?
200
AUDIO
Symptom:
FRONT OUTPUT SHORT
FRONT OUTPUT SHORT

Set Condition: The radio has sensed a short on the front output for more than 10 seconds.
POSSIBLE CAUSES
DETERMINE FAULT
LEFT I/P SPEAKER
LEFT FRONT DOOR SPEAKER
RIGHT I/P SPEAKER
RIGHT FRONT DOOR SPEAKER

Turn the Radio on.
Does the DRBIIIt display FRONT OUTPUT SHORT?
Yes → Go To 2


Disconnect the Left I/P Speaker harness connector.
Turn the radio on.
Yes → Go To 3
No → Replace the Left I/P Speaker.

201
AUDIO
FRONT OUTPUT SHORT — Continued

Disconnect the Left Front Door Speaker harness connector.
Turn the radio on.
Yes → Go To 4
No → Replace the Left Front Door Speaker. Note: On the premium
system, check the I/P speaker circuits between the LF door
speaker and the Left I/P speaker for a short to ground or shorted
together condition before replacing speaker.

Disconnect the Right I/P Speaker harness connector.
Turn the radio on.
Yes → Go To 5
No → Replace the Right I/P Speaker.

Disconnect the Right Front Door Speaker harness connector.
Turn the radio on.
Yes → Go To 6
No → Replace the Right Front Door Speaker. Note: On the premium

system, check the I/P speaker circuits between the RF door
speaker and the Right I/P speaker for a short to ground or shorted

Disconnect the Radio C2 harness connector.
Measure the resistance between ground and each front speaker (+) circuit.
Yes → Repair the front speaker (+) circuit for a short to ground.
No → Go To 7
202
AUDIO
FRONT OUTPUT SHORT — Continued

Measure the resistance between ground and each front speaker (-) circuit.
Yes → Repair the front speaker (-) circuit for a short to ground.
No → Go To 8

Measure the resistance between each front speaker (+) circuit and each front speaker
(-) circuit.
Yes → Repair the front speaker circuits shorted together.

No → Go To 9

Repair
Replace the Radio.
203
AUDIO
Symptom:
LEFT OUTPUT SHORT
LEFT OUTPUT SHORT

Set Condition: The radio has sensed a short on the left output for more than 10 seconds.
POSSIBLE CAUSES
DETERMINE FAULT
LEFT I/P SPEAKER
LEFT FRONT DOOR SPEAKER
LEFT REAR PILLAR SPEAKER
LEFT REAR SPEAKER

Turn the Radio on.
Does the DRBIIIt display LEFT OUTPUT SHORT?
Yes → Go To 2


Turn the radio on.
Yes → Go To 3
No → Replace the Left I/P Speaker.

204
AUDIO
LEFT OUTPUT SHORT — Continued

Turn the radio on.
Yes → Go To 4
No → Replace the Left Front Door Speaker. Note: On the premium
system, check the I/P speaker circuits between the LF door
speaker and the Left I/P speaker for a short to ground or shorted
4 NOTE: If vehicle is not equipped with this speaker, answer Yes to the All
question.
Disconnect the Left Rear Pillar Speaker harness connector.
Turn the radio on.
Yes → Go To 5
No → Replace the Left Rear Pillar Speaker.

Disconnect the Left Rear Speaker harness connector.
Turn the radio on.
Yes → Go To 6
No → Replace the Left Rear Speaker. Note: On the premium system,

check the pillar speaker circuits between the LR speaker and the
left rear pillar speaker for a short to ground or shorted together
condition before replacing speaker.
205
AUDIO
LEFT OUTPUT SHORT — Continued

Disconnect the Left Rear Pillar Speaker harness connector (If Equipped).
Measure the resistance between ground and each left speaker (+) circuit.
Yes → Repair the left speaker (+) circuit for a short to ground.
No → Go To 7

Disconnect the Radio C1 and C2 harness connector.
Measure the resistance between ground and each left speaker (-) circuit.
Yes → Repair the left speaker (-) circuit for a short to ground.
No → Go To 8

Measure the resistance between each left speaker (+) circuit and each left speaker (-)
circuit.
Yes → Repair the left speaker circuits shorted together.
No → Go To 9
Repair
Replace the Radio.
206
AUDIO
Symptom List:
NBS OUTPUT 1 OPEN
NBS OUTPUT 2 OPEN
The title for the tests will be NBS OUTPUT 1 OPEN.
NBS OUTPUT 1 OPEN

When Monitored: Continuously.
Set Condition: If the FCM detects no voltage present on the NBS relay control circuit.
NBS OUTPUT 2 OPEN

Set Condition: If the FCM detects no voltage present on the NBS relay control circuit.
POSSIBLE CAUSES
CHECK DTCS
FUSED B+ CIRCUIT OPEN
NBS RELAY OPEN
NBS RELAY CONTROL CIRCUIT OPEN
FRONT CONTROL MODULE

NOTE: If neither DTC will reset or is active, refer to the wiring diagrams
located in the service information to help isolate a possible intermittent
condition.
With the DRB, read the FCM DTC’s.
Are both the NBS Output 1 Open and the NBS Output 2 Open DTC’s set?
Yes → Go To 2
No → Replace the Front Control Module in accordance with the Service

Information.
2 Remove the NBS Relay from the IPM. All

Using a 12-volt test light connected to ground, probe cavity 86 of the NBS Relay
connector.
Is the test light illuminated?
Yes → Go To 3
No → Check IPM Fuse #14 for an open. If OK, replace the Intelligent
Power Module (IPM).
207
AUDIO
NBS OUTPUT 1 OPEN — Continued

Install a substitute relay in place of the NBS Relay.
With the DRB, erase DTCs.
Turn the Radio on.
With the DRB, read DTCs.
Did these DTCs reset?
Yes → Go To 4
No → Replace the original NBS Relay.


Remove the Front Control Module from the IPM.
Remove the NBS Relay from the IPM.
Measure the resistance of the NBS Relay Control circuit between the FCM connector
cavity 11 and the NBS Relay connector cavity 85.
Yes → Replace the Front Control Module in accordance with the Service
Information.
No → Replace the Intelligent Power Module (IPM).
208
AUDIO
Symptom List:
NBS OUTPUT 1 SHORT TO BATT
The title for the tests will be NBS OUTPUT 1 SHORT TO
BATT.

When Monitored: With the ignition on and the Radio on.
Set Condition: The FCM detects excessive current when attempting to close the NBS
relay.

When Monitored: With the ignition on and the Radio on.
Set Condition: The FCM detects excessive current when attempting to close the NBS
relay.
POSSIBLE CAUSES
CHECK DTCS
NBS RELAY SHORTED
NBS RELAY CONTROL CIRCUIT SHORTED TO BATTERY

Turn the Radio on.
condition.
Are both the NBS Output 1 Short to Batt and the NBS Output 2 Short to Batt DTC’s
set?
Yes → Go To 2

Information.
209
AUDIO
NBS OUTPUT 1 SHORT TO BATT — Continued

Install a substitute relay in place of the NBS Relay.
Turn the Radio on.
Yes → Go To 3
No → Replace the original NBS Relay.


Remove the NBS Relay from the IPM.
Using a 12-volt test light connected to ground, probe the NBS Relay connector cavity
85.
Yes → Replace the Intelligent Power Module (IPM).

Information.
210
AUDIO
Symptom:
NO ANTENNA CONNECTION
POSSIBLE CAUSES
BAD ANTENNA CONNECTION
TEST ANTENNA
RADIO

Disconnect the Radio Antenna connector.
Inspect the Radio Antenna connection.
Was the Antenna connection clean and tight?
Yes → Go To 2
No → Repair Antenna connection as needed.
2 Refer to the Audio System in the service information and test the Antenna in All
accordance with the service procedure.
Is the Antenna ok?
Yes → Go To 3
No → Repair or replace the Antenna assembly as necessary.
3 Note: Reconnect all previously disconnected components. All

Turn the ignition and Radio on.
With the DRBIIIt, erase the audio DTC’s, put the radio in scan mode and wait
approximately 2 minutes before proceeding.
Did this DTC reset?

211
AUDIO
Symptom List:
NO VIN RECEIVED
VIN MISMATCH
The title for the tests will be NO VIN RECEIVED.
NO VIN RECEIVED
When Monitored: With the ignition and the Radio on.
Set Condition: The Radio does not receive a VIN number.
VIN MISMATCH
When Monitored: With the ignition and the Radio on.
Set Condition: The Radio does not receive the correct VIN number.
POSSIBLE CAUSES
NO VIN RECEIVED/VIN MISMATCH
POWERTRAIN CONTROL MODULE

With the DRB, enter Engine, Miscellaneous then Check VIN.
Compare the VIN that is programmed into the PCM with the VIN plate on the
vehicle.
Does the PCM receive a VIN and do the VIN(s) match?
Yes → Erase the DTC. If DTC resets, replace the Radio.

No → Replace and program the Powertrain Control Module in accor-

dance with the Service Information.
212
AUDIO
Symptom:
POWER SUPPLY TOO HIGH

When Monitored: Continuously with the ignition and Radio turned on.
Set Condition: The code will set if the radio detects voltage above 16.0 volts for 5 seconds.
POSSIBLE CAUSES
POWER SUPPLY OF RADIO

Start the engine.
Measure the voltage of the Fused B+ circuit.
Yes → Repair the charging system as necessary.
No → Replace the Radio.

213
AUDIO
Symptom:
REAR OUTPUT SHORT
REAR OUTPUT SHORT

Set Condition: The radio has sensed a short on the rear output for more than 10 seconds.
POSSIBLE CAUSES
DETERMINE FAULT
LEFT REAR PILLAR SPEAKER
LEFT REAR SPEAKER
RIGHT REAR PILLAR SPEAKER
RIGHT REAR SPEAKER

Turn the Radio on.
Does the DRBIIIt display REAR OUTPUT SHORT?
Yes → Go To 2

question.
Disconnect the Left Rear Pillar Speaker harness connector.
Turn the radio on.
Yes → Go To 3
No → Replace the Left Rear Pillar Speaker.
214
AUDIO
REAR OUTPUT SHORT — Continued

Turn the radio on.
Yes → Go To 4
No → Replace the Left Rear Speaker. Note: On the premium system,
check the pillar speaker circuits between the LR speaker and the
left rear pillar speaker for a short to ground or shorted together
question.
Disconnect the Right Rear Pillar Speaker harness connector.
Turn the radio on.
Yes → Go To 5
No → Replace the Right Rear Pillar Speaker.

Disconnect the Right Rear Speaker harness connector.
Turn the radio on.
Yes → Go To 6
No → Replace the Right Rear Speaker. Note: On the premium system,

check the pillar speaker circuits between the RR speaker and the
right rear pillar speaker for a short to ground or shorted together
215
AUDIO
REAR OUTPUT SHORT — Continued

Disconnect the Right Rear Pillar Speaker harness connector (If Equipped).
Measure the resistance between ground and each rear speaker (+) circuit.
Yes → Repair the rear speaker (+) circuit for a short to ground.
No → Go To 7

Measure the resistance between ground and each rear speaker (-) circuit.
Yes → Repair the rear speaker (-) circuit for a short to ground.
No → Go To 8

Measure the resistance between each rear speaker (+) circuit and each rear speaker
(-) circuit.
Yes → Repair the rear speaker circuits shorted together.
No → Go To 9
Repair
Replace the Radio.
216
AUDIO
Symptom:
REMOTE RADIO SWITCH OPEN OR *REMOTE RADIO CONTROLS
INOPERATIVE
REMOTE RADIO SWITCH OPEN OR *REMOTE RADIO CONTROLS INOPERA-

TIVE
When Monitored: With the ignition on.
Set Condition: The BCM senses voltage above 4.90 volts on its radio control mux input for
longer than 10 seconds.
POSSIBLE CAUSES
INTERMITTENT CONDITION
OPEN CLOCKSPRING
OPEN RADIO CONTROL MUX CIRCUIT
OPEN RADIO CONTROL MUX RETURN CIRCUIT
BODY CONTROL MODULE

1 With the DRB, erase DTC’s. All
Cycle the ignition switch from off to on and wait approximately 1 minute.
With the DRB, read DTC’s.
Did this DTC reset?
Yes → Go To 2

help isolate a possible intermittent open.

Disconnect the Clockspring C1 harness connector.
Connect a jumper wire between the Radio Control MUX circuit and the Radio Control
MUX Return circuit at the Clockspring C1 connector.
With the DRB, enter Body Computer then Sensors and monitor the Radio Control SW
voltage.
Is the voltage approximately 0.0 volts?
Yes → Check the circuits between the clockspring connector and the
splice for an open. If ok, replace the Clockspring.
No → Go To 3
217
AUDIO
REMOTE RADIO SWITCH OPEN OR *REMOTE RADIO CONTROLS IN-

OPERATIVE — Continued
Disconnect the BCM C5 harness connector.
Measure the resistance of the Radio Control MUX circuit between the BCM C5
connector and the Clockspring C1 connector.
Yes → Go To 4
No → Repair the Radio Control MUX circuit for an open between the
clockspring and the BCM.

Measure the resistance of the Radio Control MUX Return circuit between the BCM
C4 connector and the Clockspring C1 connector.
Yes → Go To 5
No → Repair the Radio Control MUX Return circuit for an open

between the clockspring and the BCM.

Repair
Replace the Body Control Module.
218
AUDIO
Symptom:
REMOTE RADIO SWITCH STUCK
REMOTE RADIO SWITCH STUCK

Set Condition: The code will set if the BCM detects a stuck switch or a short to ground on
the Radio Control MUX circuit for more than 10 seconds.
POSSIBLE CAUSES
LEFT REMOTE RADIO SWITCH SHORTED TO GROUND
RIGHT REMOTE RADIO SWITCH SHORTED TO GROUND
RADIO CONTROL MUX CIRCUIT SHORTED TO GROUND AT THE SWITCH
RADIO CONTROL MUX CIRCUIT SHORTED TO THE RETURN CIRCUIT AT THE SWITCH
CLOCKSPRING SHORTED TO GROUND
RADIO CONTROL MUX CIRCUIT SHORTED TO GROUND
RADIO CONTROL MUX CKT SHORTED TO THE RADIO CONTROL MUX RETURN CKT
BODY CONTROL MODULE

Did this DTC reset?
Yes → Go To 2

2 WARNING: Turn the ignition off, disconnect the battery and wait 2 minutes All
before proceeding.
CAUTION: Do not place an intact undeployed airbag module face down on
a hard surface, the airbag module will propel into the air if accidently
deployed.
Remove the Driver Airbag Module.
Disconnect the Left Remote Radio Switch harness connector.
Turn the ignition on, reconnect the battery.
voltage
Yes → Replace the Left Remote Radio Switch.
No → Go To 3
219
AUDIO
REMOTE RADIO SWITCH STUCK — Continued

3 WARNING: Turn the ignition off, disconnect the battery and wait 2 minutes All
before proceeding.
CAUTION: Do not place an intact undeployed airbag module face down on
a hard surface, the airbag module will propel into the air if accidently
deployed.
Remove the Driver Airbag Module.
Disconnect the Right Remote Radio Switch harness connector.
Turn the ignition on, reconnect the battery.
voltage
Yes → Replace the Right Remote Radio Switch.

No → Go To 4

voltage.
Yes → Go To 5
No → Go To 6

NOTE: Ensure both remote radio switches are disconnected.
Measure the resistance between ground and each Radio Control MUX circuit at the
clockspring C4 harness connector.
Yes → Repair the Radio Control MUX circuit for a short to ground
between the clockspring and the remote radio switches.
No → Repair the Radio Control MUX circuit for a short to the Radio
Control MUX Return circuit between the clockspring and the
remote radio switches.

voltage.
Yes → Replace the Clockspring.

No → Go To 7
220
AUDIO
REMOTE RADIO SWITCH STUCK — Continued

Measure the resistance between ground and the Radio Control MUX circuit.
Yes → Repair the Radio Control MUX circuit for a short to ground
between the clockspring and the BCM.
No → Go To 8

Disconnect the BCM C4 and C5 harness connectors.
Measure the resistance between the Radio Control MUX circuit and the Radio
Control MUX Return circuit.
Yes → Repair the Radio Control MUX circuit for a short to the Radio
Control MUX Return circuit between the clockspring and the
BCM.
No → Go To 9

Repair
221
AUDIO
Symptom:
RIGHT OUTPUT SHORT
RIGHT OUTPUT SHORT

Set Condition: The radio has sensed a short on the right output for more than 10 seconds.
POSSIBLE CAUSES
DETERMINE FAULT
RIGHT I/P SPEAKER
RIGHT FRONT DOOR SPEAKER
RIGHT REAR PILLAR SPEAKER
RIGHT REAR SPEAKER

Turn the Radio on.
Does the DRBIIIt display RIGHT OUTPUT SHORT?
Yes → Go To 2


Turn the radio on.
Yes → Go To 3
No → Replace the Right I/P Speaker.

222
AUDIO
RIGHT OUTPUT SHORT — Continued

Turn the radio on.
Yes → Go To 4
No → Replace the Right Front Door Speaker. Note: On the premium
system, check the I/P speaker circuits between the RF door
speaker and the Right I/P speaker for a short to ground or shorted
question.
Disconnect the Right Rear Pillar Speaker harness connector.
Turn the radio on.
Yes → Go To 5
No → Replace the Right Rear Pillar Speaker.

Turn the radio on.
Yes → Go To 6
No → Replace the Right Rear Speaker. Note: On the premium system,

check the pillar speaker circuits between the RR speaker and the
right rear pillar speaker for a short to ground or shorted together
223
AUDIO
RIGHT OUTPUT SHORT — Continued

Measure the resistance between ground and each right speaker (+) circuit.
Yes → Repair the right speaker (+) circuit for a short to ground.
No → Go To 7

Measure the resistance between ground and each right speaker (-) circuit.
Yes → Repair the right speaker (-) circuit for a short to ground.
No → Go To 8

Measure the resistance between each right speaker (+) circuit and each right speaker
(-) circuit.
Yes → Repair the right speaker circuits shorted together.
No → Go To 9
Repair
Replace the Radio.
224
Symptom List:
AC PRESSURE TOO HIGH (ACTIVE)
AC PRESSURE TOO LOW (ACTIVE)
The title for the tests will be AC PRESSURE TOO HIGH
(ACTIVE).
AC PRESSURE TOO HIGH (ACTIVE)

When Monitored: With the ignition on and the IOD fuse installed. Also monitored during
the Cooldown Test.
Set Condition: This DTC is set if the ATC reads the A/C Pressure Sensor value and it is
above 250 A/D counts.
AC PRESSURE TOO LOW (ACTIVE)

the Cooldown Test.
below 20 A/D counts.
POSSIBLE CAUSES
PCM/ECM DTC(S) PRESENT
ATC

With the DRBIIIt, read PCM/ECM DTCs.
Does the DRBIIIt display any PCM/ECM DTCs?
Yes → Refer to Powertrain Diagnostic information for the related symp-

tom(s).
With the DRBIIIt, reset the ATC after repair/replacement is
complete.
No → Replace the ATC.

complete.
225
Symptom List:
AC PRESSURE TOO HIGH (STORED)
AC PRESSURE TOO LOW (STORED)
DRIVER BLEND DOOR NOT RESPONDING (STORED)
DRIVER BLEND DOOR RANGE TOO LARGE (STORED)
DRIVER BLEND DOOR TRAVEL TOO SMALL (STORED)
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (STORED)
FRONT IR SENSOR CHANGE TOO LARGE (STORED)
FRONT IR SENSOR HIGH (STORED)
FRONT IR SENSOR LOW (STORED)
FRONT IR SENSOR NOT CALIBRATED (STORED)
FRONT KEYBOARD COMMUNICATION FAULT (STORED)
FRONT KEYBOARD FAULT (STORED)
FRONT MODE DOOR NOT RESPONDING (STORED)
FRONT MODE DOOR TRAVEL TOO LARGE (STORED)
FRONT MODE DOOR TRAVEL TOO SMALL (STORED)
PASS BLEND DOOR NOT RESPONDING (STORED)
PASS BLEND DOOR TRAVEL TOO LARGE (STORED)
PASS BLEND DOOR TRAVEL TOO SMALL (STORED)
PCI BUS SHORTED HIGH (STORED)
PCI BUS SHORTED LOW (STORED)
REAR BLEND DOOR NOT RESPONDING (STORED)
REAR BLEND DOOR RANGE TOO LARGE (STORED)
REAR BLEND DOOR TRAVEL TOO SMALL (STORED)
REAR FAN POT OPEN (STORED)
REAR FAN POT SHORTED (STORED)
REAR IR SENSOR HIGH (STORED)
REAR IR SENSOR LOW (STORED)
REAR IR SENSOR NOT CALIBRATED (STORED)
REAR KEYBOARD FAULT (STORED)
REAR MODE DOOR NOT RESPONDING (STORED)
REAR MODE DOOR TRAVEL TOO LARGE (STORED)
REAR MODE DOOR TRAVEL TOO SMALL (STORED)
REAR MODE POT OPEN (STORED)
REAR MODE POT SHORTED (STORED)
RECIRC DOOR NOT RESPONDING (STORED)
RECIRC DOOR TRAVEL TOO LARGE (STORED)
RECIRC DOOR TRAVEL TOO SMALL (STORED)
The title for the tests will be AC PRESSURE TOO HIGH
(STORED).
226
AC PRESSURE TOO HIGH (STORED) — Continued
AC PRESSURE TOO HIGH (STORED)

the Cooldown Test.
AC PRESSURE TOO LOW (STORED)

the Cooldown Test.
below 20 A/D counts.
DRIVER BLEND DOOR NOT RESPONDING (STORED)

When Monitored: With the ignition on and the IOD fuse installed.
Set Condition: This DTC is set if the ATC does not receive feedback pulses within 5
seconds of the drive voltage being applied.
DRIVER BLEND DOOR RANGE TOO LARGE (STORED)

Set Condition: This DTC is set when the ATC monitors the travel range during system
initialization and the measured range is greater than expected.
DRIVER BLEND DOOR TRAVEL TOO SMALL (STORED)

initialization and the measured range is less than expected.
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (STORED)

When Monitored: Every 8 seconds with the ignition on.
Set Condition: This condition is set if the ATC does not receive the intake air temperature
response message within 8 seconds.
FRONT IR SENSOR HIGH (STORED)

Set Condition: This DTC is set if the ATC reads the Front IR Sensor value and it is above
250 A/D counts.
FRONT IR SENSOR LOW (STORED)

Set Condition: This DTC is set if the ATC reads the Front IR Sensor value and it is below
5 A/D counts.
227
FRONT IR SENSOR NOT CALIBRATED (STORED)

Set Condition: This DTC is set if the ATC cannot read the IR sensor values or the IR
sensor values are not within a defined range of the HVAC air door motor counts.
FRONT MODE DOOR NOT RESPONDING (STORED)

FRONT MODE DOOR TRAVEL TOO LARGE (STORED)

FRONT MODE DOOR TRAVEL TOO SMALL (STORED)

PASS BLEND DOOR NOT RESPONDING (STORED)

PASS BLEND DOOR TRAVEL TOO LARGE (STORED)

PASS BLEND DOOR TRAVEL TOO SMALL (STORED)

PCI BUS SHORTED HIGH (STORED)

Set Condition: This DTC is set if the ATC detects a short to voltage on the PCI Bus circuit.
PCI BUS SHORTED LOW (STORED)

Set Condition: This DTC is set if the ATC detects a short to ground on the PCI Bus circuit.
228
REAR BLEND DOOR NOT RESPONDING (STORED)

REAR BLEND DOOR RANGE TOO LARGE (STORED)

REAR BLEND DOOR TRAVEL TOO SMALL (STORED)

REAR FAN POT OPEN (STORED)

Set Condition: This DTC is set if the ATC reads the rear blower switch value and it is
REAR FAN POT SHORTED (STORED)

Set Condition: This DTC is set if the ATC reads the rear fan switch value and it is below
5 A/D counts.
REAR IR SENSOR HIGH (STORED)

Set Condition: This DTC is set if the ATC reads the Rear IR Sensor value and it is above
250 A/D counts.
REAR IR SENSOR LOW (STORED)

Set Condition: This DTC is set if the ATC reads the Rear IR Sensor value and it is below
5 A/D counts.
REAR IR SENSOR NOT CALIBRATED (STORED)

229
REAR MODE DOOR NOT RESPONDING (STORED)

REAR MODE DOOR TRAVEL TOO LARGE (STORED)

REAR MODE DOOR TRAVEL TOO SMALL (STORED)

REAR MODE POT OPEN (STORED)

Set Condition: This DTC is set if the ATC reads the rear mode select switch value and it
is above 250 A/D counts.
REAR MODE POT SHORTED (STORED)

is below 5 A/D counts.
RECIRC DOOR NOT RESPONDING (STORED)

Set Condition: This DTC is set when the ATC does not receive feedback pulses within 5
RECIRC DOOR TRAVEL TOO LARGE (STORED)

RECIRC DOOR TRAVEL TOO SMALL (STORED)

230
POSSIBLE CAUSES
CHECK FOR ACTIVE ATC DTCS AND COOLDOWN TEST MESSAGES
STORED CODES TEST COMPLETE

1 Note: Active codes must be resolved before diagnosing stored codes. All
Anytime a code becomes active during this test, proceed to the conclusion question.
With the DRBIIIt, record and erase stored ATC DTC’s.
Cycle the ignition switch.
Start the engine.
Monitor the DRBIIIt for active ATC DTCs while performing the following test steps.
Press the ATC Power switch on.
Turn the Front Blower switch to the low position.
Turn the Rear Blower switch to the Auto position.
Set the Driver, Rear, and Pass temperature controls to 60.
Turn the Mode switch to the panel position.
Press the Recirculation mode switch on, wait 30 seconds and then press it off.
Press the A/C mode switch on, wait 30 seconds and then press it off.
Press the Rear Defogger switch on, wait 30 seconds and then press it off.
Set the Driver temperature control to the max heat setting, wait 30 seconds and then
set it to the max cool setting. Repeat this step for the Rear and Pass temperature
controls.
Turn the Mode switch to each position for 30 seconds and then turn it back to the
panel position.
Turn the Front Blower switch to each position and then turn it back to the low
position.
Press the Auto HI switch, wait 30 seconds, press the Auto LO switch, wait 30 seconds
and then turn the Front Blower switch to the low position.
Turn the Rear Blower switch to each position and then turn it to the Rear Control
position.
On the Rear ATC Control, turn the Blower switch to each position and then turn it
to the low position.
On the Rear ATC Control, set the Rear temperature control to the max heat setting,
wait 30 seconds and then set it to the max cool setting.
On the Rear ATC Control, turn the Mode switch to each position for 30 seconds.
With the DRBIIIt, perform the ATC Cool Down test.
With the DRBIIIt, reset the ATC.
Place the vehicle on a hoist, and raise the wheels off the floor.
WARNING: Be sure to keep hands and feet clear of rotating wheels. Keep
clear of the engine’s moving parts
Start engine. Place the transmission in drive. Brake off.
Does the DRBIIIt display any active ATC DTCs or Cooldown Test messages?
Yes → Return to the symptom list and choose the symptom(s)

231
Symptom:
COOLDOWN TEST FAILED
COOLDOWN TEST FAILED

When Monitored: When executing the Cooldown Test.
Set Condition: This DTC is set if the A/C system is unable to bring the evaporator
temperature down 6.7°C (20°F) within two minutes.
POSSIBLE CAUSES
OTHER COOLDOWN TEST MESSAGES PRESENT
ATC DTC(S) PRESENT
CHECK THE PCM/ECM FOR DTCS
A/C SYSTEM TESTING

1 NOTE: The work area ambient temperature must be above 10°C (50°F) to All
test A/C system operation.
Are any other messages displayed with the Cooldown Test Failed message?
Yes → Return to the symptom list and choose the symptom(s).
After the repair is complete, rerun the Cooldown Test.
No → Go To 2
With the DRBIIIt, read ATC DTCs.
Does the DRBIIIt display any ATC DTCs?

No → Go To 3
232
COOLDOWN TEST FAILED — Continued

With the DRBIIIt, check the PCM/ECM for DTCs.
Are any PCM/ECM DTCs present?
tom(s).
No → Refer to the Service Information for additional Cooldown Test
related diagnostic information and testing procedures.
233
Symptom:
DRIVER BLEND DOOR NOT RESPONDING (ACTIVE)
DRIVER BLEND DOOR NOT RESPONDING (ACTIVE)

POSSIBLE CAUSES
DRIVER BLEND DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
DRIVER BLEND DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
DRIVER BLEND DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
DRIVER BLEND DOOR DRIVER CIRCUIT (A) OPEN
DRIVER BLEND DOOR DRIVER CIRCUIT (B) OPEN
ATC
DRIVER BLEND DOOR ACTUATOR

Disconnect the Driver Blend Door Actuator harness connector.
Disconnect the ATC C1 harness connector.
Measure the resistance between ground and the Driver Blend Door Driver (A) circuit.
Is the resistance above 100k ohms?
Yes → Go To 2
No → Repair the Driver Blend Door Driver (A) circuit for a short to
ground.
complete.

Measure the resistance between ground and the Driver Blend Door Driver (B) circuit.
Yes → Go To 3
No → Repair the Driver Blend Door Driver (B) circuit for a short to
ground.
complete.
234
DRIVER BLEND DOOR NOT RESPONDING (ACTIVE) — Continued

Measure the resistance between the Driver Blend Door Driver (A) and (B) circuits.
Yes → Go To 4
No → Repair the Driver Blend Door Driver (A) and (B) circuits for a
short together.
complete.

Measure the resistance of the Driver Blend Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Driver Blend Door Driver (A) circuit for an open.
complete.

Measure the resistance of the Driver Blend Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Driver Blend Door Driver (B) circuit for an open.
complete.

Measure the resistance between the Driver Blend Door Driver (A) and (B) circuits.
Is the resistance between 26.0 and 46.0 ohms?
Yes → Replace the ATC.

complete.
No → Go To 7
Repair
Replace the Driver Blend Door Actuator.
complete.
235
Symptom:
DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE)
DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
CHECK THE ATC FOR DTCS
DRIVER BLEND DOOR LINKAGE
ATC

With the DRB, read the active ATC DTCs.
Is the DRIVER BLEND DOOR NOT RESPONDING DTC set?
Yes → Return to the symptom list and choose the symptom.
complete.
No → Go To 2

Remove the Driver Blend Door Actuator.
By hand, attempt to rotate the driver blend door motor in both directions.
Did the blend door actuator turn in either direction?
Yes → Replace the Driver Blend Door Actuator.

complete.
No → Go To 3
236
DRIVER BLEND DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Driver Blend Door Actuator. Rotate the blend door (door only). Note: This All
should rotate approximately 45 degrees from stop to stop.
Inspect the blend door linkage for excessive wear or missing linkage.
Were any mechanical problems found?
Yes → Repair or replace the driver blend door/linkage as necessary.

complete.

complete.
237
Symptom:
DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE)
DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC
OBSTRUCTED BLEND DOOR

Is the DRIVER BLEND DOOR NOT RESPONDING DTC set?
completed.
No → Go To 2

Connect a 12-volt Test Light between the Driver Blend Door Actuator harness
connector cavities.
While monitoring the test light, turn the driver blend control knob from lo to hi.
Note: Observe test light for approximately 30 seconds.
Does the test light start to flash and stay flashing?
Yes → Go To 3

completed.
238
DRIVER BLEND DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Driver Blend Door Actuator. Rotate the blend door (door only). Note: This All
Does the blend door move smoothly in both directions?
Yes → Replace the Driver Blend Door Actuator.

completed.
No → Repair or replace the driver blend door as necessary.

completed.
239
Symptom:
EEPROM CHECKSUM ERROR (ACTIVE)
EEPROM CHECKSUM ERROR (ACTIVE)

When Monitored: Ignition in RUN and IOD fuse installed after a battery disconnect.
Set Condition: This DTC is set if the calibrated check sum does not match the stored
value.
POSSIBLE CAUSES
ATC - EEPROM CHECKSUM ERROR

1 When this code is present, the ATC must be replaced. All
View repair.
Repair
Replace the ATC.
complete.
240
Symptom:
EVAP TEMP SENSOR OPEN
EVAP TEMP SENSOR OPEN

When Monitored: During the Cooldown Test.
Set Condition: This message is displayed if the ATC detects an abnormally high voltage
on the evaporator temperature sensor signal during the Cooldown Test.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
SENSOR GROUND CIRCUIT OPEN
ATC

Disconnect the in-line C202 harness connector.
Connect a jumper wire between the Evaporator Temperature Sensor Signal circuit
and the Sensor Ground circuit at the in-line C202 harness connector (HVAC side).
With the DRBIIIt in Sensor Display, read the Evaporator Temperature Sensor
voltage.
Does the DRBIIIt display: 0.0 volts?
Yes → Check the wiring harness between the in-line C202 harness
connector (plenum side) and the Evap Temp Sensor for an open.
Repair as necessary. If Ok, replace the Evaporator Temperature
Sensor.
complete.
No → Go To 2

Measure the resistance of the Evaporator Temperature Sensor Signal circuit between
the ATC C2 harness connector and the in-line C202 harness connector.
Yes → Go To 3
No → Repair the Evaporator Temperature Sensor Signal circuit be-
tween the ATC C2 harness connector and the in-line C202
harness connector (HVAC side) for an open.
complete.
241
EVAP TEMP SENSOR OPEN — Continued

Measure the resistance of the Sensor Ground circuit between the ATC C1 harness
connector and the in-line C202 harness connector.
complete.
No → Repair the Sensor Ground circuit between the ATC C2 harness
connector and the in-line C202 harness connector (HVAC side) for
an open.
complete.
242
Symptom:
EVAP TEMP SENSOR SHORTED
EVAP TEMP SENSOR SHORTED

When Monitored: During the Cooldown Test.
Set Condition: This message is displayed if the ATC detects an abnormally low voltage on
the evaporator temperature sensor signal during the Cooldown Test.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIR-
CUIT
ATC

voltage.
Does the DRBIIIt display: 5.0 volts or greater?
Yes → Check the Evap Temp Sensor Signal circuit between the in-line
C202 harness connector (plenum side) and the Evap Temp Sensor
for a short to ground. Repair as necessary. If Ok, replace the
Evaporator Temperature Sensor.
complete.
No → Go To 2

Measure the resistance between ground and the Evaporator Temperature Sensor
Signal circuit (HVAC side).
Yes → Go To 3

harness connector (HVAC side) for a short to ground.
complete.
243
EVAP TEMP SENSOR SHORTED — Continued

Measure the resistance between the Evaporator Temperature Sensor Signal circuit
and the Sensor Ground circuit (HVAC side).
complete.
harness connector (HVAC side) for a short to Sensor Ground.
complete.
244
Symptom List:
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (ACTIVE)
FRONT IR SENSOR CHANGE TOO LARGE (ACTIVE)
FRONT IR SENSOR HIGH (ACTIVE)
FRONT IR SENSOR LOW (ACTIVE)
The title for the tests will be FRONT IR SENSOR AND
CONTROL HEAD MISMATCH (ACTIVE).
FRONT IR SENSOR AND CONTROL HEAD MISMATCH (ACTIVE)

When Monitored: Every 8 seconds with the ignition on.
Set Condition: This condition is set if the ATC does not receive the intake air temperature
response message within 8 seconds.
FRONT IR SENSOR HIGH (ACTIVE)

Set Condition: This DTC is set if the ATC reads the Front IR Sensor value and it is above
250 A/D counts.
FRONT IR SENSOR LOW (ACTIVE)

Set Condition: This DTC is set if the ATC reads the Front IR Sensor value and it is below
5 A/D counts.
POSSIBLE CAUSES
ATC REMOTE SENSOR

1 This DTC indicates a fault in the ATC Remote Sensor. All
View repair.
Repair
Replace the ATC Remote Sensor.
complete.
245
Symptom List:
FRONT IR SENSOR NOT CALIBRATED (ACTIVE)
FRONT KEYBOARD FAULT (ACTIVE)
The title for the tests will be FRONT IR SENSOR NOT
CALIBRATED (ACTIVE).
FRONT IR SENSOR NOT CALIBRATED (ACTIVE)

POSSIBLE CAUSES
ATC - PROTECTED IGNITION CIRCUIT FAULT
KDB 2 CLOCK CIRCUIT SHORTED TO VOLTAGE
KDB 2 DATA CIRCUIT SHORTED TO GROUND
KDB 2 DATA CIRCUIT SHORTED TO VOLTAGE
PROTECTED IGNITION CIRCUIT OPEN
SENSOR RETURN CIRCUIT OPEN
KDB 2 CLOCK CIRCUIT SHORTED TO GROUND
KDB 2 DATA CIRCUIT OPEN
ATC - KDB 2 DATA CIRCUIT FAULT
ATC - SENSOR RETURN CIRCUIT FAULT
KDB 2 CLOCK CIRCUIT OPEN
ATC - KDB 2 CLOCK CIRCUIT FAULT
ATC REMOTE SENSOR

Disconnect the ATC Remote Sensor harness connector.
Measure the voltage of the Protected Ignition circuit.
Yes → Go To 2
No → Go To 16
246
FRONT IR SENSOR NOT CALIBRATED (ACTIVE) — Continued

Measure the voltage of the KDB 2 Data circuit.
Yes → Go To 3
No → Go To 13

Measure the voltage of the KDB 2 Data circuit.
Is the voltage above 1.0 volt?
Yes → Repair the KDB 2 Data circuit for a short to voltage.

complete.
No → Go To 4

Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
Select Lab Scope.
Select Live.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the arrows to set the voltage range to 20 volts, the Offset to 4.0, and
the Probe to x10. Press F2 again and set the divisions to 40ms/Div, then press F2
again when complete.
Connect the Black lead to the chassis ground. Connect the Red lead to the KDB 2
Clock circuit in the ATC Remote Sensor harness connector.
Observe the voltage display on the DRB Lab Scope.
NOTE: The lab scope pattern should look similar to the example given in the
support material and cycle from approximately 0 volts to 8.0 volts.
Did the lab scope pattern and voltage react as noted above?
Yes → Go To 5
No → Go To 9

Measure the resistance between ground and the Sensor Return circuit.
Is the resistance below 10 ohms?
Yes → Go To 6
No → Go To 7
247

Repair
Replace the ATC Remote Sensor.
complete.

Measure the resistance of the Sensor Return circuit.
Yes → Go To 8
No → Repair the Sensor Return circuit for an open.
complete.
Repair
Replace the ATC.
complete.

Measure the voltage of the KDB 2 Clock circuit.
Yes → Repair the KDB 2 Clock circuit for a short to voltage.

complete.
No → Go To 10

Measure the resistance between ground and the KDB 2 Clock circuit.
Yes → Go To 11
No → Repair the KDB 2 Clock circuit for a short to ground.

complete.
248

Measure the resistance of the KDB 2 Clock circuit.
Yes → Go To 12
No → Repair the KDB 2 Clock circuit for an open.

complete.
Repair
Replace the ATC.
complete.

Measure the resistance between ground and the KDB 2 Data circuit.
Yes → Go To 14
No → Repair the KDB 2 Data circuit for a short to ground.
complete.

Measure the resistance of the KDB 2 Data circuit.
Yes → Go To 15
No → Repair the KDB 2 Data circuit for an open.
complete.

Repair
Replace the ATC.
complete.
249

Measure the resistance of the Protected Ignition circuit.
complete.
No → Repair the Protected Ignition circuit for an open.
complete.
250
Symptom:
FRONT KEYBOARD COMMUNICATION FAULT (ACTIVE)
POSSIBLE CAUSES
ATC

1 This DTC indicates a fault in the ATC. All
View repair.
Repair
Replace the ATC.
complete.
251
Symptom:
FRONT MODE DOOR NOT RESPONDING (ACTIVE)
FRONT MODE DOOR NOT RESPONDING (ACTIVE)

POSSIBLE CAUSES
MODE DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
MODE DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
MODE DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
MODE DOOR DRIVER CIRCUIT (A) OPEN
MODE DOOR DRIVER CIRCUIT (B) OPEN
ATC
MODE DOOR ACTUATOR

Disconnect the Mode Door Actuator harness connector.
Measure the resistance between ground and the Mode Door Driver (A) circuit.
Yes → Go To 2
No → Repair the Mode Door Driver (A) circuit for a short to ground.
complete.

Measure the resistance between ground and the Mode Door Driver (B) circuit.
Yes → Go To 3
No → Repair the Mode Door Driver (B) circuit for a short to ground.
complete.
252
FRONT MODE DOOR NOT RESPONDING (ACTIVE) — Continued

Measure the resistance between the Mode Door Driver (B) circuit and the Mode Door
Driver (A) circuit.
Yes → Go To 4
No → Repair the Mode Door Driver (A) and (B) circuits for a short
together.
complete.

Measure the resistance of the Mode Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Mode Door Driver (A) circuit for an open.
complete.

Measure the resistance of the Mode Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Mode Door Driver (B) circuit for an open.
complete.

Measure the resistance between the Mode Door Driver (A) circuit and the Mode Door
Driver (B) circuit.

complete.
No → Go To 7
Repair
Replace the Mode Door Actuator.
complete.
253
Symptom:
FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE)
FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
MODE DOOR ACTUATOR
MODE DOOR LINKAGE
ATC

Is the FRONT MODE DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Remove the Mode Door Actuator.
By hand, attempt to rotate the Mode Door Actuator in both directions.
Did the Mode Door Actuator turn in either direction?
Yes → Replace the Mode Door Actuator.

complete.
No → Go To 3
254
FRONT MODE DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Mode Door Actuator. Rotate the mode doors (doors only). Note: These All
Inspect the mode door linkage for excessive wear or missing linkage.
Yes → Repair or replace the mode door/linkage as necessary.

complete.

complete.
255
Symptom:
FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE)
FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC
OBSTRUCTED MODE DOOR
MODE DOOR ACTUATOR

Is the FRONT MODE DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Connect a 12-volt Test Light between the Mode Door Actuator harness connector
cavities.
While monitoring the test light, turn the mode control knob in each position.
Yes → Go To 3

complete.
256
FRONT MODE DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Mode Door Actuator. Rotate the mode doors (doors only). Note: These All
Do the mode doors move smoothly in both directions?
Yes → Replace the Mode Door Actuator.

complete.
No → Repair or replace the mode door as necessary.

complete.
257
Symptom:
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERA-
TURE TOO LOW
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERATURE TOO

LOW
Set Condition: This message will be displayed if the A/C - Heater Control Module sees
evaporator temperature below 12.7°C (55°F) when executing the Cooldown Test.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE TOO LOW
ATC DTC(S) PRESENT
SENSOR GROUND CIRCUIT HIGH RESISTANCE
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT HIGH RESISTANCE

1 CAUTION: The work area ambient temperature must be above 15.6°C (60°F) All
to test A/C system operation.
Start the engine.
Turn the A/C off.
Turn the Blower on high. Allow the blower to run for 5 minutes to ensure that the
Evaporator Temperature Sensor temperature is above 12.7°C (55°F).
With the DRBIIIt, actuate the Cooldown Test.
Does the DRBIIIt display: Cooldown Test Too Cold To Start?
Yes → Go To 2
No → Perform additional testing as necessary.

With the DRBIIIt, read ATC DTCs.
Does the DRBIIIt display any ATC DTCs?
Yes → Return to the symptom list and choose the symptom(s). After the
repair is complete, with the DRBIIIt, erase the DTC(s). Cycle the
ignition switch. With the DRBIIIt, reset the ATC. With the
DRBIIIt, actuate the Cooldown Test.
No → Go To 3
258
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERATURE

TOO LOW — Continued
Are any DTCs present?
Yes → Refer to the Powertrain Diagnostic information for the related
symptom(s). After the repair is complete, with the DRBIIIt, erase
the DTC(s). Cycle the ignition switch. With the DRBIIIt, reset the
ATC. With the DRBIIIt, accuate the Cooldown Test.
No → Go To 4

Disconnect the Evaporator Temperature Sensor harness connector.
voltage.
Yes → Go To 5
No → Go To 6

and the Sensor Ground circuit at the Evaporator Temperature Sensor harness
connector.
voltage.
Is the voltage 0.0 volts?
Yes → Replace the Evaporator Temperature Sensor in accordance with
the Service Information. After the repair is complete, with the
DRBIIIt, reset the ATC. With the DRBIIIt, accuate the Cooldown
Test.
No → Go To 6
6 NOTE: Ensure that the voltmeter leads meet the terminals in the connector All
and that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Back probe the Sensor Ground circuit between the Evaporator Temperature Sensor
harness connector and the ATC harness connector.
Is the voltage below 0.10 volt?
Yes → Go To 7
No → Repair the high resistance in the Sensor Ground circuit. After the
repair is complete, with the DRBIIIt, reset the ATC. With the
DRBIIIt, accuate the Cooldown Test.
259
INVALID CONDITIONS FOR COOLDOWN TEST, EVAP TEMPERATURE

7 NOTE: Ensure the voltmeter leads meet the terminals in the connector and All
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Back probe the Evaporator Temperature Sensor Signal circuit between the Evapo-
rator Temperature Sensor harness connector and the ATC harness connector.
Yes → Replace the Automatic Temperature Control. After the repair is

complete, with the DRBIIIt, reset the ATC. With the DRBIIIt,
accuate the Cooldown Test.
No → Repair the high resistance in the Evaporator Temperature Sensor

Signal circuit. After the repair is complete, with the DRBIIIt,
reset the ATC. With the DRBIIIt, accuate the Cooldown Test.
260
Symptom:
PASS BLEND DOOR NOT RESPONDING (ACTIVE)
PASS BLEND DOOR NOT RESPONDING (ACTIVE)

POSSIBLE CAUSES
PASSENGER BLEND DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
PASSENGER BLEND DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
PASSENGER BLEND DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
PASSENGER BLEND DOOR DRIVER CIRCUIT (A) OPEN
PASSENGER BLEND DOOR DRIVER CIRCUIT (B) OPEN
ATC
PASSENGER BLEND DOOR ACTUATOR

Measure the resistance between ground and the Passenger Blend Door Driver (A)
circuit.
Yes → Go To 2
No → Repair the Passenger Blend Door Driver (A) circuit for a short to
ground.
complete.

Measure the resistance between ground and the Passenger Blend Door Driver (B)
circuit.
Yes → Go To 3
No → Repair the Passenger Blend Door Driver (B) circuit for a short to
ground.
complete.
261
PASS BLEND DOOR NOT RESPONDING (ACTIVE) — Continued

Disconnect the Passenger Blend Door Actuator harness connector.
Measure the resistance between the Passenger Blend Door Driver (A) and (B)
circuits.
Yes → Go To 4
No → Repair the Passenger Blend Door Driver (A) and (B) circuits for a
short together.
complete.

Measure the resistance of the Passenger Blend Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Passenger Blend Door Driver (A) circuit for an open.
complete.

Measure the resistance of the Passenger Blend Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Passenger Blend Door Driver (B) circuit for an open.
complete.

Measure the resistance between the Passenger Blend Door Driver (A) and (B)
circuits.

complete.
No → Go To 7
Repair
Replace the Passenger Blend Door Actuator.
complete.
262
Symptom:
PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE)
PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
PASSENGER BLEND DOOR LINKAGE
ATC

Is the PASSENGER BLEND DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Remove the Passenger Blend Door Actuator.
By hand, attempt to rotate the Passenger Blend Door Actuator in both directions.
Yes → Replace the Passenger Blend Door Actuator.

complete.
No → Go To 3
263
PASS BLEND DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Passenger Blend Door Actuator. Rotate the blend door (door only). Note: All
This should rotate approximately 45 degrees from stop to stop.
Yes → Repair or replace the blend door/linkage as necessary.

complete.

complete.
264
Symptom:
PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE)
PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC

Is the PASSENGER BLEND DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Connect a 12-volt Test Light between the Passenger Blend Door Driver (A) and (B)
circuits in the Passenger Blend Door Actuator harness connector.
While monitoring the test light, turn the passenger blend control knob from lo to hi.
Yes → Go To 3

complete.
265
PASS BLEND DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Passenger Blend Door Actuator. Rotate the blend door (door only). Note: All
This should rotate approximately 45 degrees from stop to stop.
Does the blend door move smoothly in both directions?
Yes → Replace the Passenger Blend Door Actuator.

complete.
No → Repair or replace the Passenger Blend Door as necessary.

complete.
266
Symptom List:
PCI BUS SHORTED HIGH (ACTIVE)
PCI BUS SHORTED LOW (ACTIVE)
The title for the tests will be PCI BUS SHORTED HIGH
(ACTIVE).
PCI BUS SHORTED HIGH (ACTIVE)

Set Condition: This DTC is set if the ATC detects a short to voltage on the PCI Bus circuit.
PCI BUS SHORTED LOW (ACTIVE)

Set Condition: This DTC is set if the ATC detects a short to ground on the PCI Bus circuit.
POSSIBLE CAUSES
DTC CONDITION

1 NOTE: For this code to be active, the DRB will not be able to communicate All
with any modules on the vehicle (except the PCM/ECM).
NOTE: If this code is set and active it will be necessary to replace the
Automatic Temperature Control Module for displaying a false DTC.
NOTE: If this code is NOT active do not perform this test.
Repair
Replace the ATC.
complete.
267
Symptom:
REAR BLEND DOOR NOT RESPONDING (ACTIVE)
REAR BLEND DOOR NOT RESPONDING (ACTIVE)

POSSIBLE CAUSES
REAR BLEND DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
REAR BLEND DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
REAR BLEND DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
REAR BLEND DOOR DRIVER CIRCUIT (A) OPEN
REAR BLEND DOOR DRIVER CIRCUIT (B) OPEN
ATC
REAR BLEND DOOR ACTUATOR

Disconnect the Rear Blend Door Actuator harness connector.
Measure the resistance between ground and the Rear Blend Door Driver (A) circuit.
Yes → Go To 2
No → Repair the Rear Blend Door Driver (A) circuit for a short to
ground.
complete.

Measure the resistance between ground and the Rear Blend Door Driver (B) circuit.
Yes → Go To 3
No → Repair the Rear Blend Door Driver (B) circuit for a short to
ground.
complete.
268
REAR BLEND DOOR NOT RESPONDING (ACTIVE) — Continued

Disconnect the ATC C1 harness connectors.
Measure the resistance between the Rear Blend Door Driver (A) and (B) circuits.
Yes → Go To 4
No → Repair the Rear Blend Door Driver (A) and (B) circuits for a short
together.
complete.

Measure the resistance of the Rear Blend Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Rear Blend Door Driver (A) circuit for an open.
complete.

Measure the resistance of the Rear Blend Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Rear Blend Door Driver (B) circuit for an open.
complete.

Measure the resistance between the Rear Blend Door Driver (A) and (B) circuits.

complete.
No → Go To 7
Repair
Replace the Rear Blend Door Actuator.
complete.
269
Symptom:
REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE)
REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
REAR BLEND DOOR LINKAGE
ATC

With the DRB, read the active ATC DTC’s.
Is the REAR BLEND DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Remove the Rear Blend Door Actuator.
By hand, attempt to rotate the Rear Blend Door Actuator in both directions.
Yes → Replace the Rear Blend Door Actuator.

complete.
No → Go To 3
270
REAR BLEND DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Rear Blend Door Actuator. Rotate the blend door (door only). Note: This All
Yes → Repair or replace the rear blend door/linkage as necessary.

complete.

complete.
271
Symptom:
REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE)
REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC

Is the REAR BLEND DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Connect a 12-volt Test Light across the Rear Blend Door Actuator harness connector.
While monitoring the test light, turn the rear blend control knob from lo to hi.
Yes → Go To 3

complete.
272
REAR BLEND DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Rear Blend Door Actuator. Rotate the blend door (door only). Note: This All
Does the rear blend door move smoothly in both directions?
Yes → Replace the Rear Blend Door Actuator.

complete.
No → Repair or replace the blend door as necessary.

complete.
273
Symptom List:
REAR FAN POT OPEN (ACTIVE)
REAR FAN POT SHORTED (ACTIVE)
REAR IR SENSOR HIGH (ACTIVE)
REAR IR SENSOR LOW (ACTIVE)
REAR MODE POT OPEN (ACTIVE)
REAR MODE POT SHORTED (ACTIVE)
The title for the tests will be REAR FAN POT OPEN (ACTIVE).
REAR FAN POT OPEN (ACTIVE)

Set Condition: This DTC is set if the ATC reads the rear blower switch value and it is
REAR FAN POT SHORTED (ACTIVE)

Set Condition: This DTC is set if the ATC reads the rear fan switch value and it is below
5 A/D counts.
REAR IR SENSOR HIGH (ACTIVE)

Set Condition: This DTC is set if the ATC reads the Rear IR Sensor value and it is above
250 A/D counts.
REAR IR SENSOR LOW (ACTIVE)

Set Condition: This DTC is set if the ATC reads the Rear IR Sensor value and it is below
5 A/D counts.
REAR MODE POT OPEN (ACTIVE)

is above 250 A/D counts.
REAR MODE POT SHORTED (ACTIVE)

is below 5 A/D counts.
274
REAR FAN POT OPEN (ACTIVE) — Continued
POSSIBLE CAUSES
REAR ATC SWITCH

1 This DTC indicates a fault in the Rear ATC Switch. All
View repair.
Repair
Replace the Rear ATC Switch.
complete.
275
Symptom:
REAR IR SENSOR NOT CALIBRATED (ACTIVE)
REAR IR SENSOR NOT CALIBRATED (ACTIVE)

POSSIBLE CAUSES
BCM
IGNITION SWITCH (RUN) CIRCUIT OPEN
KDB CLOCK CIRCUIT SHORTED TO VOLTAGE
KDB DATA CIRCUIT SHORTED TO GROUND
KDB DATA CIRCUIT SHORTED TO VOLTAGE
KDB CLOCK CIRCUIT SHORTED TO GROUND
KDB DATA CIRCUIT OPEN
ATC - KDB DATA CIRCUIT FAULT
KDB CLOCK CIRCUIT OPEN
ATC - KDB CLOCK CIRCUIT FAULT
REAR AUTOMATIC TEMPERATURE CONTROL SWITCH

Disconnect the Rear Automatic Temperature Control Switch harness connector.
Measure the voltage of the Ignition Switch (Run) circuit.
Yes → Go To 2
No → Go To 13

Measure the voltage of the KDB Data circuit.
Yes → Go To 3
No → Go To 10
276
REAR IR SENSOR NOT CALIBRATED (ACTIVE) — Continued

Yes → Repair the KDB Data circuit for a short to voltage.
complete.
No → Go To 4

black test probes.
Select Lab Scope.
Select Live.
Press F2 for Scope.
Connect the Black lead to the chassis ground. Connect the Red lead to the KDB Clock
circuit in the Rear Automatic Temperature Control Switch harness connector.
Yes → Go To 5
No → Go To 6
Repair
Replace the Rear Automatic Temperature Control Switch.
complete.

Measure the voltage of the KDB Clock circuit.
Yes → Repair the KDB Clock circuit for a short to voltage.

complete.
No → Go To 7
277

Measure the resistance between ground and the KDB Clock circuit.
Yes → Go To 8
No → Repair the KDB Clock circuit for a short to ground.

complete.

Measure the resistance of the KDB Clock circuit.
Yes → Go To 9
No → Repair the KDB Clock circuit for an open.

complete.

Repair
Replace the ATC.
complete.

Measure the resistance between ground and the KDB Data circuit.
Yes → Go To 11
No → Repair the KDB Data circuit for a short to ground.
complete.

Measure the resistance of the KDB Data circuit.
Yes → Go To 12
No → Repair the KDB Data circuit for an open.

complete.
278

Repair
Replace the ATC.
complete.

Measure the resistance of the Ignition Switch (Run) circuit.
Yes → Replace the BCM.

complete.
No → Repair the Ignition Switch (Run) circuit for an open.

complete.
279
Symptom:
REAR KEYBOARD FAULT (ACTIVE)
POSSIBLE CAUSES
BCM
IGNITION SWITCH (RUN) CIRCUIT OPEN
KDB CLOCK CIRCUIT SHORTED TO VOLTAGE
KDB DATA CIRCUIT SHORTED TO GROUND
KDB DATA CIRCUIT SHORTED TO VOLTAGE
KDB CLOCK CIRCUIT SHORTED TO GROUND
KDB DATA CIRCUIT OPEN
ATC - KDB DATA CIRCUIT FAULT
KDB CLOCK CIRCUIT OPEN
ATC - KDB CLOCK CIRCUIT FAULT
REAR ATC SWITCH GROUND CIRCUIT OPEN
REAR AUTOMATIC TEMPERATURE CONTROL SWITCH

Measure the resistance of the Rear ATC Switch Ground circuit.
Yes → Go To 2
No → Repair the Rear ATC Switch Ground circuit for an open.
complete.

Measure the voltage of the Ignition Switch (Run) circuit.
Yes → Go To 3
No → Go To 14

Yes → Go To 4
No → Go To 11
280
REAR KEYBOARD FAULT (ACTIVE) — Continued

Yes → Repair the KDB Data circuit for a short to voltage.
complete.
No → Go To 5

black test probes.
Select Lab Scope.
Select Live.
Press F2 for Scope.
Connect the Black lead to the chassis ground. Connect the Red lead to the KDB Clock
circuit in the Rear Automatic Temperature Control Switch harness connector.
Yes → Go To 6
No → Go To 7
Repair
Replace the Rear Automatic Temperature Control Switch.
complete.

Measure the voltage of the KDB Clock circuit.
Yes → Repair the KDB Clock circuit for a short to voltage.

complete.
No → Go To 8
281

Measure the resistance between ground and the KDB Clock circuit.
Yes → Go To 9
No → Repair the KDB Clock circuit for a short to ground.

complete.

Measure the resistance of the KDB Clock circuit.
Yes → Go To 10
No → Repair the KDB Clock circuit for an open.

complete.

Repair
Replace the ATC.
complete.

Measure the resistance between ground and the KDB Data circuit.
Yes → Go To 12
No → Repair the KDB Data circuit for a short to ground.
complete.

Measure the resistance of the KDB Data circuit.
Yes → Go To 13
No → Repair the KDB Data circuit for an open.

complete.
282

Repair
Replace the ATC.
complete.

Measure the resistance of the Ignition Switch (Run) circuit.

complete.
No → Repair the Ignition Switch (Run) circuit for an open.

complete.
283
Symptom:
REAR MODE DOOR NOT RESPONDING (ACTIVE)
REAR MODE DOOR NOT RESPONDING (ACTIVE)

POSSIBLE CAUSES
REAR MODE DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
REAR MODE DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
REAR MODE DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
REAR MODE DOOR DRIVER CIRCUIT (A) OPEN
REAR MODE DOOR DRIVER CIRCUIT (B) OPEN
ATC
REAR MODE DOOR ACTUATOR

Measure the resistance between ground and the Rear Mode Door Driver (A) circuit.
Yes → Go To 2
No → Repair the Rear Mode Door Driver (A) circuit for a short to
ground.
complete.

Measure the resistance between ground and the Rear Mode Door Driver (B) circuit.
Yes → Go To 3
No → Repair the Rear Mode Door Driver (B) circuit for a short to
ground.
complete.
284
REAR MODE DOOR NOT RESPONDING (ACTIVE) — Continued

Measure the resistance between the Rear Mode Door Driver (A) and (B) circuits.
Yes → Go To 4
No → Repair the Rear Mode Door Driver (A) and (B) circuits for a short
together.
complete.

Disconnect the Rear Mode Door Actuator harness connector.
Measure the resistance of the Rear Mode Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Rear Mode Door Driver (A) circuit for an open.
complete.

Measure the resistance of the Rear Mode Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Rear Mode Door Driver (B) circuit for an open.
complete.

Measure the resistance between the Rear Mode Door Driver (A) and (B) circuits.
complete.
No → Go To 7

Repair
Replace the Rear Mode Door Actuator.
complete.
285
Symptom:
REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE)
REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
REAR MODE DOOR LINKAGE
ATC

Is the REAR MODE DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Remove the Rear Mode Door Actuator.
By hand, attempt to rotate the Rear Mode Door Actuator in both directions.
Did the mode door actuator turn in either direction?
Yes → Replace the Rear Mode Door Actuator.

complete.
No → Go To 3
286
REAR MODE DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Rear Mode Door Actuator. Rotate the mode door (door only). Note: This All
Inspect the rear mode door linkage for excessive wear or missing linkage.
Yes → Repair or replace the rear mode door/linkage as necessary.

complete.

complete.
287
Symptom:
REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE)
REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC
OBSTRUCTED MODE DOOR

Is the REAR MODE DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Connect a 12-volt Test Light between the rear mode door driver (A) and (B) circuits
in the Rear A/C Heater Unit harness connector.
While monitoring the test light, turn the rear mode control knob from lo to hi.
Yes → Go To 3

complete.
288
REAR MODE DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Rear Mode Door Actuator. Rotate the blend door (door only). Note: This All
Does the rear mode door move smoothly in both directions?
Yes → Replace the Rear Mode Door Actuator.

complete.
No → Repair or replace the Rear Mode Door as necessary.

complete.
289
Symptom:
RECIRC DOOR NOT RESPONDING (ACTIVE)
RECIRC DOOR NOT RESPONDING (ACTIVE)

Set Condition: This DTC is set when the ATC does not receive feedback pulses within 5
POSSIBLE CAUSES
RECIRC DOOR DRIVER CIRCUIT (A) SHORTED TO GROUND
RECIRC DOOR DRIVER CIRCUIT (B) SHORTED TO GROUND
RECIRC DOOR DRIVER CIRCUITS (A) AND (B) SHORTED TOGETHER
RECIRC DOOR DRIVER CIRCUIT (A) OPEN
RECIRC DOOR DRIVER CIRCUIT (B) OPEN
ATC
RECIRCULATION DOOR ACTUATOR

Disconnect the Recirculation Door Actuator harness connector.
Measure the resistance between ground and the Recirculation Door Driver (A)
circuit.
Yes → Go To 2
No → Repair the Recirculation Door Driver (A) circuit for a short to

ground.
complete.

Measure the resistance between ground and the Recirculation Door Driver (B)
circuit.
Yes → Go To 3
No → Repair the Recirculation Door Driver (B) circuit for a short to

ground.
complete.
290
RECIRC DOOR NOT RESPONDING (ACTIVE) — Continued

Measure the resistance between the Recirculation Door Driver (A) and (B) circuits.
Yes → Go To 4
No → Repair the Recirculation Door Driver (A) and (B) circuits for a
short together.
complete.

Measure the resistance of the Recirculation Door Driver (A) circuit.
Yes → Go To 5
No → Repair the Recirculation Door Driver (A) circuit for an open.

complete.

Measure the resistance of the Recirculation Door Driver (B) circuit.
Yes → Go To 6
No → Repair the Recirculation Door Driver (B) circuit for an open.

complete.

Measure the resistance between the Recirculation Door Driver (A) and (B) circuits.

complete.
No → Go To 7
Repair
Replace the Recirculation Door Actuator.
complete.
291
Symptom:
RECIRC DOOR TRAVEL TOO LARGE (ACTIVE)
RECIRC DOOR TRAVEL TOO LARGE (ACTIVE)

POSSIBLE CAUSES
RECIRCULATION DOOR LINKAGE
ATC

Is the RECIRC DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Remove the Recirculation Door Actuator.
By hand, attempt to rotate the Recirculation Door Actuator in both directions.
Did the Recirculation Door Actuator turn in either direction?
Yes → Replace the Recirculation Door Actuator.

complete.
No → Go To 3
292
RECIRC DOOR TRAVEL TOO LARGE (ACTIVE) — Continued

3 Remove the Recirculation Door Actuator. Rotate the recirculation door (door only). All
Note: This should rotate approximately 45 degrees from stop to stop.
Inspect the recirculation door linkage for excessive wear or missing linkage.
Yes → Repair or replace the recirculation door/linkage as necessary.

complete.

complete.
293
Symptom:
RECIRC DOOR TRAVEL TOO SMALL (ACTIVE)
RECIRC DOOR TRAVEL TOO SMALL (ACTIVE)

POSSIBLE CAUSES
ATC
OBSTRUCTED RECIRC DOOR

Is the RECIRC DOOR NOT RESPONDING DTC set?
complete.
No → Go To 2

Connect a 12-volt Test Light between the Recirculation Door Driver (A) and (B)
circuits.
While monitoring the test light, press the recirculation control button from off to on.
Yes → Go To 3

complete.
294
RECIRC DOOR TRAVEL TOO SMALL (ACTIVE) — Continued

3 Remove the Recirculation Door Actuator. Rotate the recirculation door (door only). All
Note: This should rotate approximately 45 degrees from stop to stop.
Does the recirculation door move smoothly in both directions?
Yes → Replace the Recirculation Door Actuator.

complete.
No → Repair or replace the recirculation door as necessary.

complete.
295
CABIN HEATER
Symptom List:
CABIN HEATER PRE-TEST
CABIN HEATER CONTROL CIRCUIT OPEN (STORED)
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY
(STORED)
The title for the tests will be A. CABIN HEATER PRE-TEST.
CABIN HEATER CONTROL CIRCUIT OPEN (STORED)

When Monitored: When the DCHA system is off.
Set Condition: The DCHA Low Side Driver inside the FCM expects to see a system
voltage of 13.8 volts through the DCHA relay coil when the DCHA system is off. This DTC
will set if the FCM sees a voltage below 3.5 volts on the Cabin Heater Assist Control circuit
during this time.
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (STORED)

When Monitored: During DCHA activation and operation.
Set Condition: This DTC will set if the FCM sees between 5.0 and 15.0 volts on the Cabin
Heater Assist Control circuit.
POSSIBLE CAUSES
NO RESPONSE FROM CABIN HEATER MODULE
DTC(S) PRESENT
CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE
STORED DCHA DTC(S) TEST COMPLETE

1 WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH All
AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA’s EXHAUST WHEN OPERATING THE
DCHA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
With the DRBIIIt, attempt to communicate with the Cabin Heater Module.
Does the DRBIIIt display: No Response From Cabin Heater Module?
Yes → Refer to Communication for the related symptom.
Perform CABIN HEATER VERIFICATION TEST - VER 1.
No → Go To 2
296
CABIN HEATER
CABIN HEATER PRE-TEST — Continued

With the DRBIIIt, read Cabin Heater DTCs.
Is DTC B1813 Heater In Lockout Mode present?
Yes → Go To 3
No → Go To 4

Start the engine.
Allow the engine to idle.
Turn the A/C - Heater Control Module’s Power switch on.
Turn the Blower switch to the high speed position.
Set the Blend Control to the max heat position.
Remove Cabin Heater Fuse #15 from the IPM for a minimum of five seconds, then
reinstall the fuse. The DCHA may attempt to start.
Turn the Blower switch off and turn the A/C - Heater Control Module’s Power switch
off.
Turn the engine off.
View repair
Repair
Go To 4
297
CABIN HEATER
CABIN HEATER PRE-TEST — Continued

WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORM-
ING A COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
NOTE: The DCHA Control will store up to three DTCs in its memory.
NOTE: If the DCHA Control detects a new fault in the DCHA system, one
that is not already stored in its memory, the DCHA Control will clear the
oldest of the three stored DTCs, and it will store the new fault’s DTC.
NOTE: If the DCHA control detects a reoccurrence of a stored fault, the
DCHA control will overwrite that fault’s DTC with the most recent occur-
rence.
Set the Blend Control to the max cool position.
Turn the A/C - Heater Control Module’s Power switch off.
With the DRBIIIt, record and erase Cabin Heater and FCM DTCs.
Start the engine.
CAUTION: Do not activate the DCHA Field Mode Test with the engine off.
Failure to follow these instructions may result in internal damage to the
DCHA Heater Module.
NOTE: Do not disconnect the vehicle’s battery or the DCHA’s main power
supply while the DCHA is in operation or in run-down mode. Failure to
follow these instructions may result in excess emissions from the DCHA
during heater operation.
With the DRBIIIt in Cabin Heater, Systems Tests, select Field Mode and press Enter.
Set the Blend Control to the max heat position. Upon completion of the Field Mode
Test, proceed as follows:
With the DRBIIIt, read Cabin Heater and Active FCM DTCs.
off.
Yes → Return to the symptom list and choose the DTC(s). Diagnose and
repair all FCM faults prior to diagnosing DCHA faults. If DTC
B1813 Heater In Lockout Mode reset with other DTC(s), reset the
heater before diagnosing the other DTC(s).
No → Go To 5
5 Is the symptom Cabin Heater inoperable from the A/C - Heater Module? All
Yes → Refer to symptom *Cabin Heater Inoperable From A/C - Heater

Module in the Cabin Heater category.
No → Let DCHA cool. Inspect fuel line, intake & exhaust, & coolant
hoses for restrictions, obstructions, loose clamps, leakage, etc.
Check connectors. Clean & repair as necessary. Refer to Service
Manual for additional symptom based diagnosis, if necessary.
298
CABIN HEATER
Symptom:
B1000 CONTROL UNIT ERRONEOUS
B1000 CONTROL UNIT ERRONEOUS

When Monitored: During DCHA activation.
Set Condition: This DTC will set if a fault occurs with the DCHA Control Unit’s memory.
POSSIBLE CAUSES
DCHA CONTROL UNIT FAULT

CAUTION: DO NOT PERFORM THIS TEST UNLESS DIRECTED HERE BY
THE CABIN HEATER PRE-TEST. ALWAYS PERFORM THE CABIN HEATER
PRE-TEST PRIOR TO PERFORMING ANY OTHER CABIN HEATER TEST
FOR THE RESULT TO BE VALID.
View repair
Repair
Replace the DCHA Heater Module in accordance with the Service
Information.
299
CABIN HEATER
Symptom List:
B1800 NO START
B1801 FLAME OUT: DURING HEATING CYCLE
B1801 FLAME OUT: UNSTABLE OPERATION
The title for the tests will be B1800 NO START.
B1800 NO START
When Monitored: After DCHA activation.
Set Condition: This DTC will set if the Flame Sensor resistance is not within the expected
parameters 160 sections after activation.
B1801 FLAME OUT: DURING HEATING CYCLE

When Monitored: After DCHA activation, and during subsequent start attempts.
parameters.
B1801 FLAME OUT: UNSTABLE OPERATION

parameters.
POSSIBLE CAUSES
LOW FUEL LEVEL IN VEHICLE’S FUEL TANK
DOSING PUMP INOPERABLE, NO DOSING PUMP DTCS SET
DCHA FUEL LINE RESTRICTED/LEAKING/DAMAGED
DOSING PUMP
DCHA AIR INTAKE/EXHAUST RESTRICTED
DCHA HEATER MODULE FAULT
300
CABIN HEATER
B1800 NO START — Continued

Verify that there is more than an 1/8 of a tank of fuel in the vehicle’s fuel tank.
Is there more than an 1/8 of a tank of fuel in the vehicle’s fuel tank?
Yes → Go To 2
No → Add fuel to the vehicle’s fuel tank to bring the fuel level above 1/8
of a tank.

CAUTION: Do not actuate the Dosing Pump more than two times. Doing so
will put excess fuel in the DCHA Heater Module and cause smoke to emit
from the DCHA exhaust pipe when heater activation occurs.
With the DRBIIIt in Actuators, select Dosing Pump. Listen for the pump to run. A
clicking noise should be heard coming from the pump.
Press Page Back and select No to stop the Dosing Pump actuation.
Does the Dosing Pump run when actuated?
Yes → Go To 3
No → Replace the Dosing Pump in accordance with the Service Infor-
mation.
301
CABIN HEATER

Inspect the DCHA fuel line exterior for restrictions, leakage, and damage.
Verify that the DCHA fuel line is installed correctly.
NOTE: Waxed fuel can obstruct the fuel line and reduce flow. Check for the
appropriate winter grade fuel and replace as necessary.
Check for obstructions in the fuel line. Refer to Fuel Line, Cleaning in the Service
Information.
Is the DCHA fuel line Ok?
Yes → Go To 4
No → Repair the DCHA fuel line as necessary in accordance with the


Disconnect the Dosing Pump rubber insulators from the splash shield.
Disconnect the fuel line from the fuel outlet side of the Dosing Pump.
Using a suitable length of fuel line, connect one end to the fuel outlet side of the
Dosing Pump and place the other end in a suitable container.
CAUTION: For the result of this test to be valid, actuate the Dosing Pump
Prime twice if the DCHA fuel supply line was drained and then not primed
prior to performing this test.
NOTE: Allow the Dosing Pump Prime to run the full 45 seconds.
With the DRBIIIt in System Tests, select Dosing Pump Prime.
When the Dosing Pump Prime is complete, measure the amount of fuel in the
container.
Does the Dosing Pump output approx 14 ml (0.5 oz) of fuel in a single Dosing Pump
Prime activation?
Yes → Go To 5

mation.
302
CABIN HEATER

Inspect the DCHA air intake pipe and exhaust pipe for restrictions and obstructions.
Is the DCHA air intake pipe and exhaust pipe Ok?
Yes → Replace the DCHA Heater Module in accordance with the Service
Information.
No → Repair the DCHA air intake/exhaust as necessary in accordance

303
CABIN HEATER
Symptom:
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESH-
OLD
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD

When Monitored: With the engine running.
Set Condition: This DTC will set if the DCHA’s power supply voltage drops below 10.0
volts for longer than 20 seconds.
POSSIBLE CAUSES
FIELD MODE TEST RUN WITH THE ENGINE OFF
VEHICLE’S BATTERY SYSTEM
VEHICLE’S CHARGING SYSTEM NOT OPERATING PROPERLY
FUSED B+ CIRCUIT HIGH RESISTANCE

Was the Field Mode Test run with the engine off?
Yes → Rerun the Field Mode Test exactly as it is described in Test 4 of

the Cabin Heater Pre-Test. If DTC B1802 resets, Go To Test #2 of
this symptom. Otherwise, perform other diagnosis and testing as
necessary.
No → Go To 2
304
CABIN HEATER
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD —

Continued
Inspect the vehicle’s battery terminals, cable terminals, and cables for corrosion and
damage in accordance with the Service Information.
Test the vehicle’s battery in accordance with the Service Information.
Is the vehicle’s battery system Ok?
Yes → Go To 3
No → Clean/repair the vehicle’s battery system in accordance with the


Check the vehicle’s charging system for proper operation in accordance with the
Is the vehicle’s charging system operating properly?
Yes → Go To 4
No → Repair the vehicle’s charging system in accordance with the

With the DRBIIIt in Sensors, record the DCHA Operating Voltage.
Disconnect the Cabin Heater Assist C1 harness connector.
Measure the voltage between the Fused B+ circuit and ground.
Is there more than 1.0 volt difference between the Operating Voltage and the Fused
B+ voltage?
Information.
No → Go To 5
305
CABIN HEATER
B1802 POWER SUPPLY OUT OF RANGE: LOW VOLTAGE THRESHOLD —

Continued
Make sure that the Cabin Heater Assist C1 harness connector is connected to the
DCHA.
Connect a suitable voltmeter to the vehicle’s battery. Position the voltmeter where it
can be monitored while operating the DRBIIIt.
Start the engine.
DCHA Heater Module.
With the DRBIIIt in Sensors, monitor the DCHA Operating Voltage and the
voltmeter while the Field Mode Test is running. Upon completion of the Field Mode
Test proceed as follows:
off.
Was there more than 1.5 volts difference between Operating & battery voltage during
the test?
Yes → Repair the high resistance in the Fused B+ circuit.
No → Replace the DCHA Heater Module in accordance with the Service
Information.
306
CABIN HEATER
Symptom:
B1802 POWER SUPPLY OUT OF RANGE: VOLTAGE ABOVE 15.5
VOLTS
B1802 POWER SUPPLY OUT OF RANGE: VOLTAGE ABOVE 15.5 VOLTS

Set Condition: This DTC will set if the DCHA’s power supply voltage exceeds 15.5 volts
for longer than six seconds.
POSSIBLE CAUSES
VEHICLE’S CHARGING SYSTEM OVERCHARGING

Check the vehicle’s charging system for proper operation in accordance with the
Is the vehicle’s charging system operating properly?
Information.
No → Repair the vehicle’s charging system in accordance with the

307
CABIN HEATER
Symptom:
B1803 FLAME DETECTED PRIOR TO COMBUSTION
B1803 FLAME DETECTED PRIOR TO COMBUSTION

When Monitored: During DCHA start up.
parameters.
POSSIBLE CAUSES
FLAME SENSOR FAULT

View repair
Repair
Information.
308
CABIN HEATER
Symptom:
B1811 HEATER OVERHEATED
B1811 HEATER OVERHEATED

When Monitored: After DCHA activation, when the system is in a steady state of
operation.
Set Condition: This DTC will set if the Coolant Temperature Sensor resistance is not
within the expected parameters (coolant temperature in the Heater Module exceeds 125°C
[257°F]).
POSSIBLE CAUSES
DCHA HEATER MODULE FAULT
DCHA COOLANT HOSES RESTRICTED/LEAKING/DAMAGED
ENGINE’S COOLING SYSTEM FAULT
B1811 CLEARED, ADDITIONAL DTC(S) PRESENT

NOTE: If there is an internal leak in the Heater Module, a continuous loud
chunking or grinding noise may have been heard coming from the DCHA
assembly during the Field Mode test.
Check for engine coolant continuously flowing out of the DCHA exhaust pipe.
Is engine coolant coming out of the DCHA exhaust pipe?
Information.
No → Go To 2
309
CABIN HEATER
B1811 HEATER OVERHEATED — Continued

Inspect the DCHA coolant hoses for restrictions, leakage, and damage.
Are the DCHA coolant hoses Ok?
Yes → Go To 3
No → Repair the DCHA coolant hoses as necessary in accordance with

the Service Information.

Check that the engine’s cooling system is operating properly in accordance with the
Is the engine’s cooling system operating properly?
Yes → Go To 4
No → Repair the engine’s cooling system in accordance with the Service

Information.

Start the engine.
Allow the engine to reach normal operating temperature.
Allow the engine’s coolant to cool down to a temperature of 50°C (122°F).
Start the engine.
Allow the engine to reach normal operating temperature.
View repair
Repair
Go To 5
310
CABIN HEATER

Start the engine.
Remove the Cabin Heater fuse from the IPM for a minimum of five seconds, then
off.
View repair
Repair
Go To 6
311
CABIN HEATER

rence.
With the DRBIIIt, erase Cabin Heater DTCs.
Start the engine.
DCHA Heater Module.
off.
Yes, B1811 & B1813 reset
Information.
Yes, B1811 Cleared, Other DTC(s) Present
Return to the symptom list and choose the DTC(s).
312
CABIN HEATER
Symptom:
B1813 HEATER IN LOCKOUT MODE
B1813 HEATER IN LOCKOUT MODE

When Monitored: During DCHA activation.
Set Condition: This DTC will set if six continuous attempts to start heater operation fail
due to one or more faults in the DCHA system.
POSSIBLE CAUSES
B1813 AND ADDITIONAL DTC(S) PRESENT
B1813 RESET, NO ADDITIONAL DTC(S) PRESENT
B1813 CLEARED, ADDITIONAL DTC(S) PRESENT
STORED DCHA DTC(S) TEST COMPLETE

Start the engine.
Turn the Blower Switch to the high speed position.
Remove Cabin Heater Fuse #15 from the IPM for a minimum of five seconds, then
off.
View repair
Repair
Go To 2
313
CABIN HEATER
B1813 HEATER IN LOCKOUT MODE — Continued

rence.
With the DRBIIIt, record and erase Cabin Heater DTCs.
Start the engine.
DCHA Heater Module.
off.
Yes, B1813 & Other DTC(s) Present
Return to the symptom list and choose the additional DTC(s) first,
then diagnose B1813.
Yes, B1813 Reset with No Other DTC(s)
Allow DCHA to cool. Inspect DCHA intake & exhaust pipes for
restrictions & obstructions. Repair as necessary. After repair,
repeat Test 2 of this procedure. If intake & exhaust pipes are Ok,
replace DCHA Heater Module in accordance with Service Info.
Yes, B1813 Cleared, Other DTC(s) Present

Return to the symptom list and choose the DTC(s).
No → Allow DCHA to cool. Inspect fuel line & coolant hoses for restric-
tions, obstructions, loose clamps, leakage, etc. Repair as neces-
sary. Check connectors. Clean & repair as necessary. Refer to
Service Manual for additional symptom diagnosis, if necessary.
314
CABIN HEATER
Symptom:
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY

Set Condition: This DTC will set if the DCHA Control detects no-load voltage on the
Dosing Pump circuit output pin.
POSSIBLE CAUSES
DOSING PUMP CONTROL CIRCUIT SHORTED HIGH
DOSING PUMP CONTROL CIRCUIT OPEN
GROUND CIRCUIT OPEN
DOSING PUMP

NOTE: If present, diagnose and repair DTC B1811 Heater Overheated and
any other conditions relating to overheating before diagnosing this DTC.
Measure the voltage between the Dosing Pump Control circuit and ground.
Yes → Repair the Dosing Pump Control circuit for a short to voltage.
No → Go To 2
315
CABIN HEATER
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY —

Continued
Disconnect the Dosing Pump harness connector.
Measure the resistance of the Dosing Pump Control circuit between the Dosing Pump
harness connector and the Cabin Heater Assist C1 harness connector.
Yes → Go To 3
No → Repair the Dosing Pump Control circuit for an open.


Measure the resistance of the Ground circuit between the Dosing Pump harness
connector and the Cabin Heater Assist C2 harness connector.
Yes → Go To 4
No → Repair the Ground circuit for an open.
316
CABIN HEATER
B1820 DOSING PUMP CIRCUIT: OPEN OR SHORT TO BATTERY —

Continued
Disconnect the Dosing Pump rubber insulators from the splash shield.
Measure the resistance of the Dosing Pump.
Information.

mation.
317
CABIN HEATER
Symptom:
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND

When Monitored: During Dosing Pump activation.
Set Condition: This DTC will set if the DCHA Control detects a high current draw on the
Dosing Pump circuit output pin.
POSSIBLE CAUSES
DOSING PUMP SHORTED TO GROUND
DOSING PUMP CONTROL CIRCUIT SHORTED TO THE GROUND CIRCUIT
DOSING PUMP CONTROL CIRCUIT SHORTED TO GROUND
318
CABIN HEATER
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND — Continued

NOTE: If present, diagnose and repair DTC B1811 Heater Overheated and
any other conditions relating to overheating before diagnosing this DTC.
With the DRBIIIt, erase Cabin Heater DTCs.
Start the engine.
DCHA Heater Module.
With the DRBIIIt, read Cabin Heater DTCs.
off.
Is DTC B1820 Dosing Pump Circuit: Short to Ground present?
Yes → Go To 2

mation.
319
CABIN HEATER
B1820 DOSING PUMP CIRCUIT: SHORT TO GROUND — Continued

CAUTION: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORM-
Disconnect the battery in accordance with the Service information.
Disconnect the Cabin Heater Assist C1 and C2 harness connectors.
Measure the resistance between the Dosing Pump Control circuit and the Ground
circuit.
Is the resistance below 10K ohms?
Yes → Repair the Dosing Pump Control circuit for a short to the Ground
circuit.
No → Go To 3

Measure the resistance between ground and the Dosing Pump Control circuit.
Yes → Repair the Dosing Pump Control circuit for a short to ground.

Information.
320
CABIN HEATER
Symptom List:
B1821 COMBUSTION AIR FAN CIRCUIT: OPEN
B1821 COMBUSTION AIR FAN CIRCUIT: SHORT TO GROUND
The title for the tests will be B1821 COMBUSTION AIR FAN
CIRCUIT: OPEN.
B1821 COMBUSTION AIR FAN CIRCUIT: OPEN

operation.
Set Condition: This DTC will set if the DCHA Control detects no-load voltage on the
Combustion Air Fan circuit output pin.
B1821 COMBUSTION AIR FAN CIRCUIT: SHORT TO GROUND

operation.
Set Condition: This DTC will set if the DCHA Control detects a high current draw on the
Combustion Air Fan circuit output pin.
POSSIBLE CAUSES
COMBUSTION AIR FAN/DCHA CONTROL UNIT FAULT

NOTE: If present, diagnose and repair DTC B1801 Flame Out before diag-
nosing this DTC.
View repair
Repair
Information.
321
CABIN HEATER
Symptom List:
B1822 GLOW PIN/FLAME SENSOR: OPEN
B1822 GLOW PIN/FLAME SENSOR: SHORT TO GROUND
The title for the tests will be B1822 GLOW PIN/FLAME SEN-
SOR: OPEN.
B1822 GLOW PIN/FLAME SENSOR: OPEN

Set Condition: This DTC will set if the Glow Pin resistance is not within the expected
parameters.
B1822 GLOW PIN/FLAME SENSOR: SHORT TO GROUND

operation.
Set Condition: This DTC will set if the Glow Pin resistance is not within the expected
parameters.
POSSIBLE CAUSES
GLOW PIN/HEATER MODULE FAULT

View repair
Repair
Information.
322
CABIN HEATER
Symptom List:
B1823 WATER PUMP CIRCUIT: OPEN
B1823 WATER PUMP CIRCUIT: SHORT TO GROUND
The title for the tests will be B1823 WATER PUMP CIRCUIT:
OPEN.
B1823 WATER PUMP CIRCUIT: OPEN

Set Condition: This fault is erroneous for this DCHA assembly.
B1823 WATER PUMP CIRCUIT: SHORT TO GROUND

POSSIBLE CAUSES

View repair
Repair
Information.
323
CABIN HEATER
Symptom:
B1824 FAN SWITCH LINE SHORT TO GROUND
B1824 FAN SWITCH LINE SHORT TO GROUND

POSSIBLE CAUSES

View repair
Repair
Information.
324
CABIN HEATER
Symptom:
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE)
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE)

When Monitored: When the DCHA system is off
Set Condition: The DCHA Low Side Driver inside the FCM expects to see a system
voltage of 13.8 volts through the DCHA relay coil when the DCHA system is off. This DTC
will set if the FCM sees a voltage below 3.5 volts on the Cabin Heater Assist Control circuit
during this time.
POSSIBLE CAUSES
NO RESPONSE FROM CABIN HEATER MODULE
CABIN HEATER ASSIST CONTROL CIRCUIT OPEN TO IPM
IPM, OPEN CIRCUIT
FCM, OPEN CIRCUIT
FCM FAULT
CABIN HEATER ASSIST CONTROL CIRCUIT SHORTED TO THE GROUND CIRCUIT
CABIN HEATER ASSIST CONTROL CIRCUIT SHORTED TO GROUND
CABIN HEATER ASSIST CONTROL CIRCUIT OPEN

With the DRBIIIt, attempt to communicate with the Cabin Heater Module.
Does the DRBIIIt display: No Response From Cabin Heater Module?
Yes → Refer to Communication for the related symptom.

No → Go To 2
325
CABIN HEATER
CABIN HEATER CONTROL CIRCUIT OPEN (ACTIVE) — Continued

While back probing, measure the voltage of the Cabin Heater Assist Control circuit
in the In-Line C330 harness connector.
Is battery voltage present?
Yes → Go To 3
No → Go To 5

Disconnect the IPM C3 harness connector.
Disconnect the In-Line C330 harness connector.
Measure the resistance of the Cabin Heater Assist Control circuit between the
In-Line C330 harness connector and the IPM C3 harness connector.
Yes → Go To 4
No → Repair the Cabin Heater Assist Control circuit for an open.

Remove the FCM in accordance with the Service Information.
Measure the resistance of the Cabin Heater Assist Control circuit in the IPM
(between IPM Cavity 11 for the C3 harness connector and IPM Cavity 15 for the FCM
connector).
Yes → Replace the FCM in accordance with the Service Information.
No → Replace the IPM in accordance with the Service Information.

326
CABIN HEATER

Ensure the IPM and Cabin Heater harness connectors are connected.
Reconnect the battery in accordance with the Service information.
While back probing, measure the voltage of the Cabin Heater Assist Control circuit
in the In-Line C330 harness connector.
Is battery voltage present?
No → Go To 6

Disconnect the Cabin Heater Assist C1, C2, and Dosing Pump harness connectors.
Measure the resistance between the Cabin Heater Assist Control circuit and the
Ground circuit.
Yes → Repair the Cabin Heater Assist Control circuit for a short to the
Ground circuit.
No → Go To 7
327
CABIN HEATER

Measure the resistance between ground and the Cabin Heater Assist Control circuit.
Yes → Repair the Cabin Heater Assist Control circuit for a short to
ground.
No → Go To 8

Measure the resistance of the Cabin Heater Assist Control circuit between the Cabin
Heater Assist C1 harness connector and the IPM C3 harness connector.
Information.
No → Repair the Cabin Heater Assist Control circuit for an open.

328
CABIN HEATER
Symptom:
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (AC-
TIVE)
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE)

Set Condition: This DTC will set if the FCM sees a voltage between 5.0 and 15.0 volts on
the Cabin Heater Assist Control circuit.
POSSIBLE CAUSES
CABIN HEATER ASSIST CONTROL CIRCUIT SHORTED TO THE FUSED B(+) CIRCUIT
FCM FAULT
CABIN HEATER ASSIST CONTROL CIRCUIT SHORTED HIGH

With the DRBIIIt in FCM, read the active DTCs.
Is the Cabin Heater Relay Short To Battery DTC still active?
Yes → Go To 2
Information.
329
CABIN HEATER
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE) —

Continued
Measure the voltage between the Cabin Heater Assist Control circuit and ground.
Yes → Go To 3
No → Replace the FCM in accordance with the Service Information.

Disconnect the Cabin Heater Assist C1 and C2 harness connectors.
Measure the resistance between the Cabin Heater Assist Control circuit and the
Fused B(+) circuit.
Yes → Repair the Cabin Heater Assist Control circuit for a short to the
Fused B(+) circuit.
No → Go To 4
330
CABIN HEATER
CABIN HEATER CONTROL CIRCUIT SHORT TO BATTERY (ACTIVE) —

Continued
Disconnect the battery in accordance with the Service Information.
Reconnect the IPM C3 harness connector.
Reconnect the battery in accordance with the Service Information.
Measure the voltage between the Cabin Heater Assist Control circuit and ground.
Yes → Repair the Cabin Heater Assist Control circuit for a short to
voltage.
No → Replace the FCM in accordance with the Service Information.
331
CABIN HEATER
Symptom:
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE
POSSIBLE CAUSES
DCHA ACTIVATION CRITERIA NOT MET
ATTEMPT TO COMMUNICATE WITH THE FCM AND THE HVAC MODULE
FCM OR HAVC DTCS PRESENT
VERIFY DCHA IS INOPERABLE FROM A/C - HEATER MODULE
A/C - HEATER CONTROL MODULE FAULT

Verify that all of the following criteria was met during the attempt to activate the
DCHA from the A/C - Heater Control Module.
The engine was running.
The engine coolant temperature was below 66°C (151°F).
The vehicle’s fuel tank had more than 1/8 of a tank of fuel.
The A/C - Heater Control Module’s Power switch was on.
The Blend Control was set above 95% reheat.
Was all criteria met during the attempt to activate the DCHA from the A/C - Heater
Control Module?
Yes → Go To 2
No → Attempt to activate the DCHA when all of the operating criteria
are met.

With the DRBIIIt, attempt to communicate with the FCM and the HVAC Module.
Was the DRBIIIt able to communicate with the FCM and the HVAC Module?
Yes → Go To 3
No → Refer to Communication for the related symptom(s)
332
CABIN HEATER
*CABIN HEATER INOPERABLE FROM A/C - HEATER MODULE —

Continued
With the DRBIIIt, check for FCM and HVAC DTCs.
Does the DRBIIIt display any FCM or HVAC DTCs?
Yes → For FCM DTCs, return to the symptom list and choose the
symptom(s). Also, refer to Intelligent Power Module for related
symptom(s). For HVAC DTCs, refer to Heater & A/C for related
symptom(s).
No → Go To 4

Start the engine.
CAUTION: Do not activate the Diesel Cabin Heater Test with the engine off.
DCHA Heater Module.
With the DRBIIIt in HVAC, Systems Tests, select Diesel Cabin Heater Test and press
#1.
With the DRBIIIt in HVAC, Systems Tests, Diesel Cabin Heater Test, read the Cabin
Heater Status.
Does the Status display: On?

No → Replace the A/C - Heater Control Module in accordance with the

333
CHIME
Symptom:
*CHIME INOPERATIVE
POSSIBLE CAUSES
CHIME DRIVER CIRCUIT - OPEN
CHIME DRIVER CIRCUIT - SHORT TO GROUND
CHIME DRIVER CIRCUIT - SHORT TO VOLTAGE
INSTRUMENT CLUSTER
BCM

1 With the DRBIIIt, actuate the CHIME. (BCM actuator) All
Does chime sound a warning?
Yes → Test Complete.
No → Go To 2
2 Disconnect the Instrument Cluster harness connector(s). All

Disconnect the BCM harness connector(s).
Using a 12-volt test light connected to 12-volts, check the chime driver circuit for a
short to ground.
Does the test light illuminate brightly?
Yes → Repair the chime driver circuit for a short to ground.

No → Go To 3
3 Disconnect the Instrument Cluster harness connector(s). All

Using a DVOM connected to ground, check the chime driver circuit for a short to
voltage.
Yes → Repair the chime driver circuit for a short to voltage.
No → Go To 4
4 Reconnect the BCM if disconnected in previous step. All

Disconnect the Instrument Cluster harness connectors.
Using a 12-volt test light connected to 12-volts, check the chime driver circuit at the
Instrument Cluster connector.
With the DRBIIIt, actuate the CHIME. (BCM actuator)
Does the test light illuminate ON and OFF?
Yes → Replace the Instrument Cluster.

No → Go To 5
334
CHIME
*CHIME INOPERATIVE — Continued

5 Disconnect the Instrument Cluster harness connectors. All
Measure the resistance of the chime driver circuit between the Instrument Cluster
connector and the BCM connector.
No → Repair the chime driver circuit for an open, between the Instru-
ment Cluster and the BCM.

335
CHIME
Symptom:
*KEY IN IGNITION AND DRIVER’S DOOR OPEN CHIME NOT
OPERATING PROPERLY
POSSIBLE CAUSES
DRIVER DOOR AJAR STATUS
IGNITION SWITCH
BODY CONTROL MODULE

1 Open the driver door. All
With the DRB, in Input/Outputs, read the 9DR DOOR AJAR SW9 state.
Does the DRB display 9DR DOOR AJAR SW: CLOSED9?
Yes → Go To 2
No → Refer to symptom list for problems related to Door Ajar.

2 With the DRBIIIt in Inputs/Outputs, read the Key in Ign Sw state while inserting All
the key in and out of the ignition switch.
Does the DRBIIIt display change from open to closed?
Yes → Replace and program the Body Control Module in accordance
No → Check the Ignition Lock Cylinder for damage. If OK replace the
Ignition Switch.
336
CHIME
Symptom:
*PROBLEM WITH THE HIGH VEHICLE SPEED WARNING CHIME
POSSIBLE CAUSES
INCORRECT COUNTRY CODE PROGRAMMED IN BCM
BODY CONTROL MODULE

1 Note: The high speed warning chime is for Gulf Coast Countries only. All
With the DRBIIIt in Miscellaneous check the Body Control Module country code
setting.
Is the country code incorrect?
Yes → Program the correct country code setting.

No → Replace and program the Body Control Module in accordance
337
COMMUNICATION
Symptom:
ATC MESSAGES NOT RECEIVED
ATC MESSAGES NOT RECEIVED

When Monitored: With the ignition in run, and the IOD fuse installed.
Set Condition: The BCM does not receive any messages from the Automatic Temperature
Control (ATC) module for at least 0.125 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE AUTOMATIC TEMPERATURE CONTROL MODULE
BODY CONTROL MODULE

With the DRB, enter Body then Automatic Temp Control.
Was the DRB able to I/D or communicate with the ATC?
Yes → Go To 2
No → Refer to the Communication category for the related symptom(s).


Did this DTC reset?
Yes → Replace the Body Control Module.
338
COMMUNICATION
Symptom:
AUDIO MESSAGES NOT RECEIVED
AUDIO MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the radio for at least 5
seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE RADIO
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Radio.
Was the DRB able to I/D or communicate with the Radio?
Yes → Go To 2


Did this DTC reset?
339
COMMUNICATION
Symptom List:
BCM, PCI BUS SHORTED TO BATTERY
BCM, PCI BUS SHORTED TO GROUND
FCM, PCI BUS SHORTED TO BATTERY
FCM, PCI BUS SHORTED TO GROUND
The title for the tests will be BCM, PCI BUS SHORTED TO
BATTERY.
BCM, PCI BUS SHORTED TO BATTERY

When Monitored: Continuously
Set Condition: Anytime the BCM detects a short to battery on the PCI Bus circuit.
BCM, PCI BUS SHORTED TO GROUND

Set Condition: Anytime the BCM detects a short to ground on the PCI Bus circuit.
FCM, PCI BUS SHORTED TO BATTERY

Set Condition: Anytime the FCM detects a short to battery on the PCI Bus circuit.
FCM, PCI BUS SHORTED TO GROUND

Set Condition: Anytime the FCM detects a short to ground on the PCI Bus circuit.
340
COMMUNICATION
BCM, PCI BUS SHORTED TO BATTERY — Continued
POSSIBLE CAUSES

1 NOTE: For this code to be active, the DRB will not be able to communicate All
with any modules on the vehicle (except the PCM).
NOTE: If this code is set and active it will be necessary to perform the PCI
Bus Communication Failure symptom.
WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, wiggle the wiring
harnesses. This is to try and duplicate the complete bus failure condition.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?
Yes → Repair as necessary

341
COMMUNICATION
Symptom:
COUNTRY CODE NOT PROGRAMMED
POSSIBLE CAUSES
SELECT CORRECT COUNTRY CODE

1 With the DRB, enter Body Computer, Miscellaneous then Change Country Code. All
Select the correct country code for the vehicle.
With the DRB, erase BCM DTC’s.
With the DRB, read BCM DTC’s.
Did this DTC reset?
342
COMMUNICATION
Symptom:
FCM MESSAGES NOT RECEIVED
FCM MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Front Control Module
(FCM) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE FRONT CONTROL MODULE
BODY CONTROL MODULE

With the DRB, attempt to communicate with the FCM.
Was the DRB able to I/D or communicate with the FCM?
Yes → Go To 2


Did this DTC reset?
343
COMMUNICATION
Symptom:
FCM, BCM COMMUNICATION FAULT
FCM, BCM COMMUNICATION FAULT

Set Condition: The FCM does not receive any messages from the Body Control Module
(BCM) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE BCM

Yes → Go To 2


Did this DTC reset?
344
COMMUNICATION
Symptom:
FCM, HVAC COMMUNICATION FAULT
FCM, HVAC COMMUNICATION FAULT

Set Condition: The FCM does not receive any messages from the Automatic Temperature
Control (ATC) module or the A/C Heater Control (MTC) for at least 20 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE HVAC

With the DRB, attempt to communicate with the A/C Heater Control (MTC) or the
Automatic Temp Control (ATC).
Was the DRB able to I/D or communicate with the HVAC or the ATC?
Yes → Go To 2


Did this DTC reset?

345
COMMUNICATION
Symptom:
FCM, PCI INTERNAL FAULT

When Monitored: The FCM detects an internal fault.
Set Condition: The DTC will set if the FCM detects an internal fault.
POSSIBLE CAUSES

1 Connect the DRB to the Data Link Connector. All
With the DRB, erase FCM DTC’s.
Turn the ignition off then turn the ignition on.
With the DRB, read FCM DTC’s.
Did this DTC reset?
346
COMMUNICATION
Symptom:
FCM, PCM COMMUNICATION FAULT
FCM, PCM COMMUNICATION FAULT

Set Condition: The FCM does not receive any messages from the PCM for at least 5
seconds.
POSSIBLE CAUSES
PCM COMMUNICATION FAULT
ATTEMPT TO COMMUNICATE WITH THE PCM
PCI BUS CIRCUIT OPEN

With the DRB, enter Instrument Cluster, System Tests then PCM Monitor.
Does the DRB display: PCM is active on BUS?
Yes → Erase the DTC, if DTC resets, replace the Front Control Module.
No → Go To 2

With the DRB, attempt to communicate with the PCM.
Was the DRB able to communicate with the PCM?
Yes → Go To 3
No → Refer to the communication category and perform the appropriate

symptom.

Disconnect the PCM C2 harness connector.
Connect the diagnostic junction port tester #8339 to the diagnostic junction port.
Note: Do not connect the tester to the DRB.
Measure the resistance of the PCI Bus circuit between the diagnostic junction port
tester and the PCM C2 connector.
Yes → Replace and program the Powertrain Control Module in accor-
No → Repair the PCI Bus circuit for an open.

347
COMMUNICATION
Symptom:
FCM, RADIO COMMUNICATION FAULT
FCM, RADIO COMMUNICATION FAULT

Set Condition: The FCM does not receive any messages from the radio for at least 5
seconds.
POSSIBLE CAUSES

Yes → Go To 2


Did this DTC reset?
348
COMMUNICATION
Symptom:
FCM, TCM COMMUNICATION FAULT
FCM, TCM COMMUNICATION FAULT

Set Condition: The FCM does not receive any messages from the Transmission Control
Module (TCM) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE TCM

With the DRB, attempt to communicate with the TCM.
Was the DRB able to I/D or communicate with the TCM?
Yes → Go To 2


Did this DTC reset?
349
COMMUNICATION
Symptom:
IGNITION MUX SWITCH INPUT OPEN
IGNITION MUX SWITCH INPUT OPEN

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The Ignition MUX sense circuit voltage at the BCM goes above 4.9 volts.
POSSIBLE CAUSES
IGNITION SWITCH
IGNITION SWITCH SENSE CIRCUIT OPEN
IGNITION SWITCH SENSE RETURN CIRCUIT OPEN
BODY CONTROL MODULE
BODY CONTROL MODULE

Disconnect the ignition switch 5-way connector.
Connect a jumper wire between the Ignition Switch Sense circuit and ground.
With the DRBIIIt in Sensors, read the IGNITION SW voltage.
Does the DRBIIIt display IGNITION SW 0.0 volts?
Yes → Go To 2
No → Go To 3

Gain access to the Body Control Module C5 connector.
Backprobe a jumper wire between the Ignition Switch Sense circuit and ground.
Yes → Repair the Ignition Switch Sense circuit for an open.
No → Replace the Body Control Module.


Disconnect the ignition switch connector.
Connect a jumper wire between the Ignition Switch Sense circuit and the Ignition
Switch Sense Return circuit.
Yes → Replace the Ignition Switch.

No → Go To 4
350
COMMUNICATION
IGNITION MUX SWITCH INPUT OPEN — Continued

Backprobe a jumper wire between the Ignition Switch Sense Return circuit and
ground.
Yes → Repair the Ignition Switch Sense Return circuit for an open.

351
COMMUNICATION
Symptom:
IGNITION MUX SWITCH INPUT SHORT
IGNITION MUX SWITCH INPUT SHORT

Set Condition: The Ignition MUX Sense circuit voltage at the BCM goes below 0.5 volt for
more than 2 seconds.
POSSIBLE CAUSES
IGNITION SWITCH SENSE CIRCUIT SHORTED
IGNITION SWITCH SENSE RETURN CIRCUIT OPEN
IGNITION SWITCH SHORTED
BODY CONTROL MODULE

Disconnect the ignition switch 5-way connector.
Yes → Go To 2
No → Replace the Ignition Switch.

Gain access to the Body Control Module.
Disconnect the Body Control Module C5 connector.
Measure the resistance of the Ignition Switch Sense circuit in the BCM C5 connector.
Yes → Repair the Ignition Switch Sense circuit for a short to ground.
No → Go To 3

Gain access to the Body Control Module.
Measure the resistance of the Ignition Switch Sense Return circuit in the BCM C4
connector.
Yes → Repair the Ignition Switch Sense Return circuit for an open.

352
COMMUNICATION
Symptom:
IGNITION RUN OUTPUT SHORT
IGNITION RUN OUTPUT SHORT

Set Condition: The Ignition Switch Output circuit(s) from the BCM to the HVAC,
Overhead Console, or the ABS controller are open or go below 0.5 volt for more than 2
seconds.
POSSIBLE CAUSES
TEST FOR CURRENT DTC’S
BODY CONTROL MODULE IGNITION OUTPUT INOPERATIVE (HVAC)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT OPEN (HVAC)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT SHORTED (HVAC)
BODY CONTROL MODULE IGNITION OUTPUT INOPERATIVE (OVERHEAD)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT OPEN (OVERHEAD)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT SHORTED (OVERHEAD)
BODY CONTROL MODULE IGNITION OUTPUT INOPERATIVE (ABS)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT OPEN (ABS)
BODY CONTROL MODULE IGNITION OUTPUT CIRCUIT SHORTED (ABS)
BODY CONTROL MODULE

1 With the DRBIIIt, record and erase DTC’s. All
Cycle the ignition from ON to OFF.
Start the vehicle and observe the DRBIIIt.
Does the DRBIIIt display IGNITION RUN OUTPUT SHORT?
Yes → Go To 2
No → The condition that caused this DTC is currently not present. Use
the wiring diagram/schematic as a guide, and inspect the related
wiring harness for a possible intermittent condition.
2 A failure in the HVAC, Overhead Console, or the ABS system could cause this DTC All
to set. The Ignition Switch Run (HVAC) circuit will be diagnosed first.
Continue to the HVAC circuit for further diagnosis.
HVAC circuit diagnostics.

Go To 3
353
COMMUNICATION
IGNITION RUN OUTPUT SHORT — Continued

Disconnect the HVAC connector.
Measure the voltage of the Ignition Switch Run (HVAC) circuit in the HVAC
controller connector.
Yes → Go To Test #6. The condition that caused the DTC to set is not
present on this circuit. Further diagnostics are required to
determine the cause of the DTC.
No → Go To 4
4 Gain access to the Body Control Module C4 connector. All

While back probing, measure the voltage of the Ignition Switch Run (HVAC) circuit.
Yes → Repair the Ignition Switch Run (HVAC) circuit for an open.
No → Go To 5

Measure the resistance between ground and the Ignition Switch Run (HVAC) circuit
in the HVAC controller connector.
Yes → Repair the Ignition Switch Run (HVAC) circuit for a short to
ground.
No → Go To 6
to set. The Ignition Switch Output (Overhead Console) circuit will be diagnosed.
Continue to the OVERHEAD CONSOLE circuit for further diagnosis.
OVERHEAD CONSOLE circuit diagnostics.
Go To 7

Disconnect the Overhead Console connector.
Measure the voltage of the Ignition Switch Output circuit in the Overhead Console
connector.
Yes → Go To Test #10. The condition that caused the DTC to set is not
present on this circuit. Further diagnostics are required to
determine the cause of the DTC.
No → Go To 8
354
COMMUNICATION

While back probing, measure the voltage of the Ignition Switch Output circuit.
Yes → Repair the Ignition Switch Output circuit for an open.

No → Go To 9

Measure the resistance between ground and the Ignition Switch Output circuit in the
Overhead Console connector.
Yes → Repair the Ignition Switch Output circuit for a short to ground.
No → Go To 10
to set. The Fused Ignition Switch Output (ABS) circuit will be diagnosed.
Continue to the ABS circuit for further diagnosis.
ABS circuit diagnostics.

Go To 11

Disconnect the ABS connector.
Measure the voltage of the Fused Ignition Switch Output circuit in the ABS
connector.
Yes → The condition that caused the DTC to set is not present on this
circuit. Further diagnostics are required to determine the cause of
the DTC.
No → Go To 12

While back probing, measure the voltage of the Fused Ignition Switch Output circuit.
Yes → Repair the Ignition Switch Output circuit for an open.

No → Go To 13

Measure the resistance between ground and the Fused Ignition Switch Output
circuit in the ABS connector.
Yes → Repair the Ignition Switch Output circuit for a short to ground.
No → Go To 14
355
COMMUNICATION

14 Select the diagnostic repair. All
For this condition:

356
COMMUNICATION
Symptom:
INTERNAL BCM FAILURE

When Monitored: The BCM detects an internal fault for 10 seconds.
Set Condition: The DTC will set if the BCM detects an internal fault.
POSSIBLE CAUSES

Did this DTC reset?
357
COMMUNICATION
Symptom:
LEFT PSD MESSAGES NOT RECEIVED
LEFT PSD MESSAGES NOT RECEIVED

When Monitored: When the Body Control Module is awake.
Set Condition: The BCM does not sense a response from the Left Power Sliding Door
Module.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE LEFT SLIDING DOOR CONTROL MODULE
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Left Sliding Door Control Module.
Was the DRB able to I/D or communicate with the Left Sliding Door Control Module?
Yes → Go To 2


Did this DTC reset?
358
COMMUNICATION
Symptom:
LIFTGATE MODULE MESSAGES NOT RECEIVED
LIFTGATE MODULE MESSAGES NOT RECEIVED

Set Condition: The BCM does not sense a response from the Power Liftgate Control
Module.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE POWER LIFTGATE MODULE
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Power Liftgate Module.
Was the DRB able to I/D or communicate with the Power Liftgate Module?
Yes → Go To 2


Did this DTC reset?
359
COMMUNICATION
Symptom:
MIC MESSAGES NOT RECEIVED
MIC MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Instrument Cluster
(MIC) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE MIC
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Instrument Cluster (MIC).
Was the DRB able to I/D or communicate with the Instrument Cluster (MIC)?
Yes → Go To 2


Did this DTC reset?
360
COMMUNICATION
Symptom:
MSM MESSAGES NOT RECEIVED
MSM MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Memory Seat Module
(MSM) for at least 0.125 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE MEMORY SEAT MODULE
BODY CONTROL MODULE

With the DRB, enter Body then Memory Seat Module.
Was the DRB able to I/D or communicate with the MSM?
Yes → Go To 2


Did this DTC reset?
361
COMMUNICATION
Symptom:
NO PCI MESSAGES FROM CD CHANGER
NO PCI MESSAGES FROM CD CHANGER

When Monitored: With the ignition on and the radio on.
Set Condition:
POSSIBLE CAUSES
CD CHANGER (DIN) CABLE
CD CHANGER PCI BUS CIRCUIT OPEN
IGNITION SWITCH OUTPUT CIRCUIT OPEN
RADIO GROUND CKT OPEN
CD CHANGER

Disconnect the Radio C4 connector (DIN cable) from the Radio and the CD Changer.
Visually inspect the Radio C4 (DIN) cable for damage.
In the next step check for open wires in the DIN cable.
Measure the resistance of the each DIN cable circuit between the Radio DIN cable
connector and the CD Changer DIN cable connector.
In the next step check for wires shorted to the DIN cable metal connectors.
Measure the resistance between each Radio C4 connector ( DIN cable) circuit and the
Radio Din cable metal connector.
Is the DIN cable circuits shorted together or open?
Yes → Replace the CD Changer (DIN) cable.

No → Go To 2
362
COMMUNICATION
NO PCI MESSAGES FROM CD CHANGER — Continued

2 Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and All
black test probes.
Select DRB Standalone.
Select lab scope.
Select Live.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Press F2 again
when complete.
Disconnect the CD Changer harness connector (DIN cable).
Reconnect the Radio C4 (DIN Cable) harness connector.
Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus
circuit in the CD Changer DIN Cable connector.
Turn the Radio and CD Changer on.
Does the voltage pulse from 0 to approximately 7.5 volts?
Yes → Go To 3


Turn the Radio and the CD Changer on.
Using a 12-volt test light connected to ground, probe the Ignition Switch Output
circuit in the CD Changer DIN Cable connector.
Yes → Go To 4


Using a 12-volt test light connected to 12-volts, probe the CD Changer ground circuit
in the CD Changer connector (DIN cable).
Yes → Go To 5

Repair
Replace the CD Changer.
363
COMMUNICATION
Symptom:
ORC MESSAGES NOT RECEIVED
ORC MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Occupant Restraint
Controller (ORC) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE OCCUPANT RESTRAINT CONTROLLER
BODY CONTROL MODULE

With the DRB, attempt to communicate with the ORC.
Was the DRB able to I/D or communicate with the ORC?
Yes → Go To 2


Did this DTC reset?
364
COMMUNICATION
Symptom:
OTIS MESSAGES NOT RECEIVED
OTIS MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the overhead console for at
least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE OTIS
BODY CONTROL MODULE

With the DRB, attempt to communicate with the overhead console.
Was the DRB able to I/D or communicate with the overhead console?
Yes → Go To 2


Did this DTC reset?
365
COMMUNICATION
Symptom:
PCI INTERNAL HARDWARE FAILURE
POSSIBLE CAUSES
PCI INTERNAL HARDWARE FAILURE

Did this DTC reset?
366
COMMUNICATION
Symptom:
PCM MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the PCM for at least 5
seconds.
POSSIBLE CAUSES
PCM MESSAGE NOT RECEIVED
ATTEMPT TO COMMUNICATE WITH THE PCM

With the DRB, enter Instrument Cluster, System Tests then PCM Monitor.
Does the DRB display: PCM is active on BUS?
Yes → Erase the DTC, if DTC resets, replace the Body Control Module.
No → Go To 2

With the DRB, attempt to communicate with the PCM.
Was the DRB able to communicate with the PCM?
Yes → Go To 3
No → Refer to the communication category and perform the appropriate

symptom.

Note: Do not connect the tester to the DRB.
tester and the PCM C2 connector.

367
COMMUNICATION
Symptom:
RADIO MEM MSG NOT RECEIVED
RADIO MEM MSG NOT RECEIVED

Set Condition:
POSSIBLE CAUSES
CHECK THE MEMORY SYSTEM
BODY CONTROL MODULE

Yes → Go To 2


Operate the memory seat system.
Did the memory seat system operate properly?
Yes → Go To 3
No → Refer to the Memory Seat category and perform the appropriate
symptom.

Did this DTC reset?
368
COMMUNICATION
Symptom:
RIGHT PSD MESSAGES NOT RECEIVED
RIGHT PSD MESSAGES NOT RECEIVED

Set Condition: The BCM does not sense a response from the Right Power Sliding Door
Module.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE RIGHT SLIDING DOOR CONTROL MODULE
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Right Sliding Door Control Module.
Was the DRB able to I/D or communicate with the Right Sliding Door Control
Module?
Yes → Go To 2


Did this DTC reset?

369
COMMUNICATION
Symptom:
RUN/START HARDWIRE INPUT FAILURE
RUN/START HARDWIRE INPUT FAILURE

Set Condition: The Fused Ignition Switch Output circuit voltage at the BCM goes below
0.5 volts and the BCM detects a voltage mismatch between the two ignition switch inputs.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
IGNITION SWITCH
BODY CONTROL MODULE

Does the DRBIIIt display RUN/START HARDWIRE INPUT FAILURE?
Yes → Go To 2

Gain access to the Ignition Switch connector.
Yes → Go To 3
No → Replace the Ignition Switch.


Yes → Repair the Fused Ignition Switch Output circuit for an open.
370
COMMUNICATION
Symptom:
SKIM MESSAGES NOT RECEIVED
SKIM MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Sentry Key Immobilizer
Module (SKIM) for at least 5 seconds.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE SENTRY KEY IMMOBILIZER MODULE
BODY CONTROL MODULE

With the DRB, attempt to communicate with the SKIM.
Was the DRB able to I/D or communicate with the SKIM?
Yes → Go To 2


Did this DTC reset?
371
COMMUNICATION
Symptom:
TCM MESSAGES NOT RECEIVED
TCM MESSAGES NOT RECEIVED

Set Condition: The BCM does not receive any messages from the Transmission Control
Module (TCM) for at least 5 seconds.
POSSIBLE CAUSES
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Transmission Control Module.
Was the DRB able to I/D or communicate with the TCM?
Yes → Go To 2


Did this DTC reset?
372
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN FROM AUTOMATIC TEMPERATURE
CONTROL MODULE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
FUSED (B+) CKT OPEN
IGNITION SWITCH CIRCUIT OPEN
OPEN PCI BUS CIRCUIT
AUTOMATIC TEMPERATURE CONTROL MODULE

With the DRB, enter Body then Body Computer.
Yes → Go To 2
No → Refer to the symptom list for problems related to no communica-

tion with the BCM.

Measure the resistance between ground and the ground circuit.
Yes → Go To 3


Using a 12-volt test light connected to ground, probe the Fused B+ circuit.
Yes → Go To 4
No → Repair the Fused B+ circuit for an open or short. Refer to the

wiring diagrams in the service information.

Using a 12-volt test light connected to ground, probe the Ignition Switch circuit.
Yes → Go To 5
No → Repair the Ignition Switch circuit for an open or short. Refer to

the wiring diagrams in the service information.
373
COMMUNICATION
*BUS +/- SIGNALS OPEN FROM AUTOMATIC TEMPERATURE CON-

TROL MODULE — Continued
5 Note: Ensure there is PCI Bus communication with other modules on the All
vehicle before proceeding. If not, refer to the symptom list from the menu
and repair as necessary.
black test probes.
Select lab scope.
Select Live.
Press F2 for Scope.
when complete.
circuit in the ATC connector.
Yes → Go To 6
Repair
Replace the Automatic Temperature Control Module.
374
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN FROM MEMORY SEAT/MIRROR MODULE
POSSIBLE CAUSES
FUSED SEAT SWITCH DRIVER CIRCUIT OPEN
GROUND CIRCUIT OPEN
MEMORY SEAT/MIRROR MODULE

Yes → Go To 2

tion with the BCM.
Perform MEMORY SYSTEM VERIFICATION TEST - VER 1.

Disconnect the Memory Seat/Mirror Module C4 harness connector.
Using a 12-volt test light connected to ground, probe the Fused Seat Switch Driver
circuit.
Yes → Go To 3
No → Check the Power Seat Circuit Breaker for an open or short. If ok,
repair the Fused Seat Switch Driver circuit for an open or short.

Yes → Go To 4
No → Repair the ground circuit for an open.

375
COMMUNICATION
*BUS +/- SIGNALS OPEN FROM MEMORY SEAT/MIRROR MODULE —

Continued
black test probes.
With the DRBIIIt select Pep Module Tools.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the Memory Seat/Mirror Module connector.
Yes → Go To 5

Repair
Replace the Memory Seat/Mirror Module.
376
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN FROM SENTRY KEY IMMOBILIZER MOD-
ULE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
FUSED B(+) CIRCUIT OPEN
SENTRY KEY IMMOBILIZER MODULE

Yes → Go To 2

tion with the BCM.
Perform SKIS VERIFICATION.

Disconnect the SKIM harness connector.
Yes → Go To 3


circuit.
Yes → Go To 4
No → Repair the Ignition Switch Output circuit for an open.

Using a 12-volt test light connected to ground, probe the Fused B(+) circuit.
Yes → Go To 5
No → Repair the Fused B+ circuit for an open.

377
COMMUNICATION
*BUS +/- SIGNALS OPEN FROM SENTRY KEY IMMOBILIZER MODULE

— Continued
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the SKIM connector.
Yes → Go To 6
Repair
Replace and program the Sentry Key Immobilizer Module in
accordance with the Service Information.
378
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM BODY CON-
TROL MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH ANOTHER MODULE
FUSED (B+) CKT OPEN
OPEN GROUND CIRCUIT(S)
BODY CONTROL MODULE

With the DRB, attempt to communicate with the Airbag Control Module (ACM).
With the DRB, attempt to communicate with the Controller Antilock Brake (CAB)
module.
Was the DRB able to I/D or communicate with the ACM and the CAB?
Yes → Go To 2
No → Refer to symptom list for problems related to the PCI Bus

Communication Failure.

Yes → Go To 3
No → Check fuse #14 in the IPM for an open. If ok, repair the Fused B+
circuit for an open or short. Refer to the wiring diagrams in the
service information.

Measure the resistance between ground and both Ground circuits.
Is the resistance below 10.0 ohms for each measurement?
Yes → Go To 4
No → Repair the Ground circuit(s) for an open.
379
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM BODY CONTROL

MODULE — Continued
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the BCM connector.
Yes → Go To 5
Repair
380
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM HVAC
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
IGNITION SWITCH CIRCUIT OPEN
A/C HEATER CONTROL

Yes → Go To 2

tion with the BCM.

Disconnect the A/C Heater Control C1 harness connector.
Yes → Go To 3

Using a 12-volt test light connected to ground, probe the Ignition Switch circuit.
Yes → Go To 4
No → Repair the Ignition Switch circuit for an open or short.

381
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM HVAC — Continued

black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the A/C Heater Control connector.
Yes → Go To 5
Repair
Replace the A/C Heater Control.
382
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM INSTRUMENT
CLUSTER
POSSIBLE CAUSES
OPEN GROUND CIRCUIT
OPEN FUSED B+ CIRCUIT
INSTRUMENT CLUSTER WAKE UP SENSE CKT OPEN
INSTRUMENT CLUSTER WAKE UP SENSE CKT INTERNALLY OPEN
INSTRUMENT CLUSTER WAKE UP SENSE CKT SHORTED TO VOLTAGE
INSTRUMENT CLUSTER WAKE UP SENSE CKT INTERNALLY SHORTED TO VOLTAGE
INSTRUMENT CLUSTER
BODY CONTROL MODULE

Yes → Go To 2

tion with the BCM.

Turn all lights off.
Disconnect the Instrument Cluster harness connector.
Measure the resistance between ground and both ground circuits.
Yes → Go To 3


Yes → Go To 4
383
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM INSTRUMENT CLUS-

TER — Continued
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the Instrument Cluster connector.
Yes → Go To 5

Reconnect the Instrument Cluster harness connector.
Measure the voltage of the Instrument Cluster Wake Up Sense circuit in the BCM C4
connector.
Yes → Go To 6
No → Go To 9

Using a 12-volt test light connected to ground, probe the Instrument Cluster Wake
Up Sense circuit.
Yes → Go To 7
No → Go To 8
384
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM INSTRUMENT CLUS-

TER — Continued
Up Sense circuit.
Yes → Repair the Instrument Cluster Wake Up Sense circuit for a short
to voltage.
No → Replace the Instrument Cluster.

Reconnect the BCM C4 harness connector.
Measure the resistance between ground and the Instrument Cluster Wake Up Sense
circuit at the Instrument Cluster connector.
Open and close a door. This is done to ensure the BCM is awake.

Measure the resistance of the Instrument Cluster Wake Up Sense circuit between the
BCM C4 connector and the MIC connector.
No → Repair the Instrument Cluster Wake Up Sense circuit for an

open.
385
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM LEFT SLIDING
DOOR CONTROL MODULE
POSSIBLE CAUSES
LEFT SLIDING DOOR WAKE UP SIGNAL WIRE OPEN
LEFT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
GROUND CIRCUIT OPEN
LEFT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO GROUND
BODY CONTROL MODULE - LEFT SLIDING DOOR WAKE UP GROUND OPEN
LEFT SLIDING DOOR CONTROL MODULE - OPEN

Disconnect the Left Sliding Door Control Module C1 connector.
Measure the voltage between Fused B(+) circuit and ground.
Yes → Go To 2
No → Repair the Fused B(+) circuit for an open.

Using a 12-volt test light connected to 12-volts, check the Ground circuit.
Yes → Go To 3

386
COMMUNICATION

DOOR CONTROL MODULE — Continued
black test probes.
Select lab scope.
Select Live.
Press F2 for Scope.
when complete.
circuit in the Left Sliding Door Control Module C2 connector.
Yes → Go To 4
4 Disconnect the Left Sliding Door Control Module C2 connector. All

Measure the resistance between ground and the Left Sliding Door Wake Up Signal
circuit.
Yes → Go To 5
No → Go To 8
5 Disconnect the Body Control Module C3 connector. All

Disconnect the Left Sliding Door Module C2 connector.
Measure the voltage between the Left Sliding Door Wake Up Signal circuit and
ground.
Yes → Repair the Left Sliding Door Wake Up Signal wire for a short to
voltage.
No → Go To 6

Measure the resistance between the Left Sliding Door Wake Up Signal circuit and
ground.
Is the resistance below 100.0 ohms
ground.
No → Go To 7
387
COMMUNICATION

Repair
Replace the Left Sliding Door Control Module.

Measure the resistance of the Left Sliding Door Wake Up Signal circuit between the
BCM C3 connector and the Left Sliding Door Control Module C2 connector.

No → Repair the Left Sliding Door Wake Up Signal wire for an open.
388
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM POWER LIFT-
GATE MODULE
POSSIBLE CAUSES
BODY CONTROL MODULE - LIFTGATE WAKE UP GROUND OPEN
LIFTGATE MODULE WAKE UP SIGNAL WIRE OPEN
LIFTGATE MODULE WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
GROUND CIRCUIT OPEN
LIFTGATE MODULE WAKE UP SIGNAL WIRE SHORT TO GROUND
POWER LIFTGATE MODULE - OPEN

Disconnect the Power Liftgate Module C1 connector.
Yes → Go To 2

Yes → Go To 3

389
COMMUNICATION

black test probes.
Select lab scope.
Select Live.
Press F2 for Scope.
when complete.
circuit in the Power Liftgate Module C2 connector.
Yes → Go To 4
4 Disconnect the Power Liftgate Module C2 connector. All

Measure the resistance between ground and the Liftgate Module Wake Up Signal
circuit.
Yes → Go To 5
No → Go To 8

Measure the voltage between the Liftgate Module Wake Up Signal circuit and
ground.
Yes → Repair the Liftgate Module Wake Up Signal wire for a short to
voltage.
No → Go To 6

Measure the resistance between the Liftgate Module Wake Up Signal circuit and
ground.
ground.
No → Go To 7
390
COMMUNICATION

Repair
Replace the Power Liftgate Module.

Measure the resistance of the Liftgate Module Wake Up Signal circuit between the
BCM C2 connector and the Power Liftgate Module C2 connector.

No → Repair the Liftgate Module Wake Up Signal wire for an open.
391
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM RIGHT SLID-
ING DOOR CONTROL MODULE
POSSIBLE CAUSES
RIGHT SLIDING DOOR WAKE UP SIGNAL WIRE OPEN
RIGHT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
GROUND CIRCUIT OPEN
RIGHT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO GROUND
BODY CONTROL MODULE - RIGHT SLIDING DOOR WAKE UP GROUND OPEN
RIGHT POWER SLIDING DOOR MODULE - OPEN

Disconnect the Right Sliding Door Control Module C1 connector.
Yes → Go To 2

Yes → Go To 3

392
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM RIGHT SLIDING

black test probes.
Select lab scope.
Select Live.
Press F2 for Scope.
when complete.
circuit in the Right Sliding Door Control Module C2 connector.
Yes → Go To 4
4 Disconnect the Right Sliding Door Control Module C2 connector. All

Measure the resistance between ground and the Right Sliding Door Wake Up Signal
circuit.
Yes → Go To 5
No → Go To 8

Disconnect the Right Sliding Door Module C2 connector.
Measure the voltage between the Right Sliding Door Wake Up Signal circuit and
ground.
Yes → Repair the Right Sliding Door Wake Up Signal wire for a short to
voltage.
No → Go To 6

Measure the resistance between the Right Sliding Door Wake Up Signal circuit and
ground.
ground.
No → Go To 7
393
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM RIGHT SLIDING

Repair
Replace the Right Sliding Door Control Module.

Measure the resistance of the Right Sliding Door Wake Up Signal circuit between the
BCM C3 connector and the Right Sliding Door Control Module C2 connector.

No → Repair the Right Sliding Door Wake Up Signal wire for an open.
394
COMMUNICATION
Symptom:
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM THATCHAM
ALARM MODULE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
THATCHAM ALARM MODULE

Yes → Go To 2

tion with the BCM.

Disconnect the RKE Module 6-way harness connector.
Yes → Go To 3


Disconnect the Thatcham Alarm Module C1 harness connector.
Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
Output circuit.
Yes → Go To 4
No → Repair the Fused Ignition Switch Output circuit for an open or

short.
395
COMMUNICATION
*BUS +/- SIGNALS OPEN OR NO RESPONSE FROM THATCHAM ALARM

Disconnect the Thatcham Alarm Module C1 harness connector.
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the Thatcham Alarm Module connector.
Yes → Go To 5
Repair
Replace the Thatcham Alarm Module in accordance with the
service information.
396
COMMUNICATION
Symptom:
*NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE ECM
GROUND CIRCUIT OPEN
SCI TRANSMIT CIRCUIT OPEN
CABIN HEATER ASSIST

With the DRB, attempt to communicate with the ECM.
Was the DRB able to I/D or communicate with the ECM?
Yes → Go To 2

tion with the ECM.

Yes → Go To 3
No → Check the IPM Fuse #15 for an open. If open, check for a short to
ground on the Fused B+ circuit. If not open, repair the Fused B+
circuit for an open.

Yes → Go To 4


Disconnect the DRB from the DLC.
Measure the resistance of the SCI Transmit circuit between the Cabin Heater Assist
connector and the DLC.
Yes → Go To 5
No → Repair the SCI Transmit circuit for an open.

397
COMMUNICATION
*NO RESPONSE FROM CABIN HEATER ASSIST - DIESEL ONLY —

Continued
Repair
Replace the Cabin Heater Assist in accordance with the service
information.
398
COMMUNICATION
Symptom:
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE
POSSIBLE CAUSES
NO RESPONSE FROM CAB
GROUND CIRCUIT OPEN
OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT
CONTROLLER ANTILOCK BRAKE

Note: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, attempt to communicate with the Body Control Module (BCM).
Was the DRB able to I/D or establish communications with either of the modules?
Yes → Go To 2
No → Refer to the Communications category and perform the symptom

PCI Bus Communication Failure.
Perform ABS VERIFICATION TEST - VER 1.

Disconnect the CAB harness connector.
Measure the resistance between ground and both ground circuits.
Is the resistance below 5.0 ohms for both measurements?
Yes → Go To 3
No → Repair the ground circuit(s) for an open.

Output circuit.
Yes → Go To 4
No → Repair the Fused Ignition Switch Output circuit for an open.
399
COMMUNICATION
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — Continued

black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the CAB connector.
Yes → Go To 5
Repair
Replace the Controller Antilock Brake in accordance with the
400
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
ECM PCI NO RESPONSE
ENGINE CONTROL MODULE

NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, enter Anti-Lock Brakes.
With the DRB, enter Body then Electro/Mechanical Cluster (MIC).
With the DRB, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
Yes → Go To 2
No → Refer to symptom PCI Bus Communication Failure in the Com-
munications category.
Perform ROAD TEST VERIFICATION - VER-2.
2 With the DRB read ECM Diagnostic Trouble Codes. This is to ensure power and All
grounds to the ECM are operational.
NOTE: If the DRB will not read ECM DTC’s, follow the NO RESPONSE TO
ECM (SCI only) symptom path, if vehicle will start. For NO START Condi-
tions follow the no start symptom in the Starting category.
Disconnect the ECM harness connectors.
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
Connect the Black lead to ground. Connect the Red lead to the PCI Bus circuit in the
ECM connector.
Yes → Replace and program the Engine Control Module in accordance


401
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY
POSSIBLE CAUSES
CHECK ECM POWERS AND GROUNDS
CABIN HEATER ASSIST
SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE
SCI TRANSMIT CIRCUIT SHORTED TO GROUND

1 Perform the symptom Checking ECM Power and Ground Circuits in the Driveability All
category.
Did the vehicle pass this test?
Yes → Go To 2
No → Repair as necessary.

Measure the resistance between ground and the SCI Transmit circuit.
Yes → Go To 3
No → Go To 4

Yes → Repair the SCI Transmit circuit for a short to ground.

No → Replace the Cabin Heater Assist in accordance with the service

information.

Measure the voltage of the SCI Transmit circuit at the DLC connector (cav 7).
Yes → Repair the SCI Transmit circuit for a short to voltage.

No → Go To 5
402
COMMUNICATION
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY — Continued

Measure the resistance of the SCI Transmit circuit between the ECM connector and
the DLC.
Yes → Go To 6

Repair
Replace and program the Engine Control Module in accordance
403
COMMUNICATION
Symptom:
*NO RESPONSE FROM FRONT CONTROL MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH ANOTHER MODULE
OPEN GROUND CIRCUIT(S)

With the DRB, attempt to communicate with the Controller Antilock Brake (CAB)
module.
Was the DRB able to I/D or communicate with any of the modules?
Yes → Go To 2
No → Refer to symptom list for problems related to the PCI Bus

Communication Failure.

Yes → Go To 3
No → Repair the Ground circuit(s) for an open.
404
COMMUNICATION
*NO RESPONSE FROM FRONT CONTROL MODULE — Continued

black test probes.
Select lab scope.
Select Live.
Press F2 for Scope.
when complete.
circuit in the FCM connector.
Yes → Go To 4
Repair
405
COMMUNICATION
Symptom:
*NO RESPONSE FROM LEFT SIACM
POSSIBLE CAUSES
INTERROGATE FCM
GROUND CIRCUIT OPEN
SIACM RUN/START DRIVER CIRCUIT OPEN
LEFT SIDE IMPACT AIRBAG CONTROL MODULE

With the DRBIIIt, check the FCM for any DTC’s.
Are any FCM DTC’s present?
Yes → Refer to the appropriate category and perform the symptom.
No → Go To 2

Warning: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT
Disconnect the Left Side Impact Airbag Control Module harness connector.
Yes → Go To 3

Note: When reconnecting Airbag system components, the ignition must be
3 Warning: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT All
Turn the ignition on and then reconnect the Battery.
Measure the voltage of the SIACM Run/Start Driver circuit.
Yes → Go To 4
No → Repair the SIACM Run/Start Driver circuit for an open.


406
COMMUNICATION
*NO RESPONSE FROM LEFT SIACM — Continued

4 NOTE: Ensure there is PCI bus communication with other modules. If not, All
refer to the PCI Bus Communication Failure symptom and repair as
necessary.
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope, then enter to select channel.
when complete.
circuit in the Left Side Impact Airbag Control Module connector.
Yes → Go To 5

Yes → Replace the Left Side Impact Airbag Control Module (LSIACM) in
accordance with the Service Information. WARNING: Make sure
the battery is disconnected and wait 2 minutes before proceeding.
407
COMMUNICATION
Symptom:
*NO RESPONSE FROM ORC
POSSIBLE CAUSES
CHECKING FOR VOLTAGE AT ORC
ORC GROUND CIRCUIT OPEN
OCCUPANT RESTRAINT CONTROLLER

1 NOTE: Check the FCM for DTC’s. If DTC’s are present, go to the appropriate All
category and perform the DTC.
Ensure that the battery is fully charged.
Disconnect the Occupant Restraint Controller harness connector.
Using a 12-volt test light connected to ground, probe the ORC Run Only Driver
Circuit and the ORC Run/Start Driver Circuit at the ORC connector.
NOTE: One open circuit will not cause a NO RESPONSE condition.
Is the test light illuminated on both circuits?
Yes → Go To 2
No → Repair the ORC Run Only Driver and ORC Run/Start Driver
circuits for an open.
NOTE: When reconnecting airbag system components, the ignition must be


Yes → Go To 3
When reconnecting Airbag system components, the ignition must be turned

off and the battery must be disconnected.
408
COMMUNICATION
*NO RESPONSE FROM ORC — Continued

3 Note: Ensure there is PCI bus communication with other modules. If not, All
necessary.
black test probes.
Select lab scope.
Select Live Data.
when complete.
circuit in the Occupant Restraint Controller connector.
Yes → Go To 4

Repair
with the Service lnformation. WARNING: Make sure the battery
409
COMMUNICATION
Symptom:
*NO RESPONSE FROM OVERHEAD CONSOLE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
OVERHEAD CONSOLE

1 NOTE: Ensure there is PCI Bus communication with other modules on the All
Disconnect the Overhead Console harness connector.
Measure the resistance between ground and the ground circuit (cav 4).
Yes → Go To 2
circuit.
Yes → Go To 3
No → Repair the Ignition Switch Output circuit for an open. Refer to the
wiring diagrams located in the Service Information.
Yes → Go To 4
No → Repair the Fused B+ circuit for an open. Refer to the wiring

diagrams located in the Service Information.
410
COMMUNICATION
*NO RESPONSE FROM OVERHEAD CONSOLE — Continued

black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the Overhead Console connector.
Yes → Go To 5
Repair
Replace the Overhead Console.
411
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (PCI BUS)
POSSIBLE CAUSES
PCM PCI NO RESPONSE

the question.
Yes → Go To 2
Perform POWERTRAIN VERIFICATION TEST VER - 1.
2 With the DRB read PCM Diagnostic Trouble Codes. This is to ensure power and All
grounds to the PCM are operational.
NOTE: If the DRB will not read PCM DTC’s, follow the NO RESPONSE TO
PCM (SCI only) symptom path, if vehicle will start. For NO START Condi-
tions follow symptom NO RESPONSE in Starting category.
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
Connect the Black lead to the PCM ground. Connect the Red lead to the PCI Bus
circuit in the PCM connector.
Yes → Replace the Powertrain Control Module in accordance with the


412
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (SCI ONLY)
POSSIBLE CAUSES
CHECK PCM POWERS AND GROUNDS
TRANSMISSION CONTROL MODULE
SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE
SCI CIRCUITS SHORTED TOGETHER
SCI RECEIVE CIRCUIT SHORTED TO GROUND
SCI RECEIVE CIRCUIT OPEN
GROUND CIRCUITS AT DLC OPEN

1 Perform the symptom Checking PCM Power and Ground Circuits in the Driveability All
category.
Yes → Go To 2

Yes → Go To 3
No → Go To 4

Disconnect the TCM harness connector (if equipped).
NOTE: If vehicle is not equipped with a TCM, answer yes to the question.

No → Replace the Transmission Control Module.
413
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued

Disconnect the PCM harness connectors.
Disconnect the TCM harness connector (if equipped).

No → Go To 5

Measure the voltage of the SCI Receive circuit at the DLC connector (cav 6).
Yes → Repair the SCI Receive circuit for a short to voltage.
No → Go To 6

Measure the resistance between the SCI Transmit circuit and the SCI Receive circuit
at the PCM connector.
Yes → Repair the short between the SCI Transmit and the SCI Receive
circuits.
No → Go To 7

Measure the resistance between ground and the SCI Receive circuit.
Yes → Repair the SCI Receive circuit for a short to ground.
No → Go To 8

Measure the resistance of the SCI Receive circuit between the PCM C2 connector and
the DLC.
Yes → Go To 9
No → Repair the SCI Receive circuit for an open.
414
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued

Measure the resistance of the SCI Transmit circuit between the PCM C2 connector
and the DLC.
Yes → Go To 10


Disconnect the negative battery cable.
Measure the resistance between ground and both ground circuits at the DLC.
Yes → Go To 11
No → Repair the ground circuit that measured above 5.0 ohms for an
open.

Repair
Replace and program the Powertrain Control Module in accor-
415
COMMUNICATION
Symptom:
*NO RESPONSE FROM RADIO
POSSIBLE CAUSES
NO RESPONSE FROM RADIO
OPEN FUSED ACCESSORY RELAY OUTPUT CIRCUIT
OPEN FUSED B+ CIRCUIT
RADIO GROUND CIRCUIT OPEN
RADIO

the question.
Yes → Go To 2
No → Refer to the Communications category and perform the symptom

PCI Bus Communication Failure.

Using a 12-volt test light connected to ground, probe the Fused Accessory Relay
Output circuit.
Yes → Go To 3
No → Check fuse #5 in the IPM for an open. If ok, repair the Fused
Accessory Relay Output circuit for an open or short. Refer to the
wiring diagrams located in the Service Information.

Yes → Go To 4
No → Check fuse #14 in the IPM for an open. If ok, repair the Fused B+
circuit for an open or short. Refer to the wiring diagrams located
in the Service Information.
416
COMMUNICATION
*NO RESPONSE FROM RADIO — Continued

Disconnect the Radio ground wire.
Measure the resistance between ground and the radio ground wire.
Yes → Go To 5
No → Replace or repair the radio ground strap.

black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the Radio connector.
Yes → Go To 6


Repair
Replace the Radio.
417
COMMUNICATION
Symptom:
*NO RESPONSE FROM RIGHT SIACM
POSSIBLE CAUSES
INTERROGATE FCM
GROUND CIRCUIT OPEN
SIACM RUN/START DRIVER CIRCUIT OPEN
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE

With the DRBIIIt, check the FCM for any DTC’s.
Are any FCM DTC’s present?
Yes → Refer to the appropriate category and perform the symptom.
No → Go To 2

Warning: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT
Disconnect the Right Side Impact Airbag Control Module harness connector.
Measure the resistance between ground and the Ground circuit.
Yes → Go To 3

3 Warning: TURN IGNITION OFF, DISCONNECT THE BATTERY AND WAIT All
Measure the voltage of the SIACM Run/Start Driver circuit.
Yes → Go To 4
No → Repair the SIACM Run/Start Driver circuit for an open.


418
COMMUNICATION
*NO RESPONSE FROM RIGHT SIACM — Continued

4 NOTE: Ensure there is PCI bus communication with other modules. If not, All
necessary.
black test probes.
Select lab scope.
Select Live Data.
when complete.
circuit in the Right Side Impact Airbag Control Module connector.
Yes → Go To 5

Yes → Replace the Right Side Impact Airbag Control Module (RSIACM)
in accordance with the Service Information. WARNING: Make
sure the battery is disconnected and wait 2 minutes before
proceeding.
419
COMMUNICATION
Symptom:
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE
POSSIBLE CAUSES
NO RESPONSE FROM TRANSMISSION CONTROL MODULE
FCM OUTPUT (RUN/ST) CIRCUIT OPEN
IGNITION SWITCH OUTPUT (START) CIRCUIT OPEN
GROUND CIRCUIT(S) OPEN
TRANSMISSION CONTROL MODULE

the question.
Yes → Go To 2
No → Refer to the Body Communication category and perform the

symptom PCI Bus Communication Failure.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.

Disconnect the TCM harness connector.
Using a 12-volt test light connected to ground, probe the FCM Output (Run/St)
circuit.
Note: The light must illuminate brightly, if it does not light, or lights dimly,
the circuit must be repaired. If there is any doubt, compare the brightness
when testing the circuit, to the brightness when connected directly to the
battery positive post.
Yes → Go To 3
No → Repair the FCM Output (Run/St) circuit for an open. Refer to the
wiring diagrams location in the Service Information.
420
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE — Continued

Remove the starter relay from the IPM.
(Start) circuit.
Observe the test light while momentarily turning the ignition switch to the Start
position.
Yes → Go To 4
No → Repair the Ignition Switch Output (Start) circuit for an open.

Refer to the wiring diagrams located in the Service Information.
Note: Reinstall the original Starter Relay.

Using a 12-volt test light connected to ground, probe the Fused B(+) circuit.
Yes → Go To 5
No → Check IPM fuse #15 for an open. If OK, repair the Fused B(+)
circuit for an open. Refer to the wiring diagrams located in the

Using a 12-volt test light connected to 12-volts, probe each ground circuit in the TCM
connector.
NOTE: The light must illuminate brightly, if it does not light, or lights dimly,
battery negative post.
Is the light illuminated at all ground circuits?
Yes → Go To 6
No → Repair the Ground circuit(s) for an open. Check the main ground
connection to engine block and/or chassis. Refer to the wiring
diagrams located in the Service Information.
421
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE — Continued

black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
circuit in the TCM connector.
Yes → Go To 7
Repair
Replace the Transmission Control Module in accordance with the
422
COMMUNICATION
Symptom:
*PCI BUS COMMUNICATION FAILURE
POSSIBLE CAUSES
WITH THE DRB PERFORM A MODULE SCAN
OPEN PCI BUS CIRCUIT AT THE DATA LINK CONNECTOR
USING THE DRB, PERFORM THE PCI BUS CONTROL MODE
DISCONNECT THE MODULE(S) HARNESS CONNECTOR
PCI BUS CIRCUIT SHORTED TO VOLTAGE
DISCONNECT THE MODULE(S) HARNESS CONNECTOR
PCI BUS CIRCUIT SHORTED TO GROUND
WIRING HARNESS INTERMITTENT FAILURE

1 Note: Determine which modules this vehicle is equipped with before begin- All
ning.
Connect the Diagnostic Junction Port Tester #8339 to the DRB and to the Diagnostic
Junction Port.
Using the DRB, along with the Diagnostic Junction Port Tester #8339, select
Junction Port Tool then PCI Bus Module Scan and follow the instructions on the
DRB.
Was the DRB able to scan (I/D or communicate) with any modules?
Yes → Refer to the Communication category for the related symptom(s).

(Individual module no responses).
No → Go To 2

Measure the resistance of the PCI Bus circuit between the Data Link Connector and
the Diagnostic Junction Port connector.
Yes → Go To 3
No → Repair the PCI Bus circuit for an open between the DLC and the
Diagnostic Junction Port.
423
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE — Continued

3 Note: Determine which modules this vehicle is equipped with before begin- All
ning.
Connect the Diagnostic Junction Port Tester #8339 to the DRB and to the Diagnostic
Junction Port.
Using the DRB, along with the Diagnostic Junction Port Tester #8339, select
Junction Port Tool then PCI Bus Control Mode and follow the instructions on the
DRB.
Note: Perform this function on each pin that is equipped with a PCI Bus
circuit.
Did the DRB display No Modules Responding from any of the pins that were
scanned?
Yes → Go To 4
No → Check the PCI Bus circuit between the DLC and the Diagnostic
Junction Port connector for a short to voltage or to ground, repair
as necessary.
4 Disconnect the Diagnostic Junction Port Tester cable from the DRB. Keep the tester All
connected to the Diagnostic Junction Port.
Measure the voltage of the PCI Bus circuit on the Diagnostic Junction Port Tester
that the DRB displayed No Modules Responding.
Is the voltage steadily above 7.0 volts?
Yes → Go To 5
No → Go To 6
5 Measure the voltage of the PCI Bus circuit on the Diagnostic Junction Port tester All
that previously measured above 7.0 volts.
Note: Turn the ignition off before disconnecting any module harness
connector then turn the ignition on.
Disconnect the module harness connector(s). Note: If the problem occurred on pins 1,
3, 9 or 12 of the Diagnostic Junction Port tester, observe the voltmeter while
disconnecting each module connector one at a time.
Is the voltage steadily above 7.0 volts with the module(s) disconnected?
Yes → Repair the PCI Bus circuit that measured over 7.0 volts for a
short to voltage.
No → Replace the module that when disconnected the short to voltage
was eliminated.
6 Disconnect the Diagnostic Junction Port Tester cable from the DRB. Keep the tester All
connected to the Diagnostic Junction Port.
Disconnect the negative battery cable.
Measure the resistance between ground and the PCI Bus circuit on the Diagnostic
Junction Port Tester that the DRB displayed No Modules Responding.
Yes → Go To 7
No → Go To 8
424
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE — Continued

7 Disconnect the negative battery cable. All
Measure the resistance between ground and the PCI Bus circuit at the Diagnostic
Junction Port tester that previously measured below 100.0 ohms.
Disconnect the module harness connector(s). Note: If the problem occurred on pins 1,
3, 9 or 12 of the Diagnostic Junction Port tester, observe the ohmmeter while
disconnecting each module connector one at a time.
Is the resistance below 100.0 ohms with the module(s) disconnected?
Yes → Repair the PCI Bus circuit that measured below 100.0 ohms for a
short to ground.
No → Replace the module that when disconnected the short to ground
was eliminated.

Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
Note: Visually inspect the related wire harness connectors. Look for broken,
bent, pushed out, or corroded terminals.
Were any problems found?
Yes → Repair wiring harness/connectors as necessary.
425
DOOR AJAR
Symptom:
*HOOD AJAR CIRCUIT OPEN
POSSIBLE CAUSES
HOOD AJAR SWITCH GROUND CIRCUIT OPEN
HOOD AJAR SWITCH
HOOD AJAR SWITCH SENSE CIRCUIT OPEN
BODY CONTROL MODULE INTERNAL MALFUNCTION

1 Open the Hood. All
With the DRBIIIt in Inputs/Outputs, read the HOOD AJAR SW state.
Does the DRBIIIt display CLOSED?
Yes → The condition that caused this symptom is currently not present.
Inspect the related wiring harness for a possible intermittent
condition. Look for any chafed, pierced, pinched or partially
broken wires.
No → Go To 2
2 Disconnect the Hood Ajar switch connector. All

Using a 12-volt Test Light connected to 12-volts, test the Ground circuit for
continuity.
Does the light illuminate?
Yes → Go To 3
3 Disconnect the Hood Ajar Switch connector. All

Connect a jumper wire between Sense circuit and the Ground circuit.
Does the DRBIIIt display HOOD AJAR SW: CLOSED?
Yes → Replace the Hood Ajar Switch.
No → Go To 4
4 Disconnect the Body Control Module C3 harness connector. All

Disconnect the Hood Ajar Switch harness connector.
Measure the resistance of the Sense circuit.
No → Repair the Hood Ajar Switch Sense circuit for an open.

426
DOOR AJAR
Symptom:
*HOOD AJAR CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
HOOD AJAR SWITCH SHORTED TO GROUND
HOOD AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND

1 With the DRBIIIt in Inputs/Outputs, read the HOOD AJAR SW state. All
Does the Switch State change from CLOSED to OPEN?
Yes → Replace the Hood Ajar Switch.

No → Go To 2

Using a 12-volt Test Light connected to 12-volts, test the Sense circuit for a short to
ground.
Does the Test Light illuminate?
Yes → Repair the Hood Ajar Switch Sense circuit for a short to ground.
427
DOOR AJAR
Symptom:
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN
POSSIBLE CAUSES
LEFT FRONT DOOR AJAR SWITCH GROUND CIRCUIT OPEN
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH
LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN

1 Open the driver door. All
With the DRBIIIt in Inputs/Outputs, read the DR DOOR AJAR SW state.
broken wires.
No → Go To 2
2 Disconnect the Left Front Door Lock Motor/Ajar switch connector. All
continuity.
Yes → Go To 3
3 Disconnect the Left Front Door Lock Motor/Ajar Switch connector. All
Does the DRBIIIt display DR DOOR AJAR SW: CLOSED?
Yes → Replace the Left Front Door Lock Motor/Ajar Switch.
No → Go To 4

Disconnect the Left Front Door Lock Motor/Ajar Switch harness connector.
No → Repair the Left Front Door Ajar Switch Sense circuit for an open.
428
DOOR AJAR
Symptom:
*LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED
TO GROUND
POSSIBLE CAUSES
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH SHORTED TO GROUND
LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND

1 With the DRBIIIt in Inputs/Outputs, read the DR DOOR AJAR SW state. All
Did the Switch State change from CLOSED to OPEN?
Yes → Replace the Left Front Door Lock Motor/Ajar Switch.

No → Go To 2

ground.
Yes → Repair the Left Front Door Ajar Switch Sense circuit for a short to
ground.
429
DOOR AJAR
Symptom:
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN
LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH

1 Disconnect the Left Sliding Door Lock Motor/Ajar Switch harness connector at the All
bottom of the door.
Connect a jumper wire between the Left Sliding Door Ajar Switch Sense circuit and
ground.
With the DRBIIIt in Inputs/Outputs, read the LSLIDE DR AJAR SW state.
Did the Switch State change from OPEN to CLOSED?
Yes → Go To 2
No → Go To 4
2 Reconnect the Left Sliding Door Lock Motor/Ajar Switch connector at the bottom of All
the door.
Remove the door panel from the sliding door.
Disconnect the Left Sliding Door Lock Motor/Ajar Switch connector at the door
mechanism.
ground.
Yes → Go To 3
No → Repair the Left Sliding Door Lock Motor/Ajar Switch harness for
an open between the door mechanism and the intermediate
harness connector at the bottom of the door.
3 Disconnect the Left Sliding Door Lock Motor/Ajar Switch connector at the door All
mechanism.
the Ground circuit.
Yes → Replace the Sliding Door Lock Motor/Ajar Switch.
430
DOOR AJAR
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN — Continued

4 Disconnect the Left Sliding Door Lock Motor/Ajar Switch harness connector at the All
bottom of the sliding door.
Gain access to the BCM C3 connector.
Back probe a jumper wire from the Left Sliding Door Ajar Switch Sense circuit at the
BCM to ground.
Yes → Repair the Left Sliding Door Ajar Switch Sense circuit for an open
between the intermediate connector and the Body Control Mod-
ule.

431
DOOR AJAR
Symptom:
*LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED
TO GROUND
POSSIBLE CAUSES
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH SHORTED TO GROUND
LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH

1 With the DRBIIIt in Inputs/Outputs, read the LSLIDE DR AJAR SW state. All
Disconnect the Left Sliding Door Lock Motor/Ajar Switch harness connector at the
bottom of the door.
Yes → Go To 2
No → Go To 3
2 Reconnect the Left Sliding Door Lock Motor/Ajar Switch connector at the bottom of All
the door.
Disconnect the Left Sliding Door Lock Motor/Ajar Switch connector at the door
mechanism.
No → Repair the Left Sliding Door Lock Motor/Ajar Switch harness for
a short to ground between the door mechanism and the interme-
diate harness connector at the bottom of the door.

Disconnect the Left Sliding Door Lock Motor/Ajar Switch harness connector at the
ground.
Yes → Repair the Left Sliding Door Ajar Switch Sense circuit for a short
to ground.

432
DOOR AJAR
Symptom:
*LIFTGATE AJAR CIRCUIT OPEN
POSSIBLE CAUSES
LIFTGATE AJAR SWITCH GROUND CIRCUIT OPEN
LIFTGATE AJAR SWITCH
LIFTGATE AJAR SWITCH SENSE CIRCUIT OPEN

1 Open the Liftgate. All
With the DRBIIIt in Inputs/Outputs, read the LIFTGATE AJAR SW state.
broken wires.
No → Go To 2
2 Disconnect the Liftgate Ajar switch connector. All

continuity.
Yes → Go To 3
3 Disconnect the Liftgate Ajar Switch connector. All

Does the DRBIIIt display LIFTGATE AJAR SW: CLOSED?
Yes → Replace the Liftgate Ajar Switch.
No → Go To 4

Disconnect the Liftgate Ajar Switch harness connector.
No → Repair the Liftgate Ajar Switch Sense circuit for an open.

433
DOOR AJAR
Symptom:
*LIFTGATE AJAR CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
LIFTGATE AJAR SWITCH SHORTED TO GROUND
LIFTGATE AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND

1 With the DRBIIIt in Inputs/Outputs, read the LIFTGATE AJAR SW state. All
Does the Switch State change from CLOSED to OPEN?
Yes → Replace the Liftgate Ajar Switch.

No → Go To 2

ground.
Yes → Repair the Liftgate Ajar Switch Sense circuit for a short to
ground.
434
DOOR AJAR
Symptom:
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN
POSSIBLE CAUSES
RIGHT FRONT DOOR AJAR SWITCH GROUND CIRCUIT OPEN
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH
RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN

1 Open the passenger door. All
With the DRBIIIt in Inputs/Outputs, read the PASS DOOR AJAR SW state.
broken wires.
No → Go To 2
2 Disconnect the Right Front Door Lock Motor/Ajar switch connector. All
continuity.
Yes → Go To 3
3 Disconnect the Right Front Door Lock Motor/Ajar Switch connector. All
Does the DRBIIIt display PASS DOOR AJAR SW: CLOSED?
Yes → Replace the Right Front Door Lock Motor/Ajar Switch.
No → Go To 4

Disconnect the Right Front Door Lock Motor/Ajar Switch harness connector.
No → Repair the Right Front Door Ajar Switch Sense circuit for an
open.
435
DOOR AJAR
Symptom:
*RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED
TO GROUND
POSSIBLE CAUSES
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH SHORTED TO GROUND
RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND

1 With the DRBIIIt in Inputs/Outputs, read the PASS DOOR AJAR SW state. All
Yes → Replace the Right Front Door Lock Motor/Ajar Switch.

No → Go To 2

ground.
Yes → Repair the Right Front Door Ajar Switch Sense circuit for a short
to ground.
436
DOOR AJAR
Symptom:
*RIGHT SLIDING DOOR AJAR CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
RIGHT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN
RIGHT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH

1 Disconnect the Right Sliding Door Lock Motor/Ajar Switch harness connector at the All
bottom of the door.
Connect a jumper wire between the Right Sliding Door Ajar Switch Sense circuit and
ground.
With the DRBIIIt in Inputs/Outputs, read the RSLIDE DR AJAR SW state.
Yes → Go To 2
No → Go To 4
2 Reconnect the Right Sliding Door Lock Motor/Ajar Switch connector at the bottom of All
the door.
Disconnect the Right Sliding Door Lock Motor/Ajar Switch connector at the door
mechanism.
ground.
Yes → Go To 3
No → Repair the Right Sliding Door Lock Motor/Ajar Switch harness for
an open between the door mechanism and the intermediate
harness connector at the bottom of the door.
3 Disconnect the Right Sliding Door Lock Motor/Ajar Switch connector at the door All
mechanism.
the Ground circuit.
437
DOOR AJAR
*RIGHT SLIDING DOOR AJAR CIRCUIT OPEN — Continued

4 Disconnect the Right Sliding Door Lock Motor/Ajar Switch harness connector at the All
Gain access to the BCM C3 connector.
Back probe a jumper wire from the Right Sliding Door Ajar Switch Sense circuit at
the BCM to ground.
Yes → Repair the Right Sliding Door Ajar Switch Sense circuit for an
open between the intermediate connector and the Body Control
Module.

438
DOOR AJAR
Symptom:
*RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH SHORTED TO GROUND
RIGHT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH

1 With the DRBIIIt in Inputs/Outputs, read the RSLIDE DR AJAR SW state. All
Disconnect the Right Sliding Door Lock Motor/Ajar Switch harness connector at the
bottom of the door.
Yes → Go To 2
No → Go To 3
2 Reconnect the Right Sliding Door Lock Motor/Ajar Switch connector at the bottom of All
the door.
Disconnect the Right Sliding Door Lock Motor/Ajar Switch connector at the door
mechanism.
No → Repair the Right Sliding Door Lock Motor/Ajar Switch harness for
a short to ground between the door mechanism and the interme-
diate harness connector at the bottom of the door.

Disconnect the Right Sliding Door Lock Motor/Ajar Switch harness connector at the
ground.
Yes → Repair the Right Sliding Door Ajar Switch Sense circuit for a
short to ground.

439
Symptom:
EBL RUN ONLY RELAY OPEN
EBL RUN ONLY RELAY OPEN

When Monitored: Continuously with the ignition on.
Set Condition: The FCM has detected an open in the Rear Defogger Relay control circuit.
POSSIBLE CAUSES
OPEN B+ TO RELAY
VERIFY ACTIVE DTC
MISSING RELAY
REAR WINDOW DEFOGGER RELAY

With the DRBIIIt, erase the current Front Control Module DTC’s.
Turn the ignition off, wait 10 seconds then turn the ignition on.
With the DRBIIIt, read the current Front Control Module DTC’s.
Does the DRBIIIt display EBL RUN ONLY RELAY OPEN trouble code?
Yes → Go To 2
No → The condition that caused this symptom is currently not present
at this time.

Check the IPM to make certain the Rear Window Defogger Relay is present.
Is the Rear Window Defogger Relay present?
Yes → Go To 3
No → Replace the missing Rear Defogger Relay.

3 Remove the Rear Window Defogger relay from the IPM. All
Measure the voltage of pin 86 in the Rear Defogger Relay socket.
Yes → Go To 4
No → Repair/replace open B+ to relay as necessary.

440
EBL RUN ONLY RELAY OPEN — Continued

Install a known good relay in place of the Rear Window Defogger relay.
Attempt to operate the Rear Window Defogger.
Does the DTC reset?
Yes → Go To 5
No → Replace the Rear Defogger Relay.


Disconnect the Front Control Module from the Fuse and Relay Center.
Remove the Rear Window Defogger Relay.
Measure the resistance of the Rear Window Defogger Relay Control Circuit in the
Fuse and Relay Center.
No → Replace the Fuse and Relay Center.

441
Symptom:
EBL RUN ONLY RELAY SHORTED TO BATTERY
EBL RUN ONLY RELAY SHORTED TO BATTERY

Set Condition: The FCM has detected a short to battery voltage in the Rear Defogger
Relay control circuit.
POSSIBLE CAUSES
VERIFY ACTIVE DTC
REAR WINDOW DEFOGGER RELAY

Does the DRBIIIt display EBL RUN ONLY RELAY SHORTED TO BATTERY
trouble code?
Yes → Go To 2
No → The condition that caused this symptom is currently not present

at this time.

Install a known good relay in place of the Rear Window Defogger relay.
Attempt to operate the Rear Window Defogger.
With the DRBIIIt, read the current Front Control Module DTCs.
Did the DTC reset?
Yes → Go To 3
No → Replace the Rear Defogger Relay.


Remove the Rear Window Defogger Relay from the IPM.
Measure the voltage of the Rear Window Relay Control circuit.
Yes → Replace the Fuse and Relay Center.


442
EXTERIOR LIGHTING
Symptom:
BACKUP LAMP OUTPUT OPEN
BACKUP LAMP OUTPUT OPEN

When Monitored: Trans in reverse.
Set Condition: Voltage output status is Low.
POSSIBLE CAUSES
GROUND CIRCUIT
BACKUP LAMP
TRANS RANGE SENSOR
BACKUP LAMP DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

With the DRBIIIt, clear all BCM, IPM DTC’s.
Actuate the Backup Lamps.
With the DRBIIIt, read the DTC information.
Does the DRBIIIt read: Backup Lamp Output Open?
Yes → Go To 2
No → The condition that caused the symptom is currently not present.

Inspect the related wiring for a possible intermittent condition.
Look for any chafed, pierced,pinched, or partially broken wires.
2 Turn the ignition off All

Disconnect either rear tail lamp harness connector.
Using a 12-volt test light connected to 12-volts, check the ground circuit.
Yes → Go To 3
No → Repair the Ground Circuit.

443
EXTERIOR LIGHTING
BACKUP LAMP OUTPUT OPEN — Continued

Disconnect either rear tail lamp harness connector.
Engage the transmission to reverse.
Using a 12-volt test light connected to ground, check the Backup Lamps Output
circuit.
Yes → Replace the applicable Backup Lamp.

No → Go To 4

Disconnect the IPM harness connector.
Measure the resistance of the Backup Lamp Output Circuit and ground.
Yes → Refer to symptom list for problems related to Trans Range Sensor.
No → Go To 5

Disconnect the Body Control Module harness connector.
Measure the resistance of the Backup Lamp Driver Circuit to ground.
Is the resistance above 5.0 ohms?
Yes → Repair the Backup Lamp Driver Circuit for an open condition.
No → Go To 6

Disconnect the FCM from the IPM.
Measure the resistance of the Backup Lamp Driver Circuit and ground.
444
EXTERIOR LIGHTING
Symptom:
BACKUP LAMP OUTPUT SHORT
BACKUP LAMP OUTPUT SHORT

When Monitored: Anytime the Body Control Module is active.
Set Condition: When voltage output status is Low.
POSSIBLE CAUSES
BACKUP LAMP
BACKUP LAMP DRIVER CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

With the DRBIIIt, clear all BCM DTC’s.
Does the DRBIIIt read: Backup Lamp Output Short?
Yes → Go To 2

Disconnect the rear tail lamp harness connector.
Using a 12-volt test light connected to ground, check the Backup Lamp Output
circuit.
Yes → Replace the Backup Lamp.

No → Go To 3

Disconnect the rear tail lamp harness connector.
Measure the resistance of the Backup Lamp Driver circuit and ground.
Yes → Repair the Backup Lamp Driver circuit for a short to ground.

445
EXTERIOR LIGHTING
Symptom:
FRONT FOG LAMP RELAY OPEN
FRONT FOG LAMP RELAY OPEN

When Monitored: Ignition On.
Set Condition: The IPM detects high current from the fog lamp relay control circuit.
POSSIBLE CAUSES
MISSING RELAY
OPEN FUSE
FOG LAMP RELAY
FOG LAMP RELAY CONTROL CIRCUIT OPEN

With the DRBIIIt, clear all IPM DTC’s.
Turn the Fog Lamps on.
Does the DRBIIIt read: Front Fog Lamp Relay Open?
Yes → Go To 2
No → Go To 5

Check the IPM to make certain the Fog Lamp Relay is present.
Is the Fog Lamp Relay present?
Yes → Go To 3
No → Replace the missing Fog Lamp Relay.


Install a known good relay in place of the fog lamp relay.
Turn the Fog Lamps On.
Do the Fog Lamps operate normally?
Yes → Replace the Fog Lamp Relay.

No → Go To 4
446
EXTERIOR LIGHTING
FRONT FOG LAMP RELAY OPEN — Continued

Remove the Fog Lamp Relay.
Measure the voltage of the Fused B+ circuit of the fog lamp relay.
Is the voltage above 10 volts?

No → Replace the Intelligent Power Module.


Check the IPM Fog Lamp fuse #1.
Is the fuse open?
Yes → Replace the open fuse.

No → Go To 6

Disconnect the Front Control Module from the IPM.
Remove the Fog Lamp Relay.
Measure the resistance of the Fog Lamp Relay Control Circuit.
Yes → The condition that caused the symptom is currently not present.
No → Repair the Fog Lamp Relay Control Circuit.

447
EXTERIOR LIGHTING
Symptom:
FRONT FOG LAMP SHORTED TO BATTERY
FRONT FOG LAMP SHORTED TO BATTERY

Set Condition: When a battery fault condition is present.
POSSIBLE CAUSES
FOG LAMP RELAY

Turn the Fog Lamps on.
Does the DRBIIIt read: Front Fog Lamp Shorted To Battery?
Yes → Go To 2

Remove and install a known good relay in place of the Fog Lamp Relay.
Do the Fog Lamps operate normally?
Yes → Replace the Fog Lamp Relay.

No → Go To 3

Remove the Fog Lamp Relay from the IPM.
Measure the voltage of the Fog Lamp Relay Control circuit and ground.
Yes → Replace the Intelligent Power Module.

448
EXTERIOR LIGHTING
Symptom:
HEADLAMP SWITCH MISMATCH
HEADLAMP SWITCH MISMATCH

When Monitored: Ignition ON
Set Condition: Headlamp switch is in Auto mode and the vehicle is not EC Mirror
equipped.
POSSIBLE CAUSES
VERIFY AUTO HEADLAMP SWITCH
INTERMITTENT WIRING AND CONNECTORS
BODY CONTROL MODULE

With the DRBIIIt, record and erase DTC’s.
Turn the headlamps to the Auto position.
With the DRBIIIt, read DTCs.
Does the DRBIIIt display HEADLAMP SWITCH MISMATCH?
Yes → Go To 2
No → Go To 4
2 Visually identify the Headlamp Switch type. All

Does the Headlamp Switch Contain an Auto Headlamp position?
Yes → Replace the Auto Headlamp Switch with a non Auto Headlamp
Switch.
No → Go To 3

Repair
Replace and program the Body Control Module in accordance with
4 The conditions necessary to set this DTC are not present at this time. All
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?
Yes → Repair as necessary.
449
EXTERIOR LIGHTING
Symptom:
HEADLAMP SWITCH OPEN

Set Condition: A Sensor voltage is over 4.8 volts for more than .0625 seconds.
POSSIBLE CAUSES
HEADLAMP SWITCH MUX CIRCUIT OPEN
HEADLAMP SWITCH MUX RETURN CIRCUIT OPEN
BODY CONTROL MODULE

Turn the headlamps to the ON position.
Does the DRBIIIt display HEADLAMP SWITCH OPEN?
Yes → Go To 2
No → Go To 5

Disconnect the Headlamp Switch harness connector.
Connect a jumper wire between the Headlamp Switch MUX circuit and the
Headlamp Switch MUX Return circuit in the Headlamp Switch harness connector.
With the DRB, select Body, Body Controller and read the Headlamp Switch volts.
Does the DRB Headlamp Switch Sensor voltage read less than 0.5 Volts?
Yes → Replace the Headlamp Switch in accordance with the Service

Information.
No → Go To 3
450
EXTERIOR LIGHTING
HEADLAMP SWITCH OPEN — Continued

3 Turn the ignition off to the lock position. All
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Headlamp Switch MUX circuit from the Body Control
Module connector to the Headlamp Switch harness connector.
Yes → Repair the Headlamp Switch MUX circuit for an open.

No → Go To 4

Measure the resistance of the Headlamp Switch MUX Return circuit from the Body
Control Module connector to the Headlamp Switch harness connector.
Yes → Repair the Headlamp Switch MUX Return circuit for an open.
No → Replace the Body Control Module in accordance with the Service
Information.
circuit.

451
EXTERIOR LIGHTING
Symptom:
HEADLAMP SWITCH SHORT TO GROUND
HEADLAMP SWITCH SHORT TO GROUND

Set Condition: A Sensor voltage is below 0.488 volts for more than 0.0625 seconds.
POSSIBLE CAUSES
HEADLAMP SWITCH SHORTED
HEADLAMP SWITCH MUX CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH MUX RETURN CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH MUX CIRCUIT SHORT TO MUX RETURN CIRCUIT
BODY CONTROL MODULE

Turn the headlamps to the ON position.
Does the DRBIIIt display HEADLAMP SWITCH SHORT TO GROUND?
Yes → Go To 2
No → Go To 6

With the DRB, select Body, Body Control Module and read the Headlamp Switch
Sensor voltage..
Does the DRB display a Headlamp Switch Voltage of more than 4.8 volts?
Yes → Replace the Headlamp Switch in accordance with the Service

Information.
No → Go To 3

Measure the resistance between ground and the Headlamp Switch MUX circuit.
Is the resistance less than 5.0 ohms?
Yes → Repair the Headlamp Switch MUX Circuit for a short to ground.
No → Go To 4
452
EXTERIOR LIGHTING
HEADLAMP SWITCH SHORT TO GROUND — Continued

Measure the resistance between the Headlamp Switch MUX Return circuit and the
Headlamp Switch MUX circuit.
Yes → Repair the Headlamp Switch MUX circuit for a short to the
Headlamp Switch MUX Return circuit.
No → Go To 5

Measure the resistance between ground and the Headlamp Switch MUX Return
circuit.
Yes → Repair the Headlamp Switch MUX Return Circuit for a short to
ground.
Information.
circuit.
453
EXTERIOR LIGHTING
Symptom:
HIGH BEAM SWITCH INPUT OPEN
HIGH BEAM SWITCH INPUT OPEN

Set Condition: When voltage is below 4.8 volts.
POSSIBLE CAUSES
MULTIFUNCTION SWITCH
HIGH BEAM SWITCH MUX CIRCUIT OPEN
MULTIFUNCTION SWITCH MUX RETURN CIRCUIT OPEN
BODY CONTROL MODULE

Turn the Headlamps On.
Actuate the High Beams.
Does the DRBIIIt read: High Beam Switch Input Open?
Yes → Go To 2


Disconnect the Multifunction Switch harness connector.
Connect a jumper wire between the High Beam Switch MUX circuit and the
Multifunction Switch MUX Return circuit in the Multifunction Switch connector.
With the DRBIIIt, read the Multifunction Switch voltage.
Is the display voltage below 0.5 volts?
Yes → Replace the Multifunction Switch.
No → Go To 3
454
EXTERIOR LIGHTING
HIGH BEAM SWITCH INPUT OPEN — Continued

Measure the resistance of the High Beam Switch MUX circuit from the Body Control
Module connector to the Multifunction Switch harness connector.
Yes → Repair the High Beam Switch MUX circuit for an open.
No → Go To 4

Measure the resistance of the Multifunction Switch MUX Return circuit from the
Body Control Module connector to the Multifunction Switch harness connector.
Yes → Repair the Multifunction Switch MUX Return circuit for an open.

455
EXTERIOR LIGHTING
Symptom:
HIGH BEAM SWITCH INPUT SHORT
HIGH BEAM SWITCH INPUT SHORT

POSSIBLE CAUSES
HIGH BEAM SWITCH MUX CIRCUIT SHORT TO GROUND
HIGH BEAM SWITCH MUX SHORT TO MUX RETURN CIRCUIT
MULTIFUNCTION SWITCH MUX RETURN CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

Actuate the High Beams.
Does the DRBIIIt read: High Beam Switch Input Short?
Yes → Go To 2

No → Go To 3

Disconnect the Multifunction Switch Harness connector.
Measure the resistance between the High Beam Switch MUX circuit and ground.
Yes → Repair the High Beam Switch MUX circuit for a short to ground.
No → Go To 4
456
EXTERIOR LIGHTING
HIGH BEAM SWITCH INPUT SHORT — Continued

Measure the resistance between the Multifunction Switch MUX Return circuit and
the High Beam Switch MUX circuit.
Yes → Repair the High Beam Switch MUX circuit for a short to the
Multifunction Switch MUX Return circuit.
No → Go To 5

ground.
Yes → Repair the Multifunction Switch MUX Return circuit for a short
to ground.
457
EXTERIOR LIGHTING
Symptom:
LEFT FRONT TURN SIGNAL OUTPUT OPEN
LEFT FRONT TURN SIGNAL OUTPUT OPEN

Set Condition: When output voltage status is LOW.
POSSIBLE CAUSES
GROUND CIRCUIT
TURN SIGNAL LAMP
LEFT TURN SIGNAL OUTPUT CIRCUIT OPEN
LEFT FRONT TURN SIGNAL DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

Actuate the Turn Signals.
Does the DRBIIIt read: Left Front Turn Signal Output Open?
Yes → Go To 2


Disconnect the Left Front Turn Signal harness connector.
Yes → Go To 3

458
EXTERIOR LIGHTING
LEFT FRONT TURN SIGNAL OUTPUT OPEN — Continued

Disconnect the Left Turn Signal Lamp connector.
Turn the Left Turn Signal on.
Using a 12-volt test light connected to ground, check the Left Front Turn Signal
Output circuit.
Yes → Replace the Turn Signal Lamp.

No → Go To 4

Measure the resistance of the Left Front Turn Signal Output Circuit and ground.
Yes → Repair the Left Front Turn Signal Output Circuit for an open
condition.
No → Go To 5

Measure the resistance of the Left Front Turn Signal Driver Circuit to ground.
Yes → Repair the Left Front Turn Signal Driver Circuit for an open
condition.
No → Go To 6

Disconnect the Body Control Module C2 harness connector.
Measure the resistance of the Left Front Turn Signal Driver Circuit and ground.

459
EXTERIOR LIGHTING
Symptom:
LEFT FRONT TURN SIGNAL OUTPUT SHORT
LEFT FRONT TURN SIGNAL OUTPUT SHORT

When Monitored: Anytime the IPM is active.
Set Condition: When output voltage status is Low.
POSSIBLE CAUSES
LEFT FRONT TURN SIGNAL OUTPUT SHORT TO GROUND
TURN SIGNAL LAMP

Does the DRBIIIt read: Left Front Turn Signal Output Short?
Yes → Go To 2

Disconnect the Left Front Turn Signal Lamp connector.
Measure the resistance between the Left Front Turn Signal Output circuit and
ground.
Yes → Repair the Left Front Turn Signal Output circuit for a short to
ground.
No → Go To 3
460
EXTERIOR LIGHTING
LEFT FRONT TURN SIGNAL OUTPUT SHORT — Continued

Disconnect the Left Front Turn Signal Lamp connector.
Using a 12-volt test light connected to ground, check the Left Front Turn Signal
Output circuit.

461
EXTERIOR LIGHTING
Symptom:
LEFT HIGH BEAM HEADLAMP CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
LEFT HEADLAMP
LEFT HIGH BEAM DRIVER CIRCUIT OPEN
WIRING HARNESS INSPECTION

With the DRB, erase the Front Control Module DTC’s.
Turn the headlamps on.
Switch the headlamps between high beam and low beam several times, pausing for
5 seconds in each position.
With the DRB, read Front Control Module DTC’s.
Is this DTC present?
Yes → Go To 2
No → Go To 5

Disconnect the Left Headlamp harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Yes → Go To 3


Disconnect the Left Headlamp.
Disconnect the Front Control Module from the Intelligent Power Module.
Measure the resistance of the Left High Beam Driver circuit.
Yes → Go To 4
No → Repair the Left High Beam Driver circuit for an open.
462
EXTERIOR LIGHTING
LEFT HIGH BEAM HEADLAMP CIRCUIT OPEN — Continued

Using a 12-volt test light connected to ground, check the Left High Beam Driver
circuit in the Left Headlamp harness connector.
Turn the high beam headlamps on.
Yes → Replace the Left Headlamp Bulb.


NOTE: Visually inspect the related wiring harness and circuits. Look for
any chafed, pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
Note: Refer to any Technical Service Bulletins (TSB) that may apply.
463
EXTERIOR LIGHTING
Symptom:
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
LEFT HEADLAMP
LEFT HIGH BEAM DRIVER CIRCUIT SHORTED TO GROUND
WIRING PROBLEM

Yes → Go To 2
No → Go To 5

Measure the resistance between Ground and the Left High Beam Driver circuit.
Yes → Repair the Left High Beam Driver circuit for a short to ground
No → Go To 3

Turn the Headlamps off.
Install a substitute Headlamp Bulb in place of the Left Headlamp Bulb.
Does the DRB display this DTC?
Yes → Go To 4
No → Replace the original Left Headlamp Bulb.

464
EXTERIOR LIGHTING
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND —

Continued
Inspect the wiring and connectors associated with the Left High Beam Driver circuit.



465
EXTERIOR LIGHTING
Symptom:
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
HIGH BEAM AND LOW BEAM DRIVERS CIRCUITS SHORTED TOGETHER
LEFT HEADLAMP
LEFT HIGH BEAM DRIVER CIRCUIT SHORTED TO VOLTAGE
WIRING PROBLEM

Yes → Go To 2
No → Go To 7

Yes → Go To 3


Measure the resistance between the Left High Beam Driver circuit and the Left Low
Beam Driver circuit at the Left Headlamp harness connector.
Yes → Repair the Left High Beam Driver circuit for a short to the Left
Low Beam Driver circuit.
No → Go To 4
466
EXTERIOR LIGHTING
LEFT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE —

Continued
Measure the voltage of the Left High Beam Driver circuit.
Yes → Go To 5
No → Repair the Left High Beam Driver circuit for a short to voltage.

Yes → Go To 6

Inspect the wiring and connectors associated with the Left High Beam Driver circuit.




467
EXTERIOR LIGHTING
Symptom:
LEFT LOW BEAM HEADLAMP CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
LEFT HEADLAMP
LEFT LOW BEAM DRIVER CIRCUIT OPEN

Yes → Go To 2
No → Go To 5

Yes → Go To 3


Measure the resistance of the Left Low Beam Driver circuit.
Yes → Go To 4
No → Repair the Left Low Beam Driver circuit for an open.
468
EXTERIOR LIGHTING
LEFT LOW BEAM HEADLAMP CIRCUIT OPEN — Continued

Using a 12-volt test light connected to ground, check the Left Low Beam Driver
circuit in the Left Headlamp harness connector.
Turn the low beam headlamps on.
Yes → Replace the Left Headlamp Bulb.


469
EXTERIOR LIGHTING
Symptom:
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
LEFT HEADLAMP
LEFT LOW BEAM DRIVER CIRCUIT SHORTED TO GROUND
WIRING PROBLEM

Yes → Go To 2
No → Go To 5

Measure the resistance between Ground and the Left Low Beam Driver circuit.
Yes → Repair the Left Low Beam Driver circuit for a short to ground
No → Go To 3

Yes → Go To 4

470
EXTERIOR LIGHTING
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND —

Continued
Inspect the wiring and connectors associated with the Left Low Beam Driver circuit.



471
EXTERIOR LIGHTING
Symptom:
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
LEFT HEADLAMP
LEFT LOW BEAM DRIVER CIRCUIT SHORTED TO VOLTAGE
WIRING PROBLEM

Yes → Go To 2
No → Go To 7

Yes → Go To 3


Measure the resistance between the Left High Beam Driver circuit and the Left Low
Beam Driver circuit at the Left Headlamp harness connector.
Yes → Repair the Left High Beam Driver circuit for a short to the Left
No → Go To 4
472
EXTERIOR LIGHTING
LEFT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE —

Continued
Measure the voltage of the Left Low Beam Driver circuit.
Yes → Go To 5
No → Repair the Left Low Beam Driver circuit for a short to voltage.

Install a substitute Headlamp in place of the Left Headlamp.
Yes → Go To 6

Inspect the wiring and connectors associated with the Left Low Beam Driver circuit.




473
EXTERIOR LIGHTING
Symptom:
LEFT REAR TURN SIGNAL OUTPUT OPEN
LEFT REAR TURN SIGNAL OUTPUT OPEN

Set Condition: When Output voltage status is LOW.
POSSIBLE CAUSES
GROUND CIRCUIT
TURN SIGNAL LAMP
LEFT REAR TURN SIGNAL DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

Does the DRBIIIt read: Left Rear Turn Signal Output Open?
Yes → Go To 2


Disconnect the Left Rear Turn Signal harness connector.
Yes → Go To 3


Disconnect the Left Rear Turn Signal Lamp connector.
Using a 12-volt test light connected to ground, check the Left Rear Turn Signal
Output circuit.
No → Go To 4
474
EXTERIOR LIGHTING
LEFT REAR TURN SIGNAL OUTPUT OPEN — Continued

Measure the resistance of the Left Rear Turn Signal Driver Circuit to ground.
Yes → Repair the Left Rear Turn Signal Driver Circuit for an open
condition.

475
EXTERIOR LIGHTING
Symptom:
LEFT REAR TURN SIGNAL OUTPUT SHORT
LEFT REAR TURN SIGNAL OUTPUT SHORT

When Monitored: Anytime the BCM is active.
POSSIBLE CAUSES
LEFT REAR TURN SIGNAL DRIVER CIRCUIT SHORT TO GROUND
TURN SIGNAL LAMP
BODY CONTROL MODULE

Does the DRBIIIt read: Left Rear Turn Signal Output Short?
Yes → Go To 2

Disconnect the BCM harness connector.
Measure the resistance between the Left Rear Turn Signal Driver circuit and ground.
Yes → Repair the Left Rear Turn Signal Driver circuit for a short to
ground.
No → Go To 3
476
EXTERIOR LIGHTING
LEFT REAR TURN SIGNAL OUTPUT SHORT — Continued

Using a 12-volt test light connected to ground, check the Left Rear Turn Signal
Driver circuit.

477
EXTERIOR LIGHTING
Symptom:
LEFT SIDE PARK LAMP OPEN
LEFT SIDE PARK LAMP OPEN

When Monitored: Anytime the FCM is active.
Set Condition: When B+ voltage is below 10.0 volts.
POSSIBLE CAUSES
GROUND CIRCUIT
PARK LAMP
PARK LAMP FUSE #2
PARK LAMP RELAY
PARK LAMP OUTPUT CIRCUIT OPEN

With the DRBIIIt, clear all FCM DTC’s.
Turn the Park Lamps on.
Does the DRBIIIt read: Left Side Park Lamp Fuse Outage?
Yes → Go To 2

Disconnect the left front Park Lamp harness connector.
Yes → Go To 3
478
EXTERIOR LIGHTING
LEFT SIDE PARK LAMP OPEN — Continued

Disconnect the left front park lamp connector.
Using a 12-volt test light connected to ground, check the Park Lamp Output circuit.
Yes → Replace the Park Lamp.
No → Go To 4

Check the IPM Park Lamp Fuse #2.
Is the Fuse open?
Yes → Replace the Park Lamp Fuse #2.

No → Go To 5

Install a known good relay in place of the Park Lamp Relay.
Do the Park Lamps operate normally?
Yes → Replace the Park Lamp Relay.
No → Go To 6

Measure the resistance of the Park Lamp Output Circuit to ground.
Yes → Repair the Park Lamp Output Circuit for an open condition.
No → Go To 7

Remove the Park Lamp Relay.
Measure the voltage of the Fused B+ circuit of the Park Lamp Relay.

479
EXTERIOR LIGHTING
Symptom:
PARK LAMP OUTPUT 1 OPEN

When Monitored: Ignition on.
Set Condition: The IPM detects high current from the Park Lamp Relay Control circuit.
POSSIBLE CAUSES
MISSING RELAY
OPEN FUSE
PARK LAMP RELAY
RIGHT FRONT FUSED PARK LAMP RELAY OUTPUT CIRCUIT OPEN

Does the DRBIIIt read: Park Lamp Output 1 Open?
Yes → Go To 2
No → Go To 6

Check the IPM to make certain the Park Lamp Relay is present.
Is the Park Lamp Relay present?
Yes → Go To 3
No → Replace the missing Park Lamp Relay.


Check the IPM Park Lamp fuse #3.
Is the fuse open?

No → Go To 4
480
EXTERIOR LIGHTING
PARK LAMP OUTPUT 1 OPEN — Continued

Install a known good relay in place of the park lamp relay.
Turn the Park Lamps On.

No → Go To 5

Measure the voltage of the Fused B+ circuit of the park lamp relay.



Measure the resistance of the Park Lamp Relay Control Circuit.
No → Repair the Right Front Fused Park Lamp Relay Output circuit for
an open condition.
481
EXTERIOR LIGHTING
Symptom:
PARK LAMP OUTPUT 1 SHORT TO BATTERY

POSSIBLE CAUSES
PARK LAMP RELAY

Does the DRBIIIt read: Park Lamp Output 1 Short to BATT?
Yes → Go To 2

Remove and install a known good relay in place of the Park Lamp Relay.

No → Go To 3

Remove the Park Lamp Relay from the IPM.
Measure the voltage of the Park Lamp Relay Control circuit and ground.

482
EXTERIOR LIGHTING
Symptom:

Set Condition: The IPM detects high current from the Park Lamp Relay Control circuit.
POSSIBLE CAUSES
MISSING RELAY
OPEN FUSE
PARK LAMP RELAY
LEFT FRONT FUSED PARK LAMP RELAY OUTPUT CIRCUIT OPEN

Does the DRBIIIt read: Park Lamp Output 2 Open
Yes → Go To 2
No → Go To 6

Check the IPM to make certain the Park Lamp Relay is present.
Is the Park Lamp Relay present?
Yes → Go To 3
No → Replace the missing Park Lamp Relay.


Check the IPM Park Lamp fuse #2.
Is the fuse open?

No → Go To 4
483
EXTERIOR LIGHTING
PARK LAMP OUTPUT 2 OPEN — Continued

Install a known good relay in place of the park lamp relay.
Turn the Park Lamps On.

No → Go To 5

Measure the voltage of the Fused B+ circuit of the park lamp relay.



Measure the resistance of the Park Lamp Relay Control Circuit.
No → Repair the Left Front Fused Park Lamp Relay Output Circuit for
an open condition.
484
EXTERIOR LIGHTING
Symptom:

POSSIBLE CAUSES
PARK LAMP RELAY

Does the DRBIIIt read: Park Lamp Output 2 Short to BATT
Yes → Go To 2

Remove and install a known good relay in place of the Park Lamp Relay.

No → Go To 3

Remove the Park Lamp Relay from the IPM.
Measure the voltage of the Park Lamp Relay Control circuit and ground.

485
EXTERIOR LIGHTING
Symptom:
RIGHT FRONT TURN SIGNAL OUTPUT OPEN
RIGHT FRONT TURN SIGNAL OUTPUT OPEN

Set Condition: When the output voltage status is LOW.
POSSIBLE CAUSES
GROUND CIRCUIT
TURN SIGNAL LAMP
RIGHT FRONT TURN SIGNAL OUTPUT CIRCUIT OPEN
RIGHT FRONT TURN SIGNAL DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

Does the DRBIIIt read: Right Front Turn Signal Output Open?
Yes → Go To 2


Disconnect the Right Front Turn Signal harness connector.
Yes → Go To 3

486
EXTERIOR LIGHTING
RIGHT FRONT TURN SIGNAL OUTPUT OPEN — Continued

Disconnect the Right Turn Signal Lamp connector.
Turn the Right Turn Signal on.
Using a 12-volt test light connected to ground, check the Right Front Turn Signal
Output circuit.

No → Go To 4

Measure the resistance of the Right Front Turn Signal Output Circuit and ground.
Yes → Repair the Right Front Turn Signal Output Circuit for an open
condition.
No → Go To 5

Measure the resistance of the Right Front Turn Signal Driver Circuit to ground.
Yes → Repair the Right Front Turn Signal Driver Circuit for an open
condition.
No → Go To 6

Measure the resistance of the Right Front Turn Signal Driver Circuit and ground.

487
EXTERIOR LIGHTING
Symptom:
RIGHT FRONT TURN SIGNAL OUTPUT SHORT
RIGHT FRONT TURN SIGNAL OUTPUT SHORT

When Monitored: Anytime the IPM is active.
POSSIBLE CAUSES
RIGHT FRONT TURN SIGNAL OUTPUT SHORT TO GROUND
TURN SIGNAL LAMP

Does the DRBIIIt read: Right Front Turn Signal Output Short?
Yes → Go To 2

Disconnect the Right Front Turn Signal Lamp connector.
Measure the resistance between the Right Front Turn Signal Output circuit and
ground.
Yes → Repair the Right Front Turn Signal Output circuit for a short to
ground.
No → Go To 3
488
EXTERIOR LIGHTING
RIGHT FRONT TURN SIGNAL OUTPUT SHORT — Continued

Disconnect the Right Front Turn Signal Lamp connector.
Using a 12-volt test light connected to ground, check the Right Front Turn Signal
Output circuit.

489
EXTERIOR LIGHTING
Symptom:
RIGHT HIGH BEAM HEADLAMP CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
RIGHT HEADLAMP
RIGHT HIGH BEAM DRIVER CIRCUIT OPEN

Yes → Go To 2
No → Go To 5

Disconnect the Right Headlamp harness connector.
Yes → Go To 3


Disconnect the Right Headlamp.
Measure the resistance of the Right High Beam Driver circuit.
Yes → Go To 4
No → Repair the Right High Beam Driver circuit for an open.
490
EXTERIOR LIGHTING
RIGHT HIGH BEAM HEADLAMP CIRCUIT OPEN — Continued

Using a 12-volt test light connected to ground, check the Right High Beam Driver
circuit in the Right Headlamp harness connector.
Turn the high beam headlamps on.
Yes → Replace the Right Headlamp Bulb.


491
EXTERIOR LIGHTING
Symptom:
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
RIGHT HEADLAMP
RIGHT HIGH BEAM DRIVER CIRCUIT SHORTED TO GROUND
WIRING PROBLEM

Yes → Go To 2
No → Go To 5

Measure the resistance between Ground and the Right High Beam Driver circuit.
Yes → Repair the Right High Beam Driver circuit for a short to ground
No → Go To 3

Install a substitute Headlamp Bulb in place of the Right Headlamp Bulb.
Yes → Go To 4
No → Replace the original Right Headlamp Bulb.

492
EXTERIOR LIGHTING
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO GROUND —

Continued
Inspect the wiring and connectors associated with the Right High Beam Driver
circuit.



493
EXTERIOR LIGHTING
Symptom:
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLT-
AGE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
RIGHT HEADLAMP
RIGHT HIGH BEAM DRIVER CIRCUIT SHORTED TO VOLTAGE
WIRING PROBLEM

Yes → Go To 2
No → Go To 7

Yes → Go To 3


Measure the resistance between the Right High Beam Driver circuit and the Right
Low Beam Driver circuit at the Right Headlamp harness connector.
Yes → Repair the Right High Beam Driver circuit for a short to the Right
No → Go To 4
494
EXTERIOR LIGHTING
RIGHT HIGH BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE —

Continued
Measure the voltage of the Right High Beam Driver circuit.
Yes → Go To 5
No → Repair the Right High Beam Driver circuit for a short to voltage.

Yes → Go To 6

Inspect the wiring and connectors associated with the Right High Beam Driver
circuit.


495
EXTERIOR LIGHTING
Symptom:
RIGHT LOW BEAM HEADLAMP CIRCUIT OPEN
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
RIGHT HEADLAMP
RIGHT LOW BEAM DRIVER CIRCUIT OPEN

Yes → Go To 2
No → Go To 5

Yes → Go To 3


Measure the resistance of the Right Low Beam Driver circuit.
Yes → Go To 4
No → Repair the Right Low Beam Driver circuit for an open.
496
EXTERIOR LIGHTING
RIGHT LOW BEAM HEADLAMP CIRCUIT OPEN — Continued

Using a 12-volt test light connected to ground, check the Right Low Beam Driver
circuit in the Right Headlamp harness connector.
Turn the low beam headlamps on.
Yes → Replace the Right Headlamp Bulb.


497
EXTERIOR LIGHTING
Symptom:
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND
POSSIBLE CAUSES
RIGHT HEADLAMP
RIGHT LOW BEAM DRIVER CIRCUIT SHORTED TO GROUND
WIRING PROBLEM

Yes → Go To 2
No → Go To 5

Measure the resistance between Ground and the Right Low Beam Driver circuit.
Yes → Repair the Right Low Beam Driver circuit for a short to ground
No → Go To 3

Yes → Go To 4

498
EXTERIOR LIGHTING
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO GROUND —

Continued
Inspect the wiring and connectors associated with the Right Low Beam Driver
circuit.



499
EXTERIOR LIGHTING
Symptom:
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
RIGHT HEADLAMP
RIGHT LOW BEAM DRIVER CIRCUIT SHORTED TO VOLTAGE
WIRING PROBLEM

Yes → Go To 2
No → Go To 7

Yes → Go To 3


Measure the resistance between the Right High Beam Driver circuit and the Right
Low Beam Driver circuit at the Right Headlamp harness connector.
Yes → Repair the Right High Beam Driver circuit for a short to the Right
No → Go To 4
500
EXTERIOR LIGHTING
RIGHT LOW BEAM HEADLAMP CIRCUIT SHORTED TO VOLTAGE —

Continued
Measure the voltage of the Right Low Beam Driver circuit.
Yes → Go To 5
No → Repair the Right Low Beam Driver circuit for a short to voltage.

Yes → Go To 6

Inspect the wiring and connectors associated with the Right Low Beam Driver
circuit.


501
EXTERIOR LIGHTING
Symptom:
RIGHT REAR TURN SIGNAL OUTPUT OPEN
RIGHT REAR TURN SIGNAL OUTPUT OPEN

POSSIBLE CAUSES
GROUND CIRCUIT
TURN SIGNAL LAMP
RIGHT REAR TURN SIGNAL DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

Does the DRBIIIt read: Right Rear Turn Signal Output Open?
Yes → Go To 2


Disconnect the Right Rear Turn Signal harness connector.
Yes → Go To 3


Disconnect the Right Rear Turn Signal Lamp connector.
Using a 12-volt test light connected to ground, check the Right Rear Turn Signal
Output circuit.
No → Go To 4
502
EXTERIOR LIGHTING
RIGHT REAR TURN SIGNAL OUTPUT OPEN — Continued

Measure the resistance of the Right Rear Turn Signal Driver Circuit to ground.
Yes → Repair the Right Rear Turn Signal Driver Circuit for an open
condition.

503
EXTERIOR LIGHTING
Symptom:
RIGHT REAR TURN SIGNAL OUTPUT SHORT
RIGHT REAR TURN SIGNAL OUTPUT SHORT

When Monitored: Anytime the BCM is active.
POSSIBLE CAUSES
RIGHT REAR TURN SIGNAL DRIVER CIRCUIT SHORT TO GROUND
TURN SIGNAL LAMP
BODY CONTROL MODULE

Does the DRBIIIt read: Right Rear Turn Signal Output Short?
Yes → Go To 2

Measure the resistance between the Right Rear Turn Signal Driver circuit and
ground.
Yes → Repair the Right Rear Turn Signal Driver circuit for a short to
ground.
No → Go To 3
504
EXTERIOR LIGHTING
RIGHT REAR TURN SIGNAL OUTPUT SHORT — Continued

Using a 12-volt test light connected to ground, check the Right Rear Turn Signal
Driver circuit.

505
EXTERIOR LIGHTING
Symptom:
RIGHT SIDE PARK LAMP OPEN
RIGHT SIDE PARK LAMP OPEN

When Monitored: Anytime the FCM is active.
Set Condition: When B+ voltage is below 10.0 volts.
POSSIBLE CAUSES
GROUND CIRCUIT
PARK LAMP
PARK LAMP FUSE #3
PARK LAMP OUTPUT CIRCUIT OPEN
PARK LAMP RELAY

Does the DRBIIIt read: Right Side Park Lamp Fuse Outage?
Yes → Go To 2

Disconnect the right front Park Lamp harness connector.
Yes → Go To 3
506
EXTERIOR LIGHTING
RIGHT SIDE PARK LAMP OPEN — Continued

Disconnect the right front park lamp connector.
Using a 12-volt test light connected to ground, check the Park Lamp Output circuit.
Yes → Replace the Park Lamp.
No → Go To 4

Check the IPM Park Lamp Fuse #3.
Is the Fuse open?
Yes → Replace the Park Lamp Fuse #3.

No → Go To 5

Install a known good relay in place of the Park Lamp Relay.
No → Go To 6

Measure the resistance of the Park Lamp Output circuit to ground.
Yes → Repair the Park Lamp Output circuit for an open condition.
No → Go To 7

Measure the voltage of the Fused B+ circuit of the Park Lamp Relay.

507
EXTERIOR LIGHTING
Symptom:
TURN SIGNAL SWITCH INPUT OPEN
TURN SIGNAL SWITCH INPUT OPEN

POSSIBLE CAUSES
TURN SIGNAL SWITCH MUX CIRCUIT OPEN
BODY CONTROL MODULE

Actuate the turn signals.
Does the DRBIIIt read: Turn Signal Switch Input Open?
Yes → Go To 2


Connect a jumper wire between the Turn Signal Switch MUX circuit and the
Multifunction Switch MUX Return circuit in the Multifunction Switch connector.
Is the display voltage below 0.5 volts?
No → Go To 3
508
EXTERIOR LIGHTING
TURN SIGNAL SWITCH INPUT OPEN — Continued

Measure the resistance of the Turn Signal Switch MUX circuit from the Body Control
Module connector to the Multifunction Switch harness connector.
Yes → Repair the Turn Signal Switch MUX circuit for an open.
No → Go To 4

Measure the resistance of the Multifunction Switch MUX Return circuit from the
Body Control Module connector to the Multifunction Switch harness connector.
Yes → Repair the Multifunction Switch MUX Return circuit for an open.

509
EXTERIOR LIGHTING
Symptom:
TURN SIGNAL SWITCH INPUT SHORT
TURN SIGNAL SWITCH INPUT SHORT

Set Condition: When Input voltage falls below 0.196 volts for 62.5 msec..
POSSIBLE CAUSES
TURN SIGNAL SWITCH MUX CIRCUIT SHORT TO GROUND
TURN SIGNAL SWITCH MUX SHORT TO MUX RETURN CIRCUIT.
MULTIFUNCTION SWITCH MUX RETURN CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

Actuate the Turn Signals on.
Does the DRBIIIt read: Turn Signal Switch Input Short?
Yes → Go To 2

No → Go To 3

Measure the resistance between the Turn Signal Switch MUX circuit and ground.
Yes → Repair the Turn Signal Switch MUX circuit for a short to ground.
No → Go To 4
510
EXTERIOR LIGHTING
TURN SIGNAL SWITCH INPUT SHORT — Continued

the Turn Signal Switch MUX circuit.
Yes → Repair the Turn Signal Switch MUX circuit for a short to the
Multifunction Switch MUX Return circuit.
No → Go To 5

ground.
Yes → Repair the Multifunction Switch MUX Return circuit for a short
to ground.
511
HEATING & A/C
Symptom List:
A/C FAULT (ACTIVE) - MANUAL A/C
CHECKSUM FAILURE (ACTIVE) - MANUAL A/C
POWER FAULT (ACTIVE) - MANUAL A/C
REAR DEFOG FAILURE (ACTIVE) - MAN A/C
RECIRCULATION FAULT (ACTIVE) - MANUAL A/C
UNKNOWN FAULT DETECTED (ACTIVE) - MANUAL A/C
The title for the tests will be A/C FAULT (ACTIVE) - MANUAL
A/C.
A/C FAULT (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the A/C switch stays closed for 10 minutes.
CHECKSUM FAILURE (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the calibrated check sum does not match the stored
value.
POWER FAULT (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the Power switch stays closed for 10 minutes.
REAR DEFOG FAILURE (ACTIVE) - MAN A/C

Set Condition: This DTC will set if the Rear Window Defogger switch stays closed for 10
minutes.
RECIRCULATION FAULT (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the Recirc switch stays closed for 10 minutes.
UNKNOWN FAULT DETECTED (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Cotrol Module detects an internal
fault.
512
HEATING & A/C
A/C FAULT (ACTIVE) - MANUAL A/C — Continued
POSSIBLE CAUSES
A/C - HEATER CONTROL MODULE

1 View repair All
Repair
Replace the A/C - Heater Control Module in accordance with the
513
HEATING & A/C
Symptom List:
A/C FAULT (STORED) - MANUAL A/C
BACKLIGHT DIMMING RX FAILURE (STORED) - MANUAL A/C
BLEND OVERCURRENT (STORED) - MANUAL A/C
CHECKSUM FAILURE (STORED) - MANUAL A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN
(STORED) - MANUAL A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT
(STORED) - MANUAL A/C
LOOPBACK FAILURE (STORED) - MANUAL A/C
LOOPBACK TEST FAILURE (STORED) - MANUAL A/C
MODE OVERCURRENT (STORED) - MANUAL A/C
NO BCM MESSAGE RECEIVED (STORED) - MANUAL A/C
NO PCM MESSAGE RECEIVED (STORED) - MANUAL A/C
PCM COMMUNICATION FAILURE (STORED) - MANUAL A/C
POWER FAULT (STORED) - MANUAL A/C
REAR BLEND OVERCURRENT (STORED) - MANUAL A/C
REAR BLEND POT CIRCUIT OPEN (STORED) - MANUAL A/C
REAR BLEND POT CIRCUIT SHORT (STORED) - MANUAL A/C
REAR DEFOG FAILURE (STORED) - MANUAL A/C
REAR MODE OVERCURRENT (STORED) - MANUAL A/C
RECIRC OVERCURRENT (STORED) - MANUAL A/C
RECIRCULATION FAULT (STORED) - MANUAL A/C
TX FAILURE (STORED) - MANUAL A/C
UNKNOWN FAULT DETECTED (STORED) - MANUAL A/C
VEHICLE ODOMETER FAILURE (STORED) - MANUAL A/C
ZONE OVERCURRENT (STORED) - MANUAL A/C
The title for the tests will be A/C FAULT (STORED) - MANUAL
A/C.
A/C FAULT (STORED) - MANUAL A/C

Set Condition: This DTC will set if the A/C switch stays closed for 10 minutes.
BACKLIGHT DIMMING RX FAILURE (STORED) - MANUAL A/C

Set Condition: If the A/C - Heater Control Module does not receive the dimming function
message from the BCM for more than 5 seconds, then the A/C - Heater Control Module
LEDs will default to full brightness and the DTC will set.
514
HEATING & A/C
A/C FAULT (STORED) - MANUAL A/C — Continued
BLEND OVERCURRENT (STORED) - MANUAL A/C

When Monitored: When actuator movement is requested.
Set Condition: All (Blend, Mode, Recirc, and Zone) Overcurrent DTCs will set if the A/C
- Heater Control Module detects an excessive current draw on the Common Door Drive
circuit(s).
CHECKSUM FAILURE (STORED) - MANUAL A/C

Set Condition: This DTC will set if the calibrated check sum does not match the stored
value.
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (STORED) - MANUAL

A/C
Set Condition: This DTC will set if the Evaporator Temperature Sensor/sensor circuit is
open.
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (STORED) - MAN-

UAL A/C
shorted low.
LOOPBACK FAILURE (STORED) - MANUAL A/C

When Monitored: When the A/C - Heater Control Module executes an internal loopback
test.
Set Condition: If the A/C - Heater Control Module fails to send a message, or none of the
expected messages arrive for 5 seconds, an internal loopback test is executed. If the
internal loopback test fails, the DTC will set.
LOOPBACK TEST FAILURE (STORED) - MANUAL A/C

test.
MODE OVERCURRENT (STORED) - MANUAL A/C

circuit(s).
515
HEATING & A/C
NO BCM MESSAGE RECEIVED (STORED) - MANUAL A/C

When Monitored: With the igntion on.
NO PCM MESSAGE RECEIVED (STORED) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Control Module does not see any
messages from the PCM for more than 5 seconds.
PCM COMMUNICATION FAILURE (STORED) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Control Module does not receive the
Fuel message from the PCM for more than 5 seconds.
POWER FAULT (STORED) - MANUAL A/C

Set Condition: This DTC will set if the Power switch stays closed for 10 minutes.
REAR BLEND OVERCURRENT (STORED) - MANUAL A/C

circuit(s).
REAR BLEND POT CIRCUIT OPEN (STORED) - MANUAL A/C

Set Condition: This DTC will set if the Rear Blower Rear Control Switch, Rear Blend
Potentiometer/circuit is open.
REAR BLEND POT CIRCUIT SHORT (STORED) - MANUAL A/C

When Monitored: When the ignition is on.
Potentiometer/5 Volt Supply/Rear Temperature Feedback Signal circuit is shorted low or
high.
REAR DEFOG FAILURE (STORED) - MANUAL A/C

Set Condition: This DTC will set if the Rear Window Defogger switch stays closed for 10
minutes.
516
HEATING & A/C
REAR MODE OVERCURRENT (STORED) - MANUAL A/C

circuit(s).
RECIRC OVERCURRENT (STORED) - MANUAL A/C

circuit(s).
RECIRCULATION FAULT (STORED) - MANUAL A/C

Set Condition: This DTC will set if the Recirc switch stays closed for 10 minutes.
TX FAILURE (STORED) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Control Module is unable to send a
message.
UNKNOWN FAULT DETECTED (STORED) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Cotrol Module detects an internal
fault.
VEHICLE ODOMETER FAILURE (STORED) - MANUAL A/C

Vehicle Odometer message from the PCM for more than 5 seconds.
ZONE OVERCURRENT (STORED) - MANUAL A/C

circuit(s).
517
HEATING & A/C
POSSIBLE CAUSES
CHECK FOR ACTIVE HVAC DTCS, & COOLDOWN TEST & DOOR RECALIBRATION MESSAGES
STORED CODE(S) TEST COMPLETE

1 NOTE: Active codes must be resolved before diagnosing stored codes. All
NOTE: Anytime a code becomes active during this test, proceed to the
conclusion question.
With the DRBIIIt, record and erase stored HVAC DTC’s.
Cycle the ignition switch.
Start the engine.
Monitor the DRBIIIt for active HVAC DTCs while performing the following test
steps.
Manually press the A/C - Heater Control power switch on.
Turn the front blower motor control switch knob to the low position.
If equipped, turn the rear blower motor control switch knob to the low position.
Set the passenger blend control switch to the full cold position.
If equipped, set the zone/driver blend control switch to the full cold position.
Turn the mode select switch knob to the panel position.
Manually press the recirculation mode switch on, wait 30 seconds then press it off.
Manually press the A/C mode switch on, wait 30 seconds then press it off.
Manually press the rear window defogger switch on, wait 30 seconds then press it off.
Manually sweep the passenger blend control switch from full cold to full hot then
back to full cold.
If equipped, manually sweep the zone/driver blend control switch from full cold to full
hot then back to full cold.
Manually sweep the front blower motor control switch knob through all positions.
If equipped, manually sweep the rear blower motor control switch knob through all
positions.
If equipped, turn the rear blower motor control switch knob to the rear position.
If equipped, on the Rear Blower Rear Control, manually sweep the rear blower motor
control switch knob through all positions.
If equipped, on the Rear Blower Rear Control, manually sweep the rear blend/mode
control switch knob from full cold to full hot then back to full cold.
With the DRBIIIt, actuate the AC Cooldown Test.
With the DRBIIIt, actuate the HVAC Door Recalibration Test.
Place the vehicle on a hoist, and raise the wheels off the floor.
WARNING: Be sure to keep hands and feet clear of rotating wheels. Keep
clear of the engine’s moving parts
Start the engine. Place the transmission in drive. Brake off.
Does the DRBIIIt display any active HVAC DTC(s), Cooldown Test or Door Recali-
bration message(s)?

518
HEATING & A/C
Symptom List:
BACKLIGHT DIMMING RX FAILURE (ACTIVE) - MANUAL A/C
NO BCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C
The title for the tests will be BACKLIGHT DIMMING RX
FAILURE (ACTIVE) - MANUAL A/C.
BACKLIGHT DIMMING RX FAILURE (ACTIVE) - MANUAL A/C

NO BCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C

When Monitored: With the igntion on.
POSSIBLE CAUSES
ADDITIONAL CODE(S) PRESENT
BODY CONTROL MODULE - NO DIM MESSAGE TO A/C - HEATER CONTROL MODULE

With the DRBIIIt, read the BCM codes.
Does DRBIIIt display Headlamp Switch: Mismatch; STG; Open; or Panel Dim
Output Short?
Yes → Refer to symptoms Headlamp Switch Mismatch, Headlamp

Switch Shorted To Ground, and Headlamp Switch Open in the
Exterior Lighting catagory. Refer to symptom Panel Dimming
Output Short in the Instrument Cluster catagory.
No → Go To 2
519
HEATING & A/C
BACKLIGHT DIMMING RX FAILURE (ACTIVE) - MANUAL A/C — Continued

With the DRBIIIt in Monitor Display, PCI Bus Messages, look for the VF DIM Msg
Present.
Does the DRB display: VF DIM Msg present: Yes?
Yes → Replace the A/C - Heater Control Module in accordance with the

Information.
520
HEATING & A/C
Symptom List:
BLEND CALIBRATION FAULT - MANUAL A/C
MODE CALIBRATION FAULT - MANUAL A/C
RECIRCULATION CALIBRATION FAULT - MANUAL A/C
ZONE CALIBRATION FAULT - MANUAL A/C
The title for the tests will be BLEND CALIBRATION FAULT -
MANUAL A/C.
BLEND CALIBRATION FAULT - MANUAL A/C

When Monitored: When the HVAC Door Recalibration is executed. With the ignition on
(door actuator(s)/circuit(s) shorted low only).
Set Condition: If the Blend Door (Pass) drive span found is outside the tolerance. If the
Blend Door Actuator (Pass)/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear),
Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted low. (This
will also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/Overcurrent
(Front, Rear), Recirculation Calibration/Overcurrent, Zone Calibration/Overcurrent
DTCs.)
MODE CALIBRATION FAULT - MANUAL A/C

Set Condition: If the Mode Door drive span found is outside the tolerance. If the Mode
Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear), Mode
Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted low. (This will
also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/Overcurrent
DTCs.)
RECIRCULATION CALIBRATION FAULT - MANUAL A/C

Set Condition: If the Recirculation Door drive span found is outside the tolerance. If the
Recirculation Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass,
Rear), Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s) are shorted
low. (This will also set Blend Calibration/Overcurrent (Front, Rear), Mode Calibration/
Overcurrent (Front, Rear), Recirculation Calibration/Overcurrent, Zone Calibration/
Overcurrent DTCs.)
521
HEATING & A/C
BLEND CALIBRATION FAULT - MANUAL A/C — Continued
ZONE CALIBRATION FAULT - MANUAL A/C

Set Condition: If the Blend Door (Driver [Zone]) drive span found is outside the tolerance.
If the Blend Door Actuator (Driver [Zone])/circuit is open. If the Blend Door(s) (Driver
[Zone], Pass, Rear), Mode Door(s) (Front, Rear), Recirculation Door Actuator(s)/circuit(s)
are shorted low. (This will also set Blend Calibration/Overcurrent (Front, Rear), Mode
Calibration/Overcurrent (Front, Rear), Recirculation Calibration/Overcurrent, Zone
Calibration/Overcurrent DTCs.)
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
DOOR ACTUATOR
BLEND ACTUATOR/LINKAGE/DOOR
RECIRCULATION ACTUATOR/LINKAGE/DOOR
MODE ACTUATOR/LINKAGE/DOOR
DOOR ACTUATOR DRIVER CIRCUIT OPEN
COMMON DOOR DRIVER CIRCUIT OPEN

1 NOTE: All Overcurrent DTCs must be repaired before diagnosing Calibra- All
tion messages.
With the DRBIIIt, read HVAC DTCs.
Does the DRBIIIt display any HVAC DTCs?
No → Go To 2
522
HEATING & A/C

Remove the applicable door actuator (Blend [Driver (Zone), Passenger], Recircula-
tion, Mode) from the A/C - Heater Housing Assembly.
Disconnect the door actuator harness connector.
By hand, attempt to rotate the door actuator in both directions.
Did the door actuator turn in either direction?
Yes → Replace the door actuator in accordance with the Service Infor-
mation.
No: Blend Actuator (Driver [Zone], Pass)
Go To 3
No: Recirculation Door Actuator

Go To 4
No: Mode Door Actuator
Go To 5

Remove the applicable blend door actuator (Driver [Zone], Passenger) from the A/C
- Heater Housing Assembly.
Disconnect the blend door actuator harness connector.
Set the applicable blend control switch knob (Driver [Zone], Passenger) to the full
cold position.
Connect a 12-volt Test Light across the blend door actuator harness connector.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full cold to full hot.
While monitoring the test light, manually sweep the applicable blend control switch
knob (Driver [Zone], Passenger) very slowly from full hot to full cold.
Does the test light start to flash and stay flashing through the entire range?
Yes → Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
No → Go To 6
523
HEATING & A/C

4 Turn the mode door knob to the Panel, Bi-level, or Floor position. All
Remove the Recirculation Door Actuator from the A/C - Heater Housing Assembly.
Connect a 12-volt Test Light across the Recirculation Door Actuator harness
connector.
If the LED on the recirculation mode switch is illuminated, manually press the
recirculation mode switch to turn the recirculation mode off.
While monitoring the test light, manually press the recirculation mode switch on
(LED on).
While monitoring the test light, manually press the recirculation mode switch off
(LED off).
Does the test light flash 4 times after pressing the switch on and 2 times after
pressing it off?
Yes → Inspect the linkage and the actuator for broken and missing
teeth. Check the door for binding and loss of full range. Repair as
necessary. If Ok, replace the door actuator in accordance with the
No → Go To 6

Remove the Mode Door Actuator from the A/C - Heater Housing Assembly.
Turn the mode select switch knob to the panel position, then to the defrost position,
then back to the panel position.
Connect a 12-volt Test Light across the Mode Door Actuator harness connector.
While monitoring the test light, turn the mode select switch knob to the first detent
after the panel position.
Repeat the previous step for each detent, until reaching the defrost mode position.
Does the test light flash four times after turning the mode select switch knob to each
detent?
Yes → Inspect A/C - Heater Housing for missing & broken actuator
linkage. Inspect linkage & actuator for broken & missing teeth.
Check doors for binding & loss of full range. Repair as necessary.
If Ok, replace the actuator in accordance with the Service Info.
No → Go To 6

Disconnect the A/C - Heater Control Module C1 harness connector.
Measure the resistance of the applicable door driver circuit (Blend [Driver (Zone),
Passenger], Recirculation, Mode) between the A/C - Heater Control Module C1
harness connector and the door actuator harness connector.
Yes → Go To 7
No → Repair the applicable door driver circuit (Blend [Driver (Zone),

Passenger], Recirculation, Mode) for an open.
524
HEATING & A/C

Measure the resistance of the Common Door Driver circuit between the applicable
door actuator harness connector (Blend [Driver (Zone), Passenger], Recirculation,
Mode) and the A/C - Heater Control Module C1 harness connector.
No → Repair the Common Door Driver circuit for an open.

525
HEATING & A/C
Symptom List:
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
MODE OVERCURRENT (ACTIVE) - MANUAL A/C
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C
ZONE OVERCURRENT (ACTIVE) - MANUAL A/C
The title for the tests will be BLEND OVERCURRENT (AC-
TIVE) - MANUAL A/C.
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
MODE OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
REAR BLEND OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
REAR MODE OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
RECIRC OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
526
HEATING & A/C
BLEND OVERCURRENT (ACTIVE) - MANUAL A/C — Continued
ZONE OVERCURRENT (ACTIVE) - MANUAL A/C

circuit(s).
POSSIBLE CAUSES
MODE DOOR ACTUATOR SHORTED
RECIRCULATION DOOR ACTUATOR SHORTED
PASSENGER BLEND DOOR ACTUATOR SHORTED
DRIVER BLEND DOOR ACTUATOR SHORTED
DOOR DRIVER CIRCUIT SHORTED TO GROUND
DOOR DRIVER CIRCUITS SHORTED TOGETHER
REAR BLEND DOOR ACTUATOR SHORTED
REAR MODE DOOR ACTUATOR SHORTED
REAR A/C HEATER UNIT WIRING HARNESS SHORTED

With the DRB, erase the HVAC DTCs.
Cycle the ignition switch from off to on and monitor the HVAC DTCs. Note: make
sure the active DTCs are erased at this time.
Slowly turn the mode door knob through each of it’s different positions. Perform this
step a few times.
Turn the mode door knob to the Panel, Bi-level, or Floor position.
Press and release the recirculation button. Perform this step a few times.
Slowly slide the front temperature control levers (if equipped with dual or three zone,
slide all front levers) from hot to cold and back to hot. Perform this step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot (if
equipped with rear A/C). Perform this step a few times.
With the DRB, read the active HVAC DTCs.
Did the overcurrent DTCs reset?
Yes → Go To 2
No → Replace the Mode Door Actuator in accordance with the Service

Information.
527
HEATING & A/C

sure the active DTCs are erased at this time..
step a few times.
Yes → Go To 3
No → Replace the Recirculation Door Actuator in accordance with the


step a few times.
Yes → Go To 4
No → Replace the Passenger Blend Door Actuator in accordance with

528
HEATING & A/C

4 NOTE: If vehicle is equipped with a base HVAC system, answer yes to the All
question.
Disconnect the Driver (zone) Blend Door Actuator harness connector.
step a few times.
Yes → Go To 5
No → Replace the Driver Blend Door Actuator in accordance with the
5 NOTE: If vehicle is equipped with a base HVAC or dual zone system, answer All
yes to the question.
Disconnect the Rear A/C Heater Unit harness connector.
step a few times.
Slowly turn the rear blend/mode door knob from hot to cold and back to hot. Perform
this step a few times.
Yes → Go To 6
No → Go To 8

Disconnect each door actuator harness connector (front actuators only).
Disconnect the Rear A/C Heater Unit harness connector (if equipped with rear A/C).
Measure the resistance between ground and each HVAC door driver circuit.
Is the resistance below 10K ohms for any of the measurements?
Yes → Repair all door driver circuits with a resistance below 10K ohms
for a short to ground.
No → Go To 7
529
HEATING & A/C

Disconnect each door actuator harness connector (front actuators only).
Disconnect the Rear A/C Heater Unit harness connector (if equipped with rear A/C).
Measure the resistance between the Common Door Driver circuit and each other door
driver circuit.
Measure the resistance between the Recirculation Door Driver circuit and each other
door driver circuit.
Measure the resistance between the Mode Door Driver circuit and each other door
driver circuit.
Measure the resistance between the Passenger Blend Air Door Driver circuit and
each other door driver circuit.
Measure the resistance between the Driver Blend Door Driver circuit and each other
door driver circuit (if equipped with dual or 3 zone).
Measure the resistance between the Rear Common Door Driver circuit and each
other door driver circuit (if equipped with rear A/C).
Measure the resistance between the Rear Blend Door Driver circuit and each other
door driver circuit (if equipped with rear A/C).
Measure the resistance between the Rear Mode Door Driver circuit and each other
door driver circuit (if equipped with rear A/C).
Is the resistance below 10K ohms for any of the measurements?
Yes → Repair the door driver circuits that measured below 10K ohms for
a short to each other.

Reconnect the Rear A/C Heater Unit harness connector.
step a few times.
Yes → Go To 9
No → Replace the Rear Blend Door Actuator in accordance with the

530
HEATING & A/C

Reconnect the Rear A/C Heater Unit harness connector.
step a few times.
Yes → Repair the Rear A/C Heater Unit wiring harness for a short to
ground or shorted together door driver circuits between the Rear
A/C Heater Unit and the rear mode and blend doors.
No → Replace the Rear Mode Door Actuator in accordance with the
531
HEATING & A/C
Symptom List:
COOLDOWN TEST EXCESSIVE FAULT - MANUAL A/C
COOLDOWN TEST SENSOR FAILURE - MANUAL A/C
The title for the tests will be COOLDOWN TEST EXCESSIVE
FAULT - MANUAL A/C.
COOLDOWN TEST EXCESSIVE FAULT - MANUAL A/C

Set Condition: This message will be displayed if the A/C system is unable to bring the
evaporator temperature down -6.7°C (20°F) within two minutes.
COOLDOWN TEST SENSOR FAILURE - MANUAL A/C

Set Condition: This message will be displayed if a fault is detected with the Evaporator
Temperature Sensor/circuit when executing the Cooldown Test.
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
A/C SYSTEM TESTING

1 CAUTION: The evaporator temperature must be above 12.7°C (55°F) to test All
A/C system operation.
Yes → Return to the symptom list and choose the symptoms(s).
After repair is complete, rerun the Cooldown Test.
No → Go To 2
532
HEATING & A/C
COOLDOWN TEST EXCESSIVE FAULT - MANUAL A/C — Continued

2 CAUTION: The evaporator temperature must be above 12.7°C (55°F) to test All
A/C system operation.
tom(s).
No → Refer to the Service Information for additional Cooldown Test
related diagnostic information and testing procedures.
533
HEATING & A/C
Symptom:
COOLDOWN TEST SET UP FAULT - MANUAL A/C
COOLDOWN TEST SET UP FAULT - MANUAL A/C

Set Condition: This message will be displayed if the front blower is not operating at high
speed when executing the Cooldown Test.
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
TEST SET UP CONDITIONS NOT MET
FRONT BLOWER/RELATED CIRCUITS

Yes → Return to the symptom list and choose the symptoms(s). After the
ignition switch. With the DRBIIIt, actuate the Cooldown Test.
No → Go To 2
2 Was the Front Blower Front Control switch set to high speed when the Cooldown Test All
was actuated?
Yes → Check the front blower motor and related circuits for front blower
operation problems. Repair as necessary. After repair is complete,
with the DRBIIIt, actuate the Cooldown Test.
No → Start the engine. Set the Front Blower Front Control switch to
high speed. With the DRBIIIt, actuate the Cooldown Test.
534
HEATING & A/C
Symptom:
COOLDOWN TEST TOO COLD TO START - MANUAL A/C
COOLDOWN TEST TOO COLD TO START - MANUAL A/C

Set Condition: This message will be displayed if the A/C - Heater Control Module sees
evaporator temperature below 12.7°C (55°F) when executing the Cooldown Test.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE TOO LOW
HVAC DTC(S) PRESENT
SENSOR GROUND CIRCUIT HIGH RESISTANCE
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT HIGH RESISTANCE

Start the engine.
Turn the A/C off.
Turn the Blower on high. Allow the blower to run for 5 minutes to ensure that the
Evaporator Temperature Sensor temperature is above 12.7°C (55°F).
With the DRBIIIt, actuate the Cooldown Test.
Does the DRBIIIt display: Cooldown Test Too Cold To Start?
Yes → Go To 2
No → Perform additional testing as necessary.
Yes → Return to the symptom list and choose the symptom(s). After the
ignition switch. With the DRBIIIt, actuate the Cooldown Test.
No → Go To 3
535
HEATING & A/C
COOLDOWN TEST TOO COLD TO START - MANUAL A/C — Continued

tom(s). After the repair is complete, with the DRBIIIt, erase the
DTC(s). Cycle the ignition switch. With the DRBIIIt, actuate the
Cooldown Test.
No → Go To 4

voltage.
Yes → Go To 5
No → Go To 6

and the Sensor Ground circuit at the Evaporator Temperature Sensor harness
connector.
voltage.
Yes → Replace the Evaporator Temperature Sensor in accordance with
the Service Information. After repair is complete, rerun the
Cooldown Test.
No → Go To 6
6 NOTE: Ensure that the voltmeter leads meet the terminals in the connector All
and that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Back probe the Sensor Ground circuit between the Evaporator Temperature Sensor
harness connector and the A/C - Heater Control Module C1 harness connector.
Yes → Go To 7
No → Repair the high resistance in the Sensor Ground circuit. After

repair is complete, rerun the Cooldown Test.
536
HEATING & A/C
COOLDOWN TEST TOO COLD TO START - MANUAL A/C — Continued

7 NOTE: Ensure the voltmeter leads meet the terminals in the connector and All
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Back probe the Evaporator Temperature Sensor Signal circuit between the Evapo-
rator Temperature Sensor harness connector and the A/C - Heater Control Module C1
harness connector.
Service Information. After repair is complete, rerun the Cooldown
Test.
No → Repair the high resistance in the Evaporator Temperature Sensor

Signal circuit. After repair is complete, rerun the Cooldown Test.
537
HEATING & A/C
Symptom:
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE)
- MANUAL A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE) - MANUAL

A/C
open.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN

Open the glove box door. Disconnect the glove box door roller latch from each side of
the glove box. Roll the glove box downward toward the floor.
and the Sensor Ground circuit at the in-line C202 harness connector (HVAC side).
voltage.
Does the DRBIIIt display: 0.0 volts?
Yes → Check the wiring harness between the in-line C202 harness
connector (plenum side) and the Evap Temp Sensor for an open.
Repair as necessary. If Ok, replace the Evaporator Temperature
Sensor in accordance with the Service Information.
No → Go To 2
538
HEATING & A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT OPEN (ACTIVE) -

MANUAL A/C — Continued
Measure the resistance of the Evaporator Temperature Sensor Signal circuit between
the A/C - Heater Control Module C1 harness connector and the in-line C202 harness
connector.
Yes → Go To 3
tween the A/C - Heater Control Module C1 harness connector and
the in-line C202 harness connector (HVAC side) for an open.

Measure the resistance of the Sensor Ground circuit between the A/C - Heater
Control Module C1 harness connector and the in-line C202 harness connector.
No → Repair the Sensor Ground circuit between the A/C - Heater
Control Module C1 harness connector and the in-line C202
harness connector (HVAC side) for an open.
539
HEATING & A/C
Symptom:
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (AC-
TIVE) - MANUAL A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (ACTIVE) - MANUAL

A/C
shorted low.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIR-
CUIT

voltage.
Does the DRBIIIt display: 5.0 volts or greater?
Yes → Check the Evap Temp Sensor Signal circuit between the in-line
C202 harness connector (plenum side) and the Evap Temp Sensor
for a short to ground. Repair as necessary. If Ok, replace the
Evaporator Temperature Sensor in accordance with the Service
Info.
No → Go To 2
540
HEATING & A/C
EVAPORATOR TEMPERATURE SENSOR CIRCUIT SHORT (ACTIVE) -

MANUAL A/C — Continued
Measure the resistance between ground and the Evaporator Temperature Sensor
Signal circuit (HVAC side).
Is the resistance above 10K ohms?
Yes → Go To 3
the in-line C202 harness connector (HVAC side) for a short to
ground.

Measure the resistance between the Evaporator Temperature Sensor Signal circuit
and the Sensor Ground circuit (HVAC side).
the in-line C202 harness connector (HVAC side) for a short to
Sensor Ground.
541
HEATING & A/C
Symptom List:
FRONT AND REAR BLOWER OUTPUT 1 OPEN
The title for the tests will be FRONT AND REAR BLOWER
OUTPUT 1 OPEN.

Set Condition: If the FCM detects no voltage present on the Front/Rear Blower Motor
Relay Control circuit.

Set Condition: If the FCM detects no voltage present on the Front/Rear Blower Motor
Relay Control circuit.
POSSIBLE CAUSES
CHECK DTCS
B+ CIRCUIT OPEN
FRONT AND REAR BLOWER RELAYS OPEN
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT SHORTED TO GROUND
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT OPEN

condition.
Are both the Front/Rear Blower Output 1 Open and the Front/Rear Blower Output
2 Open DTC’s set?
Yes → Go To 2
No → Replace the Front Control Module (FCM) in accordance with the

542
HEATING & A/C
FRONT AND REAR BLOWER OUTPUT 1 OPEN — Continued

2 Remove either the Front Blower Motor Relay or the Rear Blower Motor Relay, if All
equipped, from the IPM.
Using a 12-volt test light connected to ground, probe cavity 86 of the blower relay
connector.
Yes → Go To 3
No → Check the B+ feed to the Intelligent Power Module (IPM) for an

open. If OK, replace the IPM in accordance with the Service
Information.

Install a substitute relay in place of the existing Front Blower Motor Relay and the
existing Rear Blower Motor Relay, if equipped.
Turn the ignition off, wait 30 seconds, then turn the ignition on.
Yes → Go To 4
No → Replace the Front Blower Motor Relay and the Rear Blower
Motor Relay, if equipped.

Remove the Front Blower Motor Relay and the Rear Blower Motor Relay, if equipped,
from the IPM.
Measure the resistance between ground and the Front/Rear Blower Motor Relay
Control circuit (FCM connector cavity 30).
Yes → Replace the Intelligent Power Module (IPM) in accordance with
No → Go To 5

Remove the Front Blower Motor Relay from the IPM.
Measure the resistance of the Front/Rear Blower Motor Relay Control circuit
between the FCM connector cavity 30 and the Front Blower Motor Relay connector
cavity 85.
Yes → Replace the Front Control Module (FCM) in accordance with the
No → Replace the Intelligent Power Module (IPM) in accordance with

543
HEATING & A/C
Symptom List:
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT
The title for the tests will be FRONT AND REAR BLOWER
OUTPUT 1 SHORT TO BATT.

Set Condition: The FCM detects excessive current when attempting to close the Front/
Rear Blower Motor Relays.

Set Condition: The FCM detects excessive current when attempting to close the Front/
Rear Blower Motor Relays.
POSSIBLE CAUSES
CHECK DTCS
FRONT BLOWER MOTOR RELAY SHORTED
REAR BLOWER MOTOR RELAY SHORTED
FRONT/REAR BLOWER MOTOR RELAY CONTROL CIRCUIT SHORTED TO BATTERY

condition.
Are both of these DTCs set?
Yes → Go To 2
544
HEATING & A/C
FRONT AND REAR BLOWER OUTPUT 1 SHORT TO BATT — Continued

Install a substitute relay in place of the existing Front Blower Motor Relay.
Yes, equipped with rear blower motor
Go To 3
Yes, not equipped with rear blower motor

Go To 4
No → Replace the original Front Blower Motor Relay.


Install a substitute relay in place of the existing Rear Blower Motor Relay.
Yes → Go To 4
No → Replace the original Rear Blower Motor Relay.


Remove the Front Blower Motor Relay and the Rear Blower Motor Relay, if equipped,
from the IPM.
Using a 12-volt test light connected to ground, probe the Front Blower Motor Relay
connector cavity 85.
Yes → Replace the Intelligent Power Module (IPM) in accordance with


545
HEATING & A/C
Symptom List:
LOOPBACK FAILURE (ACTIVE) - MANUAL A/C
LOOPBACK TEST FAILURE (ACTIVE) - MANUAL A/C
The title for the tests will be LOOPBACK FAILURE (ACTIVE)
- MANUAL A/C.
LOOPBACK FAILURE (ACTIVE) - MANUAL A/C

test.
LOOPBACK TEST FAILURE (ACTIVE) - MANUAL A/C

test.
POSSIBLE CAUSES

Does the DRBIIIt display any additional HVAC DTCs?


546
HEATING & A/C
Symptom List:
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C
PCM COMMUNICATION FAILURE (ACTIVE) - MANUAL A/C
VEHICLE ODOMETER FAILURE (ACTIVE) - MANUAL A/C
The title for the tests will be NO PCM MESSAGE RECEIVED
(ACTIVE) - MANUAL A/C.
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Control Module does not see any
messages from the PCM for more than 5 seconds.
PCM COMMUNICATION FAILURE (ACTIVE) - MANUAL A/C

Fuel message from the PCM for more than 5 seconds.
VEHICLE ODOMETER FAILURE (ACTIVE) - MANUAL A/C

Vehicle Odometer message from the PCM for more than 5 seconds.
POSSIBLE CAUSES
MESSAGE NOT RECEIVED
ATTEMPT TO COMMUNICATE WITH THE PCM/ECM
POWERTRAIN/ENGINE CONTROL MODULE

With the DRBIIIt, enter HVAC, System Tests then PCM Monitor.
Does the DRBIIIt display: PCM is active on BUS?
No → Go To 2
547
HEATING & A/C
NO PCM MESSAGE RECEIVED (ACTIVE) - MANUAL A/C — Continued

With the DRBIIIt, attempt to communicate with the PCM/ECM.
Was the DRBIIIt able to communicate with the PCM/ECM?
Yes → Go To 3
No → Refer to Communication for the related symptom(s)


Disconnect the PCM C2/ECM C1 harness connector.
NOTE: Do not connect the tester to the DRB.
tester and the PCM C2/ECM C1 connector.
Yes → Replace and program the Powertrain/Engine Control Module in


548
HEATING & A/C
Symptom List:
REAR BLEND CALIBRATION FAULT - MANUAL A/C
REAR MODE CALIBRATION FAULT - MANUAL A/C
The title for the tests will be REAR BLEND CALIBRATION
FAULT - MANUAL A/C.
REAR BLEND CALIBRATION FAULT - MANUAL A/C

Set Condition: If the Rear Blend Door drive span found is outside the tolerance. If the
Rear Blend Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear),
DTCs.)
REAR MODE CALIBRATION FAULT - MANUAL A/C

Set Condition: If the Rear Mode Door drive span found is outside the tolerance. If the
Rear Mode Door Actuator/circuit is open. If the Blend Door(s) (Driver [Zone], Pass, Rear),
DTCs.)
POSSIBLE CAUSES
HVAC DTC(S) PRESENT
REAR BLEND DOOR ACTUATOR DRIVER CIRCUIT(S) OPEN
REAR MODE DOOR ACTUATOR DRIVER CIRCUIT(S) OPEN
DOOR ACTUATOR
ACTUATOR/LINKAGE/DOOR
DOOR ACTUATOR DRIVER CIRCUIT OPEN
COMMON DOOR DRIVER CIRCUIT OPEN
549
HEATING & A/C
REAR BLEND CALIBRATION FAULT - MANUAL A/C — Continued

NOTE: All Overcurrent DTCs must be repaired before diagnosing Calibra-
tion messages.
No: Rear Blend Calibration message set.

Go To 2
No: Rear Mode Calibration message set.
Go To 4

Turn the A/C - Heater Control, rear blower control switch knob to the Rear position.
Set the Rear Blower Rear Control, blend control switch knob to the full cold position.
Disconnect the Rear A/C - Heater Unit harness connector.
Connect a 12-volt Test Light between the Rear Blend Door Driver circuit and the
Rear Common Door Driver circuit (Cavity 8) at the Rear A/C - Heater Unit harness
connector (HVAC side).
While monitoring the test light, manually sweep the Rear Blower Rear Control, rear
blend control switch knob very slowly from full cold to full hot.
blend control switch knob very slowly from full hot to full cold.
Yes → Go To 3
No → Go To 7

Remove the Rear Blend Door Actuator from the Rear A/C - Heater Housing.
Measure the resistance of the Rear Blend Door Driver circuit between the Rear Blend
Door Actuator harness connector and the Rear A/C - Heater Unit harness connector
(plenum side).
Measure the resistance of the Rear Common Door Driver circuit between the Rear
Blend Door Actuator harness connector and the Rear A/C - Heater Unit harness
connector (Cavity 8) (plenum side).
Is the resistance below 5.0 ohms for both circuits?
Yes → Go To 6
No → Repair the circuit with the resistance above 5 ohms for an open.
550
HEATING & A/C

Turn the A/C - Heater Control, rear blower control switch knob to the Rear position.
Set the Rear Blower Rear Control, blend control switch knob to the full cold position.
Connect a 12-volt Test Light between the Rear Mode Door Driver circuit and the Rear
Common Door Driver circuit (Cavity 2) at the Rear A/C - Heater Unit harness
connector (HVAC side).
blend control switch knob very slowly from full cold to full hot.
blend control switch knob very slowly from full hot to full cold.
Yes → Go To 5
No → Go To 7

Remove the Rear Mode Door Actuator from the Rear A/C - Heater Housing.
Measure the resistance of the Rear Mode Door Driver circuit between the Rear Mode
Door Actuator harness connector and the Rear A/C - Heater Unit harness connector
(plenum side).
Measure the resistance of the Rear Common Door Driver circuit between the Rear
Mode Door Actuator harness connector and the Rear A/C - Heater Unit harness
connector (Cavity 2) (plenum side).
Is the resistance below 5.0 ohms for both circuits?
Yes → Go To 6
No → Repair the circuit with the resistance above 5 ohms for an open.

Remove the applicable door actuator (Rear Blend, Rear Mode) from the Rear A/C -
Heater Housing.
By hand, attempt to rotate the door actuator in both directions.
Did the door actuator turn in either direction?
Yes → Replace the door actuator in accordance with the Service Infor-
mation.
No → Inspect the Rear A/C - Heater Housing for missing and broken
actuator linkage. Inspect the linkage and the actuator for broken
and missing teeth. Check the doors for binding and loss of full
range. Repair as necessary.
551
HEATING & A/C

Heater Housing.
Measure the resistance of the applicable door driver circuit (Rear Blend, Rear Mode)
between the A/C - Heater Control Module C1 harness connector and the door actuator
harness connector.
Yes → Go To 8
No → Repair the applicable door driver circuit (Rear Blend, Rear Mode)
for an open.

Heater Housing.
Measure the resistance of the Common Door Driver circuit between the applicable
door actuator harness connector (Rear Blend, Rear Mode) and the A/C - Heater
Control Module C1 harness connector.
No → Repair the Common Door Driver circuit for an open.
552
HEATING & A/C
Symptom:
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C

Potentiometer/circuit is open.
POSSIBLE CAUSES
REAR TEMPERATURE RETURN CIRCUIT OPEN
REAR BLEND POTENTIOMETER
REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT OPEN
5 VOLT SUPPLY CIRCUIT OPEN

Disconnect the Rear Blower Rear Control Switch C2 harness connector.
Measure the voltage between the 5 Volt Supply circuit and ground.
Yes → Go To 2
No → Go To 6

Measure the voltage between the Rear Temperature Feedback Signal circuit and
ground.
Yes → Go To 3
No → Go To 5
553
HEATING & A/C
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C — Continued

Measure the resistance of the Rear Temperature Return circuit between the A/C -
Heater Control Module C1 harness connector and the Rear Blower Rear Control
Switch C2 harness connector.
Yes → Go To 4
No → Repair the Rear Temperature Return circuit between the A/C -

Heater Control Module C1 harness connector and the Rear
Blower Rear Control Switch C2 harness connector for an open.

NOTE: Make sure that the Rear Blower Rear Control Switch C2 harness
connector is connected to the Rear Blower Rear Control Switch.
Measure the resistance of the Rear Blower Rear Control Switch, Rear Blend
Potentiometer as follows:
Turn the Rear Blend knob to full hot.
Measure the resistance between the 5 Volt Supply circuit and the Rear Temperature
Feedback Signal circuit at the A/C - Heater Control Module C1 harness connector.
The resistance should be approximately 2K ohms.
Slowly rotate the Rear Blend knob from full hot to full cold while viewing the DVOM.
The reading should change fluidly from approximately 2K to 10.5K ohms.
Return circuit at the A/C - Heater Control Module C1 harness connector. The
resistance should be approximately 10.9K ohms.
The reading should stay steady at approximately 10.9K ohms.
Measure the resistance between the Rear Temperature Return circuit and the Rear
Temperature Feedback Signal circuit at the A/C - Heater Control Module C1 harness
connector. The resistance should be approximately 10.2K ohms.
The reading should change fluidly from approximately 10.2K to 1.9K ohms.
Are all of the resistance measurements as specified?
No → Replace the Rear Blower Rear Control Switch in accordance with

554
HEATING & A/C
REAR BLEND POT CIRCUIT OPEN (ACTIVE) - MANUAL A/C — Continued

Measure the resistance of the Rear Temperature Feedback Signal circuit between the
A/C - Heater Control Module C1 harness connector and the Rear Blower Rear Control
Switch C2 harness connector.
No → Repair the Rear Temperature Feedback Signal circuit between
the A/C - Heater Control Module C1 harness connector and the
Rear Blower Rear Control C2 harness connector for an open.

Measure the resistance of the 5 Volt Supply circuit between the A/C - Heater Control
Module C1 harness connector and the Rear Blower Rear Control Switch C2 harness
connector.
No → Repair the 5 Volt Supply circuit between the A/C - Heater Control
Module C1 harness connector and the Rear Blower Rear Control
C2 harness connector for an open.
555
HEATING & A/C
Symptom:
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C

Potentiometer/5 Volt Supply/Rear Temperature Feedback Signal circuit is shorted low or
high.
POSSIBLE CAUSES
REAR BLEND POTENTIOMETER SHORTED
5 VOLT SUPPLY CIRCUIT SHORTED TO REAR TEMPERATURE RETURN CIRCUIT
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND
REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT SHORTED TO GROUND
5 VOLT SUPPLY CIRCUIT SHORTED TO REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT
5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
REAR TEMPERATURE FEEDBACK SIGNAL CIRCUIT SHORTED TO VOLTAGE
REAR TEMPERATURE FEEDBACK SIGNAL CKT SHORTED TO REAR TEMPERATURE RETURN
CKT

With the DRBIIIt in Input/Output Display, read the Rear Blend position status.
What is the Rear Blend position status?
Open
Replace the Rear Blower Rear Control Switch in accordance with
Full Cold
Go To 2
Full Hot
Go To 5
556
HEATING & A/C
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C — Continued

Return circuit.
Yes → Go To 3
No → Repair the 5 Volt Supply circuit for a short to the Rear Temper-
ature Return circuit.

Measure the resistance between ground and the 5 Volt Supply circuit.
Yes → Go To 4
No → Repair the 5 Volt Supply circuit for a short to ground.


Measure the resistance between ground and the Rear Temperature Feedback Signal
circuit.
No → Repair the Rear Temperature Feedback Signal circuit for a short

to ground.

Feedback Signal circuit.
Yes → Go To 6
No → Repair the 5 Volt Supply circuit for a short to the Rear Temper-
ature Feedback Signal circuit.
557
HEATING & A/C
REAR BLEND POT CIRCUIT SHORT (ACTIVE) - MANUAL A/C — Continued

Measure the voltage between the 5 Volt Supply circuit and ground.
Yes → Repair the 5 Volt Supply circuit for a short to voltage.
No → Go To 7

Measure the voltage between the Rear Temperature Feedback Signal circuit and
ground.
Yes → Repair the Rear Temperature Feedback Signal circuit for a short
to voltage.
No → Go To 8

Measure the resistance between the Rear Temperature Feedback Signal circuit and
the Rear Temperature Return circuit.
No → Repair the Rear Temperature Feedback Signal circuit for a short

to the Rear Temperature Return circuit.
558
HEATING & A/C
Symptom:
TX FAILURE (ACTIVE) - MANUAL A/C
TX FAILURE (ACTIVE) - MANUAL A/C

Set Condition: This DTC will set if the A/C - Heater Control Module is unable to send a
message.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE HVAC MODULE
ATTEMPT TO COMMUNICATE WITH THE PCM/ECM, BCM, AND FCM

With the DRBIIIt, attempt to communicate with the HVAC Module.
Was the DRBIIIt able to I/D or communicate with the HVAC Module?
Yes → Go To 2
No → Refer to Communication for the related symptom(s).


Does the DRBIIIt display any additional HVAC DTCs?

No → Go To 3

With the DRBIIIt, attempt to communicate with the PCM/ECM.
With the DRBIIIt, attempt to communicate with the BCM.
With the DRBIIIt, attempt to communicate with the FCM.
Was the DRBIIIt able to I/D or communicate with the PCM/ECM, BCM and FCM?
Yes → Go To 4
No → Refer to Communication for the related symptom(s).

559
HEATING & A/C
TX FAILURE (ACTIVE) - MANUAL A/C — Continued

With the DRBIIIt, erase HVAC DTCs.
Cycle the ignition switch and wait approximately 1 minute.
With the DRBIIIt, read HVAC DTC’s.
Did this DTC reset?
560
INSTRUMENT CLUSTER
Symptom:
ABS LAMP CKT SHORT
POSSIBLE CAUSES
EMIC - INTERNAL ERROR

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
561
INSTRUMENT CLUSTER
Symptom:
ABS LAMP OPEN
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
562
INSTRUMENT CLUSTER
Symptom:
AIRBAG LAMP CKT SHORT
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
563
INSTRUMENT CLUSTER
Symptom:
AIRBAG LAMP OPEN
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
564
INSTRUMENT CLUSTER
Symptom:
EL PANEL SHORT
POSSIBLE CAUSES
CHECK EXTERIOR ILLUMINATION
CHECK OPERATION OF ALL GAUGES
VERIFY CONCERN
PANEL LAMP DRIVER CIRCUIT SHORT TO GROUND
PANEL LAMP DRIVER OPEN CIRCUIT
OPEN GROUND CIRCUIT
BCM PANEL LAMP DRIVER CIRCUIT INTERNAL FAILURE
INSTRUMENT CLUSTER PANEL LAMPS DRIVER INTERNAL FAILURE

1 Ignition on, engine not running. All
Turn the Headlamp Switch to the ON position.
Monitor the Instrument Cluster gauges for illumination.
Are any Instrument Cluster gauges illuminated?
Yes → Go To 3
No → Go To 2

Turn the Headlamp Switch to the ON position.
Are all of the Instrument Cluster gauges illuminated?
Yes → Go To 3

Turn the headlamp switch to the ON position.
Monitor the Headlamps for illumination.
Are the Headlamps illuminated?
Yes → Go To 4
No → Refer to EXTERIOR ILLUMINATION for the related symp-

tom(s).

With the DRBIIIt, erase DTCs.
Cycle the ignition switch from OFF to ON.
Wait 1 to 2 minutes for the system to cycle.
Did the DTC reset?
Yes → Go To 5
No → Perform the Instrument Cluster Self-Test and verify the concern.

565
INSTRUMENT CLUSTER
EL PANEL SHORT — Continued

Measure the resistance between ground and the Panel Lamps Driver circuit
(Instrument Cluster harness).
Is the resistance above 10,000 ohms?
Yes → Go To 6
No → Repair the Panel Lamps Driver Circuit for a Short to Ground.


Measure the resistance of the Panel Lamps Driver circuit between the BCM C2
connector and the Instrument Cluster connector.
Yes → Go To 7
No → Repair the Panel Lamp Driver Circuit for an open.


Measure the resistance of the Instrument Cluster harness ground circuits.
Are the resistances below 5.0 ohms?
Yes → Go To 8
No → Repair Instrument Cluster ground circuit for an open.

Connect a jumper wire between Panel Lamps Driver circuit (BCM C2 harness) and
B(+).
Did the Instrument Cluster gauges illuminate?
Yes → Replace the Body Control Module. With the DRBIII, erase DTC’s.
566
INSTRUMENT CLUSTER
Symptom:
FRONT FOG LAMP INDICATOR OPEN
POSSIBLE CAUSES
FRONT FOG LAMP INDICATOR CIRCUIT OPEN
FRONT FOG LAMP INDICATOR GROUND CIRCUIT OPEN
FRONT FOG LAMP INDICATOR CIRCUIT SHORT TO VOLTAGE
HEADLAMP SWITCH
BODY CONTROL MODULE

With the DRBIIIt, record and erase Body Control Module DTC’s.
Turn on the Front Fog Lamps.
Does the DRBIIIt display FRONT FOG LAMP INDICATOR OPEN?
Yes → Go To 2
No → Go To 8

Ignition on, engine not running.
Turn ON the Front Fog Lamps.
Using a 12-volt test light connected to ground, back probe the Front Fog Lamp
Indicator circuit in the Headlamp Switch harness connector.
Yes → Go To 3
No → Go To 6

Measure the resistance of the Front Fog Lamp Indicator Ground circuit from the
Body Control Module harness connector to the Headlamp Switch harness connector.
Yes → Repair the Front Fog Lamp Indicator Ground circuit for an open.
No → Go To 4
567
INSTRUMENT CLUSTER
FRONT FOG LAMP INDICATOR OPEN — Continued

Measure the voltage of the Front Fog Lamp Indicator circuit in the Headlamp Switch
harness connector.
Yes → Repair the Front Fog Lamp Indicator circuit for a short to voltage.
No → Go To 5
Repair
Replace the Headlamp Switch.

Measure the resistance of the Front Fog Lamp Indicator circuit from the Body
Control Module harness connector to the Headlamp Switch harness connector.
Yes → Repair the Front Fog Lamp Indicator circuit for an open.
No → Go To 7
Repair
circuit.

568
INSTRUMENT CLUSTER
Symptom:
FRONT FOG LAMP INDICATOR SHORT TO GROUND
POSSIBLE CAUSES
FRONT FOG LAMP INDICATOR CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH
BODY CONTROL MODULE

Does the DRBIIIt display FRONT FOG LAMP INDICATOR SHORT TO GROUND?
Yes → Go To 2
No → Go To 6

Turn ON the Front Fog Lamps.
Using a 12-volt test light connected to ground, back probe the Rear Fog Lamp
Yes → Go To 3
No → Go To 4

Repair

Measure the resistance between ground and the Front Fog Lamp Indicator circuit.
Yes → Repair the Front Fog Lamp Indicator circuit for a short to ground.
No → Go To 5
Repair
569
INSTRUMENT CLUSTER
FRONT FOG LAMP INDICATOR SHORT TO GROUND — Continued

circuit.
570
INSTRUMENT CLUSTER
Symptom:
FUEL GAUGE CHECKSUM FAILURE
POSSIBLE CAUSES

Repair
Replace the EMIC.
571
INSTRUMENT CLUSTER
Symptom:
FUEL LEVEL SENDING UNIT INPUT OPEN
FUEL LEVEL SENDING UNIT INPUT OPEN

Set Condition: Fuel Level Input to the BCM is greater than 9.8 volts for greater than 62.5
milliseconds.
POSSIBLE CAUSES
FUEL LEVEL SENSOR SIGNAL SHORTED TO B+
GROUND CIRCUIT OPEN
FUEL LEVEL SENDING UNIT OPERATION
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
BCM

Cycle the ignition off and on, leaving ignition key on for at least 15 seconds.
With the DRBIIIt in Body Computer, read DTCs.
Does the DTC reset?
Yes → Go To 2
No → Go To 7

Disconnect the Fuel Tank Module harness connector.
NOTE: The BCM sends out a low current 12 volt signal on the Fuel Level
Sensor Signal circuit. This low current should not illuminate a 12 volt test
light.
Using a 12-volt test light connected to ground, probe the Fuel Level Sensor Signal
circuit in the Fuel Tank Module harness connector.
Does the test light illuminate?
Yes → Repair the Fuel Level Sensor Signal circuit shorted to battery
voltage.
No → Go To 3
572
INSTRUMENT CLUSTER
FUEL LEVEL SENDING UNIT INPUT OPEN — Continued

Measure the resistance of the Ground circuits in the Fuel Tank Module harness
connector.
Yes → Go To 4


With the DRBIIIt in Body Computer then Sensors, monitor the Fuel Sensor.
Using a jumper wire, jumper the Fuel Level Sensor Signal circuit to the ground
circuit in the Fuel Tank Module harness connector.
Does the DRB display below 0.5 volt?
Yes → Replace the Fuel Level Sending Unit.
No → Go To 5

Measure the resistance of the Fuel Level Sensor Signal circuit between the Fuel Tank
Module harness connector and the BCM harness connector.
Yes → Go To 6
No → Repair the Fuel Level Sensor Signal for an open.
Repair
7 WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A All

With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
573
INSTRUMENT CLUSTER
Symptom:
FUEL LEVEL SENDING UNIT INPUT SHORT
FUEL LEVEL SENDING UNIT INPUT SHORT

Set Condition: Fuel Level Input to the BCM is less than 2 volts for greater than 62.5
milliseconds.
POSSIBLE CAUSES
FUEL LEVEL SENDING UNIT OPERATION
FUEL LEVEL SENSOR SIGNAL SHORTED TO GROUND
BCM

Cycle the ignition off and on, leaving ignition key on for at least 15 seconds.
Does the DTC reset?
Yes → Go To 2
No → Go To 5

With the DRBIIIt in Body Computer and then Sensors, monitor the Fuel Sensor.
Does the Fuel Sensor voltage go above 9.5 volts?
Yes → Replace the Fuel Level Sending Unit.

No → Go To 3

Disconnect Fuel Tank Module harness connector.
Measure the resistance of the Fuel Level Sensor Signal circuit in the BCM harness
connector to ground.
Yes → Repair the Fuel Level Sensor Signal circuit for a short to ground.
No → Go To 4
574
INSTRUMENT CLUSTER
FUEL LEVEL SENDING UNIT INPUT SHORT — Continued

Repair

575
INSTRUMENT CLUSTER
Symptom:
IOD WAKEUP CLUSTER OUTPUT OPEN
IOD WAKEUP CLUSTER OUTPUT OPEN

Set Condition: The BCM is active and the Instrument Cluster does not responed on the
Instrument Cluster Wake Up Sense circuit.
POSSIBLE CAUSES
INSTRUMENT CLUSTER WAKE UP SENSE CKT OPEN
INSTRUMENT CLUSTER WAKE UP SENSE CKT SHORT TO GROUND
INSTRUMENT CLUSTER
BODY CONTROL MODULE

Cycle the ignition off and on several times, leaving ignition key on for at least 15
seconds.
Does the DTC reset?
Yes → Go To 2
No → Go To 5

Measure the voltage of the Instrument Cluster Wake Up Sense circuit in the BCM C4
harness connector.

No → Go To 3
576
INSTRUMENT CLUSTER
IOD WAKEUP CLUSTER OUTPUT OPEN — Continued

Measure the resistance of the Instrument Cluster Wake Up Sense circuit between the
BCM C4 harness connector and the MIC harness connector.
Yes → Go To 4
No → Repair the Instrument Cluster Wake Up Sense circuit for an

open.

Measure the resistance of the Instrument Cluster Wake Up Sense circuit in the MIC
harness connector to ground.
Yes → Repair the Instrument Cluster Wake Up Sense circuit for a
shorted to ground.


577
INSTRUMENT CLUSTER
Symptom:
IOD WAKEUP CLUSTER OUTPUT SHORT
IOD WAKEUP CLUSTER OUTPUT SHORT

Set Condition: The BCM is active and senses the Instrument Cluster Wake Up Sense
circuit shorted high.
POSSIBLE CAUSES
INSTRUMENT CLUSTER WAKE UP SENSE CKT SHORTED TO VOLTAGE
INSTRUMENT CLUSTER
BODY CONTROL MODULE

Cycle the ignition off and on several times, leaving the ignition key on for at least 15
seconds.
Does the DTC reset?
Yes → Go To 2
No → Go To 4

Up Sense circuit.
Yes → Go To 3

578
INSTRUMENT CLUSTER
IOD WAKEUP CLUSTER OUTPUT SHORT — Continued

Up Sense circuit.
Yes → Repair the Instrument Cluster Wake Up Sense circuit for a short
to voltage.


579
INSTRUMENT CLUSTER
Symptom:
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE)
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE)

Set Condition: The BCM detects an open in the Left Turn Indicator Driver.
POSSIBLE CAUSES
FUSED B+ CIRCUIT
MESSAGE CENTER OPERATION
LEFT TURN INDICATOR DRIVER SHORTED TO GROUND
LEFT TURN INDICATOR DRIVER OPEN
BCM

Monitor the Left Turn Signal Indicator.
Operate the Left Turn Signal.
Is the Indicator lamp operating correctly?
Yes → Go To 2
No → Go To 3


580
INSTRUMENT CLUSTER
LEFT TURN SIGNAL INDICATOR OPEN (HIGHLINE) — Continued

Disconnect the Message Center harness connector.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the
Message Center harness connector.
Yes → Go To 4
No → Repair the Fused B+ circuit.


Using a 12-volt test light connected to 12-volts, probe the Left Indicator Driver circuit
in the Message Center harness connector.
Operate the Multi-Function Switch and turn the Left Indication on.
Does the test light flash on and off?
Yes → Remove and inspect the Bulb. If OK, replace the Message Center.
No → Go To 5

Measure the resistance of the Left Turn Indicator Driver circuit at the Message
Center harness connector to ground.
Yes → Repair the Left Turn Indicator for a short to ground.

No → Go To 6

Measure the resistance of the Left Turn Indicator Driver circuit between the BCM
harness connector and the Message Center harness connector.
Yes → Go To 7
No → Repair the Left Turn Indicator for an open.

7 If there are no possible causes remaining, view repair? All
Repair
581
INSTRUMENT CLUSTER
Symptom:
LEFT TURN SIGNAL INDICATOR OPEN (LOWLINE)
LEFT TURN SIGNAL INDICATOR OPEN (LOWLINE)

Set Condition: The BCM detects an open in the Left Turn Indicator Driver.
POSSIBLE CAUSES
FUSED B+ CIRCUIT
INSTRUMENT CLUSTER OPERATION
LEFT TURN INDICATOR DRIVER SHORTED TO GROUND
LEFT TURN INDICATOR DRIVER OPEN
BCM

Yes → Go To 2
No → Go To 3


582
INSTRUMENT CLUSTER
LEFT TURN SIGNAL INDICATOR OPEN (LOWLINE) — Continued

Instrument Cluster harness connector.
Yes → Go To 4


in the Instrument Cluster harness connector.
Yes → Remove and inspect the Bulb. If OK, replace the Instrument
Cluster printed circuit board.
No → Go To 5

Measure the resistance of the Left Turn Indicator Driver circuit at the Instrument
Cluster harness connector to ground.
Yes → Repair the Left Turn Indicator for a short to ground.
No → Go To 6

Measure the resistance of the Left Turn Indicator Driver circuit between the BCM
harness connector and the Instrument Cluster harness connector.
Yes → Go To 7
No → Repair the Left Turn Indicator for an open.
Repair
583
INSTRUMENT CLUSTER
Symptom:
LEFT TURN SIGNAL INDICATOR SHORT (HIGHLINE)
LEFT TURN SIGNAL INDICATOR SHORT (HIGHLINE)

Set Condition: The BCM detects a short to voltage in the Left Turn Indicator Driver.
POSSIBLE CAUSES
FUSED B+ CIRCUIT
LEFT TURN INDICATOR DRIVER SHORTED TO VOLTAGE
BCM

Yes → Go To 2
No → Go To 3


584
INSTRUMENT CLUSTER
LEFT TURN SIGNAL INDICATOR SHORT (HIGHLINE) — Continued

Yes → Go To 4


in the Message Center harness connector.
Yes → Remove and inspect the bulb. If OK, replace the Message Center.
No → Go To 5

Measure the voltage of the Left Turn Indicator Driver circuit at the Message Center
harness connector.
Yes → Repair the Left Turn Indicator for a short to voltage.
No → Go To 6
Repair
585
INSTRUMENT CLUSTER
Symptom:
LEFT TURN SIGNAL INDICATOR SHORT (LOWLINE)
LEFT TURN SIGNAL INDICATOR SHORT (LOWLINE)

POSSIBLE CAUSES
FUSED B+ CIRCUIT
LEFT TURN INDICATOR DRIVER SHORTED TO VOLTAGE
BCM

Yes → Go To 2
No → Go To 3


586
INSTRUMENT CLUSTER
LEFT TURN SIGNAL INDICATOR SHORT (LOWLINE) — Continued

Yes → Go To 4


in the Instrument Cluster harness connector.
Yes → Remove and inspect the bulb. If OK, replace the Instrument
No → Go To 5

Measure the voltage of the Left Turn Indicator Driver circuit at the Instrument
Cluster harness connector.
Yes → Repair the Left Turn Indicator for a short to voltage.
No → Go To 6
Repair
587
INSTRUMENT CLUSTER
Symptom:
LOOPBACK FAILURE
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
588
INSTRUMENT CLUSTER
Symptom:
NO ABS BUS MESSAGES RECEIVED
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE ANTI-LOCK BRAKE SYSTEM MODULE
INSTRUMENT CLUSTER

With the DRB, attempt to communicate with the ABS module.
Was the DRB able to I/D or communicate with the ABS module?
Yes → Go To 2


Turn the ignition on and wait approximately 1 minute.
Did this DTC reset?

589
INSTRUMENT CLUSTER
Symptom:
NO BCM BUS MESSAGES RECEIVED
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE BODY CONTROL MODULE
INSTRUMENT CLUSTER

Yes → Go To 2


Did this DTC reset?

590
INSTRUMENT CLUSTER
Symptom:
NO FCM BUS MESSAGES RECEIVED
POSSIBLE CAUSES
INSTRUMENT CLUSTER

With the DRBIII, attempt to communicate with the FCM.
Was the DRBIII able to I/D or communicate with the FCM?
Yes → Go To 2

2 With the DRBIII, erase DTC’s. All

With the DRBIII, read DTC’s.
Did this DTC reset?

591
INSTRUMENT CLUSTER
Symptom:
NO ORC BUS MESSAGES RECEIVED
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE OCCUPANT RESTRAINT CONTROLLER
INSTRUMENT CLUSTER

With the DRBIII, attempt to communicate with the ORC.
Was the DRBIII able to I/D or communicate with the ORC?
Yes → Go To 2


Did this DTC reset?

592
INSTRUMENT CLUSTER
Symptom:
NO PCM BUS MESSAGES RECEIVED
POSSIBLE CAUSES
PCM MESSAGE NOT RECEIVED
INSTRUMENT CLUSTER

With the DRBIII, attempt to communicate with the PCM.
Was the DRBIII able to I/D or communicate with the PCM?
Yes → Go To 2


Did this DTC reset?

593
INSTRUMENT CLUSTER
Symptom:
NO TCM BUS MESSAGES RECEIVED
POSSIBLE CAUSES
INSTRUMENT CLUSTER

With the DRBIII, attempt to communicate with the Transmission Control Module.
Was the DRBIII able to I/D or communicate with the TCM?
Yes → Go To 2


Did this DTC reset?

594
INSTRUMENT CLUSTER
Symptom:
PANEL DIMMING OUTPUT SHORT
POSSIBLE CAUSES
EMIC DIMMING CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH DIMMING CIRCUIT SHORT TO GROUND
HVAC MODULE DIMMING CIRCUIT SHORT TO GROUND
I/P MULTI-FUNCTION SWITCH DIMMING CIRCUIT SHORT TO GROUND
MIRROR SWITCH DIMMING CIRCUIT SHORT TO GROUND
RADIO DIMMING CIRCUIT SHORT TO GROUND
REAR BLOWER CONTROL SWITCH DIMMING CIRCUIT SHORT TO GROUND
EMIC
HEADLAMP SWITCH
I/P MULTI-FUNCTION SWITCH
MIRROR SWITCH
RADIO
REAR BLOWER CONTROL SWITCH
BODY CONTROL MODULE
HVAC MODULE

Turn on the Headlamps.
Does the DRBIIIt display PANEL DIMMING OUTPUT SHORT?
Yes → Go To 2
No → Go To 17

With the DRBIIIt, erase Body Control Module DTCs.
Turn the ignition off to the lock position.
Disconnect the EMIC harness connector.
Turn the Headlamps on.
Yes → Go To 3
No → Replace the EMIC in accordance with the Service Information.
595
INSTRUMENT CLUSTER
PANEL DIMMING OUTPUT SHORT — Continued

Yes → Go To 4
No → Replace the Headlamp Switch in accordance with the Service

Information.

Disconnect the I/P Multi-Function Switch harness connector.
Yes → Go To 5
No → Replace the I/P Multi-Function Switch in accordance with the

Disconnect the Mirror Switch harness connector.
Yes → Go To 6
No → Replace the Mirror Switch in accordance with the Service Infor-
mation.

Disconnect the Rear Blower Control Switch harness connector.
Yes → Go To 7
No → Replace the Rear Blower Control Switch in accordance with the

596
INSTRUMENT CLUSTER

Disconnect the HVAC Module harness connector.
Yes → Go To 8
No → Replace the HVAC Module in accordance with the Service Infor-
mation.

Disconnect the Radio harness connector.
Yes → Go To 9
No → Replace the Radio in accordance with the Service Information.

Disconnect the EMIC harness connector.
Measure the resistance between ground and the EMIC Dimming circuit.
Yes → Repair the EMIC Dimming circuit for a short to ground.
No → Go To 10

Measure the resistance between ground and the Headlamp Switch Dimming circuit.
Yes → Repair the Headlamp Switch Dimming circuit for a short to

ground.
No → Go To 11
597
INSTRUMENT CLUSTER

Disconnect the HVAC Module harness connector.
Measure the resistance between ground and the HVAC Module Dimming circuit.
Yes → Repair the HVAC Module Dimming circuit for a short to ground.
No → Go To 12

Disconnect the I/P Multi-Function Switch harness connector.
Measure the resistance between ground and the I/P Multi-Function Switch Dimming
circuit.
Yes → Repair the I/P Multi-Function Switch Dimming circuit for a short
to ground.
No → Go To 13

Disconnect the Mirror Switch harness connector.
Measure the resistance between ground and the Mirror Switch Dimming circuit.
Yes → Repair the Mirror Switch Dimming circuit for a short to ground.
No → Go To 14

Disconnect the Rear Blower Control Switch harness connector.
Measure the resistance between ground and the Rear Blower Control Switch
Dimming circuit.
Yes → Repair the Rear Blower Control Switch Dimming circuit for a
short to ground.
No → Go To 15
598
INSTRUMENT CLUSTER

Disconnect the Radio harness connector.
Measure the resistance between ground and the Radio Dimming circuit.
Yes → Repair the Radio Dimming circuit for a short to ground.
No → Go To 16
Repair
circuit.

599
INSTRUMENT CLUSTER
Symptom:
REAR FOG INDICATOR OUTPUT OPEN
POSSIBLE CAUSES
REAR FOG LAMP INDICATOR CIRCUIT OPEN
REAR FOG LAMP INDICATOR GROUND CIRCUIT OPEN
REAR FOG LAMP INDICATOR CIRCUIT SHORT TO VOLTAGE
HEADLAMP SWITCH
BODY CONTROL MODULE

Turn on the Rear Fog Lamps.
Does the DRBIIIt display REAR FOG LAMP INDICATOR OPEN?
Yes → Go To 2
No → Go To 8

Turn ON the Rear Fog Lamps.
Yes → Go To 3
No → Go To 6

Measure the resistance of the Rear Fog Lamp Indicator Ground circuit from the Body
Control Module harness connector to the Headlamp Switch harness connector.
Yes → Repair the Rear Fog Lamp Indicator Ground circuit for an open.
No → Go To 4
600
INSTRUMENT CLUSTER
REAR FOG INDICATOR OUTPUT OPEN — Continued

Measure the voltage of the Rear Fog Lamp Indicator circuit in the Headlamp Switch
harness connector.
Yes → Repair the Rear Fog Lamp Indicator circuit for a short to voltage.
No → Go To 5
Repair

Measure the resistance of the Rear Fog Lamp Indicator circuit from the Body Control
Module harness connector to the Headlamp Switch harness connector.
Yes → Repair the Rear Fog Lamp Indicator circuit for an open.
No → Go To 7
Repair
circuit.

601
INSTRUMENT CLUSTER
Symptom:
REAR FOG INDICATOR OUTPUT SHORT
POSSIBLE CAUSES
REAR FOG LAMP INDICATOR CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH
BODY CONTROL MODULE

Does the DRBIIIt display REAR FOG LAMP INDICATOR SHORT TO GROUND?
Yes → Go To 2
No → Go To 6

Turn ON the Rear Fog Lamps.
Yes → Go To 3
No → Go To 4

Repair

Measure the resistance between ground and the Rear Fog Lamp Indicator circuit.
Yes → Repair the Rear Fog Lamp Indicator circuit for a short to ground.
No → Go To 5
Repair
602
INSTRUMENT CLUSTER
REAR FOG INDICATOR OUTPUT SHORT — Continued

circuit.
603
INSTRUMENT CLUSTER
Symptom:
RIGHT TURN SIGNAL INDICATOR OPEN (HIGHLINE)
RIGHT TURN SIGNAL INDICATOR OPEN (HIGHLINE)

Set Condition: The BCM detects an open in the Right Turn Indicator Driver.
POSSIBLE CAUSES
FUSED B+ CIRCUIT
RIGHT TURN INDICATOR DRIVER SHORTED TO GROUND
RIGHT TURN INDICATOR DRIVER OPEN
BCM

Monitor the Right Turn Signal Indicator.
Operate the Right Turn Signal.
Yes → Go To 2
No → Go To 3


604
INSTRUMENT CLUSTER
RIGHT TURN SIGNAL INDICATOR OPEN (HIGHLINE) — Continued

Yes → Go To 4


Using a 12-volt test light connected to 12-volts, probe the Right Indicator Driver
circuit in the Message Center harness connector.
Operate the Multi-Function Switch and turn the Right Indication on.
Yes → Remove and inspect the Bulb. If OK, replace the Message Center.
No → Go To 5

Measure the resistance of the Right Turn Indicator Driver circuit at the Message
Center harness connector to ground.
Yes → Repair the Right Turn Indicator for a short to ground.

No → Go To 6

Measure the resistance of the Right Turn Indicator Driver circuit between the BCM
harness connector and the Message Center harness connector.
Yes → Go To 7
No → Repair the Right Turn Indicator for an open.

Repair
605
INSTRUMENT CLUSTER
Symptom:
RIGHT TURN SIGNAL INDICATOR OPEN (LOWLINE)
RIGHT TURN SIGNAL INDICATOR OPEN (LOWLINE)

Set Condition: The BCM detects an open in the Right Turn Indicator Driver.
POSSIBLE CAUSES
RIGHT TURN INDICATOR DRIVER SHORTED TO GROUND
FUSED B+ CIRCUIT
RIGHT TURN INDICATOR DRIVER OPEN
BCM

Yes → Go To 2
No → Go To 3


606
INSTRUMENT CLUSTER
RIGHT TURN SIGNAL INDICATOR OPEN (LOWLINE) — Continued

Yes → Go To 4


circuit in the Instrument Cluster harness connector.
Yes → Remove and inspect the Bulb. If OK, replace the Instrument
No → Go To 5

Measure the resistance of the Right Turn Indicator Driver circuit between the BCM
harness connector and the Instrument Cluster harness connector.
Yes → Go To 6
No → Repair the Right Turn Indicator for an open.


Measure the resistance of the Right Turn Indicator Driver circuit at the Instrument
Cluster harness connector to ground.
Yes → Repair the Right Turn Indicator for a short to ground.

No → Go To 7
Repair
607
INSTRUMENT CLUSTER
Symptom:
RIGHT TURN SIGNAL INDICATOR SHORT (HIGHLINE)
RIGHT TURN SIGNAL INDICATOR SHORT (HIGHLINE)

Set Condition: The BCM detects a short to voltage in the Right Turn Indicator Driver.
POSSIBLE CAUSES
FUSED B+ CIRCUIT
RIGHT TURN INDICATOR DRIVER SHORTED TO VOLTAGE
BCM

Yes → Go To 2
No → Go To 3


608
INSTRUMENT CLUSTER
RIGHT TURN SIGNAL INDICATOR SHORT (HIGHLINE) — Continued

Yes → Go To 4


circuit in the Message Center harness connector.
Yes → Remove and inspect the bulb. If OK, replace the Message Center.
No → Go To 5

Measure the voltage of the Right Turn Indicator Driver circuit at the Message Center
harness connector.
Yes → Repair the Right Turn Indicator for a short to voltage.
No → Go To 6
Repair
609
INSTRUMENT CLUSTER
Symptom:
RIGHT TURN SIGNAL INDICATOR SHORT (LOWLINE)
RIGHT TURN SIGNAL INDICATOR SHORT (LOWLINE)

POSSIBLE CAUSES
FUSED B+ CIRCUIT
RIGHT TURN INDICATOR DRIVER SHORTED TO VOLTAGE
BCM

Yes → Go To 2
No → Go To 3


610
INSTRUMENT CLUSTER
RIGHT TURN SIGNAL INDICATOR SHORT (LOWLINE) — Continued

Yes → Go To 4


circuit in the Instrument Cluster harness connector.
Yes → Remove and inspect the bulb. If OK, replace the Instrument
No → Go To 5

Measure the voltage of the Right Turn Indicator Driver circuit at the Instrument
Cluster harness connector.
Yes → Repair the Right Turn Indicator for a short to voltage.

No → Go To 6
Repair
611
INSTRUMENT CLUSTER
Symptom:
SPEEDOMETER CHECKSUM FAILURE
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
612
INSTRUMENT CLUSTER
Symptom:
TACHOMETER CHECKSUM FAILURE
POSSIBLE CAUSES

Did the DTC return?
Yes → Go To 2

Repair
Replace the EMIC.
613
INSTRUMENT CLUSTER
Symptom:
TCM MESSAGE MISMATCH
POSSIBLE CAUSES
TCM COMMUNICATION FAILURE
INSTRUMENT CLUSTER, TCM MESSAGE MISMATCH

With the DRBIIIt, ensure PCI Bus communications with the TCM.
Is the TCM communicating on the PCI Bus?
Yes → Go To 2
No → Refer to COMMUNICATION category for the related symptom.


Repair
Replace the Instrument Cluster.
614
INSTRUMENT CLUSTER
Symptom:
TEMPERATURE GAUGE CHECKSUM FAILURE
POSSIBLE CAUSES

Repair
Replace the EMIC.
615
INSTRUMENT CLUSTER
Symptom:
*ANY PCI BUS INDICATOR INOPERATIVE
POSSIBLE CAUSES
NO RESPONSE - PCI BUS
NO RESPONSE - INSTRUMENT CLUSTER
NO RESPONSE - ECM / PCM
INDICATOR INOPERATIVE
INSTRUMENT CLUSTER

With the DRBIIIt, select J1850 Module Scan.
Does the DRBIIIt display MIC PRESENT on the BUS?
Yes → Go To 2
No → Refer to the COMMUNICATION category and perform the ap-

propriate symptom.

With the DRBIIIt, Select Body, MIC, the MODULE DISPLAY.
Does the DRBIIIt display NO RESPONSE from MIC?
Yes → Refer to the symptom list for problems related to *NO RE-
SPONSE FROM THE INSTRUMENT CLUSTER.
No → Go To 3

With the DRBIIIt, select Body, MIC, SYSTEM TESTS, PCM MONITOR.
Does the DRBIIIt display PCM INACTIVE on the BUS?
Yes → Refer to the symptom list for problems related to *NO RE-
SPONSE FROM THE POWERTRAIN CONTROL MODULE
(Gas) / or *NO RESPONSE FROM THE ENGINE CONTROL
MODULE (Diesel)
No → Go To 4
4 NOTE: Diagnose and repair any PCM (gas) or ECM (diesel) DTCs before All
proceeding with this test.
Perform the Instrument Cluster diagnostic Self Test.
Observe the indicator in question during the Self Test.
Did the indicator illuminate?
Yes → Refer to the appropriate Servic Information category to diagnose

the related system.
No → Replace the Instrument Cluster in accordance with the Service

Information.
616
Symptom:
ACCESSORY POWER OUTPUT #1 OPEN

Set Condition: The FCM has detected an open in the Accessory Relay control circuit.
POSSIBLE CAUSES
FUSE & RELAY CENTER INTERNAL MALFUNCTION
ACCESSORY RELAY

Does the DRBIIIt display both the ACCESSORY POWER OUTPUT OPEN trouble
codes?
Yes → Go To 2
No → Go To 3

Disconnect the Accessory Relay from the Fuse & Relay Center.
Connect a known good relay to the Accessory Relay location in the Fuse & Relay
Center.
Does the DRBIIIt display both the ACCESSORY POWER OUTPUT OPEN trouble
codes?
No → Replace the original Accessory Relay.

617
ACCESSORY POWER OUTPUT #1 OPEN — Continued

Does the DRBIIIt display the ACCESSORY POWER OUTPUT 1 OPEN trouble code?

No → Go To 4

Does the DRBIIIt display the ACCESSORY POWER OUTPUT #2 OPEN trouble
code?

No → This symptom represents an internal malfunction in the Front

Control Module. The condition that caused this symptom is
currently not present.
618
Symptom:
ACCESSORY POWER OUTPUT #1 SHORTED TO BATTERY

Set Condition: The FCM has detected a short to battery voltage in the Accessory Relay
control circuit.
POSSIBLE CAUSES
ACCESSORY RELAY

Does the DRBIIIt display both ACCESSORY POWER OUTPUT SHORTED TO
BATTERY trouble codes?
Yes → Go To 2
No → Go To 3

Center.

619
ACCESSORY POWER OUTPUT #1 SHORTED TO BATTERY — Continued

Does the DRBIIIt display the ACCESSORY POWER OUTPUT #1 SHORTED TO
BATTERY trouble code?

No → Go To 4

code?


620
Symptom:

Set Condition: The FCM has detected an open in the Accessory Relay control circuit.
POSSIBLE CAUSES
ACCESSORY RELAY
FCM

Does the DRBIIIt display both ACCESSORY POWER OUTPUT OPEN trouble
codes?
Yes → Go To 2
No → Go To 3

Center.
Does the DRBIIIt display both ACCESSORY POWER OUTPUT OPEN trouble
codes?
No → Replace the Accessory Relay.

621
ACCESSORY POWER OUTPUT #2 OPEN — Continued

code?

No → Go To 4

code?


622
Symptom:

Set Condition: The FCM has detected a short to battery voltage in the Accessory Relay
control circuit.
POSSIBLE CAUSES
ACCESSORY RELAY

Yes → Go To 2
No → Go To 3

Center.

623
ACCESSORY POWER OUTPUT #2 SHORTED TO BATTERY — Continued


No → Go To 4



624
Symptom:
CPA NOT ENGAGED
CPA NOT ENGAGED

Set Condition: If the connector positive assurance lock is not fully engaged, the Front
Control Module will detect battery voltage on the B(+) Sense circuit. With voltage present,
the FCM determines that there is a poor connection at connector C5 of the Fuse and Relay
Center.
POSSIBLE CAUSES
FRONT CONTROL MODULE INTERNAL MALFUNCTION
FUSE AND RELAY CENTER INTERNAL MALFUNCTION
CONNECTOR POSITIVE ASSURANCE LOCK

Does the DRBIIIt display: CPA NOT ENGAGED?
Yes → Go To 2
No → The condition that caused this symptom is currently not present.

condition.

Measure the voltage of the B(+) Sense circuit at the Fuse and Relay Center side of the
FCM connector.
Yes → Go To 3

625
CPA NOT ENGAGED — Continued

Inspect connector C5 on the Fuse and Relay Center, ensure the connector lock is
properly seated into the connector.
Measure the voltage of the B(+) Sense circuit at the Fuse and Relay Center side of the
FCM connector.
No → Verify the Connector Positive Assurance lock is correctly seated.

626
Symptom:
IGN RUN/START INPUT WIRING
IGN RUN/START INPUT WIRING

Set Condition: The Fused Ignition Switch Output circuit voltage at the FCM goes below
0.5 volts.
POSSIBLE CAUSES

1 With the DRBIIIt, record and erase the current Front Control Module DTC’s. All
Does the DRBIIIt display: IGNITION RUN-START INPUT WIRING?
Yes → Go To 2

Measure the voltage of the Fused Ignition Switch Output circuit (cavity 37) at the
Fuse and Relay Center side of the FCM connector.

No → Go To 3
627
IGN RUN/START INPUT WIRING — Continued

Gain access to the bottom of the Fuse and Relay Center.
Disconnect connector C9 from the Fuse and Relay Center.
Measure the resistance of the Fused Ignition Switch Output circuit between the FCM
connector cavity 37 and the Fuse and Relay Center connector C9 cavity 2.
Yes → Repair the Fused Ignition Switch Output circuit for an open
between the Fuse and Relay Center and the ignition switch.
628
Symptom:
IGNITION START INPUT WIRING
IGNITION START INPUT WIRING

Set Condition: The Fused Ignition Switch Output (Start) circuit voltage at the FCM goes
below 0.5 volts.
POSSIBLE CAUSES

1 With the DRBIIIt, record and erase the current Front Control Module DTC’s. All
Does the DRBIIIt display: IGNITION START INPUT WIRING?
Yes → Go To 2

Measure the voltage of the Fused Ignition Switch Output circuit (cavity 37) at the

No → Go To 3
629
IGNITION START INPUT WIRING — Continued

Gain access to the bottom of the Fuse and Relay Center.
Disconnect connector C9 from the Fuse and Relay Center.
Measure the resistance of the Fused Ignition Switch Output circuit between the FCM
connector cavity 37 and the Fuse and Relay Center connector C9 cavity 2.
Yes → Repair the Fused Ignition Switch Output circuit for an open
between the Fuse and Relay Center and the ignition switch.
630
Symptom:
INTERNAL DRIVER FAULT #1

Set Condition: The Front Control Module has detected an internal malfunction of the
module.
POSSIBLE CAUSES

Does the DRBIIIt display: INTERNAL DRIVER FAULT #1?

631
Symptom:

module.
POSSIBLE CAUSES


632
Symptom:

module.
POSSIBLE CAUSES


633
INTERIOR LIGHTING
Symptom:
DOME LAMP OUTPUT SHORT
DOME LAMP OUTPUT SHORT

POSSIBLE CAUSES
PANEL LAMPS DIMMER SIGNAL CIRCUIT SHORT
BODY CONTROL MODULE
COURTESY LAMPS DRIVER DOME CIRCUIT SHORT

Turn the Dome Lamps on.
Does the DRBIIIt read: Dome Lamp Output Short?
Yes → Go To 2
No → Repair the Panel Lamps Dimmer Signal Circuit for a short
condition.

Measure the resistance of the Headlamp Switch MUX Return Circuit.
ground.
No → Go To 3

Measure the resistance of the Courtesy Lamps Driver - Dome Circuit.

No → Repair the Courtesy Lamps Driver - Dome Circuit for a short
condition.
634
INTERIOR LIGHTING
Symptom:
DOME SWITCH INPUT OPEN
DOME SWITCH INPUT OPEN

When Monitored: Dome Lamps Off.
Set Condition: When Voltage is below 4.8 volts for 62.5 msec.
POSSIBLE CAUSES
HEADLAMP SWITCH MUX RETURN CIRCUIT OPEN
PANEL LAMPS DIMMER SIGNAL CIRCUIT OPEN
BODY CONTROL MODULE
HEADLAMP SWITCH

Turn the Dome Lamps on.
Does the DRBIIIt display: Dome Switch Input Open?
Yes → Go To 2
No → Repair the Headlamp Switch MUX Return Circuit for an open
condition.

Measure the resistance of the Panel Lamps Dimmer Signal Circuit.
Yes → Go To 3
No → Repair the Panel Lamps Dimmer Signal Circuit for an open

condition.

Measure the voltage of the Headlamp Switch MUX Return Circuit.
Is the voltage below 4.8 volts?

No → Replace the Headlamp Switch.
635
INTERIOR LIGHTING
Symptom:
DOME SWITCH INPUT SHORT
DOME SWITCH INPUT SHORT

When Monitored: Dome Lamps Off.
Set Condition: When Voltage has gone below 0.196 volts for 62.5 msec.
POSSIBLE CAUSES
PANEL LAMPS DIMMER SIGNAL CIRCUIT SHORT
PANEL LAMPS DIMMER SIGNAL CIRCUIT SHORT TO GROUND
HEADLAMP SWITCH
BODY CONTROL MODULE

Measure the resistance between the Panel Lamps Dimmer Signal Circuit and the
Headlamp Switch MUX Return Circuit.
Is either circuit below 1000 ohms?
Yes → Go To 2
No → Repair the Panel Lamps Dimmer Signal Circuit shorted to the

Headlamp Switch MUX Return Circuit.

Measure the resistance of the Panel Lamps Dimmer Signal Circuit to ground.
Yes → Repair the Panel Lamps Dimmer Signal Circuit for a short to
ground.
No → Go To 3

Measure the resistance of the Headlamp Switch MUX Return Circuit to ground.
ground.
No → Go To 4
636
INTERIOR LIGHTING
DOME SWITCH INPUT SHORT — Continued

Measure the resistance of the Panel Lamps Dimmer Signal Circuit and the
Headlamp Switch MUX Return Circuit to ground.
Is the resistance of either circuit below 1000 ohms?
Yes → Replace the Headlamp Switch.

637
INTERIOR LIGHTING
Symptom:
FRONT COURTESY LAMPS OUTPUT SHORT
FRONT COURTESY LAMPS OUTPUT SHORT

Set Condition: When the voltage of the Headlamp Switch MUX Return Circuit falls below
5.0 volts for 10 seconds.
POSSIBLE CAUSES
HEALAMP SWITCH MUX RETURN CIRCUIT SHORT TO GROUND
COURTESY LAMPS DRIVER CIRCUIT OPEN
PANEL LAMPS DIMMER SIGNAL CIRCUIT OPEN
BODY CONTROL MODULE
HEADLAMP SWITCH

Turn the courtesy lamps on.
Does the DRBIIIt read: Front Courtesy Lamps Output Short?
ground condition.
No → Go To 2

Remove and inspect the inoperative courtesy lamp bulb.
With the DRBIIIt, measure the resistance of the Courtesy Lamps Driver- Dome
Circuit.
Is the resistance above 1000 ohms?
Yes → Go To 3
No → Repair the Open Courtesy Lamps Driver-Dome Circuit and re-

place the bulb.

Measure the resistance of the Panel Lamps Dimmer Signal Circuit.
Yes → Go To 4
No → Repair the Open Panel Lamps Dimmer Signal Circuit.

638
INTERIOR LIGHTING
FRONT COURTESY LAMPS OUTPUT SHORT — Continued

Measure the voltage of the Headlamp Switch MUX Return Circuit.
Is the voltage below 5.0 volts?
No → Replace the Headlamp Switch.

639
INTERIOR LIGHTING
Symptom:
HALO/DOOR/LIFTGATE LAMP OUTPUT SHORT
POSSIBLE CAUSES
COURTESY LAMPS DRIVER - DOOR CIRCUIT SHORT TO GROUND
COURTESY LAMPS DRIVER - LIFTGATE CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE
HALO LAMP DRIVER CIRCUIT SHORT TO GROUND

1 With the DRBIIIt, clear all present DTC’s. All
Open the Drivers and Front Passenger door.
Does the DRBIIIt read: Halo/Door/Liftgate Lamp Output Short?
Yes → Go To 2
No → Repair the Courtesy Lamps Driver - Door Circuit for a short to
ground.
2 With the DRBIIIt, clear all present DTC’s All

Open the Liftgate.
Does the DRBIIIt read: Halo/Door/Liftgate Lamp Output Short?
Yes → Go To 3
No → Repair the Courtesy Lamps Driver - Liftgate Circuit for a short

condition.

Disconnect the Body Control Module harness connector C4.
Measure the resistance of the Halo Lamp Driver Circuit.

No → Repair the Halo Lamp Driver Circuit for a short to ground.

640
INTERIOR LIGHTING
Symptom:
READING LAMP OUTPUT SHORT
READING LAMP OUTPUT SHORT

POSSIBLE CAUSES
READING LAMPS DRIVER CIRCUIT SHORT
COURTESY LAMPS DRIVER READING LAMPS CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

Turn the reading lamps on.
Does then DRBIIIt display : Reading Lamps Output Short?
Yes → Go To 2
No → Repair the Reading Lamps Driver Circuit for a short condition.

Disconnect the Body Control Module C2 harness connector
Measure the resistance of the Courtesy Lamps Driver Reading Lamps Circuit.
Yes → Repair the Courtesy Lamps Driver Reading Lamps Circuit for a
short to ground.
641
MEMORY SEAT
Symptom:
BCM MESSAGE NOT RECEIVED
BCM MESSAGE NOT RECEIVED

When Monitored: Continuously when the PCI bus is active.
Set Condition: If the Memory Seat Mirror Module does receive this Bus message from the
BCM. Code will remain for 50 ignition cycles.
POSSIBLE CAUSES
BCM RESPONSE
STORED CODE/PCI BUS COMMUNICATION PROBLEMS
MEMORY SEAT MIRROR MODULE
INTERMITTENT PROBLEM

With the DRBIIIt select Body Control Module.
Is there a response from the Body Control Module?
Yes → Go To 2
No → Refer to symptom *NO RESPONSE FROM BODY CONTROL

MODULE in the COMMUNICATION category
2 With the DRBIIIt, erase the DTC from Memory Seat Mirror Module. All
Turn the ignition switch to the Off position then start the engine and let run for one
minute.
Now be sure that there is still communication with the Body Control module, if not
repair as necessary.
With the DRB check for the same DTC to reset in the MSMM.
Did the same DTC reset?
Yes → Go To 3
No → Test complete.
3 NOTE: Visually inspect the related wiring harness including the PCI bus All
wire. Look for any chafed, pierced, pinched, or partially broken wires.
Note: Visually inspect the related wiring harness connectors. Look for
Note: Refer to any technical service bulletins that may apply.
No → Replace the Memory Seat Mirror Module.

642
MEMORY SEAT
Symptom:
CHARGING VOLTAGE HIGH MESSAGE
CHARGING VOLTAGE HIGH MESSAGE

When Monitored: During cranking or with the engine running.
Set Condition: When the Memory Seat Mirror Module receives three high charging
system voltage messages above 15.94 volts over the PCI Bus. Code will remain for 50
ignition cycles.
POSSIBLE CAUSES
PCM TROUBLE CODES
STORED CODE COMMUNICATION PROBLEMS

With the DRBIIIt read Engine DTCs.
Is the DTC P1594 Charging System Voltage Too High set in the Power Control
Module?
Yes → Refer to symptom *P1594-CHARGING SYSTEM VOLTAGE TOO
HIGH in the CHARGING category
No → Go To 2
minute.
Yes → Go To 3
3 Note: Visually inspect the related wiring harness. Look for any chafed, All
643
MEMORY SEAT
Symptom:
CHARGING VOLTAGE LOW MESSAGE
CHARGING VOLTAGE LOW MESSAGE

When Monitored: During cranking or with the engine running.
Set Condition: When the Memory Seat Mirror Module receives three low charging system
voltage messages below 9 volts over the PCI Bus. Code will remain for 50 ignition cycles.
POSSIBLE CAUSES
PCM TROUBLE CODES
STORED CODE COMMUNICATION PROBLEMS

With the DRBIIIt read Engine DTCs.
Is the DTC P1682 Charging System Voltage Too Low set in the Power Control
Module?
Yes → Refer to symptom *P1682-CHARGING SYSTEM VOLTAGE TOO

LOW in the CHARGING category
No → Go To 2
minute.
Yes → Go To 3
3 Note: Visually inspect the related wiring harness. Look for any chafed, All

644
MEMORY SEAT
Symptom:
EEPROM REFRESH FAILURE

When Monitored: With the ignition in the on position.
Set Condition: The Memory Seat Mirror Module has a internal EEPROM failure.
POSSIBLE CAUSES

Repair
Replace the Memory Seat Mirror Module.
645
MEMORY SEAT
Symptom:
FRONT RISER DOWN POSITION STUCK
FRONT RISER DOWN POSITION STUCK

Set Condition: If the seat switch is active for 30 seconds, this code will set and the
Memory Seat Mirror Module will ignore the input until the state has changed. Three
seconds after the stuck condition is removed, the seat will resume to normal operation.
Code will remain for 50 ignition cycles.
POSSIBLE CAUSES
STORED DIAGNOSTIC TROUBLE CODE
POWER SEAT SWITCH
SEAT FRONT DOWN SWITCH SENSE WIRE SHORT TO VOLTAGE

Operate the driver’s power seat and memory system.
minute.
Yes → Go To 2
No → Using the wiring diagram/schematic as a guide, inspect the

wiring and connectors for an intermittent condition.
2 Disconnect the Power Seat Switch connector. All

Measure the voltage of the Seat Front Down Switch Sense circuit.
Yes → Go To 3
No → Replace the Power Seat Switch.


Disconnect the Memory Seat Mirror Module C1 connector.
Measure the voltage of the Seat Front Down Switch Sense circuit to ground..
Yes → Repair the Seat Front Down Switch Sense wire for a short to
voltage.
No → Go To 4
646
MEMORY SEAT
FRONT RISER DOWN POSITION STUCK — Continued

Repair
647
MEMORY SEAT
Symptom:
FRONT RISER SENSOR OUT OF RANGE HIGH
FRONT RISER SENSOR OUT OF RANGE HIGH

Set Condition: This condition is immediately set when the seat motor potentiometer
feeds a value higher than the Memory Seat Mirror Module has stored in EEPROM. Code
will remain for 50 ignition cycles.
POSSIBLE CAUSES
MEMORY SEAT MIRROR MODULE SENSOR GROUND OPEN
SEAT POSITION SENSOR GROUND WIRE OPEN
5 VOLT SUPPLY SHORTED HIGH
CHECK VOLTAGE ON FRONT RISER POSITION SIGNAL CIRCUIT
FRONT RISER SENSOR HIGH
FRONT RISER SENSOR SHORT TO MOTOR
MEMORY SEAT MIRROR MODULE FRONT RISER HIGH

minute.
Yes → Go To 2

2 Turn ignition off. All

Disconnect the Driver Power Seat Front Riser Position Sensor connector.
Measure the resistance of the Seat Position Sensor Ground circuit at the Driver
Power Seat Front Riser Position Sensor connector.
Yes → Go To 3
No → Go To 8
648
MEMORY SEAT
FRONT RISER SENSOR OUT OF RANGE HIGH — Continued

3 Disconnect the Driver Power Seat Front Riser Position Sensor connector. All
Measure the voltage between Seat Sensor 5 volt supply circuit and ground.
Turn ignition on.
Yes → Repair the Seat Sensor 5 Volt Supply circuit for a short to battery.
No → Go To 4

Disconnect the Driver Power Seat Front Riser Position Sensor Connector.
Disconnect the Memory Seat Mirror Module C1 Connector.
Turn ignition on.
Measure the voltage between Front Riser Position Signal circuit and ground.
Yes → Repair the Front Riser Position Signal circuit for a short to
voltage.
No → Go To 5

Ensure the Memory Seat Mirror Module is fully connected before proceeding.
Turn ignition on.
With the DRBIIIt in Body Memory Seat Sensors
Read the Front Riser Position Sensor voltage.
Yes → Go To 6
No → Replace the Seat Track Assembly.
6 Ensure all seat and sensor connectors are connected and front riser motor is All
operational.
With the DRBIIIt in Body Memory Seat Sensors monitor the Front Riser Position
Sensor while operating the front riser motor to both limits.
Did the voltage ever go above 7.0 volts only when the motor was in operation?
Yes → Replace the Seat Track Assembly.
No → Go To 7
Repair
649
MEMORY SEAT
FRONT RISER SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Seat Position Sensor Ground wire between the Driver
Power Seat Front Riser Position Sensor connector and the MSMM C2 connector.
Yes → Replace the Memory Seat Mirror Module.
No → Repair the open Seat Position Sensor Ground wire.

650
MEMORY SEAT
Symptom:
FRONT RISER SENSOR OUT OF RANGE LOW
FRONT RISER SENSOR OUT OF RANGE LOW

Set Condition: This code is immediately set when the seat motor potentiometer feeds a
value lower than the Memory Seat Mirror Module has stored in EEPROM. Code will
remain for 50 ignition cycles.
POSSIBLE CAUSES
MEMORY SEAT MIRROR MODULE 5 VOLT SUPPLY
SEAT 5 VOLT SUPPLY WIRE SHORT TO GROUND
SEAT SENSOR 5 VOLT SUPPLY WIRE OPEN
FRONT RISER POSITION SIGNAL CIRCUIT OPEN
FRONT RISER POSITION SIGNAL CIRCUIT SHORT TO GROUND
FRONT RISER SENSOR LOW
MEMORY SEAT MIRROR MODULE FRONT RISER LOW

minute.
Yes → Go To 2

2 Ensure the Memory Seat Mirror Module is fully connected before proceeding. All
Turn ignition on.
Measure the voltage of the Seat Sensor 5 Volt Supply circuit at front riser connector.
Yes → Go To 3
No → Go To 7
651
MEMORY SEAT
FRONT RISER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Front Riser Position Signal circuit between the front
riser sensor and the Memory Seat Mirror Module connector.
Yes → Go To 4
No → Repair the Front Riser Position Signal circuit for an open.


Measure the resistance of the Front Riser Position Signal circuit to ground.
Yes → Repair the Front Riser Position Signal circuit a short to ground.
No → Go To 5

Connect a jumper wire between Seat Sensor 5 volt Supply and Front Riser Position
Signal circuits.
Turn ignition on.
With the DRBIIIt select Body Memory Seat Sensors.
Read the Front Riser Position Sensor voltage.
No → Go To 6
Repair

Measure the resistance of the Seat Sensor 5 volt supply circuit to body ground.
Yes → Repair the Seat 5 Volt Supply circuit for a short to ground.
No → Go To 8
652
MEMORY SEAT
FRONT RISER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Seat Sensor 5 Volt Supply wire between the Front Riser
Sensor connector and the C2 connector.
Yes → Go To 9
No → Repair the Seat Sensor 5 Volt Supply circuit for an open.

9 If there are no possible cause remaining, view repair. All
Repair
653
MEMORY SEAT
Symptom:
FRONT RISER UP POSITION STUCK
FRONT RISER UP POSITION STUCK

Set Condition: If the seat switch is active for 30 seconds, this code will set and the MSMM
will ignore the input until the state has changed. Three seconds after the stuck condition
is removed, the seat will resume to normal operation. Code will remain for 50 ignition
cycles.
POSSIBLE CAUSES
POWER SEAT SWITCH
SEAT FRONT UP SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Seat Front Up Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Seat Front Up Switch Sense circuit to ground..
Yes → Repair the Seat Front Up Switch Sense wire for a short to voltage.
No → Go To 4
654
MEMORY SEAT
FRONT RISER UP POSITION STUCK — Continued

Repair
655
MEMORY SEAT
Symptom:
HORIZONTAL FORWARD POSITION STUCK
HORIZONTAL FORWARD POSITION STUCK

POSSIBLE CAUSES
DRIVER POWER SEAT SWITCH
HORIZONTAL FORWARD SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Seat Horizontal Forward Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Horizontal Forward Switch Sense circuit to ground..
Yes → Repair the Horizontal Forward Switch Sense wire for a short to
voltage.
No → Go To 4
656
MEMORY SEAT
HORIZONTAL FORWARD POSITION STUCK — Continued

Repair
657
MEMORY SEAT
Symptom:
HORIZONTAL REARWARD POSITION STUCK
HORIZONTAL REARWARD POSITION STUCK

Memory Seat Mirror Module will ignore the input until the state has changed. Once the
stuck condition is removed, the seat will resume to normal operation. Code will remain for
50 ignition cycles.
POSSIBLE CAUSES
SEAT HORIZONTAL REARWARD SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Seat Horizontal Rearward Switch Sense circuit.
Yes → Go To 3

658
MEMORY SEAT
HORIZONTAL REARWARD POSITION STUCK — Continued

Measure the voltage of the Seat Horizontal Rearward Switch Sense circuit to
ground..
Yes → Repair the Seat Horizontal Rearward Switch Sense wire for a
short to voltage.
No → Go To 4
Repair
659
MEMORY SEAT
Symptom:
HORIZONTAL SENSOR OUT OF RANGE HIGH
HORIZONTAL SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
SEAT SENSOR GROUND WIRE OPEN
CHECK VOLTAGE ON HORIZONTAL POSITION SIGNAL CIRCUIT
HORIZONTAL SENSOR HIGH
CHECK HORIZONTAL SENSOR SHORT TO MOTOR
MEMORY SEAT MIRROR MODULE HORIZONTAL SENSOR HIGH

minute.
Yes → Go To 2


Disconnect the Driver Power Seat Horizontal Position Sensor connector.
Measure the resistance of the Seat Position Sensor Ground circuit at the driver
power seat Horizontal connector.
Yes → Go To 3
No → Go To 8
660
MEMORY SEAT
HORIZONTAL SENSOR OUT OF RANGE HIGH — Continued

3 Disconnect the Driver Power Seat Horizontal Position Sensor connector. All
Turn ignition on.
No → Go To 4

Disconnect the Driver Power Seat Horizontal Position Sensor Connector.
Turn ignition on.
Measure the voltage between Horizontal Position Signal circuit and ground.
Yes → Repair the Horizontal Position Signal circuit for a short to

voltage.
No → Go To 5

Turn ignition on.
Read the Horizontal Position Sensor voltage.
Yes → Go To 6
6 Ensure all seat and sensor connectors are connected and Horizontal motor is All
operational.
With the DRBIIIt in Body Memory Seat Sensors monitor the Horizontal Position
sensor while operating the seat Horizontal motor to both limits.
No → Go To 7
Repair
661
MEMORY SEAT
HORIZONTAL SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Seat Position Sensor Ground wire between the
Horizontal Sensor connector and the C2 connector.
No → Repair the open Seat Sensor Ground wire.

662
MEMORY SEAT
Symptom:
HORIZONTAL SENSOR OUT OF RANGE LOW
HORIZONTAL SENSOR OUT OF RANGE LOW

feeds a value lower than the Memory Seat Mirror Module has stored in EEPROM. Code
POSSIBLE CAUSES
HORIZONTAL POSITION SIGNAL CIRCUIT OPEN
HORIZONTAL POSITION SIGNAL CIRCUIT SHORT TO GROUND
HORIZONTAL SENSOR LOW
MEMORY SEAT MIRROR MODULE HORIZONTAL LOW

minute.
Yes → Go To 2

Turn ignition on.
Measure the voltage of the Seat Sensor 5 Volt Supply circuit at Horizontal sensor
connector.
Yes → Go To 3
No → Go To 7
663
MEMORY SEAT
HORIZONTAL SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Horizontal Position Signal circuit between the
Horizontal sensor and the Memory Seat Mirror Module connector.
Yes → Go To 4
No → Repair the Horizontal Position Signal circuit for an open.


Measure the resistance of the Horizontal Position Signal circuit to ground.
Yes → Repair the Horizontal Position Signal circuit a short to ground.
No → Go To 5

Connect a jumper wire between Seat Sensor 5 volt Supply and Horizontal Position
Signal circuits.
Turn ignition on.
Read the Horizontal Position Sensor voltage.
No → Go To 6
Repair

No → Go To 8
664
MEMORY SEAT
HORIZONTAL SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Seat Sensor 5 Volt Supply wire between the Horizontal
Yes → Go To 9

Repair
665
MEMORY SEAT
Symptom:
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH

When Monitored: Continuously when the PCI bus is active
Set Condition: This code is set when the mirror sensor feedback to the Memory Seat
Mirror Module is greater than the mirror out of range high value stored in EEPROM. Code
POSSIBLE CAUSES
LEFT MIRROR HORIZONTAL POSITION WIRE SHORTED TO VOLTAGE
LEFT MIRROR SENSOR GROUND WIRE OPEN
LEFT MIRROR HORIZONTAL POSITION SIGNAL OPEN
LEFT POWER MIRROR
MEMORY SEAT MIRROR MODULE HORIZONTAL POSITION SIGNAL
MEMORY SEAT MIRROR MODULE SENSOR GROUND

minute.
Yes → Go To 2


Disconnect the Left Power Mirror connector.
Measure the voltage of the Left Mirror Horizontal Position Signal circuit in the Left
Power Mirror harness connector.
Is the voltage between 4.5 and 5.5 volts?
Yes → Go To 3
No → Go To 6
666
MEMORY SEAT
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Left Mirror Sensor Ground circuit in the harness
Yes → Go To 4
No → Go To 5
Repair
Replace the Left Power Mirror.

Measure the resistance of Left Mirror Sensor Ground circuit between the Memory
Seat Mirror Module connector and the Left Power Mirror connector.
No → Repair the open Sensor Ground circuit.

Measure the voltage of Left Mirror Horizontal Position Signal circuit.
Yes → Repair the Left Mirror Horizontal Position Signal circuit for a
short to voltage.
No → Go To 7

Measure the resistance of the Left Mirror Horizontal Position Signal circuit from the
Left Power Mirror connector to the Memory Seat Mirror Module connector.
No → Repair the open Left Mirror Horizontal Position Signal wire.

667
MEMORY SEAT
Symptom:
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW

Set Condition: This code is set when the mirror sensor feedback to the MSMM is less than
the mirror out of range low value stored in EEPROM. Code will remain for 50 ignition
cycles.
POSSIBLE CAUSES
MSMM HORIZONTAL POSITION LOW
LEFT MIRROR HORIZONTAL POSITION SIGNAL WIRE SHORT TO GROUND
LEFT POWER MIRROR

minute.
Yes → Go To 2


Measure the voltage of the Left Mirror Horizontal Position Signal circuit in the Left
Yes → Replace the Left Power Mirror.

No → Go To 3
668
MEMORY SEAT
LEFT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Left Mirror Horizontal Position Signal circuit to
ground at the Left Power Mirror harness side connector.
Yes → Repair the Left Mirror Horizontal Position Signal wire for a short
to ground.
669
MEMORY SEAT
Symptom:
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
LEFT MIRROR SENSOR GROUND WIRE OPEN
LEFT MIRROR VERTICAL POSITION WIRE SHORTED TO VOLTAGE
LEFT MIRROR VERTICAL POSITION SIGNAL OPEN
LEFT POWER MIRROR
MEMORY SEAT MIRROR MODULE VERTICAL POSITION SIGNAL

minute.
Yes → Go To 2


Measure the voltage of the Left Mirror Vertical Position Signal circuit in the Left
Yes → Go To 3
No → Go To 6
670
MEMORY SEAT
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Left Mirror Sensor Ground circuit in the harness
Yes → Go To 4
No → Go To 5
Repair
Replace the Left Power Mirror.

Measure the resistance of Left Mirror Sensor Ground circuit between the Memory
Seat Mirror Module connector and the Left Power Mirror connector.

Measure the voltage of Left Mirror Vertical Position Signal circuit.
Yes → Repair the Left Mirror Vertical Position Signal circuit for a short
to voltage.
No → Go To 7

Measure the resistance of the Left Mirror Vertical Position Signal circuit from the left
power mirror connector to the Memory Seat Mirror Module connector.
No → Repair the open Left Mirror Vertical Position Signal wire.

671
MEMORY SEAT
Symptom:
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE LOW
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE LOW

Mirror Module is less than the mirror out of range low value stored in EEPROM. Code will
remain for 50 ignition cycles
POSSIBLE CAUSES
MSMM VERTICAL POSITION LOW
LEFT MIRROR VERTICAL POSITION SIGNAL WIRE SHORT TO GROUND
LEFT POWER MIRROR

minute.
Yes → Go To 2


Measure the voltage of the Left Mirror Vertical Position Signal circuit in the Left
Yes → Replace the Left Power Mirror.

No → Go To 3
672
MEMORY SEAT
LEFT MIRROR VERTICAL SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Left Mirror Vertical Position Signal circuit to ground
at the Left Power Mirror harness side connector.
Yes → Repair the Left Mirror Vertical Position Signal wire for a short to
ground.
673
MEMORY SEAT
Symptom:
MEMORY POSITION SWITCH STUCK
MEMORY POSITION SWITCH STUCK

When Monitored: Anytime the Body Control Module is awake.
Set Condition: If the Memory switch is active for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
MEMORY SET SWITCH STUCK
MEMORY SELECT SWITCH MUX SHORT TO GROUND
BODY CONTROL MODULE

Cycle the ignition OFF then back ON.
Operate the Memory Set switch several times while monitoring the DRBIII.
Does the DRBIIIt display MEMORY SWITCH INPUT STUCK?
Yes → Go To 2
2 Disconnect the Memory Set Switch connector All

With the DRBIIIt in Sensors, read the Memory Select SW Volts.
Yes → Replace the Memory Set Switch.

No → Go To 3

Disconnect the Memory Set switch connector.
Measure the resistance between ground and the Memory Select Switch MUX circuit.
Yes → Go To 4
No → Repair the Memory Select Switch MUX circuit for a short to

ground.
674
MEMORY SEAT
MEMORY POSITION SWITCH STUCK — Continued

Repair
675
MEMORY SEAT
Symptom:
MEMORY SWITCH INPUT OPEN
MEMORY SWITCH INPUT OPEN

Set Condition: If the Memory Set switch voltage is greater than 4.8 volts for over 10
seconds.
POSSIBLE CAUSES
DTC PRESENT
MEMORY SET SWITCH OPEN
MEMORY SELECT SWITCH MUX OPEN
MEMORY SELECT SWITCH RETURN OPEN
BODY CONTROL MODULE

Does the DRBIIIt display MEMORY SWITCH INPUT OPEN?
Yes → Go To 2


Connect a jumper wire between Memory Select Switch MUX and Memory Select
Switch Return.

No → Go To 3
676
MEMORY SEAT
MEMORY SWITCH INPUT OPEN — Continued

Measure the resistance of the Memory Select Switch MUX circuit between the
Memory Set Switch connector and the BCM C1 connector.
Yes → Go To 4
No → Repair the Memory Select Switch MUX circuit for an open.


Measure the resistance of the Memory Select Switch Return circuit between the
Memory Set Switch connector and the BCM C1 connector.
Yes → Go To 5
No → Repair the Memory Select Switch Return circuit for an open.


Repair
677
MEMORY SEAT
Symptom:
MEMORY SWITCH INPUT SHORT
MEMORY SWITCH INPUT SHORT

Set Condition: If the Memory Set switch voltage is less than 1.35 volts for over 10
seconds.
POSSIBLE CAUSES
DTC PRESENT
MEMORY SET SWITCH SHORTED
MEMORY SELECT SWITCH MUX SHORTED
BODY CONTROL MODULE

Does the DRBIIIt display MEMORY SWITCH INPUT SHORT?
Yes → Go To 2


No → Go To 3

Measure the resistance between ground and the Memory Select Switch MUX circuit.
Yes → Go To 4
No → Repair the Memory Select Switch MUX circuit for a short to

ground.
678
MEMORY SEAT
MEMORY SWITCH INPUT SHORT — Continued

Repair
679
MEMORY SEAT
Symptom:
REAR RISER DOWN POSITION STUCK
REAR RISER DOWN POSITION STUCK

POSSIBLE CAUSES
SEAT REAR DOWN SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Seat Rear Down Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Seat Rear Down Switch Sense circuit to ground..
Yes → Repair the Seat Rear Down Switch Sense wire for a short to
voltage.
No → Go To 4
680
MEMORY SEAT
REAR RISER DOWN POSITION STUCK — Continued

Repair
681
MEMORY SEAT
Symptom:
REAR RISER SENSOR OUT OF RANGE HIGH
REAR RISER SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
CHECK VOLTAGE ON REAR RISER POSITION SIGNAL CIRCUIT
REAR RISER SENSOR HIGH
CHECK REAR RISER SHORT TO MOTOR
MEMORY SEAT MIRROR MODULE REAR RISER HIGH

minute.
Yes → Go To 2


Disconnect the Driver Power Seat Rear Riser Position Sensor connector.
power seat rear riser connector.
Yes → Go To 3
No → Go To 8
682
MEMORY SEAT
REAR RISER SENSOR OUT OF RANGE HIGH — Continued

3 Disconnect the Rear Riser Position Sensor connector. All
Turn ignition on.
No → Go To 4

Disconnect the Driver Power Seat Rear Riser Position Sensor Connector.
Turn ignition on.
Measure the voltage between Rear Riser Position Signal circuit and ground.
Yes → Repair the Rear Riser Position Signal circuit for a short to
voltage.
No → Go To 5

Turn ignition on.
Read the Rear Riser Position Sensor voltage.
Yes → Go To 6
6 Ensure all seat and sensor connectors are connected and rear riser motor is All
operational.
With the DRBIIIt in Body Memory Seat Sensors monitor the Rear Riser Position
sensor while operating the seat rear riser to both limits.
No → Go To 7
Repair
683
MEMORY SEAT
REAR RISER SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Seat Position Sensor Ground wire between the Rear
Riser Sensor connector and the C2 connector.

684
MEMORY SEAT
Symptom:
REAR RISER SENSOR OUT OF RANGE LOW
REAR RISER SENSOR OUT OF RANGE LOW

POSSIBLE CAUSES
REAR RISER POSITION SIGNAL CIRCUIT OPEN
REAR RISER POSITION SIGNAL CIRCUIT SHORT TO GROUND
REAR RISER SENSOR LOW
MEMORY SEAT MIRROR MODULE REAR RISER LOW

minute.
Yes → Go To 2

Disconnect the Driver Power Seat Rear Riser Sensor connector.
Turn ignition on.
Measure the voltage of the Seat Sensor 5 Volt Supply circuit at rear riser connector.
Yes → Go To 3
No → Go To 7
685
MEMORY SEAT
REAR RISER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Rear Riser Position Signal circuit between the rear
riser sensor and the Memory Seat Mirror Module connector.
Yes → Go To 4
No → Repair the Rear Riser Position Signal circuit for an open.


Measure the resistance of the Rear Riser Position Signal circuit to ground.
Yes → Repair the Rear Riser Position Signal circuit a short to ground.
No → Go To 5

Connect a jumper wire between Seat Sensor 5 volt Supply and Rear Riser Position
Signal circuits.
Turn ignition on.
Read the Rear Riser Position Sensor voltage.
No → Go To 6
Repair

No → Go To 8
686
MEMORY SEAT
REAR RISER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Seat Sensor 5 Volt Supply wire between the Rear Riser
Yes → Go To 9

Repair
687
MEMORY SEAT
Symptom:
REAR RISER UP POSITION STUCK
REAR RISER UP POSITION STUCK

cycles.
POSSIBLE CAUSES
SEAT REAR UP SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Seat Rear Up Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Seat Rear Up Switch Sense circuit to ground..
Yes → Repair the Seat Rear Up Switch Sense wire for a short to voltage.
No → Go To 4
688
MEMORY SEAT
REAR RISER UP POSITION STUCK — Continued

Repair
689
MEMORY SEAT
Symptom:
RECLINER DOWN POSITION STUCK
RECLINER DOWN POSITION STUCK

cycles.
POSSIBLE CAUSES
SEAT RECLINER DOWN SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Recliner Down Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Recliner Down Switch Sense circuit to ground..
Yes → Repair the Recliner Down Switch Sense wire for a short to
voltage.
No → Go To 4
690
MEMORY SEAT
RECLINER DOWN POSITION STUCK — Continued

Repair
691
MEMORY SEAT
Symptom:
RECLINER SENSOR OUT OF RANGE HIGH
RECLINER SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
CHECK VOLTAGE ON RECLINER POSITION SIGNAL CIRCUIT
RECLINER SENSOR HIGH
CHECK RECLINER SENSOR SHORT TO MOTOR
MEMORY SEAT MIRROR MODULE RECLINER SENSOR HIGH

minute.
Yes → Go To 2


Disconnect the Driver Power Seat Recliner Position Sensor connector.
power seat Recliner connector to ground.
Yes → Go To 3
No → Go To 8
692
MEMORY SEAT
RECLINER SENSOR OUT OF RANGE HIGH — Continued

3 Disconnect the Driver Power Seat Recliner Position Sensor connector. All
Turn ignition on.
No → Go To 4

Disconnect the Driver Power Seat Recliner Position Sensor Connector.
Turn ignition on.
Measure the voltage between Recliner Position Signal circuit and ground.
Yes → Repair the Recliner Position Signal circuit for a short to voltage.
No → Go To 5

Turn ignition on.
Read the Recliner Position Sensor voltage.
Yes → Go To 6
6 Ensure all seat and sensor connectors are connected and Recliner motor is opera- All
tional.
With the DRBIIIt in Body Memory Seat Sensors monitor the Recliner Position sensor
while operating the seat Recliner motor to both limits.

No → Go To 7

Repair
693
MEMORY SEAT
RECLINER SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Seat Position Sensor Ground wire between the Recliner

694
MEMORY SEAT
Symptom:
RECLINER SENSOR OUT OF RANGE LOW
RECLINER SENSOR OUT OF RANGE LOW

POSSIBLE CAUSES
RECLINER POSITION SIGNAL CIRCUIT OPEN
RECLINER POSITION SIGNAL CIRCUIT SHORT TO GROUND
RECLINER SENSOR LOW
MEMORY SEAT MIRROR MODULE RECLINER LOW

minute.
Yes → Go To 2

Turn ignition on.
Measure the voltage of the Seat Sensor 5 Volt Supply circuit at Recliner sensor
connector.
Yes → Go To 3
No → Go To 7
695
MEMORY SEAT
RECLINER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Recliner Position Signal circuit between the Recliner
sensor and the Memory Seat Mirror Module connector.
Yes → Go To 4
No → Repair the Recliner Position Signal circuit for an open.


Measure the resistance of the Recliner Position Signal circuit to ground.
Yes → Repair the Recliner Position Signal circuit a short to ground.
No → Go To 5

Connect a jumper wire between Seat Sensor 5 volt Supply and Recliner Position
Signal circuits.
Turn ignition on.
Read the Recliner Position Sensor voltage.
No → Go To 6
Repair

No → Go To 8
696
MEMORY SEAT
RECLINER SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Seat Sensor 5 Volt Supply wire between the Recliner
Yes → Go To 9

Repair
Replace the Memory Mirror Module.
697
MEMORY SEAT
Symptom:
RECLINER UP POSITION STUCK
RECLINER UP POSITION STUCK

POSSIBLE CAUSES
RECLINER UP SWITCH SENSE WIRE SHORT TO VOLTAGE

minute.
Yes → Go To 2


Measure the voltage of the Recliner Up Switch Sense circuit.
Yes → Go To 3


Measure the voltage of the Recliner Up Switch Sense circuit to ground..
Yes → Repair the Recliner Up Switch Sense wire for a short to voltage.
No → Go To 4
698
MEMORY SEAT
RECLINER UP POSITION STUCK — Continued

4 If there are no possible causes remaining, view 9Repair9. All
Repair
699
MEMORY SEAT
Symptom:
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
RIGHT MIRROR HORIZONTAL POSITION WIRE SHORTED TO VOLTAGE
RIGHT MIRROR SENSOR GROUND WIRE OPEN
RIGHT MIRROR HORIZONTAL POSITION SIGNAL OPEN
RIGHT POWER MIRROR
MEMORY SEAT MIRROR MODULE HORIZONTAL POSITION SIGNAL

minute.
Yes → Go To 2


Disconnect the Right Power Mirror connector.
Measure the voltage of the Right Mirror Horizontal Position Signal circuit in the
Right Power Mirror harness connector.
Yes → Go To 3
No → Go To 6
700
MEMORY SEAT
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE HIGH —

Continued
Measure the resistance of the Right Mirror Sensor Ground circuit in the harness
Yes → Go To 4
No → Go To 5
Repair
Replace the Right Power Mirror.

Measure the resistance of Right Mirror Sensor Ground circuit between the Memory
Seat Mirror Module connector and the Right Power Mirror connector.

Measure the voltage of Right Mirror Horizontal Position Signal circuit.
Yes → Repair the Right Mirror Horizontal Position Signal circuit for a
short to voltage.
No → Go To 7

Measure the resistance of the Right Mirror Horizontal Position Signal circuit from
the Right power mirror connector to the Memory Seat Mirror Module connector.
No → Repair the open Right Mirror Horizontal Position Signal wire.

701
MEMORY SEAT
Symptom:
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW

POSSIBLE CAUSES
MSMM HORIZONTAL POSITION LOW
RIGHT MIRROR HORIZONTAL POSITION SIGNAL WIRE SHORT TO GROUND
RIGHT POWER MIRROR

minute.
Yes → Go To 2


Measure the voltage of the Right Mirror Horizontal Position Signal circuit in the
Right Power Mirror harness connector.
Yes → Replace the Right Power Mirror.

No → Go To 3
702
MEMORY SEAT
RIGHT MIRROR HORIZONTAL SENSOR OUT OF RANGE LOW —

Continued
Measure the resistance of the Right Mirror Horizontal Position Signal circuit to
ground at the Right Power Mirror harness side connector.
Yes → Repair the Right Mirror Horizontal Position Signal wire for a
short to ground.
703
MEMORY SEAT
Symptom:
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH

POSSIBLE CAUSES
RIGHT MIRROR SENSOR GROUND WIRE OPEN
RIGHT MIRROR VERTICAL POSITION WIRE SHORTED TO VOLTAGE
RIGHT MIRROR VERTICAL POSITION SIGNAL OPEN
RIGHT POWER MIRROR
MEMORY SEAT MIRROR MODULE VERTICAL POSITION SIGNAL

minute.
Yes → Go To 2


Measure the voltage of the Right Mirror Vertical Position Signal circuit in the Right
Yes → Go To 3
No → Go To 6
704
MEMORY SEAT
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE HIGH — Continued

Measure the resistance of the Right Mirror Sensor Ground circuit in the harness
Yes → Go To 4
No → Go To 5
Repair
Replace the Right Power Mirror.

Measure the resistance of Right Mirror Sensor Ground circuit between the Memory
Seat Mirror Module connector and the Right Power Mirror connector.

Measure the voltage of Right Mirror Vertical Position Signal circuit.
Yes → Repair the Right Mirror Vertical Position Signal circuit for a short
to voltage.
No → Go To 7

Measure the resistance of the Right Mirror Vertical Position Signal circuit from the
Right power mirror connector to the Memory Seat Mirror Module connector.
No → Repair the open Right Mirror Vertical Position Signal wire.

705
MEMORY SEAT
Symptom:
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE LOW
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE LOW

POSSIBLE CAUSES
MSMM VERTICAL POSITION LOW
RIGHT MIRROR VERTICAL POSITION SIGNAL WIRE SHORT TO GROUND
RIGHT POWER MIRROR

minute.
Yes → Go To 2


Measure the voltage of the Right Mirror Vertical Position Signal circuit in the Right
Yes → Replace the Right Power Mirror.

No → Go To 3
706
MEMORY SEAT
RIGHT MIRROR VERTICAL SENSOR OUT OF RANGE LOW — Continued

Measure the resistance of the Right Mirror Vertical Position Signal circuit to ground
at the Right Power Mirror harness side connector.
Yes → Repair the Right Mirror Vertical Position Signal wire for a short
to ground.
707
OVERHEAD CONSOLE
Symptom:
BUS MESSAGES MISSING
BUS MESSAGES MISSING

When Monitored: While the EVIC is performing a series of tests on the microprocessor,
compass coil, and internal circuitry.
Set Condition: The code will be set, if during the self test the EVIC does not receive
messages from the BCM, FCM, EATX or PCM.
POSSIBLE CAUSES
BCM COMMUNICATION
PCM COMMUNICATION
FCM COMMUNICATION
EATX COMMUNICATION
EVIC

With the DRBIIIt, attempt to communicate with BCM.
Can communication be established with the BCM.
Yes → Go To 2
No → Refer to Communication Category and perform the appropriate

system.

With the DRBIIIt, access Body Control Module.
Select Body Controller and System test.
Does the DRBIIIt display PCM Active on the Bus?
Yes → Go To 3

system.

With the DRBIIIt, attempt to communicate with the FCM.
Can communication be established with the FCM?
Yes → Go To 4
system.
708
OVERHEAD CONSOLE
BUS MESSAGES MISSING — Continued

With the DRBIIIt, attempt to communicate with the EATX.
Can communication be established with the EATX?
Yes → Go To 5

system.
Repair
Replace the EVIC Module.
709
OVERHEAD CONSOLE
Symptom:
COMPASS TEST FAILURE
COMPASS TEST FAILURE

When Monitored: During the EVIC self test.
Set Condition:
POSSIBLE CAUSES
COMPASS VARIANCE

1 Refer to the Service Information for the Compass Variance Procedure. All
View Repair for Verification Test.
Repair
When the Compass Variance Procedure is complete perform the
Verification Test.
710
OVERHEAD CONSOLE
Symptom:
DEMAGNETIZE COMPASS AS PER SERVICE MANUAL
DEMAGNETIZE COMPASS AS PER SERVICE MANUAL

When Monitored: During the EVIC self test.
Set Condition: Compass has been magnetize.
POSSIBLE CAUSES
DEMAGNETIZE COMPASS

1 Refer to the Service Information for the Demagnetizing Procedure. All
View Repair for Verification Test.
Repair
When the Demagnetiizing Procedure is complete perform the
Verification Test.
711
OVERHEAD CONSOLE
Symptom:
EC MIRROR DAY/NIGHT LINE FAULT
EC MIRROR DAY/NIGHT LINE FAULT

Set Condition: The EVIC Module does not receive any messages from the EC Mirror.
POSSIBLE CAUSES
AUTOMATIC DAY/NIGHT MIRROR OPERATION
AUTOMATIC HEADLAMP SWITCH SENSOR CIRCUIT OPEN
AUTOMATIC HEADLAMP SWITCH SENSOR CIRCUIT SHORTED TO GROUND
AUTOMATIC HEADLAMP SWITCH SENSOR CIRCUIT SHORTED TO VOLTAGE
CMTC/EVIC MODULE

1 With the DRBIIIt, erase the DTC. All
Cycle the ignition on and off several times, leaving the ignition on for at least 15
seconds.
Did the DTC reset?
Yes → Go To 2
No → Go To 7

Disconnect the Automatic Day/Night Mirror harness connector.
Measure the voltage of the Automatic Headlamp Switch Sensor circuit in the
Automatic Day/Night Mirror harness connector.
Yes → Replace the Automatic Day/Night Mirror.

No → Go To 3

Disconnect the EVIC harness connector.
Measure the resistance of the Automatic Headlamp Switch Sensor circuit between
the Automatic Day/Night Mirror harness connector and the EVIC harness connector.
Yes → Go To 4
No → Repair the Automatic Headlamp Switch Sensor circuit for an
open.
712
OVERHEAD CONSOLE
EC MIRROR DAY/NIGHT LINE FAULT — Continued

Measure the resistance of the Automatic Headlamp Switch Sensor circuit in the
EVIC harness connector to ground.
Yes → Repair the Automatic Headlamp Switch Sensor circuit for a short
to ground.
No → Go To 5

Using a 12 volt test light connected to ground, probe the Automatic Headlamp Switch
Sensor circuit in the Automatic Day/Night Mirror harness connector.
Does the test illuminate brightly?
Yes → Repair the Automatic Headlamp Switch Sensor circuit for a
shorted to voltage.
No → Go To 6

Repair
Replace the CMTC/EVIC Module.

713
OVERHEAD CONSOLE
Symptom:
EVIC INTERNAL FAILURE

When Monitored: When a SELF TEST command is received from the DRBIII, the EVIC
performs a series of tests on the microprocessor, compass coil, and internal circuitry.
Set Condition: The code will be set, if during the self test the EVIC detects a problem the
microprocessor, compass coil, and internal circuitry.
POSSIBLE CAUSES

With the DRBIIIt, erase the DTC.
Cycle the ignition on and off several times leaving the ignition in the on position for
at least 15 second each time.
Does the DTC reset?
Yes → Replace Electronic Vehicle Information Center.
714
OVERHEAD CONSOLE
Symptom:
OTIS MODULE MESSAGE MISMATCH
OTIS MODULE MESSAGE MISMATCH

Set Condition: BCM has learned EC Mirror but the vehicle is Not equipped with EC
Mirror.
POSSIBLE CAUSES
EVIC COMMUNICATION
CMTC/EVIC MODULE
BODY CONTROL MODULE

1 NOTE: All communication DTC(s) that may have set along with this DTC All
must be diagnosed before continuing.
NOTE: If the DTC EC Mirror Day/Night Line Fault is present in the EVIC
along with this DTC, diagnose the EC Mirror Day/Night Line Fault first
before continuing.
seconds.
Did the DTC OTIS Module Message Mismatch reset?
Yes → Go To 2
No → Go To 4

With the DRBIIIt, attempt to communicate with the CMTC/EVIC Module.
Can communication be established with the CMTC/EVIC Module?
Yes → Go To 3
No → Refer to the Communication Category and perform the appropri-

ate symptom.
715
OVERHEAD CONSOLE
OTIS MODULE MESSAGE MISMATCH — Continued

Install a substitute CMTC/EVIC Module in place of the original module.
Cycle the ignition on and off, leaving the ignition in the on position for at least 15
seconds each time.
Did the DTC reset?

No → Replace the CMTC/EVIC Module.


716
OVERHEAD CONSOLE
Symptom:
OTIS MODULE MESSAGE MISMATCH (DIESEL)
OTIS MODULE MESSAGE MISMATCH (DIESEL)

Set Condition: FCM has learned EC Mirror but the vehicle is Not equipped with EC
Mirror.
POSSIBLE CAUSES
CMTC/EVIC COMMUNICATION
CMTC/EVIC MODULE

1 NOTE: All communication DTC(s) that may have set along with this DTC All
must diagnosed before continuing.
NOTE: If the DTC EC Mirror Day/Night Line Fault is present in the EVIC
along with this DTC, diagnose the EC Mirror Day/Night Line Fault first
before continuing.
seconds.
Did the DTC OTIS Module Message Mismatch reset?
Yes → Go To 2
No → Go To 4

With the DRBIIIt, attempt to communicate with the CMTC/EVIC Module.
Can communication be established with the CMTC/EVIC Module?
Yes → Go To 3
No → Refer to the Communication Category and perform the appropri-

ate symptom.
717
OVERHEAD CONSOLE
OTIS MODULE MESSAGE MISMATCH (DIESEL) — Continued

Install a substitute CMTC/EVIC Module in place of the original module.
Cycle the ignition on and off, leaving the ignition in the on position for at least 15
seconds each time.
Did the DTC reset?

No → Replace the CMTC/EVIC Module.


718
OVERHEAD CONSOLE
Symptom:
*REPAIRING CMTC DISPLAYS DOUBLE DASH ( - - ) IN TEMP
DISPLAY
POSSIBLE CAUSES
*NO RESPONSE - PCI BUS FRONT CONTROL MODULE
*CMTC BUS MESSAGE FAILURE
*COMPASS MINI-TRIP COMPUTER
*AMBIENT TEMPERATURE SENSOR
*AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR CIRCUIT
*AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
*AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
*AMBIENT TEMPERATURE SENSOR RETURN CIRCUIT OPEN
*INTELLIGENT POWER MODULE
*FRONT CONTROL MODULE

With the DRBIIIt, select System Monitors, J1850 Module Scan.
Does the DRBIIIt display FCM on the BUS?
Yes → Go To 2
No → Refer to the COMMUNICATIONS category and perform the

appropriate symptom.

With the DRBIIIt, select Body, Compass Mini-Trip, System Tests, then Auto Self
Test.
Does the DRBIIIt display TEST FAILED: Bus Message Failure?
Yes → Refer to the COMMUNICATIONS category and perform the

appropriate symptom.
No → Go To 3

With the DRBIIIt, select Body, Compass Mini-Trip, System Tests, then Auto Self
Test.
Does the DRBIIIt display TEST FAILED: Internal EVIC Failure?
Yes → Replace the Compass Mini-Trip Computer in accordance with the

No → Go To 4
719
OVERHEAD CONSOLE
*REPAIRING CMTC DISPLAYS DOUBLE DASH ( - - ) IN TEMP DISPLAY

— Continued
Disconnect the Ambient Temperature Sensor harness connector.
Measure the resistance of the Ambient Temperature Sensor.
At -40°C (-40°F) Sensor Resistance = 336 kilohms
At 55°C (140°F) Sensor Resistance = 2.488 kilohms
Does the Ambient Temperature Sensor measure within specifications?
Yes → Go To 5
No → Replace the Ambient Temperature Sensor in accordance with the


Measure the resistance of the Ambient Temperature Sensor Signal circuit to the
Sensor Return circuit.
Does the resistance measure less than 5.0 ohms?
Yes → Repair the Ambient Temperature Sensor Signal circuit shorted to

the Sensor Return circuit.
No → Go To 6

Measure the resistance of the Ambient Temperature Sensor Signal circuit to ground.
Yes → Repair the short to ground in the Ambient Temperature Sensor
Signal circuit.
No → Go To 7

Measure the resistance of the Ambient Temperature Sensor Signal circuit.
Yes → Go To 8
No → Repair the open in the Ambient Temperature Sensor Signal
circuit.
720
OVERHEAD CONSOLE
*REPAIRING CMTC DISPLAYS DOUBLE DASH ( - - ) IN TEMP DISPLAY

— Continued
Measure the resistance of the Ambient Temperature Sensor Return circuit.
Yes → Go To 9
No → Repair the open in the Ambient Temperature Sensor Return

circuit.

Disconnect and isolate the battery negative cable.
Measure the resistance of the Ambient Temperature Sensor Signal circuit and the
Return circuit through the IPM.
Does each circuit resistance measure less than 5.0 ohms?
Yes → Replace the Front Control Module in accordance with the Service
Information.
No → Replace the Intelligent Power Module in accordance with the
721
Symptom:
DRIVER DOOR LOCK SWITCH INPUT OPEN
DRIVER DOOR LOCK SWITCH INPUT OPEN

When Monitored: At all times when battery power is supplied to the Body Control
Module.
Set Condition: When the BCM senses voltage to the door lock switch above 4.6 volts for
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - DRIVER DOOR LOCK SWITCH VOLTAGE LOW
DOOR LOCK SWITCH GROUND OPEN
DOOR LOCK SWITCH MUX CIRCUIT OPEN
DOOR LOCK SWITCH OPEN

Operate the door locks from the Driver Door Lock Switch while monitoring the
DRBIIIt.
Does the DRBIIIt display DR DOOR LOCK SW INPUT OPEN?
Yes → Go To 2

wiring and connectors.
2 With the DRBIIIt in Sensors, read the DR DOOR LOCK SW voltage. All
Does the DRBIIIt display 4.6 volts or greater?
Yes → Go To 3

3 Disconnect the Driver Door Lock Switch connector. All

Yes → Go To 4

722
DRIVER DOOR LOCK SWITCH INPUT OPEN — Continued

Measure the voltage between Door Lock Switch Mux circuit and ground.
Yes → Go To 5
No → Repair the Door Lock Switch Mux circuit for an open.


Repair
Replace the Door Lock Switch.
723
Symptom:
DRIVER DOOR LOCK SWITCH INPUT SHORT
DRIVER DOOR LOCK SWITCH INPUT SHORT

Module.
Set Condition: When the BCM senses voltage to the door lock switch below .5 volts for
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
DOOR LOCK SWITCH SHORTED
DOOR LOCK SWITCH MUX SHORTED
BODY CONTROL MODULE - DOOR LOCK SWITCH VOLTAGE SHORTED

Operate the door locks several times from the Driver Door Lock Switch while
monitoring the DRBIIIt.
Does the DRBIIIt display DR DOOR LOCK SW INPUT SHORT?
Yes → Go To 2

2 Disconnect the Door Lock Switch connector. All

With the DRBIIIt in Sensors, read the DR DOOR SW MUX circuit
Yes → Replace the Door Lock Switch.
No → Go To 3

Measure the resistance between Door Lock Switch Mux circuit and ground.
Yes → Repair the Door Lock Switch Mux circuit for a short to ground.
No → Go To 4
724
DRIVER DOOR LOCK SWITCH INPUT SHORT — Continued

Repair
725
Symptom:
DRIVER DOOR LOCK SWITCH INPUT STUCK
DRIVER DOOR LOCK SWITCH INPUT STUCK

Module.
Set Condition: When the BCM senses voltage to the door lock switch between 1.3 and
3.25 for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - DOOR LOCK SWITCH VOLTAGE INCORRECT
DOOR LOCK SWITCH MUX OPEN
DOOR LOCK SWITCH STUCK

Operate the door lock several times from the Driver Door Lock Switch while
Does the DRBIIIt display DR DOOR LOCK SW INPUT STUCK?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the DR DOOR LOCK SW voltage. All
Does the DRBIIIt display voltage between 1.3 and 3.25 volts?
Yes → Go To 3


Yes → Go To 4

726
DRIVER DOOR LOCK SWITCH INPUT STUCK — Continued

Yes → Go To 5


Repair
727
Symptom:
LEFT CYLINDER LOCK SWITCH INPUT OPEN
LEFT CYLINDER LOCK SWITCH INPUT OPEN

Module.
Set Condition: When the BCM senses voltage to the cylinder lock switch above 4.6 volts
for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LEFT CYLINDER LOCK SWITCH VOLTAGE LOW
CYLINDER LOCK SWITCH GROUND OPEN
CYLINDER LOCK SWITCH MUX OPEN
CYLINDER LOCK SWITCH OPEN

1 NOTE: When this code is present, the VTSS indicator will illuminate solid during the All
arming process.
Operate the door locks several times from the Left Cylinder Lock Switch while
Does the DRBIIIt display LEFT CYL LOCK SW INPUT OPEN?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the LEFT CYL LOCK SW voltage. All
Yes → Go To 3

3 Disconnect the Left Cylinder Lock Switch connector. All

Yes → Go To 4

728
LEFT CYLINDER LOCK SWITCH INPUT OPEN — Continued

Measure the voltage between Cylinder Lock Switch Mux circuit and ground.
Yes → Go To 5
No → Repair the Cylinder Lock Switch Mux circuit for an open.


Repair
Replace the Cylinder Lock Switch.
729
Symptom:
LEFT CYLINDER LOCK SWITCH INPUT SHORT
LEFT CYLINDER LOCK SWITCH INPUT SHORT

Module.
Set Condition: When the BCM senses voltage to the cylinder lock switch below .5 volts for
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
CYLINDER LOCK SWITCH SHORTED
CYLINDER LOCK SWITCH MUX CIRCUIT SHORTED
BODY CONTROL MODULE - LEFT CYLINDER LOCK SWITCH VOLTAGE SHORTED

1 NOTE: When this code is present, the VTSS indicator will stay on solid during the All
arming process.
Does the DRBIIIt display LEFT CYL LOCK SW INPUT SHORT?
Yes → Go To 2


With the DRBIIIt in Sensors, read the LEFT CYL SW MUX circuit
Yes → Replace the Cylinder Lock Switch.

No → Go To 3
3 Disconnect the Right Cylinder Lock Switch connector. All

Measure the resistance between Cylinder Lock Switch Mux circuit and ground.
Yes → Repair the Cylinder Lock Switch Mux circuit for a short to
ground.
No → Go To 4
730
LEFT CYLINDER LOCK SWITCH INPUT SHORT — Continued

Repair
731
Symptom:
LEFT CYLINDER LOCK SWITCH INPUT STUCK
LEFT CYLINDER LOCK SWITCH INPUT STUCK

Module.
Set Condition: When the BCM senses voltage to the cylinder lock switch between 1.3 and
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LEFT CYLINDER LOCK SWITCH VOLTAGE INCORRECT
LEFT CYLINDER LOCK SWITCH GROUND OPEN
LEFT CYLINDER LOCK SWITCH MUX OPEN
CYLINDER LOCK SWITCH STUCK

arming process.
Operate the door lock several times from the Left Cylinder Lock Switch while
Does the DRBIIIt display LEFT CYL LOCK SW INPUT STUCK?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the LEFT CYL LOCK SW voltage. All
Yes → Go To 3


Yes → Go To 4

732
LEFT CYLINDER LOCK SWITCH INPUT STUCK — Continued

Yes → Go To 5
No → Repair the Left Cylinder Lock Switch Mux circuit for an open.

Repair
733
Symptom:
LEFT UNLOCK OUTPUT FAILURE
LEFT UNLOCK OUTPUT FAILURE

Module.
Set Condition: When the BCM senses a short condition on the left side door unlock
circuits for over 125 milliseconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LEFT DOOR UNLOCK DRIVER SHORT TO GROUND
LEFT FRONT DOOR UNLOCK DRIVER SHORT TO GROUND
LEFT SLIDING DOOR UNLOCK DRIVER SHORT TO GROUND
LEFT FRONT DOOR LOCK MOTOR - SHORT TO GROUND
LEFT SLIDING DOOR LOCK MOTOR - SHORT TO GROUND

1 NOTE: When this code is present all unlock outputs are turned off. All
Does the DRBIIIt display LEFT UNLOCK OUTPUT FAILURE?
Yes → Go To 2


Measure the resistance between ground and the Left Front Door Unlock Driver
circuit and then the Left Sliding Door Unlock Driver circuit.
Select the appropriate reading.
Left Front Door Unlock under 1000.0 ohms
Go To 3
Left Sliding Door Unlk under 1000.0 ohms

Go To 4
Neither circuit under 1000.0 ohms.

734
LEFT UNLOCK OUTPUT FAILURE — Continued

Disconnect the Left Front Door Lock Motor/Ajar Switch connector.
Measure the resistance between ground and the Left Front Door Unlock Driver
circuit.
Yes → Repair the Left Front Door Unlock Driver circuit for a short to
ground.
No → Replace the Door Lock Motor.


Disconnect the Left Sliding Door Lock Motor connector.
Measure the resistance between ground and the Left Sliding Door Unlock Driver
circuit.
Yes → Repair the Left Sliding Door Unlock Driver circuit for a short to
ground.
No → Replace the Sliding Door Lock Motor (latch assembly).
735
Symptom:
LIFTGATE CYLINDER SWITCH INPUT OPEN
LIFTGATE CYLINDER SWITCH INPUT OPEN

Module.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LIFTGATE CYLINDER SWITCH VOLTAGE LOW
LIFTGATE CYLINDER SWITCH GROUND OPEN
LIFTGATE CYLINDER SWITCH MUX OPEN
LIFTGATE CYLINDER SWITCH OPEN

arming process.
Operate the Liftgate Cylinder Switch several times while monitoring the DRBIIIt.
Does the DRBIIIt display LGATE CYL SW INPUT OPEN?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the LGATE CYL SW voltage. All
Yes → Go To 3

3 Disconnect the Liftgate Cylinder Switch connector. All

Yes → Go To 4

736
LIFTGATE CYLINDER SWITCH INPUT OPEN — Continued

Yes → Go To 5
No → Repair the Liftgate Cylinder Lock Switch Mux circuit for an open.

Repair
Replace the Liftgate Cylinder Switch.
737
Symptom:
LIFTGATE CYLINDER SWITCH INPUT SHORT
LIFTGATE CYLINDER SWITCH INPUT SHORT

Module.
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
LIFTGATE CYLINDER SWITCH SHORTED
LIFTGATE CYLINDER LOCK SWITCH MUX CIRCUIT SHORTED
BODY CONTROL MODULE - LIFTGATE CYLINDER LOCK SWITCH MUX SHORTED

arming process.
Does the DRBIIIt display LGATE CYL LOCK SW INPUT SHORT?
Yes → Go To 2


With the DRBIIIt in Sensors, read the LGATE CYL SW voltage.
Yes → Replace the Liftgate Cylinder Switch.
No → Go To 3

Yes → Repair the Liftgate Cylinder Lock Switch Mux circuit for a short
to ground.
No → Go To 4
738
LIFTGATE CYLINDER SWITCH INPUT SHORT — Continued

Repair
739
Symptom:
LIFTGATE CYLINDER SWITCH INPUT STUCK
LIFTGATE CYLINDER SWITCH INPUT STUCK

Module.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LIFTGATE CYLINDER SWITCH VOLTAGE INCORRECT
LIFTGATE CYLINDER SWITCH GROUND OPEN
LIFTGATE CYLINDER LOCK SWITCH MUX OPEN

arming process.
Does the DRBIIIt display LGATE CYL SW INPUT STUCK?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the LGATE CYL LOCK SW voltage. All
Yes → Go To 3


Yes → Go To 4

740
LIFTGATE CYLINDER SWITCH INPUT STUCK — Continued

4 Disconnect the Liftgate Cylinder Lock Switch connector. All
Yes → Go To 5
No → Repair the Liftgate Cylinder Lock Switch Mux circuit for an open.

Repair
741
Symptom:
LIFTGATE UNLOCK POWER OUTPUT SHORT
LIFTGATE UNLOCK POWER OUTPUT SHORT

When Monitored: Continuously for non power liftgate vehicles
Set Condition: When the Body Control Module senses a low output on the Liftgate
Release Driver circuit for longer than 125 ms during a liftgate release actuation.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - LIFTGATE RELEASE DRIVER SHORTED
LIFTGATE RELEASE DRIVER WIRE SHORT TO GROUND
LIFTGATE RELEASE MOTOR SHORTED

1 Ensure vehicle is unlocked before proceeding. All
Operate the Liftgate Release several times from the Liftgate Handle Switch while
Does the DRBIIIt display LIFTGATE UNLOCK POWER OUTPUT SHORT?
Yes → Go To 2

Measure the resistance between ground and the Liftgate Release Driver circuit.
Yes → Go To 3

3 Disconnect the Liftgate Ajar Switch connector. All

Measure the resistance between Liftgate Release Driver circuit and ground.
Yes → Repair the Liftgate Release Driver circuit for a short to ground.
No → Go To 4
742
LIFTGATE UNLOCK POWER OUTPUT SHORT — Continued

Repair
Replace the Liftgate Release Motor.
743
Symptom:
LOCK OUTPUT FAILURE
LOCK OUTPUT FAILURE

Module.
Set Condition: When the BCM senses a short condition on the door lock circuits for over
125 milliseconds.
POSSIBLE CAUSES
DTC PRESENT
DOOR LOCK DRIVER SHORT TO GROUND
LEFT FRONT DOOR LOCK DRIVER SHORT GROUND
LEFT SLIDING DOOR LOCK DRIVER WIRE SHORT TO GROUND
RIGHT FRONT DOOR LOCK DRIVER WIRE SHORT TO GROUND
RIGHT SLIDING DOOR LOCK DRIVER WIRE SHORT TO GROUND
LEFT FRONT DOOR LOCK MOTOR - SHORT TO GROUND
LEFT SLIDING DOOR LOCK MOTOR - SHORT TO GROUND
RIGHT FRONT DOOR LOCK MOTOR - SHORT TO GROUND
RIGHT SLIDING DOOR LOCK MOTOR - SHORT TO GROUND

monitoring the DRBIIIt
Does the DRBIIIt display LOCK OUTPUT FAILURE?
Yes → Go To 2

wiring and connectors for an intermittent problem.
744
LOCK OUTPUT FAILURE — Continued

Measure the resistance between ground and each of the Door Lock Driver circuits.
Right Front Door Lock under 1000.0 ohm

Go To 3
Right Sliding Door Lock under 1000.0 ohm

Go To 4
Left Front Door Lock under 1000.0 ohm

Go To 5
Left Sliding Door Lock under 1000.0 ohm
Go To 6
None of the circuits under 1000.0 ohms.


Disconnect the Right Front Door Lock Motor/Ajar Switch connector.
Measure the resistance between ground and the Right Front Door Lock Driver
circuit.
Yes → Repair the Right Front Door Lock Driver wire for a short to
ground.

Disconnect the Right Sliding Door Lock Motor connector.
Measure the resistance between ground and the Right Sliding Door Lock Driver
circuit.
Yes → Repair the Right Sliding Door Lock Driver wire for a short to
ground.
No → Replace the Right Sliding Door Lock Motor (Latch assy.)


Disconnect the Left Front Door Lock Motor connector.
Measure the resistance between ground and the Left Front Door Lock Driver circuit.
Yes → Repair the Left Front Door Lock Driver circuit for a short to
ground.

745
LOCK OUTPUT FAILURE — Continued

Disconnect the Left Sliding Door Lock Motor connector.
Measure the resistance between ground and the Left Sliding Door Lock Driver
circuit.
Yes → Repair the Left Sliding Door Lock Driver wire for a short to
ground.
No → Replace the Left Sliding Door Lock Motor (Latch assy.)

746
Symptom:
PASSENGER DOOR LOCK SWITCH INPUT OPEN
PASSENGER DOOR LOCK SWITCH INPUT OPEN

Module.
Set Condition: When the BCM senses voltage to the door lock switch above 4.6 volts for
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - PASSENGER DOOR LOCK SWITCH VOLTAGE LOW
DOOR LOCK SWITCH OPEN

Operate the door locks several times from the Passenger Door Lock Switch while
Does the DRBIIIt display PASS DOOR LOCK SW INPUT OPEN?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the PASS DOOR LOCK SW voltage. All
Yes → Go To 3

3 Disconnect the Passenger Door Lock Switch connector. All

Yes → Go To 4

747
PASSENGER DOOR LOCK SWITCH INPUT OPEN — Continued

Yes → Go To 5


Repair
748
Symptom:
PASSENGER DOOR LOCK SWITCH INPUT SHORT
PASSENGER DOOR LOCK SWITCH INPUT SHORT

Module.
Set Condition: When the BCM senses voltage to the door lock switch below .5 volts for
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
PASSENGER DOOR LOCK SWITCH SHORTED
DOOR LOCK SWITCH MUX SHORTED
BODY CONTROL MODULE - PASSENGER DOOR LOCK SWITCH VOLTAGE SHORTED

Cycle ignition ON to OFF..
monitoring the DRBIII.
Does the DRBIIIt display DR DOOR LOCK SW INPUT SHORT?
Yes → Go To 2


With the DRBIIIt in Sensors, read the PASS DOOR SW MUX circuit
Yes → Replace the Door Lock Switch.
No → Go To 3

Measure the resistance between Door Lock Switch Mux circuit and ground.
Yes → Repair the Door Lock Switch Mux circuit for a short to ground.
No → Go To 4
749
PASSENGER DOOR LOCK SWITCH INPUT SHORT — Continued

Repair
750
Symptom:
PASSENGER DOOR LOCK SWITCH INPUT STUCK
PASSENGER DOOR LOCK SWITCH INPUT STUCK

Module.
Set Condition: When the BCM senses voltage to the door lock switch between 1.3 and
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - PASSENGER DOOR LOCK SWITCH VOLTAGE INCORRECT
DOOR LOCK SWITCH STUCK

Cycle the ignition ON to OFF.
Operate the door lock several times from the Passenger Door Lock Switch while
monitoring the DRBIII.
Does the DRBIIIt display PASS DOOR LOCK SW INPUT STUCK?
Yes → Go To 2

2 With the DRBIIIt in Sensors, read the PASS DOOR LOCK SW voltage. All
Yes → Go To 3


Yes → Go To 4

751
PASSENGER DOOR LOCK SWITCH INPUT STUCK — Continued

Yes → Go To 5


Repair
752
Symptom:
RIGHT CYLINDER LOCK SWITCH INPUT OPEN
RIGHT CYLINDER LOCK SWITCH INPUT OPEN

Module.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - RIGHT CYLINDER LOCK SWITCH VOLTAGE LOW
CYLINDER LOCK SWITCH GROUND OPEN
CYLINDER LOCK SWITCH MUX OPEN
CYLINDER LOCK SWITCH OPEN

arming process.
Operate the door locks several times from the Right Cylinder Lock Switch while
Does the DRBIIIt display RIGHT CYL LOCK SW INPUT OPEN?
Yes → Go To 2
2 With the DRBIIIt in Sensors, read the RIGHT CYL LOCK SW voltage. All
Yes → Go To 3


Yes → Go To 4

753
RIGHT CYLINDER LOCK SWITCH INPUT OPEN — Continued

Yes → Go To 5
No → Repair the Cylinder Lock Switch Mux circuit for an open.


Repair
754
Symptom:
RIGHT CYLINDER LOCK SWITCH INPUT SHORT
RIGHT CYLINDER LOCK SWITCH INPUT SHORT

Module.
over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
CYLINDER LOCK SWITCH SHORTED
CYLINDER LOCK SWITCH MUX CIRCUIT SHORTED
BODY CONTROL MODULE - RIGHT CYLINDER LOCK SWITCH VOLTAGE SHORTED

arming process.
Does the DRBIIIt display RIGHT CYL LOCK SW INPUT SHORT?
Yes → Go To 2

With the DRBIIIt in Sensors, read the RIGHT CYL SW MUX circuit
Yes → Replace the Cylinder Lock Switch.
No → Go To 3

Yes → Repair the Cylinder Lock Switch Mux circuit for a short to
ground.
No → Go To 4
755
RIGHT CYLINDER LOCK SWITCH INPUT SHORT — Continued

Repair
756
Symptom:
RIGHT CYLINDER LOCK SWITCH INPUT STUCK
RIGHT CYLINDER LOCK SWITCH INPUT STUCK

Module.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - RIGHT CYLINDER LOCK SWITCH VOLTAGE INCORRECT
RIGHT CYLINDER LOCK SWITCH GROUND OPEN
RIGHT CYLINDER LOCK SWITCH MUX OPEN

arming process.
Operate the door lock several times from the Right Cylinder Lock Switch while
Does the DRBIIIt display RIGHT CYL LOCK SW INPUT STUCK?
Yes → Go To 2
2 With the DRBIIIt in Sensors, read the RIGHT CYL LOCK SW voltage. All
Yes → Go To 3


Yes → Go To 4

757
RIGHT CYLINDER LOCK SWITCH INPUT STUCK — Continued

Yes → Go To 5
No → Repair the Right Cylinder Lock Switch Mux circuit for an open.

Repair
758
Symptom:
RIGHT UNLOCK OUTPUT FAILURE
RIGHT UNLOCK OUTPUT FAILURE

Module.
Set Condition: When the BCM senses a short condition on the right side door unlock
circuits for over 125 milliseconds.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - RIGHT DOOR UNLOCK DRIVER SHORT TO GROUND
RIGHT FRONT DOOR UNLOCK DRIVER SHORT TO GROUND
RIGHT SLIDING DOOR UNLOCK DRIVER SHORT TO GROUND
RIGHT FRONT DOOR LOCK MOTOR - SHORT TO GROUND
RIGHT SLIDING DOOR LOCK MOTOR - SHORT TO GROUND

Cycle the ignition ON to OFF.
Operate the door locks several times from the Right Door Lock Switch while
Does the DRBIIIt display RIGHT UNLOCK OUTPUT FAILURE?
Yes → Go To 2


Measure the resistance between ground and the Right Front Door Unlock Driver
circuit and then the Right Sliding Door Unlock Driver circuit.
Right Front Door Unlock under 1000.0 ohm
Go To 3
Right Sliding Door Unlk under 1000.0 ohm

Go To 4
Neither circuit under 1000.0 ohms.

759
RIGHT UNLOCK OUTPUT FAILURE — Continued

Disconnect the Right Front Door Lock Motor/Ajar Switch connector.
Measure the resistance between ground and the Right Front Door Unlock Driver
circuit.
Yes → Repair the Right Front Door Unlock Driver circuit for a short to
ground.


Disconnect the Right Sliding Door Lock Motor connector.
Measure the resistance between ground and the Right Sliding Door Unlock Driver
circuit.
Yes → Repair the Right Sliding Door Unlock Driver circuit for a short to
ground.
No → Replace the Sliding Door Lock Motor (latch assembly).
760
Symptom:
RKE PROGRAM LINE OUTPUT OPEN
RKE PROGRAM LINE OUTPUT OPEN

When Monitored: With ignition in the RUN position.
Set Condition: When the BCM senses an open or short to ground signal on the RKE
Module Program Enable circuit for longer than 0.125 msec.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - RKE MODULE PROGRAM ENABLE CIRCUIT OPEN OR SHORT TO
GROUND
RKE MODULE PROGRAM ENABLE WIRE OPEN
RKE MODULE PROGRAM ENABLE WIRE SHORT TO GROUND
RKE MODULE - PROGRAM ENABLE CIRCUIT OPEN

Operate the RKE transmitter while monitoring the DRBIII.
Does the DRBIIIt display RKE PROGRAM LINE OUTPUT OPEN?
Yes → Go To 2

Measure the voltage of the RKE Module Program Enable circuit between ground and
the BCM C4 connector.

No → Go To 3

Disconnect the Remote Keyless Entry Module connector.
Measure the resistance of the RKE Module Program Enable circuit between the RKE
Module connector and the BCM C4 connector.
Yes → Go To 4
No → Repair the RKE Module Program Enable wire for an open

761
RKE PROGRAM LINE OUTPUT OPEN — Continued

Disconnect the Remote Keyless Entry Module connector.
Measure the resistance of the RKE Module Program Enable circuit to ground.
Yes → Repair the RKE Module Program Enable wire for a short to
ground.
No → Go To 5
Repair
Replace the Remote Keyless Entry Module.
762
Symptom:
RKE PROGRAM LINE OUTPUT SHORT
RKE PROGRAM LINE OUTPUT SHORT

When Monitored: With ignition in the RUN position.
Set Condition: When the BCM senses an over current on the RKE Module Program
Enable circuit and the RKE is in PROGRAM or DIAGNOSTIC mode.
POSSIBLE CAUSES
DTC PRESENT
REMOTE KEYLESS ENTRY MODULE - RKE MODULE PROGRAM ENABLE CIRCUIT SHORT TO
VOLTAGE
RKE MODULE PROGRAM ENABLE WIRE SHORT TO VOLTAGE
BODY CONTROL MODULE - SHORT TO VOLTAGE

With the DRBIIIt, enter PROGRAM RKE.
Does the DRBIIIt display RKE PROGRAM LINE OUTPUT SHORT?
Yes → Go To 2

2 Disconnect the Remote Keyless Entry Module connector. All

Cycle the ignition key and wait 30 seconds.
Does the DRBIIIt display RKE PROGRAM LINE OUTPUT OPEN?
No → Go To 3
Yes → Replace the Remote Keyless Entry Module.

3 Disconnect the Remote Keyless Entry Module connector. All

Measure the voltage between RKE Module Program Enable circuit and ground.
Yes → Repair the RKE Module Program Enable wire for a short to
voltage.

763
Symptom:
AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN

When Monitored: Whenever the Power Liftgate Module is awake.
Set Condition: If the module senses a resistance above 382K ohms on the Liftgate
Temperature Sensor Signal circuit, this code will set. The normal range for the sensor is
1.2K to 382K ohms. At room temperature (68° F) the resistance will be between 11.2 K and
13.5K ohms.
POSSIBLE CAUSES
DTC PRESENT
POWER LIFTGATE MODULE - TEMPERATURE SENSE OPEN
LIFTGATE TEMPERATURE SENSOR SIGNAL WIRE OPEN
GROUND WIRE OPEN
LIFTGATE TEMPERATURE SENSOR

Operate the liftgate several times.
Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN?
Yes → Go To 2
2 Remove the power liftgate motor trim panel. All

Measure the resistance of the liftgate Temperature Sensor Signal circuit to the
Ground circuit (cavity 20) in the PLG C2 connector.
Is the resistance between 1.2k and 382K ohms?
Yes → Replace the Power Liftgate Module.
No → Go To 3
764
AMBIENT TEMPERATURE SENSOR CIRCUIT OPEN — Continued

Disconnect the License Lamp (light bar) connector.
Measure the resistance of the liftgate Temperature Sensor Signal circuit between the
License Lamp connector and the PLG C2 connector.
Yes → Go To 4
No → Repair the Liftgate Temperature Sensor Signal circuit for an

open.

Measure the resistance of the Ground circuit between the PLG C2 connector (cavity
20) and the License Lamp connector (cavity 8).
Yes → Go To 5
No → Repair the Liftgate Temperature Sensor Ground wire for an open.


Repair
Replace the Liftgate Temperature Sensor (light bar).
765
Symptom:
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND

When Monitored: Whenever the Power Liftgate Module is awake.
Set Condition: If the module senses a resistance below 1000 ohms on the Liftgate
Temperature Sensor Signal circuit, this code will set. The normal range for the sensor is
1.2K to 382K ohms. At room temperature (68° F) the resistance will be between 11.2 K and
13.5K ohms.
POSSIBLE CAUSES
DTC PRESENT
LIFTGATE TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND.
POWER LIFTGATE MODULE - TEMP SENSE SHORT TO GROUND
LIFTGATE TEMPERATURE SENSOR SIGNAL WIRE SHORT TO GROUND WIRE
LIFTGATE TEMPERATURE SENSOR

Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT
TO GROUND?
Yes → Go To 2


Measure the resistance between ground and the liftgate Temperature Sensor Signal
circuit.
Yes → Repair the Liftgate Temperature Sensor Signal circuit for a short
to ground.
No → Go To 3
766
AMBIENT TEMPERATURE SENSOR CIRCUIT SHORT TO GROUND —

Continued
Yes → Go To 4
No → Replace the Power Liftgate Module.


Yes → Repair the Liftgate Temperature Sensor Signal wire for a short to
the Ground wire.
No → Replace the Liftgate Temperature Sensor (light bar).

767
Symptom:
CONTROL MODULE FAILURE - INTERNAL FAILURE

When Monitored: Anytime the module is awake.
Set Condition: Whenever the module senses an internal failure (EEPROM, ROM, ADC)
this code will set. The module must be replaced.
POSSIBLE CAUSES
POWER LIFTGATE MODULE - INTERNAL FAILURE

1 View repair. All
Repair
768
Symptom:
INCOMPLETE LATCH CINCH - NO CURRENT

When Monitored: During the liftgate closing operation.
Set Condition: The cinch operation has not completed in 4 seconds and the current did
not build up to the stall level.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
CLUTCH GROUND OPEN
LIFTGATE LATCH CLUTCH DRIVER WIRE OPEN
LIFTGATE LATCH RELEASE DRIVER WIRE OPEN
LIFTGATE LATCH CINCH DRIVER WIRE OPEN
LATCH ASSEMBLY

Operate the power liftgate several times if possible.
With the DRBIIIt, read ACTIVE DTCs.
Does the DRBIIIt display INCOMPLETE LATCH CINCH - NO CURRENT?
Yes → Go To 2
wiring and connectors for an intermittent condition. Operate the
door several times and check for any binding or other obstruc-
tions.
2 Examine the liftgate for proper fit and alignment, lose/hard or torn seals, latch All
striker or anything that would cause an obstruction to proper operation.
Manually operate the liftgate of a known good vehicle and notice the effort needed to
open and close.
Compare the effort needed on the disabled liftgate.
Does it take more effort to operate the liftgate than it should?
Yes → Refer to Service information for the related symptom(s).

No → Go To 3
769
INCOMPLETE LATCH CINCH - NO CURRENT — Continued

Disconnect the Liftgate Cinch/Release Motor connector.
Using a 12-volt test light connected to 12-volts, check the Ground circuit (cavity 4).
Wiggle the harness and check for an intermittent open condition.
Yes → Go To 4
No → Repair the Clutch Ground wire for an open.


Measure the resistance of the Liftgate Latch Release Driver circuit between the
Power Liftgate Control Module C2 connector and the Liftgate Cinch/Release Motor
connector.
Yes → Go To 5
No → Repair the Liftgate Latch Release Driver wire for an open.


Measure the resistance of the Liftgate Latch Clutch Driver circuit between the
Sliding Door Control Module C1 connector and the Cinch/Release Motor connector.
Yes → Go To 6
No → Repair the Liftgate Latch Clutch Driver wire for an open.


Measure the resistance of the Liftgate Latch Cinch Driver circuit between the PLG
C2 connector to the Liftgate Cinch/Release Motor connector.
Yes → Go To 7
No → Repair the Liftgate Latch Cinch Driver wire for an open.


Repair
Replace the Latch Assembly.
770
Symptom:
INCOMPLETE LATCH CINCH - NO PAWL TRANSITION

When Monitored: Whenever the power liftgate in performing a cinching operation.
Set Condition: The pawl switch was not detected as returning to ground during the
transition between secondary and primary cinch operation. NOTE: The liftgate may not be
fully cinched during this condition. The liftgate may cinch to primary but not be fully
seated and may pop off back to secondary.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
GROUND WIRE OPEN
LIFTGATE PAWL SWITCH SENSE WIRE OPEN
LIFTGATE PAWL SWITCH SENSE WIRE SHORT TO GROUND
PAWL SWITCH

1 NOTE: This DTC will only set after the cinching operation. This may make All
it difficult to reproduce.
Does the DRBIIIt display INCOMPLETE LATCH CINCH - NO PAWL TRANSI-
TION?
Yes → Go To 2

tions.
2 Examine the liftgate for proper fit and alignment, lose/hard or torn seals, misaligned All
latch striker or anything that would cause an obstruction to proper operation.
open and close.

No → Go To 3
771
INCOMPLETE LATCH CINCH - NO PAWL TRANSITION — Continued

3 Disconnect the Power Liftgate C2 connector. All
Measure the resistance of the Ground wire between the PLG C2 connector (cavity 20)
and the Liftgate Cinch/Release Motor connector (cavity 1).
Wiggle the harness while observing the ohmmeter.
Yes → Go To 4
No → Repair the Ground wire for an open.


Measure the resistance of the Liftgate Pawl Switch Sense wire between the PLG C2
connector and the Liftgate Cinch/Release Motor connector.
Yes → Go To 5
No → Repair the Liftgate Pawl Switch Sense wire for an open.


Measure the resistance between ground and the Liftgate Pawl Switch Sense circuit.
Yes → Repair the Liftgate Pawl Switch Sense wire for a short to ground.
No → Go To 6

Repair
Replace the Pawl Switch (latch assembly).
772
Symptom:
INCOMPLETE LATCH CINCH - OVERCURRENT

When Monitored: Whenever the power liftgate is performing a cinching operation.
Set Condition: The latch motor stall current of 6.2 amps has been detected, or a time-out
has occurred with no pawl or ratchet failure. This code is set during the power cinching
operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
LIFTGATE LATCH RELEASE DRIVER OPEN
LIFTGATE LATCH CINCH DRIVER WIRE SHORT TO GROUND
LIFTGATE LATCH CINCH DRIVER WIRE SHORT TO HARNESS GROUND
LIFTGATE LATCH RELEASE DRIVER WIRE SHORT TO GROUND
LIFTGATE LATCH RELEASE DRIVER WIRE SHORT TO HARNESS GROUND
LATCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH CINCH - OVERCURRENT?
Yes → Go To 2

liftgate several times and check for any binding or other obstruc-
tions.
2 Examine the liftgate for proper alignment, worn or binding hinges, weak liftgate prop All
assembly, loose/ hard weatherstrip, and gear teeth on the power liftgate motor
assembly for wear or anything that would cause an obstruction to proper operation.
If necessary manually operate the power liftgate on a known good vehicle and notice
the effort needed to open and close for comparison.
Especially notice the effort needed to unlatch and close the liftgate.
Were there any mechanical problems found?

No → Go To 3
773
INCOMPLETE LATCH CINCH - OVERCURRENT — Continued

Measure the resistance of the Liftgate Latch Cinch Driver circuit between the Power
Liftgate Module C2 connector and the Liftgate Cinch/Release Motor connector.
Yes → Go To 4


Power Liftgate Module C2 connector and the Liftgate Cinch/Release Motor connector.
Yes → Go To 5

Measure the resistance between ground and the Liftgate Latch Cinch Driver circuit.
Wiggle the harness and check for an intermittent short condition.
Yes → Go To 6
No → Repair the Liftgate Latch Cinch Driver wire for a short to ground.

Measure the resistance between the Ground circuit (cavity 20) and the Liftgate Latch
Cinch Driver circuit.
Yes → Go To 7
No → Repair the Liftgate Latch Cinch Driver wire for a short to the
Ground circuit.
774

Measure the resistance between ground and the Liftgate Latch Release Driver
circuit.
Yes → Go To 8
No → Repair the Liftgate Latch Release Driver wire for a short to

ground.

Release Driver circuit.
Yes → Go To 9
No → Repair the Liftgate Latch Release Driver wire for a short to the
Ground circuit.
Repair
775
Symptom:
INCOMPLETE LATCH CINCH - PAWL SWITCH FAILURE

When Monitored: During the liftgate close operation.
Set Condition: The cinch operation was not completed in 4 seconds. The ratchet switch
was detected as open, but the pawl switch did not change to open.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
CLUTCH GROUND OPEN
PAWL SWITCH SENSE WIRE SHORT TO GROUND
PAWL SWITCH SENSE WIRE SHORT TO HARNESS GROUND
POWER LIFTGATE MODULE - PAWL SWITCH SENSE
PAWL SWITCH

1 NOTE: This DTC will only set during the cinching operation after the 4 All
second time out. This may make it difficult to reproduce.
Does the DRBIIIt display INCOMPLETE LATCH CINCH - PAWL SWITCH FAIL-
URE?
Yes → Go To 2

tions.
open and close.
No → Go To 3
776
INCOMPLETE LATCH CINCH - PAWL SWITCH FAILURE — Continued

3 With the DRBIIIt in Inputs/Outputs, read the PAWL SWITCH state. All
Open the liftgate to full open position.
Using a screwdriver, click the latch to the first detent while observing the DRB111t.
Unlatch the latch by pulling the handle switch and observe the DRB111t for a state
change.
Repeat this step several times while moving the door in different positions and
wiggling the wiring harness to check for an intermittent short..
Did the DRB111t show the switch state changes correctly every time?
Yes → Go To 4
No → Go To 7

Yes → Go To 5


Measure the resistance of the Liftgate Latch Clutch Driver circuit between the Power
Yes → Go To 6

Repair

Measure the resistance between ground and the Liftgate Pawl Switch Sense circuit.
Yes → Repair the Liftgate Pawl Switch Sense wire for a short to ground.
No → Go To 8
777

Measure the resistance between the Ground circuit (cavity 20) and the Liftgate Pawl
Switch Sense circuit.
Yes → Repair the Liftgate Pawl Switch Sense wire for a short to the
Ground circuit.
No → Go To 9
Repair
778
Symptom:
INCOMPLETE LATCH CINCH - RATCHET SWITCH FAILURE

When Monitored: Whenever the power liftgate is operating in the closing direction.
Set Condition: The cinch operation was not completed in 4 seconds. The pawl switch was
detected open but the ratchet switch remained closed. This code will set only in the cinch
operation after a 4 second time out.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
RATCHET CIRCUIT
CLUTCH GROUND OPEN
GROUND WIRE OPEN
LIFTGATE AJAR SWITCH SENSE WIRE OPEN
LIFTGATE AJAR SWITCH SENSE WIRE SHORT TO GROUND
LIFTGATE AJAR SWITCH SENSE WIRE SHORT TO HARNESS GROUND
RATCHET SWITCH

Does the DRBIIIt display INCOMPLETE LATCH CINCH - RATCHET SWITCH
FAILURE?
Yes → Go To 2

tions.
779
INCOMPLETE LATCH CINCH - RATCHET SWITCH FAILURE — Continued

open and close.
No → Go To 3
3 With the DRBIIIt in Inputs/Outputs, read the RATCHET SWITCH state. All
Using a screwdriver, click the latch to the second detent while observing the
DRB111t.
Unlatch the latch by pressing the handle switch and observe the DRB111t for a state
change.
Repeat this step several times while moving the liftgate in different positions and
wiggling the wiring harness to check for an intermittent short.
Yes → Replace the Power Sliding Door Module.

No → Go To 4

Yes → Go To 5


Measure the resistance of the Liftgate Latch Clutch Driver circuit between the Power
Yes → Go To 6


Yes → Go To 7

780

Measure the resistance of the Liftgate Ajar Switch Sense wire between the PLG C2
Wiggle the harness and move the door in different positions while observing the
ohmmeter.
Yes → Go To 8
No → Repair the Liftgate Ajar Switch Sense wire for an open.


NOTE: The Ratchet Switch Sense circuit is called the Liftgate Ajar Switch
Sense circuit. They are one in the same as they perform two functions.
Measure the resistance between ground and the Liftgate Ajar Switch Sense circuit.
No → Go To 9
Yes → Repair the Liftgate Ajar Switch Sense wire for a short to ground.

NOTE: The Ratchet Switch Sense circuit is called the Liftgate Ajar Switch
Sense circuit. They are one in the same as they perform two functions.
Measure the resistance between the Ground circuit (cavity 20) and the Liftgate Ajar
Yes → Go To 10
No → Repair the Liftgate Ajar Switch Sense wire for a short to the
Ground circuit.
Repair
Replace the Ratchet Switch (latch assembly).
781
Symptom:
INCOMPLETE LATCH RELEASE - NO CURRENT

When Monitored: Whenever the power liftgate module is awake and performing a power
operation.
Set Condition: When the release operation was not completed in 4 seconds and current
did not build up to the stall level, this code will set.
POSSIBLE CAUSES
DTC PRESENT
LIFTGATE LATCH CINCH/RELEASE DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE LATCH CINCH/RELEASE DRIVER CIRCUIT SHORT TO HARNESS GROUND
LATCH CINCH DRIVER WIRE OPEN
LATCH RELEASE DRIVER WIRE OPEN
LATCH ASSEMBLY
POWER LIFTGATE MODULE

1 NOTE: This DTC will only set during the release operation after the 4 All
NOTE: This code can also be set during a repetitive release and may be a
normal occurrence.
Does the DRBIIIt display INCOMPLETE LATCH RELEASE - NO CURRENT?
Yes → Go To 2
tions.

Disconnect the Power Liftgate Control Module C2 connector.
Measure the resistance between the Liftgate Latch Cinch Driver circuit and the
Liftgate Latch Release Driver circuit.
Yes → Go To 3
No → Go To 6
782
INCOMPLETE LATCH RELEASE - NO CURRENT — Continued

Yes → Repair the Liftgate Latch Cinch/Release Driver circuit for a short
to ground. This could be the Latch Cinch Driver wire or the Latch
Release Driver wire or the motor itself.
No → Go To 4

Measure the resistance between the Ground circuit and the Liftgate Latch Cinch
Driver circuit.
Yes → Repair the Liftgate Latch Cinch/Release Driver circuit for a short
to the Ground circuit This could be the Latch Cinch Driver wire or
the Latch Release Driver wire or the motor itself.
No → Go To 5

Repair

Yes → Go To 7


Yes → Go To 8

783

Repair
784
Symptom:
INCOMPLETE LATCH RELEASE - RATCHET SWITCH FAILURE

When Monitored: Whenever the power liftgate is performing a release operation.
Set Condition: The release operation was not completed in 4 seconds or a stall condition
was detected in the release operation. The pawl switch was grounded but the ratchet
switch remained open. This code will set only in the release operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER LIFTGATE MODULE - RATCHET CIRCUIT
GROUND WIRE OPEN
RATCHET SWITCH

1 NOTE: This DTC will only set during the releasing operation after the 4 All
Does the DRBIIIt display INCOMPLETE LATCH RELEASE - RATCHET SWITCH
FAILURE?
Yes → Go To 2

tions.
2 Examine the liftgate for proper fit and alignment, loose/ hard or torn seals, worn All
teeth on the gears or anything that would cause an obstruction to proper operation.
open and close.
No → Go To 3
785
INCOMPLETE LATCH RELEASE - RATCHET SWITCH FAILURE —

Continued
3 With the DRBIIIt in Inputs/Outputs, read the RATCHET state. All
DRBIIIt.
Unlatch the latch by pressing the handle switch or using the key and observe the
DRBIIIt for a state change.

No → Go To 4

Yes → Go To 5

Disconnect the Liftgate Cinch/Release Motor connector (latch assembly).
Measure the resistance of the Liftgate Ajar Switch Sense wire between the PLG C2
Wiggle the harness and move the liftgate in different positions while observing the
ohmmeter.
Yes → Go To 6


Repair
786
Symptom:
INCOMPLETE LATCH RELEASE- OVERCURRENT

When Monitored: Whenever the power liftgate is operating.
Set Condition: The latch motor stall current of 6.2 amps was detected during a release.
The main causes of this code setting is some type of blockage during the release. This code
is set during the power releasing operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
LATCH ASSEMBLY

1 NOTE: This DTC can be set if a redundant release command is sent during All
a cinching operation. In that case it would not signify a failure of any
components.
Does the DRBIIIt display INCOMPLETE LATCH RELEASE - OVER CURRENT?
Yes → Go To 2
tions.
2 Examine the liftgate for proper fit and alignment, loose/hard or torn seals, struts or All
anything that would cause an obstruction to proper operation.
open and close.
No → Replace the Latch Assembly.

787
Symptom:
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE

When Monitored: Whenever the power liftgate is operating in an opening direction.
Set Condition: The release operation was not completed in 4 seconds or the release
operation has detected a stall condition. The ratchet switch was detected as grounded but
the pawl remained open. This code is set during the power releasing operation from a fully
closed liftgate.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER LIFTGATE MODULE - PAWL CIRCUIT
GROUND WIRE OPEN
PAWL SWITCH SENSE WIRE OPEN
PAWL SWITCH

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - PAWL SWITCH
FAILURE?
Yes → Go To 2

tions.
2 Examine the liftgate for proper fit and alignment, loose/ hard or torn seals, worn All
teeth on the gears or anything that would cause an obstruction to proper operation.
open and close.
No → Go To 3
788
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE — Continued

3 With the DRBIIIt in Inputs/Outputs, read the PAWL state. All
Unlatch the latch by pressing the handle switch or using the key and observe the
DRB111t for a state change.
wiggling the wiring harness to check for an intermittent open..

No → Go To 4

Yes → Go To 5
5 Disconnect the Sliding Door Control Module C2 connector. All

Disconnect the Liftgate Cinch/Release Motor connector (latch assembly).
Measure the resistance of the Liftgate Pawl Switch Sense circuit between the PLG
C2 connector and the Liftgate Cinch/Release Motor connector.
Yes → Go To 6

Repair
Replace the Liftgate Pawl Switch (latch assembly).
789
Symptom:
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAIL-
URE
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE

When Monitored: Whenever the power liftgate is operating.
Set Condition: If the cinch release motor takes longer than 700 ms to perform a release
operation this code will set. The main causes of this code setting is some type of sticking
situation preventing the sector gear in the cinch release motor assembly to return to its
neutral position.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
LIFTGATE CINCH RELEASE MOTOR ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - SECTOR GEAR
RETURN FAILURE?
Yes → Go To 2

tions.
2 Examine the liftgate for proper fit and alignment, loose/hard or torn seals, struts or All
open and close.
No → Replace the Liftgate Cinch Release Motor Assembly..
790
Symptom:
INCOMPLETE POWER CLOSE - FULL OPEN SWITCH FAILURE

When Monitored: Whenever the power liftgate is closing.
Set Condition: The Full Open Switch was detected as closed before 200 hall effect pulses
were counted since the start of the close operation. May be triggered by an intermittent full
open switch failure, or non gear engagement
POSSIBLE CAUSES
DTC PRESENT
OBSTRUCTION OR STICKING FULL OPEN SWITCH
FULL OPEN SWITCH SHORT TO GROUND
POWER LIFTGATE MOTOR ASSEMBLY - FULL OPEN SWITCH

Does the DRBIIIt display INCOMPLETE POWER CLOSE - FULL OPEN SWITCH
FAILURE?
Yes → Go To 2

liftgate several times and check for any binding cables or other
obstructions.
2 Examine the liftgate for proper fit and alignment, foreign material in the drive unit All
or anything that would cause an obstruction to proper operation of the Full Open
Switch.
With the DRBIIIt in Inputs/Outputs, read the FULL OPEN SWITCH state.
Manually operate the liftgate while monitoring the DRBIIIt.
Does the switch status change smoothly as the liftgate is pulled down from the full
open position.
Yes → Go To 3
No → Refer to Service information for the related symptom(S).
791
INCOMPLETE POWER CLOSE - FULL OPEN SWITCH FAILURE —

Continued
3 With the DRBIIIt in Inputs/Outputs, read the FULL OPEN SWITCH state. All
Open the liftgate to mid position.
While monitoring the DRBIIIt, wiggle the wiring harness from the Power Liftgate
Module to the Full Open Switch on the Power Liftgate Motor assembly.
Did the switch status ever change?
Yes → Repair the Liftgate Full Open Switch Sense circuit for a short to
ground.
No → Go To 4
Repair
Replace the Power Liftgate Motor assembly.
792
Symptom:
INCOMPLETE POWER CLOSE - MISSING HALL SIGNAL

When Monitored: Anytime the power liftgate is in the closing cycle.
Set Condition: If the Power Liftgate Module detects a missing hall effect signal for longer
than 300 ms. during a closing operation, this code will set. This is a redundant safety
feature in the software and will set if the obstacle detection feature becomes inoperative
due to a hall sensor/connection malfunction.
POSSIBLE CAUSES
DTC PRESENT
POWER LIFTGATE MODULE - HALL EFFECT OPEN
BINDING LIFTGATE
HALL EFFECT GROUND CIRCUIT OPEN
LIFTGATE HALL EFFECT SUPPLY WIRE OPEN
LIFTGATE HALL EFFECT SUPPLY WIRE SHORT TO GROUND
LIFTGATE HALL EFFECT SUPPLY WIRE SHORT TO HARNESS GROUND
LIFTGATE HALL EFFECT SIGNAL WIRE OPEN
LIFTGATE HALL EFFECT SIGNAL WIRE SHORT TO GROUND
LIFTGATE HALL EFFECT SIGNAL WIRE SHORT TO HARNESS GROUND
POWER LIFTGATE MOTOR ASSEMBLY

Operate the power liftgate several times from stop to stop if possible.
Does the DRBIIIt display INCOMPLETE POWER CLOSE - MISSING HALL
SIGNAL?
Yes → Go To 2

liftgate several times and check for any binding conditions.
793
INCOMPLETE POWER CLOSE - MISSING HALL SIGNAL — Continued


No → Go To 3
3 Operate the liftgate from the full open position and put an obstacle in its path to All
make it reverse.
Did the liftgate reverse back to the open position?
Yes → Go To 4
4 Disconnect the Power Liftgate Motor connector. All

Yes → Go To 5
No → Repair the hall effect ground circuit for an open.


Measure the resistance of the Liftgate Hall Effect Supply circuit between the Power
Liftgate Motor connector and the Power Liftgate Module C2 connector.
Yes → Go To 6
No → Repair the Liftgate Hall Effect Supply wire for an open.

Measure the resistance between ground and the Liftgate Hall Effect Supply circuit.
Yes → Repair the Liftgate Hall Effect Supply wire for a short to ground.
No → Go To 7

Measure the resistance between the Ground circuit (cavity 20) and the Liftgate Hall
Effect Supply circuit.
Yes → Repair the Liftgate Hall Effect Supply wire for a short to the
Ground circuit.
No → Go To 8
794

Measure the resistance of the Liftgate Hall Effect Signal circuit between the Power
Yes → Go To 9
No → Repair the Liftgate Hall Effect Signal wire for an open.


Measure the resistance between ground and the Liftgate Hall Effect Signal circuit.
Yes → Repair the Liftgate Hall Effect Signal wire for a short to ground.
No → Go To 10

Effect Signal circuit.
Yes → Repair the Liftgate Hall Effect Signal wire for a short to the
Ground circuit.
No → Go To 11

Repair
Replace the Power Liftgate Motor Assembly (hall effect switch).
795
Symptom:
INCOMPLETE POWER CLOSE - OVER CURRENT
INCOMPLETE POWER CLOSE - OVER CURRENT

When Monitored: Anytime the liftgate is in a closing operation.
Set Condition: The drive motor stall current of over 24 amps has been detected for over
500 ms. during a close operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
GROUND CIRCUIT OPEN
LIFTGATE CLOSE DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE LATCH RELEASE DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE LATCH RELEASE DRIVER CIRCUIT SHORT TO HARNESS GROUND
LIFTGATE GEAR ENGAGE DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE GEAR ENGAGE DRIVER CIRCUIT SHORT TO HARNESS GROUND
LIFTGATE MODULE
POWER LIFTGATE MOTOR

Operate the power liftgate several times (if possible).
Does the DRBIIIt display INCOMPLETE POWER CLOSE- OVERCURRENT?
Yes → Go To 2

2 Examine the liftgate for proper alignment, worn or binding hinges, weak or binding All
liftgate prop rods, loose/ hard weatherstrip, and gear teeth on the power liftgate
motor assembly for wear or anything that would cause an obstruction to proper
operation.
Compare the effort needed on the disabled vehicle.

No → Go To 3
796
INCOMPLETE POWER CLOSE - OVER CURRENT — Continued

Yes → Go To 4


Measure the resistance between ground and the Liftgate Close Driver circuit.
Wiggle the harness and check for an intermittent short circuit condition.
Yes → Repair the Liftgate Close Driver circuit for a short to ground.
No → Go To 5

Measure the resistance between ground and the Liftgate Latch Release Driver
circuit.
Yes → Repair the Liftgate Latch Release Driver circuit for a short to
ground.
No → Go To 6

Release Driver circuit.
Yes → Repair the Liftgate Latch Release Driver circuit for a short to the
Ground circuit.
No → Go To 7

Measure the resistance between ground and the Liftgate Gear Engage Driver circuit.
Yes → Repair the Liftgate Gear Engage Driver circuit for a short to
ground.
No → Go To 8
797
INCOMPLETE POWER CLOSE - OVER CURRENT — Continued

Measure the resistance between the Ground circuit (cavity 20) and the Liftgate Gear
Engage Driver circuit.
Yes → Repair the Liftgate Gear Engage Driver circuit for a short to the
Ground circuit.
No → Go To 9
9 Ensure all module and motor connectors are connected at this time. All
Try to operate the liftgate in the close position.
Did the motor start to close the liftgate but was very slow and labored extensively?
Yes → Replace the Power Liftgate Motor assembly.
No → Replace the Power Liftgate Module
798
Symptom:
INCOMPLETE POWER CLOSE - TIME OUT

When Monitored: During Power Liftgate close cycle.
Set Condition: The power close operation was not completed within 20 seconds. This may
be caused by very high closing effort. A weak hall effect signal, low motor output or high
prop rod pressure could also set this code.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER LIFTGATE MOTOR ASSEMBLY

Operate the power liftgate several times from stop to stop - if possible.
Does the DRBIIIt display INCOMPLETE POWER CLOSE - TIME-OUT?
Yes → Go To 2
tions.

No → Replace the Power Liftgate Motor Assembly.
799
Symptom:
INCOMPLETE POWER OPEN - FULL OPEN SWITCH FAILURE

When Monitored: During the Power Liftgate open cycle.
were counted since the start of the open operation. May be triggered by an intermittent full
open switch failure or a non gear engagement.
POSSIBLE CAUSES
DTC PRESENT
OBSTRUCTION OR STICKING FULL OPEN SWITCH
POWER LIFTGATE MOTOR ASSEMBLY - FULL OPEN SWITCH

Does the DRBIIIt display INCOMPLETE POWER OPEN - FULL OPEN SWITCH
FAILURE?
Yes → Go To 2

liftgate several times and check for any binding or obstructions.
2 Examine the liftgate for proper fit and alignment, foreign material in the drive unit All
or anything that would cause an obstruction to proper operation of the Full Open
Switch.
Manually operate the liftgate while monitoring the DRBIIIt.
Does the switch status change smoothly as the liftgate is pulled down from the full
open position.
Yes → Go To 3

800
INCOMPLETE POWER OPEN - FULL OPEN SWITCH FAILURE —

Continued
Open the liftgate to mid position.
While monitoring the DRBIIIt, wiggle the wiring harness from the Power Liftgate
Module to the Full Open Switch on the Power Liftgate Motor assembly.
Yes → Repair the Full Open Switch Sense circuit for a short to ground.
No → Go To 4
Repair
801
Symptom:
INCOMPLETE POWER OPEN - LATCH FAILURE

When Monitored: During the Power Liftgate open cycle.
Set Condition: The power open operation was not completed due to latch failure. This
DTC is set during a power open cycle.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
LIFTGATE LATCH CINCH DRIVER CIRCUIT SHORT TO HARNESS GROUND
LIFTGATE LATCH CINCH DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE LATCH RELEASE DRIVER WIRE OPEN
POWER LIFTGATE MODULE - FULL OPEN CIRCUIT OPEN
POWER LIFTGATE MODULE - PAWL CIRCUIT OPEN
POWER LIFTGATE MODULE - RATCHET CIRCUIT OPEN
GROUND WIRE OPEN
GROUND WIRE OPEN
GROUND WIRE OPEN
LIFTGATE FULL OPEN SWITCH SENSE WIRE OPEN
LIFTGATE PAWL SWITCH SENSE WIRE OPEN
LIFTGATE FULL OPEN SWITCH SENSE WIRE SHORT TO GROUND
LIFTGATE FULL OPEN SWITCH SENSE WIRE SHORT TO HARNESS GROUND
LIFTGATE CINCH/RELEASE MOTOR
LIFTGATE CINCH/RELEASE MOTOR
LIFTGATE FULL OPEN SWITCH
LIFTGATE PAWL SWITCH
RATCHET SWITCH
802
INCOMPLETE POWER OPEN - LATCH FAILURE — Continued

Does the DRBIIIt display INCOMPLETE POWER OPEN - LATCH FAILURE?
Yes → Go To 2

tions.
assembly, loose/ hard weatherstrip, and gear teeth on the Power Liftgate Motor

No → Go To 3
3 With the DRBIIIt in Inputs/Outputs, read the PAWL, RATCHET and FULL OPEN All
switch state.
While observing the FULL OPEN switch state, manually lower the liftgate from full
open to part open. The switch should toggle from CLOSED to OPEN.
Open the Liftgate to full open position. While observing the PAWL switch state, click
the latch with a screwdriver to the first detent. The PAWL should toggle from
CLOSED to OPEN.
Open the Liftgate to the full open position. While observing the RATCHET switch
state, click the latch with a screwdriver to the second detent. The RATCHET should
toggle from CLOSED to OPEN.
Repeat the above steps several times.
Select which switch failed:
FULL OPEN Switch
Go To 4
PAWL Switch
Go To 10
RATCHET Switch
Go To 14
All switches operated properly.

Go To 18
803

Measure the resistance between ground and the Liftgate Full Open Switch Sense
circuit.
Open the liftgate completely then partially close it. Repeat this step while observing
the ohmmeter.
Did the resistance change from below 15 ohms to above 1000.0 ohms when door was
partially closed?

No → Go To 5

Disconnect the Full Open Switch connector.
and the Full Open Switch connector.
Yes → Go To 6


Disconnect the Power Liftgate Motor connector.
Measure the resistance of the Liftgate Full Open Switch Sense wire between the
Power Liftgate Module C2 connector and the Power Liftgate Motor connector.
Yes → Go To 7
No → Repair the Liftgate Full Open Switch Sense wire for an open.

Measure the resistance between ground and the Liftgate Full Open Switch Sense
circuit.
Yes → Repair the Liftgate Full Open Switch Sense wire for a short to
ground.
No → Go To 8

Measure the resistance between the Ground circuit and the Liftgate Full Open
Yes → Repair the Liftgate Full Open Switch Sense wire for a short to the
Ground circuit.
No → Go To 9
804

Repair

Measure the resistance between the Ground circuit (cavity 20) and the Pawl Switch
Sense circuit.
Open the Liftgate.
Using a screwdriver, close the liftgate latch to the first detent while observing the
ohmmeter.
Release the liftgate latch. Repeat this step while observing the ohmmeter.
Did the resistance change from below 15 ohms to above 1000.0 ohms when the latch
changed states?
No → Go To 11

Yes → Go To 12


Measure the resistance of the Liftgate Pawl Switch Sense wire between the Power
Yes → Go To 13

Repair
Replace the Liftgate Cinch Release Motor.
805

NOTE: The Liftgate Ajar Switch Sense circuit is also the Ratchet Switch
Sense circuit for the liftgate.
Measure the resistance between the Ground circuit and the Liftgate Ajar Switch
Sense circuit.
Open the Liftgate completely.
Using a screwdriver, close the latch to the second detent while observing the
ohmmeter.
Release the latch with the handle. Repeat this step while observing the ohmmeter.
changed states?

No → Go To 15

Yes → Go To 16

Measure the resistance of the Liftgate Ajar Switch Sense wire between the Power
Yes → Go To 17


Repair

Measure the resistance between the Liftgate Latch Cinch Driver circuit and the
Liftgate Latch Release Driver circuit.
Yes → Go To 19
No → Go To 21
806

Driver circuit.
Wiggle the harness and check for an intermittent short to the Ground circuit
condition.
Yes → Repair the Liftgate Latch Cinch Driver circuit for a short to the
Ground circuit. This could be the Liftgate Latch Cinch Driver or
Liftgate Latch Release Driver or the motor itself.
No → Go To 20

Wiggle the harness and check for an intermittent short to ground condition.
Yes → Repair the Liftgate Latch Cinch Driver circuit for a short to
ground. This could be the Liftgate Latch Cinch Driver or Liftgate
Latch Release Driver or the motor itself.
No → Replace the Liftgate Cinch Release Motor.

Yes → Go To 22


Yes → Go To 23


Repair
807
Symptom:
INCOMPLETE POWER OPEN - MISSING HALL SIGNAL

When Monitored: During Power Liftgate opening cycle.
Set Condition: If the Power Liftgate Module detects a missing hall effect signal for longer
than 300 ms. during an opening operation, this code will set. This is a redundant safety
feature in the software and will set if the obstacle detection feature becomes inoperative
due to a hall sensor/connection malfunction.
POSSIBLE CAUSES
DTC PRESENT
POWER LIFTGATE MODULE - HALL EFFECT OPEN
BINDING LIFTGATE
LIFTGATE HALL EFFECT SUPPLY WIRE OPEN
LIFTGATE HALL EFFECT SUPPLY WIRE SHORT TO GROUND
LIFTGATE HALL EFFECT SUPPLY WIRE SHORT TO HARNESS GROUND
LIFTGATE HALL EFFECT SIGNAL WIRE OPEN
LIFTGATE HALL EFFECT SIGNAL WIRE SHORT TO GROUND
LIFTGATE HALL EFFECT SIGNAL WIRE SHORT TO HARNESS GROUND

Operate the Power Liftgate several times from stop to stop if possible.
Does the DRBIIIt display INCOMPLETE POWER OPEN - MISSING HALL SIG-
NAL?
Yes → Go To 2

808
INCOMPLETE POWER OPEN - MISSING HALL SIGNAL — Continued


No → Go To 3
3 Operate the liftgate from the full closed position and put an obstacle in it’s path to All
make it reverse.
Did the door reverse back to the closed position?
Yes → Go To 4

Yes → Go To 5


Measure the resistance of the Liftgate Hall Effect Supply circuit between the Power
Yes → Go To 6
No → Repair the Liftgate Hall Effect Supply wire for an open.

Measure the resistance between ground and the Liftgate Hall Effect Supply circuit.
Yes → Repair the Door Motor Hall Effect Supply wire for a short to
ground.
No → Go To 7
809

Effect Supply circuit.
Yes → Repair the Door Motor Hall Effect Supply wire for a short to the
Ground circuit.
No → Go To 8

Measure the resistance of the Power Liftgate Hall Effect Signal circuit between the
Power Liftgate Motor connector and the Power Liftgate Module C2 connector.
Yes → Go To 9
No → Repair the Liftgate Hall Effect Signal wire for an open.

Measure the resistance between ground and the Liftgate Hall Effect Signal circuit.
Yes → Repair the Liftgate Hall Effect Signal wire for a short to ground.
No → Go To 10

Effect Signal circuit.
Yes → Repair the Liftgate Hall Effect Signal wire for a short to the
Ground circuit.
No → Go To 11
Repair
810
Symptom:
INCOMPLETE POWER OPEN - OVERCURRENT

When Monitored: Anytime the Power Liftgate is in a power open operation.
500 ms. during an open operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE
GROUND CIRCUIT OPEN
LIFTGATE LATCH CINCH DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE LATCH CINCH DRIVER CIRCUIT SHORT TO HARNESS GROUND
LIFTGATE GEAR ENGAGE DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE OPEN DRIVER CIRCUIT SHORT TO GROUND
LIFTGATE GEAR ENGAGE DRIVER CIRCUIT SHORT TO HARNESS GROUND
LIFTGATE MODULE

Does the DRBIIIt display INCOMPLETE POWER OPEN - OVERCURRENT?
Yes → Go To 2

If necessary manually operate the liftgate of a known good vehicle and notice the
effort needed.

No → Go To 3
811
INCOMPLETE POWER OPEN - OVERCURRENT — Continued

Yes → Go To 4


Wiggle the harness and check for an intermittent shorted condition.
Yes → Repair the Liftgate Latch Cinch Driver circuit for a short to
ground.
No → Go To 5

Driver circuit.
Wiggle the harness and check for an intermittent shorted condition.
Yes → Repair the Liftgate Latch Cinch Driver circuit for a short to the
Ground circuit.
No → Go To 6

Measure the resistance between ground and the Liftgate Gear Engage Driver circuit.
Yes → Repair the Liftgate Gear Engage Driver circuit for a short to
ground.
No → Go To 7

Measure the resistance between ground and the Liftgate Open Driver circuit.
Yes → Repair the Liftgate Open Driver circuit for a short to ground.
No → Go To 8
812

Measure the resistance between the Ground circuit and the Liftgate Gear Engage
Driver circuit.
Yes → Repair the Liftgate Gear Engage Driver circuit for a short to the
Ground circuit.
No → Go To 9
9 Ensure all connections to the module and liftgate motor are connected at this time. All
Operate the Power Liftgate in both directions if possible.
Does the motor start to lift the liftgate but is very slow and labors extensively?
Yes → Replace the Power Liftgate Motor assembly.
No → Replace the Power Liftgate Module
813
Symptom:
INCOMPLETE POWER OPEN - TIME OUT

When Monitored: Anytime the Power Liftgate is operating.
Set Condition: The power open operation was not completed within 20 seconds.
POSSIBLE CAUSES
DTC PRESENT
BINDING LIFTGATE

Does the DRBIIIt display INCOMPLETE POWER OPEN - TIME-OUT?
Yes → Go To 2

No → Replace the Power Liftgate Motor assembly.
814
Symptom:
IOD WAKE UP OPEN - PLG
IOD WAKE UP OPEN - PLG

Set Condition: If the BCM does not sense a signal circuit from the Liftgate Module this
code will set.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - IOD WAKE UP OPEN
LIFTGATE MODULE WAKE UP SIGNAL WIRE OPEN

Wait 10 seconds.
Does the DRBIIIt display IOD WAKE UP OPEN?
Yes → Go To 2

2 Disconnect the BCM C2 connector. All

ground.
No → Go To 3

Measure the resistance of the Liftgate Module Wake Up Signal circuit between the
BCM C2 connector and the Power Liftgate Module C2 connector.
Yes → Go To 4
No → Repair the Liftgate Module Wake Up Signal wire for an open.

815
IOD WAKE UP OPEN - PLG — Continued

ground.
ground.
No → Go To 5
Repair
816
Symptom:
LOOPBACK TEST FAILURE

When Monitored: Anytime the Power Liftgate Module is awake.
Set Condition: The Power Liftgate Module did not receive its own transmitted message
on the PCI bus back (loopback) for longer than 1 second.
POSSIBLE CAUSES
DTC PRESENT

Operate the power liftgate several times from stop to stop if possible.
Does the DRBIIIt display LOOPBACK TEST FAILURE?

door several times and check for any binding conditions.
817
Symptom:
LOSS OF BCM MESSAGES

When Monitored: Whenever the ignition is on.
Set Condition: If the PLG Module losses communication with the BCM for over 5 seconds,
this code will set.
POSSIBLE CAUSES
POWER LIFTGATE MODULE - LOSS OF BCM MESSAGES

With the DRBIIIt, enter Body then Body Computer.
Was the DRBIIIt able to I/D or communicate with the BCM?
Yes → Go To 2
2 With the DRBIIIt, erase DTC’s. All

Did this DTC reset?
818
Symptom:
LOSS OF EATX MESSAGES

When Monitored: Whenever the ignition is in the UNLOCK or RUN position.
Set Condition: If the PLG Module does not receive a PRNDL message for over 5 seconds,
this code will set.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE TRANSMISSION CONTROL MODULE
POWER LIFTGATE MODULE - LOSS OF EATX MESSAGES

With the DRBIIIt select Transmission.
Was the DRBIIIt able to I/D or communicate with the Transmission?
Yes → Go To 2
No → Refer to the Communication category for the related symptom(S).

Did this DTC reset?
819
Symptom:
LOSS OF FCM MESSAGES

When Monitored: Whenever the ignition is in the RUN position.
Set Condition: If the PLG Module does not receive a temperature message from the Front
Control Module for over 5 seconds, this code will set.
POSSIBLE CAUSES
POWER LIFTGATE MODULE - LOSS OF FCM MESSAGES

With the DRBIIIt, enter Body then Front Control Module.
Was the DRBIIIt able to I/D or communicate with the FCM?
Yes → Go To 2

Did this DTC reset?
820
Symptom:
LOSS OF SBEC MESSAGES

When Monitored: Whenever the ignition is in the RUN position.
Set Condition: If the PLG Module does not receive a speed message from the Powertrain
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE POWERTRAIN CONTROL MODULE
POWER LIFTGATE MODULE - LOSS OF SBEC MESSAGES

With the DRBIIIt, select Engine.
Was the DRBIIIt able to I/D or communicate with the Powertrain Control Module?
Yes → Go To 2

Did this DTC reset?
821
Symptom:
OUTSIDE LIFTGATE HANDLE INPUT SHORT
OUTSIDE LIFTGATE HANDLE INPUT SHORT

When Monitored: Whenever the Body Control Module is awake.
Set Condition: When the BCM senses a voltage of less than 1.0 volts on the Liftgate
Handle Switch Sense circuit for longer than 10 seconds this code will set.
POSSIBLE CAUSES
LIFTGATE HANDLE SWITCH SHORTED
LIFTGATE HANDLE SWITCH SENSE CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE - LIFTGATE HANDLE SWITCH SHORT TO GROUND

1 Disconnect the License Lamp connector (light bar). All
Does the DRBIIIt display Outside Liftgate Handle Input Short?
Yes → Go To 2
No → Replace the Liftgate Handle Switch.

2 Disconnect the License Lamp connector. All

Measure the resistance between ground and the Liftgate Handle Switch Sense
circuit.
Yes → Repair the Liftgate Handle Switch Sense circuit for a short to
ground.
No → Go To 3

Repair
822
Symptom:
OUTSIDE LIFTGATE HANDLE INPUT STUCK
OUTSIDE LIFTGATE HANDLE INPUT STUCK

When Monitored: Whenever the Body Control Module is awake.
Set Condition: When the BCM senses a liftgate handle input on the Liftgate Handle
Switch Sense circuit for longer than 10 seconds this code will set.
POSSIBLE CAUSES
LIFTGATE HANDLE SWITCH STUCK
LIFTGATE HANDLE SWITCH SENSE CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE - LIFTGATE HANDLE SWITCH SHORT TO GROUND

1 Disconnect the License Lamp connector (light bar). All
Wait 10 seconds.
Does the DRBIIIt display Outside Liftgate Handle Input Stuck?
Yes → Go To 2
No → Replace the Liftgate Handle Switch.

2 Disconnect the License Lamp connector. All

Measure the resistance between ground and the Liftgate Handle Switch Sense
circuit.
Yes → Repair the Liftgate Handle Switch Sense circuit for a short to
ground.
No → Go To 3

Repair
823
Symptom:
OVERHEAD LIFTGATE SWITCH INPUT STUCK
OVERHEAD LIFTGATE SWITCH INPUT STUCK

When Monitored: Whenever the BCM is awake.
Set Condition: When the BCM senses a overhead liftgate switch input for over 10
seconds, this code will set.
POSSIBLE CAUSES
DTC PRESENT
OVERHEAD LIFTGATE SWITCH SHORTED
LIFTGATE SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - OVERHEAD LIFTGATE SWITCH MUX SHORTED

Operate the Liftgate from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD LIFTGATE SWITCH INPUT STUCK?
Yes → Go To 2
2 With the DRBIIIt, erase DTCs. All

Disconnect the Overhead Console Switch connector.
Wait 10 seconds.
Does the DRBIIIt display OVERHEAD LIFTGATE SWITCH INPUT STUCK?
No → Replace the Power Sliding Door Button Module.
Yes → Go To 3

Measure the resistance of the Liftgate Switch Mux circuit to ground.
Yes → Repair the Liftgate Switch Mux wire for a short to ground.
824
Symptom:
OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN
OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN

Set Condition: When the BCM senses a overhead liftgate switch input that is greater
than 4.8 volts for over 10 seconds, this code will set.
POSSIBLE CAUSES
DTC PRESENT
SLIDING DOORS OVERHEAD SWITCH MUX CIRCUIT SHORT TO VOLTAGE
LIFTGATE SWITCH MUX WIRE OPEN
BODY CONTROL MODULE - OVERHEAD SWITCH OPEN
OVERHEAD SWITCH OPEN

Operate the power sliding door from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN?
Yes → Go To 2


Measure the voltage of the Sliding Doors Overhead Switch Mux circuit to ground.
Yes → Repair the Sliding Doors Overhead Switch Mux circuit for a short
to voltage.
No → Go To 3

Measure the resistance between ground and the Liftgate Switch Mux circuit.
Yes → Go To 4
No → Go To 5

Repair
825
OVERHEAD LIFTGATE/LOCKOUT SWITCHES OPEN — Continued

Disconnect the Overhead Console connector.
Measure the resistance of the Liftgate Switch Mux circuit between the BCM
connector and the Overhead Console connector.
Yes → Replace the Power Sliding Door Button Module.
No → Repair the Liftgate Switch Mux circuit for an open.

826
Symptom:
OVERHEAD LIFTGATE/LOCKOUT SWITCHES SHORT
OVERHEAD LIFTGATE/LOCKOUT SWITCHES SHORT

Set Condition: When the BCM senses a overhead liftgate switch input that drops to below
0.24 volts for over 10 seconds, this code will set.
POSSIBLE CAUSES
DTC PRESENT
OVERHEAD LIFTGATE SWITCH SHORTED
LIFTGATE SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - OVERHEAD LIFTGATE SWITCH MUX SHORTED

Operate the Liftgate from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD SWITCH #1 SHORT?
Yes → Go To 2

Wait 10 seconds.
Does the DRBIIIt display OVERHEAD SWITCH #1 SHORT?
Yes → Go To 3

Measure the resistance of the Liftgate Switch Mux circuit to ground.
Yes → Repair the Liftgate Switch Mux wire for a short to ground.
827
Symptom:
PINCH SENSOR CIRCUIT OPEN
PINCH SENSOR CIRCUIT OPEN

When Monitored: Whenever the Power Liftgate is operating.
Set Condition: The power liftgate module has detected the pinch sensor circuit voltage is
above 4.6 volts.
POSSIBLE CAUSES
DTC PRESENT
POWER LIFTGATE MODULE - PINCH SENSOR OPEN
RIGHT PINCH SENSOR SIGNAL WIRE OPEN
PINCH SENSOR GROUND OPEN
RIGHT PINCH SENSOR OPEN
LEFT PINCH SENSOR OPEN
RIGHT PINCH SENSOR SIGNAL WIRE OPEN

Does the DRBIIIt display PINCH SENSOR CIRCUIT OPEN?
Yes → Go To 2

Measure the resistance of the Pinch Sensor Signal circuit between the Pinch Sensor
Signal and the Ground circuit (cavity 20) in the C2 connector.
No → Go To 3

828
PINCH SENSOR CIRCUIT OPEN — Continued

3 Remove the Liftgate trim panel. All
Disconnect the Liftgate Right Pinch Sensor connector.
Disconnect the Liftgate Left Pinch Sensor connector.
Measure the resistance of the Right Pinch Sensor Signal circuit between the Liftgate
Left Pinch Sensor connector and the Liftgate Right Pinch Sensor connector.
Yes → Go To 4
No → Repair the Right Pinch Sensor Signal wire for an open.

4 Remove the Power Liftgate Motor trim panel. All

Remove the Liftgate trim panel.
Measure the resistance of the Ground circuit between the Liftgate Right Pinch
Sensor connector and the PLG C2 connector.
Yes → Go To 5


Connect a jumper wire between the Right Pinch Sensor Signal circuit and the
Ground circuit in the Liftgate Right Pinch Sensor connector.
Signal and the Ground circuit (cav 20) in the C2 connector.
Yes → Replace the Right Pinch Sensor.
No → Go To 6

Remove the liftgate trim panel.
Connect a jumper wire between the Pinch Sensor Signal circuit and the Right Pinch
Sensor Signal circuit in the Liftgate Left Pinch Sensor connector.
Signal and the Ground circuit (cav 20) in the C2 connector.
Yes → Replace the Left Pinch Sensor.
No → Go To 7
829
PINCH SENSOR CIRCUIT OPEN — Continued

Measure the resistance of the Pinch Sensor Signal circuit between the PLG C2
connector and the Liftgate Left Pinch Sensor connector.
No → Repair the Pinch Sensor Signal wire for an open.

830
Symptom:
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND

When Monitored: Whenever the Power Liftgate is operating.
Set Condition: The power liftgate module has detected the pinch sensor circuit voltage is
shorted to ground.
POSSIBLE CAUSES
DTC PRESENT
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND CIRCUIT
POWER LIFTGATE MODULE - SHORT TO GROUND
RIGHT PINCH SENSOR - SHORT TO GROUND
RIGHT PINCH SENSOR SIGNAL WIRE - SHORT TO GROUND
LEFT PINCH SENSOR - SHORT TO GROUND
RIGHT PINCH SENSOR SIGNAL WIRE SHORT TO GROUND

Does the DRBIIIt display PINCH SENSOR CIRCUIT SHORT TO GROUND?
Yes → Go To 2

Signal and the Ground circuits in the C2 connector.
Yes → Repair the Pinch Sensor Signal circuit for a short to the Ground
circuit.
No → Go To 3

Measure the resistance between ground and the Pinch Sensor Signal circuit.
Yes → Go To 4

831
PINCH SENSOR SIGNAL CIRCUIT SHORT TO GROUND — Continued

Disconnect the Right Pinch Sensor connector
Yes → Go To 5
No → Replace the Right Pinch Sensor.

5 Remove the Liftgate trim panel. All

Disconnect the Right Pinch Sensor connector.
Disconnect the Left Pinch Sensor connector.
Measure the resistance between ground and the Right Pinch Sensor Signal circuit.
Yes → Repair the Right Pinch Sensor Signal wire for a short to ground.
No → Go To 6

Disconnect the Left Pinch Sensor connector
Yes → Go To 7
No → Replace the Left Pinch Sensor.

Repair
Repair the Pinch Sensor Signal wire for a short to ground.
832
Symptom:
*POWER LIFTGATE INOPERATIVE
POSSIBLE CAUSES
DTC’S PRESENT
MODULE RESPONSE
SYSTEM TESTS

1 With the DRBIIIt check for response from the Body Computer and the Power All
Liftgate Modules
Is there response from both modules?
Yes → Go To 2
No → Refer to symptom list for problems related to COMMUNICA-

TION.
2 With the DRBIIIt, read DTCs in POWER LIFTGATE and BODY COMPUTER. All
Are any Power Liftgate related codes present?
Yes → Refer to symptom list for problems related to POWER LIFT-
GATE.
No → Go To 3
3 This test will determine what inhibited the Power Liftgate from operating properly. All
With the DRBIIIt, select POWER LIFTGATE, MISCELLANEOUS, LAST INHIBIT
MONITOR.
Does the DRBIIIt display any INHIBIT REASONS?
Yes → Check for any binding conditions or other restrictions that may
prevent proper operation. Using the wiring diagram/schematic as
a guide, inspect the wiring and connectors.
No → Go To 4
4 Ensure Liftgate is fully closed before proceeding. All

With the DRBIIIt select SYSTEM TEST.
Perform the Open, Close, Latch Cinch, Latch Release and Relay tests.
Did any test fail?
Yes → Using the wiring diagram/schematic as a guide, inspect the
833
Symptom:

When Monitored: Anytime the Power Sliding Door Module is awake.
Set Condition: If the Power Sliding Door Modules internal thermistor becomes open, this
code will set.
POSSIBLE CAUSES
DTC PRESENT
POWER SLIDING DOOR MODULE

Operate the power sliding door several times from stop to stop if possible.
Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT HIGH?

834
Symptom:

Set Condition: If the Power Sliding Door Modules internal thermistor is shorted, this
code will set.
POSSIBLE CAUSES
DTC PRESENT

Does the DRBIIIt display AMBIENT TEMPERATURE SENSOR CIRCUIT LOW?

835
Symptom:

When Monitored: Anytime the module is awake.
Set Condition: Whenever the module senses an internal failure (EEPROM, ROM, ADC)
this code will set. The module must be replaced.
POSSIBLE CAUSES
SLIDING DOOR CONTROL MODULE - INTERNAL FAILURE

1 View repair. All
Repair
Replace the Sliding Control Module.
836
Symptom:

When Monitored: Whenever the power sliding door in operating in the closing direction.
Set Condition: The cinch operation was not completed in 4 seconds and the current did
not build up to stall level. This code is set only during the cinching operation after a 4
second time out.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
CINCH/RELEASE MOTOR CLUTCH DRIVER WIRE OPEN
CINCH/RELEASE MOTOR LATCH DRIVER WIRE OPEN
CINCH/RELEASE MOTOR UNLATCH DRIVER WIRE OPEN
LATCH ASSEMBLY

Operate the power sliding door several times if possible.
Does the DRBIIIt display INCOMPLETE LATCH CINCH - NO CURRENT?
Yes → Go To 2

tions.
2 Examine the door for proper fit and alignment, loose/ hard or torn seals, worn teeth All
on the rack and gear (lower drive unit) or anything that would cause an obstruction
to proper operation.
Manually operate the other sliding door or of a known good vehicle and notice the
effort needed to open and close.
Compare the effort needed on the disabled door.
Does it take more effort to operate the door than it should?

No → Go To 3
837
INCOMPLETE LATCH CINCH - NO CURRENT — Continued

Disconnect the Sliding Door Control Module C2 connector.
Disconnect the Cinch/Release Motor connector.
Measure the resistance of the Cinch/Release Motor Latch Driver circuit between the
Yes → Go To 4
No → Repair the Cinch/Release Motor Latch Driver wire for an open.


Measure the resistance of the Cinch/Release Motor Clutch Driver circuit between the
Yes → Go To 5
No → Repair the Cinch/Release Motor Clutch Driver wire for an open.

Measure the resistance between of the Cinch/Release Motor Unlatch Driver circuit
from the PSD C2 connector to the Cinch/Release Motor connector.
Yes → Go To 6
No → Repair the Cinch/Release Motor Unlatch Driver wire for an open.
Repair
838
Symptom:

When Monitored: Whenever the power sliding door in operating.
Set Condition: The pawl switch was not detected as returning to ground during the
transition between secondary and primary cinch operation. NOTE: The door may not be
fully cinched during this condition. The door may cinch to primary but not be fully seated
and may pop off back to secondary.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
GROUND WIRE OPEN
PAWL SWITCH

Does the DRBIIIt display INCOMPLETE LATCH CINCH - NO PAWL TRANSI-
TION?
Yes → Go To 2

tions.
No → Go To 3
839
INCOMPLETE LATCH CINCH - NO PAWL TRANSITION — Continued

Disconnect the Sliding Door Latch Sensing Switch connector (latch assembly).
Measure the resistance of the Ground wires (both) between the PSD C2 connector
(cavity 20) and the Sliding Door Latch Sensing Switch connector.
Is the resistance below 5.0 ohms on both ground wires?
Yes → Go To 4


Measure the resistance of the Pawl Switch Sense wire between the PSD C2 connector
and the Sliding Door Latch Sensing Switch connector.
Yes → Go To 5
No → Repair the Pawl Switch Sense wire for an open.


Measure the resistance between ground and the Pawl Switch Sense circuit.
Yes → Repair the Pawl Switch Sense wire for a short to ground.
No → Go To 6

Repair
840
Symptom:

When Monitored: Whenever the power sliding door is operating in the closing direction.
Set Condition: The latch motor stall current of 6.2 amps has been detected, or a time-out
has occurred with no pawl or ratchet failure. This code is set during the power cinching
operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
CINCH/RELEASE MOTOR LATCH DRIVER WIRE SHORT TO GROUND
CINCH/RELEASE MOTOR UNLATCH DRIVER WIRE SHORT TO GROUND
LATCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH CINCH-OVERCURRENT?
Yes → Go To 2

tions.

No → Go To 3
841

Yes → Go To 4


Measure the resistance of the Cinch/Release Motor Unlatch Driver circuit between
the Sliding Door Control Module C2 connector and the Cinch/Release Motor connec-
tor.
Yes → Go To 5

Measure the resistance between ground and the Cinch/Release Motor Latch Driver
circuit.
Yes → Go To 6
No → Repair the Cinch/Release Motor Latch Driver wire for a short to

ground.

Measure the resistance between ground and the Cinch/Release Motor Unlatch Driver
circuit.
Yes → Go To 7
No → Repair the Cinch/Release Motor Unlatch Driver wire for a short to

ground.

Repair
842
Symptom:

Set Condition: The cinch operation was not completed in 4 seconds. This code will set only
in the cinch operation after a 4 second time out.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
CLUTCH GROUND OPEN
POWER SLIDING DOOR MODULE - PAWL SWITCH SENSE
PAWL SWITCH

Does the DRBIIIt display INCOMPLETE LATCH CINCH - PAWL SWITCH FAIL-
URE?
Yes → Go To 2
tions.

No → Go To 3
843

Open the sliding door to full open position.
change.
Yes → Go To 4
No → Go To 7

Yes → Go To 5


Yes → Go To 6

Repair
Replace the Power Sliding Door Module.

Yes → Repair the Pawl Switch Sense wire for a short to ground.
No → Go To 8
Repair
844
Symptom:

Set Condition: The cinch operation was not completed in 4 seconds. This code will set only
in the cinch operation after a 4 second time out.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
RATCHET CIRCUIT
CLUTCH GROUND OPEN
GROUND WIRE OPEN
SLIDING DOOR AJAR SWITCH SENSE WIRE OPEN
SLIDING DOOR AJAR SWITCH SENSE WIRE SHORT TO GROUND
RATCHET SWITCH

Does the DRBIIIt display INCOMPLETE LATCH CINCH - RATCHET SWITCH
FAILURE?
Yes → Go To 2
tions.
845


No → Go To 3

DRB111t.
change.
No → Go To 4

Yes → Go To 5

Yes → Go To 6

846

Yes → Go To 7


Measure the resistance of the Sliding Door Ajar Switch Sense wire between the PSD
C2 connector and the Sliding Door Latch Sensing Switch connector.
ohmmeter.
Yes → Go To 8
No → Repair the Sliding Door Ajar Switch Sense wire for an open.

NOTE: The Ratchet Switch Sense circuit is called the Sliding Door Ajar
Switch Sense circuit. They are one in the same as they perform two
functions.
Yes → Go To 9
No → Repair the Sliding Door Ajar Switch Sense wire for a short to
ground.
Repair
847
Symptom:
INCOMPLETE LATCH RELEASE - FULL OPEN SWITCH FAILURE
INCOMPLETE LATCH RELEASE - FULL OPEN SWITCH FAILURE

Set Condition: The release operation had stalled or the current was exceeded before the
full open switch had changed state during the release. This code will set only in power
closing operation.
POSSIBLE CAUSES
DTC PRESENT
FULL OPEN SWITCH GROUND OPEN
STICKING CABLES OR LATCH
FULL OPEN SWITCH WIRE OPEN
FULL OPEN SWITCH WIRE SHORT TO GROUND
LATCH ASSEMBLY - HOLD OPEN RELEASE
POWER SLIDING DOOR MODULE - FULL OPEN SWITCH
FULL OPEN SW ITCH

Does the DRBIIIt display INCOMPLETE LATCH RELEASE- FULL OPEN
SWITCH FAILURE?
Yes → Go To 2

door several times and check for any binding cables or other
obstructions.
848
INCOMPLETE LATCH RELEASE - FULL OPEN SWITCH FAILURE —

Continued
2 Examine the door for proper fit and alignment, foreign material in the lower drive All
unit or anything that would cause an obstruction to proper operation of the Full Open
Switch.
Open the sliding door to the full open position.
Hold the door in the full open position and observe the hold open latch in the lower
drive unit.
Manually operate the door handle (pull and release) while observing the hold open
latch.
Repeat this step several times while observing the latch.
Does the latch work smoothly as the handle is pulled and released?
Yes → Go To 3
No → Determine if the problem is a sticking cable or hold open latch

(lower drive unit). Refer to Service information for the related
symptom(s).
3 Hold the door in the full open position and observe the hold open latch in the lower All
drive unit.
With the DRBIIIt in SYSTEM TEST, perform the SLIDING DOOR LATCH RE-
LEASE TEST.
Repeat this step several times while observing the latch.
Does the latch work smoothly as the latch is activated?
Yes → Go To 4
No → Replace the Latch Assembly (hold open release actuator).
While observing the FULL OPEN switch state, manually move the door from full
Did the switch status change as the door was moved from full open to part open?
No → Go To 5
5 Disconnect the Full Open Switch connector. All

Yes → Go To 6
No → Repair the ground wire for an open.

6 Disconnect the Power Sliding Door C2 connector. All

Measure the resistance of the Full Open Switch circuit from the Power Sliding Door
Module C2 connector to the Full Open Switch connector on the lower drive unit.
Yes → Go To 7
No → Repair the Full Open Switch Sense wire for an open.

849
INCOMPLETE LATCH RELEASE - FULL OPEN SWITCH FAILURE —

Continued
7 Disconnect the Power Sliding Door C2 connector. All
Measure the resistance between ground and the Full Open Switch circuit.
Yes → Repair the Full Open Switch Sense wire for a short to ground.
No → Go To 8
Repair
Replace the Full Open Switch (Lower Drive Unit).
850
Symptom:

When Monitored: Whenever the PSD module is awake and performing a power opera-
tion.
Set Condition: When the release operation was not completed in 4 seconds and current
did not build up to the stall level, this code will set.
POSSIBLE CAUSES
CINCH/RELEASE MOTOR LATCH DRIVER CIRCUIT SHORT TO GROUND
LATCH ASSEMBLY

Measure the resistance between the Cinch/Release Motor Latch Driver circuit and
the Cinch/Release Motor Unlatch Driver circuit.
Yes → Go To 2
No → Go To 3

circuit.
Yes → Repair the Cinch/Release Motor Latch Driver circuit for a short to
ground. This could be the Cinch/Release Motor Latch Driver or
Unlatch Driver or the motor itself.
No → Replace the Power Sliding Door Module.

851

Yes → Go To 4


tor.
Yes → Go To 5

Repair
852
Symptom:

When Monitored: Whenever the power sliding door is operating in an opening direction.
Set Condition: The release operation was not completed in 4 seconds or a stall condition
was detected in the release operation. The pawl switch was grounded but the ratchet
switch remained open. This code will set only in the release operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER SLIDING DOOR MODULE - RATCHET CIRCUIT
GROUND WIRE OPEN
RATCHET SWITCH

second time out. This may make it difficult to reproduce
Does the DRBIIIt display INCOMPLETE LATCH RELEASE - RATCHET SWITCH
FAILURE?
Yes → Go To 2

tions.
Especially notice the effort needed to unlatch and close the door.
No → Go To 3
853
INCOMPLETE LATCH RELEASE - RATCHET SWITCH FAILURE —

Continued
DRB111t.
change.

No → Go To 4

Yes → Go To 5

ohmmeter.
Yes → Go To 6

Repair
854
Symptom:
INCOMPLETE LATCH RELEASE- NO REVERSE TO UNLOAD
CLUTCH
INCOMPLETE LATCH RELEASE- NO REVERSE TO UNLOAD CLUTCH

When Monitored: Whenever the power sliding door is operating.
neutral position.
POSSIBLE CAUSES
DTC PRESENT
BINDING LATCH
CINCH RELEASE MOTOR ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - NO REVERSE TO
UNLOAD CLUTCH?
Yes → Go To 2
No → Operate the door several times and check for any binding or other
obstructions. To test the reverse action, open the sliding door part
way and continue holding the handle for 4 seconds. The motor
should run for approximately 100ms.
2 Examine the sliding door for proper fit and alignment, loose/hard or torn seals or All
Manually operate the sliding door of a known good vehicle and notice the effort
needed to open and close.
Compare the effort needed on the disabled sliding door.
Especially notice the effort needed to unlatch and latch the door.
No → Replace the Cinch Release Motor Assembly..
855
Symptom:

Set Condition: The latch motor stall current of 6.2 amps was detected during a
non-redundant release. The main causes of this code setting is some type of blockage
during the release. This code is set during the power releasing operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
LATCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - OVER CURRENT?
Yes → Go To 2
tions.
2 Examine the door for proper fit and alignment, lose/ hard or torn seals, worn teeth on All
the rack and gear (lower drive unit) or anything that would cause an obstruction to
proper operation.
Yes → Refer to Service information for the related symptom(S).


856
Symptom:

Set Condition: The release operation was not completed in 4 seconds or the release
operation has detected a stall condition. The ratchet switch was detected as grounded but
the pawl remained open. This code is set during the power releasing operation from a fully
closed door.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER SLIDING DOOR MODULE - PAWL CIRCUIT
GROUND WIRE OPEN
PAWL SWITCH

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - PAWL SWITCH
FAILURE?
Yes → Go To 2

tions.
857
INCOMPLETE LATCH RELEASE- PAWL SWITCH FAILURE — Continued


No → Go To 3

change.
wiggling the wiring harness to check for an intermittent open.
No → Go To 4

Yes → Go To 5


Measure the resistance of the Pawl Switch Sense circuit between the PSD C2
connector and the Sliding Door Latch Sensing Switch connector.
Yes → Go To 6

Repair
858
Symptom:
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAIL-
URE
INCOMPLETE LATCH RELEASE- SECTOR GEAR RETURN FAILURE

When Monitored: Whenever the power sliding door is operating.
neutral position.
POSSIBLE CAUSES
DTC PRESENT
BINDING SLIDING DOOR
CINCH RELEASE MOTOR ASSEMBLY

Does the DRBIIIt display INCOMPLETE LATCH RELEASE - SECTOR GEAR
RETURN FAILURE?
Yes → Go To 2

tions.
2 Examine the sliding door for proper fit and alignment, loose/hard or torn seals or All
needed to open and close.
Compare the effort needed on the disabled sliding door.
No → Replace the Cinch Release Motor Assembly..
859
Symptom:

were counted since the start of the close operation.
POSSIBLE CAUSES
DTC PRESENT
STICKING CABLES OR SWITCH
FULL OPEN SWITCH

Does the DRBIIIt display INCOMPLETE POWER CLOSE - FULL OPEN SWITCH
FAILURE?
Yes → Go To 2

obstructions.
Switch.
Manually operate the door handle while monitoring the DRBIIIt.
Does the switch status change smoothly as the handle is pulled and released?
Yes → Go To 3

860
INCOMPLETE POWER CLOSE - FULL OPEN SWITCH FAILURE —

Continued
Open the Sliding Door to mid position.
While monitoring the DRBIIIt, wiggle the wiring harness from the Power Sliding
Door Module to the Full Open Switch on the lower drive unit.
No → Go To 4
Repair
Replace the Full Open Switch (lower drive unit).
861
Symptom:
INCOMPLETE POWER CLOSE - LATCH FAILURE
INCOMPLETE POWER CLOSE - LATCH FAILURE

Set Condition: The power close operation was not completed due to latch failure. This
DTC is set during a power close cycle.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER SLIDING DOOR MODULE - FULL OPEN CIRCUIT OPEN
POWER SLIDING DOOR MODULE - PAWL CIRCUIT OPEN
POWER SLIDING DOOR MODULE - RATCHET CIRCUIT OPEN
GROUND WIRE OPEN - FULL OPEN SWITCH
GROUND WIRE OPEN - PAWL SWITCH
GROUND WIRE OPEN - RATCHET SWITCH
FULL OPEN SWITCH SENSE WIRE OPEN
FULL OPEN SWITCH SENSE WIRE SHORT TO GROUND
FULL OPEN SWITCH
LATCH ASSEMBLY
LATCH ASSEMBLY
PAWL SWITCH
RATCHET SWITCH
862
INCOMPLETE POWER CLOSE - LATCH FAILURE — Continued

Yes → Go To 2

tions.
2 Examine the door for proper fit and alignment, lose/ hard or torn seals, worn teeth on All
the rack and gear (lower drive unit) or anything that would cause an obstruction to
proper operation.

No → Go To 3
switch state.
Move the door to the full open position. While observing the PAWL switch state, click
CLOSED to OPEN.
Move the door to the full open position. While observing the RATCHET switch state,
click the latch with a screwdriver to the second detent. The RATCHET should toggle
from CLOSED to OPEN.
FULL OPEN Switch
Go To 4
PAWL Switch
Go To 9
RATCHET Switch
Go To 13

Go To 17
863

Measure the resistance between the Ground circuit (cavity 20) and the Full Open
Open the sliding door completely then partially close it. Repeat this step while
observing the ohmmeter.
Did the resistance change from below 15 ohms to above 1000.0 ohms when the door
was moved.

No → Go To 5

Disconnect the Full open Switch Sense wire at the lower drive unit.
Measure the resistance of the Ground wires between the PSD C2 connector (cavity
20) and the Full Open Switch connector.
Yes → Go To 6


Measure the resistance of the Full Open Switch Sense wire between the PSD C2
connector and the Full Open Switch connector.
Yes → Go To 7

Measure the resistance between ground and the Full Open Switch Sense circuit.
No → Go To 8

Repair
864

Open the sliding door completely.
Using a screwdriver, close the latch to the first detent while observing the ohmmeter.
was closed.

No → Go To 10

Disconnect the Sliding Door Latch Sensing Switch connector.
Measure the resistance of the both Ground wires between the PSD C2 connector
Is the resistance below 5.0 ohms in both ground wires at the switch connector?
Yes → Go To 11


Yes → Go To 12
Repair

NOTE: The Sliding Door Ajar Switch Sense circuit is also the Ratchet
Switch Sense circuit on power doors.
Measure the resistance between the Ground circuit (cavity 20) and the Sliding Door
Ajar Switch Sense circuit.
ohmmeter.
was closed.

No → Go To 14
865

Measure the resistance of the both Ground wires between the PSD C2 connector
Is the resistance below 5.0 ohms in both ground wires at the switch connector?
Yes → Go To 15


Yes → Go To 16
Repair

Yes → Go To 18
No → Go To 19

circuit.
866

Yes → Go To 20


tor.
Yes → Go To 21

Repair
867
Symptom:

When Monitored: Anytime the power sliding door is in the closing cycle.
Set Condition: If the Power Sliding Door Module detects a missing hall effect signal for
longer than 300 ms. during a closing operation, this code will set. This is a redundant
safety feature in the software and will set if the obstacle detection feature becomes
inoperative due to a hall effect sensor or connection malfunction.
POSSIBLE CAUSES
DTC PRESENT
POWER SLIDING DOOR MODULE - HALL EFFECT OPEN
BINDING DOOR
DOOR MOTOR HALL EFFECT SUPPLY WIRE OPEN
DOOR MOTOR HALL EFFECT SUPPLY WIRE SHORT TO GROUND
DOOR MOTOR HALL EFFECT SIGNAL WIRE OPEN
DOOR MOTOR HALL EFFECT SIGNAL WIRE SHORT TO GROUND
DOOR MOTOR /CLUTCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE POWER CLOSE - MISSING HALL
SIGNAL?
Yes → Go To 2

868

Manually operate the sliding door on the other side or of a known good vehicle and
notice the effort needed to open and close.

No → Go To 3
3 Operate the door from the full open position and put an obstacle in its path to make All
it reverse.
Did the door reverse back to the open position?
Yes → Go To 4
4 Disconnect the Sliding Door Motor connector. All

Yes → Go To 5


Measure the resistance of the Door Motor Hall Effect Supply circuit between the
Sliding Door Motor connector and the PSD Module C2 connector.
Yes → Go To 6
No → Repair the Door Motor Hall Effect Supply wire for an open.

Measure the resistance between ground and the Door Motor Hall Effect Supply
circuit.
ground.
No → Go To 7
869

Measure the resistance of the Door Motor Hall Effect Signal circuit between the
Yes → Go To 8
No → Repair the Door Motor Hall Effect Signal wire for an open.

Measure the resistance between ground and the Door Motor Hall Effect Signal
circuit.
Yes → Repair the Door Motor Hall Effect Signal wire for a short to
ground.
No → Go To 9
Repair
Replace the Motor/Clutch Assembly (hall effect switch).
870
Symptom:
INCOMPLETE POWER CLOSE - OVERCURRENT
INCOMPLETE POWER CLOSE - OVERCURRENT

When Monitored: Anytime the Power Sliding Door is operating in the closing direction.
500 ms. during a close operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
GROUND CIRCUIT OPEN
SLIDING DOOR CLOSE DRIVER CIRCUIT SHORT TO GROUND
CINCH/RELEASE MOTOR UNLATCH DRIVER CIRCUIT SHORT TO GROUND
DOOR MOTOR CLUTCH DRIVER CIRCUIT SHORT TO GROUND
POWER SLIDING DOOR MOTOR/CLUTCH

Does the DRBIIIt display INCOMPLETE POWER CLOSE - OVERCURRENT?
Yes → Go To 2
Manually operate the other sliding door or one of a known good vehicle and notice the
effort needed.

No → Go To 3
871
INCOMPLETE POWER CLOSE - OVERCURRENT — Continued

Yes → Go To 4


Measure the resistance between ground and the Sliding Door Close Driver circuit.
Yes → Repair the Sliding Door Close Driver circuit for a short to ground.
No → Go To 5

Measure the resistance between ground and the Cinch/Release Motor Unlatch Driver
circuit.
Yes → Repair the Cinch/Release Motor Unlatch Driver circuit for a short
to ground.
No → Go To 6

Measure the resistance between ground and the Door Motor Clutch Driver circuit.
Yes → Repair the Door Motor Clutch Driver circuit for a short to ground.
No → Go To 7

Repair
Replace the Power Sliding Door Motor/Clutch assembly.
872
Symptom:

When Monitored: Anytime the Power Sliding Door is operating in the closing direction.
Set Condition: The power close operation was not completed within 20 seconds. This may
be caused by very high opening effort. A weak hall effect signal, low motor output or
defective clutch could also set this code.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
MOTOR/CLUTCH ASSEMBLY

Operate the power sliding door several times from stop to stop - if possible.
Does the DRBIIIt display INCOMPLETE POWER CLOSE - TIME-OUT?
Yes → Go To 2
tions.
Manually operate the sliding door of a known good vehicle or the other sliding door
and notice the effort needed.

No → Replace the Motor/Clutch Assembly.
873
Symptom:

When Monitored: Whenever the power sliding door is operating in the opening direction.
were counted since the start of the open operation.
POSSIBLE CAUSES
DTC PRESENT
STICKING CABLES OR SWITCH
FULL OPEN SWITCH SENSE CIRCUIT SHORT TO GROUND
FULL OPEN SWITCH

Does the DRBIIIt display INCOMPLETE POWER OPEN - FULL OPEN SWITCH
FAILURE?
Yes → Go To 2

obstructions.
Switch.
Manually operate the door handle while monitoring the DRBIIIt.
Does the switch status change smoothly as the handle is pulled and released?
Yes → Go To 3

874
INCOMPLETE POWER OPEN - FULL OPEN SWITCH FAILURE —

Continued
Open the Sliding Door to mid position.
While monitoring the DRBIIIt, wiggle the wiring harness from the Power Sliding
Door Module to the Full Open Switch on the lower drive unit.
No → Go To 4
Repair
875
Symptom:

When Monitored: Whenever the power sliding door is operating in the opening direction.
Set Condition: The power open operation was not completed due to latch failure. This
DTC is set during a power open cycle.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
POWER SLIDING DOOR MODULE - FULL OPEN CIRCUIT OPEN
POWER SLIDING DOOR MODULE - PAWL CIRCUIT OPEN
POWER SLIDING DOOR MODULE - RATCHET CIRCUIT OPEN
FULL OPEN SWITCH SENSE WIRE OPEN
FULL OPEN SWITCH SENSE WIRE SHORT TO GROUND
FULL OPEN SWITCH
LATCH ASSEMBLY
LATCH ASSEMBLY
PAWL SWITCH
RATCHET SWITCH

Yes → Go To 2
tions.
876


No → Go To 3
switch state.
Move the door to the full open position. While observing the PAWL switch state, click
CLOSED to OPEN.
Move the door to the full open position. While observing the RATCHET switch state,
click the latch with a screwdriver to the second detent. The RATCHET should toggle
from CLOSED to OPEN.
FULL OPEN Switch

Go To 4
PAWL Switch
Go To 8
RATCHET Switch
Go To 11

Go To 14

Open the sliding door completely then partially close it. Repeat this step while
observing the ohmmeter.
Did the resistance change from below 15 ohms to above 1000.0 ohms while moving
the door?

No → Go To 5

Measure the resistance of the Full Open Switch Sense wire between the PSD C2
connector and the Full Open Switch connector.
Yes → Go To 6
877

No → Go To 7
Repair

Using a screwdriver, close the latch to the first detent while observing the ohmmeter.
Did the resistance change from below 15 ohms to above 1000.0 ohms while moving
the door?

No → Go To 9

Yes → Go To 10
Repair

NOTE: The Sliding Door Ajar Switch Sense circuit is also the Ratchet
Switch Sense circuit on power doors.
Measure the resistance between ground and the Sliding Door Ajar Switch Sense
circuit.
ohmmeter.
changed states?
No → Go To 12
878

Yes → Go To 13
Repair

Yes → Go To 15
No → Go To 16

circuit.


Yes → Go To 17
879

tor.
Yes → Go To 18
Repair
880
Symptom:

When Monitored: Anytime the power sliding door is in the opening cycle.
Set Condition: If the Power Sliding Door Module detects a missing hall effect signal for
longer than 300 ms. during an opening operation, this code will set. This is a redundant
safety feature in the software and will set if the obstacle detection feature becomes
inoperative due to a hall effect sensor or connector malfunction.
POSSIBLE CAUSES
DTC PRESENT
POWER SLIDING DOOR MODULE - HALL EFFECT OPEN
BINDING DOOR
DOOR MOTOR HALL EFFECT SUPPLY WIRE OPEN
DOOR MOTOR HALL EFFECT SUPPLY WIRE SHORT TO GROUND
DOOR MOTOR HALL EFFECT SIGNAL WIRE OPEN
DOOR MOTOR HALL EFFECT SIGNAL WIRE SHORT TO GROUND
DOOR MOTOR /CLUTCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE POWER OPEN - MISSING HALL SIG-
NAL?
Yes → Go To 2

881

Manually operate the sliding door on the other side or of a known good vehicle and
notice the effort needed to open and close.

No → Go To 3
3 Operate the door from the full closed position and put an obstacle in it’s path to make All
it reverse.
Did the door reverse back to the closed position?
Yes → Go To 4

Yes → Go To 5


Measure the resistance of the Door Motor Hall Effect Supply circuit between the
Yes → Go To 6
No → Repair the Door Motor Hall Effect Supply wire for an open.

Measure the resistance between ground and the Door Motor Hall Effect Supply
circuit.
ground.
No → Go To 7
882

Measure the resistance of the Door Motor Hall Effect Signal circuit between the
Yes → Go To 8
No → Repair the Door Motor Hall Effect Signal wire for an open.

Measure the resistance between ground and the Door Motor Hall Effect Signal
circuit.
Yes → Repair the Door Motor Hall Effect Signal wire for a short to
ground.
No → Go To 9
Repair
Replace the Motor/Clutch Assembly (hall effect switch).
883
Symptom:

When Monitored: Anytime the Power Sliding Door is in a power open operation.
500 ms. during an open operation.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
GROUND CIRCUIT OPEN
SLIDING DOOR OPEN DRIVER CIRCUIT SHORT TO GROUND
CINCH/RELEASE MOTOR LATCH DRIVER CIRCUIT OPEN
DOOR MOTOR CLUTCH DRIVER CIRCUIT SHORT TO GROUND
POWER SLIDING DOOR MOTOR/CLUTCH

Does the DRBIIIt display INCOMPLETE POWER OPEN - OVERCURRENT?
Yes → Go To 2
needed.

No → Go To 3
884

Yes → Go To 4


Measure the resistance between ground and the Sliding Door Open Driver circuit.
Yes → Repair the Sliding Door Open Driver circuit for a short to ground.
No → Go To 5

Yes → Go To 6
No → Repair the Cinch/Release Motor Latch Driver circuit for an open.

circuit.
ground.
No → Go To 7

Measure the resistance between ground and the Door Motor Clutch Driver circuit.
Yes → Repair the Door Motor Clutch Driver circuit for a short to ground.
No → Go To 8
Repair
Replace the Power Sliding Door Motor/Clutch assembly.
885
Symptom:

When Monitored: Anytime the Power Sliding Door is operating in an opening operation.
Set Condition: The power open operation was not completed within 20 seconds. This may
be caused by very high opening effort. A weak hall effect signal, low motor output or
defective clutch could also set this code.
POSSIBLE CAUSES
DTC PRESENT
BINDING DOOR
MOTOR/CLUTCH ASSEMBLY

Does the DRBIIIt display INCOMPLETE POWER OPEN - TIME-OUT?
Yes → Go To 2
needed.

No → Replace the Motor/Clutch Assembly.
886
Symptom:
IOD WAKE UP OPEN - PSD
IOD WAKE UP OPEN - PSD

Set Condition: If the BCM does not sense a signal circuit from the Sliding Door Module
this code will set.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - IOD WAKE UP OPEN
SLIDING DOOR WAKE UP SIGNAL WIRE OPEN
SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO GROUND
SLIDING DOOR MODULE - IOD WAKE UP OPEN

Wait 10 seconds.
Does the DRBIIIt display IOD WAKE UP OPEN?
Yes → Go To 2

2 Disconnect the BCM C3 connector. All

Measure the voltage between the appropriate Sliding Door Wake Up Signal circuit
and ground.
No → Go To 3
887
IOD WAKE UP OPEN - PSD — Continued

Disconnect the appropriate Sliding Door Control Module C2 connector.
Measure the resistance of the appropriate Sliding Door Wake Up Signal circuit
between the BCM C3 connector and the Sliding Door Control Module C2 connector.
Yes → Go To 4
No → Repair the appropriate Sliding Door Wake Up Signal wire for an

open.

ground.
ground.
No → Go To 5
5 NOTE: If this vehicle is equipped with 2 power sliding doors, this test must All
be repeated for each door.
Disconnect the appropriate Sliding Door Control Module C2 connector.
Measure the resistance between the appropriate Sliding Door Wake Up Signal circuit
and ground.
Yes → Repair the appropriate Sliding Door Wake Up Signal wire for a
short to ground.
No → Go To 6
Repair
Replace the Sliding Door Module.
888
Symptom:
IOD WAKE UP PSD & PLG SHORT
IOD WAKE UP PSD & PLG SHORT

Set Condition: If the BCM senses an over current signal on any of the Wake Up Signal
circuits this code will set.
POSSIBLE CAUSES
DTC PRESENT
BODY CONTROL MODULE - IOD WAKE UP SHORT
LEFT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
LIFTGATE MODULE WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
RIGHT SLIDING DOOR WAKE UP SIGNAL WIRE SHORT TO VOLTAGE
LEFT SLIDING DOOR MODULE - IOD WAKE UP SHORT TO VOLTAGE
POWER LIFTGATE MODULE - IOD WAKE UP SHORT TO VOLTAGE
RIGHT SLIDING DOOR MODULE - IOD WAKE UP SHORT TO VOLTAGE

Turn the ignition off, wait 1 minute then turn the ignition on.
Wait 10 seconds.
Does the DRBIIIt display IOD WAKE UP SHORT?
Yes → Go To 2
2 Disconnect the BCM C2 and C3 connectors. All

Using a 12-volt test light connected to ground, check each Wake Up Signal circuit.
On which circuit did the test light illuminate?
Left Sliding Door Wake Up Signal.

Go To 3
Right Sliding Door Wake Up Signal.
Go To 4
Liftgate Module Wake Up Signal.

Go To 5
Did not illuminate.

889
IOD WAKE UP PSD & PLG SHORT — Continued

Measure the voltage between the Left Sliding Door Wake Up Signal circuit and
ground.
voltage.
No → Replace the Sliding Door Module.


Measure the voltage between the Right Sliding Door Wake Up Signal circuit and
ground.
voltage.
No → Replace the Sliding Door Module.

ground.
voltage.
890
Symptom:
LEFT B-PILLAR SWITCH INPUT OPEN
LEFT B-PILLAR SWITCH INPUT OPEN

When Monitored: Continuously when the BCM is awake.
Set Condition: When the BCM senses an input greater than 4.8 volts for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
LEFT SLIDING DOOR PILLAR SWITCH MUX CIRCUIT SHORT TO VOLTAGE
GROUND CIRCUIT OPEN
LEFT SLIDING DOOR PILLAR SWITCH MUX WIRE OPEN
LEFT B-PILLAR SWITCH OPEN
BODY CONTROL MODULE - LEFT SLIDING DOOR PILLAR SWITCH OPEN

Operate the left power sliding door from the Left B-Pillar Switch.
Does the DRBIIIt display LEFT B-PILLAR SWITCH INPUT OPEN?
Yes → Go To 2

Measure the voltage between Left Sliding Door Pillar Switch Mux circuit and ground.
Yes → Repair the Left Sliding Door Pillar Switch Mux circuit for a short
to voltage.
No → Go To 3

Measure the resistance between Left Sliding Door Pillar Switch Mux circuit and
ground.

No → Go To 4
891
LEFT B-PILLAR SWITCH INPUT OPEN — Continued

4 Disconnect the B-Pillar Switch connector. All
Using a 12-volt test light connected to 12-volts, check the Ground circuit in the
B-Pillar Switch connector.
Yes → Go To 5


Disconnect the Left B-Pillar Switch connector.
Measure the resistance of the Left Sliding Door Pillar Switch Mux circuit between
the BCM C3 connector and the Left B-Pillar Switch connector.
Yes → Go To 6
No → Repair the Left Sliding Door Pillar Switch Mux wire for an open.

Repair
Replace the B-Pillar Switch.
892
Symptom:
LEFT B-PILLAR SWITCH INPUT SHORT
LEFT B-PILLAR SWITCH INPUT SHORT

Set Condition: When the BCM senses a B-pillar switch input less than .24 volts for over
10 seconds.
POSSIBLE CAUSES
DTC PRESENT
LEFT B-PILLAR SWITCH SHORTED
LEFT SLIDING DOOR PILLAR SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - LEFT SLIDING DOOR PILLAR SWITCH CIRCUIT SHORTED

Does the DRBIIIt display LEFT B-PILLAR SWITCH INPUT SHORT?
Yes → Go To 2
2 Disconnect the Left B-Pillar Switch connector. All

Wait 10 seconds.
Yes → Replace the B-Pillar Switch.
No → Go To 3

Measure the resistance of the Left Sliding Door Pillar Switch Mux circuit to ground.
Yes → Repair the Left Sliding Door Pillar Switch Mux wire for a short to
ground.
893
Symptom:
LEFT B-PILLAR SWITCH INPUT STUCK
LEFT B-PILLAR SWITCH INPUT STUCK

Set Condition: When the BCM senses an active B-pillar switch input for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
LEFT B-PILLAR SWITCH SHORTED
LEFT SLIDING DOOR PILLAR SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - LEFT SLIDING DOOR PILLAR SWITCH CIRCUIT SHORTED

Does the DRBIIIt display LEFT B-PILLAR SWITCH INPUT STUCK?
Yes → Go To 2
2 Disconnect the Left B-Pillar Switch connector. All

Wait 10 seconds.
No → Go To 3

Measure the resistance of the Left Sliding Door Pillar Switch Mux circuit to ground.
Yes → Repair the Left Sliding Door Pillar Switch Mux wire for a short to
ground.
894
Symptom:

Set Condition: The Power Sliding Door Module did not receive its own transmitted
message on the PCI bus back (loopback) for longer than 1 second.
POSSIBLE CAUSES
DTC PRESENT

Does the DRBIIIt display LOOPBACK TEST FAILURE?

895
Symptom:

Set Condition: If the PSD Module losses communication with the BCM for over 5 seconds,
this code will set.
POSSIBLE CAUSES
POWER SLIDING DOOR MODULE - LOSS OF BCM MESSAGES

With the DRBIIIt, enter Body then Body Computer.
Was the DRBIIIt able to I/D or communicate with the BCM?
Yes → Go To 2

Did this DTC reset?
896
Symptom:

Set Condition: If the PSD Module does not receive a PRNDL message for over 5 seconds,
this code will set.
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE TRANSMISSION CONTROL MODULE
POWER SLIDING DOOR MODULE - LOSS OF EATX MESSAGES

With the DRBIIIt, select Transmission.
Yes → Go To 2

Did this DTC reset?
897
Symptom:

When Monitored: Whenever the ignition is in the RUN position and the PRNDL is not in
PARK position.
Set Condition: If the PSD Module does not receive a temperature message from the Front
POSSIBLE CAUSES
POWER SLIDING DOOR MODULE - LOSS OF FCM MESSAGES

With the DRBIIIt, enter Body then Front Control Module.
Was the DRBIIIt able to I/D or communicate with the FCM?
Yes → Go To 2

Did this DTC reset?

898
Symptom:

When Monitored: Whenever the ignition is in RUN position and the PRNDL is not in
PARK position.
Set Condition: If the PSD Module does not receive a speed message from the Powertrain
POSSIBLE CAUSES
ATTEMPT TO COMMUNICATE WITH THE POWERTRAIN CONTROL MODULE
POWER SLIDING DOOR MODULE - LOSS OF SBEC MESSAGES

With the DRBIIIt, select Engine.
Yes → Go To 2

Cycle the ignition switch from OFF to RUN and wait approximately 1 minute.
Did this DTC reset?

899
Symptom:
OVERHEAD LEFT SWITCH INPUT STUCK
OVERHEAD LEFT SWITCH INPUT STUCK

Set Condition: When the BCM senses an active switch input for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
OVERHEAD LEFT SWITCH SHORTED
SLIDING DOORS OVERHEAD SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - SLIDING DOORS OVERHEAD SWITCH CIRCUIT SHORTED

Operate the left power sliding door from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD LEFT SWITCH INPUT STUCK?
Yes → Go To 2
2 Disconnect the Overhead Console connector. All

Wait 10 seconds.
Does the DRBIIIt display OVERHEAD LEFT SWITCH INPUT STUCK?
Yes → Go To 3


Measure the resistance of the Sliding Doors Overhead Switch Mux circuit to ground.
Yes → Repair the Sliding Doors Overhead Switch Mux wire for a short to
ground.
900
Symptom:
OVERHEAD RIGHT SWITCH INPUT STUCK
OVERHEAD RIGHT SWITCH INPUT STUCK

POSSIBLE CAUSES
DTC PRESENT
OVERHEAD RIGHT SWITCH SHORTED
BODY CONTROL MODULE - SLIDING DOORS OVERHEAD SWITCH CIRCUIT SHORTED

Operate the right power sliding door from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD RIGHT SWITCH INPUT STUCK?
Yes → Go To 2
2 Disconnect the Overhead Console Switch connector. All

Wait 10 seconds.
Does the DRBIIIt display OVERHEAD RIGHT SWITCH INPUT STUCK?
Yes → Go To 3

ground.
901
Symptom:
OVERHEAD RIGHT/LEFT SWITCHES SHORT
OVERHEAD RIGHT/LEFT SWITCHES SHORT

Set Condition: When the BCM senses less than 1.0 volts on the Sliding Doors Overhead
Switch Mux circuit for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
OVERHEAD SWITCH SHORTED
BODY CONTROL MODULE - SLIDING DOORS OVERHEAD SWITCH INPUT SHORTED

Operate the power sliding door from the Overhead Console Switch.
Does the DRBIIIt display OVERHEAD RIGHT/LEFT SWITCHES SHORT?
Yes → Go To 2
2 Disconnect the Overhead Console Switch connector. All

Wait 10 seconds.
Does the DRBIIIt display OVERHEAD SWITCH #2 INPUT SHORT?
Yes → Go To 3

ground.
902
Symptom:
RIGHT B-PILLAR SWITCH INPUT OPEN
RIGHT B-PILLAR SWITCH INPUT OPEN

Set Condition: When the BCM senses an input greater than 4.8 volts for over 10 seconds.
POSSIBLE CAUSES
DTC PRESENT
RIGHT SLIDING DOOR PILLAR SWITCH MUX CIRCUIT SHORT TO VOLTAGE
GROUND CIRCUIT OPEN
RIGHT SLIDING DOOR PILLAR SWITCH MUX WIRE OPEN
RIGHT B-PILLAR SWITCH OPEN
BODY CONTROL MODULE - RIGHT SLIDING DOOR PILLAR SWITCH OPEN

Operate the right power sliding door from the Right B-Pillar Switch.
Does the DRBIIIt display RIGHT B-PILLAR SWITCH INPUT OPEN?
Yes → Go To 2

Measure the voltage between Right Sliding Door Pillar Switch Mux circuit and
ground.
Yes → Repair the Right Sliding Door Pillar Switch Mux circuit for a
short to voltage.
No → Go To 3
3 Disconnect the B-Pillar Switch connector. All

Using a 12-volt test light connected to 12-volts, check the Ground circuit in the
B-Pillar Switch connector.
Yes → Go To 4

903
RIGHT B-PILLAR SWITCH INPUT OPEN — Continued

Disconnect the Right B-Pillar Switch connector.
Measure the resistance of the Right Sliding Door Pillar Switch Mux circuit between
the BCM C3 connector and the Right B-Pillar Switch connector.
Yes → Go To 5
No → Repair the Right Sliding Door Pillar Switch Mux wire for an open.

Measure the resistance between Right Sliding Door Pillar Switch Mux circuit and
ground.

No → Go To 6

Repair
Replace the B-Pillar Switch.
904
Symptom:
RIGHT B-PILLAR SWITCH INPUT SHORT
RIGHT B-PILLAR SWITCH INPUT SHORT

Set Condition: When the BCM senses a switch input less than .24 volts for over 10
seconds.
POSSIBLE CAUSES
DTC PRESENT
RIGHT B-PILLAR SWITCH SHORTED
RIGHT SLIDING DOOR PILLAR SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - RIGHT SLIDING DOOR PILLAR SWITCH CIRCUIT SHORTED

Does the DRBIIIt display RIGHT B-PILLAR SWITCH INPUT SHORT?
Yes → Go To 2
2 Disconnect the Right B-Pillar Switch connector. All

Wait 10 seconds.
No → Go To 3

Measure the resistance of the Right Sliding Door Pillar Switch Mux circuit to ground.
Yes → Repair the Right Sliding Door Pillar Switch Mux wire for a short
to ground.
905
Symptom:
RIGHT B-PILLAR SWITCH INPUT STUCK
RIGHT B-PILLAR SWITCH INPUT STUCK

POSSIBLE CAUSES
DTC PRESENT
RIGHT B-PILLAR SWITCH SHORTED
RIGHT SLIDING DOOR PILLAR SWITCH MUX WIRE SHORT TO GROUND
BODY CONTROL MODULE - RIGHT SLIDING DOOR PILLAR SWITCH CIRCUIT SHORTED

Does the DRBIIIt display RIGHT B-PILLAR SWITCH INPUT STUCK?
Yes → Go To 2
2 Disconnect the Right B-Pillar Switch connector. All


No → Go To 3

Measure the resistance of the Right Sliding Door Pillar Switch Mux circuit to ground.
Yes → Repair the Right Sliding Door Pillar Switch Mux wire for a short
to ground.
906
Symptom:
*POWER SLIDING DOOR INOPERATIVE
POSSIBLE CAUSES
DTC’S PRESENT
MODULE RESPONSE
SYSTEM TESTS

1 With the DRBIIIt check for response from the Body Computer and the Power Sliding All
Door Modules
Is there response from both modules?
Yes → Go To 2
No → Refer to symptom list for problems related to COMMUNICA-

TION.
2 With the DRBIIIt, read DTCs in POWER SLIDING DOOR and BODY COMPUTER. All
Are any Power Sliding Door related codes present?
Yes → Refer to symptom list for problems related to POWER SLIDING
DOORS.
No → Go To 3
3 This test will determine what inhibited the Power Sliding Door from operating All
properly.
With the DRBIIIt, select POWER SLIDING DOOR, MISCELLANEOUS, LAST
INHIBIT MONITOR.
Does the DRBIIIt display any INHIBIT REASONS?
Yes → Check for any binding conditions or other restrictions that may
prevent proper operation. Using the wiring diagram/schematic as
a guide, inspect the wiring and connectors.
No → Go To 4
4 Ensure the sliding door is fully closed before proceeding. All

With the DRBIIIt select SYSTEM TEST.
Perform the Open, Close, Latch Cinch, Latch Release and Relay tests.
Did any test fail?
Yes → Using the wiring diagram/schematic as a guide, inspect the

907
Symptom:
FOLD MIRROR OUTPUT FAILURE
POSSIBLE CAUSES
LEFT POWER MIRROR
RIGHT POWER MIRROR
LEFT FOLDING MIRROR UNFOLD DRIVER SHORT TO VOLTAGE
RIGHT FOLDING MIRROR UNFOLD DRIVER SHORT TO VOLTAGE
LEFT FOLDING MIRROR UNFOLD DRIVER SHORT TO GROUND
RIGHT FOLDING MIRROR UNFOLD DRIVER SHORT TO GROUND
BODY CONTROL MODULE

NOTE: Doors must be closed to allow the mirrors to fold with the power folding
mirror switch.
Attempt to operate the power folding mirror system with the power folding mirror
switch and by opening and closing both front doors with mirrors folded.
Does the same DTC reset?
Yes → Go To 2
2 Disconnect the Left Power Mirror connector. All

With the DRBIIIt, erase DTC’s.
Operate the Power Folding Mirror switch.
Yes → Go To 3
No → Replace the Left Power Mirror.

3 Disconnect the Right Power Mirror connector. All

Yes → Go To 4
No → Replace the Right Power Mirror.

908
FOLD MIRROR OUTPUT FAILURE — Continued

4 Disconnect the Left and Right Power Mirror connectors. All
Measure for unwanted voltage on the Left Folding Mirror Unfold Driver circuit in the
BCM C2 connector.
Yes → Repair the Left Folding Mirror Unfold Driver circuit for a short to
voltage.
No → Go To 5

Measure for unwanted voltage on the Right Folding Mirror Unfold Driver circuit in
the relay connector.
Yes → Repair the Right Folding Mirror Unfold Driver circuit for a short
to voltage.
No → Go To 6

Measure the resistance between ground and the Left Folding Mirror Unfold Driver
circuit in the BCM C2 connector.
Yes → Repair the Left Folding Mirror Unfold Driver circuit for a short to
ground.
No → Go To 7

Measure the resistance between ground and the Right Folding Mirror Unfold Driver
circuit in the relay connector.
Yes → Repair the Right Folding Mirror Unfold Driver circuit for a short
to ground.
909
Symptom:
PASSENGER MIRROR RELAY OUTPUT OPEN
POSSIBLE CAUSES
PASSENGER FOLDING MIRROR RELAY
PASSENGER FOLDING MIRROR RELAY CONTROL CIRCUIT SHORTED TO GROUND
PASSENGER FOLDING MIRROR RELAY CONTROL CIRCUIT OPEN
BODY CONTROL MODULE

mirror switch.
Yes → Go To 2
2 Disconnect the Passenger Folding Mirror Relay connector. All

Using a 12-volt test light connected to ground, check the Fused B+ circuit in the relay
connector.
The test light must illuminate brightly. Compare the brightness to that of a direct
connection to the battery.
Yes → Go To 3

3 Remove the Passenger Folding Mirror Relay. All

Install a substitute relay in place of the Passenger Folding Mirror Relay.
mirror switch.
Yes → Go To 4
No → Replace the Passenger Folding Mirror Relay.
910
PASSENGER MIRROR RELAY OUTPUT OPEN — Continued

Measure the resistance between ground and the Passenger Folding Mirror Relay
Control circuit in the relay connector.
Yes → Repair the Passenger Folding Mirror Relay Control circuit for a
short to ground.
No → Go To 5

Measure the resistance of the Passenger Folding Mirror Relay Control circuit
between the relay connector and the BCM C4 connector.
No → Repair the Passenger Folding Mirror Relay Control circuit for an
open.
911
Symptom:
PASSENGER MIRROR RELAY OUTPUT SHORT
POSSIBLE CAUSES
PASSENGER FOLDING MIRROR RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
BODY CONTROL MODULE

mirror switch.
Yes → Go To 2
2 Remove the Passenger Folding Mirror Relay. All

Install a substitute relay in place of the Passenger Folding Mirror Relay.
mirror switch.
Yes → Go To 3


Measure the voltage of the Passenger Folding Mirror Relay Control circuit in the
relay connector.
Yes → Repair the Passenger Folding Mirror Relay Control circuit for a
short to voltage.
912
Symptom:
UNFOLD MIRROR OUTPUT FAILURE
POSSIBLE CAUSES
LEFT POWER MIRROR
RIGHT POWER MIRROR
DRIVER FOLDING MIRROR FOLD DRIVER SHORT TO VOLTAGE
PASSENGER FOLDING MIRROR RELAY OUTPUT SHORT TO VOLTAGE
PASSENGER FOLDING MIRROR RELAY INPUT SHORT TO VOLTAGE
DRIVER FOLDING MIRROR FOLD DRIVER SHORT TO GROUND
PASSENGER FOLDING MIRROR RELAY OUTPUT SHORT TO GROUND
PASSENGER FOLDING MIRROR RELAY INPUT SHORT TO GROUND
BODY CONTROL MODULE

mirror switch.
Yes → Go To 2
2 Install a substitute relay in place of the Passenger Folding Mirror Relay. All
mirror switch.
Yes → Go To 3

913
UNFOLD MIRROR OUTPUT FAILURE — Continued

3 Disconnect the Left Power Mirror connector. All
Yes → Go To 4
No → Replace the Left Power Mirror.

4 Disconnect the Right Power Mirror connector. All

Yes → Go To 5
No → Replace the Right Power Mirror.


Measure for unwanted voltage on the Driver Folding Mirror Fold Driver circuit in the
BCM C2 connector.
Yes → Repair the Driver Folding Mirror Fold Driver circuit for a short to
voltage.
No → Go To 6

Disconnect the Passenger Folding Mirror Relay.
Measure for unwanted voltage on the Passenger Folding Mirror Relay Output circuit
in the relay connector.
Yes → Repair the Passenger Folding Mirror Relay Output circuit for a
short to voltage.
No → Go To 7

Measure for unwanted voltage on the Passenger Folding Mirror Relay Input circuit
in the relay connector.
Yes → Repair the Passenger Folding Mirror Relay Input circuit for a
short to voltage.
No → Go To 8
914
UNFOLD MIRROR OUTPUT FAILURE — Continued

Measure the resistance between ground and the Driver Folding Mirror Fold Driver
circuit in the BCM C2 connector.
Yes → Repair the Driver Folding Mirror Fold Driver circuit for a short to
ground.
No → Go To 9

Output circuit in the relay connector.
Yes → Repair the Passenger Folding Mirror Relay Output circuit for a
short to ground.
No → Go To 10

Input circuit in the relay connector.
Yes → Repair the Passenger Folding Mirror Relay Input circuit for a
short to ground.

915
Symptom:
*BOTH MIRRORS DO NOT UNFOLD EXCEPT WITH EITHER
FRONT DOOR
POSSIBLE CAUSES
RELATED DIAGNOSTIC TROUBLE CODES
POWER FOLDING MIRROR SWITCH
FOLDING MIRROR SWITCH SIGNAL SHORT TO GROUND
BODY CONTROL MODULE

1 With the DRBIIIt, read DTCs. All
Does the DRBIIIt display any related DTC’s?
Yes → Refer to symptom list for problems related to Power Folding
Mirrors.
No → Go To 2
2 Disconnect the Power Folding Mirror Switch connector. All

Did the mirrors unfold?
Yes → Replace the Power Folding Mirror Switch.

No → Go To 3

Measure the resistance of the Folding Mirror Switch Signal circuit at the Power
Folding Mirror Switch connector to ground.
Yes → Repair the Folding Mirror Switch Signal circuit for a short to
ground.
916
Symptom:
*BOTH POWER FOLDING MIRRORS DO NOT FOLD
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
POWER FOLDING MIRROR SWITCH
FOLDING MIRROR SWITCH SIGNAL OPEN
BODY CONTROL MODULE

Mirrors.
No → Go To 2
2 Disconnect the Power Folding Mirror switch connector All

Measure the resistance of the ground circuit.
Yes → Go To 3

With the DRBIIIt in Inputs/Outputs, read the Foldaway Switch state.
Connect a jumper wire between the Folding Mirror Switch Signal circuit and ground.
Does the DRBIIIt display change?
Yes → Replace the Power Folding Mirror Switch.
No → Go To 4

Measure the resistance of the Folding Mirror Switch Signal circuit between the BCM
C4 connector and the Power Folding Mirror Switch connector.
No → Repair the Folding Mirror Switch Signal circuit for an open.

917
Symptom:
*DRIVER FOLDING MIRROR DOES NOT FOLD
POSSIBLE CAUSES
POWER MIRROR
FOLDING MIRROR UNFOLD DRIVER CIRCUIT OPEN
DRIVER FOLDING MIRROR FOLD DRIVER CIRCUIT OPEN
BODY CONTROL MODULE

1 With the DRBIIIt, read Body Computer DTCs. All
Mirrors.
No → Go To 2
2 Disconnect the inoperative Power Mirror connector. All

Connect one lead of a test light to the Passenger Folding Mirror Relay Output circuit
and the other lead to the appropriate Folding Mirror Unfold Driver in the power
mirror harness connector.
With the DRBIIIt, actuate the Folding Mirrors.
Yes → Replace the appropriate Power Mirror.
No → Go To 3

Measure the appropriate Folding Mirror Unfold Driver circuit from the BCM C2
connector to the power mirror harness connector.
Yes → Go To 4
No → Repair the appropriate Folding Mirror Unfold Driver circuit for

an open.
918
*DRIVER FOLDING MIRROR DOES NOT FOLD — Continued

Measure the Driver Folding Mirror Fold Driver circuit from the BCM C2 connector
to the mirror harness connector.
No → Repair the Driver Folding Mirror Fold Driver circuit for an open.
919
Symptom:
*PASSENGER FOLDING MIRROR DOES NOT FOLD
POSSIBLE CAUSES
POWER MIRROR
FOLDING MIRROR UNFOLD DRIVER CIRCUIT OPEN
PASSENGER FOLDING MIRROR RELAY OUTPUT CIRCUIT OPEN
PASSENGER FOLDING MIRROR RELAY INPUT CIRCUIT OPEN
BODY CONTROL MODULE

1 With the DRBIIIt, read Body Computer DTCs. All
Mirrors.
No → Go To 2
2 Disconnect the Passenger Folding Mirror Relay. All

Connect a substitute relay in place of the Passenger Folding Mirror Relay.
mirror switch.
Does the system now operate properly?
Yes → Replace the Passenger Folding Mirror Relay.

No → Go To 3
3 Connect Passenger Folding Mirror Relay if disconnected in previous step. All

Disconnect the inoperative Power Mirror connector.
Connect one lead of a test light to the Passenger Folding Mirror Relay Output circuit
and the other lead to the appropriate Folding Mirror Unfold Driver in the power
mirror harness connector.
With the DRBIIIt, actuate the Folding Mirrors.
Yes → Replace the appropriate Power Mirror.

No → Go To 4
920
*PASSENGER FOLDING MIRROR DOES NOT FOLD — Continued

Measure the appropriate Folding Mirror Unfold Driver circuit from the BCM C2
connector to the power mirror harness connector.
Yes → Go To 5
No → Repair the appropriate Folding Mirror Unfold Driver circuit for

an open.

Measure the Passenger Folding Mirror Relay Output circuit from the relay connector
to the mirror harness connector.
Yes → Go To 6
No → Repair the Passenger Folding Mirror Relay Output circuit for an

open.

Measure the Passenger Folding Mirror Relay Input circuit from the relay connector
to the BCM C2 connector.
No → Repair the Passenger Folding Mirror Relay Input circuit for an
open.
921
Symptom:
BCM MESSAGES NOT RECEIVED
BCM MESSAGES NOT RECEIVED

Set Condition: The RKE/Thatcham Alarm Module does not receive any messages from
the BCM for at least 5 seconds.
POSSIBLE CAUSES
BCM COMMUNICATION FAILURE
RKE/THATCHAM ALARM MODULE - INTERNAL MALFUNCTION

With the DRBIIIt, attempt to communicate with the BCM.
Was the DRBIIIt able to communicate with the BCM?
Yes → Go To 2
No → Refer to the Communication category and perform the appropri-

ate symptom.
Perform VTSS VERIFICATION TEST - 1A.

With the DRBIIIt, attempt to communicate with the RKE/Thatcham Alarm Module.
Was the DRBIIIt able to communicate with the RKE/Thatcham Alarm Module?
condition.
No → Go To 3

Disconnect the RKE/Thatcham Alarm Module C1 harness connector.
NOTE: Do not connect the tester to the DRBIIIt.
tester and the RKE/Thatcham Alarm Module C1 connector (cavity 13).
Yes → Replace the RKE/Thatcham Alarm Module.

922
Symptom:
HORN INPUT STUCK
HORN INPUT STUCK

Set Condition: The FCM has detected a fault in the Horn Switch Sense circuit.
POSSIBLE CAUSES
HORN SWITCH SENSE CIRCUIT SHORTED TO GROUND

Does the DRBIIIt display: HORN INPUT STUCK?
Yes → Go To 2
condition.

Measure the resistance between ground and the Horn Switch Sense circuit at the
Yes → Go To 3


Disconnect connector C7 on the Fuse and Relay Center.
Measure the resistance between ground and the Horn Switch Sense circuit at the
Fuse and Relay Center C7 connector.
Yes → Repair the Horn Switch Sense circuit for a short to ground.
923
Symptom:
HORN RELAY OPEN
HORN RELAY OPEN

Set Condition: The FCM has detected an open in the Horn Relay Control circuit.
POSSIBLE CAUSES
HORN RELAY

Does the DRBIIIt display: HORN RELAY OPEN?
Yes → Go To 2
condition.

Measure the voltage of the Horn Relay Control circuit at the Fuse and Relay Center
side of the FCM connector.
No → Go To 3

Disconnect the Horn Relay from the Fuse and Relay Center.
Measure the resistance of the Horn Relay Control circuit between the FCM connector
cavity 10 and the Horn Relay connector cavity 85.
Yes → Replace the Horn Relay.

924
Symptom:
HORN RELAY SHORTED TO BATTERY
HORN RELAY SHORTED TO BATTERY

Set Condition: The FCM has detected a short to battery in the Horn Relay Control circuit.
POSSIBLE CAUSES
HORN RELAY

Does the DRBIIIt display: HORN RELAY SHORTED TO BATTERY?
Yes → Go To 2
condition.

Substitute the original Horn Relay with a known good relay.
Attempt to operate the horn.
Does the DRBIIIt display: HORN RELAY SHORTED TO BATTERY?
Yes → Go To 3
No → Replace the Horn Relay.
925
HORN RELAY SHORTED TO BATTERY — Continued

Measure the voltage of the Horn Relay Control circuit at the Fuse and Relay Center
side of the FCM connector.

926
Symptom:
INTERNAL EEPROM WRITE ERROR
INTERNAL EEPROM WRITE ERROR

When Monitored: During a EEPROM write event.
Set Condition: If the EEPROM write time exceeds 16ms.
POSSIBLE CAUSES

With the DRBIIIt, erase the current RKE/Thatcham Alarm Module DTC’s.
With the DRBIIIt, read the current RKE/Thatcham Alarm Module DTC’s.
Does the DRBIIIt display: INTERNAL EEPROM WRITE ERROR?

condition.
927
Symptom:
INTERNAL TRANSMIT FAILURE
INTERNAL TRANSMIT FAILURE

When Monitored: Continuously with the ignition on during a message transmission.
Set Condition: After 8 internal attempts to transmit the RKE/Thatcham Alarm Module
Bus messages.
POSSIBLE CAUSES

Does the DRBIIIt display: INTERNAL TRANSMIT FAILURE?

condition.
928
Symptom:
INTERNAL ULTRASONIC FAULT
INTERNAL ULTRASONIC FAULT

When Monitored: During the initial 6 seconds of an ignition on cycle.
Set Condition: After 5 consecutive ignition cycles without detecting any ultrasonic
movement.
POSSIBLE CAUSES
FRONT INTRUSION SENSOR
FRONT INTRUSION SENSOR
FRONT INTRUSION SENSOR SIGNAL CIRCUIT OPEN
FRONT INTRUSION SENSOR SIGNAL CIRCUIT OPEN
FRONT SENSOR GROUND CIRCUIT OPEN
FRONT SENSOR GROUND CIRCUIT OPEN
INTRUSION SENSOR DETECTION
REAR INTRUSION SENSOR
REAR INTRUSION SENSOR
REAR INTRUSION SENSOR SIGNAL CIRCUIT OPEN
REAR INTRUSION SENSOR SIGNAL CIRCUIT OPEN
REAR SENSOR GROUND CIRCUIT OPEN
REAR SENSOR GROUND CIRCUIT OPEN
929
INTERNAL ULTRASONIC FAULT — Continued

Cycle the ignition on and off 5 times.
Does the DRBIIIt display: INTERNAL ULTRASONIC FAULT?
Yes → Go To 2
No → Go To 12

Disconnect the Front Intrusion Sensor connector.
Connect a voltmeter to the Front Intrusion Sensor Signal circuit at the Intrusion
Sensor connector.
Turn the ignition on while observing the voltmeter.
NOTE: Voltage will only be present during the first 6 seconds when the
ignition is turned on.
Is the voltage above 10.0 volts when the ignition is initially turned on?
Yes → Go To 3
No → Go To 11

Measure the resistance of the Sensor Ground circuit at the Front Intrusion Sensor
connector.
Yes → Go To 4
No → Go To 10
4 Replace the Front Intrusion Sensor with a known good sensor. All
With the DRBIIIt, monitor the Intrusion Sensor.
Does the DRBIIIt show: INTRUSION DETECTED?
Yes → Replace the Front Intrusion Sensor.

No → Go To 5

Disconnect the Rear Intrusion Sensor connector.
Connect a voltmeter to the Rear Intrusion Sensor Signal circuit at the Intrusion
Sensor connector.
Yes → Go To 6
No → Go To 9
930

Measure the resistance of the Sensor Ground circuit at the Rear Intrusion Sensor
connector.
Yes → Go To 7
No → Go To 8
7 Replace the Rear Intrusion Sensor with a known good sensor. All
Does the DRBIIIt show INTRUSION DETECTED?
Yes → Replace the Rear Intrusion Sensor.

No → Replace the RKE/Thatcham Alarm Module.

8 Gain access to the RKE/Thatcham Alarm Module. All

Disconnect the RKE/Thatcham Alarm Module C1 connector.
Measure the resistance of the Sensor Ground circuit between the RKE/Thatcham
Alarm Module C1 connector and the Intrusion Sensor connector.
No → Repair the Rear Sensor Ground circuit for an open.

Gain access to the RKE/Thatcham Alarm Module C1 connector.
While back probing, measure the voltage of the Rear Intrusion Sensor Signal circuit.
Yes → Repair the Rear Intrusion Sensor Signal circuit for an open.



No → Repair the Front Sensor Ground circuit for an open.

931

While back probing, measure the voltage of the Front Intrusion Sensor Signal circuit.
Yes → Repair the Front Intrusion Sensor Signal circuit for an open.

NOTE: The Intrusion Sensors will only detect movement during initial
ignition on.
Does the DRBIIIt show INTRUSION DETECTED when the ignition is initially
turned on?
condition.
No → Go To 13

Disconnect the Front Intrusion Sensor connector.
Connect a voltmeter to the Front Intrusion Sensor Signal circuit at the Intrusion
Sensor connector.
Yes → Go To 14
No → Go To 22

Measure the resistance of the Sensor Ground circuit at the Front Intrusion Sensor
connector.
Yes → Go To 15
No → Go To 21
15 Replace the Intrusion Sensor with a known good sensor. All

Yes → Replace the Front Intrusion Sensor.

No → Go To 16
932

Disconnect the Rear Intrusion Sensor connector.
Connect a voltmeter to the Rear Intrusion Sensor Signal circuit at the Intrusion
Sensor connector.
Yes → Go To 17
No → Go To 20

Measure the resistance of the Sensor Ground circuit at the Rear Intrusion Sensor
connector.
Yes → Go To 18
No → Go To 19
18 Replace the Rear Intrusion Sensor with a known good sensor. All
Yes → Replace the Rear Intrusion Sensor.


No → Repair the Rear Sensor Ground circuit for an open.

While back probing, measure the voltage of the Rear Intrusion Sensor Signal circuit.
Yes → Repair the Rear Intrusion Sensor Signal circuit for an open.

933

No → Repair the Front Sensor Ground circuit for an open.


While back probing, measure the voltage of the Front Intrusion Sensor Signal circuit.
Yes → Repair the Front Intrusion Sensor Signal circuit for an open.
934
Symptom:
LOOPBACK ERROR
LOOPBACK ERROR
When Monitored: During power up, following detection of any other Bus errors.
Set Condition: Internally transmitted message on the PCI Bus is not received correctly.
POSSIBLE CAUSES

Does the DRBIIIt display: LOOPBACK ERROR?

condition.
935
Symptom:
NO VALID MESSAGES RECEIVED
NO VALID MESSAGES RECEIVED

Set Condition: The RKE/Thatcham Alarm Module does not receive any valid messages on
the PCI Bus for a minimum of 5 seconds.
POSSIBLE CAUSES

Does the DRBIIIt display: NO VALID MESSAGES RECEIVED?

condition.
936
Symptom:
PCI BUS SHORTED TO BATTERY
PCI BUS SHORTED TO BATTERY

Set Condition: The RKE/Thatcham Alarm Module has detected a short to battery voltage
on the PCI Bus.
POSSIBLE CAUSES
PCI BUS MALFUNCTION

1 NOTE: If this code is set and active it will be necessary to perform the PCI All

broken wires.
937
Symptom:
PCI BUS SHORTED TO GROUND
PCI BUS SHORTED TO GROUND

Set Condition: The RKE/Thatcham Alarm Module has detected a short to ground on the
PCI Bus.
POSSIBLE CAUSES
PCI BUS MALFUNCTION

1 NOTE: If this code is set and active it will be necessary to perform the PCI All

broken wires.
938
Symptom:

Set Condition: The RKE/Thatcham Alarm Module does not receive any messages from
the PCM for at least 5 seconds.
POSSIBLE CAUSES
PCM COMMUNICATION FAILURE

With the DRBIIIt, attempt to communicate with the PCM.
Was the DRBIIIt able to communicate with the PCM?
Yes → Go To 2
No → Refer to the Communication category and perform the appropri-

ate symptom.

With the DRBIIIt, attempt to communicate with the RKE/Thatcham Alarm Module.
Was the DRBIIIt able to communicate with the RKE/Thatcham Alarm Module?
condition.
No → Go To 3

NOTE: Do not connect the tester to the DRBIIIt.
tester and the RKE/Thatcham Alarm Module C1 connector (cavity 13).

939
Symptom:
VEHICLE THEFT ALARM INDICATOR OUTPUT OPEN
VEHICLE THEFT ALARM INDICATOR OUTPUT OPEN

Set Condition: The BCM has detected an open in the VTSS Indicator Driver circuit.
POSSIBLE CAUSES
VTA LAMP FUNCTIONAL TEST
VTSS INDICATOR DRIVER CIRCUIT OPEN

With the DRBIIIt, erase the current Body Control Module DTC’s.
With the DRBIIIt, read the current Body Control Module DTC’s.
Does the DRBIIIt display: VTA INDICATOR OUTPUT OPEN?
Yes → Go To 2
condition.
2 With the DRBIIIt, actuate the VTA Indicator Lamp. All

Did the VTA Lamp flash on and off during the actuation?

No → Go To 3
3 Disconnect the Message Center harness connector. All

Measure the resistance of the VTSS Indicator Driver circuit.

No → Repair the VTSS Indicator Driver circuit for an open.

940
Symptom:
VEHICLE THEFT ALARM INDICATOR OUTPUT SHORT
VEHICLE THEFT ALARM INDICATOR OUTPUT SHORT

Set Condition: The BCM has detected a short to ground in the VTSS Indicator Driver
circuit.
POSSIBLE CAUSES
MESSAGE CENTER INTERNAL MALFUNCTION
VTSS INDICATOR DRIVER CIRCUIT SHORTED TO GROUND

With the DRBIIIt, erase the current Body Control Module DTC’s.
With the DRBIIIt, read the current Body Control Module DTC’s.
Does the DRBIIIt display: VTA INDICATOR OUTPUT OPEN?
Yes → Go To 2
condition.

Measure the resistance between ground and the VTSS Indicator Driver circuit.
Yes → Go To 3


Disconnect the Message Center connector.
Measure the resistance of the VTSS Indicator Driver circuit to ground.
Yes → Repair the VTSS Indicator Driver circuit for a short to ground.
No → Replace the Message Center assembly.

941
Symptom:
*ALARM TRIPS ON ITS OWN
POSSIBLE CAUSES
ALARM TRIPPED BY

1 With the DRBIIIt, read the Alarm Tripped By status. All
Were there any causes displayed?
Yes → Refer to Symptom List for problems related to the component

indicated by the DRBIIIt.
broken wires.
942
Symptom:
*HOOD DOES NOT TRIP VTSS
POSSIBLE CAUSES
CHECK DRBIIIt FOR HOOD AJAR SWITCH RESPONSE
BODY CONTROL MODULE

1 With the DRBIIIt, read the HOOD AJAR SW status. All
Open the hood.

No → Refer to symptom HOOD AJAR CKT OPEN in the DOOR AJAR
category.
943
Symptom:
*LEFT FRONT DOOR DOES NOT TRIP VTSS
POSSIBLE CAUSES
BODY CONTROL MODULE
CHECK DRBIIIt FOR DRIVER DOOR AJAR RESPONSE

1 With the DRBIIIt, read the DRVR DOOR AJAR SW status. All
Open the driver door.

No → Refer to symptom DRIVER DOOR AJAR CKT OPEN in the
DOOR AJAR category.
944
Symptom:
*LEFT SLIDING DOOR DOES NOT TRIP VTSS
POSSIBLE CAUSES
MONITOR DRBIIIt FOR LEFT SLIDING DOOR AJAR STATUS
BODY CONTROL MODULE

1 With the DRBIIIt, read the LSLIDE DR AJAR SW status. All
Open the left sliding door.
Does the DRBIIIt display the switch state as CLOSED?

No → Refer to symptom LEFT SLIDING DOOR AJAR CKT OPEN in
the DOOR AJAR category.
945
Symptom:
*LIFTGATE DOES NOT TRIP VTSS
POSSIBLE CAUSES
CHECK DRBIIIt FOR LIFTGATE SW RESPONSE
BODY CONTROL MODULE

1 With the DRBIIIt, read the LIFTGATE AJAR SW status. All
Open the liftgate.

No → Refer to symptom LIFTGATE AJAR CKT OPEN in the DOOR
AJAR category.
946
Symptom:
*REPEATER LAMPS INOPERATIVE WITH ALARM
POSSIBLE CAUSES
HAZARD SWITCH SENSE CIRCUIT OPEN
REPEATER LAMPS INOPERATIVE
HAZARD SWITCH SENSE CIRCUIT OPEN

1 With the DRBIIIt, actuate the Hazard Lamps. All
Do the Hazard Lamps light while actuating?
Yes → Go To 2
No → Refer to the appropriate Service Information to repair the Hazard
Lamps.
2 Turn the hazard lamp switch on. All

Do the Hazard Lamps operate?
Yes → Go To 3
No → Repair the Hazard Switch Sense circuit for an open between the
BCM and the splice.

Connect a jumper wire between cavity 15 of the RKE/Thatcham Alarm Module C1
Do the hazard lamps light with the jumper wire connected?
No → Repair the Hazard Switch Sense circuit for an open between the
RKE/Thatcham Alarm Module and the splice.
947
Symptom:
*RIGHT FRONT DOOR DOES NOT TRIP VTSS
POSSIBLE CAUSES
CHECK DRBIIIt FOR PASSENGER DOOR AJAR RESPONSE
BODY CONTROL MODULE

1 With the DRBIIIt, read the PASS DOOR AJAR SW status. All
Open the passenger door.

No → Refer to symptom PASSENGER DOOR AJAR CKT OPEN in the
DOOR AJAR category.
948
Symptom:
*RIGHT SLIDING DOOR DOES NOT TRIP VTSS
POSSIBLE CAUSES
CHECK DRBIIIt FOR RIGHT REAR DOOR AJAR RESPONSE
BODY CONTROL MODULE

1 With the DRBIIIt, read the RSLIDE DR AJAR SW status. All
Open the right sliding door.

No → Refer to symptom RIGHT SLIDING DOOR AJAR CKT OPEN in
the DOOR AJAR category.
949
Symptom:
*VTSS INDICATOR INOPERATIVE
POSSIBLE CAUSES
OPEN VTSS INDICATOR FUSED B(+) SUPPLY
OPEN VTSS LED

Measure the voltage of the Fused B+ circuit.
Yes → Go To 2
No → Repair the Fused B(+) (Hazard) circuit for an open.


With a 12-volt test light connected to 12-volts, connect the test light probe to the
VTSS Indicator Driver circuit.
With the DRBIIIt in Vehicle Theft, actuate the VTSS Indicator lamp.
Does the test light illuminate when the VTSS Indicator lamp is actuated?
Yes → Replace the Message Center assembly.
No → Go To 3

950
Symptom:
*VTSS INDICATOR LAMP INOPERATIVE
POSSIBLE CAUSES
VTSS INDICATOR SUPPLY CIRCUIT OPEN
OPEN VTSS LED

1 With the DRBIIIt, actuate the VTSS INDICATOR LAMP. All
Does the VTSS Indicator Lamp flash while actuating.
No → Go To 2
2 Disconnect the VTSS Indicator Lamp harness connector. All

Measure the voltage of the VTSS Indicator Supply circuit.
Yes → Go To 3
No → Repair the VTSS Indicator Supply circuit for an open.


With a 12-volt test light connected to 12-volts, connect the test light probe to the
VTSS Indicator Driver circuit.
With the DRBIIIt in Vehicle Theft, actuate the VTSS Indicator lamp.
Does the test light illuminate when the VTSS Indicator lamp is actuated?
Yes → Replace the VTSS Indicator LED Lamp.
No → Go To 4


951
Symptom:
*VTSS SIREN INOP
POSSIBLE CAUSES
SIREN SIGNAL CONTROL CIRCUIT OPEN
SIREN SIGNAL RETURN CIRCUIT OPEN
SIREN SUPPLY CIRCUIT OPEN
VTSS SIREN
RKE/THATCHAM ALARM MODULE - INTERNAL MALFUNCTON
VTSS SIREN - INTERNAL MALFUNCTION

1 With the DRBIIIt, actuate the VTSS Siren. All
Does the Siren sound while actuating?
broken wires.
No → Go To 2
2 Gain access to the VTSS Siren. All

Disconnect the VTSS Siren connector.
Measure the voltage of the Siren Supply circuit (cavity 3) in the VTSS Siren
connector.
Yes → Go To 3
No → Go To 9
3 With the VTSS Siren connector disconnected. All

Measure the resistance of the Siren Signal Return circuit to ground.
Yes → Go To 4
No → Go To 7
952
*VTSS SIREN INOP — Continued

4 With the VTSS Siren connector disconnected. All
Measure the voltage of the Siren Signal Control circuit (cavity 2) in the VTSS Siren
connector.
Yes → Replace the VTSS Siren.
No → Go To 5
5 Gain access to the RKE/Thatcham Alarm Module C1 harness connector. All

While back probing, measure the voltage of the Siren Signal Control circuit.
Yes → Go To 6

6 Disconnect the RKE/Thatcham Alarm Module C1 harness connector. All

Measure the resistance of the Siren Signal Control circuit between the RKE/
Thatcham Alarm Module and the VTSS Siren connector.
No → Repair the Siren Signal Control circuit for an open.

While back probing, measure the resistance of the Siren Signal Return circuit.
Yes → Go To 8

Measure the resistance of the Siren Signal Return circuit between the RKE/
Thatcham Alarm Module and the VTSS Siren connector.
No → Repair the Siren Signal Return circuit for an open.


While back probing, measure the voltage of the Siren Supply circuit.
Yes → Go To 10

953
*VTSS SIREN INOP — Continued

Measure the resistance of the Siren Supply circuit between the RKE/Thatcham
Alarm Module and the VTSS Siren connector.

No → Repair the Siren Supply circuit for an open.

954
Symptom:
*VTSS WILL NOT ARM
POSSIBLE CAUSES
CHECK THE VTSS STATUS
CHECK FOR DTCS AND VTSS ARMING INHIBITORS
BODY CONTROL MODULE

1 With the DRBIIIt, check that the Theft Alarm is enabled. All
Was the Theft Alarm enabled?
Yes → Go To 2
No → With the DRBIIIt, enable the Vehicle Theft Security System
(VTSS).
2 Ensure the liftgate, and all doors are closed. All

With the DRBIIIt, read the active DTC’s and the ajar switch states.
Does the DRBIIIt display any closed switches or VTSS related DTC’s?
Yes → Refer to the Symptom List and diagnose the appropriate symp-
tom in the DOOR AJAR or VTSS category.
955
Symptom:
FR WIPER HI-LO RELAY OPEN
POSSIBLE CAUSES
FUSED B(+) CIRCUIT
COMMON CIRCUIT OPEN
WIPER HI/LOW RELAY
WIPER ON/OFF RELAY
WIPER HI/LOW RELAY CONTROL CIRCUIT OPEN
FCM-ON/OFF RELAY DRIVER OPEN

Remove the Wiper On/Off Relay from the PDC.
Using a 12-volt test light connected to ground, probe both Fused B(+) circuits in the
PDC.
Does the test light illuminate brightly at each terminal?
Yes → Go To 2
No → Repair the Fused B(+) circuit(s) for an open.
2 Install a substitute relay in place of the Wiper On/Off Relay. All

Turn the wipers on.
Does the system operate correctly?
Yes → Replace the Wiper On/Off Relay.
No → Go To 3

Remove the wiper High/Low Relay from the PDC.
Remove the wiper On/Off Relay from the PDC.
Measure the resistance of the Common circuit between the High/Low Relay and the
On/Off relay in the PDC.
Yes → Go To 4
No → Repair the Common circuit for an open.

4 Install a substitute relay in place of the Wiper Hi/Low Relay. All

Turn the wipers on.
Yes → Replace the Wiper Hi/Low Relay.

No → Go To 5
956
FR WIPER HI-LO RELAY OPEN — Continued

Remove the Wiper Hi/Low Relay from the PDC.
Connect a jumper wire between the Wiper Hi/Low Relay Control circuit at the IPM
Measure the resistance between ground and the Wiper Hi/Low Relay Control circuit
in the PDC.

No → Repair the Wiper Hi/Low Relay Control circuit for an open.
957
Symptom:
FR WIPER HI-LO RELAY SHORT TO BATT
POSSIBLE CAUSES
WIPER HI/LOW RELAY
WIPER HI/LOW RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
FCM

Remove the Wiper Hi/Low Relay from the PDC.
Measure the voltage of the Wiper Hi/Low Relay Control circuit at the PDC connector.
Yes → Repair the Wiper Hi/Low Relay Control circuit for a short to
voltage.
No → Go To 2
2 Install a substitute relay in place of the Wiper Hi/Low Relay. All

Turn the wipers on.
Yes → Replace the Wiper Hi/Low Relay.

958
Symptom:
FRONT WASH SWITCH INPUT STUCK
POSSIBLE CAUSES
HIGH BEAM/FRONT WASHER SWITCH MUX CIRCUIT SHORTED TO GROUND
MULTI-FUNCTION SWITCH
FCM

With the DRB, select Body, Front Control Module and read the F Washer Switch
state.
Does the DRB display switch state as Closed?
Yes → Go To 2
No → Go To 4

Disconnect the Multi-Function Switch harness connector.
With the DRB, select Body, Front Control Module and read the F Washer Switch
state.
Does the DRB display switch state as Open?
Yes → Replace the Multi-Function Switch.

No → Go To 3

Measure the resistance between ground and the High Beam/Front Washer Switch
MUX circuit.
Yes → Repair the High Beam/Front Washer Switch MUX circuit for a
short to ground.

959
FRONT WASH SWITCH INPUT STUCK — Continued

With the DRBIIIt, erase all BCM and FCM DTCs.

960
Symptom:
FRONT WASHER OUTPUT OPEN
POSSIBLE CAUSES
FRONT WASHER MOTOR CONTROL CIRCUIT OPEN
FUSED ACCESSORY RELAY OUTPUT CIRCUIT
FRONT WASHER MOTOR CONTROL CIRCUIT SHORT TO VOLTAGE
FRONT WASHER PUMP MOTOR

1 Ignition on, engine off. All
Press the Front Washer Switch.
Does the Front Washer Motor Function?
Yes → Go To 2
No → Go To 3

The conditions necessary to set this DTC are not present at this time.
circuit.

Disconnect the Front Washer Pump Motor harness connector.
Ignition on, engine off.
Using a 12-volt test light connected to ground, check the Fused Accessory Relay
Output circuit in the Front Washer Pump Motor harness connector.
Yes → Go To 4
No → Repair the Fused Accessory Relay Output circuit for an open.

961
FRONT WASHER OUTPUT OPEN — Continued

Ignition on, engine off.
Using a 12-volt test light connected to 12 Volts, check the Front Washer Pump Motor
Control circuit in the Front Washer Pump Motor harness connector while pressing
the Front Washer Switch.
Yes → Replace the Front Washer Pump Motor in accordance with the
No → Go To 5

Disconnect the Front Control Module harness connector.
Measure the resistance of the Rear Washer Pump Motor Control Circuit from the
Front Control Module connector to the Rear Washer Pump Motor harness connector.
Yes → Repair the Front Washer Pump Motor Control Circuit for an open.
No → Go To 6

Disconnect the Front Control Module connector.
Using a 12-volt test light connected to ground, check the Front Washer Pump Motor
Control circuit.
Yes → Repair the Front Washer Pump Motor Control Circuit for a short
to voltage.
Information.
962
Symptom:
FRONT WIPER NOT PARKED
POSSIBLE CAUSES
FRONT WIPER MODULE
MECHANICAL PROBLEM
FRONT WIPER PARK SWITCH SENSE CIRCUIT OPEN

With the DRB, select Body, Front Control Module, Inputs/Outputs and read the
Wiper Park Sw state.
Does the DRB display Closed?
Yes → Go To 2
No → Go To 3


Inspect all of the moving components associated with the Front Wiper system. Look
for broken or damaged components which may prevent the wipers from parking
properly.
Are the any mechanical problems?

No → Go To 4
963
FRONT WIPER NOT PARKED — Continued

Disconnect the Front Wiper Module harness connector.
With the DRB, select Body, Body Computer then Inputs/Outputs and read the Wiper
Park Sw state.
Connect one end of a jumper wire to the Front Wiper Park Switch Sense circuit at the
Front Wiper Module harness connector.
Momentarily connect the other end of the jumper wire to ground. Repeat this several
times.
Did the Switch state change between Open and Closed when connecting and
disconnecting the jumper?
Yes → Replace the Front Wiper Module.

No → Go To 5

Measure the resistance of the Front Wiper Park Switch Sense circuit.
No → Repair the Front Wiper Park Switch Sense circuit for an open.
964
Symptom:
FRONT WIPER ON RELAY OPEN
POSSIBLE CAUSES
FUSED B(+) CIRCUIT
WIPER ON/OFF RELAY
WIPER ON/OFF RELAY CONTROL CIRCUIT OPEN
FCM-ON/OFF RELAY DRIVER OPEN

Using a 12-volt test light connected to ground, probe both Fused B(+) circuits in the
PDC.
Does the test light illuminate brightly at each terminal?
Yes → Go To 2
No → Repair the Fused B(+) circuit(s) for an open.

Turn the wipers on.
No → Go To 3

Connect a jumper wire between the Wiper On/Off Relay Control circuit at the IPM
Measure the resistance between ground and the Wiper On/Off Relay Control circuit
in the PDC.

No → Repair the Wiper On/Off Relay Control circuit for an open.

965
Symptom:
FRONT WIPER ON RELAY SHORT TO BATT
POSSIBLE CAUSES
WIPER ON/OFF RELAY
WIPER ON/OFF RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
FCM

Measure the voltage of the Wiper On/Off Relay Control circuit at the PDC connector.
Yes → Repair the Wiper On/Off Relay Control circuit for a short to
voltage.
No → Go To 2

Turn the wipers on.

966
Symptom:
FRONT WIPER PARK SWITCH SHORT TO GND
POSSIBLE CAUSES
FRONT WIPER MODULE
FRONT WIPER PARK SWITCH SENSE CIRCUIT SHORTED TO GROUND

Turn the Wipers on one of the intermittent settings.
With the DRB, select Body, Front Control Module, Inputs/Outputs and read the
Wiper Park Sw state.
Does the switch state change from Open to Closed during wiper operation?
Yes → Go To 2
No → Go To 3


Measure the resistance between ground and the Front Wiper Park Switch Sense
circuit.
Yes → Repair the Front Wiper Park Switch Sense circuit for a short to
ground.
No → Go To 4
967
FRONT WIPER PARK SWITCH SHORT TO GND — Continued

Turn the front wipers to an intermittent setting.
Using a 12-volt test light connected to 12-volts, back probe the Front Wiper Park
Switch Sense circuit at the Front Wiper Module harness connector.
NOTE: The test light should illuminate when the wipers are parked, then
turn off when the wipers move off of the parked position.
Does the test light turn on and off properly?

No → Replace the Front Wiper Module.
968
Symptom:
FRONT WIPER SWITCH MUX INPUT OPEN
POSSIBLE CAUSES
WINDSHIELD WIPER SWITCH MUX CIRCUIT OPEN
WIPER MUX CIRCUIT SHORTED TO VOLTAGE
BCM

With the DRB, select Body, Body Controller and read the Front Wiper Sw volts.
Yes → Go To 2
No → Go To 6

Measure the resistance of the Front Wiper Switch MUX circuit between the BCM C5
harness connector and the Multi-Function Switch harness connector.
Yes → Go To 3
No → Repair the Front Wiper Switch MUX circuit for an open.

Measure the resistance of the Multi-Function Switch MUX Return circuit between
the BCM C4 harness connector and the Multi-Function Switch harness connector.
Yes → Go To 4
No → Repair the Multi-Function Switch MUX Return circuit for an

open.

Measure the voltage of the Front Wiper MUX Switch Signal circuit.
Yes → Repair the Front Wiper Switch MUX circuit for a short to voltage.
No → Go To 5
969
FRONT WIPER SWITCH MUX INPUT OPEN — Continued

Connect a jumper wire between the Front Wiper Switch MUX circuit and the
Mulit-Function Switch MUX Return circuit.
With the DRB, read the Front Wiper Sw volts?



970
Symptom:
FRONT WIPER SWITCH MUX INPUT SHORT TO GROUND
POSSIBLE CAUSES
BCM
FRONT WIPER SWITCH MUX CIRCUIT SHORTED TO GROUND
FRONT WIPER SWITCH MUX CIRCUIT SHORTED TO M/F MUX RETURN CIRCUIT

With the DRB, select Body, Body Controller and read the Front Wiper Sw volts?
Yes → Go To 2
No → Go To 3



Measure the resistance of the Front Wiper Switch MUX circuit between the BCM C5
harness connector and ground.
Yes → Repair the Front Wiper Switch MUX circuit for a short to ground.
No → Go To 4
971
FRONT WIPER SWITCH MUX INPUT SHORT TO GROUND — Continued

Measure the between the Front Wiper Switch MUX circuit and the Multi-Function
Switch MUX Return circuit.
Yes → Repair the Front Wiper Switch MUX circuit for a short to the
Multi-Function Switch MUX Return circuit.
No → Go To 5

With the DRB, read the Front Wiper Sw volts?

972
Symptom:
HEADLAMP WASHER RELAY OPEN
POSSIBLE CAUSES
OPEN GROUND CIRCUIT
HEADLAMP WASHER RELAY CONTROL CIRCUIT OPEN
HEADLAMP WASHER RELAY OUTPUT CIRCUIT OPEN
HEADLAMP WASHER PUMP MOTOR
HEADLAMP WASHER RELAY

Disconnect the Washer Pump connector.
Measure the resistance of the Washer Pump ground circuit.
Yes → Go To 2
No → Repair the open Washer Pump ground circuit.

Disconnect the Headlamp Washer Relay.
Measure the voltage of the Fused B+ Circuit.
Yes → Go To 3
No → Repair the Fused B+ Circuit for an open condition.


Disconnect the FCM harness connector.
Measure the resistance of the Headlamp Washer Relay Control Circuit.
Yes → Go To 4
No → Repair the Headlamp Washer Relay Control Circuit for an open.

4 Disconnect the Headlamp Washer Relay. All

Disconnect the Headlamp Washer Pump Motor.
Measure the resistance of the Headlamp Washer Relay Output Circuit.
Yes → Go To 5
No → Repair the Headlamp Washer Relay Output Circuit for an open.

973
HEADLAMP WASHER RELAY OPEN — Continued

Disconnect the Headlamp Washer Pump Motor connector.
Actuate the washers.
Measure the voltage of the Washer Pump Output Circuit.
Yes → Replace the Headlamp Washer Pump Motor.
No → Go To 6

Install a known good relay in place of the Headlamp Washer Relay.
Turn the Washers on.
Do the Headlamp Washers operate normally?
Yes → Replace the Headlamp Washer Relay.

974
Symptom:
HEADLAMP WASHER RELAY SHORT TO BATT
POSSIBLE CAUSES
HEADLAMP WASHER RELAY CONTROL CIRCUIT OPEN
HEADLAMP WASHER PUMP MOTOR
HEADLAMP WASHER RELAY

Measure the voltage of the Fused B+ Circuit.
Yes → Go To 2
No → Repair the Fused B+ Circuit for an open condition.

Disconnect the FCM harness connector.
Measure the resistance of the Headlamp Washer Relay Control Circuit.
Yes → Go To 3
No → Repair the Headlamp Washer Relay Control Circuit for an open.


Disconnect the Headlamp Washer Pump Motor connector.
Actuate the washers.
Measure the voltage of the Washer Pump Output Circuit.
Yes → Replace the Headlamp Washer Pump Motor.
No → Go To 4

Install a known good relay in place of the Headlamp Washer Relay.
Turn the Washers on.
Do the Headlamp Washers operate normally?
Yes → Replace the Headlamp Washer Relay.

975
Symptom:
REAR WASH SWITCH INPUT STUCK
REAR WASH SWITCH INPUT STUCK

Set Condition: Switch is applied for more than 10 seconds.
POSSIBLE CAUSES
REAR WASHER SWITCH STUCK
REAR WASHER SWITCH MUX CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

With the DRB, select Body, Front Control Module and read the R Washer Switch
state.
Does the DRB display switch state as Closed?
Yes → Go To 2
No → Go To 4

Disconnect the Rear Washer Switch harness connector.
With the DRB, select Body, Front Control Module and read the R Washer Switch
state.
Does the DRB display switch state as Open?
Yes → Replace the Rear Washer Switch in accordance with the Service
Information.
No → Go To 3

Disconnect the Rear Washer Switch harness connector.
Measure the resistance between ground and the Rear Washer Switch MUX circuit.
Yes → Repair the Rear Washer Switch MUX circuit for a short to ground.

Information.
976
REAR WASH SWITCH INPUT STUCK — Continued

circuit.

977
Symptom:
REAR WASHER OUTPUT OPEN
REAR WASHER OUTPUT OPEN

Set Condition:
POSSIBLE CAUSES
FUSED ACCESSORY RELAY OUTPUT CIRCUIT
REAR WASHER MOTOR CONTROL CIRCUIT OPEN
REAR WASHER MOTOR CONTROL CIRCUIT SHORT TO VOLTAGE
REAR WASHER PUMP MOTOR

Press the Rear Washer Switch.
Does the Rear Washer Motor Function?
Yes → Go To 2
No → Go To 3

circuit.
978
REAR WASHER OUTPUT OPEN — Continued

Disconnect the Rear Washer Pump Motor harness connector.
Using a 12-volt test light connected to ground, check the Fused Accessory Relay
Output circuit in the Rear Washer Pump Motor harness connector.
Yes → Go To 4
No → Repair the Fused Accessory Relay Output circuit for an open.

Using a 12-volt test light connected to 12 Volts, check the Rear Washer Pump Motor
Control circuit in the Rear Washer Pump Motor harness connector while pressing the
Rear Washer Switch.
Yes → Replace the Rear Washer Pump Motor in accordance with the
No → Go To 5

Disconnect the Front Control Module harness connector.
Measure the resistance of the Rear Washer Pump Motor Control Circuit from the
Front Control Module connector to the Rear Washer Pump Motor harness connector.
Yes → Repair the Rear Washer Pump Motor Control Circuit for an open.
No → Go To 6

Disconnect the Front Control Module connector.
Using a 12-volt test light connected to ground, check the Rear Washer Pump Motor
Control circuit.
Yes → Repair the Rear Washer Pump Motor Control Circuit for a short
to voltage.

Information.
979
Symptom:
REAR WIPER OUTPUT OPEN
REAR WIPER OUTPUT OPEN

Set Condition: The Output is ON, the Output Driver Status is LOW and there is no Park
signal.
POSSIBLE CAUSES
REAR WIPER MOTOR CONTROL CIRCUIT OPEN
REAR WIPER MOTOR GROUND OPEN
REAR WIPER MOTOR CONTROL CIRCUIT SHORT TO VOLTAGE
REAR WIPER MOTOR
BODY CONTROL MODULE

Turn on the Rear Wiper.
Does the Rear Wiper Function?
Yes → Go To 2
No → Go To 3

circuit.
980
REAR WIPER OUTPUT OPEN — Continued

Disconnect the Rear Wiper Motor harness connector.
Using a 12-volt test light connected to ground, check the Rear Wiper Motor Control
circuit in the Rear Wiper Motor harness connector.
Turn ON the Rear Wiper Motor.
Yes → Go To 4
No → Go To 5

Using a 12-volt test light connected to 12 Volts, check the Rear Wiper Motor ground
circuit in the Rear Wiper Motor harness connector.
Yes → Replace the Rear Wiper Motor in accordance with the Service
Information.
No → Repair the Rear Wiper Motor ground circuit for an open.


Measure the resistance of the Rear Wiper Motor Control Circuit from the Body
Control Module harness connector to the Rear Wiper Motor harness connector.
Yes → Repair the Rear Wiper Motor Control Circuit for an open.
No → Go To 6

Using a 12-volt test light connected to ground, check the Rear Wiper Motor Control
circuit.
Is the test light on?
Yes → Repair the Rear Wiper Motor Control Circuit for a short to
voltage.

Information.
981
Symptom:
REAR WIPER OUTPUT SHORT TO GROUND
REAR WIPER OUTPUT SHORT TO GROUND

Set Condition:
POSSIBLE CAUSES
REAR WIPER MOTOR FUNCTION
REAR WIPER MOTOR CONTROL CIRCUIT SHORT TO GROUND
BODY CONTROL MODULE

Turn on the Rear Wiper.
Does the Rear Wiper Function?
Yes → Go To 2
No → Go To 3

circuit.


Measure the resistance between ground and the Rear Wiper Motor Control circuit.
Yes → Repair the Rear Wiper Motor Control Circuit for a short to
ground.
No → Go To 4
982
REAR WIPER OUTPUT SHORT TO GROUND — Continued

Connect a 20A Fused jumper wire between B+ and the Rear Wiper Motor Signal
circuit in the Body Control Module connector harness.
NOTE: An internal short in the Wiper Motor may cause the fuse to open.
Does the Wiper Motor function?
Yes → Replace the Body Control Module in accordance with the Service
Information.
No → Replace the Rear Wiper Motor in accordance with the Service
Information.
983
Symptom:
REAR WIPER SWITCH MUX INPUT OPEN
REAR WIPER SWITCH MUX INPUT OPEN

Set Condition: A Sensor voltage is over 4.76 volts for more than .125 seconds.
POSSIBLE CAUSES
REAR WIPER SWITCH MUX CIRCUIT OPEN
REAR WIPER SWITCH MUX RETURN CIRCUIT OPEN
REAR WIPER SWITCH OPEN
BODY CONTROL MODULE

With the DRB, select Body, Body Control Module and read the R Wiper Switch Sensor
voltage.
Does the DRB display a Switch voltage greater than 4.5 volts?
Yes → Go To 2
No → Go To 5

Disconnect the Rear Wiper Switch harness connector.
Connect a jumper wire between the Rear Wiper Switch MUX circuit and the Rear
Wiper Switch MUX Return circuit in the Rear Wiper Switch harness connector.
With the DRB, select Body, Body Controller and read the Rear Wiper SW volts.
Does the DRB R Wiper Switch Sensor voltage read less than 0.3 Volts?
Yes → Replace the Rear Wiper Switch in accordance with the Service
Information.
No → Go To 3

Measure the resistance of the Rear Wiper Switch MUX circuit from the Body Control
Module connector to the Rear Wiper Switch harness connector.
Yes → Repair the Rear Wiper Switch MUX circuit for an open.
No → Go To 4
984
REAR WIPER SWITCH MUX INPUT OPEN — Continued

Measure the resistance of the Rear Wiper Switch MUX Return circuit from the Body
Control Module connector to the Rear Wiper Switch harness connector.
Yes → Repair the Rear Wiper Switch MUX Return circuit for an open.
Information.

circuit.

985
Symptom:
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND

Set Condition: A Sensor voltage is below 0.24 volts for more than 0.125 seconds.
POSSIBLE CAUSES
REAR WIPER SWITCH SHORTED
REAR WIPER SWITCH MUX CIRCUIT SHORT TO GROUND
REAR WIPER SWITCH MUX RETURN CIRCUIT SHORT TO GROUND
REAR WIPER SWITCH MUX CIRCUIT SHORT TO MUX RETURN CIRCUIT
BODY CONTROL MODULE

voltage.
Does the DRB display a Switch voltage less than 0.4 volts?
Yes → Go To 2
No → Go To 6

voltage..
Does the DRB display more than 4.8 volts?
Yes → Replace the Rear Wiper Switch in accordance with the Service
Information.
No → Go To 3

Measure the resistance between ground and the Rear Wiper Switch MUX circuit.
Yes → Repair the Rear Wiper Switch MUX Circuit for a short to ground.
No → Go To 4
986
REAR WIPER SWITCH MUX INPUT SHORT TO GROUND — Continued

Measure the resistance between the Rear Wiper Switch MUX Return circuit and the
Rear Wiper Switch MUX circuit.
Yes → Repair the Rear Wiper Switch MUX Circuit for a short to the Rear
Wiper Switch MUX Return circuit.
No → Go To 5

Measure the resistance between ground and the Rear Wiper Switch MUX Return
circuit.
Yes → Repair the Rear Wiper Switch MUX Return Circuit for a short to
ground.
Information.

circuit.

987
VERIFICATION TESTS
Verification Tests
41TE TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY
1. Connect the DRBIIIt to the Data Link Connector (DLC). All
2. Reconnect any disconnected components.
3. With the DRBIIIt, erase all Transmission DTC’s, also erase the PCM DTC’s.
4. NOTE: Erase DTC P0700 in the PCM to turn the Malfunction Indicator Lamp (MIL)
off after making Transmission repairs.
5. With the DRBIIIt, display Transmission Temperature. Start and run the engine until the
Transmission Temperature is HOT - above 43.33° C or 110° F.
6. Check the Transmission Fluid and adjust if necessary. Refer to the Service information for
the Fluid Fill procedure.
7. NOTE: If the Transmission Control Module or Torque Converter has been replaced
or if the Transmission has been repaired or replaced it is necessary to perform the
DRBIIIt Quick Learn Procedure and reset the (Pinion Factor(
8. NOTE: If the Torque Converter is replaced, or if a TCM is replaced on a vehicle
whose Torque Converter has less than 3750 miles and less than 360 minutes of
PEMCC, then with the DRBIIIt restart the TCC Break-In. This is in order to avoid
possible shudder.
9. Road test the vehicle. With the DRBIIIt, monitor the engine RPM. Make 15 to 20 1-2, 2-3,
3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle
opening of 20 to 25 degrees.
10. Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least 5
seconds each in 2nd and 3rd gear between each kickdown.
11. For a specific DTC, drive the vehicle to the Symptom’s When Monitored/When Set
conditions to verify the DTC repair.
12. NOTE: Use the EATX OBDII Task Manager to run Good Trip time in each gear, this
will confirm the repair and to ensure that the DTC has not re-matured.
13. Check for Diagnostic Trouble Codes (DTC’s) during the road test. If a DTC sets during the
road test , return to the Symptom list and perform the appropriate Symptom.
Were there any Diagnostic Trouble Codes (DTCs) set during the road test?
Yes → Refer to the Symptom List for appropriate Symptom(s).

No → Repair is complete.
ABS VERIFICATION TEST - VER 1 APPLICABILITY

1. Turn the ignition off. All
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIIIt, erase all Diagnostic Trouble Codes
from ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the
system that was malfunctioning.
5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read
DTC’s from ALL modules.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. If there are no DTC’s present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
8. Caution: Ensure braking capability is available before road testing.
9. Again, with the DRBIIIt read DTC’s. If any DTC’s are present, return to Symptom list.
10. If there are no Diagnostic Trouble Codes (DTC’s) present, and the customer’s concern can
no longer be duplicated, the repair is complete.
Are any DTC’s present or is the original concern still present?
Yes → Repair is not complete, refer to appropriate symptom.

988
VERIFICATION TESTS
Verification Tests — Continued
AIRBAG VERIFICATION TEST - VER 1 APPLICABILITY

1. Remove any special tools or jumper wires and reconnect all previously disconnected All
components - except the Battery.
2. Turn the Ignition key On and reconnect the Battery.
3. Connect the DRB to the Data Link Connector - use the most current software available.
4. Use the DRB III and erase the stored codes.
5. Turn the Ignition Off, and wait 15 seconds before turning the Ignition On.
6. Wait one minute, and read active codes and if there are none present read the stored codes.
7. Note: If equipped with Passenger Airbag On-Off switch, read the DTC’s in all switch
positions.
8. If the DRB shows any active or stored codes, return to the Symptom list and follow path
specified for that trouble code. If no active or stored codes are present, the repair is complete.
Are any DTC’s present or is the original condition still present?
YES
Repair is not complete, refer to appropriate symptom.
NO
Repair is complete.
989
VERIFICATION TESTS
BODY VERIFICATION TEST - VER 1 APPLICABILITY

1. Disconnect all jumper wires and reconnect all previously disconnected components and All
connectors.
2. With the DRBIIIt, record and erase all DTCs from ALL modules. Cycle the ignition on then
off
3. If the Sentry Key Immobilizer Module (SKIM), the Powertrain Control Module (PCM), or the
Engine Control Module (ECM) was replaced, proceed to number 9. If the SKIM, PCM, or ECM
was not replaced, continue to the next number.
4. If the Body Control Module (BCM) was replaced, turn the ignition on for 15 seconds (to allow
the new BCM to learn VIN) or engine may not start (if VTSS equipped). If the vehicle is
equipped with VTSS, use the DRBIIIt and enable VTSS.
5. Program all other options as needed.
6. If any actuators were replaced in the HVAC System, with the DRBIIIt in HVAC, select
System Tests then select HVAC Door Recalibration (manual temperature system only).
7. If any actuators were replaced in the ATC System, with the DRBIIIt in Automatic Temp
Control, select Miscellaneous then select Reset ATC Head.
8. If any repairs were made to the power sliding door or power liftgate, use the DRBIIIt and
perform the open and close system tests. Observe the instructions on the DRBIIIt screen.
Proceed to number 16.
9. Obtain the vehicle’s unique PIN assigned to it’s original SKIM from either the vehicle’s
invoice or from Chrysler’s Customer Assistance Center (1-800-992-1997).
10. NOTE: Once Secured Access Mode is active, the SKIM will remain in that mode for 60
seconds.
11. With the DRBIIIt, select THEFT ALARM, SKIM, MISCELLANEOUS and select SKIM
REPLACED. Enter the 4 digit PIN to put the SKIM in Secured Access Mode.
12. The DRBIIIt will prompt for the following steps. (1) Program the country code into the
SKIM’s memory. (2) Program the vehicle’s VIN into the SKIM memory. (3) Transfer the
vehicle’s Secret Key data from the PCM.
13. Using the DRBIIIt, program all customer keys into the SKIM memory. This requires that
the SKIM be in Secured Access Mode, using the 4 digit PIN.
14. Note: If the PCM or ECM is replaced, the VIN and the unique Secret Key data must be
transferred from the SKIM to the PCM or ECM. This procedure requires the SKIM to be placed
in Secured Access Mode using the 4-digit PIN.
15. Note: If 3 attempts are made to enter Secured Access Mode using an incorrect PIN, Secured
Access Mode will be locked out for 1 hour which causes the DRBIIIt to display 9No Resp from
SKIM9. To exit this mode, turn ignition to Run for 1 hour.
16. Ensure that all accessories are turned off and the battery is fully charged.
17. Start and run the engine for 2 minutes. Operate all functions of the system that caused the
original concern.
18. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIIIt, read
DTCs from ALL modules.
Yes → Repair is not complete, refer to the appropriate symptom.
990
VERIFICATION TESTS
CABIN HEATER VERIFICATION TEST - VER 1 APPLICABILITY

1. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A All
GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS
VENT THE DCHA’s EXHAUST WHEN OPERATING THE DCHA. FAILURE TO FOL-
LOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.
2. WARNING: ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A
COMPONENT INSPECTION/REPAIR/REPLACEMENT. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
3. NOTE: The DCHA Control will store up to three DTCs in its memory.
4. NOTE: If the DCHA Control detects a new fault in the DCHA system, one that is not
already stored in its memory, the DCHA Control will clear the oldest of the three
stored DTCs, and it will store the new fault’s DTC.
5. NOTE: If the DCHA control detects a reoccurrence of a stored fault, the DCHA
control will overwrite that fault’s DTC with the most recent occurrence.
6. Verify that the vehicle’s battery is fully charged.
7. Verify that there is more than 1/8 of a tank of fuel in the vehicle’s fuel tank. Add fuel, if
necessary.
8. Verify that all DCHA coolant hoses and fuel lines are securely fastened to their respective
components.
9. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
10. If a heater installation/cooling system service was performed, purge the coolant circuit of
air in accordance with the Service Information.
11. Turn the ignition on.
12. Set the Blend Control to the max cool position.
13. Ensure that all accessories are turned off.
14. If a fuel system service requiring fuel to drain out of the DCHA fuel line was performed,
prime the DCHA Dosing Pump in accordance with the Service Information.
15. With the DRBIIIt, record and erase all DTCs from the Diesel Cabin Heater Assist (DCHA)
Control and the Front Control Module (FCM). Cycle the ignition off then on.
16. Start the engine.
17. Allow the engine to idle.
18. Turn the A/C - Heater Control Module’s Power switch on.
19. Turn the Blower switch to the high speed position.
20. CAUTION: Do not activate the Diesel Cabin Heater Test with the engine off.
Failure to follow these instructions may result in internal damage to the DCHA
Heater Module.
21. NOTE: Do not disconnect the vehicle’s battery or the DCHA’s main power supply
while the DCHA is in operation or in run-down mode. Failure to follow these
instructions may result in excess emissions from the DCHA during heater operation.
22. NOTE: While performing the Diesel Cabin Heater Test, inspect the coolant and
fuel connections for leakage.
23. With the DRBIIIt in HVAC, Systems Tests, select Diesel Cabin Heater Test and press #1.
24. Set the Blend Control to the max heat position. Allow the Diesel Cabin Heater Test to run
for five minutes. Upon completion of the test, proceed as follows:
25. Set the Blend Control to the max cool position.
26. Press #2 on the DRBIIIt keyboard.
27. Turn the Blower switch off.
28. Turn the A/C - Heater Control Module’s Power switch off.
29. Turn the ignition off, wait 5 seconds, then turn the ignition on.
30. Using the DRBIIIt, read the Cabin Heater and Active FCM DTCs.
991
VERIFICATION TESTS
MEMORY SYSTEM VERIFICATION TEST - VER 1 APPLICABILITY

1. Reconnect all previously disconnected components and connectors. All
2. If any Memory Seat Memory Module Trouble Codes are present, erase at this time.
3. With the Memory Switch on the Driver’s Door, program the Driver’s Seat #1 Button to a
desired position and Driver #2 Button to a different position.
4. Remove the Ignition Key and close all Doors to allow the Body Control Module to time out,
about 30 seconds.
5. Verify that both Memory positions can be recalled from the RKE transmitter and the
Memory Switch on the Driver’s Door.
6. Turn the ignition on, and with the DRBIII, erase all Diagnostic Trouble Codes from ALL
modules. Start the engine and allow it to run for 2 minutes and fully operate the system that
was malfunctioning.
Are any DTC’s present or is the original complaint still present?
POWERTRAIN VERIFICATION TEST VER - 1 APPLICABILITY

1. NOTE: If the PCM has been replaced and the correct VIN and mileage have not All
been programmed, a DTC will be set in the ABS Module, Airbag Module and the
SKIM.
2. NOTE: If the vehicle is equipped with a Sentry Key Immobilizer System, Secret
Key data must be updated. Refer to the Service Information for the PCM, SKIM and
the Transponder (ignition key) for programming information.
3. Inspect the vehicle to ensure that all components related to the repair are connected
properly.
4. Inspect the engine oil for fuel contamination. Replace the oil and filter as necessary.
5. Attempt to start the engine.
6. If the No Start condition is still present, refer to the symptom list and perform the diagnostic
testing as necessary. refer to and Technical Service Bulletins that may apply.
7. Run the engine for one warm-up cycle to verify operation.
8. With the DRBIIIt, confirm that no DTCs or Secondary Indicators are present and that all
components are functioning properly.
9. If a DTC is present, refer to the appropriate category and select the corresponding symptom.
992
VERIFICATION TESTS
ROAD TEST VERIFICATION - VER-2 APPLICABILITY

1. Inspect the vehicle to ensure that all engine components are properly installed and All
connected. Reassemble and reconnect components as necessary.
2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) (diesel only) or Powertrain Control Module (PCM) has
not been changed, perform steps 7 and 8, otherwise, continue with step 9.
7. With the DRB, erase all diagnostic trouble codes (DTCs), then disconnect the DRB.
8. Turn the ignition off for at least 10 seconds.
9. Ensure no DTCs remain by performing steps 10 through 13.
10. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
11. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
12. Upon completion of the road test, turn the engine off and check for DTCs with the DRB.
13. If the repaired DTC has reset, the repair is not complete. Check for any pertinent Technical
Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the repair was
successful and is now complete.
Are any DTCs or symptoms remaining?
SKIS VERIFICATION APPLICABILITY

2. Obtain the vehicle’s unique Personal Identification Number (PIN) assigned to it’s original
SKIM. This number can be obtained from the vehicle’s invoice or Chrysler’s Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow 3 consecutive attempts to enter the correct PIN. If 3 consecutive incorrect
PIN’s are entered the SKIM will Lock Out the DRB III for 1 hour.
4. To exit Lock Out mode, the ignition key must remain in the Run position continually for 1
hour. Turn off all accessories and connect a battery charger if necessary.
5. With the DRB III, select Theft Alarm, SKIM and Miscellaneous. Then select desired
procedure and follow the steps that will be displayed.
6. If the SKIM has been replaced, ensure all of the vehicle ignition keys are programmed to the
new SKIM.
7. NOTE: Prior to returning vehicle to the costumer, perform a module scan to be
sure that all DTC’s are erased. Erase any DTC’s that are found.
8. With the DRB III erase all DTC’s. Perform 5 ignition key cycles leaving the key on for at least
90 seconds per cycle.
9. With the DRB III, read the SKIM DTC’s.
Are there any SKIM DTC’s?
993
VERIFICATION TESTS
VTSS VERIFICATION TEST - 1A APPLICABILITY

1. Ensure all doors, hood, and liftgate are closed. All
2. Open the driver’s door.
3. Remove the ignition key (but keep in hand).
4. Lower the driver door window and lock the doors with the RKE transmitter.
5. Close the driver’s door.
6. Observe the VTSS Indicator.
7. The VTSS Indicator will flash rapidly for approximately 15 seconds and then begin to flash
slowly. If the VTSS Indicator is not performing as described, this indicates a system fault. Refer
to symptom list for problems related to THEFT ALARM WILL NOT ARM.
8. Perform a system test on the VTSS by duplicating the original complaint.
9. Disarm the system and with the DRBIIIt, read DTC’s.
10. If the original complaint is corrected and there are no DTC’s the repair is complete.
Are any DTC’s present or is the original complaint still present?
994
COMPONENT LOCATIONS
C
8.0 COMPONENT LOCATIONS O
M
8.1 AIRBAG SYSTEM P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
995
COMPONENT LOCATIONS
C
O 8.2 BODY CONTROL MODULE
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.3 ENGINE CONTROL MODULE
8.4 HEATING & A/C

8.4.1 ACTUATORS – FRONT LHD
996
COMPONENT LOCATIONS
C
8.4.2 ACTUATOR – FRONT RHD O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.4.3 ACTUATOR – FRONT LHD
997
COMPONENT LOCATIONS
C
O 8.4 HEATING & A/C (Continued)
M
8.4.4 ACTUATOR – FRONT RHD
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.4.5 EVAPORATOR TEMPERATURE SENSOR LHD
998
COMPONENT LOCATIONS
C
8.4.6 EVAPORATOR TEMPERATURE SENSOR RHD O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.4.7 C202 CONNECTOR
999
COMPONENT LOCATIONS
C
O 8.4 HEATING & A/C (Continued)
M
8.4.8 ACTUATORS – REAR
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.4.9 REAR A/C HEATER UNIT CONNECTOR
1000
COMPONENT LOCATIONS
C
8.5 CABIN HEATER O
M
8.5.1 DIESEL CABIN HEATER ASSIST (CABIN HEATER) ASSEMBLY P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
1001
COMPONENT LOCATIONS
C
O 8.5 CABIN HEATER (Continued)
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.7 MEMORY SYSTEM

8.7.1 MEMORY SEAT MIRROR MEDULE/SEAT MOTORS
1002
COMPONENT LOCATIONS
C
8.7.2 MEMORY SEAT MIRROR MODULE CIRCUIT BREAKER O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.8 OVERHEAD SWITCHES
8.9 POWER FOLDING MIRRORS
1003
COMPONENT LOCATIONS
C
O 8.10 POWER LIFTGATE SYSTEM
M
P
8.10.1 MODULE
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.10.2 PINCH SENSORS (TAPE SWITCH)
1004
COMPONENT LOCATIONS
C
8.10.3 LATCH ASSEMBLY O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.11 POWER DOOR LOCK/RKE SYSTEM

8.11.1 DOOR LOCK MOTOR/AJAR SWITCH
8.11.1 CYLINDER LOCK SWITCH
1005
COMPONENT LOCATIONS
C
O 8.11 POWER DOOR LOCK/RKE SYSTEM (Continued)
M
8.11.3 REMOTE KEYLESS ENTRY MODULE
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.12 POWER SLIDING DOOR

8.12.1 MODULE
8.12.2 LOWER DRIVE UNIT
1006
COMPONENT LOCATIONS
C
8.12.3 LATCH ASSEMBLY O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.13 VEHICLE THEFT SECURITY SYSTEM

8.13.1 RKE/THATCHAM ALARM MODULE
8.13.2 RKE/THATCHAM ALARM MODULE CONNECTORS
1007
COMPONENT LOCATIONS
C
O 8.13 VEHICLE THEFT SECURITY SYSTEM (Continued)
M
8.13.3 VTSS LED
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.13.4 VTSS SIREN
1008
COMPONENT LOCATIONS
C
O
8.13.5 FRONT INTRUSION SENSOR M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.13.6 REAR INTRUSION SENSOR
1009
NOTES
1010
CONNECTOR PINOUTS
9.0 CONNECTOR PINOUTS
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY
CAV CIRCUIT FUNCTION
1 Z24 18BK/OR GROUND
2 C121 20DB/DG SENSOR GROUND
3 C22 20LB/WT (3 ZONE REAR TEMPERATURE FEEDBACK SIGNAL
HVAC)
4 - -
5 F850 20LB/PK (3 ZONE 5 VOLT SUPPLY
HVAC)
6 C900 18LB/VT WIPER DE-ICER DRIVER
7 C32 20DB/TN RECIRCULATION DOOR DRIVER (A)
8 C54 20LB/YL (3 ZONE REAR BLEND DOOR DRIVER
HVAC)
9 C34 20DB/LB COMMON DOOR DRIVER (B)
10 D25 20WT/VT PCI BUS
11 - -
12 C121 20DB/DG (3 ZONE REAR TEMPERATURE RETURN
HVAC)
13 F504 20GY/PK IGNITION SWITCH OUTPUT (RUN)
14 E12 20OR/GY PANEL LAMPS DRIVER
15 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
C
16 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A)
O
17 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A)
N
18 C35 20LB/OR MODE DOOR DRIVER (A)
N
19 C53 20LB (3 ZONE HVAC) REAR MODE DOOR DRIVER
E
20 C154 20LB/OR (3 ZONE REAR COMMON DOOR DRIVER
HVAC) C
T
A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY
O
CAV CIRCUIT FUNCTION R
1 - -
2 C75 12DB/GY BLOWER MOTOR HIGH DRIVER P
3 C74 12DB/WT BLOWER MOTOR M3 DRIVER I
4 Z134 12BK/OR GROUND N
5 C71 16DB/BR BLOWER MOTOR LOW DRIVER O
6 - - U
7 - - T
8 - - S
9 C73 14DB/VT BLOWER MOTOR M2 DRIVER
10 C72 16DB/OR BLOWER MOTOR M1 DRIVER
AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAY

1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G931 18VT/BR AMBIENT TEMPERATURE SENSOR RETURN
1011
CONNECTOR PINOUTS
ATC REMOTE SENSOR (ATC) - 4 WAY

1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO. 2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
AUTO TEMP CONTROL C1 - WHITE 13 WAY

1 C161 20LB/WT DRIVER BLEND DOOR DRIVER (B)
3 C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B)
5 C132 20DB/YL RECIRCULATION DOOR DRIVER (B)
6 C32 20DB/TN RECIRCULATION DOOR DRIVER (A)
7 C135 20DB/GY MODE DOOR DRIVER (B)
9 C53 20LB REAR MODE DOOR DRIVER (A)
C 10 C154 20LB/OR REAR MODE DOOR DRIVER (B)
O 11 C54 20LB/YL REAR BLEND DOOR DRIVER (A)
N 12 C169 20DB/OR REAR BLEND DOOR DRIVER (B)
N 13 - -
E
C AUTO TEMP CONTROL C2 - BLACK 13 WAY
T CAV CIRCUIT FUNCTION
O 1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
R 2 C121 20DB/DG SENSOR GROUND

3 E12 20OR/GY PANEL LAMPS DRIVER
P 4 A114 20GY/RD FUSED B(+) (I.O.D.)
I 5 F504 20GY/PK IGNITION SWITCH OUTPUT (RUN)
N 6 D25 20WT/VT PCI BUS
O 7 C56 20DB/LB BLOWER MOTOR CONTROL
U 8 C59 20DB/LB REAR BLOWER MOTOR CONTROL
T 9 D22 20WT/TN KDB CLOCK
S 10 D17 20WT/DG KDB DATA

12 C200 20LB/DG TXV SOLENOID FEED
13 C900 18LB/VT WIPER DE-ICER DRIVER
AUTO TEMP CONTROL C3 - 4 WAY

1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO.2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
1012
CONNECTOR PINOUTS
BLOWER MOTOR RESISTOR C1 (MTC) - BLACK 6 WAY

1 C75 12DB/GY BLOWER MOTOR HIGH DRIVER
2 C74 12DB/WT BLOWER MOTOR M3 DRIVER
3 C73 14DB/VT BLOWER MOTOR M2 DRIVER
4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
5 C72 16DB/OR BLOWER MOTOR M1 DRIVER
6 C71 16DB/BR BLOWER MOTOR LOW DRIVER
BLOWER MOTOR RESISTOR C2 (MTC) - BLACK 2 WAY

1 C70 12DG REAR BLOWER HIGH SPEED
2 C7 12BK HIGH SPEED BLOWER MOTOR
C
O
N
N
BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY E
CAV CIRCUIT FUNCTION C
1 A102 12WT/RD FUSED B(+) T
2 A701 16BR/RD FUSED B(+) (HAZARD) O
3 Z100 12BK/TN GROUND R
4 - -
5 A101 12VT/RD FUSED B(+) P
6 - - I
N
O
U
T
S
1013
CONNECTOR PINOUTS
BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY
1 L61 18WT/LG LEFT FRONT TURN SIGNAL DRIVER
2 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER
3 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
5 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START)
6 G25 20VT/TN (HIGH LINE) LIFTGATE SWITCH MUX
7 A114 20GY/RD FUSED B(+) (I.O.D.)
8 - -
9 L1 18WT/LG BACK-UP LAMP DRIVER
10 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER
11 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER
12 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER
13 - -
14 - -
15 Z15 18BK/TN GROUND
16 G920 20VT/YL (MEMORY) MEMORY SEAT SWITCH RETURN
17 G153 20VT/YL (POWER LIFTGATE MODULE WAKE UP SIGNAL
LIFTGATE)
18 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER
C 20 P5 20TN/OR LEFT SLIDING DOOR UNLOCK DRIVER
O 21 P164 18LG/DB (BUILT-UP- PASSENGER FOLDING MIRROR RELAY INPUT
N EXPORT)
N 22 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE
E 23 - -
C 24 G200 20VT/BR (MEMORY) MEMORY SEAT SET SWITCH MUX
T 25 M22 20YL/OR COURTESY LAMPS DRIVER
O 26 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER
R 27 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER
28 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER
P 29 P159 20TN/DG (BUILT-UP- DRIVER FOLDING MIRROR FOLD DRIVER
I EXPORT)
N 30 P174 20TN/LB (BUILT-UP- RIGHT FOLDING MIRROR UNFOLD DRIVER

EXPORT)
O 31 P171 20TN/YL (BUILT-UP- LEFT FOLDING MIRROR UNFOLD DRIVER
U EXPORT)
T 32 W13 18BR/LG REAR WIPER MOTOR CONTROL
S 33 M24 20YL/WT COURTESY LAMPS DRIVER
34 L38 20WT/YL (BUILT-UP- REAR FOG LAMP SWITCH OUTPUT
EXPORT)
1014
CONNECTOR PINOUTS
BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY
1 G23 20VT/DB (POWER SLIDING DOORS OVERHEAD SWITCH MUX
SLIDING DOOR)
2 D23 20WT/BR FLASH PROGRAM ENABLE
3 G152 20VT/GY (POWER RIGHT SLIDING DOOR WAKE UP SIGNAL
SLIDING DOOR)
4 G151 20VT/BR (POWER LEFT SLIDING DOOR WAKE UP SIGNAL
SLIDING DOOR)
5 G76 20VT/YL RIGHT SLIDING DOOR AJAR SWITCH SENSE
6 G75 20VT (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE
6 G74 20VT/WT (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
7 G75 20VT (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE
7 G74 20VT/WT (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
8 G77 20VT/GY LEFT SLIDING DOOR AJAR SWITCH SENSE
9 E10 20OR/GY (ATC ) (3 PANEL LAMPS DRIVER (REAR BLOWER SWITCH)
ZONE HVAC)
10 - -
11 L162 20WT/VT (BUILT-UP- RIGHT SIDE REPEATER LAMP FEED
EXPORT)
12 G42 20VT/YL (POWER RIGHT SLIDING DOOR PILLAR SWITCH MUX
SLIDING DOOR)
13 G165 20VT/GY LIFTGATE CYLINDER LOCK SWITCH MUX
14 G163 20VT/LB LEFT CYLINDER LOCK SWITCH MUX C
15 G162 20VT/WT RIGHT CYLINDER LOCK SWITCH MUX O
16 - - N
17 F503 20WT/PK IGNITION SWITCH OUTPUT (RUN) N
18 G41 20VT/DG (POWER LEFT SLIDING DOOR PILLAR SWITCH MUX E
SLIDING DOOR)
19 L163 20WT/BR (BUILT-UP- LEFT SIDE REPEATER LAMP FEED
C
EXPORT) T
20 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL O
21 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX R
21 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX
22 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX P
22 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX I
23 D25 20WT/VT PCI BUS N
24 - - O
25 M11 20YL/VT COURTESY LAMPS DRIVER U
26 P31 20TN/YL (POWER RE- LIFTGATE RELEASE DRIVER T
LEASE) (EXCEPT BUILT- S
UP-EXPORT LHD SWB
GAS)
26 P31 20TN/DG (POWER LIFTGATE RELEASE DRIVER
RELEASE) (BUILT-UP-
EXPORT LHD SWB GAS)
27 - -
28 - -
29 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE
30 G70 20VT/LB HOOD AJAR SWITCH SENSE
31 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
32 - -
33 M21 20YL/BR COURTESY LAMPS DRIVER
34 M27 20YL/LB READING LAMPS DRIVER
1015
CONNECTOR PINOUTS
BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY
1 E18 20OR/LB (POWER PANEL LAMPS DRIVER (MIRROR SWITCH)
MIRRORS)
2 E12 20OR/GY PANEL LAMPS DRIVER (HVAC)
3 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH)
4 D9 20WT/GY RKE MODULE PROGRAM ENABLE
5 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
6 E17 20OR/YL (EXCEPT PARADE MODE SIGNAL (RADIO)
BUILT-UP-EXPORT)
7 P162 20LG/DG (BUILT-UP- PASSENGER FOLDING MIRROR RELAY CONTROL
EXPORT)
8 G69 20VT/WT (HIGH LINE) VTSS INDICATOR DRIVER
9 L161 20WT/LG LEFT TURN INDICATOR DRIVER
11 E14 20OR/TN PANEL LAMPS DRIVER (RADIO)
12 E13 20OR/YL PANEL LAMPS DRIVER (INSTRUMENT CLUSTER)
13 X920 20GY/OR RADIO CONTROL MUX RETURN
14 G900 20VT/OR IGNITION SWITCH SENSE RETURN
15 - -
16 - -
17 L160 20WT/TN RIGHT TURN INDICATOR DRIVER
C 18 M26 20YL/DB HALO LAMP DRIVER
O 19 - -
N 20 - -
N 21 - -
E 22 G902 20VT/OR MULTI-FUNCTION SWITCH MUX RETURN
C 23 - -
T 24 - -
O 25 - -
R 26 M28 20YL/TN GLOVE BOX LAMP DRIVER

27 - -
P 28 - -
I 29 - -
N 30 - -
O 31 G96 20VT/DG REMOTE KEYLESS ENTRY INTERFACE
U 32 B27 20DG/WT TRACTION CONTROL SWITCH SENSE
T 33 P136 20TN/YL (BUILT-UP- FOLDING MIRROR SWITCH SENSE

EXPORT)
S 34 G26 20VT/OR CHIME DRIVER
1016
CONNECTOR PINOUTS
BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY
1 L91 20WT/DB HAZARD SWITCH SENSE
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 G20 20VT/BR IGNITION SWITCH SENSE
11 - -
12 - -
13 - -
14 - -
15 - -
16 G926 20VT/WT REAR WIPER SWITCH MUX RETURN
17 L900 20WT/YL HEADLAMP SWITCH MUX RETURN
18 L307 20WT/BR HEADLAMP SWITCH MUX
19 - -
20 - - C
21 - - O
22 - - N
23 - - N
24 - - E
25 L36 20WT/DB (BUILT-UP- REAR FOG LAMP INDICATOR DRIVER C
EXPORT)
26 X20 20GY/WT RADIO CONTROL MUX
T
27 G194 20VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
O
28 W26 20BR/DB REAR WIPER SWITCH MUX
R
29 W52 20BR/YL FRONT WIPER SWITCH MUX
30 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL
P
31 L305 20WT/LB TURN SIGNAL SWITCH MUX
I
32 - -
N
33 - -
O
34 L39 20WT/OR (HIGH LINE) FRONT FOG LAMP INDICATOR DRIVER
U
T
S
1017
CONNECTOR PINOUTS
C200 - GRAY (BODY SIDE)
CAV CIRCUIT
1 C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
1 C151 18LB/DG (3 ZONE HVAC)
2 A106 20LB/RD
3 A108 18LG/RD
4 C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL)
4 C152 16LB/LG (3 ZONE HVAC)
5 C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
5 P159 20TN/DG (BUILT-UP-EXPORT)
6 K32 18DB/YL (GAS)
7 C53 20LB (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC)
8 C16 18DB/GY (BUILT-UP-EXPORT)
8 C16 20DB/GY (EXCEPT BUILT-UP-EXPORT)
9 C22 20LB/WT (3 ZONE HVAC)
9 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL)
10 L13 20WT/YL (BUILT-UP-EXPORT)
10 C50 12DB/OR (3 ZONE HVAC)
11 C7 12DB
12 D22 20WT/TN (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
12 Z135 12BK/LB (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)

C
12 C153 12DB/BR (3 ZONE HVAC)
O
13 Z849 12BK/OR
N
14 A105 16DB/RD (BUILT-UP-EXPORT)
N
14 A105 18DB/RD (EXCEPT BUILT-UP-EXPORT)
E
15 A114 16GY/RD
C
16 F306 16DB/PK
T
O 17 C169 20DB/OR (AUTOMATIC TEMPERATURE CONTROL)
R 17 C154 20LB/OR (3 ZONE HVAC)
18 C121 20DB/DG (3 ZONE HVAC)
P 18 D22 20WT/TN (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
I 18 P171 20TN/YL (BUILT-UP-EXPORT)
N 19 P160 18TN/LG (BUILT-UP-EXPORT)
O 20 F302 18GY/PK
U 21 F2 18PK/WT (GAS)
T 22 L78 18WT/OR (BUILT-UP-EXPORT)
S 23 P174 20TN/LB (BUILT-UP-EXPORT)
24 D25 20WT/VT
25 D25 20WT/VT
26 D25 20WT/VT
27 D25 20WT/VT
28 D25 20WT/VT
29 F20 20PK/WT
30 F100 18PK/VT
31 F201 18PK/OR
32 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL)
32 F850 20LB/PK (3 ZONE HVAC)
33 P7 20LG/DG
34 P8 20LG/WT
35 P64 20TN (MEMORY)
1018
CONNECTOR PINOUTS
C200 - GRAY (BODY SIDE) - CONTINUED
CAV CIRCUIT
36 P65 20TN/VT (MEMORY)
37 P66 20TN/LG (MEMORY)
38 P67 20TN/OR (MEMORY)
39 P68 20TN/YL (MEMORY)
40 P69 20TN/WT (MEMORY)
41 P70 18TN/LB (MEMORY)
42 P71 18TN/DG (EXCEPT BUILT-UP-EXPORT) (MEMORY)
42 P71 18TN/GY (BUILT-UP-EXPORT) (MEMORY)
43 P72 18TN/GY (MEMORY)
44 P73 18TN/LB (EXCEPT BUILT-UP-EXPORT) (MEMORY)
44 P73 18TN/VT (BUILT UP-EXPORT) (MEMORY)
45 P74 18TN/DB (MEMORY)
46 P75 18TN/LG (EXCEPT BUILT-UP-EXPORT) (MEMORY)
46 P75 18TN/DB (BUILT-UP-EXPORT) (MEMORY)
47 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT) (POWER MIRRORS)
47 D23 20WT/BR (RHD)
48 B25 20DG/WT (BUILT-UP-EXPORT)
48 P114 20TN/WT (EXCEPT BUILT-UP-EXPORT) (POWER MIRRORS)
49 C154 20LB/OR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) C

50 Z104 18BK/LG O
51 X156 20GY/LB (PREMIUM 8 SPEAKER) N
52 - N
53 R57 18LG/GY E
54 R58 18LB/GY C
55 R59 18LG/TN T
56 R60 18LB/TN
O
57 P162 18LG/DG (BUILT-UP-EXPORT)
R
57 T55 20YL/VT (AUTOSTICK)
58 T751 20YL
P
I
59 X15 16GY/DG (PREMIUM 8 SPEAKER)
N
60 V37 20VT
O
61 X3 20DG/VT
U
62 C54 20LB/YL (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC)
T
63 A701 16BR/RD
S
64 X51 20DG/DB
65 X52 20GY/DB
66 X53 20DG
67 X54 20GY
68 X55 20DG/BR
69 X56 20GY/BR
70 X57 20DG/OR
71 X58 20GY/OR
72 X153 20DG/YL (PREMIUM 8 SPEAKER)
73 X154 20GY/YL (PREMIUM 8 SPEAKER)
74 X155 20DG/LB (PREMIUM 8 SPEAKER)
1019
CONNECTOR PINOUTS
C200 - GRAY (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
1 C151 18LB/DG (3 ZONE HVAC)
2 A106 20LB/RD
3 A108 18LG/RD
4 C152 16LB/LG (3 ZONE HVAC)
4 C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL)
5 C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CON-
TROL)
5 P159 20TN/DG (BUILT-UP-EXPORT)
6 K32 18DB/YL
7 C53 20LB (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC)
8 C16 20DB/GY (POWER MIRRORS)
9 C22 20 LB/WT (3 ZONE HVAC)
9 D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL)
10 C50 12DB/OR (3 ZONE HVAC)
10 L13 20WT/YL (BUILT-UP-EXPORT)
11 C7 12DB
12 C153 12DB/BR (3 ZONE HVAC)
12 Z135 12BK/LB (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CON-
TROL)
C 12 D22 20WT/TN (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
O 13 Z849 12BK/OR
N 14 A105 16DB/RD
N 15 A114 16GY/RD
E 16 F306 16DB/PK
C 17 C154 20LB/OR (3 ZONE HVAC)
T 17 C169 20DB/OR (AUTOMATIC TEMPERATURE CONTROL)
O 18 C121 20DB/DG (3 ZONE HVAC)
R 18 D22 20WT/TN (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CON-
TROL)
P 18 P171 20TN/YL (BUILT-UP-EXPORT)
I 19 P160 18TN/LG (BUILT-UP-EXPORT)
N 20 F302 18GY/PK
O 21 F2 18PK/YL
U 22 L78 20WT/OR (BUILT-UP-EXPORT)
T 23 P174 20TN/LB (BUILT-UP-EXPORT)
S 24 D25 18WT/VT
25 D25 20WT/VT
26 D25 20WT/VT
27 D25 20WT/VT
28 D25 20WT/VT
29 F20 20PK/WT
30 F100 18PK/VT
31 F201 18PK/OR
32 F850 20LB/PK (3 ZONE HVAC)
32 F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL)
33 P7 20LG/DG
34 P8 20LG/WT
35 P64 20TN (MEMORY)
38 P67 20TN/OR (MEMORY)
39 P68 20TN/YL (MEMORY)
40 P69 20TN/WT (MEMORY)
1020
CONNECTOR PINOUTS
C200 - GRAY (INSTRUMENT PANEL SIDE) - CONTINUED
CAV CIRCUIT
41 P70 18TN/LB (MEMORY)
42 P71 18TN/DG (MEMORY)
43 P72 18TN/GY (MEMORY)
45 P74 18TN/DB (MEMORY)
47 P112 20TN/OR (EXCEPT BUILT-UP-EXPORT) (POWER MIRRORS)
47 D23 20WT/BR (RHD)
48 P114 20TN/WT (EXCEPT BUILT-UP-EXPORT) (POWER MIRRORS)
48 B25 20DG/WT (BUILT-UP-EXPORT)
49 C154 20LB/OR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC)
50 Z104 18BK/LG
51 X156 20GY/LB (PREMIUM 8 SPEAKER)
52 -
53 R57 18LG/GY
54 R58 18LB/GY
55 R59 18LG/TN
56 R60 18LB/TN
57 P162 20LG/DG (BUILT-UP-EXPORT) C
58 T751 20YL O
59 X15 16GY/DG (PREMIUM 8 SPEAKER) N
60 V37 20VT N
61 X3 20DG/VT E
62 C54 20LB/YL (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC) C
63 A701 16BR/RD T
64 X51 20DG/DB O
65 X52 20GY/DB R
66 X53 20DG
67 X54 20GY P
68 X55 20DG/BR I
69 X56 20GY/BR N
70 X57 20DG/OR O
71 X58 20GY/OR U
72 X153 20DG/YL (PREMIUM 8 SPEAKER) T
73 X154 20GY/YL (PREMIUM 8 SPEAKER) S
74 X155 20DG/LB (PREMIUM 8 SPEAKER)
C201 - YELLOW (BODY SIDE)

CAV CIRCUIT
1 R53 18LG/YL
2 R55 18LG/DG
3 R54 18LB/YL
4 R56 18LB/DG
1021
CONNECTOR PINOUTS
C201 - YELLOW (INSTRUMENT PANEL SIDE)

CAV CIRCUIT
1 R53 18LG/YL
2 R55 18LG/DG
3 R54 18LB/YL
4 R56 18LB/DG
C202 - GRAY (COMPONENT SIDE)

CAV CIRCUIT
1 Z134 12BK/OR (AUTOMATIC
TEMPERATURE CONTROL)
2 C34 20DB/LB (MANUAL
2 C56 20DB/LB (AUTOMATIC
3 C32 20DB/TN
4 C33 20LB/BR
5 C61 20LB/WT (MTC)
5 C61 20DB/LG (ATC)
6 C35 20LB/OR
7 C7 12DB (AUTOMATIC
C TEMPERATURE CONTROL)
O 8 C132 20DB/YL (AUTOMATIC
N
9 C133 20DB/WT (AUTOMAT-
N IC TEMPERATURE CON-
E TROL)
C 10 C161 20LB/WT (AUTOMAT-
IC TEMPERATURE CON-
T TROL)
O 11 C135 20DB/GY (AUTOMAT-
R IC TEMPERATURE CON-
TROL)
12 C21 20DB/LG
P
13 C121 20DB/DG
I
N
O
U
T
S
1022
CONNECTOR PINOUTS
C202 - GRAY (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 Z134 12BK/OR (AUTOMATIC
2 C34 20DB/LB (MANUAL
2 C56 20DB/LB (AUTOMATIC
3 C32 20DB/TN
4 C33 20LB/BR
5 C61 20DB/LG
6 C35 20LB/OR
7 C7 12DB (AUTOMATIC
8 C132 20DB/YL (AUTOMATIC
9 C133 20DB/WT (AUTOMAT-
IC TEMPERATURE CON-
TROL)
10 C161 20LB/WT (AUTOMAT-
IC TEMPERATURE CON-
TROL)
11 C135 20DB/GY (AUTOMAT-
IC TEMPERATURE CON-
TROL)
12 C21 20DB/LG C
13 C121 20DB/DG O
N
N
C304 - YELLOW (BODY SIDE) E
CAV CIRCUIT C
1 R54 18LB/YL (RHD) T
1 R53 18LG/YL (LHD) O
2 R56 18LB/DG (RHD) R
2 R55 18LG/DG (LHD)
3 R31 18LG/OR P
4 R33 18LG/WT I
N
O
C304 - YELLOW (SEAT SIDE) U
CAV CIRCUIT
T
1 R54 18LB/YL (RHD)
S
1 R53 18LG/YL (LHD)
2 R56 18LB/DG (RHD)
2 R55 18LG/DG (LHD)
3 R31 18LG/OR
4 R33 18LG/WT
1023
CONNECTOR PINOUTS
CAV CIRCUIT
1 Z849 12BK/OR
2 R57 18LG/GY
3 R59 18LG/TN
4 P7 20LG/DG
5 A210 14OR/RD
6 F503 20WT/PK
7 A110 12OR/RD
8 -
9 -
10 -
11 -
12 -
13 -
C306 - YELLOW (BODY SIDE)

CAV CIRCUIT
1 R53 18LG/YL (RHD)
1 R54 18LB/YL (LHD)
2 R55 18LG/DG (RHD)
C 2 R56 18LB/DG (LHD)
O 3 R32 18LB/OR
N 4 R34 18LB/WT
N
E C306 - YELLOW (SEAT SIDE)
C CAV CIRCUIT
T 1 R53 18LG/YL (RHD)
O 1 R54 18LB/YL (LHD)
R 2 R55 18LG/DG (RHD)
2 R56 18LB/DG (LHD)
P 3 R32 18LB/OR
I 4 R34 18LB/WT
N
O
U C307 - GRAY (BODY SIDE)
CAV CIRCUIT
T
1 Z848 12BK/OR
S
2 R58 18LB/GY
3 R60 18LB/TN
4 P8 20LG/WT
5 A210 14OR/RD
6 F503 20WT/PK
7 -
8 -
9 -
10 -
11 -
12 -
1024
CONNECTOR PINOUTS
C307 - GRAY (SEAT SIDE)
CAV CIRCUIT
1 Z848 18BK/OR (POWER/
HEATED SEAT)
2 R58 18LB/GY
3 R60 18LB/TN
4 P8 20LG/WT (HEATED
SEAT)
5 A210 14OR/RD (POWER/
HEATED SEAT)
6 F503 20WT/PK (HEATED
SEAT)
7 -
8 -
9 -
10 -
11 -
12 -

CAV CIRCUIT
1 C153 12DB/BR (3 ZONE
HVAC)
2 F850 20LB/PK (3 ZONE C
HVAC) O
2 F504 20GY/PK (AUTOMATIC N
N
3 C121 20DB/DG (3 ZONE
HVAC) E
3 D22 20WT/TN (AUTOMATIC C
TEMPERATURE CONTROL) T
4 C22 20LB/WT (3 ZONE O
HVAC)
R
4 D17 20WT/DG (AUTOMATIC
5 C151 18LB/DG (3 ZONE P
HVAC) I
6 - N
7 C152 16LB/LG (3 ZONE O
HVAC)
U
8 E10 20OR/DG
T
9 Z409 20BK/OR (3 ZONE
HVAC) S
9 Z27 18BK/DG (AUTOMATIC
10 C50 12DB/OR (3 ZONE
HVAC)
1025
CONNECTOR PINOUTS
C311 - GRAY (REAR A/C JUMPER SIDE)
CAV CIRCUIT
1 C153 12 DB/BR (3 ZONE
HVAC)
2 F850 20LB/PK (3 ZONE
HVAC)
2 F504 20GY/PK (AUTOMATIC
3 C121 20DB/DG (3 ZONE
HVAC)
3 D22 20WT/TN (AUTOMATIC
4 C22 20LB/DB (3 ZONE
HVAC)
4 D17 20WT/DG (AUTOMATIC
5 C151 18LB/DG (3 ZONE
HVAC)
6 -
7 C152 16LB/LG (3 ZONE
HVAC)
8 E10 20OR/DG
9 Z409 20BK/OR (3 ZONE
HVAC)
9 Z27 18BK/DG (AUTOMATIC
C TEMPERATURE CONTROL)
O 10 C50 12DB/OR (3 ZONE
N HVAC)
N
E C314 (HIGH LINE) - BLACK (BODY SIDE)
C CAV CIRCUIT
T 1 G32 20VT/LB (POWER LIFT-

GATE)
O
2 L77 18WT/BR
R
3 L50 18WT/TN
4 P30 20TN/DG
P
5 P31 20TN/DG (POWER
I RELEASE/BUILT-UP-EXPORT
N LHD SWB GAS)
O 5 P31 20TN/YL (POWER

RELEASE/EXCEPT BUILT-
U UP-EXPORT LHD SWB
T GAS)
S 6 Q60 20OR/YL (POWER

LIFTGATE)
7 Q84 18TN/GY (POWER
LIFTGATE)
8 Z87 20BK/LG (POWER LIFT-
GATE)
9 Q83 18OR/GY (POWER
LIFTGATE)
10 Z800 12BK
1026
CONNECTOR PINOUTS
C314 (HIGH LINE) - BLACK (LIFTGATE SIDE)
CAV CIRCUIT
1 G32 20VT/LB (POWER LIFT-
GATE)
2 L77 18WT/BR
3 L50 18WT/TN
4 P30 20TN/DG
5 P31 20TN/YL (POWER RE-
LEASE)
6 Q60 20OR/YL (POWER
LIFTGATE)
7 Q84 18TN/GY (POWER
LIFTGATE)
8 Z87 20BK/LG (POWER LIFT-
GATE)
9 Q83 18OR/GY (POWER
LIFTGATE)
10 Z800 12BK
C315 (HIGH LINE) - BLACK (BODY SIDE)

CAV CIRCUIT
1 C15 12DB/WT
2 Q76 20OR/LB (POWER
LIFTGATE)
C
3 G78 20VT/OR
O
4 M11 20YL/VT
N
5 G165 20VT/GY
N
6 Q85 18TN/WT (POWER
LIFTGATE) E
7 Q94 20TN/LG (POWER C
LIFTGATE) T
8 W13 18BR/LG O
9 F302 18GY/PK R
10 Z245 18BK/GY (POWER
LIFTGATE)
P
I
C315 (HIGH LINE) - BLACK (LIFTGATE SIDE) N
CAV CIRCUIT
O
1 C15 12DB/WT
U
2 Q76 20OR/LB (POWER
LIFTGATE) T
3 G78 20VT/OR S
4 M11 20YL/VT
5 G165 20VT/GY
6 Q85 18TN/WT (POWER
LIFTGATE)
7 Q94 20TN/LG (POWER
LIFTGATE)
8 W13 18BR/LG
9 F302 18GY/PK
10 Z245 18BK/GY (POWER
LIFTGATE)
1027
CONNECTOR PINOUTS
C316 (POWER SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY SIDE)
CAV CIRCUIT
1 P5 20BK/DB
2 P32 20BK/TN
3 G77 20BK/DG
4 Z825 14BK
5 -
6 -
7 G151 20BK/GY
8 D25 20BK/VT
9 -
10 A113 14BK/RD
C316 (POWER SLIDING DOOR) - BLACK (LEFT SLIDING DOOR SIDE)

CAV CIRCUIT
1 P5 20TN/OR
2 P32 20TN/VT
3 G77 20TN/OR
4 Z825 14BK/WT
5 -
6 -
C 7 G151 20VT/BR
O 8 D25 20WT/VT
N 9 -
N 10 A113 14WT/RD
E
C C317 (POWER SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE)
T CAV CIRCUIT
O 1 P38 20BK/DB
R 2 P34 20BK/TN
3 G76 20BK/DG
P 4 Z824 14BK
I 5 -
N 6 -
O 7 G152 20BK/GY
U 8 D25 20BK/VT
T 9 -
S 10 A113 14BK/RD
C317 (POWER SLIDING DOOR) - BLACK (RIGHT SLIDING DOOR SIDE)

CAV CIRCUIT
1 P38 20TN/DB
2 P34 20TN/LB
3 G76 20TN/OR
4 Z824 14BK/WT
5 -
6 -
7 G152 20VT/GY
8 D25 20WT/VT
9 -
10 A113 14WT/RD
1028
CONNECTOR PINOUTS
C322 (MEMORY) - BLACK (BODY SIDE)
CAV CIRCUIT
1 P69 20TN/WT
2 P67 20TN/OR
3 P64 20TN
4 P66 20TN/LG
5 P68 20TN/YL
6 P65 20TN/VT
7 D25 20WT/VT
8 P73 18TN/VT (EXCEPT
BUILT-UP-EXPORT)
8 P73 18TN/LB (BUILT-UP-
EXPORT)
9 P75 18TN/LG (EXCEPT
BUILT-UP-EXPORT)
9 P75 18TN/DB (BUILT-UP-
EXPORT)
10 P71 18TN/DG (EXCEPT
BUILT-UP-EXPORT)
10 P71 18TN/GY (BUILT-UP-
EXPORT)
11 P70 18TN/LB
12 P74 18TN/DB
13 P72 18TN/GY C
14 - O
N
C322 (MEMORY) - BLACK (POWER SEAT SIDE) N
CAV CIRCUIT E
1 P69 20TN/WT C
2 P67 20OR T
3 P64 20TN/OR O
4 P66 20WT R
5 P68 20YL
6 P65 20TN/YL P
7 D25 20WT/VT I
8 P73 18TN/LB N
9 P75 18DB O
10 P71 18TN/GY U
11 P70 18LB T
12 P74 18TN/DB S
13 P72 18GY
14 -
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY SIDE
CAV CIRCUIT
1 P5 20BK/DB
2 P32 20BK/TN
3 G77 20BK/DG
4 Z77 20BK
1029
CONNECTOR PINOUTS
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT MANUAL SLIDING DOOR SIDE)
CAV CIRCUIT
1 P5 20BK/DB
2 P32 20BK/TN
3 G77 20BK/DG
4 Z77 20BK
C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY SID
CAV CIRCUIT
1 P38 20BK/DB
2 P34 20BK/TN
3 G76 20BK/DG
4 Z76 20BK
C
O
N C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT MANUAL SLIDING DOOR SIDE)
N CAV CIRCUIT
E 1 P38 20BK/DB
C 2 P34 20BK/TN
T 3 G76 20BK/DG
O 4 Z76 20BK
R
P
I C326 - YELLOW (SAFETY SEAT SIDE)
N CAV CIRCUIT
O 1 -
U 2 -
T 3 R33 18WT/BK (BUILT-UP-
S EXPORT)
3 R33 18LG/WT (EXCEPT
BUILT-UP-EXPORT)
4 R31 18LG/OR (EXCEPT
BUILT-UP-EXPORT)
4 R31 18DG/WT (BUILT-UP-
EXPORT)
C326 - YELLOW (SEAT SIDE)

CAV CIRCUIT
1 -
2 -
3 R33 18LG/WT
4 R31 18LG/OR
1030
CONNECTOR PINOUTS
C327 - YELLOW (SAFETY SEAT SIDE)
CAV CIRCUIT
1 -
2 -
3 R34 18LB/WT (EXCEPT
BUILT-UP-EXPORT)
3 R34 18WT/BK (BUILT-UP-
EXPORT)
4 R32 18DG/WT (BUILT-UP-
EXPORT)
4 R32 18LB/OR (EXCEPT
BUILT-UP-EXPORT)
C327 - YELLOW (SEAT SIDE)

CAV CIRCUIT
1 -
2 -
3 R34 18LB/WT
4 R32 18LB/OR
C
O
C330 (DIESEL) - GRAY (CABIN HEATER JUMPER SIDE)
CAV CIRCUIT
N
1 A119 16RD/OR
N
2 C41 20LB/DG
E
3 D21 20WT
C
4 Z149 16BK/DB
T
O
R
P
I
C330 (DIESEL) - LT. GRAY (BODY SIDE) N
CAV CIRCUIT O
1 A119 16RD/OR U
2 C41 20LB/DG T
3 D21 20WT/BR S
4 Z149 16BK/DB
C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE)

CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT
4 Z149 18BK/DB
1031
CONNECTOR PINOUTS
C331 (DIESEL) - GRAY (CABIN HEATED COMPONENT SIDE)

CAV CIRCUIT
1 A119 14RD/OR
2 C41 20DB/OR
3 D21 20WT/DB
4 Z149 14BK/DB
CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAY

1 - -
2 D21 20WT/DB SCI TRANSMIT
3 - -
4 - -
5 C41 20DB/OR CABIN HEATER ASSIST CONTROL
6 18RD DOSING PUMP CONTROL
C
O
N
N
E
C CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY
O 1 A119 14RD/OR FUSED B(+)
R 2 Z149 14BK/DB GROUND
P
I
N
O
U
T
S
1032
CONNECTOR PINOUTS
CD CHANGER - 8 WAY
1 X40 20GY/WT (EXCEPT AUDIO OUT RIGHT
BUILT-UP-EXPORT)
1 X40 24GY/WT (BUILT-UP- AUDIO OUT RIGHT
EXPORT)
2 E14 18OR/TN (EXCEPT PANEL LAMPS DRIVER
BUILT-UP-EXPORT)
2 E14 24OR/TN (BUILT-UP- PANEL LAMPS DRIVER
EXPORT)
3 D25 20WT/VT (EXCEPT PCI BUS
BUILT-UP-EXPORT)
3 D25 24VT/YL (BUILT-UP- PCI BUS
EXPORT)
4 X112 20RD (EXCEPT IGNITION SWITCH OUTPUT
BUILT-UP-EXPORT)
4 X112 24RD (BUILT-UP- IGNITION SWITCH OUTPUT
EXPORT)
5 X41 20DG/WT (EXCEPT AUDIO OUT LEFT
BUILT-UP-EXPORT)
5 X41 24DG/WT (BUILT-UP- AUDIO OUT LEFT
EXPORT)
6 Z140 24BK/OR (BUILT-UP- GROUND
EXPORT)
6 Z140 18BK/OR (EXCEPT GROUND
BUILT-UP-EXPORT) C
7 Z141 18BK/TN (EXCEPT GROUND O
BUILT-UP-EXPORT)
7 Z141 22BK/TN (BUILT-UP- GROUND
N
EXPORT) N
8 X160 20GY/YL (EXCEPT B(+) E
BUILT-UP-EXPORT) C
8 X160 22GY/YL (BUILT-UP- B(+) T
EXPORT)
O
R
P
CENTER DOME LAMP (BASE/HIGH LINE) - GRAY 3 WAY I
CAV CIRCUIT FUNCTION N
1 M22 20YL/OR COURTESY LAMPS DRIVER O
2 Z327 20BK/OR GROUND U
3 M27 20YL/LB READING LAMPS DRIVER T
S
CLOCKSPRING C1 - WHITE 6 WAY

1 X920 20GY/OR RADIO CONTROL MUX RETURN
2 X20 20GY/WT RADIO CONTROL MUX
3 X3 20DG/VT HORN SWITCH SENSE
4 V37 20VT SPEED CONTROL SWITCH SIGNAL
5 Z23 20BK/LB SPEED CONTROL SWITCH GROUND
6 - -
1033
CONNECTOR PINOUTS
CLOCKSPRING C2 - YELLOW 4 WAY

1 R61 18LG/VT DRIVER SQUIB 2 LINE 1
2 R63 18LG/WT DRIVER SQUIB 2 LINE 2
3 R43 18LG/BR DRIVER SQUIB 1 LINE 1
4 R45 18LG/OR DRIVER SQUIB 1 LINE 2
CLOCKSPRING C4 - BLACK 2 WAY

1 X20 20RD/BK RADIO CONTROL MUX
2 X920 20RD/DB RADIO CONTROL MUX RETURN
C
O
N CLOCKSPRING C5 - YELLOW 4 WAY
N
1 R45 18OR/LB DRIVER SQUIB 1 LINE 2
E
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
C
3 R63 18TN/LB DRIVER SQUIB 2 LINE 2
T
O
R
P
I
N
O
U
T
S
1034
CONNECTOR PINOUTS
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY
1 Z107 12BK/TN (EXCEPT GROUND
BUILT-UP-EXPORT/ 2.4L)
1 Z107 12BK/DG (OTHER) GROUND
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
4 - -
6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
8 - -
9 A111 12DG/RD FUSED B(+)
10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 - -
12 - -
13 - -
14 - -
15 - -
16 Z127 12BK/DG GROUND
17 - -
18 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
C
20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
O
21 - -
N
22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL
N
23 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
E
24 A107 12TN/RD FUSED B(+)
C
T
O
DATA LINK CONNECTOR - BLACK 16 WAY
R
1 - -
P
I
3 - -
N
4 Z11 18BK/LG GROUND
O
5 Z111 18BK/WT (EXCEPT GROUND
BUILT-UP-EXPORT) U
5 Z111 20BK/WT (BUILT-UP- GROUND T
EXPORT) S
6 D20 20WT/LG (GAS) SCI RECEIVE
7 D21 20WT/BR SCI TRANSMIT
8 - -
10 - -
11 - -
12 - -
13 - -
14 D16 20WT/OR (GAS) SCI RECEIVE
15 - -
16 A105 20DB/RD FUSED B(+)
1035
CONNECTOR PINOUTS
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY
1 D25 20WT/VT PCI BUS (PCM/SKIM/ECM/THATCHAM)
2 D25 20WT/VT PCI BUS (HVAC)
3 D25 20WT/VT PCI BUS (RADIO)
4 D25 20WT/VT PCI BUS (ORC)
5 D25 20WT/VT PCI BUS (CLUSTER)
6 D25 20WT/VT PCI BUS (BCM)
7 D25 20WT/VT PCI BUS (DLC)
8 D25 20WT/VT PCI BUS (OVERHEAD CONSOLE)
9 D25 20WT/VT PCI BUS (FCM/TCM/CAB)
10 D25 20WT/VT PCI BUS (LSIACM)
11 D25 20WT/VT (MEMORY) PCI BUS (MEMORY)
12 D25 20WT/VT PCI BUS (PWR DOOR LT/RT/LIFTGATE)
13 D25 20WT/VT PCI BUS (RSIACM)
14 - -
15 - -
16 - -
C
DOSING PUMP - BLACK 2 WAY
O
N
1 18RD DOSING PUMP CONTROL
N
2 Z149 18BK/DB GROUND
E
C
T
O
R
P
I
N DRIVER AIRBAG C1 - BROWN 2 WAY
O CAV CIRCUIT FUNCTION
U 1 R43 18BK/LB DRIVER SQUIB 1 LINE 1
T 2 R45 18OR/LB DRIVER SQUIB 1 LINE 2
DRIVER AIRBAG C2 - BLACK 2 WAY

2 R63 18TN/LB DRIVER SQUIB 2 LINE 2
1036
CONNECTOR PINOUTS
DRIVER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY

2 C161 20LB/WT DRIVER BLEND DOOR DRIVER (B)
DRIVER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY

1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B)
1 C61 20LB/WT(RHD) DRIVER BLEND DOOR DRIVER (A)
2 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B)
2 C61 20LB/WT (LHD) DRIVER BLEND DOOR DRIVER (A) C
O
N
N
E
DRIVER DOOR LOCK SWITCH - BLACK 3 WAY C
CAV CIRCUIT FUNCTION T
1 F304 16WT/PK (EXCEPT FUSED ACCESSORY RELAY OUTPUT O
POWER WINDOWS)
R
1 F304 16WT/PK (POWER FUSED WINDOW CIRCUIT BREAKER OUTPUT
WINDOWS)
2 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX P
2 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX I
3 Z461 20BK/DG (LHD) GROUND N
3 Z460 20BK/LG (RHD) GROUND O
U
T
S
DRIVER SEAT BELT SWITCH - WHITE 2 WAY

1 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1
2 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2
1037
CONNECTOR PINOUTS
DRIVER SEAT BELT TENSIONER - 2 WAY

1 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
2 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY

1 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
2 - -
C
O
N
N
ELECTRIC WIPER DE-ICER C2 - WHITE 2 WAY
E CAV CIRCUIT FUNCTION
C 1 C900 18LB/VT WIPER DE-ICER DRIVER
T 2 - -
O
R
P
I
N
O
U
T
S
1038
CONNECTOR PINOUTS
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
1 Z130 14BK/BR GROUND
3 K20 14BR/GY GENERATOR FIELD CONTROL
4 K342 14BR/WT ECM/PCM RELAY OUTPUT
6 - -
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 N1 20DB/OR FUEL HEATER RELAY OUTPUT
20 Z138 20BK/OR GROUND C
21 K900 20DB/DG SENSOR GROUND O
22 F202 20PK/GY IGNITION SWITCH OUTPUT (RUN-START) N
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B N
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1 E
25 - - C
26 - - T
27 - - O
28 - - R
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL P
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL I
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL N
33 - - O
34 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND U
35 K853 20DB/BR ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY T
36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL S
37 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Z122 18WT GROUND (DRAIN)
43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
44 - -
45 - -
46 - -
48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
49 T751 20YL IGNITION SWITCH OUTPUT (START)
50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
1039
CONNECTOR PINOUTS
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY - CONTINUED
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
C 70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
O 71 - -
N 72 N21 20DB/TN LIFT PUMP RELAY CONTROL
N 73 - -
E 74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
C 75 - -
T 76 - -
O 77 K152 20DB/WT GLOW PLUG RELAY CONTROL
R 78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL

79 - -
P 80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
I 81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
N
O
U
T
S
1040
CONNECTOR PINOUTS
82 - -
83 - -
84 - -
85 - -
86 T753 20DG/YL IGNITION SWITCH OUTPUT (START)
87 - -
88 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - - C
102 - - O
103 - - N
104 - - N
105 - - E
106 - - C
107 - - T
108 - - O
109 - - R
110 - -
111 - - P
112 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE I
113 - - N
114 - - O
115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL U
116 K111 14DB/LB COMMON INJECTOR DRIVER T
117 - - S
118 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL
119 K12 14TN FUEL INJECTOR NO. 2 CONTROL
120 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL
121 - -
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY

1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG SENSOR GROUND
1041
CONNECTOR PINOUTS
FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY

1 - -
3 C56 20DB/LB BLOWER MOTOR CONTROL
FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY

1 C7 12DB (EXCEPT BUILT- HIGH SPEED BLOWER MOTOR
UP-EXPORT)
1 C7 12DG (BUILT-UP- HIGH SPEED BLOWER MOTOR
EXPORT)
2 C70 12BK (BUILT-UP- REAR BLOWER HIGH SPEED
EXPORT)
2 C70 12DB/YL (EXCEPT REAR BLOWER HIGH SPEED
BUILT-UP-EXPORT)
C
O
N
N FRONT READING LAMPS/SWITCH - BLACK 6 WAY
E
1 E15 20OR/DB (EXCEPT ASH/RECEIVER LAMP FEED
C BASE)
T 2 Z137 20BK/LB GROUND
O 3 - -
R 4 M27 20YL/LB READING LAMPS DRIVER
5 M24 20YL/WT COURTESY LAMPS DRIVER
P 6 - -
I
N
O
U
T GLOVE BOX LAMP - BLUE 2 WAY
S CAV CIRCUIT FUNCTION
1 M28 20YL/TN GLOVE BOX LAMP DRIVER
HALO LAMP - BLUE 2 WAY

2 M26 20YL/DB HALO LAMP DRIVER
1042
CONNECTOR PINOUTS
HEADLAMP SWITCH - BLACK 13 WAY
1 Z403 20BK/YL (BUILT-UP- GROUND
EXPORT)
2 L78 20WT/OR (BUILT-UP- FUSED PARK LAMP RELAY OUTPUT
EXPORT)
3 - -
5 L36 20WT/DB (BUILT-UP- REAR FOG LAMP INDICATOR DRIVER
EXPORT)
6 L900 20WT/YL HEADLAMP SWITCH MUX RETURN
7 L13 20WT/YL (BUILT-UP- HEADLAMP ADJUST SIGNAL
EXPORT)
8 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH)
9 - -
10 L39 20WT/OR (HIGH LINE) FRONT FOG LAMP INDICATOR DRIVER
11 L307 20WT/BR HEADLAMP SWITCH MUX
12 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL
13 - -
C
HEADLAMP WASHER PUMP MOTOR (BUILT-UP-EXPORT) - BLACK 2 WAY O
N
1 V53 12BR/OR HEADLAMP WASHER RELAY OUTPUT
N
E
C
T
O
R
IGNITION SWITCH - BLACK 5 WAY P

CAV CIRCUIT FUNCTION I
1 G900 20VT/OR IGNITION SWITCH SENSE RETURN N
2 G20 20VT/BR IGNITION SWITCH SENSE O
3 F20 20PK/WT (LHD) IGNITION SWITCH OUTPUT (RUN-START) U
3 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START) T
4 T751 20YL IGNITION SWITCH OUTPUT (START) S
5 A106 20LB/RD FUSED B(+)
1043
CONNECTOR PINOUTS
INSTRUMENT CLUSTER - BLACK 13 WAY
1 E13 20OR/YL PANEL LAMPS DRIVER
2 L160 20WT/TN (LOW RIGHT TURN INDICATOR DRIVER
LINE)
3 G7 20VT/GY (HIGH LINE) LOW OIL PRESSURE INDICATOR DRIVER
4 G3 20VT/LB (HIGH LINE) MALFUNCTION INDICATOR LAMP DRIVER
5 L134 20WT/GY (HIGH HIGH BEAM INDICATOR DRIVER
LINE)
6 A701 16BR/RD FUSED B(+) (HAZARD)
8 L161 20WT/LG (LOW LEFT TURN INDICATOR DRIVER
LINE)
10 B25 20DG/WT (RHD) PARK BRAKE SWITCH SENSE
10 B25 16DG/WT (LHD) PARK BRAKE SWITCH SENSE
11 G26 20VT/OR CHIME DRIVER
12 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
13 Z18 18BK/LB GROUND
INTELLIGENT POWER MODULE C1 - LT. GREEN/RED 20 WAY

C 1 F301 18VT/PK FUSED ACCESSORY RELAY OUTPUT
O 2 - -
N 3 - -
N 4 L43 18WT/DB LEFT LOW BEAM DRIVER
E 5 Z344 16BK/TN GROUND
C 6 L34 16WT/GY RIGHT HIGH BEAM DRIVER
T 7 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
O 8 L33 18WT/LG LEFT HIGH BEAM DRIVER
R 9 G31 18VT/LG (EXCEPT AMBIENT TEMPERATURE SENSOR SIGNAL

BASE)
10 L44 16WT/TN RIGHT LOW BEAM DRIVER
P
11 F300 18OR/PK FUSED ACCESSORY RELAY OUTPUT
I
12 - -
N
O
14 - -
U
15 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
T
16 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
S
17 - -
18 G931 18VT/BR (EXCEPT AMBIENT TEMPERATURE SENSOR RETURN
BASE)
19 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
1044
CONNECTOR PINOUTS
INTELLIGENT POWER MODULE C2 - GREEN/BLUE 10 WAY
1 N173 18DB/VT (EXCEPT RADIATOR FAN RELAY CONTROL
BUILT-UP-EXPORT/GAS)
1 N173 16DB/VT (BUILT-UP- RADIATOR FAN RELAY CONTROL
EXPORT/GAS)
2 V53 12BR/OR (BUILT-UP- HEADLAMP WASHER RELAY OUTPUT
EXPORT)
3 L60 18WT/TN (EXCEPT RIGHT FRONT TURN SIGNAL DRIVER
BUILT-UP-EXPORT)
3 L60 16WT/TN (BUILT-UP- RIGHT FRONT TURN SIGNAL DRIVER
EXPORT)
4 L13 18WT/YL (BUILT-UP- HEADLAMP ADJUST SIGNAL
EXPORT)
5 X2 18DG/OR HORN RELAY OUTPUT
6 L90 18WT/OR (FOG FRONT FOG LAMP RELAY OUTPUT
LAMPS)
7 L61 18WT/LG (EXCEPT LEFT FRONT TURN SIGNAL DRIVER
BUILT-UP-EXPORT)
7 L61 16WT/LG (BUILT-UP- LEFT FRONT TURN SIGNAL DRIVER
EXPORT)
8 - -
9 A112 12OR/RD FUSED B(+)
10 L89 18WT/YL (FOG FRONT FOG LAMP RELAY OUTPUT
LAMPS)
C
O
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY
N
N
1 N21 20DB/TN LIFT PUMP RELAY CONTROL
E
2 - -
C
T
4 T2 18DG/WT TRS REVERSE SENSE
O
5 N2 18DB/YL LIFT PUMP RELAY OUTPUT
R
6 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
P
I
N
10 A119 16RD/OR FUSED B(+)
O
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL
U
T
13 - -
S
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
18 - -
20 - -
1045
CONNECTOR PINOUTS
INTELLIGENT POWER MODULE C3 (GAS) - NATURAL/RED 20 WAY
1 Z115 20BK/OR (EATX) GROUND
(3.3L/3.8L)
1 Z115 18BK/OR (EATX) GROUND
(2.4L)
2 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
3 T751 18YL (EATX) IGNITION SWITCH OUTPUT (START)
5 T16 18YL/OR (EATX) TRANSMISSION CONTROL RELAY OUTPUT
6 T15 18YL/BR (EATX) TRANSMISSION CONTROL RELAY CONTROL
8 K31 18BR FUEL PUMP RELAY CONTROL
10 A104 18YL/RD (EATX) FUSED B(+)
11 - -
12 - -
13 D25 18WT/VT (EATX) PCI BUS (EATX)
14 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
16 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
C 18 K173 18BR/VT RADIATOR FAN RELAY CONTROL
O 19 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
N 20 A109 18OR/RD FUSED B(+)
N
E INTELLIGENT POWER MODULE C4 - BLUE 10 WAY
C CAV CIRCUIT FUNCTION
T 1 Z127 12BK/DG (GAS) GROUND
O 2 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
R 3 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
3 K342 16BR/WT (GAS) AUTOMATIC SHUTDOWN RELAY OUTPUT
P 4 F500 16DG/PK (EXCEPT FUSED IGNITION SWITCH OUTPUT (RUN)
I MTX))
N 5 - -
O 6 D25 16WT/VT (ANTILOCK PCI BUS

BRAKES)
U
7 A107 12TN/RD (ANTILOCK FUSED B(+)
T BRAKES)
S 8 A111 12DG/RD (ANTILOCK FUSED B(+)
BRAKES)
9 A701 14BR/RD (GAS) B(+) (HAZARD FEED)
9 A710 14BR/RD (DIESEL) B(+) (HAZARD FEED)
10 - -
INTELLIGENT POWER MODULE C5 - BLACK 4 WAY

1 A1 4RD B(+)
2 - -
3 - -
4 - -
1046
CONNECTOR PINOUTS
INTELLIGENT POWER MODULE C6 - NATURAL 10 WAY
1 A101 12VT/RD FUSED B(+)
2 Z117 16BK/WT GROUND
3 Z118 16BK/YL GROUND
4 A110 12OR/RD (POWER FUSED B(+)
SEAT)
5 - -
6 - -
8 F307 16LB/PK (BATTERY FUSED B(+)
POSITION)
8 F307 16LB/PK (ACCESSO- FUSED ACCESORY RELAY OUTPUT
RY RELAY POSITION)
9 A113 12WT/RD (POWER FUSED B(+)
SLIDING DOOR)
10 - -
INTELLIGENT POWER MODULE C7 - BLACK/RED 20 WAY

1 C16 20DB/GY (EXCEPT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
BUILT-UP-EXPORT)
1 C16 18DB/GY (BUILT-UP- FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
EXPORT) C
2 T751 20YL (EXCEPT IGNITION SWITCH OUTPUT (START) O
BUILT-UP-EXPORT)
N
2 T141 20YL/OR (BUILT-UP- IGNITION SWITCH OUTPUT (START)
EXPORT) N
3 D25 20WT/VT PCI BUS E
4 L13 20WT/YL (BUILT-UP- HEADLAMP ADJUST SIGNAL C
EXPORT) T
5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL O
6 - - R
7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE P
9 F201 18PK/OR FCM OUTPUT (RUN-START) I
10 F214 18PK/LG FCM OUTPUT (RUN-START) N
11 A106 20LB/RD FUSED B(+) O
12 - - U
13 F2 18PK/WT (GAS) FCM OUTPUT (UNLOCK-RUN-START) T
14 - - S
18 X1 16DG/BR (PREMIUM 8 NAME BRAND SPEAKER RELAY OUTPUT
SPEAKER)
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT FCM OUTPUT (RUN)
1047
CONNECTOR PINOUTS
INTELLIGENT POWER MODULE C8 - ORANGE 10 WAY
1 W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 T751 20YL (EXCEPT IGNITION SWITCH OUTPUT (START)
BUILT-UP-EXPORT)
2 N1 16DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD FUSED B(+)
3 A108 18LG/RD (BUILT-UP- FUSED B(+)
EXPORT)
4 A103 18GY/RD FUSED B(+)
6 W4 12BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
7 C51 12LB/BR (AUTOMATIC FUSED REAR BLOWER MOTOR RELAY OUTPUT
(3 ZONE HVAC)
8 - -
INTELLIGENT POWER MODULE C9 - BLACK 10 WAY

1 A102 12WT/RD FUSED B(+)
C
O
3 C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
N
N
5 L61 18WT/LG LEFT FRONT TURN SIGNAL DIVER
E
C
T
7 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
O
8 F30 12PK/YL (POWER FUSED ACCESSORY RELAY OUTPUT
R WINDOWS)
9 A115 12YL/RD (POWER FUSED B(+)
P LIFTGATE)
I 10 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
N
O
U
T
LEFT B-PILLAR SWITCH - GRAY 3 WAY
S CAV CIRCUIT FUNCTION
2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
3 G41 20VT/DG LEFT SLIDING DOOR PILLAR SWITCH MUX
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY

1 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER
3 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER
1048
CONNECTOR PINOUTS
LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY

2 G163 20VT/LB LEFT CYLINDER LOCK SWITCH MUX
LEFT DOOR SPEAKER - BLACK/RED 6 WAY

1 X153 20DG/YL (HIGH LEFT FRONT INSTRUMENT PANEL SPEAKER (+)
LINE)
2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND
3 X155 20DG/LB (HIGH LEFT FRONT INSTRUMENT PANEL SPEAKER (-)
LINE)
4 X53 20DG LEFT FRONT SPEAKER (+)
5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT
6 X55 20DG/BR LEFT FRONT SPEAKER (-)
C
O
N
N
LEFT FOG LAMP - WHITE 2 WAY
E
A L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT T
B Z349 18BK/YL GROUND O
R
P
I
N
O
U
T
S
LEFT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY
1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE
1049
CONNECTOR PINOUTS
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE
3 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER
4 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER
LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY

1 L61 18WT/LG LEFT FRONT TURN SIGNAL DRIVER
C
O
N
N
E
C
T
O
R
P
I LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY
N CAV CIRCUIT FUNCTION
O 1 Q53 20OR LEFT FULL OPEN SWITCH SENSE
U 2 Z77 20BK/GY GROUND
T
S
LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY

1 L43 18WT/DB LEFT LOW BEAM DRIVER
3 L33 18WT/LG LEFT HIGH BEAM DRIVER
1050
CONNECTOR PINOUTS
LEFT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY

1 Z343 16BR GROUND
1 Z343 16BR GROUND
2 L33 16GY LEFT HIGH BEAM DRIVER
LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY

1 X153 20DG/YL LEFT FRONT I/P SPEAKER (+)
2 X155 20DG/LB LEFT FRONT I/P SPEAKER (-)
C
O
N
LEFT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY N
E
1 Z343 16BR GROUND
C
2 L43 16WT LEFT LOW BEAM DRIVER
T
O
R
P
I
N
O
U
LEFT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY T
CAV CIRCUIT FUNCTION S
1 Z343 16BR GROUND
2 L77 16BK FUSED PARK LAMP RELAY OUTPUT(LEFT)
1051
CONNECTOR PINOUTS
LEFT POWER MIRROR - BLACK 12 WAY
1 P171 20TN/YL (BUILT-UP- LEFT FOLDING MIRROR UNFOLD DRIVER
EXPORT)
2 P112 20TN/OR (EXCEPT MIRROR B(+)
BUILT-UP-EXPORT/
MEMORY)
3 P114 20TN/WT (EXCEPT MIRROR B(-)
BUILT-UP-EXPORT/
MEMORY)
4 P65 20TN/VT (MEMORY) LEFT MIRROR HORIZONTAL POSITION SIGNAL
5 P69 20TN/WT (MEMORY) LEFT MIRROR SENSOR GROUND
6 P64 20TN (MEMORY) LEFT MIRROR VERTICAL POSITION SIGNAL
7 P160 20TN/LG (BUILT-UP- PASSENGER FOLDING MIRROR RELAY OUTPUT
EXPORT/RHD)
7 P159 20TN/DG (BUILT-UP- DRIVER FOLDING MIRROR FOLD DRIVER
EXPORT/LHD)
9 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
10 P73 20TN/VT LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P71 20TN/DG LEFT MIRROR HORIZONTAL DRIVER
12 P75 20TN/LG LEFT MIRROR VERTICAL DRIVER
C
O
N LEFT REAR PILLAR SPEAKER - BLACK 2 WAY
N
1 X157 20DG LEFT REAR PILLAR SPEAKER (+)
E
2 X151 20DG/WT LEFT REAR PILLAR SPEAKER (-)
C
T
O
R
P
I LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY
O 1 M22 20YL/OR COURTESY LAMPS DRIVER
U 2 Z327 20BK/OR GROUND
T 3 M27 20YL/LB READING LAMPS DRIVER
S
LEFT REAR SPEAKER - BLACK/RED 6 WAY

1 X151 20DG/WT LEFT REAR PILLAR SPEAKER (-)
2 X15 16GY/DG AMPLIFIED SPEAKER GROUND
3 X157 20DG LEFT REAR PILLAR SPEAKER (+)
4 X51 20DG/DB LEFT REAR SPEAKER (+)
5 X13 16DG/GY RADIO CHOKE OUTPUT
6 X57 20DG/OR LEFT REAR SPEAKER (-)
1052
CONNECTOR PINOUTS
LEFT REMOTE RADIO SWITCH - BLACK 2 WAY

1 X20 20RD/BK RADIO CONTROL MUX
2 X920 20RD/DB RADIO CONTROL MUX RETURN
LEFT SEAT AIRBAG - YELLOW 2 WAY

1 R31 18LG/OR (EXCEPT LEFT SEAT SQUIB LINE 1
BUILT-UP-EXPORT)
1 R33 18WT/BK (BUILT-UP- LEFT SEAT SQUIB LINE 2
EXPORT)
2 R31 18DG/WT (BUILT-UP- LEFT SEAT SQUIB LINE 1
EXPORT)
2 R33 18LG/WT (EXCEPT LEFT SEAT SQUIB LINE 2
BUILT-UP-EXPORT)
C
O
LEFT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY N
N
1 R31 18LG/OR LEFT SEAT SQUIB LINE 1
E
2 R33 18LG/WT LEFT SEAT SQUIB LINE 2
C
3 - -
T
O
5 F214 18PK/LG FCM OUTPUT (RUN-START)
R
P
I
N
O
LEFT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY
U
1 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER
T
2 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER
S
3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER
4 - -
6 - -
7 - -
1053
CONNECTOR PINOUTS
LEFT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - BLACK/RED 20 WAY
1 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY
2 - -
3 Q35 20OR/GY LEFT DOOR LOCK SENSE
4 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SENSE
5 - -
6 - -
7 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER
8 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER
9 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER
10 - -
12 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE
13 Q59 20OR/YL LEFT PAWL SWITCH SENSE
14 Q53 20OR LEFT FULL OPEN SWITCH SENSE
16 Q57 20OR/VT LEFT DOOR CHILD LOCKOUT SWITCH SENSE
17 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL
18 - -
19 G151 20VT/BR LEFT SLIDING DOOR WAKE UP SIGNAL
C 20 Z25 20BK/TN GROUND
O
N
N
E LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY
C
1 Z77 20BK/GY GROUND
T
2 Q59 20OR/YL LEFT PAWL SWITCH SENSE
O
3 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE
R
5 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SENSE
P
6 Q57 20OR/VT LEFT DOOR CHILD LOCKOUT SWITCH SENSE
I
N
O
U
T
S
LEFT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY
1 P5 20TN/OR LEFT SLIDING DOOR LOCK UNLOCK DRIVER
2 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER
3 Q35 20OR/GY LEFT DOOR LOCK SENSE
1054
CONNECTOR PINOUTS
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY
1 P5 20BK/DB LEFT SLIDING DOOR UNLOCK DRIVER
2 P32 20BK/TN LEFT SLIDING DOOR LOCK DRIVER
3 G77 20BK/DG LEFT SLIDING DOOR AJAR SWITCH SENSE
4 Z77 20BK GROUND
LEFT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY

1 - -
2 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY
3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER
5 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER
6 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER
8 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL C
O
N
N
LEFT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY E
C
T
O
2 Z1 18BK/DG GROUND
R
2 Z1 18BK/DG GROUND
3 L73 18YL LEFT STOP SIGNAL
P
I
N
5 L615 18OR LEFT COMBINATION SIGNAL
O
U
T
S
LEFT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY

A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMP DRIVER
1055
CONNECTOR PINOUTS
LICENSE LAMP (POWER LIFTGATE) - DK. GRAY 8 WAY
3 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE
5 Q94 20TN/LG LIFTGATE CHIME DRIVER
7 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL
LICENSE LAMP (POWER RELEASE) - DK. GRAY 4 WAY

3 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE
C
O
N
N
E
C
T
O LIFTGATE AJAR SWITCH (MANUAL RELEASE) - BLACK 2 WAY
R CAV CIRCUIT FUNCTION
P 2 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE
I
N
O
U
T
S
LIFTGATE AJAR SWITCH (POWER RELEASE) - BLACK 4 WAY

3 P31 20TN/YL LIFTGATE RELEASE DRIVER
1056
CONNECTOR PINOUTS
LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) - BLUE 7 WAY

3 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE
5 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER
6 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER
7 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER
LIFTGATE CYLINDER LOCK SWITCH - BLACK 2 WAY

2 G165 20VT/GY LIFTGATE CYLINDER LOCK SWITCH MUX
C
O
N
N
E
C
LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY T
CAV CIRCUIT FUNCTION O
1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL R
2 Q76 20OR/LB PINCH SENSOR SIGNAL
P
I
N
O
U
T
S
LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY
1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL
1057
CONNECTOR PINOUTS
MEMORY POWER SEAT SWITCH - GREEN 10 WAY
2 P43 14LG/VT DRIVER SEAT RECLINER DOWN SWITCH SENSE
3 P17 20LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH SENSE
4 P41 14LG/GY DRIVER SEAT RECLINER UP SWITCH SENSE
5 P9 20LG/OR DRIVER SEAT SWITCH B(+) SUPPLY
6 P15 20LG/WT DRIVER SEAT HORIZONTAL FORWARD SWITCH SENSE
7 P19 20LG/LB DRIVER SEAT FRONT UP SWITCH SENSE
8 P11 20LG/YL DRIVER SEAT REAR UP SWITCH SENSE
9 P13 20LG/OR DRIVER SEAT REAR DOWN SWITCH SENSE
10 P21 20LG/TN DRIVER SEAT FRONT DOWN SWITCH SENSE
MEMORY SEAT FRONT VERTICAL MOTOR - RED 2 WAY

1 P119 14LG/DG DRIVER SEAT FRONT UP DRIVER
2 P121 14LG/DB DRIVER SEAT FRONT DOWN DRIVER
C
O
N
N
E
C
MEMORY SEAT FRONT VERTICAL POSITION SENSOR - BLACK 3 WAY
T
O
A P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
R
B P26 20LG FRONT RISER POSITION SIGNAL
C P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
P
I
N
O
U
T
S MEMORY SEAT HORIZONTAL MOTOR - BLACK 2 WAY
1 P117 14LG/LB (LHD) DRIVER SEAT HORIZONTAL REARWARD DRIVER
1 P115 14LG (RHD) DRIVER SEAT HORIZONTAL FORWARD DRIVER
2 P115 14LG (LHD) DRIVER SEAT HORIZONTAL FORWARD DRIVER
2 P117 14LG/LB (RHD) DRIVER SEAT HORIZONTAL REARWARD DRIVER
MEMORY SEAT HORIZONTAL POSITION SENSOR - BLACK 3 WAY

A P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
B P25 20LG/VT DRIVER SEAT HORIZONTAL POSITION SIGNAL
C P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
1058
CONNECTOR PINOUTS
MEMORY SEAT REAR VERTICAL MOTOR - RED 2 WAY

1 P111 14LG/YL DRIVER SEAT REAR UP DRIVER
2 P113 14LG/WT DRIVER SEAT REAR DOWN DRIVER
MEMORY SEAT REAR VERTICAL POSITION SENSOR - BLACK 3 WAY

A P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
B P27 20LG/LB REAR RISER POSITION SIGNAL
C P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
C
O
N
MEMORY SEAT RECLINER MOTOR - GREEN 2 WAY
1 P141 14LG/BR DRIVER SEAT RECLINER UP DRIVER E
2 P143 14LG/GY DRIVER SEAT RECLINER DOWN DRIVER C
T
O
R
P
I
N
MEMORY SEAT RECLINER POSITION SENSOR - BLACK 3 WAY O
U
A P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
T
B P47 20LG/LB RECLINER POSITION SIGNAL
S
C P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
MEMORY SEAT SWITCH - BLACK 2 WAY

1 G200 20VT/BR MEMORY SEAT SET SWITCH MUX
2 G920 20VT/YL MEMORY SEAT SWITCH RETURN
1059
CONNECTOR PINOUTS
MEMORY SEAT/MIRROR MODULE C1 - GRAY 2 WAY

2 A210 14OR/RD FUSED SEAT SWITCH DRIVER

1 P69 20TN/WT LEFT MIRROR SENSOR GROUND
2 P25 20LG/VT DRIVER SEAT HORIZONTAL POSITION SIGNAL
3 P27 20LG/LB REAR RISER POSITION SIGNAL
4 - -
5 - -
6 P67 20OR RIGHT MIRROR VERTICAL POSITION SIGNAL
7 P64 20TN/OR LEFT MIRROR VERTICAL POSITION SIGNAL
8 P21 20LG/TN DRIVER SEAT FRONT DOWN SWITCH SENSE
9 P13 20LG/OR DRIVER SEAT REAR DOWN SWITCH SENSE
10 P15 20LG/WT DRIVER SEAT HORIZONTAL FORWARD SWITCH SENSE
C 11 P43 14LG/VT DRIVER SEAT RECLINER DOWN SWITCH SENSE
O 12 - -
N 13 - -
N 14 P66 20WT RIGHT MIRROR SENSOR GROUND
E 15 P26 20LG FRONT RISER POSITION SIGNAL
C 16 P47 20LG/LB RECLINER POSITION SIGNAL
T 17 - -
O 18 - -
R 19 P68 20YL RIGHT MIRROR HORIZONTAL POSITION SIGNAL
20 P65 20TN/YL LEFT MIRROR HORIZONTAL POSITION SIGNAL
P 21 P19 20LG/LB DRIVER SEAT FRONT UP SWITCH SENSE
I 22 P11 20LG/YL DRIVER SEAT REAR UP SWITCH SENSE
N 23 P17 20LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH SENSE
O 24 P41 14LG/GY DRIVER SEAT RECLINER UP SWITCH SENSE
U 25 - -
T 26 D25 20WT/VT PCI BUS
S
1 - -
2 - -
3 P73 18TN/LB LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
4 P75 18DB LEFT MIRROR HORIZONTAL DRIVER
5 P71 18TN/GY LEFT MIRROR VERTICAL DRIVER
6 P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
7 - -
8 - -
9 - -
10 - -
11 P70 18LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
12 P74 18TN/DB RIGHT MIRROR HORIZONTAL DRIVER
13 P72 18GY RIGHT MIRROR VERTICAL DRIVER
14 - -
15 - -
16 P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
1060
CONNECTOR PINOUTS
MEMORY SEAT/MIRROR MODULE C4 - WHITE 12 WAY
1 P111 14LG/YL DRIVER SEAT REAR UP DRIVER
2 P115 14LG DRIVER SEAT HORIZONTAL FORWARD DRIVER
3 P119 14LG/DG DRIVER SEAT FRONT UP DRIVER
4 P113 14LG/WT DRIVER SEAT REAR DOWN DRIVER
5 P121 14LG/DB DRIVER SEAT FRONT DOWN DRIVER
6 - -
7 P143 14LG/GY DRIVER SEAT RECLINER DOWN DRIVER
8 P9 20LG/OR DRIVER SEAT SWITCH B(+) SUPPLY
9 - -
10 P141 14LG/BR DRIVER SEAT RECLINER UP DRIVER
11 P117 14LG/LB DRIVER SEAT HORIZONTAL REARWARD DRIVER
12 - -
MODE DOOR ACTUATOR (ATC) - GRAY 2 WAY

1 C135 20DB/GY MODE DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A) C
O
N
N
E
C
T
O
R
MODE DOOR ACTUATOR (MTC) - GRAY 2 WAY
P
1 C34 20DB/LB COMMON DOOR DRIVER (B)
I
N
O
U
T
S
MULTI-FUNCTION SWITCH - BLACK 4 WAY

1 W52 20BR/YL FRONT WIPER SWITCH MUX
2 G902 20VT/OR MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 20VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
1061
CONNECTOR PINOUTS
OCCUPANT RESTRAINT CONTROLLER - YELLOW/RED 23 WAY
1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
3 R62 18LB/VT PASSENGER SQUIB 2 LINE 2
4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1
5 R42 18LB/BR PASSENGER SQUIB 1 LINE 2
6 R44 18LB/OR PASSENGER SQUIB 1 LINE 1
7 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
8 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
9 R61 18LG/VT DRIVER SQUIB 2 LINE 1
10 R63 18LG/WT DRIVER SQUIB 2 LINE 2
11 R43 18LG/BR DRIVER SQUIB 1 LINE 1
12 R45 18LG/OR DRIVER SQUIB 1 LINE 2
13 - -
14 F201 18PK/OR FCM OUTPUT (RUN-START)
15 F100 18PK/VT FCM OUTPUT (RUN)
17 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1
18 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2
19 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1
C 20 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
O 21 D25 18WT/VT PCI BUS
N 22 - -
N 23 - -
E
C OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY
O 1 G23 20VT/DB SLIDING DOORS OVERHEAD SWITCH MUX
R 2 G25 20VT/TN LIFTGATE SWITCH MUX

P 4 Z113 20BK/DB GROUND
I 5 A114 20GY/RD FUSED B(+) (I.O.D.)
N 6 F503 20WT/PK IGNITION SWITCH OUTPUT (RUN)
O 7 Z13 20BK/WT GROUND
U 8 E15 20OR/DB ASH/RECEIVER LAMP FEED
T 9 - -
S 10 - -
11 L24 20BK/GY (EXCEPT AUTOMATIC HEADLAMP SWITCH SENSOR
BUILT-UP-EXPORT)
(PREMIUM/LUXURY)
12 L1 20BK/WT (PREMIUM/ BACK-UP LAMP FEED
LUXURY)
1062
CONNECTOR PINOUTS
PASSENGER AIRBAG - YELLOW 4 WAY

1 R42 18LB/BR PASSENGER SQUIB 1 LINE 2
2 R44 18LB/OR PASSENGER SQUIB 1 LINE 1
3 R62 18LB/VT PASSENGER SQUIB 2 LINE 2
4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1
PASSENGER BLEND DOOR ACTUATOR (ATC) - GRAY 2 WAY

1 C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B)
C
O
N
N
E
PASSENGER BLEND DOOR ACTUATOR (MTC) - GRAY 2 WAY
1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B) T
1 C33 20LB/BR (RHD) PASSENGER BLEND DOOR DRIVER (A) O
2 C33 20LB/BR (LHD) PASSENGER BLEND DOOR DRIVER (A) R
P
I
N
O
U
PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY T
S
1 F304 16WT/PK (EXCEPT FUSED ACCESSORY RELAY OUTPUT
POWER WINDOWS)
1 F304 16WT/PK (POWER FUSED WINDOW CIRCUIT BREAKER OUTPUT
WINDOWS)
2 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX
2 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX
3 Z460 20BK/LG (LHD) GROUND
3 Z461 20BK/DG (RHD) GROUND
1063
CONNECTOR PINOUTS
PASSENGER FOLDING MIRROR RELAY (BUILT-UP-EXPORT) - BLUE 9 WAY

1 - -
2 - -
3 - -
4 A108 18LG/RD FUSED B(+)
5 P164 18LG/DB PASSENGER FOLDING MIRROR RELAY INPUT
6 P162 18LG/DG PASSENGER FOLDING MIRROR RELAY CONTROL
7 - -
8 P160 18TN/LG PASSENGER FOLDING MIRROR RELAY OUTPUT
9 - -
PASSENGER SEAT BELT SWITCH - 2 WAY

C 1 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1
O 2 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
N
N
E
C
T
O
R
P PASSENGER SEAT BELT TENSIONER - 2 WAY

I CAV CIRCUIT FUNCTION
N 1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
O 2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
U
T
S
1064
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
1065
CONNECTOR PINOUTS
FUSES (IPM)
FUSE AMPS FUSED CIRCUIT FUNCTION
NO.
1 20A INTERNAL FUSED B(+)
2 15A INTERNAL FUSED PARK LAMP RELAY OUTPUT
5 20A F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
6 20A F307 16LB/PK (BATTERY POSITION) FUSED B(+)
6 20A F307 16LB/PK (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT
10 40A C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
11 20A F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
12 25A C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
13 40A C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
14 15A INTERNAL FUSED B(+) (I.O.D.)
15 20A INTERNAL (EATX) FUSED B(+)
19 40A A101 12VT/RD FUSED B(+)
20 40A A102 12WT/RD FUSED B(+)
21 25A A111 12DG/RD FUSED B(+)
C
22 40A A110 12OR/RD FUSED B(+)
O
23 10A A106 20LB/RD FUSED B(+)
N 24 20A A701 16BR/RD FUSED B(+) (HAZARD)
N 26 20A A103 18GY/RD FUSED B(+)
E 27 40A A112 12OR/RD FUSED B(+)
C 28 40A F30 12PK/YL FUSED ACCESSORY RELAY OUTPUT
T 30 40A INTERNAL (RG) FUSED B(+)
O 31 40A A113 12WT/RD FUSED B(+)
R 32 40A A115 12YL/RD FUSED B(+)
33 15A INTERNAL FUSED ACCESSORY RELAY OUTPUT
P
I ACCESSORY RELAY
O 30 INTERNAL B(+)
U 85 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
T 86 INTERNAL B(+)
S 87 INTERNAL FUSED ACCESSORY RELAY OUTPUT
87A - -
DEFOGGER RELAY
30 INTERNAL B(+)
85 FCM 31 REAR WINDOW DEFOGGER RELAY CONTROL
86 INTERNAL B(+)
87 INTERNAL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
87A - -
FRONT BLOWER MOTOR RELAY

30 INTERNAL B(+)
85 FCM 30 FRONT BLOWER MOTOR RELAY CONTROL
86 INTERNAL B(+)
87A - -
1066
CONNECTOR PINOUTS
FRONT CONTROL MODULE - BLACK 49 WAY
1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7 - NOT USED
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 FCM 11 NAME BRAND SPEAKER RELAY CONTROL
12 - SPARE
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 (GAS) IGNITION SWITCH OUTPUT (START)
20 A114 FUSED B(+) (I.O.D.) C
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT) O
22 D25 PCI BUS N
23 G931 AMBIENT TEMPERATURE SENSOR RETURN N
24 - SPARE E
25 G31 AMBIENT TEMPERATURE SENSOR SIGNAL C
26 L13 (RG) HEADLAMP ADJUST SIGNAL T
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START) O
28 F214 FCM OUTPUT (RUN-START) (SIACM) R
29 F100 FCM OUTPUT (RUN) (ORC)
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL P
31 FCM 31 REAR WINDOW DEFOGGER RELAY CONTROL I
32 FCM 32 (BUILT-UP- HEADLAMP WASHER RELAY CONTROL N
EXPORT))
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
O
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
U
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
T
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
S
37 F20 IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+)
39 T2 TRS REVERSE SENSE
40 T753 (DIESEL) IGNITION SWITCH OUTPUT (START)
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D23 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 PRIMARY BRAKE SWITCH SIGNAL
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL
48 F201 FCM OUTPUT (RUN-START) (ORC)
49 - NOT USED
1067
CONNECTOR PINOUTS
FRONT FOG LAMP RELAY
30 INTERNAL FUSED B(+)
85 FCM 33 FRONT FOG LAMP RELAY CONTROL
87 INTERNAL FRONT FOG LAMP RELAY OUTPUT
87A - -
HEADLAMP WASHER RELAY (BUILT-UP-EXPORT)

85 FCM 32 HEADLAMP WASHER RELAY CONTROL
87 V53 12BR/OR HEADLAMP WASHER RELAY OUTPUT
87A - No Function Defined
NAME BRAND SPEAKER RELAY

30 INTERNAL FUSED B(+) (I.O.D.)
85 FCM 11 NAME BRAND SPEAKER (NBS) RELAY CONTROL
C 86 INTERNAL FUSED B(+) (I.O.D.)
O 87 X1 16DG/BR NAME BRAND SPEAKER (NBS) RELAY OUTPUT
N 87A - -
N
E PARK LAMP RELAY
T 30 INTERNAL B(+)
O 85 FCM 13 PARK LAMP RELAY CONTROL
R 86 INTERNAL B(+)
87 INTERNAL PARK LAMP RELAY OUTPUT
P 87A - -
I
N POSITIVE TEMPERATURE COEFFICIENTS
O FUSE AMPS FUSED CIRCUIT FUNCTION
U NO.
T 4 8A C16 18DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
S 7 13A A105 18DB/RD FUSED B(+)
REAR BLOWER MOTOR RELAY

30 INTERNAL B(+)
85 FCM 30 REAR BLOWER MOTOR RELAY CONTROL
86 INTERNAL B(+)
87 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
87A - -
1068
CONNECTOR PINOUTS
POWER FOLDING MIRROR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY

2 P136 20TN/YL FOLDING MIRROR SWITCH SENSE
POWER LIFTGATE MODULE C1 - BLACK 8 WAY

1 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER
2 Q88 16TN/BR (EXCEPT LIFTGATE OPEN DRIVER
BUILT-UP-EXPORT)
2 Q88 14TN/BR (BUILT-UP- LIFTGATE OPEN DRIVER
EXPORT)
3 Q89 16TN/OR (EXCEPT LIFTGATE CLOSE DRIVER C
BUILT-UP-EXPORT)
O
3 Q89 14TN/OR (BUILT-UP- LIFTGATE CLOSE DRIVER
EXPORT) N
4 - - N
5 A115 12YL/RD FUSED B(+) E
6 - - C
7 - - T
8 Z125 14BK/WT GROUND O
R
POWER LIFTGATE MODULE C2 - BLACK/RED 20 WAY
P
1 Q90 20TN/VT LIFTGATE HALL EFFECT SIGNAL
I
2 - -
N
3 Q151 20TN/DB LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
O
4 - -
U
5 Q76 20OR/LB PINCH SENSOR SIGNAL
T
6 - -
S
7 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER
8 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER
9 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER
10 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER
13 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE
14 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE
15 - -
16 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL
17 Q91 20TN/LG LIFTGATE HALL EFFECT SIGNAL
18 Q94 20TN/LG LIFTGATE CHIME DRIVER
19 G153 20VT/YL LIFTGATE MODULE WAKE UP SIGNAL
1069
CONNECTOR PINOUTS
POWER LIFTGATE MOTOR - BLACK 10 WAY
BUILT-UP-EXPORT)
1 Z87 20BK/LG (BUILT-UP- GROUND
EXPORT)
2 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE
3 Q151 20TN/DB LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
4 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER
5 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER
6 Q88 16TN/BR (EXCEPT LIFTGATE OPEN DRIVER
BUILT-UP-EXPORT)
6 Q88 14TN/BR (BUILT-UP- LIFTGATE OPEN DRIVER
EXPORT)
7 Q90 20TN/VT LIFTGATE HALL EFFECT SUPPLY
8 Q91 20TN/LG LIFTGATE HALL EFFECT SIGNAL
10 Q89 14TN/OR (BUILT-UP- LIFTGATE CLOSE DRIVER
EXPORT)
10 Q89 16TN/OR (EXCEPT LIFTGATE CLOSE DRIVER
BUILT-UP-EXPORT)
C
O
N
N POWER SEAT CIRCUIT BREAKER (30A) - GRAY 2 WAY
E CAV CIRCUIT FUNCTION
C 1 A110 12OR/RD FUSED B(+)
T 2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
O 2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
P
I
N
O
U
T
S
1070
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C1 (2.4L/3.3L/3.8L) - GRAY/BLACK 40-WAY
1 - -
2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4 - -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
9 - -
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START) C
21 - - O
22 - - N
23 - - N
24 - - E
25 K42 18DB/YL KNOCK SENSOR SIGNAL C
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL T
27 K902 18BR/DG OXYGEN SENSOR GROUND O
28 - - R
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL P
31 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL I
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL N
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL O
34 - - U
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL T
36 K1 18VT/BR MANIFOLD ABOLUTE PRESSURE SENSOR SIGNAL S
38 - -
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
1071
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C2 (2.4L/3.3L/3.8L) - GRAY/GRAY 40 WAY
41 V37 18VT SPEED CONTROL SWITCH SIGNAL
42 C18 18LB/BR A/C PRESSURE SENSOR SIGNAL
43 K900 18DB/DG SENSOR GROUND
44 F888 18BR/PK 8 VOLT SUPPLY
45 - -
47 - -
48 K40 18BR/LG (2.4L) IDLE AIR CONTROL NO. 3 DRIVER
49 K60 18VT/LG (2.4L) IDLE AIR CONTROL NO. 2 DRIVER
49 K39 18VT/DG (3.3L/3.8L) IDLE AIR CONTROL NO. 1 DRIVER
51 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL
52 - -
53 - -
54 - -
55 - -
56 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL
57 K39 18VT/DG (2.4L) IDLE AIR CONTROL NO. 1 DRIVER
57 K60 18VT/LG (3.3L/3.8L) IDLE AIR CONTROL NO. 2 DRIVER
C 58 K59 18BR/DG (2.4L) IDLE AIR CONTROL NO. 4 DRIVER
O 59 D25 18WT/VT PCI BUS
N 60 - -
N 61 F855 18PK/YL 5 VOLT SUPPLY
E 62 B29 18DG/WT SECONDARY BRAKE SWITCH SIGNAL
C 63 T10 18DG/LG (EATX) TORQUE MANAGEMENT REQUEST SENSE
T 64 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
O 65 D21 18WT/BR SCI TRANSMIT
R 66 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL

67 K51 18BR/WT AUTOMATIC SHUTDOWN RELAY CONTROL
P 68 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
I 69 - -
N 70 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
O 71 - -
U 72 K107 18VT/WT (EXCEPT LEAK DETECTION PUMP SWITCH SENSE

BUILT-UP-EXPORT)
T 73 K173 18BR/VT RADIATOR FAN RELAY CONTROL
S 74 K31 18BR FUEL PUMP RELAY CONTROL
75 D20 18WT/LG SCI RECEIVE
76 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
77 K106 18VT/LB (EXCEPT LEAK DETECTION PUMP SOLENOID CONTROL
BUILT-UP-EXPORT)
78 K54 18DB/WT (ATX) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
79 - -
80 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL
1072
CONNECTOR PINOUTS
RADIO C1 - GRAY 7 WAY
1 - -
2 X155 20DG/LB (LOW LINE) LEFT FRONT I/P SPEAKER (-)
2 X55 20DG/BR LEFT FRONT SPEAKER (-)
3 X156 20GY/LB (LOW LINE) RIGHT FRONT I/P SPEAKER (-)
3 X56 20GY/BR RIGHT FRONT SPEAKER (-)
4 E17 20OR/YL (EXCEPT PARADE MODE SIGNAL
BUILT-UP-EXPORT)
5 E14 20OR/TN PANEL LAMPS DRIVER
6 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
RADIO C2 - BLACK 7 WAY

1 X60 20GY/YL (BUILT-UP- RADIO 12 VOLT OUTPUT
EXPORT)
2 X51 20DG/DB LEFT REAR SPEAKER (+)
3 X52 20GY/DB RIGHT REAR SPEAKER (+)
4 X153 20DG/YL (LOW LINE) LEFT FRONT I/P SPEAKER (+)
4 X53 20DG LEFT FRONT SPEAKER (+)
5 X154 20GY/YL (LOW LINE) RIGHT FRONT I/P SPEAKER (+)
5 X54 20GY RIGHT FRONT SPEAKER (+) C
6 X57 20DG/OR LEFT REAR SPEAKER (-) O
7 X58 20GY/OR RIGHT REAR SPEAKER (-) N
N
E
C
T
RADIO C3 - WHITE/RED 2 WAY
O
CAV CIRCUIT FUNCTION R
2 - - P
I
N
O
U
T
S
1073
CONNECTOR PINOUTS
RADIO C4 - 8 WAY
1 E14 18OR/TN (EXCEPT PANEL LAMPS DRIVER
BUILT-UP-EXPORT)
1 E14 24OR/TN (BUILT-UP- PANEL LAMPS DRIVER
EXPORT)
2 X40 20GY/WT (EXCEPT AUDIO OUT RIGHT
BUILT-UP-EXPORT)
2 X40 24GY/WT (BUILT-UP- AUDIO OUT RIGHT
EXPORT)
3 D25 20WT/VT (EXCEPT PCI BUS
BUILT-UP-EXPORT)
3 D25 24VT/YL (BUILT-UP- PCI BUS
EXPORT)
4 X112 20RD (EXCEPT IGNITION SWITCH OUTPUT
BUILT-UP-EXPORT)
4 X112 24RD (BUILT-UP- IGNITION SWITCH OUTPUT
EXPORT)
5 X41 20DG/WT (EXCEPT AUDIO OUT LEFT
BUILT-UP-EXPORT)
5 X41 24DG/WT (BUILT-UP- AUDIO OUT LEFT
EXPORT)
BUILT-UP-EXPORT)
6 Z140 24BK/OR (BUILT-UP- GROUND
C EXPORT)
O 7 Z141 18BK/TN (EXCEPT GROUND

BUILT-UP-EXPORT)
N 7 Z141 22BK/TN (BUILT-UP- GROUND
N EXPORT)
E 8 X160 22GY/YL (BUILT-UP- B(+)
C EXPORT)
T 8 X160 20GY/YL (EXCEPT B(+)

BUILT-UP-EXPORT)
O
R
P
I
N RADIO CHOKE - LT. GRAY 2 WAY
U 1 X1 16DG/BR NAME BRAND SPEAKER RELAY OUTPUT
T 2 X13 16DG/GY RADIO CHOKE OUTPUT
S
REAR A/C-HEATER UNIT (3 ZONE HVAC) - LT. GREEN 10 WAY

1 C53 20LB REAR MODE DOOR DRIVER
2 C154 20LB/OR REAR COMMON DOOR DRIVER
3 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
4 C152 16LB/LG REAR BLOWER MOTOR MED
5 C151 18LB/DG REAR BLOWER MOTOR LOW
6 C153 12DB/BR REAR BLOWER MOTOR HIGH
7 C54 20LB/YL REAR BLEND DOOR DRIVER
7 Z141 18BK/TN (EXCEPT GROUND
BUILT-UP-EXPORT)
8 C154 20LB/OR REAR COMMON DOOR DRIVER
9 - -
1074
CONNECTOR PINOUTS
REAR AUTO TEMP CONTROL SWITCH (ATC) - BLACK 13 WAY
3 D22 20WT/TN KDB CLOCK
4 D17 20WT/DG KDB DATA
5 E10 20OR/DG PANEL LAMPS DRIVER
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
REAR BLOWER MOTOR POWER MODULE C1 (ATC) - RED/BLACK 4 WAY

1 C51 12DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
C
O
2 C59 18 DB/LB BLOWER MOTOR CONTROL
N
N
4 - -
E
C
T
O
R
P
I
REAR BLOWER MOTOR POWER MODULE C2 (ATC) - BLACK 2 WAY
N
CAV CIRCUIT FUNCTION O
1 12BK GROUND U
2 12DG POWER FEED T
S
REAR DOME LAMP (EXCEPT LUXURY) - GRAY 3 WAY

1 M22 20YL/OR COURTESY LAMPS DRIVER
3 - -
1075
CONNECTOR PINOUTS
REAR MODE MOTOR (ATC) - GRAY 2 WAY

1 C154 18LB/GY REAR MODE DOOR DRIVER (B)
2 C53 18LB REAR MODE DOOR DRIVER (A)
REAR TEMPERATURE MOTOR (ATC) - GRAY 2 WAY

1 C54 18LB/YL REAR BLEND DOOR DRIVER (A)
2 C169 18LB/TN REAR BLEND DOOR DRIVER (B)
C
O
N
N
E
C
T
O
R RECIRCULATION DOOR ACTUATOR (ATC) - GRAY 2 WAY
P 1 C132 20DB/YL RECIRCULATION DOOR DRIVER (B)
I 2 C32 20DB/TN RECIRCULATION DOOR DRIVER (A)
N
O
U
T
S
RECIRCULATION DOOR ACTUATOR (MTC) - GRAY 2 WAY

1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B)
1 C32 20DB/TN (RHD) RECIRCULATION DOOR DRIVER (A)
2 C32 20DB/TN (LHD) RECIRCULATION DOOR DRIVER (A)
1076
CONNECTOR PINOUTS
REMOTE KEYLESS ENTRY ANTENNA (JAPAN) - BLACK 2 WAY

1 D10 18WT REMOTE KEYLESS ENTRY ANTENNA (+)
2 D10 18WT/LB REMOTE KEYLESS ENTRY ANTENNA (-)
REMOTE KEYLESS ENTRY MODULE - BLACK/RED 6 WAY

1 G96 20VT/DG REMOTE KEYLESS ENTRY INTERFACE
2 D9 20WT/GY RKE MODULE PROGRAM ENABLE
4 D10 18WT (RHD) REMOTE KEYLESS ENTRY ANTENNA (+) C
5 D10 18WT/LB (RHD) REMOTE KEYLESS ENTRY ANTENNA (-) O
6 A114 20GY/RD FUSED B(+) (I.O.D.) N
N
E
C
T
O
RIGHT B-PILLAR SWITCH - GRAY 3 WAY R
1 Z62 20BK/YL GROUND P
2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT I
3 G42 20VT/YL RIGHT SLIDING DOOR PILLAR SWITCH MUX N
O
U
T
S
RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY

1 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
3 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
1077
CONNECTOR PINOUTS
RIGHT CYLINDER LOCK SWITCH - BLACK 2 WAY

2 G162 20VT/WT RIGHT CYLINDER LOCK SWITCH MUX
RIGHT DOOR SPEAKER - BLACK/RED 6 WAY

1 X154 20GY/YL (HIGH RIGHT FRONT INSTRUMENT PANEL SPEAKER (+)
LINE)
2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND
3 X156 20GY/LB (HIGH RIGHT FRONT INSTRUMENT PANEL SPEAKER (-)
LINE)
4 X54 20GY RIGHT FRONT SPEAKER (+)
5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT
6 X56 20GY/BR RIGHT FRONT SPEAKER (-)
C
O
N
N
E
C
T RIGHT FOG LAMP - WHITE 2 WAY
O
A L90 18WT/OR FRONT FOG LAMP RELAY OUTPUT
R
B Z348 18BK/OR GROUND
P
I
N
O
U
T
S
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE
3 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER
4 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER
1078
CONNECTOR PINOUTS
RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY

RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY

1 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
C
O
N
N
E
C
T
O
RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY R
1 L44 16WT/TN RIGHT LOW BEAM DRIVER P
2 Z344 16BK/TN GROUND I
3 L34 16WT/GY RIGHT HIGH BEAM DRIVER N
O
U
T
S
RIGHT HIGH BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY

1 Z344 16BR GROUND
1 Z344 16BR GROUND
2 L34 16GY RIGHT HIGH BEAM DRIVER
1079
CONNECTOR PINOUTS
RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY

1 X154 20GY/YL RIGHT FRONT I/P SPEAKER (+)
2 X156 20GY/LB RIGHT FRONT I/P SPEAKER (-)
RIGHT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY

1 Z344 16BR GROUND
2 L44 16WT RIGHT LOW BEAM DRIVER
C
O
N
N
E
C RIGHT PARK LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
O 1 Z344 16BR GROUND
R 2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
P
I
N
O
U RIGHT POWER MIRROR - BLACK 12 WAY
S 1 P174 20TN/LB (BUILT-UP- RIGHT FOLDING MIRROR UNFOLD DRIVER
EXPORT)
2 - -
3 - -
4 P68 20TN/YL (MEMORY) RIGHT MIRROR HORIZONTAL POSITION SIGNAL
5 P66 20TN/LG (MEMORY) RIGHT MIRROR SENSOR GROUND
6 P67 20TN/OR (MEMORY) RIGHT MIRROR VERTICAL POSITION SIGNAL
7 P160 20TN/LG (BUILT-UP- PASSENGER FOLDING MIRROR RELAY OUTPUT
EXPORT/LHD)
7 P159 20TN/DG (BUILT-UP- DRIVER FOLDING MIRROR FOLD DRIVER
EXPORT/RHD)
8 Z216 20BK/DB GROUND
9 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
10 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P72 20TN/GY RIGHT MIRROR VERTICAL DRIVER
12 P74 20TN/DB RIGHT MIRROR HORIZONTAL DRIVER
1080
CONNECTOR PINOUTS
RIGHT REAR PILLAR SPEAKER - BLACK 2 WAY

1 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+)
2 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-)
RIGHT REAR SPEAKER - BLACK/RED 6 WAY

1 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-)
2 X15 16GY/DG AMPLIFIED SPEAKER GROUND
3 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+)
4 X52 20GY/DB RIGHT REAR SPEAKER (+)
5 X13 16DG/GY RADIO CHOKE OUTPUT
6 X58 20GY/OR RIGHT REAR SPEAKER (-)
C
O
N
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY N
CAV CIRCUIT FUNCTION E
1 X20 20RD/BK RADIO CONTROL MUX C
2 X920 20RD/DB RADIO CONTROL MUX RETURN T
O
R
P
I
RIGHT SEAT AIRBAG - YELLOW 2 WAY N
O
1 R34 18WT/BK (BUILT UP RIGHT SEAT SQUIB LINE 2
EXPORT) U
1 R32 18LB/OR (EXCEPT RIGHT SEAT SQUIB LINE 1 T
BUILT-UP-EXPORT) S
2 R34 18LB/WT (EXCEPT RIGHT SEAT SQUIB LINE 2
BUILT-UP-EXPORT)
2 R32 18DG/WT (BUILT UP RIGHT SEAT SQUIB LINE 1
EXPORT)
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY

1 R32 18LB/OR RIGHT SEAT SQUIB LINE 1
2 R34 18LB/WT RIGHT SEAT SQUIB LINE 2
3 - -
5 F214 18PK/LG FCM OUTPUT (RUN-START)
6 - -
1081
CONNECTOR PINOUTS
RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY
1 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
2 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER
3 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER
4 - -
6 - -
7 - -
8 Z124 14BK GROUND
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - BLACK/RED 20 WAY
1 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY
2 - -
3 Q34 20OR/GY RIGHT DOOR LOCK SENSE
4 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SENSE
5 - -
6 - -
7 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER
C
8 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
O
9 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
N
10 - -
N
E
12 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
C
13 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
T
14 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
O
15 - -
R
16 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE
17 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL
P
18 - -
I
19 G152 20VT/GY RIGHT SLIDING DOOR WAKE UP SIGNAL
N
O
U
T
S
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY
2 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
3 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
5 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SENSE
6 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE
1082
CONNECTOR PINOUTS
RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY
1 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER
2 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER
3 Q34 20OR/GY RIGHT DOOR LOCK SENSE
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY
1 P38 20BK/DB RIGHT SLIDING DOOR LOCK DRIVER
2 P34 20BK/TN RIGHT SLIDING DOOR UNLOCK DRIVER
3 G76 20BK/DG RIGHT SLIDING DOOR AJAR SWITCH SENSE
4 Z76 20BK GROUND
C
O
N
N
RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY
E
1 - - T
2 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY O
3 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER R
5 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER P
6 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER I
7 Z34 20BK/TN GROUND N
8 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL O
U
T
S
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
1 - -
3 - -
SIREN (UNITED KINGDOM) - BLACK 4 WAY

1 D97 18WT/OR SIREN SIGNAL OUTPUT
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A600 18RD/LB SIREN SUPPLY
4 G944 18LB/BR SIREN SIGNAL RETURN
1083
CONNECTOR PINOUTS
THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY
1 - -
2 - -
3 G22 20YL VTSS INDICATOR SUPPLY
5 D97 20WT/OR SIREN SIGNAL OUTPUT
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 G944 20LB/BR SIREN SIGNAL RETURN
9 - -
10 - -
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
16 A600 20RD/LB SIREN SUPPLY
C THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAY

N 1 18BK/LB REAR INTRUSION SENSOR SIGNAL
N 4 18BK/WT SENSOR GROUND
E 2 18BK/LB FRONT INTRUSION SENSOR SIGNAL
C 3 18BK/WT SENSOR GROUND
T
O
R
P
I
N
O
U
T
S
1084
CONNECTOR PINOUTS
TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY
1 T1 18DG/LB TRS T1 SENSE
2 - -
3 T3 18DG/DB TRS T3 SENSE
4 - -
5 - -
6 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
9 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
12 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
13 T13 18DG/VT SPEED SENSOR GROUND
14 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
15 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
16 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
17 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
18 - -
19 T19 18YL/DB 2-4 SOLENOID CONTROL
20 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
21 - -
22 - - C
23 - - O
24 - - N
25 - -
N
26 - -
E
27 - -
28 - -
C
29 - -
T
30 - - O
31 - - R
32 - -
33 - - P
34 - - I
35 - - N
36 - - O
37 - -
U
38 - -
T
39 - -
40 - -
S
41 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE
41 T41 18YL/DB (2.4L) TRS T41 SENSE
42 T42 18DG/YL TRS T42 SENSE
44 - -
45 - -
46 D16 18WT/OR SCI RECEIVE
47 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
48 - -
49 - -
50 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
52 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
54 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT
56 A104 18YL/RD FUSED B(+)
59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
60 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
1085
CONNECTOR PINOUTS
TXV SOLENOID (ATC) - 2 WAY

C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
1086
SCHEMATIC DIAGRAMS
10.0 SCHEMATIC DIAGRAMS
10.1 AIRBAG SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1087
SCHEMATIC DIAGRAMS
10.2 AUDIO SYSTEM
10.2.1 PREMIUM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1088
SCHEMATIC DIAGRAMS
10.2.2 BASE
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1089
SCHEMATIC DIAGRAMS
10.2 AUDIO SYSTEM (Continued)
10.2.3 CD CHANGER
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1090
SCHEMATIC DIAGRAMS
10.2.4 REMOTE RADIO CONTROLS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1091
SCHEMATIC DIAGRAMS
10.3 CABIN HEATER
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1092
SCHEMATIC DIAGRAMS
10.4 AUTOMATIC TEMPERATURE CONTROL SYSTEM
10.4.1 FRONT ATC
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1093
SCHEMATIC DIAGRAMS
10.4.2 REAR ATC
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1094
SCHEMATIC DIAGRAMS
10.5 COMMUNICATION
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1095
SCHEMATIC DIAGRAMS
10.5 COMMUNICATION (Continued)
10.5.1 PCM COMMUNICATION
10.5.2 ECM & CABIN HEATER ASSIST COMMUNICATION - DIESEL ONLY
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1096
SCHEMATIC DIAGRAMS
10.6 DOOR AJAR WITH POWER SLIDING DOORS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1097
SCHEMATIC DIAGRAMS
10.7 DOOR AJAR WITHOUT POWER SLIDING DOORS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1098
SCHEMATIC DIAGRAMS
10.8 EXTERIOR LIGHTING
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1099
SCHEMATIC DIAGRAMS
10.9 IGNITION SWITCH
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1100
SCHEMATIC DIAGRAMS
10.10 INSTRUMENT CLUSTER — BASE
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1101
SCHEMATIC DIAGRAMS
10.11 INSTRUMENT CLUSTER & MESSAGE CENTER
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1102
SCHEMATIC DIAGRAMS
10.12 INTELLIGENT POWER MODULE/BODY CONTROL MODULE POWER AND GROUNDS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1103
SCHEMATIC DIAGRAMS
10.13 INTERIOR LIGHTING
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1104
SCHEMATIC DIAGRAMS
10.14 MANUAL TEMPERATURE CONTROLS
10.14.1 BASE MANUAL TEMPERATURE CONTROL SYSTEM LHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1105
SCHEMATIC DIAGRAMS
10.14 MANUAL TEMPERATURE CONTROLS (Continued)
10.14.2 BASE MANUAL TEMPERATURE CONTROL SYSTEM RHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1106
SCHEMATIC DIAGRAMS
10.14.3 DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM LHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1107
SCHEMATIC DIAGRAMS
10.14 MANUAL TEMPERATURE CONTROLS (Continued)
10.14.4 DUAL-ZONE MANUAL TEMPERATURE CONTROL SYSTEM RHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1108
SCHEMATIC DIAGRAMS
10.14.5 BLOWER MOTOR
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1109
SCHEMATIC DIAGRAMS
10.15 MEMORY SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1110
SCHEMATIC DIAGRAMS
10.16 OVERHEAD CONSOLE
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1111
SCHEMATIC DIAGRAMS
10.17 POWER FOLDING MIRROR LHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1112
SCHEMATIC DIAGRAMS
10.18 POWER FOLDING MIRROR RHD
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1113
SCHEMATIC DIAGRAMS
10.19 POWER DOOR LOCKS/RKE
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1114
SCHEMATIC DIAGRAMS
10.20 POWER LIFTGATE SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1115
SCHEMATIC DIAGRAMS
10.21 POWER SLIDING DOOR SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1116
SCHEMATIC DIAGRAMS
10.22 REAR DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1117
SCHEMATIC DIAGRAMS
10.23 SLIDING DOOR AND LIFTGATE SWITCHES
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1118
SCHEMATIC DIAGRAMS
10.24 VEHICLE THEFT SECURITY SYSTEM
10.24.1 BASE ALARM SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1119
SCHEMATIC DIAGRAMS
10.24 VEHICLE THEFT SECURITY SYSTEM (Continued)
10.24.2 THATCHAM ALARM SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1120
SCHEMATIC DIAGRAMS
10.25 WIPERS - FRONT AND REAR
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
1121
NOTES
1122
CHARTS AND GRAPHS
11.0 CHARTS AND GRAPHS C
H
A
11.1 KDB LAB SCOPE PATTERN R
T
S
A
N
D
G
R
A
P
H
S
1123
CHARTS AND GRAPHS
C 11.2 PCI BUS LAB SCOPE PATTERN
H
A
R
T
S
A
N
D
G
R
A
P
H
S
1124
NOTES
1125
NOTES
1126
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.1 TEVES MARK 20 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2 TRACTION CONTROL SYSTEM (TCS) DESCRIPTION . . . . . . . . . . . . . . . . . . . .1
3.3 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.3.1 ABS AND BRAKE WARNING INDICATORS. . . . . . . . . . . . . . . . . . . . . . .2
3.3.2 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . . .2
3.3.3 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.4 SWITCHES/SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.5 SYSTEM INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.6 DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . . .4
3.5.1 DRBIIIT DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.4 DRBIIIT SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . . .6
4.4 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
BRAKES (CAB)
BUS SYSTEM COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CAB INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
CLUSTER LAMP FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
LEFT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
LEFT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
RIGHT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
RIGHT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
LEFT FRONT WHEEL SPEED SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
LEFT REAR WHEEL SPEED SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PUMP CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
i
RIGHT REAR WHEEL SPEED SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SYSTEM OVERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
SYSTEM UNDERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
VALVE POWER FEED FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
*BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
*TRAC OFF INDICATOR NEVER/ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
*TRAC ON INDICATOR NEVER/ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
8.1 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

8.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
8.3 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
8.4 TRACTION CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
8.4.1 TRACTION CONTROL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.5 WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.5.1 FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.5.2 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.5A WHEEL SPEED SENSOR CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.5A.1 FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.5A.2 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.6 BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .47

DATA LINK CONNECTOR - WHITE 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
INTELLIGENT POWER MODULE C4 - GRAY 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . .48
LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .48
LEFT FRONT WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY . .49
LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . .49
LEFT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY . . .49
FUSES (IPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
PUMP MOTOR CONNECTOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . .52
RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
(SENSOR SIDE) - 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .52
RIGHT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY . .53
TRACTION CONTROL SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

TEVES MARK 20 ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 55
ii
GENERAL INFORMATION
1.0 INTRODUCTION • problem isolation
• repair of isolated problem
The procedures contained in this manual include • verification of proper operation
all the specifications, instructions, and graphics
needed to diagnose Mark 20 Antilock Braking Sys-
tem (ABS) and Mark 20 Antilock Braking System 2.0 IDENTIFICATION OF
with Traction Control. The diagnostics in this man- SYSTEM
ual are based on the failure condition or symptom
being present at time of diagnosis. Vehicles equipped with the Teves Mark 20 an-
Please follow the recommendations below when tilock brake system can be identified by the pres-
choosing your diagnostic path. ence of the controller antilock brake module located
1. First make sure the DRBIIIt is communicating beneath the master cylinder.
with the CAB. If the DRBIIIt displays a “No
Response” condition, you must diagnose that
first. 3.0 SYSTEM DESCRIPTION AND
2. Read DTC’s (diagnostic trouble codes) with the FUNCTIONAL OPERATION
DRBIIIt.
3. If no DTC’s are present, identify the customer 3.1 TEVES MARK 20 SYSTEM
complaint.
DESCRIPTION
4. Once the DTC or customer complaint is identi-
fied, locate the matching test in the Table of The controller antilock brake module is used to
Contents and begin to diagnose the symptom. monitor wheel speeds and to modulate (control)
All component location views are in Section 8.0. hydraulic pressure in each brake channel. The
All connector pinouts are in Section 9.0. All sche- modulated hydraulic pressure is used to prevent
matics are in Section 10.0. wheel lock-up during braking.
An * placed before the symptom description indi- The Teves Mark 20 system uses a diagonal split
cates a concern with no associated DTC. hydraulic brake system. In the standard brake mode
When repairs are required, refer to the appropri- the master cylinder primary circuit supplies pressure
ate service manual for the proper removal and to the right front and left rear wheel brakes, and the
repair procedure. secondary master cylinder circuit supplies pressure
Diagnostic procedures change every year. New to the left front and right rear wheel brakes.
diagnostic systems may be added; carry over sys-
tems may be enhanced. READ THIS MANUAL 3.2 TRACTION CONTROL SYSTEM (TCS)
BEFORE TRYING TO DIAGNOSE A VEHICLE
CODE. It is recommended that you review the
DESCRIPTION
entire manual to become familiar with all new and The main purpose of traction control is to reduce
changed diagnostic procedures. wheel slip and maintain traction at the driven
After using this book, if you have any comments wheels when road surfaces are slippery. The trac-
or recommendations, please fill out the form at the tion control system reduces wheel slip by braking
back of the book and mail it back to us. the wheel that is losing traction. The system is
designed to operate at speeds below 56 km/h (35
1.1 SYSTEM COVERAGE mph).
The Controller Antilock Brake (CAB) monitors
This diagnostic procedure manual covers the an-
wheel speeds. If, during acceleration, the module
tilock braking system (ABS) and traction control
detects front (drive) wheel slip and the brakes are
system found on: 2001 Chrysler Town and Country,
not applied, the CAB will enter traction control
Dodge Caravan and Grand Caravan.
mode. Traction control works in the following order
when drive wheel slip is detected.
1.2 SIX-STEP TROUBLESHOOTING
1. Close the (normally open) isolation valves.
PROCEDURE
2. Start pump/motor and supply volume/pressure
Diagnosis of the controller antilock brake module to front hydraulic circuits (pump runs continu-
is done in six basic steps: ously during traction control).
• verification of complaint 3. Open and close build and decay valves to main-
• verification of any related symptoms tain minimum wheel slip and maximum trac-
tion.
• symptom analysis
1
GENERAL INFORMATION
The cycling of the build and decay valves is After repair of a sensor signal fault or a pump motor
similar to the ABS except that they work to control fault, the CAB must sense all four wheels at 25
wheel spin by applying brakes. ABS function is to km/h (15 mph) before it will extinguish the ABS and
control wheel skid by releasing brakes. TRAC OFF Indicators.
Two pressure relief valves allow excess fluid vol- The Instrument Cluster will illuminate the ABS
ume to return to the reservoir when not used by the Warning Indicator if it loses communication with
build/decay cycles. These are required because the the CAB.
pump supplies more volume than the traction con- The red BRAKE warning indicator is also located
trol system requires. in the instrument cluster. It can be activated in
If at any time the brake pedal is applied during a several ways. Application of the parking brake or a
traction control cycle, the brake lamp switch will low fluid signal from the fluid level switch located in
trigger the CAB to switch off the traction control. the master cylinder reservoir will cause the indica-
The traction control system will be enabled at tor to come on.
each ignition cycle. It may be turned off by depress-
ing the Traction Control Switch. The traction con- 3.3.2 CONTROLLER ANTILOCK BRAKE
trol system function lamp will illuminate “TRAC
OFF” immediately upon depressing the traction
(CAB)
control switch button. Only the “TRAC” portion of The Controller Antilock Brake (CAB) is a
the “TRAC OFF” indicator will illuminate during a microprocessor-based device that monitors wheel
traction control event. If the CAB calculates that speeds and controls the antilock functions. The
the brake temperatures are high, the traction con- CAB contains two microprocessors that receive
trol system will become inoperative until a time-out identical sensor signals and then independently
period has elapsed. When in this thermal protection process the information. The results are then com-
mode, the traction control “TRAC OFF” lamp will pared to make sure that they agree. Otherwise, the
illuminate; however, a fault will not be registered. CAB will turn off the antilock and turn on the ABS
amber warning indicator.
3.3 SYSTEM COMPONENTS The primary functions of the CAB are to:
• detect wheel locking tendencies
• controller antilock brake (CAB) • control fluid pressure modulation to the brakes
• vacuum booster during antilock stop
• master cylinder • monitor the system for proper operation
• ABS integrated electronic control module/ • manage traction control functions
hydraulic control unit (HCU), valve block assem- • provide communication to the DRBIIIt while in
bly: 8 valve solenoids (4 inlet valves, 4 outlet diagnostic mode
valves, 2 accumulators) 1 motor, 2 pump
• store diagnostic information in non-volatile memory
• ABS integrated electronic control module with The CAB continuously monitors the speed of each
traction control same as above but has 10 valve wheel. When a wheel locking tendency is detected,
solenoids. the CAB will command the appropriate valve to
• 4 wheel speed sensor/tone wheel assemblies modulate brake fluid pressure in its hydraulic unit.
• ABS warning indicator Brake pedal position is maintained during an an-
tilock stop by being a closed system with the use of
• fuses and wiring harness 2 accumulators. The CAB continues to control pres-
• fluid reservoir sure in individual hydraulic circuits until a wheel
• TRAC/TRAC OFF indicator locking tendency is no longer present. The CAB
turns on the pump motor during an antilock stop.
3.3.1 ABS AND BRAKE WARNING The antilock brake system is constantly moni-
tored by the CAB for proper operation. If the CAB
INDICATORS detects a system malfunction, it can disable the
The amber ABS warning indicator is located in antilock system and turn on the ABS warning
the instrument cluster. It is used to inform the indicator. If the antilock function is disabled, the
driver that the antilock function has been turned system will revert to standard base brake system
off. The ABS warning indicator is controlled by the operation.
CAB. The CAB controls the lamp with a command The CAB inputs include the following:
over the PCI bus. • diagnostic communication
The ABS Warning Indicator will remain lit during
• four wheel speed sensors
every key cycle until a circuit or component fault is
repaired and the CAB no longer detects the fault.
2
GENERAL INFORMATION
• three power feeds: valves, pump and microproces- 3.3.4 SWITCHES/SENSORS
sor
Master Cylinder: The master cylinder is a stan-
• brake switch dard tandem compensating port design for ABS and
• traction control switch non ABS systems. Traction control vehicles use a
The CAB outputs include the following: dual center port master cylinder. For proper trac-
• ABS warning indicator actuation tion control operation the standard master cylinder
must not be used.
• 12 volts power to wheel speed sensors
A fluid level switch is located in the master
• eight valves cylinder fluid reservoir. The switch closes when a
• ten valves with traction control low fluid level is detected. The fluid level switch
• diagnostic communication turns on the brake warning indicator by grounding
the indicator circuit. This switch does not disable
• PCI bus communication
the ABS system.
• traction control lamp illumination Wheel Speed Sensors and Tone Wheels: One
active wheel speed sensor (WSS) is located at each
3.3.3 HYDRAULIC CONTROL UNIT wheel and sends a small signal to the control
The hydraulic control unit (HCU) contains the module (CAB). This signal is generated when a
valve block assembly, two accumulators, and pump/ toothed sensor ring (tone wheel) passes by a station-
motor assembly. The HCU is attached to the CAB. ary wheel speed sensor. The CAB converts the
Valve Block Assembly: The valve block assem- signals into digital signals for each wheel.
bly contains valves with four inlet valves and four Because of internal circuitry, correct wheel speed
outlet valves. The inlet valves are spring-loaded in sensor function cannot be determined by a continu-
the open position and the outlet valves are spring ity or resistance check through the sensor.
loaded in the closed position. During an antilock The front wheel speed sensor is attached to a boss
stop, these valves are cycled to maintain the proper in the steering knuckle. The tone wheel is an
slip ratio for each wheel. If a wheel detects slip, the integral part of the front axle shaft. The rear speed
inlet valve is closed to prevent and further pressure sensor is mounted though the bearing cover and the
increase. Then the outlet valve is opened to release rear tone wheel is an integral part of the rear
the pressure to the accumulators until the wheel is bearing hub. The wheel speed sensor air gap is not
no longer slipping. Once the wheel is no longer adjustable. Refer to the service manual for wheel
slipping, the outlet valve is closed and the inlet speed sensor air gap and resistance specifications.
valve is opened to reapply pressure. If the wheel is The four wheel speed sensors are serviced indi-
decelerating within its predetermined limits (prop- vidually. The front tone wheels are serviced as an
er slip ratio), the inlet valve will close to hold the assembly with the outer constant velocity (C.V.)
pressure constant. On vehicles which are equipped joint housing. The rear tone wheels are serviced as
with a traction control system, there are two addi- an assembly.
tional valves that isolate the master cylinder and Correct antilock system operation is dependent
rear wheels. During a traction control event the on tone wheel speed signals from the wheel speed
brakes are applied to reduce wheel slippage. sensors. The vehicle’s wheels and tires should all be
Pump Motor Assembly: The pump motor as- the same size and type to generate accurate signals.
sembly provides the extra amount of fluid needed In addition, the tires should be inflated to the
during antilock braking. The pump is supplied fluid recommended pressure for optimum system opera-
that is released to the accumulators when the outlet tion. Variation in wheel and tire size or significant
valve is opened during an antilock stop. The pump variations in inflation pressure can produce inaccu-
is also used to drain the accumulator circuits after rate wheel speed signals; however, the system will
the antilock stop is complete. The pump is operated continue to function when using the mini-spare.
by an integral electric motor. This DC-type motor is
controlled by the CAB. The CAB may turn on the 3.3.5 SYSTEM INITIALIZATION
pump motor when an antilock stop is detected. The System initialization starts when the key is
pump continues to run during the antilock stop and turned to “run”. At this point, the CAB performs a
is turned off after the stop is complete. Under some complete self-check of all electrical components in
conditions, the pump motor will run to drain the the antilock systems.
accumulators during the next drive off. The CAB Between 8-17 km/h (5-10 mph), a dynamic test is
monitors the pump motor operation internally. performed. This will momentarily cycle the inlet
Accumulators: The accumulators provide tem- and outlet valves, check wheel speed sensor cir-
porary fluid storage during an antilock stop and are cuitry, and run the pump motor at 25 km/h (15
drained by the pump motor. mph). The CAB will try to test the pump motor. If
3
GENERAL INFORMATION
the brake pedal is applied the test will be run at 40 3.5 DRBIIIT ERROR MESSAGES AND
km/h (24 mph) regardless of brake switch state. If,
BLANK SCREEN
during the dynamic test, the brake pedal is applied,
the driver may feel the test through brake pedal Under normal operation, the DRBIIIt will dis-
pulsations. This is a normal condition. play one of only two error messages:
If any component exhibits a trouble condition
during system initialization or dynamic check, the – User-Requested WARM Boot or User-
CAB will illuminate the ABS warning indicator and Requested COLD Boot.
If the DRBIIIt should display any other error
TRAC OFF lamp if equipped.
message, record the entire display and call the
STAR Center for information. This is a sample of
3.3.6 DIAGNOSTIC MODE
such an error message display:
To enter diagnostic mode, a vehicle speed must be
below 10 km/h (6 mph) and no ABS condition ver: 2.14
present. If vehicle speed is not below 10 km/h
date: 26 Jul93
file: key_itf.cc
(6 mph), a “No Response” message could be dis- date: Jul 26 1993
played by the DRBIIIt. The following are charac- line: 548
teristics of diagnostic mode: err. 0x1
– The amber ABS warning indicator will blink User-Requested COLD boot Press MORE to
rapidly (about 1/2 second ON and 1/2 second switch between this display
OFF). If a hard trouble code, such as Valve and the application screen.
Power Feed Failure code is present, the indi- Press F4 when done noting information.
cator will be illuminated without blinking un-
til the trouble condition is cleared. 3.5.1 DRBIIIT DOES NOT POWER UP
– Antilock operation is disabled. If the LED’s do not light or no sound is emitted at
– The HCU valves cannot be actuated when the start up, check for loose cable connections or a bad
vehicle speed is above 8 km/h (5 mph). If valve cable. Check the vehicle battery voltage (data link
actuation is attempted above 8 km/h (5 mph), a connector cavity 16). A minimum of 11 volts is
“No Response” message will be displayed on required to adequately power the DRBIIIt.
the DRBIIIt. If all connections are proper between the
DRBIIIt and the vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
3.4 DIAGNOSTIC TROUBLE CODES
DRBIIIt may be the result of faulty cable or vehicle
The controller antilock brake may report any of wiring.
the following diagnostic trouble codes:
CLUSTER LAMP FAILURE 3.5.2 DISPLAY IS NOT VISIBLE
VALVE POWER FEED FAILURE Low temperatures will affect the visibility of the
BUS SYSTEM COMMUNICATION FAILURE display. Adjust the contrast to compensate for this
CAB INTERNAL FAILURE condition.
LEFT FRONT SENSOR CIRCUIT FAILURE
LEFT FRONT WHEEL SPEED SIGNAL
FAILURE
LEFT REAR SENSOR CIRCUIT FAILURE
LEFT REAR WHEEL SPEED SIGNAL
FAILURE
PUMP CIRCUIT FAILURE
RIGHT FRONT SENSOR CIRCUIT FAILURE
RIGHT FRONT WHEEL SPEED SIGNAL
FAILURE
RIGHT REAR SENSOR CIRCUIT FAILURE
RIGHT REAR WHEEL SPEED SIGNAL
FAILURE
SYSTEM OVERVOLTAGE
SYSTEM UNDERVOLTAGE
4
GENERAL INFORMATION
4.0 DISCLAIMERS, SAFETY, 4.2.4 DRBIIIT SAFETY INFORMATION
WARNINGS
WARNING: EXCEEDING THE LIMITS OF THE
DRB MULTIMETER IS DANGEROUS. IT CAN
4.1 DISCLAIMERS EXPOSE YOU TO SERIOUS OR POSSIBLY
FATAL INJURY. CAREFULLY READ AND
All information, illustrations, and specifications UNDERSTAND THE CAUTIONS AND THE
contained in this manual are based on the latest
SPECIFICATION LIMITS.
information available at the time of publication.
The right is reserved to make changes at any time • Follow the vehicle manufacturer’s service speci-
without notice. fications at all times.
• Do not use the DRBIIIt if it has been damaged.
4.2 SAFETY • Do not use the test leads if the insulation is
4.2.1 TECHNICIAN SAFETY INFORMATION • To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
WARNING: ENGINES PRODUCE CARBON • Choose the proper range and functions for the
MONOXIDE THAT IS ODORLESS, CAUSES measurement. Do not try voltage or current mea-
SLOWER REACTION TIME, AND CAN LEAD surements that may exceed the rated capacity.
TO SERIOUS INJURY. WHEN THE ENGINE IS • Do not exceed the limits shown in the table below:
OPERATING, KEEP SERVICE AREAS WELL FUNCTION INPUT LIMIT
VENTILATED OR ATTACH THE VEHICLE
Volts 0 - 500 peak volts AC
EXHAUST SYSTEM TO THE SHOP EXHAUST
0 - 500 volts DC
REMOVAL SYSTEM.
Set the parking brake and block the wheels before Ohms (resistance)* 0 -1.12 megohms
testing or repairing the vehicle. It is especially Frequency Measured 0 - 10 kHz
important to block the wheels on front-wheel drive Frequency Generated
vehicles; the parking brake does not hold the drive
wheels. Temperature -58 - 1100°F
When servicing a vehicle, always wear eye pro- -50 - 600°C
tection, and remove any metal jewelry such as * Ohms cannot be measured if voltage is present.
rings, watchbands or bracelets that might make an Ohms can be measured only in a non-powered
inadvertent electrical contact. circuit.
When diagnosing a chassis problem, it is impor-
• Voltage between any terminal and ground must
tant to follow approved procedures where applica-
not exceed 500v DC or 500v peak AC.
ble. These procedures can be found in the service
manual. Following these procedures is very impor- • Use caution when measuring voltage above 25v
tant to the safety of individuals performing diag- DC or 25v AC.
nostic tests. • Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
4.2.2 VEHICLE PREPARATION FOR circuits exceeding 10A.
TESTING • When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
Make sure the vehicle being tested has a fully
rectly. Take a reading of a known voltage or
charged battery. If is does not, false diagnostic codes
or error messages may occur.
• When measuring current, connect the meter in
4.2.3 SERVICING SUB-ASSEMBLIES series with the load.
• Disconnect the live test lead before disconnecting
Some components of the chassis system are in-
tended to be serviced as an assembly only. Attempt- the common test lead.
ing to remove or repair certain system sub- • When using the meter function, keep the
components may result in personal injury and/or DRBIIIt away from spark plug or coil wires to
improper system operation. Only those components avoid measuring error from outside interference.
5
GENERAL INFORMATION
4.3 WARNINGS appropriate test by locating the matching test in
the Table of Contents and begin to diagnose the
symptom.
4.3.1 VEHICLE DAMAGE WARNINGS 5. If there are no diagnostic trouble codes present,
Before disconnecting any control module, make identify the customer complaint. Select “Inputs/
sure the ignition is ‘‘off ’’. Failure to do so could Outputs” and read the brake switch input as you
damage the module. press and release the brake pedal. If the display
When testing voltage or continuity at any control does not match the state of the pedal, perform
module, use the terminal side (not the wire end) of the proper test by locating the matching test in
the connector. Do not probe a wire through the the Table of Contents and begin to diagnose the
insulation, this will damage it and eventually cause symptom. If a problem exists with the yellow
it to fail because of corrosion. “ABS” warning indicator or the red “Brake”
Be careful when performing electrical tests so as indicator exists, refer to the proper tests by
to prevent accidental shorting of terminals. Such locating the matching test in the Table of Con-
mistakes can damage fuses or components. Also, a tents and begin to diagnose the symptom. Read
second code could be set, making diagnosis of the the traction control switch input as you press
original problem more difficult. and release the switch. If the display does not
match the state of the indicator perform the
4.3.2 ROAD TESTING A COMPLAINT proper test by locating the matching test in the
Table of Contents and begin to diagnose the
VEHICLE symptom.
Some complaints will require a test drive as part 6. If no other problems are found, it will be neces-
of the repair verification procedure. The purpose of sary to road test the vehicle. Perform several
the test drive is to try to duplicate the diagnostic antilock stops from above 50 Km/h (30 mph) and
code or symptom condition. then repeat step 4. If any diagnostic trouble
codes are present, proceed to the appropriate test.
WARNING: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL 7. The following conditions should be considered
“NORMAL” operation, and no repairs should be
COMPONENTS ARE REASSEMBLED.
attempted to correct them.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRB SCREEN WHILE IN MOTION. – Brake pedal feedback during an ABS stop
(clicking, vibrating).
DO NOT HANG THE DRBIIIT FROM THE
REAR VIEW MIRROR OR OPERATE IT – Clicking, groaning or buzzing at 25 Km/h (15
YOURSELF. HAVE AN ASSISTANT mph) or 40 Km/h (24 mph) (drive off self test).
AVAILABLE TO OPERATE THE DRBIIIT. – Groaning noise during an ABS stop.
– Slight brake pedal drop and pop noise when
4.4 DIAGNOSIS ignition is initially turned on.
– Brake pedal ratcheting down at the end of an
1. Your diagnostic test procedure must begin with a ABS stop.
thorough visual inspection of the ABS system for 8. If the complaint is ABS “cycling” at the end of a
damaged components or disconnected connec- stop at low speeds, it may be caused by a
tors. The brake lamps must be operational, and marginal wheel speed sensor signal. The sensor
if they are not, repair them prior to continuing. air gap, tone wheel condition, and/or brakes
2. Connect the DRBIIIt to the data link connector, hanging up are possible causes of this condition.
which is located under the dash to the left of the 9. After a road test in which no problems were
steering column. If the DRBIIIt does not power found, refer to any Technical Service Bulletins
up, check the power and ground supplies to the that may apply.
connector.
3. Turn the ignition on. Select “Antilock Brakes”. If
the DRBIIIt displays “No Response” condition 5.0 REQUIRED TOOLS AND
you must diagnose that first. EQUIPMENT
4. Read and record all ABS diagnostic trouble
codes. If the “CAB Power Feed Circuit” diagnos- DRBIIIt (diagnostic read-out box)
tic trouble code is present, it must be repaired jumper wires
prior to addressing any other DTC’s. If any ohmmeter
additional DTC’s are present, proceed to the voltmeter
test light
6
GENERAL INFORMATION
6.0 GLOSSARY OF TERMS IFR inlet front right
IRL inlet rear left
ABS antilock brake system
IRR inlet rear right
CAB controller antilock brake
JBLK junction block
CCD Chrysler Collision Detection
OFL outlet front left
DLC data link connector
OFR outlet front right
DRB diagnostic read-out box
ORL outlet rear left
EDW electrical distribution wiring
ORR outlet rear right
EMI electro magnetic interference
PDC power distribution center
HCU hydraulic control unit
P/M pump motor
ICU integrated control unit
RFI radio frequency interference
IFL inlet front left
WSS wheel speed sensor
7
NOTES
8
7.0
PROCEDURES
9
BRAKES (CAB)
Symptom:
BUS SYSTEM COMMUNICATION FAILURE
BUS SYSTEM COMMUNICATION FAILURE

When Monitored: Ignition ON, every 7 ms.
Set Condition: When the CAB does not receive a message from the instrument cluster for
10 seconds.
POSSIBLE CAUSES
CHECK COMMUNICATION TO MIC
CAB-- INTERNAL FAULT

With the DRBIIIt, attempt to communicate with the MIC
Was the DRB able to I/D or communicate with the MIC?
Yes → Go To 2
No → Refer to the Communication category and perform the symptom

Bus +/- Signals Open from the Controller Anti-Lock Brake.

Did this DTC reappear?
Yes → Replace the Controller Anti-Lock Brake in accordance with the

10
BRAKES (CAB)
Symptom:
CAB INTERNAL FAILURE
CAB INTERNAL FAILURE

When Monitored: Ignition on. The CAB monitors its internal microprocessors for correct
operation.
Set Condition: If the CAB detects an internal fault, the DTC is set.
POSSIBLE CAUSES
CAB - INTERNAL CONCERN

1 The only possible cause is a CAB internal concern. All
View repair.
11
BRAKES (CAB)
Symptom:
CLUSTER LAMP FAILURE
CLUSTER LAMP FAILURE

When Monitored: Key ON. After Key-ON bulb check.
Set Condition: When the instrument cluster informs the CAB that the cluster cannot
turn on the ABS Lamp.
POSSIBLE CAUSES
CLUSTER DTC PRESENT
CLUSTER INTERNAL FAULT
CAB -- NO ABS INDICATOR MESSAGE
CAB -- ABS INDICATOR FAULT

Are there any Instrument Cluster DTCs present?
Yes → Refer to the INSTRUMENT CLUSTER category for the related
symptom(s).
No → Go To 2

Observe the instrument cluster indicators.
Did the ABS Indicator illuminate for several seconds and then go out?
Yes → Go To 3
No → Go To 4
3 NOTE: The DRBIIIt communication with the CAB must be operational for All
the result of this test to be valid.
Remove Fuse 21 (ABS valve power) from the IPM.
Perform the Key-on Bulb Check.
Does the ABS Indicator remain on after the bulb check?
No → Replace the Controller Antilock Brake in accordance with the

12
BRAKES (CAB)
CLUSTER LAMP FAILURE — Continued

4 NOTE: The purpose of this test is to perform the Instrument Cluster self All
test.
Depress and hold the Odometer Reset Button.
Turn the Key from OFF to ON and then back to OFF.
Release the Odometer Reset Button.
Do the Instrument Cluster Indicators and Gauges activate and deactivate?
Yes → Replace the Controller Antilock Brake in accordance with the

Information.
13
BRAKES (CAB)
Symptom List:
The title for the tests will be LEFT FRONT SENSOR CIRCUIT
FAILURE.

When Monitored: Ignition on. The CAB monitors the wheel speed circuit every 7
milliseconds (ms).
Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit, the
Diagnostic Trouble Code (DTC) will set.

milliseconds (ms).

milliseconds (ms).

milliseconds (ms).
POSSIBLE CAUSES
SENSOR OR CONNECTOR DAMAGE
WHEEL SPEED SENSOR FAULT
SENSOR CIRCUITS SHORTED OR OPEN
14
BRAKES (CAB)
LEFT FRONT SENSOR CIRCUIT FAILURE — Continued
POSSIBLE CAUSES
CAB - INTERNAL FAULT
INTERMITTENT CIRCUIT DTC

Does the DRBIIIt display a Wheel Speed Sensor Circuit Failure DTC?
Yes → Go To 2
No → Go To 5

Inspect the affected Wheel Speed Sensor and Connector.
Is the Sensor or Connector Damaged?
No → Go To 3

Disconnect the affected Wheel Speed Sensor connector.
Note: Check connector - Clean/repair as necessary.
Using a 12-volt test light connected to ground, check the Sensor 12 volt Supply
circuit.
Measure the resistance between ground and the Sensor Signal circuit.
Was the test light bright and the resistance between 100 and 300 ohms?
Yes → Replace the Wheel Speed Sensor in accordance with the Service
Information.
No → Go To 4

Disconnect the affected Wheel Speed Sensor connector.
Disconnect the CAB connector.
Check the Wheel Speed Sensor 12 volt Supply and Signal circuits for a short to
battery, ground, to each other and for an open.
For the purposes of this test, a short to ground must be below 15k ohms.
Was any circuit short or open found?
Yes → Repair the Wheel Speed Sensor circuit short or open.

15
BRAKES (CAB)
LEFT FRONT SENSOR CIRCUIT FAILURE — Continued

Visually inspect the related wire harness connectors. Look for broken, bent, pushed
Refer to any Hotline letters or Technical Service Bulletins that may apply.

16
BRAKES (CAB)
Symptom:
LEFT FRONT WHEEL SPEED SIGNAL FAILURE
LEFT FRONT WHEEL SPEED SIGNAL FAILURE

When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds
(ms). Sensor signal continuity is checked every 7 milliseconds. Wheel speed phase length
supervision is checked every 7 milliseconds.
Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an
extended length of time, and does not see a corresponding wheel speed change, the
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
POSSIBLE CAUSES
SENSOR OR TONE WHEEL CONCERN
DTC INTERMITTENT
LEFT FRONT WHEEL SPEED SENSOR INOPERATIVE
INTERMITTENT SIGNAL DTC

Start the engine.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Using the DRBIIIt, monitor the Left Front Wheel Speed Sensor while an assistant
drives the vehicle.
With the DRBIIIt, monitor all wheel speed sensors.
Is Left Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?
Yes → Go To 2
No → Go To 3
2 Inspect the Left Front Wheel Speed Sensor, Connector and Tone Wheel. All
NOTE: Inspect components for damage and correct installation.
Are there any visible Sensor, Connector or Tone Wheel concerns?
Yes → Correct the sensor, connector or tone wheel concern as necessary.
The vehicle must be driven at 25 km/h (15 mph) to extinguish the
ABS indicator.
No → Replace the Left Front Wheel Speed Sensor in accordance with
the Service Information. The vehicle must be driven at 25 km/h
(15 mph) to extinguish the ABS indicator.
17
BRAKES (CAB)
LEFT FRONT WHEEL SPEED SIGNAL FAILURE — Continued

Did the DTC reoccur?
Yes → Replace the Wheel Speed Sensor in accordance with the Service
Information.
No → Go To 4

Visually inspect wheel speed sensor.
Visually inspect tone wheel.
Visually inspect wiring harness.
Visually inspect brakes for locking up due to lining contamination or overheating.
Inspect all Components for defects which may cause a Signal DTC to set.
Is any Component Damaged?
Yes → Repair as necessary. The vehicle must be driven at 25 km/h (15

mph) to extinguish the ABS indicator.
18
BRAKES (CAB)
Symptom:
LEFT REAR WHEEL SPEED SIGNAL FAILURE
LEFT REAR WHEEL SPEED SIGNAL FAILURE

(ms). Wheel speed circuit continuity is checked every 7 milliseconds. Wheel speed phase
length supervision is checked every 7 milliseconds.
erratic.
POSSIBLE CAUSES
DTC INTERMITTENT
LEFT REAR WHEEL SPEED SENSOR INOPERATIVE

Start the engine.
Using the DRBIIIt, monitor the Left Rear Wheel Speed Sensor while an assistant
drives the vehicle.
Is Left Rear WSS Signal 0 km/h (0 mph) or differing from others by more than 5 km/h
(3 mph)?
Yes → Go To 2
No → Go To 3
2 Inspect the Left Rear Wheel Speed Sensor, Connector and Tone Wheel. All
ABS indicator.
No → Replace the Left Rear Wheel Speed Sensor in accordance with the
Service Information. The vehicle must be driven at 25 km/h (15
19
BRAKES (CAB)
LEFT REAR WHEEL SPEED SIGNAL FAILURE — Continued

Yes →
No → Go To 4

20
BRAKES (CAB)
Symptom:

When Monitored: Ignition on. The CAB commands the pump on at 20 km/h (12 mph) to
check its operation, if the brake switch is not applied. If the brake is applied, the test will
run at 40 km/h (25 mph). The CAB monitors pump voltage every 7 milliseconds.
Set Condition: The DTC is stored when the CAB detects: 1) Improper voltage decay after
the pump was turned off. 2) Pump not energized by the CAB, but voltage is present for 3.5
seconds. 3) Pump is turned on by the CAB, but without sufficient voltage to operate it.
POSSIBLE CAUSES
PUMP HARNESS DISCONNECTED
CAB - PUMP MOTOR RUNNING CONTINUOUSLY
ABS PUMP MOTOR INTERMITTENT DTC
GROUND CIRCUIT HIGH RESISTANCE
GROUND CIRCUIT OPEN
CAB - SETTING FALSE CODE

Monitor the pump motor for continuous operation.
Is the pump motor running continuously?
Yes → Replace the Controller Anti-Lock Brake in accordance with the

No → Go To 2

With the DRBIIIt, actuate the ABS pump motor.
Did the Pump Motor operate when actuated?
Yes → Go To 3
No → Go To 4
21
BRAKES (CAB)
PUMP CIRCUIT FAILURE — Continued


No → Replace the Controller Anti-Lock Brake in accordance with the
4 Check the short Wiring Harness between the ABS Pump and the CAB. All
Check for disconnect and damage.
Is the harness disconnected or damaged?
Yes → Reconnect or repair the Pump Harness as necessary.

No → Go To 5

Disconnect CAB Connector.
Measure the resistance of the CAB ground circuits.
Is the resistance below 1.0 ohm?
Yes → Go To 6
No → Repair the ground circuit for an open. The vehicle must be driven
at 25 km/h (15 mph) to extinguish the ABS indicator.

With the DRBIIIt, enable pump motor actuation.
NOTE: Pump motor will not operate, but voltage will be applied.
Measure the voltage drop across the ABS ground circuit connection, with pump motor
actuation enabled.
Yes → Go To 7
No → Repair the Ground circuit for high resistance. The vehicle must be
driven at 25 km/h (15 mph) to extinguish the ABS indicator.
22
BRAKES (CAB)
PUMP CIRCUIT FAILURE — Continued

Using a 12-volt test light connected to ground, check the Pump Motor Fused B+
circuit.
Yes → Go To 8
No → Repair the Fused B(+) circuit for an open. The vehicle must be
driven at 25 km/h (15 mph) to extinguish the ABS indicator.
Repair
Replace the Controller Anti-Lock Brake in accordance with the
23
BRAKES (CAB)
Symptom:
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE

(ms). Wheel speed continuity is checked every 7 milliseconds. Wheel speed phase length
supervision is checked every 7 milliseconds.
erratic.
POSSIBLE CAUSES
DTC INTERMITTENT
RIGHT FRONT WHEEL SPEED SENSOR INOPERATIVE
CAB - WON’T RESPOND TO RIGHT FRONT WHEEL SPEED SENSOR SIGNAL

Start the engine.
Using the DRBIIIt, monitor the Right Front Wheel Speed Sensor while an assistant
drives the vehicle.
Is Right Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?
Yes → Go To 2
No → Go To 3
2 Inspect the Right Front Wheel Speed Sensor, Connector and Tone Wheel. All

ABS indicator.
No → Replace the Right Front Wheel Speed Sensor in accordance with

the Service Information. The vehicle must be driven at 25 km/h
(15 mph) to extinguish the ABS indicator.
24
BRAKES (CAB)
RIGHT FRONT WHEEL SPEED SIGNAL FAILURE — Continued

No → Go To 4

25
BRAKES (CAB)
Symptom:
RIGHT REAR WHEEL SPEED SIGNAL FAILURE
RIGHT REAR WHEEL SPEED SIGNAL FAILURE

(ms). Wheel speed circuit continuity is checked every 7 milliseconds. Wheel speed phase
length supervision is checked every 7 milliseconds.
erratic.
POSSIBLE CAUSES
DTC INTERMITTENT
RIGHT REAR WHEEL SPEED SENSOR INOPERATIVE

Start the engine.
Using the DRBIIIt, monitor the Right Rear Wheel Speed Sensor while an assistant
drives the vehicle.
Is Right Rear WSS Signal 0 km/h (0 mph) or differing from others by more than 5
km/h (3 mph)?
Yes → Go To 2
No → Go To 3
2 Inspect the Right Rear Wheel Speed Sensor, Connector and Tone Wheel. All
ABS indicator.
No → Replace the Left Rear Wheel Speed Sensor in accordance with the
26
BRAKES (CAB)
RIGHT REAR WHEEL SPEED SIGNAL FAILURE — Continued

Yes →
No → Go To 4

27
BRAKES (CAB)
Symptom:
SYSTEM OVERVOLTAGE
SYSTEM OVERVOLTAGE
When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for
proper system voltage.
Set Condition: If the voltage is above 16.5 volts for greater than 420 milliseconds (ms),
the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
BATTERY OVERCHARGED
FUSED IGNITION SWITCH OUTPUT HIGH
GROUND CIRCUIT OPEN
INTERMITTENT DTC

Start the engine.
Does the DRBIIIt display System Overvoltage DTC?
Yes → Go To 2
No → Go To 6

Inspect for battery charger connected to battery.
Is a battery charger connected to the battery?
Yes → Charge battery to proper level. Disconnect the battery charger.
Clear DTC’s.
No → Go To 3
28
BRAKES (CAB)
SYSTEM OVERVOLTAGE — Continued

Start the engine.
Raise engine speed above 1,800 RPM.
Measure the battery voltage.
Is the voltage above 16.5 volts ?
Yes → Refer to appropriate service information for charging system

testing and repair.
No → Go To 4

Measure the resistance of the ground circuits.
Is the resistance below 1.0 ohm?
Yes → Go To 5

5 If there are no potential causes remaining, view repair. All

Repair
Replace the Controller Antilock Brake.

29
BRAKES (CAB)
Symptom:
SYSTEM UNDERVOLTAGE
SYSTEM UNDERVOLTAGE
When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output
circuit voltage above 10 km/h (6 mph) every 7 milliseconds for proper system voltage.
Set Condition: If the voltage is below 9.5 volts, the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW
INTERMITTENT DTC
FUSED IGNITION SWITCH OUTPUT CIRCUIT HIGH RESISTANCE

Start the engine.
Drive the vehicle above 16 km/h (10 mph) for at least 20 seconds.
Stop the vehicle
Does the DRBIIIt display System Undervoltage DTC?
Yes → Go To 2
No → Go To 5
2 Engine Running. All

Measure the battery voltage.
Is the battery voltage below 10 volts?
Yes → Refer to appropriate service information for charging system
testing and repair.
No → Go To 3
3 Disconnect the CAB harness connector. All

Measure the voltage of the Fused Ignition Switch circuit.
Yes → Go To 4
No → Repair the Fused Ignition Switch Output Circuit for high resis-
tance
30
BRAKES (CAB)
SYSTEM UNDERVOLTAGE — Continued

4 If there are no potential causes remaining, view repair. All
Repair
Replace the Controller Antilock Brake.

31
BRAKES (CAB)
Symptom:
VALVE POWER FEED FAILURE
VALVE POWER FEED FAILURE

When Monitored: Ignition ON for at least 3.5 seconds. ABS Power Relay closed. Valve
command for a particular solenoid not present.
Set Condition: Low feedback voltage from the low side of all the solenoids for over 20
consecutive controller checks spaced 5 ms apart.
POSSIBLE CAUSES
INTERMITTENT DTC
BLOWN FUSE - FUSED B(+) CIRCUIT
NO B+ SUPPLY TO FUSE
B(+) CIRCUIT SHORTED TO GROUND
CAB - FUSED B(+) CIRCUIT OPEN
CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND

Drive the vehicle above 25 km/h (15 mph) for at least 10 seconds.
Stop the vehicle.
Does the DRBIIIt display Valve Power Feed Circuit DTC present right now?
Yes → Go To 2
No → Go To 9

Remove and Inspect the ABS Fuse 21 in the IPM.
Is the Fuse blown?
Yes → Go To 3
No → Go To 6
32
BRAKES (CAB)
VALVE POWER FEED FAILURE — Continued

Remove the ABS Fuse 21 from the IPM.
Using a test light connected to 12 volts, probe the Fused B(+) Circuit.
Yes → Repair the Fused B(+) Circuit short to ground.
No → Go To 4

The CAB must be connected for the results of this test to be valid.
Using a test light connected to 12 volts, probe the Fused B(+) Circuit at the IPM fuse
terminal.
No → Go To 5

If there are no potential causes remaining, view repair.
Continue
Replace the Fuse.
6 Remove the ABS Fuse 21 from the IPM. All

Measure the voltage of the Fused B+ supply to Fuse 21 in the IPM.
Yes → Go To 7
No → Repair the B+ Supply circuit for an open.

Measure the resistance of the Fused B(+) circuit between IPM Fuse terminal 21 and
the CAB connector.
Yes → Go To 8
No → Repair the Fuse B+ circuit for an open.


Repair
33
BRAKES (CAB)
VALVE POWER FEED FAILURE — Continued


34
BRAKES (CAB)
Symptom:
*BRAKE LAMP SWITCH
POSSIBLE CAUSES
CHECK BRAKE LAMP SWITCH OUTPUT
BRAKE LAMP SWITCH B+ OPEN
BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORT OR OPEN
BRAKE LAMP SWITCH OPEN
CAB -- INTERNAL OPEN

1 With the DRBIIIt in Inputs/Outputs, read the Brake Lamp Switch state. All
Press and release the brake pedal.
Does the DRBIIIt display PRESSED and RELEASED?
Yes → The Brake Lamp Switch is OK.
No → Go To 2
2 Disconnect the Brake Lamp Switch harness connector. All

Using a 12-volt test light connected to ground, check the Brake Lamp Switch Fused
B+ circuit.
Does the test light illuminate brightly ?
Yes → Go To 3
No → Repair the Brake Lamp Switch Fused B+ circuit for an open.

Connect a jumper wire between the Brake Lamp Switch B+ and Output circuits.
With the DRBIIIt in Inputs/Outputs, read the Brake Lamp Switch state.
Does the DRBIIIt display PRESSED?
Yes → Replace the Brake Lamp Switch in accordance with the Service
Information.
No → Go To 4
4 Disconnect the CAB harness connector. All

Disconnect the Brake Lamp Switch harness connector.
Check the Brake Lamp Switch Output circuit for a short to voltage and an open.
Is the Brake Lamp Switch Output circuit shorted or open?
Yes → Repair the Brake Lamp Switch Output circuit for a short to
voltage or an open.
No → Replace the Controller Anti-Lock Brake in accordance with the

35
BRAKES (CAB)
Symptom:
*TRAC OFF INDICATOR NEVER/ALWAYS ON
POSSIBLE CAUSES
TRAC OFF SW GROUND OPEN
TRAC OFF SWITCH OPEN
TRAC OFF SWITCH SENSE CIRCUIT SHORT TO B+ OR OPEN
BCM -- NO TRAC OFF MESSAGE
CLUSTER INTERNAL FAULT-- TRAC OFF INDICATOR INOPERATIVE
CLUSTER-PERMANENT TRAC OFF INDICATOR
TRAC OFF SWITCH INTERNAL SHORT
TRAC OFF SWITCH SENSE CIRCUIT SHORT TO GROUND
BCM -- PERMANENT TRAC OFF MESSAGE

1 Note: If any DTC’s are present, they must be repaired prior to performing All
this test.
Observe the TRAC OFF indicator.
Did the TRAC OFF indicator come on for several seconds then go out?
Yes → Go To 2
No. TRAC OFF Indicator does not come on.

Go To 5
No. TRAC OFF Indicator does not go out.

Go To 6
2 Disconnect the TRAC OFF Switch harness connector. All

Using a 12-volt test light connected to 12-volts, check the TRAC OFF Switch Ground
circuit.
Yes → Go To 3
No → Repair the TRAC OFF Switch Ground circuit for an open.

Disconnect the TRAC OFF Switch harness connector.
Connect and disconnect a jumper wire between TRAC OFF Switch Ground and
TRAC OFF Switch Sense circuits.
Does the TRAC OFF Indicator light and then go out?
Yes → Replace the TRAC OFF switch.
No → Go To 4
36
BRAKES (CAB)
*TRAC OFF INDICATOR NEVER/ALWAYS ON — Continued

Check the TRAC OFF Switch Sense circuit for short to B+ and for an open.
Is the Sense circuit shorted or open?
Yes → Repair the TRAC OFF Switch Sense circuit for a short to battery
or for an open.
Information.

NOTE: The purpose of this test is to perform the Instrument Cluster self
test.
Yes → Replace the Body Control Module in accordance with the Service
Information.
Information.
test.
Yes → Go To 7
Information.

Does the TRAC OFF Indicator light and then go out?
Yes → Replace the TRAC OFF switch.

No → Go To 8
37
BRAKES (CAB)
*TRAC OFF INDICATOR NEVER/ALWAYS ON — Continued

Check the TRAC OFF Switch Sense circuit for short to ground.
Is the Sense circuit shorted to ground?
Yes → Repair the TRAC OFF Switch Sense circuit for a short to ground.

Information.
38
BRAKES (CAB)
Symptom:
*TRAC ON INDICATOR NEVER/ALWAYS ON
POSSIBLE CAUSES
CAB -- INTERNAL FAULT
CHECK TRACTION CONTROL SYSTEM
CLUSTER FAILS SELF TEST
CAB - NO TRAC MESSAGE

1 NOTE: The DRBIIIt must be able to communicate with the CAB prior to All
performing this test.
NOTE: Note: If any CAB DTC’s are present, they must be repaired prior to
performing this test.
Perform the KEY-ON bulb test.
Did the TRAC Indicator illuminate and then go out?
Yes → Go To 2
No → Go To 3
2 Make sure the Traction Control system has not been deactivated with the TRAC OFF All
switch.
NOTE: The purpose of this test is to determine if the Traction Control
system is operating.
With the DRBIIIt in Inputs/Outputs, read the ABS Pump Motor voltage state.
Accelerate sufficient to cause drive wheel slip.
Does the TRAC Indicator illuminate and the DRBIIIt display approximately 9 volts?
Yes → The traction control system is functioning normally.

test.


Information.
39
VERIFICATION TESTS
Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the ignition off. All
2. Connect all previously disconnected components and connectors.
3. Ensure all accessories are turned off and the battery is fully charged.
4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from
ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system
that was malfunctioning.
6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new
or recurring symptom.
7. If there are no DTC’s present after turning ignition on, road test the vehicle for at least 5
minutes. Perform several antilock braking stops.
8. Caution: Ensure braking capability is available before road testing.
9. Again, with the DRBIIIt read DTC’s. If any DTC’s are present, return to Symptom list.
10. If there are no Diagnostic Trouble Codes (DTC’s) present, and the customer’s concern can
no longer be duplicated, the repair is complete.
Are any DTC’s present or is the original concern still present?

40
COMPONENT LOCATIONS
C
M
8.1 CONTROLLER ANTILOCK BRAKE (CAB) P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.2 DATA LINK CONNECTOR
41
COMPONENT LOCATIONS
C
O 8.3 FUSES
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.4 TRACTION CONTROL SWITCH
42
COMPONENT LOCATIONS
C
8.4.1 TRACTION CONTROL INDICATORS O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.5 WHEEL SPEED SENSORS

8.5.1 FRONT
43
COMPONENT LOCATIONS
C
O 8.5.2 REAR
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.5A WHEEL SPEED SENSOR CONNECTORS

8.5A.1 FRONT
44
COMPONENT LOCATIONS
C
8.5A.2 REAR O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.6 BRAKE LAMP SWITCH
45
NOTES
46
CONNECTOR PINOUTS
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
4 - -
6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
8 - -
9 A111 12DG/RD FUSED B(+)
10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT
11 - -
12 - -
13 - -
14 - -
15 - -
17 - -
18 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT C
19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY O
20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR SIGNAL N
21 - - N
22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY E
23 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR SIGNAL C
24 A107 12TN/RD FUSED B(+) T
O
DATA LINK CONNECTOR - WHITE 16 WAY R
1 - - P
2 D25 20WT/VT PCI BUS I
3 - - N
4 Z11 18BK/LG GROUND O
5 Z111 18BK/WT GROUND U
6 D20 20WT/LG SCI RECEIVE T
7 D21 20WT/BR SCI TRANSMIT S
8 - -
10 - -
11 - -
12 - -
13 - -
14 D16 20WT/OR SCI RECEIVE
15 - -
47
CONNECTOR PINOUTS
DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY
1 D25 20WT/VT PCI BUS (PCM/SKIM)
2 D25 20WT/VT PCI BUS (HVAC)
3 D25 20WT/VT PCI BUS (RADIO)
4 D25 20WT/VT PCI BUS (ORC)
5 D25 20WT/VT PCI BUS (CLUSTER)
6 D25 20WT/VT PCI BUS (BCM)
7 D25 20WT/VT PCI BUS (DLC)
8 D25 20WT/VT PCI BUS (OVERHEAD CONSOLE)
9 D25 20WT/VT PCI BUS (IPM)
10 D25 20WT/VT PCI BUS (LSIACM)
11 D25 20WT/VT PCI BUS (MEMORY SEAT/MIRROR)
12 D25 20WT/VT PCI BUS (PWR DOOR/ LT, RT LIFTGATE)
13 D25 20WT/VT PCI BUS (RSIACM)
14 - -
15 - -
16 - -
INTELLIGENT POWER MODULE C4 - GRAY 10 WAY

C 1 Z127 12BK/DG GROUND
N 3 K342 16BR/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
N 4 F500 18DG/PK (ANTILOCK FUSED IGNITION SWITCH RELAY OUTPUT (RUN)

BRAKES)
E
5 - -
C
6 D25 16WT/VT (ANTILOCK PCI BUS
T BRAKES)
O 7 A107 12TN/RD (ANTILOCK FUSED B(+)
R BRAKES)
8 A111 12DG/RD (ANTILOCK FUSED B(+)
BRAKES)
P
9 A701 14BR/RD FUSED B(+)
I
10 - -
N
O
U
T
S
LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY
1 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR SIGNAL
2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
48
CONNECTOR PINOUTS
LEFT FRONT WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY

1 RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
2 RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
C
LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
O
1 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR SIGNAL N
2 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY E
C
T
O
R
P
I
N
O
U
T
S
LEFT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY
1 LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL
2 LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
49
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
50
CONNECTOR PINOUTS
FUSES (IPM)
FUSE AMPS FUSED CIRCUIT FUNCTION
NO.
5 20A F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
6 20A F307 16LB/PK (BATTERY POSITION) FUSED B(+)
6 20A F307 16LB/PK (ACCESSORY RELAY POSITION) FUSED ACCESSORY RELAY OUTPUT
10 40A C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
11 20A F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
12 25A C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
13 40A C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
14 15A INTERNAL FUSED B(+) (I.O.D.)
C
19 40A A101 12VT/RD FUSED B(+)
O
N
21 25A A111 12DG/RD FUSED B(+)
N
E
23 10A A106 20LB/RD FUSED B(+)
C
24 20A A701 16BR/RD FUSED B(+) (HAZARD)
T
26 20A A103 18GY/RD FUSED B(+)
O
R
28 40A F30 12PK/YL FUSED ACCESSORY RELAY OUTPUT
30 40A SPARE SPARE
P
I
32 40A A115 12YL/RD FUSED B(+)
N
33 15A INTERNAL FUSED ACCESSORY RELAY OUTPUT
O
U
T
S
51
CONNECTOR PINOUTS
PUMP MOTOR CONNECTOR - 2 WAY

1 TN GROUND
2 RD PUMP/MOTOR RELAY OUTPUT
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY

1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
C
O
N
N
E
C
T
O
R
P
I RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY
N
1 WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
O
2 WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
U
T
S
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY

1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
52
CONNECTOR PINOUTS
RIGHT REAR WHEEL SPEED SENSOR CONNECTOR (SENSOR SIDE) - 2 WAY

1 YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
2 YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
TRACTION CONTROL SWITCH - BLACK 2 WAY

1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE C
2 Z427 20BK/WT GROUND O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
53
NOTES
54
SCHEMATIC DIAGRAMS
TEVES MARK 20 ANTILOCK BRAKE SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
55
NOTES
56
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2 FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2.1 ECM ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2.2 ECM OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.3 MONITORED CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.4 SKIS OVERIVEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.5 SKIS ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.6 SKIS OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.1 HARD CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.2 INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.3 ECM DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.4 SKIM DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . .6
3.3.5 HANDLING NO TROUBLE CODE PROBLEMS . . . . . . . . . . . . . . . . . . .6
3.4 USING THE DRBIIIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.4.1 DRBIIIT DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.4.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . .7
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2.4 DRBIIIT SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.3 WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3.1 ROAD TEST WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3.2 VEHICLE DAMAGE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
COMMUNICATION
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . . .10
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . .11
DRIVEABILITY - DIESEL
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY POSITIVE AREA . . . . . . . . . . . . . .13
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH . . . . . . . . . . . . . . .13
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW . . . . . . . . . . . . . . .13
i
P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW . . . . . .13
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH . . . . . . .20
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW. . . . . . . .20
P0606-ECM ERROR GATE ARRAY - COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . .20
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERIFIED. . . . . . . . . .20
P0606-ECM ERROR GATE ARRAY - QUANTITY STOP . . . . . . . . . . . . . . . . . . . . . . . .20
P0606-ECM ERROR RECOVERY HAS OCCURRED . . . . . . . . . . . . . . . . . . . . . . . . . .20
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING . . . . . . . . . . . . . . . . . .20
P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . .20
P1206-CALCULATED INJECTOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . .20
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . .20
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . .20
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE . . . . . . . . . . . .20
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY . . . . . . . . . . . . . . . . . . . . .20
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . .20
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . .20
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . .20
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING . . . . . . . .20
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . .20
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR . . . . . . . . . . . . . . . . .20
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR . . . . . . . . . . . . . . . . . . . . .20
P1680-EEPROM PLAUSIBILITY WRITE ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
P1696-EEPROM MEMORY WRITE DENIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH . . . . . .24
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW. . . . . . .27
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL
VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH . . . . .34
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW . . . . .38
P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE
TOO HIGH OR LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH . . . . . . . .41
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW . . . . . . . .44
P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE . . . . . . . . . . . . . . .46
P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP . . . . . . . . . . . . . . . . . . . . . . . .46
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE. . . . . . . . . . .46
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE . . . . . . . . . . .46
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH. . . . . . . . . . . . .64
ii
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW . . . . . . . . . . . . .67
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW . . . .70
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION . . . . . . . . .73
P0340-CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY . . . . . . . . . . . . .75
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAILURE . . . . . . . . . . .77
P0340-CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH . . . . .80
P0340-CMP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY. . . . . . . . . . . . . . .80
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
P0380-GLOW PLUG CIRCUIT A SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0480-FAN 1 CONTROL CIRCUIT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .92
P0480-FAN 1 CONTROL CIRCUIT SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .94
P0481-FAN 2 CONTROL CIRCUIT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .96
P0481-FAN 2 CONTROL CIRCUIT SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .98
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH . . . . . . . . . . . . . . . . . .100
P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION. . . . . . . . . . . . . . . . . . .100
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . .100
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH . . . . . . . . . . . . . .100
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH . . . . . . .104
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY . . . . . . . . . . . . . . . . . .107
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW .110
P0530-A/C PRESSURE SENSOR CIRCUIT PLAUSIBILITY . . . . . . . . . . . . . . . . . . . .112
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH . . . . . . .112
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW . . . . . . .112
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
P0560-SYSTEM VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
P0560-SYSTEM VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
*CHECKING THE CHARGING SYSTEM OPERATION - DIESEL . . . . . . . . . . . . . . . .120
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . .124
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE
DEVIATION TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
DEVIATION TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH . . .126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW. . . .126
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW . . . .126
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT . . . . . . . . . . . . . . . . .126
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT . . . . . . . . . . . . . . . .126
P0620-GENERATOR FIELD CONTROL MALF UNSTABLE CURRENT . . . . . . . . . . .126
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN CIRCUIT . . . . . . . . . .129
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORT CIRCUIT . . . . . . . . .131
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH . . . . . . . . . .133
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH. . . . . . . . . .133
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW . . . . . . . . . .136
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW . . . . . . . . . .136
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . .139
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . .142
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY . . . . . . . .145
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE . . . . . . . . . .147
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH
REDUNDANT CONTACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
iii
P0703-BRAKE SWITCH SIGNAL CKTS PLAUS W/REDUNDANT CONTACT
AFTER INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
P0833-CLUTCH PEDAL PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED . . . . . . . . . .155
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW . . . . . . . . .155
P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN . . . . . . . . . . . . .155
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . .158
P1131-FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER-RUN. . . . . . . . . . . .158
P1131-FUEL PRESSURE SOLENOID SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .158
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . .162
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . .164
P1605-IGNITION SWITCH PLAUSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED. . . . . . . . . . . . . . . . . . . . . . .168
P1685-SKIM SYSTEM INVALID SECRET KEY IN EEPROM. . . . . . . . . . . . . . . . . . . .168
P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT . . . . . . . . . . . . . . . . . . .168
P1685-SKIM SYSTEM SKIM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
P1685-SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE . . . . . . . . . . . . . . . .168
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY . . . . . . . . . . . . . . . .170
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH
POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH . . .170
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW . . .170
P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO
HIGH OR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
*CHECKING THE A/C CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION . . .181
*CHECKING THE BOOST PRESSURE SENSOR CALIBRATION. . . . . . . . . . . . . . . .182
*CHECKING THE ECM POWER AND GROUND CIRCUITS. . . . . . . . . . . . . . . . . . . .183
*CHECKING THE EGR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION . . . . . . . . . . . . . . . . . . .186
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION . .193
*CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . .194
*CHECKING THE GLOW PLUG OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
*CHECKING THE LIFT PUMP MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .197
*CHECKING THE MAF SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
*CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .201
*CHECKING THE VEHICLE SPEED SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
*ENGINE CRANKS BUT WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
*ENGINE WILL NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
ANTENNA FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
COP FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
EEPROM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
RAM FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
SERIAL LINK INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
STACK OVERFLOW FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
PCM STATUS FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
iv
SERIAL LINK EXTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
ROLLING CODE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
VIN MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
TRANSPONDER COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE . . . . . . . . . . . . .220
TRANSPONDER ID MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
TRANSPONDER RESPONSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
VERIFICATION TESTS
VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
8.1 CONTROL MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

8.2 CONTROLS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
8.3 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
8.4 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
8.5 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
8.6 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
8.7 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

A/C PRESSURE SENSOR - GRAY 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY. . . . . . . .231
BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY. . . . . . . . . . . . . . . .231
BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . .232
BRAKE LAMP SWITCH - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . .232
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY . . . . . . . . . . . . . . . . . . .232
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . .232
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY. . . . . . . . . . . . . . . . . .234
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY . . . . . . . . . . . . . . . . .236
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . . .237
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . .237
FUEL HEATER (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . .237
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . .238
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .238
GENERATOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY . . . . . . . . .239
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .239
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY. . . . . . . . . . . . . . . . . . . . . .240
v
A/C COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
ECM/PCM RELAY (DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
FUEL HEATER RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
LIFT PUMP RELAY (DIESEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
STARTER MOTOR RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY . . . . . . . . . . . . . . . . . . . . . .243
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .244
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .244
VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . .244
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .244
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
10.1 2001 RG 2.5L TURBO DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
11.0 CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
vi
GENERAL INFORMATION
1.0 INTRODUCTION 2.0 IDENTIFICATION OF
SYSTEM
The procedures contained in this manual include
all the specifications, instructions and graphics The ECM is located in the left side of the engine
needed to diagnose engine control module (ECM) compartment between the left front headlamp and
and sentry key immobilizer system (SKIS) prob- the intelligent power module. The sentry key immo-
lems; they are no start, diagnostic trouble code bilizer module (SKIM) is located below the steering
(DTC), and no trouble code problems for the ECM. column behind the steering wheel.
The diagnostics in this manual are based on the
trouble condition or symptom being present at the
time of diagnosis. 3.0 SYSTEM DESCRIPTION AND
When repairs are required, refer to the appropri- FUNCTIONAL OPERATION
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New 3.1 GENERAL DESCRIPTION
diagnostic systems may be added; carryover sys-
tems may be enhanced. IT IS RECOMMENDED The 2.5L VM diesel engine system is equipped
THAT YOU REVIEW THE ENTIRE MANUAL TO with the latest in technical advances. The on-board
BECOME FAMILIAR WITH ALL NEW AND diagnostics incorporated in the engine control mod-
CHANGED DIAGNOSTIC PROCEDURES. ule and SKIM are intended to assist the field
This manual is designed to begin all diagnosis at technician in repairing vehicle problems by the
the DTC TEST, which is located at the beginning of quickest means.
Section 7.0. This will cover all the necessary re- The engine system incorporates a common rail
quirements to begin a logical diagnostic path for fuel delivery design. This design utilizes electroni-
each problem. If there is a diagnostic trouble code cally controlled solenoid valve type fuel injectors.
(DTC) detected, it will direct you to the trouble code Each injector is controlled individually by the ECM.
test. If there are no DTCs present, it will direct you Injector timing and fuel quantity are controlled by
by symptom to a no trouble code test. the ECM based on inputs from the various sensors.
This book reflects many suggested changes from The precision control of the injectors by the ECM
readers of past issues. After using this book, if you helps to reduce the engine noise, odor and smoke.
have any comments or recommendations, please fill
out the form at the back of the book and mail it back 3.2 FUNCTIONAL OPERATION
to us.
1.1 SYSTEM COVERAGE 3.2.1 ECM ON-BOARD DIAGNOSTICS

The ECM has been programmed to monitor many
This diagnostic procedures manual covers all different circuits of the diesel fuel injection system.
2001 RG body vehicles equipped with the 2.5L VM This monitoring is called on-board diagnostics.
diesel engine. Certain criteria must be met for a trouble code to
be entered into the ECM memory. The criteria may
1.2 SIX-STEP TROUBLESHOOTING be a range of: engine rpm, engine temperature, time
PROCEDURE or other input signals to the ECM. If all of the
criteria for monitoring a system or circuit are met,
Diagnosis of the engine control module (ECM) and a problem is sensed, then a DTC will be stored
and sentry key immobilizer system (SKIS) is done in the ECM memory.
in six basic steps: It is possible that a DTC for a monitored circuit
• verification of complaint may not be entered into the ECM memory, even
• verification of any related symptom though a malfunction has occurred. This may hap-
pen when the monitoring criteria has not been met.
• symptom analysis
The ECM compares input signal voltages from
• problem isolation each input device with specifications (the estab-
• repair of isolated problem lished high and low limits of the input range) that
• verification of proper operation are programmed into it for that device. If the input
NOTE: All tests in this manual should be per- voltage is not within the specifications and other
formed with the engine at operating temperature, trouble code criteria are met, a DTC will be stored
unless specified within a particular test. in the ECM memory.
1
GENERAL INFORMATION
3.2.2 ECM OPERATING MODES with expected values. Other systems are monitored
indirectly when the ECM conducts a rationality test
As input signals to the ECM change, the ECM
to identify problems.
adjusts its response to the output devices. For
Although most subsystems of the engine control
example, the ECM must calculate a different fuel
module are either directly or indirectly monitored,
quantity and fuel timing for engine idle condition
there may be occasions when diagnostic trouble
than it would for a wide open throttle condition.
codes are not immediately identified. For a trouble
There are several different modes of operation that
code to set, a specific set of conditions must occur
determine how the ECM responds to the various
and unless these conditions occur, a DTC will not
input signals.
set.
Ignition Switch On (Engine Off)
When the ignition switch is turned on, the ECM
3.2.4 SKIS OVERIVEW
activates the glow plug relay for a time period that The sentry key immobilizer system (SKIS) is
is determined by engine coolant temperature, atmo- designed to prevent unauthorized vehicle opera-
spheric temperature and battery voltage. The ECM tion. The system consists of a sentry key immobi-
also activates the lift pump to prime the fuel sys- lizer module (SKIM), ignition key(s) equipped with
tem. a transponder chip and the ECM. When the ignition
switch is turned on, the SKIM interrogates the
Engine Start-up Mode ignition key. If the ignition key is Valid or Invalid,
The ECM uses the engine temperature sensor the SKIM sends a PCI Bus message to the ECM
and the crankshaft position sensor (engine speed) indicating ignition key status. Upon receiving this
inputs to determine fuel injection quantity. message the ECM will terminate engine operation
or allow the engine to continue to operate.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration 3.2.5 SKIS ON-BOARD DIAGNOSTICS
and wide open throttle modes are controlled based The sentry key immobilizer module (SKIM) has
on all of the sensor inputs to the ECM. The ECM been programmed to transmit and monitor many
uses these sensor inputs to adjust fuel quantity and different coded messages as well as PCI Bus mes-
fuel injector timing. sages. This monitoring is called On-Board Diagnos-
tics. Certain criteria must be met for a DTC to be
Overheat Protection Mode entered into SKIM memory. The criteria may be a
If engine temperature is above 106° C (223° F) range of; input voltage, PCI Bus message or coded
and vehicle speed is above 40 km/h (25 MPH) the messages to the SKIM. If all of the criteria for
ECM will activate the high speed fan and will limit monitoring a circuit or function are met and a fault
fuel quantity for engine protection. is detected, a DTC will be stored in the SKIM
memory.
Limp-In Mode
If there is a fault detected with the accelerator 3.2.6 SKIS OPERATION
pedal position sensor, the ECM will set the engine
When ignition power is supplied to the SKIM, the
speed at 1100 RPM.
SKIM performs an internal self-test. After the self-
test is complete, the SKIM energizes the antenna
Overspeed Detection Mode
(this activates the transponder chip) and sends a
If the ECM detects engine RPM that exceeds
challenge to the transponder chip. The transponder
5000 RPM, the ECM will set a DTC in memory and
chip responds to the challenge by generating an
limit engine RPM to no more that 2500 RPM until
encrypted response message using the following:
the DTC(s) is cleared.
Secret Key - This is an electronically stored value
(identification number) that is unique to each SKIS.
After-Run Mode
The secret key is stored in the SKIM, ECM and all
The ECM transfers RAM information to ROM
ignition key transponders.
and performs an Input/Output state check.
Challenge - This is a random number that is gen-
erated by the SKIM at each ignition key cycle.
3.2.3 MONITORED CIRCUITS The secret key and challenge are the two vari-
The ECM is able to monitor and identify most ables used in the algorithm that produces the
driveability related trouble conditions. Some cir- encrypted response message. The transponder uses
cuits are directly monitored through ECM feedback the crypto algorithm to receive, decode and respond
circuitry. In addition, the ECM monitors the voltage to the message sent by SKIM. After responding to
state of some circuits and compares those states the coded message, the transponder sends a tran-
2
GENERAL INFORMATION
sponder ID message to the SKIM. The SKIM com- determining the cause of the DTC as well as no
pares the transponder ID message to the available trouble code problems. It is not necessary to per-
valid key codes in SKIM memory (8 key maximum form all of the tests in this book to diagnose an
at any one time). After validating the ignition key, individual code.
the SKIM sends a PCI Bus message called a seed Always begin diagnosis by reading the DTC’s
request to the ECM, then waits for the ECM re- using the DRBIIIt.
sponse. If the ECM does not respond, the SKIM will
send the seed request again. After three failed 3.3.1 HARD CODE
attempts, the SKIM will stop sending the seed A DTC that comes back within one cycle of the
request and store a trouble code in memory. If the ignition key is a hard code. This means that the
ECM sends a seed response, the SKIM sends a problem is current every time the ECM/SKIM
valid/invalid key message to the ECM. This is an checks that circuit or function. Procedures in this
encrypted message that is generated using the manual verify if the DTC is a hard code at the
following: beginning of each test. When the fault is not a hard
VIN - Vehicle Identification Number. code, an intermittent test must be performed.
Seed - This is a random number that is generated NOTE: If the DRBIIIt displays faults for multiple
by the ECM at each ignition key cycle. components (i.e. ECT, VSS, Oil Temp sensors) iden-
The VIN and seed are two variables used in the tify and check the shared circuits for possible prob-
rolling code algorithm that encrypts the valid/ lems before continuing (i.e. sensor grounds or 5-volt
invalid key message. The ECM uses the rolling code supply circuits). Refer to the appropriate schematic
algorithm to receive, decode and respond to the to identify shared circuits.
valid/invalid key message sent by the SKIM. After
sending the valid/invalid key message, the SKIM 3.3.2 INTERMITTENT CODE
waits 3.5 seconds for an ECM status message from
the ECM. If the ECM does not respond with a valid A DTC that is not current every time the ECM/
key message to the SKIM, a fault is detected and a SKIM checks the circuit or function is an intermit-
code is stored. tent code. Most intermittent DTCs are caused by
The SKIS incorporates a warning lamp located in wiring or connector problems. Problems that come
the information center. The lamp receives switched and go like this are the most difficult to diagnose;
ignition voltage and is hardwired to the body con- they must be looked for under specific conditions
trol module. The lamp is actuated when the SKIM that cause them. The following checks may assist
sends a PCI Bus message to the body control you in identifying a possible intermittent problem.
module requesting the lamp on. The body control • Visually inspect the related wire harness connec-
module then provides the ground for the lamp. tors. Look for broken, bent, pushed out, or cor-
The SKIM will request lamp operation for the roded terminals.
following: • Visually inspect the related wire harness. Look
– bulb check at ignition on for chafed, pierced, or partially broken wire.
– to alert the vehicle operator to a SKIS malfunc- • Refer to hotlines or technical service bulletins
tion that may apply.
– when the SKIM is in customer key programming NOTE: Electromagnetic (radio) interference can
mode cause an intermittent system malfunction. This
For all faults except transponder faults the lamp interference can interrupt communication between
remains on steady. In the event of a transponder the ignition key transponder and the SKIM.
fault the lamp will flash at a rate of 1Hz (once per
second). If a fault is present, the lamp will remain
3.3.3 ECM DIAGNOSTIC TROUBLE CODES
on or flashing for the complete ignition cycle. If a
fault is stored in SKIM memory which prevents the IMPORTANT NOTE: Before replacing the ECM
system from operating properly, the ECM will allow for a failed driver, control circuit or ground circuit,
the engine to start and idle for 2 seconds then stall. be sure to check the related component/circuit in-
This may occur up to six times. After the sixth tegrity for failures not detected due to a double fault
attempt, the ECM disables the starter relay until in the circuit. Most ECM driver/control circuit fail-
the fault is corrected. ures are caused by internal failures to components
(i.e. relays and solenoids) and shorted circuits (i.e.
3.3 DIAGNOSTIC TROUBLE CODES sensor pull-ups, drivers and ground circuits). These
faults are difficult to detect when a double fault has
Each diagnostic trouble code (DTC) is diagnosed occurred and only one DTC has set.
by following a specific procedure. The diagnostic If the DRB displays faults for multiple compo-
test procedure contains step-by-step instruction for nents (i.e. VSS, ECT, Batt Temp, etc.), identify and
3
GENERAL INFORMATION
check the shared circuits for possible problems CYLINDER 3-INJECTOR CIRCUIT CURRENT
before continuing (i.e. Sensor Grounds or 5-Volt DECREASE
Supply circuits). Refer to the appropriate wiring CYLINDER 4-INJECTOR CIRCUIT OVERCUR-
diagrams to identify shared circuits. RENT HIGH SIDE
MASS AIR FLOW SENSOR SIGNAL VOLTAGE CYLINDER 4-INJECTOR CIRCUIT OVERCUR-
TOO HIGH RENT LOW SIDE
MASS AIR FLOW SENSOR SIGNAL VOLTAGE CYLINDER 4-INJECTOR CIRCUIT LOAD
TOO LOW DROP
MASS AIR FLOW SENSOR SUPPLY VOLTAGE CYLINDER 4-INJECTOR CIRCUIT CURRENT
TOO HIGH OR LOW DECREASE
MASS AIR FLOW SENSOR PLAUSIBILITY BOOST PRESSURE SENSOR SIGNAL VOLT-
MASS AIR FLOW SENSOR SIGNAL PLAUSI- AGE TOO HIGH
BILITY POSITIVE AREA BOOST PRESSURE SENSOR SIGNAL VOLT-
BAROMETRIC PRESSURE CIRCUIT SIGNAL AGE TOO LOW
VOLTAGE TOO HIGH BOOST PRESSURE SENSOR SUPPLY VOLT-
BAROMETRIC PRESSURE CIRCUIT SIGNAL AGE TOO HIGH OR LOW
VOLTAGE TOO LOW BOOST PRESSURE SENSOR PLAUSIBILITY
INTAKE AIR TEMP SENSOR SIGNAL VOLT- CKP POSITION SENSOR CIRCUIT OVER-
AGE TOO HIGH SPEED RECOGNITION
INTAKE AIR TEMP SENSOR SIGNAL VOLT- CKP POSITION SENSOR CIRCUIT DYNAMIC
AGE TOO LOW PLAUSIBILITY
ENGINE COOLANT TEMP SENSOR SIGNAL CKP POSITION SENSOR CIRCUIT STATIC
VOLTAGE TOO HIGH PLAUSIBILITY
ENGINE COOLANT TEMP SENSOR SIGNAL CMP POSITION SENSOR CIRCUIT CMP/CKP
VOLTAGE TOO LOW SYNC FAILURE
FUEL PRESS SENSOR CIRCUIT MALF SIG- CMP POSITION SENSOR CIRCUIT DYNAMIC
NAL VOLTAGE TOO HIGH PLAUSIBILITY
FUEL PRESS SENSOR CIRCUIT MALF SIG- CMP POSITION SENSOR CIRCUIT STATIC
NAL VOLTAGE TOO LOW PLAUSIBILITY
FUEL PRESS SENSOR CIRCUIT MALF SUP- CMP POSITION SENSOR CIRCUIT SIGNAL
PLY VOLTAGE TOO HIGH OR LOW FREQUENCY TOO HIGH
OIL TEMP SENSOR CIRCUIT MALF SIGNAL CMP POSITION SENSOR CIRCUIT FUEL
VOLTAGE TOO HIGH SHUT-OFF ACTIVATED
OIL TEMP SENSOR CIRCUIT MALF SIGNAL GLOW PLUG CIRCUIT A SHORT CIRCUIT
VOLTAGE TOO LOW GLOW PLUG CIRCUIT A OPEN CIRCUIT
CYLINDER 1-INJECTOR CIRCUIT OVERCUR- EGR SOLENOID CIRCUIT OPEN CIRCUIT
RENT HIGH SIDE EGR SOLENOID CIRCUIT SHORT CIRCUIT
CYLINDER 1-INJECTOR CIRCUIT OVERCUR- EGR SOLENOID CIRCUIT IMPROPER FLOW
RENT LOW SIDE FAN 1 CONTROL CIRCUIT OPEN CIRCUIT
CYLINDER 1-INJECTOR CIRCUIT LOAD FAN 1 CONTROL CIRCUIT SHORT CIRCUIT
DROP FAN 2 CONTROL CIRCUIT OPEN CIRCUIT
CYLINDER 1-INJECTOR CIRCUIT CURRENT FAN 2 CONTROL CIRCUIT SHORT CIRCUIT
DECREASE VEHICLE SPEED SENSOR SIGNAL VOLTAGE
CYLINDER 2-INJECTOR CIRCUIT OVERCUR- TOO HIGH
RENT HIGH SIDE VEHICLE SPEED SENSOR FREQUENCY TOO
CYLINDER 2-INJECTOR CIRCUIT OVERCUR- HIGH
RENT LOW SIDE VEHICLE SPEED SENSOR HIGH LEVEL DU-
CYLINDER 2-INJECTOR CIRCUIT LOAD RATION
DROP VEHICLE SPEED SENSOR PLAUSIBILITY
CYLINDER 2-INJECTOR CIRCUIT CURRENT BATTERY TEMP SENSOR SIGNAL VOLTAGE
DECREASE TOO HIGH
CYLINDER 3-INJECTOR CIRCUIT OVERCUR- BATTERY TEMP SENSOR SIGNAL VOLTAGE
RENT HIGH SIDE TOO LOW
CYLINDER 3-INJECTOR CIRCUIT OVERCUR- OIL PRESS SENSOR CKT MALF PLAUSIBIL-
RENT LOW SIDE ITY
CYLINDER 3-INJECTOR CIRCUIT LOAD
DROP
4
GENERAL INFORMATION
A/C PRESSURE SENSOR CIRCUIT SIGNAL BRAKE SWITCH SIGNAL CIRCUITS PLAUSI-
VOLTAGE TOO HIGH BILITY WITH REDUNDANT CONTACT
A/C PRESSURE SENSOR CIRCUIT SIGNAL BRAKE SWITCH SIGNAL CIRCUITS PLAUSI-
VOLTAGE TOO LOW BILITY WITH REDUNDANT CONTACT AFTER
A/C PRESSURE SENSOR CIRCUIT SUPPLY INITIALIZATION
VOLTAGE TOO HIGH OR LOW CLUTCH UPSTOP SWITCH PERF PLAUSIBIL-
A/C PRESSURE SENSOR CIRCUIT PLAUSI- ITY
BILITY CLUTCH UPSTOP SWITCH PERF PLAUSIBIL-
SYSTEM VOLTAGE TOO HIGH ITY WITH P/N SWITCH
SYSTEM VOLTAGE TOO LOW FUEL RAIL PRESSURE MALFUNCTION
S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLT- PRESSURE TOO HIGH - LIMITATION
AGE TOO HIGH FUEL RAIL PRESSURE MALFUNCTION
S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLT- PRESSURE TOO LOW
AGE TOO LOW FUEL RAIL PRESSURE MALFUNCTION SO-
S/C SWITCH SIGNAL CIRCUIT PLAUSIBILITY LENOID OPEN
ECM ERROR RECOVERY HAS OCCURRED FUEL RAIL PRESSURE MALFUNCTION
ECM ERROR REDUNDANT OVERRUN MONI- LEAKAGE DETECTED
TORING FUEL PRESSURE SOLENOID OPEN CIRCUIT
ECM ERROR GATE ARRAY - QUANTITY STOP FUEL PRESSURE SOLENOID SHORT CIR-
ECM ERROR GATE ARRAY - COMMUNICA- CUIT
TION FUEL PRESSURE SOLENOID PLAUSIBILITY
ECM ERROR - COMMUNICATION NOT VERI- IN AFTER-RUN
FIED CALCULATED INJECTOR VOLTAGE - VOLT-
STARTER RELAY CIRCUIT OPEN CIRCUIT AGE 1 TOO LOW
STARTER RELAY CIRCUIT SHORT CIRCUIT CALCULATED INJECTOR VOLTAGE - VOLT-
GENERATOR FIELD CONTROL MALF BAT- AGE 2 TOO LOW
TERY VOLTAGE TOO HIGH BATTERY SENSE LINE 1 VOLTAGE TOO
GENERATOR FIELD CONTROL MALF BAT- HIGH
TERY VOLTAGE TOO LOW BATTERY SENSE LINE 1 VOLTAGE TOO LOW
GENERATOR FIELD CONTROL MALF OPEN FUEL PRESS REG CURRENT CONTROL SIG-
CIRCUIT NAL TOO HIGH
GENERATOR FIELD CONTROL MALF SHORT FUEL PRESS REG CURRENT CONTROL SIG-
CIRCUIT NAL TOO LOW
GENERATOR FIELD CONTROL MALF GENERATOR FIELD CURRENT TOO HIGH
CHARGING VOLTS TOO LOW GENERATOR FIELD CURRENT TOO LOW
GENERATOR FIELD CONTROL MALF BAT- CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH
TERY VOLTAGE DEVIATION TOO HIGH CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW
GENERATOR FIELD CONTROL MALF BAT- CAPACITOR VOLTAGE 2 VOLTAGE TOO HIGH
TERY VOLTAGE DEVIATION TOO LOW CAPACITOR VOLTAGE 2 VOLTAGE TOO LOW
GENERATOR FIELD CONTROL MALF UN- IGNITION SWITCH PLAUSIBILITY
STABLE CURRENT AFTER RUN SHUT OFF ERROR - ZERO
SENSOR REFERENCE VOLTAGE A CKT VOLT- QUANTITY
AGE TOO HIGH AFTERRUN SHUT OFF ERROR - INJ. POWER-
SENSOR REFERENCE VOLTAGE A CKT VOLT- STAGE
AGE TOO LOW VOLTAGE REGULATOR SIGNAL VOLTAGE
SENSOR REFERENCE VOLTAGE B CKT TOO HIGH
VOLTAGE TOO HIGH VOLTAGE REGULATOR SIGNAL VOLTAGE
SENSOR REFERENCE VOLTAGE B CKT TOO LOW
VOLTAGE TOO LOW MIL/DIAG LAMP VIA J1850 BUS IN FRAME
A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT RESPONSE ERROR
A/C CLUTCH RELAY CIRCUIT SHORT CIR- MIL/DIAG LAMP VIA J1850 BUS - STATUS
CUIT ERROR
ECM/PCM RELAY CONTROL CIRCUIT SHUTS J1850 COMMUNICATION BUS SHORT TO
OFF TOO EARLY VOLTAGE
ECM/PCM RELAY CONTROL CIRCUIT SHUTS J1850 COMMUNICATION BUS SHORT TO
OFF TOO LATE GROUND
BRAKE SWITCH SIGNAL CIRCUITS INCOR- J1850 COMMUNICATION BUS TRANSMIT
RECT CAN MESSAGE BUFFER OVERRUN
5
GENERAL INFORMATION
J1850 COMMUNICATION BUS SPI ERROR TRANSPONDER RESPONSE MISMATCH
J1850 COMMUNICATION BUS RECEIVE TIME- VIN MISMATCH
OUT
J1850 COMMUNICATION BUS UNAUTHO- 3.3.5 HANDLING NO TROUBLE CODE
RIZED RESET
EEPROM PLAUSIBILITY CHECKSUM ERROR
PROBLEMS
EEPROM PLAUSIBILITY VIN CHECKSUM After reading Section 3.0 (System Description
ERROR and Functional Operation), you should have a bet-
EEPROM PLAUSIBILITY COMMUNICATION ter understanding of the theory and operation of the
ERROR on-board diagnostics, and how this relates to the
EEPROM PLAUSIBILITY WRITE ERROR diagnosis of a vehicle that may have a driveability-
EEPROM PLAUSIBILITY VARIATION NUM- related symptom or complaint.
BER ERROR
EEPROM PLAUSIBILITY CODE WORD IN- 3.4 USING THE DRBIIIT
CORRECT OR MISSING
SKIM SYSTEM SKIM ERROR Refer to the DRBIIIt user’s guide for instructions
SKIM SYSTEM WRITE ACCESS TO EEPROM and assistance with reading the DTCs, erasing the
FAILURE DTCs, lab scope usage and other DRBIIIt func-
SKIM SYSTEM INVALID SECRET KEY IN EE- tions.
PROM
SKIM SYSTEM KEY COMMUNICATION 3.4.1 DRBIIIT DOES NOT POWER UP
TIMED OUT If the LEDs do not light or no sound is emitted at
SKIM SYSTEM INVALID KEY CODE RE- start up, check for loose cable connections or a bad
CEIVED cable. Check the vehicle battery voltage at data link
EEPROM RECOVERY OCCURRED connector cavity 16. A minimum of 11.0 volts is
EEPROM REDUNDANT OVERRUN MONI- required to adequately power the DRB. Check for
TORING proper ground connection at data link connector
EEPROM QUANTITY STOP cavities 4 and 5.
EEPROM COMMUNICATION ERROR If all connections are proper between the
EEPROM COMMUNICATION NOT VERIFIED DRBIIIt and the vehicle or other devices, and the
ACC PEDAL POSITION SENSOR 1 CKT SIG- vehicle battery is fully charged, an inoperative
NAL VOLTAGE TOO HIGH DRBIIIt may be the result of a faulty cable or
ACC PEDAL POSITION SENSOR 1 CKT SIG- vehicle wiring. For a blank screen, refer to the
NAL VOLTAGE TOO LOW appropriate diagnostic manual.
ACC PEDAL POSITION SENSOR 1 CKT SUP-
PLY VOLTAGE TOO HIGH OR LOW 3.4.2 DISPLAY IS NOT VISIBLE
ACC PEDAL POSITION SENSOR 1 CKT PLAU- Low temperatures will affect the visibility of the
SIBILITY WITH POTENTIOMETER display. Adjust the contrast to compensate for this
ACC PEDAL POSITION SENSOR 1 CKT PLAU- condition.
SIBILITY WITH BRAKE SWITCH
ACC PEDAL POSITION SENSOR 1 CKT PLAU-
SIBILITY
3.3.4 SKIM DIAGNOSTIC TROUBLE CODES

ANTENNA FAILURE
COP FAILURE
EEPROM FAILURE
PCM STATUS FAILURE
INTERNAL FAULT
RAM FAILURE
ROLLING CODE FAILURE
SERIAL LINK EXTERNAL FAULT
SERIAL LINK INTERNAL FAULT
STACK OVERFLOW FAILURE
TRANSPONDER COMMUNICATION FAILURE
TRANSPONDER CRC (CYCLIC REDUN-
DANCY CHECK) FAILURE
TRANSPONDER ID MISMATCH
6
GENERAL INFORMATION
4.0 DISCLAIMERS, SAFETY, 4.2.4 DRBIIIT SAFETY INFORMATION
WARNINGS
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIT MULTIMETER IS DANGEROUS. IT
4.1 DISCLAIMERS CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
All information, illustrations, and specifications READ AND UNDERSTAND THE CAUTIONS
contained in this manual are based on the latest
AND SPECIFICATION LIMITS.
information available at the time of publication.
Follow the vehicle manufacturer’s service specifi-
The right is reserved to make changes at any time
cations at all times.
without notice.
• Do not use the DRBIIIt if it has been damaged.
4.2 SAFETY • Do not use the test leads if the insulation is
• To avoid electrical shock, do not touch the test
4.2.1 TECHNICIAN SAFETY INFORMATION leads, tip or the circuit being tested.
• Choose the proper range and function for the
WARNING: ENGINES PRODUCE CARBON measurement. Do not try voltage or current mea-
MONOXIDE THAT IS ODORLESS, CAUSES surements that may exceed the rated capacity.
SLOWER REACTION TIME, AND CAN LEAD
• Do not exceed the limits shown in the table below:
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL FUNCTION INPUT LIMIT
VENTILATED OR ATTACH THE VEHICLE Volts 0-500 peak volts AC
EXHAUST SYSTEM TO THE SHOP EXHAUST 0-500 volts DC
REMOVAL SYSTEM. Ohms (Resistance)* 0-1.12 megohms
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially Frequency Measure 0-10 kHz
important to block the wheels on front wheel drive Frequency Generated
vehicles; the parking brake does not hold the drive Temperature -58 - +1100°F
wheels. -50 - +600°C
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as * Ohms cannot be measured if voltage is present.
watchbands or bracelets that might make electrical Ohms can be measured only in a non-powered
contact. circuit.
When diagnosing a powertrain system problem, • Voltage between any terminal and ground must
it is important to follow approved procedures where not exceed 500v DC or 500v peak AC.
applicable. These procedures can be found in the • Use caution when measuring voltage above 25v
service manual. Following these procedures is very DC or 25v AC.
important to the safety of individuals performing
• The circuit being tested must be protected by a 10
diagnostic tests.
amp fuse or circuit breaker.
4.2.2 VEHICLE PREPARATION FOR • Use the low current shunt to measure circuits up
to 10 amps. Use the high current shunt to mea-
TESTING sure circuits exceeding 10 amps.
Make sure the vehicle being tested has a fully • When testing for the presence of voltage or cur-
charged battery. If it does not, false diagnostic codes rent, make sure the meter is functioning cor-
or error messages may occur. rectly. Take a reading of a known voltage or
4.2.3 SERVICING SUB-ASSEMBLIES • When measuring current, connect the meter in
Some components of the powertrain system are series with the load.
intended to be serviced as an assembly only. At- • Disconnect the live test lead before disconnecting
tempting to remove or repair certain system sub- the common test lead.
components may result in personal injury and/or
improper system operation. Only those components
7
GENERAL INFORMATION
4.3 WARNINGS AND CAUTIONS CKP crankshaft position (sensor)
CMP camshaft position (sensor)
4.3.1 ROAD TEST WARNINGS cuts out, a steady pulsation or the inability of
misses the engine to maintain a consistent
Some complaints will require a test drive as part
rpm
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic DLC data link connector
code or symptom condition. detona- a mild to severe ping, especially un-
tion, der loaded engine conditions
CAUTION: BEFORE ROAD TESTING A spark
VEHICLE, BE SURE THAT ALL knock
COMPONENTS ARE REASSEMBLED. DUR-
ECM engine control module
ING THE TEST DRIVE, DO NOT HANG THE
DRBIIIT FROM THE REAR VIEW MIRROR. DO ECT engine coolant temperature (sensor)
NOT ATTEMPT TO READ THE DRBIIIT WHILE EGR exhaust gas recirculation
DRIVING. HAVE AN ASSISTANT AVAILABLE (solenoid/valve)
TO OPERATE THE DRBIIIT. hard the engine takes longer than usual
start to start, even though it is able to
4.3.2 VEHICLE DAMAGE CAUTIONS crank at normal speed.
Before disconnecting any control module, make IAT intake air temperature (sensor)
sure the ignition is off. Failure to do so could IPM intelligent power module
damage the module. When testing voltage or circuit
integrity at any control module, use the terminal lack of the engine power output has been
side (not the wire end) of the harness connector. Do power, reduced
not probe through the insulation; this will damage sluggish
it and eventually cause it to fail because of corro- MAF mass air flow (sensor)
sion. MIL malfunction indicator lamp
Be careful when performing electrical test so as to
prevent accidental shorting of terminals. Such a ms millisecond(s)
mistake can damage fuses or components. Also, a PDC power distribution center
second code could be set, making diagnosis of the poor fuel there is significantly less fuel mile-
original problem more difficult. economy age than other vehicles of the same
design and configuration
5.0 REQUIRED TOOLS AND runs the engine runs unevenly at idle
EQUIPMENT rough/ causing the engine to shake if it is
unstable severe enough
DRBIIIt (diagnostic read-out box) scan tool idle
vacuum gauge S/C speed control
ammeter
SKIM sentry key immobilizer module
ohmmeter
jumper wires and probes SKIS sentry key immobilizer system
oscilloscope start and The engine starts but immediately
stall dies (stalls)
6.0 GLOSSARY OF TERMS surge engine rpm fluctuation without cor-
responding change in accelerator
A/C air conditioning pedal position
APP accelerator pedal position (sensor) SRC signal range check
backfire, fuel ignites in either the intake or WIF water in fuel (sensor)
popback the exhaust system VSS vehicle speed sensor
BCM body control module
BP boost pressure (sensor)
8
7.0
PROCEDURES
9
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
ECM PCI NO RESPONSE

the question.
Yes → Go To 2
2 With the DRB read ECM Diagnostic Trouble Codes. This is to ensure power and All
grounds to the ECM are operational.
NOTE: If the DRB will not read ECM DTC’s, follow the NO RESPONSE TO
ECM (SCI only) symptom path, if vehicle will start. For NO START Condi-
tions follow the no start symptom in the Starting category.
black test probes.
Select lab scope.
Select Live Data.
Press F2 for Scope.
when complete.
Connect the Black lead to ground. Connect the Red lead to the PCI Bus circuit in the
ECM connector.


10
COMMUNICATION
Symptom:
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY
POSSIBLE CAUSES
CHECK ECM POWERS AND GROUNDS
CABIN HEATER ASSIST

1 Perform the symptom Checking ECM Power and Ground Circuits in the Driveability All
category.
Yes → Go To 2

Yes → Go To 3
No → Go To 4


No → Replace the Cabin Heater Assist in accordance with the service

information.


No → Go To 5
11
COMMUNICATION
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY — Continued

Measure the resistance of the SCI Transmit circuit between the ECM connector and
the DLC.
Yes → Go To 6

Repair
12
Symptom List:
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY POSITIVE AREA
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW
P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR
LOW
The title for the tests will be P0100-MASS AIR FLOW SENSOR
PLAUSIBILITY.
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY

Set Condition: The mass airflow measure does not correspond with the enigne load
measurements.
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH

Set Condition: The Boost Pressure Sensor Signal voltage is above 4.5 volts.
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW

Set Condition: The Mass Air Flow Sensor Signal voltage is below 0.2 volt.
P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW

Set Condition: The Sensor Reference Voltage 9A9 voltage to the MAF is below 4.8 volts or
above 5.2 volts for at least 100 ms.
POSSIBLE CAUSES
ECM - 5-VOLT SUPPLY CIRCUIT
ECM/PCM RELAY OUTPUT CIRCUIT OPEN
MAF SENSOR IDLE VOLTAGE
MAF SENSOR SIGNAL - FULL THROTTLE VOLTAGE
SENSOR GROUND OPEN
5-VOLT SUPPLY CIRCUIT OPEN
13
P0100-MASS AIR FLOW SENSOR PLAUSIBILITY — Continued
POSSIBLE CAUSES
MAF SENSOR SIGNAL CIRCUIT OPEN
5-VOLT SUPPLY CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
MAF SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
ECM SENSOR GROUND CIRCUIT OPEN
MAF SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
MAF SENSOR CIRCUIT SHORTED TO VOLTAGE
ECM - MAF SENSOR SIGNAL CIRCUIT

1 NOTE: If DTC P0641 or P0651 is present with this DTC, diagnose DTCs All
P0641 and P0651 before diagnosing this DTC.
NOTE: Inspect the turbocharger inlet tube between the MAF Sensor and the
turbocharger for damage, restriction or poor connection. Any of these
conditions can cause a MAF Plausibility DTC.
With the DRBIIIt, erase the ECM DTCs.
Test drive the vehicle.
With the DRBIIIt, read the ECM DTCs.
Does the DRB III display a Mass Air Flow Sensor DTC?
Yes → Go To 2
No → Go To 20

Disconnect the MAF Sensor harness connector.
Measure the voltage of the 5-volt Supply circuit in MAF Sensor harness connector.
Yes → Go To 3
No → Go To 13
14

Remove the ECM/PCM Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ECM/PCM Relay
connector.
Measure the voltage of the MAF Sensor Signal circuit.
Yes → Repair the MAF Sensor Signal circuit for a short to voltage.
No → Go To 4

Measure the resistance of the MAF Sensor Signal circuit.
Yes → Go To 5
No → Repair the MAF Sensor Signal circuit for an open

Measure the resistance between ground and the MAF Sensor Signal circuit.
Yes → Repair the MAF Sensor Signal circuit for a short to ground.
No → Go To 6

Measure the resistance between the MAF Sensor Signal circuit and the Sensor
Ground circuit at of the MAF Sensor harness connector.
Yes → Repair the MAF Sensor Signal for a short to Sensor Ground .
No → Go To 7

Connect a jumper wire between MAF Sensor Signal circuit and the 5-volt supply
circuit at the MAF Sensor harness connector .
With the DRBIII, read the MAF VOLTS.
Does the DRBIII display between 4.0 and 5.5 volts?
Yes → Go To 8
No → Replace and program the Engine Control Module in accordance
15

Measure the resistance of the Sensor Ground circuit between the MAF Sensor and
the ECM.
Yes → Go To 9
No → Repair the Sensor Ground circuit for an open.


Measure the voltage between the 5-volt Supply circuit and the Sensor Ground circuit
at the MAF Sensor harness connector.
Yes → Go To 10
No → Replace and program the ECM in accordance with the Service
Information.

With the DRBIIIt, actuate the ECM/PCM Relay.
Measure the voltage of the 12-volt Supply circuit at the MAF Sensor harness
connector
Yes → Go To 11
No → Repair the ECM/PCM Relay Output circuit for an open.

Turbocharger. Ensure the airflow tube properly is secured at each end and
that there is no damage, restrictions or air leaks in the tube.
With a voltmeter, backprobe the MAF Sensor Signal circuit at the MAF Sensor
harness connector.
Allow the engine to idle for at least 2 minutes.
NOTE: The engine speed must be approximately 900 rpm for this test to be
valid.
Yes → Go To 12
No → Replace the Mass Air Flow Sensor in accordance with the Service
Information.
16

Turbocharger. Ensure the airflow tube properly is secured at each end and
that there is no damage, restrictions or air leaks in the tube.
With a voltmeter, backprobe the MAF Sensor Signal circuit at the MAF Sensor
harness connector.
With the engine at operating temperature, depress the throttle completely to the Full
throttle position for 5 seconds and note the voltmeter reading.

No → Replace the Mass Air Flow Sensor in accordance with the Service
Information.

Measure the resistance of the 5-volt Supply circuit.
Yes → Go To 14
No → Repair the 5-volt Supply circuit for an open.

Measure the resistance between the 5-volt Supply circuit and the Sensor Ground
circuit at the MAF Sensor harness connector.
Yes → Go To 15
No → Repair the 5-volt Supply circuit for a short to the Sensor Ground
circuit.

Measure the resistance between ground and the 5-volt Supply circuit at the MAF
harness connector.
Yes → Repair the 5-volt Supply circuit for a short to ground.

No → Go To 16
17

connector.
Measure the voltage of the 5-volt Supply circuit in the ECM harness connector.
Yes → Repair the 5-volt Supply circuit for a short to voltage.

No → Go To 17

Disconnect the Fuel Pressure Sensor harness connector.
circuit at the Fuel Pressure Sensor harness connector.
Yes → Go To 18
circuit.

Measure the resistance between ground and the 5-volt Supply circuit at the Fuel
Pressure Sensor harness connector.
No → Go To 19

connector.
Measure the voltage of the 5-volt Supply circuit in the Fuel Pressure Sensor harness
connector.

18

With the engine running and at normal operating temperature, monitor the DRB
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.

19
Symptom List:
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO
HIGH
LOW
P0606-ECM ERROR GATE ARRAY - COMMUNICATION
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERI-
FIED
P0606-ECM ERROR GATE ARRAY - QUANTITY STOP
P0606-ECM ERROR RECOVERY HAS OCCURRED
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING
P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH
P1206-CALCULATED INJECTOR VOLTAGE TOO LOW
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR
MISSING
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR
P1680-EEPROM PLAUSIBILITY WRITE ERROR
P1696-EEPROM MEMORY WRITE DENIED
The title for the tests will be P0105-BAROMETRIC PRES-
SURE CIRCUIT SIGNAL VOLTAGE TOO HIGH.
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH

Set Condition: The Barometric Pressure Sensor Signal is above 4.75 volts.
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW

Set Condition: The Barometric Pressure Sensor Signal is below 0.66 volt.
20

HIGH — Continued
P0606-ECM ERROR GATE ARRAY - COMMUNICATION
Set Condition: The ECM detects an internal failure.
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERIFIED

P0606-ECM ERROR GATE ARRAY - QUANTITY STOP

P0606-ECM ERROR RECOVERY HAS OCCURRED

P0606-ECM ERROR REDUNDANT OVERRUN MONITORING

P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH

When Monitored: With the engine running. During every 180° of engine rotation.
Set Condition: The ECM determines that the capacitor voltage is out of range.
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW

When Monitored: With the engine running. During every 180° of engine rotation.
Set Condition: The ECM determines that the capacitor voltage is out of range.
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE

When Monitored: At ignition off.
Set Condition: The ECM detects the engine speed has not fallen below 650 RPM within
0.5 seconds after ignition off.
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY

When Monitored: At ignition off.
Set Condition: The ECM detects the engine speed has not fallen below 650 RPM within
0.5 seconds after ignition off.
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR

21

HIGH — Continued
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR

P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR

P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR

P1680-EEPROM PLAUSIBILITY WRITE ERROR

P1696-EEPROM MEMORY WRITE DENIED

POSSIBLE CAUSES

1 NOTE: This DTC indicates an internal ECM problem. All
With the DRB, erase ECM DTCs.
Perform several engine run cycles, turning the ignition off for at least 20 seconds
between each engine run cycle.
With the DRBIIIt, read the ECM DTC’s.
Did this DTC reset?

No → Go To 2
22

HIGH — Continued

23
Symptom:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE
TOO HIGH
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH

Set Condition: The Intake Air Temperature Sensor Signal voltage is above 4.85 volts.
POSSIBLE CAUSES
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTAKE AIR TEMP SENSOR GROUND CIRCUIT OPEN
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT OPEN
TURBOCHARGER BOOST PRESSURE/IAT SENSOR

Monitor the DRB for ECM DTCs.
Did this DTC reset?
Yes → Go To 2
No → Go To 6

Disconnect the Turbocharger Boost Pressure/IAT Sensor harness connector.
connector.
Measure the voltage on the IAT Sensor Signal circuit.
Yes → Go To 3
No → Repair the Intake Air Temperature Sensor Signal circuit for a
short to voltage.
NOTE: Remove the jumper wire.
24
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO

HIGH — Continued
Disconnect the Boost Pressure/IAT Sensor harness connector.
Measure the resistance of the Intake Air Temperature Sensor Signal circuit.
Yes → Go To 4
No → Repair the Intake Air Temperature Sensor Signal circuit for an

open.

Connect a jumper wire between the IAT Sensor Signal and IAT Sensor Ground
circuits in the Boost Pressure/IAT Sensor harness connector.
Does the DRB display P0110 INTAKE AIR TEMP. SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW?
Yes → Replace the Turbocharger Boost Pressure/Intake Air Tempera-

ture Sensor.
No → Go To 5

Measure the resistance of the Sensor Ground circuit between the ECM harness
connector and the Boost Pressure Sensor harness connector.
No → Repair the Intake Air Temperature Sensor Ground circuit for an

open.
25

HIGH — Continued

26
Symptom:
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE
TOO LOW
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW

Set Condition: The Intake Air Temperature Sensor Signal voltage is below 0.21 volt.
POSSIBLE CAUSES
INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
TURBOCHARGER BOOST PRESSURE/IAT SENSOR

Did this DTC reset?
Yes → Go To 2
No → Go To 5

Measure the resistance between ground and the Intake Air Temperature Sensor
Signal circuit.
Yes → Go To 3
No → Repair the Intake Air Temperature Sensor Signal circuit for a

short to ground.

Does the DRB display P0110 INTAKE AIR TEMP SIGNAL VOLTAGE TOO HIGH?

ture Sensor.
No → Go To 4
27

LOW — Continued
Repair

28
Symptom:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT-
AGE TOO HIGH
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO

HIGH
Set Condition: The Engine Coolant Temperature Sensor Signal voltage is above 4.95 volts
for more than 1 second.
POSSIBLE CAUSES
ECM ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECT SENSOR GROUND CIRCUIT OPEN
ECT SENSOR
ECT SENSOR SIGNAL CIRCUIT OPEN

1 NOTE: If multiple DTCs are present, the most likely cause is a 5-Volt Supply All
or Sensor Ground circuit shorted to voltage or ground. Refer to the Service
Information Wiring section for circuits that would affect multiple DTCs.
With the DRB, monitor the Engine Coolant Temperature (ECT) Sensor voltage.
Is the ECT Sensor voltage above 4.5 volts?
Yes → Go To 2
No → Go To 7

Disconnect the ECT Sensor harness connector.
Measure the voltage on the ECT Sensor Signal circuit.
Yes → Repair the ECM ECT Sensor Signal circuit for a short to voltage.
No → Go To 3
29
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE

TOO HIGH — Continued
Connect a jumper wire between the ECT Sensor harness connector cavities.
With the DRB, read the ECT Sensor voltage.
Yes → Replace the ECT Sensor in accordance with the Service Informa-
tion.
No → Go To 4

Measure the resistance of the ECT Sensor Ground circuit.
Yes → Go To 5
No → Repair the ECT Sensor Ground circuit for an open.


Measure the resistance of the ECT Sensor Signal circuit.
Yes → Go To 6
No → Repair the ECT Sensor Signal circuit for an open.

Repair
30

TOO HIGH — Continued

31
Symptom:
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT-
AGE TOO LOW
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO

LOW
Set Condition: The Engine Coolant Temperature Sensor Signal voltage is below 0.2 volt
for more than 1 second.
POSSIBLE CAUSES
ECT SENSOR
ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ECT SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER

With the DRB, monitor the Engine Coolant Temperature (ECT) Sensor voltage.
Is the ECT Sensor voltage below 0.3 volt?
Yes → Go To 2
No → Go To 6

With the DRB, read the ECT Sensor voltage.
Yes → Replace the ECT Sensor in accordance with the Service Informa-
tion.
No → Go To 3

Measure the resistance between ground and the ECT Sensor Signal circuit.
Yes → Go To 4
No → Repair the ECT Sensor Signal circuit for a short to ground.

32

Measure the resistance between the ECT Sensor Signal circuit and Sensor Ground
circuit.
Yes → Go To 5
No → Repair the ECT Sensor Signal and Ground circuits for a short
together.
Repair

33
Symptom:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE
TOO HIGH
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH

Set Condition: The Fuel Rail Pressure Sensor Signal voltage is above 4.8 volts.
POSSIBLE CAUSES
ECM - FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - FUEL PRESSURE SENSOR SIGNAL OPEN
FUEL PRESSURE SENSOR SIGNAL CIRCUIT OPEN
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
FUEL PRESSURE SENSOR

1 WARNING: THE FUEL INJECTION PUMP SUPPLIES HIGH PRESSURE All
FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH-PRESSURE
FUEL LINES. FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN
AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING.
With the DRB III, erase ECM DTCs.
Cycle the ignition key on and off several times, leaving the key on for at least 10
seconds at a time.
With the DRB III, read ECM DTCs.
Did this DTC reset?
Yes → Go To 2
No → Go To 10
34
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO

HIGH — Continued
Measure the voltage of the Fuel Pressure Sensor Signal circuit.
Select the appropriate voltage reading.
Voltage is above 5.5 volts.
Go To 3
Voltage is between 4.7 and 5.4 volts.

Go To 4
Voltage is below 4.7 volts.
Go To 9

Remove the ECM/PCM Relay from the IPM.
connector.
No → Repair the Fuel Pressure Sensor Signal circuit for a short to

voltage.

Measure the resistance of the Sensor Ground circuit.
Yes → Go To 5


Measure the resistance of the 5-Volt Supply circuit.
Yes → Go To 6

35

HIGH — Continued
connector.
Measure the voltage of the Sensor Ground circuit at the Fuel Pressure Sensor and
ECM harness connectors.
Is the voltage above 1.0 volt at either connector?
Yes → Repair the Sensor Ground circuit for a short to voltage.
No → Go To 7
NOTE: If the Sensor Ground circuit had a short to voltage on it, the ECM
may have been damaged. Retest the Fuel Pressure Sensor circuit.

Connect a jumper wire between the Fuel Pressure Sensor Signal circuit and the
Sensor Ground circuit in the Fuel Pressure Sensor harness connector.
Turn the ignition on and monitor the DRB for DTCs.
Is DTC P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
LOW present?
Yes → Replace the Fuel Pressure Sensor.
No → Go To 8

Repair

Measure the resistance of the Fuel Pressure Sensor Signal circuit.

No → Repair the Fuel Pressure Sensor Signal circuit for an open.

36

HIGH — Continued

37
Symptom:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE
TOO LOW
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW

Set Condition: The Fuel Rail Pressure Sensor Signal voltage is below 0.2 volt.
POSSIBLE CAUSES
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
ECM - FUEL PRESSURE SENSOR SIGNAL SHORTED TO GROUND

NOTE: If DTC P0641 or P0651 is present with this DTC, diagnose DTCs
seconds at a time.
Did this DTC reset?
Yes → Go To 2
No → Go To 6

Yes → Replace the Fuel Pressure Sensor.

No → Go To 3
38

LOW — Continued
Measure the resistance between ground and the Fuel Pressure Sensor Signal circuit.
Yes → Go To 4
No → Repair the Fuel Pressure Sensor Signal circuit for a short to

ground.

Measure the resistance between the Sensor Ground circuit and the Fuel Pressure
Sensor Signal circuit.
Yes → Go To 5
No → Repair the Fuel Pressure Sensor Signal circuit for a short to the
Sensor Ground circuit.

Repair


39
Symptom:
P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE
TOO HIGH OR LOW
P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR

LOW
Set Condition: The Fuel Pressure Sensor 5-Volt Supply voltage is below 4.7 volts or above
5.1 volts for 100 ms.
POSSIBLE CAUSES
CHECK FOR SENSOR REFERENCE VOLTAGE A CIRCUIT DTCS

Is the High or Low DTC for P0641 SENSOR REFERENCE VOLTAGE A CIRCUIT
set with this DTC?
Yes → Refer to the symptom list for the related symptom(s).

40
Symptom:
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
HIGH
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH

Set Condition: The Oil Temperature Sensor Signal voltage is above 4.95 volts for at least
2 seconds.
POSSIBLE CAUSES
ENGINE OIL TEMPERATURE SENSOR GROUND CIRCUIT OPEN
ENGINE OIL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE OIL TEMPERATURE SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
ENGINE OIL TEMPERATURE SENSOR
ENGINE OIL TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN

With the DRB, monitor the Engine Oil Temperature Sensor voltage.
Is the Engine Oil Temperature Sensor voltage above 4.5 volts?
Yes → Go To 2
No → Go To 8

Disconnect the Engine Oil Temperature Sensor harness connector.
Measure the voltage on the Engine Oil Temperature Sensor Signal circuit.
Yes → Repair the Engine Oil Temperature Sensor Signal circuit for a
short to voltage.
No → Go To 3
41

— Continued
connector.
Measure the voltage of the Sensor Ground circuit at the Engine Oil Temperature
Sensor and ECM harness connectors.
Yes → Repair the Engine Oil Temperature Sensor Ground circuit for a
short to voltage.
No → Go To 4
may have been damaged. Retest the Engine Oil Temperature Sensor circuit.

Connect a jumper wire between the Engine Oil Temperature Sensor harness
connector cavities.
With the DRB, read the Oil Temp Sensor voltage.
Yes → Replace the Engine Oil Temperature Sensor.
No → Go To 5

Connect a jumper wire between ground and the Engine Oil Temperature Sensor
Signal circuit.
With the DRB, read the Oil Temp Sensor voltage.
Yes → Repair the Engine Oil Temperature Sensor Ground circuit for an
open.
No → Go To 6

Measure the resistance of the Engine Oil Temperature Sensor Signal circuit.
Yes → Go To 7
No → Repair the Engine Oil Temperature Sensor Signal circuit for an

open.
42

— Continued
Repair

43
Symptom:
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO
LOW
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW

Set Condition: The Oil Temperature Sensor Signal voltage is below 0.2 volt for at least 2
seconds.
POSSIBLE CAUSES
OIL TEMPERATURE SENSOR
OIL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
OIL TEMPERATURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER

With the DRB, monitor the Oil Temperature (OT) Sensor voltage.
Is the OT Sensor voltage below 0.3 volt?
Yes → Go To 2
No → Go To 6

Disconnect the OT Sensor harness connector.
With the DRB, read the OT Sensor voltage.
Yes → Replace the Oil Temperature Sensor.

No → Go To 3

Measure the resistance between ground and the OT Sensor Signal circuit.
Yes → Go To 4
No → Repair the OT Sensor Signal circuit for a short to ground.

44
P0195-OIL TEMP SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW

— Continued
Measure the resistance between the OT Sensor Signal circuit and Sensor Ground
circuit.
Yes → Go To 5
No → Repair the OT Sensor Signal and Ground circuits for a short

together.
Repair

45
Symptom List:
P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE
P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH
SIDE
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW
SIDE
The title for the tests will be P0201-CYLINDER 1-INJECTOR
CIRCUIT CURRENT DECREASE.

Set Condition: The ECM detects an incorrect rate of current decrease after injection
occurs.

Set Condition: The ECM detects insufficient current through the injector driver.
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE

Set Condition: The ECM detects excessive current on the common driver circuit.
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE

Set Condition: The ECM detects excessive current on the injector driver circuit.
POSSIBLE CAUSES
COMMON DRIVER CIRCUIT OPEN
COMMON DRIVER CIRCUIT SHORTED TO GROUND
FUEL INJECTOR
FUEL INJECTOR #1 DRIVER CIRCUIT OPEN
FUEL INJECTOR #1 DRIVER CIRCUIT SHORTED TO GROUND
46
P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE —

Continued
POSSIBLE CAUSES
COMMON DRIVER CIRCUIT SHORTED TO VOLTAGE
FUEL INJECTOR #1 DRIVER CIRCUIT SHORTED TO VOLTAGE

Does the DRB III display DTC P0201?
Yes → Go To 2
No → Go To 9

Disconnect the Cylinder #1 Injector harness connector.
Measure the resistance of the Fuel Injector #1 Driver circuit.
Yes → Go To 3
No → Repair the Fuel Injector #1 Driver circuit for an open.


Measure the resistance between ground and the Fuel Injector #1 Driver circuit.
Yes → Repair the Fuel Injector #1 Driver circuit for a short to ground.
No → Go To 4

Disconnect the Cylinder #1 Fuel Injector harness connector.
connector.
Measure the voltage of the Fuel Injector #1 Driver circuit.
Yes → Repair the Fuel Injector #1 Driver circuit for a short to voltage.
No → Go To 5
47

Continued
Measure the resistance of the Common Driver circuit.
Yes → Go To 6
No → Repair the Common Driver circuit for an open.


Measure the resistance between ground and the Common Driver circuit.
Yes → Repair the Common Driver circuit for a short to ground.

No → Go To 7

connector.
Measure the voltage of the Common Driver circuit.
Yes → Repair the Common Driver circuit for a short to voltage.

No → Go To 8

Replace the Cylinder #1 Fuel Injector in accordance with the Service Information.
Does the DRBIIIt display this DTC?
48

Continued

49
Symptom List:
SIDE
SIDE

occurs.



POSSIBLE CAUSES
FUEL INJECTOR
50

Continued
POSSIBLE CAUSES

Yes → Go To 2
No → Go To 9

Yes → Go To 3


No → Go To 4

connector.
No → Go To 5
51

Continued
Yes → Go To 6



No → Go To 7

connector.

No → Go To 8

52

Continued

53
Symptom List:
SIDE
SIDE

occurs.



POSSIBLE CAUSES
FUEL INJECTOR
54

Continued
POSSIBLE CAUSES

Yes → Go To 2
No → Go To 9

Yes → Go To 3


No → Go To 4

connector.
No → Go To 5
55

Continued
Yes → Go To 6



No → Go To 7

connector.

No → Go To 8

56

Continued

57
Symptom List:
SIDE
SIDE

occurs.



POSSIBLE CAUSES
FUEL INJECTOR
58

Continued
POSSIBLE CAUSES

Yes → Go To 2
No → Go To 9

Yes → Go To 3


No → Go To 4

connector.
No → Go To 5
59

Continued
Yes → Go To 6



No → Go To 7

connector.

No → Go To 8

60

Continued

61
Symptom:
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY

When Monitored: With the engine speed below 950 rpm.
Set Condition: When the engine is idling, the turbocharger boost pressure sensor input
does not agree with the atmospheric pressure sensor input for at least 5 seconds.
POSSIBLE CAUSES
HIGH RESISTANCE IN THE BOOST PRESSURE SENSOR SIGNAL CIRCUIT
HIGH RESISTANCE IN THE BOOST PRESSURE SENSOR GROUND CIRCUIT
HIGH RESISTANCE IN THE 5-VOLT SUPPLY CIRCUIT
TURBOCHARGER BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR

Turn the ignition off, wait 30 seconds, then start and idle the engine for at least 30
seconds.
NOTE: Engine idle speed must be below 870 RPM.
With the DRB, read ECM DTCs.
Did this DTC reset?
Yes → Go To 2
No → Go To 6

Measure the resistance of the Boost Pressure Sensor Signal circuit.
Yes → Go To 3
No → Repair the Boost Pressure Sensor Signal circuit for high resis-
tance.
62
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY — Continued

Yes → Go To 4
No → Repair the Boost Pressure Sensor Ground circuit for high resis-
tance.

Yes → Go To 5
No → Repair the 5-volt Supply circuit for high resistance.

Replace the Turbocharger Boost Pressure/Intake Air Temperature Sensor.
Test drive the vehicle, pausing several times to cycle the ignition.
Did this DTC reset?
No → The repair is complete.



63
Symptom:
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH

Set Condition: The Boost Pressure Sensor Signal voltage exceeds 4.8 volts for at least 2
seconds.
POSSIBLE CAUSES
BOOST PRESSURE SENSOR GROUND CIRCUIT OPEN
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
POOR CONNECTOR TERMINAL CONTACT
ENGINE CONTROL MODULE (5-VOLT SUPPLY SHORTED TO VOLTAGE)
ENGINE CONTROL MODULE (INTERNAL)
ENGINE CONTROL MODULE (SENSOR SIGNAL SHORTED TO VOLTAGE)

With the DRB, read the Turbocharger Boost Pressure Sensor voltage.
NOTE: Ensure the turbocharger wastegate is operating properly. This code
can be set if turbocharger boost pressure is too high.
Yes → Go To 2
No → Go To 9

Measure the voltage between ground and the Turbocharger Boost Pressure Sensor
5-volt Supply circuit.
Yes → Go To 3
No → Go To 4
64
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH —

Continued
Remove the ASD/Diesel Power Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ASD/Diesel Power
Relay connector.
Measure the voltage between ground and the 5-volt Supply circuit.



Measure the voltage between ground and the Boost Pressure Sensor Signal circuit.
Yes → Go To 5
No → Go To 6

Remove the ASD/Diesel Power Relay from the PDC.
Connect a jumper wire between cavity 30 and cavity 87 of the ASD/Diesel Power
Relay connector.
Measure the voltage between ground and the Boost Pressure Sensor Signal circuit.
Yes → Repair the Boost Pressure Sensor Signal circuit for a short to
voltage.


Yes → Go To 7
No → Repair the Boost Pressure Sensor Ground circuit for an open.

65
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH —

Continued
NOTE: Ensure all harness connectors are connected.
Measure the voltage of the Boost Pressure Sensor Signal circuit by backprobing ECM
harness connector C1, cavity 40.
ture Sensor.
No → Go To 8

Did this DTC reset?
No → Ensure good terminal contact between the Turbocharger Boost

Pressure/IAT Sensor harness connector and the sensor. The
repair is complete.

66
Symptom:
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW

Set Condition: The Turbocharger Boost Pressure Sensor Signal voltage is below 0.15 volt
for at least 2 seconds.
POSSIBLE CAUSES
5-VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
BOOST PRESSURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER
BOOST PRESSURE SENSOR SIGNAL CIRCUIT OPEN

Yes → Go To 2
No → Go To 8

Measure the voltage between ground and the 5-volt Supply circuit.
Yes → Go To 3
No → Repair the 5-volt Supply circuit for an open or short to ground.

67
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW —

Continued
Connect a jumper wire between the Boost Pressure Sensor Signal and 5-volt Supply
circuits.
Is the Boost Pressure Sensor voltage above 4.5 volts?

ture Sensor.
No → Go To 4

Measure the resistance between ground and the Boost Pressure Sensor Signal
circuit.
Yes → Go To 5
No → Repair the Boost Pressure Sensor Signal circuit for a short to
ground.

Measure the resistance between the Boost Pressure Sensor Signal circuit and Sensor
Ground circuit.
Yes → Go To 6
No → Repair the Boost Pressure Sensor Signal circuit for a short to the

Measure the resistance of the Boost Pressure Sensor Signal circuit.
Yes → Go To 7
No → Repair the Boost Pressure Sensor Signal circuit for an open.


Repair
68
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW —

Continued

69
Symptom:
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH
OR LOW
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW

Set Condition: The Sensor Reference Voltage 9B9 voltage to the Boost Pressure Sensor is
below 4.8 volts or above 5.2 volts for at least 100 ms.
POSSIBLE CAUSES
5-VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND
APP SENSOR 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
APP SENSOR 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE

Did this DTC reset?
Yes → Go To 2
No → Go To 7

connector.
Measure the voltage between ground and the 5-volt Supply circuit at the Boost
Pressure/IAT Sensor harness connector.

No → Go To 3
70
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR

LOW — Continued
Measure the resistance between ground and the 5-volt Supply circuit at the Boost
Yes → Go To 4
No → Repair the 5-volt Supply circuit for a short to ground.


Measure the resistance between Sensor Ground and the 5-volt Supply circuit at the
Boost Pressure/IAT Sensor harness connector.
Yes → Go To 5
No → Repair the 5-volt Supply circuit for a short to Sensor Ground.


Disconnect the APP Sensor harness connector.
Measure the resistance between ground and the 5-volt Supply circuit at the Boost
Yes → Go To 6
No → Repair the APP Sensor 5-volt Supply circuit for a short to ground.

connector.
Measure the voltage between ground and the 5-volt Supply circuit at the APP Sensor
harness connector.
Yes → Repair the APP Sensor 5-volt Supply circuit for a short to voltage.
71
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR

LOW — Continued

72
Symptom:
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNI-
TION
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION

Set Condition: The engine speed sensor signal indicates engine speed is above 5100 RPM
for at least 500 milliseconds. NOTE: Engine damage is possible when the engine speed
exceeds 5100 RPM.
POSSIBLE CAUSES
CHECK FOR OTHER DTCS
OPEN SHIELD CIRCUIT
REPLACE THE CRANKSHAFT POSITION SENSOR

1 CAUTION: Engine damage is possible when engine speed exceeds 5000 All
RPM.
NOTE: This DTC indicates the Engine Speed Sensor has seen an engine
speed above 5000 RPM. This can occur if the vehicle is in 5th gear and the
vehicle operator performs a downshift and accidentally downshifts from
5th gear to 2nd gear.
With the DRB, check for other Engine Speed Sensor DTCs.
Are other Engine Speed Sensor DTCs present?
Yes → Refer to symptom list for problems related to other DTCs before
continuing.
No → Go To 2

Test drive the vehicle and monitor the DRB for ECM DTCs.
Did this DTC reset?
Yes → Go To 3
No → Go To 5
73
P0335-CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION

— Continued
Disconnect the CKP Sensor harness connector.
Measure the resistance of the Shield circuit.
Yes → Go To 4
No → Repair the Shield circuit for an open.

4 Replace the Crankshaft Position Sensor in accordance with the Service Information. All
Perform several drive cycles, turning the ignition off for at least 10 seconds between
each drive cycle.
Did this DTC reset?
No → The repair is complete. Refer to the Service Information to check

for engine mechanical problems that may have occurred due to
excessive engine speed.

Check the Engine Speed Sensor wiring harness for incorrect routing which may
cause EMI interference.
74
Symptom:
P0340-CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBIL-
ITY
P0340-CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY

When Monitored: The engine speed is above 790 RPM.
Set Condition: The ECM detects a change in engine speed that has occurred more rapidly
than the engine is capable of changing speed.
POSSIBLE CAUSES
CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT(S) SHORTED TO GROUND
CKP SENSOR CIRCUITS SHORTED TOGETHER
CKP SENSOR SIGNAL CIRCUITS OPEN
CKP SENSOR SIGNAL CIRCUIT(S) SHORTED TO VOLTAGE
CRANKSHAFT POSITION SENSOR

1 Attempt to start the engine. All
Did the engine start?
Yes → Go To 2
No → Go To 3

75
P0340-CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY —

Continued
Measure the resistance between ground and the both of the CKP Sensor Signal
circuits.
Is the resistance above 1000 ohms for both measurements?
Yes → Go To 4
No → Repair the CKP Sensor Signal circuit(s) for a short to ground.


Measure the resistance between the CKP Sensor Signal circuits.
Yes → Go To 5
No → Repair the CKP Sensor Signal circuits for a short together.

Measure the resistance of CKP Sensor Signal circuits.
Yes → Go To 6
No → Repair the CKP Sensor Signal circuit(s) for an open.

Measure the voltage of both CKP Sensor Signal circuits.
Is the voltage below 1.0 volt for both measurements?
Yes → Go To 7
No → Repair the CKP Sensor Signal circuit(s) for a short to voltage.

7 NOTE: Ensure the ECM and CKP Sensor harness connectors are connected. All
Connect, by back probing, a voltmeter capable of reading frequency to ECM harness
connector C2 cavity 67.
Crank the engine while monitoring the voltmeter.
Is the frequency between 16 and 20 Hz while cranking?

No → Replace the Crankshaft Position Sensor in accordance with the

76
Symptom:
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAIL-
URE
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAILURE

Set Condition: The ECM determines that the camshaft position sensor signal frequency
is not plausible with the crankshaft position sensor signal frequency.
POSSIBLE CAUSES
CHECK CAMSHAFT POSITION SENSOR SIGNAL
CHECK CRANKSHAFT POSITION SENSOR SIGNAL
CHECKING CKP SENSOR FOR DAMAGE
CHECKING CMP SENSOR FOR DAMAGE
GEAR ALIGNMENT

Attempt to start the engine.
Does the DRB III display this DTC?
Yes → Go To 3
No → Go To 2

Yes → Go To 3
No → Go To 8

Remove the CMP Sensor.
Inspect the camshaft Position Sensor for conditions such as loose mounting screws,
damage or debris, also check the camshaft for cracked teeth.
Is there any evidence of these conditions?
No → Go To 4
77
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAILURE —

Continued
Remove the CKP Sensor.
Inspect the Crankshaft Position Sensor for conditions such as loose mounting screws,
damage or debris.
No → Go To 5

Using the DRB lab scope, backprobe the CMP Sensor Signal circuit at the CMP
Sensor harness connector.
Start the engine, if the engine will not start, crank the engine for several seconds
while monitoring the DRB.
NOTE: Refer to Charts and Graphs to view a correct CMP Sensor signal.
Does the DRB display a steady clean CMP Signal pattern?
Yes → Go To 6
No → Perform Test for DTC P0340-Camshaft Position Sensor Circuit

Static Plausibility.

Using the DRB lab scope, backprobe both of the CKP Sensor Signal circuits at the
CKP Sensor harness connector.
NOTE: Refer to Charts and Graphs to view a correct CKP Sensor signal.
Does the DRB display a steady clean CKP Signal pattern for each circuit?
Yes → Go To 7
No → Perform Test for DTC P0340-Crankshaft Position Sensor Circuit

Dynamic Plausibility.
7 Refer to the Service Information and check alignment of the camshaft sprocket, All
crankshaft sprocket and injection pump sprocket.
Are all of the sprockets aligned correctly?

No → Repair or adjust as necessary.
78
P0340-CMP POSITION SENSOR CIRCUIT CMP/CKP SYNC FAILURE —

Continued

79
Symptom List:
P0340-CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY
TOO HIGH
P0340-CMP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY
The title for the tests will be P0340-CMP POSITION SENSOR
CIRCUIT SIGNAL FREQUENCY TOO HIGH.
P0340-CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH

Set Condition: The ECM detects more than three camshaft sensor signals within a 10 ms
time period.
POSSIBLE CAUSES
CHECKING FOR DAMAGE
ECM
ECM MONITOR
VERIFY ECM/PCM RELAY OUTPUT
CMP SENSOR SIGNAL CIRCUIT OPEN
CAMSHAFT POSITION SENSOR
CMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
CMP SENSOR OPERATION DURING CRANKING CRANK
ECM SENSOR GROUND CIRCUIT OPEN
CMP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
CMP SENSOR CIRCUIT SHORTED TO VOLTAGE

1 NOTE: The Timing Belt must be correctly installed and operational before All
diagnosis can be made. Refer to the Service Information to ensure the
timing belt is properly installed.
Yes → Go To 3
No → Go To 2
80
P0340-CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO

HIGH — Continued
Yes → Go To 3
No → Go To 13

Disconnect the CMP Sensor harness connector.
Using a 12-volt test light connected to ground, check the ECM/PCM Relay Output
circuit in CMP Sensor harness connector.
Yes → Go To 4

Measure the voltage of the CMP Sensor Signal circuit.
Yes → Go To 5
No → Go To 10

Using a 12-volt test light connected to ground, check the CMP Sensor Signal circuit.
Yes → Repair the CMP Sensor Signal circuit for a short to voltage.
No → Go To 6

With the DRB III, read the CMP Sensor RPM.
Connect one end of a jumper wire to the CMP signal circuit and tap the other end of
the jumper wire to ground while observing the DRB.
Does the DRB III display an RPM change while tapping the jumper wire to ground?
Yes → Go To 7
Information.
81

HIGH — Continued
With the DRB III, read the CMP Sensor RPM.
Connect one end of a jumper wire to the CMP signal circuit and tap the other end of
the jumper wire to Sensor Ground at the CMP harness connector while observing the
DRB.
Does the DRB III display an RPM change while tapping the jumper wire to Sensor
Ground?
Yes → Go To 8

Information.

With the DRB III lab scope lead, backprobe the CMP Signal circuit.
Set the DRB lab scope settings as follows: Time = 0.1s/Div, 20 volts scale, Offset =
0.00volts, Probe = X10, Coupling = DC
While observing the DRB III display, crank the engine.
NOTE: The DRB III should display a digital signal (square wave) similar to
that shown in the support material.
Does the DRB display an uninterrupted digital signal (square wave)?
Yes → Go To 9
No → Replace the Camshaft Position Sensor in accordance with the

Remove the CMP Sensor.
Inspect the camshaft for conditions such as loose mounting screws, damage, debris or
cracked teeth.
No → Replace the Camshaft Position Sensor.

Measure the resistance of the CMP Sensor Signal circuit.
Yes → Go To 11
No → Repair the CMP Sensor Signal circuit for an open


Measure the resistance between ground and the CMP Sensor Signal circuit.
Yes → Repair the CMP Sensor Signal circuit for a short to ground.
No → Go To 12
82

HIGH — Continued
Measure the resistance between the CMP Sensor Signal circuit and the Sensor
Ground circuit at of the CMP Sensor harness connector.
Yes → Repair the CMP Sensor Signal and Sensor Ground circuits for a
short together.

Remove the CMP Sensor and the CKP Sensor, checking for loose mounting screws
and debris on the sensor magnets that can corrupt the sensor signal.
83
Symptom List:
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT
P0380-GLOW PLUG CIRCUIT A SHORT CIRCUIT
The title for the tests will be P0380-GLOW PLUG CIRCUIT A
OPEN CIRCUIT.
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT

When Monitored: With the ignition on and glow plug operation not active.
Set Condition: The ECM does not detect voltage on the Glow Plug Relay Control circuit
when the relay is commanded off.
P0380-GLOW PLUG CIRCUIT A SHORT CIRCUIT

When Monitored: With the ignition on and when attempting to activate the Glow Plug
Relay.
Set Condition: The ECM detects excessive current on the Glow Plug Relay Control circuit
when the glow plug relay is commanded on.
POSSIBLE CAUSES
SUBSTITUTE GLOW PLUG RELAY
GLOW PLUG RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
GLOW PLUG RELAY CONTROL CIRCUIT SHORTED TO GROUND
GLOW PLUG RELAY CONTROL CIRCUIT OPEN

With the DRB, actuate the Glow Plug Relay.
Is the Glow Plug Relay clicking?
Yes → Go To 2
No → Go To 3
84
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT — Continued



Disconnect the Glow Plug Relay harness connector.
circuit.
Yes → Go To 4


Install a substitute relay in place of the Glow Plug Relay.
Perform several ignition key cycles, pausing for at least 10 seconds between each
cycle.
Did this DTC reset?
Yes → Go To 5
No → Replace the Glow Plug Relay.


connector.
Measure the voltage on the Glow Plug Relay Control circuit.
Yes → Repair the Glow Plug Relay Control circuit for a short to voltage.
No → Go To 6
85
P0380-GLOW PLUG CIRCUIT A OPEN CIRCUIT — Continued

Measure the resistance between ground and the Glow Plug Relay Control circuit.
Yes → Go To 7
No → Repair the Glow Plug Relay Control circuit for a short to ground.

Measure the resistance of the Glow Plug Relay Control circuit.
Yes → Go To 8
No → Repair the Glow Plug Relay Control circuit for an open.

Repair
86
Symptom:
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT

Set Condition: The ECM detects an open or short to ground on the EGR Solenoid Control
circuit.
POSSIBLE CAUSES
EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
EGR SOLENOID CONTROL CIRCUIT OPEN
SUBSTITUTE EGR SOLENOID

Perform several ignition cycles, turning the ignition off for at least 10 seconds
between each ignition cycle.
Did this DTC reset?
Yes → Go To 2
No → Go To 7

Disconnect the EGR Solenoid harness connector.
circuit.
Yes → Go To 3

87
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT — Continued

Measure the resistance between ground and the EGR Solenoid Control circuit.
Yes → Go To 4
No → Repair the EGR Solenoid Control circuit for a short to ground.


Measure the resistance of the EGR Solenoid Control circuit.
Yes → Go To 5
No → Repair the EGR Solenoid Control circuit for an open.

Install a substitute EGR Solenoid in place of the vehicle’s EGR Solenoid.
NOTE: Ensure the ECM and EGR Solenoid harness connectors are con-
nected.
With the DRB, check for this DTC to reset.
Did this DTC reset?
Yes → Go To 6
No → Replace the EGR Solenoid.

Repair
88
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT — Continued

NOTE: The conditions that set the DTC are not present at this time.The

89
Symptom:
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT

Set Condition: The ECM detects excessive current draw on the EGR Solenoid Control
circuit.
POSSIBLE CAUSES
EGR SOLENOID
EGR SOLENOID CONTROL SHORTED TO VOLTAGE
ENGINE CONTROL MODULE - INTERNAL
ENGINE CONTROL MODULE - INTERNAL SHORT TO VOLTAGE

Test drive the vehicle and monitor the DRB for ECM DTCs.
Did this DTC reset?
Yes → Go To 2
No → Go To 5

Does the DRB display P0403 EGR OPEN CIRCUIT?
Yes → Replace the EGR Solenoid.
No → Go To 3

Measure the voltage of the EGR Solenoid Control circuit at the EGR Solenoid
harness connector.
No → Go To 4
90
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT — Continued

connector.
Measure the voltage of the EGR Solenoid Control circuit.

No → Repair the EGR Solenoid Control circuit for a short to voltage.


91
Symptom:
P0480-FAN 1 CONTROL CIRCUIT OPEN CIRCUIT

Set Condition: The ECM detects an open or short to ground on the Radiator Fan Relay
No. 1 Control circuit.
POSSIBLE CAUSES
RADIATOR FAN RELAY NO. 1
LOW SPEED RADIATOR FAN CONTROL CIRCUIT SHORTED TO GROUND
LOW SPEED RADIATOR FAN CONTROL CIRCUIT OPEN

With the DRB, actuate the Low Speed Radiator Fan Relay.
Does the Radiator Fan cycle on and off?
Yes → Go To 2
No → Go To 3


92
P0480-FAN 1 CONTROL CIRCUIT OPEN CIRCUIT — Continued

Disconnect the Radiator Fan Relay No. 1 harness connector.
circuit.
Did the test light illuminate brightly?
Yes → Go To 4


Install a substitute relay in place of the Radiator Fan Relay No. 1.
With the DRB, actuate the Low Speed Fan Relay.
Do the Radiator Fans cycle on and off?
Yes → Replace Radiator Fan Relay No. 1.
No → Go To 5

Measure the resistance between ground and the Low Speed Radiator Fan Control
circuit.
Is the resistance below 100k ohms?
Yes → Repair the Low Speed Radiator Fan Control circuit for a short to
ground.
No → Go To 6

Measure the resistance of the Low Speed Radiator Fan Control circuit.
Yes → Go To 7
No → Repair the Low Speed Radiator Fan Control circuit for an open.
Repair
93
Symptom:
P0480-FAN 1 CONTROL CIRCUIT SHORT CIRCUIT

Set Condition: The ECM detects a short to voltage on the Radiator Fan Relay No. 1
Control circuit.
POSSIBLE CAUSES
LOW SPEED RADIATOR FAN CONTROL CIRCUIT SHORTED TO VOLTAGE

Yes → Go To 2
No → Go To 3


94
P0480-FAN 1 CONTROL CIRCUIT SHORT CIRCUIT — Continued

Install a substitute relay in place of the Radiator Fan Relay No. 1.
Do the Radiator Fans cycle on and off?
No → Go To 4

connector.
Measure the voltage of the Low Speed Radiator Fan Control circuit.
Yes → Go To 5
No → Repair the Low Speed Radiator Fan Control circuit for a short to
voltage.

Repair
95
Symptom:

Set Condition: The ECM detects an open or short to ground on the Radiator Fan Relay
No. 2 Control circuit.
POSSIBLE CAUSES
RADIATOR FAN RELAY NO. 2 OR 3
HIGH SPEED RADIATOR FAN CONTROL CIRCUIT SHORTED TO GROUND
HIGH SPEED RADIATOR FAN CONTROL CIRCUIT OPEN

With the DRB, actuate the High Speed Radiator Fan Relay.
Yes → Go To 2
No → Go To 3


96
P0481-FAN 2 CONTROL CIRCUIT OPEN CIRCUIT — Continued

circuit.
Yes → Go To 4


One at a time, install a substitute relay in place of Radiator Fan Relays No. 2 and No.
3.
With the DRB, actuate the High Speed Fan Relay.
Does one Radiator Fan cycle on and off?
Yes → Replace the Radiator Fan Relay that the substitute relay caused
the radiator fan to cycle on and off.
No → Go To 5

Disconnect the Radiator Fan Relays No. 2 and No. 3 harness connectors.
Measure the resistance between ground and the High Speed Radiator Fan Control
circuit.
Yes → Go To 6
No → Repair the High Speed Radiator Fan Control circuit for a short to
ground.

Measure the resistance of the High Speed Radiator Fan Control circuit.
Yes → Go To 7
No → Repair the High Speed Radiator Fan Control circuit for an open.
Repair
97
Symptom:

Set Condition: The ECM detects a short to voltage on the Radiator Fan Relay No. 2
Control circuit.
POSSIBLE CAUSES
RADIATOR FAN RELAY NO. 1 OR 3
HIGH SPEED RADIATOR FAN CONTROL CIRCUIT SHORTED TO VOLTAGE

Yes → Go To 2
No → Go To 3


98
P0481-FAN 2 CONTROL CIRCUIT SHORT CIRCUIT — Continued

One at a time, install a substitute relay in place of Radiator Fan Relays No. 2 and
then No. 3.
Does one Radiator Fan cycle on and off?
Yes → Replace the Radiator Fan Relay that the substitute relay caused
the radiator fan to cycle on and off.
No → Go To 4

Disconnect Radiator Fan Relays No. 2 and 3 harness connectors.
connector.
Measure the voltage of the High Speed Radiator Fan Control circuit.
Yes → Go To 5
No → Repair the High Speed Radiator Fan Control circuit for a short to
voltage.
Repair
99
Symptom List:
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH
P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH
The title for the tests will be P0500-VEHICLE SPEED SEN-
SOR FREQUENCY TOO HIGH.
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH

Set Condition: The ECM detects a vehicle speed greater than the vehicle is capable.
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY

When Monitored: With the engine under load and engine speed greater than 2400 RPM
while vehicle speed is below 20 km/h (12 MPH).
Set Condition: The ECM compares the amount of fuel the fuel injectors are delivering to
the vehicle speed from the VSS. The VSS indicates a vehicle speed that cannot be achieved
with the present amount of fuel being delivered.
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH

Set Condition: The ECM detects a vehicle speed greater than 240 km/h (149 MPH).
POSSIBLE CAUSES
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
SPEEDOMETER PINION AND DRIVE TEETH DAMAGED
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE CONTROL MODULE - SHORTED TO VOLTAGE
VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN
VEHICLE SPEED SENSOR
ENGINE CONTROL MODULE - INTERNAL FAULT
100
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH — Continued

With the DRB, read Vehicle Speed.
Does the DRB display an accurate Vehicle Speed??
Yes → Go To 2
No → Go To 3


Remove the Vehicle Speed Sensor.
Inspect the Speedometer Pinion and drive teeth on the Output Shaft (located in the
transmission).
Inspect the VSS for metal debris and damage to the Sensor and connector.
Are both components OK?
Yes → Go To 4
No → Repair or replace the Speedometer Pinion or internal components

as necessary in accordance with the Service Information.

Disconnect the Vehicle Speed Sensor harness connector.
Measure the voltage of the Ignition Switch Output circuit in the Vehicle Speed Sensor
harness connector.
Yes → Go To 5
101

Measure the voltage of the Vehicle Speed Sensor Signal circuit.
Yes → Go To 6
No → Go To 8

connector.
Yes → Go To 7
No → Repair the Vehicle Speed Sensor Signal circuit for a short to

voltage.

Repair

Measure the resistance between ground and the Vehicle Speed Sensor Signal circuit.
Yes → Go To 9

ground.

Measure the resistance of the Vehicle Speed Sensor Signal circuit.
Yes → Go To 10
No → Repair the Vehicle Speed Sensor Signal circuit for an open.
102

Measure the resistance of the Vehicle Speed Sensor Ground circuit.
Yes → Go To 11
No → Repair the Vehicle Speed Sensor Ground circuit for an open.


NOTE: Ensure the ECM harness connectors are connected before continu-
ing.
Connect a jumper wire to the Vehicle Speed Sensor Signal circuit in the VSS harness
connector.
With the DRB, monitor the VEHICLE SPEED while tapping the other end of the
jumper wire to ground.
Does the DRB display km/h (MPH) greater than 0?
Yes → Replace the Vehicle Speed Sensor.

No → Go To 12

Measure the resistance between the Vehicle Speed Sensor Signal circuit and the
Yes → Go To 13
No → Repair the Vehicle Speed Sensor Signal circuit for a short to the

Repair
103
Symptom:
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO
HIGH
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH

Set Condition: The ECM detects Battery Temperature Sensor Signal voltage above 4.72
volts.
POSSIBLE CAUSES
BATTERY TEMPERATURE SENSOR GROUND CIRCUIT OPEN
BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
BATTERY TEMPERATURE SENSOR
BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN

With the DRB, monitor the Battery Temperature Sensor voltage.
Yes → Go To 2
No → Go To 6

Disconnect the Battery Temperature Sensor harness connector.
Measure the voltage on the Battery Temperature Sensor Signal circuit.
Yes → Repair the Battery Temperature Sensor Signal circuit for a short
to voltage.
No → Go To 3
104

— Continued
Connect a jumper wire between the Battery Temperature Sensor harness connector
cavities.
With the DRB, read the Battery Temperature Sensor voltage.
Yes → Replace the Battery Temperature Sensor in accordance with the

No → Go To 4

Connect a jumper wire between ground and the Battery Temperature Sensor Signal
circuit.
With the DRB, read the Battery Temperature Sensor voltage.
Yes → Repair the Sensor Ground circuit for an open.

No → Go To 5

Measure the resistance of the Battery Temperature Sensor Signal circuit.
No → Repair the Battery Temperature Sensor Signal circuit for an

open.
105

— Continued

106
Symptom:
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY

When Monitored: At engine start-up.
Set Condition: The oil pressure signal is below the lower limit for four seconds after
engine start-up.
POSSIBLE CAUSES
ECM - OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ECM - OIL PRESSURE SENSOR SIGNAL SHORT TO GROUND
INCORRECT OIL PRESSURE
OIL PRESSURE SENSOR FAILURE
OIL PRESSURE SENSOR SIGNAL CIRCUIT OPEN
OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

1 NOTE: If DTC P0641 or P0651 is present with this DTC, diagnose these All
DTC’s before diagnosing this DTC.
seconds at a time.
Did this DTC reset?
Yes → Go To 2
No → Go To 10
2 Refer to the Service Information and perform the Oil Pressure Test. All
Is the oil pressure within specification?
Yes → Go To 3
107
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY — Continued

Disconnect the Oil Pressure Sensor harness connector.
Measure the voltage of the Oil Pressure Sensor Signal circuit.
Select the appropriate voltage reading.
Voltage is above 5.5 volts.
Go To 4
Voltage is between 4.7 and 5.4 volts.

Go To 5
Voltage is below 4.7 volts.
Go To 7

connector.
Measure the voltage of the Oil Pressure Sensor Signal circuit.
No → Repair the Oil Pressure Sensor Signal circuit for a short to

voltage.

Measure the resistance of the 5_Volt Supply circuit between the ECM harness
connector and the Oil Pressure Sensor harness connector.
Yes → Go To 6
No → Repair the 5-Volt Supply circuit for an open.


Yes → Replace the Oil Pressure Sensor.


108
P0520- OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY — Continued

Measure the resistance of the Oil Pressure Sensor Signal circuit.
Yes → Go To 8
No → Repair the Oil Pressure Sensor Signal circuit for an open.


Measure the resistance between ground and the Oil Pressure Sensor Signal circuit.
Yes → Go To 9
No → Repair the Oil Pressure Sensor Signal circuit for a short to
ground.

Measure the resistance between Sensor Ground and the Oil Pressure Sensor Signal
circuit.

No → Repair the Oil Pressure Sensor Signal circuit for a short to the


109
Symptom:
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO
HIGH OR LOW
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW
Set Condition: The Sensor Reference Voltage 9A9 voltage to the Oil Pressure Sensor is
POSSIBLE CAUSES

Turn the ignition off, wait 30 seconds, then start and idle the engine.
Did this DTC reset?
Yes → Go To 2
No → Go To 5

connector.
Measure the voltage between ground and the 5-volt Supply circuit at the Oil Pressure

No → Go To 3
110
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR

LOW — Continued
Measure the resistance between ground and the 5-volt Supply circuit at the Oil
Pressure Sensor harness connector.
Yes → Go To 4
No → Repair the 5-volt Supply circuit for a short to ground.


Measure the resistance between Sensor Ground and the 5-volt Supply circuit at the
Oil Pressure Sensor harness connector.
No → Repair the 5-volt Supply circuit for a short to Sensor Ground.


111
Symptom List:
P0530-A/C PRESSURE SENSOR CIRCUIT PLAUSIBILITY
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO
HIGH
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO
LOW
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO
HIGH OR LOW
The title for the tests will be P0530-A/C PRESSURE SENSOR
CIRCUIT PLAUSIBILITY.
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH

Set Condition: The A/C Pressure Sensor Signal voltage is above 4.84 volts.
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW

Set Condition: The A/C Pressure Sensor Signal voltage is below 0.1 volt.
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR

LOW
Set Condition: The Sensor Reference Voltage 9B9 voltage to the A/C Pressure Sensor is
POSSIBLE CAUSES
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO 5 VOLT SUPPLY CIRCUIT
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
A/C PRESSURE SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
A/C PRESSURE SENSOR
A/C PRESSURE SENSOR SIGNAL CIRCUIT OPEN
A/C PRESSURE SENSOR
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
112
P0530-A/C PRESSURE SENSOR CIRCUIT PLAUSIBILITY — Continued
POSSIBLE CAUSES
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT
ECM - A/C PRESSURE SENSOR SIGNAL
ECM - SIGNAL VOLTAGE HIGH

NOTE: Ensure the A/C refrigerant System is properly charged per the
Start the engine.
With the DRBIIIt, read the A/C Pressure Sensor voltage.
Select the choice that best reflects the DRBIIIt reading.
Above 4.6 volts

Go To 2
Between 0.7 and 4.6 volts
Go To 9
Below 0.7 volt

Go To 10

Disconnect the A/C Pressure Sensor harness connector.
Disconnect the ECM harness connector.
Measure the resistance between the A/C Pressure Sensor Signal circuit and the 5-volt
Supply circuit in the A/C Pressure Sensor harness connector.
Yes → Go To 3
No → Repair the A/C Pressure Sensor Signal circuit for a short to the
5-volt Supply circuit.

connector.
Measure the voltage of the Sensor Ground circuit at the A/C Pressure Sensor and
ECM harness connectors.
Yes → Repair the A/C Pressure Sensor Ground circuit for a short to
voltage.
No → Go To 4
may have been damaged. Retest the A/C Pressure Sensor circuit.
113

Measure the voltage of the A/C Pressure Sensor Signal circuit in the A/C Pressure
Yes → Repair the A/C Pressure Sensor Signal circuit for a short to
voltage.
No → Go To 5

Connect a jumper wire between the A/C Pressure Sensor Signal circuit and the
With the DRBIIIt, monitor the A/C Pressure Sensor voltage.
Yes → Replace the A/C Pressure Sensor.

No → Go To 6

Measure the resistance of the A/C Pressure Sensor Signal circuit.
Yes → Go To 7
No → Repair the A/C Pressure Sensor Signal circuit for an open.

Measure the resistance between ground and the Sensor Ground circuit.
Yes → Go To 8
Repair
114



Measure the voltage of the Sensor Reference Voltage 9B9 circuit in the A/C Pressure
Yes → Go To 11
No → Go To 15

With the DRBIIIt, monitor the A/C Pressure Sensor voltage.
Yes → Replace the A/C Pressure Sensor.

No → Go To 12

Measure the resistance between ground and the A/C Pressure Sensor Signal circuit.
Yes → Go To 13
No → Repair the A/C Pressure Sensor Signal circuit for a short to

ground.
115

Measure the resistance between the A/C Pressure Sensor Signal circuit and the
Yes → Go To 14
No → Repair the A/C Pressure Sensor Signal circuit for a short to the
Repair

Yes → Go To 16
Repair
116
Symptom:
P0560-SYSTEM VOLTAGE TOO HIGH
P0560-SYSTEM VOLTAGE TOO HIGH

Set Condition: The ECM detects battery voltage is above 17.5 volts.
POSSIBLE CAUSES
ECM - TARGET CHARGING VOLTAGE TOO LOW
GENERATOR FIELD DRIVER CIRCUIT SHORTED TO GROUND
GROUND CIRCUIT HIGH RESISTANCE
BATTERY SUPPLY CIRCUIT HIGH RESISTANCE
GENERATOR INTERNALLY SHORTED TO GROUND
ECM - FIELD DRIVER SHORTED TO GROUND

1 NOTE: The battery must be fully charged and the generator belt must be in All
good condition and tensioned properly before continuing.
With the DRB, actuate the Generator Field.
Measure the voltage between ground and the Generator Field Driver circuit by back
probing the Generator Field harness connector with a voltmeter.
Does the voltage cycle from B+ to below 2.0 volts?
Yes → Go To 2
No → Go To 6
NOTE: With the DRB, stop the Generator Field actuation.
2 Start the engine. All

With the DRB, read the Target Charging voltage.
Is the Target Charging voltage above 13.0 volts?
Yes → Go To 3

Perform CHARGING VERIFICATION - VER-3.
117
P0560-SYSTEM VOLTAGE TOO HIGH — Continued

Using a 12-volt test light connected to 12-volts, check all of the ECM Ground circuits.
Does the test light illuminate brightly for each circuit?
Yes → Go To 4
No → Repair the Ground circuit(s) for high resistance.


Using a 12-volt test light connected to ground, check all of the ECM Battery Supply
circuits.
Does the test light illuminate brightly for each circuit?
Yes → Go To 5
No → Repair the Battery Supply circuit(s) for high resistance.



Disconnect ECM harness connectors.
Disconnect the Generator Field harness connector.
Measure the resistance between ground and the Generator Field Driver circuit.
Yes → Go To 7
No → Repair the Generator Field Driver circuit for a short to ground.

118
P0560-SYSTEM VOLTAGE TOO HIGH — Continued

Measure the resistance between ground and the Generator Field Driver terminal on
the back of the Generator.
Yes → Go To 8
No → Repair or replace the Generator as necessary.

Repair
119
Symptom List:
P0560-SYSTEM VOLTAGE TOO LOW
*CHECKING THE CHARGING SYSTEM OPERATION - DIESEL
The title for the tests will be P0560-SYSTEM VOLTAGE TOO
LOW.
P0560-SYSTEM VOLTAGE TOO LOW

Set Condition: The ECM detects the system voltage at least 0.5 volt below the target
charging voltage for at least 3 seconds.
POSSIBLE CAUSES
CHECK FOR CYCLING VOLTAGE ON THE GENERATOR FIELD DRIVER CIRCUIT
GENERATOR BELT CONDITION OR TENSION
HIGH RESISTANCE IN THE FUEL HEATER RELAY OUTPUT CIRCUIT TO THE ECM
GENERATOR FIELD DRIVER CIRCUIT SHORTED TO VOLTAGE
GENERATOR FUSED B+ CIRCUIT HIGH RESISTANCE
GENERATOR GROUND CIRCUIT HIGH RESISTANCE
GENERATOR FIELD DRIVER CIRCUIT OPEN

1 NOTE: If there are any Battery Sense DTCs (P1511 or P1512) present with All
this DTC, diagnose the Battery Sense DTCs first.
NOTE: Inspect the vehicle for aftermarket accessories that may exceed the
Generator capacity.
NOTE: The battery must be fully charged before continuing.
Inspect the generator belt condition and tension.
Is the generator belt in good condition and tensioned properly?
Yes → Go To 2
120
P0560-SYSTEM VOLTAGE TOO LOW — Continued

With the DRB, actuate the Generator Field.
Measure the voltage between ground and the Generator Field Driver circuit by back
probing the Generator Field harness connector with a voltmeter.
NOTE: The voltage should cycle from Battery voltage to below 2.0 volts
every 1.4 seconds.
While monitoring the voltmeter, wiggle the generator field harness and connectors
between the generator, ECM and the ECM/PCM Relay (in the PDC).
Was there any interruption of the normal voltage cycling?
Yes → Repair the harness as necessary where the wiggling caused the
interruption.
No → Go To 3
NOTE: With the DRB, stop the Generator Field actuation.
3 Connect the positive lead of a voltmeter to the generator B+ (12V) terminal and the All
negative lead to the battery positive (+) post.
Start the engine.
Is the voltage on the voltmeter below 0.4 volt?
Yes → Go To 4
No → Repair the Generator Fused B+ circuit for high resistance.
4 Connect the positive lead of a voltmeter to the generator case (housing) and the All
negative lead to the battery negative (-) post.
Start the engine.
Is the voltage on the voltmeter below 0.4 volt?
Yes → Go To 5
No → Repair the Generator Ground circuit for high resistance.

5 Turn the ignition off, then on. All

With the DRB, read and record the Battery Voltage.
With a voltmeter, measure and record the voltage between the Battery terminals.
Compare the DRB Battery Voltage reading to the voltmeter reading.
Is the difference between the two readings less than 0.5 volt?
Yes → Go To 6
No → Go To 7
121



With a voltmeter, measure and record the voltage between the Battery terminals.
Measure the voltage of the Fuel Heater Relay Output circuit in the ECM C1 harness
connector.
Are the voltage measurements within 0.5 volt of each other?
Yes → Go To 8
No → Repair the Fuel Heater Relay Output circuit to the Engine
Control Module for high resistance.

connector.
Measure the voltage of the Generator Field Driver circuit.
Yes → Go To 9
No → Repair the Generator Field Driver circuit for a short to voltage.

122

connector.
Measure the voltage of the ECM/PCM Relay Output circuit in ECM harness
connector C1, cavities 4 and 5.
Yes → Go To 10

Measure the resistance of the Generator Field Driver circuit.
Yes → Go To 11
No → Repair the Generator Field Driver circuit for an open.

Repair
123
Symptom:
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT

Set Condition: The ECM detects a short to voltage on the Starter Relay Control circuit.
POSSIBLE CAUSES
SUBSTITUTE ECM/PCM RELAY
STARTER RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE

Attempt to start the engine several times, pausing for at least 10 seconds between
each cycle.
Did this DTC reset?
Yes → Go To 2
No → Go To 4

Install a substitute relay in place of the Starter Relay.
Attempt to start the engine several times, pausing for at least 10 seconds between
each cycle.
Did this DTC reset?
Yes → Go To 3
No → Replace the Starter Relay.


Remove the Starter Relay from the IPM.
Measure the voltage of the Starter Relay Output circuit.

No → Repair the Starter Relay Output circuit for a short to voltage.

124
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT — Continued


125
Symptom List:
DEVIATION TOO HIGH
DEVIATION TOO LOW
TOO HIGH
TOO LOW
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS
TOO LOW
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT
P0620-GENERATOR FIELD CONTROL MALF UNSTABLE CUR-
RENT
The title for the tests will be P0620-GENERATOR FIELD
CONTROL MALF BATTERY VOLTAGE DEVIATION TOO
HIGH.
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH

Set Condition: The ECM senses battery voltage above 16.5 volts.
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW

Set Condition: The ECM senses battery voltage that is 1 or greater below target voltage.
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT

Set Condition: The ECM detects an open or short to ground on the Generator Field
Control circuit.
126
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI-

ATION TOO HIGH — Continued
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT
Set Condition: The ECM detects a short to voltage on the Generator Field Control circuit.
POSSIBLE CAUSES
GENERATOR FIELD
GENERATOR FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE
GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND
GENERATOR FIELD CONTROL CIRCUIT OPEN

Perform several ignition cycles, turning the ignition off for at least 10 seconds
between each ignition cycle.
Did this DTC reset?
Yes → Go To 2
No → Go To 7

Measure the resistance of the Field Control terminals on the back of the Generator.
Is the resistance between 2 and 6 ohms?
Yes → Go To 3
No → Repair or replace the Generator as necessary.


connector.
Measure the voltage of the Generator Field Control circuit.
Yes → Go To 4
No → Repair the Generator Field Control circuit for a short to voltage.
127
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI-

ATION TOO HIGH — Continued
Disconnect ECM harness connectors.
Measure the resistance between ground and the Generator Field Control circuit.
Yes → Go To 5
No → Repair the Generator Field Control circuit for a short to ground.


Measure the resistance of the Generator Field Control circuit.
Yes → Go To 6
No → Repair the Generator Field Control circuit for an open.

Repair


128
Symptom:
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN CIR-
CUIT
POSSIBLE CAUSES
IGNITION SWITCH (RUN/START) CIRCUIT OPEN
FUEL LIFT PUMP RELAY
FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORTED TO GROUND
FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN

With the DRB, actuate the Fuel Lift Pump Relay.
Does the Fuel Lift Pump Relay cycle on and off?
Yes → Go To 2
No → Go To 3



Remove the Fuel Lift Pump Relay from the IPM.
Using a 12-volt test light connected to ground, check the Ignition Switch (RUN/
START) circuit.
Yes → Go To 4
No → Repair the Ignition Switch (RUN/START) circuit for an open.
129
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT OPEN CIRCUIT —

Continued
Install a substitute relay in place of the Fuel Lift Pump Relay.
Yes → Replace the Fuel Lift Pump Relay.
No → Go To 5

Measure the resistance between ground and the Fuel Lift Pump Relay Control
circuit.
Yes → Go To 6
No → Repair the Fuel Lift Pump Relay Control circuit for a short to
ground.

Measure the resistance of the Fuel Lift Pump Relay Control circuit.
Yes → Go To 7
No → Repair the Fuel Lift Pump Relay Control circuit for an open.

Repair
130
Symptom:
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORT CIR-
CUIT
POSSIBLE CAUSES
FUEL LIFT PUMP RELAY
FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE

Yes → Go To 2
No → Go To 3



Install a substitute relay in place of the Fuel Lift Pump Relay.
Yes → Replace the Fuel Lift Pump Relay.
No → Go To 4
131
P0627-FUEL LIFT PUMP RELAY CONTROL CIRCUIT SHORT CIRCUIT —

Continued
connector.
Measure the voltage of the Fuel Lift Pump Relay Control circuit.
Yes → Go To 5
No → Repair the Fuel Lift Pump Relay Control circuit for a short to
voltage.
Repair
132
Symptom List:
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO
HIGH
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO
HIGH
The title for the tests will be P0641-SENSOR REFERENCE
VOLTAGE A CKT VOLTAGE TOO HIGH.
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH

Set Condition: The ECM detects a short to voltage on the Sensor Reference Voltage A
circuit.
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH

Set Condition: The ECM detects a short to voltage on the Sensor Reference Voltage B
circuit.
POSSIBLE CAUSES
SENSOR REFERENCE VOLTAGE A OR 5-VOLT CIRCUIT SHORTED TO VOLTAGE
SENSOR REFERENCE VOLTAGE B OR 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE

Did this DTC reset?
Yes → Go To 2
No → Go To 7
133
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH —

Continued
connector.
Measure the voltage on the Sensor Reference Voltage A and MAF 5-Volt Supply
circuits.
Is the voltage above 1.0 volt on either circuit?
Yes → Repair the Sensor Reference Voltage A or MAF 5-Volt Supply
circuit that measured above 1.0 volt for a short to voltage.
No → Go To 3
NOTE: Remove the jumper wire and reinstall the ECM/PCM Relay.

Disconnect the Boost Pressure Sensor harness connector.
Disconnect the Engine Oil Pressure Sensor harness connector.
connector.
Measure the voltage on the Sensor Reference Voltage B, Boost Pressure Sensor 5-Volt
Supply, A/C Pressure Sensor 5-Volt Supply and Engine Oil Pressure Sensor 5-Volt
Supply circuits.
Is the voltage above 1.0 volt on any of the circuits?
Yes → Repair the Sensor Reference Voltage B or the 5-Volt Supply circuit
that measured above 1.0 volt for a short to voltage.
No → Go To 4

connector.
Measure the voltage on the Fuel Pressure Sensor 5-Volt Supply circuit.
Yes → Go To 5
No → Repair the Fuel Pressure Sensor 5-Volt Supply circuit for a short
to voltage.
134
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH —

Continued
Disconnect the Accelerator Pedal Position Sensor harness connector.
connector.
Measure the voltage on the Accelerator Pedal Position Sensor 5-Volt Supply circuit.
Yes → Go To 6
No → Repair the Accelerator Pedal Position Sensor 5-Volt Supply circuit
for a short to voltage.

Repair


135
Symptom List:
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW
The title for the tests will be P0641-SENSOR REFERENCE
VOLTAGE A CKT VOLTAGE TOO LOW.
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW

Set Condition: The ECM detects an open or short to ground on the Sensor Reference
Voltage A circuit.
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW

Set Condition: The ECM detects an open or short to ground on the Sensor Reference
Voltage B circuit.
POSSIBLE CAUSES
MAF, OIL PRESS, BOOST PRESS, A/C PRESS, APP OR FUEL PRESS SENSOR SHORT TO
GROUND
SENSOR REFERENCE VOLTAGE OR 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
SENSOR REFERENCE VOLTAGE OR 5-VOLT SUPPLY CIRCUIT SHORTED TO SENSOR
GROUND

Did this DTC reset?
Yes → Go To 2
No → Go To 8
136
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW —

Continued
With the DRBIIIt in Sensors, monitor the MAF, Oil Pressure, Boost Pressure, A/C
Pressure, APP and Fuel Pressure Sensors.
NOTE: If any sensor reading is above zero before disconnecting, it is not
necessary to disconnect it for this test.
One at a time while monitoring the DRB sensor readings, disconnect the MAF, Oil
Pressure, Boost Pressure, A/C Pressure, APP and Fuel Pressure Sensor harness
connectors.
NOTE: If one of the sensors is shorted to ground internally, disconnecting it
will cause the voltage reading on the DRB to rise for all sensors.
Did the DRB sensor voltage readings rise?
Yes → Replace the Sensor that, when disconnected, caused the DRB
sensor readings to rise.
No → Go To 3

Measure the resistance between ground and the Sensor Reference Voltage A circuit,
then ground and the MAF Sensor 5-Volt Supply circuit.
Disconnect the Boost Pressure Sensor, Engine Oil Pressure Sensor, and A/C Pressure
Sensor harness connectors.
Measure the resistance between ground and the Sensor Reference Voltage B circuit,
then ground and the 5-Volt Supply circuits to the Boost Pressure Sensor, A/C
Pressure Sensor and Engine Oil Pressure Sensor.
Is the resistance above 100k ohms for all of the measurements?
Yes → Go To 4
No → Repair the Sensor Reference Voltage or 5-Volt Supply circuit that
measured less than 100k ohms for a short to ground.

Measure the resistance between the Sensor Reference Voltage A circuit and the MAF
Disconnect the Boost Pressure Sensor, Engine Oil Pressure Sensor, and A/C Pressure
Sensor harness connectors.
Measure the resistance between the Sensor Reference Voltage B circuit and the Boost
Pressure Sensor Ground circuit, then the A/C Pressure Sensor Ground circuit, and
finally the Engine Oil Pressure Sensor Ground circuit.
Is the resistance above 100k ohms for all measurements?
Yes → Go To 5
No → Repair the Sensor Reference Voltage or 5-Volt Supply circuit that
measured less than 100k ohms for a short to the Sensor Ground
circuit.
137
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW —

Continued
Measure the resistance between ground and the Fuel Pressure Sensor 5-Volt Supply
circuit.
Measure the resistance between ground and the Accelerator Pedal Position Sensor
5-Volt Supply circuit.
Is the resistance above 100k ohms for each measurement?
Yes → Go To 6
No → Repair the 5-Volt Supply circuit(s) that measured less than 100k
ohms for a short to ground.

Measure the resistance between the Fuel Pressure Sensor 5-Volt Supply circuit and
the Sensor Ground circuit.
Measure the resistance between the Accelerator Pedal Position Sensor 5-Volt Supply
circuit and the Sensor Ground circuit.
Is the resistance above 100k ohms for each measurement?
Yes → Go To 7
No → Repair the 5-Volt Supply circuit(s) that measured less than 100k
ohms for a short to the Sensor Ground circuit.
Repair


138
Symptom:
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT

Set Condition: The ECM detects an open or short to ground on the A/C Clutch Relay
Control circuit.
POSSIBLE CAUSES
A/C CLUTCH RELAY CONTROL CIRCUIT SHORT TO GROUND
A/C CLUTCH RELAY INTERMITTENT OPERATION
A/C CLUTCH RELAY
IPM FUSE & RELAY CENTER
A/C CLUTCH RELAY CONTROL CKT OPEN
ECM

With the DRBIIIt, actuate the A/C Clutch Relay.
Is the A/C Clutch Relay operating?
Yes → Go To 2
No → Go To 4

Wiggle the wiring harness from the A/C Clutch Relay to the ECM while the relay is
actuating.
Did the A/C Clutch Relay stop when wiggling the wiring harness?

No → Go To 3
139
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT — Continued

3 WARNING: KEEP CLEAR OF THE ENGINE’S MOVING PARTS. All
Review the DRB Freeze Frame information. If possible, try to duplicate the

Remove the A/C Clutch Relay from the IPM.
circuit in the IPM.
Yes → Go To 5
No → Go To 10

Using a 12-volt test light connected to 12-volts, probe the A/C Clutch Relay Control
circuit in the IPM.
Does the test light cycle on and off?
Yes → Replace the A/C Clutch Relay.

No → Go To 6

Disconnect the Intelligent Power Module C3 harness connector.
circuit in the IPM harness connector.
Yes → Replace the IPM Fused & Relay Center.

No → Go To 7
140
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT — Continued

Measure the resistance of the A/C Clutch Relay Control circuit between the
Intelligent Power Module C3 harness connector and the ECM harness connector.
Is the resistance below 5.0 ohms.
Yes → Go To 8
No → Repair the A/C Clutch Relay Control circuit for an open.


Measure the resistance of the A/C Clutch Relay Control circuit in the Intelligent
Power Module C3 harness connector to ground.
Is the resistance below 5.0 ohms.
Yes → Repair the A/C Clutch Relay Control circuit for a short to ground.
No → Go To 9

Repair

Yes → Replace the IPM Fuse & Relay Center.

141
Symptom:
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT

Set Condition: The ECM detects a short to voltage on the A/C Clutch Relay Control
circuit.
POSSIBLE CAUSES
A/C CLUTCH RELAY INTERMITTENT OPERATION
A/C CLUTCH RELAY
IPM FUSE & RELAY CENTER
A/C CLUTCH RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
ECM

Is the A/C Clutch Relay operating?
Yes → Go To 2
No → Go To 4

Wiggle the wiring harness from the A/C Clutch Relay to the ECM while the relay is
actuating.
Did the A/C Clutch Relay stop when wiggling the wiring harness?

No → Go To 3
142
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT — Continued

3 WARNING: KEEP CLEAR OF THE ENGINE’S MOVING PARTS. All
Review the DRB Freeze Frame information. If possible, try to duplicate the

circuit in the IPM.
Yes → Go To 5
No → Go To 9

circuit in the IPM.
Does the test light cycle on and off?

No → Go To 6

Yes → Replace the IPM Fused & Relay Center.

No → Go To 7
143
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT — Continued

connector.
Measure the voltage of the A/C Clutch Relay Control circuit.
Yes → Repair the A/C Clutch Relay Control circuit for a short to voltage.
No → Go To 8
Repair

Yes → Replace the IPM Fuse & Relay Center.


144
Symptom:
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO
EARLY
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY

When Monitored: During after-run.
Set Condition: The internal ECM timer determines that the ECM/PCM Relay has shut
off before the AFTER-RUN mode of operation has been completed.
POSSIBLE CAUSES
ECM/PCM RELAY CONTROL CIRCUIT OPEN INTERMITTENTLY

With the DRB, check for additional DTCs.
Are other DTCs present?
Yes → Refer to the Symptom List for diagnosis of the other DTCs before
continuing.
No → Go To 2

cycle.
Did this DTC reset?
Yes → Go To 3
No → Go To 5
145
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY —

Continued
Install a substitute relay in place of the ECM/PCM Relay.
cycle.
Did this DTC reset?
Yes → Go To 4
No → Replace the ECM/PCM Relay.


Measure the resistance of the ECM/PCM Relay Control circuit while wiggling the
wiring harness and connectors between the ECM and the IPM.
Was the resistance above 5.0 ohms at any time while wiggling the wiring harness and
connectors?
Yes → Repair the ECM/PCM Relay Control circuit for an intermittent

open.

146
Symptom:
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO
LATE
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE

When Monitored: During after-run.
Set Condition: The internal ECM timer determines that the ECM/PCM Relay remains on
too long when AFTER-RUN mode of operation has been completed.
POSSIBLE CAUSES
ECM/PCM RELAY CONTROL CIRCUIT SHORTED TO GROUND INTERMITTENTLY
ECM/PCM RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE

With the DRB, check for additional DTCs.
Are other DTCs present?
Yes → Refer to the Symptom List for diagnosis of the other DTCs before
continuing.
No → Go To 2

cycle.
Did this DTC reset?
Yes → Go To 3
No → Go To 6
147
P0685-ECM/PCM RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE —

Continued
Install a substitute relay in place of the ECM/PCM Relay.
cycle.
Did this DTC reset?
Yes → Go To 4
No → Replace the ECM/PCM Relay.


Measure the resistance between ground and the ECM/PCM Relay Control circuit
while wiggling the wiring harness and connectors.
Was the resistance below 5.0 ohms at any time while wiggling the wiring harness and
connectors?
Yes → Repair the ECM/PCM Relay Control circuit for an intermittent

short to ground.
No → Go To 5

Measure the voltage of the ECM/PCM Relay Output circuit.
No → Repair the ECM/PCM Relay Output circuit for a short to voltage.



148
Symptom List:
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH
REDUNDANT CONTACT
P0703-BRAKE SWITCH SIGNAL CKTS PLAUS W/REDUNDANT
CONTACT AFTER INITIALIZATION
The title for the tests will be P0703-BRAKE SWITCH SIGNAL
CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT.
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT

CONTACT
Set Condition: The ECM detects the Primary Brake Switch Signal circuit and Secondary
Brake Switch Signal circuit inputs to the ECM do not agree. NOTE: An out of adjustment
brake lamp switch may also cause a reduction in engine power.
P0703-BRAKE SWITCH SIGNAL CKTS PLAUS W/REDUNDANT CONTACT AF-

TER INITIALIZATION
Set Condition: The ECM detects the Primary Brake Switch Signal circuit and Secondary
Brake Switch Signal circuit inputs to the ECM do not agree. NOTE: An out of adjustment
brake lamp switch may also cause a reduction in engine power.
POSSIBLE CAUSES
BRAKE LAMP SWITCH - SECONDARY OPEN
BRAKE LAMP SWITCH FUSED B+ CIRCUIT OPEN
SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND
BRAKE LAMP SWITCH - PRIMARY OPEN
SECONDARY BRAKE SWITCH GROUND CIRCUIT OPEN
SECONDARY BRAKE SWITCH SIGNAL CIRCUIT OPEN
PRIMARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE
PRIMARY BRAKE SWITCH SIGNAL CIRCUIT OPEN
ENGINE CONTROL MODULE - INTERNAL
ENGINE CONTROL MODULE - PRIMARY BRAKE SIGNAL
ENGINE CONTROL MODULE - SECONDARY BRAKE SIGNAL
149
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH RE-

DUNDANT CONTACT — Continued
While observing the PRIM BRAKE SWITCH status on the DRB display, press and
release the brake pedal several times.
Does the DRB display PRIM BRAKE SWITCH: PRESSED and RELEASED for the
appropriate pedal position?
Yes → Go To 2
No → Go To 11

While observing the SEC BRAKE SWITCH status on the DRB display, press and
release the brake pedal several times.
Does the DRB display SEC BRAKE SWITCH: PRESSED and RELEASED for the
appropriate pedal position?
Yes → Go To 3
No → Go To 4


Measure the voltage between the Secondary Brake Switch Signal circuit and ground.
Yes → Go To 5
No → Go To 8
150

While monitoring the SEC BRAKE SWITCH status with the DRB, connect a jumper
wire between ground and the Secondary Brake Switch Signal circuit.
Does the DRB display change from PRESSED to RELEASED?
Yes → Adjust or replace the Brake Lamp Switch in accordance with the
No → Go To 6

Measure the resistance between ground and the Secondary Brake Switch Ground
circuit.
Yes → Go To 7
No → Repair the Secondary Brake Switch Ground circuit for an open.
Repair

Measure the resistance between ground and the Secondary Brake Switch Signal
circuit.
Yes → Go To 9
No → Repair the Secondary Brake Switch Signal circuit for a short to
ground.

Measure the resistance of the Secondary Brake Switch Signal circuit.
Yes → Go To 10
No → Repair the Secondary Brake Switch Signal circuit for an open.

Repair
151

Using a 12-volt test light connected to ground, check the Fused B+ circuit.
Yes → Go To 12
No → Repair the Brake Lamp Switch Fused B+ circuit for an open.


While monitoring the PRIM BRAKE SWITCH status with the DRB, connect a
jumper wire between the Primary Brake Switch Signal circuit and the Fused B(+)
circuit.
Does the DRB display change from RELEASED to PRESSED?
Yes → Adjust or replace the Brake Lamp Switch in accordance with the
No → Go To 13

Measure the voltage between the Primary Brake Switch Signal circuit and ground.
Yes → Repair the Primary Brake Switch Signal circuit for a short to
voltage.
No → Go To 14

Measure the resistance of the Primary Brake Switch Signal circuit.

No → Repair the Primary Brake Switch Signal circuit for an open.

152
Symptom:
P0833-CLUTCH PEDAL PLAUSIBILITY
POSSIBLE CAUSES
CLUTCH PEDAL SWITCH
CLUTCH PEDAL SWITCH SENSE CIRCUIT OPEN
CLUTCH PEDAL SWITCH SENSE CIRCUIT SHORTED TO GROUND
ECM

With the DRBIIIt in Inputs/Outputs, read the Clutch switch states while pressing
and releasing the Clutch Pedal several times.
Did the DRB indicate the correct clutch pedal state when pressing and releasing the
Clutch Pedal?
Yes → Go To 2
No → Go To 3


Disconnect the Clutch Pedal Switch harness connector.
With the DRBIIIt in Inputs/Outputs, read the Clutch Switch state while using a
jumper wire to connect the Clutch Pedal Switch Sense circuit to ground at the Clutch
Pedal Switch harness connector.
NOTE: Leave jumper connected to ground for 5 seconds then disconnect
jumper and note DRB reading for both conditions.
Does the DRB display RELEASED and PRESSED?
Yes → Replace the Clutch Pedal Switch.
No → Go To 4

Measure the resistance of the Clutch Pedal Switch Sense circuit.
Yes → Go To 5
No → Repair the Clutch Pedal Switch Sense circuit for an open.
153
P0833-CLUTCH PEDAL PLAUSIBILITY — Continued

Measure the resistance between ground and the Clutch Pedal Switch Sense circuit.
Yes → Repair the Clutch Pedal Switch Sense circuit for a short to
ground.

Information.
154
Symptom List:
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DE-
TECTED
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO
HIGH-SHUT OFF
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO
LOW
P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN
The title for the tests will be P1130-FUEL RAIL PRESSURE
MALFUNCTION LEAKAGE DETECTED.
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED

Set Condition: The ECM detects the desired flow of fuel at idle is greater than 5000
mm/sec.
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT

OFF
Set Condition: The fuel rail pressure sensor indicates fuel pressure above 21,000 PSI
with the engine off.
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW

Set Condition: The ECM determines that the fuel rail pressure is too low for a given
engine speed.
P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN

Set Condition: The ECM detects a higher rate of fuel pressure than the target pressure.
POSSIBLE CAUSES
CHECKING FOR OTHER DTC’S
CHECKING THE FUEL PRESSURE
FUEL INJECTOR CONTROL CIRCUIT SHORTED TO GROUND
FUEL SYSTEM LEAK
155
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED —

Continued
POSSIBLE CAUSES
INJECTOR COMMON DRIVER CIRCUIT OPEN

Are there any other DTC’s present?
Yes → Refer to symptom list for problems related to the DTC other than
P1130.
No → Go To 2

Test drive the vehicle under various load and speed conditions to attempt to duplicate
the fault.
Yes → Go To 3
No → Go To 7

Inspect the entire fuel system for leakage.
Is there any evidence of leakage?
Yes → Repair as necessary in accordance with the Service Information.
No → Go To 4

Disconnect all of the Fuel Injector harness connectors.
Measure the resistance between ground and each of the Fuel Injector Control
circuits.
Is the resistance below 1000 ohms for any of the measurements?
Yes → Repair the appropriate Fuel Injector Control circuit for a short to
ground.
No → Go To 5

Disconnect all of the Fuel Injector harness connectors.
Measure the resistance of the Common Injector Driver circuit between the ECM
harness connector and each Fuel Injector harness connector.
Yes → Go To 6
No → Repair the Injector Common Driver circuit for an open.
156
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED —

Continued
6 Refer to the appropriate Service Information and perform the Fuel Pressure Test. All
NOTE: The following is a list of problems that can cause the fuel pressure to
become out of specification: restricted fuel filter or fuel lines, failed fuel
pressure solenoid, air in fuel system, failed fuel sending unit, gelled fuel,
faulty injector.
Is the fuel pressure within specification?
Yes → Replace the Fuel Pressure Sensor in accordance with the Service
Information.
No → Repair as necessary in accordance with the Service Information.

157
Symptom List:
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT
P1131-FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER-
RUN
P1131-FUEL PRESSURE SOLENOID SHORT CIRCUIT
The title for the tests will be P1131-FUEL PRESSURE SOLE-
NOID OPEN CIRCUIT.
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT

Set Condition: The ECM detects an open or short to ground on the Fuel Pressure Solenoid
Control circuit.
P1131-FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER-RUN

When Monitored: When the ignition is turned off.
Set Condition: The ECM detects engine speed does not fall below 650 RPM within 0.5
second after ignition off.
P1131-FUEL PRESSURE SOLENOID SHORT CIRCUIT

Set Condition: The ECM detects a short to voltage on the Fuel Pressure Solenoid Control
circuit.
POSSIBLE CAUSES
FUEL PRESSURE SOLENOID CONTROL SHORTED TO VOLTAGE
FUEL PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
FUEL PRESSURE SOLENOID CONTROL CIRCUIT OPEN
FUEL PRESSURE SOLENOID
158
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT — Continued

Start the engine several times, turning the ignition off for at least 30 seconds
between each run cycle.
Did this DTC reset?
Yes → Go To 2
No → Go To 8

Disconnect the Fuel Pressure Solenoid harness connector.
circuit.
Yes → Go To 3

connector.
Measure the voltage of the Fuel Pressure Solenoid Control circuit.
Yes → Go To 4
No → Repair the Fuel Pressure Solenoid Control circuit for a short to
voltage.

Measure the resistance between ground and the Fuel Pressure Solenoid Control
circuit.
NOTE: The Fuel Pressure Solenoid Control circuit is duplicated at ECM
cavities C2-80 and C2-81.
Yes → Go To 5
No → Repair the Fuel Pressure Solenoid Control circuit for a short to

ground.
159

Measure the resistance of the Fuel Pressure Solenoid Control circuit.
Yes → Go To 6
No → Repair the Fuel Pressure Solenoid Control circuit for an open.


NOTE: The DRB should display P1131-FUEL PRESSURE SOLENOID OPEN
CIRCUIT.
Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Pressure Solenoid
harness connector.
NOTE: The DRB should display P1131-FUEL PRESSURE SOLENOID
SHORT CIRCUIT.
Does the DRB display the appropriate DTC for each condition?
Yes → Replace the Fuel Pressure Solenoid/Fuel Pump Assembly in

No → Go To 7

Repair
160

NOTE: The conditions that set the DTC are not present at this time.The

161
Symptom:
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH

Set Condition: The ECM detects Battery Sense circuit voltage above 17.50 volts.
POSSIBLE CAUSES
BATTERY(-) SENSE CIRCUIT OPEN
BATTERY(-) SENSE CIRCUIT SHORT TO VOLTAGE

Yes → Go To 2
No → Go To 5

Measure the resistance between the Battery negative terminal and the Battery(-)
Sense circuit.
Yes → Go To 3
No → Repair the Battery(-) Sense circuit for an open.


connector.
Measure the voltage of the Battery (-) Sense circuit.
Yes → Go To 4
No → Repair the Battery(-) Sense circuit for a short to voltage.
162
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH — Continued

Repair

163
Symptom:
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW

Set Condition: The ECM detects Battery Sense Signal voltage below 7.98 volts.
POSSIBLE CAUSES
FUSE 17 OPEN
FUEL HEATER RELAY
BATTERY(+) SENSE CIRCUIT SHORTED TO GROUND
BATTERY(+) SENSE CIRCUIT OPEN

Yes → Go To 2
No → Go To 7

Remove the Fuel Heater Relay from the IPM.
Measure the resistance of the Battery(+) Sense circuit.
Yes → Go To 3
No → Repair the Battery(+) Sense circuit for an open.


Remove and inspect Fuse 17 from the IPM.
Is the fuse OK?
Yes → Go To 4
No → Repair the short that caused the fuse to open and replace the fuse.
164
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW — Continued

Install a substitute relay in place of the Fuel Heater Relay.
Using a 12-volt test light connected to ground, check the Fuel Heater Relay Output
circuit.
Yes → Replace the initial Fuel Heater Relay.

No → Go To 5

Disconnect the Crankcase Vent Heater harness connector.
Disconnect the Fuel Heater harness connector.
Remove the Fuel Heater Relay from the IPM.
Measure the resistance between ground and the Battery(+) Sense circuit.
Yes → Go To 6
No → Repair the Battery(+) Sense circuit for a short to ground.

Repair


165
Symptom:
P1605-IGNITION SWITCH PLAUSIBILITY
P1605-IGNITION SWITCH PLAUSIBILITY

Set Condition: The ECM detects a short to voltage on the Ignition Switch Sense circuit.
POSSIBLE CAUSES
ECM/PCM RELAY
IGNITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE
ECM/PCM RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
ECM/PCM RELAY CONTROL CIRCUIT SHORTED TO GROUND

Cycle the ignition switch on and off several times, pausing for at least 10 seconds at
each key off and key on.
Did this DTC reset?
Yes → Go To 2
No → Go To 6

Measure the voltage of all cavities in the ECM harness connectors.
Is the voltage above 2.0 volts on any of the cavities?
Yes → Go To 3

Measure the voltage on ECM harness connector C1, cavity 22.
Is voltage present on ECM harness connector C1, cavity 22?
Yes → Go To 4
No → Repair the Ignition Switch Sense circuit that measured above 2.0
volts for a short to voltage.
166
P1605-IGNITION SWITCH PLAUSIBILITY — Continued

Measure the voltage on ECM harness connector C1 cavities 4 and 5.
Is the voltage below 2.0 volts on both circuits?
Yes → Go To 5
No → Repair the ECM/PCM Relay Output circuit for a short to voltage.


Measure the resistance between ground and the ECM/PCM Relay Control circuit.
Yes → Replace the ECM/PCM Relay.
No → Repair the ECM/PCM Relay Control circuit for a short to ground.



167
Symptom List:
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED
P1685-SKIM SYSTEM INVALID SECRET KEY IN EEPROM
P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT
P1685-SKIM SYSTEM SKIM ERROR
P1685-SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE
The title for the tests will be P1685-SKIM SYSTEM INVALID
KEY CODE RECEIVED.
P1685-SKIM SYSTEM SKIM ERROR

When Monitored: With the ignition on and the immobilizer disarmed.
Set Condition: The ECM detects an open, short to ground, or short to voltage on the
immobilizer signal circuit.
P1685-SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE

Set Condition: The ECM determines that the coded message from the PCM does not
match the message programmed into memory.
POSSIBLE CAUSES
SKIM
CHECK FOR SKIM COMMUNICATION AND DTCS

With the DRB, check for Sentry Key Immobilizer Module communication and DTCs.
Are any SKIS problems or DTCs present?
Yes → Refer to symptom list for problems related to SKIM Communica-

tion and DTCs before continuing.
No → Go To 2
168
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED — Continued

With the DRBIIIt, erase ECM DTCs.
Turn the ignition on and off several times pausing 10 seconds between each key cycle.
Are any P1685 DTCs present?
Yes → Go To 3
No → Go To 4
3 Replace and program the SKIM in accordance with the Service Information. All
With the DRBIIIt, erase ECM DTCs.
Turn the ignition on and off several times pausing for 10 seconds between key cycles.
With the DRBIIIt, read ECM DTCs.
Are there any P1685 DTC’s present?
Yes → Replace and program the ECM in accordance with the Service
Information.

169
Symptom List:
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY
WITH BRAKE SWITCH
WITH POTENTIOMETER
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE
TOO HIGH
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE
TOO LOW
P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE
TOO HIGH OR LOW
The title for the tests will be P2120-ACC PEDAL POSITION
SENSOR 1 CKT PLAUSIBILITY.

Set Condition: The Accelerator Pedal Position Sensor Signal is below 2% or above 21%
and the idle switch is not in the correct state. NOTE: The idle switch is designed to
transition when the accel position is approximately 16% (1.00 volt). This code sets the ECM
to Limp-in Mode, which includes a fixed engine speed of 1100 RPM.
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE

SWITCH
Set Condition: The ECM detects the Accelerator Pedal and the Brake Pedal have been
depressed at the same time for longer than the allowable time.
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH POTENTI-

OMETER
Set Condition: The Accelerator Pedal Position Sensor Signal is below 0.20 volts, the idle
switch transitions at too high a percentage intermittently or the idle switch is not in the
correct state intermittently. NOTE: The idle switch is designed to transition when the accel
position is approximately 16% (1.00 volt). This code sets the ECM to Limp-in Mode, which
includes a fixed engine speed of 1100 RPM.
170
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH

Set Condition: The ECM detects voltage on the Accelerator Pedal Position Sensor Signal
circuit above 4.5 volts.
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW

Set Condition: The ECM detects voltage on the Accelerator Pedal Position Sensor Signal
circuit 0.0 volt.
P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH OR

LOW
Set Condition: The Accelerator Pedal Position Sensor 5-Volt Supply voltage is too high or
too low.
POSSIBLE CAUSES
APP SENSOR IDLE VOLTAGE
APP SENSOR WIDE OPEN THROTTLE VOLTAGE
LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND
SENSOR GROUND OPEN (APP SENSOR)
SENSOR GROUND OPEN (IDLE SWITCH)
APP SENSOR SIGNAL CIRCUIT OPEN
LOW IDLE POSITION SWITCH SENSE CIRCUIT OPEN
VERIFY LOW IDLE POSITION SWITCH OPERATION
APP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
VERIFY APP SENSOR OPERATION
APP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT
LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO THE SENSOR GROUND CIR-
CUIT
ECM - SENSOR GROUND OPEN
APP SENSOR CIRCUIT SHORTED TO VOLTAGE
171
POSSIBLE CAUSES
APP SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE
LOW IDLE POSITION SWITCH SENSE GROUND CIRCUIT SHORTED TO VOLTAGE
VERIFY CORRECT SWITCHING
ECM - APP SENSOR SIGNAL CIRCUIT

1 NOTE: The brake switch must be operational for the result of this test to be All
valid.
Connect one end of a jumper wire to the Low Idle Position Sense circuit at the APP
With the DRB III, monitor the Low Idle Position Switch input while tapping the other
end of the jumper wire to the Sensor Ground circuit at the APP Sensor harness
connector.
Does the DRB III change between IDLE and ABOVE IDLE when tapping the jumper
wire?
Yes → Go To 2
No → Go To 20

With the DRB III observe the Low Idle Position Switch input.
Press and release the accelerator pedal several times while observing the DRB III
display.
NOTE: The Low Idle Position Switch input should change from IDLE to
ABOVE IDLE when pressing and releasing the accelerator pedal.
Did Low Idle Position Switch input change between IDLE and ABOVE IDLE?
Yes → Go To 3
No → Replace the Accelerator Pedal Position Sensor in accordance with

Measure the voltage of the 5-volt Supply circuit in APP Sensor harness connector.
Yes → Go To 4
No → Go To 16
172

Connect a jumper wire between APP Sensor Signal circuit and the 5-volt supply
circuit at the APP Sensor harness connector .
With the DRBIII, read the PEDAL OUTPUT VOLTS.
Does the DRBIII display between 4.0 and 5.5 volts?
Yes → Go To 5
No → Go To 12

Connect a jumper wire between cavity 30 and cavity 87 ECM/PCM Relay connector.
Measure the voltage of the APP Sensor Ground circuit.
Yes → Repair the App Sensor Ground circuit for a short to voltage.
No → Go To 6

Measure the resistance of the Sensor Ground circuit between the APP Sensor and the
ECM.
Yes → Go To 7
No → Repair the APP Sensor Ground circuit for an open.

With the DRB III, read the PEDAL OUTPUT VOLTS with the accelerator pedal in
the at rest position.
Does the DRB III display between 0.28 and 0.38 volt?
Yes → Go To 8

Fully depress the accelerator pedal.
With the DRBIII, read the PEDAL OUTPUT VOLTS.
Does the DRB III display between 4.1 and 4.6 volts?
Yes → Go To 9

173

With the DRB III, read the PEDAL OUTPUT VOLTS.
With the accelerator pedal in the idle position, slowly depress the accelerator pedal
until the pedal is fully depressed.
NOTE: The PEDAL OUTPUT VOLTS should increase smoothly as the pedal
is depressed.
Does the voltage increase smoothly with the accelerator pedal travel?
Yes → Go To 10


With the DRB III, select Engine and with the custom display feature select Low Idle
Switch input and the Accel Pedal %.
Slowly depress and release the accelerator pedal several times while monitoring the
DRB III display.
NOTE: The Low Idle Switch state should change between 5% and 10% of
Accelerator Pedal position.
Did the Low Idle Switch state change between 5% and 10% of Accelerator Pedal
position?
Yes → Go To 11
No → Replace the Accelerator Pedal Position Sensor.


Measure the resistance of the APP Sensor Signal circuit.
Yes → Go To 13
No → Repair the APP Sensor Signal circuit for an open

174

Measure the resistance between ground and the APP Sensor Signal circuit.
Yes → Repair the APP Sensor Signal circuit for a short to ground.
No → Go To 14

Measure the resistance between the APP Sensor Signal circuit and the Sensor
Ground circuit at of the APP Sensor harness connector.
Yes → Repair the APP Sensor Signal and Sensor Ground circuits for a
short together.
No → Go To 15

connector.
Measure the voltage of the APP Sensor Signal circuit.
Yes → Repair the APP Sensor Signal circuit for a short to voltage.


Yes → Go To 17

175

circuit at the APP Sensor harness connector.
Is the resistance above 1000 ohms for both of the measurements?
Yes → Go To 18
circuit.

Measure the resistance between ground and the 5-volt Supply circuit.
No → Go To 19

connector.
Measure the voltage of the 5-volt Supply circuit in the ECM harness connector.



Measure the resistance of the Low Idle Position Switch Sense circuit.
Yes → Go To 21
No → Repair the Low Idle Position Switch Sense circuit for an open.
176

Measure the resistance between ground and the Low Idle Position Switch Sense
circuit.
Yes → Go To 22
No → Repair the Low Idle Position Switch Sense circuit for a short to
ground.

Measure the resistance between the Low Idle Position Switch Sense circuit and the
Sensor Ground circuit at the APP Sensor harness connector.
Yes → Go To 23
No → Repair the Low Idle Position Switch Sense circuit and Sensor
Ground circuit for a short together.

Measure the voltage of the Low Idle Position Switch Sense circuit.
Yes → Repair the Low Idle Position Switch Sense circuit for a short to
voltage.
No → Go To 24

Measure the voltage of the Low Idle Position Switch Ground circuit.
Yes → Repair the Low Idle Position Switch Sense Ground circuit for a
short to voltage.
No → Go To 25
177

Measure the resistance of the Low Idle Switch Sensor Ground circuit between the
APP Sensor and the ECM.
No → Repair the Low Idle Switch Sensor Ground circuit for an open.
178
Symptom:
*CHECKING THE A/C CLUTCH OPERATION
POSSIBLE CAUSES
CHECK THE A/C CLUTCH OPERATION
A/C CLUTCH RELAY
A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO GROUND
A/C CLUTCH RELAY OUTPUT CIRCUIT OPEN
A/C CLUTCH GROUND CIRCUIT OPEN
A/C CLUTCH

1 NOTE: Ensure that the refrigerant system is properly charged. Refer to the All
appropriate Service Information.
Is the A/C Clutch actuating?
Yes → The A/C Clutch System is operating properly at this time.
No → Go To 2
2 NOTE: If the A/C Clutch fuse is open, refer to the system schematics for all All
circuits that are powered by the A/C Clutch fuse to determine the cause of
the blown fuse.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the IPM.
Yes → Go To 3
No → Repair the Fused B+ circuit. Inspect fuse and replace as neces-

sary.

Install a substitute relay in place of the A/C Clutch Relay.
Does the A/C Clutch Relay cycle on and off?

No → Go To 4
179
*CHECKING THE A/C CLUTCH OPERATION — Continued

Disconnect the A/C Clutch harness connector.
Measure the voltage of the A/C Clutch Relay Output circuit.
Yes → Repair the A/C Clutch Relay Output circuit for a short to voltage.
No → Go To 5

Measure the resistance between ground and the A/C Clutch Relay Output circuit.
Yes → Go To 6
No → Repair the A/C Clutch Relay Output circuit for a short to ground.
Inspect fuse and replace as necessary.

Measure the resistance of the A/C Clutch Relay Output circuit.
Yes → Go To 7
No → Repair the A/C Clutch Relay Output circuit for an open.

Using a 12-volt test light connected to 12-volts, check the A/C Clutch Ground circuit.
Yes → Go To 8
No → Repair the A/C Clutch Ground circuit for an open.

Repair
Replace the A/C Clutch.
180
Symptom:
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR
CALIBRATION
POSSIBLE CAUSES
APP SENSOR
APP SENSOR - IDLE
APP SENSOR - WOT

1 NOTE: Ensure the Accelerator pedal is free from any restriction or binding All
before continuing.
While back probing, measure the voltage of the APP Sensor Signal circuit at the
ECM.
NOTE: The accelerator pedal must be released (Idle) for this step.
Yes → Go To 2

ECM.
Monitor the voltmeter while slowly pressing the accelerator pedal completely down.
Did the voltage increase smoothly with pedal travel?
Yes → Go To 3


ECM.
Press the accelerator pedal completely down.
Is the voltage above 3.7 volts with the accelerator pedal fully depressed?

181
Symptom:
*CHECKING THE BOOST PRESSURE SENSOR CALIBRATION
POSSIBLE CAUSES
TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION

1 Allow the engine to idle. All
With the DRB, select Engine, Bosch then Sensors. Read the Boost Pressure Voltage.
Is the Boost Pressure Voltage between 1.50 and 2.00 volts?
No → Replace the Turbocharger Boost Pressure Sensor.

182
Symptom:
*CHECKING THE ECM POWER AND GROUND CIRCUITS
POSSIBLE CAUSES
ECM GROUND CIRCUIT(S) OPEN
ECM/PCM RELAY OUTPUT CIRCUIT(S) OPEN
FUSED ECM/PCM RELAY BATTERY SUPPLY CIRCUIT OPEN

Using a 12-volt test light connected to 12-volts, check both of the ECM ground
circuits in ECM harness connector C1 cavities 1 and 2.
Did the test light illuminate for both cavities?
Yes → Go To 2
No → Repair the ECM Ground circuit(s) for an open.

Using a 12-volt test light connected to ground, check the Fused Ignition Switch
Output circuit in ECM harness connector C1 cavity 22.
Yes → Go To 3

Using a 12-volt test light connected to ground, check the Fused ECM/PCM Relay
Battery Supply circuit in ECM/PCM Relay connector cavity 30.
Yes → Go To 4
No → Repair the Fused ECM/PCM Relay Battery Supply circuit for an
open.
183
*CHECKING THE ECM POWER AND GROUND CIRCUITS — Continued

Connect a jumper wire between cavity 30 and cavity 87 in the ECM/PCM Relay
connector.
circuit in ECM harness connector C1 cavities 4 and 5.
Did the test light illuminate for both circuits?

No → Repair the ECM/PCM Relay Output circuit(s) for an open.
184
Symptom:
*CHECKING THE EGR SYSTEM
POSSIBLE CAUSES
EGR SOLENOID CONTROL CIRCUIT OPEN
EGR VALVE
VACUUM SUPPLY HOSE

1 Disconnect the Vacuum Supply Hose at the EGR solenoid. All
Connect a vacuum gauge to the Vacuum Supply Hose.
Start the engine and allow the engine to idle.
Is the vacuum above 10 inches of mercury at idle?
Yes → Go To 2
No → Repair leaking or restricted Vacuum Supply Hose or faulty
Vacuum Supply Pump.

circuit at the EGR Solenoid harness connector.
Yes → Go To 3

Measure the resistance of the EGR Solenoid Control circuit.
Yes → Go To 4
No → Repair the EGR Solenoid Control circuit for an open.
4 NOTE: The Vacuum Output Hose must not be leaking or restricted for the All
result of this test to be valid.
Disconnect the Vacuum Supply and Vacuum Output Hoses in the EGR Solenoid
vacuum connector.
Connect the Vacuum Supply Hose to the Vacuum Output Hose.
Test drive the vehicle and observe vehicle performance.
Is there a power reduction on vehicle acceleration?
No → Replace the EGR Valve.

185
Symptom:
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION
POSSIBLE CAUSES
ACTUATE THE HIGH AND LOW SPEED RADIATOR FAN WITH THE DRB
CHECK FOR RADIATOR FAN RELAY CONTROL DTCS
RADIATOR FAN RELAY NO. 1 OUTPUT CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN NO. 1 CONTROL CIRCUIT SHORTED TO VOLTAGE
RADIATOR FAN RELAY NO. 1 FUSED B+ CIRCUIT OPEN
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT SHORTED TO GROUND
RADIATOR FAN NO. 1 CONTROL CIRCUIT SHORTED TO GROUND
RADIATOR FAN RELAY NO. 1 - INTERNAL SHORT TO VOLTAGE
RADIATOR FAN RELAY NO. 2 OR NO. 3 - INTERNAL SHORT TO VOLTAGE
RADIATOR FAN NO. 1 - SHORTED
RADIATOR FAN NO. 2 - SHORTED
RADIATOR FAN RELAY NO. 1 OUTPUT CIRCUIT SHORTED TO GROUND
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT OPEN FROM RELAY NO.
2
RADIATOR FAN RELAY NO. 3 GROUND CIRCUIT OPEN
HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL CIRCUIT OPEN
RADIATOR FAN RELAY NO. 1 OUTPUT CIRCUIT OPEN
RADIATOR FAN NO. 1 CONTROL CIRCUIT OPEN
RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT CIRCUIT OPEN FROM RELAY NO.
3
RADIATOR FAN - OPEN
RADIATOR FAN NO. 2 - OPEN
186
*CHECKING THE ELECTRIC RADIATOR FAN OPERATION — Continued

Are any Radiator Fan DTCs present?
Yes → Refer to symptom list for problems related to Radiator Fan

control.
No → Go To 2
2 NOTE: The engine temperature must not be hot enough to cause the All
radiator fans to be on with the key off.
Observe the radiator fans with the key off.
Is either radiator fan running with the key off?
Yes → Go To 3
No → Go To 6
Observe the radiator fans with the key off.
Which radiator fan(s) are running?
Fan 1 and Fan 2
Go To 4
Fan 2 Only
Go To 5
Remove Radiator Fan Relay No. 1.
Observe the radiator fans.
Did the radiator fans stop running?
No → Repair the Radiator Fan Relay No. 1 Output circuit for a short to
voltage.
One at a time, remove Radiator Fan Relay No. 2 and then Radiator Fan Relay No. 3.
Observe the radiator fans after disconnecting each relay.
Did the radiator fan stop running?
Yes → Replace Radiator Fan Relay that caused the radiator fan to stop.
No → Repair the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit for a short to voltage.
187

With the DRB, actuate the Low Speed Rad Fan and observe the Radiator Fans.
NOTE: Both Radiator Fans should operate at low speed.
Did both Radiator Fans operate as they should?
Yes → Go To 7
Fans do not operate on Low

Go To 15
Fan 1 on High/Fan 2 not on

Go To 23
Fan 1 not on/Fan 2 on High

Go To 26

With the DRB, actuate the High and Low Speed Rad Fans at the same time and
observe the Radiator Fans.
NOTE: Both Radiator Fans should operate at high speed.
Did both Radiator Fans operate as they should?
Yes → The test is complete. Ensure the ECM will turn the fans on when
the engine is hot.
Fan 1 on High/Fan 2 not on
Go To 8
Fan 1 not on/Fan 2 on High
Go To 11

Yes → Go To 9
No → Repair the Radiator Fan Relay No. 2 Fused B+ circuit for an open.

Install a substitute relay in place of Radiator Fan Relay No. 2.
With the DRB, actuate the High Speed Fan Relay.
Does Radiator Fan No. 2 cycle on and off?

No → Go To 10
188

Disconnect the Radiator Fan No. 2 harness connector.
Measure the resistance of the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 2.
circuit from Radiator Fan Relay No. 2 for an open.

Yes → Go To 12

With the DRB, actuate the High Speed Fan Relay and then actuate the Low Speed
Fan Relay.
Does Radiator Fan No. 2 cycle on and off and then both fans cycle on and off when
requested?
No → Go To 13

Using a 12-volt test light connected to 12-volts, check the Radiator Fan Relay No. 3
Ground circuit at the Radiator Fan Relay No. 3 harness connector.
Yes → Go To 14
No → Repair the Radiator Fan Relay No. 3 Ground circuit for an open.

Measure the resistance of the High Speed Radiator Fan Dual Relay Control circuit.
No → Repair the High Speed Radiator Fan Dual Relay Control circuit
for an open.
189

Yes → Go To 16

Do both Radiator Fans cycle on and off?

No → Go To 17

Output circuit in the Radiator Fan Relay No. 1 harness connector.
Did the test light illuminate?
Yes → Repair the Radiator Fan Relay No. 1 Output circuit for a short to
ground.
No → Go To 18

Ground circuit at the Radiator Fan Relay No. 3 harness connector.
Yes → Go To 19
No → Repair the Radiator Fan Relay No. 3 Ground circuit for an open.

Measure the resistance of the Radiator Fan Relay No. 1 Output circuit.
Yes → Go To 20
No → Repair the Radiator Fan Relay No. 1 Output circuit for an open.
190

Measure the resistance of the Radiator Fan No. 1 Control circuit.
Yes → Go To 21
No → Repair the Radiator Fan No. 1 Control circuit for an open.


Measure the resistance of the Radiator Fan Relay No. 2 and No. 3 Common Output
circuit from Radiator Fan Relay No. 3.
Yes → Go To 22
circuit from Radiator Fan Relay No. 3 for an open.

Connect a fused jumper wire between the Radiator Fan No. 1 harness connector
cavities.
Did Radiator Fan No. 2 activate on High speed?
Yes → Replace Radiator Fan No. 1.

No → Replace Radiator Fan No. 2.

23 NOTE: Radiator Fan No. 2 is fed voltage from Radiator Fan Relay No. 3 All
during low speed operation and then fed voltage from Radiator Fan Relay
No. 2 during high speed operation by a common circuit connected to both
relays.
Measure the resistance between ground and the Radiator Fan Relay No. 2 and No. 3
Common Output circuit.
Yes → Go To 24
circuit for a short to ground.
191

Using a 12-volt test light connected to 12-volts, check the Radiator Fan No. 1 Control
circuit.
Did the test light illuminate?
Yes → Repair the Radiator Fan No. 1 Control circuit for a short to
ground.
No → Go To 25
Repair
Replace the Radiator Fan No. 2.

Measure the voltage on the Radiator Fan No. 1 Control circuit.
Yes → Repair the Radiator Fan No. 1 Control circuit for a short to
voltage.
No → Go To 27
Repair
Replace Radiator Fan No. 1.
192
Symptom:
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR
CALIBRATION
POSSIBLE CAUSES
ECT SENSOR - COLD
ECT SENSOR - HOT

1 NOTE: The thermostat must be operating correctly for this test to be valid. All
With the DRB, read and note the engine coolant temperature.
Using a temperature probe, measure the engine block temperature near the ECT
Sensor.
NOTE: The engine temperature should be below 50*C (120*F)
Are the readings within 7°C (13°F) of each other?
Yes → Go To 2
No → Replace the Engine Coolant Temperature Sensor.

2 NOTE: The thermostat must be operating correctly for this test to be valid. All
Start the engine and bring the engine to operating temperature (thermostat open).
Turn the engine off and wait 10 minutes to allow the engine temperature to stabilize.
Using a temperature probe, measure the engine block temperature near the ECT
Sensor.
Using the DRB, select Engine, then Sensors and read the engine coolant tempera-
ture.
Are the readings within 7°C (13°F) of each other?

No → Replace the Engine Coolant Temperature Sensor.
193
Symptom:
*CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS

1 NOTE: The following items should be checked as a possible cause of a All
Driveability or No-Start problem.
WARNING: Do not attempt to remove or separate high pressure fuel line.
Attempting to do so could result in severe bodily injury or death.
Engine Valve Timing - must be within specification
Engine Compression - must be within specifications
Camshaft Lobes - check for abnormal wear
Camshaft Position Sensor - check the camshaft position sensor tooth for debris and
deterioration
Crankshaft Position Sensor - check the crankshaft tone wheel for debris and
deterioration
Engine Exhaust System - must be free of any restriction
Engine Drive Sprocket - must be properly positioned
Power Brake Booster - must be free of any vacuum leaks
Fuel - must have adequate supply and must be free of contamination and gasoline
Fuel Injectors - must not be plugged or restricted
Fuel Injection Pump - must be producing the correct output volume and pressure
Inspect the Fuel Lines, Fuel Filter and Fuel Pressure Relief Valve for signs of
restriction and leaks
NOTE: Check for any Technical Service Bulletins that may relate to the
problem.
Are there any problems evident?
194
Symptom:
*CHECKING THE GLOW PLUG OPERATION
POSSIBLE CAUSES
CHECKING THE GLOW PLUGS
GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO GROUND
GLOW PLUG RELAY OUTPUT CIRCUIT OPEN
GLOW PLUG RELAY

Disconnect the Glow Plug harness connectors for all cylinders.
With the DRB, actuate the Glow Plug Relay.
Using a 12-volt test light connected to ground, probe each Glow Plug harness
connector during actuator test.
Does the test light cycle on and off for each circuit during the actuator test?
Yes → Go To 2
No → Go To 3
2 Refer to the Service Information and perform the Glow Plug Test. All
Are all Glow Plugs operating properly?

No → Replace the Glow Plug(s) as necessary.
3 NOTE: If the Glow Plug Relay fuse or fuselink is open, refer to the system All
schematics for all circuits that are powered by the Glow Plug Relay fuse or
fuselink to determine the cause of the blown fuse/fuselink.
Remove the Glow Plug Relay.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the Glow
Plug Relay connector, cavity 30 in the IPM.
Yes → Go To 4
No → Repair the Fused B+ (Fuse/Fuselink) circuit for an open.


Disconnect all the Glow Plug harness connectors.
Measure the voltage on the Glow Plug Relay Output circuit.
Yes → Repair the Glow Plug Relay Output circuit for a short to voltage.
No → Go To 5
195
*CHECKING THE GLOW PLUG OPERATION — Continued

Measure the resistance between ground and the Glow Plug Relay Output circuit.
Yes → Go To 6
No → Repair the Glow Plug Relay Output circuit for a short to ground.
Inspect the fuse or fuselink and replace as necessary.

Connect a jumper wire across Glow Plug Relay connector cavities 30 and 87.
Using a 12-volt test light connected to ground, check the Glow Plug Relay Output
circuit at each Glow Plug harness connector.
Is the test light on at each Glow Plug harness connector?
Yes → Go To 7
No → Repair the Glow Plug Relay Output circuit for an open.

7 Refer to the Service Information and perform the Glow Plug Test. All
Are all Glow Plugs operating properly?
Yes → Go To 8
No → Replace the Glow Plug(s) as necessary.


Repair
Replace the Glow Plug Relay.
196
Symptom:
*CHECKING THE LIFT PUMP MOTOR OPERATION
POSSIBLE CAUSES
LIFT PUMP OUTPUT TEST
LIFT PUMP RELAY
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE
LIFT PUMP RELAY OUTPUT CIRCUIT SHORTED TO GROUND
LIFT PUMP RELAY OUTPUT CIRCUIT OPEN
LIFT PUMP GROUND CIRCUIT OPEN
LIFT PUMP MOTOR

1 NOTE: If any Fuel Lift Pump DTCs are present, diagnose the DTCs first. All
With the DRB, actuate the Lift Pump Relay.
Gain access to the Lift Pump Motor to determine if it is cycling on and off.
Does the Lift Pump Motor cycle on and off?
Yes → Go To 2
No → Go To 3
2 NOTE: The Lift Pump fuel output must be sufficient to prime the Injector All
Pump.
Refer to the Service Information to test the Lift Pump pressure and volume output.
Did the Lift Pump pass the Lift Pump pressure and volume test?
3 NOTE: If the Lift Pump Relay fuse is open, refer to the system schematics All
for all circuits that are powered by the Lift Pump Relay fuse to determine
the cause of the blown fuse.
Remove the Lift Pump Relay from the IPM.
Using a 12-volt test light connected to ground, probe the Fused B+ circuit in the Lift
Pump Relay connector in the IPM.
Yes → Go To 4
No → Repair the Fused B+ (Fuse) circuit for an open.

197
*CHECKING THE LIFT PUMP MOTOR OPERATION — Continued

Install a substitute relay in place of the Lift Pump Relay.
With the DRB, actuate the Lift Pump Relay.
Does the Lift Pump Motor cycle on and off?
Yes → Replace the Lift Pump Relay.
No → Go To 5

Disconnect the Lift Pump Motor harness connector.
Remove the Lift Pump Relay.
Measure the voltage on the Lift Pump Relay Output circuit.
Yes → Repair the Lift Pump Relay Output circuit for a short to voltage.
No → Go To 6

Measure the resistance between ground and the Lift Pump Relay Output circuit.
Yes → Go To 7
No → Repair the Lift Pump Relay Output circuit for a short to ground.
Inspect the fuse and replace as necessary.

Connect a jumper wire across Lift Pump Relay connector cavities 30 and 87.
Using a 12-volt test light connected to ground, check the Lift Pump Relay Output
circuit.
Is the test light illuminated brightly?
Yes → Go To 8
No → Repair the Lift Pump Relay Output circuit for an open.


Using a 12-volt test light connected to 12-volts, check the Lift Pump Ground circuit.
Is the test light illuminated brightly?
Yes → Go To 9
No → Repair the Lift Pump Ground circuit for an open.

198
*CHECKING THE LIFT PUMP MOTOR OPERATION — Continued

Repair
Replace the Lift Pump Motor in accordance with the Service
Information.
199
Symptom:
*CHECKING THE MAF SENSOR CALIBRATION
POSSIBLE CAUSES
CHECKING THE MAF SIGNAL AT 2000 RPM
CHECKING THE MAF SIGNAL AT IDLE

1 Allow the engine to idle for 2 minutes. All
NOTE: The induction tubes connected to the MAF Sensor and the turbo-
charger must be properly connected and without damage or restrictions.
With the DRBIIIt in Sensors, read the MASS AIR FLOW Volts.
Yes → Go To 2
No → Replace the Mass Air Flow Sensor.

With the transmission in Neutral and the parking brake set, increase engine speed
to 2000 rpm and note the DRB reading.
Yes → Go To 3

to 3000 rpm and note the DRB reading.
Yes → Go To 4

to 4000 rpm for 5.0 seconds and note DRB reading.
200
Symptom:
*CHECKING THE SPEED CONTROL OPERATION
POSSIBLE CAUSES
CHECKING CRUISE SWITCHES
CHECKING THE BRAKE SWITCH INPUT
CHECKING THE ECM FOR DTC’S
CHECKING THE VSS SIGNAL
CLUTCH PEDAL SWITCH
CLUTCH PEDAL SWITCH SENSE CIRCUIT OPEN
CLUTCH PEDAL SWITCH SENSE CIRCUIT SHORTED TO GROUND
ECM
ECM

Are there any ECM DTC’s present?
Yes → Refer to symptom list for problems related to the ECM DTC.
Perform SPEED CONTROL VERIFICATION - VER-4.
No → Go To 2
2 Test drive the vehicle above 60 Km/h (35 mph). All

Attempt to Set the Speed Control.
Is the Speed Control function operating properly?
No → Go To 3
3 Start the engine. All

With the DRB, read the CRUISE SW VOLTS.
Observe the cruise switch volts on the DRB while pressing and holding each cruise
button separately.
NOTE: Pressing each cruise button should result in the following voltages:
ON/OFF 0.0 - 0.3v, SET 3.58 - 3.99v, RESUME/ACCEL 4.19 - 4.59v, CANCEL 1.28
- 1.68v, COAST 2.69 - 3.01v, No Button Pressed 4.8 - 5.2v
Does each switch provide the correct voltage?
Yes → Go To 4
No → Refer to symptom list for problems related to S/C Switches.

201
*CHECKING THE SPEED CONTROL OPERATION — Continued

With the DRBIIIt in Sensors, read the Vehicle Speed Sensor signal.
Have an assistant drive the vehicle while you are observing the Vehicle Speed Signal
on the DRB.
While observing vehicle speed signal note any rapid changes (signal drop-outs) in the
reading that do not correspond with actual vehicle speed.
Is the DRB displaying an accurate Vehicle Speed Signal?
Yes → Go To 5
No → Refer to symptom list for problems related to the Vehicle Speed

Sensor.

With the DRBIIIt in Inputs/Outputs, read the Primary and Secondary switch states
while pressing and releasing the Brake Pedal several times.
Did the DRB indicate the correct brake pedal state when pressing and releasing the
Brake Pedal?
Yes → Go To 6
No → Refer to symptom list for problems related to Brake Switch input.


With the DRBIIIt in Inputs/Outputs, read the Clutch switch states while pressing
and releasing the Clutch Pedal several times.
Did the DRB indicate the correct clutch pedal state when pressing and releasing the
Clutch Pedal?
Yes → Go To 7
No → Go To 8



Information.
202
*CHECKING THE SPEED CONTROL OPERATION — Continued

With the DRBIIIt in Inputs/Outputs, read the Clutch Switch state while using a
jumper wire to connect the Clutch Pedal Switch Sense circuit to ground at the Clutch
Pedal Switch harness connector.
NOTE: Leave jumper connected to ground for 5 seconds then disconnect
jumper and note DRB reading for both conditions.
Does the DRB display RELEASED and PRESSED?
Yes → Replace the Clutch Pedal Switch.

No → Go To 9

Measure the resistance of the Clutch Pedal Switch Sense circuit.
Yes → Go To 10
No → Repair the Clutch Pedal Switch Sense circuit for an open.


Measure the resistance between ground and the Clutch Pedal Switch Sense circuit.
Yes → Repair the Clutch Pedal Switch Sense circuit for a short to
ground.

Information.
203
Symptom:
*CHECKING THE VEHICLE SPEED SIGNAL
POSSIBLE CAUSES
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
CHECK FOR VSS DTC
SPEEDOMETER PINION AND DRIVE TEETH DAMAGED
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE CONTROL MODULE - SHORTED TO VOLTAGE
VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN
VEHICLE SPEED SENSOR
ENGINE CONTROL MODULE - INTERNAL FAULT

With the DRB, select Engine, then Sensors.
While an assistant is test driving the vehicle, note the Vehicle Speed reading on the
DRB.
While reading the VSS Signal, note any rapid changes (signal drop-outs) that do not
correspond with actual vehicle speed.
Does the DRB display an accurate vehicle speed reading?

No → Go To 2

Are any VSS DTCs present?
Yes → Refer to symptom list for problems related to VSS DTCs.

No → Go To 3

Remove the Vehicle Speed Sensor.
Inspect the Speedometer Pinion and drive teeth on the Output Shaft (located in the
transmission).
Inspect the VSS for metal debris and damage to the Sensor and connector.
Are both components OK?
Yes → Go To 4
No → Repair or replace the Speedometer Pinion or internal components

as necessary in accordance with the Service Information.
204
*CHECKING THE VEHICLE SPEED SIGNAL — Continued

Measure the voltage of the Ignition Switch Output circuit in the Vehicle Speed Sensor
harness connector.
Yes → Go To 5


Yes → Go To 6
No → Go To 8

connector.
Yes → Go To 7
voltage.
Repair

Measure the resistance between ground and the Vehicle Speed Sensor Signal circuit.
Yes → Go To 9
ground.
205
*CHECKING THE VEHICLE SPEED SIGNAL — Continued

Measure the resistance of the Vehicle Speed Sensor Signal circuit.
Yes → Go To 10
No → Repair the Vehicle Speed Sensor Signal circuit for an open.


Measure the resistance of the Vehicle Speed Sensor Ground circuit.
Yes → Go To 11
No → Repair the Vehicle Speed Sensor Ground circuit for an open.

NOTE: Ensure the ECM harness connectors are connected before continu-
ing.
Connect a jumper wire to the Vehicle Speed Sensor Signal circuit in the VSS harness
connector.
With the DRB, monitor the VEHICLE SPEED while tapping the other end of the
jumper wire to ground.
Does the DRB display km/h (MPH) greater than 0?
Yes → Replace the Vehicle Speed Sensor.
No → Go To 12

Measure the resistance between the Vehicle Speed Sensor Signal circuit and the
Yes → Go To 13
No → Repair the Vehicle Speed Sensor Signal circuit for a short to the

Repair
206
Symptom:
*ENGINE CRANKS BUT WILL NOT START
POSSIBLE CAUSES
CHECKING FOR ECM CODES
CHECKING FOR SKIM CODES
CHECKING THE ECT SENSOR
CHECKING THE GLOW PLUG OPERATION
ENGINE DRIVE BELT
FUEL INJECTOR DRIVER CIRCUIT(S) SHORTED TO GROUND
FUEL PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
FUEL PRESSURE SENSOR SIGNAL CIRCUIT OPEN
FUEL SUPPLY CONTAMINATION
FUEL SYSTEM PRESSURE MECHANICAL
FUEL SYSTEM RESTRICTION
SENSOR GROUND OPEN

Does the DRBIIIt display any ECM DTCs?
Yes → Refer to symptom list for problems related to ECM DTC.
Perform NO START VERIFICATION - VER-1.
No → Go To 2

With the DRBIIIt, read the SKIM DTCs.
Does the DRBIIIt display any SKIM DTCs?
Yes → Refer to symptom list for problems related to SKIM DTC.

No → Go To 3
3 Using a temperature probe, check the vehicle temperature near the ECT Sensor. All
With the DRBIIIt in Sensors, read the ECT Sensor temperature.
Compare the temperature probe reading with the DRB reading.
Are the two readings within 10°C of each other?
Yes → Go To 4
207
*ENGINE CRANKS BUT WILL NOT START — Continued

4 NOTE: Prior to performing this test, be sure to check the Glow Plug Relay All
operation. Refer to CHECKING GLOW PLUG OPERATION for the related
symptom(s).
Refer to the Service Information and check the Glow Plugs for proper operation.
Are the Glow Plugs operating properly?
Yes → Go To 5

Disconnect all 4 Fuel Injector harness connectors.
Measure the resistance between Ground and each Fuel Injector Driver circuit at it’s
respective Fuel Injector harness connector.
Is the resistance below 1000 ohms for any of the measurements?
Yes → Repair the Fuel Injector Driver circuit(s) for a short to ground.
No → Go To 6
6 Inspect and fuel system lines for restrictions, leaks or other problems. All
Is there any evidence of problems?
No → Go To 7

Using the DRB lab scope, backprobe the CMP Sensor Signal circuit at the CMP
NOTE: Refer to Charts and Graphs to view a correct CMP Sensor signal.
Does the DRB display a steady clean CMP Signal pattern?
Yes → Go To 8
No → Perform Test for DTC P0340-Camshaft Position Sensor Circuit
Static Plausibility.

Using the DRB lab scope, backprobe both of the CKP Sensor Signal circuits at the
CKP Sensor harness connetor.
NOTE: Refer to Charts and Graphs to view a correct CKP Sensor signal.
Does the DRB display a steady clean CKP Signal pattern for each circuit?
Yes → Go To 9
No → Perform Test for DTC P0340-Crankshaft Position Sensor Circuit

Dynamic Plausibility.
208
*ENGINE CRANKS BUT WILL NOT START — Continued

9 Refer to the Service Information and perform the fuel pressure test. All
Is the fuel pressure within specification?
Yes → Go To 10
10 Refer to the Service Information and perform the fuel pressure test. Note the test All
results.
Using the DRB, read the Fuel Pressure PSI and compare the two readings.
Are the two readings within 500 psi of each other?
Yes → Go To 11
No → Go To 12
11 Refer to the Service Information to ensure the Engine Drive Belt is installed correctly All
and the camshaft and crankshaft gears are timed correctly.
No → Check the fuel supply for contamination.


Measure the resistance of the Fuel Pressure Sensor Signal circuit.
Yes → Go To 13
No → Repair the Fuel Pressure Sensor Signal circuit for an open.

Measure the resistance of the Fuel Pressure Sensor 5-volt Supply circuit.
Yes → Go To 14
No → Repair the Fuel Pressure Sensor 5-volt Supply circuit for an open.

Yes → Replace the Fuel Pressure Sensor in accordance with the Service
Information.

209
Symptom:
*ENGINE WILL NOT CRANK
POSSIBLE CAUSES
BATTERY CABLE HIGH RESISTANCE
CHECKING FOR SKIM CODES
CLUTCH INTERLOCK SWITCH
CLUTCH INTERLOCK SWITCH OUTPUT CIRCUIT
ECM
IGNITION SWITCH START OUTPUT CIRCUIT OPEN
IGNITION SWITCH START OUTPUT CIRCUIT OPEN
INSPECT BATTERY CABLES
MECHANICAL PROBLEM
OPEN FUSED BATTERY (+) CIRCUIT
STARTER MOTOR
STARTER RELAY
STARTER RELAY CONTROL CIRCUIT OPEN
STARTER RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
STARTER RELAY OUTPUT CIRCUIT OPEN

NOTE: The battery must be fully charged before diagnosing a no crank
condition.
Inspect the battery cables for corrosion, looseness or other problems.
Is there evidence of problems?
No → Go To 2

Does the DRBIIIt display any SKIM DTCs?
Yes → Refer to symptom list for problems related to SKIM.

No → Go To 3
210
*ENGINE WILL NOT CRANK — Continued

Remove the Starter Relay from the PDC.
WARNING: THE TRANSMISSION MUST BE IN NEUTRAL AND THE PARK
BRAKE MUST BE SET FOR THIS TEST.
WARNING: THE ENGINE MAY CRANK IN THE NEXT STEP. WHEN THE
ENGINE IS CRANKING, DO NOT STAND IN A DIRECT LINE WITH THE
FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
DO NOT WEAR LOOSE CLOTHING.
Momentarily jumper Starter Relay connector cavities 30 and 87 in the IPM
connector.
Did the engine crank?
Yes → Go To 4
No → Go To 11
4 Remove the Starter Relay from the PDC. All

Using a 12-volt test light connected to ground, check the Ignition Switch Start
Output circuit while fully depressing the clutch pedal and turning the ignition switch
to the START position.
Does the test light illuminate with the ignition switch in the START position?
Yes → Go To 5
No → Go To 9

Remove the Starter Relay From the PDC.
Install a substitute relay in place of the Starter Relay.
Does the engine crank?
Yes → Replace the Starter Relay.

No → Go To 6

Using a 12-volt test light connected to ground, probe ECM harness connector cavity
49 while fully depressing the clutch pedal and turning the ignition switch to the
START position.
Does the test light illuminate while the ignition is in the Start position.
Yes → Go To 7
No → Repair the Ignition Switch Start Output circuit to the ECM.

211

Using a jumper wire, connect ECM/PCM relay connector cavities 30 and 87 in the
IPM.
Measure the voltage of the Starter Relay Control circuit.
Yes → Repair the Starter Relay Control circuit for a short to voltage.
No → Go To 8

Measure the resistance of the Starter Relay Control circuit.
Yes → Replace and program the ECM in accordance with the Service
Information.
No → Repair the Starter Relay Control circuit for an open.

Disconnect the Clutch Interlock Switch harness connector.
Connect a jumper wire across the Clutch Interlock Switch harness connector.
Using a 12-volt test light connected to ground, check the Ignition Switch Start
Output circuit at the Starter Relay connector in the PDC and turning the ignition
switch to the crank position.
Does the test light illuminate with the ignition switch in the crank position?
Yes → Replace the Clutch Interlock Switch.
No → Go To 10

Disconnect the Clutch Interlock Switch harness connector.
Measure the resistance of the Clutch Interlock Switch Output circuit between the
PDC and the Clutch Interlock Switch harness connector.
Yes → Repair the Ignition Switch Start Output circuit to the Clutch
Interlock Switch.
No → Repair the Clutch Interlock Switch Output circuit for an open.

212

11 Remove the Starter Relay from the PDC. All
Yes → Go To 12


Disconnect the Starter Relay Output wire from the Starter Solenoid.
Connect the Starter Relay Output wire (at the Starter) to ground.
Using a 12-volt test light connected to 12-volts, check the Starter Relay Output
circuit at the Starter Relay connector in the IPM.
Yes → Go To 13
No → Repair the Starter Relay Output circuit for an open.
13 Using the Service Information, check the battery cables for high resistance. All
Did either battery cable have a voltage drop greater than 0.2 volts?
Yes → Replace the battery cable(s).

No → Go To 14

Attempt to manually rotate the crankshaft 360°.
Is the crankshaft able to rotate 360°?
Yes → Replace the Starter Motor.

No → Repair the engine mechanical problem.
213
Symptom List:
ANTENNA FAILURE
COP FAILURE
EEPROM FAILURE
INTERNAL FAULT
RAM FAILURE
The title for the tests will be ANTENNA FAILURE.
ANTENNA FAILURE
When Monitored: Every 250 milliseconds with the ignition on.
Set Condition: The SKIM’s microcontroller determines that an antenna circuit fault has
occurred for 2.0 consecutive seconds.
COP FAILURE
Set Condition: The COP timer is not reset by the microcontroller every 65.5 milliseconds
EEPROM FAILURE
Set Condition: When the value written to EEPROM memory does not equal the value
read back after the write operation.
INTERNAL FAULT
Set Condition: The SKIM has detected a fault during an internal self test.
RAM FAILURE
Set Condition: The RAM fails a test that checks the RAM’s ability to retain memory.

Set Condition: The SKIM fails an internal J1850 communication self test.

Set Condition: The microcontroller has exceeded its stack space limit.
214
ANTENNA FAILURE — Continued
POSSIBLE CAUSES
SKIM INTERNAL DTC FAILURE

1 Note: This trouble code indicates an internal SKIM fault. All
With the DRBIIIt, read and record the SKIM DTCs and then erase the SKIM DTCs
Perform 10 ignition key cycles, leaving the ignition key on for a minimum of 90
seconds per cycle.
With the DRBIIIt , read the SKIM DTCs.
Did the same SKIM DTC return?
Yes → Replace and program the Sentry Key Immobilizer Module in
215
Symptom List:
PCM STATUS FAILURE
The title for the tests will be PCM STATUS FAILURE.
PCM STATUS FAILURE

Set Condition: This DTC exists when a PCM STATUS message was not received from the
PCM for at least 20.0 consecutive seconds.

When Monitored: At ignition on, after ignition on during any rolling code handshake that
occurs with the PCM due to a SKIM reset, or during SECRET KEY transfers to the PCM.
Set Condition: When the SKIM does not receive an expected PCI BUS message trans-
mission acknowledgement from the PCM after 3 transmit attempts.
POSSIBLE CAUSES
INTERMITTENT WIRING HARNESS PROBLEM
SKIM/PCM

1 NOTE: Ensure the PCM has proper power and ground connections before All
continuing.
With the DRB III, read and record the SKIM DTC’s then erase the SKIM DTC’s.
Wait 2 minutes.
With the DRB III, read the SKIM DTC’s.
Does the DRB III display the DTC that was previously erased?
Yes → Go To 2
No → Go To 4
216
PCM STATUS FAILURE — Continued

NOTE: Visually inspect the related wiring harness and CCD/PCI Bus
(whichever applicable) circuits. Look for any chafed, pierced, pinched, or

No → Go To 3
3 NOTE: Before proceeding it will be necessary to obtain the SKIM PIN All
number.
With the DRBIIIt, display and erase all PCM and SKIM DTC’s.
Perform 5 ignition key cycles, leaving the ignition key on for a minimum of 90 seconds
per cycle.
With the DRBIIIt, read the SKIM DTC’s.
Does the code appear?

217
Symptom List:
VIN MISMATCH
The title for the tests will be ROLLING CODE FAILURE.

When Monitored: At ignition on, after ignition on during any rolling code handshake that
occurs with the PCM due to a SKIM or PCM reset.
Set Condition: When a PCM STATUS message with a Valid Key status is not received by
the SKIM within 3.5 seconds of transmitting the last Valid Key Code message to the PCM.
VIN MISMATCH
Set Condition: When the VIN received from the PCM does not match the VIN stored in
the SKIM’s EEPROM.
POSSIBLE CAUSES
VERIFYING PCM VIN
PCM

1 With the DRBIIIt, erase the SKIM DTC’s. All
Wait 10 seconds.
Turn the ignition on and wait 2 minutes.
Does the DRBIIIt display the DTC that was previously erased?
Yes → Go To 2
No → Go To 4
218
ROLLING CODE FAILURE — Continued

2 NOTE: Ensure that a VIN has been programmed into the PCM. If a VIN is not All
displayed, attempt to program the PCM with the correct vehicle VIN before
continuing.
With the DRBIIIt, select Engine system from the main menu.
Display and record the Vehicle Identification Number.
Does the VIN recorded from the PCM match the VIN of the vehicle?
Yes → Go To 3
No → Replace and program the Powertrain Control Module in accor-


Replace and program the Sentry Key Immobilizer Module in accordance with the
With the DRBIIIt, display and clear all PCM and SKIM DTC’s.
Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle.
With the DRBIIIt, check for SKIM DTC’s.
Does the DRBIIIt display the same DTC?

219
Symptom List:
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE
TRANSPONDER RESPONSE MISMATCH
The title for the tests will be TRANSPONDER COMMUNICA-
TION FAILURE.

When Monitored: At ignition on and during Key Programming Mode.
Set Condition: When the SKIM does not receive a transponder response after 8 consec-
utive transponder read attempts within 2.0 seconds.
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE

Set Condition: When 5 consecutive transponder signal transmissions are sent to the
SKIM with the correct message format but with invalid data.
Set Condition: When the transponder ID read by the SKIM does not match any of the
transponder ID’s stored in the SKIM’s memory.
TRANSPONDER RESPONSE MISMATCH

Set Condition: When the transponder’s crypto algorithm result fails to match the SKIM’s
result.
POSSIBLE CAUSES
CHECKING MULTIPLE KEY OPERATION
SKIM
REPLACE IGNITION KEY
220
TRANSPONDER COMMUNICATION FAILURE — Continued

1 With the DRBIIIt, read and record the SKIM DTCs. All
With the DRBIIIt, erase the SKIM DTCs.
NOTE: Perform the following test several times to ensure the DTC is
current.
Wait 10 seconds.
Does the DRBIIIt display the DTC that was previously erased?
Yes → Go To 2
No → Go To 7
2 Are there multiple vehicle ignition keys available? All
Yes → Go To 3
No → Go To 4
3 NOTE: Perform the following steps using one of the vehicle ignition keys. All
When finished, repeat the procedure using each of the other vehicle keys
one at a time.
With the DRBIIIt, erase the SKIM DTC’s.
Wait 10 seconds.
Is the DTC present for all ignition keys?
Yes → Replace the Sentry Key Immobilizer Module in accordance with

4 With the DRBIIIt, attempt to reprogram the ignition keys to the SKIM. All
With the DRBIIIt, erase the SKIM DTC’s.
Wait 10 seconds.
Does the DTC reset?
Yes → Go To 5
5 Replace the ignition key with a new key. All

With the DRBIIIt, program the new ignition key to the SKIM.
With the DRBIIIt, erase the SKIM DTC’s
Wait 10 seconds.
Does the DTC reset?
Yes → Go To 6
221
TRANSPONDER COMMUNICATION FAILURE — Continued

Repair
Replace and program the Sentry Key Immobilizer Module in

222
VERIFICATION TESTS
Verification Tests
CHARGING VERIFICATION - VER-3 APPLICABILITY
2. If the PCM has been replaced, perform step 3. Otherwise, continue with step 4.
3. If the vehicle is equipped with a factory theft alarm, start the engine at least 20 times in
order to be able to activate the alarm system when desired.
4. With the DRB, erase all diagnostic trouble codes (DTCs).
5. Start the engine.
6. Raise the engine speed to 2000 RPM for at least 30 seconds.
7. Allow the engine to idle.
8. Turn the ignition off for 20 seconds.
9. Turn the ignition on.
10. With the DRB, read ECM and PCM DTCs.
11. If this DTC has reset, or another DTC has set, look for any Technical Service Bulletins
(TSBs) that may relate to this condition. Return to the Symptom List if necessary.
12. If the charging system is functioning correctly and there are no DTCs, the repair is now
complete.

NO START VERIFICATION - VER-1 APPLICABILITY

1. NOTE: IMPORTANT! If the Engine Control Module, Sentry Key Immobilizer All
Module or Powertrain Control Module have been replaced, ensure the programming
procedures for these modules have been performed in accordance with the Service
Information.
2. Inspect the vehicle to ensure that all engine components are properly installed and
3. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter.
6. Attempt to start the engine.
7. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may
relate to this condition. Return to the Symptom List if necessary.
8. If the engine starts and continues to run, the repair is now complete.
223
VERIFICATION TESTS
ROAD TEST VERIFICATION - VER-2 APPLICABILITY

2. If this verification procedure is being performed after a non-DTC test, perform steps 3 and
4.
3. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom
no longer exists, the repair was successful and testing is now complete.
4. If the initial or another symptom exists, the repair is not complete. Check all pertinent
Technical Service Bulletins (TSBs) and return to the Symptom List if necessary.
5. For previously read DTCs that have not been dealt with, return to the Symptom List and
follow the diagnostic path for that DTC; otherwise, continue.
6. If the Engine Control Module (ECM) (diesel only) or Powertrain Control Module (PCM) has
not been changed, perform steps 7 and 8, otherwise, continue with step 9.
7. With the DRB, erase all diagnostic trouble codes (DTCs), then disconnect the DRB.
9. Ensure no DTCs remain by performing steps 10 through 13.
10. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test
is for an A/C Relay Control Circuit, drive the vehicle for at least 5 minutes with the A/C on.
11. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart
the engine and continue.
12. Upon completion of the road test, turn the engine off and check for DTCs with the DRB.
13. If the repaired DTC has reset, the repair is not complete. Check for any pertinent Technical
Service Bulletins (TSBs) and return to the Symptom List. If there are no DTCs, the repair was
successful and is now complete.
SKIS VERIFICATION APPLICABILITY

2. Obtain the vehicle’s unique Personal Identification Number (PIN) assigned to it’s original
SKIM. This number can be obtained from the vehicle’s invoice or Chrysler’s Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow 3 consecutive attempts to enter the correct PIN. If 3 consecutive incorrect
PINs are entered, the SKIM will Lock Out the DRB III for 1 hour.
4. To exit Lock Out mode, the ignition key must remain in the Run position continually for 1
hour. Turn off all accessories and connect a battery charger if necessary.
5. With the DRBIIIt, select Theft Alarm, SKIM and Miscellaneous. Then, select the desired
procedure and follow the steps that will be displayed.
6. If the SKIM has been replaced, ensure all of the vehicle ignition keys are programmed to the
new SKIM.
7. NOTE: Prior to returning vehicle to the customer, perform a module scan to be
sure that all DTCs are erased. Erase any DTCs that are found.
8. With the DRBIIIt, erase all DTCs. Perform 5 ignition key cycles leaving the key on for at
least 90 seconds per cycle.
9. With the DRBIIIt, read the SKIM DTCs.
Are there any SKIM DTCs?
224
VERIFICATION TESTS
SPEED CONTROL VERIFICATION - VER-4 APPLICABILITY

2. If the ECM has been replaced, perform step 3. Otherwise, continue with step 4.
3. If the vehicle is equipped with a factory theft alarm, start the engine at least 20 times in
order to be able to activate the alarm system when desired.
5. Road test the vehicle at a speed above 58 km/h (35 MPH).
6. Turn the speed control ON/OFF switch on.
7. Depress and release the SET switch. If the speed control does not engage, the repair is not
complete, continue with step 15.
8. Quickly depress and release the RESUME/ACCEL switch. If the vehicle speed does not
increase by 3 km/h (2 MPH), the repair is not complete, continue with step 15.
9. Using caution, depress and release the brake pedal. If the speed control does not disengage,
the repair is not complete, continue with step 15.
10. With the vehicle speed at least 56 km/h (35 MPH), depress the RESUME/ACCEL switch.
If the speed control does not resume at the previously set speed, the repair is not complete,
continue with step 15.
11. Hold down the COAST switch. If the vehicle does not decelerate, the repair is not complete,
continue with step 15.
12. While still holding down the COAST switch, ensure the vehicle speed is at least 56 km/h (35
MPH) and release the COAST switch. If the vehicle does not adjust and set a new vehicle speed,
the repair is not complete, continue with step 15.
13. With the speed control engaged, depress the ON/OFF switch. If the speed control does not
disengage, the repair is not complete, continue with step 15.
14. If the vehicle did not successfully perform all of the previous steps, check for Technical
Service Bulletins (TSBs) that pertain to this speed control problem and then, if necessary,
return to the Symptom List.
15. If the vehicle successfully performed all of the previous steps, the speed control system is
now functioning as designed. The repair is now complete.

225
NOTES
226
COMPONENT LOCATIONS
C
M
8.1 CONTROL MODULES P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.2 CONTROLS AND SOLENOIDS
8.3 DATA LINK CONNECTOR
227
COMPONENT LOCATIONS
C
O
M 8.4 FUEL SYSTEM
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.5 RELAYS
228
COMPONENT LOCATIONS
C
8.6 SENSORS O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
229
COMPONENT LOCATIONS
C
O 8.6 SENSORS (Continued)
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
8.7 SWITCHES
230
CONNECTOR PINOUTS
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY

A/C PRESSURE SENSOR - GRAY 4 WAY

1 K900 18DB/DG (GAS) SENSOR GROUND
1 C918 20BK/LB (DIESEL) A/C PRESSURE SENSOR GROUND
2 F855 18PK/YL (GAS) 5 VOLT SUPPLY
2 F851 20LB/PK (DIESEL) SENSOR REFERENCE VOLTAGE B
C
3 C18 18LB/BR (GAS) A/C PRESSURE SENSOR SIGNAL
O
3 C18 20LB/BR (DIESEL) A/C PRESSURE SENSOR SIGNAL
N
4 - -
N
E
C
T
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY
O
R
1 - -
2 - -
P
I
4 - -
N
O
6 - -
U
T
8 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
S
9 - -
10 F852 20VT/PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY
BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY

1 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
231
CONNECTOR PINOUTS
BOOST PRESSURE SENSOR (DIESEL) - BLACK 4 WAY

3 F851 18LB/PK SENSOR REFERENCE VOLTAGE B
BRAKE LAMP SWITCH - BLACK 6 WAY

1 A103 18GY/RD FUSED B(+)
3 V30 20VT/WT (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT
4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE
C
O
N
N
E
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY
T 1 K944 20BK/GY CAMSHAFT POSITION SENSOR GROUND
O 2 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
R 3 K342 16BR/WT ECM/PCM RELAY OUTPUT
P
I
N
O
U
T
S
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY
1 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY

2 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
232
CONNECTOR PINOUTS
DATA LINK CONNECTOR - BLACK 16 WAY
1 - -
3 - -
5 Z111 18BK/WT (EXCEPT GROUND
BUILT-UP-EXPORT)
5 Z111 20BK/WT (BUILT-UP- GROUND
EXPORT)
6 D20 20WT/LG (GAS) SCI RECEIVE
8 - -
10 - -
11 - -
12 - -
13 - -
14 D16 20WT/OR (GAS) SCI RECEIVE
15 - -
C
O
N
N
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY
E
C
T
O
R
P
I
N
O
U
T
S
233
CONNECTOR PINOUTS
6 - -
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
14 - -
17 - -
18 - -
C 20 Z138 20BK/OR GROUND
O 21 K900 20DB/DG SENSOR GROUND
N 22 F202 20PK/GY IGNITION SWITCH OUTPUT (RUN-START)
N 23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
E 24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
C 25 - -
T 26 - -
O 27 - -
R 28 - -
29 - -
P 30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
I 31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
N 32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
O 33 - -
U 34 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
T 35 K853 20DB/BR ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY
S 36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL

38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
44 - -
45 - -
46 - -
234
CONNECTOR PINOUTS
51 - -
53 - -
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
59 - -
62 - -
65 - -
67 - -
68 - -
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL C
71 - - O
72 N21 20DB/TN LIFT PUMP RELAY CONTROL N
73 - - N
74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL E
75 - - C
76 - - T
77 K152 20DB/WT GLOW PLUG RELAY CONTROL O
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL R
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL P
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL I
N
O
U
T
S
235
CONNECTOR PINOUTS
82 - -
83 - -
84 - -
85 - -
87 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
C 101 - -
O 102 - -
N 103 - -
N 104 - -
E 105 - -
C 106 - -
T 107 - -
O 108 - -
R 109 - -
110 - -
P 111 - -
I 112 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
N 113 - -
O 114 - -
U 115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
T 116 K111 14DB/LB COMMON INJECTOR DRIVER
S 117 - -
121 - -
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY

236
CONNECTOR PINOUTS
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY

2 K900 20DB/OR SENSOR GROUND
C
O
N
N
FUEL HEATER (DIESEL) - BLACK 2 WAY E
1 N1 16RD FUEL HEATER RELAY OUTPUT T
2 Z201 18RD GROUND O
R
P
I
N
O
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY U
CAV CIRCUIT FUNCTION T
1 K111 14DB/LB COMMON INJECTOR DRIVER S
FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY

1 K111 14DB/LB COMMON INJECTOR DRIVER
237
CONNECTOR PINOUTS


2 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
C
O
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
N
N
E
C
T
O
R
P
I
N FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY
O
U
2 K87 16BR FUEL PRESSURE SOLENOID CONTROL
T
S
GENERATOR - BLACK 2 WAY

1 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
1 K342 16BR/WT (GAS) AUTOMATIC SHUTDOWN RELAY OUTPUT
2 K20 18BR/GY (GAS) GENERATOR FIELD CONTROL
2 K20 14BR/GY (DIESEL) GENERATOR FIELD CONTROL
238
CONNECTOR PINOUTS
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY

1 A202 10RD/WT FUSED B(+)
2 K152 20DB/WT GLOW PLUG RELAY CONTROL
4 K154 10BR/OR GLOW PLUG RELAY OUTPUT
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY

2 - -
9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL C
10 A119 16RD/OR FUSED B(+) O
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL N
12 T753 20DG/YL IGNITION SWITCH OUTPUT (START) N
13 - - E
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL C
15 Z116 18BK/VT GROUND T
16 K51 20BR/WT ECM/PCM RELAY CONTROL O
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START) R
18 - -
19 K342 16BR/WT ECM/PCM RELAY OUTPUT P
20 - - I
N
O
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY
U
T
A V37 20VT/TN (BUILT-UP- SPEED CONTROL SWITCH SIGNAL
EXPORT) S
A V37 20DG/VT (EXCEPT SPEED CONTROL SWITCH SIGNAL
BUILT-UP-EXPORT)
B Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY

1 N2 18OR LIFT PUMP RELAY OUTPUT
2 Z201 18OR GROUND
239
CONNECTOR PINOUTS
MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY

1 - -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
240
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
241
CONNECTOR PINOUTS
A/C COMPRESSOR CLUTCH RELAY
85 C13 18LB/OR (GAS) A/C COMPRESSOR CLUTCH RELAY CONTROL
85 C13 20LB/OR (DIESEL) A/C COMPRESSOR CLUTCH RELAY CONTROL
86 F202 18PK/GY (GAS) IGNITION SWITCH OUTPUT (RUN-START)
86 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
87A - -
ECM/PCM RELAY (DIESEL)
87A - -
FUEL HEATER RELAY (DIESEL)
86 INTERNAL IGNITION SWITCH OUTPUT (RUN-START)
C 87A - -
LIFT PUMP RELAY (DIESEL)
O
N
N
E
86 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
C
T
87A - -
O STARTER MOTOR RELAY
R CAV CIRCUIT FUNCTION
P 85 T752 18DG/OR (GAS) ENGINE STARTER MOTOR RELAY CONTROL
I 85 T752 20DG/OR (DIESEL) ENGINE STARTER MOTOR RELAY CONTROL
N 86 INTERNAL IGNITION SWITCH OUTPUT (START)
U 87A - -
T
S
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY

1 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
242
CONNECTOR PINOUTS
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY

1 Z823 12BK GROUND
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON OUTPUT
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY

1 - -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3 - -
5 - -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7 - -
8 A201 12RD/LG FUSED B(+)
C
9 - -
O
N
N
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY E
C
1 - -
T
O
3 - -
R
5 - -
P
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
I
7 - -
N
O
9 - -
U
T
S
RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY
1 - -
2 Z823 12BK GROUND
3 - -
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7 - -
8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
9 - -
243
CONNECTOR PINOUTS
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY

A V37 20VT/TN (BUILT UP SPEED CONTROL SWITCH SIGNAL
EXPORT)
A V37 20DG/VT (EXCEPT SPEED CONTROL SWITCH SIGNAL
BUILT-UP-EXPORT)
B Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY

1 - -
3 - -
C
VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY
N 1 F888 18BR/PK (2.4L) 8 VOLT SUPPLY
N 1 F202 18PK/GY (DIESEL) IGNITION SWITCH OUTPUT (RUN-START)
E 2 K900 18DB/DG (2.4L) SENSOR GROUND
C 2 K900 20DB/DG (DIESEL) SENSOR GROUND
T 3 N7 18DB/OR (2.4L) VEHICLE SPEED SENSOR SIGNAL
O 3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
R
P
I
N
O
U WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY
T
1 F853 20RD WATER IN FUEL SENSOR SIGNAL
S
2 K900 18RD SENSOR GROUND
244
SCHEMATIC DIAGRAMS
10.1 2001 RG 2.5L TURBO DIESEL
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
245
NOTES
246
CHARTS AND GRAPHS
11.0 CHARTS AND GRAPHS C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
247
NOTES
248
GROUP TAB LOCATOR
IN Introduction 8M Message Systems
INa Introduction 8N Power Systems
0 Lubrication & Maintenance 8Na Power Systems
0a Lubrication & Maintenance 8O Restraints
2 Suspension 8P Speed Control
2a Suspension 8Q Vehicle Theft Security
3 Differential & Driveline 8R Wipers/Washers
5 Brakes 8Wa Wiring
5a Brakes 9 Engine
6a Clutch 9a Engine
7 Cooling 11 Exhaust System
7a Cooling 11a Exhaust System
8A Audio 13 Frame & Bumpers
8Aa Audio 14 Fuel System
8B Chime/Buzzer 14a Fuel System
8Ba Chime/Buzzer 19 Steering
8E Electronic Control Modules 19a Steering
8F Engine Systems 21 Transmission/Transaxle
8Fa Engine Systems 21a Transmission/Transaxle
8G Heated Systems 22 Tires/Wheels
8H Horn 23 Body
8I Ignition Control 24 Heating & Air Conditioning
8J Instrument Cluster 24a Heating & Air Conditioning
8Ja Instrument Cluster 25 Emissions Control
8L Lamps 25a Emissions Control

8La Lamps Service Manual Comment Forms
RS INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE SAFETY CERTIFICATION LABEL FASTENER IDENTIFICATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE IDENTIFICATION NUMBER FASTENER USAGE
VECI LABEL METRIC SYSTEM
BODY CODE PLATE TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTERNATIONAL SYMBOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......4
VEHICLE SAFETY VEHICLE IDENTIFICATION

CERTIFICATION LABEL NUMBER
DESCRIPTION DESCRIPTION
A vehicle safety certification label (Fig. 1) is located The Vehicle Identification Number (VIN) can be
on the rearward facing of the driver’s door. This label viewed through the windshield at the upper left cor-
indicates date of manufacture (month and year), Gross ner of the instrument panel, near the left windshield
Vehicle Weight Rating (GVWR), Gross Axle Weight pillar (Fig. 2). The VIN consists of 17 characters in a
Rating (GAWR) front, Gross Axle Weight Rating combination of letters and numbers that provide spe-
(GAWR) rear and the Vehicle Identification Number cific information about the vehicle. Refer to VIN Code
(VIN). The Month, Day and Hour (MDH) of manufac- Breakdown Chart for decoding information.
ture is also included. To protect the consumer from theft and possible
When it is necessary to contact the manufacturer fraud the manufacturer is required to include a Check
regarding service or warranty, the information on the Digit at the ninth position of the Vehicle Identification
Vehicle Safety Certification Label would be required. Number. The check digit is used by the manufacturer
and government agencies to verify the authenticity of
the vehicle and official documentation. The formula to
use the check digit is not released to the general public.
Fig. 1 Vehicle Safety Certification Label
Fig. 2 Vehicle Identification Number (VIN Plate)

1 - DEFROSTER OUTLET
2 - VIN #
3 - HEATED WINDSHIELD GRID
2 INTRODUCTION RS
VEHICLE IDENTIFICATION NUMBER (Continued)
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Built in the United States by DaimlerChrysler
2 = Built in Canada by DaimlerChrysler Canada
Inc.
2 Make B = Dodge
C = Chrysler
3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air
Bags
8 = Multipurpose Pass. Vehicle With Side Air
Bags
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)
5 Car Line P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
T = Chrysler, Town & Country - AWD
T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
6 Series 2 = Low Line
4 = High Line
5 = Premium
6 = Sport
7 = Special
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16-VALVE DOHC
G = 3.3 L 6 cyl. Ethanol Flexible Fuel MPI
R = 3.3 L 6 cyl. Gas MPI
L = 3.8 L 6 cyl. Gas MPI
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant B = St. Louis South
R = Windsor
12 through 17 Sequence Number A six digit number assigned by assembly plant.
RS INTRODUCTION 3
VECI LABEL BODY CODE PLATE – LINE 3

DIGITS 1 THROUGH 12
DESCRIPTION
All models have a Vehicle Emission Control Infor- Vehicle Order Number
mation (VECI) Label. Chrysler permanently attaches
DIGITS 13 THROUGH 17
the label in the engine compartment. It cannot be
Open space
removed without defacing information and destroying
the label. DIGITS 18 AND 19
The label contains the vehicle’s emission specifica-
Vehicle Shell Line
tions and vacuum hose routings. All hoses must be
• NS
connected and routed according to the label.
DIGIT 20
BODY CODE PLATE Carline
FWD
DESCRIPTION • H = Plymouth
The Body Code Plate (Fig. 3) is located in the
• K = Dodge
engine compartment on the radiator closure panel
• Y = Chrysler
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used AWD
to define service information. Information reads from • C = Chrysler
left to right, starting with line 3 in the center of the • D = Dodge
plate to line 1 at the bottom of the plate. • P = Plymouth
DIGIT 21
Price Class
• H = Highline
• L = Lowline
• P = Premium
• S = Luxury
• X = Premium
DIGITS 22 AND 23
Body Type
• 52 = Short Wheel Base
• 53 = Long Wheel Base
BODY CODE PLATE LINE 2

DIGITS 1, 2 AND 3
Fig. 3 Body Code Plate Paint procedure
1 - PRIMARY PAINT
DIGIT 4
2 - SECONDARY PAINT
3 - VINYL ROOF Open Space
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL DIGITS 5 THROUGH 7
6 - PAINT PROCEDURE Primary paint
7 - ENGINE Refer to Group 23, Body for color codes.
8 - TRIM
9 - TRANSMISSION DIGIT 8 AND 9
10 - MARKET Open Space
11 - VIN
Secondary Paint
4 INTRODUCTION RS
BODY CODE PLATE (Continued)
DIGIT 13 AND 14 DIGIT 5
Open Space Market Code
• C = Canada
DIGITS 15 THROUGH 18 • B = International
Interior Trim Code • M = Mexico
• U = United States
DIGIT 19
Open Space DIGIT 6
Open Space
DIGITS 20, 21, AND 22
Engine Code DIGITS 7 THROUGH 23
• EDZ = 2.4 L 4 cyl. DOHC Gasoline Vehicle Identification Number
• EFA = 3.0 L 6 cyl. Gasoline • Refer to Vehicle Identification Number (VIN)
• EGA = 3.3 L 6 cyl. Gasoline paragraph for proper breakdown of VIN code.
• EGH = 3.8 L 6 cyl. Gasoline
• EGM = 3.3 L 6 cyl. Ethanol Flexible Fuel IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
DIGIT 23 lowed by END. When two plates are required, the
Open Space last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
BODY CODE PLATE LINE 1 spaces of each line will not be used due to overlap of
the plates.
DIGITS 1, 2, AND 3
Transaxle Codes
• DGB = 41TH 4-speed Automatic Transaxle INTERNATIONAL SYMBOLS
• DGL = 41TE 4-speed Electronic Automatic Tran-
saxle DESCRIPTION
• DGM = 31TH 3-speed Automatic Transaxle The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
DIGIT 4 used to identify various instrument controls. The
Open Space symbols correspond to the controls and displays that
are located on the instrument panel.
RS INTRODUCTION 5
INTERNATIONAL SYMBOLS (Continued)
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
FASTENER IDENTIFICATION FASTENER USAGE

DESCRIPTION DESCRIPTION - FASTENER USAGE
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater WARNING: USE OF AN INCORRECT FASTENER
the bolt strength. Identification is determined by the MAY RESULT IN COMPONENT DAMAGE OR PER-
line marks on the top of each bolt head. The actual SONAL INJURY.
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt Figure art, specifications and torque references in
strength classes are 9.8 and 10.9. The metric this Service Manual are identified in metric and SAE
strength class identification number is imprinted on format.
the head of the bolt. The higher the class number, During any maintenance or repair procedures, it is
the greater the bolt strength. Some metric nuts are important to salvage all fasteners (nuts, bolts, etc.)
imprinted with a single-digit strength class on the for reassembly. If the fastener is not salvageable, a
nut face. Refer to the Fastener Identification and fastener of equivalent specification must be used.
Fastener Strength Charts.
6 INTRODUCTION RS
FASTENER USAGE (Continued)
FASTENER IDENTIFICATION
RS INTRODUCTION 7
FASTENER STRENGTH
8 INTRODUCTION RS
DESCRIPTION - THREADED HOLE REPAIR METRIC SYSTEM

Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoilt recommen- DESCRIPTION - METRIC SYSTEM
dations for application and repair procedures. The metric system is based on quantities of one,
ten, one hundred, one thousand and one million .
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
(60° F)
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/ x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
Hr. (Km/h) (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
RS INTRODUCTION 9
METRIC SYSTEM (Continued)
METRIC CONVERSION CHART

10 INTRODUCTION RS
TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts.
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
TORQUE SPECIFICATIONS
RG INTRODUCTION 1a
INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE TORQUE REFERENCES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FASTENER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FASTENER USAGE VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THREADED HOLE REPAIR E-MARK LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTERNATIONAL VEHICLE CONTROL & VECI LABEL
DISPLAY SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........5 MANUFACTURE PLATE
METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ........6
BODY CODE PLATE

DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATE – LINE 3

DIGITS 1 THROUGH 12
Vehicle Order Number
Open space Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
DIGITS 18 AND 19 2 - SECONDARY PAINT
Vehicle Shell Line 3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
• RG
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
DIGIT 20
7 - ENGINE
Carline 8 - TRIM
9 - TRANSMISSION
FWD 10 - MARKET
• Y = Chrysler 11 - VIN
AWD
• C = Chrysler
2a INTRODUCTION RG
BODY CODE PLATE (Continued)
DIGIT 21 BODY CODE PLATE LINE 1
Price Class
• H = Highline DIGITS 1, 2, AND 3
• L = Lowline Transaxle Codes
• P = Premium • DGB = 41TH 4-speed Automatic Transaxle
• S = Luxury • DGL = 41TE 4-speed Electronic Automatic
• X = Premium Transaxle
• DGM = 31TH 3-speed Automatic Transaxle
DIGITS 22 AND 23
Body Type DIGIT 4
• 52 = Short Wheel Base Open Space
• 53 = Long Wheel Base
DIGIT 5
BODY CODE PLATE LINE 2 Market Code
• C = Canada
DIGITS 1, 2 AND 3 • B = International
Paint procedure • M = Mexico
• U = United States
DIGIT 4
Open Space DIGIT 6
Open Space
DIGITS 5 THROUGH 7
Primary paint(Refer to 23 - BODY/PAINT - SPEC- DIGITS 7 THROUGH 23
IFICATIONS). Vehicle Identification Number
• Refer to Vehicle Identification Number (VIN)
DIGIT 8 AND 9 paragraph for proper breakdown of VIN code.
Open Space
IF TWO BODY CODE PLATES ARE REQUIRED
DIGITS 10 THROUGH 12 The last code shown on either plate will be fol-
Secondary Paint lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
DIGIT 13 AND 14 When a second plate is required, the first four
Open Space spaces of each line will not be used due to overlap of
the plates.
Interior Trim Code
FASTENER IDENTIFICATION
DIGIT 19
Open Space DESCRIPTION
The SAE bolt strength grades range from grade 2
DIGITS 20, 21, AND 22 to grade 8. The higher the grade number, the greater
Engine Code the bolt strength. Identification is determined by the
• ENC = 2.5 L 4 cyl. Turbo Diesel line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
DIGIT 23 marks plus 2. The most commonly used metric bolt
Open Space strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
RG INTRODUCTION 3a
FASTENER IDENTIFICATION (Continued)
Fig. 2 FASTENER IDENTIFICATION

4a INTRODUCTION RG
FASTENER IDENTIFICATION (Continued)
Fig. 3 FASTENER STRENGTH

RG INTRODUCTION 5a
FASTENER USAGE THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using
WARNING: USE OF AN INCORRECT FASTENER a Helicoilt. Follow the vehicle or Helicoilt recommen-
MAY RESULT IN COMPONENT DAMAGE OR PER- dations for application and repair procedures.
SONAL INJURY.
Figure art, specifications and torque references in INTERNATIONAL VEHICLE

this Service Manual are identified in metric and SAE
format.
CONTROL & DISPLAY
During any maintenance or repair procedures, it is SYMBOLS
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a DESCRIPTION
fastener of equivalent specification must be used. The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
6a INTRODUCTION RG
METRIC SYSTEM The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
versa.
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x = Newton Meters N·m x 8.851 = in-lbs
0.11298 (N·m)
ft-lbs x = Newton Meters N·m x = ft-lbs
1.3558 (N·m) 0.7376
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x = Inches Hg
0.2961
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x = Inches
0.03937
Feet x = Meters (M) M x 3.281 = Feet
0.3048
Yards x = Meters M x = Yards
0.9144 1.0936
mph x = Kilometers/Hr. Km/h x = mph
1.6093 (Km/h) 0.6214
Feet/Sec x = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
0.3048
mph x = Meters/Sec (M/S) M/S x 2.237 = mph
0.4470
Kilometers/Hr. (Km/h) x = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
0.27778
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
RG INTRODUCTION 7a
METRIC SYSTEM (Continued)
METRIC CONVERSION CHART

8a INTRODUCTION RG
TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts.
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
RG INTRODUCTION 9a
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 5). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the Fig. 5 Vehicle Identification Number (VIN Plate)
authenticity of the vehicle and official documenta- 1 - DEFROSTER OUTLET
tion. The formula to use the check digit is not 2 - VIN #
released to the general public. 3 - HEATED WINDSHIELD GRID
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Built in the Graz Austria by DaimlerChrysler
2 Make C = Chrysler
3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags
8 = Multipurpose Pass. Vehicle With Side Air Bags
4 Gross Vehicle Weight G = 2268 - 2721 kg. (5001 - 6000 lbs.)
Rating
5 Car Line Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Right Hand Drive
I = Caravan FWD
6 Series 2 = Low Line
4 = High Line
5 = Premium
6 = Sport
7 = Special
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16 - VALVE DOHC
R = 3.3 L 6 cyl. Gasoline MPI
M = 2.5 L 4 cyl. Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant U = Graz Austria
12 through 17 Sequence Number A six digit number assigned by assembly plant.
10a INTRODUCTION RG
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 6) is located
on the rearward facing of the driver’s door. This label
indicates date of manufacture (month and year),
Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR) front, Gross Axle Weight Rat-
ing (GAWR) rear and the Vehicle Identification Num-
ber (VIN). The Month, Day and Hour (MDH) of
manufacture is also included.
When it is necessary to contact the manufacturer
regarding service or warranty, the information on the
Vehicle Safety Certification Label would be required.
Fig. 7 E-Mark Label
1 - Country Code
2 - Regulation Number
3 - Approval Number
4 - Amendment Number
removed without defacing information and destroying

the label.
The label contains the vehicle’s emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
MANUFACTURE PLATE
DESCRIPTION
Fig. 6 Vehicle Safety Certification Label The Manufacturer Plate (Fig. 8) is located in the
engine compartment on the passenger side strut
E-MARK LABEL tower. The plate contains five lines of information:
• Vehicle Identification Number (VIN)
DESCRIPTION • Gross Vehicle Mass (GVM)
An E-mark Label (Fig. 7) is located on the rear • Gross Train Mass (GTM)
shut face of the driver’s door. The label contains the • Gross Front Axle Rating (GFAR)
following information: • Gross Rear Axle Rating (GRAR)
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches Fig. 8 Manufacturer Plate
the label in the engine compartment. It cannot be
RS LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE

TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INTERNATIONAL SYMBOLS HOISTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......1 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 16
PARTS & LUBRICANT RECOMMENDATION HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE . . . . . . . . . . . . . ......2 JUMP STARTING
LUBRICANT CLASSIFICATIONS. . . . . . . ......2 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 16
PARTS AND LUBRICANT JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . 16
RECOMMENDATIONS . . . . . . . . . . . . . . ......2 TOWING
FLUID TYPES STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......3 TOWING RECOMMENDATIONS . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . ......7
FLUID FILL/CHECK LOCATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......7
LUBRICATION & DESCRIPTION SPECIFICATION

MAINTENANCE AWD Rear Carrier 0.7 L (1.48 pts.)
*(includes oil filter)
SPECIFICATIONS **(includes heater and recovery/reserve bottle)
SPECIFICATIONS - FLUID CAPACITIES

INTERNATIONAL SYMBOLS
DESCRIPTION SPECIFICATION DESCRIPTION
Fuel Tank 75 L (20 gal.) DaimlerChrysler Corporation uses international
Engine Oil* - 2.4L 4.7 L (5.0 qts.) symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 1).
Engine Oil* - 3.3/3.8L 4.0 L (4.5 qts.)
Cooling System** - 2.4L 10.7 L (11.4 qts.)
Cooling System** - 12.6 L (13.4 qts.)
3.3/3.8L without Rear
Heater
Cooling System** - 15.4 L (16.3 qts.)
3.3/3.8L with Rear Heater
Automatic Transaxle - 3.8 L (4.0 qts.)
Service Fill
31TH Overhaul Fill
41TE Overhaul Fill
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.) Fig. 1 International Symbols
AWD Bi-directional 0.575 L (1.22 pts.)
Overrunning Clutch
0-2 LUBRICATION & MAINTENANCE RS
PARTS & LUBRICANT Multi-Fuel, Variable Fuel, Flexible Fuel, etc. These
engine oils are preferred for use in Flexible Fuel
RECOMMENDATION engines.
STANDARD PROCEDURE - Classification of CAUTION: If Flexible Fuel engine oil is not used
Lubricants when using E-85 fuel, engine wear or damage may
Only lubricants that bear designations defined by result.
the following organization should be used to service a
DaimlerChrysler vehicle. GEAR LUBRICANTS
• Society of Automotive Engineers (SAE)
SAE ratings also apply to multiple grade gear
• American Petroleum Institute (API) (Fig. 2)
lubricants. In addition, API classification defines the
• National Lubricating Grease Institute (NLGI)
lubricants usage.
(Fig. 3)
LUBRICANTS AND GREASES
ENGINE OIL Lubricating grease is rated for quality and usage
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY by the NLGI. All approved products have the NLGI
symbol (Fig. 3)on the label. At the bottom NLGI sym-
An SAE viscosity grade is used to specify the vis-
bol is the usage and quality identification letters.
cosity of engine oil. Engine oils also have multiple
Wheel bearing lubricant is identified by the letter
viscosities. These are specified with a dual SAE vis-
“G”. Chassis lubricant is identified by the latter “L”.
cosity grade which indicates the cold-to-hot tempera-
The letter following the usage letter indicates the
ture viscosity range.
quality of the lubricant. The following symbols indi-
• SAE 30 = single grade engine oil.
cate the highest quality.
• SAE 10W-30 = multiple grade engine oil.Daim-
lerChrysler only recommends multiple grade engine
oils.
API QUALITY CLASSIFICATION

This symbol (Fig. 2) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler.
Refer to Group 9, Engine for gasoline engine oil
specification.
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
STANDARD PROCEDURE - PARTS AND

LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Motor
Corporation recommends that only Mopart brand
parts, lubricants and chemicals be used. Mopar pro-
Fig. 2 API Symbol
vides the best engineered products for servicing
FLEXIBLE FUEL ENGINE OIL – 3.3L ENGINE DaimlerChrysler Corporation vehicles.
Engine Oil Selection for Operating on E-85
Fuel If vehicle operates on E-85 fuel either full or ENGINE COOLANT
part-time, use only Mopart Flexible Fuel SAE 5W-30 The green coolant MUST NOT BE MIXED with
engine oil or an equivalent that meets the orange or magenta coolants. When replacing cool-
DaimlerChrysler Standard MS-9214. Equivalent com- ant the complete system flush must be performed
mercial Flexible Fuel engine oils may be labeled as before using the replacement coolant. (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
FLUID TYPES consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION
E-85 GENERAL INFORMATION ENGINE OIL
The information in this section is for Flexible Fuel
WARNING: NEW OR USED ENGINE OIL CAN BE
Vehicles (FFV) only. These vehicles can be identified
IRRITATING TO THE SKIN. AVOID PROLONGED OR
by the unique Fuel Filler Door Label that states
REPEATED SKIN CONTACT WITH ENGINE OIL.
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
tion only covers those subjects that are unique to
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
these vehicles. Please refer to the other sections of
YOUR HEALTH. THOROUGHLY WASH EXPOSED
this manual for information on features that are
SKIN WITH SOAP AND WATER. DO NOT WASH
common between Flexible Fuel and gasoline only
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
powered vehicles.
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
ETHANOL FUEL (E-85) PROPERLY. CONTACT YOUR DEALER OR GOVERN-
E-85 is a mixture of approximately 85% fuel etha-
MENT AGENCY FOR LOCATION OF COLLECTION
nol and 15% unleaded gasoline.
CENTER IN YOUR AREA.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never API SERVICE GRADE CERTIFIED
have any smoking materials lit in or near the vehi- Use an engine oil that is API Service Grade Certi-
cle when removing the fuel filler tube cap (gas cap) fied. MOPARt provides engine oils that conform to
or filling the tank. Do not use E-85 as a cleaning this service grade.
agent and never use it near an open flame.
SAE VISCOSITY
FUEL REQUIREMENTS An SAE viscosity grade is used to specify the vis-
The vehicle will operate on both unleaded gasoline cosity of engine oil. Use only engine oils with multi-
with an octane rating of 87, or E-85 fuel, or any mix- ple viscosities such as 5W-30 or 10W-30. These are
ture of these two. specified with a dual SAE viscosity grade which indi-
For best results, a refueling pattern that alternates cates the cold-to-hot temperature viscosity range.
between E-85 and unleaded gasoline should be Select an engine oil that is best suited to your par-
avoided. When you do switch fuels, it is recom- ticular temperature range and variation (Fig. 4).
mended that
• you do not switch when the fuel gauge indicates
less than 1/4 full
• you do not add less than 5 gallons when refuel-
ing
• you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0°F. In Fig. 4 Temperature/Engine Oil Viscosity
the range of 0°F to 32°F, you may experience an
increase in the time it takes for your engine to start, ENERGY CONSERVING OIL
and a deterioration in driveability (sags and/or hesi- An Energy Conserving type oil is recommended for
tations) until the engine is fully warmed up. gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
CRUISING RANGE tainer.
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
FLUID TYPES (Continued)
CONTAINER IDENTIFICATION NOTE: The 41TE transaxle has a common transmis-
Standard engine oil identification notations have sion and differential sump. Filling the transaxle
been adopted to aid in the proper selection of engine accommodates the differential as well.
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 5). TRANSMISSION FLUID
This symbol on the front of an oil container means Mopart ATF+4 (Automatic Transmission Fluid-
that the oil has been certified by the American Petro- Type 9602) is required in this transaxle. Substitute
leum Institute (API) to meet all the lubrication fluids can induce torque converter clutch shudder.
requirements specified by DaimlerChrysler. Mopart ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
Fig. 5 Engine Oil Container Standard Notations FLUID ADDITIVES
FLEXIBLE FUEL ENGINE OIL - 3.3L DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
Engine Oil Selection for Operating on E-85 Fuel those automatic transmission fluids listed above.
If vehicle operates on E-85 fuel either full or part- Exceptions to this policy are the use of special dyes
time, use only Mopart Flexible Fuel 5W-30 engine oil to aid in detecting fluid leaks.
or an equivalent that meets DaimlerChrysler Stan- Various “special” additives and supplements exist
dard MS-9214. Equivalent commercial Flexible Fuel that claim to improve shift feel and/or quality. These
engine oils may be labeled as Multi-Fuel, Variable additives and others also claim to improve converter
Fuel, Flexible Fuel, etc. These engine oils may be clutch operation and inhibit overheating, oxidation,
satisfactory if they meet the DaimlerChrysler Stan- varnish, and sludge. These claims have not been sup-
dard. ported to the satisfaction of DaimlerChrysler and
SAE 5W-30 engine oil is preferred for use in Flex- these additives must not be used. The use of trans-
ible Fuel engines. mission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
CAUTION: If Flexible Fuel engine oil is not used seals.
when using E-85 fuel, engine wear or damage may
result. DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
DESCRIPTION - AUTOMATIC TRANSMISSION formance when using high quality unleaded gasoline
FLUID having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
NOTE: Refer to the maintenance schedules for the gasoline will provide no benefit over high quality reg-
recommended maintenance (fluid/filter change) ular gasoline, and in some circumstances may result
intervals for this transaxle. in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
NOTE: For fluid level checking procedures, (Refer spark knock at high speeds can cause damage and
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - immediate service is required. Engine damage result-
31TH/FLUID - STANDARD PROCEDURE) (Refer to 21 ing from operation with a heavy spark knock may
- TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE/ not be covered by the new vehicle warranty.
FLUID - STANDARD PROCEDURE) Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have emission standards, your vehicles will operate satis-
issued and endorsed consistent gasoline specifications factorily on fuels meeting federal specifications, but
(the Worldwide Fuel Charter, WWFC) to define fuel emission control system performance may be
properties necessary to deliver enhanced emissions, adversely affected. Gasoline sold outside of California
performance and durability for your vehicle. We rec- is permitted to have higher sulfur levels which may
ommend the use of gasolines that meet the WWFC affect the performance of the vehicle’s catalytic con-
specifications if they are available. verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
REFORMULATED GASOLINE light to illuminate. We recommend that you try a dif-
Many areas of the country require the use of ferent brand of unleaded gasoline having lower sulfur
cleaner burning gasoline referred to as “reformulat- to determine if the problem is fuel related prior to
ed” gasoline. Reformulated gasoline contain oxygen- returning your vehicle to an authorized dealer for
ates, and are specifically blended to reduce vehicle service.
emissions and improve air quality.
We strongly supports the use of reformulated gas- CAUTION: If the Malfunction Indicator Lamp (MIL),
oline. Properly blended reformulated gasoline will Check Engine or Service Engine Soon light is flash-
provide excellent performance and durability for the ing, immediate service is required; see on-board
engine and fuel system components. diagnostics system section.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with MATERIALS ADDED TO FUEL
oxygenates such as 10% ethanol, MTBE, and ETBE. All gasoline sold in the United States and Canada
Oxygenates are required in some areas of the country are required to contain effective detergent additives.
during the winter months to reduce carbon monoxide Use of additional detergents or other additives is not
emissions. Fuels blended with these oxygenates may needed under normal conditions.
be used in your vehicle.
FUEL SYSTEM CAUTIONS
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage CAUTION: Follow these guidelines to maintain your
critical fuel system components. vehicle’s performance:
• The use of leaded gas is prohibited by Federal

MMT IN GASOLINE law. Using leaded gasoline can impair engine perfor-
MMT is a manganese-containing metallic additive mance, damage the emission control system, and
that is blended into some gasoline to increase octane. could result in loss of warranty coverage.
Gasoline blended with MMT provide no performance • An out-of-tune engine, or certain fuel or ignition
advantage beyond gasoline of the same octane num- malfunctions, can cause the catalytic converter to
ber without MMT. Gasoline blended with MMT overheat. If you notice a pungent burning odor or
reduce spark plug life and reduce emission system some light smoke, your engine may be out of tune or
performance in some vehicles. We recommend that malfunctioning and may require immediate service.
gasolines free of MMT be used in your vehicle. The Contact your dealer for service assistance.
MMT content of gasoline may not be indicated on the • When pulling a heavy load or driving a fully
gasoline pump; therefore, you should ask your gaso- loaded vehicle when the humidity is low and the tem-
line retailer whether or not his/her gasoline contains perature is high, use a premium unleaded fuel to
MMT. help prevent spark knock. If spark knock persists,
It is even more important to look for gasoline with- lighten the load, or engine piston damage may result.
out MMT in Canada because MMT can be used at • The use of fuel additives which are now being
levels higher than allowed in the United States. sold as octane enhancers is not recommended. Most
MMT is prohibited in Federal and California refor- of these products contain high concentrations of
mulated gasoline. methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
SULFUR IN GASOLINE or additives is not the responsibility of Daimler-
If you live in the northeast United States, your Chrysler Corporation and may not be covered under
vehicle may have been designed to meet California the new vehicle warranty.
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
NOTE: Intentional tampering with emissions control CAUTION: MoparT Antifreeze/Coolant, 5 Year/
systems can result in civil penalties being assessed 100,000 Mile Formula (MS-9769) may not be mixed
against you. with any other type of antifreeze. Doing so will
reduce the corrosion protection and may result in
premature water pump seal failure. If non-HOAT
GEAR LUBRICATION – RATINGS coolant is introduced into the cooling system in an
SAE ratings also apply to multiple grade gear emergency, it should be replaced with the specified
lubricants. In addition, API classification defines the coolant as soon as possible.
lubricants usage.
DESCRIPTION - ENGINE COOLANT DESCRIPTION - LUBRICANTS AND GREASES

When service is required, DaimlerChrysler Corpo-
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL ration recommends that only Mopart brand parts,
BASE COOLANT AND IS HARMFUL IF SWAL- lubricants and chemicals be used. Mopart provides
LOWED OR INHALED. IF SWALLOWED, DRINK the best engineered products for servicing
TWO GLASSES OF WATER AND INDUCE VOMIT- DaimlerChrysler Corporation vehicles.
ING. IF INHALED, MOVE TO FRESH AIR AREA. Only lubricants bearing designations defined by
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT the following organization should be used to service a
STORE IN OPEN OR UNMARKED CONTAINERS. Chrysler Corporation vehicle.
WASH SKIN AND CLOTHING THOROUGHLY AFTER • Society of Automotive Engineers (SAE)
COMING IN CONTACT WITH ETHYLENE GLYCOL. • American Petroleum Institute (API) (Fig. 6)
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF • National Lubricating Grease Institute (NLGI)
GLYCOL BASE COOLANT PROPERLY, CONTACT (Fig. 7)
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR SAE VISCOSITY RATING
AREA. DO NOT OPEN A COOLING SYSTEM WHEN An SAE viscosity grade is used to specify the vis-
THE ENGINE IS AT OPERATING TEMPERATURE OR cosity of engine oil. These are specified with a dual
HOT UNDER PRESSURE, PERSONAL INJURY CAN SAE viscosity grade which indicates the cold-to-hot
RESULT. AVOID RADIATOR COOLING FAN WHEN temperature viscosity range. Example SAE 5W-30 =
ENGINE COMPARTMENT RELATED SERVICE IS multiple grade engine oil.
PERFORMED, PERSONAL INJURY CAN RESULT. DaimlerChrysler Corporation only recommends
multiple grade engine oils.
CAUTION: Use of Propylene Glycol based coolants API QUALITY CLASSIFICATION
is not recommended, as they provide less freeze This symbol (Fig. 6) on the front of an oil container
protection and less corrosion protection. means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
The cooling system is designed around the coolant.
cation requirements specified by DaimlerChrysler
The coolant must accept heat from engine metal, in
Corporation.
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Mopart Antifreeze/Coolant, 5 Year/
100,000 Mile Formula (MS-9769), or the equivalent
ethylene glycol base coolant with organic corrosion
inhibitors (called HOAT, for Hybrid Organic Additive
Technology) is recommended. This coolant offers the
best engine cooling without corrosion when mixed Fig. 6 API Symbol
with 50% Ethylene Glycol and 50% distilled water to GEAR LUBRICANTS
obtain a freeze point of -37°C (-35°F). If it loses color SAE ratings also apply to multiple grade gear
or becomes contaminated, drain, flush, and replace lubricants. In addition, API classification defines the
with fresh properly mixed coolant solution. lubricants usage. Such as API GL-5 and SAE 80W-
90.
LUBRICANTS AND GREASES FLUID FILL/CHECK
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
LOCATIONS
symbol (Fig. 7) on the label. At the bottom NLGI
symbol is the usage and quality identification letters. DESCRIPTION
Wheel bearing lubricant is identified by the letter The fluid check/fill points and lubrication locations
“G”. Chassis lubricant is identified by the latter “L”. are located in each applicable Sections.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
MAINTENANCE SCHEDULES
DESCRIPTION
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule – A. It lists all the scheduled
maintenance to be performed under “normal” operat-
ing conditions.
Second is Schedule – B. It is a schedule for vehi-
cles that are operated under the following conditions:
• Frequent short trip driving less than 10 miles
Fig. 7 NLGI Symbol (16.2 km)
• Frequent driving in dusty conditions
1 - WHEEL BEARINGS
• Frequent off-road or desert operation
2 - CHASSIS LUBRICATION
• Frequent trailer towing
• Day and night temperatures are below freezing
• Frequent long periods of engine idling
OPERATION • Frequent stop and go driving
The cooling system is designed around the coolant. • More than 50% of your driving is at sustained
The coolant must accept heat from engine metal, in high speeds during hot weather, above 90°F (32°C)*
the cylinder head area near the exhaust valves and • Taxi, police or delivery service
engine block. Then coolant carries the heat to the • If equipped for and operation with E-85
radiator where the tube/fin radiator can transfer the (ethanol) fuel.
heat to the air.
DESCRIPTION
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL- At Each Stop For Fuel
LOWED OR INHALED. IF SWALLOWED, DRINK • Check engine oil level and add as required.
TWO GLASSES OF WATER AND INDUCE VOMIT- • Check windshield washer solvent and add as
ING. IF INHALED, MOVE TO FRESH AIR AREA. required.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS. Once A Month
WASH SKIN AND CLOTHING THOROUGHLY AFTER • Check tire pressure and look for unusual wear
COMING IN CONTACT WITH ETHYLENE GLYCOL. or damage.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF • Check fluid levels of coolant reservoir, brake
GLYCOL BASE COOLANT PROPERLY, CONTACT master cylinder, power steering and transmission.
YOUR DEALER OR GOVERNMENT AGENCY FOR Add fluid as required.
LOCATION OF COLLECTION CENTER IN YOUR • Check all lights and all other electrical items for
AREA. DO NOT OPEN A COOLING SYSTEM WHEN correct operation.
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN At Each Oil Change
RESULT. AVOID RADIATOR COOLING FAN WHEN • Change oil filter
ENGINE COMPARTMENT RELATED SERVICE IS • Inspect the exhaust system.
PERFORMED, PERSONAL INJURY CAN RESULT. • Inspect brake hoses.
• Inspect the CV joints and front suspension com-
ponent boots and seals.
• Rotate the tires at each oil change interval
shown on Schedule – A (7,500 miles - 12 000 km) or
MAINTENANCE SCHEDULES (Continued)
every other interval on Schedule – B (6,000 miles - 60,000 Miles (96 000 km) or at 48 months
10 000 km). • Change the engine oil.
• Check the engine coolant level, hoses, and • Replace the engine oil filter.
clamps. • Replace the engine air cleaner element (fil-
ter).
EMISSION CONTROL SYSTEM MAINTENANCE • Check the PCV valve and replace, if neces-
The scheduled emission maintenance listed in bold sary.*
type on the Maintenance Schedules, must be done at • Inspect the serpentine drive belt, replace if nec-
the mileage specified to assure the continued proper essary.
functioning of the emission control system. These, • Inspect the tie rod ends and boot seals.
and all other maintenance services included in this
manual, should be done to provide the best vehicle 67,500 Miles (108 000 km) or at 54 months
performance and reliability. More frequent mainte- • Change the engine oil.
nance may be needed for vehicles in severe operating • Replace the engine oil filter.
conditions such as dusty areas and very short trip • Inspect the brake linings.
driving.
75,000 Miles (120 000 km) or at 60 months
DESCRIPTION - MAINTENANCE SCHEDULES • Change the engine oil.
• Replace the engine oil filter.
SCHEDULE – A – CHRYSLER TOWN AND • Inspect the serpentine drive belt and replace if
COUNTRY VEHICLES necessary. This maintenance is not required if the
belt was previously replaced.
7,500 Miles (12 000 km) or at 6 months • Flush and replace engine coolant at 60 months.
• Change the engine oil.
• Replace the engine oil filter. 82,500 Miles (132 000 km) or at 66 months
15,000 Miles (24 000 km) or at 12 months • Replace the engine oil filter.
• Replace the engine oil filter. 90,000 Miles (144 000 km) or at 72 months
22,500 Miles (36 000 km) or at 18 months • Replace the engine oil filter.
• Change the engine oil. • Replace the engine air cleaner element (fil-
• Replace the engine oil filter. ter).
• Inspect the brake linings. • Check the PCV valve and replace, if neces-
sary. Not required if previously changed.*
30,000 Miles (48 000 km) or at 24 months • Inspect the serpentine drive belt, replace if nec-
• Change the engine oil. essary. This maintenance is not required if the belt
• Replace the engine oil filter. was previously replaced.
• Replace the engine air cleaner element (fil- • Inspect the tie rod ends and boot seals.
ter). • Inspect the brake linings.
• Inspect the tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months • Change the engine oil.
• Change the engine oil. • Replace the engine oil filter.
100,000 Miles (160,000 km)
45,000 Miles (72 000 km) or at 36 months • Replace the spark plugs.
• Change the engine oil. • Replace the ignition cables.
• Replace the engine oil filter. • Flush and replace engine coolant at 60 months
• Inspect the brake linings. or 100,000 miles (160,000 km).
52,500 Miles (84 000 km) or at 42 months 105,000 Miles (168 000 km) or at 84 months
• Change the engine oil. • Change the engine oil.
• Replace the engine oil filter. • Replace the engine oil filter.
• Inspect the serpentine drive belt and replace if
necessary. This maintenance is not required if the
belt was previously replaced.
112,500 Miles (180 000 km) or at 90 months 15,000 Miles (24 000 km)
• Inspect the brake linings. • Inspect the engine air cleaner element (fil-
ter). Replace as necessary.*
120,000 Miles (192 000 km) or at 96 months • Change the All Wheel Drive (AWD) power trans-
• Change the engine oil. fer unit fluid. (See the note at the end of Schedule –
• Replace the engine oil filter. B.)
• Replace the engine air cleaner element (fil-
ter). 18,000 Miles (29 000 km)
• Check and replace the PCV valve, if neces- • Change the engine oil.
sary.* • Replace the engine oil filter.
• Inspect the serpentine drive belt. Not required if • Inspect the brake linings.
replaced at 75,000, 90,000 or 105,000 miles.
• Inspect the tie rod ends and boot seals. 21,000 Miles (34 000 km)
*This maintenance is recommended by Daimler- • Change the engine oil.
Chrysler Corporation to the owner but is not • Replace the engine oil filter.
required to maintain the emissions warranty. • Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
NOTE: Inspection and service should also be per- of Schedule – B.)
formed anytime a malfunction is observed or sus-
pected. Retain all receipts. 24,000 Miles (38 000 km)
SCHEDULE – B – CHRYSLER TOWN AND
COUNTRY VEHICLES 27,000 Miles (43 000 km)
Follow this schedule if the vehicle is usually oper- • Change the engine oil.
ates under one or more of the following conditions. • Replace the engine oil filter.
• Frequent short trip driving less than 5 miles (8 • Inspect the brake linings.
km)
• Frequent driving in dusty conditions 30,000 Miles (48 000 km)
• Frequent trailer towing • Change the engine oil.
• Day and night temperatures are below freezing • Replace the engine oil filter.
• Frequent long periods of engine idling • Replace the engine air cleaner element (fil-
• Frequent stop and go driving ter).
• More than 50% of your driving is at sustained • Inspect the PCV valve, replace as neces-
high speeds during hot weather, above 90°F (32°C)* sary.*
• Taxi, police or delivery service • Change the All Wheel Drive (AWD) power trans-
• If equipped for and operation with E-85 fer unit fluid. (See the note at the end of Schedule –
(ethanol) fuel. B.)
3,000 Miles (5 000 km)
• Change the engine oil. 33,000 Miles (53 000 km)
• Replace the engine oil filter. • Change the engine oil.
6,000 Miles (10 000 km)
9,000 Miles (14 000 km) • Inspect the brake linings.
• Replace the engine oil filter. 39,000 Miles (62 000 km)
• Inspect the brake linings. • Change the engine oil.
12,000 Miles (19 000 km)
0 - 10 LUBRICATION & MAINTENANCE RS
42,000 Miles (67 000 km) 66,000 Miles (106 000 km)
• Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end 69,000 Miles (110 000 km)
of Schedule – B.) • Change the engine oil.
45,000 Miles (72 000 km)
• Inspect the engine air cleaner element (fil- • Replace the engine oil filter.
ter). Replace as necessary.* • Inspect the brake linings.
• Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule – 75,000 Miles (120 000 km)
B.) • Change the engine oil.
• Inspect the brake linings. • Replace the engine oil filter.
• Inspect the engine air cleaner element (fil-
48,000 Miles (77 000 km) ter) and replace as necessary.*
• Change the engine oil. • Replace the spark plugs.
• Replace the engine oil filter. • Replace the ignition cables.
• Drain and refill the automatic transmission fluid • Inspect the serpentine drive belt and replace if
and replace the filter. (See the note at the end of necessary. This maintenance is not required if belt
Schedule – B.) was previously replaced.
• Change the All Wheel Drive (AWD) power trans-
51,000 Miles (82 000 km) fer unit fluid. (See the note at the end of Schedule –
• Change the engine oil. B.)
54,000 Miles (86 000 km) 78,000 Miles (125 000 km)
• Inspect the brake linings.
81,000 Miles (130 000 km)
57,000 Miles (91 000 km) • Change the engine oil.
• Replace the engine oil filter. • Inspect the brake linings.
60,000 Miles (96 000 km) 84,000 Miles (134 000 km)
• Replace the engine air cleaner element (fil- • Change the All Wheel Drive (AWD) overrunning
ter). clutch and rear carrier fluid. (See the note at the end
• Inspect the PCV valve and replace if neces- of Schedule – B.)
sary.*
• Inspect the serpentine drive belt and replace if 87,000 Miles (139 000 km)
necessary. • Change the engine oil.
• Change the All Wheel Drive (AWD) power trans- • Replace the engine oil filter.
fer unit fluid. (See the note at the end of Schedule –
B.) 90,000 Miles (144 000 km)
• Inspect the tie rod ends and boot seals. • Change the engine oil.
63,000 Miles (101 000 km) • Replace the engine air cleaner element (fil-
• Change the engine oil. ter).
• Replace the engine oil filter. • Check the PCV valve and replace if neces-
• Inspect the brake linings. sary. Not required if previously changed.*
• Change the All Wheel Drive (AWD) overrunning • Inspect the serpentine drive belt and replace if
clutch and rear carrier fluid. (See the note at the end necessary. This maintenance is not required if belt
of Schedule – B.) was previously replaced.
RS LUBRICATION & MAINTENANCE 0 - 11
• Change the All Wheel Drive (AWD) power trans- 117,000 Miles (187 000 km)
fer unit fluid. (See the note at the end of Schedule – • Change the engine oil.
B.) • Replace the engine oil filter.
• Inspect the tie rod ends and boot seals. • Inspect the brake linings.
120,000 Miles (192 000 km)
• Replace the engine oil filter. • Replace the engine air cleaner element (fil-
ter).
96,000 Miles (154 000 km) • Inspect the PCV valve and replace as nec-
• Change the engine oil. essary.*
• Replace the engine oil filter. • Inspect the serpentine drive belt. Not required if
• Drain and refill the automatic transmission fluid replaced at 75,000, 90,000 or 105,000 miles.
and replace the filter. (See the note at the end of • Change the All Wheel Drive (AWD) power trans-
Schedule – B.) fer unit fluid. (See the note at the end of Schedule –
B.)
99,000 Miles (158 000 km) • Inspect the tie rod ends and boot seals.
• Change the engine oil. *This maintenance is recommended by Daimler-
• Replace the engine oil filter. Chrysler Corporation to the owner but is not
• Inspect the brake linings. required to maintain the emissions warranty.
100,000 Miles (160 000 km) NOTE: Operating the vehicle more than 50% in
• Flush and replace the engine coolant at 60 heavy traffic during hot weather, above 90°F (32°C),
months or 100,000 miles (160 000 km). using the vehicle for police, taxi, limousine type
operation or trailer towing require the more fre-
102,000 Miles (163 000 km) quent transaxle service noted in Schedule – B. Per-
• Change the engine oil. form these services if vehicle usually operates
• Replace the engine oil filter. under these conditions.
105,000 Miles (168 000 km)

• Change the engine oil. NOTE: Inspection and service should also be per-
• Replace the engine oil filter. formed anytime a malfunction is observed or sus-
• Inspect the engine air cleaner element (fil- pected.
ter) and replace as necessary.*
• Inspect the serpentine drive belt and replace if
necessary. This maintenance is not required if belt DESCRIPTION
was previously replaced.
• Change the All Wheel Drive (AWD) power trans- SCHEDULE – A – DODGE CARAVAN, CHRYSLER
fer unit fluid. (See the note at the end of Schedule – VOYAGER
B.)
• Change the All Wheel Drive (AWD) overrunning 7,500 Miles (12 000 km) or at 6 months
clutch and rear carrier fluid. (See the note at the end • Change the engine oil.
of Schedule – B.) • Replace the engine oil filter.
108,000 Miles (173 000 km) 15,000 Miles (24 000 km) or at 12 months
• Replace the engine oil filter. • Inspect the brake linings.
114,000 Miles (182 000 km) 30,000 Miles (48 000 km) or at 24 months
• Replace the engine air cleaner element (fil- 90,000 Miles (144 000 km) or at 72 months
ter). • Change the engine oil.
• Replace the spark plugs on 2.4 liter engines. • Replace the engine oil filter.
• Inspect and adjust the power steering pump belt • Replace the engine air cleaner element (fil-
tension on 2.4 liter engines. ter).
• Inspect the tie rod ends and boot seals. • Check the PCV valve and replace, if necessary.
Not required if previously changed.*
37,500 Miles (60 000 km) or at 30 months • Replace the spark plugs on 2.4 liter engines.
• Change the engine oil. • Inspect and adjust the power steering pump belt
• Replace the engine oil filter. tension on 2.4 liter engines.
• Inspect the generator belt on 2.4 liter engines
45,000 Miles (72 000 km) or at 36 months and replace if necessary.
• Change the engine oil. • Inspect the serpentine drive belt on 3.3 liter and
• Replace the engine oil filter. 3.8 liter engines, and replace if necessary. This main-
• Inspect the generator belt on 2.4 liter engines tenance is not required if belt was previously
and replace if necessary. replaced.
• Inspect the brake linings. • Inspect the tie rod ends and boot seals.
• Change the engine oil. 97,500 Miles (156 000 km) or at 78 months
• Replace the engine oil filter. • Replace the spark plugs 3.3 liter and 3.8 liter
• Replace the engine air cleaner element (fil- engines.
ter). • Replace the ignition cables 2.4 liter, 3.3 liter
• Check the PCV valve and replace, if necessary.* and 3.8 liter engines.
• Replace the spark plugs on 2.4 liter engines. • Flush and replace the engine coolant 60 months
• Inspect the power steering pump belt tension, or 100,000 miles (160 000 km).
and replace the belt, if necessary, on 2.4 liter
engines. 105,000 Miles (168 000 km) or at 84 months
• Inspect the serpentine drive belt on 3.3 liter and • Change the engine oil.
3.8 liter engines, and replace if necessary. • Replace the engine oil filter.
• Inspect the tie rod ends and boot seals. • Inspect the serpentine drive belt on 3.3 liter and
3.8 liter engines, and replace if necessary. This main-
67,500 Miles (108 000 km) or at 54 months tenance is not required if belt was previously
• Change the engine oil. replaced.
• Replace the engine oil filter. • Inspect the generator belt on 2.4 liter engines
• Inspect the brake linings. and replace if necessary.
75,000 Miles (120 000 km) or at 60 months 112,500 Miles (180 000 km) or at 90 months
• Inspect the generator belt on 2.4 liter engines • Inspect the brake linings.
and replace if necessary.
• Inspect the serpentine drive belt on 3.3 liter and 120,000 Miles (192 000 km) or at 96 months
3.8 liter engines, and replace if necessary. This main- • Change the engine oil.
tenance is not required if belt was previously • Replace the engine oil filter.
replaced. • Replace the engine air cleaner element (fil-
• Flush and replace engine coolant at 60 months. ter).
• Check and replace the PCV valve, if necessary.*
82,500 Miles (132 000 km) or at 66 months • Replace the spark plugs 2.4 liter engines.
• Change the engine oil. • Inspect the power steering pump belt tension,
• Replace the engine oil filter. replace belt if necessary on 2.4 liter engines.
• Inspect the generator belt on 2.4 liter engines 18,000 Miles (29 000 km)
and replace if necessary. • Change the engine oil.
• Inspect the serpentine drive belt on 3.3 liter and • Replace the engine oil filter.
3.8 liter engines. Not required if replaced at 75,000, • Inspect the brake linings.
90,000 or 105,000 miles.
• Replace the engine timing belt on 2.4 liter 21,000 Miles (34 000 km)
engine only. • Change the engine oil.
• Inspect the tie rod ends and boot seals. • Replace the engine oil filter.
* This maintenance is recommended by Daimler- • Change the All Wheel Drive (AWD) overrunning
Chrysler Corporation to the owner but is not clutch and rear carrier fluid. (See the note at the end
required to maintain the emissions warranty. of Schedule – B.)
Inspection and service should also be performed
anytime a malfunction is observed or suspected. 24,000 Miles (38 000 km)
Retain all receipts. • Change the engine oil.
SCHEDULE – B – DODGE VEHICLES, CHRYSLER
VOYAGER 27,000 Miles (43 000 km)
Follow this schedule if the vehicle is usually oper- • Change the engine oil.
ates under one or more of the following conditions. • Replace the engine oil filter.
• Frequent short trips of less than 5 miles • Inspect the brake linings.
• Frequent driving in dusty conditions
• Frequent trailer towing 30,000 Miles (48 000 km)
• Day and night temperatures are below freezing • Change the engine oil.
• Frequent stop and go driving • Replace the engine oil filter.
• Extensive periods of idling • Replace the engine air cleaner element (fil-
• Frequent operation at sustained high speeds ter).
during hot weather, above 90°F (32°C) • Inspect the PCV valve and replace as neces-
• Use of E-85 (ethanol) fuel in 3.3 liter engines. sary.*
• Replace the spark plugs 2.4 liter engines.
3,000 Miles (5 000 km) • Inspect and adjust the generator belt and power
• Change the engine oil. steering pump belt tension on 2.4 liter engines.
• Replace the engine oil filter. • Change the All Wheel Drive (AWD) power trans-
6,000 Miles (10 000 km) B.)
• Change the engine oil. • Inspect the tie rod ends and boot seals.
33,000 Miles (53 000 km)
• Inspect the brake linings. 36,000 Miles (58 000 km)
12,000 Miles (19 000 km) • Replace the engine oil filter.
• Change the engine oil. • Inspect the brake linings.
39,000 Miles (62 000 km)
• Inspect the engine air cleaner element (fil- 42,000 Miles (67 000 km)
ter). Replace as necessary.* • Change the engine oil.
• Change the All Wheel Drive (AWD) power trans- • Replace the engine oil filter.
fer unit fluid. (See the note at the end of Schedule – • Change the All Wheel Drive (AWD) overrunning
B.) clutch and rear carrier fluid. (See the note at the end
• Inspect the generator belt on 2.4 liter engines of Schedule – B.)
45,000 Miles (72 000 km) 66,000 Miles (106 000 km)
• Inspect the engine air cleaner element (fil-
ter). Replace as necessary.* 69,000 Miles (110 000 km)
• Inspect the generator belt on 2.4 liter engines • Change the engine oil.
and replace if necessary. • Replace the engine oil filter.
• Change the All Wheel Drive power transfer unit
fluid. (See the note at the end of Schedule – B.) 72,000 Miles (115 000 km)
• Inspect the brake linings. • Change the engine oil.
48,000 Miles (77 000 km) • Inspect the brake linings.
• Drain and replace the automatic transmission • Change the engine oil.
fluid and filter. • Replace the engine oil filter.
• Adjust bands on 3–speed transmission. (See the • Inspect the engine air cleaner element (fil-
note at the end of Schedule – B.) ter) and replace as necessary.*
• Replace the spark plugs 3.3 liter and 3.8 liter
51,000 Miles (82 000 km) engines.
• Change the engine oil. • Replace the ignition cables 2.4 liter, 3.3 liter
• Replace the engine oil filter. and 3.8 liter engines.
• Inspect the generator belt on 2.4 liter engines
54,000 Miles (86 000 km) and replace if necessary.
• Change the engine oil. • Inspect the serpentine drive belt on 3.3 liter and
• Replace the engine oil filter. 3.8 liter engines, and replace if necessary. This main-
• Inspect the brake linings. tenance is not required if belt was previously
replaced.
57,000 Miles (91 000 km) • Change the All Wheel Drive power transfer unit
• Change the engine oil. fluid. (See the note at the end of Schedule – B.)
78,000 Miles (125 000 km)
• Replace the engine air cleaner element (fil- 81,000 Miles (130 000 km)
ter). • Change the engine oil.
• Inspect the PCV valveand replace if necessary.* • Replace the engine oil filter.
• Replace the spark plugs on 2.4 liter engines. • Inspect the brake linings.
• Inspect the generator belt and power steering
pump belt tension, replace belt if necessary on 2.4 84,000 Miles (134 000 km)
liter engines. • Change the engine oil.
• Inspect the serpentine drive belt on 3.3 liter and • Replace the engine oil filter.
3.8 liter engines and replace if necessary. • Change the All Wheel Drive (AWD) overrunning
• Change the All Wheel Drive (AWD) power trans- clutch and rear carrier fluid. (See the note at the end
fer unit fluid. (See the note at the end of Schedule – of Schedule – B.)
B.)
• Inspect the tie rod ends and boot seals. 87,000 Miles (139 000 km)
• Change the All Wheel Drive (AWD) overrunning • Change the engine oil.
clutch and rear carrier fluid. (See the note at the end • Replace the engine oil filter.
of Schedule – B.) • Replace the engine air cleaner element (fil-
• Inspect the brake linings. ter).
• Check the PCV valve and replace if necessary. 108,000 Miles (173 000 km)
Not required if previously changed.* • Change the engine oil.
• Replace the spark plugs on 2.4 liter engines. • Replace the engine oil filter.
• Inspect the generator belt on 2.4 liter engines • Inspect the brake linings.
• Inspect the serpentine drive belt (3.3 liter and 111,000 Miles (178 000 km)
3.8 liter engines) and replace if necessary. This main- • Change the engine oil.
tenance is not required if belt was previously • Replace the engine oil filter.
replaced.
• Change the All Wheel Drive (AWD) power trans- 114,000 Miles (182 000 km)
fer unit fluid. (See the note at the end of Schedule – • Change the engine oil.
B.) • Replace the engine oil filter.
• Inspect the brake linings. 117,000 Miles (187 000 km)
• Change the engine oil. • Inspect the brake linings.
120,000 Miles (192 000 km)
• Replace the engine oil filter. • Replace the engine air cleaner element (fil-
• Drain and replace the automatic transmission ter).
fluid and filter. • Inspect the PCV valve and replace as neces-
• Adjust bands on 3–speed transmission. (See the sary.*
note at the end of Schedule – B.) • Replace the spark plugs on 2.4 liter engines.
• Inspect the generator belt and power steering
99,000 Miles (158 000 km) pump belt tension, replace the belt if necessary on
• Change the engine oil. 2.4 liter engines.
• Replace the engine oil filter. • Inspect the serpentine drive belt on 3.3 liter and
• Inspect the brake linings. 3.8 liter engines. Not required if replaced at 75,000,
90,000 or 105,000 miles.
100,000 Miles (160 000 km) • Replace the engine timing belt on 2.4 liter
• Flush and replace engine coolant at 60 months engines.
or 100,000 miles (160 000 km). • Change the All Wheel Drive (AWD) power trans-
102,000 Miles (163 000 km) B.)
• Change the engine oil. • Inspect the tie rod ends and boot seals.
• Replace the engine oil filter. * This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
105,000 Miles (168 000 km) required to maintain the emissions warranty.
• Replace the engine oil filter. NOTE: Operating the vehicle more than 50% in
• Inspect the engine air cleaner element (fil- heavy traffic during hot weather, above 90°F (32°C),
ter) and replace as necessary.* using vehicle for police, taxi, limousine type opera-
• Inspect the generator belt on 2.4 liter engines tion or trailer towing require the more frequent tran-
and replace if necessary. saxle service noted in Schedule – B. Perform these
• Inspect the serpentine drive belt on 3.3 liter and services if vehicle usually operate under these con-
3.8 liter engines and replace if necessary. This main- ditions.
tenance is not required if the belt was previously
replaced.
• Change the All Wheel Drive (AWD) power trans- NOTE: The AWD power transfer unit fluid and the
fer unit fluid. (See the note at the end of Schedule – AWD overrunning clutch/rear carrier fluid must be
B.) changed at the more frequent intervals shown in
• Change the All Wheel Drive (AWD) overrunning schedule B if the vehicle is operated under any of
clutch and rear carrier fluid. (See the note at the end the conditions noted by an asterisk at the begin-
of Schedule – B.) ning of the schedule.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to Owner’s Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING

POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on any

suspension component, including the front suspen-
sion crossmember, the rear leaf springs, and the
rear axle. Do not hoist on the front and rear
bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
Fig. 8 HOISTING AND JACKING POINTS
on the sill or the front engine mount.
1 - DRIVE ON LIFT
FOR PROPER HOIST PLACEMENT REFER 2 - FRAME CONTACT LIFT (SINGLE POST)
TO (Fig. 8). CHASSIS LIFT (NON-AXLE DUAL POST)
OUTBOARD LIFT (DUAL POST)
The hoisting points are identified by S.A.E.
FLOOR JACK
inverted triangle hoisting symbols (Fig. 8). The front
3 - S.A.E. HOISTING SYMBOLS
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250mm
behind the front suspension crossmember. When JUMP STARTING
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate con- TO JUMP START A DISABLED VEHICLE:
tact between the hoist arm and the down standing (1) Raise hood on disabled vehicle and visually
flange on the sill. The rear hoisting points are the inspect engine compartment for:
leaf spring front mounting brackets. The hoist pad • Battery cable clamp condition, clean if necessary.
must be positioned to pick up the flanges on the • Frozen battery.
bracket, not the leaf spring. • Yellow or bright color test indicator, if equipped.
When servicing the leaf springs or the leaf spring • Low battery fluid level.
mounting brackets, special provisions are required to • Generator drive belt condition and tension.
support the rear of the vehicle. Position the rear • Fuel fumes or leakage, correct if necessary.
hoist pads under the horizontal surface on the bot-
tom of the sill, inboard adjacent to the flange and CAUTION: If the cause of starting problem on dis-
centered fore/aft between the jacking indicator tabs abled vehicle is severe, damage to booster vehicle
on the lower flange. DO NOT HOIST ON THE charging system can result.
FLANGE. Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the fin- (2) When using another vehicle as a booster
ish. source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
JUMP STARTING (Continued)
transmission in NEUTRAL and turn the ignition • When using a Booster vehicle, disconnect
OFF. BLACK cable clamp from battery negative terminal.
(3) On disabled vehicle, place gear selector in park Disconnect RED cable clamp from battery positive
or neutral and set park brake. Turn off all accesso- terminal.
ries. • Disconnect RED cable clamp from battery posi-
(4) Connect jumper cables to booster battery. RED tive terminal on disabled vehicle.
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result. TOWING
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable TOWING RECOMMENDATIONS
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the WARNINGS AND CAUTIONS
ground cable attaching point as possible (Fig. 9).
(6) Start the engine in the vehicle which has the WARNING: DO NOT ALLOW TOWING ATTACHMENT
booster battery, let the engine idle a few minutes, DEVICES TO CONTACT THE FUEL TANK OR LINES,
then start the engine in the vehicle with the dis- FUEL LEAK CAN RESULT.
charged battery. DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-

tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Fig. 9 Jumper Cable Clamp Connections
Refer to state and local rules and regulations before
1 - BATTERY POSITIVE CABLE
towing a vehicle.
2 - POSITIVE JUMPER CABLE
Do not allow weight of towed vehicle to bear on
3 - TEST INDICATOR
4 - BATTERY NEGATIVE CABLE lower fascia, air dams, or spoilers.
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
7 - ENGINE GROUND RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
CAUTION: Do not crank starter motor on disabled • FWD vehicles, use a flat bed towing device or
vehicle for more than 15 seconds, starter will over- wheel lift is recommended (Fig. 10).
heat and could fail. • AWD vehicles, a flat bed towing device or wheel
lift and towing dolly is recommended (Fig. 10).
(7) Allow battery in disabled vehicle to charge to
When using a wheel lift towing device, be sure the
at least 12.4 volts (75% charge) before attempting to
disabled vehicle has at least 100 mm (4 in.) ground
start engine. If engine does not start within 15 sec-
clearance. If minimum ground clearance cannot be
onds, stop cranking engine and allow starter to cool
reached, use a towing dolly. If a flat bed device is
(15 minutes), before cranking again.
used, the approach angle should not exceed 15
DISCONNECT CABLE CLAMPS AS FOLLOWS: degrees.
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
TOWING (Continued)
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using

the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between the
bumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
Fig. 10 Recommended Towing
equipped with a rear sway bar have brackets at this
1 - WHEEL LIFT location.
2 - FLAT BED
TOWING – FRONT WHEEL LIFT
GROUND CLEARANCE If the vehicle is being towed from the front, when-
ever possible ensure at lest 10 inches road clearness
CAUTION: If vehicle is towed with wheels removed, to the tires.
install lug nuts to retain brake drums or rotors.
TOWING – REAR WHEEL LIFT
A towed vehicle should be raised until the lifted If a vehicle cannot be towed with the front wheels
wheels are a minimum 100 mm (4 in.) from the lift, the rear wheels can be lifted provided the follow-
ground. Be sure there is at least 100 mm (4 in.) ing guide lines are observed.
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of CAUTION: Do not use steering column lock to
the vehicle and lower the vehicle closer to the secure steering wheel during towing operation.
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching • On AWD vehicles, all four wheels must be free to
studs to retain brake drums or rotors. rotate. Use towing dollies at unlifted end of vehicle.
• Unlock steering column and secure steering
LOCKED VEHICLE TOWING wheel in straight ahead position with a clamp device
When a locked vehicle must be towed with the designed for towing.
front wheels on the ground, use a towing dolly or flat • Three speed automatic transaxle vehicles can be
bed hauler. flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
FLAT TOWING WITH TOW BAR umn must be unlocked and gear selector in neutral.
• Three speed automatic transaxle vehicles can be • Four speed electronic automatic transaxle vehi-
flat towed at speeds not to exceed 40 km/h (25 mph) cles can be flat towed at speeds not to exceed 72
for not more than 25 km (15 miles). The steering col- km/h (44 mph) for not more than 160 km (100 miles).
umn must be unlocked and gear selector in neutral. The steering column must be unlocked and gear
• Four speed electronic automatic transaxle vehi- selector in neutral.
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
• AWD models should not be flat towed. For addi-
tional information, refer to RECOMMENDED TOW-
ING EQUIPMENT in this section.
RG LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL 0a - 1
LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO

DIESEL
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE - RG - 2.5 L HOISTING

TURBO DIESEL STANDARD PROCEDURE . . . . . . . ............7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . ....1 HOISTING . . . . . . . . . . . . . . . . . ............7
INTERNATIONAL SYMBOLS JUMP STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ....2 STANDARD PROCEDURE . . . . . . . ............8
FLUID TYPES JUMP STARTING . . . . . . . . . . . . ............8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ....2 TOWING
FLUID FILL/CHECK LOCATIONS STANDARD PROCEDURE . . . . . . . ............8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ....5 TOWING RECOMMENDATIONS . ............8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ....5
LUBRICATION & DESCRIPTION SPECIFICATION

MAINTENANCE - RG - 2.5 L Cooling System** - 2.5 L 16.6 L (17.5 qts.)
TURBO DIESEL Turbo Diesel with
Auxiliary Heater
SPECIFICATIONS Service Fill
SPECIFICATIONS - FLUID CAPACITIES 31TH Overhaul Fill
DESCRIPTION SPECIFICATION
41TE Overhaul Fill
Fuel Tank 75 L (20 gal.)
Manual Transaxle (T850 2.4-2.7 L (2.5-2.9 qts.)
Fuel Tank (Diesel) 75 L (20 gal.) 5-speed)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.) AWD Power Transfer Unit 1.15 L (2.4 pts.)
Engine Oil* - 3.3 L 4.0 L (4.5 qts.) Power Steering 1.2 L (2.5 pts.)
Engine Oil* - 2.5 L 5.22 L (5.52 qts.) AWD Bi-directional 0.575 L (1.22 pts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.) Overrunning Clutch
Cooling System** - 3.3 L 12.6 L (13.4 qts.) AWD Rear Carrier 0.7 L (1.48 pts.)
without Auxiliary Heater *(includes oil filter)
Cooling System** - 3.3 L 15.4 L (16.3 qts.) **(includes heater and recovery/reserve bottle)
with Auxiliary Heater
Cooling System** - 2.5 L 13.8 L (14.6 qts.)
Turbo Diesel without
Auxiliary Heater
0a - 2 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL RG
INTERNATIONAL SYMBOLS SAE VISCOSITY

An SAE viscosity grade is used to specify the vis-
DESCRIPTION cosity of engine oil. Use only engine oils with multi-
DaimlerChrysler Corporation uses international ple viscosities such as 5W-30 or 10W-30. These are
symbols to identify engine compartment lubricant specified with a dual SAE viscosity grade which indi-
and fluid check and fill locations (Fig. 1). cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 2).
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY

Fig. 1 International Symbols
ENERGY CONSERVING OIL
FLUID TYPES An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
DESCRIPTION - ENGINE OIL AND LUBRICANTS SERVING is located on the label of an engine oil con-
tainer.
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR CONTAINER IDENTIFICATION
REPEATED SKIN CONTACT WITH ENGINE OIL. Standard engine oil identification notations have
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY been adopted to aid in the proper selection of engine
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO oil. The identifying notations are located on the front
YOUR HEALTH. THOROUGHLY WASH EXPOSED label of engine oil plastic bottles and the top of
SKIN WITH SOAP AND WATER. DO NOT WASH engine oil cans (Fig. 3).
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR This symbol means that the oil has been certified
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO by the American Petroleum Institute (API). Diamler-
NOT POLLUTE, DISPOSE OF USED ENGINE OIL Chrysler only recommend API Certified engine oils
PROPERLY. CONTACT YOUR DEALER OR GOVERN- that meet the requirements of Material Standard
MENT AGENCY FOR LOCATION OF COLLECTION MS-6395. Use Mopar or an equivalent oil meeting
CENTER IN YOUR AREA. the specification MS-6395.
When service is required, DaimlerChrysler Corpo-

ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI) Fig. 3 API Symbol
API SERVICE GRADE CERTIFIED GEAR LUBRICANTS
Use an engine oil that is API Certified. MOPARt SAE ratings also apply to multigrade gear lubri-
provides engine oils, meeting Material Standard cants. In addition, API classification defines the lubri-
MS-6395, that meet or exceed this requirement. cants usage. Such as API GL-5 and SAE 75W-90.
LUBRICANTS AND GREASES The cooling system is designed around the coolant.
Lubricating grease is rated for quality and usage The coolant must accept heat from engine metal, in
by the NLGI. All approved products have the NLGI the cylinder head area near the exhaust valves and
symbol (Fig. 4) on the label. At the bottom NLGI engine block. Then coolant carries the heat to the
symbol is the usage and quality identification letters. radiator where the tube/fin radiator can transfer the
Wheel bearing lubricant is identified by the letter heat to the air.
“G”. Chassis lubricant is identified by the latter “L”. The use of aluminum cylinder blocks, cylinder
The letter following the usage letter indicates the heads, and water pumps requires special corrosion
quality of the lubricant. The following symbols indi- protection. Mopart Antifreeze/Coolant, 5
cate the highest quality. Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolant MUST NOT BE MIXED with
Fig. 4 NLGI Symbol the orange or magenta coolants. When replacing cool-
1 - WHEEL BEARINGS ant the complete system flush must be performed
2 - CHASSIS LUBRICATION before using the replacement coolant.
CAUTION: MoparT Antifreeze/Coolant, 5
SPECIALIZED LUBRICANTS AND OILS Year/100,000 Mile Formula (MS-9769) may not be
Some maintenance or repair procedures may mixed with any other type of antifreeze. Doing so
require the use of specialized lubricants or oils. Con- will reduce the corrosion protection and may result
sult the appropriate sections in this manual for the in premature water pump seal failure. If non-HOAT
correct application of these lubricants. coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
DESCRIPTION - ENGINE COOLANT coolant as soon as possible.
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL

BASE COOLANT AND IS HARMFUL IF SWAL- DESCRIPTION - AUTOMATIC TRANSMISSION
LOWED OR INHALED. IF SWALLOWED, DRINK FLUID
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA. NOTE: Refer to the maintenance schedules for the
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT recommended maintenance (fluid/filter change)
STORE IN OPEN OR UNMARKED CONTAINERS. intervals for this transaxle.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
NOTE: For fluid level checking procedures, (Refer
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
GLYCOL BASE COOLANT PROPERLY, CONTACT
31TH/FLUID - STANDARD PROCEDURE).
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN NOTE: The 31TH transaxle has a common transmis-
THE ENGINE IS AT OPERATING TEMPERATURE OR sion and differential sump. Filling the transaxle
HOT UNDER PRESSURE, PERSONAL INJURY CAN accommodates the differential as well.
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT. TRANSMISSION FLUID
Mopart ATF+4 (Automatic Transmission Fluid-
Type 9602) is required in this transaxle. Substitute
CAUTION: Use of Propylene Glycol based coolants fluids can induce torque converter clutch shudder.
is not recommended, as they provide less freeze
protection and less boiling protection.
Mopart ATF+4 (Automatic Transmission Fluid- DESCRIPTION - DIESEL ENGINE OIL
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in API SERVICE GRADE CERTIFIED
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid WARNING: NEW OR USED ENGINE OIL CAN BE
condition. As the vehicle is driven, the ATF will begin IRRITATING TO THE SKIN. AVOID PROLONGED OR
to look darker in color and may eventually become REPEATED SKIN CONTACT WITH ENGINE OIL.
brown. This is normal. A dark brown/black fluid CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
accompanied with a burnt odor and/or deterioration INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
in shift quality may indicate fluid deterioration or YOUR HEALTH. THOROUGHLY WASH EXPOSED
transmission component failure. SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
FLUID ADDITIVES SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
DaimlerChrysler strongly recommends against the NOT POLLUTE, DISPOSE OF USED ENGINE OIL
addition of any fluids to the transmission, other than PROPERLY. CONTACT YOUR DEALER OR GOVERN-
those automatic transmission fluids listed above. MENT AGENCY FOR LOCATION OF COLLECTION
Exceptions to this policy are the use of special dyes CENTER IN YOUR AREA.
to aid in detecting fluid leaks.
Various “special” additives and supplements exist Standard engine oil identification notations have
that claim to improve shift feel and/or quality. These been adopted to aid in the proper selection of engine
additives and others also claim to improve converter oil. The identifying notations are located on the label
clutch operation and inhibit overheating, oxidation, of engine oil plastic bottles and the top of engine oil
varnish, and sludge. These claims have not been sup- cans.
ported to the satisfaction of DaimlerChrysler and these In diesel engines, use an engine oil that conforms
additives must not be used. The use of transmission to API Service Grade CF-4 or CG-4/SH (Fig. 5).
“sealers” should also be avoided, since they may MOPARt provides an engine oil that conforms to this
adversely affect the integrity of transmission seals. particular grade.
DESCRIPTION - FUEL REQUIREMENTS -

DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Fig. 5 API Service Grade Certification Label—Diesel
Use good quality diesel fuel from a reputable sup- Engine Oil
plier. For most year-round service, number 2 diesel SAE VISCOSITY
fuel meeting ASTM specification D-975 will provide An SAE viscosity grade is used to specify the vis-
good performance. If the vehicle is exposed to cosity of engine oil. SAE 15W–40 specifies a multiple
extreme cold (below -18°C/0°F) or is required to oper- viscosity engine oil.
ate at colder than normal conditions for prolonged When choosing an engine oil, consider the range of
periods, use climatize No. 2 diesel fuel or dilute the temperatures the vehicle will be operated in before the
No. 2 diesel fuel with 50% No. 1 diesel fuel. This will next oil change. Select an engine oil that is best suited
provide better protection from fuel gelling or wax to your area’s particular ambient temperature range
plugging of the fuel filters. and variation. For diesel engines, refer to (Fig. 6).
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and follow
the cold weather advice above, fuel conditioners should
not be required in your vehicle. If available in your
area, a high cetane “premium” diesel fuel may offer
improved cold starting and warm up performance.
At Each Oil Change
• Replace the engine oil filter at each oil change.
• Inspect exhaust system.
• Inspect brake hoses
• Inspect the CV joints and front suspension com-
ponents
• Rotate the tires at each oil change interval
shown on schedule “A” 20 000 km or every other
interval shown on schedule “B” 20 000 km.
• Check the coolant level, hoses, and clamps.
Fig. 6 Engine Oil Viscosity Recommendation – • Inspect brake linings, hoses and calipers.
Diesel Engines • Inspect engine accessory drive belts.
• Inspect for presence of water in fuel filter/water
FLUID FILL/CHECK separator, drain if necessary.
LOCATIONS
SCHEDULE “A”
DESCRIPTION
The fluid check/fill points and lubrication locations 20 000 km (12 000 miles)
are located in each applicable service manual section. • Change engine oil. (1)
• Replace engine oil filter.
• Inspect air filter element. Replace as necessary.
40 000 km (24 000 Miles)
MAINTENANCE SCHEDULES - DIESEL ENGINE • Change engine oil. (1)
There are two maintenance schedules that show • Replace engine oil filter.
proper service for the vehicle. • Replace air filter element.
First is Schedule “A”. It lists all the scheduled • Replace fuel filter/water separator element. (2)
maintenance to be performed under “normal” operat- • Check alignment.
ing conditions.
Second is Schedule “B”. It is a schedule for vehi- 60 000 km (37 000 Miles)
cles that are operated under the conditions listed at • Change engine oil. (1)
the beginning of the schedule. • Replace engine oil filter.
Use the schedule that best describes the driving • Inspect air filter element. Replace as necessary.
conditions.
80 000 km (49 000 Miles)
Where time and mileage are listed, follow the
interval that occurs first. • Change engine oil. (1)
At Each Stop for Fuel • Replace air filter element.
• Check the engine oil level, add as required. • Replace fuel filter/water separator element. (2)
• Check the windshield washer solvent and add if • Check alignment.
required.
100 000 km (62 000 Miles)
Once a Month • Change engine oil. (1)
• Check the tire pressure and look for unusual • Replace engine oil filter.
wear or damage. • Inspect air filter element. Replace as necessary.
• Inspect the battery and clean and tighten termi-
120 000 km (75 000 Miles)
nals as required.
• Check the fluid levels of coolant reservoir, brake • Change engine oil. (1)
master cylinder, power steering and transaxle and • Replace engine oil filter.
add as needed. • Replace air filter element.
• Check all lights and all other electrical items for • Replace fuel filter/water separator element. (2)
correct operation. • Check alignment.
• Check the rubber seals on each side of the radi-
140 000 km (86 000 miles)
ator for proper fit.
• Change engine oil. (1)
• Inspect air filter element. Replace as necessary.
160 000 km (100 000 miles) 40 000 km (24 000 Miles)
• Change engine oil. (1) • Change engine oil. (1)
• Replace engine oil filter. • Replace engine oil filter.
• Replace air filter element. • Replace air filter element.
• Replace fuel filter/water separator element. (2) • Replace fuel filter/water separator element. (2)
• Check alignment. • Check alignment.
• Flush and replace engine coolant. (3) • Change manual transaxle fluid.
180 000 km (110 000 miles) 50 000 km (31 000 Miles)

• Change engine oil. (1) • Change engine oil. (1)
• Replace engine oil filter. • Replace engine oil filter.
• Inspect air filter element. Replace as necessary. • Inspect air filter element.
IMPORTANT: Inspection and service should also 60 000 km (37 000 Miles)
be performed any time a malfunction is observed or • Change engine oil. (1)
suspected. Retain all receipts. • Replace engine oil filter.
• Change oil every 12 months regardless of mile- • Replace air filter element.
age. • Replace fuel filter/water separator element. (2)
• The fuel filter/water separator element should • Check alignment.
be replaced once a year if the vehicle is driven less
than 40 000 km annually or if power loss from fuel 70 000 km (43 000 Miles)
starvation is detected. • Change engine oil. (1)
• Flush and replace engine coolant every 60 months • Replace engine oil filter.
even if the vehicle is driven less than 160 000 km. • Inspect air filter element.
80 000 km (49 000 Miles)
SCHEDULE “B”
Follow this schedule if the vehicle is operated
under one or more of the following conditions.
• Replace air filter element.
• Day or night temperatures are below 0° C
• Replace fuel filter/water separator element. (2)
(32° F).
• Check alignment.
• Stop and go driving.
• Change manual transaxle fluid.
• Extensive engine idling.
• Driving in dusty conditions. 90 000 km (55 000 Miles)
• Short trips of less than 16.2 km (10 miles). • Change engine oil. (1)
• More than 50% of driving is at sustained high • Replace engine oil filter.
speeds during hot weather, above 32° C (90° F). • Inspect air filter element.
• Trailer towing.
• Taxi, police, or delivery service (commercial ser- 100 000 km (62 000 Miles)
vice). • Change engine oil. (1)
10 000 km (6 000 Miles) • Replace air filter element.
• Change engine oil. (1) • Replace fuel filter/water separator element. (2)
• Replace engine oil filter. 110 000 km (68 000 Miles)
• Inspect air filter element.
20 000 km (12 000 Miles) • Replace engine oil filter.
• Inspect air filter element.
• Replace fuel filter/water separator element. (2)
• Check alignment.
• Replace air filter element.
• Replace fuel filter/water separator element. (2) 120 000 km (74 000 Miles)
• Check alignment. • Change engine oil. (1)
30 000 km (18 000 Miles) • Replace air filter element.
• Change engine oil. (1) • Change manual transaxle fluid.
• Inspect air filter element. 130 000 km (80 000 Miles)
• Inspect air filter element. The hoisting points are identified by S.A.E.
• Replace fuel filter/water separator element. (2) inverted triangle hoisting symbols (Fig. 7). The front
• Check alignment. hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250mm
140 000 km (86 000 Miles)
behind the front suspension crossmember. When
• Change engine oil. (1) using outboard lift hoists, verify that the hoist lift
• Replace engine oil filter. pads have been properly adjusted to eliminate con-
• Replace air filter element. tact between the hoist arm and the down standing
150 000 km (93 000 Miles) flange on the sill. The rear hoisting points are the
• Change engine oil. (1) leaf spring front mounting brackets. The hoist pad
• Replace engine oil filter. must be positioned to pick up the flanges on the
• Inspect air filter element. bracket, not the leaf spring.
• Replace fuel filter/water separator element. (2) When servicing the leaf springs or the leaf spring
• Check alignment. mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
160 000 km (100 000 Miles) hoist pads under the horizontal surface on the bot-
• Change engine oil. (1) tom of the sill, inboard adjacent to the flange and
• Replace engine oil filter. centered fore/aft between the jacking indicator tabs
• Replace air filter element. on the lower flange. DO NOT HOIST ON THE
• Flush and replace engine coolant. (3) FLANGE. Place a soft pad between the hoist and the
• Change oil every 12 months regardless of mile- painted surface on the sill to avoid scratching the fin-
age. ish.
• The fuel filter/water separator element should
be replaced once a year if the vehicle is driven less
than 20 000 km annually or if power loss from fuel
starvation is detected.
• Flush and replace engine coolant every 60 months
even if the vehicle is driven less than 160 000 km.
• Change manual transaxle fluid.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to Owner’s Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING

POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on any

suspension component, including the front suspen- Fig. 7 HOISTING AND JACKING POINTS
sion crossmember, the rear leaf springs, and the 1- Drive On Lift
rear axle. Do not hoist on the front and rear 2- Frame Contact Lift (Single Post)
bumpers, the lower liftgate crossmember, the lower Chassis Lift (Non-Axle Dual Post)
radiator crossmember, the down standing flanges Outboard Lift (Dual Post)
on the sill or the front engine mount. Floor Jack
3- S.A.E. Hoisting Symbols
FOR PROPER HOIST PLACEMENT REFER
TO (Fig. 7).
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-

abled vehicle is severe, damage to booster vehicle
charging system can result.
Fig. 8 Jumper Cable Clamp Connections
(2) When using another vehicle as a booster
1 - BATTERY POSITIVE CABLE
source, park the booster vehicle within cable reach.
2 - POSITIVE JUMPER CABLE
Turn off all accessories, set the parking brake, place 3 - TEST INDICATOR
the automatic transmission in PARK or the manual 4 - BATTERY NEGATIVE CABLE
transmission in NEUTRAL and turn the ignition 5 - BATTERY
OFF. 6 - NEGATIVE JUMPER CABLE
(3) On disabled vehicle, place gear selector in park 7 - ENGINE GROUND
or neutral and set park brake. Turn off all accessories.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg- TOWING
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result. TOWING RECOMMENDATIONS
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable WARNINGS AND CAUTIONS
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the WARNING: DO NOT ALLOW TOWING ATTACHMENT
ground cable attaching point as possible (Fig. 8). DEVICES TO CONTACT THE FUEL TANK OR LINES,
(6) Start the engine in the vehicle which has the FUEL LEAK CAN RESULT.
booster battery, let the engine idle a few minutes, DO NOT LIFT OR TOW VEHICLE BY FRONT OR
then start the engine in the vehicle with the dis- REAR BUMPER.
charged battery. DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
CAUTION: Do not crank starter motor on disabled DO NOT ALLOW PASSENGERS TO RIDE IN A
vehicle for more than 15 seconds, starter will over- TOWED VEHICLE.
heat and could fail. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec- CAUTION: Do not damage brake lines, exhaust sys-
onds, stop cranking engine and allow starter to cool tem, shock absorbers, sway bars, or any other
(15 minutes), before cranking again. under vehicle components when attaching towing
device to vehicle.
DISCONNECT CABLE CLAMPS AS FOLLOWS: Do not secure vehicle to towing device by the use
• Disconnect BLACK cable clamp from engine of front or rear suspension or steering components.
ground on disabled vehicle. Remove or secure loose or protruding objects from
• When using a Booster vehicle, disconnect a damaged vehicle before towing.
BLACK cable clamp from battery negative terminal. Refer to state and local rules and regulations before
Disconnect RED cable clamp from battery positive towing a vehicle.
terminal. Do not allow weight of towed vehicle to bear on
• Disconnect RED cable clamp from battery posi- lower fascia, air dams, or spoilers.
tive terminal on disabled vehicle.
TOWING (Continued)
RECOMMENDED TOWING EQUIPMENT for not more than 25 km (15 miles). The steering col-
To avoid damage to bumper fascia and air dams umn must be unlocked and gear selector in neutral.
use: • Four speed electronic automatic transaxle vehi-
• FWD vehicles, use a flat bed towing device or cles can be flat towed at speeds not to exceed 72
wheel lift is recommended (Fig. 9). km/h (44 mph) for not more than 160 km (100 miles).
• AWD vehicles, a flat bed towing device or wheel The steering column must be unlocked and gear
lift and towing dolly is recommended (Fig. 9). selector in neutral.
When using a wheel lift towing device, be sure the • AWD models should not be flat towed. For addi-
disabled vehicle has at least 100 mm (4 in.) ground tional information, refer to RECOMMENDED TOW-
clearance. If minimum ground clearance cannot be ING EQUIPMENT in this section.
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15 FLAT BED TOWING TIE DOWNS
degrees.
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using the

two pair of front slots on the bottom surface of the
rails, behind the front wheels. The two pair of rear
slots on the bottom of the rail between the bumper
extension bolts and on the bottom of the rail just rear-
ward of the jounce bumper. Vehicles equipped with a
rear sway bar have brackets at this location.
Fig. 9 Recommended Towing TOWING – FRONT WHEEL LIFT

1 - WHEEL LIFT If the vehicle is being towed from the front, when-
2 - FLAT BED ever possible ensure at lest 10 inches road clearness
to the tires.
GROUND CLEARANCE TOWING – REAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
CAUTION: If vehicle is towed with wheels removed,
lift, the rear wheels can be lifted provided the follow-
install lug nuts to retain brake drums or rotors.
ing guide lines are observed.
A towed vehicle should be raised until the lifted
CAUTION: Do not use steering column lock to
wheels are a minimum 100 mm (4 in.) from the
secure steering wheel during towing operation.
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If • On AWD vehicles, all four wheels must be free to
necessary, remove the wheels from the lifted end of rotate. Use towing dollies at unlifted end of vehicle.
the vehicle and lower the vehicle closer to the • Unlock steering column and secure steering
ground, to increase the ground clearance at the rear wheel in straight ahead position with a clamp device
of the vehicle. Install lug nuts on wheel attaching designed for towing.
studs to retain brake drums or rotors. • Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
LOCKED VEHICLE TOWING for not more than 25 km (15 miles). The steering col-
When a locked vehicle must be towed with the umn must be unlocked and gear selector in neutral.
front wheels on the ground, use a towing dolly or flat • Four speed electronic automatic transaxle vehi-
bed hauler. cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
FLAT TOWING WITH TOW BAR The steering column must be unlocked and gear
• Three speed automatic transaxle vehicles can be selector in neutral.
flat towed at speeds not to exceed 40 km/h (25 mph)
RS SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 46

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FRONT
TABLE OF CONTENTS
page page
FRONT LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 LOWER BALL JOINT SEAL BOOT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 LOWER CONTROL ARM
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HUB / BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STABILIZER BAR
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HUB AND BEARING (FRONT) . . . . . . . . . . . . . . 5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
KNUCKLE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STRUT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . 20
LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT OPERATION - FRONT SUSPENSION

The front suspension allows each wheel on a vehi-
DESCRIPTION - FRONT SUSPENSION cle to adapt to different road surfaces and conditions
This vehicle has a MacPherson Strut type front without greatly affecting the opposite wheel and the
suspension (Fig. 1). ability to control the vehicle. Each side of the front
suspension is allowed to pivot so the vehicle can be
steered in the direction preferred.
2-2 FRONT RS
FRONT (Continued)
Fig. 1 Front Suspension

1 - TOWER 9 - CRADLE/CROSSMEMBER REINFORCEMENT
2 - CROSSMEMBER TAPPING PLATES 10 - BALL JOINT
3 - LEFT STRUT ASSEMBLY 11 - ISOLATOR BUSHING
4 - LEFT STEERING KNUCKLE (WITH HUB AND BEARING) 12 - STEERING GEAR TIE ROD
5 - STABILIZER BAR LINK 13 - RIGHT STEERING KNUCKLE
6 - STABILIZER BAR 14 - RIGHT HUB AND BEARING
7 - LEFT LOWER CONTROL ARM 15 - RIGHT STRUT ASSEMBLY
8 - CRADLE/CROSSMEMBER
A strut assembly is used in place of the front sus- STANDARD PROCEDURE - LUBRICATION
pension upper control arm and upper ball joint.
There are no serviceable lubrication points on the
When a vehicle strikes a bump, the force is trans-
front suspension. The ball joints are sealed-for-life
ferred through the hub, bearing, and knuckle, into
and require no maintenance. The lower ball joints
the strut assembly to absorb the force and dampen it.
have special grease fitting caps that prevent normal
The top of the strut is mounted directly to the strut
grease gun attachment. This has been done to elimi-
tower of the vehicle. During steering maneuvers, the
nate the possibility of over-filling, damaging the non-
strut assembly (through a pivot bearing in the upper
vented seal. Do not attempt to remove the special
strut mount) and steering knuckle (through the lower
grease fitting cap and replace it with a normal grease
ball joint) turn as an assembly.
zirc fitting.
CAUTION: No attempt should be made to replace

the ball joint grease fitting cap with a normal zirc
fitting or fill the ball joint with grease. Damage to
the grease seal can result.
RS FRONT 2-3
FRONT (Continued)
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Ball Joint Nut 108 80 —
Cradle Crossmember
163 120 — Press, Ball Joint C-4212F
Mounting Bolts
Disc Brake Adapter
169 125 —
Mounting Bolts
Hub And Bearing Mounting
65 45 —
Bolts
Hub And Bearing Axle Hub
244 180 —
Nut
Lower Control Arm Pivot
183 135 —
Bolt
Installer, Ball Joint 6758
Lower Control Arm Rear
61 45 —
Bushing Retainer bolts
Stabilizer Bar Bushing
68 50 —
Retainer Bolts
Stabilizer Bar Link Nuts 88 65 —
Strut Body/Tower Mounting
28 21 250
Nuts
Strut Clevis-to-Knuckle Nuts 81 + 60 +
90° 90° —
turn turn Wrench, Strut Rod Nut 6864
Strut Shaft Nut 100 75 —
Tie Rod Adjuster Jam Nut 75 55 —
Tie Rod Steering Arm Nut 75 55 —
Wheel Mounting (Lug) Nuts 135 100 —
SPECIAL TOOLS
FRONT SUSPENSION
REMOVER/INSTALLER, BUSHING 8460
Puller C-3894A
REMOVER/INSTALLER, BALL JOINT 8490

2-4 FRONT RS
BUSHINGS
REMOVAL - STABILIZER BAR CUSHION
(1) Raise Vehicle. Refer to Hoisting in Lubrication
and Maintenance.
(2) Remove the 2 bolts fastening the emission leak
detection pump to the cradle crossmember reinforce-
ment.
(3) Move the leak detection pump to the side
allowing access to the stabilizer bar cushion retain-
ers.
(4) Remove the nut and bolt securing each stabi-
lizer bar cushion retainer to the cradle crossmember
(Fig. 2) and remove the retainers.
Fig. 3 Correctly Installed Stabilizer Bar Cushion

1 - SLIT
2 - SQUARE CORNER
3 - STABILIZER BAR
4 - STABILIZER BAR CUSHION (BUSHING)
(4) Install each mounting bolt from rear of cradle

crossmember through retainer. Install the two nuts
and tighten to 68 N·m (50 ft. lbs.) torque.
(5) Reattach emission leak detection pump to cra-
dle crossmember reinforcement with two mounting
bolts.
(6) Lower the vehicle.
Fig. 2 Front Stabilizer Bar Cushion Retainers HUB / BEARING

1 - STEERING GEAR
2 - STABILIZER BAR DESCRIPTION
3 - RAISED BEAD The front wheel bearing and front wheel hub of
4 - FRONT CRADLE CROSSMEMBER this vehicle are a hub and bearing unit type assem-
5 - RETAINERS bly. This unit combines the front wheel mounting
hub (flange) and the front wheel bearing into a
(5) Remove each stabilizer bar cushion from the sealed one-piece unit. The hub and bearing is
stabilizer bar by opening the slit in the cushion and mounted to the center of the steering knuckle (Fig.
peeling it off the stabilizer bar. 1). It is retained by four mounting bolts accessible
from the rear of the steering knuckle. The hub flange
INSTALLATION - STABILIZER BAR CUSHION has five wheel mounting studs.
(1) Install each new cushion on stabilizer bar by The wheel mounting studs used to mount the tire
spreading cushion at slit and forcing it onto stabilizer and wheel to the vehicle are the only replaceable
bar. components of the hub and bearing assembly. Other-
wise, the hub and bearing is serviced only as a com-
NOTE: Cushions must be installed on stabilizer bar plete assembly.
so the square corner of the bushing will be down
and slit in cushion will be facing the rear of the OPERATION
vehicle when the stabilizer bar is installed (Fig. 3). The hub and bearing has internal bearings that
allow the hub to rotate with the driveshaft, along
(2) Place stabilizer bar into mounted position with with the tire and wheel. The five wheel mounting
cushions properly aligned. studs mount the tire and wheel, and brake rotor to
(3) Hook each retainer into cradle crossmember the vehicle.
mounting hole and over cushion.
RS FRONT 2-5
HUB / BEARING (Continued)
DIAGNOSIS AND TESTING - HUB AND

BEARING (FRONT)
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
Fig. 4 Hub Nut
from the left and to the right. This will load and
unload the bearings and change the noise level. 1 - HUB NUT
2 - NUT LOCK
Where axle bearing damage is slight, the noise is
3 - COTTER PIN
usually not noticeable at speeds above 48 km/h (30
4 - WAVE WASHER
mph).
REMOVAL - HUB AND BEARING

NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand, it will
have to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle on jack stands or centered on a

frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove wheel lug nuts, and front tire and Fig. 5 Front Brake Mounting
wheel assembly.
1 - BRAKE ROTOR
(3) Remove the cotter pin, nut lock and spring 2 - HUB AND BEARING
washer from the stub axle (Fig. 4). 3 - STEERING KNUCKLE
(4) With aid of a helper applying the brakes to 4 - ADAPTER MOUNTING BOLTS
keep the front hub from turning, remove the hub nut 5 - BRAKE CALIPER
(Fig. 4). 6 - ADAPTER
(5) Remove disc brake caliper and adapter as an 7 - CLIP
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire. (8) Remove the four hub and bearing mounting
Do not allow caliper hang by brake hose. bolts from the rear of steering knuckle (Fig. 6). Use
(6) Remove brake rotor from hub and bearing (Fig. care not to come in contact with and damage
5). the ABS tone wheel on the driveshaft stub shaft
(7) Push in on end of driveshaft stub shaft, push- upon bolt removal.
ing its splines out of the hub splines. (9) Remove the hub and bearing assembly from
the steering knuckle.
2-6 FRONT RS
(1) Install hub and bearing onto stub axle and into
steering knuckle until squarely seated on the face of
the steering knuckle.
(2) Install the 4 hub and bearing mounting bolts
from the rear of the knuckle. Equally tighten all 4
mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front of
steering knuckle. Tighten mounting bolts to a torque
of 65 N·m (45 ft. lbs.)
(3) Install the brake rotor on the hub and bearing
(Fig. 5).
(4) Install brake caliper and adapter assembly
back over brake rotor and align with mounting holes
on steering knuckle (Fig. 5). Install the mounting
bolts and tighten to 169 N·m (125 ft. lbs.) torque.
(5) Install the hub nut on the end of the stub axle
Fig. 6 Hub And Bearing Mounting Bolts (Fig. 4). With aid of a helper applying the brakes to
1 - HUB
keep the front hub from turning, tighten the hub nut
2 - STEERING KNUCKLE to Install the mounting bolts and tighten to 244 N·m
3 - MOUNTING BOLTS (4) (180 ft. lbs.) torque.
4 - DRIVESHAFT (6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
INSTALLATION - HUB AND BEARING tion. Then repeat the tightening sequence to the full
specified torque of 135 N·m (100 ft. lbs.).
CAUTION: Hub and bearing assembly mounting (7) Lower vehicle to the ground.
surfaces on the steering knuckle and stub axle (Fig. (8) Check the front wheel alignment toe setting
7) must be smooth and completely free of foreign and reset if not within specifications.
material or nicks prior to installing hub and bearing
assembly.
KNUCKLE
DESCRIPTION
The steering knuckle is a single aluminum cast-
ing with legs machined for attachment of the strut
assembly, steering linkage, disc brake caliper
adapter, lower control arm ball joint and steering
linkage (Fig. 1). The hub and bearing assembly is
mounted in the center of the steering knuckle using
4 bolts. The driveshaft’s constant velocity (C/V) stub
axle is splined through the center of the hub and
bearing and is held in place using a nut, nut lock and
cotter pin.
Service replacement of the front hub and bearing
assembly can be done with the steering knuckle
remaining on the vehicle.
Fig. 7 Mounting Surfaces (Typical)
1 - BEARING SEAL
OPERATION
2 - STUB AXLE The steering knuckle pivots with the strut assem-
3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS bly between the lower ball joint and the pivot bearing
BEFORE INSTALLING BEARING ASSEMBLY in the strut assembly. The steering gear outer tie rod
4 - STEERING KNUCKLE end connects to the trailing end of each knuckle,
allowing the vehicle to be steered.
CAUTION: When installing hub and bearing into The center of the knuckle supports the hub and
steering knuckle, be careful not to damage the bearing and axle shaft.
bearing seal (Fig. 7) on the outer C/V joint.
RS FRONT 2-7
KNUCKLE (Continued)
REMOVAL - STEERING KNUCKLE

frame contact type hoist. Refer to Hoisting in Lubri-
cation And Maintenance.
(2) Remove the wheel and tire assembly from the
vehicle.
(3) Remove the cotter pin, nut lock and spring
washer from the end of the stub axle and hub nut
(Fig. 8).
Fig. 9 Front Brake Mounting

1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 8 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - WAVE WASHER
(4) Have a helper apply the vehicle’s brakes to

keep hub from turning, loosen and remove the hub
nut (Fig. 8).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 9). Hang
assembly out of the way using a bungee cord or wire
(Fig. 10). Do not allow caliper to hang by brake
hose.
(6) Remove nut attaching outer tie rod end to
steering knuckle by holding the tie rod end stud
while loosening and removing nut with a wrench
(Fig. 11).
(7) Remove tie rod end from steering knuckle
using Remover, Special Tool C-3894–A (Fig. 12).
(8) If equipped with antilock brakes, remove the
front wheel speed sensor from the steering knuckle
(Fig. 13).
(9) Remove the two steering knuckle-to-strut clevis
bracket attaching bolts.
(10) Tip the knuckle outward and remove the
driveshaft stub axle from the hub and bearing. Sus-
Fig. 10 CALIPER AND DRIVESHAFT SUSPENDED
pend driveshaft straight outward using a bungee
1 - HANGER SUSPENDING CALIPER
cord or wire (Fig. 10). Do not allow driveshaft to
2 - HANGER SUSPENDING DRIVESHAFT
hang by inner joint.
3 - DRIVESHAFT
4 - BRAKE CALIPER
2-8 FRONT RS
KNUCKLE (Continued)
Fig. 11 Removing Tie Rod End Attaching Nut Fig. 13 Front Wheel Speed Sensor
1 - TIE ROD END 1 - MOUNTING BOLT
2 - STEERING KNUCKLE 2 - WHEEL SPEED SENSOR
3 - WRENCH 3 - STEERING KNUCKLE
4 - SOCKET
5 - TIE ROD END STUD
(11) Remove ball joint nut by holding ball joint
stud with hex wrench while loosening and removing
nut with a wrench (Fig. 14).
Fig. 14 BALL JOINT NUT REMOVAL/INSTALLATION

1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
CAUTION: Do not remove ball joint stud from steer-

ing knuckle using a hammer. Damage to the Alumi-
Fig. 12 TIE ROD REMOVAL WITH TOOL C-3894-A num knuckle, ball joint or control arm will result.
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A (12) Release ball joint stud from steering knuckle
3 - STEERING KNUCKLE using Remover, Special Tool C-4150A, as shown (Fig.
15).
RS FRONT 2-9
KNUCKLE (Continued)
the four mounting bolts and tighten them to a torque
of 65 N·m (45 ft. lbs.).
CAUTION: Before installing the knuckle on the ball

joint stud, wipe the ball joint stud and knuckle con-
tact area free of any grease or debris, otherwise
damage to the knuckle can occur. Use a clean shop
cloth with MoparT Brake Parts Cleaner applied to it
for proper cleaning.
(2) Place the knuckle on the ball joint stud.

(3) Install a NEW steering knuckle to ball joint
stud nut. Tighten the nut by holding ball joint stud
with hex wrench while turning nut with a wrench
(Fig. 14). Using a crowsfoot wrench on a torque
wrench, tighten the nut to a torque of 108 N·m (80 ft.
lbs.).
(4) Slide driveshaft stub axle into hub and bearing
assembly.
CAUTION: The steering knuckle to strut assembly

attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckle.
Fig. 15 BALL JOINT RELEASED USING C-4150A CAUTION: If the vehicle being serviced is equipped
1 - ALUMINUM KNUCKLE with eccentric strut assembly attaching bolts, the
2 - SPECIAL TOOL C-4150A eccentric bolt must be installed in the bottom (slot-
3 - LOWER CONTROL ARM ted) hole on the strut clevis bracket (Fig. 16).
(13) Remove the steering knuckle from the vehicle.

(14) If the hub and bearing needs to be trans-
ferred, remove the four bolts attaching the hub and
bearing to the knuckle, then remove the hub and
bearing.
INSPECTION - STEERING KNUCKLE

Inspect the knuckle for the following:
• Cracks or breaks
• Dents or damage
• Stress marks indicating a bend
The front suspension knuckle is not a repairable
component of the vehicles front suspension. If bent,
broken or damaged in any way, do not attempt to
straighten or repair the steering knuckle. It must be
replaced. Fig. 16 Correctly Installed Eccentric Attaching Bolt
If inspection leads to the hub and bearing, (Refer 1 - STEERING KNUCKLE
to 2 - SUSPENSION/FRONT/HUB / BEARING - 2 - FLANGED BOLT IN TOP HOLE
DIAGNOSIS AND TESTING) 3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
INSTALLATION - STEERING KNUCKLE
(1) If the hub and bearing needs to be installed in NOTE: The strut clevis-to-steering knuckle bolts are
the knuckle, place the hub and bearing squarely into installed differently on each side. Left hand side
the center hole of the steering knuckle aligning the bolts are to be installed from vehicle rear to front.
threaded mounting holes of the hub and bearing with Right side bolts are to be installed from vehicle
the mounting holes in the steering knuckle. Install front to rear.
2 - 10 FRONT RS
KNUCKLE (Continued)
(5) Install steering knuckle in clevis bracket of (15) Install wheel and tire assembly. Install and
strut damper assembly. Install the strut clevis-to- tighten the wheel mounting nuts in proper sequence
steering knuckle attaching bolts. Tighten both bolts until all nuts are torqued to half the required speci-
to a torque of 81 N·m (60 ft. lbs.) plus an additional fication. Then repeat the tightening sequence to the
1/4 (90°) turn. full specified torque of 135 N·m (100 ft. lbs.).
(6) Install tie rod end into knuckle steering arm. (16) Lower vehicle.
Start nut onto stud of tie rod end. While holding stud (17) Set front wheel alignment camber and toe as
of tie rod end stationary using a socket (Fig. 11), necessary. (Refer to 2 - SUSPENSION/WHEEL
tighten tie rod end to steering knuckle attaching nut. ALIGNMENT - STANDARD PROCEDURE)
Then using a crowfoot on a torque wrench (Fig. 17),
tighten the tie rod end nut to a torque of 75 N·m (55
ft. lbs.). LOWER BALL JOINT
DESCRIPTION
The ball joint is an integral part of the lower con-
trol arm (Fig. 1). The ball joint has a tapered stud
that is pressed into the aluminum knuckle. The ball
joint stud is threaded on the end for a retainer nut.
The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield (Fig. 18).
Fig. 17 Torquing Tie Rod End Attaching Nut

(Typical)
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
(7) If equipped with antilock brakes, install wheel Fig. 18 Ball Joint Seal Boot (Typical)
speed sensor and mounting bolt on steering knuckle 1 - BALL JOINT SEAL BOOT
(Fig. 13). Tighten the speed sensor bolt to a torque of 2 - BALL JOINT STUD
7 N·m (60 in. lbs.). 3 - LOWER CONTROL ARM
(8) Install brake rotor on hub and bearing (Fig. 9). 4 - SHIELD
(9) Install disc brake caliper and adapter assembly
on steering knuckle. Install adapter amounting bolts The ball joint used in the lower control arm of this
and tighten to 169 N·m (125 ft. lbs.). vehicle is a sealed-for-life ball joint and requires no
(10) Clean any debris from the threads of the maintenance lubrication. The ball joint has been
outer C/V joint stub axle. lubricated-for-life during the manufacturing process.
(11) Install the washer and hub nut on stub axle. A special fitting cap is installed on the fill port. This
(12) Have a helper apply the vehicle’s brakes to cap must not be removed and replaced with a com-
keep hub from turning, then tighten hub nut to a mon zirc fitting. The special cap is there to eliminate
torque of 244 N·m (180 ft. lbs.). the possibility of lubrication latter during the ball
(13) Install the spring wave washer on the end of joints life, thus damaging the non-vented seal boot.
the stub axle.
(14) Install the hub nut lock, and a new cotter pin NOTE: The ball joint does not require any type of
(Fig. 8). Wrap cotter pin prongs tightly around the additional lubrication for the life of the vehicle. No
hub nut lock. attempt should be made to ever add any lubrication
to the lower ball joint.
RS FRONT 2 - 11
LOWER BALL JOINT (Continued)
OPERATION
The ball joint is a pivotal joint on the lower control
arm that allows the knuckle to move up and down,
and turn with ease.
DIAGNOSIS AND TESTING - LOWER BALL

JOINT
With the weight of the vehicle resting on the road
wheels, grasp the special fitting cap on the bottom of
the ball joint and with no mechanical assistance or
added force, attempt to rotate the grease fitting.
If the ball joint is worn, the grease fitting will
rotate easily. If movement is noted, replacement of
the ball joint is recommended.
Fig. 20 Ball Joint Seal Boot Installed Position

LOWER BALL JOINT SEAL (Typical)
BOOT 1 - BALL JOINT SEAL BOOT
2 - BALL JOINT STUD
REMOVAL - BALL JOINT SEAL BOOT 3 - LOWER CONTROL ARM
(1) Remove steering knuckle from vehicle. (Refer 4 - SHIELD
to 2 - SUSPENSION/FRONT/KNUCKLE -
REMOVAL) CAUTION: Do not use an arbor press to install the
(2) Using a screw driver or other suitable tool, pry sealing boot on the ball joint. Damage to the seal-
the seal boot off of the ball joint (Fig. 19) ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(3) Place Installer, Special Tool 6758, over seal

boot and squarely align it with bottom edge of seal
boot (Fig. 21). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
(4) Wipe any grease off the ball joint stem.
CAUTION: Do not attempt to install a normal grease

zirc in the ball joint an lubricate the joint through
the zirc fitting.
(5) Reinstall steering knuckle on vehicle. (Refer to

2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
Fig. 19 Ball Joint Seal Boot Removal (Typical)
2
3
-
-
BALL JOINT STUD
SEAL BOOT
LOWER CONTROL ARM
4 - SCREW DRIVER
5 - BALL JOINT ASSEMBLY DESCRIPTION
The lower control arm is mounted to the front sus-
pension crossmember using a pivot bolt through the
INSTALLATION - BALL JOINT SEAL BOOT center of the front pivot bushing, and the front sus-
(1) Place a liberal dab of Mopart Wheel Bearing pension cradle crossmember reinforcement traps the
Grease around the base of the ball joint stem at the rear bushing in the crossmember (Fig. 1).
socket.
(2) Install a NEW seal boot by hand as far as pos-
sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 20).
2 - 12 FRONT RS
LOWER CONTROL ARM (Continued)
(3) Remove the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 22).
Fig. 21 Installing Ball Joint Seal Boot

1 - SHIELD
2 - SPECIAL TOOL 6758
4 - BALL JOINT SEAL BOOT
The lower control arm is an iron casting with two

rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed Fig. 22 POWER STEERING COOLER
into the lower control arm. The standard lower con-
1 - CRADLE CROSSMEMBER REINFORCEMENT
trol arm rear bushing is a push-on bushing that is 2 - POWER STEERING COOLER
pushed over a stem on the rear of the lower control
arm. The optional lower control arm rear bushing is
a hydro-bushing that is pressed on. It has liquid (5) Remove the lower control arm rear bushing
filled voids that provide more effective dampening retainer bolts located on each side of each lower con-
than the standard bushing. Vehicles with rear hydro- trol arm rear bushing.
bushings utilize a different lower control arm than
NOTE: The bolts fastening the cradle crossmember
vehicles with standard bushings. They have a
reinforcement are of two different thread sizes. Note
straight slightly tapered round stem where the
the location of the various sizes.
hydro-bushing is mounted whereas the standard arm
has a straight stem with a squared knob on the end (6) Remove the bolts attaching the cradle cross-
to retain the bushing. member reinforcement to the front suspension cradle
The lower control arm ball joint is pressed into the crossmember (Fig. 23). Remove the 2 bolts fastening
outer end of the arm. The ball joint has a tapered the reinforcement and rear of cradle crossmember to
stud and retainer nut for fastening it to the steering the body of the vehicle. Remove the reinforcement.
knuckle. (7) Remove the pivot bolt attaching the front bush-
ing of the lower control arm to the front suspension
OPERATION cradle crossmember.
The lower control arm supports the lower end of (8) Remove the lower control arm.
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and DISASSEMBLY - LOWER CONTROL ARM
rebound travel. The lower control arm ball joint con-
nects the arm to the steering knuckle.
(REAR BUSHING - STANDARD)
(1) Remove the lower control arm from the front
REMOVAL - LOWER CONTROL ARM suspension cradle. (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - REMOVAL)
(2) Mount the lower control arm in a vise without
using excessive clamping force.
and Maintenance.
(2) Remove wheel and tire assembly.
RS FRONT 2 - 13
Fig. 24 Slit Lower Control Arm Rear Bushing

1 - REAR BUSHING
2 - SLIT CUT IN BUSHING
Fig. 23 CRADLE CROSSMEMBER REINFORCEMENT

ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
Fig. 25 HYDRO-BUSHING REMOVAL
1 - REMOVAL PIN (8460-3)
(3) Using a sharp knife (such as a razor), slit the 2 - BRIDGE (8460-1)
bushing lengthwise (Fig. 24) to allow its removal 3 - HYDRO-BUSHING
from the lower control arm (Fig. 24). 4 - LOWER CONTROL ARM
(4) Remove the bushing from the lower control
arm.
(4) Tighten forcing screw of Bridge (Special Tool
8460–1), removing bushing from lower control arm.
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO) INSPECTION - LOWER CONTROL ARM
(1) Remove the lower control arm from the front Inspect lower control arm for signs of damage from
suspension cradle. (Refer to 2 - SUSPENSION/ contact with the ground or road debris. If lower con-
FRONT/LOWER CONTROL ARM - REMOVAL) trol arm shows any sign of damage, inspect lower
(2) Mount the lower control arm in a vise without control arm for distortion. Do not attempt to repair
using excessive clamping force. or straighten a broken or bent lower control arm. If
(3) Install Remover, Special Tool 8460, on hydro- damaged, the lower control arm casting is serviced
bushing as shown (Fig. 25). Removal Pin, Special only as a complete component.
Tool 8460–3, must extend though hole in center of Inspect both lower control arm isolator bushings
bushing rear. for severe deterioration, and replace as required.
Inspect the rear hydro-bushing for seepage. Both
2 - 14 FRONT RS
type rear bushings are serviceable. If the front bush- ASSEMBLY - LOWER CONTROL ARM (REAR
ing fails, the lower control arm must be replaced.
BUSHING - HYDRO)
Inspect and test the ball joint per the procedure
listed in Lower Ball Joint. (Refer to 2 - SUSPEN- CAUTION: Do not apply grease or any other type of
SION/FRONT/LOWER BALL JOINT - DIAGNOSIS lubricant to the arm stem where the bushing is to
AND TESTING) be mounted. Such action will reduce proper bush-
ing adhesion to arm.
ASSEMBLY - LOWER CONTROL ARM (REAR
BUSHING - STANDARD) (1) Secure lower control arm in a vise.
CAUTION: Do not apply grease or any other type of NOTE: Hydro bushings and grooves on control arm
lubricant other than the silicone lubricant specified stems are unique for right and left sides. Left side
below to the control arm bushing. bushing master spline and control arm groove are
on the top (when mounted on vehicle). Right side
(1) Apply Mopar Silicone Spray Lube or an equiv- bushing master spline and control arm groove are
alent, to the hole in lower control arm rear bushing. on the bottom (when mounted on vehicle).
This will aid in the installation of the bushing on the
lower control arm. (2) Align master spline on bushing inner sleeve
(2) With the lower control arm held securely in a with groove on lower control arm rear bushing stem
vise, install bushing on lower control arm. Install (Fig. 27). Start bushing on stem by hand.
bushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure that
when bushing is installed it is past the upset on the
end of the lower control arm (Fig. 26).
(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown (Fig. 26).
Fig. 27 BUSHING MASTER SPLINE LINED UP WITH

GROOVE (RIGHT SIDE SHOWN)
1 - GROOVE
2 - HYDRO-BUSHING
3 - MASTER SPLINE
Fig. 26 Correctly Installed Lower Control Arm (3) Install Remover/Installer, Special Tool 8460,
Bushing over bushing and lower control arm as shown (Fig.
1 - ROUND SURFACE OF BUSHING 28). Engage flange on lower control arm with tips of
2 - LOWER CONTROL ARM Bridge, Special Tool 8460–1 as shown (Fig. 28). The
3 - LOWER CONTROL ARM REAR BUSHING
contoured side of Installer Cup, Special Tool 8460–2,
4 - UPSET
should be fitted up against rear of the bushing.
5 - FLAT SURFACE OF BUSHING
(4) Begin to tighten forcing screw. As bushing
nears lower control arm flange, place Spacer Plate,
(4) Install lower control arm on vehicle. (Refer to 2 Special Tool 8460–4 between flange and bushing
- SUSPENSION/FRONT/LOWER CONTROL ARM - inner sleeve, straddling the stem as shown (Fig. 29).
INSTALLATION) (5) Install bushing up against Spacer Plate, tight-
ening the bridge forcing screw with a torque wrench
until approximately 50 N·m (37 ft. lbs.) torque is
RS FRONT 2 - 15
(2) Install NEW pivot bolt attaching front bushing
of lower control arm to front suspension cradle cross-
member (Fig. 30). Do not tighten or torque pivot
bolt at this time.
Fig. 28 HYDRO-BUSHING INSTALLATION

1 - LOWER CONTROL ARM FLANGE
2 - INSTALLER CUP (8460-2)
3 - BRIDGE (8460-1)
4 - HYDRO-BUSHING
Fig. 30 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
1 - PIVOT BOLT
3 - FRONT SUSPENSION CRADLE CROSSMEMBER
(3) Install the reinforcement on the front suspen-

sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 23). Tighten the M-14 size bolts to a torque of
163 N·m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N·m (80 ft. lbs.).
(4) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
(5) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
Fig. 29 SPACER PLATE POSITIONED body of vehicle (Fig. 23). Tighten bolts to a torque of
1 - SPACER PLATE (8460-4) 163 N·m (120 ft. lbs.).
2 - LOWER CONTROL ARM FLANGE (6) Install the power steering cooler (Fig. 22).
3 - BRIDGE (8460-1)
Tighten bolts to a torque of 11 N·m (100 in. lbs.).
4 - INSTALLER CUP (8460-2)
(7) Reinstall steering knuckle, brake rotor and cal-
5 - HYDRO-BUSHING
iper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE
- INSTALLATION)
reached. This will properly space bushing on the
stem in relation to the flange. CAUTION: When locating jack stands under lower
(6) Back off the forcing screw and remove tool. control arms, do not place the jack stands under
(7) Install lower control arm on vehicle. (Refer to 2 the ball joints (Fig. 31).
- SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION) (8) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 31).
INSTALLATION - LOWER CONTROL ARM Lower the vehicle onto the jack stands until the jack
(1) Position lower control arm assembly into front stands are supporting the total weight of the vehicle.
suspension cradle crossmember guiding bushings into (9) Tighten front lower control arm pivot bolt to a
mounting position (Fig. 23). torque of 183 N·m (135 ft. lbs.).
2 - 16 FRONT RS
to minimize the body roll of the vehicle during sus-
pension movement.
Connecting the stabilizer bar links to the strut
assemblies helps reduce the fore-and-aft rate of the
stabilizer bar from the rest of the front suspension.
REMOVAL - STABILIZER BAR

and Maintenance.
(2) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 32).
Fig. 31 Jack Stands Supporting Vehicle Weight

1 - LOWER CONTROL ARMS
2 - BALL JOINT
3 - JACK STANDS
4 - BALL JOINT
(10) Install the wheel and tire assembly. Install

and tighten the wheel mounting stud nuts in proper
tion. Then repeat the tightening sequence to the full
(11) Raise vehicle, remove jack stands and lower
vehicle to the ground.
(12) Perform front wheel alignment as necessary.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
Fig. 32 POWER STEERING COOLER
STABILIZER BAR 1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
DESCRIPTION
The stabilizer bar interconnects both front struts of (3) Remove the lower control arm rear bushing
the vehicle and is attached to the front crossmember retainer bolts located on each side of each lower con-
(Fig. 1) . trol arm rear bushing.
Attachment of the stabilizer bar to the front cross-
member is through 2 rubber-isolator cushion bush- NOTE: The bolts fastening the cradle crossmember
ings and retainers. A double ball jointed stabilizer reinforcement are of two different thread sizes. Note
bar link is used to attach each end of the stabilizer the location of the various sizes.
bar to the front strut assemblies. All parts of the sta-
(4) Remove the bolts attaching the cradle cross-
bilizer bar are replaceable as individual components.
member reinforcement to the front suspension cradle
The stabilizer bar to front crossmember cushion
crossmember (Fig. 33). Remove the 2 bolts fastening
bushings are split for easy removal and installation.
The split in the bushings should be positioned toward
the body of the vehicle. Remove the reinforcement.
the rear of the vehicle, with the square corner facing
down, when the stabilizer bar is installed. CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
OPERATION rotate in it’s socket. Hold the stud from rotating by
Jounce and rebound movements affecting one placing an open-end wrench on the flat machined
wheel are partially transmitted to the opposite wheel into the stud (Fig. 34).
of the vehicle through the stabilizer bar. This helps
RS FRONT 2 - 17
STABILIZER BAR (Continued)
Fig. 34 Stabilizer Bar Link To Stabilizer Bar

Attachment
1 - RATCHET
2 - WRENCH
3 - STRUT
4 - STABILIZER BAR LINK
5 - NUT
6 - STABILIZER BAR
Fig. 33 CRADLE CROSSMEMBER REINFORCEMENT

ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
(5) Remove the stabilizer bar links from each end

of the stabilizer bar (Fig. 34). To do so, place an open-
end wrench on the flat machined into the link’s
mounting stud, then remove the nut while holding
the wrench in place. Push each stud out of the hole
in the stabilizer bar. Fig. 35 Front Stabilizer Bar Retainers
(6) Remove the stabilizer bar bushing (cushion) 1 - STEERING GEAR
retainers from the front suspension cradle crossmem- 2 - STABILIZER BAR
ber (Fig. 35). 3 - RAISED BEAD
(7) Remove the stabilizer bar and bushings (cush- 4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
ions) as an assembly from the front suspension cra-
dle crossmember.
INSTALLATION - STABILIZER BAR
INSPECTION - STABILIZER BAR
Inspect for broken or distorted stabilizer bar bush- NOTE: Two different diameter stabilizer bars are
ings (cushions), bushing retainers, and worn or dam- available for this vehicle. Therefore, two different
aged stabilizer bar links. size bushings/cushions are also used. Use the cor-
rect bushing/cushion on the correct stabilizer bar.
2 - 18 FRONT RS
(1) If the stabilizer bar to front suspension cradle
bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar.
Bushings are replaced by opening slit on bushings
and peeling them off stabilizer bar. Install new bush-
ings on stabilizer bar by spreading bushing at slit
and forcing them on the stabilizer bar. Bushings
must be installed on stabilizer bar so slit in
bushing will be facing toward the rear of vehi-
cle with the square corner toward the ground,
when the stabilizer bar is installed on the vehi-
cle (Fig. 36).
Fig. 37 Stabilizer Bar Bushing Retainer Installation

1 - SWAY BAR
2 - SWAY BAR BUSHING
3 - BUSHING SPLIT
4 - FRONT SUSPENSION CRADLE
5 - BUSHING CUT-OUT
6 - BUSHING RETAINER
7 - RAISED BEAD
Fig. 36 Correctly Installed Stabilizer Bar To Cradle

Bushing
1 - SWAY BAR ISOLATOR BUSHING
2 - SLIT IN SWAY BAR BUSHING
3 - SWAY BAR
(2) Position stabilizer bar into front suspension

cradle so stabilizer bar bushings are aligned with
depressions in cradle. Install stabilizer bar bushing
retainers onto crossmember aligning raised bead on
retainer with cutouts in bushings (Fig. 37). Do not
tighten Stabilizer bar bushing retainers bolts at
this time. Fig. 38 Stabilizer Bar Correctly Positioned In Cradle
(3) Check position of the stabilizer bar in the front 1 - RAISED BEAD
suspension cradle. The center of the curved section of 2 - SWAY BAR
the stabilizer bar must be aligned with the raised 3 - WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE
line in the center of the front suspension cradle (Fig. SUSPENSION CRADLE MUST BE IN THE CENTER OF RADIUS
IN SWAY BAR
38).
4 - FRONT SUSPENSION CRADLE
(4) Install the stabilizer bar link mounting stud
through the hole in each end of the stabilizer bar
(Fig. 34). (5) Hand-thread the nut on the end of each stabi-
lizer bar link stud. Hold the studs from turning by
CAUTION: When installing the nut on the mounting placing an open-end wrench on the flat machined
stud of the stabilizer bar link, do not allow the stud into the link’s mounting stud, then tighten each nut
to rotate in it’s socket. Hold the stud from rotating while holding the wrench in place (Fig. 34). Tighten
by placing an open-end wrench on the flat each nut to a torque of 88 N·m (65 ft. lbs.).
machined into the stud (Fig. 34).
RS FRONT 2 - 19
(6) Tighten the stabilizer bar bushing retainer to STRUT
cradle attaching bolts (Fig. 35) to 68 N·m (50 ft. lbs.)
torque.
DESCRIPTION - STRUT ASSEMBLY
(7) Install the reinforcement on the front suspen-
A Macpherson type strut assembly is used in place
sion cradle crossmember and install the bolts attach-
of a conventional front suspension’s upper control
ing the reinforcement to the cradle crossmember
arm and upper ball joint. The bottom of the strut
(Fig. 33). Tighten the M-14 size bolts to a torque of
mounts directly to the steering knuckle using two
163 N·m (120 ft. lbs.). Tighten the M-12 size bolts to
bolts and nuts going through the strut clevis bracket
and steering knuckle. The top of the strut mounts
(8) Install the lower control arm rear bushing
directly to the strut tower of the vehicle using the
retainer bolts through reinforcement on each side of
threaded studs on the strut assemblies upper mount.
each lower control arm rear bushing. Tighten bolts to
The strut assembly includes the components listed
in the figure (Fig. 39).
(9) Install the two bolts and bushings attaching
Each component is serviced by removing the strut
assembly from the vehicle and disassembling it.
body of vehicle (Fig. 33). Tighten bolts to a torque of
The coil springs are side-oriented. Springs on the
163 N·m (120 ft. lbs.).
left side of the vehicle have a left-hand wind top-to-
(10) Install the power steering cooler (Fig. 32).
bottom while springs on the right side have a right-
Tighten bolts to a torque of 11 N·m (100 in. lbs.).
hand wind top-to-bottom. This helps provide better
vehicle stability during jounce and rebound maneu-
vers of the front suspension. Left and right springs
must not be interchanged. Coil springs are rated sep-
Fig. 39 STRUT ASSEMBLY

1 - NUT 7 - DUST SHIELD
2 - UPPER MOUNT 8 - JOUNCE BUMPER
3 - PIVOT BEARING 9 - LOWER SPRING ISOLATOR
4 - UPPER SPRING SEAT 10 - STRUT (DAMPER)
5 - UPPER SPRING ISOLATOR
6 - COIL SPRING
2 - 20 FRONT RS
STRUT (Continued)
arately for each corner or side of the vehicle depend-
ing on optional equipment and type of vehicle
service. If the coil springs require replacement, be
sure that the springs are replaced with springs meet-
ing the correct load rating and spring rate for the
vehicle and its specific options.
OPERATION - STRUT ASSEMBLY

The strut assembly cushions the ride of the vehicle,
controlling vibration, along with jounce and rebound
of the suspension.
The coil spring controls ride quality and maintains
proper ride height.
The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con-
tact with the upper seat and strut.
The jounce bumper limits suspension travel and Fig. 40 Strut Assembly Leakage Inspection (Typical)
metal-to-metal contact under full jounce condition. 1 - DUST BOOT
The strut dampens jounce and rebound motions of 2 - STRUT SHAFT
the coil spring and suspension. 3 - STRUT FLUID RESERVOIR
During steering maneuvers, the strut assembly 4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
(through a pivot bearing in the upper strut mount) LEAKAGE
and steering knuckle (through the lower ball joint)
turn as an assembly. (3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
DIAGNOSIS AND TESTING - STRUT ASSEMBLY which side of the vehicle they were removed from.
(FRONT) (4) Remove the hydraulic brake hose routing
(1) Inspect for damaged or broken coil springs bracket and the speed sensor cable routing bracket
(Fig. 39). from the strut damper brackets (Fig. 41).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 39).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 40) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage
between the strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly (Fig. 40). Also inspect jounce bumpers for
signs of damage or deterioration.
REMOVAL - STRUT ASSEMBLY

WARNING: DO NOT REMOVE THE NUT FROM THE Fig. 41 Brake Hose And Speed Sensor Cable
STRUT ROD WHILE STRUT ASSEMBLY IS Routing
INSTALLED IN VEHICLE, OR BEFORE STRUT
1 - STRUT DAMPER
ASSEMBLY SPRING IS COMPRESSED. 2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
(1) Raise the vehicle. See Hoisting in Lubrication 4 - HYDRAULIC BRAKE HOSE
and Maintenance. 5 - ATTACHING BOLT
(2) Remove the wheel and tire assembly from loca- 6 - ROUTING BRACKET
tion on front of vehicle requiring strut removal.
RS FRONT 2 - 21
STRUT (Continued)
CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it’s socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 42).
(5) Remove the stabilizer bar link from the bracket

on the strut assembly (Fig. 42). To do so, place an
open-end wrench on the flat machined into the link’s
mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.
Fig. 43 Strut Damper Attachment To Steering

Knuckle
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
Fig. 42 Stabilizer Bar Link To Strut Attachment

1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
CAUTION: The steering knuckle to strut assembly

attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 strut assembly clevis bracket to

steering knuckle attaching bolts (Fig. 43). Fig. 44 Strut Assembly To Strut Tower Attaching
(7) Remove the 3 nuts attaching the strut assem- Nuts (Typical)
bly upper mount to the strut tower (Fig. 44) and 1 - WINDSHIELD WIPER MODULE
remove the strut assembly from the vehicle. 2 - STRUT TOWER
(8) To disassemble the strut assembly, (Refer to 2 - 3 - STRUT MOUNT ATTACHING BOLTS
SUSPENSION/FRONT/STRUT - DISASSEMBLY). 4 - UPPER STRUT MOUNT
DISASSEMBLY - STRUT ASSEMBLY WARNING: DO NOT REMOVE THE STRUT SHAFT

The strut assembly must be removed from the NUT BEFORE THE COIL SPRING IS COMPRESSED.
vehicle for it to be disassembled and assembled. THE COIL SPRING IS HELD UNDER PRESSURE
For the disassembly and assembly of the strut AND MUST BE COMPRESSED, REMOVING SPRING
assembly, use of Strut Spring Compressor, Pentastar TENSION FROM THE UPPER MOUNT AND PIVOT
Service Equipment (PSE) tool W-7200, or the equiva- BEARING, BEFORE THE SHAFT NUT IS REMOVED.
lent, is recommended to compress the coil spring.
Follow the manufacturer’s instructions closely.
2 - 22 FRONT RS
STRUT (Continued)
(1) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Position the lower hooks on the coil
spring first. The strut clevis bracket should be posi-
tioned straight outward from the compressor.
(2) Turn the upper mount of the strut assembly
toward the inside of the compressor as shown to
allow positioning of the compressor upper hooks (Fig.
45). Position the upper hooks on top of the coil spring
upper seat approximately 1 inch from outside diame-
ter of seat (Fig. 48). Do not allow hooks to be
placed closer to edge. Place a clamp on the lower
end of the coil spring, so the strut is held in place
once the strut shaft nut is removed.
Fig. 46 Retaining Nut Removal/Installation (Typical)

1 - UPPER MOUNT
(8) Release the tension from the coil spring by

backing off the compressor drive fully. Push back the
compressor upper hooks and remove the upper spring
seat.
(9) Remove the coil spring from the spring com-
pressor.
(10) Remove the dust shield and jounce bumper as
an assembly from the strut shaft by pulling both
straight up and off the strut shaft. The dust shield
cannot be separated from the jounce bumper until
Fig. 45 MOUNT ROTATED AND HOOKS POSITIONED after it is removed from strut shaft.
1 - UPPER MOUNT TURNED TOWARD COMPRESSOR (11) Remove the jounce bumper from the dust
2 - COMPRESSOR UPPER HOOKS shield. The jounce bumper is removed from the dust
3 - UPPER SPRING SEAT shield by collapsing the dust shield until the jounce
bumper can be pulled free from the dust boot.
(3) Compress the coil spring until all coil spring (12) Remove the spring isolator from the lower
tension is removed from the upper mount. spring seat on the strut (Fig. 39).
(4) Install Strut Nut Socket, Special Tool 6864, on (13) Inspect the strut assembly components (Fig.
the strut shaft retaining nut (Fig. 46). Next, install a 39) for the following and replace as necessary:
10 mm socket on the hex on the end of the strut • Inspect the strut for any condition of shaft bind-
shaft. While holding the strut shaft from turning, ing over the full stroke of the shaft.
remove the nut from the strut shaft. • Check the upper mount for cracks and distortion
(5) Remove the upper mount from the strut shaft. and its retaining studs for any sign of damage.
(6) If the pivot bearing needs to be serviced, • Check the upper seat for stress cracks and wear.
remove it from the top of the coil spring upper seat • Check the upper spring isolator for severe dete-
by pulling it straight up. rioration.
(7) Remove the clamp from the bottom of the coil • Check for binding of the strut assembly pivot
spring and remove the strut out through the bottom bearing.
of the coil spring. • Inspect the dust shield for rips and deteriora-
tion.
NOTE: If the coil spring or upper spring seat needs • Inspect the jounce bumper for cracks and signs
to be serviced, proceed with the next step, other- of deterioration.
wise, proceed with step 10.
RS FRONT 2 - 23
STRUT (Continued)
ASSEMBLY - STRUT ASSEMBLY (Fig. 48). This will allow proper clearance for upper
For the disassembly and assembly of the strut mount installation without pinching the hooks in-be-
assembly, use of Strut Spring Compressor, Pentastar tween the two pieces. Do not allow hooks to be
Service Equipment (PSE) tool W-7200, or the equiva- placed closer to edge.
lent, is recommended to compress the coil spring.
Follow the manufacturer’s instructions closely.
NOTE: Coil Springs on this vehicle are side-ori-

ented. Springs on the left side of the vehicle have a
left-hand wind top-to-bottom while springs on the
right side have a right-hand wind top-to-bottom.
Left and right springs must not be interchanged.
NOTE: If the coil spring has been removed from the

spring compressor, proceed with the next step, oth-
erwise, proceed with step 5.
(1) Place the coil spring in the compressor lower

hooks following the manufacturers instructions.
Proper orientation of the spring to the strut (once
installed) is necessary. Consider the following when Fig. 48 HOOK PLACEMENT ON UPPER SEAT
placing the coil spring in the compressor: From 1 - HOOKS POSITIONED 1 INCH FROM EDGE
above, the compressor back is at the 12 o’clock posi- 2 - PIVOT BEARING AND UPPER SEAT
tion and you, standing in the front of the machine,
are at the 6 o’clock position. Place the lower coil (4) Compress the coil spring far enough to allow
spring end at the 6 o’clock position for both left and strut installation.
right springs. (Fig. 47). (5) If the pivot bearing has been removed form the
upper seat, install the pivot bearing on the top of the
upper spring seat (Fig. 49). The bearing must be
installed on upper seat with the smaller diameter
side of the pivot bearing toward the spring seat. Be
sure the pivot bearing is sitting flat on the spring
seat once mounted.
Fig. 47 SPRING POSITIONED IN COMPRESSOR

(RIGHT SPRING SHOWN)
1 - COMPRESSOR LOWER HOOKS
2 - COIL SPRING END
(2) Install the upper seat and upper isolator on top

of the coil spring. Position the notch in the perimeter Fig. 49 PIVOT BEARING INSTALLATION
of the upper seat toward the front of the compressor 1 - PIVOT BEARING
(same 6 o’clock position as in step 1). 2 - UPPER SEAT
(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span approxi- (6) Install the spring isolator on the lower spring
mately 1 inch past outside diameter of upper seat seat of the strut (Fig. 39).
2 - 24 FRONT RS
STRUT (Continued)
(7) Install the jounce bumper on the strut shaft NOTE: Before releasing the tension the compressor
(Fig. 39). The jounce bumper is to be installed with has on the spring, using the following figure as ref-
the small end pointing downward. erence (Fig. 51), make sure the upper spring seat,
(8) Install the dust shield on the strut. Collapse coil spring and strut clevis bracket are all lined up
and stretch the dust shield down over the top of the properly (within 5° of one another).
jounce bumper until the dust shield snaps into the
slot on the jounce bumper. The jounce bumper will be
at the top of the inner dust boot. Return the dust
shield to its fully extended length.
(9) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. The clevis bracket on the strut
should point straight outward away from the com-
pressor (to the 6 o’clock position). This position
should be within 5° of the lower end tip of the coil
spring (Fig. 50). If necessary, reposition the strut or
coil spring in the compressor so both of these line up
straight outward away from the compressor (to the 6
o’clock position). Install the clamp to hold the strut
and coil together.
Fig. 51 COMPONENTS LINED UP

1 - IMAGINARY VERTICAL LINE
2 - CLEVIS BRACKET
3 - END OF COIL SPRING
4 - NOTCH IN UPPER SPRING SEAT
(12) Slowly release the tension from the coil spring

by backing off the compressor drive fully. As the ten-
sion is relieved, make sure the upper mount, pivot
Fig. 50 COIL SPRING POSITIONING bearing and upper seat are align properly. Remove
1 - FRONT OF VEHICLE the clamp from the lower end of the coil spring and
2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT strut. Push back the spring compressor upper and
3 - LOWER SEATS OF STRUTS lower hooks, then remove the strut assembly from
4 - STRUT CLEVIS BRACKETS
the spring compressor.
5 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT
(13) Install strut assembly on the vehicle. (Refer to
2 - SUSPENSION/FRONT/STRUT - INSTALLA-
(10) Install the strut mount over the strut shaft TION)
and onto the top of the pivot bearing and upper seat
as shown (Fig. 45). Loosely install the retaining nut INSTALLATION - STRUT ASSEMBLY
on the strut shaft.
(11) Install Strut Nut Socket (on the end of a CAUTION: Front strut coil springs are side-oriented.
torque wrench), Special Tool 6864, on the strut shaft When installing a strut assembly, make sure the
retaining nut (Fig. 46). Next, install a 10 mm socket strut being installed has the correct coil spring for
on the hex on the end of the strut shaft. While hold- that side of the vehicle. Springs on the left side of
ing the strut shaft from turning, tighten the strut the vehicle have a left-hand wind top-to-bottom
shaft retaining nut to a torque of 100 N·m (75 ft. while springs on the right side have a right-hand
lbs.). wind top-to-bottom (Fig. 50). Do not interchange the
two sides.
RS FRONT 2 - 25
STRUT (Continued)
(1) Install strut assembly into strut tower, aligning torque of 81 N·m (60 ft. lbs.) plus an additional 1/4
and installing the 3 studs on the upper strut mount (90°) turn after specified torque is met.
into the holes in shock tower. Install the 3 upper (3) Install the stabilizer bar link mounting stud
strut mount attaching nut/washer assemblies (Fig. through the bracket on the strut assembly (Fig. 42).
44). Then using a crow foot. tighten the 3 attaching
nuts to a torque of 28 N·m (250 in. lbs.). CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
CAUTION: The steering knuckle to strut assembly to rotate in it’s socket. Hold the stud from rotating
attaching bolts are serrated and must not be turned by placing an open-end wrench on the flat
during installation. Install nuts while holding bolts machined into the stud (Fig. 42).
stationary in the steering knuckles.
(4) Hand thread the nut on the end of the stabi-
lizer bar link stud. Hold the stud from turning by
NOTE: The strut clevis-to-steering knuckle bolts are placing an open-end wrench on the flat machined
installed differently on each side of the vehicle. Left into the link’s mounting stud, then tighten the nut
hand side bolts are to be installed from vehicle rear while holding the wrench in place (Fig. 42). Tighten
to front. Right side bolts are to be installed from the nut to a torque of 88 N·m (65 ft. lbs.).
vehicle front to rear. (5) Install the hydraulic brake hose and speed sen-
sor cable routing brackets on the strut assembly
(2) Align strut assembly with steering knuckle. brackets (Fig. 41). Tighten the routing bracket
Position arm of steering knuckle into strut assembly attaching bolts to a torque of 13 N·m (10 ft. lbs.).
clevis bracket. Align the strut assembly clevis (6) Install the wheel/tire assembly on the vehicle.
bracket mounting holes with the steering knuckle (7) Install and tighten the wheel mounting stud
mounting holes. Install the 2 strut assembly to steer- nuts in proper sequence until all nuts are torqued to
ing knuckle attaching bolts (Fig. 43). If strut assem- half specification. Then repeat the tightening
bly is attached to steering knuckle using a cam sequence to the full specified torque of 135 N·m (100
bolt, the cam bolt must be installed in the lower ft. lbs.).
slotted hole on strut clevis bracket. Tighten the
strut clevis-to-steering knuckle attaching bolts to a
2 - 26 REAR RS
REAR
TABLE OF CONTENTS
page page
REAR SPRING - AWD

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BUSHINGS SPRING - FWD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
HUB / BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPRING MOUNTS - FRONT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HUB AND BEARING (REAR). . . . . . . . . . . . . . . 30 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SPRING MOUNTS - REAR
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
JOUNCE BUMPER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 STABILIZER BAR
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SHOCK ABSORBER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 TRACK BAR
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REAR springs, but does not use isolator bushings between

the rear axle and the leaf springs.
Each side of the rear suspension consists of these
DESCRIPTION - REAR SUSPENSION
major components:
The rear suspension design on this vehicle uses
• Leaf spring
leaf springs, and a tube and casting axle (Fig. 1) (Fig.
• Jounce bumper
2). The leaf springs used on the rear suspension of
• Shock absorber
this vehicle are of either a mono-leaf or multi-leaf
• Hub and bearing
design.
• Track bar (one per suspension)
There are 2 different rear suspension designs
• Stabilizer bar (one per suspension)
available:
• Front-Wheel-Drive
• All-Wheel-Drive
OPERATION - REAR SUSPENSION
This rear suspension is designed to handle the var-
The rear axle used on Front-Wheel-Drive applica-
ious load requirements of the vehicle yet allow for a
tions of this vehicle is mounted to the rear leaf
comfortable ride.
springs using isolator bushings at the axle mounting
The rear wheel bearings used are similar to the
brackets.
bearings used in the front suspension. A hub and
The rear axle used on All-Wheel-Drive applications
bearing assembly is used.
of this vehicle is also mounted to the rear leaf
RS REAR 2 - 27
REAR (Continued)
Fig. 1 Front-Wheel-Drive Rear Suspension

1 - SHACKLE 7 - LEAF SPRING (MONO-LEAF)
2 - REAR MOUNT (HANGER) 8 - ISOLATOR
3 - TRACK BAR 9 - FWD REAR AXLE
4 - SPRING PLATE 10 - STABILIZER BAR LINKS
5 - ISOLATOR 11 - STABILIZER BAR
6 - FRONT MOUNT (HANGER)
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Hub And Bearing Mounting
129 95 —
Bolts
Hub And Bearing Axle Hub Nut 244 180 —
Jounce Bumper Mounting Bolt 33 24 290
Leaf Spring Front Mount-To-
61 45 —
Body Bolts
Leaf Spring Front Pivot Bolt 156 115 —
Leaf Spring Plate-To-Axle Bolts 102 75 —
Fig. 2 All-Wheel-Drive Rear Suspension Leaf Spring Rear Mount-To-
1 - SHACKLE 61 45 —
Body Bolts
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
Leaf Spring Shackle Plate Nuts 61 45 —
4 - AWD REAR AXLE Shock Absorber Mounting Bolts 102 75 —
2 - 28 REAR RS
REAR (Continued)
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Stabilizer Bar Bushing Retainer
61 45 —
Bolts
Stabilizer Bar Link Nuts 61 45 —
Stabilizer Bar Link Frame
61 45 —
Bracket Mounting Bolts
Track Bar Bracket-To-Body
61 45 —
Mount Bolts Press, Ball Joint C-4212F
Track Bar Pivot Bolts 95 70 —
Wheel Mounting (Lug) Nut 135 100 — BUSHINGS
SPECIAL TOOLS REMOVAL - LEAF SPRING FRONT BUSHING

(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
REAR SUSPENSION of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 3).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
REMOVER, HUB/BEARING 8458
Fig. 3 LIFTING POINT AND SPRING MOUNT

1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact
axle.
RS REAR 2 - 29
BUSHINGS (Continued)
(3) Remove shock absorber lower mounting bolt.
NOTE: If shock absorber bolt deflects upward dur-

ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Remove four bolts securing leaf spring front

mounting bracket to the body (Fig. 3).
(5) Using jack, slowly lower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.
(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
(7) Straighten the retainer tabs on the bushing
(Fig. 4). Fig. 5 TOOL 8459 MOUNTED FOR BUSHING
REMOVAL
1 - BUSHING
2 - BEARING
3 - WASHER
4 - NUT
5 - BODY (8459-1)
6 - PIN
7 - REMOVER PLATE (8459-2)
8 - SET SCREW
Set Screw securing Installer Plate (8459–3) to tool

threaded shaft.
(3) Tighten nut (Fig. 6), installing bushing in
spring eye. Tighten nut until bushing is fully seated
and bushing flange bottoms against spring eye. Do
not over-tighten causing tool and bushing to bind.
Fig. 4 STRAIGHTENED RETAINING TABS (4) Remove Remover/Installer from the bushing
1 - SPRING EYE and leaf spring.
2 - RETAINING TABS (5) Bend the retainer tabs on bushing outward
against spring eye.
(6) Position spring mounting bracket over spring
(8) Place Remover/Installer, Special Tool 8459 on
eye and install pivot bolt through center of bushing
leaf spring and bushing as shown (Fig. 5) and tighten
from the outboard side.
Set Screw securing Remover Plate to tool threaded
shaft. NOTE: The pivot bolt must be installed from the
(9) Tighten nut (Fig. 5), removing bushing from outboard side to allow proper bracket to body
spring eye. mounting.
(10) Remove the tool from spring, then remove
bushing from tool. (7) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
INSTALLATION - LEAF SPRING FRONT (8) Raise the under-hoist utility jack or transmis-
BUSHING sion jack, guiding the forward mounting bracket into
(1) Install by hand NEW bushing in left side of place against the body. It may help to use a drift
leaf spring eye. punch placed through the hole centered between the
(2) Place Remover/Installer, Special Tool 8459 on mounting bolt holes in the bracket and the pilot hole
leaf spring and bushing as shown (Fig. 6) and tighten in the body of the vehicle as a guide. When the four
mounting bolt holes line up with their threads in the
2 - 30 REAR RS
BUSHINGS (Continued)
Front-Wheel-Drive vehicles with antilock brakes
have an internally mounted wheel speed sensor and
tone wheel. This hub and bearing can be identified
by the rounded cap and molded in connector on the
rear of the assembly (Fig. 7). The sensor and tone
wheel cannot be serviced separately from the hub
and bearing.
Fig. 6 TOOL 8459 MOUNTED FOR BUSHING

INSTALLATION
1 - NUT
2 - WASHER
3 - BEARING
Fig. 7 HUB AND BEARING - FWD WITH ABS
4 - LEAF SPRING EYE
5 - BUSHING OPERATION
6 - INSTALLER PLATE (8459-3)
The hub and bearing has internal bearings that
7 - PIN
8 - BODY (8459-1)
allow the hub to rotate with the tire and wheel
assembly (and driveshaft on All-Wheel-Drive vehi-
cles). The five wheel mounting studs mount the tire
body, Install the mounting bolts (Fig. 3). Tighten the and wheel assembly, and disc brake rotor to the vehi-
four mounting bolts to 61 N·m (45 ft. lbs.) torque. cle.
(9) Raise or lower the jack until shock absorber On All-Wheel-Drive vehicles, the splined mating of
lower eye aligns with threads in axle housing. Install the driveshaft stub axle and hub allows the drive-
shock absorber lower mounting bolt. Do not fully shaft to rotate with the hub and wheel.
tighten bolt at this time. Front-Wheel-Drive vehicles equipped with antilock
(10) Lower the vehicle and remove hoist arms and brakes have a wheel speed sensor and tone wheel
block of wood from under vehicle. mounted to the rear of the hub and bearing. The tone
(11) Tighten the spring front pivot bolt to 156 N·m wheel rotates with the hub which is sensed by the
(115 ft. lbs.) torque. wheel speed sensor.
(12) Tighten the lower shock absorber mounting
bolt to 102 N·m (75 ft. lbs.) torque. DIAGNOSIS AND TESTING - HUB AND
BEARING (REAR)
HUB / BEARING The bearing contained in the hub and bearing
assembly will produce noise and vibration when worn
DESCRIPTION or damaged. The noise will generally change when
The rear wheel bearing and rear wheel hub of this the bearings are loaded. A road test of the vehicle is
vehicle are a one-piece sealed unit, or hub and bear- normally required to determine the location of a
ing unit type assembly. The hub and bearing is worn or damaged bearing.
mounted to the center of the rear axle using 4 Find a smooth level road surface and bring the
mounting bolts. It has five wheel mounting studs on vehicle up to a constant speed. When vehicle is at a
the hub flange. constant speed, swerve the vehicle back and forth
All-Wheel-Drive vehicles have a hub and bearing from the left and to the right. This will load and
unit with a splined hole in the center of the hub for
rear driveshaft stub axle acceptance.
RS REAR 2 - 31
unload the bearings and change the noise level. (6) If hub and bearing cannot be removed from the
When bearing damage is slight, the noise is usually axle by hand, use Remover, Special Tool 8458 (Fig. 9)
not noticeable at speeds above 48 km/h (30 mph). and following procedure to press the hub and bearing
out of the axle.
REMOVAL - HUB AND BEARING
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove wheel and tire.
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. Refer to Brakes.
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
Fig. 9 REMOVAL USING SPECIAL TOOL 8458

1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
(a) Thread Threaded Guide Pins into hub and

bearing mounting bolt holes.
(b) Remove the two outboard spring plate bolts.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458–2, as shown (Fig.
9).
(d) Place Push Plate, Special Tool 8458–1, on
Fig. 8 SENSOR CONNECTOR AT HUB AND ends of Threaded Guide Pins
BEARING (e) Place a dab of grease in dimple of Push
1 - SECONDARY SENSOR RETAINING CLIP Plate.
2 - METAL SENSOR RETAINING CLIP (f) Tighten the Forcing Screw, Special Tool
3 - HUB AND BEARING 8458–3, up against dimple in Push Plate and press
hub and bearing out of axle by continuing to
(5) Remove the 4 bolts attaching the hub and bear- tighten screw.
ing to the rear axle. (g) Remove the tool.
(h) Reinstall the two outboard spring plate bolts.
CAUTION: Corrosion may occur between the hub Tighten the bolts to 102 N·m (75 ft. lbs.) torque.
and bearing, and the axle. If this occurs the hub (7) Remove the hub/bearing from the rear axle and
and bearing will be difficult to remove from the brake support plate.
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the ALL-WHEEL-DRIVE VEHICLES
hub and bearing to remove it from the axle. Damage (1) Set the parking brake. The parking brake is
will occur. Use the following procedure. set to keep the hub and bearing, and axle shaft
from rotating when loosening the hub nut.
2 - 32 REAR RS
(2) Raise vehicle. See Hoisting in Lubrication And (15) Remove the hub/bearing to axle mounting
Maintenance. bolts (Fig. 13).
(3) Remove the wheel/tire assembly.
(4) Remove the cotter pin and nut retainer (Fig. CAUTION: Corrosion may occur between the hub/
19) from the stub shaft of the outer C/V joint. bearing and the axle. If this occurs the hub/bearing
(5) Remove the spring washer (Fig. 18) from the will be difficult to remove from the axle. If the hub/
stub shaft of the outer C/V joint. bearing will not come out of the axle by pulling on
(6) Remove the hub nut and washer (Fig. 16) from it by hand, do not pound on the hub/bearing to
the stub shaft of the outer C/V joint. remove it from the axle. Pounding on the hub/bear-
(7) Remove the 6 bolts (Fig. 17) mounting the ing to remove it from the axle will damage the hub/
driveshaft inner joint to the output shaft of the rear bearing. This damage will result in noise or failure
drive line module. of the hub/bearing. To remove a hub/bearing which
(8) Remove the rear wheel speed sensor (Fig. 20) is corroded to the axle, lightly tap the disc brake
from the rear hub/bearing. caliper adapter using a soft faced hammer. This will
(9) Release the parking brake. remove both the disc brake caliper adapter and
(10) Remove the disc brake caliper to adapter hub/bearing from the axle. The hub/bearing will
guide pin bolts (Fig. 15). then need to be removed from the caliper adapter.
(11) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up (16) Remove the hub/bearing from the axle. (Fig.
from the adapter. Then pull the front of the caliper 12).
and the outboard brake shoe anti-rattle clip out from (17) If the disc brake caliper adapter and hub/
under the front abutment on the adapter (Fig. 14). bearing were removed as an assembly from the axle
(12) Support caliper to prevent the weight of the and the hub/bearing cannot be removed from the
caliper from damaging the flexible brake hose (Fig. adapter by hand, use the following procedure to
10). remove it from the adapter. With a helper supporting
the caliper adapter in his hands, position Remover,
Special Tool 8214-1 on the cast housing of hub/bear-
ing (Fig. 11). Do not position special tool on
inner race of hub/bearing. Lightly strike Remover,
Special Tool 8214-1 with a hammer to remove the
hub/bearing from the caliper adapter.
Fig. 10 Correctly Supported Caliper

1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 11 Hub/Bearing Removal From Caliper Adapter
(13) Remove the rotor from the hub/bearing. 1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
(14) Remove driveshaft from rear drive line mod-
3 - DISC BRAKE CALIPER ADAPTER
ule and hub/bearing. Driveshaft is removed by first
4 - HUB/BEARING
compressing the inner joint on the driveshaft and
removing it from the drive line module. Then, slide
the outer joint of the driveshaft out of the hub/bear-
ing.
RS REAR 2 - 33
INSTALLATION - HUB AND BEARING

FRONT-WHEEL-DRIVE VEHICLES
(1) Install the 4 hub and bearing to axle mounting
bolts into the holes in the flange of the rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.
(3) Align the rear hub and bearing with the 4
mounting bolts and start mounting bolts into hub
and bearing. Tighten the 4 bolts in a crisscross pat-
tern until the hub nd bearing and brake support
plate is fully and squarely seated onto flange of rear
axle. Tighten the 4 mounting bolts to a torque of 129
N·m (95 ft. lbs.)
NOTE: If equipped with antilock brakes, make sure Fig. 12 Hub/Bearing Removal And Installation
wheel speed sensor stays clean and dry as it is
1 - PARK BRAKE BRAKE SHOE
installed into the hub and bearing cap.
2 - HUB/BEARING
3 - PARK BRAKE BRAKE SHOE
(4) If the vehicle is equipped with antilock brakes,
perform the following:
(a) If metal sensor retaining clip is not in the
neutral installed position on hub and bearing cap,
install from the bottom, if necessary, and push clip
upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side (Fig. 8).
(5) Install brake drum or disc brake rotor and
brake caliper. Refer to Brakes.
(6) Install wheel and tire. Tighten the wheel nuts
in the proper sequence to a torque of 135 N·m (100
ft. lbs.). Fig. 13 Hub/Bearing Mounting Bolts
(7) Adjust the rear brakes as necessary. Refer to
1 - HUB/BEARING
Brakes.
2 - AXLE
(8) Lower vehicle. 3 - MOUNTING BOLTS
(9) Road test vehicle to ensure proper operation of 4 - CALIPER ADAPTER
brakes.
ALL-WHEEL-DRIVE VEHICLES shaft into the hub/bearing and then compressing the
(1) Install hub/bearing on end of axle. (Fig. 12). inner joint on the driveshaft and installing it on the
(2) Install the hub/bearing mounting bolts. In a output shaft the drive line module.
progressive crisscross pattern, tighten the 4 hub/ (4) Install rotor on hub/bearing.
bearing mounting bolts (Fig. 13) until the disc brake (5) Carefully lower disc brake caliper and brake
caliper adapter and hub/bearing are squarely seated shoes over rotor and onto caliper adapter by revers-
against the axle. Then tighten the hub/bearing ing the removal procedure (Fig. 14).
mounting bolts to a torque of 129 N·m (95 ft. lbs.).
CAUTION: When installing guide pin bolts extreme
(3) Install driveshaft in hub/bearing and on output
caution should be taken not to cross-thread the cal-
shaft of rear drive line module. Driveshaft is
iper guide pin bolts.
installed by first sliding the outer joint of the drive-
2 - 34 REAR RS
Fig. 14 Removing / Installing Caliper

1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST Fig. 16 Hub Nut And Washer
2 - DISC BRAKE CALIPER
1 - CALIPER
3 - ADAPTER ABUTMENT
2 - HUB NUT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
3 - WASHER
5 - OUTBOARD BRAKE SHOE
4 - ROTOR
6 - ROTOR
5 - ADAPTER
7 - ADAPTER
(9) Set the park brake. This is required to keep

(6) Install the disc brake caliper guide pin bolts
the driveshaft from rotating when tightening
(Fig. 15). Tighten the guide pin bolts to a torque of
and torquing the hub nut and driveshaft inner
22 N·m (192 in. lbs.).
joint to driveline module mounting nuts.
(10) Raise vehicle.
(11) Tighten the driveshaft inner joint to drive line
module output shaft mounting bolts (Fig. 17) to a
torque of 61 N·m (45 ft. lbs.).
Fig. 15 Caliper Guide Pin Bolts

1 - STUD PIN BOLTS
3 - DRIVESHAFT
4 - AXLE
5 - DISC BRAKE CALIPER ADAPTER Fig. 17 Driveshaft Attachment To Driveline Module
1 - DRIVESHAFT
2 - BOLTS
(7) Clean all foreign material off the threads of the 3 - DRIVE LINE MODULE
outer C/V joint stub shaft. Install the washer and 4 - DRIVESHAFT INNER JOINT
hub nut (Fig. 16) on the stub shaft of the outer C/V
joint.
(8) Lower vehicle. (12) Tighten the outer C/V joint hub nut (Fig. 16)
to a torque of 244 N·m (180 ft. lbs.).
RS REAR 2 - 35
(13) Install the spring washer (Fig. 18) on the stub
shaft of the outer C/V joint.
Fig. 20 Wheel Speed Sensor

1 - MOUNTING BOLT
Fig. 18 Spring Washer 2 - WHEEL SPEED SENSOR
1 - HUB NUT
2 - STUB SHAFT (17) Tighten the wheel mounting stud nuts in
3 - ROTOR proper sequence until all nuts are torqued to half
4 - SPRING WASHER specification. Then repeat the tightening sequence to
the full specified torque of 135 N·m (100 ft. lbs.).
(14) Install the nut retainer and cotter pin (Fig. (18) Remove jackstands or lower hoist.
19) on the stub shaft of the outer C/V joint.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(19) Road test vehicle to ensure proper operation

of the brake system.
JOUNCE BUMPER
DESCRIPTION
There are two jounce bumpers used in the rear
suspension. One mounts to each frame rail above the
rear axle.
OPERATION
The jounce bumper limits suspension travel and
Fig. 19 Cotter Pin And Nut Retainer metal-to-metal contact of the rear axle with the
1 - CALIPER frame under full jounce conditions.
2 - COTTER PIN
3 - ROTOR REMOVAL - AWD AND HEAVY DUTY
4 - NUT RETAINER
(1) Using slip-joint pliers grasp the base of the
5 - OUTER C/V JOINT
jounce bumper. Turn the base counterclockwise (Fig.
21).
(15) Install the wheel speed sensor on the hub/ (2) Remove the jounce bumper from the frame rail.
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 20). Tighten the wheel speed sen- REMOVAL - FRONT-WHEEL-DRIVE
sor attaching bolt to a torque of 12 N·m (105 in. lbs). (1) Remove the bolt attaching the jounce bumper
(16) Install wheel and tire. to frame rail (Fig. 22).
(2) Remove the jounce bumper from the frame rail.
2 - 36 REAR RS
JOUNCE BUMPER (Continued)
SHOCK ABSORBER
DESCRIPTION
There is one shock absorber on each side of the
rear suspension. The top of each shock absorber is
bolted to the frame rail. The bottom of each shock
absorber is bolted to the rear axle.
This vehicle is available with either standard type
or load-leveling shock absorbers. On the exterior,
load-leveling shock absorbers are larger in diameter
than standard shock absorbers. The load-leveling
shock absorbers mount the same as the standard
shock absorbers.
OPERATION
Fig. 21 Jounce Bumper The shock absorber dampens jounce and rebound
motions of the spring and suspension.
1 - JOUNCE BUMPER
Each load-leveling shock absorber is a self-leveling,
self-contained vehicle leveling system and shock
absorber combined. It does not require an external
compressor, hoses, or height leveling sensors. All the
height leveling sensors, hydraulic pump, etc., are
contained inside the shock absorber. It uses road
inputs (bumps, stops, starts, turns, acceleration,
deceleration, etc.) to activate pumping, which results
in the extension and compression of the shock
absorber.
REMOVAL - SHOCK ABSORBER

(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Support the rear axle of the vehicle using 2
jackstands positioned at the outer ends of the axle.
Fig. 22 Jounce Bumper - FWD NOTE: If the shock absorber lower mounting bolt
1 - JOUNCE BUMPER deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
absorber bolt deflects downward during removal,
INSTALLATION - AWD AND HEAVY DUTY lower the axle by adjusting the support jack.
(1) Install jounce bumper through bumper support
plate and thread into welded nut in frame rail. (3) Remove the shock absorber lower mounting
(2) Tighten the jounce bumper to 33 N·m (290 in. bolt.
lbs.) torque. (4) While holding shock absorber, remove the
shock absorber upper mounting bolt and shock
INSTALLATION - FRONT-WHEEL-DRIVE absorber.
(1) Hook the forward end of the jounce bumper
bracket in the mounting hole of the frame rail, then DISASSEMBLY - SHOCK ABSORBER (UPPER
install the mounting bolt in the opposite end, secur- BUSHING)
ing the bumper to the frame rail. Tighten the jounce (1) Remove the shock absorber from the vehicle.
bumper mounting bolt to 33 N·m (290 in. lbs.) torque. (2) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 23).
RS REAR 2 - 37
SHOCK ABSORBER (Continued)
ASSEMBLY - SHOCK ABSORBER (UPPER

BUSHING)
(1) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 25). Position the Driver this way
to seat the bushing to its correct depth.
Fig. 23 Special Tools Positioned For Removal

1 - SCREW DRIVE
NOTE: It works well to place the Ball Joint Press,

Special Tool C-4212F, in a bench vise as shown
(Fig. 23) to perform this procedure.
(3) Place the shock absorber upper mounting eye

in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 24). Fig. 25 Special Tools Positioned For Installation
1 - SCREW DRIVE
(2) Place the shock absorber upper mounting eye

in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 26).
Fig. 24 Removing Bushing From Shock Absorber

1 - SCREW DRIVE
2 - SHOCK ABSORBER
3 - NOTCH
(4) Tighten the screw drive until the Driver con- Fig. 26 Installing Bushing In Shock Absorber
tacts the outer circumference of the bushing evenly 1 - BUSHING
(Fig. 24). Continue to tighten the screw drive until 2 - SCREW DRIVE
the bushing is pressed completely out of the shock 3 - SHOCK ABSORBER
absorber eye and into the Receiver. 4 - NOTCH
(5) Back off the screw drive and remove the bush-
ing from the Receiver.
2 - 38 REAR RS
SHOCK ABSORBER (Continued)
(3) Position the bushing between the shock
absorber eye and the Driver (Fig. 26). Tighten the
screw drive until the Driver, bushing, and shock
absorber eye are touching and squarely aligned.
(4) Press the bushing into the shock absorber eye
until the Driver bottoms against the face of the eye.
(5) Back off the Ball Joint Press screw drive and
remove the shock absorber from the press.
(6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.
INSTALLATION - SHOCK ABSORBER

(1) While holding shock absorber in position
against the frame rail, install the shock absorber
upper mounting bolt.
(2) Install the shock absorber lower mounting bolt
securing the lower end of the shock absorber to the
axle.
(3) Remove the support jack. Fig. 27 LIFTING POINT AND SPRING MOUNT
(4) Lower the vehicle to the ground so the full curb 1 - BODY SILL AREA
weight of the vehicle is supported by the suspension. 2 - MOUNTING BOLTS
(5) Tighten the upper and lower shock absorber 3 - SPRING MOUNTING BRACKET
mounting bolt to a torque of 101 N·m (75 ft. lbs.). 4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
SPRING - AWD
NOTE: If shock absorber bolt deflects upward dur-
DESCRIPTION ing removal, raise axle by adjusting support jack. If
The leaf springs used on the rear suspension of shock absorber bolt deflects downward during
this vehicle are of either a mono-leaf or multi-leaf removal, lower axle by adjusting support jack (or by
design depending on model and options. pulling on axle).
Since the rear springs come in various designs and
rates, be sure the correct spring is in use. (3) Begin removal of the shock absorber lower
mounting bolt (Fig. 28).
OPERATION
The leaf spring controls ride quality and maintains
ride height.
REMOVAL - AWD
of the vehicle to be serviced against a block of wood
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing Fig. 28 Rear Shock Absorber Mounting Bolt
spring replacement. Jack pad should just contact 1 - SHOCK BOLT
axle.
RS REAR 2 - 39
SPRING - AWD (Continued)
(4) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.
(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 29).
Fig. 30 All-Wheel-Drive Rear Suspension

1 - SHACKLE
4 - AWD REAR AXLE
Fig. 29 Axle Plate Bolts

1 - LEAF SPRING
2 - AXLE PLATE BOLTS (4)
3 - AXLE PLATE
4 - AXLE
(6) Using the jack stands slowly lower the rear

axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts at the front
mount of the rear leaf spring (Fig. 27).
(8) Loosen and remove the 2 bolts and the 2 pin
nuts from the spring shackle for the rear leaf spring
(Fig. 30). Then remove the inner half of the spring
shackle from the outer half hanger of the spring
hanger and the spring.
(9) Remove the rear leaf spring from the outer half
of the spring shackle.
(10) Remove the leaf spring from the vehicle. Fig. 31 Leaf Spring Front Mount (Typical)
(11) Loosen and remove the pivot bolt from the 1 - LEAF SPRING
front mount of the rear leaf spring. (Fig. 31). 2 - SPRING MOUNT
INSTALLATION - AWD (3) Install the rear of the leaf spring onto the outer
half of the rear shackle. Install the inner half of the
CAUTION: Pivot bolt must face inboard to prevent rear hanger. Install the pin nuts and bolts on the
structural damage during installation of spring. rear shackle, but do not tighten at this time.
(4) Raise axle assembly into correct position with
(1) Install the front eyelet of the rear leaf spring axle centered under spring locator post.
into the spring mount. Install the pivot bolt and nut. (5) Install axle plate bolts (Fig. 29). Tighten bolts
Do not tighten the pivot bolt at this time. to 101 N·m (75 ft. lbs.) torque.
(2) Position the front spring mount for the rear (6) Install shock absorber bolts. Do not tighten
leaf spring against the floor pan of the vehicle. at this time.
Install the 4 mounting bolts for the front spring (7) Lower the vehicle and remove hoist arms and
mount (Fig. 27). Tighten the 4 mounting bolts to a block of wood from under vehicle.
torque of 61 N·m (45 ft. lbs.).
2 - 40 REAR RS
SPRING - AWD (Continued)
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
(8) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N·m
(10) Tighten rear spring shackle inner to outer
half retaining bolts to 61 N·m (45 ft. lbs.) torque.
(11) Tighten the lower shock absorber mounting
bolt to 102 N·m (75 ft. lbs.) torque.
SPRING - FWD Fig. 32 LIFTING POINT AND SPRING MOUNT

1 - BODY SILL AREA
DESCRIPTION 2 - MOUNTING BOLTS
The leaf springs used on the rear suspension of 3 - SPRING MOUNTING BRACKET
this vehicle are of either a mono-leaf or multi-leaf 4 - LEAF SPRING
design depending on model and options. 5 - HOIST LIFT ARM
Since the rear springs come in various designs and 6 - WOODEN BLOCK
rates, be sure the correct spring is in use.
OPERATION
The leaf spring controls ride quality and maintains
ride height.
REMOVAL - FWD
level.
(2) Position an under-hoist utility jack or transmis- Fig. 33 Rear Shock Mounting Bolt
sion jack under rear axle toward the side needing 1 - SHOCK BOLT
spring replacement. Jack pad should just contact
axle.
(4) Using 2 jack stands positioned under the outer
(3) Remove the shock absorber lower mounting
ends of the axle, raise the axle enough to remove the
bolt (Fig. 33).
weight of the axle from the rear springs.
NOTE: If shock absorber bolt deflects upward dur- (5) Loosen and remove the spring plate bolts from
ing removal, raise axle by adjusting support jack. If the rear axle (Fig. 34).
shock absorber bolt deflects downward during (6) Remove the spring plate from the rear axle and
removal, lower axle by adjusting support jack (or by the leaf spring (Fig. 35).
pulling on axle). (7) Using the jack stands slowly lower the rear
axle, permitting the rear springs to hang free.
RS REAR 2 - 41
SPRING - FWD (Continued)
Fig. 34 Spring Plate Bolts

1 - SPRING PLATE Fig. 36 Rear Spring Hanger
1 - SHACKLE PLATE
2 - SPRING HANGER
(2) Raise front of spring and install four mounting

bolts (Fig. 32). Tighten bolts to 61 N·m (45 ft. lbs.)
torque.
(3) Install rear of spring onto rear spring shackle.
Install shackle plate. Do not tighten.
(4) Verify lower leaf spring isolator is in position.
(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
37).
Fig. 35 Spring Plate

1 - SPRING PLATE
(8) Loosen and remove the 4 bolts securing the

front mount of the leaf spring to the vehicle (Fig. 32).
(9) Loosen and remove the nuts from the spring
hanger (Fig. 36) for the rear leaf spring. Then
remove the hanger plate from the hanger and remove
the spring from the spring hanger (Fig. 36).
(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. Remove mount. Fig. 37 Leaf Spring Locator Post
1 - LEAF SPRING ISOLATOR
INSTALLATION - FWD 2 - LEAF SPRING
(1) Assemble front spring mount to front of spring 3 - LOCATOR POST
eye and install pivot bolt and nut. Do not tighten
at this time. (6) Verify that the leaf spring isolator is correctly
positioned in the spring plate.
CAUTION: Pivot bolt must face inboard to prevent (7) Install spring plate in position on the spring
structural damage during installation of spring. (Fig. 34).
2 - 42 REAR RS
SPRING - FWD (Continued)
(8) Install spring plate bolts (Fig. 34). Tighten
bolts to 101 N·m (75 ft. lbs.) torque.
(9) Install lower shock absorber bolt. Do not
tighten at this time.
(10) Remove jack under axle.
(11) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.

nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
(12) Tighten the spring front pivot bolt to 156 N·m
(13) Tighten rear spring shackle pin nuts to 61 Fig. 38 LIFTING POINT AND SPRING MOUNT
N·m (45 ft. lbs.) torque. 1 - BODY SILL AREA
(14) Tighten rear spring shackle inner to outer 2 - MOUNTING BOLTS
half retaining bolts to 61 N·m (45 ft. lbs.) torque. 3 - SPRING MOUNTING BRACKET
(15) Tighten the lower shock absorber mounting 4 - LEAF SPRING
bolt to 102 N·m (75 ft. lbs.) torque. 5 - HOIST LIFT ARM
6 - WOODEN BLOCK
SPRING MOUNTS - FRONT be necessary to place a wooden block between the

spring and vehicle to hold forward end of the spring
REMOVAL in place.
(1) Raise vehicle on frame-contact hoist as follows: (6) Remove leaf spring forward pivot bolt, then
(a) Position the hoist arm supporting the corner remove mounting bracket.
placed on the body sill as shown (Fig. 38). INSTALLATION
(b) Position the remaining hoist arms at each (1) Position spring mounting bracket over spring
corner of the vehicle in the normal fashion. (Refer eye and install pivot bolt through center of bushing
to LUBRICATION & MAINTENANCE/HOISTING from the outboard side.
(c) Raise the vehicle to a comfortable working NOTE: The pivot bolt must be installed from the
level. outboard side to allow proper bracket to body
(2) Position an under-hoist utility jack or transmis- mounting.
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact (2) Install the nut on the pivot bolt and lightly
axle. tighten. Do not fully tighten bolt at this time.
(3) Remove shock absorber lower mounting bolt. (3) Raise the under-hoist utility jack or transmis-
sion jack, guiding the forward mounting bracket into
NOTE: If shock absorber bolt deflects upward dur- place against the body. It may help to use a drift
ing removal, raise axle by adjusting support jack. If punch placed through the hole centered between the
shock absorber bolt deflects downward during mounting bolt holes in the bracket and the pilot hole
removal, lower axle by adjusting support jack (or by in the body of the vehicle as a guide. When the four
pulling on axle). mounting bolt holes line up with their threads in the
body, Install the mounting bolts (Fig. 38). Tighten the
(4) Remove four bolts securing leaf spring front four mounting bolts to 61 N·m (45 ft. lbs.) torque.
mounting bracket to the body (Fig. 38). (4) Raise or lower the jack until shock absorber
(5) Using jack, slowly lower rear axle, permitting lower eye aligns with threads in axle housing. Install
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
RS REAR 2 - 43
SPRING MOUNTS - FRONT (Continued)
shock absorber lower mounting bolt. Do not fully (2) Install a jackstand under the side of the axle
tighten bolt at this time. having the leaf spring mount removed. Using the
(5) Lower the vehicle and remove hoist arms and jackstand, support the weight of the axle and leaf
block of wood from under vehicle. spring.
(6) Tighten the spring front pivot bolt to 156 N·m (3) Remove the lower mounting bolt from the
(115 ft. lbs.) torque. shock absorber.
(7) Tighten the lower shock absorber mounting (4) Remove the bolts attaching the leaf spring rear
bolt to 102 N·m (75 ft. lbs.) torque. mount to the body of the vehicle (Fig. 41).
SPRING MOUNTS - REAR

REMOVAL
(1) Remove the attaching nuts and bolts from the
leaf spring rear shackle (Fig. 39) and (Fig. 40).
Fig. 41 Rear Spring Mount

1 - LEAF SPRING MOUNT
(5) Lower the jackstand and the rear of the leaf

spring. Remove the shackle from the leaf spring
bushing.
Fig. 39 Leaf Spring Shackle Nuts (FWD)
1 - SHACKLE PLATE
INSTALLATION
nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to
outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid
bending the spring hanger.
(1) For installation, reverse removal procedure. Do

not tighten rear spring shackle nuts fully until vehi-
cle is lowered and the full vehicle weight is applied
to the rear wheels. Tighten rear spring mount bolts
to 61 N·m (45 ft. lbs.). Tighten shackle nuts to 61
N·m (45 ft. lbs.).
Fig. 40 All-Wheel-Drive Rear Suspension

1 - SHACKLE
4 - AWD REAR AXLE
2 - 44 REAR RS
STABILIZER BAR
DESCRIPTION
(1) Front-wheel-drive models use a stabilizer bar
that is mounted behind the rear axle. All-wheel-drive
models use a stabilizer bar that is mounted in front
of the rear axle.
The stabilizer bar interconnects both sides of the
rear axle and attaches to the rear frame rails using 2
rubber isolated link arms.
Both type stabilizer bars have the same basic com-
ponents. Attachment to the rear axle tube, and rear
frame rails is through rubber-isolated bushings.
The 2 rubber isolated links are connected to the
rear frame rails by brackets. These brackets are
bolted to the bottom of the frame rails.
OPERATION
Jounce and rebound movements affecting one
Fig. 42 REAR STABILIZER BAR MOUNTING TO AWD
wheel are partially transmitted to the opposite wheel
AXLE
to reduce body roll.
1 - RETAINER
2 - BUSHING
REMOVAL - AWD 3 - AWD AXLE
(1) Raise vehicle. See Hoisting in Lubrication and 4 - STABILIZER BAR
Maintenance.
(2) Remove the bolts securing the stabilizer bar to
links on each end of the bar. (3) Install the bushing retainers over bushings and
(3) While holding the stabilizer bar in place, aligning bolt holes.
remove the bolts that attach the stabilizer bar bush- (4) Install bushing retainers bolts. Do not tighten
ing retainers to the rear axle (Fig. 42). at this time.
(4) Remove the stabilizer bar from the vehicle. (5) Install bolts connecting links to stabilizer bar.
(5) Remove the bushings from the bar utilizing the Do not tighten at this time.
slits in the bushings. (6) Lower the vehicle so that the full weight of the
(6) If the links need to be serviced, remove the vehicle is on all four tires. With the vehicle at its
upper link arm to bracket bolt. Then remove link curb height, tighten the following bolts to the torques
arm from frame rail attaching bracket. listed:
• Stabilizer bar bushing retainer-to-axle bracket
REMOVAL - FWD bolts — 61 N·m (45 ft. lbs.)
• Stabilizer bar-to-link bolts — 61 N·m (45 ft. lbs.)
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove the bolts securing the stabilizer bar to INSTALLATION - FWD
links on each side of bar. (1) Lift the stabilizer bar onto the rear axle and
(3) While holding the stabilizer bar in place, install the two retainer mounting bolts. DO NOT
remove the bolts that attach the stabilizer bar bush- TIGHTEN.
ing retainers to the rear axle. (2) Install the bolts attaching the stabilizer bar
(4) Remove the stabilizer bar from the vehicle. links to the stabilizer bar. DO NOT TIGHTEN.
(3) Lower the vehicle so that the full weight of the
INSTALLATION - AWD vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
(1) Install bushings on stabilizer bar utilizing slits
listed:
in bushings.
• Stabilizer bar bushing retainer-to-axle bracket
(2) Install the stabilizer bar on the rear axle (Fig.
bolts — 61 N·m (45 ft. lbs.)
42).
• Stabilizer bar-to-link — 61 N·m (45 ft. lbs.)
RS REAR 2 - 45
TRACK BAR with the head of the bolt facing toward the rear of
the vehicle (Fig. 45) . Do not tighten.
DESCRIPTION
On front-wheel-drive applications of this vehicle
that are equipped with single leaf rear springs, a
track bar is used on the rear axle (Fig. 1).
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
body of the vehicle by an isolator bushing located in
each end of the track bar.
OPERATION
The track bar prevents excessive side-to-side move-
ment of the rear axle. The track bar is used to keep
the location of the axle in the correct position for
optimum handling and control of the vehicle.
REMOVAL Fig. 44 Track Bar Installation

(1) Remove the nut and bolt mounting the track
1 - TRACK BAR REPLACEMENT
bar to the rear axle (Fig. 43) .
Fig. 43 Track Bar Mounting To Axle

1 - LOWER TRACK BAR BOLT INSTALLATION Fig. 45 Track Bar Bolt Installation
1 - TRACK BAR BOLT
(2) Remove the nut and bolt attaching the track

bar to the track bar mount on the body of the vehicle. (2) Install the track bar into its mounting bracket
Remove the track bar from the track bar mount. on the rear axle (Fig. 43) . Install the track bar bolt
with the head of the bolt facing toward the rear of
INSTALLATION the vehicle. Do not tighten.
(1) Install the track bar first into the body mount (3) Lower the vehicle to the ground until the full
for the track bar (Fig. 44) . Install the track bar bolt weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 N·m (70 ft. lbs.).
2 - 46 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 51

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 51
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 49 CURB HEIGHT MEASUREMENT . . . . . . . . . . . 54
SUSPENSION AND STEERING . . . . . . . . . . . . 49 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 55
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT
Vehicle wheel alignment is the positioning of all
interrelated front and rear suspension angles. These
angles affect the handling and steering of the vehicle
when it is in motion. Proper wheel alignment is
essential for efficient steering, good directional stabil-
ity, and proper tire wear.
The method of checking a vehicle’s front and rear
wheel alignment varies depending on the manufac-
turer and type of equipment used. The manufactur-
er’s instructions should always be followed to ensure
accuracy of the alignment, except when
DaimlerChrysler Corporation’s wheel alignment spec-
ifications differ.
On this vehicle, the suspension angles that can be
adjusted are as follows:
• Front Camber (with camber bolt package and
standard procedure)
• Front Toe
Check the wheel alignment and make all wheel
alignment adjustments with the vehicle standing at
its proper curb height specification. Curb height is
the normal riding height of the vehicle. It is mea-
sured from a certain point on the vehicle to the
ground or a designated area while the vehicle is sit-
ting on a flat, level surface. Refer to Curb Height
Measurement in this section for additional informa-
tion.
Typical wheel alignment angles and measurements Fig. 1 Camber
are described in the following paragraphs. 1 - WHEELS TILTED OUT AT TOP
2 - WHEELS TILTED IN AT TOP
CAMBER
Camber is the inward or outward tilt of the top of
the tire and wheel assembly (Fig. 1). Camber is mea- CROSS CAMBER
sured in degrees of angle relative to a true vertical Cross camber is the difference between left and
line. Camber is a tire wearing angle. right camber. To achieve the cross camber reading,
• Excessive negative camber will cause tread wear subtract the right side camber reading from the left.
at the inside of the tire. For example, if the left camber is +0.3° and the right
• Excessive positive camber will cause tread wear camber is 0.0°, the cross camber would be +0.3°.
on the outside of the tire.
RS WHEEL ALIGNMENT 2 - 47
WHEEL ALIGNMENT (Continued)
CASTER Toe-in and toe-out can occur at the front wheels
Caster is the forward or rearward tilt of the steer- and the rear wheels.
ing knuckle in reference to the position of the upper Toe is measured in degrees or inches. The mea-
and lower ball joints. Caster is measured in degrees surement identifies the amount that the front of the
of angle relative to a true vertical center line. This wheels point inward (toe-in) or outward (toe-out). Toe
line is viewed from the side of the tire and wheel is measured at the spindle height. Zero toe means
assembly (Fig. 2). the front and rear edges of the wheels on the same
• Forward tilt (upper ball joint ahead of lower) axle are equally distant.
results in a negative caster angle.
• Rearward tilt (upper ball joint trailing lower)
results in a positive caster angle.
Although caster does not affect tire wear, a caster
imbalance between the two front wheels may cause
the vehicle to lead to the side with the least positive
caster.
Fig. 3 Toe
Fig. 2 Caster 1 - TOE-IN
2 - TOE-OUT
CROSS CASTER
Cross caster is the difference between left and
right caster. TOE-OUT ON TURNS
Toe-out on turns is the relative positioning of the
TOE front wheels while steering through a turn (Fig. 4).
Toe is the inward or outward angle of the wheels This compensates for each front wheel’s turning
as viewed from above the vehicle (Fig. 3). radius. As the vehicle encounters a turn, the out-
• Toe-in is produced when the front edges of the board wheel must travel in a larger radius circle
wheels on the same axle are closer together than the than the inboard wheel. The steering system is
rear edges. designed to make each wheel follow its particular
• Toe-out is produced when the front edges of the radius circle. To accomplish this, the front wheels
wheels on the same axle are farther apart than the must progressively toe outward as the steering is
rear edges. turned from center. This eliminates tire scrubbing
and undue tire wear when steering a vehicle through
a turn.
Fig. 5 S.A.I. and I.A.

Fig. 4 Toe-Out On Turns
1 - S.A.I.
1 - TOE-OUT ON TURNS 2 - CAMBER
3 - I.A.
DYNAMIC TOE PATTERN

Dynamic toe pattern is the inward and outward toe INCLUDED ANGLE (I. A.)
movement of the front and rear tires through the Included angle is the sum of the S.A.I. angle plus
suspension’s jounce and rebound travel. As the vehi- or minus the camber angle, depending on whether or
cle’s suspension moves up and down, the toe pattern not the wheel has positive or negative camber (Fig.
varies. Toe pattern is critical in controlling the direc- 5). If camber is positive, add the camber angle to the
tional stability of the vehicle while in motion. Front S.A.I. angle. If camber is negative, subtract the cam-
and rear dynamic toe pattern is preset by the factory ber angle from the S.A.I. angle. Included angle is not
at the time the vehicle is assembled. adjustable, but can be used to diagnose a frame mis-
It is not necessary to check or adjust front or rear alignment or bent suspension component (spindle,
dynamic toe pattern when doing a normal wheel strut).
alignment. The only time dynamic toe pattern needs
to be checked or adjusted is if the frame of the vehi- THRUST ANGLE
cle has been damaged. Thrust angle is the averaged direction the rear
wheels are pointing in relation to the vehicle’s center
STEERING AXIS INCLINATION (S. A. I.) line (Fig. 6). The presence of negative or positive
Steering axis inclination is the angle between a thrust angle causes the rear tires to track improperly
true vertical line starting at the center of the tire at to the left or right of the front tires (dog tracking).
the road contact point and a line drawn through the • Negative thrust angle means the rear tires are
center of the upper ball joint (or strut) and the lower tracking to the left of the front tires.
ball joint (Fig. 5). S.A.I. is built into the vehicle and • Positive thrust angle means the rear tires are
is not an adjustable angle. If S.A.I. is not within tracking to the right of the front tires.
specifications, a bent or damaged suspension compo- Improper tracking can cause undue tire wear, a
nent may be the cause. lead or pull and a crooked steering wheel. Excessive
thrust angle can usually be corrected by adjusting
the rear wheel toe so that each wheel has one-half of
the total toe measurement.
Fig. 6 Thrust Angle
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or 1. Defective wheel bearing 1. Replace wheel bearing

Grinding On Turns 2. Engine mount grounding 2. Check for motor mount hitting frame
rail and reposition engine as required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap 1. Loose lug nuts 1. Verify wheel lug nut torque
On Turns 2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body 7. Tighten strut attachment to specified

attachment torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With 1. Defective wheel bearing 1. Replace wheel bearing
Vehicle Going Straight At A 2. Incorrect wheel alignment 2. Check and reset wheel alignment
Constant Speed
4. Worn or defective transaxle gears or 4. Replace transaxle gears or bearings
bearings
Front End Growl Or 1. Engine mount grounding 1. Reposition engine as required

Grinding With Vehicle 2. Worn or broken C/V joint 2. Replace C/V joint
Going Straight At A
Constant Speed
Front End Whine When 1. Worn or defective transaxle gears or 1. Replace transaxle gears or bearings
Accelerating Or bearings
Decelerating
Front End Clunk When 1. Worn or broken engine mount 1. Replace engine mount
Accelerating Or 2. Worn or defective transaxle gears or 2. Replace transaxle gears or bearings
Decelerating bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure

2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft 6. Replace steering coupler
coupling
7. Excessive friction in strut upper 7. Replace strut bearing
bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended

pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
Play 2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque
4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive 4. Correctly adjust power steering pump
belt drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering coupler 7. Replace steering coupler
STANDARD PROCEDURE - WHEEL ALIGNMENT WHEEL ALIGNMENT SETUP

(1) Position the vehicle on an alignment rack.
PRE-WHEEL ALIGNMENT INSPECTION (2) Install all required alignment equipment on
Before any attempt is made to change or correct the vehicle per the alignment equipment manufactur-
the wheel alignment, the following inspection and er’s instructions. On this vehicle, a four-wheel align-
necessary corrections must be made to ensure proper ment is recommended.
alignment.
(1) Verify that the fuel tank is full of fuel. If the NOTE: Prior to reading the vehicle’s alignment
tank is not full, the reduction in weight will affect readouts, the front and rear of vehicle should be
the curb height of the vehicle and the alignment jounced. Induce jounce (rear first, then front) by
angles. grasping the center of the bumper and jouncing
(2) The passenger and luggage compartments of each end of vehicle an equal number of times. The
the vehicle should be free of any load that is not fac- bumper should always be released when vehicle is
tory equipment. at the bottom of the jounce cycle.
(3) Check the tires on the vehicle. All tires must be
the same size and in good condition with approxi- (3) Read the vehicle’s current front and rear align-
ment settings. Compare the vehicle’s current align-
mately the same amount of tread wear. Inflate all
ment settings to the vehicle specifications for camber,
the tires to the recommended air pressure.
caster and toe-in. (Refer to 2 - SUSPENSION/
(4) Check the front wheel and tire assemblies for
WHEEL ALIGNMENT - SPECIFICATIONS)
excessive radial runout.
(4) If front camber and caster are not within spec-
(5) Inspect lower ball joints and all steering link-
ifications, proceed to CAMBER AND CASTER below.
age for looseness, binding, wear or damage. Repair as
If caster and camber are within specifications, pro-
necessary.
ceed to TOE which can be found following CAMBER
(6) Check suspension fasteners for proper torque
AND CASTER. Rear camber, caster and toe are not
and retighten as necessary.
adjustable. If found not to be within specifications,
(7) Inspect all suspension component rubber bush-
reinspect for damaged suspension or body compo-
ings for signs of wear or deterioration. Replace any
nents and replace as necessary.
faulty bushings or components before aligning the
vehicle.
(8) Check the vehicle’s curb height to verify it is
CAMBER AND CASTER
Camber and caster settings on this vehicle are
within specifications. Refer to Curb Height Measure-
determined at the time the vehicle is designed, by
ment.
the location of the vehicle’s suspension components.
This is referred to as NET BUILD. The result is no
required adjustment of camber and caster after the
vehicle is built or when servicing the suspension
components. Thus, when performing a wheel align-
ment, caster and camber are not normally considered
adjustable angles. Camber and caster should be
checked to ensure they meet vehicle specifications.
If front camber is found not to meet alignment
specifications, it can be adjusted using an available
camber adjustment bolt package. Before installing a
camber adjustment bolt package on a vehicle found
to be outside the specifications, inspect the suspen-
sion components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles

wheel; alignment by heating, bending or by per-
forming any other modification to the vehicle’s front
suspension components or body. Fig. 7 Clevis Bracket To Steering Knuckle Attaching
Bolts
If camber readings are not within specifications,
use the following procedure to install the front cam-
2 - ATTACHING BOLTS
ber adjustment bolt package and then adjust front 3 - TIE ROD END
camber. 4 - ROTOR
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2
flange bolts, 2 cam bolts, 2 dog bone washers, and 4 CAUTION: When slotting the bottom mounting hole
nuts. This package services both sides of the vehicle. on the strut clevis bracket, do not enlarge the hole
Use the package to attach the strut clevis bracket to beyond the indentations on the sides of the strut
the steering knuckle after the strut clevis bracket clevis bracket (Fig. 8).
has been modified. To install and adjust the camber
(4) Using an appropriate grinder and grinding
adjustment bolt package, follow the procedure below.
wheel, slot the bottom hole in both sides of the strut
(1) Raise the vehicle until its tires are not support-
clevis bracket (Fig. 8).
ing the weight of the vehicle.
(2) Remove the front tire and wheel assemblies.
CAUTION: When removing the steering knuckle

from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
brake flex hose when removed from the strut
assembly. If necessary use a wire hanger to sup-
port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem-
bly.
CAUTION: The knuckle to strut assembly attaching

bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area
bolts stationary.
1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE
2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON
(3) Remove the top and bottom, strut clevis CLEVIS BRACKET
bracket to steering knuckle attaching bolts (Fig. 3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
7)and discard. Separate the steering knuckle from 4 - STRUT CLEVIS BRACKET
the strut clevis bracket and position steering knuckle
so it is out of the way of the strut.
CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.
(5) Position the knuckle back into the strut clevis

bracket. Install a flanged bolt from the service pack-
age into the upper mounting hole. Install a cam bolt
into the bottom mounting hole. Both bolts should
point forward once installed (Fig. 9).
Fig. 10 Dog Bone Washer And Nuts Installed

2 - DOG BONE WASHER
4 - ATTACHING NUTS
strut to steering knuckle attaching bolts to 81 N·m

(60 ft. lbs.) plus an additional 1/4 (90°) turn after the
required torque is met.
Fig. 9 Package Bolts Correctly Installed (Left Side

Shown)
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
(6) Install a dog bone washer on the steering

knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service pack-
age (Fig. 10). Tighten the bolts just enough to hold
the steering knuckle in position when adjusting cam-
ber, while still allowing the steering knuckle to move Fig. 11 Camber Adjustment Cam Bolt
in clevis bracket. 1 - STEERING KNUCKLE
(7) Repeat the procedure to the other side strut 2 - CLEVIS BRACKET CAM STOP AREAS
clevis bracket. 3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT
(8) Reinstall both front tire and wheel assemblies
and tighten to specifications.
(11) If toe readings obtained are not within the
(9) Lower the vehicle. Jounce the front and rear of
required specification range, adjust toe to meet the
vehicle an equal amount of times.
preferred specification setting. Toe is adjustable
(10) Adjust the front camber to the preferred set-
using the following procedure.
ting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket (Fig.
11). When camber is set, tighten the upper strut cle-
TOE
(1) Center the steering wheel and lock in place
vis bracket bolt and lower cam bolt. Again jounce
using a steering wheel clamp.
front and rear of vehicle an equal amount of times
and verify front camber setting. Torque both front
CAUTION: Do not twist front inner tie rod to steer- (4) Adjust steering gear to tie rod boots at the
ing gear rubber boots during front wheel Toe inner tie rod.
adjustment. (5) Remove steering wheel clamp.
(6) Remove the alignment equipment.
(2) Loosen front inner to outer tie rod end jam (7) Road test the vehicle to verify the steering wheel
nuts (Fig. 12). Grasp inner tie rods at serrations and is straight and the vehicle does not wander or pull.
rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2 STANDARD PROCEDURE - CURB HEIGHT
- SUSPENSION/WHEEL ALIGNMENT - SPECIFI-
MEASUREMENT
CATIONS)
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
Fig. 12 Front Wheel Toe Adjustment spring. The heights should vary if the suspect spring
1 - INNER TIE ROD SERRATION is weak.
2 - OUTER TIE ROD JAM NUT (1) Measure from the inboard edge of the wheel
3 - OUTER TIE ROD END opening fender lip directly above the wheel center
4 - INNER TIE ROD (spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Tighten tie rod jam nuts (Fig. 12) to 75 N·m (3) Compare the measurements to the specifica-
(55 ft. lbs.) torque. tions listed in the following CURB HEIGHT SPECI-
FICATIONS chart.
CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES

TIRE SALES CODE/TIRE SIZE FRONT REAR
754 mm 6 10 mm 770 mm 6 10 mm
TM4 / 215/70 R 15
29.68 in. 6 0.39 in. 30.31 in. 6 0.39 in.
755 mm 6 10 mm 771 mm 6 10 mm
TM5 / 215/65 R 16
29.72 in. 6 0.39 in. 30.35 in. 6 0.39 in.
758 mm 6 10 mm 774 mm 6 10 mm
TTU / 215/60 R 17
29.84 in. 6 0.39 in. 30.47 in. 6 0.39 in.
CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES

755 mm 6 10 mm 770 mm 6 10 mm
TM4 / 215/70 R 15
29.72 in. 6 0.39 in. 30.31 in. 6 0.39 in.
756 mm 6 10 mm 771 mm 6 10 mm
TM5 / 215/65 R 16
29.76 in. 6 0.39 in. 30.35 in. 6 0.39 in.
SPECIFICATIONS NOTE: All wheel alignments are to be set at curb

height. (Refer to 2 - SUSPENSION/WHEEL ALIGN-
WHEEL ALIGNMENT MENT - STANDARD PROCEDURE)
NOTE: All specifications are given in degrees.
FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER +0.10° -0.30° to +0.50°
Cross-Camber (Maximum side-to-side 0.0° 0.50°
difference)
CASTER* +2.31° +1.31° to +3.31°
Cross-Caster (Maximum side-to-side difference) 0.0° 1.00°
TOTAL TOE** +0.10° −0.10° to +0.30°
Maximum side-to-side difference 0.0° 0.06°
REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER* 0.0° -0.25° to +0.25°
TOTAL TOE* ** 0.0° −0.20° to +0.20°
THRUST ANGLE* 0.0° -0.30° to +0.30°
Notes:
* For reference only. These are non-adjustable angles.
** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between
each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe
is toe-out
RG SUSPENSION 2a - 1
SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION ......................1 WHEEL ALIGNMENT .......................3
FRONT SUSPENSION
TABLE OF CONTENTS
page page
LOWER BALL JOINT SEAL BOOT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LOWER BALL JOINT SEAL (3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
BOOT boot (Fig. 1). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
DESCRIPTION surface of lower control arm.
The lower ball joint seal boot is a two piece unit. It
consists of a seal boot and a separate shield that is
located in a groove at the top of the seal boot.
NOTE: The seal boot should only be replaced if

damaged during vehicle service. The entire lower
control arm should be replaced if the joint has been
contaminated.
REMOVAL
(1) Remove steering knuckle from vehicle. (Refer to 2
- SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(2) Remove shield from seal boot by gently pulling
on it.
(3) Using a screw driver or other suitable tool, pry
seal boot off of the lower ball joint.
Fig. 1 Installing Ball Joint Seal Boot (Typical)
INSTALLATION 1 - SHIELD (NOT ON RG VEHICLE)
(1) Place a liberal dab of Mopart Wheel Bearing 2 - SPECIAL TOOL 6758
Grease around the base of the ball joint stem at the
4 - BALL JOINT SEAL BOOT
socket.
(2) Install a NEW seal boot by hand as far as pos-
sible on the ball joint. (4) Wipe any grease off the ball joint stem.
(5) Place the shield over the top of the seal boot
CAUTION: Do not use an arbor press to install the and stretch it into the groove at the top of the seal
sealing boot on the ball joint. Damage to the seal- boot.
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
2a - 2 FRONT SUSPENSION RG
LOWER BALL JOINT SEAL BOOT (Continued)
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to

2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
RG WHEEL ALIGNMENT 2a - 3
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT CURB HEIGHT MEASUREMENT . . . . . . . . . . . . 3

STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 3
WHEEL ALIGNMENT for bent or weak suspension components. Compare

the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
STANDARD PROCEDURE - CURB HEIGHT
match. Once removed from the vehicle, compare the
MEASUREMENT coil spring height to a correct new or known good coil
The wheel alignment is to be checked and all align- spring. The heights should vary if the suspect spring
ment adjustments made with the vehicle at its is weak.
required curb height specification. (1) Measure from the inboard edge of the wheel
Vehicle height is to be checked with the vehicle on opening fender lip directly above the wheel center
a flat, level surface, preferably a vehicle alignment (spindle), to the floor or alignment rack surface.
rack. The tires are to be inflated to the recommended (2) When measuring, the maximum left-to-right
pressure. All tires are to be the same size as stan- differential is not to exceed 12.5 mm (0.5 in.).
dard equipment. Vehicle height is checked with the (3) Compare the measurements to the specifica-
fuel tank full of fuel, and no passenger or luggage tions listed in the following Curb Height Specifica-
compartment load. tions charts.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF SUSPENSION

756 mm ± 10 mm 772 mm ± 10 mm
TMM / 215/65 R 16
29.76 in. ± 0.39 in. 30.39 in. ± 0.39 in.
CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF + SER
SUSPENSION

756 mm ± 10 mm 771 mm ± 10 mm
TMM / 215/65 R 16
29.76 in. ± 0.39 in. 30.35 in. ± 0.39 in.
CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES

755 mm ± 10 mm 770 mm ± 10 mm
TMM / 215/65 R 16
29.72 in. ± 0.39 in. 30.31 in. ± 0.39 in.
RS DIFFERENTIAL & DRIVELINE 3-1
DIFFERENTIAL & DRIVELINE

TABLE OF CONTENTS
page page
HALF SHAFT - FRONT . . . . . . . . . . . . . . . . . . . . . 1 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 24

HALF SHAFT - REAR . . . . . . . . . . . . . . . . . . . . . 16 REAR DRIVELINE MODULE . . . . . . . . . . . . . . . . 26
HALF SHAFT - FRONT
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CV BOOT - OUTER
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 OUTER CV JOINT BEARING SHIELD
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CV BOOT - INNER
REMOVAL . . . . . . . . . . . . . ..................7
HALF SHAFT - FRONT a snap ring located in the stub shaft of the tripod
joint. The outer CV joint has a stub shaft that is
splined into the wheel hub and retained by a steel
DESCRIPTION
hub nut.
All vehicles use an unequal length half shaft sys-
tem (Fig. 1).
The left half shaft uses a tuned rubber damper
DIAGNOSIS AND TESTING - HALF SHAFT
weight. When replacing the left half shaft, be sure
the replacement half shaft has the same damper
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
weight as the original.
tripod joint and outboard CV joint; this is a sign of
All half shaft assemblies use the same type of
inner or outer joint seal boot or seal boot clamp dam-
inner and outer joints. The inner joint of both half
age.
shaft assemblies is a tripod joint, and the outer joint
(2) A light film of grease may appear on the right
of both half shaft assemblies is a Rzeppa joint. Both
inner tripod joint seal boot; this is considered normal
tripod joints and Rzeppa joints are true constant
and should not require replacement of the seal boot.
velocity (CV) joint assemblies. The inner tripod joint
allows for the changes in half shaft length through
the jounce and rebound travel of the front suspen-
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
sion.
be caused by one of the following conditions:
On vehicles equipped with ABS brakes, the outer
• Damaged outer CV or inner tripod joint seal
CV joint is equipped with a tone wheel used to deter-
boot or seal boot clamps. This will result in the loss
mine vehicle speed for ABS brake operation.
and/or contamination of the joint grease, resulting in
The inner tripod joint of both half shafts is splined
inadequate lubrication of the joint.
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle using
3-2 HALF SHAFT - FRONT RS
HALF SHAFT - FRONT (Continued)
Fig. 1 Unequal Length Half Shaft System

1 - STUB AXLE 9 - RIGHT HALFSHAFT
2 - OUTER C/V JOINT 10 - INNER TRIPOD JOINT BOOT
3 - OUTER C/V JOINT BOOT 11 - INNER TRIPOD JOINT
4 - TUNED RUBBER DAMPER WEIGHT 12 - INNER TRIPOD JOINT
5 - INTERCONNECTING SHAFT 13 - INNER TRIPOD JOINT BOOT
6 - OUTER C/V JOINT BOOT 14 - INTERCONNECTING SHAFT & LEFT HALFSHAFT
7 - STUB AXLE
8 - OUTER C/V JOINT
• Noise may also be caused by another component VIBRATION AT HIGHWAY SPEEDS

of the vehicle coming in contact with the half shafts. This problem could be a result of:
• Foreign material (mud, etc.) packed on the back-
CLUNKING NOISE DURING ACCELERATION side of the wheel(s).
This noise may be a result of one of the following • Out of balance tires or wheels. (Refer to 22 -
conditions: TIRES/WHEELS - STANDARD PROCEDURE)
• A torn seal boot on the inner or outer joint of the • Improper tire and/or wheel runout. (Refer to 22 -
half shaft assembly. TIRES/WHEELS - DIAGNOSIS AND TESTING)
• A loose or missing clamp on the inner or outer
joint of the half shaft assembly. REMOVAL
• A damaged or worn half shaft CV joint. (1) Raise vehicle on jack stands or centered on a
frame contact type hoist.
SHUDDER OR VIBRATION DURING ACCELERATION (2) Remove the cotter pin and nut lock (Fig. 2)
This problem could be a result of: from the end of the half shaft.
• A worn or damaged half shaft inner tripod joint. (3) Remove the wave washer (Fig. 3) from the end
• A sticking tripod joint spider assembly (inner tri- of the half shaft.
pod joint only). (4) Remove the wheel and tire assembly from the
• Improper wheel alignment. (Refer to 2 - SUS- vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
PENSION/WHEEL ALIGNMENT - STANDARD (5) With the vehicle’s brakes applied to keep hub
PROCEDURE) from turning, loosen and remove the half shaft
nut.
(6) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).
RS HALF SHAFT - FRONT 3-3
Fig. 2 Half Shaft Retaining Nut

1 - HUB/BEARING
1 - BRAKE ROTOR
2 - NUT LOCK
2 - HUB AND BEARING
3 - COTTER PIN
4 - HALF SHAFT
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 3 Wave Washer

1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - HALF SHAFT Fig. 5 Correctly Supported Disc Brake Caliper -
Typical
(7) Remove the disc brake caliper assembly from 1 - STEERING KNUCKLE
the steering knuckle. Caliper assembly is removed by 2 - BRAKE FLEX HOSE
first rotating top of caliper assembly away from 3 - CALIPER ASSEMBLY
steering knuckle and then removing bottom of assem- 4 - WIRE HANGER
5 - STRUT ASSEMBLY
bly out from under machined abutment on steering
knuckle.
(8) Support disc brake caliper assembly by using a (10) Remove nut attaching outer tie rod end to
wire hook and suspending it from the strut assembly steering knuckle (Fig. 6). Nut is to be removed
(Fig. 5). Do not allow the brake caliper assembly from tie rod end using the following procedure,
to hang by the brake flex hose. hold tie rod end stud with a socket while loos-
(9) Remove the brake rotor from the hub and bear- ening and removing nut with a wrench.
ing assembly. (11) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 7).
Fig. 6 Removing Tie Rod End Attaching Nut Fig. 8 Strut To Steering Knuckle Attaching Bolts
1 - TIE ROD END 1 - STRUT CLEVIS BRACKET
2 - STEERING KNUCKLE 2 - NUTS AND BOLTS
3 - WRENCH 3 - STEERING KNUCKLE
4 - SOCKET
5 - TIE ROD END STUD
steering knuckle, end of half shaft must be sup-
ported.
(14) Pull steering knuckle assembly down and

away from the outer C/V joint of the half shaft
assembly while pulling the joint out of the hub bear-
ing.
(15) Support the outer end of the half shaft assem-
bly. Insert a pry bar between inner tripod joint and
transaxle case (Fig. 9). Pry against inner tripod joint,
until tripod joint retaining snap-ring is disengaged
from transaxle side gear.
Fig. 7 Tie Rod End Removal From Steering Knuckle

Arm
1 - TIE ROD END
2 - SPECIAL TOOL MB-991113
3 - STUD
4 - STEERING KNUCKLE ARM
(12) Remove the steering knuckle to strut attach-

ment bolts (Fig. 8) from the steering knuckle.
(13) Pull the steering knuckle from the strut clevis
bracket. Fig. 9 Disengaging Inner Tripod Joint From
Transaxle
NOTE: Care must be taken not to separate the inner 1 - INNER TRIPOD JOINT
C/V joint during this operation. Do not allow half 2 - TRANSAXLE CASE
shaft to hang by inner C/V joint after removing 3 - PRY BAR
outer C/V Joint from the hub/bearing assembly in
(16) Hold inner tripod joint and interconnecting
shaft of half shaft assembly. Remove inner tripod
joint from transaxle, by pulling it straight out of
transaxle side gear and transaxle oil seal (Fig. 10).
When removing tripod joint, do not let spline or
snap-ring drag across sealing lip of the trans-
axle to tripod joint oil seal.
Fig. 11 Outer CV Joint Inspection

1 - OUTER CV JOINT
2 - THIS AREA OF OUTER CV JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
(6) Slide half shaft back into front hub and bear-
ing assembly.
Fig. 10 Tripod Joint Removal from Transaxle
1 - INNER TRIPOD JOINT CAUTION: The steering knuckle to strut assembly
2 - TRANSAXLE attaching bolts are serrated and must not be turned
3 - SPLINE during installation. Install nuts while holding bolts
4 - OIL SEAL stationary in the steering knuckle.
5 - SNAP-RING
6 - INTERCONNECTING SHAFT
CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
INSTALLATION eccentric bolt must be installed in the bottom (slot-
(1) Thoroughly clean spline and oil seal sealing ted) hole on the strut clevis bracket (Fig. 12).
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding half shaft assembly by tripod joint and
interconnecting shaft, install tripod joint into trans-
axle side gear as far as possible by hand (Fig. 10).
(3) Grasp inner tripod joint an interconnecting
shaft. Forcefully push the tripod joint into side gear
of transaxle, until snap-ring is engaged with trans-
axle side gear. Test that snap-ring is fully
engaged with side gear by attempting to
remove tripod joint from transaxle by hand. If
snap-ring is fully engaged with side gear, tripod
joint will not be removable by hand.
(4) Clean all debris and moisture out of steering
knuckle, in the area were outer CV joint will be
installed into steering knuckle.
(5) Ensure that front of outer CV joint which fits Fig. 12 Correctly Installed Eccentric Attaching Bolt
against the face of the hub and bearing is free of 1 - STEERING KNUCKLE
debris and moisture before installing outer CV joint 2 - FLANGED BOLT IN TOP HOLE
into hub and bearing assembly (Fig. 11). 3 - CAM BOLT IN BOTTOM HOLE
(7) Install steering knuckle in clevis bracket of (12) Clean all foreign matter from the threads of
strut damper assembly. Install the strut damper to the outer CV joint. Install the washer and half shaft
steering knuckle attaching bolts. Tighten both bolts to hub/bearing assembly nut on half shaft and
to a torque of 81 N·m (60 ft. lbs.) plus an additional securely tighten nut.
1/4 turn. (13) Install front wheel and tire assembly. Install
(8) Install tie rod end into steering knuckle. Start and tighten the wheel mounting stud nuts in proper
attaching nut onto stud of tie rod end. While holding sequence until all nuts are torqued to half the
stud of tie rod end stationary using a socket, (Fig. 6) required specification. Then repeat the tightening
tighten tie rod end to steering knuckle attaching nut. sequence to the full specified torque of 135 N·m (100
Then using a crowfoot and socket (Fig. 13), tighten ft. lbs.).
the tie rod end attaching nut to a torque of 75 N·m (14) Lower vehicle.
(55 ft. lbs.). (15) With the vehicle’s brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N·m (180 ft. lbs.) (Fig. 14).
Fig. 13 Torquing Tie Rod End Attaching Nut

2 - TIE ROD END Fig. 14 Torquing Front Half Shaft To Hub Nut
3 - CROWFOOT 1 - TORQUE WRENCH
4 - SOCKET
5 - TORQUE WRENCH
(16) Install the spring wave washer on the end of
the half shaft.
(9) Install braking disc on hub and bearing assem- (17) Install the hub nut lock, and a new cotter pin
bly. (Fig. 2). Wrap cotter pin prongs tightly around the
(10) Install disc brake caliper assembly on steering hub nut lock as shown in (Fig. 2).
knuckle. Caliper is installed by first sliding bottom of (18) Check for correct fluid level in transaxle
caliper assembly under abutment on steering assembly. (Refer to 21 - TRANSMISSION/TRANS-
knuckle, and then rotating top of caliper against top AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
abutment. PROCEDURE)
(11) Install disc brake caliper adapter to steering (19) Set front toe on vehicle to required specifica-
knuckle attaching bolts (Fig. 4). Tighten the disc tion.
brake caliper adapter attaching bolts to a torque of
169 N·m (125 ft. lbs.).
SPECIFICATIONS
SPECIFICATIONS - HALF SHAFT - FRONT
DESCRIPTION N·m Ft. Lbs. In. Lbs.

Bolts, Caliper Adapter to Knuckle 169 125 -
Nut, Hub 244 180 -
Nuts, Front Wheel Lug 135 100 -
Nut, Tie Rod End to Knuckle 75 55 -
Nut, Strut Clevis to Knuckle 81 +90° 60 +90° -
CV BOOT - INNER
REMOVAL
(1) Remove the half shaft requiring boot replace-
ment from the vehicle. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/HALF SHAFT - REMOVAL)
(2) Remove large boot clamp which retains inner
tripod joint sealing boot to tripod joint housing and
discard.
(3) Remove small clamp which retains inner tripod
joint sealing boot to interconnecting shaft and dis-
card.
(4) Remove the sealing boot from the tripod hous-
ing and slide it down the interconnecting shaft.
CAUTION: When removing the tripod joint housing

Fig. 15 Spider Assembly Removal from Tripod Joint
from the spider assembly, hold the bearings in
Housing
place on the spider trunions to prevent the bearings
1 - TRIPOD JOINT HOUSING
from falling away.
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
(5) Slide the tripod joint housing off the spider
assembly and the interconnecting shaft (Fig. 15).
(6) Remove snap-ring which retains spider assem- (8) Slide sealing boot off interconnecting shaft.
bly to interconnecting shaft (Fig. 16). Do not hit the (9) Thoroughly clean and inspect spider assembly,
outer tripod bearings in an attempt to remove tripod joint housing, and interconnecting shaft for
spider assembly from interconnecting shaft. any signs of excessive wear. If any parts show
(7) Remove the spider assembly from interconnect- signs of excessive wear, the half shaft assembly
ing shaft. If spider assembly will not come off inter- will require replacement. Component parts of
connecting shaft by hand, it can be removed by these half shaft assemblies are not serviceable.
tapping spider assembly with a brass drift (Fig. 17).
CV BOOT - INNER (Continued)
Fig. 18 Sealing Boot Installation on Interconnecting

Fig. 16 Spider Assembly Retaining Snap-Ring Shaft
1 - INTERCONNECTING SHAFT 1 - SEALING BOOT
2 - SPIDER ASSEMBLY 2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
3 - RETAINING SNAP RING 3 - GROOVE
(2) Install spider assembly onto interconnecting

shaft (Fig. 19). Spider assembly must be installed on
interconnecting shaft far enough to fully install spi-
der retaining snap-ring. If the spider assembly will
not fully install on interconnecting shaft by hand, it
can be installed by tapping the spider body with a
brass drift (Fig. 20). Do not hit the outer tripod
bearings in an attempt to install spider assem-
bly on interconnecting shaft.
Fig. 17 Spider Assembly Removal from

Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN
REMOVING SPIDER ASSEMBLY
3 - BRASS DRIFT
INSTALLATION
(1) Slide inner CV joint seal boot retaining clamp,
onto the interconnecting shaft. Then, slide the Fig. 19 Spider Assembly Installation on
replacement inner CV joint sealing boot onto the Interconnecting Shaft
interconnecting shaft. Inner CV joint seal boot
1 - SPIDER ASSEMBLY
MUST be positioned on interconnecting shaft
so the raised bead on the inside of the small
diameter end of the seal boot is in mating
groove on interconnecting shaft (Fig. 18). (3) Install the spider assembly to interconnecting
shaft retaining snap-ring into groove on end of inter-
connecting shaft (Fig. 21). Be sure the snap-ring is
fully seated into groove on interconnecting shaft.
Fig. 20 Installing Spider Assembly on Fig. 22 Installing Tripod Housing on Spider

Interconnecting Shaft Assembly
1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER 1 - TRIPOD JOINT HOUSING
ASSEMBLY
2 - SPIDER ASSEMBLY
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
4 - BRASS DRIFT
(6) Install inner CV joint seal boot to interconnect-
ing shaft clamp evenly on sealing boot.
(7) Place crimping tool C-4975-A over bridge of
clamp (Fig. 23).
(8) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 24).
Fig. 21 Spider Assembly Retaining Snap-Ring

Installed
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP RING
(4) Distribute 1/2 the amount of grease provided in Fig. 23 Crimping Tool Installed on Sealing Boot
the seal boot service package (DO NOT USE ANY Clamp - Typical
OTHER TYPE OF GREASE) into tripod housing. Put 1 - SPECIAL TOOL C-4975A
the remaining amount into the sealing boot. 2 - INTERCONNECTING SHAFT
(5) Align tripod housing with spider assembly and 3 - CLAMP
then slide tripod housing over spider assembly and 4 - SEALING BOOT
interconnecting shaft (Fig. 22).
3 - 10 HALF SHAFT - FRONT RS
(11) Insert a trim stick between the CV joint hous-
ing and the sealing boot insert to vent inner CV joint
assembly (Fig. 25). When inserting trim stick
between tripod housing and sealing boot
ensure trim stick is held flat and firmly against
the tripod housing. If this is not done damage
to the sealing boot can occur.
Fig. 24 Sealing Boot Retaining Clamp Installed -

Typical
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
4 - SEALING BOOT
CAUTION: Seal must not be dimpled, stretched or Fig. 25 Trim Stick Inserted for Venting CV Joint
out of shape in any way. If seal is NOT shaped cor- 1 - INNER TRIPOD JOINT SEALING BOOT
rectly, equalize pressure in seal and shape it by 2 - SEALING BOOT CLAMP
hand. 3 - INNER TRIPOD JOINT HOUSING
4 - TRIM STICK
(9) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp (12) With trim stick inserted between sealing boot
evenly on sealing boot. insert and the CV joint housing, position the inter-
(10) Position trilobal boot to interface with the tri- connecting shaft so it is at the center of its travel in
pod housing. The lobes of the boot must be properly the tripod joint housing. Remove the trim stick from
aligned with the recess’s of the tripod housing. between the sealing boot insert and the CV joint
housing. This procedure will equalize the air
CAUTION: The following positioning procedure
pressure in the CV joint, preventing premature
determines the correct air pressure inside the inner
sealing boot failure.
CV joint assembly prior to clamping the sealing
(13) Clamp CV joint sealing boot to CV joint, using
boot to inner CV joint housing. If this procedure is
required procedure for type of boot clamp application.
not done prior to clamping sealing boot to CV joint
housing sealing boot durability can be adversely
CRIMP TYPE BOOT CLAMP
affected.
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
CAUTION: When venting the inner CV joint assem- (1) Place crimping tool C-4975-A over bridge of
bly, use care so that the inner CV sealing boot does clamp (Fig. 26).
not get punctured, or in any other way damaged. If (2) Tighten nut on crimping tool C-4975-A until
sealing boot is punctured, or damaged in any way jaws on tool are closed completely together, face to
while being vented, the sealing boot can not be face (Fig. 27).
used.
RS HALF SHAFT - FRONT 3 - 11
Fig. 26 Crimping Tool Installed on Sealing Boot Fig. 28 Clamping Tool Installed on Sealing Boot
Clamp Clamp
1 - CLAMP 1 - CLAMP
2 - TRIPOD JOINT HOUSING 2 - SPECIAL TOOL YA3050
3 - SPECIAL TOOL C-4975A 3 - SEALING BOOT
4 - SEALING BOOT
Fig. 29 Sealing Boot Clamp Correctly Installed

Fig. 27 Sealing Boot Retaining Clamp Installed
1 - INNER TRIPOD JOINT HOUSING
1 - CLAMP 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
2 - TRIPOD HOUSING SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SPECIAL TOOL C-4975A 3 - SEALING BOOT
5 - SEALING BOOT (3) Install the half shaft back into the vehicle.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the CV BOOT - OUTER
retaining clamp.
(1) Place prongs of clamp locking tool in the holes REMOVAL
of the clamp (Fig. 28). (1) Remove half shaft assembly requiring boot
(2) Squeeze tool together until top band of clamp is replacement from vehicle. (Refer to 3 - DIFFEREN-
latched behind the two tabs on lower band of clamp TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(Fig. 29).
CV BOOT - OUTER (Continued)
(2) Remove large boot clamp retaining CV joint
sealing boot to CV joint housing (Fig. 30) and dis-
card.
(3) Remove small clamp that retains outer CV
joint sealing boot to interconnecting shaft and dis-
card.
(4) Remove sealing boot from outer CV joint hous-
ing and slide it down interconnecting shaft.
Fig. 31 Outer CV Joint Removal From

Interconnecting Shaft
1 - SPREAD RETAINING RING EARS AND PULL JOINT OFF
SHAFT
2 - RETAINING RING
3 - RETAINING RING
4 - OUTER CV JOINT ASSEMBLY
Fig. 30 Outer CV Joint Seal Boot Clamps

1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
(5) Wipe away grease to expose outer CV joint to

interconnecting shaft retaining ring.
(6) Spread ears apart on CV joint assembly to
interconnecting shaft retaining ring (Fig. 31).
(7) Slide outer CV joint assembly off end of inter-
connecting shaft.
(8) Slide sealing boot off interconnecting shaft.
(9) Thoroughly clean and inspect outer CV joint
assembly and interconnecting joint for any signs of
excessive wear. If any parts show signs of exces-
Fig. 32 Outer CV Joint Installed On Interconnecting
sive wear, the half shaft assembly will require
Shaft
replacement. Component parts of these half
shaft assemblies are not serviceable.
2 - RETAINING RING
3 - OUTER CV JOINT ASSEMBLY
INSTALLATION
(1) Slide the new small diameter seal boot retain-
ing clamp onto the interconnecting shaft. Then slide (3) Distribute 1/2 the amount of grease provided in
the replacement outer CV joint assembly sealing boot seal boot service package (DO NOT USE ANY
onto the interconnecting shaft. OTHER TYPE OF GREASE) into outer CV joint
(2) Install the outer CV joint assembly onto the assembly housing. Put the remaining amount into
interconnecting shaft. Joint is installed on intercon- the sealing boot.
necting shaft, by pushing interconnecting shaft into (4) Install outer CV joint seal boot retaining
outer CV joint, until retaining ring is seated in clamp, onto interconnecting shaft. Install replace-
groove on interconnecting shaft (Fig. 32). Verify that ment outer CV joint sealing boot onto interconnecting
the retaining ring is fully seated into groove on inter- shaft. Outer CV joint seal boot MUST be posi-
connecting shaft. tioned on interconnecting shaft, so that only
the thinnest (sight) groove on interconnecting
shaft is visible (Fig. 33).
Fig. 35 Sealing Boot Retaining Clamp Installed

1 - CLAMP
Fig. 33 Seal Boot Correctly Positioned On 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
Interconnecting Shaft COMPLETELY TOGETHER HERE
1 - SEALING BOOT 3 - INTERCONNECTING SHAFT
2 - INTERCONNECTING SHAFT THINNEST GROOVE 4 - SEALING BOOT
4 - BOOT CLAMP
(7) Position outer CV joint sealing boot into its
retaining groove on outer CV joint housing.
(5) Place crimping tool C-4975-A over bridge of (8) Install sealing boot to outer CV joint retaining
clamp (Fig. 34). clamp evenly on sealing boot.
(6) Tighten nut on crimping tool C-4975-A until (9) Place crimping tool C-4975-A over bridge of
jaws on tool are closed completely together, face to clamp (Fig. 36).
face (Fig. 35). (10) Tighten nut on crimping tool C-4975-A until
face (Fig. 37).
Fig. 34 Crimping Tool Installed on Sealing Boot Clamp

1 - SPECIAL TOOL C-4975A
2 - INTERCONNECTING SHAFT Fig. 36 Crimping Tool Installed on Sealing Boot
3 - CLAMP Clamp - Typical
4 - SEALING BOOT 1 - CLAMP
CAUTION: Seal must not be dimpled, stretched, or
4 - SEALING BOOT
out-of-shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.

Typical Fig. 38 Removing Bearing Shield from Outer CV
1 - CLAMP Joint
2 - TRIPOD HOUSING
1 - DRIFT
2 - OUTER CV JOINT
COMPLETELY TOGETHER HERE 3 - BEARING SHIELD
5 - SEALING BOOT
(11) Install the half shaft requiring boot replace-

ment back on the vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT -
INSTALLATION)
OUTER CV JOINT BEARING

SHIELD
REMOVAL
(1) Clamp half shaft in a vise by the interconnect-
ing shaft.
(2) Using a drift (Fig. 38) tap around the entire
edge of the bearing shield until it is removed from
the outer CV joint. Fig. 39 Special Tools for Installing Bearing Shield
1 - SPECIAL TOOL C-4698-2
INSTALLATION 2 - SPECIAL TOOL C-4698-1
(1) Install bearing shield by hand on outer CV 3 - BEARING SHIELD
4 - OUTER CV JOINT
Joint so that it is installed squarely on the CV joint.
(2) Position installer, Special Tool C-4698-2, and
handle, Special Tool C-4698-1, on face of bearing
shield (Fig. 39).
CAUTION: If bearing shield is not installed flush

against the face of the outer CV joint, interference
with steering knuckle will occur when driveshaft is
installed.
OUTER CV JOINT BEARING SHIELD (Continued)
(3) Using a hammer, drive the bearing shield on
the outer CV joint until it is flush against the front
of the outer CV joint (Fig. 40).
Fig. 40 Correctly Installed Bearing Shield

1 - HAMMER
3 - BEARING SHIELD
4 - BEARING SEAL MUST BE FLUSH WITH FRONT OF OUTER
CV JOINT
3 - 16 HALF SHAFT - REAR RS
HALF SHAFT - REAR
TABLE OF CONTENTS
page page
HALF SHAFT - REAR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 16 CV BOOT - INNER/OUTER
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HALF SHAFT - REAR • A torn seal boot on the inner or outer joint of the
half shaft assembly.
• A loose or missing clamp on the inner or outer
DESCRIPTION
joint of the half shaft assembly.
The inner and outer joints of both half shaft
• A damaged or worn half shaft CV joint.
assemblies are tripod joints. The tripod joints are
true constant velocity (CV) joint assemblies, which
SHUDDER OR VIBRATION DURING ACCELERATION
allow for the changes in half shaft length through
This problem could be a result of:
the jounce and rebound travel of the rear suspension.
• A worn or damaged half shaft inner tripod joint.
On vehicles equipped with ABS brakes, the outer
• A sticking tripod joint spider assembly (inner tri-
CV joint is equipped with a tone wheel used to deter-
pod joint only).
mine vehicle speed for ABS brake operation.
• Improper wheel alignment. (Refer to 2 - SUS-
The inner tripod joint of both half shafts is bolted
PENSION/WHEEL ALIGNMENT - STANDARD
rear differential assembly’s output flanges. The outer
PROCEDURE)
CV joint has a stub shaft that is splined into the
wheel hub and retained by a steel hub nut.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of:
DIAGNOSIS AND TESTING - HALF SHAFT • Foreign material (mud, etc.) packed on the back-
side of the wheel(s).
VEHICLE INSPECTION • Out of balance tires or wheels. (Refer to 22 -
(1) Check for grease in the vicinity of the inboard
TIRES/WHEELS - STANDARD PROCEDURE)
tripod joint and outboard CV joint; this is a sign of
• Improper tire and/or wheel runout. (Refer to 22 -
inner or outer joint seal boot or seal boot clamp dam-
TIRES/WHEELS - DIAGNOSIS AND TESTING)
age.
(2) A light film of grease may appear on the right
REMOVAL
inner tripod joint seal boot; this is considered normal
(1) Lift vehicle on hoist so that the wheels hang
and should not require replacement of the seal boot.
freely.
(2) Remove rear wheel.
NOISE AND/OR VIBRATION IN TURNS
(3) Remove cotter pin, nut lock, and wave washer
A clicking noise and/or a vibration in turns could
(Fig. 1).
be caused by one of the following conditions:
(4) Remove hub nut and washer.
• Damaged outer CV or inner tripod joint seal
boot or seal boot clamps. This will result in the loss CAUTION: The half shaft outer CV joint, when
and/or contamination of the joint grease, resulting in installed, acts as a bolt and secures the hub/bear-
inadequate lubrication of the joint. ing assembly. If the vehicle is to be supported or
• Noise may also be caused by another component moved on its wheels, install and torque a bolt
of the vehicle coming in contact with the half shafts. through the hub. This will ensure that the hub/bear-
ing assembly cannot loosen.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following (5) Remove inner half shaft retaining bolts (Fig. 2).
conditions:
RS HALF SHAFT - REAR 3 - 17
HALF SHAFT - REAR (Continued)
Fig. 1 Cotter Pin, Nut Lock, And Wave Washer

1 - HUB NUT
2 - NUT LOCK Fig. 3 Half Shaft Removal
3 - COTTER PIN
1 - BRAKE BACKING PLATE
4 - WAVE WASHER
2 - HALF SHAFT
Fig. 2 Inner Half Shaft Bolts

Fig. 4 Half Shaft Installation
1 - SHAFT
2 - FLANGE 1 - BRAKE BACKING PLATE
2 - HALF SHAFT
(6) The half shaft is spring loaded. Compress inner

half shaft joint slightly and pull downward to clear (3) Install the inner half shaft retaining bolts (Fig.
rear differential output flange. Then pull half shaft 5). Torque the bolts to 61 N·m (45 ft.lbs.).
assembly outward to remove (Fig. 3). (4) Install the half shaft washer and hub nut.
Torque the hub nut to 244 N·m (180 ft.lbs.).
INSTALLATION (5) Install the wave washer, nut lock, and a new
cotter pin (Fig. 6). Be sure to wrap the cotter pin
(1) Install the outer CV joint stub shaft through
prongs tightly around the hub nut lock.
the hub bearing (Fig. 4).
(6) Install rear wheel. Torque the lug nuts to 135
(2) The half shaft is spring loaded. Compress inner
N·m (100 ft.lbs.).
half shaft joint slightly and push upward until the
inner CV joint flange engages the rear differential
output flange.
HALF SHAFT - REAR (Continued)
Fig. 6 Cotter Pin, Nut Lock, And Wave Washer

1 - HUB NUT
Fig. 5 Inner Half Shaft Bolts 2 - NUT LOCK
1 - SHAFT 3 - COTTER PIN
2 - FLANGE 4 - WAVE WASHER
SPECIFICATIONS
SPECIFICATIONS - HALF SHAFT - FRONT

Nut, Hub 244 180 -
Nuts, Rear Wheel Lug 135 100 -
Bolt, Half Shaft to Output Flange 61 45 -
CV BOOT - INNER/OUTER
REMOVAL
(1) Remove half shaft from vehicle. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL)
(2) Clamp the half shaft into a suitable vise with
protective jaws clamped onto the interconnecting
shaft (Fig. 7).
(3) Remove the large and small diameter retaining
clamps holding the CV boot to the CV joint and the
interconnecting shaft (Fig. 8).
(4) Pull the boot back from the CV joint (Fig. 9).
(5) Remove the CV housing from the interconnect-
ing shaft and tripod assembly (Fig. 10).
(6) Remove the snap-ring holding the tripod
assembly onto the interconnecting shaft (Fig. 11). Fig. 7 Clamp Shaft In Soft Jawed Vice
1 - HALF SHAFT BOOT
2 - HALF SHAFT
3 - VISE
CV BOOT - INNER/OUTER (Continued)
Fig. 8 Remove Boot Clamps

1 - HALF SHAFT BOOT
2 - CLAMP
Fig. 10 Remove CV Housing

1 - HALF SHAFT JOINT HOUSING
2 - BOOT
Fig. 9 Pull Back Boot

1 - HALF SHAFT BOOT
2 - HALF SHAFT JOINT
(7) Remove the tripod assembly from the intercon- Fig. 11 Remove Snap-Ring
necting shaft (Fig. 12). 1 - SNAP-RING
(8) Remove the CV boot from the interconnecting 2 - HALF SHAFT BOOT
shaft (Fig. 13). 3 - TRIPOD ASSEMBLY
4 - SNAP-RING PLIERS
INSTALLATION
(1) Clean the interconnecting shaft and inner CV
joint of any residual grease and dirt.
(2) Slide the new small diameter retaining clamp
onto the interconnecting shaft.
(3) Install the CV boot onto the interconnecting
shaft (Fig. 14).
Fig. 12 Slide Tripod Off The Shaft

1 - TRIPOD ASSEMBLY
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 14 Install CV Boot Onto Interconnecting Shaft

1 - HALF SHAFT BOOT
(4) Install the tripod assembly onto the intercon-

necting shaft (Fig. 15).
(5) Install the snap-ring to hold the tripod assem-
bly onto the interconnecting shaft (Fig. 16).
(6) Install the new large diameter retaining clamp
onto the CV joint housing.
(7) Distribute 1/2 the amount of grease provided in
the seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into tripod housing. Put
the remaining amount into the sealing boot.
(8) Install the CV housing onto the interconnecting
shaft and tripod assembly (Fig. 17).
(9) Clamp the half shaft into a suitable vise with
protective jaws clamped onto the interconnecting
shaft.
(10) Position the inner CV joint boot on intercon-
necting shaft so the raised bead on the inside of the
Fig. 13 Remove Boot small diameter end of the seal boot is in mating
1 - HALF SHAFT BOOT groove on interconnecting shaft (Fig. 18).
Fig. 17 Install CV Housing

Fig. 15 Slide Tripod Onto The Interconnecting Shaft 1 - HALF SHAFT JOINT HOUSING
1 - TRIPOD ASSEMBLY 2 - BOOT
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 18 Sealing Boot Installation on Interconnecting

Shaft
1 - SEALING BOOT
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
3 - GROOVE
(11) Install inner CV joint seal boot to intercon-

necting shaft clamp evenly on sealing boot.
Fig. 16 Install Snap-Ring (12) Place crimping tool C-4975-A over bridge of
1 - SNAP-RING clamp (Fig. 19).
2 - HALF SHAFT BOOT (13) Tighten nut on crimping tool C-4975-A until
3 - TRIPOD ASSEMBLY jaws on tool are closed completely together, face to
4 - SNAP-RING PLIERS face (Fig. 20).
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
(1) Place crimping tool C-4975-A over bridge of
clamp (Fig. 21).
(2) Tighten nut on crimping tool C-4975-A until
face (Fig. 22).
Fig. 19 Crimping Tool Installed on Sealing Boot

Clamp - Typical
3 - CLAMP
4 - SEALING BOOT
Fig. 21 Crimping Tool Installed on Sealing Boot

Clamp - Typical
1 - CLAMP
4 - SEALING BOOT

Typical
1 - CLAMP
4 - SEALING BOOT
CAUTION: The boot must not be dimpled, stretched

or out of shape in any way. If boot is NOT shaped Fig. 22 Sealing Boot Retaining Clamp Installed -
correctly, equalize pressure in boot and shape it by Typical
hand. 1 - CLAMP
2 - TRIPOD HOUSING
(14) Position CV boot into the CV housing retain- 3 - SPECIAL TOOL C-4975A
ing groove. Install the boot large diameter retaining 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
clamp evenly onto the boot. COMPLETELY TOGETHER HERE
(15) Clamp the CV joint boot to the CV joint, using 5 - SEALING BOOT
required procedure for type of boot clamp application.
LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the
retaining clamp.
(1) Place prongs of clamp locking tool in the holes
of the clamp (Fig. 23).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 24).
Fig. 24 Sealing Boot Clamp Correctly Installed

1 - INNER TRIPOD JOINT HOUSING
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SEALING BOOT
(3) Install the half shaft into the vehicle. (Refer to

3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION)
Fig. 23 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - SPECIAL TOOL YA3050
3 - SEALING BOOT
3 - 24 PROPELLER SHAFT RS
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25
PROPELLER SHAFT connected to power transfer unit (PTU) or rear driv-

eline module flanges. A helper is required.
DESCRIPTION (1) Make sure transaxle is in neutral (N). Using
chalk, mark propeller shaft flanges at PTU and rear
WARNING: Due to propeller shaft imbalance con-
driveline module for installation reference.
cerns, the propeller shaft can only be serviced as
(2) Remove six propeller shaft-to-power transfer
an assembly.
unit bolts.
AWD models utilize a “two-piece” propeller shaft (3) Have helper remove three propeller shaft rub-
(Fig. 1) to transmit power to the rear driveline mod- ber coupler-to-driveline module bolts while he/she
ule assembly. This two-piece design consists of: supports rear shaft by hand.
• Front and rear shaft segments. (4) Remove center bearing support-to-crossmember
• Plunging center CV joint bolts, while supporting front shaft with two hands.
• Center support bearing (5) Lower propeller shaft assembly to ground,
• Rubber coupler at driveline module flange using care not to damage fore and aft flanges (Fig.
The front shaft segment utilizes a CV joint at the 1).
power transfer unit connection, and a plunging CV
joint at the center bearing location. INSTALLATION
The rear shaft segment utilizes a center support
CAUTION: Propeller shaft installation is a two-man
bearing at the forward position, and a rubber coupler
operation. Never allow propeller shaft to hang while
at the driveline module flange.
connected to power transfer unit (PTU) or rear driv-
eline module flanges. A helper is required.
OPERATION
The propeller shaft (Fig. 1) is used to transmit (1) Make sure transaxle is in Neutral (N) position.
torque from the transaxle power transfer unit (PTU) (2) Obtain a helper and lift propeller shaft assem-
to the rear driveline module of AWD equipped mod- bly into position (Fig. 1).
els. (3) While helper supports front half of shaft level
The propeller shaft front half utilizes a CV joint at to underbody, align paint marks at driveline module
the PTU flange, and a plunging CV joint at the cen- flange and install three propeller shaft rubber cou-
ter bearing location. These joints are flexible, allow- pler-to-rear driveline module bolts by hand. Do not
ing for torsional movement of the powertrain. torque at this time.
The propeller shaft rear half utilizes a center sup- (4) While helper supports front half of shaft level
port bearing, which supports this two-piece assembly. to underbody, align chalk marks at PTU flange.
The bearing also stabilizes the rear shaft segment to Install six propeller shaft-to-PTU flange bolts and
minimize axle wind-up. The rubber coupler at the torque to 30 N·m (22 ft. lbs.). Torque bolts alternately
driveline module flange dampens out propeller shaft to ensure proper flange mating.
torsional vibrations, as the driveline module it con- (5) Place center bearing into position. Install and
nects to is fastened to the vehicle body. torque center bearing-to-crossmember bolts to 54
N·m (40 ft. lbs.).
REMOVAL (6) Torque propeller shaft rubber coupler-to-rear
driveline module assembly to 54 N·m (40 ft. lbs.).
CAUTION: Propeller shaft removal is a two-man
operation. Never allow propeller shaft to hang while
RS PROPELLER SHAFT 3 - 25
PROPELLER SHAFT (Continued)
Fig. 1 Propeller Shaft Removal/Installation

1 - PTU FLANGE 5 - BOLT-CENTER SUPPORT BEARING-TO-CROSSMEMBER
2 - CROSSMEMBER 6 - PROPELLER SHAFT ASSEMBLY
3 - REAR DRIVELINE MODULE
4 - BOLT-PROPELLER SHAFT COUPLER-T0-DRIVELINE
MODULE
SPECIFICATIONS
SPECIFICATIONS - PROPELLER SHAFT

Bolt, Propeller Shaft Front Flange-to-PTU
30 22 —
Flange
Bolt, Propeller Shaft Rear Flange-to-
54 40 —
Driveline Module Flange
Bolt, Center Support Bearing-to-Body 54 40 —
3 - 26 REAR DRIVELINE MODULE RS
REAR DRIVELINE MODULE
TABLE OF CONTENTS
page page
REAR DRIVELINE MODULE FLUID - DIFFERENTIAL ASSEMBLY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 44
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DIFFERENTIAL ASSEMBLY FLUID CHANGE . . 44
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 27 FLUID
REAR DRIVELINE MODULE NOISE . . . . . . . . . 27 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 44
REAR DRIVELINE MODULE OPERATION . . . . 29 OVERRUNNING CLUTCH HOUSING FLUID
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 VISCOUS COUPLER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 37 TORQUE ARM
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BI-DIRECTIONAL OVERRUNNING CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 INPUT FLANGE SEAL
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DIFFERENTIAL ASSEMBLY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 OUTPUT FLANGE SEAL
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REAR DRIVELINE MODULE • Torque Arm

• Vents
• Fasteners
DESCRIPTION
The rear driveline module assembly (Fig. 1) con-
sists of four main components:
OPERATION
• Bi-Directional Overrunning Clutch (BOC) The primary benefits of All Wheel Drive are:
• Viscous Coupling • Superior straight line acceleration, and corner-
• Differential Assembly ing on all surfaces
• Torque Arm • Better traction and handling under adverse con-
The viscous coupling and bi-directional overrun- ditions, resulting in improved hill climbing ability
ning clutch are contained within an overrunning and safer driving.
clutch housing, which fastens to the differential The heart of the system is an inter-axle viscous
assembly. The overrunning clutch housing and differ- coupling. The vehicle retains predominantly front-
ential assembly have unique fluid sumps, each wheel drive characteristics, but the All Wheel Drive
requiring their own type and capacity of fluid. The capability takes effect when the front wheels start to
overrunning clutch housing requires Mopart ATF+4 slip. Under normal level road, straight line driving,
(Automatic Transmission Fluid—Type 9602) or equiv- 100% of the torque is allocated to the front wheels.
alent. The differential assembly requires The viscous coupling controls and distributes torque/
Driveline module service is limited to the following power to the rear wheels. The viscous coupling trans-
components: mits torque to the rear wheels in proportion of the
• Differential Assembly (serviced only as assem- amount of the slippage at the front wheels. Thais
bly) variable torque distribution is automatic with no
• Viscous Coupling driver inputs required. The coupling is similar to a
• Bi-Directional Overrunning Clutch (BOC) multi-plate clutch. It consists of a series of closely
• Overrunning Clutch Housing spaced discs, which are alternately connected to the
• Seals (Input Flange, Output Flange, Overrun- front and rear drive units. The unit is totally sealed
ning Clutch Housing O-rings) and partially filled with silicone fluid. There is no
• Input Flange/Shield
RS REAR DRIVELINE MODULE 3 - 27
REAR DRIVELINE MODULE (Continued)
Fig. 1 AWD Driveline Module Assembly

1 - TORQUE ARM 11 - SHIM (SELECT)
2 - INPUT FLANGE 12 - O-RING
3 - FLANGE NUT 13 - DIFFERENTIAL ASSEMBLY
4 - WASHER 14 - PLUG-DIFFERENTIAL FILL
5 - SHIELD 15 - PLUG-OVERRUNNING CLUTCH HOUSING DRAIN
6 - VENT 16 - SNAP RING
7 - O-RING 17 - BEARING
8 - WASHER 18 - OVERRUNING CLUTCH HOUSING
9 - BI-DIRECTIONAL OVERRUNNING CLUTCH (BOC) 19 - SEAL-INPUT FLANGE
10 - VISCOUS COUPLER
adjustment, maintenance or fluid checks required DIAGNOSIS AND TESTING - REAR DRIVELINE
during the life of the unit.
The overrunning clutch allows the rear wheels to MODULE NOISE
overrun the front wheels during a rapid front wheel Different sources can be the cause of noise that the
lock braking maneuver. The overrunning action pre- rear driveline module assembly is suspected of mak-
vents any feed-back of front wheel braking torque to ing. Refer to the following causes for noise diagnosis.
the rear wheels. It also allows the braking system to
control the braking behavior as a two wheel drive DRIVELINE MODULE ASSEMBLY NOISE
(2WD) vehicle. The most important part of driveline module ser-
The overrunning clutch housing has a separate oil vice is properly identifying the cause of failures and
sump and is filled independently from the differen- noise complaints. The cause of most driveline module
tial. The fill plug is located on the side of the over- failures is relatively easy to identify. The cause of
running clutch case. When filling the overrunning driveline module noise is more difficult to identify.
clutch with lubricant use Mopart ATF+4 (Automatic If vehicle noise becomes intolerable, an effort
Transmission Fluid—Type 9602) or equivalent. should be made to isolate the noise. Many noises that
The differential assembly contains a conventional are reported as coming from the driveline module
open differential with hypoid ring gear and pinion may actually originate at other sources. For example:
gear set. The hypoid gears are lubricated by SAE
80W-90 gear lubricant.
• Tires is the result of insufficient or incorrect lubricant in
• Road surfaces the carrier housing.
• Wheel bearings Abnormal gear noise can be easily recognized. It
• Engine produces a cycling tone that will be very pronounced
• Transmission within a given speed range. The noise can occur dur-
• Exhaust ing one or more of the following drive conditions:
• Propeller shaft (vibration) • Drive
• Vehicle body (drumming) • Road load
Driveline module noises are normally divided into • Float
two categories: gear noise or bearing noise. A thor- • Coast
ough and careful inspection should be completed to Abnormal gear noise usually tends to peak within
determine the actual source of the noise before a narrow vehicle speed range or ranges. It is usually
replacing the driveline module. more pronounced between 30 to 40 mph (48 to 64
The rubber mounting bushings help to dampen-out km/h) and 50 to 60 mph (80 to 96 km/h). When objec-
driveline module noise when properly installed. tionable gear noise occurs, note the driving condi-
Inspect to confirm that no metal contact exists tions and the speed range.
between the driveline module case and the body. The
complete isolation of noise to one area requires BEARING NOISE (DRIVE PINION AND
expertise and experience. Identifying certain types of DIFFERENTIAL)
vehicle noise baffles even the most capable techni- Defective bearings produce a rough growl that is
cians. Often such practices as: constant in pitch and varies with the speed of vehi-
• Increase tire inflation pressure to eliminate tire cle. Being aware of this will enable a technician to
noise. separate bearing noise from gear noise.
• Listen for noise at varying speeds with different Drive pinion bearing noise that results from defec-
driveline load conditions tive or damaged bearings can usually be identified by
• Swerving the vehicle from left to right to detect its constant, rough sound. Drive pinion front bearing
wheel bearing noise. is usually more pronounced during a coast condition.
All driveline module assemblies produce noise to a Drive pinion rear bearing noise is more pronounced
certain extent. Slight carrier noise that is noticeable during a drive condition. The drive pinion bearings
only at certain speeds or isolated situations should be are rotating at a higher rate of speed than either the
considered normal. Carrier noise tends to peak at a differential side bearings or the axle shaft bearing.
variety of vehicle speeds. Noise is NOT ALWAYS an Differential side bearing noise will usually produce
indication of a problem within the carrier. a constant, rough sound. The sound is much lower in
frequency than the noise caused by drive pinion bear-
TIRE NOISE ings.
Tire noise is often mistaken for driveline module Bearing noise can best be detected by road testing
noise. Tires that are unbalanced, worn unevenly or the vehicle on a smooth road (black top). However, it
are worn in a saw-tooth manner are usually noisy. is easy to mistake tire noise for bearing noise. If a
They often produce a noise that appears to originate doubt exists, the tire treads should be examined for
in the driveline module. irregularities that often causes a noise that resem-
Tire noise changes with different road surfaces, but bles bearing noise.
driveline module noise does not. Inflate all four tires
with approximately 20 psi (138 kPa) more than the ENGINE AND TRANSMISSION NOISE
recommended inflation pressure (for test purposes Sometimes noise that appears to be in the driv-
only). This will alter noise caused by tires, but will eline module assembly is actually caused by the
not affect noise caused by the differential. Rear axle engine or the transmission. To identify the true
noise usually ceases when coasting at speeds less source of the noise, note the approximate vehicle
than 30 mph (48 km/h); however, tire noise contin- speed and/or RPM when the noise is most noticeable.
ues, but at a lower frequency, as the speed is Stop the vehicle next to a flat brick or cement wall
reduced. (this will help reflect the sound). Place the transaxle
After test has been completed lower tire pressure in NEUTRAL. Accelerate the engine slowly up
back to recommended pressure. through the engine speed that matches the vehicle
speed noted when the noise occurred. If the same
GEAR NOISE (DRIVE PINION AND RING GEAR) noise is produced, it usually indicates that the noise
Abnormal gear noise is rare and is usually caused is being caused by the engine or transaxle.
by scoring on the ring gear and drive pinion. Scoring
DIAGNOSIS AND TESTING - REAR DRIVELINE

MODULE OPERATION
Driveline module operation requires relatively
straight-forward diagnosis. Refer to the following
chart:
DRIVELINE MODULE DIAGNOSIS CHART

Rear wheels not 1) Bi-directional overrunning clutch 1) Replace overrunning clutch
overrunning failure components as required
No AWD in forward or 1) Bi-directional overrunning clutch 1) Replace overrunning clutch
reverse directions, propeller failure components as required
shaft turning 2) Viscous coupling failure 2) Replace viscous coupling
3) Rear differential failure 3) Replace the rear differential
assembly
No AWD in forward or 1) Power transfer unit failure. 1) Replace power transfer unit
reverse directions, propeller components as necessary
shaft not turning
Vibration at all speeds, 1) Mis-matched tires, worn tires on 1) Replace worn or incorrect
continuous torque transfer front axle. (mis-matched) tires with same
make and size
REMOVAL (5) Remove torque arm mount to body bolts.

(1) Raise vehicle on hoist. (6) Position transmission jack to driveline module
(2) Drain fluid from overrunning clutch housing assembly and secure assembly to jack.
and/or differential assembly if necessary. (7) Remove two driveline module-to-body bolts
(3) Remove propeller shaft. (Refer to 3 - DIFFER- (Fig. 3).
ENTIAL & DRIVELINE/PROPELLER SHAFT -
REMOVAL)
(4) Disconnect left and right rear halfshafts from
output flanges (Fig. 2).
Fig. 3 Rear Drive Line Module Assembly Mounting

Bolts
1 - DRIVELINE MODULE RETAINING BOLT (2)
2 - RUBBER ISOLATOR
Fig. 2 Half Shaft Mounting Bolts 3 - WASHER
1 - SHAFT
2 - FLANGE (8) Lower driveline module from vehicle and
remove from jack.
DISASSEMBLY (3) Remove input flange (Fig. 6).
WARNING: Differential is only to be serviced as an

assembly, and no disassembly is required.
(1) Remove six torque arm-to-differential case

bolts and remove torque arm assembly (Fig. 4).
Fig. 6 Input Flange

1 - INPUT FLANGE/SHIELD
(4) Remove input flange seal from overrunning

clutch housing using suitable screwdriver (Fig. 7).
Fig. 4 Torque Arm Fasteners
1 - TORQUE ARM ASSEMBLY
2 - BOLT (SIX)
(2) Remove input flange nut and washer using

Tool 6958 and a breaker bar (Fig. 5).
Fig. 7 Input Flange Seal Removal

1 - INPUT FLANGE SEAL
2 - SCREWDRIVER
(5) Remove four overrunning clutch housing-to-dif-

ferential assembly bolts (Fig. 8) and remove housing.
Fig. 5 Input Flange Nut (6) Remove front bearing snap ring (Fig. 14).
(7) Remove front bearing (Fig. 14).
1 - INPUT FLANGE
(8) Remove o-ring and washer from overrunning
2 - TOOL 6958
clutch assembly (Fig. 14).
Fig. 8 Overrunning Clutch Housing Bolts Fig. 10 Viscous Coupler

1 - OVERRUNNING CLUTCH HOUSING 1 - VISCOUS COUPLER
2 - BOLT (FOUR) 2 - DIFFERENTIAL PINION
(9) Remove overrunning clutch assembly from vis-

cous coupler (Fig. 9).
Fig. 11 Shim (Select)

1 - SHIM (SELECT)
Fig. 9 Overrunning Clutch 2 - DIFFERENTIAL PINION
1 - OVERRUNNING CLUTCH
2 - VISCOUS COUPLER (12) Remove overrunning clutch housing large
o-ring from differential assembly (Fig. 14).
(10) Remove viscous coupler from differential pin- (13) Remove output flanges using suitable screw-
ion shaft (Fig. 10). drivers and wood blocks to protect casting (Fig. 12).
(11) Remove shim (select) from differential pinion (14) Remove output flange seals (Fig. 13).
gear (Fig. 11).
ASSEMBLY
(1) Install output flange seals using tools C4171
and 8493 (Fig. 15).
(2) Install large overrunning clutch housing o-ring
to differential assembly (Fig. 14).
(3) Install shim to differential pinion shaft (Fig.
16).
(4) Install viscous coupler to differential pinion
shaft (Fig. 17).
(5) Install overrunning clutch assembly to viscous
coupler (Fig. 18).
(6) Install washer to overrunning clutch (Fig. 14).
(7) Install o-ring to overrunning clutch (Fig. 14).
(8) Align overrunning clutch ground tab to 12
o’clock position (Fig. 19).
(9) Install overrunning clutch housing into posi-
tion, making sure ground tab engages with notch in
housing (Fig. 20).
(10) Install and torque overrunning clutch hous-
ing-to-differential assembly bolts (Fig. 21) to 60 N·m
(44 ft. lbs.).
(11) Install input flange seal using tool 8802 (Fig.
22).
Fig. 12 Output Flange Removal (12) Install flange/shield assembly (Fig. 23).
1 - WOOD BLOCK (13) Install input flange washer and nut. Using
2 - PRYBAR tool 6958 (Fig. 24), torque nut to 135 N·m (100 ft.
3 - OUTPUT SHAFT
lbs.).
4 - PRYBAR
5 - WOOD BLOCK
(14) Install torque arm assembly into position.
6 - DIFFERENTIAL CASE Install and torque torque arm-to-differential assem-
bly bolts (Fig. 25) to 60 N·m (44 ft. lbs.).
Fig. 13 Output Flange Seal Removal

1 - OUTPUT FLANGE SEAL
2 - SCREWDRIVER
Fig. 14 Drive Line Module

1 - NUT, INPUT FLANGE 9 - WASHER
2 - WASHER, INPUT FLANGE NUT 10 - BI-DIRECTIONAL OVERRUNNING CLUTCH
3 - INPUT FLANGE/SHIELD 11 - VISCOUS COUPLER
4 - SEAL, INPUT FLANGE 12 - O-RING, OVERRUNNING CLUTCH HOUSING
5 - OVERRUNNING CLUTCH HOUSING BOLT 13 - SHIM (SELECT)
6 - BEARING, FRONT 14 - DIFFERENTIAL ASSEMBLY
7 - SNAP RING, BEARING RETAINER
8 - O-RING
Fig. 15 Output Flange Seal Installation Fig. 16 Shim (Select)

1 - DRIVER HANDLE C4171 1 - SHIM (SELECT)
2 - INSTALLER 8493 2 - DIFFERENTIAL PINION
Fig. 17 Viscous Coupler Fig. 19 Grounding Tab at 12 O’clock

1 - VISCOUS COUPLER 1 - OVERRUNNING CLUTCH
2 - DIFFERENTIAL PINION 2 - GROUND TAB
Fig. 18 Overrunning Clutch Fig. 20 Overrunning Clutch Housing

1 - OVERRUNNING CLUTCH 1 - OVERRUNNING CLUTCH HOUSING
2 - VISCOUS COUPLER 2 - NOTCH
Fig. 21 Overrunning Clutch Housing Bolts Fig. 23 Input Flange/Shield

1 - OVERRUNNING CLUTCH HOUSING 1 - INPUT FLANGE/SHIELD
2 - BOLT (FOUR)
Fig. 24 Input Flange Nut

Fig. 22 Input Flange Seal Installation 1 - INPUT FLANGE
1 - TOOL 8802 2 - TOOL 6958
2 - HAMMER
Fig. 26 Rear Drive Line Module Assembly Rear

Mounting Bolts
1 - DRIVELINE MODULE RETAINING BOLT (2)
Fig. 25 Torque Arm Fasteners 2 - RUBBER ISOLATOR
1 - TORQUE ARM ASSEMBLY 3 - WASHER
2 - BOLT (SIX)
INSTALLATION
(1) Install rear driveline module assembly to
transmission jack and secure.
(2) Raise rear driveline module into position and
install and torque mounting bolts (Fig. 26) to 54 N·m
(40 ft. lbs.).
(3) Remove transmission jack.
(4) Install and torque torque arm mount-to-body
bolts to 54 N·m (40 ft. lbs.).
(5) Install halfshafts to differential output flanges
and torque bolts (Fig. 27) to 61 N·m (45 ft. lbs.).
(6) Install propeller shaft. (Refer to 3 - DIFFER-
INSTALLATION)
(7) Lower vehicle.
Fig. 27 Half Shaft Mounting Bolts
1 - SHAFT
2 - FLANGE
SPECIFICATIONS
SPECIFICATIONS - REAR DRIVELINE MODULE


Bolt, Driveline Module-to-Body 54 40 —
Bolt, Halfshaft-to-Ouput Flange 61 45 —
Bolt, Overrunning Clutch Housing-to-
60 44 —
Differential
Bolt, Torque Arm-to-Differential Assembly 60 44 —
Bolt, Torque Arm Mount-to-Body 54 40 —
Nut, Input Flange 135 100 —
Plug, Differential Drain/Fill 35 26 —
Plug, Overrunning Clutch Housing Drain/Fill 30 22 —
Vent, Differential/Overrunning Clutch
12 — 110
Housing
SPECIAL TOOLS
SPECIAL TOOLS
Tool 8802
BI-DIRECTIONAL
Tool 6958
OVERRUNNING CLUTCH
DESCRIPTION
The bi-directional overrunning clutch (BOC) (Fig.
28) works as a mechanical disconnect between the
front and rear axles, preventing torque from being
transferred from the rear axle to the front. The BOC
is a simply an overrunning clutch which works in
both clockwise and counter-clockwise rotations. This
means that when the output (the rear axle) is rotat-
ing faster in one direction than the input (front axle),
there is no torque transmission. But when the input
Tool 8493 speed is equal to the output speed, the unit becomes
locked. The BOC provides significant benefits regard-
ing braking stability, handling, and driveline durabil-
ity. Disconnecting the front and the rear driveline
during braking helps to maintain the braking stabil-
ity of an AWD vehicle. In an ABS/braking event, the
locking of the rear wheels must be avoided for stabil-
ity reasons. Therefore brake systems are designed to
BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued)
lock the front wheels first. Any torque transfer from STEADY STATE, LOW TO MODERATE SPEED, NO
the rear axle to the front axle disturbs the ABS/brak- FRONT WHEEL SLIP, FORWARD DIRECTION
ing system and causes potential instabilities on a During normal driving conditions, (no wheel slip),
slippery surface. The BOC de-couples the rear driv- the inner shaft (front axle) and outer race (viscous
eline as soon the rear wheels begin to spin faster coupler) are running at different speeds due to the
than the front wheels (front wheels locked) in order different gear ratios between the front and rear dif-
to provide increased braking stability. Furthermore ferentials. In this condition, the outer race is always
the BOC also reduces the likelihood of throttle off spinning faster (overdriving between 5-32 rpm) than
over-steer during cornering. In a throttle off maneu- the inner shaft. When the BOC (Fig. 29) is running
ver, the BOC once again de-couples the rear driveline under these conditions, at low vehicle speeds the
forcing all the engine brake torque to the front drag shoes and the cage keep the rollers up on the
wheels. This eliminates the chance of lateral slip on left side (forward side) of the inner shaft flats. This is
the rear axle and increases it on the front. The vehi- what is known as “overrunning mode.” Notice that
cle will therefore tend to understeer, a situation when the clutch is in overrunning mode, the rollers
which is considered easier to manage in most circum- are spinning clockwise and with the outer race, thus
stances. During this maneuver, and during the ABS no torque is being transferred.
braking event, the BOC does not transmit torque
through to the rear wheels. The rear driveline mod- NOTE: Low speed, forward and reverse operation is
ule, with the BOC, will perform the same as a front identical, just in opposite directions. (Fig. 29)
wheel drive vehicle during these events. The gear shows forward direction in reverse the rollers are
ratio offset between the front and rear differentials on the other side of the flats due to a reversal of
force the BOC into the overrunning mode most of the the cage force.
time. This allows BOC to significantly reduce the
rolling resistance of the vehicle, which improves fuel
consumption, allows the downsizing of the driveline TRANSIENT CONDITION (BOC LOCKED), FRONT
components, and prevents the PTU and propshaft WHEEL SLIP, FORWARD DIRECTION
joints from overheating. When the front wheels lose traction and begin to
slip, the propeller shaft and rear axle pinion speed
OPERATION difference decreases to zero. At this point the input
In order to achieve all-wheel drive operation in shaft (cam) becomes the driving member of the BOC
reverse, the overrunning clutch locking functional (Fig. 30), compressing the rollers against the outer
direction must be reversible. The bi-directional over- race. This locks the input shaft with the outer race
running clutch (BOC) changes the operational mode and transmits torque to the housing of the viscous
direction depending on the propeller shaft direction. coupler, that in turn transmits torque to the rear
The propeller shaft rotates in the clockwise (when axle pinion. It should also be noted that when the
viewed from the front) direction when the vehicle is device is locked, the inner shaft and the outer race
moving forward, which indexes the BOC to the for- are rotating at the same speed. The rollers are
ward overrunning position. When the vehicle is in pinched at this point and will stay locked until a
reverse, the propeller shaft will rotate counter-clock- torque reversal (no front wheel slip) occurs. When
wise and index the BOC to the reverse overrunning locked, the viscous coupler slips during the torque
position. transfer and the amount of torque transferred is
The BOC acts as a mechanical stator. It is active dependent on the coupling characteristic and the
(transmitting torque), or it is not active and in over- amount of front wheel slip.
running mode (not transmitting torque). This “all or
nothing” approach to torque transfer would cause a
sudden application of all available power to the rear
wheels, which is not desirable. Therefore it is run in
series with a viscous coupler to smooth, dampen, and
limit the transmission of torque to the rear axle and
to prevent a step style torque input to the rear axle.
Fig. 28 Bi-directional Overrunning Clutch and Viscous Coupler

1 - POWERFLOW - BOC OVERUNNING 6 - VISCOUS COUPLER
2 - POWERFLOW - BOC LOCKED 7 - BOC ROLLER CAGE
3 - BOC GROUND TAB 8 - BOC INPUT SHAFT
4 - FRICTION BRAKE SHOES 9 - INPUT FLANGE
5 - BOC ROLLERS
STEADY STATE, HIGH SPEED, NO WHEEL SLIP
The roller cage positions the rollers on the input
shaft flats during low and high speed overrunning
and during initial BOC lockup. The roller cage is
rotating at input shaft (propeller shaft) speed at all
times. At low speeds, the friction shoes (Fig. 31) are
pressed against the friction ground via the garter
spring (Fig. 32), creating a drag force on the roller
cage. The drag force positions the cage, which in turn
positions the rollers to one side of the flat. The direc-
tion of this drag force (position of the roller) is depen-
dent on the input (propeller shaft) rotational
direction. Since the rollers are always in contact with
the outer race, due to centrifugal forces, the rollers
want to follow the outer race due to drag. During
overrunning operation, the outer race is rotating
faster than the input; causing the rollers to want to
traverse the flat from one side to the other. During
low speeds, the brake shoes counteract this effect. To
avoid excessive wear, the ground shoes are designed
to lift off from the friction ground due to centrifugal
forces at higher rotational speeds.
Fig. 29 BOC Operation at Low Speeds With No
Front Wheel Slip
1 - CAGE
2 - ROLLER
3 - INPUT SHAFT
Fig. 31 Front View of BOC

1 - GARTER SPRING
2 - FRICTION BRAKE SHOES
3 - FRICTION GROUND CONNECTED TO GROUND TAB
4 - INPUT SHAFT
Fig. 30 BOC Operation with Front Wheel Slip

Fig. 32 Location of the Grounding Element

1 - DIFFERENTIAL HOUSING
2 - GROUND TAB
3 - GARTER SPRING
To keep the rollers in the overrunning position and

avoid undesired 9high speed lockup9, a high speed Fig. 33 BOC High Speed Latch (Not Engaged)
latch (Fig. 33) positions the cage before the ground 1 - TOOTH (TWO PLACES)
shoes lift off. A further explanation of the high speed 2 - GARTER SPRING
3 - TABS AT BOTH ENDS FIT INTO SLOTS IN CAGE
effects follows as well. Utilizing only the friction
4 - TWO PART DESIGN
shoes approach means that at high speed the
required ground shoe drag torque would cause exces-
sive brake shoe wear or the roller will begin to high speed latch is a one way device and does not
migrate to the opposite side of the flat due to the prevent high-speed lockup in the reverse direction. At
drag force of the outer race. This would result in sys- high speeds, the BOC provides the same function as
tem lock-up. (Fig. 34) shows the BOC as it crosses low speeds, transferring torque to the viscous coupler
the speed where the brake shoe force is overcome by only when front wheel slip overcomes the axle ratio
the roller drag on the outer race. Notice that the offset.
roller is locking up on the opposite side of the flat At high speed, the rollers are forced outward to the
and the cage supplies no force on the rollers. outer race because of centrifugal force. At high
This lock-up is not desired, and requires the use of speeds, the friction shoes can no longer prevent lock-
another mechanism to prevent the lock-up. The up. When the teeth on the high-speed latch engage
device that prevents undesired high-speed lock-up is into the input shaft, it keeps the rollers centered
called a 9high speed latch9. above the flats because the tabs on the latch are
Similar to the friction shoes, the two-piece high- locked into the cage. (Fig. 36) shows the roller config-
speed latch will separate from each other at high uration with the High-Speed Latch engaged.
rotational speeds due to centrifugal effects. (Fig. 35) On the BOC shaft, the high speed latch teeth lock
shows the high speed latch engaged. The gap 9x9 up in the grooved areas, shown in (Fig. 37), when the
increases with speed, eventually locking into one of turning speed reaches the critical value. (Fig. 37)
the slots in the BOC shaft. When the high-speed also shows the outer race/viscous coupler. Notice the
latch is activated (propeller shaft speed reaches X surface (outer race) the rollers mate against when
amount), the cage is partially fixed, and cannot lock transferring torque.
on the wrong side of the flat as shown (Fig. 34). The
Fig. 34 BOC Operation During High Speed Lock-up Without High Speed Latch
Fig. 35 High Speed Latch Engaged Fig. 36 BOC Operation at High Speed with High
1 - CAGE FORCE EXERTED BY ROLLERS AT HIGH SPEED Speed Latch
Fig. 38 Differential Operation—Straight Ahead

Fig. 37 BOC Input Shaft Driving
1 - GROOVED AREA (2 LOCATIONS) 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - ROLLER MATING SURFACE
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
DIFFERENTIAL ASSEMBLY
When turning corners, the outside wheel must
DESCRIPTION travel a greater distance than the inside wheel to
The differential gear system divides the torque
complete a turn. The difference must be compensated
between the axle shafts. It allows the axle shafts to
for to prevent the tires from scuffing and skidding
rotate at different speeds when turning corners.
through turns. To accomplish this, the differential
Each differential side gear is splined to an axle
allows the axle shafts to turn at unequal speeds (Fig.
shaft. The pinion gears are mounted on a pinion
39). In this instance, the input torque applied to the
mate shaft and are free to rotate on the shaft. The
pinion gears is not divided equally. The pinion gears
pinion gear is fitted in a bore in the differential case
now rotate around the pinion mate shaft in opposite
and is positioned at a right angle to the axle shafts.
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
OPERATION speed.
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear
• The ring gear (bolted to the differential case)
rotates the case
• The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig.
38).
Fig. 39 Differential Operation—On Turns

1 - PINION GEARS ROTATE ON PINION SHAFT
FLUID - DIFFERENTIAL The correct fill level is to the bottom of the fill plug
hole. Be sure the vehicle is on a level surface, or is
ASSEMBLY hoisted in a level manner, in order to obtain the cor-
rect fill level.
STANDARD PROCEDURE - DIFFERENTIAL (1) Raise the vehicle on a hoist.
ASSEMBLY FLUID CHANGE (2) Position a drain pan under the differential
The drain plug (Fig. 40) for the differential assem- drain plug (Fig. 40).
bly is located in the bottom of the differential assem- (3) Remove the drain plug and allow the fluid to
bly case, toward the rear of the unit. drain into the pan.
(4) Install the drain plug and torque to 35 N·m (26
ft. lbs.).
(5) Re-position the drain pan under the differential
fill plug.
(6) Remove the differential fill plug (Fig. 41).
(7) Using a suction gun (Fig. 42) or equivalent, fill
the differential assembly with 0.7 L (1.48 pts.) of
Mopart Gear and Axle Lubricant (80W-90).
(8) Install the fill plug and torque to 35 N·m (26 ft.
lbs.).
Fig. 40 Differential Drain Plug

1 - DIFFERENTIAL DRAIN PLUG
The fill plug (Fig. 41) for the differential assembly

is located on the rear of the assembly case.
Fig. 42 Filling Differential

1 - DIFFERENTIAL ASSEMBLY
2 - SUCTION GUN
FLUID
STANDARD PROCEDURE - OVERRUNNING
CLUTCH HOUSING FLUID CHANGE
(1) Raise vehicle on hoist.
(2) Position a drain pan under overrunning clutch
housing drain plug.
Fig. 41 Differential Fill Plug

1 - DIFFERENTIAL FILL PLUG
FLUID (Continued)
(3) Remove overrunning clutch housing drain plug
and drain fluid (Fig. 43).
Fig. 45 Filling Overrunning Clutch Case

1 - OVERRUNNING CLUTCH HOUSING FILL HOLE
Fig. 43 Overrunning Clutch Case Drain Plug 2 - SUCTION GUN
1 - OVERRUNNING CLUTCH HOUSING DRAIN PLUG
VISCOUS COUPLER
(4) Install the drain plug and torque to 30 N·m (22
ft. lbs.). DESCRIPTION
(5) Re-position the drain pan under the overrun- The heart of the all-wheel drive system is the inter-
ning clutch housing fill plug. axle viscous coupling and bi-directional overrunning
(6) Remove fill plug (Fig. 44). clutch. Under normal driving the vehicle retains pre-
dominantly front wheel drive characteristics. The all-
wheel drive takes effect when the front wheels start to
slip. Under normal level road, straight line driving,
100% of the torque is allocated to the front wheels.
The viscous coupler allows more torque to the rear
wheels in accordance with the amount of slippage at
the front wheels. The variable torque distribution is
automatic with no driver inputs required.
OPERATION
The viscous coupler (Fig. 46) is a housing nearly
filled with a high viscosity silicone liquid and thin
metal plates alternately splined to an inner and
outer drum. The viscous coupler provides torque in
the following modes:
• Shear mode (normal operation)
• Hump mode (locked mode)
The inner plates are slotted around the radius and
Fig. 44 Overrunning Clutch Housing Fill Plug the outer plates have holes in them. In the shear
mode (normal operation), the plates are evenly
1 - OVERRUNNING CLUTCH HOUSING FILL PLUG
2 - FUEL TANK
spaced and the torque is created by the shearing of
the plates through the fluid and 90-100% of the
torque is applied to the rear axle. During the shear
(7) Using a suction gun (Fig. 45), add 0.58 L (1.22 mode, a fluid flow pattern is created from this design
pts.) of Mopart ATF+4 (Automatic Transmission Flu- (holes and slots). This fluid flow causes high pressure
id—Type 9602). on each side of each pair of plates and low pressure
(8) Install fill plug and torque to 30 N·m (22 ft. lbs.). between each pair of plates.
VISCOUS COUPLER (Continued)
Fig. 46 Bi-directional Overrunning Clutch (BOC) and Viscous Coupler Powerflow

1 - POWERFLOW - BOC OVERUNNING 6 - VISCOUS COUPLER
2 - POWERFLOW - BOC LOCKED 7 - BOC ROLLER CAGE
3 - BOC GROUND TAB 8 - BOC INPUT SHAFT
4 - FRICTION BRAKE SHOES 9 - INPUT FLANGE
5 - BOC ROLLERS
VISCOUS COUPLER (Continued)
When a high speed difference (shear) occurs INPUT FLANGE SEAL
because of loss of traction (one axle spinning faster
than the other), the silicone fluid expands as it heats
REMOVAL
from this shearing. When the silicone expands to fill
the viscous coupler completely, this pressure differ-
(2) Remove propeller shaft. (Refer to 3 - DIFFER-
ence is high enough to squeeze each pair of plates
together. The resulting hump torque is up to 8 times
REMOVAL)
higher than the shear torque. When the viscous cou-
(3) Using tool 6958, remove input flange nut and
pler is in the hump mode, it does not lock the axles
washer (Fig. 48).
(undifferentiated 4-Wheel Drive). It controls the
amount of slippage while delivering maximum power
to the axle having greatest traction. Once the speed
difference equalizes the fluid and plates cool down
and the viscous coupler goes back to the shear mode.
TORQUE ARM
REMOVAL
(2) Remove rear driveline module assembly. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIV-
ELINE MODULE - REMOVAL)
(3) Remove six torque arm-to-differential assembly
bolts (Fig. 47). Remove torque arm.

1 - INPUT FLANGE
2 - TOOL 6958
(4) Remove input flange (Fig. 49).

(5) Using suitable screwdriver, remove input
flange seal from overrunning clutch housing (Fig.
50).
INSTALLATION
(1) Using tool 8802, install input flange seal to
overrunning clutch case (Fig. 51).
(2) Install input flange (Fig. 52).
(3) Install flange nut and washer. Using tool 6958,
torque flange nut to 135 N·m (100 ft. lbs.) (Fig. 53).
Fig. 47 Torque Arm Fasteners (4) Install propeller shaft. (Refer to 3 - DIFFER-
1 - TORQUE ARM ASSEMBLY ENTIAL & DRIVELINE/PROPELLER SHAFT -
2 - BOLT (SIX) INSTALLATION)
(5) Lower vehicle.
INSTALLATION
(1) Install six torque arm-to-differential assembly
bolts (Fig. 47) and torque to 60 N·m (44 ft. lbs.).
(2) Install rear driveline module assembly. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIV-
ELINE MODULE - INSTALLATION)
(3) Lower vehicle.
INPUT FLANGE SEAL (Continued)
Fig. 49 Input Flange Fig. 51 Input Flange Seal Installation

1 - INPUT FLANGE/SHIELD 1 - TOOL 8802
2 - HAMMER
Fig. 50 Input Flange Seal Removal

1 - INPUT FLANGE SEAL Fig. 52 Input Flange
2 - SCREWDRIVER 1 - INPUT FLANGE/SHIELD
INPUT FLANGE SEAL (Continued)

1 - INPUT FLANGE
2 - TOOL 6958
Fig. 55 Output Flange Removal

OUTPUT FLANGE SEAL 1 - WOOD BLOCK
2 - PRYBAR
3 - OUTPUT SHAFT
REMOVAL 4 - PRYBAR
(1) Raise vehicle on hoist. 5 - WOOD BLOCK
(2) Remove rear halfshaft inner joint at differen- 6 - DIFFERENTIAL CASE
tial output flange (Fig. 54).
Fig. 54 Inner Half Shaft Bolts

1 - SHAFT
2 - FLANGE
Fig. 56 Output Flange Seal Removal
(3) Using two screwdrivers and wood blocks to pro- 1 - OUTPUT FLANGE SEAL
tect differential housing casting, pry output flange 2 - SCREWDRIVER
out of differential (Fig. 55).
(4) Use suitable screwdriver to remove output
flange seal (Fig. 56).
OUTPUT FLANGE SEAL (Continued)
INSTALLATION (2) Install ouput flange to differential assembly.

(1) Install output flange seal to differential hous- Verify that it is seated all the way into position by
ing using tool C4171A and 8493 (Fig. 57). attempting to pull out by hand.
(3) Install rear halfshaft inner joint to output
flange.
(4) Install and torque bolts to 61 N·m (45 ft. lbs.)
(Fig. 58).
Fig. 57 Output Flange Seal Installation

1 - DRIVER HANDLE C4171 Fig. 58 Inner Half Shaft Bolts
2 - INSTALLER 8493 1 - SHAFT
2 - FLANGE
(5) Check differential assembly fluid level and

adjust as required. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/REAR DRIVELINE MODULE/FLUID -
STANDARD PROCEDURE)
RS BRAKES 5-1
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISC BRAKE CALIPERS - FRONT
CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 3 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . 6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DISC BRAKE CALIPERS - REAR
BRAKE FLUID LEVEL SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
HYDRAULIC/MECHANICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DISC BRAKE CALIPER ADAPTER
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 12 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DRUM BRAKE AUTOMATIC ADJUSTER . . . . . . 12 DISC BRAKE CALIPER GUIDE PINS
BRAKE LINES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DRUM
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 31
BRAKE PADS/SHOES - FRONT BRAKE DRUM MACHINING . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 FLUID
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 31
BRAKE PADS/SHOES - REAR DISC BRAKE FLUID CONTAMINATION . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 32
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 BRAKE FLUID LEVEL CHECKING . . . . . . . . . . 32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BRAKE PADS/SHOES - REAR DRUM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-2 BRAKES - BASE RS
JUNCTION BLOCK BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . 44

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BRAKE ROTOR MACHINING . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MASTER CYLINDER SUPPORT PLATE - DRUM BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 49
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 34 WHEEL CYLINDERS
MASTER CYLINDER BLEEDING . . . . . . . . . . . 34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PARKING BRAKE
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
POWER BRAKE BOOSTER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PARKING BRAKE AUTOMATIC ADJUSTER
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 38 MECHANISM RELEASE . . . . . . . . . . . . . . . . . . 51
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 38 PARKING BRAKE AUTOMATIC ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 LEVER - PARKING BRAKE
PROPORTIONING VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SHOES - PARKING BRAKE
PROPORTIONING VALVE (HEIGHT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SENSING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 CABLES - PARKING BRAKE
ROTORS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 44 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 66
BRAKES - BASE For information on the brake lamp switch, (Refer

to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)
DESCRIPTION - BASE BRAKES
Vehicles equipped with the optional antilock brake
The base brake system consists of the following
system (ABS) use a system designated Mark 20e. It
components:
is available with or without traction control. This
• Brake pedal
system shares most base brake hardware used on
• Power brake booster
vehicles without ABS. ABS components are described
• Master cylinder
in detail in ANTILOCK BRAKE SYSTEM.
• Brake tubes and hoses
• Proportioning valve (non-ABS vehicles only)
• Disc brakes
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
• Drum brakes
applies the brake pedal. The brake pedal pushes the
• Brake lamp switch
input rod of the power brake booster into the booster.
• Brake fluid level switch
The booster uses vacuum to ease pedal effort as force
• Parking brakes
is transferred through the booster to the master cyl-
Front disc brakes control the braking of the front
inder. The booster’s output rod pushes in the master
wheels; rear braking is controlled by rear drum
cylinder’s primary and secondary pistons applying
brakes or rear disc brakes depending on options.
hydraulic pressure through the chassis brake tubes
The hydraulic brake system is diagonally split on
to the brakes at each tire and wheel assembly.
both the non-antilock braking systems and antilock
The parking brakes are foot-operated. When
braking systems. That means the left front and right
applied, the parking brake lever pulls on cables that
rear brakes are on one hydraulic circuit and the right
actuate brake shoes at each rear wheel. These shoes
front and left rear are on the other.
come in contact with a hub mounted drum (drum for
RS BRAKES - BASE 5-3
BRAKES - BASE (Continued)
disc/drum brakes or drum-in-hat for disc/disc brakes) 1), for the installation of any metal fasteners into
and hold it in place. the shock tower. Because of the minimum clear-
ance in this area (Fig. 1), installation of metal fas-
teners could damage the coil spring coating and
lead to a corrosion failure of the spring. If a plastic
WARNING: DUST AND DIRT ACCUMULATING ON clip is missing, or is lost or broken during servicing
BRAKE PARTS DURING NORMAL USE MAY CON- a vehicle, replace only with the equivalent part
TAIN ASBESTOS FIBERS FROM PRODUCTION OR listed in the Mopar parts catalog.
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
Fig. 1 Shock Tower To Spring Minimum Clearance
(OSHA) AND THE ENVIRONMENTAL PROTECTION
Area
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY 1 - SHOCK TOWER
2 - COIL SPRING
CONTAIN ASBESTOS FIBERS.
3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER
METAL FASTENERS ARE TO BE INSTALLED INTO SHOCK
TOWER IN THIS AREA. ALSO, NO HOLES ARE TO BE DRILLED
INTO SHOCK TOWER IN THIS SAME AREA.
CAUTION: During service procedures, grease or CAUTION: Only the recommended jacking or hoist-
any other foreign material must be kept off brake ing positions for this vehicle are to be used when-
shoe assemblies, and braking surfaces of brake ever it is necessary to lift a vehicle. Failure to raise
rotor or drum, and external surfaces of hub and a vehicle from the recommended locations could
bearing assembly. result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
CAUTION: Handling of brake rotors and calipers
in damage to the mounting bracket and the hydrau-
must be done in such a way as to avoid damage to
lic control unit.
the rotor and scratching or nicking of brake lining
on the brake shoes.
DIAGNOSIS AND TESTING - BASE BRAKE
CAUTION: At no time when servicing a vehicle, can SYSTEM
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an NOTE: There are three diagnosis charts following
original plastic clip. Also, NO holes can be drilled that cover the RED BRAKE WARNING INDICATOR
into the front shock tower in the area shown in (Fig. LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
RED BRAKE WARNING 1. Parking brake lever not fully 1. Release parking brake lever.
LAMP ON released.
2. Parking brake warning lamp 2. Inspect and replace switch as necessary.
switch on parking brake lever.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster 5. Refer to appropriate Diagnostic
(MIC) problem. information.
6. Amber ABS Warning Indicator 6. Refer to appropriate Diagnostic
Lamp also illuminated. information.
BRAKE NOISE

CLICK OR SQUAWK ON 1. Brake lamp switch. 1. Replace switch.
PEDAL APPLICATION
2. Brake Transmission Shift Interlock 2. Lubricate BTSI linkage.
Linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper 2. Lubricate brake caliper slides.
slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR 1. Broken or missing anti-rattle 1. Replace brake shoes.
CLUNK spring clips on shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT 1. Brake shoe linings. 1. Replace brake shoes.
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe 1. Lubricate shoe contact areas on brake
support plate where shoes ride. shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined 1. Reface or replace drake drums as
braking surface. necessary.
DRUM BRAKE HOWL OR 1. Lack of lubricant on brake shoe 1. Lubricate shoe contact areas on brake
MOAN support plate where shoes ride and shoe support plates and at the anchor.
at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING 1. ABS wheel speed sensor or tone 1. Inspect, correct or replace faulty
OR WHIRRING wheel. component(s).

SCRAPING (METAL-TO- 1. Foreign object interference with 1. Inspect brakes and remove foreign
METAL). brakes. object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
BRAKES CHATTER 1. Rear brake drum out of round or 1. Isolate condition as rear or front.
disc brake rotor has excessive Reface or replace brake drums or
thickness variation. rotors as necessary.
BRAKES DRAG (FRONT 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
OR ALL) system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted 5. Straighten mounting bracket and
properly and mounting bracket is bent. replace brake lamp switch.
BRAKES DRAG (REAR 1. Parking brake cables binding or 1. Check cable routing. Replace cables
ONLY) froze up. as necessary.
2. Parking brake cable return spring 2. Replace cables as necessary.
not returning shoes.
3. Service brakes not adjusted 3. Follow the procedure listed in the
properly (rear drum brakes only). adjustment section.
4. Rear disc brake parking brake not Adjust parking brake shoes.
properly adjusted.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster 2. Refer to power brake booster
assist. diagnosis and testing.
EXCESSIVE PEDAL 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.

EFFORT
2. Low power brake booster assist 2. Refer to power brake booster
(vacuum leak). diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake 4. Reface or replace brake rotors as
rotor. necessary. Replace brake shoes.
EXCESSIVE PEDAL 1. Air in brake lines. 1. Bleed brakes.

TRAVEL (VEHICLE
STOPS OK)
2. Rear drum brake auto-adjuster 2. Inspect and replace drum brake
malfunctioning. components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL 1. One of the two hydraulic circuits to 1. Inspect system for leaks. Check
TRAVEL (ONE FRONT the front brakes is malfunctioning. master cylinder for internal malfunction.
WHEEL LOCKS UP
DURING HARD
BRAKING)
PEDAL PULSATES/ 1. Rear brake drum out of round or 1. Isolate condition as rear or front.
SURGES DURING disc brake rotor has excessive Reface or replace brake drums or
BRAKING thickness variation. rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.

2. Power brake booster runout 2. Check booster vacuum hose and
(vacuum assist). engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
WHEEL LOCKUP Repair source of contamination.
2. Inoperative proportioning valve 2. Refer to proportioning valve
(non-ABS vehicles). diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster 3. Refer to power brake booster in the
assist. diagnosis and testing section.
STOP/BRAKE LAMPS 1. Brake lamp switch out of 1. Replace brake lamp switch.
STAY ON adjustment.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing 4. Replace power brake booster.
pedal to return completely.
VEHICLE PULLS TO 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
RIGHT OR LEFT ON Bleed brakes.
BRAKING
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE - 1. Rear drum brakes or rear disc 1. Adjust rear drum brake shoes, or
EXCESSIVE HANDLE brake parking brake shoes out of rear parking brake shoes on vehicles
TRAVEL adjustment. with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
BLEEDING
der fluid reservoir to prevent dirt and other foreign
NOTE: This bleeding procedure is only for the vehi- matter from dropping into the master cylinder fluid
cle’s base brakes hydraulic system. For bleeding reservoir.
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)
NOTE: The following wheel sequence should be CAUTION: “Just cracking” the bleeder screw often
used when bleeding the brake hydraulic system. restricts fluid flow, allowing only a slow, weak fluid
The use of this wheel sequence will ensure ade- discharge of fluid. This practice will NOT get all the
quate removal of all trapped air from the brake air out. Make sure the bleeder is opened at least 1
hydraulic system. full turn when bleeding.
• Left Rear Wheel (3) Release the brake pedal only after the bleeder
• Right Front Wheel screw is closed.
• Right Rear Wheel (4) Repeat steps 1 through 3, four or five times, at
• Left Front Wheel each bleeder screw in the proper sequence. This
should pass a sufficient amount of fluid to expel all
NOTE: When bleeding the brake system, some air the trapped air from the brake system. Be sure to
may be trapped in the brake lines or valves far monitor the fluid level in the master cylinder, so it
upstream, as much as ten feet from the bleeder stays at a proper level so air will not enter the brake
screw (Fig. 2). Therefore, it is essential to have a system through the master cylinder.
fast flow of a large volume of brake fluid when (5) Check pedal travel. If pedal travel is excessive
bleeding the brakes to ensure all the air gets out. or has not been improved, enough fluid has not
passed through the system to expel all the trapped
air. Continue to bleed system as necessary.
(6) Perform a final adjustment of the rear brake
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid.
PRESSURE BLEEDING PROCEDURE

CAUTION: Use bleeder tank Special Tool C-3496-B
or equivalent with Adapter, Special Tool 6921, to
pressurize the hydraulic system for bleeding.
Follow pressure bleeder manufacturer’s instruc-

tions for use of pressure bleeding equipment.
Fig. 2 Trapped Air In Brake Fluid Line
(1) Install the Adapter Master Cylinder Pressure
1 - TRAPPED AIR
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 3). Attach the fluid hose
The brakes may be manually bled or pressure bled. from the pressure bleeder to the fitting on Special
Refer to the appropriate following procedure. Tool 6921.
(2) Attach a clear plastic hose to the bleeder screw
MANUAL BLEEDING PROCEDURE at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid.
NOTE: Correct manual bleeding of the brakes (3) Open the left rear wheel bleeder screw at least
hydraulic system will require the aid of a helper. one full turn or more to obtain an adequate flow of
brake fluid.
NOTE: To adequately bleed the brakes using the CAUTION: “Just cracking” the bleeder screw often
manual bleeding procedure the rear brakes must be restricts fluid flow, allowing only a slow, weak fluid
correctly adjusted. Prior to the manual bleeding of discharge of fluid. This practice will NOT get all the
the brake hydraulic system, correctly adjust the air out. Make sure the bleeder is opened at least 1
rear brakes. full turn when bleeding.
(1) Pump the brake pedal three or four times and (4) After 4 to 8 ounces of brake fluid has been bled
hold it down before the bleeder screw is opened. through the hydraulic system, and an air-free flow is
(2) Push the brake pedal toward the floor and hold maintained in the hose and jar, this will indicate a
it down. Then open the left rear bleeder screw at good bleed of the hydraulic system has been
least 1 full turn. When the bleeder screw opens the obtained.
brake pedal will drop all the way to the floor. (5) Repeat the procedure at all the other remain-
ing bleeder screws.
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Disc Brake Caliper Guide 35 26 —
Pin Bolts
Disc Brake Caliper Bleeder 15 — 125
Screw
Drum Brake Wheel Cylinder 8 — 75
Mounting Bolts
Drum Brake Wheel Cylinder 10 — 80
Mounting Bleeder screw
Drum Brake Support Plate 130 95 —
Mounting Bolts
Junction Block (Non-ABS 28 21 250
Brakes) Mounting Bolts
Fig. 3 TOOL 6921 INSTALLED ON MASTER Master Cylinder Mounting 25 19 225
CYLINDER Nuts
Power Brake Booster 28 21 250
2 - FLUID RESERVOIR
Mounting Nuts
Proportioning Valve 54 40 —
(6) Check pedal travel. If pedal travel is excessive
Mounting Bolts
or has not been improved, enough fluid has not
passed through the system to expel all the trapped Proportioning Valve Axle 20 — 175
air. Be sure to monitor the fluid level in the pressure Bracket Mounting Bolt
bleeder, so it stays at a proper level so air will not Parking Brake Lever (Pedal) 28 21 250
enter the brake system through the master cylinder. Mounting Bolts And Nut
(7) Perform a final adjustment of the rear brake Wheel Mounting (Lug) Nuts 135 100 —
shoes (when applicable), then test drive vehicle to be
sure brakes are operating correctly and that pedal is
solid. SPECIAL TOOLS
SPECIFICATIONS BASE BRAKE SYSTEM
BRAKE FASTENER TORQUE
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
ABS ICU Mounting Bolts To
11 — 97
Bracket
ABS ICU Mounting
28 21 250
Bracket-To-Cradle Bolts
Tubes, Master Cylinder Bleeding 6920
ABS CAB-To-HCU Mounting
2 — 17
Screws
ABS Wheel Speed Sensor
12 — 105
Mounting Bolt
Brake Tube Nuts 17 — 145
Brake Hose Intermediate 12 — 105
Bracket Bolt
Brake Hose-To-Caliper 47 35 —
Mounting Bolt
Installer, Dust Boot C-4689 or C-4842
BRAKE FLUID LEVEL SWITCH

Tubes, Master Cylinder Bleed 8358
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 4).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:
Adapter, Master Cylinder Pressure Bleed Cap 6921 • Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system.
• Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
Dial Indicator, C-3339 ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid. If
the brake fluid level has dropped below the add
line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
Gauge, Brake Safe-Set REMOVAL

(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 4).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch.
(3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.
(2) Connect vehicle wiring harness connector to
Handle, Universal C–4171 brake fluid level switch (Fig. 4).
5 - 10 BRAKES - BASE RS
BRAKE FLUID LEVEL SWITCH (Continued)
Fig. 4 MASTER CYLINDER AND BOOSTER Fig. 5 FRONT DISC BRAKE CALIPERS
1 - POWER BRAKE BOOSTER 1 - CONTINENTAL TEVES CALIPER (66 mm bore)
2 - BOOSTER IDENTIFICATION LABEL 2 - TRW CALIPER (64 mm bore)
3 - FLUID LEVEL SWITCH CONNECTOR 3 - GUIDE PIN BOLT
4 - PRIMARY BRAKE TUBE NUT 4 - GUIDE PIN AND BOOT
5 - SECONDARY BRAKE TUBE NUT 5 - CALIPER ADAPTER
6 - MASTER CYLINDER 6 - GUIDE PIN BOLT
7 - GUIDE PIN BUSHING
8 - CALIPER ADAPTER
HYDRAULIC/MECHANICAL
DESCRIPTION - DISC BRAKES (FRONT)
Each front disc brake consists of the following com-
ponents:
• Brake Rotor
• Brake Caliper
• Brake Caliper Adapter
• Shoes (Pads)
There are two non-interchangeable front disc brake
systems depending on whether the vehicle is
equipped with rear drum or rear disc brakes. Vehi-
cles with the front disc/rear drum brake combination
utilize a system manufactured by TRW. Vehicles with
front disc/rear disc brakes utilize a system manufac-
tured by Continental Teves.
CAUTION: Components used on the disc/drum Fig. 6 Guide Pins And Boots
combination brakes are not interchangeable with 1 - PINS
the disc/disc combination brakes. The two different 2 - BOOTS
systems must not be mixed. Improper performance,
noise and increased stopping distance can occur.
eter bore (Fig. 5) with a phenolic piston. The caliper
The TRW front brake caliper is a one piece casting mounts to a caliper adapter using two guide pin bolts
containing a single 64 mm diameter piston bore (Fig. that thread into the caliper adapter and slide on
5) with a phenolic piston. The caliper mounts to a bushings mounted in the caliper.
caliper adapter using two guide pin bolts that thread
CAUTION: TRW and Continental Teves calipers are
into guide pins slid into the caliper adapter (Fig. 6).
not interchangeable. Each caliper is specifically
The pins are lubricated and have boots that seal
designed for the unique brake system. If calipers
them in place in the adapter.
are interchanged, improper performance, noise and
The Continental Teves front brake caliper is a one
increased stopping distance can occur.
piece casting containing a single piston 66 mm diam-
RS BRAKES - BASE 5 - 11
HYDRAULIC/MECHANICAL (Continued)
The two different brake calipers use different
devices to control rattling. While the TRW brakes use
spring clips that mount at the ends of the shoes in
the adapters, Continental Teves brakes use a clip on
the rear of the inboard pad to hold it to the piston
and a larger clip on the outside of the caliper, holding
it to the adapter (Fig. 7).
Fig. 8 Externally and Internally Vented Rotors

(Cross-Sectional View)
1 - EXTERNAL VENTS (TRW)
2 - INTERNAL VENTS (Continetal Teves)
Fig. 7 ANTI-RATTLE DEVICES ON CALIPERS

1 - CONTINENTAL TEVES CALIPER
2 - TRW CALIPER
3 - ANTI-RATTLE CLIP
4 - ANTI-RATTLE CLIP
All brake caliper adapters mount to the steering

knuckle in the same way using two mounting bolts.
The brake rotors are also different depending on
brake system. The TRW (disc/drum) front brakes uti-
lize an inverted-hat style rotor. This rotor is exter-
nally vented meaning the inner most diameter of the
braking disc vents to the outboard side (or face) of
the rotor (Fig. 8). The Continental Teves (disc/disc)
front brakes utilize the familiar internally-vented hat
style rotor. Internally-vented refers to the fact that
the inner most diameter of the braking disc vents to
the inboard side of the rotor (Fig. 8). Fig. 9 Rear Disc Brakes
1 - CALIPER
CAUTION: TRW and Continental Teves brake rotors 2 - COTTER PIN
are not interchangeable. If brake rotors are inter- 3 - ROTOR
changed, noise and wear problems can result. 4 - NUT RETAINER
5 - OUTER C/V JOINT
DESCRIPTION - DISC BRAKES (REAR) drum-in-hat style because of its dual role as a brak-
There are several distinctive features to the rear ing disc and parking brake drum.
disc brakes on this vehicle (Fig. 9). The single piston, The parking brake system on vehicles equipped
floating caliper rear disc brake system includes a hub with rear disc brakes consists of a small duo-servo
and bearing assembly, adapter, rotor, caliper, and drum brake mounted to the caliper adapter and uses
brake shoes. the interior of the rear disc brake rotor as a drum
This vehicle is equipped with a caliper having a 42 (hat section of drum-in-hat style brake rotor).
mm (1.65 in.) piston and uses a 15 inch solid non-
vented brake rotor. The brake rotor is described as a
The outboard rear disc brake shoes (pads) are side- As disc brake shoe linings wear, master cylinder
oriented. The shoes are marked indicating which side reservoir brake fluid level will drop. Adjust as neces-
they belong on. sary. Fluid level should always be checked after
replacing shoes.
DESCRIPTION - DRUM BRAKES (REAR)
This vehicle’s rear wheel drum brakes are a two-
shoe, internal-expanding type with an automatic
adjuster screw. The automatic adjuster screw is
located directly below the wheel cylinder that is
mounted near the top of the brake assembly (Fig.
10). These and two brake shoes (and attaching parts)
are mounted to a support plate at each rear wheel. A
brake drum covers each brake assembly.
Fig. 11 Caliper Piston Seal Function For Automatic

Adjustment
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
OPERATION - DISC BRAKES (REAR)

The rear disc brakes operate similarly to front disc
brakes, however, there are some features that require
Fig. 10 Drum Brake Assembly (Right Shown) different service procedures.
1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING DIAGNOSIS AND TESTING - DRUM BRAKE
3 - AUTOMATIC ADJUSTER LEVER AUTOMATIC ADJUSTER
4 - TENSION CLIP
The rear drum brakes on this vehicle automatically
5 - AUTOMATIC ADJUSTER ASSEMBLY
adjust when required during the normal operation of
the vehicle every time the brakes are applied. Use
OPERATION - DISC BRAKES (FRONT) the following procedure to test the operation of the
When the brakes are applied, fluid pressure is sent automatic adjuster.
to each brake caliper. The pressure at the caliper is Place the vehicle on a hoist with a helper in the
exerted equally against the caliper piston. The pres- driver’s seat to apply the brakes. Remove the access
sure applied to the piston is transmitted directly to plug from the adjustment hole in each brake support
the inboard brake shoe. This forces the shoe lining plate to provide visual access of the brake adjuster
against the inner surface of the brake rotor. At the star wheel.
same time, fluid pressure within the caliper piston To eliminate the condition where maximum adjust-
bore forces the caliper to slide inward on its guide ment of the rear brake shoes does not allow the auto-
pins. This action brings the outboard shoe lining into matic adjuster to operate when tested, back the star
contact with the outer surface of the brake rotor. wheel off approximately 30 notches. It will be neces-
This pressure on both sides of the brake rotor causes sary to hold the adjuster lever away from the star
friction, bringing the vehicle to a stop. wheel to permit this adjustment.
When the brake pedal is released, so is the fluid Have the helper apply the brakes. Upon applica-
pressure. The piston seal inside the caliper is tion of the brake pedal, the adjuster lever should
designed to pull the piston back into the bore of the move down, turning the adjuster star wheel. Thus, a
caliper when the brake pedal is released (Fig. 11). definite rotation of the adjuster star wheel can be
This action helps maintain the proper brake shoe-to-
rotor clearance.
observed if the automatic adjuster is working prop- BRAKE PADS/SHOES - FRONT
erly. If one or more adjusters do not function prop-
erly, the respective drum must be removed for
REMOVAL - FRONT DISC BRAKE SHOES
adjuster servicing.
(DISC/DISC BRAKES)
(1) Raise the vehicle. (Refer to LUBRICATION &
BRAKE LINES MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
DESCRIPTION - BRAKE TUBES AND HOSES (2) Remove both front wheel and tire assemblies.
The brake tubes are steel with a corrosion-resis- (3) Begin on one side of the vehicle.
tant nylon coating applied to the external surfaces. (4) Remove the anti-rattle clip from the outboard
The flex hoses are made of reinforced rubber with fit- side of the caliper and adapter.
tings at each end. (5) Remove the two caliper guide pin bolts.
The primary and secondary brake tubes leading (6) Remove caliper from caliper adapter and brake
from the master cylinder to the ABS ICU Hydraulic rotor.
Control Unit (HCU) or the non-ABS junction block
have a special flexible section. This flexible section is CAUTION: Supporting weight of caliper by the flex-
required due to cradle movement while the vehicle is ible brake fluid hose can damage the hose.
in motion (The ICU and non-ABS junction block are
(7) Using wire or cord, hang the caliper from the
mounted to the cradle). If replacement of these
front strut assembly (Fig. 12). Support the caliper
lines is necessary, only the original factory
firmly to prevent weight of caliper from being sup-
brake line containing the flexible section must
ported by the brake fluid hose.
be used.
OPERATION - BRAKE TUBES AND HOSES

The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle’s suspension.
INSPECTION - BRAKE TUBES AND HOSES

Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
Fig. 12 Stored Front Disc Brake Caliper
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme- 1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
diately. Eventual deterioration of the hose can take
3 - CALIPER ASSEMBLY
place with possible burst failure. Faulty installation
4 - WIRE HANGER
can cause twisting, resulting in wheel, tire, or chassis 5 - STRUT ASSEMBLY
interference.
The brake tubing should be inspected periodically
for evidence of physical damage or contact with mov- (8) Remove the outboard brake shoe from the cali-
ing or hot components. per adapter.
The flexible brake tube sections used on this vehi- (9) Pull the inboard brake shoe away from the cal-
cle in the primary and secondary tubes from the iper piston until the retaining clip on shoe is free
master cylinder to the ABS hydraulic control unit from the cavity in the caliper piston (Fig. 13).
connections must also be inspected. This flexible tub- (10) Repeat the above procedure on other side of
ing must be inspected for kinks, fraying and contact the vehicle.
with other components or with the body of the vehi-
cle.
BRAKE PADS/SHOES - FRONT (Continued)
Fig. 13 Removing Inboard Shoe Fig. 14 Brake Caliper Mounting (Typical)

1 - INBOARD BRAKE SHOE 1 - BRAKE HOSE
2 - HANGER WIRE 2 - ADAPTER MOUNTING BOLTS
3 - CALIPER ASSEMBLY 3 - BANJO BOLT
4 - RETAINING CLIP 4 - CALIPER GUIDE PIN BOLTS
5 - PISTON
REMOVAL - FRONT DISC BRAKE SHOES DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
(DISC/DRUM BRAKES) ING ASBESTOS FIBERS IN AN IMPERMEABLE
(1) Raise the vehicle. Refer to HOISTING in CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LUBRICATION AND MAINTENANCE. LOW PRACTICES PRESCRIBED BY THE OCCUPA-
NOTE: Perform Step 2 through Step 5 on each side (OSHA) AND THE ENVIRONMENTAL PROTECTION
of the vehicle. AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
(2) Remove the front tire and wheel assembly.
(3) Remove the two brake caliper guide pin bolts
(Fig. 14).
(4) Remove the disc brake caliper from the disc INSPECTION - DISC BRAKE SHOES
brake adapter and hang out of the way using wire or Visually inspect brake shoes (pads) for uneven lin-
a bungee cord. Use care not to overextend the brake ing wear. Also inspect for excessive lining deteriora-
hose when doing this. tion. Check the clearance between the tips of the
(5) Remove the brake shoes from the disc brake wear indicators on the shoes (if equipped) and the
caliper adapter. brake rotors.
If a visual inspection does not adequately deter-
CLEANING - DISC BRAKE SHOES mine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear,
WARNING: DUST AND DIRT ACCUMULATING ON
remove the disc brake shoes from the calipers.
BRAKE PARTS DURING NORMAL USE MAY CON-
Measure each brake shoe. The combined brake
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
shoe and its lining material thickness should be mea-
sured at its thinnest point.
• For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95
mm (5/16 inch), they should be replaced.
• For rear disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.0
mm (9/32 inch), they should be replaced.
Replace both disc brake shoes (inboard and out-
board) on each caliper. It is necessary to replace the
BRAKE PADS/SHOES - FRONT (Continued)
shoes on the opposite side of the vehicle as well as (15) Road test the vehicle and make several stops
the shoes failing inspection. to wear off any foreign material on the brakes and to
If the brake shoe assemblies do not require seat the brake shoes.
replacement, be sure to reinstall the brake shoes in
the original position they were remove from. INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DRUM BRAKES)
INSTALLATION - FRONT DISC BRAKE SHOES
(DISC/DISC BRAKES) NOTE: Perform steps Step 1 through Step 5on each
(1) Begin on one side of the vehicle or the other. side of the vehicle.
(2) Completely retract the caliper piston back into
its bore in the brake caliper (This is required for cal- (1) Place the brake shoes in the adapter anti-rattle
iper installation on the brake rotor with new brake clips.
shoes installed). (2) Completely retract the caliper piston back into
(3) If applied, remove the protective paper from the bore of the caliper.
the noise suppression gasket on the rear of both the
CAUTION: Use care when installing the caliper onto
inner and outer brake shoe assemblies.
the disc brake adapter to avoid damaging the boots
(4) Install the new inboard brake shoe into the cal-
on the caliper guide pins.
iper piston by firmly pressing its retaining clip into
the piston bore. Be sure the inboard brake shoe is (3) Install the disc brake caliper over the brake
positioned squarely against the face of the caliper shoes on the brake caliper adapter.
piston. (4) Align the caliper guide pin bolt holes with the
(5) Lubricate both adapter abutments where the guide pins. Install the caliper guide pin bolts and
shoes slide with a small amount of Mopart Multipur- tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
pose Lubricant, or equivalent. 14).
(6) Slide the new outboard brake shoe into the cal- (5) Install the tire and wheel assembly. Tighten
iper adapter up against the outside of the brake the wheel mounting nuts to a torque of 135 N·m (100
rotor. ft. lbs.).
CAUTION: Use care when installing the caliper
(7) Pump the brake pedal several times. This will
assembly onto the steering knuckle, so the caliper
set the shoes to the brake rotor.
guide pin bushings do not get damaged by the
(8) Check and adjust the brake fluid level as nec-
steering knuckle bosses.
essary.
(7) Carefully position the brake caliper over the (9) Road test the vehicle and make several stops to
brake rotor and adapter. wear off any foreign material on the brakes and to
(8) Install the caliper guide pin bolts and tighten seat the brake shoes.
to a torque of 35 N·m (26 ft. lbs.). Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
BRAKE PADS/SHOES - REAR
(9) Install the anti-rattle clip on the outboard side DISC
of the caliper. Start the clip into the holes on the cal-
iper, then stretch the clip legs past the abutments on REMOVAL - REAR DISC BRAKE SHOES
the caliper adapter. (1) Raise vehicle on jackstands or centered on a
(10) Install the wheel and tire assembly. Tighten hoist. (Refer to LUBRICATION & MAINTENANCE/
the wheel mounting nuts in proper sequence until all HOISTING - STANDARD PROCEDURE).
nuts are torqued to half specification, then repeat the (2) Remove rear wheel and tire assemblies from
tightening sequence to the full specified torque of 135 vehicle.
N·m (100 ft. lbs.). (3) Remove the caliper to adapter guide pin bolts
(11) Repeat the above procedure on other side of (Fig. 15).
the vehicle. (4) Remove rear caliper from adapter using the fol-
(12) Lower vehicle. lowing procedure. First rotate rear of caliper up from
(13) Pump the brake pedal several times. This will the adapter. Then pull the front of the caliper and
set the shoes to the brake rotor. the outboard brake shoe anti-rattle clip out from
(14) Check and adjust brake fluid level as neces- under the front abutment on the adapter (Fig. 16).
sary.
BRAKE PADS/SHOES - REAR DISC (Continued)
Fig. 15 Caliper Guide Pin Bolts Fig. 17 Correctly Supported Caliper

1 - DISC BRAKE CALIPER 1 - WIRE
2 - ADAPTER 2 - CALIPER
3 - AXLE 3 - ADAPTER
4 - GUIDE PIN BOLTS 4 - ROTOR
5 - DRIVESHAFT (AWD MODELS ONLY) 5 - INNER FENDER
toward the piston, disengaging the two metal protru-

sions on the shoe back, then sliding the brake shoe
off the caliper.
(8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 18).
Fig. 16 Removing/Installing Caliper

1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
6 - ROTOR
7 - ADAPTER
Fig. 18 Removing Inboard Brake Shoe

(5) Support caliper to prevent the weight of the 1 - INBOARD BRAKE SHOE
caliper from damaging the flexible brake hose (Fig. 2 - HANGER WIRE
17). 3 - CALIPER ASSEMBLY
(6) If the brake rotor needs to be removed it can be 4 - RETAINING CLIP
removed by removing the retainer clips and then 5 - PISTON
pulling the rotor straight off the wheel mounting
studs.
(7) Remove the outboard brake shoe from the cali-
per. Brake shoe is removed by pushing the shoe
BRAKE PADS/SHOES - REAR DISC (Continued)
CLEANING - DISC BRAKE SHOES INSTALLATION - REAR DISC BRAKE SHOES

(1) Completely retract caliper piston back into pis-
WARNING: DUST AND DIRT ACCUMULATING ON ton bore of caliper assembly.
BRAKE PARTS DURING NORMAL USE MAY CON- (2) Lubricate both adapter abutments where the
TAIN ASBESTOS FIBERS FROM PRODUCTION OR shoes contact with a liberal amount of Mopart Mul-
AFTERMARKET BRAKE LININGS. BREATHING tipurpose Lubricant, or equivalent.
EXCESSIVE CONCENTRATIONS OF ASBESTOS (3) If removed, install the brake rotor on the hub,
FIBERS CAN CAUSE SERIOUS BODILY HARM. making sure it is squarely seated on the face of the
EXERCISE CARE WHEN SERVICING BRAKE hub.
PARTS. DO NOT SAND OR GRIND BRAKE LINING (4) Install the inboard brake shoe into the caliper
UNLESS EQUIPMENT USED IS DESIGNED TO CON- piston by firmly pressing it into the piston bore using
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE your thumbs. Be sure inboard brake shoe is posi-
PARTS WITH COMPRESSED AIR OR BY DRY tioned squarely against the face of the caliper piston.
BRUSHING. CLEANING SHOULD BE DONE BY (5) Install the outboard brake shoe on the disc
DAMPENING THE BRAKE COMPONENTS WITH A brake caliper. Be sure the outboard shoe is positioned
FINE MIST OF WATER, THEN WIPING THE BRAKE squarely against the outboard fingers of the caliper.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN- CAUTION: Use care when installing the caliper
ING ASBESTOS FIBERS IN AN IMPERMEABLE assembly onto the adapter, so the caliper guide pin
CONTAINER WITH THE APPROPRIATE LABEL. FOL- bushings do not get damaged by the mounting
LOW PRACTICES PRESCRIBED BY THE OCCUPA- bosses.
(OSHA) AND THE ENVIRONMENTAL PROTECTION (6) Carefully lower caliper and brake shoes over
AGENCY (EPA) FOR THE HANDLING, PROCESSING, rotor and onto adapter, reversing the removal proce-
AND DISPOSING OF DUST OR DEBRIS THAT MAY dure (Fig. 16).
CAUTION: When installing the caliper guide pin
bolts extreme caution should be taken not to
INSPECTION - DISC BRAKE SHOES crossthread the guide pin bolts.
Visually inspect brake shoes (pads) for uneven lin-
ing wear. Also inspect for excessive lining deteriora- (7) Install the caliper guide pin bolts. Tighten the
tion. Check the clearance between the tips of the guide pin bolts to a torque of 35 N·m (26 ft. lbs.).
wear indicators on the shoes (if equipped) and the (8) Install the wheel and tire assembly. Tighten
brake rotors. the wheel mounting nuts in proper sequence until all
If a visual inspection does not adequately deter- nuts are torqued to half specification. Then repeat
mine the condition of the lining, a physical check will the tightening sequence to the full specified torque of
be necessary. To check the amount of lining wear, 135 N·m (100 ft. lbs.).
remove the disc brake shoes from the calipers. (9) Remove jackstands or lower hoist.
Measure each brake shoe. The combined brake
CAUTION: Before moving vehicle, pump the brake
shoe and its lining material thickness should be mea-
pedal several times to insure the vehicle has a firm
sured at its thinnest point.
brake pedal to adequately stop the vehicle.
• For front disc brake shoes, when a set of brake
shoes are worn to a thickness of approximately 7.95 (10) Pump brake pedal several times to set brake
mm (5/16 inch), they should be replaced. shoes to rotors.
• For rear disc brake shoes, when a set of brake (11) Check fluid level in reservoir.
shoes are worn to a thickness of approximately 7.0 (12) Road test the vehicle and make several stops
mm (9/32 inch), they should be replaced. to wear off any foreign material on the brakes and to
Replace both disc brake shoes (inboard and out- seat the brake shoe linings.
board) on each caliper. It is necessary to replace the
shoes on the opposite side of the vehicle as well as
the shoes failing inspection.
If the brake shoe assemblies do not require
replacement, be sure to reinstall the brake shoes in
the original position they were remove from.
BRAKE PADS/SHOES - REAR

DRUM
REMOVAL - REAR DRUM BRAKE SHOES
DURE).
(2) Remove the rear wheel and tire assemblies
from the vehicle.
(3) Remove rear brake drum to hub retaining clips
(if equipped), then remove rear brake drums.
NOTE: When creating slack in the park brake cables

by locking out the automatic adjuster, (Fig. 19) be
sure that the park brake pedal is in the released Fig. 20 Adjustment Lever Actuating Spring
(most upward) position. 1 - TRAILING BRAKE SHOE
2 - LEADING BRAKE SHOE
(4) Create slack in the rear park brake cables. 3 - AUTOMATIC ADJUSTER LEVER
Slack is created by grabbing exposed section of front 4 - ADJUSTER LEVER ACTUATING SPRING
park brake cable and pulling it down and rearward.
Slack is maintained in the park brake cable by
installing a pair of locking pliers on the park brake (6) Remove adjustment lever (Fig. 21) from leading
cable just rearward of only the rear body outrigger brake shoe.
bracket. (Fig. 19)
Fig. 21 Adjustment Lever

1 - AUTOMATIC ADJUSTER
Fig. 19 Locked Out Park Brake Automatic Adjuster 3 - AUTOMATIC ADJUSTER LEVER
2 - REAR BODY OUTRIGGER BRACKET
3 - LOCKING PLIERS
(7) Remove the brake shoe to brake shoe lower
return springs (Fig. 22) and (Fig. 23).
(8) Remove the tension clip (Fig. 24) attaching the
(5) Remove adjustment lever spring (Fig. 20) from upper return spring to the automatic adjuster assem-
adjustment lever and front brake shoe. bly.
BRAKE PADS/SHOES - REAR DRUM (Continued)
Fig. 22 Remove/Install Brake Shoe Lower Return Fig. 24 Tension Clip Attachment To Adjuster
Spring 1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
1 - ANCHOR PLATE
3 - AUTOMATIC ADJUSTER LEVER
2 - LOWER BRAKE SHOE RETURN SPRING
4 - TENSION CLIP
3 - REAR BRAKE SHOE
5 - AUTOMATIC ADJUSTER ASSEMBLY
4 - FRONT BRAKE SHOE
5 - BRAKE SUPPORT PLATE
Fig. 25 Brake Shoe Upper Return Spring

1 - BRAKE SHOE RETURN SPRING
Fig. 23 Brake Shoe Lower Return Spring 2 - LEADING BRAKE SHOE
1 - TRAILING BRAKE SHOE 3 - TRAILING BRAKE SHOE
3 - RETURN SPRING
(10) Remove the trailing brake shoe assembly to
brake support plate hold down spring and pin (Fig.
(9) Remove the brake shoe to brake shoe upper 26) from the brake shoe assembly.
return spring (Fig. 25).
Fig. 26 Trailing Brake Shoe Hold Down Spring And Fig. 28 Leading Brake Shoe Hold Down Spring And
Pin Pin
1 - BRAKE SUPPORT PLATE 1 - PARK BRAKE ACTUATING LEVER
2 - HOLD DOWN SPRING AND PIN 2 - BRAKE SUPPORT PLATE
3 - TRAILING BRAKE SHOE 3 - LEADING BRAKE SHOE
4 - HOLD DOWN SPRING AND PIN
(11) Remove the trailing brake shoe assembly from

the brake support plate, park brake actuating lever (13) Remove the park brake actuator (Fig. 29)
and park brake actuating strut (Fig. 27). Remove the from the leading brake shoe and transfer to the
automatic adjuster assembly from the leading brake replacement brake shoe.
shoe.
Fig. 29 Park Brake Actuator Plate

1 - RETAINING CLIP
Fig. 27 Trailing Brake Shoe Removal/Installation 2 - BRAKE SHOE ASSEMBLY
3 - ACTUATOR PLATE
3 - PARK BRAKE ACTUATING LEVER
4 - PARK BRAKE ACTUATING STRUT
INSPECTION - REAR DRUM BRAKE SHOE
5 - TRAILING BRAKE SHOE LINING
(1) Remove the tire and wheel assembly from the
(12) Remove the leading brake shoe assembly to vehicle
brake support plate hold down spring and pin (Fig. (2) Remove the rear brake adjusting hole plug
28) from the brake shoe. Remove the leading brake found in the brake support.
shoe from the brake support plate. (3) Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the
notches on the adjusting screw star wheel.
(4) Insert Tool C-3784 into brake adjusting hole
and engage notches of brake adjusting screw star
wheel. Release brake by prying down with adjusting
tool.
(5) Remove the rear brake drum from the rear hub
and bearing assembly.
(6) Inspect brake lining for wear, shoe alignment,
and or contamination from grease or brake fluid.
INSTALLATION - REAR DRUM BRAKE SHOES

(1) Lubricate the eight shoe contact areas on the
support plate and anchor, (Fig. 30) using the
required special Mopart Brake Lubricant or equiva-
lent.
Fig. 31 Park Brake Components Assembled On

Leading Brake Shoe
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER
(7) Install the tension clip (Fig. 24) attaching the

upper return spring to the automatic adjuster assem-
bly.
(8) Install the brake shoe to brake shoe lower
return springs on the brake shoes (Fig. 22) and (Fig.
23).
(9) Install automatic adjustment lever on the lead-
Fig. 30 Brake Support Plate Contact Areas ing brake shoe of the rear brake assembly (Fig. 21).
1 - REAR BRAKE SUPPORT PLATE (10) Install the actuating spring on the automatic
adjustment lever and leading brake shoe assembly
(Fig. 20).
(2) Install leading brake shoe on brake support
(11) Verify that the automatic adjuster lever has
plate. Install the leading brake shoe hold down
positive contact with the star wheel on the automatic
spring and pin (Fig. 28) on the brake shoe.
adjuster assembly.
(3) Install the park brake actuator strut (Fig. 31)
(12) When all components of both rear brake
on the leading brake shoe. Then install the park
assemblies are correctly and fully installed, remove
brake actuator lever on the strut (Fig. 31).
the locking pliers from the front park brake cable.
(4) Install the automatic adjuster screw on the
(13) Adjust brake shoes assemblies so as not to
leading brake shoe. Then install the trailing brake
interfere with brake drum installation.
shoe on the park brake actuating lever and park
(14) Install the rear brake drums on the hubs.
brake actuating strut (Fig. 27). Position trailing
(15) Adjust rear brake shoes.
brake shoe on brake support plate.
(16) Install the wheel and tire assembly.
(5) Install the brake shoe hold down pin and
(17) Tighten the wheel mounting stud nuts in
spring on the trailing brake shoe (Fig. 26).
proper sequence until all nuts are torqued to half
(6) Install the brake shoe to brake shoe upper
specification. Then repeat the tightening sequence to
return spring (Fig. 25).
CAUTION: When installing the tension clip on the (18) Lower the vehicle.
automatic adjuster, it must be located on only the (19) Push the parking brake lever (pedal) to the
threaded area of the adjuster assembly (Fig. 24). If floor once and release pedal. This will automatically
it is located on a non-threaded area of the adjuster, remove the slack from and correctly adjust the park-
the function of the automatic adjuster will be ing brake cables.
affected.
(20) Road test vehicle. The automatic adjuster will (4) Remove the banjo bolt connecting the brake
continue the brake adjustment during the road test hose to the brake caliper. There are two washers (one
of the vehicle. on each side of the brake hose fitting) that will come
off with the banjo bolt. Discard these washers.
ADJUSTMENT - REAR DRUM BRAKE SHOES (5) Remove the 2 caliper guide pin bolts.
(6) Remove the brake caliper from the adapter.
NOTE: Normally, self-adjusting drum brakes do not
require manual brake shoe adjustment. Although, in REMOVAL - FRONT DISC BRAKE CALIPER
the event of a brake shoe replacement, it is advis- (DISC/DRUM BRAKES)
able to make the initial adjustment manually to (1) Using a brake pedal holding tool, depress the
speed up the adjusting time. brake pedal past its first one inch of travel and hold
it in this position. This will isolate the master cylin-
NOTE: Before raising the vehicle, verify the parking der from the brake hydraulic system and will not
brake lever is fully released. allow the brake fluid to drain out of the master cyl-
inder reservoir when the lines are opened.
(1) Raise the vehicle. (Refer to LUBRICATION & (2) Raise the vehicle. Refer to HOISTING in
MAINTENANCE/HOISTING - STANDARD PROCE- LUBRICATION AND MAINTENANCE.
DURE). (3) Remove the front tire and wheel assembly.
(2) Remove rubber plug from rear brake adjusting (4) Remove the banjo bolt connecting the brake
hole in the rear brake support plate. hose to the brake caliper (Fig. 32). There are two
(3) Insert a thin screwdriver through the adjusting washers (one on each side of the flex hose fitting)
hole in the support plate and against the star wheel that will come off with the banjo bolt. Discard the
of the adjusting screw. Move handle of the tool washers.
upward rotating the star wheel until a slight drag is
felt when tire and wheel assembly is rotated.
(4) Insert a second thin screwdriver or piece of
welding rod into brake adjusting hole and push the
adjusting lever out of engagement with the star
wheel. Care should be taken so as not to bend
adjusting lever or distort lever spring.
(5) While holding the adjusting lever out of
engagement, back off the star wheel just enough to
ensure a free wheel with no brake shoe drag.
(6) Repeat the above adjustment at the other rear
wheel.
(7) Install the adjusting hole rubber plugs back in
the rear brake support plates.
Fig. 32 Brake Caliper Mounting (Typical)

DISC BRAKE CALIPERS -
1 - BRAKE HOSE
FRONT 2 - ADAPTER MOUNTING BOLTS
3 - BANJO BOLT
REMOVAL - FRONT DISC BRAKE CALIPER 4 - CALIPER GUIDE PIN BOLTS
(DISC/DISC BRAKES)
(1) Depress the brake pedal past its first inch of (5) Remove the two brake caliper guide pin bolts
travel and hold it in this position using a brake pedal (Fig. 32).
depressor (holding) tool. This is done to isolate the (6) Remove the disc brake caliper from the disc
master cylinder from the brake hydraulic system dis- brake adapter.
allowing the brake fluid to completely drain out of
the brake fluid reservoir.
DURE).
(3) Remove front wheel and tire assembly.
DISC BRAKE CALIPERS - FRONT (Continued)
DISASSEMBLY - CALIPER GUIDE PIN (4) Mount the caliper in a vise equipped with pro-
tective jaws.
BUSHINGS (DISC/DISC BRAKES)
(5) Remove the piston dust boot from the caliper
Before disassembling the brake caliper, clean and
and discard.
inspect it. Refer to CLEANING or INSPECTION in
this section. NOTE: Do not use a screw driver or other metal tool
(1) Using your fingers, collapse one side of the rub- for seal removal. Using such tools can scratch the
ber guide pin bushing. Pull the guide pin bushing out bore or leave burrs on the seal groove edges.
the other side of the brake caliper mounting boss.
(2) Repeat this procedure on the remaining bush- (6) Using a soft tool such as a plastic trim stick,
ing. work the piston seal out of its groove in caliper pis-
ton bore (Fig. 33). Discard the old seal.
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,

clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from

the caliper bore is to use the hydraulic pressure of
the vehicle’s brake system.
(1) Following the removal procedure in DISC

BRAKE SHOES found in this section, remove the
caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of Fig. 33 Removing Piston Seal
wood between the piston and caliper fingers. 1 - PLASTIC TRIM STICK
(2) Carefully depress the brake pedal to hydrauli- 2 - CALIPER
cally push piston out of its bore. Once completed, 3 - PISTON SEAL GROOVE
apply and hold down the brake pedal to any position 4 - PISTON SEAL
beyond the first inch of pedal travel using a brake
pedal holding tool. This will prevent the fluid in the (7) Clean the piston bore and drilled passage ways
master cylinder reservoir from completely draining using alcohol or a suitable solvent. Wipe it dry using
out. only a lint-free cloth.
(3) Disconnect the brake fluid flex hose from the (8) Inspect the piston bore for scoring or pitting.
caliper assembly and remove it from the vehicle. Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
CAUTION: Do not use excessive force when clamp-
using crocus cloth.
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
CLEANING - CALIPER the caliper housing. The bushing flanges should be

seated evenly on both sides of the bushing hole.
WARNING: DUST AND DIRT ACCUMULATING ON (4) Lubricate inside surfaces of bushing using
BRAKE PARTS DURING NORMAL USE MAY CON- Mopart Dielectric Grease or equivalent.
TAIN ASBESTOS FIBERS FROM PRODUCTION OR (5) Repeat the procedure for remaining bushing.
EXCESSIVE CONCENTRATIONS OF ASBESTOS ASSEMBLY - CALIPER PISTON AND SEAL
EXERCISE CARE WHEN SERVICING BRAKE NOTE: Never use an old piston seal.
UNLESS EQUIPMENT USED IS DESIGNED TO CON- (1) Dip the new piston seal in clean brake fluid
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE and install it in the groove of the caliper bore. The
PARTS WITH COMPRESSED AIR OR BY DRY seal should be started at one area of the groove and
BRUSHING. CLEANING SHOULD BE DONE BY gently worked around and into the groove (Fig. 34)
DAMPENING THE BRAKE COMPONENTS WITH A using only your clean fingers to seat it.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
To clean or flush the internal passages of the brake

caliper, use fresh brake fluid or Mopart Non-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
Fig. 34 Installing New Piston Seal
ids will damage rubber cups and seals.
1 - CALIPER
2 - PISTON SEAL
INSPECTION - CALIPER 3 - SEAL GROOVE
Inspect the disc brake caliper for the following:
• Brake fluid leaks in and around boot area and
inboard lining (2) Coat the new piston boot with clean brake
• Ruptures, brittleness or damage to the piston fluid.
dust boot (3) Position the dust boot over the piston after
• Damaged, dry or brittle guide pin dust boots coating it with brake fluid.
If caliper fails inspection, disassemble and recondi-
CAUTION: Force applied to the piston to seat it in
tion caliper, replacing the seals and dust boots.
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
(DISC/DISC BRAKES) (4) Install piston into caliper bore pushing it past
(1) Fold the guide pin bushing in half lengthwise. the piston seal until it bottoms in the caliper bore
(Fig. 35).
NOTE: To avoid damage to the bushing, do not use (5) Position the dust boot into the counterbore of
a sharp object to install the guide pin bushing. the caliper assembly piston bore.
(6) Using a hammer and Installer, Special Tool
(2) Insert the folded bushing into the caliper C-4689 or C-4842 (depending on piston size), and
mounting boss using your fingers from the rear of Handle, Special Tool C-4171, drive the boot into the
the caliper. counterbore of the caliper as necessary (Fig. 36).
(3) Unfold the bushing using your fingers or a
wooden dowel until the bushing is fully seated into
INSTALLATION - FRONT DISC BRAKE CALIPER

(DISC/DISC BRAKES)
CAUTION: TRW and Continental Teves brake cali-
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system (TRW -
disc/drum brake combination and Continental Teves
- disc/disc brake combination). If calipers are inter-
changed, improper performance, noise and
increased stopping distance can occur.
(1) Completely retract the caliper piston back into

piston bore of the caliper. Use a C-clamp to retract
the piston if necessary. Place a wood block over the
piston before installing the C-clamp to avoid damag-
ing the piston.
CAUTION: Use care when installing the brake cali-

per assembly onto the steering knuckle, so that the
Fig. 35 Installing Piston Into Caliper Bore seals on the caliper guide pin bushings do not get
1 - BOOT damaged by the steering knuckle bosses.
2 - PISTON
3 - CALIPER (2) Carefully position the brake caliper and shoes
over the brake rotor and adapter.
(3) Install the caliper guide pin bolts and tighten
to a torque of 35 N·m (26 ft. lbs.). Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
(4) Install the anti-rattle clip on the outboard side
of the caliper. Start the clip into the holes on the cal-
iper, then stretch the clip legs past the abutments on
the caliper adapter.
CAUTION: When connecting the brake hose to the

caliper, install new brake hose to caliper special
copper washers.
(5) Install the brake hose on the caliper. To do

this, first place one NEW special fitting washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N·m (35 ft.
lbs.).
(6) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification, then
Fig. 36 Installing Dust Boot repeat the tightening sequence to the full specified
1 - HAMMER torque of 135 N·m (100 ft. lbs.).
2 - SPECIAL TOOL C-4171 (7) Lower the vehicle.
3 - SPECIAL TOOL C-4689 or C-4842 (8) Remove the brake pedal depressor (holding)
4 - CALIPER tool.
(9) Bleed the hydraulic brake circuit to the brake
(7) Reinstall the caliper on the vehicle and bleed caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
the brakes as necessary. Refer to Installation in this DURE)
section.
(10) Road test the vehicle and make several stops and scratching or nicking of lining on the brake
to wear off any foreign material on the brakes and to shoes.
seat the brake shoe linings.
(1) Depress the brake pedal past its first inch of
INSTALLATION - FRONT DISC BRAKE CALIPER travel and hold it in this position using a brake pedal
depressor (holding) tool. This is done to isolate the
(DISC/DRUM BRAKES)
master cylinder from the brake hydraulic system dis-
CAUTION: TRW and Continental Teves brake cali- allowing the brake fluid to completely drain out of
pers are not interchangeable. Each caliper is specif- the brake fluid reservoir.
ically designed for the unique brake system (TRW - (2) Raise the vehicle. (Refer to LUBRICATION &
disc/drum brake combination and Continental Teves MAINTENANCE/HOISTING - STANDARD PROCE-
- disc/disc brake combination). If calipers are inter- DURE)
changed, improper performance, noise and (3) Remove rear wheel and tire assembly from
increased stopping distance can occur. vehicle.
(4) Remove the banjo bolt connecting the brake
(1) Completely retract the caliper piston back into hose to the brake caliper. There are two washers (one
the bore of the caliper. Use a C-clamp to retract the on each side of the brake hose fitting) that will come
piston if necessary. Place a wood block over the pis- off with the banjo bolt. Discard these washers.
ton before installing the C-clamp to avoid damaging (5) Remove the disc brake caliper to adapter guide
the piston. pin bolts (Fig. 37).

(2) Install the disc brake caliper over the brake

shoes on the brake caliper adapter.
(3) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
32).
(4) Install the banjo bolt connecting the brake hose
to the brake caliper (Fig. 32). Install NEW copper
washers on each side of the hose fitting as the banjo
bolt is guided through the fitting. Thread the banjo
bolt into the caliper and tighten it to a torque of 47
N·m (35 ft. lbs.).
(5) Install the tire and wheel assembly. Tighten Fig. 37 Caliper Guide Pin Bolts
the wheel mounting nuts to a torque of 135 N·m (100 1 - DISC BRAKE CALIPER
2 - ADAPTER
ft. lbs.).
3 - AXLE
4 - GUIDE PIN BOLTS
(7) Remove the brake pedal holding tool. 5 - DRIVESHAFT (AWD MODELS ONLY)
(8) Bleed the caliper as necessary. (Refer to 5 -
BRAKES - BASE - STANDARD PROCEDURE).
(9) Road test the vehicle and make several stops to (6) Remove rear caliper from adapter using the fol-
wear off any foreign material on the brakes and to lowing procedure. First rotate rear of caliper up from
seat the brake shoes. the adapter. Then pull the front of the caliper and
the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 38).
DISC BRAKE CALIPERS - (7) If the brake rotor requires removal, it can now
be removed by first removing the retainer clips from
REAR the wheel mounting studs, then pulling the rotor
straight off the studs.
REMOVAL - REAR DISC BRAKE CALIPER
NOTE: Handling of the rotor and caliper, must be
done in such a way as to avoid damage to the rotor
DISC BRAKE CALIPERS - REAR (Continued)
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-

ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-

tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool

for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
Fig. 38 Removing/Installing Caliper (6) Using a soft tool such as a plastic trim stick,
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST work the piston seal out of its groove in caliper pis-
2 - DISC BRAKE CALIPER ton bore (Fig. 39). Discard the old seal.
6 - ROTOR
7 - ADAPTER
DISASSEMBLY - CALIPER PISTON AND SEAL

WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,

clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from

the caliper bore is to use the hydraulic pressure of
the vehicle’s brake system. Fig. 39 Removing Piston Seal
(1) Following the removal procedure in DISC 1 - PLASTIC TRIM STICK
2 - CALIPER
BRAKE SHOES found in this section, remove the
3 - PISTON SEAL GROOVE
caliper from the brake rotor and hang the assembly
4 - PISTON SEAL
on a wire hook away from rotor and body of the vehi-
cle so brake fluid cannot get on these components.
Remove the brake shoes, and place a small piece of (7) Clean the piston bore and drilled passage ways
wood between the piston and caliper fingers. using alcohol or a suitable solvent. Wipe it dry using
(2) Carefully depress the brake pedal to hydrauli- only a lint-free cloth.
cally push piston out of its bore. Once completed, (8) Inspect the piston bore for scoring or pitting.
apply and hold down the brake pedal to any position Bores that show light scratches or corrosion can usu-
beyond the first inch of pedal travel using a brake ally be cleared of the light scratches or corrosion
pedal holding tool. This will prevent the fluid in the using crocus cloth.
master cylinder reservoir from completely draining
out.
CLEANING - CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
COMPONENTS CLEAN WITH A DAMPENED CLOTH. Fig. 40 Installing New Piston Seal
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN- 1 - CALIPER
ING ASBESTOS FIBERS IN AN IMPERMEABLE 2 - PISTON SEAL
CONTAINER WITH THE APPROPRIATE LABEL. FOL- 3 - SEAL GROOVE
CAUTION: Force applied to the piston to seat it in
the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
CONTAIN ASBESTOS FIBERS. (4) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
To clean or flush the internal passages of the brake
(Fig. 41).
caliper, use fresh brake fluid or Mopart Non-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
• Brake fluid leaks in and around boot area and
inboard lining
• Ruptures, brittleness or damage to the piston
dust boot
• Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY - CALIPER PISTON AND SEAL

NOTE: Never use an old piston seal.
(1) Dip the new piston seal in clean brake fluid Fig. 41 Installing Piston Into Caliper Bore
and install it in the groove of the caliper bore. The 1 - BOOT
seal should be started at one area of the groove and 2 - PISTON
gently worked around and into the groove (Fig. 3 - CALIPER
40)using only your clean fingers to seat it.
(2) Coat the new piston boot with clean brake
(5) Position the dust boot into the counterbore of
fluid.
the caliper assembly piston bore.
(3) Position the dust boot over the piston after
coating it with brake fluid.
(6) Using a hammer and Installer, Special Tool (4) Install the caliper guide pin bolts. Tighten the
C-4689 or C-4842 (depending on piston size), and guide pin bolts to a torque of 35 N·m (26 ft. lbs.).
Handle, Special Tool C-4171, drive the boot into the
counterbore of the caliper as necessary (Fig. 42). CAUTION: When connecting the brake hose to the
caliper, install new brake hose to caliper special
washers.
(5) Install the brake hose on the caliper. To do

this, first place one NEW special copper washer on
each side of the hose fitting, then slide the banjo bolt
through the fitting. Next, thread the banjo bolt into
the threaded port on the rear of the brake caliper.
Tighten the banjo bolt to a torque of 47 N·m (35 ft.
lbs.).
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
(9) Remove the brake pedal depressor (holding)
tool.
(10) Bleed the hydraulic brake circuit to the brake
caliper. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE)
(11) Road test the vehicle and make several stops
to wear off any foreign material on the brakes and to
Fig. 42 Installing Dust Boot seat the brake shoe linings.
1 - HAMMER
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842 DISC BRAKE CALIPER
4 - CALIPER
ADAPTER
(7) Reinstall the caliper on the vehicle and bleed REMOVAL - FRONT DISC BRAKE CALIPER
the brakes as necessary. Refer to Installation in this
section. ADAPTER
INSTALLATION - REAR DISC BRAKE CALIPER MAINTENANCE/HOISTING - STANDARD PROCE-
(1) Completely retract caliper piston back into pis- DURE)
ton bore of the caliper. (2) Remove front wheel and tire assembly, disc
(2) If removed, install the brake rotor on the hub, brake caliper and brake shoes. (Refer to 5 - BRAKES/
making sure it is squarely seated on the face of the HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
hub. - REMOVAL)
(3) Remove two bolts fastening adapter to steering
CAUTION: Use care when installing the caliper knuckle, then remove disc brake caliper adapter.
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting INSTALLATION - FRONT DISC BRAKE CALIPER
bosses. ADAPTER
(1) Place adapter over brake rotor and align
(3) Carefully lower caliper and brake shoes over adapter mounting holes to knuckle.
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 38). CAUTION: Adapter mounting bolts have a special
DacrometT coating applied to resist corrosion. If
CAUTION: When installing guide pin bolts extreme mounting bolts need to be replaced, use only
caution should be taken not to cross-thread the cal- MoparT replacement parts.
DISC BRAKE CALIPER ADAPTER (Continued)
(2) Install adapter mounting bolts and tighten to
169 N·m (125 ft. lbs.) torque.
(3) Install brake shoes, disc brake caliper and
wheel and tire assembly. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
INSTALLATION)
(4) Lower vehicle.
(5) Pump the brake pedal several times to set the
pads to the brake rotor.
(6) Check and adjust brake fluid level as neces-
sary.
DISC BRAKE CALIPER GUIDE

PINS
Fig. 44 Guide Pins And Boots
REMOVAL - DISC BRAKE CALIPER GUIDE PINS 1 - PINS
(DISC/DRUM BRAKES) 2 - BOOTS
(1) Raise the vehicle. Refer to HOISTING in
LUBRICATION AND MAINTENANCE.
(2) Remove the front tire and wheel assembly. INSTALLATION - DISC BRAKE CALIPER GUIDE
(3) Remove the two brake caliper guide pin bolts PINS (DISC/DRUM BRAKES)
(Fig. 43). (1) Lubricate the guide pins and inside the boots
with the packet supplied with the service kit, Syth-
eso GLK-1 lubricant or equivalent.
(2) Install the guide pins and boots in the adapter
as shown (Fig. 44). The boots have grooves built into
their inner lips to fit onto the pins and adapter.

(3) Install the disc brake caliper over the brake

shoes on the brake caliper adapter.
(4) Align the caliper guide pin bolt holes with the
guide pins. Install the caliper guide pin bolts and
tighten them to a torque of 35 N·m (26 ft. lbs.) (Fig.
43).
(5) Install the tire and wheel assembly. Tighten
Fig. 43 Brake Caliper Mounting
the wheel mounting nuts to a torque of 135 N·m (100
1 - BRAKE HOSE ft. lbs.).
3 - BANJO BOLT
(7) Pump the brake pedal several times before
4 - CALIPER GUIDE PIN BOLTS
moving the vehicle to set the shoes to the brake
rotor.
(4) Remove the disc brake caliper from the disc
brake caliper adapter and hang it out of the way
using wire or a bungee cord. Use care not to overex-
tend the brake hose when doing this.
(5) Remove the guide pins and boots from the
adapter as shown (Fig. 44).
DRUM (3) Remove the rear brake shoe adjusting hole

cover plug.
(4) Insert a thin screwdriver into brake adjusting
STANDARD PROCEDURE - BRAKE DRUM
hole and hold adjusting lever away from notches of
MACHINING adjusting screw star wheel.
Measure the runout and diameter of the rear brake (5) Insert another thin screwdriver into brake
using only accurate measuring equipment. There adjusting hole and engage notches of brake adjusting
should be no variation in the drum diameter greater screw star wheel. Release brake adjustment by pry-
than 0.090 mm (0.004 inch). Drum runout should not ing down with adjusting tool.
exceed 0.15 mm (0.006 inch) out of round. If the (6) Remove rear brake drum from rear hub/bear-
drum runout or diameter variation exceed these val- ing assembly.
ues the drum should be refaced. For best results in
eliminating the irregularities that cause brake rough- INSTALLATION
ness and surge, the amount of material removed dur- (1) Adjust brake shoe assemblies so as not to inter-
ing a single cut should be limited to 0.13 mm (0.005 fere with brake drum installation.
inch). When the entire braking surface has been (2) Install the rear brake drums on the hubs.
cleaned, a final cut of 0.0254 mm (0.001 inch) will (3) Adjust drum brake shoes as necessary per pro-
assure a good drum surface providing the equipment cedure found in the Adjustment section of this ser-
used is capable of the precision required for resurfac- vice manual group (Refer to 5 - BRAKES/
ing brake drums. Deeper cuts are permissible for the HYDRAULIC/MECHANICAL/DRUM -
sole purpose of removing deep score marks. Do not ADJUSTMENTS).
reface more than 1.52 mm (0.060 inch) over the (4) Install wheel and tire assembly.
standard drum diameter. (5) Tighten the wheel mounting stud nuts in
All drums will show markings of maximum allow- proper sequence until all nuts are torqued to half
able diameter (Fig. 45). For example, a drum will specification. Then repeat the tightening sequence to
have a marking of MAX. DIA. 251.55 mm (9.90 inch). the full specified torque of 135 N·m (100 ft. lbs.).
This marking includes 0.76 mm (0.030 inch) for (6) Lower the vehicle.
allowable drum wear beyond the recommended 1.52
mm (0.060 inch) of drum refacing.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
Fig. 45 Rear Brake Drum Maximum Diameter
tioning valve, caliper seals, wheel cylinder seals,
Identification
Antilock Brake hydraulic unit and all hydraulic fluid
1 - MAXIMUM DIAMETER OF BRAKE DRUM SHOWN ON THIS hoses.
SURFACE
2 - BRAKE DRUM
REMOVAL
DURE).
(2) Remove the tire and wheel assembly from the
vehicle
FLUID (Continued)
STANDARD PROCEDURE - BRAKE FLUID ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
LEVEL CHECKING
located on the driver’s side of the front suspension
Check master cylinder reservoir fluid level a mini-
cradle/crossmember below the master cylinder (Fig.
mum of twice annually.
46).
Fluid reservoirs are marked with the words FULL
It has six threaded ports to which the brake tubes
and ADD to indicate proper brake fluid fill level of
connect. Two are for the primary and secondary
the master cylinder.
brake tubes coming from the master cylinder. The
If necessary, add brake fluid to bring the level to
remaining four are for the chassis brake tubes going
the bottom of the FULL mark on the side of the mas-
to each brake assembly.
ter cylinder fluid reservoir.
Use only Mopart brake fluid or equivalent from a
sealed container. Brake fluid must conform to DOT 3
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
specifications (DOT 4 or DOT 4+ are acceptable).
ing from the master cylinder primary and secondary
DO NOT use brake fluid with a lower boiling
ports to the four chassis brake tubes leading to the
point, as brake failure could result during prolonged
brakes at each wheel. Since the junction block
hard braking.
mounts in the same location as the ABS integrated
Use only brake fluid that was stored in a tightly-
sealed container. control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
DO NOT use petroleum-based fluid because seal
damage will result. Petroleum based fluids would be is equipped with or without ABS.
items such as engine oil, transmission fluid, power
NOTE: Although the brake tubes coming from the
steering fluid etc.
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
SPECIFICATIONS unique to each brake system application.
BRAKE FLUID REMOVAL - NON-ABS JUNCTION BLOCK

The brake fluid used in this vehicle must conform
(1) Using a brake pedal depressor, move and lock
to DOT 3 specifications (DOT 4 and DOT 4+ are
the brake pedal to a position past its first 1 inch of
acceptable) and SAE J1703 standards. No other type
travel. This will prevent brake fluid from draining
of brake fluid is recommended or approved for usage
out of the master cylinder when the brake tubes are
in the vehicle brake system. Use only Mopart Brake
removed from the junction block.
Fluid or equivalent from a tightly sealed container.
(2) Disconnect the battery negative cable.
CAUTION: Never use reclaimed brake fluid or fluid (3) If the vehicle is equipped with speed control,
from an container which has been left open. An perform the following:
open container of brake fluid will absorb moisture (a) Disconnect the battery positive cable.
from the air and contaminate the fluid. (b) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(c) Disconnect the vacuum hose connector at the
CAUTION: Never use any type of a petroleum-based tank built into the battery tray.
fluid in the brake hydraulic system. Use of such (d) Remove the screw securing the coolant filler
type fluids will result in seal damage of the vehicle neck to the battery tray.
brake hydraulic system causing a failure of the (e) Remove the battery tray (Refer to 8 - ELEC-
vehicle brake system. Petroleum based fluids would TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
be items such as engine oil, transmission fluid, (f) Remove the fasteners and move the speed
power steering fluid, etc. control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from

the junction block, the junction block and the brake
JUNCTION BLOCK tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
DESCRIPTION - NON-ABS JUNCTION BLOCK hydraulic system.
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
JUNCTION BLOCK (Continued)
(4) Remove the four chassis brake tubes from the (d) Install the screw securing the coolant filler
top of the junction block (Fig. 46). neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
Fig. 46 NON-ABS JUNCTION BLOCK MASTER CYLINDER

1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
DESCRIPTION
4 - MOUNTING BOLTS The master cylinder is located on the power brake
booster in the engine compartment on the driver’s
side (Fig. 47). This vehicle uses 3 different master
(5) Remove the primary and secondary brake cylinders. Master cylinder usage depends on what
tubes from the top of the junction block. type of brake system the vehicle is equipped with.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem- CAUTION: Master cylinders are not interchangeable
ber (Fig. 46), then remove the junction block. between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
INSTALLATION - NON-ABS JUNCTION BLOCK inder is installed on the vehicle.
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 46).
Install the mounting bolts and tighten to a torque of
28 N·m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N·m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N·m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
Fig. 47 MASTER CYLINDER AND BOOSTER
mounting nuts.
LOCATION
(b) Connect the wiring harness to the speed con-
1 - MASTER CYLINDER
trol servo.
2 - POWER BRAKE BOOSTER
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
MASTER CYLINDER (Continued)
For information on master cylinder application, (1) Clamp the master cylinder in a vise using only
bore and type, view the following table: the mounting flange.
NOTE: Two different size bleeding tubes need to be

MASTER CYLINDER
BRAKE SYSTEM used depending on which type of master cylinder
BORE/TYPE
the vehicle is equipped with. Vehicles equipped
23.8 mm Conventional with traction control have different size brake tubes
Disc/Drum - ABS
Compensating Port and nuts at the master cylinder than the non-trac-
23.8 mm Conventional tion control equipped vehicles. Be sure the correct
Disc/Drum - Non-ABS
Compensating Port size bleeding tubes are used when bleeding the
25.4 mm (1-1/16 in.) master cylinder.
Disc/Disc - ABS Conventional
(2) Thread Bleeding Tubes, Special Tool 8358, for a
Compensating Port
non-traction control master cylinder or Special Tool
Disc/Disc ABS With 25.4 mm (1-1/16 in.) Dual 8129 for a traction control master cylinder into mas-
Traction Control Center Port ter cylinder primary and secondary ports. Position
outlet ends of bleeding tubes in reservoir with the
CAUTION: When replacing a master cylinder, be outlets below surface of brake fluid when reservoir is
sure to use the correct master cylinder for the type filled to its proper level.
of brake system the vehicle is equipped with. (3) Fill brake fluid reservoir with Mopart brake
fluid or equivalent conforming to DOT 3 (DOT 4 and
The body of the master cylinder is an anodized alu- DOT 4+ are acceptable) specifications.
minum casting. It has a machined bore to accept the (4) Using a wooden dowel, depress push rod slowly,
master cylinder pistons and threaded ports with and then allow pistons to return to released position.
seats for the hydraulic brake line connections. Repeat several times until all air bubbles are
The brake fluid reservoir is mounted on the top of expelled from master cylinder.
the master cylinder. It is made of a see-through (5) Remove bleeding tubes from master cylinder
polypropylene type plastic for easy fluid level view- outlet ports, and then plug outlet ports and install
ing. A brake fluid level switch is attached to the fill cap on reservoir.
brake fluid reservoir. (6) Remove master cylinder from vise.
The master cylinder is not a repairable component (7) Install the filler cap on master cylinder fluid
and must be replaced if diagnosed to be functioning reservoir.
improperly. The brake fluid reservoir and brake fluid (8) Install master cylinder. (Refer to 5 - BRAKES -
level switch can be replaced separately. BASE/HYDRAULIC/MECHANICAL/MASTER CYL-
INDER - INSTALLATION)
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
REMOVAL - MASTER CYLINDER
OPERATION CAUTION: Vacuum in the power brake booster must
When the brake pedal is depressed, the master cyl- be pumped down (removed) before removing mas-
inder primary and secondary pistons apply brake ter cylinder from power brake booster. This is nec-
pressure through the chassis tubes to the brakes at essary to prevent the power brake booster from
each tire and wheel assembly. sucking in any contamination as the master cylin-
The master cylinder primary outlet port supplies der is removed. This can be done simply by pump-
hydraulic pressure to the right front and left rear ing the brake pedal, with the vehicle’s engine not
brakes. The secondary outlet port supplies hydraulic running, until a firm feeling brake pedal is achieved.
pressure to the left front and right rear brakes. (1) With engine not running, pump brake pedal
until a firm pedal is achieved (4-5 strokes).
STANDARD PROCEDURE - MASTER CYLINDER (2) Disconnect negative battery terminal.
BLEEDING (3) Disconnect positive battery terminal.
(4) Remove battery shield.
CAUTION: When clamping master cylinder in vise, (5) Remove nut and clamp securing battery to tray,
only clamp master cylinder by its mounting flange, remove battery.
do not clamp on primary piston, seal or body of
master cylinder.
(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as Mopart Brake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 48).
Fig. 49 MASTER CYLINDER MOUNTING

1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 48 MASTER CYLINDER AND BOOSTER removed from master cylinder by carefully pulling it
1 - POWER BRAKE BOOSTER off the rear of master cylinder. Do not attempt to
2 - BOOSTER IDENTIFICATION LABEL pry the seal off the master cylinder by inserting
3 - FLUID LEVEL SWITCH CONNECTOR a sharp tool between seal and master cylinder
4 - PRIMARY BRAKE TUBE NUT casting.
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(8) Disconnect primary and secondary brake tubes (1) Clean master cylinder housing and brake fluid
from master cylinder housing (Fig. 48). Install seal- reservoir. Use only a solvent such as Mopar Brake
ing plugs in the now open brake tube outlet ports. Parts Cleaner or an equivalent.
(2) Remove brake fluid reservoir cap. Using a
CAUTION: Before removing the master cylinder syringe or equivalent type tool empty as much brake
from the power brake vacuum booster, the master fluid as possible from the reservoir.
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles CAUTION: When removing fluid reservoir from the
from falling into the power brake vacuum booster. master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
(9) Clean area where master cylinder assembly cylinder housing.
attaches to power brake booster. Use only a solvent
such as Mopart Brake Parts Cleaner or equivalent. (3) Remove the master cylinder assembly from the
(10) Remove two nuts attaching master cylinder to power brake vacuum booster. (Refer to 5 - BRAKES -
power brake booster (Fig. 49). BASE/HYDRAULIC/MECHANICAL/MASTER CYL-
(11) Slide master cylinder straight out of power INDER - REMOVAL).
brake booster. (4) Mount the master cylinder in a vise using the
master cylinder mounting flange.
CAUTION: A seal on the rear of the master cylinder (5) Using correct size pin punch, remove the two
is used to create the seal for holding vacuum in the retaining pins between the fluid reservoir and master
power brake vacuum booster. The vacuum seal on cylinder housing (Fig. 50).
the master cylinder MUST be replaced whenever the (6) Rock the brake fluid reservoir from side to side
master cylinder is removed from the power brake while pulling up to remove it from the seal grommets
vacuum booster. in master cylinder housing.
(7) Remove the two master cylinder housing to
(12) Remove vacuum seal located on the mounting
brake fluid reservoir seal grommets (Fig. 51).
flange of the master cylinder. The vacuum seal is
(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 50).
(5) Install the master cylinder assembly on the
power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER CYLINDER -
INSTALLATION)
(6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION - MASTER CYLINDER

CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
Fig. 50 Fluid Reservoir Retaining Pins (Typical) system the vehicle is equipped with.
1 - FLUID RESERVOIR
2 - RETAINING PINS
CAUTION: When replacing the master cylinder on a
3 - MASTER CYLINDER
vehicle, a NEW vacuum seal MUST be installed on
(1) Install a NEW vacuum seal on master cylinder

making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 49). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).
CAUTION: When tightening the primary and sec-

ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
Fig. 51 Master Cylinder To Fluid Reservoir Seal ible sections of the tubes. This is required due to
Grommets the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
1 - SEAL GROMMETS
2 - MASTER CYLINDER
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
ASSEMBLY - MASTER CYLINDER (FLUID 48). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
RESERVOIR) tube nuts to a torque of 17 N·m (145 in. lbs.).
(1) Install new master cylinder housing to brake
(5) Install wiring harness connector to brake fluid
fluid reservoir sealing grommets in master cylinder
level switch mounted in brake fluid reservoir (Fig.
housing (Fig. 51).
48).
(2) Lubricate reservoir mounting area with fresh
(6) Install battery, clamp and nut.
clean brake fluid. Place reservoir in position over
(7) Install battery shield.
sealing grommets. Seat reservoir into sealing grom-
(8) Connect positive battery terminal.
mets using a rocking motion while firmly pressing
(9) Connect negative battery terminal.
down on fluid reservoir.
(10) Fill master cylinder with clean, fresh Mopart
(3) Be sure fluid reservoir is positioned properly on
Brake Fluid or equivalent.
master cylinder. Bottom of fluid reservoir is to be
(11) Road test vehicle to ensure proper operation of
touching the top of both sealing grommets
brakes.
when properly installed on master cylinder
housing.
POWER BRAKE BOOSTER booster face is not repairable, but it can be

replaced separately from the power brake booster.
DESCRIPTION
The power brake booster mounts on the engine
compartment side of the dash panel. It is connected
to the brake pedal by the input (push) rod (Fig. 52).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
Fig. 53 MASTER CYLINDER AND BOOSTER

2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
6 - MASTER CYLINDER
The different engine combinations used in this

vehicle require different vacuum hose routings to the
power brake booster. All vacuum hoses must be
routed from the engine to the power brake booster
without kinks or excessively tight bends.
Fig. 52 Power Brake Booster (Typical)
1 - VACUUM CHECK VALVE
2 - POWER BRAKE BOOSTER ASSEMBLY
OPERATION
3 - INPUT ROD
The power brake booster reduces the amount of
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING force required by the driver to obtain the necessary
STUDS (4) hydraulic pressure to stop a vehicle.
5 - MASTER CYLINDER MOUNTING STUDS (2) The power brake booster is vacuum operated. The
6 - OUTPUT ROD vacuum is supplied from the intake manifold on the
engine through a vacuum hose and the power brake
All vehicles use a 270 mm single diaphragm vac- booster check valve (Fig. 52).
uum power brake booster. As the brake pedal is depressed, the power brake
Vehicles equipped with Disc/Disc brakes use a dif- booster’s input rod moves forward (Fig. 52). This
ferent power brake booster than vehicles equipped opens and closes valves in the power booster allowing
with Disc/Drum brakes. Differences between the two atmospheric pressure to enter on one side of a dia-
are internal. Service is the same for all boosters. phragm. Engine vacuum is always present on the
The power brake booster can be identified by the other side. This difference in pressure forces the out-
tag attached to the body of the booster (Fig. 53). This put rod of the power brake booster out against the
tag contains the production part number, the date it primary piston of the master cylinder. As the pistons
was built, and who the manufacturer of the power in the master cylinder move forward this creates the
brake booster is. hydraulic pressure in the brake system.
NOTE: The power brake booster assembly is not a

repairable component and must be replaced as a
complete assembly if found to be faulty in any way.
The check valve located on the power brake
POWER BRAKE BOOSTER (Continued)
DIAGNOSIS AND TESTING - POWER BRAKE Do not move the pedal once the pressure is applied
BOOSTER or the test results may vary.
(7) Have an assistant reattach the vacuum line
BASIC TEST pliers to the vacuum supply hose.
(1) With engine off, depress and release the brake (8) Allow 5 seconds for stabilization, then observe
pedal several times to purge all vacuum from the the vacuum gauge.
power brake booster. If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
(2) Depress and hold the pedal with light effort (15 in 15 seconds, repeat the above steps to confirm the
to 25 lbs. pressure), then start the engine. reading. The vacuum loss should be less than 3.0
The pedal should fall slightly, then hold. Less effort inches Hg in 15 seconds time span. If the loss is
should be needed to apply the pedal at this time. If more than 3.0 inches Hg, replace the power brake
the pedal fell as indicated, perform the VACUUM booster. If it is not, the booster is not defective.
LEAK TEST listed after the BASIC TEST. If the (9) Remove the pliers and vacuum gauge.
pedal did not fall, continue on with this BASIC TEST.
(3) Disconnect the vacuum hose on the vacuum REMOVAL - POWER BRAKE BOOSTER
check valve, then place a vacuum gauge in line
CAUTION: Reserve vacuum in power brake booster
between the vacuum hose and the valve.
must be pumped down (removed) before removing
(4) Start the engine.
master cylinder from booster. This is necessary to
(5) When the engine is at warm operating temper-
prevent booster from sucking in any contamination
ature, allow it to idle and check the vacuum at the
as master cylinder is removed. This can be done
gauge.
simply by pumping the brake pedal, with the vehi-
If the vacuum supply is 12 inches Hg (40.5 kPa) or
cle’s engine not running, until a firm feeling brake
more, the power brake booster is defective and must
pedal is achieved.
be replaced. If the vacuum supply is below 12 inches
Hg, continue on with this BASIC TEST. (1) With engine not running, pump the brake
(6) Shut off the engine. pedal until a firm pedal is achieved (4-5 strokes).
(7) Connect the vacuum gauge to the vacuum ref- (2) Remove negative battery cable terminal from
erence port on the engine intake manifold. battery.
(8) Start the engine and observe the vacuum (3) Remove positive battery cable terminal from
gauge. battery.
If the vacuum is still low, check the engine tune (4) Remove battery thermal guard shield.
and repair as necessary. If the vacuum is above 12 (5) Remove battery clamp, nut and battery from
inches Hg, the hose or check valve to the booster has the battery tray.
a restriction or leak. (6) Remove screw securing engine coolant filler
Once an adequate vacuum supply is obtained, tube to battery tray.
repeat the BASIC TEST. (7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
VACUUM LEAK TEST into the battery tray.
(1) Disconnect the vacuum hose on the vacuum
(8) Remove the two nuts and one bolt securing bat-
check valve, then place a vacuum gauge in line
tery tray in place. Remove battery tray.
between the vacuum hose and the valve.
(9) If vehicle is equipped with speed control:
(2) Start the engine.
(a) Disconnect wiring harness connector from
(3) Allow the engine to warm up to normal operat-
the speed control servo.
ing temperature and engine idle.
(b) Remove the two servo mounting nuts.
(4) Using vacuum line pliers, close off the vacuum
(c) Lay speed control servo off to the side, out of
supply hose near the booster, but before the vacuum
the way.
gauge, then observe the vacuum gauge.
(10) Remove the wiper module (unit). (Refer to 8 -
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa)
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
in one minute, repeat the above steps to confirm the
ULE - REMOVAL)
reading. The vacuum loss should be less than 1.0
(11) Disconnect wiring harness connector from
inch Hg in one minute time span. If the loss is more
brake fluid level switch in master cylinder fluid res-
than 1.0 inch Hg, replace the power brake booster. If
ervoir (Fig. 54).
it is not, continue on with this test.
(5) Remove the pliers from the hose temporarily.
(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.
Fig. 54 MASTER CYLINDER AND BOOSTER Fig. 55 MASTER CYLINDER MOUNTING

1 - POWER BRAKE BOOSTER 1 - MASTER CYLINDER MOUNTING NUTS
2 - BOOSTER IDENTIFICATION LABEL 2 - MASTER CYLINDER
3 - FLUID LEVEL SWITCH CONNECTOR 3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY BRAKE TUBE NUT 4 - PRIMARY TUBE NUT AT ICU
6 - MASTER CYLINDER
(16) Disconnect vacuum hose from check valve
located on vacuum booster. DO NOT REMOVE
CAUTION: Before removing the master cylinder CHECK VALVE FROM POWER BRAKE
from the power brake vacuum booster, the master BOOSTER.
cylinder and vacuum booster must be thoroughly (17) Inside vehicle, remove silencer panel under
cleaned. This must be done to prevent dirt particles instrument panel below steering column.
from falling into the power brake vacuum booster. (18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
(12) Clean area where master cylinder assembly small screwdriver between the center tang on the
attaches to power brake booster. Use only a solvent power brake booster input rod to brake pedal pin
such as Mopart Brake Parts Cleaner or equivalent. retaining clip (Fig. 56).
(13) Disconnect primary and secondary brake
tubes from ABS integrated control unit or non-ABS
junction block (Fig. 55). Install sealing plugs in the
now open brake tube ports and install caps on ends
of tubes.
NOTE: It is not necessary to remove the brake

tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove two nuts attaching master cylinder to

power brake booster (Fig. 55).
(15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder

is used to create the seal for holding vacuum in the
Fig. 56 Vacuum Booster Input Rod Retaining Pin
power brake vacuum booster. The vacuum seal on
1 - BRAKE PEDAL
the master cylinder MUST be replaced whenever the
2 - INPUT ROD
master cylinder is removed from the power brake
3 - SCREWDRIVER
vacuum booster. 4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
(19) Rotate screwdriver enough to allow retaining INSTALLATION - POWER BRAKE BOOSTER
clip center tang to pass over end of brake pedal pin. (1) Position power brake booster on dash panel
Then pull retaining clip off brake pedal pin. Discard using the reverse procedure of its removal (Fig. 58).
retaining clip. It is not to be reused. Replace It may be necessary to push in on booster input rod
only with a new retaining clip when assem- as it is guided through the dash panel.
bling. (2) Install the four nuts mounting the booster to
(20) Slide booster input rod off pedal pin. the dash panel (Fig. 57). Tighten the mounting nuts
(21) Remove the four nuts attaching power brake to a torque of 29 N·m (250 in. lbs.).
booster to dash panel (Fig. 57). (3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on

the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin

and install a NEW retaining clip (Fig. 59).
Fig. 57 BOOSTER MOUNTING

1 - DASH BRACKET
3 - BRAKE PEDAL ASSEMBLY
(22) Slide power brake booster forward and remove

through engine compartment (Fig. 58).
Fig. 59 Retaining Pin Installed On Brake Pedal Pin

1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
CAUTION: Do not reuse the original brake lamp

switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch

with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
Fig. 58 BOOSTER REMOVAL/INSTALLATION SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
CAUTION: Do not attempt to disassemble the power LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
brake vacuum booster it is serviced ONLY as a SWITCH - INSTALLATION)
complete assembly. (6) Install the silencer panel below the steering
column.
(7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is (16) Install the battery tray. Install the two nuts
used to create the seal for holding vacuum in the and one bolt attaching the battery tray to the vehicle.
vacuum booster. The vacuum seal on the master Tighten the bolt and nuts to a torque of 14 N·m (124
cylinder MUST be replaced with a NEW seal when- in. lbs.).
ever the master cylinder is removed from the vac- (17) If vehicle is equipped with speed control, con-
uum booster. nect the servo vacuum hose to the vacuum tank on
the battery tray.
(18) Install the air inlet resonator and hoses as an
CAUTION: When removing the vacuum seal from assembly on the throttle body and air cleaner hous-
the master cylinder do not use a sharp tool. ing. Securely tighten hose clamp at air cleaner hous-
ing and throttle body.
(8) Using a soft tool such as a trim stick, remove
(19) Secure the engine coolant filler neck to the
the vacuum seal from the master cylinder mounting
battery tray with its mounting screw.
flange.
(20) Install the battery, clamp and mounting nut.
(9) Install a NEW vacuum seal on rear mounting
(21) Install the positive battery cable on the bat-
flange of the master cylinder (Fig. 60).
tery.
(22) Install the negative battery cable on the bat-
tery.
(23) Install the battery thermal guard shield.
(24) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(25) Road test vehicle to ensure operation of the
brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
Fig. 60 Vacuum Seal (Typical)
lize electronic brake distribution which is controlled
1 - MASTER CYLINDER ASSEMBLY through the ABS integrated control unit.
2 - VACUUM SEAL
Vehicles not equipped with ABS use a height sens-
(10) Position master cylinder on studs of booster, ing proportioning valve. It is mounted to the body of
aligning push rod on booster with master cylinder the vehicle above the rear axle (Fig. 61). It has an
piston. actuator lever that attaches to the rear axle and
(11) Install the two nuts mounting the master cyl- moves with the axle to help the valve sense the vehi-
inder to the booster (Fig. 55). Tighten both mounting cle height.
(12) Connect wiring harness connector to brake CAUTION: The height sensing proportioning valve
fluid level switch in the master cylinder fluid reser- is not adjustable. No attempt should be made to
voir (Fig. 54). adjust it. It is replaced as a complete assembly.
(13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 55). CAUTION: The use of after-market load leveling or
Tighten the tube nuts to 17 N·m (145 in lbs.). load capacity increasing devices on this vehicle are
(14) Install wiper module (unit). (Refer to 8 - prohibited. Using air shock absorbers or helper
ELECTRICAL/WIPERS/WASHERS/WIPER MOD- springs on this vehicle will cause the height sens-
ULE - INSTALLATION) ing proportioning valve to inappropriately reduce
(15) If equipped with speed control, install speed the hydraulic pressure to the rear brakes. This inap-
control servo and connect wiring connector. Tighten propriate reduction in hydraulic pressure potentially
the mounting nuts to a torque of 14 N·m (124 in. could result in increased stopping distance of the
lbs.). vehicle.
PROPORTIONING VALVE (Continued)
vehicle through the movement of the proportioning
valve actuator lever (Fig. 61). As the position of the
rear axle changes, depending on the load the vehicle
is carrying, the movement is transferred to the pro-
portioning valve. The proportioning valve adjusts the
hydraulic pressure accordingly.
The height sensing proportioning valve allows the
brake system to maintain the optimal front to rear
brake balance regardless of the vehicle load condi-
tion. Under a light load condition, hydraulic pressure
to the rear brakes is minimized. As the rear load con-
dition increases, so does the hydraulic pressure to
the rear brakes.
DIAGNOSIS AND TESTING - PROPORTIONING

VALVE (HEIGHT SENSING)
Fig. 61 HEIGHT SENSING PROPORTIONING VALVE
1 - PROPORTIONING VALVE CAUTION: The use of aftermarket load leveling or
2 - ACTUATOR LEVER load capacity increasing devices on this vehicle is
3 - AXLE BRACKET prohibited. Using air shock absorbers or helper
4 - REAR AXLE springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
OPERATION - PROPORTIONING VALVE propriate reduction in hydraulic pressure potentially
(HEIGHT SENSING) could result in increased stopping distance of the
Vehicles not equipped with ABS use a height sens- vehicle.
ing proportioning valve.
The height sensing proportioning valve operates When a premature rear wheel skid is obtained on a
similarly to a standard proportioning valve in the fol- brake application, it may be an indication that the
lowing way. As hydraulic pressure is applied to the hydraulic pressure to the rear brakes is above the
valve, full input hydraulic pressure is supplied to the specified output from the proportioning valve. This
rear brakes up to a certain pressure point, called the condition indicates a possible malfunction of the
split point. Beyond the split point, the proportioning height sensing proportioning valve, which will
valve reduces the amount of hydraulic pressure to require testing to verify that it is properly controlling
the rear brakes according to a given ratio. Thus, on the hydraulic pressure allowed to the rear brakes.
light brake applications, approximately equal Premature rear wheel skid may also be caused by
hydraulic pressure will be transmitted to both the contaminated front or rear brake linings.
front and rear brakes. Upon heavier brake applica- Prior to testing a proportioning valve for function,
tions, the hydraulic pressure transmitted to the rear check that all tire pressures are correct. Also, ensure
brakes will be lower than the front brakes. This will the front and rear brake linings are in satisfactory
prevent premature rear wheel lockup and skid. condition. It is also necessary to verify that the
Here is how the height sensing proportioning valve brakes shoe assemblies on a vehicle being
differs from a standard proportioning valve. As the tested are either original equipment manufac-
height of the rear suspension changes, the height turers (OEM) or original replacement brake
sensing portion of the proportioning valve changes shoe assemblies meeting the OEM lining mate-
the split point of the proportioning valve. When the rial specification. This vehicles brake system is
height of the rear suspension is low, the proportion- not balanced for aftermarket brake shoe assem-
ing valve interprets this as extra load and the split bly lining material.
point of the proportioning valve is raised to a higher If both front and rear brakes check OK, proceed
pressure to allow for more rear braking. When the with the following test procedure for the height sens-
height of the rear suspension is high, the proportioning proportioning valve.
ing valve interprets this as a light load and the split (1) Road test the vehicle to determine which rear
point of the proportioning valve is lowered to a lower wheel brake is exhibiting premature wheel skid.
pressure and rear braking is reduced.
The height sensing proportioning valve regulates
the pressure by sensing the load condition of the
(2) Raise vehicle. (Refer to LUBRICATION & is equipped with and the pressure specification
MAINTENANCE/HOISTING - STANDARD PROCE- shown on the following table, compare the pressure
DURE) reading on the outlet gauge to the specification. If
(3) Remove the chassis brake tube going to the outlet pressure at the proportioning valve is not
rear brake in question at the proportioning valve. within specification when required inlet pressure is
Remove the chassis brake tube coming from the junc- obtained, replace the proportioning valve. (Refer to 5
tion block at the proportioning valve (Fig. 62). - BRAKES/HYDRAULIC/MECHANICAL/PROPOR-
(4) Install the appropriate fittings from Pressure TIONING VALVE - REMOVAL)
Test Fittings, Special Tool 6833, into the open ports
of the proportioning valve. CAUTION: Do not attempt to adjust the height sens-
(5) Install the previously removed brake lines into ing proportioning valve. If found to be defective,
the Pressure Test Fittings. Tighten all tube nuts to replace the valve.
17 N·m (145 in. lbs.).
(6) Install a pressure gauge from Gauge Set, Spe- (9) Remove the pressure test fittings and pressure
cial Tool C-4007-A into the open port on each pres- gauges from the proportioning valve.
sure test fitting. Bleed air out of hose from pressure (10) Install the chassis brake lines in the correct
test fittings to pressure gauges at the pressure ports of the proportioning valve. Tighten all tube
gauges. Then bleed air out of the brake line being nuts to 17 N·m (145 in. lbs.).
tested at that rear wheel brake bleeder. (11) If necessary, repeat the above steps on the
(7) Remove the screw fastening the proportioning remaining side of the proportioning valve which con-
valve actuator lever bracket to the rear axle. Raise trol the other rear wheel brake.
the actuator lever to the full-upward position. (12) Attach the actuator lever and bracket to the
(8) With the aid of a helper, apply pressure to the rear axle.
brake pedal until a pressure of 6895 kPa (1000 psi) is (13) Bleed rear brakes. (Refer to 5 - BRAKES -
obtained on the proportioning valve inlet gauge. STANDARD PROCEDURE)
Then, based on the type of brake system the vehicle (14) Road test vehicle.
INLET OUTLET
WHEEL DRIVE SPLIT
SALES CODE BRAKE SYSTEM SLOPE PRESSURE PRESSURE
BASE TRAIN POINT
PSI PSI
159 DISC/DRUM
SWB FWD BRB-BGF VAR. .59 1000 PSI 675-875 PSI
W/O ANTILOCK
REMOVAL - PROPORTIONING VALVE (HEIGHT (5) Slide the bracket out from under rear track bar
bracket. Lower the valve down enough to pull its
SENSING)
actuator lever out of the axle bracket and remove the
proportioning valve from the vehicle.
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
INSTALLATION - PROPORTIONING VALVE
removed from the proportioning valve. (HEIGHT SENSING)
(2) Raise vehicle on jackstands or centered on a (1) Install the end of the actuator lever through
hoist. (Refer to LUBRICATION & MAINTENANCE/ the axle bracket grommet and slide the proportioning
HOISTING - STANDARD PROCEDURE). valve bracket under the rear track bar body bracket
(Fig. 62).
CAUTION: Before removing the brake tubes from (2) Install the proportioning valve attaching bolts
the proportioning valve, the proportioning valve and (Fig. 62). Tighten the attaching bolts to a torque of
the brake tubes must be thoroughly cleaned. This is 54 N·m (40 ft. lbs.).
required to prevent contamination from entering the (3) Install the four chassis brake lines into the
proportioning valve or the brake tubes. inlet and outlet ports of the proportioning valve (Fig.
62). Tighten all tube nuts to a torque of 17 N·m (145
(3) Remove the four brake tubes from the inlet and in. lbs.).
outlet ports of the proportioning valve (Fig. 62).
(4) Remove the two bolts attaching the proportion- CAUTION: The height sensing proportioning valve
ing valve and bracket to the vehicle (Fig. 62). is not adjustable. No attempt should be made to
adjust it.
new brake shoes are installed, improper wear of the
shoes will result.
If a vehicle has not been driven for a period of
time, the rotor’s braking surface will rust in the
areas not covered by the brake shoes at that time.
Once the vehicle is driven, noise and chatter from
the disc brakes can result when the brakes are
applied.
Some discoloration or wear of the rotor surface is
normal and does not require resurfacing when lin-
ings are replaced. If cracks or burned spots are evi-
dent, the rotor must be replaced.
ROTOR MINIMUM THICKNESS

Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if it is worn
Fig. 62 PROPORTIONING VALVE MOUNTING below minimum thickness or if machining the rotor
1 - LEFT REAR OUTLET TUBE will cause its thickness to fall below specifications.
2 - RIGHT REAR OUTLET TUBE
3 - RIGHT REAR INLET TUBE CAUTION: Do not machine the rotor if it will cause
4 - MOUNTING BOLTS the rotor to fall below minimum thickness.
5 - LEFT REAR INLET TUBE
Minimum thickness specifications are cast on the
rotor’s unmachined surface (Fig. 63). Limits can also
(4) Bleed the brake system thoroughly to ensure
be found in the table at the end of this brake rotor
that all air has been expelled from the hydraulic sys-
information.
tem. (Refer to 5 - BRAKES - BASE - STANDARD
PROCEDURE).
(5) Lower the vehicle to the ground.
(6) Road test the vehicle to verify proper operation
ROTORS
DIAGNOSIS AND TESTING - BRAKE ROTOR
Any servicing of the rotor requires extreme care to
maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase
pedal travel due to piston knock-back. This increases
guide pin sleeve wear due to the tendency of the cal- Fig. 63 Minimum Brake Rotor Thickness Markings
iper to follow the rotor wobble. (Typical)
When diagnosing a brake noise or pulsation, the 1 - ROTOR MINIMUM THICKNESS MARKING
machined disc braking surface should be checked and 2 - ROTOR
inspected.
BRAKING SURFACE INSPECTION ROTOR THICKNESS VARIATION

Thickness variation in a rotor’s braking surface
Light braking surface scoring and wear is accept-
can result in pedal pulsation, chatter and surge. This
able. If heavy scoring or warping is evident, the rotor
can also be caused by excessive runout in the rotor or
must be refaced or replaced. (Refer to 5 - BRAKES/
the hub.
HYDRAULIC/MECHANICAL/ROTORS - STAN-
Rotor thickness variation measurements should be
DARD PROCEDURE).
made in conjunction with measuring runout. Mea-
Excessive wear and scoring of the rotor can cause
sure thickness of the brake rotor at 12 equal points
improper lining contact on the rotor’s braking sur-
around the rotor braking surface with a micrometer
face. If the ridges on the rotor are not removed before
at a radius approximately 25 mm (1 inch) from edge
of rotor (Fig. 64). If thickness measurements vary by
ROTORS (Continued)
more than 0.013 mm (0.0005 inch), the rotor should
be refaced or replaced. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - STANDARD
PROCEDURE).
Fig. 65 Checking Rotor Runout

1 - SPECIAL TOOL SP-1910
2 - 10 MILLIMETERS FROM EDGE
3 - DISC SURFACE
Fig. 64 Checking Rotor For Thickness

1 - CALIPER
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP-
1910 on steering arm. The dial indicator plunger
should contact braking surface of rotor approximately Fig. 66 Marking Rotor and Wheel Stud
ten millimeters from edge of rotor (Fig. 65). Check 1 - CHALK MARK
lateral runout on both sides of the rotor, marking the
low and high spots on both. Runout limits can be NOTE: Clean the hub face surface before checking
found in the table at the end of this brake rotor runout. This provides a clean surface to get an
information. accurate indicator reading.
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing the Mount Dial Indicator, Special Tool C-3339, and
rotor from the hub, place a chalk mark across both Mounting Adaptor, Special Tool SP-1910, to the steer-
the rotor and the one wheel stud closest to where the ing knuckle. Position the indicator stem so it contacts
high runout measurement was taken. This way, the the hub face near the outer diameter. Care must be
original mounting spot of the rotor on the hub is taken to position stem outside of the stud circle, but
indexed (Fig. 66). inside of the chamfer on the hub rim (Fig. 67).
Remove the rotor from the hub. Hub runout should not exceed 0.03 mm (0.0012
inch). If runout exceeds this specification, the hub
ROTORS (Continued)
chalk marks on the rotor with a wheel mounting
stud, two studs apart from the original stud (Fig. 68).
Tighten nuts in the proper sequence and torque to
specifications.
Fig. 67 Checking Hub Runout Fig. 68 Index Rotor And Wheel Stud
1 - HUB SURFACE 1 - CHALK MARK
3 - SPECIAL TOOL SP-1910
Recheck brake rotor runout to see if the runout is
now within specifications.
must be replaced. (Refer to 2 - SUSPENSION/ If runout is not within specifications, reface or
FRONT/HUB / BEARING - REMOVAL). replace the brake rotor. (Refer to 5 - BRAKES/HY-
If the hub runout does not exceed this specifica- DRAULIC/MECHANICAL/ROTORS - STANDARD
tion, install the rotor back on the hub, aligning the PROCEDURE).
BRAKE ROTOR LIMITS
Minimum Rotor Rotor Thickness Rotor Runout*

Braking Rotor Rotor Thickness
Thickness Variation
Front Rotor -
27.87–28.13 mm 25.3 mm 0.009 mm 0.035 mm
Disc/Drum Brakes
1.097-1.107 in. 0.996 in. 0.0004 in. 0.0014 in.
(TRW)
Front Rotor -
27.90–28.10 mm 25.3 mm 0.008 mm 0.035 mm
Disc/Disc Brakes
1.098-1.106 in. 0.996 in. 0.0003 in. 0.0014 in.
(Teves)
12.25–12.75 mm 11.25 mm 0.013 mm 0.14 mm
Rear Rotor
0.482 -0.502 in. 0.443 in. 0.0005 in. 0.0055 in.
*
TIR Total Indicator Reading (Measured On Vehicle)
ROTORS (Continued)
STANDARD PROCEDURE - BRAKE ROTOR

MACHINING
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is
foreseen.
Any servicing of the rotor requires extreme care to

maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or
there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a
hub-mounted on-car brake lathe (Fig. 69), or
replaced. Fig. 70 Front Brake Rotor
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
Fig. 71 Rear Brake Rotor Minimum Thickness

Markings
1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM
DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE
2 - REAR ROTOR
Fig. 69 On-Car Brake Lathe
1 - ON-CAR BRAKE LATHE
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
The use of a hub-mounted on-car brake lathe is tamination.
highly recommended to eliminate the possibility of When mounting and using the brake lathe, strict
excessive runout. It trues the brake rotor to the vehi- attention to the brake lathe manufacturer’s operating
cle’s hub and bearing. instructions is required.
Machine both sides of the brake rotor at the same
NOTE: All rotors have markings for minimum allow- time. Cutting both sides at the same time minimizes
able thickness cast on an un-machined surface of the possibility of a tapered or uneven cut.
the rotor (Fig. 70) (Fig. 71).
SPECIFICATIONS AND LIMITS
Minimum allowable thickness is the minimum
When refacing a rotor, the required TIR and thick-
thickness which the brake rotor machined surface
ness variation limits MUST BE MAINTAINED.
may be cut to.
Extreme care in the operation of rotor turning equip-
CAUTION: Do not machine the rotor if it will cause ment is required.
the rotor to fall below minimum thickness.
ROTORS (Continued)
BRAKE ROTOR LIMITS
Minimum Rotor Rotor

Rotor
Braking Rotor Rotor Thickness Runout*
Thickness
Thickness Variation
27.87–28.13
Front Rotor -
mm 25.3 mm 0.009 mm 0.035 mm
Disc/Drum Brakes
1.097-1.107 0.996 in. 0.0004 in. 0.0014 in.
(TRW)
in.
27.90–28.10
Front Rotor -
mm 25.3 mm 0.008 mm 0.035 mm
Disc/Disc Brakes
1.098-1.106 0.996 in. 0.0003 in. 0.0014 in.
(Teves)
in.
12.25–12.75
mm 11.25 mm 0.013 mm 0.14 mm
Rear Rotor
0.482 -0.502 0.443 in. 0.0005 in. 0.0055 in.
in.
*
TIR Total Indicator Reading (Measured On Vehicle)
REMOVAL - FRONT BRAKE ROTOR (4) Remove the disc brake caliper and adapter as
(1) Raise vehicle on jackstands or centered on a an assembly from the steering knuckle (Fig. 72).
frame contact type hoist. See Hoisting in Lubrication Hang the assembly out of the way using wire or a
and Maintenance. bungee cord. Use care not to overextend the brake
(2) Remove the front wheel and tire assembly. hose when doing this.
(3) Remove the two mounting bolts securing the (5) Remove any retainer clips from the wheel
disc brake caliper adapter with brake caliper to the mounting studs.
steering knuckle (Fig. 72). (6) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 72).
INSTALLATION - FRONT BRAKE ROTOR

(1) Install the brake rotor back on the hub and
bearing (Fig. 72).
(2) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 72).
(3) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N·m (125 ft. lbs.) torque.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
tion, then repeat the tightening sequence to the full
(5) Lower vehicle to the ground.
1 - BRAKE ROTOR
2 - HUB AND BEARING SUPPORT PLATE - DRUM
BRAKE
5 - BRAKE CALIPER
6 - ADAPTER REMOVAL
7 - CLIP (1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
SUPPORT PLATE - DRUM BRAKE (Continued)
out of master cylinder when brake tube is remove (2) Install the rear brake support plate on the 4
from wheel cylinder. mounting bolts installed in the flange of the rear axle
(2) Raise vehicle. (Refer to LUBRICATION & (Fig. 74).
DURE).
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
(9) Disconnect the park brake cable from the park
brake actuation lever.
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 73) or an aircraft type hose clamp, com- Fig. 74 Brake Support Plate Mounted On Bearing
press the flared legs on park brake cable retainer. Attaching Bolts
Then pull the park brake cable out of brake support 1 - REAR BRAKE SUPPORT PLATE
plate. 2 - HUB/BEARING MOUNTING BOLTS
(3) Install the rear hub and bearing (and connect

wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer to 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION)
(4) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(5) Install the park brake cable on the park brake
actuation lever.
(6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N·m (75 in. lbs.)
torque.
Fig. 73 Removing Park Brake Cable From Brake (8) Install brake tube into wheel cylinder. Tighten
Support Plate tube nut to a torque of 17 N·m (145 in. lbs.) torque.
1 - PARK BRAKE CABLE (9) Install the rear brake shoes on the brake sup-
2 - CABLE RETAINER port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
3 - 14 mm BOX WRENCH CHANICAL/BRAKE PADS/SHOES -
4 - BRAKE SUPPORT PLATE INSTALLATION).
(10) Install brake drum.
(11) Remove the rear hub and bearing. (Refer to 2 (11) Install wheel and tire.
- SUSPENSION/REAR/HUB / BEARING - (12) Tighten wheel stud nuts to 135 N·m (100 ft.
REMOVAL) lbs.).
(12) Remove the rear brake support plate from the (13) Adjust drum brake shoes. (Refer to 5 -
rear axle. BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
INSTALLATION (14) Remove brake pedal depressor tool.
(1) Install the 4 hub and bearing to axle mounting (15) Bleed the brake system as necessary. (Refer to
bolts into the mounting holes in the flange of the 5 - BRAKES - BASE - STANDARD PROCEDURE).
rear axle. (16) Lower the vehicle.
WHEEL CYLINDERS (9) Bleed the brake system as necessary. (Refer to

5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch PARKING BRAKE
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
DESCRIPTION
from wheel cylinder.
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
DURE).
of the brake pedal (Fig. 75). It is a automatic-adjust-
ing type lever.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new Fig. 75 Parking Brake Lever (Pedal)
parts installed. 1 - PARK BRAKE PEDAL ASSEMBLY
If a wheel cylinder is leaking and the brake lining 2 - PARK BRAKE PEDAL
material is saturated with brake fluid, the brake 3 - CARPET
shoes must be replaced. 4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in The vehicle has four flexible steel parking brake
the brake support plate. cables. They are:
(2) Install wheel cylinder onto brake support. • Front
Install and tighten the wheel cylinder to brake sup- • Intermediate
port plate attaching bolts to 8 N·m (75 in. lbs.) • Left rear
torque. • Right rear
(3) Install brake tube into wheel cylinder. Tighten The front parking brake cable extends from the
tube nut to a torque of 17 N·m (145 in. lbs.) torque. parking brake lever. A steel equalizer bracket con-
(4) Install the rear brake shoes on the brake sup- nects the front parking brake cable to the left rear
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME- and intermediate cable. The intermediate cable is
CHANICAL/BRAKE PADS/SHOES - connected to the right rear cable using a parking
INSTALLATION). brake cable connector.
(5) Install brake drum. On vehicles equipped with rear drum brakes, the
(6) Install wheel and tire. Install and tighten rear service brakes also act as the vehicle’s parking
wheel lug nuts to 135 N·m (100 ft. lbs.). brakes.
(7) Adjust drum brake shoes. (Refer to 5 - Vehicles equipped with rear disc brakes use a
BRAKES/HYDRAULIC/MECHANICAL/BRAKE small duo-servo brake assembly mounted to the each
PADS/SHOES - ADJUSTMENTS) rear disc brake caliper adapter as the parking brake.
(8) Remove brake pedal depressor tool. The inside of the brake rotor (hat section of drum-in-
PARKING BRAKE (Continued)
hat style brake rotor) is used as the parking brake
drum.
OPERATION
The automatic-adjusting feature in the foot oper-
ated parking brake lever continuously applies mini-
mal tension to the parking brake cables when the
parking brake lever is in the released position to
keep them in adjustment at all times. Due to this
feature, the parking brake cables require no periodic
adjustment.
When the parking brake lever is applied, the
cables are pulled, thus applying the brake shoes
(rear drum brakes) or parking brake shoes (rear disc
brakes) at each rear wheel.
The brake shoes are mechanically operated by an
internal lever and strut connected to the rear park- Fig. 76 Locking Out Automatic Adjuster
ing brake cables. 1 - PARK BRAKE CABLE
An equalizer bracket is used at the rear end of the 2 - REAR BODY OUTRIGGER BRACKET
front parking brake cable to distribute tension 3 - LOCKING PLIERS
equally to each parking brake cable.
STANDARD PROCEDURE - PARKING BRAKE

AUTOMATIC ADJUSTER TENSION RELEASE
The parking brake lever (pedal) mechanism used
in this vehicle is designed so that the automatic
adjuster is not required to be locked out when servic-
ing the parking brake lever (pedal) or the parking
brake cables.
This parking brake lever (pedal) mechanism is
designed so that the adjuster mechanism will rotate
only half a turn when the tension is released from
the parking brake cable. This eliminates the require-
ment to lock out the automatic adjuster when servic-
ing the parking brake lever (pedal) mechanism and
cables.
Use the following procedure to release the tension Fig. 77 Parking Brake Cable Attachment To
from the parking brake cables and the automatic Equalizer
adjuster in the parking brake lever (pedal) mecha-
1 - EQUALIZER
nism.
2 - LEFT REAR PARKING BRAKE CABLE
(1) Grasp the exposed section of the front parking 3 - LOCKING NUT
brake cable and pull rearward on it. While holding 4 - INTERMEDIATE PARKING BRAKE CABLE
the park brake in this position, install a pair of lock- 5 - FRONT PARKING BRAKE CABLE
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket (Fig. 76).
BRAKES/PARKING BRAKE - STANDARD PROCE-
(2) Remove the left rear and intermediate parking
DURE).
brake cables from the parking brake cable equalizer
(Fig. 77).
(3) Remove the equalizer from the front parking STANDARD PROCEDURE - PARKING BRAKE
brake cable. AUTOMATIC ADJUSTER TENSION RESET
(4) Remove the locking pliers from the front park- The parking brake lever (pedal) mechanism used
ing brake cable. This will allow the adjuster in the in this vehicle is designed so that the automatic
parking brake lever (pedal) mechanism to rotate adjuster is not required to be locked out when servic-
around to its stop. This will remove the tension from ing the parking brake lever (pedal) or the parking
the adjuster and front park brake cable (Refer to 5 - brake cables.
PARKING BRAKE (Continued)
(1) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
(2) Install the equalizer on the front parking brake
cable.
(3) Install the left rear and intermediate park
brake cable in the correct location on the parking
brake cable equalizer (Fig. 77).
(4) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever (pedal) mechanism to tension the
park brake cables.
(5) Apply and release the parking brake lever
(pedal) one time. This will seat the parking brake Fig. 78 Parking Brake Cable Equalizer
cables and allow the auto adjuster in the parking
1 - EQUALIZER
brake lever (pedal) mechanism to correctly tension
the parking brake cables. 3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
LEVER - PARKING BRAKE
REMOVAL (11) Remove the lower bolt mounting the park
(1) Manually release the automatic self-adjusting brake pedal to the body (Fig. 79).
mechanism tension of the parking brake lever (pedal) (12) Remove the forward nut mounting the park
assembly. (Refer to 5 - BRAKES/PARKING BRAKE - brake pedal to the body (Fig. 79).
STANDARD PROCEDURE). (13) Remove the upper bolt mounting the park
(2) Disconnect negative (ground) cable from the brake pedal to the body (Fig. 79).
battery and isolate cable from battery terminal.
(3) Remove sill scuff plate from left door sill.
(4) Remove the left side kick panel.
(5) Remove the silencer panel under the instru-
ment panel.
(6) Remove the steering column cover from the
lower instrument panel.
(7) Remove the reinforcement from the lower
instrument panel.
(8) Remove the front parking brake cable from the
parking brake cable equalizer (Fig. 78).
(9) Remove tension from front park brake cable.
Tension is removed by releasing the locking pliers
from the front park brake cable.
(10) Remove the 3 bolts mounting the wiring junc-
tion block to the instrument panel.
Fig. 79 PARKING BRAKE LEVER MOUNTING
NOTE: When removing the lower mounting bolt, 1 - WIRE HARNESS CONNECTOR
push the park brake pedal down 5 clicks to access 2 - LEVER MECHANISM
the lower mounting bolt. 3 - FRONT CABLE
LEVER (Continued)
(14) Pull downward on front park brake cable (19) Install the silencer panel under the instru-
while rotating park brake pedal mechanism out from ment panel.
behind junction block. (20) Install the left side kick panel.
(15) Remove park brake pedal release link from (21) Install the sill scuff plate on the lower sill of
park brake mechanism. the left door.
(16) Remove the warning lamp ground switch con- (22) Install the negative (ground) cable on the bat-
nector from the park brake pedal mechanism (Fig. tery.
79). (23) Cycle the park brake pedal one time. This will
(17) Remove front park brake cable button from seat the park brake cables and will allow the auto-
park brake pedal mechanism. Tap end housing for matic self adjuster to properly tension the park brake
front park brake cable out of park brake pedal mech- cables.
anism.
INSTALLATION SHOES - PARKING BRAKE

(1) Install park brake cable end housing into park
brake pedal mechanism. REMOVAL
(2) Install cable retainer onto the park brake cable (1) Set the parking brake. The parking brake is
strand and then install retainer into pedal bracket. set to keep the hub/bearing and axle shaft from
(3) Install cable strand button into the clevis on rotating when loosening the hub nut.
the park brake pedal mechanism. (2) Raise vehicle. (Refer to LUBRICATION &
(4) Install wiring harness connector on warning MAINTENANCE/HOISTING - STANDARD PROCE-
indicator lamp ground switch. DURE).
(5) Install the park brake release rod on the (3) Remove the wheel and tire assembly.
release mechanism of the park brake pedal. (4) Remove the cotter pin and nut retainer (Fig.
(6) Position the park brake pedal mechanism into 80) from the stub shaft of the outer C/V joint.
its installed position on the body of the vehicle.
(7) Loosely install the top bolt mounting the park
brake pedal mechanism to the body (Fig. 79).
(8) Loosely install the forward nut mounting the
park brake pedal mechanism to the body (Fig. 79).
(9) Loosely install the lower bolt mounting the
park brake pedal mechanism to the body (Fig. 79).
(10) Tighten pedal mechanism attaching bolts and
nut to 28 N·m (250 in. lbs.).
(11) Verify that the park brake pedal is in the fully
released (full up) position.
(12) Raise vehicle.
(13) Install the front park brake cable on the park
brake cable equalizer (Fig. 78).
NOTE: If the original lever assembly is being used,

the lever mechanism auto adjuster spring tension
Fig. 80 Cotter Pin And Nut Retainer
will need to be reset. (Refer to 5 - BRAKES/PARK-
1 - CALIPER
ING BRAKE - STANDARD PROCEDURE)
2 - COTTER PIN
3 - ROTOR
(14) Lower vehicle.
4 - NUT RETAINER
(15) Remove the lock-out pin (if a new lever has
5 - OUTER C/V JOINT
been installed) from the automatic cable adjuster on
the park brake pedal mechanism.
(16) Install the electrical junction block on the (5) Remove the spring washer (Fig. 81) from the
instrument panel. stub shaft of the outer C/V joint.
(17) Install the reinforcement on the lower instru- (6) Remove the hub nut and washer (Fig. 82) from
ment panel. the stub shaft of the outer C/V joint.
(18) Install the steering column lower cover on the (7) Release the parking brake.
lower instrument panel.
SHOES (Continued)
Fig. 81 Spring Washer Fig. 83 Locking Out Automatic Adjuster

1 - HUB NUT 1 - PARK BRAKE CABLE
2 - STUB SHAFT 2 - REAR BODY OUTRIGGER BRACKET
3 - ROTOR 3 - LOCKING PLIERS
4 - SPRING WASHER
(9) Remove the disc brake caliper to adapter guide

pin bolts (Fig. 84).
Fig. 82 Hub Nut And Washer

1 - CALIPER Fig. 84 Removing Caliper Guide Pin Bolts
2 - HUB NUT 1 - DISC BRAKE CALIPER
3 - WASHER 2 - ADAPTER
4 - ROTOR 3 - AXLE
5 - ADAPTER 4 - GUIDE PIN BOLTS
5 - DRIVESHAFT (AWD MODELS ONLY)
(8) Create slack in the rear park brake cables by

locking the out the automatic adjuster as described. (10) Remove rear caliper from adapter using the
Grasp the exposed section of front park brake cable following procedure. First rotate rear of caliper up
and pull downward on it. Then install a pair of lock- from the adapter. Then pull the front of the caliper
ing pliers on the front park brake cable just rearward and the outboard brake shoe anti-rattle clip out from
of the second body outrigger bracket (Fig. 83). under the front abutment on the adapter (Fig. 85).
SHOES (Continued)
Fig. 85 Removing/Installing Caliper

1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
Fig. 87 Park Brake Cable Attachment To Actuator
2 - DISC BRAKE CALIPER 1 - ADAPTER
3 - ADAPTER ABUTMENT 2 - PARK BRAKE CABLE
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP 3 - ACTUATOR
5 - OUTBOARD BRAKE SHOE 4 - AXLE
6 - ROTOR 5 - DRIVESHAFT
7 - ADAPTER 6 - PARK BRAKE CABLE RETAINER
7 - HORSESHOE CLIP
(11) Support caliper to prevent the weight of the

caliper from damaging the flexible brake hose (Fig. (15) Remove the end of the park brake cable from
86). the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in (Fig. 88) to compress
the locking tabs on the park brake cable retainer.
Fig. 86 Correctly Supported Caliper

1 - WIRE
2 - CALIPER
3 - ADAPTER
Fig. 88 Park Brake Cable Removal From Adapter
4 - ROTOR 1 - DRIVESHAFT
5 - INNER FENDER 2 - 1/2” WRENCH
4 - PARK BRAKE CABLE RETAINER
(12) Remove the rotor from the hub/bearing. 5 - ADAPTER
(13) Remove the horseshoe clip (Fig. 87) from the
retainer on the end of the park brake cable.
(14) Remove the end of the park brake cable from (16) Remove the attaching bolt from the wheel
the actuator lever on the adapter (Fig. 87). speed sensor (Fig. 89). Then remove wheel speed sen-
sor from hub/bearing and adapter.
SHOES (Continued)
Fig. 89 Speed Sensor Attaching Bolt Fig. 91 Hub/Bearing Removal And Installation
1 - ADAPTER 1 - PARK BRAKE BRAKE SHOE
2 - TONE WHEEL 2 - OUTER C/V JOINT
3 - WHEEL SPEED SENSOR 3 - HUB/BEARING
4 - AXLE 4 - PARK BRAKE BRAKE SHOE
5 - BOLT 5 - STUB SHAFT
6 - DRIVESHAFT
(19) Remove the adapter from the rear axle.

(17) Remove the hub/bearing to axle mounting (20) Mount the adapter in a vise using the anchor
bolts (Fig. 90). boss for the park brake cable (Fig. 92).
Fig. 90 Hub/Bearing Mounting Bolts Fig. 92 Adapter Mounted In Vise

1 - DRIVESHAFT 1 - ADAPTER
2 - MOUNTING BOLTS 2 - PARK BRAKE CABLE BOSS
3 - AXLE 3 - VISE
4 - MOUNTING BOLTS 4 - PARK BRAKE BRAKE SHOES
5 - ADAPTER
(21) Remove the lower return spring (Fig. 93) from

(18) Remove the hub/bearing from the axle and the the leading and trailing park brake shoes.
stub shaft of the outer C/V joint (Fig. 91).
SHOES (Continued)
Fig. 93 Lower Return Spring Fig. 95 Brake Shoe Adjuster

1 - ADAPTER 1 - LEADING PARK BRAKE SHOE
2 - LEADING PARK BRAKE SHOE 2 - ADJUSTER
3 - RETURN SPRING 3 - TRAILING PARK BRAKE SHOE
4 - TRAILING PARK BRAKE SHOE
(22) Remove the hold down spring and pin (Fig.

94) from the leading park brake shoe.
Fig. 96 Primary Brake Shoe Remove/Install

1 - PARK BRAKE ACTUATOR
2 - ANCHOR
3 - LEADING PARK BRAKE SHOE
Fig. 94 Leading Brake Shoe Hold Down Pin And 4 - UPPER RETURN SPRINGS
Spring 5 - TRAILING PARK BRAKE SHOE
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - ALLEN WRENCH
(25) Remove the upper return springs (Fig. 97)
4 - HOLD DOWN SPRING/PIN from the trailing park brake shoe.
(26) Remove the hold down spring and pin (Fig.
98) from the trailing park brake shoe.
(23) Remove the adjuster (Fig. 95) from the lead- (27) Remove the trailing park brake shoe from the
ing and trailing park brake shoe. adapter.
(24) Remove the leading park brake shoe (Fig. 96) (28) Remove the park brake shoe actuator from
from the adapter. Leading brake shoe is removed by the adapter and inspect for signs of abnormal wear
rotating the bottom of the brake shoe inward (Fig. and binding at the pivot point.
96) until the top of the brake shoe can be removed
from the brake shoe anchor. Then remove the upper
return springs (Fig. 96) from the leading brake shoe.
SHOES (Continued)
(3) Install the upper return springs (Fig. 97) on
the trailing park brake shoe.
(4) Install the upper return springs on the leading
park brake shoe (Fig. 96). Then position the top of
the leading park brake shoe at the upper anchor and
rotate the bottom of the shoe outward until correctly
installed on the adapter.
(5) Install the adjuster (Fig. 95) between the lead-
ing and trailing park brake shoe.
NOTE: When the hold down pin is installed, the

long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold
down pin is correctly engaged with the adapter.
(6) Install the hold down spring and pin (Fig. 94)
Fig. 97 Upper Return Springs on the leading park brake shoe.
(7) Install the lower return spring (Fig. 93) on the
1 - TRAILING PARK BRAKE SHOE
2 - ADAPTER
leading and trailing park brake shoes.When install-
3 - PARK BRAKE ACTUATOR ing the hold down spring it is to be installed
4 - UPPER RETURN SPRINGS behind the park brake shoes (Fig. 93).
(8) Install the 4 mounting bolts for the adapter
and hub/bearing into the bolt holes in the axle.
(9) Position the adapter on the 4 mounting bolts
installed in the rear axle (Fig. 99).
Fig. 98 Trailing Brake Shoe Hold Down Pin And

Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER Fig. 99 Adapter Installed On Mounting Bolts
3 - PARK BRAKE ACTUATOR 1 - DRIVESHAFT OUTER C/V JOINT
4 - TRAILING PARK BRAKE SHOE 2 - MOUNTING BOLTS
5 - ALLEN WRENCH 3 - ADAPTER
4 - PARK BRAKE SHOES
5 - MOUNTING BOLTS
INSTALLATION
(1) Install the trailing brake shoe on the adapter.
(10) Install the hub/bearing on the stub shaft of
NOTE: When the hold down pin is installed, the outer C/V joint and into the end of the axle. (Fig. 91).
long part of the hold down pin is to be positioned (11) In a progressive crisscross pattern, tighten the
strait up and down. This will ensure that the hold 4 hub/bearing mounting bolts until the hub/bearing
down pin is correctly engaged with the adapter. is squarely seated against the axle. Then tighten the
hub/bearing mounting bolts to a torque of 129 N·m
(2) Install the hold down spring and pin (Fig. 98) (95 ft. lbs.).
on the trailing park brake shoe.
SHOES (Continued)
(12) Install the wheel speed sensor on the hub/ until all nuts are torqued to half specification. Then
bearing and adapter. Install the wheel speed sensor repeat the tightening sequence to the full specified
attaching bolt (Fig. 89). Tighten the wheel speed sen- torque of 135 N·m (100 ft. lbs.).
sor attaching bolt to a torque of 12 N·m (105 in. lbs). (27) Lower vehicle.
(13) Install the park brake cable into its mounting (28) Fully apply and release the park brake pedal
hole in the adapter. Be sure all the locking tabs one time. This will seat and correctly adjust the park
on the park brake cable retainer are expanded brake cables.
out to ensure the cable will not pull out of the
adapter. CAUTION: Before moving vehicle, pump the brake
(14) Install the end of the park brake cable on the pedal several times to insure the vehicle has a firm
park brake actuator lever (Fig. 87). brake pedal to adequately stop vehicle.
NOTE: The horseshoe clip must be installed and (29) Road test the vehicle and make several stops
installed properly when the park brake cable is to wear off any foreign material on the brakes and to
installed in the adapter. The purpose of the horse- seat the brake shoe linings.
shoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not ADJUSTMENT - PARKING BRAKE SHOES
installed the park brake cable retainer will rattle in
the adapter. CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
(15) Install a NEW horseshoe clip on the park released position. If park brake pedal is not in the
brake cable retainer (Fig. 87). The horseshoe clip is fully released position, the park brake shoes can
installed between the retainer for the park brake not be accurately adjusted.
cable and the adapter. Horseshoe clip must be
installed with the curved end of the clip pointing (1) Raise vehicle.
straight up and the edge of the curved end facing (2) Remove tire and wheel.
toward the rear of the vehicle (Fig. 87). (3) Remove disc brake caliper from caliper adapter
(16) Remove the locking pliers (Fig. 83) from the (Fig. 100). (Refer to 5 - BRAKES/HYDRAULIC/ME-
front park brake cable. CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(17) Adjust the park brake drum-in-hat brake
shoes. (Refer to 5 - BRAKES/PARKING BRAKE/
SHOES - ADJUSTMENTS).
(18) Install the rotor on the hub/bearing.
(19) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 85).
CAUTION: When installing guide pin bolts extreme

caution should be taken not to crossthread the cal-
(20) Install the caliper guide pin bolts (Fig. 84).

Tighten the guide pin bolts to a torque of 22 N·m
(192 in. lbs.).
(21) Clean all foreign material off the threads of
the outer C/V joint stub shaft. Install the washer and
Fig. 100 Disc Brake Caliper
hub nut (Fig. 82) on the stub shaft of the outer C/V
joint.
2 - ADAPTER
(22) Set the parking brake.
3 - AXLE
(23) Tighten the hub nut to a torque of 244 N·m 4 - GUIDE PIN BOLTS
(180 ft. lbs.). 5 - DRIVESHAFT (AWD MODELS ONLY)
(24) Install the spring washer (Fig. 81) on the stub
shaft of the outer C/V joint.
(25) Install the nut retainer and cotter pin (Fig. (4) Remove rotor from hub/bearing.
80) on the stub shaft of the outer C/V joint.
(26) Install the wheel and tire assembly. Tighten
the wheel mounting stud nuts in proper sequence
SHOES (Continued)
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Using Gauge, Brake Shoe, Special Tool C-3919

or an equivalent, accurately measure the inside
diameter of the park brake drum portion of the rotor
(Fig. 101).
Fig. 103 Setting Gauge To Park Brake Shoe

Measurement
1 - RULER
(8) Place Gauge, Brake Shoe, Special Tool C-3919,

or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
Fig. 101 Measuring Park Brake Drum Diameter of the park brake shoes.
(6) Using a ruler that reads in 64th of an inch, (9) Using the star wheel adjuster, adjust the park
accurately read the measurement of the inside diam- brake shoes until the lining on the park brake shoes
eter of the park brake drum from the special tool just touches the jaws on the special tool.
(Fig. 102). (10) Repeat step 8 above and measure shoes in
both directions.
(11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum.
(13) Install disc brake caliper on caliper adapter
(Fig. 100). (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION).
(14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
Fig. 102 Reading Park Brake Drum Diameter specified torque. Then repeat the tightening sequence
1 - SPECIAL TOOL C-3919 to the full specified torque of 129 N·m (95 ft. lbs.).
2 - RULER (16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
(7) Reduce the inside diameter measurement of
brake cables.
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, CAUTION: Before moving vehicle, pump brake
Special Tool C-3919 or the equivalent used, so that pedal several times to ensure the vehicle has a firm
the outside measurement jaws are set to the reduced enough pedal to stop the vehicle.
measurement (Fig. 103).
SHOES (Continued)
(18) Road test the vehicle to ensure proper func-
tion of the vehicle’s brake system.
CABLES - PARKING BRAKE

REMOVAL - PARKING BRAKE CABLE (FRONT)
(1) Raise vehicle on jackstands or centered on a
hoist. (Refer to LUBRICATION & MAINTENANCE/
HOISTING - STANDARD PROCEDURE).
(2) Manually release the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
(3) Remove the intermediate and left rear park
brake cable from the park brake cable equalizer (Fig.
104). Fig. 105 Front Park Brake Cable Attachment To
Body
1 - CABLE HOUSING RETAINER
2 - BODY OUTRIGGER BRACKET
3 - PUSH WRENCH OVER END OF RETAINER HERE
4 - FRONT PARK BRAKE CABLE
Fig. 104 Park Brake Cable Attachment To Equalizer

1 - EQUALIZER
3 - LOCKING NUT
Fig. 106 Front Park Brake Cable At Floor Pan

(4) Remove the front park cable housing retainer
1 - PARK BRAKE PEDAL ASSEMBLY
from body outrigger bracket (Fig. 105). Cable is
2 - PARK BRAKE PEDAL
removable by sliding a 14 mm box wrench over cable 3 - CARPET
retainer and compressing the three retaining fingers. 4 - FRONT PARK BRAKE CABLE
Alternate method is to use an aircraft type hose 5 - SEAL
clamp and screwdriver. 6 - FLOOR PAN
(5) Lower vehicle.
(6) Remove the left front door sill molding.
(10) Remove cable retainer from the parking brake
(7) Remove the left front kick panel for access to
lever (pedal) assembly bracket.
the park brake cable and park brake pedal assembly.
(11) Pull front parking brake cable assembly out of
(8) Lift floor mat for access to park brake cable
vehicle through hole in floor pan.
and floor pan. Pull the seal and the park brake cable
(Fig. 106) out of the floor pan of vehicle.
(9) Pull parking brake cable strand end forward
and disconnect button from clevis. Tap cable housing
end fitting out of pedal assembly bracket.
CABLES (Continued)
REMOVAL - PARKING BRAKE CABLE

(INTERMEDIATE)
DURE).
(2) Manually lock out the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
izer, do not remove the locking pliers until
reinstallation of the cable is complete.
(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 107).
Fig. 108 Intermediate Cable Attachment To Right

1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
REMOVAL - PARKING BRAKE CABLE (RIGHT

REAR)
(2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable.
Fig. 107 Parking Brake Cable Attachment To (4) Create slack in the rear parking brake cables
Equalizer by locking out the automatic adjuster as described
1 - EQUALIZER here. Grasp an exposed section of front parking
2 - LEFT REAR PARKING BRAKE CABLE brake cable near the equalizer and pull down on it.
3 - LOCKING NUT At this time install a pair of locking pliers on the
4 - INTERMEDIATE PARKING BRAKE CABLE cable just rearward of the second body outrigger
5 - FRONT PARKING BRAKE CABLE bracket (Fig. 109).
(4) Remove the locking nut securing the interme-

diate cable housing to the side bracket on the frame
rail (Fig. 107).
from the cable connector attaching it to the right
rear parking brake cable (Fig. 108). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 108).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank
far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
from the side brackets and vehicle.
Fig. 109 Locking Out Automatic Adjuster
3 - LOCKING PLIERS
CABLES (Continued)
(5) Disconnect the right rear parking brake cable (7) Remove the brake shoes from the brake sup-
from the connector on the intermediate cable (Fig. port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
110). CHANICAL/BRAKE PADS/SHOES - REMOVAL).
(8) Disconnect parking brake cable from parking
brake actuator lever.
(9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 112).
Remove the cable.
Fig. 110 Right Rear Cable Connection To

Intermediate Cable
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
(6) To remove the right parking brake cable hous-

ing from the body bracket, slide a 14 mm box end Fig. 112 Removing Park Brake Cable From Brake
wrench over the end of cable retainer to compress the Support Plate
retaining fingers (Fig. 111). The alternate method 1 - PARK BRAKE CABLE RETAINER
using an aircraft type hose clamp will not work on 2 - PARK BRAKE CABLE
the right side of the vehicle. 3 - 14MM BOX WRENCH
REMOVAL - PARKING BRAKE CABLE (LEFT

REAR)
(2) Remove rear tire and wheel assembly.
(3) Remove rear brake drum from the rear wheel
of the vehicle requiring service to the rear park
brake cable.
(4) Create slack in rear park brake cables by lock-
ing out the automatic adjuster as described here.
Grasp an exposed section of front park brake cable
near the equalizer and pull down on it. Then install
a pair of locking pliers on the cable just rearward of
Fig. 111 Right Park Brake Cable Removal From the second body outrigger bracket (Fig. 113).
Body Bracket (5) Disconnect the left rear parking brake cable
1 - RIGHT REAR BODY BRACKET from the parking brake cable equalizer (Fig. 114).
3 - 14MM WRENCH
4 - LEAF SPRING AND BRACKET
CABLES (Continued)
Fig. 113 Locked Out Park Brake Automatic Adjuster Fig. 115 Parking Brake Cable Removal From Body
1 - PARK BRAKE CABLE Bracket
2 - REAR BODY OUTRIGGER BRACKET 1 - LEFT REAR PARK BRAKE CABLE
3 - LOCKING PLIERS 2 - BODY BRACKET
3 - LEAF SPRING MOUNTING BRACKET
4 - CABLE RETAINER
5 - 14MM BOX WRENCH
(9) Remove the parking brake cable housing

retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 116).
Fig. 114 Parking Brake Cables At Equalizer

1 - EQUALIZER
3 - LOCKING NUT
(6) To remove parking brake cable housing from Fig. 116 Removing Parking Brake Cable From Brake
the body bracket, slide a 14 mm box end wrench over Support Plate
retainer end compressing the three fingers (Fig. 115). 1 - PARK BRAKE CABLE RETAINER
Alternate method is to use an aircraft type hose 2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
clamp.
(7) Remove the brake shoes from the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
(8) Disconnect parking brake cable from parking
brake actuator lever.
CABLES (Continued)
INSTALLATION - PARKING BRAKE CABLE (4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
(FRONT)
cable (Fig. 108).
(1) Pass front parking brake cable assembly
(5) Install the intermediate park brake cable on
through hole in floor pan from the inside of the vehi-
the cable equalizer (Fig. 107).
cle.
(6) Remove the locking pliers from the front park
(2) Pass cable strand button through the hole in
brake cable. This will activate the automatic adjuster
the lever (pedal) assembly bracket.
and correctly adjust the parking brake cables.
(3) Install cable retainer onto the park brake cable
(7) Install and position the foam collar on the
and then install cable retainer into pedal assembly
parking brake cable to prevent it from rattling
bracket.
against the vehicle’s floor.
(4) Install the end of the park brake cable into the
(8) Lower the vehicle and apply the park brake
retainer previously installed into the park brake
pedal 1 time, this will seat the park brake cables.
pedal bracket.
(5) Install cable strand button into the clevis on
the park brake pedal mechanism.
INSTALLATION - PARKING BRAKE CABLE
(6) Install the front park brake cable floor pan seal (RIGHT REAR)
into hole in floor pan . Seal is to be installed so the (1) Install the rear parking brake cable in the
flange on the seal is flush with the floor pan (Fig. brake support plate. Insert cable housing retainer
106). Fold carpeting back down on floor. into brake support plate making certain that cable
(7) Raise vehicle. housing retainer fingers lock the housing and
(8) Insert brake cable and housing into body out- retainer firmly into place.
rigger bracket making certain that housing retainer (2) Attach the parking brake cable onto the park-
fingers lock the housing firmly into place (Fig. 105). ing brake actuator lever.
(9) Manually reset the automatic self-adjusting (3) Install the brake shoes on the rear brake sup-
mechanism tension of the parking brake lever (pedal) port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
assembly. (Refer to 5 - BRAKES - STANDARD PRO- CHANICAL/BRAKE PADS/SHOES -
CEDURE). INSTALLATION).
(10) Assemble the park brake cables onto the park (4) Insert cable housing retainer into body outrig-
brake cable equalizer (Fig. 104). ger bracket making certain that cable housing
(11) Lower vehicle and apply the park brake pedal retainer fingers lock the housing firmly into place.
1 time. This will seat the parking brake cables. (5) Connect the right rear parking brake cable to
the connector on the intermediate parking brake
INSTALLATION - PARKING BRAKE CABLE cable (Fig. 110).
(6) Install the brake drum, then the wheel and tire
(INTERMEDIATE)
assembly.
(1) Install the ends of the park brake cables
(7) Remove the locking pliers from the front park
through the frame rails and into the side brackets.
brake cable. This will automatically adjust the park
(2) Install the locking nuts at each end of the cable
brake cables.
and securely tighten (Fig. 107) (Fig. 108).
(3) If the vehicle is a short-wheel-base model, it
(9) Apply and release park brake pedal 1 time.
will be necessary to reinstall the fuel tank to its nor-
This will seat the park brake cables.
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION).
CABLES (Continued)
INSTALLATION - PARKING BRAKE CABLE ADJUSTMENT - CABLES

(LEFT REAR) The park brake cables on this vehicle have an
(1) Install the rear parking brake cable in the automatic self adjuster built into the park brake
brake support plate. Insert cable housing retainer pedal mechanism. When the foot operated park brake
into brake support plate making certain that cable pedal is in its released (upward most) position, a
housing retainer fingers lock the housing and clock spring automatically adjusts the park brake
retainer firmly into place. cables. The park brake cables are adjusted (ten-
(2) Attach the parking brake cable onto the park sioned) just enough to remove all the slack from the
brake actuator lever. cables. The automatic adjuster system will not over
(3) Install the brake shoes on the rear brake sup- adjust the cables causing rear brake drag.
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME- Due to the automatic adjust feature of the park
CHANICAL/BRAKE PADS/SHOES - brake pedal, adjustment of the parking brake cables
INSTALLATION). on these vehicles relies on proper drum brake and
(4) Insert cable housing retainer into body outrig- park brake shoe adjustment. (Refer to 5 - BRAKES/
ger bracket making certain that cable housing HYDRAULIC/MECHANICAL/DRUM - ADJUST-
retainer fingers lock the housing firmly into place. MENTS) and (Refer to 5 - BRAKES/PARKING
(5) Connect rear parking brake cable to the equal- BRAKE/SHOES - ADJUSTMENTS).
izer bracket (Fig. 114). When the park brake pedal is applied the self
(6) Install brake drum, and wheel and tire assem- adjuster is by-passed and the pedal operates nor-
bly. mally to engage the park brakes.
(7) Remove the locking pliers from the front park When a service procedure needs to be performed on
brake cable. This will automatically adjust the park the park brake pedal or the park brake cables, the
brake cables. automatic self adjuster can be manually locked out
(8) Apply and release park brake pedal 1 time. by the service technician.
This will seat the park brake cables.
RS BRAKES - ABS 5 - 67
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 TONE WHEEL
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 TRACTION CONTROL SWITCH
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 70 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 74
ANTILOCK BRAKE SYSTEM BLEEDING . . . . . 70 TRACTION CONTROL SWITCH . . . . . . . . . . . . 74
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 71 ICU (INTEGRATED CONTROL UNIT)
FRONT WHEEL SPEED SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
REAR WHEEL SPEED SENSOR - AWD DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR WHEEL SPEED SENSOR - FWD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
BRAKES - ABS HYDRAULIC SHUTTLE VALVES

Two pressure relief hydraulic shuttle valves are
DESCRIPTION - ANTILOCK BRAKE SYSTEM included on vehicles with traction control. These
This section covers the physical and operational valves are located inside the HCU and cannot be ser-
descriptions and the on-car service procedures for the viced separately from the HCU.
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control. TRACTION CONTROL LAMP
The purpose of the antilock brake system (ABS) is The traction control function lamp is located in the
to prevent wheel lockup under braking conditions on transmission range indicator display of the instru-
virtually any type of road surface. Antilock braking is ment cluster, displaying TRAC, TRAC OFF or nei-
desirable because a vehicle that is stopped without ther depending on system mode.
locking the wheels retains directional stability and The TRAC OFF lamp is controlled by a Traction
some steering capability. This allows the driver to Control Off switch that is a momentary contact type
retain greater control of the vehicle during braking. switch. The Traction Control Off switch is located on
the steering column upper shroud.
DESCRIPTION - ELECTRONIC BRAKE
OPERATION - ANTILOCK BRAKE SYSTEM
DISTRIBUTION There are a few performance characteristics of the
Vehicles equipped with ABS use electronic brake
Mark 20e Antilock Brake System that may at first
distribution (EBD) to balance front-to-rear braking.
seem abnormal, but in fact are normal. These char-
The EBD is used in place of a rear proportioning
acteristics are described below.
valve. The EBD system uses the ABS system to con-
trol the slip of the rear wheels in partial braking NORMAL BRAKING
range. The braking force of the rear wheels is con-
Under normal braking conditions, the ABS func-
trolled electronically by using the inlet and outlet
tions the same as a standard base brake system with
valves located in the integrated control unit (ICU).
a diagonally split master cylinder and conventional
vacuum assist.
DESCRIPTION - TRACTION CONTROL SYSTEM
Traction control reduces wheel slip and maintains ABS BRAKING
traction at the driving wheels at speeds below 56 ABS operation is available at all vehicle speeds
km/h (35 mph) when road surfaces are slippery. The above 3–5 mph. If a wheel locking tendency is
traction control system reduces wheel slip by braking detected during a brake application, the brake sys-
the wheel that is losing traction.
5 - 68 BRAKES - ABS RS
BRAKES - ABS (Continued)
tem enters the ABS mode. During ABS braking, Complete wheel lockup normally leaves black tire
hydraulic pressure in the four wheel circuits is mod- marks on dry pavement. The ABS will not leave dark
ulated to prevent any wheel from locking. Each black tire marks since the wheel never reaches a
wheel circuit is designed with a set of electric sole- fully locked condition. However, tire marks may be
noids to allow modulation, although for vehicle sta- noticeable as light patched marks.
bility, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at START-UP CYCLE
the very end of an ABS stop and is considered nor- When the ignition is turned on, a popping sound
mal. and a slight brake pedal movement may be noticed.
During an ABS stop, the brakes hydraulic system The ABS warning lamp will also be on for up to 5
is still diagonally split. However, the brake system seconds after the ignition is turned on. When the
pressure is further split into three control channels. vehicle is first driven off, a humming may be heard
During antilock operation of the vehicle’s brake sys- or felt by the driver at approximately 20–40 kph
tem, the front wheels are controlled independently (12–25 mph). All of these conditions are a normal
and are on two separate control channels, and the function of ABS as the system is performing a diag-
rear wheels of the vehicle are controlled together. nosis check.
The system can build and release pressure at each
wheel, depending on signals generated by the wheel PREMATURE ABS CYCLING
speed sensors (WSS) at each wheel and received at Symptoms of premature ABS cycling include: click-
the controller antilock brake (CAB). ing sounds from the solenoid valves; pump/motor
running; and pulsations in the brake pedal. Prema-
NOISE AND BRAKE PEDAL FEEL ture ABS cycling can occur at any braking rate of the
During ABS braking, some brake pedal movement vehicle and on any type of road surface. Neither the
may be felt. In addition, ABS braking will create red BRAKE warning lamp, nor the amber ABS warn-
ticking, popping, or groaning noises heard by the ing lamp, illuminate and no fault codes are stored in
driver. This is normal and is due to pressurized fluid the CAB.
being transferred between the master cylinder and Premature ABS cycling is a condition that needs to
the brakes. If ABS operation occurs during hard be correctly assessed when diagnosing problems with
braking, some pulsation may be felt in the vehicle the antilock brake system. It may be necessary to use
body due to fore and aft movement of the suspension a DRB scan tool to detect and verify premature ABS
as brake pressures are modulated. cycling.
At the end of an ABS stop, ABS is turned off when Check the following common causes when diagnos-
the vehicle is slowed to a speed of 3–4 mph. There ing premature ABS cycling: damaged tone wheels;
may be a slight brake pedal drop anytime that the incorrect tone wheels; damaged steering knuckle
ABS is deactivated, such as at the end of the stop wheel speed sensor mounting bosses; loose wheel
when the vehicle speed is less than 3 mph or during speed sensor mounting bolts; excessive tone wheel
an ABS stop where ABS is no longer required. These runout; or an excessively large tone wheel-to-wheel
conditions exist when a vehicle is being stopped on a speed sensor air gap. Give special attention to these
road surface with patches of ice, loose gravel, or sand components when diagnosing a vehicle exhibiting
on it. Also, stopping a vehicle on a bumpy road sur- premature ABS cycling.
face activates ABS because of the wheel hop caused After diagnosing the defective component, repair or
by the bumps. replace it as required. When the component repair or
replacement is completed, test drive the vehicle to
TIRE NOISE AND MARKS verify that premature ABS cycling has been cor-
Although the ABS system prevents complete wheel rected.
lockup, some wheel slip is desired in order to achieve
optimum braking performance. Wheel slip is defined OPERATION - ELECTRONIC BRAKE
as follows: 0 percent slip means the wheel is rolling DISTRIBUTION
freely and 100 percent slip means the wheel is fully Upon entry into EBD the inlet valve for the rear
locked. During brake pressure modulation, wheel slip brake circuit is switched on so that the fluid supply
is allowed to reach up to 25–30 percent. This means from the master cylinder is shut off. In order to
that the wheel rolling velocity is 25–30 percent less decrease the rear brake pressure, the outlet valve for
than that of a free rolling wheel at a given vehicle the rear brake circuit is pulsed. This allows fluid to
speed. This slip may result in some tire chirping, enter the low pressure accumulator (LPA) in the
depending on the road surface. This sound should not hydraulic control unit (HCU) resulting in a drop in
be interpreted as total wheel lockup. fluid pressure to the rear brakes. In order to increase
the rear brake pressure, the outlet valve is switched If the CAB calculates that the brake temperatures
off and the inlet valve is pulsed. This increases the are high, the traction control system becomes inoper-
pressure to the rear brakes. This back-and-forth pro- ative until a time-out period has elapsed. During this
cess will continue until the required slip difference is “thermo-protection mode,” the traction control func-
obtained. At the end of EBD braking (brakes tion lamp illuminates TRAC OFF; note that no trou-
released) the fluid in the LPA drains back to the ble code is registered.
master cylinder by switching on the outlet valve and
draining through the inlet valve check valve. At the CAUTION
same time the inlet valve is switched on in case of The ABS uses an electronic control module, the
another brake application. CAB. This module is designed to withstand normal
The EBD will remain functional during many ABS current draws associated with vehicle operation.
fault modes. If both the red BRAKE, and amber ABS Care must be taken to avoid overloading the CAB
warning indicators are illuminated, the EBD may not circuits.
be functioning.
CAUTION: In testing for open or short circuits, do
OPERATION - TRACTION CONTROL SYSTEM not ground or apply voltage to any of the circuits
The traction control module monitors wheel speed. unless instructed to do so for a diagnostic proce-
During acceleration, if the module detects front dure.
(drive) wheel slip and the brakes are not applied, the
module enters traction control mode. Traction control
CAUTION: These circuits should only be tested
operation proceeds in the following order:
using a high impedance multi-meter or the DRBIIIT
(1) Close the normally open isolation valves.
scan tool as described in this section. Power
(2) Start the pump/motor and supply volume and
should never be removed or applied to any control
pressure to the front (drive) hydraulic circuit. (The
module with the ignition in the ON position. Before
pump/motor runs continuously during traction con-
removing or connecting battery cables, fuses, or
trol operation.)
connectors, always turn the ignition to the OFF
(3) Open and close the build and decay valves to
position.
maintain minimum wheel slip and maximum trac-
tion.
The cycling of the build and decay valves during CAUTION: The CAB 24-way connector should never
traction control is similar to that during antilock be connected or disconnected with the ignition
braking, except the valves work to control wheel spin switch in the ON position.
by applying the brakes, whereas the ABS function is
to control wheel skid by releasing the brakes.
If the brakes are applied at anytime during a trac- CAUTION: Use only factory wiring harnesses. Do
tion control cycle, the brake lamp switch triggers the not cut or splice wiring to the brake circuits. The
controller to switch off traction control. addition of aftermarket electrical equipment (car
phone, radar detector, citizen band radio, trailer
HYDRAULIC SHUTTLE VALVES lighting, trailer brakes, etc.) on a vehicle equipped
Two pressure relief hydraulic shuttle valves allow with antilock brakes may affect the function of the
pressure and volume to return to the master cylinder antilock brake system.
reservoir when not consumed by the build and decay
valves. These valves are necessary because the
CAUTION: When performing any service procedure
pump/motor supplies more volume than the system
on a vehicle equipped with ABS, do not apply a
requires.
12-volt power source to the ground circuit of the
TRACTION CONTROL LAMP pump motor in the HCU. Doing this will damage the
pump motor and will require replacement of the
The traction control system is enabled at each igni-
entire HCU.
tion cycle. It may be turned off by depressing the
Traction Control Off switch button when the ignition
is in the ON position. The traction control function CAUTION: An attempt to remove or disconnect cer-
lamp (TRAC OFF) illuminates immediately upon tain system components may result in improper
depressing the button. system operation. Only those components with
The traction control function lamp illuminates dur- approved removal and installation procedures in
ing a traction control cycle, displaying TRAC. this manual should be serviced.
CAUTION: If welding work is to be performed on the with ABS is to be bled the same as any non-ABS sys-
vehicle, using an electric arc welder, the CAB con- tem.
nector should be disconnected during the welding The ABS portion of the brake system must be bled
operation. separately. Use the following procedure to properly
bleed the brake hydraulic system including the ABS.
CAUTION: Many components of the ABS System BLEEDING

are not serviceable and must be replaced as an When bleeding the ABS system, the following
assembly. Do not disassemble any component bleeding sequence must be followed to insure com-
which is not designed to be serviced. plete and adequate bleeding.
(1) Make sure all hydraulic fluid lines are installed
CAUTION: Only the recommended jacking or hoist- and properly torqued.
ing positions for this vehicle are to be used when- (2) Connect the DRBIIIt scan tool to the diagnos-
ever it is necessary to lift a vehicle. Failure to raise tics connector. The diagnostic connector is located
a vehicle from the recommended locations could under the lower steering column cover to the left of
result in lifting a vehicle by the hydraulic control the steering column.
unit mounting bracket. Lifting a vehicle by the (3) Using the DRB, check to make sure the CAB
hydraulic control unit mounting bracket will result does not have any fault codes stored. If it does, clear
in damage to the mounting bracket and the hydrau- them using the DRB.
lic control unit.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM
WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
CAUTION: Brake fluid will damage painted surfaces. MUST BE ATTACHED TO THE BLEEDER SCREWS
If brake fluid is spilled on any painted surface, AND SUBMERGED IN A CLEAR CONTAINER FILLED
wash off with water immediately. PART WAY WITH CLEAN BRAKE FLUID. DIRECT
THE FLOW OF BRAKE FLUID AWAY FROM YOUR-
SELF AND THE PAINTED SURFACES OF THE VEHI-
STANDARD PROCEDURE - ANTILOCK BRAKE CLE. BRAKE FLUID AT HIGH PRESSURE MAY
SYSTEM BLEEDING COME OUT OF THE BLEEDER SCREWS WHEN
The base brake’s hydraulic system must be bled OPENED.
anytime air enters the hydraulic system. The ABS
(4) Bleed the base brake system using the stan-
though, particularly the ICU (HCU), should only be
dard pressure or manual bleeding procedure. (Refer
bled when the HCU is replaced or removed from the
to 5 - BRAKES - BASE - STANDARD PROCEDURE)
vehicle. The ABS must always be bled anytime it is
(5) Using the DRB, select ANTILOCK BRAKES,
suspected that the HCU has ingested air. Under
followed by MISCELLANEOUS, then BLEED
most circumstances that require the bleeding of the
BRAKES. Follow the instructions displayed. When
brakes hydraulic system, only the base brake
the scan tool displays TEST COMPLETED, discon-
hydraulic system needs to be bled.
nect the scan tool and proceed.
It is important to note that excessive air in the
(6) Bleed the base brake system a second time.
brake system will cause a soft or spongy feeling
Check brake fluid level in the reservoir periodically
brake pedal.
to prevent emptying, causing air to enter the hydrau-
During the brake bleeding procedure, be sure the
lic system.
brake fluid level remains close to the FULL level in
(7) Fill the master cylinder reservoir to the full
the master cylinder fluid reservoir. Check the fluid
level.
level periodically during the bleeding procedure and
(8) Test drive the vehicle to be sure the brakes are
add DOT 3 brake fluid as required.
operating correctly and that the brake pedal does not
The ABS must be bled as two independent braking
feel spongy.
systems. The non-ABS portion of the brake system
SPECIFICATIONS
SPECIFICATIONS - ABS FASTENER TORQUE
(Refer to 5 - BRAKES - BASE - SPECIFICA-
TIONS)
TONE WHEEL RUNOUT
Front Tone Wheel
0.15 mm (0.006 in.)
Maximum Runout
Rear Tone Wheel
0.15 mm (0.006 in.)
Maximum Runout
WHEEL SPEED SENSOR AIR GAP

Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
DESCRIPTION SPECIFICATION 2 - WHEEL SPEED SENSOR
0.35 – 1.20 mm 3 - DRIVESHAFT
Front Sensor 4 - TONE WHEEL
0.014 – 0.047 in.
0.40 – 1.20 mm
Rear Sensor
0.016 – 0.047 in.
INSTALLATION - WHEEL SPEED SENSOR
FRONT WHEEL SPEED (FRONT)
SENSOR CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
REMOVAL - WHEEL SPEED SENSOR (FRONT) Be sure that cables are installed in retainers. Fail-
(1) Raise vehicle. (Refer to LUBRICATION & ure to install cables in retainers as shown in this
MAINTENANCE/HOISTING - STANDARD PROCE- section may result in contact with moving parts and
DURE) over extension of cables, resulting in an open cir-
(2) Remove the tire and wheel assembly. cuit.
(3) Remove the sensor cable routing clamp screws.
(1) Connect the front wheel speed sensor cable to
CAUTION: When disconnecting the wheel speed the vehicle wiring harness connector. Be sure speed
sensor from vehicle wiring harness, be careful not sensor cable connector is fully seated and locked into
to damage pins on connector vehicle wiring harness connector.
(2) Install the bolts attaching the routing clamps
(4) Remove speed sensor cable grommets from to the body of the vehicle. Tighten the bolts to a
intermediate bracket on strut. torque of 11 N·m (95 in. lbs.).
(5) Disconnect speed sensor cable from vehicle wir- (3) Insert speed sensor cable grommets into inter-
ing harness behind fender well shield. mediate bracket on strut.
(6) Remove the wheel speed sensor head mounting (4) Install the wheel speed sensor head mounting
bolt (Fig. 1). bolt (Fig. 1). Tighten the bolt to a torque of 12 N·m
(7) Remove sensor head from steering knuckle. If (105 in. lbs.)
sensor has seized due to corrosion, DO NOT USE (5) Install the wheel and tire assembly on vehicle.
PLIERS ON SENSOR HEAD. Use a hammer and a (6) Lower vehicle.
punch and tap edge of sensor ear, rocking the sensor (7) Road test vehicle to ensure proper operation of
side-to-side until free. the base and ABS brake systems.
(8) Remove front wheel speed sensor from vehicle.
REAR WHEEL SPEED SENSOR punch and tap mounting flange edge side-to-side,
rocking the sensor until free.
- AWD
(5) Remove wheel speed sensor head attaching
REMOVAL - WHEEL SPEED SENSOR bolt.
(REAR-AWD) (6) Remove wheel speed sensor head from the axle,
(1) Raise vehicle. (Refer to LUBRICATION & and remove sensor from vehicle.
DURE) INSTALLATION - WHEEL SPEED SENSOR
(REAR-AWD)
CAUTION: When disconnecting speed sensor cable
from vehicle wiring harness be careful not to dam- CAUTION: Proper installation of wheel speed sen-
age pins on the electrical connectors. Also, inspect sor cables is critical to continued system operation.
connectors for any signs of previous damage. Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as indicated may
(2) Remove grommet from floor pan of vehicle and result in contact with moving parts or over-exten-
disconnect speed sensor cable connector from vehicle sion of cables, resulting in an open circuit.
wiring harness (Fig. 2).
(1) Install wheel speed sensor head in axle flange.
CAUTION: Prior to installing the speed sensor head

attaching bolt, the plastic anti-rotation pin must be
fully seated into the bearing flange.
(2) Install wheel speed sensor head attaching bolt.

Tighten bolt to a torque 12 N·m (105 in. lbs.).
(3) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone
wheel. (Refer to 5 - BRAKES - SPECIFICATIONS)
CAUTION: When installing wheel speed sensor

cable in the routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake hose if damaged.
Fig. 2 WHEEL SPEED SENSOR CONNECTOR
(4) Install speed sensor cable under leaf spring
1 - CONNECTOR
2 - FLOOR PAN
onto brake hose and tubing utilizing routing clips to
3 - GROMMET secure it in place.
(5) Install metal routing clip on speed sensor cable
and mount it to rear of axle with mounting bolt.
CAUTION: When removing rear wheel speed sensor Tighten mounting bolt to 16 N·m (140 in. lbs.).
cable from routing clips, be sure not to damage the (6) Connect wheel speed sensor cable to vehicle
routing clips. Routing clips that are molded onto wiring harness (Fig. 2).Be sure speed sensor cable
the brake hose will require replacement of the brake connector is fully seated and locked into vehi-
hose if damaged during removal or installation of cle wiring harness connector.
the speed sensor cable. (7) Install speed sensor cable grommet into the
floor pan, being sure the grommet is fully seated into
(3) Carefully remove speed sensor cable from
the access hole.
press-in routing clips along brake hose and tubing.
(8) Lower vehicle.
(4) Remove bolt securing wheel speed sensor cable
metal clip to rear of axle. Remove metal clip from
the base and ABS braking systems.
cable if necessary.
CAUTION: If speed sensor head has seized due to

corrosion, do not use pliers on speed sensor head
in an attempt to remove it. Use a hammer and a
REAR WHEEL SPEED SENSOR

- FWD
REMOVAL - WHEEL SPEED SENSOR
(REAR-FWD)
DURE)
CAUTION: When disconnecting speed sensor cable

from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Remove grommet from floor pan of vehicle and

disconnect speed sensor cable connector from vehicle Fig. 4 SPEED SENSOR CABLE ROUTING
wiring harness (Fig. 3).
1 - METAL CLIP AND MOUNTING BOLT
2 - ROUTING CLIPS
(6) Push up on metal retaining clip (Fig. 5) until it

bottoms. This will release wheel speed sensor head
from hub and bearing. While holding metal clip up,
pull back on wheel speed sensor head removing it
from hub and bearing.
Fig. 3 WHEEL SPEED SENSOR CONNECTOR

1 - CONNECTOR
2 - FLOOR PAN
3 - GROMMET
CAUTION: When removing rear wheel speed sensor

cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto Fig. 5 SENSOR CONNECTION AT HUB AND
the brake hose will require replacement of the brake BEARING
hose if damaged during removal or installation of 1 - SECONDARY SENSOR RETAINING CLIP
the speed sensor cable. 2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
(3) Carefully remove speed sensor cable from
press-in routing clips (Fig. 4).
(4) Remove bolt securing metal routing clip to rear (7) Remove wheel speed sensor assembly from
of axle and remove sensor cable from metal clip (Fig. vehicle.
4).
(5) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 5).
REAR WHEEL SPEED SENSOR - FWD (Continued)
INSTALLATION - WHEEL SPEED SENSOR Tone wheels can cause erratic wheel speed sensor
signals. Inspect tone wheels for the following possible
(REAR-FWD)
causes.
CAUTION: Proper installation of wheel speed sen- • missing, chipped, or broken teeth
sor cable is critical to continued system operation. • contact with the wheel speed sensor
Be sure that cable is installed in routing retainers/ • wheel speed sensor to tone wheel alignment
clips. Failure to install cable in retainers may result • wheel speed sensor to tone wheel clearance
in contact with moving parts or over extension of • excessive tone wheel runout
cable, resulting in an open circuit. • tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement,
the drive shaft must be replaced. No attempt should
NOTE: Make sure wheel speed sensor stays clean be made to replace just the tone wheel. (Refer to 3 -
and dry as it is installed into the hub and bearing DIFFERENTIAL & DRIVELINE/HALF SHAFT -
cap. REMOVAL)
If a rear tone wheel is found to need replacement
(1) If metal sensor retaining clip is not in the neu- on an all-wheel-drive model, the drive shaft must be
tral installed position on hub and bearing cap, install replaced. No attempt should be made to replace just
from the bottom, if necessary, and push clip upward the tone wheel. (Refer to 3 - DIFFERENTIAL &
until it snaps into position. DRIVELINE/HALF SHAFT - REMOVAL)
(2) Install wheel speed sensor head into rear of If wheel speed sensor to tone wheel contact is evi-
hub and bearing aligning index tab with the notch in dent, determine the cause and correct it before
the top of the mounting hole. Push the sensor in replacing the wheel speed sensor or tone wheel.
until it snaps into place on the metal retaining clip. Check the gap between the speed sensor head and
(3) Install secondary (yellow) retaining clip over the tone wheel to ensure it is within specifications.
wheel speed sensor head and engage the tabs on each (Refer to 5 - BRAKES - ABS/ELECTRICAL - SPEC-
side. IFICATIONS)
(4) Route sensor cable under leaf spring along rear Excessive wheel speed sensor runout can cause
of axle. Install speed sensor cable into routing clips erratic wheel speed sensor signals. Refer to SPECI-
on rear brake flex hose (Fig. 4). FICATIONS in this section of the service manual for
(5) Install cable into metal routing clip and attach the maximum allowed tone wheel runout (Refer to 5 -
it to the rear axle with mounting bolt (Fig. 4). BRAKES - ABS/ELECTRICAL - SPECIFICATIONS).
Tighten mounting bolt to 16 N·m (140 in. lbs.). If tone wheel runout is excessive, determine if it is
(6) Connect wheel speed sensor cable to vehicle caused by a defect in the driveshaft assembly or hub
wiring harness (Fig. 3). Be sure speed sensor and bearing. Replace as necessary.
cable connector is fully seated and locked into Tone wheels are pressed onto their mounting sur-
vehicle wiring harness connector. faces and should not rotate independently from the
(7) Install speed sensor cable grommet into hole in mounting surface. Replacement of the front drive-
floor pan making sure grommet is fully seated into shaft, rear driveshaft (AWD only) or rear hub and
hole. bearing is necessary.
(8) Lower vehicle.
the base and ABS braking systems. TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
TONE WHEEL CONTROL SWITCH
(1) Remove lower column shroud.
INSPECTION - TONE WHEEL (2) Disconnect traction control switch harness from
NOTE: Rear tone wheels for front-wheel-drive vehi- column harness below column.
cles are sealed within the hub and bearing assem- (3) Using an ohmmeter, check for continuity read-
bly and cannot be inspected or replaced. ing between pins. Refer to test table and (Fig. 6).
Replacement of the hub and bearing is necessary.
TRACTION CONTROL SWITCH (Continued)
Fig. 6 TRACTION CONTROL SWITCH CONNECTOR

TRACTION CONTROL SWITCH CONTINUITY
SWITCH POSITION CONTINUITY BETWEEN

ACTUATED PINS 1 AND 2
ILLUMINATION PINS 1 AND 3 Fig. 8 ICU LOCATION IN VEHICLE
2 - MASTER CYLINDER
ICU (INTEGRATED CONTROL 3 - ICU
UNIT)
block that is approximately one inch longer than a
DESCRIPTION HCU on a vehicle that is equipped with ABS only.
The hydraulic control unit (HCU) and the control- The ABS-only ICU consists of the following compo-
ler antilock brake (CAB) used with this antilock nents: the CAB, eight (build/decay) solenoid valves
brake system are combined (integrated) into one (four inlet valves and four outlet valves), valve block,
unit, which is called the integrated control unit (ICU) fluid accumulators, a pump, and an electric motor.
(Fig. 7). The ICU is located below the master cylinder The ABS-with traction control ICU consists of the
in the engine compartment (Fig. 8). following components: the CAB, eight (build/decay)
solenoid valves (four inlet valves and four outlet
valves), two traction control (ASR) valves, two
hydraulic shuttle valves, valve block, fluid accumula-
tors, a pump, and an electric motor.
The replaceable components of the ICU are the
HCU and the CAB. No attempt should be made to
service any individual components of the HCU or
CAB. For information on the CAB, (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/CONTROLLER ANTILOCK BRAKE -
DESCRIPTION).
OPERATION
For information of the ICU, refer to these individ-
ual components of the ICU:
• CONTROLLER ANTILOCK BRAKE (CAB)
Fig. 7 INTEGRATED CONTROL UNIT (ICU) (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
1 - PUMP/MOTOR
TROL MODULES/CONTROLLER ANTILOCK
2 - HCU BRAKE - OPERATION)
3 - PUMP/MOTOR CONNECTOR • HYDRAULIC CONTROL UNIT (HCU) (Refer to
4 - CAB 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
HCU (HYDRAULIC CONTROL UNIT) - OPERA-
TION)
Two different ICU’s (HCU and CAB) are used on
For information on the ICU’s hydraulic circuits,
this vehicle depending on whether or not the vehicle
refer to HYDRAULIC CIRCUITS AND VALVE
is equipped with traction control. The HCU on a
OPERATION. (Refer to 5 - BRAKES - ABS/HY-
vehicle equipped with traction control has a valve
DRAULIC/MECHANICAL - OPERATION)
ICU (INTEGRATED CONTROL UNIT) (Continued)
REMOVAL - ICU
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Remove the battery shield.
(3) Remove the battery (Refer to 8 - ELECTRI-
(4) Disconnect the vacuum hose connector at the
(5) Remove the screw securing the engine coolant
filler neck to the battery tray.
(6) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
the brake pedal to a position past the first inch of
pedal travel. This will prevent brake fluid from
draining out of the master cylinder once the
brake tubes are removed from the HCU. Fig. 9 BRAKE TUBE NUTS AT ICU
1 - PRIMARY BRAKE TUBE
CAUTION: Do not apply a 12–volt power source to 2 - SECONDARY BRAKE TUBE
any terminals of the 24-way CAB connector when 3 - CHASSIS BRAKE TUBES
disconnected.
(8) Disconnect the wiring harness connector from

(9) Remove the speed control servo mounting nuts
and move the servo out of the way.
(10) Disconnect the 24–way connector from the
CAB. To disconnect the 24–way connector, grasp the
lock on the 24–way connector and pull it as far up as
possible. This will unlock the 24–way connector from
the socket on the CAB.
CAUTION: Before removing the brake tubes from

the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(11) Thoroughly clean all surfaces of the ICU and

brake tube nuts. Use only a solvent such as Mopart
Brake Parts Cleaner or equivalent to clean the ICU.
(12) Remove the brake tubes (4) from the outlet
ports on the HCU (Fig. 9).
(13) Remove the primary and secondary brake
tubes from the inlet ports on the HCU (Fig. 9).
(14) Center and prop the steering wheel. Fig. 10 LOWER COUPLING AND DASH SEAL
(15) Remove the silencer panel under the instru- 1 - COUPLING
ment panel, below the steering column. 2 - DASH SEAL
(16) Remove the pinch bolt and disconnect the 3 - SILENCER
steering shaft coupling. 4 - MOUNTING SCREWS
(17) Remove the two clips securing silencer to dash 5 - RETAINING CLIPS
6 - DASH
seal (Fig. 10).
(18) Remove the three screws securing the dash
seal (Fig. 10). (21) If required, to separating the CAB from the
(19) Remove the 3 bolts attaching the ICU to its HCU, (Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
mounting bracket (Fig. 11). CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
(20) Remove ICU from the vehicle through engine DISASSEMBLY).
compartment.
Fig. 11 ICU MOUNTING BOLTS Fig. 13 (TYPICAL) CAB Attaching Bolts

1 - ICU MOUNTING BOLTS 1 - MOUNTING BOLTS
2 - COUPLER 2 - CAB
3 - HCU VALVE BLOCK
DISASSEMBLY - ICU
(1) Remove the ICU from the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - REMOVAL)
(2) Disconnect the pump/motor wiring harness
(Fig. 12) from the CAB.
Fig. 14 (TYPICAL) Remove/Install CAB

1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
(2) Install the 4 bolts mounting the CAB (Fig. 13)

Fig. 12 INTEGRATED CONTROL UNIT (ICU) to the HCU. Tighten the CAB mounting bolts to a
1 - PUMP/MOTOR torque of 2 N·m (17 in. lbs.).
2 - HCU (3) Plug the pump/motor wiring harness into the
3 - PUMP/MOTOR CONNECTOR CAB.
4 - CAB (4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
(3) Remove the 4 bolts (Fig. 13) attaching the CAB BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
to the HCU. GRATED CONTROL UNIT) - INSTALLATION)
(4) Remove the CAB from the HCU (Fig. 14).
INSTALLATION - ICU
ASSEMBLY - ICU (1) Place the ICU in its bracket below the master
(1) Install the CAB (Fig. 14) on the HCU. cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2 NOTE: Before installing the 24–way connector in
mounting bolts attaching the ICU to the mounting the CAB be sure the seal is properly installed in the
bracket (Fig. 11). Tighten all 3 mounting bolts to a connector.
torque of 11 N·m (97 in. lbs.).
(3) Install the dash seal and three mounting (10) Install the 24–way connector on the CAB by,
screws (Fig. 10). first, positioning the 24–way connector in the socket
(4) Install the silencer on top of the dash seal (Fig. of the CAB and carefully pushing it down as far as
10). possible. Once connector is fully seated by hand into
(5) Connect the steering shaft coupling and install the CAB socket, push down on connector lock. This
the pinch bolt (Fig. 10). Tighten the pinch bolt to 28 will pull the connector into the socket of the CAB
N·m (250 in. lbs.). and lock it in the installed position.
(6) Install the silencer panel below the steering (11) Install any routing clips on the brake tubes.
column under the instrument panel. (12) Remove the brake pedal holder.
(7) Remove the steering wheel holder. (13) Install the speed control servo with its mount-
ing nuts.
CAUTION: Because of the flexible section in the pri- (14) Connect the wiring harness to the speed con-
mary and secondary brake tubes, the brake tubes trol servo.
must be held in proper orientation when tightened (15) Install the battery tray (Refer to 8 - ELEC-
and torqued. These tubes must not contact each TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
other or other vehicle components when installed. TION).
Also, after the brake tubes are installed on the HCU, (16) Install the screw securing the coolant filler
ensure all spacer clips are reinstalled on the brake neck to the battery tray.
tubes. (17) Reconnect the vacuum hose connector at the
(8) Install the primary and secondary brake tubes (18) Install the battery (Refer to 8 - ELECTRI-
into their correct port locations on the HCU valve CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
block (Fig. 9). Tighten the tube nuts to a torque of 17 TION).
N·m (145 in. lbs.). (19) Install the battery shield.
(20) Remove the brake pedal holder.
CAUTION: When installing the chassis brake tubes (21) Connect negative cable back on negative post
on the HCU valve block, they must be located cor- of the battery.
rectly in the valve block to ensure proper ABS oper- (22) Bleed the Base and ABS brake hydraulic sys-
ation. tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
NOTE: The chassis brake tube attachment locations (23) Road test vehicle to ensure proper operation
to the HCU, are marked on the bottom of the CAB. of the base and antilock brake systems.
(9) Install the (4) chassis brake tubes into their

correct port locations on the HCU valve block as
shown (Fig. 9). Tighten the tube nuts to a torque of
17 N·m (145 in. lbs.).
RG BRAKES 5a - 1
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE POWER BRAKE BOOSTER - RHD

DESCRIPTION . . . . . . . . . . . . . . . . . ...........1 REMOVAL . . . . . . . . . . . . . . . . . . .............4
HYDRAULIC/MECHANICAL INSTALLATION. . . . . . . . . . . . . . . .............6
DESCRIPTION . . . . . . . . . . . . . . . . . ...........1 ROTORS
FLUID SPECIFICATIONS . . . . . . . . . . . . .............8
STANDARD PROCEDURE . . . . . . . . ...........1 PARKING BRAKE
BRAKE FLUID LEVEL CHECKING ...........1 DESCRIPTION . . . . . . . . . . . . . . . .............8
MASTER CYLINDER - RHD CABLES - PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . ...........2 REMOVAL . . . . . . . . . . . . . . . . . . .............8
REMOVAL . . . . . . . . . . . . . . . . . . . . ...........2 INSTALLATION. . . . . . . . . . . . . . . .............8
INSTALLATION. . . . . . . . . . . . . . . . . ...........3 LEVER - PARKING BRAKE
PEDAL TORQUE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . .............8
REMOVAL . . . . . . . . . . . . . . . . . . . . ...........3 INSTALLATION. . . . . . . . . . . . . . . .............9
INSTALLATION. . . . . . . . . . . . . . . . . ...........4
BRAKES - BASE FLUID

DESCRIPTION - BASE BRAKES STANDARD PROCEDURE - BRAKE FLUID
Four-Wheel Disc Antilock Brakes are standard on LEVEL CHECKING
all models. Right hand drive vehicles feature a brake fluid res-
ervoir with the same markings as left hand drive res-
ervoirs.
HYDRAULIC/MECHANICAL Check master cylinder reservoir fluid level a mini-
mum of twice annually.
DESCRIPTION - DISC BRAKES Fluid reservoirs are marked with the words FULL
All vehicles are equipped with Four-Wheel-Disc and ADD to indicate proper brake fluid fill level of
brakes. Both 15” (BRE) and 16” (BR3) disc/disc brake the master cylinder.
systems are available. The disc brakes are manufac- If necessary, add brake fluid to bring the level to
tured by Continental Teves. The BR3 system is stan- the bottom of the FULL mark on the side of the mas-
dard equipment on all-wheel drive and all right-hand ter cylinder fluid reservoir.
drive models. It is optional on other models. Use only Mopart brake fluid or equivalent from a
The BR3 system features larger, externally vented sealed container. Brake fluid must conform to DOT 3
front brake rotors. specifications (DOT 4 or DOT 4+ are acceptable).
Although there are different disc/disc systems, they DO NOT use brake fluid with a lower boiling
are serviced using the same service procedures. Some point, as brake failure could result during prolonged
specifications differ. hard braking.
5a - 2 BRAKES - BASE RG
FLUID (Continued)
Use only brake fluid that was stored in a tightly- der is removed. This can be done simply by pump-
sealed container. ing the brake pedal, with the vehicle’s engine not
DO NOT use petroleum-based fluid because seal running, until a firm feeling brake pedal is achieved.
damage will result. Petroleum based fluids would be (1) With engine not running, pump brake pedal
items such as engine oil, transmission fluid, power until a firm pedal is achieved (4 or 5 strokes).
steering fluid etc. (2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
MASTER CYLINDER - RHD (5) Remove nut and clamp securing battery to tray,
remove battery.
DESCRIPTION (6) Thoroughly clean all surfaces of the brake fluid
The master cylinder used on right hand drive reservoir and master cylinder. Use only solvent such
(RHD) vehicles functions similarly to that used on as Mopart Brake Parts Cleaner or equivalent.
left hand drive (LHD) vehicles. The RHD master cyl- (7) Remove wiring harness connector from brake
inder, as well as the RHD power brake booster, is fluid level switch in master cylinder brake fluid res-
located in the same area, but lower in the engine ervoir (Fig. 1).
compartment than LHD models (Fig. 1). For that (8) Disconnect primary and secondary brake tubes
reason an extension manifold is placed between the from master cylinder housing (Fig. 2). Install sealing
fluid reservoir and master cylinder housing allowing plugs in the now open brake tube outlet ports.
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
Fig. 2 RHD MASTER CYLINDER MOUNTING

Fig. 1 RHD MASTER CYLINDER AND POWER 2 - SECONDARY BRAKE TUBE NUT
BRAKE BOOSTER 3 - MASTER CYLINDER MOUNTING NUTS
2 - BRAKE FLUID LEVEL SWITCH CAUTION: Before removing the master cylinder
3 - FLUID RESERVOIR from the power brake vacuum booster, the master
4 - MASTER CYLINDER
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
REMOVAL from falling into the power brake vacuum booster.
CAUTION: Vacuum in the power brake booster must (9) Clean area where master cylinder assembly
be pumped down (removed) before removing mas- attaches to power brake booster. Use only a solvent
ter cylinder from power brake booster. This is nec- such as Mopart Brake Parts Cleaner or equivalent.
essary to prevent the power brake booster from (10) Remove two nuts attaching master cylinder to
sucking in any contamination as the master cylin- power brake booster (Fig. 2).
brake booster.
RG BRAKES - BASE 5a - 3
MASTER CYLINDER - RHD (Continued)
CAUTION: A seal on the rear of the master cylinder (10) Fill master cylinder with clean, fresh Mopart
is used to create the seal for holding vacuum in the Brake Fluid or equivalent.
power brake vacuum booster. The vacuum seal on (11) Road test vehicle to ensure proper operation of
the master cylinder MUST be replaced whenever the brakes.
vacuum booster.
PEDAL TORQUE SHAFT
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is REMOVAL
removed from master cylinder by carefully pulling it (1) Remove the instrument panel. (Refer to 23 -
off the rear of master cylinder. Do not attempt to BODY/INSTRUMENT PANEL/INSTRUMENT
pry the seal off the master cylinder by inserting PANEL ASSEMBLY - REMOVAL)
a sharp tool between seal and master cylinder (2) Remove the HVAC housing. (Refer to 24 -
casting. HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
INSTALLATION (3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Remove
CAUTION: Different types of master cylinders are the link from the torque shaft. Discard the retaining
used on this vehicle depending on brake options. If clip. It is not to be reused. Replace with a new clip
a new master cylinder is being installed, be sure it when reassembled.
is the correct master cylinder for the type of brake (4) Locate the booster input rod-to-brake pedal
system the vehicle is equipped with. torque shaft connection and remove the retaining clip
(Fig. 3). Discard the retaining clip. It is not to be
CAUTION: When replacing the master cylinder on a reused. Replace with a new clip when reassembled.
vehicle, a NEW vacuum seal MUST be installed on
(1) Install a NEW vacuum seal on master cylinder

making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 2). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).
CAUTION: When tightening the primary and sec-

ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex- Fig. 3 POWER BRAKE BOOSTER BRACKET
ible sections of the tubes. This is required due to
1 - BOOSTER BRACKET
the movement between the ABS ICU and the master 2 - PEDAL TORQUE SHAFT
cylinder while the vehicle is in motion. 3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig. 2).
Brake tubes must be held securely when tightened to (5) Remove the four (4) brake booster retaining
control orientation of flex section. Tighten tube nuts nuts from inside the passenger compartment (Fig. 4).
to a torque of 17 N·m (145 in. lbs.). (6) Remove the retaining nut from the brake
(5) Install wiring harness connector to brake fluid booster bracket located above the booster in the
level switch mounted in brake fluid reservoir (Fig. 1). engine compartment (Fig. 4).
(6) Install battery, clamp and nut. (7) Remove the power brake booster bracket.
(7) Install battery shield. (8) Rotate the pedal torque shaft and remove it out
(8) Connect positive battery terminal. the left side of the vehicle.
(9) Connect negative battery terminal.
PEDAL TORQUE SHAFT (Continued)
(6) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 3).
CAUTION: When installing the brake pedal link on

the brake pedal torque shaft pin, do not reuse the
old retaining clip.
(7) Connect the brake pedal link to the torque

shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)

Fig. 4 BOOSTER, TORQUE SHAFT AND PEDAL installed and adjusted.
MOUNTING
1 - PEDAL MOUNTING NUT (10) Remove and replace the brake lamp switch
2 - BRAKE PEDAL ASSEMBLY with a NEW switch. (Refer to 8 - ELECTRICAL/
3 - PEDAL MOUNTING NUT LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
4 - PEDAL TORQUE SHAFT SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
5 - BOOSTER MOUNTING NUT LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
6 - BOOSTER BRACKET SWITCH - INSTALLATION)
8 - BOOSTER BRACKET MOUNTING NUT
the brakes.
INSTALLATION
(1) Lubricate both ends of the torque shaft with POWER BRAKE BOOSTER -
MS-4517 Lubricant or equivalent and install the RHD
torque shaft from the left side reversing the removal
procedure. REMOVAL
(2) Install the brake booster bracket on the left
end of the shaft. CAUTION: Reserve vacuum in power brake booster
(3) Install the four brake booster retaining nuts must be pumped down (removed) before removing
inside the passenger compartment. Tighten the master cylinder from booster. This is necessary to
mounting nuts to a torque of 29 N·m (250 in. lbs.). prevent booster from sucking in any contamination
(4) Install the retaining nut for the brake booster as master cylinder is removed. This can be done
bracket in the engine compartment. Tighten the simply by pumping the brake pedal, with the vehi-
mounting nuts to a torque of 29 N·m (250 in. lbs.). cle’s engine not running, until a firm feeling brake
(5) Using lubriplate, or equivalent, coat the sur- pedal is achieved.
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod. Also coat the surface of (1) With engine not running, pump the brake
the brake pedal torque shaft pin where it contacts pedal until a firm pedal is achieved (4 or 5 strokes).
the brake pedal link. (2) Remove negative battery cable terminal from
battery.
CAUTION: When installing the power brake booster (3) Remove positive battery cable terminal from
input rod on the brake pedal torque shaft pin, do battery.
not reuse the old retaining clip. (4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
POWER BRAKE BOOSTER - RHD (Continued)
(6) If the vehicle is equipped with speed control, (12) Remove two nuts attaching master cylinder to
disconnect the vacuum hose at the vacuum tank built power brake booster (Fig. 6).
into the battery tray.
(7) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(8) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
(b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(9) If the vehicle is equipped with the 2.5L diesel
engine, remove the coolant recovery pressure con-
tainer and bracket. (Refer to 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
REMOVAL)
(10) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 5).
Fig. 6 RHD MASTER CYLINDER MOUNTING
3 - MASTER CYLINDER MOUNTING NUTS

brake booster. Lay master cylinder with primary and
secondary tubes to the side, out of the way.
CAUTION: A seal on the rear of the master cylinder

is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
vacuum booster.
(14) Disconnect vacuum hose from check valve

Fig. 5 RHD MASTER CYLINDER AND POWER located on booster. DO NOT REMOVE CHECK
BRAKE BOOSTER VALVE FROM POWER BRAKE BOOSTER.
1 - POWER BRAKE BOOSTER (15) Under the instrument panel, remove booster
2 - BRAKE FLUID LEVEL SWITCH input rod trim cover.
3 - FLUID RESERVOIR (16) Locate the booster input rod to brake pedal
4 - MASTER CYLINDER torque shaft connection under the instrument panel.
Position a small screwdriver between the center tang
CAUTION: Before removing the master cylinder on the retaining clip (Fig. 7).
from the power brake vacuum booster, the master (17) Rotate screwdriver enough to allow retaining
cylinder and vacuum booster must be thoroughly clip center tang to pass over end of brake pedal pin.
cleaned. This must be done to prevent dirt particles Then pull retaining clip off brake pedal torque shaft
from falling into the power brake vacuum booster. pin. Discard retaining clip. It is not to be
reused. Replace only with a new retaining clip
(11) Clean area where master cylinder assembly when assembling.
attaches to power brake booster. Use only a solvent (18) Remove booster input rod from pedal torque
such as Mopart Brake Parts Cleaner or equivalent. shaft pin.
(19) Remove the three easily accessed mounting
NOTE: It is not necessary to remove the brake nuts attaching power brake booster to dash panel
tubes from the master cylinder when removing the and loosen fourth (Fig. 8). As fourth nut is loosened,
master cylinder from the booster. push the booster forward periodically until the nut
can be completely removed.
(20) Slide power brake booster forward and remove
through engine compartment (Fig. 9).
Fig. 7 Booster Input Rod Pin Retaining Clip

(Typical)
1 - BRAKE PEDAL Fig. 9 RHD BOOSTER REMOVAL/INSTALLATION
2 - INPUT ROD 1 - POWER BRAKE BOOSTER
3 - SCREWDRIVER 2 - MASTER CYLINDER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.
INSTALLATION
(1) Position power brake booster on dash panel
using the reverse procedure of its removal (Fig. 9).
(2) Below instrument panel, first install the two
upper nuts mounting the booster to the dash panel,
drawing it into place, then install the two lower
mounting nuts. Tighten the mounting nuts to a
(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod.
CAUTION: When installing the brake pedal torque

shaft pin on the power brake booster input rod, do
not re-use the old retaining clip.
(4) Install booster input rod on brake pedal torque

shaft pin and install a NEW retaining clip (Fig. 10).
Fig. 8 BOOSTER, TORQUE SHAFT AND PEDAL (5) Install booster input rod trim cover.
MOUNTING (6) Connect vacuum hose to check valve on power
brake booster.
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
CAUTION: The master cylinder (and its rear seal) is
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
used to create the seal for holding vacuum in the
5 - BOOSTER MOUNTING NUT vacuum booster. The vacuum seal on the master
6 - BOOSTER BRACKET cylinder MUST be replaced with a NEW seal when-
7 - POWER BRAKE BOOSTER ever the master cylinder is removed from the vac-
8 - BOOSTER BRACKET MOUNTING NUT uum booster.
(9) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(10) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 6). Tighten both mounting
(11) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 5).
(12) If the vehicle is equipped with the 2.5L diesel
engine, install the coolant recovery pressure con-
tainer and bracket. (Refer to 7 - COOLING/ENGINE/
COOLANT RECOVERY PRESS CONTAINER -
INSTALLATION)
(13) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
Fig. 10 Retaining Pin Installed On Brake Pedal Pin the mounting nuts to a torque of 14 N·m (124 in.
(Typical) lbs.).
1 - BRAKE PEDAL (14) Install the battery tray. Install the two nuts
2 - RETAINING CLIP and one bolt attaching the battery tray to the vehicle.
3 - BOOSTER INPUT ROD Tighten the bolt and nuts to a torque of 14 N·m (124
in. lbs.).
CAUTION: When removing the vacuum seal from (15) If vehicle is equipped with speed control, con-
the master cylinder, do not use a sharp tool. nect the servo vacuum hose to the vacuum tank on
the battery tray.
(7) Using a soft tool such as a trim stick, remove (16) Install the battery, clamp and mounting nut.
the vacuum seal from the master cylinder mounting (17) Install the positive battery cable on the bat-
flange. tery.
(8) Install a NEW vacuum seal on rear mounting (18) Install the negative battery cable on the bat-
flange of the master cylinder (Fig. 11). tery.
(19) Install the battery thermal guard shield.

(20) Remove and replace the brake lamp switch

with a NEW switch. (Refer to 8 - ELECTRICAL/
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
SWITCH - INSTALLATION)
(21) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
Fig. 11 Vacuum Seal (Typical) (22) Road test vehicle to ensure proper operation
1 - MASTER CYLINDER ASSEMBLY of the brakes.
2 - VACUUM SEAL
ROTORS When refacing a rotor, the required TIR (Total

Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
SPECIFICATIONS ation of rotor turning equipment is required.
BRAKE ROTOR
NOTE: Use the following information on all 4 wheel
disc brake vehicles that are equipped with BR3
sales code.
SPECIFICATIONS/LIMITS
Rotor
Brake Minimum Rotor Rotor Micro
Rotor Thickness Thickness Rotor Runout *
Rotor Thickness Finish
Variation
27.9-28.1 mm 26.5 mm 0.010 mm 0.030 mm
Front 15-80 RMS
1.098 -1.106 in. 1.043 in 0.0004 in. 0.0012 in.
12.25-12.75 mm 11.25 mm 0.013 mm 0.14 mm
Rear 15-80 RMS
0.482-0.502 in. 0.443 in. 0.0005 in. 0.0055 in.
* TIR Total Indicator Reading (Measured On Vehicle)
PARKING BRAKE
DESCRIPTION
The parking brake system on this vehicle features
a hand-operated parking brake lever. The lever is
located between the two front seats and requires a
special front cable.
CABLES - PARKING BRAKE

REMOVAL - FRONT CABLE
(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - REMOVAL)
INSTALLATION - FRONT CABLE Fig. 12 Locking Out Automatic Adjuster

(Refer to 5 - BRAKES - BASE/PARKING BRAKE/
LEVER - INSTALLATION)
3 - LOCKING PLIERS
LEVER - PARKING BRAKE

(3) Remove the left rear and intermediate parking
REMOVAL - PARKING BRAKE LEVER AND brake cables from the parking brake cable equalizer
(Fig. 13).
FRONT CABLE
(4) Remove the equalizer from the front parking
brake cable.
(5) Remove the locking pliers from the front park-
DURE)
ing brake cable. This will allow the adjuster in the
(2) Grasp the exposed section of the front parking
parking brake lever mechanism to rotate around to
brake cable and pull rearward on it. While holding
its stop and remove the tension from the adjuster
the park brake in this position, install a pair of lock-
and front park brake cable.
LEVER - PARKING BRAKE (Continued)
INSTALLATION - PARKING BRAKE LEVER AND

FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle.
(2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket.
(3) Hook the end of the parking brake cable on the
parking brake lever mechanism.
(4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan.
(5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
Fig. 13 Parking Brake Cable Equalizer SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
1 - EQUALIZER - INSTALLATION)
2 - LEFT REAR PARKING BRAKE CABLE (6) Install the floor console. (Refer to 23 - BODY/
3 - LOCKING NUT INTERIOR/FLOOR CONSOLE - INSTALLATION)
4 - INTERMEDIATE PARKING BRAKE CABLE (7) Raise the vehicle.
5 - FRONT PARKING BRAKE CABLE (8) Install the four mounting nuts securing the
parking brake lever bracket in place.
(6) Remove the front parking brake cable housing (9) Install the front park cable housing retainer to
from body outrigger bracket. Cable is removable by the body outrigger bracket. Press the cable housing
sliding a 14 mm box wrench over the cable retainer into the outrigger hole until all three retaining fin-
and compressing the three retaining fingers. Alter- gers lock the cable in place.
nate method: Use an aircraft type hose clamp and (10) Grasp the exposed section of the front parking
screwdriver. brake cable and pull rearward on it. While holding
(7) Remove the four mounting nuts from the bot- the park brake in this position, install a pair of lock-
tom of the parking brake lever bracket. ing pliers on the front parking brake cable just rear-
(8) Lower vehicle. ward of the second body outrigger bracket.
(9) Remove the floor console. (Refer to 23 - BODY/ (11) Install the equalizer on the front parking
INTERIOR/FLOOR CONSOLE - REMOVAL) brake cable and install the left rear and intermediate
(10) If equipped with a manual transaxle, remove park brake cable in the correct location on the park-
the gearshift mechanism. (Refer to 21 - TRANSMIS- ing brake cable equalizer (Fig. 13).
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM (12) Remove the locking pliers from the front park-
- REMOVAL) ing brake cable. This will allow the adjuster in the
(11) Unhook the end of the parking brake cable park brake lever mechanism to tension the parking
from the lever mechanism. brake cables.
(12) Compress the parking brake cable retainer by (13) Lower the vehicle.
sliding a 14 mm wrench over the cable retainer and (14) Apply and release the parking brake lever one
compress the three (3) retaining fingers. time. This will seat the parking brake cables and
(13) Remove the three screws from the parking allow the auto adjuster in the parking brake lever
brake grommet on the floor pan of the passenger mechanism to correctly tension the parking brake
compartment. cables.
(14) Lift the parking brake lever and slide the
parking brake cable out.
(15) Pull the cable through the floor pan from
inside the vehicle.
5a - 10 BRAKES - ABS RG
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ICU (INTEGRATED CONTROL UNIT) - RHD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKES - ABS CAUTION: Do not apply a 12 volt power source to

any terminals of the HCU connector when discon-
nected.
DESCRIPTION - ANTILOCK BRAKE SYSTEM
Four-wheel disc antilock brakes are standard on all (5) Remove the 24-way connector (Fig. 1) from the
models. The Mark 20e antilock brake system is used CAB. The 24-way connector is removed from the CAB
on all models. Depending on whether the vehicle is a using the following procedure. Grasp the lock on the
left-hand drive (LHD) or right-hand drive (RHD) 24-way connector (Fig. 1) and pull it as far out as
model, the integrated control unit (ICU) is located in possible (Fig. 2). This will raise and unlock the
one of two locations. On LHD models, the ICU is 24-way connector from the socket on the CAB.
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
ICU (INTEGRATED CONTROL

UNIT) - RHD
REMOVAL - RHD
NOTE: Before proceeding, review all WARNINGS
AND CAUTIONS.
(1) Disconnect the negative (ground) cable from

the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock Fig. 1 CAB 24-Way Connector
the brake pedal to a position past the first inch of
1 - CAB WIRING HARNESS
pedal travel. This will prevent brake fluid from 2 - 24–WAY CONNECTOR
draining out of the master cylinder when the 3 - FLOOR PAN
brake tubes are removed from the HCU. 4 - HCU
(3) Raise vehicle. See Hoisting in the Lubrication 5 - CAB
And Maintenance. 6 - HCU MOUNTING BRACKET
(4) Remove the routing clip attaching the ICU wir- 7 - CONNECTOR LOCK
ing harness to the ICU mounting bracket (Fig. 1).
RG BRAKES - ABS 5a - 11
ICU (INTEGRATED CONTROL UNIT) - RHD (Continued)
Fig. 2 Unlocked 24-Way CAB Connector Fig. 3 Brake Tube Connections To HCU
1 - HCU 1 - LEFT REAR WHEEL BRAKE TUBE
2 - CAB 2 - SECONDARY BRAKE TUBE FROM MASTER CYLINDER
3 - 24–WAY CONNECTOR 3 - LEFT FRONT WHEEL BRAKE TUBE
4 - CONNECTOR LOCK (UNLOCKED) 4 - CAB
5 - RIGHT REAR WHEEL BRAKE TUBE
CAUTION: Before removing the brake tubes from 6 - HCU MOUNTING BRACKET
7 - BRAKE TUBE TO HCU CONNECTION LOCATION LEGEND
the HCU, the HCU must be thoroughly cleaned. This
8 - RIGHT FRONT WHEEL BRAKE TUBE
must be done to prevent dirt particles from falling
9 - PRIMARY BRAKE TUBE FROM MASTER CYLINDER
into the ports of HCU or entering the brake tubes.
(6) Thoroughly clean all surfaces of the HCU, and

all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(7) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 3).
(8) Remove the 3 bolts (Fig. 4) attaching the ICU
mounting bracket to the front suspension crossmem-
ber.
(9) Remove ICU and the mounting bracket as a
unit from the vehicle.
(10) Remove the 3 bolts (Fig. 5) mounting the ICU
to the mounting bracket. Separate the ICU from the
mounting bracket.
(11) For the procedure on separating and attaching
the CAB to the HCU, refer to DISASSEMBLY.
Fig. 4 ICU To Suspension Cradle Mounting Bolts
1 - HCU MOUNTING BRACKET BOLTS
2 - HCU MOUNTING BRACKET BOLT
3 - CAB
4 - HCU MOUNTING BRACKET
5 - HCU
DISASSEMBLY
(1) Remove the ICU from the vehicle. (Refer to 5 -
GRATED CONTROL UNIT) - REMOVAL)
(2) Disconnect the pump/motor wiring harness
from the CAB (Fig. 6).
5a - 12 BRAKES - ABS RG
Fig. 5 ICU Mounting Bolts

Fig. 7 (TYPICAL) CAB Attaching Bolts
1 - HCU
1 - MOUNTING BOLTS
2 - HCU MOUNTING BOLTS
2 - CAB
3 - HCU MOUNTING BRACKET
3 - HCU VALVE BLOCK
Fig. 6 INTEGRATED CONTROL UNIT (ICU) Fig. 8 (TYPICAL) Remove/Install CAB

1 - PUMP/MOTOR 1 - CAB
2 - HCU 2 - HCU VALVES
3 - PUMP/MOTOR CONNECTOR 3 - HCU VALVE BLOCK
4 - CAB
ASSEMBLY
(3) Remove the 4 bolts (Fig. 7) attaching the CAB
(1) Install the CAB (Fig. 8) on the HCU.
to the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 7) to
(4) Remove the CAB from the HCU (Fig. 8).
the HCU. Tighten the CAB mounting bolts to a
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
GRATED CONTROL UNIT) - INSTALLATION)
RG BRAKES - ABS 5a - 13
INSTALLATION - RHD (4) Install the 24-way connector (Fig. 1) on the

(1) Install the ICU on the mounting bracket (Fig. CAB using the following procedure. Position the
5). Install the 3 bolts (Fig. 5) attaching the ICU to 24-way connector in the socket of the CAB and care-
the mounting bracket. Tighten the 3 mounting bolts fully push it down as far as possible. When connector
to a torque of 11 N·m (97 in. lbs.). is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 2). This will pull the connec-
CAUTION: The ICU mounting bracket to front sus- tor into the socket of the CAB and lock it in the
pension cradle mounting bolts have a unique corro- installed position.
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi- NOTE: The CAB wiring harness must be clipped to
nal equipment Mopar replacement bolts can be the ICU mounting bracket. This will ensure the wir-
used to mount the ICU bracket to the front suspen- ing harness is properly routed and does not contact
sion crossmember. the brake tubes or the body of the vehicle.
(2) Install the ICU and its mounting bracket as an (5) Clip the cab wiring harness (Fig. 1) to the ICU
assembly on the front suspension crossmember. mounting bracket.
Install the 3 bolts attaching the ICU bracket to the (6) Install the routing clips (Fig. 9) on the brake
crossmember (Fig. 4). Tighten the 3 mounting bolts tubes.
to a torque of 28 N·m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-

mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes

on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 3) for the correct chassis brake
Fig. 9 Brake Tube Routing Clips
tube locations.
1 - ROUTING CLIP
2 - HCU
NOTE: The chassis brake tube attachment locations 3 - BRAKE TUBES
to the HCU, are marked on the bottom of the ICU 4 - ROUTING CLIP
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor- (8) Connect negative cable back on negative post of
rect port locations on the HCU valve block as shown the battery.
in (Fig. 3). Tighten the tube nuts to a torque of 17 (9) Bleed the base and ABS hydraulic systems.
N·m (145 in. lbs.). Refer to ANTILOCK BRAKE SYSTEM BLEEDING.
(10) Road test vehicle to ensure proper operation
NOTE: Before installing the 24-way connector in the of the base and antilock brake systems.
CAB be sure the seal is properly installed in the
connector.
RG CLUTCH 6a - 1
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MASTER CYLINDER - RHD
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MODULAR CLUTCH ASSY - 2.4L GAS
DIAGNOSIS AND TESTING - DRIVE PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MISALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - CLUTCH SLAVE CYLINDER - RHD
COVER AND DISC RUNOUT . . . . . . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHATTER COMPLAINTS . . . . . . . . . . . . . . . . . . 7 CLUTCH DISC AND PRESSURE PLATE - 2.5L
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TD
CLUTCH RELEASE CABLE - LHD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FLYWHEEL
CLUTCH RELEASE LEVER AND BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CLUTCH
DESCRIPTION
CLUTCH COMPONENTS
Models equipped with a 2.4L Gas engine utilize a
modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.
Models equipped with the 2.5L Turbo Diesel engine
utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it is highly
recommended that the clutch cover and disc be Fig. 1 Modular Clutch Assembly—2.4L Gas Engines
replaced as a set. 1 - MODULAR CLUTCH ASSEMBLY
6a - 2 CLUTCH RG
CLUTCH (Continued)
Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines

1 - FLYWHEEL 3 - PRESSURE PLATE
2 - DISC
RELEASE SYSTEM
Left-Hand Drive (LHD) models utilize a cable-actu-
ated clutch release system, consisting of a cable that
connects the clutch pedal to the clutch release lever
in the transaxle (Fig. 3) (Fig. 4). When the driver
depresses the clutch pedal, the clutch release cable
pulls the release lever (Fig. 5). This forces the release
bearing into the clutch diaphragm spring via lever-
age, releasing the clamping force on the clutch disc,
allowing the engine crankshaft to rotate indepen-
dently from the transaxle input shaft.
Right-Hand Drive (RHD) models utilize a hydraulic
clutch release system, conisting of a clutch master
cylinder attached to the clutch pedal (Fig. 6), and a
slave cylinder fastened to the transaxle which oper-
ates the clutch release lever (Fig. 7). When the driver
depresses the clutch pedal, the master cylinder push-
rod travels through the cylinder bore, displacing fluid
through the master cylinder plumbing. This fluid dis-
placement forces the slave cylinder piston to travel,
forcing the clutch release bearing into the clutch dia-
phragm spring via the release lever and leverage
(Fig. 8). This releases the clamping force on the Fig. 3 Clutch Cable at Clutch Pedal
clutch disc, allowing the engine crankshaft to rotate 1 - UPSTOP SPACER
independently from the transaxle input shaft. 2 - RELEASE CABLE
RG CLUTCH 6a - 3
CLUTCH (Continued)
Fig. 4 Clutch Release Cable at Transaxle

1 - RELEASE LEVER
2 - RELEASE CABLE Fig. 6 Clutch Master Cylinder (RHD)—Typical
1 - GROMMET
2 - HYDRAULIC CLUTCH MASTER CYLINDER
3 - STOP
4 - CLUTCH PEDAL
5 - SELF-RETAINING SNAP-ON BUSHING
Fig. 5 Release Bearing and Lever (LHD)

1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 7 Slave Cylinder Removal/Installation

1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
6a - 4 CLUTCH RG
CLUTCH (Continued)
DIAGNOSIS AND TESTING - CLUTCH SYSTEM

Clutch problem diagnosis will generally require a
road test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
Fig. 8 Release Bearing and Lever (RHD)

1 - RELEASE LEVER
2 - RELEASE BEARING
SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER

CLUTCH DISC FACING Oil leak at engine rear main or Correct leak and replace modular clutch
COVERED WITH OIL OR transaxle input shaft seal. assembly (2.4L Gas) or clutch cover and
GREASE disc (2.5L TD).
Too much grease applied to splines Apply lighter coating of grease to splines.
of disc and input shaft.
NO FAULT FOUND WITH Problem actually related to Further diagnosis required. Check
CLUTCH suspension or driveline component. engine/transmission mounts, suspension
COMPONENTS attaching parts and other driveline
components as needed.
Engine related problems. Check EFI and ignition systems.
PARTIAL ENGAGEMENT Clutch cover, spring, or release Replace modular clutch assembly (2.4L
OF CLUTCH DISC fingers bent, distorted (rough Gas) or clutch cover and disc (2.5L TD).
handling, improper assembly).
Clutch disc damaged or distorted. Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch misalignment. Verify modular clutch pilot plate alignment
to crankshaft. Replace the modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD) if the pilot plate is loose or
bent.
Improper transaxle-to-engine Verify transaxle is properly installed to
installation. engine.
RG CLUTCH 6a - 5
CLUTCH (Continued)
SERVICE DIAGNOSIS - CLUTCH SLIPS

DISC FACING WORN OUT Normal wear. Replace modular clutch assembly (2.4L
Driver frequently rides (slips) clutch, Replace modular clutch assembly (2.4L
results in rapid wear, overheating. Gas) or clutch cover and disc (2.5L TD).
Insufficient clutch cover diaphragm Replace modular clutch assembly (2.4L
spring tension Gas) or clutch cover and disc (2.5L TD).
CLUTCH DISC FACING Leak at rear main oil seal or Replace leaking seals. Replace modular
CONTAMINATED WITH transaxle input shaft seal clutch assembly (2.4L Gas) or clutch cover
OIL OR GREASE and disc (2.5L TD).
Excessive amount of grease applied Apply less grease to input shaft. Replace
to input shaft splines modular clutch assembly (2.4L Gas) or
clutch cover and disc (2.5L TD).
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING Release bearing sticking or binding, Verify that bearing is actually binding. Then,
PARTIALLY DISENGAGED does not return to normal running replace bearing and transmission front
position. bearing retainer if sleeve surface is
damaged.
Clutch pedal not returning to static Inspect pedal assembly for damage and/or
position. obstructions. Replace componnents as
necessary.
Cable self-adjuster mechanism (LHD Verify that self-adjuster is free to move.
Models) sticking or binding causing Replace clutch release cable if necessary.
high preload.
Clutch master cylinder (RHD Models) Replace clutch master cylinder assembly.
or pushrod damaged causing high
preload.
Slave cylinder binding or stuck (RHD Replace slave cylinder.
Models).
CLUTCH DISC FACINGS Leak at rear main or transaxle input Replace seal. Replace modular clutch
HAVE FRACTURED INTO shaft seal assembly (2.4L Gas) or clutch cover and
SMALL PIECES disc (2.5L TD)..
Excessive heat from slippage Replace modular clutch assembly (2.4L
6a - 6 CLUTCH RG
CLUTCH (Continued)
SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE

CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft
INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly,
or clutch disc, and/or input shaft if splines
are severely damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on Clean input shaft splines and disc splines,
splines of input shaft and disc then lube
CLUTCH DISC RUSTED Occurs in vehicles stored or not Replace modular clutch assembly (2.4L
TO FLYWHEEL AND/OR driven for extended period of time. Gas) or clutch cover and disc (2.5L TD).
PRESSURE PLATE Also occurs after steam cleaning if
vehicle is not used for extended
period.
CLUTCH WILL NOT Disc bent, distorted during transaxle Replace modular clutch assembly (2.4L
DISENGAGE PROPERLY installation Gas) or clutch cover and disc (2.5L TD).
Clutch cover diaphragm spring Replace modular clutch assembly (2.4L
damaged during transaxle installation Gas) or clutch cover and disc (2.5L TD).
Release fork bent, loose, or Replace fork if worn or damaged
damaged
Clutch cable (LHD Models) binding Check and correct cable routing.
or routed incorrectly.
Self-adjuster in cable (LHD Models) Pull on cable conduit at transaxle (as if
not functioning properly, resulting in disconnecting cable) to check adjuster
excess cable slack. operation.
Air in clutch hydraulic circuit (RHD Allow system to self-bleed or replace
models). hydraulic components.
Leak in clutch hydraulic circuit (RHD Replace worn/damaged/leaking hydraulic
models). components.
Clutch pedal requires Clutch cable routed incorrectly (LHD Check and correct cable routing.
excessive force (high models).
release load).
Clutch cable is worn, having high Replace clutch release cable.
friction or drag (LHD model).
Clutch disc is worn. Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models) and clutch release cable.
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE

CLUTCH PEDAL Pedal bushings worn out or Replace or lubricate bushings at clutch
SQUEAKS WHEN inadequate lubrication pedal pivot or master cylinder pushrod.
DEPRESSED TO FLOOR
Clutch pedal return spring worn out Lubricate or replace return spring
CLUTCH PEDAL Clutch release lever pivot stud has Lubricate or replace clutch release lever
SQUEAKS DURING inadequate lubrication
OPERATION
RG CLUTCH 6a - 7
CLUTCH (Continued)
DIAGNOSIS AND TESTING - DRIVE PLATE SPECIAL TOOLS

MISALIGNMENT
Common causes of misalignment are: SPECIAL TOOLS - T850 TRANSAXLE
• Heat warping
• Mounting drive plate on a dirty crankshaft
flange
• Incorrect bolt tightening
• Improper seating on the crankshaft shoulder
• Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout. Disconnect Tool, 6638A
DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
DIAGNOSIS AND TESTING - CLUTCH CHATTER

COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly. Remover/Installer, 6891
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
CLUTCH RELEASE CABLE -
complaints have been satisfied. If not: LHD
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky REMOVAL
or binding. Replace bearing, if needed. (1) Disconnect battery negative cable.
(c) Check linkage for excessive wear on the pivot (2) Raise vehicle on hoist.
stud and fork fingers. Replace all worn parts. (3) Diesel models: Remove underbody splash
(d) Check clutch assembly for contamination shield.
(dirt, oil). Replace clutch assembly, if required. (4) Remove clutch bellhousing cap.
(e) Check to see if the clutch disc hub splines (5) Some models will have a clutch cable retainer
are damaged. Replace with new clutch assembly, if clip at the transaxle to secure it to the case (Fig. 9).
necessary. If retainer clip is installed, dislodge clip from from
(f) Check input shaft splines for damage. inside bellhousing using a suitable screwdriver (Fig.
Replace, if necessary. 10), pull outward on cable conduit, guiding cable core
(g) Check for uneven wear on clutch fingers. wire through slot in bellhousing and disengaging
(h) Check for broken clutch cover diaphragm cable “T” from clutch release lever (Fig. 11). If
spring fingers. Replace with new clutch assembly, retainer is not installed, disengage clutch cable from
if necessary. transaxle by pulling outward on cable conduit, guid-
6a - 8 CLUTCH RG
CLUTCH RELEASE CABLE - LHD (Continued)
ing cable core wire through slot in bellhousing, and
disengaging cable “T” from clutch release lever (Fig.
11).
Fig. 11 Clutch Release Cable at Transaxle

1 - RELEASE LEVER
2 - RELEASE CABLE
Fig. 9 Clutch Cable Retainer Clip (If Equipped)
1 - RETAINER CLIP (9) Disconnect clutch cable core from upstop spacer
as shown in (Fig. 12)
Fig. 10 Disengaging Clip from Case (If Equipped)

1 - CABLE RETAINER
2 - SCREWDRIVER
Fig. 12 Clutch Cable at Upstop Spacer
(6) Lower vehicle. 1 - UPSTOP SPACER
2 - RELEASE CABLE
(7) Remove steering column lower panel.
(8) Remove knee bolster.
RG CLUTCH 6a - 9
(10) Remove clutch cable from retainer clips under
hood.
(11) Pull clutch cable out of dash from underhood
(Fig. 13).
Fig. 14 Clutch Cable at Pedal Bracket Assembly

1 - CLUTCH RELEASE CABLE
2 - DASH PANEL
Fig. 13 Clutch Cable at Pedal Bracket Assembly

2 - DASH PANEL
INSTALLATION
NOTE: The clutch release cable should be secured
to the transaxle case using a wire retainer. If cable
does not have this retainer upon disassembly,
obtain one from parts and use upon assembly.
(1) Route clutch release cable through retainers

and into dash panel hole (Fig. 14).
(2) From inside passenger compartment, secure
cable core to upstop spacer as shown in (Fig. 15)
(3) From underhood, route clutch release cable
downward as shown in (Fig. 16) (Fig. 17).
(4) Raise vehicle.
(5) If clutch cable does not have retainer, obtain
retainer and install to conduit as shown in (Fig. 18).
(6) Insert clutch cable “T” to clutch release lever,
pulling cable core wire through slot in bellhousing
and securing cable conduit to transaxle with retainer Fig. 15 Clutch Cable at Upstop Spacer
(Fig. 11). Verify cable conduit is properly seated to 1 - UPSTOP SPACER
bellhousing, and that retainer is properly seated as 2 - RELEASE CABLE
shown in (Fig. 19).
6a - 10 CLUTCH RG
Fig. 18 Clutch Cable Retainer

1 - RETAINER
2 - CABLE GROMMET
Fig. 16 Clutch Cable Routing - 2.4L Gas
2 - COOLANT RECOVERY BOTTLE
Fig. 19 Proper Cable Retainer Installatiion

1 - RETAINER
2 - GROMMET
(9) Lower vehicle.

(10) Verify proper clutch pedal/cable operation.
Fig. 17 Clutch Cable Routing - 2.5L TD (11) Install knee bolster.
1 - CLUTCH RELEASE CABLE (12) Install steering column lower panel.
2 - CABLE GUIDE (13) Connect battery negative cable.
(7) Install bellhousing cap.

(8) Diesel models: Install underbody splash
shield.
RG CLUTCH 6a - 11
CLUTCH RELEASE LEVER AND

BEARING
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (2.4L Gas models only).
(3) Grasp clutch release lever and bearing (Fig. 20)
(Fig. 21) with both hands and pull outward using
moderate pressure to release lever from pivot ball(s).

1 - RELEASE LEVER
2 - RELEASE BEARING

1 - RELEASE BEARING
2 - RELEASE LEVER
(4) Separate release bearing from lever.
NOTE: Remove release lever pivot ball(s) ONLY if

replacement is necessary.
(5) Remove pivot ball(s) using slide hammer

C-3752 and remover/installer 6891 (Fig. 22).
Fig. 22 Pivot Ball Removal/Installation

1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
6a - 12 CLUTCH RG
CLUTCH RELEASE LEVER AND BEARING (Continued)
INSTALLATION
(1) If removed, install new release lever pivot
ball(s) using slide hammer C-3752 and remover/in-
staller 6891 (Fig. 23) (Fig. 24) (Fig. 25).
Fig. 25 Pivot Ball Position (RHD)

1 - PIVOT BALL (1)
(2) Install clutch release bearing to lever. Apply

grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 26).
Fig. 23 Pivot Ball Removal/Installation

1 - C-3752 SLIDE HAMMER
2 - REMOVER/INSTALLER 6891
3 - PIVOT BALL
Fig. 26 Release Bearing-to-Lever

1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
(3) Apply grease to pivot ball(s), and on RHD

Fig. 24 Pivot Ball Position (LHD) release lever at slave cylinder contact point.
1 - PIVOT BALLS (2)
RG CLUTCH 6a - 13
CLUTCH RELEASE LEVER AND BEARING (Continued)
(4) Install clutch release bearing/lever assembly MASTER CYLINDER - RHD
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
REMOVAL
release lever to pivot ball(s) (Fig. 27) (Fig. 28). A
(1) Disconnect battery negative cable.
“pop” sound should be heard. Make sure LHD lever
(2) Remove master cylinder to clutch pedal pin
is secured to BOTH pivot balls. Verify proper
retainer clip. Disengage pushrod from clutch pedal
engagement by lightly pulling outward on lever at
pin (Fig. 30).
pivot ball location, and then actuating lever and
(3) Disengage master cylinder grommet from cowl
bearing to ensure proper operation.
panel.
(4) Remove battery and tray.
(5) Diesel models: Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)
(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
“quick-connect” fitting (Fig. 29).

1 - RELEASE BEARING
2 - RELEASE LEVER
Fig. 29 Disconnect Quick-Connect Using Tool 6638A

1 - QUICK CONNECT FITTING
2 - TOOL 6638A
(9) Remove clutch master cylinder tubing from

retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45° clockwise
and pulling outward towards engine (Fig. 30).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.

1 - RELEASE LEVER
2 - RELEASE BEARING
6a - 14 CLUTCH RG
MASTER CYLINDER - RHD (Continued)
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8) Diesel models: Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MODULAR CLUTCH ASSY -

2.4L GAS
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (Fig. 31).
Fig. 30 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45° clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45° counter-clockwise, secur-
ing it to pedal bracket (Fig. 30).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 30).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder “quick connect” fitting. An audible
“click” should be heard. Verify connection by pulling Fig. 31 Modular Clutch Assembly
outward.
1 - MODULAR CLUTCH ASSEMBLY
2 - INPUT SHAFT
RG CLUTCH 6a - 15
MODULAR CLUTCH ASSY - 2.4L GAS (Continued)
INSTALLATION INSTALLATION
(1) Install modular clutch assembly to transaxle (1) Install clutch slave cylinder into position, not-
input shaft (Fig. 31). ing orientation of different sized lugs. While depress-
(2) Install transaxle to vehicle. (Refer to 21 - ing inward, rotate slave cylinder clockwise until
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL- nylon locating tab rests in transaxle case cutout, and
LATION) the hydraulic tube is vertical (Fig. 32).
(2) Connect “quick-connect” connection until an
audible “click” is heard. Verify connection by pulling
SLAVE CYLINDER - RHD outward on connection.
(3) Diesel models: Install underbody splash
REMOVAL shield.
(1) Raise vehicle on hoist. Diesel models: Remove (4) Lower vehicle.
underbody splash shield.
(2) Using Tool 6638A, disconnect hyrdraulic clutch
circuit quick connect fitting. CLUTCH DISC AND PRESSURE
(3) Remove clutch slave cylinder (Fig. 32) by lifting PLATE - 2.5L TD
nylon tab with a small screwdriver, and then
depressing cylinder inward towards case and rotating REMOVAL
cylinder 60° counter-clockwise. (1) Remove transaxle assembly. (Refer to 21 -
REMOVAL)
(2) Remove six (6) clutch pressure plate-to-fly-
wheel bolts. Remove pressure plate and disc from fly-
wheel (Fig. 33).
(3) Inspect flywheel. Resurface/replace as neces-
sary.
(4) Inspect clutch release bearing and lever.
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
INSTALLATION
(1) Install clutch release bearing and lever (if
removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE
BEARING - INSTALLATION)
(2) Install clutch disc and pressure plate to fly-
wheel (Fig. 33). Install clutch alignment tool, and
install and torque pressure plate-to-flywheel bolts to
28 N·m (250 in. lbs.).
(3) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
Fig. 32 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
6a - 16 CLUTCH RG
FLYWHEEL (Continued)
Fig. 33 Clutch Disc and Pressure Plate

1 - FLYWHEEL 3 - PRESSURE PLATE
2 - DISC
FLYWHEEL
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
REMOVAL)
(2) Remove clutch pressure plate and disc. (Refer
to 6 - CLUTCH/CLUTCH DISC - REMOVAL)
(3) Remove flywheel assembly (Fig. 34).
INSTALLATION
(1) Install NEW flywheel-to-crankshaft bolts by
hand.
(2) Torque bolts in a criss-cross sequence to 25
N·m (18 ft. lbs.) (Fig. 34).
(3) Torque bolts in a criss-cross sequence an addi-
tional 60°.
(4) Install clutch pressure plate and disc. (Refer to
6 - CLUTCH/CLUTCH DISC - INSTALLATION)
Fig. 34 Flywheel Bolt Torque Sequence
(5) Install transaxle assembly. (Refer to 21 -
INSTALLATION)
RS COOLING 7-1
COOLING
TABLE OF CONTENTS
page page
COOLING COOLING SYSTEM - DRAINING . . . . . . . . . . . . 4

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 COOLING SYSTEM - REFILLING . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 COOLANT - ADDING ADDITIONAL . . . . . . . . . . . 4
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .3 COOLANT LEVEL CHECK - ROUTINE . . . . . . . . 5
COOLING SYSTEM LEAK TEST. . . . . . . . . . . . .3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM FLOW CHECK . . . . . . . . . .3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM AERATION . . . . . . . . . . . . .3 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 7
COOLING SYSTEM DEAERATION . . . . . . . . . . .3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .4 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 36
COOLING
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS

The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopart equipment spring
type clamp.
CAUTION: A number or letter is stamped into the

tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1). Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
OPERATION - COOLING SYSTEM • When engine is cold: thermostat is closed, cool-

The engine cooling systems primary purpose is to ing system has no flow through the radiator. The
maintain engine temperature in a range that will coolant bypass flows through the engine only.
provide satisfactory engine performance and emission • When engine is warm: thermostat is open, cool-
levels under all expected driving conditions. It also ing system has bypass flow and coolant flow through
provides hot water (coolant) for heater performance radiator.
and cooling for automatic transmission oil. It does Coolant flow circuits for the 2.4L and 3.3/3.8L
this by transferring heat from engine metal to cool- engines are shown in (Fig. 2).
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.
7-2 COOLING RS
COOLING (Continued)
Fig. 2 Cooling System Flow

1 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP
2 - HEATER - FRONT 7 - RADIATOR
3 - ENGINE 8 - COOLANT RECOVERY/RESERVE CONTAINER
4 - THERMOSTAT 9 - COOLANT FLOW - PRESSURE CAP VACUUM
5 - ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 10 - COOLANT FLOW - PRESSURE CAP RELIEF
OPERATION - HOSE CLAMPS

The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 3) to compress the
hose clamp.
Fig. 3 Hose Clamp Tool

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
RS COOLING 7-3
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
LEAK
If the needle on the dial does not fluctuate, raise
WARNING: THE WARNING WORDS “DO NOT OPEN
the engine rpm a few times. If an abnormal amount
HOT” ON THE RADIATOR PRESSURE CAP IS A
of coolant or steam emits from the tailpipe, it may
SAFETY PRECAUTION. WHEN HOT, PRESSURE
indicate a coolant leak caused by a faulty head gas-
BUILDS UP IN COOLING SYSTEM. TO PREVENT
ket, cracked engine block, or cracked cylinder head.
SCALDING OR INJURY, THE RADIATOR CAP
There may be internal leaks that can be deter-
SHOULD NOT BE REMOVED WHILE THE SYSTEM
mined by removing the oil dipstick. If water globules
IS HOT OR UNDER PRESSURE.
appear intermixed with the oil it will indicate an
With engine not running, remove radiator pressure internal leak in the engine. If there is an internal
cap and wipe the radiator filler neck sealing seat leak, the engine must be disassembled for repair.
clean. The radiator should be full.
Attach the Cooling System Tester 7700 or equiva- DIAGNOSIS AND TESTING - COOLING SYSTEM
lent to the radiator, as shown in (Fig. 4) and apply FLOW
104 kPa (15 psi) pressure. If the pressure drops more To determine whether coolant is flowing through
than 13.8 kPa (2 psi) in 2 minutes, inspect all points the cooling system, use the following procedures:
for external leaks. (1) If engine is cold, idle engine until normal oper-
All radiator and heater hoses should be shaken ating temperature is reached. Then feel the upper
while at 104 kPa (15 psi), since some leaks occur only radiator hose. If it is hot, coolant is circulating.
while driving due to engine movement.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
(2) Remove pressure cap when engine is cold,

remove small amount of coolant Idle engine until
thermostat opens, you should observe coolant flow
while looking down the filler neck. Once flow is
detected install the pressure cap.
DIAGNOSIS AND TESTING - COOLING SYSTEM

AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
• High reading shown on the temperature gauge.
• Loss of coolant flow through the heater core.
Fig. 4 Pressure Testing • Corrosion in the cooling system.
If there are no external leaks, after the gauge dial • Water pump seal may run dry, increasing the
shows a drop in pressure, detach the tester. Start risk of premature seal failure.
engine and run until the thermostat opens, allowing • Combustion gas leaks into the coolant can also
the coolant to expand. Reattach the cooling system cause the above problems.
tester. If the needle on the dial fluctuates it indicates
a combustion leak, usually a head gasket leak. DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
WARNING: WITH TOOL IN PLACE, PRESSURE WILL As air is removed from the cooling system, it gath-
BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, ers in the coolant bottle. This pressure is released
BY CONTINUOUS ENGINE OPERATION, MUST BE into the atmosphere through the pressure valve
located in the pressure cap when pressure reaches 96
7-4 COOLING RS
COOLING (Continued)
- 124 kPa (14 - 18 psi). This air is replaced with cool- STANDARD PROCEDURE - COOLING SYSTEM
ant from the coolant bottle.
FILLING
NOTE: Deaeration does not occur at engine idle— Remove radiator pressure cap (Fig. 6) and fill sys-
higher engine speeds are required. Normal driving tem, using a 50/50 mix of Mopart Antifreeze/Coolant,
will deaerate cooling system. 5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full. Be careful not
To effectively deaerate the system, multiple ther- to spill coolant on drive belts or the generator.
mal cycles of the system may be required. Fill coolant recovery/reserve container (Fig. 6) to at
least the MAX mark with 50/50 solution. It may be
STANDARD PROCEDURE - COOLING SYSTEM necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
DRAINING
to maintain coolant level between the MAX and MIN
WARNING: DO NOT REMOVE OR LOOSEN THE mark. This will allow trapped air to be removed from
COOLANT PRESSURE CAP, CYLINDER BLOCK the system.
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE STANDARD PROCEDURE - ADDING
BECAUSE SERIOUS BURNS FROM THE COOLANT ADDITIONAL COOLANT
CAN OCCUR. The radiator cap should not be removed.
When additional coolant is needed to maintain this
(1) Without removing radiator pressure cap level, it should be added to the coolant recovery/re-
and with system not under pressure, open the serve container (Fig. 6). Use only 50/50 mix of ethyl-
draincock. The draincock is located on the lower left ene glycol type antifreeze and distilled water. For the
side of radiator (Fig. 5). recommeded antifreeze/coolant type (Refer to LUBRI-
(2) After the coolant recovery/reserve container is CATION & MAINTENANCE/FLUID TYPES -
empty, then remove coolant pressure cap (Fig. 6). DESCRIPTION).
(3) Remove the cylinder block drain plug(s).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
DESCRIPTION).
Fig. 5 Draincock Location

1 - LEFT SIDE FRAME RAIL
2 - DRAINCOCK
RS COOLING 7-5
COOLING (Continued)
Fig. 6 Cooling System Service Locations

1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
STANDARD PROCEDURE - COOLANT LEVEL

CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual

method for determining the coolant level without
removing the radiator cap. With the engine cold
and not running, simply observe the level of the
coolant in the recovery/reserve container (Fig. 7). The
coolant level should be between the MIN and MAX
marks.
Fig. 7 Coolant Recovery Container

7-6 COOLING RS
SPECIFICATIONS SPECIAL TOOLS

TORQUE COOLING SYSTEM
DESCRIPTION N·m Ft. In.

Lbs. Lbs.
Accessory Drive Belt Tensioner 28 — 250
Assembly (3.3/3.8L)—Bolt
Generator & A/C Compressor Drive 28 — 250
Belt Tensioner Assembly (2.4L)—
Bolt Cooling System Tester 7700
Coolant Outlet Connector/
Thermostat Housing
(2.4 & 3.3/3.8L)—Bolts 28 — 250
Water Pump
(2.4 & 3.3/3.8L)—Bolts 12 — 105
Water Pump Inlet Tube (2.4L)— 12 — 105
Bolts
Water Pump Inlet Tube (3.3/3.8L)— 28 — 250 Coolant Refractometer 8286
Bolts
Water Pump Pulley (3.3/3.8L)— 28 — 250
Bolts
Radiator to A/C Condenser— 5 — 45
Screws
Radiator Fan—Screws 5 — 45
Radiator Mounting (Upper 8 — 70
Bracket)—Nuts Fig. 8 Belt Tension Gauge 7198
RS ACCESSORY DRIVE 7-7
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE ACCESSORY DRIVE BELT. . . . . . . . . . . . . . . . . 8

SPECIFICATIONS . . . . . . . ..................7 DRIVE BELTS - 2.4L
BELT TENSIONER - 2.4L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . ..................7 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . ..................7 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BELT TENSIONER - 3.3/3.8L INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . ..................8 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION. . . . . . . . . . ..................8 DRIVE BELTS - 3.3/3.8L
DRIVE BELTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION . . . . . . . . . . ..................8 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . ..................8 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING ..................8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ACCESSORY DRIVE (3) Remove the generator/A/C drive belt. (Refer to

7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
SPECIFICATIONS (4) Remove the belt tensioner (Fig. 1).
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE GAUGE

BELT
2.4L ENGINE
A/C Compressor/
Dynamic Tensioner
Generator
New Belt: 616 N (140

lbs.)
Power Steering
Used Belt: 396 N (90
lbs.)
Fig. 1 Belt Tensioner - 2.4L
3.3/3.8L ENGINES
1 - BELT TENSIONER
A/C Compressor 2 - BOLT
Generator/Water Dynamic Tensioner
Pump/Power Steering
INSTALLATION
(1) Install belt tensioner and bolt (Fig. 1). Tighten
BELT TENSIONER - 2.4L bolt to 28 N·m (250 in. lbs.).
(2) Install generator/A/C compressor drive belt.
REMOVAL (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)
(3) Install splash shield.
(2) Remove the drive belt shield.
7-8 ACCESSORY DRIVE RS
BELT TENSIONER - 3.3/3.8L

REMOVAL
(2) Remove the drive belt shield.
(3) Remove the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
(4) Remove the belt tensioner (Fig. 2).
INSTALLATION
(1) Install the belt tensioner and bolt (Fig. 2).
Tighten bolt to 28 N·m (250 in. lbs.).
(2) Install the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION)
(3) Install the drive belt shield.
Fig. 2 BELT TENSIONER - 3.3/3.8L
1 - BELT TENSIONER
2 - BOLT
DRIVE BELTS
OPERATION
DESCRIPTION The accessory drive belts form the link between
The drive belts are a Poly-V type belt. Belt widths the engine crankshaft and the engine driven accesso-
vary depending on the various engine and accessory ries.
packages. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY 1. Belt too loose 1. (a) Replace belt (auto-tensioned

OUTPUT DUE TO BELT SLIPPAGE belts)
(b) Adjust power steering belt

tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN 1. Belts too loose 1. (a) Replace belt (auto-tensioned
ACCELERATING ENGINE belts)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)

2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric 5. Replace pulley
pulley
RS ACCESSORY DRIVE 7-9
DRIVE BELTS (Continued)
BELT ROLLED OVER IN GROOVE 1. Broken cord in belt 1. Replace belt

OR BELT JUMPS OFF 2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
pulley
DRIVE BELTS - 2.4L POWER STEERING PUMP

(1) From top of the vehicle, loosen locking nuts (D)
REMOVAL and (F) (Fig. 4).
(2) From under the vehicle, loosen the pivot bolt
GENERATOR AND AIR CONDITIONING BELT (E). Loosen adjusting bolt (G) until belt can be
(1) Raise vehicle on hoist. removed.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-

SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug

(Fig. 3).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 3).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
Fig. 4 Power Steering Pump

1 - REAR LOCKING NUT (D)
Fig. 3 A/C & GENERATOR BELT TENSION RELEASE 2 - ADJUSTING BOLT (G)
1 - BELT TENSIONER 3 - PIVOT BOLT (E)
2 - WRENCH 4 - FRONT LOCKING NUT (F)
7 - 10 ACCESSORY DRIVE RS
DRIVE BELTS - 2.4L (Continued)
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
• Excessive wear
• Frayed cords
• Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 5).
NOTE: Do not use any type of belt dressing or

restorer on Poly-V Belts.
Fig. 6 Accessory Drive Belts - 2.4L

1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
POWER STEERING PUMP

(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 6).
(2) Apply an initial snug torque to fasteners (D),
(E), and (F) (Fig. 4).
(3) Tighten adjusting bolt (G) until the proper ten-
sion obtained (Fig. 4). Refer to Belt Tension Specifi-
cations (Refer to 7 - COOLING/ACCESSORY DRIVE
- SPECIFICATIONS).
(4) Tighten locking nuts (D) and (F) to 54 N·m (40
ft. lbs.) (Fig. 4).
Fig. 5 Drive Belt Wear Pattern (5) Tighten pivot bolt (E) to 54 N·m (40 ft. lbs.)
1 - NORMAL CRACKS - BELT OK (Fig. 4).
2 - NOT NORMAL CRACKS - REPLACE BELT
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
INSTALLATION ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
GENERATOR AND AIR CONDITIONING BELT 7198. Because of space limitations in the engine com-
(1) Install belt onto all pulleys except for the partment, the use of this gauge may be restricted.
crankshaft (Fig. 6). Raise the vehicle on a hoist and the remove the
(2) Rotate belt tensioner clockwise until belt can splash shield to gain access to the drive belts, if nec-
be installed onto the crankshaft pulley (Fig. 3). essary. Adjust belt tension for either a New or Used
Slowly release belt tensioner. belt. For specifications, (Refer to 7 - COOLING/AC-
(3) Verify belt is properly routed and engaged on CESSORY DRIVE - SPECIFICATIONS).
all pulleys (Fig. 6).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
RS ACCESSORY DRIVE 7 - 11
DRIVE BELTS - 3.3/3.8L (5) Remove the drive belt (Fig. 10).
(6) Carefully return tensioner to its relaxed posi-
tion.
REMOVAL
(2) Remove the drive belt shield (Fig. 7).
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
• Excessive wear
• Frayed cords
• Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 9).
NOTE: Do not use any type of belt dressing or

restorer on Poly-V Belts.
Fig. 7 Accessory Drive Belt Shield
1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD
WARNING: DO NOT ALLOW DRIVE BELT TEN-

SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug

(Fig. 8).
(4) Release belt tension by rotating the tensioner
counterclockwise (Fig. 8).
Fig. 9 Drive Belt Wear Pattern

1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 8 DRIVE BELT TENSION RELEASE

1 - BLET TENSIONER LUG
2 - WRENCH
7 - 12 ACCESSORY DRIVE RS
DRIVE BELTS - 3.3/3.8L (Continued)
INSTALLATION (2) Rotate belt tensioner counterclockwise until

(1) Route and position the drive belt onto all pul- belt can be installed onto the crankshaft pulley (Fig.
leys, except for the crankshaft (Fig. 10). 8). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
Fig. 10 ACCESSORY DRIVE BELT

1 - DRIVE BELT
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
RS ENGINE 7 - 13
ENGINE
TABLE OF CONTENTS
page page
ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 14 RADIATOR DRAINCOCK
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 RADIATOR PRESSURE CAP
COOLANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 17 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLANT CONCENTRATION TESTING. . . . . . 17 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 18 COOLING SYSTEM PRESSURE CAP
COOLANT SERVICE. . . . . . . . . . . . . . . . . . . . . 18 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLANT RECOVERY CONTAINER RADIATOR CAP TO FILLER NECK SEAL . . . . . 26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 19 RADIATOR FAN
COOLANT RECOVERY SYSTEM CHECK . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE BLOCK HEATER RADIATOR FAN MOTOR TEST. . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 19 RADIATOR FAN RELAY
ENGINE BLOCK HEATER TESTING . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE COOLANT TEMP SENSOR - 2.4L INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 WATER PUMP - 2.4L
ENGINE COOLANT TEMP SENSOR - 3.3/3.8L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE COOLANT THERMOSTAT WATER PUMP - 3.3/3.8L
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 22 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE COOLANT THERMOSTAT - 2.4L INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22 WATER PUMP INLET TUBE - 2.4L
ENGINE COOLANT THERMOSTAT - 3.3/3.8L DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RADIATOR WATER PUMP INLET TUBE - 3.3/3.8L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 - 14 ENGINE RS
ENGINE VISUAL INSPECTION

If the cooling system problem is not caused by a
DIAGNOSIS AND TESTING - ENGINE COOLING driving condition, perform a visual inspection to
determine if there was a recent service or accident
SYSTEM repair, including the following:
Establish what driving condition caused the cooling • Loose/damaged water pump drive belt
system complaint. The problem may be caused by an • Incorrect cooling system refilling (trapped air or
abnormal load on the system such as the following: low level)
prolonged idle, very high ambient temperature, slight • Brakes possibly dragging
tail wind at idle, slow traffic speed, traffic jam, high • Damaged hoses
speed, steep grade. • Loose/damaged hose clamps
• Damaged/incorrect engine thermostat
DRIVING TECHNIQUES • Damaged cooling fan motor, fan blade and fan
To avoid overheating the cooling system:
shroud
(1) Idle with A/C off when temperature gauge is at
• Damaged head gasket
end of normal range.
• Damaged water pump
(2) Do not increase engine speed for more air flow
• Damaged radiator
and coolant flow because the electric motor fan sys-
• Damaged coolant recovery system
tems are not responsive to engine RPM. The added
• Damaged heater core
cooling from higher coolant flow rate is more than
• Open/shorted electrical circuits
offset by increased heat rejection (engine heat added
If the visual inspection reveals none of the above
to coolant).
as cause for a cooling system complaint, refer to the
following diagnostic charts.
TRAILER TOWING
Consult the owner’s manual under Trailer Towing
and do not exceed specified limits.
COOLING SYSTEM DIAGNOSIS CHART
PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap
OFF STEAM AND/OR COOLANT. cap is defective, or was not and cap seal. (Refer to 7 -
TEMPERATURE GAUGE READING properly seated. COOLING/ENGINE/RADIATOR
MAY BE ABOVE NORMAL BUT PRESSURE CAP - DIAGNOSIS
NOT HIGH. COOLANT LEVEL MAY AND TESTING) Replace cap as
BE HIGH IN COOLANT RESERVE/ necessary.
OVERFLOW TANK.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT PRESSURE system hoses, water pump or necessary. (Refer to 7 - COOLING -
CAP BLOWOFF. GAUGE IS engine. DIAGNOSIS AND TESTING)
READING HIGH OR HOT.
RS ENGINE 7 - 15
ENGINE (Continued)
DETONATION OR PRE-IGNITION 1. Engine overheating. 1. Check reason for overheating

(NOT CAUSED BY IGNITION and repair as necessary.
SYSTEM). GAUGE MAY NOT BE
READING HIGH. 2. Freeze point of coolant not 2. Check concentration level of the
correct. Mixture too concentrated or coolant. (Refer to 7 - COOLING/
too diluted. ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
3. Incorrect cooling system 3. Install correct pressure cap.
pressure cap.
HOSE(S) COLLAPSE AS ENGINE 1. Vacuum created in cooling 1. (a) Pressure cap relief valve
COOLS DOWN. system on engine cool-down is not stuck. (Refer to 7 - COOLING/
being relieved through coolant ENGINE/RADIATOR PRESSURE
recovery system. CAP - DIAGNOSIS AND TESTING)
Replace as necessary.
(b) Hose between the radiator and
overflow container is plugged. Clean
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent
(d) Reserve/overflow container is
internally blocked. Clean and repair
as necessary.
INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean
PERFORMANCE (COOLING restricted, obstructed, or dirty as necessary.
SYSTEM SUSPECTED). (insects, leaves, etc.).
2. Electrical radiator fan not 2. For test procedure (Refer to
operating when A/C is operated. appropriate Diagnostic Information).
Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition.
be transferred from radiator to A/C
condenser). High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.
4. All models are equipped with air 4. Check for missing or damaged air
seals at the radiator and/or A/C seals and repair as necessary.
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
INADEQUATE HEATER 1. Check for a Diagnostic trouble 1. For procedures, (Refer to

PERFORMANCE. code (DTC). appropriate Diagnostic Information).
2. Coolant level low. 2. (Refer to 7 - COOLING -
STANDARD PROCEDURE) Repair
as necessary.
7 - 16 ENGINE RS
ENGINE (Continued)
3. Obstructions in heater hose 3. Remove heater hoses at both

fitting at engine or at heater core. ends and check for obstructions.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping 5. When the engine is fully warmed
coolant to heater core. up, both heater hoses should be hot
to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly. Replace
components as necessary.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain driveline components. One replace or repair as necessary.
or more of these shields may be
missing.
2. Temperature gauge reading 2. Refer to Gauge Is Reading High
above the normal range. in Temperature Gauge Indicatication
Diagnosis Chart.
3. Radiator fan operating 3. (Refer to 7 - COOLING/ENGINE/
incorrectly. RADIATOR FAN - OPERATION)
4. Undercoating been applied to an 4. Clean undercoating as necessary.
unnecessary component.
5. Engine may be running rich, 5. (Refer to Appropriate Diagnostic
causing the catalytic converter to Information) Repair as necessary.
overheat
POOR DRIVEABILITY 1. The engine thermostat must be 1. (Refer to Appropriate Diagnostic

(THERMOSTAT POSSIBLY STUCK operating correctly for proper Information) Replace thermostat, if
OPEN). GAUGE MAY BE READING driveability, clean vehicle emissions, necessary.
LOW. and the prevention of sludge
buildup in the engine oil. Check for
a diagnostic trouble code.
STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from
OF VEHICLE NEAR GRILL AREA (snow, ice, rain, or condensation) this area is normal. No repair is
WHEN WEATHER IS WET, on the radiator will evaporate when necessary.
ENGINE WARMED UP AND the thermostat opens. The
RUNNING WITH VEHICLE thermostat opening allows heated
STATIONARY, OR JUST SHUT coolant into the radiator. When the
OFF. TEMPERATURE GAUGE IS moisture contacts the hot radiator,
NORMAL. steam may be emitted. This usually
occurs in cold weather with no fan
or air flow to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Check the freeze point of the
an indication of adequate corrosion coolant. (Refer to 7 - COOLING/
or temperature protection. Do not ENGINE/COOLANT - DIAGNOSIS
rely on coolant color for determining AND TESTING) Adjust the ethylene
condition of coolant. glycol-to-water ratio as necessary.
RS ENGINE 7 - 17
ENGINE (Continued)
COOLANT LEVEL CHANGES IN 1. Level changes are to be 1. A normal condition. No repair is

COOLANT BOTTLE. expected as coolant volume necessary.
TEMPERATURE GAUGE IS IN fluctuates with engine temperature.
NORMAL RANGE. The coolant level will also drop as
the system removes air from a
recent filling.
TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART
TEMPERATURE GAUGE READING 1. Normal reaction to fan and/or 1. A normal condition. No correction
IS INCONSISTENT (FLUCTUATES, thermostat cycle 1, Examples B is necessary.
CYCLES OR IS ERRATIC). and C. During cold weather
operation with the heater blower in
the high position, the gauge reading
may drop slightly 1, Example D.
Fluctuation is also influenced by
outside temperature and heavy
loads 1, Example E.
2. Gauge reading rises when 2. A normal condition. No correction
vehicle is brought to a stop after is necessary. Gauge reading should
heavy use (engine still running) 1, return to normal range 1, Example
Example F. A, after vehicle is driven.
3. Gauge reading high after 3. A normal condition. No correction
restarting a warmed-up (hot) is necessary. The gauge should
engine. return to normal range 1, Example
A, after a few minutes of engine
operation.
4. Temperature gauge or engine 4. Check operation of gauge or
coolant temperature sensor engine coolant temperature sensor
defective or shorted. Also, corroded and repair, if necessary.
or loose wiring in the electrical
circuit.
CLEANING COOLANT
Drain cooling system and refill with clean water.
Refer to procedures in this section. Run engine with DIAGNOSIS AND TESTING - COOLANT
radiator cap installed until upper radiator hose is
CONCENTRATION
hot. Stop engine and drain water from system. If
Coolant concentration should be checked when any
water is dirty; fill, run, and drain system again, until
additional coolant was added to system or after a cool-
water runs clear.
ant drain, flush and refill. The coolant mixture offers
optimum engine cooling and protection against corrosion
INSPECTION when mixed to a freeze point of -37°C (-34°F) to -59°C
After performing a cleaning/flush procedure,
(-50°F). The use of a hydrometer or a refractometer can
inspect all hoses, clamps and connections for deterio-
be used to test coolant concentration.
ration and leaks. Inspect radiator and heater core for
A hydrometer will test the amount of glycol in a
leaks.
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
7 - 18 ENGINE RS
COOLANT (Continued)
Fig. 1 Temperature Gauge Indications

A refractometer will test the amount of glycol in a
coolant mixture by measuring the amount a beam of COOLANT RECOVERY
light bends as it passes through the fluid. CONTAINER
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol DESCRIPTION
is the most common new coolant. However, propylene The coolant recovery/reserve system container is
glycol based coolants do not provide the same freez- mounted in the engine compartment (Fig. 2). The
ing protection and corrosion protection and is not rec- container is made of plastic.
ommended.
OPERATION
CAUTION: Do not mix types of coolant—corrosion
The coolant recovery system works with the radia-
protection will be severely reduced.
tor pressure cap to use thermal expansion and con-
traction of the coolant to keep the coolant free of
STANDARD PROCEDURE - COOLANT SERVICE trapped air. Provides a convenient and safe method
for checking coolant level and adjusting level at
For engine coolant recommended service schedule,
atmospheric pressure without removing the radiator
(Refer to LUBRICATION & MAINTENANCE/MAIN-
pressure cap. It also provides some reserve coolant to
TENANCE SCHEDULES - DESCRIPTION).
cover deaeration, evaporation, or boiling losses.
RS ENGINE 7 - 19
COOLANT RECOVERY CONTAINER (Continued)
DIAGNOSIS AND TESTING - COOLANT (4) Raise the vehicle on hoist.

(5) Install the lower attaching screws and tighten
RECOVERY SYSTEM
to 8.5 N·m (75 in. lbs.) (Fig. 2).
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator.
(7) Add coolant to container as necessary. (Refer to
(1) With the engine off and cooling system not
7 - COOLING - STANDARD PROCEDURE)
under pressure, drain several ounces of coolant from
the radiator draincock while observing the coolant
recovery container. Coolant level in the container ENGINE BLOCK HEATER
should drop.
(2) Remove the radiator pressure cap. The coolant
DESCRIPTION
level should be full to the top radiator neck. If not,
The engine block heater is available as an optional
and the coolant level in the container is at or above
accessory on all models. The heater is operated by
the MIN mark, there is an air leak in the coolant
ordinary house current (110 Volt A.C.) through a
recovery system.
power cord located behind the radiator grille. This
(3) Check hose and hose connections to the con-
provides easier engine starting and faster warm-up
tainer, radiator filler neck or the pressure cap seal to
when vehicle is operated in areas having extremely
the radiator filler neck for leaks.
low temperatures. The heater is mounted in a core
hole (in place of a core hole plug) in the engine block,
REMOVAL with the heating element immersed in coolant.
(1) Raise the vehicle on hoist.
(2) Remove the lower attaching screws (Fig. 2).
OPERATION
The block heater element is submerged in the cool-
(4) Remove the upper attaching screw (Fig. 2).
ing system’s coolant. When electrical power (110 volt
(5) Disconnect recovery hose from container (Fig. 2).
A.C.) is applied to the element, it creates heat. This
(6) Remove the recovery container.
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
DIAGNOSIS AND TESTING - ENGINE BLOCK

HEATER
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
(2) Disconnect the power cord plug from heater.
Fig. 2 COOLANT RECOVERY CONTAINER (3) Loosen screw in center of heater. Remove the
1 - UPPER BOLT ATTACHING TO BATTERY TRAY heater assembly.
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
INSTALLATION
5 - LOWER BOLT (QTY. 2)
(1) Clean block core hole and heater seat.
6 - LEFT SIDE FRAME RAIL (2) Insert heater assembly with element loop posi-
tioned upward.
(3) With heater seated, tighten center screw
INSTALLATION securely to assure a positive seal.
(1) Connect the recovery hose to container (Fig. 2). (4) Install power cord plug to heater.
(2) Position the recovery container on the frame (5) Fill cooling system with coolant to the proper
rail (Fig. 2). level. (Refer to 7 - COOLING - STANDARD PROCE-
(3) Install the upper attaching screw and tighten DURE)
to 7 N·m (60 in. lbs.) (Fig. 2).
7 - 20 ENGINE RS
ENGINE COOLANT TEMP ENGINE COOLANT TEMP

SENSOR - 2.4L SENSOR - 3.3/3.8L
The engine coolant temperature sensor threads The engine coolant temperature sensor threads
into the top of the thermostat housing (Fig. 3). New into a coolant passage on lower intake manifold near
sensors have sealant applied to the threads. the thermostat (Fig. 6). New sensors have sealant
applied to the threads.
REMOVAL
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM WARNING: HOT, PRESSURIZED COOLANT CAN
MUST BE PARTIALLY DRAINED BEFORE REMOV- CAUSE INJURY BY SCALDING. COOLING SYSTEM
ING THE COOLANT TEMPERATURE SENSOR. MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Drain the cooling system below thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE- (1) Drain cooling system below engine coolant tem-
DURE) perature sensor level. (Refer to 7 - COOLING -
(2) Disconnect coolant temperature sensor electri- STANDARD PROCEDURE)
cal connector. (2) Remove power steering reservoir and relocate
(3) Remove coolant temperature sensor (Fig. 3). (Fig. 4). Do not disconnect hoses.
Fig. 3 Engine Coolant Temperature Sensor - 2.4L Fig. 4 Power Steering Fluid Reservoir
1 - MAP SENSOR
1 - POWER STEERING RESERVOIR
2 - COOLANT TEMPERATURE SENSOR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
INSTALLATION
(1) Install coolant temperature sensor (Fig. 3).
Tighten sensor to 7 N·m (60 in. lbs.).
(2) Connect electrical connector to sensor.
(3) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
RS ENGINE 7 - 21
ENGINE COOLANT TEMP SENSOR - 3.3/3.8L (Continued)
(3) Remove ignition coil and bracket (Fig. 5).
Fig. 6 Engine Coolant Temperature Sensor

1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 5 Fuel Rail, Ignition Coil and Bracket
1 - FUEL RAIL
2 - BOLT - FUEL RAIL ENGINE COOLANT
3 - NUT - IGNITION COIL THERMOSTAT
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
DESCRIPTION
7 - STUD - IGNITION COIL The engine cooling thermostats are a wax pellet
8 - SEPARATOR - SPARK PLUG CABLE driven, reverse poppet choke type. The thermostat is
9 - BRACKET - SPARK PLUG CABLE SEPARATOR mounted in a housing on the coolant outlet of the
10 - BOLT - SEPARATOR BRACKET engine (Fig. 8) or (Fig. 10).
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
OPERATION
(4) Disconnect coolant sensor electrical connector The engine cooling thermostat is a wax pellet
(Fig. 6). driven, reverse poppet choke type. The thermostat is
(5) Remove coolant sensor (Fig. 6). designed to provide the fastest warm up possible by
preventing leakage through it and to guarantee a
INSTALLATION minimum engine operating temperature of 88 to
(1) Install engine coolant temperature sensor (Fig. 93°C (192 to 199°F). The thermostat also will auto-
6). Tighten sensor to 7 N·m (60 in. lbs.). matically reach wide open so it will not restrict flow
(2) Connect electrical connector to sensor (Fig. 6). to the radiator as temperature of the coolant rises in
(3) Install ignition coil bracket (Fig. 5). hot weather to around 104°C (220°F). Above this
(4) Install ignition coil (Fig. 5). temperature the coolant temperature is controlled by
(5) Install power steering reservoir (Fig. 4). the radiator, fan, and ambient temperature, not the
(6) Fill cooling system. (Refer to 7 - COOLING - thermostat.
STANDARD PROCEDURE) The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolant
reaches a predetermined temperature, the wax
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
7 - 22 ENGINE RS
ENGINE COOLANT THERMOSTAT (Continued)
DIAGNOSIS AND TESTING - ENGINE COOLANT

THERMOSTAT
The thermostat is operated by a wax filled cham-
ber (pellet) which is sealed. When heated coolant
reaches a predetermined temperature the wax pellet
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Coolant leakage into the pellet will cause a thermo-
stat to fail open. Do not attempt to free up a thermo-
stat with a screwdriver.
Thermostat diagnostics is included in powertrain
control module’s (PCM) programing for on-board
diagnosis. The malfunction indicator light (MIL) will
illuminate and a diagnostic trouble code (DTC) will
be set when an “open too soon” condition occurs. Do
not change a thermostat for lack of heater perfor-
mance or temperature gauge position, unless a DTC
is present. For other probable causes, (Refer to 7 -
COOLING/ENGINE - DIAGNOSIS AND TESTING) .
Thermostat failing shut is the normal long term
mode of failure, and normally, only on high mileage
vehicles. The temperature gauge will indicate this
(Refer to 7 - COOLING/ENGINE - DIAGNOSIS AND Fig. 7 RADIATOR HOSES TO ENGINE - 2.4L
TESTING) . 1 - UPPER HOSE
2 - LOWER HOSE
ENGINE COOLANT
THERMOSTAT - 2.4L
REMOVAL
(1) Drain cooling system below the thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Remove radiator upper hose from the coolant
outlet housing (Fig. 7).
(3) Remove coolant outlet housing bolts and hous-
ing (Fig. 8).
(4) Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION Fig. 8 Thermostat and Outlet Connector - 2.4L

(1) Place a new gasket (dipped in clean water) on Engine
the coolant outlet connector surface. Position thermo-
1 - THERMOSTAT
stat with air bleed at the 12 o’clock position in ther-
2 - GASKET
mostat housing (Fig. 8). 3 - COOLANT OUTLET CONNECTOR
(2) Position the coolant outlet connector and gas- 4 - BOLT
ket over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Position outlet connector to thermostat housing
and install bolts (Fig. 8). Tighten bolts to 28 N·m
(250 in. lbs.).
(4) Install the radiator upper hose to coolant outlet
housing (Fig. 7).
(5) Refill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
RS ENGINE 7 - 23
ENGINE COOLANT
THERMOSTAT - 3.3/3.8L
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. (Refer to 7 - COOLING - STANDARD
PROCEDURE)
(2) Remove radiator upper hose from coolant outlet
connector (Fig. 9).
Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE

1 - COOLANT OUTLET CONNECTOR
2 - BOLT
3 - THERMOSTAT
4 - GASKET
Fig. 9 RADIATOR HOSES TO ENGINE - 3.3/3.8L

1 - UPPER HOSE
2 - LOWER HOSE
(3) Remove coolant outlet connector bolts and con-

nector (Fig. 10).
(4) Remove thermostat from outlet connector.
(5) Discard gasket and clean both gasket sealing
surfaces.
Fig. 11 Connector Staking Material Removal
INSTALLATION 1 - STAKE
2 - OUTLET CONNECTOR
(1) To ensure proper seating of replacement ther-
mostat, carefully remove the bulged metal from the
wall of the outlet connector recess that was created (3) Position a new gasket over the thermostat and
during the staking procedure that held the OEM connector making sure thermostat is in proper posi-
thermostat in place (Fig. 11). It is not necessary to tion and in the recess provided.
restake the replacement thermostat into the connec- (4) Install thermostat and connector assembly to
tor. the intake manifold (Fig. 10). Tighten bolts to 28
(2) Position thermostat to coolant outlet connector. N·m (250 in. lbs.).
Align the two locating notches on thermostat to the (5) Install the radiator upper hose to coolant outlet
connector (Fig. 12). This position will ensure proper connector (Fig. 9).
location of the thermostat air bleed. (6) Refill the cooling system to the proper level.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
7 - 24 ENGINE RS
ENGINE COOLANT THERMOSTAT - 3.3/3.8L (Continued)
(5) Disconnect coolant reserve/recovery hose.
(6) Remove vapor purge solenoid from mounting
bracket.
(7) Disconnect upper and lower hoses from the
radiator (Fig. 13) or (Fig. 14).
Fig. 12 Thermostat Position In Outlet Connector

1 - LOCATING NOTCH
2 - THERMOSTAT Fig. 13 Radiator Hoses to Radiator - 2.4L
3 - COOLANT OUTLET CONNECTOR
1 - UPPER HOSE
2 - LOWER HOSE
3 - HOSE SUPPORT CLIP
RADIATOR
DESCRIPTION
The radiator is a cross-flow type (horizontal tubes)
with design features that provide greater strength
along with sufficient heat transfer capabilities to
keep the engine satisfactorily cooled. The radiator
has plastic side tanks and aluminum cooling tubes.
OPERATION
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove radiator upper crossmember support.
Fig. 14 Radiator Hoses to Radiator - 3.3/3.8L
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
REINFORCEMENT - REMOVAL) 1 - UPPER HOSE
2 - LOWER HOSE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK (8) Remove the A/C condenser side brackets to
WITH THE SYSTEM HOT AND UNDER PRESSURE radiator attaching screws (Fig. 15). Separate the con-
BECAUSE SERIOUS BURNS FROM COOLANT CAN denser from the radiator by lifting upward to disen-
OCCUR. gage from lower mounts (Fig. 15). Allow the
condenser to rest in front of radiator.
(3) Drain the cooling system. (Refer to 7 - COOL- (9) Radiator can now be lifted free from engine
ING - STANDARD PROCEDURE) compartment. Care should be taken not to dam-
(4) Remove the radiator fans. (Refer to 7 - COOL- age radiator cooling fins or water tubes during
ING/ENGINE/RADIATOR FAN - REMOVAL) removal.
RS ENGINE 7 - 25
RADIATOR (Continued)
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.
NOTE: It is not necessary to remove draincock dur-

ing a routine coolant drain.
(1) Drain the cooling system. (Refer to 7 - COOL-

(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 16) from the radiator
tank.
Fig. 15 Radiator to A/C Condenser Mounting (left

mount shown, right similar)
1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
2 - LOWER MOUNT
3 - A/C CONDENSER
INSTALLATION
(1) Be sure the air seal is in position before
radiator is installed. Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the Fig. 16 Draincock
radiator lower mounts and install upper screws (Fig.
1 - RADIATOR TANK
15). Tighten fasteners to 5 N·m (45 in. lbs.). 2 - DRAINCOCK
(3) Install the radiator upper and lower hoses (Fig.
13) or (Fig. 14).
(4) Connect the coolant reserve/recovery hose. INSTALLATION
(5) Connect the vapor purge solenoid to the mount- (1) Align draincock stem to radiator tank opening.
ing bracket. (2) Push draincock into the radiator tank opening.
(6) Install the radiator fans. (Refer to 7 - COOL- (3) Tighten the draincock by turning clockwise
ING/ENGINE/RADIATOR FAN - INSTALLATION) until it stops.
(7) Install the radiator upper crossmember sup- (4) Fill the cooling system. (Refer to 7 - COOLING
port. (Refer to 23 - BODY/EXTERIOR/GRILLE - STANDARD PROCEDURE)
OPENING REINFORCEMENT - INSTALLATION)
(8) Fill the cooling system. (Refer to 7 - COOLING
(9) Connect negative cable to battery.
7 - 26 ENGINE RS
RADIATOR PRESSURE CAP DIAGNOSIS AND TESTING - COOLING SYSTEM

PRESSURE CAP
DESCRIPTION Dip the pressure cap in water. Clean any deposits
The cooling system pressure cap is located on the off the vent valve or its seat and apply cap to end of
radiator. The cap construction includes; stainless the Pressure Cap Test Adaptor that is included with
steel swivel top, rubber seals, and retainer, main the Cooling System Tester 7700. Working the
spring, and a spring loaded valve (Fig. 17) . plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at
least 97 kPa (14 psi), replace the pressure cap.
CAUTION: The Cooling System Tester Tool is very

sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm
that cap is bad.
If the pressure cap tests properly while positioned

on Cooling System Tester (Fig. 18), but will not hold
Fig. 17 Cooling System Pressure Cap Filler Neck pressure or vacuum when positioned on the radiator.
1 - OVERFLOW NIPPLE Inspect the radiator filler neck and cap top gasket for
2 - MAIN SPRING irregularities that may prevent the cap from sealing
3 - GASKET RETAINER properly.
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling Fig. 18 Testing Cooling System Pressure Cap
system from coolant reserve system tank by vacuum 1 - PRESSURE CAP
through a connecting hose. If valve is stuck shut, 2 - PRESSURE TESTER
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 17) and inspect cool- DIAGNOSIS AND TESTING - RADIATOR CAP
ant recovery hose routing, to ensure proper TO FILLER NECK SEAL
sealing when boiling point is reached. The pressure cap upper gasket (seal) pressure
The gasket in the cap seals the filler neck, so that relief can be checked by removing the overflow hose
vacuum can be maintained, allowing coolant to be at the radiator filler neck nipple (Fig. 19). Attach the
drawn back into the radiator from the reserve tank. Radiator Pressure Tool to the filler neck nipple and
If the gasket is dirty or damaged, a vacuum pump air into the radiator. Pressure cap upper gas-
may not be achieved, resulting is loss of coolant ket should relieve at 69-124 kPa (10-18 psi) and hold
and eventual overheating due to low coolant pressure at 55 kPa (8 psi) minimum.
level in radiator and engine.
RS ENGINE 7 - 27
RADIATOR PRESSURE CAP (Continued)
INSPECTION
Hold the cap in your hand, top side up (Fig. 20).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand, upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap. Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
Fig. 19 Radiator Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK

BUILDS UP IN COOLING SYSTEM. TO PREVENT Fig. 20 Cooling System Pressure Cap
SCALDING OR INJURY, THE RADIATOR CAP 1 - OVERFLOW NIPPLE
SHOULD NOT BE REMOVED WHILE THE SYSTEM 2 - MAIN SPRING
IS HOT OR UNDER PRESSURE. 3 - GASKET RETAINER
There is no need to remove the radiator cap at any 5 - RUBBER SEALS
6 - VENT VALVE
time except for the following purposes:
7 - THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
(1) Check and adjust coolant freeze point.
8 - FILLER NECK
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
RADIATOR FAN
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN DESCRIPTION
PLACE A SHOP TOWEL OVER THE CAP AND WITH- The dual radiator fans are mounted to the back
OUT PUSHING DOWN ROTATE COUNTERCLOCK- side of the radiator (Fig. 21). The radiator fan consist
WISE TO THE FIRST STOP. ALLOW FLUIDS TO of the fan blade, electric motor and a support shroud
ESCAPE THROUGH THE OVERFLOW TUBE AND which are all serviced as an assembly.
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
7 - 28 ENGINE RS
RADIATOR FAN (Continued)
OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE TRANSAXLE OIL

TEMPERATURE
Fan
Operation Initial Max Initial Max Initial Max
Speeds:
Fan On: 104°C 110°C 1,724 Kpa 2,068 Kpa 96°C (204°F) 111°C (232°F)
(220°F) (230°F) Fan (250 psi) (300 psi) Fan Fan Speed
Speed Speed Duty Cycles
Duty-Cycles Duty-Cycles (Ramps-up)
(Ramps-up) (Ramps-up) from 30% to
from 30% to from 30% to 99%
99% 99%
Fan Off: 101°C Fan Speed 1,710 Kpa Fan Speed 89°C (192°F) Fan Speed
(214°F) Duty-Cycles (248 psi) Duty-Cycles Duty Cycles
(Ramps- (Ramps- (Ramps-down)
down) from down) from from 99% to
99% to 30% 99% to 30% 30%
DIAGNOSIS AND TESTING - RADIATOR FAN

MOTOR
RADIATOR FAN DIAGNOSIS CHART
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding 2. Locate point of fan blade contact
object. and repair as necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions and/or
condenser. clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
NOT OPERATE module (PCM), coolant temperature Information) Repair as necessary.
sensor, or wiring defective.
2. Defective A/C pressure 2. (Refer to Appropriate Diagnostic
transducer. Information) Repair as necessary.
ELECTRIC RADIATOR FAN 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
OPERATES ALL THE TIME module (PCM), coolant temperature Information) Repair as necessary.
sensor or wiring defective.
2. Check for low coolant level. 2. Add coolant as necessary.
RS ENGINE 7 - 29
REMOVAL RADIATOR FAN RELAY

There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or DESCRIPTION
otherwise damaged, it must be replaced as an assem- The radiator fan relay is a solid state type and is
bly (Fig. 21). located on the front bumper reinforcment (Fig. 22).
(1) Remove the radiator upper crossmember. (Refer Refer to WIRING DIAGRAMS for a circuit sche-
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- matic.
FORCEMENT - REMOVAL)
(2) Disconnect the radiator fan electrical connec- OPERATION
tors. The solid state radiator fan relay is controlled by
(3) Remove radiator fan(s) retaining screw (Fig. the Powertrain Control Module (PCM) by way of a
21). Pulse Width Modulated (PWM) signal. The relay con-
(4) Remove the radiator fan(s) by lifting upward to trol circuit supplies a 12 volt signal to the PCM. The
release from mounts. PCM then pulses the ground circuit to achieve fan on
time. The relay provides a voltage to the fan motors
which is proportional to the pulse width it receives
from the PCM. The duty cycle ranges from 30% for
low speed operation, then ramps-up to 100% for high
speed operation. This fan control system provides
infinitely variable fan speeds, allowing for improved
fan noise, A/C performance, better engine cooling,
and additional vehicle power.
To control operation of the relay, the PCM looks at
inputs from:
• Engine coolant temperature
• A/C pressure transducer
• Ambient temperature from the body controller
Fig. 21 Radiator Fans • Vehicle speed
• Transmission oil temperature
1 - SCREWS - RADIATOR FAN ATTACHING
The PCM uses these inputs to determine when the
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN fan should operate and at what speed. For further
4 - CLIPS - RADIATOR FAN LOWER information on fan operation, (Refer to 7 - COOL-
5 - MOUNT - LEFT RADIATOR FAN ING/ENGINE/RADIATOR FAN - OPERATION).
6 - RADIATOR FAN - LEFT
REMOVAL
(1) Open hood.
INSTALLATION (2) Disconnect and isolate the battery negative
(1) Install the radiator fan(s) into mounts and cable.
attaching clips on the radiator. (3) Remove the radiator crossmember to front fas-
(2) Install radiator fan(s) attaching screws (Fig. cia closure panel.
21). Tighten to 5 N·m (45 in. lbs.). (4) Disconnect the relay electrical connector (Fig.
(3) Connect the radiator fan(s) electrical connec- 22).
tors. (5) Remove the rivet attaching the relay to the
(4) Install the radiator upper support crossmem- front bumper beam (Fig. 22).
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN- (6) Remove the relay.
ING REINFORCEMENT - INSTALLATION)
(5) Install the upper radiator mounts to the cross- INSTALLATION
member bolts, if removed. Tighten to 8 N·m (70 in.
lbs.). CAUTION: The relay mounting location is designed
(6) Install the radiator upper hose to the support to dissipate heat. Ensure the relay is securely
clip (2.4L engine). attached to prevent relay “thermal” shutdown and
relay damage, resulting in possible engine over-
heating.
7 - 30 ENGINE RS
RADIATOR FAN RELAY (Continued)
Fig. 23 Water Pump

1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 22 Radiator Fan Relay
1 - FRONT FASCIA
2 - FAN RELAY
REMOVAL
3 - RIVET (1) Disconnect negative cable from battery.
4 - A/C CONDENSER (FRONT SIDE) (2) Raise vehicle on a hoist.
(3) Remove the right inner splash shield.
(4) Remove the accessory drive belts. (Refer to 7 -
(1) Position relay and install a new rivet (Fig. 22).
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
(2) Connect electrical connector to relay.
REMOVAL)
(3) Install closure panel and attaching screws.
(6) Support engine from the bottom and remove
WATER PUMP - 2.4L right engine mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/RIGHT MOUNT - REMOVAL)
(7) Remove right engine mount bracket.
DESCRIPTION (8) Remove the timing belt. (Refer to 9 - ENGINE/
The water pump has a cast aluminum body and
VALVE TIMING/TIMING BELT/CHAIN AND
housing with a stamped steel impeller. The water
SPROCKET(S - REMOVAL)
pump bolts directly to the block (Fig. 23). The cylin-
(9) Remove timing belt idler pulley.
der block to water pump seal is provided by a rubber
(10) Hold camshaft sprocket with Special tool
O-ring. The water pump is driven by the engine tim-
C-4687 and adaptor C-4687-1 while removing bolt.
ing belt.
Remove both cam sprockets.
(11) Remove the timing belt rear cover (Refer to 9
OPERATION - ENGINE/VALVE TIMING/TIMING BELT / CHAIN
The water pump is the heart of the cooling system. COVER(S) - REMOVAL) .
The coolant is pumped through the engine block, cyl- (12) Remove the generator and bracket (Fig. 24).
inder head, heater core, and radiator.
RS ENGINE 7 - 31
WATER PUMP - 2.4L (Continued)
Fig. 24 Generator Bracket

1 - BRACKET - ENGINE MOUNT 5 - BOLT
2 - BOLT 6 - TENSIONER - DRIVE BELT
3 - GENERATOR 7 - BOLT
4 - BOLT 8 - BOLT
(13) Remove water pump attaching screws to improperly located O-ring may be damaged and
engine (Fig. 25). cause a coolant leak.
CLEANING (2) Assemble pump body to block and tighten

Clean gasket mating surfaces as necessary. screws to 12 N·m (105 in. lbs.) (Fig. 25). Pressurize
cooling system to 103.4 Kpa (15 psi) with pressure
INSPECTION tester and check water pump shaft seal and O-ring
Replace water pump body assembly if it has any of for leaks.
these defects: (3) Rotate pump by hand to check for freedom of
(1) Cracks or damage on the body. movement.
(2) Coolant leaks from the shaft seal, evident by (4) Install the timing belt rear cover. (Refer to 9 -
wet coolant traces on the pump body. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(3) Loose or rough turning bearing. COVER(S) - INSTALLATION)
(4) Impeller rubs either the pump body or the (5) Install camshaft sprockets and torque bolts to
engine block. 101 N·m (75 ft. lbs.).
(5) Impeller loose or damaged. (6) Install timing belt idler pulley and torque
(6) Sprocket or sprocket flange loose or damaged. mounting bolt to 61 N·m (45 ft. lbs.).
(7) Install the timing belt. (Refer to 9 - ENGINE/
INSTALLATION VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKET(S - INSTALLATION)
(1) Install new O-ring gasket in water pump body
(8) Install the generator mount bracket. (Fig. 24)
O-ring groove (Fig. 26).
(9) Install the generator.
CAUTION: Make sure O-ring is properly seated in (10) Install right engine mount bracket and engine
water pump groove before tightening screws. An mount. (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - INSTALLATION)
7 - 32 ENGINE RS
WATER PUMP - 2.4L (Continued)
(12) Install the accessory drive belts. (Refer to 7 -
INSTALLATION)
(13) Lower vehicle and connect battery cable.
WATER PUMP - 3.3/3.8L

DESCRIPTION
The water pump has a die-cast aluminum body
and a plastic impeller. It bolts directly to the timing
chain case cover, using an rubber seal for sealing
(Fig. 27). It is driven by the accessory drive belt.
Fig. 25 Water Pump - 2.4L

1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 27 Water Pump - 3.3/3.8L Engine

1 - WATER PUMP
2 - PULLEY - WATER PUMP
3 - BOLT - PULLEY
4 - BOLT - WATER PUMP
5 - SEAL - WATER PUMP
OPERATION
The water pump is the heart of the cooling system.
The coolant is pumped through the engine block, cyl-
inder head, heater core, and radiator.
REMOVAL
Fig. 26 Water Pump Body (2) Remove the accessory drive belt shield.
1 - IMPELLER (3) Remove the accessory drive belt. (Refer to 7 -
2 - PUMP BODY COOLING/ACCESSORY DRIVE/DRIVE BELTS -
3 - O-RING REMOVAL)
(4) Remove water pump pulley bolts (Fig. 27).
(11) Fill the cooling system. (Refer to 7 - COOL-
RS ENGINE 7 - 33
WATER PUMP - 3.3/3.8L (Continued)
NOTE: To remove the water pump pulley, it MUST
first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rotate pulley until openings in pulley align

with water pump drive hub spokes (Fig. 28). Move
pulley inward between pump housing and hub (Fig.
28).
Fig. 29 Water Pump Bolts - 3.3/3.8L Engine (Shown

Without Pulley)
1 - WATER PUMP
2 - BOLTS
15–18 psi and observe the weep area. If weep area

remains unchanged, do not replace the water pump
Fig. 28 Water Pump Pulley Positioning for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
weep hole/reservoir slot (Fig. 30) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 29).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
(8) Remove and discard the seal.
(9) Clean seal groove and sealing surfaces on
pump and timing chain case cover. Take care not to
scratch or gouge sealing surfaces.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; this will be evident by a wet
stream of coolant running down the pump body and
components below. A thin stain below the weep hole
reservoir slot (Fig. 30) is considered normal opera- Fig. 30 Water Pump Inspection - 3.3/3.8L Engine
tion. INSTALLATION
(3) Impeller rubs inside of chain case cover.
(1) Install new seal into water pump housing
(4) Excessively loose or rough turning bearing.
groove (Fig. 31).
NOTE: A weepage stain that is black, brown, or grey
NOTE: The water pump pulley MUST be positioned
is considered normal, if it is dry. If the weep
loosely between the pump housing and drive hub
appears wet; pressure test the cooling system at
BEFORE water pump installation.
7 - 34 ENGINE RS
WATER PUMP - 3.3/3.8L (Continued)
Fig. 32 Water Pump Inlet Tube—2.4L Engine

1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 31 Water Pump Seal
1 - WATER PUMP HOUSING
(3) Remove radiator lower (Fig. 7) and heater
2 - SEAL
hoses from the inlet tube (Fig. 33).
3 - IMPELLER
(4) Remove the two fasteners that hold the inlet
tube to the block.
(2) Position the water pump pulley loosely between (5) Rotate tube while removing the tube from the
pump housing and drive hub (Fig. 28). engine block (Fig. 33).
(3) Install water pump and pulley to the timing
chain case cover (Fig. 27). Tighten water pump bolts
to 12 N·m (105 in. lbs.).
(4) Position pulley on water pump hub. Install
bolts and tighten to 30 N·m (250 in. lbs.) (Fig. 27).
(5) Rotate pump by hand to check for freedom of
movement.
(6) Install the accessory drive belt. (Refer to 7 -
INSTALLATION)
(7) Install drive belt shield.
WATER PUMP INLET TUBE -

2.4L Fig. 33 Water Pump Inlet Tube Hose Connections
2 - HOSE - HEATER RETURN
DESCRIPTION 3 - COOLANT INLET
The 2.4L engine uses a metal tube to connect the
engine block to the lower radiator hose and heater
return (Fig. 32). The tube has an O-ring for block to INSTALLATION
tube sealing and bolts attach the tube to the engine (1) Inspect the O-ring for damage before installing
block. the tube into the cylinder block (Fig. 32).
(2) Lube O-ring with coolant and install inlet tube
REMOVAL into the cylinder block opening (Fig. 32).
(1) Drain the cooling system. (Refer to 7 - COOL- (3) Install the two inlet tube fasteners and tighten
ING - STANDARD PROCEDURE) to 12 N·m (105 in. lbs.).
(2) Remove radiator upper hose to access the hose (4) Connect the radiator lower hose and heater
connections at the inlet tube. hose to inlet tube.
RS ENGINE 7 - 35
WATER PUMP INLET TUBE - 2.4L (Continued)
(5) Install the radiator upper hose.
WATER PUMP INLET TUBE -

3.3/3.8L
REMOVAL
(2) Raise vehicle on hoist and remove the belt
splash shield.
(3) Remove the radiator lower hose from inlet tube
(Fig. 34).
Fig. 35 Engine Oil Cooler Hoses (Engine Oil Cooler
Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L

1 - UPPER HOSE
2 - LOWER HOSE
(4) Remove the oil cooler outlet/heater return hose

from inlet tube (only if equipped with engine oil Fig. 36 WATER PUMP INLET TUBE
cooler) (Fig. 35). 1 - TIMING CHAIN COVER
(5) Remove the inlet tube bolts (Fig. 36). 2 - INLET TUBE
(6) Remove the inlet tube (Fig. 36). Discard the 3 - BOLT
4 - BOLT
O-ring seal.
5 - O-RING
INSTALLATION
(1) Clean the inlet tube O-ring sealing surfaces on (5) Connect radiator lower hose (Fig. 34) and
the timing cover housing and tube. heater return hose (if equipped with engine oil
(2) Apply Mopart Dielectric Grease or equivalent cooler) (Fig. 35) to the inlet tube.
to the O-ring before installation. (6) Install the drive belt splash shield and lower
(3) Position new O-ring seal on inlet tube (Fig. 36). vehicle.
(4) Install the inlet tube (Fig. 36). Tighten bolts to (7) Fill the cooling system. (Refer to 7 - COOLING
28 N·m (250 in. lbs.). - STANDARD PROCEDURE)
7 - 36 TRANSMISSION RS
TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 36 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TRANS OIL COOLER FLOW TESTING . . . . . . . 36 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 37 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FLUSHING COOLERS AND TUBES . . . . . . . . . 37 TRANS COOLER LINES
TRANS COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TRANSMISSION adapter, connect Special Tool 8392 flow meter in-se-

ries with the oil cooler flow circuit (Fig. 1).
(3) Start engine and run at curb idle speed.
DIAGNOSIS AND TESTING - TRANSMISSION
Observe the flow meter gauge. Refer to the following
OIL COOLER FLOW chart for specifications.
To determine proper transmission oil flow through
the oil cooler perform the following procedure:
COOLER FLOW SPECIFICATION (Min.)
(1) Disconnect the hose from the “cooler return”
fitting on the transmission. (Refer to 7 - COOLING/ 2.6 LPM (0.7 GPM)
TRANSMISSION/TRANS COOLER LINES -
(4) If oil flow is below minimum specifications, fur-
REMOVAL)
ther diagnosis must be performed.
(2) Using Special Tool adaptors 6906-1-3 with a 9
(a) Perform Oil Pump Volume Check. (Refer to
mm (3/8 in.) transmission hose attached to one
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
Fig. 1 TRANS COOLER FLOW TEST

1 - SPECIAL TOOL 8392 4 - TRANS HOSE - 9 mm (3/89 I.D.)
2 - SPECIAL TOOL 6906-1-3 5 - FROM COOLER
3 - TO TRANS
RS TRANSMISSION 7 - 37
TRANSMISSION (Continued)
- 31TH/OIL PUMP - STANDARD PROCEDURE) 15 TO 20 SECONDS. REMOVE CONTAMINATED
(Refer to 21 - TRANSMISSION/TRANSAXLE/AU- CLOTHING AND WASH AFFECTED SKIN WITH
TOMATIC - 41TE/OIL PUMP - STANDARD PRO- SOAP AND WATER. SEEK MEDICAL ATTENTION.
CEDURE)
(b) If oil pump volume is within specification, a (1) Remove cover plate filler plug on Tool 6906.
possible restriction in the cooler lines or cooler has Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
occurred. Use Mopart Transmission Cooler Flush (MS-552) or
(c) If oil pump volume is not within specification, equivalent solution conforming to MS-552. Flushing
possible internal transmission restrictions, compo- solvents are petroleum based solutions generally
nent wear or damage has occurred. (Refer to 21 - used to clean automatic transmission components.
TRANSMISSION/TRANSAXLE/AUTOMATIC - DO NOT use solvents containing acids, water, gaso-
31TH - DIAGNOSIS AND TESTING) (Refer to 21 - line, or any other corrosive liquids.
TRANSMISSION/TRANSAXLE/AUTOMATIC - (2) Reinstall filler plug on Tool 6906.
41TE - DIAGNOSIS AND TESTING) (3) Verify pump power switch is turned OFF. Con-
(d) If an oil cooler restriction is suspected, per- nect red alligator clip to positive (+) battery post.
form further inspections and flow meter testing by Connect black (-) alligator clip to a good ground.
isolating components (i.e. lines, coolers).
(e) After a restriction is isolated, perform cooler NOTE: When flushing transmission cooler and
flush procedure. (Refer to 7 - COOLING/TRANS- lines, ALWAYS reverse flush.
MISSION - STANDARD PROCEDURE)
(4) Connect the BLUE pressure line to the OUT-
(f) Re-test cooler flow. If cooler flow does not
LET (From) cooler line.
exceed minimum specification, replace compo-
(5) Connect the CLEAR return line to the INLET
nent(s) as necessary.
(To) cooler line
(6) Turn pump ON for two to three minutes to
STANDARD PROCEDURE - FLUSHING flush cooler and lines.
COOLERS AND TUBES (7) Turn pump OFF.
The recommended procedure for cooler flushing is (8) Disconnect CLEAR suction line from reservoir
to use Tool 6906 Cooler Flusher. at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
WARNING: (9) Turn pump ON for 30 seconds to purge flush-
WEAR PROTECTIVE EYEWEAR THAT MEETS THE ing solution from cooler and lines. Turn pump OFF.
REQUIREMENTS OF OSHA AND ANSI Z87.1–1968. (10) Place CLEAR suction line into a one quart
WEAR STANDARD INDUSTRIAL RUBBER GLOVES. container of Mopart ATF+4 (Automatic Transmission
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, Fluid—Type 9602).
AND OTHER IGNITION SOURCES AWAY FROM THE (11) Turn pump ON until all transmission fluid is
AREA TO PREVENT THE IGNITION OF COMBUSTI- removed from the one quart container and lines. This
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE purges any residual cleaning solvent from the trans-
EXTINGUISHER IN THE AREA WHERE THE mission cooler and lines. Turn pump OFF.
FLUSHER WILL BE USED. (12) Disconnect alligator clips from battery. Recon-
KEEP THE AREA WELL VENTILATED. nect flusher lines to cover plate, and remove flushing
DO NOT LET FLUSHING SOLVENT COME IN CON- adapters from cooler lines.
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
7 - 38 TRANSMISSION RS
TRANS COOLER CLEANING

Check the external cooler for debris on the cooling
DESCRIPTION fin surfaces. Clean as necessary. For internal clean-
The transmission oil cooler is an external oil-to-air ing/flushing procedures, (Refer to 7 - COOLING/
type cooler is mounted between the front of the radi- TRANSMISSION - STANDARD PROCEDURE).
ator and back side of the A/C condensor (Fig. 3). Use
only approved transmission oil cooler hoses that are INSPECTION
molded to fit the space available. Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
REMOVAL only approved transmission oil cooler hoses that are
(1) Remove the radiator. (Refer to 7 - COOLING/ molded to fit the space available.
ENGINE/RADIATOR - REMOVAL) Inspect external coolers for leaks, loose mounts, or
(2) Disconnect lines from oil cooler (Fig. 2). damage. Replace as necessary.
INSTALLATION
(1) Install transaxle oil cooler and mounting
screws (Fig. 3).
NOTE: When replacing the transmission oil cooler,

the cooler hoses must be replaced.
(2) Connect the new cooler hoses and install

clamps (Fig. 2).
(3) Install the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION)
(4) Start engine. Check and adjust the fluid level
as necessary.
TRANS COOLER LINES

Fig. 2 TRANSMISSION COOLER HOSES
1 - TRANSAXLE COOLER HOSES REMOVAL
2 - FITTING - COOLER OUTLET (1) Using appropriate hose clamp pliers, release
3 - FITTING - COOLER INLET tension on clamps and move off fittings.
NOTE: When the transaxle cooler lines are removed

(3) Remove oil cooler attaching screws (Fig. 3).
from the rolled-groove type fittings at the cooler
(4) Remove the oil cooler.
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(2) Remove the hoses (Fig. 4) or (Fig. 5).
Fig. 3 Transmission Oil Cooler

1 - TRANSAXLE OIL COOLER
2 - SCREWS
3 - A/C CONDENSOR (REAR SIDE)
RS TRANSMISSION 7 - 39
TRANS COOLER LINES (Continued)
Fig. 4 TRANS OIL COOLER LINES - 41TE Fig. 5 TRANSAXLE OIL COOLER LINES - 31TH
1 - FITTING - COOLER RETURN 1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY 2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER 3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET 4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET 5 - FITTING - COOLER INLET
occur. To prevent potential leakage, the cooler

hoses must be replaced.
INSTALLATION
(1) Connect hoses to cooler and transaxle fittings
NOTE: When the transaxle cooler lines are removed (Fig. 4) or (Fig. 5).
from the rolled-groove type fittings at the cooler (2) Using appropriate pliers, position clamps over
and transaxle, damage to the inner wall of hose will fittings and release tension.
(3) Start engine and check transaxle fluid level.
Adjust fluid level as necessary.
RG COOLING 2.5L TURBO DIESEL 7a - 1
COOLING 2.5L TURBO DIESEL

TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL COOLING SYSTEM AERATION . . . . . . . . . . . . . 7

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
COOLING SYSTEM LEAK TEST. . . . . . . . . . . . .6 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 9
COOLING SYSTEM FLOW CHECK . . . . . . . . . .7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COOLING 2.5L TURBO DIESEL DIAGNOSIS AND TESTING - COOLING SYSTEM

Establish what driving conditions caused the com-
DESCRIPTION - COOLING SYSTEM plaint. Abnormal loads on the cooling system such as
The cooling system regulates engine operating tem- the following may be the cause:
perature. It allows the engine to reach normal oper- (1) PROLONGED IDLE, VERY HIGH AMBIENT
ating temperature as quickly as possible, maintains TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
normal operating temperature and prevents over- SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
heating. OR STEEP GRADES.
The cooling system also provides a means of heat- Driving techniques that avoid overheating are:
ing the passenger compartment. The cooling system • Idle with A/C off when temperature gauge is at
is pressurized and uses a centrifugal water pump to end of normal range.
circulate coolant throughout the system. A separate • Increasing engine speed for more air flow is rec-
and remotely mounted, pressurized coolant tank ommended.
using a pressure/vent cap is used. (2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
COOLING SYSTEM COMPONENTS Do not exceed limits.
The cooling system consists of: (3) RECENT SERVICE OR ACCIDENT REPAIR:
• Charge Air Cooler Determine if any recent service has been per-
• Electric Cooling Fans formed on vehicle that may effect cooling system.
• A aluminum-core radiator with plastic side This may be:
tanks • Engine adjustments (incorrect timing)
• A separate pressurized coolant tank • Slipping engine accessory drive belt
• A pressure/vent cap on the coolant tank • Brakes (possibly dragging)
• Fan shroud • Changed parts (incorrect water pump)
• Thermostat • Reconditioned radiator or cooling system refill-
• Coolant ing (possibly under filled or air trapped in system).
• Low coolant warning lamp
• Coolant temperature gauge NOTE: If investigation reveals none of the previous
• Water pump items as a cause for an engine overheating com-
• Hoses and hose clamps plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference

only.
7a - 2 COOLING 2.5L TURBO DIESEL RG
COOLING 2.5L TURBO DIESEL (Continued)
COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE
TEMPERATURE GAUGE 1. Diesel engines, due to their 1. The low gauge reading may
READS LOW inherent effiency are slower to warm be normal. Refer to thermostats
up than gasoline powered engines, in the manual text for
and will operate at lower information. See Thermostat
temperatures when the vehicle is Diagnosis-Diesel Engine.
unloaded.
2. Is the temperature gauge 2. Check, the engine
connected to the temperature gauge temperature sensor connector
coolant sensor on the engine? in the engine compartment.
3. Is the temperature gauge 3. Check gauge operation.
operating OK? Repair as necessary.
4. Coolant level low in cold ambient 4. Check coolant level in the
temperatures accompanied with poor coolant tank. Inspect system for
heater performance. leaks. Repair leaks as
necessary. Refer to the Coolant
section for WARNINGS and
precautions before removing
the pressure cap.
5. Improper operation of internal 5. Inspect heater and repair as
heater doors or heater controls. necessary. Refer to Heating
and Air Conditioning for
procedures.
TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill 1. This may be a temporary
READS HIGH. COOLANT is being climbed, vehicle is operated condition and repair is not
MAY OR MAY NOT BE in slow moving traffic, or engine is necessary. Turn off the air
LOST OR LEAKING FROM being idled with very high ambient conditioning and attempt to
COOLING SYSTEM (outside) temperature and the air drive the vehicle without any of
conditioning is on. Higher altitudes the previous conditions.
could aggravate these conditions. Observe the temperature
gauge. The gauge should return
to the normal range. If the
gauge does not return to
normal range, determine the
cause for the overheating and
repair.
2. Temperature gauge reading 2. Check gauge. Refer to I/P
incorrectly. group.
3. Coolant low in coolant tank and 3. Check for coolant leaks and
radiator. repair as necessary.
4. Pressure cap not installed tightly. 4. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap
and cap seals. (b) Check
condition of coolant tank filler
neck. Make sure it does not
leak pressure.
6. Freeze point of antifreeze not 6. Check antifreeze. Adjust

correct. Mixture may be too rich. antifreeze-to-water ratio as
required.
7. Coolant not flowing through 7. Check for coolant flow in
system. coolant tank with engine warm
and thermostat open. Coolant
should be observed flowing
through the tank. If flow is not
observed, determine reason for
lack of flow and repair as
necessary.
8. Radiator or A/C condensor fins 8. Clean debris from radiator or
are dirty or clogged. A/C condensor
9. Radiator core is corroded or 9. Have radiator re-cored or
plugged. replaced.
10. Aftermarket A/C installed without 10. Install proper A/C
proper A/C condensor. condensor.
11. Dragging Brakes. 11. Check and correct as
necessary.
12. Non-factory bug screen is being 12. Only a factory screen
used reducing airflow. should be used.
13. Thermostat partially or 13. Check thermostat and
completely shut. This is more replace if necessary.
prevalent on high mileage vehicles.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket
for leaks.
15. Heater core leaking. 15. Check heater cor for leaks.
TEMPERATURE GAUGE 1. During cold weather operation, 1. A normal condition. No

READING IS with the heater blower in the high correction is necessary.
INCONSISTENT position, the gauge reading may
(FLUCTUATES, CYCLES drop slightly. Fluctuation is also
OR IS ERRATIC) influenced by loads, outside
temperature and extended idle time
with diesel engines.
2. Temperature gauge or engine 2. Check operation of gauge
mounted gauge sensor defective or and repair as necessary.
shorted. Also, corroded or loose
wiring in this circuit.
3. Gauge reading rises when vehicle 3. A normal condition. No
is brought to a stop after heavy use correction needed. Gauge
(engine still running). should return to normal range
after vehicle is driven.
4. Gauge reading high after starting 4. A normal condition. No
a warm-iup (hot) engine. correction needed. Gauge
should return to normal after a
few minutes of engine
operation.
5. Coolant level low in the coolant 5. Check and correct coolant

tank (air will build up in the cooling leaks.
system causing the thermostat to
open late).
6. Cylinder head gasket leaking 6. (a) Check for cylinder head
allowing exhaust gases to enter the gasket leaks with a
cooling system causing the commercially available leak
thermostat to open late. tester. (b) Check for coolant in
engine oil. Inspect for white
steam emitting from exhaust
system. Repair as necessary.
7. Water pump impeller loose on 7. Check water pump and
shaft. replace as necessary.
8. Loose accessory drive belt (water 8. Check and correct as
pump slipping). necessary.
9. Air leak on the suction side of the 9. Locate leak and repair as
water pump allowing air to build up necessary.
in the cooling system causing the
thermostat to open late.
PRESSURE CAP IS 1. Pressure relief valve in pressure/ 1. Check condition of

BLOWING OFF STEAM vent cap is defective. pressure/vent cap and cap
AND/OR COOLANT. seals.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT TANK
2. Head gasket leak or cracked 2. Repair as necessary.
cylinder head.
COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test cooling system
GROUND WITHOUT system hoses, water pump, or and repair as necessary.
PRESSURE CAP engine.
BLOWOFF. GAUGE IS
READING HIGH OR HOT
HOSE OR HOSES 1. Vacuum created in cooling system 1. Cap relief valve stuck.
COLLAPSE WHEN on engine cool-down is not being Replace if necessary.
ENGINE IS COOLING relieved through pressure/vent cap.
NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan

assembly.
2. Cooling fan blades striking a 2. Locate point of fan blade
surrounding object. contact and repair as
necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions or
condensor. clean debris from radiator or
A/C condensor.
INADEQUATE AIR 1. Radiator and/or A/C condensor is 1. Remove restriction or clean

CONDITIONER restricted, obstructed or dirty debris from radiator or A/C
PERFORMANCE (insects, leaves, etc.) condensor.
(COOLING SYSTEM
SUSPECTED)
2. Engine is overheating (heat may 2. Correct overheating
be transferred from radiator to A/C condition.
condensor. High underhood
temperatures due to engine
overheating may also transfer heat
to A/C condensor).
3. The cooling system is equipped 3. Check for missing or
with air seals at the radiator and/or damaged air seals. Repair as
A/C condensor. If these seals are necessary.
missing or damaged, not enough air
flow will be pulled through the
radiator and A/C condensor.
INADEQUATE HEATER 1. Diesel engines, due to their 1. The lower gauge reading
PERFORMANCE. MAY BE inherent efficiency are slower to may be normal.
ACCOMPANIED BY LOW warm up than gasoline powered
GAUGE READING engines, and will operate at lower
temperatures when the vehicle is
unloaded.
2. Coolant level low. 2. Pressure test cooling system.
Repair leaks as necessary.
3. Obstruction in heater hose fitting 3. Remove heater hoses and
at engine. check for obstructions. Repair
as necessary.
4. Heater hose kinked. 4. Locate kinked area. Repair
as necessary.
5. Water pump is not pumping water 5. Refer to water pumps in this
to heater core. When the engine is group. Repair as necessary. If a
fully warmed up, both heater hoses slipping belt is detected, refer to
should be hot to the touch. If only Engine Accessory Drive Belts in
one of the hoses is hot the water this group. Repair as
pump may not be operating correctly. necessary.
The accessory drive belt may also
be slipping causing poor water pump
operation.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields.
certain drive line components. One Repair or replace as necessary.
or more of these shields may be
missing.
2. Is temerature gauge reading 2. Refer to the previous
above the normal range? Temperature Gauge Reads
High in these Diagnostic
Charts. Repair as necessary.
3. Is the Cooling fan operating 3. Refer to Cooling System Fan
correctly? in this group for diagnosis.
4. Has undercoating been applied to 4. Clean undercoating as

any unnecessary components? necessary.
STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting
FRONT OF VEHICLE (snow, ice, or rain condensation) on from this area is normal. No
NEAR GRILL AREA WHEN the radiator will evaporate when the repair is necessary.
WEATHER IS WET, thermostat opens. This opening
ENGINE IS WARMED UP allows heated water into the radiator.
AND RUNNING, AND When the moisture contacts the hot
VEHICLE IS STATIONARY. radiator, steam may be emitted. This
TEMPERATURE GAUGE usually occurs in cold weather with
IS IN NORMAL RANGE no fan or airflow to blow it away.
COOLANT ODOR 1. Coolant color is not necessarily an 1. Refer to Coolant in this group
indication of adequate corrosion or for antifreeze tests. Adjust
temperature protection. Do not rely antifreeze-to-water ratio as
on coolant color for determining necessary.
condition of coolant.
COOLANT LEVEL 1. Level changes are to be expected 1. This a normal condition. No

CHANGES IN COOLANT as coolant volume fluctuates with repair necessary.
TANK. TEMPERATURE engine temperature. If the level in
GAUGE IS IN NORMAL the tank was between the HOT and
RANGE COLD marks at normal engine
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
DIAGNOSIS AND TESTING - COOLING SYSTEM engine and run until the thermostat opens, allowing
the coolant to expand. Reattach the cooling system
LEAK TEST
tester. If the needle on the dial fluctuates it indicates
WARNING: THE WARNING WORDS “DO NOT OPEN a combustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, raise
With engine not running, remove pressure/vent cap
the engine rpm a few times. If an abnormal amount
from the coolant recovery pressure container and
of coolant or steam emits from the tailpipe, it may
wipe the filler neck sealing seat clean. The coolant
indicate a coolant leak caused by a faulty head gas-
recovery pressure container should be full.
ket, cracked engine block, or cracked cylinder head.
Attach the Cooling System Tester 7700 or equiva-
There may be internal leaks that can be deter-
lent to the radiator, as shown in (Fig. 1) and apply
mined by removing the oil dipstick. If water globules
104 kPa (15 psi) pressure. If the pressure drops more
appear intermixed with the oil it will indicate an
than 13.8 kPa (2 psi) in 2 minutes, inspect all points
internal leak in the engine. If there is an internal
for external leaks.
leak, the engine must be disassembled for repair.
All radiator and heater hoses should be shaken
while at 104 kPa (15 psi), since some leaks occur only
while driving due to engine movement.
If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Start
(2) Remove pressure/vent cap when engine is cold,
idle engine until thermostat opens, you should
observe coolant flow while looking down in the cool-
ant recovery pressure container. Once flow is
detected install the pressure/vent cap.

AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
• High reading shown on the temperature gauge.
• Loss of coolant flow through the heater core.
• Corrosion in the cooling system.
• Water pump seal may run dry, increasing the
risk of premature seal failure.
• Combustion gas leaks into the coolant can also
cause the above problems.
Fig. 1 PRESSURE TESTING COOLING SYSTEM
1 - COOLING SYSTEM PRESSURE TESTER CLEANING
2 - COOLANT RECOVERY PRESSURE CONTAINER Drain cooling system and refill with clean water.
Refer to procedures in this section. Run engine with
DIAGNOSIS AND TESTING - COOLING SYSTEM pressure/vent cap installed until upper radiator hose
is hot. Stop engine and drain water from system. If
FLOW CHECK
water is dirty; fill, run, and drain system again, until
To determine whether coolant is flowing through
water runs clear.
the cooling system, use the following procedures:
(1) If engine is cold, idle engine until normal oper-
ating temperature is reached. Then feel the upper
INSPECTION
After performing a cleaning/flush procedure,
radiator hose. If it is hot, coolant is circulating.
inspect all hoses, clamps and connections for deterio-
WARNING: DO NOT REMOVE THE COOLING SYS- ration and leaks. Inspect radiator and heater core for
TEM PRESSURE CAP WITH THE SYSTEM HOT AND leaks.
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS

Water Pump Housing Nuts 24.4 18 215
Thermostat Housing Bolts 27.5 21 —
Accessory Drive Belt 47.1 35 —
Tensioner Bolt
Accessory Drive Belt Idler 53 39 —
Bolt
SPECIFICATIONS - COOLING SYSTEM

CAPACITY
SPECIFICATIONS
Cooling System With 16.6 Liters (17.5 qts.)
Auxiliary Heater
Cooling System With Out 13.8 Liters (14.6 qts.)
Auxiliary Heater
RG ACCESSORY DRIVE 7a - 9
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE DRIVE BELTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BELT TENSIONER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . 11
IDLER PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ACCESSORY DRIVE
SPECIFICATIONS
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE GAUGE

BELT
2.5L DIESEL ENGINE
A/C Compressor/
Dynamic Tensioner
Generator
Power Steering Belt 300 N (67 lbs.)
BELT TENSIONER
REMOVAL
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE THE AUTO- Fig. 1 BELT TENSIONER AND IDLER PULLEY
MATIC BELT TENSIONER. THE TENSIONER IS SER-
1 - BELT TENSIONER RETAINING BOLT
VICED AS AN ASSEMBLY.
2 - BELT TENSIONER
3 - IDLER PULLEY
(1) Remove the power steering belt (Refer to 7 -
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
COOLING/ACCESSORY DRIVE/DRIVE BELTS - 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
REMOVAL). BOLTS
(2) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS - (2) Install the accessory drive belt (Refer to 7 -
INSTALLATION). COOLING/ACCESSORY DRIVE/DRIVE BELTS -
(3) Remove the belt tensioner retaining bolt and INSTALLATION).
remove tensioner (Fig. 1). (3) Install the power steering belt (Refer to 7 -
INSTALLATION INSTALLATION).
(1) Install belt tensioner and retaining bolt (Fig.
1). Torque bolt to 47 N·m (35ft. lbs.).
7a - 10 ACCESSORY DRIVE RG
IDLER PULLEY DRIVE BELTS

REMOVAL DESCRIPTION - ACCESSORY DRIVE BELT
(1) Remove the accessory drive belt (Refer to 7 - The accessory drive belt is a serpentine type belt
COOLING/ACCESSORY DRIVE/DRIVE BELTS - (Fig. 3). Satisfactory performance of these belts
REMOVAL). depends on belt condition and proper belt tension.
CAUTION: IDLER PULLEY RETAINING BOLT HAS

LEFT HAND THREAD
(2) Remove the idler pulley (Fig. 2).
Fig. 3 ACCESSORY DRIVE BELT ROUTING

1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
Fig. 2 BELT TENSIONER AND IDLER PULLEY 5 - POWER STEERING BELT
1 - BELT TENSIONER RETAINING BOLT 6 - CRANKSHAFT DAMPER/PULLEY
2 - BELT TENSIONER 7 - BELT TENSIONER
3 - IDLER PULLEY 8 - ACCESSORY DRIVE BELT
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS DESCRIPTION - POWER STEERING BELT
The power steering belt is a serpentine type belt
(Fig. 3). Satisfactory performance of this belt depends
INSTALLATION on condition of the belt.
(1) Install the idler pulley (Fig. 2). Torque retain-
ing bolt to 22 N·m (16 ft. lbs.).
OPERATION-ACCESSORY DRIVE BELT
(2) Install the accessory drive belt (Refer to 7 -
The accessory drive belts form the link between
the engine crankshaft and the engine driven accesso-
INSTALLATION).
ries.
(3) Install the power steering belt (Refer to 7 -
INSTALLATION).
OPERATION-POWER STEERING BELT
The power steering belt forms a link between the
engine crankshaft and the power steering pump.
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
INSUFFICIENT ACCESSORY 1. Belt too loose 1. (a) Replace belt (auto-tensioned

OUTPUT DUE TO BELT belts)
SLIPPAGE
2. Faulty belt tensioner 2. Replace tensioner as necessary
3. Belt excessively glazed or worn 3. Replace belt
BELT SQUEAL WHEN 1. Belts too loose 1. Check and replace belt tensioner if
ACCELERATING ENGINE necessary
2. Belt glazed 2. Replace belt
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt
2. Dirt or paint imbedded in belt 2. Replace belt

3. Non-uniform belt 3. Replace belt
pulley
BELT ROLLED OVER IN 1. Broken cord in belt 1. Replace belt

GROOVE OR BELT JUMPS 2. Belt too loose, or too tight 2. Replace belt
OFF
pulley
REMOVAL-ACCESSORY DRIVE BELT REMOVAL

(1) Remove the power steering belt (Refer to 7 - (1) Raise vehicle on hoist.
COOLING/ACCESSORY DRIVE/DRIVE BELTS - (2) Remove right front fender inner splash shield.
REMOVAL). (3) Install power steering belt remover tool on
(2) Relieve tension on belt tensioner using a suit- crankshaft damper (Fig. 6).
able wrench (Fig. 4) and lock tensioner with a drift (4) Rotate engine clockwise to remove belt (Fig. 7).
punch (Fig. 5).
(3) Remove the accessory drive belt. INSTALLATION-ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper posi-
tion (Fig. 8).
(2) Unlock belt tensioner by removing punch and
apply tension to accessory drive belt (Fig. 9).
(3) Install the power steering belt (Refer to 7 -
INSTALLATION).
7a - 12 ACCESSORY DRIVE RG
Fig. 4 ACCESSORY DRIVE BELT REMOVAL Fig. 6 POWER STEERING BELT REMOVAL TOOL
1 - BELT TENSIONER 1 - VIBRATION DAMPER
2 - ACCESSORY DRIVE BELT 2 - POWER STEERING PULLEY
3 - IDLER PULLEY 3 - POWER STEERING BELT
4 - A/C COMPRESSOR CLUTCH 4 - POWER STEERING BELT REMOVER
5 - CRANKSHAFT DAMPER/PULLEY
6 - WRENCH
Fig. 7 POWER STEERING BELT REMOVAL

1 - VIBRATION DAMPER
Fig. 5 LOCKING/LOCKING BELT TENSIONER 2 - POWER STEERING BELT
3 - POPWER STEERING BELT REMOVER
INSTALLATION-POWER STEERING BELT

(1) Install power steering belt installation tool
(Fig. 10).
(2) Install power steering belt on crankshaft and
rotate crankshaft clockwise until belt is fully
installed on crankshaft (Fig. 10).
Fig. 8 ACCESSORY DRIVE BELT ROUTING

1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
5 - POWER STEERING BELT
6 - CRANKSHAFT DAMPER/PULLEY
7 - BELT TENSIONER Fig. 10 POWER STEERING BELT INSTALLATION
8 - ACCESSORY DRIVE BELT 1 - POWER STEERING BELT
2 - HOLDING HOOK
4 - VIBRATION DAMPER
5 - POWER STEERING BELT INSTALLATION TOOL
(3) Remove installation tool from crankshaft.

(4) Install right front fender inner splash shield.
(5) Lower vehicle from hoist.
Fig. 9 LOCKING/UNLOCKING BELT TENSIONER

7a - 14 ENGINE RG
ENGINE
TABLE OF CONTENTS
page page
COOLANT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 WATER PUMP
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT CONCENTRATION TESTING. . . . . . 15 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT SERVICE. . . . . . . . . . . . . . . . . . . . . 15 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADDING ADDITIONAL COOLANT . . . . . . . . . . . 15 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . 16 RADIATOR PRESSURE CAP
REFILLING COOLING SYSTEM . . . . . . . . . . . . 16 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DRAINING COOLING SYSTEM. . . . . . . . . . . . . 16 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COOLANT RECOVERY PRESS CONTAINER DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 COOLING SYSTEM PRESSURE CAP. . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PRESSURE RELIEF TEST . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE COOLANT TEMP SENSOR RADIATOR FAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19 RADIATOR FAN MOTOR . . . . . . . . . . . . . . . . . 26
ENGINE COOLANT THERMOSTAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HOSE CLAMPS
RADIATOR RADIATOR FAN RELAY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 COOLANT SYSTEM HOSES
RADIATOR DRAINCOCK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT against freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentration must always be a minimum of
44 percent, year-round in all climates. If percentage
DESCRIPTION
is lower than 44 percent, engine parts may be
Coolant flows through the engine water jackets
eroded by cavitation, and cooling system com-
and cylinder heads absorbing heat produced by the
ponents may be severely damaged by corrosion.
engine during operation. The coolant carries heat to
Maximum protection against freezing is provided
the radiator and heater core. Here it is transferred to
with a 68 percent antifreeze concentration, which
ambient air passing through the radiator and heater
prevents freezing down to -67.7 deg. C (-90 deg. F). A
core fins.
higher percentage will freeze at a warmer tempera-
The required ethylene-glycol (antifreeze) and water
ture. Also, a higher percentage of antifreeze can
mixture depends upon the climate and vehicle oper-
cause the engine to overheat because the specific
ating conditions. The recommended mixture of 50/50
heat of antifreeze is lower than that of water.
ethylene-glycol and water will provide protection
RG ENGINE 7a - 15
COOLANT (Continued)
100 Percent Ethylene-Glycol—Should Not Be Used in DIAGNOSIS AND TESTING - COOLANT
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
CONCENTRATION TESTING
Coolant concentration should be checked when any
mation of additive deposits in the system, as the cor-
additional coolant was added to system or after a
rosion inhibitive additives in ethylene-glycol require
coolant drain, flush and refill. The coolant mixture
the presence of water to dissolve. The deposits act as
offers optimum engine cooling and protection against
insulation, causing temperatures to rise to as high as
corrosion when mixed to a freeze point of -37°C
149 deg. C (300 deg. F). This temperature is hot
(-34°F) to -59°C (-50°F). The use of a hydrometer or a
enough to melt plastic and soften solder. The
refractometer can be used to test coolant concentra-
increased temperature can result in engine detona-
tion.
tion. In addition, 100 percent ethylene-glycol freezes
A hydrometer will test the amount of glycol in a
at -22 deg. C (-8 deg. F ).
mixture by measuring the specific gravity of the mix-
Propylene-glycol Formulations—Should Not Be Used in ture. The higher the concentration of ethylene glycol,
Chrysler Vehicles the larger the number of balls that will float, and
Propylene-glycol formulations do not meet higher the freeze protection (up to a maximum of
Chrysler coolant specifications. It’s overall effec- 60% by volume glycol).
tive temperature range is smaller than that of ethyl- A refractometer will test the amount of glycol in a
ene-glycol. The freeze point of 50/50 propylene-glycol coolant mixture by measuring the amount a beam of
and water is -32 deg. C (-26 deg. F). 5 deg. C higher light bends as it passes through the fluid.
than ethylene-glycol’s freeze point. The boiling point Some coolant manufactures use other types of gly-
(protection against summer boil-over) of propylene- cols into their coolant formulations. Propylene glycol
glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), is the most common new coolant. However, propylene
compared to 128 deg. C (263 deg. F) for ethylene-gly- glycol based coolants do not provide the same freez-
col. Use of propylene-glycol can result in boil-over or ing protection and corrosion protection and is not rec-
freeze-up in Chrysler vehicles, which are designed for ommended.
ethylene-glycol. Propylene glycol also has poorer heat
CAUTION: Do not mix types of coolant—corrosion
transfer characteristics than ethylene glycol. This
protection will be severely reduced.
can increase cylinder head temperatures under cer-
tain conditions.
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be STANDARD PROCEDURE - COOLANT SERVICE

Used in Chrysler Vehicles For engine coolant recommended service schedule,
Propylene-glycol/ethylene-glycol Mixtures can (Refer to LUBRICATION & MAINTENANCE/MAIN-
cause the destabilization of various corrosion inhibi- TENANCE SCHEDULES - DESCRIPTION).
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy- STANDARD PROCEDURE - ADDING
lene-glycol based coolants are mixed in the vehicle, ADDITIONAL COOLANT
conventional methods of determining freeze point will The pressure/vent cap should not be removed
not be accurate. Both the refractive index and spe- from the coolant recovery pressure container.
cific gravity differ between ethylene glycol and propy- When additional coolant is needed to maintain this
lene glycol. level, it should be added to the coolant recovery pres-
sure container (Fig. 1). Use only 50/50 mix of ethyl-
CAUTION: Richer antifreeze mixtures cannot be ene glycol type antifreeze and distilled water. For the
measured with normal field equipment and can recommeded antifreeze/coolant type (Refer to LUBRI-
cause problems associated with 100 percent ethyl- CATION & MAINTENANCE/FLUID TYPES -
ene-glycol. DESCRIPTION).
CAUTION: Do not use well water, or suspect water

supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
DESCRIPTION).
7a - 16 ENGINE RG
COOLANT (Continued)
Fig. 1 UNDERHOOD FLUID FILL LOCATIONS

1 - COOLANT PRESSURE/VENT CAP 6 - OIL DIPSTICK
2 - BRAKE MASTER CYLINDER 7 - WINDSHIELD SOLVENT RESEVOIR
3 - INTELLIGENT POWER MODULE 8 - AIR FILTER HOUSING
4 - BATTERY 9 - ENGINE OIL FILL CAP
5 - COOLANT RECOVERY PRESSURE CONTAINER
STANDARD PROCEDURE - COOLANT LEVEL STANDARD PROCEDURE - DRAINING COOLING

CHECK SYSTEM
NOTE: Do not remove pressure/vent cap for routine WARNING: DO NOT REMOVE OR LOOSEN THE
coolant level inspections. COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
The coolant reserve system provides a quick visual THE SYSTEM IS HOT AND UNDER PRESSURE
method for determining the coolant level without BECAUSE SERIOUS BURNS FROM THE COOLANT
removing the pressure/vent cap. With the engine CAN OCCUR.
cold and not running, simply observe the level of
the coolant in the coolant recovery pressure container (1) Without removing pressure/vent cap and
(Fig. 2). The coolant level should be between the MIN with system not under pressure, open the drain-
and MAX marks. cock. The draincock is located on the lower right side
of radiator (Fig. 3).
STANDARD PROCEDURE - REFILLING (2) After the coolant recovery pressure container is
COOLING SYSTEM empty, then remove coolant pressure/vent cap.
Remove pressure/vent cap (Fig. 1) and fill system,
using a 50/50 mix of Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula and distilled water.
Continue filling system until full. Be careful not
to spill coolant on drive belts or the generator.
Fill coolant recovery pressure container (Fig. 1) to
at least the MAX mark with 50/50 solution. It may
be necessary to add coolant to the coolant recovery
pressure container after three or four warm up/cool
down cycles to maintain coolant level between the
MAX and MIN mark. This will allow trapped air to
be removed from the system.
RG ENGINE 7a - 17
COOLANT (Continued)
Fig. 3 DRAINCOCK LOCATION

1 - RADIATOR
2 - DRAINCOCK
3 - LOWER RADIATOR SUPPORT
Fig. 2 COOLANT RECOVERY PRESSURE 4 - ELECTRIC COOLING FAN
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAINING
CLIP
6 - ENGINE COVER
COOLANT RECOVERY PRESS

CONTAINER
DESCRIPTION
The coolant recovery pressure container is
mounted in the engine compartment next to the bat-
tery. The coolant recovery pressure container is made
of plastic (Fig. 4).
OPERATION
The coolant recovery pressure container works
with the pressure/vent cap to use thermal expansion
and contraction of the coolant to keep the coolant
Fig. 4 COOLANT RECOVERY PRESSURE
free of trapped air. Provides a convenient and safe
CONTAINER LOCATION
method for checking coolant level and adjusting level
at atmospheric pressure without removing the pres-
sure/vent cap. It also provides some reserve coolant
3 - BATTERY
to cover deaeration, evaporation, or boiling losses. 4 - BATTERY SHIELD
CLIP
6 - ENGINE COVER
7a - 18 ENGINE RG
COOLANT RECOVERY PRESS CONTAINER (Continued)
REMOVAL
(1) Drain cooling system below level of coolant
recovery pressure bottle. (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE)
(2) Disconnect coolant bypass and overflow hoses
from coolant recovery pressure container (Fig. 6).
(3) Unclip the coolant recovery pressure container
retaining clip (Fig. 5).

CONTAINER
2 - COOLANT BYPASS HOSE
3 - OUTLET HOSE

CONTAINER LOCATION
3 - BATTERY
4 - BATTERY SHIELD
CLIP
6 - ENGINE COVER
(4) Raise coolant recovery pressure container from

mounting bracket and disconnect coolant hose from
bottom of container (Fig. 6).
(5) Remove coolant recovery pressure bottle.
INSTALLATION
(1) Connect coolant hose at bottom of coolant
recovery pressure container (Fig. 6) and install in
mounting bracket. Fig. 7 COOLANT TEMPERATURE SENSOR
(2) Connect coolant recovery pressure container LOCATION
retaining clip (Fig. 5). 1 - EGR SOLENOID
(3) Connect coolant bypass and overflow hoses to 2 - UPPER RADIATOR HOSE
coolant recovery pressure container. 3 - COOLANT TEMPERATURE SENSOR
(4) Refill cooling system. (Refer to 7 - COOLING/ 4 - INTAKE MANIFOLD INLET
ENGINE/COOLANT - STANDARD PROCEDURE) 5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
RG ENGINE 7a - 19
ENGINE COOLANT TEMP

SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
The coolant temperature (ECT) sensor is a nega-
tive temperature coefficient (NTC) thermistor (resis-
tance varies inversley with temperature). This means
at cold tempertures its resistance is high so the volt-
age signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal to the ECM.
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER Fig. 8 COOLANT TEMPERATURE SENSOR
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN LOCATION
THE SYSTEM IS HOT AND UNDER PRESSURE 1 - EGR SOLENOID
BECAUSE SERIOUS BURNS FROM THE COOLANT 2 - UPPER RADIATOR HOSE
CAN OCCUR. 3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
(1) Drain the cooling system. (Refer to 7 - COOL- 5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Disconnect coolant temperature sensor electri- OPERATION
cal connector (Fig. 8). The thermostat starts to open at 80°C (176°F).
(3) Remove coolant temperature sensor from cylin- Above this temperature, coolant is allowed to flow to
der head (Fig. 8). the radiator. This provides quicker engine warmup
and overall temperature control.
INSTALLATION The same thermostat is used for winter and sum-
(1) Install coolant temperature sensor in cylinder mer seasons. An engine should not be operated with-
head (Fig. 8). out a thermostat, except for servicing or testing.
(2) Connect coolant temperature sensor electrical Operating without a thermostat causes other prob-
connector (Fig. 8). lems. These are: longer engine warmup time, unreli-
(3) Refill the cooling system. (Refer to 7 - COOL- able warmup performance, increased exhaust
ING/ENGINE/COOLANT - STANDARD PROCE- emissions and crankcase condensation. This conden-
DURE). sation can result in sludge formation.
(4) Connect the negative battery cable.
REMOVAL
ENGINE COOLANT NOTE: The thermostat is not serviced separately.

The thermostat and housing must be replaced as
THERMOSTAT an assembly.
DESCRIPTION (1) Disconnect negative battery cable.

A pellet-type thermostat controls the operating (2) Drain cooling system (Refer to 7 - COOLING/
temperature of the engine by controlling the amount ENGINE/COOLANT - STANDARD PROCEDURE).
of coolant flow to the radiator (Fig. 9). (3) Remove front wiper unit to gain access to ther-
mostat housing(Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
7a - 20 ENGINE RG
ENGINE COOLANT THERMOSTAT (Continued)
Fig. 9 THERMOSTAT HOUSING LOCATION

1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED Fig. 10 THERMOSTAT HOUSING ASSEMBLY
4 - WATER PUMP 1 - THERMOSTAT HOUSING GASKET
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING 2 - THERMOSTAT HOUSING
BYPASS HOSE
3 - RETAINING BOLTS
6 - EGR VALVE
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
(4) Disconnect upper radiator hose adapter tube,
water pump hose, and EGR hose at thermostat hous-
keep the engine satisfactorily cooled. The radiator
ing.
has plastic side tanks and aluminum cooling tubes.
(5) Remove both thermostat housing attaching
bolts and housing (Fig. 10).
OPERATION
The radiator functions as a heat exchanger, using
INSTALLATION air flow across the exterior of the radiator tubes. This
(1) Install thermostat housing, gasket, and retain-
heat is then transferred from the coolant and into
ing bolts (Fig. 10). Torque bolts to 27.5N·m.
the passing air.
(2) Connect upper radiator hose adapter tube,
water pump hose, and EGR cooler hose to thermostat
REMOVAL
housing.
(1) Disconnect negative cable from battery.
(3) Install front wiper unit (Refer to 8 - ELECTRI-
(2) Remove radiator upper crossmember support.
CAL/WIPERS/WASHERS/WIPER MODULE -
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
INSTALLATION).
REINFORCEMENT - REMOVAL).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE). WARNING: DO NOT REMOVE THE CYLINDER
(5) Connect negative battery cable. BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
RADIATOR OCCUR.
DESCRIPTION (3) Drain the cooling system (Refer to 7 - COOL-
The radiator is a cross-flow type (horizontal tubes) ING/ENGINE/COOLANT - STANDARD PROCE-
with design features that provide greater strength DURE).
along with sufficient heat transfer capabilities to
RG ENGINE 7a - 21
RADIATOR (Continued)
(4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Disconnect coolant bypass hose (Fig. 11).
(6) Disconnect upper and lower hoses from the
radiator (Fig. 11).
Fig. 12 Radiator to A/C Condenser Mounting (left

mount shown, right similar)
Fig. 11 UPPER AND LOWER RADIATOR HOSES 1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
1 - COOLANT BYPASS HOSE 2 - LOWER MOUNT
2 - RADIATOR ASSEMBLY 3 - A/C CONDENSER
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
INSTALLATION
6 - CHARGE AIR COOLER (1) Be sure the air seal is in position before
7 - RADIATOR BRACKET radiator is installed. Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(7) Remove the A/C condenser side brackets to
(2) Position air conditioning condenser onto the
radiator attaching screws (Fig. 12). Separate the con-
radiator lower mounts and install upper screws (Fig.
denser from the radiator by lifting upward to disen-
12). Tighten fasteners to 5 N·m (45 in. lbs.).
gage from lower mounts (Fig. 12). Allow the
(3) Install the radiator upper and lower hoses (Fig.
condenser to rest in front of radiator.
11).
(8) Radiator can now be lifted free from engine
(4) Connect the coolant bypass hose.
compartment. Care should be taken not to dam-
(5) Install the radiator fans. (Refer to 7 - COOL-
age radiator cooling fins or water tubes during
ING/ENGINE/RADIATOR FAN - INSTALLATION)
removal.
(6) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(7) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
7a - 22 ENGINE RG
RADIATOR DRAINCOCK WATER PUMP

REMOVAL DESCRIPTION
The water pump on the 2.5L CRD diesel has a die
CAUTION: Use of pliers on draincock is not recom- cast aluminum housing. It bolts to a aluminum hous-
mended. Damage may occur to radiator or draining which attaches to the engine block (Fig. 14).
cock.
NOTE: It is not necessary to remove draincock dur-

ing a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOL-

ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator
tank.
Fig. 14 WATER PUMP

1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 13 Draincock OPERATION

1 - RADIATOR TANK
The water pump is used to circulate coolant
2 - DRAINCOCK through the cooling system. The coolant is pumped
through the engine block, cylinder head, heater core,
EGR cooler, cabin heater, and radiator.
INSTALLATION
(1) Align draincock stem to radiator tank opening. REMOVAL - WATER PUMP
(2) Push draincock into the radiator tank opening. (1) Disconnect negative battery cable.
(3) Tighten the draincock by turning clockwise (2) Drain cooling system (Refer to 7 - COOLING/
until it stops. ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Fill the cooling system (Refer to 7 - COOLING/ (3) Remove timing belt inner and outer covers
ENGINE/COOLANT - STANDARD PROCEDURE). (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Remove water pump retaining bolts and pump
(Fig. 15).
RG ENGINE 7a - 23
WATER PUMP (Continued)
Fig. 15 WATER PUMP LOCATION Fig. 16 THERMOSTAT HOUSING LOCATION

1 - CYLINDER HEAD 1 - CYLINDER HEAD COVER
2 - ENGINE BLOCK 2 - THERMOSTAT HOUSING
3 - OIL COOLER 3 - AIR BLEED
4 - OIL FILTER HOUSING 4 - WATER PUMP
5 - WATER PUMP 5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - EGR VALVE
REMOVAL - WATER PUMP HOUSING
(1) Disconnect negative battery cable. (5) Connect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE). INSTALLATION - WATER PUMP HOUSING
(3) Remove both outer and inner timing belt covers (1) Clean mating serfaces of water pump housing
(Refer to 9 - ENGINE/VALVE TIMING/TIMING and engine block as necessary.
BELT / CHAIN COVER(S) - REMOVAL). (2) Place new o-ring in groove in water pump
(4) Disconnect water pump housing to thermostat housing (Fig. 18).
housing bypass hose (Fig. 16). (3) Be sure lower radiator hose tube o-ring is in
(5) Remove the water pump housing retaining place.
nuts (Fig. 17). (4) Install water pump housing on lower radiator
(6) Remove water pump housing from engine block hose tube and push on mounting studs (Fig. 17).
(Fig. 17). Torque retaining nuts to 24.4N·m.
(5) Connect water pump housing to thermostat
CLEANING housing bypass hose (Fig. 16).
Clean gasket mating surfaces as necessary. (6) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
INSTALLATION - WATER PUMP BELT / CHAIN COVER(S) - INSTALLATION).
(1) Clean gasket mating surfaces as necessary. (7) Refill cooling system (Refer to 7 - COOLING/
(2) Place water pump and gasket in place. Install ENGINE/COOLANT - STANDARD PROCEDURE).
water pump retaining bolts (Fig. 15). Torque bolts to (8) Connect negative battery cable.
24.4N·m.
(3) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
7a - 24 ENGINE RG
WATER PUMP (Continued)
RADIATOR PRESSURE CAP

DESCRIPTION
The cooling system pressure cap is located on the
radiator. The cap construction includes; stainless
steel swivel top, rubber seals, and retainer, main
spring, and a spring loaded valve (Fig. 19).
Fig. 19 Cooling System Pressure Cap Filler Neck

Fig. 17 WATER PUMP ASSEMBLY 1 - OVERFLOW NIPPLE
1 - WATER PUMP HOUSING STUDS 2 - MAIN SPRING
2 - WATER PUMP 3 - GASKET RETAINER
3 - RETAINING NUTS 4 - STAINLESS-STEEL SWIVEL TOP
4 - OIL COOLER RETAINING STUD 5 - RUBBER SEALS
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT 6 - VENT VALVE
6 - OIL COOLER COOLANT HOSE 7 - PRESSURE BOTTLE
7 - ENGINE BLOCK 8 - FILLER NECK
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling
system from coolant reserve system tank by vacuum
through a connecting hose. If valve is stuck shut,
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 19) and inspect cool-
Fig. 18 WATER PUMP HOUSING O-RING ant recovery hose routing, to ensure proper
1 - WATER PUMP sealing when boiling point is reached.
2 - WATER PUMP HOUSING O-RING The gasket in the cap seals the filler neck, so that
3 - WATER PUMP HOUSING vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
RG ENGINE 7a - 25

PRESSURE CAP
Dip the pressure cap in water. Clean any deposits
off the vent valve or its seat and apply cap to end of
the Pressure Cap Test Adaptor that is included with
the Cooling System Tester 7700. Working the
plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at
least 97 kPa (14 psi), replace the pressure cap.
CAUTION: The Cooling System Tester Tool is very

sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be Fig. 21 Radiator Pressure Cap Filler Neck
replaced just because it leaks slowly when tested 1 - OVERFLOW NIPPLE
with this tool. Add water to the tool. Turn tool 2 - MAIN SPRING
upside down and recheck pressure cap to confirm 3 - GASKET RETAINER
that cap is bad.
5 - RUBBER SEALS
6 - VENT VALVE
If the pressure cap tests properly while positioned
7 - PRESSURE BOTTLE
on Cooling System Tester (Fig. 20), but will not hold
8 - FILLER NECK
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing WARNING: THE WARNING WORDS “DO NOT OPEN
properly. HOT” ON THE RADIATOR PRESSURE CAP IS A
There is no need to remove the radiator cap at any

time except for the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,

WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
Fig. 20 Testing Cooling System Pressure Cap
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
1 - PRESSURE CAP
ESCAPE THROUGH THE OVERFLOW TUBE AND
2 - PRESSURE TESTER
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DIAGNOSIS AND TESTING - PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COM-
RELIEF TEST PLETELY. SQUEEZING THE RADIATOR INLET HOSE
The pressure cap upper gasket (seal) pressure WITH A SHOP TOWEL (TO CHECK PRESSURE)
relief can be checked by removing the overflow hose BEFORE AND AFTER TURNING TO THE FIRST
at the radiator filler neck nipple (Fig. 21). Attach the STOP IS RECOMMENDED.
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gas-
ket should relieve at 69-124 kPa (10-18 psi) and hold
CLEANING
Use only a mild soap to clean the pressure cap.
pressure at 55 kPa (8 psi) minimum.
7a - 26 ENGINE RG
INSPECTION RADIATOR FAN

Hold the cap in your hand, top side up (Fig. 21).
The vent valve at the bottom of the cap should open. DESCRIPTION
If the rubber gasket has swollen, preventing the The dual radiator fans are mounted to the back
valve from opening, replace the cap. side of the radiator (Fig. 22). The radiator fan consist
Hold the cleaned cap in your hand, upside down. of the fan blade, electric motor and a support shroud
If any light can be seen between vent valve and the which are all serviced as an assembly.
rubber gasket, replace the cap. Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE

Fan Operation
Initial Max Initial Max
Speeds:
Fan On: 104°C (220°F) 110°C (230°F) Fan 1,724 Kpa (250 psi) 2,068 Kpa (300 psi)
Speed Duty-Cycles Fan Speed
(Ramps-up) from Duty-Cycles
30% to 99% (Ramps-up) from
30% to 99%
Fan Off: 101°C (214°F) Fan Speed 1,710 Kpa (248 psi) Fan Speed
Duty-Cycles Duty-Cycles
(Ramps-down) from (Ramps-down) from
99% to 30% 99% to 30%
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR

RADIATOR FAN DIAGNOSIS CHART
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
FAN - REMOVAL)
2. Fan blade striking a surrounding 2. Locate point of fan blade contact
object. and repair as necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions and/or
condenser. clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
NOT OPERATE module (PCM), coolant temperature Information) Repair as necessary.
sensor, or wiring defective.
RG ENGINE 7a - 27
ELECTRIC RADIATOR FAN 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
OPERATES ALL THE TIME module (PCM), coolant temperature Information) Repair as necessary.
sensor or wiring defective.
2. Check for low coolant level. 2. Add coolant as necessary.
REMOVAL (5) Install the upper radiator mounts to the cross-

There are no repairs to be made to the fan or member bolts, if removed. Tighten to 8 N·m (70 in.
shroud assembly. If the fan is warped, cracked, or lbs.).
otherwise damaged, it must be replaced as an assem- (6) Install the radiator upper hose to the support
bly (Fig. 22). clip (2.4L engine).
(1) Remove the radiator upper crossmember. (Refer
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
HOSE CLAMPS
(2) Disconnect the radiator fan electrical connec-
tors. DESCRIPTION - HOSE CLAMPS
(3) Remove radiator fan(s) retaining screw (Fig. The cooling system uses spring type hose clamps.
22). If a spring type clamp replacement is necessary,
(4) Remove the radiator fan(s) by lifting upward to replace with the original Mopart equipment spring
release from mounts. type clamp.
CAUTION: A number or letter is stamped into the

tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 23).
Fig. 22 Radiator Fans

1 - SCREWS - RADIATOR FAN ATTACHING
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
4 - CLIPS - RADIATOR FAN LOWER
5 - MOUNT - LEFT RADIATOR FAN
6 - RADIATOR FAN - LEFT
INSTALLATION
(1) Install the radiator fan(s) into mounts and Fig. 23 Spring Clamp Size Location
attaching clips on the radiator. 1 - SPRING CLAMP SIZE LOCATION
(2) Install radiator fan(s) attaching screws (Fig.
22). Tighten to 5 N·m (45 in. lbs.).
(3) Connect the radiator fan(s) electrical connec-
tors.
(4) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION).
7a - 28 ENGINE RG
HOSE CLAMPS (Continued)
OPERATION - HOSE CLAMPS

The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 24) to compress the
hose clamp.
Fig. 25 RELAY LOCATIONS

1 - GLOW PLUG RELAY
2 - UPPER RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - RADIATOR FAN RELAYS
Fig. 24 Hose Clamp Tool 6 - EGR SOLENOID
1 - HOSE CLAMP TOOL 6094

2 - HOSE CLAMP (1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Drain cooling system (Refer to 7 - COOLING/
RADIATOR FAN RELAY ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove upper radiator hose (Fig. 26).
DESCRIPTION
The low and high speed fan relays are mounted to REMOVAL - LOWER RADIATOR HOSE
the upper radiator support above the charge air
cooler (Fig. 25). WARNING: THE WARNING WORDS “DO NOT OPEN
OPERATION SAFETY PRECAUTION. WHEN HOT, PRESSURE
The cooling system uses two fans. Both fans oper- BUILDS UP IN COOLING SYSTEM. TO PREVENT
ate at two different speeds, low and high. Depending SCALDING OR INJURY, THE RADIATOR CAP
on engine coolant temperature and A/C system high SHOULD NOT BE REMOVED WHILE THE SYSTEM
side pressure, the fans operate at either low or high. IS HOT OR UNDER PRESSURE.
The ignition switch supplies voltage to the coil side of
the relay. When the ECM grounds the coil side of the (1) Drain cooling system (Refer to 7 - COOLING/
relay, the contacts close and the battery supplies ENGINE/COOLANT - STANDARD PROCEDURE).
power to the fans. (2) Remove lower radiator hose (Fig. 26).
REMOVAL - COOLANT BYPASS HOSE

COOLANT SYSTEM HOSES
REMOVAL - UPPER RADIATOR HOSE HOT” ON THE RADIATOR PRESSURE CAP IS A
WARNING: THE WARNING WORDS “DO NOT OPEN BUILDS UP IN COOLING SYSTEM. TO PREVENT
HOT” ON THE RADIATOR PRESSURE CAP IS A SCALDING OR INJURY, THE RADIATOR CAP
SAFETY PRECAUTION. WHEN HOT, PRESSURE SHOULD NOT BE REMOVED WHILE THE SYSTEM
BUILDS UP IN COOLING SYSTEM. TO PREVENT IS HOT OR UNDER PRESSURE.
SHOULD NOT BE REMOVED WHILE THE SYSTEM (1) Drain cooling system (Refer to 7 - COOLING/
IS HOT OR UNDER PRESSURE. ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove the coolant bypass hose (Fig. 26).
RG ENGINE 7a - 29
COOLANT SYSTEM HOSES (Continued)
INSTALLATION - UPPER RADIATOR HOSE

(1) Install upper radiator hose (Fig. 26).
(3) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
INSTALLATION - LOWER RADIATOR HOSE

(1) Install lower radiator hose (Fig. 26).
INSTALLATION - COOLANT BYPASS HOSE

(1) Install cooling system bypass hose (Fig. 26).
Fig. 26 UPPER AND LOWER RADIATOR HOSES

1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RS AUDIO 8A - 1
AUDIO
TABLE OF CONTENTS
page page
AUDIO INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION . . . . . . . . . . ..................1 DOOR MOUNTED SPEAKER
OPERATION . . . . . . . . . . . ..................1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING ..................1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ANTENNA BODY & CABLE QUARTER PANEL SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .3 RADIO
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CD CHANGER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 RADIO NOISE SUPPRESSION COMPONENTS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6 REMOTE SWITCHES
CHOKE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING ..................6 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D-PILLAR SPEAKER DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . ..................6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . ..................7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DASH PANEL SPEAKER
REMOVAL . . . . . . . . . . . . . ..................7
AUDIO OPERATION
Operating instructions for the factory installed
DESCRIPTION audio systems can be found in the Owner’s Manual
There are four different system combinations avail- provided with this vehicle.
able on the RS models. The available radio options
are: DIAGNOSIS AND TESTING
• AM/FM Cassette
• AM/FM Compact Disc with Compact Disc WARNING:
Changer ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
• AM/FM Cassette with single Compact Disc TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
Player ING ANY STEERING WHEEL, STEERING COLUMN,
• AM/FM Cassette with Compact Disc Changer OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
All factory installed radio receivers are stereo Elec- OR SERVICE. FAILURE TO TAKE THE PROPER
tronically Tuned Radios (ETR) and include and elec- PRECAUTIONS COULD RESULT IN ACCIDENTAL
tronic digital clock function. AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
8A - 2 AUDIO RS
AUDIO (Continued)
AUDIO SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION

NO AUDIO. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR 2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
FAULTY. REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SPEAKERS FAULTY. 6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.

NO DISPLAY. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.



NO MEMORY. 1. FUSE FAULTY. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.



POOR RADIO 1. ANTENNA FAULTY. 1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR OR
RECEPTION. REPLACE ANTENNA, IF REQUIRED.


RS AUDIO 8A - 3
AUDIO (Continued)

4. POOR ANTENNA 4. SEAT CONNECTOR.
CONNECTION AT
RADIO OR IN LINE.
NO/POOR TAPE 1. FAULTY TAPE. 1. INSERT KNOWN GOOD TAPE AND TEST OPERATION.
OPERATION.
2. FOREIGN OBJECTS 2. REMOVE FOREIGN OBJECTS AND TEST OPERATION.
BEHIND TAPE DOOR.
3. DIRTY CASSETTE 3. CLEAN HEAD WITH MOPAR CASSETTE HEAD CLEANER.

TAPE HEAD.
4. FAULTY TAPE DECK. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO COMPACT 1. FAULTY CD. 1. INSERT KNOWN GOOD CD AND TEST OPERATION.
DISC
OPERATION
2. FOREIGN MATERIAL 2. CLEAN CD AND TEST OPERATION.
ON CD.
3. CONDENSATION ON 3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO

CD OR OPTICS. STABILIZE AND TEST OPERATION.
4. FAULTY CD PLAYER. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
ANTENNA BODY & CABLE ING ANY STEERING WHEEL, STEERING COLUMN,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THE PROPER
DESCRIPTION
PRECAUTIONS COULD RESULT IN ACCIDENTAL
All models use a fixed-length stainless steel rod-
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
type antenna mast, installed at the right front fender
INJURY.
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not The ohmmeter test lead connections for each test
grounded to any part of the vehicle. are shown in (Fig. 1).
OPERATION
To minimize static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional dis-
connect, located near the right end of the instrument
panel. This additional disconnect allows the instru-
ment panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios
(ETRs) automatically compensate for radio antenna
trim. Therefore, no antenna trimmer adjustment is
required or possible when replacing the receiver or
the antenna.
DIAGNOSIS AND TESTING

WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT-
Fig. 1 Antenna Test Points
8A - 4 AUDIO RS
ANTENNA BODY & CABLE (Continued)
TEST 1 (6) Hoist and support vehicle on safety stands.
Test 1 determines of the antenna mast is insulated (7) Remove front wheel.
from the base. Proceed as follows: (8) Remove front wheelhouse splash shield. (Refer
(1) Unplug the antenna coaxial cable from the to 23 - BODY/EXTERIOR/LF WHEELHOUSE
radio chassis and isolate. Remove the antenna mast. SPLASH SHIELD - REMOVAL).
(2) Connect an ohmmeter test lead to the inside (9) Remove antenna mast from antenna base (Fig.
center of the antenna base. Connect the other test 3).
lead to a metallic portion on the outside of the (10) Remove plastic cap from the cap nut. Using
antenna base. Check for continuity. cap nut tool, remove cap nut holding antenna base to
(3) There should be no continuity. If continuity is front fender (Fig. 4).
found, replace the faulty or damaged antenna base (11) Remove antenna base from under front fender.
and cable assembly.
ANTENNA EXTENSION CABLE
TEST 2 (1) Remove glove box. (Refer to 23 - BODY/IN-
Test 2 checks the antenna for an open circuit as STRUMENT PANEL/GLOVE BOX - REMOVAL).
follows: (2) Disconnect extension cable end from antenna
(1) Unplug the antenna coaxial cable connector cable end.
from the radio chassis. Remove the antenna mast. (3) Disconnect cable hanger clip from HVAC unit.
The painted mast prevents measurement directly (4) Remove radio as necessary to gain access to
through the mast. extension cable. (Refer to 8 - ELECTRICAL/AUDIO/
(2) Connect an ohmmeter test lead to the inside RADIO - REMOVAL).
center of the antenna base. Connect the other test (5) Disconnect extension cable from back of radio.
lead to the center pin of the antenna coaxial cable (6) Remove extension cable from vehicle.
connector.
(3) Continuity should exist (the ohmmeter should INSTALLATION
only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable ANTENNA MAST AND CABLE LEAD
assembly. Replace the faulty base and cable if (1) Install antenna base to underside of front
required. fender.
(2) Install cap nut holding antenna base to front
TEST 3 fender.
Test 3 checks the condition of the ground between (3) Install plastic cap to the cap nut.
the antenna base and the vehicle body as follows: (4) Install antenna mast to antenna base.
(1) Connect one ohmmeter test lead to the fender (5) Install front wheelhouse splash shield.
on an exposed metal area (paint and e-coat must be (6) Install front wheel.
penetrated to obtain continuity). Connect the other (7) Lower vehicle.
test lead to the outer crimp on the antenna coaxial (8) Push antenna cable through opening in hinge
cable connector. pillar.
(2) The resistance should be less than (1) ohm. (9) Insert rubber grommet into door hinge pillar.
(3) If the resistance is more than (1) ohm, clean (10) Install kick panel.
and/or tighten the antenna base to the fender mount- (11) Connect antenna cable connector to extension
ing hardware. cable.
(12) Install glove box to instrument panel.
REMOVAL
ANTENNA EXTENSION CABLE
ANTENNA MAST AND CABLE LEAD (1) Install extension cable to vehicle.
(1) Remove glove box from instrument panel, (2) Connect extension cable to back of radio.
(Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE (3) Install radio. (Refer to 8 - ELECTRICAL/AU-
BOX - REMOVAL). DIO/RADIO - INSTALLATION).
(2) Disconnect antenna cable connector from exten- (4) Connect cable hanger clip to HVAC unit.
sion cable (Fig. 2). (5) Connect extension cable end to antenna cable
(3) Remove right kick trim panel. end.
(4) Disengage rubber grommet insulator from door (6) Install glove box. (Refer to 23 - BODY/IN-
hinge pillar. STRUMENT PANEL/GLOVE BOX - INSTALLA-
(5) Pull antenna cable through hinge pillar into TION).
opening between door hinges.
RS AUDIO 8A - 5
ANTENNA BODY & CABLE (Continued)
Fig. 2 Antenna Cable

1 - CAP NUT 6 - RUBBER GROMMET
2 - ADAPTER 7 - ANTENNA CABLE AND BODY ASSEMBLY
3 - FENDER 8 - RUBBER GROMMET
4 - CABLE TO RADIO (EXTENSION CABLE)
5 - A-PILLAR
Fig. 3 Antenna Mast

1 - ANTENNA MAST Fig. 4 Antenna Cap Nut
2 - ADAPTER 1 - CAP NUT
3 - CAP NUT 2 - ANTENNA ADAPTER
3 - TOOL
8A - 6 AUDIO RS
CD CHANGER
DESCRIPTION
The 4 Disc In-Dash CD Changer (if equipped) is
located in the instrument panel below the radio. The
remote changer does not use a cartridge or magazine
for the CD’s. Up to 4 CD’s can be directly loaded into
this unit.
OPERATION
Due to its compact design, the CD changer can
carry out only one operation at a time. For example,
you can not load a new disc while playing another at
the same time. Each operation happens sequentially.
The radio unit provides control over all features of
the CD changer with the exception of the CD load
Fig. 5 CD - PLAYER
and eject functions, which are controlled by buttons
1 - CD-PLAYER
located on the front of the CD changer. All features
2 - POWER OUTLET
you would expect, such as Disc Up/Down, Track
Up/Down, Random and Scan are controlled by the
radio, which also displays all relevant CD changer
information on the radio display.
CHOKE
The CD changer contains a Load/Eject button and
an indicator LED for each of the four disc positions DIAGNOSIS AND TESTING
as well as an illuminated disc opening. The individ- If the audio system is cutting in and out at higher
ual LED indicates whether a CD is currently loaded volumes, check for continuity across the choke con-
in that particular chamber of the CD changer. Press- nector. If no continuity, replace the choke assembly.
ing the individual Load/Eject button for a particular The choke is located on the junction block/body con-
chamber will eject a disc currently present in that trol module.
chamber. If the chamber is currently empty, actuat-
ing the Load/Eject button will position that chamber
to receive and load a new disc in that chamber.
D-PILLAR SPEAKER
REMOVAL REMOVAL
(1) Disconnect and isolate the battery negative
cable. PASSENGER SIDE
(2) Remove screws holding CD changer. (1) Disconnect and isolate the battery negative
(3) Disconnect the wire connector from the back of cable.
the CD changer. (2) Remove rear header trim.
(4) Remove the CD changer from the vehicle (Fig. (3) Remove liftgate scuff plate.
5). (4) Remove upper seat belt bolt. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT OUT-
INSTALLATION BOARD FRONT - REMOVAL).
(5) Partially remove quarter trim panel to access
(1) Reconnect the wire connector to the CD
the D-pillar speaker.
changer.
(6) Slide the speaker from the retainer (Fig. 6).
(2) Insert the CD changer into the instrument
(7) Disconnect the wire harness connector from the
panel.
speaker.
NOTE: Use care when inserting CD changer so that
cable is not pinched or trapped against instrument DRIVER SIDE
panel. (1) Disconnect and isolate the negative battery
cable.
(3) Install screws holding CD changer. (2) Remove jack cover.
(4) Reconnect the battery negative cable. (3) Remove liftgate scuff plate.
(4) Partially remove quarter trim panel to access
the D-pillar speaker.
RS AUDIO 8A - 7
D-PILLAR SPEAKER (Continued)
(2) Remove the A-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - REMOVAL).
(3) Remove instrument panel top pad.
(4) Remove speaker screws (Fig. 7).
Fig. 6 D-PILLAR SPEAKER

1 - SPEAKER
2 - RETAINER
3 - TRIM PANEL
Fig. 7 DASH SPEAKER

(5) Slide the speaker from the retainer. 1 - DASH SPEAKER
(6) Disconnect the wire harness connector from the 2 - HARNESS CONNECTOR
speaker.
(5) Disconnect wire harness connector from
INSTALLATION speaker.
PASSENGER SIDE INSTALLATION
(1) Connect the wire harness connector to the
(1) Connect wire harness connector to the speaker.
speaker.
(2) Install speaker screws.
(2) Slide the speaker into the retainer.
(3) Install instrument panel top pad.
(3) Install quarter panel trim.
(4) Install the A-pillar trim. (Refer to 23 - BODY/
(4) Install upper seat belt bolt. (Refer to 8 - ELEC-
INTERIOR/A-PILLAR TRIM - INSTALLATION).
TRICAL/RESTRAINTS/SEAT BELT OUTBOARD
(5) Connect the battery negative cable.
FRONT - INSTALLATION).
(5) Install liftgate scuff plate.
(6) Install rear header trim. DOOR MOUNTED SPEAKER
(7) Connect battery negative cable.
REMOVAL
DRIVER SIDE (1) Disconnect and isolate the battery negative
(1) Connect the wire harness to the speaker.
cable.
(2) Slide the speaker into the retainer.
(2) Remove the door trim panel. (Refer to 23 -
(3) Install quarter panel trim.
BODY/DOOR - FRONT/TRIM PANEL - REMOVAL).
(4) Install liftgate scuff plate.
(3) Remove the speaker mounting screws (Fig. 8).
(5) Install jack cover.
(4) Remove wire harness connector from speaker.
INSTALLATION
DASH PANEL SPEAKER (1) Connect wire harness connector to speaker.
(2) Install the speaker mounting screws.
REMOVAL (3) Install the door trim panel. (Refer to 23 -
BODY/DOOR - FRONT/TRIM PANEL - INSTALLA-
TION).
cable.
8A - 8 AUDIO RS
DOOR MOUNTED SPEAKER (Continued)
INSTALLATION
(1) Connect the wire harness to the speaker.
(2) Install the speaker retaining screws.
(3) Install speaker grill by pressing into the trim
panel.
RADIO
If the vehicle is equipped with remote radio
switches located on the backs of the steering wheel
spokes, and the problem being diagnosed is related to
one of the symptoms listed below, be certain to check
the remote radio switches and circuits as described
Fig. 8 DOOR SPEAKER in this group, prior to attempting radio diagnosis or
1 - DOOR SPEAKER repair.
2 - HARNESS CONNECTOR • Stations changing with no remote radio switch
input
(4) Connect battery negative cable. • Radio memory presets not working properly
• Volume changes with no remote radio switch
input
QUARTER PANEL SPEAKER • Remote radio switch buttons taking on other
functions
REMOVAL • CD player skipping tracks
(1) Disconnect and isolate the battery negative • Remote radio switch inoperative.
cable. For circuit descriptions and diagrams, refer to the
(2) Remove speaker grill by prying away from trim appropriate wiring information. The wiring informa-
panel. tion includes wiring diagrams, proper wire and con-
(3) Remove speaker retaining screws (Fig. 9). nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
WARNING:
ING ANY STEERING WHEEL, STEERING COLUMN,
INJURY.
CAUTION:
The speaker output of the radio is a “floating
Fig. 9 QUARTER PANEL SPEAKER ground” system. Do not allow any speaker lead to
1 - SPEAKER short to ground, as damage to the radio may result.
2 - TRIM PANEL (1) Check the fuse(s) in the junction block and the
Intelligent Power Module. If OK, go to Step 2. If not
OK, repair the shorted circuit or component as
(4) Disconnect wire harness connector from required and replace the faulty fuse(s).
speaker. (2) Check for battery voltage at the fuse in the
Intelligent Power Module. If OK, go to Step 3. If not
RS AUDIO 8A - 9
RADIO (Continued)
OK, repair the open circuit to the battery as
required.
(3) Turn the ignition switch to the ON position.
Check for battery voltage at the fuse in the junction
block. If OK, go to Step 4. If not OK, repair the open
circuit to the ignition switch as required.
(4) Turn the ignition switch to the OFF position.
Remove the radio, but do not unplug the wire har-
ness connectors. Check for continuity between the
radio chassis and a good ground. There should be
continuity. If OK, go to Step 5. If not OK, repair the
open radio chassis ground circuit as required.
(5) Connect the battery negative cable. Turn the
ignition switch to the ON position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the left (gray) radio wire harness connector. Fig. 10 RADIO
If OK, go to Step 6. If not OK, repair the open circuit 1 - RADIO
as required. 2 - CD-PLAYER
(6) Turn the ignition switch to the OFF position.
Check for battery voltage at the fused B(+) circuit
cavity of the left (gray) radio wire harness connector. RADIO NOISE SUPPRESSION
If OK, replace the faulty radio. If not OK, repair the
open circuit to the Ignition-Off Draw (IOD) fuse as
COMPONENTS
required.
DESCRIPTION
REMOVAL
cable.
(2) Remove cup holder.
(3) Remove trim panel above cupholder by pulling
straight out.
(4) Remove center instrument panel trim panel.
(5) Remove screws holding radio to instrument
panel.
(6) Pull radio rearward to gain access to the back
of radio (Fig. 10).
(7) Disconnect antenna cable from back of radio.
(8) Remove bolt holding ground strap to the radio.
(9) Disconnect the wire connectors from the back
of the radio.
Fig. 11 Motor Mount to Frame Rail Ground
INSTALLATION 1 - GROUND STRAP
(1) Connect wire harness to back of radio.
(2) Install bolt holding ground strap to the radio.
(3) Connect antenna cable to back of radio. Numerous ground straps are placed throughout the
(4) Position radio into instrument panel. vehicle for interference elimination (Fig. 11), (Fig.
(5) Install screws holding radio to instrument 12), (Fig. 13), (Fig. 14).
panel.
(6) Install center instrument panel trim. OPERATION
(7) Install trim panel above cupholder. If receiving ignition/engine interference noise on
(8) Install cupholder. the radio stations, check and clean all engine and
(9) Connect battery negative cable. body ground connections. Ensure all ground connec-
tions are without corrosion. Tighten properly after
cleaning.
8A - 10 AUDIO RS
RADIO NOISE SUPPRESSION COMPONENTS (Continued)
Fig. 12 2.4L Engine Ground Locations Fig. 14 3.3/3.8L Engine Ground Locations
1 - GROUND STRAP 1 - GROUND STRAP
Fig. 13 2.4L Engine Ground Locations Fig. 15 Remote Radio Switch Operational View
1 - GROUND WIRES 1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
REMOTE SWITCHES 5 - VOLUME DOWN
6 - SEEK DOWN
DESCRIPTION
A remote radio control switch option is available on
some models. Two rocker-type switches are mounted OPERATION
on the back (instrument panel side) of the steering These switches are resistor multiplexed units that
wheel spokes (Fig. 15). The switch on the left spoke are hard-wired to the Body Control Module (BCM)
is the seek switch and has seek up, seek down, and through the clockspring. The BCM sends the proper
preset station advance functions. The switch on the messages on the Chrysler Collision Detection (CCD)
right spoke is the volume control switch and has vol- data bus network to the radio receiver. For diagnosis
ume up, and volume down functions. The switch on of the BCM or the CCD data bus, the use of a DRB
the right spoke also includes a “mode” control that scan tool and the proper Diagnostic Procedures man-
allows the driver to sequentially select AM radio, FM ual are recommended. For more information on the
radio, cassette player, CD player or CD changer (if operation of the remote radio switch controls, refer to
equipped). the owner’s manual in the vehicle glove box.
RS AUDIO 8A - 11
REMOTE SWITCHES (Continued)
DIAGNOSIS AND TESTING NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
WARNING: right/left remote radio switch orientation is with the
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER steering wheel installed, and driver in drivers seat.
ING ANY STEERING WHEEL, STEERING COLUMN, (4) If the switch resistance checks OK, go to Step
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS 5. If not OK, replace the faulty switch.
OR SERVICE. FAILURE TO TAKE THE PROPER (5) Check for continuity between the ground cir-
PRECAUTIONS COULD RESULT IN ACCIDENTAL cuit cavity of the switch wire harness connector and
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL a good ground. There should be continuity. If OK, go
INJURY. to Step 6. If not OK, repair the open circuit as
required.
(1) Disconnect and isolate the battery negative (6) Unplug the 24-way white wire harness connec-
cable. Wait two minutes for the airbag system capac- tor from the Body Control Module (BCM). Check for
itor to discharge before further service. continuity between the radio control circuit cavity of
(2) Remove the remote radio switch(es) from the the remote radio switch wire harness connector and a
steering wheel. (Refer to 8 - ELECTRICAL/AUDIO/ good ground. There should be no continuity. If OK, go
REMOTE SWITCHES - REMOVAL). to Step 7. If not OK, repair the short circuit as
(3) Use an ohmmeter to check the switch resis- required.
tance as shown in the Remote Radio Switch Test (7) Check for continuity between the radio control
table (Fig. 16). circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the CCD data bus. If not OK, repair the open circuit
as required.
REMOVAL
WARNING:
INJURY.

Fig. 16 Remote Radio Switches cable. Wait two minutes for the airbag system capac-
1 - WHITE REAR SWITCH
itor to discharge before further service.
2 - BLACK REAR SWITCH (2) Remove the driver side airbag module from the
vehicle. Refer to ELECTRICAL/RESTRAINTS/
DRIVER AIR BAG.
REMOTE RADIO SWITCH TEST (3) Remove the steering wheel from the steering
column. Refer to STEERING/COLUMN/STEERING
SWITCH POSITION RESISTANCE WHEEL.
VOLUME UP 7320 OHMS (4) Unplug the wire harness connector from the
remote radio switch (s).
VOLUME DOWN 1210 OHMS
(5) Remove three screws securing steering wheel
SEEK UP 4530 OHMS rear cover.
SEEK DOWN 2050 OHMS (6) Remove the remote radio switch from the steer-
PRE-SET STATION ADVANCE 10 OHMS ing wheel by depressing tabs on each side of each
switch.
8A - 12 AUDIO RS
REMOTE SWITCHES (Continued)
NOTE: The right remote radio switch back is white (1) Install remote radio switch to the steering
in color. The left switch back is black in color. The wheel.
right/left remote radio switch orientation is with the (2) Install three screws securing steering wheel
steering wheel installed, and driver in drivers seat. rear cover.
(3) Connect the wire harness to the remote radio
switch.
INSTALLATION (4) Install the steering wheel. Refer to STEERING/
COLUMN/STEERING WHEEL.
WARNING: (5) Install the driver side airbag module. Refer to
ON VEHICLES EQUIPPED WITH AIRBAGS, REFER ELECTRICAL/RESTRAINTS/DRIVER AIRBAG.
TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPT- (6) Connect the battery negative cable.
INJURY.
RG AUDIO 8Aa - 1
AUDIO
TABLE OF CONTENTS
page page
QUARTER GLASS INTEGRAL ANTENNA OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 ANTENNA MODULE . . . . . . . . . . . . . . . . . . . . . .2
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
QUARTER GLASS INTEGRAL ANTENNA . . . . . .1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ANTENNA MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . .....2
QUARTER GLASS INTEGRAL OPERATION

The integral antenna receives RF (Radio Frequen-
ANTENNA cies) and sends them to the antenna module for
amplification.
DESCRIPTION
The quarter glass integral antenna element is DIAGNOSIS AND TESTING - QUARTER GLASS
bonded to the right rear quarter glass and is replaced
with the glass assembly only (Fig. 1). INTEGRAL ANTENNA
The antenna grid pattern is divided into two sepa-
rate patterns. Each terminal connects to a separate
grid pattern, one for AM and the other for FM.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
nectors, splices and grounds. To detect breaks in the
integral antenna elements, the following procedure is
required:
(1) Disconnect the antenna module connector from
the antenna terminals on the glass.
(2) Using an ohmmeter, place a lead on one of the
terminals and check each end of the grid pattern con-
nected to this terminal for continuity. If continuity is
Fig. 1 QUARTER GLASS INTEGRAL ANTENNA not present, move one lead through the grid in pro-
1 - REAR QUARTER GLASS gression starting at the terminal with the other lead
2 - ANTENNA on the terminal until continuity is lost. Repeat pro-
cedure for the other terminal. A break in the antenna
grid can be repaired using a Mopar Rear Window
Defogger Repair Kit (Part Number 4267922) or
equivalent. (Refer to 8 - ELECTRICAL/HEATED
GLASS/WINDSHIELD GRID - STANDARD PROCE-
DURE).
8Aa - 2 AUDIO RG
ANTENNA MODULE located on the right rear quarter glass. There is also
an electrical connector for battery voltage and a coax
cable connector.
DESCRIPTION
The antenna module is an electromagnetic circuit
component designed to capture and enhance RF
OPERATION
The antenna module receives both AM and FM
(Radio Frequency) signals in both the AM and FM
radio signals supplied by the side window integral
broadcast bands. The antenna module is mounted to
radio antenna system and selectively amplifies them.
the right rear roof rail under the headliner. The mod-
The amplified signal is then sent through the body
ule is grounded through the mounting bracket and
length coax cable to the radio input.
fastener. The module has a two wire electrical con-
nector that connects to the integral radio antenna,
DIAGNOSIS AND TESTING - ANTENNA MODULE

NO AM RECEPTION, 1. Antenna module to antenna 1. Repair open, reconnect
WEAK FM RECEPTION connector open or disconnected. antenna module connector to
glass mounted antenna.
2. Coax open or disconnected. 2. Repair open, reconnect coax.
3. No battery power at antenna 3. Check fuse. if okay, repair
module. open in battery voltage circuit.
NO AM OR FM 1. Coax disconnected at radio. 1. Reconnect coax.
RECEPTION
2. Coax shorted to ground. 2. Repair or Replace coax
WEAK OR NO AM/FM 1. Antenna Module faulty. 1. Substitute known good
RECEPTION module. If reception improves,
Antenna Module was faulty.
REMOVAL
cable.
(2) Lower headliner as necessary to access
antenna module (Fig. 2).
(3) Disconnect antenna coax cable lead and electri-
cal harness connector from antenna module.
(4) Disconnect the antenna module connector from
the quarter glass.
(5) Remove the mounting screw and the antenna
module.
INSTALLATION
(1) Install the antenna module and the mounting
fastener.
(2) Connect the antenna connector to the quarter
glass. Fig. 2 ANTENNA MODULE
(3) Connect the antenna lead and electrical con- 1 - ANTENNA MODULE
nector to the antenna module. 2 - ANTENNA MODULE CONNECTOR
(4) Raise and install headliner.
RS CHIME/BUZZER 8B - 1
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER EXTERIOR LAMPS ON CHIME. . . . . . . . . . . . . .2

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . .2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 LOW OIL PRESSURE CHIME . . . . . . . . . . . . . . .2
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .1 SEAT BELT CHIME. . . . . . . . . . . . . . . . . . . . . . .3
CHIME SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . .1 SEAT BELT LAMP . . . . . . . . . . . . . . . . . . . . . . .3
DOME LAMP ON CHIME . . . . . . . . . . . . . . . . . .2 TURN SIGNAL ON CHIME . . . . . . . . . . . . . . . . .3
ENGINE TEMPERATURE CRITICAL CHIME . . . .2 WARNING LAMP ANNOUNCEMENT CHIME. . . .3
CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME SYSTEM
DESCRIPTION NO TONE WHEN IGNITION SWITCH IS TURNED ON

AND DRIVER’S SEAT BELT IS NOT BUCKLED.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Using a DRBIIIt scan tool, actuate chime
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (BCM actuates).
ATTEMPTING ANY STEERING WHEEL, STEERING (2) Using a voltmeter, check for voltage:
COLUMN, OR INSTRUMENT PANEL COMPONENT (a) BCM has two battery feeds at pin 1 and pin
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- 5 of the 6–way connector.
LATE THE BATTERY NEGATIVE (GROUND) CABLE, (b) Pin 5 of the (BX2) 32 way connector of the
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- BCM for ignition feed.
TEM CAPACITOR TO DISCHARGE BEFORE PER- (c) Check voltage (PX2) connector, pin 34 for 12v.
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS (d) If voltage OK, go to step Step 3
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG (e) If NO voltage repair as necessary. Refer to
SYSTEM. FAILURE TO TAKE THE PROPER PRE- the appropriate wiring information. The wiring
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- information includes wiring diagrams, proper wire
BAG DEPLOYMENT AND POSSIBLE PERSONAL and connector repair procedures, further details on
INJURY. wire harness routing and retention, as well as pin-
out and location views for the various wire harness
The chime/buzzer system provides the driver with connectors, splices and grounds.
warning chimes for: (3) Check driver’s seat belt buckle switch input
• Seat Belt (form ORC) for a closed circuit when not buckled. If
• Exterior Lamps ON input not seen, look for open in wiring or switch. The
• Key-In Ignition switch is grounded when belt is not buckled.
• Engine Temperature Critical (4) Verify PCI data bus communication between
• Turn Signals ON ORC and BCM.
• Dome Lamp ON
• Low Oil Pressure NO FASTEN SEAT BELT LAMP WHEN IGNITION
• High Speed Warning SWITCH IS TURNED ON.
• Warning Lamp Announcement (1) Check for burned out lamp.
• Key-In Accessory (2) Using a voltmeter check for voltage at the clus-
ter conncctor:
OPERATION (a) Pin 2 of the mechanical instrument cluster
The Chime/Buzzer Warning System is diagnosed for battery feed.
using a DRBIIIt scan tool. Refer to the proper Body (b) Pin 11 of the mechanical instrument cluster
Diagnostic Procedures Manual. for ignition voltage.
(3) Repair as necessary.
8B - 2 CHIME/BUZZER RS
CHIME/BUZZER (Continued)
FASTEN SEAT BELT LAMP OR TONE CONTINUES DIAGNOSIS AND TESTING - EXTERIOR LAMPS
FOR MORE THAN 10 SECONDS AFTER SEAT ON CHIME
BELTS ARE FASTENED AND DRIVER’S DOOR IS The exterior lamp on chime will warn the driver
CLOSED. that the exterior lights have been left on.
Refer to the proper Body Diagnostic Procedures With the ignition switch OFF/key out of ignition:
manual. • Driver’s door is open (door ajar switch is closed
to ground)
NO TONE WHEN PARK OR HEADLAMPS ARE ON • Parking lamps or headlamps ON (parking lamp
AND DRIVER’S DOOR IS OPEN. switch is closed to ground)
Make sure ignition is in lock position with the key The chime will sound until lights are turned OFF,
removed. driver’s door closed or until the battery protection
(1) Check the BCM DTC’s and BCM sensors to time out of 3 minutes has expired.
verify the door is open. Repair as necessary. Chime rate: 168 to 192 chimes per minute.
(2) Actuate Chime (BCM actuates). To test the exterior lamps left on function:
(3) Inspect BCM connectors and wires for proper • Turn ignition off
connection. • Remove ignition key
(4) Measure with a voltmeter the voltage (12v) on • Turn exterior lamps on with driver’s door open.
BCM connector (PX2) pin 34 with harness connected. Chime should sound until lamps are turned off or
driver’s door is closed.
DIAGNOSIS AND TESTING - DOME LAMP ON
DIAGNOSIS AND TESTING - KEY-IN IGNITION
CHIME
The dome lamp on chime will warn the driver that CHIME
the dome lamps have been left on. The key-in ignition chime will act as a warning to
When the ignition is OFF: the driver that the ignition key has been left in the
• Driver’s door OPEN (door ajar switch is closed to ignition switch.
ground) and With the ignition switch is in OFF position ONLY:
• Dome lamps are ON (dome lamp switch is closed • Driver’s door is open/ajar (door ajar switch is
to ground), closed to ground)
The chime will sound continuously until driver’s • Key is in the ignition switch (ignition is in the
door is closed, dome lamps tuned OFF or until the LOCK position)
battery protection time out of 15 minutes has The chime will sound until one of the above condi-
expired. Chime rate: 168 to 192 chimes per minute. tions is removed or until battery protection time out
(15 min.) has expired. Chime rate: 168 to 192 chimes
DIAGNOSIS AND TESTING - ENGINE per minute.
To test the key-in ignition function, insert key into
TEMPERATURE CRITICAL CHIME the ignition and open driver’s door. Do not turn igni-
The engine temperature critical chime will warn tion ON. Chime should sound until key is removed
the driver that the vehicle’s engine is overheating. from ignition or driver’s door is closed.
While monitoring the coolant temperature, the Pow- For diagnosis and testing of the Key-In Accessory
ertrain Control Module (PCM) will send on the PCI chime, use the same testing procedure as above but
data bus as engine temperature every 1.376 seconds with the key in the accessory position.
to the cluster. The MIC calculates engine tempera-
ture and determines if a warning should occur. This DIAGNOSIS AND TESTING - LOW OIL
feature is functional only with the Ignition Switch in
the Run/Start position. PRESSURE CHIME
When the engine temperature reaches 122°C The low oil pressure chime will warn the driver
(252°F) the MIC requests a chime from the BCM and that the engine oil pressure is low. The oil pressure
the engine temperature lamp comes ON. The MIC switch will close to ground during a low oil pressure
turns OFF the lamp when the engine temperature condition. The oil pressure lamp will illuminate in
reaches 117°C (242°F). The MIC will chime continu- the message center. The PCM will monitor the oil
ously (request from the BCM). The chime will turn pressure switch and signal a low oil pressure condi-
OFF after four minutes or when the temperature tion. A continuous four minute warning chime will
reaches 117°C (242°F), which ever occurs first. sound and the oil pressure lamp will come ON when
the following conditions are met:
• Ignition on and engine not cranking
RS CHIME/BUZZER 8B - 3
CHIME/BUZZER (Continued)
• Engine running at 420 to 480 rpm for 10 sec- nal is turned OFF. If vehicle speed drops below 24
onds km/h (15 mph) prior to the warning being activated,
• Oil pressure switch closed to ground for (1 sec- the accumulated distance traveled will be reset. The
ond minimum, 2 seconds maximum) turn signal chime is not activated when the emer-
Chime rate: 168 to 192 chimes per minute. gency flashers are turned on. Chime rate: 50 6 12
chimes per minute.
DIAGNOSIS AND TESTING - SEAT BELT CHIME For the turn signal warning system to operate:
The seat belt chime will sound for 4 to 8 seconds, • Must have input from either the right or left
when the ignition is turned on and the driver’s seat turn signal lamps. Creates a voltage change between
belt is not buckled (seat belt switch is closed to 0 and battery voltage.
ground). This is a reminder to the driver to buckle • The vehicle speed sensor sends a message to the
the seat belt. The seat belt lamp is controlled by the Powertrain Control Module that vehicle has exceeded
ORC. The cluster will also bulb check the seat belt 24 km/h (15 mph) for 1/4.0 mile).
warning lamp for 6 seconds. Buckling the driver’s • When the above two conditions are met, the
seat belt before the time out has expired will cause chime will sound. The chime will stop when no fur-
the chime to stop immediately. Chime rate: 38 to 62 ther voltage change is detected.
chimes per minute but the lamp will remain on until • If hazard warning signals are pulsing, no chime
6 seconds have expired. will sound.
To test the seat belt warning system, the ignition • If speed drops below 24 km/h (15 mph) before
switch must be in the OFF position for 1 minute the warning is issued, the warning will not be issued
before starting the test. Turn the ignition switch to and the distance counter will be reset.
the on position with the driver’s seat belt not buck- • If turn signal lamps are not working properly,
led. The seat belt warning lamp should light and the the chime will not sound.
chime should sound 4 to 8 seconds. • When using the scan tool, refer to the proper
Body Diagnostic Manual for the procedure.
DIAGNOSIS AND TESTING - SEAT BELT LAMP
The seat belt lamp in the instrument cluster sig- DIAGNOSIS AND TESTING - WARNING LAMP
nals the vehicle passengers to fasten their seat belts. ANNOUNCEMENT CHIME
The seat belt lamp is illuminated directly by the The warning lamp announcement chime will warn
instrument cluster for 6 seconds after the instrument the driver to scan the instrument cluster to observe
cluster receives the message from the ORC. The seat which warning lamp is illuminated. Whenever the
belt lamp is therefore illuminated for 6 seconds volts, low fuel, airbag, door ajar or gate ajar lamps
whenever the ignition switch is moved to run/start are first illuminated, the chime will sound one tone.
position. The door/liftgate ajar warning lamp announcement
(1) While ignition is off, the seat belt lamp will not chime sounds only if the vehicle speed is above 4
be illuminated. m.p.h.
(2) The ignition power feed status will be updated Two seconds after ignition switch is turned ON or
every 250 milliseconds or on change. until the seat belt warning chime ends, all warning
(3) This lamp will be checked by the instrument announcement chimes will be consolidated into one
cluster for 6 seconds with every run/start cycle of the warning announcement. This will occur 2 seconds
ignition switch. after the seat belt warning chime ends. If a warning
announcement should occur while another warning
DIAGNOSIS AND TESTING - TURN SIGNAL ON chime in progress (turn signal, low oil pressure or
CHIME high speed warnings), no additional chimes will
The turn signal on chime will warn the driver that sound after the chime in progress ends. All associ-
the turn signals have been left on. When the body ated lamps will be illuminated, and the active chime
control module receives a turn signal input for 1/4.0 will be the warning announcement.
mile, vehicle speed is greater than 24 km/h (15 mph),
the chime will sound continuously until the turn sig-
RG CHIME/BUZZER 8Ba - 1
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHIME/BUZZER OPERATION
DESCRIPTION HIGH SPEED WARNING

When the vehicle speed sensor sees 120 ± 3 kph
HIGH SPEED WARNING (75 ± 2 mph), it sends a PCI data bus message to the
The chime will sound, acting as a warning to the Body Control Module (BCM). The BCM then turns on
driver that the vehicle speed has exceeded 120 ± 3 the chime to let the driver know that the vehicle has
kph (75 ± 2 mph). reached a speed greater than 120 ± 3 kph (75 ± 2
mph). This audible message will continue until the
vehicle is slowed below the predetermined speed.
RS ELECTRONIC CONTROL MODULES 8E - 1
ELECTRONIC CONTROL MODULES

TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

STANDARD PROCEDURE . . . . . . . . . . . . . ......1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PCM/SKIM PROGRAMMING. . . . . . . . . . ......1 POWERTRAIN CONTROL MODULE
BODY CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 OBTAINING DIAGNOSTIC TROUBLE
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONTROLLER ANTILOCK BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SENTRY KEY IMMOBILIZER MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DATA LINK CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . ......5 SLIDING DOOR CONTROL MODULE
FRONT CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT CONTROL MODULE . . . . . . . . . . . . . . .6 TRANSMISSION CONTROL MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MEMORY HEATED SEAT/MIRROR MODULE STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . ......7 PINION FACTOR PROCEDURE . . . . . . . . . . . . 27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . ......7 QUICK LEARN PROCEDURE . . . . . . . . . . . . . . 27
POWER LIFTGATE MODULE TCC BREAK-IN VIEW/RESET PROCEDURE. . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ......7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . ......7 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ELECTRONIC CONTROL When a PCM (SBEC) and the SKIM are replaced
at the same time perform the following steps in
MODULES order:
(1) Program the new PCM (SBEC)
STANDARD PROCEDURE - PCM/SKIM (2) Program the new SKIM
PROGRAMMING (3) Replace all ignition keys and program them to
the new SKIM.
NOTE: Before replacing the PCM for a failed driver,
control circuit or ground circuit, be sure to check PROGRAMMING THE PCM (SBEC)
the related component/circuit integrity for failures The SKIS Secret Key is an ID code that is unique
not detected due to a double fault in the circuit. to each SKIM. This code is programmed and stored
Most PCM driver/control circuit failures are caused in the SKIM, PCM and transponder chip (ignition
by internal component failures (i.e. relay and sole- keys). When replacing the PCM it is necessary to
noids) and shorted circuits (i.e. pull-ups, drivers program the secret key into the new PCM using the
and switched circuits). These failures are difficult to DRB III. Perform the following steps to program the
detect when a double fault has occurred and only secret key into the PCM.
one DTC has set.
8E - 2 ELECTRONIC CONTROL MODULES RS
ELECTRONIC CONTROL MODULES (Continued)
(1) Turn the ignition switch on (transmission in PROGRAMMING IGNITION KEYS TO THE SKIM
park/neutral). (1) Turn the ignition switch on (transmission in
(2) Use the DRB III and select THEFT ALARM, park/neutral).
SKIM then MISCELLANEOUS. (2) Use the DRB III and select THEFT ALARM,
(3) Select PCM REPLACED (GAS ENGINE). SKIM then MISCELLANEOUS.
(4) Enter secured access mode by entering the (3) Select PROGRAM IGNITION KEY’S.
vehicle four-digit PIN. (4) Enter secured access mode by entering the
(5) Select ENTER to update PCM VIN. vehicle four-digit PIN.
NOTE: If three attempts are made to enter secure NOTE: A maximum of eight keys can be learned to
access mode using an incorrect PIN, secured each SKIM. Once a key is learned to a SKIM it (the
access mode will be locked out for one hour. To key) cannot be transferred to another vehicle.
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN. If ignition key programming is unsuccessful, the
(Ensure all accessories are turned off. Also monitor DRB III will display one of the following messages:
the battery state and connect a battery charger if Programming Not Attempted - The DRB III
necessary). attempts to read the programmed key status and
there are no keys programmed into SKIM memory.
(6) Press ENTER to transfer the secret key (the Programming Key Failed (Possible Used Key From
SKIM will send the secret key to the PCM). Wrong Vehicle) - SKIM is unable to program key due
(7) Press Page Back to get to the Select System to one of the following:
menu and select ENGINE, MISCELLANEOUS, and • faulty ignition key transponder
SRI MEMORY CHECK. • ignition key is programmed to another vehicle.
(8) The DRB III will ask, Is odometer reading 8 Keys Already Learned, Programming Not Done -
between XX and XX? Select the YES or NO button on SKIM transponder ID memory is full.
the DRB III. If NO is selected, the DRB III will read, (5) Obtain ignition keys to be programmed from
Enter odometer Reading<From I.P. odometer>. Enter customer (8 keys maximum).
the odometer reading from the Instrument Panel and (6) Using the DRB III, erase all ignition keys by
press ENTER. selecting MISCELLANEOUS and ERASE ALL CUR-
RENT IGN. KEYS.
PROGRAMMING THE SKIM (7) Program all ignition keys.
(1) Turn the ignition switch on (transmission in Learned Key In Ignition - Ignition key transponder
park/neutral). ID is currently programmed in SKIM memory.
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE). BODY CONTROL MODULE
(4) Program the vehicle four-digit PIN into SKIM.
(5) Select COUNTRY CODE and enter the correct DESCRIPTION
country. The Body Control Module (BCM) is concealed
below the driver side end of the instrument panel in
NOTE: Be sure to enter the correct country code. If the passenger compartment, where it is secured to
the incorrect country code is programmed into the dash panel.
SKIM, the SKIM must be replaced. The BCM utilizes integrated circuitry and informa-
tion carried on the Programmable Communications
(6) Select YES to update VIN (the SKIM will learn
Interface (PCI) data bus network along with many
the VIN from the PCM).
hard wired inputs to monitor many sensor and
(7) Press ENTER to transfer the secret key (the
switch inputs throughout the vehicle. In response to
PCM will send the secret key to the SKIM).
those inputs, the internal circuitry and programming
(8) Program ignition keys to SKIM.
of the BCM allow it to control and integrate many
NOTE: If the PCM and the SKIM are replaced at the electronic functions and features of the vehicle
same time, all vehicle keys will need to be replaced through both hard wired outputs and the transmis-
and programmed to the new SKIM. sion of electronic message outputs to other electronic
modules in the vehicle over the PCI data bus.
BODY CONTROL MODULE (Continued)
OPERATION trols it when the vehicle is in an ABS stop. The CAB

The Body Control Module (BCM) is designed to is mounted to the HCU as part of the integrated con-
control and integrate many of the electronic features trol unit (ICU) (Fig. 1). The CAB uses a 24-way elec-
and functions of the vehicle. The microprocessor- trical connector on the vehicle wiring harness. The
based BCM hardware and software monitors many power source for the CAB is through the ignition
hard wired switch and sensor inputs as well as those switch in the RUN or ON position. The CAB is on
resources it shares with other electronic modules in the PCI bus.
the vehicle through its communication over the PCI
data bus network. The internal programming and all
of these inputs allow the BCM microprocessor to
determine the tasks it needs to perform and their
priorities, as well as both the standard and optional
features that it should provide. The BCM program-
ming then performs those tasks and provides those
features through both PCI data bus communication
with other electronic modules and through hard
wired low current outputs to a number of relays.
These relays provide the BCM with the ability to
control numerous high current accessory systems in
the vehicle.
The BCM monitors its own internal circuitry as
well as many of its input and output circuits, and
will store a Diagnostic Trouble Code (DTC) in elec-
tronic memory for any failure it detects. These DTCs Fig. 1 INTEGRATED CONTROL UNIT (ICU)
can be retrieved and diagnosed using a DRBIIIt scan 1 - PUMP/MOTOR
tool. Refer to the appropriate diagnostic information. 2 - HCU
3 - PUMP/MOTOR CONNECTOR
REMOVAL 4 - CAB
cable.
(2) Remove lower steering column cover and knee OPERATION
blocker reinforcement. The primary functions of the controller antilock
(3) Disconnect two wire connectors from bottom of brake (CAB) are to:
Body Control Module (BCM) • Monitor the antilock brake system for proper
(4) Remove bolts holding the BCM to the dash operation.
panel mounting bracket. • Detect wheel locking or wheel slipping tenden-
(5) Remove the BCM from the mounting bracket. cies by monitoring the speed of all four wheels of the
vehicle.
INSTALLATION • Control fluid modulation to the wheel brakes
(1) Install the BCM onto the mounting bracket. while the system is in an ABS mode.
(2) Install the bolts holding the BCM to dash • Store diagnostic information.
panel mounting bracket. • Provide communication to the DRBIIIt scan tool
(3) Connect two wire connectors to the bottom of while in diagnostic mode.
the BCM. • Illuminate the amber ABS warning indicator
(4) Install the lower steering column cover and lamp.
knee blocker reinforcement. • (With traction control only) Illuminate the TRAC
(5) Connect the battery negative cable. ON lamp in the message center on the instrument
panel when a traction control event occurs.
• (with traction control only) Illuminate the TRAC
CONTROLLER ANTILOCK OFF lamp when the amber ABS warning indicator
lamp illuminates.
BRAKE The CAB constantly monitors the antilock brake
system for proper operation. If the CAB detects a
DESCRIPTION fault, it will turn on the amber ABS warning indica-
The controller antilock brake (CAB) is a micropro- tor lamp and disable the antilock braking system.
cessor-based device which monitors the antilock
brake system (ABS) during normal braking and con-
CONTROLLER ANTILOCK BRAKE (Continued)
The normal base braking system will remain opera- (6) Pull up on the CAB connector lock and discon-
tional. nect the 24–way electrical connector and the pump/
motor connector from the CAB (Fig. 2)
NOTE: If the vehicle is equipped with traction con-
trol, the TRAC OFF lamp will illuminate anytime the
amber ABS warning indicator lamp illuminates.
The CAB continuously monitors the speed of each

wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The coils then open and close the valves in the
HCU that modulate brake fluid pressure in some or
all of the hydraulic circuits. The CAB continues to
control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that
monitors the antilock brake system for system faults.
When a fault is detected, the amber ABS warning
indicator lamp is turned on and the fault diagnostic
trouble code (DTC) is then stored in a diagnostic pro-
gram memory. These DTC’s will remain in the CAB
memory even after the ignition has been turned off. Fig. 2 CAB CONNECTOR LOCK
The DTC’s can be read and cleared from the CAB 1 - CONNECTOR LOCK
memory by a technician using the DRBIIIt scan tool. 2 - CAB
If not cleared with a DRBIIIt scan tool, the fault
occurrence and DTC will be automatically cleared (7) Remove the screws securing the CAB to the
from the CAB memory after the identical fault has vehicle (Fig. 3)
not been seen during the next 3,500 miles.
CAB INPUTS
• Wheel speed sensors (four)
• Brake lamp switch
• Ignition switch
• System and pump voltage
• Ground
• Traction control switch (if equipped)
• Diagnostic communication (PCI)
CAB OUTPUTS
• Amber ABS warning indicator lamp actuation
(via BUS)
• Instrument cluster (MIC) communication (PCI)
• Traction control lamps (if equipped)
• Diagnostic communication (PCI, via BUS)
Fig. 3 CAB MOUNTING SCREWS
REMOVAL 1 - HCU
2 - MOUNTING SCREWS
(1) Disconnect the battery cables.
3 - CAB
(2) Remove the battery (Refer to 8 - ELECTRI-
(3) Disconnect the vacuum hose connector at the INSTALLATION
tank built into the battery tray. (1) Install screws to secure the CAB to the vehicle
(4) Remove the screw securing the coolant filler (Fig. 3) Tighten the mounting screws to 2 N·m (17 in
neck to the battery tray. lbs).
(5) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
CONTROLLER ANTILOCK BRAKE (Continued)
(2) Reconnect the 24–way electrical and the pump/
motor connector. (Fig. 2)
(3) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(4) Install the screw securing the coolant filler
neck to the battery tray.
(5) Reconnect the vacuum hose to the coolant tank
built into the battery tray.
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reconnect the battery cables.
(8) Connect a DRBIIIt to the vehicle and initialize
the system.
DATA LINK CONNECTOR

DESCRIPTION
The data link connector is located inside the vehi-
cle, below instrument panel next to the center col-
umn (Fig. 4) .
Fig. 5 FRONT CONTROL MODULE

1 - FRONT CONTROL MODULE
Module (IPM). The intelligent power module connects

directly to the battery and provides the primary
means of circuit protection and power distribution for
all vehicle electrical systems. The front control mod-
ule controls power to some of these vehicle systems
electrical and electromechanical loads based on
inputs received from hard wired switch inputs and
data received on the PCI bus circuit (J1850).
For information on the Intelligent Power Mod-
ule (IPM) Refer to the Power Distribution Sec-
tion of the service manual.
OPERATION
As messages are sent over the PCI bus circuit, the
front control module reads these messages and con-
Fig. 4 DATA LINK CONNECTOR trols power to some of the vehicles electrical systems
by completing the circuit to ground (low side driver)
OPERATION or completing the circuit to 12 volt power (high side
The data link connector (diagnostic connector) driver). The following functions are controlled by
links the DRB scan tool with the Powertrain Control the Front Control Module:
Module (PCM). Refer to On-Board Diagnostics in the • Occupant Restraint Controller Voltage
General Diagnosis section of this group. • Headlamp Power with Voltage Regulation
• Side Airbag Voltage
• Electronic Transaxle (Gasoline engine Vehicles)
FRONT CONTROL MODULE • Brake Transmission Shift Interlock Functions
(BTSI)
DESCRIPTION • Front Windshield Wiper “ON” Relay Actuation
The Front Control Module (FCM) is a micro con- • Front Windshield Wiper “HI” & “LO” Relay
troller based module located in the engine compart- Actuation
ment (Fig. 5). This FCM mates to the power • Front Washer Motor
distribution center to form the Intelligent Power • Rear Washer Motor
FRONT CONTROL MODULE (Continued)
• Front Fog Lamp Relay Actuation (3) Using a long flat-pladed screwdriver, gently
• Front and Rear Blower Motor Relay Actuation twist the Intelligent Power Module (IPM) retaining
• Accessory Relay Actuation clip outboard to free the intelligent power module
• Electronic Back Light (EBL) Rear Defogger from its mounting bracket (Fig. 6). Rotate intelligent
• Horn Relay Actuation power module upward to access the Front Control
• Park Lamp Relay Actuation Module (FCM) retaining screws.
• Name Brand Speaker (NBS) Relay Actuation
• Headlamp Washer Relay Actuation
• Diesel Cabin Heater (Diesel Engine Vehicles)
The following inputs are Received/Monitored by
the Front Control Module:
• B+ Connection Detection
• Ambient Temperature Sensing
• Right/Left Park Lamp Outage
• Ignition Switch Start Only
• Ignition Switch Run and Start Only
• Washer Fluid Level
• Windshield Wiper Park
• Brake Fluid Level
• Back-Up switch
• Stop Lamp Sense
• Engine Crank Signal (Diesel Engine Vehicles)
• Horn Input
DIAGNOSIS AND TESTING - FRONT CONTROL

MODULE
The front control module is a printed circuit board
based module with a on-board micro-processor. The Fig. 6 REMOVING INTELLIGENT POWER MODULE
front control module interfaces with other electronic (4) Remove the front control module retaining
modules in the vehicle via the Programmable Com- screws.
munications Interface (PCI) data bus (J1850). In (5) Using both hands, pull the front control module
order to obtain conclusive testing the Programmable straight from the intelligent power module assembly
Communications Interface (PCI) data bus network to disconnect the 49-way electrical connector (Fig. 7)
and all of the electronic modules that provide inputs and remove the front control module from the vehi-
to, or receive outputs from the front control module cle.
must be checked. All PCI (J1850) communication
faults must be resolved prior to further diagnosing INSTALLATION
any front control module related issues. (1) Install the front control module in the intelli-
The front control module was designed to be diag- gent power module assembly by pushing the 49-way
nosed with an appropriate diagnostic scan tool, such electrical connector straight in (Fig. 7).
as the DRB IIIt. The most reliable, efficient, and (2) Install the front control module retaining
accurate means to diagnose the front control module screws. Torque the screws to 7 in. lbs.
requires the use of a DRB IIIt scan tool and the (3) Rotate the intelligent power module assembly
proper Body Diagnostic Procedures manual. downward to secure in mounting bracket.
Before any testing of the front control module is (4) Install the battery in the vehicle. Refer to the
attempted, the battery should be fully charged and procedure in Battery Systems.
all wire harness and ground connections inspected (5) Connect the positive and negative battery
around the affected areas on the vehicle. cables.
REMOVAL NOTE: If the vehicle is not equipped with Name

(1) Disconnect the positive and negative battery Brand Speakers (NBS, Infinity) or Headlamp Wash-
cables from the battery. ers the DRB IIIT must be used to Disable the appro-
(2) Remove the battery from the vehicle. Refer to priate relays in the Intelligent Power Module
the procedure in Battery Systems. Assembly.
FRONT CONTROL MODULE (Continued)
Fig. 7 FRONT CONTROL MODULE Fig. 8 LIFTGATE CONTROL MODULE

1 - POWER LIFTGATE CONTROL MODULE 1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
MEMORY HEATED SEAT/ 4 - POWER LIFTGATE MOTOR
MIRROR MODULE 5 - MODULE ELECTRICAL CONNECTORS
REMOVAL switches except for the outside handle switch. This

(1) Disconnect and isolate the negative battery module also contains the software technology to
cable. detect liftgate obstructions and stop and / or reverse
(2) Move seat to full forward position. the door accordingly.
(3) Working under the seat, disconnect the module
wire harness connectors. OPERATION
(4) Remove the module retaining screws. The PLG control module contains the electronic cir-
(5) Remove the module from under the seat. cuitry and software used to control the sequence of
events for the PLG system. This module comunicates
INSTALLATION on the PCI bus circuit with the vehicles body control
(1) Install the module under the seat. module to monitor many different inputs and outputs
(2) Install the module retaining screws. such as door lock status, transmission gear selector
(3) Working under the seat, connect the module position and vehicle speed. Refer to PLG system
wire harness connectors. operation for more information.
(4) Connect and isolate the negative battery cable.
REMOVAL
(1) Disconnect and isolate the negative battery
POWER LIFTGATE MODULE cable.
(2) Remove left D-pillar trim panel from the vehi-
DESCRIPTION cle. Refer to Body for the procedure.
Vehicles equipped with a power liftgate (PLG) uti- (3) Disconnect the wire harness connections from
lize a PLG control module. This module is located on the PLG motor assembly (Fig. 9).
the vehicles left side D-pillar just below the motor (4) Remove the screw holding the PLG control
assembly (Fig. 8) and contains a microprocessor, module to the D-pillar (Fig. 9).
which is used to communicate to the vehicles body (5) Remove the PLG control module from the vehi-
control module. The PLG control module receives and cle.
monitors logic inputs from all the PLG system
POWER LIFTGATE MODULE (Continued)
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
Fig. 9 LIFTGATE CONTROL MODULE

1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
Fig. 10 Powertrain Control Module (PCM)
1 - Battery
INSTALLATION 2 - Power Distribution Center
(1) Install the PLG control module on the D-pillar 3 - Powertrain Control Module
and install retaining screw. Torque the screw to 14.5
in. lbs. NOTE: PCM Inputs:
(2) Connect the wire harness connections on the
PLG control module. Be certain to slide connector • Air Conditioning Pressure Transducer
locks to the locked position. • ASD Relay
(3) Install the D-pillar trim panel on the vehicle. • Battery Voltage
Refer to the Body section for the procedure. • Brake Switch
(4) Connect the negative battery cable. • Camshaft Position Sensor
(5) Using an appropriate scan tool, check any • Crankshaft Position Sensor
erase any PLG control module diagnostic trouble • Distance Sensor (from transmission control mod-
codes. ule)
(6) Verify PLG system operation. Cycle the PLG • EGR Position Feedback
through one complete open and close cycle, this will • Engine Coolant Temperature Sensor
allow the PLG control module to relearn its cycle • Heated Oxygen Sensors
with the new components. • Ignition sense
• Intake Air Temperature Sensor
• Knock Sensor
POWERTRAIN CONTROL • Leak Detection Pump Feedback
MODULE • Manifold Absolute Pressure (MAP) Sensor
• Park/Neutral (from transmission control module)
• PCI Bus
DESCRIPTION
• Power Steering Pressure Switch
The Powertrain Control Module (PCM) is a digital
• Proportional Purge Sense
computer containing a microprocessor (Fig. 10). The
• SCI Receive
PCM receives input signals from various switches
• Speed Control
POWERTRAIN CONTROL MODULE (Continued)
• Throttle Position Sensor The PCM adjusts ignition timing based on the fol-
• Torque Management Input (From TCM) lowing inputs.
• Transaxle Control Module (TCM) • Intake Air Temperature
• Transaxle Gear Engagement (From TCM) • Engine Coolant Temperature
• Vehicle Speed (from transmission control mod- • Engine Speed (crankshaft position sensor)
ule) • Knock Sensor
• Manifold Absolute Pressure
NOTE: PCM Outputs: • Park/Neutral (transmission gear selection)
• Transaxle Gear Engagement
• Air Conditioning Clutch Relay • Throttle Position
• Automatic Shut Down (ASD) and Fuel Pump The automatic shut down (ASD) and fuel pump
Relays relays are mounted externally, but turned on and off
• Data Link Connector (PCI and SCI Transmit) by the powertrain control module through the same
• Double Start Override circuit.
• EGR Solenoid The camshaft and crankshaft signals are sent to
• Fuel Injectors the powertrain control module. If the PCM does not
• Generator Field receive both signals within approximately one second
• High Speed Fan Relay of engine cranking, it deactivates the ASD and fuel
• Idle Air Control Motor pump relays. When these relays are deactivated,
• Ignition Coils power is shut off to the fuel injectors, ignition coils,
• Leak Detection Pump fuel pump and the heating element in each oxygen
• Low Speed Fan Relay sensor.
• MTV Actuator The PCM contains a voltage converter that
• Proportional Purge Solenoid changes battery voltage to a regulated 8.0 volts. The
• SRV Valve 8.0 volts power the camshaft position sensor, crank-
• Speed Control Relay shaft position sensor and vehicle speed sensor. The
• Speed Control Vent Relay PCM also provides a 5.0 volts supply for the engine
• Speed Control Vacuum Relay coolant temperature sensor, intake air temperature
• 8 Volt Output sensor, manifold absolute pressure sensor and throt-
• 5 Volt Output tle position sensor.
Based on inputs it receives, the powertrain control The PCM engine control strategy prevents reduced
module (PCM) adjusts fuel injector pulse width, idle idle speeds until after the engine operates for 320 km
speed, ignition timing, and canister purge operation. (200 miles). If the PCM is replaced after 320 km (200
The PCM regulates the cooling fans, air conditioning miles) of usage, update the mileage in new PCM. Use
and speed control systems. The PCM changes gener- the DRB scan tool to change the mileage in the PCM.
ator charge rate by adjusting the generator field. Refer to the appropriate Powertrain Diagnostic Man-
The PCM adjusts injector pulse width (air-fuel ual and the DRB scan tool.
ratio) based on the following inputs.
• Battery Voltage DIAGNOSTIC TROUBLE CODE
• Intake Air Temperature Sensor
• Engine Coolant Temperature DESCRIPTION
• Engine Speed (crankshaft position sensor) A Diagnostic Trouble Code (DTC) indicates the
• Exhaust Gas Oxygen Content (heated oxygen PCM has recognized an abnormal condition in the
sensors) system.
• Manifold Absolute Pressure Remember that DTC’s are the results of a sys-
• Throttle Position tem or circuit failure, but do not directly iden-
The PCM adjusts engine idle speed through the tify the failed component or components.
idle air control motor based on the following inputs.
• Brake Switch NOTE: For a list of DTC’s, refer to the charts in this
• Engine Coolant Temperature section.
• Engine Speed (crankshaft position sensor)
• Park/Neutral (transmission gear selection)
• Transaxle Gear Engagement
• Throttle Position
• Vehicle Speed (from Transmission Control Mod-
ule)
(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC SCAN DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
TOOL CODE
P0071 Ambient Temp Sensor Preformance Ambient change less than 3° C in 200 Miles
P0106 (M) Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
P0111 (M) Intake Air Temp Sensor Preformance Intake Air change less than 3° C in 200 Miles
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 Engine Coolant Temp Performance A rationatilty error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the minimum
acceptable voltage.
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
maximum acceptable voltage.
P0121 (M) TPS Voltage Does Not Agree With TPS signal does not correlate to MAP sensor signal.
MAP
P0122 (M) Throttle Position Sensor Voltage Throttle position sensor input below the acceptable voltage
Low range.
P0123 (M) Throttle Position Sensor Voltage Throttle position sensor input above the maximum
High acceptable voltage.
P0125 (M) Engine Coolant Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0130 1/1 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0136 1/2 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG
operating range.
operating range.
P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected.
TOOL CODE
sensor.
P0143 1/3 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0144 1/3 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0145 1/3 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
P0146 1/3 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor.
P0147 1/3 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
operating range.
P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal
operating range.
P0153 (M) 2/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
sensor.
operating range.
operating range.
P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
sensor.
P0165 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an abnormally
rich correction factor.
P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an abnormally
lean correction factor.
P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an abnormally
rich correction factor.
P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an abnormally
lean correction factor.
P0178 Water in Fuel Sensor Voltage Too Flex fuel sensor input below minimum acceptable voltage.
Low
P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable voltage.
TOOL CODE
P0182 CNG Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage below
acceptable voltage.
P0183 CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage above
acceptable voltage.
P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.
P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.
P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly to
the control signal.
P0206 (M) Injector #6 Control Circuit Injector #6 output driver stage does not respond properly to
the control signal.
P0207 Injector #7 Control Circuit Injector #7 output driver stage does not respond properly to
the control signal.
the control signal.
the control signal.
the control signal.
P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1.
P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7
P0320 No Crank Referance Signal at PCM No reference signal (crankshaft position sensor) detected
during engine cranking.
P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0340 (M) No Cam Signal At PCM No fuel sync
TOOL CODE
P0350 Ignition Coil Draws Too Much A coil (1-5) is drawing too much current.
Current
P0351 (M) Ignition Coil # 1 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
dwell time.
dwell time.
dwell time (High Impedance).
dwell time (High Impedance).
dwell time (high impedance).
P0357 Ignition Coil # 7 Primary Circuit Peak primary circuit current not achieved with maximum
P0358 Ignition Coil # 8 Primary Circuit Peak primary circuit current not achieved with maximum
P0401 (M) EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 (M) EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid
control circuit.
P0404 (M) EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR duty
cycle.
P0405 (M) EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
P0406 (M) EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary air
(air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during
evaporative emission system operation.
P0442 (M) Evap Leak Monitor 0.040 Leak A 0.040 leak has been detected in the evaporative system.
Detected
P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge
solenoid control circuit.
P0455 (M) Evap Leak Monitor Large Leak A large leak has been detected in the evaporative system.
Detected
P0456 Evap Leak Monitor 0.020 Leak A 0.020 leak has been detected in the evaporative system.
Detected
P0460 Fuel Level Unit No Change Over No movement of fuel level sender detected.
Miles
TOOL CODE
P0461 Fuel Level Unit No Changeover No level of fuel level sender detected.
Time
P0462 Fuel Level Sending Unit Volts Too Fuel level sensor input below acceptable voltage.
Low
P0463 Fuel Level Sending Unit Volts Too Fuel level sensor input above acceptable voltage.
High
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0505 (M) Idle Air Control Motor Circuits Replace
P0508 Idle Air Control Motor Circuit Low Idle Air Control Motor Circuit input below acceptable current
P0509 Idle Air Control Motor Circuit High Idle Air Control Motor Circuit input above acceptable current
P0522 Oil Pressure Sens Low Oil pressure sensor input below acceptable voltage.
P0523 Oil Pressure Sens High Oil pressure sensor input above acceptable voltage.
P0551 (M) Power Steering Switch Failure Incorrect input state detected for the power steering switch
circuit. PL: High pressure seen at high speed.
P0600 (M) PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum) detected.
P0604 Internal Trans Controller Transmission control module RAM self test fault detected.
-Aisin transmission.
P0605 Internal Trans Controller Transmission control module ROM self test fault detected
-Aisin transmission.
P0622 (G) Generator Field Not Switching An open or shorted condition detected in the generator field
Properly control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay
control circuit.
P0700 (M) EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or Aisin
controller has an active fault and has illuminated the MIL via
a CCD (EATX) or SCI (Aisin) message. The specific fault
must be acquired from the EATX via CCD or from the Aisin
via ISO-9141.
P0703 (M) Brake Switch Stuck Pressed or Incorrect input state detected in the brake switch circuit.
Released (Changed from P1595).
P0711 Trans Temp Sensor, No Temp Rise Relationship between the transmission temperature and
After Start overdrive operation and/or TCC operation indicates a failure
of the Transmission Temperature Sensor. OBD II Rationality.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage.
P0713 Trans Temp Sensor Voltage Too Transmission fluid temperature sensor input above
P0720 Low Output SPD Sensor RPM, The relationship between the Output Shaft Speed Sensor
Above 15 MPH and vehicle speed is not within acceptable limits.
TOOL CODE
P0740 (M) Torq Con Clu, No RPM Drop at Relationship between engine and vehicle speeds indicated
Lockup failure of torque convertor clutch lock-up system (TCC/PTU
sol).
P0743 Torque Converter Clutch Solenoid/ An open or shorted condition detected in the torque
Trans Relay Circuits converter clutch (part throttle unlock) solenoid control circuit.
Shift solenoid C electrical fault - Aisin transmission
P0748 Governor Pressur Sol Control/Trans An open or shorted condition detected in the Governor
Relay Circuits Pressure Solenoid circuit or Trans Relay Circuit in JTEC RE
transmissions.
P0751 O/D Switch Pressed (Lo) More Than Overdrive override switch input is in a prolonged depressed
5 Minutes state.
P0753 Trans 3-4 Shift Sol/Trans Relay An open or shorted condition detected in the overdrive
Circuits solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions.
P0756 AW4 Shift Sol B (2-3) Functional Shift solenoid B (2-3) functional fault - Aisin transmission
Failure
P0783 3-4 Shift Sol, No RPM Drop at The overdrive solenoid is unable to engage the gear change
Lockup from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open An open or shorted condition detected in the transmission
or Short reverse gear lock-out solenoid control circuit.
P01192 Inlet Air Temp. Circuit Low Inlet Air Temp. sensor input below acceptable voltage
P01193 Inlet Air Temp. Circuit High Inlet Air Temp. sensor input above acceptable voltage.
P1195 (M) 1/1 O2 Sensor Slow During Catalyst A slow switching oxygen sensor has been detected in bank
Monitor 1/1 during catalyst monitor test. (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst A slow switching oxygen sensor has been detected in bank
P1197 1/2 O2 Sensor Slow During Catalyst A slow switching oxygen sensor has been detected in bank
P1198 Radiator Temperature Sensor Volts Radiator coolant temperature sensor input above the
Too High maximum acceptable voltage.
P1199 Radiator Temperature Sensor Volts Radiator coolant temperature sensor input below the
Too Low minimum acceptable voltage.
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating
temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay
control circuit.
P1288 Intake Manifold Short Runner An open or shorted condition detected in the short runner
Solenoid Circuit tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold tuning
valve solenoid control circuit.
P1290 CNG Fuel System Pressure Too Compressed natural gas system pressure above normal
High operating range.
P1291 No Temp Rise Seen From Intake Energizing Heated Air Intake does not change intake air
Heaters temperature sensor an acceptable amount.
TOOL CODE
P1292 CNG Pressure Sensor Voltage Too Compressed natural gas pressure sensor reading above
P1293 CNG Pressure Sensor Voltage Too Compressed natural gas pressure sensor reading below
Low acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been detected.
P1297 (M) No Change in MAP From Start To No difference is recognized between the MAP reading at
Run engine idle and the stored barometric pressure reading.
P1298 Lean Operation at Wide Open A prolonged lean condition is detected during Wide Open
Throttle Throttle.
P1299 (M) Vacuum Leak Found (IAC Fully MAP Sensor signal does not correlate to Throttle Position
Seated) Sensor signal. Possible vacuum leak.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG
P1389 No ASD Relay Output Voltage At No Z1 or Z2 voltage sensed when the auto shutdown relay
PCM is energized.
P1390 (M) Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct.
P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position sensor
has occurred. For PL 2.0L
P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensor’s signal in
preparation for Misfire Diagnostics. Probable defective Crank
Sensor.
P1399 Wait To Start Lamp Cicuit An open or shorted condition detected in the Wait to Start
Lamp circuit.
P1403 No 5 Volts to EGR Sensor Loss of 5v feed to the EGR position sensor.
P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during
aspirator test.(was P0411)
P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during
aspirator test (was P0411).
P1478 (M) Battery Temp Sensor Volts Out of Internal temperature sensor input voltage out of an
Limit acceptable range.
P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission
fan relay circuit.
P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV solenoid
circuit.
P1482 Catalyst Temperature Sensor Circuit Catalyst temperature sensor circuit shorted low.
Shorted Low
P1483 Catalyst Temperature Sensor Circuit Catalyst temperature sensor circuit shorted high.
Shorted High.
P1484 Catalytic Converter Overheat A catalyst overheat condition has been detected by the
Detected catalyst temperature sensor.
TOOL CODE
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 (M) Evap Leak Monitor Pinched Hose LDP has detected a pinched hose in the evaporative hose
Found system.
P1487 Hi Speed Rad Fan CTRL Relay An open or shorted condition detected in the control circuit
Circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too Auxiliary 5 volt sensor feed is sensed to be below an
Low acceptable limit.
P1489 (M) High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control circuit
of the high speed radiator fan control relay.
P1490 (M) Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 (M,G) Ambient/Batt Temp Sen Volts Too External temperature sensor input above acceptable voltage.
High
P1493 (M,G) Ambient/Batt Temp Sen Volts Too External temperature sensor input below acceptable voltage.
Low
P1494 (M) Leak Detection Pump Sw or Incorrect input state detected for the Leak Detection Pump
Mechanical Fault (LDP) pressure switch.
P1495 (M) Leak Detection Pump Solenoid An open or shorted condition detected in the Leak Detection
Circuit Pump (LDP) solenoid circuit.
P1496 (M) 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable limit.
( < 4v for 4 sec ).
P1498 High Speed Rad Fan Ground CTRL An open or shorted condition detected in the control circuit
Rly Circuit of the #3 high speed radiator fan control relay.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the speed
control vacuum or vent solenoid control circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1602 PCM not Programmed
P1680 Clutch Released Switch Circuit
P1681 No I/P Cluster CCD/J1850 No CCD/J1850 messages received from the cluster control
Messages Received module.
TOOL CODE
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in voltage
detected during active test of generator output circuit.
P1683 SPD CTRL PWR Relay; or S/C 12v An open or shorted condition detected in the speed control
Driver CKT servo power control circuit. (SBECII: ext relay).
P1684 Battery Loss In The Last 50 Starts The battery has been disconnected within the last 50 starts.
P1685 Skim Invalid Key The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1693 DTC Detected in Companion Module A fault has been generated in the companion engine control
module.
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission.
P1695 No CCD/J1850 Message From Body No CCD/J1850 messages received from the body control
Control Module module.
P1696 (M) PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the
control module.
P1697 (M) PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder Indicator
(SRI or EMR) mileage in the control module EEPROM.
P1698 (M) No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin transmission
controller.
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1756 GOV Press Not Equal to Target @ The requested pressure and the actual pressure are not
15-20 PSI within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control shifts
for 1st, 2nd, and 3rd gear. (Mid Pressure Malfunction)
P1757 GOV Press Not Equal to Target @ The requested pressure and the actual pressure are not
15-20 PSI within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control shifts
for 1st, 2nd, and 3rd gear (Zero Pressure Malfunction)
P1762 Gov Press Sen Offset Volts Too Low The Governor Pressure Sensor input is greater than a
or High calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1763 Governor Pressure Sensor Volts Too The Governor Pressure Sensor input is above an acceptable
Hi voltage level.
P1764 Governor Pressure Sensor Volts Too The Governor Pressure Sensor input is below an acceptable
Low voltage level.
P1765 Trans 12 Volt Supply Relay CTRL An open or shorted condition is detected in the Transmission
Circuit Relay control circuit. This relay supplies power to the TCC>
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
OPERATION - SENSOR RETURN - PCM INPUT There are two different areas of operation, OPEN
The sensor return circuit provides a low electrical LOOP and CLOSED LOOP.
noise ground reference for all of the systems sensors. During OPEN LOOP modes the PCM receives
The sensor return circuit connects to internal ground input signals and responds according to preset PCM
circuits within the Powertrain Control Module programming. Inputs from the upstream and down-
(PCM). stream heated oxygen sensors are not monitored dur-
ing OPEN LOOP modes, except for heated oxygen
OPERATION - SCI RECEIVE - PCM INPUT sensor diagnostics (they are checked for shorted con-
SCI Receive is the serial data communication ditions at all times).
receive circuit for the DRB scan tool. The Powertrain During CLOSED LOOP modes the PCM monitors
Control Module (PCM) receives data from the DRB the inputs from the upstream and downstream
through the SCI Receive circuit. heated oxygen sensors. The upstream heated oxygen
sensor input tells the PCM if the calculated injector
OPERATION - IGNITION SENSE - PCM INPUT pulse width resulted in the ideal air-fuel ratio of 14.7
to one. By monitoring the exhaust oxygen content
The ignition sense input informs the Powertrain
through the upstream heated oxygen sensor, the
Control Module (PCM) that the ignition switch is in
PCM can fine tune injector pulse width. Fine tuning
the crank or run position.
injector pulse width allows the PCM to achieve opti-
mum fuel economy combined with low emissions.
OPERATION - PCM GROUND
For the PCM to enter CLOSED LOOP operation,
Ground is provided through multiple pins of the
the following must occur:
PCM connector. Depending on the vehicle there may
(1) Engine coolant temperature must be over 35°F.
be as many as three different ground pins. There are
• If the coolant is over 35° the PCM will wait 44
power grounds and sensor grounds.
seconds.
The power grounds are used to control the ground
• If the coolant is over 50°F the PCM will wait 38
side of any relay, solenoid, ignition coil or injector.
seconds.
The signal ground is used for any input that uses
• If the coolant is over 167°F the PCM will wait
sensor return for ground, and the ground side of any
11 seconds.
internal processing component.
(2) For other temperatures the PCM will interpo-
The SBEC III case is shielded to prevent RFI and
late the correct waiting time.
EMI. The PCM case is grounded and must be firmly
(3) O2 sensor must read either greater than 0.745
attached to a good, clean body ground.
volts or less than 0.1 volt.
Internally all grounds are connected together, how-
(4) The multi-port fuel injection systems has the
ever there is noise suppression on the sensor ground.
following modes of operation:
For EMI and RFI protection the case is also
• Ignition switch ON (Zero RPM)
grounded separately from the ground pins.
• Engine start-up
• Engine warm-up
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT • Cruise
The PCM supplies 8 volts to the crankshaft posi- • Idle
tion sensor, camshaft position sensor. • Acceleration
• Deceleration
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT • Wide Open Throttle
The PCM supplies 5 volts to the following sensors: • Ignition switch OFF
• A/C pressure transducer (5) The engine start-up (crank), engine warm-up,
• Engine coolant temperature sensor deceleration with fuel shutoff and wide open throttle
• Manifold absolute pressure sensor modes are OPEN LOOP modes. Under most operat-
• Throttle position sensor ing conditions, the acceleration, deceleration (with
• Linear EGR solenoid A/C on), idle and cruise modes, with the engine at
operating temperature are CLOSED LOOP modes.
OPERATION - MODES OF OPERATION
As input signals to the PCM change, the PCM IGNITION SWITCH ON (ZERO RPM) MODE
adjusts its response to output devices. For example, When the ignition switch activates the fuel injec-
the PCM must calculate a different injector pulse tion system, the following actions occur:
width and ignition timing for idle than it does for • The PCM monitors the engine coolant tempera-
Wide Open Throttle (WOT). There are several differ- ture sensor and throttle position sensor input. The
ent modes of operation that determine how the PCM
responds to the various input signals.
PCM determines basic fuel injector pulse width from ENGINE WARM-UP MODE
this input. This is an OPEN LOOP mode. The following inputs
• The PCM determines atmospheric air pressure are received by the PCM:
from the MAP sensor input to modify injector pulse • Engine coolant temperature
width. • Manifold Absolute Pressure (MAP)
When the key is in the ON position and the engine • Inlet/Intake air temperature (IAT)
is not running (zero rpm), the Auto Shutdown (ASD) • Crankshaft position (engine speed)
and fuel pump relays de-energize after approximately • Camshaft position
1 second. Therefore, battery voltage is not supplied to • Knock sensor
the fuel pump, ignition coil, fuel injectors and heated • Throttle position
oxygen sensors. • A/C switch
• Battery voltage
ENGINE START-UP MODE • Vehicle speed
This is an OPEN LOOP mode. If the vehicle is in • Speed control
park or neutral (automatic transaxles) or the clutch • O2 sensors
pedal is depressed (manual transaxles) the ignition The PCM adjusts injector pulse width and controls
switch energizes the starter relay. The following injector synchronization by turning the individual
actions occur when the starter motor is engaged. ground paths to the injectors On and Off.
• If the PCM receives the camshaft position sensor The PCM adjusts ignition timing and engine idle
and crankshaft position sensor signals, it energizes speed. Engine idle speed is adjusted through the idle
the Auto Shutdown (ASD) relay and fuel pump relay. air control motor.
If the PCM does not receive both signals within
approximately one second, it will not energize the CRUISE OR IDLE MODE
ASD relay and fuel pump relay. The ASD and fuel When the engine is at operating temperature this
pump relays supply battery voltage to the fuel pump, is a CLOSED LOOP mode. During cruising or idle
fuel injectors, ignition coil and heated oxygen sen- the following inputs are received by the PCM:
sors. • Inlet/Intake air temperature
• The PCM energizes the injectors (on the 69° • Engine coolant temperature
degree falling edge) for a calculated pulse width until • Manifold absolute pressure
it determines crankshaft position from the camshaft • Crankshaft position (engine speed)
position sensor and crankshaft position sensor sig- • Camshaft position
nals. The PCM determines crankshaft position within • Knock sensor
1 engine revolution. • Throttle position
• After determining crankshaft position, the PCM • Exhaust gas oxygen content
begins energizing the injectors in sequence. It adjusts • A/C control positions
injector pulse width and controls injector synchroni- • Battery voltage
zation by turning the individual ground paths to the • Vehicle speed
injectors On and Off. The PCM adjusts injector pulse width and controls
• When the engine idles within 664 RPM of its injector synchronization by turning the individual
target RPM, the PCM compares current MAP sensor ground paths to the injectors On and Off.
value with the atmospheric pressure value received The PCM adjusts engine idle speed and ignition
during the Ignition Switch On (zero RPM) mode. timing. The PCM adjusts the air/fuel ratio according
Once the ASD and fuel pump relays have been to the oxygen content in the exhaust gas (measured
energized, the PCM determines injector pulse width by the upstream and downstream heated oxygen sen-
based on the following: sor).
• Battery voltage The PCM monitors for engine misfire. During
• Engine coolant temperature active misfire and depending on the severity, the
• Engine RPM PCM either continuously illuminates or flashes the
• Inlet/Intake air temperature (IAT) malfunction indicator lamp (Check Engine light on
• MAP instrument panel). Also, the PCM stores an engine
• Throttle position misfire DTC in memory.
• The number of engine revolutions since cranking The PCM performs several diagnostic routines.
was initiated They include:
During Start-up the PCM maintains ignition tim- • Oxygen sensor monitor
ing at 9° BTDC. • Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
• Fuel system monitor WIDE-OPEN-THROTTLE MODE
• EGR monitor This is an OPEN LOOP mode. During wide-open-
• Purge system monitor throttle operation, the following inputs are used by
• All inputs monitored for proper voltage range. the PCM:
• All monitored components (refer to the Emission • Inlet/Intake air temperature
section for On-Board Diagnostics). • Engine coolant temperature
The PCM compares the upstream and downstream • Engine speed
heated oxygen sensor inputs to measure catalytic • Knock sensor
convertor efficiency. If the catalyst efficiency drops • Manifold absolute pressure
below the minimum acceptable percentage, the PCM • Throttle position
stores a diagnostic trouble code in memory. When the PCM senses a wide-open-throttle condi-
During certain idle conditions, the PCM may enter tion through the Throttle Position Sensor (TPS) it de-
a variable idle speed strategy. During variable idle energizes the A/C compressor clutch relay. This
speed strategy the PCM adjusts engine speed based disables the air conditioning system.
on the following inputs. The PCM does not monitor the heated oxygen sen-
• A/C sense sor inputs during wide-open-throttle operation except
• Battery voltage for downstream heated oxygen sensor and both
• Battery temperature shorted diagnostics. The PCM adjusts injector pulse
• Engine coolant temperature width to supply a predetermined amount of addi-
• Engine run time tional fuel.
• Inlet/Intake air temperature
• Vehicle mileage IGNITION SWITCH OFF MODE
When the operator turns the ignition switch to the
ACCELERATION MODE OFF position, the following occurs:
This is a CLOSED LOOP mode. The PCM recog- • All outputs are turned off, unless 02 Heater
nizes an abrupt increase in Throttle Position sensor Monitor test is being run. Refer to the Emission sec-
output voltage or MAP sensor output voltage as a tion for On-Board Diagnostics.
demand for increased engine output and vehicle • No inputs are monitored except for the heated
acceleration. The PCM increases injector pulse width oxygen sensors. The PCM monitors the heating ele-
in response to increased fuel demand. ments in the oxygen sensors and then shuts down.
DECELERATION MODE STANDARD PROCEDURES - OBTAINING

This is a CLOSED LOOP mode. During decelera-
DIAGNOSTIC TROUBLE CODES
tion the following inputs are received by the PCM:
• A/C sense
BULB CHECK
• Battery voltage
Each time the ignition key is turned to the ON
• Inlet/Intake air temperature
position, the malfunction indicator (check engine)
• Engine coolant temperature
lamp on the instrument panel should illuminate for
• Crankshaft position (engine speed)
approximately 2 seconds then go out. This is done for
• Exhaust gas oxygen content (upstream heated
a bulb check. When the key is in the power on, but
oxygen sensor)
engine off position, the MIL will remain illuminated
• Knock sensor
for regulatory purposes.
• Manifold absolute pressure
• Throttle position
OBTAINING DTC’S USING DRB SCAN TOOL
• IAC motor control changes in response to MAP
(1) Connect the DRB scan tool to the data link
sensor feedback
(diagnostic) connector. This connector is located in
The PCM may receive a closed throttle input from
the passenger compartment; at the lower edge of
the Throttle Position Sensor (TPS) when it senses an
instrument panel; near the steering column.
abrupt decrease in manifold pressure. This indicates
(2) Turn the ignition switch on and access the
a hard deceleration. In response, the PCM may
“Read Fault” screen.
momentarily turn off the injectors. This helps
(3) Record all the DTC’s and “freeze frame” infor-
improve fuel economy, emissions and engine braking.
mation shown on the DRB scan tool.
(4) To erase DTC’s, use the “Erase Trouble Code”
data screen on the DRB scan tool. Do not erase any
DTC’s until problems have been investigated
and repairs have been performed.
OBTAINING DTC’S USING IGNITION KEY

(1) Cycle the ignition key On - Off - On - Off - On
within 5 seconds.
(2) The Odometer will show the P-code for the
DTC code number. Refer to the Emission section for
the DTC chart for a detailed explanation of the DTC
codes.
(3) If no DTC’s are present, the cluster will display
one of two texts: “P1684” and “done” or only “done”.
• P1684 is only a status and indicates that the
PCM memory has been cleared within the last 50
ignition cycles and does not indicate a problem.
• done indicates that NO DTCs are present and
the procedure is complete.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the battery shield, refer to the Battery Fig. 12 PCM LOWER BOLT
section for more information. (7) Remove PCM.
(3) Remove the 2 upper PCM bracket bolts (Fig.
11). INSTALLATION
(1) Install the PCM.
(2) Install the lower PCM mounting bolt. Tighten
bolt.
(3) Install the 2 upper PCM bracket bolts. Tighten
bolt.
(4) Install the headlamp, refer to the Lamps sec-
tion for more information.
(5) Install the 2 PCM connectors.
(6) Install the battery shield, refer to the Battery
section for more information.
SENTRY KEY IMMOBILIZER

MODULE
DESCRIPTION
The Sentry Key Immobilizer Module (SKIM) con-
tains a Radio Frequency (RF) transceiver and a
microprocessor. The SKIM retains in memory the ID
numbers of any Sentry Key that is programmed to it.
The maximum number of keys that may be pro-
Fig. 11 PCM grammed to each module is eight (8). The SKIM also
1 - Attaching Bolts communicates over the PCI bus with the Powertrain
Control Module (PCM), the Body Control Module
(4) Remove the 2 PCM connectors. (BCM), and the DRB IIIt scan tool. The SKIM trans-
(5) Remove the headlamp, refer to the Lamps sec- mits and receives RF signals through a tuned
tion for more information. antenna enclosed within a molded plastic ring forma-
(6) Remove the lower PCM mounting bolt (Fig. 12). tion that is integral to the SKIM housing. When the
SENTRY KEY IMMOBILIZER MODULE (Continued)
SKIM is properly installed on the steering column, SKIM detects an invalid key OR a key-related fault
the antenna ring fits snugly around the circumfer- exists, the indicator light will flash following the
ence of the ignition lock cylinder housing. If this ring indicator light test. The SKIM may also request an
is not mounted properly, communication problems audible chime if the customer key programming fea-
may arise in the form of transponder-related faults. ture is available and the procedure is being utilized.
For added system security, each SKIM is pro- Refer to Electrical, Vehicle Theft Security, Transpon-
grammed with a unique 9Secret Key9 code. This code der Key, Standard Procedure - Transponder Program-
is stored in memory and is sent over the PCI bus to ming.
the PCM and to each key that is programmed to
work with the vehicle. The 9Secret Key9 code is there- REMOVAL
fore a common element found in all components of (1) Disconnect and isolate the battery negative
the Sentry Key Immobilizer System (SKIS). In the cable.
event that a SKIM replacement is required, the (2) Remove Lower Instrument Panel Cover. Refer
9Secret Key9 code can be restored from the PCM by to Body, Instrument Panel, Lower Instrument Panel
following the SKIM replacement procedure found in Cover, Removal.
the DRB IIIt scan tool. Proper completion of this (3) Remove the steering column upper and lower
task will allow the existing ignition keys to be repro- shrouds. Refer to Steering, Column, Column Shroud,
grammed. Therefore, new keys will NOT be needed. Removal.
In the event that the original 9Secret Key9 code can (4) Disengage the steering column wire harness
not be recovered, new ignition keys will be required. from the Sentry Key Immobilizer Module (SKIM).
The DRB IIIt scan tool will alert the technician if (5) Remove the one screws securing the SKIM to
key replacement is necessary. Another security code, the steering column.
called a PIN, is used to gain secured access to the (6) Rotate the SKIM upwards and then to the side
SKIM for service. The SKIM also stores in its mem- away from the steering column to slide the SKIM
ory the Vehicle Identification Number (VIN), which it antenna ring from around the ignition switch lock
learns through a bus message from the assembly cylinder housing.
plant tester. The SKIS scrambles the information (7) Remove the SKIM from the vehicle.
that is communicated between its components in
order to reduce the possibility of unauthorized SKIM INSTALLATION
access and/or disabling. (1) Slip the SKIM antenna ring around the igni-
tion switch lock cylinder housing. Rotate the SKIM
OPERATION downwards and then towards the steering column.
When the ignition switch is moved to the RUN (2) Install the one screws securing the SKIM to
position, the SKIM transmits an RF signal to the the steering column.
transponder in the ignition key. The SKIM then (3) Engage the steering column wire harness from
waits for a response RF signal from the transponder the Sentry Key Immobilizer Module (SKIM).
in the key. If the response received identifies the key (4) Install the steering column upper and lower
as valid, the SKIM sends a 9valid key9 message to shrouds. Refer to Steering, Column, Column Shroud,
the PCM over the PCI bus. If the response received Installation.
identifies the key as invalid or no response is (5) Install the Lower Instrument Panel Cover.
received from the transponder in the ignition key, the Refer to Body, Instrument Panel, Lower Instrument
SKIM sends an 9invalid key9 message to the PCM. Panel Cover, Installation.
The PCM will enable or disable engine operation (6) Connect the battery negative cable.
based upon the status of the SKIM messages. It is
important to note that the default condition in the
PCM is 9invalid key.9 Therefore, if no response is SLIDING DOOR CONTROL
received by the PCM, the engine will be immobilized MODULE
after two (2) seconds of running.
The SKIM also sends indicator light status mes-
DESCRIPTION
sages to the BCM to operate the light. This is the
Vehicles equipped with a power sliding door utilize
method used to turn the light ON solid or to flash it
a sliding door control module. The sliding door con-
after the indicator light test is complete to signify a
trol module is located behind the sliding door trim
fault in the SKIS. If the light comes ON and stays
panel in the center of the door, just above the sliding
ON solid after the indicator light test, this signifies
door motor. This module controls the operation of the
that the SKIM has detected a system malfunction
door through the Programmable Communication
and/or that the SKIS has become inoperative. If the
Interface (PCI) J1850 data bus circuit and the Body
SLIDING DOOR CONTROL MODULE (Continued)
Control Module. The sliding door control module con- from module) and depress connector retaining tab,
tains software technology which enables it to detect while pulling straight apart.
resistance to door travel and to reverse door travel in (5) Remove the control module retaining screw.
order to avoid damage to the door or to avoid possible (6) Remove the module from the vehicle.
personal injury if the obstruction is a person. This
feature functions in both the opening and closing INSTALLATION
cycles. If the power sliding door system develops any (1) Position the control module and install the
problems the control module will store and recall retaining screw.
Diagnostic Trouble Codes (DTC). The use of a diag- (2) Connect the control module electrical connec-
nostic scan tool, such as the DRB IIIt is required to tors. Slide the locking tab into the locked position.
read and troubleshoot these trouble codes. The slid- (3) Install the appropriate door trim panel on the
ing door control module can be reflashed if necessary. vehicle. Refer to Body for the procedure.
Refer to the latest Technical Service Bulletin (TSB) (4) Install the weather shield. Refer to Body for
Information for any updates. the procedure.
The power door control module is a replaceable (5) Connect the negative battery cable.
component and cannot be repaired, if found to be (6) Using an appropriate scan tool, check and
faulty it must be replaced. Consult your Mopary erase any power door control module diagnostic trou-
parts catalog for a specific part number. ble codes.
(7) Verify power door system operation. Cycle the
OPERATION power door through one complete open and close
The power sliding door control module serves as cycle.
the main computer for the power sliding side door
system. All power door functions are processed
through the power door control module and/or the TRANSMISSION CONTROL
vehicles body control module (BCM). At the start of a MODULE
power open command, a signal is sent to the BCM
and then to the power door control module via the DESCRIPTION
J1850 data bus circuit. This signal, generated by any The Transmission Control Module (TCM) is located
of the power door command switches, tells the power behind the left fender and is fastened with three
door control module to activate a power latch release, screws to three clips in the left frame rail forward of
engage the clutch assembly and drive the door into the suspension (Fig. 13).
the full open position. If an obstacle is felt during
this power open cycle, the module will reverse direc-
OPERATION
tion and close the door. This process is also enabled
The TCM is the controlling unit for all electronic
during a power close cycle. This process will repeat
operations of the transaxle. The TCM receives infor-
three times, and if a fourth obstacle is detected, the
mation regarding vehicle operation from both direct
door will go into full manual mode. Once the full
and indirect inputs, and selects the operational mode
open position is obtained, a hold open latch assembly
of the transaxle. Direct inputs are hardwired to, and
mounted full open switch tells the control module
used specifically by the TCM. Indirect inputs origi-
that the door has reached the full open position. If
nate from other components/modules, and are shared
the power sliding door system develops any problems
with the TCM via the communication bus.
the control module will store and recall Diagnostic
Some examples of direct inputs to the TCM are:
Trouble Codes (DTC). The use of a diagnostic scan
• Battery (B+) voltage
tool, such as the DRB IIIt is required to read and
• Ignition “ON” voltage
troubleshoot these trouble codes.
• Transmission Control Relay (Switched B+)
• Throttle Position Sensor
REMOVAL • Crankshaft Position Sensor (CKP)
• Transmission Range Sensor (TRS)
cable.
• Pressure Switches (L/R, 2/4, OD)
(2) Remove the appropriate door trim panel from
• Transmission Temperature Sensor (Integral to
the vehicle. Refer to Body for the procedure.
TRS)
(3) Remove the weather shield. Refer to Body for
• Input Shaft Speed Sensor
the procedure.
(4) Disconnect the power door control module elec-
trical connectors. Slide the red locking tab out (away
TRANSMISSION CONTROL MODULE (Continued)
• Diagnostic capabilities (with DRB scan tool)
CLUTCH VOLUME INDEX (CVI)

An important function of the TCM is to monitor
Clutch Volume Index (CVI). CVIs represent the vol-
ume of fluid needed to compress a clutch pack.
The TCM monitors gear ratio changes by monitor-
ing the Input and Output Speed Sensors. The Input,
or Turbine Speed Sensor sends an electrical signal to
the TCM that represents input shaft rpm. The Out-
put Speed Sensor provides the TCM with output
shaft speed information.
By comparing the two inputs, the TCM can deter-
mine transaxle gear ratio. This is important to the
CVI calculation because the TCM determines CVIs
by monitoring how long it takes for a gear change to
occur (Fig. 14).
Fig. 13 Transmission Control Module (TCM)

Location
1 - TRANSMISSION CONTROL MODULE (TCM)
• Output Shaft Speed Sensor

Some examples of indirect inputs to the TCM
are:
• Engine/Body Identification
• Manifold Pressure
• Target Idle
• Torque Reduction Confirmation
• Speed Control ON/OFF Switch
• Engine Coolant Temperature
• Ambient/Battery Temperature
• Brake Switch Status
• DRB Communication
Based on the information received from these var-
ious inputs, the TCM determines the appropriate
shift schedule and shift points, depending on the
present operating conditions and driver demand. Fig. 14 Example of CVI Calculation
This is possible through the control of various direct 1 - OUTPUT SPEED SENSOR
and indirect outputs. 2 - OUTPUT SHAFT
Some examples of TCM direct outputs are: 3 - CLUTCH PACK
• Transmission Control Relay 4 - SEPARATOR PLATE
• Solenoids (LR/CC, 2/4, OD and UD) 5 - FRICTION DISCS
• Vehicle Speed (to PCM) 6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
• Torque Reduction Request (to PCM)
8 - PISTON AND SEAL
An example of a TCM indirect output is:
• Transmission Temperature (to PCM)
In addition to monitoring inputs and controlling Gear ratios can be determined by using the DRB
outputs, the TCM has other important responsibili- Scan Tool and reading the Input/Output Speed Sen-
ties and functions: sor values in the “Monitors” display. Gear ratio can
• Storing and maintaining Clutch Volume Indices be obtained by dividing the Input Speed Sensor value
(CVI) by the Output Speed Sensor value.
• Storing and selecting appropriate Shift Sched- For example, if the input shaft is rotating at 1000
ules rpm and the output shaft is rotating at 500 rpm,
• System self-diagnostics then the TCM can determine that the gear ratio is
2:1. In direct drive (3rd gear), the gear ratio changes Certain mechanical problems within the clutch
to 1:1. The gear ratio changes as clutches are applied assemblies (broken return springs, out of position
and released. By monitoring the length of time it snap rings, excessive clutch pack clearance, improper
takes for the gear ratio to change following a shift assembly, etc.) can cause inadequate or out-of-range
request, the TCM can determine the volume of fluid clutch volumes. Also, defective Input/Output Speed
used to apply or release a friction element. Sensors and wiring can cause these conditions. The
The volume of transmission fluid needed to apply following chart identifies the appropriate clutch vol-
the friction elements are continuously updated for umes and when they are monitored/updated:
adaptive controls. As friction material wears, the vol-
ume of fluid need to apply the element increases.
CLUTCH VOLUMES
When Updated Proper Clutch
Clutch
Shift Sequence Oil Temperature Throttle Angle Volume
2-1 or 3-1 coast
L/R > 70° < 5° 35 to 83
downshift
2/4 1-2 shift 20 to 77
5 - 54°
OD 2-3 shift > 110° 48 to 150
UD 4-3 or 4-2 shift > 5° 24 to 70
SHIFT SCHEDULES • Engine load

As mentioned earlier, the TCM has programming • Fluid temperature
that allows it to select a variety of shift schedules. • Software level
Shift schedule selection is dependent on the follow- As driving conditions change, the TCM appropri-
ing: ately adjusts the shift schedule. Refer to the follow-
• Shift lever position ing chart to determine the appropriate operation
• Throttle position expected, depending on driving conditions.
Schedule Condition Expected Operation

Extreme Cold Oil temperature at start-up below Park, Reverse, Neutral and 2nd
-16° F gear only (prevents shifting which
may fail a clutch with frequent
shifts)
Cold Oil temperature at start-up above – Delayed 2-3 upshift
-12° F and below 36° F (approximately 22-31 mph)
– Delayed 3-4 upshift (45-53 mph)
– Early 4-3 costdown shift
(approximately 30 mph)
– Early 3-2 coastdown shift
(approximately 17 mph)
– High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
– No EMCC
Warm Oil temperature at start-up above – Normal operation (upshift,
36° F and below 80 degree F kickdowns, and coastdowns)
– No EMCC
Schedule Condition Expected Operation

Hot Oil temperature at start-up above – Normal operation (upshift,
80° F kickdowns, and coastdowns)
– Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
Overheat Oil temperature above 240° F or – Delayed 2-3 upshift (25-32 mph)
engine coolant temperature above – Delayed 3-4 upshift (41-48 mph)
244° F
– 3rd gear FEMCC from 30-48 mph
– 3rd gear PEMCC from 27-31 mph
Super Overheat Oil temperature above 260° F – All 9Overheat9 shift schedule
features apply
– 2nd gear PEMCC above 22 mph
– Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE - PINION FACTOR NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
SETTING
formed:
NOTE: This procedure must be performed if the
• Transaxle Assembly Replacement
Transmission Control Module (TCM) has been
• Transmission Control Module Replacement
replaced with a NEW or replacement unit. Failure to
• Solenoid/Pressure Switch Assembly Replacement
perform this procedure will result in an inoperative
• Clutch Plate and/or Seal Replacement
or improperly calibrated speedometer.
• Valve Body Replacement or Recondition
The vehicle speed readings for the speedometer are To perform the Quick Learn Procedure, the follow-
taken from the output speed sensor. The TCM must ing conditions must be met:
be calibrated to the different combinations of equip- • The brakes must be applied
ment (final drive and tires) available. Pinion Factor • The engine speed must be above 500 rpm
allows the technician to set the Transmission Control • The throttle angle (TPS) must be less than 3
Module initial setting so that the speedometer read- degrees
ings will be correct. To properly read and/or reset the • The shift lever position must stay until
Pinion Factor, it is necessary to use a DRB scan tool. prompted to shift to overdrive
(1) Plug the DRB scan tool into the diagnostic con- • The shift lever position must stay in overdrive
nector located under the instrument panel. after the Shift to Overdrive prompt until the DRB
(2) Select the Transmission menu. indicates the procedure is complete
(3) Select the Miscellaneous menu. • The calculated oil temperature must be above
(4) Select Pinion Factor. Then follow the instruc- 60° and below 200°
tions on the DRB scan tool screen. (1) Plug the DRB scan tool into the diagnostic con-
nector. The connector is located under the instrument
STANDARD PROCEDURE - QUICK LEARN panel.
(2) Go to the Transmission screen.
PROCEDURE (3) Go to the Miscellaneous screen.
The quick learn procedure requires the use of the (4) Select Quick Learn Procedure. Follow the
DRB scan tool. This program allows the electronic instructions of the DRB to perform the Quick Learn
transaxle system to recalibrate itself. This will pro- Procedure.
vide the best possible transaxle operation.
2001 RS Service Manual
TRANSMISSION CONTROL MODULE (Continued) Publication No. 81-370-1005
TSB 26-03-01 March, 2001
STANDARD PROCEDURE - TCC BREAK-IN (1) Disconnect battery negative cable.

VIEW/RESTART PROCEDURE
(3) Remove left front tire/wheel assembly.
The Transmission Control Module (TCM) employs
(4) Pull back splash shield to gain access to TCM
a strategy which modifies torque converter clutch
location.
(TCC) operation. This strategy conditions the torque
(5) Disconnect TCM 60-way connector (Fig. 15).
converter clutch disc for optimum converter clutch
engagement and feel throughout the life of the trans-
axle. The cycle inhibits FEMCC until six hours of
PEMCC operation have taken place, or the vehicle
has been driven 6,035 km (3750 miles). The cycle
automatically terminates when either the time or
mileage has been achieved, however, the mileage
may vary slightly from vehicle to vehicle.
The TCC break-in cycle must be restarted using
the DRB Scan Tool, and upon:
• Replacement of TCM on vehicle with less than
6,035 km (3750 miles) or less than 6 hours of
PEMCC operation
• Replacement of torque converter assembly at
any vehicle mileage
NOTE: Failure to restart the TCC Break-In Cycle

upon TCM replacement in vehicles with less than Fig. 15 Transmission Control Module 60-way
six hours of PEMCC or less than 6,035 km (3750 Connector
miles), or upon torque converter replacement at any 1 - TRANSMISSION CONTROL MODULE (TCM)
mileage, may result in vehicle shudder during cer- 2 - 60-WAY CONNECTOR
tain operating conditions.
(6) Remove three (3) TCM-to-rail screws and
Procedure remove TCM from vehicle (Fig. 16).
The DRB Scan Tool is required to view and/or
restart the TCC Break-In cycle.
(1) Connect the DRB Scan Tool to the vehicle diag-
nostic connector.
(2) Navigate to “TCC Break-In” via Transmission/
Transmission Control Module/Miscellaneous.
(3) View or Start TCC Break-In as prompted by
DRB menu.
REMOVAL
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE) If vehicle has less than 6,035 km
Fig. 16 Transmission Control Module Removal/
(3750 miles), the Torque Converter Clutch (TCC)
Installation
Break-In Strategy reset procedure must also be per-
1 - SCREW
3 - CLIP
MODULE - STANDARD PROCEDURE) 4 - LEFT RAIL
2001 RS Service Manual
TRANSMISSION CONTROL MODULE (Continued) Publication No. 81-370-1005
TSB 26-03-01 March, 2001
INSTALLATION (2) Install TCM harness 60–way connector (Fig.

18) and torque to 4 N·m (35 in. lbs.).
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
NOTE: If TCM is replaced and vehicle has less than

6,035 km (3750 miles), the Torque Converter Clutch
(TCC) Break-In Strategy reset procedure must also
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
Fig. 18 Transmission Control Module 60-way
(1) Install TCM into position (Fig. 17). Install Connector
three (3) screws and torque to 3 N·m (30 in. lbs.). 1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
(3) Install splash shield into position with fasten-

ers.
(4) Install left front wheel/tire assembly.
(5) Lower vehicle.
(7) If TCM was replaced, reset Pinion Factor and
Quick Learn. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE).
(8) If TCM was replaced and vehicle has less than
6,035 km (3750 miles), perform TCC Break-In reset
procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC
MODULE - STANDARD PROCEDURE)
Fig. 17 Transmission Control Module Removal/
Installation
1 - SCREW
3 - CLIP
4 - LEFT RAIL
RS ENGINE SYSTEMS 8F - 1
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BATTERY HOLDDOWN
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BATTERY CABLES
BATTERY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 8 BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 BATTERY TRAY
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKING BATTERY ELECTROLYTE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BUILT- IN INDICATOR TEST . . . . . . . . . . . . . . . 11 THERMAL GUARD
HYDROMETER TEST . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . 12 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 14 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8F - 2 BATTERY SYSTEM RS
BATTERY SYSTEM sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
DESCRIPTION
of electrical energy to supplement the charging sys-
A single 12-volt battery system is standard factory-
tem for short durations while the engine is running
installed equipment on this model. All of the compo-
and the electrical current demands of the vehicle
nents of the battery system are located within the
exceed the output of the charging system. In addition
engine compartment of the vehicle. The service infor-
to delivering, and storing electrical energy for the
mation for the battery system in this vehicle covers
vehicle, the battery system serves as a capacitor and
the following related components, which are covered
voltage stabilizer for the vehicle electrical system. It
in further detail elsewhere in this service manual:
absorbs most abnormal or transient voltages caused
• Battery - The storage battery provides a reli-
by the switching of any of the electrical components
able means of storing a renewable source of electrical
or circuits in the vehicle.
energy within the vehicle.
• Battery Cable - The battery cables connect the
battery terminal posts to the vehicle electrical sys-
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
tem.
vehicle operate with one another and must be tested
• Battery Holddown - The battery holddown
as a single complete system. In order for the engine
hardware secures the battery in the battery tray in
to start and the battery to charge properly, all of the
the engine compartment.
components that are used in these systems must per-
• Battery Thermoguard - The battery thermo-
form within specifications. It is important that the
guard insulates the battery to protect it from engine
battery, starting, and charging systems be thoroughly
compartment temperature extremes.
tested and inspected any time a battery needs to be
• Battery Tray - The battery tray provides a
charged or replaced. The cause of abnormal battery
secure mounting location in the vehicle for the bat-
discharge, overcharging or early battery failure must
tery and an anchor point for the battery holddown
be diagnosed and corrected before a battery is
hardware.
replaced and before a vehicle is returned to service.
For battery system maintenance schedules and
The service information for these systems has been
jump starting procedures, see the owner’s manual in
separated within this service manual to make it eas-
the vehicle glove box. Optionally, refer to Lubrication
ier to locate the specific information you are seeking.
and Maintanance for the recommended battery main-
However, when attempting to diagnose any of these
tenance schedules and for the proper battery jump
systems, it is important that you keep their interde-
starting procedures. While battery charging can be
pendency in mind.
considered a maintenance procedure, the battery
The diagnostic procedures used for the battery,
charging procedures and related information are
starting, and charging systems include the most
located in the standard procedures section of this ser-
basic conventional diagnostic methods, to the more
vice manual. This was done because the battery must
sophisticated On-Board Diagnostics (OBD) built into
be fully-charged before any battery system diagnosis
the Powertrain Control Module (PCM). Use of an
or testing procedures can be performed. Refer to
induction-type milliampere ammeter, a volt/ohmme-
Standard procedures for the proper battery charging
ter, a battery charger, a carbon pile rheostat (load
procedures.
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
OPERATION
Each monitored circuit is assigned a Diagnostic Trou-
The battery system is designed to provide a safe,
ble Code (DTC). The PCM will store a DTC in elec-
efficient, reliable and mobile means of delivering and
tronic memory for any failure it detects. Refer to
storing electrical energy. This electrical energy is
Charging System for the proper charging system on-
required to operate the engine starting system, as
board diagnostic test procedures.
well as to operate many of the other vehicle acces-
RS BATTERY SYSTEM 8F - 3
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS 1. The battery has an 1. Refer to Battery Specifications for the proper
WEAK OR DEAD WHEN incorrect size or rating for size and rating. Replace an incorrect battery, as
ATTEMPTING TO START this vehicle. required.
THE ENGINE.
2. The battery is physically 2. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the damaged
battery, as required.
3. The battery terminal 3. Refer to Battery Cable for the proper cable
connections are loose or diagnosis and testing procedures. Clean and
corroded. tighten the battery terminal connections, as
required.
4. The battery is discharged. 4. Determine the battery state-of-charge. Refer to
Standard Procedures for the proper test
procedures. Charge the faulty battery, as
required.
5. The electrical system 5. Refer to Standard Procedures for the proper
ignition-off draw is excessive. test procedures. Repair the faulty electrical
system, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity. Refer
to Standard Procedures for the test procedures.
Replace the faulty battery, as required.
7. The starting system is 7. Determine if the starting system is performing
faulty. to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The charging system is 8. Determine if the charging system is performing
faulty. to specifications. Refer to Charging System for
the proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery Specifications for the proper
CHARGE CANNOT BE incorrect size or rating for specifications. Replace an incorrect battery, as
MAINTAINED. this vehicle. required.
2. The battery terminal 2. Refer to Battery Cable for the proper cable
connections are loose or diagnosis and testing procedures. Clean and
corroded. tighten the battery terminal connections, as
required.
3. The generator drive belt is 3. Refer to Cooling System for the proper
slipping. accessory drive belt diagnosis and testing
procedures. Replace or adjust the faulty
generator drive belt, as required.
4. The electrical system 4. Refer to Standard Procedures for the proper
ignition-off draw is excessive. test procedures. Repair the faulty electrical
system, as required.
5. The battery is faulty. 5. Determine the battery cranking capacity. Refer
to Standard Procedures for the proper test
procedures. Replace the faulty battery, as
required.
6. The starting system is 6. Determine if the starting system is performing
faulty. to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
7. The charging system is 7. Determine if the charging system is performing
faulty. to specifications. Refer to Charging System for
the proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
8. Electrical loads exceed the 8. Inspect the vehicle for aftermarket electrical
output of the charging equipment which might cause excessive electrical
system. loads.
9. Slow driving or prolonged 9. Advise the vehicle operator, as required.
idling with high-amperage
draw systems in use.
THE BATTERY WILL NOT 1. The battery is faulty. 1. Refer to Standard Procedures for the proper
ACCEPT A CHARGE. battery charging procedures. Charge or replace
the faulty battery, as required.
ABNORMAL BATTERY DISCHARGING • Slow driving speeds (heavy traffic conditions) or

Any of the following conditions can result in abnor- prolonged idling, with high-amperage draw systems
mal battery discharging: in use.
• Corroded or loose battery posts and terminal • A faulty circuit or component causing excessive
clamps. ignition-off draw.
• A loose or worn generator drive belt. • A faulty or incorrect charging system compo-
• Electrical loads that exceed the output of the nent. Refer to Charging System for the proper charg-
charging system. This can be due to equipment ing system diagnosis and testing procedures.
installed after manufacture, or repeated short trip
use.
• A faulty or incorrect starting system component. parts cleaning brush to remove any acid film (Fig. 2).
Refer to Starting System for the proper starting sys- Rinse the battery with clean water. Ensure that the
tem diagnosis and testing procedures. cleaning solution does not enter the battery cells
• A faulty or incorrect battery. Refer to Standard through the vent holes. If the battery is being
Procedures for the proper battery diagnosis and test- replaced, refer to Battery Specifications for the facto-
ing procedures. Refer to Battery System Specifica- ry-installed battery specifications. Confirm that the
tions for the proper specifications. replacement battery is the correct size and has the
correct ratings for the vehicle.
CLEANING
The following information details the recommended
cleaning procedures for the battery and related com-
ponents. In addition to the maintenance schedules
found in this service manual and the owner’s man-
ual, it is recommended that these procedures be per-
formed any time the battery or related components
must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 1).
Fig. 2 Clean Battery - Typical

1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
(4) Clean the battery thermal guard with a sodium

bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.
(5) Clean any corrosion from the battery terminal
posts with a wire brush or a post and terminal
cleaner, and a sodium bicarbonate (baking soda) and
Fig. 1 Clean Battery Cable Terminal Clamp - Typical warm water cleaning solution (Fig. 3).
1 - TERMINAL BRUSH
2 - BATTERY CABLE INSPECTION
The following information details the recommended
inspection procedures for the battery and related
(2) Clean the battery tray and battery holddown
components. In addition to the maintenance sched-
hardware of all corrosion. Remove any corrosion
ules found in this service manual and the owner’s
using a wire brush and a sodium bicarbonate (baking
manual, it is recommended that these procedures be
soda) and warm water cleaning solution. Paint any
performed any time the battery or related compo-
exposed bare metal.
nents must be removed for vehicle service.
(3) If the removed battery is to be reinstalled,
(1) Inspect the battery cable terminal clamps for
clean the outside of the battery case and the top
damage. Replace any battery cable that has a dam-
cover with a sodium bicarbonate (baking soda) and
aged or deformed terminal clamp.
warm water cleaning solution using a stiff bristle
Fig. 4 Removing Battery Cell Caps - Typical

1 - PUTTY KNIFE
BATTERY
Fig. 3 Clean Battery Terminal Post - Typical BATTERY
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
(2) Inspect the battery tray and battery holddown

hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case.
Inspect the battery case for cracks or other damage
that could result in electrolyte leaks. Also, check the
battery terminal posts for looseness. Batteries with
damaged cases or loose terminal posts must be
replaced.
(4) Inspect the battery thermal guard for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged.
(5) Inspect the electrolyte level in the battery. Use
a putty knife or another suitable wide flat-bladed tool Fig. 5 Low-Maintenance Battery - Typical
to pry the cell caps off (Fig. 4). DO NOT USE A
1 - POSITIVE POST
SCREWDRIVER. Add distilled water to each bat- 2 - VENT
tery cell until the liquid reaches the bottom of the 3 - CELL CAP
vent well or one centimeter above the battery plates. 4 - TEST INDICATOR
DO NOT OVERFILL THE BATTERY CELLS. 5 - CELL CAP
(6) Inspect the battery built-in test indicator sight 6 - VENT
glass for an indication of the battery condition. If the 7 - NEGATIVE POST
battery is discharged, charge as required. Refer to 8 - GREEN BALL
Standard Procedures for the proper battery built-in 9 - ELECTROLYTE LEVEL
indicator test procedures. Also refer to Standard Pro- 10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
cedures for the proper battery charging procedures.
DESCRIPTION
A large capacity, low-maintenance storage battery
(Fig. 5) is standard factory-installed equipment on this
model. Male post type terminals made of a soft lead
BATTERY (Continued)
material protrude from the top of the molded plastic The battery Group Size number, the Cold Cranking
battery case to provide the means for connecting the Amperage (CCA) rating, and the Reserve Capacity
battery to the vehicle electrical system. The battery (RC) rating or Ampere-Hours (AH) rating can be
positive terminal post is visibly larger in diameter found on the original equipment battery label. Be
than the negative terminal post, for easy identification. certain that a replacement battery has the correct
The letters POS and NEG are also molded into the Group Size number, as well as CCA, and RC or AH
top of the battery case adjacent to their respective ratings that equal or exceed the original equipment
positive and negative terminal posts for additional specification for the vehicle being serviced. Refer to
identification confirmation. Refer to Battery Cables Battery Specifications in this group for the loca-
in the index of this service manual for the location of tion of the proper factory-installed battery specifica-
more information on the battery cables that connect tions. Battery sizes and ratings are discussed in more
the battery to the vehicle electrical system. detail below.
This battery is designed to provide a safe, efficient
and reliable means of storing electrical energy in a Group Size
chemical form. This means of energy storage allows • The outside dimensions and terminal placement
the battery to produce the electrical energy required of the battery conform to standards established by
to operate the engine starting system, as well as to the Battery Council International (BCI). Each bat-
operate many of the other vehicle accessory systems tery is assigned a BCI Group Size number to help
for limited durations while the engine and/or the identify a correctly-sized replacement.
charging system are not operating. The battery is
made up of six individual cells that are connected in Cold Cranking Amperage
series. Each cell contains positively charged plate • The Cold Cranking Amperage (CCA) rating spec-
groups that are connected with lead straps to the ifies how much current (in amperes) the battery can
positive terminal post, and negatively charged plate deliver for thirty seconds at -18° C (0° F). Terminal
groups that are connected with lead straps to the voltage must not fall below 7.2 volts during or after
negative terminal post. Each plate consists of a stiff the thirty second discharge period. The CCA required
mesh framework or grid coated with lead dioxide is generally higher as engine displacement increases,
(positive plate) or sponge lead (negative plate). Insu- depending also upon the starter current draw
lators or plate separators made of a non-conductive requirements.
material are inserted between the positive and nega-
tive plates to prevent them from contacting or short- Reserve Capacity
ing against one another. These dissimilar metal • The Reserve Capacity (RC) rating specifies the
plates are submerged in a sulfuric acid and water time (in minutes) it takes for battery terminal volt-
solution called an electrolyte. age to fall below 10.5 volts, at a discharge rate of 25
Some factory-installed batteries have a built-in test amperes. RC is determined with the battery fully-
indicator (hydrometer). The color visible in the sight charged at 26.7° C (80° F). This rating estimates how
glass of the indicator will reveal the battery condi- long the battery might last after a charging system
tion. For more information on the use of the built-in failure, under minimum electrical load.
test indicator, refer to Standard Procedures The
factory-installed low-maintenance battery has Ampere-Hours
removable battery cell caps. Distilled water can • The Ampere-Hours (AH) rating specifies the cur-
be added to this battery. The battery is not sealed rent (in amperes) that a battery can deliver steadily
and has vent holes in the cell caps. The chemical for twenty hours, with the voltage in the battery not
composition of the metal coated plates within the falling below 10.5 volts. This rating is also sometimes
low-maintenance battery reduces battery gassing and identified as the twenty-hour discharge rating.
water loss, at normal charge and discharge rates.
Therefore, the battery should not require additional OPERATION
water in normal service. If the electrolyte level in The battery is designed to store electrical energy in
this battery does become low, distilled water must be a chemical form. When an electrical load is applied to
added. However, rapid loss of electrolyte can be the terminals of the battery, an electrochemical reac-
caused by an overcharging condition. Be certain to tion occurs. This reaction causes the battery to dis-
diagnose the charging system after replenishing the charge electrical current from its terminals. As the
water in the battery for a low electrolyte condition
and before returning the vehicle to service. Refer to
Charging System for additional information.
BATTERY (Continued)
battery discharges, a gradual chemical change takes WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
place within each cell. The sulfuric acid in the elec- AND AROUND THE BATTERY. DO NOT SMOKE,
trolyte combines with the plate materials, causing USE FLAME, OR CREATE SPARKS NEAR THE BAT-
both plates to slowly change to lead sulfate. At the TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
same time, oxygen from the positive plate material AGE MAY RESULT.
combines with hydrogen from the sulfuric acid, caus-
ing the electrolyte to become mainly water. The
chemical changes within the battery are caused by WARNING: THE BATTERY CONTAINS SULFURIC
the movement of excess or free electrons between the ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
positive and negative plate groups. This movement of CONTACT WITH THE SKIN, EYES, OR CLOTHING.
electrons produces a flow of electrical current IN THE EVENT OF CONTACT, FLUSH WITH WATER
through the load device attached to the battery ter- AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
minals. OF THE REACH OF CHILDREN.
As the plate materials become more similar chem-
ically, and the electrolyte becomes less acid, the volt- WARNING: IF THE BATTERY IS EQUIPPED WITH
age potential of each cell is reduced. However, by REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
charging the battery with a voltage higher than that OF THE CELL CAPS ARE IN PLACE AND TIGHT
of the battery itself, the battery discharging process BEFORE THE BATTERY IS RETURNED TO SER-
is reversed. Charging the battery gradually changes VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
the sulfated lead plates back into sponge lead and AGE MAY RESULT FROM LOOSE OR MISSING
lead dioxide, and the water back into sulfuric acid. CELL CAPS.
This action restores the difference in the electron
charges deposited on the plates, and the voltage The condition of a battery is determined by two cri-
potential of the battery cells. For a battery to remain teria:
useful, it must be able to produce high-amperage cur- • State-Of-Charge - This can be determined by
rent over an extended period. A battery must also be checking the specific gravity of the battery electrolyte
able to accept a charge, so that its voltage potential (built-in indicator test or hydrometer test), or by
may be restored. checking the battery voltage (open-circuit voltage
The battery is vented to release excess hydrogen test).
gas that is created when the battery is being charged • Cranking Capacity - This can be determined
or discharged. However, even with these vents, by performing a battery load test, which measures
hydrogen gas can collect in or around the battery. If the ability of the battery to supply high-amperage
hydrogen gas is exposed to flame or sparks, it may current.
ignite. If the electrolyte level is low, the battery may First, determine the battery state-of-charge. This
arc internally and explode. If the battery is equipped can be done in one of three ways. If the battery has a
with removable cell caps, add distilled water when- built-in test indicator, perform the built-in indicator
ever the electrolyte level is below the top of the test to determine the state-of-charge. If the battery
plates. If the battery cell caps cannot be removed, the has no built-in test indicator but does have remov-
battery must be replaced if the electrolyte level able cell caps, perform the hydrometer test to deter-
becomes low. mine the state-of-charge. If the battery cell caps are
not removable, or a hydrometer is not available, per-
DIAGNOSIS AND TESTING - BATTERY form the open-circuit voltage test to determine the
The battery must be completely charged and the state-of-charge. Refer to open-circuit voltage test in
top, posts and terminal clamps should be properly the Standard Procedures section of this group.
cleaned and inspected before diagnostic procedures Second, determine the battery cranking capacity by
are performed. Refer to Battery System Cleaning for performing a load test. The battery must be charged
the proper cleaning procedures, and Battery System before proceeding with a load test if:
Inspection for the proper battery inspection proce- • The battery built-in test indicator has a black or
dures. Refer to Standard Procedures for the proper dark color visible.
battery charging procedures. • The temperature corrected specific gravity of the
battery electrolyte is less than 1.235.
WARNING: IF THE BATTERY SHOWS SIGNS OF • The battery open-circuit voltage is less than 12.4
FREEZING, LEAKING OR LOOSE POSTS, DO NOT volts.
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY A battery that will not accept a charge is faulty,
MAY ARC INTERNALLY AND EXPLODE. PERSONAL and must be replaced. Further testing is not
INJURY AND/OR VEHICLE DAMAGE MAY RESULT. required. A fully-charged battery must be load tested
BATTERY (Continued)
to determine its cranking capacity. A battery that is TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
fully-charged, but does not pass the load test, is MAY ARC INTERNALLY AND EXPLODE. PERSONAL
faulty and must be replaced. INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
NOTE: Completely discharged batteries may take

several hours to accept a charge. Refer to Standard WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
Procedures for the proper battery charging proce- AND AROUND THE BATTERY. DO NOT SMOKE,
dures. USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
A battery is fully-charged when: AGE MAY RESULT.
• All battery cells are gassing freely during charg-
ing.
• A green color is visible in the sight glass of the WARNING: THE BATTERY CONTAINS SULFURIC
battery built-in test indicator. ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
• Three corrected specific gravity tests, taken at CONTACT WITH THE SKIN, EYES, OR CLOTHING.
one-hour intervals, indicate no increase in the spe- IN THE EVENT OF CONTACT, FLUSH WITH WATER
cific gravity of the battery electrolyte. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
• Open-circuit voltage of the battery is 12.4 volts OF THE REACH OF CHILDREN.
or greater.
WARNING: IF THE BATTERY IS EQUIPPED WITH
STANDARD PROCEDURE - CHECKING BATTERY REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
ELECTROLYTE LEVEL OF THE CELL CAPS IS IN PLACE AND TIGHT
The following procedure can be used to check the BEFORE THE BATTERY IS RETURNED TO SER-
electrolyte level in the battery. VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
(1) Remove the battery caps. AGE MAY RESULT FROM LOOSE OR MISSING
(2) Look through the battery cap holes to deter- CELL CAPS.
mine the level of the electrolyte in the battery. The
electrolyte should be approximately 1 centimeter
above the battery plates or until the hook inside the CAUTION: Always disconnect and isolate the bat-
battery cap holes is covered. tery negative cable before charging a battery. Do
(3) Add only distilled water until the electrolyte not exceed sixteen volts while charging a battery.
level is approx. one centimeter above the plates. Damage to the vehicle electrical system compo-
nents may result.
STANDARD PROCEDURE - BATTERY
CHARGING CAUTION: Battery electrolyte will bubble inside the
Battery charging is the means by which the bat- battery case during normal battery charging. Elec-
tery can be restored to its full voltage potential. A trolyte boiling or being discharged from the battery
battery is fully-charged when: vents indicates a battery overcharging condition.
• All of the battery cells are gassing freely during Immediately reduce the charging rate or turn off the
battery charging. charger to evaluate the battery condition. Damage
• A green color is visible in the sight glass of the to the battery may result from overcharging.
battery built-in test indicator.
• Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor- CAUTION: The battery should not be hot to the
rected specific gravity of the battery electrolyte. touch. If the battery feels hot to the touch, turn off
• Open-circuit voltage of the battery is 12.4 volts the charger and let the battery cool before continu-
or above. ing the charging operation. Damage to the battery
may result.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C [30° F] OR After the battery has been charged to 12.4 volts or
LOWER) BATTERY. THE BATTERY MAY ARC INTER- greater, perform a load test to determine the battery
NALLY AND EXPLODE. PERSONAL INJURY AND/OR cranking capacity. Refer to Standard Procedures for
VEHICLE DAMAGE MAY RESULT. the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
WARNING: IF THE BATTERY SHOWS SIGNS OF and must be replaced.
FREEZING, LEAKING, LOOSE POSTS, DO NOT
BATTERY (Continued)
Clean and inspect the battery hold downs, tray, tery may be good and the charging should be
terminals, posts, and top before completing battery completed in the normal manner.
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat- CHARGE RATE TABLE
tery System Inspection for the proper battery system
inspection procedures. Voltage Hours
16.0 volts maximum up to 4 hours
CHARGING A COMPLETELY DISCHARGED 14.0 to 15.9 volts up to 8 hours
BATTERY 13.9 volts or less up to 16 hours
The following procedure should be used to recharge
a completely discharged battery. Unless this proce- CHARGING TIME REQUIRED
dure is properly followed, a good battery may be
The time required to charge a battery will vary,
needlessly replaced.
depending upon the following factors:
(1) Measure the voltage at the battery posts with a
• Battery Capacity - A completely discharged
voltmeter, accurate to 1/10 (0.10) volt (Fig. 6). If the
heavy-duty battery requires twice the charging time
reading is below ten volts, the battery charging cur-
of a small capacity battery.
rent will be low. It could take some time before the
• Temperature - A longer time will be needed to
battery accepts a current greater than a few milliam-
charge a battery at -18° C (0° F) than at 27° C (80°
peres. Such low current may not be detectable on the
F). When a fast battery charger is connected to a cold
ammeters built into many battery chargers.
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
• Charger Capacity - A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies
twenty amperes or more will require a shorter charg-
ing time.
• State-Of-Charge - A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
Fig. 6 Voltmeter - Typical The Battery Charging Time Table gives an indica-
tion of the time required to charge a typical battery
(2) Disconnect and isolate the battery negative at room temperature based upon the battery state-of-
cable. Connect the battery charger leads. Some bat- charge and the charger capacity.
tery chargers are equipped with polarity-sensing cir-
cuitry. This circuitry protects the battery charger and
the battery from being damaged if they are improp- BATTERY CHARGING TIME TABLE
erly connected. If the battery state-of-charge is too Charging 10
5 Amps 20 Amps
low for the polarity-sensing circuitry to detect, the Amperage Amps
battery charger will not operate. This makes it Open Circuit Hours Charging @ 21° C (70°
appear that the battery will not accept charging cur- Voltage F)
rent. See the instructions provided by the manufac-
12.25 to 12.49 6 hours 3 hours 1.5
turer of the battery charger for details on how to
hours
bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltage 12.00 to 12.24 10 hours 5 hours 2.5
and current they provide. The amount of time hours
required for a battery to accept measurable charging 10.00 to 11.99 14 hours 7 hours 3.5
current at various voltages is shown in the Charge hours
Rate Table. If the charging current is still not mea- Below 10.00 18 hours 9 hours 4.5
surable at the end of the charging time, the battery hours
is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the bat-
BATTERY (Continued)
STANDARD PROCEDURE - BUILT-IN for more information on the possible causes of the
discharged battery condition.
INDICATOR TEST
• Clear or Bright - Indicates a low battery elec-
An indicator (hydrometer) built into the top of the
trolyte level. The electrolyte level in the battery is
battery case provides visual information for battery
below the built-in indicator. Distilled water must be
testing (Fig. 7). Like a hydrometer, the built-in indi-
added to a low-maintenance battery with removable
cator measures the specific gravity of the battery
cell caps before it is charged. Refer to Standard Pro-
electrolyte. The specific gravity of the electrolyte
cedures for the proper battery filling procedures. A
reveals the battery state-of-charge; however, it will
low electrolyte level may be caused by an overcharg-
not reveal the cranking capacity of the battery. A load
ing condition. Refer to Charging System for the
test must be performed to determine the battery
proper charging system diagnosis and testing proce-
cranking capacity. Refer to Standard Procedures for
dures.
the proper battery load test procedures.
Fig. 7 Built-In Indicator

1 - SIGHT GLASS Fig. 8 Built-In Indicator Sight Glass Chart
2 - BATTERY TOP
3 - GREEN BALL STANDARD PROCEDURE - HYDROMETER TEST
4 - PLASTIC ROD The hydrometer test reveals the battery state-of-
charge by measuring the specific gravity of the elec-
trolyte. This test cannot be performed on
Before testing, visually inspect the battery for any
maintenance-free batteries with non-removable
damage (a cracked case or cover, loose posts, etc.)
cell caps. If the battery has non-removable cell caps,
that would cause the battery to be faulty. In order to
refer to Diagnosis and Testing for alternate methods
obtain correct indications from the built-in indicator,
of determining the battery state-of-charge.
it is important that the battery be level and have a
Specific gravity is a comparison of the density of
clean sight glass. Additional light may be required to
the battery electrolyte to the density of pure water.
view the indicator. Do not use open flame as a
Pure water has a specific gravity of 1.000, and sulfu-
source of additional light.
ric acid has a specific gravity of 1.835. Sulfuric acid
To read the built-in indicator, look into the sight
makes up approximately 35% of the battery electro-
glass and note the color of the indication (Fig. 8). The
lyte by weight, or 24% by volume. In a fully-charged
battery condition that each color indicates is
battery the electrolyte will have a temperature-cor-
described in the following list:
rected specific gravity of 1.260 to 1.290. However, a
• Green - Indicates 75% to 100% battery state-of-
specific gravity of 1.235 or above is satisfactory for
charge. The battery is adequately charged for further
the battery to be load tested and/or returned to ser-
testing or return to service. If the starter will not
vice.
crank for a minimum of fifteen seconds with a fully-
Before testing, visually inspect the battery for any
charged battery, the battery must be load tested.
damage (a cracked case or cover, loose posts, etc.)
Refer to Standard Procedures for the proper battery
that would cause the battery to be faulty. Then
load test procedures.
remove the battery cell caps and check the electrolyte
• Black or Dark - Indicates 0% to 75% battery
level. Add distilled water if the electrolyte level is
state-of-charge. The battery is inadequately charged
below the top of the battery plates. Refer to Battery
and must be charged until a green indication is visi-
System Cleaning for the proper battery inspection
ble in the sight glass (12.4 volts or more), before the
procedures.
battery is tested further or returned to service. Refer
to Standard Procedures for the proper battery charg-
ing procedures. Also refer to Diagnosis and Testing
BATTERY (Continued)
See the instructions provided by the manufacturer (1) Determine the number of degrees above or
of the hydrometer for recommendations on the cor- below 26.7° C (80° F): 26.6° C - -12.2° C = 38.8° C
rect use of the hydrometer that you are using. (80° F - 10° F = 70° F)
Remove only enough electrolyte from the battery cell (2) Divide the result from Step 1 by 5.5° C (10°
so that the float is off the bottom of the hydrometer F): 38.8° C 4 5.5° C = 7 (70° F 4 10° F = 7)
barrel with pressure on the bulb released. To read (3) Multiply the result from Step 2 by the temper-
the hydrometer correctly, hold it with the top surface ature correction factor (0.004): 7 X 0.004 = 0.028
of the electrolyte at eye level (Fig. 9). (4) The temperature at testing was below 26.7° C
(80° F); therefore, the temperature correction factor
CAUTION: Exercise care when inserting the tip of is subtracted: 1.240 - 0.028 = 1.212
the hydrometer into a battery cell to avoid damag- (5) The corrected specific gravity of the battery cell
ing the plate separators. Damaged plate separators in this example is 1.212.
can cause early battery failure. Test the specific gravity of the electrolyte in each
battery cell. If the specific gravity of all cells is above
1.235, but the variation between cells is more than
fifty points (0.050), the battery should be replaced. If
the specific gravity of one or more cells is less than
1.235, charge the battery at a rate of approximately
five amperes. Continue charging the battery until
three consecutive specific gravity tests, taken at one-
hour intervals, are constant. If the cell specific grav-
ity variation is more than fifty points (0.050) at the
end of the charge period, replace the battery.
When the specific gravity of all cells is above 1.235,
and the cell variation is less than fifty points (0.050),
the battery may be load tested to determine its
the proper battery load test procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT

VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used in place of the hydrometer test
Fig. 9 Hydrometer - Typical when a hydrometer is not available, or for mainte-
1 - BULB nance-free batteries with non-removable cell caps.
2 - SURFACE COHESION Before proceeding with this test, completely charge
3 - SPECIFIC GRAVITY READING the battery. Refer to Standard Procedures for the
4 - TEMPERATURE READING proper battery charging procedures.
5 - HYDROMETER BARREL (1) Before measuring the open-circuit voltage, the
6 - FLOAT surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
Hydrometer floats are generally calibrated to indi- allow up to five minutes for the battery voltage to
cate the specific gravity correctly only at 26.7° C (80° stabilize.
F). When testing the specific gravity at any other (2) Disconnect and isolate both battery cables, neg-
temperature, a correction factor is required. The cor- ative cable first.
rection factor is approximately a specific gravity (3) Using a voltmeter connected to the battery
value of 0.004, which may also be identified as four posts (see the instructions provided by the manufac-
points of specific gravity. For each 5.5° C above 26.7° turer of the voltmeter), measure the open-circuit volt-
C (10° F above 80° F), add four points. For each 5.5° age (Fig. 10).
C below 26.7° C (10° F below 80° F), subtract four See the Open-Circuit Voltage Table. This voltage
points. Always correct the specific gravity for temper- reading will indicate the battery state-of-charge, but
ature variation. will not reveal its cranking capacity. If a battery has
EXAMPLE: A battery is tested at -12.2° C (10° F) an open-circuit voltage reading of 12.4 volts or
and has a specific gravity of 1.240. Determine the greater, it may be load tested to reveal its cranking
actual specific gravity as follows: capacity. Refer to Standard Procedures for the proper
BATTERY (Continued)
Fig. 10 Testing Open-Circuit Voltage - Typical Fig. 11 Volt-Ammeter-Load Tester - Typical

battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE

Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - LOAD TEST

A battery load test will verify the battery cranking
capacity. The test is based on the Cold Cranking Fig. 12 Volt-Ammeter-Load
Amperage (CCA) rating of the battery. To determine 1 - INDUCTION AMMETER CLAMP
the battery CCA rating, see the label affixed to the 2 - NEGATIVE CLAMP
battery case or refer to Battery Specifications for the 3 - POSITIVE CLAMP
proper factory-installed specifications.
Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures.
(1) Disconnect and isolate both battery cables, neg-
ative cable first. The battery top and posts should be
clean. Refer to Battery System Cleaning for the
proper cleaning procedures.
(2) Connect a suitable volt-ammeter-load tester
(Fig. 11) to the battery posts (Fig. 12). See the
instructions provided by the manufacturer of the
tester you are using. Check the open-circuit voltage
(no load) of the battery. Refer to Standard Procedures
for the proper battery open-circuit voltage test proce-
dures. The battery open-circuit voltage must be 12.4
volts or greater.
(3) Rotate the load control knob (carbon pile rheo- Fig. 13 Remove Surface Charge from Battery
stat) to apply a 300 ampere load to the battery for
fifteen seconds, then return the control knob to the
Off position (Fig. 13). This will remove the surface
charge from the battery.
BATTERY (Continued)
(4) Allow the battery to stabilize to open-circuit STANDARD PROCEDURE - IGNITION-OFF
voltage. It may take up to five minutes for the bat-
DRAW TEST
tery voltage to stabilize.
The term Ignition-Off Draw (IOD) identifies a nor-
(5) Rotate the load control knob to maintain a load
mal condition where power is being drained from the
equal to 50% of the CCA rating of the battery (Fig.
battery with the ignition switch in the Off position. A
14). After fifteen seconds, record the loaded voltage
normal vehicle electrical system will draw from five
reading, then return the load control knob to the Off
to thirty-five milliamperes (0.005 to 0.035 ampere)
position.
with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working
order. Up to thirty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the
vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Power Distribution Center (PDC). This will
reduce battery discharging.
Excessive IOD can be caused by:
• Electrical items left on.
Fig. 14 Load 50% CCA Rating - Note Voltage - • Faulty or improperly adjusted switches.
Typical • Faulty or shorted electronic modules and compo-
nents.
(6) The voltage drop will vary with the battery • An internally shorted generator.
temperature at the time of the load test. The battery • Intermittent shorts in the wiring.
temperature can be estimated by using the ambient If the IOD is over thirty-five milliamperes, the
temperature during the past several hours. If the problem must be found and corrected before replac-
battery has been charged, boosted, or loaded a few ing a battery. In most cases, the battery can be
minutes prior to the test, the battery will be some- charged and returned to service after the excessive
what warmer. See the Load Test Temperature Table IOD condition has been corrected.
for the proper loaded voltage reading. (1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
LOAD TEST TEMPERATURE TABLE all doors. If the vehicle is equipped with an illumi-
Temperature nated entry system or an electronically tuned radio,
Minimum Voltage allow the electronic timer function of these systems
°F °C
to automatically shut off (time out). This may take
9.6 volts 70° and above 21° and above up to three minutes. See the Electronic Module Igni-
9.5 volts 60° 16° tion-Off Draw Table for more information.
9.4 volts 50° 10°
9.3 volts 40° 4°
9.1 volts 30° -1°
8.9 volts 20° -7°
8.7 volts 10° -12°
8.5 volts 0° -18°
(7) If the voltmeter reading falls below 9.6 volts, at
a minimum battery temperature of 21° C (70° F), the
battery is faulty and must be replaced.
BATTERY (Continued)
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE

Time Out? IOD After Time
Module IOD
(If Yes, Interval And Wake-Up Input) Out
1 to 3
Radio No N/A
milliamperes
Audio Power up to 1
No N/A
Amplifier milliampere
5.90
Body Control Module
No milliamperes N/A
(BCM)
(max.)
Powertrain Control
No 0.95 milliampere N/A
Module (PCM)
Transmission Control
Module (TCM) 4.7L YES (20 minutes, ignition on) 130 milliamperes 0.64 milliampere
w/45RFE
ElectroMechanical
Instrument Cluster No 0.44 milliampere N/A
(EMIC)
Combination Flasher No 0.08 milliampere N/A
(2) Disconnect the battery negative cable. tify the circuit that is the source of the high-amper-
(3) Set an electronic digital multi-meter to its age IOD. If the amperage reading remains high after
highest amperage scale. Connect the multi-meter removing and replacing each fuse and circuit
between the disconnected battery negative cable ter- breaker, disconnect the wire harness from the gener-
minal clamp and the battery negative terminal post. ator. If the amperage reading now becomes very low
Make sure that the doors remain closed so that the or nonexistent, refer to Charging System for the
illuminated entry system is not activated. The multi- proper charging system diagnosis and testing proce-
meter amperage reading may remain high for up to dures. After the high-amperage IOD has been cor-
three minutes, or may not give any reading at all rected, switch the multi-meter to progressively lower
while set in the highest amperage scale, depending amperage scales and, if necessary, repeat the fuse
upon the electrical equipment in the vehicle. The and circuit breaker remove-and-replace process to
multi-meter leads must be securely clamped to the identify and correct all sources of excessive IOD. It is
battery negative cable terminal clamp and the bat- now safe to select the lowest milliampere scale of the
tery negative terminal post. If continuity between the multi-meter to check the low-amperage IOD.
battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD CAUTION: Do not open any doors, or turn on any
test, the electronic timer function will be activated electrical accessories with the lowest milliampere
and all of the tests will have to be repeated. scale selected, or the multi-meter may be damaged.
(4) After about three minutes, the high-amperage (5) Observe the multi-meter reading. The low-am-
IOD reading on the multi-meter should become very perage IOD should not exceed thirty-five milliam-
low or nonexistent, depending upon the electrical peres (0.035 ampere). If the current draw exceeds
equipment in the vehicle. If the amperage reading thirty-five milliamperes, isolate each circuit using the
remains high, remove and replace each fuse or circuit fuse and circuit breaker remove-and-replace process
breaker in the Intelligent Power Module (IPM), one in Step 4. The multi-meter reading will drop to
at a time until the amperage reading becomes very within the acceptable limit when the source of the
low, or nonexistent. Refer to the appropriate wiring excessive current draw is disconnected. Repair this
information in this service manual for complete Intel- circuit as required; whether a wiring short, incorrect
ligent Power Module fuse, circuit breaker, and circuit switch adjustment, or a component failure is at fault.
identification. This will isolate each circuit and iden-
BATTERY (Continued)
REMOVAL - BATTERY (3) Connect the battery cables to the battery posts,
positive cable first. Torque terminal fasteners to 8.5
WARNING: A SUITABLE PAIR OF HEAVY DUTY N·m (75 in. lbs.).
RUBBER GLOVES SHOULD BE WORN WHEN
REMOVING OR SERVICING A BATTERY.
BATTERY HOLDDOWN
WARNING: SAFETY GLASSES SHOULD BE WORN DESCRIPTION
WHEN REMOVING OR SERVICING A BATTERY. The battery hold down hardware consists of a
molded plastic lip that is integral to the outboard
WARNING: REMOVE METALLIC JEWELRY TO edge of the battery tray and support unit, a molded
AVOID INJURY BY ACCIDENTAL ARCING OF BAT- steel hold down bracket and a single hex nut with a
TERY CURRENT. coned washer.
When installing a battery into the battery tray, be
(1) Verify that the ignition switch and all accesso- certain that the hold down hardware is properly
ries are OFF. installed and that the fasteners are tightened to the
(2) Disconnect the battery cables from the battery proper specifications. Improper hold down fastener
posts, negative first (Fig. 15). tightness, whether too loose or too tight, can result in
(3) Remove the battery hold down retaining nut. damage to the battery, the vehicle or both. Refer to
Battery Hold Downs in this section of this service
manual for the location of the proper battery hold
down installation procedures, including the proper
hold down fastener tightness specifications.
OPERATION
The battery holddown secures the battery in the
battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removal and lubrica-
tion of the battery holddown hardware is recom-
mended to prevent hardware seizure at a later date.
NOTE: Never operate a vehicle without a battery

holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
All of the battery hold down hardware can be ser-
viced without removal of the battery or the battery
tray and support unit.
(1) Turn the ignition switch to the Off position. Be
Fig. 15 BATTERY POSITION & ORIENTATION certain that all electrical accessories are turned off.
1 - BATTERY THERMAL GUARD (2) Remove the nut with washer that secures the
2 - INTELLIGENT POWER MODULE battery hold down bracket to the battery tray and
3 - FRONT CONTROL MODULE support unit.
(3) Remove the battery hold down bracket from
(4) Remove the battery hold down bracket. the battery tray and support unit.
(5) Remove the battery from the vehicle.
INSTALLATION
INSTALLATION (1) Install the battery hold down bracket in the
(1) Position the battery in the battery tray. battery tray and support unit.
(2) Install the battery hold down bracket and (2) Install the nut with washer that secures the
retaining nut. Torque the nut to 20 N·m (180 in. lbs.). battery hold down bracket to the battery tray and
support unit. Torque to 20 N·m (180 in. lbs.).
BATTERY CABLES The battery positive cable terminal clamp is die

cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
DESCRIPTION
to the B(+) terminal stud of the Intelligent Power
The battery cables are large gauge, stranded cop-
Module (IPM), and the other wire has an eyelet ter-
per wires sheathed within a heavy plastic or syn-
minal that connects the battery positive cable to the
thetic rubber insulating jacket. The wire used in the
B(+) terminal stud of the engine starter motor sole-
battery cables combines excellent flexibility and reli-
noid. The battery negative cable terminal clamp is
ability with high electrical current carrying capacity.
also die cast onto the ends of two wires. One wire
Refer to Wiring Diagrams in the index of this ser-
has an eyelet terminal that connects the battery neg-
vice manual for the location of the proper battery
ative cable to the vehicle powertrain through a stud
cable wire gauge information.
on the left side of the engine cylinder block. The
A clamping type female battery terminal made of
other wire has an eyelet terminal that connects the
soft lead is die cast onto one end of the battery cable
battery negative cable to the vehicle body through a
wire. A square headed pinch-bolt and hex nut are
ground screw on the left front fender inner shield,
installed at the open end of the female battery termi-
near the battery.
nal clamp. Large eyelet type terminals are crimped
onto the opposite end of the battery cable wire and
then solder-dipped. The battery positive cable wires
DIAGNOSIS AND TESTING - BATTERY CABLE
A voltage drop test will determine if there is exces-
have a red insulating jacket to provide visual identi-
sive resistance in the battery cable terminal connec-
fication and feature a larger female battery terminal
tions or the battery cable. If excessive resistance is
clamp to allow connection to the larger battery posi-
found in the battery cable connections, the connec-
tive terminal post. The battery negative cable wires
tion point should be disassembled, cleaned of all cor-
have a black insulating jacket and a smaller female
rosion or foreign material, then reassembled.
battery terminal clamp.
Following reassembly, check the voltage drop for the
The battery cables cannot be repaired and, if dam-
battery cable connection and the battery cable again
aged or faulty they must be replaced. Both the bat-
to confirm repair.
tery positive and negative cables are available for
When performing the voltage drop test, it is impor-
service replacement only as a unit with the battery
tant to remember that the voltage drop is giving an
wire harness, which may include portions of the wir-
indication of the resistance between the two points at
ing circuits for the generator and other components
which the voltmeter probes are attached. EXAM-
on some models. Refer to Wiring Diagrams in the
PLE: When testing the resistance of the battery pos-
index of this service manual for the location of more
itive cable, touch the voltmeter leads to the battery
information on the various wiring circuits included in
positive cable terminal clamp and to the battery pos-
the battery wire harness for the vehicle being ser-
itive cable eyelet terminal at the starter solenoid
viced.
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
OPERATION
terminal at the starter solenoid B(+) terminal stud,
The battery cables connect the battery terminal
you are reading the combined voltage drop in the
posts to the vehicle electrical system. These cables
battery positive cable terminal clamp-to-terminal
also provide a path back to the battery for electrical
post connection and the battery positive cable.
current generated by the charging system for restor-
ing the voltage potential of the battery. The female
VOLTAGE DROP TEST
battery terminal clamps on the ends of the battery
The following operation will require a voltmeter
cable wires provide a strong and reliable connection
accurate to 1/10 (0.10) volt. Before performing this
of the battery cable to the battery terminal posts.
test, be certain that the following procedures are
The terminal pinch bolts allow the female terminal
accomplished:
clamps to be tightened around the male terminal
• The battery is fully-charged and load tested.
posts on the top of the battery. The eyelet terminals
Refer to Standard Procedures for the proper battery
secured to the opposite ends of the battery cable
charging and load test procedures.
wires from the female battery terminal clamps pro-
• Fully engage the parking brake.
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
BATTERY CABLES (Continued)
• If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
• Verify that all lamps and accessories are turned
off.
• To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location.
(1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg- Fig. 17 Test Battery Positive Connection Resistance
ative lead of the voltmeter to the battery negative - Typical
cable terminal clamp (Fig. 16). Rotate and hold the
1 - VOLTMETER
ignition switch in the Start position. Observe the
2 - BATTERY
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post. (3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 18). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.
Fig. 16 Test Battery Negative Connection

Resistance - Typical
1 - VOLTMETER
2 - BATTERY
(2) Connect the positive lead of the voltmeter to

the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable Fig. 18 Test Battery Positive Cable Resistance -
terminal clamp (Fig. 17). Rotate and hold the ignition Typical
switch in the Start position. Observe the voltmeter. If 1 - BATTERY
voltage is detected, correct the poor connection 2 - VOLTMETER
between the battery positive cable terminal clamp 3 - STARTER MOTOR
and the battery positive terminal post.
BATTERY CABLES (Continued)
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 19). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
Fig. 20 BATTERY TRAY - TYPICAL

1 - ENGINE VACUUM RESERVOIR
Fig. 19 Test Ground Circuit Resistance - Typical 2 - BATTERY TRAY ASSEMBLY
3 - DRAINAGE HOSE
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND could result in damage to the vehicle, the battery, or
both.
The battery tray used on this model also includes a
BATTERY TRAY engine vacuum reservoir and drainage hose. The vac-
uum reservoir provides a storage container for engine
DESCRIPTION vacuum. Refer to the engine section of the service
The battery is mounted in a molded plastic battery manual for more engine vacuum information. The
tray and support unit located in the left front corner drainage hose provides means for any liquid that
of the engine compartment. The battery tray and might collect in the bottom of the battery tray to
support unit is secured with two nuts, one is located drain under the vehicle.
directly under the battery and the other is located on
the right side of the tray which also serves as a cool- REMOVAL
ant bottle neck retaining bolt. An additional bolt is (1) Disconnect and isolate the negative battery
located directly under the battery. cable.
The battery tray and support unit also includes a (2) Remove the battery from the vehicle. Refer to
engine vacuum reservoir, located in the rear of the the procedure in this section.
unit (Fig. 20). And a drainage hose, located in the (3) Remove the battery tray retaining fasteners
front of the unit (Fig. 20). (Fig. 21).
(4) Pull battery tray up far enough to disconnect
OPERATION the engine vacuum harness hose from the battery
The battery tray provides a secure mounting loca- tray mounted, vacuum reservoir.
tion and supports the battery. The battery tray also (5) Remove the battery tray from the vehicle.
provides the anchor point for the battery holddown
hardware. The battery tray and the battery hold- INSTALLATION
down hardware combine to secure and stabilize the (1) Position the battery tray in the vehicle.
battery in the engine compartment, which prevents (2) Connect the engine vacuum harness hose on
battery movement during vehicle operation. Unre- the battery tray mounted vacuum reservoir.
strained battery movement during vehicle operation (3) Position drainage hose and install the battery
tray retaining fasteners (Fig. 21).
BATTERY TRAY (Continued)
Fig. 21 BATTERY TRAY POSITION & ORIENTATION Fig. 22 BATTERY POSITION & ORIENTATION
1 - BATTERY TRAY RETAINING FASTENERS 1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
(4) Install the battery in the vehicle. Refer to the
procedure in this section.
(5) Connect the negative battery cable. REMOVAL
(1) Remove the battery thermal guard retaining
fastener on the radiator closure panel (Fig. 22).
THERMAL GUARD (2) Remove the push pin retainer near the cowl
trim panel.
DESCRIPTION (3) Lift the battery thermal guard straight up to
A one-piece molded plastic clam shell-type thermal remove from the engine compartment.
guard unit shields the battery case from engine com-
partment heat (Fig. 22). Two molded latches secure INSTALLATION
the side of the thermal guard to the battery tray. The (1) Position the thermal guard on the battery tray
front is secured by a retaining fastener at the radia- molded retaining latches.
tor closure panel and the rear by a push pin type (2) Install the battery thermal guard retaining fas-
retainer, near the cowl panel. tener on the radiator closure panel.
(3) Install the push pin retainer near the cowl trim
OPERATION panel.
The thermal guard protects the battery from
engine compartment temperature extremes. The tem-
perature of the battery can affect battery perfor-
mance. The air trapped between the plastic plies of
the thermal guard create a dead air space, which
helps to insulate the sides of the battery case from
the air temperature found in the surrounding engine
compartment.
RS CHARGING 8F - 21
CHARGING
TABLE OF CONTENTS
page page
CHARGING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 GENERATOR DECOUPLER PULLEY
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . 22 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 22 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 23 GENERATOR DECOUPLER . . . . . . . . . . . . . . . 25
BATTERY TEMPERATURE SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 VOLTAGE REGULATOR
GENERATOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHARGING The amount of DC current produced by the gener-

ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
DESCRIPTION - CHARGING SYSTEM
nected in series with the second rotor field terminal
The charging system consists of:
and ground.
• Generator
A battery temperature sensor is used to sense bat-
• Decoupler Pulley (If equipped)
tery temperature. This temperature data, along with
• Electronic Voltage Regulator (EVR) circuitry
data from monitored line voltage, is used by the PCM
within the Powertrain Control Module (PCM)
to vary the battery charging rate. This is done by
• Ignition switch (refer to the Ignition System sec-
cycling the ground path to control the strength of the
tion for information)
rotor magnetic field. The PCM then compensates and
• Battery (refer to the Battery section for informa-
regulates generator current output accordingly to
tion)
maintain system voltage at the targeted system volt-
• Battery temperature sensor
age based on battery temperature.
• Voltmeter (refer to the Instrument Cluster sec-
All vehicles are equipped with On-Board Diagnos-
tion for information)
tics (OBD). All OBD-sensed systems, including EVR
• Wiring harness and connections (refer to the
(field control) circuitry, are monitored by the PCM.
Wiring section for information)
Each monitored circuit is assigned a Diagnostic Trou-
• Accessory drive belt (refer to the Cooling section
ble Code (DTC). The PCM will store a DTC in elec-
for more information)
tronic memory for certain failures it detects. Refer to
On-Board Diagnostics in the Electronic Control Mod-
OPERATION - CHARGING SYSTEM ules(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
The charging system is turned on and off with the TROL MODULES/POWERTRAIN CONTROL
ignition switch. The system is on when the engine is
MODULE - DESCRIPTION) section for more DTC
running and the ASD relay is energized. When the information.
ASD relay is on, voltage is supplied to the ASD relay The Check Gauges Lamp (if equipped) monitors:
sense circuit at the PCM. This voltage is connected charging system voltage, engine coolant tempera-
through the PCM and supplied to one of the genera- ture and engine oil pressure. If an extreme condition
tor field terminals (Gen. Source +) at the back of the is indicated, the lamp will be illuminated. This is
generator. done as reminder to check the three gauges. The sig-
The generator is driven by the engine through a
nal to activate the lamp is sent via the PCI bus cir-
serpentine belt and pulley or decoupler pulley cuits. The lamp is located on the instrument panel.
arrangement. Refer to the Instrument Cluster section for additional
information.
8F - 22 CHARGING RS
CHARGING (Continued)
DIAGNOSIS AND TESTING - ON-BOARD cedures be followed in sequence, to understand what

caused a DTC to be set.
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors ERASING DIAGNOSTIC TROUBLE CODES
critical input and output circuits of the charging sys-
The DRBIIIt Scan Tool must be used to erase a
tem, making sure they are operational. A Diagnostic
DTC.
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are SPECIFICATIONS
checked only under certain conditions.
If the OBD system senses that a monitored circuit GENERATOR
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed Type Engine Minimun Test
to clear the memory after 50 engine starts if the Amperage
problem does not occur again. Denso 2.4 L 135 Amp
Denso 3.3/3.8L 135 Amp or 160
DIAGNOSTIC TROUBLE CODES Amp
A DTC description can be read using the DRBt
Test Specification:
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information. 1. Engine RPM : 2500 RPM 620 RPM
A DTC does not identify which component in a cir- 2. Voltage Output : 14.0 V 6 0.5 V
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some 3. Field Current : 5 amps 6 0.1 amps
cases, because of the design of the diagnostic test
Part number is located on the side of the generator.
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
TORQUE

Battery Hold Down Clamp 20 14.7 180
Bolt
Generator B+ Nut 12.4 9.2 110
Battery Terminal Nut 4 35
Generator Mounting Bolt 28.2 20.8 250
2.4L
Starter Solenoid Battery 54.2 40
Nut 3.3/3.8L
Generator Decoupler 109.8 81
RS CHARGING 8F - 23
SPECIAL TOOLS REMOVAL

The battery temperature sensor is not a serviced
SPECIAL TOOLS separately. If replacement is necessary, the PCM
must be replaced.
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine. It is
serviced only as a complete assembly. The generator
produces DC voltage at the B+ terminal. If the gen-
erator is failed, the generator assembly subcompo-
nents (generator and decoupler pulley) must be
inspected for individual failure and replaced accord-
ingly.
Fig. 1 GENERATOR DECOUPLER 8433
OPERATION
BATTERY TEMPERATURE As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
SENSOR rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
DESCRIPTION provides the current needed to energize the rotor.
The PCM incorporates a Battery Temperature Sen- The Y type stator winding connections deliver the
sor (BTS) on its circuit board. induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
OPERATION current is delivered to the vehicles electrical system
The PCM uses the temperature of the battery area through the generator, battery, and ground terminals.
to control the charge rate. This temperature data, Noise emitting from the generator may be caused
along with data from monitored line voltage, is used by:
by the PCM to vary the battery charging rate. The • Worn, loose or defective bearings
system voltage is higher at cold temperatures and is • Loose or defective drive pulley (2.4L) or decou-
gradually reduced as temperature around the battery pler (3.3/3.8L)
increases. • Incorrect, worn, damaged or misadjusted drive
The function of the battery temperature sensor belt
(BTS) is to enable control of the generator output • Loose mounting bolts
based upon ambient battery temperature. As battery • Misaligned drive pulley
temperature increases, the charging rate should • Defective stator or diode
decrease. As battery temperature decreases, the • Damaged internal fins
charging rate should increase. The sensor functions
similar to the ECT sensor with one major difference, REMOVAL - 2.4L
the ambient sensor does not have a dual temperature (1) Release hood latch and open hood.
range program. The PCM maintains the optimal out- (2) Disconnect battery negative cable.
put of the generator by monitoring battery voltage (3) Disconnect the Inlet Air Temperature sensor.
and controlling battery voltage to a range of (4) Remove the Air Box, refer to the Engine/Air
13.5-14.7 volts based on battery temperature. Cleaner for more information.
The battery temperature sensor is also used for (5) Remove the EVAP Purge solenoid from its
OBD II diagnostics. Certain faults and OBD II mon- bracket and reposition.
itors are either enabled or disabled depending upon (6) Disconnect the push-in field wire connector
the battery temperature sensor input (example: dis- from back of generator.
able purge and EGR, enable LDP). Most OBD II (7) Remove nut holding B+ wire terminal to back
monitors are disabled below 20°F. of generator.
(8) Separate B+ terminal from generator.
(9) Remove accessory drive belt, refer to the Cool-
ing System section for proper procedures.
(10) Remove the generator.
8F - 24 CHARGING RS
GENERATOR (Continued)
REMOVAL - 3.3/3.8L
(1) Release hood latch and open hood.
(3) Disconnect the push-in field wire connector
from back of generator.
(4) Remove nut holding B+ wire terminal to back
of generator.
(5) Separate B+ terminal from generator.
(6) Raise vehicle and support.
(7) Remove the right front lower splash shield.
(9) Remove the lower oil dip stick tube bolt (Fig.
2).
(10) Remove wiring harness from the oil dip stick
tube
Fig. 3 GENERATOR 3.3/3.8L

(7) Install the Air Box, refer to the Engine/Air
Cleaner for more information.
(8) Connect the Inlet Air Temperature sensor.
INSTALLATION - 3.3/3.8L
(1) Roll and place generator in position on vehicle
(Fig. 3).
(2) Install upper bolts to hold generator in place.
(3) Lubricate the o-ring. Install oil dip stick tube.
(4) Install the upper oil dip stick tube bolt.
(5) Place B+ terminal in position on generator.
(6) Install nut to hold B+ wire terminal to back of
generator.
(7) Connect the push-in field wire connector into
Fig. 2 DIP STICK LOWER BOLT back of generator.
(11) Remove the 3 mounting bolts.
(9) Install the lower mounting bolt and tighten.
(12) Lower vehicle.
(10) Install the lower oil dip stick tube bolt and
(13) Remove oil dip stick tube from vehicle.
tighten (Fig. 2).
(14) Roll and remove the generator from vehicle
(11) Install accessory drive belt, refer to the Cool-
(Fig. 3).
(12) Install the right front lower splash shield.
INSTALLATION - 2.4L (13) Lower vehicle.
(1) Install the generator. (14) Install wiring harness to the oil dip stick tube
(2) Install the accessory drive belt, refer to the (15) Connect battery negative cable.
Cooling System section for proper procedures. (16) Verify generator output rate.
(3) Connect B+ terminal to generator.
(4) Install nut holding B+ wire terminal to back of
generator.
(5) Connect the push-in field wire connector to
back of generator.
(6) Install the EVAP Purge solenoid to its bracket.
RS CHARGING 8F - 25
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The Generator Decoupler is a one way clutch (Fig.
4). It is attached to the generator and replaces the
standard pulley. It is a non-serviceable item and is to
be replaced as an assembly. It is a dry operation (no
grease or lubricants). The operation of it is not tem-
perature sensitive and has a low sensitivity to elec-
trical load.
OPERATION
The generator decoupler is a one way clutch and
should be replaced as an assembly. It is designed to
help reduce belt tension fluctuation, reduce fatigue
loads, improve belt life, reduce hubloads on compo-
Fig. 4 GENERATOR DECOUPLER 3.3/3.8L
nents, and reduce noise.
DIAGNOSIS AND TESTING -

Does not drive generator Clutch failure Replace Decoupler
(Generator not Charging)
REMOVAL
(4) Remove the right front lower splash shield.
ing System section for proper procedures (Fig. 5).
(6) Lower vehicle.
(7) Remove the Air Box, refer to the Engine section
for more information.
(8) Use Special Tool #8433 (Fig. 6) to loosen the
Generator Decoupler.
(9) Remove the tool.
(10) Remove the Generator Decoupler.
Fig. 5 DRIVE BELT 3.3/3.8L

8F - 26 CHARGING RS
GENERATOR DECOUPLER PULLEY (Continued)
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and
battery temperature or inlet air temperature sensor
(refer to Battery Temperature Sensor or Inlet Air
Temperature Sensor for more information). It then
determines a target charging voltage. If sensed bat-
Fig. 6 SPECIAL TOOL 8433 AND DECOUPLER
tery voltage is 325 mv or lower than the target volt-
INSTALLATION age, the PCM grounds the field winding until sensed
(1) Install the Generator Decoupler to the genera- battery volage is 325 mv above target voltage. A cir-
tor shaft. cuit in the PCM cycles the ground side of the gener-
(2) Use Special Tool #8433 (Fig. 6) to tighten the ator field up to 250 times per second (250Hz), but
Generator Decoupler. Refer to the torque chart for has the capability to ground the field control wire
the proper torque. 100% of the time (full field) to achieve the target
(3) Install the Air Box, refer to the Engine section voltage. If the charging rate cannot be monitored
for more information. (limp-in), a duty cycle of 25% is used by the PCM in
(4) Raise vehicle and support. order to have some generator output. Also refer to
(5) Install accessory drive belt, refer to the Cooling Charging System Operation for additional informa-
System section for proper procedures (Fig. 5). tion.
(6) Install the right front lower splash shield.
(7) Lower vehicle. REMOVAL
(8) Connect battery negative cable. The electronic voltage regulator is not a serviced
separately. If replacement is necessary, the PCM
must be replaced.
RS STARTING 8F - 27
STARTING
TABLE OF CONTENTS
page page
STARTING FEED CIRCUIT RESISTANCE TEST . . . . . . . . . 31

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . 31
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 27 STARTER MOTOR
STARTING SYSTEM TEST . . . . . . . . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . 29 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTING
DESCRIPTION
The starting system has (Fig. 1):
• Ignition switch
• Starter relay
• Transmission Range Sensor or Park/Neutral
Switch
• Wiring harness
• Battery
• Starter motor with an integral solenoid
• Powertrain Control Module (PCM)
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
STARTING SYSTEM TEST

For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, REFER TO THE PASSIVE RESTRAINT SYS- Fig. 1 Starting System Schematic
TEMS BEFORE ATTEMPTING STEERING WHEEL, 1 - SOLENOID TERMINAL
STEERING COLUMN, OR INSTRUMENT PANEL 2 - STARTER SOLENOID
COMPONENT DIAGNOSIS OR SERVICE. FAILURE 3 - STARTER MOTOR
4 - STARTER RELAY CONNECTOR
TO TAKE THE PROPER PRECAUTIONS COULD
5 - PCM
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
6 - GROUND CIRCUIT
AND POSSIBLE PERSONAL INJURY. 7 - TRANSMISSION RANGE SENSOR/PARK/NEUTRAL SENSE
8 - IGNITION SWITCH
9 - IGNITION FEED
INSPECTION 10 - BATTERY
Before removing any unit from the starting system 11 - BATTERY RELAY FEED
for repair or diagnosis, perform the following inspec- 12 - POSITIVE CABLE
tions: 13 - NEGATIVE CABLE
8F - 28 STARTING RS
STARTING (Continued)
• Battery - Visually inspect the battery for indi- • Starter - Visually inspect the starter for indica-
cations of physical damage and loose or corroded tions of physical damage and loose or corroded wire
cable connections. Determine the state-of-charge and harness connections.
cranking capacity of the battery. Charge or replace • Starter Solenoid - Visually inspect the starter
the battery, if required. Refer to the Battery section solenoid for indications of physical damage and loose
for more information. or corroded wire harness connections.
• Ignition Switch - Visually inspect the ignition • Wiring - Visually inspect the wire harness for
switch for indications of physical damage and loose damage. Repair or replace any faulty wiring, as
or corroded wire harness connections. required. Check for loose or corroded wire harness
• Transmission Range Sensor - Visually inspect connections at main engine ground and remote jump
the transmission range sensor for indications of phys- post.
ical damage and loose or corroded wire harness con- • Power Distribution Center (PDC) - Visually
nections. inspect the B+ connections at the PDC for physical
• Starter Relay - Visually inspect the starter damage and loose or corroded harness connections.
relay for indications of physical damage and loose or
corroded wire harness connections.
STARTING SYSTEM DIAGNOSIS
STARTER FAILS 1. BATTERY 1. REFER TO THE BATTERYSECTION FOR MORE

TO ENGAGE. DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY, IF
FAULTY. REQUIRED.
2. STARTING CIRCUIT 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
WIRING FAULTY. CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY 3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
FAULTY. RELAY, IF NECESSARY.
4. IGNITION SWITCH 4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
FAULTY. SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL 5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
POSITION SWITCH TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
(AUTO TRANS) FAULTY SWITCH, IF NECESSARY.
OR MIS-ADJUSTED.
6. CLUTCH PEDAL 6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
POSITION SWITCH THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
(MAN TRANS) FAULTY.
7. STARTER SOLENOID 7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
FAULTY. STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY 8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
FAULTY. CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON 9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
RING GEAR. GEAR REPLACED IF DAMAGED.
STARTER 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE

ENGAGES, DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY AS
FAILS TO TURN FAULTY. NECESSARY.
ENGINE.
2. STARTING CIRCUIT 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
WIRING FAULTY. THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
RS STARTING 8F - 29

4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE 5. INSPECT FOR LOOSE CONNECTIONS.
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.
6. FAULTY TEETH ON 6. ROTATE FLYWHEEL 360°, AND INSPECT TEETHAND RING
STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
ENGAGES, STARTER RING GEAR. IF NECESSARY.
SPINS OUT
BEFORE
ENGINE
STARTS.
STARTER DOES 1. STARTER 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING

NOT IMPROPERLY HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
DISENGAGE. INSTALLED.
2. STARTER RELAY 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
FAULTY. RELAY, IF NECESSARY.
3. IGNITION SWITCH 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
FAULTY. SECTION.. REPLACE SWITCH, IF NECESSARY.
5. FAULTY TEETH ON 5. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
CONTROL CIRCUIT TEST STARTER SOLENOID

The starter control circuit has:
• Starter motor with integral solenoid WARNING: CHECK TO ENSURE THAT THE TRANS-
• Starter relay MISSION IS IN THE PARK POSITION WITH THE
• Transmission range sensor, or Park/Neutral PARKING BRAKE APPLIED.
Position switch with automatic transmissions
(1) Verify battery condition. Battery must be in
• Ignition switch
good condition with a full charge before performing
• Battery
any starter tests. Refer to Battery Tests.
• All related wiring and connections
(2) Perform Starter Solenoid test BEFORE per-
• Powertrain Control Module (PCM)
forming the starter relay test.
CAUTION: Before performing any starter tests, the (3) Perform a visual inspection of the starter/
ignition and fuel systems must be disabled. starter solenoid for corrosion, loose connections or
faulty wiring.
• To disable ignition and fuel systems, disconnect (4) Locate and remove the starter relay from the
the Automatic Shutdown Relay (ASD). The ASD relay Power Distribution Center (PDC). Refer to the PDC
is located in the Power Distribution Center (PDC). label for relay identification and location.
Refer to the PDC cover for the proper relay location.
8F - 30 STARTING RS
(5) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not crank or solenoid chatters,
check wiring and connectors from starter relay to
starter solenoid for loose or corroded connections.
Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter. Starter Relay Pinout
CAV FUNCTION
STARTER RELAY
30 B (+)
WARNING: CHECK TO ENSURE THAT THE TRANS- 85 P/N POSITION SW.SENSE
MISSION IS IN THE PARK/NEUTRAL POSITION (AUTO)
WITH THE PARKING BRAKE APPLIED.
86 IGNITION SWITCH
OUTPUT
RELAY TEST 87 STARTER RELAY OUTPUT
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer RELAY CIRCUIT TEST
to the PDC label for relay identification and location. (1) The relay common feed terminal cavity (30) is
Remove the starter relay from the PDC as connected to battery voltage and should be hot at all
described in this group to perform the following tests: times. If OK, go to Step 2. If not OK, repair the open
(1) A relay in the de-energized position should circuit to the PDC fuse as required.
have continuity between terminals 87A and 30, and (2) The relay normally closed terminal (87A) is
no continuity between terminals 87 and 30. If OK, go connected to terminal 30 in the de-energized position,
to Step 2. If not OK, replace the faulty relay. but is not used for this application. Go to Step 3.
(2) Resistance between terminals 85 and 86 (elec- (3) The relay normally open terminal (87) is con-
tromagnet) should be 75 65 ohms. If OK, go to Step nected to the common feed terminal (30) in the ener-
3. If not OK, replace the faulty relay. gized position. This terminal supplies battery voltage
(3) Connect a battery B+ lead to terminals 86 and to the starter solenoid field coils. There should be
a ground lead to terminal 85 to energize the relay. continuity between the cavity for relay terminal 87
The relay should click. Also test for continuity and the starter solenoid terminal at all times. If OK,
between terminals 30 and 87, and no continuity go to Step 4. If not OK, repair the open circuit to the
between terminals 87A and 30. If OK, refer to Relay starter solenoid as required.
Circuit Test procedure. If not OK, replace the faulty (4) The coil battery terminal (86) is connected to
relay. the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position.
Check for battery voltage at the cavity for relay ter-
minal 86 with the ignition switch in the Start posi-
tion, and no voltage when the ignition switch is
released to the On position. If OK, go to Step 5. If
not OK, check for an open or short circuit to the igni-
tion switch and repair, if required. If the circuit to
the ignition switch is OK, see the Ignition Switch
Test procedure in this group.
Starter Relay Pinout

RS STARTING 8F - 31
(5) The coil ground terminal (85) is connected to (b) Connect positive lead of the voltmeter to the
the electromagnet in the relay. It is grounded battery positive post, and negative lead to the bat-
through the transmission range sensor only when the tery positive cable clamp. Rotate and hold the igni-
gearshift selector lever is in the Park or Neutral tion switch key in the START position. Observe the
positions. Check for continuity to ground at the cav- voltmeter. If voltage is detected, correct poor con-
ity for relay terminal 85. If not OK with an auto- tact between the cable clamp and post.
matic transmission, check for an open or short circuit (c) Connect negative lead of voltmeter to battery
to the transmission range sensor and repair. negative terminal, and positive lead to engine
block near the battery cable attaching point.
SAFETY SWITCHES Rotate and hold the ignition switch in the START
For diagnostics of the Transmission Range Sensor, position. If voltage reads above 0.2 volt, correct
refer to the Transaxle section for more information. poor contact at ground cable attaching point. If
If equipped with Clutch Interlock/Upstop Switch, voltage reading is still above 0.2 volt after correct-
refer to Diagnosis and Testing in the Clutch section. ing poor contacts, replace ground cable.
(4) Connect positive voltmeter lead to the starter
IGNITION SWITCH motor housing and the negative lead to the battery
After testing starter solenoid and relay, test igni- negative terminal. Hold the ignition switch key in
tion switch and wiring. Refer to the Ignition Section the START position. If voltage reads above 0.2 volt,
or Wiring Diagrams for more information. Check all correct poor starter to engine ground.
wiring for opens or shorts, and all connectors for (a) Connect the positive voltmeter lead to the
being loose or corroded. battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid. Rotate and
BATTERY hold the ignition switch in the START position. If
For battery diagnosis and testing, refer to the Bat- voltage reads above 0.2 volt, correct poor contact at
tery section for procedures. battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
ALL RELATED WIRING AND CONNECTORS replace battery positive cable.
Refer to Wiring Diagrams for more information. (b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag- FEED CIRCUIT TEST
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter, NOTE: The following results are based upon the
accurate to 1/10 of a volt. vehicle being at room temperature.
CAUTION: Ignition and Fuel systems must be dis- The following procedure will require a suitable
abled to prevent engine start while performing the volt-ampere tester (Fig. 2).
following tests.
(1) To disable the Ignition and Fuel systems, dis-

connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) Remove the air cleaner assembly for access to
battery terminals. Refer to the Fuel section for ser-
vice procedures.
(3) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp. Rotate and hold the
ignition switch in the START position. Observe the Fig. 2 Volt Ampere Tester
voltmeter. If voltage is detected, correct poor con- CAUTION: Before performing any starter tests, the
tact between cable clamp and post. ignition and fuel systems must be disabled.
8F - 32 STARTING RS
(1) Check battery before performing this test. Bat- equipment and connect ASD relay. Start the vehicle
tery must be fully charged. several times to assure the problem has been cor-
(2) Connect a volt-ampere tester to the battery ter- rected.
minals. Refer to the operating instructions provided
with the tester being used.
(3) To disable the ignition and fuel systems, dis- SPECIFICATIONS
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen- STARTER
ter (PDC). Refer to the PDC cover for proper relay
location. MANUFACTURER NIPPONDENSO
(4) Verify that all lights and accessories are OFF,
Engine Application 2.4L /3.3/3.8L
and the transmission shift selector is in the PARK
and SET parking brake. Power rating 1.2 Kw
Voltage 12 VOLTS
CAUTION: Do not overheat the starter motor or
No. of Fields 4
draw the battery voltage below 9.6 volts during
cranking operations. No. of Poles 4
Brushes 4
(5) Rotate and hold the ignition switch in the
Drive Conventional Gear Train
START position. Observe the volt-ampere tester (Fig.
2). Free running Test
• If voltage reads above 9.6 volts, and amperage Voltage 11
draw reads above 280 amps, check for engine seizing
Amperage Draw 73 Amp
or faulty starter.
• If voltage reads 12.4 volts or greater and amper- Minimum Speed 3401 RPM
age reads 0 to 10 amps, check for corroded cables SolenoidClosing Voltage 7.5 Volts
and/or bad connections.
Cranking Amperage Draw 150 - 200 Amps.
• Voltage below 9.6 volts and amperage draw
test
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal. Engine should be up to operating temperature.
(6) After the starting system problems have been Extremely heavy oil or tight engine will increase
corrected, verify the battery state-of-charge and starter amperage draw.
charge battery if necessary. Disconnect all testing
Torques

Starter Mounting Bolts 47.4 35
Starter Solenoid Battery 11.3 8.3 100
Nut
RS STARTING 8F - 33
STARTER MOTOR (4) Remove nut holding B+ wire to terminal.

(5) Disconnect solenoid and B+ wires from starter
terminals.
REMOVAL - 2.4L
(6) Remove the lower bolt.
(1) Release hood latch and open hood (Fig. 3).
(7) Remove the upper bolt and ground wire (Fig.
5).
Fig. 3 STARTER 2.4L

(2) Disconnect and isolate the battery negative Fig. 5 Upper Bolt and Ground Wire
cable.
(8) Remove starter.
(3) Disconnect solenoid wire connector from termi-
nal (Fig. 4).
REMOVAL - 3.3/3.8L
cable.
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 6).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 7).
(7) Remove starter from bellhousing (Fig. 8).
(8) Separate starter spacer from transaxle bell-
housing.
Fig. 4 BATTERY CABLE AND FIELD WIRE 2.4L

8F - 34 STARTING RS
STARTER MOTOR (Continued)
Fig. 8 STARTER 3.3/3.8L

1 - BELL HOUSING PLATE
2 - FLYWHEEL
Fig. 6 Starter
3 - ENGINE MOUNT
1 - SOLENOID CONNECTOR 4 - STARTER
2 - B+ CONNECTOR 5 - SPACER
(3) Install the upper bolt and ground wire (Fig. 5).
(4) Place solenoid and B+ wires in position on
starter terminals (Fig. 4).
(5) Install nut to hold B+ wire to terminal.
(6) Connect solenoid wire connector onto terminal.
(8) Verify starter operation.
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install bolts and ground wire (Fig. 5) to hold
starter to transaxle bellhousing.
Fig. 7 Starter Bolts (4) Connect solenoid connector into starter.
1 - STARTER (5) Install nut to hold B+ terminal to starter sole-
2 - STARTER BOLTS noid.
3 - TRANSAXLE (6) Lower vehicle.
4 - ENGINE MOUNT (7) Connect battery negative cable.
(8) Verify starter operation.
INSTALLATION - 2.4L
(1) Place starter in position on vehicle.
(2) Install the lower bolts to hold starter to tran-
saxle bellhousing.
RG ENGINE SYSTEMS 8Fa - 1
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM - RG ONLY . . . . . . . . . . . . . . . . 1 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY SYSTEM - RG ONLY
TABLE OF CONTENTS
page page
BATTERY BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BATTERY CABLES
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY
DESCRIPTION
There are two different batteries available on this
model. Vehicles equipped with a diesel engine utilize
a spiral wound plate designed battery with recombi-
nation technology. This is a maintenance-free battery
that is capable of delivering more power than a con-
ventional battery. This additional power is required
by a diesel engine during cold cranking. Vehicles
equipped with a gasoline engine utilize a conven-
tional battery. Refer to the following information for
detailed differences and descriptions of these two bat-
teries.
SPIRAL PLATE BATTERY - DIESEL ENGINE

Spiral plate technology takes the elements of tradi-
tional batteries - lead and sulfuric acid - to the next
level. By tightly winding layers of spiral grids and
acid-permeated vitreous separators into cells, the
manufacturer has developed a battery with more
power and service life than conventional batteries the
same size. The spiral plate battery is completely, per- Fig. 1 MAINTENANCE-FREE DIESEL ENGINE
manently sealed. Through gas recombination, hydro- BATTERY
gen and oxygen within the battery are captured The acid inside an spiral plate battery is bound
during normal charging and reunited to form the within the vitreous separators, ending the threat of
water within the electrolyte, eliminating the need to acid leaks. This feature allows the battery to be
add distilled water. Therefore, these batteries have installed in any position anywhere in the vehicle.
non-removable battery vent caps (Fig. 1). Water can-
not be added to this battery.
8Fa - 2 BATTERY SYSTEM - RG ONLY RG
BATTERY (Continued)
Spiral plate technology is the process by which the these batteries may require additional distilled water
plates holding the active material in the battery are after years of service.
wound tightly in coils instead of hanging flat, like Conventional batteries are made up of six individ-
conventional batteries. This design has a lower inter- ual cells that are connected in series. Each cell con-
nal resistance and also increases the active material tains positive charged plate groups made of lead
surface area. oxide, and negatively charged plate groups made of
sponge lead. The plates are submerged in a sulfuric
WARNING: NEVER EXCEED 14.4 VOLTS WHEN acid and water solution called electrolyte.
CHARGING A SPIRAL PLATE BATTERY. PERSONAL Both batteries are used to store electrical energy
INJURY AND/OR BATTERY DAMAGE MAY RESULT. potential in a chemical form. When an electrical load
is applied to the battery terminals, an electrochemi-
Due to the maintanance-free design, distilled water cal reaction occurs within the battery. This reaction
cannot be added to this battery. Therefore, if more causes the battery to discharge electrical current.
than 14.4 volts are used during the spiral plate bat- Refer to the RS service information for additional
tery charging process, water vapor can be exhausted Battery System information.
through the pressure-sensitive battery vents and lost
for good. This can permanently damage the spiral STANDARD PROCEDURE - CHECKING BATTERY
plate battery. Never exceed 14.4 volts when charging
a spiral plate battery. Personal injury and/or battery ELECTROLYTE LEVEL
damage may result. The following procedure can be used to check the
electrolyte level in a lead-acid battery.
CONVENTIONAL BATTERY - GASOLINE ENGINE (1) Unscrew and remove the battery cell caps with
a flat-bladed screw driver (Fig. 3).
Fig. 2 BATTERY CELL CAP REMOVAL/ Fig. 3 BATTERY CELL CAP REMOVAL/
INSTALLATION - LOW-MAINTANANCE GASOLINE INSTALLATION- CONVENTIONAL BATTERY ONLY
ENGINE BATTERY 1 - BATTERY CELL CAP
1 - BATTERY CELL CAP 2 - BATTERY CASE
2 - BATTERY CASE
WARNING: NEVER PUT YOUR FACE NEAR A GAS-
SING, HOT OR SWELLED BATTERY. SERIOUS PER-
Low-maintenance conventional batteries are used SONAL INJURY MAY RESULT.
on vehicles equipped with a gasoline engine, these
batteries have removable battery cell caps (Fig. 2). (2) Wearing safety glasses, look through the bat-
Water can be added to this battery. Under normal tery cell cap holes to determine the level of the elec-
service, the composition of this battery reduces gas- trolyte in the battery. The electrolyte should be above
sing and water loss at normal charge rates. However the hooks inside the battery cells (Fig. 4).
RG BATTERY SYSTEM - RG ONLY 8Fa - 3
BATTERY (Continued)
After the battery has been charged to 12.6 volts or
greater, perform a load test to determine the battery
the proper battery load test procedures. If the battery
will endure a load test, return the battery to service.
If the battery will not endure a load test, it is faulty
and must be replaced.
Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
service. Refer to Battery System Cleaning for the
proper battery system cleaning procedures, and Bat-
tery System Inspection for the proper battery system
inspection procedures.
CHARGING A COMPLETELY DISCHARGED

BATTERY – SPIRAL PLATE BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce-
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure the voltage at the battery posts with a
Fig. 4 HOOK INSIDE BATTERY CELLS - voltmeter, accurate to 1/10 (0.10) volt (Fig. 5). If the
CONVENTIONAL BATTERY ONLY reading is below ten volts, the battery charging cur-
1 - TOP OF BATTERY rent will be low. It could take some time before the
2 - HOOK INSIDE BATTERY CELLS battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
(3) Add only distilled water until the electrolyte
is above the hooks inside the battery cells (Fig. 4).
STANDARD PROCEDURE - SPIRAL PLATE

BATTERY CHARGING
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
• Open-circuit voltage of the battery is 12.65 volts
or above.
• Battery passes Load Test multiple times.
WARNING: IF THE BATTERY SHOWS SIGNS OF

FREEZING, LEAKING, LOOSE POSTS OR LOW
ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-
BOOST, OR CHARGE. THE BATTERY MAY ARC Fig. 5 Voltmeter - Typical
INTERNALLY AND EXPLODE. PERSONAL INJURY
AND/OR VEHICLE DAMAGE MAY RESULT.
cable. Connect the battery charger leads. Some bat-
tery chargers are equipped with polarity-sensing cir-
CAUTION: Always disconnect and isolate the bat- cuitry. This circuitry protects the battery charger and
tery negative cable before charging a battery. Do the battery from being damaged if they are improp-
not exceed 14.4 volts while charging a battery. erly connected. If the battery state-of-charge is too
low for the polarity-sensing circuitry to detect, the
battery charger will not operate. This makes it
CAUTION: The battery should not be hot to the appear that the battery will not accept charging cur-
touch. If the battery feels hot to the touch, turn off rent. See the instructions provided by the manufac-
the charger and let the battery cool before continu- turer of the battery charger for details on how to
ing the charging operation. Damage to the battery bypass the polarity-sensing circuitry.
may result.
8Fa - 4 BATTERY SYSTEM - RG ONLY RG
BATTERY (Continued)
(3) Battery chargers vary in the amount of voltage BATTERY CHARGING TIME TABLE
and current they provide. The amount of time
required for a battery to accept measurable charging Charging
5 Amps 8 Amps
current at various voltages is shown in the Charge Amperage
Rate Table. If the charging current is still not mea- Open Circuit Hours Charging @ 21°
surable at the end of the charging time, the battery Voltage C (70° F)
is faulty and must be replaced. If the charging cur- 10.00 to 11.99 14 hours 7 hours
rent is measurable during the charging time, the bat-
Below 10.00 18 hours 9 hours
tery may be good and the charging should be
completed in the normal manner.
BATTERY CABLES
CHARGE RATE TABLE
Voltage Hours REMOVAL
14.4 volts maximum up to 4 hours The battery cables on this model may include por-
tions of wiring circuits for the generator and other
13.0 to 14 volts up to 8 hours components on the vehicle. If battery cable replace-
12.9 volts or less up to 16 hours ment is required, it will be necessary to extract the
cables out of the engine wire harness assembly. Use
CHARGING TIME REQUIRED care not to damage the other wires and circuits
The time required to charge a battery will vary, which are also packaged into the engine wire harness
depending upon the following factors: assembly.
• Battery Capacity - A completely discharged (1) Turn the ignition switch to the Off position. Be
heavy-duty battery requires twice the charging time certain that all electrical accessories are turned off.
of a small capacity battery. (2) Disconnect and isolate the negative battery
• Temperature - A longer time will be needed to cable terminal.
charge a battery at -18° C (0° F) than at 27° C (80° (3) Remove the battery thermal guard from the
F). When a fast battery charger is connected to a cold battery tray (Refer to 8 - ELECTRICAL/BATTERY
battery, the current accepted by the battery will be SYSTEM/THERMAL GUARD - REMOVAL).
very low at first. As the battery warms, it will accept (4) Remove the tape from the engine wire harness
a higher charging current rate (amperage). assembly, to access the desired battery cable.
• Charger Capacity - A battery charger that (5) One at a time, trace and disconnect the battery
supplies only five amperes will require a longer cable retaining fasteners and routing clips until the
charging time. A battery charger that supplies eight desired cable is free from the vehicle.
amperes will require a shorter charging time. (6) Feed the battery cable out of the vehicle.
• State-Of-Charge - A completely discharged bat-
tery requires more charging time than a partially INSTALLATION
discharged battery. Electrolyte is nearly pure water (1) Position the battery cable in the vehicle.
in a completely discharged battery. At first, the (2) One at a time, trace and install the battery
charging current (amperage) will be low. As the bat- cable retaining fasteners and routing clips until the
tery charges, the specific gravity of the electrolyte desired cable is properly installed in the engine wire
will gradually rise. harness assembly.
The Battery Charging Time Table gives an indica- (3) Install the tape on the engine wire harness
tion of the time required to charge a typical battery assembly.
at room temperature based upon the battery state-of- (4) Install the battery thermal guard on the bat-
charge and the charger capacity. tery tray (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/THERMAL GUARD - INSTALLATION).
BATTERY CHARGING TIME TABLE (5) Connect the negative battery cable terminal.
Charging
5 Amps 8 Amps
Amperage
Open Circuit Hours Charging @ 21°
Voltage C (70° F)
12.25 to 12.49 6 hours 3 hours
12.00 to 12.24 10 hours 5 hours
RG CHARGING 8Fa - 5
CHARGING
TABLE OF CONTENTS
page page
GENERATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERATOR (3) Raise vehicle and support.

(4) Turn wheels to the right. Remove the right
front splash shield (Fig. 3).
REMOVAL
(1) Disconnect the negative battery cable (Fig. 1).
Fig. 3 SPLASH SHIELD

Fig. 1 BATTERY CONNECTION
(5) Remove the generator drive belt (Fig. 4).
(2) Remove the engine cover (Fig. 2).
Fig. 2 ENGINE COVER Fig. 4 GENERATOR BELT

8Fa - 6 CHARGING RG
GENERATOR (Continued)
(6) Lower vehicle.
(7) Disconnect the generator battery connection
(Fig. 5).
Fig. 7 AIR BOX REMOVED
Fig. 5 GENERATOR CONNECTIONS

1 - BATTERY CONNECTION
2 - FIELD CONNECTION
(8) Disconnect the field connection (Fig. 5).

(9) Relocate the wiring harness on upper generator
bracket (Fig. 6).
Fig. 8 GENERATOR LOWER BOLTS

1 - LOWER MOUNTING BOLTS
INSTALLATION
(1) Install generator.
(2) Install the 2 lower mounting Bolts (Fig. 8).
(3) Install the Air Cleaner Box (Fig. 7).
(4) Install the upper support bracket (Fig. 6).
(5) Install the wiring harness on upper generator
bracket (Fig. 6).
(6) Connect the field connection (Fig. 5).
Fig. 6 UPPER SUPPORT BRACKET (7) Connect the generator battery connection (Fig. 5).
1 - WIRING HARNESS (8) Raise vehicle and support.
2 - UPPER BRACKET (9) Install the generator drive belt (Fig. 4).
(10) Install the right front splash shield (Fig. 3).
(10) Remove the Air Cleaner Box (Fig. 7). (11) Lower vehicle.
(11) Remove the 2 lower mounting Bolts (Fig. 8). (12) Install the engine cover (Fig. 2).
(12) Remove generator. (13) Connect the negative battery cable (Fig. 1).
RG STARTING 8Fa - 7
STARTING
TABLE OF CONTENTS
page page
STARTER MOTOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STARTER MOTOR
REMOVAL
(3) Remove the lower engine splash shield.
(4) Remove the electrical connectors from the
starter (Fig. 1).
Fig. 2 STARTER MOUNTING BOLTS

1 - STARTER
2 - MOUNTING BOLTS
INSTALLATION
(2) Install the starter.
(3) Install the starter mounting bolts (Fig. 2).
Fig. 1 STARTER LOCATION (4) Install the electrical connectors to the starter
(Fig. 1).
(5) Remove the starter mounting bolts (Fig. 2). (5) Install the lower engine splash shield.
(6) Remove the starter. (6) Connect the negative battery cable.
(7) Lower vehicle.
RS HEATED SYSTEMS 8G - 1
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 7

HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS REAR WINDOW DEFOGGER SWITCH

DESCRIPTION . . . . . . . . . . . . . . . .............1 DESCRIPTION . . . . . . . . . . . . . . . . . . . .........2
OPERATION . . . . . . . . . . . . . . . . .............2 OPERATION . . . . . . . . . . . . . . . . . . . . .........2
DEFOGGER RELAY WINDSHIELD GRID
DESCRIPTION . . . . . . . . . . . . . . . .............2 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .3
REAR WINDOW DEFOGGER GRID SYSTEM TEST. . . . . . . . . . . . . . . . . . . . . . . . . .3
STANDARD PROCEDURE . . . . . . .............2 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .3
GRID LINE REPAIR-REAR . . . . .............2 GRID LINE AND TERMINAL REPAIR . . . . . . . . .3
HEATED GLASS
DESCRIPTION
Fig. 2 (TYPICAL) Heated Windshield Wiper De-icer

1 - DEFROSTER OUTLET
2 - VIN #
3 - HEATED WINDSHIELD GRID
Fig. 1 REAR WINDOW DEFOGGER (TYPICAL)
1 - REAR DEFOGGER GRID
2 - REAR WINDOW Windshield Wiper De-icer (Fig. 2) is available on
select models.
The electrically heated Rear Window Defogger (Fig.
1), Heated Power Side View Mirrors, and Heated
8G - 2 HEATED GLASS RS
HEATED GLASS (Continued)
OPERATION REAR WINDOW DEFOGGER

The Rear Window Defogger (Fig. 1) system consists
of two vertical bus bars linked by a series of grid
SWITCH
lines on the inside surface of the rear window. The
electrical circuit consists of the rear defogger switch DESCRIPTION
in the HVAC control assembly and a relay with timer
switch to turn OFF the system after ten minutes.
The main feed circuit is protected by fuse 13 (40
amp) in the Power Distribution Center (PDC) which
is integrated as a unit call Integrated Power Module
(IPM). The rear defogger switch and relay also acti-
vates the heated power side view mirrors and heated
windshield wiper de-icer. The heated windshield
wiper de-icer is powered by the RUN/ACC relay in
the IPM and feed thru fuse #11 (20 amp) in the PDC.
The heated mirror circuit is protected by a non-servi-
cable Positive Temperature Coefficient (PTC) located
inside the PDC. The heated windshield wiper de-icer
circuit is protected by fuse 11 (20 amp) in the PDC.
The Heated Windshield Wiper Deicer is also acti-
vated when the DEFROST mode is selected on the
HVAC. In the DEFROST mode the rear defogger Fig. 3 HVAC CONTROL PANEL
relay/timer is bypassed, the heated windshield wiper 1 - Trim Bezel
de-icer will stay ON until the another mode is 2 - ACT Sensor
selected. For circuit information and component loca- 3 - A/C Request Switch
tion refer to appropriate section for Wiring Diagrams. 4 - Rear Window Defogger/Heated Mirrors Switch Combo
5 - Front Window Defroster Mode Selector
CAUTION:
Since grid lines can be damaged or scraped off
The rear window defogger switch is integrated into
with sharp instruments, care should be taken in
the HVAC control panel assembly (Fig. 3)
cleaning the glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
OPERATION
mended. A LED indicator will illuminate when the switch is
activated. The switch energizes the HVAC control
assembly when it requests the Front Control Module
(FCM) to activate the rear window defogger relay.
DEFOGGER RELAY The relay controls the current to flow to the grids of
the rear window defogger, heated power side view
DESCRIPTION mirrors and the heated windshield wiper de-icer. The
There is no heated glass relay it is integrated into defogger relay will be on for approximately 10 min-
the (E.B.L) relay that is located in the IPM in the utes or until the control switch or ignition is turned
engine compartment. off.
REAR WINDOW DEFOGGER

GRID
STANDARD PROCEDURE - GRID LINE
REPAIR-REAR
For Grid repair procedure for the rear window
defogger (Refer to 8 - ELECTRICAL/HEATED
GLASS/WINDSHIELD GRID - STANDARD PROCE-
DURE).
RS HEATED GLASS 8G - 3
WINDSHIELD GRID
DIAGNOSIS AND TESTING - SYSTEM TEST
Electrically heated rear window defogger or the
heated windshield wiper deicer operation can be
checked on the vehicle in the following manner:
(1) Turn the ignition switch to the ON position.
(2) Using a ammeter on the battery, turn the rear
defogger control switch to the ON position, a distinct
increase in amperage draw should be noted.
(3) The rear window defogger or the heated wind-
shield wiper deicer operation can be checked by feel-
ing the glass. A distinct difference in temperature
between the grid lines and adjacent clear glass can
be detected in 3 to 4 minutes of operation.
(4) Using a DC voltmeter (Fig. 4) contact terminal Fig. 4 Grid Line Test
B with the negative lead, and terminal A with the
1 - VOLTMETER
positive lead. The voltmeter should read 10-14 volts. 2 - TERMINAL B
(5) Indicator light illumination means that there is 3 - FEED WIRE
power available at the switch only and does not nec- 4 - MID-POINT C (TYPICAL)
essarily verify system operation. 5 - HEATED REAR WINDOW GRIDS
(6) If turning the defogger switch ON, no distinct 6 - GROUND WIRE
current draw on the ammeter the problem should be 7 - TERMINAL A
isolated in the following manner:
• Confirm that ignition switch is ON.
• Ensure that the heated rear window or the STANDARD PROCEDURE - GRID LINE AND
heated windshield wiper deicer feed pigtail is con- TERMINAL REPAIR
nected to the wiring harness and that the ground
pigtail is in fact grounded. WARNING:
• Ensure that the proper fuse in the PDC is OK. REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
(7) When the above steps have been completed and CONTAINS EPOXY RESIN AND AMINE TYPE HARD-
the system is still inoperative it may be necessary to ENER, HARMFUL IF SWALLOWED. AVOID CON-
connect a DRBIII scan tool and refer to the Diagnos- TACT WITH SKIN AND EYES. FOR SKIN, WASH
tic Service Manual, you may also check for the fol- AFFECTED AREAS WITH SOAP AND WATER. DO
lowing being defective: NOT TAKE INTERNALLY. IF TAKEN INTERNALLY,
• HVAC control assembly INDUCE VOMITING; CALL A PHYSICIAN IMMEDI-
• Rear window defogger relay in the IPM. ATELY. IF IN CONTACT WITH EYES, FLUSH WITH
• Check for loose connector or a wire pushed out PLENTY OF WATER. USE WITH ADEQUATE VENTI-
of connector. LATION. DO NOT USE NEAR FIRE OR FLAME. CON-
• Rear window or the windshield grid lines (all TENTS CONTAINS 3% FLAMMABLE SOLVENTS.
grid lines would have to be broken, or one of the feed KEEP OUT OF REACH OF CHILDREN.
pigtails not connected to the bus bar, for no ammeter
deflection). The repair for the front windshield or the rear win-
(8) If turning the switch ON produces severe volt- dow grids are the same.
meter deflection, the circuit should be closely checked The repair of grid lines and replacement of the ter-
for a shorting condition. minal is possible using the Mopart Repair Package
(9) If the system operation has been verified but or equivalent.
indicator LED does not light, replace the HVAC con- (1) Clean area surrounding grid line or terminal
trol assembly. by gently rubbing area with steel wool.
(10) For detailed wiring information, refer to the (2) Wipe area with clean cloth soaked in alcohol or
appropriate section for Wiring Diagrams. similar solvent. It is necessary that all contaminants
be removed from repair area.
8G - 4 HEATED GLASS RS
WINDSHIELD GRID (Continued)
(3) Remove package separator clamp and mix plas- (10) After epoxy is properly cured remove wedge
tic conductive epoxy thoroughly. from terminal and check the operation of the rear
(4) For grid line, mark off area to be repaired with window defogger.
masking tape (Fig. 5).
(5) Apply conductive epoxy through slit in masking
tape. Overlap both ends of the break.
(6) For a terminal replacement, apply a thin layer
of epoxy to area where terminal was fastened.
(7) Apply a thin layer of epoxy on terminal and
place terminal on desired location. To prevent termi-
nal from falling off use a wooden wedge to secure it.
(8) Carefully remove masking tape from grid line.
CAUTION:
Do not allow the laminated windshield glass surface
to exceed 82° C (180° F) or the glass may fracture.
The rear window glass surface should not exceed
204° C (400° F).
Fig. 5 Grid Line Repair
(9) Allow epoxy to cure 24 hours at room tempera- 1 - BREAK
ture. 2 - GRID LINE
3 - MASKING TAPE
RS HEATED MIRRORS 8G - 5
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS OPERATION . . . . . . . . . . . ..................5

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 HEATED MIRROR GRID
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 STANDARD PROCEDURE . ..................6
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .5 HEATED MIRROR . . . . . ..................6
HEATED MIRROR TEST. . . . . . . . . . . . . . . . . . .5 RELAY
MIRROR SWITCH DESCRIPTION . . . . . . . . . . ..................6
DESCRIPTION . . . . . . . . . . ..................5
HEATED MIRRORS DIAGNOSIS AND TESING - HEATED MIRROR

TEST
DESCRIPTION Heated mirrors are available on models with
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The
Power Mirrors and Rear Window Defogger only. heated mirror is controlled by the rear window defog-
ger switch. The heated mirror is ON when the rear
OPERATION window defogger is ON.
The heated mirror is controlled by the rear window (1) The mirror glass should be warm to the touch.
defogger switch. The heated mirror is ON when the (2) If not, check the 20 amp fuse (11) in the Power
rear window defogger is ON (Fig. 1) Distribution Center (PDC) part of the Integrated
Power Module (IPM) in the engine compartment.
(3) Test voltage at rear window defogger switch.
• If no voltage repair wire.
• Remove mirror glass and test the wires for con-
tinuity. If no continuity repair wires.
• If wires are OK, replace mirror glass.
• To test defogger switch refer to the appropriate
section in Electrical.
MIRROR SWITCH
DESCRIPTION
The heated mirror switch is integrated into the
rear window defogger switch located in the HVAC
control panel (Fig. 1)
Fig. 1 HVAC CONTROL PANEL OPERATION
1 - Trim Bezel A LED indicator will illuminate when the switch is
2 - ACT Sensor
activated. The switch energizes the HVAC control
3 - A/C Request Switch
assembly when it requests the Front Control Module
4 - Rear Window Defogger/Heated Mirrors Switch Combo
5 - Front Window Defroster Mode Selector
(FCM) to activate the rear window defogger relay.
The relay controls the current to flow to the grids of
the rear window defogger, heated power side view
mirrors and the heated windshield wiper de-icer. The
defogger relay will be on for approximately 10 min-
utes or until the control switch or ignition is turned
off.
8G - 6 HEATED MIRRORS RS
HEATED MIRROR GRID RELAY

STANDARD PROCEDURE - HEATED MIRROR DESCRIPTION
Replacement of the mirror is necessary if the grid There is no heated mirror relay it is integrated
is damaged and diagnostics have been performed into the (E.B.L) relay that is located in the IPM in
(Refer to 23 - BODY/EXTERIOR/SIDE VIEW MIR- the engine compartment.
ROR - REMOVAL).
RS HEATED SEAT SYSTEM 8G - 7
HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HEATED SEAT ELEMENT . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HEATED SEAT SENSOR
DRIVER HEATED SEAT SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HEATED SEAT SENSOR. . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 9 PASSENGER HEATED SEAT SWITCH
HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEATED SEAT ELEMENT HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . 12
HEATED SEAT SYSTEM seat heating ranges, Low or High, or to turn the indi-
vidual seat heaters Off using the heated seat
switches located in the instrument panel center bezel
DESCRIPTION
near the bottom of the HVAC outlets (Fig. 1). The
heated seat switch circuit operates on ignition
switched battery current supplied through a fuse in
the intelligent power module, only when the ignition
switch is in the On position.
This section covers the following components of the
heated seat system:
• Heated seat elements
• Heated seat sensors
• Heated seat switches
The Heated seat module (or memory heated seat
module) can be found in the Electronic Control Mod-
ules section of the service manual.
The heated seat system also relies upon resources
shared with other electronic modules in the vehicle
over the Programmable Communications Interface
(PCI) J1850 data bus network. The J1850 (PCI) data
bus network allows the sharing of sensor informa-
tion. This helps to reduce wire harness complexity,
internal controller hardware, and component sensor
current loads. At the same time, this system provides
increased reliability, enhanced diagnostics, and
allows the addition of many new feature capabilities.
Fig. 1 HEATED SEAT SWITCHES For diagnosis of these electronic modules or of the
Individually controlled driver and passenger side J1850 (PCI) data bus network, the use of a DRB IIIt
electrically heated front seats are available factory- scan tool, or equivalent and the proper Diagnostic
installed optional equipment on this model, when it Procedures manual are recommended.
is also equipped with the power seat option. The The electronic modules that may affect heated seat
heated seat system allows both the driver and the system operation are as follows:
front seat passenger the option to select one of two • Body Control Module (BCM) - Refer to Body
Control Module in Electronic Control Modules for
more information.
8G - 8 HEATED SEAT SYSTEM RS
HEATED SEAT SYSTEM (Continued)
• Remote Keyless Entry Module (RKE) - Refer module. However, the HSM or MHSM will automati-
to Remote Keyless Entry Module in Power Locks cally turn off the heating elements if it detects an
for more information. open in the sensor circuit, a short in the heating ele-
• Electronic Vehicle Information Center ment circuit causing an excessive current draw, or
(EVIC) - Refer to Electronic Vehicle Information when the ignition switch is turned to the Off posi-
Center in Overhead Console for more information. tion.
• Heated Seat Module (HSM) - Refer to Heated See the owner’s manual in the vehicle glove box for
Seat Module in Electronic Control Modules for more more information on the features, use and operation
information. of the heated seat system.
• Memory Heated Seat Module (MHSM) - If
the vehicle is equipped with the Memory System,
refer to Memory Seat Mirror Module (MSMM) in DRIVER HEATED SEAT
Electronic Control Modules for more information. SWITCH
Refer to Wiring Diagrams for complete circuit
diagrams. Following are general descriptions of the DESCRIPTION
major components in the heated seat system.
OPERATION
The heated seat system will only operate when the
ignition switch is in the On position, and the surface
temperature at the front seat heating element sen-
sors is below the designed temperature set points of
the system. The heated seat system will not operate
in ambient temperatures greater than about 41° C
(105° F). The front seat heating elements and sensors
are hard wired to the Heated Seat Module (HSM) or
the Memory Heated Seat Module (MHSM).
The heated seat switches are hard wired to the
Body Control Module (BCM). The BCM monitors the
heated seat switch inputs, then sends heated seat
switch status messages to the HSM or MHSM over
the Programmable Communications Interface J1850
(PCI) data bus. The HSM or MHSM contains the con-
trol logic for the heated seat system. The HSM or
MHSM responds to the heated seat switch status
messages, ignition switch status messages, and the
front seat heating element sensor inputs by control-
ling the output to the front seat heating elements
through integral solid-state relays. Fig. 2 HEATED SEAT SWITCHES
When a seat heater is turned on, the sensor The heated seat switches are mounted in the
located on the seat cushion electric heater element instrument panel center bezel (Fig. 2). The two three-
provides the HSM or MHSM with an input indicating position rocker-type switches, one switch for each
the surface temperature of the seat cushion. If the front seat, are incorporated into one large switch
surface temperature input is below the temperature assembly that also includes the hazzard, rear window
set point for the selected Low or High heated seat wiper and washer switches. The heated seat switches
switch position, the HSM or MHSM energizes the provide a resistor multiplexed signal to the Body
integral solid-state relay, which supplies battery cur- Control Module (BCM) through separate hard wired
rent to the heating elements in the seat cushion and circuits. Each switch has an Off, Low, and High posi-
back. When the sensor input indicates the correct tion so that both the driver and the front seat pas-
temperature set point has been achieved, the HSM or senger can select a preferred seat heating mode.
MHSM de-energizes the solid-state relay. The HSM Each switch has two Light-Emitting Diodes (LED)
or MHSM will continue to cycle the solid-state relay which light to indicate that the heater for the seat is
as needed to maintain the temperature set point. turned on.
The HSM or MHSM and the seat heater elements The heated seat switches and their LEDs cannot
operate on non-switched battery current supplied be repaired. If either switch or LED is faulty or dam-
through the power seat fuse in the intelligent power aged, the entire switch assembly must be replaced.
DRIVER HEATED SEAT SWITCH (Continued)
OPERATION harness connector for the inoperative heated seat

There are three positions that can be selected with switch(es) and a good ground. There should be conti-
each of the heated seat switches: Off, Low, or High. nuity. If OK, go to Step 4. If not OK, repair the open
When the left side of the switch rocker is fully ground circuit to ground as required.
depressed, the Low position is selected and the high (4) Reconnect the battery negative cable. Turn the
position LED indicator illuminates. When the right ignition switch to the On position. Check for battery
side of the switch rocker is fully depressed, the High voltage at the fused ignition switch output (run) cir-
position is selected and the low position LED indica- cuit cavity of the instrument panel wire harness con-
tor illuminates. When the switch rocker is moved to nector for the inoperative heated seat switch(es). If
its neutral position (middle), Off is selected and both OK, turn the ignition switch to the Off position, dis-
LED indicators are extinguished. connect and isolate the battery negative cable, and go
Both switches provide separate resistor multi- to Step 5. If not OK, repair the open fused ignition
plexed hard wire inputs to the BCM to indicate the switch output (run) circuit to the intelligent power
selected switch position. The BCM monitors the module fuse as required.
switch inputs and sends heated seat switch status (5) Test the heated seat switch(es) as shown in the
messages to the Heated Seat Module (HSM) or the Heated Seat Switch Test chart (Fig. 3). If OK, go to
Memory Heated Seat Module (MHSM) over the Pro- Step 6. If not OK, replace the faulty heated seat
grammable Communications Interface (PCI) data switch(es).
bus. The HSM or MHSM responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36° C (97° F),
and the High heat position set point is about 41° C
(105° F).
DIAGNOSIS & TESTING - HEATED SEAT

SWITCH
For complete circuit diagrams, refer to Wiring
Diagrams.

BAGS, REFER TO THE RESTRAINTS SECTION OF
THIS MANUAL BEFORE ATTEMPTING ANY STEER-
ING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused ignition switch output (run) Fig. 3 SWITCH CONNECTOR
fuse in the intelligent power module. If OK, go to
Step 2. If not OK, repair the shorted circuit or com- DRIVER HEATED SEAT SWITCH TEST
ponent as required and replace the faulty fuse. SWITCH RESISTANCE RESISTANCE
(2) Turn the ignition switch to the On position. POSITION BETWEEN (OHMS)
Check for battery voltage at the fused ignition switch
Off Pin 4 & 5 OPEN
output (run) fuse in the intelligent power module. If
OK, go to Step 3. If not OK, repair the open fused Low Pin 4 & 5 3570
ignition switch output (run) circuit to the ignition High Pin 4 & 5 1430
switch as required. All resistance values are 61%.
cable. Remove the center bezel from the instrument
(6) Disconnect the instrument panel wire harness
panel and disconnect the instrument panel wire har-
connector from the Body Control Module (BCM) con-
ness connectors from the heated seat switch connec-
nector receptacle. Check for continuity between the
tor receptacle. Check for continuity between the
seat heater switch sensor ground circuit cavity of the
ground circuit cavity of the instrument panel wire
instrument panel wire harness connector for the
DRIVER HEATED SEAT SWITCH (Continued)
inoperative heated seat switch(es) and a good ground.
There should be no continuity. If OK, go to Step 7. If
not OK, repair the shorted seat heater switch sensor
ground circuit as required.
(7) Check for continuity between the seat heater
switch sensor ground circuit cavities of the instru-
ment panel wire harness connector for the in opera-
tive heated seat switch and the instrument panel
wire harness connector for the BCM. There should be
open seat heater switch sensor ground circuit as
required.
switch mux circuit cavity of the instrument panel
wire harness connector for the inoperative heated
seat switch and a good ground. There should be no
shorted seat heater switch mux circuit as required.
seat switch and the instrument panel wire harness
connector for the BCM. There should be continuity. If Fig. 4 SWITCH RETAINING SCREWS
OK, use a DRB IIIt scan tool and the proper Diag- 1 - HEATED SEAT SWITCH ASSEMBLY
nostic Procedures manual to test the BCM. If not 2 - RETAINING SCREWS
OK, repair the open seat heater switch mux circuit
as required.
panel center bezel. Tighten the screws to 1.5 N·m (13
in. lbs.) (Fig. 4).
REMOVAL (3) Install the center bezel onto the instrument
panel. Refer to Instrument Panel Center Bezel in
the Body section for the procedure.
(4) Reconnect the battery negative cable.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system includes two seat heating
INJURY.
elements in each front seat, one for the seat cushion
(1) Disconnect and isolate the battery negative and the other for the seat back. The two elements for
cable. each seat that are connected in series with the
(2) Remove the instrument panel center bezel. Heated Seat Module (HSM). The temperature sensor
Refer to Instrument Panel Center Bezel in the is a Negative Temperature Coefficient (NTC) ther-
Body section for the procedure. mistor. One temperature sensor is used for each seat,
(3) Remove the three screws (Fig. 4) that secure and it is located on the seat cushion heating element
the heated seat switch to the back of the instrument for all models.
panel center bezel. The seat heating elements are sewn into the seat
(4) Remove the heated seat switch from the back cushion cover trim and seat back cover trim units.
of the instrument panel center bezel. The heated seat elements and the temperature sen-
sor cannot be adjusted or repaired and, if faulty or
INSTALLATION damaged, the seat cushion or seat back assembly
(1) Position the heated seat switch onto the back must be replaced. Refer to Seat Cushion or Seat
of the instrument panel center bezel. Back in the Removal and Installation section of
(2) Install and tighten the three screws that secure Body for the seat cushion and seat back service pro-
the heated seat switch to the back of the instrument cedures.
HEATED SEAT ELEMENT (Continued)
OPERATION HEATED SEAT SENSOR

The heated seat elements resist the flow of electri-
cal current. When battery current is passed through DESCRIPTION
the elements, the energy lost by the resistance of the The heated seat temperature sensor is a Negative
elements to the current flow is released in the form Temperature Coefficient (NTC) thermistor. One tem-
of heat. The temperature sensor is a NTC thermistor. perature sensor is used for each seat, and is inte-
When the temperature of the seat cushion cover grated into the seat cushion heating element.
rises, the resistance of the sensor decreases. The
HSM or MHSM supplies a five-volt current to one DIAGNOSIS & TESTING - HEATED SEAT
side of each sensor, and monitors the voltage drop
through the sensor on a return circuit. The MSM or
SENSOR
MHSM uses this temperature sensor input to moni- For complete circuit diagrams, refer to Wiring
tor the temperature of the seat, and regulates the Diagrams.
current flow to the seat heating elements accordingly. (1) Disconnect and isolate the battery negative
cable. Disconnect the 4-way heated seat cushion ele-
ment wire harness connector from the power seat
DIAGNOSIS & TESTING - HEATED SEAT
wire harness. The power seat wire harness connec-
ELEMENT tors for the seat cushion and seat back heating ele-
The wire harness connectors for the seat cushion ments are secured to a bracket located under the
and seat back heating elements are located under the rear edge of the seat cushion frame.
seat, near the rear edge of the seat cushion frame. (2) Using an ohmmeter, check the resistance
For circuit descriptions and diagrams, refer to Group between the seat sensor circuit and the seat temper-
8W, Wiring Diagrams. ature sensor input circuit cavities of the 4-way
heated seat cushion element wire harness connector.
SEAT CUSHION The sensor resistance should be between 2 kilohms
(1) Disconnect and isolate the battery negative at 15° C (60° F) and 200 kilohms at 30° C (85° F). If
cable. Unplug the 4-way heated seat cushion wire not OK, replace the faulty seat cushion cover trim
harness connector. and sensor unit.
(2) Check for continuity between the two heated
seat driver circuit cavities of the seat cushion cover
half of the heated seat cushion wire harness connec- PASSENGER HEATED SEAT
tor. There should be continuity. If OK, go to Step 3. If
not OK, replace the faulty seat cushion cover.
SWITCH
(3) Check for continuity between one of the heated
seat driver circuit cavities of the seat cushion cover DESCRIPTION
half of the heated seat cushion wire harness connec- The heated seat switches are mounted in the
tor and the seat cushion frame. There should be no instrument panel center bezel (Fig. 5). The two three-
continuity. If OK, go to the Seat Back test. If not OK, position rocker-type switches, one switch for each
replace the faulty seat cushion cover. front seat, are incorporated into one large switch
assembly that also includes the hazzard, rear window
SEAT BACK wiper and washer switches. The heated seat switches
(1) Disconnect and isolate the battery negative provide a resistor multiplexed signal to the Body
cable. Unplug the 2-way heated seat back wire har- Control Module (BCM) through separate hard wired
ness connector. circuits. Each switch has an Off, Low, and High posi-
(2) Check for continuity between the heated seat tion so that both the driver and the front seat pas-
driver circuit cavity and the ground circuit cavity of senger can select a preferred seat heating mode.
the seat back cover half of the heated seat back wire Each switch has two Light-Emitting Diodes (LED)
harness connector. There should be continuity. If OK, which light to indicate that the heater for the seat is
go to Step 3. If not OK, replace the faulty seat back turned on.
cover. The heated seat switches and their LEDs cannot
(3) Check for continuity between the heated seat be repaired. If either switch or LED is faulty or dam-
driver circuit cavity of the seat back cover half of the aged, the entire switch assembly must be replaced.
heated seat back wire harness connector and the seat
back frame. There should be no continuity. If OK, OPERATION
test the heated seat sensor as described in this There are three positions that can be selected with
group. If not OK, replace the faulty seat back cover. each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
PASSENGER HEATED SEAT SWITCH (Continued)
INJURY.
(1) Check the fused ignition switch output (run)

fuse in the intelligent power module. If OK, go to
Step 2. If not OK, repair the shorted circuit or com-
ponent as required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run) fuse in the intelligent power module. If
OK, go to Step 3. If not OK, repair the open fused
ignition switch output (run) circuit to the ignition
switch as required.
cable. Remove the center bezel from the instrument
panel and disconnect the instrument panel wire har-
ness connectors from the heated seat switch connec-
tor receptacle. Check for continuity between the
ground circuit cavity of the instrument panel wire
harness connector for the inoperative heated seat
switch(es) and a good ground. There should be conti-
nuity. If OK, go to Step 4. If not OK, repair the open
Fig. 5 HEATED SEAT SWITCHES ground circuit to ground as required.
(4) Reconnect the battery negative cable. Turn the
depressed, the Low position is selected and the high
ignition switch to the On position. Check for battery
position LED indicator illuminates. When the right
voltage at the fused ignition switch output (run) cir-
side of the switch rocker is fully depressed, the High
cuit cavity of the instrument panel wire harness con-
position is selected and the low position LED indica-
nector for the inoperative heated seat switch(es). If
tor illuminates. When the switch rocker is moved to
OK, turn the ignition switch to the Off position, dis-
its neutral position (middle), Off is selected and both
connect and isolate the battery negative cable, and go
LED indicators are extinguished.
to Step 5. If not OK, repair the open fused ignition
Both switches provide separate resistor multi-
switch output (run) circuit to the intelligent power
plexed hard wire inputs to the BCM to indicate the
module fuse as required.
selected switch position. The BCM monitors the
(5) Test the heated seat switch(es) as shown in the
switch inputs and sends heated seat switch status
Heated Seat Switch Test chart (Fig. 6). If OK, go to
messages to the Heated Seat Module (HSM) or the
Step 6. If not OK, replace the faulty heated seat
Memory Heated Seat Module (MHSM) over the Pro-
switch(es).
grammable Communications Interface (PCI) data
bus. The HSM or MHSM responds to the heated seat
switch status messages by controlling the output to PASSENGER HEATED SEAT SWITCH TEST
the seat heater elements of the selected seat. The SWITCH RESISTANCE RESISTANCE
Low heat position set point is about 36° C (97° F), POSITION BETWEEN (OHMS)
and the High heat position set point is about 41° C Off Pin 3 & 4 OPEN
(105° F).
Low Pin 3 & 4 3570
DIAGNOSIS & TESTING - HEATED SEAT High Pin 3 & 4 1430
SWITCH All resistance values are 61%.
For complete circuit diagrams, refer to Wiring
Diagrams. (6) Disconnect the instrument panel wire harness
connector from the Body Control Module (BCM) con-
WARNING: ON VEHICLES EQUIPPED WITH AIR- nector receptacle. Check for continuity between the
BAGS, REFER TO THE RESTRAINTS SECTION OF seat heater switch sensor ground circuit cavity of the
THIS MANUAL BEFORE ATTEMPTING ANY STEER- instrument panel wire harness connector for the
ING WHEEL, STEERING COLUMN, SEAT OR inoperative heated seat switch(es) and a good ground.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR There should be no continuity. If OK, go to Step 7. If
SERVICE. FAILURE TO TAKE THE PROPER PRE- not OK, repair the shorted seat heater switch sensor
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- ground circuit as required.
PASSENGER HEATED SEAT SWITCH (Continued)
INJURY.

cable.
(2) Remove the instrument panel center bezel.
Refer to Instrument Panel Center Bezel in the
Body section for the procedure.
(3) Remove the three screws (Fig. 7) that secure
the heated seat switch to the back of the instrument
panel center bezel.
Fig. 6 SWITCH CONNECTOR

switch sensor ground circuit cavities of the instru-
ment panel wire harness connector for the in opera-
tive heated seat switch and the instrument panel
wire harness connector for the BCM. There should be
open seat heater switch sensor ground circuit as
required.
seat switch and a good ground. There should be no Fig. 7 SWITCH RETAINING SCREWS
continuity. If OK, go to Step 9. If not OK, repair the 1 - HEATED SEAT SWITCH ASSEMBLY
shorted seat heater switch mux circuit as required. 2 - RETAINING SCREWS
switch mux circuit cavity of the instrument panel (4) Remove the heated seat switch from the back
wire harness connector for the inoperative heated of the instrument panel center bezel.
seat switch and the instrument panel wire harness
connector for the BCM. There should be continuity. If INSTALLATION
OK, use a DRB IIIt scan tool and the proper Diag- (1) Position the heated seat switch onto the back
nostic Procedures manual to test the BCM. If not of the instrument panel center bezel.
OK, repair the open seat heater switch mux circuit (2) Install and tighten the three screws that secure
as required. the heated seat switch to the back of the instrument
panel center bezel. Tighten the screws to 1.5 N·m (13
REMOVAL in. lbs.) (Fig. 4).
(3) Install the center bezel onto the instrument
panel. Refer to Instrument Panel Center Bezel in
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
RS HORN 8H - 1
HORN
TABLE OF CONTENTS
page page
HORN INSTALLATION. . . . . . . . . . ..................5

DESCRIPTION . . . . . . . . . . ..................1 HORN RELAY
OPERATION . . . . . . . . . . . ..................1 DIAGNOSIS AND TESTING ..................5
DIAGNOSIS AND TESTING ..................1 REMOVAL . . . . . . . . . . . . . ..................5
HORN INSTALLATION. . . . . . . . . . ..................5
DIAGNOSIS AND TESTING ..................3 HORN SWITCH
REMOVAL . . . . . . . . . . . . . ..................4 DESCRIPTION . . . . . . . . . . ..................5
HORN DIAGNOSIS AND TESTING

Refer to Horn System Test below. If the horn does
DESCRIPTION not sound, check horn fuse located in the intelligent
power module. If the fuse is blown, replace with the
HORN SYSTEM correct fuse. If the horns fail to sound and the new
fuse blows when depressing the horn switch, a short
WARNING: circuit in the horn or the horn wiring between the
ON VEHICLES EQUIPPED WITH AIRBAG, REFER TO fuse terminal and the horn is responsible, or a defec-
ELECTRICAL, RESTRAINTS FOR SAFETY PRECAU- tive horn switch allowed the horn to burn out is
TIONS. DISCONNECT THE NEGATIVE CABLE FROM responsible.
THE BATTERY BEFORE SERVICING COMPONENTS If the fuse is OK, test horn relay (Refer to 8 -
INVOLVING THE AIRBAG SYSTEM. ACCIDENTAL ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS
DEPLOYMENT OF AIRBAG AND PERSONAL INJURY AND TESTING).
CAN RESULT. If the relay is OK, test horn. Refer to Horn System
Test.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and intelligent power mod- CAUTION:
ule. The horn switch is a membrane switch located in Continuous sounding of horn may cause horn relay
the airbag trim cover. The horns are located forward to fail.
of the left front wheel behind the bumper fascia.
Should the horn sound continuously:
OPERATION • Unplug the horn relay from intelligent power
The horn relay plugs into the intelligent power module.
module which is located in the engine compartment. • Refer to (Refer to 8 - ELECTRICAL/HORN/
For circuit information and component locations, HORN RELAY - DIAGNOSIS AND TESTING).
refer to the appropriate wiring information. The wir- Refer to the appropriate wiring information. The
ing information includes wiring diagrams, proper wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out harness routing and retention, connector pin-out
information and location views for the various wire information and location views for the various wire
harness connectors, splices and grounds. harness connectors, splices and grounds.
The horns will not function if the switch is
“CLOSED” for more than 30 seconds. Once the
switch is “OPEN”, a 20–30 second delay will occur
before the horns are functional again.
8H - 2 HORN RS
HORN (Continued)
HORN SYSTEM TEST

HORN SOUNDS CONTINUOUSLY. (1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY
NOTE: IMMEDIATELY UNPLUG TEST.
HORN RELAY IN THE
INTELLIGENT POWER MODULE.
(2) HORN CONTROL CIRCUIT TO (2) CHECK TERMINAL 85 IN
RELAY SHORTED TO GROUND. INTELLIGENT POWER MODULE
FOR CONTINUITY TO GROUND.
IF CONTINUITY TO GROUND
INDICATES:
(A) STEERING WHEEL HORN
SWITCH/LEAD SHORTED TO
GROUND.
(B) WIRING HARNESS SHORTED
TO GROUND. FIND THE SHORT
AND REPAIR AS NECESSARY.
(3) PINCHED HORN SWITCH (3) REPLACE DRIVER AIRBAG
WIRE UNDER DRIVER AIRBAG MODULE TRIM.
MODULE.
(4) FAULTY HORN SWITCH. (4) REPLACE DRIVER AIRBAG
MODULE TRIM.
(5) FAULTY CLOCKSPRING. (5) REPLACE CLOCKSPRING.
HORN SOUND INTERMITTENTLY (1) HORN RELAY CONTROL (1) REMOVE DRIVER AIRBAG
AS THE STEERING WHEEL IS CIRCUIT X3 IS SHORTED TO MODULE AND/OR WHEEL.
TURNED. GROUND INSIDE STEERING CHECK FOR RUBBING OR
COLUMN OR WHEEL. LOOSE WIRE/CONNECTOR,
REPAIR AS NECESSARY.
(2) PINCHED HORN SWITCH (2) REPLACE DRIVER AIRBAG
WIRE UNDER DRIVER AIRBAG MODULE TRIM.
MODULE.
MODULE TRIM.
HORN DOES NOT SOUND (1) CHECK FUSE 8 IN (1) REPLACE FUSE IF BLOWN
INTELLIGENT POWER MODULE. REPAIR AS NECESSARY.
(2) NO VOLTAGE AT HORN (2) NO VOLTAGE, REPAIR THE
RELAY TERMINALS 30 & 86, AND CIRCUIT AS NECESSARY.
FUSE IS OK.
(3) OPEN CIRCUIT FROM (3) REPAIR CIRCUIT AS

TERMINAL 85 OF THE HORN NECESSARY.
RELAY TO HORN SWITCH, X3
CIRCUIT.
(4) FAULTY OR DAMAGED HORN. (4) VOLTAGE AT HORN WHEN
HORN SWITCH IS PRESSED,
REPLACE HORN.
MODULE TRIM.
RS HORN 8H - 3
HORN (Continued)

FUSE BLOWS WHEN HORN (1) SHORT CIRCUIT IN HORN OR (1) REMOVE HORN RELAY,
SOUNDS HORN WIRING. CHECK FOR SHORTED HORN OR
HORN WIRING. DISCONNECT
HORN WIRE HARNESS TO
ISOLATE SHORT AND REPAIR AS
NECESSARY.
FUSE BLOWS WITHOUT (1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL
BLOWING HORN NEW FUSE, IF FUSE DOES NOT
BLOW REPLACE HORN RELAY. IF
FUSE BLOWS WITH RELAY
REMOVED, CHECK FOR SHORT
TO GROUND WITH OHMMETER
ON CIRCUIT BETWEEN
TERMINALS 30 & 86 AND THE
FUSE TERMINAL. REPAIR AS
NECESSARY.
HORN routing and retention, connector pin-out information

nectors, splices and grounds.
(a) If continuity is detected, proceed to step Step
3.
HORN
(b) If NO continuity, replace the horn relay.
(1) Disconnect wire connector at horn.
(3) Remove the airbag trim cover from the steering
(2) Using a voltmeter, connect one lead to ground
wheel and disengage horn connector.
terminal and the other lead to the positive wire ter-
(4) Install horn relay into intelligent power mod-
minal (Fig. 1).
ule.
(3) Depress the horn switch, battery voltage
(a) If horn does not sound, replace airbag trim
should be present.
cover.
(4) If no voltage, refer to HORNS WILL NOT
(b) If horn sounds, repair grounded X3 circuit
SOUND. If voltage is OK, go to step Step 5.
from intelligent power module to clockspring in the
(5) Using ohmmeter, test ground wire for continu-
steering column. Refer to the appropriate wiring
ity to ground.
information. The wiring information includes wir-
(6) If no ground repair as necessary.
ing diagrams, proper wire and connector repair
(7) If wires test OK and horn does not sound,
procedures, details of wire harness routing and
replace horn.
retention, connector pin-out information and loca-
tion views for the various wire harness connectors,
HORNS SOUND CONTINUOUSLY
splices and grounds.
CAUTION:
Continuous sounding of horns may cause relay to HORNS WILL NOT SOUND
fail. Check horn fuse # 8 in the intelligent power mod-
ule. If fuse is blown, check for a shorted switch in the
The horn switch (membrane) sometimes can be the airbag module. and refer to FUSE BLOWN section. If
cause without the switch being depressed. fuse is OK, refer to FUSE OK section.
(1) Remove the horn relay from the intelligent
power module. FUSE BLOWN
(2) Using a continuity tester, test continuity from (1) Verify condition of battery terminals and volt-
the X3 cavity of the horn relay to ground. Refer to age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
the appropriate wiring information. The wiring infor- - DIAGNOSIS AND TESTING). If battery connec-
mation includes wiring diagrams, proper wire and tions and battery charge is OK proceed to Step 2.
connector repair procedures, details of wire harness
8H - 4 HORN RS
HORN (Continued)
(2) Using a voltmeter, test for battery voltage at (3) Using a suitable jumper wire, jump across the
both sides of horn fuse 7. If voltage is OK, on both fuse F62 cavity and the X2 cavity of the horn relay in
sides of fuse, proceed to Fuse OK. If voltage is OK, the Junction Block.
on one side of fuse, the fuse is blown, proceed to Step (a) If the horn sounds, replace the horn relay.
3. (b) If the horn does not sound, proceed to Step 4.
(3) Using a suitable ammeter in place of the fuse, (4) Remove airbag trim cover from steering wheel.
test amperage draw of the horn circuit. If amperage Refer to ELECTRICAL, RESTRAINTS.
draw is greater than 20 amps without the horn (5) Test continuity across horn switch connectors
switch depressed, a grounded circuit exists between with horn switch depressed.
the fuse and the horn relay. Proceed to Step 4. If (a) If continuity is detected, repair open circuit
amperage draw is greater than 20 amps with the between the relay and the horn switch.
horn switch depressed, a grounded circuit exists (b) If NO continuity, replace airbag trim cover.
between the horn relay and the horn. Proceed to step (6) Install horn relay into intelligent power mod-
Step 5. ule.
(4) Remove the horn relay from the intelligent (7) Disengage wire connectors from horns.
power module. If the amperage draw drops to 0 (8) Using a voltmeter, with the horn switch
amps, the horn switch or circuit is shorted. Refer to depressed test voltage across horn connector termi-
the appropriate wiring information. The wiring infor- nals of the wire harness (Fig. 1).
mation includes wiring diagrams, proper wire and (a) If voltage is detected, replace horns.
connector repair procedures, details of wire harness (b) If NO voltage, proceed to step Step 9.
nectors, splices and grounds. If the amperage draw
does not drop to 0 amps, repair short at the intelli-
gent power module.
(5) Disengage a wire connector from one of the
horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does not
drop with both horns disconnected and the horn
switch depressed, proceed to Step 6.
(6) Using a continuity tester, with the horns dis-
connected test continuity of the X2 cavity of the horn
relay to ground. Refer to the appropriate wiring
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce-
Fig. 1 Horn Connector
dures, details of wire harness routing and retention,
connector pin-out information and location views for (9) With the horn switch depressed, test for volt-
the various wire harness connectors, splices and age between the X2 circuit and ground.
grounds. If continuity is detected, the circuit is (a) If voltage OK, repair system ground at right
grounded between the Junction Block and the horns. cowl area. Refer to the appropriate wiring informa-
Locate and repair pinched harness. tion. The wiring information includes wiring dia-
grams, proper wire and connector repair
FUSE OK procedures, details of wire harness routing and
(1) Remove the horn relay from the intelligent retention, connector pin-out information and loca-
power module. tion views for the various wire harness connectors,
(2) Using a continuity tester, Depress horn switch splices and grounds.
and test continuity from the X3 cavity of the horn (b) If NO voltage, repair open X2 circuit between
relay to ground. Refer to the appropriate wiring the relay and the horns.
information. The wiring information includes wiring
diagrams, proper wire and connector repair proce- REMOVAL
dures, details of wire harness routing and retention, (1) Disconnect and isolate the battery negative
connector pin-out information and location views for cable.
the various wire harness connectors, splices and (2) Hoist and support the front of the vehicle on
grounds. safety stands.
(a) If continuity is detected, proceed to Step 3.
(b) If NO continuity, proceed to Step 4.
RS HORN 8H - 5
HORN (Continued)
(3) From behind the front fascia and forward of (b) If NO voltage check fuse 8 of the intelligent
the left front wheel, disconnect the wire connectors power module.
from horn. (c) If incorrect voltage, repair as necessary. Refer
(4) Remove the mounting bracket attaching nut to the appropriate wiring information. The wiring
from the bottom of radiator closure panel. Do not information includes wiring diagrams, proper wire
remove the horn from mounting bracket. and connector repair procedures, details of wire
(5) Separate the horn(s) from vehicle. harness routing and retention, connector pin-out
information and location views for the various wire
INSTALLATION harness connectors, splices and grounds.
(1) Install the horns to the vehicle. (5) Insert a jumper wire between terminal 30 and
(2) Install the mounting bracket nut. 87 of the intelligent power module.
(3) Reconnect the wire connectors to the horns. (a) If horn sounds replace relay.
(4) Lower the vehicle. (b) If the horn does not sound, install horn relay
(5) Reconnect the battery negative cable. and refer to Horn Test.
REMOVAL
HORN RELAY (1) Disconnect and isolate the battery negative
cable.
DIAGNOSIS AND TESTING (2) Remove cover from the intelligent power mod-
(1) Remove horn relay. ule.
(2) Using ohmmeter, test between relay connector (3) Remove relay from intelligent power module.
terminals 85 to 86 for 70 to 75 ohms resistance. If
resistance not OK, replace relay. INSTALLATION
(3) Test for continuity between ground and termi- (1) Push relay into intelligent power module.
nal 85 of horn relay. (2) Install cover.
(a) When the horn switch is not depressed, no (3) Reconnect battery negative cable.
continuity should be present.
(b) Continuity to ground when horn switch is
depressed. HORN SWITCH
(c) If continuity is not correct repair horn
switch or wiring as necessary, refer to the appro- DESCRIPTION
priate wiring information. The wiring information The horn switch is molded into the airbag trim
includes wiring diagrams, proper wire and connec- cover. The horn switch can not be serviced separately.
tor repair procedures, details of wire harness rout- For service procedures, refer to ELECTRICAL /
ing and retention, connector pin-out information RESTRAINTS.
and location views for the various wire harness
connectors, splices and grounds.
(4) Using voltmeter, test voltage at:
(a) Terminals 30 and 86 of the horn relay to
body ground.
RS IGNITION CONTROL 8I - 1
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL REMOVAL . . . . . . . . .......................6

DESCRIPTION . . . . . . . . . . . . . ...............1 INSTALLATION. . . . . .......................6
OPERATION . . . . . . . . . . . . . . ...............1 KNOCK SENSOR
SPECIFICATIONS . . . . . . . . . . ...............1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AUTO SHUT DOWN RELAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
DESCRIPTION . . . . . . . . . . . . . ...............3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . ...............3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CAMSHAFT POSITION SENSOR SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 DESCRIPTION . . . . . .......................8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 REMOVAL . . . . . . . . .......................9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 INSTALLATION. . . . . .......................9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .5 SPARK PLUG CABLE
IGNITION COIL DESCRIPTION . . . . . .......................9
DESCRIPTION . . . . . . . . . . . . . ...............6 REMOVAL . . . . . . . . .......................9
OPERATION . . . . . . . . . . . . . . ...............6 INSTALLATION. . . . . .......................9
IGNITION CONTROL an ignition coil for every cylinder, it is mounted

directly over the each spark plug.
DESCRIPTION - IGNITION SYSTEM
OPERATION - IGNITION SYSTEM
NOTE: All engines use a fixed ignition timing sys- The crankshaft position sensor and camshaft posi-
tem. Basic ignition timing is not adjustable. All tion sensor are hall effect devices. The camshaft posi-
spark advance is determined by the Powertrain tion sensor and crankshaft position sensor generate
Control Module (PCM). pulses that are inputs to the PCM. The PCM deter-
mines engine position from these sensors. The PCM
The distributorless ignition system used on these calculates injector sequence and ignition timing from
engines is referred to as the Direct Ignition System crankshaft & camshaft position. For a description of
(DIS). The system’s three main components are the both sensors, refer to Camshaft Position Sensor and
coils, crankshaft position sensor, and camshaft posi- Crankshaft Position Sensor in this section.
tion sensor. The coil on plug ignition system utilizes
SPECIFICATIONS
TORQUE

2.4L Target Magnet Screw 3 30
2.4L Camshaft Sensor Screw 12.9 115
3.3/3.8L Camshaft Sensor Screw 14.1 125
2.4L Ignition coil bolts 11.8 105
3.3/3.8L Ignition coil bolts 11.8 105
Spark Plugs 17.5 13
Knock Sensor 10 7
8I - 2 IGNITION CONTROL RS
SPECIFICATIONS (Continued)
SPARK PLUG CABLE RESISTANCE 3.3/3.8L

2.4L
CABLE Maximum Resistance
CABLE Maximum Resistance #1 22.5K ohms
1, 2, 3, & 4 10.8K ohms #2 22.8K ohms
#3 19.3K ohms
#4 19.3K ohms
#5 13.6K ohms
#6 16.4K ohms
SPARK PLUG
Engine Spark Plug Gap Thread Size

2.4L RE14MCC5 0.048 TO 0.053 14mm (1 in.) reach
Engine Spark Plug Gap Thread Size

3.3L RN14PMP5 0.048 TO 0.053 14mm (1 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (1 in. ) reach
FIRING ORDER
Fig. 1 Firing Order 3.3/3.8L
FIRING ORDER 2.4L

AUTO SHUT DOWN RELAY sprocket. Four crankshaft pulses follow each group of
camshaft pulses.
DESCRIPTION
The relay is located in the Power Distribution Cen-
ter (PDC). For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary
OPERATION
The ASD sense circuit informs the PCM when the
ASD relay energizes. A 12 volt signal at this input
indicates to the PCM that the ASD has been acti-
vated. This input is used only to sense that the ASD
relay is energized.
When energized, the ASD relay supplies battery
voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM
does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Fig. 2 Camshaft Position Sensor
Code (DTC). 1 - ELECTRICAL CONNECTOR
When energized, the ASD relay provides power to 2 - O-RING
operate the injectors, ignition coil, generator field, O2 3 - PAPER SPACER
sensor heaters (both upstream and downstream), and
also provides a sense circuit to the PCM for diagnos- When the PCM receives 2 cam pulses followed by
tic purposes. The PCM energizes the ASD any time the long flat spot on the camshaft sprocket, it knows
there is a Crankshaft Position sensor signal that that the crankshaft timing marks for cylinder 1 are
exceeds a predetermined value. The ASD relay can next (on driveplate). When the PCM receives one
also be energized after the engine has been turned camshaft pulse after the long flat spot on the
off to perform an O2 sensor heater test, if vehicle is sprocket, cylinder number 2 crankshaft timing marks
equipped with OBD II diagnostics. are next. After 3 camshaft pulses, the PCM knows
As mentioned earlier, the PCM energizes the ASD cylinder 4 crankshaft timing marks follow. One cam-
relay during an O2 sensor heater test. This test is shaft pulse after the 3 pulses indicates cylinder 5.
performed only after the engine has been shut off. The 2 camshaft pulses after cylinder 5 signals cylin-
The PCM still operates internally to perform several der 6 (Fig. 3). The PCM can synchronize on cylinders
checks, including monitoring the O2 sensor heaters. 1 or 4.
When metal aligns with the sensor, voltage goes
low (less than 0.3 volts). When a notch aligns with
CAMSHAFT POSITION the sensor, voltage switches high (5.0 volts). As a
SENSOR group of notches pass under the sensor, the voltage
switches from low (metal) to high (notch) then back
DESCRIPTION to low. The number of notches determine the amount
The camshaft position sensorfor the 3.3/3.8L is of pulses. If available, an oscilloscope can display the
mounted in the front of the timing case cover (Fig. 7) square wave patterns of each timing event.
and the camshaft position sensor for the 2.4L is Top Dead Center (TDC) does not occur when
mounted on the end of the cylinder head (Fig. 4). notches on the camshaft sprocket pass below the cyl-
inder. TDC occurs after the camshaft pulse (or
OPERATION pulses) and after the 4 crankshaft pulses associated
The camshaft position sensor provides cylinder with the particular cylinder. The arrows and cylinder
identification to the Powertrain Control Module call outs on Figure 4 represent which cylinder the
(PCM) (Fig. 2). The sensor generates pulses as flat spot and notches identify, they do not indicate
groups of notches on the camshaft sprocket pass TDC position.
underneath it (Fig. 3). The PCM keeps track of
crankshaft rotation and identifies each cylinder by REMOVAL - 2.4L
the pulses generated by the notches on the camshaft The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
CAMSHAFT POSITION SENSOR (Continued)
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft and remove magnet (Fig. 5).
Fig. 5 Target Magnet Removal/Installation

Fig. 3 Camshaft Sprocket 1 - TARGET MAGNET
1 - CAMSHAFT SPROCKET 2 - MOUNTING BOLT
2 - CYL #6 3 - REAR OF CYLINDER HEAD
3 - CYL #5
4 - CYL #4
5 - CYL #3 REMOVAL - 3.3/3.8L
6 - CYL #2 (1) Disconnect the negative battery cable.
7 - CYL #1 (2) Remove the air box cover and inlet tube (Fig.
6).
(2) Disconnect electrical connectors from the cam-
shaft position sensor (Fig. 4).
Fig. 6 AIR BOX COVER

(3) Disconnect camshaft position sensor electrical
Fig. 4 EGR/CAM SENSOR 2.4L connector from the wiring harness connector (Fig. 7).
CAMSHAFT POSITION SENSOR (Continued)
(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3 N·m (30 in. lbs.) torque.
Over torqueing could cause cracks in magnet. If mag-
net cracks replace it.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 12.9 N·m (115 in. lbs.) torque.
(3) Carefully attach electrical connector to cam-
shaft position sensor. Installation at an angle may
damage the sensor pins.
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW
SPACER must be attached to the face before
installation. Inspect O-ring for damage, replace if
necessary. If the sensor is being replaced, confirm
that the paper spacer is attached to the face and
O-ring is positioned in groove of the new sensor (Fig.
9).
Fig. 7 CAMSHAFT POSITION SENSOR

(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
(6) Pull sensor up out of the chain case cover. Do
not pull on the sensor lead. There is an O-ring on
the sensor case. The O-ring may make removal diffi-
cult. A light tap to top of sensor prior to removal may
reduce force needed for removal.
INSTALLATION - 2.4L
The target magnet has locating dowels that fit into
machined locating holes in the end of the camshaft
(Fig. 8).
Fig. 9 Camshaft Position Sensor and Spacer

1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
(1) Apply a couple drops of clean engine oil to the

O-ring prior to installation.
(2) Install sensor in the chain case cover and
rotate into position.
(3) Push sensor down until contact is made with
the camshaft gear. While holding the sensor in this
position, install and tighten the retaining bolt 14
N·m (125 in. lbs.) torque.
(4) Connect camshaft position sensor electrical
connector to harness connector.
Fig. 8 Target Magnet Installation (5) Install the air box cover and inlet hose (Fig. 6).
1 - LOCATING DOWELS (6) Connect the negative battery cable.
2 - LOCATING HOLES (2)
IGNITION COIL
DESCRIPTION
The ignition coil assembly consists of 2 or 3 inde-
pendent coils molded together (Fig. 10) or (Fig. 11).
The coil assembly for the 3.3/3.8L is mounted on the
intake manifold. The coil assembly for the 2.4L is
mounted on the cylinder head cover. Spark plug
cables route to each cylinder from the coil.
Fig. 11 IGNITION COIL - 3.3/3.8L

1 - IGNITION COIL
(4) Remove coil pack and heat shield (Fig. 10).
REMOVAL - 3.3/3.8L
(2) Remove the throttle and speed control cables
from clip.
Fig. 10 IGNITION COIL - 2.4L (3) Remove 2 bolts from the Power steering reser-
voir to intake manifold.
OPERATION (4) Loosen the lower nut for the power steering
The coil fires two spark plugs every power stroke. reservoir from stud on ignition coil bracket.
One plug is the cylinder under compression, the (5) Reposition the Power steering reservoir (Fig.
other cylinder fires on the exhaust stroke. The Pow- 12).
ertrain Control Module (PCM) determines which of (6) Remove the ignition cables from the ignition
the coils to charge and fire at the correct time. coil.
The Auto Shutdown (ASD) relay provides battery (7) Disconnect the electrical connector from the
voltage to the ignition coil. The PCM provides a ignition coil.
ground contact (circuit) for energizing the coil. When (8) Remove 2 nuts from the ignition coil studs.
the PCM breaks the contact, the magnetic energy in (9) Remove 2 bolts from ignition coil, remove coil.
the coil transfers to the secondary causing the spark.
The PCM will de-energize the ASD relay if it does INSTALLATION - 2.4L
not receive the crankshaft position sensor and cam- (1) Install ignition coil and heat shield to valve
shaft position sensor inputs. Refer to Auto Shutdown cover and tighten bolts.
(ASD) Relay—PCM Output, in this section for relay (2) Connect the electrical connector to the ignition
operation. coil.
(3) Transfer spark plug cables to new coil pack.
REMOVAL - 2.4L The coil pack towers are numbered with the cylinder
The electronic ignition coil pack attaches directly identification. Be sure the ignition cables are fully
to the valve cover. seated onto the towers.
(1) Diconnect the negative battery cable. (4) Connect the negative battery cable.
(2) Disconnect electrical connector from coil pack
(3) Remove coil pack mounting bolts.
IGNITION COIL (Continued)
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal’s vibration increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
Fig. 12 IGNITION COIL BRACKET 3.3/3.8L ing retard can be calibrated.
Short term memory is allowed to retard timing up
INSTALLATION - 3.3/3.8L to a preset amount under all operating conditions (as
(1) Install coil over studs on bracket. long as rpm is above the minimum rpm) except WOT.
(2) Install 2 bolts to ignition coil. The PCM, using short term memory, can respond
(3) Install 2 nuts to the ignition coil studs. Tighten quickly to retard timing when engine knock is
nuts and bolts. detected. Short term memory is lost any time the
(4) Connect the electrical connector to the ignition ignition key is turned off.
coil.
(5) Install the ignition cables to the ignition coil. NOTE: Over or under tightening affects knock sen-
(6) Reposition the Power steering reservoir. Slide sor performance, possibly causing improper spark
bracket over the mounting stud (Fig. 12). control.
(7) Install 2 bolts the Power steering reservoir to
intake manifold.
(8) Tighten the lower nut to stud on ignition coil REMOVAL - 2.4L
bracket. The knock sensor threads into the side of the cyl-
(9) Install the throttle and speed control cables to inder block in front of the starter (Fig. 13).
clip. (1) Disconnect electrical connector from knock sen-
(10) Connect the negative battery cable. sor.
(2) Use a crow foot socket to remove the knock
sensors.
KNOCK SENSOR
REMOVAL - 3.8L
DESCRIPTION The knock sensor threads into the side of the cyl-
The knock sensor threads into the cylinder block. inder block in the rear.
The knock sensor is designed to detect engine vibra- (1) Disconnect the negative battery cable.
tion that is caused by detonation. (2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU
OPERATION (Power Transfer Unit), refer to the Transmission sec-
When the knock sensor detects a knock in one of tion for more information.
the cylinders, it sends an input signal to the PCM. In (4) Disconnect electrical connector from knock sen-
response, the PCM retards ignition timing for all cyl- sor.
inders by a scheduled amount. (5) Use a crow foot socket to remove the knock
sensor.
KNOCK SENSOR (Continued)
INSTALLATION - 2.4L SPARK PLUG

The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 13). DESCRIPTION - STANDARD 2.4L
(1) Install knock sensor. Tighten knock sensor to All engines use resistor spark plugs. They have
10 N·m (7 ft. lbs.) torque. Over or under tighten- resistance values ranging from 6,000 to 20,000 ohms
ing effects knock sensor performance, possibly when checked with at least a 1000 volt spark plug
causing improper spark control. tester.
(2) Attach electrical connector to knock sensor. Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Refer to the Specifications section for gap and type
of spark plug.
DESCRIPTION - PLATINUM 3.3/3.8L

These engines utilize platinum spark plugs. Refer
to the maintenance schedule.
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
The spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal
driving conditions per schedule A in this manual. The
spark plugs have a recommended service life of
75,000 miles for severe driving conditions per sched-
ule B in this manual. A thin platinum pad is welded
to both electrode ends as show in (Fig. 14). Extreme
Fig. 13 Knock Sensor care must be used to prevent spark plug cross
threading, mis-gaping and ceramic insulator damage
1 - GENERATOR
2 - INTAKE MANIFOLD
during plug removal and installation.
3 - KNOCK SENSOR
4 - STARTER
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Install knock sensor. Tighten knock sensor to
10 N·m (7 ft. lbs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
(4) Lower vehicle.
(5) Connect the negative cable. Fig. 14 Platinum Pads
1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
SPARK PLUG (Continued)
CAUTION: Cleaning of the platinum plug may dam- (1) To avoid cross threading, start the spark plug
age the platinum tip. into the cylinder head by hand.
(2) Tighten spark plugs to 17.5 N·m (13 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
SPARK PLUG CABLE

DESCRIPTION
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual
spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.
Check the spark plug cable connections for good
contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
Fig. 15 Setting Spark Plug Electrode Gap plugs. Spark plug cables with insulators that are
1 - TAPER GAUGE cracked or torn must be replaced.
Clean Spark Plug cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
REMOVAL Check for brittle or cracked insulation. The spark
When replacing the spark plugs and spark plug plug cables and spark plug boots are made from high
cables, route the cables correctly and secure them in temperature silicone materials. All spark plug cable
the appropriate retainers. Failure to route the cables leads are properly identified with cylinder numbers.
properly can cause the radio to reproduce ignition The inside of most the spark plug boot is coated with
noise, cross ignition of the spark plugs or short cir- a special high temperature silicone grease for greater
cuit the cables to ground. sealing and to minimize boot bonding to the spark
Always remove cables by grasping at the boot, plug insulator.
rotating the boot 1/2 turn, and pulling straight back
in a steady motion. REMOVAL
(1) Prior to removing the spark plug, spray com- Failure to route the cables properly could cause the
pressed air around the spark plug hole and the area radio to reproduce ignition noise, cross ignition of the
around the spark plug. spark plugs or short circuit the cables to ground.
(2) Remove the spark plug using a quality socket Remove spark plug cable from coil first.
with a foam insert. Always remove the spark plug cable by grasping
(3) Inspect the spark plug condition. the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION
When replacing the spark plugs and spark plug INSTALLATION
cables, route the cables correctly and secure them in Failure to route the cables properly could cause the
the appropriate retainers. Failure to route the cables radio to reproduce ignition noise, cross ignition of the
properly can cause the radio to reproduce ignition spark plugs or short circuit the cables to ground.
noise, cross ignition of the spark plugs or short cir- Install spark plug insulators over spark plugs.
cuit the cables to ground. Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube.Then connect the
other end to coil pack.
RS INSTRUMENT CLUSTER 8J - 1
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MECHANICAL TRANSMISSION RANGE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INDICATOR
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 1 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 RED BRAKE WARNING INDICATOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUSTER LENS OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Refer to the vehicle Owner’s Manual for operation
DESCRIPTION instructions and conditions for the Instrument Clus-
The instrumentation gauges are contained in a ter Gauges.
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the DIAGNOSIS AND TESTING - SELF-
cluster gauges becomes faulty, the entire cluster DIAGNOSTICS
would require replacement. The instrument clusters are equipped with a self
The mechanical instrument cluster with a tachom- diagnostic test feature to help identify electronic
eter is equipped with a electronic vacuum fluorescent problems. Prior to any test, perform the Self-Diag-
transmission range indicator (PRND3L), odometer, nostic Test. The self diagnostic system displays
and trip odometer display. instrument cluster stored fault codes in the odometer
The mechanical instrument cluster without a display, sweeps the gauges to the calibration points,
tachometer is equipped with a cable operated trans- and bulb checks the warning indicators. When the
mission range indicator (PRND21) and a vacuum key is in the ON position with the engine not run-
flourescent odometer display. ning, the MIL will remain illuminated for regulatory
The instrument cluster is equipped with the follow- purposes.
ing warning lamps. To activate the Self-Diagnostic program:
• Lift Gate Ajar (1) With the ignition switch in the OFF position,
• Low Fuel Level depress the TRIP ODOMETER RESET button.
• Low Windshield Washer Fluid Level (2) Continue to hold the TRIP ODOMETER
• Cruise RESET button until Sof and a number (software ver-
• Battery Voltage sion number (i.e. Sof 3.2) appears in the odometer
• Fasten Seat Belt window (about five seconds) then release the button.
• Door Ajar If a fault code is present, the cluster will display it in
• Headlamp Out the odometer display. When all fault codes have been
• Coolant Temperature displayed, the cluster will display “end” in the odom-
• Anti-Lock Brake eter display. Refer to the table to determine what
• Brake each trouble code means.
• Airbag
• Traction Control
• Autostick
8J - 2 INSTRUMENT CLUSTER RS
INSTRUMENT CLUSTER (Continued)
INSTRUMENT CLUSTER DTC’S CLUSTER CALIBRATION
DTC DESCRIPTION SPEEDOMETER CALIBRATION POINT

100.00 LOOP-BACK FAILURE 1 0 MPH (0 KM/H)
100.1 ABS COMMUNICATION FAULT 2 20 MPH (40 KM/H)
100.2 BCM COMMUNICATION FAULT 3 60 MPH (100 KM/H)
100.3 EATX COMMUNICATION FAULT 4 100 MPH (160 KM/H)
100.4 PCM COMMUNICATION FAULT TACHOMETER
100.5 ORC COMMUNICATION FAULT 1 0 RPM
100.6 SBEC/DEC/MCM COMMUNICATION 2 1000 RPM
FAULT 3 3000 RPM
200.0 AIRBAG LED SHORT 4 6000 RPM
200.1 AIRBAG LED OPEN FUEL GAUGE
200.2 ABS LED SHORT 1 EMPTY
200.3 ABS LED OPEN 2 1/4 FILLED
200.6 EL INVERTER TIME-OUT 3 1/2 FILLED
200.7 EATX MISMATCH 4 FULL
TEMPERATURE
DIM TEST GAUGE
When CHEC-0 is displayed in the odometer win-
dow, the cluster’s Vacuum Fluorescent (VF) displays 1 COLD
will dim down. If the VF display brightness does not 2 1/4
change, a problem exists in the cluster. 3 3/4
CALIBRATION TEST 4 HOT
dow, each of the cluster’s gauge pointers will move ODOMETER SEGMENT TEST
sequentially through each calibration point. The When CHEC-2 is displayed in the odometer win-
table contains the proper calibration points for each dow, each digit of the odometer will illuminate
gauge. If the gauge pointers are not calibrated, a sequentially. If a segment in the odometer does not
problem exists in the cluster. If any gauge is out of illuminate normally, a problem exists in the display.
calibration, replace the cluster.
ELECTRONIC TRANSMISSION RANGE INDICATOR
SEGMENT TEST
dow, each segment of the transmission range indica-
tor will illuminate sequentially. If a segment in the
transmission range indicator does not illuminate nor-
mally, a problem exists in the display board.
CONDITIONS • ODOMETER DIAGNOSIS
Refer to the following tables for possible problems, • ELECTRONIC GEAR INDICATOR DISPLAY
causes, and corrections. DIAGNOSIS
• INSTRUMENT CLUSTER • MECHANICAL TRANSMISSION RANGE INDI-
• SPEEDOMETER DIAGNOSIS CATOR (PRND21) DIAGNOSIS
• TACHOMETER DIAGNOSIS
• FUEL GAUGE DIAGNOSIS NOTE: Always check the functionality of the cluster
• TEMPERATURE GAUGE DIAGNOSIS by running the self test prior to troubleshooting.
INSTRUMENT CLUSTER

INSTRUMENT CLUSTER NO PCI BUS MESSAGES 1. USE A DRB IIIT SCAN TOOL TO CHECK THE
INOPERATIVE. FROM THE BCM. BCM. IF OK, LOOK FOR ANOTHER POSSIBLE
NO RESPONSE FROM CAUSE FOR CLUSTER FAILURE. IF NOT OK,
INSTRUMENT CLUSTER. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL.
SPREAD TERMINAL(S) 1. REMOVE CLUSTER FROM INSTRUMENT PANEL
ON WIRING HARNESS AND CHECK WIRING HARNESS CONNECTOR FOR
CLUSTER CONNECTOR. SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING 1. USE A DRB IIIT SCAN TOOL TO VERIFY IGNITION
PROPER INPUT FROM SWITCH STATUS INTO THE BCM. IF NOT OK, GO
THE IGNITION SWITCH. TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER 1. REPLACE CLUSTER.
FAILURE.
WAKE UP CIRCUIT VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
FAULTY. BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND IF NO RESPONSE FROM THE MIC, CHECK FOR
MISSING. POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
SPEEDOMETER DIAGNOSIS
NO POINTER 1. INTERNAL CLUSTER 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

MOVEMENT FAILURE. AND CHECK FOR FAULT CODES.
• IF SPEEDOMETER POINTER MOVES TO
CALIBRATION POINTS DURING TEST LOOK FOR
ANOTHER POSSIBLE CAUSE OF FAILURE.
• IF THE POINTER DOESN’T MOVE DURING TEST,
CHECK FOR POWER AND GROUND TO THE MIC.
IF POWER AND GROUND ARE PRESENT GO TO
STEP 1.B.
1.B. REPLACE CLUSTER. GO TO STEP 1.C.
1.C. CONNECT CLUSTER INTO INSTRUMENT
PANEL WIRING HARNESS. PLACE IT BACK INTO
THE PROPER POSITION IN THE INSTRUMENT
PANEL. PUT IN THE TOP FOUR MOUNTING
SCREWS AND SECURE THE CLUSTER TO THE
INSTRUMENT PANEL.
2. NO SPEED PCI BUS 2.A. CHECK THE PCM (CODE 10) USING A DRB IIIT
MESSAGE OR ZERO SCAN TOOL. IF OK, GO TO STEP 2.B. IF NOT OK,
MPH PCI SPEED BUS REFER TO THE PROPER ENGINE DIAGNOSTIC
MESSAGE. PROCEDURES MANUAL TO REPAIR THE PCM.
2.B. CHECK THE SPEED SIGNAL INPUT INTO THE
PCM. THE SPEED SIGNAL ORIGINATES FROM ONE
OF THE FOLLOWING SOURCES:
• A DISTANCE SENSOR FOR VEHICLES WITH 3
SPEED AUTOMATIC TRANSMISSION. CHECK
CONTINUITY FROM DISTANCE SENSOR TO PCM.
IF OK, REPLACE DISTANCE SENSOR. IF NOT OK,
REPAIR WIRING.
• THE TCM FOR VEHICLES WITH THE 4 SPEED
ELECTRONIC TRANSMISSIONS. CHECK
CONTINUITY FROM TCM TO PCM. IF OK, USE A
DRB IIIT SCAN TOOL TO CHECK TCM. REFER TO
THE PROPER TRANSMISSION DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE TCM. IF
NOT OK, REPAIR WIRING.
ERRATIC POINTER 1. ERRATIC MESSAGE 1.A. CHECK THE BCM USING A DRB IIIT SCAN
MOVEMENT FROM ANOTHER TOOL IF OK, GO TO STEP 1.B. IF NOT OK, REFER
MODULE. TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE BCM.
1.B. CHECK THE PCM USING A DRB IIIT SCAN
TOOL. IF OK, GO TO STEP 1.C. IF NOT OK, REFER
TO THE ENGINE DIAGNOSTIC PROCEDURES
MANUAL TO REPAIR THE PCM.
1.C. CHECK THE SPEED SIGNAL INPUT INTO THE
PCM. THE SPEED SIGNAL ORIGINATES FROM ONE
OF THE FOLLOWING SOURCES:
• A DISTANCE SENSOR FOR VEHICLES WITH 3
SPEED AUTOMATIC TRANSMISSION. CHECK
CONTINUITY FROM DISTANCE SENSOR TO PCM.
IF OK, REPLACE DISTANCE SENSOR. IF NOT OK,
REPAIR WIRING.
• THE TCM FOR VEHICLES WITH THE 4 SPEED
ELECTRONIC TRANSMISSIONS. CHECK
CONTINUITY FROM TCM TO ENGINE
CONTROLLER. IF OK, USE A DRB IIIT SCAN TOOL
TO CHECK TCM. REFER TO THE PROPER
TRANSMISSION DIAGNOSTIC PROCEDURES
MANUAL TO REPAIR THE TCM. IF NOT OK, REPAIR
WIRING.
2. INTERNAL CLUSTER 2.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

FAILURE. AND CHECK FOR FAULT CODES.
• IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, THEN GO TO STEP 2.B.
2.B. REPLACE CLUSTER ASSEMBLY.
SPEEDOMETER 1. SPEEDOMETER OUT 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.

INACCURATE. OF CALIBRATION. • IF SPEEDOMETER IS ACCURATE TO THE
CALIBRATION POINTS THEN LOOK FOR ANOTHER
POSSIBLE CAUSE OF INACCURACY.
• IF SPEEDOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. WRONG 2.A. IF VEHICLE HAS A 4 SPEED ELECTRONIC
SPEEDOMETER PINION TRANSMISSION GO TO STEP 2.C. OTHERWISE GO
SIZE FOR TIRE SIZE. TO STEP 2.B.
2.B. CHECK IF CORRECT SPEEDOMETER PINION
IS BEING USED WITH TIRES ON VEHICLE. REFER
TO TRANSMISSION FOR DIAGNOSIS AND
TESTING.
• IF THE INCORRECT PINION IS IN TRANSMISSION
THEN REPLACE WITH CORRECT PINION.
• IF THE CORRECT PINION IS IN THE
TRANSMISSION, CHECK TIRE SIZE.
2.C. USE A DRB IIIT SCAN TOOL TO CHECK THE
TCM TO SEE IF THE CORRECT TIRE SIZE HAS
BEEN PROGRAMMED INTO THE TCM.
• IF THE INCORRECT TIRE SIZE WAS SELECTED,
SELECT THE PROPER TIRE SIZE.
• IF THE CORRECT TIRE SIZE WAS SELECTED,
CHECK SPEED SENSOR.
3. BAD SPEED SENSOR. 3. REFER TO TRANSMISSION, SPEED SENSOR,
DIAGNOSIS AND TESTING.
TACHOMETER DIAGNOSIS

NO POINTER 1. INTERNAL 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND
MOVEMENT CLUSTER FAILURE. CHECK FOR FAULT CODES.
• IF TACHOMETER POINTER MOVES TO CALIBRATION
POINTS DURING TEST, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
CHECK FOR POWER AND GROUND TO THE MIC.
IF POWER AND GROUND ARE PRESENT GO TO
STEP 1.B.
1.B. REPLACE CLUSTER. GO TO STEP 1.C.
2. 9NO RPM9 PCI BUS 2. CHECK THE PCM USING A DRB IIIT SCAN TOOL.
MESSAGE OR 9ZERO REFER TO THE PROPER ENGINE DIAGNOSTIC
RPM9 PCI BUS PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
MESSAGE FROM REPAIR.
PCM.

ERRATIC POINTER 1. BAD PCI BUS 1. CHECK THE PCM USING A DRB IIIT SCAN TOOL.
MOVEMENT. MESSAGE FROM REFER TO THE PROPER ENGINE DIAGNOSTIC
PCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
REPAIR.
2. INTERNAL 2.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND

CLUSTER FAILURE. CHECK FOR FAULT CODES.
• IF THE POINTER MOVES DURING TEST BUT STILL
APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY.
TACHOMETER 1. TACHOMETER OUT 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
INACCURATE. OF CALIBRATION. • IF TACHOMETER IS ACCURATE TO THE CALIBRATION
POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF
INACCURACY.
• IF TACHOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY.
FUEL GAUGE DIAGNOSIS

NO POINTER 1. INTERNAL CLUSTER 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
MOVEMENT. FAILURE. • IF FUEL GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER ASSEMBLY. IF NO, DETERMINE CAUSE
OF NO POWER OR GROUND.
2. NO PCI FUEL 2.A. CHECK THE BCM USING A DRB IIIT SCAN
MESSAGE OR EMPTY TOOL. IF OK, GO TO STEP 2.B. IF NOT OK, REFER
PCI BUS MESSAGE TO THE PROPER BODY DIAGNOSTIC
FROM BODY PROCEDURES MANUAL TO PROPERLY DIAGNOSE
CONTROLLER. AND REPAIR.
2.B. REFER TO THE FUEL SECTION OF THE
SERVICE MANUAL FOR THE FUEL LEVEL SENDING
UNIT TEST PROCEDURE. TEST UNIT AND REPAIR
AS INSTRUCTED.
ERRATIC POINTER 1. BAD PCI FUEL 1.A. USE A DRB IIIT SCAN TOOL TO CHECK THE
MOVEMENT. MESSAGE FROM THE BCM. IF OK, GO TO STEP 2.B. IF NOT OK, REFER
BODY CONTROLLER. TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2.B. REFER TO THE FUEL SECTION OF THE
SERVICE MANUAL FOR THE FUEL LEVEL SENDING
UNIT TEST PROCEDURE. TEST UNIT. IF OK, LOOK
FOR ANOTHER POSSIBLE CAUSE FOR FUEL
GAUGE FAILURE. IF NOT OK, REPAIR SENDING
UNIT.

2. INTERNAL CLUSTER 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
FUEL GAUGE 1. FUEL GAUGE OUT OF 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF
INACCURATE. CALIBRATION. POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE. IF POINTER IS INACCURATE TO THE
ASSEMBLY.
2. FUEL LEVEL SENDING 2. REFER TO THE FUEL SECTION OF THE SERVICE
UNIT IS OUT OF MANUAL FOR TESTING AND REPAIR PROCEDURE.
CALIBRATION.
TEMPERATURE GAUGE DIAGNOSIS

NO POINTER 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
MOVEMENT FAILURE. AND CHECK.
• IF TEMPERATURE GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER. IF NO, DETERMINE CAUSE OF NO
POWER OR NO GROUND.
2. NO PCI 2.A. CHECK PCM FAULT CODES USING A DRB IIIT

TEMPERATURE SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
MESSAGE OR COLD PCI STEP 2.B. IF THERE ARE FAULTS, REFER TO THE
BUS MESSAGE FROM PROPER ENGINE DIAGNOSTIC PROCEDURES
THE POWERTRAIN MANUAL TO PROPERLY DIAGNOSE AND REPAIR.
CONTROL MODULE. 2.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
ERRATIC POINTER 1. BAD PCI BUS 1.A. CHECK PCM FAULT CODES USING A DRB IIIT
MOVEMENT. MESSAGE FROM THE SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
POWERTRAIN CONTROL STEP 1.B. IF THERE ARE FAULTS, REFER TO THE
MODULE. ENGINE DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
1.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.

TEMPERATURE GAUGE 1. TEMPERATURE 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
INACCURATE. GAUGE OUT OF • IF POINTER IS ACCURATE TO THE CALIBRATION
CALIBRATION. POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE.
• IF POINTER IS INACCURATE TO THE
ASSEMBLY.
2. COOLANT SENSOR 2. REFER TO FUEL, COOLANT TEMPERATURE
OUT OF CALIBRATION. SENSOR FOR TEST AND REPAIR PROCEDURE.
ODOMETER DIAGNOSIS

NO DISPLAY 1. NO PCI BUS 1. USE A DRB IIIT SCAN TOOL TO CHECK THE
ODOMETER MESSAGE BCM. REFER TO THE PROPER BODY DIAGNOSTIC
FROM BCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
• IF ODOMETER PASSES THE SEGMENT CHECK,
LOOK FOR ANOTHER POSSIBLE CAUSE OF
FAILURE. IF IT FAILS VERIFY POWER AND
GROUND ARE BEING PROVIDED TO THE
CLUSTER. IF YES, REPLACE CLUSTER. IF NO,
DETERMINE CAUSE OF NO POWER OR GROUND.
ERRATIC DISPLAY 1. INTERNAL CLUSTER 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF ODOMETER PASSES THE SEGMENT TEST,
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
VERIFY GOOD POWER AND GROUND
CONNECTIONS. IF CONNECTIONS ARE GOOD AND
NO OTHER PROBLEMS ARE FOUND, REPLACE
CLUSTER ASSEMBLY.
2. BAD PCI BUS 2. USE A DRB IIIT SCAN TOOL TO CHECK THE
MESSAGE FROM THE BCM. REFER TO THE PROPER BODY DIAGNOSTIC
BCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
ODOMETER WON’T GO 1. TRIP SWITCH 1. IF CLUSTER WILL NOT GO INTO SELF
INTO TRIP MODE. DOESN’T WORK. DIAGNOSTIC MODE AND CANNOT TOGGLE
BETWEEN ODOMETER AND TRIP ODOMETER,
REPLACE CLUSTER.
TRIP ODOMETER WON’T 1. RESET SWITCH 1. IF CLUSTER WILL NOT GO INTO SELF
RESET. DOESN’T WORK. DIAGNOSTIC MODE AND TRIP ODOMETER WILL
NOT RESET, REPLACE CLUSTER.
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS

NO DISPLAY 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF
IT FAILS, REPLACE CLUSTER ASSEMBLY.
ERRATIC DISPLAY 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. BAD PCI BUS 2. USE A DRB IIIT SCAN TOOL TO CHECK THE
MESSAGE FROM THE TCM. REFER TO THE PROPER TRANSMISSION
TCM. DIAGNOSTIC PROCEDURES MANUAL TO
ALL SEGMENTS ARE ON 1. NO PCI BUS 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
MESSAGE FROM THE IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
TCM. PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL.
1.B. CHECK THE TCM USING A DRB IIIT SCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS

INDICATOR DOES NOT MIS-ADJUSTED 1.A. VERIFY TRANSMISSION SHIFT SYSTEM IS
SHOW PROPER GEAR CORRECTLY ADJUSTED.
OR NO INDICATION. 1.B. VERIFY CORRECT ROUTING AND
ATTACHMENT OF PRNDL CABLE AND GUIDE TUBE.
1.C. RE-ADJUST PRNDL INDICATOR IN NEUTRAL
USING ADJUSTER WHEEL BELOW STEERING
COLUMN.
INDICATOR DOES NOT NOT ATTACHED 1.A. VERIFY INDICATOR CABLE CONNECTED TO
FOLLOW GEAR SHIFT SHIFT LEVER PIN IN THE GROOVE.
LEVER. 1.B. VERIFY THAT THE INDICATOR CLIP IS SECURE,
AND ATTACHED TO THE MOUNTING BRACKET.
MAKE SURE THAT THE CLIP IS NOT BROKEN. IF
THE CLIP IS BROKEN, REPLACE CLIP ON
INDICATOR.

INDICATOR DOES NOT 1. CABLE DISLODGED 1. VERIFY CORRECT ATTACHMENT OF INDICATOR
MAKE FULL TRAVEL (“P” FROM ITS PATH ON THE CABLE TO SHIFT LEVER PIN (UNDER HOOP OF
< > “1”). INDICATOR BASE. TRANS. SHIFT CABLE) AND CLIP ONTO THE
MOUNTING BRACKET.
2. INCORRECT 2. VERIFY INDICATOR TRAVEL BY PULLING ON
ATTACHMENT OF CABLE CABLE GENTLY OVER FULL TRAVEL RANGE. IF
TO SHIFT LEVER PIN. THERE IS STILL A PROBLEM, REMOVE CLUSTER
TO ACCESS INDICATOR BASE AND CONFIRM
CABLE PATH.
REMOVAL (12) Disconnect the cluster harness connector.

(13) Remove the instrument cluster carefully while
WITH ELECTRONIC TRANSMISSION RANGE guiding the range indicator cable and guide tube
INDICATOR through the opening to avoid any damage.
cable. INSTALLATION
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull. WITH ELECTRONIC TRANSMISSION RANGE
(3) Remove the four cluster bezel attaching screws. INDICATOR
(4) Tilt the steering column in the full down posi- (1) Connect the instrument cluster wire connector.
tion. (2) Rotate top of cluster inward as placing into
(5) Pull rearward on the cluster bezel and remove. instrument panel opening.
(6) Remove the four screws holding instrument (3) Install the four screws holding instrument clus-
cluster to instrument panel. ter to instrument panel.
(7) Rotate top of cluster outward. (4) Position cluster bezel into place.
(8) Disconnect the cluster harness connector. (5) Install the four bezel attaching screws.
(9) Remove instrument cluster from instrument (6) Install the Over Steering Column Bezel by
panel. firmly snapping into place.
WITH MECHANICAL TRANSMISSION RANGE
INDICATOR WITH MECHANICAL TRANSMISSION RANGE
(1) Disconnect and isolate the battery negative INDICATOR
cable. (1) Guide the range indicator cable and guide tube
(2) Remove the lower steering column cover. Refer through the opening of instrument panel.
to Body, Instrument Panel, Lower Steering Column (2) Connect the instrument cluster wire connector.
Cover, Removal. (3) Rotate top of cluster inward as placing into
(3) Remove the plastic knee blocker reinforcement. instrument panel opening.
Refer to Body, Instrument Panel, Knee Blocker Rein- (4) Install the four screws holding instrument clus-
forcement, Removal. ter to instrument panel.
(4) Disconnect the transmission range indicator (5) Position cluster bezel into place.
cable end from shift lever by flexing the HOOP on (6) Install the four bezel attaching screws.
the transmission shift cable rearward and slip the (7) Install the Over Steering Column Bezel by
indicator cable loop off the lever pin. firmly snapping into place.
(5) Disconnect the clip holding the indicator cable (8) Connect the clip holding the indicator cable to
to the mounting bracket. the mounting bracket.
(6) Remove Over Steering Column Bezel by lifting (9) Connect the transmission range indicator cable
it straight up with a firm pull. end to the shift lever by flexing the HOOP on the
(7) Remove the four bezel attaching screws. transmission shift cable forward and slip the indica-
(8) Tilt the steering column in the full down posi- tor cable loop on the lever pin.
tion. (10) Install the plastic knee blocker reinforcement.
(9) Pull rearward on the cluster bezel and remove. Refer to Body, Instrument Panel, Knee Blocker Rein-
(10) Remove the four cluster attaching screws. forcement, Installation.
(11) Rotate top of the cluster rearward.
(11) Install the lower steering column cover. Refer indicator and then remove it fromt instrument clus-
to Body, Instrument Panel, Lower Steering Column ter.
Cover, Installation.
(12) Connect the battery negative cable. INSTALLATION
(1) Insert the mechanical transmission range indi-
cator into the backside of the instrument cluster and
CLUSTER LENS install the two screws.
(2) Install the instrument cluster. Refer to Electri-
REMOVAL cal, Instrument Cluster, Installation.
(1) Remove the instrument cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Remove the screws holding the lens to the RED BRAKE WARNING
instrument cluster. INDICATOR
(3) Press down on the snap features of the lens
and remove the lens from the cluster.
DESCRIPTION
The red BRAKE warning indicator (lamp) is
INSTALLATION located in the instrument panel cluster and is used to
(1) Insert the lens snap features into the cluster.
indicate a low brake fluid condition or that the park-
(2) Install the screws holding the lens to the
ing brake is applied. In addition, the brake warning
instrument cluster.
indicator is turned on as a bulb check by the ignition
(3) Install the instrument cluster. Refer to Electri-
switch every time the ignition switch is placed in the
cal, Instrument Cluster, Installation.
crank position.
MECHANICAL TRANSMISSION OPERATION

The red BRAKE warning indicator (lamp) is sup-
RANGE INDICATOR plied a 12-volt ignition feed anytime the ignition
switch is on. The bulb is then illuminated by com-
REMOVAL pleting the ground circuit either through the switch
(1) Remove the instrument cluster and disconnect on the parking brake lever, the brake fluid level
the range indicator cable at both attaching points. switch in the master cylinder reservoir, or the igni-
Refer to Electrical, Instrument Cluster, Removal. tion switch when it is placed in the crank position.
(2) From the backside of the cluster, remove two
screws holding the mechanical transmission range
RG INSTRUMENT CLUSTER 8Ja - 1
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION WATER IN FUEL LAMP

The Water In Fuel Sensor is a resistive type
WATER IN FUEL LAMP switch. It is calibrated to sense the different resis-
The Water In Fuel Lamp is located in the instru- tance between diesel fuel and water. When water
ment cluster. When moisture is found within the fuel enters the fuel system, it is caught in the bottom of
system, the sensor sends a message via the PCI data the fuel filter/water separator assembly, where the
bus to the instrument cluster. The sensor is located sensor is located. Water has less resistance than die-
underneath the vehicle, directly above the rear axle. sel fuel. The sensor then sends a PCI data bus mes-
The sensor is housed within the fuel filter/water sep- sage to the instrument cluster to illuminate the
arator assembly cover. The sensor is not serviced sep- lamp.
arately. If found defective, the entire assembly cover If the lamp is inoperative, perform the self diag-
must be replaced. nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RS LAMPS 8L - 1
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR . . . . . . . . . . . . . . . 17
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR HEADLAMP SWITCH

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 11
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7 HEADLAMP UNIT
BRAKE LAMP SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 7 LICENSE PLATE LAMP
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MULTI-FUNCTION SWITCH
CENTER HIGH MOUNTED STOP LAMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 15
CENTER HIGH MOUNTED STOP LAMP UNIT MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FOG LAMP PARK/TURN SIGNAL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FOG LAMP UNIT TAIL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TAIL LAMP UNIT
HEADLAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8L - 2 LAMPS/LIGHTING - EXTERIOR RS
LAMPS/LIGHTING - EXTERIOR headlamp switch is in the AUTO position, RPM >

450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
DESCRIPTION
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
LAMP SYSTEMS
if the instrumentation and exterior illumination
RS vehicles use lighting on the interior and exte-
lamps should remain ON base upon the current
rior of the vehicle for illuminating and indicating
ambient light level.
purposes. Lighting circuits are protected by fuses.
Lighting circuits require an overload protected power
HEADLAMP SYSTEM
source, on/off device, lamps and body ground to oper-
The configuration of the headlamp system of head-
ate properly. Plastic lamps require a wire in the har-
lamps, park lamps and fog lamps is determined by
ness to supply body ground to the lamp socket.
the BCM. The BCM determines the lighting configu-
Replace sockets and bulbs that are corroded.
ration as a result of the inputs from the ignition
Some of the interior and exterior lighting functions
switch, headlamp switch and multifunction switch. A
are governed by the Body Control Module. The head-
J1850 is transmitted from the BCM to the FCM to
lamp, dome, and the door ajar switches provide sig-
enable the necessary drivers to set the illumination
nals to the Body Control Module. The Body Control
configuration. Four wires are connected between the
Module in turn sends a J1850 message to the Front
headlamp switch and the BCM. The first wire con-
Control Module (FCM) to enable the necessary driv-
tains information regarding the position of the head-
ers to set the required illumination configuration.
lamp switch (Off, Automatic Headlamps, Automatic
Wire connectors can make intermittent contact or
Headlamp switch fog, Park with Fog, Head, or Head
become corroded. Before coupling wire connectors,
with Fog Lamps). The second wire contains informa-
inspect the terminals inside the connector. Male termi-
tion regarding the position of the dimmer switch
nals should not be bent or disengaged from the insu-
(Dome Lamp, Daytime Brightness, Dimming Level or
lator. Female terminals should not be sprung open or
Off). The third wire is a dedicated signal return
disengaged from the insulator. Bent and sprung termi-
(ground) wire. The fourth wire provides power to the
nals can be repaired using needle nose pliers and pick
front fog lamp indicator.
tool. Corroded terminals appear chalky or green. Cor-
roded terminals should be replaced to avoid recur-
HEADLAMP TIME DELAY SYSTEM
rence of the problem symptoms.
The headlamp time delay system is controlled by
Begin electrical system failure diagnosis by testing
the Body Control Module (BCM) via a J1850 message
related fuses in the fuse block and intelligent power
transmitted by the BCM to the FCM to turn off the
module. Verify that bulbs are in good condition and
headlamps.
test continuity of the circuit ground. Refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
OPERATION
nector repair procedures, details of wire harness
AUTOMATIC HEADLAMP SYSTEM
and location views for the various wire harness con- Automatic headlamps are controlled by the Body
nectors, splices and grounds. Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
AUTOMATIC HEADLAMP SYSTEM lamp, parking, side marker, tail and instrumentation
The Automatic Headlamp system turns the instru- lamps based on ambient light levels. Ambient light
mentation and exterior illumination lamps ON when levels are monitored by the BCM using the Day/
the ambient light levels are Night and OFF when Night signal and Electrochromatic Mirror (ECM)
light levels are Day. present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
DAYTIME RUNNING LAMPS ror (ECM). Ambient light readings are averaged to
Operating the high-beam headlamps at reduced limit cycling the lamps ON and OFF when passing
power provides daytime running lamps, which are through areas with varying light levels. The auto-
required on all new Canadian vehicles. matic headlamps will only function when the engine
is running with RPM > 450. When the headlamp
HEADLAMPS ON WITH WINDSHIELD WIPERS switch is in the AUTO position (Automatic mode), the
For vehicles equipped with the Automatic Head- Headlamp Time Delay system will function when the
lamp System, the instrumentation and exterior illu- ignition switch is placed in any position other than
mination lamps will be turned ON when the run/start.
RS LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
DAYTIME RUNNING LAMPS OPTICAL HORN/HIGH BEAMS
Power is reduced using pulse-width modulation to When the multifunction switch is pulled to the first
the high beams, where by the power is switched on detent (optical horn) signal, the headlamps are ON,
and off rapidly instead of remaining on continuously. key-in the ignition the BCM shall send a message via
The duration and interval of the power pulses is pro- J1850 to the FCM to turn on the headlamps drivers
grammed into the Front Control Module (FCM). to illuminate all four filaments (Low and High
beams). When the multifunction switch is pulled to
HEADLAMP SYSTEM the second detent (high beam) signal and the head-
The headlamp system will default to headlamps lamps are ON, the BCM shall send a message via
ON position when ignition switch is ON and when an J1850 to the FCM to turn on the headlamps drivers.
open or short circuit failure occurs on the headlamp The High Beams are illuminated and the Low Beams
switch input. The system will return to normal oper- and Fog Lamps (if ON) are extinguished. If the head-
ation when the open or short is repaired. A fault will lamps were in the high beam configuration when
be reported by the BCM when a failure occurs on the power was removed from the headlamps, the head-
dimmer or headlamp switch input. lamps will be configured as low beam the next time
If the exterior lamps are ON and the headlamp they are activated.
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3 DIAGNOSIS AND TESTING
minutes the BCM sends a message via J1850 to the
FCM informing the FCM to turn off the headlamps, WARNING: EYE PROTECTION SHOULD BE USED
park lamps and fog lamps. This feature prevents the WHEN SERVICING GLASS COMPONENTS. PER-
vehicle battery from being discharged when the vehi- SONAL INJURY CAN RESULT.
cle lights have been left ON.
CAUTION: Do not touch the glass of halogen bulbs
HEADLAMP TIME DELAY SYSTEM with fingers or other possibly oily surface, reduced
The headlamp time delay system is activated by bulb life will result. Do not use bulbs other than
turning the headlamps ON (high or low beam) while those indicated in the Bulb Application table. Dam-
the engine is running, turning the ignition switch age to lamp and/or Daytime Running Lamp Module
OFF, and then turning the headlamp switch OFF can result. Do not use fuses, circuit breakers or
within 45 seconds. The system will not activate if relays having greater amperage value than indi-
more than 45 seconds elapse between ignition switch cated on the fuse panel or in the Owners Manual.
OFF and headlamp switch OFF. The BCM will allow
When a vehicle experiences problems with the
the headlamps to remain ON for 90 seconds (config-
headlamp system, verify the condition of the battery
urable) before they automatically turn off (If the key
connections, fuses, charging system, headlamp bulbs,
is in the ignition during the headlamp time delay
wire connectors, relay, high beam switch, dimmer
mode, then both the headlamps and park lamps
switch, and headlamp switch. Refer to the appropri-
(including panel dimming) will be ON). Refer to the
ate wiring information. The wiring information
Owner’s Manual for more information.
includes wiring diagrams, proper wire and connector
If the headlamp switch is in the Auto Headlamp
repair procedures, details of wire harness routing
Position, the headlamps are ON due to the night sig-
and retention, connector pin-out information and
nal from the CMTC and the ignition switch is in any
location views for the various wire harness connec-
position other than run/start, the BCM shall enter a
tors, splices and grounds.
90 second (configurable) Auto Headlamps time delay
Each vehicle is equipped with various lamp assem-
mode. If the key is in the ignition during the head-
blies. A good ground is necessary for proper lighting
lamp time delay mode, then both the headlamps and
operation. Grounding is provided by the lamp socket
park lamps (including panel dimming) will be ON. If
when it comes in contact with the metal body, or
the key is not in the ignition, then only the head-
through a separate ground wire.
lamps will be ON. The BCM will allow the head-
When changing lamp bulbs check the socket for
lamps to remain ON for 90 seconds before they
corrosion. If corrosion is present, clean it with a wire
automatically turn OFF. Refer to the Owner’s Man-
brush.
ual for more information.
When it is necessary to remove components to ser-
LAMP OUTAGE vice another, it should not be necessary to apply
If one or more of the following lamps (Low and/or excessive force or bend a component to remove it.
High beams) are out, then a “lamps out” indicator Before damaging a trim component, verify hidden
located in the cluster will illuminate. fasteners or captured edges are not holding the com-
ponent in place.
HEADLAMPS
HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING and posts.
OR IGNITION TURNED 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
OFF
3. Charging system output too low. 3. Test and repair charging system, refer
to Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of -charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical,
Battery System.
6. Poor lighting circuit Z343/Z344- 6. Test for voltage drop across Z343/Z344-
ground. ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS BURN 1. Intelligent Power Module (IPM) not 1. Test and repair Intelligent Power
OUT FREQUENTLY controlling voltage. Module.
2. Loose or corroded terminals or 2. Inspect and repair all connectors and
splices in circuit. splices. Refer to Electrical, Wiring
Information.
HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer
WITH ENGINE RUNNING to Electrical, Wiring Information.
ABOVE IDLE
2. Poor lighting circuit Z343/Z344- 2. Test for voltage drop across Z343/Z344-
ground. ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp 3. Test amperage draw of headlamp
circuit. circuit.
HEADLAMPS FLASH 1. Poor lighting circuit Z343/Z344- 1. Test for voltage drop across Z343/Z344-
RANDOMLY ground. ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp 2. Test amperage draw of headlamp
circuit. circuit.
splices in circuit. splices, refer to Electrical, Wiring
Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to

ILLUMINATE Electrical, Wiring Information.
2. No Z343/Z344-ground at 2. Repair circuit ground, refer to Electrical,
headlamps. Wiring Information.
3. Broken connector terminal or wire 3. Repair connector terminal or wire splice.
splice in headlamp circuit.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module malfunction. 5. Refer to appropriate Body Control
Module diagnostics.
6. J1850 Bus Communication 6. Verify messages being transmitted by

BCM and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM
diagnostics.
HEADLAMPS ON WITH 1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
IGNITION IN RUN, WITH logged faults).
HEADLAMP SWITCH OFF
2. Diagnostic tool indicates (4.7 - 2. Inspect and repair terminals, connectors
5.0V) on headlamp switch input to and open circuits.
BCM.
3. J1850 Bus Communication. 3. Verify messages being transmitted by
BCM and received by FCM.
FOG LAMPS
FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING and posts.
OR IGNITION TURNED
OFF. 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical,
Battery System.
6. Poor lighting circuit Z349/Z248 6. Test for voltage drop across Z349/248
ground. ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system. Refer to
OUT FREQUENTLY Electrical, Charging.

Information.
FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to
WITH ENGINE RUNNING Electrical, Charging.
ABOVE IDLE 2. Poor lighting circuit Z349/Z248 2. Test for voltage drop across Z349/Z248
ground. ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH 1. Poor lighting circuit Z349/Z248 1. Test for voltage drop across Z349/Z248
RANDOMLY ground. ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp 2. Test amperage draw of fog lamp circuit.
circuit.
3. Faulty fog lamp switch (part of 3. Replace headlamp switch.

headlamp switch).
Information.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. J1850 Bus Communication. 6. Verify J1850 message (fog lamp info)
transmitted from BCM and received by
FCM.
FOG LAMPS DO NOT 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
ILLUMINATE Information.
2. No Z349/Z248 ground at fog 2. Repair circuit ground. Refer to Electrical,
lamps. Wiring Information.
3. Faulty fog lamp switch (part of 3. Replace headlamp switch.
headlamp switch).
4. Broken connector terminal or wire 4. Repair connector terminal or wire splice.
splice in fog lamp circuit.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. J1850 Bus Communication. 7. Verify J1850 message (fog lamp info)
transmitted from BCM and received by
FCM.
DAYTIME RUNNING LAMP (CANADA ONLY)
DAYTIME RUNNING
LAMPS DO NOT
WORK
1. Parking brake engaged. 1. Disengage parking brake.
2. Parking brake circuit shorted to 2. Check cluster telltale, refer to the appropriate
ground. wiring information. The wiring information
includes wiring diagrams, proper wire and
connector repair procedures, further details on
wire harness routing and retention, as well as
pin-out and location views for the various wire
harness connectors, splices and grounds.
3. Headlamp circuit shorted to ground. 3. Refer to the appropriate wiring information.
The wiring information includes wiring
diagrams, proper wire and connector repair
procedures, further details on wire harness
routing and retention, as well as pin-out and
location views for the various wire harness
connectors, splices and grounds.
4. Faulty DRL relay. 4. Replace DRL relay.
5. Body controller not programed with 5. Check country code.
Canadian country code.
SPECIFICATIONS completing the circuit. The switch for terminals 3

and 4 is open and so is the switch for 5 and 6.
EXTERIOR LAMPS When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
CAUTION: Do not use bulbs other than those listed The switch for terminals 1 and 2 is now open while
in the Bulb Application Table. Damage to lamp can the other two switches are now closed, completing
result. their circuits.
DIAGNOSIS AND TESTING - BRAKE LAMP

CAUTION: Do not touch halogen bulbs with fingers
SWITCH
or other oily surfaces. Bulb life will be reduced.
NOTE: Before proceeding with this diagnostic test,
BULB APPLICATION TABLE
verify the adjustment of the brake lamp switch to
rule out misadjustment. If misadjusted, replace the
LAMP BULB switch. It cannot be readjusted.
BACK-UP 3057
If the electrical circuit has been tested and the
CENTER HIGH 921
brake lamp switch is suspected of being faulty, it can
MOUNTED STOP
be tested using the following method.
FRONT SIDE MARKER/ 3157A (1) Remove the switch from the vehicle. Refer to
PARK/TURN Removal And Installation in this section.
FOG LAMP 9040 (2) With the switch in the released position (plung-
er extended), use an ohmmeter to test each of the
HEADLAMP 9007
three internal switches as shown (Fig. 1). You should
LICENSE 168 achieve the results as listed in the figure.
TAIL, STOP 3057
TURN SIGNAL 3057
BRAKE LAMP SWITCH

DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It’s main function is to control opera-
tion of the vehicle’s brake lamps. Other functions
include speed control deactivation, brake sense for
the antilock brake system and brake sense for the
brake transmission shift interlock.
CAUTION: The switch can only be adjusted once.

That is during initial installation of the switch. If the Fig. 1 Switch Test - Released Position
removed for some service, a new switch must be (3) Gently push the plunger on the brake lamp
installed and adjusted. switch in until it stops.
(4) With the switch in this depressed position
(plunger pushed in), use an ohmmeter to test each of
OPERATION the three internal switches as shown (Fig. 2). You
When the brake pedal is pressed, the plunger on should achieve the results as listed in the figure.
the outside of the brake lamp switch extends out- If you do not achieve the results as listed in both
ward. This action opens or closes the contacts of the figures, the switch is faulty and must be replaced.
three switches inside the brake lamp switch. Refer to Removal And Installation in this section.
With the brake pedal is pressed down (plunger If the switch is found to be operating properly, do
extended), the switch for terminals 1 and 2 is closed not reinstall it, replace the switch. Refer to Removal
And Installation in this section.
BRAKE LAMP SWITCH (Continued)
Fig. 2 Switch Test - Depressed Position

CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
removed for some service, a new switch must be Fig. 3 PEDAL AND BRAKE LAMP SWITCH
1 - SWITCH BRACKET
2 - BRAKE LAMP SWITCH
3 - WIRING CONNECTOR
REMOVAL - BRAKE LAMP SWITCH 4 - PEDAL AND BRACKET
cable from its post on the battery.
(2) Remove silencer panel below steering column to the full vertical position as shown (Fig. 4). This
and knee blocker. will adjust the brake lamp switch to the vehicle.
(3) Remove the brake lamp switch by rotating the
switch in a counterclockwise direction approximately
30 degrees and pulling it out of the bracket (Fig. 3).
(4) Discard the brake lamp switch. It must not be
reused.
INSTALLATION - BRAKE LAMP SWITCH

(1) Mount and adjust the NEW brake lamp switch

using the following procedure: Fig. 4 Adjustment Lever Movement
(a) Install the switch in its bracket by aligning
(2) Install silencer panel below steering column
the index tab on the switch with the slot in the
knee blocker.
mounting bracket.
(3) Reconnect the battery negative terminal.
(b) When the switch is fully seated in its
(4) Check the stop lamps to verify they are operat-
bracket, rotate the switch clockwise approximately
ing properly and not staying on when the pedal is in
30° to lock the switch into place (Fig. 3).
the released position.
(c) With the brake pedal in the fully released
(5) Road test the vehicle to ensure proper opera-
position, move the lever on the back of the brake
tion of the brakes (including ABS if equipped) and
lamp switch from the angled non-adjusted position
speed control (if equipped).
CENTER HIGH MOUNTED

STOP LAMP
REMOVAL
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 6).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable. Fig. 6 CHMSL BULB
1 - CHMSL
2 - CHMSL BULB
CENTER HIGH MOUNTED
STOP LAMP UNIT
FOG LAMP
REMOVAL
(1) Disconnect and isolate the battery negative REMOVAL
cable. (1) Disconnect and isolate the battery negative
(2) Remove the two retaining screws (Fig. 5). cable.
(2) From behind the bumper fascia, twist bulb
counter-clockwise, and remove bulb. (Fig. 7).
(3) Remove the wire connector from the fog lamp
bulb.
Fig. 5 CHMSL
1 - CHMSL
2 - LIFT GATE
(3) Disconnect the rear window washer hose.

(4) Remove bulb socket from lamp unit (Fig. 6).
Fig. 7 FOG LAMP
INSTALLATION
1 - FOGLAMP MOUNTING NUT
(1) Install bulb socket to lamp unit.
2 - FOGLAMP BULB
(2) Reconnect the rear window washer hose.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable. INSTALLATION
(1) Reconnect wire harness to bulb.
(2) Install bulb and twist clockwise.
(3) Install battery negative cable.
FOG LAMP UNIT ADJUSTMENT
REMOVAL FOG LAMP ALIGNMENT

(1) Disconnect and isolate the battery negative Prepare an alignment screen. (Refer to 8 - ELEC-
cable. TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
(2) From behind the bumper fascia, disconnect the LAMP UNIT - ADJUSTMENTS). A properly aligned
wire harness from the fog lamp bulb (Fig. 7). fog lamp will project a pattern on the alignment
(3) Remove mounting nuts. screen 100 mm (4 in.) below the fog lamp center line
and straight ahead (Fig. 8). To improve visual inter-
INSTALLATION pretation of the fog lamp pattern on the alignment
(1) Install mounting nuts. screen, the headlamps should be in the “off” position.
(2) Reconnect the wire harness to the fog lamp The fog lamps are adjusted by a adjustment screw
bulb. located through the lens on Dodge vehicles, and by a
(3) Reconnect the battery negative cable. knob on the back of the lamp on Chrysler vehicles.
Fig. 8 Fog Lamp Alignment

1 - HIGH INTENSITY AREA 5 - 7.62 METERS (25 FT.)
2 - CENTER OF VEHICLE 6 - FRONT OF FOG LAMP
3 - HORIZONTAL CENTER OF FOG LAMP
4 - 100MM (4 IN.)
HEADLAMP
REMOVAL
(1) Disconnect and isolate the battery negative cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
(4) Remove wiring connector from bulb.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
Fig. 10 HEADLAMP SWITCH CONNECTOR

HEADLAMP SWITCH CONTINUITY
HEADLAMP SWITCH 13 - WAY RESISTANCE VALUE

POSITION CONNECTOR
TERMINAL
OFF 11 TO 6 3651 - 3729
PARKING LAMPS ON 11 TO 6 1697 - 2517
PARKING LAMPS 11 TO 6 5765 - 5886
WITH FRONT FOG
LAMPS ON
Fig. 9 HEADLAMP BULB HEADLAMPS ON 11 TO 6 788 - 809
AUTO ON 11 TO 6 10056 - 10264
1 - HEADLAMP BULB
HEADLAMPS ON 11 TO 6 1171 - 1200
2 - HEADLAMP UNIT WITH FRONT FOG
LAMPS
AUTO ON WITH 11 TO 6 24278 - 24773
(6) Pull headlamp bulb and remove from headlamp FRONT FOG LAMPS
unit (Fig. 9). ON
DIMMER POSITION 13 - WAY RESISTANCE VALUE
CONNECTOR
INSTALLATION TERMINAL
(1) Install headlamp bulb to the headlamp unit. DOME 12 TO 6 15568 - 23357
(2) Install headlamp bulb retaining ring. PARADE 12 TO 6 5168 - 7757
(3) Connect wiring connector to bulb. DIM HIGH 12 TO 6 2288 - 3437
DIM LOW 12 TO 6 688 - 1037
(4) Install the headlamp unit.
OFF 12 TO 6 240 - 365
(5) Install headlamp unit retaining screws.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
HEADLAMP SWITCH headlamp switch. Firmly push out on the headlamp
switch assembly.
DIAGNOSIS AND TESTING (4) Disconnect the wiring connectors.
Using a Digital Multi-meter, perform the test (Fig. (5) Remove switch from vehicle.
10).
If the Headlamp Switch is not within specifications INSTALLATION
replace as necessary. (1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
REMOVAL and firmly snap into place.
(1) Disconnect and isolate the battery negative (3) Install the Instrument Panel Lower Steering
cable. Column Cover. Refer to Body, Instrument Panel,
(2) Remove the Instrument Panel Lower Steering Lower Steering Column Cover, Installation.
Column Cover. Refer to Body, Instrument Panel, (4) Connect the battery negative cable.
Lower Steering Column Cover, Removal.
HEADLAMP UNIT (4) Remove wire harness retainer from back of

headlamp unit.
(5) Remove the headlamp unit.
REMOVAL
cable.
INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Remove the three retaining screws (Fig. 11).
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
ADJUSTMENT
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
Fig. 11 HEADLAMP FASTENERS (5) Verify that luggage area is loaded as the vehi-
1 - HEADLAMP RETAINING SCREW cle is routinely used.
2 - HEADLAMP UNIT (6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
(3) Disconnect the wiring harness from the bulbs gallon of missing fuel.
(Fig. 12).
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 13).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
Fig. 12 HEADLAMP ASSEMBLY

1 - HEADLAMP UNIT
2 - HEADLAMP BULB
3 - PARK/TURN SIGNAL BULB
4 - WIRE HARNESS RETAINER
HEADLAMP UNIT (Continued)
Fig. 13 Headlamp Alignment Screen

1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
HEADLAMP ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline 6 50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 14). To adjust headlamp verti-
cal alignment, rotate adjustment screw to achieve the
specified low beam cut-off location.
Fig. 15 LICENSE PLATE LAMPS

1 - SCREW
2 - LICENSE PLATE LAMP
Fig. 14 HEADLAMP ADJUSTMENT

1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
LICENSE PLATE LAMP

REMOVAL
Fig. 16 LICENSE PLATE LAMP BULB
cable. 1 - LICENSE PLATE LAMP
2 - BULB
(2) Remove two screws (Fig. 15).
(3) Twist bulb socket and remove (Fig. 16).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket. DESCRIPTION - TURN SIGNAL SYSTEM
(2) Install socket into lamp. The turn signals are actuated with a lever on
(3) Install two screws. Multi-Function Switch, located on the left side of the
(4) Reconnect the battery negative cable. steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position. The multi-function switch is a resistive
MUX switch that feeds inputs to the BCM.
MULTI-FUNCTION SWITCH (Continued)
OPERATION - TURN SIGNAL SYSTEM INSTALLATION

Lane change signaling is actuated by applying par- (1) Position the switch on to the steering column.
tial turn signal stalk movement toward the direction (2) Install the two retaining screws.
desired until the indicator lamps flashes in the (3) Connect the wire harness connector.
instrument cluster. When the switch stalk is released (4) Install the upper and lower steering column
the stalk will spring back into the neutral position shrouds. Refer to Steering, Column, Shroud, Installa-
turning OFF the turn signal. tion.
With the ignition switch ON and the turn signal (5) Connect the battery negative cable.
switch stalk actuated left or right, current flows
through the:
• Multi-function switch PARK/TURN SIGNAL LAMP
• Body Control Module
• Integrated Power Module (IPM) REMOVAL
• Turn indicator lamp
• Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 0.5 mile and a speed of 15
mph, with the turn signal ON.
DIAGNOSIS AND TESTING - MULTI-FUNCTION

SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the continuity read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
table. Fig. 17 PARK/TURN SIGNAL BULB
MULTI-FUNCTION SWITCH CONTINUITY 1 - PARK/TURN SIGNAL BULB
2 - BULB SOCKET
SWITCH POSITION CONTINUITY BETWEEN
LEFT 2 AND 3 (1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
RIGHT 2 AND 3
(3) Twist socket counter - clockwise and remove
OPTICAL HORN 2 AND 4 (Fig. 17).
HI BEAM 2 AND 4 (4) Pull bulb from socket.
REMOVAL INSTALLATION
(1) Disconnect and isolate battery negative cable. (1) Push bulb into socket.
(2) Remove upper and lower steering column (2) Twist socket into headlamp.
shrouds. Refer to Steering, Column, Shroud, (3) Install headlamp retaining screws.
Removal. (4) Reconnect battery negative cable.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
TAIL LAMP
REMOVAL
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 18).
Fig. 19 REAR TAIL LAMP FASTENERS

1 - TAIL LAMP FASTENER
2 - TAIL LAMP
Fig. 18 TAIL LAMP SOCKET

1 - BULB SOCKET
2 - TAIL LAMP UNIT
(4) Pull bulb from lamp socket.
INSTALLATION Fig. 20 TAIL LAMP REMOVAL/INSTALL

(1) Push bulb into the lamp socket. 1 - WIRE HARNESS CONNECTOR
(2) Install bulb socket into the tail lamp unit. 2 - TAIL LAMP
Ensure that both retaining tabs engage with an audi-
ble click.
(3) Install the tail lamp unit. (Refer to 8 - ELEC- INSTALLATION
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL (1) Reconnect wire harness connector to the tail
LAMP UNIT - INSTALLATION). lamp. Slide lock into position.
(4) Reconnect the battery negative cable. (2) Place lamp into position on quarter panel.
(3) Engage hook attaching forward end of lamp to
quarter panel.
TAIL LAMP UNIT (4) Insert the two retaining fasteners by pressing
into position. Ensure that the head of the fastener is
REMOVAL open before inserting.
(1) Disconnect and isolate the battery negative (5) Close the liftgate.
cable. (6) Reconnect the battery negative cable.
(2) Raise the liftgate.
(3) Remove the two retaining fasteners by prying
under the head of the fastener with a flat bladed tool
(Fig. 19).
(4) Disengage hook attaching forward end of lamp
to quarter panel opening.
(5) Disconnect wire harness connector from tail
lamp unit by sliding the red lock, then pressing
release tab (Fig. 20).
RS LAMPS/LIGHTING - INTERIOR 8L - 17
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 17 GLOVE BOX LAMP SWITCH
CENTER CONSOLE LAMP SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 LIFTGATE LAMP
CLUSTER ILLUMINATION LAMPS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 READING LAMP
COURTESY LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VANITY LAMP
DOME LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LAMPS/LIGHTING - INTERIOR LAMP BULB

LOW FUEL INDICATOR LED
SPECIFICATIONS LOW WASHER FLUID LED
INDICATOR
MALFUNCTION INDICATOR LED
BULB APPLICATION TABLE (BASE CLUSTER)
MALFUNCTION INDICATOR PC74
LAMP BULB OIL INDICATOR (BASE LED
ABS LED CLUSTER)
AIRBAG LED OIL INDICATOR PC74
ALARM SET PC74 OVERHEAD CONSOLE PC579
AUTOSTICK VFD* READING
BRAKE SYSTEM WARNING LED OVERDRIVE OFF VFD*

INDICATOR
CONSOLE 194
READING 578
CRUISE INDICATOR VFD*
SEAT BELT INDICATOR LED
DOME/RAIL LAMPS 578
TEMPERATURE INDICATOR LED
DOOR AJAR INDICATOR LED
TRAC OFF INDICATOR VFD*
DOOR COURTESY LAMP 578
TURN SIGNAL INDICATOR LED
FRONT DOOR COURTESY 567 (BASE CLUSTER)
GLOVE BOX 194 TURN SIGNAL INDICATOR PC74
HIGH BEAM INDICATOR LED VISOR VANITY 6501966
(BASE CLUSTER)
VOLTAGE INDICATOR LED
HIGH BEAM INDICATOR PC74
* VACUUM
INSTRUMENT CLUSTER PC74 FLUORESCENT
LIFTGATE 578 DISPLAY
LIFTGATE AJAR LED
8L - 18 LAMPS/LIGHTING - INTERIOR RS
CENTER CONSOLE LAMP

SWITCH
REMOVAL
cable.
(2) Open console lid and remove tray.
(3) Using a flat bladed tool, pry up on the switch.
(4) Remove bulb from switch.
INSTALLATION
(1) Install bulb into switch.
(2) Push switch into console opening. Fig. 1 COURTESY LAMP
(3) Install tray and close lid. 1 - WIRE HARNESS
(4) Connect battery negative cable. 2 - COURTESY LAMP
CLUSTER ILLUMINATION DOME LAMP

LAMPS
REMOVAL
REMOVAL (1) Disconnect and isolate the battery negative
(1) Remove the Instrument Cluster. Refer to Elec- cable.
trical, Instrument Cluster, Removal. (2) Using a flat bladed tool, pry off the lamp lens.
(2) Turn over cluster and expose the illumination (3) Remove bulb from lamp.
bulb sockets.
(3) Identify which bulb is defective and twist it out INSTALLATION
of the cluster using a counterclockwise motion. (1) Install bulb to lamp.
(2) Press lens into place.
INSTALLATION (3) Connect battery negative cable.
(1) Install the new bulb socket into the cluster
using a clockwise motion.
(2) Install the Instrument Cluster. Refer to Electri- GLOVE BOX LAMP SWITCH
cal, Instrument Cluster, Installation.
REMOVAL
COURTESY LAMP cable.
(2) Open glove box door.
REMOVAL (3) Push switch through from behind (Fig. 2).
cable.
(2) Using a trim stick, pry lamp from door panel
(Fig. 1).
(3) Disconnect wire harness from the lamp.
(4) Remove lens from the lamp and remove bulb.
INSTALLATION
(1) Install bulb and lens to lamp.
(2) Reconnect wire harness to lamp.
(3) Press lamp into the door panel.
(4) Reconnect battery negative cable.
Fig. 2 GLOVE BOX LAMP/SWITCH

1 - GLOVE BOX BULB
2 - GLOVE BOX LAMP SWITCH
RS LAMPS/LIGHTING - INTERIOR 8L - 19
GLOVE BOX LAMP SWITCH (Continued)
(4) Disconnect wire harness from switch. READING LAMP
(5) Pull bulb from switch.
REMOVAL
INSTALLATION The front reading lamps are incorporated into the
(1) Push bulb into switch.
overhead console. If the reading lamps require replace-
(2) Connect wire harness to switch.
ment, the overhead console must be replaced. (Refer to
(3) Push switch into instrument panel.
8 - ELECTRICAL/OVERHEAD CONSOLE - REMOV-
(4) Close glove box door.
AL). The rear reading lamps are incorporated into the
assist handle. If the rear reading lamps require
replacement, the assist handle must be replaced.
LIFTGATE LAMP (Refer to 23 - BODY/INTERIOR/ASSIST HANDLE -
REMOVAL). The bulbs can be serviced separately.
REMOVAL cable.
(2) Using a flat bladed tool, pry off the lamp lens
cable.
(Fig. 4), (Fig. 5).
(2) Using a flat bladed tool, pry lamp from trim
panel (Fig. 3).
Fig. 3 LIFTGATE LAMP

1 - LIFTGATE LAMP Fig. 4 OVERHEAD CONSOLE
2 - WIRE HARNESS 1 - LAMP LENS
2 - OVERHEAD CONSOLE
(3) Disconnect wire harness connector from lamp.
(4) Pry off lens and remove bulb. (3) Remove bulb from lamp (Fig. 6), (Fig. 7).
INSTALLATION
(1) Install bulb and snap lens into place.
(2) Reconnect wire harness connector to lamp.
(3) Position lamp onto trim panel and snap into
place.
(4) Reconnect battery negative cable.
Fig. 5 COURTESY/READING LAMP

1 - HVAC LOUVER
2 - ASSIST HANDLE
3 - LAMP LENS
8L - 20 LAMPS/LIGHTING - INTERIOR RS
READING LAMP (Continued)
VANITY LAMP
REMOVAL
The vanity lamp is incorporated into the visor
assembly. If the vanity lamp needs to be replaced,
the entire visor must be replaced. The bulbs are ser-
viced separately.
cable.
(2) Using a pick or other suitable tool, pry the
lens from the lamp (Fig. 8).
Fig. 6 OVERHEAD CONSOLE BULB

1 - BULB
2 - OVERHEAD CONSOLE
Fig. 8 VANITY LAMP

1 - VISOR
2 - BULB
3 - LENS
(3) Remove bulb.

Fig. 7 COURTESY/READING LAMP BULB
1 - BULB INSTALLATION
(1) Install bulb.
(2) Snap lamp lens into position.
INSTALLATION (3) Connect the battery negative cable.
(1) Install bulb to lamp.
(2) Press lens into place.
RG LAMPS 8La - 1
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR DIAGNOSIS AND TESTING . . . . . . ............4

SPECIFICATIONS . . . . . . . . . . . . . ............1 HEADLAMP LEVELING SWITCH ............4
FOG LAMP HEADLAMP SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . ............1 DIAGNOSIS AND TESTING . . . . . . ............5
INSTALLATION. . . . . . . . . . . . . . . . ............2 HEADLAMP SWITCH . . . . . . . . . ............5
FOG LAMP UNIT HEADLAMP UNIT
ADJUSTMENTS . . . . . . . . . . . . . . . ............2 ADJUSTMENTS . . . . . . . . . . . . . . . ............6
FRONT POSITION LAMP PARK/TURN SIGNAL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . ............3 REMOVAL . . . . . . . . . . . . . . . . . . . ............7
INSTALLATION. . . . . . . . . . . . . . . . ............3 INSTALLATION. . . . . . . . . . . . . . . . ............7
HEADLAMP REAR FOG LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . ............3 DESCRIPTION . . . . . . . . . . . . . . . . ............7
INSTALLATION. . . . . . . . . . . . . . . . ............3 REPEATER LAMP
HEADLAMP LEVELING MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . ............7
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .4 INSTALLATION. . . . . . . . . . . . . . . . ............7
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . .4 TAIL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 REMOVAL . . . . . . . . . . . . . . . . . . . ............8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .4 INSTALLATION. . . . . . . . . . . . . . . . ............8
HEADLAMP LEVELING SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . ............4
LAMPS/LIGHTING - EXTERIOR FOG LAMP

REMOVAL
SPECIFICATIONS (1) Disconnect and isolate the battery negative
cable.
EXTERIOR LAMPS (2) Remove access cover from under bumper fascia.
BULB APPLICATION CHART (3) Disengage spring clip from fog lamp (Fig. 1).
LAMP BULB TYPE

HEADLAMP H7
FRONT POSITION W5W
FRONT TURN SIGNAL PY21W
SIDE REPEATER T4W
LICENSE PLATE W5W/168
REAR TAIL AND STOP P21/5W
REAR TURN SIGNAL PY21W
BACK-UP P21W
REAR FOG P21W
CENTER HIGH W16W/921
MOUNTED STOP LAMP
Fig. 1 FOG LAMP
For additional bulb applications refer to the domestic
1 - SPRING CLIP
Lamps section of the service manual. 2 - FOG LAMP BULB
8La - 2 LAMPS RG
FOG LAMP (Continued)
(4) Remove bulb from lamp. FOG LAMP UNIT
(5) Disconnect wire harness connector.
ADJUSTMENT
INSTALLATION
(1) Connect wire harness connector. FOG LAMP ALIGNMENT
(2) Install bulb to lamp.
Prepare an alignment screen. (Refer to 8 - ELEC-
(3) Engage spring clip to fog lamp.
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
(4) Install access cover under bumper fascia.
LAMP UNIT - ADJUSTMENTS). A properly aligned
fog lamp will project a pattern on the alignment
screen 200 mm (8 in.) below the fog lamp center line
and straight ahead (Fig. 2). To improve visual inter-
pretation of the fog lamp pattern on the alignment
screen, the headlamps should be in the “off” position.
The fog lamps are adjusted by a adjustment screw
located on the underside of the fog lamp unit.
Fig. 2 FOG LAMP ALIGNMENT

1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP 6 - FRONT OF FOG LAMP
RG LAMPS 8La - 3
FRONT POSITION LAMP HEADLAMP

REMOVAL REMOVAL
(1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative
cable. cable.
(2) Remove the headlamp unit (Fig. 3). (2) Remove the headlamp unit.
(3) Remove the cover (high beam lamp) or rubber
boot (low beam lamp) to access bulbs (Fig. 4).
Fig. 3 FRONT POSITION LAMP

1 - TURN SIGNAL LAMP
2 - HIGH BEAM LAMP Fig. 4 HEADLAMP UNIT
3 - FRONT POSITION LAMP 1 - HIGH BEAM LAMP
4 - LOW BEAM LAMP 2 - HEADLAMP LEVELING MOTOR
3 - LOW BEAM LAMP
(3) Remove the plastic cover from the back of the 4 - TURN LAMP
headlamp unit.
(4) Pull front position lamp socket from headlamp (4) Disconnect the wire harness connector.
unit. (5) Disengage spring clip from headlamp.
(5) Pull bulb straight out of socket. (6) Pull headlamp bulb from back of headlamp
unit.
INSTALLATION
(1) Push bulb into the bulb socket. INSTALLATION
(2) Insert bulb socket into headlamp unit. (1) Insert headlamp bulb into headlamp unit.
(3) Install cover to the back of the headlamp unit. (2) Engage spring clip to headlamp.
(4) Install the headlamp unit. (3) Connect wire harness connector.
(5) Connect the battery negative cable. (4) Install the cover (high beam lamp) or rubber
boot (low beam lamp) to headlamp unit.
8La - 4 LAMPS RG
HEADLAMP LEVELING MOTOR

DIAGNOSIS AND TESTING - HEADLAMP
LEVELING MOTOR
HEADLAMP LEVELING MOTOR DIAGNOSIS

ONE MOTOR DOES NOT 1. Poor electrical connection at 1. Check for proper electrical
OPERATE motor connection at motor
2. No voltage at motor 2. Repair no voltage condition.
Refer to Wiring Diagrams
3. No ground at motor 3. Repair no ground condition.
4. Defective motor 4. Replace leveling motor
BOTH MOTORS DO NOT 1. No voltage at or from headlamp 1. Repair no voltage condition.
OPERATE leveling switch Check for proper headlamp
leveling switch operation
2. No voltage at leveling motors 2. Repair no voltage condition.
3. No ground at leveling motors 3. Repair no ground condition.
4. Both motors defective 4. Replace both motors
REMOVAL
cable.
(2) Remove headlamp unit.
(3) Disconnect electrical connector from headlamp
leveling motor.
(4) Remove the two mounting screws.
(5) Gently pry motor from headlamp unit (Fig. 5).
INSTALLATION
(1) Press motor into position.
(2) Install the two mounting screws.
(3) Connect the electrical connector to motor.
Fig. 5 HEADLAMP LEVEL MOTOR

HEADLAMP LEVELING 1 - HIGH BEAM HEADLAMP
2 - HEADLAMP LEVELING MOTOR
SWITCH 3 - LOW BEAM HEADLAMP
DESCRIPTION
the headlamp leveling switch is faulty or damaged,
Some vehicles are equipped with a remote head-
the headlamp switch must be replaced.
lamp leveling system. This system allows the driver
to adjust the vertical headlamp aim from the interior
of the vehicle to compensate for passenger or cargo DIAGNOSIS AND TESTING - HEADLAMP
load. LEVELING SWITCH
The headlamp leveling switch is located next to the The headlamp leveling switch is located next to the
headlamp switch on the instrument panel (Fig. 6). If headlamp switch on the instrument panel. (Refer to 8
RG LAMPS 8La - 5
HEADLAMP LEVELING SWITCH (Continued)
HEADLAMP SWITCH CONTINUITY TABLE
HEADLAMP 13 - WAY RESISTANCE

SWITCH CONNECTOR VALUE
POSITION TERMINAL
OFF 11 TO 6 3651 - 3729
PARKING 11 TO 6 1697 - 2517
LAMPS ON
PARKING 11 TO 6 5765 - 5886
LAMPS WITH
FRONT FOG
LAMPS ON
HEADLAMPS 11 TO 6 788 - 809
ON
Fig. 6 HEADLAMP LEVELING SWITCH HEADLAMPS 11 TO 6 1171 - 1200
1 - POWER MIRROR SWITCH
ON WITH
2 - HEADLAMP SWITCH FRONT FOG
3 - INTERIOR DIMMER LAMPS
4 - HEADLAMP LEVELING SWITCH REAR FOG 11 TO 6 271 -277
LAMPS
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ FRONT FOG 10 TO 4 LED
HEADLAMP SWITCH - DIAGNOSIS AND TEST- INDICATOR
ING) for diagnosis of the headlamp leveling switch. If REAR FOG 5 TO 4 LED
the headlamp leveling switch is faulty, the headlamp INDICATOR
switch must be replaced.
ILLUMINATION 8 TO 4 CONTINUITY
DIMMER 13 - WAY RESISTANCE
HEADLAMP SWITCH POSITION CONNECTOR VALUE
TERMINAL
DIAGNOSIS AND TESTING - HEADLAMP DOME 12 TO 6 15568 - 23357
SWITCH PARADE 12 TO 6 5168 - 7757
Using a Digital Multi-meter, refer to the headlamp
switch continuity table (Fig. 7). DIM HIGH 12 TO 6 2288 - 3437
If the Headlamp Switch is not within specifications DIM LOW 12 TO 6 688 - 1037
replace as necessary. OFF 12 TO 6 240 - 365
HEADLAMP 13 - WAY RESISTANCE
LEVELING CONNECTOR VALUE
SWITCH TERMINAL
POSITION
0 1 TO 7 3238 - 3456
1 TO 2 3181 - 3400
1 1 TO 7 1195 - 1225
2 1 TO 7 746 - 765
Fig. 7 HEADLAMP SWITCH CONNECTOR

8La - 6 LAMPS RG
HEADLAMP UNIT ALIGNMENT SCREEN PREPARATION

(1) Position vehicle on a level surface perpendicu-
ADJUSTMENT lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 8).
HEADLAMP ALIGNMENT PREPARATION (2) If necessary, tape a line on the floor 10 meters
(1) Verify headlamp dimmer switch and high beam (32.8 ft.) away from and parallel to the wall.
indicator operation. (3) Rock vehicle side-to-side three times and allow
(2) Verify that the headlamp leveling switch is in suspension to stabilize.
the “0” position. (4) Jounce front suspension three times by pushing
(3) Inspect and correct damaged or defective com- downward on front bumper and releasing.
ponents that could interfere with proper headlamp (5) Measure the distance from the center of head-
alignment. lamp lens to the floor. Transfer measurement to the
(4) Verify proper tire inflation. alignment screen (with tape). Use this line for
(5) Clean headlamp lenses. up/down adjustment reference.
(6) Verify that luggage area is loaded as the vehi-
cle is routinely used. HEADLAMP ADJUSTMENT
(7) Fuel tank should be FULL. Add 2.94 kg (6.5 The low beam headlamp will project on the screen
lbs.) of weight over the fuel tank for each estimated upper edge of the beam (cut-off) at the horizontal
gallon of missing fuel. lamp centerline ± 20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 9). To adjust headlamp align-
ment, rotate adjustment screws to achieve the speci-
fied low beam cut-off location.
Fig. 8 HEADLAMP ALIGNMENT SCREEN

1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.)
2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE
3 - 15° CUT-OFF LINE 7 - 110 mm (4.3 in.)
4 - FRONT OF HEADLAMP
RG LAMPS 8La - 7
(4) Twist bulb and remove from bulb socket.
INSTALLATION
(1) Install bulb to bulb socket.
(2) Install bulb socket to headlamp unit.
(3) Install headlamp unit.
REAR FOG LAMP

DESCRIPTION
The rear fog lamps are incorporated into the tail
lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/TAIL LAMP - REMOVAL)
for service procedures.
Fig. 9 HEADLAMP ADJUSTMENT
1 - HEADLAMP ADJUSTMENT - HORIZONTAL
2 - HEADLAMP ADJUSTMENT - VERTICAL REPEATER LAMP
REMOVAL
PARK/TURN SIGNAL LAMP (1) Disconnect and isolate the battery negative
cable.
REMOVAL (2) Push the side repeater lamp to one side and
(1) Disconnect and isolate the battery negative release retaining tab.
cable. (3) Pull side repeater lamp out and disengage bulb
(2) Remove the headlamp unit. socket from lamp.
(3) Twist bulb socket and remove from headlamp (4) Depress, then rotate and pull bulb from socket.
unit (Fig. 10).
INSTALLATION
(1) Install bulb to socket.
(2) Push lamp socket into the side repeater lamp.
(3) Position side repeater lamp to hole in fender.
(4) Push side repeater lamp to one side and seat
retaining tab into fender.
Fig. 10 PARK/TURN SIGNAL LAMP

1 - LOW BEAM HEADLAMP
2 - PARK/TURN SIGNAL LAMP
8La - 8 LAMPS RG
TAIL LAMP
REMOVAL
cable.
(2) Remove the tail lamp unit (Refer to 8 - ELEC-
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on housing retaining the
bulbs and remove from the tail lamp unit (Fig. 11).
(4) Remove bulbs by depressing, then turning
counter-clockwise.
INSTALLATION
(1) Install bulbs by turning clockwise.
(2) Install housing to tail lamp unit.
Fig. 11 TAIL LAMP BULBS
(3) Install the tail lamp unit (Refer to 8 - ELEC-
1 - TAIL LAMP UNIT
2 - BRAKE/PARK LAMP BULB
LAMP UNIT - INSTALLATION).
3 - TURN SIGNAL BULB
(4) Connect the battery negative cable. 4 - BACK UP LAMP BULB
5 - REAR FOG LAMP BULB
RS MESSAGE SYSTEMS 8M - 1
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . . . . . . 1 OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . . . . . . . 2
MESSAGE CENTER
TABLE OF CONTENTS
page page
MESSAGE CENTER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MESSAGE CENTER NOTE: If the message center lamp needs replacing,

twist out defective bulb socket and replace with a
known good bulb and socket.
REMOVAL
cable. INSTALLATION
(2) Using a trim stick (special tool #C-4755) or (1) Connect the wiring connector to message cen-
equivalent, gently pry up on the front side of the ter.
message center and lift out of instrument panel open- (2) Place message center in position on instrument
ing. panel and firmly snap into place.
(3) Disconnect the wire connector from the back of (3) Connect battery negative cable.
message center.
(4) Remove message center from vehicle.
8M - 2 OVERHEAD CONSOLE RS
OVERHEAD CONSOLE
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE COMPASS/MINI-TRIP COMPUTER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .3 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 10
DIAGNOSIS & TESTING. . . . . . . . . . . . . . . . . . .3 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COURTESY LAMP REPLACEMENT . . . . . . . . . .4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPASS CALIBRATION. . . . . . . . . . . . . . . . . .4 UNIVERSAL TRANSMITTER
COMPASS DEMAGNETIZING. . . . . . . . . . . . . . .4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPASS VARIATION ADJUSTMENT . . . . . . . .5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6 UNIVERSAL GARAGE DOOR OPENER . . . . . . 11
ELECTRONIC VEHICLE INFO CENTER AMBIENT TEMP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . .7 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 11
TRAVELER MESSAGES . . . . . . . . . . . . . . . . . . .7 AMBIENT TEMPERATURE SENSOR. . . . . . . . . 11
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . .8 AMBIENT TEMPERATURE SENSOR
EVIC PROGRAMMING . . . . . . . . . . . . . . . . . . . .8 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .9 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OVERHEAD CONSOLE less than forty-eight seconds. This will reorient the
compass unit to its vehicle.
The compass unit also will compensate for magne-
DESCRIPTION
tism the body of the vehicle may acquire during nor-
The available overhead consoles on RS models can
mal use. However, avoid placing anything magnetic
include the Electronic Vehicle Information Center
directly on the roof of the vehicle. Magnetic mounts
(EVIC), Compass Mini-Trip Computer (CMTC) or a
for an antenna, a repair order hat, or a funeral pro-
Compass Temperature Computer (CT). All consoles
cession flag can exceed the compensating ability of
are equipped with two reading/courtesy lamps and if
the compass unit if placed on the roof panel. Mag-
the vehicle is equipped with a power liftgate or
netic bit drivers used on the fasteners that hold the
power sliding door(s) the overhead console will also
overhead console assembly to the roof header can
include command switches for these features. The
also affect compass operation. If the vehicle roof
overhead console is mounted with one screw and two
should become magnetized, the demagnetizing and
snap clips to a molded plastic retainer bracket
calibration procedures found in this section may be
located above the headliner.
required to restore proper compass operation.
DESCRIPTION - COMPASS DESCRIPTION - THERMOMETER
All the available overhead consoles on this model
All the available overhead consoles on this model
include Compass information. While in the compass/
include Temperature information. The thermometer
thermometer mode, the compass will display the
displays the outside ambient temperature in whole
direction in which the vehicle is pointed using the
degrees. The temperature display can be toggled
eight major compass headings (Examples: north is N,
from Fahrenheit to Celsius by selecting the desired
northeast is NE). The self-calibrating compass unit
U.S./Metric option from the customer programmable
requires no adjusting in normal use. The only cali-
features. The displayed temperature is not an instant
bration that may prove necessary is to drive the vehi-
reading of conditions, but an average temperature. It
cle in three complete circles at 5 to 8 kilometers-per-
may take the thermometer display several minutes
hour (3 to 5 miles-per-hour), on level ground, in not
to respond to a major temperature change, such as
RS OVERHEAD CONSOLE 8M - 3
OVERHEAD CONSOLE (Continued)
driving out of a heated garage into winter tempera- output (run/start) fuse in the intelligent power mod-
tures. ule. If OK, go to Step 5. If not OK, repair the open
When the ignition switch is turned to the Off posi- fused ignition switch output (run/start) circuit to the
tion, the last displayed temperature reading stays in ignition switch as required.
the electronic control modules (CT, CMTC, EVIC) (5) Turn the ignition switch to the Off position.
memory. When the ignition switch is turned to the Disconnect and isolate the battery negative cable.
On position again, the electronic module will display Remove the overhead console. Check for continuity
the memory temperature for one minute; then update between the ground circuit cavity of the roof wire
the display to the current average temperature read- harness connector for the electronics module and a
ing within five minutes. good ground. There should be continuity. If OK, go to
The thermometer function is supported by an Step 6. If not OK, repair the open ground circuit to
ambient temperature sensor. The sensor is mounted ground as required.
outside the passenger compartment near the front (6) Connect the battery negative cable. Check for
and center of the vehicle, and is hard wired to the battery voltage at the fused B(+) circuit cavity of the
Front Control Module (FCM). The FCM sends tem- roof wire harness connector for the electronics mod-
perature status messages to the module over the ule. If OK, go to Step 7. If not OK, repair the open
J1850 PCI data bus circuit. fused B(+) circuit to the fused B(+) fuse in the intel-
Following are general descriptions of the major ligent power module as required.
components used in the overhead console. Refer to (7) Turn the ignition switch to the On position.
Wiring Diagrams for complete circuit schematics. Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the roof wire har-
OPERATION ness connector for the electronics module. If OK,
Refer to the vehicle Owner’s Manual for specific refer to Self-Diagnostic Test later this group for
operation of each overhead console and its systems. further diagnosis of the electronics module and the
J1850 PCI data bus circuit. If not OK, repair the
DIAGNOSIS & TESTING - OVERHEAD open fused ignition switch output (run/start) circuit
CONSOLE to the fuse in the intelligent power module as
required.
If the problem with the overhead console is an
inaccurate or scrambled display, refer to Self-Diag-
nostic Test later in this group. If the problem with
SELF-DIAGNOSTIC TEST
the overhead console is incorrect Vacuum Fluorescent A self-diagnostic test is used to determine that the
Display (VFD) dimming levels, use a DRB IIIt scan electronics module is operating properly, and that all
tool and the proper Diagnostic Procedures manual to the J1850 PCI data bus messages are being received
test for the correct dimming message inputs being for initial operation. Initiate the self-diagnostic test
received from the Body Control Module (BCM) or as follows:
Front Control Module (FCM) over the J1850 Pro- (1) With the ignition switch in the Off position, on
grammable Communications Interface (PCI) data bus Electronic Vehicle Information Center (EVIC) and
circuit. If the problem is a no-display condition, use Compass Mini-Trip Computer (CMTC) equipped vehi-
the following procedures. For complete circuit dia- cles simultaneously depress and hold the STEP and
grams, refer to Overhead Console in the Wiring the RESET buttons. On Compass Temperature
Diagrams section of the service manual. Module (CT) equipped vehicles depress the C/T and
(1) Check the fused B(+) fuse in the intelligent the US/M push buttons.
power module. If OK, go to Step 2. If not OK, repair (2) Turn the ignition switch to the On position.
the shorted circuit or component as required and (3) Following completion of these tests, the elec-
replace the faulty fuse. tronics module will display one of the following mes-
(2) Check for battery voltage at the fused B(+) fuse sages:
in the intelligent power module. If OK, go to Step 3. • Pass Self Test (EVIC only), PASS (CT,
If not OK, repair the open fused B(+) circuit to the CMTC) - The electronics module is working properly.
fused B(+) fuse in the intelligent power module as • Failed Self Test (EVIC only), FAIL (CT,
required. CMTC) - The electronics module has an internal fail-
(3) Check the fused ignition switch output (run/ ure. The electronics module is faulty and must be
start) fuse in the intelligent power module. If OK, go replaced.
to Step 4. If not OK, repair the shorted circuit or • Failed J1850 Communication (EVIC only),
component as required and replace the faulty fuse. BUS (CT, CMTC)- The electronics module is not
(4) Turn the ignition switch to the On position. receiving proper message input through the J1850
Check for battery voltage at the fused ignition switch PCI data bus circuit. This can result from one or
more faulty electronic modules in the vehicle, or from cles, large buildings, or bridges; or, near overhead or
a faulty PCI data bus. The use of a DRB IIIt scan underground power lines.
tool and the proper Diagnostic Procedures manual
are required for further diagnosis. NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. Refer
NOTE: If the compass functions, but accuracy is to Compass Variation Adjustment in this group.
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass Calibrate the compass manually as follows:
unit to accommodate variations in the earth’s mag- (1) Turn the ignition switch to the On position. If
netic field strength, based on geographic location. the compass/thermometer data is not currently being
Refer to Compass Variation Adjustment in the Ser- displayed, momentarily depress and release the C/T
vice Procedures section of this group. push button to reach the compass/thermometer dis-
play.
(2) On Electronic Vehicle Information Center
NOTE: If the compass reading displays dashes, and (EVIC) and Compass Mini-Trip Computer (CMTC)
only “CAL” appears in the display, demagnetizing equipped vehicles depress the Reset push button and
may be necessary to remove excessive residual hold the button down until “CAL” appears in the dis-
magnetic fields from the vehicle. Refer to Compass play. This takes about ten seconds, and appears
Demagnetizing in the Service Procedures section of about five seconds after “VAR = XX” is displayed. On
this group. Compass Temperature Module (CT) equipped vehicles
depress the C/T push button and US/M push button
down until “CAL” appears in the display. This takes
STANDARD PROCEDURE - READING/ about ten seconds, and appears about five seconds
COURTESY LAMP REPLACEMENT after “VAR = XX” is displayed.
(1) Open hood, disconnect and isolate the negative (3) Release the push button(s).
battery cable remote terminal from the remote bat- (4) Drive the vehicle on a level surface, away from
tery post. large metal objects and power lines, through three or
(2) Remove the reading/courtesy lamp lens. Using more complete circles at between five and eight kilo-
a trim stick, gently pry the forward edge of the read- meters-per-hour (three and five miles-per-hour) in
ing/courtesy lamp lens outward. not less than 48 seconds. The “CAL” message will
(3) Remove the reading/courtesy lamp socket from disappear from the display to indicate that the com-
the overhead console. Rotate the reading/courtesy pass is now calibrated.
lamp socket one quarter turn counter clockwise.
(4) Remove the lamp and socket assembly. NOTE: If the “CAL” message remains in the display,
(5) Reverse the above procedure to install. either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
STANDARD PROCEDURE - COMPASS procedure one more time.
CALIBRATION
NOTE: If the wrong direction is still indicated in the
CAUTION: Do not place any external magnets, such compass display, the area selected for calibration
as magnetic roof mount antennas, in the vicinity of may be too close to a strong magnetic field. Repeat
the compass. Do not use magnetic tools when ser- the calibration procedure in another location.
vicing the overhead console.
The electronic compass unit features a self-cali- STANDARD PROCEDURE - COMPASS

brating design, which simplifies the calibration pro-
cedure. This feature automatically updates the DEMAGNETIZING
compass calibration while the vehicle is being driven. A degaussing tool (Special Tool 6029) is used to
This allows the compass unit to compensate for small demagnetize, or degauss, the overhead console for-
changes in the residual magnetism that the vehicle ward mounting screw and the roof panel above the
may acquire during normal use. If the compass read- overhead console. Equivalent units must be rated as
ings appear to be erratic or out of calibration, per- continuous duty for 110/115 volts and 60 Hz. They
form the following calibration procedure. Also, new must also have a field strength of over 350 gauss at 7
service replacement Electronic Modules (EVIC, millimeters (0.25 inch) beyond the tip of the probe.
CMTC, CT) must have their compass calibrated To demagnetize the roof panel and the overhead
using this procedure. Do not attempt to calibrate the console forward mounting screw, proceed as follows:
compass near large metal objects such as other vehi-
(1) Be certain that the ignition switch is in the Off (8) Slowly approach the center line of the roof
position, before you begin the demagnetizing proce- panel at the windshield header, with the degaussing
dure. tool connected.
(2) Connect the degaussing tool to an electrical (9) Contact the roof panel with the plastic coated
outlet, while keeping the tool at least 61 centimeters tip of the degaussing tool. Be sure that the template
(2 feet) away from the compass unit. is in place to avoid scratching the roof panel. Using a
(3) Slowly approach the head of the overhead con- slow, back-and-forth sweeping motion, and allowing
sole forward mounting screw with the degaussing 13 millimeters (0.50 inch) between passes, move the
tool connected. tool at least 11 centimeters (4 inches) to each side of
(4) Contact the head of the screw with the plastic the roof center line, and 28 centimeters (11 inches)
coated tip of the degaussing tool for about two sec- back from the windshield header.
onds. (10) With the degaussing tool still energized,
(5) With the degaussing tool still energized, slowly slowly back it away from the roof panel. When the
back it away from the screw. When the tip of the tool tip of the tool is at least 61 centimeters (2 feet) from
is at least 61 centimeters (2 feet) from the screw the roof panel, disconnect the tool.
head, disconnect the tool. (11) Calibrate the compass and adjust the compass
(6) Place a piece of paper approximately 22 by 28 variance. Refer to Compass Variation Adjustment
centimeters (8.5 by 11 inches), oriented on the vehicle and Compass Calibration in the Standard Proce-
lengthwise from front to rear, on the center line of dures section of this group for the procedures.
the roof at the windshield header (Fig. 1). The pur-
pose of the paper is to protect the roof panel from STANDARD PROCEDURE - COMPASS
scratches, and to define the area to be demagnetized. VARIATION ADJUSTMENT
Compass variance, also known as magnetic decli-
nation, is the difference in angle between magnetic
north and true geographic north. In some geographic
locations, the difference between magnetic and geo-
graphic north is great enough to cause the compass
to give false readings. If this problem occurs, the
compass variance setting may need to be changed.
To set the compass variance:
(1) Using the Variance Settings map, find your
geographic location and note the zone number (Fig.
2).
(2) Turn the ignition switch to the On position. If
the compass/thermometer data is not currently being
displayed, momentarily depress and release the C/T
push button to reach the compass/thermometer dis-
play.
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles depress the Reset push button and
hold the button down until “VAR = XX” appears in
the display. This takes about five seconds. On Com-
pass Temperature Module (CT) equipped vehicles
depress the C/T push button and US/M push button
down until “VAR = XX” appears in the display. This
takes about five seconds.
(4) Release the push button(s). “VAR =XX ” will
remain in the display. “XX” equals the current vari-
ance zone setting.
Fig. 1 Roof Demagnetizing Pattern (EVIC) and Compass Mini-Trip Computer (CMTC)
(7) Connect the degaussing tool to an electrical equipped vehicles momentarily depress and release
outlet, while keeping the tool at least 61 centimeters the Step push button to step through the zone
(2 feet) away from the compass unit. numbers, until the zone number for your geographic
location appears in the display. On Compass Temper-
Fig. 2 Variance Settings

ature Module (CT) equipped vehicles depress the INSTALLATION
US/M push button to step through the zone num-
(1) Position the overhead console in the vehicle.
bers, until the zone number for your geographic loca-
(2) Connect the EVIC, CMTC or CT electronic
tion appears in the display.
module and the reading/courtesy lamps electrical
connector.
(EVIC) and Compass Mini-Trip Computer (CMTC)
(3) Using your fingertips, grasp the sides of the
equipped vehicles momentarily depress and release
overhead console and push straight up evenly to
the Reset push button to enter the displayed zone
engage the two snap clips at the rear of the unit.
number into the EVIC/CMTC module memory. On
Compass Temperature Module (CT) equipped vehicles CAUTION: DO NOT PRESS ON THE SUNGLASS
depress the C/T push button to enter the displayed STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY
zone number into the electronic module memory. RESULT.
(7) Confirm that the correct directions are now
indicated by the compass. (4) Install the overhead console retaining screw,
located in the front of console. Torque the screw to
REMOVAL - OVERHEAD CONSOLE 1.2 N·m (10 in. lbs.).
(1) Disconnect and isolate the remote negative bat- (5) Connect the remote negative battery cable.
tery cable.
(2) Remove the overhead console retaining screw,
located in the front of console. ELECTRONIC VEHICLE INFO
(3) Using your fingertips, grasp the sides of the CENTER
overhead console and pull straight down evenly to
disengage the two snap clips at the rear of the unit. DESCRIPTION
(4) Lower the overhead console far enough to
The Electronic Vehicle Information Center (EVIC)
access the wire harness connectors.
is a module located in the overhead console on some
(5) Disconnect the EVIC, CMTC or CT electronic
models. The EVIC module features a large Vacuum
module and the reading/courtesy lamps electrical
Fluorescent Display (VFD) screen for displaying
connector.
information, and back-lit push button switches
(6) Remove the overhead console from the vehicle.
labeled C/T (compass/thermometer), RESET, STEP,
and MENU.
ELECTRONIC VEHICLE INFO CENTER (Continued)
The EVIC module contains a central processing position, momentarily depressing and releasing the
unit and interfaces with other electronic modules in C/T (compass/thermometer) push button switch will
the vehicle over the Programmable Communications cause the EVIC to return to the compass/thermome-
Interface (PCI) J1850 data bus circuit. The PCI data ter/trip computer display mode from any other mode.
bus circuit allows the sharing of sensor information. While in the compass/thermometer/trip computer dis-
This helps to reduce wire harness complexity, reduce play mode, momentarily depressing and releasing the
internal controller hardware, and reduce component Step push button will step through the available trip
sensor current loads. At the same time, this system computer display options.
provides increased reliability, enhanced diagnostics, The EVIC trip computer features several functions
and allows the addition of many new feature capabil- that can be reset. The functions that can be reset
ities. are: average fuel economy, trip odometer and elapsed
The EVIC “Menu” push button provides the vehicle time. With the ignition switch in the On position and
operator with a user interface, which allows the with one of the functions of the trip computer that
selection of several optional customer programmable can be reset currently displayed, depressing the
electronic features to suit individual preferences. Reset push button twice within three seconds will
Refer to ELECTRONIC VEHICLE INFORMA- perform a global reset, and all of the trip computer
TION CENTER PROGRAMMING in the Service information that can be reset will be reset to zero.
Procedures section of this group for more information With the ignition switch in the On position and the
on the customer programmable feature options. function that is to be reset currently displayed,
If the vehicle is equipped with the optional momentarily depressing and releasing the Reset
Homelinkt transceiver, the EVIC will also display push button once will perform a local reset, and only
messages and an icon indicating when the the value of the displayed function will be reset to
Homelinkt transceiver is being trained, which of the zero. A global or local reset will only occur if the
three transmitter buttons is transmitting, and when function currently displayed is a function that can be
the transceiver is cleared. reset. The distance to service function can also be
Data input for all EVIC functions, including VFD reset using the local reset method, but it will reset
dimming level, is received through the J1850 PCI back to the Service Interval distance that is set in
data bus circuit. The EVIC module uses its internal the EVIC programmable features mode. Refer to
programming and all of its data inputs to calculate ELECTRONIC VEHICLE INFORMATION CEN-
and display the requested data. If the data displayed TER PROGRAMMING in the Service Procedures
is incorrect, perform the self-diagnostic tests as section of this group for more information on setting
described in this group. If these tests prove inconclu- the Service Interval.
sive, the use of a DRBIIIt scan tool and the proper For more information on the features, control func-
Diagnostic Procedures manual are recommended for tions and setting procedures for the EVIC module,
further testing of the EVIC module and the J1850 see the owner’s manual in the vehicle glove box.
PCI data bus circuit.
The EVIC module cannot be repaired, and is avail- DIAGNOSIS & TESTING - ELECTRONIC
able for service only as a unit. This unit includes the VEHICLE INFORMATION CENTER
plastic module and display lens. If any of these com- Electronic Vehicle Information Center (EVIC) data
ponents is faulty or damaged, the complete EVIC is obtained from the Body Control Module (BCM) on
module must be replaced. the J1850 Data Bus circuit. The EVIC will display
dashes (- -) for any of the screens it did not receive
OPERATION the bus messages. The label corresponding to the
The EVIC has access to both non-switched and missing information will be lit. If no EVIC data is
ignition switched sources of battery current so that displayed, check the J1850 Data Bus circuit commu-
some of its features remain operational at any time, nications and the BCM. If the brightness level is
while others may only operate with the ignition improper check the J1850 Data Bus circuit.
switch in the On position. When the ignition switch The DRB IIIt is recommended for checking the
is turned to the On position, the EVIC module VFD J1850 Data Bus circuit and the BCM. Perform the
will return to the last function being displayed before EVIC self diagnosis before replacing the EVIC mod-
the ignition was turned to the Off position. ule.
The compass/thermometer display is the normal
EVIC display. With the ignition switch in the On
STANDARD PROCEDURE - ELECTRONIC The default is 12000 kilometers (7500 miles). The
selected distance becomes the interval at which the
VEHICLE INFORMATION CENTER
Perform Service warning message will be displayed
PROGRAMMING by the EVIC. If a new distance is selected, a second
programmable feature appears, RESET SERVICE
EVIC PROGRAMMING MODE DISTANCE? - The options include No and Yes. The
Some vehicles are equipped with a Electronic Vehi- default is Yes. When Yes is selected, the accumulated
cle Information Center (EVIC) equipped overhead distance since the last previous Perform Service
console. The Electronic Vehicle Information Center warning message will be reset to zero because the
(EVIC) provides the vehicle operator with a user service interval has been changed. When No is
interface, which allows the selection of several selected, the distance until the next Perform Service
optional customer programmable electronic features warning message is reduced by the accumulated dis-
to suit individual preferences. The EVIC must be tance since the last previous message.
placed into its programming mode in order to view or • USE FACTORY SETTINGS? - The options
change the programmable features. To enter the include Yes and No. The default is Yes. When yes is
EVIC programming mode and to view or change the selected all the programmable features will return to
selected programmable features options, proceed as there defaults and the rest of the programmable fea-
follows: tures will not be displayed. If No is selected the rest
(1) Turn the ignition switch to the On position. of the programmable features will be displayed at
(2) Depress and release the Menu push button. there default values. This feature will automatically
The first item in the programmable features menu return to the Yes default under two conditions. First,
list will appear in the EVIC display. if no programmable features are changed from there
(3) Momentarily depress and release the Menu defaults. Second, if all the programmable features
push button to step through the programmable fea- equal there defaults.
tures list. Each programmable feature and its cur- • AUTO DOOR LOCKS? - The options include
rently selected option will appear on the EVIC Yes and No. The default is Yes. When Yes is selected,
display in the sequence shown in the Programmable all doors and the liftgate lock automatically when
Features list that follows. vehicle speed reaches 25 kilometers-per-hour (15
(4) Momentarily depress and release the Step push miles-per-hour). If YES is selected, a second program-
button to step through the available options for the mable feature appears, AUTO UNLOCK ON EXIT?
programmable feature being displayed. - The options again include Yes and No. The default
(5) The option that last appears in the display is No. When Yes is selected, following each Auto Door
with a programmable feature before exiting the pro- Lock event all doors and the liftgate will automati-
gramming mode, becomes the newly selected pro- cally unlock when the driver door is opened, if the
grammable feature option. vehicle is stopped and the transmission gear selector
(6) The EVIC exits the programming mode and is in Park or Neutral. The Auto Door Unlock event
returns to its normal operating mode when the C/T will only occur once following each Auto Door Lock
push button is depressed or when the end of the pro- event.
grammable features menu list is reached, whichever • REMOTE UNLOCK - The options include
occurs first. Driver Door 1st and All Doors. The default is Driver
Door 1st. When Diver Door 1st is selected, only the
PROGRAMMABLE FEATURES driver door unlocks when the Unlock button of the
• LANGUAGE? - The options include English, Remote Keyless Entry (RKE) transmitter is
Francaise, Deutsch, Italiana, or Espanol. The default depressed once. The Unlock button of the RKE trans-
is English. All EVIC display nomenclature, including mitter must be depressed twice to unlock all doors.
the trip computer functions, warning messages and When All Doors is selected, all doors unlock when the
the programmable features appear in the selected Unlock button of the RKE transmitter is depressed
language. once.
• DISPLAY U.S. OR METRIC? - The options • REMOTE LINKED TO MEMORY? - This pro-
include U.S. and M. The default is U.S. This feature grammable feature only applies to vehicles equipped
toggles the trip computer temperature, fuel economy with the optional memory / heated system. The
and odometer display readings between U.S. and options include Yes and No. The default is No. When
metric units of measure. It also changes the odome- Yes is selected, the memory system will recall the
ter display in the instrument cluster. Driver 1 or Driver 2 memory settings assigned to the
• SERVICE INTV. = - The options include from RKE transmitter being used to unlock the vehicle.
1000 to 12000 kilometers in 1000 kilometer incre- When No is selected, the memory system will only
ments (2000 to 7500 miles in 500 mile increments).
recall memory settings when the Driver 1 or Driver 2 (2) Remove overhead console. Refer to Overhead
push buttons of the memory switch on the driver side Console Removal and Installation in this section(Re-
front door trim panel are depressed. fer to 8 - ELECTRICAL/OVERHEAD CONSOLE -
• SOUND HORN ON LOCK? - The options REMOVAL) .
include Yes and No. The default is No. When Yes is (3) Remove the ten screws holding the EVIC mod-
selected, a short horn chirp will provide an audible ule in the overhead console.
confirmation when the RKE receiver recognizes a (4) Remove EVIC module from console assembly.
valid Lock signal from an RKE transmitter. When No
is selected, no horn chirp will occur with the RKE INSTALLATION
Lock event. This feature may be selected indepen- (1) Position the EVIC module in the overhead con-
dent of the FLASH LIGHTS WITH LOCKS? pro- sole.
grammable feature. (2) Install the ten screws holding the EVIC module
• FLASH LIGHTS WITH LOCKS? - The options in the overhead console.
include Yes and No. The default is Yes. When Yes is (3) Install the overhead console. Refer to Overhead
selected, a single flash of the hazard warning lamps Console Removal and Installation in this section.
will provide an optical confirmation when the RKE (4) Connect the battery negative cable.
receiver recognizes a valid Lock signal from an RKE
transmitter, and two flashes of the same lamps will NOTE: If a new EVIC module has been installed, the
occur when the RKE receiver recognizes a valid compass will have to be calibrated and the variance
Unlock signal from an RKE transmitter. When No is set. Refer to Compass Variation Adjustment and
selected, no lamp flash will occur with the RKE Lock Compass Calibration in the Service Procedures sec-
or Unlock event. This feature may be selected inde- tion of this group for the procedures.
pendent of the SOUND HORN ON LOCK? pro-
grammable feature.
• HEADLAMP DELAY = - The options include
Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec.
COMPASS/MINI-TRIP
When a time interval is selected, the headlamps will COMPUTER
remain on for that length of time when the head-
lamps are turned off after the ignition is turned off, DESCRIPTION
or if the Auto mode is selected on vehicles with the The Compass Mini-Trip Computer (CMTC) and
Auto Headlamps option. When Off is selected, the Compass Temperature (CT) computer are modules
headlamp delay feature is disabled. located in the overhead console. Vehicles are
• HEADLAMPS ON WITH WIPERS? - This pro- equipped with either the CMTC or the CT computers
grammable feature only applies to vehicles equipped not both. The CMTC is different in the fact that it is
with the optional Auto Headlamps. The options equipped with the mini-trip feature. The CMTC, CT
include Yes and No. The default is No. When Yes is consists of a electronic control module with a vacuum
selected, the headlamps will turn on automatically fluorescent display (VFD) and function switches. The
when the windshield wipers are turned on. The head- CMTC, CT consists of a electronic module that dis-
lamps will turn off when the wipers are turned off, plays compass, trip computer (CMTC only), and tem-
as long as the headlamp switch is in the Auto or Off perature features. Actuating the STEP push button
positions. When No is selected, the headlamps will (CMTC only) will cause the CMTC to change mode of
only turn on if manually selected or if the Auto mode operation when ignition is ON. Actuating the STEP
is selected and the outside ambient light levels dic- push button (CMTC only) will cause the CMTC to
tate that they should be on. change mode of operation when ignition is ON.
• POWER ACCESSORY DELAY? - The options Example:
include Yes and No. The default is Yes. When No is • Average miles per gallon (ECO)
selected, the accessory powered components will turn • Distance to empty (DTE)
off automatically when the ignition key is turned off. • Instant miles per gallon (ECO)
When Yes is selected, the accessory powered compo- • Trip odometer (ODO)
nents will remain on for 45 seconds when the igni- • Elapsed time (ET)
tion key is turned off. • Off
Actuating the C/T push button will cause the
REMOVAL CMTC, CT to change to Compass/Temperature dis-
(1) Disconnect and isolate the battery negative play.
cable.
COMPASS/MINI-TRIP COMPUTER (Continued)
OPERATION UNIVERSAL TRANSMITTER

The Compass Mini-Trip Computer (CMTC), Com-
pass Temperature (CT) module in the overhead con- DESCRIPTION
sole has buttons used to select various functions. The On some RS models a Homelinkt transceiver is
CMTC, CT selector buttons will not operate until the standard factory-installed equipment. The Homelinkt
ignition is in the RUN position. transceiver is integral to the Electronic Vehicle Infor-
When the ignition switch is first turned to the mation Center (EVIC) and the Compass Mini-Trip
RUN position the CMTC, CT display; Computer (CMTC), which is located in the overhead
• Blanks momentarily console. The only visible component of the Homelinkt
• All segments of the VFD will light for one second are the three transmitter push buttons centered
• Blanks momentarily between the modules push buttons located just rear-
• Returns to the last mode setting selected before ward of the display screen in the overhead console.
the ignition was last switched OFF. The three Homelinkt transmitter push buttons are
identified with one, two or three light indicators so
DIAGNOSIS & TESTING - COMPASS MINI-TRIP that they be easily identified by sight or by feel.
COMPUTER Each of the three Homelinkt transmitter push but-
Compass Mini-Trip Computer (CMTC) and Com- tons controls an independent radio transmitter chan-
pass Temperature (CT) data is obtained from the nel. Each of these three channels can be trained to
Body Control Module (BCM) on the J1850 Data Bus transmit a different radio frequency signal for the
circuit. The CMTC and CT will display dashes (- -) remote operation of garage door openers, motorized
for any of the screens it did not receive the bus mes- gate openers, home or office lighting, security sys-
sages. The label corresponding to the missing infor- tems or just about any other device that can be
mation will be lit. If no compass mini-trip computer equipped with a radio receiver in the 286 to 399
data is displayed, check the J1850 Data Bus circuit MegaHertz (MHz) frequency range for remote opera-
communications and the BCM. If the brightness level tion. The Homelinkt is capable of operating systems
is improper check the J1850 Data Bus circuit. using either rolling code or non-rolling code technol-
The DRB IIIt is recommended for checking the ogy.
J1850 Data Bus circuit and the BCM. Perform the The electronics module displays messages and a
CMTC, CT self diagnosis before replacing the CMTC small house-shaped icon with one, two or three dots
or CT module. corresponding to the three transmitter buttons to
indicate the status of the Homelinkt. The EVIC mes-
REMOVAL sages are:
(1) Disconnect and isolate the battery negative • Cleared Channels - Indicates that all of the
cable. transmitter codes stored in the Homelinkt have been
(2) Remove overhead console. Refer to Overhead successfully cleared.
Console Removal and Installation in this section(Re- • Training - Indicates that the Homelinkt is in
fer to 8 - ELECTRICAL/OVERHEAD CONSOLE - its transmitter learning mode.
REMOVAL) . • Trained - Indicates that the Homelinkt has
(3) Remove the screws holding Compass Mini-Trip successfully acquired a new transmitter code.
Computer module in the overhead console. • Transmit - Indicates that a trained Homelinkt
(4) Remove CMTC module from console assembly. transmitter button has been depressed and that the
Homelinkt is transmitting.
INSTALLATION The Homelinkt cannot be repaired, and is avail-
(1) Position the compass mini-trip computer mod- able for service only as a unit with the EVIC or
ule in the overhead console. CMTC modules. If any of these components is faulty
(2) Install the ten screws holding the compass or damaged, the complete EVIC or CMTC module
mini-trip computer module in the overhead console. must be replaced.
(3) Install the overhead console. Refer to Overhead
Console Removal and Installation in this section. OPERATION
(4) Connect the battery negative cable. The Homelinkt operates on a non-switched source
of battery current so the unit will remain functional,
NOTE: If a new module has been installed, the com- regardless of the ignition switch position. For more
pass will have to be calibrated and the variance set. information on the features, programming procedures
Refer to Compass Variation Adjustment and Com- and operation of the Homelinkt, see the owner’s
pass Calibration in the Service Procedures section manual in the vehicle glove box.
of this group for the procedures.
UNIVERSAL TRANSMITTER (Continued)
DIAGNOSIS & TESTING - HOMELINKT temperature sensor circuit fails, the Front Control
If the Homelinkt is inoperative, but the Electronic Module will self-diagnose the circuit.
Vehicle Information Center (EVIC) or Compass Mini- The ambient temperature sensor circuit can also be
Trip Computer is operating normally, see the owner’s diagnosed by referring to Diagnosis and Testing -
manual in the vehicle glove box for instructions on Ambient Temperature Sensor, and Diagnosis
training the Homelinkt. Retrain the Homelinkt with and Testing - Ambient Temperature Sensor Cir-
a known good transmitter as instructed in the own- cuit. If the temperature sensor and circuit are con-
er’s manual and test the Homelinkt operation again. firmed to be OK, but the temperature display is
If the unit is still inoperative, replace the faulty inoperative or incorrect, refer to Diagnosis and
Homelinkt and EVIC/CMTC module as a unit. If Testing - Overhead Console in this group. For
both the Homelinkt and the EVIC/CMTC module are complete circuit diagrams, refer to the appropriate
inoperative, refer to Overhead Console Diagnosis wiring information.
and Testing earlier in this group for further diagno-
sis. For complete circuit diagrams, refer to Over- DIAGNOSIS AND TESTING - AMBIENT
head Console in Wiring Diagrams. TEMPERATURE SENSOR
(1) Turn the ignition switch to the Off position.
AMBIENT TEMP SENSOR Disconnect the ambient temperature sensor wire har-
ness connector.
DESCRIPTION (2) Measure the resistance of the ambient temper-
Ambient air temperature is monitored by the over- ature sensor. At –40° C (–40° F), the sensor resis-
head console through ambient temperature messages tance is 336 kilohms. At 55° C (140° F), the sensor
received from the Front Control Module (FCM) over resistance is 2.488 kilohms. The sensor resistance
the Programmable Communications Interface (PCI) should read between these two values. If OK, refer to
J1850 data bus circuit. The FCM receives a hard Diagnosis and Testing - Ambient Temperature
wired input from the ambient temperature sensor. Sensor Circuit in this group. If not OK, replace the
The ambient temperature sensor is a variable resis- faulty ambient temperature sensor.
tor mounted to a bracket that is secured with a screw
to the right side of the headlamp mounting module DIAGNOSIS AND TESTING - AMBIENT
grille opening, behind the radiator grille and in front TEMPERATURE SENSOR CIRCUIT
of the engine compartment. (1) Turn the ignition switch to the Off position.
Refer to Front Control Module in Electronic Disconnect and isolate the battery negative cable.
Control Modules. For complete circuit diagrams, refer Disconnect the ambient temperature sensor wire har-
to the appropriate wiring information. The ambient ness connector and the Front Control Module wire
temperature sensor cannot be adjusted or repaired harness connector.
and, if faulty or damaged, it must be replaced. (2) Connect a jumper wire between the two termi-
nals in the body half of the ambient temperature sen-
OPERATION sor wire harness connector.
The ambient temperature sensor is a variable (3) Check for continuity between the sensor return
resistor that operates on a five-volt reference signal circuit and the ambient temperature sensor signal
sent to it by the Front Control Module. The resis- circuit cavities of the Front Control Module wire har-
tance in the sensor changes as temperature changes, ness connector. There should be continuity. If OK, go
changing the temperature sensor signal circuit volt- to Step 4. If not OK, repair the open sensor return
age to the Front Control Module. Based upon the circuit or ambient temperature sensor signal circuit
resistance in the sensor, the Front Control Module to the ambient temperature sensor as required.
senses a specific voltage on the temperature sensor (4) Remove the jumper wire from the body half of
signal circuit, which it is programmed to correspond the ambient temperature sensor wire harness con-
to a specific temperature. The Front Control Module nector. Check for continuity between the sensor
then sends the proper ambient temperature mes- return circuit cavity of the Front Control Module
sages to the EVIC, CMTC over the PCI J1850 data wire harness connector and a good ground. There
bus. should be no continuity. If OK, go to Step 5. If not
The thermometer function is supported by the OK, repair the shorted sensor return circuit as
ambient temperature sensor, a wiring circuit, the required.
Front Control Module, the Programmable Communi- (5) Check for continuity between the ambient tem-
cations Interface (PCI) data bus, and a portion of the perature sensor signal circuit cavity of the Front
Electronics module. If any portion of the ambient Control Module wire harness connector and a good
AMBIENT TEMP SENSOR (Continued)
ground. There should be no continuity. If OK, refer to (3) From behind front bumper fascia, remove
Diagnosis and Testing - Overhead Console in screw holding sensor to radiator closure panel.
this group. If not OK, repair the shorted ambient (4) Remove sensor from vehicle.
temperature sensor signal circuit as required.
INSTALLATION
REMOVAL (1) Position the sensor in the vehicle.
(1) Disconnect and isolate the battery negative (2) From behind the front bumper fascia, install
cable. the screw holding sensor to radiator closure panel.
(2) Raise and support vehicle on safety stands. (3) Connect the battery negative cable.
RS POWER SYSTEMS 8N - 1
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . 1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 45

POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . 19 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 60
POWER LIFTGATE SYSTEM
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM TRANSVERSE BRACKET

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - POWER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 4 LIFT GEAR & LINK ROD
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFTGATE ADJUSTMENT . . . . . . . . . . . . . . . . . . 9 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER LIFTGATE LEARN CYCLE . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PINCH SENSOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LATCH
FULL OPEN SWITCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LATCH ACTUATOR
LIFTGATE MOTOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 EXTERIOR HANDLE SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGAGE ACTUATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CHIME/THERMISTOR
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8N - 2 POWER LIFTGATE SYSTEM RS
POWER LIFTGATE SYSTEM

DESCRIPTION
Fig. 1 POWER LIFTGATE INTRODUCTION
Some vehicles are equipped with an automatic and ratchet switches are part of the latch assembly.
opening and closing power liftgate system (Fig. 1). The pinch sensor or sensors are located along the
This power liftgate system is a complex system con- right and left sides of the power liftgate, just above
sisting of many components. Some of these compo- the body line. The liftgate handle switch is an power
nents are the liftgate gear motor assembly, latch release switch and is located in the rear light bar
assembly, lift gear and rod, liftgate control module, assembly, just above the license plate. The overhead
chime/thermistor, full open switch, engage actuator, console switch is an power open and close command
pinch sensor, liftgate handle switch, overhead console switch located in the vehicles overhead console.
switch, key fob switches (Fig. 2), pawl switch and Safety is of the utmost concern with the power lift-
ratchet switch. gate system. Software technology has enabled the
The power liftgate system has its own door control power liftgate control module to detect resistance to
module, located on the vehicles left body D-pillar liftgate travel, which allows the power liftgate to stop
behind the trim panel. (Refer to 8 - ELECTRICAL/ and reverse direction anytime an obstruction is felt
ELECTRONIC CONTROL MODULES/DOOR CON- or any of the command switches are operated (only in
TROL MODULE - DESCRIPTION) The power closing direction). Battery voltage is supplied to the
liftgate gear motor assembly is located just above the power liftgate system through a 40 amp fuse, located
control module. The latch assembly is located in the in the Intelligent Power Module (IPM) assembly (Fig.
bottom center of the power liftgate, below the exte- 3). In the unlikely event that the power liftgate sys-
rior liftgate handle switch. The power liftgate full tem develops a fault the power liftgate can still be
open switch, engage actuator, lift gear and rod are operated manually with a key, just like a standard
part of the liftgate gear motor assembly. The pawl manual liftgate.
RS POWER LIFTGATE SYSTEM 8N - 3
POWER LIFTGATE SYSTEM (Continued)
the power liftgate control module via the PCI bus cir-
cuit. A diagnostic scan tool, such as the DRB IIIt is
used to read and troubleshoot these Diagnostic Trou-
ble Codes (DTC). Refer to the Body Diagnostic Man-
ual for a complete list of diagnostic routines.
For additional information refer to Power Liftgate
Operation. For a complete system wiring schematic
refer to Wiring Diagrams. For system operation
instructions refer to the vehicles owner manual.
Refer to the Body section of the service manual
for additional information on liftgate components
such as the prop rods, hinges, door alignment and
striker alignment.
WARNING: BE CERTAIN TO READ ALL WARNINGS

AND CAUTIONS (NOTED BELOW) IN POWER LIFT-
GATE SYSTEM OPERATION BEFORE ATTEMPTING
ANY SERVICE OF THE POWER LIFTGATE SYSTEM
OR COMPONENTS.
OPERATION
Fig. 2 KEY FOB With the push of a power liftgate open/close com-
mand switch (key fob or overhead console mounted) a
1 - LEFT SLIDING DOOR SWITCH
2 - RIGHT SLIDING DOOR SWITCH
signal is sent out on the J1850 PCI Data Bus circuit.
3 - LIFTGATE SWITCH This signal is detected at the body control module
(BCM). The BCM then sends a signal out on the
J1850 PCI Data Bus circuit to the power liftgate
module. The power liftgate module then signals the
power liftgate motor to start an open or close cycle,
depending on what position the liftgate is in open or
closed.
During a liftgate open or close cycle, if the power
liftgate module detects sufficient resistance to liftgate
travel, such as an obstruction in the liftgates path,
the power liftgate control module will immediately
stop the liftgate movement and reverse travel to the
full open or closed position. The ability for the power
liftgate module to detect resistance to liftgate travel
is accomplished by hall effect sensors, drive motor
speed and pinch sensors (tape switches).
The power liftgate control module has the ability to
learn. Anytime the liftgate is opened or closed using
the power liftgate system the module learns from its
cycle. If a replacement power liftgate component is
installed or a liftgate adjustment is made, the mod-
ule will relearn the effort and/or time required to
open or close the door. This learn cycle can be per-
formed with a Diagnostic Scan Tool, such as the DRB
IIIt or with a complete cycle of the liftgate, using
Fig. 3 LIFTGATE FUSE LOCATION any one of the command switches. Refer to Standard
The power liftgate control module communicates Procedures in this section for detailed instructions.
on the J1850 Programmable Communication Inter- The power liftgate system is designed with a num-
face (PCI) Bus Circuit. Therefore, the power liftgate ber of system inhibitors. These inhibitors are neces-
control module can generate and store its own Diag- sary for safety and / or feasibility of the power
nostic Trouble Codes (DTC). The vehicles Body Con- liftgate system. Refer to power liftgate system inhib-
trol Module (BCM) receives and supplies messages to itors noted below:
POWER LIFTGATE SYSTEM INHIBITORS DAMAGE THE VEHICLE, POWER LIFTGATE SYS-
• The Power Liftgate may not operate in extreme TEM COMPONENTS AND/OR CAUSE PERSONAL
temperatures. These extreme temperatures will be INJURY.
approximately -12° F (-24.4° C) on the low side and
143° F (61.6° C) for the high side. A chime/thermister
assembly in the rear light bar assembly monitors the DIAGNOSIS AND TESTING - POWER LIFTGATE
outside temperature. SYSTEM
• The vehicles transmission must be in park or The power opening and closing power liftgate sys-
neutral for the power liftgate to start a cycle. tem is a complex system containing many compo-
• If multiple obstacles are detected during the nents and modules. In order to obtain conclusive
same power open or close cycle the liftgate goes into testing the Programmable Communications Interface
manual operation. (J1850) data bus network and all of the electronic
• If severe Diagnostic Trouble Codes (DTC) are modules that provide inputs to, or receive outputs
stored in the power liftgate control module. from the power liftgate system must be checked.
The power liftgate system was designed to be diag-
POWER LIFTGATE SYSTEM CAUTIONS AND nosed with an appropriate diagnostic scan tool, such
WARNINGS as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the power liftgate system
WARNING: ALWAYS DISCONNECT THE NEGATIVE requires the use of a DRB IIIt scan tool and the
BATTERY CABLE BEFORE ATTEMPTING ANY proper Body Diagnostic Procedures manual. The
POWER LIFTGATE SYSTEM SERVICE. DRB IIIt can be used to observe various switch sta-
tuses throughout the power liftgate system to help
the technician diagnose a defective switch or compo-
WARNING: THERE IS A SMALL AREA ON BOTH nent. The DRB IIIt can also be used to actuate var-
SIDES OF THE LOWER POWER LIFTGATE WHICH ious components throughout the power liftgate
ARE NOT PROTECTED BY PINCH SENSORS. system to help the technician diagnose a defective
EXTREME CARE MUST BE TAKEN TO PREVENT component.
OBJECTS FROM ENTERING THIS AREA ONCE THE Before any testing of the power liftgate system is
LIFTGATE REACHES THE SECONDARY LATCH attempted, the battery should be fully charged, all
CONTACT (APPROXIMATELY 1/2 INCH BEFORE built-in power liftgate system inhibitors read and
FULLY CLOSED). understood (Refer to power liftgate system operation)
and all wire harness and ground connections
WARNING: NEVER ATTEMPT TO ENTER OR EXIT inspected around the affected areas on the vehicle.
THE VEHICLE WITH THE LIFTGATE IN MOTION. Following are quick reference diagnostic tables to
YOU COULD DAMAGE THE POWER LIFTGATE SYS- help when diagnosing and testing the power liftgate
TEM AND/OR COMPONENTS AND/OR CAUSE PER- system.
SONAL INJURY.
WARNING: NEVER STICK OBJECTS IN THE POWER

LIFTGATE WHEN CINCHING CLOSED. YOU COULD
LIFTGATE SYSTEM DIAGNOSIS

Liftgate opens unexpectedly Failure of Power Liftgate or Body Disconnect then reconnect battery to reset
Control module module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Failure of latch assembly Check wiring connections and for blown
fuse
Check for trouble codes, replace latch if
necessary
Failure of open/close command Check for shorted or defective switch
switch
Liftgate will not open from Failure of key cylinder assembly Check for broken key cylinder assembly
outside of vehicle manually
Check link rod connections at the latch and

key cylinder assembly
Check for binds or kinks in link rod

Check for foreign matter preventing the
operation of key cylinder assembly
Replace the necessary components
Failure of latch assembly Check wire connections and for blown fuse

operation of latch assembly
Replace latch assembly, if necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace necessary components

Liftgate will not open/close Failure of Power Liftgate or Body Disconnect then reconnect battery to reset
under power Control Module module, function liftgate, if no function
procedures

Troubleshoot using Body Diagnostic
Manual Replace latch assembly, if
necessary
Failure of motor assembly Troubleshoot using Body Diagnostic
Manual
Failure of full open switch Troubleshoot using Body Diagnostic
Manual

Binding or sticking of components Establish location of binding and replace
necessary components
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Power loss during Liftgate Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
operation Refer to wiring diagrams
Low battery voltage Charge battery
Failure of Power Liftgate or Body Disconnect then reconnect battery to reset
Control Module module, function liftgate, if no function
procedures
Failure of motor assembly Check for no drive condition
No power latching in Failure of latch assembly Check wire connections and for blown fuse
primary and/or secondary
positions

Manual. Replace latch assembly, if
necessary
procedures
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter or other possible obstruction
Failure of motor assembly Check for no drive condition
Latch will not fully release Failure of latch assembly Check wire connections and for blown fuse
from primary position
Check for foreign matter or damaged

components preventing the operation of
latch assembly
Troubleshoot using body electrical
troubleshooting manual Replace latch
assembly, if necessary
Failure of outside handle switch Troubleshoot using Body Diagnostic
Manual Replace switch, if necessary
procedures

Key fob, Outside Handle or Blown Fuse Check fuse and replace
overhead console switches
do not power operate
liftgate
Battery voltage low Charge or replace battery in key fob or
vehicle
Failure of latch assembly Check for foreign matter preventing the
Check wire connection

Pawl and/or ratchet switch inoperative
Replace latch if necessary
Failure of Body Control Module Check electrical connections
(BCM)
Refer to the Body electrical troubleshooting

guide for additional checks
Replace BCM if necessary
Failure of key fob Reprogram key fob
Replace key fob if necessary

Failure of Power Liftgate Module Disconnect then reconnect battery to reset
module, function liftgate, if no function
procedures
Failure of liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections

Motor clutch does not engage, replace
assembly
Full open switch inoperative, replace
switch, if necessary
Manual Replace motor, if necessary
Liftgate does not stay open Failure of liftgate prop rods Replace prop rods, if necessary
Check for broken attachments

High inside/outside opening Failure of liftgate prop rods Replace prop rods, if necessary
effort
Check for broken attachments

Gear motor did not disengage Troubleshoot using Body Diagnostic
Manual Replace components, if necessary

Liftgate continues to cinch Failure of latch assembly Check wire connections and for blown fuse
closed during power mode

Manual Replace components, if necessary
procedures
Liftgate continues to open Failure of Power Liftgate or Body Disconnect then reconnect battery to reset
during power mode Control Module module, function liftgate, if no function
(runaway motor) exists check for loose wire connections,
procedures
Failure of full open switch Check wire connections
Replace switch, if necessary

Failure of motor assembly Check for continuous drive condition
Liftgate opens very slowly Failure of liftgate motor assembly Check wire connections
Replace motor assembly, if necessary

Failure of liftgate prop rods Replace prop rods, if necessary
Grade of vehicle too steep for power Operate liftgate manually
operation
Squeaks, Noises and rattles Foreign material in door Remove foreign material
compartment
Loose components Check and tighten loose components
STANDARD PROCEDURE - LIFTGATE PINCH SENSOR

ADJUSTMENT
In order for the power liftgate system to function DESCRIPTION
properly the liftgate must move freely and smoothly.
The power liftgate system can acommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanicaly adjusted for proper fit and
finish. Refer to the Liftgate Adjustment procedure in
the Body section of the service manual for detailed
instructions.
If a problem exists with the power liftgate and it is
suspected to be extreme effort check the liftgate prop
rods and hinges for free movement. Use a known
good vehicle for liftgate effort comparison.
NOTE: Routine application of Mopar MP-50T or

equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
STANDARD PROCEDURE - POWER LIFTGATE

LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn Fig. 4 PINCH SENSOR LOCATION
cycle must be performed. This learn cycle enables the
1 - LIFTGATE
power liftgate control module to learn or relearn
2 - PINCH SENSOR ASSEMBLY
information (travel limits, resistance to door travel, 3 - POWER LIFTGATE LINK ROD
etc.) which allows it to perform properly and safely. 4 - PINCH SENSOR WIRE HARNESS CONNECTOR
To perform a learn cycle do the following: 5 - PINCH SENSOR WIRE HARNESS
(1) Obtain a DRB IIIt scan tool.
(2) Connect the DRB IIIt to the vehicle and check
Vehicles equipped with a power liftgate utilize two
for any power liftgate system stored trouble codes,
pinch sensors, one is located on each side of the lift-
correct and erase any stored codes.
gate (Fig. 4). These sensors look like weather-strips,
(3) Using the DRB IIIt, Go into Test Routine
however they consist of pieces of electrically conduc-
Menu and select the power open command.
tive rubber (tapeswitch), wires, resistor, double sided
(4) Select the power close command.
tape, and a plastic carrier. They are used to indicate
(5) The liftgate learn cycle is complete.
an obstruction during a power close cycle.
If a DRB IIIt scan tool is not available the learn
cycle can be performed by actuating the liftgate by
using any of the normal command switches. Be cer-
OPERATION
tain to cycle the liftgate through a complete open and During a power liftgate close cycle, if either of the
close cycle before returning the vehicle to service. two conductive rubber strips (tapeswitch) of the
pinch sensor come in contact with an obstacle, the
NOTE: If the power liftgate will not complete a full pinch sensor circuit is completed. This tells the
cycle a problem exists with the power liftgate sys- power liftgate control module that a obstruction is
tem. (Refer to 8 - ELECTRICAL/POWER DOORS - felt. The control module will stop the liftgate imme-
DIAGNOSIS AND TESTING) . diately and return it to the full open position.
REMOVAL
cable.
(2) Remove trim panel from liftgate. Refer to Body
for the procedure.
PINCH SENSOR (Continued)
(3) Disconnect the pinch sensor wire harness con-
nector (Fig. 4).
(4) Remove screws holding the pinch sensor to lift-
gate.
(5) Feed the pinch sensor wire harness out of the
liftgate and remove the sensor from the vehicle.
INSTALLATION
(1) Position the pinch sensor and install screws
holding the sensor to the liftgate. Torque screws to
25 in. lbs.
(2) Install wire harness grommet in liftgate flange
and route, connect the pinch sensor wire harness
connector.
(3) Install the trim panel on the liftgate. Refer to
(5) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes related to the pinch sensor.
(6) Verify power liftgate system and pinch sensor
operation. Cycle the power liftgate through one com-
plete open and close cycle, during the final close cycle Fig. 5 FULL OPEN SWITCH LOCATION
press the pinch sensor to verify the power liftgate 1 - FULL OPEN SWITCH
detects an obstruction and returns to the full open 2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
position.
WARNING: USE EXTREME CAUTION WHEN TEST- REMOVAL

ING PINCH SENSOR OPERATION. (1) Disconnect and isolate the negative battery
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
FULL OPEN SWITCH DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
DESCRIPTION switch or back the wires out of the electrical connec-
Vehicles equipped with a power liftgate utilize a tor (Fig. 5). Refer to the Wiring section of the service
full open switch. This switch is located on the gear manual for detailed instructions.
motor housing (Fig. 5) and is used to signal the (4) Remove the full open switch retaining screw
power liftgate module when the liftgate is in the full and remove the full open switch from the gear motor
open position. Two wires are used from the full open housing assembly.
switch contacts to the gear motor assemblies main
electrical connector. INSTALLATION
The full open switch is a serviceable component. (1) Perform a wiring repair on the full open switch
Consult your Mopar parts catalog for a specific part wires following the approved procedure in the Wiring
number. section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
OPERATION gate motor electrical connector.
When the power liftgate reaches the full open posi- (2) Position and install the full open switch retain-
tion, the gear motor housing mounted full open ing screw.
switch electrical contacts come in contact with each (3) Install the power liftgate lift gear and link rod
other. This sends a ground signal to the power lift- assembly. (Refer to 8 - ELECTRICAL/POWER
gate control module, telling the module that the lift- DOORS/CONTROL ROD - INSTALLATION)
gate has reached the full open position. (4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
FULL OPEN SWITCH (Continued)
(6) Verify power liftgate system and full open Serviceable components of the power liftgate gear
switch operation. Cycle the power liftgate through motor assembly are the complete gear motor assem-
one complete open and close cycle, this will allow the bly, motor and wire harness, lift gear and control rod,
power liftgate control module to relearn its cycle with engage actuator, full open switch and the transverse
the new components. bracket. Refer to additional information in this group
for more component details.
LIFTGATE MOTOR OPERATION

With the push of a power liftgate command switch
DESCRIPTION (liftgate closed), the power liftgate control module
will signal the latch assembly to release the door
from its primary closed and latched position to the
released and movable position. The liftgate motor
mounted, engage actuator then engages the liftgate
motor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate motor can be serviced in two
different ways. The first of which is called out here,
the complete gear motor assembly. The second way
includes the motor, aluminum housing, drive gears
and wire harness assembly. To perform this service
procedure, use the following procedure to remove the
gear motor assembly from the vehicle. Then refer to
the other procedures called out this section to trans-
fer the remaining components (engage actuator, full
open switch, transverse bracket and lift gear and
rod) to the replacement motor assembly.
Fig. 6 POWER LIFTGATE COMPONENTS (1) Disconnect and isolate the negative battery
1 - POWER LIFTGATE GEAR MOTOR ASSEMBLY
cable.
2 - POWER LIFTGATE CONTROL MODULE (2) Remove the left rear D-pillar trim panel from
3 - ELECTRICAL GROUND LOCATION the vehicle. Refer to the Body section for the proce-
dure.
(3) Disconnect the wire harness connector from the
Vehicles equipped with a power liftgate, utilize a
motor assembly (Fig. 6).
liftgate gear motor assembly (Fig. 6). The gear motor
(4) Remove the two bolts from the motor housing
assembly consists of a DC motor, hall effect sensor,
and the one bolt from the transverse mount bracket.
engage actuator, full open switch, lift gear, aluminum
(5) Grab the liftgate motor assembly and lift
housing, drive gears and wire harness. The gears and
upward and out to unhook the motor assembly from
motor portion of the assembly provides the power
the D-pillar.
and torque required to open or close the liftgate
(6) Remove the liftgate motor assembly from the
under the worst case conditions. The hall effect sen-
vehicle.
sor is used to provide the liftgate control module with
a speed reading, which is used to monitor the resis-
tance of liftgate travel. This speed reading also
INSTALLATION
(1) Using the motor housing tab, hook the liftgate
allows the power liftgate control module to detect
motor assembly on the D-pillar.
obstructions and move the liftgate accordingly. The
(2) Install the three motor assembly retaining
engage actuator is used to toggle between power
bolts. Torque the two rear most bolts first to 9.5 N·m
open/close mode and full manual mode when desired.
(85 in. lbs.). Torque the remaining bolt next to the
The full open switch is used to let the power liftgate
window actuator to 9.5 N·m (85 in. lbs.).
control module know when the liftgate is approach-
(3) Connect the liftgate motor assembly electrical
ing the full open position.
connector.
LIFTGATE MOTOR (Continued)
(4) Install the D-pillar trim panel on the vehicle. power liftgate control module signals the engage
Refer to Body for the procedure. actuator to move its lever to the engaged position.
(5) Connect the negative battery cable. This engages the gear motor to the lift gear, so when
(6) Using an appropriate scan tool, check any the motor turns the lift gate moves upward or down-
erase any power liftgate control module diagnostic wards depending on its current position.
trouble codes related to the door motor assembly. During a manual liftgate open or close cycle the
(7) Verify power liftgate system operation. Cycle engage actuator is disengaged, allowing unrestricted
the power liftgate through one complete open and liftgate movement.
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components. REMOVAL
cable.
ENGAGE ACTUATOR (2) Remove the left rear D-pillar trim from the
vehicle. Refer to Body for the procedure.
DESCRIPTION (3) Using your hand manually engage the actuator
link rod, this must be done to access one of the
engage actuator retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 8).
Fig. 7 LIFTGATE GEAR MOTOR ASSEMBLY

1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR Fig. 8 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
Vehicles equipped with a power liftgate utilize a 2 - LIFT GEAR RETAINING BOLTS
power liftgate engage actuator (Fig. 7). The 12 volt
engage actuator provides the engagement and disen- (5) Disconnect the engage actuator electrical con-
gagement of the liftgate gear motor to the lift gear by nector and remove the engage actuator from the
way of an over center link, activated by a lever. vehicle.
The engage actuator is a serviceable component
and cannot be repaired, if found to be faulty it must INSTALLATION
be replaced. (1) Position the engage actuator and connect the
engage actuator electrical connector.
OPERATION (2) Install the two engage actuator retaining
The engage actuators normal position is disen- screws.
gaged. When a power liftgate open or close command (3) Manually disengage the actuator.
is generated from any of the command switches, the
ENGAGE ACTUATOR (Continued)
(4) Install the left rear D-pillar trim on the vehi- support and secure the power liftgate gear motor
cle. Refer to Body for the procedure. assembly to the vehicles left rear body D-pillar.
(5) Connect the negative battery cable. The transverse bracket is a serviceable power lift-
(6) Using an appropriate scan tool, check and gate component. Consult your Mopar™ parts catalog
erase any power liftgate control module diagnostic for a specific part number.
trouble codes.
(7) Verify power liftgate system and engage actua- OPERATION
tor operation. Cycle the power liftgate through one The power liftgate transverse bracket supports the
complete open and close cycle. gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
TRANSVERSE BRACKET bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
DESCRIPTION
REMOVAL
cable.
(2) Remove the left D-pillar trim from the vehicle.
Refer to Body for the procedure.
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 10).
(6) Remove the transverse bracket from the vehi-
cle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N·m (85 in. lbs.)..
Fig. 9 LIFTGATE GEAR MOTOR ASSEMBLY Do not tighten the transverse bracket retaining bolt,
1 - TRANSVERSE BRACKET located under the window actuator at this time.
2 - ENGAGE ACTUATOR (3) Torque the gear motor assembly retaining bolts
3 - LIFT GEAR AND ROD ASSEMBLY to 9.5 N·m (85 in. lbs.)..
4 - LIFTGATE MOTOR (4) Torque the final transverse bracket retaining
bolt to 9.5 N·m (85 in. lbs.).
Vehicles equipped with a power liftgate utilize a (5) Connect the gear motor assembly electrical con-
transverse bracket (Fig. 9). This bracket is not differ- nector and engage retaining pushpin.
ent than any other metal bracket which is used to (6) Install the appropriate D-pillar trim from the
LIFT GEAR & LINK ROD OPERATION

One end of the rod assembly is attached to the lift-
DESCRIPTION gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Remove the left rear D-pillar trim from the
(2) Remove the lift gear retaining bolts (Fig. 11).
Fig. 10 LIFTGATE GEAR MOTOR ASSEMBLY

1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Vehicles equipped with a power liftgate utilize a

lift gear and rod assembly. This lift gear and rod Fig. 11 LIFTGATE GEAR MOTOR ASSEMBLY
assembly are located in the left rear of the vehicle 1 - ENGAGE ACTUATOR RETAINING SCREWS
and are visible without removing the D-pillar trim 2 - LIFT GEAR RETAINING BOLTS
(Fig. 10). The lift gear provides the leverage to move
the liftgate from the closed to the open position. The (3) Remove the lift gear and rod from the vehicle.
lift gear attaches to a bearing on the gear motor
assembly with four bolts. On the outboard side of the INSTALLATION
lift gear are rivited on teeth, which mesh with the (1) Position the lift gear assembly and install the
gear motor assembly drive gears during a open or retaining bolts. Torque the bolts to 28 N·m (21 ft.
close operation. The rod assembly is a steel shaft, lbs.).
equipped with two spherical rod ends which attaches (2) Install the left rear D-pillar trim on the vehi-
the lift gear to the liftgate. cle. Refer to Body for the procedure.
The lift gear and rod assembly are serviceable com-
ponents. Consult your Mopar™ parts catalog for a CAUTION: Torque link rod to liftgate attachment
part number. bolt to 250 in. lbs. Care must be taken not to over-
torque link rod bolt.
LATCH OPERATION
On the power cinch/release latch, the latch
DESCRIPTION mounted actuator provides the torque required to
close the power liftgate from the secondary to the pri-
mary closed and latched position. On the power
cinch/release latch and the power release only latch,
the actuator releases the liftgate from the primary
closed and latched position to the fully unlatched and
movable position.
REMOVAL
(1) Open the hood, disconnect and isolate the neg-
ative battery cable.
(2) Open the liftgate and remove the liftgate trim
panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 12).
(4) Remove the power latch retaining bolts.
(5) Disconnect the liftgate lock cylinder link rod
from the key cylinder or latch assembly. To discon-
nect from latch, rotate the plastic retaining clip 90 °
to unsnap clip from linkrod. Then pull link rod
straight out of latch arm.
INSTALLATION
(1) Connect the liftgate lock cylinder link rod on
Fig. 12 POWER LATCH ORIENTATION
the cinch latch assembly. Rotate the plastic retaining
1 - LATCH & ACTUATOR ASSEMBLY
clip 90 ° to lock retaining clip on linkrod.
2 - LATCH ELECTRICAL CONNECTOR
(2) Connect the link rod on the lock cylinder.
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
(3) Install the power latch retaining bolts. Torque
to 10 N·m (90 in. lbs.).
(4) Connect the power latch electrical connector
Vehicles equipped with a power liftgate, utilize a and secure push pin retainers.
power cinch/release latch. This latch performs the (5) Connect the negative battery cable.
same features as a manual liftgate latch as well as (6) Using an appropriate scan tool, check and
the power cinch and / or release capability. A second erase any power liftgate control module diagnostic
type of power latch can also be found on some RS trouble codes related to the power latch.
models, this latch is designed to perform a power (7) Verify power liftgate system and power cinch /
release only. The power cinch and release capability release latch operation. Cycle the power liftgate
is accomplished by an actuator mounted to the lead- through one complete open and close cycle, this will
ing edge of the latch assembly. The latch is located in allow the power liftgate control module to relearn its
the lower center of the liftgate assembly (Fig. 12) and cycle with the new components.
contains integral pawl and ratchet switches. The (8) Verify power liftgate manual operation. Using
ratchet switch acts as a liftgate ajar switch. liftgate key rotate the lock cylinder to verify door
The power latch assembly can be serviced as a operation. Pull door open using exterior liftgate han-
complete assembly, latch without actuator or just the dle / switch.
actuator. Consult your Mopar parts catalog for spe- (9) Install the liftgate trim panel. Refer to Body for
cific part numbers. the procedure.
LATCH ACTUATOR REMOVAL

DESCRIPTION cable.
(2) Open the liftgate and remove the lower liftgate
trim panel. Refer to Body for the procedure.
(3) Disconnect the power latch electrical connector
(Fig. 13).
(4) Remove the three latch retaining bolts.
(5) Grab the latch assembly and unhook the key
cylinder link rod from the key cylinder (Fig. 13).
(6) Place the latch assembly on a bench and locate
the three wires leading from the actuator portion of
the latch assembly.
(7) Disengage the main connector retaining push
pins from the latch actuator housing.
(8) Back the three wires out of the main latch elec-
trical connector. Refer to the wiring section of the
service manual for detailed instructions.
(9) Flip the latch assembly over and remove the
latch actuator retaining screw(s).
(10) Remove the latch actuator from the latch
assembly.
INSTALLATION
(1) Install the latch actuator on the latch assem-
bly.
Fig. 13 POWER LATCH ORIENTATION
(2) Install the three latch actuator retaining
1 - LATCH & ACTUATOR ASSEMBLY screws. Torque the screws to 4 in. lbs.
2 - LATCH ELECTRICAL CONNECTOR
(3) Install the three wires in the main latch elec-
3 - LOCK CYLINDER LINK ROD
trical connector. Refer to the wiring section of the
4 - LIFTGATE LOCK CYLINDER
service manual for detailed instructions.
Vehicles equipped with a power liftgate utilize a NOTE: Be certain wires are reinstalled in the correct
power cinch latch or power release latch (Fig. 13). wire cavities. Failure to do so could result in dam-
The power cinch and/or power release is made possi- age to the latch actuator. Refer to Wiring Diagrams
ble by a latch actuator attached to the leading edge if previous notes were not made.
of the power latch assembly. This 12 volt latch actua-
tor contains a small drive gear that meshes with the (4) Secure the main connector retaining push pins
latch assemblies internal gears to perform the power on the latch actuator housing.
cinch close / power release operations. Refer to the (5) Grab the latch assembly and hook the key cyl-
Latch assembly for more information. inder link rod on the key cylinder.
The power cinch/release actuator is serviceable (6) Position the latch and install the three latch
component. Consult your Mopar™ parts catalog for retaining bolts. Torque to 10 N·m (90 in. lbs.).
specific part numbers. (7) Connect the power latch electrical connector.
(8) Install the lower liftgate trim panel. Refer to
OPERATION Body for the procedure.
During a power close cycle, the power cinch actua- (9) Connect the negative battery cable.
tor provides the torque required to close the power
liftgate from the secondary to the primary closed and
latched position. During a power open cycle, the
power release actuator releases the liftgate from the
primary closed and latched position to the fully
unlatched and movable position.
EXTERIOR HANDLE SWITCH

DESCRIPTION
Vehicles equipped with a power liftgate or power
locks utilize a exterior handle switch. The exterior
handle switch is a electronic release switch mounted
to the rear license plate lamp housing assembly,
located just above the license plate. This switch con-
trols the power liftgate release function and is also
capable of reversing the power liftgate when it is in
motion. A full power open cycle cannot be performed
using this switch, only one of the power open com-
mand switches (key fob and overhead console
mounted) can be used to perform a full power open
cycle.
The exterior handle switch is a serviceable compo-
nent. Consult your Mopar™ parts catalog for a spe-
cific part number.
Fig. 14 REAR LIGHT BAR
OPERATION
1 - CHIME / THERMISTOR
When the exterior handle switch is depressed, with
2 - ELECTRIC RELEASE HANDLE SWITCH
the liftgate in the closed position. A message is sent
3 - LICENSE PLATE LAMPS
to the Body Control Module (BCM). The Body Con-
trol Module then sends a signal to the power liftgate
control module via the J1850 PCI data bus circuit. (2) Locate the two wires going to the exterior han-
The power liftgate control module then sends a sig- dle switch. Install the wires through the grommet
nal to the power latch mounted actuator, which and in the large connector. Secure with a tie strap.
moves the liftgate from the primary closed and Refer to the Wiring section of the service manual for
latched position to the open and movable position. If detailed instructions.
the liftgate is not pulled open once the latch releases
within a few seconds, the latch will cinch closed NOTE: Be certain wires are reinstalled in the correct
again. wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to Wiring Diagrams
REMOVAL if previous notes were not made.
(1) Disconnect and isolate the negative battery (3) Install the rear light bar. Refer to the Body sec-
cable. tion of the service manual for the procedure.
(2) Open the liftgate and remove the liftgate trim (4) Install the liftgate trim panel. Refer to the
panel. Refer to the Body section of the service man- Body section of the service manual for the procedure.
ual for the procedure. (5) Connect the negative battery cable.
(3) Remove the rear lamp bar assembly from the (6) Using an appropriate scan tool, check any
vehicle. Refer to the Body section of the service man- erase any power liftgate control module diagnostic
ual for the procedure. trouble codes.
(4) Locate the two wires going to the exterior han- (7) Verify power liftgate system and handle switch
dle switch. Cut the tie strap and trace the wires to operation. Cycle the power liftgate through one com-
the large electrical connector and back the wires out plete open and close cycle, this will allow the power
of the large connector and through the grommet. liftgate control module to relearn its cycle with the
Refer to the Wiring section of the service manual for new components.
detailed instructions.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 14).
INSTALLATION
(1) Install the handle switch in the light bar
assembly.
CHIME/THERMISTOR OPERATION
The chime/thermistor assembly performs two dif-
DESCRIPTION ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate module. The
chime/thermistor assembly is hardwired to the power
liftgate module. Second the thermistor provides a
outside temperature reading by way of a resistance
reading (V - ohms) supplied to the power liftgate
module. As temperature increases the resistance
reading (V - ohms) increases, as temperature
decreases the resistance reading (V - ohms)
decreases.
REMOVAL
cable.
(2) Remove the rear light bar assembly from the
(3) Using your hands, grasp the light bar at its
sides next to thermistor/chime assembly and gently
pull the two sides of the light bar apart until the
thermistor/chime assembly can be removed.
Fig. 15 REAR LIGHT BAR
1 - CHIME / THERMISTOR
INSTALLATION
2 - ELECTRIC RELEASE HANDLE SWITCH
(1) Gently pull the two sides of the light bar apart
3 - LICENSE PLATE LAMPS
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
Vehicles equipped with a power liftgate utilize a cle. Refer to the Body section of the service manual
chime/thermistor assembly. The chime/thermistor for the procedure.
assembly is a small capacitor shaped electrical com- (3) Connect the negative battery cable.
ponent mounted to the rear license plate lamp hous-
ing assembly (Fig. 15), located just above the license
plate. The chime portion of the assembly controls the
audible chime sound heard at the rear of the vehicle
when the power liftgate is in motion. The thermistor
portion of the assembly is a temperature sensor, used
by the power liftgate module.
The chime/thermistor assembly is a serviceable
component. Consult your Mopar™ parts catalog for a
specific part number.
RS POWER SLIDING DOOR SYSTEM 8N - 19
POWER SLIDING DOOR SYSTEM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 RIGHT B-PILLAR SWITCH
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 22 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - POWER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SLIDING DOOR SYSTEM . . . . . . . . . . . . . . . . . 22 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 28 LOWER DRIVE UNIT
WELLNUT REPLACEMENT . . . . . . . . . . . . . . . 28 DESCRIPTION . . . . . . . . . . ........ . . . . . . . . . 33
POWER DOOR LEARN CYCLE . . . . . . . . . . . . 28 OPERATION. . . . . . . . . . . . ........ . . . . . . . . . 33
SLIDING DOOR ADJUSTMENT . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . ........ . . . . . . . . . 33
LATCH INSTALLATION. . . . . . . . . . ........ . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 LOWER DRIVE UNIT TRACK & RACK
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . ........ . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 OPERATION. . . . . . . . . . . . ........ . . . . . . . . . 34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . ........ . . . . . . . . . 34
SLIDING DOOR MOTOR INSTALLATION. . . . . . . . . . ........ . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 WIRING HARNESS
FULL OPEN SWITCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FLEX DRIVE
LEFT B-PILLAR SWITCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER SLIDING DOOR TRONIC CONTROL MODULES/DOOR CONTROL

MODULE - DESCRIPTION) The power side door
SYSTEM motor is located in the front portion of the door, on
the inner door panel sheet metal. The latch assembly
DESCRIPTION is located in the rear of the power side door, near the
Some vehicles are equipped with a power opening body line. The lower drive unit is attached to the
and closing sliding door system (Fig. 1). Depending lower door hinge. The flex drive assembly connects
on how the vehicle is ordered it may be equipped the door motor to the lower drive unit. The wire har-
with only a right side power door or right and left ness and track and the lower drive unit track are vis-
side power doors. This power sliding door system is a ible with the door open in the lower door sill area.
complex system consisting of many components. The power side door full open switch is located under
Some of these components are the door motor, latch the lower drive unit and is part of the hold open
assembly, sliding door control module, lower drive latch assembly. The pawl, ratchet, handle and child
unit, flex drive assembly, wire harness and track, lockout switches are all located on the power side
lower drive unit track and rack assembly, full open door latch assembly. The B-pillar switch, as it will be
switch, B-pillar switch, overhead console switch, key referred to, is an open and close command switch
fob switches (Fig. 2), pawl switch, ratchet switch and located on the vehicles interior body side B-pillar
child lockout and handle switches. trim. The overhead console switch, is an open and
Each power side door has its own door control mod- close command switch located in the vehicle’s over-
ule, located in the center of the door behind the door head console. More detailed information can be found
trim panel. (Refer to 8 - ELECTRICAL/ELEC- on these components later in this section.
8N - 20 POWER SLIDING DOOR SYSTEM RS
POWER SLIDING DOOR SYSTEM (Continued)
Fig. 1 POWER SLIDING DOOR INTRODUCTION

Safety is of the utmost concern with the power
sliding door system. Software technology has enabled
the power sliding door control module to detect resis-
tance to door travel. This allows the power sliding
door to stop and reverse direction any time an
obstruction is felt or any of the command switches
are operated (while closing only). Battery voltage is
supplied to the power sliding door system through a
40 amp fuse, located in the Intelligent Power Module
(IPM) assembly (Fig. 3). The child lockout switch pre-
vents children from opening or actuating the power
sliding door system when desired. In the unlikely
event that the power sliding door system develops a
fault, the power sliding door can still be operated
manually from the interior or exterior door handle,
just like a standard manual sliding door.
The power sliding door control module communi-
cates on the J1850 PCI Data Bus Circuit. Therefore,
the power sliding door control module can generate
and store its own diagnostic trouble codes (DTC). A
diagnostic scan tool, such as the DRB IIIt is used to
read and diagnose these trouble codes. Refer to the
Fig. 2 KEY FOB Body Diagnostic Manual for a complete list of diag-
1 - LEFT SLIDING DOOR SWITCH nostic routines.
2 - RIGHT SLIDING DOOR SWITCH
3 - LIFTGATE SWITCH
closed position. The ability for the power sliding door
module to detect resistance to door travel is accom-
plished by hall effect sensors and the door motor
speed.
The power sliding door control module has the abil-
ity to learn. Anytime a door is opened or closed using
the power sliding door system the module learns
from its cycle. If a replacement power sliding door
component is installed or a door adjustment is made,
the module must re-learn the effort required to open
or close the door. A learn cycle can be performed with
a Diagnostic Scan Tool, such as the DRB IIIt, or with
a complete cycle of the door, using any one of the
command switches. Refer to Standard Procedures in
this section for detailed instructions.
The power sliding door system is designed with a
number of system inhibitors. These inhibitors are
necessary for safety and/or feasibility of the power
sliding door system. See the power sliding door sys-
tem inhibitors noted below:
POWER SLIDING DOOR SYSTEM INHIBITORS

Fig. 3 POWER SIDE DOOR FUSE LOCATION • The power sliding door must be in the full open
or closed position in order for the power sliding door
NOTE: It may be possible to generate Sliding Door
system to start a cycle. If the door is not in this posi-
Diagnostic Trouble Codes during normal power
tion (based on the input from the full open, pawl or
sliding door operation. Refer to the Body Diagnos-
ratchet switches) the door control module will not
tic Manual for a complete list of diagnostic routines.
respond to command switch inputs.
For additional information, (Refer to 8 - ELECTRI-
• The vehicles transmission must be in park or
CAL/POWER DOORS - OPERATION) . For a com-
neutral in order for the power sliding door system to
plete power sliding door system wiring schematic,
start a cycle.
refer to Wiring Diagrams. For power sliding door sys-
• The vehicles child lockout switch must be in the
tem operation instructions, refer to the vehicle owner
“UNLOCKED” position in order for the power sliding
manual.
door systems B-pillar switches to function.
WARNING: BE CERTAIN TO READ ALL WARNINGS • If multiple obstacles are detected during the
AND CAUTIONS IN POWER SLIDING DOOR OPER- same power open or close cycle the power sliding
ATION BEFORE ATTEMPTING ANY SERVICE OF door may go into full manual mode.
POWER SLIDING DOOR SYSTEM OR COMPO- • If severe Diagnostic Trouble Codes (DTC) are
NENTS. stored in the power sliding door control module the
power sliding door may go into full manual mode.
• Due to the high pressure created in the passen-
OPERATION ger compartment with the blower motor on high, the
With the push of a power sliding door open/close power sliding door may not complete a power close
command switch (key fob, overhead console or B-pil- cycle unless a window is cracked, allowing the pres-
lar mounted) a signal is sent out to the Body Control sure to escape. This situation will only be experi-
Module (BCM). The BCM then sends a signal out on enced on some vehicles, or vehicles with brand new
the PCI Data Bus circuit (J1850) to the power sliding side door weather seals installed. Refer to the Side
door module. The power sliding door module then Door Adjustment procedure in the Standard Proce-
signals the power sliding door latch to release the dures section of this group.
door to the unlatched and movable position. The • The vehicles fuel tank filler door must be in the
motor then starts an open cycle. closed position. Due to the sliding door interference
During the door open cycle, if the power sliding with the open fuel tank filler door, mechanical link-
door module detects sufficient resistance to door age prevents the side door from opening and striking
travel, such as an obstruction in the door’s path, the the fuel door. Refer to the Body section of this man-
power sliding door module will immediately stop door ual for detailed information on the fuel door lockout
movement and reverse door travel to the full open or feature.
POWER SLIDING DOOR SYSTEM WARNINGS DIAGNOSIS AND TESTING - POWER SLIDING
DOOR SYSTEM
WARNING: ALWAYS DISCONNECT THE NEGATIVE
The power opening and closing power sliding door
BATTERY CABLE BEFORE ATTEMPTING ANY
system is a complex system containing many compo-
POWER SLIDING DOOR SYSTEM SERVICE.
nents and modules. In order to obtain conclusive
testing, the Programmable Communications Interface
WARNING: EXTREME CARE MUST BE TAKEN TO (J1850) data bus network and all of the electronic
PREVENT OBJECTS FROM ENTERING THE DOORS modules that provide inputs to, or receive outputs
PATH ONCE THE DOOR REACHES THE CINCH from the power sliding door system must be checked.
MOTOR CONTACT (APPROXIMATELY 1 INCH The power sliding door system was designed to be
BEFORE FULLY CLOSED). diagnosed with an appropriate diagnostic scan tool,
such as the DRB IIIt. The most reliable, efficient,
and accurate means to diagnose the power sliding
WARNING: NEVER ATTEMPT TO ENTER OR EXIT door system requires the use of a DRB IIIt scan tool
THE VEHICLE WHILE THE POWER SLIDING DOOR and the proper Body Diagnostic Procedures manual.
IS IN MOTION. YOU COULD DAMAGE THE POWER The DRB IIIt can be used to observe various switch
SLIDING DOOR SYSTEM OR COMPONENTS statuses throughout the power sliding door system to
AND/OR CAUSE PERSONAL INJURY. help the technician diagnose a defective switch or
component. The DRB IIIt can also be used to actuate
various components throughout the power sliding
WARNING: NEVER ATTEMPT TO DRIVE AWAY WITH
door system to help the technician diagnose a defec-
THE POWER SLIDING DOOR IN MOTION. YOU
tive component.
COULD DAMAGE THE POWER SLIDING DOOR SYS-
Before any testing of the power sliding door system
TEM OR COMPONENTS AND/OR CAUSE PER-
is attempted, the battery should be fully charged, all
SONAL INJURY.
built-in power sliding door system inhibitors read
and understood (Refer to 8 - ELECTRICAL/POWER
WARNING: NEVER STICK OBJECTS IN THE POWER DOORS - OPERATION) and all wire harness and
SLIDING DOOR WHEN CINCHING CLOSED. YOU ground connections inspected around the affected
COULD DAMAGE THE VEHICLE, POWER SLIDING areas on the vehicle.
DOOR SYSTEM OR COMPONENTS AND/OR CAUSE The following are quick reference diagnostic tables
PERSONAL INJURY. to help when diagnosing and testing the power slid-
ing door system.
POWER SLIDING DOOR SYSTEM DIAGNOSIS

Door opens unexpectedly Failure of sliding door control or Disconnect then reconnect battery to reset
body control module module, function door, if no function exists
check for loose wire connections, Refer to
the Body Diagnostic Manual for detailed
procedures
Failure of latch assembly Check wiring/cable connections and for
blown fuse
Check for trouble codes, replace latch if
necessary
Failure of open/close command Check for shorted or defective switch
switch
Failure of striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Door will not open manually Failure of inside handle assembly Check for broken inside handle assembly
using inside handle
Check cable connections at latch and
handle assembly.
Check for binds or kinks in cable.

operation of handle assembly
Replace the handle if necessary
Failure of latch assembly Check cable connections

Failure of inside handle cable Check cable for binding
assembly
Check cable for broken condition

Replace the cable, if necessary
operation of door

Door will not open manually Failure of outside handle assembly Check for broken outside handle assembly
using outside handle
Check cable connections at latch and

handle assembly.
Check for binds or kinks in cable.

operation of handle assembly

Replace the handle if necessary

Failure of outside handle cable Check cable for binding
assembly
Check cable for broken condition
Replace the cable, if necessary

operation of door

Sliding door will not Binding or sticking of components Establish location of binding. Disconnect
open/close manually flex drive and recheck. Replace necessary
components

Sliding door will not Failure of sliding door control or Disconnect then reconnect battery to reset
open/close under power body control module module, function door, if no function exists
check for loose wire connections, see Body
Diagnostic Manual for detailed procedures
Check cable connections

Troubleshoot using body diagnostic manual
Failure of motor assembly Troubleshoot using body diagnostic manual
Failure of full open switch assembly Troubleshoot using body diagnostic manual
Failure of flex drive assembly Disconnect flex drive and check for broken
condition
Failure of lower drive unit assembly Remove lower drive unit and check for
broken condition
Power loss during power Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
door operation Refer to wiring diagrams

Low battery voltage Charge battery
Failure of sliding door control or Disconnect then reconnect battery to reset
Failure of drive assembly Remove lower drive unit and check for no
drive condition
No latching in primary Failure of inside/outside handle Go to that 9POSSIBLE CAUSE9 and review
and/or secondary positions assembly 9CORRECTIONS9

Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter. Refer to Door adjustment in
the Body section of the service manual for
specifications
drive condition
Striker damaged
Latch will not fully release Failure of latch assembly Check wire connections and for blown fuse
from primary position

Failure of fuel filler door lockout Check operation of fuel filler door lockout
mechanism mechanism. Refer to the Body section for
information

Striker damaged
Cables worn and stretched Replace cables as necessary
Key fob, B-pillar or Blown Fuse Check fuse and replace
overhead console switch
does not power operate
door
Battery voltage low Charge or replace battery
Failure of latch assembly Check for foreign matter preventing the
Check wire connection

Pawl and/or ratchet switch inoperative
Failure of body control module Check electrical connections
Refer to the body diagnostic manual for

additional checks
Replace BCM if necessary
Failure of key fob Replace key fob battery
Replace key fob if necessary

Failure of sliding door control module Disconnect then reconnect battery to reset
module, function door, if no function exists
Failure of door motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections

Gear motor clutch does not engage,
replace assembly
Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Failure of hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary

Failure of hold open latch striker Replace hold open latch striker, if
necessary
High inside/outside opening Failure of latch assembly Check wire connections and for blown fuse
effort


Failure of inside/outside handle Go to that 9POSSIBLE CAUSE9 and review
assembly 9CORRECTIONS9
Door continues to cinch Failure of latch assembly Check wire connections and for blown fuse
closed during power mode

Door continues to open Failure of sliding door control or Disconnect then reconnect battery to reset
during power mode body control module module, function door, if no function exists
(runaway motor) check for loose wire connections, see Body
Failure of hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary

drive condition
Door opens very slowly Failure of door motor assembly Check wire/cable connections
Replace motor assembly, if necessary

Squeaks, Noises and rattles Foreign material in door Remove foreign material
compartment
Loose components Check and tighten loose components
Poor door track lubrication Lubricate the front portions of the side door
tracks with 9Door EaseT9 or equivalent
STANDARD PROCEDURE - WELLNUT STANDARD PROCEDURE - POWER DOOR

REPLACEMENT LEARN CYCLE
Vehicles equipped with a power sliding door utilize Any time a power side door component is removed,
wellnuts. These wellnuts are used to hold and isolate replaced, door adjustment is performed or diagnostic
the power sliding door motor to and from the door trouble codes are addressed and erased, a learn cycle
inner panel. The wellnut functions like a expandable must be performed. This learn cycle enables the
rubber core plug, as the screw fastener is threaded power side door control module to learn or relearn its
into the wellnut and tightened the wellnuts diameter critical information (travel limits, resistance to door
increases. This secures the door motor assembly to travel, etc.) which allows it to perform properly and
the inner panel and keeps the audible motor vibra- safely. It also tells the technician that the system is
tions to a minimum. If a wellnut shows signs of wear, performing properly and is able to be returned to ser-
it must be replaced. Follow the procedure below if vice. To perform a power door learn cycle do the fol-
replacement is necessary. lowing:
(1) Remove the door motor from the door inner (1) Obtain a DRB IIIt scan tool.
panel. (Refer to 8 - ELECTRICAL/POWER DOORS/ Connect the DRB IIIt to the vehicle and check for
MOTOR - REMOVAL) . any power side door system stored diagnostic trouble
(2) Remove the wellnuts from the inner panel by codes, erase any stored codes. Operate the system
pulling them straight out (Fig. 4). If a wellnut is dif- and check to see if any trouble codes return. If any
ficult to remove, use a high leverage cutting tool to diagnostic trouble codes return, diagnose, correct and
cut the wellnut in half and remove the two halves erase the codes before performing the learn cycle. If a
from the door assembly. DRB IIIt scan tool is not available, the learn cycle
can be performed by opening and closing the power
side door using any of the normal open/close com-
mand switches. Be certain to cycle the side door
through a complete open and close cycle or the pro-
cedure will not be complete.
(2) Using the DRB IIIt, Go into Test Routine
Menu and select a power open command.
(3) Select a power close command.
(4) The power side door learn cycle is complete.
NOTE: If the power side door will not complete a

full cycle a problem exists with the power side door
system. Refer to Power Side Door Diagnosis and
Testing.
STANDARD PROCEDURE - SLIDING DOOR

ADJUSTMENT
In order for the power sliding door system to func-
tion properly the door must move freely and
smoothly. The power sliding door system can accom-
modate for some minor changes in the effort required
to move the door. However, in extreme conditions the
Fig. 4 SIDE DOOR MOTOR WELLNUTS
door may need to be mechanically adjusted for proper
1 - WELLNUTS
fit. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
2 - SIDE DOOR INNER PANEL
ING DOOR - ADJUSTMENTS) .
If a problem exists with the power sliding door and
(3) Install the replacement wellnuts in the inner it is suspected to be extreme effort, check for proper
panel and install the door motor(Refer to 8 - ELEC- door alignment and adjustment first, then check the
TRICAL/POWER DOORS/MOTOR - INSTALLA- door tracks and drive unit for free manual operation.
TION) . Use a known good vehicle for side door comparison
data. Refer to the Side Door Adjustment procedure in
CAUTION: Be certain to use the correct torque the Body section of the service manual for detailed
specification (35 in.lbs.) when installing the door instructions.
motor retaining screws.
LATCH position (determined by pawl and ratchet switches).

During a power open cycle, the power release actua-
tor will stop once the side door has moved from pri-
DESCRIPTION
mary latch position (determined by ratchet switch).
The power latch uses inputs from the lock/unlock
actuator, power side door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. Refer to
Power Side Door Operation for additional informa-
tion.
REMOVAL
cable.
(2) Remove the appropriate side door trim panel.
Refer to the Body section for the procedure.
(3) Remove the weather shield if necessary. Refer
to the Body section for the procedure.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 6).
Fig. 5 POWER LATCH POSITION & ORIENTATION

1 - POWER LATCH ASSEMBLY
Vehicles equipped with a power side door or doors

utilize a power latch. One power latch is used for
each power door. The latch is located on the trailing
edge of the side door assembly (Fig. 5). This power
latch assembly is comprised of many different compo-
nents which have the ability to perform the power
cinch, release, lock, unlock and safety related opera-
tions. These components are the door latch, lock/un-
lock actuator, cinch/release actuator and child
lockout, pawl, ratchet and handle switches. The
ratchet switch is used to indicate the primary locked
position. The pawl switch is used to indicate the sec-
ondary position. The cinch latch also provides a con-
nection point for the interior handle, exterior handle Fig. 6 REMOVING LATCH RETAINING BOLTS
and hold open latch cables. 1 - LATCH RETAINING BOLTS
The power latch is a replaceable component. Con- 2 - SIDE DOOR
sult your Mopar parts catalog for specific part num-
bers.
(5) Partially close the door and pull the latch
assembly out of the side door inner panel.
OPERATION (6) Disconnect all electrical connectors leading to
The power latch performs the same operation as a
the latch assembly.
full manual door latch as well as power cinch,
(7) Disconnect the inside and outside handle cables
release, lock and unlock operations. The power latch
from the latch assembly. Refer to the Body Section of
mounted actuator cinches the door closed and latches
the service manual for the procedure.
it in its primary latched position. During a power
close cycle, the power cinch actuator will not operate
until the side door has reached its secondary latch
LATCH (Continued)
(8) Disconnect the hold open latch cable from the
latch assembly. Refer to the Body Section of the ser-
vice manual for the procedure.
(9) Disconnect lock actuator link rod from the
latch assembly.
(10) Remove the latch assembly from the vehicle.
INSTALLATION
(1) Position the latch assembly in the vehicle. Be
certain all latch mounted components are installed
on the replacement latch assembly. If not, transfer
components from the old latch to the new latch
assembly.
(2) Connect the lock actuator link rod on the latch
assembly.
(3) Connect the hold open latch cable on the latch
assembly. Refer to the procedure in this section for
detailed instructions.
(4) Connect the inside and outside handle cables
on the latch assembly. Refer to the procedure in the
Body section for detailed instructions.
(5) Connect all electrical connectors leading to the
latch assembly. Fig. 7 SIDE DOOR COMPONENTS
(6) With assistance from another person, position 1 - SLIDING DOOR CONTROL MODULE
the side door and install the door latch retaining 2 - MODULE RETAINING SCREW
bolts. Torque to 10 - 12 N·m (100 in. lbs.). 3 - MODULE ELECTRICAL CONNECTORS
(7) Install the weathershield if necessary. Refer to 4 - DOOR MOTOR ASSEMBLY
the procedure in the Body section for detailed 5 - FLEX DRIVE ASSEMBLY
instructions. 6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
(8) Install the appropriate side door trim panel.
Refer to the procedure in the Body section for
detailed instructions. The door motor is replaced as a complete assembly,
(9) Connect the negative battery cable. which includes the DC motor, gear reduction and
clutch assemblies. Consult your Mopar parts catalog
for specific part numbers.
SLIDING DOOR MOTOR
OPERATION
DESCRIPTION With the push of a Power Side Door (PSD) com-
Vehicles equipped with a power sliding door utilize mand switch, the PSD control module will signal the
a door motor assembly. The door motor is located in latch assembly to release the door from its primary
the center of the side door (Fig. 7) and is comprised locked position. The drive motor will then take over
of three parts. The three parts of the door motor to provide the power to open the door to its full open
assembly are the motor, gear reduction and clutch or closed position. The gear reduction portion of the
assembly. The door motor assembly provides the motor assembly reduces the speed of the motor from
power and torque to move the sliding door from the 5800 to 260 rpm and also increases the torque to the
open/closed position to full closed/open position, after lower drive unit. The clutch portion of the motor
the power latching mechanism has released. assembly engages the motor to drive the door under
Special wellnuts and screws are used in the side power and disengages it so the door can be moved
door inner panel to retain the door motor to the door easily under manual operation.
panel. Refer to Standard Procedures in this section
for additional wellnut information.
SLIDING DOOR MOTOR (Continued)
REMOVAL (7) Install the door trim panel on the side door.
(1) Disconnect and isolate the negative battery Refer to Body for the procedure.
cable.
(2) Remove the door trim panel from the appropri-
ate side door. Refer to the Body section for the pro-
FULL OPEN SWITCH
cedure.
(3) Remove water shield as necessary to gain DESCRIPTION
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 8). Pull flex drive cable straight
out of the motor assembly.
Fig. 9 FULL OPEN SWITCH POSITION &

ORIENTATION
1 - HOLD OPEN LATCH ASSEMBLY
2 - HOLD OPEN LATCH CABLE
Fig. 8 SIDE DOOR MOTOR CLIP 3 - FULL OPEN SWITCH
1 - FLEX DRIVE CABLE RETAINING CLIP

2 - FLEX DRIVE CABLE Vehicles equipped with a power sliding door utilize
3 - MOTOR ASSEMBLY a full open switch. This switch is located in the hold
open latch (Fig. 9) under the side door lower hinge.
(5) Disconnect door motor electrical connector. When the power side door module receives a ground
(6) Remove the 4 screws holding the motor to the signal input from the full open switch, and as long as
inner door panel. the cinching latch actuator is not in power mode or
(7) Remove the motor assembly from the vehic

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Welcome to the

2001 RS/RG Technical Publications

Click on the icon for the desired manual

Gas Powertrain Diesel Powertrain Body Chassis Transmission

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DaimlerChrysler Corporation reserves the right

Copyright © DaimlerChrysler Corporation

1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

3.1 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM . . . . . . . .2

4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .31

AUTOMATIC TEMPERATURE CONTROL

ELECTRICALLY HEATED SYSTEMS

HEATING & A/C

INTELLIGENT POWER MODULE

POWER DOOR LOCKS/RKE

POWER DOORS - LIFTGATE

POWER DOORS - SLIDING

POWER MIRROR – FOLDING

WINDSHIELD WIPER & WASHER

8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995

8.1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .995

9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1011

A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY . . . . . . . . . . . . . . . . . . .1011

10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1087

10.1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1087

11.0 CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1122

11.1 KDB LAB SCOPE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1123

This diagnostic procedures manual covers all

ACTIVE DTC CONDITIONS SQUIB STATUS

AIRBAG SQUIB STATUS

ACTIVE DTC CONDITIONS SQUIB STATUS

3.7.1 HEADLAMP POWER

3.7.2 HEADLAMP SWITCH

3.7.3 PARK LAMP RELAY

3.7.4 FOG LAMP RELAY

3.9.2.2 CABIN HEATER 3.9.2.6 DOOR ACTUATORS

Recirculation Switch Blend Switch – Dual Zone

3.14 OVERHEAD CONSOLE

3.14.1 COMPASS/MINI-TRIP COMPUTER

3.20.1 BASE ALARM SYSTEM

3.21.8 WIPE AFTER WASH

3.22 USING THE DRBIIIT

3.22.1 DRBIIIT ERROR MESSAGES

Press MORE to switch between this display 4.2 SAFETY

4.2.4 DRBIIIT SAFETY INFORMATION 4.3 WARNINGS

WARNING: EXCEEDING THE LIMITS OF THE 4.3.1 VEHICLE DAMAGE WARNINGS

When Monitored and Set Condition:

FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE

FCM, ORC RUN ONLY DRIVER OVER CURRENT - ACTIVE

FCM, ORC RUN ONLY DRIVER OVER TEMP - ACTIVE

FCM, ORC RUN ONLY DRIVER OVER VOLT - ACTIVE

FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE — Continued

FCM, ORC RUN ONLY DRIVER SHORT TO GROUND - ACTIVE

ORC, LOSS OF IGNITION RUN ONLY - ACTIVE

FCM, ORC RUN ONLY DRIVER OPEN - ACTIVE — Continued

TEST ACTION APPLICABILITY

2. ORC RUN ONLY DRIVER OVER VOLTAGE

4. ORC RUN ONLY DRIVER OVER CURRENT