Crossfire 2004 Service Manual

GROUP TAB LOCATOR
Introduction
0 Lubrication & Maintenance
2 Suspension
3 Differential & Driveline
5 Brakes
6 Clutch
7 Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Center
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
PCODE Index
Service Manual Comment Forms (Rear of Manual)

ZH INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE SAFETY CERT LABEL THREADED HOLE REPAIR ...............6

DESCRIPTION . . . . . . . . . . . . . . . ...........1 METRIC SYSTEM
VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . ................6
DESCRIPTION . . . . . . . . . . . . . . . ...........2 TORQUE REFERENCES
INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . ................8
DESCRIPTION . . . . . . . . . . . . . . . ...........2 VECI LABEL
FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . ................9
DESCRIPTION . . . . . . . . . . . . . . . ...........3
FASTENER USAGE
DESCRIPTION
FASTENER USAGE . . . . . . . . . . ...........6
VEHICLE SAFETY CERT LABEL

DESCRIPTION
A vehicle safety certification label is attached to the rear shut-
face 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 Rating
(GAWR) rear and the Vehicle Identification Number (VIN). The
Month, Day and Hour of manufacture is also included.
All communications or inquiries regarding the vehicle should
include the Month-Day-Hour and Vehicle Identification Number.
2 INTRODUCTION ZH
VEHICLE IDENTIFICATION NUMBER

DESCRIPTION
The Vehicle Identification Number (VIN) is located on the upper left corner of the dash panel, inside the windshield
opening. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information
about the vehicle. Refer to VIN Code Breakdown table for decoding information.
CROSSFIRE VIN CODE BREAKDOWN
POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Other K = Restraint System Front Air Bags Next Generation
(CGW) With Standard Side Air Bag Supplement (CGS)
5 Car Line N = Crossfire (LHD)
P = Crossfire (RHD)
6 Series 6 = “S” Series
6 - Export Transmission C = 6 Speed Manual (DED)
E = 5 Speed Automatic (DGU)
7 Body Style 9 = Specialty Coupe
8 Engines L = 3.2L V6 SOHC 18 Valve
9 Check Digit See explanation in this section
10 Model Year 4 = Model Year
11 Plant X = Osnabrueck Germany
12 through 17 Sequence Number 6 Digit Sequential Number Assigned By Assembly Plant.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify
various instrument controls. The symbols correspond to the controls and displays that are located on the instrument
panel.
ZH INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)
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
DESCRIPTION
The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt
strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade
corresponds to the number of line marks plus 2. The most commonly used metric bolt 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.
4 INTRODUCTION ZH
ZH INTRODUCTION 5
6 INTRODUCTION ZH
FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL
INJURY.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-
bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for
application and repair procedures.
METRIC SYSTEM
DESCRIPTION
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 x 8.851 = in-lbs
(N·m)
ft-lbs x 1.3558 = Newton Meters N·m x 0.7376 = ft-lbs
(N·m)
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
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 x 0.6214 = mph
(Km/h)
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/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (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
ZH INTRODUCTION 7
METRIC SYSTEM (Continued)
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.).
8 INTRODUCTION ZH
TORQUE REFERENCES
DESCRIPTION
Individual torque charts appear within many of the groups. Refer to the Standard Torque Specifications Chart for
torque references not listed in the individual torque charts.
ZH INTRODUCTION 9
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Information (VECI)
Label. Chrysler permanently attaches the label in the engine
compartment. It cannot be removed without defacing information
and destroying the label.
The label contains the vehicle’s emission specifications and vac-
uum hose routings. All hoses must be connected and routed
according to the label.
ZH LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE TOWING

SPECIFICATIONS - FLUID CAPACITIES .......1 STANDARD PROCEDURE - TOWING . . . . . . . . . 6
FLUID TYPES JUMP STARTING
DESCRIPTION STANDARD PROCEDURE
ENGINE OIL AND LUBRICANTS . . . ........2 JUMP STARTING ......................8
DESCRIPTION - HOAT COOLANT . . ........4 HOISTING
DESCRIPTION - AUTOMATIC STANDARD PROCEDURE - HOISTING . . . . . . . 10
TRANSMISSION FLUID . . . . . . . . . . ........5 MAINTENANCE SCHEDULES
DESCRIPTION - DIFFERENTIAL DESCRIPTION - FLEXIBLE SERVICE SYSTEM
LUBRICANT . . . . . . . . . . . . . . . . . . . ........6 (FSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTERNATIONAL SYMBOLS LUBRICATION POINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . ........6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FLUID FILL/CHECK LOCATIONS EMERGENCY TOW HOOKS
DESCRIPTION . . . . . . . . . . . . . . . . . . ........6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
LUBRICATION & MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES
FLUID CAPACITY
Automatic Transmission Fluid 8.0 L (8.5 qts.)
Brake System 0.5 L (0.5 qts.)
Cooling System 11.2 L (11.8 qts.)
Engine Oil W/ Filter 5.5 L (6.1 qts.)
Fuel 60.0 L (15.8 gal.)
Manual Transmission Fluid 1.5 L (1.6 qts.)
Power Steering 1.0 L (1.1 qts.)
Rear Axle 1.3 L (1.4 qts.)
PARTS AND LUBRICANT RECOMMENDATIONS

When service is required, DaimlerChrysler Motor Corporation recommends that only MoparT brand parts, lubricants
and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation
vehicles.
AUTOMATIC TRANSMISSION FLUID

Use ShellT 3403 automatic transmission fluid or equavalent.
ENGINE COOLANT
The green and the orange engine coolant MUST NOT BE MIXED.
0-2 LUBRICATION & MAINTENANCE ZH
FUEL
Crossfire engines require the use of unleaded fuel to reduce exhaust emissions. Use premium unleaded gasoline
having a minimum octane rating of 91 (R+M)/2. Higher octane premium unleaded gasoline can be used if desired.
FLUID CHECK/FILL POINTS AND LUBRICATION LOCATIONS

The fluid check/fill points and lubrication locations are located in each applicable Sections.
FLUID TYPES
DESCRIPTION
ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTER-
NAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH
SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS,
HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CON-
TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi-
cles.
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)
API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified. MOPART provides engine oils, that meet or exceed this requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of
engine oil. Use only engine oils with multiple viscosities such
as 5W-30 or 10W-30. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot temperature vis-
cosity range. Select an engine oil that is best suited to your
particular temperature range and variation.
ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING
is located on the label of an engine oil container.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted
to aid in the proper selection of engine oil. The identifying
notations are located on the front label of engine oil plastic
bottles and the top of engine oil cans.
This symbol means that the oil has been certified by the Amer-
ican Petroleum Institute (API). DiamlerChrysler only recom-
mend API Certified engine oils. Use MoparT engine oil or
equivalent.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the lubricants usage.
Such as API GL-5 and SAE 75W-90.
LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage by the NLGI.
All approved products have the NLGI symbol on the label. At
the bottom of the NLGI symbol is the usage and quality iden-
tification letters. Wheel bearing lubricant is identified by the let-
ter “G”. Chassis lubricant is identified by the letter “L”. The
letter following the usage letter indicates the quality of the
lubricant. The following symbols indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS

Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appro-
priate sections in this manual for the correct application of these lubricants.
DESCRIPTION - HOAT COOLANT

WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE
TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED
CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-
GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CON-
AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT
UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze pro-
tection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in 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 cool-
ant 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 solution.
CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any
other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in
engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protec-
tion.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions.
The coolant performance of various mixtures follows:
Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat
transfer only. Water also freezes at a higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to
dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as
high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature
can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C
(-35°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If per-
centage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a
68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob-
lems associated with 100 percent ethylene-glycol.
COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT,
for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without cor-
rosion when mixed with 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 solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID

Note: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals
for this transmission.
Note: For fluid level checking procedures, Refer to Page 21-294 .
TRANSMISSION FLUID
ShellT 3403 Automatic Transmission Fluid (ATF) when new is red in color. The ATF is dyed red so it can be iden-
tified 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. 3403 also has a unique odor that may change with age. Consequently, odor and
color cannot be used to indicate the fluid condition or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those auto-
matic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid
leaks.
Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and
others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge.
These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be
used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of
transmission seals.
DESCRIPTION - DIFFERENTIAL LUBRICANT

Note: Refer to the Owner’s Manual for the recommended differential lubricant change intervals for this axle.
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid inspection and
fill locations.
FLUID FILL/CHECK LOCATIONS

DESCRIPTION
The fluid fill/check point locations are located in each applicable service manual section.
TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND PRECAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT. DO NOT VENTURE 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 system, shock absorbers, sway bars, or any other under
vehicle components when attaching towing device to vehicle. Remove or secure loose or protruding objects
from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehi-
cle. Do not allow weight of towed vehicle to bear on lower fascia, grill or front structure.
To avoid damage to the front fascia and grille use of a flat bed towing device is recommended. DO NOT attempt to
tow the vehicle from the front or the rear. Towing from the front is not possible without sustaining damage to the
nose/front fascia due to the extended distance between the wheels and the pointed nose/front fascia. Towing from
the rear is not possible without sustaining damage to the rear fascia and the exhaust system.
TOWING RECOMMENDATIONS
Flat bed towing should be the only method used for the Chrysler Crossfire. The flat bed must have an approach
angle less then 13.3° or something must be used (such as wood slats) to raise the overall height of the vehicle
during loading.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake rotors.
A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure
there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels
from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the
rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake rotors.
JUMP STARTING
STANDARD PROCEDURE
JUMP STARTING
WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED.
WARNING: DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR.
WARNING: DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
WARNING: DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
WARNING: DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT.
CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can
be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:

WARNING: SHIELD EYES AND FACE FROM BATTERIES AT ALL TIMES
CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charg-
ing system can result.
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.
2. When using another vehicle as a booster 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 transmission in NEUTRAL and turn
the ignition OFF.
3. On disabled vehicle, place gear selector in park or neutral
and set park brake. Turn off all accessories.
4. Connect positive jumper cable to positive (+) terminal of the
disabled battery.
5. Connect other end of positive jumper cable to positive ter-
minal (+) booster battery.
6. Connect negative jumper cable to negative (-) terminal of
the booster battery.
7. Make final connection of the negative (-) jumper cable to
the ENGINE GROUND of disabled vehicle, away from
battery.
CAUTION: Do not crank starter motor on disabled vehicle

for more than 15 seconds, starter will overheat and could
fail.
8. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the
engine in the vehicle with the discharged battery.
9. 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 seconds, stop cranking engine and allow starter to cool (15 minutes), before
cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:

1. Disconnect the negative (-) jumper cable clamp from engine ground on disabled vehicle.
2. Disconnect the negative (-) jumper cable clamp from booster vehicle.
3. Disconnect positive (+) jumper cable from battery positive (+) terminal on disabled vehicle.
4. Disconnect positive (+) jumper cable from battery positive (+) terminal on booster vehicle.
0 - 10 LUBRICATION & MAINTENANCE ZH
HOISTING
STANDARD PROCEDURE - HOISTING
WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN
THE ENGINE, TRANSMISSION 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 suspension components, damage to vehicle can result.
The vehicle can be lifted with:

• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.
FLOOR JACK
When properly positioned, a floor jack can be used to lift the vehicle. Support the vehicle in the raised position with
jack stands at the front and rear ends of the frame rails.
CAUTION: Do not lift vehicle with a floor jack positioned under:

• An axle shaft.
• A body side sill.
• A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
• A front suspension arm.
ZH LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES
DESCRIPTION - FLEXIBLE SERVICE SYSTEM (FSS)
The Flexible Service System (FSS) is a demand-activated
engine oil service system. The FSS will illuminate a symbol (2)
in the instrument cluister to indicate to the driver when a par-
ticular service is due. After a level has dropped below a warn-
ing threshold, the remaining distance or the remaining time
and the tool symbol (2) are displayed in the panel of the
odometer.
The FSS is supplied the time intervals from the digital clock in
the instrument cluster. The remaining information is supplied
by the Powertrain Control Module (PCM) and the Controller
Antilock Brake (CAB) via the Controller Area Network (CAN)
data bus. The data required for FSS from the CAN includes
the following:
• The four wheel speed sensors from the CAB.
• Coolant temperature from the PCM.
• Engine speed from the PCM.
• Load torque from the PCM.
TRIP ODOMETER, FSS INDICATOR

This display in the instrument cluster shows the distance traveled since last reset.
To reset:
• Press the button to the left of the display once (with the key in the ON/RUN position).
• Press the button twice (with the key removed or in the OFF/ACC position).
MAIN ODOMETER
This shows the total distance the vehicle has traveled.
The FSS permits a flexible service schedule that is directly related to the operating conditions of the vehicle.
There are two symbols which will appear in the main odometer display field prior to the next suggested service.
This symbol represents Service A.
The second symbol represents Service B.
Depending on operating conditions throughout the year, the

next service is calculated and displayed next to the this sym-
bol in days remaining before the next service is required.
ZH LUBRICATION & MAINTENANCE 0 - 13
The next service may be calculated and displayed next to this

symbol as distance remaining before the next service is
required.
The counter can also be reset by any individual after the indi-
cated service has been performed. To do so:
1. Turn the key to the ON/RUN position.
2. Within one second press the knob/button to the left of the display twice.
3. The present status for days remaining or distance traveled is displayed. Within ten seconds turn the key to OFF.
4. Press and hold the knob/button to the left of the display, while turning the key to ON/RUN again. The present
status for days remaining or distance traveled is displayed once more. Continue to hold the knob/button to the
left of the display.
After approximately ten seconds, a tone sounds and the display shows 6,000 miles (10,000 km) for approximately
ten seconds.
5. Release the knob/button to the left of the display.
If the FSS counter was inadvertently reset, the counter must be reset.
The message is displayed for approximately ten seconds when turning the key to the ON/RUN position, or while
driving when reaching the service warning threshold. It can be cancelled manually by pressing the knob/button to
the left of the display.
Once the suggested term has passed, the message, plus either the symbol for Service A or the symbol for Service
B preceded by a “–” (minus symbol) blinks for approximately thirty seconds and a tone sounds every time when
turning the key to the ON/RUN position.
The FSS display can also be called up for approximately ten seconds with the display illuminated by pressing the
knob/button to the left of the display twice within one second.
Note: When disconnecting the battery for one or more days at a time, such days will not be counted. Any
such days not counted by the FSS can be added.
The interval between services is determined by the type of vehicle operation. Driving at extreme speeds, and cold
starts combined with short distance driving in which the engine does not reach normal operating temperature,
reduce the interval between services.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each applicable Section.
EMERGENCY TOW HOOKS

DESCRIPTION
WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS.
THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY.
The tow hooks should be used for EMERGENCY purposes only.
CAUTION: DO NOT USE EMERGENCY TOW HOOKS FOR TOW TRUCK HOOK-UP OR HIGHWAY TOWING.
ZH SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION WHEEL ALIGNMENT ......................4

DIAGNOSIS AND TESTING - SUSPENSION FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 14
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 48
SPECIAL TOOLS
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT 2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
2-2 SUSPENSION ZH
VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.

SIDE DURING BRAKING
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.

DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON 2. Brakes dragging. 2. Repair brake as necessary.
UNCROWNED ROAD 3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
7. Cross caster out of specification. 7. Align vehicle.
KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
3. Worn shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
SPECIAL TOOLS
SUSPENSION
9150 Rear Spring Compressor
C-3894–A Tie Rod Puller

ZH SUSPENSION 2-3
9150 Rear Spring Compressor 9168 Ball Joint Puller
9152 Spring Compressor Plates 9199 Bearing Tool

2-4 WHEEL ALIGNMENT ZH
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT CHECKING AND ADJUSTING FRONT AXLE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....4 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....5 STANDARD PROCEDURE - CHECKING AND
STANDARD PROCEDURE ADJUSTING FRONT TOE-IN . . . . . . . . . . . . . 10
STANDARD PROCEDURE - WHEEL STANDARD PROCEDURE - CHECKING
ALIGNMENT INSPECTION . . . . . . . . . . . . ....6 TOE-OUT ON TURNS . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - CHASSIS STANDARD PROCEDURE - CHECKING
ALIGNMENT INSPECTION . . . . . . . . . . . . ....7 REAR AXLE CAMBER . . . . . . . . . . . . . . . . . . 11
INSPECTING AND ADJUSTING VEHICLE STANDARD PROCEDURE - CHECKING AND
LEVEL AT FRONT AND REAR AXLES . . . ....8 ADJUSTING REAR AXLE TOE . . . . . . . . . . . . 12
INSPECTING AND ADJUSTING VEHICLE SPECIFICATIONS
LEVEL AT FRONT AND REAR AXLES SPECIFICATIONS - WHEEL ALIGNMENT . . . . 13
WITH AN ELECTRONIC INCLINOMETER . ....8 SPECIFICATIONS - SUSPENSION . . . . . . . . . 13
WHEEL ALIGNMENT
DESCRIPTION
CAUTION: Never attempt to modify suspension or steering components by heating or bending.
CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot
in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to
align the cotter pin hole.
Note: Periodic lubrication of the front suspension/steering system components may be required. Rubber
bushings must never be lubricated.
Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accom-
plished through suspension and steering linkage adjustments. An alignment is considered essential for efficient
steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are
caster, camber and toe position.
ZH WHEEL ALIGNMENT 2-5
OPERATION
CASTER
Is the forward or rearward tilt of the steering knuckle from ver-
tical. Tilting the top of the knuckle rearward provides positive
caster. Tilting the top of the knuckle forward provides negative
caster. Caster is a directional stability angle. This angle
enables the front wheels to return to a straight ahead position
after turns. (2) Indicates the spring location. (1) Is the repair
bolt for adjusting caster.
• +3 mm Range of adjustment ±25’ Caster.
CAMBER
Is the inward or outward tilt of the wheel relative to the center
of the vehicle. Tilting the top of the wheel inward provides neg-
ative camber (NEG.). Tilting the top of the wheel outward pro-
vides positive camber (POS.). Incorrect camber will cause
wear on the inside or outside edge of the tire.
• +3 mm Range of adjustment ±25’ Camber.
WHEEL TOE POSITION

Is the difference between the leading inside edges (B) and
trailing inside edges (A) of the front tires. Incorrect wheel toe
position is the most common cause of unstable steering and
uneven tire wear. The wheel toe position is the final front
wheel alignment adjustment.
• Negative Toe (Toe Out) B > A.
• Positive Toe (Toe In) B < A.
TOE-OUT ON TURNS
Toe-out on turns is the relative positioning (1) of the front
wheels while steering through a turn. This compensates for
each front wheel’s turning radius. As the vehicle encounters a
turn, the outboard wheel must travel in a larger radius circle
than the inboard wheel. The steering system is designed to
make each wheel follow its particular radius circle. To accom-
plish this, the front wheels must progressively toe outward as
the steering is turned from center. This eliminates tire scrub-
bing and undue tire wear when steering a vehicle through a
turn.
STEERING AXIS INCLINATION ANGLE

Is measured in degrees and is the angle that the steering knuckles are tilted. The inclination angle has a fixed
relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The
angle is not adjustable, damaged component(s) must be replaced to correct the steering axis inclination angle.
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT INSPECTION
1. Inspect the overall condition of the vehicle.
• The vehicle should be properly aligned and adjusted to a ready to drive condition in which it is most fre-
quently used. The chassis alignment inspection is carried out in reference to the vehicle level.
2. Use the measurement sheet for the chassis alignment inspection.
3. Inspect the tire condition.
• Perform a visual inspection for wear pattern, tread depth and any damage to the tires.
4. Inspect the wheel condition
• Perform a visual inspection for any damage to the wheels.
5. Inspect the tire pressure.
• Compare the tire pressure from the door placcard to the current tire pressure, correct the tire pressures if
necessary.
6. Inspect the underside of the vehicle.
• Inspect for any damage, corrosion of chassis parts and supporting body parts, leaks from any components
and pipes.
7. Inspect the wheel bearing play.
Note: For the next step the vehicle must be sitting on its wheels.
8. Inspecting the condition of the steering mechanism.

• With the ignition OFF, inspect the steering wheel play. Permissible play around circumference of steering
wheel with steering in its center position is a maximum of .984 in. (25 mm).
• Inspect the play of the tie rods and the drag links.
• Inspect the track rod and drag link joints by pulling the tire back and forth with force or move
steering wheel from left to right and vice versa approx. 100 mm while having a second mechanic
feel the track rod and drag link joints.
Note: The right-hand is the pivot joint. This prevents any pivot movement in the drag links. If any play
exists replace the tie rod link or the drag link.
• Inspect the seals and condition of the rubber boots. If the rubber boot is not tight replace the tie rod link or
replace the drag link.
• Inspect the steering coupling. It must not have any play. If necessary, replace the steering coupling.
• Inspect the steering gear for play. If play exists, adjust the vehicle’s steering gear.
STANDARD PROCEDURE - CHASSIS ALIGNMENT INSPECTION

1. Observe the general information on chassis alignment inspection. Refer to Page 2-6.
2. Drive the vehicle onto an electronic measuring system.
3. Unlock the turntables and the sliding platforms.
4. Install a brake pedal winch on the brake pedal.
5. Attach the wheel sensors.
6. Perform the initial measurement process.
7. Inspect the vehicle level at the front and the rear axles and adjust if necessary. Refer to Page 2-6.
8. Inspect the vehicle level at the front and the rear axles with an electronic inclinometerand adjust if necessary.
Refer to Page 2-6.
9. Inspect and adjust the rear axle toe. Refer to Page 2-6.
10. Inspect and adjust the front axle camber and caster. Refer to Page 2-6.
11. Inspect the rear axle camber. Refer to Page 2-6.
12. Inspect and adjust the front axle toe. Refer to Page 2-6.
13. Perform the final measurement of the vehicle.
14. Detach the sensors.
15. Remove the brake pedal winch.
16. Carefully drive the vehicle off the measuring system.
17. Lock the turntables.
INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES

2. Inspect the vehicle level at the front axle by performing the following:
• Insert measuring device between the retaining bolts of the lower control arm bearing.
• Position the contact arm of measuring device on the control arm and read off the plumb value of vehicle
level, viewed from the center of the vehicle. Refer to Page 2-6.
3. Inspect the vehicle level at the rear axle by performing the following:
1. Loosen right rear frame brace and swivel to one side.
2. Position contact arm on the rear axle shaft and read off the plumb value of the vehicle level, viewed from
the center of the vehicle. Refer to Page 2-6.
Note: If the vehicle level at the front or rear axle is outside the tolerance, adjust the vehicle level by chang-
ing the springs or spring rubber mounts.
4. Adjust the vehicle level at the front and rear axles.
INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES

WITH AN ELECTRONIC INCLINOMETER
CAUTION: The measuring plate is magnetic. Information on data media, e.g. floppy disks, credit cards, etc.,
could be rendered unusable.
Note: Be sure to clean measurement points on the lower wishbone.
Note: Remove any metal shavings on the measuring plate.
2. Install the measuring plate in the recessed area in the lower control arm. The groove in the measuring plate
should be at an angle of 90° towards the direction of travel.
3. Inspect the vehicle level at the front axle via control arm inclination. Refer to Page 2-6.
4. Inspect the vehicle level at the rear axle via the rear axle shaft inclination. Refer to Page 2-6.
5. Adjust the vehicle level at the front and rear axles. If the vehicle level is outside the allowed tolerance at the front
or rear axle: Perform the following.
• Adjust the vehicle level by changing the springs or the spring rubber mounts. Refer to Page 2-6.
CHECKING AND ADJUSTING FRONT AXLE CAMBER AND CASTER

CHECKING
1. Observe the general information on chassis alignment check. Refer to Page 2-6.
2. Check the vehicle level at the front and rear axles. Refer to Page 2-6.
3. Check the vehicle level at the front and rear axles with an electronic clinometer and adjust if necessary. Refer to
Page 2-6.
4. Check the camber and assign to tabular value. Refer to Page 2-13.
Note: Measure with the wheels turned to 20°.
5. Check the caster and assign to tabular value. Refer to Page 2-13.
ADJUSTING
1. Raise and support the vehicle.
2. Cover all the attached parts remaining in the vehicle. (area to be repaired)
WARNING: RISK OF INJURY WITH TRAPPED OR CRUSHED FINGERS WHEN WORKING ON SPRINGS OR
SPRING-LOADED COMPONENTS.
CAUTION: Use only approved tensioning devices; additionally shield off hazardous area if necessary.
CAUTION: Inspect special tools for damage and proper operation (visual inspection). Wear protective
gloves.
Note: Inspect for prior installation of the alignment bolt.
3. For camber, compress the front spring (1). Refer to Page

2-42.
4. Install the repair bolt (2). Screw on the nut from the repair
kit as far as it will go, but do not tighten it so that the rub-
ber mount on the wishbone can turn when the suspension
is compressed and rebounded.
5. Release the front spring (1).
6. Lower the vehicle and settle the suspension by pulling and
pushing firmly several times.
Note: Inspect for prior installation of the alignment bolt.
7. For caster, compress the front spring (2). Refer to Page

2-42.
8. Install the repair bolt (1). Screw on the nut from the repair
kit as far as it will go, but do not tighten it so that the rub-
ber mount on the wishbone can turn when the suspension
is compressed and rebounded.
9. Release the front spring (2).
10. Lower the vehicle and settle the suspension by pulling and
pushing firmly several times.
Note: The vehicle level must correlate with the dimension

established on the initial measurement.
11. Recheck the vehicle level at the front axle after adjusting the camber and caster.
• Vehicle level at the front axle. Refer to Page 2-6.
• With an electronic inclinometer. Refer to Page 2-6.
Note: After repairing, the adjusting screw must not be turned by the shims, and must be countered when
tightening the hexagon nut.
2 - 10 WHEEL ALIGNMENT ZH
12. Tighten the nut from the repair kit to 120 N·m (88 ft. lbs.)
13. Adjust the rear axle toe. Refer to Page 2-6.
14. Adjust the front axle toe. Refer to Page 2-6.
STANDARD PROCEDURE - CHECKING AND ADJUSTING FRONT TOE-IN

1. Set the steering wheel in the center position.
Note: The steering gear is in the center position when the

separating joint of the steering coupling and the marking
notch on the steering gear are above each other. Offset
the steering wheel by a maximum of one tooth, if neces-
sary.
2. Check the center position of the steering gear and steering

wheel.
Note: The flexible mount of the control arms results in a

correspondingly large toe-in value which reduces to the
correct dimension in the ready-to-drive condition
3. Install a wheel spreader on the inside of the wheel in the

forward direction of travel.
Note: After adjusting toe-in, check rubber boot on inner

joint for twisting.
4. Adjust the toe-in by rotating the tie rods. Tighten the lock nut to 50 N·m (37 ft. lbs.).
• Negative Toe (Toe Out) B > A.
• Positive Toe (Toe In) B < A.
ZH WHEEL ALIGNMENT 2 - 11
STANDARD PROCEDURE - CHECKING TOE-OUT ON TURNS
1. Check and adjust the toe-in at the front axle. Refer to Page 2-6.
2. Check the toe-out on turns. To check steering geometry measure toe-out on turns. This is the difference in the
wheel angle between the wheel on the outside of a curve and the wheel on the inside of a curve when the wheel
on the inside of the curve is turned 20°. Greater deviations may be caused as follows whereby it is assumed that
camber and caster are adjusted correctly: Refer to Page 2-6.
• Toe-in not adjusted with steering gear in straight ahead position resulting in unequal tie rod lengths.
• Steering knuckle, steering column or steering intermediate arm bent.
• On vehicles involved in an accident excessive deviations in the front end (longitudinal frame member, frame
cross member, wheelhouse and firewall, or on front axle carrier) which have a negative effect on the adjust-
ment range for camber and caster which can result in greater differences in the toe-out on turns between left
and right.
STANDARD PROCEDURE - CHECKING REAR AXLE CAMBER

1. Check the vehicle level at the front and rear axles and adjust if necessary. Refer to Page 2-6.
2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. Refer
to Page 2-6.
2 - 12 WHEEL ALIGNMENT ZH
3. Check the rear axle camber. (POS+) = Positive Camber,

(NEG-) = Negative Camber. The camber on the rear axle is
not adjustable. If a substantial deviations in the rear axle
camber are found, the cause may be one of the following:
Refer to Page 2-13.
• Too great a difference in the vehicle level between the
right and left-hand sides of vehicle.
• Camber strut bent.
• Accident damage to the frame floor. Level differences
at the mounting points for the rear axle carrier between
the left and right sides of the body. Experience shows
that bending caused by an accident also has an effect on
the toe.
STANDARD PROCEDURE - CHECKING AND

ADJUSTING REAR AXLE TOE
1. Check the vehicle level at the front and rear axles and adjust if necessary. Refer to Page 2-6.
2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. Refer
to Page 2-6.
3. Adjust the toe with the cam bolt on the mounting of the left and right tie rod on rear axle carrier.
ZH WHEEL ALIGNMENT 2 - 13
SPECIFICATIONS
SPECIFICATIONS - WHEEL ALIGNMENT
DESCRIPTION SPECIFICATION
Vehicle level - front axle 1.4° (-2.1/+1.4)
Vehicle level - rear axle 0.4° (±0.8)
Ball point position 30,5±2 mm
Front axle toe-in 0° 20’±10’
Toe-out on turns with wheel on the inside of the curve
-1° 25’±30’
steered through 20°
Total rear axle toe 0 ° 33’±7’
ALIGNMENT SPECIFICATIONS
Front Axle Toe 2.5°
Rear Axle Toe 1.2°
Front Camber -1° 13’ (-1.22°)
Front Caster 5° 12’ (5.20°)
Rear Camber -1° 08’ (-1.13°)
Permissible difference in front axle camber between
20’
right and left side of vehicle
SPECIFICATIONS - SUSPENSION
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.

Steering idler arm to bearing
30 22 266
bushing
Repair Nut 120 88.5 1060
Lock Nut 50 37 443
Cam bolt, rear axle tie rod 70 52 620
2 - 14 FRONT SUSPENSION ZH
FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION LOWER CONTROL ARM

SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TORQUE CHART - FRONT SUSPENSION . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
KNUCKLE UPPER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20 SHOCK
HUB / BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING SPRING
ADJUSTING WHEEL BEARING . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 STABILIZER BAR
LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT SUSPENSION
SPECIFICATIONS
TORQUE CHART - FRONT SUSPENSION

Front Shock Absorber
18 13 159
Upper Nut
Front Shock Absorber
55 41 487
Lower Nut
Front Sway Bar To Lower
20 15 177
Control Arm Nut
Front Sway Bar Bushing
Nuts
M10 40 30 354
M8 20 15 177
Front Sway Bar To Frame
60 44 531
Nut
Upper Control Arm Joint
45 33 398
To Steering Knuckle
Clamping Nut 11 8 97
Lower Ball Joint To
140 103 1240
Steering Knuckle
ZH FRONT SUSPENSION 2 - 15

Lower Ball Joint To lower
105 77 929
Control Arm
Upper Control Arm To
65 50 575
Body Nut
Lower Control Arm To
120 88 1060
Frame Nut
KNUCKLE
DESCRIPTION
1 - UPPER CONTROL ARM 9 - HUB NUT

2 - TIE ROD END 10 - BEARING
3 - WHEEL SPEED SENSOR 11 - HUB
4 - UPPER BALL JOINT NUT 12 - DUST SHIELD
5 - DUST SHIELD BOLT 13 - TIE ROD END NUT
6 - ROTOR LOCK BOLT 14 - LOWER BALL JOINT NUT
7 - ROTOR 15 - CALIPER BOLT
8 - DUST CAP 16 - LOWER BALL JOINT
The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has
machined mounting locations for the front brake calipers and hub bearing.
REMOVAL
CAUTION: When removing the steering knuckle the shock
absorber must remain installed.

2. Remove the front wheel and tire assembly.
3. Remove the front disc brake caliper (1). Refer to Page
5-25.
4. Remove the front disc brake rotor (1). Refer to Page 5-38.
5. Remove the front wheel hub (3). Refer to Page 2-25.
6. Remove the disc brake dust shield by removing the three

hex bolts (1).
7. Remove the Wheel Speed Sensor (WSS) by removing the

bolt and pulling the sensor straight out of the steering
knuckle.
CAUTION: Do not use pneumatic tools to tighten the bolt

on the special tool.
Note: Check the ball joint rubber boot for any wear or
damage. Repair as necessary.
Note: The use of a allen wrench may be required to hold

the stud while turning the nut.
8. Remove the tie rod end from the steering knuckle by

removing the nut from the tie rod joint stud. Using Special
Tool C-3894-A Two Jaw Puller. Slowly tighten the bolt until
the tie rod end joint is pushed out of the steering knuckle.


9. Remove the lower control arm supporting ball joint from the
steering knuckle by removing the nut (1) from the ball joint
stud.
10. Using Special Tool 9168 Ball Joint Puller (2) slowly tighten
the bolt until the ball joint (1) is pushed out of the steering
knuckle.


11. Remove the steering knuckle from the upper control arm
by removing the nut (1) from the upper ball joint stud.
12. Using Special Tool 9168 Ball Joint Puller slowly tighten the
bolt until the upper ball joint is pushed out of the steering
knuckle.
CHECKING
1. Check the lower control arm supporting ball joint by performing the following:
2. Remove the nuts (1) from the lower control arm supporting
ball joint.
3. Using Special Tool 9168 Ball Joint Puller (2) press out the
lower control arm supporting ball joint (1).
4. Check the lower control arm supporting ball joint. It should

be possible to move the ball pivot without any play, jam-
ming or creaking noises. Move the ball pivot in all directions
with a tube approximately 6 in. (150 mm) in length. Check
the boot for any cracks or damage. If the boot is leaking,
replace supporting or follower joint.
5. Measure the steering knuckle, if necessary.
INSTALLATION
1. Install the steering knuckle and nut (1) to the upper ball
joint stud. Tighten to 45 N·m (33 ft. lbs.).
2. Install the steering knuckle and nut to the lower ball joint
stud (1). Tighten to 105 N·m (77 ft. lbs.).
3. Install the tie rod end and nut onto the steering knuckle.
Tighten to 50 N·m (37 ft. lbs.).
4. Install the Wheel Speed Sensor (WSS) and bolt. Tighten to

22 N·m (16 ft. lbs.).
5. Install the disc brake dust shield and three hex bolts (1).
6. Install the front wheel hub (3). Refer to Page 2-27.

7. Install the front disc brake rotor (1). Refer to Page 5-40.
8. Install the front disc brake caliper (1). Refer to Page 5-32.
9. Install the front wheel and tire assembly. Refer to Page
22-42.
10. Lower the vehicle and check vehicle alignment. Refer to
Page 2-13.
HUB / BEARING
DESCRIPTION
1 - HUB 4 - DUST CAP

2 - BEARING 5 - ROTOR
3 - HUB NUT 6 - CALIPER
The bearing (2) used in the front hub (1) of this vehicle is a roller bearing unit type. This assembly combines the
front wheel hub (1) and the front wheel bearing (2) into a two piece unit. The hub nut (3) holds the bearing (2) and
the front hub (1) to the steering knuckle’s spindle. The hub nut (3) has a locking bolt that locks the hub nut into
position on the spindle. The bearing is protected from outside elements by a metal dust cap (4). The bearings (2)
can only be replaced as a set. The bearings and the wheel hub can be replaced independently of one another.
DIAGNOSIS AND TESTING

ADJUSTING WHEEL BEARING
1 - WHEEL BOLT 4 - HUB NUT

2 - DUST CAP 5 - ROTOR LOCK BOLT
3 - ROTOR
1. Remove the wheel and tire assembly.

2. Install a wheel bolt (1) on the opposite side from the brake rotor retaining bolt (5).
3. Press the brake pads back in the brake caliper making sure they do not come in contact with the brake rotor.
4. Remove the dust cap (2).
5. Loosen the hub nut bolt. Turn the hub nut (4) back until a slight end play is achieved.
6. Attach a dial indicator.
CAUTION: Do not turn the wheel hub while taking the measurement.
7. Adjust the wheel bearing end play by turning the hub nut (4) in stages while pushing and pulling the rotor firmly
back and forth. Adjust end play to 0.01–0.02mm.
8. Tighten the hub nut bolt to 11 N·m (8 ft. lbs.) and recheck the wheel bearing end play.
9. Remove the dial indicator.
10. Install the wheel hub dust cap (2).
11. Remove the wheel bolt from the rotor.
12. Install the front wheel and tire assembly. Refer to Page 22-42.
REMOVAL
1. Raise and support vehicle.
3. Remove and inspect the front disc brake caliper (1). Refer
to Page 5-25. Inspect for any damage or wear.
4. Remove and inspect the front disc brake rotor (1). Refer to
Page 5-38. Inspect for any damage or wear.
5. Remove the front wheel hub dust cap (4).

6. Loosen the hub nut bolt then remove the hub nut (3) and
then remove the tapered roller bearing (2).
7. Remove the front wheel hub (1) from the spindle.
INSPECTING HUB AND BEARINGS

1. Remove the bolts (1) and inspect the front disc brake dust
shield and replace if necessary.
Note: Discoloration may be caused by generated heat due

to incorrect bearing end play settings.
CAUTION: Only replace the tapered roller bearing and

bearing races in pairs.
2. Inspect the spindle for any discoloration or wear on the

bearing seats or the contact surface of the radial seal ring.
Replace if necessary. Refer to Page 2-16.
3. Inspect the front wheel hub (1). Inspect the threaded bores
and the rotor teeth for any wear or damage.
4. Inspect the tapered roller bearing (2), bearing races and the
radial seal ring. The tapered roller bearings and bearing
races can be reused if:
• The tapered rollers and bearing races have a smooth,
grey running track.
• No discoloration (indicating, intense heat) is evident.
• The roller cage and the face ends of the tapered roll-
ers are not worn or damaged.
• The bearing races sit tight in the wheel hub.
INSTALLATION
1. Pack the front wheel hub (1) with grease, coat the radial
seal ring and also pack the space between the sealing lip
and the tapered roller bearing (2) with grease. Install the
front wheel hub (1) with the inner tapered roller bearing (2)
and the radial seal ring onto spindle.
2. Install the hub nut (3) tight enough to hold the rotor (5) in
place.
5. Adjust the wheel bearing end play. Refer to Page 2-24.

6. Install the dust cap (4).
CAUTION: Before driving the vehicle, operate the brake

pedal several times until pressure in the brake system is
built up and maintained.
7. Install the wheel and tire assembly. Refer to Page 22-42.
LOWER BALL JOINT

REMOVAL
3. Remove the front disc brake caliper (1). Refer to Page
5-25.
4. Remove the front disc brake rotor (1). Refer to Page 5-38.
5. Remove the front dust shield by removing the three hex

bolts (1).
6. Remove the front shock absorber bolt (1). Refer to Page

2-40.
7. Remove the front spring (1). Refer to Page 2-42.

8. Remove the nuts (1 and 2) from the lower ball joint.

outer ball joint stud from the steering knuckle.
upper ball joint stud from the lower control arm.
INSTALLATION
1. Clean the ball joint tapered bolt and the mounting hole of
the steering knuckle.
2. Install the lower ball joint onto the steering knuckle and the
lower control arm.
3. Install both nuts (1 and 2). Tighten to 105 N·m (77 ft. lbs.).
4. Install the front disc brake dust shield by installing and

tightening the three hex bolts (1).
7. Install the compressed front spring (1). Refer to Page 2-44.

8. Install the front shock absorber bolt and nut (1). Refer to
Page 2-41.

22-42.
LOWER CONTROL ARM

REMOVAL
2. Remove the front spring. Refer to Page 2-42.
3. Remove the shock absorber lower mounting nut and bolt

(1).
4. Pull the shock absorber out of the mounting bracket.
5. Remove the sway bar from the lower control arm by remov-
ing the two nuts (1) then removing the clamp.
6. Remove the nut (1) attaching the lower control arm to the
lower ball joint.

outer ball joint stud from the steering knuckle.
8. Remove the two bolts (1) attaching the lower control arm to
the frame.
9. Remove the lower control arm from the vehicle.
INSTALLATION
1. Install the lower control arm to the vehicle.
2. Install the two bolts (1) attaching the lower control arm to
the frame. Tighten to 120 N·m (88 ft. lbs.).
3. Install the nut (2) attaching the lower control arm to the
steering knuckle lower ball joint. Tighten to 45 N·m (33 ft.
lbs.).
4. Install the sway bar clamp and bolts (1) to the lower control
arm. Tighten to 20 N·m (15 ft. lbs.).
5. Install the shock absorber bolt and nut (1) to the lower con-
trol arm. Tighten to 55 N·m (41 ft. lbs.).
6. Install the front spring (1). Refer to Page 2-44.

Page 2-6.
22-42.
UPPER CONTROL ARM

REMOVAL
Note: If working on the right side remove the air cleaner
housing to access the upper control arm bolt and nut.
Note: To remove the upper control arm the shock

absorber must remain installed.

2. Wire tie the steering knuckle to the shock absorber (arrow).
This is to hold the steering knuckle from falling away from
the vehicle.
3. Remove the ball joint nut (3) from the upper control arm
(2).
CAUTION: Do not subject the brake hose and any electri-

cal cables to any tension.

on the tool.
4. Using Special Tool 9168 Ball Joint Puller, press the upper
ball joint out of the steering knuckle.
5. Remove the upper control arm (2) from the body by remov-
ing the nut and bolt (1) from the inside of the engine com-
partment on the shock tower.
INSTALLATION
WARNING: TIGHTEN ALL NUTS AND BOLTS WITH THE
VEHICLE AT NORMAL RIDE HEIGHT.
1. Install the upper control arm (2) and the bolt and nut (1) to
the body. Tighten to 65 N·m (48 ft. lbs.)
Note: Clean the ball joint tapered bolt and mounting hole
of the steering knuckle.
2. Install the upper ball joint (3) to the steering knuckle.

Tighten to 45 N·m (33 ft. lbs.)
3. Remove the wire tie attaching the steering knuckle to the
shock absorber.
Page 2-6.
SHOCK
REMOVAL
Note: The vehicle must be standing on its wheels when
removing the upper shock absorber mounting.
1. Remove the shock absorber upper mounting nut (1).

2. Remove the washer and rubber mounts.
4. Remove the shock absorber nut and bolt (1) from the lower
control arm. Then remove the shock from the vehicle by
pulling it down and out of the vehicle.
5. Remove any mounting parts from the shock absorber.
6. Inspect all mounting parts for any damage or cracks.
INSTALLATION
1. Install the mounting hardware and bushings to the lower
mount and the shock absorber upper mounting stud.
2. Install the shock absorber to the vehicle by inserting the top
first and then aligning the lower control arm mounting
bracket to the shock absorber.
3. Install the shock absorber lower bolt and nut (1) to the
lower control arm shock. Tighten to 55 N·m (41 ft. lbs.).
4. Slowly lower the vehicle making sure to guide the upper
shock stud through the mounting hole.
5. Install the rubber mount and washer over the shock

absorber stud.
6. Install the shock absorber upper mounting nut (1). Tighten
to 18 N·m (13 ft. lbs.).
Page 2-6.
SPRING
REMOVAL
1. With the vehicle resting on its wheels remove the upper
shock absorber nut (1).
2. Remove the washer and rubber mount.
3. Raise and support the vehicle then remove the lower shock
absorber bolt and nut (1). Remove the shock from the
vehicle.
4. Support the lower control arm with a suitable supporting

device. Raise the lower control arm up until it is almost
level.
WARNING: ONLY USE APPROVED CLAMPING DEVICES

AND IF APPROPRIATE ALSO SCREEN OFF THE DANGER
AREA. INSPECT SPECIAL TOOLS FOR DAMAGE AND
FUNCTION. WEAR SAFETY GLOVES AND EYE PROTEC-
TION.
CAUTION: Risk of injury from hands and fingers being

trapped or crushed when working on preloaded springs or
spring bodies.
5. Using Special Tool 9151 Spring Compressor and 9152

Clamping Plates (1), carefully compress the front spring.
6. Remove the nuts from the lower control arm mounting

bolts.
7. Carefully remove the lower control arm mounting bolts from
the body.
8. Lower the supporting device and swing the lower control
arm down while holding the front spring. When enough
clearance has been achieved from the lower control arm
and the upper spring perch, remove the front spring from
the vehicle.
INSTALLATION
1. Install the compressed front spring (1) with the rubber
mount to the vehicle.
2. Swing the lower control arm up to its mounting position and

install the bolts and nuts (1).
Note: To avoid suspension preload, the vehicle must be at

normal ride height before tightening lower control arm
bolts.
3. Install the supporting device to the lower control arm. Posi-

tion the lower control arm so the distance between the
spring and the upper and lower perches is snug making
sure the spring is in its correct mounting position.
4. Slowly release the front spring making sure it is in its cor-
rect mounting position.
5. Lower and remove the supporting device so the lower con-
trol arm is in its down position.
6. Install the lower shock mounting hardware (1).
7. Lower the vehicle while guiding the shock into the upper
mounting surface.
8. Install the rubber mount and washer over the shock
absorber stud.
9. Install the shock absorber upper mounting nut (1). Tighten
to 18 N·m (13 ft. lbs.).
10. Tighten the lower control arm to 120 N·m (88 ft. lbs.).
Page 2-6.
STABILIZER BAR
REMOVAL
1 - STABILIZER BAR BRACKETS 4 - RETAINER BRACKET BOLTS AND NUTS

2 - LOWER CONTROL ARM 5 - RUBBER BUSHINGS
3 - RUBBER BUSHING 6 - STABILIZER BAR
1. Remove the stabilizer bar brackets (1) from the right and left lower control arms.
2. Remove the stabilizer bar bracket (4) from the retainer bracket.
3. Remove retainer bracket (4) and bracket mounting plate (if necessary).
4. Remove the stabilizer bar (6) from the vehicle.
5. Pull all rubber bushings (3 and 5) off of the stabilizer bar (6).
INSTALLATION
1 - STABILIZER BAR BRACKETS 4 - RETAINER BRACKET BOLTS AND NUTS

2 - LOWER CONTROL ARM 5 - RUBBER BUSHINGS
3 - RUBBER BUSHING 6 - STABILIZER BAR
1. Install both right and left stabilizer bar bushings (3 and 5) onto the stabilizer bar (6).
Note: The lower control arms (2) may need to be raised to accept the stabilizer bar bushing (2) to its mating
surface.
2. Install the stabilizer bar (6) to the vehicle by loosely installing the bolts and nuts to all four brackets (1 and 4).
3. Align the stabilizer bar (6) so it is centered in the vehicle.
Note: Due to the preload of the bracket, install the hexagon socket bolt first.
4. Tighten both stabilizer bar bolts to frame.

5. Tighten both stabilizer bar hexagon socket bolts to the retainer (4).
6. Tighten both right and left stabilizer bar bracket nuts to the lower control arm (2). Torque to 20 N·m (15 ft. lbs.).
7. Install the stabilizer bar retainer and mounting plate (if removed).
8. Tighten the retainer bolt (4) to frame (if removed). Torque to 60 N·m (44 ft. lbs.).
9. Tighten the lower retainer nut to the fastening bracket (if removed). Torque to 20 N·m (15 ft. lbs.).
10. Tighten upper retainer lever nut to the fastening bracket (if removed). Torque to 40 N·m (29 ft. lbs.).
11. Lower the vehicle and check vehicle alignment. Refer to Page 2-6.
2 - 48 REAR SUSPENSION ZH
REAR SUSPENSION
TABLE OF CONTENTS
page page
REAR SUSPENSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 48 HUB / BEARING
CAMBER STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 STABILIZER BAR
TRAILING LINK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 SHOCK
LATERAL LINK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 SPRING
TRACK BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53 REAR AXLE CARRIER
LOWER CONTROL ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
KNUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR SUSPENSION
SPECIFICATIONS
Torque Specifications
Description N·M Ft. Lbs. In. Lbs.

Stabilizer Link to Stabilizer
30 22 266
Bar
Stabilizer Bar to Stabilizer
20 15 177
Link Nut
Bolt, Stabilizer Bar Clamp 20 15 177
Upper Shock Nut 18 13 159
Shock Absorber to Lower
55 41 487
Control Arm
Front Rear Axle Carrier
90 66 797
Nut
Rear Axle Carrier Rear
90 66 797
Axle Nut
Rear Axle Center
Assembly At Front to Rear 50 37 443
Axle Carrier
ZH REAR SUSPENSION 2 - 49
Description N·M Ft. Lbs. In. Lbs.

Rear Axle Center
Assembly At Rear to Rear 110 81 974
Axle Carrier
Lower Control Arm to
70 52 620
Rear Axle Carrier
Lower Control Arm to
120 88 1060
Wheel Carrier
Camber Strut to Rear Axle
70 52 620
Carrier
Camber Strut to Wheel
70 52 620
Carrier
Trailing Link to Rear Axle
70 52 620
Carrier
Trailing Link to Wheel
70 52 620
Carrier
Lateral Link to Rear Axle
70 52 620
Carrier
Lateral Link to Wheel
30 22 266
Carrier
Track Bar to Rear Axle
70 52 620
Carrier
Track Bar to Wheel
70 52 620
Carrier
CAMBER STRUT
REMOVAL
3. Remove the inner camber strut bolt (1) attaching the cam-
ber strut to the rear axle carrier.
4. Remove the outer camber strut bolt (2) attaching the cam-
ber strut to the wheel carrier.
Note: Lightly tap the camber strut with a plastic headed

hammer to loosen or guide the rubber mounts out of their
mounting flanges.
5. Remove the camber strut.

INSTALLATION
1. Install the camber strut onto the vehicle.
CAUTION: Do not tighten to torque value at this point. The

vehicle must be in ready-to-drive position.
2. Install the outer camber strut bolt attaching the camber strut
to the wheel carrier.

vehicle must be in its ready-to-drive position.
3. Install the inner camber strut bolt attaching the camber strut
to the rear axle carrier.
4. Install the wheel and tire assembly.
5. Lower the vehicle so it is not being supported by the lift.
6. Tighten the outer camber strut bolt attaching the camber
strut to the wheel carrier to 70 N·m (52 ft. lbs.).
7. Tighten the inner camber strut bolt attaching the camber
strut to the rear axle carrier to 70 N·m (52 ft. lbs.).
8. Check vehicle alignment. Refer to Page 2-6.
TRAILING LINK
REMOVAL
3. Remove the inner trailing link bolt (1) attaching the trailing
link to the rear axle carrier.
4. Remove the outer trailing link bolt (2) attaching the trailing
link to the wheel carrier.
Note: Lightly tap the trailing link with a plastic headed

mounting flanges.
5. Remove the trailing link.

INSTALLATION
1. Install the trailing link onto the vehicle.

2. Install the outer trailing link bolt (2) attaching the trailing link

3. Install the inner trailing link bolt (1) attaching the trailing link
6. Tighten the outer trailing link bolt attaching the trailing link
to the wheel carrier to 70 N·m (52 ft. lbs.).
7. Tighten the inner trailing link bolt attaching the trailing link
to the rear axle carrier to 70 N·m (52 ft. lbs.).
LATERAL LINK
REMOVAL
3. Remove the inner lateral link bolt attaching the lateral link
4. Remove the lateral link ball joint nut (2).

on the tool.
5. Using Special Tool 9168 Ball Joint Puller, remove the outer
lateral link ball joint attaching the lateral link to the wheel
carrier.
Note: Lightly tap the lateral link with a plastic headed

mounting flanges.
6. Remove the lateral link (1).

INSTALLATION
1. Install the lateral link onto the vehicle.
CAUTION: The rear axle shaft must be horizontal when

tightening the lateral link nuts.
2. Install the outer lateral link ball joint attaching the lateral link
CAUTION: The rear axle shaft must be horizontal when

tightening the lateral link nuts.
3. Install the inner lateral link bolt attaching the lateral link to
the rear axle carrier.
CAUTION: Tighten the nuts and bolts in the “ready-to-

drive” position.
4. Tighten the outer lateral link ball joint attaching the lateral
link to the wheel carrier to 30 N·m (22 ft. lbs.).
5. Tighten the inner lateral link bolt attaching the lateral link to
the rear axle carrier to 70 N·m (52 ft. lbs.).
TRACK BAR
REMOVAL
3. Remove the inner track bar bolt attaching the track bar to
the rear axle carrier.
4. Remove the outer track bar bolt attaching the track bar to
the wheel carrier.
Note: Lightly tap the track bar with a plastic headed ham-
mer to loosen or guide the rubber mounts out of their
mounting flanges.
5. Remove the track bar.

INSTALLATION
1. Install the track bar onto the vehicle.

vehicle must be in its “ready-to-drive” position.
2. Install the outer track bar bolt attaching the track bar to the
wheel carrier.

vehicle must be in its “ready-to-drive” position.
3. Install the inner track bar bolt attaching the track bar to the
rear axle carrier.
6. Tighten the outer track bar bolt attaching the track bar to
the wheel carrier to 70 N·m (52 ft. lbs.).
7. Tighten the inner track bar bolt attaching the track bar to
the rear axle carrier to 70 N·m (52 ft. lbs.).
LOWER CONTROL ARM

REMOVAL
1. Remove the rear tire and wheel assembly.
2. Remove the rear lower control arm plastic shield by remov-
ing the bolts (1) attaching it to the lower control arm.
3. Remove the rear spring (1). Refer to Page 2-83.
4. Remove the rear shock absorber (1). Refer to Page 2-80.
5. Remove the rear stabilizer bar link (1) from the rear lower
control arm.
6. Remove the bolt attaching the rear lower control arm to the
rear wheel carrier.
7. Remove the rear lower control arm (4) from the vehicle.
INSTALLATION
1. Install the bolt attaching the rear lower control arm (4) to
the rear wheel carrier. Tighten to 70 N·m (52 ft. lbs.)
2. Install the rear shock absorber (1). Refer to Page 2-81.
3. Install the rear spring (1). Refer to Page 2-85.
4. Install the rear lower control arm to the vehicle. Tighten to

70 N·m (52 ft. lbs.).
5. Install the rear stabilizer bar link (1) to the rear lower con-
trol arm. Tighten to 20 N·m (15 ft. lbs.).
6. Install the rear lower control arm plastic shield bolt (1).
KNUCKLE
REMOVAL
1 - TRAILING LINK 6 - PARKING BRAKE CABLE

2 - CAMBER STRUT 7 - TRACK BAR
3 - DUST SHIELD 8 - LOWER CONTROL ARM
4 - HUB 9 - LATERAL LINK
5 - AXLE NUT

3. Remove the rear disc brake caliper (1). Refer to Page
5-25.
4. Remove the disc brake rotor. Refer to Page 5-38.
5. Remove the parking brake shoe assembly. Refer to Page

5-70.
6. Remove the parking brake cable (2). Refer to Page 5-61.

7. Remove the rear Wheel Speed Sensor (2) (WSS). Refer to

Page 5-197.
8. Remove the rear axle halfshaft from the rear hub assembly.
Refer to Page 3-4.
9. Remove the rear disc brake dust shield by removing the

hex bolts (1) from the rear hub assembly.
10. Remove the camber strut, nuts and bolts (1-2). Refer to
Page 2-49.
11. Remove the trailing link, nuts and bolts (1-2). Refer to
Page 2-50.
12. Remove the lateral link, nuts and bolts (1-2). Refer to
Page 2-51.
13. Remove the track bar. Refer to Page 2-52.

14. Remove the lower control arm. Refer to Page 2-53.
15. Remove the knuckle from the vehicle.

16. Inspect the bearing assembly (5) for any wear or damage,
replace if necessary. Refer to Page 2-67.
INSTALLATION
1 - TRAILING LINK 6 - PARKING BRAKE CABLE

2 - CAMBER STRUT 7 - TRACK BAR
3 - DUST SHIELD 8 - LOWER CONTROL ARM
4 - HUB 9 - LATERAL LINK
5 - AXLE NUT
CAUTION: The rear axle halfshaft must be horizontal when

tightening all nuts and bolts.
1. Install the knuckle to the vehicle.

2. Install the trailing link, nuts and bolts (1-2). Refer to Page
2-50.
3. Install the trailing link nuts and bolts (1-2). Refer to Page
2-51.
4. Install the lateral link nuts and bolts (1-2). Refer to Page
2-52.
5. Install the track bar nuts and bolts (1-2). Refer to Page
2-53.
6. Install the lower control arm. Refer to Page 2-55.
7. Install the rear disc brake dust shield by installing the bolts
(1) to the rear hub assembly.
8. Install the rear axle halfshaft to the rear hub assembly.

Refer to Page 3-5.
9. Install the rear Wheel Speed Sensor (2) (WSS). Refer to

Page 5-198.
10. Install the parking brake cable (2). Refer to Page 5-64.
11. Install the parking brake shoe assembly (1-5). Refer to

Page 5-73.
12. Install the disc brake rotor (1). Refer to Page 5-40.
13. Install the rear disc brake caliper and bolts (1). Refer to
Page 5-32.
HUB / BEARING
REMOVAL
1. Remove the disc brake calipers and bolts (1).
2. Remove rear disc brake rotor (1). Refer to Page 5-38.
3. Remove the parking brake shoes (1-5). Refer to Page

5-70.
4. Remove the rear axle halfshaft. Refer to Page 3-4.

5. Remove the snap ring (4) from the rear hub assembly
housing.
6. Using the Special Tool 9181 Bearing Tool, remove the bear-
ing (4) on the hub (1).
CAUTION: Be sure not to mar or damage the rear axle

halfshaft flange while in a vise.
7. Remove the inner bearing race from the rear axle halfshaft
flange by screwing the clamping pliers onto the puller then
tighten.
8. Clamp the rear axle halfshaft flange in vise.
9. Fit the thrust piece with the large diameter on the rear axle
halfshaft flange.
10. Place the complete puller over the inner bearing race.
11. Clamp it firmly at the upper grooves of the clamping pliers
over the tapered sleeve of the puller.
12. Pull the inner bearing race off the rear axle halfshaft
flange using the puller.
13. Check the lateral and radial runout of the rear axle half-
shaft flange. Replace rear axle halfshaft flange if test val-
ues are exceeded.
• Permissible lateral runout 0.001 18 in. (0.03 mm).
• Permissible radial runout 0.001 18 in. (0.03 mm).
INSTALLATION
1. Using the Special Tool 9199 Bearing Tool (1) install the
bearing (2) by pulling it into the wheel carrier (3) until it
touches the shoulder of the wheel carrier.
Note: Make sure that the snap ring is correctly fitted in the
rear wheel carrier.
2. Install the snap ring (4) into the rear wheel carrier.
Note: Make sure that the pressure plate lies flush against
the bearings inner race during insertion.
3. Install the rear axle halfshaft flange (1).

4. Install the parking brake shoes (1-5). Refer to Page 5-73.
5. Install the disc brake rotor (1). Refer to Page 5-40.
6. Install the rear disc brake caliper bolts (1). Refer to Page
5-32.
7. Install the rear axle halfshaft. Refer to Page 3-5.

8. Install wheel and tire assembly. Refer to Page 22-42.
STABILIZER BAR
REMOVAL
2. Remove both wheel and tire assemblies.
3. Remove the right and left wheel speed sensors (2). Refer
to Page 5-197.
4. Remove the rear brake hoses (1) from the rear brake cali-
pers. Refer to Page 5-12.
5. Remove the rear springs (1). Refer to Page 2-83.
6. Remove the rear shocks (1). Refer to Page 2-80.

7. Remove the rear parking brake cables (2) from the parking
brake equalizer (1). Refer to Page 5-61.
8. Remove the propeller shaft from the rear axle differential

carrier. Refer to Page 3-26.
9. Remove the rear stabilizer bar links (2) from the stabilizer
bar (1).
10. Block and support the rear axle carrier (1) with a suitable
lifting device (2).
11. Remove the two bolts (1) attaching the rear axle carrier to
the front portion of the frame.
12. Remove the two bolts (2) attaching the rear axle carrier to
the rear portion of the frame.
13. Lower the rear differential housing down approximately 4 -
5 inches allowing enough room for the stabilizer bar to be
removed from the vehicle.
14. Remove the rear stabilizer bar clamps (3) by removing the
nuts (1) from the studs and then removing the stabilizer
bar (2).
15. Remove the rear stabilizer bar from the vehicle by maneu-
vering it over the axle carrier and away from the vehicle.
INSTALLATION
1. Install the rear stabilizer bar into the vehicle.
2. Raise the rear differential housing and install the four bolts
(1) attaching it to the vehicle. Tighten to 90 N·m (66 ft. lbs.).
3. Install the rear spring (1). Refer to Page 2-85.
4. Install the rear shock (1). Refer to Page 2-81.
5. Loosely install the rear stabilizer clamps (1-3).

6. Install the rear stabilizer bar links (2) to the rear control
arm. Tighten to 30 N·m (22 ft. lbs.).
7. Tighten the rear stabilizer clamp nuts (1). Tighten to 20 N·m

(15 ft. lbs.).
8. Install the propeller shaft to the rear differential carrier.

Refer to Page 3-28.
9. Install the rear parking brake cables (2) to the parking

brake equalizer (1). Refer to Page 5-64.
10. Install the rear brake hoses (1) to the rear brake calipers.
Refer to Page 5-73.
11. Install the rear wheel speed sensors (2). Refer to Page
5-198.
SHOCK
REMOVAL
Note: The vehicle must be standing on its wheels before
removing the top shock absorber mounting hardware.
1. Remove the shock absorber upper mounting hardware (1).

3. Remove the lower control arm plastic cover by removing

the bolts (1) attaching the cover to the lower control arm.
4. Remove the shock absorber (1) from the lower control arm.
5. Inspect the shock absorber.
INSTALLATION
1. Install the shock absorber (1) onto the lower control arm
then install the bolt and nut (2). Tighten to 55 N·m (41 ft.
lbs.).
2. Install the lower control arm plastic cover and bolt (1).
3. Slowly lower the vehicle while guiding the top of the shock
into the mounting hole in the frame.
4. Install the top shock absorber mounting hardware (1).
SPRING
REMOVAL
3. Remove the control arm cover by removing the bolts (1)
from the cover.
4. Remove the lower shock bolts (2) from the lower control
arm.
5. Brace the rear suspension lower control arm with a suitable

lifting device. Raise the control arm until the half shaft is
horizontal. Using Special Tool 9152 Compressor Plates and
9150 Spring Compressor (1) compress the rear spring.
6. Remove the rear bolts on the lower control arm (4) attach-
ing it to the frame. Remove the lifting device.
7. Swing the lower control arm (2) down away from the
mounting tabs (1) to release the rear spring.
8. Remove the spring from the vehicle.
INSTALLATION
1. Install the spring.
2. Swing the lower control arm (2) up and install the bolt
attaching it to the frame (1).
3. Unclamp the spring (1) making sure the spring properly

matches the spring perch detents.
4. Install the lower shock mount (1) to the lower control arm.
5. Install the control arm cover and bolts (1).

REAR AXLE CARRIER

REMOVAL
3. Remove the rear disc brake calipers and bolts (1) relocate
away from the suspension components with mechanics
wire. Refer to Page 5-25.
4. Remove rear portion of the exhaust pipes including muffler.

Refer to Page 11-10.
5. Remove the parking brake rear cables (2) from the parking
brake cable equalizer (1). Refer to Page 5-61.
6. Remove the right and left Wheel Speed Sensors (2). Refer
to Page 5-197.
7. Remove the rear axle halfshafts. Refer to Page 3-4.

8. Remove the rear springs (1). Refer to Page 2-83.
9. Remove the rear shock absorbers (1). Refer to Page 2-80.
CAUTION: Be sure not to disconnect any of the fuel hoses

and lines from the fuel pump assembly.
10. Relocate the fuel pump assembly by removing the bolts

(1) and tying it away from the rear axle carrier with
mechanics wire.
11. Remove the propeller shaft assembly from the rear axle
differential carrier. Refer to Page 3-26.
12. Remove the rear axle differential carrier. Refer to Page

3-41.
13. Remove the front two bolts (1) from the rear axle carrier
attaching it to the frame.
14. Remove the rear two bolts (2) from the rear axle carrier
attaching it to the frame.
15. Remove the rear axle carrier (1) from the frame by lower-
ing it to the ground with a suitable tool (2).
Note: Only remove the following components from the

rear axle carrier.
16. Remove the camber strut bolt (1). Refer to Page 2-49.
17. Remove the trailing link bolt (1). Refer to Page 2-50.
18. Remove the lateral link bolt (1). Refer to Page 2-51.
19. Remove the track bar bolt (inner). Refer to Page 2-52.
20. Remove the stabilizer bar link (2). Refer to Page 2-72.
21. Remove the lower control arm. Refer to Page 2-53.
INSTALLATION
1. Install the camber strut bolt (1). Refer to Page 2-50.
2. Install the trailing link bolt (1). Refer to Page 2-51.
3. Install the lateral link bolt (1). Refer to Page 2-52.
4. Install the track bar bolt. Refer to Page 2-53.

5. Install the stabilizer bar link (2). Refer to Page 2-76.

6. Install the lower control arm. Refer to Page 2-55.
7. Install the rear axle carrier (1) by raising it up and installing

the four bolts to the frame. Tighten to 90 N·m (66 ft. lbs.).
8. Install the rear axle differential carrier. Refer to Page 3-42.

9. Install the propeller shaft assembly to the rear axle differ-

ential carrier. Refer to Page 3-28.
10. Install the fuel pump assembly bolts (1).
11. Install the rear shock absorbers (1). Refer to Page 2-81.
12. Install the rear springs (1). Refer to Page 2-85.
13. Install the rear axle halfshafts. Refer to Page 3-5.
14. Install the right and left Wheel Speed Sensors (2). Refer
to Page 5-198.
15. Install the parking brake rear cables (2) to the parking
brake cable equalizer (1). Refer to Page 5-64.
16. Install the rear portion of the exhaust pipes including

muffler.
17. Install the rear disc brake calipers and bolts (1). Refer to
Page 5-32.
ZH DIFFERENTIAL & DRIVELINE 3-1
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
HALFSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . 37

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 22
HALFSHAFTS
TABLE OF CONTENTS
page page
HALFSHAFTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION . . . . . . . . . . . . . . . . . . . ... . . . .2 CV BOOT - OUTER
OPERATION . . . . . . . . . . . . . . . . . . . . . ... . . . .3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - DRIVELINE .. . . . .3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL ...................... ... . . . .4 CV JOINT
INSTALLATION . . . . . . . . . . . . . . . . . . . ... . . . .5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS - TORQUE . . . . . . . . ... . . . .6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CV BOOT - INNER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL ...................... .......7
3-2 HALFSHAFTS ZH
HALFSHAFTS
DESCRIPTION
1 - CV JOINT OUTER RACE 8 - JOINT RING (INNER SHOWN, OUTER SIMILAR)

2 - RETAINING CLAMP 9 - BEARING (INNER SHOWN, OUTER SIMILAR)
3 - OUTER BOOT 10 - CIRCLIP
4 - RETAINING CLAMP 11 - INNER CV JOINT COVER
5 - AXLE SHAFT 12 - OUTER BEARING RETAINER (INNER SHOWN, OUTER
6 - INNER BOOT SIMILAR)
7 - INNER SEAL (INNER SHOWN, OUTER SIMILAR)
Articulated halfshafts deliver power from the rear differential to the wheels through constant velocity (CV) joints that
minimize vibration.
ZH HALFSHAFTS 3-3
OPERATION
Halfshaft assemblies are designed to transmit power from the differential to the wheels, while allowing for powertrain
and suspension flex.
DIAGNOSIS AND TESTING - DRIVELINE

HALFSHAFT VISUAL INSPECTION
1. Check for grease in the vicinity of the inboard and outboard CV joint. If grease is present, this may be a sign that
the inner or outer boots, or the retaining clamps are damaged.
2. A light film of grease may appear on the inner CV boot; this is considered normal and should not require replace-
ment of the boot. All inner CV boots are made of silicone rubber; which will allow weeping of the joint lubricant
to pass through the boot while in operation.
NOISE AND/OR VIBRATION IN TURNS

A clicking noise and/or a vibration could be caused by one of the following conditions:
1. Damaged inner or outer CV boots or retaining clamps. This will result in the loss and/or contamination of the joint
grease, resulting in inadequate lubrication of the joint.
2. Noise may also be caused by another component of the vehicle coming in contact with the halfshafts.
CLUNKING NOISE DURING ACCELERATION

This noise may be a result of one of the following conditions:
1. A torn boot on the inner or outer CV joint of the halfshaft assembly.
2. A loose or missing retaining clamp on the inner or outer CV boot of the halfshaft assembly.
3. A damaged or worn halfshaft CV joint.
3-4 HALFSHAFTS ZH
SHUDDER OR VIBRATION DURING ACCELERATION

This problem could be a result of:
1. A worn or damaged halfshaft inner joint.
2. A sticking CV joint assembly.
3. Improper wheel alignment.
VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of:
1. Foreign material (mud, snow, etc. packed on the backside of the wheels).
2. Out of balance tires or wheels.
3. Improper tire and/or wheel runout.
REMOVAL
2. Remove the rear wheels.
3. Remove the muffler. Refer to Page 11-10.
4. Place an index mark across the halfshaft (1) and the differ-
ential connecting flange (2) (as shown).
5. Remove the halfshaft outer retaining nut (1).

6. Push the halfshaft outer end through the wheel hub.
ZH HALFSHAFTS 3-5
7. Remove the halfshaft retaining bolts and flanges (1).

8. Separate the halfshaft from the differential connecting
flange and remove the halfshaft from the vehicle.
INSTALLATION
1. Insert the halfshaft outer end through the wheel hub.
2. Align the index marks on the differential connecting flange
(1) and the halfshaft flange (2).
3-6 HALFSHAFTS ZH
Note: New halfshaft bolts must be used.
3. Lubricate the halfshaft bolts (1) with oil. Install the half-
shafts and bolts on the connecting flanges. Tighten the half-
shaft bolts to 70 N·m (52 ft. lbs.).
Note: A new halfshaft outer retaining nut must be used.
4. Install the halfshaft outer retaining nut (1). Tighten the nut
to 220 N·m (164 ft. lbs.).
5. Install the muffler. Refer to Page 11-12.
6. Install the rear wheels. Refer to Page 22-42.
SPECIFICATIONS - TORQUE

Halfshaft Outer Retaining
220 164 —
Nut
Halfshaft Connecting
70 52 —
Flange Bolts
ZH HALFSHAFTS 3-7
CV BOOT - INNER
REMOVAL
1. Remove the halfshaft from the vehicle. Refer to Page 3-4.
2. Remove and discard both inner CV boot retaining clamps
(1).
3. Clamp the halfshaft in a vise.

4. Use a suitable tool to remove the inner CV joint cover (1)
from the bearing retainer.
3-8 HALFSHAFTS ZH
5. Slide the CV boot away from the inner seal (1).

6. Use a suitable tool and remove the inner seal (1) from the
bearing retainer.
7. Slide the CV boot, inner seal, and the bearing retainer
down the axle shaft away from the inner bearing.
8. Remove the CV joint circlip from the axle shaft.
9. Using a press, remove the CV joint bearing (1) from the

axle shaft.
10. Slide the bearing retainer, inner seal, and the inner CV
boot off of the axle shaft.
ZH HALFSHAFTS 3-9
INSTALLATION
1. Clean and inspect the CV joint for wear and pitting.
Replace as required. Refer to Page 3-16.
2. Remove any road grime and debris from the axle shaft
splines.
3. Before installing the CV boot, cover the shaft splines to pro-
tect the CV boot during installation.
4. Slide the inner CV boot on the axle shaft.
5. Remove the protective cover from the axle shaft splines.
6. Install the CV joint bearing to the axle shaft.
7. Install the CV joint circlip to the axle shaft.
8. Pack the bearing cavity with grease supplied in the repair
kit.
9. Apply a bead of sealant to the outer sealing surface of the
inner CV joint ring (as shown).
10. Using a mallet, tap on a new inner CV joint cover (1).

3 - 10 HALFSHAFTS ZH
11. Install the CV boot into the sealing groove of the inner
seal.
12. Position the inner and outer retaining clamps (1) on the
CV boot.
13. Position the crimping tool (1) on the retaining clamp (3).
Note: The jaws of the crimping tool must be closed com-

pletely for proper sealing.
14. Crimp the new CV boot retaining clamp (3).

15. Install the halfshaft to the vehicle. Refer to Page 3-5.
ZH HALFSHAFTS 3 - 11
CV BOOT - OUTER
REMOVAL
Note: The outer boot the of the halfshaft can only be
replaced after disassembling the inner CV joint.

2. Remove the inner CV boot from the halfshaft. Refer to
Page 3-7.
3. Remove the outer CV boot retaining clamps (1).
4. Remove the outer CV boot (2) from the CV joint inner seal.
5. Slide the outer CV boot off of the axle shaft.

INSTALLATION
1. Pack the outer CV joint cavity with grease supplied in the
repair kit.
2. Install the outer CV (1) boot into the sealing groove (2) of
the inner seal.
3. Position the inner and outer retaining clamps (1) on the CV

boot (2).


6. Install the halfshaft (2) to the vehicle. Refer to Page 3-5.
CV JOINT
REMOVAL
2. Remove and discard both inner CV boot retaining clamps
(1).
3. Clamp the halfshaft in a vise.

4. Use a suitable tool to remove the inner CV joint cover (1)
from the bearing retainer.
5. Slide the CV boot away from the inner seal (1).

6. Use a suitable tool and remove the inner seal (1) from the
bearing retainer.
7. Slide the CV boot, inner seal, and the bearing retainer
down the axle shaft away from the inner bearing.
8. Remove the CV joint circlip from the axle shaft.
9. Using a press, remove the CV joint bearing (1) from the

axle shaft.
INSPECTION
DISASSEMBLING
1. Before disassembling the CV joint assembly, mark the posi-
tions of joint ring, joint hub and the bearing cage with a
suitable marking tool.
2. Tilt the joint hub with the bearing cage (arrow) and remove
the bearing balls one at a time.
3. Remove the joint hub and the bearing cage from the joint
ring.
4. Pivot the joint hub 90° relative to the bearing cage and
remove it from the assembly.
5. Thoroughly clean all the parts.
INSPECTION
1. Inspect the roller tracks in the joint ring (1), joint hub (4)
and the bearing cage (2). Check the bearing balls (3) them-
selves for signs of pitting or wear.
2. If these parts are extremely worn, the entire CV joint must
be replaced. Smooth areas and tracks caused by the ball
bearings are no reason to replace the CV joint.
ASSEMBLING
1. Hold the joint hub vertically relative to bearing cage, then
guide it into place.
2. Insert one bearing ball, paying attention to the marks on the

joint hub and bearing cage.
3. Insert the joint hub with the bearing cage and the bearing
ball in the joint ring while ensuring that the markings are
properly aligned.
4. If no markings are present when installing the joint ring,

ensure that the narrow side of the roller track is always
opposite the wide side of the joint hub.
5. Tilt the joint hub out with the bearing cage to allow the
bearing balls to be inserted one after the other.
INSTALLATION
1. Before installing the CV boot, cover the shaft splines to pro-
tect the CV boot during installation.
2. Slide the inner CV boot on the axle shaft.
3. Remove the protective cover from the axle shaft splines.
4. Install the CV joint bearing to the axle shaft.
5. Install the CV joint circlip to the axle shaft.
6. Pack the bearing cavity with grease supplied in the repair
kit.
7. Apply a bead of sealant to the outer sealing surface of the

inner CV joint ring (as shown).
8. Using a mallet, tap on a new inner CV joint cover (1).
9. Install the CV boot into the sealing groove of the inner seal.
10. Position the inner and outer retaining clamps (1) on the
CV boot.


13. Install the halfshaft (2) to the vehicle. Refer to Page 3-5.
3 - 22 PROPELLER SHAFT ZH
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 SINGLE CARDAN UNIVERSAL JOINTS
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - PROPELLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CENTERING AND FITTED SLEEVES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL - CENTERING SLEEVES . . . . . . . 35
SPECIFICATIONS REMOVAL - FITTED SLEEVES . . . . . . . . . . . 35
SPECIFICATIONS - CENTERING SLEEVES . 30 INSTALLATION
SPECIFICATION - RUNOUT .......... . . . 30 INSTALLATION - CENTERING SLEEVES . . . . 36
SPECIFICATIONS - TORQUE ......... . . . 30 INSTALLATION - FITTED SLEEVES . . . . . . . . 36
CENTER BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ZH PROPELLER SHAFT 3 - 23
PROPELLER SHAFT
DESCRIPTION
1 - TRANSMISSION 5 - CENTER BEARING

2 - FLEXIBLE DISK 6 - UNIVERSAL JOINT
3 - FRONT SECTION 7 - REAR SECTION
4 - SLIP JOINT 8 - REAR DIFFERENTIAL
A two-piece driveshaft links the transmission and rear axle through two flexible disks and one universal joint to
minimize driveline vibrations.
WARNING
Use exact replacement hardware for attaching the propeller shafts. Exact replacement with original Mopar parts will
ensure safe operation. The specified torque must always be applied when tightening any fasteners.
CAUTION: Propeller shafts are balanced by the manufacturer. Before undercoating a vehicle, the propeller
shaft and universal joints should be covered. This will prevent the undercoating from causing an unbal-
anced condition and vibration.
CAUTION: Never allow the propeller shaft to drop or hang from universal joint during removal. Suspend the
shaft to the vehicles underside with wire to prevent damage to the universal joints.
CAUTION: Protect the machined external surface of the slip yoke from damage after propeller shaft removal.
If damaged, the transmission extension seal could be damaged and cause a leak.
DIAGNOSIS AND TESTING - PROPELLER SHAFT

VIBRATION
Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration.
Brake rotors that are unbalanced will cause a harsh, low frequency vibration.
Driveline vibration can also result from loose or damaged engine mounts.
Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed
range is not usually caused by a propeller shaft being unbalanced. Defective universal joints, or an incorrect pro-
peller shaft angle, are usually the cause of such a vibration.
DRIVELINE VIBRATION
PROPELLER SHAFT NOISE 1. Undercoating or other foreign 1. Clean exterior of shaft and wash
material on shaft. with solvent.
2. Loose or bent U-joint yoke or 2. Install new yoke.
excessive runout.
3. Incorrect driveline angularity. 3. Measure and correct driveline
angles.
4. Worn U-joint bearings. 4. Install new U-joint.
5. Propeller shaft damaged or out 5. Install new propeller shaft.
of balance.
6. Excessive runout or unbalanced 6. Re-index propeller shaft, test, and
condition. evaluate.
7. Excessive axle yoke deflection. 7. Inspect and replace yoke if
necessary.
UNIVERSAL JOINT NOISE 1. Lack of lubrication. 1. Replace U-joints as necessary.
BALANCE
If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure:
2. Clean all the foreign material from the propeller shaft and the universal joints.
Note: If the propeller shaft is bent, it must be replaced.
3. Inspect the propeller shaft for missing balance weights, broken welds, and bent areas.
4. Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with
the shaft.
5. Check the universal joint clamp bolts for proper torque.
6. Check the propeller shaft to transmission and differential flange retaining bolts for proper torque.
7. Remove the wheels and tires. Install the wheel mounting studs to retain the brake rotors.
8. Mark and number the propeller shaft six inches from the transmission end at four positions 90° apart.
9. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop
the engine.
10. Install a screw clamp (1) at position 1.

11. Start the engine and re-check for vibration. If there is little
or no change in vibration, move the clamp to one of the
other three positions. Repeat the vibration test.
12. If there is no difference in vibration at the other positions,
the source of the vibration may not be the propeller shaft.
13. If the vibration decreased, install a second clamp and

repeat the test.
14. If the additional clamp causes an additional vibration, sep-

arate the clamps 0.5 inch (13 mm.) above and below the
mark). Repeat the vibration test.
15. Increase the distance between the clamps and repeat the
test until the amount of vibration is at the lowest level.
Bend the slack end of the clamps so the screws will not
loosen.
16. If the vibration remains unacceptable, apply the same
steps to the differential end of the propeller shaft.
17. Install the wheels and tires. Refer to Page 22-42.
18. Lower the vehicle.
RUNOUT
1. Remove dirt, rust, paint, and undercoating from the propeller shaft surface where the dial indicator will contact
the shaft.
2. The dial indicator must be installed perpendicular to the shaft surface.
3. Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the
effects of the weld process will not enter into the measurements.
4. Refer to Runout Specifications chart.
5. If the propeller shaft runout is out of specification, remove the propeller shaft, index the shaft 180°, and re-install
the propeller shaft. Measure shaft runout again.
6. If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation.
7. If the propeller shaft runout is not within specifications, verify that the runout of the transmission and axle flanges
are within specifications. Correct as necessary and re-measure propeller shaft runout.
8. Replace the propeller shaft if the runout still exceeds the limits.
REMOVAL
Note: Mark the location of the front and rear propeller
shaft flange to the transmission output flange and the rear
axle pinion flange to maintain proper balance of the driv-
eline.

2. Remove the exhaust system. Refer to Page 11-5.
3. Remove the center exhaust heat shield nuts (1) and the
center heat shield.
4. Remove the rear transmission tunnel support bracket bolts

(1) and the bracket.
5. Support the transmission with a jack stand.

6. Remove the transmission mount bolts (1).
7. Remove the transmission crossmember bolts (2).
8. Remove the transmission crossmember from the vehicle.
9. Remove the three rear propeller shaft bolts (1) from the
rear axle pinion flange.
10. Remove the rear propeller shaft from the rear axle pinion
flange.
11. Remove the three front propeller shaft bolts from the
transmission output flange.
12. Remove the front propeller shaft from the transmission
output flange.
13. Remove the center bearing bracket bolts (1).

14. Carefully remove the propeller shaft from the vehicle.
INSTALLATION
Note: Align the marks of the front and rear propeller shaft
flange to the transmission output flange and the rear axle
pinion flange. Failure to do so will not maintain the proper
balance of the driveline.
Note: All self locking nuts and bolts must be replaced.
1. Position the propeller shaft in the vehicle.

2. Support the propeller shaft with a jack stand.
3. Align the center bearing bracket and install the bolts (1).
Tighten the bolts to 30 N·m (22 ft. lbs.).
4. Install the rear propeller shaft to the rear axle pinion flange.
5. Install the three rear propeller shaft bolts (1) to the rear
axle pinion flange. Tighten the bolts to 60 N·m (44 ft. lbs.).
6. Install the front propeller shaft to the transmission output
flange.
7. Install the three front propeller shaft bolts to the transmis-
sion output flange. Tighten the bolts to 60 N·m (44 ft. lbs.).
8. Install the transmission tunnel support bracket.

9. Install the transmission tunnel support bracket bolts (1).
10. Position the transmission crossmember and transmission

mount on the vehicle.
11. Install the transmission mount bolts (1). Tighten the bolts
to 45 N·m (33 ft. lbs.).
12. Install the transmission crossmember bolts (2). Tighten the
bolts to 45 N·m (33 ft. lbs.).
13. Install the rear exhaust heat shield and nuts (1). Tighten
the nuts to 10 N·m (89 in. lbs.).
14. Remove the jack stand supporting the transmission.
15. Install the exhaust system. Refer to Page 11-7.
SPECIFICATIONS
SPECIFICATIONS - CENTERING SLEEVES
CENTERING SLEEVE SPECIFICATIONS
DESCRIPTION In mm
Automatic Transmission Front 1.13 28.8
Sleeve
Automatic Transmission Rear 0.98 24.9
Sleeve
Manual Transmission Front Sleeve 1.06 26.8
Manual Transmission Rear Sleeve 1.06 26.9
SPECIFICATION - RUNOUT
Note: Measure front/rear runout approximately 3 inches (76 mm) from the weld seam at each end of the
shaft tube for tube lengths over 30 inches. For tube lengths under 30 inches the maximum allowed runout
is 0.020 in. (0.50 mm) for the full length of the tube.
RUNOUT SPECIFICATIONS
LOCATION In. mm
Front Of Shaft 0.020 0.50
Center Of Shaft 0.025 0.63
Rear Of Shaft 0.020 0.50

Center Bearing Bracket
45 33 —
Bolts
Heat Shield Nuts 10 — 89
Rear Axle Pinion Flange
60 44 —
Bolts
Transmission
45 33 —
Crossmember Bolts
Transmission Mount Bolts 45 33 —
Transmission Output
60 44 —
Flange Bolts
Transmission Tunnel
20 15 —
Support Bracket Bolts
CENTER BEARING
REMOVAL
1. Remove the propeller shaft. Refer to Page 3-31.
2. Separate the propeller shaft sections.
3. Use a jaw puller to remove the rubber mount and the bear-
ing (2) from the propeller shaft (1).
INSTALLATION
1. Press the bearing into the rubber mount.
2. Press the bearing and rubber mount onto the propeller
shaft using a shop press and bearing adapter.
3. Grease the propeller shaft splines with MoparT heavy duty
grease.
4. Fit the two propeller shaft sections together.
5. Install the propeller shaft in the vehicle. Refer to Page
3-28.
SINGLE CARDAN UNIVERSAL JOINTS

DISASSEMBLY
Note: Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be
replaced as an assembly.

2. Tap the outside of the bearing cap assembly with a drift to loosen the snap ring.
3. Remove the snap rings (1) from both sides of the yoke.
4. Set the yoke in an arbor press or vise with a socket whose

inside diameter is large enough to receive the bearing cap
positioned beneath the yoke.
5. Position the yoke with the grease fitting, if equipped, pointing up.
6. Place a socket (2) with an outside diameter smaller than

the upper bearing cap on the upper bearing cap and press
(1) the cap through the yoke to release the lower bearing
cap.
7. If the bearing cap will not pull out of the yoke by hand after
pressing, tap the yoke ear near the bearing cap to dislodge
the cap.
CAUTION: If the cross or bearing cap are not straight dur-

ing installation, the bearing cap will score the walls of the
yoke bore and damage can occur.
8. To remove the opposite bearing cap, turn the yoke over

and straighten the universal joint in the open hole. Then,
carefully press the end of the universal joint until the
remaining bearing cap can be removed.
ASSEMBLY
1. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to the inside of the yoke bores.
2. Position the universal joint (1) in the yoke (2) with its lube
fitting, if equipped, pointing up.
3. Place a bearing cap (1) over the trunnion (2) and align the
cap with the yoke bore. Keep the needle bearings upright in
the bearing cap.
4. Press the bearing cap into the yoke bore enough to clear
the snap ring groove.
5. Install a snap ring.
Note: If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings.
6. Repeat the procedure to install the opposite bearing cap.

7. Add grease to the lube fitting, if equipped.
8. Install the propeller shaft. Refer to Page 3-28.
CENTERING AND FITTED SLEEVES

REMOVAL
REMOVAL - CENTERING SLEEVES
1. Remove propeller shaft. Refer to Page 3-26.
2. Mark flexible disk (4) relative to flange (2).
3. Remove flexible disk (4) from flange (2).
4. Remove the centering sleeve (3). Use a hammer and chisel
if necessary.
REMOVAL - FITTED SLEEVES

2. Remove the flange bolt and nut.
3. Use a drift punch (2) or extension to loosen the fitted
sleeve (1).
4. Remove the fitted sleeve (1).
INSTALLATION
INSTALLATION - CENTERING SLEEVES
1. Inspect centering sleeves and flexible disks for cracks and wear. Replace as required.
2. Fill centering sleeve cavities with heavy duty Mopar grease.
3. Press in new sleeves.
4. Measure sleeve depth from top of sleeve to face of flange.
5. Assemble the flange and flexible disk with the new sleeve as marked.
INSTALLATION - FITTED SLEEVES

1. Clean and inspect the flexible disk and flange. Replace any worn or damaged parts.
2. Install the new fitted sleeve or sleeves. Tighten the bolts and nuts to 40 N·m (30 ft. lbs.).
ZH REAR DIFFERENTIAL 3 - 37
REAR DIFFERENTIAL
TABLE OF CONTENTS
page page
REAR DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37 PINION FLANGE SEAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
STANDARD PROCEDURE - DRAIN AND DIFFERENTIAL CONNECTING FLANGE SEAL
REFILL ...................... . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIAL TOOLS ................ . . . . . . . 41
REAR DIFFERENTIAL HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REAR DIFFERENTIAL
DESCRIPTION
The rear axle is equipped with a 3.27:1 ratio for the optimum combination of performance and economy.
OPERATION
The axle receives power from the transmission through the propeller shaft. The propeller shaft is connected to the
pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case.
The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are
splined to the axle shafts.

GEAR NOISE
Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, tooth contact,
worn/damaged gears, or the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving
condition. These conditions are acceleration, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle
to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the
noise stops or changes greatly:
• Check for insufficient lubricant.
• Incorrect ring gear backlash.
• Gear damage.
Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during
straight-ahead driving when the gears are unloaded. The side gears are loaded during vehicle turns. A worn pinion
shaft can also cause a snapping or a knocking noise.
3 - 38 REAR DIFFERENTIAL ZH
BEARING NOISE
The halfshafts, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be
either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will
be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing noise
occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front
pinion bearing is the source.
Worn or damaged differential bearings usually produce a low pitch noise. Differential bearing noise is similar to
pinion bearing noise. The pitch of differential bearing noise is also constant and varies only with vehicle speed.
Rear wheel hub bearings produce noise and vibration when worn or damaged. The noise generally changes when
the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the
bearings and change the noise level. Where bearing damage is slight, the noise is usually not noticeable at speeds
above 30 mph.
LOW SPEED KNOCK

Low speed knock is generally caused by worn universal joints. A worn pinion shaft bore will also cause a low speed
knock.
VIBRATION
Vibration at the rear of the vehicle is usually caused by a:
• Damaged propeller shaft.
• Missing propeller shaft balance weight(s).
• Worn or out-of-balance wheels.
• Loose wheel studs.
• Worn U-joint(s).
• Damaged rear wheel hub bearings.
• Loose pinion gear nut.
• Excessive pinion yoke run out.
• Damaged halfshafts.
Check for loose or damaged front-end components or engine/transmission mounts. These components can contrib-
ute to what appears to be a rear end vibration. Do not overlook engine accessories, brackets and drive belts.
All driveline components should be examined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by:
• High engine idle speed.
• Transmission shift operation.
• Loose engine/transmission.
• Worn U-joints.
• Loose pinion gear nut and yoke.
• Excessive ring gear backlash.
• Excessive side gear to case clearance.
• Damaged halfshafts.
The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise and support the
vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the
noise, a mechanics stethoscope is helpful in isolating the source of a noise.
DIAGNOSTIC CHART
WHEEL NOISE 1. Wheel loose. 1. Tighten loose wheel bolts.
2. Faulty wheel hub bearing. 2. Replace bearing.
DIFFERENTIAL CRACKED 1. Improper adjustment of the

1. Replace differential.
differential bearings.
2. Excessive ring gear backlash. 2. Replace differential.

3. Erratic clutch operation. 3. Replace differential.
DIFFERENTIAL GEARS SCORED 1. Replace differential. Fill

1. Insufficient lubrication. differential with the correct fluid type
and quantity.
2. Replace differential. Fill

2. Improper grade of lubricant. differential with the correct fluid type
and quantity.
LOSS OF LUBRICANT 1. Drain lubricant to the correct

1. Lubricant level too high.
level.
2. Worn differential side seals. 2. Replace seals.

3. Cracked differential housing. 3. Replace as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Differential cover not properly
6. Remove, clean, and reseal cover.
sealed.
AXLE OVERHEATING 1. Lubricant level low. 1. Fill differential to correct level.
2. Fill differential with the correct

2. Improper grade of lubricant.
fluid type and quantity.
GEAR TEETH BROKE 1. Overloading. 1. Replace differential.
2. Erratic clutch operation. 2. Replace differential.

3. Ice-spotted pavement. 3. Replace differential.
4. Improper adjustments. 4. Replace differential.
DIFFERENTIAL NOISE 1. Fill differential with the correct

1. Insufficient lubricant.
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
3. Unmatched ring gear and pinion. 3. Replace differential.
4. Worn teeth on ring gear and/or
pinion.
5. Loose pinion bearings. 5. Replace differential.
6. Loose differential bearings. 6. Replace differential.
7. Misaligned or sprung ring gear. 7. Replace differential.
STANDARD PROCEDURE - DRAIN AND REFILL
1. Drive the vehicle until the differential lubricant is at the normal operating temperature.
3. Remove the differential housing fill plug (1).
4. Position a drain pan under the differential housing drain.
5. Remove the differential housing drain plug (2).
6. Drain the differential housing completely.
7. Install the differential housing drain plug (2). Tighten the drain plug to 50 N·m (37 ft. lbs.).
8. Fill the rear axle to proper specifications.
9. Install the differential housing fill plug (1). Tighten the fill plug to 50 N·m (37 ft. lbs.).

Differential Housing Cover 30 + 45° 22 + 45° —
Bolts
Differential Housing Front 110 82 —
Mounting Bolts
Differential Housing Rear 45 33 —
Mounting Bolts
Pinion Shaft Nut 180 133 —
SPECIAL TOOLS
PINION SEAL INSTALLER 9231
AXLE FLANGE SEAL INSTALLER 9223
REAR DIFFERENTIAL HOUSING

REMOVAL
3. Drain the rear differential housing. Refer to Page 3-40.
4. Support the differential housing with a jack.
5. Separate the halfshafts from the differential connecting
flanges and tie them to the rear differential carrier. Refer to
Page 3-4.
6. Remove the differential housing front mounting bolt (1).
7. Remove the two differential housing rear mounting bolts

(1).
8. Remove the differential housing from the vehicle.
INSTALLATION
Note: Replace the self locking bolts and shims. Lightly oil
the bolt at the thread and bolt head contact surfaces.
1. Position the differential housing in the vehicle and support it

with a jack.
2. Install the two differential housing rear mounting bolts (1)
and washers.
3. Install the differential housing front mounting bolt (1).

4. Tighten the differential housing rear mounting bolts to 110
N·m (82 ft. lbs.).
5. Tighten the differential housing front mounting bolt and nut
to 45 N·m (33 ft. lbs.).
6. Connect the halfshafts to the rear differential connecting

flanges. Refer to Page 3-5.
7. Remove the differential housing support jack.
9. Fill the differential housing to proper specification. Refer to
Page 3-40.
PINION FLANGE SEAL

REMOVAL
2. Drain the differential housing. Refer to Page 3-40.
4. Disconnect the propeller shaft from the rear pinion flange
and position out of way. Refer to Page 3-26.
5. Disconnect the halfshafts at the differential connecting
flanges and position them aside. Refer to Page 3-4.
6. Use the torque meter (1) to measure resistance to rotation
at the pinion flange. Record the amount of friction torque.
7. Using the Special Tool C-3281 Flange Wrench (2) to hold

the pinion flange (1).
8. Remove and discard the collared nut.
9. Remove the pinion flange (1).
10. Remove the pinion flange seal (1) with a suitable prying
tool.
INSTALLATION
1. Remove any burrs or nicks from the seal bore.
2. Drive in a new pinion flange seal (1) using Special Tool
9231 Drift and a mallet.
3. Install the pinion flange.

4. Install a new pinion shaft collared nut. Hold the pinion
flange (1) with Special Tool C-3281 Flange Wrench (2).
Tighten the nut to 180 N·m (133 ft. lbs.).
5. Check the resistance to rotation torque. If the resistance is
less than the previously recorded value, tighten the pinion
in 5 N·m (44 in. lbs.) increments until the resistance amount
is reached.
6. Connect the halfshafts to the differential connecting flanges.
Refer to Page 3-5.
9. Fill the differential housing to specification. Refer to Page
3-40.
DIFFERENTIAL CONNECTING FLANGE SEAL

REMOVAL
1. Remove the differential housing and place on a suitable
work bench. Refer to Page 3-41.
Note: If a replacement end cover is fitted, be sure to

check whether or not the sealing surface is machined.
Use appropriate sealant. Install end cover.
2. Remove the differential housing cover bolts (1) and the

cover.
3. Remove the differential connecting flange locking ring (1).

4. Remove the differential connecting flange from the differen-
tial housing assembly.
5. Inspect the differential connecting flange for galling or
grooving. Replace the differential connecting flange if there
are signs of wear.
CAUTION: Do not scrape or damage the surface of the

seal bore.
6. Remove the differential connecting flange oil seal (1) with a

suitable prying tool.
INSTALLATION
1. Using the Special Tool 9223 Drift (1), drive the new differ-
ential connecting flange oil seal (2) into the differential
housing.
2. Lubricate the seal with hypoid gear oil.
3. Inspect the differential connecting flange sealing surface (1)

and dust shield (2). Install the differential connecting flange
to the differential housing assembly.
4. Install the differential connecting flange locking ring (1).

Check for proper fit.
5. Check axial end play between the differential connecting
flange and the differential housing. (.03 mm to .3 mm).
Note: If a replacement cover is fitted, be sure to check

whether or not the sealing surface is machined. Use
appropriate sealant. Install end cover.
6. Apply a 1.5 mm to 2.0 mm bead of Hylomar sealant to the

differential housing cover sealing surface.
7. Install the differential housing cover.

8. Install the differential housing cover bolts (1). Tighten the
bolts to 30 N·m (22 ft. lbs.) plus 45°.
9. Install the differential. Refer to Page 3-42.
ZH BRAKES 5-1
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS SERVICE INFORMATION . . . . . . 187

BRAKES - ABS ELECTRICAL DIAGNOSTICS . . . . 79
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE REMOVAL

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FRONT DISC BRAKE CALIPER . . . . . . . . . . . 25
WARNING .............................4 REMOVAL - REAR BRAKE CALIPER . . . . . . . 28
DIAGNOSIS AND TESTING DISASSEMBLY - FRONT DISC BRAKE
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . 5 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE CLEANING - DISC BRAKE CALIPER . . . . . . . . . 30
MANUAL BLEEDING . . . . . . . . . . . . . . . . . . . . 9 INSPECTION - DISC BRAKE CALIPER . . . . . . . 30
STANDARD PROCEDURE - PRESSURE ASSEMBLY - FRONT DISC BRAKE CALIPER . . 31
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION
SPECIFICATIONS FRONT DISC BRAKE CALIPER . . . . . . . . . . . 32
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . 10 INSTALLATION - REAR DISC BRAKE
BRAKE LINES CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 ROTORS
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING
BRAKE HOSES AND LINES . . . . . . . . . . . . . . 10 DISC BRAKE ROTORS . . . . . . . . . . . . . . . . . 36
STANDARD PROCEDURE STANDARD PROCEDURE
DOUBLE INVERTED FLARING . . . . . . . . . . . 11 DISC BRAKE ROTOR MACHINING . . . . . . . . 38
STANDARD PROCEDURE - ISO FLARING . . 11 REMOVAL
REMOVAL FRONT DISC BRAKE ROTOR . . . . . . . . . . . . 38
FRONT BRAKE HOSE . . . . . . . . . . . . . . . . . . 12 REMOVAL - REAR DISC BRAKE ROTOR . . . 39
REAR BRAKE HOSE . . . . . . . . . . . . . . . . . . . 13 INSTALLATION
INSTALLATION FRONT DISC BRAKE ROTOR . . . . . . . . . . . . 40
FRONT BRAKE HOSE . . . . . . . . . . . . . . . . . . 14 INSTALLATION - REAR DISC BRAKE
INSTALLATION - REAR BRAKE HOSE . . . . . . 16 ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
BRAKE PADS/SHOES FLUID
REMOVAL DIAGNOSIS AND TESTING
FRONT DISC BRAKE PADS . . . . . . . . . . . . . 17 BRAKE FLUID CONTAMINATION . . . . . . . . . . 42
REMOVAL - REAR DISC BRAKE PADS . . . . . 19 STANDARD PROCEDURE
INSTALLATION MASTER CYLINDER FLUID LEVEL . . . . . . . . 43
FRONT DISC BRAKE PADS . . . . . . . . . . . . . 20 SPECIFICATIONS
INSTALLATION - REAR DISC BRAKE PADS . 23 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 43
DISC BRAKE CALIPERS MASTER CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 44
5-2 BRAKES - BASE ZH
OPERATION DIAGNOSIS AND TESTING

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 44 PARKING BRAKE ....... . . . . . . . . . . . . . . 58
DIAGNOSIS AND TESTING ADJUSTMENTS
MASTER CYLINDER/POWER BOOSTER . . . . 44 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 59
DIAGNOSIS AND TESTING - MASTER CABLES
CYLINDER FLUID LOSS . . . . . . . . . . . . . . . . 45 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
MASTER CYLINDER BLEEDING LEVER
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 46 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47 SHOES
POWER BRAKE BOOSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 BRAKE FLUID LEVEL SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 75
PEDAL BRAKE PRESSURE SENSOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 TRAVEL SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
PARKING BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ZH BRAKES - BASE 5-3
BRAKES - BASE
DESCRIPTION
1 - BAS BRAKE BOOSTER 8 - BAS DIAPHRAGM TRAVEL SENSOR

2 - BAS SOLENOID VALVE 9 - COMPRESSION SPRING
3 - AIR FILTER 10 - OUTPUT ROD
4 - AIR FILTER 11 - CABLE CONNECTOR FOR RELEASE SWITCH AND
5 - POPPET VALVE SOLENOID VALVE
6 - BAS RELEASE SWITCH 12 - VACUUM CONNECTION
7 - VACUUM PISTON 13 - POWER DIAPHRAGM
Power brake assist is supplied by a vacuum operated, power brake booster.

Single piston brake calipers (3) are used on the front and on
the rear. Ventilated disc brake rotors (2) are used on the front
and solid disc brake rotors are used on the rear.
The master cylinder is used for all applications. The master

cylinder has an aluminum body and a nylon reservoir with a
single filler cap. A fluid level indicator (2) is molded into the top
of the reservoir. The fill levels (1) are located on the side.
Factory installed brake linings consist of organic base material

combined with metallic particles.
WARNING
WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN
ASBESTOS FIBERS FROM AFTERMARKET LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF
ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. USE A VACUUM
CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF ASBESTOS FIBERS FROM BRAKE COMPO-
NENTS. IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS
DESIGNED TO CONTAIN THE DUST RESIDUE. DISPOSE OF ALL RESIDUE CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS TO MINIMIZE EXPOSURE TO YOURSELF AND OTHERS. FOLLOW
PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION AND THE
ENVIRONMENTAL PROTECTION AGENCY FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST
OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing min-
eral oil to clean the system components. These fluids damage rubber cups and seals. Use only fresh brake
fluid or Mopar brake cleaner to clean or flush brake system components. These are the only cleaning mate-
rials recommended. If system contamination is suspected, check the fluid for dirt, discoloration, or separa-
tion into distinct layers. Also check the reservoir cap seal for distortion. Drain and flush the system with
new brake fluid if contamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent quality fluid meeting SAE/DOT standards J1703 and DOT
4. Brake fluid must be clean and free of contaminants. Use fresh fluid from sealed containers only to ensure
proper antilock component operation.
CAUTION: Use Mopar multi-mileage or high temperature grease to lubricate caliper slide surfaces, drum
brake pivot pins, and shoe contact points on the backing plates. Use multi-mileage grease or GE 661 or
Dow 111 silicone grease on caliper slide pins to ensure proper operation.

BASE BRAKE SYSTEM
The base brake system components consist of front and rear brake pads and calipers. Rear park brake drums and
shoes which are internal to the rear rotor. Front and rear brake rotors and brake lines. The master cylinder, booster
and the HCU.
Brake diagnosis involves determining if the concern is related to a mechanical, hydraulic, electrical or vacuum oper-
ated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK

(1) Check the condition of the tires and wheels. Damaged wheels and worn, damaged or under inflated tires can
cause a pull, shudder, vibration and a condition similar to grab.
(2) If a complaint was based on noise while braking, check the suspension components. Jounce the front and the
rear of vehicle and listen for anything that might be caused by a loose, worn or damaged suspension or steering
component.
(3) Inspect the brake fluid level and condition. Note that the brake reservoir fluid level will decrease in proportion to
normal lining wear. ALSO NOTE THAT BRAKE FLUID TENDS TO DARKEN OVER TIME. THIS IS NORMAL AND
SHOULD NOT BE MISTAKEN FOR CONTAMINATION.
(a) If the fluid level is abnormally low, look for any evidence of leaks at the calipers, brake lines, master cylinder and
at the HCU.
(b) If the fluid appears to be contaminated, drain out a sample to examine. The system will have to be flushed if the
fluid is separated into layers , or contains a substance other than brake fluid. The system seals, cups, hoses, master
cylinder and HCU will also have to be replaced after flushing. Use clean brake fluid to flush the system.
(4) Check the parking brake operation. Verify free movement and full release of the cables and the lever. Also note
if the vehicle was being operated with parking brake partially applied.
(5) Check the brake pedal operation. Verify that pedal does not bind and has adequate free play. If the pedal lacks
free play, check the pedal and the power booster for being loose or for a bind condition. DO NOT road test the
vehicle until the condition is located and corrected.
(6) Check the boosters vacuum check valve and hose.
(7) If the components checked appear to be OK, road test the vehicle.
ROAD TESTING
(1) If the complaint involved a low brake pedal, pump the pedal and note if it comes back up to the normal height.
(2) Check the brake pedal response with the transmission in neutral and the engine running. The pedal should
remain firm under constant foot pressure.
(3) During the road test, make normal and firm brake stops in the 25-40 m.p.h. range. Note any faulty brake oper-
ation such as: low pedal, hard pedal, fade, pedal pulsation, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking brake only. DO NOT exceed 25 m.p.h. Note any grab, drag, noise,
etc.
PEDAL FALLS AWAY

A brake pedal that falls away under steady foot pressure is generally the result of a system leak. The leak point
could be a brake line, fitting hose or caliper. If the leaking is severe, fluid will be evident at or around the leaking
component.
Internal leakage (seal by-pass) in the master cylinder is caused by worn or damaged piston cups, may also be the
concern.
An internal leaking ABS system may also be the problem with no visual leak.
LOW PEDAL
If a low pedal is experienced, pump the pedal several times. If the pedal comes back up, the most likely causes are
worn linings, rotors or calipers that are not sliding on the slide pins. The proper course of action is to inspect and
replace all the worn components.
SPONGY PEDAL
A spongy pedal is most often caused by air in the system. However, substandard brake hoses can cause a spongy
pedal. The proper course of action is to bleed the system, and replace the substandard quality brake hoses if sus-
pected.
HARD PEDAL OR HIGH PEDAL EFFORT

A hard pedal or high pedal effort may be due to a pad that is water soaked, contaminated, glazed or badly worn.
The power booster, check valve, check valve seal/grommet or a vacuum leak could also cause hard pedal or high
pedal effort.
PEDAL PULSATION
Pedal pulsation is caused by components that are loose or beyond tolerance limits.
The primary cause of a pulsation are, disc brake rotors with excessive lateral runout or thickness variation, loose
wheel bearings or calipers and worn or damaged tires.
Note: Some pedal pulsation may be felt during ABS activation.
BRAKE DRAG
Brake drag occurs when the lining is in constant contact with the rotor. Drag can occur at one wheel, all wheels,
fronts only or rears only.
Drag is a product of an incomplete brake release. Drag can be minor or severe enough to overheat the linings,
rotors and park brake drums.
A minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in the rotors and
the park brake drums from the overheat-cool down process. In most cases, the rotors, wheels and tires are quite
warm to the touch after the vehicle is stopped.
A severe drag can char the brake linings all the way through. It can also distort and score the rotors to the point of
replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the linings may gen-
erate smoke as it chars from over-heating.
Common causes of brake drag are:
• Parking Brake partially applied
• Loose/warn wheel bearings
• Seized caliper
• Caliper binding
• Loose caliper mounting
• Mis-assembled components
• Damaged brake lines
If the brake drag occurs at the front, rear or at all wheels, the problem may be related to a blocked master cylinder
return port, faulty power booster (binds does not release) or the ABS system.
BRAKE FADE
Brake fade is usually a product of overheating caused by brake drag. However, brake overheating and resulting
fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a short time span,
or constant braking on steep mountain roads. Refer to the Brake Drag information in this section for causes.
BRAKE PULL
A front brake pull condition could result from:
• Contaminated lining in one caliper
• Seized caliper piston
• Binding caliper
• Loose caliper
• Rusty caliper slide surfaces
• Improper brake pads
• Damaged rotor
• Wheel alignment
• Tire pressure
A worn, damaged wheel bearing or suspension component are further cases of pull. A damaged front tire (bruised,
ply separation) can also cause a pull.
A common and frequently misdiagnosed pull condition is where direction of pull changes after a few stops. The
cause is a combination of brake drag followed by fade at one of the brake units.
As the dragging brake overheats, efficiency is so reduced that fade occurs. Since the opposite brake units are still
functioning normally, its braking effect is magnified. This causes the pull to switch direction in favor of the normally
functioning brake unit.
An additional point when diagnosing a change in pull condition concerns brake cool down. Remember that the pull
will return to the original direction, if the dragging brake unit is allowed to cool down (and is not seriously damaged).
REAR BRAKE DRAG OR PULL

Rear drag or pull may be caused by an improperly adjusted park brake shoe or a seized parking brake shoe or a
seized parking brake cable, contaminated lining, bent or binding shoes or improperly assembled components. This
is particularly true when only one wheel is involved. However, when both rear wheels are effected, the master cyl-
inder or ABS system could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES

This condition is generally caused by water soaked brake linings. If the lining is only wet, it can be dried by driving
with the brakes lightly applied for a mile or two. However, if the lining is both soaked and dirt contaminated, cleaning
and or replacement of the pad will be necessary.
BRAKE LINING CONTAMINATION

Brake lining contamination is mostly a product of leaking calipers or worn seals, driving through deep water puddles,
or a lining that has become covered with grease or grit during repair. A contaminated lining should be replaced to
avoid further brake concerns.
WHEEL AND TIRE PROBLEMS

Some conditions attributed to brake components may actually be caused by a wheel or tire concern.
A damaged wheel can cause a shudder, vibration and a pull. A worn or damaged tire can also cause pull.
Note: Propshaft angle can also cause vibration/shudder.
Severely worn tires with very little tread left can produce a grab-like condition as the tire loses and recovers traction.
Flat spotted tires can cause vibration and generate shudder during brake operation. Tire damage such as a severe
bruise, cut, ply separation, low air pressure can cause pull and vibration.
BRAKE NOISES
Some brake noise is common on some disc brakes during the first few stops after a vehicle has been parked over-
night or stored. This is primarily due to the formation of trace corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfaces after a few brake applications causing the noise to subside.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease or oil. Glazed
linings and rotors can also contribute to squeak, Dirt or foreign material embedded in the brake lining will also cause
brake squeal.
A very loud squeak or squeal is frequently a sign of severely worn brake lining. If the lining has worn through the
brake shoes in spots, metal-to-metal contact occurs. If the condition is allowed to continue, rotors may become so
scored that replacement is necessary.
BRAKE CHATTER
Brake chatter is usually caused by loose or worn components, or glazed/burnt linings. Rotors with hard spots can
also contribute to chatter. Additional causes of chatter are out-of-tolerance rotors, brake linings not securely attached
to the shoes, loose wheel bearings and contaminated brake linings.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are frequently NOT caused by brake components. In many cases, such
noises are caused by loose or damaged steering, suspension or engine components.
STANDARD PROCEDURE
MANUAL BLEEDING
CAUTION: Do not get brake fluid on any painted surface. Brake fluid can damage paint.
Use MoparT brake fluid, or an equivalent quality fluid meeting SAE J1703–F and DOT 3 standards only. Use fresh,
clean fluid from a sealed container at all times.
DO NOT pump brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that
are distributed throughout the hydraulic system. This will make additional bleeding operations necessary.
DO NOT allow the master cylinder to run out of fluid during bleeding operations. An empty cylinder will allow addi-
tional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed.
Bleed only one brake component at a time in the following sequence:
1. Fill the master cylinder reservoir with brake fluid.
2. If calipers are overhauled, open the caliper bleed screws. Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more before proceeding.
3. Attach one end of the bleed hose (1) to the bleed screw
and insert the opposite end in a glass container (2) partially
filled with brake fluid. Be sure the end of the bleed hose is
immersed in the brake fluid.
4. Open up the bleeder screw, then have a helper press down
on the brake pedal. Once the pedal is down, close the
bleeder screw. Repeat bleeding until fluid stream is clear
and free of bubbles. Then move to the next wheel.
STANDARD PROCEDURE - PRESSURE

BLEEDING
CAUTION: Do not get brake fluid on any painted surface. Brake fluid can damage paint.
Use MoparT brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 4 standards only. Use fresh,
clean fluid from a sealed container at all times.
DO NOT pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles
that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary.
DO NOT allow the master cylinder to run out of fluid during bleeding operations. An empty cylinder will allow addi-
tional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed.
Follow the manufactures instructions carefully when using pressure equipment. DO NOT exceed the tank manufac-
tures pressure recommendations. Generally, a tank pressure of 51-67 kPa (15-20 psi) is sufficient for bleeding.
Fill the bleeder tank with recommended brake fluid and purge air from the tank lines before bleeding.
DO NOT pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or draw-
ing air back into the system. Use an adapter provided with the equipment.
5 - 10 BRAKES - BASE ZH
SPECIFICATIONS
BRAKE COMPONENTS
SPECIFICATIONS
Front Disc Brake Type Floating
Front Disc Brake Caliper Piston Single
Front Disc Brake Rotor Type Ventilated
Front Disc Brake Rotor Diameter 300mm
Front Disc Brake Rotor Max. Thickness Variation 28mm
Rear Disc Brake Caliper Type Fixed
Rear Disc Brake Rotor Type Diameter Solid
Rear Disc Brake Rotor Max. Thickness Variation 9mm
Rear Disc Brake Rotor Min. Thickness 7.6mm

Brake Booster Mouting Nuts 20 15 177
Front Caliper Anchor Bolts 115 85 1020
Front Caliper Bleed Screw 7 5 62
Front Caliper Slide Pins 25 18 221
Master Cylinder Mounting Nuts 20 15 177
Master Cylinder Primary Brake Line 14 10 124
Master Cylinder Secondary Brake Line 14 10 124
Rear Caliper Anchor Bolts 55 41 487
Rear Caliper Bleed Screw 7 5 62
BRAKE LINES
DESCRIPTION
A flexible rubber hose is used at both front and rear brakes. Double walled steel tubing is used to connect the
master cylinder to the major hydraulic braking components and then to the flexible rubber hoses. Double inverted
style and ISO style flares are used on the brake lines.

BRAKE HOSES AND LINES
A flexible rubber hose is used at both front brakes and rear brakes. Inspect the hoses whenever the brake system
is serviced, at every engine oil change, or whenever the vehicle is in for service.
Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric
casing of the hose is exposed due to cracks or abrasions.
Also check brake hose installation. Faulty installation can result in kinked, twisted hoses, or contact with the wheels
and tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure.
ZH BRAKES - BASE 5 - 11
The steel brake lines should be inspected periodically for evidence of corrosion, twists, kinks, leaks, or other dam-
age. Heavily corroded lines will eventually rust through causing leaks. In any case, corroded or damaged brake lines
should be replaced.
Factory replacement brake lines and hoses are recommended to ensure proper quality and correct length. Care
should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs.
Also remember that right and left brake hoses are not interchangeable.
STANDARD PROCEDURE
DOUBLE INVERTED FLARING
A pre-formed metal tube is recommended and preferred for all repairs. However, double-wall steel tube can be used
for emergency repair when factory replacement parts are not readily available.
Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed
to make double inverted flares or ISO flares.
1. Cut off damaged tube with a Tubing Cutter.
2. Ream the cut edges of the tubing to ensure a proper flare.
3. Install the replacement tube nut on the tube.
4. Insert the tube in the flaring tool.
5. Place the gauge form over the end of the tube.
6. Push the flaring tool through the flaring tool jaws until the
tube contacts the recessed notch in the gauge that
matches the tube diameter.
7. Tighten the tool bar on the tool.
8. Insert the plug on the gauge in the tube. Then swing the
compression disc over the gauge and center the tapered
flaring screw in the recess of the compression disc.
9. Tighten the tool handle until the plug gauge is squarely
seated on the jaws of the flaring tool. This will start the
inverted flare.
10. Remove the plug gauge and complete the inverted flare.
STANDARD PROCEDURE - ISO FLARING

A pre-formed metal tube is recommended and preferred for all repairs. However, double-wall steel tube can be used
for emergency repair when factory replacement parts are not readily available.
Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed
to make double inverted flares or ISO flares.
To make an ISO flare use Snap-OnT Flaring Tool TFM-428 or equivalent.
1. Cut off the damaged tube with a tubing cutter.

2. Remove any burrs from the inside of the tube.
3. Install the tube nut onto the tube.
4. Position the tube in the flaring tool flush with the top of the
tool bar. Then tighten the tool bar on the tube.
5. Install the correct size adapter on the flaring tool yoke
screw.
6. Lubricate the adapter.
7. Align the adapter and the yoke screw over the tube.
8. Turn the yoke screw in until the adapter is squarely seated
on the tool bar.
REMOVAL
FRONT BRAKE HOSE
CAUTION: Do not get brake fluid on any painted surface.
Brake fluid can damage paint.

3. Disconnect the brake hose (4) from the caliper (3).
4. Disconnect the brake hose (3) at the brake line (2) connect-
ing point and remove the hose.
REAR BRAKE HOSE

CAUTION: Do not get brake fluid on any painted surface.
Brake fluid can damage paint.

3. Disconnect the brake hose (1) from the brake line
connection.
4. Disconnect the brake hose at the caliper (3) and remove

the hose.
INSTALLATION
FRONT BRAKE HOSE
1. Connect the brake hose (3) to the brake line connection
(2).
2. Route the brake hose (1) behind the steering knuckle (2)
and connect to the caliper.
3. Connect the brake hose (4) at the caliper (3).

6. Fill and bleed the brake system. Refer to Page 5-9. or
Refer to Page 5-9.
INSTALLATION - REAR BRAKE HOSE

1. Connect the brake hose (1) to the brake line connection.
2. Route the brake hose (1) behind the rear shock (2) and
connect to the caliper (3).
5. Fill and bleed the brake system. Refer to Page 5-9. or
Refer to Page 5-9.
BRAKE PADS/SHOES
REMOVAL
FRONT DISC BRAKE PADS
3. Drain a small amount of fluid from master cylinder brake
reservoir with a clean suction gun.
4. Bottom the caliper pistons into the caliper by prying the cal-
iper over.
5. Remove the caliper support spring (2) by prying the spring
out of the holes (3) in the caliper (1).
6. Disconnect the brake pad wear indicator harness

connector.
7. Remove the caliper slide pin caps (3) and then remove the
caliper slide pins (2) from the caliper (1).
CAUTION: Never allow the disc brake caliper to hang from

the brake hose. Damage to the brake hose will result. Pro-
vide a suitable support to hang the caliper securely.
8. Remove the caliper (1) from the mounting bracket (2).
9. Remove the inboard (2) and outboard (3) brake pads from
the caliper.
REMOVAL - REAR DISC BRAKE PADS

3. Drain a small amount of fluid from the master cylinder
brake reservoir with a clean suction gun.
4. Remove the caliper mounting bolts (1) and remove the cal-
iper from the knuckle.
5. Remove the brake hose (1) from the caliper (2) by rotating
the caliper while holding the brake hose with a line wrench.
6. Using a suitable punch (1) knock out the retaining pin (4)
that holds the pads in place.
7. Remove the anti-rattle clip (3) and remove the brake pads
from the caliper (2).
INSTALLATION
FRONT DISC BRAKE PADS
Note: If the caliper is not bottomed out you must do so in
order to install the caliper onto the rotor. Use a C-clamp to
bottom out caliper.
1. Install the inboard and outboard brake pads (2 and 3) onto

the caliper (1).
2. Lubricate the slide pins (2) and slide pin caps with silicone
grease.
3. Install the caliper (1) on the caliper mounting bracket (2).
4. Install the caliper slide pins (2) and tighten to 29-41 N·m
(21-30 ft. lbs.).
5. Install the caliper slide pin caps (3).
6. Connect the brake pad wear indicator harness connector.
7. Install the caliper support spring (2) in the top end of the
caliper under the caliper mounting bracket (1). Then install
the other end into the lower caliper hole (3). Hold the spring
(2) into the caliper (1) with your thumb while prying the end
of the spring (2) out and down under the caliper mounting
bracket with a screwdriver.
8. Install wheel and tire assembly. Refer to Page 22-42.
9. Lower the vehicle
10. Pump the brake pedal until the caliper pistons and the
brake shoes are seated and a firm brake pedal is
achieved.
11. Top off the brake fluid reservoir with new fluid and check
for leaks.
INSTALLATION - REAR DISC BRAKE PADS

Note: If the caliper is not bottomed out you must do so in
order to install the caliper onto the rotor. Use a C-clamp to
bottom out caliper.
1. Install the brake pads into the caliper by sliding them

through the hole in the top of the caliper.
2. Install the anti-rattle clip (3).
Note: Hold the anti-rattle clip down with your thumb while
tapping the retaining clip into position.
3. Install the retaining pin (4) through the hole in the side of
the caliper (2). Tap the pin (4) into the caliper (2) until it is
threaded through both brake pads and over the anti-rattle
clip (3).
4. Install the brake hose (1) to the caliper (2) by holding the
hose with a line wrench and rotating the caliper until tight.
5. Install the caliper onto the knuckle over the rotor.

6. Install mounting bolts (1) and tighten to 29-41 N·m (21-30
ft. lbs.).
7. Install the tire and wheel assembly. Refer to Page 22-42.
8. Remove the support and lower the vehicle.
9. Pump the brake pedal until the caliper pistons and the
brake shoes are seated and a firm brake pedal is achieved.
10. Top off the brake fluid reservoir with new fluid and check
for leaks.
11. Fill and bleed the brake system.
• Manual Refer to Page 5-9.
• Pressure Refer to Page 5-9.
DISC BRAKE CALIPERS

DESCRIPTION
The calipers are a single piston type. The calipers are free to slide laterally on the anchor, this allows continuous
compensation for lining wear.
The rear disc brakes consist of fixed single piston style calipers and solid rotors. The rear caliper is mounted to the
rear wheel hub. The calipers are directly bolted to the wheel hub with mounting bolts. The disc brake rotor dust
shield is mounted to the hub. The disc brake rotor has a built in drum used for the parking brakes. The parking
brake shoes are mounted to the wheel hub.
OPERATION
When the brakes are applied fluid pressure is exerted against
the caliper piston (2). The fluid pressure is exerted equally and
in all directions. This means pressure exerted against the cal-
iper piston (2) and within the caliper bores (3) will be equal.
Fluid pressure applied to the pistons is transmitted directly to
the inboard brake pad. This forces the pad lining (6) against
the inner surface of the disc brake rotor. At the same time,
fluid pressure within the piston bores forces the caliper to slide
inward on the slide pins. This action brings the outboard brake
pad lining into contact with the outer surface of the disc brake
rotor.
Fluid pressure acting simultaneously on the pistons (2) and
caliper (1) to produces a strong clamping action. When suffi-
cient force is applied, friction will stop the rotors from turning
and bring the vehicle to a stop.
Application and release of the brake pedal generates only a
very slight movement of the caliper (1) and piston (2). Upon
release of the pedal, the caliper and pistons return to a rest
position. The brake pads (5 and 6) do not retract an apprecia-
ble distance from the rotor. In fact, clearance is usually at, or
close to zero. The reasons for this are to keep road debris
from getting between the rotor and lining and in wiping the
rotor surface clear each revolution.
The caliper piston seals (5) control the amount of piston (1)
extension needed to compensate for normal lining wear.
During brake application the seals (6) are deflected outward by
fluid pressure and piston (1) movement. When the brakes (and
fluid pressure) are released, the seals (3) relax and retract the
piston (1).
The front outboard brake pads have electronic wear indicators.
Which when wear is preasant the wear indicator will illuminate
a MIL light on the instrument panel telling the operator of the
brake pad wear concern.
REMOVAL
FRONT DISC BRAKE CALIPER
4. Disconnect the brake pad wear indicator harness
connector.
5. Remove brake pad wear indicator (1) from caliper (2) by

removing the retaining bolt.
6. Bottom the caliper piston into the caliper by prying the cal-
iper over.
7. Remove the caliper support spring (2) by prying the spring

out of the caliper (1).
8. Remove the caliper slide pin caps (3) and slide pins (2)
9. Remove the caliper (1) from the mounting bracket (2).
CAUTION: DO NOT get the brake fluid on any painted sur-

faces. Brake fluid can damage paint.
10. Remove the brake hose (4) from the caliper (3).
11. Remove the inboard and outboard brake pads (2 and 3)

12. Disassemble the caliper to clean and inspect for wear and
damage. Refer to Page 5-29.
REMOVAL - REAR BRAKE CALIPER

2. Remove the rear tire and wheel assembly.
4. Remove caliper mounting bolts (1). Then remove the cali-
per from the knuckle.
CAUTION: DO NOT get the brake fluid on any painted sur-

faces. Brake fluid can damage paint.
5. Remove the brake hose (1) by rotating the caliper (2) while
holding the brake hose (1) with a wrench.
6. Using a suitable punch (1) knock out the retaining pin (4)
that holds the pads in place.
7. Remove the anti-rattle clip (3) and remove the brake pads
8. Disassemble the caliper to check for wear or damage.
Refer to Page 5-29.
DISASSEMBLY - FRONT DISC BRAKE CALIPER

1. Drain the brake fluid from the caliper.
2. Take a piece of wood and pad it with a one-inch thickness
of shop towels. Place this piece (1) in the outboard shoe
side of the caliper (2) in front of the piston.
WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS

IT LEAVES THE BORE THIS COULD RESULT IN PER-
SONAL INJURY.
WARNING: DO NOT BLOW THE PISTON OUT OF THE

BORE WITH SUSTAINED AIR PRESSURE. THIS COULD
RESULT IN A CRACKED PISTON.
3. Remove the caliper piston (2) by using short bursts of low

pressure air with a blow gun (1) through the brake hose
port. Use only enough air pressure to ease the caliper pis-
ton out.
4. Remove the piston dust boot (2) with a suitable pry tool (1)
and discard.
CAUTION: DO NOT SCRATCH PISTON BORE WHILE

REMOVING THE SEALS.
5. Remove piston seal (2) from the caliper with a suitable tool
(1).
6. Remove the caliper bleed screw.
7. Clean the caliper. Refer to Page 5-30.
CLEANING - DISC BRAKE CALIPER

CAUTION: DO NOT use gasoline, kerosene, paint thinner or similar solvents. These products may leave a
residue that could damage the piston and seal.
Clean the caliper components with clean brake fluid or Brake CleanT only. Wipe the caliper and piston dry with lint
free towels or use low pressure compressed air. Refer to Page 5-30.
INSPECTION - DISC BRAKE CALIPER

CAUTION: If the caliper piston is replaced, install the same type piston in the caliper. Never interchange
phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances
are different.
Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a
polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chrome-
plated surface is damaged.
Clean aluminum version with anodized surfaces (piston and housing bore) with soft rag only.
If the piston is jammed or if the cylinder bores are scored or rusted, replace the complete fixed brake caliper and
with the floating brake caliper, replace the cylinder housing. Remove small, light rust spots in the cylinder bore with
a polishing cloth. Remove heavy rust spots in front of the groove for the piston seal using fine-grained emery paper
(grain size 380 to 500).
ASSEMBLY - FRONT DISC BRAKE CALIPER
1 - CALIPER 3 - CALIPER PISTON

2 - CALIPER PISTON SEAL 4 - DUST BOOT
CAUTION: Dirt, oil, and solvents can damage caliper seals. Be sure the assembly area is clean and dry.
1. Lubricate the caliper piston, piston seals and piston bore with clean brake fluid.
Note: Verify seal is fully seated into seal groove and not twisted.
2. Install the new piston seal (2) into the seal groove.
3. Install the new dust boot (4) on the caliper piston (3) and seat the dust boot lip into the piston groove.
4. Stretch the dust boot (4) rearward to straighten the boot folds, then move the boot forward until the fold snaps
into place.
5. Install the piston (3) into the caliper bore and press the piston down to the bottom of the caliper bore by hand or
with the handle of a hammer.
6. Seat the dust boot (4) in caliper (1).
7. Install the new caliper bleed screw.
8. Install the caliper. Refer to Page 5-32.
INSTALLATION
FRONT DISC BRAKE CALIPER
1. Install the inboard and outboard brake pads (2 and 3) onto
the caliper (1).
2. Lubricate the slide pins (2) and slide pin bushings with sil-
icone grease.
3. Install the caliper (1) on the mounting bracket (2).
4. Install the caliper slide pins (2) and tighten to 115 N·m (85
ft. lbs.). Then install the caliper slide pin caps (3).
5. Install the brake pad wear indicator (2) onto the caliper.
Tighten the bolt to 8 N·m (6 ft. lbs.).
6. Connect the brake wear indicator to the brake pad.
7. Install the caliper support spring (2) in the top end of the
caliper and under the mounting bracket (1). Then install the
other end into the lower caliper hole (3). Hold the spring (2)
into the caliper hole (3) with your thumb while prying the
end of the spring (2) out and down under the mounting
bracket with a screwdriver.
CAUTION: Verify brake hose is not twisted or kinked

before tightening the fitting.
8. Connect the brake hose (4) to the caliper (3).

9. Fill and bleed brake system.
• Manual. Refer to Page 5-9.
• Pressure. Refer to Page 5-9.
WARNING: DO NOT MOVE THE VEHICLE UNTIL A FIRM

BRAKE PEDAL IS ACHIEVED.
11. Verify the brake fluid level and pump up the brake system
until the brake pedal is firm.
INSTALLATION - REAR DISC BRAKE CALIPER

1. Install the rear brake pads. Refer to Page 5-20.
2. Install the brake hose (1) to caliper (2) by holding the brake
hose (1) with a wrench and rotating caliper (2) until snug.
Fully tighten the brake hose after the caliper is installed.
CAUTION: Verify the brake hose is not twisted or kinked

before installing the caliper to the knuckle.
3. Install the caliper to the knuckle. Install the mounting bolts.


WARNING: DO NOT MOVE VEHICLE UNTIL FIRM BRAKE

PEDAL IS OBTAINED.
6. Pump the brake pedal until a firm pedal is achieved.

ROTORS
DISC BRAKE ROTORS
REAR ROTOR MINIMUM THICKNESS
Minimum usable thickness of the rear disc brake rotor is 0.299
in. (7.6 mm). The thickness specification is located on the cen-
ter section of the rotor.
Never resurface a rotor if at minimum thickness. Machining the
rotor would cause the thickness to fall below the limit.
Measure rotor (2) thickness at the center of the brake shoe
contact surface using a micrometer (1). Replace the rotor if
worn below minimum thickness, or if refinishing would reduce
thickness below the allowable minimum.
REAR ROTOR THICKNESS VARIATION

Variations in rotor thickness will cause pedal pulsation, noise and shudder.
Measure rotor thickness at a minimum of six points around the rotor face. Position the micrometer approximately 3/4
in.(19 mm) from the rotor outer circumference for each measurement.
Thickness should not vary by more than 0.0005 in. (0.0127 mm.) from point to point on the rotor. Refinish or replace
the rotor if necessary.
REAR ROTOR LATERAL RUNOUT

Check rotor lateral runout whenever diagnosis indicates pedal
pulsation and rapid, uneven brake lining wear.
The rotor must be securely clamped to the hub to ensure an
accurate runout measurement. Secure the rotor with the wheel
nuts and 4 or 5 large diameter flat washers on each stud.
Use a dial indicator (1) to check rotor lateral runout. Maximum
allowable lateral runout is 0.76 mm (0.003 in.).
FRONT ROTOR MINIMUM THICKNESS

Rotor minimum thickness is 0.889 in. (22.6 mm). Do not resurface a rotor if at minimum thickness. Machining would
cause thickness to fall below this limit.
Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if worn below the min-
imum thickness, or if refinishing would reduce thickness below the allowable limit.
FRONT ROTOR THICKNESS VARIATION

Variations in rotor thickness will cause pedal pulsation, noise
and shudder.
Measure rotor (2) thickness a minimum of six points around
the rotor face with a micrometer (1). Position the micrometer
approximately 3/4 in. (19 mm) from the rotor outer circumfer-
ence for each measurement.
Thickness should not vary by more than 0.0005 in. (0.0127
mm) from point to point on the rotor. Refinish or replace the
rotor if necessary.
Note: A hub mounted on-vehicle lathe is recommended.

This type of lathe trues the rotor to the vehicles hub/bear-
ing.
Front rotors and hub/bearings are matched mounted for mini-

mum lateral runout. Before removing the rotor, mark the rotor
and hub/bearing to maintain original orientation.
FRONT ROTOR LATERAL RUNOUT

Check rotor lateral runout whenever pedal pulsation, or rapid,
uneven brake lining wear has occurred.
The rotor must be securely clamped to the hub to ensure an
accurate runout measurement. Secure the rotor with a mini-
mum of 3 lug nuts and large diameter flat washers on each
stud.
Use a dial indicator (1) to check lateral runout.
Maximum allowable rotor lateral runout is 0.002 in. (0.05 mm).
STANDARD PROCEDURE
DISC BRAKE ROTOR MACHINING
WARNING: BRAKE ROTORS THAT DO NOT MEET MINIMUM THICKNESS SPECIFICATIONS BEFORE OR
AFTER MACHINING MUST BE REPLACED.
Note: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles
hub/bearing.
The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simulta-
neously with dual cutter heads. The rotor mounting surface must be clean before placing on the lathe. Equipment
capable of machining only one side at a time may produce a tapered rotor.
REMOVAL
FRONT DISC BRAKE ROTOR
3. Disconnect the brake pad wear indicator.
4. Remove the caliper bracket mounting bolts (3) and remove

the caliper (1) and bracket as an assembly from the steer-
ing knuckle (2).

the brake hose. Damage to the brake hose can result. Pro-
vide a suitable support to hang the caliper securely.
5. Remove the retaining bolt (2) and then remove the brake
rotor (1) from the wheel hub (3).
REMOVAL - REAR DISC BRAKE ROTOR

3. Remove the caliper mounting bolts (1) and remove the cal-
iper from the knuckle.

the brake hose. Damage to the hose can result. Provide a
suitable support to hang the caliper securely.
4. Remove the rotor retaining bolt (2) and remove the rotor
from the wheel hub (3).
INSTALLATION
FRONT DISC BRAKE ROTOR
1. Install the rotor (1) onto the wheel hub (3).
2. Install the retaining bolt (2). Tighten to 10 N·m (7 ft. lbs.).
3. Install the caliper and bracket assembly (1) on the knuckle

(2). Install the mounting bolts (3) and tighten to 90-115 N·m
(66-85 ft. lbs.).
4. Connect the brake pad wear indicator.

WARNING: DO NOT MOVE VEHICLE UNTIL FIRM BRAKE

PEDAL IS OBTAINED.
6. Pump the brake pedal to seat caliper pistons and brake

pads.
INSTALLATION - REAR DISC BRAKE ROTOR

1. Install the rotor (1) onto the wheel hub (3).
2. Install the rotor retaining bolt (2). Tighten to 10 N·m (7 ft.
lbs.).
3. Install caliper assembly onto rotor.
4. Install caliper mounting bolts (1). Tighten to 90-115 N·m

(66-85 ft. lbs.).
WARNING: DO NOT MOVE THE VEHICLE UNTIL A FIRM

BRAKE PEDAL IS OBTAINED.
6. Pump the brake pedal to seat the caliper pistons and the
brake shoes.
FLUID
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 separates into layers,
there is mineral oil or other fluid contamination of the brake fluid.
If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder with reservoir, caliper
seals, HCU and all hydraulic fluid hoses.
STANDARD PROCEDURE
MASTER CYLINDER FLUID LEVEL
Always clean the master cylinder reservoir and cap before
adding fluid. This will prevent dirt from falling in the reservoir
and contaminating the brake fluid.
The reservoir (2) has a 9MIN” and a “MAX” mark (1) on the
side. Always fill to the “MAX” mark.
SPECIFICATIONS
BRAKE FLUID
CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open
container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type
fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake
system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid,
etc.
The brake fluid used in this vehicle must conform to DOT 4 specifications and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage in the vehicle brake system. Use only MoparT brake fluid or
an equivalent from a tightly sealed container.
MASTER CYLINDER
DESCRIPTION
MASTER CYLINDER
The master cylinder body is made of aluminum and contains a
primary and secondary piston assembly. The cylinder body
including the piston assemblies are not serviceable. If diagno-
sis indicates an internal problem with the cylinder body, it must
be replaced as an assembly. The master cylinder has a
removable reservoir and fluid level indicator (2). The reservoir,
reservoir grommets, reservoir cap and fluid level switch are the
only replaceable parts on the master cylinder.
OPERATION
MASTER CYLINDER
The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure
to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. The master cylinder res-
ervoir stores reserve brake fluid for the hydraulic brake circuits.

MASTER CYLINDER/POWER BOOSTER
Note: Inspect and repair any external fluid leaks before performing test.
1. Start the engine and inspect the booster vacuum hose connections. A hissing noise indicates a vacuum leak.
Correct any vacuum leaks before proceeding.
2. Stop the engine and shift the transmission into Neutral.
3. Pump the brake pedal until all the vacuum reserve in the booster is depleted.
4. Press and hold the brake pedal under a light foot pressure. The pedal should hold firm, if the pedal falls away
the master cylinder or HCU may be faulty (internal leakage).
5. Start the engine and note the pedal action. It should fall away slightly under a light foot pressure and then hold
firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to
the POWER BOOSTER VACUUM TEST.
6. If the POWER BOOSTER VACUUM TEST passes, rebuild the booster vacuum reserve as follows: Release the
brake pedal. Increase the engine speed to 1500 rpm, close the throttle and then turn off the engine.
7. Wait a minimum of 90 seconds and try the brake action again. The booster should provide two or more vacuum
assisted pedal applications. If the vacuum assist is not provided, some component of the booster is faulty.
POWER BOOSTER VACUUM TEST

1. Connect the vacuum gauge (7) to the booster check valve
(3) with the short length of hose (2) and the T-fitting (1).
2. Start and run the engine at a curb idle speed for one
minute.
3. Observe the vacuum supply. If the vacuum supply is not
adequate, repair the vacuum supply.
4. Clamp the hose shut (5) between the vacuum source and
the check valve.
5. Stop the engine and observe the vacuum gauge (7).
6. If the vacuum drops more than one inch HG (33 millibars)
within 15 seconds, the booster diaphragm, check valve or
check valve seal/grommet is faulty.
POWER BOOSTER CHECK VALVE TEST

1. Disconnect the vacuum hose from the check valve.
2. Remove the check valve (1) and the valve seal (3) from the
booster.
3. Use a hand operated vacuum pump for this test.
4. Apply 51-67 kPa (15-20 in.) of vacuum at the large end of
the check valve (2).
5. The vacuum should hold steady. If the gauge on the pump
indicates a vacuum loss the check valve and seal should
be replaced.
DIAGNOSIS AND TESTING - MASTER

CYLINDER FLUID LOSS
In case of brake fluid loss which is not visible, it should be checked whether brake fluid has entered the brake
booster through a leaking secondary seal in the master brake cylinder:
1. Remove master brake cylinder.
2. Visually inspect the inside of the brake booster for traces of brake fluid.
3. Replace the brake booster if brake fluid is present.
STANDARD PROCEDURE
MASTER CYLINDER BLEEDING PROCEDURE
A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes
and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line.
1. Mount the master cylinder in a vise with brass jaws.
2. Attach the bleed tubes to the cylinder outlet ports. Then
position each tube end into the bottom of the reservoir.
3. Fill the reservoir with fresh brake fluid.
4. Press the cylinder pistons inward with the wood dowel.
Then release the pistons and allow them to return under
spring pressure. Continue the bleeding operations until all
the air bubbles are no longer visible in fluid.
REMOVAL
1 - FLUID RESERVOIR 5 - O-RING

2 - FLUID LEVEL SENSOR CONNECTOR 6 - BRAKE LINES
3 - POWER BOOSTER 7 - MASTER CYLINDER
4 - MASTER CYLINDER NUTS
CAUTION: Do not get brake fluid on any painted surfaces. Brake fluid can damage paint.
1. Disconnect the brake fluid level sensor harness connector (2) from the reservoir (1).
2. Disconnect the master cylinder brake fluid pressure sensor harness connectors.
3. Remove brake lines (6) from master cylinder (7).
4. Remove the nuts (4) that attach the master cylinder to the booster studs.
WARNING: DO NOT TILT THE MASTER BRAKE CYLINDER WHEN REMOVING FROM THE BRAKE BOOSTER.
IF TILTED, THE BRAKE ROD CAN BE DISCONNECTED FROM THE MASTER CYLINDER.
5. Remove the master cylinder (7) from the booster (3).
INSTALLATION
1 - FLUID RESERVOIR 5 - O-RING

2 - FLUID LEVEL SENSOR CONNECTOR 6 - BRAKE LINES
3 - POWER BOOSTER 7 - MASTER CYLINDER
4 - MASTER CYLINDER NUTS
1. Bleed the master cylinder on a bench. Refer to Page 5-46.

2. Install the master cylinder (7) to the booster (3). Install the mounting nuts (4) and tighten to 20 N·m (15 lb. lbs.).
3. Install the brake lines (6) to the master cylinder (7). Tighten to 14 N·m (10 ft. lbs.).
4. Connect the fluid level sensor harness connector (2) to the fluid reservoir (1).
POWER BRAKE BOOSTER

DESCRIPTION

The vacuum-powered brake booster has two diaphragms. The BAS solenoid valve (2) and the BAS release switch
(6) are built into the vacuum-powered brake booster (1) and cannot be serviced. The entire vacuum-powered brake
booster must be replaced if the BAS solenoid valve (2) or the BAS release switch (6) need to be replaced.
The BAS diaphragm travel sensor (8) and if necessary the BAS control module (NOT SHOWN) are the only com-
ponents that can be serviced.
OPERATION

The BAS vacuum-powered brake booster functions like a typical brake booster.
An emergency stop is detected by the BAS control module by the BAS diaphragm travel sensor (8). In the case of
a BAS brake application, the BAS solenoid valve (2) opens the poppet valve (5), which admits atmospheric pressure
from inside the vehicle from the air filters (3-4) located at the rear of the BAS vacuum-powered brake booster (1).
The full assistance from the brake booster is transmitted to the master cylinder from the output rod (10). When the
brake application is terminated, the control module receives a signal from the BAS release switch (6) and the BAS
solenoid valve (2) closes again. The BAS assistance is terminated.
REMOVAL
1. Remove the master cylinder. Refer to Page 5-46.
2. Disconnect the vacuum hose (1) at the booster check valve
(2).
3. Remove the brake rod pin retaining clip (4) that holds the
boosters push rod (1) to the pedal (3). Then slide the push
rod off the pin (2).
4. Remove the booster retaining nuts (2) and the gasket (3)
that attach the booster (1) to the dash panel.
5. Slide booster forward, tilt the booster upward slightly, then
remove the booster from the engine compartment.
INSTALLATION
1. Install a new booster gasket (3).
2. Align and position the booster (1) on the dash panel.
3. Lubricate the pedal pin with Mopar multi-mileage grease.
4. Install the booster retaining nuts (2). Tighten to 39 N·m (29
ft. lbs.).
5. Install the brake rod pin (2) and retaining clip (4).
6. Check the condition of the grommet (2) that secures the

check valve in the booster (3). Replace the grommet if it is
worn or damaged. Install the vacuum hose (1) to booster
check valve.
7. Install the master cylinder with a new gasket and retaining
nuts. Refer to Page 5-47.
WARNING: THE MASTER CYLINDER INSTALLATION PRO-

CEDURE MUST BE PERFORM AS WRITTEN OR DAMAGE
TO THE BOOSTER/MASTER CYLINDER MAY OCCUR.

PEDAL
DESCRIPTION
A suspended type brake pedal (5) is used, the pedal pivots on
a shaft (3) mounted in the pedal support bracket. The bracket
is attached to the bulkhead.
OPERATION
The brake pedal (3) is attached to the booster push rod (1).
When the pedal is depressed, the primary booster push rod is
depressed which moves the booster secondary rod. The
booster secondary rod depresses the master cylinder piston.
REMOVAL
1. Remove the instrument panel lower cover (2) off of the
instrument panel.
2. Disconnect the stop lamp connector from the stop lamp

switch (1).
3. Remove the return spring (7).

4. Remove the c-clip (1).
5. Remove the washer (2).
6. Remove the bushing (3).
7. Remove the brake pedal from the bracket (5).
INSTALLATION
1. Install the brake pedal (5) to the bracket.
2. Install the bushing (3).
3. Install the washer (2).
4. Install the c-clip (1).
5. Install the return spring (7).
6. Install the stop lamp switch electrical connector (1) to the

stop lamp switch.
7. Install the instrument panel lower cover (2) to the instru-

ment panel.
PARKING BRAKE
OPERATION
The parking brakes are operated by an automatic tensioner
mechanism built into the hand lever (2) and cable system (1).
The front cable (1) is connected to the hand lever and the
equalizer.
A set of drum type brake shoes are used for parking brakes.
The shoes are mounted to the rear wheel hub. The parking
brake drum is integrated into the rear disc brake rotor. The
parking brake system consists of the adjuster (1), upper and
lower return springs (2-5), hold down springs (3) and the
actuator (4).
Parking brake cable (2) adjustment is controlled by an cable

equalizer mechanism (1). The rear cables (2) are attached to
the equalizer which uses a return spring to maintain tension
and slides on the body. The front cable (5) is bolted to the
equalizer (1) and the parking brake lever. The equalizer ten-
sioner bolt (3) is used to take up the slack in the cables and
as a final adjustment to the parking brake system.
The rear cables (2) attached to the equalizer and then to the
parking brake shoe actuator (3) which pushes the brake shoes
against the drum in the rear rotor.

PARKING BRAKE
Note: Parking brake adjustment is controlled by an equalizer cable tensioner and does require adjustment.
The only adjustment that may be necessary would be to the equalizer tensioning bolt.
The parking brake switch is in circuit with the red warning lamp in the dash. The switch will cause the lamp to
illuminate only when the parking brakes are applied. If the lamp remains on after parking brake release, the switch
or wires are faulty.
If the red lamp comes on a fault has occurred in the front or rear brake hydraulic system.
If the red warning lamp and yellow warning lamp come on, the electronic brake distribution may be at fault.
In most cases, the actual cause of an improperly functioning parking brake (too loose/too tight/won’t hold), can be
traced to a parking brake component.
Note: The leading cause of improper parking brake operation, is excessive clearance between the parking
brake shoes and the shoe braking surface. Excessive clearance is a result of lining and/or drum wear, drum
surface machined oversize.
Excessive parking brake lever travel (sometimes described as a loose lever or too loose condition), is the result of
worn brake shoes, improper brake shoe adjustment, or improperly assembled brake parts.
A too loose condition can also be caused by inoperative or improperly assembled parking brake shoe parts.
A condition where the parking brakes do not hold, will most probably be due to a wheel brake component.
Items to look for when diagnosing a parking brake problem, are:
• Brake shoe wear
• Drum surface (in rear rotor) machined oversize
• Front cable not secured to lever
• Rear cable not attached to actuator
• Rear cable seized
• Parking brake lever not seated
• Parking brake lever bind
ADJUSTMENTS
ADJUSTMENT
Note: Adjust the parking brake only if the hand brake lever
can be pulled up more than 3 notches without having an
adequate solid braking effect.

2. Loosen the parking brake cable tensioning bolt (3).
3. Remove one wheel bolt on each rear wheel.
4. Rotate the rear wheel (2) until the parking brake adjuster
wheel (1) can be seen through the removed rear wheel
bolt. Then using a screwdriver or suitable tool (3), turn the
adjusting wheel (1) until the parking brake shoes are
applied and the rear wheel (2) no longer turns freely.
• Right side: Turn the adjusting wheel from the bottom to
top.
• Left side: Turn the adjusting wheel from the top to bot-
tom.
Note: When slackening the adjusting wheels ensure that

both sides are turned back by the same number of teeth.
5. Turn the adjusting wheel back until the rear wheel turns
freely.
6. Tighten the parking brake cable tensioning bolt (3) until the
parking brake cables (2) no longer sag.
7. Firmly apply the parking brake several times.
8. To fine adjust the parking brake. Tighten the parking brake

tensioning bolt (3) until the parking brake lever can be
moved one tooth with a moderate effort of approximately
90-120 N·m.
9. Install the wheel bolt and tighten to 110 N·m (81 ft. lbs.).
CABLES
REMOVAL
3. Remove the rear caliper assembly bolts (1). Refer to Page
5-25.
4. Remove the rear brake rotor (1). Refer to Page 5-38.

5. Remove the parking brake shoe assembly (1-5). Refer to

Page 5-70.
6. Loosen the parking brake cable equalizer tensioner bolt (3).
7. Remove the front parking brake cable to the parking brake

cable equalizer (1) retaining bolt (5).
8. Remove the parking brake cables (2) from the parking

brake cable equalizer (1).
9. Remove the parking brake shoe actuator arm by pulling the

actuator arm (3) away from the rear wheel carrier assem-
bly.
10. Open the actuator arm (3) top cover exposing the parking
brake cable pin.
11. Push the cable pin through the arm and remove the actua-
tor from the cable (2).
12. Remove the parking brake cable (2) from the rear wheel
carrier assembly (4) by removing the mounting bolt (1).
13. Pull the parking brake cable (2) from the eyelets and
remove it from vehicle.
INSTALLATION
1. Install the parking brake cable through the eyelets.
2. Attach the parking brake cable (2) to the rear wheel carrier
assembly (4) by installing the mounting bolt (1). Tighten to
20 N·m (15 ft. lbs.).
3. Push the cable pin through the arm (3) attaching the actua-
tor to the cable (2).
4. Close the actuator arm top cover (3) encasing the cable
pin.
5. Install the actuator arm (3) to the rear wheel carrier assem-
bly (4) ensuring the actuator rests on the brass pins and it
is not binding.
6. Install the parking brake cables (2) to the parking brake

cable equalizer.
7. Install the parking brake cable equalizer to the front parking
brake cable mounting bolt (5).
8. Install the parking brake shoe assembly (1-5). Refer to

Page 5-73.
9. Install the rear brake rotor (1). Refer to Page 5-40.
10. Install the rear caliper assembly bolts (1). Refer to Page
5-32.
11. Adjust the parking brakes. Refer to Page 5-59.
13. Lower vehicle and verify parking brake operation. If park-
ing brakes need to be adjusted. Refer to Page 5-59.
LEVER
REMOVAL
1. Remove the parking brake equalizer (1) return spring (4).
2. Loosen the parking brake equalizer tensioning bolt (3).
3. Remove the bolt (6) at the parking brake equalizer (1)
attaching the front parking brake cable to the equalizer.
Note: The rubber handle can only be removed from the

parking brake lever with great force (suction). If necessary
cut open with a suitable tool.
4. Remove the shifter bezel (1). Refer to Page 23-173.

5. Pull the rubber handle (1) off of the parking brake lever.
6. Remove the center console (2). Refer to Page 23-173.
7. Disconnect the parking brake switch harness connector.
Note: The front parking brake cable will come with the
parking brake handle as an assembly.
8. Remove the mounting bolts (2) and pull out the parking
brake lever assembly (1) using a forward motion.
INSTALLATION
1. Install the front parking brake cable (1) through the hole in
the floor. Then install the parking brake lever and bolts (2).
2. Connect the parking brake switch harness connector.
3. Install the center console (2). Refer to Page 23-183.

4. Install the rubber handle (1) onto the parking brake lever.
5. Install the shift bezel (1). Refer to Page 23-183.
6. Install the parking brake cable equalizer (1) to the front

parking brake cable mounting bolts (5).
7. Tighten the parking brake equalizer tensioning bolt (3).

8. Attach the return spring (4) from the equalizer (1) to the
body frame.
9. Adjust the parking brake. Refer to Page 5-59.
SHOES
REMOVAL
2. Remove wheel and tire assembly.
3. Remove the caliper assembly bolts (1). Refer to Page
5-25.
4. Remove the disc brake rotor (1). Refer to Page 5-38.

5. Release the parking brake equalizer tensioning bolt (3).
6. Remove the parking brake shoe (1) return spring using a

hooked pick (2).
7. Remove the parking brake shoe (1) hold down spring (3)
using a pair of needle-nose pliers (2).
8. Remove the parking brake shoes (1) by lifting them over
rear axle shaft flange.
9. Remove the upper parking brake shoe return spring (2).

10. Remove the expanding lock (4).
11. The parking brake shoe assembly consists of the following

components:
• (1) Adjuster.
• (2) Upper return spring.
• (3) Hold down spring.
• (4) Expanding lock.
• (5) Lower return spring.
INSTALLATION
Note: Coat all bearing and sliding surfaces on the expand-
ing lock with Anti-seize.
1. Install the parking brake adjuster (1).

2. Install the upper return spring (2).
3. Install the parking brake shoes by placing the assembly
over rear axle shaft flange.
4. Install the hold down spring (3) by using a pair of needle-
nose pliers (2).
5. Install the return spring by using a hooked tool or needle-

nose pliers (2).
6. Tighten the bolt (3) on the parking brake cable equalizer.

Refer to Page 5-64.
7. Install the disc brake rotors (1). Refer to Page 5-40.
8. Install the caliper assembly bolts (1). Refer to Page 5-32.

BRAKE FLUID LEVEL SENSOR

REMOVAL
CAUTION: Do not get brake fluid on any painted surfaces.
Brake fluid can damage painted surfaces.
Note: The brake fluid level sensor cannot be replaced by

itself. You must remove the fluid reservoir.
1. Disconnect the brake fluid level sensor harness connector.

2. Remove the screw attaching the fluid reservoir to the mas-
ter cylinder.
3. Remove the fluid reservoir from the master cylinder.
INSTALLATION
1. Install the fluid reservoir to the master cylinder.
2. Install the screw (1) attaching the fluid reservoir to the mas-
ter cylinder.
3. Connect the brake fluid level sensor harness connector.
4. Fill the reservoir with MOPART brake fluid to the proper
level.
5. Bleed the braking system. Refer to Page 5-46. and Refer
to Page 5-9.
BRAKE PRESSURE SENSOR

REMOVAL
1. Remove the master cylinder (1). Refer to Page 5-46.
2. Remove the brake pressure sensors (1) from the master

cylinder.
INSTALLATION
1. Install the brake pressure sensors (1).
2. Install the master cylinder (1). Refer to Page 5-47.

3. Bleed the braking system. Refer to Page 5-9.
TRAVEL SENSOR
REMOVAL
WARNING: THE DIAPHRAGM TRAVEL SENSOR SEALING
RING MAY BE SUCKED INTO THE BRAKE BOOSTER IF
VACUUM IS PRESENT. IF THIS HAPPENS, THE BRAKE
BOOSTER MUST BE REPLACED.
1. Operate the brake pedal several times until the vacuum in

the brake booster is reduced.
2. Unplug the BAS diaphragm travel sensor harness connec-
tor.
3. Remove the locking ring (1) by using a suitable pick tool to
lift the locking ring up and off the BAS diaphragm travel
sensor.
4. Pull the BAS diaphragm travel sensor out of the brake
booster.
5. Remove the O-ring from the BAS diaphragm travel sensor.
INSTALLATION
1. Insert a new O-ring into the groove in the brake booster
and ensure that it is correctly seated.
2. Rub some soapy water onto the front of the diaphragm
travel sensor so that the O-ring does not bind when
inserted.
3. Replace locking ring (1) and ensure that it is correctly
seated.
4. Connect the electrical harness connector to the travel
sensor.
ZH BRAKES - ABS ELECTRICAL DIAGNOSTICS 5 - 79
BRAKES - ABS ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
ELECTRICAL - ESP ELECTRICAL ESP BRAKE PRESSURE SENSOR 2

DIAGNOSTICS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DIAGNOSIS AND TESTING ESP LATERAL ACCELERATION SENSOR
CAB INTERNAL FAILURE . . . . . . . . . . . . . . . 80 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
CAB SYSTEM UNDERVOLTAGE . . . . . . . . . . 82 BRAKE LAMP SWITCH CIRCUIT . . . . . . . . . 143
CAB SYSTEM OVERVOLTAGE . . . . . . . . . . . 85 ABS VERIFICATION TEST . . . . . . . . . . . . . . 148
CAN BUS COMMUNICATION GENERAL SCHEMATICS AND DIAGRAMS ........ . . . 149
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 88 ELECTRICAL - BAS ELECTRICAL
NO CAN COMMUNICATIONS WITH PCM . . . 90 DIAGNOSTICS
NO CAN COMMUNICATIONS WITH TCM . . . 92 DIAGNOSIS AND TESTING
PCM NOT IDENTIFIED OR INCORRECT . . . . 94 CAB INTERNAL FAILURE . . . . . . . . . . . . . . 153
LEFT FRONT WHEEL SPEED SENSOR CAB SYSTEM UNDERVOLTAGE . . . . . . . . . 155
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 CAB SYSTEM OVERVOLTAGE . . . . . . . . . . 158
RIGHT FRONT WHEEL SPEED SENSOR PCM NOT IDENTIFIED OR INCORRECT . . . 161
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 CAN BUS COMMUNICATION GENERAL
LEFT REAR WHEEL SPEED SENSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . .. . 162
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 NO CAN COMMUNICATIONS WITH PCM . . 164
RIGHT REAR WHEEL SPEED SENSOR BAS RELEASE SWITCH CIRCUIT . . . . . .. . 166
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 BAS TRAVEL SENSOR CIRCUIT . . . . . . .. . 171
ESP YAW RATE SENSOR CIRCUIT . . . . . . . 119 BRAKE LAMP SWITCH CIRCUIT . . . . . . .. . 176
STEERING ANGLE SENSOR CIRCUIT . . . . 124 BAS SOLENOID VALVE CIRCUIT ..... .. . 181
ESP BRAKE PRESSURE SENSOR 1 ABS VERIFICATION TEST . . . . . . . . . . . .. . 185
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 SCHEMATICS AND DIAGRAMS ........ .. . 186
ELECTRICAL - ESP ELECTRICAL DIAGNOSTICS

5 - 80 BRAKES - ABS ELECTRICAL DIAGNOSTICS ZH
CAB INTERNAL FAILURE
CAB INTERNAL FAILURE — CONTINUED
When Monitored and Set Condition
• When Monitored: Continuous.
• Set Condition: If the Controller Antilock Brake (CAB) detects an internal malfunction, the DTC is set.
POSSIBLE CAUSES
FUSED B(+) CIRCUIT
CONTROLLER ANTILOCK BRAKE
For a complete Electronic Stability Program (ESP) Circuit Diagram Refer to Page 5-149.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE CAB FUSED B(+) CIRCUIT

Turn the ignition off.
Disconnect the CAB harness connector.
Note: Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage of the Fused B(+) circuit at cavity 45 of the CAB har-
ness connector.
Is the voltage between 12 and 16 volts?

Yes >> Go to 2
No >> System voltage must be between 12 and 16 volts. Repair
the voltage concern as necessary.
Perform ABS VERIFICATION TEST.

With the ignition on.
ness connector.

Yes >> Replace the Controller Antilock Brake. Refer to Page
8E-63.
No >> System voltage must be between 12 and 16 volts.
Repair the voltage concern as necessary.
CAB SYSTEM UNDERVOLTAGE
CAB SYSTEM UNDERVOLTAGE — CONTINUED
• When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit voltage
above 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

FUSED B(+) CIRCUIT OPEN
Diagnostic Test
1. WITH THE DRB IIIT, READ DTCs

With the DRB IIIT, erase DTCs.
Start the engine.
Drive the vehicle above 10 MPH for at least 20 seconds.
Stop the vehicle.
With the DRB IIIT, read DTCs.
Does the DRB IIIT display a System Undervoltage DTC?

Yes >> Go to 2
No >> The condition that caused this DTC to set is currently not
present. Inspect the related wiring harness for a possible
intermittent condition.
2. MEASURE THE BATTERY VOLTAGE

Start the engine.
Measure the battery voltage with the engine running.
Is the battery voltage below 10 volts?

Yes >> Refer to the appropriate service information for charging
system testing and repair.
No >> Go to 3
3. MEASURE THE VOLTAGE OF THE FUSED B(+) CIRCUIT
ness connector.
Is the voltage above 10 volts?

Yes >> Go to 4
No >> Repair the Fused B(+) circuit for an open.

ness connector.

8E-63.
CAB SYSTEM OVERVOLTAGE
CAB SYSTEM OVERVOLTAGE — CONTINUED
• When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit at all
times for proper system voltage.
• Set Condition: If the voltage is above 16 volts for greater than 500 milliseconds (ms), the Diagnostic Trou-
ble Code (DTC) is set.
POSSIBLE CAUSES
SYSTEM VOLTAGE HIGH

GROUND CIRCUIT OPEN
Diagnostic Test

Start the engine.
Does the DRB IIIT display a System Overvoltage DTC?

Yes >> Go to 2

Start the engine.
Raise engine speed above 1,800 RPM.
Measure the battery voltage.

No >> Go to 3
3. MEASURE THE RESISTANCE OF THE GROUND CIRCUIT
Disconnect the CAB connector.
Measure the resistance between ground and the Ground circuit at cavity
46 of the CAB harness connector.
Is the resistance below 5.0 ohms?

Yes >> Go to 4
No >> Repair the Ground circuit for an open.

With the ignition off.

8E-63.
CAN BUS COMMUNICATION GENERAL MALFUNCTION
CAN BUS COMMUNICATION GENERAL MALFUNCTION — CONTINUED
• When Monitored: With the ignition on.
• Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the CAN
Bus network.
POSSIBLE CAUSES
CAN BUS CIRCUIT(S) OPEN
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE CAN C BUS (+) CIRCUIT

Disconnect the harness connectors of the other modules on the CAN Bus
network.
Measure the resistance of the CAN C Bus (+) circuit from the CAB har-
ness connector to the harness connectors of the other modules on the
CAN Bus network.
Is the resistance below 1.0 ohm?

Yes >> Go to 2
No >> Repair the CAN C Bus (+) circuit for an open.
2. MEASURE THE RESISTANCE OF THE CAN C BUS (-) CIRCUIT

Measure the resistance of the CAN C Bus (-) circuit from the CAB harness
connector to the harness connectors of the other modules on the CAN
Bus network.

8E-63.
No >> Repair the CAN C Bus (-) circuit for an open.
NO CAN COMMUNICATIONS WITH PCM
NO CAN COMMUNICATIONS WITH PCM — CONTINUED
• Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the
Powertrain Control Module (PCM).
POSSIBLE CAUSES
Diagnostic Test

Disconnect the PCM harness connector.
ness connector to the PCM harness connector.

Yes >> Go to 2

connector to the PCM harness connector.

8E-63.
NO CAN COMMUNICATIONS WITH TCM
NO CAN COMMUNICATIONS WITH TCM — CONTINUED
Transmission Control Module (TCM).
POSSIBLE CAUSES
Diagnostic Test

Disconnect the TCM harness connector.
ness connector to the TCM harness connector.

Yes >> Go to 2

connector to the TCM harness connector.

8E-63.
PCM NOT IDENTIFIED OR INCORRECT
• Set Condition: If the Controller Antilock Brake (CAB) detects an
invalid Powertrain Control Module (PCM), the DTC is set.
POSSIBLE CAUSES
Diagnostic Test

Start the engine.
CAUTION: Ensure braking capability is available before road testing.
Stop the vehicle.
Does the DRB IIIT display a PCM Not Identified or Incorrect DTC?
8E-63.
No >> The condition that caused this DTC to set is currently
not present.
LEFT FRONT WHEEL SPEED SENSOR CIRCUIT
LEFT FRONT WHEEL SPEED SENSOR CIRCUIT — CONTINUED
• When Monitored (Supply circuit): Ignition on. The Controller Antilock Brake (CAB) monitors the wheel speed
circuit every 7 milliseconds (ms).
• When Monitored (Signal circuit): 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 (Supply circuit): If the CAB detects an open or shorted wheel speed sensor circuit, the
Diagnostic Trouble Code (DTC) will set.
• Set Condition (Signal circuit): 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
WHEEL SPEED SENSOR MALFUNCTION

SENSOR CIRCUITS SHORTED OR OPEN
SENSOR OR TONE WHEEL DAMAGE
WHEEL SPEED SENSOR
Diagnostic Test

With the DRB IIIT, record and erase DTCs.
Does the DRB IIIT display a Left Front Wheel Speed Sensor Circuit
Failure DTC?
Yes >> Go to 2
No >> Go to 12
2. INSPECT THE LEFT FRONT WHEEL SPEED SENSOR

Inspect the Left Front Wheel Speed Sensor and connector.
Is the Sensor or Connector damaged?

Yes >> Repair as necessary.
No >> Go to 3
3. MEASURE THE VOLTAGE OF THE LEFT FRONT WHEEL SPEED
SENSOR 12 VOLT SUPPLY CIRCUIT

Disconnect the Left Front Wheel Speed Sensor harness connector.
Measure the voltage of the Left Front Wheel Speed Sensor 12 Volt Supply
circuit at the Left Front Wheel Speed Sensor harness connector.
Is the voltage approximately 12 volts?

Yes >> Go to 7
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE LEFT FRONT WHEEL SPEED


Measure the voltage of the Left Front Wheel Speed Sensor 12 Volt Supply
circuit at the Left Front Wheel Speed Sensor harness connector.
Is the voltage 0 volts?

Yes >> Go to 5
No >> Replace the Controller Antilock Brake. Refer to Page
8E-63.
5. MEASURE THE RESISTANCE BETWEEN GROUND AND THE LEFT

FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
CIRCUIT

Measure the resistance between ground and the Left Front Wheel Speed
Sensor 12 Volt Supply circuit at the CAB harness connector.
Is the resistance below 15k ohms?

Yes >> Repair the Left Front Wheel Speed Sensor 12 Volt Supply
circuit for a short to ground.
No >> Go to 6
6. MEASURE THE RESISTANCE OF THE LEFT FRONT WHEEL SPEED

Measure the resistance of the Left Front Wheel Speed Sensor 12 Volt
Supply circuit from the CAB harness connector to the Left Front Wheel
Speed Sensor harness connector.

Yes >> Go to 7
No >> Repair the Left Front Wheel Speed Sensor 12 Volt Sup-
ply circuit for an open.

SENSOR SIGNAL CIRCUIT

Reconnect the CAB harness connector.
Sensor Signal circuit.
Is the resistance less than 100 ohms?

Yes >> Go to 10
No >> Go to 8


Is the resistance greater than 300 ohms?

Yes >> Go to 9
No >> Replace the Left Front Wheel Speed Sensor. Refer to
Page 5-194.

Measure the resistance of the Left Front Wheel Speed Sensor Signal cir-
cuit from the CAB harness connector to the Left Front Wheel Speed Sen-
sor harness connector.

Yes >> Go to 11
No >> Repair the Left Front Wheel Speed Sensor Signal circuit
for an open.
10. MEASURE THE RESISTANCE BETWEEN GROUND AND THE

LEFT FRONT WHEEL SPEED SENSOR SIGNAL
CIRCUIT

Sensor Signal circuit at the CAB harness connector.

Yes >> Repair the Left Front Wheel Speed Sensor Signal circuit for
a short to ground.
No >> Go to 11
11. MEASURE THE RESISTANCE BETWEEN THE LEFT FRONT

WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT
AND THE SENSOR SIGNAL CIRCUIT

Measure the resistance between the Left Front Wheel Speed Sensor 12
Volt Supply circuit and the Left Front Wheel Speed Sensor Signal circuit at
the CAB harness connector.

Yes >> Repair the Left Front Wheel Speed Sensor 12 Volt Supply
circuit for a short to the Left Front Wheel Speed Sensor
Signal circuit.
8E-63.
12. VISUALLY INSPECT COMPONENTS FOR DAMAGE AND
CORRECT INSTALLATION
Visually inspect the related wiring harness and connectors. Look for any
chafed, pierced, pinched, or partially broken wires. Look for broken, bent,
pushed out, or corroded terminals.
Visually inspect the Left Front Wheel Speed Sensor, connector and tone
wheel for damage and correct installation.
Are there any visible Sensor, connector or tone wheel concerns?

Yes >> Correct the sensor, connector or tone wheel concerns as
necessary.
No >> Go to 13
13. MONITOR ALL WHEEL SPEED SENSORS WITH THE DRB IIIT
Start the engine.
With an assistant to drive, use the DRB IIIT to monitor all wheel speed
sensors. Slowly accelerate as straight as possible from a stop to 15 MPH.
Is the Left Front Wheel Speed Sensor Signal 0 or differing from

others by more than 3 MPH?
Yes >> Replace the Left Front Wheel Speed Sensor. Refer to
Page 5-194.
No >> Inspect and repair the related wiring harness for a
possible intermittent condition.
RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT
RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT — CONTINUED
POSSIBLE CAUSES

WHEEL SPEED SENSOR
Diagnostic Test

Does the DRB IIIT display a Right Front Wheel Speed Sensor Cir-
cuit Failure DTC?
Yes >> Go to 2
No >> Go to 12
2. INSPECT THE RIGHT FRONT WHEEL SPEED SENSOR

Inspect the Right Front Wheel Speed Sensor and connector.

No >> Go to 3
3. MEASURE THE VOLTAGE OF THE RIGHT FRONT WHEEL SPEED

Disconnect the Right Front Wheel Speed Sensor harness connector.
Measure the voltage of the Right Front Wheel Speed Sensor 12 Volt Sup-
ply circuit at the Right Front Wheel Speed Sensor harness connector.

Yes >> Go to 7
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE RIGHT FRONT WHEEL SPEED


Measure the voltage of the Right Front Wheel Speed Sensor 12 Volt Sup-
ply circuit at the Right Front Wheel Speed Sensor harness connector.

Yes >> Go to 5
8E-63.
5. MEASURE THE RESISTANCE BETWEEN GROUND AND THE RIGHT

FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY
CIRCUIT

Measure the resistance between ground and the Right Front Wheel Speed

Yes >> Repair the Right Front Wheel Speed Sensor 12 Volt Supply
No >> Go to 6
6. MEASURE THE RESISTANCE OF THE RIGHT FRONT WHEEL
SPEED SENSOR 12 VOLT SUPPLY CIRCUIT

Measure the resistance of the Right Front Wheel Speed Sensor 12 Volt
Supply circuit from the CAB harness connector to the Right Front Wheel

Yes >> Go to 7
No >> Repair the Right Front Wheel Speed Sensor 12 Volt Sup-

SPEED SENSOR SIGNAL CIRCUIT


Yes >> Go to 10
No >> Go to 8



Yes >> Go to 9
No >> Replace the Right Front Wheel Speed Sensor. Refer to
Page 5-194.

Measure the resistance of the Right Front Wheel Speed Sensor Signal cir-
cuit from the CAB harness connector to the Right Front Wheel Speed
Sensor harness connector.

Yes >> Go to 11
No >> Repair the Right Front Wheel Speed Sensor Signal cir-
cuit for an open.

RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
CIRCUIT


Yes >> Repair the Right Front Wheel Speed Sensor signal circuit
for a short to ground.
No >> Go to 11
11. MEASURE THE RESISTANCE BETWEEN THE RIGHT FRONT


Measure the resistance between the Right Front Wheel Speed Sensor 12
Volt Supply circuit and the Right Front Wheel Speed Sensor Signal circuit
at the CAB harness connector.

Yes >> Repair the Right Front Wheel Speed Sensor 12 Volt Supply
circuit for a short to the Right Front Wheel Speed Sensor
Signal circuit.
8E-63.
Visually inspect the Right Front Wheel Speed Sensor, connector and tone

necessary.
No >> Go to 13
Start the engine.
Is the Right Front Wheel Speed Sensor Signal 0 or differing from

Yes >> Replace the Right Front Wheel Speed Sensor. Refer to
Page 5-194.
LEFT REAR WHEEL SPEED SENSOR CIRCUIT
LEFT REAR WHEEL SPEED SENSOR CIRCUIT — CONTINUED
POSSIBLE CAUSES

WHEEL SPEED SENSOR
Diagnostic Test

Does the DRB IIIT display a Left Rear Wheel Speed Sensor Circuit
Failure DTC?
Yes >> Go to 2
No >> Go to 12
2. INSPECT THE LEFT REAR WHEEL SPEED SENSOR

Inspect the Left Rear Wheel Speed Sensor and connector.

No >> Go to 3
3. MEASURE THE VOLTAGE OF THE LEFT REAR WHEEL SPEED

Disconnect the Left Rear Wheel Speed Sensor harness connector.
Measure the voltage of the Left Rear Wheel Speed Sensor 12 Volt Supply
circuit at the Left Rear Wheel Speed Sensor harness connector.

Yes >> Go to 7
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE LEFT REAR WHEEL SPEED


Measure the voltage of the Left Rear Wheel Speed Sensor 12 Volt Supply
circuit at the Left Rear Wheel Speed Sensor harness connector.

Yes >> Go to 5
8E-63.

REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
CIRCUIT

Measure the resistance between ground and the Left Rear Wheel Speed

Yes >> Repair the Left Rear Wheel Speed Sensor 12 Volt Supply
No >> Go to 6
6. MEASURE THE RESISTANCE OF THE LEFT REAR WHEEL SPEED

Measure the resistance of the Left Rear Wheel Speed Sensor 12 Volt
Supply circuit from the CAB harness connector to the Left Rear Wheel

Yes >> Go to 7
No >> Repair the Left Rear Wheel Speed Sensor 12 Volt Sup-



Yes >> Go to 10
No >> Go to 8



Yes >> Go to 9
No >> Replace the Left Rear Wheel Speed Sensor. Refer to
Page 5-197.

Measure the resistance of the Left Rear Wheel Speed Sensor Signal cir-
cuit from the CAB harness connector to the Left Rear Wheel Speed Sen-

Yes >> Go to 11
No >> Repair the Left Rear Wheel Speed Sensor Signal circuit
for an open.

LEFT REAR WHEEL SPEED SENSOR SIGNAL CIRCUIT


Yes >> Repair the Left Rear Wheel Speed Sensor Signal circuit for
a short to ground.
No >> Go to 11
11. MEASURE THE RESISTANCE BETWEEN THE LEFT REAR WHEEL

SPEED SENSOR 12 VOLT SUPPLY CIRCUIT AND THE

Measure the resistance between the Left Rear Wheel Speed Sensor 12
Volt Supply circuit and the Left Rear Wheel Speed Sensor Signal circuit at
the CAB harness connector.

Yes >> Repair the Left Rear Wheel Speed Sensor 12 Volt Supply
circuit for a short to the Left Rear Wheel Speed Sensor Sig-
nal circuit.
8E-63.
Visually inspect the Left Rear Wheel Speed Sensor, connector and tone

necessary.
No >> Go to 13
Start the engine.
Is the Left Rear Wheel Speed Sensor Signal 0 or differing from oth-
ers by more than 3 MPH?
Yes >> Replace the Left Rear Wheel Speed Sensor. Refer to Page
5-197.
RIGHT REAR WHEEL SPEED SENSOR CIRCUIT
RIGHT REAR WHEEL SPEED SENSOR CIRCUIT — CONTINUED
POSSIBLE CAUSES

WHEEL SPEED SENSOR
Diagnostic Test

Does the DRB IIIT display a Right Rear Wheel Speed Sensor Circuit
Failure DTC?
Yes >> Go to 2
No >> Go to 12
2. INSPECT THE RIGHT REAR WHEEL SPEED SENSOR

Inspect the Right Rear Wheel Speed Sensor and connector.

No >> Go to 3
3. MEASURE THE VOLTAGE OF THE RIGHT REAR WHEEL SPEED

Disconnect the Right Rear Wheel Speed Sensor connector.
Measure the voltage of the Right Rear Wheel Speed Sensor 12 Volt Sup-
ply circuit at the Right Rear Wheel Speed Sensor harness connector.

Yes >> Go to 7
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE RIGHT REAR WHEEL SPEED


Measure the voltage of the Right Rear Wheel Speed Sensor 12 Volt Sup-
ply circuit at the Right Rear Wheel Speed Sensor harness connector.

Yes >> Go to 5
8E-63.

REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
CIRCUIT

Measure the resistance between ground and the Right Rear Wheel Speed

Yes >> Repair the Right Rear Wheel Speed Sensor 12 Volt Supply
No >> Go to 6
6. MEASURE THE RESISTANCE OF THE RIGHT REAR WHEEL SPEED

Measure the resistance of the Right Rear Wheel Speed Sensor 12 Volt
Supply circuit from the CAB harness connector to the Right Rear Wheel

Yes >> Go to 7
No >> Repair the Right Rear Wheel Speed Sensor 12 volt sup-



Yes >> Go to 10
No >> Go to 8



Yes >> Go to 9
No >> Replace the Right Rear Wheel Speed Sensor. Refer to
Page 5-197.

Measure the resistance of the Right Rear Wheel Speed Sensor Signal cir-
cuit from the CAB harness connector to the Right Rear Wheel Speed Sen-

Yes >> Go to 11
No >> Repair the Right Rear Wheel Speed Sensor Signal circuit
for an open.

RIGHT REAR WHEEL SPEED SENSOR SIGNAL
CIRCUIT


Yes >> Repair the Right Rear Wheel Speed Sensor Signal circuit
No >> Go to 11
11. MEASURE THE RESISTANCE BETWEEN THE RIGHT REAR


Measure the resistance between the Right Rear Wheel Speed Sensor 12
Volt Supply circuit and the Right Rear Wheel Speed Sensor Signal circuit
at the CAB harness connector.

Yes >> Repair the Right Rear Wheel Speed Sensor 12 Volt Supply
circuit for a short to the Right Rear Wheel Speed Sensor
Signal circuit.
8E-63.
Visually inspect the Right Rear Wheel Speed Sensor, connector and tone

necessary.
No >> Go to 13
Start the engine.
Is the Right Rear Wheel Speed Sensor Signal 0 or differing from

Yes >> Replace the Right Rear Wheel Speed Sensor. Refer to
Page 5-197.
ESP YAW RATE SENSOR CIRCUIT
ESP YAW RATE SENSOR CIRCUIT — CONTINUED
• When Monitored: Ignition on.
• Set Condition: The Controller Antilock Brake (CAB) detects an Electronic Stability Program (ESP) Yaw
Rate Sensor malfunction.
POSSIBLE CAUSES
YAW RATE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

YAW RATE SENSOR SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT
YAW RATE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
YAW RATE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT
YAW RATE SENSOR SIGNAL CIRCUIT OPEN
YAW RATE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
YAW RATE SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
YAW RATE SENSOR GROUND CIRCUIT OPEN
YAW RATE SENSOR
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE ESP YAW RATE SENSOR

SIGNAL CIRCUIT

Disconnect the ESP Yaw Rate Sensor harness connector.
Measure the voltage of the ESP Yaw Rate Sensor Signal circuit at the
ESP Yaw Rate Sensor harness connector.
Is voltage present?
Yes >> Repair the ESP Yaw Rate Sensor Signal circuit for a short
to voltage.
No >> Go to 2
2. MEASURE THE RESISTANCE BETWEEN THE ESP YAW RATE
SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY CIRCUIT

Measure the resistance between the ESP Yaw Rate Sensor Signal circuit
and the 5-Volt Supply circuit in the ESP Yaw Rate Sensor harness con-
nector.
Is the resistance below 10K ohms?

to the 5-Volt Supply circuit.
No >> Go to 3
3. MEASURE THE RESISTANCE OF THE ESP YAW RATE SENSOR

SIGNAL CIRCUIT

Measure the resistance of the ESP Yaw Rate Sensor Signal circuit from
the CAB harness connector to the ESP Yaw Rate Sensor harness con-
nector.

Yes >> Go to 4
No >> Repair the ESP Yaw Rate Sensor Signal circuit for an
open.
4. MEASURE THE RESISTANCE BETWEEN GROUND AND THE ESP

YAW RATE SENSOR GROUND CIRCUIT

Measure the resistance between ground and the Sensor Ground circuit.

Yes >> Repair the Sensor Ground circuit for a short to ground.
No >> Go to 5
5. MEASURE THE VOLTAGE OF THE 5-VOLT SUPPLY CIRCUIT
Measure the voltage of the 5-Volt Supply circuit at the ESP Yaw Rate Sen-
Is the voltage between 4.5 and 5.0 volts?

Yes >> Go to 6
No >> Go to 8

YAW RATE SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the ESP Yaw Rate Sensor
Signal circuit.

to ground.
No >> Go to 7
7. MEASURE THE RESISTANCE BETWEEN THE ESP YAW RATE

SENSOR SIGNAL CIRCUIT AND THE SENSOR GROUND
CIRCUIT

Measure the resistance between the ESP Yaw Rate Sensor Signal circuit
and the Sensor Ground circuit in the ESP Yaw Rate Sensor harness con-
nector.

to the Sensor Ground circuit.
No >> Replace the ESP Yaw Rate Sensor. Refer to Page
5-201.
YAW RATE SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the resistance between ground and the 5-Volt Supply circuit.

Yes >> Repair the 5-Volt Supply circuit for a short to ground.
No >> Go to 9
9. MEASURE THE RESISTANCE OF THE ESP YAW RATE SENSOR

5-VOLT SUPPLY CIRCUIT

Measure the resistance of the 5-Volt Supply circuit from the ESP Yaw
Rate Sensor harness connector to the CAB harness connector.

8E-63.
No >> Repair the ESP Yaw Rate Sensor 5-Volt Supply circuit
for an open.
STEERING ANGLE SENSOR CIRCUIT
STEERING ANGLE SENSOR CIRCUIT — CONTINUED
• When Monitored: With the ignition on. The Controller Antilock Brake (CAB) monitors the status of the Steer-
ing Angle Sensor.
• Set Condition: The DTC will set if a malfunction is detected between the CAB and the Steering Angle
Sensor.
POSSIBLE CAUSES

STEERING ANGLE SENSOR SIGNAL CIRCUIT OPEN
STEERING ANGLE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
STEERING ANGLE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE
STEERING ANGLE SENSOR
Diagnostic Test
1. MEASURE STEERING ANGLE SENSOR FUSED B(+) CIRCUIT

VOLTAGE
Note: Inspect Fuse 14 located in the Underhood Accessory Fuse

Block. If the fuse is open, repair the cause of the open fuse before
continuing.
Disconnect the Steering Angle Sensor harness connector.
Measure the voltage of the Fused B(+) circuit at the Steering Angle Sen-

Yes >> Go to 2
No >> Repair the Steering Angle Sensor Fused B(+) circuit.
2. MEASURE THE STEERING ANGLE SENSOR SIGNAL CIRCUIT
RESISTANCE

Measure the resistance of the Steering Angle Sensor Signal circuit from
the CAB harness connector to the Steering Angle Sensor harness connec-
tor.

Yes >> Go to 3
No >> Repair the Steering Angle Sensor Signal circuit for an
open.
3. MEASURE THE STEERING ANGLE SENSOR SIGNAL CIRCUIT

RESISTANCE

Measure the resistance between ground and the Steering Angle Sensor
Signal circuit.

Yes >> Repair the Steering Angle Sensor Signal circuit for a short
to ground.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE STEERING ANGLE SENSOR

SIGNAL CIRCUIT

Measure the voltage of the Steering Angle Sensor Signal circuit at the
Steering Angle Sensor harness connector.
Is voltage present?
Yes >> Repair the Steering Angle Sensor Signal circuit for a short
to voltage.
No >> Go to 5
5. MEASURE THE STEERING ANGLE SENSOR GROUND CIRCUIT
RESISTANCE


Yes >> Replace the Steering Angle Sensor. Refer to Page 5-200.
No >> Repair the Sensor Ground circuit for an open.
ESP BRAKE PRESSURE SENSOR 1 CIRCUIT
ESP BRAKE PRESSURE SENSOR 1 CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects an Electronic Stability Program (ESP) Brake
Pressure Sensor 1 malfunction.
POSSIBLE CAUSES
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT OPEN
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
BRAKE PRESSURE SENSOR GROUND CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE ESP BRAKE PRESSURE

SENSOR 1 SIGNAL CIRCUIT

Disconnect the ESP Brake Pressure Sensor 1 harness connector.
Measure the voltage of the ESP Brake Pressure Sensor 1 Signal circuit at
the ESP Brake Pressure Sensor 1 harness connector.
Is voltage present?
Yes >> Repair the ESP Brake Pressure Sensor 1 Signal circuit for
a short to voltage.
No >> Go to 2
2. MEASURE THE RESISTANCE BETWEEN THE ESP BRAKE
PRESSURE 1 SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY
CIRCUIT

Measure the resistance between the ESP Brake Pressure Sensor 1 Signal
circuit and the 5-Volt Supply circuit in the ESP Brake Pressure Sensor 1
harness connector.

a short to the 5-Volt Supply circuit.
No >> Go to 3
3. MEASURE THE RESISTANCE OF THE ESP BRAKE PRESSURE


Measure the resistance of the ESP Brake Pressure Sensor 1 Signal circuit
from the CAB harness connector to the ESP Brake Pressure Sensor 1
harness connector.

Yes >> Go to 4
No >> Repair the ESP Brake Pressure Sensor 1 Signal circuit
for an open.

BRAKE PRESSURE SENSOR 1 GROUND CIRCUIT


No >> Go to 5
Measure the voltage of the 5-Volt Supply circuit at the ESP Brake Pres-
sure Sensor 1 harness connector.

Yes >> Go to 6
No >> Go to 8

BRAKE PRESSURE SENSOR 1 SIGNAL CIRCUIT

Measure the resistance between ground and the ESP Brake Pressure
Sensor 1 Signal circuit.

a short to ground.
No >> Go to 7

PRESSURE SENSOR 1 SIGNAL CIRCUIT AND THE
SENSOR GROUND CIRCUIT

circuit and the Sensor Ground circuit in the ESP Brake Pressure Sensor 1
harness connector.

a short to the Sensor Ground circuit.
No >> Replace the ESP Brake Pressure Sensor 1. Refer to
Page 5-201.
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT


No >> Go to 9

SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the 5-Volt Supply circuit from the ESP Brake
Pressure Sensor 1 harness connector to the CAB harness connector.

8E-63.
No >> Repair the ESP Brake Pressure Sensor 5-Volt Supply
circuit for an open.
ESP BRAKE PRESSURE SENSOR 2 CIRCUIT
• Set Condition: The Controller Antilock Brake (CAB) detects an Electronic Stability Program (ESP) Brake
Pressure Sensor 2 malfunction.
POSSIBLE CAUSES
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT
BRAKE PRESSURE SENSOR SIGNAL CIRCUIT OPEN
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
BRAKE PRESSURE SENSOR GROUND CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE ESP BRAKE PRESSURE


Disconnect the ESP Brake Pressure Sensor 2 harness connector.
Measure the voltage of the ESP Brake Pressure Sensor 2 Signal circuit at
the ESP Brake Pressure Sensor 2 harness connector.
Is voltage present?
a short to voltage.
No >> Go to 2
PRESSURE 2 SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY
CIRCUIT

circuit and the 5-Volt Supply circuit in the ESP Brake Pressure Sensor 2
harness connector.

a short to the 5-Volt Supply circuit.
No >> Go to 3


Measure the resistance of the ESP Brake Pressure Sensor 2 Signal circuit
from the CAB harness connector to the ESP Brake Pressure Sensor 2
harness connector.

Yes >> Go to 4
No >> Repair the ESP Brake Pressure Sensor 2 Signal circuit
for an open.

BRAKE PRESSURE SENSOR 2 GROUND CIRCUIT


No >> Go to 5
Measure the voltage of the 5-Volt Supply circuit at the ESP Brake Pres-
sure Sensor 2 harness connector.

Yes >> Go to 6
No >> Go to 8

BRAKE PRESSURE SENSOR 2 SIGNAL CIRCUIT

Measure the resistance between ground and the ESP Brake Pressure
Sensor 2 Signal circuit.

a short to ground.
No >> Go to 7

PRESSURE SENSOR 2 SIGNAL CIRCUIT AND THE

circuit and the Sensor Ground circuit in the ESP Brake Pressure Sensor 2
harness connector.

No >> Replace the ESP Brake Pressure Sensor 2. Refer to
Page 5-201.
BRAKE PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT


No >> Go to 9

SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the 5-Volt Supply circuit from the ESP Brake
Pressure Sensor 2 harness connector to the CAB harness connector.

8E-63.
No >> Repair the ESP Brake Pressure Sensor 5-Volt Supply
ESP LATERAL ACCELERATION SENSOR CIRCUIT
ESP LATERAL ACCELERATION SENSOR CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects an Electronic Stability Program (ESP) Lateral
Acceleration Sensor malfunction.
POSSIBLE CAUSES
LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT
LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT SHORT TO GROUND
LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT
LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT OPEN
LATERAL ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
LATERAL ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
LATERAL ACCELERATION SENSOR GROUND CIRCUIT OPEN
LATERAL ACCELERATION SENSOR
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE ESP LATERAL ACCELERATION


Disconnect the ESP Lateral Acceleration Sensor harness connector.
Measure the voltage of the ESP Lateral Acceleration Sensor Signal circuit
at the ESP Lateral Acceleration Sensor harness connector.
Is voltage present?
Yes >> Repair the ESP Lateral Acceleration Sensor Signal circuit
for a short to voltage.
No >> Go to 2
2. MEASURE THE RESISTANCE BETWEEN THE ESP LATERAL
ACCELERATION SIGNAL CIRCUIT AND THE 5-VOLT
SUPPLY CIRCUIT

Measure the resistance between the ESP Lateral Acceleration Sensor Sig-
nal circuit and the 5-Volt Supply circuit in the ESP Lateral Acceleration

for a short to the 5-Volt Supply circuit.
No >> Go to 3
3. MEASURE THE RESISTANCE OF THE ESP LATERAL

ACCELERATION SENSOR SIGNAL CIRCUIT

Measure the resistance of the ESP Lateral Acceleration Sensor Signal cir-
cuit from the CAB harness connector to the ESP Lateral Acceleration Sen-

Yes >> Go to 4
No >> Repair the ESP Lateral Acceleration Sensor Signal circuit
for an open.

LATERAL ACCELERATION SENSOR GROUND CIRCUIT


No >> Go to 5
Measure the voltage of the 5-Volt Supply circuit in the ESP Lateral Accel-
eration Sensor harness connector.

Yes >> Go to 6
No >> Go to 8

LATERAL ACCELERATION SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the ESP Lateral Acceleration

No >> Go to 7
7. MEASURE THE RESISTANCE BETWEEN THE ESP LATERAL

ACCELERATION SENSOR SIGNAL CIRCUIT AND THE

Measure the resistance between the ESP Lateral Acceleration Sensor Sig-
nal circuit and the Sensor Ground circuit in the ESP Lateral Acceleration

for a short to the Sensor Ground circuit.
No >> Replace the ESP Lateral Acceleration Sensor. Refer
to Page 5-200.
LATERAL ACCELERATION SENSOR 5-VOLT SUPPLY
CIRCUIT


No >> Go to 9
9. MEASURE THE RESISTANCE OF THE ESP LATERAL

ACCELERATION SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the 5-Volt Supply circuit from the ESP Lateral
Acceleration Sensor harness connector to the CAB harness connector.

8E-63.
No >> Repair the ESP Lateral Acceleration Sensor 5-Volt
Supply circuit for an open.
BRAKE LAMP SWITCH CIRCUIT
BRAKE LAMP SWITCH CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects an abnormal condition on the Brake Lamp
Switch circuit.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

BRAKE LAMP SWITCH OUTPUT CIRCUIT OPEN
BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORTED
BRAKE LAMP SWITCH
BRAKE LAMP RELAY
Diagnostic Test
1. MEASURE BRAKE LAMP SWITCH VOLTAGE

Note: Inspect Fuse 2 located in the Illumination Control Module/IP
Fuse Block. If the fuse is open, repair the cause of the open fuse
before continuing.
Disconnect the Brake Lamp Switch harness connector.
Measure the voltage of the Fused Ignition Switch Output circuit at the
Brake Lamp Switch harness connector.

Yes >> Go to 2
No >> Repair the Fused Ignition Switch Output circuit for an
open.
2. MEASURE THE RESISTANCE BETWEEN THE BRAKE LAMP

SWITCH AND THE BRAKE LAMP RELAY

Remove the Brake Lamp Relay.
Measure the resistance of the circuit from the Brake Lamp Switch harness
connector B cavity 2 to the Brake Lamp Relay harness connector cavity 8.

Yes >> Go to 3
No >> Repair the circuit for an open.
SWITCH AND THE CAB

Measure the resistance of the Brake Lamp Switch Output circuit from the
Brake Lamp Switch harness connector to the CAB harness connector.

Yes >> Go to 4
No >> Repair the Brake Lamp Switch Output circuit for an open.
4. MEASURE BRAKE LAMP RELAY VOLTAGE

Reconnect the Brake Lamp Switch harness connector.
Have an assistant depress the brake pedal while measuring the voltage at
the Brake Lamp Relay harness connector cavity 8.

Yes >> Go to 5
No >> Replace the Brake Lamp Switch.
5. MEASURE THE RESISTANCE BETWEEN THE BRAKE LAMP RELAY

AND THE CAB

Measure the resistance of the Brake Lamp Relay Control circuit between
the Brake Lamp Relay harness connector and the CAB harness connec-
tor.

Yes >> Go to 6
No >> Repair the Brake Lamp Relay control circuit between the
Brake Lamp Relay and the CAB for an open.
6. MEASURE BRAKE LAMP RELAY CONTROL CIRCUIT VOLTAGE
Measure the voltage of the Brake Lamp Relay Control circuit at the CAB
harness connector.
Is voltage present?
Yes >> Repair the Brake Lamp Relay Control circuit for a short to
voltage.
No >> Go to 7

Install a jumper wire between cavities 4 and 6 of the Brake Lamp Relay
harness connector.
harness connector.

Yes >> Go to 8
No >> Repair the Brake Lamp Relay Control circuit for an open.
8. MEASURE BRAKE LAMP RELAY OUTPUT CIRCUIT RESISTANCE

With the ignition off and the jumper wire removed from the Brake Lamp
Relay harness connector.
Measure the resistance of the Brake Lamp Relay Output circuit from the
Brake Lamp Relay harness connector to the CAB harness connector.

Yes >> Go to 9
No >> Repair the Brake Lamp Relay Output circuit for an open.
9. MEASURE BRAKE LAMP RELAY OUTPUT CIRCUIT VOLTAGE
Measure the voltage of the Brake Lamp Relay Output circuit at the CAB
harness connector.
Is voltage present?
Yes >> Repair the Brake Lamp Relay Output circuit for a short to
voltage.
No >> Go to 10

harness connector.
Have an assistant depress the brake pedal while measuring the voltage of
the Brake Lamp Relay Output circuit at the CAB harness connector.

8E-63.
No >> Replace the Brake Lamp Relay.
ABS VERIFICATION TEST
1.
Disconnect all jumper wires and reconnect all previously disconnected
components and connectors.
With the DRB IIIT, erase all Diagnostic Trouble Codes (DTCs) from ALL
modules. Start the engine and allow it to run for 2 minutes.
Turn the ignition off and wait 5 seconds. Turn the ignition on and using the
DRB IIIT, read DTCs from ALL modules.
Note: For sensor signal and pump motor faults, the CAB must sense
all 4 wheels at 25 km/h (15 MPH) before the CAB will extinguish the
indicator lamp.
Road test the vehicle for a minimum of 5 minutes. Perform several
antilock braking stops.
Again, with the DRB IIIT, confirm that no DTCs are present and that all
components are functioning properly.
If there are no DTCs present and all components are functioning properly,
the repair is complete.
Are any DTCs present?

YES >> Repair is not complete, refer to appropriate symptom.
NO >> Repair is complete.
SCHEMATICS AND DIAGRAMS
ELECTRONIC STABILITY PROGRAM CIRCUIT DIAGRAM (2 OF 3)

5 - 150
ZH

ZH
5 - 151

ELECTRICAL - BAS ELECTRICAL DIAGNOSTICS

CAB INTERNAL FAILURE
CAB INTERNAL FAILURE — CONTINUED
• Set Condition: If the Controller Antilock Brake (CAB) detects an internal malfunction, the DTC is set.
POSSIBLE CAUSES
FUSED B(+) CIRCUIT
For a complete Brake Assist System (BAS) Circuit Diagram Refer to Page 5-149.
Diagnostic Test

ness connector.

Yes >> Go to 2

ness connector.

8E-63.
CAB SYSTEM UNDERVOLTAGE
• When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit voltage
above 6 MPH every 7 milliseconds for proper system voltage.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW

Diagnostic Test

Start the engine.
Stop the vehicle.

Yes >> Go to 2

Start the engine.

No >> Go to 3
ness connector.

Yes >> Go to 4

ness connector.

8E-63.
CAB SYSTEM OVERVOLTAGE
• When Monitored: Ignition on. The Controller Antilock Brake (CAB) monitors the Fused B(+) circuit at all
times for proper system voltage.
• Set Condition: If the voltage is above 16 volts for greater than 500 milliseconds (ms), the Diagnostic Trou-
ble Code (DTC) is set.
POSSIBLE CAUSES
SYSTEM VOLTAGE HIGH

GROUND CIRCUIT OPEN
Diagnostic Test

Start the engine.

Yes >> Go to 2

Start the engine.
Raise engine speed above 1,800 RPM.

No >> Go to 3
Disconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.

Yes >> Go to 4


8E-63.
PCM NOT IDENTIFIED OR INCORRECT
• Set Condition: If the Controller Antilock Brake (CAB) detects an
invalid Powertrain Control Module (PCM), the DTC is set.
POSSIBLE CAUSES
Diagnostic Test

Start the engine.
Stop the vehicle.
Does the DRB IIIT display a PCM Not Identified or Incorrect DTC?
8E-63.
not present.
• Set Condition: CAN Bus communication failure between the Controller Antilock Brake (CAB) and the CAN
Bus network.
POSSIBLE CAUSES
Diagnostic Test

network.
ness connector to the harness connectors of the other modules on the
CAN Bus network.

Yes >> Go to 2
2. MEASURE THE RESISTANCE OF THE CAN C (-) BUS CIRCUIT

connector to the harness connectors of the other modules on the CAN
Bus network.

8E-63.
Powertrain Control Module (PCM).
POSSIBLE CAUSES
Diagnostic Test


Yes >> Go to 2

connector to the PCM harness connector.

8E-63.
BAS RELEASE SWITCH CIRCUIT
BAS RELEASE SWITCH CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Release Switch
malfunction.
POSSIBLE CAUSES
BAS RELEASE SWITCH SENSE (REFERENCE) CIRCUIT SHORT TO VOLTAGE

BAS RELEASE SWITCH SENSE (REFERENCE) CIRCUIT SHORT TO SENSE (APPLIED) CIRCUIT
BAS RELEASE SWITCH SENSE (REFERENCE) CIRCUIT SHORT TO GROUND
BAS RELEASE SWITCH SENSE (REFERENCE) CIRCUIT SHORT TO 12 VOLT SUPPLY CIRCUIT
BAS RELEASE SWITCH SENSE (REFERENCE) CIRCUIT OPEN
BAS RELEASE SWITCH SENSE (APPLIED) CIRCUIT OPEN
BAS RELEASE SWITCH SENSE (APPLIED) CIRCUIT SHORT TO GROUND
BAS RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT OPEN
BAS RELEASE SWITCH
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE BAS RELEASE SWITCH SENSE

(APPLIED) CIRCUIT

Disconnect the BAS Brake Booster harness connector.
Measure the voltage of the BAS Release Switch Sense (Applied) circuit at
the BAS Brake Booster harness connector.
Is the voltage above 5.0 volts?

Yes >> Repair the BAS Release Switch Sense (Applied) circuit for
a short to voltage.
No >> Go to 2
2. MEASURE THE RESISTANCE BETWEEN THE BAS RELEASE
SWITCH SENSE (APPLIED) CIRCUIT AND THE SENSE
(REFERENCE) CIRCUIT

Measure the resistance between the BAS Release Switch Sense (Applied)
circuit and the Sense (Reference) circuit in the BAS Brake Booster har-
ness connector.

a short to the Sense (Reference) circuit.
No >> Go to 3
3. MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH

SENSE (APPLIED) CIRCUIT

Measure the resistance of the BAS Release Switch Sense (Applied) circuit
from the CAB harness connector to the BAS Brake Booster harness con-
nector.

Yes >> Go to 4
No >> Repair the BAS Release Switch Sense (Applied) circuit
for an open.
4. MEASURE THE RESISTANCE BETWEEN GROUND AND THE BAS

RELEASE SWITCH 12 VOLT SUPPLY CIRCUIT

Measure the resistance between ground and the BAS Release Switch 12
Volt Supply circuit.
Is the resistance below 100 ohms?

Yes >> Repair the BAS Release Switch 12 Volt Supply circuit for a
short to ground.
No >> Go to 5
5. MEASURE THE VOLTAGE OF THE SENSE (REFERENCE) CIRCUIT
Measure the voltage of the BAS Release Switch Sense (Reference) circuit
at the BAS Brake Booster harness connector.

Yes >> Go to 6
No >> Go to 8

RELEASE SWITCH SENSE (APPLIED) CIRCUIT

Measure the resistance between ground and the BAS Release Switch
Sense (Applied) circuit.

a short to ground.
No >> Go to 7
7. MEASURE THE RESISTANCE BETWEEN THE BAS RELEASE

SWITCH SENSE (APPLIED) CIRCUIT AND THE 12 VOLT
SUPPLY CIRCUIT

Measure the resistance between the BAS Release Switch Sense (Applied)
circuit and the BAS Release Switch 12 Volt Supply circuit in the BAS
Brake Booster harness connector.

a short to the BAS Release Switch 12 Volt Supply circuit.
No >> Replace the BAS Brake Booster. Refer to Page 5-50.
RELEASE SWITCH SENSOR (RELEASED) CIRCUIT

Measure the resistance between ground and the BAS Release Switch
Sensor (Released) circuit at the BAS Brake Booster harness connector.

Yes >> Repair the BAS Release Switch Sensor (Released) circuit
No >> Go to 9
9. MEASURE THE RESISTANCE OF THE BAS RELEASE SWITCH

SENSE (RELEASED) CIRCUIT

Measure the resistance of the BAS Release Switch Sensor (Released) cir-
cuit at the BAS Brake Booster harness connector and the CAB harness
connector.

8E-63.
No >> Repair the BAS Release Switch Sensor (Released)
BAS TRAVEL SENSOR CIRCUIT
BAS TRAVEL SENSOR CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Travel Sensor
malfunction.
POSSIBLE CAUSES
BAS TRAVEL SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

BAS TRAVEL SENSOR SIGNAL CIRCUIT SHORT TO 5-VOLT SUPPLY CIRCUIT
BAS TRAVEL SENSOR SIGNAL CIRCUIT SHORT TO GROUND
BAS TRAVEL SENSOR SIGNAL CIRCUIT SHORT TO GROUND CIRCUIT
BAS TRAVEL SENSOR SIGNAL CIRCUIT OPEN
BAS TRAVEL SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
BAS TRAVEL SENSOR 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
BAS TRAVEL SENSOR GROUND CIRCUIT OPEN
BAS TRAVEL SENSOR
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE BAS TRAVEL SENSOR SIGNAL

CIRCUIT

Measure the voltage of the BAS Travel Sensor Signal circuit at the BAS

Yes >> Repair the BAS Travel Sensor Signal circuit for a short to
voltage.
No >> Go to 2
2. MEASURE THE RESISTANCE BETWEEN THE BAS TRAVEL
SENSOR SIGNAL CIRCUIT AND THE 5-VOLT SUPPLY
CIRCUIT

Measure the resistance between the BAS Travel Sensor Signal circuit and
the 5-Volt supply circuit in the BAS Brake Booster harness connector.

the 5-Volt Supply circuit.
No >> Go to 3
3. MEASURE THE RESISTANCE OF THE BAS TRAVEL SENSOR

SIGNAL CIRCUIT

Measure the resistance of the BAS Travel Sensor Signal circuit from the
CAB harness connector to the BAS Brake Booster harness connector.

Yes >> Go to 4
No >> Repair the BAS Travel Sensor Signal circuit for an open.

TRAVEL SENSOR GROUND CIRCUIT

Measure the resistance between ground and the BAS Travel Sensor
Ground circuit.

Yes >> Repair the BAS Travel Sensor Ground circuit for a short to
ground.
No >> Go to 5
Measure the voltage of the BAS Travel Sensor 5-Volt Supply circuit at the
BAS Brake Booster harness connector.

Yes >> Go to 6
No >> Go to 8

TRAVEL SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the BAS Travel Sensor Sig-
nal circuit.

ground.
No >> Go to 7
7. MEASURE THE RESISTANCE BETWEEN THE BAS TRAVEL

SENSOR SIGNAL CIRCUIT AND THE GROUND CIRCUIT

Measure the resistance between the BAS Travel Sensor Signal circuit and
the BAS Travel Sensor Ground circuit in the BAS Brake Booster harness
connector.

the BAS Travel Sensor Ground circuit.
TRAVEL SENSOR 5-VOLT SUPPLY CIRCUIT


No >> Go to 9
9. MEASURE THE RESISTANCE OF THE BAS TRAVEL SENSOR


Measure the resistance of the 5-Volt Supply circuit from the BAS Brake
Booster harness connector to the CAB harness connector.

8E-63.
No >> Repair the BAS Travel Sensor 5-Volt Supply circuit for
an open.
BRAKE LAMP SWITCH CIRCUIT
• Set Condition: The Controller Antilock Brake (CAB) detects an abnormal condition on the Brake Lamp
Switch circuit.
POSSIBLE CAUSES

BRAKE LAMP SWITCH OUTPUT CIRCUIT OPEN
BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORTED
BRAKE LAMP SWITCH
BRAKE LAMP RELAY
Diagnostic Test
1. MEASURE BRAKE LAMP SWITCH VOLTAGE

before continuing.
Disconnect the Brake Lamp Switch harness connector.
Brake Lamp Switch harness connector.

Yes >> Go to 2
open.

SWITCH AND THE BRAKE LAMP RELAY

Remove the Brake Lamp Relay.
Measure the resistance of the circuit from the Brake Lamp Switch harness
connector B cavity 2 to the Brake Lamp Relay harness connector cavity 8.

Yes >> Go to 3
No >> Repair the circuit for an open.
SWITCH AND THE CAB

Measure the resistance of the Brake Lamp Switch Output circuit from the
Brake Lamp Switch harness connector to the CAB harness connector.

Yes >> Go to 4
No >> Repair the Brake Lamp Switch Output circuit for an open.
4. MEASURE BRAKE LAMP RELAY VOLTAGE

Reconnect the Brake Lamp Switch harness connector.
Have an assistant depress the brake pedal while measuring the voltage at
the Brake Lamp Relay harness connector cavity 8.

Yes >> Go to 5
No >> Replace the Brake Lamp Switch.
5. MEASURE THE RESISTANCE BETWEEN THE BRAKE LAMP RELAY

AND THE CAB

Measure the resistance of the Brake Lamp Relay Control circuit between
the Brake Lamp Relay harness connector and the CAB harness connec-
tor.

Yes >> Go to 6
No >> Repair the Brake Lamp Relay control circuit between the
Brake Lamp Relay and the CAB for an open.
harness connector.
Is voltage present?
Yes >> Repair the Brake Lamp Relay Control circuit for a short to
voltage.
No >> Go to 7

harness connector.
harness connector.

Yes >> Go to 8
No >> Repair the Brake Lamp Relay Control circuit for an open.
8. MEASURE BRAKE LAMP RELAY OUTPUT CIRCUIT RESISTANCE

With the ignition off and the jumper wire removed from the Brake Lamp
Measure the resistance of the Brake Lamp Relay Output circuit from the
Brake Lamp Relay harness connector to the CAB harness connector.

Yes >> Go to 9
No >> Repair the Brake Lamp Relay Output circuit for an open.
Measure the voltage of the Brake Lamp Relay Output circuit at the CAB
harness connector.
Is voltage present?
Yes >> Repair the Brake Lamp Relay Output circuit for a short to
voltage.
No >> Go to 10

harness connector.
Have an assistant depress the brake pedal while measuring the voltage of
the Brake Lamp Relay Output circuit at the CAB harness connector.

8E-63.
No >> Replace the Brake Lamp Relay.
BAS SOLENOID VALVE CIRCUIT
BAS SOLENOID VALVE CIRCUIT — CONTINUED
• Set Condition: The Controller Antilock Brake (CAB) detects a Brake Assist System (BAS) Solenoid Valve
malfunction.
POSSIBLE CAUSES
BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE

BAS SOLENOID VALVE CONTROL CIRCUIT SHORT TO VOLTAGE
BAS SOLENOID VALVE CIRCUITS SHORT TO EACH OTHER
BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT SHORT TO GROUND
BAS SOLENOID VALVE CONTROL CIRCUIT SHORT TO GROUND
BAS SOLENOID VALVE 5-VOLT SUPPLY CIRCUIT OPEN
BAS SOLENOID VALVE CONTROL CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE BAS SOLENOID VALVE


Measure the resistance of the BAS Solenoid Valve 5-Volt Supply circuit
from the CAB harness connector to the BAS Brake Booster harness con-
nector.

Yes >> Go to 2
No >> Repair the BAS Solenoid Valve 5-Volt Supply circuit for
an open.
CONTROL CIRCUIT

Measure the resistance of the BAS Solenoid Valve Control circuit from the
CAB harness connector to the BAS Brake Booster harness connector.

Yes >> Go to 3
No >> Repair the BAS Solenoid Valve Control circuit for an
open.

CIRCUITS

Measure the resistance between the BAS Solenoid Valve circuits at the

Yes >> Repair the BAS Solenoid Valve circuits for a short to each
other.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE 5-VOLT

SUPPLY CIRCUIT

Measure the voltage of the BAS Solenoid Valve 5-Volt Supply circuit at the
Is voltage present?
Yes >> Repair the BAS Solenoid Valve 5-Volt Supply circuit for a
short to voltage.
No >> Go to 5
5. MEASURE THE VOLTAGE OF THE BAS SOLENOID VALVE
CONTROL CIRCUIT

Measure the voltage of the BAS Solenoid Valve Control circuit at the BAS
Is voltage present?
Yes >> Repair the BAS Solenoid Valve Control circuit for a short to
voltage.
No >> Go to 6


Measure the resistance between ground and the BAS Solenoid Valve
5-Volt Supply circuit.

Yes >> Repair the BAS Solenoid Valve 5-Volt Supply circuit for a
short to ground.
No >> Go to 7

CONTROL CIRCUIT

Measure the resistance between ground and the BAS Solenoid Valve Con-
trol circuit.

Yes >> Repair the BAS Solenoid Valve Control circuit for a short to
ground.
1.
modules. Start the engine and allow it to run for 2 minutes.
Note: For sensor signal and pump motor faults, the CAB must sense
all 4 wheels at 25 km/h (15 MPH) before the CAB will extinguish the
indicator lamp.
Road test the vehicle for a minimum of 5 minutes. Perform several
antilock braking stops.
Again, with the DRB IIIT, confirm that no DTCs are present and that all
components are functioning properly.

BRAKE ASSIST SYSTEM CIRCUIT DIAGRAM

ZH BRAKES - ABS SERVICE INFORMATION 5 - 187
BRAKES - ABS SERVICE INFORMATION
TABLE OF CONTENTS
page page
BRAKES - ESP SERVICE INFORMATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

DESCRIPTION .................... . . . . 188 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 201
OPERATION - ELECTRONIC STABILITY BRAKE PRESSURE SENSOR
PROGRAM (ESP) . . . . . . . . . . . . . . . . . . . . . 189 DESCRIPTION ..................... . . . 201
DIAGNOSIS AND TESTING - INSPECTION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 201
AND ROAD TEST . . . . . . . . . . . . . . . . . . . . . 191 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
SPECIFICATIONS - TORQUE CHART . . . . . . . 192 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 201
FRONT WHEEL SPEED SENSOR TRAVEL SENSOR
DESCRIPTION .................... . . . . 193 DESCRIPTION ..................... . . . 201
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 193 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 195 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 202
REAR WHEEL SPEED SENSOR SOLENOID VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
LATERAL ACCELERATION SENSOR RELEASE SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
STEERING ANGLE SENSOR HYDRAULIC/MECHANICAL
DESCRIPTION .................... . . . . 200 STANDARD PROCEDURE - BLEEDING ABS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 200 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 203
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 HCU (HYDRAULIC CONTROL UNIT)
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 200 DESCRIPTION ..................... . . . 204
YAW RATE SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 204
DESCRIPTION .................... . . . . 201 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 201 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 206
5 - 188 BRAKES - ABS SERVICE INFORMATION ZH
BRAKES - ESP SERVICE INFORMATION

DESCRIPTION
1 - MASTER BRAKE CYLINDER 4 - LEFT FRONT WHEEL SPEED SENSOR

2 - RIGHT REAR WHEEL SPEED SENSOR 5 - ABS HYDRAULIC UNIT
3 - LEFT REAR WHEEL SPEED SENSOR 6 - RIGHT FRONT WHEEL SPEED SENSOR
This section covers the physical and operational descriptions and the on-car service procedures for Electronic Sta-
bility Program (ESP).
The purpose of this four-channel design ESP is to prevent wheel lockup under braking conditions on virtually any
type of road surface. Antilock braking is desirable because a vehicle that is stopped without locking the wheels
retains directional stability and some steering capability. This allows the driver to retain greater control of the vehicle
during braking. The ABS system features the following components. Refer to the proper repair procedures for further
diagnosis.
• Master brake cylinder. Refer to Page 5-44.
• Front wheel speed sensors. Refer to Page 5-193.
• Rear wheel speed sensors. Refer to Page 5-196.
• ABS hydraulic system. Refer to Page 5-204 - DESCRIPTION).
OPERATION - ELECTRONIC STABILITY PROGRAM (ESP)

NORMAL BRAKING

Under normal braking conditions, the ABS functions are the same as a standard base brake system with a diago-
nally split master cylinder and conventional vacuum assist.
ABS BRAKING
ABS operation is available at vehicle speeds above 5 mph (8 km/h). If a wheel locking is detected during a brake
application, the brake system enters the ABS mode. During ABS braking, hydraulic pressure in the four wheel cir-
cuits is modulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric solenoids
to allow modulation. Wheel lockup may be perceived at the very end of an ABS stop and is considered normal.
During an ABS stop, the brakes hydraulic system is still diagonally split. However, the brake system pressure is
further split into four control channels. During antilock operation of the vehicle’s brake system, the wheels are con-
trolled independently and are on separate control channels.
The system can build, hold and release pressure at each wheel, depending on signals generated by the wheel
speed sensors (WSS) at each wheel and received at the controller antilock brake (CAB).
NOISE AND BRAKE PEDAL FEEL

During ABS braking, some brake pedal movement may be felt. In addition, ABS braking will create a ticking, pop-
ping, or groaning noises heard by the driver. This is normal and is due to the pressurized fluid being transferred
between the master cylinder and the brakes themselves. If an ABS operation occurs during hard braking, some
pulsation may be felt in the vehicle body due to fore-and-aft movement of the suspension as brake pressures are
modulated.
At the end of an ABS stop, the ABS is turned off when the vehicle is slowed to a speed of 3 mph (5 km/h). There
may be a slight brake pedal drop anytime that the ABS is deactivated, such as at the end of the stop when the
vehicle speed is less than 3 mph (5 km/h) or during an ABS stop where the ABS is no longer required. These
conditions exist when a vehicle is being stopped on a road surface with patches of ice, loose gravel, or sand. Also,
stopping a vehicle on a bumpy road surface activates the ABS system due to “wheel hop” caused by bumps in the
road.
TIRE NOISE AND MARKS

Although the ABS system prevents complete wheel lockup, some wheel slip is desired in order to achieve optimum
braking performance. Wheel slip is defined as follows: “0” percent slip means the wheel is rolling freely. “100” per-
cent slip means the wheel is fully locked. During brake pressure modulation, wheel slip is allowed to reach up to “25
- 30” percent. This means that the wheel rolling velocity is “25 - 30” percent less than that of a free rolling wheel at
a given vehicle speed. This slip may result in some tire chirping, depending on the road surface. This sound should
not be interpreted as a total wheel lockup.
Complete wheel lockup normally leaves heavy black tire marks on dry pavement. An ABS stop will not leave heavy
black tire marks since the wheel never reaches a fully locked condition. However, tire marks may be noticeable as
light patched marks. This is a normal ABS occurrence.
START-UP CYCLE
There is a antilock warning indicator lamp in the instrument
cluster. When the ignition is switched on (ignition switch in
position 929), the antilock warning indicator lamp in the instru-
ment cluster illuminates, this is referred to as a bulb check the
antilock warning indicator lamp then goes out after the engine
is started. If the antilock warning indicator lamp illuminates
when the engine is running, there may be a fault in the ABS
system. The system is at this point inoperative, but full opera-
tion of the normal braking system is retained without ABS
protection.
DRIVE MODE
The system carries out a self-check after start-up. At the same
time, the return pump in the hydraulic control unit (HCU) also
starts up briefly (this may be felt in the brake pedal). If a fault
is found in the process, the antilock warning indicator lamp illu-
minates. Any system faults which occur while driving also
cause the antilock warning indicator lamp to illuminate and
stay on constantly.
If the antilock warning indicator lamp comes on while driving
and then goes out again after a short time, the cause may be
a battery under-voltage.
PREMATURE ABS CYCLING

Symptoms of premature ABS cycling include: clicking sounds from the solenoid valves, pump/motor running, and
pulsations in the brake pedal. Premature ABS cycling can occur at any braking rate of the vehicle and on any type
of road surface. The amber antilock warning indicator lamp may illuminate but no fault codes are stored in the con-
troller antilock brake (CAB).
Premature ABS cycling is a condition that needs to be correctly assessed when diagnosing problems with the
antilock brake system. It may be necessary to use a DRBIIIT scan tool to detect and verify any premature ABS
cycling.
Check the following common causes when diagnosing premature ABS cycling: damaged tone wheels, incorrect tone
wheels, damaged steering knuckle wheel speed sensor mounting bosses, loose wheel speed sensor mounting bolts,
excessive tone wheel runout, excessively large tone wheel-to-wheel speed sensor air gap, or a damaged speed
sensor head face. Give special attention to these components when diagnosing a vehicle exhibiting premature ABS
cycling.
After diagnosing a defective component, repair or replacement is required. When the component repair or replace-
ment is completed, test drive the vehicle to verify that any premature ABS cycling has been corrected.
DIAGNOSIS AND TESTING - INSPECTION AND ROAD TEST

1. Visually inspect the ABS for any damaged or disconnected components or connectors.
2. Verify that the brake lamps are operational. If they are not, repair them prior to continuing.
3. Connect the DRB IIIT scan tool to the Data Link Connector located under the instrument panel to the left of the
steering column. If the DRB IIIT does not power-up, check the power and ground supplies to the connector.
4. Turn the ignition key to the ON position. Select ANTILOCK BRAKES.
5. Read and record any Diagnostic Trouble Codes (DTCs). If any DTCs are present, refer to the appropriate diag-
nostic information.
Note: Diagnostic trouble codes (DTCs) are kept in the controller’s memory until either erased by the tech-
nician using the DRB IIIT, or erased automatically after 3500 miles or 255 ignition key cycles, whichever
occurs first. DTCs are retained by the controller even if the ignition is turned off or the battery is discon-
nected. More than one DTC can be stored at a time. When accessed, the number of occurrences and the
DTC that is stored are displayed.
If no concerns are observed, it may be necessary to road test the vehicle.

Many ABS conditions perceived to be a concern by the driver may be a normal operating condition. To become
familiarized with the normal operating characteristics of this antilock brake system, Refer to Page 5-189.
WARNING: CONDITIONS THAT RESULT IN TURNING ON THE AMBER ANTILOCK WARNING INDICATOR
LAMP MAY INDICATE REDUCED BRAKING ABILITY.
Before road testing a brake complaint vehicle, note whether the red brake warning indicator lamp or the amber
antilock warning indicator lamp, or both are turned on. If it is the red brake warning indicator lamp, there is a brake
hydraulic problem that must be corrected before driving the vehicle. Refer to Page 5-5 . If the red brake warning
indicator lamp is illuminated, there may also be a possibility that there is an ABS problem and the amber antilock
warning indicator lamp is not able to illuminate, so the instrument cluster turns on the red brake warning indicator
lamp by default.
If the amber antilock warning indicator lamp is on; road test the vehicle as described below. While only the amber
antilock warning indicator lamp is on, the ABS is not functional. The ability to stop the car using the normal brake
system should not be affected.
6. Turn the key to the OFF position and then back to the ON position. Note whether the amber antilock warning
indicator lamp continues to stay on.
7. If the amber antilock warning indicator lamp stays on, drive
the car to a speed of approximately 15 mph (25 km/h) to
complete the “ABS Start-Up” and “Drive-Off Cycle. Refer to
Page 5-44. If at this time the amber antilock warning indi-
cator lamp stays on, refer to the Appropriate Diagnostic
Information.
8. If the amber antilock warning indicator lamp goes out at
any time, drive the vehicle a short distance. Accelerate the
vehicle to a speed of at least 40 mph (64 km/h). Bring the
vehicle to a complete stop, braking hard enough to cause
the ABS to cycle. Repeat this action several times. Using
the DRB IIIT, read and record any Diagnostic Trouble
Codes (DTCs). If any DTCs are present, refer to the Appro-
priate Diagnostic Information.
SPECIFICATIONS - TORQUE CHART

Wheel Speed Sensors 12-14 — 106-124
Front Sensor Bolt
Wheel Speed Sensors 12-14 — 106-124
Rear Sensor Bolt
FRONT WHEEL SPEED SENSOR

DESCRIPTION

A wheel speed sensor is used at each wheel. The front sensors are mounted to the steering knuckles. Tone wheels
are mounted to the outboard ends of the front axle shafts. The gear type tone wheel serves as the trigger mech-
anism for each sensor. The wheel speed sensor’s function is to supply the current wheel speed to the CAB.
OPERATION
The wheel speed sensors convert the wheel speed into a digital signal. The CAB sends 12 volts to the wheel speed
sensors. The wheel speed sensor has an internal magneto resistance bridge that alters the voltage and amperage
of the signal circuit. This voltage and amperage is changed by magnetic induction when the toothed tone wheel
passes by the wheel speed sensor head. This digital signal is sent to the CAB. The CAB measures the voltage and
amperage of the digital signal for each wheel. The magnetic field of the wheel speed sensor is intersected by the
teeth of a rotor. This changes the magnetic field and the coil induces an AC voltage. The frequency of this alter-
nating current, governed by the number of teeth on the reluctor, fluctuates to reflect variations in wheel speed, is
also proportional to wheel speed.
REMOVAL
1. Remove the bolts (2) attaching the flange to the steering
knuckle.
2. Remove the wheel speed sensor (1) from the steering
knuckle.
3. Disconnect the wheel speed / brake wear indicator wire

harness connector (2) from the body mount connector (1).
INSTALLATION
1. Connect the wheel speed sensor / brake wear indicator
wire harness connector (2) to the body mount connector
(1).
2. Install the wheel speed sensor (1) to the steering knuckle.

3. Install the bolts (2) attaching the flange to the steering
knuckle. Tighten to 12 N·m (106 in. lbs.).
REAR WHEEL SPEED SENSOR

DESCRIPTION

A wheel speed sensor is used at each rear wheel. The gear type tone wheel serves as the trigger mechanism for
each of the front wheel speed sensors.
OPERATION
The sensors convert wheel speed into a digital signal. The CAB sends 12 volts to the sensors. The sensor has an
internal magneto resistance bridge that alters the voltage and amperage of the signal circuit. This voltage and
amperage is changed by magnetic induction when the toothed tone wheel passes the wheel speed sensor. This
digital signal is sent to the CAB. The CAB measures the voltage and amperage of the digital signal for each wheel.
REMOVAL
1. Remove the bolt (1) attaching the wheel speed sensor to
the rear knuckle.
2. Remove the rear wheel speed sensor (2) from the knuckle.
3. Pull the rubber grommet (1) out of the body. Unhook the
wheel speed sensor wire harness from the mount (2).
4. Disconnect the wheel speed sensor harness connector (1).
INSTALLATION
1. Connect the wheel speed sensor wire harness connector
(1).
2. Install the rubber grommet (1) to the body and then hook
the wheel speed sensor wire harness to the mount (2).
3. Install the wheel speed sensor (2) to the knuckle.

4. Install the bolt (1) attaching the wheel speed sensor to the
knuckle. Tighten to 12 N·m (106 in. lbs.).
LATERAL ACCELERATION SENSOR

DESCRIPTION
The lateral acceleration sensor is located under the the center console behind the gear shifter assembly. This sen-
sor is used to inform the ESP control module the amount of lateral acceleration forces during cornering.
OPERATION
The lateral acceleration sensor measures the amount of lateral acceleration during cornering. This sensor uses a
spring/mass type element to measure the amount of lateral acceleration. The lateral acceleration that occurs during
cornering causes the spring/mass element to move from its normal position to a position corresponding to the mag-
nitude of the lateral acceleration. Every change in the spring/mass element position changes the output voltage of
the sensor.
REMOVAL
1. Remove the rear center console. Refer to Page 23-173.
2. Disconnect the lateral acceleration sensor harness connector.
3. Unclip the lateral acceleration sensor.
INSTALLATION
1. Install the lateral acceleration sensor.
2. Connect the lateral acceleration harness connector.
3. Install the rear center console. Refer to Page 23-183.
STEERING ANGLE SENSOR

DESCRIPTION
A steering angle sensor is used to sense the steering angle
specified by the driver’s actions. The steering angle sensor is
part of the clock spring assembly within the steering column.
OPERATION
The steering angle sensor is a digital sensor with nine light-emitting diodes. The diodes within the sensor are used
to detect rotation and position of the steering wheel. This sensor can detect the steering wheel rotation and position
up to 720° of rotation. The steering angle sensor has continous battery voltage supplied by fuse 14 in the under-
hood accessory fuse block.
REMOVAL
Refer to the clockspring removal procedure Refer to Page 8O-94.
INSTALLATION
Refer to the clockspring installation procedure Refer to Page 8O-96.
YAW RATE SENSOR

DESCRIPTION
The yaw rate sensor is located under the the center console behind the gear shifter assembly. This sensor is used
to detect the swerving motion of the vehicle.
OPERATION
The yaw rate sensor is used to measure the yaw rate of the vehicle. When the vehicle turns, acceleration forces are
produced which cause torsion. This torsion change within the sensor is proportional of the yaw rate of the vehicle.
REMOVAL
2. Disconnect the yaw rate sensor harness connector.
3. Remove the two nuts, then remove the yaw rate sensor.
INSTALLATION
1. Install the yaw rate sensor and the nuts.
2. Connect the yaw rate sensor harness connector.

DESCRIPTION
There are two brake pressure sensors incorporated into the master cylinder on this vehicle. These sensors are used
to monitor brake pressures for the front and rear brake hydraulic systems.
OPERATION
These sensors are used to measure brake fluid pressure within the master cylinder. The sensors send a analog
voltage signal to the ESP/BAS control module.
REMOVAL
Refer to Page 5-76
INSTALLATION
Refer to Page 5-77
TRAVEL SENSOR
DESCRIPTION
The BAS travel sensor is a device used to detect an emergency stop. The BAS travel sensor is located on the
power brake booster.
OPERATION
The BAS travel sensor (3) reports the position of the brake
booster diaphragm plate to the Controller Antilock Brake
(CAB). The BAS travel sensor rod is attached to the brake
booster diaphragm plate (2). The diaphragm plate is located
internal to the brake booster (1), and the sensor rod moves
proportionally to the travel of the brake pedal. The travel sen-
sor is used as an input to the CAB to determine the amount of
driver braking effort.
REMOVAL
1. For the travel sensor removal procedure Refer to Page 5-78.
INSTALLATION
1. For the travel sensor installation procedure, Refer to Page 5-78.
SOLENOID VALVE
DESCRIPTION
The BAS solenoid valve is an electrically activated device used to increase brake assist.
OPERATION
The BAS solenoid valve is activated by the Controller Antilock Brake (CAB) Module. When activated, a poppet valve
opens and allows atmospheric pressure to enter the rear of the power brake booster diaphragm and increases the
brake pressure.
REMOVAL
The solenoid valve is part of the brake booster assembly. Refer to the brake booster removal procedure Refer to
Page 5-50.
INSTALLATION
The solenoid valve is part of the brake booster assembly. Refer to the brake booster installation procedure Refer to
Page 5-51.
RELEASE SWITCH
DESCRIPTION
The BAS release switch is a device used to signal the Controller Antilock Brake (CAB) module that the brake is
released.
OPERATION
When the force on the brake pedal is removed, movement on the brake booster control valve occurs. When this
occurs, the signal is sent to the Controller Antilock Brake (CAB) Module.
REMOVAL
The release switch is part of the brake booster assembly. Refer to the brake booster removal procedure Refer to
Page 5-50.
INSTALLATION
The release switch is part of the brake booster assembly. Refer to the brake booster installation procedure Refer to
Page 5-51.
HYDRAULIC/MECHANICAL
STANDARD PROCEDURE - BLEEDING ABS BRAKE SYSTEM
The base brake’s hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, partic-
ularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS
must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require
the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled.
When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate
bleeding.
1. Make sure all hydraulic fluid lines are installed and properly torqued.
2. Connect the DRB IIIT scan tool to the Data Link Connector. The connector is located under the lower steering
column cover to the left of the steering column.
3. Using the DRB IIIT, check to make sure the CAB does not have any fault codes stored. If it does, clear them
using the DRB IIIT.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF
AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF
THE BLEEDER SCREWS WHEN OPENED.
4. Bleed the base brake system using the standard pressure Refer to Page 5-9.
5. Using the DRB IIIT, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow
the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and pro-
ceed.
6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emp-
tying, causing air to enter the hydraulic system.
7. Fill the master cylinder reservoir to the full level.
8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel
spongy.
HCU (HYDRAULIC CONTROL UNIT)

DESCRIPTION
The CAB is a microprocessor-based device which monitors the
Antilock Brake System (ABS) during normal braking and con-
trols it when the vehicle is in an ABS stop. The CAB is
mounted to the Hydraulic Control Unit (HCU) (3) as part of the
Integrated Control Unit (ICU). The CAB uses a 47-way electri-
cal connector on the vehicle wiring harness. The power source
for the CAB is through the Hot at All Times 50 amp Engine
Fuse Block (2) (fuse 3).
OPERATION
All switching components of the ABS system are combined in the ABS hydraulic unit. A 2/2-way valve for build-up/
hold pressure or hold/reduce pressure functions is used on each wheel for control. At the rear, the same valves are
used for both wheels. The return pump integrated in the hydraulic unit is used to return the brake fluid during the
pressure reduction phase.
An increase in pressure compared to the pressure controlled by the master brake cylinder is not possible during the
ABS control phase. A muffler is fitted for each brake circuit to reduce delivery noise. During the ABS pressure reduc-
tion phase, the brake fluid flows back to the return pumps via the low-pressure accumulators.
NORMAL BRAKING FUNCTION

When the driver is applying the brake pedal during a no wheel spin or slip situation, the vehicle builds pressure in
the brake hydraulic system to engage the brakes and stop the vehicle. The hydraulic shuttle valve internal to the
ICU closes with every brake pedal application so pressure is not created at the inlet to the pump/motor and the
vehicle stops normally.
ABS BRAKING FUNCTION

During a stop where one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than
is allowed by the surface on which the tires are riding, the hydraulic shuttle valve closes upon brake application so
that the pump/motor cannot siphon brake fluid from the master cylinder. The normally open and normally closed
valves modulate (build/decay) the brake hydraulic pressure as required. The pump/motor is switched on so that the
brake fluid from the low pressure accumulators is returned to the master cylinder circuits. The brake fluid is routed
to either the master cylinder or the wheel brake, depending on the position of the normally open valve.
ABS TRACTION CONTROL FUNCTION

The vehicle in the traction control TC (ASR) mode. If the drive wheel is spinning and brake pressure is required to
reduce its speed. The normally open TC (ASR) valve is energized to isolate the brake fluid being pumped from the
master cylinder and to isolate the driven wheel. The normally open TC (ASR) valve bypasses the pump output back
to the master cylinder at a fixed pressure setting. The normally open and normally closed valves modulate (build/
decay) the brake pressure as required to slow the spinning wheel.
REMOVAL
1. Clean off the top of the HCU, especially around the hydrau-
lic lines (1-6). Be sure there is not any debris that could fall
into the brake line holes.
Note: Risk of confusion! Mark the hydraulic lines and the

corresponding connections before removing them from
the HCU.
2. Remove the hydraulic lines from the HCU. Seal off the
hydraulic lines and connections with suitable plugs.
• Right rear wheel (1)
• Master cylinder front (2)
• Right front wheel (3)
• Left front wheel (4)
• Left rear wheel (5)
• Master cylinder rear (6)
3. Disconnect the hydraulic controller unit harness connector

(1) from the CAB.
4. Remove the HCU upwards, by carefully pushing the
hydraulic lines to one side and carefully pull up.
INSTALLATION
1. Inspect the seating and condition of the rubber grommets
and replace if necessary.
CAUTION: Do not wrongfully connect hydraulic lines.

Trace the line routing to the corresponding wheel if nec-
essary.
2. Install the brake lines (1-6). Pay very close attention to the
locations when installing the hydraulic lines. DO NOT cross
thread.
• Right rear wheel (1)
• Master cylinder front (2)
• Right front wheel (3)
• Left front wheel (4)
• Left rear wheel (5)
• Master cylinder rear (6)
3. Connect the hydraulic controler unit harness connector (1)

to the CAB.
4. Bleed the brake system. Refer to Page 5-9.
5. Connect the DRBIIIT and read any DTCs, then clear any
applicable codes.
ZH CLUTCH 6-1
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RELEASE BEARING/SLAVE CYLINDER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
WARNING .............................2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING ................2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MASTER CYLINDER BLEEDING . . . . . . . . . . . 7 FLYWHEEL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS ........................8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLUTCH DISC DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 21
REMOVAL .............................9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CLUTCH COVER PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CLUTCH PEDAL
MASTER CYLINDER - CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, a single, dry-
type disc, and a diaphragm style clutch cover. A hydraulic link-
age is used to operate the clutch release bearing. The
flywheel is bolted to the rear flange of the crankshaft. The
clutch pressure plate is bolted to the flywheel with the clutch
disc located between these two components. The clutch sys-
tem provides a mechanical, but still easily detachable, link
between the engine and the transmission. The system is
designed to ensure that the full torque output of the engine is
transfered to the transmission while isolating the transmission
from the engine firing pulses to minimize concerns such as
gear rattle.
6-2 CLUTCH ZH
OPERATION
The clutch operates with leverage, clamping force and friction. The disc serves as the friction element, the dia-
phragm-style clutch cover provides the clamping force. The clutch pedal, hydraulic linkage and the release bearing
provide the leverage.
The reservoir is mounted on the dash panel. The clutch master cylinder push rod is connected to the clutch pedal.
When the clutch pedal is depressed, the slave cylinder is operated by the clutch master cylinder mounted on the
pedal assembly. The release bearing then depresses the clutch cover spring fingers, thereby releasing pressure on
the clutch disc and allowing the engine crankshaft to spin independently of the transmission input shaft.
WARNING
WARNING: EXERCISE CARE WHEN SERVICING CLUTCH COMPONENTS. FACTORY INSTALLED CLUTCH
DISCS DO NOT CONTAIN ASBESTOS FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY CONTAIN ASBES-
TOS FIBERS FROM AFTERMARKET COMPONENTS. BREATHING EXCESSIVE CONCENTRATIONS OF THESE
FIBERS CAN CAUSE SERIOUS BODILY HARM. WEAR A RESPIRATOR DURING SERVICE AND NEVER
CLEAN CLUTCH COMPONENTS WITH COMPRESSED AIR OR WITH A DRY BRUSH. EITHER CLEAN THE
COMPONENTS WITH A WATER DAMPENED RAG OR USE A VACUUM CLEANER SPECIFICALLY DESIGNED
FOR REMOVING ASBESTOS FIBERS AND DUST. DO NOT CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS IN SEALED BAGS OR CONTAINERS. THIS WILL HELP
MINIMIZE EXPOSURE TO YOURSELF AND TO OTHERS. FOLLOW ALL RECOMMENDED SAFETY PRAC-
TICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE
ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR THE HANDLING AND DISPOSAL OF PRODUCTS CON-
TAINING ASBESTOS.

Drive the vehicle at normal speeds. Shift the transmission through all gear ranges and observe clutch action. If the
clutch chatters, grabs, slips or does not release properly, remove and inspect the clutch components. If the problem
is noise or hard shifting, further diagnosis may be needed as the transmission or another driveline component may
be at fault.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, water or hydraulic clutch fluid on the clutch disc
and pressure plate surfaces will cause chatter, slip and grab. Inspect components for oil, hydraulic fluid or water/
road splash contamination.
Oil contamination indicates a leak at either the rear main seal or transmission input shaft. Hydraulic clutch fluid
leaks are usually from damaged slave cylinder seals. Heat buildup caused by slippage between the clutch cover,
disc and flywheel can bake the oil residue onto the components. The glaze-like residue ranges in color from amber
to black.
Road splash contamination is dirt/water entering the clutch housing due to loose bolts, housing cracks. Driving
through deep water puddles can force water/road splash into the housing through such openings.
IMPROPER RELEASE OR IMPROPER CLUTCH ENGAGEMENT

Clutch release or engagement problems are caused by wear or damaged clutch components. A visual inspection of
the release components will usually reveal the problem component.
Release problems can result in hard shifting and noise. Look for leaks at the clutch hydraulic cylinders and inter-
connecting line. Also worn/loose clutch disc, clutch cover or release bearing.
Engagement problems can result in slip, chatter/shudder and noisy operation. The causes may be clutch disc con-
tamination, wear, distortion or flywheel damage. Visually inspect to determine the actual cause of the problem.
ZH CLUTCH 6-3
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment
caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch
release.
CLUTCH COVER AND DISC RUNOUT

Check the clutch disc before installation. Axial (face) runout of a new disc should not exceed 0.50 mm (0.020 in.).
Measure runout about 6 mm (1/4 in.) from the outer edge of the disc facing. Obtain another disc if runout is exces-
sive.
Check condition of the clutch before installation. A warped cover or diaphragm spring will cause grab and incom-
plete release or engagement. Be careful when handling the cover and disc. Impact can distort the cover, diaphragm
spring, release fingers and the hub of the clutch disc.
Use an alignment tool when positioning the disc on the flywheel. The tool prevents accidental misalignment which
could result in cover distortion and disc damage.
A frequent cause of clutch cover distortion (and subsequent misalignment) is improper bolt tightening.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the flywheel face with a dial indicator.
Common causes of runout are:
• Heat warpage
• Improper machining
• Incorrect bolt tightening
• Improper seating on crankshaft flange shoulder
• Foreign material on crankshaft flange
Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machin-
ing will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface
grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock
removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.).
Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the fly-
wheel and interfere with proper clutch release.
Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the fly-
wheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar Lock
And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub
causing runout.
6-4 CLUTCH ZH
DIAGNOSIS CHART
The diagnosis chart describes common clutch problems, causes and correction. Conditions, causes and corrective
action are outlined in the indicated columns.
DISC FACING WORN OUT 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the 2. Replace cover and disc.

clutch. Results in rapid overheating
and wear.
3. Insufficient clutch cover 3. Replace cover and disc.
diaphragm spring tension.
CLUTCH DISC FACING 1. Leak at rear main engine seal or 1. Replace appropriate seal.
CONTAMINATED WITH OIL, transmission input shaft seal.
GREASE, OR HYDRAULIC
CLUTCH FLUID. 2. Excessive amount of grease 2. Remove grease and apply the
applied to the input shaft splines. correct amount of grease.
3. Road splash, water entering 3. Replace clutch disc. Clean clutch
housing. cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic slave cylinder.
CLUTCH IS RUNNING PARTIALLY 1. Release bearing sticking or 1. Verify failure. Replace the release
DISENGAGED. binding and does not return to the bearing/slave cylinder and
normal running position. transmission front bearing retainer
as necessary.
FLYWHEEL BELOW MINIMUM 1. Improper flywheel machining. 1. Replace flywheel.

THICKNESS SPECIFICATION. Flywheel has excessive taper or
excessive material removal.
CLUTCH DISC, COVER AND/OR 1. Rough handling. Impact bent 1. Replace disc or cover as
DIAPHRAGM SPRING WARPED cover, spring, or disc. necessary.
OR DISTORTED.
2. Improper bolt tightening 2. Tighten clutch cover using proper
procedure. procedure.
FACING ON FLYWHEEL SIDE OF 1. Flywheel surface scored or 2. Correct surface condition if

DISC TORN, GOUGED, OR nicked. possible. Replace flywheel and disc
WORN. as necessary.
2. Clutch disc sticking or binding on 2. Lubricate splines with high

transmission input shaft. temperature grease.
CLUTCH DISC FACING BURNT. 1. Frequent operation under high 1. Correct condition of flywheel and
FLYWHEEL AND COVER loads or hard acceleration pressure plate surface. Replace
PRESSURE PLATE SURFACES conditions. clutch cover and disc. Alert driver to
HEAVILY GLAZED. problem cause.
2. Driver frequently rides (slips) 2. Correct condition of flywheel and

clutch. Results in rapid wear and pressure plate surface. Replace
overheating of disc and cover. clutch cover and disc. Alert driver to
problem cause.
ZH CLUTCH 6-5
CLUTCH DISC BINDS ON INPUT 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub
SHAFT SPLINES. during installation. splines if possible. Replace disc if
necessary.
2. Input shaft splines rough, 2. Clean, smooth, and lubricate

damaged, or corroded. shaft splines if possible. Replace
input shaft if necessary.
CLUTCH DISC RUSTED TO 1. Clutch not used for an extended 1. Sand rusted surfaces with 180
FLYWHEEL AND/OR PRESSURE period of time (e.g. long term grit sanding paper. Replace clutch
PLATE. vehicle storage). cover and flywheel if necessary.
PILOT BEARING SEIZED, LOOSE, 1. Bearing cocked during 1. Install and lubricate a new
OR ROLLERS ARE WORN. installation. bearing.
2. Bearing defective. 2. Install and lubricate a new

bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
CLUTCH WILL NOT DISENGAGE 1. Low hydraulic clutch fluid level. 1. Replace hydraulic clutch
PROPERLY. components as necessary.
2. Clutch cover loose. 2. Follow proper bolt tightening

procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring 4. Replace clutch cover.
bent or warped.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Clutch master or slave cylinder 6. Replace hydraulic components as
failure. necessary.
CLUTCH PEDAL SQUEAK. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not 2. Lubricate master cylinder

lubricated. bushing.
3. Pedal bushings worn out or 3. Replace and lubricate bushings.
cracked.
CLUTCH MASTER OR SLAVE 1. Master or slave cylinder 1. Replace hydraulic clutch

CYLINDER PLUNGER DRAGGING components worn or corroded. components as necessary.
AND/OR BINDING
RELEASE BEARING IS NOISY. 1. Release bearing defective or 1. Replace release bearing/slave

damaged. cylinder.
6-6 CLUTCH ZH
CONTACT SURFACE OF 1. Clutch cover incorrect or release 1. Replace clutch cover and release
RELEASE BEARING DAMAGED. fingers bent or distorted. bearing/slave cylinder.
2. Release bearing defective or 2. Replace the release bearing/

damaged. slave cylinder.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
PARTIAL ENGAGEMENT OF 1. Clutch pressure plate position 1. Replace clutch disc and cover.
CLUTCH DISC. ONE SIDE OF incorrect.
DISC IS WORN AND THE OTHER 2. Clutch cover, spring, or release 2. Replace clutch disc and cover.
SIDE IS GLAZED AND LIGHTLY fingers bent or distorted.
WORN.
3. Clutch disc damaged or 2. Replace clutch disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc and clutch cover.
Correct as necessary.
ZH CLUTCH 6-7
STANDARD PROCEDURE
MASTER CYLINDER BLEEDING
WARNING: RISK OF POISONING DUE TO SWALLOWING BRAKE FLUID. RISK OF INJURY DUE TO BRAKE
FLUID COMING INTO CONTACT WITH THE SKIN AND EYES.
Note: Only pour brake fluid into suitable, appropriately marked containers. Wear protective clothing and
safety glasses when handling brake fluid.
1. Remove the brake master cylinder reservoir cap.

2. Connect a pressure bleeder to the brake master cylinder
reservoir.

4. Open the bleeder screw (1) on the slave cylinder.
5. Allow the brake fluid to flow until there are no bubbles and
fluid is clear.
6. Close the bleeder screw.
8. Disconnect the pressure bleeder.
9. Install the brake master cylinder reservoir cap.
10. Check the operation of the clutch.
6-8 CLUTCH ZH
SPECIFICATIONS

Flywheel Bolts 45 33 398
Slave Cylinder Bolts 10 7 89
Clutch Cover Bolts 25 18 221
SPECIAL TOOLS
9102 FLYWHEEL LOCKING TOOL

ZH CLUTCH 6-9
CLUTCH DISC
REMOVAL
1. Remove the transmission Refer to Page 21-344.
Note: Remove clutch cover bolts 1 to 1 1/2 turns at a time.
2. Loosen the bolts (1) on the clutch cover.

3. Mark the relation of the clutch cover to the flywheel.
4. Remove the bolts (1) on the clutch cover.
5. Remove the clutch cover (1) and the clutch disc (2).
6 - 10 CLUTCH ZH
INSTALLATION
1. If the clutch cover is to be reused adjustment is required.

Use an old release bearing or a length of pipe to release
diaphragm pressure. Set the adjusting ring to the mark as
shown.
2. Position the clutch disc and clutch cover on the flywheel.
3. Loosely install the clutch cover bolts (1).
ZH CLUTCH 6 - 11
4. Install a universal clutch alignment tool (1).

5. Align the clutch disc.
Note: Tighten the clutch cover bolts 1 to 11⁄2 turns at a

time.
6. Tighten the clutch cover bolts (1) until all bolts are fully
seated. Tighten the bolts to 25 N·m (18 ft. lbs.).
7. Remove the clutch alignment tool (1).

8. Install the transmission Refer to Page 21-347.
6 - 12 CLUTCH ZH
CLUTCH COVER
DESCRIPTION
The clutch cover assembly is a diaphragm type with a one-piece spring and multiple release fingers. The clutch
cover is attached to the engine flywheel with eight bolts.
OPERATION
The clutch cover (1) assembly clamps the clutch disc against
the flywheel. When the release bearing is depressed, the pres-
sure exerted on the clutch disc by the clutch cover spring is
decreased. As additional force is applied to the release bear-
ing, the bearing presses the diaphragm spring fingers (2)
inward on the fulcrums. This action moves the clutch cover (1)
rearward relieving the clamped force on the disc. The clutch
disc is disengaged and freewheeling at this point.
REMOVAL
2. Loosen the bolts (1) on the clutch cover.
3. Mark the relation of the clutch cover to the flywheel.
Note: Remove clutch cover bolts 1 to 1 1/2 turns at a time.
4. Remove the bolts (1) on the clutch cover.

ZH CLUTCH 6 - 13
5. Remove the clutch cover (1).
INSTALLATION
1. If the clutch cover is to be reused, adjustment is required.

Use an old release bearing or a length of pipe to release
diaphragm pressure. Set the adjusting ring to the mark as
shown.
6 - 14 CLUTCH ZH
2. Position the clutch disc and clutch cover on the flywheel.

3. Loosely install the clutch cover bolts (1).
4. Install a universal clutch alignment tool (1).

5. Align the clutch disc.
Note: Tighten the clutch cover bolts 1 to 11⁄2 turns at a

time.
6. Tighten the clutch cover bolts (1) until all bolts are fully
seated. Tighten to 25 N·m (18 ft. lbs.).
ZH CLUTCH 6 - 15
7. Remove the clutch alignment tool (1).

MASTER CYLINDER - CLUTCH

REMOVAL
WARNING: RISK OF POISONING DUE TO SWALLOWING
BRAKE FLUID. RISK OF INJURY DUE TO BRAKE FLUID
COMING INTO CONTACT WITH THE SKIN AND EYES.
Note: Only pour brake fluid into suitable, appropriately

marked containers. Wear protective clothing and safety
glasses when handling brake fluid.
1. Remove the lower driver side instrument panel (5) Refer to

Page 23-149.
2. Remove the illumination control module (4).
6 - 16 CLUTCH ZH
CAUTION: Avoid contamination in interior with brake fluid.
3. Clamp the clutch master cylinder supply hose (1) from the
brake master cylinder reservoir.
4. Disconnect the clutch master cylinder supply hose (1) at
the clutch master cylinder.
5. Disconnect the clutch master cylinder pressure line (1) at

the clutch master cylinder and cap the line.
6. Remove the clutch pedal spring (3), circlip (1), and retain-
ing nuts (2).
7. Rotate the clutch master cylinder counter-clockwise and
remove from the vehicle.
ZH CLUTCH 6 - 17
INSTALLATION

1. Position the clutch master cylinder on the pedal and pivot it

clockwise.
2. Install the retaining nuts (2) on the bracket assembly.
Tighten nuts to 10 N·m (89 in. lbs.).
3. Install the circlip (1) at the pedal stud.
4. Install the spring (3) to the pedal.
5. Connect the clutch master cylinder fluid pressure line (1).

6 - 18 CLUTCH ZH
6. Connect the clutch master cylinder fluid supply hose (1).

7. Remove the clamp from the clutch master cylinder supply
hose.
8. Install the illumination control module (4).

9. Install the lower drivers side instrument panel (5) Refer to
Page 23-155.
10. Bleed the hydraulic clutch system Refer to Page 6-7.
11. Check for proper clutch actuation.
ZH CLUTCH 6 - 19
RELEASE BEARING/SLAVE CYLINDER

DESCRIPTION
1 - SLAVE CYLINDER 3 - RELEASE BEARING

2 - FLUID LINE 4 - BLEEDER SCREW
The clutch release bearing is integrated with the clutch slave cylinder for smooth operation. By eliminating the clutch
release fork, less effort is required to release the clutch. Even pressure application to the release bearing increases
the life of the bearing.
OPERATION
The release bearing is operated by a slave cylinder in the clutch housing. The slave cylinder force causes the
release bearing to move into contact with the diaphragm spring. As additional force is applied, the bearing presses
the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward relieving clamp-
ing force on the clutch disc. Releasing pedal pressure removes clutch hydraulic pressure. The release bearing then
moves away from the diaphragm spring which allows the pressure plate to exert clamping force on the clutch disc.
6 - 20 CLUTCH ZH
REMOVAL


2. Remove the clutch slave cylinder/release bearing bolts (1).
3. Remove the clutch slave cylinder/release bearing and plas-
tic washer from transmission bell housing.
4. Inspect the clutch slave cylinder/release bearing for signs of
leakage and wear.
5. Replace all worn parts as necessary.
INSTALLATION
1. Position the slave cylinder/release bearing in the bell hous-
ing.
2. Install the slave cylinder/release bearing bolts (1). Tighten
the bolts to 10 N·m (89 in. lbs.).
4. Bleed the hydraulic clutch system Refer to Page 6-7.
ZH CLUTCH 6 - 21
FLYWHEEL
DESCRIPTION
The flywheel is a heavy plate bolted to the rear of the crankshaft. The flywheel incorporates the ring gear around the
outer circumference to mesh with the starter to permit engine cranking. The rear face of the flywheel serves as the
driving member to the clutch disc.
OPERATION
The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the rotating
mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain. The crank-
shaft has the tendency to attempt to speed up and slow down in response to the cylinder firing pulses. The flywheel
dampens these impulses by absorbing energy when the crankshaft speeds and releasing the energy back into the
system when the crankshaft slows down.

Check flywheel runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the flywheel face with a dial indicator.
Common causes of runout are:
• Heat warpage
• Improper machining
• Incorrect bolt tightening
• Improper seating on crankshaft flange shoulder
• Foreign material on crankshaft flange
6 - 22 CLUTCH ZH
REMOVAL
1. Remove the clutch Refer to Page 6-9.
2. Install Special Tool 9102 (1) Flywheel. Locking Tool.
3. Remove and discard the flywheel bolts (1).

4. Remove the flywheel spacer (2) and the flywheel (3).
5. Inspect the flywheel for wear or cracking.
6. Inspect the starter ring gear for wear and missing teeth.
ZH CLUTCH 6 - 23
INSTALLATION
Note: If a new flywheel is installed, perform initialization in
the Powertrain Control Module with the DRBIII in the menu
point (Control module adaptation(.
Note: Align flywheel on straight pin in crankshaft.
1. Position the flywheel (3) on the crankshaft.

2. Install the spacer (2) and new flywheel bolts (1).
3. Install Special Tool 9102 (1) Flywheel Locking Tool.

4. Tighten the flywheel bolts to 45 N·m (33 ft. lbs.). For final
torque, rotate the flywheel bolts an additional 45° clockwise.
5. Install the clutch Refer to Page 6-10.
6. Remove Special Tool 9102 Flywheel Locking Tool.
PILOT BEARING
REMOVAL
1. Remove the transmission.
2. Remove pressure plate and clutch disc.
3. Remove pilot bearing with an internal (blind hole) puller.
INSTALLATION
1. Lubricate new bearing with Mopar high temperature bearing grease or equivalent.
2. Start new bearing into crankshaft by hand, then seat bearing with clutch alignment tool.
3. Lightly scuff sand flywheel surface with 180 grit emery cloth. Then clean surface with wax and grease remover.
4. Install clutch disc and clutch cover Refer to Page 6-10.
6 - 24 CLUTCH ZH
CLUTCH PEDAL
REMOVAL
1. Remove the driver side lower instrument panel Refer to
Page 23-149.
2. Remove the driver side upper instrument panel (1) Refer to
Page 23-149.
3. Disconnect the clutch master cylinder fluid pressure line (1)

Refer to Page 6-15.
ZH CLUTCH 6 - 25
4. Disconnect the clutch pedal position switch.

5. Remove the circlip (2) and the return spring (3).
6. Remove the clutch pedal from the pivot (1).
INSTALLATION
1. Install the clutch pedal on the bracket the pivot (1).
2. Install the return spring (3) and the circlip (2).
6 - 26 CLUTCH ZH
3. Install the clutch master cylinder fluid pressure line (1)

Refer to Page 6-17.
4. Install the driver side upper instrument panel (1) Refer to

Page 23-155.
5. Install the driver side lower instrument panel Refer to Page
23-155.
ZH COOLING 7-1
COOLING
TABLE OF CONTENTS
page page
COOLING - ELECTRICAL DIAGNOSTICS . . . . . . . . 1 COOLING - SERVICE INFORMATION . . . . . . . . . . 11
COOLING - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
COOLING - ELECTRICAL DIAGNOSTICS *RADIATOR COOLING FAN ALWAYS ON . . . . . 6

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWERTRAIN VERIFICATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TEST – VER 3 . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 10
*RADIATOR COOLING FAN INOPERATIVE . . . 2
COOLING - ELECTRICAL DIAGNOSTICS

DESCRIPTION
The radiator cooling fan system is comprised of the radiator fan control module, powertrain control module, and the
radiator fan motor. The radiator fan control module acts as the “relay” for the cooling fan circuit. The module is
mounted to the inner fender. The powertrain control module acts as the “input” to the module to command the fan
operation. The radiator cooling fan is made up of a multiple bladed fan. The cooling fan motor is a high speed DC
type.
OPERATION
The radiator cooling fan is designed to keep the cooling system operating at a set temperature. The cooling fan
operates when the engine coolant temperature exceeds 106 degrees Celsius or when the A/C has been requested
on. The powertrain control module sends an input to the radiator fan control module to activate the cooling fan. The
radiator fan control module receives voltage from fuse 2 (50 amp) in the engine fuse block. The radiator fan control
module is grounded through G100.

7-2 COOLING - ELECTRICAL DIAGNOSTICS ZH
*RADIATOR COOLING FAN INOPERATIVE
ZH COOLING - ELECTRICAL DIAGNOSTICS 7-3
*RADIATOR COOLING FAN INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RADIATOR FAN CONTROL MODULE OUTPUT CIRCUIT OPEN
RADIATOR FAN CONTROL MODULE GROUND CIRCUIT OPEN
RADIATOR FAN CONTROL CIRCUIT OPEN
RADIATOR FAN CONTROL MODULE
RADIATOR FAN MOTOR
For a complete Radiator Cooling Fan Circuit Diagram, Refer to Page 7-10.
Diagnostic Test
1. ACTUATE RADIATOR COOLING FAN WITH DRB IIIT

With the DRB IIIT, actuate the Radiator Cooling Fan.
Is the Radiator Cooling Fan operating?

Yes >> Replace the Powertrain Control Module. Refer to Page
8E-56
Perform POWERTRAIN VERIFICATION TEST - VER 3.
No >> Go to 2
2. CHECKING THE FUSED B(+) CIRCUIT

Disconnect the Radiator Fan Control Module harness connector.
Note: Check connectors — Clean/repair as necessary.
Measure the voltage of the Fused B(+) circuit at the Radiator Fan Control
Module harness connector.

Yes >> Go to 3
Perform POWERTRAIN VERIFICATION TEST - VER
3.
3. CHECKING THE GROUND CIRCUIT
Measure the resistance between ground and the module Ground circuit.

Yes >> Go to 4
No >> Repair the module Ground circuit for an open.
3.
4. CHECKING THE RADIATOR FAN CONTROL CIRCUIT

Disconnect the Powertrain Control Module (PCM) C4 harness connector.
Measure the resistance of the Radiator Fan Control circuit from the Radi-
ator Fan Control Module harness connector to the PCM harness connec-
tor.

Yes >> Go to 5
No >> Repair the Radiator Fan Control circuit for an open.
3.
5. CHECKING THE RADIATOR FAN CONTROL MODULE OUTPUT

CIRCUIT

Disconnect the Radiator Fan Motor harness connector.
Measure the resistance of the Radiator Fan Control Module Output circuit
from the Radiator Fan Control Module harness connector to the Radiator
Fan Motor harness connector.

Yes >> Go to 6
No >> Repair the Radiator Fan Control Module Output circuit for
an open.
3.
6. CHECKING THE RADIATOR FAN CONTROL MODULE GROUND
CIRCUIT

Measure the resistance of the Radiator Fan Control Module Ground circuit
from the Radiator Fan Control Module harness connector to the Radiator
Fan Motor harness connector.

Yes >> Go to 7
No >> Repair the Radiator Fan Control Module Ground circuit
for an open.
3.
7. CHECKING THE RADIATOR FAN MOTOR

Measure the resistance of the Radiator Fan Motor.

Yes >> Replace the Radiator Fan Control Module. Refer to Page
7-29
No >> Replace the Radiator Fan Motor. Refer to Page 7-26
Perform POWERTRAIN VERIFICATION TEST -
VER 3.
*RADIATOR COOLING FAN ALWAYS ON
*RADIATOR COOLING FAN ALWAYS ON — CONTINUED
POSSIBLE CAUSES
RADIATOR FAN CONTROL CIRCUIT SHORTED TO GROUND

A/C SWITCH CIRCUIT MALFUNCTION
POWERTRAIN CONTROL MODULE
For a complete Radiator Cooling Fan Circuit Diagram, Refer to Page 7-10.
Diagnostic Test
1. CHECKING DRBIIIT FOR A/C SWITCH STATUS

Insure that the A/C Switch is off.
With the DRBIIIT in Inputs/Outputs, check the status of the A/C Switch.
Does the DRBIIIT display A/C Switch ON?

Yes >> Repair the A/C Switch circuit.
No >> Go to 2
2. CHECKING THE RADIATOR FAN CONTROL CIRCUIT

Disconnect the Powertrain Control Module (PCM) C4 harness connector.
Measure the resistance between ground and the Radiator Fan Control cir-
cuit.

Yes >> Repair the Radiator Fan Control circuit for a short to
ground.
No >> Go to 3
*RADIATOR COOLING FAN ALWAYS ON — CONTINUED
3. CHECKING THE POWERTRAIN CONTROL MODULE
Reconnect the PCM C4 harness connector.
cuit at the Radiator Fan Control Module harness connector.

8E-56
No >> Replace the Radiator Fan Control Module. Refer to
Page 7-29
VER 3.
POWERTRAIN VERIFICATION TEST – VER 3
1.
Note: If the PCM has been replaced, the PCM version coding must be
updated with the DRB IIIT.
Inspect the vehicle to ensure that all components related to the repair are
connected properly.
With the DRB IIIT, clear DTCs and Reset Memory for all engine values.
Run the engine for one warm-up cycle to verify operation.
Road test the vehicle. Use all accessories that may be related to this
repair.
With the DRB IIIT, confirm that no DTCs are present and that all compo-
nents are functioning properly.
If this test is being performed after a No Trouble Code test, verify the
symptom is no longer present.
If the symptom is still present, or any other symptom or DTC is present
refer to the appropriate category and perform the corresponding symptom.
Refer to any Technical Service Bulletins that may apply.

7 - 10 COOLING - ELECTRICAL DIAGNOSTICS ZH
RADIATOR COOLING FAN CIRCUIT DIAGRAM

ZH COOLING - SERVICE INFORMATION 7 - 11
COOLING - SERVICE INFORMATION
TABLE OF CONTENTS
page page
COOLING - SERVICE INFORMATION CLEANING . . . . . . . . . . . . ... . . . . . . . . . . . . . 14

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSPECTION .......... ... . . . . . . . . . . . . . 14
OPERATION SPECIFICATIONS-TORQUE .. . . . . . . . . . . . . . 14
ENGINE COOLING SYSTEM . . . . . . . . . . . . . 12 SPECIAL TOOLS . . . . . . . . ... . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING ENGINE ............... ... . . . . . . . . . . . . . 16
ENGINE COOLING SYSTEM OVERHEATING . 12 ACCESSORY DRIVE . . . . . . ... . . . . . . . . . . . . . 42
COOLING SYSTEM LEAK . . . . . . . . . . . . . . . 13 TRANSMISSION ......... ... . . . . . . . . . . . . . 49
COOLING - SERVICE INFORMATION

DESCRIPTION
A conventional cross-flow aluminum core radiator (4) cools the engine. The coolant recovery reservoir (1) includes
a coolant level sensor. A bypass circuit and additional coolant circulation pump can continue to circulate coolant
through the heater core when the engine is off. A level sensor in the coolant recovery reservoir notifies the driver if
there is insufficient coolant by illuminating the low engine coolant warning lamp in the instrument cluster. An electric
fan (2) which is switched on and off by the radiator fan control module draws air for added cooling when needed.
7 - 12 COOLING - SERVICE INFORMATION ZH
OPERATION
ENGINE COOLING SYSTEM
CAUTION: The cooling system is designed to function with a 50/50 mixture of MoparT Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) or equivalent, and distilled water. Higher concentrations may result in
poor cooling performance and premature water pump seal failure. This antifreeze/coolant may not be mixed
or substituted with any other type.
1 - COOLANT RESERVOIR 5 - COOLANT CIRCULATION PUMP

2 - ENGINE BLOCK 6 - THERMOSTAT
3 - HEATER CORE 7 - RADIATOR
4 - COOLANT CIRCULATION VALVE
• When engine is cold: Thermostat (6) is closed, cooling system has no flow through the radiator (7). The
coolant flows through the engine, heater core (3), coolant recovery reservoir (1) and an internal engine by-
pass.
• When engine (2) is warm: Thermostat (6) is open, coolant flows through the radiator (7), heater core (3),
coolant recovery reservoir (1) and by-pass.
The cooling systems primary purpose is to maintain engine temperature in a range that will provide satisfactory
engine performance and emission levels under all expected driving conditions. It also provides hot coolant for
heater, and cooling for automatic transmission fluid. It does this by transferring heat from engine metal to coolant,
moving this heated coolant to the radiator, and then transferring this heat to the ambient air.

ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following
may be the cause:
• Prolonged Idle
• Very High Ambient Temperature

• Slight Wind At Idle
• Slow Traffic
• Traffic Jams
• High Speed
• Steep Grades
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at end of normal range.
1. RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been performed on vehicle that may affect cooling system. This may be:
• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt(s)
• Brakes (possibly dragging)
• Changed parts. Incorrect water pump, or pump rotating in wrong direction due to belt not correctly routed.
• Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system).
COOLING SYSTEM LEAK

With engine not running, wipe the coolant recovery reservoir neck sealing seat clean.
Attach a radiator pressure tester (1) to the coolant recovery
reservoir with Special Tool 9107 Pressure Tester Adaptor (2).
Apply 104 kPa (15 psi) pressure to the cooling system. If the
pressure drops more than 2 psi in 2 minutes inspect all points
for external leaks.
All hoses, radiator and heater, should be moved while at 15
psi since some leaks occur while driving due to engine rock,
vibration, etc.
If there are no external leaks after the gauge dial shows a
drop in pressure, detach the tester. Start engine and run the
engine to normal operating temperature in order to open the
thermostat and allow the coolant to expand. Reattach the
tester. If the needle on the dial fluctuates it indicates a com-
bustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE PRESSURE BUILDS UP

FAST. ANY EXCESSIVE AMOUNT OF PRESSURE BUILT UP
BY CONTINUOUS ENGINE OPERATION MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER PER-
MIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, race the engine a
few times. If an abnormal amount of coolant or steam is emit-
ted from the tail pipe, it may indicate a faulty head gasket,
cracked engine block or cylinder head.
There may be internal leaks which can be determined by
removing the oil dipstick. If water globules appear intermixed
with the oil it will indicate an internal leak in the engine. If
there is an internal leak, the engine must be disassembled for
repair.
7 - 14 COOLING - SERVICE INFORMATION ZH
CLEANING
Drain cooling system and refill with clean water. Refer to drain and fill procedures in this section. Refer to Page
7-18.
Run engine with radiator cap installed until upper radiator hose is hot. Stop engine and drain water from system. If
water is dirty; fill, run, and drain system again, until water runs clear. Refill cooling system with a 50/50 mixture of
the recommended antifreeze/coolant and distilled water.
INSPECTION
After performing a cleaning/flush procedure, inspect all hoses, clamps and connections for deterioration and leaks.
Inspect radiator and heater core for leaks.
SPECIFICATIONS-TORQUE

Belt Tensioner Bolts 14 10 —
Condensor Bolts 10 — 89
Coolant Recovery 5 — 44
Reservoir Nuts
Idler Pulley Screw 10 — 89
Transmission Cooler Line 20 15 —
Nuts
Transmission Cooler Line 20 15 —
Banjp Bolts
Transmission Cooler Line 10 — 89
Reainer Bolts
Water Outlet Housing 10 — 89
Bolts
Water Pump Pulley Bolts 10 — 89
Water Pump M6 Bolts 10 — 89
Water Pump M8 Bolts 35 26 —
SPECIAL TOOLS
PRESSURE TESTER ADAPTER 9107 REFRACTOMETER 8286

7 - 16 ENGINE ZH
ENGINE
TABLE OF CONTENTS
page page
COOLANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION - HOAT COOLANT . . . . . . . . . . . 16 RADIATOR FAN CONTROL MODULE
DIAGNOSIS AND TESTING - COOLANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
CONCENTRATION TESTING . . . . . . . . . . . . . 17 ENGINE COOLANT TEMPERATURE SENSOR
STANDARD PROCEDURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DRAINING COOLING SYSTEM . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE - REFILLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 18 RADIATOR
STANDARD PROCEDURE - COOLING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
SYSTEM REVERSE FLUSHING . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
COOLANT LEVEL SENSOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSPECTION ....................... . . . 34
ENGINE COOLANT THERMOSTAT PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 22 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 WATER PUMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
COOLANT RECOVERY RESERVOIR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSPECTION ....................... . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR FAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLANT
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE
TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED
CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-
GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CON-
AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT
UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze pro-
tection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in 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.
ZH ENGINE 7 - 17
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. MoparT Anti-
freeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic cor-
rosion 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 solution.
CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other
type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine dam-
age that may not be covered under the new vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions.
The coolant performance of various mixtures follows:
Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat
transfer only. Water also freezes at a higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to
dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as
high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature
can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C
(-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If per-
centage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a
68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob-
lems associated with 100 percent ethylene-glycol.
COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT,
for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without cor-
rosion when mixed with 50% distilled water to obtain 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 solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
OPERATION
Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling
fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the antifreeze/coolant pre-
vents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.
DIAGNOSIS AND TESTING - COOLANT CONCENTRATION TESTING

Coolant concentration should be checked when any additional coolant was added to the cooling system or after a
coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion
when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be
used to test coolant concentration.
A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher
the concentration of antifreeze/coolant, the larger the number of balls that will float, and higher the freeze protection.
A Refractometer, Special Tool 8286, will test the amount of antifreeze/coolant in a coolant mixture by measuring the
amount a beam of light bends as it passes through the fluid.
CAUTION: Do not mix types of coolant—corrosion protection will be severely reduced.

7 - 18 ENGINE ZH
STANDARD PROCEDURE
DRAINING COOLING SYSTEM
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
1. DO NOT remove pressure cap first. With engine cold, raise and support the vehicle on a hoist and locate radi-
ator draincock.
Note: Radiator draincock is located on the left/lower side of radiator facing to rear of vehicle.
2. Attach one end of a hose to the draincock (2). Put the other end into a clean container. Open draincock and
drain coolant from radiator. This will empty the coolant recovery reservoir (1). The coolant does not have to be
removed from the tank unless the system is being refilled with a fresh mixture. When tank is empty, remove
pressure cap and continue draining cooling system.
STANDARD PROCEDURE - REFILLING COOLING SYSTEM

1. Tighten the radiator draincock and the cylinder block drain plug(s) (if removed).
CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe
engine damage.
2. Fill system using a 50/50 mixture of antifreeze/coolant and low mineral content water. Fill the coolant recovery
reservoir to service line and install pressure cap.
ZH ENGINE 7 - 19
Note: The engine cooling system will push any remaining air into the coolant recovery reservoir within
about an hour of normal driving. As a result, a drop in coolant level in the coolant recovery reservoir may
occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant
recovery reservoir, this coolant will be drawn back into the cooling system ONLY IF THE PRESSURE CAP IS
LEFT ON RESERVOIR. Removing the pressure cap breaks the vacuum path between the two bottle sections
and the coolant will not return to cooling system.
3. With heater control unit in the HEAT position, operate engine with coolant recovery reservoir cap in place.
4. Add coolant to coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoir
when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
Note: The coolant recovery reservoir has two chambers. Coolant will normally only be in the outboard (larg-
er) of the two. The inboard chamber is only to recover coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally be empty. If there is coolant in the overflow side of the
coolant recovery reservoir (after several warm/cold cycles of the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose at the radiator and lower it into a clean container. Allow
coolant to drain into the container until emptied. Reconnect overflow hose to radiator.
STANDARD PROCEDURE - COOLING SYSTEM REVERSE FLUSHING

CAUTION: The cooling system normally operates at 97-110 kPa (14-16 psi) pressure. Exceeding this pres-
sure may damage the radiator or hoses.
Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done using air
pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with
evidence of partial plugging.
CHEMICAL CLEANING
If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar Radiator Kleen
or equivalent) before flushing. This will soften scale and other deposits and aid the flushing operation.
CAUTION: Be sure instructions on the container are followed.
REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator. Attach a section of radiator hose to the radiator bottom outlet fitting
and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.
CAUTION: The cooling system normally operates at 97-110 kPa (14 -16 psi) pressure. Exceeding this pres-
sure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to refill between
blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. For
more information, refer to operating instructions supplied with flushing equipment. Have radiator cleaned more
extensively by a radiator repair shop.
7 - 20 ENGINE ZH
COOLANT LEVEL SENSOR

REMOVAL
1. Partially drain the cooling system. Refer to Page 7-18.
2. Disconnect the coolant level sensor harness connector (1).
3. Depress the locking tabs and pull the coolant level sensor
(2) from the coolant recovery reservoir.
INSTALLATION
1. Lubricate the new coolant level sensor o-ring with coolant.
2. Push the coolant level sensor (2) into the coolant recovery
reservoir until it snaps into place.
3. Connect the coolant level sensor harness connector (1).
4. Refill the cooling system. Refer to Page 7-18.
5. Start the engine and check for coolant leaks.
6. Recheck the coolant level and adjust as necessary.
ZH ENGINE 7 - 21
ENGINE COOLANT THERMOSTAT

DESCRIPTION
CAUTION: Do not operate an engine without a thermostat, except for servicing or testing.
A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow
to the radiator. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is
allowed to flow to the radiator. This provides quick engine warm up and overall temperature control.
The same thermostat is used for winter and summer seasons.
An engine should not be operated without a thermostat, except
for servicing or testing. Operating without a thermostat causes
other problems. These are:
• Longer engine warm-up time
• Unreliable warm-up performance
• Increased exhaust emissions
• Crankcase condensation
This condensation can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet
expands, overcoming closing spring tension and water pump pressure to force the valve to open.
7 - 22 ENGINE ZH
1. Remove the thermostat. Refer to Page 7-23.

2. Suspend the thermostat in a container of water.
CAUTION: Never use a welding torch or soldering torch as the sudden introduction of heat alters the struc-
ture of the metal!
3. Heat the container and thermostat.
Note: The rate of increase should not be more than 1°C to 2°C/min from about 8 °C below the start of open-
ing of the coolant thermostat.
4. Measure the temperature of the water.

5. Heat water to the fully open temperature of the thermostat and then measure the stroke.
6. If the specifications are not achieved, install a new coolant thermostat.
ZH ENGINE 7 - 23
REMOVAL
1. Remove the air cleaner housing. Refer to Page 9-608.

3. Disconnect the upper radiator hose.
Note: The thermostat housing and the thermostat are serviced as an assembly. The thermostat cannot be
service separately.
4. Remove the thermostat housing retaining bolts and remove the thermostat and housing from the engine.
INSTALLATION
1. Install the thermostat housing with a new o-ring. Tighten the bolts to 10 N·m (89 in. lbs.).
2. Connect the upper radiator hose.
3. Fill the cooling system. Refer to Page 7-18.
5. Recheck the coolant level and adjust as necessary.
7 - 24 ENGINE ZH
COOLANT RECOVERY RESERVOIR

OPERATION
The pressure chamber keeps the coolant free of trapped air, provides a volume for expansion and contraction, and
provides a convenient and safe method for checking and adjusting coolant level at atmospheric pressure. It also
provides some reserve coolant to cover minor leaks, evaporation or boiling losses. The overflow chamber allows
coolant recovery in case of an overheat.
REMOVAL
1. Disconnect the negative battery cable.
3. Disconnect the coolant hose from the radiator (1).
4. Disconnect the coolant level sensor harness connector (2)
at the coolant recovery reservoir.
5. Disconnect the coolant overflow hose (1).

6. Remove the two retaining nuts (2) and lift the coolant
recovery reservoir from the engine compartment.
ZH ENGINE 7 - 25
INSTALLATION
1. Position the coolant recovery reservoir in the engine com-
partment.
2. Install the two retaining nuts (2). Tighten the nuts to 5 N·m
(44 in. lbs.).
3. Connect the coolant overflow hose (1).
4. Connect the coolant level sensor harness connector (2).

5. Connect the coolant hose (1) from the radiator.
8. Recheck the coolant level.
9. Connect the negative battery cable.
7 - 26 ENGINE ZH
RADIATOR FAN
REMOVAL
2. Disconnect the radiator fan harness connector (1).
3. Remove the coolant hose (1) from the mounting bracket

(2).
ZH ENGINE 7 - 27
4. Remove the radiator fan hold down clamps (1).
5. Lift the radiator fan up and out of the vehicle.
INSTALLATION
Note: The two retaining studs of the radiator fan must be
located at the bottom in the rubber mounts. Lightly lubri-
cate the two retaining studs (1).
1. Position the radiator fan in the rubber mounts.

7 - 28 ENGINE ZH
2. Install
. the radiator fan hold down clamps (1).
3. Route the coolant hose (1) through the bracket (2) on the
radiator fan.
4. Connect the radiator fan harness connector (1).

ZH ENGINE 7 - 29

REMOVAL
2. Disconnect the radiator fan control module harness connec-
tor (2).
3. Remove the retaining nuts at the top and bottom of the
cooling fan module (1).
4. Remove the cooling fan module from the engine compart-
ment.
INSTALLATION
1. Position the radiator fan control module on the inner fender well studs.
2. Install the upper and lower retaining nuts and tighten to 10 N·m (89 in. lbs.).
3. Connect the radiator fan control module harness connector.
ENGINE COOLANT TEMPERATURE SENSOR

OPERATION
The engine coolant temperature sensor provides an input to the powertrain control module (PCM). As coolant tem-
perature varies, the engine coolant temperture sensor resistance changes, resulting in a different input voltage to
the PCM.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal
operating temperatures are reached.
The engine coolant sensor input also determines operation of the radiator fan.
REMOVAL
7 - 30 ENGINE ZH
3. Disconnect the engine coolant temperature sensor harness

connector (1).
4. Remove the engine coolant temperature sensor retaining

clip (1) and the sensor.
ZH ENGINE 7 - 31
INSTALLATION
1. Clean any debris or corrosion from the engine coolant tem-
perature sensor mounting surface.
2. Use a small amount of petroleum jelly to lubricate the sen-
sor seal.
3. Install the engine coolant temperature sensor and retaining
clip.
4. Connect the engine coolant temperature sensor harness
connector (1).
7 - 32 ENGINE ZH
RADIATOR
DESCRIPTION
The Crossfire has a cross flow type radiator (4) with plastic side tanks (3).
Plastic tanks, while stronger than brass, are subject to damage by impact, such as from tools or wrenches. Handle
radiator with care.
ZH ENGINE 7 - 33
REMOVAL

2. Remove the radiator fan. Refer to Page 7-26.
3. Drain the cooling system. Refer to Page 7-18.
4. Remove the air cleaner inlet tubes.
5. Disconnect the upper radiator hose (4).
6. Disconnect the lower radiator hose (7) and coolant recovery
reservoir hose (5).
7. Disconnect the transmission cooler lines and fit together
with coupler (automatic transmission only). Refer to Page
7-49.
7 - 34 ENGINE ZH
8. Remove the radiator hold down clamps (1).
9. Tilt the radiator forward and remove the A/C condenser to

the radiator retaining bolts (1).
10. Remove the radiator from the vehicle.
CLEANING
Clean radiator fins with the engine cold, apply cold water and compressed air to the back (engine side) of the radi-
ator to flush the radiator of debris.
INSPECTION
The radiator cooling fins should be checked for damage or deterioration. Inspect cooling fins to make sure they are
not bent or crushed, these areas result in reduced heat exchange causing the cooling system to operate at higher
temperatures. Inspect the plastic end tanks for cracks, damage or leaks.
ZH ENGINE 7 - 35
INSTALLATION
1. Position the radiator in vehicle.

2. Connect the lower radiator hose (7) and the coolant recov-
ery reservoir hose (5).
3. Connect the upper radiator hose (4).
4. Install the A/C condenser to the radiator retaining bolts.
Tighten the bolts to 10 N·m (89 in. lbs.).
5. Install the radiator retaining clamps (1).
6. Install the radiator fan. Refer to Page 7-27.
7. Connect the transmission cooler lines (automatic transmis-
sion only). Refer to Page 7-50.
8. Install the air inlet tubes.
7 - 36 ENGINE ZH
PRESSURE CAP
OPERATION
The pressure cap allows the cooling system to operate at higher than atmospheric pressure which raises the cool-
ant boiling point, thus allowing increased radiator cooling capacity. The pressure cap releases pressure at some
point within a range of 110 kPa ± 14 kPa (16 psi ± 2 psi).
CAUTION: Use only the pressure cap specified for this vehicle. Use of other pressure caps can lead to cool-
ant loss and overheating.
WARNING
WARNING: THE WARNING WORDS DO NOT OPEN HOT ON THE COOLANT RECOVERY RESERVOIR PRES-
SURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE COOLANT RECOVERY RESERVOIR PRESSURE CAP SHOULD NOT BE
REMOVED WHILE THE SYSTEM IS HOT AND/OR UNDER PRESSURE.
There is no need to remove the pressure cap at any time except for the following purposes:
• Checking and adjust antifreeze freeze point.
• Refilling system with new coolant.
• Conducting service procedures.
• Checking for vacuum leaks.
CLEANING
Clean the radiator pressure cap using a mild soap and water only.
WATER PUMP
DESCRIPTION
The water pump has a die cast aluminum housing and a swept vane impeller. It bolts directly to the timing chain
cover.
ZH ENGINE 7 - 37
REMOVAL
1 - BOLT M6X19 5 - BOLT M8X110

3 - BOLT M8X80 7 - BOLT M10X110
4 - BOLT M8X90

3. Remove the air cleaner.
5. Remove the accessory drive belt. Refer to Page 7-45.
6. Remove the belt tensioner. Refer to Page 7-44.
7 - 38 ENGINE ZH
7. Disconnect the lower radiator (2) hose and the coolant

bypass hose (1).
8. Remove the water pump pulley (2) and the idler pulley (1).
9. Remove the water pump retaining bolts and water pump.
INSPECTION
Note: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on
water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a
heavy deposit or a steady flow of engine coolant is evident from the weep hole. This indicates a shaft seal
failure and pump must be replaced. Be sure to perform a thorough analysis before replacing water pump.
ZH ENGINE 7 - 39
Inspect and replace the water pump if it has any of the following defects:
1. Damage or cracks on the pump body.
2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of dried coolant draining from
the pump weep hole. A thin black stain below pump weep hole/passage is considered normal operation.
3. Impeller rubs against the engine front cover.
4. Excessively loose or rough turning bearing.
7 - 40 ENGINE ZH
INSTALLATION

3 - BOLT M8X80 7 - BOLT M10X110
4 - BOLT M8X90
1. Clean all gasket surfaces.

2. Position the water pump with a new gasket on the timing
chain cover.
3. Install the water pump bolts in the correct positions. Tighten
the bolts to 35 N·m (26 ft. lbs.).
4. Install the belt tensioner. Refer to Page 7-44.
ZH ENGINE 7 - 41
5. Install the water pump pulley and bolts (2). Tighten the
water pump pulley bolts to 10 N·m (89 in. lbs.).
6. Install the idler pulley and screw. Tighten the idler pulley
screw to 10 N·m (89 in. lbs.).
7. Connect the lower radiator hose (2) and coolant by pass
hose (1).
8. Install the accessory drive belt. Refer to Page 7-46.
9. Install the radiator fan. Refer to Page 7-27.
10. Install the air cleaner.
7 - 42 ACCESSORY DRIVE ZH
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE DRIVE BELT

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42 REMOVAL . . . .... . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CLEANING . . .... . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSIS AND TESTING - ACCESSORY INSPECTION .... . . . . . . . . . . . . . . . . . . . . . . 45
DRIVE BELT .................... . . . . . 43 INSTALLATION ... . . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS-TORQUE . . . . . . . . . . . . . . . 43 IDLER PULLEY
BELT TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
ACCESSORY DRIVE
DESCRIPTION
A single, serpentine style belt drives all of the engine accessories. The accessory drive includes an automatic ten-
sioner, making adjustments unnecessary for the life of the belt.
OPERATION
The accessory drive belt provides the link between the engine
crankshaft and the engine accessories. Tension on the acces-
sory drive belt is maintained by an automatic belt tensioner.
1. Crankshaft
2. A/C Compressor
3. Power Steering Pump
4. Idler Pulley
5. Generator
6. Water Pump
7. Tensioner
ZH ACCESSORY DRIVE 7 - 43
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT ACCESSORY 1. Belt too loose. 1. Check engine accessories and

OUTPUT DUE TO BELT SLIPPAGE replace belt tensioner as necessary.
2. Belt excessively glazed or worn. 2. Replace the belt.
BELT SQUEAL WHEN 1. Belt too loose. 1. Check engine accessories and
ACCELERATING ENGINE replace belt tensioner as necessary.
2. Belt glazed. 2. Replace belt.
BELT CHIRP AT IDLE 1. Belt too loose. 1. Check engine accessories and
replace belt tensioner as necessary.
2. Foreign material imbedded in 2. Replace belt.

belt.
3. Non-uniform belt. 3. Replace belt.
4. Misaligned pulley(s). 4. Align accessories.
5. Non-uniform groove or eccentric 5. Replace pulley(s).
pulley.
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. Check engine accessories and
replace belt tensioner as necessary.
3. Misaligned pulleys. 3. Align accessories.
4. Non-uniform grooves or eccentric 4. Replace pulley(s).
pulley.
SPECIFICATIONS-TORQUE

Idler Pulley Screw 20 15 —
Belt Tensioner Bolts 25 18 —
BELT TENSIONER
REMOVAL
2. Remove the belt tensioner retaining bolts (1) and the belt
tensioner (2).
INSTALLATION
1. Position the belt tensioner (2) on the timing chain cover.
2. Install the belt tensioner bolts (1). Tighten the bolts to 25
N·m (18 ft. lbs.).
DRIVE BELT
REMOVAL
1. Rotate the belt tensioner (1) with a wrench and lock in
place with a 5mm pin (2) or drift.
2. Remove the accessory drive belt from the pulleys.
3. Inspect the accessory drive belt. Refer to damage patterns.
Refer to Page 7-45.
4. Inspect the pulleys for wear or damage.
5. Replace the accessory drive belt or pulleys as required.
CLEANING
Clean all foreign debris from the belt pulley grooves. The belt pulleys must be free of oil, grease, and coolant before
installing the drive belt.
INSPECTION
Belt replacement is necessary for any or all of the following
conditions:
• Excessive wear
• Frayed cords
• Severe glazing
The accessory drive belt may develop minor cracks across the
ribbed side (1) due to reverse bending. These minor cracks
are considered normal and acceptable. Parallel cracks (2) are
not considered normal and should be cause for belt replace-
ment.
Note: Do not use any type of belt dressing or restorer on the accessory drive belt.
INSTALLATION
1. Position the accessory drive belt on the pulleys.
1. Crankshaft
2. A/C Compressor
3. Power Steering Pump
4. Idler Pulley
5. Generator
6. Water Pump
7. Tensioner
2. Rotate the belt tensioner (1) clockwise and remove the

5mm pin (2).
3. Allow the belt tensioner (1) to rest on the accessory drive
belt.
4. Release the belt tensioner and remove the wrench.
IDLER PULLEY
REMOVAL
1. Remove accessory drive belt. Refer to Page 7-45.
2. Remove the idler pulley screw cover (1).
3. Remove the screw (1) and idler pulley from the water
pump.
4. Check the pulley bearing for looseness and noise. Replace
if necessary.
INSTALLATION
1. Position the idler pulley (2) on the water pump with the
screw (1).
2. Tighten the idler pulley screw to 20 N·m (15 ft. lbs.).
3. Install the screw cover (1) on the idler pulley.

ZH TRANSMISSION 7 - 49
TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION COOLER LINES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSMISSION COOLER LINES

REMOVAL
1. TRANSMISSION LINE RETAINERS 4. STEEL LINES

2. BANJO BOLTS 5. COPPER LINES
3. FLEXIBLE LINES
Note: To service the front copper transmission cooler lines (5) the radiator must be removed. Refer to Page
7-33.

2. Remove the lower splash shield.
3. Disconnect the fittings at either end of the line being serviced.
4. Remove the line retainers (1) and the cooler line(s) as necessary.
7 - 50 TRANSMISSION ZH
INSTALLATION
1. Position the cooler line(s) and loosely connect the fittings.
2. Install the retainers and bolts for the cooler line(s).
Note: Replace the copper washers if the banjo bolts are removed.
3. Tighten the cooler line fittings or banjo bolts to 20 N·m (15 ft. lbs.).
4. Tighten the transmission cooler line retaining bolts to 10 N·m (89 in. lbs.).
6. Install the radiator if removed. Refer to Page 7-35.
7. Check the transmission fluid level. Refer to Page 21-294.
ZH AUDIO/VIDEO 8A - 1
AUDIO/VIDEO
TABLE OF CONTENTS
page page
AUDIO - ELECTRICAL DIAGNOSTICS. . . . . . . . . . . 1 AUDIO - SERVICE INFORMATION . . . . . . . . . . . . 18
AUDIO - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
AUDIO - ELECTRICAL DIAGNOSTICS *NO SOUND FROM RIGHT DOOR

DIAGNOSIS AND TESTING SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
*RADIO INOPERATIVE . . . . . . . . . . . . . . . . . . 2 *NO SOUND FROM LEFT REAR SPEAKER . 12
*NO SOUND FROM ALL SPEAKERS . . . . . . . . 5 *NO SOUND FROM RIGHT REAR SPEAKER . 14
*NO SOUND FROM LEFT DOOR BODY VERIFICATION TEST . . . . . . . . . . . . . 16
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 17
AUDIO - ELECTRICAL DIAGNOSTICS

8A - 2 AUDIO - ELECTRICAL DIAGNOSTICS ZH
*RADIO INOPERATIVE
ZH AUDIO - ELECTRICAL DIAGNOSTICS 8A - 3
*RADIO INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RADIO
For a complete Audio System Circuit Diagram, Refer to Page 8A-17.
Diagnostic Test
1. MEASURE RADIO FUSED IGNITION SWITCH OUTPUT CIRCUIT

VOLTAGE
Note: Inspect Fuse 5 and Fuse 8 located in the Underhood Accessory

Fuse Block. If either fuse is open, repair the cause of the open fuse
before continuing.
Disconnect the Radio harness connector.
Radio harness connector cavity 7 (connector A).

Yes >> Go to 2
No >> Repair the Radio Fused Ignition Switch Output circuit for
an open.
Perform BODY VERIFICATION TEST.
2. MEASURE RADIO FUSED B(+) CIRCUIT VOLTAGE

Measure the voltage of the Fused B(+) circuit at the Radio harness con-
nector cavity 4 (connector A).

Yes >> Go to 3
No >> Repair the Radio Fused B(+) circuit for an open.
*RADIO INOPERATIVE — CONTINUED
3. MEASURE RADIO GROUND CIRCUIT RESISTANCE
Measure the resistance between ground and the Ground circuit at cavity 8
(connector A) of the Radio harness connector.

Yes >> Replace the Radio. Refer to Page 8A-27.
*NO SOUND FROM ALL SPEAKERS
*NO SOUND FROM ALL SPEAKERS — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
POWER AMPLIFIER
Diagnostic Test
1. MEASURE POWER AMPLIFIER FUSED IGNITION SWITCH OUTPUT

CIRCUIT VOLTAGE

continuing.
Disconnect the Power Amplifier harness connector.
Power Amplifier harness connector cavity 1 (connector B).

Yes >> Go to 2
No >> Repair the Power Amplifier Fused Ignition Switch Output
2. MEASURE POWER AMPLIFIER FUSED IGNITION SWITCH OUTPUT

CIRCUIT VOLTAGE

Power Amplifier harness connector cavity 9 (connector B).

Yes >> Go to 3
No >> Repair the Power Amplifier Fused Ignition Switch Output
*NO SOUND FROM ALL SPEAKERS — CONTINUED
3. MEASURE POWER AMPLIFIER GROUND CIRCUIT RESISTANCE
11 (connector A) of the Power Amplifier harness connector.

Yes >> Go to 4
4. MEASURE POWER AMPLIFIER GROUND CIRCUIT RESISTANCE

Measure the resistance between ground and the Ground circuit at cavity 4
(connector A) of the Power Amplifier harness connector.

Yes >> Replace the Power Amplifier. Refer to Page 8A-20.
*NO SOUND FROM LEFT DOOR SPEAKERS
*NO SOUND FROM LEFT DOOR SPEAKERS — CONTINUED
POSSIBLE CAUSES
AMPLIFIED LEFT DOOR SPEAKER (+) CIRCUIT OPEN

AMPLIFIED LEFT DOOR SPEAKER (-) CIRCUIT OPEN
POWER AMPLIFIER
Diagnostic Test
1. MEASURE LEFT DOOR SPEAKER CIRCUIT RESISTANCE

Disconnect the Left Door Speaker harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Iline harness
connector C229.
Measure the resistance between cavity 8 (connector B) and cavity 18
(connector B) of the Power Amplifier harness connector.

No >> Repair the Amplified Left Door Speaker (+) or (-) cir-
cuit for an open.
*NO SOUND FROM RIGHT DOOR SPEAKERS
*NO SOUND FROM RIGHT DOOR SPEAKERS — CONTINUED
POSSIBLE CAUSES
AMPLIFIED RIGHT DOOR SPEAKER (+) CIRCUIT OPEN

AMPLIFIED RIGHT DOOR SPEAKER (-) CIRCUIT OPEN
POWER AMPLIFIER
Diagnostic Test
1. MEASURE RIGHT DOOR SPEAKER CIRCUIT RESISTANCE

Disconnect the Right Door Speaker harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Iline harness
connector C231.

No >> Repair the Amplified Right Door Speaker (+) or (-) cir-
cuit for an open.
*NO SOUND FROM LEFT REAR SPEAKER
*NO SOUND FROM LEFT REAR SPEAKER — CONTINUED
POSSIBLE CAUSES
AMPLIFIED LEFT REAR SPEAKER (+) CIRCUIT OPEN

AMPLIFIED LEFT REAR SPEAKER (-) CIRCUIT OPEN
LEFT REAR SPEAKER SUPPLY VOLTAGE CIRCUIT OPEN
LEFT REAR SPEAKER GROUND CIRCUIT OPEN
LEFT REAR SPEAKER
Diagnostic Test
1. MEASURE LEFT REAR SPEAKER CIRCUIT RESISTANCE

Disconnect the Left Rear Speaker harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Left Rear
Speaker harness connector.

Yes >> Go to 2
No >> Repair the Amplified Left Rear Speaker (+) or (-) circuit
for an open.
2. MEASURE LEFT REAR SPEAKER CIRCUIT RESISTANCE

Connect a jumper wire between cavity 3 and cavity 4 of the Left Rear

Yes >> Replace the Left Rear Speaker. Refer to Page 8A-29.
No >> Repair the Left Rear Speaker Ground circuit or Supply
Voltage circuit for an open.
*NO SOUND FROM RIGHT REAR SPEAKER
*NO SOUND FROM RIGHT REAR SPEAKER — CONTINUED
POSSIBLE CAUSES
AMPLIFIED RIGHT REAR SPEAKER (+) CIRCUIT OPEN

AMPLIFIED RIGHT REAR SPEAKER (-) CIRCUIT OPEN
RIGHT REAR SPEAKER SUPPLY VOLTAGE CIRCUIT OPEN
RIGHT REAR SPEAKER GROUND CIRCUIT OPEN
RIGHT REAR SPEAKER
Diagnostic Test
1. MEASURE RIGHT REAR SPEAKER CIRCUIT RESISTANCE

Disconnect the Right Rear Speaker harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Right Rear

Yes >> Go to 2
No >> Repair the Amplified Right Rear Speaker (+) or (-) circuit
for an open.
2. MEASURE RIGHT REAR SPEAKER CIRCUIT RESISTANCE

Connect a jumper wire between cavity 3 and cavity 4 of the Right Rear

Yes >> Replace the Right Rear Speaker. Refer to Page 8A-29.
No >> Repair the Right Rear Speaker Ground circuit or Sup-
ply Voltage circuit for an open.
BODY VERIFICATION TEST
1.
Note: If the SKREEM or the PCM was replaced, refer to the service
information for proper programming procedures.
If the Body Control Module was replaced, turn the ignition on for 15 sec-
onds (to allow the new BCM to learn VIN) or engine may not start.
Program all RKE transmitters and other options as necessary.
modules. Start the engine and allow it to run for 2 minutes. Operate all
functions of the system that caused the original complaint.
Ensure that all accessories are turned off and the battery is fully charged.
Are any DTCs present or is the original complaint still present?

AUDIO SYSTEM CIRCUIT DIAGRAM

8A - 18 AUDIO - SERVICE INFORMATION ZH
AUDIO - SERVICE INFORMATION
TABLE OF CONTENTS
page page
AUDIO - SERVICE INFORMATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 RADIO
DIAGNOSIS AND TESTING - AUDIO SYSTEM . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
AMPLIFIER SPEAKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 LOWER DOOR SPEAKER . . . . . . . . . . . . . . . 29
REAR WINDOW ANTENNA MODULE REMOVAL - REAR PANEL SPEAKER .. . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL - TWEETER SPEAKER . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION
REAR WINDOW ANTENNA LOWER DOOR SPEAKER . . . . . . . . . . . . . . . 31
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION - REAR PANEL SPEAKER . . . 33
STANDARD PROCEDURE - ANTENNA GRID INSTALLATION - TWEETER SPEAKER . . . . . 34
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ZH AUDIO - SERVICE INFORMATION 8A - 19
AUDIO - SERVICE INFORMATION

DESCRIPTION
1 - CD BUTTON 7 - DISPLAY
2 - FM RADIO BUTTON 8 - VOLUME CONTROL — ON/OFF SWITCH
3 - AM RADIO BUTTON 9 - CD EJECT BUTTON
4 - MANUAL FREQUENCY SETTING BUTTON 10 - MUTE BUTTON
5 - RIGHT ROTARY CONTROL/PUSH BUTTON 11 - SOUND BUTTON
6 - MULTIFUNCTION BUTTONS 12 - SUB-MENU SELECTION BUTTON
The audio system is standard factory-installed equipment. The system uses an ignition switched source of battery
current so that the system will only operate when the ignition switch is in the ON/RUN or START positions.
The audio system includes the following components:
• Antenna
• Rear Window Antenna Module
• Power Amplifier
• Radio Receiver
• Speakers
OPERATION
For detailed operation instructions for the factory installed audio system, refer to the Understanding Your Instrument
Panel section in the Owner’s Manual.
DIAGNOSIS AND TESTING - AUDIO SYSTEM

For complete audio system diagnosis, see audio electrical diagnostics in this section.
SPECIAL TOOLS
Radio Removal Tool 3241
AMPLIFIER
REMOVAL
2. Remove the passenger door sill trim panel and kick trim
panel.
3. Fold back the carpeting in the passenger footwell.
4. Remove the insulating panel.
Note: It is not necessary to remove the electrical connec-

tors to rotate the base plate in the passenger footwell.
5. Remove the plastic retaining nuts (1) from the floor panel
and rotate the base plate exposing the amplifier.
6. Remove the four amplifier retaining screws (1) from the

base plate, and disconnect the amplifier harness connector.
Remove the amplifier from the base plate.
INSTALLATION
1. Connect the amplifier harness connector and attach the
amplifier to the base plate with the four retaining screws
(1).
2. Rotate the base plate and install it over the mounting studs
on the floor panel.
Note: Be sure not to pinch or cause interference with the

wiring harnesses while locating the base plate to the floor
mounting studs.
3. Install the plastic retaining nuts (1) and secure the base
plate to the vehicle floor.
4. Install the insulating panel.

5. Install the carpeting in the passenger footwell.
6. Install the door sill panel and kick trim panel.
REAR WINDOW ANTENNA MODULE

REMOVAL
2. Remove the liftgate interior trim panel. Refer to Page
23-48.
3. Disconnect the antenna module harness connectors.
4. Remove the retaining screw (1) and remove the antenna
module from the vehicle.
INSTALLATION
1. Install the rear window antenna module to the liftgate and
attach with the retaining screw (3) and secure.
2. Install the rear window antenna module harness connectors
(2).
Note: Use care when routing harnesses and allow suffi-

cient clearance near trim panel pinch points.
3. Install the liftgate interior trim panel. Refer to Page 23-49.

REAR WINDOW ANTENNA

DESCRIPTION
The liftgate glass contains the audio antenna (4) attached to
the inside surface. Grid lines running horizontally form the
antenna, which terminates to bus bars (1) at either side. Blade
type terminals, also attached to the inside glass surface at the
bus bars, form the beginning connection point for the radio fre-
quency signal.
STANDARD PROCEDURE - ANTENNA GRID REPAIR

Repair of the rear glass antenna bus bars and terminals can be accomplished using a Mopar Rear Window Defog-
ger Repair Kit (Part Number 4267922) or equivalent.
WARNING: MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. THE KIT
CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID
CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP
AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTER-
NALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADE-
QUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP
OUT OF THE REACH OF CHILDREN.
1. Mask the repair area (3) on the inside of the rear glass so
that the conductive epoxy can be applied neatly. Extend the
epoxy application onto the rear glass antenna (2) or bus
bar on each side of the break (1).
2. Follow the instructions in the repair kit for preparing the

damaged area.
3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the pack-
aging. Fold the package in half and cut the center corner to dispense the epoxy.
4. For rear glass antenna bus bar repairs, mask the area to be repaired with masking tape or a template.
5. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 0.75
inch (19 mm).
6. For a rear glass antenna terminal replacement, mask the adjacent areas so the epoxy can be extended onto the
adjacent bus bar. Apply a thin layer of epoxy to the area where the terminal was previously fastened and onto
the adjacent bus bar line.
7. Apply a thin layer of conductive epoxy to the terminal and place it in the proper location on the rear glass
antenna bus bar. To prevent the terminal from moving while the epoxy is curing, it must be wedged or clamped.
8. Carefully remove the masking tape or template.
CAUTION: Do not allow the glass surface to exceed 400° F (204° C) or the glass may fracture.
9. Allow the epoxy to cure for 24 hours at room temperature.

10. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal. Do not attach the
wire harness connectors until the curing process is complete.
11. Check the operation of the rear glass antenna bus bar and/or terminal(s) with the audio system performance
levels.
REMOVAL
WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24
HOURS OF REAR WINDOW GLASS INSTALLATION. IT
TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE
TO CURE. IF IT IS NOT CURED, THE REAR WINDOW
GLASS MAY NOT PERFORM PROPERLY IN AN ACCIDENT.
BE SURE TO REFER TO THE URETHANE MANUFAC-
TURE’S DIRECTIONS FOR CURING TIME SPECIFICA-
TIONS, AND DO NOT USE ADHESIVE AFTER ITS
EXPIRATION DATE.
CAUTION: Open the door glass before installing the rear

window to avoid pressurizing the passenger compartment
if a door is slammed before the urethane bonding is fully
cured. Water leaks can result.

2. Open the liftgate and remove the liftgate interior trim panel.
3. Disconnect the center high mount stop lamp (CHMSL) har-
ness connector and remove the CHMSL assembly from the
liftgate. Refer to Page 8L-92.
4. Disconnect the rear window defogger (1) and rear window

antenna (2) harness connectors from the liftgate glass ter-
minals.
5. Remove the liftgate glass.
INSTALLATION
1. Install the liftgate glass.
2. Connect the rear window defogger (3) and the rear window
antenna (1) harness connectors to the liftgate glass termi-
nals.
3. Install the center high mount stop lamp (CHMSL) assembly
to the liftgate (2), and connect the CHMSL harness connec-
tor. Refer to Page 8L-93.
RADIO
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING COL-
UMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE
AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
1. Record customer defined presets.

3. Remove the radio by performing the following:
• Using Special Tool 3291 Radio Removal tool, insert
the tools into the slots with the jagged edge toward the
center of the radio until a slight click is heard.
• Gently pull the tool rings along with the radio rearward.
4. Press in on the flexible detents at the sides of the radio

after you have removed it to release the tools.
5. Disconnect the radio harness connectors.

6. Remove the radio.
INSTALLATION
1. Connect the radio harness connectors.
2. Align and gently guide the radio into the opening fully until
it clicks.
4. Restore customer defined presets.
SPEAKER
REMOVAL
LOWER DOOR SPEAKER

2. Remove the door interior trim panel. Refer to Page 23-108.
3. Disconnect the lower door speaker harness connector.
4. Remove the lower door speaker retaining screws (1).
5. Remove the lower door speaker together with the plastic
frame and the speaker cover.
REMOVAL - REAR PANEL SPEAKER

1. Move the seats and tilt the seat back all the way to the
front position.
2. Remove the door sill molding.
3. Remove the edge plate and the door edge molding.
CAUTION: The speaker grille is plastic and may break if

too much force is applied in one place.
4. Using a trim stick, remove the speaker grille (3) from the
back panel carpet.
5. Fold the back panel carpet to one side, enough to see the
retaining nuts (4).
6. Remove the retaining nuts (4), then remove the speaker
shroud (1) from the inner mounting frame (2).
7. Disconnect the rear panel speaker harness connector (2).

8. Remove the inner mounting frame (1) together with the left
or right rear panel speaker from the vehicle.
REMOVAL - TWEETER SPEAKER


2. Remove the door interior trim panel (1). Refer to Page
23-108.
3. Disconnect the tweeter speaker harness connector (2).

4. Release the retaining tabs and remove the tweeter speaker
(1) from the door interior trim panel.
INSTALLATION
LOWER DOOR SPEAKER
1. Install the lower door speaker together with the plastic

frame (1) and the speaker cover (2).
2. Connect the lower door speaker harness connector (4).
3. Install the lower door speaker retaining screws (3) and
secure.
4. Install the door interior trim panel. Refer to Page 23-109.

INSTALLATION - REAR PANEL SPEAKER
1 - EDGE PLATE 5 - SPEAKER SHROUD

2 - EDGE MOLDING 6 - SPEAKER GRILLE
3 - SPEAKER HARNESS CONNECTOR 7 - RETAINING NUT
4 - INNER MOUNTING FRAME
1. Install the inner mounting frame (4) together with the left or
right rear panel speaker into the opening of the rear panel.
2. Connect the rear panel speaker harness connector (3).
3. Install the speaker shroud (5) to the inner mounting frame
(4).
4. Install the retaining nuts (7) and secure, then unfold the
back panel carpet.
5. Install the rear panel speaker grille (6).
6. Install the door edge molding (2) and the edge plate (1).
7. Install the door sill molding.
8. Move seats and seat back into normal position.
INSTALLATION - TWEETER SPEAKER

1. Install the tweeter speaker (1) into the door interior trim
panel (2).
2. Connect the tweeter speaker harness connector (3).
3. Install the door interior trim panel (2). Refer to Page
23-109.
ZH CHIME/BUZZER 8B - 1
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME/BUZZER - ELECTRICAL DIAGNOSTICS . . . 1 CHIME/BUZZER - SERVICE INFORMATION . . . . . . 3
CHIME/BUZZER - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page

SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . 2
8B - 2 CHIME/BUZZER - ELECTRICAL DIAGNOSTICS ZH

WARNING CHIME CIRCUIT DIAGRAM

ZH CHIME/BUZZER - SERVICE INFORMATION 8B - 3
CHIME/BUZZER - SERVICE INFORMATION
TABLE OF CONTENTS
page page
CHIME TONE GENERATOR DIAGNOSIS AND TESTING - CHIME

DESCRIPTION WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHIME TONE GENERATOR

DESCRIPTION
DESCRIPTION
1 - HEADLAMP SWITCH 4 - ILLUMINATION CONTROL MODULE

2 - DOOR AJAR SWITCH 5 - INSTRUMENT CLUSTER
3 - SEAT BELT SWITCH
The chime warning system uses a single chime tone generator that is integral to the Instrument Cluster to provide
an audible indication of vehicle conditions that may require the attention of the vehicle operator. The chime warning
system includes the following major components:
• Headlamp Switch
• Door Ajar Switch
• Seat Belt Switch
8B - 4 CHIME/BUZZER - SERVICE INFORMATION ZH
• Ignition Switch
• Instrument Cluster
• Coolant Level Sensor
• Fuel Level Sensor
• Washer Fluid Level Sensor
Hard wired circuitry connects many of the chime warning system components to each other through the electrical
system of the vehicle.
If the Instrument Cluster or the chime tone generator are damaged or faulty, the Instrument Cluster assembly must
be replaced.
DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM

Refer to the appropriate wiring information. Conventional diagnostic methods may not prove conclusive in the diag-
nosis of the Instrument Cluster. The most reliable, efficient and accurate means to diagnose the Instrument Cluster
and the Controller Area Network (CAN) data bus network inputs for the chime warning system requires the use of
a DRB IIIT scan tool and the appropriate diagnostic information.
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE
THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE
ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
CHIME WARNING SYSTEM DIAGNOSIS
NO SEAT BELT WARNING 1. Seat belt switch ground 1. Check for continuity between the ground circuit
CHIME WITH SEAT BELT circuit open. of the wire harness connector for the seat belt
UNBUCKLED, BUT OTHER switch and a good ground. Repair the ground
CHIME FEATURES OK circuit, if required.
2. Seat belt switch sense 2. Check for continuity between the seat belt
circuit open. switch sense circuit of the wire harness connector
for the seat belt switch and the instrument cluster
wire harness connector. Repair the seat belt
switch sense circuit, if required.
3. Faulty seat belt switch. 3. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
continuity with the seat belt unbuckled. Replace
the faulty seat belt, if required.
SEAT BELT WARNING 1. Seat belt switch sense 1. With the wire harness connector for the seat
CHIME SOUNDS WITH circuit shorted. belt switch and the instrument cluster wire
SEAT BELT BUCKLED harness connector disconnected, there should be
no continuity between the seat belt switch sense
circuit and a good ground. Repair the seat belt
2. Faulty seat belt switch. 2. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
no continuity with the seat belt buckled. Replace
the faulty seat belt, if required.
ZH CHIME/BUZZER - SERVICE INFORMATION 8B - 5
NO KEY IN IGNITION OR 1. Faulty door ajar switch or 1. Check that interior lights illuminate with the
HEADLAMPS-ON WARNING circuits. driver door open. If not OK, repair the interior
CHIME WITH DRIVER SIDE lighting system as required.
DOOR OPEN 2. Faulty headlamp switch 2. Check for proper exterior lighting operation. If
(illumination control module) not OK, repair the exterior lighting system as
or circuits. required.
3. Key in ignition switch 2. Check for continuity between the key in ignition
sense circuit open. switch sense circuit of the instrument panel wire
harness connector for the ignition switch and the
body wire harness connector for the underhood
accessory fuse block. Repair the key in ignition
4. Faulty ignition switch. 3. Check for continuity between the two terminals
in the ignition switch connector. There should be
continuity with a key in the ignition lock cylinder.
Replace the faulty ignition switch, if required.
CHIME SOUNDS WITH 1. Key in ignition switch 1. Disconnect the instrument panel wire harness
DRIVER SIDE FRONT sense circuit shorted. connector for the ignition switch and the body
DOOR OPEN wire harness connector for the underhood
accessory fuse block. There should be no
continuity between the key in ignition switch
sense circuit of the instrument panel wire harness
connector for the ignition switch and a good
ground. Repair the key in ignition switch sense
circuit, if required.
2. Faulty ignition switch. 2. Check for continuity between the two terminals
in the ignition switch connector. There should be
no continuity with the key removed from the
ignition lock cylinder. Replace the faulty ignition
switch, if required.
NO CHIMES AT ALL TIMES 1. Faulty Instrument Cluster. 1. Use a DRB IIIT scan tool and refer to the
appropriate diagnostic information. Replace the
faulty Instrument Cluster, if required
OPERATION
The chime warning system components operate on battery voltage received through fuse 35 in the Underhood
Accessory Fuse Block on a non-switched B(+) circuit so that the system may operate regardless of the ignition
switch position.
The chime warning system provides an audible indication to the vehicle operator under the following conditions:
• Fasten Seat Belt Warning - The Instrument Cluster chime tone generator will generate repetitive chimes to
announce that an input from the seat belt switch indicates the driver side seat belt is not fastened. Unless the
driver side seat belt is fastened, the chimes will continue to sound for a short duration each time the ignition
switch is turned to the On position or until the driver side seat belt is fastened.
• Head/Park Lights-On Warning - The Instrument Cluster chime tone generator will generate repetitive
chimes to indicate that the exterior lamps are turned On with the driver side door opened. The chime will
continue to sound until the exterior lamps are turned Off, the driver side door is closed, or the ignition switch
is turned to the On position.
8B - 6 CHIME/BUZZER - SERVICE INFORMATION ZH
• Key-In-Ignition Warning - The Instrument Cluster chime tone generator will generate repetitive chimes at a
fast rate to indicate that the key is in the ignition cylinder with the driver side door opened and the ignition
switch in the Off position. The chime will continue to sound until the key is removed from the ignition lock
cylinder, the driver side door is closed, or the ignition switch is turned to the On position.
• Warning Beep Support - The Instrument Cluster chime tone generator will generate a short series of beeps
to provide an audible alert to the vehicle operator of certain visual warning indications displayed by the Instru-
ment Cluster.
The Instrument Cluster provides chime tones for all available features in the chime warning system. The Instrument
Cluster relies upon message inputs received from other modules over the Controller Area Network (CAN) data bus
network to provide chime tones for all of the remaining chime warning system features.
The internal programming of the Instrument Cluster determines the priority of each chime tone request input that is
received, as well as the rate and duration of each chime tone that is to be generated.
ZH ELECTRONIC CONTROL MODULES 8E - 1
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES - ELECTRONIC CONTROL MODULES - SERVICE

ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . 1 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ELECTRONIC CONTROL MODULES - ELECTRICAL

DIAGNOSTICS
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES - *NO RESPONSE FROM CONTROLLER

ELECTRICAL DIAGNOSTICS ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING *NO RESPONSE FROM SHIFT LEVER
*DRB IIIT DOES NOT POWER UP . . . . . . . . . . 2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 29
*NO RESPONSE FROM POWERTRAIN *NO RESPONSE FROM TRANSMISSION
CONTROL MODULE . . . . . . . . . . . . . . . . . . . . 4 CONTROL MODULE . . . . . . . . . . . . . . . . . . . 33
*NO RESPONSE FROM OCCUPANT *NO RESPONSE FROM BODY CONTROL
RESTRAINT CONTROLLER . . . . . . . . . . . . . . 10 MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
*NO RESPONSE FROM INSTRUMENT *NO RESPONSE FROM SENTRY KEY
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOTE ENTRY MODULE . . . . . . . . . . . . . . 40
*NO RESPONSE FROM UNIVERSAL BODY VERIFICATION TEST . . . . . . . . . . . . . 44
GARAGE DOOR OPENER/TIRE SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 45
PRESSURE MONITOR . . . . . . . . . . . . . . . . . 17
*NO RESPONSE FROM A/C HEATER
CONTROL MODULE . . . . . . . . . . . . . . . . . . . 21
ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS

8E - 2 ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS ZH
*DRB IIIT DOES NOT POWER UP
ZH ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS 8E - 3
*DRB IIIT DOES NOT POWER UP — CONTINUED
POSSIBLE CAUSES
GROUND CIRCUIT OPEN
For a complete Data Link Connector Circuit Diagram, Refer to Page 8E-45.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE DLC POWER CIRCUIT

Note: If the LEDs do not light or no sound is emitted at start up,
check for loose cable connections or a bad cable. Check the vehicle
battery voltage (data link 16-way connector cavity 16). A minimum of
11 volts is required to adequately power the DRB IIIT. Check for a
proper ground at DLC cavity 4. If all connections are proper between
the DRB IIIT and the vehicle or other devices and the vehicle battery
is fully charged, an inoperative DRB IIIT may be the result of a faulty
cable.
Measure the voltage of the Fused B(+) circuit at cavity 16 of the Data Link
Connector.

Yes >> Go to 2
No >> System voltage must be above 11 volts. Check Fuse 14
in the Underhood Accessory Fuse Block. Repair the volt-
age concern as necessary.
2. MEASURE THE RESISTANCE OF THE DLC GROUND CIRCUIT

Measure the resistance between ground the Ground circuit at cavity 4 of
the Data Link Connector.

Yes >> Inspect the DRB IIIT for a possible malfunction.
No >> Repair the DLC Ground circuit for an open.
*NO RESPONSE FROM POWERTRAIN CONTROL MODULE
*NO RESPONSE FROM POWERTRAIN CONTROL MODULE — CONTINUED
POSSIBLE CAUSES
FUSED B+ CIRCUIT OPEN

FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN
PCM GROUND CIRCUITS
SCI RECEIVE CIRCUIT OPEN
SCI RECEIVE CIRCUIT SHORTED TO GROUND
SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE
SCI TRANSMIT CIRCUIT OPEN
SCI TRANSMIT CIRCUIT SHORTED TO GROUND
SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE
SENSOR GROUND CIRCUIT OPEN
SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
Diagnostic Test
1. FUSED B(+) CIRCUIT OPEN

Disconnect the PCM C5 harness connector.
Note: Check connector — Clean/repair as necessary.
PCM C5 harness connector.

Yes >> Go to 2
open.
2.
2. FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN
Measure the voltage of the Fused Engine Control Relay Output circuit at
the PCM C5 harness connector.

Yes >> Go to 3
No >> Repair the Fused Engine Control Relay Output circuit for
an open.
2.
3. PCM GROUND CIRCUITS OPEN

Measure the resistance of the Ground circuits from the PCM C5 harness
connector.
Is the resistance below 5.0 ohms on each ground circuit?

Yes >> Go to 4
No >> Repair the Ground circuit(s) for an open.
2.
4. SCI RECEIVE CIRCUIT OPEN

Measure the resistance of the PCM SCI Receive circuit from the PCM C4
harness connector to the DLC.

Yes >> Go to 5
No >> Repair the PCM SCI Receive circuit for an open.
2.
5. SCI RECEIVE CIRCUIT SHORTED TO GROUND
Measure the resistance between ground and the PCM SCI Receive circuit.
Is the resistance below 100 kohms?

Yes >> Repair the PCM SCI Receive circuit for a short to ground.
No >> Go to 6
6. SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the PCM SCI Receive circuit at the DLC.
Is the voltage above 0.5 volt?

Yes >> Repair the PCM SCI Receive circuit for a short to voltage.
No >> Go to 7
7. SCI TRANSMIT CIRCUIT OPEN

Measure the resistance of the PCM SCI Transmit circuit from the PCM

Yes >> Go to 8
No >> Repair the PCM SCI Transmit circuit for an open.
2.
8. SCI TRANSMIT CIRCUIT SHORTED TO GROUND
Measure the resistance between ground and the PCM SCI Transmit cir-
cuit.

Yes >> Repair the PCM SCI Transmit circuit for a short to ground.
No >> Go to 9
9. SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the PCM SCI Transmit circuit at the DLC.

Yes >> Repair the PCM SCI Transmit circuit for a short to voltage.
No >> Go to 10
10. SENSOR GROUND CIRCUIT OPEN

Measure the resistance of the Sensor Ground circuit from the PCM C5
harness connector, cavity 10, to the DLC.

Yes >> Go to 11
2.
11. SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
Measure the voltage of the Sensor Ground circuit at the DLC.

Yes >> Repair the Sensor Ground circuit for a short to voltage.
No >> Replace the Powertrain Control Module. Refer to

Page 8E-56.
VER 2.
*NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER
*NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER — CONTINUED
POSSIBLE CAUSES

ORC GROUND CIRCUIT OPEN
OCCUPANT RESTRAINT CONTROLLER
Diagnostic Test
1. FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN

WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY
AND WAIT TWO MINUTES BEFORE PROCEEDING.
Disconnect the Occupant Restraint Controller (ORC) harness connector.
ORC harness connector.

Yes >> Go to 2
open.
WARNING: WHEN RECONNECTING AIRBAG SYSTEM COMPONENTS,
THE IGNITION MUST BE TURNED OFF AND THE BATTERY MUST BE
DISCONNECTED.
Perform AIRBAG VERIFICATION TEST.
2. ORC GROUND CIRCUIT OPEN

Measure the resistance of the Ground circuit from the ORC harness con-
nector.

Yes >> Go to 3
DISCONNECTED.
*NO RESPONSE FROM OCCUPANT RESTRAINT CONTROLLER — CONTINUED
Measure the resistance of the SCI Transmit circuit from the ORC harness
connector to the DLC.

Yes >> Go to 4
No >> Repair the SCI Transmit circuit for an open.
DISCONNECTED.

Measure the resistance between ground and the SCI Transmit circuit.

Yes >> Repair the SCI Transmit circuit for a short to ground.
DISCONNECTED.
No >> Go to 5

Measure the voltage of the SCI Transmit circuit at the ORC connector.

Yes >> Repair the SCI Transmit circuit for a short to voltage.
DISCONNECTED.
No >> Replace the Occupant Restraint Controller. Refer to
Page 8O-89.
WARNING: IF THE OCCUPANT RESTRAINT CONTROLLER IS
DROPPED AT ANY TIME, IT MUST BE REPLACED.
DISCONNECTED.
*NO RESPONSE FROM INSTRUMENT CLUSTER
*NO RESPONSE FROM INSTRUMENT CLUSTER — CONTINUED
POSSIBLE CAUSES

FUSED IGNITION SWITCH OUTPUT CIRCUIT(S) OPEN
IC GROUND CIRCUIT(S) OPEN
INSTRUMENT CLUSTER
Diagnostic Test
1. FUSED B+ CIRCUIT OPEN

Disconnect the IC harness connectors.
Measure the voltage of the Fused B+ circuit at the IC harness connector.

Yes >> Go to 2
No >> Repair the Fused B+ circuit for an open.
2. FUSED IGNITION SWITCH OUTPUT CIRCUIT(S) OPEN

Measure the voltage of the Fused Ignition Switch Output circuits at the IC
harness connectors.

Yes >> Go to 3
No >> Repair the Fused Ignition Switch Output circuit(s) for an
open.
3. GROUND CIRCUIT(S) OPEN
Measure the resistance of the Ground circuits from the IC harness con-
nector.

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the IC harness

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the IC.

No >> Replace the Instrument Cluster. Refer to Page 8J-83.
*NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR
*NO RESPONSE FROM UNIVERSAL GARAGE DOOR OPENER/TIRE PRESSURE MONITOR — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
UGDO/TIRE PRESSURE MONITOR
Diagnostic Test

Disconnect the UGDO/TPM harness connector.
Measure the voltage of the Fused B+ circuit at the UGDO/TPM harness
connector.

Yes >> Go to 2

UGDO/TPM harness connector.

Yes >> Go to 3
open.
3. GROUND CIRCUIT OPEN
Measure the resistance of the Ground circuit from the UGDO/TPM har-
ness connector.

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the UGDO/TPM

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the UGDO.

No >> Replace the Universal Garage Door Opener/Tire Pres-
sure Monitor. Refer to Page 8M-3.
*NO RESPONSE FROM A/C HEATER CONTROL MODULE
*NO RESPONSE FROM A/C HEATER CONTROL MODULE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
A/C HEATER CONTROL MODULE
Diagnostic Test

Disconnect the A/C Heater Control Module harness connector.
Measure the voltage of the Fused B+ circuit at the A/C Heater Control

Yes >> Go to 2

Measure the voltage of the Fused Ignition Switch Output circuits at the
A/C Heater Control Module harness connector.

Yes >> Go to 3
open.
Measure the resistance of the Ground circuit from the A/C Heater Control

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the A/C Heater
Control Module harness connector to the DLC.

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the A/C Heater Control
Module.

No >> Replace the A/C Heater Control Module. Refer to
Page 24-79 .
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — CONTINUED
POSSIBLE CAUSES
FUSED B+ CIRCUIT(S) OPEN

TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN
GROUND CIRCUIT(S) OPEN
CONTROLLER ANTILOCK BRAKE MODULE
Diagnostic Test
1. FUSED B+ CIRCUIT(S) OPEN

Measure the voltage of the Fused B+ circuits at the CAB harness connec-
tor.

Yes >> Go to 2
No >> Repair the Fused B+ circuit(s) for an open.
2. TRACTION SYSTEM RELAY OUTPUT CIRCUIT OPEN

Measure the voltage of the Traction System Relay Output circuit at the
CAB harness connector.

Yes >> Go to 3
No >> Repair the Traction System Relay Output circuit for an
open.
Measure the resistance of the Ground circuits from the CAB harness con-
nector.

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the CAB harness

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the CAB.

No >> Replace the Controller Antilock Brake Module. Refer
to Page 8E-63.
*NO RESPONSE FROM SHIFT LEVER ASSEMBLY
*NO RESPONSE FROM SHIFT LEVER ASSEMBLY — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
SHIFT LEVER ASSEMBLY
Diagnostic Test

Disconnect the SLA harness connector.
SLA harness connector.

Yes >> Go to 2
open.
Perform NAG1 TRANSMISSION VERIFICATION
TEST.

Measure the voltage of the Fused Ignition Switch Output circuit at the SLA
harness connector.

Yes >> Go to 3
open.
TEST.
Measure the resistance of the Ground circuit from the SLA harness con-
nector.

Yes >> Go to 4
TEST.

Measure the resistance of the SCI Transmit circuit from the SLA harness

Yes >> Go to 5
Perform NAG1 TRANSMISSION VERIFICATION TEST.


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the SLA.

No >> Replace the Shift Lever Assembly. Refer to Page
21-340 .
TEST.
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
TRANSMISSION CONTROL MODULE
Diagnostic Test

Disconnect the TCM harness connector.
TCM harness connector.

Yes >> Go to 2
open.
TEST.

Measure the resistance of the Ground circuit from the TCM harness con-
nector.

Yes >> Go to 3
TEST.
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE — CONTINUED
Measure the resistance of the SCI Transmit circuit from the TCM harness

Yes >> Go to 4


No >> Go to 5

Measure the voltage of the SCI Transmit circuit at the TCM.

No >> Replace the Transmission Control Module. Refer to
Page 8E-60 .
TEST.
*NO RESPONSE FROM BODY CONTROL MODULE
*NO RESPONSE FROM BODY CONTROL MODULE — CONTINUED
POSSIBLE CAUSES
FUSED B+ CIRCUIT(S) OPEN

GROUND CIRCUIT(S) OPEN
BODY CONTROL MODULE
Diagnostic Test
1. FUSED B+ CIRCUIT(S) OPEN

Disconnect the BCM harness connectors.
Measure the voltage of the Fused B+ circuits at the BCM harness con-
nector.

Yes >> Go to 2
No >> Repair the Fused B+ circuit(s) for an open.

Measure the voltage of the Fused Ignition Switch Output circuits at the
BCM harness connectors.

Yes >> Go to 3
open.
Measure the resistance of the Ground circuits from the BCM harness con-
nector.

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the BCM harness

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the BCM.

No >> Replace the Body Control Module. Refer to Page
8E-72.
*NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE
*NO RESPONSE FROM SENTRY KEY REMOTE ENTRY MODULE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
SENTRY KEY REMOTE ENTRY MODULE
Diagnostic Test

Disconnect the SKREEM C1 harness connector.
Measure the voltage of the Fused B+ circuit at the SKREEM harness con-
nector.

Yes >> Go to 2

SKREEM harness connector.

Yes >> Go to 3
open.
Measure the resistance of the Ground circuit from the SKREEM harness
connector.

Yes >> Go to 4

Measure the resistance of the SCI Transmit circuit from the SKREEM har-
ness connector to the DLC.

Yes >> Go to 5


No >> Go to 6
Measure the voltage of the SCI Transmit circuit at the SKREEM.

No >> Replace the Sentry Key Remote Entry Module. Refer
to Page 8E-70 .
1.

CAN B BUS - AUTOMATIC TRANSMISSION

CAN C BUS
CAN B BUS - MANUAL TRANSMISSION

DATA LINK CONNECTOR CIRCUIT DIAGRAM

BODY CONTROL MODULE CIRCUIT DIAGRAM (1 OF 3)



8E - 52 ELECTRONIC CONTROL MODULES - SERVICE INFORMATION ZH
ELECTRONIC CONTROL MODULES - SERVICE

INFORMATION
TABLE OF CONTENTS
page page
COMMUNICATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DATA LINK CONNECTOR SECURITY SYSTEM MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
POWERTRAIN CONTROL MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SENTRY KEY REMOTE ENTRY MODULE
STANDARD PROCEDURE - PCM/SKREEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 54 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57 SKREEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
TRANSMISSION CONTROL MODULE INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 58 SKREEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 BODY CONTROL MODULE
STANDARD PROCEDURE - TCM QUICK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
COMMUNICATION
DESCRIPTION
The Controller Area Network (CAN) data bus system is a multiplex system used for vehicle communications. Mul-
tiplexing is a system that enables the transmission of several messages over a single channel or circuit.
Many of the control modules in a vehicle require information from the same sensing device. Multiplexing reduces
wire harness complexity, sensor current loads and controller hardware because each sensing device is connected to
only one controller, which reads and distributes the sensor information to the other controllers over the data bus.
Also, because each controller on the data bus can access the controller sensor inputs to every other controller on
the data bus, more function and feature capabilities are possible.
A multiplex system allows the information flowing between controllers to be monitored using a diagnostic scan tool.
This system allows a control module to broadcast message data out onto the bus where all other control modules
can read the messages that are being sent. When a module reads a message on the data bus that it requires, it
relays that message to its microprocessor. Each module ignores the messages on the data bus that it does not
recognize.
OPERATION
Data exchange between modules is achieved by serial transmission of encoded data over a broadcast network. The
Controller Area Network (CAN) data bus messages are carried over the bus in the form of variable pulse width
modulated signals. The engine CAN data bus speed is 125 Kilo-bits per second (Kbps) (ignition on) while the inte-
rior CAN data bus speed is 83 Kilo-bits per second (Kbps).
ZH ELECTRONIC CONTROL MODULES - SERVICE INFORMATION 8E - 53
The voltage network used to transmit messages requires biasing and termination. Each module on the CAN data
bus system provides its own biasing and termination. Each module terminates the bus through a terminating resistor
and a terminating capacitor. The Powertrain Control Module is the dominant node for the CAN engine data bus
system and the Body Control Module is the dominant node for the CAN interior data bus system.
The CAN bus uses low and high voltage levels to generate signals. The voltage on the bus varies between zero and
two and one-half volts. The low and high voltage levels are generated by means of variable-pulse width modulation
to form signals of varying length.
When a module is transmitting on the bus, it is reading the bus at the same time to ensure message integrity.
DATA LINK CONNECTOR

DESCRIPTION
The Data Link Connector (DLC) (1) is located at the lower
edge of the instrument panel (3) near the hood release (2).
The exposed connector terminals are protected by a plastic
cover which flips open if access is needed.
OPERATION
The 16-way Data Link Connector (DLC) provides a link between the DRBIIIT scan tool and the vehicle electronic
control modules.

DESCRIPTION
The Powertrain Control Module (1) is concealed in the engine
compartment inside the Control Module Box (2) located next to
the Battery (3).
The Powertrain Control Module utilizes integrated circuitry and
information carried on the Controller Area Network (CAN) data
bus along with many hard wired inputs to monitor many sensor
and switch inputs throughout the vehicle. In response to those
inputs, the internal circuitry and programming of the Powertrain
Control Module allow it to control and integrate many elec-
tronic functions and features of the vehicle through both hard
wired outputs and the transmission of electronic message out-
puts to other electronic modules in the vehicle over the CAN
data bus.
The Powertrain Control Module for this model is serviced only
as a complete unit. A Powertrain Control Module can only be
repaired by, or replaced through an authorized electronic war-
ranty repair station. Refer to the latest version of the warranty
policies and procedures manual for a current listing of autho-
rized electronic repair stations.
OPERATION
The Powertrain Control Module is a pre-programmed, microprocessor-based digital computer. It regulates ignition
timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air
conditioning compressor clutch engagement and idle speed. The Powertrain Control Module can adapt its program-
ming to meet changing operating conditions.
The Powertrain Control Module receives input signals from various switches and sensors. Based on these inputs,
the Powertrain Control Module regulates various engine and vehicle operations through different system compo-
nents. These components are referred to as Powertrain Control Module outputs. The sensors and switches that
provide inputs to the Powertrain Control Module are considered Powertrain Control Module inputs.
The Powertrain Control Module adjusts ignition timing based upon inputs it receives from sensors that react to:
engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection
(automatic transmission), vehicle speed and the brake switch.
The Powertrain Control Module adjusts idle speed based on inputs it receives from sensors that react to: throttle
position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the
air conditioning clutch switch and brake switch.
Based on inputs that it receives, the Powertrain Control Module adjusts ignition timing. The Powertrain Control Mod-
ule also adjusts the generator charge rate through control of the generator field and provides speed control oper-
ation.
STANDARD PROCEDURE - PCM/SKREEM PROGRAMMING

Note: Before replacing the PCM, be sure to check the related component/circuit integrity for failures not
detected due to a double fault in the circuit. Most PCM failures are caused by internal component failures
(i.e. relays and solenoids) and shorted circuits (i.e. pull-ups, drivers, and switched circuits). These failures
are difficult to detect when a double fault has occurred and only one DTC has been set.
When a Powertrain Control Module (PCM) and the Sentry Key Remote Entry Module (SKREEM) are replaced at the
same time, perform the following steps:
1. Program the new PCM.
2. Program the new Sentry Key Remote Entry Module.
3. Replace all ignition keys and program them to the new Sentry Key Remote Entry Module.
PROGRAMMING THE PCM

The Sentry Key Remote Entry System Secret Key is an ID code that is unique to each Sentry Key Remote Entry
Module. This code is programmed and stored in the Sentry Key Remote Entry Module, the PCM, and the ignition
key transponder chip(s). When replacing the PCM, it is necessary to program the secret key into the new PCM
using the DRBIIIT scan tool.
Note: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode
will be locked out for one hour. To exit this lockout mode, turn the ignition switch to the ON position for one
hour, then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and
connect a battery charger if necessary).
PROGRAMMING THE SENTRY KEY REMOTE ENTRY MODULE

Note: Be sure to enter the correct country code. If the incorrect country code is programmed into the Sentry
Key Remote Entry Module, it cannot be changed and the Sentry Key Remote Entry Module must be
replaced.
1. Program ignition keys to the Sentry Key Remote Entry Module.
Note: If the PCM and the Sentry Key Remote Entry Module are replaced at the same time, all vehicle ignition
keys will need to be replaced and programmed to the new Sentry Key Remote Entry Module.
PROGRAMMING IGNITION KEYS TO THE SENTRY KEY REMOTE ENTRY MODULE

Note: A maximum of eight keys can be learned to each Sentry Key Remote Entry Module. Once a key is
learned to an Sentry Key Remote Entry Module it (the key) cannot be transferred to another vehicle.
1. Obtain ignition keys to be programmed from the customer (8 keys maximum).

2. Using the DRBIIIT, erase all ignition keys.
3. Program all of the ignition keys.
If ignition key programming is unsuccessful, the DRBIIIT will display a failure message.
REMOVAL
1 - CONTROL MODULE BOX COVER 4 - CONTROL MODULE BOX COOLING FAN

2 - POWERTRAIN CONTROL MODULE 5 - CONTROL MODULE BOX
3 - RELAY CONTROL MODULE 6 - BODY CONTROL MODULE

2. Slide the clips forward to remove the plastic control module box cover (1).
3. Holding the metal powertrain control module retaining clip back, pull the powertrain control module (2) up and out
of the control module box (5).
4. Disconnect the electrical connectors and remove the powertrain control module (2).
INSTALLATION

1. Connect the electrical connectors to the powertrain control module (2).

2. Install the powertrain control module into the control module box (5).
3. Install the plastic control module box cover (1) and slide the clips rearward to lock the cover.

DESCRIPTION
The Transmission Control Module (1) is located in the interior
passenger compartment on the passenger side. It is mounted
behind a base plate (3) in the passenger side footwell next to
the Radio Amplifier (2). The carpet must be pulled pack and
the base plate unfastened and flipped down in order to access
the Transmission Control Module.
OPERATION
The Transmission Control Module controls all electronic operations of the transmission. The Transmission Control
Module receives information regarding vehicle operation from both direct and indirect inputs and selects the oper-
ational mode of the transmission. Direct inputs are hardwired to and used specifically by the Transmission Control
Module. Indirect inputs originate from other components/modules and are shared with the Transmission Control
Module via the vehicle Controller Area Network (CAN) bus.
Some examples of direct inputs to the Transmission Control Module are:
• Battery (B+) Voltage
• Traction System Relay
• Trans Temp Sensor - P/N Switch
• N2 and N3 Speed Sensors
• Transmission Oil Temperature Sensor
Some examples of indirect inputs to the Transmission Control Module are:
• Controller Area Network (CAN) Bus Modules
• DRBIIIT Scan Tool Communication
• Shift Lever Assembly
• Brake Lamp Switch
Based on the information received from these various inputs, the Transmission Control Module determines the
appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This
is possible through the control of various direct and indirect outputs.
Some examples of Transmission Control Module direct outputs are:
• 1-2/4-5 Solenoid
• 2-3 Solenoid
• 3-4 Solenoid
• TCC Solenoid
• Modulation Pressure Solenoid
• Shift Pressure Solenoid
Some examples of Transmission Control Module indirect outputs are:

• Transmission Temperature (to Powertrain Control Module)
• Shift Lever Position (to Powertrain Control Module)
In addition to monitoring inputs and controlling outputs, the Transmission Control Module has other important
responsibilities and functions:
• Storing and selecting appropriate Shift Schedules
• System self-diagnostics
• Diagnostic capabilities (with DRBIIIT scan tool)
Note: If the TCM has been replaced, the “TCM Quick Learn” procedure must be performed. Refer to Page
8E-58.
BATTERY FEED
A fused, direct battery feed to the Transmission Control Module is used for continuous power. This battery voltage
is necessary to retain adaptive learn values in the Transmission Control Module’s RAM (Random Access Memory).
When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is
detected by the Transmission Control Module and a Diagnostic Trouble Code (DTC) is set.
LIMP-HOME MODE
In order to ensure safe driving and to prevent further damage to the automatic transmission, the Transmission Con-
trol Module switches to limp-home mode in the event of a critical failure. A diagnostic trouble code assigned to the
failure is stored in memory. All solenoid and regulating valves are thus de-energized. The result is that the gear last
engaged remains engaged, the modulating pressure and shift pressure rise to the maximum levels, and the torque
converter lockup clutch is disarmed. In order to preserve the operability of the vehicle to some extent, the automatic
transmission internal hydraulic control can be used to engage second gear or reverse by: stopping the vehicle,
switching off the engine, moving the shift selector lever to Park, waiting at least ten seconds, starting the engine,
and moving the shift selector lever to drive to access second gear, or moving the shift selector lever to Reverse if
needed. The limp-home function remains active until the failure is corrected or the stored diagnostic trouble code is
erased. Sporadic failures may also be reset by switching the ignition switch from Off to On.
STANDARD PROCEDURE - TCM QUICK LEARN

The quick learn procedure requires the use of the DRB IIIT scan tool.
This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission
operation. The quick learn procedure should be performed if any of the following procedures are performed:
• Transmission Assembly Replacement
• Transmission Control Module Replacement
• Solenoid Pack Replacement
• Clutch Plate and/or Seal Replacement
• Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the following conditions must be met:
• The brakes must be applied
• The engine speed must be above 500 rpm
• The shift lever position must stay in Park until prompted to shift to Drive
• The shift lever position must stay in Drive after the Shift to Drive prompt until the DRBIIIT indicates the
procedure is complete
• The calculated oil temperature must be above 60° and below 200°
REMOVAL
1 - TRANSMISSION CONTROL MODULE 3 - BASE PLATE

2 - POWER AMPLIFIER

2. Remove the passenger floor mat and pull the carpet back in the front portion of the footwell.
3. Remove the plastic nuts holding the base plate (3) to the passenger footwell and pull the base plate (3) down.
4. Remove the screws holding the transmission control module (1) to the base plate (3).
5. Disconnect the electrical connectors and remove the transmission control module (1).
INSTALLATION
1 - TRANSMISSION CONTROL MODULE 3 - BASE PLATE

2 - POWER AMPLIFIER
1. Connect the electrical connectors to the transmission control module (1).

2. Install the screws holding the transmission control module (1) to the base plate (3).
3. Turn the base plate (3) and realign it with the mounting studs on the vehicle floor.
Note: Be sure not to pinch or cause interference with the wiring harnesses while locating the base plate to
the vehicle floor studs.
4. Install the plastic nuts and secure the base plate (3) to the passenger side lower dash panel.
5. Push the carpet in the front part of the passenger footwell up into its original position and install the passenger
floor mat.

DESCRIPTION
The Controller Antilock Brake (CAB) (1) is located in the
engine compartment in front of the Underhood Accessory Fuse
Block (2).
The CAB is a microprocessor-based device which monitors the
Antilock Brake System (ABS) during normal braking and con-
trols it when the vehicle is in an ABS stop. The CAB is
mounted to the Hydraulic Control Unit (HCU) (3) as part of the
Integrated Control Unit (ICU). The CAB uses a 47-way electri-
cal connector on the vehicle wiring harness. The CAB is pow-
ered through Fuse 3 (50 amp) located in the engine fuse
block.
OPERATION
The primary functions of the Controller Antilock Brake (CAB) are to:
• Monitor the Antilock Brake System (ABS) for proper operation.
• Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle.
• Control fluid modulation to the wheel brakes while the system is in an ABS mode.
• Store diagnostic information.
• Provide communication to the DRBIIIT scan tool while in diagnostic mode.
• Illuminate the amber ABS warning indicator lamp.
• Illuminate the brake assist (BAS)/electronic stability program (ESP) lamp on the instrument panel when a
traction control event occurs.
The CAB constantly monitors the Antilock Brake System for proper operation. If the CAB detects a fault, it will turn
on the amber ABS warning indicator lamp and disable the Antilock Braking System. The normal base braking sys-
tem will remain operational.
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 actuate. The coils then open and close the valves in the Hydraulic Control Unit (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 Diagnostic Trouble Code (DTC) is then
stored in a diagnostic program memory. These DTCs will remain in the CAB memory even after the ignition has
been turned off. The DTCs can be read and cleared from the CAB memory by a technician using the DRBIIIT scan
tool.
CAB INPUTS
• Wheel speed sensors (four)
• Brake lamp switch
• System and pump voltage
• Ground
• ESP OFF switch
• Diagnostic communication
CAB OUTPUTS
• Amber ABS warning indicator lamp actuation (via CAN Bus)
• Instrument cluster communication (via CAN Bus)
• BAS/ESP indicator lamp
• Diagnostic communication
REMOVAL
2. Clean the top of the Hydraulic Control Unit (HCU) near the
hydraulic lines.
Note: Risk of confusion! Mark hydraulic lines and corre-

sponding connections before disassembling.
3. Unscrew the hydraulic lines (1–6) from the HCU. Seal off
the hydraulic lines and connections with plugs.
4. Disconnect the Controller Antilock Brake (CAB) harness

connector.
5. Unscrew the retaining bracket from the Integrated Control
Unit (ICU).
6. Pull the ICU upwards, carefully pushing the hydraulic lines
to one side.
7. Unscrew the CAB from the HCU and pull off carefully.
INSTALLATION
1. Install the Controller Antilock Brake (CAB) to the Hydraulic
Control Unit (HCU) with the screws.
2. Check the seating and condition of the Integrated Control
Unit (ICU) rubber grommets and replace if necessary.
3. Install the ICU to the retaining bracket with the screws.
CAUTION: Do not wrongfully connect hydraulic lines.

Trace the line routing to the corresponding wheel if nec-
essary.
4. Install the brake lines (1-6). Pay close attention to the

markings when attaching the hydraulic lines.
5. Reconnect the CAB harness connector (1).

7. Bleed the brake system. Refer to Page 5-9.
8. Read the fault memory and erase.
SECURITY SYSTEM MODULE

DESCRIPTION
The Central Locking Pump/Security System Module (3) uses a
combination of electrical wires (2) and air pressure/vacuum
lines (1). The Central Locking Pump/Security System Module
is located in the right rear of the luggage compartment under-
neath the trunk floor covering (4). It is wrapped in a sound
deadening material in order to operate quietly without disturb-
ing the vehicle operator.
The Central Locking Pump/Security System Module controls
the air and vacuum lines that handle the locking and unlocking
of the vehicle doors, the liftgate, and the fuel tank door.
OPERATION
VEHICLE LOCKING/UNLOCKING
To unlock, the Body Control Module is actuated by the SKREEM. The Body Control Module then sends the signal
to the Central Locking Pump/Security System Module (CLP/SSM) via the Controller Area Network (CAN) Bus. The
CLP/SSM pump motor starts running and supplies air pressure. The door lock actuators are pressurized. When a
pressure threshold is reached in the system, the pump is switched off by an internal pressure switch. The pressure
in the system is then released by the CLP/SSM and the unlocking operation is completed. The locking procedure is
accomplished in a fashion opposite to the unlocking operation. However, the next time the remote control button is
pressed, the CLP/SSM is also actuated by connecting it to ground by the second control lead on the SKREEM. The
direction of rotation for the CLP/SSM pump motor is reversed, thereby providing the vacuum required to lock. In
order to avoid unlocking the vehicle unintentionally, the vehicle is relocked by the CLP/SSM via the SKREEM.
Relocking is accomplished after unlocking with the remote control when: a door is not opened within 40 seconds,
the key is not inserted into the ignition lock, the interior power door lock switch is not actuated, only the liftgate is
opened after unlocking. The CLP/SSM reads the signals (door contacts, trunk lid, interior power door lock switch)
and actuates the power door lock actuators. The vehicle security alarm is also activated by the relocking function.
AUTOMATIC LOCKING/UNLOCKING
Upon reaching a speed of 15 km/h (9 MPH), the vehicle doors are locked automatically. The fuel tank flap remains
unlocked. If, after automatic locking, the vehicle is unlocked with the interior power door lock switch, this state is
maintained until a door is opened or until the ignition is switched off. Automatic locking is accomplished again only
upon reaching the specified speed. The logic circuitry for this function is integrated into the CLP/SSM. The auto-
matic locking function can be activated or deactivated with the DRB IIIT. An alternative is to use the interior power
door lock switch with the ignition switched on by pressing and holding the door lock switch for more than 5 seconds
in either the lock (auto locking switched on) or unlock (auto locking switched off) position. The alternative of
enabling/disabling the auto locking system by using the interior power door lock switch can also be inhibited with the
DRB IIIT.
EMERGENCY UNLOCKING
In the event of a vehicle collision, the doors are unlocked automatically by a crash sensor integrated into the CLP/
SSM. The doors are unlocked after a delay time of 8 to 11 seconds. The emergency unlocking function interrupts all
functions performed by the CLP/SSM, which are reactivated only after interrupting the ignition. The emergency
unlocking function is only active when the vehicle is unlocked from the outside.
VEHICLE RELOCKING
In order to avoid unlocking the vehicle unintentionally, the vehicle is relocked by the CLP/SSM via the SKREEM.
the key is not inserted into the ignition lock, or the interior power door lock switch is not actuated. The CLP/SSM
reads the signals (door contacts, interior power door lock switch) and actuates the power door lock actuators. The
vehicle security alarm is also activated by the relocking function.
ANTI-THEFT SYSTEM
Once the anti-theft alarm system is set, the anti-theft alarm can be triggered if:
• The doors, hood, or hatch is opened
• The radio is removed (disconnected electrically)
• The ignition is jumped
• The glove box is opened
• The anti-theft tow sensor is tripped
• The alarm siren is tripped
The inputs ready for triggering an alarm are checked twice per second by the CLP/SSM. If two sequential checks
of the same input indicate that the input is not in the non-actuated state, the audible alarm Siren is triggered and the
front and rear lamps flash.
SIREN
The vehicle theft system alarm Siren contains a built in rechargeable battery back up and can sound if its electrical
circuits are disconnected or if the vehicle battery cables are disconnected. The Siren can also sound if the electrical
circuits between it and the CLP/SSM are disconnected. Once triggered, the Siren can only be silenced by unlocking
the vehicle with the RF key transmitter or by unlocking the vehicle with the mechanical key.
ANTI-THEFT SWITCH/ANTI-THEFT TOW SENSOR

The Anti-Theft Tow Sensor is an inclination sensor that contains electrodes which are partially immersed in an elec-
trically conductive liquid. If the conductive value between the electrodes changes, the sensor recognizes a change
in the inclination of the vehicle. When the vehicle is parked, the value for the vehicle position is stored. If the vehicle
is moved with a certain inclination in longitudinal and/or lateral direction for a certain time when the anti-theft alarm
system is activated, the Anti-Theft Tow Sensor transmits an alarm signal to the CLP/SSM. In order to allow the
vehicle to be towed or transported without sounding the alarm Siren, the Anti-Theft Tow Sensor can be deactivated
by pressing the Anti-Theft Switch which is located in the passenger compartment on the center console in front of
the shift lever.
REMOVAL
1 - AIR LINES 3 - CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE

2 - ELECTRICAL CONNECTORS

2. Remove the trunk floor covering.
3. Remove the vehicle jacking assembly.
4. Remove the sound deadening foam material from the central locking pump/security system module.
5. Disconnect the air lines (1) and the electrical connectors (2) from the central locking pump/security system mod-
ule (3) and remove the module.
INSTALLATION

1. Install the central locking pump/security system module (3) into the trunk and connect the air lines (1) and the
electrical connectors (2).
2. Install the sound deadening foam covering to the central locking pump/security system module.
3. Install the vehicle jacking assembly into the trunk next to the central locking pump/security system module.
4. Install the trunk floor covering.

DESCRIPTION
The Sentry Key Remote Entry Module (SKREEM) (1) is
located underneath the top pad of the instrument panel (2)
behind the Instrument Cluster. The SKREEM works in conjunc-
tion with the vehicle locking/unlocking remote control and the
Central Locking Pump/Security System Module to lock and
unlock the vehicle.
The SKREEM is also the primary component of the sentry key
system. The SKREEM has a halo-like Antenna Ring that con-
nects by wires to the SKREEM and is mounted around the
Ignition Lock Cylinder. The SKREEM cannot be adjusted or
repaired. If faulty or damaged, the unit must be replaced.
OPERATION
The Sentry Key Remote Entry Module (SKREEM) has the following functions: receiving and evaluating the Radio
Frequency (RF) keyless entry remote signal, actuation of door locks in conjunction with the Central Locking Pump/
Security System Module, and enabling the vehicle theft security alarm with confirmation via the turn signals. When
the RKE transmitter is operated, an RF signal is transmitted. If the SKREEM recognizes the RF signal as valid, it
actuates the Central Locking Pump/Security System Module through the Body Control Module. The vehicle is then
locked or unlocked through the power locks system. Connected to the SKREEM is a Sentry Key Antenna Ring
which surrounds the ignition lock cylinder. When the ignition is switched on, the Sentry Key Antenna Ring is sup-
plied with power. A data block is transmitted inductively via the Sentry Key Antenna Ring to the SKREEM and then
on to the Powertrain Control Module. If the antenna ring data block content is invalid or if vehicle battery power is
too low to build up enough power for the antenna ring, the Powertrain Control Module will not receive the proper
signal. This is displayed with the message “Start Error” in the Instrument Cluster.
The SKREEM contains an RF transceiver and a microprocessor. The SKREEM transmits RF signals to and receives
RF signals from the ignition key transponder through a tuned Sentry Key Antenna Ring that is wired to the
SKREEM. If the Sentry Key Antenna Ring is not mounted properly around the ignition lock cylinder housing, com-
munication problems between the SKREEM and the ignition key may arise. These communication problems will
result in ignition key transponder-related faults. The SKREEM also communicates over the Controller Area Network
(CAN) data bus with the Powertrain Control Module (PCM), the Instrument Cluster, the Body Control Module (BCM),
and/or the DRB IIIT scan tool.
The SKREEM retains in memory the ID numbers of any ignition key transponder that is programmed into it. For
added system security each SKREEM is programmed with a unique secret key code. This code is stored in mem-
ory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every ignition key that is pro-
grammed into the SKREEM.
In the event that a SKREEM replacement is required, the secret key code can be transferred to the new SKREEM
from the PCM using the DRB IIIT scan tool and the ignition key system replacement programming procedure.
Proper completion of the ignition key system initialization will allow the existing ignition keys to be programmed into
the new SKREEM so that new keys will not be required. In the event that the original secret key code cannot be
recovered, SKREEM replacement will also require new ignition keys. The DRB IIIT scan tool will alert the technician
during the key reprogramming procedure if new ignition keys are required.
The sentry key system performs a self-test each time the ignition switch is turned to the On position and will store
fault information in the form of Diagnostic Trouble Codes (DTCs) in SKREEM memory if a system malfunction is
detected. The SKREEM can be diagnosed and any stored DTCs can be retrieved using a DRB IIIT scan tool. Refer
to the appropriate diagnostic information.
REMOVAL
SKREEM
2. Remove the instrument cluster. Refer to Page 8J-83.
3. Disconnect the 2-pin CAN bus harness connector (1) from
the SKREEM.
4. Disconnect the 2-pin harness connector for the sentry key
antenna ring.
5. Disconnect the 18-pin harness connector (1) from the
SKREEM.
6. Press the retaining tabs apart.
7. Remove the SKREEM from the base plate.
INSTALLATION
SKREEM
1. Install the SKREEM to the base plate.
2. Connect the 18-pin harness connector and the 2-pin CAN
bus harness connector (1) to the SKREEM.
3. Connect the 2-pin harness connector for the sentry key
antenna ring.
4. Install the instrument cluster. Refer to Page 8J-84.
BODY CONTROL MODULE

DESCRIPTION
BODY CONTROL MODULE
The Body Control Module (BCM) (1) is concealed in the
engine compartment inside of the Control Module Box (2)
located next to the battery (3).
The BCM utilizes integrated circuitry and information carried
on the Controller Area Network (CAN) bus along with many
hardwired inputs to monitor many sensor and switch inputs
throughout the vehicle. In response to those inputs, the inter-
nal circuitry and programming of the BCM allows it to control
and integrate many electronic functions and features of the
vehicle through both hardwired outputs and the transmission of
electronic message outputs to other electronic modules in the
vehicle over the CAN data bus.
The BCM for this model is serviced only as a complete unit. A
BCM can only be repaired by or replaced through an autho-
rized electronic warranty repair station. Refer to the latest ver-
sion of the Warranty Policies and Procedures manual for a
current listing of authorized electronic repair stations.
CONTROL MODULE COOLING FAN

A Control Module Cooling Fan is located inside of the front lower section of the Control Module Box (2). The Cooling
Fan is wired to the BCM and is switched on when the ignition is On. The Cooling Fan is attached to a duct which
pulls cabin temperature air from the passenger compartment and circulates it into the Control Module Box in order
to decrease the heat that may be generated by the Powertrain Control Module (PCM), the BCM, and the Relay
Control Module.
OPERATION
The Body Control Module is designed to control and integrate many of the electronic features and functions of the
vehicle. The microprocessor-based Body Control Module hardware and software monitors many hardwired switch
and sensor inputs as well as those resources it shares with other electronic modules in the vehicle through its com-
munication over the Controller Area Network (CAN) bus. The internal programming of the Body Control Module
microprocessor allows the Body Control Module to determine the tasks it needs to perform and their priorities. The
Body Control Module programming then performs those tasks and provides features through both CAN bus com-
munication with other electronic modules and hardwired outputs to a number of relays. These relays provide the
Body Control Module with the ability to control numerous high current accessory systems in the vehicle.
The Body Control Module circuitry operates on battery current received through fuses in the Underhood Accessory
Fuse Block on a non-switched fused B(+) circuit, a fused ignition switch output (start-on/run) circuit, and a fused
ignition switch output (start-on/run-accessory) circuit. This arrangement allows the Body Control Module to provide
some features regardless of the ignition switch position. The Body Control Module circuitry is grounded through the
chassis behind the right side lower A-pillar kick panel.
The Body Control Module monitors its own internal circuitry as well as many of its input and output circuits and will
store a Diagnostic Trouble Code (DTC) in electronic memory for any failure it detects. These DTCs can be retrieved
and diagnosed using a DRBIIIT scan tool. Refer to the appropriate diagnostic information.
REMOVAL


2. Slide the clips forward to remove the plastic control module box cover (1).
3. Holding the metal body control module retaining clip back, pull the body control module (6) up and out of the
control module box (5).
4. Disconnect the electrical connectors by first sliding the grey windshield wiper connector lock to the right and
removing the windshield wiper electrical connector. Then, pull the metal body control module connector lock up
to unlock and disconnect the rest of the body control module electrical connectors.
INSTALLATION

1. Connect the electrical connectors to the body control module (6) and push the metal body control module con-
nector lock down to lock the connector assembly. Then, connect the windshield wiper electrical connector to the
body control module and slide the grey windshield wiper connector lock to the left to lock it.
2. Install body control module into the control module box (5).
3. Install the plastic control module box cover (1) and slide the clips rearward to lock the cover.
ZH ENGINE SYSTEMS 8F - 1
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 32

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 24
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM STANDARD PROCEDURE - IGNITION-OFF

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STANDARD PROCEDURE - CHECKING
DIAGNOSIS AND TESTING - BATTERY BATTERY ELECTROLYTE LEVEL . . . . . . . . . 16
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL - BATTERY ................ . . . 17
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION - BATTERY . . . . . . . . . . . . . . . . 18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CABLES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS ........................7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY DIAGNOSIS AND TESTING - BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CABLES ......................... . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TRAY
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CHARGING BATTERY . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE - USING MICRO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
420 BATTERY TESTER . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 13
8F - 2 BATTERY SYSTEM ZH
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery is standard factory-installed equipment on this model. All of the components of the battery
system are located within the engine compartment of the vehicle. The battery system for this vehicle covers the
following related components, which are covered in further detail later in this section of the service manual:
• Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy
within the vehicle.
• Battery Cables - The battery cables connect the battery terminal posts to the vehicle electrical system.
• Battery Hold-down - The battery hold-down hardware secures the battery in the battery tray in the engine
compartment.
• Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an
anchor point for the battery hold-down hardware.
For battery system maintenance schedules and jump starting procedure, see the owner’s manual in the vehicle
glove box. Optionally, refer to the Lubrication and Maintenance section of this manual for the recommended battery
maintenance schedules and for the proper battery jump starting procedure. While battery charging can be consid-
ered a maintenance procedure, the battery charging procedures and related information are located later in this
section of this service manual. This was done because the battery must be fully charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and storing
electrical energy. This electrical energy is required to operate the engine starting system, as well as to operate many
of the other vehicle accessory 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 of electrical energy to supplement the charging
system for short durations while the engine is running and the electrical current demands of the vehicle exceed the
output of the charging system. In addition to delivering and storing electrical energy for the vehicle, the battery sys-
tem serves as a capacitor and voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or tran-
sient voltages caused by the switching of any of the electrical components or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM

The battery, starting, and charging systems in the vehicle operate with one another and must be tested as a com-
plete system. In order for the engine to start and the battery to maintain its charge properly, all of the components
that are used in these systems must perform within specifications. It is important that the battery, starting, and
charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The
cause of abnormal battery discharge, overcharging or early battery failure must be diagnosed and corrected before
a battery is replaced and before a vehicle is returned to service. The service information for these systems has been
separated within this service manual to make it easier to locate the specific information you are seeking. However,
when attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.
The diagnostic procedures used for the battery, starting, and charging systems include the most basic conventional
diagnostic methods, to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module
(PCM). Use of an induction-type milliampere ammeter, a volt/ohmmeter, a battery charger, a carbon pile rheostat
(load tester) and a 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each
monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for
any failure it detects. Refer to Charging System Refer to Page 8F-24 for the proper charging system on-board
diagnostic test procedures.
ZH BATTERY SYSTEM 8F - 3
MICRO 420 ELECTRICAL SYSTEM TESTER

The Micro 420 automotive battery tester is designed to help
dealership technicians diagnose a defective battery. Follow the
instruction manual supplied with the tester to properly diag-
nose a vehicle. If the instruction manual is not available, refer
to the standard procedure in this section, which includes the
directions for using the Micro 420 electrical system tester.
THE BATTERY SEEMS WEAK 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST
OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test procedures.
ATTEMPTING TO START THE Repair the excessive ignition-off draw as required.
ENGINE. 2. The charging system is 2. Determine if the charging system is performing to
faulty. specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery as required.
4. The battery terminal 4. Refer to Battery Cables for the proper battery
connections are loose or cable diagnosis and testing procedures. Clean and
corroded. tighten the battery terminal connections as required.
5. The battery has an incorrect 5. Refer to Battery System Specifications for the
size or rating for this vehicle. proper size and rating. Replace an incorrect battery
as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Replace the faulty battery as required.
7. The starting system is 7. Determine if the starting system is performing to
faulty. specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system as
required.
8. The battery is physically 8. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the damaged
battery as required.
THE BATTERY STATE OF 1. The battery has an incorrect 1. Refer to Battery System Specifications for the
CHARGE CANNOT BE size or rating for this vehicle. proper specifications. Replace an incorrect battery
MAINTAINED. as required.
2. The battery terminal 2. Refer to Battery Cable for the proper cable
connections are loose or diagnosis and testing procedures. Clean and tighten
corroded. the battery terminal connections as required.
3. The electrical system 3. Refer to the IGNITION-OFF DRAW TEST
ignition-off draw is excessive. Standard Procedure for the proper test procedures.
Repair the faulty electrical system as required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for additional
test procedures. Replace the faulty battery as
required.
5. The starting system is 5. Determine if the starting system is performing to
faulty. specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system as
required.
6. The charging system is 6. Determine if the charging system is performing to
faulty. specifications using the Micro 420 battery. Refer to
Charging System for additional charging system
diagnosis and testing procedures. Repair the faulty
charging system as required.
7. Electrical loads exceed the 7. Inspect the vehicle for aftermarket electrical
output of the charging system. equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged 8. Advise the vehicle operator as required.
idling with high-amperage
draw systems in use.
THE BATTERY WILL NOT 1. The battery is faulty. 1. Test the battery using the Micro 420 battery
ACCEPT A CHARGE. tester. Charge or replace the faulty battery as
required.
ABNORMAL BATTERY DISCHARGING

Any of the following conditions can result in abnormal battery discharging:
1. A faulty or incorrect charging system component. Refer to Charging System for additional charging system
diagnosis and testing procedures. Refer to Page 8F-24.
2. A faulty or incorrect battery. Use the Micro 420 battery tester and refer to Battery System for additional
battery diagnosis and testing procedures.
3. A faulty circuit or component causing excessive ignition-off draw.
4. Electrical loads that exceed the output of the charging system. This can be due to equipment installed after
manufacture, or repeated short trip use.
5. A faulty or incorrect starting system component. Refer to Starting System for the proper starting system
diagnosis and testing procedures. Refer to Page 8F-33.
6. Corroded or loose battery posts and/or terminal clamps.
7. Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw systems in use.
CLEANING
The following information details the recommended cleaning procedures for the battery and related components. In
addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended
that these procedures be performed any time the battery or related components must be removed for vehicle ser-
vice.
1. Clean the battery cable terminal clamps (2) of all corrosion.
Remove any corrosion using a wire terminal brush (1) or a
post and terminal cleaning tool, and a sodium bicarbonate
(baking soda) and warm water cleaning solution.
2. Clean the battery tray and battery hold-down hardware of

all corrosion. Remove any corrosion using a wire brush and
a sodium bicarbonate (baking soda) and warm water clean-
ing solution. Paint any exposed bare metal.
3. If the removed battery (3) is to be reinstalled, clean the out-
side of the battery case and the top cover with a sodium
bicarbonate (baking soda) and warm water cleaning solu-
tion (2) using a stiff bristle parts cleaning brush (1) to
remove any acid film. Rinse the battery with clean water.
Ensure that the cleaning solution does not enter the battery
cells through the vent holes. If the battery is being
replaced, refer to Battery System Specifications for the fac-
tory-installed battery specifications. Confirm that the
replacement battery is the correct size and has the correct
ratings for the vehicle.
4. Clean any corrosion from the battery (3) and the battery
terminal posts and battery cables (2) with a wire brush or a
post and terminal cleaner (1), and a sodium bicarbonate
(baking soda) and warm water cleaning solution.
INSPECTION
The following information details the recommended inspection procedures for the battery and related components. In
addition to the maintenance schedules found in this service manual and the owner’s manual, it is recommended that
these procedures be performed any time the battery or related components must be removed for vehicle service.
1. Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a damaged or
deformed terminal clamp.
2. Inspect the battery tray and battery hold-down hardware for damage. Replace any damaged parts.
3. 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.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating
or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement
battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original
equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below.
• Group Size - The outside dimensions and terminal placement of the battery conform to standards estab-
lished by the Battery Council International (BCI). Each battery is assigned a BCI Group Size number to help
identify a correctly-sized replacement.
• Cold Cranking Amperage - The Cold Cranking Amperage (CCA) rating specifies how much current (in
amperes) the battery can deliver for thirty seconds at -18° C (0° F). Terminal voltage must not fall below 7.2
volts during or after the thirty second discharge period. The CCA required is generally higher as engine dis-
placement increases, depending also upon the starter current draw requirements.
• Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery
terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes. RC is determined with the battery
fully-charged at 26.7° C (80° F). This rating estimates how long the battery might last after a charging system
failure, under minimum electrical load.
• Ampere-Hours - The Ampere-Hours (AH) rating specifies the current (in amperes) that a battery can deliver
steadily for twenty hours, with the voltage in the battery not falling below 10.5 volts. This rating is also some-
times identified as the twenty-hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
BCI Group Size Cold Cranking Reserve Ampere - Load Test

Part Number
Classification Amperage Capacity Hours Amperage
48 700 74 265
SPECIAL TOOLS
Micro 420 Battery Tester
BATTERY
DESCRIPTION
A large capacity, low-maintenance storage battery (3) is stan-
dard factory-installed equipment on this model. Male post type
terminals made of a soft lead material protrude from the top of
the molded plastic battery case to provide the means for con-
necting the battery to the vehicle electrical system. The battery
positive terminal post (2) is visibly larger in diameter than the
negative terminal post (4), for easy identification. The symbols
+ and – are also molded into the top of the battery case adja-
cent to their respective positive and negative terminal posts for
additional identification confirmation. Refer to Battery Cables in
the index of this service manual for the location of more infor-
mation on the battery cables that connect the battery to the
vehicle electrical system. Refer to Page 8F-19.
This battery is designed to provide a safe, efficient and reliable means of storing electrical energy in a chemical
form. This means of energy storage allows the battery to produce the electrical energy required to operate the
engine starting system, as well as to operate many of the other vehicle accessory systems for limited durations
while the engine and/or the charging system are not operating. The battery is made up of six individual cells that are
connected in series. Each cell contains positively charged plate groups that are connected with lead straps to the
positive terminal post, and negatively charged plate groups that are connected with lead straps to the negative ter-
minal post. Each plate consists of a stiff mesh framework or grid coated with lead dioxide (positive plate) or sponge
lead (negative plate). Insulators or plate separators made of a non-conductive material are inserted between the
positive and negative plates to prevent them from contacting or shorting against one another. These dissimilar metal
plates are submerged in a sulfuric acid and water solution called an electrolyte.
The factory-installed low-maintenance battery has removable battery cell caps (1). Distilled water can be added to
this battery. The battery is not sealed and has a vent (5). The chemical composition of the metal coated plates
within the low-maintenance battery reduces battery gassing and water loss, at normal charge and discharge rates.
Therefore, the battery should not require additional water in normal service. If the electrolyte level in this battery
does become low, distilled water must be added. However, rapid loss of electrolyte can be caused by an overcharg-
ing condition. Be certain to diagnose the charging system after replenishing the water in the battery for a low elec-
trolyte condition and before returning the vehicle to service. Refer to Page 8F-24.
For battery maintenance schedules and jump starting procedures, see the owner’s manual in the vehicle glove box.
Optionally, refer to Maintenance Schedules and Jump Starting, Towing and Hoisting in the index of this service man-
ual for the location of the recommended battery maintenance schedules and the proper battery jump starting pro-
cedures. While battery charging can be considered a maintenance procedure, the battery charging procedures and
information are located in the service procedures section of this service manual. This was done because the battery
must be fully-charged before any battery diagnosis or testing procedures can be performed. Refer to Page 8F-10.
OPERATION
The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the
terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical
current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The
sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sul-
fate. At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, caus-
ing the electrolyte to become mainly water. The chemical changes within the battery are caused by the movement
of excess or free electrons between the positive and negative plate groups. This movement of electrons produces a
flow of electrical current through the load device attached to the battery terminals.
As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential
of each cell is reduced. However, by charging the battery with a voltage higher than that of the battery itself, the
battery discharging process is reversed. Charging the battery gradually changes the sulfated lead plates back into
sponge lead and lead dioxide, and the water back into sulfuric acid. This action restores the difference in the elec-
tron charges deposited on the plates, and the voltage potential of the battery cells. For a battery to remain useful,
it must be able to produce high-amperage current over an extended period. A battery must also be able to accept
a charge, so that its voltage potential may be restored.
The battery is vented to release excess hydrogen gas that is created when the battery is being charged or dis-
charged. However, even with these vents, hydrogen gas can collect in or around the battery. If hydrogen gas is
exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may arc internally and explode.
If the battery is equipped with removable cell caps, add distilled water whenever the electrolyte level is below the
top of the plates. If the battery cell caps cannot be removed, the battery must be replaced if the electrolyte level
becomes low.
DIAGNOSIS AND TESTING - BATTERY

The battery must be completely charged and the terminals should be properly cleaned and inspected before diag-
nostic procedures are performed. Refer to Battery System Cleaning for the proper cleaning procedures Refer to
Page 8F-5, and Battery System Inspection Refer to Page 8F-6 for the proper battery inspection procedures. Refer
to Standard Procedure for the proper battery charging procedures. Refer to Page 8F-10.
MICRO 420 BATTERY TESTER

The Micro 420 automotive battery tester is designed to help dealership technicians diagnose the cause of a defec-
tive battery. Follow the instruction manual supplied with the tester to properly diagnose a vehicle. If the instruction
manual is not available refer to the standard procedure in this section, which includes the directions for using the
Micro 420 battery tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT TEST,
ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY
AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL
A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.
A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-charged
battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the
load test, is faulty and must be replaced.
Note: Completely discharged batteries may take several hours to accept a charge. Refer to Standard Pro-
cedure for the proper battery charging procedures. Refer to Page 8F-10.
STANDARD PROCEDURE
CHARGING BATTERY
Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-
charged when:
• Micro 420 electrical system tester indicates battery is OK.
• All of the battery cells are gassing freely during battery charging.
• Three hydrometer tests, taken at one-hour intervals, indicate no increase in the temperature-corrected spe-
cific gravity of the battery electrolyte.
• Open-circuit voltage of the battery is 12.4 volts or above.
WARNING: NEVER EXCEED TWENTY AMPERES WHEN CHARGING A COLD (-1° C [30° F] OR LOWER) BAT-
TERY. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, DO NOT TEST,
ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY
AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER AND CALL
A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS.
CAUTION: Always disconnect and isolate the battery negative cable before charging a battery. Do not
exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may
result.
CAUTION: Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte
boiling or being discharged from the battery vents indicates a battery overcharging condition. Immediately
reduce the charging rate or turn off the charger to evaluate the battery condition. Damage to the battery
may result from overcharging.
CAUTION: The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing the charging operation. Damage to the battery may
result.
After the battery has been charged to 12.4 volts or greater, perform a load test to determine the battery cranking
capacity. Refer to Standard Procedure for the proper battery load test procedures Refer to Page 8F-10. If the bat-
tery 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 Refer to Page 8F-5, and Battery Sys-
tem Inspection for the proper battery system inspection procedures Refer to Page 8F-6.
CHARGING A COMPLETELY DISCHARGED BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is prop-
erly followed, a good battery may be needlessly replaced.
1. Measure the voltage at the battery posts with a voltmeter,
accurate to 1/10 (0.10) volt. If the reading is below ten
volts, the battery charging current will be low. It could take
some time before the battery accepts a current greater than
a few milliamperes. Such low current may not be detectable
on the ammeters built into many battery chargers.
2. Disconnect and isolate the battery negative cable. Connect
the battery charger leads. Some battery chargers are
equipped with polarity-sensing circuitry. This circuitry pro-
tects the battery charger and the battery from being dam-
aged if they are improperly 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
appear that the battery will not accept charging current.
See the instructions provided by the manufacturer of the
battery charger for details on how to bypass the polarity-
sensing circuitry.
3. Battery chargers vary in the amount of voltage and current

they provide. The amount of time required for a battery to
accept measurable charging current at various voltages is
shown in the Charge Rate Table. If the charging current is
still not measurable at the end of the charging time, the
battery is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the battery
may be good and the charging should be completed in the
normal manner.
CHARGE RATE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors:
• Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small
capacity battery.
• Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F).
When a fast battery charger is connected to a cold 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 charging time.
• State-Of-Charge - A completely discharged battery 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 battery charges, the specific gravity of the electrolyte will gradually rise.
The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room tem-
perature based upon the battery state-of-charge and the charger capacity.
BATTERY CHARGING TIME
Charging 10 20
5 Amps
Amperage Amps Amps
Open Circuit
Hours Charging @ 21° C (70° F)
Voltage
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - USING MICRO 420 BATTERY TESTER

Always use the Micro 420 Instruction Manual that was supplied with the tester as a reference. If the Instruction
Manual is not available the following procedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE PROTECTION AND USE EXTREME CAUTION WHEN WORK-
ING WITH BATTERIES.
BATTERY TESTING
1. If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before testing. If the battery
is equipped with side post terminals, install and tighten the supplied lead terminal stud adapters. Do not use steel
bolts. Failure to properly install the stud adapters, or using stud adapters that are dirty or worn-out may result in
false test readings.
2. If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF, including the
ignition. The preferred test position is at the battery terminal. If the battery is not accessible, you may test
using both the positive and negative jumper posts. Select TESTING AT JUMPER POST when connecting to that
location.
3. Connect the tester to the battery or jumper posts, the red

clamp to positive (+) and the black clamp to negative (–).
Note: Multiple batteries connected in parallel must have

the ground cable disconnected to perform a battery test.
Failure to disconnect may result in false battery test read-
ings.
4. Using the ARROW key select in or out of vehicle testing

and press ENTER to make a selection.
5. If not selected, choose the Cold Cranking Amp (CCA) bat-
tery rating. Or select the appropriate battery rating for your
area (see menu). The tester will then run its self pro-
grammed test of the battery and display the results. Refer
to the test result table noted below.
CAUTION: If REPLACE BATTERY is the result of the test,

this may mean a poor connection between the vehicle’s
cables and battery exists. After disconnecting the vehi-
cle’s battery cables from the battery, retest the battery
using the OUT-OF-VEHICLE test before replacing.
6. While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits
of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and
move to the next digit. Then press the ENTER button to view the SERVICE CODE. Pressing the CODE button
a second time will return you to the test results.
BATTERY TEST RESULTS
GOOD BATTERY Return to service

GOOD - RECHARGE Fully charge battery and return to service
CHARGE & RETEST Fully charge battery and retest battery
REPLACE BATTERY Replace the battery and retest complete system
BAD-CELL REPLACE Replace the battery and retest complete system
Note: The SERVICE CODE is required on every warranty claim submitted for battery replacement.
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 when a hydrometer is not available, or for maintenance-free batteries with
non-removable cell caps.
Before proceeding with this test, completely charge the battery. Refer to Page 8F-10.
1. Before measuring the open-circuit voltage, the surface charge must be removed from the battery. Turn on the
headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.
2. Disconnect and isolate both battery cables, negative cable first.
3. Using a voltmeter connected to the battery posts (see the instructions provided by the manufacturer of the volt-
meter), measure the open-circuit voltage.
See the Open-Circuit Voltage Table. This voltage reading will indicate the battery state-of-charge, but will not reveal
its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or greater, it may be load tested
to reveal its cranking capacity. Refer to Page 8F-10.
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 - IGNITION-OFF DRAW TEST

The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with
the ignition switch in the Off position. A normal vehicle electrical system will draw from five to thirty-five milliamperes
(0.005 to 0.035 ampere) 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 Control
Module (PCM), and other modules which may vary with the vehicle equipment.
A vehicle that has not been operated for approximately 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 negative battery cable from the
battery. This will reduce battery discharging.
Excessive IOD can be caused by:
• Electrical items left on.
• Faulty or improperly adjusted switches.
• Faulty or shorted electronic modules and components.
• An internally shorted generator.
• Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a battery. In
most cases, the battery can be charged and returned to service after the excessive IOD condition has been cor-
rected.
1. Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and close all doors. If the
vehicle is equipped with an illuminated entry system or an electronically tuned radio, allow the electronic timer
function of these systems to automatically shut off (time out). This may take up to three minutes. See the Elec-
tronic Module Ignition-Off Draw Table for more information.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD)
Time Out? (If Yes, Interval And Wake-Up IOD After Time
Module IOD
Input) Out
Controller Antilock
No N/A
Brake (CAB)
Body Control Module
No N/A
(BCM)
Powertrain Control
No N/A
Module (PCM)
Transmission Control
No N/A
Module (TCM)
Instrument Cluster No N/A
Shift Lever Assembly No N/A
Garage Door Opener
/ Tire Pressure No N/A
Monitor
A/C Heater Control
No N/A
Module
Occupant Restraint
No N/A
Control Module
Pneumatic System
Equipment (PSE) No N/A
Control Module
RKE Module No N/A

3. Set an electronic digital multi-meter to its highest amperage scale. Connect the multi-meter between the discon-
nected battery negative cable terminal clamp and the battery negative terminal post. Make sure that the doors
remain closed so that the illuminated entry system is not activated. The multi-meter amperage reading may
remain high for up to three minutes, or may not give any reading at all while set in the highest amperage scale,
depending upon the electrical equipment in the vehicle. The multi-meter leads must be securely clamped to the
battery negative cable terminal clamp and the battery negative terminal post. If continuity between the battery
negative terminal post and the negative cable terminal clamp is lost during any part of the IOD test, the elec-
tronic timer function will be activated and all of the tests will have to be repeated.
4. After about three minutes, the high-amperage IOD reading on the multi-meter should become very low or non-
existent, depending upon the electrical equipment in the vehicle. If the amperage reading remains high, remove
each fuse in the Underhood Accessory Fuse Block, one at a time until the amperage reading becomes very low,
or nonexistent. If the amperage reading is still high, remove each fuse one at a time in the Illumination Control
Module until the amperage reading becomes very low or nonexistent. If the amperage reading is still high,
remove each fuse one at a time in the Relay Control Module until the amperage reading becomes very low or
nonexistent. Refer to the appropriate wiring information in this service manual for complete Underhood Accessory
Fuse, Illumination Control Module Fuse, Relay Control Module Fuse and circuit identification. This will isolate
each circuit and identify the circuit that is the source of the high-amperage IOD. If the amperage reading remains
high after removing and replacing each fuse, disconnect the wire harness from the generator. If the amperage
reading now becomes very low or nonexistent, refer to Charging System for the proper charging system diag-
nosis and testing procedures Refer to Page 8F-24. After the high-amperage IOD has been corrected, switch the
multi-meter to progressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker
remove-and-replace process to identify and correct all sources of excessive IOD. It is now safe to select the
lowest milliampere scale of the multi-meter to check the low-amperage IOD.
CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale
selected, or the multi-meter may be damaged.
5. Observe the multi-meter reading. The low-amperage IOD should not exceed thirty-five milliamperes (0.035
amperes). If the current draw exceeds thirty-five milliamperes, isolate each circuit using the fuse remove-and-
replace process in Step 4. The multi-meter reading will drop to within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch
adjustment, or a component failure is at fault.
STANDARD PROCEDURE - CHECKING BATTERY ELECTROLYTE LEVEL

The following procedure can be used to check the battery electrolyte level.
1. Remove the battery (2) cell cap (1).
2. Look through the battery cap holes (1) to determine the

level of the electrolyte in the battery. The electrolyte should
be approximately 1 centimeter above the battery plates or
until the lip (2) inside the battery cap holes is covered.
3. Add only distilled water until the electrolyte level is approx-
imately one centimeter above the plates.
REMOVAL - BATTERY
1 - PLASTIC CAP 4 - NEGATIVE BATTERY CABLE

2 - POSITIVE BATTERY CABLE 5 - BATTERY
3 - BATTERY HOLD DOWN NUT
WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOV-
ING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR
LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.
1. Disconnect the negative battery cable (4). If necessary, use a battery terminal puller to remove the terminal
clamp from the battery post.
2. Remove the protective plastic cap (1).
3. Disconnect the positive battery cable (2). If necessary, use a battery terminal puller to remove the terminal clamp
from the battery post.
4. Remove the battery hold down nut (3) and strap from the battery.
5. Remove the battery (5) from the battery tray.
INSTALLATION - BATTERY
1 - PLASTIC CAP 4 - NEGATIVE BATTERY CABLE

2 - POSITIVE BATTERY CABLE 5 - BATTERY
3 - BATTERY HOLD DOWN NUT
1. Clean and inspect the battery. Refer to the procedures in this section.
CAUTION: The battery cable terminal clamps must reach the correct battery terminal post without stretching
the cables.
2. Position the battery (5) onto the battery tray. Ensure that the battery positive and negative terminal posts are
correctly positioned.
3. Install the battery hold down onto the battery with the hold down nut (3). Tighten the battery hold down nut to 8
N·m (71 in. lbs.).
CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery terminal
posts. Reverse battery polarity may damage electrical components of the vehicle.
4. Clean the battery cable terminal clamps and the battery terminal posts.
5. Connect the positive battery cable (2). Tighten the terminal clamp pinch-bolt hex nut to 7 N·m (60 in. lbs.).
6. Install the positive battery terminal plastic cap (1).
7. Connect the negative battery cable (4). Tighten the terminal clamp pinch-bolt hex nut to 7 N·m (60 in. lbs.).
CABLES
DESCRIPTION
The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insu-
lating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical cur-
rent carrying capacity. Refer to Wiring Diagrams for battery cable wire gauge information.
A clamping type female battery terminal made of soft lead is die cast onto one end of the battery cable wire. A
square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large
eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The bat-
tery positive cable has a larger female battery terminal clamp to allow connection to the larger battery positive ter-
minal post. The battery negative cable has a smaller female battery terminal clamp.
The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive
and negative cables are available for service replacement only as a unit with the battery wire harness, which may
include portions of the wiring circuits for the generator and other components. Refer to Wiring Diagrams for more
information on the various wiring circuits included in the battery wire harness for the vehicle being serviced.
OPERATION
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a
path back to the battery for electrical current generated by the charging system for restoring the voltage potential of
the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable
connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the
opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable con-
nection of the battery cables to the vehicle electrical system.
The battery positive cable terminal clamp is die cast onto the ends of two wires. One wire has an eyelet terminal
that connects the battery positive cable to the B(+) terminal stud of the Engine Fuse Block, and the other wire has
an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp is die cast onto the end of one wire. The wire has an eyelet
terminal that connects the battery negative cable to the vehicle body through a ground bolt on the right front fender
inner shield, near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLES

A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the
battery cable. If excessive resistance is found in the battery cable connections, the connection point should be dis-
assembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage
drop for the battery cable connection and the battery cable again to confirm repair.
When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of
the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the
resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to
the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are read-
ing the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the bat-
tery positive cable.
VOLTAGE DROP TEST

The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain
that the following procedures are accomplished:
• The battery is fully-charged and load tested. Refer to Standard Procedures for the proper battery charging
Refer to Page 8F-10 and load test procedures Refer to Page 8F-10.
• Fully engage the parking brake.
• If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park posi-
tion. If the vehicle is equipped with a manual 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 ignition coil fuse. The ignition coil fuse is located in the
Underhood Accessory Fuse Block, in the engine compartment. See the fuse layout label affixed to the under-
side of the fuse block cover for ignition coil fuse identification and location.
1. Connect the positive lead of the voltmeter (1) to the battery
(2) negative terminal post. Connect the negative lead of the
voltmeter (1) to the battery (2) negative cable terminal
clamp. Rotate and hold the ignition switch in the Start posi-
tion. Observe the voltmeter. If voltage is detected, correct
the poor connection between the battery negative cable ter-
minal clamp and the battery negative terminal post.

(2) positive terminal post. Connect the negative lead of the
voltmeter (1) to the battery (2) positive cable terminal
clamp. Rotate and hold the ignition switch in the Start posi-
tion. Observe the voltmeter. If voltage is detected, correct
the poor connection between the battery positive cable ter-
minal clamp and the battery positive terminal post.
3. Connect the voltmeter (2) to measure between the battery

(1) positive cable terminal clamp and the starter solenoid
(3) B(+) terminal stud. Rotate and hold the ignition switch in
the Start position. Observe the voltmeter (2). If the reading
is above 0.2 volt, clean and tighten the battery (1) positive
cable eyelet terminal connection 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.

(2) negative cable terminal clamp and a good clean ground
on the engine block (3). Rotate and hold the ignition switch
in the Start position. Observe the voltmeter (1). If the read-
ing is above 0.2 volt, clean and tighten the battery (2) neg-
ative 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.
TRAY
DESCRIPTION
The battery is mounted in a battery tray (1) located in the right
rear corner of the engine compartment. The battery tray and
support unit is secured at the front with a bolt (2) on the front
wheelhouse inner panel, and at the rear with a bolt (2) on a
bracket from the bulkhead.
OPERATION
The battery tray provides a secure mounting location and supports the battery. The battery tray also provides the
anchor points for the battery hold-down hardware. The battery tray and the battery hold-down hardware combine to
secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle oper-
ation. Unrestrained battery movement during vehicle operation could result in damage to the vehicle, the battery, or
both.
REMOVAL
1 - BATTERY TRAY 2 - BOLTS
1. Remove the battery. Refer to Page 8F-17.

2. Remove the battery tray (1) retaining bolts (2).
3. Remove the battery tray (1).
INSTALLATION
1. Install the battery tray (1).
2. Install the battery tray (1) retaining bolts (2). Tighten the bolts to 15 N·m (11 ft. lbs.).
3. Install the battery. Refer to Page 8F-18.
8F - 24 CHARGING SYSTEM ZH
CHARGING SYSTEM
TABLE OF CONTENTS
page page
CHARGING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DIAGNOSIS AND TESTING - CHARGING VOLTAGE REGULATOR
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 26 OPERATION
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS - GENERATOR . . . . . . . . . 27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS - TORQUE ...... . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 31
GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHARGING SYSTEM
DESCRIPTION
The charging system consists of:
• Generator
• Electronic Voltage Regulator
• Ignition Switch
• Battery
• Generator Lamp
• Check Gauges Lamp
• Wiring harness and connections
OPERATION
The charging system is turned on and off with the ignition switch. The system is on when the engine is running. The
Check Gauges Lamp monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an
extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges.
The lamp is located on the instrument panel. Refer to Instrument Cluster for additional information. Refer to Page
8J-56.
DIAGNOSIS AND TESTING - CHARGING SYSTEM

The following procedures may be used to diagnose the charging system if:
• the check gauges lamp is illuminated with the engine running.
• an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often caused by:
• accessories being left on with the engine not running.
• a faulty or improperly adjusted switch that allows a lamp to stay on.
INSPECTION
The Powertrain Control Module (PCM) monitors critical input and output circuits of the charging system, making
sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit monitored
by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked continuously, and some are
checked only under certain conditions.
ZH CHARGING SYSTEM 8F - 25
To perform a complete test of the charging system, perform the following inspections.
1. Inspect the battery condition.
2. Inspect condition of battery cable terminals, battery posts, connections at engine block, and starter solenoid.
They should be clean and tight. Repair as required.
3. Inspect all fuses in the Underhood Accessory Fuse Block for tightness in receptacles. They should be properly
installed and tight. Repair or replace as required.
4. Inspect generator mounting bolts for tightness. Replace or tighten bolts if required.
5. Inspect accessory drive belt condition and tension. Tighten or replace belt as required.
6. Inspect the automatic belt tensioner.
7. Inspect generator electrical connections at generator field, battery output, and ground terminal. Also check gen-
erator ground wire connection at engine. They should all be clean and tight. Repair as required or replace gen-
erator if necessary.
CHARGING SYSTEM CIRCUIT DIAGRAM

SPECIFICATIONS
SPECIFICATIONS - GENERATOR
TYPE PART NUMBER RATED SAE AMPS ENGINE MINIMUM TEST AMPS
BOSCH 05097756AA 120 3.2L V-6 120@2200RPM
DESCRIPTION N-m Ft. Lbs. In. Lbs.

Generator Mounting Bolts 42 31 —
Generator B+ Terminal Nut 15 11 —
GENERATOR
DESCRIPTION
The generator (1) is belt-driven by the engine using a serpen-
tine type accessory drive belt (2). It is serviced only as a com-
plete assembly. If the generator fails for any reason, the entire
assembly must be replaced. The only component that is
replaceable is the voltage regulator.
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the
windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current
needed to energize the rotor.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rec-
tification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator
battery terminal.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive
pulley; incorrect, worn, damaged or misadjusted drive belt; loose mounting bolts; a misaligned drive pulley or a
defective stator or diode.
REMOVAL
1 - GENERATOR 4 - ELECTRICAL CONNECTOR

2 - UPPER GENERATOR BOLT 5 - GENERATOR B+ PROTECTIVE PLASTIC CAP
3 - LOWER GENERATOR BOLT

2. Remove the right side air inlet tube.
CAUTION: The accessory drive belt tensioner pulley is spring loaded and can cause damage to hands and
fingers if allowed to spring back.
3. Remove the accessory drive belt from the generator pulley. Refer to Page 7-45.
• Pull the tensioning pulley in a counter clockwise direction.
• Lock the tensioning pulley with a pin or slowly release the pulley after the belt is free from the area.
4. Remove the upper generator bolt (2).
5. Remove the lower generator bolt (3) and reposition the generator to access the generator harness connectors.
6. Remove the protective plastic cap from the generator B+ cable retaining nut (5).
7. Disconnect the generator B+ cable and the generator harness connectors (4) from the rear of the generator.
8. Remove the generator (1).
INSTALLATION
1 - GENERATOR 4 - ELECTRICAL CONNECTOR

2 - UPPER GENERATOR BOLT 5 - GENERATOR B+ PROTECTIVE PLASTIC CAP
3 - LOWER GENERATOR BOLT
1. Connect the generator B+ cable with the retaining nut and connect the generator harness connector (4). Tighten
the generator B+ cable retaining nut to 15 N·m (11 ft. lbs.).
2. Install the protective plastic cap on the generator B+ cable nut (5).
3. Install the generator (1) into the mounting bracket.
4. Install the upper and lower generator mounting bolts. Tighten the generator mounting bolts to 42 N·m (31 ft. lbs.).
CAUTION: Be sure to check proper installation on all pulleys.

6. Install the right side air inlet tube.
VOLTAGE REGULATOR
DESCRIPTION
The voltage regulator (2) is a separate component attached to
the rear of the generator assembly (1). If replacement is nec-
essary, the voltage regulator can be replaced separately from
the generator.
OPERATION
OPERATION
The amount of DC current produced by the generator is controlled by the voltage regulator circuitry. This circuitry is
connected in series with the generators second rotor field terminal and its ground.
REMOVAL
1 - GENERATOR 3 - SCREWS
2 - VOLTAGE REGULATOR 4 - VOLTAGE REGULATOR COVER
1. Remove the generator (1). Refer to Page 8F-28.

2. Unclip the plastic voltage regulator cover (4) and remove.
3. Remove the screws (3) attaching the voltage regulator to the generator.
4. Remove the voltage regulator (2).
INSTALLATION
1. Insert the voltage regulator (2), ensure that the ground lug is making contact to the voltage regulator.
2. Install the screws (3) attaching the voltage regulator to the generator.
3. Install the plastic voltage regulator cover (4) with the clips.
4. Install the generator (1). Refer to Page 8F-29
8F - 32 STARTING SYSTEM ZH
STARTING SYSTEM
TABLE OF CONTENTS
page page
STARTING SYSTEM TORQUE SPECIFICATIONS ...... . . . . . . . 40

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32 STARTER MOTOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DIAGNOSIS AND TESTING - STARTER
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 39 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
STARTING SYSTEM
DESCRIPTION
An electrically operated engine starting system is standard factory-installed equipment on this model. The starting
system is designed to provide the vehicle operator with a convenient, efficient and reliable means of cranking and
starting the internal combustion engine used to power the vehicle and all of its accessory systems from within the
safe and secure confines of the passenger compartment. See the owner’s manual in the vehicle glove box for more
information and instructions on the recommended use and operation of the factory-installed starting system.
The starting system consists of the following components:
• Battery
• Starter Motor
• Starter Solenoid
• Ignition Switch
• Wire harnesses and connections (including the battery cables).
This section provides complete service information for the starter motor. Complete service information for the other
starting system components can be located as follows:
• Refer to Page 8F-2.
• Refer to Page 8I-3.
• Refer to Page 8F-41 for complete service information and circuit diagrams for the starting system wiring
components.
Group 8F - Engine Systems covers the Battery, Starting Systems, and Charging System. We have combined these
systems to make it easier to locate the information you are seeking within this Service Manual. However, when
attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.
The battery, starting, and charging systems in the vehicle operate with one another, and must be tested as a com-
plete system. In order for the vehicle to start and charge properly, all of the components that are used in these
systems must perform within specifications.
The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods, to
the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt
test lamp may be required.
All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code
(DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to On-Board Diagnostic
Test For Charging System in the Diagnosis and Testing section of Charging System for more information. Refer to
Page 8F-33.
ZH STARTING SYSTEM 8F - 33
OPERATION
The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter
motor between 150 and 350 amperes, and a low-amperage control circuit that operates on less than 20 amperes.
The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the
starter solenoid, and the starter motor. The low-amperage control circuit components include the ignition switch, the
pulse module, the electromagnetic windings of the starter solenoid, and the connecting wire harness components.
Battery voltage is supplied through the low-amperage control circuit to the pulse module when the ignition switch is
turned to the momentary Start position. When the starter solenoid coil windings are energized, the solenoid pull-in
coil pulls in the solenoid plunger. The solenoid plunger pulls the shift lever in the starter motor. This engages the
starter overrunning clutch and pinion gear with the starter ring gear on the flywheel.
As the solenoid plunger reaches the end of its travel, the solenoid contact disc completes the high-amperage starter
feed circuit and energizes the solenoid plunger hold-in coil. Current now flows between the solenoid battery terminal
and the starter motor, energizing the starter.
When the solenoid plunger hold-in coil is de-energized, the solenoid plunger return spring returns the plunger to its
relaxed position. This causes the contact disc to open the starter feed circuit, and the shift lever to disengage the
overrunning clutch and pinion gear from the starter ring gear.
Once the engine starts, the pulse module prevents starter motor damage by only allowing the starter to be engaged
until the engine is running. Once the engine fires and achieves an rpm threshold that the Powertrain Control Module
(PCM) defines as “engine running”, the starter motor is automatically disengaged by the PCM through the pulse
module. The pulse module further prevents starter motor damage by not allowing the starter motor to be engaged
if the engine is already running.
DIAGNOSIS AND TESTING - STARTING SYSTEM

The battery, starting, and charging systems operate with one another, and must be tested as a complete system. In
order for the vehicle to start and charge properly, all of the components involved in these systems must perform
within specifications.
Group 8F - Engine Systems covers the Battery, Starting System, and Charging System. We have combined these
systems to make it easier to locate the information you are seeking within this Service Manual. However, when
attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.
The diagnostic procedures used in this group includes most conventional diagnostic methods. The use of an induc-
tion-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test
lamp may be required.
STARTING SYSTEM DIAGNOSIS
STARTER FAILS TO 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of
OPERATE. faulty. Group 8F - Engine Systems. Charge or replace the
battery, if required.
2. Starting circuit wiring 2. Refer to Starting System in Group 8W - Wiring
faulty. Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
4. Park/Neutral position 4. Refer to Park/Neutral Position Switch in the Diagnosis
switch faulty or and Testing section of Group 21 - Transmission. Replace
misadjusted. the park/neutral position switch, if required.
5. Starter solenoid faulty. 5. Refer to Starter Motor in the Diagnosis and Testing
section of Group 8F - Engine Systems. Replace the
starter motor assembly, if required.
6. Starter motor faulty. 6. If all other starting system components and circuits test
OK, replace the starter motor assembly.
STARTER ENGAGES, 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of
FAILS TO TURN faulty. Group 8F - Engine Systems. Charge or replace the
ENGINE. battery, if required.
2. Starting circuit wiring 2. Refer to Starting System in Group 8W - Wiring
faulty. Diagrams. Test and repair the starter feed and/or control
circuits, if required.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine.
STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor in the Removal and Installation
SPINS OUT BEFORE section of Group 8F - Engine Systems. Remove the
ENGINE STARTS. starter motor to inspect the starter ring gear. Replace the
starter ring gear, if required.
STARTER DOES NOT 1. Starter motor 1. Refer to Starter Motor in the Removal and Installation
DISENGAGE. improperly installed. section of Group 8F - Engine Systems. Tighten the starter
mounting hardware to the correct tightness specifications.
2. Ignition switch faulty. 2. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
INSPECTION
For complete wiring diagrams, refer to Starting System in the Contents of Group 8W - Wiring Diagrams. Before
removing any unit from the starting system for repair or diagnosis, perform the following inspections:
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
• Visually inspect the battery for indications of physical damage and loose or corroded cable connections.
Determine the state-of-charge and cranking capacity of the battery. Charge or replace the battery, if required.
in the proper section of Group 8F - Engine Systems for complete service information for the battery. Refer to
Page 8F-7.
• - Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness
connections. in the proper section of Group 8D - Ignition System for complete service information for the igni-
tion switch. Refer to Page 8I-5.
• Visually inspect the starter motor for indications of physical damage and loose or corroded wire harness
connections.
• Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness
connections.
• Visually inspect the wire harnesses for damage. Repair or replace any faulty wiring, as required. Refer to
the proper section of Group 8W - Wiring Diagrams for complete service information and circuit diagrams for
the starting system wiring components. Refer to Page 8W-01-1.
TESTING
COLD CRANKING TEST
For complete wiring diagrams, refer to Starting System in the Contents of Group 8W - Wiring Diagrams. The bat-
tery must be fully-charged and load-tested before proceeding. Refer to Battery in the Diagnosis and Testing section
of Group 8F - Engine Systems for the procedures. Refer to Page 8F-9.
1. Connect a suitable volt-ampere tester (3) to the battery ter-
minals (1,2). See the instructions provided by the manufac-
turer of the volt-ampere tester being used.
2. Fully engage the parking brake.
3. Place the automatic transmission gearshift selector lever in
the Park position or place the manual transmission gear-
shift selector in the Neutral position.
4. Verify that all lamps and accessories are turned off.
5. Prevent the engine from starting.
6. Rotate and hold the ignition switch in the Start position.
Note the cranking voltage and current (amperage) draw
readings shown on the volt-ampere tester.
a. If the voltage reads below 9.6 volts, refer to Starter
Motor in the Diagnosis and Testing section of this
group Refer to Page 8F-41. If the starter motor is
OK, refer to Engine Diagnosis in the Diagnosis
and Testing section of Group 9 - Engine for further
testing of the engine Refer to Page 9-4. If the
starter motor is not OK, replace the faulty starter
motor.
b. If the voltage reads above 9.6 volts and the current (amperage) draw reads below specifications, refer to
Feed Circuit Test in this section.
c. If the voltage reads 12.5 volts or greater and the starter motor does not turn, refer to Control Circuit
Testing in this section.
d. If the voltage reads 12.5 volts or greater and the starter motor turns very slowly, refer to Feed Circuit
Test in this section.
Note: A cold engine will increase the starter current (amperage) draw reading, and reduce the battery volt-
age reading.
FEED CIRCUIT TEST
The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in the high-amper-
age feed circuit. For complete wiring diagrams, refer to Starting System in the Contents of Group 8W - Wiring
Diagrams. Refer to Page 8W-01-1.
When performing these tests, it is important to remember that the voltage drop is giving an indication of the resis-
tance between the two points at which the voltmeter probes are attached.
Example: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive
cable clamp and the cable connector at the starter solenoid. If you probe the battery positive terminal post and the
cable connector at the starter solenoid, you are reading the combined voltage drop in the battery positive cable
clamp-to-terminal post connection and the battery positive cable.
The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing the tests, be certain
that the following procedures are accomplished:
• Battery is fully-charged and load-tested. Refer to Battery in the Diagnosis and Testing section of Group 8F
- Engine Systems for the procedures. Refer to Page 8F-9.
• Fully engage the parking brake.
• Place the automatic transmission gearshift selector lever in the Park position or place the manual transmis-
sion gearshift selector in the Neutral position.
• Verify that all lamps and accessories are turned off.
• Prevent the engine from starting.
(2) negative terminal post. Connect the negative lead of the
voltmeter (1) to the battery (2) negative cable clamp. Rotate
and hold the ignition switch in the Start position. Observe
the voltmeter. If voltage is detected, correct the poor con-
tact between the cable clamp and the terminal post.

(2) positive terminal post. Connect the negative lead of the
voltmeter (1) to the battery (2) positive cable clamp. Rotate
and hold the ignition switch in the Start position. Observe
the voltmeter. If voltage is detected, correct the poor con-
tact between the cable clamp and the terminal post.

(1) positive terminal post and the starter (3) solenoid bat-
tery terminal stud. 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 cable connec-
tion at the solenoid. Repeat the test. If the reading is still
above 0.2 volt, replace the faulty battery positive cable.

(2) negative terminal post and a good clean ground on the
engine block (3). 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
attachment on the engine block. Repeat the test. If the
reading is still above 0.2 volt, replace the faulty battery neg-
ative cable.
5. Connect the positive lead of the voltmeter (3) to the starter

(1) housing. Connect the negative lead of the voltmeter to
the battery (2) negative terminal post. Rotate and hold the
ignition switch in the Start position. Observe the voltmeter.
If the reading is above 0.2 volt, correct the poor starter to
engine block ground contact.
If the resistance tests detect no feed circuit problems, refer to

Starter Motor in the Diagnosis and Testing section of this
Group 8F - Engine Systems. Refer to Page 8F-41.
CONTROL CIRCUIT TESTING
The starter control circuit components should be tested in the order in which they are listed, as follows:
• Starter Solenoid - Refer to Starter Motor in the Diagnosis and Testing section of Group 8F - Engine Sys-
tems for the procedures. Refer to Page 8F-41.
• Ignition Switch - Refer to Ignition Switch and Key Lock Cylinder in the Diagnosis and Testing section of
Group 8D - Ignition System for the procedures. Refer to Page 8I-3.
• Wire harnesses and connections - Refer to Starting System in the Contents of Group 8W - Wiring Dia-
grams for complete circuit diagrams. Refer to Page 8W-01-1.
STARTING SYSTEM CIRCUIT DIAGRAM

SPECIFICATIONS
STARTER MOTOR
Starter Motor and Solenoid

Manufacturer
Engine Application 3.2L
Power Rating
Voltage 12 Volts
Number of Fields
Number of Poles
Number of Brushes
Drive Type
Free Running Test Voltage
Free Running Test Maximum Amperage Draw
Free Running Test Minimum Speed
Solenoid Closing Maximum Voltage Required
*Cranking Amperage Draw Test
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

Starter Motor (B+) Terminal 14 10 —
Starter Motor Ground Terminal 6 — 52
Starter Motor Retaining Bolts 42 31 —
STARTER MOTOR
DESCRIPTION
The starter motor (2) is mounted with two bolts to the trans-
mission housing and is located on the right side of the engine.
The starter motor incorporates several features to create a reli-
able, efficient, compact, lightweight and powerful unit. The
electric motor of the starter features electromagnetic field coils
wound around pole shoes, and brushes contact the motor
commutator. The starter motor is serviced only as a unit and
cannot be repaired. The entire starter motor (2) and starter
solenoid unit (1) must be replaced if either component is faulty
or damaged.
OPERATION
The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists
of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with
a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased
torque through the starter pinion gear to the starter ring gear.
The starter motor is activated by an integral heavy duty starter solenoid switch mounted to the overrunning clutch
housing. This electromechanical switch connects and disconnects the feed of battery voltage to the starter motor
and actuates a shift fork that engages and disengages the starter pinion gear with the starter ring gear.
DIAGNOSIS AND TESTING - STARTER MOTOR

Correct starter motor operation can be confirmed by performing the following free running bench test. This test can
only be performed with the starter motor removed from the vehicle. Refer to Starting System in the Specifications
section of this group for the starter motor specifications. Refer to Page 8F-39.
1. Remove the starter motor from the vehicle. Refer to Starter Motor in the Removal and Installation section of this
group for the procedures. Refer to Page 8F-43 and Refer to Page 8F-44.
2. Mount the starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting
flange of the starter motor. Never clamp on the starter motor by the field frame.
3. Connect a suitable volt-ampere tester and a 12-volt battery to the starter motor in series, and set the ammeter
to the 100 ampere scale. See the instructions provided by the manufacturer of the volt-ampere tester being used.
4. Install a jumper wire from the solenoid terminal to the solenoid battery terminal. The starter motor should operate.
If the starter motor fails to operate, replace the faulty starter motor assembly.
5. Adjust the carbon pile load of the tester to obtain the free running test voltage. Refer to Starting System in the
Specifications section of this group for the starter motor free running test voltage specifications. Refer to Page
8F-39.
6. Note the reading on the ammeter and compare this reading to the free running test maximum amperage draw.
Refer to Starting System in the Specifications section of this group for the starter motor free running test max-
imum amperage draw specifications. Refer to Page 8F-39.
7. If the ammeter reading exceeds the maximum amperage draw specification, replace the faulty starter motor
assembly.
STARTER SOLENOID
This test can only be performed with the starter motor removed from the vehicle.
1. Remove the starter motor from the vehicle. Refer to Page 8F-43.
2. Disconnect the wire from the solenoid field coil terminal.
3. Check the solenoid (1) for continuity between the solenoid
terminal (2) and the solenoid field coil terminal (4) with a
continuity tester (3). There should be continuity. If OK, go to
Step 4. If not OK, replace the faulty starter motor assembly.
4. Using a continuity tester (3), check for continuity between

the solenoid terminal (2) and the solenoid case (1). There
should be continuity. If not OK, replace the faulty starter
motor assembly.
REMOVAL
1 - STARTER BOLTS 3 - STARTER POSITIVE CABLE PROTECTIVE PLASTIC CAP

2 - STARTER GROUND CABLE NUT 4 - STARTER

3. Remove the lower engine panel.
4. Disconnect the right O2 sensor electrical connector.
5. Remove the right side exhaust pipe from the exhaust manifold to the rear exhaust system. Refer to Page 11-5
6. Remove the starter bolts (1) and reposition the starter to access the starter electrical cables.
7. Remove the starter positive cable protective plastic cap (3).
8. Disconnect the starter cables by removing the ground cable nut (2) and the positive cable nut.
9. Remove the starter (4) from the vehicle.
INSTALLATION
1 - STARTER BOLTS 3 - STARTER POSITIVE CABLE PROTECTIVE PLASTIC CAP

2 - STARTER GROUND CABLE NUT 4 - STARTER
1. Install the starter (4).

2. Connect the starter cable and the ground cable with the nuts. Tighten the starter positive cable nut to 14 N·m (10
ft. lbs.). Tighten the starter ground cable nut (2) to 6 N·m (52 in. lbs.)
3. Install the starter positive cable protective plastic cap (3).
4. Install the starter bolts (1). Tighten to 42 N·m (31 ft. lbs.).
5. Install the right side exhaust pipe. Refer to Page 11-7.
6. Connect the right side O2 sensor.
7. Install the lower engine panel.
ZH HEATED SYSTEMS 8G - 1
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS - ELECTRICAL DIAGNOSTICS . . . 1 HEATED MIRRORS - SERVICE INFORMATION . . 22

HEATED GLASS - SERVICE INFORMATION . . . . . 10 HEATED SEATS - ELECTRICAL DIAGNOSTICS. . . 25
HEATED MIRRORS - ELECTRICAL HEATED SEATS - SERVICE INFORMATION . . . . . 36
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEATED GLASS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
HEATED GLASS - ELECTRICAL DIAGNOSTICS *REAR WINDOW DEFOGGER

DIAGNOSIS AND TESTING INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR DEFOGGER SWITCH SENSE BODY VERIFICATION TEST . . . . . . . . . . . . . . 8
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . 9
HEATED GLASS - ELECTRICAL DIAGNOSTICS

8G - 2 HEATED GLASS - ELECTRICAL DIAGNOSTICS ZH
REAR DEFOGGER SWITCH SENSE CIRCUIT
ZH HEATED GLASS - ELECTRICAL DIAGNOSTICS 8G - 3
REAR DEFOGGER SWITCH SENSE CIRCUIT — CONTINUED
• Set Condition: The Body Control Module (BCM) detects a short to power, ground, or an open on the Rear
Defogger Switch Sense circuit.
POSSIBLE CAUSES
REAR DEFOGGER SWITCH SENSE CIRCUIT SHORT TO VOLTAGE

REAR DEFOGGER SWITCH SENSE CIRCUIT SHORT TO GROUND
REAR DEFOGGER SWITCH SENSE CIRCUIT OPEN
BODY CONTROL MODULE
For a complete Heated Glass Circuit Diagram Refer to Page 8G-9.
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE REAR DEFOGGER SWITCH

SENSE CIRCUIT

Disconnect the BCM harness connector.
Measure the resistance of the Rear Defogger Switch Sense circuit from
the BCM harness connector to the A/C Heater Control Module harness
connector.

Yes >> Go to 2
No >> Repair the Rear Defogger Switch Sense circuit for an
open.
2. MEASURE THE VOLTAGE OF THE REAR DEFOGGER SWITCH

SENSE CIRCUIT

Measure the voltage of the Rear Defogger Switch Sense circuit at the A/C
Heater Control Module harness connector.
Is voltage present?
Yes >> Repair the Rear Defogger Switch Sense circuit for a short
to voltage.
No >> Go to 3
REAR DEFOGGER SWITCH SENSE CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE REAR DEFOGGER SWITCH
SENSE CIRCUIT

Measure the resistance between ground and the Rear Defogger Switch
Sense circuit.

Yes >> Repair the Rear Defogger Switch Sense circuit for a short
to ground.
8E-72.
*REAR WINDOW DEFOGGER INOPERATIVE
*REAR WINDOW DEFOGGER INOPERATIVE — CONTINUED
POSSIBLE CAUSES
REAR WINDOW DEFOGGER FUSED B(+) CIRCUIT OPEN

REAR WINDOW DEFOGGER GRID OPEN
REAR WINDOW DEFOGGER GRID GROUND CIRCUIT OPEN
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE
For a complete Heated Glass Circuit Diagram Refer to Page 8G-9.
Diagnostic Test
1. INSPECT THE REAR WINDOW DEFOGGER INDICATOR ON THE

Activate the Rear Window Defogger.
Is the rear window defogger indicator blinking?

Yes >> Lower the electrical load on the vehicle until the light stops
blinking. Once the rear window defogger indicator stops
blinking, the system will resume normal operation.
No >> Go to 2
2. MEASURE REAR WINDOW DEFOGGER FUSED B(+) CIRCUIT

VOLTAGE

continuing.
Disconnect the Central Locking Pump/Security System Module (CLP/SSM)
harness connector.
Measure the voltage of the Fused B(+) circuit at the CLP/SSM harness
connector.

Yes >> Go to 3
No >> Repair the CLP/SSM Fused B(+) circuit for an open.
*REAR WINDOW DEFOGGER INOPERATIVE — CONTINUED
3. MEASURE REAR WINDOW DEFOGGER GRID VOLTAGE
Disconnect the Rear Window Defogger Grid harness connector terminal 1.
Reconnect the CLP/SSM harness connector.
Measure the voltage at the Rear Window Defogger Grid harness connec-
tor terminal 1.

Yes >> Repair the Rear Window Defogger Ground circuit for an
open.
No >> Go to 4
4. MEASURE REAR WINDOW DEFOGGER SUPPLY CIRCUIT

VOLTAGE

Disconnect the Rear Window Defogger Grid harness connector terminal 2.
Measure the voltage at the Rear Window Defogger Grid harness connec-
tor terminal 2.

Yes >> Repair or replace the Rear Window Defogger Grid. Refer to
Page 8G-13.
No >> Go to 5
5. MEASURE REAR WINDOW DEFOGGER SUPPLY CIRCUIT

RESISTANCE

Disconnect the CLP/SSM harness connector.
Measure the resistance of the Rear Window Defogger Grid Supply circuit
from the CLP/SSM harness connector to the Rear Window Defogger Grid
harness connector terminal 2.

Yes >> Replace the Central Locking Pump/Security System Mod-
ule. Refer to Page 8Q-48.
No >> Repair the Rear Window Defogger Grid Supply circuit
for an open.
1.

REAR WINDOW DEFOGGER CIRCUIT DIAGRAM

8G - 10 HEATED GLASS - SERVICE INFORMATION ZH
HEATED GLASS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
HEATED GLASS - SERVICE INFORMATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 REAR WINDOW DEFOGGER GRID
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - REAR WINDOW
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER GRID . . . . . . . . . . . . . . . . . . . . . 12
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . 11 STANDARD PROCEDURE - REAR GLASS
REAR WINDOW DEFOGGER SWITCH HEATING GRID REPAIR . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEATED GLASS - SERVICE INFORMATION

DESCRIPTION
Electric rear window defogger is standard equipment. A push
button rear window defogger switch (2) located in the center
console turns the system ON and is illuminated with instru-
mentation lighting for easy night time use. An LED (1) in the
push button switch illuminates when the rear window defogger
is working. When energized, a grid on the inside of the liftgate
window heats up to help clear the outside surface of ice, snow
or fog.
ZH HEATED GLASS - SERVICE INFORMATION 8G - 11
OPERATION
When the rear window defogger switch is pressed with the
ignition switch turned to the ON/RUN position, electrical cur-
rent from fuses 25 and 26 in the Underhood Accessory Fuse
Block is applied to a series of horizontal silver-ceramic grid
lines (1) through the two vertical bus bars (2) on the glass
inside surface. When the circuit is operating, the grid lines pro-
vide heat in the form of resistance. The heat is transferred to
the outside surface to clear fog or snow. The grid lines com-
prise a parallel electrical circuit and are bonded to the glass
permanently. Both the horizontal grid lines (1) and the vertical
bus bars (2) are highly resistant to abrasion. However, it is
possible for an open circuit to occur in an individual grid line
resulting in no current flow. Care should be taken when clean-
ing the glass or removing foreign materials, decals or stickers.
Normal glass cleaning solvents or hot water is recommended
for cleaning. The grid lines and bus bars are repairable if they
become damaged. For complete heated grid line and bus bar
repair instructions see rear window defogger grid standard pro-
cedure in this section. Refer to Page 8G-13.
DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER SYSTEM

For complete heated glass electrical diagnosis with schematics and diagrams, see the appropriate heated glass
electrical diagnostics in this section.
The operation of the electrically heated rear window defogger system can be confirmed in the following manner:
1. Turn the ignition switch to the ON/RUN position.
2. Press the defogger switch to the ON position. The rear window defogger operation can be checked by
feeling the rear window glass. A distinct difference in temperature between the grid lines and the adjacent clear
glass can be detected within three to four minutes of operation.
3. Using a 12-volt DC voltmeter, contact the rear glass heating grid terminal (right side) with the negative lead
and the opposite terminal (left side) with the positive lead. The voltmeter should read battery voltage.
The above checks will confirm system operation. Illumination of the defogger switch indicator lamp means that there
is electrical current available at the A/C - Heater Control Module but does not confirm that the electrical current is
reaching the rear glass heating grid lines.
If the defogger system does not operate, the problem should be isolated in the following manner:
1. Confirm that the ignition switch is in the ON/RUN position.
2. Ensure that the rear glass heating grid feed and ground wires are connected to the glass. Confirm that the
ground wire has continuity to ground.
3. Check fuses 25 and 26 in the Underhood Accessory Fuse Block. The fuses must be tight in their receptacles and
all electrical connections must be clean and secure.
When the above steps have been completed and the rear glass heating grid is still inoperative, one or more of the
following is faulty:
• Defogger switch
• A/C - Heater Control Module circuitry
• Rear window grid lines (all grid lines would have to be broken or one of the feed wires disconnected for the
entire system to be inoperative)
REAR WINDOW DEFOGGER SWITCH

REMOVAL
WARNING: REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY DOOR, SEAT, STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
The rear window defogger switch (2) is an integrated part of

the A/C Heater Control Module (3). For complete rear window
defogger switch removal procedures, see heater control
removal in the HVAC section. Refer to Page 24-79.
INSTALLATION
The rear window defogger switch is an integrated part of the A/C Heater Control Module. For complete rear window
defogger switch installation procedures, heater control installation in the Heating and Air Conditioning section of this
manual Refer to Page 24-81.
REAR WINDOW DEFOGGER GRID

DIAGNOSIS AND TESTING - REAR WINDOW DEFOGGER GRID
For complete rear window defogger grid electrical diagnosis with schematics and diagrams, see heated glass elec-
trical diagnostics in this section. Refer to Page 8G-9.
To detect breaks in the grid lines, the following procedure is required:
1. Turn the ignition switch to the ON/RUN position. Press the defogger switch to the ON position. The indicator
lamp in the defogger switch should light. If OK, go to step 2. If not OK, see heated glass electrical diagnostics
in this section.
ZH HEATED GLASS - SERVICE INFORMATION 8G - 13
2. Using a 12-volt DC voltmeter, contact a good body ground

point with the negative lead. With the positive lead, contact
the vertical bus bar (1) on the left side of the vehicle. The
voltmeter should read battery voltage. If OK, go to step 2. If
not OK, repair the open circuit to the A/C - Heater Control
Module as required.
3. With the negative lead of the voltmeter, contact the vertical
bus bar (2) on the right side of the vehicle. The voltage
reading should not change. If OK, go to step 3. If not OK,
repair the circuit to ground as required.
4. Connect the negative lead of the voltmeter to the right side
bus bar (2) and touch each grid line (5) at its midpoint (4)
with the positive lead. A reading of approximately six volts
indicates a line is good. A reading of zero volts indicates a
break in the grid line (5) between the midpoint (4) of the
grid line and the left side bus bar (1). A reading of ten to
fourteen volts indicates a break between the midpoint (4) of
the grid line and the right side bus bar (2). Move the posi-
tive lead on the grid line (5) towards the break and the volt-
age reading will change as soon as the break is crossed.
STANDARD PROCEDURE - REAR GLASS HEATING GRID REPAIR

Repair of the rear glass heating grid lines, bus bars, terminals or pigtail wires can be accomplished using a MoparT
Rear Window Defogger Repair Kit (Part Number 4267922) or equivalent.
WARNING: MATERIALS CONTAINED IN THE REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. THE KIT
CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID
CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP
AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTER-
NALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADE-
QUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP
OUT OF THE REACH OF CHILDREN.
1. Mask the repair area (3) so that the conductive epoxy can
be applied neatly. Extend the epoxy application onto the
grid line (2) or the bus bar on each side of the break (1).
2. Follow the instructions in the repair kit for preparing the

damaged area.
3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the pack-
aging. Fold the package in half and cut the center corner to dispense the epoxy.
4. For grid line repairs, mask the area to be repaired with masking tape or a template.
5. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19
millimeters (0.75 inch).
6. For a terminal or pigtail wire replacement, mask the adjacent areas so the epoxy can be extended onto the
adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal or pigtail wire
was fastened and onto the adjacent grid line.
7. Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper
location on the bus bar. To prevent the terminal or pigtail wire from moving while the epoxy is curing, it must be
wedged or clamped.
8. Carefully remove the masking tape or template.
CAUTION: Do not allow the glass surface to exceed 204° C (400° F) or the glass may fracture.
9. Allow the epoxy to cure 24 hours at room temperature or use a heat gun that will not over heat the glass. Hold
the heat gun approximately 25.4 centimeters (10 inches) from the repair.
10. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal or pigtail wire. Do
not attach the wire harness connectors until the curing process is complete.
11. Check the operation of the rear window defogger glass heating grid.
ZH HEATED MIRRORS - ELECTRICAL DIAGNOSTICS 8G - 15
HEATED MIRRORS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
HEATED MIRRORS - ELECTRICAL *RIGHT HEATED MIRROR INOPERATIVE . . . 18

DIAGNOSTICS BODY VERIFICATION TEST . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 21
*LEFT HEATED MIRROR INOPERATIVE . . . . 16
HEATED MIRRORS - ELECTRICAL DIAGNOSTICS

8G - 16 HEATED MIRRORS - ELECTRICAL DIAGNOSTICS ZH
*LEFT HEATED MIRROR INOPERATIVE
*LEFT HEATED MIRROR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
LEFT MIRROR HEATER ELEMENT FUSED B(+) CIRCUIT OPEN

LEFT MIRROR HEATER ELEMENT GROUND CIRCUIT OPEN
LEFT MIRROR HEATER ELEMENT
For a complete Heated Mirrors Circuit Diagram Refer to Page 8G-21.
Diagnostic Test
1. MEASURE LEFT MIRROR HEATER ELEMENT FUSED B(+) CIRCUIT

VOLTAGE

Disconnect the Left Power Mirror harness connector.
Measure the voltage of the Fused B(+) circuit at the Left Power Mirror har-
ness connector.

Yes >> Go to 2
No >> Repair the Left Mirror Heater Element Fused B(+) circuit
for an open.
2. MEASURE LEFT MIRROR HEATER ELEMENT GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Left Mirror Heater Ele-
ment Ground circuit.

Yes >> Replace the Left Power Mirror. Refer to Page 8N-72.
No >> Repair the Left Mirror Heater Element Ground circuit
for an open.
*RIGHT HEATED MIRROR INOPERATIVE
*RIGHT HEATED MIRROR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
RIGHT MIRROR HEATER ELEMENT FUSED B(+) CIRCUIT OPEN

RIGHT MIRROR HEATER ELEMENT GROUND CIRCUIT OPEN
RIGHT MIRROR HEATER ELEMENT
For a complete Heated Mirrors Circuit Diagram Refer to Page 8G-21.
Diagnostic Test
1. MEASURE RIGHT MIRROR HEATER ELEMENT FUSED B(+)

CIRCUIT VOLTAGE

Disconnect the Right Power Mirror harness connector.
Measure the voltage of the Fused B(+) circuit at the Right Power Mirror
harness connector.

Yes >> Go to 2
No >> Repair the Right Mirror Heater Element Fused B(+) cir-
cuit for an open.
2. MEASURE RIGHT MIRROR HEATER ELEMENT GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Right Mirror Heater Ele-
ment Ground circuit.

Yes >> Replace the Right Power Mirror. Refer to Page 8N-72.
No >> Repair the Right Mirror Heater Element Ground circuit
for an open.
1.

HEATED MIRRORS CIRCUIT DIAGRAM

8G - 22 HEATED MIRRORS - SERVICE INFORMATION ZH
HEATED MIRRORS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
HEATED MIRRORS - SERVICE INFORMATION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 22

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 HEATED MIRROR GRID
HEATED MIRRORS - SERVICE INFORMATION

DESCRIPTION
The exterior mirrors are equipped with heater elements located
behind the mirror glass (1) on each sideview mirror. With the
ignition switch turned to the ON/RUN or START positions, the
sideview mirror heater elements are powered. The heater ele-
ments behind each sideview mirror cannot be repaired. If
faulty or damaged, the entire sideview mirror assembly must
be replaced. For complete sideview mirror removal proce-
dures, see sideview mirror removal in this section. Refer to
Page 8N-72.
OPERATION
The exterior mirror heater elements receive power through fuse 6 in the Underhood Accessory Fuse Block any time
the ignition switch is turned to the ON/RUN or START position.

The operation of the heated mirror system can be confirmed in the following manner:
ZH HEATED MIRRORS - SERVICE INFORMATION 8G - 23
• Turn the ignition switch to the ON/RUN position. The

heated mirror operation can be checked by feeling the
outside rear view mirror glass. A distinct difference in
temperature between the unheated and heated mirror
glass can be detected within three to four minutes of sys-
tem activation.
If no difference in temperature can be detected on the side-

view mirror glass surface, refer to heated mirror electrical
diagnostics in this section.
Note: If the interior dome lamp dims or flickers while a door is opened and the ignition switch is in the
ON/RUN position, inspect the door wire harness section that flexes near the door hinge. It is possible to
have an intermittent open or short circuit in the mirror heating grid B+ or ground circuits when the door is
not in a stationary position.
HEATED MIRROR GRID

DESCRIPTION
WARNING: REFER TO RESTRAINTS BEFORE ATTEMPTING ANY DOOR, SEAT, STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER-
SONAL INJURY.
8G - 24 HEATED MIRRORS - SERVICE INFORMATION ZH
The heated mirror grid is attached to the back of the sideview

mirror glass and cannot be adjusted or repaired. If faulty or
damaged, the entire sideview mirror assembly must be
replaced as a unit. For complete sideview mirror removal pro-
cedures, see sideview mirror removal. Refer to Page 8N-72.
ZH HEATED SEATS - ELECTRICAL DIAGNOSTICS 8G - 25
HEATED SEATS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
HEATED SEATS - ELECTRICAL DIAGNOSTICS *BOTH HEATED SEATS INOPERATIVE . . . . . 32

DIAGNOSIS AND TESTING BODY VERIFICATION TEST . . . . . . . . . . . . . 34
*LEFT HEATED SEAT INOPERATIVE . . . . . . . 26 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 35
*RIGHT HEATED SEAT INOPERATIVE . . . . . . 29
HEATED SEATS - ELECTRICAL DIAGNOSTICS

8G - 26 HEATED SEATS - ELECTRICAL DIAGNOSTICS ZH
*LEFT HEATED SEAT INOPERATIVE
*LEFT HEATED SEAT INOPERATIVE — CONTINUED
POSSIBLE CAUSES
LEFT SEAT BACK/CUSHION HEATER ELEMENT

LEFT HEATED SEAT OUTPUT CIRCUIT OPEN
LEFT HEATED SEAT GROUND CIRCUIT OPEN
HEATED SEAT MODULE
For a complete Heated Seats Circuit Diagram Refer to Page 8G-35.
Diagnostic Test
1. TEST THE LEFT HEATED SEAT

Disconnect the Heated Seat Module harness connector.
Connect a fused jumper wire from B(+) to cavity 3 (LHD) of the Heated
Seat Module harness connector.
With the jumper wire connected, does the Left Heated Seat warm
up?
Yes >> Replace the Heated Seat Module. Refer to Page 8G-41.
No >> Go to 2
2. MEASURE LEFT HEATED SEAT OUTPUT CIRCUIT RESISTANCE

Disconnect the Left Heated Seat Back/Heated Seat Cushion harness con-
nector.
Measure the resistance of the Left Heated Seat Output circuit from the
Heated Seat Module harness connector to the Left Heated Seat Back/
Heated Seat Cushion harness connector.

Yes >> Go to 3
No >> Repair the Left Heated Seat Output circuit for an open.
*LEFT HEATED SEAT INOPERATIVE — CONTINUED
3. MEASURE LEFT HEATED SEAT GROUND CIRCUIT RESISTANCE
Measure the resistance between ground and the Left Heated Seat Ground
circuit.

Yes >> Replace the Left Heated Seat Back/Heated Seat Cushion
Element. Refer to Page 8G-40.
No >> Repair the Left Heated Seat Ground circuit for an

open.
*RIGHT HEATED SEAT INOPERATIVE
*RIGHT HEATED SEAT INOPERATIVE — CONTINUED
POSSIBLE CAUSES
RIGHT SEAT BACK/CUSHION HEATER ELEMENT

RIGHT HEATED SEAT OUTPUT CIRCUIT OPEN
RIGHT HEATED SEAT GROUND CIRCUIT OPEN
HEATED SEAT MODULE
Diagnostic Test
1. TEST THE RIGHT HEATED SEAT

Connect a fused jumper wire from B(+) to cavity 1 (LHD) of the Heated
Seat Module harness connector.
With the jumper wire connected, does the Right Heated Seat warm
up?
No >> Go to 2
2. MEASURE RIGHT HEATED SEAT OUTPUT CIRCUIT RESISTANCE

Disconnect the Right Heated Seat Back/Heated Seat Cushion harness
connector.
Measure the resistance of the Right Heated Seat Output circuit between
the Heated Seat Module harness connector and the Right Heated Seat
Back/Heated Seat Cushion harness connector.

Yes >> Go to 3
No >> Repair the Right Heated Seat Output circuit for an open.
*RIGHT HEATED SEAT INOPERATIVE — CONTINUED
3. MEASURE RIGHT HEATED SEAT GROUND CIRCUIT RESISTANCE
Measure the resistance between ground and the Right Heated Seat
Ground circuit.

Yes >> Replace the Right Heated Seat Back/Heated Seat Cushion
Element. Refer to Page 8G-40.
No >> Repair the Right Heated Seat Ground circuit for an

open.
*BOTH HEATED SEATS INOPERATIVE
*BOTH HEATED SEATS INOPERATIVE — CONTINUED
POSSIBLE CAUSES

HEATED SEAT MODULE
Diagnostic Test
1. MEASURE HEATED SEAT MODULE FUSED B(+) CIRCUIT VOLTAGE

Note: Inspect Fuse 1 and Fuse 24 located in the Underhood Acces-
sory Fuse Block. If either fuse is open, repair the cause of the open
fuse before continuing.
Measure the voltage of the Fused B(+) circuit at the Heated Seat Module
harness connector.

Yes >> Go to 2
No >> Repair the Heated Seat Module Fused B(+) circuit for an
open.
2. MEASURE HEATED SEAT MODULE FUSED IGNITION SWITCH

OUTPUT CIRCUIT VOLTAGE

Heated Seat Module harness connector.

No >> Repair the Heated Seat Module Fused Ignition Switch
Output circuit for an open.
1.

HEATED SEATS CIRCUIT DIAGRAM

8G - 36 HEATED SEATS - SERVICE INFORMATION ZH
HEATED SEATS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
HEATED SEATS - SERVICE INFORMATION REMOVAL - HEATED SEAT BACK ELEMENT . 40

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 HEATED SEAT CUSHION ELEMENT . . . . . . . 41
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 37 INSTALLATION - HEATED SEAT BACK
HEATED SEAT SWITCH ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 HEATED SEAT MODULE
HEATED SEAT ELEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL
HEATED SEAT CUSHION ELEMENT . . . . . . . 40
HEATED SEATS - SERVICE INFORMATION

DESCRIPTION
Electrically heated seats are standard equipment on this
model. Each seat has a separate control switch (1 and 2)
located in the center console and individual heating elements,
one set within the seat cushion, and the other within the seat
back. The heated seat system features two heating stages.
Stage one is for normal heating operation and stage two is for
quick heat-up. Each control switch (1 and 2) contains LED
lights that indicate the heating stage the switch is in.
OPERATION
The heated seat system will operate only when the ignition switch is in the ACC or ON/RUN position. The heated
seat module receives switched power through fuse 1 and non-switched power through fuse 24 in the Underhood
Accessory Fuse Block. Individual illuminated heated seat switches control each seat and are designed as toggle
switches that return automatically to their original position after being pressed. The switches and control module for
the heated seats are consolidated into a block with other switches to form a switch group. Switch illumination is
provided through instrumentation lighting. The heated seat control module controls the differing electrical power con-
sumption requirements of the heated seats in each heating stage and heating time.
ZH HEATED SEATS - SERVICE INFORMATION 8G - 37
The heated seats are switched from heating stage two to heat-
ing stage one automatically after 5 minutes and completely
switched off after approximately 30 minutes of continuous
operation. Heating stage one (1) is indicated by a single LED
being illuminated within the switch and heating stage two (2) is
indicated by two LEDs being illuminated. If the battery voltage
drops below 11 volts, the heated seats are deactivated auto-
matically and are prevented from being activated again until
sufficient battery voltage is available. This state is indicated by
a flashing LED in the heated seat switch. The heated seat ele-
ments are bonded to either the seat cushions or seat covers
and are serviced only with their respective assemblies.

Before testing the individual components of the heated seat system, ensure the battery is fully charged, then check
the following:
• If the heated seat switch LED indicators do not illuminate with the ignition switch in the ACC or ON/RUN
position and the switch pressed, check fuse 1 and fuse 24 in the Underhood Accessory Fuse Block. If OK, see
heated seat electrical diagnostics in this section. Refer to Page 8G-35. If not OK, repair the shorted circuit or
component as required and replace the fuse.
• If the heated seat switch LED indicators illuminate but the heating elements do not heat, inspect the heated
seat system harness connections for looseness or corrosion. Clean and tighten all the connections to ensure
proper circuit continuity and ground paths as necessary, then retest the system. For complete heated seat
diagnosis, see heated seat diagnostics in this section. Refer to Page 8G-35.
Note: The heated seat system utilizes a unique low voltage cut-off feature. This feature deactivates the
power seat system anytime the available system voltage is below 11 volts. Be certain to check the vehicle
electrical system for proper operation anytime the heated seat system appears inoperable.
HEATED SEAT SWITCH

REMOVAL
Note: The heated seat switches and heated seat control

module are integral and serviced together.

2. Remove the center console interior trim panel. Refer to

Page 23-173.
3. Disconnect the heated seat switch harness connectors (1).
4. Press the locking tabs inward and remove the heated seat
switches from the interior trim panel.
INSTALLATION
1. Align the heated seat switch with the center console interior
trim panel and press together until the locking tabs engage
fully.
2. Connect the heated seat switch harness connectors.
3. Install the center console interior trim panel. Refer to Page
23-183.
HEATED SEAT ELEMENT

DESCRIPTION
The heated seat elements (1 and 5) are an integrated part of the seat cushion (4) or seat back cushion (2). The
heated seat elements are only serviced with the cushion assemblies. The seat covers (6) are serviced separately
and are attached to the seat frame (3).
REMOVAL
HEATED SEAT CUSHION ELEMENT
Note: Disconnect the negative battery cable before remov-
ing the seat or attempting seat electrical repair.
The heated seat cushion element (2) is part of the seat cush-
ion assembly (3). To access the element, the seat must be
removed and the seat cover (1) disassembled. For complete
seat cushion removal procedures, see seat cushion removal in
the body section. Refer to Page 23-211.
REMOVAL - HEATED SEAT BACK ELEMENT

Note: Disconnect the negative battery cable before remov-
ing the seat or attempting seat electrical repair.
The heated seat back element (2) is part of the seat back
assembly (3). To access the element the seat must be
removed and the seat cover (1) disassembled. For complete
seat back removal procedures, see seat back removal in the
body section. Refer to Page 23-204.
INSTALLATION
HEATED SEAT CUSHION ELEMENT
The heated seat cushion element (2) is an integral part of the
seat cushion (3). For complete seat cushion installation proce-
dures, see seat cushion installation in the body section. Refer
to Page 23-213.
INSTALLATION - HEATED SEAT BACK

ELEMENT
The heated seat back element (2) is an integral part of the
seat back cushion (3). For complete seat back installation pro-
cedures, see seat back installation in the body section. Refer
to Page 23-205.
HEATED SEAT MODULE

REMOVAL
The heated seat control module (1) is integrated within the

heated seat switch (2) assembly. For complete heated seat
control module removal procedures, see heated seat switch
removal in this section. Refer to Page 8G-37.
INSTALLATION
The heated seat control module is integrated within the heated
seat switch assembly. For complete heated seat control mod-
ule installation procedures, see heated seat switch installation
in this section. Refer to Page 8G-38.
ZH HORN 8H - 1
HORN
TABLE OF CONTENTS
page page
HORN - ELECTRICAL DIAGNOSTICS . . . . . . . . . . . 1 HORN - SERVICE INFORMATION . . . . . . . . . . . . . . 9
HORN - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
HORN - ELECTRICAL DIAGNOSTICS *HORNS ALWAYS ON . . . . . . . . . . . . . . . . . . . 5

DIAGNOSIS AND TESTING BODY VERIFICATION TEST . . . . . . . . . . . . . . 7
*HORNS INOPERATIVE . . . . . . . . . . . . . . . . . . 2 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . 8
HORN - ELECTRICAL DIAGNOSTICS

8H - 2 HORN - ELECTRICAL DIAGNOSTICS ZH
*HORNS INOPERATIVE
ZH HORN - ELECTRICAL DIAGNOSTICS 8H - 3
*HORNS INOPERATIVE — CONTINUED
POSSIBLE CAUSES

HORNS SWITCH CIRCUIT OPEN
RELAY CONTROL MODULE
CLOCKSPRING
GROUND CIRCUIT OPEN
HORNS
For a complete Horns Circuit Diagram, Refer to Page 8H-8.
Diagnostic Test
1. TEST THE HORNS

Note: Inspect the Horn Fuse located in the Relay Control Module. If
the fuse is open, repair the cause of the open fuse before continuing.
Disconnect the Relay Control Module connector “E”.
Connect a fused jumper wire from cavity 1 of the Relay Control Module
connector “E” to B(+).
Did the Horns sound?

Yes >> Go to 3
No >> Go to 2
2. MEASURE HORNS CIRCUIT RESISTANCE

Disconnect the Horns harness connectors.
Install jumper wires into the Horns harness connectors between cavity 1
and cavity 2.
Measure the resistance between cavity 1 of the Relay Control Module har-
ness connector “E” and ground.

Yes >> Replace the Horns. Refer to Page 8H-11.
No >> Repair the Horns circuit for an open.
*HORNS INOPERATIVE — CONTINUED
3. MEASURE HORNS SWITCH CIRCUIT RESISTANCE
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 SERI-
OUS OR FATAL INJURY.
Disconnect the Driver airbag.
Disconnect the Relay Control Module harness connector “D”.
Connect a jumper wire between the Horn Switch connector cavities.
Measure the resistance of the Horns Switch circuit between cavity 1 of the
Relay Control Module connector “D” and ground.

Yes >> Replace the Relay Control Module. Refer to Page
8W-97-4.
No >> Go to 4
4. MEASURE HORNS SWITCH CIRCUIT RESISTANCE

Disconnect the Clockspring harness connector.
Connect a jumper wire between cavities 1 and 2 of the Clockspring har-
ness connector.
Measure the resistance of the Horns Switch circuit between cavity 1 of the
Relay Control Module connector “D” and ground.

Yes >> Replace the Clockspring. Refer to Page 8O-94.
No >> Repair the Horns Switch circuit for an open.
*HORNS ALWAYS ON
*HORNS ALWAYS ON — CONTINUED
POSSIBLE CAUSES
HORNS CIRCUIT SHORT TO BATTERY

HORNS SWITCH CIRCUIT SHORT TO BATTERY
CLOCKSPRING
For a complete Horns Circuit Diagram, Refer to Page 8H-8.
Diagnostic Test
1. TEST THE HORNS CIRCUIT

Disconnect the Relay Control Module connector “E”.
Did the Horns sound?

Yes >> Repair the Horns circuit for a short to voltage.
No >> Go to 2
2. MEASURE HORNS SWITCH CIRCUIT VOLTAGE

Remove the Driver Airbag. Refer to Page 8O-100.
Disconnect the Relay Control Module harness connector “D”.
WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BAT-
TERY.
Measure the voltage of the Horns Switch circuit between the Horns Switch
connector terminals.
Is voltage present?
Yes >> Repair the Horns Switch circuit for a short to voltage.
No >> Replace the Relay Control Module. Refer to Page
8W-97-4.
1.

HORN CIRCUIT DIAGRAM

ZH HORN - SERVICE INFORMATION 8H - 9
HORN - SERVICE INFORMATION
TABLE OF CONTENTS
page page
HORN - SERVICE INFORMATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HORN SWITCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - HORN SYSTEM . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS - HORN . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HORN HORN RELAY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
HORN - SERVICE INFORMATION

DESCRIPTION
A dual-note electro-magnetic horn system is standard factory installed equipment on this model. The horn circuit
consists of a horn switch, fuse, horn relay, and horns. Both high and low note horn units are located behind the front
grille, below and in the center of the radiator core support crossmember.
OPERATION

8H - 10 HORN - SERVICE INFORMATION ZH
The horn circuit feed is from the fuse to the horn relay within the relay control module (3), both of which are located
inside the control module box (5). When the horn switch is depressed, it completes the ground circuit to the horn
relay. The horn relay coil closes a set of contacts which allows current to flow to the horns.
DIAGNOSIS AND TESTING - HORN SYSTEM

SONAL INJURY.
CAUTION: Continuous sounding of horns will cause horn to fail.
For complete horn system diagnosis, see horn electrical diagnostics in this section.
HORN SOUNDS 1. Faulty horn relay. 1. Refer to horn electrical

CONTINUOUSLY. NOTE: diagnostics in this section.
IMMEDIATELY REMOVE 2. Horn control circuit to relay 2. Check horn relay circuit for
FUSE IN CONTROL shorted to ground. short to ground.
MODULE BOX AND
3. Pinched horn switch wire under 3. Check horn switch harness
DISCONNECT HORN
driver airbag module. and repair as necessary.
4. Faulty horn switch. 4. Replace horn switch.
HORN SOUNDS 1. Pinched horn switch wire under 1. Check horn switch harness
INTERMITTENTLY AS THE driver airbag module. and repair as necessary.
STEERING WHEEL IS
TURNED 2. Faulty or damaged clockspring. 2. Replace clockspring.
HORN DOES NOT SOUND 1. Faulty or damaged horn. 1. Voltage present at horn when
horn switch is pressed, replace
horn.
SPECIFICATIONS - HORN

HORN MOUNTING 11.3 8.3 100
BRACKET BOLT
HORN
REMOVAL
2. Remove the grille. Refer to Page 23-110.
3. Disconnect the horn harness connector (1).
Note: Do not disconnect the horn from the horn mounting

bracket.
4. Remove the horn bracket mounting bolt (2) from the core
support brace (1), and remove the horn.
INSTALLATION
1. Position the horn(s) (1) onto the vehicle core support and
install the horn bracket mounting bolt. Tighten the bolt to
11.3 N·m (100 in. lbs.).
2. Connect the horn harness connector.
3. Install the grille. Refer to Page 23-111.
HORN SWITCH
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIR BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
The horn switch is comprised of two separate contact plates

suspended by pre-loaded springs. It may be tested in the fol-
lowing manner:
2. Remove the driver airbag. Refer to Page 8O-100.
3. Disconnect the horn switch harness connectors (1) and (2).
4. Using an ohmmeter, connect one lead to the ground wire
terminal (1) and the other lead to the positive wire terminal
(2). No continuity should be present.
5. Depress the horn switch outer plate and check for continu-
ity. If no continuity is present between the terminals, replace
the switch contact plates.
For complete horn system diagnosis, see horn electrical diag-

nostics in this section.
REMOVAL

2. Remove the driver airbag. Refer to Page 8O-100.
3. Disconnect the horn switch harness connector (1).
4. Remove the horn switch retaining nuts (2), and remove the
horn switch from the steering wheel.
INSTALLATION
1. Install the horn switch into the steering wheel, then route
the driver airbag harness and connector (3) through the
opening in the horn switch.
Note: Be sure the horn switch preload springs are cen-

tered over the mounting studs (2).
2. Press downward evenly on the horn switch and install the

horn switch retaining nuts. Tighten the nuts to 5 N·m (44 in.
lbs.).
3. Connect the horn switch harness connector (1).
4. Install the airbag. Refer to Page 8O-100.
HORN RELAY
DESCRIPTION
The horn relay is housed within the relay control module (1)
located inside the control module box (3) in the passenger
side of the engine compartment. The relay control module also
contains the fuse (2) for the horn relay circuitry. The relay con-
trol module cannot be adjusted or repaired. If faulty or dam-
aged, the entire module must be replaced as an assembly. For
complete relay control module removal procedures, see relay
control module removal in the power distribution section.
ZH IGNITION CONTROL 8I - 1
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION SYSTEM - ELECTRICAL IGNITION SYSTEM - SERVICE INFORMATION. . . . 3

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page
IGNITION SYSTEM - ELECTRICAL

DIAGNOSTICS
8I - 2 IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS ZH
IGNITION SYSTEM - ELECTRICAL DIAGNOSTICS

IGNITION SYSTEM CIRCUIT DIAGRAM

ZH IGNITION SYSTEM - SERVICE INFORMATION 8I - 3
IGNITION SYSTEM - SERVICE INFORMATION
TABLE OF CONTENTS
page page
IGNITION SYSTEM - SERVICE INFORMATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS SPARK PLUG
SPECIFICATIONS - SPARK PLUGS . . . . . ....4 DESCRIPTION - PLATINUM PLUGS . . . . . . . . . . 7
SPECIFICATIONS - TORQUE ......... ....4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CAMSHAFT POSITION SENSOR DIAGNOSIS AND TESTING - SPARK PLUG
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....4 CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . ....4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . ....5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
IGNITION COIL SPARK PLUG CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . ....5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . ....5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
KNOCK SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....6
IGNITION SYSTEM - SERVICE INFORMATION

DESCRIPTION
The High Energy Ignition (HEI) system uses one coil and two spark plugs per cylinder. Individual coils for each
cylinder ensure consistent performance at high rpms and allow individual cylinder spark control. Dual spark plugs
provide more complete combustion, particularly near the cylinder walls, thus decreasing emissions. Also, HEI
enhances combustion efficiency when firing mixtures diluted by EGR (Exhaust Gas Recirculation), which in turn
improves overall efficiency and lowers emissions.
OPERATION
The crankshaft position sensor and camshaft position sensor are hall effect devices. The camshaft position sensor
and crankshaft position sensor generate pulses that are inputs to the PCM. The PCM determines engine position
from these sensors. The PCM calculates injector sequence and ignition timing from crankshaft & camshaft position.
For a description of both sensors Camshaft Position Sensor, Refer to Page 8I-4, and Crankshaft Position Sensor,
The two spark plugs per cylinder are fired slightly out of phase to prevent the cylinder pressures from rising too
quickly, which could cause knocking. To prevent one spark plug from eroding more quickly than the other, they
alternately lead each other. Under normal conditions, the timing is the same for all cylinders, but the timing can be
delayed in individual cylinders if knocking is present in one or more. Highly sensitive anti-knock sensors, Refer to
Page 8I-6, can distinguish knocking conditions in individual cylinders and retard the ignition timing on the cylinders
that are knocking. This anti-knock control prevents damage to the engine and allows operation on lower grade fuel,
but only in emergencies. Premium grade fuel is required under normal operating conditions to ensure full power and
economy, and because the anti-knock control system may not be able to prevent knocking on low grade fuels under
all operating conditions.
8I - 4 IGNITION SYSTEM - SERVICE INFORMATION ZH
SPECIFICATIONS
SPECIFICATIONS - SPARK PLUGS
Bosch F 8 DPER
Champion KC 11 PYP
NGK IFR5D 10
Spark Plug Gap .80 mm 0.040 in
Firing Order 1-4-3-6-2-5

Camshaft Sensor Bolt 8 6 71
Coil Retaining Bolt 8 6 71
Knock Sensor Bolt 20 15 177
Spark Plugs 28 21 248
CAMSHAFT POSITION SENSOR

OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor
generates pulses. The PCM determines engine position from the camshaft position sensor and crankshaft position
sensor inputs. The PCM uses the input to determine fuel injection synchronization and to determine which ignition
coil to energize.
REMOVAL
2. Disconnect the camshaft position sensor harness connector
(1).
3. Remove the retaining bolt (2) and the camshaft position
sensor.
INSTALLATION
Note: Lubricate the camshaft position sensor o-ring with engine oil.
1. Position the camshaft position sensor on the cylinder head.

2. Install the retaining bolt (2) and tighten to 8 N·m (71 in. lbs.).
3. Connect the camshaft position sensor harness connector.
IGNITION COIL
DESCRIPTION
Coils are mounted on the cylinder head cover and are connected to the spark plugs via short cables. Platinum-tip
spark plugs allow 100,000-mile (161,000-km) replacement intervals in normal service.
REMOVAL
1. Disconnect the negative battery.
2. Remove the air cleaner housing.
3. Disconnect the ignition coil wire harness connector (1).
4. Disconnect the spark plug cables (4) from the spark plug.
5. Remove the retaining bolt (2) and the ignition coil (3) from
the cylinder head cover.
INSTALLATION
1. Position the ignition coil (3) on the cylinder head cover.
2. Install and tighten the retaining bolt (2) to 8 N·m (71 in. lbs.).
Note: When replacing the spark plug and coil cables, route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also
cause cross ignition of the plugs or short circuit the cables to ground.
Note: When installing new cables, make sure a positive connection is made. A snap should be felt when a
good connection is made between the plug cable and the spark plug.
3. Connect the spark plug cables (4) to the spark plug.

4. Connect the ignition coil wire harness connector (1).
5. Install the air cleaner housing.
KNOCK SENSOR
DESCRIPTION
The knock sensors bolt onto the cylinder block below the intake manifold. They are designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
Highly sensitive anti-knock sensors can distinguish knocking conditions in individual cylinders and retard the ignition
timing on the cylinders that are knocking. This anti-knock control prevents damage to the engine and allows oper-
ation on lower grade fuel, but only in emergencies. Premium grade fuel is required under normal operating condi-
tions to ensure full power and economy, and because the anti-knock control system may not be able to prevent
knocking on low grade fuels under all operating conditions.
REMOVAL
1. Remove the intake manifold. Refer to Page 9-678.
2. Disconnect the wire harness connectors at the knock sen-
sors (1) and remove the retaining bolts. Remove the knock
sensors from the engine block.
INSTALLATION
1. Position the knock sensors (1) on the engine block.
Note: The knock sensor bolt torque is higher than other sensors. If the proper torque is not applied to the
knock sensor, driveability can be affected.
2. Install the retaining bolts. Tighten the bolts to 20 N·m (15 ft. lbs.).
3. Connect the wire harness connectors.
4. Install the intake manifold. Refer to Page 9-680.
SPARK PLUG
DESCRIPTION - PLATINUM PLUGS
The engine uses platinum tip resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when
checked with at least a 1000 volt tester. For spark plug identification and specifications, Refer to Page 8I-4.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading.
Spark plugs using either a single or double platinum tips have
a recommended service life of 100,000 miles for normal driv-
ing conditions per schedule A in this manual. The spark plugs
have a recommended service life of 75,000 miles for severe
driving conditions. A thin platinum pad is welded to both or just
the center electrode (2) end(s). Extreme care must be used to
prevent spark plug cross threading, mis-gapping and ceramic
insulator damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may damage the

platinum tip.
OPERATION
Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insula-
tors. Keep the spark plugs arranged in the order in which they were removed from the engine. An isolated spark
plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder.
Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Adjust the gap between
the electrodes to 1.00 mm (.039 in.).
Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the
spark plug gap or damage to the cylinder head. Tighten the spark plugs to 28 N·m (21 ft. lbs.).
DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS

NORMAL OPERATING
The few deposits present on the spark plug will probably be

light tan or slightly gray in color. This is evident with most
grades of commercial gasoline. There will not be evidence of
electrode burning. Gap growth will not average more than
approximately 0.025 mm (.001 in) per 3200 km (2000 miles) of
operation. Spark plugs that have normal wear (1) can usually
be cleaned, have the gap set and then be installed.
Some fuel refiners in several areas of the United States have
introduced a manganese additive (MMT) for unleaded fuel.
During combustion, fuel with MMT causes the entire tip of the
spark plug to be coated with a rust colored deposit (2). This
rust color can be misdiagnosed as being caused by coolant in
the combustion chamber. Spark plug performance may be
affected by MMT deposits.
COLD FOULING/CARBON FOULING
Cold fouling is sometimes referred to as carbon fouling. The

deposits that cause cold fouling are basically carbon. A dry,
black deposit on one or two plugs in a set may be caused by
sticking valves or defective spark plug cables. Cold (carbon)
fouling of the entire set of spark plugs may be caused by a
clogged air cleaner element or repeated short operating times
(short trips).
WET FOULING OR GAS FOULING
A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve
guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling
may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning with
solvent and reinstalling the plugs.
OIL OR ASH ENCRUSTED
If one or more spark plugs are oil or oil ash encrusted, evalu-
ate engine condition for the cause of oil entry into that partic-
ular combustion chamber.
ELECTRODE GAP BRIDGING
Electrode gap bridging may be traced to loose deposits in the

combustion chamber. These deposits (2) accumulate on the
spark plugs during continuous stop-and-go driving. When the
engine is suddenly subjected to a high torque load, deposits
partially liquefy and bridge the gap between electrodes (3).
This short circuits the electrodes. Spark plugs with electrode
gap bridging (1) should be replaced.
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yellow. They

may appear to be harmful, but this is a normal condition
caused by chemical additives in certain fuels. These additives
are designed to change the chemical nature of deposits and
decrease spark plug misfire tendencies. Notice that accumula-
tion on the ground electrode (1) and shell area may be heavy,
but the deposits are easily removed. Spark plugs with scaven-
ger deposits can be considered normal in condition and can
be cleaned using solvent.
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator (3) usually results from bending

the center electrode (2) while adjusting the spark plug elec-
trode gap. Under certain conditions, severe detonation can
also separate the insulator from the center electrode. Spark
plugs with this condition must be replaced.
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive combustion

chamber temperature. The center electrode (2) dissolves first
and the ground electrode (1) dissolves somewhat later. Insula-
tors appear relatively deposit free. Determine if the spark plug
has the correct heat range rating for the engine. Determine if
ignition timing is over advanced or if other operating conditions
are causing engine overheating. (The heat range rating refers
to the operating temperature of a particular type spark plug.
Spark plugs are designed to operate within specific tempera-
ture ranges. This depends upon the thickness and length of
the center electrode’s porcelain insulator.)
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center electrode

insulator that also appears blistered. The increase in electrode
gap will be considerably in excess of the normal 0.025 mm
(.001 in.) per 3200 km (2000 miles) of operation. This sug-
gests that a plug with a cooler heat range rating should be
used. Over advanced ignition timing, detonation and cooling
system malfunctions can also cause spark plug overheating
(1).
REMOVAL
1. Pull and turn the metal clad spark plug cable boots (2) to
remove them from the spark plugs.
Note: Avoid allowing debris to fall into the spark holes

during replacement.
2. Clean the cylinder head spark plug recesses (2) using low
pressure compressed air.
CAUTION: Do not use power tools to replace spark plugs.

Damage to the cylinder head can result.
3. Use a rubber insulated spark plug socket and a hand

ratchet to remove the spark plugs (1).
INSTALLATION
1. Using a gap gauge (1), gap the spark plugs to 1.00 mm
(.039 in.) before installing them.
2. Tighten the spark plugs to 28 N·m (21 ft. lbs.).
Note: A snap should be felt when a good connection is

made between the cable and the spark plug.
3. Install the spark plug cables.

SPARK PLUG CABLE

DESCRIPTION
Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from
the electronic ignition coils to the individual spark plugs at each cylinder. The nonmetallic spark plug cables have
built in resistance. 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 at the spark plugs. Terminals should be
fully seated with audible click. The nipples and spark plug covers should be in good condition. Nipples should fit
tightly on the coil and spark plug cover should fit tight around spark plug insulators. Loose cable connections can
cause ignition malfunctions by permitting water to enter the towers, corroding, and increasing resistance. To main-
tain proper sealing at the terminal connections, the connections should not be broken unless testing indi-
cates high resistance, an open circuit or other damage.
Clean high tension cables with a cloth moistened with a non-flammable solvent and wipe dry. Check for brittle or
cracked insulation.
REMOVAL
CAUTION: When disconnecting a high tension cable from
a spark plug or from the ignition coil, twist the rubber
boot slightly (1/2 turn) to break it loose. Grasp the boot
(not the cable) and pull it off with a steady, even force.
1. Remove the spark plug cable boot from the ignition coil (1).
2. Turn and pull the spark plug cable metal clad boot (2) from
the spark plug.
INSTALLATION
Note: When replacing the spark plug cables, route the cables correctly and secure in the proper retainers.
Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause
cross ignition of the plugs or short circuit the cables to ground.
Note: When installing new cables, make sure a positive connection is made. A snap should be felt when a
good connection is made between the cable and the spark plug.
Install the spark plug cables in the proper engine cylinder firing order, Refer to Page 8I-4.
ZH INSTRUMENT CLUSTER 8J - 1
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER - ELECTRICAL INSTRUMENT CLUSTER - SERVICE

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER - ELECTRICAL CAN BUS COMMUNICATION GENERAL

DIAGNOSTICS MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING *LEFT TURN SIGNAL INDICATOR
COOLANT LEVEL SENSOR/WASHER FLUID INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 38
LEVEL SWITCH CIRCUIT . . . . . . . . . . . . . . . . 2 *RIGHT TURN SIGNAL INDICATOR
LAMP OUTAGE INDICATOR CIRCUIT . . . . . . . 5 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 40
FUEL LEVEL SENSOR CIRCUIT . . . . . . . . . . . 7 *HIGH BEAM INDICATOR INOPERATIVE . . . . 42
AMBIENT TEMPERATURE SENSOR *BRAKE WARNING INDICATOR
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 44
NO COMMUNICATION FROM INSTRUMENT *BATTERY VOLTAGE INDICATOR
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 46
NO COMMUNICATION TO INSTRUMENT *SEAT BELT INDICATOR INOPERATIVE . . . . 48
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 *TELESCOPING WHEEL INDICATOR
NO CAN COMMUNICATIONS WITH PCM . . . 18 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 50
NO CAN COMMUNICATIONS WITH CAB . . . . 24 BODY VERIFICATION TEST . . . . . . . . . . . . . 52
NO CAN COMMUNICATIONS WITH TCM . . . 30 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 53
INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS

8J - 2 INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS ZH
COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT
ZH INSTRUMENT CLUSTER - ELECTRICAL DIAGNOSTICS 8J - 3
COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT — CONTINUED
• Set Condition: Coolant Level Sensor/Washer Fluid Level Switch circuit failure.
POSSIBLE CAUSES
INDICATOR CIRCUIT OPEN

COOLANT LEVEL SENSOR MALFUNCTION
WASHER FLUID LEVEL SWITCH MALFUNCTION
INDICATOR LAMP
INSTRUMENT CLUSTER
For a complete Instrument Cluster Circuit Diagram, Refer to Page 8J-53.
Diagnostic Test
1. INSPECT THE LOW COOLANT INDICATOR LAMP

Remove the Low Coolant Indicator Lamp from the Instrument Cluster and
inspect the lamp for an open filament.
Is the lamp filament open?

Yes >> Replace the Low Coolant Indicator Lamp. Refer to Page
8J-75.
No >> Go to 2
2. INSPECT THE LOW WASHER FLUID INDICATOR LAMP

Remove the Low Washer Fluid Indicator Lamp from the Instrument Cluster
and inspect the lamp for an open filament.

Yes >> Replace the Low Washer Fluid Indicator Lamp. Refer to
Page 8J-75.
No >> Go to 3
COOLANT LEVEL SENSOR/WASHER FLUID LEVEL SWITCH CIRCUIT — CONTINUED
3. MEASURE COOLANT LEVEL SENSOR RESISTANCE
Disconnect the Coolant Level Sensor harness connector.
Measure the resistance between cavity 1 and cavity 2 of the Coolant Level
Sensor connector.
Is the resistance between 102 and 120 ohms?

Yes >> Go to 4
No >> Replace the Coolant Level Sensor. Refer to Page 7-20.
4. MEASURE WASHER FLUID LEVEL SWITCH RESISTANCE

Disconnect the Washer Fluid Level Switch harness connector.
Measure the resistance between cavity 1 and cavity 2 of the Washer Fluid
Level Switch connector.

Yes >> Go to 5
No >> Replace the Washer Fluid Level Switch. Refer to Page
8R-26.
5. MEASURE COOLANT LEVEL SENSOR/WASHER FLUID LEVEL

SWITCH CIRCUIT RESISTANCE

Disconnect the Instrument Cluster C1 harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Coolant Level
Connect a jumper wire between cavity 1 and cavity 2 of the Washer Fluid
Level Switch harness connector.
Measure the resistance between cavity 4B and 12B of the Instrument
Cluster C1 harness connector.

Yes >> Replace the Instrument Cluster. Refer to Page 8J-83.
No >> Repair the Coolant Level Sensor/Washer Fluid Level
Switch circuit for an open.
LAMP OUTAGE INDICATOR CIRCUIT
LAMP OUTAGE INDICATOR CIRCUIT — CONTINUED
• Set Condition: Lamp Outage Indicator circuit failure between the Illumination Control Module and the
Instrument Cluster.
POSSIBLE CAUSES

INDICATOR LAMP
ILLUMINATION CONTROL MODULE
INSTRUMENT CLUSTER
Diagnostic Test
1. THE LAMP OUTAGE INDICATOR LAMP/INSTRUMENT CLUSTER

Measure the voltage of the Lamp Outage Indicator circuit at the Instrument
Cluster C1 harness connector.

Yes >> Inspect the Lamp Outage Indicator Lamp. If OK, replace the
Instrument Cluster. Refer to Page 8J-83.
No >> Go to 2
2. MEASURE LAMP OUTAGE INDICATOR CIRCUIT RESISTANCE

Disconnect the Illumination Control Module harness connector.
Measure the resistance of the Lamp Outage Indicator circuit from the Illu-
mination Control Module D harness connector to the Instrument Cluster
C1 harness connector.

Yes >> Replace the Illumination Control Module. Refer to Page
8L-105.
No >> Repair the Lamp Outage Indicator circuit for an open.
FUEL LEVEL SENSOR CIRCUIT
FUEL LEVEL SENSOR CIRCUIT — CONTINUED
• Set Condition: Fuel Level Sensor circuit failure between the Fuel Level Sensor and the Instrument Clus-
ter.
POSSIBLE CAUSES
FUEL LEVEL SENSOR CIRCUIT(S) OPEN

FUEL LEVEL SENSOR
INSTRUMENT CLUSTER
Diagnostic Test
1. MEASURE FUEL LEVEL SENSOR CIRCUIT VOLTAGE

Disconnect the Fuel Level Sensor harness connector.
Measure the voltage between cavity 1 and cavity 2 of the Fuel Level Sen-
Is the voltage approximately .7 of a volt?

Yes >> Replace the Fuel Level Sensor. Refer to Page 14-13.
No >> Go to 2
2. MEASURE FUEL LEVEL SENSOR CIRCUIT RESISTANCE

Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Level
Measure the resistance of the Fuel Level Sensor circuit from cavity D4 to
cavity D5 at the Instrument Cluster C2 harness connector.

No >> Repair the appropriate Fuel Level Sensor circuit for an
open.
AMBIENT TEMPERATURE SENSOR CIRCUIT
AMBIENT TEMPERATURE SENSOR CIRCUIT — CONTINUED
• Set Condition: The Instrument Cluster reports an abnormally high or low voltage that is detected on the
Ambient Temperature Sensor Signal circuit.
POSSIBLE CAUSES
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

AMBIENT TEMPERATURE SENSOR OPEN
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
AMBIENT TEMPERATURE SENSOR GROUND OPEN
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
INSTRUMENT CLUSTER
Diagnostic Test
1. READ AMBIENT TEMPERATURE SENSOR VOLTAGE WITH DRB IIIT

With the DRB IIIT, read the Ambient Temperature Sensor voltage.
Does the DRB IIIT display AMBIENT TEMP: 5.0 VOLTS or greater?
Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE AMBIENT TEMPERATURE


Disconnect the Ambient Temperature Sensor harness connector.
Measure the voltage of the Ambient Temperature Sensor Signal circuit at
the Ambient Temperature Sensor harness connector.

Yes >> Repair the Ambient Temperature Sensor Signal circuit for a
short to voltage.
No >> Go to 3
Connect a jumper wire between the Ambient Temperature Sensor Signal
circuit and the Sensor Ground circuit.
Yes >> Go to 4
No >> Replace the Ambient Temperature Sensor. Refer to
Page 24-82.
4. MEASURE THE RESISTANCE OF THE AMBIENT TEMPERATURE


Disconnect the Instrument Cluster harness connector.
Measure the resistance of the Ambient Temperature Sensor Signal circuit
from the Instrument Cluster harness connector to the Ambient Tempera-
ture Sensor harness connector.

Yes >> Go to 5
No >> Repair the Ambient Temperature Sensor Signal circuit for
an open.
5. MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT

Measure the resistance of the Sensor Ground circuit from the Instrument
Cluster harness connector to the Ambient Temperature Sensor harness
connector.

Yes >> Go to 7
No >> Go to 9
7. READ A/C HEATER CONTROL MODULE DTC’S WITH DRB IIIT

Reconnect the Ambient Temperature Sensor connector.
With the DRB IIIT, read A/C Heater Control Module DTC’s.
Wait two minutes.
Does the DRB IIIT display Ambient Temperature Sensor Failure

DTC?
Yes >> Replace the Ambient Temperature Sensor. Refer to Page
24-82.
No >> Go to 8

Ensure the Ambient Temperature Sensor is connected at this time.
Start the engine.
Turn the A/C system on and run for at least five minutes.

DTC?
24-82.
not present. Inspect the related wiring harness for a
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the Ambient Temperature
Signal circuit.

short to ground.
No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE AMBIENT

TEMPERATURE SENSOR SIGNAL CIRCUIT TO THE

Measure the resistance from the Ambient Temperature Sensor Signal cir-
cuit to the Sensor Ground circuit at the Ambient Temperature Sensor con-
nector.

short to the Sensor Ground circuit.
NO COMMUNICATION FROM INSTRUMENT CLUSTER
NO COMMUNICATION FROM INSTRUMENT CLUSTER — CONTINUED
• Set Condition: Serial Communication K1 failure between the A/C Heater Control Module and the Instru-
ment Cluster.
POSSIBLE CAUSES
SERIAL COMMUNICATION K1 CIRCUIT OPEN
INSTRUMENT CLUSTER
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE SERIAL COMMUNICATION

K1 CIRCUIT

Measure the resistance of the Serial Communication K1 circuit from the
Instrument Cluster harness connector to the A/C Heater Control Module
harness connector.

No >> Repair the Serial Communication K1 circuit for an
open.
NO COMMUNICATION TO INSTRUMENT CLUSTER
NO COMMUNICATION TO INSTRUMENT CLUSTER — CONTINUED
ment Cluster.
POSSIBLE CAUSES
INSTRUMENT CLUSTER
Diagnostic Test

K2 CIRCUIT

harness connector.

open.
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Powertrain
Control Module (PCM).
POSSIBLE CAUSES
OPEN CAN C BUS (+)/(-) CIRCUIT

CAN C BUS (+)/(-) CIRCUIT SHORTED TO GROUND
CAN C BUS (+)/(-) CIRCUIT SHORTED TO VOLTAGE
INSTRUMENT CLUSTER
Diagnostic Test
1. CHECK TO SEE IF PCM DTCS ARE PRESENT

Turn ignition on.
With the DRB IIIT, read PCM DTCs.
Are any performance or Bus related DTCs present?

Yes >> Repair all PCM DTCs before proceeding.
No >> Go To 2
2. VERIFY DTCS
Turn the ignition off, then back on.
Monitor the DRB IIIT for this DTC.
Did this DTC set again?

Yes >> Go To 3
No >> Go To 12
3. PCM AND SKREEM CAN C BUS TERMINATION
Measure the resistance of the PCM CAN C Bus termination by back prob-
ing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the PCM C4
harness connector.

Yes >> Go To 11
No >> Go To 4
4. PCM CAN C BUS TERMINATION

Measure the resistance of the SKREEM CAN C Bus termination by back
probing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the PCM
Is the SKREEM CAN C Bus termination resistance between 110 and

130 ohms?
Yes >> Replace and program the Powertrain Control Module. Refer
to Page 8E-56.
No >> Go To 5
5. SKREEM TERMINATION
probing the CAN C Bus (+) circuit to the CAN C Bus (-) circuit at the
SKREEM C2 harness connector.

Yes >> Go To 6
No >> Replace the SKREEM. Refer to Page 8E-70.
6. CAN C BUS (-) CIRCUIT OPEN
Measure the resistance of the CAN C Bus (-) circuit from the SKREEM C2
harness connector to the PCM C4 harness connector.

Yes >> Go To 7
7. CAN C BUS (+) CIRCUIT OPEN

Measure the resistance of the CAN C Bus (+) circuit from the PCM C4
harness connector to the SKREEM C2 harness connector.

Yes >> Go To 8
8. CAN C BUS (+) CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the CAN C Bus (+) circuit at the PCM C4 harness
connector.

Yes >> Repair the CAN C Bus (+) circuit for a short to voltage.
No >> Go To 9
9. CAN C BUS (-) CIRCUIT SHORTED TO VOLTAGE
Measure the voltage of the CAN C Bus (-) circuit at the PCM C4 harness
connector.

Yes >> Repair the CAN C Bus (-) circuit for a short to voltage.
No >> Go To 10
10. CAN C BUS (-) CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the CAN C Bus (-) circuit.

Yes >> Repair the CAN C Bus (-) circuit for a short to ground.
No >> Repair the CAN C Bus (+) circuit for a short to ground.
11. CAN C BUS (-) CIRCUIT OPEN FROM INSTRUMENT CLUSTER TO

PCM

Measure the resistance of the CAN C Bus (-) circuit from the Instrument
Cluster C1 harness connector to the PCM C4 harness connector.

Yes >> Repair the CAN C Bus (+) circuit for an open between the
PCM C4 harness and the Instrument Cluster C1 harness
connector.
No >> Repair the CAN C Bus (-) circuit for an open between
the PCM C4 harness and the Instrument Cluster C1
harness connector.
12. INTERMITTENT WIRING AND CONNECTORS
The conditions necessary to set this DTC are not present at this time.
Note: Check connectors — Clean/repair as necessary. Poor pin to ter-
minal connections can set DTCs.
Note: Check for any Technical Service Bulletins that may apply.
Using the wiring diagram/schematic as a guide, inspect the wiring and
connectors specific to this DTC. Wiggle the wires while checking for shorts
and/or open circuits.
Were there any problems found?

Perform POWERTRAIN VERIFICATION TEST VER.
NO CAN COMMUNICATIONS WITH CAB
NO CAN COMMUNICATIONS WITH CAB — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Controller
Antilock Brake (CAB).
POSSIBLE CAUSES

For a complete Instrument Cluster Circuit Diagram. Refer to Page 8J-53.
Diagnostic Test
1. CHECK TO SEE IF CAB DTCS ARE PRESENT

Turn ignition on.
With the DRB IIIT, read CAB DTCs.

Yes >> Repair all CAB DTCs before proceeding.
No >> Go To 2
2. VERIFY DTCS

Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6

Yes >> Go To 7


Yes >> Go To 8

connector.

No >> Go To 9
connector.

No >> Go To 10


11. CAN C BUS (-) CIRCUIT OPEN FROM CAB TO INSTRUMENT

CLUSTER

connector to the Instrument Cluster C1 harness connector.

Instrument Cluster C1 harness and the CAB harness con-
nector.
the Instrument Cluster C1 harness and the CAB har-
ness connector.

NO CAN COMMUNICATIONS WITH TCM
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Trans-
mission Control Module (TCM).
POSSIBLE CAUSES

Diagnostic Test
1. CHECK TO SEE IF TCM DTCS ARE PRESENT

Turn ignition on.
With the DRB IIIT, read TCM DTCs.

Yes >> Repair all TCM DTCs before proceeding.
No >> Go To 2
2. VERIFY DTCS

Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6

Yes >> Go To 7


Yes >> Go To 8

connector.

No >> Go To 9
connector.

No >> Go To 10


11. CAN C BUS (-) CIRCUIT OPEN FROM TCM TO INSTRUMENT

CLUSTER

Disconnect the TCM C3 harness connector.
Measure the resistance of the CAN C Bus (-) circuit from the TCM C3 har-
ness connector to the Instrument Cluster C1 harness connector.

Instrument Cluster C1 harness and the TCM C3 harness
connector.
the Instrument Cluster C1 harness and the TCM C3
harness connector.

• Set Condition: CAN Bus communication failure between the Instrument Cluster and the CAN Bus net-
work.
POSSIBLE CAUSES
INSTRUMENT CLUSTER
Diagnostic Test

network.
Measure the resistance of the CAN C Bus (+) circuit from the Instrument
Cluster harness connector to the harness connectors of the other modules
on the CAN Bus network.

Yes >> Go to 2

Cluster harness connector to the harness connectors of the other modules
on the CAN Bus network.

*LEFT TURN SIGNAL INDICATOR INOPERATIVE
*LEFT TURN SIGNAL INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. INSPECT THE LEFT TURN SIGNAL INDICATOR LAMP

Remove the Left Turn Signal Indicator Lamp from the Instrument Cluster

Yes >> Replace the Left Turn Signal Indicator Lamp. Refer to Page
8J-75.
No >> Go to 2
2. MEASURE LEFT TURN SIGNAL INDICATOR DRIVER CIRCUIT

RESISTANCE

Disconnect the Remote Keyless Entry Relay.
Measure the resistance of the Left Turn Signal Indicator Driver circuit from
the RKE Relay harness connector cavity 2 to the Instrument Cluster C1
harness connector cavity 1A.

No >> Repair the Left Turn Signal Indicator Driver circuit for
an open.
*RIGHT TURN SIGNAL INDICATOR INOPERATIVE
*RIGHT TURN SIGNAL INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. INSPECT THE RIGHT TURN SIGNAL INDICATOR LAMP

Remove the Right Turn Signal Indicator Lamp from the Instrument Cluster

Yes >> Replace the Right Turn Signal Indicator Lamp. Refer to
Page 8J-75.
No >> Go to 2
2. MEASURE RIGHT TURN SIGNAL INDICATOR CIRCUIT

RESISTANCE

Disconnect the Remote Keyless Entry Relay.
Measure the resistance of the Right Turn Signal Indicator circuit from the
RKE Relay harness connector cavity 5 to the Instrument Cluster C1 har-
ness connector cavity A10.

No >> Repair the Right Turn Signal Indicator Driver circuit for
an open.
*HIGH BEAM INDICATOR INOPERATIVE
*HIGH BEAM INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. HIGH BEAM INDICATOR LAMP

Turn the High Beams on.
Measure the voltage of the High Beam Indicator Lamp circuit at the Instru-
ment Cluster C1 harness connector.

Yes >> Check the High Beam Indicator Lamp. If the lamp is OK,
Replace the Instrument Cluster. Refer to Page 8J-83.
No >> Go to 2
2. MEASURE HIGH BEAM INDICATOR CIRCUIT RESISTANCE

Measure the resistance of the High Beam Indicator circuit from the Illumi-
nation Control Module harness connector cavity 7 to the Instrument Clus-
ter C1 harness connector cavity A2.

Yes >> Replace the Illumination Control Module. Refer to Page
8J-83.
No >> Repair the High Beam Indicator circuit for an open.
*BRAKE WARNING INDICATOR INOPERATIVE
*BRAKE WARNING INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

BRAKE FLUID LEVEL SWITCH
INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. BRAKE WARNING INDICATOR SWITCH

Disconnect the Brake Fluid Level Switch harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Brake Fluid
Is the Brake Warning Indicator lamp on?

Yes >> Replace the Brake Fluid Level Switch. Refer to Page 5-75.
No >> Go to 2
2. MEASURE BRAKE WARNING INDICATOR CIRCUIT RESISTANCE

Connect a jumper wire between cavity 1 and cavity 2 of the Brake Fluid
Measure the resistance between ground and the Brake Warning Indicator
circuit.

Yes >> Check the Brake Warning Indicator lamp. If the lamp is OK,
replace the Instrument Cluster. Refer to Page 8J-83.
No >> Repair the Brake Warning Indicator circuit for an open.
*BATTERY VOLTAGE INDICATOR INOPERATIVE
*BATTERY VOLTAGE INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

INDICATOR LAMP
GENERATOR
INSTRUMENT CLUSTER
Diagnostic Test
1. GENERATOR OUTPUT
Start the engine.
Measure the voltage of the Battery Voltage Indicator circuit at the Instru-
ment Cluster harness connector.

Yes >> Check the Battery Voltage Indicator Lamp. If the lamp is
OK, replace the Instrument Cluster. Refer to Page 8J-75.
No >> Go to 2
2. MEASURE BATTERY VOLTAGE INDICATOR CIRCUIT RESISTANCE

Disconnect the Generator harness connector.
Measure the resistance of the Battery Voltage Indicator circuit from the
Generator harness connector to the Instrument Cluster C1 harness con-
nector.

Yes >> Replace the Generator. Refer to Page 8F-28.
No >> Repair the Battery Voltage Indicator circuit for an
open.
*SEAT BELT INDICATOR INOPERATIVE
*SEAT BELT INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. SEAT BELT INDICATOR SWITCH

Disconnect the Seat Belt Indicator Switch harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Driver Seat
Belt Switch harness connector.
Is the Seat Belt Indicator Lamp on?

Yes >> Replace the Seat Belt Indicator Switch. Refer to Page
8O-116
No >> Go to 2
2. SEAT BELT INDICATOR CIRCUIT

Measure the resistance between ground and the Seat Belt Indicator cir-
cuit.

Yes >> Check the Seat Belt Indicator lamp. If the lamp is OK,
replace the Instrument Cluster. Refer to Page 8J-83.
No >> Repair the Seat Belt Indicator circuit for an open.
*TELESCOPING WHEEL INDICATOR INOPERATIVE
*TELESCOPING WHEEL INDICATOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

SWITCH MALFUNCTION
INDICATOR LAMP
INSTRUMENT CLUSTER
Diagnostic Test
1. INSPECT THE TELESCOPING WHEEL INDICATOR LAMP

Note: The Telescoping Wheel Indicator circuit is hardwired to the
Telescopic Steering Switch. If replacement is necessary, the Switch
and harness are replaced together.
Remove the Telescoping Wheel Indicator Lamp from the Instrument Clus-
ter and inspect the lamp for an open filament.

Yes >> Replace the Telescoping Wheel Indicator Lamp. Refer to
Page 8J-75.
No >> Go to 2
2. MEASURE TELESCOPING WHEEL INDICATOR CIRCUIT

RESISTANCE

With the Telescopic Steering Switch depressed, measure the resistance
between ground and the Telescoping Wheel Indicator circuit.

No >> Replace the Telescopic Steering Switch.
1.

INSTRUMENT CLUSTER CIRCUIT DIAGRAM (1 OF 2)



8J - 56 INSTRUMENT CLUSTER - SERVICE INFORMATION ZH
INSTRUMENT CLUSTER - SERVICE INFORMATION
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER - SERVICE RESETTING THE FSS MAINTENANCE

INFORMATION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56 RESETTING THE FSS MAINTENANCE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 INDICATOR AFTER AN OIL CHANGE . . . . . . . 78
DIAGNOSIS AND TESTING - FUNCTION STANDARD PROCEDURE - INSTRUMENT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 CLUSTER BULBS . . . . . . . . . . . . . . . . . . . . . 81
STANDARD PROCEDURE REMOVAL - INSTRUMENT CLUSTER . . . . . . . . 83
DISPLAY OF REMAINING FSS MILEAGE AT INSTALLATION - INSTRUMENT CLUSTER . . . . 84
DRIVER’S REQUEST . . . . . . . . . . . . . . . . . . . 75
INSTRUMENT CLUSTER - SERVICE INFORMATION

DESCRIPTION
The Instrument Cluster (IC) is used to inform the driver about important vehicle operating conditions and to warn the
driver about potentially critical operating conditions. For this, the IC has indicator lamps, display gauges and audible
tones. The IC’s indicator lamps are displayed by text overlays that show the lamp’s function. The information
required for the indicator lamps and audible tones is transmitted from their sensors to the IC via direct lines or from
their control modules to the IC via the Controller Area Network (CAN) data bus.
The IC has a microprocessor for analyzing the incoming data for the indicator lamps and audible tones. The pro-
gram and the data required are stored in an electronic memory chip called the erasable electronic programable read
only memory (EEPROM).
The indicator lamps are listed below according to their type and actuation method (direct lines / CAN Bus).
INDICATOR LAMPS ACTUATED OVER DIRECT LINES

• Low tire pressure indicator lamp
• Left turn signal indicator lamp
• Right turn signal indicator lamp
• High beam indicator lamp
• Low fuel level indicator lamp
• Low washer fluid indicator lamp
• Low coolant level indicator lamp
• Battery voltage indicator lamp
• Seat belt indicator lamp
• Lamp outage indicator lamp
• Malfunction indicator lamp (MIL)
• Brake Assist System (BAS) MIL
• Electronic Stability Program (ESP) warning lamp
• Supplemental Restraint System (SRS) MIL
INDICATOR LAMPS ACTUATED OVER THE CAN DATA BUS

• Brake warning indicator lamp
• Brake wear indicator lamp
• Antilock Brake System (ABS) warning indicator lamp
ZH INSTRUMENT CLUSTER - SERVICE INFORMATION 8J - 57
AUDIBLE TONE AND INDICATOR LAMPS ACTUATED OVER DIRECT LINES

• Turn signal ticker (audible tone / indicator lamp)
• Seat belt reminder (audible tone / indicator lamp)
• Switched - on headlamps reminder (audible tone)
• Key warning (audible tone)
AUDIBLE TONE ACTUATED OVER THE CAN DATA BUS

• Parking brake warning
FLEXIBLE SERVICE SYSTEM (FSS) INDICATOR

The Flexible Service System (FSS) indicator (2) draws the
attention of the driver to a particular service that is due. The
FSS indicator (2) is a mileage/time-activated engine service
system for recommended oil change intervals. In addition to
time (in days) and distance criteria, other factors, such as
extreme speeds or cold starts that are in combination with
short distances, are taken into account for adjusting the pro-
grammed service intervals. If the oil level drops below a warn-
ing threshold, the remaining distance (1) or the remaining time
(1) and the tool symbol (2) are displayed. The FSS indicator
(2) has its own microprocessor in the IC. The FSS indicator (2)
obtains time information from the digital clock integrated into
the IC. The other data required is obtained via the CAN data
bus from the Controller Antilock Brake (CAB) and the Power-
train Control Module (PCM).
1 - INSTRUMENT CLUSTER (IC) 8 - FLEXIBLE SERVICE SYSTEM (FSS) MICROPROCESSOR

2 - LEFT FRONT WHEEL SPEED SENSOR (LFWSS) 9 - DISPLAY
3 - RIGHT FRONT WHEEL SPEED SENSOR (RFWSS) 10 - CONTROLLER AREA NETWORK (CAN) DATABUS LINE
4 - CONTROLLER ANTILOCK BRAKE (CAB) 11 - POWERTRAIN CONTROL MODULE (PCM)
5 - RIGHT REAR SPEED SENSOR (RRWSS) 12 - OIL LEVEL INDICATOR SWITCH
6 - LEFT REAR WHEEL SPEED SENSOR (LRWSS) 13 - OIL SENSOR (OIL LEVEL/TEMPERATURE)
7 - DIGITAL CLOCK 14 - COOLANT TEMPERATURE SENSOR
CAN data required for the FSS indicator:

• 4 WSS signals for calculating vehicle speed and distance from the CAB
• Coolant temperature from the PCM
• Engine speed from the PCM
• Load torque from the PCM
OPERATION
INSTRUMENT CLUSTER GAUGES
The instrument cluster includes four analog gauges.

1. Speedometer The speedometer has a 0–160 Miles Per
Hour (MPH) primary scale with Kilometers Per Hour (km/h)
on the secondary scale. The speedometer receives wheel
speed data from the CAB via the CAN data bus and can be
verified by comparing the speed signal viewed by the
DRBIIIT from the wheel speed sensors (WSS) and the out-
put seen on the IC. The Electronic Stability Program (ESP)
indicator lamp located between the left and right turn sig-
nals in the speedometer face illuminates when it is acti-
vated by the Controller Antilock Brake (CAB), indicating the
need to adjust driving behavior to the prevailing road con-
ditions. Also located in the speedometers face are the trip
odometer and the Flexible Service System (FSS) indicator/
odometer (1). To the right and left of the speedometer face,
mounted in the IC, are the rotary dials (2-3) for the FSS
and the digital clock.
2. Tachometer The 7000 rpm tachometer is red-lined at 6200

rpm The tachometer also contains the digital clock and the
transmission range indicator.
3. Fuel level and Coolant temperature

The fuel level gauge is displayed in increments of one-quarter
marks displaying F (Full), 1/2 (one half tank) and E (Empty).
The temperature gauge is displayed as H (High) and L (Low).
The outside ambient air temperature digital display is located
in the lower center portion of the coolant temperature / fuel
gauge and is calibrated in degrees Fahrenheit (°F).
INSTRUMENT CLUSTER DIGITAL DISPLAYS

Five electronic digital displays show cumulative odometer, trip
odometer, time, outside ambient air temperature, and, if
equipped, automatic transmission range or gear. The transmis-
sion display shows P, R, N or D under normal driving condi-
tions. The clock is also located in the base of the tachometer.
A knob between the tachometer and the speedometer resets
the digital clock.
The trip odometer (1) can be reset at anytime. The odometer

(1) display also shows the distance remaining to the next reg-
ular maintenance service as calculated by the FSS. Pressing
the dial to the left (3) of the speedometer resets the trip odom-
eter. One press is used if the ignition switch is in the “RUN”
position, two presses with the ignition switch in other positions
or with the key removed. The trip and cumulative odometer
displays are also used to show engine oil level.
The outside ambient air temperature digital display adapts to

outside ambient air temperature in steps depending on the fol-
lowing driving conditions; stop and go traffic, constant speed
driving, and the level of temperature change. During idling or
slow driving, the temperature reading may be affected by road
or engine heat because the sensor is located in the lower por-
tion of the front fascia. The outside ambient air temperature
sensor is not a scientific weather tool for calculating the exact
outside temperature. The outside ambient air temperature sen-
sor does not take into account the relative humidity or the cur-
rent wind chill. Therefore, there may be a difference in
temperature readings and actual current outside temperatures.
WARNING INDICATORS
There are eighteen indicator lamps that warn of malfunctions or vehicle components and operating conditions that
need attention. The indicator lamps are grouped together in two windows, one to the left of the Fuel/Temperature
gauge and the other to the right of the Tachometer. All of the indicator lamps illuminate each time the engine is
started to verify system operation and to perform an IC bulb check. The following eighteen indicators are present:
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DIS-

ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL, STEER-
ING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG,
SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE
CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE
THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAGNOSIS
OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE
THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
1. Airbag warning indicator lamp (SRS) The Airbag warning

indicator lamp illuminates if there is a malfunction in the
Supplemental Restrain System (SRS). During its bulb
check, the Airbag warning indicator lamp stays illuminated
for approximately six seconds, then goes out. If the Airbag
warning indicator lamp fails to perform a bulb check or
stays illuminated, there may be a malfunction in the SRS
and should be checked using the DRBIIIT for any DTCs
that may be present.
2. Antilock warning indicator lamp (ABS) The Antilock

warning indicator lamp illuminates if there is a malfunction
in the ABS. If the Antilock warning indicator lamp stays illu-
minated after the bulb check or any service performed, it
should be checked using the DRBIIIT for any DTCs that
may be present. If the Antilock warning indicator lamp is
illuminated, the brake system will operate as if it did not
have ABS.
3. Battery voltage indicator lamp The Battery voltage indi-

cator lamp illuminates when the charging system falls
below current demand causing the battery to not receive a
full charge during operation.
4. Brake assist indicator lamp (BAS), Electronic Stability

Program (ESP) The BAS/ESP indicator lamp illuminates if
there is a malfunction in the BAS/ESP. If the BAS/ESP indi-
cator lamp illuminates at any time during or after any ser-
vice is performed it should be checked using the DRBIIIT to
verify any DTCs that may be present.
5. Brake warning indicator lamp The Brake warning indica-

tor lamp illuminates when the brake fluid in the brake fluid
reservoir drops below the minimum level indicated on the
side of the brake fluid Reservoir.
6. Brake wear indicator lamp The Brake wear indicator lamp

illuminates when the front brake pads reach their replace-
ment threshold.
7. Electronic Stability Program indicator lamp (ESP) The

Electronic Stability Program indicator lamp located between
the left and right turn signal indicators illuminates when the
ESP button, located on the center console, is pushed, acti-
vating the ESP system. The Electronic Stability Program
indicator lamp will go out if the ESP button is pressed
again, deactivating the system. When the Electronic Stabil-
ity Program is activated, the ESP indicator lamp will illumi-
nate to warn the driver of compensations being made by
the ESP system.
8. High beam indicator lamp The High beam indicator lamp

illuminates when the high beam lamps are activated by the
multifunction switch located in the steering column.
9. Lamp outage indicator lamp The Lamp outage indicator

lamp illuminates if there is an exterior lamp failure such as
a headlamp or taillamp failure.
10. Low coolant indicator lamp The Low coolant indicator

lamp illuminates if the engine coolant drops below its
threshold indicating a low engine coolant level.
11. Low fuel warning lamp The Low fuel warning lamp,
located on the left side of the cluster, illuminates when the
fuel level in the fuel tank reaches approximately 8 liters
(2.1 gallons) to indicate a low fuel level.
12. Low tire pressure indicator lamp The Low tire pressure
indicator lamp illuminates if any of the tires loses pressure
or is inflated above the recommended pressure.
13. Low washer fluid indicator lamp The Low washer fluid
indicator lamp illuminates to indicate a low windshield
washer fluid level.
14. Malfunction Indicator Lamp (MIL) The Malfunction Indi-

cator Lamp illuminates when there is a malfunction or
DTC present in the Powertrain Control Module (PCM) or
Transmission Control Module (TCM).
15. Oil level indicator lamp The Oil level indicator lamp illu-
minates if the engine oil drops below 4.25 liters (4.5
quarts), indicating that the engine oil has dropped by 1.9
liters (2 quarts).
16. Seat belt indicator lamp The Seat belt indicator lamp illu-
minates if the driver’s seat belt is not buckled.
17. Telescoping wheel indicator lamp The Telescoping

wheel indicator lamp illuminates if the manually telescop-
ing wheel is not locked into position.
18. Turn signal indicator lamp The Turn signal indicator

lamps, located in the upper portion of the speedometer on
the right and left of the ESP indicator, illuminate when
either the right or left turn signal is activated by the multi-
function switch on the steering column. Both lamps will
illuminate when the Emergency Flasher switch has been
activated.
The cluster gives audible tone signals to notify the driver to

take the following actions:
Note: With the key removed and the door open, the audible tone sounds if the headlamps or parking lamps
are on. Operation of the standing lamps, which are intended for use when the vehicle is unoccupied, will
not trigger this warning.
• Release the parking brake

• Switch off headlamps.
• Remove the key from the ignition.
Turn signal indicator ticking, activating the turn signal switch is indicated audibly by the turn signal indicator tick-
ing. The driver’s attention is brought to a problem in the turn signal system by the turn signal indicator ticking at a
higher frequency. The turn signal indicator ticking is generated electromagnetically. The frequency corresponds to
that of the turn signal indicator lamp.
Parking Brake-on reminder, an audible sound is emitted via a small speaker whenever the cluster detects the
parking brake switch is in the ON position at a speed of 5 km/h (3 MPH) or more.
Headlamps-on reminder, the Headlamps-on reminder sounds when the headlamp switch is in the ON position, the
ignition key is removed from the ignition, and the driver’s door is open.
Key-in-ignition reminder, the Key-in-ignition reminder sounds when the driver’s door is open with the key in the
ignition.
INDICATOR LAMPS AND AUDIBLE TONES TRIGGERED OVER DIRECT LINES

• Left and Right turn signals — from the illumination control module.
• Brake warning indicator lamp — from the brake fluid level switch.
• Low washer fluid indicator lamp — from a single line to the instrument cluster and is voltage-encoded.
• Low coolant indicator lamp — from a single line to the instrument cluster and is voltage-encoded.
• Low fuel warning lamp — from the Instrument Cluster. The lamp illuminates whenever the fuel level drops
to 8 liters (2.1 gallons) The lamp extinguishes after refueling is detected. If fuel is added with the ignition key
in the ON position, refueling is detected only after 7.9 liters (2 gallons) or more of fuel is added.
• Lamp outage indicator lamp — from the illumination control module.
• Airbag warning lamp — from the Occupant Restraint Controller (ORC).
INDICATOR LAMPS AND AUDIBLE TONES TRIGGERED BY THE CAN DATA BUS
• Brake wear indicator lamp — from the CAB.
• Oil level indicator lamp — from the PCM.
• Antilock warning indicator lamp (ABS) — from the CAB.
• Malfunction Indicator Lamp (MIL) — from the PCM.
• Electronic Stability Program (ESP) indicator lamp — from the CAB. The lamp is illuminated if there is a fault
in the ESP system or whenever the system is making compensations for driving conditions.
INSTRUMENTS ACTUATED BY THE CAN DATA BUS

• Odometer (1), the input is transmitted by the Control-
ler Antilock Brake (CAB) and is determined using input
from the four wheel speed sensors.
• Speedometer, the input is transmitted by the Control-
ler Antilock Brake (CAB) and is determined using input
from the four wheel speed sensors. The individual wheel
speeds are compared and checked for logic. If significant
differences in individual speed signals are recognized,
the speed is determined from the speed of one of the
front wheels. If the speed signals differ significantly, it
may be due to wheel spin, cornering, or a defective
speed sensor. If the computer identifies by means of sen-
sor comparisons (comparison of each side) that the vehi-
cle is cornering, the speed is determined from the value
of the front wheel speeds. If the comparisons indicate
one or more different wheel speeds, the vehicle speed is
determined from the highest wheel speed. This also
applies if a fault indication is received instead of a wheel
speed signal. In this case, an error bit is also set. If any
fault indications are received for all wheel speeds, the
speed displayed is 909.
Tachometer, the engine speed signal is transmitted by the

PCM and determined from the crankshaft position sensor
signal.
APPEARANCE AND LIGHTING

Black instrument faces have a blue-green backlighting when the exterior lamps are on. Digital displays also have a
blue-green backlighting. A rotary dial to the left of the speedometer adjusts the lamp intensity. Digital displays acti-
vate when a door is opened, when the ignition switch is in the ON/RUN position, or by pressing the lamp intensity
adjustment knob when the ignition is off.
CONTROL BUTTONS
The instrument cluster has two control dials which are to the
left and right of the speedometer face.
• The right control dial (2) is used to adjust the time.
Refer to the Owner’s Manual.
• The left control button (3) is used to regulate the
instrument illumination, activate the display illumination,
reset the trip odometer display, and operate the FSS
maintenance display.
OUTSIDE AMBIENT AIR TEMPERATURE

To display the outside ambient air temperature requires the fol-
lowing:
• outside air temperature
• wheel speed signal
• engine run time
• engine coolant temperature
The outside ambient air temperature is determined by the out-
side ambient air temperature sensor. The temperature sensor
is installed at the front left of the vehicle under the bumper fas-
cia and is connected to the IC. The wheel speed signal,
engine run time, and engine coolant temperature are deter-
mined internally by the IC. Since the outside ambient air tem-
perature display depends on the wheel speed, engine run
time, and engine coolant temperature, temperatures (influ-
enced by the heat generated by the engine, for example) are
not updated when the vehicle is stationary or moving slowly.
• When the ignition is in the ON position and the engine
coolant temperature < 60°C (140°F), the current air tem-
perature is always stored and displayed.
• When the ignition is in the OFF position and the engine coolant temperature < 60°C (140°F), the air tem-
perature last measured is stored and displayed.
• When the ignition is in the ON position and the engine coolant temperature < 60°C (140°F), the stored air
temperature is displayed.
• At vehicle speeds of 19–60 km/h (12-37 MPH), outside air temperatures are displayed after a delay of
approximately 5 minutes.
• At vehicle speeds over 60 km/h (37 MPH), outside air temperatures are displayed after a delay of approx-
imately 2 minutes.
FLEXIBLE SERVICE SYSTEM (FSS) MAINTENANCE INDICATOR

The FSS maintenance indicator informs the driver when main-
tenance is due. The FSS maintenance indicator operates
based on distance traveled and time between service criteria.
After exceeding a total distance or total time set at the factory,
the FSS maintenance indicator activates: The tool symbol (2)
comes on and the FSS maintenance information (1) is dis-
played instead of the total mileage. The FSS maintenance indi-
cator obtains its time information from the digital clock
integrated into the IC. The odometer signal calculated in the IC
is used for the mileage information. For this purpose, the IC
receives four wheel speed signals from the CAB via the CAN
data bus. (Speedometer, Odometer and the FSS maintenance
indicator are therefore, closely interrelated).
The remaining mileage is compared with the remaining time at key-on. When the time criterion has reached the
priority level, the display (1) switches to the remaining time. The remaining mileage display (1) will be displayed
automatically with the ignition switch in the “RUN” position after 5 seconds or while driving after reaching the warn-
ing threshold. The tool symbol (2) and the current remaining mileage (1) appear for 10 seconds, then automatically
with the ignition switch in the “RUN” position after 5 seconds or while driving when the remaining mileage (1) has
been exceeded. In this case, the display (1-2) flashes and the 9remaining mileage9 (1) is indicated with a negative
sign (minus sign). After reaching the display overrun at -99,000 km (or -99,000 miles), the display (1) will remain at
this value.
The remaining mileage (1) is displayed to a resolution of 100 km (or 100 miles). Normally, the remaining mileage is
always displayed. However, to ensure that 9occasional drivers9 are also made aware when FSS maintenance ser-
vice is due, the mileage (1) and time information are always processed in the background. The data remains stored
even in the event of a system voltage failure.
The time remaining until the next FSS maintenance service is calculated starting with the total time set at the fac-
tory. The total time means the time specified between two FSS maintenance intervals. The remaining time means
the time remaining until the next FSS maintenance service is due. The remaining time is strictly a time criterion. The
remaining time is reduced by one day each day regardless of the mileage. The tool symbol (2), the current remain-
ing time (1), and 9D9 for days will appear for 10 seconds and automatically with the ignition switch in the “RUN”
position after 5 seconds or while driving when the remaining time (1) has exceeded the time threshold. In this case,
the display flashes and the 9remaining time9 is indicated with a negative sign (minus sign). After reaching the display
overrun at -730 days, the display remains at this value. The display has a resolution of 1 day.
ACKNOWLEDGING THE FSS MAINTENANCE INDICATOR

The display of the remaining mileage (1) as well as the
remaining time (1) can be acknowledged and canceled by
pressing the left rotary dial (3) on the IC for at least one sec-
ond. It makes no difference what caused the information to be
displayed.
DIAGNOSIS AND TESTING - FUNCTION CHECK

INSTRUMENT CLUSTER BULBS
If the individual indicator lamps/malfunction indicator lamps do not illuminate or extinguish during operation, the sys-
tems concerned are to be checked or the fluid levels corrected.
1. Move the ignition switch to the 9RUN9 position, all of the indicator lamps and malfunction indicator lamps illumi-
nate.
2. Start the engine, all of the indicator lamps and malfunction indicator lamps extinguish at an engine speed of >
480 rpm if the systems are functioning correctly.
3. The following indicator lamps and malfunction indicator lamps extinguish independently of the engine running:
SRS malfunction indicator lamp after approximately 4 seconds and the seat belt indicator lamp after approxi-
mately 6 seconds.
DISPLAY INSTRUMENTS
The display instruments must indicate according to operating
conditions seen with the DRBIIIT.
The speedometer display must coincide with the DRBIIIT
readout.
The coolant temperature gauge and the fuel level gauge must
indicate according to operating conditions seen with the
DRBIIIT.
WARNING BUZZER OPERATIONAL CHECK

The light outage indicator lamp, parking brake warning, key-in-ignition warning and the seat belt reminder warning
buzzer stays on for approximately 6 seconds. The warning tone seat belt warning buzzer will be interrupted as soon
as the driver’s seat belt is inserted into the seat belt buckle.
MAINTENANCE DISPLAY
Move the ignition switch to the 9RUN9 position and press the
left instrument cluster button twice within 1 second. The tool
symbol (2) will appear and the current remaining distance
appear for 10 seconds.
STANDARD PROCEDURE
DISPLAY OF REMAINING FSS MILEAGE AT DRIVER’S REQUEST
The remaining FSS mileage (1) can be displayed at the
request of the driver.
Note: The tool symbol appears for 10 seconds together

with the current remaining mileage.
1. Press the left rotary dial (3) on the Instrument Cluster (IC)
twice within one second.
RESETTING THE FSS MAINTENANCE

INDICATOR
The FSS maintenance indicator can be reset to the total mile-
age (1) or total time in two ways:
Automatically when the odometer (1) is reset to 0 within the

first 155 miles. (The FSS maintenance indicator is reset to the
values set at the factory).
Manually by driver by:
1. Hold the left rotary dial (3) depressed.
2. Simultaneously move the ignition switch to the “RUN” posi-

tion (3).
3. Continue to hold the rotary dial (3) down for 10 seconds.

After the audible tone 15,000 km (7,500 miles) appears on
the display. The remaining mileage (1) is displayed again.
RESETTING THE FSS MAINTENANCE INDICATOR AFTER AN OIL CHANGE

1. Move the ignition switch to the “RUN” position (3).
2. Within 4 seconds of moving the ignition switch into the

“RUN” position, press the reset button for the trip odometer
(3) twice within one second. The display for the FSS ser-
vice request (1) is activated for 10 seconds.
3. During the 10 seconds the FSS service request is dis-

played, move the ignition switch to the “OFF” position (1).
The FSS service request will continue to be displayed.
4. Press the reset button (3) for the trip odometer (1) and
hold.
5. Move the ignition switch to the “RUN” position (3).

6. Continue to press and hold the reset button for the trip
odometer (about 10 seconds) until the audible signal
sounds and the new start distance appears (1) in the dis-
play. The tool symbol (2) should disappear at this time.
STANDARD PROCEDURE - INSTRUMENT CLUSTER BULBS
1 - ELECTRONIC STABILITY PROGRAM (ESP) WARNING LAMP 14 - INSTRUMENT CLUSTER ILLUMINATION

2 - LEFT TURN SIGNAL INDICATOR LAMP 15 - INSTRUMENT CLUSTER ILLUMINATION
3 - INSTRUMENT CLUSTER ILLUMINATION 16 - HIGH BEAM INDICATOR LAMP
4 - INSTRUMENT CLUSTER ILLUMINATION 17 - BATTERY VOLTAGE INDICATOR LAMP
5 - OIL LEVEL INDICATOR LAMP 18 - SEAT BELT INDICATOR LAMP
6 - LOW COOLANT INDICATOR LAMP 19 - BRAKE ASSIST INDICATOR LAMP (BAS)
7 - LOW WASHER FLUID INDICATOR LAMP 20 - ANTILOCK WARNING INDICATOR LAMP (ABS)
8 - AIRBAG WARNING INDICATOR LAMP (SRS) 21 - LAMP OUTAGE INDICATOR LAMP
9 - BRAKE WEAR INDICATOR LAMP 22 - BRAKE WARNING INDICATOR LAMP
10 - MALFUNCTION INDICATOR LAMP (MIL) 23 - INSTRUMENT CLUSTER ILLUMINATION
11 - TELESCOPING WHEEL INDICATOR LAMP 24 - INSTRUMENT CLUSTER (IC)
12 - INSTRUMENT CLUSTER ILLUMINATION 25 - INSTRUMENT CLUSTER ILLUMINATION
13 - LOW FUEL WARNING LAMP 26 - RIGHT TURN SIGNAL INDICATOR LAMP
INSTRUMENT CLUSTER BULB REMOVAL

1. To remove the instrument cluster bulbs, turn the bulb
counter clockwise and remove it from the back of the
instrument cluster housing.
INSTRUMENT CLUSTER BULB INSTALLATION

1. To install the instrument cluster bulbs, place the bulb into
the instrument cluster housing back and then turn the bulb
clockwise until it locks.
REMOVAL - INSTRUMENT CLUSTER

2. Remove the steering wheel. Refer to Page 19-25.
3. Remove the lower instrument panel cover (2).
4. Remove the instrument cluster bezel (1).

5. Remove the retaining screws from instrument cluster.
6. Move the instrument cluster toward the rear of the vehicle.
7. Unlock and disconnect the Instrument Cluster harness con-
nectors from the back of the instrument cluster.
8. Remove the instrument cluster from the vehicle.
INSTALLATION - INSTRUMENT CLUSTER
1. Install the instrument cluster.

2. Connect and lock the Instrument Cluster harness connec-
tors.
3. Install the retaining screws to the instrument cluster.
4. Install the instrument cluster bezel (1). Refer to Page

23-155.
5. Install the lower instrument panel cover (2). Refer to Page

23-155.
6. Install the steering wheel. Refer to Page 19-26.
ZH LAMPS 8L - 1
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR - ELECTRICAL LAMPS/LIGHTING - INTERIOR - ELECTRICAL

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 117
LAMPS/LIGHTING - EXTERIOR - SERVICE LAMPS/LIGHTING - INTERIOR - SERVICE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 84 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 136
LAMPS/LIGHTING - EXTERIOR - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR - ELECTRICAL *LEFT REAR SIDE MARKER LAMP

DIAGNOSTICS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING *RIGHT REAR SIDE MARKER LAMP
*LEFT FOG LAMP INOPERATIVE . . . . . . . . . . 2 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 41
*RIGHT FOG LAMP INOPERATIVE . . . . . . . . . 5 *LEFT TAIL LAMP INOPERATIVE . . . . . . . . . . 44
*LEFT PARK LAMP INOPERATIVE .........8 *LEFT STOP LAMP INOPERATIVE ..... . . . 47
*LEFT FRONT TURN LAMP INOPERATIVE . . 11 *LEFT BACK UP LAMP INOPERATIVE . . . . . . 50
*RIGHT PARK LAMP INOPERATIVE . . . . . . . 14 *LEFT REAR TURN LAMP INOPERATIVE . . . 53
*RIGHT FRONT TURN LAMP INOPERATIVE . 17 *RIGHT TAIL LAMP INOPERATIVE . . . . . . . . . 56
*LEFT LOW BEAM HEADLAMP *RIGHT STOP LAMP INOPERATIVE .... . . . 59
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 20 *RIGHT BACK UP LAMP INOPERATIVE . . . . 62
*LEFT HIGH BEAM HEADLAMP *RIGHT REAR TURN LAMP INOPERATIVE . . 65
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 23 *CENTER HIGH MOUNTED STOP LAMP
*RIGHT LOW BEAM HEADLAMP INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 68
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 26 *LICENSE LAMP NO.1 INOPERATIVE . . . . . . 71
*RIGHT HIGH BEAM HEADLAMP *LICENSE LAMP NO.2 INOPERATIVE . . . . . . 74
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 29 BODY VERIFICATION TEST . . . . . . . . . . . . . 77
*LEFT FRONT SIDE MARKER LAMP SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 78
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 32
*RIGHT FRONT SIDE MARKER LAMP
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 35
LAMPS/LIGHTING - EXTERIOR - ELECTRICAL DIAGNOSTICS

8L - 2 LAMPS/LIGHTING - EXTERIOR - ELECTRICAL DIAGNOSTICS ZH
*LEFT FOG LAMP INOPERATIVE
ZH LAMPS/LIGHTING - EXTERIOR - ELECTRICAL DIAGNOSTICS 8L - 3
*LEFT FOG LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT FOG LAMP BULB
For a complete Exterior Lamps Circuit Diagram, Refer to Page 8L-78.
Diagnostic Test
1. INSPECT THE LEFT FOG LAMP BULB

Note: If both of the fog lamps are inoperative, inspect Fuse 9 located
in the Illumination Control Module/IP Fuse Block. If the fuse is open,
repair the cause of the open fuse before continuing.
Remove the Left Fog Lamp bulb and inspect for an open filament.
Is the Bulb filament open?

Yes >> Replace the Left Fog Lamp bulb. Refer to Page 8L-93.
No >> Go to 2
2. MEASURE FUSED B(+) CIRCUIT RESISTANCE

Disconnect the Left Fog Lamp harness connector.
Measure the resistance of the Fused B(+) circuit from the Left Fog Lamp
harness connector to the Illumination Control Module harness connector.

Yes >> Go to 3
No >> Repair the Fused B(+) circuit for an open between the
Left Fog Lamp and the Illumination Control Module.
*LEFT FOG LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT FOG LAMP VOLTAGE
Connect the Illumination Control Module harness connector.
Turn the fog lamps on.
Measure the voltage of the Fused B(+) circuit at the Left Fog Lamp har-
ness connector cavity 2.

Yes >> Go to 4
No >> Replace the Illumination Control Module. Refer to Page
8L-105.
4. MEASURE LEFT FOG LAMP GROUND CIRCUIT RESISTANCE

Turn the fog lamps off.
Measure the resistance between ground and the Left Fog Lamp harness
connector cavity 1.

Yes >> Ensure that the Left Fog Lamp bulb is installed properly and
replace the bulb socket if necessary.
No >> Repair the Left Fog Lamp ground circuit for an open.
*RIGHT FOG LAMP INOPERATIVE
*RIGHT FOG LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT FOG LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT FOG LAMP BULB

Note: If both of the fog lamps are inoperative, inspect Fuse 9 located
Remove the Right Fog Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Fog Lamp bulb. Refer to Page 8L-93.
No >> Go to 2

Disconnect the Right Fog Lamp harness connector.
Measure the resistance between the Right Fog Lamp harness connector
and the Illumination Control Module harness connector.

Yes >> Go to 3
Right Fog Lamp and the Illumination Control Module.
*RIGHT FOG LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT FOG LAMP VOLTAGE
Turn the fog lamps on.
Measure the voltage between the Right Fog Lamp harness connector cav-
ity 2 and ground.

Yes >> Go to 4
8L-105.
4. MEASURE RIGHT FOG LAMP GROUND CIRCUIT RESISTANCE

Turn the fog lamps off.
Measure the resistance between the Right Fog Lamp harness connector
cavity 1 and ground.

Yes >> Ensure that the Right Fog Lamp bulb is installed properly
and replace the bulb socket if necessary.
No >> Repair the Right Fog Lamp ground circuit for an open.
*LEFT PARK LAMP INOPERATIVE
*LEFT PARK LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT PARK LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT PARK LAMP BULB

Note: If the left front side marker lamp, the left park lamp, the left
rear side marker lamp, and the left tail lamp are inoperative, inspect
Fuse 10 located in the Illumination Control Module/IP Fuse Block. If
Remove the Left Park Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Park Lamp bulb. Refer to Page 8L-97.
No >> Go to 2

Disconnect the Left Park Lamp harness connector.
Measure the resistance between the Left Park Lamp harness connector

Yes >> Go to 3
Left Park Lamp and the Illumination Control Module.
*LEFT PARK LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT PARK LAMP VOLTAGE
Turn the park lamps on.
Measure the voltage between the Left Park Lamp harness connector cav-
ity 2 and ground.
Is voltage present?
Yes >> Go to 4
8L-105.
4. MEASURE LEFT PARK LAMP GROUND CIRCUIT RESISTANCE

Turn the park lamps off.
Measure the resistance between the Left Park Lamp harness connector

Yes >> Ensure that the Left Park Lamp bulb is installed properly
No >> Repair the Left Park Lamp ground circuit for an open.
*LEFT FRONT TURN LAMP INOPERATIVE
*LEFT FRONT TURN LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT FRONT TURN LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT FRONT TURN LAMP BULB

Note: If all of the turn signal lamps and both of the back up lamps
are inoperative, inspect Fuse 4 located in the Illumination Control
Module/IP Fuse Block. If the fuse is open, repair the cause of the
open fuse before continuing.
Remove the Left Front Turn Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Front Turn Lamp bulb. Refer to Page
8L-98.
No >> Go to 2

Disconnect the Left Front Lamp Assembly harness connector.
Disconnect the Multi-Function Switch harness connector.
Measure the resistance between the Left Front Lamp Assembly harness
connector and the Multi-Function Switch harness connector.

Yes >> Go to 3
Left Front Turn Lamp and the Multi-Function Switch.
*LEFT FRONT TURN LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT FRONT TURN LAMP VOLTAGE
Connect the Multi-Function Switch harness connector.
Turn the left turn signal on.
Measure the voltage between the Left Front Lamp Assembly harness con-
nector cavity 1 and ground.
Is voltage present?
Yes >> Go to 4
No >> Replace the Multi-Function Switch. Refer to Page
8L-112.
4. MEASURE LEFT FRONT TURN LAMP GROUND CIRCUIT

RESISTANCE

Turn the left turn signal off.
connector cavity 2 and ground.

Yes >> Ensure that the Left Front Turn Lamp bulb is installed prop-
erly and replace the bulb socket if necessary.
No >> Repair the Left Front Lamp Assembly ground circuit
for an open.
*RIGHT PARK LAMP INOPERATIVE
*RIGHT PARK LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT PARK LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT PARK LAMP BULB

Note: If the right front side marker lamp, the right park lamp, the
right rear side marker lamp, and the right tail lamp are inoperative,
inspect Fuse 7 located in the Illumination Control Module/IP Fuse
continuing.
Remove the Right Park Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Park Lamp bulb. Refer to Page 8L-98.
No >> Go to 2

Disconnect the Right Park Lamp harness connector.
Measure the resistance between the Right Park Lamp harness connector

Yes >> Go to 3
Right Park Lamp and the Illumination Control Module.
*RIGHT PARK LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT PARK LAMP VOLTAGE
Turn the park lamps on.
Measure the voltage between the Right Park Lamp harness connector
Is voltage present?
Yes >> Go to 4
8L-105.
4. MEASURE RIGHT PARK LAMP GROUND CIRCUIT RESISTANCE

Turn the park lamps off.
Measure the resistance between the Right Park Lamp harness connector

Yes >> Ensure that the Right Park Lamp bulb is installed properly
No >> Repair the Right Park Lamp ground circuit for an
open.
*RIGHT FRONT TURN LAMP INOPERATIVE
*RIGHT FRONT TURN LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT FRONT TURN LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT FRONT TURN LAMP BULB

Remove the Right Front Turn Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Front Turn Lamp bulb. Refer to Page
8L-98.
No >> Go to 2

Disconnect the Right Front Lamp Assembly harness connector.
Measure the resistance between the Right Front Lamp Assembly harness

Yes >> Go to 3
Right Front Turn Lamp and the Multi-Function Switch.
*RIGHT FRONT TURN LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT FRONT TURN LAMP VOLTAGE
Turn the right turn signal on.
Measure the voltage between the Right Front Lamp Assembly harness
Is voltage present?
Yes >> Go to 4
8L-112.
4. MEASURE RIGHT FRONT TURN LAMP GROUND CIRCUIT

RESISTANCE

Turn the right turn signal off.

Yes >> Ensure that the Right Front Turn Lamp bulb is installed
properly and replace the bulb socket if necessary.
No >> Repair the Right Front Lamp Assembly ground circuit
for an open.
*LEFT LOW BEAM HEADLAMP INOPERATIVE
*LEFT LOW BEAM HEADLAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT LOW BEAM HEADLAMP BULB
Diagnostic Test
1. INSPECT THE LEFT LOW BEAM HEADLAMP BULB

before continuing.
Remove the Left Low Beam Headlamp bulb and inspect for an open fila-
ment.

Yes >> Replace the Left Low Beam Headlamp bulb. Refer to Page
8L-103.
No >> Go to 2

connector cavity 3 and the Illumination Control Module harness connector.

Yes >> Go to 3
Left Front Lamp Assembly and the Illumination Control
Module.
*LEFT LOW BEAM HEADLAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT LOW BEAM HEADLAMP VOLTAGE
Turn the low beam headlamps on.

Yes >> Go to 4
8L-105.
4. MEASURE LEFT LOW BEAM HEADLAMP GROUND CIRCUIT

RESISTANCE

Turn the low beam headlamps off.

Yes >> Ensure that the Left Low Beam Headlamp bulb is installed
for an open.
*LEFT HIGH BEAM HEADLAMP INOPERATIVE
*LEFT HIGH BEAM HEADLAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT HIGH BEAM HEADLAMP BULB
Diagnostic Test
1. INSPECT THE LEFT HIGH BEAM HEADLAMP BULB

before continuing.
Remove the Left High Beam Headlamp bulb and inspect for an open fila-
ment.

Yes >> Replace the Left High Beam Headlamp bulb. Refer to Page
8L-103.
No >> Go to 2


Yes >> Go to 3
Left Front Lamp Assembly and the Illumination Control
Module.
*LEFT HIGH BEAM HEADLAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT HIGH BEAM HEADLAMP VOLTAGE
Turn the high beam headlamps on.

Yes >> Go to 4
8L-105.
4. MEASURE LEFT HIGH BEAM HEADLAMP GROUND CIRCUIT

RESISTANCE

Turn the high beam headlamps off.

Yes >> Ensure that the Left High Beam Headlamp bulb is installed
for an open.
*RIGHT LOW BEAM HEADLAMP INOPERATIVE
*RIGHT LOW BEAM HEADLAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT LOW BEAM HEADLAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT LOW BEAM HEADLAMP BULB

before continuing. INSPECT THE RIGHT LOW BEAM HEADLAMP
BULB
Remove the Right Low Beam Headlamp bulb and inspect for an open fil-
ament.

Yes >> Replace the Right Low Beam Headlamp bulb. Refer to
Page 8L-103.
No >> Go to 2


Yes >> Go to 3
Right Front Lamp Assembly and the Illumination Control
Module.
*RIGHT LOW BEAM HEADLAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT LOW BEAM HEADLAMP VOLTAGE
Turn the low beam headlamps on.

Yes >> Go to 4
8L-105.
4. MEASURE RIGHT LOW BEAM HEADLAMP GROUND CIRCUIT

RESISTANCE

Turn the low beam headlamps off.

Yes >> Ensure that the Right Low Beam Headlamp bulb is installed
for an open.
*RIGHT HIGH BEAM HEADLAMP INOPERATIVE
*RIGHT HIGH BEAM HEADLAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT HIGH BEAM HEADLAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT HIGH BEAM HEADLAMP BULB

Note: If both the right high beam headlamp and the high beam indi-
cator are inoperative, inspect Fuse 3 located in the Illumination Con-
trol Module/IP Fuse Block. If the fuse is open, repair the cause of the
Remove the Right High Beam Headlamp bulb and inspect for an open fil-
ament.

Yes >> Replace the Right High Beam Headlamp bulb. Refer to
Page 8L-103.
No >> Go to 2


Yes >> Go to 3
Right Front Lamp Assembly and the Illumination Control
Module.
*RIGHT HIGH BEAM HEADLAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT HIGH BEAM HEADLAMP VOLTAGE
Turn the high beam headlamps on.

Yes >> Go to 4
8L-105.
4. MEASURE RIGHT HIGH BEAM HEADLAMP GROUND CIRCUIT

RESISTANCE

Turn the high beam headlamps off.

Yes >> Ensure that the Right High Beam Headlamp bulb is
installed properly and replace the bulb socket if necessary.
for an open.
*LEFT FRONT SIDE MARKER LAMP INOPERATIVE
*LEFT FRONT SIDE MARKER LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT FRONT SIDE MARKER LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT FRONT SIDE MARKER LAMP BULB

Remove the Left Front Side Marker Lamp bulb and inspect for an open
filament.

Yes >> Replace the Left Front Side Marker Lamp bulb. Refer to
Page 8L-98.
No >> Go to 2

Disconnect the Left Front Side Marker Lamp harness connector.
Measure the resistance between the Left Front Side Marker Lamp harness
connector and the Illumination Control Module harness connector.

Yes >> Go to 3
Left Front Side Marker Lamp and the Illumination Control
Module.
*LEFT FRONT SIDE MARKER LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT FRONT SIDE MARKER LAMP VOLTAGE
Turn the side marker lamps on.
Measure the voltage between the Left Front Side Marker Lamp harness

Yes >> Go to 4
8L-105.
4. MEASURE LEFT FRONT SIDE MARKER LAMP GROUND CIRCUIT

RESISTANCE

Turn the side marker lamps off.
Measure the resistance between the Left Front Side Marker Lamp harness

Yes >> Ensure that the Left Front Side Marker Lamp bulb is
No >> Repair the Left Front Side Marker Lamp ground circuit
for an open.
*RIGHT FRONT SIDE MARKER LAMP INOPERATIVE
*RIGHT FRONT SIDE MARKER LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT FRONT SIDE MARKER LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT FRONT SIDE MARKER LAMP BULB

continuing.
Remove the Right Front Side Marker Lamp bulb and inspect for an open
filament.

Yes >> Replace the Right Front Side Marker Lamp bulb. Refer to
Page 8L-98.
No >> Go to 2

Disconnect the Right Front Side Marker Lamp harness connector.
Measure the resistance between the Right Front Side Marker Lamp har-
ness connector and the Illumination Control Module harness connector.

Yes >> Go to 3
Right Front Side Marker Lamp and the Illumination Con-
trol Module.
*RIGHT FRONT SIDE MARKER LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT FRONT SIDE MARKER LAMP VOLTAGE
Measure the voltage between the Right Front Side Marker Lamp harness

Yes >> Go to 4
8L-105.
4. MEASURE RIGHT FRONT SIDE MARKER LAMP GROUND CIRCUIT

RESISTANCE

Measure the resistance between the Right Front Side Marker Lamp har-
ness connector cavity 1 and ground.

Yes >> Ensure that the Right Front Side Marker Lamp bulb is
No >> Repair the Right Front Side Marker Lamp ground cir-
cuit for an open.
*LEFT REAR SIDE MARKER LAMP INOPERATIVE
*LEFT REAR SIDE MARKER LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT REAR SIDE MARKER LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT REAR SIDE MARKER LAMP BULB

Remove the Left Rear Side Marker Lamp bulb and inspect for an open
filament.

Yes >> Replace the Left Rear Side Marker Lamp bulb. Refer to
Page 8L-98.
No >> Go to 2

Disconnect the Left Rear Side Marker Lamp harness connector.
Measure the resistance between the Left Rear Side Marker Lamp harness

Yes >> Go to 3
Left Rear Side Marker Lamp and the Illumination Control
Module.
*LEFT REAR SIDE MARKER LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT REAR SIDE MARKER LAMP VOLTAGE
Measure the voltage between the Left Rear Side Marker Lamp harness

Yes >> Go to 4
8L-105.
4. MEASURE LEFT REAR SIDE MARKER LAMP GROUND CIRCUIT

RESISTANCE

Measure the resistance between the Left Rear Side Marker Lamp harness

Yes >> Ensure that the Left Rear Side Marker Lamp bulb is
No >> Repair the Left Rear Side Marker Lamp ground circuit
for an open.
*RIGHT REAR SIDE MARKER LAMP INOPERATIVE
*RIGHT REAR SIDE MARKER LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT REAR SIDE MARKER LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT REAR SIDE MARKER LAMP BULB

continuing.
Remove the Right Rear Side Marker Lamp bulb and inspect for an open
filament.

Yes >> Replace the Right Rear Side Marker Lamp bulb. Refer to
Page 8L-98.
No >> Go to 2

Disconnect the Right Rear Side Marker Lamp harness connector.
Measure the resistance between the Right Rear Side Marker Lamp har-
ness connector and the Illumination Control Module harness connector.

Yes >> Go to 3
Right Rear Side Marker Lamp and the Illumination Con-
trol Module.
*RIGHT REAR SIDE MARKER LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT REAR SIDE MARKER LAMP VOLTAGE
Measure the voltage between the Right Rear Side Marker Lamp harness

Yes >> Go to 4
8L-105.
4. MEASURE RIGHT REAR SIDE MARKER LAMP GROUND CIRCUIT

RESISTANCE

Measure the resistance between the Right Rear Side Marker Lamp har-

Yes >> Ensure that the Right Rear Side Marker Lamp bulb is
No >> Repair the Right Rear Side Marker Lamp ground cir-
cuit for an open.
*LEFT TAIL LAMP INOPERATIVE
*LEFT TAIL LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT TAIL/STOP LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT TAIL/STOP LAMP BULB

Remove the Left Tail/Stop Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Tail/Stop Lamp bulb. Refer to Page
8L-113.
No >> Go to 2

Disconnect the Left Rear Lamp Assembly harness connector.
Measure the resistance between the Left Rear Lamp Assembly harness

Yes >> Go to 3
Left Rear Lamp Assembly and the Illumination Control
Module.
*LEFT TAIL LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT TAIL/STOP LAMP VOLTAGE
Turn the tail lamps on.
Measure the voltage between the Left Rear Lamp Assembly harness con-

Yes >> Go to 4
No >> Replace the Illumination Control Module.
4. MEASURE LEFT TAIL/STOP LAMP GROUND CIRCUIT RESISTANCE

Turn the tail lamps off.
connector and ground.

Yes >> Ensure that the Left Tail/Stop Lamp bulb is installed prop-
No >> Repair the Left Rear Lamp Assembly ground circuit for
an open.
*LEFT STOP LAMP INOPERATIVE
*LEFT STOP LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT TAIL/STOP LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT TAIL/STOP LAMP BULB

Note: If all stop lamps are inoperative, inspect Fuse 2 located in the
Illumination Control Module/IP Fuse Block. If the fuse is open, repair
the cause of the open fuse before continuing.
Remove the Left Tail/Stop Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Tail/Stop Lamp bulb. Refer to Page
8L-113.
No >> Go to 2


Yes >> Go to 3
Module.
*LEFT STOP LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT TAIL/STOP LAMP VOLTAGE
Depress the brake pedal.

Yes >> Go to 4
4. MEASURE LEFT TAIL/STOP LAMP GROUND CIRCUIT RESISTANCE

Release the brake pedal.

Yes >> Ensure that the Left Tail/Stop Lamp bulb is installed prop-
No >> Repair the Left Rear Lamp Assembly ground circuit fro
an open.
*LEFT BACK UP LAMP INOPERATIVE
*LEFT BACK UP LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT BACK UP LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT BACK UP LAMP BULB

Remove the Left Back Up Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Back Up Lamp bulb. Refer to Page 8L-88.
No >> Go to 2


Yes >> Go to 3
Module.
*LEFT BACK UP LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT BACK UP LAMP VOLTAGE
Move the transmission shift lever into reverse.
Is voltage present?
Yes >> Go to 4
4. MEASURE LEFT BACK UP LAMP GROUND CIRCUIT RESISTANCE

Move the transmission shift lever into park.

Yes >> Ensure that the Left Back Up Lamp bulb is installed prop-
an open.
*LEFT REAR TURN LAMP INOPERATIVE
*LEFT REAR TURN LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LEFT REAR TURN LAMP BULB
Diagnostic Test
1. INSPECT THE LEFT REAR TURN LAMP BULB

Remove the Left Rear Turn Lamp bulb and inspect for an open filament.

Yes >> Replace the Left Rear Turn Lamp bulb. Refer to Page
8L-113.
No >> Go to 2


Yes >> Go to 3
Left Rear Turn Lamp and the Multi-Function Switch.
*LEFT REAR TURN LAMP INOPERATIVE — CONTINUED
3. MEASURE LEFT REAR TURN LAMP VOLTAGE
Turn the left turn signal on.
Is voltage present?
Yes >> Go to 4
8L-112.
4. MEASURE LEFT REAR TURN LAMP GROUND CIRCUIT

RESISTANCE

Turn the left turn signal off.

Yes >> Ensure that the Left Rear Turn Lamp bulb is installed prop-
an open.
*RIGHT TAIL LAMP INOPERATIVE
*RIGHT TAIL LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT TAIL/STOP LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT TAIL/STOP LAMP BULB

continuing.
Remove the Right Tail/Stop Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Tail/Stop Lamp bulb. Refer to Page
8L-113.
No >> Go to 2

Disconnect the Right Rear Lamp Assembly harness connector.
Measure the resistance between the Right Rear Lamp Assembly harness

Yes >> Go to 3
Right Rear Lamp Assembly and the Illumination Control
Module.
*RIGHT TAIL LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT TAIL/STOP LAMP VOLTAGE
Turn the tail lamps on.
Measure the voltage between the Right Rear Lamp Assembly harness

Yes >> Go to 4
4. MEASURE RIGHT TAIL/STOP LAMP GROUND CIRCUIT

RESISTANCE
Turn the tail lamps off.


Yes >> Ensure that the Right Tail/Stop Lamp bulb is installed prop-
No >> Repair the Right Rear Lamp Assembly ground circuit
for an open.
*RIGHT STOP LAMP INOPERATIVE
*RIGHT STOP LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT TAIL/STOP LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT TAIL/STOP LAMP BULB

Remove the Right Tail/Stop Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Tail/Stop Lamp bulb. Refer to Page
8L-113.
No >> Go to 2


Yes >> Go to 3
Module.
*RIGHT STOP LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT TAIL/STOP LAMP VOLTAGE

Yes >> Go to 4
4. MEASURE RIGHT TAIL/STOP LAMP GROUND CIRCUIT

RESISTANCE


Yes >> Ensure that the Right Tail/Stop Lamp bulb is installed prop-
for an open.
*RIGHT BACK UP LAMP INOPERATIVE
*RIGHT BACK UP LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT BACK UP LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT BACK UP LAMP BULB

Remove the Right Back Up Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Back Up Lamp bulb. Refer to Page
8L-88.
No >> Go to 2


Yes >> Go to 3
Module.
*RIGHT BACK UP LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT BACK UP LAMP VOLTAGE
Move the transmission shift lever into reverse.
Is voltage present?
Yes >> Go to 4
4. MEASURE RIGHT BACK UP LAMP GROUND CIRCUIT RESISTANCE

Move the transmission shift lever into park.

Yes >> Ensure that the Right Back Up Lamp bulb is installed prop-
for an open.
*RIGHT REAR TURN LAMP INOPERATIVE
*RIGHT REAR TURN LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
RIGHT REAR TURN LAMP BULB
Diagnostic Test
1. INSPECT THE RIGHT REAR TURN LAMP BULB

Remove the Right Rear Turn Lamp bulb and inspect for an open filament.

Yes >> Replace the Right Rear Turn Lamp bulb. Refer to Page
8L-113.
No >> Go to 2


Yes >> Go to 3
Right Rear Turn Lamp and the Multi-Function Switch.
*RIGHT REAR TURN LAMP INOPERATIVE — CONTINUED
3. MEASURE RIGHT REAR TURN LAMP VOLTAGE
Turn the right turn signal on.
Is voltage present?
Yes >> Go to 4
8L-112.
4. MEASURE RIGHT REAR TURN LAMP GROUND CIRCUIT

RESISTANCE

Turn the right turn signal off.

Yes >> Ensure that the Right Rear Turn Lamp bulb is installed
for an open.
*CENTER HIGH MOUNTED STOP LAMP INOPERATIVE
*CENTER HIGH MOUNTED STOP LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
CENTER HIGH MOUNTED STOP LAMP
Diagnostic Test

Disconnect the Center High Mounted Stop Lamp harness connector.
Measure the resistance between the Center High Mounted Stop Lamp
harness connector and the Illumination Control Module harness connector.

Yes >> Go to 2
Center High Mounted Stop Lamp and the Illumination
Control Module.
2. MEASURE CENTER HIGH MOUNTED STOP LAMP VOLTAGE

Measure the voltage between the Center High Mounted Stop Lamp har-
Is the voltage present?

Yes >> Go to 3
8L-105.
*CENTER HIGH MOUNTED STOP LAMP INOPERATIVE — CONTINUED
3. MEASURE CENTER HIGH MOUNTED STOP LAMP GROUND
CIRCUIT RESISTANCE

Measure the resistance between the Center High Mounted Stop Lamp
harness connector cavity 1 and ground.

Yes >> Replace the Center High Mounted Stop Lamp. Refer to
Page 8L-92.
No >> Repair the Center High Mounted Stop Lamp ground
*LICENSE LAMP NO.1 INOPERATIVE
*LICENSE LAMP NO.1 INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LICENSE LAMP BULB
Diagnostic Test
1. INSPECT THE LICENSE LAMP BULB

Note: If both license lamps are inoperative, inspect Fuse 11 located
Remove the License Lamp bulb and inspect for an open filament.

Yes >> Replace the License Lamp bulb. Refer to Page 8L-109.
No >> Go to 2

Disconnect the License Lamp No.1 harness connector.
Measure the resistance between the License Lamp No.1 harness connec-
tor and the Illumination Control Module harness connector.

Yes >> Go to 3
License Lamp No.1 and the Illumination Control Module.
3. MEASURE LICENSE LAMP VOLTAGE
Turn the license lamps on.
Measure the voltage between the License Lamp No.1 harness connector

Yes >> Go to 4
8L-105.
4. MEASURE LICENSE LAMP GROUND CIRCUIT RESISTANCE

Turn the license lamps off.
Measure the resistance between the License Lamp No. 1 harness connec-
tor cavity 1 and ground.

Yes >> Ensure that the License Lamp bulb is installed properly and
No >> Repair the License Lamp No.1 ground circuit for an
open.
*LICENSE LAMP NO.2 INOPERATIVE
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
LICENSE LAMP BULB
Diagnostic Test
1. INSPECT THE LICENSE LAMP BULB

Note: If both license lamps are inoperative, inspect Fuse 11 located
Remove the License Lamp bulb and inspect for an open filament.

Yes >> Replace the License Lamp bulb. Refer to Page 8L-109.
No >> Go to 2

Disconnect the License Lamp No.2 harness connector.
Measure the resistance between the License Lamp No.2 harness connec-
tor and the Illumination Control Module harness connector.

Yes >> Go to 3
License Lamp No.2 and the Illumination Control Module.
3. MEASURE LICENSE LAMP VOLTAGE
Turn the license lamps on.
Measure the voltage between the License Lamp No.2 harness connector

Yes >> Go to 4
8L-105.
4. MEASURE LICENSE LAMP GROUND CIRCUIT RESISTANCE

Turn the license lamps off.
Measure the resistance between the License Lamp No. 2 harness connec-

Yes >> Ensure that the License Lamp bulb is installed properly and
No >> Repair the License Lamp No.2 ground circuit for an
open.
1.

EXTERIOR LIGHTING CIRCUIT DIAGRAM (1 OF 6)






8L - 84 LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION ZH
LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR - SERVICE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100

INFORMATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 85 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 HEADLAMP
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 103
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . 86 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SPECIFICATIONS - EXTERIOR LAMPS . . . . . . . 87 REMOVAL
BACKUP LAMP LOW BEAM BULB . . . . . . . . . . . . . . . . . . . . 103
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 REMOVAL - HIGH BEAM BULB . . . . . . . . . . 103
BACKUP LAMP SWITCH LOW BEAM BULB . . . . . . . . . . . . . . . . . . . . 104
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 89 INSTALLATION - HIGH BEAM BULB . . . . . . 105
BRAKE LAMP RELAY HEADLAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 90 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
BRAKE LAMP SWITCH HEADLAMP UNIT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92 LICENSE PLATE LAMP
CENTER HIGH MOUNTED STOP LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 MARKER LAMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93 REMOVAL
FOG LAMP REAR MARKER LAMP . . . . . . . . . . . . . . . . . 110
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 REMOVAL - FRONT MARKER LAMP . . . . . . 110
FOG LAMP UNIT REAR MARKER LAMP . . . . . . . . . . . . . . . . . 111
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 INSTALLATION - FRONT MARKER LAMP . . . 111
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96 MULTI-FUNCTION SWITCH
FRONT POSITION LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 TAIL LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 98 TAIL LAMP UNIT . . . . . . . . . . . . . . . . . . . . . 113
FRONT TURN SIGNAL LAMP REMOVAL - TAIL/STOP . . . . . . . . . . . . . . . . 114
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 REMOVAL - TURN SIGNAL . . . . . . . . . . . . . 114
HAZARD FLASHER TAIL LAMP UNIT . . . . . . . . . . . . . . . . . . . . . 115
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 99 INSTALLATION - TAIL/STOP . . . . . . . . . . . . . 115
HAZARD SWITCH INSTALLATION - TURN SIGNAL . . . . . . . . . . 116
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
ZH LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION 8L - 85
LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION

DESCRIPTION
The exterior lighting system includes the following components:
• Backup Lamps
• Brake Lamps
• Center High Mounted Stop Lamp
• Daytime Running Lamps
• Front Fog Lamps
• Front Position Lamps
• Hazard Warning Lamps
• Headlamps
• License Plate Lamps
• Marker Lamps
• Park Lamps
• Tail/Stop Lamps
• Turn Signal Lamps
Other components of the exterior lighting system for this model include:
• Backup Lamp Switch
• Brake Lamp Switch
• Brake Lamp Relay
• Hazard Flasher
• Hazard Switch
• Headlamp Switch
• Illumination Control Module
• Multifunction Switch
Vehicles use lighting on both the interior and exterior for illuminating and indicating purposes. Lighting circuits are
protected by fuses or circuit breakers. Lighting circuits require an overload protected power source, on/off device,
lamps and body ground to operate properly. Plastic lamp sockets require a wire in the harness to supply body
ground to the lamp socket. Lamp sockets that are exposed to moisture should be coated with MoparT Multi-purpose
Grease or equivalent to avoid corrosion. If a socket has become corroded, clean the socket and bulb base with an
abrasive fiber sanding pad or metallic bristle brush. Replace sockets and bulbs that are deformed from corrosion
that could prevent a continuous body ground.
Wire connectors can make intermittent contact or become corroded. Before coupling wire connectors, inspect the
terminals inside the connector. Male terminals should not be bent or disengaged from the insulator. Female termi-
nals should not be sprung open or disengaged from the insulator. Bent and sprung terminals can be repaired using
needle nose pliers and pick tools. Corroded terminals appear chalky or green. Corroded terminals should be
replaced to avoid recurrence of intermittent connections or other problem symptoms. Wire connector terminals
should be coated with MoparT Multi-purpose grease or equivalent to avoid corrosion.
Begin electrical system failure diagnosis by testing related fuses and circuit breakers in the fuse block and engine
compartment. Verify that bulbs are in good condition and test continuity of the circuit ground.
OPERATION
The exterior lighting system lamps are actuated through a series of controls, switches, relays and circuitry. Fuse 32
in the Underhood Accessory Fuse Block powers the system. All brake lamps, both high and low beam headlamps,
turn signal lamps, fog lamps, backup lamps, marker lamps and license plate lamps are individually protected by
fuses within the illumination control module. The headlamp switch is part of the illumination control module and is
located behind a cover at the end of the instrument panel on the driver side.

LAMPS/LIGHTING - EXTERIOR
EXTERIOR LAMPS
WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL
INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb
life will result. Do not use bulbs other than those indicated in the Bulb Application table. Damage to lamp
and/or Illumination Control Module can result. Do not use fuses, circuit breakers or relays having greater
amperage value than indicated on the fuse panel or in the Owner’s Manual.
When a vehicle experiences problems with the exterior lamp system, verify the condition of the battery connections,
fuses, charging system, wire connectors, multifunction switch and headlamp switch.
Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation.
Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate
ground wire.
When changing bulbs, check the socket for loose pin connections and/or evidence of corrosion. Repair as neces-
sary.
When it is necessary to remove a component to service another, it should not be necessary to apply excessive
force to bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured
edges are not holding the component in place.
HEADLAMPS
If a vehicle experiences problems with the headlamp system, verify the following are in operational condition:
• Battery connections
• Charging system
• Headlamp bulbs
• High beam dimmer switch
• Headlamp switch
• Wiring harness connectors
For complete headlamp and exterior lighting diagnosis, see exterior lighting electrical diagnostics section.
HEADLAMP DIAGNOSIS

HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery
WITH ENGINE IDLING OR cable clamps and posts.
IGNITION TURNED OFF
2. Loose or worn generator drive 2. Adjust or replace generator
belt. drive belt.
3. Charging system output too low. 3. Test and repair charging
system.
4. Battery has insufficient charge. 4. Test battery state-of-charge.
5. Battery is sulfated or shorted. 5. Load test battery.
6. Both headlamp bulbs are 6. Replace both headlamp
defective. bulbs.
HEADLAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging
OUT FREQUENTLY system.
2. Loose or corroded terminals or 2. Inspect and repair all

splices in circuit. connectors and splices.
HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging
WITH ENGINE RUNNING system.
ABOVE IDLE
2. Both headlamp bulbs defective. 2. Replace both headlamp
bulbs.
HEADLAMPS FLASH 1. Faulty headlamp switch. 1. Replace headlamp switch.

RANDOMLY
2. Loose or corroded terminals or 2. Inspect and repair all
splices in circuit. connectors and splices.
HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Check fuse. If good, repair

ILLUMINATE open headlamp circuit.
2. No ground at headlamps. 2. Repair circuit ground.
3. Faulty headlamp switch. 3. Replace headlamp switch.
SPECIFICATIONS - EXTERIOR LAMPS

CAUTION: Do not use bulbs other than those listed in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced.
BULB APPLICATION TABLE
LAMP BULB
Backup Lamp 21W
Front Fog Lamp HB4 55W
Front Marker Lamp W5W
Front Position Lamp W5W
Front Turn Signal Y21W
Headlamp-High Beam 12V55W H7U
Headlamp-Low Beam 12V55W H7U
Rear Marker Lamp W5W
Turn Signal Lamp Y21W
Tail/Stop Lamp 21/5W
BACKUP LAMP
REMOVAL
2. Remove the access panel in the interior trim panel.
3. Rotate the backup lamp socket (1) counterclockwise and
pull it from the rear lamp unit.
4. Remove the bulb from backup lamp socket.
INSTALLATION
1. Install the bulb (2) into the backup lamp socket (1).
2. Insert the backup lamp socket (1) into the rear lamp unit
(4) and rotate clockwise to lock.
3. Install the access panel into the interior trim panel.
BACKUP LAMP SWITCH

DESCRIPTION
BACKUP LAMP SWITCH (Manual Transmission)
The backup lamp switch (2) for manual transmission models is
mounted directly on the outside housing of the transmission.
For complete backup lamp switch removal procedures, see
back up lamp switch removal in the manual transmission sec-
tion. Refer to Page 21-353.
BACKUP LAMP SWITCH (Automatic

Transmission)
The backup lamp switch for automatic transmission models is
an integrated component and function of the shifter mecha-
nism (4) and cannot be adjusted, or repaired. If faulty, worn or
damaged, the entire shifter mechanism assembly must be
replaced. For complete backup lamp switch removal proce-
dures, see shifter mechanism removal in the automatic trans-
mission section. Refer to Page 21-340.
BRAKE LAMP RELAY

DESCRIPTION
The brake lamp relay is located in the underhood accessory fuse block in the engine compartment. The brake lamp
relay is a micro relay and is contained within a small, rectangular, molded plastic housing. All of the required inputs
and outputs are connected to 9 blades that extend from the bottom of the relay base.
OPERATION
The brake lamp relay uses a low current input from the illumination control module to control a high current output
to the brake lamps. When the relay coil is energized, an electromagnetic field is produced by the coil windings. The
field draws the moveable relay contact point away from the fixed normally open contact point and holds it against
the fixed normally closed contact point.
The brake lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the
underhood accessory fuse block.
REMOVAL
2. Remove the underhood accessory fuse block cover and
relay cover panel.
3. Pull upward on the brake lamp relay (1) and remove it from
the underhood accessory fuse block.
INSTALLATION
1. Insert the brake lamp relay into the underhood accessory fuse block.
2. Install the relay cover panel and the underhood accessory fuse block cover.
BRAKE LAMP SWITCH

DESCRIPTION
The plunger type brake lamp switch is mounted to a bracket attached to the brake pedal assembly under the instru-
ment panel. The brake lamp switch cannot be adjusted or repaired. If faulty, worn, or damaged, the entire unit must
be replaced.
OPERATION
The brake lamp switch has three internal switches with a single, six blade harness connection at one end. When the
brake pedal is in the released position, the plunger on the outside of the brake lamp switch is forced inward, which
opens the circuit. When the brake pedal is pressed the plunger is released, and the circuit is closed. This action
completes the brake lamp circuit, and allows the brake lamps and center high mounted brake lamp to illuminate.
REMOVAL
2. Remove the lower instrument panel cover (5). Refer to
Page 23-149.
3. Disconnect the brake lamp switch harness connectors (1).

4. Press the locking tab (2) and rotate the brake lamp switch
(4) clockwise.
5. Remove the brake lamp switch (4) from the brake pedal
brace (3).
INSTALLATION
1. Install the brake lamp switch into the brake pedal brace (2)
and rotate counterclockwise to stop.
2. Connect the brake lamp switch harness connector (1).
3. Install the lower instrument panel cover. Refer to Page
23-155.
CENTER HIGH MOUNTED STOP LAMP

DESCRIPTION
The center high mounted stop lamp (CHMSL) uses LED’s for illumination, they cannot be adjusted or repaired. If
faulty or damaged, the entire CHMSL assembly must be replaced. For complete CHMSL removal procedures, see
center high mounted stop lamp removal in this section. For complete CHMSL system wiring information and diag-
nosis, see exterior lamps/lighting electrical diagnostics also in this section.
REMOVAL
2. Remove the liftgate interior trim panel. Refer to Page
23-48.
3. Remove the retaining screws (2) from the liftgate.
4. Disconnect the center high mounted stop lamp (CHMSL)
harness connector (3).
5. Slide the CHMSL assembly (1) outward and remove from
the liftgate.
INSTALLATION
1. Insert the center high mount stop lamp (CHMSL) assembly
into the liftgate, install the retaining screws and tighten.
2. Connect the CHMSL harness connector.
FOG LAMP
REMOVAL
3. Rotate the steering wheel fully in one direction and open
the access panel (1) in the front inner fender liner.
4. Remove the fog lamp harness connector (1) from the fog
lamp bulb (2).
5. Rotate the fog lamp bulb (2) counterclockwise and remove
from the fog lamp unit (3).
INSTALLATION
1. Insert and rotate the fog lamp bulb (2) clockwise into the
fog lamp unit (3).
2. Connect the fog lamp harness connector (1) to the fog
lamp bulb (2).
3. Close the access panel (1) in the front inner fender liner.
FOG LAMP UNIT

REMOVAL
3. Remove the lower engine splash shield retaining nuts (1),
and remove the splash shield.
4. Disconnect the fog lamp harness connector (2) from the fog
lamp bulb (1).
5. Remove the fog lamp unit attachment bolts (3) and remove
the fog lamp unit from the fascia panel.
INSTALLATION
1. Position the fog lamp unit into the fascia panel.
2. Insert the fog lamp unit attachment bolts (1) and secure.
3. Connect the fog lamp harness connector to the fog lamp
bulb (2).
4. Install the lower engine splash shield.
FRONT POSITION LAMP

DESCRIPTION
All vehicles are equipped with front position lamps (1). One
front position lamp is incorporated into each of the headlamp
units. These lamps utilize a clear lens and clear bulb, and
function in the same way as parking lamps. The front position
lamp is built into the headlamp, and therefore does not require
its own lamp housing.
OPERATION
The front position lamps are turned on or off with the headlamp switch. These lamps function in the same way that
parking lamps do. The bulbs for the front position lamps are serviceable when the headlamp unit is removed, how-
ever they cannot be adjusted. If the housing is faulty, worn, or damaged, the entire headlamp unit must be replaced.
REMOVAL
2. Remove the headlamp unit. Refer to Page 8L-103.
3. Rotate the front position lamp socket (1) counterclockwise
and pull the bulb from the socket.
INSTALLATION
1. Press the front position lamp bulb into the socket and insert
it into the headlamp unit (1), rotating clockwise to lock.
2. Install the headlamp unit. Refer to Page 8L-104.
FRONT TURN SIGNAL LAMP

REMOVAL
3. Rotate the turn signal bulb housing (1) counterclockwise
and remove from the headlamp unit (2). Remove the bulb
from the bulb housing.
INSTALLATION
1. Insert the turn signal bulb (2) into the bulb housing (1) and
install into the headlamp unit (3) by rotating clockwise.
HAZARD FLASHER
DESCRIPTION
The hazard flasher (1) is integrated within the hazard switch
assembly (2) and cannot be adjusted or repaired. If faulty,
worn, or damaged, the entire hazard switch assembly must be
replaced. For complete hazard switch removal procedures, see
hazard switch removal in this section. Refer to Page 8L-100.
HAZARD SWITCH
DESCRIPTION
The hazard switch (1) is actuated by a push button located in
the center of the instrument panel directly below the radio. The
hazard switch is identified with a triangular shape and is red in
color. Push and release the button (1) to turn the hazard func-
tion ON or OFF. When pushed, the button will move out from
the panel in the ON position and remain in toward the panel in
the OFF position.
OPERATION
Push and release the hazard switch to turn the hazard function ON or OFF. The button will move out from the
center console panel when in the ON position, and will remain in toward the center console panel when in the OFF
position.
REMOVAL
ABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR INSTRU-
AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE

2. Remove the center console cover. Refer to Page 23-173.
3. Disconnect the center console switch harness connectors
(1) and press the locking tabs to remove the outer gang of
switches.
4. Press the hazard switch locking tabs and remove the haz-
ard switch (2) from the center console cover (1).
INSTALLATION
1. Insert the hazard switch (1) into the center console cover
(2) and press to engage the locking tabs.
2. Install the outer gang of switches into the center console
cover and press to engage the locking tabs.
3. Connect the center console switch harness connectors.
4. Install the center console cover. Refer to Page 23-183.

HEADLAMP
DESCRIPTION
The headlamp units are unique and modular in design. The headlamp unit contains four separate bulbs:
• Low Beam Lamp
• High Beam Lamp
• Front Position Lamp
• Front Turn Signal Lamp
OPERATION
The headlamps and front position lamps are controlled by the illumination control module, which contains a dedi-
cated headlamp switch. The turn signal lamps are controlled by the multifunction switch. The headlamps are ser-
viceable separately. For complete exterior lamp replacement procedures, see exterior lamps/lighting removal
procedures in this section.
REMOVAL
LOW BEAM BULB
3. Remove the headlamp bulb access plug.
4. Disconnect the headlamp bulb harness connector (2).
5. Disengage the bulb retaining clip (1) and remove the bulb
from the headlamp unit.
REMOVAL - HIGH BEAM BULB

3. Remove the headlamp bulb access plug.

4. Disconnect the headlamp bulb harness connector (1).
5. Disengage the bulb retaining clip (2) and remove the bulb
(3) from the headlamp unit.
INSTALLATION
LOW BEAM BULB
1. Install the headlamp bulb (1) into the headlamp unit (2) and
engage the retaining clip (3).
2. Connect the headlamp bulb harness connector.
3. Install the headlamp bulb access plug.
INSTALLATION - HIGH BEAM BULB

1. Install the headlamp bulb (3) into the headlamp unit and
engage the retaining clip (2).
2. Connect the headlamp bulb harness connector (1).
3. Install the headlamp bulb access plug.
HEADLAMP SWITCH
DESCRIPTION
The headlamp switch is part of the illumination control module. A knob on the face of the module controls exterior
lighting functions. The exterior lighting and headlamp switch portions of the illumination control module cannot be
adjusted or repaired. If faulty or damaged, the entire module assembly must be replaced as a unit.
OPERATION
The headlamp switch has an off, parking lamp, fog lamp, and headlamp on position. High beam headlamps are
controlled by the fore/aft movement of the multi function switch stalk. The fog lamps are activated by pulling rear-
ward on the headlamp switch knob.
REMOVAL

2. Remove the lower instrument panel. Refer to Page 23-149.
3. Unlock and disconnect the harness connectors (4) on the

rear of the headlamp switch.
4. Remove the headlamp switch interior trim panel (2).
5. Remove the headlamp switch attachment screws (3) and
(5).
6. Remove the headlamp switch from the lower instrument
panel.
INSTALLATION
1. Position the headlamp switch into the lower instrument

panel (1).
2. Install the headlamp switch attachment screws (1) and (2),

and secure.
3. Install the headlamp switch interior tram panel.
4. Connect the harness connectors at the rear of the head-
lamp switch and lock to secure.
5. Install the lower instrument panel. Refer to Page 23-155.
HEADLAMP UNIT
DESCRIPTION
The headlamp unit is a housing that integrates separate bulbs
for low beam (3) and high beam (1) headlamps. It also
includes the turn signal (2) and front position (6) bulbs as well.
The low beam, high beam and turn signal bulbs are enclosed
with access covers for protection. One single harness connec-
tor (5) supplies ground and power from fuses within the illumi-
nation control module/IP fuse block.
The entire headlamp unit is mounted onto the front of the core
support structure and aimed with built in adjustment screws
(4).
REMOVAL
2. Remove the headlamp unit upper retaining bolts (1).
3. Open the access panel in the inner fender well.
4. Remove the lower headlamp unit retaining bolts (2).
5. Lift the headlamp unit from the front fascia and disconnect
the harness connector and the front position lamp socket.
INSTALLATION
1. Install the front position lamp socket and the headlamp unit
harness connector.
2. Position the headlamp unit into the fascia area.
3. Install the upper retaining bolts (1) finger tight.
4. Install the lower retaining bolts finger tight.
5. Tighten all retaining bolts to torque specification.
6. Close the access panel in the inner fender well.
LICENSE PLATE LAMP

REMOVAL

2. Open the liftgate and remove the license plate lamp lens attachment screws (3).
3. Remove the license plate lamp lens (2) and pull the bulb (1) outward from the lamp socket.
INSTALLATION
1. Insert the bulb into the lamp socket and place the license
plate lamp lens (2) into position.
2. Install the attachment screws and secure. Close the liftgate.
MARKER LAMP
REMOVAL
REAR MARKER LAMP
2. Insert a trim stick (2) at the front edge of the rear marker
lamp lens (1), gently depress rearward and lift out from the
fascia.
3. Rotate the socket counterclockwise and remove the rear
marker lamp bulb from the socket.
REMOVAL - FRONT MARKER LAMP

2. Insert a trim stick (2) at the rear edge of the front marker
lamp lens (1), gently depress forward and lift out from the
fascia.
3. Rotate the socket counterclockwise and remove the front
marker lamp bulb from the socket.
INSTALLATION
REAR MARKER LAMP
1. Insert the rear marker bulb into the socket (1) and rotate
clockwise into the rear marker lamp lens (2).
2. Install the back edge of the rear marker lamp lens first into
the fascia (3), then press the forward edge in at the front.
INSTALLATION - FRONT MARKER LAMP

1. Insert the front marker bulb into the socket (1) and rotate
clockwise into the front marker lamp lens (3).
2. Install the forward edge of the front marker lamp lens first
into the fascia (2), then press the rear edge in at the back.
MULTI-FUNCTION SWITCH
REMOVAL
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR, SIDE
PERSONAL INJURY.

3. Remove the clockspring. Refer to Page 8O-94.
5. Remove the screw (1) attaching the speed control switch to
the multifunction switch.
6. Remove the bracket below the speed control switch.
7. Remove the screws (2) attaching the multifunction switch to
the steering column.
8. Disconnect the multifunction switch harness connectors.

9. Remove the wire harness from the steering column.
10. Remove the multifunction switch from the steering column.
INSTALLATION
1. Install the multifunction switch to the steering column.

2. Install the wire harness to the steering column.
3. Connect the multifunction switch harness connectors.
4. Install the screws (2) attaching the multifunction switch to
the steering column.
5. Install the bracket on the top of the multifunction switch.
6. Install the screw (1) attaching the speed control switch to
the multifunction switch.
8. Install the clockspring. Refer to Page 8O-96.
TAIL LAMP UNIT

REMOVAL
TAIL LAMP UNIT
2. Remove the access panel from the cargo area interior trim
panel.
3. Disconnect the tail lamp unit harness connector (2), and
remove the retaining nuts (1).
REMOVAL - TAIL/STOP
panel.
3. Rotate the tail/stop lamp socket (2) counterclockwise and
pull it from the tail lamp unit (1).
4. Remove the bulb from tail/stop lamp socket (2).
REMOVAL - TURN SIGNAL

panel.
3. Rotate the turn signal lamp socket (2) counterclockwise and
pull it from the tail lamp unit (1).
4. Remove the bulb from turn signal lamp socket (2).
INSTALLATION
TAIL LAMP UNIT
1. Insert the tail lamp unit into the rear body panel (1) and
install the retaining nuts.
2. Connect the harness connector and install the access panel
into the rear cargo area interior trim panel.
INSTALLATION - TAIL/STOP
1. Install the bulb (2) into the tail/stop lamp socket (1).
2. Insert the tail/stop lamp socket (1) into the tail lamp unit (3)
and rotate clockwise to lock.
3. Install the access panel into the cargo area interior trim
panel.
INSTALLATION - TURN SIGNAL

1. Install the bulb (2) into the turn signal lamp socket (1).
2. Insert the turn signal lamp socket (1) into the tail lamp unit
(3) and rotate clockwise to lock.
3. Install the access panel into the cargo area interior trim
panel.
ZH LAMPS/LIGHTING - INTERIOR - ELECTRICAL DIAGNOSTICS 8L - 117
LAMPS/LIGHTING - INTERIOR - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR - ELECTRICAL *CARGO LAMP INOPERATIVE . . . . . . ... . . 124

DIAGNOSTICS *GLOVE BOX LAMP INOPERATIVE . . ... . . 127
DIAGNOSIS AND TESTING *ASH RECEIVER LAMP INOPERATIVE .. . . 130
HAZARD SWITCH CIRCUIT . . . . . . . . . . . . . 118 BODY VERIFICATION TEST ....... ... . . 133
DOME LAMP CIRCUIT . . . . . . . . . . . . . . . . . 121 SCHEMATICS AND DIAGRAMS ...... ... . . 134
LAMPS/LIGHTING - INTERIOR - ELECTRICAL DIAGNOSTICS

8L - 118 LAMPS/LIGHTING - INTERIOR - ELECTRICAL DIAGNOSTICS ZH
HAZARD SWITCH CIRCUIT
HAZARD SWITCH CIRCUIT — CONTINUED
• Set Condition: The Body Control Module (BCM) reports a short to power, ground, or an open on the
Hazard Switch circuit.
POSSIBLE CAUSES
HAZARD SWITCH CIRCUIT SHORT TO VOLTAGE

HAZARD SWITCH CIRCUIT SHORT TO GROUND
HAZARD SWITCH CIRCUIT OPEN
BODY CONTROL MODULE INTERNAL FAILURE
For a complete Interior Lamps Circuit Diagram, Refer to Page 8L-134.
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE HAZARD SWITCH CIRCUIT

Disconnect the Console Switch Group harness connector.
Measure the resistance of the Hazard Switch circuit between the BCM
harness connector and the Console Switch Group harness connector.

Yes >> Go to 2
No >> Repair the Hazard Switch circuit for an open.
2. MEASURE THE VOLTAGE OF THE HAZARD SWITCH CIRCUIT

Measure the voltage of the Hazard Switch circuit between the Console
Switch Group harness connector and Ground.
Is voltage present?
Yes >> Repair the Hazard Switch circuit for a short to battery.
No >> Go to 3
HAZARD SWITCH CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE HAZARD SWITCH CIRCUIT
Measure the resistance of the Hazard Switch circuit between the Console
Switch Group harness connector and ground.

Yes >> Repair the Hazard Switch circuit for a short to ground.
8E-72.
DOME LAMP CIRCUIT
DOME LAMP CIRCUIT — CONTINUED
• Set Condition: The Body Control Module (BCM) reports a short to power, ground, or an open on the
Dome Lamp circuit.
POSSIBLE CAUSES
DOME LAMP CIRCUIT SHORT TO VOLTAGE

DOME LAMP CIRCUIT SHORT TO GROUND
DOME LAMP CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE DOME LAMP CIRCUIT

Disconnect the Dome Lamp harness connector.
Measure the resistance of the Dome Lamp circuit between the BCM har-
ness connector and the Dome Lamp harness connector.

Yes >> Go to 2
No >> Repair the Dome Lamp circuit for an open.
2. MEASURE THE VOLTAGE OF THE DOME LAMP CIRCUIT

Measure the voltage of the Dome Lamp circuit between the Dome Lamp
harness connector and Ground.
Is voltage present?
Yes >> Repair the Dome Lamp circuit for a short to battery.
No >> Go to 3
DOME LAMP CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE DOME LAMP CIRCUIT
Measure the resistance of the Dome Lamp circuit between the Dome
Lamp harness connector and ground.

Yes >> Repair the Dome Lamp circuit for a short to ground.
8E-72.
*CARGO LAMP INOPERATIVE
*CARGO LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
CARGO LAMP BULB
Diagnostic Test
1. INSPECT THE CARGO LAMP BULB

Note: If any BCM DTCs are set, diagnose them first before continu-
ing.
Remove the Cargo Lamp Bulb and inspect for an open filament.

Yes >> Replace the Cargo Lamp bulb. Refer to Page 8L-137.
No >> Go to 2
2. MEASURE CARGO LAMP VOLTAGE

Disconnect the Cargo Lamp harness connector.
Measure the voltage between ground and the Cargo Lamp harness con-
nector cavity 2.

Yes >> Go to 3
*CARGO LAMP INOPERATIVE — CONTINUED
3. MEASURE CARGO LAMP GROUND CIRCUIT RESISTANCE
Disconnect the Dome Lamp harness connector.
Measure the resistance from the Cargo Lamp harness connector cavity 1
to the Dome Lamp harness connector cavity 1.

Yes >> Replace the Dome Lamp. Refer to Page 8L-140.
No >> Repair the open circuit between the Cargo Lamp and
the Dome Lamp.
*GLOVE BOX LAMP INOPERATIVE
*GLOVE BOX LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
GLOVE BOX LAMP BULB
Diagnostic Test
1. INSPECT THE GLOVE BOX LAMP BULB

ing.
continuing.
Remove the Glove Box Lamp Bulb and inspect for an open filament.

Yes >> Replace the Glove Box Lamp bulb. Refer to Page 8L-146.
No >> Go to 2
2. MEASURE GLOVE BOX LAMP VOLTAGE

Disconnect the Glove Box Lamp harness connector.
Measure the voltage between ground and the Glove Box Lamp harness
connector cavity 2.

Yes >> Go to 3
*GLOVE BOX LAMP INOPERATIVE — CONTINUED
3. MEASURE GLOVE BOX LAMP GROUND CIRCUIT RESISTANCE
Measure the resistance between ground and the Glove Box Lamp harness
connector cavity 1.

Yes >> Replace the Glove Box Lamp. Refer to Page 8L-146.
No >> Repair the Glove Box Lamp ground circuit for an
open.
*ASH RECEIVER LAMP INOPERATIVE
*ASH RECEIVER LAMP INOPERATIVE — CONTINUED
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
ASH RECEIVER LAMP BULB
Diagnostic Test
1. INSPECT THE ASH RECEIVER LAMP BULB

ing.
before continuing.
Remove the Ash Receiver Lamp Bulb and inspect for an open filament.

Yes >> Replace the Ash Receiver Lamp bulb. Refer to Page
23-173.
No >> Go to 2

Disconnect the Ash Receiver Lamp harness connector.
Measure the resistance of the Fused B(+) circuit from the Ash Receiver
Lamp harness connector to the Illumination Control Module harness con-
nector.

Yes >> Go to 3
Ash Receiver Lamp and the Illumination Control Module.
*ASH RECEIVER LAMP INOPERATIVE — CONTINUED
3. MEASURE ASH RECEIVER LAMP VOLTAGE
Turn the parking lamps on.
Measure the voltage between the Ash Receiver Lamp harness connector

Yes >> Go to 4
8L-105.
4. MEASURE ASH RECEIVER LAMP GROUND CIRCUIT RESISTANCE

Turn the parking lamps off.
Measure the resistance between the Ash Receiver Lamp harness connec-

Yes >> Ensure that the Ash Receiver Lamp bulb is installed prop-
No >> Repair the Ash Receiver Lamp ground circuit for an
open.
1.

INTERIOR LIGHTING CIRCUIT DIAGRAM (1 OF 2)

INTERIOR LIGHTING CIRCUIT DIAGRAM (2 OF 2)

8L - 136 LAMPS/LIGHTING - INTERIOR - SERVICE INFORMATION ZH
LAMPS/LIGHTING - INTERIOR - SERVICE INFORMATION
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR - SERVICE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 144

INFORMATION REMOVAL
DIAGNOSIS AND TESTING - LAMPS/ DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . 145
LIGHTING-INTERIOR . . . . . . . . . . . . . . . . . . 136 REMOVAL - LIFTGATE AJAR SWITCH . . . . . 145
SPECIFICATIONS - INTERIOR LAMPS . . . . . . 137 INSTALLATION
CARGO LAMP DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . 146
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 INSTALLATION - LIFTGATE AJAR SWITCH . 146
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138 GLOVE BOX LAMP
CARGO LAMP UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140 GLOVE BOX LAMP/SWITCH
COURTESY LAMP DESCRIPTION ...................... . . 148
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
COURTESY LAMP DEFEAT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 149
DESCRIPTION .................. . . . . . . 141 HEATER SWITCH ILLUMINATION
COURTESY LAMP SWITCH/UNIT DESCRIPTION ...................... . . 150
DESCRIPTION .................. . . . . . . 142 T/C RANGE INDICATOR ILLUMINATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 142 DESCRIPTION ...................... . . 150
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 ASH RECEIVER LAMP
DIMMER SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153
DESCRIPTION .................. . . . . . . 144
DOOR AJAR SWITCH
DESCRIPTION .................. . . . . . . 144
LAMPS/LIGHTING - INTERIOR - SERVICE INFORMATION

DIAGNOSIS AND TESTING - LAMPS/LIGHTING-INTERIOR
WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL
INJURY CAN RESULT.
CAUTION: Do not use bulbs other than those indicated in the Bulb Application table. Damage to lamp
and/or Illumination Control Module can result. Do not use fuses, circuit breakers or relays having greater
amperage value than indicated on the fuse panel or in the Owner’s Manual.
If a vehicle experiences problems with the interior lighting system, verify the following are in operational condition:
• Battery connections
• Charging system
• Interior lamp bulbs
• Illumination Control Module/Headlamp switch
• Wiring harness connectors
For complete interior lamp system schematics and diagrams, see interior lamps/lighting schematics and diagrams in
this section. Refer to Page 8L-134.
ZH LAMPS/LIGHTING - INTERIOR - SERVICE INFORMATION 8L - 137
Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation.
Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate
ground wire.
When diagnosing the interior lighting circuits, remember that high generator output can burn out bulbs rapidly and
repeatedly; and that dim or flickering bulbs can be caused by low generator output or poor battery condition.
When changing lamp bulbs, check the socket for loose pin connections and/or evidence of corrosion. Repair as
necessary.
When it is necessary to remove a component to service another, it should not be necessary to apply excessive
force to bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured
edges are not holding the component in place.
For additional interior lamp diagnosis, see interior lamp diagnostics in this section.
SPECIFICATIONS - INTERIOR LAMPS

CAUTION: Do not use bulbs other than those listed in the Bulb Application Table. Damage to lamp can
result.
BULB APPLICATION TABLE
LAMP BULB
Cargo Lamp C5W
Cluster Illumination 12/2W 1K
12/1.5W
Courtesy Lamp C5W
Glove Box Lamp C5W
Heater Switch Illumination LED
T/C Range Indicator Illumination LED
CARGO LAMP
REMOVAL
2. Remove the cargo lamp unit (1). Refer to Page 8L-139.
3. Remove the bulb (1) from the cargo lamp unit (2).
INSTALLATION
1. Insert the bulb (1) into the cargo lamp unit (2).
2. Install the cargo lamp unit (2) into the liftgate trim (3).
Refer to Page 8L-140.
CARGO LAMP UNIT

REMOVAL
2. Gently pry the cargo lamp unit (1) away from the cargo
area interior trim panel (2).
3. Disconnect the cargo lamp unit harness connector (1) and

remove from the vehicle.
INSTALLATION
1. Connect the harness connector (1) into cargo lamp unit and
insert into the cargo area interior trim panel (2).
COURTESY LAMP
REMOVAL
1. Remove the courtesy lamp switch/unit from the roof frame.
2. Rotate the lamp socket (1) counterclockwise in the courtesy
lamp switch/unit and remove.
3. Remove the bulb from the lamp socket.
INSTALLATION
1. Insert the bulb into the lamp socket.
2. Install the lamp socket into the courtesy lamp switch/unit by
rotating clockwise.
3. Install the courtesy lamp switch/unit to the roof frame.

COURTESY LAMP DEFEAT SWITCH

DESCRIPTION
With the courtesy lamp defeat switch in the “O” position (1),
the courtesy lamps are prevented from illuminating when the
doors are opened. With the courtesy lamp defeat switch in the
“—” position, the courtesy lamps illluminate when the doors
are opened, then fade to off after approximately 8 second-
s.The courtesy lamp defeat switch is an integrated part of the
courtesy lamp unit assembly and cannot be adjusted or
repaired. If faulty, worn, or damaged, the entire assembly must
be replaced. For complete courtesy lamp unit removal proce-
dures, see courtesy lamp unit removal in this section. Refer to
Page 8L-142.
COURTESY LAMP SWITCH/UNIT

DESCRIPTION
The courtesy lamps (1) provide overhead interior illumination
when the doors are opened and the courtesy lamp defeat
switch (3) in the “—” position, or when the courtesy lamp
switch (2) is pressed. The courtesy lamp defeat switch (3) can
prevent the courtesy lamps operation when the doors are
opened if the “O” position is selected. The courtesy lamp
switch/unit cannot be adjusted or repaired. If faulty, worn, or
damaged, the entire assembly must be replaced. For complete
courtesy lamp switch/unit removal procedures, see courtesy
lamp switch/unit removal in this section.
OPERATION
Regardless of the ignition switch position, the courtesy lamps illuminate when either door is opened if the courtesy
lamp defeat switch is in the “—” position, or the courtesy lamp switch is pressed. Non-switched power is supplied
through Fuse 9 in the Underhood Accessory Fuse Block, and ground is provided by the Body Control Module.
REMOVAL
2. Using a trim stick (1) press the clips located on the edge of
the courtesy lamp switch/unit body (2) and release the lens
cover.
3. Remove the retaining screws and lower the courtesy lamp

switch/unit from the headliner opening.
4. Disconnect the courtesy lamp switch/unit harness connector
and remove from the vehicle.
INSTALLATION
1. Connect the courtesy lamp switch/unit harness connector
(1) and align into the headliner opening.
2. Install the retaining screws and secure.
3. Install the lens cover into the courtesy lamp switch/unit
body.
DIMMER SWITCH
DESCRIPTION
The dimmer switch (3) is an integrated part of the instrument
cluster and is located at the left side of the speedometer. It
controls the brightness of the adjustable interior illumination
when rotated to the left or right. The dimmer switch cannot be
repaired. If it is found faulty or damaged, the entire instrument
cluster must be replaced. For complete instrument cluster
removal procedures, see instrument cluster removal in the
electrical section. Refer to Page 8J-83.
DOOR AJAR SWITCH

DESCRIPTION
There are three door ajar switches, one at each door and one in the liftgate latch. The door switches are located in
the B-pillar directly below the latch striker plate, and the liftgate switch is integral to the liftgate latch assembly. A
door or body harness connector with a service loop connects each switch to the vehicle electrical system. The door
ajar switches cannot be adjusted or repaired, and if faulty or damaged, the switch itself or the liftgate latch must be
replaced as an assembly. For complete door ajar switch removal procedures, see the appropriate removal proce-
dure in this section.
OPERATION
The door ajar switches are actuated by either the door closing against the jamb, or the liftgate latch mechanism
striker plate. When a door or the liftgate is closed and properly latched, its ajar switch is an open circuit. When a
door or the liftgate is only partially latched, its ajar switch is a closed circuit. The ajar switches are connected via a
harness connector to a body ground and the central locking pump/security system module.
REMOVAL
DOOR AJAR SWITCH
2. Using a trim stick, press and release the retaining tab (1) at
the top of the door ajar switch.
3. Pull the top of the door ajar switch out and downward away
from the B-pillar (2), then disconnect the door ajar switch
harness connector.
REMOVAL - LIFTGATE AJAR SWITCH

The liftgate ajar switch (1) is an integral part of the liftgate
handle assembly and cannot be adjusted or repaired. If faulty,
worn, or damaged, the entire liftgate handle assembly must be
replaced. For complete liftgate handle removal procedures,
see liftgate handle removal in the body section. Refer to Page
23-34.
INSTALLATION
DOOR AJAR SWITCH
1. Connect the door ajar switch harness connector (1).
2. Install the lower edge of the door ajar switch into the B-pil-
lar opening (2) first, then rotate upward until fully seated.
INSTALLATION - LIFTGATE AJAR SWITCH

The liftgate ajar switch is an integral part of the liftgate handle
assembly. For complete liftgate handle installation procedures,
see liftgate handle installation in the body section of this man-
ual. Refer to Page 23-37.
GLOVE BOX LAMP

REMOVAL
1. Remove the glove box lamp/switch assembly. Refer to

Page 8L-148.
2. Press the bulb retaining arm aside and remove the bulb (1)
from the glove box lamp/switch (2).
INSTALLATION
1. Press the bulb retaining arm (2) aside and install the bulb
(1) into the glove box lamp/switch assembly.
2. Install the glove box lamp/switch assembly. Refer to Page
8L-149.
GLOVE BOX LAMP/SWITCH

DESCRIPTION
The glove box lamp/switch (1) is a self-contained set of
switches, lamp, and housing assembly that provides illumina-
tion into the glove box compartment whenever the glove box
door is opened. It is located behind the glove box door at the
top of the liner, just to the left of the latch striker.
OPERATION
The glove box lamp/switch contains two separate switches; one for control of the illumination, and the other to
sense the glove box door position. Power is supplied through fuse 31 in the Underhood Accessory Fuse Block for
the lamp illumination switch. The central locking pump/security system module receives a ground signal from the
second switch when the glove box is opened. Neither of these switches can be adjusted or repaired. If faulty, worn,
or damaged, the entire glove box lamp/switch assembly must be replaced. For complete glove box lamp/switch
removal procedures, see glove box lamp/switch removal in this section.
REMOVAL

2. Open the glove box door and depress the lens retaining
clips with a trim stick (1). Gently pry the glove box lamp/
switch (2) from the glove box liner (3).
3. Disconnect the glove box lamp/switch harness connector
and remove the glove box lamp/switch (2) from the vehicle.
INSTALLATION
1. Connect the glove box lamp/switch harness connector (1).

2. Insert the glove box lamp/switch (2) into the opening in the
glove box liner and close the glove box door.
HEATER SWITCH ILLUMINATION

DESCRIPTION
The heater switch (3) is illuminated with LEDs whenever the
headlamps or marker lamps are on. The lamp brightness is
adjustable with the dimmer switch located in the instrument
cluster. The heater switch LEDs cannot be adjusted or
repaired. If faulty or damaged, the entire heater switch assem-
bly must be replaced as a unit. For complete heater switch
removal procedures, see heater control removal in the heating
and air conditioning section. Refer to Page 24-79.
T/C RANGE INDICATOR ILLUMINATION

DESCRIPTION
The T/C range indicator is illuminated with LEDs whenever the
headlamps or marker lamps are on. The lamp brightness is
adjustable with the dimmer switch located in the instrument
cluster. The T/C range indicator LEDs cannot be adjusted or
repaired. If faulty or damaged, the entire T/C range indicator
assembly must be replaced as a unit. For complete T/C range
indicator removal procedures, see shift mechanism removal in
the automatic transmission section. Refer to Page 21-340.
ASH RECEIVER LAMP

REMOVAL
1. Remove the cover on the center console. Refer to Page
23-173.
2. Remove the screws (1-3) attaching the ashtray (2) to the

center console.
3. Press the ashtray housing (1) to the left and remove it

toward the right (arrows).
4. Disconnect the ashtray harness connector for the courtesy

lamp on the back of the ashtray (1).
5. Remove the ashtray lamp from the ashtray harness
connector.
INSTALLATION
1. Install the ashtray lamp into the ashtray lamp harness con-
nector.
2. Connect the ashtray lamp harness connector to the ashtray
(1).
3. Install the ashtray housing (1) to the right and push it

toward the left.
4. Install the screws (1-3) attaching the ashtray (2) to the cen-
ter console.
5. Install the cover (1) on the center console. Refer to Page

23-183.
ZH MESSAGE SYSTEMS 8M - 1
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
UNIVERSAL TRANSMITTER STANDARD PROCEDURE - UNIVERSAL

DESCRIPTION . . . . . . . . . .................1 TRANSMITTER PROGRAMMING . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . .................2 REMOVAL .............................3
DIAGNOSIS AND TESTING - UNIVERSAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMITTER . . . . . . . .................2
UNIVERSAL TRANSMITTER
DESCRIPTION
The Universal Garage Door Opener/Tire Pressure Monitor
Module (1) is located in the headliner near the inside rear view
mirror (2). The Tire Pressure Monitoring (TPM) system utilizes
a control module to monitor and operate the system. The con-
trol module also has a universal garage door opener inte-
grated along with it.
8M - 2 MESSAGE SYSTEMS ZH
The tire pressure monitoring system utilizes transmitters that

are located in the valve stem (1) of each tire (2) to communi-
cate the tire pressure condition to the module. If a tire has low
air pressure, an indicator light on the Instrument Cluster is illu-
minated. The vehicle operator must check the tire pressure of
each tire in order to determine which tire has a low pressure
condition.
OPERATION
The Universal Garage Door Opener/Tire Pressure Monitoring (TPM) module has a microprocessor controller that
can monitor the transmissions from the sensor/transmitters anytime the ignition is on. It can store the last 32 trans-
missions. There are two important values included in these transmissions. They are:
• Why the transmission was sent
• Low tire pressure
The module compares the transmitted tire pressure to the pressure threshold. If the module determines that the tire
pressure transmitted is below the low pressure thresholds, it will signal for the “Low Tire” pressure warning lamp to
come on.
The TPM module performs diagnostic routines, stores diagnostic trouble codes and provides the appropriate lamp
status to the Body Control Module (BCM). When the module determines there is a fault, the low tire pressure indi-
cator lamp circuit is grounded and the BCM turns on the “Low Tire Pressure” indicator lamp.
The UGDO/TPM module also stores its own identification number, module version and the date of manufacture.
DIAGNOSIS AND TESTING - UNIVERSAL TRANSMITTER

If the universal transmitter is inoperative, see the owner’s manual in the vehicle glove box for instructions on training
the universal transmitter. Retrain the transmitter using a known good remote as instructed in the owner’s manual
and test the transmitter operation again. If the transmitter is still inoperative, test the universal transmitter with a
Radio Frequency Detector special tool.
1. Turn the Radio Frequency (RF) Detector “ON”. A “chirp” will sound and the green power LED will light. If the
green LED does not light, replace the battery.
2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any one of the transmitter
buttons.
3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test three
times.
4. If a RF signal is not detected, replace the universal transmitter and reprogram as instructed in the owner’s
manual.
ZH MESSAGE SYSTEMS 8M - 3
STANDARD PROCEDURE - UNIVERSAL TRANSMITTER PROGRAMMING

ERASING CODES
To erase previously programmed Garage Door Opener codes, simply hold down the two outside buttons until the
red LED begins to flash.
PROGRAMMING CODES
1. Turn off the engine.
2. Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins
to flash.
3. Choose one of the three buttons to program. Place the manufacturer’s hand-held transmitter within one inch of
the vehicle Universal Garage Door Opener and push the buttons on both transmitters. The red light on the Uni-
versal Garage Door Opener will begin to flash slowly.
4. When the red light on the Universal Garage Door Opener begins to flash rapidly (this may take as long as 60
seconds), release both buttons. The Universal Garage Door Opener is now programmed. Advise the vehicle
owner to be sure to keep the manufacturer’s hand-held transmitter in case it is needed to reprogram the Uni-
versal Garage Door Opener.
REMOVAL
2. Using a plastic wedge, slide the wedge under the Universal
Garage Door Opener/Tire Pressure Monitor module and the
headliner and pry the Universal Garage Door Opener/Tire
Pressure Monitor module away from the headliner.
3. Disconnect the Universal Garage Door Opener/Tire Pres-
sure Monitor module harness connector.
8M - 4 MESSAGE SYSTEMS ZH
INSTALLATION
1. Connect the harness connector to the Universal Garage
Door Opener/Tire Pressure Monitor module.
2. Install the Universal Garage Door Opener/Tire Pressure
Monitor module by snapping it into the headliner.
ZH POWER SYSTEMS 8N - 1
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS - ELECTRICAL DIAGNOSTICS. . . . 1 POWER SEATS - SERVICE INFORMATION. . . . . . 95

POWER LOCKS - SERVICE INFORMATION . . . . . 30 POWER WINDOWS - ELECTRICAL
POWER MIRRORS - ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 109
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 52 POWER WINDOWS - SERVICE
POWER MIRRORS - SERVICE INFORMATION. . . 66 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 121
POWER SEATS - ELECTRICAL DIAGNOSTICS . . . 73
POWER LOCKS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
POWER LOCKS - ELECTRICAL DIAGNOSTICS CLP/SSM SYSTEM OVERVOLTAGE . . . . . . . 17

DIAGNOSIS AND TESTING NO COMMUNICATION WITH BODY
DRIVER DOOR LOCK ACTUATOR SLOW CONTROL MODULE AND CENTRAL
RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 LOCKING PUMP/SECURITY SYSTEM
FUEL DOOR LOCK ACTUATOR SLOW MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DOOR LOCK/DOOR UNLOCK SWITCH
PASSENGER DOOR/LIFTGATE LOCK SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 22
ACTUATOR SLOW RESPONSE . . . . . . . . . . . . 8 CENTRAL LOCKING PUMP/SECURITY
BODY CONTROL MODULE INTERNAL SYSTEM MODULE INTERNAL FAILURE . . . . 26
FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BODY VERIFICATION TEST . . . . . . . . . . . . . 28
CLP/SSM SYSTEM UNDERVOLTAGE . . . . . . 14 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 29
POWER LOCKS - ELECTRICAL DIAGNOSTICS

8N - 2 POWER LOCKS - ELECTRICAL DIAGNOSTICS ZH
DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE
ZH POWER LOCKS - ELECTRICAL DIAGNOSTICS 8N - 3
DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE — CONTINUED
• Set Condition: The Central Locking Pump/Security System Module (CLP/SSM) reports a short to power,
ground, or an open that is detected by the Body Control Module (BCM) on the Door Lock Switch Mux cir-
cuit. A pressure/vacuum leak in the Driver Door Lock Actuator/Pneumatic Line can also set this DTC.
POSSIBLE CAUSES
DOOR LOCK SWITCH MUX CIRCUIT SHORT TO VOLTAGE

DOOR LOCK SWITCH MUX CIRCUIT SHORT TO GROUND
DOOR LOCK SWITCH MUX CIRCUIT OPEN
DRIVER DOOR LOCK ACTUATOR/PNEUMATIC LINE LEAK
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE INTERNAL FAILURE
For a complete Power Locks Circuit Diagram, Refer to Page 8N-29.
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE DOOR LOCK SWITCH MUX

CIRCUIT

Measure the resistance of the Door Lock Switch Mux circuit from the BCM
harness connector to the Console Switch Group harness connector.

Yes >> Go to 2
No >> Repair the Door Lock Switch Mux circuit for an open.
2. MEASURE THE VOLTAGE OF THE DOOR LOCK SWITCH MUX

CIRCUIT

Measure the voltage of the Door Lock Switch Mux circuit at the Console
Switch Group harness connector.
Is voltage present?
Yes >> Repair the Door Lock Switch Mux circuit for a short to volt-
age.
No >> Go to 3
DRIVER DOOR LOCK ACTUATOR SLOW RESPONSE — CONTINUED
CIRCUIT

Measure the resistance between ground and the Door Lock Switch Mux
circuit at the BCM harness connector.

Yes >> Repair the Door Lock Switch Mux circuit for a short to
ground.
No >> Go to 4
4. INSPECT THE DRIVER DOOR LOCK ACTUATOR/PNEUMATIC LINE

FOR A PRESSURE/VACUUM LEAK
Connect the BCM harness connector.
Connect the Console Switch Group harness connector.
Actuate the Door Lock Switch and listen for an air leak from the Driver
Door Lock Actuator while locking and unlocking the doors. Also, visually
inspect the door and body routed pneumatic lines for damage.
Is the Driver Door Lock Actuator/Pneumatic line damaged or leak-

ing?
Yes >> Replace the Driver Door Lock Actuator or the leaking Pneu-
matic line.
No >> Replace the Central Locking Pump/Security System
Module. Refer to Page 8Q-48.
FUEL DOOR LOCK ACTUATOR SLOW RESPONSE
FUEL DOOR LOCK ACTUATOR SLOW RESPONSE — CONTINUED
cuit. A pressure/vacuum leak in the Fuel Door Lock Actuator/Pneumatic Line can also set this DTC.
POSSIBLE CAUSES

FUEL DOOR LOCK ACTUATOR/PNEUMATIC LINE LEAK
Diagnostic Test

CIRCUIT


Yes >> Go to 2

CIRCUIT

Is voltage present?
age.
No >> Go to 3
FUEL DOOR LOCK ACTUATOR SLOW RESPONSE — CONTINUED
CIRCUIT


ground.
No >> Go to 4
4. INSPECT THE FUEL DOOR LOCK ACTUATOR/PNEUMATIC LINE

FOR A PRESSURE/VACUUM LEAK
Actuate the Door Lock Switch and have an assistant listen for an air leak
from the Fuel Door Lock Actuator while locking and unlocking the doors.
Also, visually inspect the body routed pneumatic lines for damage.
Is the Fuel Door Lock Actuator/Pneumatic line damaged or leak-

ing?
Yes >> Replace the Fuel Door Lock Actuator. Refer to Page 8N-44
or the leaking Pneumatic line.
PASSENGER DOOR/LIFTGATE LOCK ACTUATOR SLOW RESPONSE
PASSENGER DOOR/LIFTGATE LOCK ACTUATOR SLOW RESPONSE — CONTINUED
cuit. A pressure/vacuum leak in the Passenger Door/Liftgate Lock Actuator/Pneumatic Line can also set this
DTC.
POSSIBLE CAUSES

PASSENGER DOOR/LIFTGATE LOCK ACTUATOR/PNEUMATIC LINE LEAK
Diagnostic Test

CIRCUIT


Yes >> Go to 2

CIRCUIT

Is voltage present?
age.
No >> Go to 3
PASSENGER DOOR/LIFTGATE LOCK ACTUATOR SLOW RESPONSE — CONTINUED
CIRCUIT


ground.
No >> Go to 4
4. INSPECT THE PASSENGER DOOR/LIFTGATE LOCK ACTUATOR/

PNEUMATIC LINE FOR A PRESSURE/VACUUM LEAK
Actuate the Door Lock Switch and listen for an air leak from the Passen-
ger Door Lock Actuator or have an assistant listen for an air leak from the
Liftgate Lock Actuator while locking and unlocking the doors. Also, visually
inspect the door, body, and hatch routed pneumatic lines for damage.
Is the Passenger Door/Liftgate Lock Actuator/Pneumatic line dam-

aged or leaking?
Yes >> Replace the Passenger Door/Liftgate Lock Actuator or the
leaking Pneumatic line. Refer to Page 8N-46.
BODY CONTROL MODULE INTERNAL FAILURE — CONTINUED
• Set Condition: If the Body Control Module (BCM) detects an internal malfunction, the DTC is set.
POSSIBLE CAUSES
NO POWER TO BODY CONTROL MODULE
BODY CONTROL MODULE
For a complete Body Control Module (BCM) Circuit Diagram, Refer to Page 8N-29.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE BCM POWER CIRCUIT

Measure the voltage of the Fused B(+) circuit (cavity 75) at the BCM C4
harness connector.

Yes >> Go to 2

harness connector.

Yes >> Go to 3
harness connector.

Yes >> Replace the Body Control Module. Refer to Page 8E-72.
CLP/SSM SYSTEM UNDERVOLTAGE
CLP/SSM SYSTEM UNDERVOLTAGE — CONTINUED
• When Monitored: Ignition on. The Central Locking Pump/Security System Module (CLP/SSM) monitors the
Fused B(+) circuit voltage for proper system voltage.
• Set Condition: If the voltage is below 11 volts, the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW

FUSED B(+) CIRCUIT HIGH RESISTANCE
Diagnostic Test

Start the engine.

Yes >> Go to 2


No >> Go to 3
CLP/SSM SYSTEM UNDERVOLTAGE — CONTINUED
Measure the voltage of the Fused B(+) circuit (cavity 2) at the CLP/SSM

Yes >> Go to 4
No >> Repair the Fused B(+) circuit for high resistance.


CLP/SSM SYSTEM OVERVOLTAGE
CLP/SSM SYSTEM OVERVOLTAGE — CONTINUED
Fused B(+) circuit at all times for proper system voltage.
• Set Condition: If the voltage is above 16 volts, the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
SYSTEM VOLTAGE HIGH

GROUND CIRCUIT OPEN
Diagnostic Test

Start the engine.

Yes >> Go to 2

Start the engine.
Raise the engine speed above 1800 RPM.

No >> Go to 3
CLP/SSM SYSTEM OVERVOLTAGE — CONTINUED
Measure the resistance between ground and the Ground circuit.

NO COMMUNICATION WITH BODY CONTROL MODULE AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE
NO COMMUNICATION WITH BODY CONTROL MODULE AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE — CONTINUED
• Set Condition: CAN Bus communication failure between the Body Control Module (BCM) and the Central
Locking Pump/Security System Module (CLP/SSM).
POSSIBLE CAUSES
CAN B BUS (+) CIRCUIT OPEN

CAN B BUS (-) CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE CAN B BUS (+) CIRCUIT

Measure the resistance of the CAN B Bus (+) circuit from the CLP/SSM
harness connector to the BCM harness connector.

Yes >> Go to 2
No >> Repair the CAN B Bus (+) circuit for an open.
2. MEASURE THE RESISTANCE OF THE CAN B BUS (-) CIRCUIT

Measure the resistance of the CAN B Bus (-) circuit from the CLP/SSM

No >> Repair the CAN B Bus (-) circuit for an open.
DOOR LOCK/DOOR UNLOCK SWITCH SENSE CIRCUIT
DOOR LOCK/DOOR UNLOCK SWITCH SENSE CIRCUIT — CONTINUED
ground, or an open circuit failure that is detected between the Body Control Module (BCM) and the Sentry
Key Remote Entry Module (SKREEM) on the Door Lock/Unlock Switch Sense circuit.
POSSIBLE CAUSES
DOOR LOCK/UNLOCK SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

DOOR LOCK/UNLOCK SWITCH SENSE CIRCUITS SHORTED TOGETHER
DOOR LOCK/UNLOCK SWITCH SENSE CIRCUIT SHORTED TO GROUND
DOOR LOCK/UNLOCK SWITCH SENSE CIRCUIT OPEN
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE DOOR LOCK SWITCH

SENSE CIRCUIT

Disconnect the SKREEM harness connector.
Measure the resistance of the Door Lock Switch Sense circuit from the
BCM harness connector to the SKREEM harness connector.

Yes >> Go to 2
No >> Repair the Door Lock Switch Sense circuit for an open.
2. MEASURE THE RESISTANCE OF THE DOOR UNLOCK SWITCH

SENSE CIRCUIT
Measure the resistance of the Door Unlock Switch Sense circuit from the

Yes >> Go to 3
No >> Repair the Door Unlock Switch Sense circuit for an open.
3. MEASURE THE RESISTANCE OF THE DOOR LOCK/UNLOCK
SWITCH SENSE CIRCUITS
Measure the resistance between the Door Lock/Unlock Switch Sense cir-
cuits at the SKREEM harness connector.

Yes >> Repair the Door Lock/Unlock Switch Sense circuits for a
short together.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE DOOR LOCK SWITCH SENSE

CIRCUIT

Measure the voltage of the Door Lock Switch Sense circuit at the
Is voltage present?
Yes >> Repair the Door Lock Switch Sense circuit for a short to
voltage.
No >> Go to 5
5. MEASURE THE VOLTAGE OF THE DOOR UNLOCK SWITCH SENSE

CIRCUIT
Measure the voltage of the Door Unlock Switch Sense circuit at the
Is voltage present?
Yes >> Repair the Door Unlock Switch Sense circuit for a short to
voltage.
No >> Go to 6
SENSE CIRCUIT

Measure the resistance between ground and the Door Lock Switch Sense
circuit at the SKREEM harness connector.

ground.
No >> Go to 7

SENSE CIRCUIT
Measure the resistance between ground and the Door Unlock Switch
Sense circuit at the SKREEM harness connector.

ground.
8E-72.
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE INTERNAL FAILURE — CONTINUED
• Set Condition: If the Central Locking Pump/Security System Module (CLP/SSM) detects an internal mal-
function, the DTC is set.
POSSIBLE CAUSES
NO POWER TO CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE CLP/SSM POWER CIRCUIT


Yes >> Go to 2


1.

POWER DOOR LOCKS CIRCUIT DIAGRAM

8N - 30 POWER LOCKS - SERVICE INFORMATION ZH
POWER LOCKS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
POWER LOCKS - SERVICE INFORMATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30 DRIVER DOOR LOCK SWITCH
DIAGNOSIS AND TESTING - POWER LOCKS . . 32 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
STANDARD PROCEDURE - TOGGLING FUEL DOOR LOCK ACTUATOR
CUSTOMER PREFERENCES . . . . . . . . . . . . . 35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIFICATIONS - POWER LOCKS . . . . . . . . . 35 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
CENTRAL LOCKING PUMP LIFTGATE LOCK SWITCH
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
KEYLESS ENTRY TRANSMITTER LIFTGATE LOCK ACTUATOR
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
STANDARD PROCEDURE - TRANSMITTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 37 SENTRY KEY REMOTE ENTRY MODULE
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 37 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 47
POWER LOCK SWITCH REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38 SKREEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 REMOVAL - RELAY . . . . . . . . . . . . . . . . . . . . 48
DOOR LATCH ASSEMBLY SKREEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION - RELAY ......... . . . . . . . 50
POWER LOCKS - SERVICE INFORMATION

DESCRIPTION
Power locks are standard equipment. Two ignition keys with integral Remote Keyless Entry (RKE) transmitters are
supplied with the vehicle. They operate the ignition and the
locks in the driver’s door and glove box. The driver’s door lock
cylinder is the only external key cylinder on the vehicle. The
power lock system enables the doors, liftgate and fuel door to
be locked and unlocked in the following ways:
• with the driver’s door lock cylinder.
• with the RKE transmitter.
• with the power lock switch located on the center con-
sole (except fuel door).
Each door can be locked or unlocked mechanically and inde-
pendently with either its inside lock knob, inside remote
release handle, or the outside key cylinder lock (driver door
only). All power locks, including the rear liftgate and fuel door,
can be remotely locked or unlocked with the Remote Keyless
Entry (RKE) transmitter.
ZH POWER LOCKS - SERVICE INFORMATION 8N - 31
Central Locking
Central Locking is a part of the power locking system and the vehicle theft security system. Central Locking oper-
ates both door locks, rear liftgate lock, and the fuel door lock from a single point depending on the Customer Pref-
erences setting. It uses the Body Control Module (BCM), Central Locking Pump/Security System Module and
SKREEM Module for collective logic.
Door Lock Inhibit

The Door Lock Inhibit feature is part of central locking and prevents locking with a door lock button or the Remote
Keyless Entry transmitter when the ignition switch is in the ON/RUN position. It also prevents locking if either door
is not closed.
Sentry Key Remote Entry

The Sentry Key Remote Entry system allows unlocking (1) and
locking (2) of the vehicle doors, the rear liftgate, and the fuel
door by remote control using a hand held radio frequency key-
less entry transmitter. It also has a red panic button (6), and
incorporates a flip out (3) ignition key (4) with an LED (5) bat-
tery check indicator lamp.
OPERATION
The power lock system is operated with pneumatic supply lines connected to actuators at each power lock. Locking
and unlocking is accomplished when the Body Control Module (BCM) is actuated by the Sentry Key Remote Entry
Module (SKREEM). The BCM in turn transmits a signal to the Central Locking Pump/Security System Module via
the Controller Area Network (CAN) bus. The Central Locking Pump/Security System Module incorporates a pump to
supply pressure or vacuum and valves which direct the supply via pneumatic supply lines to the power lock system
component.
For additional information about the BCM, SKREEM or Central Locking Pump/Security System Module functions as
they relate to the power locks system, refer to electronic control modules in this section.
Note: The power door locks and rear liftgate lock actuators are not serviced separately. They are part of the
door lock or rear liftgate lock assemblies. Refer to door latch assembly or liftgate lock actuator in this sec-
tion for removal and installation information.
Central Locking
To operate central locking using the ignition key, turn the driver’s door lock cylinder counterclockwise to lock and
clockwise to unlock both doors, rear liftgate, and fuel door. Using the keyless entry transmitter, press the lock button
to lock the doors, rear liftgate, and fuel door and the unlock button to unlock the doors (driver’s door an fuel door
only in selective mode), rear liftgate and fuel door. Using the power lock switch, press the upper portion to unlock
and the lower portion to lock both doors, and the rear liftgate. Unlocking the vehicle with the ignition key or the
keyless entry transmitter operates the central locking system and disarms the anti-theft alarm.
Remote Keyless Entry

The Remote Keyless entry transmitter has four buttons for operation. They are UNLOCK, LOCK, PANIC, and IGNI-
TION KEY RELEASE. Both the Lock and Unlock buttons have embossed ISO symbols. The Remote Keyless Entry
transmitter has the ability to toggle the system between a Global mode or a Selective mode. Refer to Page 8N-35.
The Unlock button when pressed will unlock the doors, rear liftgate and fuel door, and flash the turn signal lamps
one time to indicate the vehicle is unlocked. The Lock button when pressed will lock the doors, rear liftgate and fuel
door, and flash the turn signal lamps three times to indicate the vehicle is locked. If the lamps do not flash during
locking, a door or rear liftgate is not closed properly. The Panic button when pressed for at least one second will
cause the exterior lamps to flash and a panic alarm to sound for three minutes. To deactivate, press the Panic
button a second time or turn the ignition switch to the ON/RUN position. The Ignition Key Release button allows the
key blade in the Remote Keyless Entry transmitter to flip open from the stored position.
The Sentry Key Remote Entry Module (SKREEM) transceiver is capable of retaining an access code even when
power is removed. The module retains in memory the ID numbers of any Ignition Key transponder that is pro-
grammed into it. For added system security, each SKREEM is programmed with a unique secret key code. Addi-
tional and/or replacement keys can be obtained only from a Chrysler dealer.
Automatic Relocking Function

To avoid unlocking the vehicle unintentionally, the vehicle is automatically relocked by the Central Locking Pump/
Security System Module via the SKREEM. Automatic Relocking takes place after the vehicle has been unlocked
with the remote control whenever:
• a door is not opened within 40 seconds.
• the key is not inserted into the ignition.
• the power lock switch is not actuated.
• only the rear liftgate is opened when global unlocking is active.
Automatic Locking
The power lock switch in the center console operates the automatic locking feature. With the ignition switch in the
ON/RUN position, pressing and holding the upper portion of the power lock switch for at least five seconds activates
automatic locking. With the automatic locking feature activated, the doors and rear liftgate will lock upon reaching a
speed of approximately 15 km/h (9 MPH). If after automatic locking is active, the vehicle is unlocked with the interior
power lock switch, this state is maintained until a door is opened, or until the ignition is turned off. Automatic locking
is accomplished again only upon reaching the specified speed. The logic circuitry for automatic locking is integrated
into the Central Locking Pump/Security System Module. The automatic locking feature can also be toggled or inhib-
ited with the DRB IIIT, for additional information see Toggling Customer Preferences in this section.
Emergency Unlocking
In the event of a vehicle collision, the doors are unlocked automatically by a crash sensor integrated into the Central
Locking Pump/Security System Module. The doors are unlocked after a delay time of 8 to 11 seconds. The emer-
gency unlocking function interrupts all functions performed by the Central Locking Pump/Security System Module,
which are reactivated only after interrupting the ignition. The emergency unlocking function is only active when the
vehicle is unlocked from the outside.
DIAGNOSIS AND TESTING - POWER LOCKS

The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a
DRB IIIT scan tool and the proper Diagnostic Procedures. Refer to power locks electrical diagnostics in this
section.
WARNING: REFER TO RESTRAINTS Refer to Page 8O-82 BEFORE ATTEMPTING ANY DOOR, SEAT, STEER-
ING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL-
URE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
When trouble shooting problems with the power locks system, always verify that the power lock switch is functional.
If the doors, rear liftgate, or fuel door do not lock/unlock with the power lock switch, the following system compo-
nents should be analyzed:
• Power door lock switch
• Body Control Module (BCM)
• Remote Keyless Entry Relay
• Power Lock/Actuator assemblies
• Sentry Key Remote Entry Module (SKREEM)
• Central Locking Pump/Security System Module
• Pneumatic supply lines
There are three main electronic control modules which are interdependent on each other to com-
plete lock/unlock commands, they are the BCM, SKREEM, and Central Locking Pump/Security
System Module. These modules cannot be adjusted or repaired. For complete power locks diag-
nosis procedures, see power locks electrical diagnostics in this section.
PNEUMATIC SUPPLY LINES
1 - PASSENGER DOOR LOCK 5 - PNEUMATIC DASH POT

2 - DISTRIBUTOR 6 - DRIVER DOOR LOCK
3 - FUEL DOOR ACTUATOR 7 - PSE CONTROL MODULE
4 - REAR HATCH LOCK ACTUATOR
The power lock actuators are controlled by pneumatic supply lines that transfer either vacuum or pressure from the
Central Locking Pump/Security System Module to the component through distributors. When trouble shooting prob-
lems related to the pneumatic portion of the power lock system, a preliminary inspection should be performed to
determine that the pneumatic supply lines and harness connectors are free from kink or blockage damage. If nec-
essary, repairs to the pneumatic supply lines or harness connectors must be performed first before proceeding with
additional power lock system diagnosis.
SUPPLY LINE/ACTUATOR TESTING

When trouble shooting a pneumatic supply line or actuator for the power lock system, perform the following steps:
Entire System
1. Disconnect the pneumatic supply line connected to the Central Locking Pump/Security System Module.
2. Using a hand held vacuum pump, connect an appropriate rubber hose 2 in. (50 mm) long to the disconnected
pneumatic supply line.
3. Apply 600 mbar (17.7 in. Hg) pressure to the pneumatic supply line for 1 minute.
If after 1 minute the vacuum loss is less than 30 mbar (.9 in. Hg), the pneumatic supply lines and actuators are not
the cause of the fault. If after 1 minute the vacuum loss is greater than 30 mbar (.9 in. Hg), perform the Pneumatic
line with actuator test.
Pneumatic Line with Actuator

1. Disconnect the pneumatic supply line (1) connected to the
pneumatic distributor.
2. Using a hand held vacuum pump, connect an appropriate
rubber hose 2 in. (50 mm) long to the disconnected pneu-
matic supply line (1).
3. Apply 600 mbar (17.7 in. Hg) pressure to the pneumatic
supply line for 1 minute.
If after 1 minute the vacuum loss is less than 30 mbar (.9 in.
Hg), the pneumatic supply lines and actuator are not the
cause of the fault. If after 1 minute the pressure loss is greater
than 30 mbar (.9 in. Hg), perform the Pneumatic line test.
Pneumatic Line
1. Disconnect the pneumatic supply line connected to the pneumatic distributor and block off.
2. Disconnect the pneumatic supply line connected to the actuator and connect a hand held vacuum pump.
3. Apply 300 mbar (8.9 in. Hg) vacuum to the pneumatic supply line for 1 minute.
If after 1 minute the vacuum loss is 0 mbar (0 in. Hg), then replace the actuator. If after 1 minute the vacuum loss
is greater than 0 mbar (0 in. Hg), repair the pneumatic supply line.
STANDARD PROCEDURE - TOGGLING CUSTOMER PREFERENCES

Automatic Locking
The automatic locking function can be activated or deactivated with the DRB IIIT. The interior power door lock
switch may also be used with the ignition switched on by pressing and holding the power door lock switch for more
than 5 seconds in either the lock (auto locking switched on) or unlock (auto locking switched off) position. The
interior power door lock switch can be inhibited with the DRB IIIT.
Global/Selective Central Locking

The keyless entry system has a Global or Selective mode function for central locking that can be programed by the
customer. The factory setting is Global, which will lock and unlock both doors, rear liftgate and fuel door centrally
when the respective button is pressed once. The Selective mode will only change which power locks unlock. To
activate the Selective mode, press both the Unlock and Lock buttons simultaneously for approximately five seconds
until the battery check lamp in the transmitter flashes twice. The Unlock button will then only unlock the driver door
and the fuel door when it is pressed once. Pressing the Unlock button a second time, unlocks the passenger’s door
and the rear liftgate. The factory setting can be restored by pressing both the Unlock and Lock buttons simulta-
neously again for approximately five seconds until the battery check lamp in the transmitter flashes twice. If the
vehicle was locked using the power lock switch in the center console while in the Selective mode, opening a door
from inside unlocks that door only. If the vehicle was locked using the power lock switch in the center console while
in the Global mode, opening a door from the inside unlocks both doors and the rear liftgate. If the vehicle was
locked using the RKE transmitter, the doors and rear liftgate cannot be unlocked using the power lock switch in the
center console. If the vehicle was locked from the outside, opening a door from the inside will not unlock other
openings but it will trigger the alarm.
SPECIFICATIONS - POWER LOCKS

PNEUMATIC SPECIFICATIONS
Allowable system leakage of 300 mbar (8.9 in Hg) 30 mbar (.9 in Hg)
vacuum in 1 minute.
Allowable leakage of actuators with line at 300 mbar ≤ 25 mbar (.74 in Hg)
(8.9 in Hg) vacuum in 1 minute.

DOOR LOCK
8 — 70
ATTACHMENT SCREWS
CENTRAL LOCKING PUMP

DESCRIPTION

The Central Locking Pump/Security System Module (3) is the pressure/vacuum supply pump for the power lock
system. It is located in the right rear quarter panel area beneath the floor covering. For complete Central Locking
Pump/Security System Module removal procedures, see Central Locking Pump/Security System Module removal in
the electronic control modules section.

When trouble shooting problems related to the pneumatic portion of the power lock system, a preliminary inspection
should be performed to determine that the supply lines, actuators, and harness connectors are free from damage.
If necessary, repairs to the pneumatic supply system must be performed before proceeding with additional power
lock system diagnosis. For wiring diagrams and diagnostic information, see Electronic Control Modules in this sec-
tion. Refer to Page 8E-45.
KEYLESS ENTRY TRANSMITTER

Note: If the transmitter unlock button has been pressed repeatedly while out of range of the receiver, syn-
chronization may have to be restored. To do so, perform the transmitter programming procedure in this
section.
Using Special Tool 9001, first test to ensure that the transmit-
ter is functioning. Typical testing distance is 1 in. (2.5 cm) for
Asian transmitters and 12 in. (30.5 cm) for all others. To test,
position the transmitter as shown. Press any transmitter but-
ton, then test each button individually. The tool will beep if a
radio signal strength that lights five or more LEDs is detected.
Repeat this test three times. If transmitter fails any of the
tests, refer to the Electrical Diagnostic portion of this section.
STANDARD PROCEDURE - TRANSMITTER PROGRAMMING

The Remote Keyless Entry (RKE) Transmitter(s) can be programmed by the customer without special tools.
PROGRAMMING PROCEDURE
Transmitter programming by the customer is done by performing the following steps:
1. Press either the lock or unlock button momentarily twice.
2. Turn the key in the ignition switch to the ON/RUN position within 30 seconds.
SPECIFICATIONS
TRANSMITTER
BATTERY TESTING
The batteries in the Remote Keyless Entry transmitter can be tested by pressing and holding both the lock and
unlock buttons simultaneously for more than one second. The batteries are charged sufficiently if the LED next to
the ignition key blade lights up briefly.
BATTERY REPLACEMENT
The transmitter has two 3 volt batteries, which can be
removed and replaced without special tools. First, release the
key from the closed position; then insert a coin in the side slot
of the transmitter and twist. The cover should separate from
the body of the transmitter where the batteries are stacked on
top of each other. The batteries are available at local retail
stores. Recommended replacement batteries are PanasonicT
CR 2025 lithium or equivalent. Battery life for normal use is
about two years.
Note: The transmitter MUST be reprogrammed after the

batteries are replaced.
RANGE
Operation range is within 20 meters (66 feet) of the module/receiver.
POWER LOCK SWITCH

DESCRIPTION
The mounting arrangement of the power lock switch is unique and integrated with additional switches within the trim
panel on the center console. The power lock switch is not serviceable separately. When replacement is necessary,
the service part includes additional switches.
REMOVAL
WARNING: REFER TO RESTRAINTS Refer to Page 8O-82
BEFORE ATTEMPTING ANY DOOR, SEAT, STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER-
SONAL INJURY.

2. Remove the center console interior trim panel. Refer to
Page 23-173.
3. Disconnect the power lock switch harness connectors (1).
4. Press the locking tabs inward and remove the outer gang
of switches.
5. Press the locking tabs inward and remove the power lock
switch from the trim panel.
INSTALLATION
1. Align the power lock switch with the center console interior
trim panel and press together until the locking tabs engage
fully.
2. Align the outer gang of switches over the power lock switch
and press together until the locking tabs engage fully.
3. Connect the power lock switch harness connectors.
4. Install the trim panel on the center console. Refer to Page
23-183.
DOOR LATCH ASSEMBLY

REMOVAL
SONAL INJURY.

2. Remove the door lock cylinder. Refer to Page 23-105.
3. Gently peel back the door watershield (1) enough to
expose the door latch assembly installation opening.
Note: Before removal, be sure to mark the installed posi-

tion of the guide rail for realignment during installation.
4. Remove the lower cover plug (3) and remove the guide rail
attachment bolts (2). Remove the guide rail through the
installation opening.
5. Remove the inside handle release cable (8) and the driver
door latch assembly harness connector.
6. Disconnect the pneumatic supply line (2) from the lock

actuator on the door latch assembly.
7. Remove the door latch assembly attachment screws (1)
and remove the door latch assembly (3) from the door
through the installation opening.
INSTALLATION
1. Align the door latch assembly (6) into the door through the
installation opening. Install the door latch assembly attach-
ment screws (7) and torque to 8 N·m.
2. Install the pneumatic supply line to the lock actuator on the
door latch assembly.
3. Install the inside handle release cable (8) and the driver
door harness connector (driver door only).
Note: The guide rail must be aligned with the installed

position mark before securing proper glass adjustment.
4. Align the guide rail into the door through the installation
opening and install the attachment bolts (2). Install the
lower cover plug (3).
Note: Inspect the door watershield for damage and

replace if necessary.
5. Install the door watershield.

6. Install the door lock cylinder. Refer to Page 23-106.
DRIVER DOOR LOCK SWITCH

REMOVAL
SONAL INJURY.

3. Gently peel back the door watershield enough to expose
the driver door lock switch.
4. Release the locking tab (1) attaching the driver door lock
switch to the door latch assembly.
5. Disconnect the pneumatic supply line (2) from the door lock
actuator.
6. Disconnect the remaining door harness connectors, and
remove the driver door lock switch.
INSTALLATION
Note: Ensure the harness is routed and secured in its original position to avoid potential interference with
moving parts.
1. Install the door harness assembly into the door.

2. Install the driver door lock switch into the door latch assembly.
FUEL DOOR LOCK ACTUATOR

REMOVAL
1. Open the access panel in the right rear interior quarter trim
panel.
2. Remove the pneumatic supply line (2) from the fuel door
lock actuator.
Note: Use caution when removing fragile pneumatic sup-

ply line fitting.
3. Release the lock pin from the lock actuator by pulling the
handle (1) fully rearward.
4. Press the locking tab on the fuel door lock actuator and
rotate the fuel door latch (1) 90°. Remove the fuel door lock
actuator from the vehicle.
INSTALLATION
1. Install the fuel door lock actuator through the access panel
in the right rear interior quarter trim panel and align it with
the mounting hole.
2. Install the fuel door latch into the access hole and rotate
90°. Press the handle (1) in fully to guide the fuel door
latch.
3. Insert the fuel door lock actuator into the fuel door latch
and press together firmly until locking tab is seated fully.
4. Install the pneumatic supply line (2) to the fuel door lock
actuator.
5. Close the right rear interior quarter trim panel access panel.
LIFTGATE LOCK SWITCH

REMOVAL
The liftgate lock switch (1) is serviced with the liftgate latch
assembly. For complete liftgate latch removal procedures, see
liftgate latch removal in the body section. Refer to Page
23-43.
INSTALLATION
The liftgate lock switch is serviced with the liftgate latch assembly. For complete liftgate latch installation procedures,
see liftgate latch installation in the body section. Refer to Page 23-43.
LIFTGATE LOCK ACTUATOR

REMOVAL
The liftgate lock actuator (2) is serviced with the liftgate exte-
rior handle assembly. For complete liftgate exterior handle
removal procedures, see liftgate exterior handle removal in the
body section. Refer to Page 23-34.
INSTALLATION
The liftgate lock actuator is serviced with the liftgate exterior handle assembly. For complete liftgate exterior handle
installation procedures, see liftgate exterior handle installation in the body section. Refer to Page 23-37.

DESCRIPTION
The Sentry Key Remote Entry Module (SKREEM) (1) is an
integral component of the power lock system. It is responsible
for processing operator inputs for the power lock system in
addition to other systems and is located behind the instrument
cluster within the instrument panel (2).

When troubleshooting problems related to the pneumatic portion of the power lock system, a preliminary inspection
should be performed to determine that the supply lines, actuators, and harness connectors are free from damage.
If necessary, repairs to the pneumatic supply system must be performed before proceeding with additional power
lock system diagnosis. For complete power lock system diagnosis, see power locks electrical diagnostics in this
section.
REMOVAL
SKREEM
3. Disconnect the 2-pin CAN bus harness connector (1) from
the SKREEM.
4. Disconnect the 2-pin harness connector for the sentry key
antenna ring.
5. Disconnect the 18-pin harness connector (1) from the
SKREEM.
REMOVAL - RELAY
1. Remove the underhood accessory fuse block lid (1).
2. Carefully release the four tabs (1) to remove the underhood

accessory fuse block cover panel (2).
3. Remove the remote keyless entry relay (1).
INSTALLATION
SKREEM
2. Connect the 18-pin harness connector and the 2-pin CAN
bus harness connector (1) to the SKREEM.
3. Connect the 2-pin harness connector for the sentry key
antenna ring.
INSTALLATION - RELAY
1. Install the remote keyless entry relay (1).
2. Install the underhood accessory fuse block cover panel (2)

and secure it by snapping the retention tabs (1) into place.
3. Install the underhood accessory fuse block lid (1).

8N - 52 POWER MIRRORS - ELECTRICAL DIAGNOSTICS ZH
POWER MIRRORS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
POWER MIRRORS - ELECTRICAL *BOTH POWER MIRRORS INOPERATIVE . . . 57

DIAGNOSTICS *AUTOMATIC DAY/NIGHT MIRROR
DIAGNOSIS AND TESTING INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 59
*LEFT POWER MIRROR INOPERATIVE . . . . 53 BODY VERIFICATION TEST . . . . . . . . . . . . . 62
*RIGHT POWER MIRROR INOPERATIVE . . . 55 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 63
POWER MIRRORS - ELECTRICAL DIAGNOSTICS

ZH POWER MIRRORS - ELECTRICAL DIAGNOSTICS 8N - 53
*LEFT POWER MIRROR INOPERATIVE
*LEFT POWER MIRROR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
LEFT POWER MIRROR

LEFT POWER MIRROR CIRCUIT
POWER MIRROR SWITCH
For a complete Power Mirrors Circuit Diagram, Refer to Page 8N-63.
Diagnostic Test
1. MEASURE LEFT POWER MIRROR CIRCUIT RESISTANCE

Disconnect the Power Mirror Switch harness connector.
Disconnect the Left Power Mirror harness connector.
Connect a jumper wire between cavity 4 and cavity 5 of the Left Power
Mirror harness connector.
Measure the resistance between cavity 3 and cavity 7 of the Power Mirror
Switch harness connector.

Yes >> Go to 2
No >> Repair the Left Power Mirror circuit for an open.
2. TEST THE LEFT POWER MIRROR

Remove the jumper wire from the Left Power Mirror harness connector.
Reconnect the Left Power Mirror harness connector.
Connect a jumper wire between cavity 3 and ground of the Power Mirror
Connect a jumper wire between cavity 6 and cavity 7 of the Power Mirror
With the jumper wires connected, does the Left Power Mirror
move?
Yes >> Replace the Power Mirror Switch. Refer to Page 8N-71.
No >> Replace the Left Power Mirror. Refer to Page 8N-72.
*RIGHT POWER MIRROR INOPERATIVE
*RIGHT POWER MIRROR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
RIGHT POWER MIRROR

RIGHT POWER MIRROR CIRCUIT
POWER MIRROR SWITCH
Diagnostic Test
1. MEASURE RIGHT POWER MIRROR CIRCUIT RESISTANCE

Disconnect the Right Power Mirror harness connector.
Connect a jumper wire between cavity 5 and cavity 6 of the Right Power
Measure the resistance between cavity 4 and cavity 8 of the Power Mirror

Yes >> Go to 2
No >> Repair the Right Power Mirror circuit for an open.
2. TEST THE RIGHT POWER MIRROR

Remove the jumper wire from the Right Power Mirror harness connector.
Reconnect the Right Power Mirror harness connector.
Connect a jumper wire between cavity 4 and ground of the Power Mirror
Connect a jumper wire between cavity 6 and cavity 8 of the Power Mirror
With the jumper wires connected, does the Right Power Mirror
move?
No >> Replace the Right Power Mirror. Refer to Page
8N-72.
*BOTH POWER MIRRORS INOPERATIVE
*BOTH POWER MIRRORS INOPERATIVE — CONTINUED
POSSIBLE CAUSES
FUSED B(+) CIRCUIT

POWER MIRROR SWITCH GROUND CIRCUIT OPEN
POWER MIRROR SWITCH
Diagnostic Test
1. MEASURE POWER MIRROR SWITCH FUSED B(+) CIRCUIT

VOLTAGE

continuing.
Measure the voltage of the Fused B(+) circuit at the Power Mirror Switch
harness connector.

Yes >> Go to 2
No >> Repair the Power Mirror Switch Fused B(+) circuit for an
open.
2. MEASURE POWER MIRROR SWITCH GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Power Mirror Switch har-
ness connector.

No >> Repair the Ground circuit between the Power Mirror
Switch harness connector and ground for an open.
*AUTOMATIC DAY/NIGHT MIRROR INOPERATIVE
*AUTOMATIC DAY/NIGHT MIRROR INOPERATIVE — CONTINUED
POSSIBLE CAUSES

AUTOMATIC DAY/NIGHT MIRROR GROUND CIRCUIT OPEN
AUTOMATIC DAY/NIGHT MIRROR
Diagnostic Test
1. MEASURE AUTOMATIC DAY/NIGHT MIRROR FUSED B(+) CIRCUIT

VOLTAGE

continuing.
Disconnect the Automatic Day/Night Mirror harness connector.
Measure the voltage of the Fused B(+) circuit at the Automatic Day/Night

Yes >> Go to 2
No >> Repair the Automatic Day/Night Mirror Fused B(+) circuit
for an open.
2. MEASURE AUTOMATIC DAY/NIGHT MIRROR GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Automatic Day/Night Mir-
ror Ground circuit.

Yes >> Go to 3
*AUTOMATIC DAY/NIGHT MIRROR INOPERATIVE — CONTINUED
3. MEASURE THE VOLTAGE OF THE BACKUP LAMP FEED CIRCUIT
Put the automatic transmission shift lever assembly or the manual trans-
mission gear shift lever into Reverse.
Measure the voltage of the Backup Lamp Feed circuit at the Automatic
Day/Night Mirror harness connector.
Is battery voltage present?

Yes >> Repair the Automatic Day/Night Mirror Backup Lamp Feed
circuit for a short to voltage.
No >> Replace the Automatic Day/Night Mirror. Refer to
Page 8N-68.
1.

AUTO DIMMING DAY/NIGHT MIRROR CIRCUIT DIAGRAM

POWER FOLDING MIRRORS CIRCUIT DIAGRAM (EXPORT)

POWER MIRRORS CIRCUIT DIAGRAM

8N - 66 POWER MIRRORS - SERVICE INFORMATION ZH
POWER MIRRORS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
POWER MIRRORS - SERVICE INFORMATION INSTALLATION - REARVIEW MIRROR

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66 SUPPORT BRACKET . . . . . . . . . . . . . . . . . . . 69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 POWER MIRROR SWITCH
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 66 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
AUTOMATIC DAY / NIGHT MIRROR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 68 SIDEVIEW MIRROR
INSTALLATION
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . 69
POWER MIRRORS - SERVICE INFORMATION

DESCRIPTION
This group covers the following components of the power mirror system:
• Power sideview mirrors.
• Automatic day/night inside rearview mirror.
• Power mirror switch.
Driver and passenger power operated sideview mirrors are standard equipment. The power mirror system allows
the driver to adjust both sideview mirrors electrically from the driver seat by operating a four position switch located
in the center console.
An inside automatic day/night rear view mirror is also standard equipment. It is located in the traditional location at
the top and center of the windshield. The automatic day/night mirror position is manually adjustable, however the
automatic dimming feature of the mirror is not.
OPERATION
Both sideview mirrors are automatically heated and each housing can manually fold in for protection. Mirror selec-
tion and movement direction is controlled by a 4-way double-pole switch. Two electric motors inside each sideview
mirror housing actuate the glass surface in the corresponding direction that the switch is moved. The inside rear
view mirror is fully automatic and darkens to prevent glare during night driving. It operates when the following con-
ditions are simultaneously met:
• The ignition switch is in the ON position
• Reverse gear is not selected
• The interior lights are switched off
• Headlamp glare from behind falls on the sensor

SONAL INJURY.
ZH POWER MIRRORS - SERVICE INFORMATION 8N - 67
BOTH SIDEVIEW 1. Faulty fuse. 1. Replace fuse.

MIRRORS INOPERATIVE
2. Poor connection at switch harness 2. Secure harness connector.
connector.
3. No voltage to adjustment motors. 3. Refer to power mirrors
electrical diagnostics in this
section.
4. Mirror ground circuit fault. 4. Repair ground circuit.
ONE SIDEVIEW MIRROR 1. Faulty switch assembly 1. Refer to power mirrors

INOPERATIVE electrical diagnostics in this
section.
2. Poor connection at mirror harness 2. Secure connector
connector.
3. No voltage to adjustment motor. 3. Refer to power mirrors
section.
SIDEVIEW MIRROR(S) 1. Faulty or worn motor 1. Replace mirror assembly.

VERTICAL OR
HORIZONTAL MOVEMENT
SLUGGISH OR
INOPERATIVE
2. Poor connection at mirror harness 2. Secure connector.
connector.
3. Faulty switch assembly. 3. Refer to power mirrors
section.
SIDEVIEW MIRROR(S) DO 1. Faulty fuse. 1. Replace fuse.

NOT CLEAR IN COLD
WEATHER
2. Poor connection at mirror harness 2. Secure connector.
connector.
3. No voltage to heater grid. 3. Refer to heated mirrors
electrical diagnostics.
AUTOMATIC DAY/NIGHT 1. Faulty fuse. 1. Replace fuse.

MIRROR DOES NOT
DARKEN
2. Interior lighting system faulty. 2. Refer to lamps /lighting-
interior electrical diagnositics.
3. Reverse lamp circuit fault. 3. Repair circuit.
(manual trans)
4. Shifter assembly fault. (automatic 4. Refer to transmission
trans) electrical diagnostics.
AUTOMATIC DAY/NIGHT 1. Short to voltage. 1. Refer to power mirrors

MIRROR CONTINUALLY electrical diagnostics in this
DARKENED section.
AUTOMATIC DAY / NIGHT MIRROR

DESCRIPTION
An automatic day/night rear view mirror system is standard on
this model. It is a completely self-contained unit (2) which is
located at the top and center of the windshield. The mirror
sensitivity cannot be repaired or adjusted; if any components
of the mirror unit itself are faulty or damaged, the entire auto-
matic day/night inside rear view mirror assembly must be
replaced.
OPERATION
A thin layer of electrochromatic material between two pieces of conductive glass make up the face of the mirror. The
system will automatically change the reflectance of the inside rear view mirror to protect the driver from the
unwanted headlight glare of trailing vehicles while driving at night. The self-dimming feature is defeated if the interior
lights are switched on, or the system senses the backup light circuit is energized whenever the transmission is
shifted into reverse.
REMOVAL
2. Insert a 5 mm metal dowel into the hole on the windshield
side of the mirror base.
3. Rotate the mirror base approximately 90 degrees to the left
or right.
4. Remove the courtesy lamp. Refer to Page 8L-142.
5. Disconnect the mirror harness connector.
6. Feed the harness connector and harness past the opening
in the headliner and remove the mirror assembly.
INSTALLATION
REARVIEW MIRROR
1. Feed the mirror harness connector into the headliner and
connect.
2. Install the courtesy lamp. Refer to Page 8L-143.
3. Position the mirror base over the mounting plate so that it
is flush with the windshield surface.
4. Rotate the mirror base approximately 90 degrees until the

hole is positioned downward.
INSTALLATION - REARVIEW MIRROR

SUPPORT BRACKET
1. Mark the position for the mirror bracket on the outside of
the windshield glass with a wax pencil.
2. Clean the bracket contact area on the glass. Use a mild
powdered cleanser on a cloth saturated with isopropyl (rub-
bing) alcohol. Finally, clean the glass with a paper towel
dampened with alcohol.
3. Sand the surface on the support bracket with fine grit-sand-
paper. Wipe the bracket surface clean with a paper towel.
4. Apply adhesive accelerator to the surface on the bracket

according to the following instructions:
a. Crush the vial to saturate the felt applicator.
b. Remove the paper sleeve.
c. Apply adhesive accelerator to the contact surface
on the bracket.
d. Allow the adhesive accelerator to dry for five min-
utes.
e. Do not touch the bracket contact surface after the
adhesive accelerator has been applied.
5. Apply adhesive accelerator to the bracket contact surface

on the windshield glass. Allow the adhesive accelerator to
dry for one minute. Do not touch the glass contact surface
after the adhesive accelerator has been applied.
6. Install the bracket according to the following instructions:
a. Apply one drop of adhesive at the center of the
bracket contact-surface on the windshield glass.
b. Apply an even coat of adhesive to the contact sur-
face on the bracket.
c. Align the bracket with the marked position on the
windshield glass.
d. Press and hold the bracket in place for at least one
minute.
Note: Verify that the mirror support bracket is correctly

aligned because the adhesive will cure rapidly.
7. Allow the adhesive to cure for 8-10 minutes. Remove any

excess adhesive with an alcohol-dampened cloth.
8. Allow the adhesive to cure for an additional 8-10 minutes
before installing the mirror.
POWER MIRROR SWITCH

REMOVAL

2. Remove the center console. Refer to Page 23-173.
3. Release the retaining clip using a suitable tool (1) and
remove the power mirror switch from the center console.
INSTALLATION
1. Install the power mirror switch into the center console.
2. Install the center console. Refer to Page 23-183.
SIDEVIEW MIRROR
REMOVAL

3. Disconnect the mirror harness connector.
4. Rotate the sideview mirror upward so the screws are
exposed.
5. Remove the two screws attaching the mirror to the door
and remove the mirror.
INSTALLATION
1. Install the screws (1) attaching the mirror to the door.
2. Connect the sideview mirror harness connector.
4. Rotate the mirror back to its rest position.
ZH POWER SEATS - ELECTRICAL DIAGNOSTICS 8N - 73
POWER SEATS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
POWER SEATS - ELECTRICAL DIAGNOSTICS *DRIVER POWER SEAT FRONT RISER

DIAGNOSIS AND TESTING MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . 85
*DRIVER POWER SEAT INOPERATIVE . . . . . 74 *DRIVER POWER SEAT REAR RISER
*PASSENGER POWER SEAT MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . 87
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 76 *PASSENGER POWER SEAT RECLINER
*BOTH POWER SEATS INOPERATIVE . . . . . 78 MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . 89
*DRIVER POWER SEAT RECLINER MOTOR *PASSENGER POWER SEAT HORIZONTAL
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 81 MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . 91
*DRIVER POWER SEAT HORIZONTAL BODY VERIFICATION TEST . . . . . . . . . . . . . 93
MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . 83 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 94
POWER SEATS - ELECTRICAL DIAGNOSTICS

8N - 74 POWER SEATS - ELECTRICAL DIAGNOSTICS ZH
*DRIVER POWER SEAT INOPERATIVE
*DRIVER POWER SEAT INOPERATIVE — CONTINUED
POSSIBLE CAUSES

DRIVER POWER SEAT SWITCH GROUND CIRCUIT OPEN
DRIVER POWER SEAT SWITCH
For a complete Power Seats Circuit Diagram, Refer to Page 8N-94.
Diagnostic Test
1. MEASURE DRIVER POWER SEAT SWITCH FUSED B(+) CIRCUIT

VOLTAGE

continuing.
Disconnect the Driver Power Seat Switch harness connector.
Measure the voltage of the Fused B(+) circuit at the Driver Power Seat

Yes >> Go to 2
2. MEASURE DRIVER POWER SEAT SWITCH GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Driver Power Seat
Switch Ground circuit.

Yes >> Replace the Driver Power Seat Switch. Refer to Page
8N-96.
*PASSENGER POWER SEAT INOPERATIVE
*PASSENGER POWER SEAT INOPERATIVE — CONTINUED
POSSIBLE CAUSES

PASSENGER POWER SEAT SWITCH GROUND CIRCUIT OPEN
PASSENGER POWER SEAT SWITCH
Diagnostic Test
1. MEASURE PASSENGER POWER SEAT SWITCH FUSED B(+)

CIRCUIT VOLTAGE

continuing.
Disconnect the Passenger Power Seat Switch harness connector.
Measure the voltage of the Fused B(+) circuit at the Passenger Power
Seat Switch harness connector.

Yes >> Go to 2
2. MEASURE PASSENGER POWER SEAT SWITCH GROUND CIRCUIT

RESISTANCE

Measure the resistance between ground and the Passenger Power Seat
Switch Ground circuit.

Yes >> Replace the Passenger Power Seat Switch. Refer to Page
8N-96.
*BOTH POWER SEATS INOPERATIVE
*BOTH POWER SEATS INOPERATIVE — CONTINUED
POSSIBLE CAUSES
POWER SEAT RELAY FUSED B(+) CIRCUIT OPEN

POWER SEAT RELAY GROUND CIRCUIT OPEN
POWER SEAT RELAY
Diagnostic Test
1. TEST THE POWER SEAT RELAY CIRCUIT

Note: Inspect Fuses 21 and 22 located in the Underhood Accessory
Fuse Block. If the fuses are open, repair the cause of the open fuse
before continuing.
Disconnect the Power Seat Relay.
Connect a jumper wire between cavity 8 and cavity 2 of the Power Seat
Actuate the Driver and Passenger Power Seat Switches.
Did the Driver and Passenger Power Seats move?

Yes >> Replace the Power Seat Relay.
No >> Go to 2
2. MEASURE POWER SEAT RELAY FUSED B(+) CIRCUIT VOLTAGE

Disconnect the jumper wire.
Measure the voltage of the Fused B(+) circuit at the Power Seat Relay
harness connector.

Yes >> Go to 3
*BOTH POWER SEATS INOPERATIVE — CONTINUED
3. MEASURE POWER SEAT RELAY GROUND CIRCUIT RESISTANCE

Yes >> Repair the open circuit between the Power Seat Relay har-
ness connector and the Underhood Accessory Fuse Block.
No >> Repair the open Ground circuit between the Power
Seat Relay harness connector and ground.
*DRIVER POWER SEAT RECLINER MOTOR INOPERATIVE
*DRIVER POWER SEAT RECLINER MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
DRIVER POWER SEAT RECLINER MOTOR

DRIVER POWER SEAT RECLINER MOTOR CIRCUIT
Diagnostic Test
1. TEST THE DRIVER POWER SEAT RECLINER MOTOR

Disconnect the Driver Power Seat Recliner Motor harness connector.
Connect a jumper wire from B(+) to one cavity of the Driver Power Seat
Recliner Motor connector (motor side).
Connect a second jumper wire from ground to the other cavity of the
Driver Power Seat Recliner Motor connector (motor side).
Note recliner movement, if no recliner movement is noted, reverse the
jumper wires at the Recliner Motor connector.
Did the Driver Power Seat Recliner move backward or forward?

Yes >> Replace the Driver Power Seat Switch.
No >> Replace the Driver Power Seat Recliner Motor. Refer
to Page 8N-103.
*DRIVER POWER SEAT HORIZONTAL MOTOR INOPERATIVE
*DRIVER POWER SEAT HORIZONTAL MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
DRIVER POWER SEAT HORIZONTAL MOTOR

DRIVER POWER SEAT HORIZONTAL MOTOR CIRCUIT
Diagnostic Test
1. TEST THE DRIVER POWER SEAT HORIZONTAL MOTOR

Disconnect the Driver Power Seat Horizontal Motor harness connector.
Horizontal Motor connector (motor side).
Driver Power Seat Horizontal Motor connector (motor side).
Note seat movement, if no seat movement is noted, reverse the jumper
wires at the Horizontal Motor connector.
Did the Driver Power Seat move backward or forward?

8N-96.
No >> Replace the Driver Power Seat Horizontal Motor.
Refer to Page 8N-101.
*DRIVER POWER SEAT FRONT RISER MOTOR INOPERATIVE
*DRIVER POWER SEAT FRONT RISER MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
DRIVER POWER SEAT FRONT RISER MOTOR
Diagnostic Test
1. TEST THE DRIVER POWER SEAT FRONT RISER MOTOR

Disconnect the Driver Power Seat Front Riser Motor harness connector.
Front Riser Motor connector (motor side).
Driver Power Seat Front Riser Motor connector (motor side).
Note seat movement, if no seat front riser movement is noted, reverse the
jumper wires at the Front Riser Motor connector.
Did the Driver Seat Front Riser move up or down?

8N-96.
No >> Replace the Driver Power Seat Front Riser Motor.
*DRIVER POWER SEAT REAR RISER MOTOR INOPERATIVE
*DRIVER POWER SEAT REAR RISER MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
DRIVER POWER SEAT FRONT RISER MOTOR
For a complete Power Seats circuit diagram, Refer to Page 8N-94.
Diagnostic Test
1. TEST THE DRIVER POWER SEAT REAR RISER MOTOR

Disconnect the Driver Power Seat Rear Riser Motor harness connector.
Rear Riser Motor connector motor side).
Driver Power Seat Rear Riser Motor connector (motor side).
Note seat movement, if no seat rear riser movement is noted, reverse the
jumper wires at the Rear Riser Motor connector.
Did the Driver Seat Rear Riser move up or down?

8N-96.
No >> Replace the Driver Power Seat Rear Riser Motor.
*PASSENGER POWER SEAT RECLINER MOTOR INOPERATIVE
*PASSENGER POWER SEAT RECLINER MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
PASSENGER POWER SEAT RECLINER MOTOR

PASSENGER POWER SEAT RECLINER MOTOR CIRCUIT
Diagnostic Test
1. TEST THE PASSENGER POWER SEAT RECLINER MOTOR

Disconnect the Passenger Power Seat Recliner Motor connector.
Connect a jumper wire from B(+) to one cavity of the Passenger Power
Seat Recliner Motor connector (motor side).
Connect a second jumper wire from ground to the other cavity of the Pas-
senger Power Seat Recliner Motor connector (motor side).
Note seat movement, if no recliner movement is noted, reverse the jumper
wires at the Recliner Motor connector.
Did the Passenger Power Seat Recliner move backward or for-

ward?
8N-96.
No >> Replace the Passenger Power Seat Recliner Motor.
*PASSENGER POWER SEAT HORIZONTAL MOTOR INOPERATIVE
*PASSENGER POWER SEAT HORIZONTAL MOTOR INOPERATIVE — CONTINUED
POSSIBLE CAUSES
PASSENGER POWER SEAT HORIZONTAL MOTOR

PASSENGER POWER SEAT HORIZONTAL MOTOR CIRCUIT
Diagnostic Test
1. TEST THE PASSENGER POWER SEAT HORIZONTAL MOTOR

Disconnect the Passenger Power Seat Horizontal Motor connector.
Connect a jumper wire from B(+) to one cavity of the Passenger Power
Seat Horizontal Motor connector (motor side).
Connect a second jumper wire from ground to the other cavity of the Pas-
senger Power Seat Horizontal Motor connector (motor side).
Note seat movement, if no seat movement is noted, reverse the jumper
wires at the Horizontal Motor connector.
Did the Passenger Power Seat move backward or forward?

8N-96.
No >> Replace the Passenger Power Seat Horizontal Motor.
1.

POWER SEATS CIRCUIT DIAGRAM

ZH POWER SEATS - SERVICE INFORMATION 8N - 95
POWER SEATS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
POWER SEATS - SERVICE INFORMATION REMOVAL - FRONT RISER MOTOR .. . . . . 102

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 95 INSTALLATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 HORIZONTAL MOTOR . . . . . . . . . . . . . . . . . 102
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 96 INSTALLATION - FRONT RISER MOTOR . . . 102
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 96 RECLINER MOTOR
POWER SEAT SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 96 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 POWER SEAT TRACK
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 98 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
REAR RISER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100
HORIZONTAL AND FRONT RISER MOTORS
REMOVAL
HORIZONTAL MOTOR . . . . . . . . . . . . . . . . . 101
POWER SEATS - SERVICE INFORMATION

DESCRIPTION
Both seats feature power adjustable positioning and power
reclining as standard equipment. Each seat contains a lower
(1) and a rear (2) power adjustment switch located on the
lower outboard seat trim panel between the seat base and the
door. The driver’s seat features 8-way adjustment while the
passenger’s seat is 4-way adjustable.
OPERATION
The power seat lower switch adjusts the bottom portion of the seat forward and backward as well as tilting upward
and downward both in the front and rear when the switch is pressed in that direction. The back portion of the seat
reclines when the power seat rear switch is tilted forward or rearward. The driver side power seat switches are
operational with the driver door open, regardless of the ignition switch key position. If the driver door is closed, the
ignition switch key must be turned to the ON/RUN position. See the owner’s manual in the glove box for more
information.
8N - 96 POWER SEATS - SERVICE INFORMATION ZH

Before any testing of the power seat system is performed, the battery should be fully charged. All the wiring harness
connectors should be inspected and cleaned, if necessary, to ensure good connections.
1. If all of the power seat functions are inoperative, check fuse 22 for the driver seat and fuse 21 for the passenger
seat in the underhood accessory fuse block.
2. With the dome lamp on, apply the power seat switch in the direction of the failure.
3. If the dome lamp dims, the seat or the power seat track may be jammed. Check under and behind the seat for
binding or obstructions.
4. If the dome lamp does not dim, proceed with testing of the individual power seat system components and cir-
cuits.
For complete power seat system diagnosis, see power seats electrical diagnostics in this section.
SPECIFICATIONS

Front Riser Motor
4 — 35
Attachment Screw
Horizontal Motor
4 — 35
Attachment Screw
Rear Riser Motor
4 — 35
Attachment Nut
POWER SEAT SWITCH

For complete power seat system diagnosis, see power seats electrical diagnostics in this section.
REMOVAL
2. Remove the front seat. Refer to Page 23-202.
3. Remove the bolt (1) attaching the side panel to the seat
base.
4. Push the side panel with the switches forward and down-
ward to remove.
5. Disconnect the power seat switch harness connectors (1)

and (2).
6. Separate the cable straps and expose the wiring harness.
7. Remove the side panel with switches from the seat base.
INSTALLATION
Note: Ensure the harness is routed and secured in its
original position to avoid potential interference with mov-
ing parts.
1. Install the power seat switch wiring harness in its original

location.
2. Connect the power seat switch harness connectors (1) and
(2).
3. Position the side panel with the switches as one part on the
seat base, then install the side panel attaching screw (1).
4. Install the front seat. Refer to Page 23-203.

REAR RISER MOTOR

REMOVAL
Note: Only disconnect the harness connector for the

defective motor.
3. Disconnect the rear riser motor harness connector (7).
4. Remove the rear riser motor rear attachment bolt (1).

5. Remove rear riser motor front attachment bolt (1).

6. Remove the rear riser motor.
INSTALLATION
1. Position the rear riser motor between the front and rear
attachment brackets.
2. Install the rear riser motor rear attachment bolt (1) and
torque nut to 4 N·m (35 in. lbs.).
3. Install the rear riser motor front attachment bolt (1) and
torque nut to 4 N·m (35 in. lbs.).
4. Connect the rear riser motor harness connector.

ing parts.

HORIZONTAL AND FRONT RISER MOTORS

REMOVAL
HORIZONTAL MOTOR
3. Disconnect the horizontal motor harness connector (1) or
the front riser motor harness connector (2).
4. Remove the horizontal motor attachment screws (1) or the

front riser motor attachment screws (2).
5. Remove the horizontal motor or the front riser motor.
REMOVAL - FRONT RISER MOTOR

For complete front riser motor removal procedures, see hori-
zontal motor removal in this section.
INSTALLATION
HORIZONTAL MOTOR
1. Position the horizontal motor or front riser motor so the
notch (3) is aligned as shown.
2. Install the horizontal motor attachment screws (1) or front
riser motor attachment screws (2) and torque to 4 N·m (35
in. lbs.).
3. Connect the horizontal motor or front riser motor harness
connector.
INSTALLATION - FRONT RISER MOTOR

For complete front riser motor installation procedures, see hor-
izontal motor installation in this section.
RECLINER MOTOR
REMOVAL
2. Remove the seat back cover enough to expose the recliner
motor. Refer to Page 23-206.
3. Remove the bolt (1) attaching the recliner motor to the seat
back frame and disconnect the recliner motor harness con-
nector (2).
4. Remove the snap ring on the shaft then remove the shaft
(2) from the seat back frame (1).
5. Remove the recliner motor.
INSTALLATION
Note: Ensure the rubber mount for the attachment bolt is
seated properly.
1. Install the shaft (2) to the seat back frame (1) and install
the snap ring.

ing parts.
2. Position the recliner motor to the seat back frame and

install the attachment bolt (1). Connect the recliner motor
harness connector (2).
3. Install the seat back cover. Refer to Page 23-208.
POWER SEAT TRACK

REMOVAL
3. Remove the power seat track front inboard attachment bolt
(1).
4. Remove the power seat track rear inboard attachment bolt

(1).
5. Remove the power seat switch assembly. Refer to Page

8N-96.
6. Remove the power seat track rear outboard bolt (1).

7. Tilt the rear track mechanism outward then remove the
power seat track front outboard attachment bolt (2).
8. Remove the power seat track power harness connector (8).

9. Remove the power seat track from the seat cushion.
INSTALLATION
Note: Ensure wire harnesses are routed and secured in
their original position to avoid potential interference with
moving parts.
1. Position the power seat track assembly over the seat cush-
ion and align the mounting points.
2. Install the power seat track power harness connector (8).
3. Install the power seat track front outboard attachment bolt

(2).
4. Tilt the rear of the track mechanism inward and install the
power seat track rear outboard attachment bolt (1).
5. Install the power seat switch assembly. Refer to Page

8N-98.
6. Install the power seat track rear inboard attachment bolt

(1).
7. Install the power seat track front inboard attachment bolt

(1).
ZH POWER WINDOWS - ELECTRICAL DIAGNOSTICS 8N - 109
POWER WINDOWS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
POWER WINDOWS - ELECTRICAL *BOTH POWER WINDOWS

DIAGNOSTICS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . 116
DIAGNOSIS AND TESTING BODY VERIFICATION TEST . . . . . . . . . . . . . 119
*LEFT FRONT POWER WINDOW SCHEMATICS AND DIAGRAMS . . . . . . . . . . . 120
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . 110
*RIGHT FRONT POWER WINDOW
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . 113
POWER WINDOWS - ELECTRICAL DIAGNOSTICS

8N - 110 POWER WINDOWS - ELECTRICAL DIAGNOSTICS ZH
*LEFT FRONT POWER WINDOW INOPERATIVE
*LEFT FRONT POWER WINDOW INOPERATIVE — CONTINUED
POSSIBLE CAUSES
LEFT FRONT POWER WINDOW SWITCH

LEFT POWER WINDOW SWITCH SENSE CIRCUIT
LEFT FRONT POWER WINDOW MOTOR
LEFT FRONT POWER WINDOW MOTOR CIRCUIT
For a complete Power Windows Circuit Diagram, Refer to Page 8N-120.
Diagnostic Test
1. TEST THE LEFT FRONT POWER WINDOW MOTOR

Disconnect the Body Control Module (BCM) harness connector.
Connect a fused jumper wire from cavity 12 of the BCM harness connec-
tor to B(+).
Connect a second fused jumper wire to cavity 13 of the BCM harness
connector and momentarily connect the jumper to ground.
Note window movement; if no left front window movement is noted,
reverse the jumper wires at the B(+) and ground connections.
Did the left front window move upward or downward?

Yes >> Go to 3
No >> Go to 2
2. MEASURE LEFT FRONT POWER WINDOW MOTOR CIRCUIT

RESISTANCE

Disconnect the Left Front Power Window Motor harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Left Front
Power Window Motor harness connector.
Measure the resistance between cavity 12 and cavity 13 of the BCM har-
ness connector.

Yes >> Replace the Left Front Power Window Motor. Refer to
Page 8N-122.
No >> Repair the Left Front Power Window Motor circuit for
an open.
*LEFT FRONT POWER WINDOW INOPERATIVE — CONTINUED
3. MEASURE THE VOLTAGE OF THE LEFT POWER WINDOW SWITCH
SENSE CIRCUIT

Disconnect the Left Front Power Window Switch harness connector.
Measure the voltage of the Left Power Window Switch Sense circuit at the
Left Front Power Window Switch connector.

Yes >> Replace the Left Front Power Window Switch. Refer to
Page 8N-124.
No >> Go to 4
4. MEASURE LEFT POWER WINDOW SWITCH SENSE CIRCUIT

RESISTANCE

Measure the resistance of the Left Power Window Switch Sense circuit
from the Left Front Power Window Switch harness connector to the BCM
harness connector.

No >> Repair the Left Power Window Switch Sense circuit
for an open.
*RIGHT FRONT POWER WINDOW INOPERATIVE
*RIGHT FRONT POWER WINDOW INOPERATIVE — CONTINUED
POSSIBLE CAUSES
RIGHT FRONT POWER WINDOW SWITCH

RIGHT POWER WINDOW SWITCH SENSE CIRCUIT
RIGHT FRONT POWER WINDOW MOTOR
RIGHT FRONT POWER WINDOW MOTOR CIRCUIT
Diagnostic Test
1. TEST THE RIGHT FRONT POWER WINDOW MOTOR

Connect a fused jumper wire from cavity 10 of the BCM harness connec-
tor to B(+).
Connect a second fused jumper wire to cavity 11 of the BCM harness con-
nector and momentarily connect the jumper to ground.
Note window movement; if no right front window movement is noted,
reverse the jumper wires at the B(+) and ground connections.
Did the right front window move upward or downward?

Yes >> Go to 3
No >> Go to 2
2. MEASURE RIGHT FRONT POWER WINDOW MOTOR CIRCUIT

RESISTANCE

Disconnect the Right Front Power Window Motor harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Right Front
Power Window Motor harness connector.
Measure the resistance between cavity 10 and cavity 11 of the BCM har-
ness connector.

Yes >> Replace the Right Front Power Window Motor. Refer to
Page 8N-122.
No >> Repair the Right Front Power Window Motor circuit for
an open.
*RIGHT FRONT POWER WINDOW INOPERATIVE — CONTINUED
3. MEASURE THE VOLTAGE OF THE RIGHT POWER WINDOW
SWITCH SENSE CIRCUIT

Disconnect the Right Front Power Window Switch harness connector.
Measure the voltage of the Right Power Window Switch Sense circuit at
the Right Front Power Window Switch harness connector.

Yes >> Replace the Right Front Power Window Switch. Refer to
Page 8N-124.
No >> Go to 4
4. MEASURE RIGHT POWER WINDOW SWITCH SENSE CIRCUIT

RESISTANCE

Measure the resistance of the Right Power Window Switch Sense circuit
from the Right Front Power Window Switch harness connector to the BCM
harness connector.

No >> Repair the Right Power Window Switch Sense circuit
for an open.
*BOTH POWER WINDOWS INOPERATIVE
*BOTH POWER WINDOWS INOPERATIVE — CONTINUED
POSSIBLE CAUSES

POWER WINDOW SWITCH GROUND CIRCUIT OPEN
Diagnostic Test
1. MEASURE POWER WINDOWS FUSED B(+) CIRCUIT VOLTAGE

continuing.
Measure the voltage at the BCM harness connector Fused B(+) circuit.

Yes >> Go to 2
No >> Repair the BCM Fused B(+) circuit for an open.
2. MEASURE LEFT FRONT POWER WINDOW SWITCH GROUND

CIRCUIT RESISTANCE

Disconnect the Left Front Power Window Switch harness connector.
Measure the resistance of the Left Front Power Window Switch Ground
circuit from the Left Front Power Window Switch harness connector to the
BCM harness connector.

Yes >> Go to 3
No >> Repair the Left Front Power Window Switch ground cir-
cuit for an open.
*BOTH POWER WINDOWS INOPERATIVE — CONTINUED
3. MEASURE RIGHT FRONT POWER WINDOW SWITCH GROUND
CIRCUIT RESISTANCE

Disconnect the Right Front Power Window Switch harness connector.
Measure the resistance of the Right Front Power Window Switch Ground
circuit from the Right Front Power Window Switch harness connector to
the BCM harness connector.

No >> Repair the Right Front Power Window Switch ground
1.

POWER WINDOWS CIRCUIT DIAGRAM

ZH POWER WINDOWS - SERVICE INFORMATION 8N - 121
POWER WINDOWS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
POWER WINDOWS - SERVICE INFORMATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123

DESCRIPTION ...................... . . 121 POWER WINDOW SWITCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 121 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 121 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
WINDOW MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
POWER WINDOWS - SERVICE INFORMATION

DESCRIPTION
The power window system allows each of the door windows to be raised and lowered with an individual switch
located on the center console.
OPERATION
Each door window motor receives power and ground individually through separate window switches. Reversing the
current to the motor within the switch will cause the motor to rotate in the opposite direction which forces the win-
dow either up or down. The switches in the center console provide one-touch opening.

Before any testing of the power window system is performed, the battery should be fully charged. All the wiring
harness connectors should be inspected and cleaned, if necessary, to ensure good connections.
1. If both of the power windows are inoperative, check fuse 19 in the underhood accessory fuse block.
2. With the dome lamp on, apply the power window switch in the direction of the failure.
3. If the dome lamp dims, the window track may be jammed. Check for obstructions in the guide tracks or worn
weatherstrips causing a binding.
4. If the dome lamp does not dim, proceed with testing of the individual power window system components and
circuits. For complete power windows system diagnosis, see power windows electrical diagnostics in this section.
8N - 122 POWER WINDOWS - SERVICE INFORMATION ZH
WINDOW MOTOR
REMOVAL
SONAL INJURY.

3. Gently peel back the door watershield (1) enough to
expose the power window motor attachment rivets and har-
ness connector.
Note: Prevent the power window motor from falling while

the attachment rivets are being removed.
ZH POWER WINDOWS - SERVICE INFORMATION 8N - 123
4. Disconnect the power window motor harness connector (1),

and drill out the power window motor attachment rivets (2).
5. Remove the power window motor from the door.
INSTALLATION
Note: Ensure the original mounting hole pattern is used
when installing the power window motor.
Note: Before installing, lightly grease the gear on the

power window motor.
1. Position the power window motor into the door.

2. Install the power window motor attachment rivets (2).
3. Connect the power window motor harness connector (1).
8N - 124 POWER WINDOWS - SERVICE INFORMATION ZH
POWER WINDOW SWITCH

REMOVAL
SONAL INJURY.

2. Remove the shifter cover trim panel. Refer to Page
23-173.
3. Disconnect the power window switch harness connector
(1).
4. Squeeze the clips together and remove the power window
switch from the shifter cover trim panel.
INSTALLATION
1. Install the power window switch to the shifter cover trim panel.
2. Connect the power window switch harness connector.
3. Install the shifter cover trim panel. Refer to Page 23-183.
ZH RESTRAINTS 8O - 1
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS - ELECTRICAL DIAGNOSTICS . . . . . 1 RESTRAINTS - SERVICE INFORMATION . . . . . . . 70
RESTRAINTS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
RESTRAINTS - ELECTRICAL DIAGNOSTICS ORC SYSTEM UNDERVOLTAGE . . . . . . . . . . 43

DIAGNOSIS AND TESTING AIRBAG WARNING INDICATOR CIRCUIT . . . 46
ORC INTERNAL FAILURE . . . . . . . . . . . . . . . . 2 PASSENGER AIRBAG ON/OFF SWITCH
DRIVER AIRBAG SQUIB CIRCUIT . . . . . . . . . . 4 SIGNAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 49
DRIVER SEAT BELT TENSIONER SQUIB DRIVER SEAT BELT TENSIONER CIRCUIT . . 53
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PASSENGER SEAT BELT TENSIONER
PASSENGER SEAT BELT TENSIONER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SQUIB CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 17 LEFT SIDE IMPACT SENSOR SIGNAL
PASSENGER AIRBAG SQUIB CIRCUIT . . . . . 23 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LEFT SIDE AIRBAG SQUIB CIRCUIT . . . . . . . 29 RIGHT SIDE IMPACT SENSOR SIGNAL
RIGHT SIDE AIRBAG SQUIB CIRCUIT . . . . . 35 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PROGRAMMING DOES NOT CORRESPOND AIRBAG VERIFICATION TEST . . . . . . . . . . . . 67
TO THE VEHICLE EQUIPMENT . . . . . . . . . . . 41 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 68
RESTRAINTS - ELECTRICAL DIAGNOSTICS

8O - 2 RESTRAINTS - ELECTRICAL DIAGNOSTICS ZH
ORC INTERNAL FAILURE
ZH RESTRAINTS - ELECTRICAL DIAGNOSTICS 8O - 3
ORC INTERNAL FAILURE — CONTINUED
• Set Condition: If the Occupant Restraint Controller (ORC) detects an internal malfunction, the DTC is set.
POSSIBLE CAUSES
FUSED IGNITION SWITCH OUTPUT CIRCUIT
For a complete Restraints System Circuit Diagram, Refer to Page 8O-68.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE ORC FUSED IGNITION SWITCH

OUTPUT CIRCUIT
Note: When reconnecting the Airbag System components, the igni-

tion must be turned off and the battery must be disconnected.
Disconnect the ORC harness connector.

Yes >> Replace the Occupant Restraint Controller. Refer to Page
8O-89.
DRIVER AIRBAG SQUIB CIRCUIT
DRIVER AIRBAG SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Driver
Squib circuits.
• Set Condition: The Occupant Restraint Controller (ORC) has detected abnormally high voltage, low resis-
tance, high resistance or an open circuit on one or both of the Driver Squib circuits.
POSSIBLE CAUSES
DRIVER SQUIB CIRCUIT(S) OPEN

DRIVER SQUIB CIRCUIT(S) SHORT TO VOLTAGE
DRIVER SQUIB CIRCUIT(S) SHORT TO GROUND
DRIVER SQUIB CIRCUITS SHORT TO EACH OTHER
DRIVER AIRBAG SQUIB
Diagnostic Test

Note: Ensure the battery is fully charged.
With the DRB IIIT, select ACTIVE or STORED DTCs.
Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 11
2. WITH THE DRB IIIT, READ ACTIVE DTCs
DOWN ON A HARD SURFACE; THE AIRBAG WILL PROPEL INTO THE
Disconnect the Driver airbag.
Connect the appropriate Load Tool to the Driver Airbag Squib connector.
TERY.
With the DRB IIIT, read the active Airbag DTCs.
Does the DRB IIIT display an active Driver Airbag Squib DTC?
Yes >> Go to 3
No >> Replace the Driver Airbag. Refer to Page 8O-100.

Disconnect the Load Tool from the Driver Airbag connector.
Disconnect the Clockspring connector.
Connect the appropriate Load Tool to the Clockspring connector.
TERY.
Does the DRB IIIT display an active Driver Airbag Squib DTC?
Yes >> Go to 4
No >> Replace the Clockspring. Refer to Page 8O-94.
4. MEASURE THE RESISTANCE OF THE DRIVER SQUIB LINE 1
CIRCUIT

Connect the appropriate harness adapter to the ORC connector.
Disconnect the Load Tool from the Clockspring connector.
Measure the resistance of the Driver Squib Line 1 circuit from the ORC
adapter to the Clockspring connector.

Yes >> Go to 5
No >> Repair the Driver Squib Line 1 circuit for an open.

CIRCUIT

Measure the resistance of the Driver Squib Line 2 circuit from the ORC
adapter to the Clockspring connector.

Yes >> Go to 6
No >> Repair the Driver Squib Line 2 circuit for an open.
6. MEASURE THE RESISTANCE OF THE DRIVER SQUIB CIRCUITS

Measure the resistance between the Driver Squib Line 1 circuit and the
Driver Squib Line 2 circuit at the Clockspring connector.

Yes >> Repair the Driver Squib circuits for a short to each other.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE DRIVER SQUIB LINE 1 CIRCUIT
TERY.
Measure the voltage of the Driver Squib Line 1 circuit at the Clockspring
connector.
Is voltage present?
Yes >> Repair the Driver Squib Line 1 circuit for a short to voltage.
No >> Go to 8
8. MEASURE THE VOLTAGE OF THE DRIVER SQUIB LINE 2 CIRCUIT

Measure the voltage of the Driver Squib Line 2 circuit at the Clockspring
connector.
Is voltage present?
Yes >> Repair the Driver Squib Line 2 circuit for a short to voltage.
No >> Go to 9

CIRCUIT

Measure the resistance between ground and the Driver Squib Line 1 cir-
cuit.

Yes >> Repair the Driver Squib Line 1 circuit for a short to ground.
No >> Go to 10
CIRCUIT

Measure the resistance between ground and the Driver Squib Line 2 cir-
cuit.

Yes >> Repair the Driver Squib Line 2 circuit for a short to ground.
No >> Replace the Occupant Restraint Controller. Refer to Page
8O-89.

With the DRB IIIT, record and erase all Restraint System DTCs.
All active codes must be resolved before diagnosing any stored codes.
Maintain a safe distance from all airbags while performing the following
steps.
With the DRB IIIT, monitor active codes as you work through the system.
Note: Read the DTCs with the Passenger Airbag On/Off Switch in
both switch positions.
Wiggle the wiring harness and connectors of the appropriate airbag sys-
tem and rotate the steering wheel from stop to stop.
You have just attempted to simulate the condition that initially set the trou-
ble code message.
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 the related harnesses. Look for chafed, pierced,
pinched or partially broken wire.
• Refer to any Wiring Diagrams that may apply.
Did the DTC become ACTIVE?

Yes >> Go to 2
present.
DRIVER SEAT BELT TENSIONER SQUIB CIRCUIT
DRIVER SEAT BELT TENSIONER SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Driver
Seat Belt Squib circuits.
tance, high resistance or an open circuit on one or both of the Driver Seat Belt Squib circuits.
POSSIBLE CAUSES
DRIVER SEAT BELT SQUIB CIRCUIT(S) OPEN

DRIVER SEAT BELT SQUIB CIRCUIT(S) SHORT TO VOLTAGE
DRIVER SEAT BELT SQUIB CIRCUIT(S) SHORT TO GROUND
DRIVER SEAT BELT SQUIB CIRCUITS SHORT TO EACH OTHER
DRIVER SEAT BELT TENSIONER SQUIB
Diagnostic Test

Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 10
Disconnect the Driver Seat Belt Tensioner connector.
Connect the appropriate Load Tool to the Driver Seat Belt Tensioner Squib
connector.
TERY.
With the DRB IIIT, read the active DTCs.
Does the DRB IIIT display an active Driver Seat Belt Tensioner
Squib DTC?
Yes >> Go to 3
No >> Replace the Driver Seat Belt Tensioner. Refer to Page
8O-122.
Perform AIRBAG VERIFICATION TEST. Refer to
Page 8O-1.
3. MEASURE THE RESISTANCE OF THE DRIVER SEAT BELT SQUIB

LINE 1 CIRCUIT

Disconnect the Load Tool from the Driver Seat Belt Tensioner Squib con-
nector.
Measure the resistance of the Driver Seat Belt Squib Line 1 circuit from
the ORC connector to the Driver Seat Belt Tensioner Squib connector.

Yes >> Go to 4
No >> Repair the Driver Seat Belt Squib Line 1 circuit for an
open.
Page 8O-1.
LINE 2 CIRCUIT

Measure the resistance of the Driver Seat Belt Squib Line 2 circuit from
the ORC connector to the Driver Seat Belt Tensioner Squib connector.

Yes >> Go to 5
No >> Repair the Driver Seat Belt Squib Line 2 circuit for an
open.
Page 8O-1.

CIRCUITS

Measure the resistance between the Driver Seat Belt Squib Line 1 circuit
and the Driver Seat Belt Squib Line 2 circuit at the Driver Seat Belt Ten-
sioner Squib connector.

Yes >> Repair the Driver Seat Belt Squib circuits for a short to
each other.
Perform AIRBAG VERIFICATION TEST. Refer to Page
8O-1.
No >> Go to 6
6. MEASURE THE VOLTAGE OF THE DRIVER SEAT BELT SQUIB LINE

1 CIRCUIT

TERY.
Measure the voltage of the Driver Seat Belt Squib Line 1 circuit at the
Squib connector.
Is voltage present?
Yes >> Repair the Driver Seat Belt Squib Line 1 circuit for a short
to voltage.
8O-1.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE DRIVER SEAT BELT SQUIB LINE
2 CIRCUIT

Measure the voltage of the Driver Seat Belt Squib Line 2 circuit at the
Squib connector.
Is voltage present?
to voltage.
8O-1.
No >> Go to 8

LINE 1 CIRCUIT

Measure the resistance between ground and the Driver Seat Belt Squib
Line 1 circuit.

to ground.
8O-1.
Note: When reconnecting Airbag system components, the ignition
must be turned off and the battery must be disconnected.
No >> Go to 9
LINE 2 CIRCUIT

Measure the resistance between ground and the Driver Seat Belt Squib
Line 2 circuit.

to ground.
8O-1.
8O-89.
8O-1.
Remove any special tools or jumper wires and reconnect all previously
disconnected components - except the battery
TERY.
steps.
ble code message.
bent, pushed out, spread, corroded or contaminated terminals.

Yes >> Go to 2
present.
Page 8O-1.
PASSENGER SEAT BELT TENSIONER SQUIB CIRCUIT
PASSENGER SEAT BELT TENSIONER SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Pas-
senger Seat Belt Squib circuits.
tance, high resistance or an open circuit on one or both of the Passenger Seat Belt Squib circuits.
POSSIBLE CAUSES
PASSENGER SEAT BELT SQUIB CIRCUIT(S) OPEN

PASSENGER SEAT BELT SQUIB CIRCUIT(S) SHORT TO VOLTAGE
PASSENGER SEAT BELT SQUIB CIRCUIT(S) SHORT TO GROUND
PASSENGER SEAT BELT SQUIB CIRCUITS SHORT TO EACH OTHER
PASSENGER SEAT BELT TENSIONER SQUIB
Diagnostic Test

Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 10

Disconnect the Passenger Seat Belt Tensioner connector.
Connect the appropriate Load Tool to the Passenger Seat Belt Tensioner
Squib connector.
TERY.
With the DRB IIIT, read the active DTCs.
Does the DRB IIIT display an active Passenger Seat Belt Tensioner
Squib DTC?
Yes >> Go to 3
No >> Replace the Passenger Seat Belt Tensioner. Refer to
Page 8O-122.
3. MEASURE THE RESISTANCE OF THE PASSENGER SEAT BELT

SQUIB LINE 1 CIRCUIT

Disconnect the Load Tool from the Passenger Seat Belt Tensioner Squib
connector.
Measure the resistance of the Passenger Seat Belt Squib Line 1 circuit
from the ORC connector to the Passenger Seat Belt Tensioner Squib con-
nector.

Yes >> Go to 4
No >> Repair the Passenger Seat Belt Squib Line 1 circuit for
an open.


Measure the resistance of the Passenger Seat Belt Squib Line 2 circuit
from the ORC connector to the Passenger Seat Belt Tensioner Squib con-
nector.

Yes >> Go to 5
No >> Repair the Passenger Seat Belt Squib Line 2 circuit for
an open.
SQUIB CIRCUITS

Measure the resistance between the Passenger Seat Belt Squib Line 1
circuit and the Passenger Seat Belt Squib Line 2 circuit at the Passenger
Seat Belt Tensioner Squib connector.

Yes >> Repair the Passenger Seat Belt Squib circuits for a short to
each other.
No >> Go to 6
6. MEASURE THE VOLTAGE OF THE PASSENGER SEAT BELT SQUIB

LINE 1 CIRCUIT

TERY.
Measure the voltage of the Passenger Seat Belt Squib Line 1 circuit at the
Squib connector.
Is voltage present?
Yes >> Repair the Passenger Seat Belt Squib Line 1 circuit for a
short to voltage.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE PASSENGER SEAT BELT SQUIB

LINE 2 CIRCUIT

Measure the voltage of the Passenger Seat Belt Squib Line 2 circuit at the
Squib connector.
Is voltage present?
short to voltage.
No >> Go to 8

Measure the resistance between ground and the Passenger Seat Belt
Squib Line 1 circuit.

short to ground.
No >> Go to 9


Measure the resistance between ground and the Passenger Seat Belt
Squib Line 2 circuit.

short to ground.
8O-89.
Remove any special tools or jumper wires and reconnect all previously
disconnected components - except the battery
TERY.
steps.
ble code message.
bent, pushed out, spread, corroded, or contaminated terminals.

Yes >> Go to 2
present.
PASSENGER AIRBAG SQUIB CIRCUIT
PASSENGER AIRBAG SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Pas-
senger Squib circuits.
tance, high resistance or an open circuit on one or both of the Passenger Squib circuits.
POSSIBLE CAUSES
PASSENGER SQUIB CIRCUIT(S) OPEN

PASSENGER SQUIB CIRCUIT(S) SHORT TO VOLTAGE
PASSENGER SQUIB CIRCUIT(S) SHORT TO GROUND
PASSENGER SQUIB CIRCUITS SHORT TO EACH OTHER
PASSENGER AIRBAG SQUIB
Diagnostic Test

Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 10
Disconnect the Passenger airbag.
Connect the appropriate Load Tool to the Passenger Airbag Squib connec-
tor.
TERY.
Does the DRB IIIT display an active Passenger Airbag Squib DTC?
Yes >> Go to 3
No >> Replace the Passenger Airbag. Refer to Page 8O-102.
3. MEASURE THE RESISTANCE OF THE PASSENGER SQUIB LINE 1

CIRCUIT

Disconnect the Load Tool from the Passenger Airbag Squib connector.
Measure the resistance of the Passenger Squib Line 1 circuit from the
ORC adapter to the Passenger Airbag Squib connector.

Yes >> Go to 4
No >> Repair the Passenger Squib Line 1 circuit for an open.
CIRCUIT
With the ignitin off.

Measure the resistance of the Passenger Squib Line 2 circuit from the
ORC adapter to the Passenger Airbag Squib connector.

Yes >> Go to 5
No >> Repair the Passenger Squib Line 2 circuit for an open.
5. MEASURE THE RESISTANCE OF THE PASSENGER SQUIB

CIRCUITS
With the ignitin off.

Measure the resistance between the Passenger Squib Line 1 circuit and
the Passenger Squib Line 2 circuit at the Passenger Airbag Squib connec-
tor.

Yes >> Repair the Passenger Squib circuits for a short to each
other.
No >> Go to 6
6. MEASURE THE VOLTAGE OF THE PASSENGER SQUIB LINE 1

CIRCUIT

TERY.
Measure the voltage of the Passenger Squib Line 1 circuit at the Squib
connector.
Is voltage present?
Yes >> Repair the Passenger Squib Line 1 circuit for a short to
voltage.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE PASSENGER SQUIB LINE 2
CIRCUIT

Measure the voltage of the Passenger Squib Line 2 circuit between at the
Squib connector.
Is voltage present?
voltage.
No >> Go to 8

CIRCUIT

Measure the resistance between ground and the Passenger Squib Line 1
circuit.

ground.
No >> Go to 9

CIRCUIT
With the igntion off.

Measure the resistance between ground and the Passenger Squib Line 2
circuit.

ground.
8O-89.
steps.
ble code message.

Yes >> Go to 2
present.
LEFT SIDE AIRBAG SQUIB CIRCUIT
LEFT SIDE AIRBAG SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Left
Side Squib circuits.
• Set Condition: The ORC has detected abnormally high voltage, low resistance, high resistance or an
open circuit on one or both of the Left Side Squib circuits.
POSSIBLE CAUSES
LEFT SIDE SQUIB CIRCUIT(S) OPEN

LEFT SIDE SQUIB CIRCUIT(S) SHORT TO VOLTAGE
LEFT SIDE SQUIB CIRCUIT(S) SHORT TO GROUND
LEFT SIDE SQUIB CIRCUITS SHORT TO EACH OTHER
LEFT SIDE AIRBAG SQUIB
Diagnostic Test

Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 10
Disconnect the Left Side airbag.
Connect the appropriate Load Tool to the Left Side Airbag Squib connec-
tor.
TERY.
Does the DRB IIIT display an active Left Side Airbag Squib DTC?
Yes >> Go to 3
No >> Replace the Left Side Airbag. Refer to Page 8O-114.
3. MEASURE THE RESISTANCE OF THE LEFT SIDE SQUIB LINE 1

CIRCUIT

Disconnect the Load Tool from the Left Side Airbag Squib connector.
Measure the resistance of the Left Side Squib Line 1 circuit from the ORC
connector to the Left Side Airbag Squib connector.

Yes >> Go to 4
No >> Repair the Left Side Squib Line 1 circuit for an open.
CIRCUIT

Measure the resistance of the Left Side Squib Line 2 circuit from the ORC
adapter to the Left Side Airbag Squib connector.

Yes >> Go to 5
No >> Repair the Left Side Squib Line 2 circuit for an open.
5. MEASURE THE RESISTANCE OF THE LEFT SIDE SQUIB CIRCUITS

Measure the resistance between the Left Side Squib Line 1 circuit and the
Left Side Squib Line 2 circuit at the Left Side Airbag Squib connector.

Yes >> Repair the Left Side Squib circuits for a short to each other.
No >> Go to 6
6. MEASURE THE VOLTAGE OF THE LEFT SIDE SQUIB LINE 1

CIRCUIT

TERY.
Measure the voltage of the Left Side Squib Line 1 circuit at the Squib con-
nector.
Is voltage present?
Yes >> Repair the Left Side Squib Line 1 circuit for a short to volt-
age.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE LEFT SIDE SQUIB LINE 2
CIRCUIT

Measure the voltage of the Left Side Squib Line 2 circuit at the Squib con-
nector.
Is voltage present?
Yes >> Repair the Left Side Squib Line 2 circuit for a short to volt-
age.
No >> Go to 8

CIRCUIT

Measure the resistance between ground and the Left Side Squib Line 1
circuit.

Yes >> Repair the Left Side Squib Line 1 circuit for a short to
ground.
No >> Go to 9

CIRCUIT

Measure the resistance between ground and the Left Side Squib Line 2
circuit.

Yes >> Repair the Left Side Squib Line 2 circuit for a short to
ground.
8O-89.
steps.
ble code message.

Yes >> Go to 2
present.
RIGHT SIDE AIRBAG SQUIB CIRCUIT
RIGHT SIDE AIRBAG SQUIB CIRCUIT — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the resistance of the Right
Side Squib circuits.
• Set Condition: The ORC has detected abnormally high voltage, low resistance, high resistance or an
open circuit on one or both of the Right Side Squib circuits.
POSSIBLE CAUSES
RIGHT SIDE SQUIB CIRCUIT(S) OPEN

RIGHT SIDE SQUIB CIRCUIT(S) SHORT TO VOLTAGE
RIGHT SIDE SQUIB CIRCUIT(S) SHORT TO GROUND
RIGHT SIDE SQUIB CIRCUITS SHORT TO EACH OTHER
RIGHT SIDE AIRBAG SQUIB
Diagnostic Test

Is the DTC ACTIVE?

Yes >> Go to 2
No >> Go to 10
DOWN ON A HARD SURFACE; THE AIRBAG WILL PROPEL INTO THE
Disconnect the Right Side airbag.
Connect the appropriate Load Tool to the Right Side Airbag Squib connec-
tor.
TERY.
Does the DRB IIIT display an active Right Side Airbag Squib DTC?
Yes >> Go to 3
No >> Replace the Right Side Airbag. Refer to Page 8O-114.
3. MEASURE THE RESISTANCE OF THE RIGHT SIDE SQUIB LINE 1

CIRCUIT

Disconnect the Load Tool from the Right Side Airbag Squib connector.
Measure the resistance of the Right Side Squib Line 1 circuit from the
ORC adapter to the Right Side Airbag Squib connector.

Yes >> Go to 4
No >> Repair the Right Side Squib Line 1 circuit for an open.
CIRCUIT

Measure the resistance of the Right Side Squib Line 2 circuit from the
ORC adapter to the Right Side Airbag Squib connector.

Yes >> Go to 5
No >> Repair the Right Side Squib Line 2 circuit for an open.
5. MEASURE THE RESISTANCE OF THE RIGHT SIDE SQUIB

CIRCUITS

Measure the resistance between the Right Side Squib Line 1 circuit and
the Right Side Squib Line 2 circuit at the Right Side Airbag Squib connec-
tor.

Yes >> Repair the Right Side Squib circuits for a short to each
other.
No >> Go to 6
6. MEASURE THE VOLTAGE OF THE RIGHT SIDE SQUIB LINE 1

CIRCUIT

TERY.
Measure the voltage of the Right Side Squib Line 1 circuit at the Squib
connector.
Is voltage present?
Yes >> Repair the Right Side Squib Line 1 circuit for a short to volt-
age.
No >> Go to 7
7. MEASURE THE VOLTAGE OF THE RIGHT SIDE SQUIB LINE 2
CIRCUIT

Measure the voltage of the Right Side Squib Line 2 circuit at the Squib
connector.
Is voltage present?
Yes >> Repair the Right Side Squib Line 2 circuit for a short to volt-
age.
No >> Go to 8

CIRCUIT

Measure the resistance between ground and the Right Side Squib Line 1
circuit.

Yes >> Repair the Right Side Squib Line 1 circuit for a short to
ground.
No >> Go to 9

CIRCUIT

Measure the resistance between ground and the Right Side Squib Line 2
circuit.

Yes >> Repair the Right Side Squib Line 2 circuit for a short to
ground.
8O-89.
steps.
ble code message.

Yes >> Go to 2
present.
PROGRAMMING DOES NOT CORRESPOND TO THE VEHICLE EQUIPMENT
PROGRAMMING DOES NOT CORRESPOND TO THE VEHICLE EQUIPMENT — CONTINUED
• Set Condition: After the Occupant Restraint Controller (ORC) has been replaced, the Airbag Warning Indi-
cator Light flashes to indicate that the ORC has not been programmed. A DTC is also set at this time.
POSSIBLE CAUSES
OCCUPANT RESTRAINT CONTROLLER NOT PROGRAMMED

OCCUPANT RESTRAINT CONTROLLER PROGRAMMING ERROR
Diagnostic Test
1. PROGRAM THE ORC WITH THE DRB IIIT

With the DRB IIIT, program the ORC.
• On the parts control modules menu, program the side airbag
equipment to YES.
• On the parts control modules menu, program the seat belt
buckle equipment to YES.
• On the parts control modules menu, program the seat occu-
pied recognition equipment to YES.
• Set the front passenger airbag to YES.
Erase DTCs, the Airbag Warning Indicator Light should flash to indicate
that the programming procedure was successful.
Does the DRB IIIT display a Programming Does Not Correspond To

The Vehicle Equipment DTC?
Yes >> Attempt the programming procedure again or replace the
Occupant Restraint Controller. Refer to Page 8O-89.
present.
ORC SYSTEM UNDERVOLTAGE
ORC SYSTEM UNDERVOLTAGE — CONTINUED
• When Monitored: Ignition on. The Occupant Restraint Controller (ORC) monitors the Fused Ignition Switch
Output circuit for proper system voltage.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW

FUSED IGNITION SWITCH OUTPUT CIRCUIT HIGH RESISTANCE
Diagnostic Test

Start the engine.
Leave the vehicle running for at least 20 seconds.

Yes >> Go to 2

Start the engine.

No >> Go to 3
ORC SYSTEM UNDERVOLTAGE — CONTINUED
3. MEASURE THE VOLTAGE OF THE FUSED IGNITION SWITCH
OUTPUT CIRCUIT


8O-89.
No >> Repair the Fused Ignition Switch Output circuit for high
resistance.
AIRBAG WARNING INDICATOR CIRCUIT
AIRBAG WARNING INDICATOR CIRCUIT — CONTINUED
• When Monitored: With the ignition on. The Occupant Restraint Controller (ORC) monitors the status of the
Airbag Warning Indicator Driver circuit.
• Set Condition: The DTC will set if the Airbag Warning Indicator Driver circuit is open or short.
POSSIBLE CAUSES

AIRBAG WARNING INDICATOR DRIVER CIRCUIT OPEN
AIRBAG WARNING INDICATOR DRIVER CIRCUIT SHORT
INDICATOR LIGHT
Diagnostic Test
1. INSPECT THE AIRBAG WARNING INDICATOR LAMP BULB

Block. If the fuse is open, repair the cause of the open first before
continuing.
Remove the Airbag Warning Indicator Lamp Bulb from the Instrument
Cluster and inspect for an open filament.

Yes >> Replace the Airbag Warning Indicator Lamp bulb. Refer to
Page 8J-75.
No >> Go to 2
2. MEASURE INSTRUMENT CLUSTER VOLTAGE

Measure the voltage of the Fused B(+) circuit at the Instrument Cluster
harness connector.

Yes >> Go to 3
AIRBAG WARNING INDICATOR CIRCUIT — CONTINUED
3. MEASURE THE VOLTAGE AT THE ORC
Connect a jumper wire between the terminals in the Instrument Cluster
harness connector.
TERY.
Measure the voltage of the Airbag Warning Indicator Driver circuit at the

Yes >> Go to 4
No >> Repair the Airbag Warning Indicator Driver circuit for an
open.
4. MEASURE THE VOLTAGE AT THE ORC

Reconnect the Instrument Cluster harness connector.
TERY.
Connect a jumper wire to ground at the ORC harness connector.
Did the Airbag Warning Indicator Light illuminate?

8O-89.
PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT
PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT — CONTINUED
Passenger Airbag On/Off Switch Signal circuit.
• Set Condition: The DTC will set if a communication fault is detected between the ORC and the Passen-
ger Seat Occupant Simulator.
POSSIBLE CAUSES

PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT OPEN
PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT SHORT TO VOLTAGE
PASSENGER AIRBAG ON/OFF SWITCH SIGNAL CIRCUIT SHORT TO GROUND
PASSENGER SEAT OCCUPANT SIMULATOR
Diagnostic Test
1. MEASURE FUSED B(+) CIRCUIT VOLTAGE

continuing.
Note: The Passenger Seat Occupant Simulator is located behind the
passenger footwell near the Power Amplifier.
Disconnect the Passenger Seat Occupant Simulator harness connector.
TERY.
Measure the voltage of the Fused B(+) circuit at the Passenger Seat
Occupant Simulator harness connector.

Yes >> Go to 2
No >> Repair the Passenger Seat Occupant Simulator Fused
B(+) circuit.
2. MEASURE THE PASSENGER AIRBAG ON/OFF SWITCH SIGNAL
CIRCUIT RESISTANCE

Measure the resistance of the Passenger Airbag ON/OFF Switch Signal
circuit from the ORC harness connector to the Passenger Seat Occupant
Simulator harness connector.

Yes >> Go to 3
No >> Repair the Passenger Airbag On/Off Switch Signal circuit
for an open.
3. MEASURE THE PASSENGER AIRBAG ON/OFF SWITCH SIGNAL

CIRCUIT RESISTANCE

Measure the resistance between ground and the Passenger Airbag On/Off
Switch Signal circuit.

Yes >> Repair the Passenger Airbag On/Off Switch Signal circuit
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE PASSENGER AIRBAG ON/OFF

SWITCH SIGNAL CIRCUIT

TERY.
Measure the voltage of the Passenger Airbag On/Off Switch Signal circuit
at the Passenger Seat Occupant Simulator harness connector.
Is voltage present?
Yes >> Repair the Passenger Airbag On/Off Switch Signal circuit
No >> Go to 5
5. MEASURE THE PASSENGER SEAT OCCUPANT SIMULATOR
GROUND CIRCUIT RESISTANCE

Measure the resistance between ground and the Passenger Seat Occu-
pant Simulator Ground circuit.

Yes >> Replace the Passenger Seat Occupant Simulator. Refer to
Page 8O-105.
No >> Repair the Passenger Seat Occupant Simulator
Ground circuit for an open.
DRIVER SEAT BELT TENSIONER CIRCUIT
DRIVER SEAT BELT TENSIONER CIRCUIT — CONTINUED
• When Monitored: The Occupant Restraint Controller (ORC) monitors the Driver Seat Belt Tensioner Switch
Sense circuit.
• Set Condition: The DTC will set if the ORC detects high voltage.
POSSIBLE CAUSES
DRIVER SEAT BELT TENSIONER SWITCH SENSE CIRCUIT SHORT

DRIVER SEAT BELT TENSIONER SWITCH
Diagnostic Test
1. READ DTCs WITH THE DRB IIIT

Disconnect the Driver Seat Belt Tensioner Switch harness connector.
Connect a jumper wire at the Driver Seat Belt Tensioner Switch harness
connector.
TERY.
With the DRB IIIT, read the DTCs.
Does the DRB IIIT display a Driver Seat Belt Tensioner Switch
DTC?
Yes >> Go to 2
No >> Replace the Driver Seat Belt Tensioner Switch. Refer to
Page 8O-122.
DRIVER SEAT BELT TENSIONER CIRCUIT — CONTINUED
2. MEASURE THE VOLTAGE OF THE DRIVER SEAT BELT TENSIONER
SWITCH SENSE CIRCUIT

Disconnect the ORC connector.
Disconnect the Driver Seat Belt Tensioner Switch connector.
TERY.
Measure the voltage of the Driver Seat Belt Tensioner Switch Sense circuit
at the Driver Seat Belt Tensioner Switch harness connector.
Is voltage present?
Yes >> Repair the Driver Seat Belt Tensioner Switch Sense circuit
Page 8O-89.
PASSENGER SEAT BELT TENSIONER CIRCUIT
PASSENGER SEAT BELT TENSIONER CIRCUIT — CONTINUED
• When Monitored: The Occupant Restraint Controller (ORC) monitors the Passenger Seat Belt Tensioner
Switch Sense circuit.
• Set Condition: The DTC will set if the ORC detects high voltage.
POSSIBLE CAUSES
PASSENGER SEAT BELT TENSIONER SWITCH SENSE CIRCUIT SHORT

PASSENGER SEAT BELT TENSIONER SWITCH
Diagnostic Test
1. READ DTCs WITH THE DRB IIIT

Disconnect the Passenger Seat Belt Tensioner Switch connector.
Connect a jumper wire at the Passenger Seat Belt Tensioner Switch con-
nector.
TERY.
With the DRB IIIT, read the DTCs.
Does the DRB IIIT display a Passenger Seat Belt Tensioner Switch
DTC?
Yes >> Go to 2
No >> Replace the Passenger Seat Belt Tensioner Switch.
Refer to Page 8O-122.
PASSENGER SEAT BELT TENSIONER CIRCUIT — CONTINUED
2. MEASURE THE VOLTAGE OF THE PASSENGER SEAT BELT
TENSIONER SWITCH SENSE CIRCUIT

Disconnect the ORC connector.
Disconnect the Passenger Seat Belt Tensioner Switch connector.
TERY.
Measure the voltage of the Passenger Seat Belt Tensioner Switch Sense
circuit at the Passenger Seat Belt Tensioner Switch harness connector.
Is voltage present?
Yes >> Repair the Passenger Seat Belt Tensioner Switch Sense
Page 8O-89.
LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT
LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT — CONTINUED
Left Side Impact Sensor Signal circuit.
• Set Condition: The DTC will set if a circuit failure is detected between the ORC and the Left Side Impact
Sensor.
POSSIBLE CAUSES

LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT OPEN
LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT SHORT
LEFT SIDE IMPACT SENSOR
Diagnostic Test
1. MEASURE LEFT SIDE IMPACT SENSOR FUSED IGNITION SWITCH

OUTPUT VOLTAGE

continuing.
Disconnect the Left Side Impact Sensor harness connector.
TERY.
Measure the voltage of the Fused Ignition Switch Output circuit at the Left
Side Impact Sensor harness connector.

Yes >> Go to 2
No >> Repair the Left Side Impact Sensor Fused Ignition Switch
Output circuit.
2. MEASURE THE LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT
RESISTANCE

Measure the resistance of the Left Side Impact Sensor Signal circuit from
the Left Side Impact Sensor harness connector to the ORC harness con-
nector.

Yes >> Go to 3
No >> Repair the Left Side Impact Sensor Signal circuit for an
open.
3. MEASURE THE LEFT SIDE IMPACT SENSOR SIGNAL CIRCUIT

RESISTANCE

Measure the resistance between ground and the Left Side Impact Sensor
Signal circuit.

Yes >> Repair the Left Side Impact Sensor Signal circuit for a short
to ground.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE LEFT SIDE IMPACT SENSOR

SIGNAL CIRCUIT

TERY.
Measure the voltage of the Left Side Impact Sensor Signal circuit at the
Left Side Impact Sensor harness connector.
Is voltage present?
Yes >> Repair the Left Side Impact Sensor Signal circuit for a short
to voltage.
No >> Go to 5
5. MEASURE THE LEFT SIDE IMPACT SENSOR GROUND CIRCUIT
RESISTANCE

Measure the resistance between ground and the Left Side Impact Sensor
Ground circuit.

Yes >> Replace the Left Side Impact Sensor. Refer to Page
8O-108.
No >> Repair the open Left Side Impact Sensor Ground cir-
cuit.
RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT
RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT — CONTINUED
Right Side Impact Sensor Signal Circuit.
• Set Condition: The DTC will set if a circuit failure is detected between the ORC and the Right Side
Impact Sensor.
POSSIBLE CAUSES

RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT OPEN
RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT SHORT
RIGHT SIDE IMPACT SENSOR
Diagnostic Test
1. MEASURE THE RIGHT SIDE IMPACT SENSOR FUSED IGNITION

SWITCH OUTPUT VOLTAGE

continuing.
Disconnect the Right Side Impact Sensor harness connector.
TERY.
Right Side Impact Sensor harness connector.

Yes >> Go to 2
No >> Repair the Right Side Impact Sensor Fused Ignition
Switch Output circuit.
2. MEASURE THE RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT
RESISTANCE

Measure the resistance of the Right Side Impact Sensor Signal circuit
from the Right Side Impact Sensor harness connector to the ORC harness
connector.

Yes >> Go to 3
No >> Repair the Right Side Impact Sensor Signal circuit for an
open.
3. MEASURE THE RIGHT SIDE IMPACT SENSOR SIGNAL CIRCUIT

RESISTANCE

Measure the resistance between ground and the Right Side Impact Sen-
sor Signal circuit.

Yes >> Repair the Right Side Impact Sensor Signal circuit for a
short to ground.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE RIGHT SIDE IMPACT SENSOR

SIGNAL CIRCUIT

TERY.
Measure the voltage of the Right Side Impact Sensor Signal circuit at the
Right Side Impact Sensor harness connector.
Is voltage present?
Yes >> Repair the Right Side Impact Sensor Signal circuit for a
short to voltage.
No >> Go to 5
5. MEASURE THE RIGHT SIDE IMPACT SENSOR GROUND CIRCUIT
RESISTANCE

Measure the resistance between ground and the Right Side Impact Sen-
sor Ground circuit.

Yes >> Replace the Right Side Impact Sensor. Refer to Page
8O-108.
No >> Repair the open Right Side Impact Sensor Ground cir-
cuit.
AIRBAG VERIFICATION TEST
1.
Remove any special tools, disconnect all jumper wires and reconnect all
previously disconnected components and connectors.
TERY.
With the DRB IIIT, erase all Diagnostic Trouble Codes (DTCs) from the
airbag system module.
Turn the ignition off, and wait 15 seconds.
Turn the ignition on, and with the DRB IIIT, confirm that no DTCs are
present and that all components are functioning properly.

RESTRAINTS SYSTEM CIRCUIT DIAGRAM (1 OF 2)

RESTRAINTS SYSTEM CIRCUIT DIAGRAM (2 OF 2)

8O - 70 RESTRAINTS - SERVICE INFORMATION ZH
RESTRAINTS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
RESTRAINTS - SERVICE INFORMATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 70 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 PASSENGER AIRBAG
DIAGNOSIS AND TESTING - SUPPLEMENTAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 101
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . 83 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 101
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
STANDARD PROCEDURE - HANDLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
NON-DEPLOYED SUPPLEMENTAL ON / OFF SWITCH INDICATOR MODULE
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 83 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
STANDARD PROCEDURE - SERVICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
AFTER A SUPPLEMENTAL RESTRAINT SIDE IMPACT SENSOR
DEPLOYMENT . . . . . . . . . . . . . . . . . . . . . . . . 84 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107
STANDARD PROCEDURE - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SUPPLEMENTAL RESTRAINT SYSTEM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
(SRS) - VERIFICATION TEST . . . . . . . . . . . . . 86 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
SPECIFICATIONS SIDE IMPACT AIRBAG
TORQUE CHART - RESTRAINTS ....... . . 87 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112
OCCUPANT RESTRAINT CONTROLLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 87 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114
STANDARD PROCEDURE - ORC SEAT BELT BUCKLE
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 89 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 115
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
CLOCKSPRING SEAT BELT & SEAT BELT TENSIONER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 120
STANDARD PROCEDURE - CLOCKSPRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
CENTERING ....................... . . 93 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
DRIVER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97
RESTRAINTS - SERVICE INFORMATION

DESCRIPTION
Occupant restraints for this vehicle include both Active and Passive types. Active restraints are those which require
the occupants to take some action to employ, such as fastening the seat belt; while Passive restraints require no
action by the occupants to be employed.
ZH RESTRAINTS - SERVICE INFORMATION 8O - 71
ACTIVE RESTRAINTS
The Active restraints include:
Front Driver and Passenger Seat Belts - Both seating positions are equipped with a three-point restraint. Seat
Belt Tensioners (SBT) that actuate to remove slack in the seat belts and to snug the occupant into the seat at the
onset of an impact event. This controls the occupant’s forward movement to reduce the likelihood of injury as a
result of contacting any interior components. Especially during the primary impact event phase, the tensioning power
of the SBTs guarantees optimum transmission of the passenger compartment deceleration to the passenger. The
vehicle’s SBTs employ load-limiting retractors that “give” with higher seat belt loads. If a given seat belt force is
exceeded, the seat belt force limiter permits a controlled forward inclination of the occupant’s upper body. This pro-
tective function reduces the risk of chest and shoulder injuries and permits the passenger to plunge deeper into the
airbag for a smooth dissipation of the occupant’s kinetic energy. The drivers SBT is mounted in the B pillar below
the belt line which locks only as a result of a sudden vehicle stop or a rapid extension of the webbing. This is called
“Emergency Locking”, it will allow free movement under normal driving conditions. To allow the retention of a child
seat, a dual-mode passenger SBT is mounted in the B pillar below the belt line and can be switched between
“Emergency Locking” and “Automatic Locking”. Seat-mounted, inboard buckles allow seat adjustment while main-
taining a consistent relationship between the buckle and the seat belt. For easy and consistent access and adjust-
ment, a free-running latch plate on each belt slides along the webbing and stops against a button near the
occupant’s shoulder when unfastened. A seat belt warning lamp in the Instrument Cluster (IC) comes on and a
warning chime sounds for a short time if the driver’s seat belt is not fastened when the ignition switch is turned to
the “RUN” position. After starting the engine, the seat belt warning indicator flashes briefly as an added precaution.
Child Restraint Anchors - The front passenger seat includes a LATCH (Lower Anchors and Tether for Children)
child seat anchorage system. LATCH-compatible child seats are those engineered for retention by direct attachment
to the vehicle’s seat structure rather than with the vehicle’s seat belts. The child seat’s lower anchors attach to the
seat structure via heavy-gauge wire loops at the intersection of the seat cushion and seat back. The child seat’s
upper tether strap attaches to a child seat tether anchor. Child seats can also be securely fastened in the passenger
seat using the seat belts. For this purpose, the passenger seat belt includes a dual-mode SBT. After the child seat
is positioned and the belt routed according to instructions for the child seat, the seat belt is pulled all the way out
of the SBT to the end of its travel. This switches the SBT to the “Automatic Locking” mode. As the seat belt retracts,
the SBT locks to prevent the belt from being pulled out again. Pulling the belt snugly over the child seat secures the
seat in place. When the belt retracts fully after child seat removal, normal “Emergency Locking” action is restored to
the SBT.
PASSIVE RESTRAINTS
The passive restraints include:
Driver and Passenger Front Airbags - This airbag system is
a passive, inflatable, Supplemental Restraint System (SRS).
Vehicles with this equipment can be readily identified by the
“SRS AIRBAG” logo molded into the driver airbag trim cover in
the steering wheel (1) and also into the passenger airbag area
(2) of the instrument panel top pad above the glove box.
Vehicles with the SRS can also be identified by the Airbag

Warning Indicator, which will illuminate in the Instrument Clus-
ter (IC) for about six seconds as a bulb test each time the igni-
tion switch is turned to the “RUN” position.
The Supplemental Restraint System (SRS) also includes the

following major components.
Occupant Restraint Controller (ORC) - The Occupant
Restraint Controller (ORC) is located on a mount on the floor
panel transmission tunnel (2) in front of the shifter, under the
front center console.
ORC System Logic - The Supplemental Restraint System
(SRS) uses an impact severity level (threshold) to determine
the appropriate response from the ORC. Impacts that exceed
the initial threshold in frontal, front-angled and rear impacts
trigger only the SBTs, only if the seat belts are fastened, but
trigger the airbags if the seat belts are not fastened. Impacts
that exceed the higher threshold always trigger the airbags.
The driver and passenger SRS systems operate independently
of one another based on seat belt use. SBT actuation occurs
only if the seat belts are buckled. After an impact that activates
an SBT, the SBT assembly must be replaced. The ORC mon-
itors operational readiness of SRS and illuminates the airbag
warning indicator lamp in the Instrument Cluster (IC) if a mal-
function should occur. The following system components are
monitored or undergo a self-check at startup. The side-impact
sensor, airbag ignition circuits (squibs), seat belt buckle
switches and the SBT. The airbag warning indicator lamp also
illuminates briefly each time the engine is started, allowing the
driver to verify its operation.
Airbag Warning Indicator Lamp - The airbag warning indica-

tor lamp is integral to the Instrument Cluster (IC), which is
located on the Instrument Panel (IP) in front of the driver.
Clockspring - The clockspring is located at the top of the

steering column, directly beneath the steering wheel where it
is attached to the column by two screws (1).
Driver Front Airbag - The driver front airbag (1) is located in

the center of the steering wheel, as part of the steering wheel
trim cover.
Passenger Front Airbag - The passenger front airbag (1) is

located on the instrument panel structural duct, beneath the
instrument panel top pad and above the glove box.
The passenger front air bag can be deactivated when a child

seat or small child occupies that seat by using the ignition key
to turn the switch (1) to the OFF position. This will illuminate
the passenger airbag OFF warning lamp on the center con-
sole. This indicates that the passenger front airbag is deacti-
vated. The passenger front airbag will not be activated until the
switch is turned to ON position and the passenger airbag OFF
warning lamp goes out.
The passenger airbag off warning lamp (1) in the center con-
sole illuminates when the air bag is deactivated.
Side Impact Sensor - Two side impact sensors (2) are

installed, one left side and one right side. One sensor is
located under the carpet directly below each of the front seats.
Side Impact Airbag - The side impact airbags are concealed

behind the door trim panels above the armrest. The side
impact airbag is riveted (1) to the door’s interior structure and
activated by a squib (2). SRS logos on the trim panels denote
the presence of the airbags. If the airbag is triggered during a
lateral collision, the airbag tears open a seam on the inner
door trim and inflates within 0.007 seconds to form a protec-
tive cushion between the passenger and the door. Thus the
impact on the passenger’s thorax and the ejecting motion of
the head, which might otherwise cause serious injuries, are
reduced.
The ORC and the Instrument Cluster (IC) each contain a cen-
tral processing unit and programming that allow them to com-
municate with each other using the Controller Area Network
(CAN). This method of communication is used by the ORC for
control of the airbag indicator lamp.
Hard wired circuitry connects the SRS components to each
other through the electrical system of the vehicle. These hard
wired circuits are integral to several wire harnesses, which are
routed throughout the vehicle and retained by many different
methods. These circuits may be connected to each other, to
the vehicle electrical system, and to the SRS components
through the use of a combination of soldered splices, splice
block connectors, and many different types of wire harness ter-
minal connectors and insulators. Refer to the appropriate wir-
ing 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 connec-
tors, splices and grounds.
OPERATION
ACTIVE RESTRAINTS
The primary passenger restraints in this or any other vehicle are the standard equipment factory-installed seat belts
and child restraint anchors. Seat belts and child restraint anchors are referred to as an active restraint because the
occupants are required to physically fasten and properly adjust these restraints in order to benefit from them. See
the Owner’s Manual in the vehicle glove box for more information on the features, use, and operation of all of the
factory-installed active restraints.
PASSIVE RESTRAINTS
The driver/passenger airbags and the driver/passenger Seat Belt Tensioners (SBT) were designed to reduce the risk
of an injury to the chest and head in the event of a head-on collision.
The side airbags were designed to protect primarily the upper body and also to help protect the head in the event
of a side collision.
Malfunctions in the SRS system are indicated on the Instrument Cluster (IC) by the airbag warning indicator lamp.
SRS - AIRBAG WARNING INDICATOR

The SRS airbag warning indicator lamp indicates that the SRS
is ready for operation. When no faults are present in the sys-
tem, the airbag warning indicator illuminates when the ignition
switch is turned to the ON or RUN position and then goes out
after approximately six seconds.
An error or malfunction is indicated in the SRS by the airbag
warning indicator not illuminating when the ignition switch is
turned to the ON or RUN position or not going out after six
seconds.
Errors and malfunctions not endangering occupant protection
are indicated by the airbag warning indicator illuminating for
approximately two minutes when the ignition switch is turned
to the ON or RUN position.
Errors and malfunctions which may endanger the occupant are
indicated by the airbag warning indicator illuminating continu-
ously.
In the case of an error or a malfunction the entire system
should be checked according to the diagnosis instructions. The
active restraints ARE NOT affected by an error or a malfunc-
tion in the SRS and remain operational.
PASSENGER AIRBAG OFF INDICATOR LAMP

The passenger Airbag Off Indicator Lamp operates in conjunction with the Passenger Airbag On/Off Switch. When
the switch is turned to either the On or the Off position, the switch position is communicated to the Passenger Seat
Occupant Simulator. The Passenger Seat Occupant Simulator then translates the switch position into a signal that
the Occupant Restraint Controller is capable of reading in order to switch the Passenger Airbag on or off depending
upon the Switch position. The Passenger Airbag Off Indicator Lamp will stay illuminated as long as the Passenger
Airbag On/Off Switch is in the Off position.
FRONT END MEDIUM-SEVERE HEAD ON COLLISION SRS OPERATION
Only the seat belt tensioners (SBT) are triggered.

The ORC registers medium-deceleration (stage-one threshold) due to a collision.
The triggering pulse is transferred only to the SBT squibs, because the restraint function of the seat belts in com-
bination with the SBT is sufficient enough to effectively protect the vehicles passengers for this type of collision.
A check is made whether the seat belts are fastened. If a seat belt is not fastened and the stage one threshold is
exceeded the driver and passenger airbags are triggered to provide protection for the front passengers.
FRONT END SEVERE HEAD-ON COLLISION SRS OPERATION
“Stage two threshold” The ORC recognizes the vehicles rapid deceleration due to a collision. The ORC routes the
triggering pulse to the driver and passenger airbag squibs. At the same time the driver and passenger SBTs are
also triggered.
REAR-END COLLISION SRS OPERATION
When the ORC registers sudden acceleration which exceeds the forward threshold value a check is made to deter-
mine which front seat belts are fastened. The ORC then activates only the SBTs which have fastened seat belts.
The driver/passenger airbags are not activated unless a frontal collision which exceeds the stage two threshold is
detected.
SIDE IMPACT COLLISION SRS OPERATION
When either the driver or passenger side impact side airbag sensor detects a sudden lateral acceleration which
exceeds the lateral threshold value a signal is sent to the ORC. The ORC then deploys the appropriate side airbag.
The SRS electrical circuits are continuously monitored and
controlled by a microprocessor and software contained within
the Occupant Restraint Controller (ORC) (1). An airbag warn-
ing indicator lamp in the Instrument Cluster (IC) illuminates for
about six seconds as a bulb test each time the ignition switch
is turned to the On or Start positions. Following the bulb test,
the airbag warning indicator lamp is turned On or Off by the
ORC to indicate the status of the SRS. If the airbag warning
indicator lamp comes on at any time other than during the bulb
test, it indicates that there is a concern in the SRS electrical
circuits. Such a problem may cause airbags to not deploy
when required, or to deploy when not required.
Deployment of the driver and passenger airbags depends upon the angle and severity of an impact. Deployment is
not based upon vehicle speed; rather, deployment is based upon the rate of deceleration as measured by the forces
of gravity (G force). When an impact is severe enough, the microprocessor in the ORC signals the inflator of the
appropriate airbag units to deploy their airbag cushions. The SBT is provided with a deployment signal by the ORC
in conjunction with the driver and passenger airbags. During a frontal vehicle impact, the seat belts are used to
restrain both the driver and the passenger in the proper position for an airbag deployment. The SBT removes the
slack from the seat belts to provide further assurance that the driver and passenger are properly positioned and
restrained for an airbag deployment.
Typically, the vehicle occupants recall more about the events preceding and following a collision than they do of an
airbag deployment itself. This is because the airbag deployment and deflation occur so rapidly. In a typical 30 mile-
per-hour (48 kilometer-per-hour) barrier impact, from the moment of impact until the airbags are fully inflated takes
about 40 milliseconds. Within one to two seconds from the moment of impact, the airbags are almost entirely
deflated. The times cited for these events are approximations, which apply only to a barrier impact at the given
speed. Actual times will vary somewhat, depending upon the vehicle speed, impact angle, severity of the impact,
and the type of collision.
When the ORC monitors a concern in any of the SRS circuits or components, including the SBT, it stores a fault
code or Diagnostic Trouble Code (DTC) in its memory circuit and sends an electronic message to the IC via the
CAN to illuminate the airbag warning indicator. Proper testing of the SRS components, CAN data bus, ORC signals,
and DTC information requires the use of a DRBIIIT scan tool. Refer to the appropriate diagnostic information.
See the Owners Manual in the vehicle glove box for more information regarding features, use, and operation of all
of the factory-installed active restraints.
WARNING
WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS,
AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS
CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS.
REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY
BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS
REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT,
NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIR-
BAG, SEAT BELT TENSIONER OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE
SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE
SONAL INJURY.
WARNING: AN AIRBAG INFLATOR UNIT MAY CONTAIN SODIUM AZIDE AND POTASSIUM NITRATE. THESE
MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY
METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE
PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. AN AIRBAG INFLATOR UNIT MAY ALSO CON-
TAIN A GAS CANISTER PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG
UNIT OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES EXCEEDING 93° C (200° F).
WARNING: WHEN HANDLING A SEAT BELT TENSIONER , PROPER CARE SHOULD BE EXERCISED TO
KEEP FINGERS OUT FROM UNDER THE TENSIONER COVER AND AWAY FROM THE SEAT BELT WEBBING
WHERE IT EXITS FROM THE TENSIONER COVER.
WARNING: REPLACE ALL RESTRAINT SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE
DAIMLERCHRYSLER MOPART PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE,
BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE RESTRAINT SYSTEM
COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE RESTRAINT SYS-
TEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS
NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPEC-
IFIED IN THE DAIMLERCHRYSLER MOPART PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN AIRBAG UNIT ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH THE STEERING WHEEL OR AIRBAG UNIT FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL RESTRAINT SYSTEM

BAG, SIDE IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON-
SONAL INJURY.
Proper diagnosis and testing of the supplemental restraint system (SRS) components, the Controller Area Network
(CAN), electronic message inputs to and outputs from the Instrument Cluster (IC) or the Occupant Restraint Con-
troller (ORC), as well as the retrieval or erasure of a Diagnostic Trouble Code (DTC) from the ORC requires the use
of a DRBIIIT scan tool. Refer to the appropriate diagnostic information.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS
WARNING: AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON
THE BACK OF A NON-DEPLOYED AIRBAG. WHEN CARRYING A NON-DEPLOYED AIRBAG, THE TRIM
COVER OR AIRBAG CUSHION SIDE OF THE UNIT SHOULD BE POINTED AWAY FROM THE BODY TO MIN-
IMIZE INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. IF THE AIRBAG UNIT IS PLACED ON A
BENCH OR ANY OTHER SURFACE, THE TRIM COVER OR AIRBAG CUSHION SIDE OF THE UNIT SHOULD
BE FACE UP TO MINIMIZE MOVEMENT IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. IN ADDITION,
THE SUPPLEMENTAL RESTRAINT SYSTEM SHOULD BE DISARMED WHENEVER ANY STEERING WHEEL,
STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SIDE IMPACT SENSOR OR INSTRUMENT
PANEL COMPONENTS REQUIRE DIAGNOSIS OR SERVICE. FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
CAUTION: All damaged, faulty or non-deployed airbags which are replaced on vehicles are to be handled
and disposed of properly. If an airbag unit is faulty or damaged and non-deployed, refer to the Hazardous
Substance Control System for proper disposal. Dispose of all non-deployed and deployed airbags in a man-
ner consistent with state, provincial, local and federal regulations.
STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT

DEPLOYMENT
Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed
restraint replaced. In addition, if the driver airbag has been deployed, the clockspring must also be replaced. If the
passenger airbag is deployed, the instrument panel top pad must be replaced. If a side airbag has been deployed,
the complete airbag unit and the door trim panel must be replaced. These components are not intended for reuse
and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be
obvious during a visual inspection.
The passenger airbag mounting points on the instrument panel structural duct must be closely inspected for dam-
age, and the instrument panel assembly must be replaced if structural duct damage is evident. It is also critical that
the mounting surfaces and/or mounting brackets for the Occupant Restraint Controller (ORC) and the side impact
sensors must be closely inspected and restored to their original conditions following any vehicle impact damage.
Because the ORC and each impact sensor are used by the SRS to monitor or confirm the direction and severity of
a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy
when required, or to deploy when not required.
All other vehicle components should be closely inspected following any SRS deployment, but are to be replaced
only as required by the extent of the visible damage incurred.
AIRBAG SQUIB STATUS

CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have
live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are sure of com-
plete deployment. Refer to the Hazardous Substance Control System for proper disposal procedures. Dis-
pose of all non-deployed and deployed airbags in a manner consistent with state, provincial, local, and
federal regulations.
Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during
the deployment event. The driver and passenger airbags in this model are deployed by electrical signals generated
by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two
initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned
during an airbag deployment event. However, it is possible for only one initiator to be used due to an airbag system
fault; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper
handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be per-
formed using a DRBIIIT scan tool to verify the status of both airbag squibs before either deployed airbag is removed
from the vehicle for disposal.
1. Be certain that the DRBIIIT scan tool contains the latest version of the proper DRBIIIT software. Connect the
DRBIIIT to the Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument
panel, outboard of the steering column.
2. Turn the ignition switch to the On position.
3. Using the DRBIIIT, read and record the active (current) Diagnostic Trouble Code (DTC) data.
Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver
and/or passenger airbag squibs.
AIRBAG SQUIB STATUS
IF the Active DTC is: Conditions Squib Status

Driver or Passenger Squib 1 AND the stored DTC minutes for both Driver or Both Squib 1 and 2 were
open Passenger squibs are within 15 minutes of each used.
Driver or Passenger Squib 2 other
open
Driver or Passenger Squib 1 AND the stored DTC minutes for Driver or Squib 1 was used; Squib 2 is
open Passenger Squib 2 open is GREATER than the live.
Driver or Passenger Squib 2 stored DTC minutes for Driver or Passenger
open Squib 1 by 15 minutes or more
Driver or Passenger Squib 1 AND the stored DTC minutes for Driver or Squib 1 is live; Squib 2 was
open Passenger Squib 1 open is GREATER than the used.
Driver or Passenger Squib 2 stored DTC minutes for Driver or Passenger
open Squib 2 by 15 minutes or more
Driver or Passenger Squib 1 AND Driver or Passenger Squib 2 open is NOT Squib 1 was used; Squib 2 is
open an active code live.
Driver or Passenger Squib 2 AND Driver or Passenger Squib 1 open is NOT Squib 1 is live; Squib 2 was
open an active code used.
If no squib open codes are active the status of the airbag squibs is unknown. In this case the airbag should be
handled and disposed of assuming that both squibs were live.
CLEANUP PROCEDURE
Following a supplemental restraint deployment, the vehicle
interior will contain a powdery residue. This residue consists
primarily of harmless by-products used to deploy a supplemen-
tal restraint. However, this residue may also contain traces of
sodium hydroxide powder, a chemical by-product of the propel-
lant material that is used to generate the inert gas which
inflates the airbag. Since sodium hydroxide powder can irritate
the skin, eyes, nose, or throat, be sure to wear safety glasses
(1), rubber gloves (2), and a long-sleeved shirt during cleanup.
WARNING: IF YOU EXPERIENCE SKIN IRRITATION DUR-

ING CLEANUP, RUN COOL WATER OVER THE AFFECTED
AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE
NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR
UNTIL THE IRRITATION CEASES. IF IRRITATION CONTIN-
UES, SEE A PHYSICIAN.
1. Begin the cleanup by using a vacuum cleaner to remove

any residual powder from the vehicle interior. Clean from
outside the vehicle and work your way inside, so that you
avoid kneeling or sitting on a non-cleaned area.
2. Be certain to vacuum the heater and air conditioning outlets
as well. Run the heater and air conditioner blower on the
lowest speed setting and vacuum any powder expelled
from the outlets.
3. Next, remove the deployed supplemental restraints from the

vehicle.
1. Driver side airbag. Refer to Page 8O-100.
2. Passenger side airbag. Refer to Page 8O-102.
3. Side impact airbag. Refer to Page 8O-114.
4. Seat belt tentioners. Refer to Page 8O-122.
4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder.
STANDARD PROCEDURE - SUPPLEMENTAL RESTRAINT SYSTEM (SRS) -

VERIFICATION TEST
The following procedure should be performed using a DRBIIIT scan tool to verify proper supplemental restraint sys-
tem (SRS) operation following the service or replacement of any SRS component.
BAG, SIDE IMPACT SENSOR OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON-
SONAL INJURY.
1. During the following test, the battery negative cable remains disconnected and isolated, as it was during the SRS
component removal and installation procedures.
2. Connect the DRBIIIT to the Data Link Connector (DLC).
3. Exit the vehicle but maintain contact with the DRBIIIT.
4. Turn the ignition switch to the On position.
5. Check to be certain that there are no occupants in the vehicle, then reconnect the battery negative cable.
6. Using the DRBIIIT, read and record any active (current) Diagnostic Trouble Code (DTC) data.
7. Next, use the DRBIIIT to read and record any stored (historical) DTC data.
8. If any DTCs are found, refer to the appropriate diagnostic information.
9. Use the DRBIIIT to erase any stored DTC data.
10. Turn the ignition switch to the Off position for about fifteen seconds, and then back to the On position. Observe
the airbag warning indicator in the instrument cluster for proper operation. If a fault is detected, refer to the
appropriate diagnostic information.
SPECIFICATIONS
TORQUE CHART - RESTRAINTS

Seat Belt Buckle Bolt 35 26 310
Seat Belt Guide Fitting
35 26 310
Bolt
Occupant Restraint
Controller Bolt to Vehicle 35 26 310
Floor
Passenger Airbag to
Instrument Panel 35 26 310
Structural Duct Bolt
Airbag to Steering Wheel
8 6 71
Screw
Seat Belt End Fitting Bolt 8 6 71
Seat Belt Tensioner (SBT)
10 8 88
to B Pillar Bolt

DESCRIPTION
The Occupant Restraint Controller (ORC) is located on the
floor beneath the center console. It is secured by four screws
to a stamped steel mounting bracket.
The arrow which is printed on the label located on the top of
the ORC housing (1) provides a visual verification of the
proper orientation and should always face the front of the vehi-
cle.
The ORC cannot be repaired or adjusted and, if damaged or
faulty, it must be replaced.
OPERATION
The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS)
logic circuits and controls all of the SRS components. The Occupant Restraint Controller (ORC) uses On-Board
Diagnostics (OBD) and Controller Area Network (CAN) to communicate with other electronic modules in the vehicle
as well as with the DRBIIIT scan tool.
The Occupant Restraint Controller (ORC) microprocessor continuously monitors all of the Supplemental Restraint
System (SRS) electrical circuits to determine the system status. If the Occupant Restraint Controller (ORC) detects
a monitored system fault, it sets an active and a stored Diagnostic Trouble Code (DTC). A message is sent to the
Instrument Cluster (IC) over the Controller Area Network (CAN) data bus to illuminate the airbag warning indicator
lamp.
The Occupant Restraint Controller (ORC) also monitors the seat belt switch which is located internal to each of the
front seat belt buckles to determine whether the seat belts are fastened properly. If the seat belt is not fastened a
signal is sent to the Instrument Cluster (IC) over the Controller Area Network (CAN) data bus to illuminate the seat-
belt indicator lamp.
The Occupant Restraint Controller (ORC) receives battery current through two circuits; a fused ignition switch output
(RUN) circuit through a fuse in the underhood accessory fuse block, and a fused ignition switch output (START-
RUN) circuit through a second fuse in the underhood accessory fuse block. The Occupant Restraint Controller
(ORC) is grounded through a ground circuit of the instrument panel floor wire harness. This has a single eyelet
terminal connector secured by the bolt to the Occupant Restraint Controller (ORC) mount on the floor panel trans-
mission tunnel. These connections allow the Occupant Restraint Controller (ORC) to be operational whenever the
ignition switch is in the Start or On positions.
The Occupant Restraint Controller (ORC) also contains a capacitor. When the ignition switch is in the Start or On
positions, this capacitor is continually being charged with enough voltage to deploy the airbags for up to one second
following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case
there is a loss of battery current supply to the Occupant Restraint Controller (ORC) during an impact.
Two sensors are contained within the Occupant Restraint Controller (ORC), an electronic impact sensor and a saf-
ing sensor. The Occupant Restraint Controller (ORC) also monitors inputs from two remote side impact sensors
located under the carpet directly below the front seats, to control the deployment of the side impact airbag units.
The safing sensor is an electronic accelerometer sensor within the Occupant Restraint Controller (ORC) that pro-
vides an additional logic input to the Occupant Restraint Controller (ORC) microprocessor. The safing sensor is used
to verify the need for a Supplemental Restraint System (SRS) deployment by detecting the impact energy of a col-
lision. The impact energy must exceed the safing threshold in order for the airbags to deploy.
Pre-programmed decision algorithms in the Occupant Restraint Controller (ORC) microprocessor determine when
the deceleration rate indicates an impact that is severe enough to require supplemental restraint system protection.
Based upon the status of the seat belt switch inputs and the severity of the monitored impact, determines the level
of front airbag deployment force required for each front seating position. When the programmed conditions are met,
the Occupant Restraint Controller (ORC) sends the proper electrical signals to deploy the front airbags and the Seat
Belt Tensioner’s (SBT) at the programmed force levels.
The Occupant Restraint Controller (ORC) determines the level of front air bag deployment force for each seating
position based on the seat belts switch input status and the severity of the impact. When the predetermined impact
conditions are met the Occupant Restraint Controller (ORC) deploys the front airbags and activates the Seat Belt
Tensioner’s (SBT).
STANDARD PROCEDURE - ORC PROGRAMMING

This procedure requires the use of the DRBIIIT scan tool.
After the Occupant Restraint Controller (ORC) has been replaced, the Airbag Warning Indicator Light in the Instru-
ment Cluster flashes. This indicates that the ORC has not yet been programmed. Follow this procedure using the
DRBIIIT scan tool:
• The side airbag equipment is programmed to YES on the parts control modules.
• The seatbelt buckle equipment is programmed to YES.
• The passenger seat occupant simulator is programmed to YES.
• The front passenger airbag is programmed to YES.
• Turn the ignition to off and then on.
• Read out and erase any DTCs.
At this time the Airbag Warning Indicator Light will flash on and off to conclude the programming. When a front
passenger airbag is retrofitted, the ORC only needs to be reprogrammed, not replaced. After finishing this proce-
dure, any programming failure is due to a defective ORC.
REMOVAL
IMPACT AIRBAG, OR INSTRUMENT PANEL COMPONENT
PERSONAL INJURY.
WARNING: THE OCCUPANT RESTRAINT CONTROLLER

CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE
SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS.
NEVER STRIKE OR DROP THE OCCUPANT RESTRAINT
CONTROLLER, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN OCCUPANT
RESTRAINT CONTROLLER IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCIDEN-
TAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL
RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT
INJURIES.
1. Disconnect and isolate the battery negative cable. Wait two

minutes for the system capacitor to discharge before further
service.
3. Disconnect the occupant restraint controller connector (2).
4. Remove the bolts (1) attaching the occupant restraint con-
troller to the transmission tunnel.
5. Remove the occupant restraint controller from the vehicle.
INSTALLATION
PERSONAL INJURY.
WARNING: THE OCCUPANT RESTRAINT CONTROLLER

CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE
SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS.
NEVER STRIKE OR DROP THE OCCUPANT RESTRAINT
CONTROLLER, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN OCCUPANT
RESTRAINT CONTROLLER IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCIDEN-
TAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL
RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT
INJURIES.
1. Carefully position the occupant restraint controller on the

mount that is welded onto the top of the floor panel trans-
mission tunnel. The arrow on the housing must point
toward the front of the vehicle.
2. Install and tighten the screws (1) that secure the occupant
restraint controller to the mount that is welded onto the top
of the floor panel transmission tunnel. Observe ground lead
mount on the left rear screw - controller module ground.
Tighten the screws to 11 N·m (95 in. lbs.).
3. Connect the occupant restraint controller electrical connec-
tor (2).

5. Do not reconnect the battery negative cable at this time.
The Supplemental Restraint System verification test proce-
dure should be performed following service of any Supple-
mental Restraint System component. Refer to Page 8O-83.
Also, the ORC Programming procedure should be per-
formed as well. Refer to Page 8O-89.
CLOCKSPRING
DESCRIPTION
The clockspring assembly is secured to the multi-function
switch mounting housing near the top of the steering column
behind the steering wheel.
Within the plastic case and wound around the rotor spool is a
long ribbon-like tape. The outer end of the tape terminates at
the connector receptacles that face the instrument panel, while
the inner end of the tape terminates at the pigtail wires and
connector receptacles on the hub of the clockspring rotor that
face the steering wheel.
Service replacement clocksprings are shipped pre-centered
and with a molded plastic locking pin installed. The locking pin
secures the centered clockspring rotor to the clockspring case
during shipment and handling, but must be removed from the
clockspring after it and the multi-function switch mounting
housing are installed on the steering column.
The clockspring cannot be repaired. If the clockspring is faulty,
damaged, or if the driver airbag has been deployed, the clock-
spring must be replaced.
OPERATION
The clockspring is used to provide continuous electrical continuity between the instrument panel and the electrical
components mounted on or in the steering wheel. The clockspring case is secured to the multi-function switch
mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring
case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instru-
ment panel wire harness.
The clockspring rotor is movable and is keyed to the hub of
the steering wheel by two large flats that are molded into the
rotor hub. The three pins (two round and one oblong) on the
lower surface of the clockspring rotor hub engage and index
the clockspring rotor to the turn signal cancel cam. The turn
signal cancel cam is integral to the multi-function switch
mounting housing and is keyed to the upper steering column
shaft. The short, black-sleeved yellow pigtail wire on the upper
surface of the clockspring rotor connect the clockspring to the
driver airbag, while a steering wheel wire harness connects
the two connector receptacles on the upper surface of the
clockspring rotor to the horn switch.
Like the clockspring in a timepiece, the clockspring tape has

travel limits and can be damaged by being wound too tightly
during full stop-to-stop steering wheel rotation. To prevent this
from occurring, the clockspring is centered when it is installed
on the steering column. Centering the clockspring indexes the
clockspring tape to the movable steering components so that
the tape can operate within its designed travel limits. However,
if the clockspring is removed from the steering column or if the
steering shaft is disconnected from the steering gear, the
clockspring spool can change position relative to the movable
steering components and must be re-centered following com-
pletion of the service or the tape may be damaged.
Service replacement clocksprings are shipped pre-centered
and with a locking pin installed. This locking pin should not be
removed until the clockspring has been installed on the steer-
ing column. If the locking pin is removed before the clock-
spring is installed on a steering column, the clockspring
centering procedure must be performed.
STANDARD PROCEDURE - CLOCKSPRING CENTERING

The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate
the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop.
Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its
designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction
from the centered position, without damaging the clockspring tape.
However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear,
the clockspring tape can change position relative to the other steering components. The clockspring must then be
re-centered following completion of such service or the clockspring tape may be damaged.
BAG, SIDE IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON-
SONAL INJURY.
Note: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the
straight-ahead position.
1. Place the front wheels in the straight-ahead position.

2. Remove the clockspring from the steering column. Refer to Page 8O-94.
3. Hold the clockspring case in one hand so that it is oriented as it would be when it is installed on the steering
column.
4. Use your other hand to rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive
torque.
5. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise, until the
arrows on the clockspring rotor label and the clockspring case are aligned. The uppermost pin on the lower sur-
face of the clockspring rotor should now be the oblong pin.
6. The clockspring is now centered. Secure the clockspring rotor to the clockspring case to maintain clockspring
centering until it is reinstalled on the steering column.
7. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column.
Refer to Page 8O-96.
REMOVAL
The clockspring cannot be repaired. It must be replaced if
faulty or damaged, or if the driver airbag has been deployed.

SIDE IMPACT SENSOR, OR INSTRUMENT PANEL COMPO-
NENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER DIAGNO-
SIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
Note: Before starting this procedure, be certain to turn the

steering wheel until the front wheels are in the straight-
ahead position.
1. Place the front wheels in the straight ahead position.

2. Remove the driver airbag screws (1) from the steering
wheel and remove the driver side airbag. Refer to Page
8O-100.
3. Remove the steering wheel’s countersunk screw (1) from

the steering column with a suitable tool (2). Refer to Page
19-25.
4. Remove the two screws (1) that secure the clockspring

case to the multi-function switch mounting housing.
5. Remove the clockspring.
6. If the removed clockspring is to be reused, be certain to
secure the clockspring rotor to the clockspring case to
maintain clockspring centering until it is reinstalled on the
steering column. If clockspring centering is not maintained,
the clockspring must be centered again before it is rein-
stalled. Refer to Page 8O-93.
INSTALLATION
1. If the removed clockspring is being reused, be certain to
remove anything securing the clockspring rotor to the clock-
spring case that was used to maintain clockspring centering
until reinstallation on the steering column. If clockspring
centering was not maintained, the clockspring must be cen-
tered again before it is installed. Refer to Page 8O-93.
2. Install the clockspring to the steering column.
3. Install the two screws (1) that secure the clockspring case
to the multi-function switch mounting housing.
4. Install the steering wheel to the steering column then install

the countersunk screw (1). Refer to Page 19-26.
5. Install the driver airbag and screws (1) to the steering

wheel. Refer to Page 8O-100.
The supplemental restraint system verification test proce-
dure should be performed following service of any supple-
mental restraint system component. Refer to Page 8O-83.
DRIVER AIRBAG
DESCRIPTION
The driver airbag (1) is located in the center of the steering
wheel, where it is secured with two screws to the steering
wheel. Concealed beneath the driver airbag trim cover are the
horn switch, the folded airbag cushion, the airbag cushion
retainer, the airbag housing, the airbag inflator, and the retain-
ers that secure the inflator to the airbag housing.
The driver airbag trim cover and the horn switch are available
for individual service replacement.
OPERATION
WARNING:
SOME OF THE CHEMICALS USED TO CREATE THE INERT GAS MAY BE CONSIDERED HAZARDOUS WHILE
IN THEIR SOLID STATE BEFORE THEY ARE BURNED, BUT THEY ARE SECURELY SEALED WITHIN THE
AIRBAG INFLATOR. TYPICALLY, BOTH INITIATORS ARE USED AND ALL POTENTIALLY HAZARDOUS CHEM-
ICALS ARE BURNED DURING AN AIRBAG DEPLOYMENT EVENT. HOWEVER, IT IS POSSIBLE FOR ONLY
ONE INITIATOR TO BE USED DURING A DEPLOYMENT DUE TO AN AIRBAG SYSTEM FAULT; THEREFORE,
IT IS NECESSARY TO ALWAYS CONFIRM THAT BOTH INITIATORS HAVE BEEN USED IN ORDER TO AVOID
THE IMPROPER DISPOSAL OF POTENTIALLY LIVE PYROTECHNIC OR HAZARDOUS MATERIALS.
THE INERT GAS THAT IS PRODUCED WHEN THE CHEMICALS ARE BURNED IS HARMLESS. HOWEVER, A
SMALL AMOUNT OF RESIDUE FROM THE BURNED CHEMICALS MAY CAUSE SOME TEMPORARY DISCOM-
FORT IF IT CONTACTS THE SKIN, EYES, OR BREATHING PASSAGES. IF SKIN OR EYE IRRITATION IS
NOTED, RINSE THE AFFECTED AREA WITH PLENTY OF COOL, CLEAN WATER. IF BREATHING PASSAGES
ARE IRRITATED, MOVE TO ANOTHER AREA WHERE THERE IS PLENTY OF CLEAN, FRESH AIR TO
BREATH. IF THE IRRITATION IS NOT ALLEVIATED BY THESE ACTIONS, CONTACT A PHYSICIAN.
The airbag used in this model is a multistage, Next Generation-type that complies with revised federal airbag stan-
dards to deploy with less force than those used in some prior models. A radial deploying fabric airbag cushion with
internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting
studs and is secured to the stamped metal airbag housing using four hex nuts with washers. The driver airbag
cannot be repaired, and must be replaced if deployed or in any way damaged.
The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC)
through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initi-
ators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the
monitored impact conditions by providing one of four delay intervals between the electrical signals provided to the
two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.
AIRBAG DEPLOYMENT SEQUENCE

1. When the actuation impact threshold for the driver side air-
bag is exceeded, an electric pulse is transmitted to the
squib in the gas generator by the Seat Belt Tensioner (SBT)
and Occupant Restraint Controller (ORC).
2. The squib ignites the solid fuel in the gas generator. The
solid fuel combusts, developing a gas which explodes
under high pressure into the airbag through a filter.
3. The airbag inflates and tears open the steering wheel cush-
ion cover at a predetermined breaking point.
4. While continuously inflating, the airbag begins to exit the

steering wheel cushion.
5. After approximately 45 ms. the airbag reaches its maximum

volume.
6. When the maximum volume is reached, the pressure in the
airbag starts decreasing immediately. The gas escapes
from the airbag through a filter and the airbag deflates.
REMOVAL
1. Before attempting any service procedure refer to the warn-
ings in this section. Refer to Page 8O-82.
2. Disconnect the negative battery cable. Wait two minutes
for the system capacitor to discharge before further
service.
3. From the underside of the steering wheel, remove the two
screws (1) that secure the driver airbag to the steering
wheel.
4. Pull the driver airbag away from the steering wheel far
enough to access the electrical connections to the steering
wheel.
5. Disconnect the steering wheel wire harness connectors for
the horn switch.
6. Disconnect the clockspring driver airbag pigtail harness
connectors.
7. Remove the driver airbag from the steering wheel.
Note: If the driver airbag has been deployed, the clock-

spring must be replaced. Refer to Page 8O-94.
INSTALLATION
1. Position the driver airbag close enough to the steering
wheel to connect the electrical connections.
2. Carefully position the driver airbag in the steering wheel.
Note: Be certain that the clockspring pigtail wires and

steering wheel wire harness in the steering wheel hub
area are not pinched between the driver airbag and the
steering wheel armature.
3. From the underside of the steering wheel, install and

tighten the two screws (1) that secure the driver airbag to
the steering wheel. Tighten to 8 N·m (71 in. lbs.).
PASSENGER AIRBAG
DESCRIPTION
The surface of the instrument panel top pad above the glove box is the most visible part of the passenger airbag.
The passenger airbag door is concealed behind the instrument panel top pad and above the glove box opening on
the instrument panel in front of the front seat passenger seating position.
The passenger airbag unit used in this model is a multistage,
Next Generation-type that complies with revised federal airbag
standards to deploy with less force than those used in some
prior models. The passenger airbag unit consists of an
extruded aluminum housing, two stamped steel end brackets,
a molded plastic inner airbag cushion cover, the rectangular
fabric airbag cushion, and the airbag inflator. The airbag hous-
ing contains the airbag inflator, while the inner cover contains
the folded airbag cushion. The inner cover completely
encloses the airbag cushion and is permanently retained to the
housing. The airbag cushion is constructed of a coated nylon
fabric. The airbag inflator is a dual-initiator, hybrid-type unit
that is secured to and sealed within the airbag housing.
Note: The passenger airbag cannot be repaired, and must

be replaced if deployed, faulty, or in any way damaged.
The passenger airbag door is serviced only as a unit with
the instrument panel top pad. If the passenger airbag is
deployed, the instrument panel top pad must also be
replaced. If inspection reveals that the passenger airbag
mounting points on the instrument panel structural duct
have been cracked or damaged by the deployment event,
the instrument panel structural duct assembly must also
be replaced.
OPERATION
The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller
(ORC) through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using
two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit
the monitored impact conditions by providing one of four delay intervals between the electrical signals provided to
the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.
AIRBAG DEPLOYMENT SEQUENCE

1. When the impact threshold for the passenger airbag is exceeded an electric pulse (firing pulse) is sent from the
ORC to the squib in the initiator.
2. The squib ignites the solid propellant in the initiator. The solid propellant burns, developing a gas which flows
explosively under high pressure into the airbag.
3. Under the pressure of the gas, the airbag rips open the airbag housing, blows the airbag flap out of the instru-
ment panel and inflates in the passenger compartment.
4. After approximately 50 ms. the airbag reaches its maximum volume.
5. After reaching the maximum volume, the pressure in the airbag starts decreasing. The gas escapes from the
airbag through a filter and the airbag deflates.
Note: Typically, both initiators are used during an airbag deployment event. However, it is possible for only
one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to
always confirm that both initiators have been used in order to avoid the improper disposal of potentially live
pyrotechnic materials.
REMOVAL
1. Before attempting any service procedures refer to the warn-
ings in the beginning of this section. Refer to Page 8O-82.
service.
3. Remove the upper section (1) of instrument panel. Refer to
Page 23-149.
4. Disconnect the passenger airbag electrical connector (1)

from the passenger side airbag.
5. Remove the four bolts (1) that secure the airbag to the
instrument panel structural duct.
6. Remove the passenger airbag as a unit.
Note: If the passenger airbag has been deployed, carefully

inspect the airbag mounting points on the instrument
panel structural duct. If the airbag mounting points have
been damaged or deformed, the instrument panel struc-
tural duct must be replaced.
INSTALLATION
1. Carefully position the passenger airbag unit onto the instru-
ment panel structural duct.
2. Install the four bolts (1) that secure the passenger airbag to
the instrument panel structural duct. Tighten to 35 N·m (26
ft. lbs.).
3. Connect the passenger airbag electrical connector (1).
4. Install the top section retaining screw (1) onto the instru-
ment panel. Refer to Page 23-155.
ON / OFF SWITCH INDICATOR MODULE

REMOVAL
2. Remove the passenger door sill trim panel and kick trim
panel.
3. Fold back the carpeting in the passenger footwell.
4. Remove the insulating panel.
Note: It is not necessary to remove the electrical connec-

tors to rotate the base plate in the passenger footwell.
5. Remove the plastic retaining nuts (1) from the floor panel
and rotate the base plate exposing the passenger seat
occupant simulator.
6. Remove the plastic tie, and disconnect the passenger seat

occupant simulator harness connector. Remove the pas-
senger seat occupant simulator (1).
INSTALLATION
1. Connect the passenger seat occupant simulator harness
connector and attach the passenger seat occupant simula-
tor (1) to the base plate with a plastic wire tie.
2. Rotate the base plate and install it over the mounting studs
on the floor panel.
Note: Be sure not to pinch or cause interference with the

wiring harnesses while locating the base plate to the floor
mounting studs.
3. Install the plastic retaining nuts (1) and secure the base
plate to the vehicle floor.
4. Install the insulating panel.
5. Install the carpeting in the passenger footwell.
6. Install the door sill panel and kick trim panel.
SIDE IMPACT SENSOR

DESCRIPTION
Two side impact sensors (2) are used, one each for the left
and right sides of the vehicle. These sensors are mounted
remotely from the bi-directional safing sensor that is internal to
the Occupant Restraint Controller (ORC). The side impact sen-
sors are secured with two bolts (1) to the floor below the car-
pet under the seats.
The impact sensor housing has an integral connector recepta-
cle and two integral mounting ears, each with a metal sleeve
to provide crush protection. A cavity in the center of the
molded black plastic impact sensor housing contains the elec-
tronic circuitry of the sensor which includes an electronic com-
munication chip and an electronic impact sensor. Potting
material fills the cavity to seal and protect the internal elec-
tronic circuitry and components. The side impact sensors are
each connected to the vehicle electrical system through a ded-
icated take out and connector of the airbag overlay wire har-
ness.
The side impact sensors cannot be repaired or adjusted and, if
damaged or faulty, they must be replaced.
OPERATION
The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration or acceleration,
which provides verification of the direction and severity of an impact. Each sensor also contains an electronic com-
munication chip that allows the unit to communicate the sensor status as well as sensor fault information to the
microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of
the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored
system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator lamp operation accordingly.
The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus
circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus
circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed and tested using
conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive
in the diagnosis of the ORC or the impact sensors. The most reliable, efficient, and accurate means to diagnose the
impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires
the use of a DRBIIIT scan tool. Refer to the appropriate diagnostic information.
REMOVAL
ings in the beginning of this section. Refer to Page 8O-82.
service.
3. Remove the ignition key.
4. Remove the door sill trim plate by pulling straight up on the
sill plate to release it from the clips below.
5. Remove the plastic cover (3) on the front of the seat track.
Then remove the front seat bolts (2).
6. Remove the rear seat bolts (1).

7. Remove the seat belt bolt (2) from the vehicle then remove
the seat.
8. Remove the carpet hold down (3) at the rear wall (1).
9. Turn the carpet to the front from the rear to gain access to
the side impact sensor which is located under the seat
area.
10. Disconnect the side impact sensor harness connector (2).

11. Remove the screws (1) attaching the side impact sensor
to the body rail.
12. Remove the side impact sensor from the vehicle.
INSTALLATION
1. Position the side impact sensor.
2. Install the bolts (1) attaching the side impact sensor to the
body rail.
3. Connect the side impact sensor harness connector (2).
4. Replace the carpet (1) making sure it is fully pushed down

into the floor of the vehicle.
5. Install the carpet hold down (3).
6. Install the front seats (1).

7. Install the front seat bolts (2) then install the plastic cover
(3) on the seat track.
8. Install the rear seat bolts (1) then install the seat belt and
bolt (2).
9. Install the door sill trim plate by pushing it straight down

onto the clips firmly.
10. Install the ignition key.
SIDE IMPACT AIRBAG

DESCRIPTION
Side air bags with a volume of about 975 cubic inches (16 liters) each are concealed behind the inner door trim
above the armrest. If the air bag is triggered during a lateral collision, the air bag tears open a seam on the inner
door trim and inflates within 0.007 seconds to form a protective cushion between the passenger and the door. Thus
the impact on the passenger’s thorax and the ejecting motion of the head, which might otherwise cause serious
injuries, are reduced.
The ORC and the IC each contain a central processing unit and programming that allow them to communicate with
each other using the Controller Area Network (CAN). This method of communication is used by the ORC for control
of the airbag warning indicator lamp.
OPERATION
Both side impact airbags are deployed individually by an electrical signal generated by the left or right side impact
sensor to which it is connected through left or right curtain airbag line 1 and line 2 (or Squib) circuits. The hybrid-
type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC
sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical
pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture
a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubu-
lar manifold so that all of the released gas is directed into the folded airbag cushion, causing the cushion to inflate.
As the airbag cushion inflates it will rip open a predetermined area in the driver or passenger door to form a cushion
to protect the vehicle occupants during a side impact collision. Following the airbag deployment, the airbag cushion
quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion
hangs down loosely from the door trim panel.
REMOVAL
ings at the beginning of this section. Refer to Page 8O-82.
service.
3. Remove the ignition key.
4. Remove the door trim panel. Refer to Page 23-108.
5. Disconnect the squib connector (2).
6. Drill out the mounting rivets (1) for the side impact airbag.
7. Remove the side impact airbag from the door.
INSTALLATION
WARNING: DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIR-
BAG, FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
1. Position the side impact airbag to the door.

2. Install new mounting rivets (1) for the side impact airbag.
3. Connect the squib connector (2).
4. Install the door trim panel. Refer to Page 23-109.
5. Install the ignition key.
SEAT BELT BUCKLE

DESCRIPTION
The left and right front seat belt buckle restraint systems
switches are located in the respective buckles. The seat belt
buckles are bolted to the base frame of the seat. The seat belt
buckles are a typical buckle design with a release button on
the top to free the seat belt.
The left and right front seat belt buckle restraint system mon-
itors the status of the driver’s and passenger’s seat belt
switch. The airbag unit can be ignited if the seat belt is not fas-
tened during the initial triggering threshold.
REMOVAL
ings at the beginning of this section. Refer to Page 8O-82.
service.
3. Remove the plastic cover (3) from the front of the seat
track then remove the front seat bolts (2).
4. Remove the seat belt bolt (1) then remove the rear seat
bolts. Remove the seat from the vehicle.
5. Disconnect the seat belt buckle harness connector and

remove the bolt (1) attaching the belt buckle to the seat.
INSTALLATION
1. Position the seat belt buckle to the seat.
2. Install the bolt (1) to the seat belt buckle. Tighten to 35 N·m
(26 ft. lbs.).
3. Connect the seat belt buckle harness connector.
4. Position the front seat in the vehicle (1).

5. Install the front seat bolts (2). Tighten to 50 N·m (37 ft.
lbs.).
6. Install the plastic cover on the seat track (3).
7. Install the rear seat bolts (1). Tighten to 50 N·m (37 ft. lbs.).
8. Install the bolt (2) attaching the seat belt to the seat.
SEAT BELT & SEAT BELT TENSIONER

DESCRIPTION
In the even of a collision (head-on or rear-end) the seat belt
tensioner eliminates the slack in the belt and prevents the seat
belt from unreeling. The tight seat belt causes the vehicle pas-
sengers to decelerate at the same rate as the body at an ear-
lier point in time. The SBT (for the driver and passenger) are
located at the bottom of the B-pillar behind the plastic trim
panel.
OPERATION
1 - GAS GENERATOR HOUSING 6 - FORCE LIMITATION TORSION ROD

2 - GAS GENERATOR CYLINDER 7 - BELT REEL SHAFT
3 - GAS GENERATOR PISTON 8 - REEL HOUSING
4 - PULL CABLE 9 - LOCKING SYSTEM
5 - TENSIONING SYSTEM (FORCE LIMITATION)
The Seat Belt Tensioners (SBT) are equipped with a force limitation device which reduces the force of the belt on
the passenger’s body, without affecting the protective function of the seat belt during an impact.
SEAT BELT TENSIONING

In the event of a collision, the Occupant Restraint Controller
(ORC) puts out an electrical signal for triggering the Seat Belt
Tensioner (SBT) after a certain delay.
The Squib in the gas generator is triggered and the resulting
combustion gas moves the piston (2) in the gas generator cyl-
inder (3) up at high speed. The pull cable (4) connected to the
piston is tensioned causing the cable pulley (5) to turn. Inertia
and centrifugal force cause the pawls (7) in the cable pulley
(5) to engage in the teeth in the toothed ring (6).
A positive connection is then present between the gas gener-
ator piston and the seat belt retractor shaft via the pull cable
(4), the cable pulley (5) and toothed plate pulling and thereby
tensioning the seat belt (1).
FORCE LIMITATION
After tensioning the seat belt, the gas pressure in the gas gen-
erator cylinder (1) decreases. The pull cable (2) is relieved and
the force on the cable pulley (4) reduced.
The force exerted by the passenger on the seat belt then
changes the direction of pull and the seat belt (8) attempts to
unwind. This is prevented by the outer locking pawls (3) in the
toothed ring (5). The change in the direction of pull simulta-
neously causes a change in the direction of rotation of the
retractor shaft. Inertia and centrifugal force cause the outer
locking pawls (3) on the toothed ring (5) to engage in the inner
teeth on the locking ring (7).
As soon as a locking pawl (3) is in contact with the teeth on
the locking ring (7) the latter turns until it locks up. The
arrested locking ring (7) causes the torsion rod (6) to arrest on
one side. The torsion rod (6) forms the heart of the retractor
shaft and therefore takes up the tension forces acting on the
seat belt.
As soon as the force on the seat belt exceeds 4 kN, the tor-
sion rod (6) deforms, counteracting a further increase in the
load and limiting the force.
As soon as the force on the seat belt decreases, the locking pawls in the toothed ring and the pawls on the cable
pulley return to their initial position as the seat belt is retracted. The locking and retracting functions of the inertia
reel are effective again.
Triggering of the emergency tensioning retractors is indicated

by the open viewing window (1) on the tensioning system
housing
In the event of another collision, the normal protective function
of the seat belt is still available. The retractor shaft is locked
up by the locking system without tensioning and force limita-
tion so that the entire force is taken up.
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY
INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARD-
WARE, RETRACTORS, TETHER STRAPS, AND ANCHORS
FOR PROPER INSTALLATION, OPERATION, OR DAMAGE.
REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A
DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR.
REPLACE ANY BELT THAT HAS A BENT OR DAMAGED
LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAM-
AGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR
CHILD RESTRAINT COMPONENT. ALWAYS REPLACE
DAMAGED OR FAULTY SEAT BELT AND CHILD
RESTRAINT COMPONENTS WITH THE CORRECT, NEW
AND UNUSED REPLACEMENT PARTS LISTED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: NEVER DISASSEMBLE THE SEAT BELT TEN-

SIONERS.
CAUTION: Never attempt to eliminate noises by lubricat-

ing with oil or grease.

ings in this section. Refer to Page 8O-82.
service.
3. Remove the ignition key from the vehicle.
4. Remove the bolt (1) on the belt end attaching it to the seat.
5. Remove the screws (1) attaching the plastic cover (3) to

the door opening.
6. Remove the plastic cover (3).
7. Remove the door edge guard (2).
8. Remove the bolt (1) attaching the belt guide to the vehicle.
9. Fold back the carpet (1) in the upper corner area.
10. Disconnect the SBT Squib harness connector (1).
11. Remove the bolt (1) attaching the SBT to the vehicle.
12. Remove the SBT.
INSPECTION
1. Check the Seat Belt Tensioner (SBT) with the DRBIIIT.
2. Read and record all DTCs.
3. Inspect for the following:
1. If the first ignition Squib has been fired electrically and
the red pin (1) is visible, all three ignition Squibs have
been fired.
2. If the first ignition Squib has been fired electrically and
the red pin (1) is not visible, not all three ignition Squibs
have been fired.
INSTALLATION
1. Position the SBT in the vehicle.
2. Install the bolt (1) attaching the SBT to the vehicle. Tighten
to 10 N·m (88 in. lbs.).
3. Connect the SBT Squib harness connector (1).
4. Install the bolt (1) on the upper belt guide. Tighten to 35

N·m (26 ft. lbs.).
5. Replace the carpet (1) in the upper corner area.

6. Position the plastic cover (3) over the seat belt.

7. Install the screws (1) attaching the plastic cover (3) to the
door opening.
8. Install the door edge guard (2).
9. Install the bolt (1) on the belt end attaching it to the seat.
10. Install the ignition key to the vehicle.
ZH SPEED CONTROL 8P - 1
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL - ELECTRICAL SPEED CONTROL - SERVICE INFORMATION. . . . . 3

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPEED CONTROL - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page
SPEED CONTROL - ELECTRICAL

DIAGNOSTICS
SPEED CONTROL - ELECTRICAL DIAGNOSTICS

8P - 2 SPEED CONTROL - ELECTRICAL DIAGNOSTICS ZH
SPEED CONTROL CIRCUIT DIAGRAM

ZH SPEED CONTROL - SERVICE INFORMATION 8P - 3
SPEED CONTROL - SERVICE INFORMATION
TABLE OF CONTENTS
page page
SPEED CONTROL - SERVICE INFORMATION SWITCH

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPEED CONTROL - SERVICE INFORMATION

DESCRIPTION
WARNING: THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT
PERMIT MAINTAINING A CONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT ARE WIND-
ING, ICY, SNOW COVERED, OR SLIPPERY.
Note: A cable and a vacuum controlled servo are not

used. This is a servo-less system.
Control of the speed control system is accomplished by a

speed control switch (1) which is located just above the multi-
function switch (2). The speed control system also uses other
components of the vehicle to accomplish its tasks. The five
other major components used are as follows; The PCM, Accel-
erator Pedal Position Sensor, Kickdown Simulator Switch,
Throttle Body and the Clutch Pedal Position Switch (Manual
Transmission). The speed control system is designed to oper-
ate at speeds above 25 m.p.h. (40 km/h).
OPERATION
When speed control operation is requested by the speed control switch, the PCM (Powertrain Control Module)
allows a set speed to be stored in its memory for speed control. To store a set speed, press either of the SET
switch functions while the vehicle is moving, at a speed above 25 m.p.h. (40 km/h). In order for the speed control
to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or
Neutral.
The speed control can be disengaged manually by:
• Stepping on the brake pedal
• Pressing the speed control switch to OFF
• Depressing the clutch pedal (if equipped).
Note: Turning the Speed Control Switch OFF or turning off the ignition switch will erase the set speed
stored in the PCM.
8P - 4 SPEED CONTROL - SERVICE INFORMATION ZH
For added safety, the speed control system is programmed to disengage for any of the following conditions:
• An indication of Park or Neutral
• A rapid increase rpm (indicates that the clutch has been disengaged)
• Excessive engine rpm (indicates that the transmission may be in a low gear)
• The speed signal increases at a rate of 10 m.p.h. per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)
• The speed signal decreases at a rate of 10 m.p.h. per second (indicates that the vehicle may have decel-
erated at an extremely high rate)
Once the speed control has been disengaged, pulling the
speed control switch forward into the RESUME position (when
speed is greater than 30 m.p.h.) restores the vehicle to the tar-
get speed that was stored in the PCM.
While the speed control is engaged, the driver can increase
the vehicle speed by pushing the speed control switch upward
into the ACCEL,SET position. The new target speed is stored
in the PCM when the ACCEL,SET switch position is released.
The PCM also has a “tap-up” feature in which vehicle speed
increases at a rate of approximately 2 m.p.h. for each momen-
tary switch activation of the ACCEL,SET switch position.
A “tap down” feature is used to decelerate without disengaging
the speed control system. To decelerate from an existing
recorded target speed, momentarily push the speed control
switch downward into the DECEL,SET switch position. For
each switch activation, speed will be lowered approximately 1
m.p.h.
SWITCH
REMOVAL
WARNING: CAREFULLY READ ALL WARNINGS AND CAU-
TIONS ASSOCIATED WITH THE AIRBAG SYSTEM. Refer to
Page 8O-82.

3. Remove the clockspring. Refer to Page 8O-94.
ZH SPEED CONTROL - SERVICE INFORMATION 8P - 5
5. Remove the screw (1) attaching the speed control switch to

the multi-function switch.
6. Disconnect the electrical connectors on the steering col-
umn.
7. Disconnect the wiring from the column.
INSTALLATION
1. Connect the wiring to the column.
2. Connect the electrical connectors on the steering column.
3. Install the screw (1) attaching the speed control switch to
the multi-function switch.

5. Install the clockspring. Refer to Page 8O-96.
ZH VEHICLE THEFT SECURITY 8Q - 1
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
VEHICLE THEFT SECURITY - ELECTRICAL VEHICLE THEFT SECURITY - SERVICE

VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
VEHICLE THEFT SECURITY - ELECTRICAL ANTI-THEFT TOW SENSOR SIGNAL

DIAGNOSTICS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING NO CAN COMMUNICATIONS WITH PCM . . . 25
CENTRAL LOCKING PUMP/SECURITY SIREN SIGNAL OUTPUT CIRCUIT . . . . . . . . . 27
SYSTEM MODULE SYSTEM CENTRAL LOCKING PUMP/SECURITY
UNDERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . 2 SYSTEM MODULE INTERNAL FAILURE . . . . 30
CENTRAL LOCKING PUMP/SECURITY *ALARM TRIPS ON ITS OWN . . . . . . . . . . . . 32
SYSTEM MODULE SYSTEM VTSS VERIFICATION TEST . . . . . . . . . . . . . . 33
OVERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . 5 SENTRY KEY REMOTE ENTRY MODULE
NO COMMUNICATION WITH BCM AND INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . 34
CENTRAL LOCKING PUMP/SECURITY INVALID TRANSMITTER . . . . . . . . . . . . . . . . 36
SYSTEM MODULE . . . . . . . . . . . . . . . . . . . . . 8 SENTRY KEY ANTENNA CIRCUIT . . . . . . . . . 38
CAN B BUS (-) CIRCUIT FAILURE . . . . . . . . . 10 REMOTE KEYLESS ENTRY RELAY
CAN B BUS (+) CIRCUIT FAILURE . . . . . . . . 13 CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . 40
DOOR LOCK SWITCH SENSE CIRCUIT . . . . 16 SENTRY KEY VERIFICATION TEST ... . . . . 43
DOOR UNLOCK SWITCH SENSE CIRCUIT . . 19 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 44
VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS

8Q - 2 VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS ZH
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM UNDERVOLTAGE
ZH VEHICLE THEFT SECURITY - ELECTRICAL DIAGNOSTICS 8Q - 3
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM UNDERVOLTAGE — CONTINUED
Fused B(+) circuit voltage for proper system voltage.
• Set Condition: If the voltage is below 11 volts, the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW

FUSED B(+) CIRCUIT HIGH RESISTANCE
For a complete Vehicle Theft Security System Circuit Diagram, Refer to Page 8Q-44.
Diagnostic Test

Start the engine.

Yes >> Go to 2


Perform VTSS VERIFICATION TEST.
No >> Go to 3
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM UNDERVOLTAGE — CONTINUED

Yes >> Go to 4


CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM OVERVOLTAGE
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM OVERVOLTAGE — CONTINUED
Fused B(+) circuit at all times for proper system voltage.
• Set Condition: If the voltage is above 16 volts, the Diagnostic Trouble Code (DTC) is set.
POSSIBLE CAUSES
SYSTEM VOLTAGE HIGH

GROUND CIRCUIT OPEN
Diagnostic Test

Start the engine.

Yes >> Go to 2

Start the engine.
Raise the engine speed above 1800 RPM.

No >> Go to 3
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE SYSTEM OVERVOLTAGE — CONTINUED

NO COMMUNICATION WITH BCM AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE
NO COMMUNICATION WITH BCM AND CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE — CONTINUED
• Set Condition: CAN Bus communication failure between the Body Control Module (BCM) and the Central
Locking Pump/Security System Module (CLP/SSM).
POSSIBLE CAUSES

Diagnostic Test

Measure the resistance of the CAN B Bus (+) circuit from the CLP/SSM

Yes >> Go to 2

Measure the resistance of the CAN B Bus (-) circuit from the CLP/SSM

CAN B BUS (-) CIRCUIT FAILURE
CAN B BUS (-) CIRCUIT FAILURE — CONTINUED
• Set Condition: CAN B Bus (-) communication failure between the Body Control Module (BCM) and the
Central Locking Pump/Security System Module (CLP/SSM).
POSSIBLE CAUSES
CAN B BUS (-) CIRCUIT SHORTED TO VOLTAGE

CAN B BUS (-) CIRCUIT SHORTED TO GROUND
Diagnostic Test

Measure the resistance of the CAN B Bus (-) circuit from the BCM har-
ness connector to the CLP/SSM harness connector.

Yes >> Go to 2
2. MEASURE THE VOLTAGE OF THE CAN B BUS (-) CIRCUIT

Measure the voltage of the CAN B Bus (-) circuit at the CLP/SSM harness
connector.
Is voltage present?
Yes >> Repair the CAN B Bus (-) circuit for a short to voltage.
No >> Go to 3
CAN B BUS (-) CIRCUIT FAILURE — CONTINUED
Measure the resistance between ground and the CAN B Bus (-) circuit at
the CLP/SSM harness connector.

Yes >> Repair the CAN B Bus (-) circuit for a short to ground.
CAN B BUS (+) CIRCUIT FAILURE
CAN B BUS (+) CIRCUIT FAILURE — CONTINUED
• Set Condition: CAN B Bus (+) communication failure between the Body Control Module (BCM) and the
Central Locking Pump/Security System Module (CLP/SSM).
POSSIBLE CAUSES
CAN B BUS (+) CIRCUIT SHORTED TO VOLTAGE

CAN B BUS (+) CIRCUIT SHORTED TO GROUND
Diagnostic Test

Measure the resistance of the CAN B Bus (+) circuit from the BCM har-
ness connector to the CLP/SSM harness connector.

Yes >> Go to 2
2. MEASURE THE VOLTAGE OF THE CAN B BUS (+) CIRCUIT

Measure the voltage of the CAN B Bus (+) circuit at the CLP/SSM harness
connector.
Is voltage present?
Yes >> Repair the CAN B Bus (+) circuit for a short to voltage.
No >> Go to 3
CAN B BUS (+) CIRCUIT FAILURE — CONTINUED
Measure the resistance between ground and the CAN B Bus (+) circuit at
the CLP/SSM harness connector.

Yes >> Repair the CAN B Bus (+) circuit for a short to ground.
DOOR LOCK SWITCH SENSE CIRCUIT
DOOR LOCK SWITCH SENSE CIRCUIT — CONTINUED
• Set Condition: The Sentry Key Remote Entry Module (SKREEM) reports a short to power, ground, or an
open circuit failure on the Door Lock Switch Sense circuit.
POSSIBLE CAUSES
DOOR LOCK SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

DOOR LOCK SWITCH SENSE CIRCUIT SHORTED TO GROUND
DOOR LOCK SWITCH SENSE CIRCUIT OPEN
Diagnostic Test

SENSE CIRCUIT

Measure the resistance of the Door Lock Switch Sense circuit from the

Yes >> Go to 2
No >> Repair the Door Lock Switch Sense circuit for an open.
2. MEASURE THE VOLTAGE OF THE DOOR LOCK SWITCH SENSE

CIRCUIT

Measure the voltage of the Door Lock Switch Sense circuit at the
Is voltage present?
voltage.
No >> Go to 3
DOOR LOCK SWITCH SENSE CIRCUIT — CONTINUED
SENSE CIRCUIT

Measure the resistance between ground and the Door Lock Switch Sense
circuit at the SKREEM harness connector.

ground.
to Page 8Q-48.
DOOR UNLOCK SWITCH SENSE CIRCUIT
DOOR UNLOCK SWITCH SENSE CIRCUIT — CONTINUED
open circuit failure on the Door Unlock Switch Sense circuit.
POSSIBLE CAUSES
DOOR UNLOCK SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

DOOR UNLOCK SWITCH SENSE CIRCUIT SHORTED TO GROUND
DOOR UNLOCK SWITCH SENSE CIRCUIT OPEN
Diagnostic Test

SENSE CIRCUIT

Measure the resistance of the Door Unlock Switch Sense circuit from the

Yes >> Go to 2
No >> Repair the Door Unlock Switch Sense circuit for an open.
2. MEASURE THE VOLTAGE OF THE DOOR UNLOCK SWITCH SENSE

CIRCUIT

Measure the voltage of the Door Unlock Switch Sense circuit at the
Is voltage present?
voltage.
No >> Go to 3
DOOR UNLOCK SWITCH SENSE CIRCUIT — CONTINUED
SENSE CIRCUIT

Measure the resistance between ground and the Door Unlock Switch
Sense circuit at the SKREEM harness connector.

ground.
to Page 8Q-48.
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT — CONTINUED
ground, or an open circuit failure on the Anti-Theft Tow Sensor Signal circuit.
POSSIBLE CAUSES
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT OPEN
ANTI-THEFT TOW SENSOR
For a complete Vehicle Theft Security System circuit diagram, Refer to Page 8Q-44.
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE ANTI-THEFT TOW SENSOR

SIGNAL CIRCUIT

Disconnect the Anti-Theft Tow Sensor harness connector.
Measure the resistance of the Anti-Theft Tow Sensor Signal circuit from
the CLP/SSM harness connector to the Anti-Theft Tow Sensor harness
connector.

Yes >> Go to 2
No >> Repair the Anti-Theft Tow Sensor Signal circuit for an
open.
2. MEASURE THE VOLTAGE OF THE ANTI-THEFT TOW SENSOR

SIGNAL CIRCUIT

Measure the voltage of the Anti-Theft Tow Sensor Signal circuit at the Anti-
Theft Tow Sensor harness connector.
Is voltage present?
Yes >> Repair the Anti-Theft Tow Sensor Signal circuit for a short
to voltage.
No >> Go to 3
ANTI-THEFT TOW SENSOR SIGNAL CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE ANTI-THEFT TOW SENSOR
SIGNAL CIRCUIT

Measure the resistance between ground and the Anti-Theft Tow Sensor
Signal circuit at the Anti-Theft Tow Sensor harness connector.

Yes >> Repair the Anti-Theft Tow Sensor Signal circuit for a short
to ground.
No >> Replace the Anti-Theft Tow Sensor. Refer to Page
8Q-57.
• Set Condition: CAN Bus communication failure between the Sentry Key Remote Entry Module (SKREEM)
and the Powertrain Control Module (PCM).
POSSIBLE CAUSES
Diagnostic Test

Measure the resistance of the CAN C Bus (+) circuit from the SKREEM
harness connector to the PCM harness connector.

Yes >> Go to 2

Measure the resistance of the CAN C Bus (-) circuit from the SKREEM
harness connector and the PCM harness connector.

Yes >> Replace the Sentry Key Remote Entry Module. Refer to
Page 8Q-48.
SIREN SIGNAL OUTPUT CIRCUIT
SIREN SIGNAL OUTPUT CIRCUIT — CONTINUED
ground, or an open circuit failure on the Siren Signal Output circuit.
POSSIBLE CAUSES
SIREN SIGNAL OUTPUT CIRCUIT SHORTED TO VOLTAGE

SIREN SIGNAL OUTPUT CIRCUIT SHORTED TO GROUND
SIREN SIGNAL OUTPUT CIRCUIT OPEN
SIREN INTERNAL FAILURE
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE SIREN SIGNAL OUTPUT

CIRCUIT

Disconnect the Siren harness connector.
Measure the resistance of the Siren Signal Output circuit from the CLP/
SSM harness connector to the Siren harness connector.

Yes >> Go to 2
No >> Repair the Siren Signal Output circuit for an open.
2. MEASURE THE VOLTAGE OF THE SIREN SIGNAL OUTPUT

CIRCUIT

Measure the voltage of the Siren Signal Output circuit at the Siren harness
connector.
Is voltage present?
Yes >> Repair the Siren Signal Output circuit for a short to voltage.
No >> Go to 3
SIREN SIGNAL OUTPUT CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE SIREN SIGNAL OUTPUT
CIRCUIT

Measure the resistance between ground and the Siren Signal Output cir-
cuit at the Siren harness connector.

Yes >> Repair the Siren Signal Output circuit for a short to ground.
No >> Replace the Siren.
CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE INTERNAL FAILURE — CONTINUED
• Set Condition: If the Central Locking Pump/Security System Module (CLP/SSM) detects an internal mal-
function, the DTC is set.
POSSIBLE CAUSES
NO POWER TO CENTRAL LOCKING PUMP/SECURITY SYSTEM MODULE
Diagnostic Test


Yes >> Go to 2


*ALARM TRIPS ON ITS OWN
POSSIBLE CAUSES
FALSE GLOVE BOX SWITCH SIGNAL

FALSE LIFTGATE LOCK SWITCH SIGNAL
FALSE HOOD AJAR SWITCH SIGNAL
FALSE LEFT DOOR AJAR SWITCH SIGNAL
FALSE RIGHT DOOR AJAR SWITCH SIGNAL
FALSE IGNITION SWITCH SIGNAL
FALSE BRAKE LAMP SWITCH SIGNAL
FALSE ANTI-THEFT TOW SENSOR SIGNAL
INTERMITTENT CONDITION
Diagnostic Test
1. MONITOR THE VEHICLE THEFT SECURITY SYSTEM WITH THE

DRB IIIT
Note: If any vehicle theft DTCs are set, diagnose them first before
continuing.
With the DRB IIIT in Inputs/Outputs, read the Central Locking Pump/Se-
curity System Module last cause state.
Were there any causes displayed?

Yes >> Check for a possible intermittent condition with the circuit
indicated by the DRB IIIT.
No >> The condition that caused the alarm is not present at
this time. Refer to any Technical Service Bulletins
(TSB) that may apply. Visually inspect related wiring
harnesses and connectors. Look for damaged wires or
connectors.
VTSS VERIFICATION TEST
1.
Ensure all doors, liftgate, and hood are closed.
Open the driver door.
Remove the ignition key (but keep in hand).
Lock the doors with the RKE transmitter.
Close the driver door.
Observe the Tow-Away Alarm Switch for flashing.
If the Tow-Away Alarm Switch fails to flash, there is a problem with the
system. Select the appropriate VTSS symptom to troubleshoot the failure.
modules. Operate all functions of the system that caused the original com-
plaint.

SENTRY KEY REMOTE ENTRY MODULE INTERNAL FAILURE
SENTRY KEY REMOTE ENTRY MODULE INTERNAL FAILURE — CONTINUED
• Set Condition: If the Sentry Key Remote Entry Module (SKREEM) detects an internal malfunction, the
DTC is set.
POSSIBLE CAUSES
NO POWER TO SENTRY KEY REMOTE ENTRY MODULE
For a complete Sentry Key Remote Entry (SKREEM) Circuit Diagram, Refer to Page 8Q-44.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE SKREEM POWER CIRCUIT

Measure the voltage of the Fused B(+) circuit (cavity 18) at the SKREEM

Yes >> Replace the Sentry Key Remote Entry Module.
Perform SENTRY KEY VERIFICATION TEST.
INVALID TRANSMITTER
INVALID TRANSMITTER — CONTINUED
• Set Condition: The Sentry Key Remote Entry Module (SKREEM) detects an ignition key micro-chip mal-
function.
POSSIBLE CAUSES
DEFECTIVE IGNITION KEY MICRO-CHIP
Diagnostic Test

Does the DRB IIIT display an Invalid Transmitter DTC?

Yes >> Replace the Ignition Key.
SENTRY KEY ANTENNA CIRCUIT
SENTRY KEY ANTENNA CIRCUIT — CONTINUED
• Set Condition: The Sentry Key Remote Entry Module (SKREEM) detects a Sentry Key Antenna circuit
malfunction.
POSSIBLE CAUSES
SENTRY KEY ANTENNA RING
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE SENTRY KEY ANTENNA

CIRCUIT
Disconnect the Sentry Key Antenna Ring connector from the SKREEM.
Measure the resistance of the Sentry Key Antenna circuit from cavity 1 to
cavity 2 of the connector.

Yes >> Replace the Sentry Key Remote Entry Module.
No >> Replace the Sentry Key Antenna Ring assembly.
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT — CONTINUED
open circuit failure on the Remote Keyless Entry Relay Control circuit.
POSSIBLE CAUSES
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE

REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT SHORTED TO GROUND
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT OPEN
REMOTE KEYLESS ENTRY RELAY
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE REMOTE KEYLESS ENTRY

RELAY CONTROL CIRCUIT

Remove the Remote Keyless Entry Relay.
Measure the resistance of the Remote Keyless Entry Relay Control circuit
from the SKREEM harness connector to the Remote Keyless Entry Relay
harness connector.

Yes >> Go to 2
No >> Repair the Remote Keyless Entry Relay Control circuit
for an open.
2. MEASURE THE VOLTAGE OF THE REMOTE KEYLESS ENTRY


Measure the voltage of the Remote Keyless Entry Relay Control circuit at
the Remote Keyless Entry Relay harness connector.
Is voltage present?
Yes >> Repair the Remote Keyless Entry Relay Control circuit for a
short to voltage.
No >> Go to 3
REMOTE KEYLESS ENTRY RELAY CONTROL CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE REMOTE KEYLESS ENTRY

Measure the resistance between ground and the Remote Keyless Entry
Relay Control circuit at the Remote Keyless Entry Relay harness connec-
tor.

Yes >> Repair the Remote Keyless Entry Relay Control circuit for a
short to ground.
No >> Replace the Remote Keyless Entry Relay.
SENTRY KEY VERIFICATION TEST
1.
modules. Operate all functions of the system that caused the original com-
plaint.
Perform 5 ignition key cycles leaving the key on for at least 90 seconds
per cycle.

VEHICLE THEFT SECURITY SYSTEM CIRCUIT DIAGRAM

SENTRY KEY REMOTE ENTRY MODULE CIRCUIT DIAGRAM

8Q - 46 VEHICLE THEFT SECURITY - SERVICE INFORMATION ZH
VEHICLE THEFT SECURITY - SERVICE INFORMATION
TABLE OF CONTENTS
page page
VEHICLE THEFT SECURITY - SERVICE REMOVAL - SENTRY KEY ANTENNA RING . . 54

INFORMATION INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46 INSTALLATION - SENTRY KEY REMOTE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ENTRY MODULE . . . . . . . . . . . . . . . . . . . . . . 55
SECURITY SYSTEM MODULE INSTALLATION - SENTRY KEY ANTENNA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 DOOR CYLINDER LOCK SWITCH
HOOD AJAR SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 INSTALLATION - DRIVER CYLINDER LOCK
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SIREN ANTI-THEFT TOW SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SENTRY KEY REMOTE ENTRY MODULE TOW-AWAY ALARM SWITCH
REMOVAL
REMOVAL - SENTRY KEY REMOTE ENTRY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
VEHICLE THEFT SECURITY - SERVICE INFORMATION

DESCRIPTION
The Central Locking Pump/Security System Module (3) uses a
combination of electrical wires (2) and air pressure/vacuum
lines (1). The Central Locking Pump/Security System Module
is located in the right rear of the luggage compartment under-
neath the trunk floor covering (4). It is wrapped in a sound
deadening material in order to operate quietly without disturb-
ing the vehicle operator.
The Central Locking Pump/Security System Module controls
the air and vacuum lines that handle the locking and unlocking
of the vehicle doors, the liftgate, and the fuel tank door.
ZH VEHICLE THEFT SECURITY - SERVICE INFORMATION 8Q - 47
OPERATION
VEHICLE LOCKING/UNLOCKING
To unlock, the Body Control Module is actuated by the SKREEM. The Body Control Module then sends the signal
to the Central Locking Pump/Security System Module (CLP/SSM) via the Controller Area Network (CAN) Bus. The
CLP/SSM pump motor starts running and supplies air pressure. The door lock actuators are pressurized. When a
pressure threshold is reached in the system, the pump is switched off by an internal pressure switch. The pressure
in the system is then released by the CLP/SSM and the unlocking operation is completed. The locking procedure is
accomplished in a fashion opposite to the unlocking operation. However, the next time the remote control button is
pressed, the CLP/SSM is also actuated by connecting it to ground by the second control lead on the SKREEM. The
direction of rotation for the CLP/SSM pump motor is reversed, thereby providing the vacuum required to lock. In
order to avoid unlocking the vehicle unintentionally, the vehicle is relocked by the CLP/SSM via the SKREEM.
the key is not inserted into the ignition lock, the interior power door lock switch is not actuated, only the liftgate is
opened after unlocking. The CLP/SSM reads the signals (door contacts, trunk lid, interior power door lock switch)
and actuates the power door lock actuators. The vehicle security alarm is also activated by the relocking function.
AUTOMATIC LOCKING/UNLOCKING
Upon reaching a speed of 15 km/h (9 MPH), the vehicle doors are locked automatically. The fuel tank flap remains
unlocked. If, after automatic locking, the vehicle is unlocked with the interior power door lock switch, this state is
maintained until a door is opened or until the ignition is switched off. Automatic locking is accomplished again only
upon reaching the specified speed. The logic circuitry for this function is integrated into the CLP/SSM. The auto-
matic locking function can be activated or deactivated with the DRB IIIT. An alternative is to use the interior power
door lock switch with the ignition switched on by pressing and holding the door lock switch for more than 5 seconds
in either the lock (auto locking switched on) or unlock (auto locking switched off) position. The alternative of
enabling/disabling the auto locking system by using the interior power door lock switch can also be inhibited with the
DRB IIIT.
EMERGENCY UNLOCKING
In the event of a vehicle collision, the doors are unlocked automatically by a crash sensor integrated into the CLP/
SSM. The doors are unlocked after a delay time of 8 to 11 seconds. The emergency unlocking function interrupts all
functions performed by the CLP/SSM, which are reactivated only after interrupting the ignition. The emergency
unlocking function is only active when the vehicle is unlocked from the outside.
VEHICLE RELOCKING
In order to avoid unlocking the vehicle unintentionally, the vehicle is relocked by the CLP/SSM via the SKREEM.
the key is not inserted into the ignition lock, or the interior power door lock switch is not actuated. The CLP/SSM
reads the signals (door contacts, interior power door lock switch) and actuates the power door lock actuators. The
vehicle security alarm is also activated by the relocking function.
ANTI-THEFT SYSTEM
Once the anti-theft alarm system is set, the anti-theft alarm can be triggered if:
• The doors, hood, or hatch is opened
• The radio is removed (disconnected electrically)
• The ignition is jumped
• The glove box is opened
• The anti-theft tow sensor is tripped
• The alarm siren is tripped
The inputs ready for triggering an alarm are checked twice per second by the CLP/SSM. If two sequential checks
of the same input indicate that the input is not in the non-actuated state, the audible alarm Siren is triggered and the
front and rear lamps flash.
SIREN
The vehicle theft system alarm Siren contains a built in rechargeable battery back up and can sound if its electrical
circuits are disconnected or if the vehicle battery cables are disconnected. The Siren can also sound if the electrical
circuits between it and the CLP/SSM are disconnected. Once triggered, the Siren can only be silenced by unlocking
the vehicle with the RF key transmitter or by unlocking the vehicle with the mechanical key.
ANTI-THEFT SWITCH/ANTI-THEFT TOW SENSOR

The Anti-Theft Tow Sensor is an inclination sensor that contains electrodes which are partially immersed in an elec-
trically conductive liquid. If the conductive value between the electrodes changes, the sensor recognizes a change
in the inclination of the vehicle. When the vehicle is parked, the value for the vehicle position is stored. If the vehicle
is moved with a certain inclination in longitudinal and/or lateral direction for a certain time when the anti-theft alarm
system is activated, the Anti-Theft Tow Sensor transmits an alarm signal to the CLP/SSM. In order to allow the
vehicle to be towed or transported without sounding the alarm Siren, the Anti-Theft Tow Sensor can be deactivated
by pressing the Anti-Theft Switch which is located in the passenger compartment on the center console in front of
the shift lever.
SECURITY SYSTEM MODULE

REMOVAL


2. Remove the trunk floor covering.
3. Remove the vehicle jacking assembly.
4. Remove the sound deadening foam material from the central locking pump/security system module.
5. Disconnect the air lines (1) and the electrical connectors (2) from the central locking pump/security system mod-
ule (3) and remove the module.
INSTALLATION

1. Install the central locking pump/security system module (3) into the trunk and connect the air lines (1) and the
electrical connectors (2).
2. Install the sound deadening foam covering to the central locking pump/security system module.
3. Install the vehicle jacking assembly into the trunk next to the central locking pump/security system module.
4. Install the trunk floor covering.
HOOD AJAR SWITCH

REMOVAL
The Hood Ajar Switch is an integral part of the hood latch
assembly (2) and cannot be adjusted or repaired. If faulty,
worn, or damaged, the entire hood latch assembly must be
replaced. Refer to Page 23-136
INSTALLATION
The Hood Ajar Switch is an integral part of the hood latch assembly. For installation procedures, see the Body
section of this manual. Refer to Page 23-137
SIREN
REMOVAL
1. Remove the cowl grille. Refer to Page 23-114
2. Remove the bolt (1) from the siren bracket.
3. Disconnect the siren electrical connector (1).
INSTALLATION
1. Connect the siren electrical connector (1).
2. Install the bolt (1) to the siren bracket.

3. Install the cowl grille. Refer to Page 23-114.

DESCRIPTION
The Sentry Key Remote Entry Module (SKREEM) (1) is
located underneath the top pad of the instrument panel (2)
behind the Instrument Cluster. The SKREEM works in conjunc-
tion with the vehicle locking/unlocking remote control and the
Central Locking Pump/Security System Module to lock and
unlock the vehicle.
The SKREEM is also the primary component of the sentry key
system. The SKREEM has a halo-like Antenna Ring that con-
nects by wires to the SKREEM and is mounted around the
Ignition Lock Cylinder. The SKREEM cannot be adjusted or
repaired. If faulty or damaged, the unit must be replaced.
OPERATION
The Sentry Key Remote Entry Module (SKREEM) has the following functions: receiving and evaluating the Radio
Frequency (RF) keyless entry remote signal, actuation of door locks in conjunction with the Central Locking Pump/
Security System Module, and enabling the vehicle theft security alarm with confirmation via the turn signals. When
the RKE transmitter is operated, an RF signal is transmitted. If the SKREEM recognizes the RF signal as valid, it
actuates the Central Locking Pump/Security System Module through the Body Control Module. The vehicle is then
locked or unlocked through the power locks system. Connected to the SKREEM is a Sentry Key Antenna Ring
which surrounds the ignition lock cylinder. When the ignition is switched on, the Sentry Key Antenna Ring is sup-
plied with power. A data block is transmitted inductively via the Sentry Key Antenna Ring to the SKREEM and then
on to the Powertrain Control Module. If the antenna ring data block content is invalid or if vehicle battery power is
too low to build up enough power for the antenna ring, the Powertrain Control Module will not receive the proper
signal. This is displayed with the message “Start Error” in the Instrument Cluster.
The SKREEM contains an RF transceiver and a microprocessor. The SKREEM transmits RF signals to and receives
RF signals from the ignition key transponder through a tuned Sentry Key Antenna Ring that is wired to the
SKREEM. If the Sentry Key Antenna Ring is not mounted properly around the ignition lock cylinder housing, com-
munication problems between the SKREEM and the ignition key may arise. These communication problems will
result in ignition key transponder-related faults. The SKREEM also communicates over the Controller Area Network
(CAN) data bus with the Powertrain Control Module (PCM), the Instrument Cluster, the Body Control Module (BCM),
and/or the DRB IIIT scan tool.
The SKREEM retains in memory the ID numbers of any ignition key transponder that is programmed into it. For
added system security each SKREEM is programmed with a unique secret key code. This code is stored in mem-
ory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every ignition key that is pro-
grammed into the SKREEM.
In the event that a SKREEM replacement is required, the secret key code can be transferred to the new SKREEM
from the PCM using the DRB IIIT scan tool and the ignition key system replacement programming procedure.
Proper completion of the ignition key system initialization will allow the existing ignition keys to be programmed into
the new SKREEM so that new keys will not be required. In the event that the original secret key code cannot be
recovered, SKREEM replacement will also require new ignition keys. The DRB IIIT scan tool will alert the technician
during the key reprogramming procedure if new ignition keys are required.
The sentry key system performs a self-test each time the ignition switch is turned to the On position and will store
fault information in the form of Diagnostic Trouble Codes (DTCs) in SKREEM memory if a system malfunction is
detected. The SKREEM can be diagnosed and any stored DTCs can be retrieved using a DRB IIIT scan tool. Refer
to the appropriate diagnostic information.
REMOVAL
REMOVAL - SENTRY KEY REMOTE ENTRY MODULE
To remove the SKREEM:
3. Disconnect the 2-pin CAN bus connector and the 18-pin
electrical connector (1) from the SKREEM.
4. Disconnect the 2-pin connector for the sentry key antenna
ring.
REMOVAL - SENTRY KEY ANTENNA RING

2. Disconnect the sentry key antenna ring electrical connector
(1) from the sentry key remote entry module (2).
Note: Pay attention to harness routing for proper installa-

tion.
3. Pull to remove the sentry key antenna ring (1) from the
ignition switch key cylinder (2).
INSTALLATION
INSTALLATION - SENTRY KEY REMOTE ENTRY MODULE
2. Connect the 18-pin electrical connector and the 2-pin CAN
bus connector (1) to the SKREEM.
3. Connect the 2-pin connector for the sentry key antenna
ring.
INSTALLATION - SENTRY KEY ANTENNA

RING
1. Install the sentry key antenna ring (1) to the ignition switch
key cylinder (2).
2. Install the sentry key antenna ring electrical connector (1)

to the sentry key remote entry module (2).
DOOR CYLINDER LOCK SWITCH

REMOVAL
The Driver Cylinder Lock Switch (1) is an integral part of the
Driver Door Lock Actuator assembly and cannot be adjusted or
repaired. If faulty, worn, or damaged, the entire assembly must
be replaced. Refer to Page 8N-43.
INSTALLATION - DRIVER CYLINDER LOCK SWITCH

The Driver Cylinder Lock Switch is an integral part of the Driver Door Lock Actuator assembly and cannot be
adjusted or repaired. If faulty, worn, or damaged, the entire assembly must be replaced. For installation procedures,
see the Body section of this manual. Refer to Page 8N-43.
ANTI-THEFT TOW SENSOR

REMOVAL
1. Remove the right side trunk inner trim panel.
2. Remove the bolt (1) from the anti-theft tow sensor bracket.
3. Disconnect the anti-theft tow sensor electrical connector

(1).
INSTALLATION
Note: Install the anti-theft tow sensor with the “UP” mark
properly positioned.
1. Connect the anti-theft tow sensor electrical connector (1).
2. Install the bolt (1) to the anti-theft tow sensor bracket.

3. Install the right side trunk inner trim panel.
TOW-AWAY ALARM SWITCH

REMOVAL
1. Remove the heated seat switches. Refer to Page 8G-37
2. Carefully depress tabs (1) inward to remove the tow-away
alarm switch (2).
INSTALLATION
1. Install the tow-away alarm switch (2) and secure it by snap-
ping the retaining tabs (1) into place.
2. Install the heated seat switches. Refer to Page 8G-38.
ZH WIPERS/WASHERS 8R - 1
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS - ELECTRICAL WIPERS/WASHERS - SERVICE INFORMATION . . 21

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
WIPERS/WASHERS - ELECTRICAL *WIPERS HIGH SPEED INOPERATIVE . . . . . 11

DIAGNOSTICS *WIPERS LOW SPEED INOPERATIVE . . . . . 13
DIAGNOSIS AND TESTING *WIPERS INTERMITTENT SPEED
VOLTAGE SUPPLY CIRCUIT OPEN . . . . .....2 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . 15
*WASHERS INOPERATIVE . . . . . . . . . . .....4 *WIPERS RUN CONTINUOUSLY WITH
*WASHERS RUN CONTINUOUSLY WITH IGNITION ON . . . . . . . . . . . . . . . . . . . . . . . . . 17
IGNITION ON . . . . . . . . . . . . . . . . . . . . . .....6 BODY VERIFICATION TEST . . . . . . . . . . . . . 19
*WIPERS INOPERATIVE . . . . . . . . . . . . .....8 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 20
WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS

8R - 2 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS ZH
VOLTAGE SUPPLY CIRCUIT OPEN
ZH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 3
VOLTAGE SUPPLY CIRCUIT OPEN — CONTINUED
• When Monitored: With the wipers/washers on.
• Set Condition: If the Body Control Module (BCM) detects a voltage supply circuit malfunction, the DTC is
set.
POSSIBLE CAUSES
BODY CONTROL MODULE
For a complete Wipers/Washers Circuit Diagram, Refer to Page 8R-20.
Diagnostic Test
1. MEASURE THE VOLTAGE OF THE FUSED IGNITON SWITCH

OUTPUT CIRCUIT

continuing.
BCM C4 harness connector.

Yes >> Replace the Body Control Module. Refer to Page 8E-72
open.
*WASHERS INOPERATIVE
*WASHERS INOPERATIVE — CONTINUED
POSSIBLE CAUSES
WASHER PUMP MOTOR CONTROL CIRCUIT OPEN
WASHER PUMP MOTOR
Diagnostic Test
1. MEASURE WASHER PUMP MOTOR CIRCUIT RESISTANCE

ing.
Disconnect the Washer Pump Motor harness connector.
Connect a jumper wire between cavity 1 and cavity 2 of the Washer Pump
Motor harness connector.
Measure the resistance between ground and the Washer Pump Motor
Control circuit at cavity 8 of the Multi-Function Switch harness connector.

Yes >> Go to 2
No >> Repair the Washer Pump Motor Control circuit for an
open.
2. MEASURE MULTI-FUNCTION SWITCH VOLTAGE

Depress the washer switch, and measure the voltage of the Washer Pump
Motor Control circuit at the Washer Pump Motor Connector.

Yes >> Replace the Washer Pump Motor. Refer to Page 8R-31
8L-112
*WASHERS RUN CONTINUOUSLY WITH IGNITION ON
*WASHERS RUN CONTINUOUSLY WITH IGNITION ON — CONTINUED
POSSIBLE CAUSES
WASHER PUMP MOTOR CONTROL CIRCUIT SHORT TO VOLTAGE
BODY CONTROL MODULE
Diagnostic Test

ing.
Connect a fused jumper wire from B(+) to cavity 11 of the Multi-Function
Switch.
Measure the voltage of the Washer Pump Motor Control circuit at the
Multi-Function Switch harness connector.
Is voltage present?
Yes >> Replace the Multi-Function Switch. Refer to Page 8L-112
No >> Go to 2
2. MEASURE WASHER PUMP MOTOR CIRCUIT VOLTAGE

Disconnect the Washer Pump Motor harness connector.
Measure the voltage of the Washer Pump Motor Control circuit at cavity 8
of the Multi-Function Switch harness connector.
Is voltage present?
Yes >> Repair the Washer Pump Motor Control circuit for a short to
voltage.
8E-72
*WIPERS INOPERATIVE
*WIPERS INOPERATIVE — CONTINUED
POSSIBLE CAUSES

WIPER SWITCH MUX CIRCUIT OPEN
BODY CONTROL MODULE
WIPER MOTOR
Diagnostic Test
1. MEASURE WIPER/WASHER FUSED B(+) CIRCUIT VOLTAGE

ing.
continuing.
Measure the voltage of the Fused B(+) circuit at the Multi-Function Switch
harness connector.

Yes >> Go to 2
2. TEST THE WIPER MOTOR

Disconnect the Body Control Module (BCM) C2 harness connector.
Connect a jumper wire between cavity 1 of the BCM C2 harness connec-
tor and B(+).
Connect a jumper wire between cavity 41 of the BCM C2 harness con-
nector and ground.
With the jumper wires connected, does the Wiper Motor move?
Yes >> Go to 3
No >> Replace the Wiper Motor. Refer to Page 8R-47
*WIPERS INOPERATIVE — CONTINUED
3. MEASURE WIPER SWITCH MUX CIRCUIT RESISTANCE
Measure the resistance of the Wiper Switch Mux circuit from the Multi-
Function Switch harness connector to the BCM harness connector.

Yes >> Go to 4
No >> Repair the Wiper Switch Mux circuit for an open.
4. MEASURE WIPER SWITCH MUX CIRCUIT VOLTAGE

Measure the voltage of the Wiper Switch Mux circuit at the BCM C3 con-
nector cavity 65 with the Wiper Switch in the High position.

Yes >> Replace the Body Control Module. Refer to Page 8E-72
8L-112
*WIPERS HIGH SPEED INOPERATIVE
*WIPERS HIGH SPEED INOPERATIVE — CONTINUED
POSSIBLE CAUSES
BODY CONTROL MODULE
WIPER MOTOR
Diagnostic Test

ing.
tor and B(+).
nector and ground.
Yes >> Go to 2
No >> Replace the Wiper Motor. Refer to Page 8R-47.

Backprobe the BCM C3 harness connector cavity 65 for voltage with the
Wiper Switch in the High position.

8L-112.
*WIPERS LOW SPEED INOPERATIVE
*WIPERS LOW SPEED INOPERATIVE — CONTINUED
POSSIBLE CAUSES
BODY CONTROL MODULE
WIPER MOTOR
Diagnostic Test

ing.
tor and B(+).
nector and ground.
Yes >> Go to 2
No >> Replace the Wiper Motor. Refer to Page 8R-47.

Disconnect the jumper wires.
Backprobe the BCM C3 harness connector cavity 65 for voltage with the
Wiper Switch in the Low position.
Is the voltage approximately 7 to 8 volts?

8L-112.
*WIPERS INTERMITTENT SPEED INOPERATIVE
*WIPERS INTERMITTENT SPEED INOPERATIVE — CONTINUED
POSSIBLE CAUSES
BODY CONTROL MODULE
Diagnostic Test

ing.
Backprobe the Body Control Module (BCM) C3 harness connector cavity
65 for voltage with the Wiper Switch in the Intermittent position.
Is the voltage approximately 3 to 4 volts?

8L-112.
*WIPERS RUN CONTINUOUSLY WITH IGNITION ON
*WIPERS RUN CONTINUOUSLY WITH IGNITION ON — CONTINUED
POSSIBLE CAUSES
WIPER MOTOR CIRCUIT SHORT TO VOLTAGE
BODY CONTROL MODULE
Diagnostic Test

ing.
Connect a fused jumper wire from B(+) to cavity 11 of the Multi-Function
Switch.
Measure the voltage of the Wiper Switch Mux circuit at cavity 7 of the
Is voltage present?
Yes >> Replace the Multi-Function Switch. Refer to Page 8L-112.
No >> Go to 2

Measure the voltage of the Wiper Switch Mux circuit at cavity 7 of the
Is voltage present?
Yes >> Repair the Wiper Switch Mux circuit for a short to voltage.
8E-72.
1.

WIPERS/ WASHERS CIRCUIT DIAGRAM

ZH WIPERS/WASHERS - SERVICE INFORMATION 8R - 21
WIPERS/WASHERS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
WIPERS/WASHERS - SERVICE INFORMATION WIPER ARMS

DIAGNOSIS AND TESTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
WINDSHIELD WIPER/WASHER SYSTEM . . . 23 ADJUSTMENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 24 ADJUSTMENT - WIPER ARMS ........ . . . 36
MULTI-FUNCTION SWITCH WIPER BLADES
WASHER FLUID LEVEL SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 STANDARD PROCEDURE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26 WINDSHIELD WIPER BLADE ALIGNMENT . . 36
WASHER HOSES / TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 WIPER LINKAGE
WASHER NOZZLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE - WASHER NOZZLE WIPER MODULE
AIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
WASHER PUMP MOTOR WIPER MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 STANDARD PROCEDURE - WIPER MOTOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31 SYNCHRONIZE . . . . . . . . . . . . . . . . . . . . . . . 46
WASHER RESERVOIR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
WIPERS/WASHERS - SERVICE INFORMATION

DESCRIPTION
An electrically operated intermittent windshield wiper and
washer system is standard safety equipment. The windshield
wiper and washer systems include the following major compo-
nents, which are described in further detail within this service
information:
• Body Control Module - The Body Control Module
(BCM) (6) is located in the engine compartment on the
passenger side inside the control module box.
• Washer Nozzle - Two fluidic washer nozzles (4) are
secured with integral snap features into dedicated open-
ings within the cowl grille at the base of the windshield.
• Washer Plumbing - The plumbing for the washer sys-
tem consists of rubber hoses and molded plastic fittings.
The plumbing is routed from behind the passenger front
inner fender liner, through the right side of the plenum,
up along the underside of the cowl grille to the washer
nozzles.
8R - 22 WIPERS/WASHERS - SERVICE INFORMATION ZH
• Washer Pump/Motor - The washer pump/motor unit (5) is located on the lower and forward side of the
washer reservoir, behind the right front inner fender liner.
• Wiper Arm - Two wiper arms (1) are secured with attachment nuts to tapered and threaded studs on the
ends of wiper pivot shafts, near the base of the windshield.
• Wiper Blade - The two wiper blades (1) are secured with an integral latch to the wiper arms. When the
system is not in operation, the wiper blades are parked on the glass at the bottom of the windshield.
• Wiper Module - The wiper module (3), except the two pivot shafts, is concealed within the cowl plenum
beneath the cowl grille. It includes the module bracket, three rubber-isolated mounts, the wiper motor, the
wiper motor crank arm, the wiper linkage and wiper pivot shafts.
• Multi-Function Switch - The multi-function switch (2) is secured to the left side and near the top of the
steering column, just below the steering wheel. Only the control stalk for the multifunction switch is visible; the
remainder of the switch and control circuitry is concealed below the steering column shrouds.
• Washer Fluid Level Switch - The washer fluid level switch (6) is located in the washer fluid reservoir,
behind the right front inner fender liner.
• Washer Reservoir - The washer reservoir (5) is concealed behind the right front inner fender liner. The
washer reservoir filler neck is the only visible portion of the reservoir, and it is accessed from the right side of
the engine compartment just forward of the battery.
OPERATION
WINDSHIELD WIPER SYSTEM
The windshield wiper system will operate when the ignition switch is in the ACC or ON/RUN position and the mul-
tifunction switch lever is rotated to the intermittent, low, or high positions. The wiper system completes the wipe
cycle and parks the wiper blades in the lowest portion of the wipe pattern when the multifunction switch lever is
rotated to the OFF position. Fuses, located in the underhood accessory fuse block protect the circuitry of the wiper
system and the vehicle. The wiper motor has permanent magnet fields. The speeds are determined by current flow
to the appropriate set of brushes.
The wiper system in addition to low and high speed has a constant intermittent delay mode. The amount of delay
is controlled by the Body Control Module (BCM) and is not adjustable.
The mist function is available by pressing the end of the multifunction switch lever inward toward the steering col-
umn to the point of resistance. If the multifunction switch lever is held in, the wipers will continue to operate. If it is
pressed inward momentarily then released, the wiper system will only cycle once. A mist and wash function is also
available if the multifunction switch lever is pressed inward past the point of resistance momentarily. This will oper-
ate the washers and cycle the wiper system twice, then return the wipers to the park position.
The most reliable, efficient, and accurate means to diagnose the BCM inputs and outputs related to the various
wiper system operating modes requires the use of a DRB IIIT scan tool.
WASHER SYSTEM
The washer system is activated by pressing inward on the multifunction switch lever whenever the ignition switch is
turned to the ACC or the ON/RUN position. The multifunction switch lever must be pressed past the point of resis-
tance for at least 0.5 seconds to get the wiper system to cycle. Holding the multifunction switch lever switch
depressed will operate the wipers and washers continuously. Releasing the switch will stop the washer pump motor,
but the wiper system will complete the current wipe cycle, followed by several more wipe cycles (±1) before the
wipers park. If the wash switch is pressed momentarily with the wipers in the OFF or INTERMITTENT position, a
pulse wipe cycle consisting of two wipes will occur.
Fluid is gravity fed from the washer reservoir to the washer pump motor. The washer fluid is forced by the washer
pump motor through rubber hoses to the cowl grille mounted nozzles which distribute the fluid streams on the sur-
face of the windshield. The washer pump motor, washer nozzles, and washer reservoir are serviced separately.

WINDSHIELD WIPER/WASHER SYSTEM
Windshield Wiper System
Whenever a windshield wiper or washer system malfunction occurs, disconnect the harness connections and clean
the terminals. Ensure the wire harness is properly connected before starting diagnosis and repair procedures. For
complete windshield wiper/washer schematics and diagrams, see wipers/washers electrical diagnostics in this sec-
tion. Refer to Page 8R-20.
Wiper System Diagnosis

WIPER ARM(S) CHATTER 1. Permanent set of blade element 1. Inspect rubber element for
ON WINDSHIELD. edge. permanent set. If not OK,
replace rubber element.
2. Bent or damaged blade structure. 2. Inspect blade. If not OK,
replace blade.
3. Bent or damaged arm. 3. Inspect arm. If not OK, adjust
blade to arm clearance. See
procedure in this section.
Reinspect, if not OK, replace
arm.
DRIVER AND/OR 1. Loose arm to pivot shaft. 1. Check arm to pivot shaft
PASSENGER ARM WILL connection for looseness.
NOT CYCLE (OPERATE). Torque attachment nut to
specification.
2. Stripped arm to pivot shaft. 2. Check arm to pivot shaft for

stripping. Torque nut to
specification. If not OK, replace
arm, pivot shaft or both.
DRIVER AND/OR 1. Arm(s) out of position. 1. Remove arm off pivot shaft,
PASSENGER ARM OR cycle module to park.
BLADE HITS COWL Reposition arm/blade to
GRILLE OR WINDSHIELD location marks on windshield.
MOLDINGS. Secure arm to pivot shaft and
torque to specification. recheck
wiper arm travel.
WIPER BLADE(S) 1. Contamination on blade element 1. Clean blade element edge
STREAK. or windshield. with mild soap or alcohol and
water. Clean windshield with
mild soap or non-abrasive
cleanser and water. Check for
proper wipe quality. If not OK,
replace blade element.
2. Blade element damaged. 2. Replace blade element.
Windshield Washer System
Washer System Diagnosis
COWL GRILLE NOZZLE 1. Frozen nozzle. 1. De-ice nozzle by allowing

WILL NOT FLOW. time for underhood engine heat
to thaw nozzle. If not OK, move
vehicle into heated area.
Ensure washer fluid is properly
blended for ambient outside
temperatures.
2. Nozzle hose not flowing. 2. Ensure nozzle hose is not
pinched, loose, broken, or
disconnected. If not OK,
properly route or repair nozzle
hose.
3. Nozzle or nozzle hose plugged by 3. Clean nozzle hose of
contamination. contamination. Determine
source of contamination;
inspect reservoir and clean
system as required.
WASHER FLUID OUTPUT 1. Partially pinched hose. 1. Ensure washer hose is not
IS LOW. partially pinched. If not OK,
properly route hose.
2. Reverse polarity to pump. 2. Check for crossed circuity to
pump. If not OK, repair circuit.
3. Nozzle or nozzle hose plugged by 3. Clean nozzle hose of
contamination. contamination. Determine
source of contamination;
inspect reservoir and clean
system as required.
COWL GRILLE NOZZLE 1. Nozzle not seated in cowl grille 1. Ensure nozzle is aligned and
STREAM OVERSHOOTS properly snapped in place properly.
WINDSHIELD. 2. Nozzle jet(s) out of adjustment. 2. Adjust nozzle jets using a
safety pin.
SPECIFICATIONS

Wiper Motor Retaining
11 8 97
Bolt
Wiper Motor Crank Arm
26 19 230
Retaining Nut
DESCRIPTION
The multifunction switch and control circuitry (3) is concealed
below the steering column shrouds and will operate when the
ignition switch is turned to the ACC or ON/RUN positions.
Fuse 32 in the underhood accessory fuse block protect the cir-
cuitry of the wiper system and the vehicle.
The wiper system in addition to HI (1) and LO (2) speeds, has

an intermittent delay (3) mode. The wipers will return to the
park position when the wiper portion of the switch is rotated to
the OFF position. A mist function can be operated by briefly
pressing the end of the multifunction switch lever inward.
The multifunction switch cannot be adjusted, or repaired. If
faulty, worn, or damaged, the entire unit must be replaced. For
complete multifunction switch removal procedures, see multi-
function switch removal in the lamps/lighting exterior section.
WASHER FLUID LEVEL SWITCH

REMOVAL
1. Remove the washer reservoir. Refer to Page 7-24.
2. Gently pry outward on the body of the washer fluid level
switch (2) and pull it away from the rubber grommet (3).
3. Remove the washer fluid level switch (2) from the washer
reservoir (1).
INSTALLATION
1. Insert the washer fluid level switch (2) into the rubber grommet (3) at the rear of the washer reservoir (1).
2. Press the washer fluid level switch inward until fully seated.
3. Install the washer reservoir. Refer to Page 8R-32.
WASHER HOSES / TUBES

REMOVAL
1. Remove the right front inner fender liner. Refer to the body
section in this manual.
2. Release the washer hose attachment clamp, then remove
the washer hose (1) from the washer pump motor (2).
3. Remove the cowl grille. Refer to Page 23-114.

4. Remove the washer hose attachment clamps (2) and

release the two washer hose retaining clips.
5. Remove the washer hose (1) from the washer nozzles (3).
6. Pull the washer hose from the cowl opening and remove
the washer hose from the vehicle.
INSTALLATION
1. Route the washer hose (1) through the cowl opening and
attach to the washer pump motor (2). Secure the attach-
ment clamp.
2. Install the washer hose attachment clamp(s) (1) over the

hose(s) (2).
3. Install the washer hose(s) (2) to the washer nozzle (3) and
secure the washer hose attachment clamp(s) (1) and the
two washer hose retaining clips.

5. Install the right front inner fender liner. Refer to the body
section in this manual.
WASHER NOZZLE
STANDARD PROCEDURE - WASHER NOZZLE AIMING
CAUTION: During adjustment, be careful not to damage inside opening of jet.
Note: Be sure to check that each washer nozzle is properly secured into the cowl grille before attempting
any adjustments.
This model is equipped with two adjustable cowl grille

mounted washer nozzles. The right and left nozzles are iden-
tical. Both nozzles emit two spray streams each onto the wiper
sweep pattern. To aim, perform the following steps:
1. Using a safety pin (1), adjust each nozzle jet as required to

aim the spray within the wiper sweep pattern.
2. Each adjustment of the jet should be checked by actuating
the washer system switch from inside the vehicle.
3. After adjustment, a final check of the spray pattern should
be done by actuating the washer system switch from inside
the vehicle with the engine idling.
REMOVAL
1. Remove the cowl grille. Refer to Page 23-114.
2. Remove the clamp(s) (1) attaching the hose to the washer
nozzle (2).
3. Insert a screwdriver into the slot between the washer noz-

zle (1) and the cowl grille (2) pressing inward to release the
retaining clip. Remove the washer nozzle.
INSTALLATION
1. Install the washer nozzle (1) into the cowl grille (2). Press
downward with a rocking motion until the retaining clip is
fully seated.
2. Install the washer hose clamps (1) onto the washer hose
(2).
3. Install the washer hose (2) over the washer nozzle (3).
4. Tighten the washer clamps (1) onto the washer nozzle (3)
allowing approximately 0.78 inch (20 mm) clearance
between the washer hoses.
WASHER PUMP MOTOR

REMOVAL
1. Remove the washer reservoir (3). Refer to Page 8R-32
2. Gently pry upward on the body of the washer pump motor
(1) and pull it out of the rubber grommet (2).
INSTALLATION
1. Insert the washer pump motor into the rubber grommet at the base of the washer reservoir.
2. Press the washer pump motor downward until fully seated.
3. Install the washer reservoir. Refer to Page 8R-32.
WASHER RESERVOIR
REMOVAL
2. Remove the rear half of the right front inner fender liner.
3. Remove the washer fluid filler tube (1) from the washer res-
ervoir.
4. Remove the washer reservoir attachment bolt.
5. Gently pull the washer reservoir (5) forward to release the
rubber mounting grommets.
6. Disconnect the washer pump motor harness connector and
remove the washer pump motor supply hose from the
washer pump motor (3).
7. Disconnect the washer fluid level switch (4) harness con-
nector.
8. Remove the washer reservoir from behind the right front
wheel.
INSTALLATION
1. Connect the washer fluid level switch harness connector.
2. Connect the washer pump motor harness connector and
install the washer pump motor supply hose.
3. Insert the washer reservoir behind the right front wheel and
align the rubber mounting grommets.
4. Install the washer reservoir attachment bolt (2).
5. Install the washer fluid filler tube (1) to the washer reser-
voir.
6. Install the right front inner fender liner.
WIPER ARMS
DESCRIPTION
The wiper arms connect the wiper pivots and the wiper blades. They feature an over-center hinge that allows easy
access to the windshield glass for cleaning and service operations. A molded black plastic cap fits over the wiper
arm attachment nut for protection. The wiper arm cannot be adjusted or repaired. If faulty or damaged, the entire
wiper arm must be replaced. For complete removal procedures, see wiper arm removal in this section.
REMOVAL
1 - HOOD PROP (EXTENDED POSITION) 4 - WIPER ARM ATTACHMENT NUT

2 - WIPER ARM (OVER CENTER POSITION) 5 - PLASTIC NUT CAP
3 - WIPER PIVOT SHAFT 6 - WIPER BLADE
WARNING: THE WINDSHIELD WIPER MECHANISM CAN PINCH, CRUSH OR, IN EXTREME CASES, EVEN
SEVER EXTREMITIES. ALWAYS REMOVE THE IGNITION KEY WHEN WORKING ON WINDSHIELD WIPER
MECHANISM.
1. Open the hood, then press the hood prop release button on the hood prop outer sleeve to extend the hood prop
fully (1).
2. Lift the wiper arm (2) to its over-center position.
3. Carefully pry the plastic nut cap (5) off of the pivot end of the wiper arm (2).
4. Remove the wiper arm attachment nut (4) from the wiper pivot shaft (3).
5. Use a suitable battery terminal puller to disengage the wiper arm from the wiper pivot shaft tapered splines.
6. Remove the wiper arm pivot end from the wiper pivot shaft (3).
INSTALLATION
1. Install the pivot end of the wiper arm (2) on the wiper pivot
shaft.
2. Install the wiper arm attachment nut (1) and secure lightly.
3. Gently set the wiper arm down so the wiper blade touches
the glass surface.
4. Align the wiper blade edge (1) with the alignment mark (2)
on the windshield and tighten the wiper arm retaining nut.
5. Press the plastic nut cap (1) into the wiper arm (2) to cover
the wiper arm attachment nut.
6. Press the hood prop release button (1) and lower the hood
prop outer sleeve (2), then close the hood.
ADJUSTMENTS
ADJUSTMENT - WIPER ARMS
1. Measure the distance between the wiper arm (1) and the
wiper blade (3).
2. If the measurement is less than 5 mm, bend the wiper arm
bracket (2) in the direction of the windshield until there is a
5 mm clearance.
WIPER BLADES
DESCRIPTION
The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the wiper arm and
sweep across the windshield to clear it of water, snow and debris.
OPERATION
When the wiper blade rubber element is exposed to the weather for a long period of time, it tends to lose wiping
ability. Periodic cleaning of the wiper blade element is suggested to remove the accumulation of salt and road film.
The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and a mild detergent or non-
abrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The driver blade element
is 600 mm in length and the passenger blade element is 550 mm in length.
STANDARD PROCEDURE
WINDSHIELD WIPER BLADE ALIGNMENT
WARNING: THE WINDSHIELD WIPER MECHANISM CAN PINCH, CRUSH OR, IN EXTREME CASES, EVEN
SEVER EXTREMITIES. ALWAYS REMOVE THE IGNITION KEY WHEN WORKING ON WINDSHIELD WIPER
MECHANISM.
1. Remove both of the wiper arms (2). Refer to Page 8R-33.
2. Turn the ignition switch to the ACC or ON/RUN position.

3. Rotate the multifunction switch to the LO position for approximately 2 seconds, then rotate back to the OFF
position. Ensure the wiper arm pivots have stopped in the park position.
4. Install the wiper arm so the blade (1) is aligned with the
mark on the windshield (2) and secure. Refer to Page
8R-34.
REMOVAL
1. Lift the wiper arm off the glass, and move the wiper arm to
the service position.
2. Squeeze the release tab (1) and slide the wiper blade (2)
away from the wiper arm.
3. Using a small screwdriver (1), gently push the two retainer

springs (2) out of their retention slots.
4. Remove the retainer springs (1) by pulling the springs from

the opposite end of the wiper blade.
5. Unhook the wiper element (1) from the wiper blade reten-
tion slots (2).
6. Remove the wiper element (1) from the wiper blade by pull-
ing the element through the guides.
INSTALLATION
1. Install the wiper element (1) onto the wiper blade by sliding
the element through the guides.
2. Index the wiper element (1) into the wiper blade retention
slots (2).
3. Install the retainer springs (1) by sliding the springs onto

the edges of the wiper blade.
4. Index the two retainer springs (2) into the retention slots.
5. Slide the wiper blade (2) onto the wiper arm until fully
seated.
6. Gently return the wiper arm to the operational position.

WIPER LINKAGE
DESCRIPTION
The wiper linkages are integral parts of the wiper module assembly. They cannot be adjusted or repaired. If faulty,
worn, or damaged, the entire wiper module must be replaced as an assembly. For complete wiper module removal
procedures, see wiper module removal in this section.
WIPER MODULE
DESCRIPTION
The wiper module holds the wiper motor and is secured with
two nuts on studs and one bolt, each through rubber isolators
to the cowl plenum panel. The ends of the two wiper pivot
shafts that protrude through openings in the cowl grille panel
and drive the wiper arms are the only visible components of
the wiper module on the exterior of the vehicle. The wiper
module consists of the following major components:
• Wiper pivot shafts (1).
• Linkage (2).
• Module frame (3).
• Crank arm (4).
• Wiper Motor (5).
REMOVAL
Note: If possible, cycle the wiper system to position the
wiper arms and linkage in the park position before
removal is attempted.

2. Remove the wiper arms. Refer to Page 8R-33.
3. Remove the cowl grille. Refer to Page 23-114
4. Remove the control module box cover (1).

5. Unlock and disconnect the wiper motor harness connector
(2) from the Body Control Module (BCM) (3).
6. Remove the wiper motor harness rubber grommet (1) from

the control module box (4).
7. Remove the wiper motor harness rubber grommet (2) from
the cowl ledge (3).
8. Rotate the cowl grille drain (1) counterclockwise, then lift

upward and remove from the cowl.
9. Remove the lower wiper module attachment bolt (3) under

the cowl ledge (2).
10. Remove the two upper wiper module attachment nuts (1).
CAUTION: Do not allow the wiper module to contact the

windshield.
11. Remove the wiper module (4) from the vehicle.
INSTALLATION
CAUTION: Do not allow the wiper module to contact the
windshield.
1. Align the wiper module into the cowl over the two upper
attachment nut mounting studs (1).
2. Install the two wiper module upper attachment nuts and
secure.
3. Install the lower wiper module attachment bolt through the
hole (2) in the cowl and secure.
4. Install the cowl grille drain (1) into the cowl and rotate
clockwise to secure. Ensure the grommet is seated fully.
Note: Ensure that the wiper motor harness and its rubber
grommets are seated and routed properly to avoid inter-
ference with moving parts.
5. Install the wiper motor harness and rubber grommet (2) into
the cowl ledge (3).
6. Install the wiper motor harness and rubber grommet (1) into
the control module box (4).
7. Connect the wiper motor harness connector (2) to the Body

Control Module (BCM) (3) and slide the locking tab fully
over the connector (2).
8. Install the control module box cover (1).

10. Install the wiper arms. Refer to Page 8R-34.

WIPER MOTOR
STANDARD PROCEDURE - WIPER MOTOR SYNCHRONIZE
Note: Ensure the multifunction switch is in the OFF position before attempting this procedure.
1. Connect the battery negative cable.

2. Connect the wiper motor harness connector (1) to the Body
Control Module (BCM) (2).
CAUTION: Be sure to keep the wiper motor clear from sur-

rounding wiper system linkage and unsecured harness
connectors.
3. Hold the wiper motor in one hand.

5. Rotate the multifunction switch to the low position.
6. Rotate the multifunction switch back to the OFF position
and wait until the wiper motor stops. It should now be in the
park position (1) and prepared for wiper motor crank instal-
lation.
7. Turn the ignition switch to the OFF/LOCK position.
8. Disconnect the wiper motor harness connector from the
BCM.
9. Disconnect the battery negative cable.
REMOVAL
WARNING: WINDSHIELD WIPER MECHANISM CAN PINCH,
CRUSH OR, IN EXTREME CASES, EVEN SEVER EXTREM-
ITIES. ALWAYS REMOVE IGNITION KEY WHEN WORKING
ON WINDSHIELD WIPER MECHANISM.

2. Remove the wiper module (1) from the vehicle. Refer to
Page 8R-42
3. Remove the crank arm attachment nut (1) from the wiper
motor shaft (2).
4. Scribe a reference mark (3) on both the wiper module and
the crank arm for proper alignment during reassembly.
5. Press the crank arm (4) off of the wiper motor shaft (2).
6. Remove the three wiper motor attachment bolts (1) from

the wiper module (2).
7. Remove the wiper motor (3) from the wiper module (2).
INSTALLATION
Before installing the wiper motor, synchronize the wiper motor
shaft into the park position. Refer to Page 8R-46.
1. Insert the wiper motor (3) into the wiper motor module (2).
2. Install the three wiper motor attachment bolts (1) and
torque to 11 N·m (8.1 ft. lbs.).
3. Align the wiper motor crank arm (1) onto the wiper motor
shaft in the park position (3) and press into place.
4. Install the wiper motor crank arm attachment nut (2) and
torque to 26 N·m (19.1 ft. lbs.).
5. Install the wiper motor module into the vehicle. Refer to
Page 8R-44.
ZH WIRING 8W - 1
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1 WARNING CHIME . . . . . . . . . . . . . . . . . . . . 8W-46-1

COMPONENT INDEX . . . . . . . . . . . . . . . . . . 8W-02-1 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1 REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1 TIRE PRESSURE MONITOR . . . . . . . . . . . . 8W-49-1
DATA LINK CONNECTOR . . . . . . . . . . . . . . 8W-17-1 FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1 REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1 TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1 WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
ENGINE COOLING . . . . . . . . . . . . . . . . . . . . 8W-29-1 REAR SPOILER . . . . . . . . . . . . . . . . . . . . . . 8W-55-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1 POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1 REMOTE KEYLESS ENTRY . . . . . . . . . . . . . 8W-65-1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 8W-40-1 SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
HORN/CIGAR LIGHTER. . . . . . . . . . . . . . . . 8W-41-1 CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1 CONNECTOR/GROUND/SPLICE
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1 POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
BODY CONTROL MODULE . . . . . . . . . . . . . 8W-45-1
ZH 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A

DESCRIPTION SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SHORT TO GROUND ON FUSES
DESCRIPTION - CIRCUIT INFORMATION . . . . 5 POWERING SEVERAL LOADS . . . . . . . . . . . 10
DESCRIPTION - SECTION IDENTIFICATION STANDARD PROCEDURE - TESTING FOR A
AND INFORMATION . . . . . . . . . . . . . . . . . . . . 5 VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - CONNECTOR, GROUND CONNECTOR
AND SPLICE INFORMATION . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARNING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARNINGS - GENERAL . . . . . . . . . . . . . . . . . 7 DIODE
DIAGNOSIS AND TESTING - WIRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE TERMINAL
STANDARD PROCEDURE - REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTROSTATIC DISCHARGE (ESD) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 9 WIRE
STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - WIRE SPLICING . . 13
VOLTAGE POTENTIAL . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . 10
WIRING DIAGRAM INFORMATION

DESCRIPTION
DESCRIPTION - HOW TO USE WIRING DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring con-
tent. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it
is important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the
ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and the key
removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is complete. A
dashed line around the component indicates that the component is being shown is not complete. Incomplete com-
ponents have a reference number to indicate the page where the component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and wiring as they
appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches
and other components are shown as simply as possible, with regard to function only.
SYMBOLS
International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used
around the world.
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION ZH
Fig. 1 WIRING DIAGRAM EXAMPLE 1

Fig. 2 WIRING DIAGRAM EXAMPLE 2

TERMINOLOGY
This is a list of terms and definitions used in the wiring diagrams.
LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand Drive Vehicles

RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Hand Drive Vehicles
A/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Transmissions-Rear Wheel Drive
M/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmissions-Rear Wheel Drive
Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicles Built For Sale In Markets Other Than North America
All Except Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicles Built For Sale In Markets Other Than Europe
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code which identifies gage of wire, and color.
WIRE COLOR CODE CHART
COLOR CODE COLOR

BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION

The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group,
it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay
is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another
group if it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices
serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the
wiring diagrams.
Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified
using the name/number on the diagram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru General information and Diagram
8W-09 Overview
8W-10 thru Main Sources of Power and
8W-19 Vehicle Grounding
8W-20 thru Starting and Charging
8W-29
8W-30 thru Powertrain/Drivetrain Systems
8W-39
8W-40 thru Body Electrical items and A/C
8W-49
8W-50 thru Exterior Lighting, Wipers and
8W-59 Trailer Tow
8W-60 thru Power Accessories
8W-69
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION

CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical
example might be the Supplemental Restraint System connectors. Always check parts availability before
attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows:
• In-line connectors located in the engine compartment are C100 series numbers
• In-line connectors located in the Instrument Panel area are C200 series numbers.
• In-line connectors located in the body are C300 series numbers.
• Jumper harness connectors are C400 series numbers.
• Grounds and ground connectors are identified with a “G” and follow the same series numbering as the in-
line connectors.
• Splices are identified with an “S” and follow the same series numbering as the in-line connectors.
• Component connectors are identified by the component name instead of a number. Multiple connectors on
a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name
(or number)/ground number/splice number and component identification. Connector/ground/splice location charts in
section 8W-91 reference the figure numbers of the illustrations.
The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness
branches out to a component. The abbreviation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings
that should be followed any time a vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PRO-
CEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMIS-
SION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN
AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR,
EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN
AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTH-
ING.
DIAGNOSIS AND TESTING - WIRING HARNESS

TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed
and explained below.
• Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open
in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A
BATTERY FEED AND GROUND.
• Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground
and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today’s vehicles are Solid State. When checking volt-
ages in these circuits, use a meter with a 10 - megohm or greater impedance rating.
• Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit
means good continuity.
CAUTION: Most of the electrical components used in today’s vehicles are Solid State. When checking resis-
tance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure
the power is disconnected from the circuit. Circuits that are powered up by the vehicle’s electrical system
can cause damage to the equipment and provide false readings.
• Probing Tools - These tools are used for probing ter-

minals in connectors. Select the proper size tool from
Special Tool Package 6807, and insert the probing end
(2) into the terminal being tested. Use the other end of
the tool(1) to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a
sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the
following items.
• Connectors are fully seated
• Spread terminals, or terminal push out
• Terminals in the wiring assembly are fully seated into the connector/component and locked into position
• Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem
• Damaged connector/component casing exposing the item to dirt or moisture
• Wire insulation that has rubbed through causing a short to ground
• Some or all of the wiring strands broken inside of the insulation
• Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS

When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and
explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle
is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are in the same
circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most
likely is occurring and where the diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem area.
6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to
the wiring diagrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a symbol is
used to indicate this. When handling any component with this
symbol, comply with the following procedures to reduce the
possibility of electrostatic charge build up on the body and
inadvertent discharge into the component. If it is not known
whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the
part. This should be repeated while handling the part and
more frequently after sliding across a seat, sitting down
from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless
instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground
lead first.
4. Do not remove the part form it’s protective packing until it
is time to install the part.
5. Before removing the part from it’s pakage, ground the pak-
age to a known good ground on the vehicle.
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL

1. Connect the ground lead of a voltmeter to a known good
ground.
2. Connect the other lead of the voltmeter to the selected test
point. The vehicle ignition may need to be turned ON to
check voltage. Refer to the appropriate test procedure.
STANDARD PROCEDURE - TESTING FOR CONTINUITY

1. Remove the fuse(1) for the circuit being checked or, discon-
nect the battery.
2. Connect one lead of the ohmmeter to one side of the circuit
being tested.
3. Connect the other lead to the other end of the circuit being
tested. Low or no resistance means good continuity.
STANDARD PROCEDURE - TESTING FOR A

SHORT TO GROUND
1. Remove the fuse and disconnect all items involved with the fuse.
2. Connect a test light or a voltmeter across the terminals of the fuse.
3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test
lamp.
4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the
wiring harness.
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES

POWERING SEVERAL LOADS
1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits.
2. Replace the blown fuse.
3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery.
4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the
short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP

1. Connect the positive lead of the voltmeter to the side of the
circuit closest to the battery.
2. Connect the other lead of the voltmeter to the other side of
the switch, component or circuit.
3. Operate the item.
4. The voltmeter will show the difference in voltage between
the two points.
CONNECTOR
REMOVAL
1. Disconnect battery.
2. Release Connector Lock(2).
3. Disconnect the connector(3) being repaired from its mating
half/component.
4. Remove the dress cover(1) (if applicable).
5. Release the Secondary Terminal Lock, if required.
6. Position the connector locking finger away from the terminal
using the proper special tool. Pull on the wire to remove the
terminal from the connector.
INSTALLATION
1. Insert the removed terminal in the same cavity on the repair connector.
2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities.
For additional connector pin-out identification, refer to the wiring diagrams.
3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to pre-
vent terminal push out.
4. Replace dress cover (if applicable).

5. Connect connector to its mating half/component.
6. Connect battery and test all affected systems.
DIODE
REMOVAL
1. Disconnect the battery.
2. Locate the diode in the harness, and remove the protective
covering.
3. Remove the diode from the harness, pay attention to the
current flow direction(1).
INSTALLATION
1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate
wiring diagram for current flow.
3. Solder the connection together using rosin core type solder only. Do not use acid core solder.
4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements.
5. Re-connect the battery and test affected systems.
TERMINAL
REMOVAL
1. Follow steps for removing terminals described in the connector removal section.
2. Cut the wire 6 inches from the back of the connector.
INSTALLATION
1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired.
2. Cut the repair wire to the proper length and remove one–half (1/2) inch of insulation.
3. Splice the repair wire to the wire harness (see wire splicing procedure). Refer to Page 8W-01-13.
4. Insert the repaired wire into the connector.
5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component.
6. Re-tape the wire harness starting at 1–1/2 inches behind the connector and 2 inches past the repair.
7. Connect battery and test all affected systems.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams.
1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.
2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
3. Place the strands of wire overlapping each other inside of
the splice clip(1).
4. Using crimping too(1)l, Mopar p/n 05019912AA, crimp the

splice clip and wires together.
5. Solder the connection(2) together using a soldering iron(3)

and rosin core type solder(1) only.
CAUTION: DO NOT USE ACID CORE SOLDER.
6. Center the heat shrink tubing(2) over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly
sealed and sealant(1) comes out of both ends of the tubing.
ZH 8W-02 COMPONENT INDEX 8W - 02 - 1
8W-02 COMPONENT INDEX
Component Page Component Page

A/C Compressor Clutch . . . . . . . . . . . . . . . . . 8W-42 Control Module Cooling Fan . . . . . . . . . . . . . 8W-45
A/C Heater Control Controller Antilock Brake . . . 8W-10, 15, 17, 18, 31,
Module . . . . . . . 8W-10, 15, 17, 40, 42, 45, 48, 49 35, 45, 47
A/C Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-42 Coolant Circulation Pump . . . . . . . . . . . . 8W-10, 42
Accelerator Pedal Position Sensor . . . . . . 8W-30, 33 Coolant Circulation Valve . . . . . . . . . . . . 8W-10, 42
Air Pump Fuse . . . . . . . . . . . . . . . . . . . . 8W-10, 30 Coolant Level Sensor . . . . . . . . . . . . . . . . 8W-40, 46
Air Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-10, 30 Crankshaft Position Sensor . . . . . . . . . . . . . . 8W-30
Air Pump Switchover Solenoid . . . . . . . . 8W-10, 30 Data Link Connector . . . . 8W-10, 15, 17, 30, 31, 35,
Air Pump . . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 30 40, 42, 43, 45, 47, 49, 65
Airbag Off Indicator Lamp . . . . . . . . . . . 8W-10, 43 Dome Lamp . . . . . . . . . . . . . . . . . 8W-10, 15, 44, 45
Ambient Temperature Sensor . . . . . . . . . . . . 8W-40 Driver Airbag Squib . . . . . . . . . . . . . . . . . . . 8W-43
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Driver Cylinder Lock Switch . . . . . . . 8W-15, 61, 65
Anti-Theft Tow Sensor . . . . . . . . . . . . . . . 8W-10, 39 Driver Door Lock Actuator . . . . . . . . . . . . . . 8W-61
Ash Receiver Lamp . . . . . . . . 8W-10, 15, 40, 44, 51 Driver Power Seat Front Riser Motor . . . . . . 8W-63
Automatic Day/Night Mirror . . . . 8W-10, 15, 51, 62 Driver Power Seat Horizontal Motor . . . . . . . 8W-63
BAS Brake Booster . . . . . . . . . . . . . . . . . . . . 8W-35 Driver Power Seat Rear Riser Motor . . . . . . . 8W-63
Backup Lamp Switch . . . . . . . . . . 8W-10, 30, 51, 62 Driver Power Seat Recliner Motor . . . . . . . . . 8W-63
Battery . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 20, 21 Driver Power Seat Switch . . . . . . . . . 8W-10, 15, 63
Blower Motor . . . . . . . . . . . . . . . . . . . 8W-10, 15, 42 Driver Seat Belt Switch . . . . . . . . . . . 8W-15, 40, 46
Body Control Module . . . . . . . 8W-10, 15, 17, 18, 35, Driver Seat Belt Tensioner Squib . . . . . . . . . 8W-43
40, 42, 44, 45, 47, 48, 50, Driver Seat Belt Tensioner Switch . . . . . . 8W-15, 43
52, 53, 55, 60, 61, 65 EGR Solenoid . . . . . . . . . . . . . . . . . . . . . 8W-10, 30
Brake Fluid Level Switch . . . . . . . . . . . . 8W-15, 40 ESP Brake Pressure Sensor 1 . . . . . . . . . . . . 8W-35
Brake Lamp Relay . . . . . . . . . . . . . . . 8W-10, 35, 51 ESP Brake Pressure Sensor 2 . . . . . . . . . . . . 8W-35
Brake Lamp Switch . . . . . . . . . . . 8W-10, 31, 35, 51 ESP Lateral Acceleration Sensor . . . . . . . . . . 8W-35
Camshaft Position Sensor . . . . . . . . . . . . 8W-10, 30 ESP Off Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 44 ESP Yaw Rate Sensor . . . . . . . . . . . . . . . . . . 8W-35
Center High Mounted Stop Lamp . . . 8W-10, 15, 51 Engine Control Fuse 1 . . . . . . . . . . . . . . . . . . 8W-10
Central Locking Pump/Security Engine Control Fuse 2 . . . . . . . . . . . . . . . . . . 8W-10
System Module . . . . . . . . . . . . 8W-10, 15, 18, 39, Engine Control Fuse 2 . . . . . . . . . . . . . . . . . . 8W-30
44, 45, 48, 50, 51, 61, 65 Engine Control Relay . . . . . . . . . . . . . . . . . . 8W-10
Charcoal Canister Shutoff Valve . . . . . . . 8W-10, 30 Engine Coolant Temperature Sensor . . . . . . . 8W-30
Cigar Lighter . . . . . . . . . . . . . . . . 8W-10, 15, 41, 44 Engine Fuse Block . . . 8W-10, 20, 21, 29, 30, 35, 63
Clockspring . . . . . . . . . . . . . . . . . 8W-10, 15, 41, 43 Engine Starter Motor . . . . . . . . . . 8W-10, 20, 21, 30
Clutch Interlock Switch . . . . . . . . . . . 8W-10, 21, 30 Evap Purge Solenoid . . . . . . . . . . . . . . . . 8W-10, 30
Clutch Pedal Position Switch . . . . . . . 8W-15, 30, 33 Evaporator Temperature Sensor . . . . . . . . . . 8W-42
Coil On Plug Driver No. 1 . . . . . . . . . . . . . . . 8W-30 Fuel Door Lock Actuator . . . . . . . . . . . . . . . . 8W-61
Coil On Plug Driver No. 2 . . . . . . . . . . . . . . . 8W-30 Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . 8W-10, 30
Coil On Plug No. 1 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . 8W-10, 30
Coil On Plug No. 2 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Level Sensor . . . . . . . . . . . . . . . . . . 8W-40, 46
Coil On Plug No. 3 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . 8W-10, 30
Coil On Plug No. 4 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . 8W-10, 30
Coil On Plug No. 5 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Pump . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 30
Coil On Plug No. 6 . . . . . . . . . . . . . . . . . . . . 8W-10 Fuel Tank Pressure Sensor . . . . . . . . . . . 8W-17, 30
Console Switch Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49, 63
Group . . . . . . . . . . . 8W-10, 15, 40, 44, 45, 52, 61 Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 29, 43
8W - 02 - 2 8W-02 COMPONENT INDEX ZH

Fuse 3 . . . . . . . . . . . . . . . . 8W-10, 30, 35, 40, 43, 46 Illumination Control
Fuse 4 . . . . . . . . . . 8W-10, 20, 21, 31, 45, 52, 53, 63 Module . . . . . . . . . . . . . 8W-10, 15, 30, 31, 35, 40,
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 47 44, 46, 50, 51, 52, 62
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 50, 62 Instrument Cluster . . 8W-10, 15, 17, 18, 20, 40, 42,
Fuse 7 . . . . . . . . . . . . . . . . . . 8W-10, 45, 50, 51, 62 43, 44, 45, 46, 49, 50, 51, 65
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 47, 50 Key In Ignition Switch . . . . . . . . . . . . 8W-10, 40, 46
Fuse 9 . . . . . . . . . . . . . . . . 8W-10, 39, 44, 45, 49, 50 Kickdown Switch . . . . . . . . . . . . . . . . 8W-15, 30, 33
Fuse 10 . . . . . . . . . . . . . . . . . . 8W-10, 30, 33, 50, 51 Left Door Ajar Switch . 8W-15, 39, 40, 44, 46, 63, 65
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 30, 51 Left Door Speaker . . . . . . . . . . . . . . . . . . . . . 8W-47
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 50 Left Door Tweeter . . . . . . . . . . . . . . . . . . . . . 8W-47
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 17, 35 Left Fog Lamp . . . . . . . . . . . . . . . . . . 8W-10, 15, 50
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 42 Left Front Brake Lining Wear Sensor . . . . . . 8W-35
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 45, 60 Left Front Brake Pad Wear Sensor . . . . . . . . 8W-15
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 45, 55 Left Front Lamp Assembly . . . 8W-10, 15, 44, 50, 52
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 63 Left Front Power Window Motor . . . . . . . 8W-45, 60
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 63 Left Front Power Window Switch . . . 8W-10, 45, 60
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 47 Left Front Side Marker Lamp . . . . . . 8W-10, 15, 50
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 63 Left Front Tire Pressure Sensor/
Fuse 25 . . . . . . . . . . . . . . . . . . . . 8W-10, 39, 48, 61 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Fuse 26 . . . . . . . . . . . . . . . . . . . . 8W-10, 39, 48, 61 Left Front Wheel Speed Sensor . . . . . . . . . . . 8W-35
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41, 44 Left Heated Seat Back . . . . . . . . . . . . . . . . . 8W-15
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 53 Left Heated Seat Cushion . . . . . . . . . . . . . . . 8W-15
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 42 Left Knock Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuse 35 . . . . . . . . . . . . . . . 8W-10, 40, 42, 44, 46, 65 Left Park Lamp . . . . . . . . . . . . . . . . . 8W-10, 15, 50
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 42 Left Power Mirror . . . . . . . . . . . . . . . 8W-10, 15, 62
Fuse 37 . . . . . . . . . . . . . . . . . . . . 8W-10, 40, 42, 65 Left Rear Lamp
G100 . . . . . 8W-15, 29, 30, 33, 35, 39, 40, 41, 50, 52 Assembly . . . . . . . . . . . 8W-10, 15, 44, 50, 51, 52
G101 . . . . . . . . . . . . . . 8W-15, 30, 33, 35, 39, 50, 53 Left Rear Side Marker Lamp . . . . . . . 8W-10, 15, 51
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52 Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . 8W-47
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 30 Left Rear Tire Pressure Sensor/Transmitter . 8W-49
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61 Left Rear Wheel Speed Sensor . . . . . . . . . . . 8W-35
G107 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 20, 21 Left Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
G200 . . . . . . . . 8W-15, 17, 35, 40, 41, 42, 44, 61, 65 Left Side Airbag Squib . . . . . . . . . . . . . . . . . 8W-43
G201 . . . . . 8W-15, 39, 40, 44, 46, 49, 61, 62, 63, 65 Left Side Impact Sensor . . . . . . . . . . . 8W-10, 15, 43
G202 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 40, 43 License Lamp No. 1 . . . . . . . . . . . . . . 8W-10, 15, 51
G203 . . . . . . . . . . . . . . . . . 8W-15, 31, 35, 47, 62, 63 License Lamp No. 2 . . . . . . . . . . . . . . 8W-10, 15, 51
G204 . . 8W-15, 30, 31, 39, 44, 45, 47, 53, 60, 61, 62, Liftgate Lock Actuator . . . . . . . . . . . . . . . . . . 8W-61
63, 65 Liftgate Lock Switch . . . . . . . 8W-15, 44, 45, 61, 65
G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 48 MAF/IAT Sensor . . . . . . . . . . . . . . . . . . . 8W-10, 30
G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 45 Manifold Absolute Pressure Sensor . . . . . . . . 8W-30
G300 . . . . . . . . . . . . . . . . . . . . 8W-15, 50, 51, 52, 55 Multi-Function Switch . . . 8W-10, 44, 45, 50, 52, 53
G301 . . . . . . . . . . . 8W-15, 39, 44, 48, 51, 52, 61, 65 N2 and N3 Speed Sensors . . . . . . . . . . . . . . . 8W-31
Generator . . . . . . . . . . . . . . . . . . . . . . 8W-10, 20, 40 Noise Suppressor No. 1 . . . . . . . . . . . 8W-10, 15, 30
Glove Box Lamp . . . . . . . . . . . . . . 8W-10, 15, 41, 44 Noise Suppressor No. 2 . . . . . . . . . . . 8W-10, 15, 30
Glove Box Switch . . . . . . . . . . . . . . . . . . . 8W-15, 44 Occupant Restraint
Heated Seat Module . . . . . . . . . . . . . . . . 8W-10, 63 Controller . . . . . . . . . . . 8W-10, 15, 17, 30, 40, 43
Heater Core Temperature Sensor . . . . . . . . . 8W-42 Oil Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Hood Ajar Switch . . . . . . . . . . . . . . . . . . . 8W-15, 39 Oxygen Sensor 1/1 Upstream . . . . . . . . . 8W-10, 30
Horn Fuse . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 41 Oxygen Sensor 1/2 Downstream . . . . . . . 8W-10, 30
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 41 Oxygen Sensor 2/1 Upstream . . . . . . . . . 8W-10, 30
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 41 Oxygen Sensor 2/2 Downstream . . . . . . . 8W-10, 30
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 41 Park Brake Switch . . . . . . . . . . . . . . . 8W-10, 15, 35
Horn Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15, 41 Passenger Airbag On/Off Switch . . . . . . . . . . 8W-43
Ignition Switch . . . . . . . . . . . . . . . 8W-10, 21, 30, 63 Passenger Airbag Squib . . . . . . . . . . . . . . . . . 8W-43
ZH 8W-02 COMPONENT INDEX 8W - 02 - 3

Passenger Door Lock Actuator . . . . . . . . . . . . 8W-61 Right Park Lamp . . . . . . . . . . . . . . . . 8W-10, 15, 50
Passenger Power Seat Horizontal Motor . . . . 8W-63 Right Power Mirror . . . . . . . . . . . . . . 8W-10, 15, 62
Passenger Power Seat Recliner Motor . . . . . . 8W-63 Right Rear Lamp Assembly . . 8W-10, 15, 44, 51, 52
Passenger Power Seat Switch . . . . . . 8W-10, 15, 63 Right Rear Side Marker Lamp . . . . . . 8W-10, 15, 51
Passenger Seat Belt Tensioner Squib . . . . . . 8W-43 Right Rear Speaker . . . . . . . . . . . . . . . . . . . . 8W-47
Passenger Seat Belt Tensioner Switch . . . 8W-15, 43 Right Rear Tire Pressure Sensor/
Passenger Seat Occupant Simulator . 8W-10, 15, 43 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Power Amplifier . . . . . . . . . . . 8W-10, 15, 35, 45, 47 Right Rear Wheel Speed Sensor . . . . . . . . . . 8W-35
Power Mirror Switch . . . . . . . . . . . . . 8W-10, 15, 62 Right Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Power Seat Relay . . . . . . . . . . . . . . . . 8W-10, 15, 63 Right Side Airbag Squib . . . . . . . . . . . . . . . . 8W-43
Powertrain Control Module . . 8W-10, 15, 17, 18, 21, Right Side Impact Sensor . . . . . . . . . 8W-10, 15, 43
29, 30, 33, 43, 51, 62 Sentry Key Antenna Ring . . . . . . . . . . . . . . . 8W-65
Pulse Module . . . . . . . . . . . . . . . . 8W-10, 15, 21, 30 Sentry Key Remote Entry
Radiator Fan Control Module . . . . 8W-10, 15, 29, 30 Module . . . . . . . . . . 8W-10, 15, 17, 18, 45, 61, 65
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . 8W-29 Shift Lever Assembly . . . . . . . 8W-10, 15, 17, 18, 31,
Radio . . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 17, 47 35, 51, 62
Rear Spoiler Limit Switch . . . . . . . . . 8W-15, 45, 55 Short Runner Valve Solenoid . . . . . . . . . . 8W-10, 30
Rear Spoiler Motor . . . . . . . . . . . . . . . . . 8W-45, 55 Siren . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 15, 39
Rear Spoiler Switch . . . . . . . . . . . . . . . . . 8W-45, 55 Speed Control Switch . . . . . . . . . . . . . 8W-10, 30, 33
Rear Window Capacitor . . . . . . . . . . . . . . 8W-15, 48 Splice Block 100 . . . . . . . . . . . . . . . . . 8W-10, 35, 63
Rear Window Defogger . . . . . . . . . . . . . . 8W-15, 48 Splice Block 101 . . . . . . . . . . . . . . 8W-10, 29, 30, 35
Recirculated Air Switchover Valve . . . . . . 8W-10, 42 Splice Block 102 . . . . . . . . . . . . . . . . . . . 8W-10, 63
Relay Control Module . 8W-10, 15, 17, 30, 31, 35, 41 Splice Block 200 . . . . . . . . . . . 8W-10, 31, 40, 44, 47
Remote Keyless Entry Antenna . . . . . . . . . . . 8W-65 Steering Angle Sensor . . . . . . . . . . . . 8W-10, 15, 35
Remote Keyless Entry Relay . . . . . . . 8W-10, 44, 65 Telescopic Steering Switch . . . . . . . . . . . . 8W-15, 40
Right Door Ajar Switch . . . . . 8W-15, 39, 44, 63, 65 Throttle Body . . . . . . . . . . . . . . . . . . . . . 8W-30, 33
Right Door Speaker . . . . . . . . . . . . . . . . . . . . 8W-47 Tow-Away Alarm Switch . . . . . . . . . . . . . . . . 8W-39
Right Door Tweeter . . . . . . . . . . . . . . . . . . . . 8W-47 Traction System Fuse . . . . . . . . . . . . . . . 8W-10, 31
Right Fog Lamp . . . . . . . . . . . . . . . . . 8W-10, 15, 50 Traction System Relay . . . . . . . . . . . . . . . 8W-10, 31
Right Front Brake Lining Wear Sensor . . . . . 8W-35 Transmission Control Module . 8W-10, 15, 17, 18, 31
Right Front Brake Pad Wear Sensor . . . . . . . 8W-15 Transmission Solenoid Assembly . . . . . . . . . . 8W-31
Right Front Lamp Assembly . . 8W-10, 15, 44, 50, 52 Transmission Temperature Sensor . . . . . . . . 8W-31
Right Front Power Window Motor . . . . . . 8W-45, 60 Underhood Accessory
Right Front Power Window Switch . . 8W-10, 45, 60 Fuse Block . . . . . . . 8W-10, 17, 30, 33, 35, 39, 40,
Right Front Side Marker Lamp . . . . . 8W-10, 15, 50 41, 42, 43, 44, 45, 46, 47, 48,
Right Front Tire Pressure Sensory 49, 50, 53, 55, 60, 61, 62, 63, 65
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 8W-49 Universal Garage Door Opener/Tire Pressure
Right Front Wheel Speed Sensor . . . . . . . . . . 8W-35 Monitor . . . . . . . . . . . . . . . 8W-10, 15, 17, 40, 49
Right Heated Seat Back . . . . . . . . . . . . . . . . 8W-15 Washer Fluid Level Switch . . . . . . . . . . . 8W-40, 46
Right Heated Seat Cushion . . . . . . . . . . . . . . 8W-15 Washer Pump Motor . . . . . . . . . . . . . 8W-15, 45, 53
Right Knock Sensor . . . . . . . . . . . . . . . . . . . . 8W-30 Wiper Motor . . . . . . . . . . . . . . . . . . . . . . 8W-45, 53
ZH 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-10 POWER DISTRIBUTION

A/C Heater Control Module . . . . . . . . . . . . . . . 8W-10-9, 13, 15 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 18
Air Pump Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 16
Air Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 18
Air Pump Switchover Solenoid . . . . . . . . . . . . . . . . . 8W-10-22 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 18
Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Airbag Off Indicator Lamp . . . . . . . . . . . . . . . . . . . 8W-10-11 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
Anti-Theft Tow Sensor . . . . . . . . . . . . . . . . . . . . . 8W-10-10 Heated Seat Module . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 14
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 16 Horn Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Automatic Day/Night Mirror . . . . . . . . . . . . . . . . 8W-10-12, 19 Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Backup Lamp Switch . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
Body Control Module . . . . . . . . . . . . . . 8W-10-10, 11, 12, 14, 19 Illumination Control Module . . . . . . . . . 8W-10-13, 16, 17, 18, 19
Brake Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 Instrument Cluster . . . . . . . . . . . . . 8W-10-11, 13, 15, 16, 17, 18
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20 Key In Ignition Switch . . . . . . . . . . . . . . . . . . . . . 8W-10-15
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . 8W-10-21 Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10 Left Front Lamp Assembly . . . . . . . . . . . . . . . . . . . 8W-10-18
Center High Mounted Stop Lamp . . . . . . . . . . . . . . . 8W-10-19 Left Front Power Window Switch . . . . . . . . . . . . . . . 8W-10-13
Central Locking Pump/Security System Module . . . 8W-10-14, 17, 18 Left Front Side Marker Lamp . . . . . . . . . . . . . . . . . 8W-10-16
Charcoal Canister Shutoff Valve . . . . . . . . . . . . . . . . 8W-10-22 Left Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11 Left Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Left Rear Lamp Assembly . . . . . . . . . . . . . . . 8W-10-17, 18, 19
Clutch Interlock Switch . . . . . . . . . . . . . . . . . . . . . 8W-10-9 Left Rear Side Marker Lamp . . . . . . . . . . . . . . . . . . 8W-10-17
Coil On Plug No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 Left Side Impact Sensor . . . . . . . . . . . . . . . . . . . . . 8W-10-11
Coil On Plug No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 License Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Coil On Plug No. 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 License Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Coil On Plug No. 4 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 MAF/IAT Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Coil On Plug No. 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 Multi-Function Switch . . . . . . . . . . . . . . . . . . . 8W-10-11, 18
Coil On Plug No. 6 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12 Noise Suppressor No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Console Switch Group . . . . . . . . . . . . . . . . . 8W-10-13, 15, 19 Noise Suppressor No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Controller Antilock Brake . . . . . . . . . . . . . . 8W-10-8, 17, 19, 20 Occupant Restraint Controller . . . . . . . . . . . . . . . . . 8W-10-11
Coolant Circulation Pump . . . . . . . . . . . . . . . . . . . 8W-10-10 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . . . . . . 8W-10-22
Coolant Circulation Valve . . . . . . . . . . . . . . . . . . . . 8W-10-10 Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . . . . . 8W-10-22
Data Link Connector . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Oxygen Sensor 2/1 Upstream . . . . . . . . . . . . . . . . . . 8W-10-22
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10 Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . . . . . 8W-10-22
Driver Power Seat Switch . . . . . . . . . . . . . . . . . . . 8W-10-14 Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22 Passenger Power Seat Switch . . . . . . . . . . . . . . . . . 8W-10-14
Engine Control Fuse 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Passenger Seat Occupant Simulator . . . . . . . . . . . . . . 8W-10-11
Engine Control Fuse 2 . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Engine Control Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 Power Mirror Switch . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Engine Fuse Block . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9 Power Seat Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 14
Engine Starter Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8 Powertrain Control Module . . . . . . . . . . . . . 8W-10-9, 19, 20, 21
Evap Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . 8W-10-22 Pulse Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9, 12
Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Radiator Fan Control Module . . . . . . . . . . . . . . . . 8W-10-8, 12
Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 11, 13
Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Recirculated Air Switchover Valve . . . . . . . . . . . . . . . 8W-10-13
Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Relay Control Module . . . . . . . . . . . . . . . . . . . . 8W-10-20, 21
Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Remote Keyless Entry Relay . . . . . . . . . . . . . . . . . . 8W-10-15
Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Right Front Lamp Assembly . . . . . . . . . . . . . . . . . . 8W-10-18
Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Right Front Power Window Switch . . . . . . . . . . . . . . 8W-10-13
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Right Front Side Marker Lamp . . . . . . . . . . . . . . . . 8W-10-16
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 16 Right Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 16 Right Power Mirror . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 18 Right Rear Lamp Assembly . . . . . . . . . . . . . . . . 8W-10-17, 19
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10 Right Rear Side Marker Lamp . . . . . . . . . . . . . . . . . 8W-10-17
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10 Right Side Impact Sensor . . . . . . . . . . . . . . . . . . . . 8W-10-11
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Sentry Key Remote Entry Module . . . . . . . . . . . . . 8W-10-13, 15
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Shift Lever Assembly . . . . . . . . . . . . . . . . . . 8W-10-13, 19, 20
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Short Runner Valve Solenoid . . . . . . . . . . . . . . . . . . 8W-10-22
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Speed Control Switch . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Splice Block 100 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Splice Block 101 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 Splice Block 102 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8 Splice Block 200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9 Steering Angle Sensor . . . . . . . . . . . . . . . . . . . . 8W-10-10, 12
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15 Traction System Fuse . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15 Traction System Relay . . . . . . . . . . . . . . . . . . . . . 8W-10-20
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 Transmission Control Module . . . . . . . . . . . . . . . . . 8W-10-20
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 18 Underhood Accessory Fuse Block . . . 8W-10-9, 10, 11, 12, 13, 14, 15
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9 Universal Garage Door Opener/Tire
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18 Pressure Monitor . . . . . . . . . . . . . . . . . . . . 8W-10-10, 11
8W - 10 - 2 8W-10 POWER DISTRIBUTION ZH
ZH 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8W-15 GROUND DISTRIBUTION

A/C Heater Control Module . . . . . . . . . . . . 8W-15-5 Left Heated Seat Back . . . . . . . . . . . . . . . . 8W-15-8
Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Left Heated Seat Cushion . . . . . . . . . . . . . 8W-15-8
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-15-5 Left Park Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Automatic Day/Night Mirror . . . . . . . . . . . 8W-15-6 Left Power Mirror . . . . . . . . . . . . . . . . . . . 8W-15-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Left Rear Lamp Assembly . . . . . . . . . . . . 8W-15-10
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Left Rear Side Marker Lamp . . . . . . . . . . 8W-15-10
Body Control Module . . . . . . . . . . . . . . . . . 8W-15-9 Left Side Impact Sensor . . . . . . . . . . . . . . . 8W-15-7
Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-15-2 License Lamp No. 1 . . . . . . . . . . . . . . . . . 8W-15-10
Center High Mounted Stop Lamp . . . . . . . 8W-15-10 License Lamp No. 2 . . . . . . . . . . . . . . . . . 8W-15-11
Central Locking Pump/Security System Liftgate Lock Switch . . . . . . . . . . . . . . . . . 8W-15-11
Module . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Noise Suppressor No. 1 . . . . . . . . . . . . . . . 8W-15-4
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Noise Suppressor No. 2 . . . . . . . . . . . . . . . 8W-15-4
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Occupant Restraint Controller . . . . . . . . . . 8W-15-7
Clutch Pedal Position Switch . . . . . . . . . . . 8W-15-2 Park Brake Switch . . . . . . . . . . . . . . . . . . . 8W-15-8
Console Switch Group . . . . . . . . . . . . . . . . 8W-15-5 Passenger Power Seat Switch . . . . . . . . . . . 8W-15-6
Controller Antilock Brake . . . . . . . . . . . . . . 8W-15-2 Passenger Seat Belt Tensioner Switch . . . . 8W-15-7
Data Link Connector . . . . . . . . . . . . . . . . . 8W-15-5 Passenger Seat Occupant Simulator . . . . . . 8W-15-7
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Power Amplifier . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Driver Cylinder Lock Switch . . . . . . . . . . . 8W-15-6 Power Mirror Switch . . . . . . . . . . . . . . . . . 8W-15-8
Driver Power Seat Switch . . . . . . . . . . . . . 8W-15-6 Power Seat Relay . . . . . . . . . . . . . . . . . . . . 8W-15-6
Driver Seat Belt Switch . . . . . . . . . . . . . . . 8W-15-6 Powertrain Control Module . . . . . . . . . . . . 8W-15-3
Driver Seat Belt Tensioner Switch . . . . . . . 8W-15-7 Pulse Module . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Radiator Fan Control Module . . . . . . . . . . . 8W-15-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Rear Spoiler Limit Switch . . . . . . . . . . . . 8W-15-10
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Rear Window Capacitor . . . . . . . . . . . . . . 8W-15-11
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Rear Window Defogger . . . . . . . . . . . . . . . . 8W-15-9
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Relay Control Module . . . . . . . . . . . . . . . . . 8W-15-9
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 Right Door Ajar Switch . . . . . . . . . . . . . . . 8W-15-9
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-3
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 Right Front Brake Pad Wear Sensor . . . . . 8W-15-3
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Right Front Lamp Assembly . . . . . . . . . . . . 8W-15-3
G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Right Front Side Marker Lamp . . . . . . . . . 8W-15-3
G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Right Heated Seat Back . . . . . . . . . . . . . . . 8W-15-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Right Heated Seat Cushion . . . . . . . . . . . . 8W-15-8
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Right Park Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-3
Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Right Power Mirror . . . . . . . . . . . . . . . . . . 8W-15-9
Glove Box Switch . . . . . . . . . . . . . . . . . . . . 8W-15-5 Right Rear Lamp Assembly . . . . . . . . . . . 8W-15-11
Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . 8W-15-2 Right Rear Side Marker Lamp . . . . . . . . . 8W-15-11
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Right Side Impact Sensor . . . . . . . . . . . . . . 8W-15-7
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Sentry Key Remote Entry Module . . . . . . . 8W-15-5
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-15-8
Illumination Control Module . . . . . . . . . . . 8W-15-5 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-15-5 Steering Angle Sensor . . . . . . . . . . . . . . . . 8W-15-5
Kickdown Switch . . . . . . . . . . . . . . . . . . . . 8W-15-3 Telescopic Steering Switch . . . . . . . . . . . . . 8W-15-5
Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-15-6 Transmission Control Module . . . . . . . . . . . 8W-15-9
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Universal Garage Door Opener/Tire Pressure
Left Front Brake Pad Wear Sensor . . . . . . 8W-15-2 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Left Front Lamp Assembly . . . . . . . . . . . . . 8W-15-2 Washer Pump Motor . . . . . . . . . . . . . . . . . . 8W-15-3
Left Front Side Marker Lamp . . . . . . . . . . 8W-15-2
8W - 15 - 2 8W-15 GROUND DISTRIBUTION ZH
ZH 8W-17 DATA LINK CONNECTOR 8W - 17 - 1
8W-17 DATA LINK CONNECTOR

A/C Heater Control Module . . . . . . . . . . . . 8W-17-3 Powertrain Control Module . . . . . . . . . . . . 8W-17-2
Body Control Module . . . . . . . . . . . . . . . . . 8W-17-4 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-17-4
Controller Antilock Brake . . . . . . . . . . . . . . 8W-17-3 Relay Control Module . . . . . . . . . . . . . . . . . 8W-17-2
Data Link Connector . . . . . . . . . . . . . 8W-17-2, 3, 4 Sentry Key Remote Entry Module . . . . . . . 8W-17-4
Fuel Tank Pressure Sensor . . . . . . . . . . . . 8W-17-2 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-17-3
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-17-2 Transmission Control Module . . . . . . . . . . . 8W-17-4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-17-4 Underhood Accessory Fuse Block . . . . . . . . 8W-17-2
Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-17-3 Universal Garage Door Opener/Tire
Occupant Restraint Controller . . . . . . . . . . 8W-17-2 Pressure Monitor . . . . . . . . . . . . . . . . . . 8W-17-3
8W - 17 - 2 8W-17 DATA LINK CONNECTOR ZH
ZH 8W-17 DATA LINK CONNECTOR 8W - 17 - 3
8W - 17 - 4 8W-17 DATA LINK CONNECTOR ZH
ZH 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8W-18 BUS COMMUNICATIONS

Body Control Module . . . . . . . . . . . . . . . . . 8W-18-4 Powertrain Control Module . . . . . . . . . . 8W-18-2, 3
Central Locking Pump/Security System Sentry Key Remote Entry Module . . . . . 8W-18-2, 3
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-18-2
Controller Antilock Brake . . . . . . . . . . . . 8W-18-2, 3 Transmission Control Module . . . . . . . . . . . 8W-18-2
Instrument Cluster . . . . . . . . . . . . . . . . . 8W-18-2, 3
8W - 18 - 2 8W-18 BUS COMMUNICATIONS ZH
ZH 8W-18 BUS COMMUNICATIONS 8W - 18 - 3
8W - 18 - 4 8W-18 BUS COMMUNICATIONS ZH
ZH 8W-20 CHARGING SYSTEM 8W - 20 - 1
8W-20 CHARGING SYSTEM

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-20-2 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Engine Starter Motor . . . . . . . . . . . . . . . . . 8W-20-2 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
8W - 20 - 2 8W-20 CHARGING SYSTEM ZH
ZH 8W-21 STARTING SYSTEM 8W - 21 - 1
8W-21 STARTING SYSTEM

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Clutch Interlock Switch . . . . . . . . . . . . . . . 8W-21-2 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-21-2 Powertrain Control Module . . . . . . . . . . . . 8W-21-2
Engine Starter Motor . . . . . . . . . . . . . . . . . 8W-21-2 Pulse Module . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
8W - 21 - 2 8W-21 STARTING SYSTEM ZH
ZH 8W-29 ENGINE COOLING 8W - 29 - 1
8W-29 ENGINE COOLING

Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-29-2 Radiator Fan Control Module . . . . . . . . . . . 8W-29-2
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-29-2 Radiator Fan Motor . . . . . . . . . . . . . . . . . . 8W-29-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-29-2 Splice Block 101 . . . . . . . . . . . . . . . . . . . . . 8W-29-2
Powertrain Control Module . . . . . . . . . . . . 8W-29-2
8W - 29 - 2 8W-29 ENGINE COOLING ZH
ZH 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-30 FUEL/IGNITION SYSTEM

Accelerator Pedal Position Sensor . . . . . . . 8W-30-3 Fuel Tank Pressure Sensor . . . . . . . . . . . . 8W-30-7
Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Air Pump Fuse . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Air Pump Relay . . . . . . . . . . . . . . . . . . . . . 8W-30-6 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Air Pump Switchover Solenoid . . . . . . . . . . 8W-30-6 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 4
Backup Lamp Switch . . . . . . . . . . . . . . . . . 8W-30-4 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 3
Camshaft Position Sensor . . . . . . . . . . . . . . 8W-30-7 G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Charcoal Canister Shutoff Valve . . . . . . . . . 8W-30-8 G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5
Clutch Interlock Switch . . . . . . . . . . . . . . . 8W-30-4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Clutch Pedal Position Switch . . . . . . . . . . . 8W-30-3 Illumination Control Module . . . . . . . . . . . 8W-30-4
Coil On Plug Driver No. 1 . . . . . . . . . . . . . 8W-30-2 Kickdown Switch . . . . . . . . . . . . . . . . . . . . 8W-30-3
Coil On Plug Driver No. 2 . . . . . . . . . . . . . 8W-30-2 Left Knock Sensor . . . . . . . . . . . . . . . . . . . 8W-30-6
Coil On Plug Driver No. 3 . . . . . . . . . . . . . 8W-30-2 MAF/IAT Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30-7
Coil On Plug Driver No. 4 . . . . . . . . . . . . . 8W-30-2 Manifold Absolute Pressure Sensor . . . . . . 8W-30-7
Coil On Plug Driver No. 5 . . . . . . . . . . . . . 8W-30-2 Noise Suppressor No. 1 . . . . . . . . . . . . . . . 8W-30-2
Coil On Plug Driver No. 6 . . . . . . . . . . . . . 8W-30-2 Noise Suppressor No. 2 . . . . . . . . . . . . . . . 8W-30-2
Crankshaft Position Sensor . . . . . . . . . . . . 8W-30-8 Occupant Restraint Controller . . . . . . . . . . 8W-30-6
Data Link Connector . . . . . . . . . . . . . . . . . 8W-30-7 Oil Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7
EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-30-6
Engine Control Fuse 2 . . . . . . . . . . . . . . . . 8W-30-6 Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-30-8
Engine Coolant Temperature Sensor . . . . . 8W-30-7 Oxygen Sensor 2/1 Upstream . . . . . . . . . . . 8W-30-6
Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-30-4 Oxygen Sensor 2/2 Downstream . . . . . . . . . 8W-30-8
Engine Starter Motor . . . . . . . . . . . . . . . . . 8W-30-4 Powertrain Control
Evap Purge Solenoid . . . . . . . . . . . . . . . . . 8W-30-8 Module . . . . . . . . . . . . . . 8W-30-2, 3, 4, 5, 6, 7, 8
Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . . 8W-30-5 Pulse Module . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . . 8W-30-5 Radiator Fan Control Module . . . . . . . . . . . 8W-30-4
Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . . 8W-30-5 Relay Control Module . . . . . . . . . . . . . . . 8W-30-5, 6
Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . . 8W-30-5 Right Knock Sensor . . . . . . . . . . . . . . . . . . 8W-30-6
Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . . 8W-30-5 Short Runner Valve Solenoid . . . . . . . . . . . 8W-30-6
Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . . 8W-30-5 Speed Control Switch . . . . . . . . . . . . . . . . . 8W-30-3
Fuel Pump Fuse . . . . . . . . . . . . . . . . . . . . . 8W-30-5 Splice Block 101 . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-30-5 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5 Underhood Accessory Fuse Block . . . . . . 8W-30-2, 3
8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ZH
ZH 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-31 TRANSMISSION CONTROL SYSTEM

Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-31-2 Relay Control Module . . . . . . . . . . . . . . . . . 8W-31-2
Controller Antilock Brake . . . . . . . . . . . . . . 8W-31-3 Shift Lever Assembly . . . . . . . . . . . . . . . 8W-31-2, 3
Data Link Connector . . . . . . . . . . . . . . . . . 8W-31-3 Splice Block 200 . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 Traction System Fuse . . . . . . . . . . . . . . . . . 8W-31-2
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2 Traction System Relay . . . . . . . . . . . . . . . . 8W-31-2
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2 Transmission Control Module . . . . . . . . . 8W-31-2, 3
Illumination Control Module . . . . . . . . . . . 8W-31-3 Transmission Solenoid Assembly . . . . . . 8W-31-2, 3
N2 and N3 Speed Sensors . . . . . . . . . . . . . 8W-31-2 Transmission Temperature Sensor . . . . . . . 8W-31-2
8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM ZH
ZH 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
ZH 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8W-33 VEHICLE SPEED CONTROL

Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2 Kickdown Switch . . . . . . . . . . . . . . . . . . . . 8W-33-2
Underhood Accessory Fuse Block . . . . . . . . 8W-33-2 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Speed Control Switch . . . . . . . . . . . . . . . . . 8W-33-2 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Accelerator Pedal Position Sensor . . . . . . . 8W-33-2 Clutch Pedal Position Switch . . . . . . . . . . . 8W-33-2
Powertrain Control Module . . . . . . . . . . . . 8W-33-2 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL ZH
ZH 8W-35 ANTILOCK BRAKES 8W - 35 - 1
8W-35 ANTILOCK BRAKES

BAS Brake Booster . . . . . . . . . . . . . . . . . . . 8W-35-2 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-4
Body Control Module . . . . . . . . . . . . . . . . . 8W-35-4 Illumination Control Module . . . . . . . . . . . 8W-35-4
Brake Lamp Relay . . . . . . . . . . . . . . . . . . . 8W-35-3 Left Front Brake Lining Wear Sensor . . . . 8W-35-5
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-35-3 Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-4
Controller Antilock Brake . . . . . . . . 8W-35-2, 3, 4, 5 Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-35-4 Park Brake Switch . . . . . . . . . . . . . . . . . . . 8W-35-4
ESP Brake Pressure Sensor 1 . . . . . . . . . . 8W-35-5 Power Amplifier . . . . . . . . . . . . . . . . . . . . . 8W-35-4
ESP Brake Pressure Sensor 2 . . . . . . . . . . 8W-35-5 Relay Control Module . . . . . . . . . . . . . . . . . 8W-35-3
ESP Lateral Acceleration Sensor . . . . . . . . 8W-35-5 Right Front Brake Lining Wear Sensor . . . 8W-35-5
ESP Off Switch . . . . . . . . . . . . . . . . . . . . . . 8W-35-4 Right Front Wheel Speed Sensor . . . . . . . . 8W-35-4
ESP Yaw Rate Sensor . . . . . . . . . . . . . . . . . 8W-35-5 Right Rear Wheel Speed Sensor . . . . . . . . . 8W-35-4
Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-35-2 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-35-4
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 Splice Block 100 . . . . . . . . . . . . . . . . . . . . . 8W-35-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3, 5 Steering Angle Sensor . . . . . . . . . . . . . . . . 8W-35-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
8W - 35 - 2 8W-35 ANTILOCK BRAKES ZH
8W - 35 - 4 8W-35 ANTILOCK BRAKES ZH
ZH 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM

Anti-Theft Tow Sensor . . . . . . . . . . . . . . . . 8W-39-3 G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Central Locking Pump/Security System G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 Right Door Ajar Switch . . . . . . . . . . . . . . . 8W-39-2
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3 Tow-Away Alarm Switch . . . . . . . . . . . . . . . 8W-39-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3 Underhood Accessory Fuse Block . . . . . . 8W-39-2, 3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM ZH
ZH 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
ZH 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-40 INSTRUMENT CLUSTER

A/C Heater Control Module . . . . . . . . . . . . 8W-40-3 G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Ambient Temperature Sensor . . . . . . . . . . . 8W-40-3 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-40-2 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-40-3 Instrument Cluster . . . . . . . . . . . . . . . 8W-40-2, 3, 4
Console Switch Group . . . . . . . . . . . . . . . . 8W-40-2 Key In Ignition Switch . . . . . . . . . . . . . . . . 8W-40-2
Coolant Level Sensor . . . . . . . . . . . . . . . . . 8W-40-3 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-40-4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-40-3 Occupant Restraint Controller . . . . . . . . . . 8W-40-4
Driver Seat Belt Switch . . . . . . . . . . . . . . . 8W-40-4 Splice Block 200 . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 8W-40-3 Telescopic Steering Switch . . . . . . . . . . . . . 8W-40-3
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4 Underhood Accessory Fuse Block . . . . . . 8W-40-2, 4
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 Universal Garage Door Opener/Tire Pressure
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 Washer Fluid Level Switch . . . . . . . . . . . . . 8W-40-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER ZH
ZH 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER ZH
ZH 8W-41 HORN/CIGAR LIGHTER 8W - 41 - 1
8W-41 HORN/CIGAR LIGHTER

Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Relay Control Module . . . . . . . . . . . . . . . . . 8W-41-2
Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Underhood Accessory Fuse Block . . . . . . . . 8W-41-2
Horn Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER ZH
ZH 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1
8W-42 AIR CONDITIONING-HEATER

A/C Compressor Clutch . . . . . . . . . . . . . . . 8W-42-3 Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
A/C Heater Control Module . . . . . . . . . . 8W-42-2, 3 Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
A/C Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-42-2 Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3 Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
Body Control Module . . . . . . . . . . . . . . . . . 8W-42-3 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
Coolant Circulation Pump . . . . . . . . . . . . . 8W-42-2 Heater Core Temperature Sensor . . . . . . . . 8W-42-2
Coolant Circulation Valve . . . . . . . . . . . . . . 8W-42-2 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-42-3
Data Link Connector . . . . . . . . . . . . . . . . . 8W-42-3 Recirculated Air Switchover Valve . . . . . . . 8W-42-3
Evaporator Temperature Sensor . . . . . . . . . 8W-42-2 Underhood Accessory Fuse Block . . . . . . 8W-42-2, 3
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER ZH
ZH 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
ZH 8W-43 AIRBAG SYSTEM 8W - 43 - 1
8W-43 AIRBAG SYSTEM

Airbag Off Indicator Lamp . . . . . . . . . . . . . 8W-43-2 Left Side Impact Sensor . . . . . . . . . . . . . . . 8W-43-3
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3 Occupant Restraint Controller . . . . . . 8W-43-2, 3, 4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-43-2 Passenger Airbag On/Off Switch . . . . . . . . . 8W-43-2
Driver Airbag Squib . . . . . . . . . . . . . . . . . . 8W-43-3 Passenger Airbag Squib . . . . . . . . . . . . . . . 8W-43-4
Driver Seat Belt Tensioner Squib . . . . . . . . 8W-43-3 Passenger Seat Belt Tensioner Squib . . . . . 8W-43-4
Driver Seat Belt Tensioner Switch . . . . . . . 8W-43-2 Passenger Seat Belt Tensioner Switch . . . . 8W-43-2
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 Passenger Seat Occupant Simulator . . . . . . 8W-43-2
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 Powertrain Control Module . . . . . . . . . . . . 8W-43-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3, 4 Right Side Airbag Squib . . . . . . . . . . . . . . . 8W-43-4
Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-43-2 Right Side Impact Sensor . . . . . . . . . . . . . . 8W-43-4
Left Side Airbag Squib . . . . . . . . . . . . . . . . 8W-43-3 Underhood Accessory Fuse Block . . . . . . . . 8W-43-2
8W - 43 - 2 8W-43 AIRBAG SYSTEM ZH
ZH 8W-43 AIRBAG SYSTEM 8W - 43 - 3
8W - 43 - 4 8W-43 AIRBAG SYSTEM ZH
ZH 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8W-44 INTERIOR LIGHTING

Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-44-2 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Body Control Module . . . . . . . . . . . . . . . 8W-44-2, 3 Glove Box Switch . . . . . . . . . . . . . . . . . . . . 8W-44-2
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Illumination Control Module . . . . . . . . . 8W-44-2, 3
Central Locking Pump/Security System Instrument Cluster . . . . . . . . . . . . . . . . . 8W-44-2, 3
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-44-2
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Left Front Lamp Assembly . . . . . . . . . . . . . 8W-44-3
Console Switch Group . . . . . . . . . . . . . . . . 8W-44-3 Left Rear Lamp Assembly . . . . . . . . . . . . . 8W-44-3
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Liftgate Lock Switch . . . . . . . . . . . . . . . . . 8W-44-2
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-44-3
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3 Remote Keyless Entry Relay . . . . . . . . . . . 8W-44-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3 Right Front Lamp Assembly . . . . . . . . . . . . 8W-44-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Right Rear Lamp Assembly . . . . . . . . . . . . 8W-44-3
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Splice Block 200 . . . . . . . . . . . . . . . . . . . . . 8W-44-3
8W - 44 - 2 8W-44 INTERIOR LIGHTING ZH
ZH 8W-44 INTERIOR LIGHTING 8W - 44 - 3
ZH 8W-45 BODY CONTROL MODULE 8W - 45 - 1
8W-45 BODY CONTROL MODULE

A/C Heater Control Module . . . . . . . . . . . . 8W-45-3 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-45-3
Body Control Module . . . . . . . . . 8W-45-2, 3, 4, 5, 6 Left Front Power Window Motor . . . . . . . . 8W-45-5
Central Locking Pump/Security System Left Front Power Window Switch . . . . . . . . 8W-45-4
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Liftgate Lock Switch . . . . . . . . . . . . . . . . . 8W-45-3
Console Switch Group . . . . . . . . . . . . . . . . 8W-45-5 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-45-5
Controller Antilock Brake . . . . . . . . . . . . . . 8W-45-2 Power Amplifier . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Control Module Cooling Fan . . . . . . . . . . . . 8W-45-6 Rear Spoiler Limit Switch . . . . . . . . . . . . . 8W-45-4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-45-3 Rear Spoiler Motor . . . . . . . . . . . . . . . . . . . 8W-45-4
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Rear Spoiler Switch . . . . . . . . . . . . . . . . . . 8W-45-4
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Right Front Power Window Motor . . . . . . . 8W-45-5
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Right Front Power Window Switch . . . . . . 8W-45-4
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Sentry Key Remote Entry Module . . . . . . . 8W-45-3
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Underhood Accessory Fuse Block . . . . . . . . 8W-45-2
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Washer Pump Motor . . . . . . . . . . . . . . . . . . 8W-45-5
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6
G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
8W - 45 - 2 8W-45 BODY CONTROL MODULE ZH
ZH 8W-46 WARNING CHIME 8W - 46 - 1
8W-46 WARNING CHIME

Coolant Level Sensor . . . . . . . . . . . . . . . . . 8W-46-2 Illumination Control Module . . . . . . . . . . . 8W-46-2
Driver Seat Belt Switch . . . . . . . . . . . . . . . 8W-46-2 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-46-2
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 8W-46-2 Key In Ignition Switch . . . . . . . . . . . . . . . . 8W-46-2
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-46-2
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2 Washer Fluid Level Switch . . . . . . . . . . . . . 8W-46-2
8W - 46 - 2 8W-46 WARNING CHIME ZH
ZH 8W-47 AUDIO SYSTEM 8W - 47 - 1
8W-47 AUDIO SYSTEM

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3 Left Door Tweeter . . . . . . . . . . . . . . . . . . . . 8W-47-4
Body Control Module . . . . . . . . . . . . . . . . . 8W-47-3 Left Rear Speaker . . . . . . . . . . . . . . . . . . . 8W-47-5
Controller Antilock Brake . . . . . . . . . . . . . . 8W-47-3 Power Amplifier . . . . . . . . . . . . . . . . . 8W-47-3, 4, 5
Data Link Connector . . . . . . . . . . . . . . . . . 8W-47-2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Right Door Speaker . . . . . . . . . . . . . . . . . . 8W-47-4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Right Door Tweeter . . . . . . . . . . . . . . . . . . 8W-47-4
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3 Right Rear Speaker . . . . . . . . . . . . . . . . . . 8W-47-5
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Splice Block 200 . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Left Door Speaker . . . . . . . . . . . . . . . . . . . 8W-47-4
8W - 47 - 2 8W-47 AUDIO SYSTEM ZH
8W - 47 - 4 8W-47 AUDIO SYSTEM ZH
ZH 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-48 REAR WINDOW DEFOGGER

A/C Heater Control Module . . . . . . . . . . . . 8W-48-2 G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Body Control Module . . . . . . . . . . . . . . . . . 8W-48-2 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Central Locking Pump/Security System Rear Window Capacitor . . . . . . . . . . . . . . . 8W-48-2
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Rear Window Defogger . . . . . . . . . . . . . . . . 8W-48-2
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER ZH
ZH 8W-49 TIRE PRESSURE MONITOR 8W - 49 - 1
8W-49 TIRE PRESSURE MONITOR

A/C Heater Control Module . . . . . . . . . . . . 8W-49-2 Right Front Tire Pressure Sensory
Data Link Connector . . . . . . . . . . . . . . . . . 8W-49-2 Transmitter . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2 Right Rear Tire Pressure Sensor/
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2 Transmitter . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-49-2 Universal Garage Door Opener/Tire Pressure
Left Front Tire Pressure Sensor/ Monitor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Transmitter . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Left Rear Tire Pressure Sensor/
Transmitter . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
8W - 49 - 2 8W-49 TIRE PRESSURE MONITOR ZH
ZH 8W-50 FRONT LIGHTING 8W - 50 - 1
8W-50 FRONT LIGHTING

Body Control Module . . . . . . . . . . . . . . . . . 8W-50-4 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-50-4
Central Locking Pump/Security System Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5 Left Front Lamp Assembly . . . . . . . . . . . 8W-50-3, 4
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 Left Front Side Marker Lamp . . . . . . . . . . 8W-50-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5 Left Park Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4 Left Rear Lamp Assembly . . . . . . . . . . . . . 8W-50-5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-50-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Right Front Lamp Assembly . . . . . . . . . . 8W-50-3, 4
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5 Right Front Side Marker Lamp . . . . . . . . . 8W-50-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3, 4, 5 Right Park Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3, 4, 5 Underhood Accessory Fuse Block . . . . . . . . 8W-50-4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Illumination Control Module . . . . . 8W-50-2, 3, 4, 5
8W - 50 - 2 8W-50 FRONT LIGHTING ZH
8W - 50 - 4 8W-50 FRONT LIGHTING ZH
ZH 8W-51 REAR LIGHTING 8W - 51 - 1
8W-51 REAR LIGHTING

Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-51-2 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3, 4
Automatic Day/Night Mirror . . . . . . . . . . . 8W-51-4 Illumination Control Module . . . . . . . 8W-51-2, 3, 4
Backup Lamp Switch . . . . . . . . . . . . . . . . . 8W-51-4 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-51-2
Brake Lamp Relay . . . . . . . . . . . . . . . . . . . 8W-51-3 Left Rear Lamp Assembly . . . . . . . . . 8W-51-2, 3, 4
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51-3 Left Rear Side Marker Lamp . . . . . . . . . . . 8W-51-2
Center High Mounted Stop Lamp . . . . . . . 8W-51-3 License Lamp No. 1 . . . . . . . . . . . . . . . . . . 8W-51-2
Central Locking Pump/Security System License Lamp No. 2 . . . . . . . . . . . . . . . . . . 8W-51-2
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Powertrain Control Module . . . . . . . . . . . . 8W-51-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Right Rear Lamp Assembly . . . . . . . . 8W-51-2, 3, 4
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Right Rear Side Marker Lamp . . . . . . . . . . 8W-51-2
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-51-4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3, 4
8W - 51 - 2 8W-51 REAR LIGHTING ZH
ZH 8W-51 REAR LIGHTING 8W - 51 - 3
8W - 51 - 4 8W-51 REAR LIGHTING ZH
ZH 8W-52 TURN SIGNALS 8W - 52 - 1
8W-52 TURN SIGNALS

Console Switch Group . . . . . . . . . . . . . . . . 8W-52-2 Left Front Lamp Assembly . . . . . . . . . . . . . 8W-52-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Left Rear Lamp Assembly . . . . . . . . . . . . . 8W-52-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-52-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Right Front Lamp Assembly . . . . . . . . . . . . 8W-52-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Right Rear Lamp Assembly . . . . . . . . . . . . 8W-52-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
8W - 52 - 2 8W-52 TURN SIGNALS ZH
ZH 8W-53 WIPERS 8W - 53 - 1
8W-53 WIPERS

Body Control Module . . . . . . . . . . . . . . . . . 8W-53-2 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-53-2
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Washer Pump Motor . . . . . . . . . . . . . . . . . . 8W-53-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
8W - 53 - 2 8W-53 WIPERS ZH
ZH 8W-55 REAR SPOILER 8W - 55 - 1
8W-55 REAR SPOILER

Body Control Module . . . . . . . . . . . . . . . . . 8W-55-2 Rear Spoiler Motor . . . . . . . . . . . . . . . . . . . 8W-55-2
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 Rear Spoiler Switch . . . . . . . . . . . . . . . . . . 8W-55-2
Rear Spoiler Limit Switch . . . . . . . . . . . . . 8W-55-2
8W - 55 - 2 8W-55 REAR SPOILER ZH
ZH 8W-60 POWER WINDOWS 8W - 60 - 1
8W-60 POWER WINDOWS

Body Control Module . . . . . . . . . . . . . . . . . 8W-60-2 Left Front Power Window Switch . . . . . . . . 8W-60-2
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2 Right Front Power Window Motor . . . . . . . 8W-60-2
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2 Right Front Power Window Switch . . . . . . 8W-60-2
Left Front Power Window Motor . . . . . . . . 8W-60-2 Underhood Accessory Fuse Block . . . . . . . . 8W-60-2
8W - 60 - 2 8W-60 POWER WINDOWS ZH
ZH 8W-61 POWER DOOR LOCKS 8W - 61 - 1
8W-61 POWER DOOR LOCKS

Body Control Module . . . . . . . . . . . . . . . 8W-61-2, 3 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3
Central Locking Pump/Security System G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2 G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Console Switch Group . . . . . . . . . . . . . . . . 8W-61-3 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Driver Cylinder Lock Switch . . . . . . . . . . . 8W-61-3 Liftgate Lock Actuator . . . . . . . . . . . . . . . . 8W-61-2
Driver Door Lock Actuator . . . . . . . . . . . . . 8W-61-2 Liftgate Lock Switch . . . . . . . . . . . . . . . . . 8W-61-2
Fuel Door Lock Actuator . . . . . . . . . . . . . . 8W-61-2 Passenger Door Lock Actuator . . . . . . . . . . 8W-61-2
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2 Sentry Key Remote Entry Module . . . . . . . 8W-61-3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
8W - 61 - 2 8W-61 POWER DOOR LOCKS ZH
ZH 8W-61 POWER DOOR LOCKS 8W - 61 - 3
ZH 8W-62 POWER MIRRORS 8W - 62 - 1
8W-62 POWER MIRRORS

Automatic Day/Night Mirror . . . . . . . . . . . 8W-62-3 Illumination Control Module . . . . . . . . . . . 8W-62-3
Backup Lamp Switch . . . . . . . . . . . . . . . . . 8W-62-3 Left Power Mirror . . . . . . . . . . . . . . . . . 8W-62-2, 4
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4 Power Mirror Switch . . . . . . . . . . . . . . . 8W-62-2, 4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3 Powertrain Control Module . . . . . . . . . . . . 8W-62-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 4 Right Power Mirror . . . . . . . . . . . . . . . . 8W-62-2, 4
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4 Shift Lever Assembly . . . . . . . . . . . . . . . . . 8W-62-3
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4 Underhood Accessory Fuse Block . . . . 8W-62-2, 3, 4
8W - 62 - 2 8W-62 POWER MIRRORS ZH
ZH 8W-62 POWER MIRRORS 8W - 62 - 3
8W - 62 - 4 8W-62 POWER MIRRORS ZH
ZH 8W-63 POWER SEATS 8W - 63 - 1
8W-63 POWER SEATS

Driver Power Seat Front Riser Motor . . . . . 8W-63-3 Heated Seat Module . . . . . . . . . . . . . . . . . . 8W-63-5
Driver Power Seat Horizontal Motor . . . . . 8W-63-3 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-63-2
Driver Power Seat Rear Riser Motor . . . . . 8W-63-3 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-63-2
Driver Power Seat Recliner Motor . . . . . . . 8W-63-3 Left Seat . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
Driver Power Seat Switch . . . . . . . . . . . . . 8W-63-3 Passenger Power Seat Horizontal Motor . . 8W-63-4
Engine Fuse Block . . . . . . . . . . . . . . . . . . . 8W-63-2 Passenger Power Seat Recliner Motor . . . . 8W-63-4
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5 Passenger Power Seat Switch . . . . . . . . . . . 8W-63-4
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-3 Power Seat Relay . . . . . . . . . . . . . . . . . . . . 8W-63-2
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5 Right Seat . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4 Splice Block 102 . . . . . . . . . . . . . . . . . . . . . 8W-63-2
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2
8W - 63 - 2 8W-63 POWER SEATS ZH
8W - 63 - 4 8W-63 POWER SEATS ZH
ZH 8W-65 REMOTE KEYLESS ENTRY 8W - 65 - 1
8W-65 REMOTE KEYLESS ENTRY

Body Control Module . . . . . . . . . . . . . . . 8W-65-2, 3 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
Central Locking Pump/Security System Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-65-4
Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3, 4 Left Door Ajar Switch . . . . . . . . . . . . . . . . . 8W-65-4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-65-2 Liftgate Lock Switch . . . . . . . . . . . . . . . . . 8W-65-3
Driver Cylinder Lock Switch . . . . . . . . . . . 8W-65-3 Remote Keyless Entry Antenna . . . . . . . . . 8W-65-3
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2 Remote Keyless Entry Relay . . . . . . . . . . . 8W-65-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3 Sentry Key Antenna Ring . . . . . . . . . . . . . . 8W-65-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3, 4 Sentry Key Remote Entry Module . . . . . 8W-65-2, 3
8W - 65 - 2 8W-65 REMOTE KEYLESS ENTRY ZH
ZH 8W-65 REMOTE KEYLESS ENTRY 8W - 65 - 3
8W - 65 - 4 8W-65 REMOTE KEYLESS ENTRY ZH
ZH 8W-70 SPLICE INFORMATION 8W - 70 - 1
8W-70 SPLICE INFORMATION

S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-9
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-9
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-10
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-10
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-11
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6 S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-11
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-11
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-12
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-12
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-13
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-13
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6 S235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-14
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-7 S236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-14
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-7 S239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-15
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-7 S240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-15
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-8
8W - 70 - 2 8W-70 SPLICE INFORMATION ZH
ZH 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
8W-80 CONNECTOR PIN-OUTS

A/C COMPRESSOR CLUTCH . . . . . . . . . . 8W-80-4 C223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
A/C HEATER CONTROL MODULE . . . . . . 8W-80-4 C224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
A/C PRESSURE SENSOR . . . . . . . . . . . . . 8W-80-5 C224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
ACCELERATOR PEDAL POSITION C226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-5 C226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
AIR PUMP SWITCHOVER SOLENOID . . . 8W-80-5 C227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
AIR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-5 C227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
AMBIENT TEMPERATURE SENSOR . . . . 8W-80-5 C228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
ANTENNA C1 . . . . . . . . . . . . . . . . . . . . . . 8W-80-6 C228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
ANTENNA C2 . . . . . . . . . . . . . . . . . . . . . . 8W-80-6 C229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
ANTI-THEFT TOW SENSOR . . . . . . . . . . . 8W-80-6 C229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
ASH RECEIVER LAMP . . . . . . . . . . . . . . . 8W-80-6 C230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
AUTOMATIC DAY/ NIGHT MIRROR . . . . 8W-80-6 C230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
BACKUP LAMP SWITCH . . . . . . . . . . . . . 8W-80-7 C231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
BAS BRAKE BOOSTER C1 . . . . . . . . . . . . 8W-80-7 C231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
BAS BRAKE BOOSTER C2 . . . . . . . . . . . . 8W-80-7 C232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . 8W-80-7 C232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
BODY CONTROL MODULE . . . . . . . . . . . 8W-80-8 CAMSHAFT POSITION SENSOR . . . . . . 8W-80-22
BODY CONTROL MODULE . . . . . . . . . . . 8W-80-9 CARGO LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-22
BODY CONTROL MODULE . . . . . . . . . . 8W-80-10 CENTER HIGH MOUNTED
BODY CONTROL MODULE . . . . . . . . . . 8W-80-10 STOP LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-22
BRAKE FLUID LEVEL SWITCH . . . . . . . 8W-80-11 CENTRAL LOCKING PUMP/ SECURITY
BRAKE LAMP RELAY . . . . . . . . . . . . . . . 8W-80-11 SYSTEM MODULE C1 . . . . . . . . . . . . 8W-80-22
BRAKE LAMP SWITCH A (A/T) . . . . . . . . 8W-80-11 CENTRAL LOCKING PUMP/ SECURITY
BRAKE LAMP SWITCH A (M/T) . . . . . . . 8W-80-11 SYSTEM MODULE C2 . . . . . . . . . . . . 8W-80-23
BRAKE LAMP SWITCH B (A/T) . . . . . . . 8W-80-12 CENTRAL LOCKING PUMP/ SECURITY
BRAKE LAMP SWITCH B (M/T) . . . . . . . 8W-80-12 SYSTEM MODULE C3 . . . . . . . . . . . . 8W-80-23
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12 CENTRAL LOCKING PUMP/ SECURITY SYSTEM
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12 MODULE C4 . . . . . . . . . . . . . . . . . . . . 8W-80-23
C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12 CHARCOAL CANISTER SHUTOFF
C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13 CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . 8W-80-24
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13 CLOCKSPRING . . . . . . . . . . . . . . . . . . . . 8W-80-24
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13 CLUTCH INTERLOCK SWITCH . . . . . . . 8W-80-24
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14 CLUTCH PEDAL POSITION SWITCH . . 8W-80-24
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14 COIL ON PLUG NO. 1 . . . . . . . . . . . . . . . 8W-80-25
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 CONSOLE SWITCH GROUP . . . . . . . . . . 8W-80-26
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 CONTROLLER ANTILOCK BRAKE . . . . 8W-80-27
C210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 COOLANT CIRCULATION PUMP . . . . . . 8W-80-28
C210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 COOLANT CIRCULATION VALVE . . . . . 8W-80-28
C211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 COOLANT LEVEL SENSOR . . . . . . . . . . 8W-80-28
C211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 CRANKSHAFT POSITION SENSOR . . . . 8W-80-28
C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 DATA LINK CONNECTOR . . . . . . . . . . . 8W-80-28
C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 DOME LAMP . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
C223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 DRIVER CYLINDER LOCK SWITCH . . . 8W-80-29
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS ZH

DRIVER POWER SEAT/ SEAT BELT . . . 8W-80-29 LEFT FRONT SIDE MARKER LAMP . . . 8W-80-41
DRIVER SEAT BELT TENSIONER LEFT FRONT WSS/ BRAKE PAD WEAR
SQUIB . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
DRIVER SEAT BELT TENSIONER LEFT HEATED SEAT BACK/ HEATED
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30 SEAT CUSHION . . . . . . . . . . . . . . . . . 8W-80-42
EGR SOLENOID . . . . . . . . . . . . . . . . . . . 8W-80-30 LEFT KNOCK SENSOR . . . . . . . . . . . . . 8W-80-42
ENGINE COOLANT TEMPERATURE LEFT PARK LAMP . . . . . . . . . . . . . . . . . 8W-80-42
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30 LEFT POWER MIRROR . . . . . . . . . . . . . 8W-80-42
ESP LATERAL ACCELERATION LEFT REAR LAMP ASSEMBLY . . . . . . . 8W-80-43
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30 LEFT REAR SIDE MARKER LAMP . . . . 8W-80-43
ESP BRAKE PRESSURE SENSOR 1 . . . . 8W-80-30 LEFT REAR SPEAKER . . . . . . . . . . . . . . 8W-80-43
ESP BRAKE PRESSURE SENSOR 2 . . . . 8W-80-31 LEFT REAR WHEEL SPEED SENSOR . . 8W-80-43
ESP OFF SWITCH . . . . . . . . . . . . . . . . . . 8W-80-31 LEFT SIDE AIRBAG SQUIB . . . . . . . . . . 8W-80-44
ESP YAW RATE SENSOR . . . . . . . . . . . . 8W-80-31 LEFT SIDE IMPACT SENSOR . . . . . . . . 8W-80-44
EVAP PURGE SOLENOID . . . . . . . . . . . . 8W-80-31 LICENSE LAMP NO. 1 . . . . . . . . . . . . . . 8W-80-44
EVAPORATOR TEMPERATURE LICENSE LAMP NO. 2 . . . . . . . . . . . . . . 8W-80-44
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31 LIFTGATE LOCK SWITCH . . . . . . . . . . . 8W-80-44
FUEL TANK PRESSURE SENSOR . . . . . 8W-80-32 MAF/ IAT SENSOR . . . . . . . . . . . . . . . . . 8W-80-45
FUEL INJECTOR NO. 1 . . . . . . . . . . . . . 8W-80-32 MANIFOLD ABSOLUTE PRESSURE
FUEL INJECTOR NO. 2 . . . . . . . . . . . . . 8W-80-32 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-45
FUEL INJECTOR NO. 3 . . . . . . . . . . . . . 8W-80-32 MULTI-FUNCTION SWITCH . . . . . . . . . 8W-80-45
FUEL INJECTOR NO. 4 . . . . . . . . . . . . . 8W-80-32 OCCUPANT RESTRAINT
FUEL INJECTOR NO. 5 . . . . . . . . . . . . . 8W-80-33 CONTROLLER . . . . . . . . . . . . . . . . . . . 8W-80-46
FUEL INJECTOR NO. 6 . . . . . . . . . . . . . 8W-80-33 OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . 8W-80-47
FUEL LEVEL SENSOR . . . . . . . . . . . . . . 8W-80-33 OXYGEN SENSOR 1/1 UPSTREAM . . . . 8W-80-47
GENERATOR . . . . . . . . . . . . . . . . . . . . . . 8W-80-33 OXYGEN SENSOR 1/2
GLOVE BOX LAMP . . . . . . . . . . . . . . . . . 8W-80-33 DOWNSTREAM . . . . . . . . . . . . . . . . . . 8W-80-47
GLOVE BOX SWITCH . . . . . . . . . . . . . . . 8W-80-33 OXYGEN SENSOR 2/1 UPSTREAM . . . . 8W-80-47
HEATED SEAT MODULE . . . . . . . . . . . . 8W-80-34 OXYGEN SENSOR 2/2
HEATER CORE TEMPERATURE DOWNSTREAM . . . . . . . . . . . . . . . . . . 8W-80-47
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34 PASSENGER AIRBAG ON/OFF
HOOD AJAR SWITCH . . . . . . . . . . . . . . . 8W-80-34 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
IGNITION SWITCH . . . . . . . . . . . . . . . . . 8W-80-34 PASSENGER AIRBAG SQUIB . . . . . . . . . 8W-80-48
ILLUMINATION CONTROL PASSENGER POWER SEAT/ SEAT
MODULE A . . . . . . . . . . . . . . . . . . . . . 8W-80-35 BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
ILLUMINATION CONTROL PASSENGER SEAT BELT TENSIONER
MODULE B . . . . . . . . . . . . . . . . . . . . . 8W-80-36 SQUIB . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
ILLUMINATION CONTROL PASSENGER SEAT BELT TENSIONER
MODULE D . . . . . . . . . . . . . . . . . . . . . 8W-80-37 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-49
ILLUMINATION CONTROL PASSENGER SEAT OCCUPANT
MODULE E . . . . . . . . . . . . . . . . . . . . . 8W-80-37 SIMULATOR C1 . . . . . . . . . . . . . . . . . . 8W-80-49
INSTRUMENT CLUSTER C1 . . . . . . . . . 8W-80-38 PASSENGER SEAT OCCUPANT
INSTRUMENT CLUSTER C2 . . . . . . . . . 8W-80-39 SIMULATOR C2 . . . . . . . . . . . . . . . . . . 8W-80-49
KEY IN IGNITION SWITCH . . . . . . . . . . 8W-80-39 POWER AMPLIFIER A . . . . . . . . . . . . . . 8W-80-49
KICKDOWN SWITCH . . . . . . . . . . . . . . . 8W-80-39 POWER AMPLIFIER B . . . . . . . . . . . . . . 8W-80-50
LEFT DOOR AJAR SWITCH . . . . . . . . . . 8W-80-40 POWER MIRROR SWITCH . . . . . . . . . . . 8W-80-50
LEFT DOOR SPEAKER . . . . . . . . . . . . . . 8W-80-40 POWER SEAT RELAY . . . . . . . . . . . . . . . 8W-80-50
LEFT DOOR TWEETER . . . . . . . . . . . . . 8W-80-40 POWERTRAIN CONTROL
LEFT FOG LAMP . . . . . . . . . . . . . . . . . . 8W-80-40 MODULE - C1 . . . . . . . . . . . . . . . . . . . 8W-80-51
LEFT FRONT LAMP ASSEMBLY . . . . . . 8W-80-40 POWERTRAIN CONTROL
LEFT FRONT POWER WINDOW MODULE - C2 . . . . . . . . . . . . . . . . . . . 8W-80-51
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41 POWERTRAIN CONTROL
LEFT FRONT POWER WINDOW MODULE - C3 . . . . . . . . . . . . . . . . . . . 8W-80-52
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41 POWERTRAIN CONTROL
MODULE - C4 . . . . . . . . . . . . . . . . . . . 8W-80-53

POWERTRAIN CONTROL RIGHT PARK LAMP . . . . . . . . . . . . . . . . 8W-80-60
MODULE - C5 . . . . . . . . . . . . . . . . . . . 8W-80-54 RIGHT POWER MIRROR . . . . . . . . . . . . 8W-80-60
PULSE MODULE A . . . . . . . . . . . . . . . . . 8W-80-54 RIGHT REAR LAMP ASSEMBLY . . . . . . 8W-80-61
PULSE MODULE B . . . . . . . . . . . . . . . . . 8W-80-54 RIGHT REAR SIDE MARKER LAMP . . . 8W-80-61
PULSE MODULE F . . . . . . . . . . . . . . . . . 8W-80-54 RIGHT REAR SPEAKER . . . . . . . . . . . . . 8W-80-61
RADIATOR FAN CONTROL MODULE . . 8W-80-54 RIGHT REAR WHEEL SPEED
RADIATOR FAN MOTOR . . . . . . . . . . . . 8W-80-55 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55 RIGHT SIDE AIRBAG SQUIB . . . . . . . . . 8W-80-62
RADIO D . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55 RIGHT SIDE IMPACT SENSOR . . . . . . . 8W-80-62
REAR SPOILER LIMIT SWITCH . . . . . . 8W-80-55 SENTRY KEY REMOTE ENTRY
REAR SPOILER MOTOR . . . . . . . . . . . . . 8W-80-56 MODULE C1 . . . . . . . . . . . . . . . . . . . . 8W-80-62
REAR SPOILER SWITCH . . . . . . . . . . . . 8W-80-56 SENTRY KEY REMOTE ENTRY
RECIRCULATED AIR SWITCHOVER MODULE C2 . . . . . . . . . . . . . . . . . . . . 8W-80-63
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56 SENTRY KEY REMOTE ENTRY
RELAY CONTROL MODULE A . . . . . . . . 8W-80-56 MODULE C3 . . . . . . . . . . . . . . . . . . . . 8W-80-63
RELAY CONTROL MODULE B . . . . . . . . 8W-80-56 SHIFT LEVER ASSEMBLY . . . . . . . . . . . 8W-80-63
RELAY CONTROL MODULE C . . . . . . . . 8W-80-57 SHORT RUNNER VALVE SOLENOID . . 8W-80-63
RELAY CONTROL MODULE D . . . . . . . . 8W-80-57 SIREN . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-63
RELAY CONTROL MODULE E . . . . . . . . 8W-80-57 SPEED CONTROL SWITCH . . . . . . . . . . 8W-80-64
REMOTE KEYLESS ENTRY RELAY . . . . 8W-80-57 STEERING ANGLE SENSOR . . . . . . . . . 8W-80-64
RIGHT DOOR AJAR SWITCH . . . . . . . . . 8W-80-58 THROTTLE BODY . . . . . . . . . . . . . . . . . . 8W-80-64
RIGHT DOOR SPEAKER . . . . . . . . . . . . . 8W-80-58 TOW - AWAY ALARM SWITCH . . . . . . . . 8W-80-64
RIGHT DOOR TWEETER . . . . . . . . . . . . 8W-80-58 TRANSMISSION CONTROL
RIGHT FOG LAMP . . . . . . . . . . . . . . . . . 8W-80-58 MODULE C1 . . . . . . . . . . . . . . . . . . . . 8W-80-65
RIGHT FRONT LAMP ASSEMBLY . . . . . 8W-80-58 TRANSMISSION CONTROL
RIGHT FRONT POWER WINDOW MODULE C2 . . . . . . . . . . . . . . . . . . . . 8W-80-65
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 TRANSMISSION CONTROL
RIGHT FRONT POWER WINDOW MODULE C3 . . . . . . . . . . . . . . . . . . . . 8W-80-65
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 TRANSMISSION SOLENOID
RIGHT FRONT SIDE MARKER LAMP . . 8W-80-59 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 8W-80-66
RIGHT FRONT WSS/ BRAKE PAD WEAR UNIVERSAL GARAGE DOOR OPENER/ TIRE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 PRESSURE MONITOR . . . . . . . . . . . . 8W-80-66
RIGHT HEATED SEAT BACK/ HEATED WASHER FLUID LEVEL SWITCH . . . . . 8W-80-66
SEAT CUSHION . . . . . . . . . . . . . . . . . 8W-80-60 WASHER PUMP MOTOR . . . . . . . . . . . . 8W-80-66
RIGHT KNOCK SENSOR . . . . . . . . . . . . 8W-80-60
A/C COMPRESSOR CLUTCH — BLACK 1 WAY

CAVITY COLOR GAUGE FUNCTION
1 BL/DG 18 A/C COMPRESSOR CLUTCH SIGNAL
A/C HEATER CONTROL MODULE — BLACK 29 WAY

1 RD/YL 18 FUSED B+
2 — — —
3 BR/YL 20 SENSOR GROUND
4 DG/BK 20 REAR DEFOGGER INDICATOR DRIVER
5 BK/WT 20 SERIAL COMMUNICATION K2
6 — — —
7 WT/RD 20 BLOWER MOTOR CONTROL
8 BR/DG 20 COOLANT CIRCULATION PUMP CONTROL
9 BR/VT 20 LEFT COOLANT CIRCULATION VALVE CON-
TROL
10 BR/RD 20 RIGHT COOLANT CIRCULATION VALVE CON-
TROL
11 — — —
12 BR 16 GROUND
13 DG/BL 20 REAR DEFOGGER SWITCH SENSE
14 RD/WT 20 A/C PRESSURE SENSOR 5 VOLT SUPPLY
15 — — —
16 BR/YL 18 RECIRCULATED AIR SWITCHOVER VALVE
CONTROL
17 BK/BL 20 SCI TRNASMIT
18 YL/VT 20 SERIAL COMMUNICATION K1
19 — — —
20 BL/DG 18 A/C COMPRESSOR CLUTCH CONTROL
21 PK/RD/BL 18 FUSED IGNITION SWITCH OUTPUT
22 BK/DG 20 FUSED IGNITION SWITCH OUTPUT
23 — — —
24 GY/RD 20 EVAPORATOR TEMPERATURE SENSOR SIG-
NAL
25 GY/DG 20 RIGHT HEATER CORE TEMPERATURE SEN-
SOR SIGNAL
26 GY/PK 20 LEFT HEATER CORE TEMPERATURE SENSOR
SIGNAL
27 BL/RD 20 A/C PRESSURE SENSOR SIGNAL
28 — — —
29 — — —
A/C PRESSURE SENSOR — BLACK 3 WAY

1 BR/YL 18 A/C PRESSURE SENSOR GROUND
ACCELERATOR PEDAL POSITION SENSOR — BLACK 6 WAY

1 YL/WT 20 ACCELERATOR PEDAL POSITION SENSOR 5
VOLT SUPPLY
2 — — —
3 OR 20 SENSOR GROUND
4 DG 20 ACCELERATOR PEDAL POSITION SENSOR
SIGNAL NO. 2
5 GY 20 ACCELERATOR PEDAL POSITION SENSOR
SIGNAL NO. 1
6 BK 20 SENSOR GROUND
AIR PUMP SWITCHOVER SOLENOID — BLACK 2 WAY

1 GY/BR 20 AIR PUMP SWITCHOVER SOLENOID CON-
TROL
2 RD/DG 20 FUSED ENGINE CONTROL RELAY OUTPUT
AIR PUMP — BLACK 2 WAY

1 RD/WT 20 AIR PUMP RELAY OUTPUT
2 BR 20 GROUND
AMBIENT TEMPERATURE SENSOR — BLACK 2 WAY

1 DG 20 AMBIENT TEMPERATURE SENSOR SIGNAL
2 BR 20 SENSOR GROUND
ANTENNA C1 — BLACK 1 WAY

1 BL/DG 18 ENABLE SIGNAL TO AMPLIFIER
ANTENNA C2 — BLACK 1 WAY

1 BK 22 ANTENNA
2 BK — SHIELD
ANTI-THEFT TOW SENSOR — BLACK 6 WAY

1 — — —
2 — — —
3 — — —
4 DG/GY 20 SENSOR GROUND
5 BR/DG 18 ANTI-THEFT TOW SENSOR SIGNAL
6 RD/YL 18 FUSED B(+)
ASH RECEIVER LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 GY 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
AUTOMATIC DAY/NIGHT MIRROR — BLACK 6 WAY

1 GY/YL 20 SHIFT LEVER ASSEMBLY REVERSE SUPPLY
VOLTAGE
2 — — —
3 BR 20 GROUND
4 PK/RD/BK 20 FUSED IGNITION SWITCH OUTPUT
5 — — —
6 — — —
BACK UP LAMP SWITCH — BLACK 2 WAY

1 PK/RD 20 FUSED ILLUMINATION CONTROL MODULE
SUPPLY VOLTAGE
2 GY/YL 20 BACKUP LAMP SWITCH OUTPUT
BAS BRAKE BOOSTER C1 — BLACK 3 WAY

1 PK/YL 20 5 VOLT SUPPLY
2 VT/DG 20 BAS TRAVEL SENSOR SIGNAL
3 YL/DG 20 SENSOR GROUND
BAS BRAKE BOOSTER C2 — BLACK 6 WAY

1 GY 20 BAS RELEASE SWITCH SENSOR (RELEASED)
2 PK 20 12 VOLT SUPPLY
3 YL/VT 18 BAS RELEASE SWITCH SENSOR (APPLIED)
4 DG/BL 18 5 VOLT SUPPLY
5 BK/VT 18 BAS CONTROL
6 — — —
BLOWER MOTOR — BLACK 3 WAY

1 BR 14 BLOWER MOTOR GROUND
2 WT/PK 20 BLOWER MOTOR CONTROL
3 RD 14 FUSED B(+)
BODY CONTROL MODULE C4 — BLACK 63 WAY

3 PK/YL/DG 12 FUSED IGNITION SWITCH OUTPUT
4 RD/YL/WT 12 FUSED B(+)
5 BR 12 GROUND
6 — — —
7 — — —
8 — — —
9 — — —
10 BK/WT 14 RIGHT FRONT POWER WINDOW DRIVER
(DOWN)
11 DG/WT 14 RIGHT FRONT POWER WINDOW DRIVER
(UP)
12 BK 14 LEFT FRONT POWER WINDOW DRIVER
(DOWN)
13 DG 14 LEFT FRONT POWER WINDOW DRIVER (UP)
14 BR/WT 16 REAR SPOILER DRIVER (UP)
15 RD/WT 16 REAR SPOILER DRIVER (DOWN)
16 — — —
17 — — —
18 BL/BR 18 DOME LAMP CONTROL
19 — — —
20 — — —
21 BK/VT 20 INSTRUMENT CLUSTER WAKE UP SIGNAL
22 — — —
23 — — —
24 — — —
25 — — —
26 — — —
27 — — —
28 BR/GY 20 SPOILER LIMIT SWITCH SIGNAL (UP)
29 BR/YL 20 SPOILER LIMIT SWITCH SIGNAL (DOWN)
30 — — —
31 BL/GY 20 LIFTGATE LOCK SWITCH SENSE (LOCK)
32 — — —
33 — — —
34 WT/DG 20 SCI TRANSMIT
35 — — —
36 — — —
37 — — —
38 WT/BL 20 RIGHT POWER WINDOW SWITCH FEED
39 DG/YL 20 LEFT POWER WINDOW SWITCH FEED
42 BR 14 GROUND
43 BR 12 GROUND
51 — — —

52 — — —
53 — — —
54 — — —
55 GY/BK 20 DOOR UNLOCK SWITCH SENSE
56 BL/DG 20 WHEEL SPEED SENSOR OUTPUT
57 BK/RD 20 DOOR LOCK SWITCH SENSE
58 PK/RD/BK 18 FUSED IGNITION SWITCH OUTPUT
59 GY/RD 20 RKE STATUS OUTPUT
60 — — —
61 BR 16 GROUND
62 DG 20 CAN B BUS (-)
68 GY/WT 20 5 VOLT SUPPLY
69 — — —
70 — — —
71 DG/WT 20 REAR SPOILER SWITCH SENSE
72 — — —
73 — — —
74 DG/WT 20 WHEEL SPEED SENSOR OUTPUT
75 RD/GY 20 FUSED B(+)
76 — — —
77 BR 20 FUSED IGNITION SWITCH OUTPUT
78 WT 20 CAN B BUS (+)

1 RD 14 WIPER LOW SPEED CONTROL
2 DG 14 WIPER HIGH SPEED CONTROL
40 WT 14 WIPER PARK SWITCH SENSE
41 BK 14 12 VOLT SUPPLY
BODY CONTROL MODULE C1 — GREY 2 WAY

50 RD 20 12 VOLT SUPPLY
67 BR 20 CONTROL MODULE COOLING FAN CONTROL
BODY CONTROL MODULE C3 — GREY 9 WAY

45 BK/BL 16 TURN SIGNAL MONITORED GROUND
46 BK/YL 16 HAZARD SWITCH SIGNAL
47 DG/BL 20 REAR DEFOGGER SWITCH SENSE
48 DG/BK 20 REAR DEFOGGER INDICATOR DRIVER
49 WT/DG 20 DOOR LOCK SWITCH MUX
63 GY 16 WASHER PUMP MOTOR CONTROL
64 — — —
65 BL 18 WIPER SWITCH MUX
66 — — —
BRAKE FLUID LEVEL SWITCH — BLACK 2 WAY

1 BR 20 GROUND
2 BR/WT 20 BRAKE FLUID LEVEL SWITCH OUTPUT
BRAKE LAMP RELAY — YELLOW 9 WAY

1 — — —
2 — — —
3 — — —
4 RD/WT 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
5 BK/RD 20 BRAKE LAMP RELAY OUTPUT
6 BK/YL 20 BRAKE LAMP RELAY CONTROL
7 — — —
8 BK/WT 18 BRAKE LAMP SWITCH OUTPUT
9 — — —
BRAKE LAMP SWITCH A (A/T) — BLACK 3 WAY

1 RD/WT 20 BRAKE LAMP SWITCH OUTPUT
2 RD/YL 20 TRACTION SYSTEM RELAY OUTPUT
3 RD/BL 20 BTSI FEED
BRAKE LAMP SWITCH A (M/T) — BLACK 2 WAY

BRAKE LAMP SWITCH B (A/T) — BLACK 3 WAY

1 RD/WT 18 FUSED B(+)
3 — — —
BRAKE LAMP SWITCH B (M/T) — BLACK 2 WAY

1 RD/WT 18 FUSED B(+)
C100 — BLACK 4 WAY F

1 BK/WT 20 LEFT TURN SIGNAL OUTPUT
2 BK/DG 20 RIGHT TURN SIGNAL OUTPUT
C100 — BLACK 4 WAY M


1 BR/RD 18 HOOD AJAR SWITCH SENSE
2 YL/RD 20 SIREN SIGNAL OUTPUT


1 BR/VT 20 AIR PUMP RELAY CONTROL
2 — — —
4 BK/YL 16 FUSED IGNITION SWITCH OUTPUT
5 BL 18 LOW BATTERY INDICATOROUTPUT
6 VT 14 ENGINE STARTER MOTOR CONTROL
7 — — —
8 — — —

1 GY/BL 20 AIR PUMP RELAY CONTROL
2 — — —
5 BL 18 LOW BATTERY INDICATOROUTPUT
6 VT 14 ENGINE STARTER MOTOR CONTROL
7 — — —
8 — — —

1 BR/VT 20 LEFT COOLANT CIRCLATION VALVE CONTROL
3 BR/RD 20 RIGHT COOLANT CIRCLATION VALVE CON-
TROL
4 BL/DG 18 HEADLAMP CLEANING SWITCH SENSE
(EXPORT ONLY)
5 VT 20 FUSED IGNITION SWITCH OUTPUT

TROL
TROL
4 BL/DG 18 HEADLAMP CLEANING SWITCH SENSE
(EXPORT ONLY)

1 YL/BL 20 ESP YAW RATE SENSOR SIGNAL
3 RD/DG 20 5 VOLT SUPPLY
4 BK/RD/WT 20 ESP LATERAL ACCELERATION SENSOR SIG-
NAL
6 BK/PK/WT 20 5 VOLT SUPPLY
7 GY/YL 20 BACKUP LAMP SWITCH SENSE
8 BL 20 LEFT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
9 BR 20 LEFT REAR WHEEL SPEED SENSOR SIGNAL
10 YL 20 RIGHT REAR WHEEL SPEED SENSOR 12V
SUPPLY
11 BR 20 RIGHT REAR WHEEL SPEED SENSOR SIGNAL
12 BK/BL 20 ESP OFF SWITCH SENSE
13 DG/VT 20 PARK BRAKE SWITCH SENSE

NAL
8 BL 20 LEFT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
10 YL 20 RIGHT REAR WHEEL SPEED SENSOR 12V
SUPPLY
C204 — BLUE 2 WAY F

1 DG/BK 20 ENHANCED ACCIDENT REPORT DRIVER
2 YL 20 SCI TRANSMIT
C204 — BLUE 2 WAY M

1 DG/WT 20 ENHANCED ACCIDENT REPORT DRIVER

2 BL 20 DRIVER CYLINDER LOCK SWITCH SENSE
(LOCK)
3 BK 20 DRIVER CYLINDER LOCK SWITCH SENSE
(UNLOCK)
4 BK/GY 20 GLOVE BOX SWITCH SENSE
5 BK/WT 20 SCI TRANSMIT
6 YL/DG 20 SCI TRANSMIT
7 RD/YL 20 SCI TRANSMIT (A/T ONLY)
8 DG 20 SCI TRANSMIT (A/T ONLY)

(LOCK)
(UNLOCK)
4 BK/GY 20 GLOVE BOX SWITCH SENSE
7 RD/YL 20 SCI TRANSMIT (A/T ONLY)
8 DG 20 SCI TRANSMIT (A/T ONLY)

1 RD/DG 20 FUSED SUPPLY VOLTAGE
3 WT 18 CAN HIGH
4 DG 18 CAN LOW

3 WT 18 CAN HIGH
4 DG 18 CAN LOW
C210 - RED 2 WAY F

1 BL/DG 20 PASSENGER SQUIB LINE 2
2 BR/DG 20 PASSENGER SQUIB LINE 1


2 BR/DG 18 OXYGEN SENSOR 1/2 HEATER CONTROL
3 — — —
4 BR/WT 18 OXYGEN SENSOR 2/2 HEATER CONTROL
5 BL/RD 18 SENSOR GROUND
6 DG/BL 20 OXYGEN SENSOR 2/2 SIGNAL
7 YL/DG 20 OXYGEN SENSOR 1/2 SIGNAL
8 RD/DG 16 FUSED B(+)

3 — — —
5 BL/RD 18 SENSOR GROUND
6 DG/BL 20 OXYGEN SENSOR 2/2 SIGNAL
C219 — ORANGE 8 WAY F

1 BK/RD 20 5 VOLT SUPPLY
3 DG 20 FUEL TANK PRESSURE SENSOR SIGNAL
5 BR/BL 18 CHARCOAL CANISTER SHUT OFF VALVE
CONTROL
6 DG/VT 20 FUSED IGNITION SWITCH OUTPUT
7 — — —
8 BK/BL 20 SCI TRANSMIT
C219 — ORANGE 8 WAY M

CONTROL
6 DG/VT 20 FUSED IGNITION SWITCH OUTPUT
7 — — —
C223 — YELLOW 2 WAY M

1 BL/RD 20 LEFT SIDE SQUIB LINE 2
2 BL/GY 20 LEFT SIDE SQUIB LINE 1


1 BL/BK 20 RIGHT SIDE SQUIB LINE 1
2 BL/WT 20 RIGHT SIDE SQUIB LINE 2
C224 — YELLOW 2 WAY M

C226 — ORANGE 8 WAY F

6 — — —
7 BL 20 SCI TRANSMIT
C226 — ORANGE 8 WAY M

6 — — —

1 DG/YL 20 SCI RECEIVE
2 RD/WT 20 SCI TRANSMIT
3 YL/BL 20 SCI TRANSMIT
6 — — —
7 BL/YL 20 STEERING ANGLE SENSOR SIGNAL
8 — — —

6 — — —
8 — — —

1 PK/RD/WT 18 FUSED IGNITION SWITCH OUTPUT
2 BR 18 GROUND
3 WT 18 LEFT MIRROR LEFT DRIVER
4 GY 18 MIRROR COMMON DRIVER
5 BK 18 LEFT MIRROR UP DRIVER
6 BR 20 GROUND
(LOCK)
(UNLOCK)

2 BR 18 GROUND
6 BR 20 GROUND
(LOCK)
(UNLOCK)

1 BK/BL 18 AMPLIFIED LEFT DOOR SPEAKER (+)
2 BR/DG 18 AMPLIFIED LEFT DOOR SPEAKER (-)
(DOWN)

(DOWN)

2 BR 18 GROUND
3 WT 18 RIGHT MIRROR UP DRIVER
5 BK 18 RIGHT MIRROR LEFT DRIVER
6 — — —
7 — — —
8 — — —

2 BR 18 GROUND
5 BK 18 RIGHT MIRROR LEFT DRIVER
6 — — —
7 — — —
8 — — —

1 BK/BL 18 AMPLFIED RIGHT DOOR SPEAKER (+)
2 BR/DG 18 AMPLIFIED RIGHT DOOR SPEAKER (-)
3 DG 14 RIGHT FRONT POWER WINDOW DRIVER
(UP)
4 BK 14 RIGHT FRONT POWER WINDOW DRIVER
(DOWN)

1 BK/BL 18 AMPLIFIED RIGHT DOOR SPEAKER (+)
(UP)
(DOWN)
C232 — RED 2 WAY F

1 VT 20 DRIVER SQUIB LINE 1
2 DG 20 DRIVER SQUIB LINE 2
C232 — RED 2 WAY M

CAMSHAFT POSITION SENSOR — BLACK 3 WAY

1 BR/DG 20 SENSOR GROUND
2 PK 20 CAMSHAFT POSITION SENSOR SIGNAL
3 RD/BL 20 FUSED ENGINE CONTROL RELAY OUTPUT
CARGO LAMP— BLACK 2 WAY

1 BR/YL 18 GROUND
CENTER HIGH MOUNTED STOP LAMP (CHMSL) — VIOLET 2 WAY

1 BR 20 GROUND
2 BK/BL 20 BRAKE LAMP RELAY OUTPUT
CENTRAL LOCKING PUMP/ SECURITY SYSTEM MODULE C1 — BLACK 18 WAY

1 — — —
2 — — —
3 — — —
4 — — —
5 — — —
6 — — —
7 — — —
8 WT 20 CAN B BUS (+)
9 DG 20 CAN B BUS (-)
10 — — —
11 — — —
12 — — —
13 BR/YL 20 LIFTGATE LOCK SWITCH SENSE (UNLOCK)
14 BR/GY 20 LEFT DOOR AJAR SWITCH SENSE
15 — — —
16 BR/PK 20 RIGHT DOOR AJAR SWITCH SENSE
17 — — —
18 — — —

1 BK 12 REAR WINDOW DEFOGGER GRID
3 BR 12 GROUND
4 BK/YL/WT 16 FUSED B(+)

1 — — —
2 — — —
3 — — —
4 DG/GY 20 SENSOR GROUND
6 WT/DG 20 TOW–AWAY ALARM SWITCH 9 VOLT SUPPLY
8 — — —
9 — — —
10 — — —
11 RD/DG 20 TOW–AWAY ALARM SWITCH SENSE
12 — — —
13 — — —
14 — — —
15 BR/DG 18
16 BR/GY 20 GLOVE BOX SWITCH SENSE
17 — — —
18 — — —

1 YL/BK 14 HEADLAMP SWITCH SENSE
2 GY/RD 18 RIGHT REAR TURN SIGNAL OUTPUT
3 — — —
4 GY/BK 18 LEFT REAR TURN SIGNAL OUTPUT
CHARCOAL CANISTER SHUTOFF VALVE — BLACK 2 WAY

1 BR/DG 18 FUSED ENGINE CONTROL RELAY OUTPUT
CONTROL
CIGAR LIGHTER — BLACK 3 WAY

1 BR 16 GROUND
2 — — —
3 BK/BL 16 FUSED IGNITION SWITCH OUTPUT
CLOCKSPRING — BLACK 4 WAY

1 BR 20 HORN GROUND
2 YL 20 FUSED B(+)
CLUTCH INTERLOCK SWITCH — BLACK 2 WAY

1 VT 20 FUSED IGNTION SWITCH OUTPUT
2 VT 20 CLUTCH INTERLOCK SWITCH OUTPUT A/T
2 VT 20 CLUTCH INTERLOCK SWITCH OUTPUT M/T
CLUTCH PEDAL POSITION SWITCH — BLACK 2 WAY

1 BR 20 GROUND
2 RD/BK 20 CLUTCH PEDAL POSITION SWITCH SIGNAL
COIL ON PLUG NO. 1 — BLACK 3 WAY

1 BK 18 COIL ON PLUG NO. 1 DRIVER
3 BK/WT 18 COIL ON PLUG NO. 1 DRIVER

1 YL 18 COIL ON PLUG DRIVER NO. 2
3 YL/WT 18 COIL ON PLUG DRIVER NO. 2

1 DG 18 COIL ON PLUG DRIVER NO. 3
3 DG/WT 18 COIL ON PLUG DRIVER NO. 3

1 BL 18 COIL ON PLUG DRIVER NO. 4
3 BL/WT 18 COIL ON PLUG DRIVER NO. 4

1 VT 18 COIL ON PLUG DRIVER NO. 5
3 VT/WT 18 COIL ON PLUG DRIVER NO. 5

1 GY 18 COIL ON PLUG DRIVER NO. 6
3 GY/WT 18 COIL ON PLUG DRIVER NO. 6
CONSOLE SWITCH GROUP — BLACK 11 WAY

3 BK/BL 16 12 VOLT SUPPLY
4 BR 20 GROUND
5 BK/YL 16 FUSED B(+)
7 BK/WT/BL 16 HAZARD SWITCH SENSE
8 WT/DG 20 DOOR LOCK SWITCH MUX
9 GY/BL 20 ILLUMINATION FEED
10 — — —
11 — — —
CONTROLLER ANTILOCK BRAKE — BLACK 47 WAY

2 BR/DG 18 BRAKE PAD WEAR INDICATOR DRIVER
3 BR 18 LEFT FRONT WHEEL SPEED SENSOR SIGNAL
4 DG 18 LEFT FRONT WHEEL SPEED SENSOR 12V SUPPLY
7 BL 20 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
10 BK/RD/WT 20 ESP LATERAL ACCELERATION SENSOR SIGNAL
11 BR/BL 20 SENSOR GROUND
12 BL/WT 20 ESP BRAKE PRESSURE SENSOR 1 SIGNAL
13 GY 20 BAS RELEASE SWITCH SENSOR (RELEASED)
14 DG/BL 18 5 VOLT SUPPLY
15 DG 20 CAN HIGH
16 WT 20 CAN LOW
20 — — —
21 VT/DG 20 BAS TRAVEL SENSOR SIGNAL
22 PK/YL 20 5 VOLT SUPPLY
23 BK/VT 20 BAS CONTROL
26 BK/RD/WT 20 5 VOLT SUPPLY
30 YL 20 ESP OFF SWITCH SENSE
32 BR 18 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
33 WT 18 RIGHT FRONT WHEEL SPEED SENSOR 12V SUPPLY
34 — — —
36 YL 20 RIGHT REAR WHEEL SPEED SENSOR 12V SUPPLY
37 YL/DG 20 SENSOR GROUND
41 DG/WT 20 ESP BRAKE PRESSURE SENSOR 2 SIGNAL
42 PK 20 12 VOLT SUPPLY
43 YL/VT 18 BAS RELEASE SWITCH SENSOR (APPLIED)
44 BR 12 GROUND
45 BK 14 FUSED B(+)
46 BR 10 GROUND
47 BK 10 FUSED B(+)
COOLANT CIRCULATION PUMP — BLACK 2 WAY

COOLANT CIRCULATION VALVE — BLACK 3 WAY

TROL
TROL
COOLANT LEVEL SENSOR — BLACK 2 WAY

1 BR/BL 20 COOLANT LEVEL SENSOR GROUND
2 BR/YL 20 COOLANT LEVEL SENSOR SIGNAL
CRANKSHAFT POSITION SENSOR — NATURAL 2 WAY

1 DG 20 SENSOR GROUND
2 DG/WT 20 CRANKSHAFT POSITION SENSOR SIGNAL
DATA LINK CONNECTOR — BLACK 16 WAY

2 — — —
4 BR 18 GROUND
5 BR/WT 20 SENSOR GROUND
6 — — —
9 RD/YL 20 SCI TRANSMIT
10 — — —
11 DG 20 SCI TRANSMIT
14 — — —
DOME LAMP — BLACK 5 WAY

1 BR/YL 18 DOME LAMP SWITCH OUTPUT
2 BR 18 GROUND
3 BL/BR 18 DOME LAMP CONTROL
5 — — —
DRIVER CYLINDER LOCK SWITCH — BLACK 3 WAY

1 BR 20 GROUND
(LOCK)
(UNLOCK)
DRIVER POWER SEAT/ SEAT BELT — BLACK 4 WAY

1 BR/DG 20 FUSED IGNITION SWITCH OUTPUT
2 BR 20 GROUND
3 BR 14 GROUND
4 RD/BK 14 FUSED POWER SEAT RELAY OUTPUT
DRIVER SEAT BELT TENSIONER SQUIB — YELLOW 3 WAY

1 BR/YL 20 DRIVER SEAT BELT SQUIB LINE 1
2 — — —
3 BL 20 DRIVER SEAT BELT SQUIB LINE 2
DRIVER SEAT BELT TENSIONER SWITCH — BLACK 4 WAY

1 BR 20 GROUND
2 GY/DG 20 DRIVER SEAT BELT TENSIONER SWITCH
SENSE
3 — — —
4 — — —
EGR SOLENOID — BLACK 2 WAY

1 GY/WT 20 EGR SOLENOID CONTROL
ENGINE COOLANT TEMPERATURE SENSOR — BLACK 2 WAY

1 DG/RD 20 ENGINE COOLANT TEMPERATURE SENSOR
SIGNAL
2 BR/WT 20 SENSOR GROUND
ESP LATERAL ACCELERATION SENSOR — BLACK 3 WAY

NAL
ESP BRAKE PRESSURE SENSOR 1 — BLACK 3 WAY

1 BR/BL 20 SENSOR GROUND
2 BL/WT 20 ESP BRAKE PRESSURE SENSOR 1 SIGNAL
ESP BRAKE PRESSURE SENSOR 2 — BLACK 3 WAY

2 DG/WT 20 ESP BRAKE PRESSURE SENSOR 2 SIGNAL
ESP OFF SWITCH — BLACK 6 WAY

1 — — —
3 — — —
4 — — —
5 — — —
6 — — —
ESP YAW RATE SENSOR — BLACK 3 WAY

EVAP PURGE SOLENOID — BLACK 2 WAY

2 BR/RD 18 EVAP PURGE SOLENOID CONTROL
EVAPORATOR TEMPERATURE SENSOR — BLACK 2 WAY

1 BR/YL 20 EVAPORATOR TEMPERATURE SENSOR
GROUND
2 GY/RD 20 EVAPORATOR TEMPERATURE SENSOR SIG-
NAL
FUEL TANK PRESSURE SENSOR — BLACK 3 WAY

3 BK/RD 20 5 VOLT REFERENCE
FUEL INJECTOR NO. 1 — BLACK 2 WAY

1 GY/BK 18 FUSED ENGINE CONTROL RELAY OUTPUT
2 GY/BK 18 FUEL INJECTOR NO. 1 CONTROL

1 GY/RD 18 FUSED ENGINE CONTROL RELAY OUTPUT
2 GY/RD 18 FUEL INJECTOR NO. 2 CONTROL

1 GY/DG 18 FUSED ENGINE CONTROL RELAY OUTPUT
2 GY/DG 18 FUEL INJECTOR NO. 3 CONTROL

1 GY/RD 18 FUSED ENGINE CONTROL RELAY OUTPUT

1 GY/YL 18 FUSED ENGINE CONTROL RELAY OUTPUT
2 GY/YL 18 FUEL INJECTOR NO. 5 CONTROL

1 GY/VT 18 FUSED ENGINE CONTROL RELAY OUTPUT
2 GY/VT 18 FUEL INJECTOR NO. 6 CONTROL
FUEL LEVEL SENSOR — BLACK 2 WAY

1 BR/DG 20 FUEL LEVEL SENSOR SIGNAL
2 BL/BK 20 FUEL LEVEL SENSOR RETURN
GENERATOR — BLACK 2 WAY

1 BL 18 LOW BATTERY INDICATOR FEED
2 — — —
GLOVE BOX LAMP— WHITE 2 WAY

1 BR 20 GROUND
2 BK/BL 16 FUSED B(+)
GLOVE BOX SWITCH — BLACK 2 WAY

1 BR 20 GLOVE BOX SWITCH OUTPUT
2 BR/DG 20 GLOVE BOX SWITCH SENSE
HEATED SEAT MODULE — BLACK 4 WAY

1 BK/VT 16 RIGHT HEATED SEAT OUTPUT
3 BK/GY 16 LEFT HEATED SEAT OUTPUT
HEATER CORE TEMPERATURE SENSOR — BLACK 3 WAY

1 GY/DG 20 RIGHT HEATER CORE TEMPERATURE SEN-
SOR SIGNAL
3 GY/PK 20 LEFT HEATER CORE TEMPERATURE SENSOR
SIGNAL
HOOD AJAR SWITCH — BLACK 2 WAY

2 BR 18 GROUND
IGNITION SWITCH — BLACK 7 WAY

1 PK/RD 12 FUSED IGNITION SWITCH OUTPUT
2 DG/WT 18 FUSED IGNITION SWITCH OUTPUT
3 PK/YL 12 FUSED IGNITION SWITCH OUTPUT
5 RD 12 FUSED B+
6 PK/DG 20 FUSED IGNITION SWITCH OUTPUT
7 RD 12 FUSED B+
ILLUMINATION CONTROL MODULE A — BLACK 21 WAY

1 GY/YL 20 BACK UP LAMP SWITCH OUTPUT
(LHD)
(LHD)
2 BK/RD 18 BACK UP LAMP SWITCH OUTPUT
(RHD)
(LHD)
(RHD) OUTPUT
(LHD)
6 BK/YL 18 BRAKE LAMP RELAY OUTPUT
(LHD)
6 GY/DG 18 FUSED ILLUMINATION CONTROL MODULE
(RHD) OUTPUT
(LHD)
8 YL/BK 14 ILLUMINATION CONTROL MODULE OUTPUT
(LHD)
(RHD)
(RHD)
11 GY/RD 18 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
12 GY/VT 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
13 GY/YL 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
14 GY/DG 18 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
14 GY/BK 18 FUSED ILLUMINATION CONTROL MODULE
(RHD) OUTPUT
(LHD) OUTPUT
16 RD/WT 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
17 — — —
OUTPUT
19 BL/BR 18 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
(RHD)
20 — — —
21 BL/VT 18 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
(RHD) OUTPUT
ILLUMINATION CONTROL MODULE B — BLACK 21 WAY

1 — — —
2 — — —
3 YL 16 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
4 WT 16 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
4 YL/BK 16 FUSED ILLUMINATION CONTROL MODULE
(RHD) OUTPUT
5 YL/BK 16 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
(RHD) OUTPUT
6 WT/BK 16 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
(RHD) OUTPUT
(LHD) OUTPUT
(RHD) OUTPUT
8 — — —
9 — — —
10 — — —
11 — — —
12 — — —
13 — — —
14 DG 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
15 — — —
16 — — —
17 — — —
18 DG/WT 18 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
(LHD) OUTPUT
19 WT 16 FUSED ILLUMINATION CONTROL MODULE
(RHD) OUTPUT
(LHD) OUTPUT
(RHD) OUTPUT
(LHD) OUTPUT
(RHD) OUTPUT
ILLUMINATION CONTROL MODULE D — VIOLET 10 WAY

1 BK/WT/BL 16 FUSED ILLUMINATION CONTROL MODULE
OUTPUT
2 WT/YL 16 ILLUMINATION CONTROL MODULE OUTPUT
(LHD)
3 BL/WT 20 FUSED ILLUMINATION CONTROL MODULE
(RHD) OUTPUT
4 BR/BK 20 LAMP OUTAGE INDICATOR LAMP
(LHD)
(RHD)
5 BR 16 GROUND
(LHD)
5 BR/BK 20 LAMP OUTAGE INDICATOR LAMP
(RHD)
6 BL/WT 20 FUSED ILLUMINATION CONTROL MODULE
(LHD) OUTPUT
(LHD) OUTPUT
(RHD) OUTPUT
9 WT 16 HEADLAMP HIGH BEAM SUPPLY
(LHD)
(RHD) OUTPUT
(LHD) OUTPUT
10 WT 16 HEADLAMP HIGH BEAM SUPPLY
(RHD)
ILLUMINATION CONTROL MODULE E — BLACK 4 WAY

1 RD 12 FUSED B(+)
3 — — —
INSTRUMENT CLUSTER C1 — BLACK 30 WAY

1B BL 20 GENERATOR OUTPUT SENSE
2B — — —
3B — — —
4B BR/YL 20 COOLANT LEVEL SENSOR
5B DG 20 AMBIENT TEMPERATURE SENSOR SIGNAL
6B BR 20 AMBIENT TEMPERATURE SENSOR GROUND
7B BR/WT 20 BRAKE FLUID LEVEL SWITCH SENSE
8B — — —
9B WT 20 CAN C BUS (+)
10B DG 20 CAN C BUS (-)
11B BK/BL 20 SCI TRANSMIT
12B BR 20
1A BK/WT 20 LEFT TURN SIGNAL OUTPUT
2A WT/BK 20 HIGH BEAM INDICATOR LIGHT
3A BR 20 GROUND
4A BL/WT 20 FUSED IGNITION SWITCH OUTPUT
5A GY/BL 18 FUSED B(+)
6A BR/GY 20 KEY IN IGNITION SWITCH SENSE
7A BR/BK 20 LAMP OUTAGE INDICATOR LAMP
8A YL/VT 20 SERIAL COMMUNICATION K1
9A PK/RD/BL 20 FUSED IGNITION SWITCH OUTPUT
10A BK/DG 20 RIGHT TURN SIGNAL OUTPUT
11A RD/YL 20 FUSED B(+)
12A BR 20 GROUND
13A GY 18 FUSED B(+)
14A — — —
15A — — —
16A — — —
17A BK/WT 20 SERIAL COMMUNICATION K2
18A — — —
INSTRUMENT CLUSTER C2 — BLACK 25 WAY

1A — — —
2A — — —
1B — — —
2B — — —
1C PK/YL/DG 20 FUSED IGNITION SWITCH OUTPUT
2C PK 20 AIRBAG WARNING INDICATOR DRIVER
1D — — —
2D — — —
3D — — —
1E — — —
1F GY/YL 20 LOW TIRE PRESSURE WARNINGINDICATOR
CONTROL
1G — — —
1H — — —
1I BR/DG 20 DRIVER SEAT BELT SWITCH SENSE
1K BK/BR 20 TELESCOPING STEERING SWITCH SENSE
1L BK/VT 20 INSTRUMENT CLUSTER WAKE UP SIGNAL
2L BR/GY 20 LEFT DOOR AJAR SWITCH SENSE
3L — — —
4L BL/BK 20 FUEL LEVEL SENSOR SIGNAL
5L BR/GY 20 FUEL LEVEL SENSOR GROUND
6L — — —
1M — — —
2M — — —
1N — — —
2N DG/VT 20 FUSED IGNITION SWITCH OUTPUT
KEY IN IGNITION SWITCH — WHITE 2 WAY

1 BR/GY 20 KEY IN IGNITION SWITCH SENSE
KICKDOWN SWITCH — BLACK 2 WAY

1 BR 20 GROUND
2 BK 20 KICKDOWN SWITCH SIGNAL
LEFT DOOR AJAR SWITCH — WHITE 3 WAY

1 BR 20 GROUND
3 — — —
LEFT DOOR SPEAKER — BLACK 2 WAY

LEFT DOOR TWEETER — BLACK 2 WAY

LEFT FOG LAMP — WHITE 2 WAY

1 BR 18 GROUND
2 GY/YL 18 SWITCHED FUSED B(+)
LEFT FRONT LAMP ASSEMBLY — BLACK 6 WAY

1 BK/WT 18
2 BR 16 GROUND
3 YL/BK 16 HEADLAMP LOW BEAM SWITCH OUTPUT
4 WT/BK 16 HEADLAMP HIGH BEAM SWITCH OUTPUT
5 — — —
6 — — —
LEFT FRONT POWER WINDOW MOTOR — BLACK 2 WAY

(DOWN)
LEFT FRONT POWER WINDOW SWITCH — BLACK 6 WAY

1 BR 20 GROUND
2 DG/YL 20 LEFT POWER WINDOW SWITCH SENSE
3 — — —
4 — — —
5 DG/BL 20 FUSED ILLUMINATION FEED
6 — — —
LEFT FRONT SIDE MARKER LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 GY/BK 18 SWITCHED FUSED B(+)
LEFT FRONT WSS/ BRAKE PAD WEAR SENSOR — BLACK 4 WAY

1 BR 20 GROUND
3 DG 18 LEFT FRONT WHEEL SPEED SENSOR 12V
SUPPLY
4 BR 18 LEFT FRONT WHEEL SPEED SENSOR SIGNAL
LEFT HEATED SEAT BACK/HEATED CUSHION — BLACK 4 WAY

1 BR 14 GROUND
2 — — —
3 — — —
4 BK/GY 14 LEFT HEATED SEAT OUTPUT
LEFT KNOCK SENSOR — BLACK 2 WAY

1 SHEILD 20 SHEILD
2 VT 20 LEFT KNOCK SENSOR SIGNAL
LEFT PARK LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 DG/WT 18 FUSED B(+)
LEFT POWER MIRROR — BLACK 6 WAY

2 BR 18 GROUND
3 — — —
4 WT 18 MIRROR HORIZONTAL DRIVER
6 BK 18 MIRROR VERTICAL DRIVER
LEFT REAR LAMP ASSEMBLY — BLACK 6 WAY

1 BR 18 GROUND
2 GY/BK 18 HEADLAMP SWITCH OUTPUT
3 BK/WT 18 TURN SIGNAL SWITCH OUTPUT
6 GY/DG 18 REAR FOG LAMPS SWITCH OUTPUT
(EXPORT)
LEFT REAR SIDE MARKER LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 BL/BR 18 SWITCHED FUSED B(+)
LEFT REAR SPEAKER — BLACK 4 WAY

1 RD 14 AMPLIFIED LEFT REAR SPEAKER (+)
2 DG 14 AMPLIFIED LEFT REAR SPEAKER (-)
3 BL 14 LEFT REAR SPEAKER SUPPLY VOLTAGE
4 BK/RD 14 LEFT REAR SPEAKER GROUND
LEFT REAR WHEEL SPEED SENSOR — BLACK 2 WAY

CAVITY COLOR CIRCUIT FUNCTION
2 YL 20 LEFT REAR WHEEL SPEED SENSOR 12V
SUPPLY
LEFT SIDE AIRBAG SQUIB — YELLOW 3 WAY

3 — — —
LEFT SIDE IMPACT SENSOR — YELLOW 3 WAY

1 BR 20 GROUND
3 BL/YL 20 LEFT SIDE IMPACT SENSOR SIGNAL
LICENSE LAMP NO. 1 — BLACK 2 WAY

1 BR 20 GROUND
2 GY/VT 18 SWITCHED FUSED B(+)
LICENSE LAMP NO. 2 — BLACK 2 WAY

1 BR 20 GROUND
LIFTGATE LOCK SWITCH — BLACK 4 WAY

1 BR 20 GROUND
2 BR/YL 20 LIFTGATE LOCK SWITCH SENSE (UNLOCK)
3 BL/GY 20 LIFTGATE LOCK SWITCH SENSE (LOCK)
4 — — —
MAF/ IAT SENSOR — WHITE 5 WAY

1 YL/DG 18 IAT SENSOR SIGNAL
4 BR/YL 18 5 VOLT SUPPLY
5 YL/WT 18 MAF SENSOR SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR — BLACK 3 WAY

1 BR/GY 20 SENSOR GROUND
2 RD/GY 20 MAP SENSOR SIGNAL
3 PK/BK 20 5 VOLT SUPPLY
MULTIFUNCTION SWITCH — BLACK 12 WAY

1 WT/YL 16 HIGH BEAM OUTPUT
2 WT 16 FLASH TO PASS OUTPUT
3 — — —
4 BK/BL 18 TURN SIGNAL MONITORED GROUND
5 — — —
6 — — —
7 BL 18 WIPER SWITCH MUX
11 BK/YL/DG 16 FUSED IGNITION SWITCH OUTPUT
12 — — —
OCCUPANT RESTRAINT CONTROLLER — ORANGE 50 WAY

1 BL 20 DRIVER SEAT BELT SQUIB LINE 2
2 BR/YL 20 DRIVER SEAT BELT SQUIB LINE 1
3 BL 20 PASSENGER SEAT BELT SQUIB LINE 2
4 BR 20 PASSENGER SEAT BELT SQUIB LINE 1
6 BR 20 GROUND
7 PK 20 AIRBAG WARNING INDICATOR DRIVER
8 GY/BL 20 PASSENGER SEAT BELT TENSIONER SWITCH SENSE
12 GY/DG 20 DRIVER SEAT BELT TENSIONER SWITCH SENSE
15 WT 20 PASSENGER AIRBAG ON/OFF SWITCH SIGNAL
20 BL/YL 20 LEFT SIDE IMPACT SENSOR SIGNAL
21 BL/YL 20 RIGHT SIDE IMPACT SENSOR SIGNAL
22 — — —
23 — — —
24 — — —
25 — — —
26 — — —
27 — — —
28 — — —
29 — — —
31 — — —
32 — — —
33 BK 20 AIRBAG OFF INDICATOR DRIVER
34 — — —
35 — — —
36 — — —
37 — — —
38 — — —
39 — — —
40 — — —
41 — — —
42 — — —
43 — — —
44 — — —
45 — — —
46 — — —
47 — — —
48 — — —
49 — — —
50 — — —
OIL SENSOR (LEVEL, TEMPERATURE, QUALITY) — BLACK 3 WAY

1 GY/BL 20 OIL SENSOR SIGNAL
2 BR/BK 20 SENSOR GROUND
3 RD/YL 20 5 VOLT SUPPLY
OXYGEN SENSOR 1/1 UPSTREAM — BLACK 4 WAY

1 RD/DG 18 FUSED ENGINE CONTROL REALY OUTPUT
2 BR/BK 18 OXYGEN SENSOR 1/1 HEATER CONTROL
4 BK 20 OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM — BLACK 4 WAY

OXYGEN SENSOR 2/1 UPSTREAM — BLACK 4 WAY

2 BR/GY 18 OXYGEN SENSOR 2/1 HEATER CONTROL
4 BK/BR 20 OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM — BLACK 4 WAY

4 YL/BK 20 OXYGEN SENSOR 2/2 SIGNAL
PASSENGER AIRBAG ON/OFF SWITCH — BLACK 2 WAY

1 BK 20 AIRBAG OFF INDICATOR DRIVER
PASSENGER AIRBAG SQUIB — YELLOW 3 WAY

2 — — —
PASSENGER POWER SEAT/ SEAT BELT — BLACK 4 WAY

1 — — —
2 — — —
3 BR 14 GROUND
4 RD/DG 14 FUSED POWER SEAT RELAY OUTPUT
PASSENGER SEAT BELT TENSIONER SQUIB — YELLOW 3 WAY

1 BR 20 PASSENGER SEAT BELT SQUIB LINE 1
2 — — —
3 BL 20 PASSENGER SEAT BELT SQUIB LINE 2
PASSENGER SEAT BELT TENSIONER SWITCH — BLACK 4 WAY

1 GY/BL 20 PASSENGER SEAT BELT TENSIONER SWITCH
SENSE
2 BR 20 GROUND
3 — — —
4 — — —
PASSENGER SEAT OCCUPANT SIMULATOR C2 — YELLOW 3 WAY

1 PK/YL/DG 20 AIRBAG ON/OFF SWITCH SENSE (ON)
2 WT 20 5 VOLT SUPPLY
3 BR 20 AIRBAG ON/OFF SWITCH SENSE (OFF)
PASSENGER SEAT OCCUPANT SIMULATOR C1 — YELLOW 3 WAY

1 YL/BL 20 FUSED IGNITION SWITCH OUTPUT
2 GY 20 PASSENGER AIRBAG ON/OFF SWITCH SIG-
NAL
3 BL/WT 20 GROUND
POWER AMPLIFIER A — BLACK 12 WAY

1 BL 18 RIGHT DOOR SPEAKER (-)
2 BL/BR 18 LEFT DOOR SPEAKER (+)
3 BL/BR 18 LEFT DOOR SPEAKER (+)
4 BR 16 GROUND
5 BK/DG 18 ENABLE SIGNAL TO AMPLIFIER
6 YL/VT 18 LEFT REAR SPEAKER (+)
7 YL 18 RIGHT REAR SPEAKER (-)
8 BL 18 RIGHT DOOR SPEAKER (-)
9 YL/VT 18 LEFT REAR SPEAKER (+)
10 YL 18 RIGHT REAR SPEAKER (-)
11 BR 16 GROUND
12 — — —
POWER AMPLIFIER B — BLACK 18 WAY

2 — — —
3 DG/WT 20 VSS SIGNAL
4 BK/RD 16 LEFT REAR SPEAKER GROUND
5 BL/RD 16 AMPLIFIED RIGHT REAR SPEAKER (+)
6 PK 16 AMPLIFIED LEFT REAR SPEAKER (+)
7 BK/PK 16 AMPLIFIED RIGHT DOOR SPEAKER (+)
10 — — —
11 — — —
12 BL 16 LEFT REAR SPEAKER SUPPLY VOLTAGE
13 RD/YL 16 RIGHT REAR SPEAKER GROUND
14 VT 16 RIGHT REAR SPEAKER SUPPLY VOLTAGE
15 BK/YL 16 AMPLIFIED RIGHT REAR SPEAKER (-)
16 DG 16 AMPLIFIED LEFT REAR SPEAKER (-)
17 BR/YL 16 AMPLIFIED RIGHT DOOR SPEAKER (-)
POWER MIRROR SWITCH — BLACK 8 WAY

1 BR 18 GROUND
2 — — —
4 GY/VT 18 LEFT MIRROR LEFT DRIVER
8 BK/VT 18 RIGHT MIRROR LEFT DRIVER
POWER SEAT RELAY — BLACK 9 WAY

2 RD/WT 12 POWER SEAT RELAY SWITCHED OUTPUT
3 RD 18 FUSED B(+)
4 PK/YL 18 FUSED IGNITION SWITCH OUTPUT
5 — — —
6 BR 18 GROUND
8 RD 12 FUSED B(+)
9 — — —
POWERTRAIN CONTROL MODULE C1 — BLACK 9 WAY

1 — — —
2 BK/WT 18 COIL ON PLUG DRIVER NO. 1
3 BL 18 SENSOR GROUND
4 GY/WT 18 COIL ON PLUG DRIVER NO. 6
5 BL/WT 18 COIL ON PLUG DRIVER NO. 4
6 BK 18 THROTTLE CONTROL MOTOR 2
7 DG/WT 18 COIL ON PLUG DRIVER NO. 3
8 — — —
9 YL/WT 18 COIL ON PLUG DRIVER NO. 2

1 — — —
2 — — —
3 — — —
4 — — —
5 — — —
6 — — —
7 GY/WT 20 EGR SOLENOID CONTROL
8 — — —
9 — — —
10 — — —
11 — — —
12 VT/WT 18 COIL ON PLUG DRIVER NO. 5
13 GY/BR 20 AIR PUMP SWITCH OVER SOLENOID CON-
TROL
14 DG/VT 20 SHORT RUNNER VALVE SOLENOID CONTROL
15 BR/GY 18 OXYGEN SENSOR 2/1 HEATER CONTROL
16 — — —
17 — — —
18 GY/VT 18 FUEL INJECTOR NO. 6 CONTROL
19 GY/DG 18 FUEL INJECTOR NO. 3 CONTROL
20 — — —
21 GY/YL 18 FUEL INJECTOR NO. 5 CONTROL
23 — — —
24 BR/BK 18 OXYGEN SENSOR 1/1 HEATER CONTROL

1 — — —
2 PK 20 CAMSHAFT POSITION SENSOR SIGNAL
4 VT 20 RIGHT KNOCK SENSOR SIGNAL
5 DG/RD 20 ENGINE COOLANT TEMPERATURE SENSOR
SIGNAL
7 BK/BR 20 OXYGEN SENSOR 2/1 SIGNAL
8 YL/DG 20 IAT SENSOR SIGNAL
10 RD/DG 20 MAP SENSOR SIGNAL
11 YL/WT 20 MAF SENSOR SIGNAL
13 DG/WT 20 CAMSHAFT POSITION SENSOR SIGNAL 1
14 — — —
15 GY/BL 20 OIL SENSOR SIGNAL
17 YL 20 LEFT KNOCK SENSOR SIGNAL
18 — — —
19 GY 20 SENSOR GROUND
20 WT 20 THROTTLE POSITION SENSOR SIGNAL 2
21 YL 20 THROTTLE POSITION SENSOR SIGNAL 1
22 VT 20 5 VOLT SUPPLY
23 BK 20 OXYGEN SENSOR 1/1 SIGNAL
24 — — —
25 BR/YL 20 5 VOLT SUPPLY
26 DG 20 CAMSHAFT POSITION SENSOR SIGNAL 2
27 GY/BK 18 FUEL INJECTOR NO. 1 CONTROL
28 GY/BL 18 FUEL INJECTOR NO. 4 CONTROL
29 — — —
30 — — —
31 — — —
32 — — —
33 — — —
34 — — —
35 — — —
36 — — —
37 — — —
38 — — —
39 RD/YL 20 5 VOLT SUPPLY
40 — — —
41 — — —
42 — — —
43 — — —
44 GY 18 COIL ON PLUG DRIVER NO. 6
45 DG 18 COIL ON PLUG DRIVER NO. 3
46 BL 18 COIL ON PLUG DRIVER NO. 4
47 BK 18 COIL ON PLUG DRIVER NO. 1
48 — — —
49 VT 18 COIL ON PLUG DRIVER NO. 5
50 YL 18 COIL ON PLUG DRIVER NO. 2
51 — — —
52 — — —

1 WT 20 CAN C BUS (+)
2 — — —
4 RD/BK 20 CLUTCH PEDAL POSITION SWITCH SIGNAL
7 DG 20 ACCELERATOR PEDAL POSITION SENSOR
SIGNAL NO. 2
8 GY 20 ACCELERATOR PEDAL POSITION SENSOR
SIGNAL NO. 1
9 — — —
11 DG 20 CAN C BUS (-)
13 — — —
14 BK 20 KICKDOWN SWITCH SIGNAL
15 YL/BK 20 OXYGEN SENSOR 2/2 SIGNAL
18 OR 20 SENSOR GROUND
19 YL/WT 20 ACCELERATOR PEDAL POSITION SENSOR 5
VOLT SUPPLY
20 — — —
21 — — —
22 GY 20 OFF SIGNAL
23 DG/RD 20 ACCEL/SET SIGNAL
24 — — —
26 DG/BL 20 ON SIGNAL
27 — — —
28 YL/DG 20 DECEL/SET SIGNAL
30 BL/RD 20 RESUME SIGNAL
31 — — —
33 — — —
34 — — —
35 PK/RD 20 SENSOR GROUND
36 BL/RD 18 FUEL PUMP RELAY CONTROL
CONTROL
38 BR/VT 20 AIR PUMP RELAY CONTROL
39 GY 12 RADIATOR FAN CONTROL

2 BR/RD 18 EVAP PURGE SOLENOID CONTROL
3 BK/DG 18 FUSED B+
5 BR 16 GROUND
6 BR 16 GROUND
7 BR 16 GROUND
8 BR 16 GROUND
9 RD/DG 18 ENGINE CONROL RELAY OUTPUT
PULSE MODULE A — BLACK 5 WAY

1 BK 12 FUSED B(+)
2 PK/RD 20 SENSOR GROUND
3 — — —
4 — — —
5 BR 12 GROUND
PULSE MODULE B — BLACK 2 WAY

PULSE MODULE F — GREY 1 WAY

1 VT/WT 12 STARTER SOLENOID OUTPUT
RADIATOR FAN CONTROL MODULE — NATURAL 7 WAY

1 BR/BK 6 RADIATOR FAN CONTROL MODULE GROUND
2 BR 6 GROUND
3 BK 6 FUSED B+
4 BK/DG 6 RADIATOR FAN CONTROL MODULE OUTPUT
5 GY 20 RADIATOR FAN CONTROL
7 — — —
RADIATOR FAN MOTOR — BLACK 2 WAY

1 BR/BK 6 RADIATOR FAN MOTOR GROUND
2 BK/DG 6 RADIATOR FAN MOTOR OUTPUT
RADIO — BLACK 16 WAY

1A — — —
2A YL/DG 20 DATA LINK CONNECTOR
3A — — —
4A RD/DG 14 FUSED B (+)
5A BL/DG 18 ENABLE SIGNAL TO AMPLIFIER
6A GY/BL 20 FUSED ILLUMINATION FEED
7A PK/YL/DG 16 FUSED B (+)
8A BR 14 GROUND
1B — — —
2B — — —
3B YL 18 RIGHT REAR SPEAKER (-)
4B YL/VT 18 LEFT REAR SPEAKER (+)
5B BL 18 RIGHT
DOOR SPEAKER (-)
6B BL/BR 18 LEFT
DOOR SPEAKER (+)
7B — — —
8B — — —
RADIO D — BLACK 1 WAY

1 BK 22 ANTENNA
2 BK — SHIELD
REAR SPOILER LIMIT SWITCH — BLACK 4 WAY

1 BR 20 GROUND
2 BR/YL 20 SPOILER LIMIT SWITCH SIGNAL (DOWN)
3 BR/GY 20 SPOILER LIMIT SWITCH SIGNAL (DOWN)
4 — — —
REAR SPOILER MOTOR — BLUE 2 WAY

1 BR/WT 14 REAR SPOILER DRIVER (UP)
2 RD/WT 14 REAR SPOILER DRIVER (DOWN)
REAR SPOILER SWITCH — BLACK 3 WAY

2 GY/WT 20 5 VOLT SUPPLY
4 — — —
6 DG/WT 20 REAR SPOILER SWITCH SENSE
RECIRCULATED AIR SWITCHOVER VALVE — GREY 2 WAY

1 BR/YL 18 RECIRCULATED AIR SWITCHOVER VALVE
CONTROL
2 PK/RD/BL 18 FUSED B(+)
RELAY CONTROL MODULE A — BLACK 4 WAY

1 GY/BL 20 AIR PUMP RELAY CONTROL
4 RD/WT 12 FUSED AIR PUMP RELAY OUTPUT
RELAY CONTROL MODULE B — BLACK 5 WAY

1 RD 12 FUSED B(+)
2 RD 12 FUSED B(+)
3 RD/DG 14 FUEL PUMP RELAY OUTPUT
4 RD 14 FUSED IGNITION SWITCH OUTPUT
5 BR 18 GROUND
RELAY CONTROL MODULE C — BLACK 5 WAY

1 — — —
2 — — —
3 — — —
4 RD/YL 18 FUSED TRACTION SYSTEM RELAY OUTPUT
5 RD/DG 18 FUSED TRACTION SYSTEM RELAY OUTPUT
RELAY CONTROL MODULE D — BLACK 3 WAY

1 YL 20 HORN SWITCH OUTPUT
3 — — —
RELAY CONTROL MODULE E — GREY 7 WAY

1 BK/PK 14 FUSED HORN RELAY OUTPUT
2 RD/WT 18 FUSED IGNITION SWITCH OUTPUT
3 BL/RD 18 FUEL PUMP RELAY CONTROL
4 BK/DG 18 FUSED B(+)
6 BK/DG 18 FUSED ENGINE CONTROL RELAY OUTPUT
7 — — —
REMOTE KEYLESS ENTRY RELAY — BLACK 9 WAY

1 — — —
2 BK/WT 18 REMOTE KEYLESS ENTRY RELAY OUTPUT
3 — — —
5 BK/DG 18 REMOTE KEYLESS ENTRY RELAY OUTPUT
6 BK/YL 20 REMOTE KEYLESS ENTRY RELAY CONTROL
7 — — —
9 — — —
RIGHT DOOR AJAR SWITCH — WHITE 3 WAY

1 BR 20 GROUND
3 — — —
RIGHT DOOR SPEAKER — BLACK 2 WAY

RIGHT DOOR TWEETER — BLACK 2 WAY

RIGHT FOG LAMP — WHITE 2 WAY

1 BR 18 GROUND
RIGHT FRONT LAMP ASSEMBLY — BLACK 6 WAY

1 BK/DG 18
2 BR 16 GROUND
3 YL 16 HEADLAMP LOW BEAM SWITCH OUTPUT
4 WT 16 HEADLAMP HIGH BEAM SWITCH OUTPUT
5 — — —
6 — — —
RIGHT FRONT POWER WINDOW MOTOR — BLACK 2 WAY

(UP)
(DOWN)
RIGHT FRONT POWER WINDOW SWITCH — BLACK 6 WAY

1 BR 20 GROUND
2 WT/BL 20 RIGHT POWER WINDOW SWITCH SENSE
3 — — —
4 — — —
5 GY/BL 20 FUSED ILLUMINATION FEED
6 — — —
RIGHT FRONT SIDE MARKER LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 GY/RD 18 SWITCHED FUSED B(+)
RIGHT FRONT WSS/ BRAKE PAD WEAR SENSOR — BLACK 4 WAY

1 BR 20 GROUND
3 WT 18 RIGHT FRONT WHEEL SPEED SENSOR 12V
SUPPLY
4 BR 18 RIGHT FRONT WHEEL SPEED SENSOR SIG-
NAL
RIGHT HEATED SEAT BACK/HEATED CUSHION — BLACK 4 WAY

1 BR 14 GROUND
2 — — —
3 — — —
4 BK/VT 14 RIGHT HEATED SEAT OUTPUT
RIGHT KNOCK SENSOR — BLACK 2 WAY

1 SHEILD 20 SHEILD
2 YL 20 RIGHT KNOCK SENSOR SIGNAL
RIGHT PARK LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 DG 18 FUSED B(+)
RIGHT POWER MIRROR — BLACK 6 WAY

2 BR 18 GROUND
3 — — —
4 WT 18 MIRROR VERTICAL DRIVER
6 BK 18 MIRROR HORIZONTAL DRIVER
RIGHT REAR LAMP ASSEMBLY — BLACK 6 WAY

1 BR 18 GROUND
2 GY/RD 18 HEADLAMP SWITCH OUTPUT
4 BK/YL 18 BRAKE LAMP RELAY OUTPUT
6 — — —
RIGHT REAR SIDE MARKER LAMP — BLACK 2 WAY

1 BR 18 GROUND
2 BK/VT 18 SWITCHED FUSED B(+)
RIGHT REAR SPEAKER — BLACK 4 WAY

1 BL/RD 14 AMPLIFIED RIGHT REAR SPEAKER (+)
2 BK/YL 14 AMPLIFIED RIGHT REAR SPEAKER (-)
3 VT 14 RIGHT REAR SPEAKER SUPPLY VOLTAGE
4 RD/YL 14 RIGHT REAR SPEAKER GROUND
RIGHT REAR WHEEL SPEED SENSOR — BLACK 2 WAY

2 BL 20 RIGHT REAR WHEEL SPEED SENSOR 12
VOLT SUPPLY
RIGHT SIDE AIRBAG SQUIB — YELLOW 2 WAY

1 BL/RD 20 RIGHT SIDE SQUIB LINE 2
2 BL/GY 20 RIGHT SIDE SQUIB LINE 1
RIGHT SIDE IMPACT SENSOR — YELLOW 3 WAY

1 BR 20 GROUND
3 BL/YL 20 RIGHT SIDE IMPACT SENSOR SIGNAL
SENTRY KEY REMOTE ENTRY MODULE C1 — BLACK 18 WAY

2 BK/YL 20 REMOTE KEYLESS ENTRY RELAY CONTROL
4 — — —
5 — — —
6 WT 20 RKE ANTENNA
7 — SHEILD SHEILD
(UNLOCK)
(LOCK)
10 PK/RD/BL 20 FUSED IGNITION SWITCH OUTPUT
12 — — —
13 — — —
14 — — —
15 — — —
16 BR 20 GROUND
SENTRY KEY REMOTE ENTRY MODULE C2 — WHITE 2 WAY

1 DG 20 CAN LOW
2 WT 20 CAN HIGH
SENTRY KEY REMOTE ENTRY MODULE C3 — BLACK 2 WAY

1 BK 16 SENTRY KEY ANTENNA
2 — SHIELD SHEILD
SHIFT LEVER ASSEMBLY — BLACK 10 WAY

1 — — —
2 GY/BL 20 PANEL LAMP DRIVER
3 RD/YL 20 SCI TRANSMIT
4 BR 20 GROUND
5 RD/BL 20 BTSI
6 WT 20 CAN C BUS (+)
7 DG 20 CAN C BUS (+)
8 RD/DG 20 TRACTION SYSTEM RELAY CONTROL
10 GY/YL 20 SHIFT LEVER ASSEMBLY REVERSE SUPPLY
VOLTAGE
SHORT RUNNER VALVE SOLENOID — BLACK 2 WAY

1 DG/VT 20 SHORT RUNNER VALVE SOLENOID CONTROL
SIREN — BLACK 3 WAY

2 BR 20 GROUND
SPEED CONTROL SWITCH — BLACK 8 WAY

1 GY 20 OFF SIGNAL
2 BK/RD 18 FUSED IGNITION SWITCH OUTPUT
3 YL/DG 20 DECEL/SET SIGNAL
4 BL/RD 20 ACCEL/SET SIGNAL
5 BL/RD 20 RESUME SIGNAL
6 DG/BL 20 ON SIGNAL
7 — — —
8 — — —
STEERING ANGLE SENSOR — BLACK 4 WAY

3 BR 20 GROUND
THROTTLE BODY — BLACK 6 WAY

1 BL 18 THROTTLE CONTROL MOTOR 1
2 VT 20 5 VOLT SUPPLY
3 GY 20 SENSOR GROUND
4 BK 18 THROTTLE CONTROL MOTOR 2
5 WT 20 THROTTLE POSITION SENSOR SIGNAL 2
6 YL 20 THROTTLE POSITION SENSOR SIGNAL 1
TOW - AWAY ALARM SWITCH — BLACK 3 WAY

2 RD/DG 20 TOW - AWAY ALARM SWITCH SENSE
4 — — —
6 WT/DG 20 TOW - AWAY ALARM SWITCH 9 VOLT SUP-
PLY
TRANSMISSION CONTROL MODULE C1 — BLACK 18 WAY

1 DG 20 SCI TRANSMIT
2 — — —
3 — — —
4 — — —
5 — — —
6 — — —
7 — — —
8 — — —
9 — — —
10 — — —
23 — — —
24 — — —
25 — — —
26 — — —
27 — — —
28 — — —
30 BR 18 GROUND

12 WT 20 N2 INPUT SPEED SENSOR
13 BL/DG 20 SENSOR SUPPLY VOLTAGE
14 GY/RD 20 1-2/4-5 SOLENOID CONTROL
15 GY/VT 20 3-4 SOLENOID CONTROL
16 GY/DG 20 2-3 SOLENOID CONTROL
17 GY/BK 20 TCC SOLENOID CONTROL
34 BL/YL 20 TEMP SENSOR P/N SWITCH
35 BK 20 N3 INPUT SPEED SWITCH
36 DG/YL 20 MODULATION PRESSURE SOLENOID CON-
TROL
37 DG 20 SHIFT PRESSURE SOLENOID CONTROL
38 RD 20 SOLENOID SUPPLY VOLTAGE

H WT 20 CAN HIGH
L DG 20 CAN LOW
TRANSMISSION SOLENOID ASSEMBLY — BLACK 13 WAY

1 BK 20 N3 INPUT SPEED SENSOR
2 DG/YL 20 MODULATION PRESSURE SOLENOID CON-
TROL
3 WT 20 N2 INPUT SPEED SENSOR
4 BL/YL 20 TEMP SENSOR P-N SWITCH
5 — — —
6 RD 18 SOLENOID SUPPLY VOLTAGE
7 BL/DG 20 SENSOR SUPPLY VOLTAGE
8 GY/DG 20 2-3 SOLENOID CONTROL
9 GY/VT 20 3-4 SOLENOID CONTROL
10 DG 20 SHIFT PRESSURE SOLENOID CONTROL
11 GY/BK 20 TCC SOLENOID CONTROL
13 GY/RD 20 1-2/3-4 SOLENOID CONTROL
UNIVERSALGARAGE DOOR OPENER/ TIRE PRESSURE MONITOR — WHITE 6 WAY

2 GY/YL 20 LOW TIRE PRESSURE WARNINGINDICATOR
CONTROL
3 BR 20 GROUND
5 RD/GY 20 FUSED B(+)
6 — — —
WASHER FLUID LEVEL SWITCH — BLACK 2 WAY

1 BR 20 GROUND
2 BR/BL 20 WASHER FLUID LEVEL SWITCH OUTPUT
FRONT WASHER PUMP — BLACK 2 WAY

2 BR 18 GROUND
ZH 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION
This section provides illustrations identifying connector, ground and splice locations in the vehicle. Connector,
ground and splice indexes are provided. Use the wiring diagrams in each section for connector, ground and splice
identification. Refer to the appropriate index for the proper figure number. For items that are not shown in this sec-
tion N/S is placed in the Fig. column.
CONNECTORS
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
A/C Compressor BK Lower Left Side of Engine 11
A/C Pressure Sensor BK Behind the Left Front Headlamp N/S
A/C Heater Control Module BK Center of Instrument Panel 16
Accelerator Pedal Position
BK Top of Accelerator Pedal N/S
Sensor
Air Pump Fuse On the Relay Control Module 8
Air Pump Relay In the Relay Control Module 8
Air Pump Switchover Solenoid BK Front of Engine 12
Airbag Off Indicator Lamp BK Center of Instrument Panel N/S
Ambient Temperature Sensor BK Lower Left Grille N/S
Antenna C1 BK Underside of Lower Liftgate N/S
Antenna C2 BK Underside Lower Liftgate N/S
Anti-Theft Switch BK Center of Instrument Panel 16
Anti-Theft Tow Sensor BK Right Rear Lower Luggage Compartment 3
Ash Receiver Lamp BK Center of Instrument Panel N/S
Automatic Day/Night Mirror BK Top of Windshield N/S
Back-Up Lamp Switch (M/T) BK Right Side of Transmission 14
BAS Brake Booster C1 BK Left Rear of Engine Compartment N/S
BAS Brake Booster C2 BK Left Rear of Engine Compartment N/S
Battery Right Rear of Engine Compartment 9
Blower Motor BK Under Passenger Side of Instrument Panel N/S
In Control Module Box at Right Rear of Engine
Body Control Module C1 GY 8
Compartment
Body Control Module C2 BK 8
Compartment
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION ZH
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Body Control Module C3 GY 8
Compartment
Body Control Module C4 BK 8
Compartment
Brake Fluid Level Switch BK Left Rear of Engine Compartment 1
Left Rear of Engine Compartment at Rear of
Brake Lamp Relay YL 4
Underhood Accessory Fuse Block
Brake Lamp Switch A (A/T) BK Top of Brake Pedal N/S
Brake Lamp Switch A (M/T) BK Top of Brake Pedal N/S
Brake Lamp Switch B (A/T) BK Top of Brake Pedal N/S
Brake Lamp Switch B (M/T) BK Top of Brake Pedal N/S
Left of Steering Column Behind the Instrument
C100 BK N/S
Panel
Left Rear of Engine Compartment Under the
C105 BK 4
In the Control Module Box at Right Rear of
C106 BK 8
Engine Compartment
C200 BK N/S
Panel
C201 BK Behind the Passenger Footwell 2
C204 BL Behind the Passenger Footwell 2
C210 (MALE) BK Behind the Passenger Footwell 2
C210 (FEMALE) RD Behind the Passenger Footwell 2
C211 BL Behind the Passenger Footwell 2
C219 OR Behind the Passenger Footwell 2
C223 (MALE) YL Lower Driver Side Behind Kickpanel N/S
C223 (FEMALE) BK Lower Driver Side Behind Kickpanel N/S
C224 (MALE) YL Lower Passenger Side Behind Kickpanel 5
C224 (FEMALE) BK Lower Passenger Side Behind Kickpanel 5
C226 OR N/S
Panel
C227 BL N/S
Panel
C228 BK Lower Driver Side Behind Kickpanel N/S
C229 BK Lower Driver Side Behind Kickpanel N/S
C230 BK Lower Passenger Side Behind Kickpanel 5
C231 BK Lower Passenger Side Behind Kickpanel 5
Left of Steering Column Behind Instrument
C232 RD N/S
Panel
Camshaft Position Sensor BK Right Front of Engine 11
Cargo Lamp BK Left Rear of the Luggage Compartment N/S
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Center High Mounted Stop
VT Top of the Liftgate N/S
Lamp (CHMSL)
Central Locking Pump/Security
BK Right Rear of the Luggage Compartment 3
System Module C1
System Module C2
System Module C3
System Module C4
Charcoal Canister Shutoff
BK Under the Right Rear in Front of the Axle N/S
Valve
Cigar Lighter BK Center of the Instrument Panel N/S
Clockspring BK Center of the Steering Wheel N/S
Clutch Interlock Switch (M/T) BK Top of the Clutch Pedal N/S
Clutch Pedal Position Switch
BK Top of the Clutch Pedal N/S
(M/T)
Coil On Plug No. 1 BK On the Right Valve Cover N/S
Coil On Plug No. 4 BK On the Left Valve Cover 11
Console Switch Group BK Center of the Instrument Panel 16
Controller Antilock Brake BK Left Rear of Engine Compartment 1
Coolant Circulation Pump BK Below Right Headlamp N/S
Right Rear of Engine Compartment in Front of
Coolant Circulation Valve BK 9
Control Module Box
Right Front of Engine Compartment Below
Coolant Level Sensor BK 9
Coolant Recovery Reservoir
Crankshaft Position Sensor NAT Rear of Engine 13
Data Link Connector BK Under Driver Side Instrument Panel N/S
Dome Lamp BK Top Center of Windshield N/S
Driver Airbag Squib YL Center of Steering Wheel N/S
Driver Cylinder Lock Switch BK Driver Door N/S
Driver Power Seat Switch BK Side of Driver Seat N/S
Driver Seat Belt Switch BK Side of Driver Seat N/S
Driver Seat Belt Tensioner
YL Driver Seat Belt Tensioner N/S
Squib
Driver Seat Belt Tensioner
BK Driver Seat Belt Tensioner N/S
Switch
EGR Solenoid BK Rear of Engine 13
Electric Air Pump BK Front of Engine 12
Engine Control Fuse 1 On the Relay Control Module 8
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Engine Control Fuse 2 On the Relay Control Module 8
Engine Control Relay In the Relay Control Module 8
Engine Coolant Temperature
BK Front of Engine 12
Sensor
Right Rear of Engine Compartment in Front of
Engine Fuse Block 8
Battery
Engine Starter Motor Right Lower Side of Engine N/S
ESP Brake Pressure Sensor 1 BK Left Rear of Engine Compartment 1
ESP Brake Pressure Sensor 2 BK Left Rear of Engine Compartment 1
ESP Lateral Acceleration
BK Under the Center Console 7
Sensor
ESP Off Switch BK Center of Instrument Panel 16
ESP Yaw Rate Sensor BK Under the Center Console 7
Evaporator Temperature
BK Right Side of Driver Footwell N/S
Sensor
EVAP Purge Solenoid BK Left Side of Engine Compartment 1
Fuel Injector No. 1 BK Right Side of Intake Manifold N/S
Fuel Injector No. 4 BK Left Side of Intake Manifold 11
Fuel Level Sensor BK Top of Fuel Tank N/S
Fuel Pump Under the Right Rear in Front of the Axle N/S
Fuel Pump Fuse On the Relay Control Module 8
Fuel Pump Relay In the Relay Control Module 8
Fuel Tank Pressure Sensor BK Top of Fuel Tank N/S
Generator BK Right Front of Engine 11
Glove Box Lamp WT Passenger Side of Instrument Panel N/S
Glove Box Switch BK Passenger Side of Instrument Panel N/S
Center of Instrument Panel to the Rear of the
Heated Seat Module BK N/S
Heated Seat Switches
Heater Core Temperature
BK Behind the Center of the Instrument Panel N/S
Sensor
Hood Ajar Switch BK Part of the Hood Latch N/S
Horn Fuse On the Relay Control Module 8
Horn No. 1 Behind Grille N/S
Horn No. 2 Behind Grille N/S
Horn Relay In the Relay Control Module 8
Horn Switch Center of Steering Wheel N/S
Ignition Switch BK Right of Steering Column N/S
Illumination Control Module A BK Left of Steering Column N/S
Illumination Control Module B BK Left of Steering Column N/S
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Illumination Control Module D VT Left of Steering Column N/S
Illumination Control Module E BK Left of Steering Column N/S
Instrument Cluster C1 BK Above Steering Column N/S
Instrument Cluster C2 BK Above Steering Column N/S
Key In Ignition Switch WT Under Ignition Key Cylinder N/S
Kickdown Switch BK Under Accelerator Pedal N/S
Left Door Ajar Switch WT Rear of Left Door N/S
Left Fog Lamp WT Left Front of Fascia Below Headlamp N/S
Left Front Brake Pad Wear
BK Left Front Brake Caliper N/S
Sensor
Left Front Door Speaker BK Lower Front of Left Door N/S
Left Front Door Tweeter BK Upper Front of Left Door N/S
Left Front Lamp Assembly BK Left Front of Vehicle N/S
Left Front Power Window
BK Inside Center of Left Door N/S
Motor
Left Front Power Window
BK Center Console N/S
Switch
Left Front Side Marker Lamp BK Left Front Fender N/S
Left Front Wheel Speed
BK Behind the Left Front Wheel N/S
Sensor
Left Heated Seat Back BK Left Seat Back N/S
Left Heated Seat Cushion BK Left Seat Cushion N/S
Left Knock Sensor BK Under Intake Manifold N/S
Left Park Lamp BK Left Corner of Lamp Assembly N/S
Left Power Mirror BK Top Front of Left Door N/S
Left Rear Lamp Assembly BK Left Rear of Vehicle N/S
Left Rear Side Marker Lamp BK Left Corner of Rear Fascia N/S
Left Rear Speaker BK In Back of Left Seat N/S
Left Rear Wheel Speed Sensor BK Left Brake Backing Plate N/S
Left Side Airbag Squib YL Rear of Left Door N/S
Left Side Impact Sensor YL Under Carpet Below Left Seat N/S
License Lamp No. 1 BK Below Liftgate N/S
License Lamp No. 2 BK Below Liftgate N/S
Liftgate Lock Switch BK Below Liftgate N/S
MAF/IAT Sensor WT Rear of Engine 13
Manifold Absolute Pressure
BK Front of Engine 12
Sensor
Multi-Function Switch BK Left Side of Steering Column N/S
Engine Compartment Above Intake Manifold
Noise Suppressor 1 N/S
Taped to Wire Harness
Engine Compartment Above Intake Manifold
Noise Suppressor 2 N/S
Taped to Wire Harness
Occupant Restraint Controller OR Under the Center Console 7
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Oil Sensor (Level,
BK Lower Right Side of Engine Oil Pan N/S
Temperature, Quality)
Oxygen Sensor 1/1 Upstream BK Rear of Left Exhaust Manifold N/S
Oxygen Sensor 1/2
BK Exhaust Pipe Rear of Catalytic Converter N/S
Downstream
Oxygen Sensor 2/1 Upstream BK Rear of Right Exhaust Manifold N/S
Oxygen Sensor 2/2
BK Exhaust Pipe Rear of Catalytic Converter N/S
Downstream
Park Brake Switch Base of Park Brake Lever N/S
Passenger Airbag On/Off
BK Passenger Side of Instrument Panel N/S
Switch
Passenger Airbag Squib YL Passenger Side of Instrument Panel N/S
Passenger Power Seat Switch BK Side of Passenger Seat N/S
Passenger Seat Belt Tensioner
YL Passenger Seat Belt Tensioner N/S
Squib
Passenger Seat Belt Tensioner
BK Passenger Seat Belt Tensioner N/S
Switch
Passenger Seat Occupant
YL Behind the Passenger Footwell 2
Simulator C1
Passenger Seat Occupant
YL Behind the Passenger Footwell 2
Simulator C2
Power Amplifier A BK Behind the Passenger Footwell 2
Power Amplifier B BK Behind the Passenger Footwell 2
Power Mirror Switch BK Center Console N/S
Left Side of Steering Column Under Instrument
Power Seat Relay BK N/S
Panel
Powertrain Control Module C1 BK 8
Compartment
Compartment
Compartment
Compartment
Compartment
Left Rear of Engine Compartment at Side of
Pulse Module A BK 4
Left Rear of Engine Compartment at Side of
Pulse Module F GY 4
Radiator Fan Control Module NAT Left Front of Engine Compartment 9
Radiator Fan Motor BK Front of Engine Compartment N/S
Radio BK Center of the Instrument Panel N/S
Rear Fog Lamp (Export) In Left Rear Lamp Assembly N/S
Rear Spoiler Limit Switch BK Below the Rear Spoiler N/S
Rear Spoiler Motor BL Below the Rear Spoiler N/S
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
Rear Spoiler Switch BK Center of the Instrument Panel N/S
Right Rear Passenger Compartment Taped to
Rear Window Capacitor N/S
Wire Harness
Rear Window Defogger Rear Window N/S
Recirculated Air Switchover
GY Lower Passenger Instrument Panel N/S
Valve
Relay Control Module A BK 8
Compartment
Relay Control Module B BK 8
Compartment
Relay Control Module C BK 8
Compartment
Relay Control Module D BK 8
Compartment
Relay Control Module E GY 8
Compartment
Left Rear of Engine Compartment at Rear of
Remote Keyless Entry Relay BK 4
Right Door Ajar Switch WT Rear of Right Door N/S
Right Fog Lamp WT Right Front of Fascia Below Headlamp N/S
Right Front Brake Pad Wear
BK Right Front Brake Caliper N/S
Sensor
Right Front Door Speaker BK Lower Front of Right Door 5
Right Front Door Tweeter BK Upper Front of Right Door 5
Right Front Lamp Assembly BK Right Front of Vehicle N/S
Right Front Power Window
BK Inside Center of Right Door 5
Motor
Right Front Power Window
BK Center Console N/S
Switch
Right Front Side Marker Lamp BK Right Front Fender N/S
Right Front Wheel Speed
BK Behind the Right Front Wheel N/S
Sensor
Right Heated Seat Back BK Right Seat Back N/S
Right Heated Seat Cushion BK Right Seat Cushion N/S
Right Knock Sensor BK Under Intake Manifold N/S
Right Park Lamp BK Right Corner of Lamp Assembly N/S
Right Power Mirror BK Top Front of Right Door N/S
Right Rear Lamp Assembly BK Right Rear of Vehicle 3
Right Rear Side Marker Lamp BK Right Corner of Rear Fascia 3
Right Rear Speaker BK In Back of Right Seat N/S
Right Rear Wheel Speed
BK Right Brake Backing Plate N/S
Sensor
Right Side Airbag Squib YL Rear of Right Door 5
Right Side Impact Sensor YL Under Carpet Below Right Seat N/S
Sentry Key Antenna Ring BK On Ignition Key Cylinder N/S
CONNECTOR NAME/
COLOR LOCATION FIG.
NUMBER
BK Behind Instrument Cluster N/S
Module C1
WT Behind Instrument Cluster N/S
Module C2
BK Behind Instrument Cluster N/S
Module C3
Shift Lever Assembly (A/T) BK Center Console 7
Short Runner Valve Solenoid BK Front of Engine N/S
Siren BK Base of Windshield Under Cowl Grille N/S
Speed Control Switch BK Left Side of Steering Column N/S
Steering Angle Sensor BK Left Side of Steering Column N/S
Throttle Body BK Rear of Engine N/S
Traction System Fuse On the Relay Control Module 8
Traction System Relay In the Relay Control Module 8
Transmission Control Module
BK Behind the Passenger Footwell 2
C1
C2
C3
Transmission Solenoid
BK Bottom of Automatic Transmission N/S
Assembly (A/T)
Underhood Accessory Fuse
Left Rear of Engine Compartment 1
Block
Universal Garage Door
WT Top Center of Windshield 6
Opener/Tire Pressure Monitor
Washer Fluid Level Switch BK Behind Right Front Wheelwell Splash Shield N/S
Washer Pump Motor BK Behind Right Front Wheelwell Splash Shield N/S
Wiper Motor Base of Windshield Under Cowl Grille N/S
GROUNDS
GROUND LOCATION FIG.

G100 Left Side of Engine Compartment N/S
G101 Right Side of Engine Compartment 8
G104 Top Front of Engine N/S
G107 Right Side of Engine Compartment, Battery Negative Ground 8
G200 Behind Left Side of Instrument Panel at Base of Windshield N/S
G201 Lower Left Footwell Behind Kickpanel N/S
G202 Under the Center Console at the Occupant Restraint Controller 7
G203 Under the Center Console 7
G204 Lower Right Footwell Behind Kickpanel 5
G205 Upper Left Rear Passenger Compartment N/S
G206 Lower Right Footwell Behind Kickpanel 5
G300 Left Luggage Compartment Behind Trim Panel N/S
G301 Lower Right Luggage Compartment Behind Trim Panel 3
G303 Upper Right Luggage Compartment Behind Trim Panel 3
SPLICES
SPLICE LOCATION FIG.

S101 Engine Compartment on Top Left of Intake Manifold N/S
S103 Right Rear of Engine Compartment in the Control Module Box 10
S105 Engine Compartment at the Front of Intake Manifold N/S
S106 Engine Compartment Behind the Engine N/S
S116 Left of Steering Column Behind the Instrument Panel N/S
S117 Left of Steering Column Behind the Instrument Panel N/S
S121 Engine Compartment at the Front of Intake Manifold N/S
S124 (A/T) Engine Compartment Behind the Engine N/S
S125 (A/T) Engine Compartment Behind the Engine N/S
S211 Behind the Instrument Cluster N/S
S215 Behind the Upper Instrument Panel N/S
SPLICE LOCATION FIG.

At the End of the Sentry Key Remote Entry Module (SKREEM)
S218 N/S
Antenna
S219 Behind the Lower Instrument Panel N/S
S225 Behind Passenger Footwell N/S
S232 Under the Center Console 7
S233 Lower Passenger Side Behind Kickpanel N/S
S241 Part of the Left Seat Assembly N/S
S242 Part of the Left Seat Assembly N/S
S243 Part of the Right Seat Assembly N/S
S244 Part of the Right Seat Assembly N/S
S246 (M/T) Behind Passenger Footwell N/S
S305 Right Rear Passenger Compartment Behind Headliner N/S
Left Rear of Engine Compartment Behind the Underhood Accessory
Splice Block 100 4
Fuse Block
Splice Block 101 4
Fuse Block
Splice Block 102 4
Fuse Block
Splice Block 200 Under the Center Console 7
Fig. 1 MODULE OVERVIEW

Fig. 2 LEFT SIDE ENGINE COMPARTMENT
Fig. 3 RIGHT SIDE FLOOR

Fig. 4 RIGHT SIDE TRUNK
Fig. 5 LEFT SIDE ENGINE COMPARTMENT (PULSE MODULE)

Fig. 6 RIGHT SIDE DOOR (Left hand similar)

Fig. 7 CENTER CONSOLE
Fig. 8 RIGHT SIDE ENGINE COMPARTMENT

Fig. 9 ENGINE COMPARTMENT
Fig. 10 RIGHT SIDE ENGINE COMPARTMENT SPLICES

Fig. 11 ENGINE SIDE VIEW
Fig. 12 ENGINE FRONT VIEW

Fig. 13 ENGINE REAR
Fig. 14 MANUAL TRANSMISSION

Fig. 15 AUTOMATIC TRANSMISSION
Fig. 16 INTERIOR
8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION REMOVAL ...................... .......4

DESCRIPTION . . . . . . . . ..................1 INSTALLATION . . . . . . . . . . . . . . . . . . . .......4
OPERATION . . . . . . . . . . ..................1 UNDERHOOD ACCESSORY FUSE BLOCK
ENGINE FUSE BLOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .5
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 REMOVAL ...................... . . . . . . .5
REMOVAL ........... . . . . . . . . . . . . . . . . . .2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .3 FUSE BLOCK
RELAY CONTROL MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . .......6
DESCRIPTION . . . . . . . . ..................3 OPERATION . . . . . . . . . . . . . . . . . . . . . .......6
OPERATION . . . . . . . . . . ..................3
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and optional power distribution components used on this model. Refer to
the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair
procedures, details of wire harness routing and retention, connector pin-out information and location views for the
various wire harness connectors, splices and grounds.
OPERATION
The power distribution system for this vehicle is designed to provide safe, reliable, centralized and convenient to
access distribution of the electrical current required to operate all of the many standard and optional factory-installed
electrical and electronic powertrain, chassis, safety, comfort and convenience systems. At the same time, these sys-
tems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the
additional current requirements of many aftermarket vehicle accessory and convenience items.
These power distribution systems also incorporate various types of circuit control and protection features, including:
• Fuses
• Fuse cartridges
• Fusible links
• Automatic resetting circuit breakers
• Relays
• Flashers
• Timers
• Circuit splice blocks
The power distribution system for this vehicle consists of the following components:
• Engine Fuse Block
• Underhood Accessory Fuse Block
• Illumination Control Module
• Relay Control Module
Following are general descriptions of the major components in the power distribution system. Refer to the owner’s
manual for more information on the features, use and operation of all of the power distribution system components.
ENGINE FUSE BLOCK

DESCRIPTION
All of the electrical current distributed throughout the vehicle is directed through the Engine Fuse Block. The Engine
Fuse Block houses three maxi-type bolt in fuses. The Engine Fuse Block is located in front of the control module
box, next to the windshield wiper solvent fill tube.
OPERATION
All of the current from the battery and the generator output enters the Engine Fuse Block through the cable and
eyelet that are secured with a nut to the Engine Fuse Block B(+) terminal stud located on one end of the Engine
Fuse Block housing. The Engine Fuse Block terminal stud cover is unlatched and opened or removed to access the
fuses.
REMOVAL
1. Disconnect and isolate the negative battery cable.
2. Open the lid (1) of the engine fuse block.
3. Remove the nuts and the electrical leads to the engine fuse
block.
4. Close the lid to the engine fuse block.
5. Push the tab at the front of the engine fuse block box and
remove it from the vehicle.
INSTALLATION
1. Install the engine fuse onto the studs.
2. Install the plate and the electrical lead to the engine fuse
block.

4. Close the lid (1) to the engine fuse block.
5. Close the hood.

DESCRIPTION
The Relay Control Module controls many of the vehicle relays. The Relay Control Module is located inside the con-
trol module box. The Relay Control Module can not be serviced and it must be replaced as a unit.
OPERATION
The Relay Control Module is a solid state device containing the following internal relays.
• Air Pump Relay
• Engine Control Relay
• Traction System Relay
• Horn Relay
• Fuel Pump Relay
REMOVAL

2. Open the lid to the control module box.
3. Move the wires away to the side of the box to access the clip (1) that holds the relay control module in the
control module box.
4. Push the clip (1) back away from the relay control module and lift the relay control module out of the control
module box.
5. Remove all of the relay harness connectors from the relay control module.
INSTALLATION
1. Install the relay control module harness connectors to the relay control module.
2. Install the relay control module into the control module box, pushing the relay control module down until the clips
snaps.
3. Install the control module box lid.
UNDERHOOD ACCESSORY FUSE BLOCK

DESCRIPTION
The Underhood Accessory Fuse Block houses many of the fuses for the vehicles electrical system. The Underhood
Accessory Fuse Block is located on the left side of the engine compartment just in front of the brake booster. The
Underhood Accessory Fuse Block can not be serviced it must be replaced as a unit.
OPERATION
All of the circuits entering and leaving the Underhood Accessory Fuse Block do so through seperate wires. There
are NO seperate wiring harness connectors that connect to the Underhood Accessary Fuse Block. Each circuit is
connected individually to the Underhood Accesssory Fuse Block, and held in place by the use of retention combs.
REMOVAL

2. Remove the lid to the underhood accessory fuse block.
3. Push the front of the underhood accessory fuse box forward releasing the tabs (1) on the underhood fuse block.
4. Pull the underhood accessory fuse block out of the box and remove all of the underhood accessory fuse block
harness connectors.
INSTALLATION
1. Install the harness connectors to the underhood accessory fuse block.
2. Push the underhood accessory fuse block down into the box until the rear tabs and the front two tabs connect.
3. Install the lid.
FUSE BLOCK
DESCRIPTION
The fuse block is part of the illumination control module. A knob on the face of the module controls the exterior
lighting functions. The exterior lighting and headlamp switch portions of the illumination control module cannot be
adjusted or repaired. If faulty or damaged, the entire module assembly must be replaced as a unit. Refer to Page
8L-105.
OPERATION
The Fuse Block on the side of the Illumination Control Module houses the fuses for the following:
• Fuse 2. Brake Lamp
• Fuse 3. Right High Beam/High Beam Indicator Lamp
• Fuse 4. Reverse Lamp/Turn Signal Lamp/Rear View Mirror
• Fuse 5. Left High Beam
• Fuse 6. Right Low Beam
• Fuse 7. Right Parking/Tail Lamp Side Marker
• Fuse 8. Left Low Beam
• Fuse 9. Fog Lamp
• Fuse 10. Left Parking/Tail Lamp Side Marker
• Fuse 11. License Plate/Instrument Cluster Lighting/Symbol Lighting
• Fuse 12. Rear Fog Lamp (Export Only)
ZH ENGINE 9-1
ENGINE
TABLE OF CONTENTS
page page
ENGINE - ELECTRICAL DIAGNOSTICS . . . . . . . . . . 1 ENGINE - SERVICE INFORMATION . . . . . . . . . . 581
ENGINE - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
ENGINE - ELECTRICAL DIAGNOSTICS (P0132) O2 SENSOR 1/1 CIRCUIT HIGH . . . . 93

DIAGNOSIS AND TESTING (P0133) O2 SENSOR 1/1 SHORT DELAY
(P0040) 1/1 AND 2/1 O2 SENSOR HARNESS TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CONNECTORS REVERSED . . . . . . . . . . . . . . 5 (P0133) O2 SENSOR 1/1 LONG
(P0101) MAF SENSOR PERFORMANCE . . . . . 8 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 99
(P0102) MASS AIR FLOW CIRCUIT . . . . . . . . 10 (P0133) O2 SENSOR 1/1 LONG DELAY TIME . 101
(P0103) MAF SENSOR CIRCUIT LOW . . . . . . 17 (P0133) O2 SENSOR 1/1 SHORT
(P0104) MAF SENSOR THROTTLE ANGLE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 103
AND SPEED . . . . . . . . . . . . . . . . . . . . . . . . . 19 (P0134) O2 SENSOR 1/1 CIRCUIT OPEN . . 105
(P0106) MAP SENSOR PERFORMANCE . . . . 21 (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
(P0107) MAP SENSOR CIRCUIT LOW . . . . . . 24 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
(P0108) MAP SENSOR CIRCUIT HIGH . . . . . 29 (P0135) O2 SENSOR 1/1 HEATER
(P0112) INTAKE AIR TEMPERATURE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 109
SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . 31 (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
(P0113) INTAKE AIR TEMPERATURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . 36 (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
(P0116) ENGINE COOLANT TEMPERATURE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
SENSOR PERFORMANCE. . . . . . . . . . . . . . . 40 (P0137) O2 SENSOR 1/2 BELOW
(P0116) ENGINE COOLANT TEMPERATURE THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . . 119
SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . 47 (P0137) O2 SENSOR 1/2 ABOVE
SENSOR CIRCUIT LOW . . . . . . . . . . . . . . . . 49 (P0137 O2 SENSOR 2/2 ABOVE
SENSOR CIRCUIT HIGH . . . . . . . . . . . . . . . . 51 (P0137) O2 SENSOR 2/2 BELOW
(P0120) ELECTRONIC THROTTLE THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . . 127
CONTROL MOTOR PERFORMANCE . . . . . . . 53 (P0138) O2 SENSOR 1/2 CIRCUIT HIGH . . . 129
(P0120) THROTTLE POSITION SENSOR 1/2 (P0138) O2 SENSOR 1/2 CIRCUIT OPEN . . 131
CORRELATION . . . . . . . . . . . . . . . . . . . . . . . 59 (P0138) O2 SENSOR 2/2 CIRCUIT LOW . . . 133
(P0121) APPS 5-VOLT SUPPLY CIRCUIT . . . . 61 (P0138) O2 SENSOR 2/2 CIRCUIT OPEN . . 135
(P0122) APPS SIGNAL #1 CIRCUIT LOW . . . 65 (P0140) O2 SENSOR 1/2 CIRCUIT LOW . . . 137
(P0123) APPS SIGNAL #1 CIRCUIT HIGH . . . 70 (P0140) O2 SENSOR 2/2 CIRCUIT HIGH . . . 139
(P0128) FORCED LIMITED POWER (P0141) O2 SENSOR 1/2 HEATER CIRCUIT
EXCESSIVE HIGH COOLANT TEMP . . . . . . . 74 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
(P0128) THERMOSTAT RATIONALITY . . . . . . 78 (P0141) O2 SENSOR 1/2 HEATER CIRCUIT
(P0131) O2 SENSOR 1/1 CIRCUIT LOW . . . . 86 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9-2 ENGINE - ELECTRICAL DIAGNOSTICS ZH
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT (P0175) FUEL SYSTEM 2/1

HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 OVERCORRECTION OF FUEL MIXTURE
(P0141) O2 SENSOR 1/2 HEATER (OFF IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . . 230
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 147 (P0175) FUEL SYSTEM 2/1 LEAN CONTROL
(P0151) O2 SENSOR 2/1 CIRCUIT LOW . . . 149 BELOW LIMIT (AT IDLE) . . . . . . . . . . . . . . . . 233
(P0152) O2 SENSOR 2/1 CIRCUIT HIGH . . . 151 (P0200) FUEL INJECTOR CIRCUIT . . . . . . . 236
(P0153) O2 SENSOR 2/1 LONG (P0201) FUEL INJECTOR #1 CIRCUIT . . . . . 238
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 153 (P0202) FUEL INJECTOR #2 CIRCUIT . . . . . 242
(P0153) O2 SENSOR 2/1 LONG DELAY TIME . 155 (P0203) FUEL INJECTOR #3 CIRCUIT . . . . . 244
(P0153) O2 SENSOR 2/1 SHORT DELAY (P0204) FUEL INJECTOR #4 CIRCUIT . . . . . 246
TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 (P0205) FUEL INJECTOR #5 CIRCUIT . . . . . 248
(P0153) O2 SENSOR 2/1 SHORT (P0206) FUEL INJECTOR #6 CIRCUIT . . . . . 250
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 159 (P0211) THROTTLE ACTUATOR STUCK . . . 252
(P0154) O2 SENSOR 2/1 CIRCUIT OPEN . . 161 (P0211) THROTTLE ACTUATOR STUCK . . . 257
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT (P0221) APPS SENSOR #1 AND #2
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 VOLTAGE CORRELATION . . . . . . . . . . . . . . 262
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT (P0221) IDLE SPEED PERFORMANCE . . . . 266
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 (P0221) ELECTRONIC THROTTLE
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT CONTROL MODULE PERFORMANCE . . . . . 270
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 (P0221) ELECTRONIC THROTTLE
(P0155) O2 SENSOR 2/1 HEATER CONTROL MODULE PROCESSOR . . . . . . . 272
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 169 (P0222) APPS SIGNAL #2 CIRCUIT LOW . . . 274
(P0161) O2 SENSOR 2/2 HEATER (P0223) APPS SIGNAL #2 CIRCUIT HIGH . . 279
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 171 (P0300) MULTIPLE CYLINDER MISFIRE . . . 283
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT (P0301) CYLINDER #1 MISFIRE ........ . 294
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 (P0302) CYLINDER #2 MISFIRE ........ . 304
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 (P0304) CYLINDER #4 MISFIRE ........ . 312
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 (P0306) CYLINDER #6 MISFIRE ........ . 320
(P0171) FUEL SYSTEM 1/1 (P0325) KNOCK SENSOR #1 CIRCUIT LOW . . 324
UNDERCORRECTION OF FUEL MIXTURE (P0325) KNOCK SENSOR #1 CIRCUIT HIGH . 328
(OFF IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . . 179 (P0330) KNOCK SENSOR #2 CIRCUIT HIGH . 330
(P0171) FUEL SYSTEM 1/1 RICH CONTROL (P0330) KNOCK SENSOR #2 CIRCUIT LOW . . 332
OVER LIMIT (AT IDLE) . . . . . . . . . . . . . . . . . 183 (P0335) CRANKSHAFT POSITION SENSOR
(P0171) FUEL SYSTEM 1/1 RICH CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
OVER LIMIT (AT LOAD) . . . . . . . . . . . . . . . . 187 (P0341) CAMSHAFT POSITION TIMING
(P0172) FUEL SYSTEM 1/1 OVER-RETARDED . . . . . . . . . . . . . . . . . . . . 340
OVERCORRECTION OF FUEL MIXTURE (P0341) CAMSHAFT POSITION TIMING
(AT IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 OVER-ADVANCED . . . . . . . . . . . . . . . . . . . . 344
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL (P0341) CAMSHAFT POSITION SENSOR
BELOW LIMIT (AT LOAD) . . . . . . . . . . . . . . . 199 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 346
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL (P0400) EGR SYSTEM PERFORMANCE . . . 350
BELOW LIMIT (AT IDLE) . . . . . . . . . . . . . . . . 207 (P0403) EGR CONTROL CIRCUIT . . . . . . . . 354
(P0173) FUEL SYSTEM 2/1 RICH CONTROL (P0410) SECONDARY AIR INJECTION
OVER LIMIT (AT LOAD) . . . . . . . . . . . . . . . . 211 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
OVER LIMIT (AT IDLE) . . . . . . . . . . . . . . . . . 218 RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 362
OVER LIMIT (AT LOAD) . . . . . . . . . . . . . . . . 221 SWITCHOVER SOLENOID CIRCUIT . . . . . . 365
(P0174) FUEL SYSTEM 2/1 LEAN CONTROL (P0422) CATALYTIC 1/1 EFFICIENCY .... . 369
BELOW LIMIT (AT LOAD) . . . . . . . . . . . . . . . 224 (P0432) CATALYTIC 2/1 EFFICIENCY .... . 372
(P0174) FUEL SYSTEM 2/1 (P0440) GENERAL EVAP SYSTEM FAILURE . . 374
UNDERCORRECTION OF FUEL MIXTURE (P0441) EVAP PURGE VALVE . . . . . . . . . . . 376
(OFF IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . . 227 (P0442) EVAP SYSTEM SMALL LEAK . . . . . 378
(P0445) EVAP PURGE SOLENOID CIRCUIT . . 380
ZH ENGINE - ELECTRICAL DIAGNOSTICS 9-3
(P0446) CHARCOAL CANISTER SHUTOFF (P0740) TRANSMISSION CONTROL

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 479
(P0446) EVAP PURGE SOLENOID STUCK (P0743) TRANSMISSION CONTROL
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 481
(P0451) FUEL TANK PRESSURE SENSOR (P0748) TRANSMISSION CONTROL
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 390 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 483
CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . 395 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 485
CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . 397 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 487
(P0455) EVAP SYSTEM LARGE LEAK . . . . . 399 (P0763) TRANSMISSION CONTROL
(P0457) EVAP PURGE VALVE LEAKING .. . 406 SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 489
(P0460) FUEL LEVEL SENSOR CIRCUIT . . . 408 (P1386) KNOCK SENSOR SYSTEM FAILURE . 491
(P0500) NO VEHICLE SPEED SIGNAL (CAB (P1600) ROUGH ROAD DETECTED ..... . 493
CAN MESSAGE) . . . . . . . . . . . . . . . . . . . . . 410 (P2513) ENHANCED ACCIDENT REPORT
(P0500) VEHICLE SPEED PERFORMANCE DRIVER CIRCUIT HIGH . . . . . . . . . . . . . . . . 499
ESP MIL REQUEST . . . . . . . . . . . . . . . . . . . 412 (P2513) ENHANCED ACCIDENT REPORT
(P0561) BATTERY SYSTEM VOLTAGE ... . 414 DRIVER CIRCUIT LOW . . . . . . . . . . . . . . . . 504
(P0562) BATTERY SYSTEM LOW . . . . . . . . 417 (P2545) ESP TORQUE MANAGEMENT
(P0563) BATTERY SYSTEM HIGH . . . . . . . . 419 REQUEST PERFORMANCE . . . . . . . . . . . . . 506
(P0571) STOP LAMP SWITCH CAN SIGNAL (P2561) HVAC CONTROL MODULE
LOST TO TRANS PERFORMANCE . . . . . . . 421 REQUESTED MIL ILLUMINATION . . . . . . . . 512
(P0571) STOP LAMP SWITCH SIGNAL COOLING FAN CONTROL CIRCUIT OPEN . 514
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 423 COOLING FAN CONTROL CIRCUIT HIGH . . 517
(P0600) INCORRECT CAN MESSAGE FROM COOLING FAN CONTROL CIRCUIT LOW . . 519
EIS CONTROL MODULE . . . . . . . . . . . . . . . 425 ENGINE OIL SENSOR LEVEL
(P0600) NO CAN MESSAGE FROM CAB PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 521
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 ENGINE OIL SENSOR OVER
(P0600) NO TRANSMISSION BUS TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 526
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 433 ENGINE OIL SENSOR PERFORMANCE .. . 531
(P0600) LOST COMM WITH ELECTRIC ENGINE OIL SENSOR QUALITY
GEAR SHIFT MODULE (SLA) . . . . . . . . . . . . 439 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 533
(P0600) NO CLUSTER BUS MESSAGE . . . . 445 ENGINE OIL SENSOR WATER
(P0602) PCM PROGRAMMED INCORRECT CONTAMINATION . . . . . . . . . . . . . . . . . . . . 538
TRANS/NO COMM FROM TCM . . . . . . . . . . 451 SAFETY FUEL SHUT OFF DETECTED ... . 540
(P0700) TRANSMISSION CONTROL SHORT RUNNER SOLENOID CIRCUIT HIGH . 545
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 453 SHORT RUNNER SOLENOID CIRCUIT LOW . . 549
(P0702) TRANSMISSION CONTROL SHORT RUNNER SOLENOID CIRCUIT . . . . 551
MODULE LOW VOLTAGE . . . . . . . . . . . . . . . 455 SPEED CONTROL SWITCH INPUT CIRCUIT . . 553
(P0702) TRANSMISSION CONTROL *CHECKING FUEL DELIVERY . . . . . . . . . . . 556
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 457 *CHECKING HARD START (FUEL SYSTEM) . 560
(P0702) LOSS OF TORQUE MANAGEMENT *ENGINE CRANKS BUT DOES NOT START . 563
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 *INTERMITTENT NO CRANK . . . . . . . . . . . . 567
(P0702) TCM TORQUE MANAGEMENT POWERTRAIN VERIFICATION TEST – VER
REQUEST PERFORMANCE . . . . . . . . . . . . . 461 1 ................................ . 569
(P0705) SLA CONTROL SYSTEM (MIL POWERTRAIN VERIFICATION TEST – VER
REQUEST) . . . . . . . . . . . . . . . . . . . . . . . . . . 463 2 ................................ . 570
(P0705) TRANSMISSION CONTROL POWERTRAIN VERIFICATION TEST – VER
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 465 3 ................................ . 571
(P0715) TRANSMISSION CONTROL POWERTRAIN VERIFICATION TEST – VER
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 467 4 ................................ . 572
(P0720) TRANSMISSION INCORRECT POWERTRAIN VERIFICATION TEST – VER
TORQUE REQUEST FROM ESP . . . . . . . . . 469 5 ................................ . 573
(P0720) TRANSMISSION CONTROL SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 574
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 475
(P0730) TRANSMISSION CONTROL
SYSTEM (MIL REQUEST) . . . . . . . . . . . . . . 477

(P0040) 1/1 AND 2/1 O2 SENSOR HARNESS CONNECTORS REVERSED
(P0040) 1/1 AND 2/1 O2 SENSOR HARNESS CONNECTORS REVERSED — CONTINUED
• Set Condition: At key on, the Powertrain Control Module (PCM) checks the voltage on the ground side of
the O2 Sensor harness connector. If the voltage is higher than two volts, this code will set.
POSSIBLE CAUSES
1/1 O2 SENSOR HARNESS IS CONNECTED TO THE 2/1 O2 SENSOR
For a complete Powertrain Control Module (PCM) Circuit Diagram Refer to Page 9-574.
Diagnostic Test
1. POWERTRAIN CONTROL MODULE

Verify that the upstream O2 Sensors harness connectors are connected to
the correct O2 Sensor and repair as necessary.
With the DRB IIIT, erase all PCM DTCs.
Start and let the engine idle.
If the DTC does not set right away it may be necessary to test drive the
vehicle.
Did DTC (P0040) 1/1 AND 2/1 O2 SENSOR HARNESS CONNEC-

TORS REVERSED set again?
Yes >>
Note: Before continuing, verify the front O2 Sensor harness connec-
tors are connected to the correct O2 Sensor with no damage or ter-
minal push out. Repair as necessary.
If OK, replace and program the Powertrain Control Module.
Refer to Page 8E-56.
No >> Go To 2
(P0040) 1/1 AND 2/1 O2 SENSOR HARNESS CONNECTORS REVERSED — CONTINUED
minal connections can set DTCs.Using the wiring diagram/schematic
as a guide, inspect the wiring and connectors specific to this DTC.
Wiggle the wires while checking for shorts and/or open circuits.
Were any problems found?

(P0101) MAF SENSOR PERFORMANCE
(P0101) MAF SENSOR PERFORMANCE — CONTINUED
• When Monitored: With the engine running and no fault in the throttle valve actuator.
• Set Condition: The Mass Air Flow (MAF) Sensor value is less than 16 kg/h when the throttle valve angle
is greater than 14° for approximately 5 seconds, or the MAF Sensor reading is greater than a calculated
value that is determined by engine speed and throttle valve angle for approximately 5 seconds.
POSSIBLE CAUSES

FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED TO GROUND
MASS AIR FLOW SENSOR SIGNAL CIRCUIT OPEN
MASS AIR FLOW SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
5-VOLT SUPPLY CIRCUIT OPEN
5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
MASS AIR FLOW SENSOR
Diagnostic Test
1. CHECK FOR CURRENT DTC

With the DRB IIIT, read the PCM DTCs.
Is this DTC present?

Yes >> For complete diagnosis of this DTC, refer to (P0102) MASS
AIR FLOW CIRCUIT.
No >> Go To 2

Wiggle the wires while checking for shorts and open circuits.

9 - 10 ENGINE - ELECTRICAL DIAGNOSTICS ZH
(P0102) MASS AIR FLOW CIRCUIT
ZH ENGINE - ELECTRICAL DIAGNOSTICS 9 - 11
(P0102) MASS AIR FLOW CIRCUIT — CONTINUED
POSSIBLE CAUSES

Diagnostic Test

Note: If the PCM detects and stores a DTC, the PCM also stores the
engine/vehicle operating conditions under which the DTC was set.
Some of these conditions are displayed on the DRB IIIT at the same
time the DTC is displayed.
Note: Before erasing stored DTCs, record these conditions. Attempt-
ing to duplicate these conditions may assist when checking for an
active DTC.
With the DRB IIIT, erase PCM DTCs.
Note: It maybe necessary to road test the vehicle for this DTC to set.

Yes >> Go To 2
No >> Go To 14
2. JUMPER THE MAF SENSOR SIGNAL AND 5-VOLT SUPPLY
CIRCUITS

Disconnect the MAF/IAT Sensor harness connector.
Connect a jumper wire between the MAF Sensor Signal circuit and the
With the DRB IIIT, read the MAF Sensor voltage.

Yes >> Go To 10
No >> Go To 3
3. CHECKING THE 5-VOLT SUPPLY

Remove the jumper wire between the MAF Sensor Signal circuit and the
Measure the voltage between ground and the 5-Volt Supply circuit.

Yes >> Go To 7
No >> If the voltage is above 5.2 Go To 6
If the voltage is below 4.7 Go To 4
4. 5-VOLT SUPPLY CIRCUIT OPEN

Measure the resistance of the 5-Volt Supply circuit.

Yes >> Go To 5
No >> Repair the 5-Volt Supply circuit for an open.
2.
5. 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND

No >> Replace and program the Powertrain Control Module.
VER 2.
6. 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the 5-Volt Supply circuit at the MAF Sensor har-
ness connector.

Yes >> Repair the 5-Volt Supply circuit for a short to voltage.
VER 2.
7. MAF SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the MAF Sensor Signal circuit.

Yes >> Go To 8
No >> Repair the MAF Sensor Signal circuit for an open.
2.
8. MAF SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
Measure the resistance between ground and the MAF Sensor Signal cir-
cuit.

Yes >> Repair the MAF Sensor Signal circuit for a short to ground.
No >> Go To 9
9. MAF SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the MAF Sensor Signal circuit at the MAF Sensor
harness connector.

Yes >> Repair the MAF Sensor Signal circuit for a short to voltage.
No >> Go To 13
10. CHECKING THE FUSED ENGINE CONTROL RELAY OUTPUT

CIRCUIT

Connect a 12-volt test light between ground and the Fused Engine Control
Relay Output circuit.
Note: The test light must illuminate brightly. Compare the brightness
to when connected directly to B(+).
Does the test light illuminate brightly?

Yes >> Go To 11
an open.
2.
11. CHECK THE SENSOR GROUND CIRCUIT

Yes >> Go To 13
No >> Go To 12

Measure the resistance of the Sensor Ground circuit.

to Page 8E-56.
VER 2.
13. CHECKING FOR AIR RESTRICTIONS OR LEAKS

Note: Check for any of the following conditions:
• Restricted air intake ducts.
• Misaligned air intake ducts.
• Dirty air cleaner element.
• Deteriorating air cleaner element.
• Any objects blocking the air inlet screen of the MAF Sensor.
• Any debris on the sensing elements.
• A restricted exhaust system.

No >> Replace the MAF Sensor. Refer to Page 14-37.
VER 2.
Using the wiring diagrams as a guide, inspect the wiring and connectors
specific to this circuit. Wiggle the wires while checking for shorts and/or
open circuits.
Note: Check for any of the following conditions:
• Restricted air intake ducts.
• Misaligned air intake ducts.
• Dirty air cleaner element.
• Deteriorating air cleaner element.
• Any objects blocking the air inlet screen of the MAF Sensor.
• Any debris on the sensing elements.
• A restricted exhaust system.

No >> Test Complete.
(P0103) MAF SENSOR CIRCUIT LOW
(P0103) MAF SENSOR CIRCUIT LOW — CONTINUED
POSSIBLE CAUSES

Diagnostic Test


AIR FLOW CIRCUIT.
No >> Go To 2


(P0104) MAF SENSOR THROTTLE ANGLE AND SPEED
(P0104) MAF SENSOR THROTTLE ANGLE AND SPEED — CONTINUED
POSSIBLE CAUSES

Diagnostic Test


AIR FLOW CIRCUIT.
No >> Go To 2


(P0106) MAP SENSOR PERFORMANCE
(P0106) MAP SENSOR PERFORMANCE — CONTINUED
• When Monitored: Engine running for at least 30 seconds and no fault in the throttle valve actuator.
• Set Condition: Low limit: The Manifold Absolute Pressure (MAP) Sensor reading is 0 mbar (0 in HG)
when the throttle valve angle is greater than 80° for approximately 5 seconds. High limit: The MAP Sensor
reading is greater than a calculated value that is determined by engine speed and throttle valve angle for
approximately 5 seconds.
POSSIBLE CAUSES
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT OPEN

MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
5 VOLT SUPPLY CIRCUIT OPEN
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND
5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
MANIFOLD ABSOLUTE PRESSURE SENSOR
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0107) MAP
SENSOR CIRCUIT LOW.
No >> Go To 2
(P0106) MAP SENSOR PERFORMANCE — CONTINUED

(P0107) MAP SENSOR CIRCUIT LOW
(P0107) MAP SENSOR CIRCUIT LOW — CONTINUED
• Set Condition: Low limit: The Manifold Absolute Pressure (MAP) Sensor reading is 0 mbar (0 in. Hg)
when the throttle valve angle is greater than 80° for approximately 5 seconds. High limit: The MAP Sensor
reading is greater than a calculated value that is determined by engine speed and throttle valve angle for
approximately 5 seconds.
POSSIBLE CAUSES
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT OPEN

MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
5 VOLT SUPPLY CIRCUIT OPEN
5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND
For a complete Powertrain Control Module Circuit Diagram Refer to Page 9-574.
Diagnostic Test

active DTC.

Yes >> Go To 2
No >> Go To 8
2. JUMPER THE MAP SENSOR SIGNAL AND 5-VOLT SUPPLY
CIRCUITS

Disconnect the MAP Sensor harness connector.
Connect a jumper wire between the MAP Sensor Signal circuit and the
With the DRB IIIT, read the MAP Sensor voltage.

Yes >> Replace the MAP Sensor. Refer to Page 14-42.
No >> Go To 3

Remove the jumper wire.
Measure the voltage of the 5-Volt Supply circuit at the MAP Sensor har-
ness connector.

Yes >> Go To 6
No >> Go To 4

Measure the resistance of the 5-Volt Supply circuit from the MAP Sensor

Yes >> Go To 5
2.

VER 2.
6. MAP SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the MAP Sensor Signal circuit from the PCM
harness connector to the MAP Sensor harness connector.

Yes >> Go To 7
No >> Repair the MAP Sensor Signal circuit for an open.
2.
7. MAP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the MAP Sensor Signal cir-
cuit.

Yes >> Repair the MAP Sensor Signal circuit for a short to ground.
VER 2.
The condition that caused this DTC to set is currently not present. Inspect
the related wiring harness for a possible intermittent condition.
Using the wiring diagrams as a guide, inspect the wiring and connectors
specific to this DTC. Wiggle the wires while checking for shorts and/or
open circuits.

(P0108) MAP SENSOR CIRCUIT HIGH
(P0108) MAP SENSOR CIRCUIT HIGH — CONTINUED
• Set Condition: The MAP Sensor reading is greater than a calculated value that is determined by engine
speed and throttle valve angle for approximately 5 seconds.
POSSIBLE CAUSES
1

MANIFOLD ABSOLUTE PRESSURE SENSOR GROUND CIRCUIT OPEN
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0107) MAP
SENSOR CIRCUIT LOW.
No >> Go To 2


(P0112) INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW
(P0112) INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW — CONTINUED
• Set Condition: The Intake Air Temperature (IAT) Sensor reading is less than 0.1 volt for approximately 1
second.
POSSIBLE CAUSES
INTAKE AIR TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN

INTAKE AIR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
INTAKE AIR TEMPERATURE SENSOR
Diagnostic Test
1. PRE-DIAGNOSTIC CHECK OUT

Note: Always perform diagnostics with a fully charged battery.
Note: Check for applicable TSBs related to the problem.
connectors. Repair as necessary.
Perform this procedure prior to symptom diagnosis.

Continue
Go To 2

ing to duplicate these conditions may assist when checking for a
DTC.

Yes >> Go To 3
No >> Go To 9
3. JUMPER THE IAT SENSOR SIGNAL AND 5-VOLT SUPPLY
CIRCUITS

Connect a jumper wire between the IAT Sensor Signal circuit and the
With the DRB IIIT, monitor the IAT Sensor voltage.

Yes >> Replace the MAF/IAT Sensor. Refer to Page 14-37.
No >> Go To 4


Yes >> Go To 7
No >> Go To 5

Measure the resistance of the 5-Volt Supply circuit.

Yes >> Go To 6
2.

No. >> Replace and program the Powertrain Control Module.
Refer to Page 8E-56
VER 2.
7. IAT SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the IAT Sensor Signal circuit.

Yes >> Go To 8
No >> Repair the IAT Sensor Signal circuit for an open.
2.
8. IAT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the IAT Sensor Signal circuit.

Yes >> Repair the IAT Sensor Signal circuit for a short to ground.
Refer to Page 8E-56
VER 2.

(P0113) INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH
(P0113) INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH — CONTINUED
• Set Condition: The Intake Air Temperature (IAT) Sensor reading is greater than 4.93 volts for approxi-
mately 1 second.
POSSIBLE CAUSES
INTAKE AIR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
Diagnostic Test


Continue
Go To 2

active DTC.

Yes >> Go To 3
No >> Go To 8
3. IAT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
With the DRB IIIT, read the IAT Sensor voltage.
Is the voltage below 0.3 volts?

Yes >> Go To 4
No >> Repair the IAT Sensor Signal circuit for a short to volt-
age.
2.
4. CHECK THE SENSOR GROUND CIRCUIT

Connect a 12-volt test light between B(+) and the Sensor Ground circuit.
Note: The test light must illuminate brightly. Compare the brightness
to when connected directly to a body ground.

Yes >> Go To 6
No >> Go To 5

Disconnect PCM harness connector.
Measure the resistance of the Sensor Ground circuit.

to Page 8E-56.
VER 2.

Yes >> Repair the 5-Volt Supply circuit for a short to voltage.
No >> Go To 7
7. JUMPER THE IAT SENSOR SIGNAL AND 5-VOLT SUPPLY

CIRCUITS

Connect a jumper wire between the IAT Sensor Signal circuit and the
With the DRB IIIT, read the IAT Sensor voltage.

Yes >> Replace the IAT Sensor. Refer to Page 14-37.
VER 2.

and open circuits.

(P0116) ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE
(P0116) ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE — CONTINUED
• Set Condition: LOW LIMIT: The ECT Sensor value is less than –39°C (-38°F ) for more than 1 second.
HIGH LIMIT: The ECT Sensor value is more than 170°C (338°F) for more than 1 second. CLOSED LOOP
TEMPERATURE NOT REACHED: The engine coolant temperature does reach 15°C (60°F) in a predeter-
mined time. Failure time varies from 2 to 20 Min and is calculated from start up temperature, engine speed,
and ambient temperature.
POSSIBLE CAUSES
ENGINE COOLANT TEMPERATURE (ECT) SENSOR SIGNAL CIRCUIT OPEN

ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE COOLANT TEMPERATURE SENSOR GROUND CIRCUIT OPEN
IMPROPER COOLANT LEVEL
Diagnostic Test

Note: Low engine coolant level can be the cause of this DTC. If the
fluid level is low locate and repair any leaks before diagnosing this
DTC.
Note: Check for applicable TSBs.

Continue
Go To 2
2. MONITOR THE ECT SENSOR TEMPERATURE
With the DRB IIIT, monitor the ECT Sensor temperature value.
Choose a conclusion that best matches the ECT Temp value.

If the value is greater than 169°C (336°F).
Go To 3
If the value is less than –39°C (-38°F ).
Go To 5
If the temp value is within normal operating range.
Go To 10
3. ECT SENSOR
Disconnect the ECT Sensor harness connector.
With the DRB IIIT, monitor the ECT Sensor temperature.
Is the value less than -38°C (-36°F)?

Yes >> Replace the ECT Sensor. Refer to Page 7-29.
No >> Go To 4
4. ECT SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

Measure the voltage of the ECT Sensor Signal circuit at the ECT harness
connector.

Yes >> Repair the ECT Sensor Signal circuit for a short to voltage.
VER 2.
5. ECT SENSOR
Connect a jumper wire between the ECT Sensor Signal circuit and the
ECT Sensor Ground circuit.
With the DRB IIIT, monitor the ECT Sensor temperature.
Is the value at or above 170°C (338°F)?

Yes >> Replace the ECT Sensor. Refer to Page 7-29.
No >> Go To 6
6. OPEN ECT SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the voltage of the ECT Sensor 5-Volt Supply circuit at the ECT
Is the voltage between 4.5 - 5.2 volts?

Yes >> Go To 8
No >> Go To 7
7. OPEN ECT SENSOR 5-VOLT SUPPLY CIRCUIT

Disconnect PCM C3 harness connector.
Measure the resistance of the ECT 5-Volt Supply circuit from the ECT har-
ness connector and the PCM C3 harness connector.
Is the resistance less than 5.0 ohms?

to Page 8E-56.
No >> Repair the ECT Sensor 5-Volt Supply circuit for an
open.
VER 2.
8. ECT SENSOR SIGNAL CIRCUIT SHORT TO GROUND
Measure the resistance between ground and ECT Sensor Signal circuit.

Yes >> Repair the ECT Sensor Signal circuit for a short to ground.
No >> Go To 9
9. OPEN ECT SENSOR SIGNAL CIRCUIT

Measure the resistance of the ECT Sensor Signal circuit from the ECT
harness connector and the PCM C3 harness connector.

to Page 8E-56.
No >> Repair the ECT Sensor Signal circuit for an open.
VER 2.
10. CHECKING THE COOLANT LEVEL AND CONDITION

WARNING: NEVER OPEN THE COOLING SYSTEM WHEN THE
ENGINE IS HOT. THE SYSTEM IS UNDER PRESSURE. EXTREME
BURNS OR SCALDING MAY RESULT. ALLOW THE ENGINE TO COOL
BEFORE OPENING THE COOLING SYSTEM.
Check the coolant level and condition.
Is the coolant level and condition OK?

Yes >> Go To 11
No >> Locate and repair any coolant leaks and add the neces-
sary amount of coolant.
2.
11. ECT SENSOR RANGE
Note: This test works best on a cold engine.
With the DRB IIIT, read the ECT Sensor value. If the vehicle was allowed
to sit overnight, the value should be reasonably close to the ambient tem-
perature.
Note: If engine coolant temperature is above 85°C (185°F), allow the
engine to cool until at least 65°C (150°F).
Start the engine.
During engine warm-up monitor the ECT Sensor value as well as the
actual engine temperature with a thermometer. The ECT temperature
value in the DRB IIIT should transition smoothly from start-up to operating
temperature.
Note: As the engine warms to operating temperature, the actual cool-
ant temperature and the ECT value in the DRB IIIT should stay rela-
tively close to each other.
Did the ECT value in the DRB IIIT and the actual temperature stay
relatively close to each other?
Yes >> Go To 12
No >> Replace the ECT Sensor. Refer to Page 7-29.
2.
12. CHECKING COOLANT THERMOSTAT OPERATION

Remove the thermostat.
Using the appropriate service information, perform thermostat diagnosis.
Did the thermostat open at the proper temperature and to the

proper stroke?
Yes >> Go To 13
No >> Replace the thermostat. Refer to Page 7-23
2.
minal connections can set DTC’s.
and open circuits.

(P0116) ENGINE COOLANT TEMPERATURE SENSOR SHORT CIRCUIT
(P0116) ENGINE COOLANT TEMPERATURE SENSOR SHORT CIRCUIT — CONTINUED
• Set Condition: The ECT Sensor value is more than 170°C (338°F) for more than 1 second.
POSSIBLE CAUSES

Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0116)
ENGINE COOLANT TEMPERATURE SENSOR PERFOR-
MANCE.
No >> Go To 2


(P0117) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
(P0117) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW — CONTINUED
• Set Condition: The ECT Sensor value is less than –39°C (-38°F ) for more than 1 second.
POSSIBLE CAUSES
ENGINE COOLANT TEMPERATURE (ECT) SENSOR SIGNAL CIRCUIT OPEN

Diagnostic Test


MANCE.
No >> Go To 2


(P0118) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH
(P0118) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH — CONTINUED
• Set Condition: The ECT Sensor value is more than 170°C (338°F) for more than 1 second.
POSSIBLE CAUSES

IMPROPER COOLANT LEVEL
Diagnostic Test


MANCE.
No >> Go To 2


(P0120) ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE
(P0120) ELECTRONIC THROTTLE CONTROL MOTOR PERFORMANCE — CONTINUED
• When Monitored: Ignition on with no MAP Sensor DTCs set.
• Set Condition: TP Sensor signals in the Throttle Body Assembly do not correlate to the MAP Sensor
signal.
POSSIBLE CAUSES
TP SENSOR SWEEP
TP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
OPEN TP SIGNAL CIRCUIT
OPEN 5-VOLT SUPPLY CIRCUIT
OPEN SENSOR GROUND CIRCUIT
TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO TP SENSOR #2 SIGNAL CIRCUIT
THROTTLE BODY ASSEMBLY
For a complete Powertrain Control Module (PCM) Circuit Diagram, Refer to Page 9-574.
Diagnostic Test

Note: Diagnose any other Throttle Body Assembly DTC(s) before
continuing.
Note: The throttle plate should be free from binding and carbon build
up.
Note: Ensure the throttle plate is at the idle position.
Note: Inspect the engine for vacuum leaks.
DTC.

Yes >> Go To 2
No >> Go To 11
2. TP SENSOR
Connect the Throttle Body harness connector.
With the DRB IIIT, monitor the TP Sensor #1 or #2 voltage.
Connect a jumper wire between the Sensor Ground circuit and the TP
Sensor #1 Signal circuit.
TP Sensor #1 voltage should change from approximately 4.5 volts to 0.5
of a volt?
For TP Sensor #2, connect a jumper wire between 5-volt supply circuit
and the TP Sensor #2 signal circuit.
TP Sensor #2 voltage should change from approximately 0 volts to 5.0
volts?
Note: Remove the jumper wire before continuing.
Is the voltage reading within the listed specifications?

Yes >> Replace the Throttle Body Assembly. Refer to Page 14-48.
No >> Go To 3
3. TP SENSOR #1 AND #2 SIGNAL CIRCUIT SHORTED TO BATTERY

VOLTAGE

Disconnect the Throttle Body Assembly harness connector.
Measure the voltage on the TP #1 Signal and the TP #2 Signal circuits at
the Throttle Body harness connector.

Yes >> Repair the short to voltage in the TP #1 or TP #2 Signal
circuit.
No >> Go To 4
4. RESISTANCE IN THE #1 AND #2 TP SENSOR SIGNAL CIRCUITS
Measure the resistance of the TP Sensor #1 Signal circuit and TP Sensor
#2 Signal circuit from the Throttle Body harness connector to the PCM
harness connector.

Yes >> Go To 5
No >> Repair the excessive resistance in the or TP Sensor Sig-
nal circuit.
2.
5. RESISTANCE BETWEEN GROUND AND THE TP SENSOR SIGNAL

CIRCUIT

Measure the resistance between ground and the TP Sensor #1 Signal cir-
cuit and TP Sensor #2 Signal circuit at the Throttle Body harness connec-
tor.

Yes >> Repair the short to ground in the Sensor #1 or Sensor #2
TP Sensor Signal circuit.
No >> Go To 6
6. RESISTANCE IN THE 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the 5-Volt Supply circuit from the Throttle Body

Yes >> Go To 7
No >> Repair the excessive resistance in the 5-Volt Supply cir-
cuit.
2.
7. RESISTANCE TO GROUND IN THE 5-VOLT SUPPLY CIRCUIT

Yes >> Repair the short to ground in the 5-Volt Supply circuit.
No >> Go To 8
8. OPEN SENSOR GROUND CIRCUIT

Measure the resistance of the Sensor Ground circuit from the Throttle
Body harness connector to the PCM harness connector.

Yes >> Go To 9
2.
9. TP SENSOR #1 SIGNAL CIRCUIT SHORTED TO TP SENSOR #2

SIGNAL CIRCUIT

Measure the resistance of the TP Sensor #1 Signal circuit and the TP
Sensor #2 Signal circuit at the Throttle Body harness connector.

Yes >> Repair the short between the TP Sensor #2 Signal circuit
and the TP Sensor #1 Signal circuit.
No >> Go To 10
10. PCM
Note: Before continuing, check the PCM harness connector terminals
for corrosion, damage, or terminal push out. Repair as necessary.
Using the schematics as a guide, inspect the wire harness and connec-
tors. Pay particular attention to all Power and Ground circuits.
If there are no possible causes remaining, review repair.

Repair >> Replace and program the Powertrain Control Module. Refer
to Page 8E-56.
11. TP SENSOR SWEEP

With the DRB IIIT, monitor the APPS TP Sensor #1 or #2 voltage.
Slowly depress the Pedal from the idle position to the wide open throttle
position.
The voltage for TP Sensor #1 should start at approximately 0.8 of a volt
and increase to above 4.2 volts.
The voltage for TP Sensor #2 should start at approximately 4.2 volts and
decrease to approximately 0.8 of a volt.
Is the voltage within the range of the listed specification for the
appropriate TP Sensor?
Yes >> Go To 12
No >> Replace the Throttle Body Assembly. Refer to Page
14-48.
2.

and open circuits.

(P0120) THROTTLE POSITION SENSOR 1/2 CORRELATION
(P0120) THROTTLE POSITION SENSOR 1/2 CORRELATION — CONTINUED
signal.
POSSIBLE CAUSES
THROTTLE POSITION SENSOR SWEEP

THROTTLE POSITION SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
THROTTLE POSITION SENSOR SIGNAL CIRCUIT OPEN
THROTTLE POSITION SENSOR GROUND CIRCUIT OPEN
THROTTLE POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO THROTTLE POSITION SENSOR #2
SIGNAL CIRCUIT
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0120) ELEC-
TRONIC THROTTLE CONTROL MOTOR PERFOR-
MANCE.
No >> Go To 2


(P0121) APPS 5-VOLT SUPPLY CIRCUIT
(P0121) APPS 5-VOLT SUPPLY CIRCUIT — CONTINUED
• Set Condition: When the PCM recognizes the APPS 5-Volt Supply circuit voltage is below 1.0 volt or
higher than 5.2 volts.
POSSIBLE CAUSES
ACCELERATOR PEDAL POSITION SENSOR 5-VOLT SUPPLY SHORTED TO (B+)

ACCELERATOR PEDAL POSITION SENSOR 5-VOLT SUPPLY SHORTED TO GROUND
ACCELERATOR PEDAL POSITION SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR
For a complete Powertrain Control Module Circuit Diagram, Refer to Page 9-574.
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 6
2. APPS 5-VOLT SUPPLY SHORTED TO GROUND

Disconnect the PCM harness connectors.
Disconnect the APPS Sensor.
Measure the resistance between ground and the APPS 5-Volt Supply cir-
cuit.

Yes >> Repair the short to ground in the APPS 5-Volt Supply cir-
cuit.
No >> Go To 3
3. APPS 5-VOLT SUPPLY SHORTED TO (B+)
Measure the voltage between ground and the APPS 5-Volt Supply circuit
at the APPS harness connector.

Yes >> Repair the APPS 5-Volt Supply circuit short to B(+).
No >> Go To 4
4. OPEN APPS 5-VOLT SUPPLY

Measure the resistance of the APPS 5-Volt Supply circuit from the APPS

Yes >> Go To 5
No >> Repair the APPS 5-Volt Supply circuit for an open.
2.
5. APPS
Connect the PCM harness connectors.
Measure the voltage between ground and the APPS 5-Volt Supply circuit
Signal circuit at the APPS harness connector.

Yes >> Replace the APPS. Refer to Page 14-26.
VER 2.
and open circuits.

(P0122) APPS SIGNAL #1 CIRCUIT LOW
(P0122) APPS SIGNAL #1 CIRCUIT LOW — CONTINUED
• When Monitored: With the ignition on and no other Accelerator Pedal Position Sensor (APPS) #1 DTCs
present.
• Set Condition: When the APPS #1 voltage is too low. Engine will only idle if the Brake pedal is pressed
or has failed. Acceleration rate and Engine output are limited.
POSSIBLE CAUSES
ACCELERATOR PEDAL POSITION SENSOR (APPS) #1 SWEEP

ACCELERATOR PEDAL POSITION SENSOR #1 SIGNAL CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO GROUND
ACCELERATOR PEDAL POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO SENSOR RETURN CIRCUIT
Diagnostic Test
1. APPS BELOW 0.25 OF A VOLT

With the DRB IIIT, read the APPS #1 voltage.
Is the voltage below 0.25 of a volt?

Yes >> Go To 2
No >> Go To 9
2. 5-VOLT SUPPLY CIRCUIT

Disconnect the APPS harness connector.
Measure the voltage of the 5-Volt Supply circuit at the APPS harness con-
nector.

Yes >> Go To 3
No >> Go To 6
3. APPS
Connect a jumper wire between the 5-Volt Supply circuit and the APPS #1
Signal circuit in the Sensor harness connector.
With the DRB IIIT, monitor the APPS #1 voltage.
Note: Remove the jumper wire after this step has been completed.

Yes >> Replace the APPS in accordance with the Service Informa-
tion. Refer to Page 14-26.
No >> Go To 4
4. APPS #1 SIGNAL CIRCUIT OPEN

Disconnect the PCM C4 harness connectors.
Measure the resistance of the APPS #1 Signal circuit from the APPS har-
ness connector to the PCM C4 harness connector terminal.

Yes >> Go To 5
No >> Repair the APPS #1 Signal circuit for an open.
2.
5. APPS SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the APPS #1 Signal circuit.

Yes >> Repair the APPS #1 Signal circuit for a short to ground.
No >> Go To 8
CAUTION: Do not probe the PCM harness connectors. Probing the
PCM harness connectors will damage the PCM terminals resulting in
poor terminal to pin connection. Perform diagnosis by back probing
the terminals of each connector.
Measure the resistance of the 5-Volt Supply circuit from the APPS Sensor

Yes >> Go To 7
2.


No >> Go To 8
8. PCM
If there are no possible causes remaining, view repair.

Repair >> Replace and program the Powertrain Control Module in
accordance with the Service Information. Refer to Page
8E-56.
9. APPS SWEEP
Slowly open the throttle from the idle position to the wide open throttle
position.
Does voltage start at approximately 0.25 of a volt and go above 4.0

volts with a smooth transition?
Yes >> Go To 10
No >> Replace the APPS in accordance with the Service
Information. Refer to Page 14-26.
VER 2.

and open circuits.

(P0123) APPS SIGNAL #1 CIRCUIT HIGH
(P0123) APPS SIGNAL #1 CIRCUIT HIGH — CONTINUED
present.
• Set Condition: When APPS #1 voltage is too high. Engine will only idle if the Brake pedal is pressed or
has failed. Acceleration rate and Engine output are limited.
POSSIBLE CAUSES
ACCELERATOR PEDAL POSITION SENSOR #1 SWEEP
ACCELERATOR PEDAL POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO VOLTAGE
ACCELERATOR PEDAL POSITION SENSOR #1 SIGNAL SHORTED TO 5-VOLT SUPPLY CIRCUIT
ACCELERATOR PEDAL POSITION SENSOR #1 GROUND CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR (APPS) #1
Diagnostic Test
1. APPS #1 VOLTAGE ABOVE 3.5 VOLTS

With the DRB IIIT in Sensors, read the APPS voltage.

Yes >> Go To 2
No >> Go To 7
2. APPS
Connect a jumper wire between the APPS 5-Volt Supply circuit and the
APPS Signal #1 circuit at the APPS harness connector.

Yes >> Replace the Accelerator Pedal Position Sensor. Refer to
Page 14-26.
No >> Go To 3
3. APPS #1 SIGNAL CIRCUIT SHORTED TO VOLTAGE
Measure the voltage of the APPS #1 Signal circuit at the APPS harness
connector.

Yes >> Repair the APPS #1 Signal circuit for a short to voltage.
No >> Go To 4
4. APPS #1 SIGNAL CIRCUIT SHORTED TO 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the APPS #1 Signal circuit and the 5-Volt Sup-
ply circuit at the APPS harness connector.

Yes >> Repair the APPS #1 Signal circuit for a short to the 5-Volt
Supply circuit.
No >> Go To 5
5. OPEN APPS #1 GROUND CIRCUIT

Measure the resistance of the APPS #1 Ground circuit from the APPS har-
ness connector to the PCM C4 harness connector.

Yes >> Go To 6
No >> Repair the APPS #1 Ground circuit for an open.
2.
6. PCM

to Page 8E-56.
7. APPS #1 SWEEP
position.

Yes >> Go To 8
No >> Replace the Accelerator Pedal Position Sensor. Refer to
Page 14-26.
2.

and open circuits.

(P0128) FORCED LIMITED POWER EXCESSIVE HIGH COOLANT TEMP
(P0128) FORCED LIMITED POWER EXCESSIVE HIGH COOLANT TEMP — CONTINUED
• When Monitored: With the ignition on engine running.
• Set Condition: The Engine Coolant Temperature (ECT) Sensor exceeds 130° C (265° F) at the PCM. One
trip Fault
POSSIBLE CAUSES
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

RADIATOR FAN
LOW COOLANT LEVEL
THERMOSTAT OPERATION
Diagnostic Test
1. LOW COOLANT LEVEL

Note: If any ECT or Radiator Fan Control Module DTCs have set
along with this DTC, diagnose them first before continuing.
Note: If a Engine Coolant Temperature (ECT) DTC is set along with
this code, diagnose the ECT DTC first.
Note: Inspect the ECT terminals and related PCM terminals. Ensure
the terminals are free from corrosion and damage.
Note: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
Check the coolant system to make sure that the coolant is in good condi-
tion and at the proper level.

Yes >> Go To 2
No >> Inspect the vehicle for a coolant leak and add the nec-
essary amount of coolant.
Perform POWERTRAIN VERIFICATION TEST VER -
2.
2. THERMOSTAT OPERATION
Note: This test works best if performed on a cold engine (cold soak).
With the DRBIIIT, read the ECT Deg value. If the engine was allowed to
sit overnight (cold soak), the temperature value should be a sensible value
that is somewhere close to the ambient temperature.
engine to cool until 65°C (150°F) is reached.
Start the Engine.
During engine warm-up, monitor the ECT Deg value. The temp deg value
change should be a smooth transition from start up to normal operating
temp 82°C (180°F). Also monitor the actual coolant temperature with a
thermometer.
Note: As the engine warms up to operating temperature, the actual
coolant temperature (thermometer reading) and the ECT Deg in the
DRB IIIT sensor should stay relatively close to each other.
Using the appropriate service information, determine the proper opening
temperature of the thermostat.
Did the thermostat open at the proper temperature?

Yes >> Go To 3
No >> Replace the thermostat. Refer to Page 7-23.
Perform POWERTRAIN VERIFICATION TEST VER -
2.
3. PCM
DTC.

to Page 8E-56.
Perform POWERTRAIN VERIFICATION TEST VER - 2.
No >> Go To 4
and open circuits.

(P0128) THERMOSTAT RATIONALITY
(P0128) THERMOSTAT RATIONALITY — CONTINUED
• When Monitored: With the engine running.
• Set Condition: The PCM predicts a coolant temperature value that it will compare to the actual coolant
temperature. If the two coolant temperature values are not within 10°C (18°F) of each other an error is
detected. Two Trip Fault.
POSSIBLE CAUSES
LOW COOLANT LEVEL

ENGINE COOLANT TEMPERATURE SIGNAL CIRCUIT SHORTED TO VOLTAGE
ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE BELOW 1.0 VOLT
ENGINE COOLANT TEMPERATURE SIGNAL CIRCUIT OPEN
ENGINE COOLANT TEMPERATURE SENSOR GROUND CIRCUIT OPEN
ENGINE COOLANT TEMPERATURE SIGNAL CIRCUIT SHORTED TO GROUND
ENGINE COOLANT TEMPERATURE SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
Diagnostic Test

Note: If any ECT, CMP, IAT or CKP sensor DTCs have set along with
P0128, diagnose them first before continuing.
active DTC.

Yes >> Go To 2
No >> Go To 14
2. CHECKING THE COOLANT LEVEL AND CONDITION
Note: If an Engine Coolant Temperature (ECT) DTC is set along with
this code, diagnose the ECT DTC first.
Note: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
Note: Extremely cold outside ambient temperatures may have caused
this DTC to set.
Check the coolant level and condition.

Yes >> Go To 3
No >> Locate and repair any coolant leaks and add the neces-
sary amount of coolant. Refer to Page 7-18.
2.
3. THERMOSTAT OPERATION
With the DRB IIIT, read the ECT Deg value. If the engine was allowed to
sit overnight (cold soak), the temperature value should be a sensible value
that is somewhere close to the ambient temperature.
Start the Engine.
During engine warm-up, monitor the ECT Deg value. The temperature
degree value change should be a smooth transition from start up to nor-
mal operating temp 82°C (180°F). Also monitor the actual coolant temper-
ature with a thermometer.
Note: As the engine warms up to operating temperature, the actual
coolant temperature (thermometer reading) and the ECT Deg in the
DRB IIIT sensor should stay relatively close to each other.
Using the appropriate service information, determine the proper opening
temperature of the thermostat.
Did the thermostat open at the proper temperature?

Yes >> Go To 4
No >> Replace the Thermostat in accordance with the Service
Information. Refer to Page 7-23 .
2.
4. INTAKE AIR TEMP SENSOR OPERATION
With the DRB IIIT, read and record the IAT Sensor Temperature value
Using the DRB IIIT Temperature Probe #CH7050, measure the ambient air
temperature near the IAT sensor.
Is the IAT Sensor value within 15°C (5°F) of the temperature probe
reading?
Yes >> Go To 5
No >> Go To 7
5. ECT SENSOR OPERATION

WARNING: MAKE SURE THE ENGINE COOLING SYSTEM IS COOL
BEFORE REMOVING THE PRESSURE CAP OR ANY HOSE. SEVERE
PERSONAL INJURY MAY RESULT FROM ESCAPING HOT COOLANT.
THE COOLING SYSTEM IS PRESSURIZED WHEN HOT.
With the DRB IIIT, read and record the ECT Sensor Temperature value
Using the DRB Temperature Probe #CH7050, measure the engine coolant
temperature.
Is the ECT Sensor value within 15°C (5°F) of the temperature probe
reading?
Yes >> Go To 6
No >> Go To 7
6. OTHER POSSIBLE CAUSES
Inspect the Temperature sensors for any physical damage.
Inspect the engine coolant. Ensure the coolant is at the proper level.
Refer to Page 7-18.
Ensure the Temperature sensors are properly mounted.
Ensure the CMP and CKP sensors are mounted properly. Check the con-
nectors for any signs of damage.
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.
Refer to any Technical Service Bulletins (TSBs) that may apply.
With the engine running at normal operating temperature, monitor the
Temperature sensor parameters while wiggling the wire harness. Look for
parameter values to change.
Visually inspect the related wire harness. Look for any chafed, pierced,
pinched, partially broken wires and broken, bent, pushed out, or corroded
terminals.
Inspect and clean all PCM, engine, and chassis grounds.
Were any problems found during the above inspections?

No >> Go To 14
7. SIGNAL CIRCUIT SHORTED TO VOLTAGE

Note: Visually inspect both the component and the PCM connectors.
Look for damage, partially broken wires and backed out or corroded
terminals
Measure the voltage of the ECT Signal circuit at the Temperature Sensor
harness connector.

Yes >> Repair the ECT Signal circuit for a short to voltage.
No >> Go To 8
8. TEMPERATURE SENSOR VOLTAGE ABOVE 4.6 VOLTS
With the DRB IIIT, read the ECT Sensor voltage.

Yes >> Go To 9
No >> Go To 12
9. ECT SENSOR VOLTAGE BELOW 1.0 VOLTS

Using a jumper wire, jumper across the ECT Sensor harness connector.
With the DRB IIIT, read the Coolant Temp voltage.
Is the voltage below 1.0 volt?

Yes >> Replace the ECT Sensor in accordance with the Service
No >> Go To 10
10. SIGNAL CIRCUIT OPEN

Measure the resistance of the ECT Signal circuit from the ECT Sensor

Yes >> Go To 11
No >> Repair the ECT Signal circuit for an open.
2.
Measure the resistance of the Sensor Ground circuit from the ECT Sensor

Yes >> Replace and program the Powertrain Control Module in
8E-56.
No >> Repair the ECT Sensor Ground circuit for an open.
VER 2.
12. SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the ECT Sensor Signal cir-
cuit.

Yes >> Repair the ECT Signal circuit for a short to ground.
No >> Go To 13
13. SIGNAL CIRCUIT SHORTED TO SENSOR GROUND

Measure the resistance between the Sensor Ground and the Signal circuit
at the ECT Sensor harness connector.

Yes >> Repair the ECT Sensor Ground circuit for a short to the
ECT Signal circuit.
No >> Replace and program the Powertrain Control Module
in accordance with the Service Information. Refer to
Page 8E-56.
VER 2.
and open circuits.

(P0131) O2 SENSOR 1/1 CIRCUIT LOW
(P0131) O2 SENSOR 1/1 CIRCUIT LOW — CONTINUED
• When Monitored: With the engine running between 1000 and 2000 RPM, engine load between 15% to 50%,
closed loop mode, the three way catalytic converter temperature is greater than 380°C (716°F), and the O2
sensor heater must be ON for at least 220 seconds to enable the signal inactive portion of the test.
• Set Condition: The high limit: O2 Sensor voltage is greater than 1.5 volts for approximately 5 seconds.
The low limit: O2 Sensor voltage is less than 0.15 volts for approximately 5 seconds. Signal stays at center:
The O2 Sensor voltage stays between 0.4 and 0.6 volts for more than approximately 15 seconds after the
O2 Sensor heater has been ON for at least 220 seconds.
POSSIBLE CAUSES
O2 SENSOR SIGNAL CIRCUIT OPEN

O2 SENSOR SIGNAL CIRCUIT SHORT TO GROUND
O2 SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE
O2 SENSOR GROUND CIRCUIT OPEN
ENGINE EXHAUST LEAK
O2 SENSOR
1. MONITOR THE O2 SENSOR VOLTAGE

With the DRB IIIT, monitor the O2 Sensor Signal voltage of the affected
Sensor.
Is the O2 Sensor voltage greater than 1.4 volts or less than 0.15
volts?
Yes >> If the value is greater than 1.4 volts, Go To 3
If the value is less than 0.15 volts, Go To 5
No >> Go To 2
2. O2 SENSOR VOLTAGE
Start the engine.
Operate the engine above 1200 RPM for 3 minutes and 40 seconds.
With the DRB IIIT, monitor the O2 Sensor Signal voltage.
Does the O2 Sensor voltage stay between 0.4 and 0.6 volts?
Yes >> Go To 11
No >> Go To 7
3. DISCONNECT THE O2 SENSOR

Disconnect the O2 Sensor harness connector of the affected sensor.
Is the O2 Sensor voltage less than 1.4 volts?

Yes >> Replace the affected O2 Sensor. Refer to Page 14-45
No >> Go To 4
4. O2 SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

Is the O2 Sensor voltage greater than 2.0 volts?

Yes >> Repair the O2 Sensor Signal circuit for a short to voltage.
VER 2.
5. DISCONNECT THE O2 SENSOR
Disconnect the O2 Sensor harness connector of the affected sensor.
Is the O2 Sensor voltage more than 0.15 volts?

Yes >>
Note: Determine the cause of any contamination before replacing the
sensor. Inspect for the following before replacing the O2 Sensor.
• Fuel contamination.
• Engine oil or coolant consumption.
• Use of improper RTV sealant.
Replace the O2 Sensor if none of the above conditions
are present. Refer to Page 14-45.
No >> Go To 6
6. O2 SENSOR SIGNAL CIRCUIT SHORT TO GROUND

Measure the resistance between ground or any ground circuit in the PCM
C3 harness connector and the O2 Sensor Signal circuit.
Is there continuity between the O2 Sensor Signal circuit and

ground or any ground circuit in the PCM C3 harness connector?
Yes >> Repair the O2 Sensor Signal circuit for a short to ground or
any ground circuit in the PCM C3 harness connector.
VER 2.
7. O2 SENSOR SYSTEM INSPECTION

Inspect for the following conditions.
• Exhaust leak. Refer to Page 11-3.
• Incorrectly installed O2 Sensor.
• Damaged wiring.
Did you find any of the above conditions?

Yes >> Repair the conditions.
No >> Go To 8
8. JUMPER THE O2 SENSOR
Disconnect the O2 Sensor harness connector of the affected O2 Sensor.
Jumper the O2 Sensor Signal circuit to a ground.
Does the O2 Sensor voltage stay between 0.4 and 0.6 volts?
Yes >> Go To 9
No >> Go To 10
9. O2 SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the O2 Sensor Signal circuit from the O2 Sen-
sor harness connector to the PCM harness connector.

to Page 8E-56.
No >> Repair the O2 Sensor Signal circuit for an open.
VER 2.
10. O2 SENSOR GROUND CIRCUIT OPEN
Measure the resistance of the O2 Sensor ground circuit from the O2 Sen-

Yes >>
Note: Determine the cause of any contamination before replacing the
sensor.Inspect for the following before replacing the O2 Sensor.
• Fuel contamination.
• Engine oil or coolant consumption.
• Use of improper RTV sealant.
Replace the Oxygen Sensor if none of the above condi-
tions are present. Refer to Page 14-45.
No >> Repair the O2 Sensor Ground circuit for an open.
VER 2.


(P0132) O2 SENSOR 1/1 CIRCUIT HIGH
(P0132) O2 SENSOR 1/1 CIRCUIT HIGH — CONTINUED
• Set Condition: O2 Sensor voltage is greater than 1.5 volts for approximately 5 seconds.
POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0131) O2
SENSOR 1/1 CIRCUIT LOW.
No >> Go To 2


(P0133) O2 SENSOR 1/1 SHORT DELAY TIME
(P0133) O2 SENSOR 1/1 SHORT DELAY TIME — CONTINUED
• When Monitored: Start and drive vehicle greater than 32 km/h (20 MPH) and less than 89 km/h (55 MPH).
Throttle open for a minimum 120 seconds. Coolant Temp greater than 70°C (158°F) Catalytic Converter Tem-
perature greater than 600°C (1112°F).
• Set Condition: The O2 sensor voltage switches only 11 times or less from lean to rich within 20 seconds
during monitoring. Two Trip Fault.
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
O2 SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
O2 SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
O2 SENSOR GROUND CIRCUIT SHORTED TO GROUND
O2 SENSOR
Diagnostic Test

Note: It is important to perform the diagnostics on the O2 Sensor
that set the DTC.
Note: Check for contaminates that may have damaged the O2 Sen-
sor: contaminated fuel, unapproved silicone, oil and coolant.
DTC.

Yes >> Go To 2
No >> Go To 5
2. EXHAUST LEAK
Start the engine.
Inspect the exhaust system for leaks between the engine and the O2 Sen-
sors.
Are there any exhaust leaks?

Yes >> Repair or replace the leaking exhaust parts as necessary.
Refer to Page 11-5.
No >> Go To 3
3. O2 SENSOR SIGNAL CIRCUIT

Disconnect the O2 Sensor harness connector.
Measure the voltage on the O2 Sensor Signal circuit at the O2 Sensor
harness connector.
Is the voltage approximately 0.47 volt?

Yes >> Go To 4
No >> Check the O2 Sensor Signal circuit for damage, short to
ground, open, or short to voltage. If OK, replace and pro-
gram the Powertrain Control Module. Refer to Page
8E-56.
2.
4. O2 SENSOR GROUND CIRCUIT

Measure the voltage on the O2 Sensor Ground circuit at the O2 Sensor
harness connector.

Yes >> Check the O2 Sensor Ground circuit for damage, short to
ground, open, or short to voltage. If OK, replace and pro-
gram the Powertrain Control Module. Refer to Page 8E-56.
No >> Replace the Oxygen Sensor. Refer to Page 14-45.
VER 2.
and open circuits.

(P0133) O2 SENSOR 1/1 LONG PERFORMANCE
(P0133) O2 SENSOR 1/1 LONG PERFORMANCE — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

SENSOR 1/1 SHORT DELAY TIME.
No >> Go To 2


(P0133) O2 SENSOR 1/1 LONG DELAY TIME
(P0133) O2 SENSOR 1/1 LONG DELAY TIME — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0133) O2 SENSOR 1/1 SHORT PERFORMANCE
(P0133) O2 SENSOR 1/1 SHORT PERFORMANCE — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0134) O2 SENSOR 1/1 CIRCUIT OPEN
(P0134) O2 SENSOR 1/1 CIRCUIT OPEN — CONTINUED
• Set Condition: O2 Sensor voltage is less than 0.15 volts for approximately 5 seconds. Signal stays at
center: The O2 Sensor voltage stays between 0.4 and 0.6 volts for more than approximately 15 seconds
after the O2 Sensor heater has been ON for at least 220 seconds.
POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


(P0135) O2 SENSOR 1/1 HEATER CIRCUIT LOW
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT LOW — CONTINUED
• When Monitored: Engine Running and Heater duty cycle greater than 0%
• Set Condition: The PCM detects the O2 Heater voltage is out of acceptable range. Below 0.0926 of a
volt.
POSSIBLE CAUSES
O2 HEATER CONTROL SHORTED TO GROUND

O2 HEATER ELEMENT
Diagnostic Test
1. O2 HEATER ELEMENT
Note: Allow the O2 Sensor to cool down to room temperature.
Measure the resistance of the O2 Sensor Heater element at the O2 Sen-
Is the O2 Sensor Heater element resistance between 8.5 and 9.5

ohms?
Yes >> Go To 2
No >> Replace the Oxygen Sensor. Refer to Page 14-45.
2.
2. O2 HEATER CONTROL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the O2 Heater Control circuit.

Yes >> Repair the O2 Heater Control circuit for a short to ground.
No >> Before continuing, check the PCM harness connector
terminals for corrosion, damage, or terminal push out.
Repair as necessary. Replace and program the Pow-
ertrain Control Module. Refer to Page 8E-56.
VER 2.
(P0135) O2 SENSOR 1/1 HEATER PERFORMANCE
(P0135) O2 SENSOR 1/1 HEATER PERFORMANCE — CONTINUED
• When Monitored: Engine Running and Heater duty cycle greater than 0%.
• Set Condition: O2 Heater Temperature does not reach 575°C (959°F) within 90 second during monitoring
conditions. Two Trip Fault.
POSSIBLE CAUSES
O2 SENSOR HEATER FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN

O2 SENSOR HEATER CONTROL CIRCUIT SHORT TO VOLTAGE
O2 SENSOR HEATER CONTROL CIRCUIT SHORT TO GROUND
O2 HEATER CONTROL CIRCUIT OPEN
O2 HEATER ELEMENT
Diagnostic Test

active DTC.

Yes >> Go To 2
No >> Go To 7
2. PCM
Measure the voltage of the O2 Sensor Heater Control circuit at the PCM
harness connector.

to Page 8E-56.
No >> Go To 3
3. O2 SENSOR HEATER CONTROL CIRCUIT SHORT TO GROUND
Measure the resistance between ground and the O2 Sensor Heater Con-
trol circuit.
Is resistance below 100 ohms?

Yes >> Repair the O2 Sensor Heater Control circuit for a short to
ground.
No >> Go To 4
4. O2 SENSOR HEATER CONTROL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the O2 Sensor Heater Control circuit at the O2

Yes >> Repair the O2 Sensor Heater Control circuit for a short to
voltage.
No >> Go To 5
5. O2 SENSOR HEATER CONTROL CIRCUIT OPEN

Measure the resistance of the O2 Sensor Heater Control circuit from the
O2 Sensor harness connector to the PCM harness connector.

Yes >> Go To 6
No >> Repair the O2 Sensor Heater Control circuit for an open.
2.
6. O2 SENSOR HEATER FUSED ENGINE CONTROL RELAY OUTPUT
CIRCUIT

Measure the voltage of the O2 Sensor Heater Fused Engine Control Relay
Output circuit at the O2 Sensor harness connector.

Yes >> Replace the O2 Sensor. Refer to Page 14-45.
No >> Repair the O2 Sensor Heater Fused Engine Control
Relay Output circuit for an open.
VER 2.

and open circuits.

(P0135) O2 SENSOR 1/1 HEATER CIRCUIT HIGH
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT HIGH — CONTINUED
POSSIBLE CAUSES
O2 HEATER ELEMENT
O2 HEATER FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN
Diagnostic Test

active DTC.

Yes >> Go To 3
No >> Go To 2
2. O2 SENSOR HEATER OPERATION

Note: Allow the O2 Sensor to cool down before continuing the test.
Raising the hood may help in reducing under hood temperatures.
With the DRB IIIT, actuate the O2 Heater Test.
With the DRB IIIT, monitor O2 Sensor voltage for at least 2 minutes.
Does the voltage stay above 0.47 volt?

Yes >> Go To 3
No >> Go To 6
3. O2 HEATER ELEMENT
Note: Allow the O2 Sensor to cool down to room temperature. Rais-
ing the hood may help in reducing under hood temperatures.
Measure the resistance of the O2 Sensor Heater element.
Note: O2 Sensor Heater Resistance Specification: 8.5 to 9.5 ohms.
Is the resistance within specifications?

Yes >> Go To 4
No >> Replace the O2 Sensor. Refer to Page 14-45.
2.
4. O2 HEATER FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT

OPEN

Measure the voltage of the O2 Heater Fused Engine Control Relay Output
circuit at the O2 Sensor harness connector.

Yes >> Go To 5
No >> Repair the O2 Heater Fused Engine Control Relay Out-
put circuit for an open.
2.
5. O2 HEATER CONTROL CIRCUIT OPEN

Measure the resistance of the O2 Heater Control circuit from the O2 Sen-

to Page 8E-56.
No >> Repair the O2 Heater Control circuit for an open.
VER 2.

(P0135) O2 SENSOR 1/1 HEATER CIRCUIT OPEN
(P0135) O2 SENSOR 1/1 HEATER CIRCUIT OPEN — CONTINUED
POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


SENSOR 1/1 HEATER CIRCUIT HIGH
No >> Go To 2


(P0137) O2 SENSOR 1/2 BELOW THRESHOLD
(P0137) O2 SENSOR 1/2 BELOW THRESHOLD — CONTINUED
Throttle open for a minimum 120 seconds. Coolant Temp greater than 70°C (158°F) and Catalytic Converter
Temperature greater than 600°C (1112°F).
• Set Condition: The O2 sensor voltage switches only 11 times or less from rich to lean within 20 seconds
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR SIGNAL CIRCUIT
O2 SENSOR GROUND CIRCUIT
O2 SENSOR
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0137 O2
SENSOR 2/2 ABOVE THRESHOLD.
No >> Go To 2


(P0137) O2 SENSOR 1/2 ABOVE THRESHOLD
(P0137) O2 SENSOR 1/2 ABOVE THRESHOLD — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


(P0137 O2 SENSOR 2/2 ABOVE THRESHOLD
(P0137 O2 SENSOR 2/2 ABOVE THRESHOLD — CONTINUED
(P0137) O2 SENSOR 2/2 ABOVE THRESHOLD

POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Note: It is important to perform the diagnostics on the O2 Sensor
that set the DTC.
active DTC.

Yes >> Go To 2
No >> Go To 5
2. EXHAUST LEAK
Start the engine.
Inspect the exhaust system for leaks between the engine and the O2 Sen-
sors. Refer to Page 11-3.

Refer to Page 11-5.
No >> Go To 3
3. O2 SIGNAL CIRCUIT
Turn the ignition off
Measure the voltage on the O2 Signal circuit in the O2 Sensor harness
connector.
Is the voltage approximately 0.47 volt?

Yes >> Go To 4
No >> Check the O2 Signal circuit for damage, short to ground,
open, or short to voltage. If OK, replace and program the
Powertrain Control Module. Refer to Page 8E-56.
2.
4. O2 GROUND CIRCUIT
Measure the resistance of the O2 Ground circuit from the O2 Sensor har-

Yes >> Replace the Oxygen Sensor. Refer to Page 14-45.
No >> Check the O2 Ground circuit for damage, short to
ground, open, or short to voltage. If OK, replace and
program the Powertrain Control Module. Refer to
Page 8E-56.
VER 2.

(P0137) O2 SENSOR 2/2 BELOW THRESHOLD — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


• Set Condition: O2 Sensor voltage is less than 0.15 volts for approximately 5 seconds.
POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


• Set Condition: The high limit: O2 Sensor voltage is greater than 1.5 volts for approximately 5 seconds.
POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


volt.
POSSIBLE CAUSES

O2 HEATER ELEMENT
Diagnostic Test


SENSOR 1/1 HEATER CIRCUIT LOW.
No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

O2 HEATER ELEMENT
Diagnostic Test


SENSOR 1/1 HEATER PERFORMANCE.
No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


(P0153) O2 SENSOR 2/1 LONG PERFORMANCE
(P0153) O2 SENSOR 2/1 LONG PERFORMANCE — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0153) O2 SENSOR 2/1 LONG DELAY TIME
(P0153) O2 SENSOR 2/1 LONG DELAY TIME — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0153) O2 SENSOR 2/1 SHORT DELAY TIME
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0153) O2 SENSOR 2/1 SHORT PERFORMANCE
(P0153) O2 SENSOR 2/1 SHORT PERFORMANCE — CONTINUED
POSSIBLE CAUSES
EXHAUST LEAK
O2 SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


POSSIBLE CAUSES

ENGINE EXHAUST LEAK
O2 SENSOR
Diagnostic Test


No >> Go To 2


volt.
POSSIBLE CAUSES

O2 HEATER ELEMENT
For complete diagnosis of this DTC, refer to (P0135) O2 SENSOR 1/1 HEATER CIRCUIT LOW.
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES

O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


volt.
POSSIBLE CAUSES

O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


POSSIBLE CAUSES
O2 HEATER ELEMENT
Diagnostic Test


No >> Go To 2


(P0171) FUEL SYSTEM 1/1 UNDERCORRECTION OF FUEL MIXTURE (OFF IDLE)
(P0171) FUEL SYSTEM 1/1 UNDERCORRECTION OF FUEL MIXTURE (OFF IDLE) — CONTINUED
• When Monitored: With the engine running in closed loop mode, the ambient/battery temperature above -7°C
(20°F), altitude below 2590m (8500 ft). and fuel level greater than 15%.
• Set Condition: If the PCM multiplies short term compensation by long term adaptive and a certain per-
centage is exceeded for two trips, the MIL illuminates and a trouble code is stored.
POSSIBLE CAUSES
RESTRICTED FUEL SUPPLY LINE

FUEL STRAINER PLUGGED
O2 SENSOR HEATER OPERATION
MANIFOLD ABSOLUTE PRESSURE SENSOR OPERATION
ENGINE COOLANT TEMPERATURE SENSOR OPERATION
ENGINE MECHANICAL PROBLEM
O2 SENSOR
FUEL PUMP
FUEL CONTAMINATION/EXHAUST LEAK
Diagnostic Test


Yes >> For complete diagnosis of this DTC, refer to (P0172) FUEL
SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT LOAD).
No >> Go To 2

(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT IDLE)
(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT IDLE) — CONTINUED
POSSIBLE CAUSES
EVAP PURGE SOLENOID OPERATION

O2 SIGNAL CIRCUIT
O2 SENSOR
FUEL FILTER/PRESSURE REGULATOR
Diagnostic Test


SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT LOAD).
No >> Go To 2

(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT LOAD)
(P0171) FUEL SYSTEM 1/1 RICH CONTROL OVER LIMIT (AT LOAD) — CONTINUED
POSSIBLE CAUSES

O2 SIGNAL CIRCUIT
O2 SENSOR
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 11
2. CHECKING FUEL PRESSURE
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE
(EVEN WITH THE ENGINE OFF). BEFORE TESTING OR SERVICING
ANY FUEL SYSTEM HOSE, FITTING OR LINE, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Install a fuel pressure gauge.
With the DRB IIIT, actuate the Fuel Pump Relay and observe the fuel
pressure gauge.
Note: Fuel pressure specification is 3.7 to 4.2 bar (54 to 61 psi).
CAUTION: Stop All Actuations.
Choose a conclusion that best matches your fuel pressure reading.

Within Specification
Go To 3
Above Specification
Replace the fuel filter/pressure regulator. Refer to Page
14-10.
2.
3. O2 SENSOR OPERATION
Start the engine.
Allow the engine to reach normal operating temperature.
With the DRB IIIT, read the O2 Sensor voltage.
Is the voltage switching between 0.4 and 0.6 volt?

Yes >> Go To 4
No >> Go To 8
4. EVAP PURGE SOLENOID OPERATION
Disconnect the hoses at the Evap Purge Solenoid.
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap
Purge Solenoid vacuum source port on the component side.
Did the Evap Purge Solenoid hold vacuum?

Yes >> Go To 5
No >> Replace the Evap Purge Solenoid. Refer to Page 25-17.
2.
5. MAP SENSOR OPERATION

Connect a Vacuum Gauge to a Manifold Vacuum source.
Start the engine.
Allow the engine to idle.
Note: If engine will not idle, maintain a constant RPM above idle.
With the DRB IIIT in Sensors, read the MAP Sensor vacuum value.
Is the DRB IIIT reading within 33.9 mbar (1 in. Hg) of the Vacuum
Gauge reading?
Yes >> Go To 6
No >> Replace the Manifold Absolute Pressure Sensor. Refer
to Page 14-42.
2.
Note: For this test to be valid, the thermostat must be operating cor-
rectly.
Turn the ignition off until the engine is cold.
With the DRB IIIT, read the Engine Coolant Temperature Sensor value. If
the engine was allowed to sit overnight (cold soak), the temperature value
should be a sensible value that is somewhere close to the ambient tem-
perature.
Start the Engine.
During engine warm-up, monitor the Engine Coolant Temperature value.
The temperature value change should be a smooth transition from start up
to normal operating temperature 82°C (180°F). The value should reach at
least 82°C (180°F).
Did the Engine Coolant Temperature value increase with a smooth

transition and did it reach at least 82°C (180°F)?
Yes >> Go To 7
No >> Replace the Engine Coolant Temperature Sensor. Refer
to Page 7-29.
2.
7. ENGINE MECHANICAL PROBLEM

Check for any of the following conditions/mechanical problems.
AIR INDUCTION SYSTEM - must be free from restrictions.
ENGINE VACUUM - must be at least 13 inches in neutral.
ENGINE VALVE TIMING - must be within specifications.
ENGINE COMPRESSION - must be within specifications.
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
TORQUE CONVERTER STALL SPEED - must be within specifications.
POWER BRAKE BOOSTER - must not have any internal vacuum leaks.
FUEL - must be free of contamination.
FUEL INJECTOR - must not be plugged or restricted; harness connectors
must be connected to the correct injectors.
Are there any engine mechanical problems?

No >> Go To 11
8. O2 SENSOR
With the DRB IIIT, monitor the O2 Sensor voltage.
The O2 Sensor voltage should read 0.47 volts on the DRB IIIT with the
connector disconnected.
Using a jumper wire, jump from the O2 Sensor Signal circuit to the O2
Sensor Ground circuit in the O2 Sensor harness connector.
Note: The voltage should drop from 0.47 volts down to 0.0 volts with
the jumper wire connected.
Did the O2 Sensor voltage drop from 0.47 volts to 0.0 volt?
No >> Go To 9
9. O2 SIGNAL CIRCUIT
Measure the voltage of the O2 Sensor Signal circuit at the O2 Sensor har-
ness connector.

Yes >> Check the O2 Signal circuit for damage, short to ground,
open, or short to voltage. Inspect the O2 Sensor harness
connector and the PCM harness connector. If OK, replace
the Powertrain Control Module. Refer to Page 8E-56.
No >> Go To 10
Measure the voltage of the O2 Sensor Ground circuit at the O2 Sensor
harness connector.

Yes >> Before continuing, check the PCM harness connector termi-
nals for corrosion, damage, or terminal push out. Repair as
necessary. Replace and program the Powertrain Control
Module. Refer to Page 8E-56.
No >> Check the O2 Sensor Ground circuit for damage,
short to ground, open, or short to voltage. Inspect the
O2 Sensor harness connector and the PCM harness
connector. If OK, replace and program the Powertrain
Control Module. Refer to Page 8E-56.
VER 2.


(P0172) FUEL SYSTEM 1/1 OVERCORRECTION OF FUEL MIXTURE (AT IDLE)
(P0172) FUEL SYSTEM 1/1 OVERCORRECTION OF FUEL MIXTURE (AT IDLE) — CONTINUED
POSSIBLE CAUSES

O2 SIGNAL CIRCUIT
O2 SENSOR
Diagnostic Test


No >> Go To 2

(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT LOAD)
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT LOAD) — CONTINUED
POSSIBLE CAUSES

O2 SENSOR
FUEL PUMP
Diagnostic Test

Note: Diagnose any Misfire, Throttle Body, or Accelerator Pedal Posi-
tion Sensor DTC(s) first, if set along with the fuel system DTC.
DTC.

Yes >> Go To 2
No >> Go To 12
pressure gauge.

Go To 3
Below Specification
Go To 11
Start the engine.

Yes >> Go To 4
No >> Go To 8


Yes >> Replace the Oxygen Sensor in accordance with the Service
No >> Go To 5
Start the engine.
Is the DRB IIIT reading within 33.9 mbar (1 in. Hg) of the Vacuum
Gauge reading?
Yes >> Go To 6
No >> Replace the Manifold Absolute Pressure Sensor in accor-
dance with the Service Information. Refer to Page
14-42.
2.

rectly.
Note: This test works best if performed on a cold engine (cold soak)
With the DRB IIIT, read the Engine Coolant Temperature (ECT) Sensor
value. If the engine was allowed to sit overnight (cold soak), the temper-
ature value should be a sensible value that is somewhere close to the
ambient temperature.
Start the Engine.
During engine warm-up, monitor the ECT Sensor value. The temperature
value change should be a smooth transition from start up to normal oper-
ating temperature 82°C (180°F). The value should reach at least 82°C
(180°F).
Did the Engine Coolant Temperature value increase with a smooth

transition and did it reach at least 82°C (180°F)?
Yes >> Go To 7
No >> Replace the Engine Coolant Temperature Sensor in
7-29.
2.
AIR INDUCTION SYSTEM - must be free from leaks.
ENGINE VACUUM - must be at least 13 inches in neutral
ENGINE VALVE TIMING - must be within specifications
ENGINE COMPRESSION - must be within specifications
ENGINE CRANKCASE VENT SYSTEM - must flow freely
TORQUE CONVERTER STALL SPEED - must be within specifications
POWER BRAKE BOOSTER - must not have any internal vacuum leaks.
FUEL - must be free of contamination
FUEL INJECTOR - must not be plugged or restricted; harness connectors
must be connected to the correct injectors.

No >> Go To 12
8. O2 SENSOR
harness connector disconnected.
Yes >> Replace the Oxygen Sensor in accordance with the Service
No >> Go To 9

Yes >> Go To 10
No >> Check the O2 Sensor Signal circuit for a short to ground,
open, or short to voltage. Inspect the O2 Sensor harness
connector and the PCM harness connector. If OK,
replace and program the Powertrain Control Module in
8E-56.
2.

Measure the voltage on the O2 Sensor Ground circuit in the O2 Sensor
harness connector.

Yes >> Check the fuel system for contaminates. Also, check the
exhaust system for any leaks. Refer to Page 11-3.
No >> Check the O2 Sensor Ground circuit for a short to
ground, open, or short to voltage. Inspect the O2 Sen-
sor harness connector and the PCM harness connec-
tor. If OK, replace and program the Powertrain Control
Module in accordance with the Service Information.
VER 2.
11. FUEL STRAINER

PRESSURE MUST BE RELEASED
Remove and inspect the Fuel Strainer.
Is the Fuel Strainer plugged?

Yes >> Replace the Fuel Strainer in accordance with the Service
No >> Replace the Fuel Pump in accordance with the Ser-
vice Information. Refer to Page 14-17.
VER 2.

(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT IDLE)
(P0172) FUEL SYSTEM 1/1 LEAN CONTROL BELOW LIMIT (AT IDLE) — CONTINUED
POSSIBLE CAUSES

O2 SENSOR
FUEL PUMP
Diagnostic Test


No >> Go To 2

POSSIBLE CAUSES

FUEL PUMP
O2 SENSOR
Diagnostic Test

Note: Diagnose any Misfire, Throttle Body, or Accelerator Pedal Posi-
tion Sensor DTC(s) first, if set along with the fuel system DTC.
DTC.

Yes >> Go To 2
No >> Go To 12
With the DRB IIIT, actuate the Fuel Pump and observe the fuel pressure
gauge.

Go To 3
Below Specification
Go To 11
Note: If one of the O2 Sensors Signal or Ground circuits are shorted
to ground or voltage, all the other O2 Sensor voltage readings will be
affected.
Note: After the repairs have been made, verify proper O2 Sensor
operation. If all the O2 Sensor voltage readings have not returned to
normal, follow the diagnostic procedure for the remaining O2 Sen-
sors.
Start the engine.

Yes >> Go To 4
No >> Go To 8

No >> Go To 5

Start the engine.
Is the DRB IIIT reading within 1 inch of the Vacuum Gauge read-
ing?
Yes >> Go To 6
No >> Replace the Manifold Absolute Pressure Sensor. Refer
to Page 14-42.
2.
rectly.
Note: This test works best if performed on a cold engine (cold soak)
Turn the engine off.
With the DRB IIIT, read the Engine Coolant Temperature (ECT) Sensor
value. If the engine was allowed to sit overnight (cold soak), the temper-
ature value should be a sensible value that is somewhere close to the
Start the engine.
During engine warm-up, monitor the ECT Sensor value. The temperature
value change should be a smooth transition from start up to normal oper-
ating temperature 82°C (180°F). The value should reach at least 82°C
(180°F).
Did the ECT value increase with a smooth transition and did it
reach at least 82°C (180°F)?
Yes >> Go To 7
to Page 7-29.
2.

AIR INDUCTION SYSTEM - must be free from leaks.
ENGINE PCV SYSTEM - must flow freely
POWER BRAKE BOOSTER - must not have any internal vacuum leaks
FUEL INJECTOR - must not have a plugged or restricted injector; or con-
trol wire not connected to correct injector

No >> Go To 12
8. O2 SENSOR
harness connector disconnected.
No >> Go To 9


Yes >> Go To 10
No >> Check the O2 Signal circuit for a short to ground, open,
or short to voltage. Inspect the O2 Sensor connector and
the PCM harness connector. If OK, replace and program
2.

Measure the voltage on the O2 Sensor Ground circuit in the O2 Sensor
harness connector.

Yes >> Check the fuel system for contaminates. Also, check the
exhaust system for any leaks. Refer to Page 11-3.
No >> Check the O2 Ground circuit for a short to ground,
open, or short to voltage. Inspect the O2 Sensor con-
nector and the PCM harness connector. If OK, replace
and program the Powertrain Control Module. Refer to
Page 8E-56.
VER 2.
11. FUEL STRAINER
PRESSURE MUST BE RELEASED

Yes >> Replace the Fuel Strainer. Refer to Page 14-10.
No >> Replace the Fuel Pump. Refer to Page 14-17.
VER 2.


(P0174) FUEL SYSTEM 2/1 RICH CONTROL OVER LIMIT (AT IDLE)
POSSIBLE CAUSES

O2 SIGNAL CIRCUIT
O2 SENSOR
Diagnostic Test


No >> Go To 2

POSSIBLE CAUSES

O2 SIGNAL CIRCUIT
O2 SENSOR
Diagnostic Test


No >> Go To 2

(P0174) FUEL SYSTEM 2/1 LEAN CONTROL BELOW LIMIT (AT LOAD)
POSSIBLE CAUSES

O2 SENSOR
FUEL PUMP
Diagnostic Test


No >> Go To 2

(P0174) FUEL SYSTEM 2/1 UNDERCORRECTION OF FUEL MIXTURE (OFF IDLE)
POSSIBLE CAUSES

O2 SENSOR
FUEL PUMP
Diagnostic Test


No >> Go To 2

(P0175) FUEL SYSTEM 2/1 OVERCORRECTION OF FUEL MIXTURE (OFF IDLE)
(P0175) FUEL SYSTEM 2/1 OVERCORRECTION OF FUEL MIXTURE (OFF IDLE) — CONTINUED
POSSIBLE CAUSES

O2 SIGNAL CIRCUIT
O2 SENSOR
Diagnostic Test


No >> Go To 2
(P0175) FUEL SYSTEM 2/1 OVERCORRECTION OF FUEL MIXTURE (OFF IDLE) — CONTINUED

(P0175) FUEL SYSTEM 2/1 LEAN CONTROL BELOW LIMIT (AT IDLE)
POSSIBLE CAUSES

O2 SENSOR
FUEL PUMP
Diagnostic Test


No >> Go To 2

(P0200) FUEL INJECTOR CIRCUIT
(P0200) FUEL INJECTOR CIRCUIT — CONTINUED
• When Monitored: With battery voltage greater than 10 volts. Engine Control Relay energized. Engine speed
less than 3000 RPM.
• Set Condition: No inductive spike is detected after injector turn off. One Trip Fault.
POSSIBLE CAUSES
INJECTOR CONTROL CIRCUIT OPEN

INJECTOR CONTROL CIRCUIT SHORTED TO GROUND
FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED TO INJECTOR CONTROL CIRCUIT
FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


(P0201) FUEL INJECTOR #1 CIRCUIT
(P0201) FUEL INJECTOR #1 CIRCUIT — CONTINUED
less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 7

Disconnect the Fuel Injector harness connector.
the Fuel Injector harness connector.

Yes >> Go To 3
an open.
2.
3. INJECTOR CONTROL CIRCUIT OPEN
Measure the resistance of the Injector Control circuit from the Fuel Injector

Yes >> Go To 4
No >> Repair the Injector Control circuit for an open.
2.
4. INJECTOR CONTROL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the Injector Control circuit.

Yes >> Repair the Injector Control circuit for a short to ground.
No >> Go To 5
5. FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED TO

INJECTOR CONTROL CIRCUIT

Measure the resistance between the Fused Engine Control Relay Output
circuit and the Injector Control circuit at the Fuel Injector harness connec-
tor.

Yes >> Repair the Injector Control circuit for a short to the Fused
Engine Control Relay Output circuit.
No >> Go To 6
6. FUEL INJECTOR
Note: The fuel injectors are polarity sensitive. If a reading is not
obtained with the meter leads connected one way, reverse the test
leads and take another reading.
Measure the resistance of the Fuel Injector.

to Page 8E-56.
No >> Replace the Fuel Injector. Refer to Page 14-33.
VER 2.


less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


less than 3000 RPM.
POSSIBLE CAUSES

FUEL INJECTOR
Diagnostic Test


INJECTOR #1 CIRCUIT
No >> Go To 2


(P0211) THROTTLE ACTUATOR STUCK
(P0211) THROTTLE ACTUATOR STUCK — CONTINUED
• When Monitored: Ignition on and battery voltage greater than 10 volts.
• Set Condition: Just after key on, the throttle is opened and closed to test the system. If the throttle plate
does not return to Limp Home Position at the end of this test, this DTC will set. One trip fault.
POSSIBLE CAUSES
THROTTLE CONTROL MOTOR 1 CIRCUIT SHORTED TO VOLTAGE
THROTTLE CONTROL MOTOR 2 CIRCUIT OPEN
THROTTLE CONTROL MOTOR 2 CIRCUIT SHORTED TO GROUND
THROTTLE PLATE - STUCK ABOVE LIMP HOME POSITION
Diagnostic Test

Note: The PCM tests the Throttle Body Motor by opening and closing
the Throttle Plate before starting the engine. If the Throttle plate does
not return to the closed position during this test, this DTC will set.
DTC.

Yes >> Go To 2
No >> Go To 10
2. THROTTLE PLATE STUCK OPEN
Note: The PCM tests the Throttle Body Motor by opening and closing
the Throttle Plate before starting the engine. If the Throttle plate does
not return to the closed position during this test, this DTC will set.
Remove the Air Cleaner Housing Refer to Page 9-608 and MAF Refer to
Page 14-37 from the Throttle Body.
Check for any signs of a foreign material causing the throttle plate to
remain open.
Manually open and close the throttle plate using your hands.
Does the Throttle Plate move without sticking?

Yes >> Go To 3
No >> Remove the debris if possible or replace the Throttle
Body Assembly. Refer to Page 14-48.
2.
3. TP #1 AND TP #2 BOTH EQUAL 2.5 VOLTS

With the DRB IIIT, read both TP voltage readings.
Are both TP readings stuck at 2.5 volts?

Yes >> Check the TP Signal circuits for excessive resistance, a
short to each other, short to the Sensor Ground circuit.
No >> Go To 4
4. THROTTLE CONTROL MOTOR 1 CIRCUIT SHORTED TO VOLTAGE

Disconnect the Throttle Body harness connector.
Measure the voltage of the Throttle Control Motor 1 circuit at the Throttle
Body harness connector.

Yes >> Repair the Throttle Control Motor 1 circuit for a short to volt-
age.
No >> Go To 5
5. THROTTLE CONTROL MOTOR 1 CKT OPEN
Measure the resistance of the Throttle Control Motor 1 circuit from the
Throttle Body harness connector to the PCM harness connector.

Yes >> Go To 6
No >> Repair the Throttle Control Motor 1 circuit for an open.
2.
6. THROTTLE CONTROL MOTOR 2 CIRCUIT OPEN

Measure the resistance of the Throttle Control Motor 2 circuit between the
Throttle Body harness connector and the PCM harness connector.

Yes >> Go To 7
2.
7. THROTTLE CONTROL MOTOR 1 CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the Throttle Control Motor 1
circuit at the PCM harness connector.

Yes >> Repair the Throttle Control Motor 1 circuit for a short to
ground.
No >> Go To 8
circuit at the PCM harness connector.

ground.
No >> Go To 9
9. PCM

to Page 8E-56.

and open circuits.

(P0211) THROTTLE ACTUATOR STUCK
• Set Condition: Just after key on, the throttle is opened and closed to test the system. If the Throttle Posi-
tion Sensor (TPS) does not quickly exceed a calibrated value this DTC will set. One trip fault.
POSSIBLE CAUSES
THROTTLE PLATE STUCK AT OR BELOW LIMP HOME POSITION
Diagnostic Test

Note: The PCM tests the Electronic Throttle Control (ETC) Motor by
opening and closing the Throttle Plate before starting the engine. If
the Throttle Plate does not open during this test, this DTC will set.
active DTC.

Yes >> Go To 2
No >> Go To 9
Note: The PCM tests the ETC Motor by opening and closing the
Throttle Plate before starting the engine. If the Throttle plate does not
return to the closed position during this test, this DTC will set.
Remove the Air Cleaner Housing Refer to Page 9-608 and MAF Refer to
Page 14-37 from the Throttle Body.
Check for any signs of a foreign material causing the Throttle to remain
open.
Does the Throttle Plate move?

Yes >> Go To 3
Body Assembly. Refer to Page 14-48.
2.
3. THROTTLE CONTROL MOTOR 2 CIRCUIT SHORT TO VOLTAGE

Disconnect the Throttle Body harness connector.

age.
No >> Go To 4
4. THROTTLE CONTROL MOTOR 1 CKT OPEN


Yes >> Go To 5
2.

Yes >> Go To 6
2.

circuit.

ground.
No >> Go To 7

circuit.

ground.
No >> Go To 8
8. PCM

to Page 8E-56.

and open circuits.

(P0221) APPS SENSOR #1 AND #2 VOLTAGE CORRELATION
(P0221) APPS SENSOR #1 AND #2 VOLTAGE CORRELATION — CONTINUED
• When Monitored: With the ignition on and no APPS #1 and APPS #2 DTC present.
• Set Condition: APPS values #1 and #2 are not coherent. Engine will only idle if the Brake pedal is
Pressed or failed. Acceleration rate and engine output are limited.
POSSIBLE CAUSES

ACCELERATOR PEDAL POSITION SENSOR GROUND CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR SIGNAL CIRCUIT OPEN
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 7
2. OPEN APPS SIGNAL CIRCUITS

Note: The following test must be performed on both APPS Signal cir-
cuits.
Measure the resistance of APPS #1 and #2 Signal circuits from the APPS

Yes >> Go To 3
No >> Repair the faulty APPS Signal circuit for an open.
2.
3. OPEN 5-VOLT SUPPLY CIRCUIT
Measure the resistance of the 5-volt Supply circuit from the APPS harness
connector to the PCM C4 harness connector.
Is the resistance above 5.0 ohms?

Yes >> Repair the 5-volt Supply circuit for an open.
No >> Go To 4
4. OPEN APPS GROUND CIRCUITS


Yes >> Repair the faulty Sensor Ground circuit for an open.
No >> Go To 5
5. CHECKING APPS #1 AND #2 W/ LAB SCOPE

With the DRB IIIT/PEP Module being used as a Dual Channel Lab Scope
with Special Tool #6801:
Backprobe APPS #1 Signal circuit using Channel 1 at the APPS harness
connector.
Backprobe APPS #2 Signal circuit using Channel 2 at the APPS harness
connector.
Slowly press and release the Accelerator Pedal while monitoring the DRB
IIIT screen.
Do the scope patterns display a normal APPS Signal scope pat-

tern?
Yes >> Go To 6
Page 14-26.
2.
6. PCM
tors. Pay particular attention to all Power and ground circuits.

to Page 8E-56.

and open circuits.

(P0221) IDLE SPEED PERFORMANCE
(P0221) IDLE SPEED PERFORMANCE — CONTINUED
• Set Condition: Low limit: The Powertrain Control Module (PCM) required engine RPM must be reached
within 25 seconds. The fault is set if the engine RPM is less than the PCM required RPM by 100 RPM or
more after 25 seconds. High limit: The PCM required engine RPM must be reached within 25 seconds. The
fault is set if the engine RPM is greater than the PCM required RPM by 200 RPM or more after 25 seconds.
POSSIBLE CAUSES
AIR INTAKE SYSTEM

VACUUM LEAKS
THROTTLE BODY OPERATION
Diagnostic Test

Note: Diagnose and repair any Throttle Body or Accelerator Pedal
Position Sensor (APPS) DTC before diagnosing this DTC.
DTC.

Yes >> Go To 2
No >> Go To 6
2. AIR INTAKE SYSTEM
Inspect the Air Intake System for the following problems.
Restrictions: Dirty Air Cleaner, Foreign material trapped in the air intake
tube, etc.
Leaks: Air Intake tube connection, Air Cleaner housing, etc.
Remove the Air Cleaner Housing Refer to Page 9-608 and MAF Sensor
Refer to Page 14-37 from the Throttle Body.
open.

Yes >> Repair or replace as necessary.
No >> Go To 3
3. VACUUM LEAKS
Start the engine.
Inspect the vehicle for external vacuum leaks.
Inspect the engine for internal leaks.
Were any vacuum leaks found?

Yes >> Repair the vacuum leak as necessary.
No >> Go To 4
4. THROTTLE BODY OPERATION

Inspect the throttle body plate for carbon build up or other restrictions.
Verify that the Accelerator Pedal and APPS are not binding.
While the vehicle is running, lightly tap on the ETC Motor with your hand
and listen for the idle to raise.

Yes >> Repair or replace as necessary.
No >> Go To 5
5. PCM

to Page 8E-56.


(P0221) ELECTRONIC THROTTLE CONTROL MODULE PERFORMANCE
(P0221) ELECTRONIC THROTTLE CONTROL MODULE PERFORMANCE — CONTINUED
signal.
POSSIBLE CAUSES

THROTTLE POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO TP SENSOR #2 SIGNAL CIRCUIT
Diagnostic Test


MANCE.
No >> Go To 2


(P0221) ELECTRONIC THROTTLE CONTROL MODULE PROCESSOR
(P0221) ELECTRONIC THROTTLE CONTROL MODULE PROCESSOR — CONTINUED
signal.
POSSIBLE CAUSES

THROTTLE POSITION SENSOR #1 SIGNAL CIRCUIT SHORTED TO TP SENSOR #2 SIGNAL CIRCUIT
Diagnostic Test


MANCE.
No >> Go To 2


(P0222) APPS SIGNAL #2 CIRCUIT LOW
present.
• Set Condition: When the APPS #2 voltage is too low. Engine will only idle if the Brake pedal is pressed
or has failed. Acceleration rate and Engine output are limited. One trip fault.
POSSIBLE CAUSES
ACCELERATOR PEDAL POSITION SENSOR (APPS) #2 SWEEP

ACCELERATOR PEDAL POSITION SENSOR #2 SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT
ACCELERATOR PEDAL POSITION SENSOR #2 SIGNAL CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR #2 SIGNAL CIRCUIT SHORTED TO GROUND
Diagnostic Test
1. APPS BELOW 0.25 VOLT

With the DRB IIIT, read the APPS #2 voltage.

Yes >> Go To 2
No >> Go To 9
Measure the voltage of the 5-Volt Supply circuit at the APPS harness con-
nector.

Yes >> Go To 3
No >> Go To 6
3. APPS
Connect a jumper wire between the 5-Volt Supply circuit and the APPS #2
Signal circuit in the Sensor harness connector.
Note: Remove the jumper wire before continuing.

Page 14-26.
No >> Go To 4
4. APPS #2 SIGNAL CIRCUIT OPEN

Measure the resistance of the APPS #2 Signal circuit from the APPS har-

Yes >> Go To 5
No >> Repair the APPS #2 Signal circuit for an open.
2.
5. APPS SIGNAL CIRCUIT SHORTED TO GROUND
Measure the resistance between ground and the APPS #2 Signal circuit.

Yes >> Repair the APPS #2 Signal circuit for a short to ground.
No >> Go To 8

Measure the resistance of the 5-Volt Supply circuit from the APPS harness

Yes >> Go To 7
2.


No >> Go To 8
8. PCM

to Page 8E-56.
9. APPS SWEEP
position.

Yes >> Go To 10
Page 14-26.
2.

and open circuits.

(P0223) APPS SIGNAL #2 CIRCUIT HIGH
present.
• Set Condition: When APPS #2 voltage is too high. Engine will only idle if the Brake pedal is Pressed or
has failed. Acceleration rate and Engine output are limited. One trip fault.
POSSSIBLE CAUSES
ACCELERATOR PEDAL POSITION SENSOR #2 SWEEP
ACCELERATOR PEDAL POSITION SENSOR #2 SIGNAL CIRCUIT SHORTED TO VOLTAGE
ACCELERATOR PEDAL POSITION SENSOR #2 SIGNAL SHORTED TO 5-VOLT SUPPLY CIRCUIT
ACCELERATOR PEDAL POSITION SENSOR #2 GROUND CIRCUIT OPEN
ACCELERATOR PEDAL POSITION SENSOR #2
Diagnostic Test
1. APPS #2 VOLTAGE ABOVE 5.0 VOLTS

With the DRB IIIT in Sensors, read the APPS voltage.

Yes >> Go To 2
No >> Go To 7
2. APPS
Connect a jumper wire between the APPS 5-Volt Supply circuit and the
APPS Signal #2 circuit at the APPS harness connector.

Page 14-26.
No >> Go To 3
3. APPS #2 SIGNAL CIRCUIT SHORTED TO VOLTAGE
Measure the voltage on the APPS #2 Signal circuit in the APPS harness
connector.

Yes >> Repair the APPS #2 Signal circuit for short to voltage.
No >> Go To 4
4. APPS #2 SIGNAL CIRCUIT SHORTED TO 5-VOLT SUPPLY CIRCUIT

Measure the resistance of the APPS #2 Signal circuit to the 5-Volt Supply
circuit at the APPS harness connector.

Yes >> Repair the APPS #2 Signal circuit for a short to the 5-Volt
Supply circuit.
No >> Go To 5
5. OPEN APPS #2 GROUND CIRCUIT

ness connector to the PCM connector.

Yes >> Go To 6
No >> Repair the APPS #2 Ground circuit for an open.
2.
6. PCM

to Page 8E-56.
7. APPS #2 SWEEP
position.
Does voltage start at approximately 0.2 volt and go above 4.3 volts
with a smooth transition?
Yes >> Go To 8
Page 14-26.
2.


(P0300) MULTIPLE CYLINDER MISFIRE
(P0300) MULTIPLE CYLINDER MISFIRE — CONTINUED
• When Monitored: Any time the engine is running, and the Target Learning Coefficient has been successfully
updated.
• Set Condition: When more than a 1.0% misfire rate is measured during two trips.
POSSIBLE CAUSES
INTERMITTENT MISFIRE
ENGINE CONTROL RELAY OUTPUT CIRCUIT
INJECTOR DRIVER CIRCUIT
FUSED IGNITION OUTPUT CIRCUIT
COIL ON PLUG
COIL ON PLUG DRIVER CIRCUIT
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 19
2. VISUAL AND PHYSICAL INSPECTION
Note: Reviewing the vehicle repair history may aid in the repair of the
misfire condition.
Visually and physically inspect the engine for any of the following condi-
tions:
- Worn serpentine belt
- Binding Engine-Driven accessories
- Misaligned water pump, P/S pump and A/C compressor pulleys
- Improper CKP Sensor mounting
- Poor connector/terminal to component connection, i.e., CKP Sensor, Fuel
Injector, Coil On Plug, etc.
- Vacuum leaks
- Restricted Air Intake system
Note: Ensure the powers and grounds for the PCM are functioning
properly.
Were any of the above conditions present?

No >> Go To 3
3. IGNITION SYSTEM OPERATION

Remove the Fuel Pump Fuse from the Relay Control Module.
Disconnect the suspect Coil On Plug harness connector.
Remove the Coil On Plug.
Note: Before continuing, inspect the Coil On Plug for the following
conditions. Damage or Carbon Tracking on the Coil or the spark plug
insulator boot. If a problem is found, replace the Coil On Plug. Refer
to Page 8I-5.
Install spark testers to the Coil On Plug.
Reconnect the Coil On Plug harness connector to the Coil On Plug.
While cranking the engine, observe the spark coming from the spark
testers.
Note: A crisp blue spark should be generated that is able to jump the
gap of the spark testers.
Note: Before continuing with next Step, reinstall Fuel Pump Fuse in
the Relay Control Module.
Is good spark present?

Yes >> Go To 4
No >> Go To 16
4. SPARK PLUG
Remove the Spark Plug.
Inspect the Spark Plug for the following conditions:
- Cracks
- Carbon Tracking
- Foreign Material
- Gap size out of specifications
- Loose or broken electrode
Note: Lightly tap the bottom of the spark plug on a solid surface. The
electrode in the spark plug should not move.

Yes >> Replace the Spark Plug(s). Refer to Page 8I-11.
No >> Go To 5

Install a fuel pressure test gauge to the fuel rail.
Start the engine and observe the fuel pressure reading.

Go To 6
Below Specification
Go To 14
Above Specification
Replace the fuel filter/pressure regulator. Refer to
Page 14-10.
VER 2.
6. CHECKING FUEL LEAK DOWN
EVEN WITH THE ENGINE OFF. BEFORE TESTING OR SERVICING
Note: Before continuing, visually and physically inspect the fuel
delivery system for external leaks or damage. Repair/replace as nec-
essary.
Note: Fuel specification is 3.7 to 4.2 bar (54 to 61 psi).
Install a substitute fuel pressure hose between the fuel pump and fuel fil-
ter.
Start the engine and allow the fuel system to reach maximum pressure.
Using Special Tool #C4390, Hose Clamp Pliers, slowly clamp off the sub-
stitute fuel pressure hose between the fuel pump and fuel filter.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
Note: The pressure should not fall below 3.0 bar (44 psi) within 5
minutes and should not fall below 2.5 bar (36 psi) within 30 minutes.
Does the fuel pressure gauge fall below the above specification?
Yes >> Repair or replace the leaking component between the Fuel
Pump and Injector(s).
No >> Go To 7
Note: Remove the hose clamp pliers before continuing with test.
7. FUEL INJECTOR OPERATION

CAUTION: After each actuation of the Fuel Injector, start the engine
to clear the cylinder of fuel. Failure to do so could cause engine
damage.
Using the DRB IIIT, actuate the Fuel Injector for the cylinder that indicated
the misfire.
Monitor the fuel pressure gauge.
Does the fuel pressure gauge indicate a drop in fuel pressure?

Yes >> Go To 8
No >> Go To 9
8. CHECKING FOR POSSIBLE MECHANICAL PROBLEM
Check for any of the following conditions/mechanical problems:
ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks
ENGINE CRANKCASE VENT SYSTEM - must flow freely
POWER BRAKE BOOSTER - must not have internal vacuum leaks

No >> Go To 19
9. ENGINE CONTROL RELAY OUTPUT CIRCUIT

Using a 12-volt test light connected to ground, probe the Engine Control
Relay Output circuit at the Fuel Injector harness connector.

Yes >> Go To 10
No >> Repair the Engine Control Relay Output circuit for an
open.
2.
10. FUEL INJECTOR

Using a 12-volt test light connected to 12-volts, probe the Injector Driver
circuit.
With the DRB IIIT, actuate the Fuel Injector.
Does the test light blink/flicker?

Yes >> Replace the Fuel Injector. Refer to Page 14-33.
No >> Go To 11
11. FUEL INJECTOR CONTROL CIRCUIT SHORTED TO VOLTAGE
Measure the voltage of the Fuel Injector Control circuit at the Fuel Injector
harness connector.

Yes >> Repair the Injector Control circuit for a short to voltage.
No >> Go To 12
12. FUEL INJECTOR CONTROL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the Fuel Injector Control cir-
cuit.

Yes >> Repair the Fuel Injector Control circuit for a short to ground.
No >> Go To 13
13. OPEN FUEL INJECTOR CONTROL CIRCUIT

Measure the resistance of the Fuel Injector Control circuit from the Fuel
Injector harness connector and the PCM harness connector.

Yes >> Repair the Injector Control circuit for an open.
No >> NOTE: Before continuing, check the PCM harness
connector terminals for corrosion, damage, or terminal
push out. Repair as necessary. Replace and program
VER 2.
14. RESTRICTED FUEL SUPPLY LINE
Raise vehicle on hoist and disconnect the fuel pressure line at the fuel
pump.
Install a fuel pressure test gauge between the disconnected fuel line and
the fuel pump.
pressure gauge.
Is the fuel pressure within specification?

Yes >> Repair or replace fuel supply line as necessary.
No >> Go To 15
15. FUEL STRAINER

WARNING: WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT
PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE TESTING OR
SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, THE FUEL
SYSTEM PRESSURE MUST BE RELEASED

No >> NOTE: Before continuing, check the Fuel Pump har-
ness connector terminals for corrosion, damage, or
terminal push out. Ensure the ground circuit is operat-
ing properly. Repair as necessary. Replace the Fuel
Pump. Refer to Page 14-17.
VER 2.
16. FUSED IGNITION SWITCH OUTPUT CIRCUIT
Disconnect the Coil On Plug harness connector.
Using a 12-volt test light connected to ground, probe the Fused Ignition
Switch Output circuit at the Coil On Plug harness connector.

Yes >> Go To 17
open.
2.
17. COIL ON PLUG

Using a 12-volt test light connected to 12-volts, probe the Coil On Plug
Driver circuit.
Crank the engine for 5 second while observing the test light.

Yes >> Replace the Coil On Plug. Refer to Page 8I-5.
No >> Go To 18
18. COIL ON PLUG DRIVER CIRCUIT

Check the Coil On Plug Driver circuits for an open, short to ground, and
short to voltage.
Was a problem found with the Coil On Plug Driver circuits?

Yes >> Repair the Coil On Plug Driver circuits for the problem
found.
VER 2.
19. INTERMITTENT MISFIRE
Note: The condition that caused this DTC to set is currently not
present. Inspect the related wiring harness for a possible intermittent
condition.
DRB IIIT parameters related to the DTC while wiggling the wire harness.
Look for parameter values to change and/or a DTC to set.
terminals.
misfire condition.
tions:
- Binding Engine-Driven accessories
- Poor connector/terminal to component connection. i.e., CKP Sensor, Fuel
- Vacuum leaks

(P0301) CYLINDER #1 MISFIRE
(P0301) CYLINDER #1 MISFIRE — CONTINUED
updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

misfire condition.
tions.
- Binding Engine-Driven accessories.
- Poor connector/terminal to component connection, i.e., CKP Sensor, Fuel
- Vacuum leaks
Note: Ensure the powers and grounds for the PCM are functioning
properly.

No >> Go To 2
2. IGNITION SYSTEM OPERATION
Remove the Coil On Plug.
Note: Before continuing, inspect the Coil On Plug for the following
conditions. Damage or Carbon Tracking on the Coil On Plug or the
spark plug insulator boot. If a problem is found, replace the Coil On
Plug. Refer to Page 8I-5.
Install spark testers to one of the Coil On Plug wires.
Reconnect the Coil On Plug harness connector to the Coil On Plug.
While cranking the engine, observe the spark coming from the spark
testers.
Note: A crisp blue spark should be generated that is able to jump the
gap of the spark testers.
Note: Before continuing with next Step, reinstall Fuel Pump Fuse in
the Relay Control Module.
Is good spark present?

Yes >> Go To 3
No >> Go To 13
3. SPARK PLUG
Remove the Spark Plug.
Inspect the Spark Plug for the following conditions.
- Cracks
- Carbon Tracking
- Foreign Material
- Gap size out of specifications
- Loose or broken electrode
Note: Lightly tap the bottom of the spark plug on a solid surface. The
electrode in the spark plug should not move.
Were any of the above condition present?

Yes >> Replace the Spark Plug. Refer to Page 8I-11.
No >> Go To 4
Install a fuel pressure gauge to the fuel rail.
Start the engine and observe the fuel pressure reading.

Go To 5
Below Specification
Go To 11
Above Specification
Replace the fuel filter/pressure regulator. Refer to
Page 14-10.
VER 2.
5. CHECKING FUEL LEAK DOWN

Note: Before continuing visually and physically inspect the fuel deliv-
ery system for external leaks or damage. Repair/replace as neces-
sary.
Install a substitute fuel pressure hose between the fuel pump and fuel fil-
ter.
Using Special Tool #C4390, Hose Clamp Pliers, slowly clamp off the sub-
stitute fuel pressure hose between the fuel pump and the fuel filter.
Note: The pressure should not fall below 3.0 bar (44 psi) within 5
minutes and should not fall below 2.5 bar (36 psi) within 30 minutes.
Does the fuel pressure gauge fall below the above specification?
Yes >> Replace the leaking component between the Fuel Pump
and Injector(s).
No >> Go To 6
Note: Remove the hose clamp pliers before continuing with test.
6. FUEL INJECTOR OPERATION
CAUTION: After each actuation of the Fuel Injector, start the engine
to clear the cylinder of fuel. Failure to do so could cause engine
damage.
Using the DRB IIIT, actuate the Fuel Injector for the cylinder that indicated
the misfire.
Monitor the fuel pressure gauge.
Does the fuel pressure gauge indicate a drop in fuel pressure?

Yes >> Go To 7
No >> Go To 8
7. CHECKING FOR POSSIBLE MECHANICAL PROBLEM

ENGINE PCV SYSTEM - must flow freely
POWER BRAKE BOOSTER - must not have internal vacuum leaks

No >> Go To 16

Using a 12-volt test light connected to ground, probe the Engine Control
Relay Output circuit at the Fuel Injector harness connector.

Yes >> Go To 9
open.
2.
9. FUEL INJECTOR
Using a 12-volt test light connected to 12-volts, probe the Injector Control
circuit.
With the DRB IIIT, actuate the Fuel Injector.

Yes >> Replace the Fuel Injector. Refer to Page 14-33.
No >> Go To 10
10. INJECTOR DRIVER CIRCUIT

Measure the resistance of the Injector Driver circuit from the Fuel Injector

Yes >> NOTE: Before continuing, check the PCM harness connec-
tor terminals for corrosion, damage, or terminal push out.
Repair as necessary. Replace and program the Powertrain
Control Module. Refer to Page 8E-56.
No >> Repair the Injector Driver circuit for an open.
VER 2.
11. RESTRICTED FUEL SUPPLY LINE
Raise vehicle on hoist and disconnect the fuel pressure line at the fuel
pump.
Attach a fuel pressure test gauge.
pressure gauge.
Is the fuel pressure within specification?

Yes >> Repair or replace fuel supply line as necessary.
No >> Go To 12
12. FUEL STRAINER

Remove the and inspect the Fuel Strainer.

No >> NOTE: Before continuing, check the Fuel Pump Mod-
ule harness connector terminals for corrosion, dam-
age, or terminal push out. Ensure the ground circuit is
operating properly. Repair as necessary. Replace the
Fuel Pump. Refer to Page 14-17.
VER 2.
13. FUSED IGNITION SWITCH OUTPUT CIRCUIT
Using a 12-volt test light connected to ground, probe the Fused Ignition
Switch Output circuit at the Coil On Plug harness connector.

Yes >> Go To 14
open.
2.
14. COIL ON PLUG

Using a 12-volt test light connected to 12-volts, probe the Coil On Plug
Driver circuit.
Crank the engine for 5 second while observing the test light.

Yes >> Replace the Coil On Plug. Refer to Page 8I-5.
No >> Go To 15
15. COIL ON PLUG DRIVER CIRCUIT

Measure the resistance of both Coil On Plug Driver circuits from the PCM
C3 harness connector to the Coil On Plug harness connector.
Was a problem found with the Coil On Plug Driver circuits?

Yes >> Repair the Coil On Plug Driver circuit for an open.
VER 2.
16. INTERMITTENT MISFIRE
Note: The condition that caused this DTC to set is currently not
present. Inspect the related wiring harness for a possible intermittent
condition.
WARNING: 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.
Refer to any Technical Service Bulletins (TSBs) that may apply.
DRB IIIT parameters related to the DTC while wiggling the wire harness.
Look for parameter values to change and/or a DTC to set.
terminals.
misfire condition.
tions.
- Binding Engine-Driven accessories.
- Poor connector/terminal to component connection. i.e., CKP Sensor, Fuel
Injector, Ignition coil, etc.
- Vacuum leaks

updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0301) CYL-
INDER #1 MISFIRE.
No >> Go To 2

updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

Is this DTC preset?

INDER #1 MISFIRE.
No >> Go To 2

updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

Is this DTC preset?

INDER #1 MISFIRE.
No >> Go To 2

updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

Is this DTC preset?

INDER #1 MISFIRE.
No >> Go To 2

updated.
POSSIBLE CAUSES
COIL ON PLUG
SPARK PLUG
FUEL PUMP
FUEL INJECTOR
Diagnostic Test

Is this DTC preset?

INDER #1 MISFIRE
No >> Go To 2

(P0325) KNOCK SENSOR #1 CIRCUIT LOW
(P0325) KNOCK SENSOR #1 CIRCUIT LOW — CONTINUED
• When Monitored: With the Engine at operating temperature, engine speed greater than 2000 RPM, load
greater than 40%, and Anti-Knock control not active.
• Set Condition: Lower limit: Knock Sensor voltage is less than 0.10 volts. Upper limit: Knock Sensor volt-
age is greater than 4.98 volts.
POSSIBLE CAUSES
KNOCK SENSOR SIGNAL CIRCUIT OPEN

KNOCK SENSOR SIGNAL CIRCUIT SHORT TO GROUND
KNOCK SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE
SENSOR GROUND CIRCUIT SHORTED TO GROUND
KNOCK SENSOR
1. KNOCK SENSOR RESISTANCE

Measure the resistance of the Knock Sensor.
Is the resistance between 4-5 mega ohms

to Page 8E-56.
No >> Go To 2
2. KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the Knock Sensor Signal cir-
cuit.

Yes >> Repair the Knock Sensor Signal circuit for a short to
ground.
No >> Go To 3
3. SENSOR GROUND CIRCUIT SHORTED TO GROUND

No >> Go To 4
4. SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the Sensor Ground circuit at the PCM C3 harness
connector.

Yes >> Repair the Sensor Ground circuit for a short to voltage.
No >> Go To 5
5. KNOCK SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the Knock Sensor Signal circuit at the PCM C3
harness connector.

Yes >> Repair the Knock Sensor Signal circuit for a short to volt-
age.
No >> Go To 6
6. OPEN KNOCK SENSOR SIGNAL CIRCUIT
Disconnect Knock Sensor harness connector.
Measure the resistance of the Knock Sensor Signal circuit from the Knock
Sensor harness connector to the PCM C3 harness connector.

Yes >> Go To 7
No >> Repair the Knock Sensor Signal circuit for an open.
2.
7. OPEN SENSOR GROUND CIRCUIT

Measure the resistance of the Sensor Ground circuit from the Knock Sen-
sor harness connector to the PCM C3 harness connector.

Yes >> Replace the Knock Sensor. Refer to Page 8I-6.
VER 2.
(P0325) KNOCK SENSOR #1 CIRCUIT HIGH
(P0325) KNOCK SENSOR #1 CIRCUIT HIGH — CONTINUED
• Set Condition: Knock Sensor voltage is greater than 4.98 volts.
POSSIBLE CAUSES

KNOCK SENSOR
Diagnostic Test

Is this DTC preset?

KNOCK SENSOR #1 CIRCUIT LOW.
No >> Go To 2


(P0330) KNOCK SENSOR #2 CIRCUIT HIGH
(P0330) KNOCK SENSOR #2 CIRCUIT HIGH — CONTINUED
• Set Condition: Knock Sensor voltage is greater than 4.98 volts.
POSSIBLE CAUSES

KNOCK SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0330) KNOCK SENSOR #2 CIRCUIT LOW
• Set Condition: Knock Sensor voltage is less than 0.10 volts.
POSSIBLE CAUSES
KNOCK SENSOR SIGNAL CIRCUIT OPEN

KNOCK SENSOR SIGNAL CIRCUIT SHORT TO GROUND
KNOCK SENSOR
Diagnostic Test

Is this DTC preset?

No >> Go To 2


(P0335) CRANKSHAFT POSITION SENSOR CIRCUIT
(P0335) CRANKSHAFT POSITION SENSOR CIRCUIT — CONTINUED
• When Monitored: Engine cranking or running.
• Set Condition: No Crankshaft Position (CKP) signal is present during engine cranking and at least 8
Camshaft Position Sensor (CMP) signals have occurred.
POSSIBLE CAUSES
INTERMITTENT CKP SIGNAL

CRANKSHAFT POSITION SENSOR (CKP) SIGNAL CIRCUIT OPEN
CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED VOLTAGE
CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED GROUND
CRANKSHAFT POSITION SENSOR GROUND CIRCUIT OPEN
CRANKSHAFT POSITION SENSOR GROUND CIRCUIT SHORTED VOLTAGE
CRANKSHAFT POSITION SENSOR GROUND CIRCUIT SHORTED GROUND
CRANKSHAFT POSITION SENSOR
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 12
2. CKP WIRE HARNESS INSPECTION
pinched, or partially broken wires.
Visually inspect the related wire harness connectors. Look for broken,
bent, pushed out, or corroded terminals.
Ensure the Crankshaft Position (CKP) Sensor and the Camshaft Position
Sensor are properly installed and the mounting bolt(s) are tight.

No >> Go To 3
3. CKP SENSOR SIGNAL CIRCUIT

Disconnect the Crankshaft Position Sensor harness connector.
Measure the voltage of the CKP Sensor Signal circuit at the CKP Sensor
harness connector.

Yes >> Go To 4
No >> Go To 8
4. CKP SENSOR GROUND CIRCUIT

Measure the voltage of the CKP Sensor Ground circuit at the CKP Sensor
harness connector.

Yes >> Go To 11
No >> Go To 5
5. CKP SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE
Disconnect the PCM C3 harness.
Measure the voltage of the CKP Sensor Ground circuit at the CKP Sensor
harness.

Yes >> Repair the CKP Sensor Ground circuit for a short to volt-
age.
No >> Go To 6
6. CKP SENSOR GROUND CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the CKP Sensor Ground cir-
cuit.

Yes >> Repair the CKP Sensor Ground circuit for a short to ground.
No >> Go To 7
7. OPEN CKP SENSOR GROUND CIRCUIT

Measure the resistance of the CKP Sensor Ground circuit from the CKP

Yes >> Repair the CKP Sensor Ground circuit for an open.
VER 2.
8. CKP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
Measure the voltage of the CKP Sensor Signal circuit at the CKP Sensor
harness connector.

Yes >> Repair the CKP Sensor Signal circuit for a short to voltage.
No >> Go To 9
9. CKP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the CKP Sensor Signal cir-
cuit.

Yes >> Repair the CKP Sensor Signal circuit for a short to ground.
No >> Go To 10
10. OPEN CKP SENSOR SIGNAL CIRCUIT

Measure the resistance of the CKP Sensor Signal circuit from the CKP

Yes >> Repair the CKP Sensor Signal circuit for an open.
VER 2.
11. TONE WHEEL/PULSE RING INSPECTION
Remove the Crankshaft Position Sensor.
Inspect the Tone Wheel/Pulse Ring for damage, foreign material, or exces-
sive movement.

Yes >> Repair or replace the Tone Wheel/Pulse Ring as necessary.
No >> Replace the Crankshaft Position Sensor. Refer to
Page 14-31.
VER 2.


(P0341) CAMSHAFT POSITION TIMING OVER-RETARDED
(P0341) CAMSHAFT POSITION TIMING OVER-RETARDED — CONTINUED
• When Monitored: Engine cranking and engine running
• Set Condition: If the Camshaft Signal (angular variation) is more or less than 15° of the Crankshaft Sig-
nal, the DTC is then set in memory.
POSSIBLE CAUSES
INTERMITTENT CAMSHAFT POSITION SENSOR SIGNAL

CAMSHAFT POSITION SENSOR WIRE HARNESS
TONE WHEEL/PULSE RING
TIMING CHAIN
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 6
2. CHECKING CMP SIGNAL
With the DRB IIIT lab scope probe and the Special Tool #6801, backprobe
the CMP Signal circuit at the CMP harness connector.
Start the engine.
Observe the lab scope screen.
Are there any irregular or missing signals?

Yes >> Go To 3
No >> Go To 6
3. CMP WIRE HARNESS INSPECTION

pinched, or partially broken wires.
Visually inspect the related wire harness connectors. Look for broken,
bent, pushed out, or corroded terminals.
Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor
are properly installed and the mounting bolt(s) tight.

No >> Go To 4
4. TONE WHEEL/PULSE RING INSPECTION

Remove the Camshaft Position Sensor.
Inspect the Tone Wheel/Pulse Ring for damage, foreign material, or exces-
sive movement.

Yes >> Repair or replace the Tone Wheel/Pulse Ring as necessary.
No >> Go To 5
5. CAMSHAFT POSITION SENSOR
Repair >> Replace the Camshaft Position Sensor. Refer to Page 8I-4.
6. INTERMITTENT CMP SIGNAL

Start the engine.
Monitor the DRB IIIT for DTCs.
Gently tap on the Camshaft Position Sensor and wiggle the Sensor har-
ness connector.
Inspect the Sensor harness connector, PCM harness connector, Sensor
connector, and PCM connector for loose, bent, corroded, or pushed out
pins/terminals.
Inspect the related wire harness and the splices in the CMP circuits.
With the DRB IIIT, read engine DTCs.
Did the DTC set again?

Yes >> Repair the wiring/connector concerns as needed or replace
the Camshaft Position Sensor. Refer to Page 8I-4.
No >> Go To 7

and open circuits.

(P0341) CAMSHAFT POSITION TIMING OVER-ADVANCED
(P0341) CAMSHAFT POSITION TIMING OVER-ADVANCED — CONTINUED
• When Monitored: Engine cranking and engine running
• Set Condition: If the Camshaft Signal (angular variation) is more or less than 15° of the Crankshaft Sig-
nal, the DTC is then set in memory.
POSSIBLE CAUSES
INTERMITTENT CAMSHAFT POSITION SENSOR SIGNAL

CAMSHAFT POSITION SENSOR WIRE HARNESS
TONE WHEEL/PULSE RING
TIMING CHAIN
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0341) CAM-
SHAFT POSITION TIMING OVER-RETARDED.
No >> Go To 2


(P0341) CAMSHAFT POSITION SENSOR PERFORMANCE
(P0341) CAMSHAFT POSITION SENSOR PERFORMANCE — CONTINUED
• When Monitored: Engine cranking/running. Battery voltage greater than 10 volts.
• Set Condition: At least 5 seconds or 2.5 engine revolutions have elapsed with Crankshaft Position Sensor
(CKP) Signals present but no Camshaft Position (CMP) Sensor Signal. One Trip Fault.
POSSIBLE CAUSES
INTERMITTENT CRANKSHAFT POSITION (CKP) SENSOR SIGNAL

INTERMITTENT CAMSHAFT POSITION (CMP) SENSOR SIGNAL (CMP)
CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT OPEN
CAMSHAFT POSITION SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
Diagnostic Test

Disconnect the CMP Sensor harness connector.
the CMP Sensor harness connector.

Yes >> Go To 2
an open.
2.
Measure the resistance of the Sensor Ground circuit from the CMP Sensor

Yes >> Go To 3
2.
3. CMP SIGNAL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the CMP Signal circuit at the CMP Sensor harness
connector.

Yes >> Repair the CMP Signal circuit for a short to voltage.
No >> Go To 4
4. CMP SIGNAL CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the CMP Signal circuit.

Yes >> Repair the CMP Signal circuit for a short to ground.
No >> Go To 5
5. CMP SIGNAL CIRCUIT OPEN
Measure the resistance of the CMP Signal circuit from the CMP Sensor

Yes >> Go To 6
No >> Repair the CMP Signal circuit for an open.
VER 2.
6. CAMSHAFT POSITION SENSOR

Replace the Camshaft Position Sensor. Refer to Page 8I-4.
Attempt to start the engine.
With the DRB IIIT, read engine DTCs.
Did the DTC, (P0341) CAMSHAFT POSITION SENSOR PERFOR-

MANCE, set again?
to Page 8E-56.
(P0400) EGR SYSTEM PERFORMANCE
(P0400) EGR SYSTEM PERFORMANCE — CONTINUED
• When Monitored: A constant engine speed between 900 and 1700 RPM and no other EGR or MAP sensor
faults.
• Set Condition: The PCM commands the EGR valve to open. The MAP sensor value must drop by a
minimum of 54 mbar (1.6 in Hg) when EGR is commanded open or a fault is set.
POSSIBLE CAUSES
EGR SOLENOID CONTROL CIRCUIT OPEN

EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
EGR SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE
EGR SOLENOID
EGR VALVE
Diagnostic Test
1. EGR OPERATION
Turn all accessories off.
Start the engine.
Does the engine run rough or stall?

Yes >> Go To 2
No >> Go To 3
2. EGR VALVE OPEN AT IDLE

Disconnect the EGR Solenoid harness connector.
Start engine. Attempt to allow the engine to idle.
Does the engine run rough or stall?

Yes >> Inspect the EGR tube assembly. If OK, replace the EGR
valve. Refer to Page 25-27.
No >> Go To 3
3. EGR SOLENOID
Disconnect the EGR solenoid harness connector.
Connect a 12-volt test lamp between the EGR Solenoid Control circuit and
the EGR Solenoid Fused Engine Control Relay Output circuit.
With the DRB IIIT, actuate the EGR solenoid.
Does the test flash on and off?

Yes >> Replace the EGR Solenoid. Refer to Page 25-24.
No >> Go To 4

the EGR Solenoid harness connector.

Yes >> Go To 6
open.
2.
5. EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the EGR solenoid control cir-
cuit.

Yes >> Repair the EGR solenoid control circuit for a short to
ground.
No >> Go To 6
6. EGR SOLENOID CONTROL CIRCUIT OPEN
Measure the resistance of the EGR Solenoid Control circuit from the EGR
Solenoid harness connector to the PCM C2 harness connector.

Yes >> Go To 7
No >> Repair the EGR Solenoid Control circuit for an open.
2.
7. EGR SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the EGR Solenoid Control circuit at the EGR Sole-
noid connector.

Yes >> Repair the EGR Solenoid Control circuit short to voltage.
VER 2.
(P0403) EGR CONTROL CIRCUIT
(P0403) EGR CONTROL CIRCUIT — CONTINUED
• When Monitored: A constant engine speed between 900 and 1700 RPM and no other EGR or MAP sensor
faults.
• Set Condition: The PCM commands the EGR valve to open. The MAP sensor value must drop by a
minimum of 54 mbar (1.6 in Hg) when EGR is commanded open or a fault is set.
POSSIBLE CAUSES
EGR SOLENOID CONTROL CIRCUIT OPEN

EGR SOLENOID CONTROL CIRCUIT SHORT TO GROUND
EGR SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE
EGR SOLENOID
EGR VALVE
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0400) EGR
SYSTEM PERFORMANCE.
No >> Go To 2


(P0410) SECONDARY AIR INJECTION SYSTEM
(P0410) SECONDARY AIR INJECTION SYSTEM — CONTINUED
• When Monitored: Once per driving cycle with the engine at idle, air conditioning is off, barometric pressure
is greater than 78 kPa (11 psi), engine coolant temperature is greater than 50°C (122°F) and no other DTC
set.
• Set Condition: When the test is enabled, the O2 Sensor must increase by at least 23% (rich).
POSSIBLE CAUSES
AIR PUMP VOLTAGE SUPPLY CIRCUIT OPEN

AIR PUMP VOLTAGE SUPPLY CIRCUIT SHORT TO GROUND
AIR PUMP GROUND CIRCUIT OPEN
CRACKING, MISSING, MISROUTED, OR PLUGGED VACUUM LINES.
AIR PUMP SWITCHOVER VALVES
AIR PUMP RELAY
AIR PUMP
For a complete Powertrain Control Module (PCM) Circuit Diagram, Refer to Page 9-574.
Diagnostic Test

DTC.

Yes >> Go To 2
No >> Go To 12
2. INSPECT THE SECONDARY AIR INJECTION SYSTEM

Inspect the Air Pump system for the following:
• Damage to any component.
• Cracked, missing, misrouted, or plugged vacuum lines.
• Damaged or misrouted electrical wires.

No >> Go To 3
3. OPERATE THE AIR PUMP
With the DRB IIIT, actuate the Air Pump Relay.
Does the Air Pump run?

Yes >> Go To 4
No >> Go To 7
4. AIR PUMP SWITCHOVER VALVE VACUUM CHECK

Disconnect the vacuum hose from the right Air Pump Switchover Valve.
Connect a vacuum gauge to the vacuum hose that was connected to the
right Air Pump Switchover Valve.
Start the engine.
Repeat this procedure for the left Air Pump Switchover Valve.
Does the vacuum gauge read greater than 10 in. Hg for both
valves?
Yes >> Go To 6
No >> Go To 5
5. MONITOR THE O2 SENSORS

With the engine running.
Monitor the voltage on both front O2 sensors.
Does the O2 sensor voltage for both sensors drop to less than 0.1
volts?
Yes >> Go To 12
No >> Remove the Switchover Valve for the affected bank and
inspect for damage or restrictions. If no problems are
found, replace the Switchover Valve. Refer to Page
25-36.
2.
6. AIR PUMP SOLENOID VACUUM CHECK
Disconnect the Air Pump solenoid vacuum feed hose from the intake man-
ifold to the Air Pump solenoid.
Connect a vacuum gauge to the vacuum hose that was connected to the
Air Pump solenoid.
Start the engine.
Does the vacuum gauge read greater than 10 in. Hg?

Yes >> Replace the Air Pump Switchover Solenoid. Refer to Page
25-34
No >> Repair the cause of no vacuum at the Air Pump sole-
noid.
VER 2.
7. DISCONNECT THE AIR PUMP

Disconnect the Air Pump harness connector.
With a 12-Volt test lamp connected to ground, probe the Fused Air Pump
Relay Output circuit at the Air Pump harness connector. The lamp should
be bright, compare to when connected across the battery.
Does the test lamp illuminate brightly?

Yes >> Go To 8
No >> Go To 9
8. AIR PUMP GROUND CIRCUIT OPEN

Measure the resistance between ground and the Air Pump Ground circuit.

Yes >> Replace the Air Pump. Refer to Page 25-32.
No >> Repair the Air Pump Ground circuit for an open.
VER 2.
9. INSPECT THE AIR PUMP FUSE
With a test lamp connected to ground, probe the 40 amp Air Pump Fuse.
The lamp should be bright, compare to when connected across the bat-
tery.
Does the test lamp illuminate brightly on at least one side of the
fuse?
Yes >> Go To 10
No >> Repair the Fused B(+) circuit to the 40 amp Air Pump
Fuse for an open.
2.
10. AIR PUMP FUSE OPEN

Inspect the 40 amp Air Pump Fuse for an open or high resistance con-
nection.
Is the 40 amp Air Pump Fuse open?

Yes >> Check the Air Pump Relay Output circuit, Relay Control
Module, and Air Pump Relay for a short to ground. Repair
as necessary. If OK, replace the Air Pump and Air Pump
Fuse. Refer to Page 25-32.
No >> Go To 11
11. JUMPER THE AIR PUMP RELAY

Disconnect the Relay Control Module A and B harness connectors.
Connect a fused jumper wire between pin 2 of the Relay Control Module B
harness connector and pin 4 of the Relay control Module A harness con-
nector.

Yes >> Replace the Relay Control Module.
No >> Repair the Fused Air Pump Relay Output circuit for an
open.
VER 2.
and open circuits.

(P0410) SECONDARY AIR INJECTION RELAY CIRCUIT
(P0410) SECONDARY AIR INJECTION RELAY CIRCUIT — CONTINUED
• When Monitored: Once per driving cycle when the Engine is at idle, Air Pump was activated at startup,
Barometric Pressure greater than 78 kPa (11 psi), Engine Coolant Temperature is greater than 50°C (122°F),
and no other DTCs
• Set Condition: When the test is enabled, the O2 Sensor must increase by at least 23% (rich).
POSSIBLE CAUSES
ENGINE CONTROL FUSE #2

AIR PUMP RELAY CONTROL CIRCUIT OPEN
AIR PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND
AIR PUMP RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE
1. OPERATE THE AIR PUMP RELAY


Yes >> Go To 5
No >> Go To 2
2. POWERTRAIN CONTROL MODULE

Measure the voltage of the Air Pump Relay Control circuit at the PCM har-
ness connector.

to Page 8E-56.
No >> Go To 3
(P0410) SECONDARY AIR INJECTION RELAY CIRCUIT — CONTINUED
3. AIR PUMP RELAY CONTROL CIRCUIT SHORT TO GROUND
Disconnect the Relay Control Module A harness connector.
Measure the resistance between ground and the Air Pump Relay Control
circuit.

Yes >> Repair the Air Pump Relay Control circuit for a short to
ground.
No >> Go To 4
4. OPEN AIR PUMP RELAY CONTROL CIRCUIT

Measure the resistance of the Air Pump Relay Control circuit from the
PCM C4 harness connector to the Relay Control Module A harness con-
nector.

Yes >> Replace the Relay Control Module.
No >> Repair the Air Pump Relay Control circuit for an open.
VER 2.


(P0412) SECONDARY AIR INJECTION SWITCHOVER SOLENOID CIRCUIT
(P0412) SECONDARY AIR INJECTION SWITCHOVER SOLENOID CIRCUIT — CONTINUED
• When Monitored: Continuously with the ignition on.
• Set Condition: An improper voltage level has been detected by the Powertrain Control Module (PCM) on
the air pump solenoid control circuit.
POSSIBLE CAUSES

GROUND CIRCUIT OPEN
FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED
AIR PUMP SWITCHOVER SOLENOID
Diagnostic Test
1. ACTUATE THE SECONDARY AIR PUMP SWITCHOVER SOLENOID

With the DRB IIIT, actuate the Air Pump Switchover Solenoid.
Does the Switchover Solenoid click on and off?

Yes >> Go To 5
No >> Go To 2
2. TESTING THE FUSED ENGINE CONTROL RELAY OUTPUT AND

GROUND CIRCUIT OF THE SECONDARY AIR PUMP
SWITCHOVER SOLENOID.

Disconnect the Air Pump Switchover Solenoid.
With the DRB IIIT, actuate the Air Pump Switchover Solenoid.
Measure the voltage between the Fused Engine Control Relay Output cir-
cuit and the Air Pump Switchover Solenoid Control circuit at the Air Pump
Switchover Solenoid harness connector.
Does the voltage toggle between B(+) and 0 volts?

Yes >> Replace the Air Pump Switchover Solenoid. Refer to Page
25-34
Perform the POWERTRAIN VERIFICATION TEST - VER
2.
No >> Go To 3
CIRCUIT AT THE AIR PUMP SWITCHOVER SOLENOID

the Air Pump Switchover Solenoid harness connector.

Yes >> Go To 4
an open.
Perform the POWERTRAIN VERIFICATION TEST -
VER 2.
4. CHECKING THE AIR PUMP SWITCHOVER SOLENOID CONTROL

CIRCUIT

Measure the resistance of the Air Pump Switchover Solenoid Control cir-
cuit from the Air Pump Switchover Solenoid harness connector to the PCM

to Page 8E-56.
2.
No >> Repair the Air Pump Switchover Solenoid Control cir-
cuit for an open.
Perform the POWERTRAIN VERIFICATION TEST -
VER 2.
and open circuits.

2.
(P0422) CATALYTIC 1/1 EFFICIENCY
(P0422) CATALYTIC 1/1 EFFICIENCY — CONTINUED
• When Monitored: The Powertrain Control Module (PCM) monitors the engine at operating temperature, in
closed loop, engine load between 22–52%, the Three Way Catalytic (TWC) converter temperature is greater
than 380°C (716°F), and no O2 Sensor or engine misfire faults.
• Set Condition: The amplitude of the O2 Sensor Signal downstream of the TWC exceeds 75% of the
amplitude of the O2 Sensor Signal upstream of the TWC for approximately 170 seconds.
POSSIBLE CAUSES
O2 SENSOR CONTAMINATION
ENGINE EXHAUST LEAKS OR DAMAGE
THREE WAY CATALYTIC CONVERTER
THREE WAY CATALYTIC CONVERTER DAMAGE
Diagnostic Test
1. INSPECT THE TWC CONVERTER

Note: Diagnose any O2 Sensor DTC(s) before continuing with this
diagnosis.
Note: Check for contaminants that may have damaged the O2 Sensor
and three way catalytic converter: contaminated fuel, unapproved sil-
icone products, oil or coolant and repair as necessary.
Note: Engine exhaust leaks can be the cause of this DTC. Inspect the
exhaust system for leaks before diagnosing this DTC.
Inspect the TWC for the following damage:
• Dents or holes.
• Severe discoloration caused by overheating the TWC.
• TWC broken internally.
• Leaking TWC.

Yes >> Repair the condition that caused the failure and replace the
three way catalytic converter. Refer to Page 11-5.
No >> Go To 2
2. INSPECT FOR EXHAUST LEAKS
Inspect the exhaust for any leak between the engine and the O2 Sensors.

No >> Replace the three way catalytic converter. Refer to
Page 11-5.
VER 2.
(P0432) CATALYTIC 2/1 EFFICIENCY
• When Monitored: The Powertrain Control Module (PCM) monitors the engine at operating temperature, in
closed loop, engine load between 22–52%, the Three Way Catalytic (TWC) converter temperature is greater
than 380°C (716°F), and no O2 Sensor or engine misfire faults.
• Set Condition: The amplitude of the O2 Sensor Signal downstream of the TWC exceeds 75% of the
amplitude of the O2 Sensor Signal upstream of the TWC for approximately 170 seconds.
POSSIBLE CAUSES
02 SENSOR CONTAMINATION
ENGINE EXHAUST LEAKS OR DAMAGE
THREE WAY CATALYTIC CONVERTER FAILURE
THREE WAY CATALYTIC CONVERTER DAMAGE
Diagnostic Test
1. INSPECT THE THREE WAY CATALYTIC CONVERTER

Note: Diagnose any O2 Sensor DTC(s) before continuing with this
diagnosis.
Note: Check for contaminants that may have damaged the O2 Sensor
and TWC converter: contaminated fuel, unapproved silicone prod-
ucts, oil or coolant and repair as necessary.
Note: Engine exhaust leaks can be the cause of this DTC. Inspect the
exhaust system for leaks before diagnosing this DTC.
Inspect the TWC for the following damage
• Dents or holes.
• Severe discoloration caused by overheating the TWC.
• TWC broken internally.
• Leaking TWC.

Yes >> Repair the condition that caused the failure and replace the
TWC converter. Refer to Page 11-5.
No >> Go To 2
2. INSPECT FOR EXHAUST LEAKS

Inspect the exhaust for any leak between the engine and the O2 Sensors.

No >> Replace the TWC converter. Refer to Page 11-5.
VER 2.
(P0440) GENERAL EVAP SYSTEM FAILURE
(P0440) GENERAL EVAP SYSTEM FAILURE — CONTINUED
• When Monitored: Engine Running. Cold start test. Fuel Level greater than 12%. Ambient Temperature
between 4°C and 32°C (39°F and 89°F) Close Loop fuel system. Test runs when small leak test is maturing.
• Set Condition: The PCM activates the Evap Purge Solenoid to pull the Evap system into a vacuum. The
PCM turns the Evap Purge solenoid off to seal the Evap system. If the Fuel Tank Pressure Sensor reads
between –1.5 to +1.0 hPa before the calibrated amount of time for a Medium leak/Small leak an error is
POSSIBLE CAUSES
EVAPORATIVE EMISSION SYSTEM LEAK
FUEL TANK PRESSURE SENSOR
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0455) EVAP
SYSTEM LARGE LEAK.
No >> Go To 2


(P0441) EVAP PURGE VALVE
(P0441) EVAP PURGE VALVE — CONTINUED
• Set Condition: An improper voltage level has been detected on the Evap Purge Solenoid Control circuit.
POSSIBLE CAUSES
EVAP PURGE SOLENOID VOLTAGE SUPPLY CIRCUIT OPEN

EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO GROUND
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE
EVAP PURGE SOLENOID
Diagnostic Test

Is this DTC preset?

PURGE SOLENOID CIRCUIT.
No >> Go To 2


(P0442) EVAP SYSTEM SMALL LEAK
(P0442) EVAP SYSTEM SMALL LEAK — CONTINUED
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

SYSTEM LARGE LEAK.
No >> Go To 2


(P0445) EVAP PURGE SOLENOID CIRCUIT
(P0445) EVAP PURGE SOLENOID CIRCUIT — CONTINUED
• Set Condition: An improper voltage level has been detected on the Evap Purge Solenoid Control circuit.
POSSIBLE CAUSES
EVAP PURGE SOLENOID VOLTAGE SUPPLY CIRCUIT OPEN

EVAP PURGE SOLENOID CONTROL CIRCUIT OPEN
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO GROUND
EVAP PURGE SOLENOID CONTROL CIRCUIT SHORT TO VOLTAGE
EVAP PURGE SOLENOID
Diagnostic Test

Note: Check for applicable TSBs.
DTC.

Yes >> Go To 2
No >> Go To 6
Disconnect the Evap Purge Solenoid harness connector.
the Evap Purge Solenoid harness connector.

Yes >> Go To 3
an open.
2.
3. DISCONNECT THE PCM

Reconnect the Evap Purge Solenoid harness connector.
Connect a fused jumper wire between ground and the Evap Purge Sole-
noid Control circuit at the PCM C5 harness connector.
Does the Evap Purge Solenoid produce an audible click?

Yes >> Go To 4
No >> Go To 5
4. EVAP PURGE SOLENOID CONTROL CIRCUIT CURRENT FLOW

Replace the EVAP Purge Solenoid. Refer to Page 25-17.
Note: The engine controls must go into closed loop and purge con-
trol must be active for at least 2 minutes.
Did the DTC, (P0445) EVAP Purge Solenoid Circuit, set again?
to Page 8E-56.
VER 2.
5. EVAP PURGE SOLENOID CONTROL CIRCUIT FAULT
Disconnect the Evap Purge Solenoid harness connector.
Check the Evap Purge Solenoid Control circuit for any fault open; short to
voltage, or a short to ground.
Was a circuit fault found?

Yes >> Repair the Evap Purge Solenoid Control circuit for the fault
found.
No >> Replace the Evap Purge Solenoid. Refer to Page
25-17.
VER 2.


(P0446) CHARCOAL CANISTER SHUTOFF VALVE
(P0446) CHARCOAL CANISTER SHUTOFF VALVE — CONTINUED
• When Monitored: The ignition on or engine running. Battery voltage greater than 10 volts.
• Set Condition:
POSSIBLE CAUSES
OPEN FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT

CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT SHORT TO GROUND
CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT OPEN
CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT SHORT TO VOLTAGE
CHARCOAL CANISTER SHUTOFF VALVE
Diagnostic Test
1. CHARCOAL CANISTER SHUTOFF VALVE

Disconnect the Charcoal Canister Shutoff Valve harness connector.
Using a 12-volt test light, jumper across the Charcoal Canister Shutoff
Valve harness connector.
Does the test light illuminate?

Yes >> Replace the Charcoal Canister Shutoff Valve. Refer to
Page 25-16.
No >> Go To 2

CIRCUIT TO THE CHARCOAL CANISTER SHUTOFF
VALVE

Connect a 12-volt test light between ground and the Fused Engine Control
Relay Output circuit and a ground of the Charcoal Canister Shutoff Valve
harness connector.
Does the test illuminate brightly?

Yes >> Go To 3
an open.
2.
(P0446) CHARCOAL CANISTER SHUTOFF VALVE — CONTINUED
3. CHECKING THE CHARCOAL CANISTER SHUTOFF VALVE
CONTROL CIRCUIT FOR AN OPEN

Measure the resistance of the Charcoal Canister Shutoff Valve Control cir-
cuit from the Charcoal Canister Shutoff Valve harness connector to the

Yes >> Go To 4
No >> Repair the Charcoal Canister Shutoff Valve Control circuit
for an open.
2.
4. CHARCOAL CANISTER SHUTOFF VALVE CONTROL CIRCUIT

SHORT TO GROUND.

Measure the resistance between ground and the Charcoal Canister Shut-
off Valve Control circuit at the Charcoal Canister Shutoff Valve harness
connector.

Yes >> Repair the Charcoal Canister Shutoff Valve Control circuit
VER 2.
(P0446) EVAP PURGE SOLENOID STUCK OPEN
(P0446) EVAP PURGE SOLENOID STUCK OPEN — CONTINUED
• When Monitored: Cold start test. Engine Running.
• Set Condition: The Powertrain Control Module (PCM) activates the Evap Purge Solenoid gradually and
increases to maximum flow. The PCM monitors the Fuel Tank Pressure Sensor and if the value falls below
–40 hPa too soon, the error is detected.
POSSIBLE CAUSES
EVAP PURGE SOLENOID
EVAP PURGE SOLENOID VACUUM SUPPLY
Diagnostic Test

Note: If any EVAP/Charcoal Canister DTCs are set, diagnose them
first before continuing with P0446.
active DTC.

Yes >> Go To 2
No >> Go To 4
2. CHECKING EVAP PURGE SOLENOID FUNCTIONALITY

Note: After disconnecting the Evap Purge vacuum connections,
inspect the lines and solenoid for any signs of contamination or for-
eign materials.
Using a hand vacuum pump, apply 10 in. Hg to the canister side of the
EVAP Purge Solenoid.
Observe the vacuum gauge.
With the DRB IIIT, actuate the EVAP Purge Solenoid.
Does the vacuum drop when the solenoid is actuated?

Yes >> Go To 3
2.
(P0446) EVAP PURGE SOLENOID STUCK OPEN — CONTINUED
3. EVAP VACUUM SUPPLY HOSE INSPECTION
Carefully inspect the Evap Purge Solenoid vacuum supply hose for proper
routing.
Check for a pinched or plugged vacuum hose to the Purge Solenoid.
Inspect the vacuum port for any damage or restriction.

Yes >> Repair the vacuum supply hose/tube as necessary.
No >> Go To 4

and open circuits.

(P0451) FUEL TANK PRESSURE SENSOR PERFORMANCE
(P0451) FUEL TANK PRESSURE SENSOR PERFORMANCE — CONTINUED
• When Monitored: With the engine running at idle speed.
• Set Condition: Low limit: The Fuel Tank Pressure Sensor voltage is less than 0.1 volt for 10 seconds.
High limit: The Fuel Tank Pressure Sensor voltage is greater than 4.7 volts for 10 seconds. Signal curve:
The Fuel Tank Pressure Sensor Performance code will be set if the signal remains constant.
POSSIBLE CAUSES
OPEN FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT

OPEN FUEL TANK PRESSURE SENSOR GROUND CIRCUIT
FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
OPEN 5-VOLT SUPPLY
5-VOLT SUPPLY SHORTED TO VOLTAGE
5-VOLT SUPPLY SHORTED TO GROUND
Diagnostic Test
1. READING FUEL TANK PRESSURE

Note: If an Evap System fault has been set, diagnose the Evap fault
before continuing.
With the DRB IIIT, monitor the Fuel Tank Press Diff.
Is the Fuel Tank Pressure above +30 hPa?

Yes >> Go To 2
No >> Go To 4
2. FUEL TANK PRESSURE SENSOR SIGNAL SHORTED TO VOLTAGE
Disconnect the Fuel Tank Pressure Sensor connector.
Measure the voltage of the Fuel Tank Pressure Sensor Signal circuit at the
Fuel Tank Pressure Sensor harness connector.

Yes >> Repair the Fuel Tank Pressure Sensor Signal for a short to
voltage.
No >> Go To 3
3. OPEN FUEL TANK PRESSURE SENSOR GROUND CIRCUIT

Measure the resistance of the Fuel Tank Pressure Sensor Ground circuit
from the Fuel Tank Pressure Sensor harness connector to the PCM har-
ness connector.

Yes >> Replace the Fuel Tank Pressure Sensor. Refer to Page
14-13.
No >> Repair the Fuel Tank Pressure Sensor Ground circuit
for an open.
VER 2.
4. FUEL TANK PRESSURE SENSOR

Disconnect the Fuel Tank Pressure Sensor harness connector.
Connect a fused jumper between the Fuel Tank Pressure Sensor Signal
circuit and the Fuel Tank Pressure Sensor 5-Volt Supply circuit.
Is the Fuel Tank Pressure above +30 hPa?

Yes >> Replace the Fuel Tank Pressure Sensor. Refer to Page
14-13.
No >> Go To 5
5. FUEL TANK PRESSURE SENSOR 5-VOLT SUPPLY
Measure the voltage of the Fuel Tank Pressure Sensor 5-Volt Supply cir-
cuit at the Fuel Tank Pressure Sensor harness connector.

Yes >> Go To 8
No >> Go To 6
6. FUEL TANK PRESSURE SENSOR 5-VOLT SUPPLY SHORTED TO

GROUND

Measure the resistance between ground and the Fuel Tank Pressure Sen-
sor 5-Volt Supply circuit.

Yes >> Repair the Fuel Tank Pressure Sensor 5-Volt Supply circuit
No >> Go To 7
7. OPEN FUEL TANK PRESSURE SENSOR 5-VOLTS SUPPLY CIRCUIT

Measure the resistance of the Fuel Tank Pressure Sensor 5-Volt Supply
circuit from the PCM harness connector and the Fuel Tank Pressure Sen-

Yes >> Repair the Fuel Tank Pressure 5-Volt Supply circuit for an
open.
VER 2.
8. OPEN FUEL TANK PRESSURE SENSOR SIGNAL
Measure the resistance of the Fuel Tank Pressure Sensor Signal circuit
from the PCM harness connector and the Fuel Tank Pressure Sensor har-
ness connector.

Yes >> Repair the Fuel Tank Pressure Sensor Signal circuit for an
open.
No >> Go To 9
9. FUEL TANK PRESSURE SENSOR SIGNAL SHORTED TO GROUND

Measure the resistance between ground and the Fuel Tank Pressure Sen-
sor Signal circuit.

Yes >> Repair the Fuel Tank Pressure Sensor Signal circuit for a
short to ground.
VER 2.
(P0452) FUEL TANK PRESSURE SENSOR CIRCUIT LOW
(P0452) FUEL TANK PRESSURE SENSOR CIRCUIT LOW — CONTINUED
POSSIBLE CAUSES
OPEN FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT

OPEN FUEL TANK PRESSURE SENSOR GROUND CIRCUIT
FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
OPEN 5-VOLT SUPPLY
5-VOLT SUPPLY SHORTED TO GROUND
Diagnostic Test

Is this DTC preset?

TANK PRESSURE SENSOR PERFORMANCE.
No >> Go To 2


(P0453) FUEL TANK PRESSURE SENSOR CIRCUIT HIGH
(P0453) FUEL TANK PRESSURE SENSOR CIRCUIT HIGH — CONTINUED
POSSIBLE CAUSES
FUEL TANK PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

5-VOLT SUPPLY SHORTED TO VOLTAGE
Diagnostic Test

Is this DTC preset?

TANK PRESSURE SENSOR PERFORMANCE.
No >> Go To 2


(P0455) EVAP SYSTEM LARGE LEAK
(P0455) EVAP SYSTEM LARGE LEAK — CONTINUED
(P0442) EVAP SYSTEM SMALL LEAK
(P0455) EVAP SYSTEM LARGE LEAK

• When Monitored: Engine Running. Cold start test. Fuel Level greater than 12%, ambient temperature
between 4°C and 32°C (39°F and 89°F), closed loop system operation. Test runs when small leak test is
maturing.
• Set Condition: The PCM activates the EVAP Purge Solenoid to pull the EVAP system into a vacuum. The
PCM turns the EVAP Purge solenoid off to seal the EVAP system. If the fuel tank pressure sensor reads
normal operating pressure sooner than expected, a Large Leak error is detected.
POSSIBLE CAUSES
Diagnostic Test

Note: Since a hot vehicle can conceal a leak, it is best to perform
this test at room temperature.
Note: A loose fuel filler cap could have caused this DTC to set. Make
sure fuel filler cap is tight and in good condition. Ensure the fuel
filler cap meets OEM specifications.
active DTC.

Yes >> Go To 2
No >> Go To 7
Perform a visual and physical inspection of the entire Evaporative Emis-
sion system.
Check for the follow conditions:
- Holes or cracks
- Loose seal points
- Evidence of damaged components
- Incorrect routing of hoses and tubes
- Fuel Filler Cap gasket seal
Were any of the above conditions found?

No >> Go To 3
3. VERIFY EVAPORATIVE EMISSION LEAK
WARNING: KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND
OTHER IGNITION SOURCES AWAY FROM THE TEST AREA TO PRE-
VENT THE IGNITION OF EXPLOSIVE GASES. KEEP THE TEST AREA
WELL VENTILATED.
Note: The fuel tank should have between 20% and 80% of fuel tank
capacity to properly test the Evap system.
To continue testing you will need Special Tool #8404 Evaporative Emission
Leak Detector (EELD).
Connect the red power lead of the EELD to the battery positive terminal
and the black ground lead to battery negative terminal.
Block the vent hose of the EVAP Canister.
Connect shop air to the EELD.
Set the smoke/air control switch to AIR.
Insert the tester’s AIR supply tip (clear hose) into the appropriate calibra-
tion orifice on the tester’s control panel (based on DTC leak size).
Press the remote smoke/air start button.
Position the red flag on the air flow meter so it is aligned with the indicator
ball.
When the calibration is complete, release the remote button. The EELD is
now calibrated the flow meter in liters per minute to the size leak indicated
by the DTC set in the PCM.
Install the service port adapter (Special Tool #8404-14) on the vehicle’s
service port.
Connect the Air supply hose from the EELD to the service port.
Press the remote button to activate AIR flow.
Note: Larger volume fuel tanks, lower fuel levels or if the vehicle is
equipped with a Flow Management Valve may indicate high flow and
will require 4 to 5 minutes to fill.
Compare the flow meter indicator ball reading to the red flag.
ABOVE the red flag indicates a leak present.
BELOW the red flag indicates a sealed system.
Is the indicator ball above the red flag?

Yes >> Go To 4
No >> Go To 7
4. EVAPORATIVE EMISSION LEAK DETECTION
Note: A thorough visual inspection of the Evap system hoses, tubes,
and connections may save time in your diagnosis. Look for any
physical damage or signs of wetness at connections. The strong
smell of fuel vapors may aid diagnosis also.
Remove the Air supply hose from the vehicle’s service port.
Connect the SMOKE supply tip (black hose) to the vehicle’s service port.
Set the smoke/air control switch to SMOKE.
Note: The flow meter indicator ball will not move in the smoke mode.
Press the remote smoke/air start button.
Note: Ensure that smoke has filled the EVAP system by continuing to
press the remote smoke/air start button, remove the vehicle’s fuel
filler cap and wait for the smoke to exit. Once smoke is indicated,
reinstall the fuel filler cap.
Note: For optimal performance, introduce smoke into the system for
an additional 60 seconds; continue introducing smoke at 15 second
intervals as necessary.
While still holding the remote smoke/air start button, use the white light
(Special Tool #8404-CLL) to follow the EVAP system path and look for the
source of the leak indicated by exiting smoke.
If a leak is concealed from view (i.e., top of fuel tank), release the remote
smoke/air start button and use the ultraviolet (UV) black light #8404-UVL
and the yellow goggles #8404-20 to look for residual traces of dye that are
left behind by the smoke.
The exiting smoke deposits a residual fluid that is either bright green or
bright yellow in color when viewed with a UV light.
Note: Carefully inspect the vent side of the EVAP Canister. Due to the
filtering system in the canister the smoke may not be as thick. Intro-
ducing smoke into the filtered side of the canister may assist in
locating the leak.
Was a leak found?

Yes >> Repair or replace the leaking component as necessary.
No >> Go To 5
5. EVAP PURGE SOLENOID OPERATION
Note: After disconnecting the Evap Purge Solenoid vapor hose con-
nections, inspect the lines and solenoid for any signs of contamina-
tion from the EVAP Canister. This may indicate a faulty rollover valve.
Replace/repair as necessary.
Disconnect the vacuum hoses at the Evap Purge Solenoid.
Using a hand vacuum pump, apply 10 in. Hg to the canister side of the
EVAP Purge Solenoid.
Note: Monitor the vacuum gauge for at least 15 seconds.
Does the EVAP Purge Solenoid hold vacuum?

Yes >> Go To 6
2.
6. FUEL TANK PRESSURE SENSOR OPERATION

Note: The fuel level must be below 85%, or the Tank Vent/Rollover
Valves and the Fuel Tank Overfill Check Valve will seal the tank.
Install the fuel filler cap adapter. Attach the fuel filler cap to the adapter.
Connect a hand-held vacuum pump to the fuel filler cap adapter.
Slowly apply vacuum while monitoring the fuel tank pressure sensor on
the DRB IIIT. Do not exceed 2 in. Hg while performing this step.
Note: The fuel tank pressure sensor reads normally –1 hPa. When
the vacuum is applied and 1 in. Hg is reached, the fuel tank pressure
sensor should be approximately –5 hPa. Once the vacuum has been
released, the fuel tank pressure sensor return to a normal reading.
Did the fuel tank pressure sensor operate as described above?

Yes >> Go To 7
No >> Replace the Fuel Level Sending Unit/Pressure Sensor.
2.
7. INTERMITTENT CONDITION
Review the DRB IIIT Freeze Frame information. If possible, try to duplicate
the conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Note: A loose fuel filler cap could have caused this DTC to set. Make
sure fuel filler cap is tight and in good condition. Ensure the fuel
filler cap meets OEM specifications.
Perform a visual and physical inspection of the entire Evaporative Emis-
sion system.
Check for the following conditions:
- Holes or cracks
- Loose seal points
- Evidence of damaged components
- Incorrect routing of hoses and tubes
- Fuel filler cap gasket seal
Were any of the above conditions found?

No >> The condition that caused this symptom is currently
(P0457) EVAP PURGE VALVE LEAKING
(P0457) EVAP PURGE VALVE LEAKING — CONTINUED
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

SYSTEM LARGE LEAK.
No >> Go To 2


(P0460) FUEL LEVEL SENSOR CIRCUIT
(P0460) FUEL LEVEL SENSOR CIRCUIT — CONTINUED
• When Monitored: The Powertrain Control Module (PCM) monitors the fuel level at ignition on.
• Set Condition: If the PCM does not see a change in the fuel level over a set amount of miles, the test will
fail. Two Trip Fault.
For a complete Electronic Control Module Circuit Diagram, Refer to Page 8E-45.
Diagnostic Test
1. FUEL GAUGE OPERATION

Perform the *FUEL GAUGE INOPERATIVE diagnostic test located in
Instrument Cluster 8J Category.
After performing the *FUEL GAUGE INOPERATIVE test, use the DRB IIIT,
erase DTCs.
Note: It may be necessary to take the vehicle on a test drive.
It may be necessary to take the vehicle on a test drive.
Does the DTC (P0460) set again?

to Page 8E-56.
(P0500) NO VEHICLE SPEED SIGNAL (CAB CAN MESSAGE)
(P0500) NO VEHICLE SPEED SIGNAL (CAB CAN MESSAGE) — CONTINUED
Diagnostic Test
1. DTC PRESENT IN CONTROLLER ANTILOCK BRAKE (CAB).

This is an informational DTC letting you know that a DTC(s) is stored in
the CAB.
Erase this DTC from the PCM after all ABS DTC(s) have been repaired.
Using the DRB IIIT, read the ABS DTC(s) and refer to the ABS Category
to perform the appropriate symptom.
PCM Diagnostic Information complete.

Continue
Test Complete.
(P0500) VEHICLE SPEED PERFORMANCE ESP MIL REQUEST
(P0500) VEHICLE SPEED PERFORMANCE ESP MIL REQUEST — CONTINUED
Diagnostic Test
1. DTC PRESENT IN CAB.

the CAB.
Erase this DTC from the PCM after all the ABS DTC(s) have been
repaired.
Using the DRB IIIT, read the ABS DTC(s) and refer to the Brake-BAS
Electrical Diagnostics Category to perform the appropriate symptom.

Continue
Test Complete.
(P0561) BATTERY SYSTEM VOLTAGE
(P0561) BATTERY SYSTEM VOLTAGE — CONTINUED
• When Monitored: 180 seconds after the engine is started.
• Set Condition: The voltage supply at the Powertrain Control Module (PCM) is less than 8 volts or greater
than 16.5 volts for at least 5 seconds.
POSSIBLE CAUSES
ENGINE CONTROL FUSE #1 OUTPUT CIRCUIT OPEN

ENGINE CONTROL FUSE #1 OUTPUT CIRCUIT SHORTED TO GROUND
ENGINE CONTROL RELAY OUTPUT CIRCUIT OPEN
ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED TO GROUND
Diagnostic Test
1. CHECK TO SEE IF BATTERY VOLTAGE DTC IS CURRENT

Note: Perform DIAGNOSIS AND TESTING - CHARGING SYSTEM
located in 8F-Engine Systems to verify the charging system is work-
ing properly before continuing.
With the DRB IIIT, read DTCs. If possible operate the vehicle within the
conditions that set the DTC.
Is the Battery System Voltage DTC displayed as ACTIVE?

Yes >> Go To 2
a. No >> Go To 5
2. ENGINE CONTROL FUSE #1 OUTPUT CIRCUIT

With a 12-Volt test lamp connected to ground, probe the Fused Engine
Control Relay Output circuit at the PCM C5 harness connector. The lamp
should be bright, compare to when connected across the battery.

Yes >> Go To 3
No >> Go To 4
(P0561) BATTERY SYSTEM VOLTAGE — CONTINUED
3. PCM
With a test lamp connected to a ground, probe the Engine Control Relay
Output circuit at PCM C5 harness connector. The lamp should be bright,
compared to when connected across the battery.

to Page 8E-56.
No >> Go To 4

Disconnect the Relay Control Module E harness connector.
Measure the resistance of the Engine Control Relay Output circuit from
the PCM C5 harness connector to the Relay Control Module E harness
connector.
Measure the resistance of the B(+) circuit from the PCM C5 harness con-
nector to the Relay Control Module E harness connector.
Is the resistance below 5.0 ohms for both circuits?

Yes >> Replace Relay Control Module.
No >> Repair the faulty circuit for an open.
VER 2.


(P0562) BATTERY SYSTEM LOW
(P0562) BATTERY SYSTEM LOW — CONTINUED
• Set Condition: The voltage supply at the Powertrain Control Module (PCM) is less than 8 volts for at least
5 seconds.
POSSIBLE CAUSES
ENGINE CONTROL FUSE #1 OUTPUT CIRCUIT OPEN

ENGINE CONTROL FUSE #1 OUTPUT CIRCUIT SHORTED TO GROUND
ENGINE CONTROL RELAY OUTPUT CIRCUIT SHORTED TO GROUND
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0561) BAT-
TERY SYSTEM VOLTAGE.
No >> Go To 2


(P0563) BATTERY SYSTEM HIGH
(P0563) BATTERY SYSTEM HIGH — CONTINUED
• Set Condition: The voltage supply at the Powertrain Control Module (PCM) is greater than 16.5 volts for
at least 5 seconds.
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0561) BAT-
TERY SYSTEM VOLTAGE.
No >> Go To 2


(P0571) STOP LAMP SWITCH CAN SIGNAL LOST TO TRANS PERFORMANCE
(P0571) STOP LAMP SWITCH CAN SIGNAL LOST TO TRANS PERFORMANCE — CONTINUED
Diagnostic Test
1. DTC PRESENT IN CONTROLLER ANTILOCK BRAKE (CAB)

the CAB.
Erase this DTC from the PCM after all ABS DTC(s) have been repaired.

Continue
Test Complete.
(P0571) STOP LAMP SWITCH SIGNAL PERFORMANCE
(P0571) STOP LAMP SWITCH SIGNAL PERFORMANCE — CONTINUED
Diagnostic Test
1. DTC PRESENT IN CONTROLLER ANTILOCK BRAKE (CAB)

the CAB.
Erase this DTC from the PCM after all CAB DTC(s) have been repaired.

Continue
Test Complete.
(P0600) INCORRECT CAN MESSAGE FROM EIS CONTROL MODULE
(P0600) INCORRECT CAN MESSAGE FROM EIS CONTROL MODULE — CONTINUED
Diagnostic Test
1. DTC PRESENT IN EIS MODULE.

the EIS MODULE.
Erase this DTC from the PCM after all EIS DTC(s) have been repaired.
Using the DRB IIIT, read the EIS DTC(s) and refer to the Instrument Clus-
ter Category to perform the appropriate symptom.

Continue
Test Complete.
(P0600) NO CAN MESSAGE FROM CAB MODULE
(P0600) NO CAN MESSAGE FROM CAB MODULE — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from Controller
POSSIBLE CAUSES
CAN C BUS (+)/(-) CIRCUIT OPEN

CAN C BUS (+)/(-) LOW CIRCUIT SHORTED TO VOLTAGE
Diagnostic Test

Turn ignition on.

No >> Go To 2
2. VERIFY DTCS
Did the DTC, (P0600) NO CAN MESSAGE FROM CAB MODULE, set
again?
Yes >> Go To 3
No >> Go To 12
Measure the resistance of the PCM CAN C BUS termination by backprob-
ing the CAN C BUS (+) circuit to the CAN C BUS (-) circuit at the PCM C4
harness connector.

Yes >> Go To 11
No >> Go To 4

Measure the resistance of the SKREEM CAN C BUS termination by back-
probing the CAN C BUS (+) circuit to the CAN C BUS (-) circuit at the
Is the SKREEM CAN C BUS termination resistance between 110

and 130 ohms?
to Page 8E-56.
No >> Go To 5
Measure the resistance of the SKREEM CAN C BUS termination by back-
probing the CAN C BUS (+) circuit to the CAN C BUS (-) circuit at the

Yes >> Go To 6
2.
Measure the resistance of the CAN C BUS (-) circuit from the SKREEM
C2 harness connector to the PCM C4 harness connector.

Yes >> Go To 7
No >> Repair the CAN C BUS (-) circuit for an open.
2.

Measure the resistance of the CAN C BUS (+) circuit from the PCM C4

Yes >> Go To 8
No >> Repair the CAN C BUS (+) circuit for an open.
2.

Measure the voltage of the CAN C BUS (+) circuit at the PCM C4 harness
connector.

Yes >> Repair the CAN C BUS (+) circuit for a short to voltage.
No >> Go To 9
Measure the voltage of the CAN C BUS (-) circuit at the PCM C4 harness
connector.

Yes >> Repair the CAN C BUS (-) circuit for a short to voltage.
No >> Go To 10

Measure the resistance between ground and the CAN C BUS (-) circuit.

Yes >> Repair the CAN C BUS (-) circuit for a short to ground.
No >> Repair the CAN C BUS (+) circuit for a short to
ground.
VER 2.
11. CAN C BUS (-) CIRCUIT OPEN FROM CAB TO PCM

Measure the resistance of the CAN C BUS (-) circuit from the CAB har-

Yes >> Repair the CAN C BUS (+) circuit for an open between the
PCM C4 harness and the CAB harness connector.
No >> Repair the CAN C BUS (-) circuit for an open between
the PCM C4 harness and the CAB harness connector.
VER 2.

(P0600) NO TRANSMISSION BUS MESSAGE
(P0600) NO TRANSMISSION BUS MESSAGE — CONTINUED
POSSIBLE CAUSES

Diagnostic Test

Turn ignition on.

No >> Go To 2
2. VERIFY DTCS
Did the DTC, (P0600) NO TRANSMISSION BUS MESSAGE set

again?
Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
2.

Yes >> Go To 7
2.


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.
11. CAN C BUS (-) CIRCUIT OPEN FROM TCM TO PCM


PCM C4 harness and the TCM C3 harness connector.
the PCM C4 harness and the TCM C3 harness con-
nector.
VER 2.

(P0600) LOST COMM WITH ELECTRIC GEAR SHIFT MODULE (SLA)
(P0600) LOST COMM WITH ELECTRIC GEAR SHIFT MODULE (SLA) — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Shift Lever
Assembly (SLA).
POSSIBLE CAUSES

CAN C BUS HIGH/LOW CIRCUIT SHORTED TO VOLTAGE
SHIFT LEVER ASSEMBLY (SLA)
For a complete Electrical Control Module Circuit Diagram, Refer to Page 8E-45.
Diagnostic Test
1. CHECK TO SEE IF SLA DTCS ARE PRESENT

Turn ignition on.
With the DRB IIIT, read SLA DTCs.

Yes >> Repair all SLA DTCs before proceeding.
No >> Go To 2
2. VERIFY DTCS
Did the DTC, (P0600) LOST COMM WITH ELECTRIC GEAR SHIFT
MODULE (SLA), set again?
Yes >> Go To 3
No >> Go To 12
Measure the resistance of the PCM CAN C Bus termination by backprob-
harness connector.

Yes >> Go To 11
No >> Go To 4

Measure the resistance of the SKREEM CAN C Bus termination by back-

130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
2.

Yes >> Go To 7
2.
7. CAN C Bus (+) CIRCUIT OPEN


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.
11. CAN C BUS (-) CIRCUIT OPEN FROM SLA TO PCM

Measure the resistance of the CAN C Bus (-) circuit from the SLA harness

PCM C4 harness and the SLA harness connector.
the PCM C4 harness and the SLA harness connector.
VER 2.

(P0600) NO CLUSTER BUS MESSAGE
(P0600) NO CLUSTER BUS MESSAGE — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Instrument
Cluster.
POSSIBLE CAUSES

INSTRUMENT CLUSTER
Diagnostic Test
1. CHECK TO SEE IF INSTRUMENT CLUSTER DTCS ARE PRESENT

Turn ignition on.
With the DRB IIIT, read Instrument Cluster DTCs.
Are any performance or BUS related DTCs present?

Yes >> Repair all Instrument Cluster DTCs before proceeding.
No >> Go To 2
2. VERIFY DTCS
Did the DTC, (P0600) NO CLUSTER BUS MESSAGE, set again?

Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
2.

Yes >> Go To 7
2.


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.
11. CAN C BUS (-) CIRCUIT OPEN FROM INSTRUMENT CLUSTER TO

PCM

Cluster C1 harness connector to the PCM C4 harness connector.

PCM C4 harness and the Instrument Cluster C1 harness
connector.
the PCM C4 harness and the Instrument Cluster C1
harness connector.
VER 2.

(P0602) PCM PROGRAMMED INCORRECT TRANS/NO COMM FROM TCM
(P0602) PCM PROGRAMMED INCORRECT TRANS/NO COMM FROM TCM — CONTINUED
POSSIBLE CAUSES

Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0600) NO
TRANSMISSION BUS MESSAGE.
No >> Go To 2


(P0700) TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
(P0700) TRANSMISSION CONTROL SYSTEM (MIL REQUEST) — CONTINUED
Diagnostic Test
1. DTC PRESENT IN TRANSMISSION CONTROL MODULE (TCM)

Erase this DTC from the PCM after all Transmission DTC(s) have been
repaired.
Using the DRB IIIT, read the Transmission Controller DTC and refer to the
Transmission Category and perform the appropriate symptom.

Continue
Test Complete.
(P0702) TRANSMISSION CONTROL MODULE LOW VOLTAGE
(P0702) TRANSMISSION CONTROL MODULE LOW VOLTAGE — CONTINUED
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
(P0702) LOSS OF TORQUE MANAGEMENT SIGNAL
(P0702) LOSS OF TORQUE MANAGEMENT SIGNAL — CONTINUED
Diagnostic Test

repaired.

Continue
Test Complete.
(P0702) TCM TORQUE MANAGEMENT REQUEST PERFORMANCE
(P0702) TCM TORQUE MANAGEMENT REQUEST PERFORMANCE — CONTINUED
Diagnostic Test

repaired.

Continue
Test Complete.
(P0705) SLA CONTROL SYSTEM (MIL REQUEST)
(P0705) SLA CONTROL SYSTEM (MIL REQUEST) — CONTINUED
Diagnostic Test
1. DTC PRESENT IN SHIFT LEVER ASSEMBLY (SLA).

the SLA.
Erase this DTC from the PCM after all SLA DTC(s) have been repaired.
Using the DRB IIIT, read the SLA DTC(s) and refer to the Shift Lever
Assembly Category to perform the appropriate symptom.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
(P0720) TRANSMISSION INCORRECT TORQUE REQUEST FROM ESP
(P0720) TRANSMISSION INCORRECT TORQUE REQUEST FROM ESP — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the Controller
POSSIBLE CAUSES

Diagnostic Test

Turn ignition on.

No >> Go To 2
2. VERIFY DTCS
Did the DTC (P0720) TRANSMISSION INCORRECT TORQUE

REQUEST FROM ESP set again?
Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
2.

Yes >> Go To 7
2.


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.
11. CAN C BUS (-) CIRCUIT OPEN FROM TCM TO PCM


PCM C4 harness and the TCM C3 harness connector.
the PCM C4 harness and the TCM C3 harness con-
nector.
VER 2.

Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
Diagnostic Test

repaired.

Continue
Test Complete.
(P1386) KNOCK SENSOR SYSTEM FAILURE
(P1386) KNOCK SENSOR SYSTEM FAILURE — CONTINUED
• When Monitored: After the Anti-knock control is shut off and the engine is at operating temperature.
• Set Condition: The Anti-knock control test has failed Ten consecutive times in a row.
POSSIBLE CAUSES
Diagnostic Test
1. CHECK PCM FOR INTERNAL FAILURE DTC

Note: This DTC will not turn on the Check Engine light.
Did the DTC (P1386) KNOCK SENSOR SYSTEM FAILURE set

again?
to Page 8E-56.
No >> Go To 2


(P1600) ROUGH ROAD DETECTED
(P1600) ROUGH ROAD DETECTED — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the CAB.
POSSIBLE CAUSES

SENTRY KEY REMOTE ENTRY MODULE (SKREEM)
Diagnostic Test

Turn ignition on.

No >> Go To 2
2. VERIFY DTCS
Did the DTC (P1600) ROUGH ROAD DETECTED set again?

Yes >> Go To 3
No >> Go To 12
3. PCM AND SKREEM CAN BUS TERMINATION
harness connector.

Yes >> Go To 11
No >> Go To 4
4. PCM CAN BUS TERMINATION


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
2.
6. CAN BUS (-) CIRCUIT OPEN

Yes >> Go To 7
2.


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.


VER 2.

(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT HIGH
(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT HIGH — CONTINUED
• Set Condition: The Occupant Restraint Controller (ORC) periodically sends out a signal to the Powertrain
Control Module (PCM). If the PCM does not receive the signal from the ORC, the PCM will set the fault
code.
POSSIBLE CAUSES
ENHANCED ACCIDENT REPORT DRIVER CIRCUIT SHORTED TO VOLTAGE

ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT SHORTED TO GROUND
ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT OPEN
Diagnostic Test
1. CHECK FOR ACTIVE DTC

active DTC.
With the DRB IIIT, check the ORC for proper communication and DTCs. If
there are any Occupant Restraint Controller (ORC) DTCs, repair them
before continuing this test.
Cycle the ignition switch on and off several times, pausing for at least 10
seconds at each key off and key on.

Yes >> Go To 2
No >> Go To 6
2. ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT
SHORTED TO VOLTAGE

DISCONNECTED.
Disconnect the Occupant Restraint Controller harness connector in accor-
dance with the Service Information.
Measure the voltage of the Enhanced Accident Report Driver Signal cir-
cuit.

Yes >> Go To 3
No >> Repair the Enhanced Accident Report Driver circuit for a
short to voltage.
2.
3. ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT

SHORTED TO GROUND

Measure the resistance between ground and the Enhanced Accident
Report Driver Signal circuit.

Yes >> Repair the Enhanced Accident Report Driver circuit for a
short to ground.
No >> Go To 4
4. ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT OPEN
Measure the resistance of the Enhanced Accident Report Driver Signal cir-
cuit from the PCM C4 harness connector to the ORC harness connector.

Yes >> Go To 5
No >> Repair the Enhanced Accident Report Driver Signal cir-
cuit for an open.
2.
5. ORC
DISCONNECTED.
Replace the Occupant Restraint Controller. Refer to Page 8O-89
Perform several engine run cycles, turning the ignition off for at least 20
seconds between each engine run cycle.

to Page 8E-56.
Note: Check connectors - Clean/repair as necessary. Poor pin to ter-

(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT LOW
(P2513) ENHANCED ACCIDENT REPORT DRIVER CIRCUIT LOW — CONTINUED
• Set Condition: The Occupant Restraint Controller (ORC) periodically sends out a signal to the Powertrain
Control Module (PCM). If the PCM does not receive the signal from the ORC, the PCM will set the fault
code.
POSSIBLE CAUSES
ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT SHORTED TO GROUND

ENHANCED ACCIDENT REPORT DRIVER SIGNAL CIRCUIT OPEN
Diagnostic Test

Is this DTC preset?

ENHANCED ACCIDENT REPORT DRIVER CIRCUIT LOW.
No >> Go To 2


(P2545) ESP TORQUE MANAGEMENT REQUEST PERFORMANCE
(P2545) ESP TORQUE MANAGEMENT REQUEST PERFORMANCE — CONTINUED
• Set Condition: This DTC is set when a CAN ID was not received in the required time from the CAB.
POSSIBLE CAUSES

SENTRY KEY REMOTE ENTRY MODULE (SKREEM) INTERNAL FAILURE
Diagnostic Test

Turn ignition on.
Are there any performance or BUS related DTCs present?

No >> Go To 2
2. VERIFY DTCS
Did the DTC (P2545) ESP TORQUE MANAGEMENT REQUEST PER-

FORMANCE set again?
Yes >> Go To 3
No >> Go To 12
harness connector.

Yes >> Go To 11
No >> Go To 4


130 ohms?
to Page 8E-56.
No >> Go To 5

Yes >> Go To 6
No >> Replace the Sentry Key Remote Entry Module. Refer to
Page 8E-70.
2.

Yes >> Go To 7
2.


Yes >> Go To 8
2.

connector.

No >> Go To 9
connector.

No >> Go To 10


VER 2.


VER 2.

(P2561) HVAC CONTROL MODULE REQUESTED MIL ILLUMINATION
(P2561) HVAC CONTROL MODULE REQUESTED MIL ILLUMINATION — CONTINUED
Diagnostic Test
1. DTC PRESENT IN A/C HEATER CONTROL MODULE.

the A/C Heater Control Module.
Erase this DTC from the PCM after all A/C-Heater Control Module DTC(s)
have been repaired.
Using the DRB IIIT, read the A/C-Heater Control Module DTC(s) and refer
to the A/C Heater Control Module Category to perform the appropriate
symptom.

Continue
Test Complete.
COOLING FAN CONTROL CIRCUIT OPEN
COOLING FAN CONTROL CIRCUIT OPEN — CONTINUED
• Set Condition: When Engine Coolant temperature is less than 70°C (158°F) and the Powertrain Control
Module (PCM) senses voltage greater than 2.5 volts on the Radiator Fan Control circuit or less than 2.0
volts above 85°C (185°F).
POSSIBLE CAUSES

RADIATOR FAN CONTROL CIRCUIT SHORTED TO VOLTAGE
Diagnostic Test
1. RADIATOR FAN CONTROL MODULE

WARNING: WHILE MONITORING ENGINE COOLANT TEMPERATURE
WITH THE DRB IIIT, DO NOT ALLOW THE ENGINE COOLANT TEM-
PERATURE TO RISE ABOVE 102°C (215°F) WITH THE RADIATOR FAN
CONTROL MODULE DISCONNECTED.
Note: If an Engine Coolant Temperature (ECT) Sensor fault has been
set, diagnose the Engine Coolant Temperature Sensor faults before
continuing.
Measure the voltage of the Radiator Fan Control circuit at the Radiator
Fan Control Module harness connector.

Yes >> 2
No >> Replace the Radiator Fan Control Module. Refer to
Page 7-29.
2.
COOLING FAN CONTROL CIRCUIT OPEN — CONTINUED
2. RADIATOR FAN CONTROL CIRCUIT OPEN
Measure the resistance of the Radiator Fan Control circuit from the PCM
C4 harness connector to the Radiator Fan Control Module harness con-
nector.

Yes >> Go To 3
No >> Repair the Radiator Fan Control circuit for an open.
2.
3. RADIATOR FAN CONTROL CIRCUIT SHORTED TO GROUND

cuit.

Yes >> Repair the Radiator Fan Control circuit for a short to
ground.
No >> Go To 4
4. RADIATOR FAN CONTROL CIRCUIT SHORTED TO VOLTAGE

Measure the voltage of the Radiator Fan Control circuit at the PCM C4
harness connector.

Yes >> Repair the Radiator Fan Control circuit for a short to volt-
age.
VER 2.
COOLING FAN CONTROL CIRCUIT HIGH
COOLING FAN CONTROL CIRCUIT HIGH — CONTINUED
Module (PCM) senses voltage greater than 2.5 volts on the Radiator Fan Control circuit.
POSSIBLE CAUSES
RADIATOR FAN CONTROL CIRCUIT SHORTED TO VOLTAGE

Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to COOLING FAN
CONTROL CIRCUIT OPEN.
No >> Go To 2


COOLING FAN CONTROL CIRCUIT LOW
COOLING FAN CONTROL CIRCUIT LOW — CONTINUED
Module (PCM) senses voltage less than 2.0 volts above 85°C (185°F).
POSSIBLE CAUSES

Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to COOLING FAN
CONTROL CIRCUIT OPEN.
No >> Go To 2


ENGINE OIL SENSOR LEVEL PERFORMANCE
ENGINE OIL SENSOR LEVEL PERFORMANCE — CONTINUED
• When Monitored: With the ignition on, engine running.
• Set Condition: Anytime the Powertrain Control Module (PCM) senses the Oil Level with the engine off is
outside the values of 34 - 62 mm and with the engine running, the values of 15 - 45 mm.
Note: Check and verify that the engine oil level is at the appropriate level.
POSSIBLE CAUSES

5-VOLT SUPPLY CIRCUIT SHORTED TO B(+)
OIL SENSOR GROUND CIRCUIT OPEN
OIL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
OIL SENSOR SIGNAL CIRCUIT SHORTED VOLTAGE
OIL SENSOR SIGNAL CIRCUIT OPEN
LOW OIL LEVEL
OIL SENSOR
Diagnostic Test
1. CHECKING FOR OIL SENSOR DTCS

Note: Normal Oil Level readings with the Engine not running is 34–62
mm and with the Engine running is 15–45 mm.
With the engine oil level at the proper level.
DTC.
Start the engine and run until operating temp is reached. (Closed Loop)
Note: It may be necessary to road test the vehicle.
Are there any Oil Sensors DTCs set?

Yes >> Go To 2
No >> Go To 10
2. CHECKING FOR OIL SENSOR LEVEL DTC
Is the Oil Level DTC the only Engine Oil Sensor DTC set?
Yes >> Replace the Oil Sensor. Refer to Page 9-672.
No >> Go To 3

Disconnect the Oil Sensor harness connector.
Measure the voltage of the 5-Volt Supply circuit at the Oil Sensor harness
connector.
Is the voltage between 4.5 to 5.0 volts?

Yes >> Go To 7
No >> Go To 4

Measure the voltage of the 5-Volt Supply circuit at the PCM C3 harness
connector.

Yes >> Repair the Oil Sensor 5-Volt Signal circuit for short to volt-
age.
No >> Go To 5

Yes >> Repair the Oil Sensor 5-Volt Signal circuit for short to
ground.
No >> Go To 6

Measure the resistance of the 5-Volt Supply circuit from the Oil Sensor

to Page 8E-56.
VER 2.
7. OPEN OIL SENSOR GROUND CIRCUIT

Measure the resistance of the Oil Sensor Ground circuit from the PCM C3
harness connector to the Oil Sensor harness connector.

Yes >> Go To 8
No >> Repair the Oil Sensor Ground circuit for an open
2.
8. OIL SENSOR SIGNAL CIRCUIT OPEN
Measure the resistance of the Oil Sensor Signal circuit from the Oil Sen-

Yes >> Go To 9
No >> Repair the Oil Sensor Signal circuit for an open.
2.
9. OIL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND.

Measure the resistance between ground and the Oil Sensor Signal circuit.

Yes >> Repair the Oil Sensor Signal Circuit for a short to ground.
VER 2.

The condition that caused this DTC to set are currently not present.
Inspect the related wiring harness for a possible intermittent condition.
and open circuits.

ENGINE OIL SENSOR OVER TEMPERATURE
ENGINE OIL SENSOR OVER TEMPERATURE — CONTINUED
• Set Condition: Anytime the Powertrain Control Module (PCM) senses the Oil Temperature rises above
121° C (250° F).
• Note: Check and verify that the engine oil level is at the appropriate level.
POSSIBLE CAUSES
LOW COOLANT LEVEL

5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
OIL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
OPEN OIL SENSOR SIGNAL CIRCUIT
OIL SENSOR
Diagnostic Test

Note: If an Engine Coolant Temperature DTC is set along with this
DTC, diagnose the Engine Coolant Temperature DTC before continu-
ing.
With the engine cooling system work correctly.
DTC.
Note: It may be necessary to road test the vehicle.
Are any Oil Sensors DTCs set?

Yes >> Go To 2
No >> Go To 10
2. CHECKING FOR OIL SENSOR LEVEL DTC
Is the Oil Over Temperature DTC the only Engine Oil Sensor DTC
set?
No >> Go To 3

connector.

Yes >> Go To 7
No >> Go To 4

connector.

age.
No >> Go To 5

ground.
No >> Go To 6


to Page 8E-56.
No >> Repair the in the 5-Volt Supply circuit for an open.
VER 2.


Yes >> Go To 8
No >> Repair the Oil Sensor Ground circuit for an open.
2.
8. OPEN OIL SENSOR SIGNAL CIRCUIT
Measure the resistance of the Oil Sensor Signal Circuit from the Oil Sen-
sor harness connector and the PCM C3 harness connector.

Yes >> Go To 9
No >> Repair the in the Oil Sensor Signal circuit for an open.
2.

Measure the resistance between ground and the Oil Sensor Signal Circuit.

Yes >> Repair the Oil Sensor Signal Circuit for a short to ground.
VER 2.

The condition that caused this DTC to set are currently not present.
and open circuits.

ENGINE OIL SENSOR PERFORMANCE
ENGINE OIL SENSOR PERFORMANCE — CONTINUED
• Set Condition: Anytime the Powertrain Control Module (PCM) senses the Oil Quality value is above 4.0
mm.
• Note: The engine oil must be changed before this test can be accurately conducted.
POSSIBLE CAUSES

WATER IN THE OIL
OIL SENSOR
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to ENGINE OIL
SENSOR QUALITY PERFORMANCE.
No >> Go To 2


ENGINE OIL SENSOR QUALITY PERFORMANCE
ENGINE OIL SENSOR QUALITY PERFORMANCE — CONTINUED
mm.
POSSIBLE CAUSES

WATER IN THE OIL
OIL SENSOR
Diagnostic Test

Note: Normal Oil quality reading will range from +1.0 to +4.0 mm
With the fresh engine oil, turn the ignition on.
DTC.
If the DTC does not reset it may be necessary to take the vehicle on a
test drive.
Are any Oil Sensor DTCs set?

Yes >> Go To 2
No >> Go To 10
2. CHECKING FOR OIL SENSOR QUALITY DTCS
Is there only one Oil Sensor Quality/Performance DTC set?

No >> Go To 3

connector.

Yes >> Go To 7
No >> Go To 4

connector.

age.
No >> Go To 5

ground.
No >> Go To 6


to Page 8E-56.
No >> Repair the in the 5-Volt Supply circuit for an open.
VER 2.


Yes >> Go To 8
No >> Repair the Oil Sensor Ground circuit for an Open
2.
8. OIL SENSOR SIGNAL CIRCUIT OPEN
Measure the resistance of the Oil Sensor Signal circuit from the Oil Sen-

Yes >> Go To 9
No >> Repair the in the Oil Sensor Signal circuit open.
2.

Measure the resistance between ground and the Oil Sensor Signal circuit.

Yes >> Repair the Oil Sensor Signal circuit for a short to ground.
VER 2.


ENGINE OIL SENSOR WATER CONTAMINATION
ENGINE OIL SENSOR WATER CONTAMINATION — CONTINUED
mm.
POSSIBLE CAUSES

WATER IN THE OIL
OIL SENSOR
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to ENGINE OIL
SENSOR QUALITY PERFORMANCE.
No >> Go To 2


SAFETY FUEL SHUT OFF DETECTED
SAFETY FUEL SHUT OFF DETECTED — CONTINUED
• Set Condition: Just after key on, the throttle is opened and closed to test the system. If the Throttle Posi-
tion Sensor (TPS) does not quickly exceed a calibrated value this DTC will set. One trip fault.
POSSIBLE CAUSES
THROTTLE PLATE STUCK AT OR BELOW LIMP HOME POSITION

Diagnostic Test

active DTC.

Yes >> Go To 2
No >> Go To 9
Remove the Air Cleaner Housing Refer to Page 9-608 and the MAF Sen-
sor Refer to Page 14-37 from the Throttle Body.
open.
Does the Throttle Plate move?

Yes >> Go To 3
Body Assembly. Refer to Page 14-48. Disconnect the
Battery when replacing the Throttle Body Assembly.
2.
3. THROTTLE CONTROL MOTOR 2 CIRCUIT SHORT TO VOLTAGE

Disconnect the PCM C1 harness connectors and the Throttle Body har-
ness connector.

age.
No >> Go To 4

Throttle Body harness connector to the PCM C1 harness connector.

Yes >> Go To 5
2.
Throttle Body harness connector to the PCM C1 harness connector.

Yes >> Go To 6
2.

circuit at the PCM C1 harness connector.

ground.
No >> Go To 7

circuit at the PCM C1 harness connector.

ground.
No >> Go To 8
8. PCM
Note: Before continuing, check the PCM C1 harness connector termi-
nals for corrosion, damage, or terminal push out. Repair as neces-
sary.

to Page 8E-56.


SHORT RUNNER SOLENOID CIRCUIT HIGH
SHORT RUNNER SOLENOID CIRCUIT HIGH — CONTINUED
• When Monitored: Engine running
• Set Condition: When the PCM is not commanding the Short Runner Valve Solenoid on and doesn’t detect
voltage at the control circuit.
POSSIBLE CAUSES
SHORT RUNNER VALVE SOLENOID CONTROL CIRCUIT OPEN

SHORT RUNNER VALVE SOLENOID CONTROL CIRCUIT SHORTED VOLTAGE
SHORT RUNNER VALVE SOLENOID CONTROL CIRCUIT SHORTED GROUND
SHORT RUNNER VALVE SOLENOID
Diagnostic Test
1. CHECKING SHORT RUNNER VALVE SOLENOID OPERATION WITH

THE DRB IIIT

With the DRB IIIT, actuate the Short Runner Valve Solenoid.
Does the Short Runner Value Solenoid rod move back and forth?
Yes >> Go To 7
No >> Go To 2
2. FUSED ENGINE CONTROL RELAY OUTPUT CIRCUIT

Disconnect the Short Runner Value Solenoid harness connector.
the Short Runner Valve Solenoid harness connector.

Yes >> Go To 3
an open.
2.
3. CHECKING THE SHORT RUNNER VALUE SOLENOID
With the DRB IIIT, actuate the Short Runner Valve Solenoid.
Using a 12-volt test light connected across the Short Runner Valve Sole-
noid harness connector.
Does the 12-volt test light flash on and off?

Yes >> Replace the Short Runner Valve Solenoid. Refer to Page
14-41.
No >> Go To 4
4. CHECKING THE SHORT RUNNER VALUE SOLENOID CONTROL

CIRCUIT FOR A SHORT TO VOLTAGE

Measure the voltage of the Short Runner Valve Solenoid control circuit at
the Short Runner Valve Solenoid harness connector.

Yes >> Repair the Short Runner Valve Solenoid control circuit for a
short to voltage.
No >> Go To 5
5. CHECKING THE SHORT RUNNER VALUE SOLENOID CONTROL

CIRCUIT FOR A SHORT TO GROUND

Measure the resistance between ground and the Short Runner Valve Sole-
noid Control circuit.

Yes >> Repair the Short Runner Valve Solenoid Control circuit for a
short to ground.
No >> Go To 6
6. CHECKING SHORT RUNNER VALUE SOLENOID CONTROL
CIRCUIT FOR AN OPEN

Measure the resistance of the Short Runner Valve Solenoid Control circuit
from the Short Runner Valve Solenoid harness connector to the PCM C2
harness connector.

to Page 8E-56.
No >> Repair the Short Runner Valve Solenoid Control circuit
for an open.
VER 2.

Wiggle the wires while checking for shorts and/or open circuits.

SHORT RUNNER SOLENOID CIRCUIT LOW
SHORT RUNNER SOLENOID CIRCUIT LOW — CONTINUED
POSSIBLE CAUSES

Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to SHORT RUN-
NER SOLENOID CIRCUIT HIGH.
No >> Go To 2


SHORT RUNNER SOLENOID CIRCUIT
SHORT RUNNER SOLENOID CIRCUIT — CONTINUED
POSSIBLE CAUSES

SHORT RUNNER VALVE SOLENOID CONTROL CIRCUIT SHORTED VOLTAGE
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to SHORT RUN-
NER SOLENOID CIRCUIT HIGH.
No >> Go To 2


SPEED CONTROL SWITCH INPUT CIRCUIT
SPEED CONTROL SWITCH INPUT CIRCUIT — CONTINUED
• Set Condition: Anytime the Powertrain Control Module (PCM) doesn’t sense the proper voltage on the
Speed Control Switch Off Signal circuit.
POSSIBLE CAUSES
OPEN FUSE #10

SPEED CONTROL SWITCH
OPEN SPEED CONTROL SWITCH OFF SIGNAL CIRCUIT
SPEED CONTROL SWITCH SIGNAL CIRCUIT SHORTED TO GROUND
Diagnostic Test
1. PCM
Measure the voltage of the Speed Control Off Signal circuit at the PCM C4
harness connector.

to Page 8E-56.
No >> Go To 2
2. SPEED CONTROL OFF SIGNAL CIRCUIT SHORT TO GROUND

Disconnect the Speed Control Switch harness connector.
Measure the resistance between ground and the Speed Control Off Signal
circuit.

Yes >> Repair the Speed Control Off Signal circuit for a short to
ground.
No >> Go To 3
SPEED CONTROL SWITCH INPUT CIRCUIT — CONTINUED
3. SPEED CONTROL OFF SIGNAL CIRCUIT OPEN
Measure the resistance of the Speed Control Off Signal circuit from the
PCM C4 harness connector to the Speed Control Switch harness connec-
tor.

Yes >> Go To 4
No >> Repair the Speed Control Off Signal circuit open.
5.
4. OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT

Speed Control Switch harness connector.

Yes >> Replace the Speed Control Switch. Refer to Page 8P-4.
open.
VER 5.
*CHECKING FUEL DELIVERY
*CHECKING FUEL DELIVERY — CONTINUED
POSSIBLE CAUSES
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN

FUEL PUMP RELAY
FUEL PRESSURE OUT OF SPECIFICATION
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP
Diagnostic Test
1. FUEL PUMP OPERATION

With the DRB IIIT, actuate the Fuel Pump Relay.
Listen for fuel pump operation.
Stop All Actuations.
Does the Fuel Pump operate?

Yes >> Go To 2
No >> Go To 4
2. FUEL PRESSURE
Install a fuel pressure gauge at the engine.
pressure gauge.
Stop All Actuations.

Below Specification
Go To 3
Test Complete.
Above Specification
Replace the fuel filter/fuel pressure regulator. Refer to
Page 14-10.
VER 3.
3. CHECKING FUEL STRAINER


VER 3.
4. FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
Disconnect the Fuel Pump harness connector.
Using a 12-volt test light connected to ground, probe the Fuel Pump Relay
Output circuit at the Fuel Pump harness connector.

Yes >> Go To 5
No >> Check for an open Fuel Pump fuse in the Relay Control
Module. Repair the Fuel Pump Relay Output circuit for
an open.
3.
5. FUEL PUMP
Note: Check connectors - It is critical that the connector is free from
any signs of corrosion or deformities. Clean/repair as necessary.
Using a 12-volt test light connected across the Fuel Pump harness con-
nector.

Yes >> Replace the Fuel Pump. Refer to Page 14-17.
No >> Repair the fuel pump ground circuit for an open.
VER 3.
*CHECKING HARD START (FUEL SYSTEM)
*CHECKING HARD START (FUEL SYSTEM) — CONTINUED
POSSIBLE CAUSES

FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FAULTY FUEL PUMP MODULE
FUEL INJECTOR(S)
FUEL CONTAMINATION
Diagnostic Test

Install a fuel pressure gauge at the engine.
With the DRB IIIT, actuate the Fuel Pump and observe the fuel pressure
gauge.

Below Specification
Go To 2
Go To 4
2. RESTRICTED FUEL FILTER

Remove the Fuel Filter and inspect for a plugged filter. Refer to Page
14-10.
Is the fuel filter plugged?

Yes >> Replace the Fuel Filter. Refer to Page 14-10.
No >> Go To 3
*CHECKING HARD START (FUEL SYSTEM) — CONTINUED
3. CHECKING FUEL STRAINER

VER 1.
4. FUEL INJECTOR(S)
Apply special tool #C-4390, Hose Clamp Pliers, between the fuel pressure
gauge and the fuel pump.
Note: The pressure should not fall below 3.0 bar (44 psi).
Does the fuel pressure drop?

Yes >> Replace the leaking fuel injectors. Refer to Page 14-33.
No >> Check the fuel for contaminants.
VER 1.
*ENGINE CRANKS BUT DOES NOT START
*ENGINE CRANKS BUT DOES NOT START — CONTINUED
POSSIBLE CAUSES
NO START PRE-TEST
POWERTRAIN FUSES OPEN
SECONDARY INDICATORS PRESENT
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL CONTAMINATION
Diagnostic Test
1. NO START PRE-TEST
Note: The following list of items must be checked before continuing
with any no start tests.
The battery must be fully charged and in good condition. A low charged
battery may produce invalid test results. If the battery is low, charge the
battery and then attempt to start the vehicle by cranking the engine for 15
seconds, 3 consecutive times.
This will allow any DTCs to set that may have been erased due to a dead
battery.
Try to communicate with PCM if not able to communicate check fuses.
Ensure the Power and Ground to the PCM are OK.
Make sure the PCM communicates with the DRB IIIT and that there are
no DTCs stored in the PCM memory. If the PCM reports a No Response
condition, refer to the Section 8E Electronic Control Module category for
the proper tests.
Read the PCM DTCs with the DRB IIIT. If any DTCs are present, they
must be repaired before continuing with any other No Start diagnostic
tests. Refer to the Section 9 Engine Diagnostics for a list of the related
P-codes that are reported by the PCM.
Ensure that the Bus is functional. Attempt to communicate with the Instru-
ment Cluster and SKREEM. If you are unable to establish communica-
tions, refer to the 8E Electronic Control Module category for the proper
symptoms.
The Sentry Key Remote Entry Module (SKREEM) System must be oper-
ating properly. Check for proper communication with the DRB IIIT and
check for DTCs that may be stored in the SKREEM. Repair the DTC(s)
before continuing.
Crank the engine several times. Using the DRB IIIT, read DTCs. If a DTC
is present perform the DTC diagnostics before continuing.

No >> Go To 2
2. OPEN FUSE
Check for open fuses.
Are there any open fuses?

Yes >> Replace the open fuse and check the related circuit(s) for a
short to ground.
No >> Go To 3
3. CHECKING FOR SECONDARY INDICATORS

With the DRB IIIT, under DTCs & Related Functions, read the Secondary
Indicators while cranking the engine.
Are there any Secondary Indicators present while cranking the

engine?
Yes >> Refer to symptom list and perform tests related to the sec-
ondary indicator that is reported by the DRB IIIT.
No >> Go To 4
4. POSSIBLE MECHANICAL PROBLEMS

ENGINE VALVE TIMING - must be within specifications, check for broken
timing components

No >> Go To 5
5. FUEL PUMP RELAY OUTPUT CKT OPEN
Disconnect the Fuel Pump harness connectors.
Verify the Fuel Pump Relay is getting voltage on the Fused Engine Control
Relay Output circuit and Fused B(+) circuit before continuing.
Measure the resistance of the Fuel Pump Relay Output circuit from the
Fuel Pump Relay Control Module B harness connector to the Fuel Pump
harness connector.

Yes >> Go To 6
No >> Repair the Fuel Pump Relay Output circuit for an open.
1.
6. FUEL PUMP DELIVERY

Verify that the Fuel tank is not empty before continuing.
Follow the diagnostics for Checking Fuel Delivery in this section of this
manual.
Was the No Start condition solved after following the above diag-
nostic test?
Yes >> Test Complete.
No >> Check for contamination/water in the fuel. Ensure the
fuel being used in this vehicle meets manufacturer’s Fuel
Requirement. Refer to the Service Information.
1.
*INTERMITTENT NO CRANK
*INTERMITTENT NO CRANK — CONTINUED
POSSIBLE CAUSES
ELECTRONIC THROTTLE CONTROL (ETC) STARTER INHIBIT
Diagnostic Test
1. ETC STARTER INHIBIT

Note: This engine will try to relearn ETC position when the key is left
in the on position for an extended period of time and will not allow
the starter to crank during this procedure. This procedure can take
up to 2.5 seconds.
To verify the cause of the no crank condition or delayed crank use the
DRB IIIT, and read the ETC Starter Inhibit mileage.
The controller will store the mileage at which the no start condition
occurred because of the ETC testing procedure.
This is considered normal operation for this vehicle and no repairs are
necessary.
Is a mileage stored under the ETC Starter Inhibit?

Yes >> Test Complete.
No >> Refer to the appropriate symptom (diagnostic procedure)
in the Starting section of the Service Information for fur-
ther assistance.
1.
1.
connected properly.
Inspect the engine oil for fuel contamination. Replace the oil and filter as
necessary.
Attempt to start the engine.
If the No Start condition is still present, refer to the symptom list and per-
form the diagnostic testing as necessary. Refer to any technical service
bulletins that may apply.
If a DTC is present, refer to the appropriate category and select the cor-
responding symptom.

1.
connected properly.
Connect the DRB IIIT to the data link connector.
Ensure the fuel tank has at least a quarter tank of fuel. Turn off all acces-
sories.
If the repaired DTC has reset, the repair is not complete. Check for any
related TSBs and return to the symptom list.
If another DTC has set, return to the symptom list and follow the path
specified for that DTC.
With the DRB IIIT, monitor the appropriate pre-test enabling conditions
until all conditions have been met. Once the conditions have been met,
switch screen to the appropriate OBD II monitor.
IF the monitor ran, and the Good Trip counter changed to one or more,
the repair was successful and is now complete.
Note: It may be necessary to drive the vehicle for the monitors for
the repaired DTC to set run.

1.
connected properly.
With the DRB IIIT, clear DTCs and Reset Memory for all engine values.
Road test the vehicle. Use all accessories that may be related to this
repair.
If this test is being performed after a No Trouble Code test, verify the
symptom is no longer present.
If the symptom is still present, or any other symptom or DTC is present
refer to the appropriate category and perform the corresponding symptom.

1.
connected properly.
With the DRB IIIT, clear DTCs.
Perform the generator output test. Refer to the appropriate service infor-
mation as necessary.
Start the engine and set engine speed to 2000 RPM for at least thirty sec-
onds.
Cycle the key off and on.

1.
connected properly.
Connect the DRBIIIT to the data link connector and erase all codes.
Turn the speed control ON.
Press and release the ACCEL/SET switch. If the speed control did not
engage, the repair is not complete. Check for TSBs that pertain to speed
control problems and then return to the symptom list.
Momentarily press the ACCEL/SET switch. If the vehicle speed did not
increase by at least 2 mph, the repair is not complete. Check for TSBs
that pertain to speed control problems and then return to the symptom list.
Press and hold the DECEL/SET switch. The vehicle speed should
decrease. If it did not decrease, the repair is not complete. Check for
TSBs that pertain to speed control problems and then return to the symp-
tom list.
Momentarily press the DECEL/SET switch. If the vehicle speed did not
decrease by at least 1 mph, the repair is not complete. Check for TSBs
that pertain to speed control problems and then return to the symptom list.
Using caution, press and release the brake pedal. If the speed control did
not disengage, the repair is not complete. Check for TSBs that pertain to
speed control problems and then return to the symptom list.
Bring the vehicle speed back up to 35 mph
Press the RESUME switch. If the speed control did not resume the previ-
ously set speed, the repair is not complete. Check for TSBs that pertain to
speed control problems and then return to the symptom list.
Ensure vehicle speed is greater than 35 mph and release the SET switch.
If vehicle did not adjust and set a new vehicle speed, the repair is not
complete. Check for TSBs that pertain to speed control problems and then
return to the symptom list.
Bring the vehicle speed back up above 35 mph and engage speed control.
Press the OFF switch to turn OFF, (cruise light will be off). If the speed
control did not disengage, the repair is not complete. Check for TSBs that
pertain to speed control problems and then return to the symptom list.
If the vehicle successfully passed all of the previous tests, the speed con-
trol system is now functioning as designed. The repair is now complete.
Did the speed control pass the above test?

YES >> Repair is complete.
NO >> Repair is not complete, refer to appropriate symptom.
POWERTRAIN CONTROL MODULE CIRCUIT DIAGRAM (1 OF 7)

ZH
9 - 575

9 - 576
ZH

ZH
9 - 577

9 - 578
ZH

ZH
9 - 579

9 - 580
ZH

ZH ENGINE - SERVICE INFORMATION 9 - 581
ENGINE - SERVICE INFORMATION
TABLE OF CONTENTS
page page
ENGINE - SERVICE INFORMATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 583 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 618
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 583 CAMSHAFT BEARING BRIDGE
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
ENGINE DIAGNOSIS - INTRODUCTION . . . 583 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 622
DIAGNOSIS AND TESTING - ENGINE ROCKER ARM / ADJUSTER ASSY
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 584 DISASSEMBLY
ENGINE DIAGNOSIS - PERFORMANCE . . . 586 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 624
DIAGNOSIS AND TESTING - CYLINDER ASSEMBLY
COMPRESSION PRESSURE TEST . . . . . . . 587 INSTALLATION .................. . . . . 625
DIAGNOSIS AND TESTING - CYLINDER CAMSHAFT
COMBUSTION PRESSURE LEAKAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 625
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 625
HYDROSTATIC LOCKED ENGINE . . . . . . . . 588 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
STANDARD PROCEDURE - REPAIR OF INSPECTION ..................... . . . . 626
DAMAGED OR WORN THREADS . . . . . . . . 589 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 626
STANDARD PROCEDURE - FORM-IN- VALVE STEM SEAL
PLACE GASKETS AND SEALERS . . . . . . . . 589 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
STANDARD PROCEDURE - ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 628
GASKET SURFACE PREPARATION . . . . . . . 590 INTAKE/EXHAUST VALVES AND SEALS
STANDARD PROCEDURE - ENGINE CORE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 630
AND OIL GALLERY PLUGS . . . . . . . . . . . . . 591 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 630
STANDARD PROCEDURE - MEASURING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
BEARING CLEARANCE USING CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
PLASTIGAGET . . . . . . . . . . . . . . . . . . . . . . . 591 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 632
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592 VALVE SPRINGS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 597 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 633
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 633
SPECIFICATIONS - ENGINE . . . . . . . . . . . . 602 ENGINE BLOCK
SPECIFICATIONS - TORQUE . . . . . . . . . . . 603 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 633
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 605 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
AIR CLEANER HOUSING INSPECTION ..................... . . . . 633
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608 CRANKSHAFT OIL SEAL - REAR
AIR CLEANER ELEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 635
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609 CRANKSHAFT OIL SEAL - FRONT
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 636
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 610 CONNECTING ROD BEARINGS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 610 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 638
DIAGNOSIS AND TESTING - CYLINDER HEAD STANDARD PROCEDURE - CONNECTING
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 RODS AND BEARINGS . . . . . . . . . . . . . . . . 638
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611 PISTON AND CONNECTING ROD
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 639
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 614 STANDARD PROCEDURE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 614 PISTON FITTING . . . . . . . . . . . . . . . . . . . . . 640
CYLINDER HEAD COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 617 INSPECTION ..................... . . . . 642
9 - 582 ENGINE - SERVICE INFORMATION ZH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 643 OIL LEVEL/TEMPERATURE SENSOR

PISTON RINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 645 OIL SPRAY NOZZLES
CRANKSHAFT AND MAIN BEARINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
DESCRIPTION .................... . . . . 647 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 674
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 647 OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647 DESCRIPTION ................ . . . . . . . . 674
VIBRATION DAMPER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 652 OIL PUMP DRIVE CHAIN
FLEX PLATE / FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 654 OIL PRESSURE RELIEF VALVE
ENGINE MOUNT BRACKETS DESCRIPTION ................ . . . . . . . . 677
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655 INTAKE MANIFOLD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 656 DESCRIPTION ................ . . . . . . . . 678
FRONT MOUNT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 678
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 DIAGNOSIS AND TESTING - INTAKE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 658 MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . 678
REAR MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 660 EXHAUST MANIFOLD
LUBRICATION DESCRIPTION ................ . . . . . . . . 680
DESCRIPTION .................... . . . . 660 REMOVAL
DIAGNOSIS AND TESTING LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 681
ENGINE OIL LEAK INSPECTION . . . . . . . . . 660 REMOVAL- RIGHT SIDE . . . . . . . . . . . . . . . 682
DIAGNOSIS AND TESTING - CHECKING INSTALLATION
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 662 LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 683
OIL LEVEL INDICATOR TUBE INSTALLATION - RIGHT SIDE . . . . . . . . . . . 684
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663 TIMING CHAIN TENSIONER
OIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 685
DESCRIPTION .................... . . . . 664 TIMING CHAIN COVER
ENGINE OIL LEVEL CHECK ........ . . . . 664 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 688
STANDARD PROCEDURE - ENGINE OIL TIMING CHAIN
AND FILTER CHANGE . . . . . . . . . . . . . . . . . 664 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
OIL FILTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 695
DESCRIPTION .................... . . . . 666 BALANCE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666 DESCRIPTION ................ . . . . . . . . 698
OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 701
REMOVAL TIMING CHAIN GUIDES
LOWER OIL PAN . . . . . . . . . . . . . . . . . . . . . 667 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
REMOVAL - UPPER OIL PAN . . . . . . . . . . . . 669 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 703
INSTALLATION ENGINE TIMING
LOWER OIL PAN . . . . . . . . . . . . . . . . . . . . . 669 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 704
INSTALLATION - UPPER OIL PAN . . . . . . . . 671
ENGINE - SERVICE INFORMATION

DESCRIPTION
The engine is a modular design. The engine uses a 90-degree V-angle rotating assembly which provides space for
long intake manifold runners which provide high torque across a broad range of engine speeds for driving ease. The
engine uses a split-pin crankshaft to provide even firing, and a balance shaft to compensate for the rocking motion
which occurs with a 90-degree V-6.
OPERATION
The engine produces 215 bhp @ 5700 rpm and 230 lb.-ft. of torque @ 3000 rpm. Its 6000 rpm maximum operating
speed is electronically limited by interrupting the fuel supply. The engine is tuned to provide high torque over a
broad range of engine speed for optimum driveability. 90% of max torque is available from about 2300-5300 rpm,
98% of max torque is available from 3000-4500 rpm.

ENGINE DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine main-
tenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine
idles rough and stalls).
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be iso-
lated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the
following:
• Cylinder Combustion Pressure Leakage Test
• Cylinder Compression Pressure Test
• Engine Cylinder Head Gasket Failure Diagnosis
• Engine Oil Leak Inspection
• Intake Manifold Leakage Diagnosis
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.

3. Thick oil 3. (a.) Change oil and filter.
(b.) Run engine to operating
temperature.
(c.) Change oil and filter again.
4. Low oil pressure. 4. Check and correct engine oil
level.
5. Dirt in tappets/lash adjusters. 5. Replace rocker arm/adjuster
assembly.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new rocker arm/adjuster
assembly.
8. Worn valve guides. 8. Ream guides and install new
valves with oversize stems.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
10. Missing adjuster pivot. 10. Replace rocker arm/adjuster
assembly.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump.
temperature.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal 6. Replace crankshaft or grind
out-of-round. surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil

pump relief valve and spring.
temperature.
clearance. Repair as necessary.
5. Excessive end play. 5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round 6. Replace crankshaft or grind
or worn. journals.
7. Loose flywheel or torque 7. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.

3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace oil pump.
7. Oil pump relief valve stuck. 7. Replace the oil pump.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump warped or cracked. 9. Install new oil pump.
clearance.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).

gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the

metal part. part.
3. Misaligned or deteriorated cup or 3. Replace as necessary.
threaded plug.
OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as
PLUGS FOULED necessary. (Refer to Appropriate
Diagnostic Manual.)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Clean pistons and install new
rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head(s).
6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT 1. Weak or discharged battery. 1. Charge or replace battery as necessary.
CRANK Check charging system.
2. Corroded or loose battery 2. Clean/tighten battery/starter connections.

connections.
3. Faulty starter or related circuits. 3. Check starting system.
4. Seized accessory drive 4. Remove accessory drive belt and
component. attempt to start engine. If engine cranks,
repair/replace seized component.
5. Engine internal mechanical failure 5. Refer to standard procedure - hydrostatic
or hydrostatic lock. locked engine.
ENGINE CRANKS BUT 1. No spark. 1. Check for spark.

WILL NOT START
2. No fuel. 2. Perform fuel pressure test.
3. Low or no engine compression. 3. Perform cylinder compression test.
ENGINE LOSS OF 1. Worn or incorrect gapped spark 1. Replace spark plugs or set gap.
POWER plugs.
2. Dirt or water in fuel system. 2. Clean system and replace fuel filter.
3. Faulty fuel pump. 3. Replace fuel pump.
4. Incorrect valve timing. 4. Correct valve timing.
5. Blown cylinder head gasket(s). 5. Replace cylinder head gasket(s).
6. Low compression. 6. Test cylinder compression.
7. Burned, warped, or pitted valves. 7. Install new or reface valves as
necessary.
8. Plugged or restricted exhaust. 8. Replace parts as necessary.
9. Faulty ignition cables. 9. Replace ignition cables as necessary.
10. Faulty coil(s). 10. Test and replace as necessary.
ENGINE STALLS OR 1. Carbon build-up on throttle 1. Remove throttle body(s) and de-carbon.
ROUGH IDLE plate(s).
2. Engine idle speed too low. 2. Check Idle Air Control circuit.
3. Worn or incorrectly gapped spark 3. Replace spark plugs or set gap.
plugs.
4. Faulty or crossed ignition cables. 4. Check for correct firing order or replace
ignition cables as necessary.
6. Intake manifold vacuum leak. 6. Inspect intake manifold gasket and
vacuum hoses. Replace as necessary.
ENGINE MISSES ON 1. Worn or incorrectly gapped spark 1. Replace spark plugs or set gap.
ACCELERATION plugs.
2. Faulty ignition cables. 2. Replace ignition cables as necessary.
3. Dirt or water in fuel system. 3. Clean system and replace fuel filter.
4. Burned, warped, or pitted valves. 4. Install new or reface valves as
necessary.
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE TEST

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the
indicated compression pressures may not be valid for diagnosis purposes.
1. Check the engine oil level and add oil if necessary.
2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other
forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly.
3. Disconnect all of the ignition coils from the spark plugs.
4. Remove one spark plug from each cylinder of the engine. As the spark plugs are being removed, check elec-
trodes for abnormal firing indicators; fouled, hot, oily, etc. Record cylinder number of spark plug for future refer-
ence.
5. Make sure the throttle blade is fully open during the compression check.
6. Insert compression gauge into the #1 spark plug hole in the cylinder head.
7. Crank the engine until maximum pressure is reached on the gauge. Record this pressure as #1 cylinder pres-
sure.
8. Repeat the previous step for all of the remaining cylinders.
9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to
cylinder.
10. If one or more cylinders have an abnormally low compression pressure, repeat the compression test.
Note: The recommended compression pressures are to be used only as a guide to diagnosing engine prob-
lems. An engine should not be disassembled to determine the cause of low compression unless some form
of malfunction is present.
11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could
indicate the existence of a problem in the cylinder in question.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seating).
• Leaks between adjacent cylinders or into water jacket.
• Any causes for combustion/compression pressure loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
1. Check the coolant level and fill as required. DO NOT install the pressure cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.
3. Clean spark plug recesses with compressed air.
4. Remove one spark plug from each cylinder.
5. Remove the oil filler cap.
6. Remove the air cleaner.
7. Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing should maintain
483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.
Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. While testing, lis-
ten for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the
coolant.
All gauge pressure indications should be equal, with no more than 25% leakage per cylinder.
FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the
cylinder.
STANDARD PROCEDURE
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following
steps should be used.
CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
1. Inspect the air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that
may possibly be in the cylinder under pressure.
4. With all the spark plugs removed, rotate the engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pis-
tons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
8. Install new spark plugs.

9. Drain the engine oil and remove the oil filter.
10. Install a new oil filter.
11. Fill the engine with the specified amount of approved oil.
13. Start the engine and check for any leaks.
STANDARD PROCEDURE - REPAIR OF DAMAGED OR WORN THREADS

CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired.
Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-CoilT
Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size.
Heli-CoilT tools and inserts are readily available from automotive parts jobbers.
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when apply-
ing form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material
unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage
while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the
proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. MoparT Engine RTV
GEN II, MoparT ATF-RTV, MoparT Gasket Maker gasket materials, and MoparT Gasket Sealant each have different
properties and can not be used in place of the other.
MOPART ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially
designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Mois-
ture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one
year. After one year this material will not properly cure. Always inspect the package for the expiration date before
use.
MOPART ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties
to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is avail-
able in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always
inspect the package for the expiration date before use.
MOPART GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when
squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for
use between two machined surfaces. Do not use on flexible metal flanges.
MOPART GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing
threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts
under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MoparT Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can
w/applicator.
SEALER APPLICATION
MoparT Gasket Maker material should be applied sparingly, 0.040 in. (1 mm) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
MoparT Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately
0.120 in. (3 mm) in diameter. All mounting holes must be circled. For corner sealing, a 1/8 or 1/4 in. (3.17 or 6.35
mm) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel.
Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of
a locating dowel is recommended during assembly to prevent smearing material off the location.
MoparT Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both
surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can
be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-
layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET SURFACE PREPARATION

To ensure a good gasket seal, proper surface preparation must be performed, especially with the use of aluminum
engine components and multi-layer steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
• Metal scraper (1)
• Abrasive pad or paper to clean cylinder block and
head (2).
• High speed power tool with an abrasive pad or a wire
brush.
Note: Multi-Layer Steel (MLS) head gaskets require a

scratch free sealing surface.
CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can damage the sealing sur-
faces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the medium (yellow, 80 grit) bris-
tle disc may be used on cast iron surfaces with care.
Only use the following for cleaning gasket surfaces:

• Solvent or a commercially available gasket remover.
• Plastic or wood scraper (3).
• Drill motor with 3M Roloc™ Bristle Disc (4) (white or yellow).
STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS

Using a blunt tool such as a drift (2) and a hammer, strike the
bottom edge of the cup plug (3). With the cup plug rotated,
grasp firmly with pliers (1) or other suitable tool and remove
plug.
CAUTION: Do not drive cup plug into the casting as

restricted cooling can result and cause serious engine
problems.
Thoroughly clean the inside of the cup plug hole in the cylinder
block or head. Be sure to remove any old sealer. Lightly coat
the inside of the cup plug hole with MoparT Stud and Bearing
Mount. Make certain the new plug is cleaned of all oil or
grease. Using the proper drive plug, drive the plug into the
hole so that the sharp edge of the plug is at least 0.020 in.
(0.5 mm) inside the lead-in chamfer.
It is not necessary to wait for the curing of the sealant. The
cooling system can be refilled and the vehicle placed in ser-
vice immediately.
STANDARD PROCEDURE - MEASURING BEARING CLEARANCE USING

PLASTIGAGET
The engine crankshaft bearing clearances can be determined by the use of a PlastigageT or equivalent. The fol-
lowing is the recommended procedure for the use of the PlastigageT:
1. Remove any oil film from the surface to be checked. The plastigage will dissolve in oil.
2. Place a piece of the PlastigageT (1) across the entire width
of the bearing shell in the cap approximately 1/4 in. (6.35
mm) off center, and away from the oil holes (In addition,
suspected areas can be checked by placing the Plastigage
in the suspected area). Torque the bearing cap bolts of the
bearing being checked to the proper torque specifications.
3. Remove the bearing cap and compare the width of the flat-
tened PlastigageT with the metric scale provided on the
package of the PlastigageT. Locate the band closest to the
same width. This band shows the amount of clearance in
thousandths of a millimeter. Differences in readings
between the ends indicate the amount of taper present.
Record all the readings taken. Compare the clearance
measurements to the specifications found in the engine
specifications. Refer to Page 9-602. PlastigageT gener-
ally is accompanied by two scales. One scale is in
inches, the other is a metric scale.
Note: Plastigage is available in a variety of clearance

ranges. Use the most appropriate range for the specifica-
tions you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.
REMOVAL
2. Remove the air cleaner housing assembly. Refer to Page
9-608.
4. Remove the radiator with the radiator fan. Refer to Page
7-33.
5. Remove the accessory drive belt.
6. Remove the mass air flow sensor.
7. Disconnect the vacuum hoses at the vacuum booster, the
intake manifold, and the purge valve.
8. Remove the oil from the power steering pump reservoir.
9. Disconnect the ground lead at the power steering pump.
10. Disconnect the pressure (2) and return (1) lines from the
power steering pump.
11. Relieve the fuel pressure at the service valve (1) on the
fuel rail. Refer to Page 14-5.
12. Disconnect the fuel supply line (1) at the fuel rail.
13. Disconnect the engine wire harness.
15. Remove the lower splash shield screws (1) and the splash
shield.
16. Drain the engine oil. Refer to Page 9-664.
18. Disconnect the ground cable (1) at the transmission.
19. Disconnect the backup lamp switch harness connector (1)

(with manual transmission).
20. Disconnect the transmission wire harness connector and
the shift selector cable (with automatic transmission).
21. Disconnect the pressure line (1) from the clutch slave cyl-
inder (manual transmission only).
22. Remove the pressure line retaining bolt (2) and position
the pressure line aside.
23. Disconnect the reverse lockout cable.
24. Disconnect the shift rod (1) from the ball stud (2) (manual
transmission only).
25. Disconnect the starter harness connectors. Refer to Page
8F-43.
26. Remove the front engine mount bolt (1).
27. Remove the lower radiator hose (1) and the coolant
bypass hose (2) from the water pump.
29. Remove the upper radiator hose (1) from the thermostat
housing.
30. Disconnect the heater hoses at the intake manifold and
the engine block.
31. Remove the A/C compressor mounting bolts. Refer to
Page 24-121.
32. Position the A/C compressor aside with lines attached.
33. Position a floor jack under the transmission and raise the
transmission slightly.
34. Remove the transmission mount bolts (1), the crossmem-
ber bolts (2) and the transmission mount with
crossmember.
35. Attach the engine lifting device to the engine lifting eyes.
36. Lower the rear of the transmission with the floor jack.
37. Remove the engine and transmission assembly from the
vehicle.
38. Separate the engine and transmission. For automatic
Refer to Page 21-210, for manual Refer to Page 21-344.
39. Remove the clutch if equipped. Refer to Page 6-9.

40. Remove the flywheel bolts (1), the spacer (2) and the fly-
wheel (3).
41. Mount the engine on an engine stand.
INSTALLATION
1. Attach the lifting device to the engine lifting eyes.
2. Remove the engine from the engine stand.
3. Install the flywheel. Refer to Page 9-654.
4. Install the clutch if equipped. Refer to Page 6-10.
5. Install the transmission to the engine. Refer to Page
21-227. Refer to Page 21-347.
6. Install the starter. Refer to Page 8F-44.
7. Position the engine and transmission in the vehicle on the
front axle carrier with the transmission resting on the floor
jack.
8. Raise the transmission with the floor jack.
9. Install the transmission mount with crossmember. Install the
transmission mount bolts (1) and the crossmember bolts (2)
11. Install the front engine mount bolt (1).

12. Tighten the crossmember to body bolts to 40 N·m (30 ft.
lbs.).
13. Tighten the transmission mount to transmission bolts to 50
N·m (36 ft. lbs.).
14. Tighten the engine mount to front axle carrier bolts to 55
N·m (41 ft. lbs.)
15. Bolt on the A/C compressor. Refer to Page 24-122.
16. Connect the shift rod (1) to the ball stud (2). Connect the
reverse lockout cable. (manual transmission).
17. Connect the pressure line (1) to the clutch slave cylinder.
Install the pressure line retainer bolt (2) and tighten to 15
N·m (11 ft. lbs.) (manual transmission).
18. Connect the backup lamp switch harness connector (1)

(manual transmission). Connect the transmission wire har-
ness connector and the shift selector cable (automatic
transmission).
19. Bolt on the ground cable at the transmission and tighten

to 40 N·m (30 ft. lbs.).
21. Connect the lower radiator hose (1) and the coolant
bypass hose (2) at the water pump.
22. Install the lower splash shield (2). Tighten the screws (1)
to 5 N·m (44 in. lbs.).

24. Connect the heater hoses at the engine block and the
intake manifold.
25. Connect the upper radiator hose (1) at the thermostat
housing.
26. Connect the engine wire harness.
27. Connect the fuel supply line (1) at the fuel rail. Tighten the
fitting to 38 N·m (28 ft. lbs.).
28. Connect the power steering pressure (2) and return line
(1) to the power steering pump. Tighten the high pressure
fitting to 45 N·m (33 ft. lbs.).
29. Connect the ground lead at the power steering pump.
30. Refill the power steering pump fluid reservoir.
31. Connect the vacuum hoses at the purge valve, brake
booster and intake manifold.
32. Install and connect the mass air flow sensor.
33. Install the accessory drive belt.

34. Install and connect the radiator with the radiator fan. Refer
to Page 7-35.
35. Install the air cleaner. Refer to Page 9-608.
38. Fill the engine with engine oil. Refer to Page 9-664.
39. Start the engine and check for leaks.
40. Recheck all fluid levels.
SPECIFICATIONS
SPECIFICATIONS - ENGINE
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine Type 90 ° Bank Angle Liquid Cooled with Dual Tuned Intake
Manifold and Twin Ignition
Displacement 3.2 L (195.2 cu. in.)
Bore 89.9 mm (3.54 in.)
Stroke 84 mm (3.31 in.)
Valve System SOHC 2 Intake and 1 Exhaust Valve per Cylinder Roller
Rocker Arms
Compression Ratio 10.0:1
Brake Horsepower 215 (160 KW) @ 5700 rpm (67.2 bhp/liter)
Torque 230 lb. ft. (312 N·m) @ 3000 rpm
Firing Order 1-4-3-6-2-5
Lubrication Pressure Feed – Full Flow Filtration
Cooling System Reverse Flow – Forced Circulation
Cylinder Block Cast Aluminum Alloy with Siltec Bore Liners
Crankshaft Forged Steel
Connecting Rods Forged Steel
Pistons Aluminum Alloy – Flat Topped
Compression Pressure 689 kPa (100 psi)
Max. Variation Between Cylinders 172 kPa (25 psi)
CYLINDER BLOCK
Cylinder Bore Diameter
Standard 89.900 – 89.915 mm (3.539 – 3.540 in.)
Repair Max. 90.150 – 90.165 mm (3.549 – 3.550 in.)
Out of Round 0.014 mm (.0005 in.)
Taper 0.03 mm (.0011 in.)
PISTONS
Piston Diameter 89.87 – 89.90 mm (3.538 –3.539 in.)
Piston Ring Groove Depth No. 1 3.1 mm (0.122 in.)
PISTON RING GAP
Compression Ring No. 1 0.20 – 0.35 mm (0.007 – 0.013 in.)
Compression Ring No. 2 0.20 – 0.40 mm (0.007 – 0.015 in.)
PISTON RING WIDTH
Compression Rings 1.5 mm (0.059 in.)
Oil Ring (Steel Rails) 3.5 mm (0.137 in.)
CONNECTING RODS
Bearing Clearance 0.026 – 0.054 mm (0.001 – 0.002 in.)
CRANKSHAFT
Main Bearing Clearance
Radial 0.030 – 0.052 mm (0.001 – 0.002 in.)
Axial 0.100 – 0.266 mm (0.003 – 0.010 in.)
CYLINDER HEAD VALVE SEAT
Valve Seat Width
Intake 31.000 – 31.016 mm (1.220 – 1.221 in.)
Exhaust 35.000 – 35.016 mm (1.378 – 1.379 in.)
VALVES
Face Angle 45° ± 15’
Stem Diameter
Intake 6.975 mm (0.274 in.)
Exhaust 6.974 mm (0.274 in.)
Head Diameter
Intake 36 ± 0.4 mm (1.417 in.)
Exhaust 41 ± 0.1 mm (1.614 in.)
Length
Intake 119.4 ± 0.2 mm (4.700 in.)
Exhaust 122.2 ± 0.2 mm (4.811 in.)
Valve Margin
Intake 1.2 mm (0.047 in.)
Exhaust 1.6 mm (0.062 in.)

A/C Compressor Bolts 20 15 177
Balance Shaft Bolts 20 15 177
Body Bolts 40 30 354
Camshaft Bearing Bridge
Stage One 15 11 133
Stage Two 90° Clockwise
Camshaft Sprocket Bolts
Stage One 50 37 443
Connecting Rod Bolts
Stage One 5 4 44
Stage Two 25 18 159
Stage Three 90° Clockwise
Cooler Line Bolts 10 7 89

Crossmember to Body
40 30 354
Bolts
Cylinder Head Cover Bolts 10 7 89
Damper Bolt
Stage One 200 148 1770
EGR Fitting 40 30 354
End Cover Bolts 10 89
Engine Mount Bolts 30 22 266
Front Engine Mount to
55 41 487
Front Axle Carrier Bolts
Engine Mount to
50 37 443
Transmission Bolts
Engine Upper Mount Bolt 55 41 487
Engine Lower Mount Bolt 35 26 310
Engine Support Bolts 20 15 177
Exhaust Flange Bolts 20 15 177
Exhaust Manifold to
35 26 310
Cylinder Head Bolts
Flywheel Bolts
Stage One 45 33 398
Fuel Supply Line to Rail 38 28 336
Cylinder Head Bolts
Stage One 20 15 177
Stage Two 50 37 443
Stage Three 60° - 70° Clockwise
Stage Four 60° - 70° Clockwise
Intake Manifold Bolts 20 15 177
Lower Splash Shield
- 5 44
Screws
Main Bearing Journal Cap
Bolts
Stage One M8 20 15 177
Stage Two M8 90° Clockwise
Stage One M10 30 22 266
Stage Two M10 90° Clockwise
Manifold Bolts 16 12 142
Oil Cooler Bolts 11 8 97
Oil Filter Adaptor Center
70 52 620
Bolt
Oil Filter Cap 25 18 97
Oil Indicator Tube Bolt 10 7 89
Oil Pan Bolts Lower 14 10 124

Oil Pan Bolts Upper
M6 10 7 89
M8 20 15 177
Oil Pan Drain Plug 30 22 266
Oil Pressure/Level Sensor
10 7 89
Screws
Oil Spray Nozzle Bolts 15 11 133
Power Steering Pump
25 18 97
Ground Bolt
Power Steering Pump
45 33 398
High Pressure Line
Timing Chain Cover Bolts 20 15 177
Timing Chain Tensioner
80 59 708
Bolt
Transmission Mount Bolts 40 30 354
SPECIAL TOOLS
RIGHT CAMSHAFT LOCATING PLATE 9104
VALVE SPRING COMPRESSOR C-3422-CF

LEFT CAMSHAFT LOCATING PLATE 9105 SLEEVE 9101
INSERTION TOOL 9103 FLYWHEEL LOCKING TOOL 9102

REAR SEAL INSTALLER 9100 PRESSURE TESTER ADAPTOR 9107
VALVE ASSEMBLY TOOL CASE 9106

AIR CLEANER HOUSING

REMOVAL
Note: The air cleaner is held in place by two rubber grom-
mets and two spring clips.
1. Remove the air inlet tubes (2).

2. Lift the air cleaner housing (1) from the rear first, then from
the front and remove it.
INSTALLATION
1. Position the air cleaner housing (1) on the mounting tabs
and push down.
2. Install the air inlet tubes (2).
AIR CLEANER ELEMENT

REMOVAL
2. Remove the screws (1) and the air cleaner element covers.
(1 cover on each side of housing.)
3. Remove the air cleaner elements (2) from the air cleaner
housing (1).
INSTALLATION
1. Position the new air cleaner elements (2) in the air cleaner housing (1).
2. Install the screws in the air cleaner element covers (3).
3. Install the air cleaner housing and air inlet tubes.
CYLINDER HEAD
DESCRIPTION
Extremely compact, single overhead camshaft aluminum alloy cylinder heads have two intake and one exhaust
valve per cylinder.
OPERATION
The cylinder heads, having three valves per cylinder minimizes exhaust port surface area, keeping more heat in the
exhaust stream to provide fast catalytic converter heating for low emissions and to reduce cooling load. A three-
valve configuration also simplifies the engine by allowing use of one cam per bank rather than two and provides
room in the combustion chamber for two spark plugs that provide more complete combustion. Valves are set at an
included angle of 35.5 degrees, forming a shallow combustion chamber. A central passage in each head that con-
nects with each cylinder delivers either assist air or recirculated exhaust if needed to reduce exhaust emissions. The
camshafts turn directly in the head; no bearing inserts are used. Transverse coolant flow within the head provides
optimal cooling of the exhaust valve seats while minimizing heat extraction from the exhaust ports to enhance cat-
alytic converter warm up.
DIAGNOSIS AND TESTING - CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent
water jacket.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the Cylinder Compres-
sion Pressure Test. Refer to Page 9-4. An engine cylinder head gasket leaking between adjacent cylinders will
result in approximately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP
REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat
opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER 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).
Install cooling system tester 7700 or equivalent and the pressure tester adapter Special Tool 9107 to pressure cap
neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a
cylinder, a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using the Bloc-ChekT Kit C-3685-A or equivalent.
Perform test following the procedures supplied with the tool kit.
REMOVAL
1. Remove the engine air cleaner housing. Refer to Page
9-608.
2. Remove the mass air flow sensor.
3. Drain the engine coolant. Refer to Page 7-18.
4. Remove the radiator with radiator fan. Refer to Page 7-26.
5. Disconnect the camshaft position sensor harness connector
(1) and remove the bolt (2) and the sensor. (right side
only).

8. Remove the intake manifold. Refer to Page 9-678.
9. Remove the cylinder head cover. Refer to Page 9-617
10. Disconnect the exhaust system at the exhaust manifolds.
Refer to Page 11-5.
11. Position the crankshaft 40° ATDC. Refer to Page 9-704.
12. Using Special Tools 9104 (1) and 9105 Camshaft Locating
Plates, lock the camshafts by placing the tool flush on the
cylinder head, and inserting it into the groove in the cam-
shaft.
13. Remove the timing chain tensioner (1).
14. Use a cable tie (1) to secure the timing chain to the right
hand camshaft sprocket.
15. Remove the camshaft sprocket bolts (1) and the sprock-
ets.
16. Remove Special Tools 9104 and 9105 Camshaft Locating
Plates.
17. Remove the camshafts. Refer to Page 9-626.
18. Loosen the cylinder head bolts using the sequence

diagram.
19. Remove the cylinder head bolts (1), the cylinder heads,
and the gaskets.
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of alumi-
num engine components and multi-layer steel cylinder head gaskets.
Note: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. Refer to Page 9-588. Be careful not to gouge or scratch
the aluminum head sealing surface.
Clean all engine oil passages.
INSPECTION
1. Before cleaning, check for leaks, damage and cracks.
2. Clean the cylinder head coolant and oil passages.
3. Check the cylinder head for flatness.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined total

dimension of the stock removal limit from cylinder head
and block top surface (Deck) together.
4. The cylinder head must be flat within:

• Standard dimension = less than 0.002 inch. (0.05 mm)
• Service Limit = 0.008 inch. (0.2 mm)
• Grinding Limit = Maximum of 0.008 inch. (0.2 mm) is
permitted.
INSTALLATION
1. Position the cylinder head gasket and the cylinder head on
the engine block dowels.
Note: Measure and inspect cylinder head bolts before

reuse. Do not reuse bolts that exceed 144 mm (1) in
length.
Note: Apply a thin coat of lubricant to head bolt threads

before installing.
2. Install, but do not tighten the cylinder head bolts (1).
3. Use the tightening sequence chart to tighten the cylinder

head bolts.
Note: Bolts numbered 9 and 10 are timing chain cover

bolts. They should be tightened after the cylinder head
bolts are tightened.
4. Tighten the cylinder head bolts in four stages.

• Stage one, 20 N·m (15 ft. lbs.)
• Stage two, 50 N·m (37 ft. lbs.)
• Stage three, Rotate bolts 60°–70° clockwise.
• Stage four Rotate bolts 60°–70° clockwise.
• Tighten bolts 9 and 10 to 25 N·m (18 ft. lbs.).
5. Using Special Tools 9104 and 9105 Camshaft Locating
Plates, lock the camshafts.
6. Install the camshaft sprockets and bolts (1).

7. Tighten the camshaft sprocket bolts in two stages.
• Stage one, 50 N·m (37 ft. lbs).
• Stage two, Rotate bolts 90° clockwise.
8. Remove the cable tie (1).
9. Install the timing chain tensioner (1). Tighten the timing

chain tensioner to 80 N·m (60 ft. lbs.).
Plates.
11. Check for a crankshaft position of 40° ATDC. Refer to
Page 9-704.
12. Connect the exhaust system at the manifold flanges and
tighten the exhaust flange bolts to 20 N·m (15 ft. lbs.).
13. Install the cylinder head covers. Refer to Page 9-618.
14. Install the intake manifold. Refer to Page 9-680.
15. Install and connect the ignition coils. Refer to Page 8I-5.

17. Install and connect the radiator fan with the radiator. Refer
to Page 7-35.
18. Install the camshaft position sensor and bolt (2). Connect
the camshaft position sensor harness connector (1).
19. Install the engine air cleaner housing.
21. Fill the engine oil. Refer to Page 9-664.
22. Start the engine and check for leaks during warm up.
23. Recheck all fluid levels.
CYLINDER HEAD COVER

DESCRIPTION
Magnesium cylinder head covers provide trouble-free sealing, are lighter than aluminum and dampen valve noise.
They are cast in two pieces to create internal ventilation passages with oil separators for crankcase vapor ventila-
tion. This ventilation system virtually prevents the possibility of oil sludge formation due to the retention of water
vapor in the engine.
REMOVAL
1. Remove the air cleaner housing. Refer to Page 9-608
2. Disconnect the ignition coil harness connectors (2).
3. Disconnect the spark plug wires (1) at the spark plugs.
4. Position aside the vacuum hoses at the cylinder head cover
retainers (3).
5. Disconnect the crankcase ventilation hose from the left cyl-
inder head cover.
6. Remove the cylinder head cover bolts (1) and the cylinder
head covers (2).
INSTALLATION
1. Check the gasket for tearing and breakage. If damage is
evident, replace the gasket.
2. Position the cylinder head covers (2) on the cylinder head.
Install the cylinder head cover bolts (1) and tighten to 10
N·m (7 ft. lbs.).
3. Route the engine vacuum hoses on the cylinder head cover

retainiers (3).
4. Connect the crankcase ventilator hose to the left cylinder
head cover, the ignition coils (2), and the spark plug wires
(1).
5. Install the air cleaner housing. Refer to Page 9-608.
CAMSHAFT BEARING BRIDGE

REMOVAL
1. Remove the cylinder head covers. Refer to Page 9-617.
Note: Rotate engine at the crankshaft in running direction

until scribe mark 40° on pulley/vibration damper corre-
sponds with scribe mark on timing chain cover. Grooves
in the camshafts must be toward the inside of the wedge.
2. Positon the engine timing at 40° ATDC. Refer to Page

9-704.
shaft.
5. Use a cable tie (1) to secure the timing chains to the cam-
shaft sprockets.
6. Remove the camshaft sprocket bolt (1) and sprocket.

7. Partially loosen the bolts in the sequence shown. (See

diagram).
8. Loosen and remove the bearing bridge bolts in the

sequence shown. Remove the camshaft bearing bridges.
INSTALLATION
1. Make sure the engine is at 40° ATDC.
2. Position the camshaft bearing bridge on the camshaft.
shaft.
4. Install, but do not tighten the bearing bridge bolts.

5. Tighten the bolts in the sequence shown to 15 N·m (11 ft.
lbs.).
6. Tighten the bolts in the sequence shown an additional 90°

clockwise.
7. Install the camshaft sprockets and bolts (1). Tighten the

8. Tighten the camshaft sprocket bolts and additional 90°
clockwise.
9. Install the timing chain tensioner (1). Tighten the tensioner

to 80 N·m (59 ft. lbs.).
10. Remove the cable tie.

11. Remove the Special Tools 9104 and 9105 Camshaft
Locating Plates.
12. Install the cylinder head covers. Refer to Page 9-618.
ROCKER ARM / ADJUSTER ASSY

DISASSEMBLY
REMOVAL
1. Remove the camshaft bearing bridge. Refer to Page 9-619.
Note: Wear protective gloves, protective clothing, and eye protection.
Note: If shaft is tapped too hard there is a risk of distorting the camshaft bearing bridge and damaging the
hollow rocker arm shaft.
2. Use a 16 mm drift (1) to drive out the rocker shaft (2).
Note: If resistance is encountered while driving rocker

shaft out of the camshaft bearing bridge, the bearing must
be heated. Do not exceed 160° C.
3. Remove the rocker arms and inspect the bearing surfaces.

4. If longitudal scoring is present on rocker arm bearing,
replace the rocker arm.
5. Clean all the parts thoroughly.
ASSEMBLY
INSTALLATION
CAUTION: Risk of injury to skin and eyes from handling hot or glowing objects.
Note: Wear protective gloves, protective clothing, and eye protection.
Note: If resistance is encountered while driving rocker shaft out of the camshaft bearing bridge, the bearing
must be heated. Do not exceed 160° C.
1. Cool the rocker arm shaft.

2. Insert the rocker arm shaft (1) into the camshaft bearing
bridge (2) and through the rocker arms by tapping it gently
with a mallet. Ensure that the rocker arms are not crooked.
3. Insert two camshaft bearing bridge bolts through the attach-
ment holes in the camshaft bearing bridge to align and
secure the rocker arm shaft. The oil supply holes in the
rocker arm shaft points downward (toward the cylinder
head).
4. Install the camshaft bearing bridge. Refer to Page 9-622.
CAMSHAFT
DESCRIPTION
The induction-hardened, forged-steel camshafts are hollow to minimize weight. The camshaft and crankshaft
sprocket teeth are rubber coated, making chain noise indiscernible from other engine noise.
OPERATION
The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined
lobes to provide accurate valve timing and duration.
REMOVAL
1. Remove the camshaft bearing bridges. Refer to Page
9-622.
2. Remove the camshaft (1).
CLEANING
Clean the camshaft with a suitable solvent.
INSPECTION
1. Inspect the camshaft bearing journals for damage or binding. If the journals are binding, check the cylinder head
for damage. Also check the cylinder head oil holes for clogging.
2. Check the camshaft lobe and the bearing surfaces for abnormal wear and damage. Replace the camshaft if it is
defective.
3. Measure the lobe actual wear and replace the camshaft if it is out of limit. The standard value is 0.001 in.
(0.0254 mm). The wear limit is 0.010 in. (0.254 mm).
INSTALLATION
1. Position the camshaft (1) on the cylinder head.
2. Install the camshaft bearing bridges. Refer to Page 9-622
VALVE STEM SEAL

REMOVAL
Note: The tools used in these valve stem seal procedures
are part of Special Tool 9106 Valve Assembly Tool Case.
1. Remove the starter. Refer to Page 8F-43

2. Remove the camshafts. Refer to Page 9-626.
3. Remove one spark plug from the cylinder to be repaired.
4. Position the cylinder to be repaired to TDC.
5. Using Special Tool 9102 Flywheel Locking Tool, lock the fly-
wheel by inserting the tool into the starter opening.
6. Pressurize the combustion chamber. Refer to Page 9-4.
7. Install the assembly tool (1). Compress the valve spring.

8. With the valve spring compressed, remove the collets (1).

9. Release the valve spring and remove the valve spring
retainer (2), the spring (3) and spring seat (4).
10. Remove the valve stem seal (2) using the seal pliers (1).
Note: Assemble the valves completely before removing

the air pressure from the cylinder.
11. Repeat these steps for each cylinder required.

12. Inspect all of the valve stems. Damaged valves must be
replaced.
INSTALLATION
Note: Valves with nicked or burred stems must be
replaced.
Note: The tools used in these valve stem seal procedures

are part of Special Tool 9106 Valve Assembly Tool Case.
1. Lubricate the new seal (3) with clean engine oil.

2. Install the protective sleeve (2) over the valve stem.
3. Press the new seal over the sleeve on to the valve stem
using the seal pliers (1).
4. Remove the protective sleeve (2).
5. Install the valve spring seat (4), valve spring (3), and the
valve spring retainer (2).
6. Compress the valve spring using the assembly tool (1).

7. Install the valve stem collets with the valve spring com-
pressed.
8. Release the valve spring slowly.
9. Be sure that the collets are seated in the valve spring
retainer.
10. Remove the assembly tool.
Note: Perform this procedure on one cylinder at a time.
11. Repeat the procedure for each valve that is to be

serviced.
12. Remove Special Tool 9102 Flywheel Locking Tool (1).

14. Install the camshafts. Refer to Page 9-626.
INTAKE/EXHAUST VALVES AND SEALS

DESCRIPTION
Two 1.42-in. (36-mm) intake valves and a single 1.61-in. (41-mm) exhaust valve per cylinder are operated by a
double-width roller chain-driven camshaft per bank using roller rocker arms. Lightweight hydraulic adjusters in the
rocker arms at the valves take up valve clearance for quiet operation. For minimum weight and maximum rigidity the
compact rocker arms are pressure-cast aluminum. They pivot through roller bearings on rocker shafts bolted to the
heads. Using computer-aided measurement and calculation techniques, valve dynamics are equivalent to that
achieved by direct valve actuation through in-line tappets, but with far less friction.
OPERATION
The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned
air/fuel mixture to exit the combustion chamber. Also, the intake and exhaust valves seal the combustion chamber
during the compression and power strokes.
REMOVAL
1. Remove the cylinder head and place on a suitable work
bench. Refer to Page 9-611.
2. Using Special Tool C-3422–CF Valve Spring Compressor,

compress the valve spring.
3. Remove the collets (1). Release the valve spring compres-

sor and remove the valve retainer (2) and the valve spring
(3) with spacer.
4. Using Special Tool 9106 (1) Valve Assembly Tool Case,

remove the valve stem seal (2).
5. Remove the valve (4) from the cylinder head.
6. Inspect the valve face and the stem for any wear or nicks.
Replace damaged valves as required.
CLEANING
1. Clean all valves thoroughly and discard burned, warped and cracked valves.
INSTALLATION
1. Install the valve into the cylinder head.
2. Install the protective sleeve (2) over valve stem.
3. Lubricate the valve stem seal before installing.
4. Using Special Tool 9106 (1) Valve Assembly Tool Case,
press the valve stem seal (3) onto valve stem.
5. Remove the protective sleeve (2).
6. Install the valve spring spacer, the spring (3), and the valve
spring retainer (2), over the valve stem (4).
7. Using Special Tool C–3422–CF Valve Spring Compressor,

compress the valve spring and install the collets (1).
8. Repeat the process for each valve.
9. Install the cylinder head. Refer to Page 9-614.
VALVE SPRINGS
DESCRIPTION
Valve springs are conical to reduce spring and retainer weight, and the exhaust valve heads are sodium filled to
keep them cool for long life.
OPERATION
The valve spring returns the valve against its seat for a positive seal of the combustion chamber.
ENGINE BLOCK
DESCRIPTION
A high-pressure die-cast aluminum alloy block uses cast-in-place cylinder bore liners made of a proprietary 9Silitec9
material for wear resistance. These aluminum-silicon alloy liners reduce block weight relative to cast iron liners while
providing the necessary wear resistance. Block construction features side walls extended below the centerline of the
crankshaft, cross-bolted main bearing caps, and a structural cast aluminum oil pan for additional rigidity.
CLEANING
Clean cylinder block thoroughly using a suitable cleaning solvent.
INSPECTION
ENGINE BLOCK
1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
2. If new core plugs are to be installed, Refer to Page 9-588.
3. Examine block and cylinder bores for cracks or fractures.
4. Check block deck surfaces for flatness. Deck surface must be within service limit of 0.004 in. (0.1 mm).
CYLINDER BORE
Note: The cylinder bores should be measured at normal room temperature, 21°C (70°F).
The cylinder walls should be checked for out-of-round and taper. Refer to Page 9-602.
CRANKSHAFT OIL SEAL - REAR

REMOVAL
1 - REAR CRANKSHAFT OIL SEAL 3 - END COVER

2 - BOLT
Note: The rear crankshaft oil seal cannot be replaced separately. The end cover and seal are assembled at
the factory and must be replaced as a set.
1. Remove the flywheel. Refer to Page 9-653.

2. Remove the crankshaft end cover bolts (2).
3. Remove the end cover (3).
4. Discard the end cover (3) and the rear crankshaft oil seal (1)
5. Clean the engine block and the oil pan gasket surfaces.
INSTALLATION
Note: The rear crankshaft oil seal cannot be replaced sep-
arately. The end cover and seal are assembled at the fac-
tory and must be replaced as a set.
Note: Parts requiring sealer must be assembled within ten

minutes after applying sealer.
1. Apply a 1.5 mm to 2 mm bead of Loctite 5203 sealer only

where shown (1) on the new end cover.
2. Install the new end cover (without seal installed) and the
end cover retaining bolts. Tighten the bolts to 10 N·m (89
in. lbs.).
Note: Ensure the edge of the mounting hole around the

entire circumference for the rear crankshaft oil seal is
clean and free of burrs.
Note: Ensure that the sealing lip of the rear crankshaft oil
seal is not damaged or compressed.
Note: The circumference and the sealing lip of the rear

crankshaft oil seal, as well as the mating contact surface
MUST be free of oil and grease.
Note: The rear crankshaft oil seal must be positioned at

right angles to the crankshaft to assure proper sealing.
3. Using Special Tool 9100 Rear Seal Installer (1), install the
rear crankshaft oil seal into the new end cover.
Note: The distance between the edge of the end cover and
the rear crankshaft oil seal must be approximately 1 mm.
(.039 in.) around the entire circumference.
4. Remove Special Tool 9100 Rear Seal Installer.

5. Install the flywheel. Refer to Page 9-654.
CRANKSHAFT OIL SEAL - FRONT

REMOVAL
2. Remove the engine cooling fan and shroud. Refer to Page
7-26.
4. Remove the vibration damper. Refer to Page 9-651.
5. Protect the crankshaft with a rag, then pry out the front
crankshaft oil seal (1) with a suitable tool.
INSTALLATION
1. Remove any burrs from the seal’s mounting surface.
Note: The circumference and the sealing lip of the front

crankshaft oil seal, as well as the mating contact surface
MUST be free of oil and grease.
2. Fit the front crankshaft oil seal onto the Special Tool 9103
Insertion Tool (2) as shown.
3. Align the slot of the tool with the crankshaft key.
4. Using a suitable tool, tap the insertion tool until the vibra-
tion damper bolt can be installed through the insertion tool.
5. Use the vibration damper bolt to push the seal into the tim-
ing chain cover until tight.
6. Remove the Special Tools.
7. Install the vibration damper. Refer to Page 9-652.
9. Install the engine cooling fan and shroud (1). Refer to

Page 7-27.
CONNECTING ROD BEARINGS

DESCRIPTION
Connecting rods are forged in one piece from steel, and cracked rather than machined along the split line, providing
a perfect fit for the two halves and reducing weight by 20 percent compared to a fully machined rod and cap while
also greatly reducing machining. The rods are drilled longitudinally to deliver oil under pressure to the wrist pins,
minimizing wear for long life. Thirty-degree offset crank pins on the crankshaft provide even, 120-degree, firing inter-
vals for smooth operation. The crankshaft with these split pins has ample strength without adding material between
the pins, keeping the engine compact and reducing weight.
STANDARD PROCEDURE - CONNECTING RODS AND BEARINGS

CONNECTING ROD BEARINGS
The bearing caps are not interchangeable and should be
marked at removal to insure correct assembly.
The bearing shells must be installed with the tangs (1) inserted
into the machined grooves in the rods and caps. Install cap
with the tangs on the same side as the rod.
Fit all rods on one bank until complete.
Limits of taper or out-of-round on any crankshaft journals
should be held to 0.0006 in.(0.015 mm). Bearings are avail-
able in standard, 0.001 in. (0.025 mm), and 0.010 in. (0.254
mm) undersizes. Install the bearings in pairs. Do not use a
new bearing half with an old bearing half. Do not file the
rods or bearing caps.
For measuring main bearing clearance and connecting rod
bearing clearance, use plastigage for bearing clearance spec-
ifications. Refer to Page 9-588.
CONNECTING ROD BOLTS

Note: The connecting rod bolts should be examined before reuse. If the threads are necked down, the bolts
must be replaced.
1. Examine connecting rod bolts for stretching. Stretching can

be checked by holding a scale or straight edge (2) against
the threads. If all the threads do not contact the scale (1)
the bolt must be replaced.
2. Tighten the connecting rod bolts to specifications.
PISTON AND CONNECTING ROD

DESCRIPTION
Flat-topped aluminum pistons (3 and 6) have machined pock-
ets for valve clearance and asymmetrical skirts for low-temper-
ature noise control. The pistons are formed from a special
aluminum alloy to cope with the high temperatures created by
dual ignition. In addition, the upper portions are hard anodized
to protect the top ring. For optimal wear protection, the piston
skirts receive an iron coating. Three, low-tension piston rings
provide compression control with low oil consumption. Forged
steel connecting rods (8) and crankshaft provide requisite
strength with light weight. Connecting rods are forged in one
piece from steel, and cracked rather than machined along the
split line, providing a perfect fit for the two halves and reducing
weight by 20 percent compared to a fully machined rod and
cap while also greatly reducing machining. The rods are drilled
longitudinally to deliver oil under pressure to the wrist pins (2
and 5), minimizing wear for long life.
STANDARD PROCEDURE
PISTON FITTING
All pistons are machined to the same weight in grams, to
maintain piston balance.
Note: Pistons and cylinder bores should be measured at

normal room temperature, 70°F (21°C).
The piston and cylinder walls must be clean and dry. Piston
diameter should be measured 90 degrees to piston pin axis.
Cylinder bores should be measured halfway down the cylinder
bore (2) and transverse to the engine crankshaft center line.
REMOVAL
1. Remove the timing chain. Refer to Page 9-693.
2. Mark the connecting rods and rod caps (1) for reassembly.
3. Mark the pistons facing direction if arrows are not visible.
4. Remove the connecting rod bolts (1) and the connecting

rod caps.
5. Remove the pistons and connecting rods from top of the

engine.
6. Perform work on a suitable surface to prevent damage to

parts.
7. Keep the piston pins matched to the pistons.
8. Remove the snap rings from the pistons (2).
9. Press out the piston pins (1).
10. Remove the piston from the connecting rod (3).
11. Inspect all parts to be reused for damage. Replace as
required.
INSPECTION
CONNECTING ROD
1. Check the connecting rods for any twisting or bending.
2. Check the condition of the large end. Use an oil stone to remove any nicks and burrs.
3. Check the condition of the pin bore in the small end of the connecting rod. Use an oil stone to remove all nicks
and burrs.
PISTON PIN
1. Inspect for free rotation of the wrist pin in the piston.
PISTON
1. Inspect all piston surfaces for nicks and scuffs.
2. Inspect piston and ring grooves for wear.
INSTALLATION
1. Fit the piston onto the connecting rod (3).
2. Press in the piston pin (1).
3. Install the snap rings (2).
4. Replace the piston rings as required. Refer to Page 9-645.
5. Load the piston/connecting rod assembly (1) into a ring

compressor (2) with light oil lubrication.
6. Drive the piston into the cylinder using a wooden drift and a
mallot.
Note: The connecting rod bearing shell with the oil drilling
(2) must be installed in the connecting rod, otherwise the
connecting rod bearings will not be lubricated. The anti-
twist locks of the connecting rod bearing shells must be
located in the slots (1) of the connecting rods and the
connecting rod bearing caps.
7. Align the connecting rod caps with the marks (1).

8. Install the connecting rod bolts.
9. Tighten the connecting rod bolts in three stages.
• Stage one, 5 N·m (44 in. lbs.)
• Stage two, 25 N·m (18 ft. lbs.)
• Stage three, rotate bolts 90° clockwise.
10. Test the engine for ease of rotation.
11. Install the timing chain. Refer to Page 9-695.
PISTON RINGS
REMOVAL
1. Remove the pistons and connecting rods. Refer to Page
9-640
CAUTION: Do not remove the oil scraper ring with the pli-
ers. The oil scraper ring must be removed and installed by
hand.
2. Using piston ring pliers, remove the piston rings.
CAUTION: Do not cut or scratch pistons while cleaning.
3. Use a ring grove cleaner or a broken ring to remove depos-

its in the ring grooves.
4. Inspect the pistons for heat scoring and distortion at the
piston pin openings and piston skirts. Replace as required.
INSTALLATION
1. Measure the end gap (1) with rings at the bottom of the cyl-
inder.
• Ring # 1 clearance is .20 mm to .35 mm.
• Ring # 2 clearance is .20 mm to .40 mm.
2. Measure the vertical clearance (2) of the piston rings (1).

3. Ring # 1 clearance is .012 mm to .060 mm.
4. Ring # 2 clearance is .010 mm to .030 mm.
5. Install the rings on the pistons as shown.

• Compression ring (1)
• Sealing ring (2)
• Oil Ring Rail (3)
• Oil Ring Expander (4)
6. The ring gaps when installed must be positioned as shown.

• Ring one (1)
• Upper side rail (2)
• Ring two and spacer expander (3)
• Lower side rail (4)
7. Install the pistons and connecting rods. Refer to Page
9-643.
CRANKSHAFT AND MAIN BEARINGS

DESCRIPTION
Thirty-degree offset crank pins on the crankshaft provide even,
120-degree, firing intervals for smooth operation. The crank-
shaft with these split pins has ample strength without adding
material between the pins, keeping the engine compact and
reducing weight.
OPERATION
The crankshaft transfers force generated by combustion within the cylinder to the flywheel or flexplate.
REMOVAL
1. Remove the upper oil pan. Refer to Page 9-663.
2. Remove the oil pump. Refer to Page 9-674.
3. Remove the rear crankshaft radial seal. Refer to Page
9-634.
Note: When rotating the crankshaft, ensure that the con-

necting rods are not twisted.
Note: Mark the connecting rod and the connecting rod

bearing cap (1) on one side next to each other for this
step.
5. Remove the connecting rod bolts (1).
Note: Do not dislodge the connecting rod bearings from

the connecting rods.
6. Remove the connecting rod caps (1) with the bearings in

place.
7. Relocate the connecting rods away from the crankshaft.
Note: Mark the crankshaft bearing caps before removing.
CAUTION: Carefully pry out the crankshaft bearing caps.
8. Remove the crankshaft main bearing journal cap side bolts

(2).
9. Remove and discard the crankshaft main bearing journal
cap bolts (1).
10. Remove the crankshaft main bearing journal cap bolts (3).
11. Remove the crankshaft (1) from the engine block.
12. Remove the crankshaft main bearing shells (1) and thrust
washers (2) from the crankcase.
13. Remove the crankshaft main bearing shells from the
crankshaft main bearing journal caps.
INSTALLATION
1 - CONNECTING ROD OIL PORT 5 - LOWER MAIN BEARING SHELL

2 - CONNECTING ROD BEARING CAP 6 - UPPER MAIN BEARING SHELL
3 - CONNECTING ROD BOLT 7 - THRUST WASHER
4 - MAIN BEARING JOURNAL CAP
Note: Clean all the journals with solvent and dry throughly
before installing bearings.
1. Fit the upper main bearing shells (6) to the engine block’s
main journals.
2. Fit the thrust washers (7) into the engine block.
3. Coat the surface of bearings lightly with engine oil.
4. Position the crankshaft in the engine block.
5. Fit the lower main bearing shells (5) into the main bearing
journal caps (4).
CAUTION: The crankshaft main bearing journal cap bolts

M8X75 and M10X90 must always be replaced otherwise
there is a risk of fracture.
6. Install the main bearing journal caps (4).

7. Follow the torque sequence shown for the crankshaft main

bearing journal cap bolts.
8. Main bearing journal caps must be tightened in two stages.
• Stage one for m8 bolts, 20 N·m (15 ft. lbs.).
• Stage two for m8 bolts, rotate 90° clockwise.
• Stage one for m10 bolts, 30 N·m (22 ft. lbs.).
• Stage two for m10 bolts, rotate 90° clockwise.
CAUTION: Connecting rod bolts exceeding 47.6 mm in

length must be replaced.
9. Install the connecting rod caps and the bolts to the con-
necting rod as marked. Refer to Page 9-643.
10. Install the oil pump. Refer to Page 9-676.
11. Install the upper oil pan. Refer to Page 9-663.
13. Install a new crankshaft rear radial seal. Refer to Page
9-635.
VIBRATION DAMPER
REMOVAL
2. Drain the cooling system into a suitable container.
3. Remove the radiator fan with the radiator. Refer to Page
7-33.
5. Remove the starter. Refer to Page 8F-43.
6. Using Special Tool 9102 Flywheel Locking Tool (1), lock the
flywheel by inserting the tool into the starter opening.
7. Remove the vibration damper bolt (1) and the vibration

damper (2) from the crankshaft.
INSTALLATION
1. Inspect for oil leaks at the front crankshaft oil seal.
2. Replace the front crankshaft oil seal if signs of leakage are
present.
3. Inspect the sealing surface of the vibration damper. Smooth
any roughness with emery paper or an oil stone.
4. Measure the vibration damper bolt. Replace the bolt if
length exceeds 78 mm.
5. Position the vibration damper on the front of the crankshaft.
6. Lubricate the bolt threads with engine oil before installing.
7. Install the vibration damper bolt and tighten:
• 1st to 200 N·m (148 ft. lbs.),
• Then retighten the bolt an additional 90° clockwise.

9. Install the radiator with the radiator fan. Refer to Page
7-35.
10. Remove the Special Tool 9102 Flywheel Locking Tool.
FLEX PLATE / FLYWHEEL

REMOVAL
1. Remove the transmission. For manual Refer to Page
21-344, for automatic Refer to Page 21-210.
flywheel by inserting the tool in the starter opening.
5. Remove and discard the flywheel bolts (1).

6. Remove the spacer (2) and the flywheel/flexplate (3).
7. Inspect the rear crankshaft oil seal for leakage. Replace if
required.
INSTALLATION
Note: New flywheel/flexplate bolts must be used.
1. Position the flywheel/flexplate (3) and align on the cranshaft

pin.
2. Install the spacer and new flywheel/flexplate bolts (1).
Tighten bolts to 45 N·m (33 ft. lbs.)
3. Rotate the flywheel/flexplate bolts an additional 90° clock-
wise.
5. Remove Special Tool 9102 Flywheel Locking Tool (1).

7. Install the transmission. Refer to Page 21-227 or Refer to
Page 21-347.
ENGINE MOUNT BRACKETS

REMOVAL
1. Remove the engine mount. Refer to Page 9-657.
2. Remove and discard the engine mount bracket bolts (1).
3. Remove the engine mount bracket.
INSTALLATION
1. Position the engine mount brackets on the engine block.
2. Install the new bolts (1) and tighten to 20 N·m (15 ft. lbs.)
3. Rotate the bolts an additional 90° clockwise.
4. Install the engine mounts. Refer to Page 9-658.
FRONT MOUNT
REMOVAL
1 - ENGINE MOUNT UPPER BOLT 3 - ENGINE MOUNT

2 - HEAT SHIELD 4 - ENGINE MOUNT LOWER BOLT

3. Attach the engine support frame.
4. Remove the engine mount upper bolt (1) and the heat
shield (2).
CAUTION: Do not stretch lines and hoses while lifting

engine.
5. Raise the engine slightly.

shield.
8. Remove the engine mount lower bolt.
9. Remove the engine mount.
INSTALLATION
1 - ENGINE MOUNT UPPER BOLT 3 - ENGINE MOUNT

2 - HEAT SHIELD 4 - ENGINE MOUNT LOWER BOLT
Note: The arrows on the engine mounts must be located

in the retaining slots on the engine bracket.
1. Position the engine mount (3) on the crossmember.

2. Install the engine mount lower bolt (4). Tighten the bolt to
35 N·m (26 ft. lbs.).
Note: The recesses of the heat shield must be located in

the anti twist slots of the engine bracket.
3. Lower the engine onto the engine mount. Install the heat
shield (2) and the engine mount upper bolt (1).
4. Tighten the engine mount upper bolt (1) to 55 N·m (41 ft.
lbs.).
5. Install the lower splash shield and screws (1). Tighten to 7
N·m (5 ft. lbs.).
7. Remove the engine support frame from the engine.
REAR MOUNT
REMOVAL
2. Support the transmission with a transmission jack.
3. Remove the rear mount lower bolts (3).
4. Raise the transmission slightly off of the rear crossmember.
5. Remove the rear mount upper bolts (1).
6. Remove the rear mount.
INSTALLATION
1. Position the rear mount on the transmission.
2. Install the rear mount upper bolts (1). Tighten the bolts to
40 N·m (30 ft. lbs.).
3. Lower the transmission on to the rear crossmember.
4. Install the rear mount lower bolts (3). Tighten the bolts to
40 N·m (30 ft. lbs.).
5. Remove the transmission jack.
LUBRICATION
DESCRIPTION
The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the
engine block. The pump inner rotor is driven by the crankshaft.

ENGINE OIL LEAK INSPECTION
Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak
source is not readily identifiable, the following steps should be followed:
1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily
stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15
minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color
under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If
the oil leak is found and identified, repair as necessary.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspec-
tion.
5. If the oil leak source is not positively identified at this time, proceed with the air leak detection test method
as follows:
• Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on the
cover.
• Remove the vent hose from the cylinder head cover. Cap or plug the nipple on the cover.
• Attach an air hose with pressure gauge and regulator to the oil level indicator tube.
CAUTION: Do not subject the crankcase to more than 20.6 kpa (3 PSI) of test pressure.
• Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected
source. Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the
leak source. If the oil leak is detected and identified, repair per service manual procedures.
• If the leakage occurs at the crankshaft rear seal area, refer to inspection for rear seal area below.
6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the vent hose
and proceed to next step.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approx-
imately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the radial seal area of the engine, a more
involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.
If the leakage occurs at the crankshaft radial oil seal area:
1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light
to check for the oil leak. If a leak is present in this area, remove transmission for further inspection.
a. Circular spray pattern generally indicates seal leakage or crankshaft damage.
b. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug,
bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items.
4. If no leaks are detected, pressurize the crankcase as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between
the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged.
The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and
scratches. The crankshaft radial seal flange is especially machined to complement the function of the rear
oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.
7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as
necessary.
DIAGNOSIS AND TESTING - CHECKING ENGINE OIL PRESSURE

1. Remove the oil pressure testing plug (1) at the base of the
oil filter housing.
2. Install oil pressure test gauge assembly.
3. Start the engine and monitor the gauge readings.
CAUTION: If oil pressure is 0 at idle, Do Not Run engine at

3000 RPM
4. Oil pressure (engine at operating temperature): Curb Idle

34.5 kPa (5 psi) minimum 3000 RPM 300–724 kPa
(45–105 psi).
5. If the oil pressure is 0 psi at idle, shut the off engine and
check the pressure relief valve; it may be stuck open or
have a clogged oil pickup screen.
6. Install the oil pressure test plug and tighten to 10 N·m (89
in. lbs.) after testing is completed.
OIL LEVEL INDICATOR TUBE

REMOVAL
1 - BOLT 3 - CABLE TIE STRAP

2 - OIL LEVEL INDICATOR TUBE

2. Remove the bolt (1) in the cylinder head cover for the oil level indicator tube (2).
3. Remove the cable tie strap (3) holding the wire loom on the oil level indicator tube.
4. Pull up and remove the oil level indicator tube (2) from the engine.
INSTALLATION
1. Replace the oil level indicator tube seal and lubricate with engine oil.
Note: The oil level indicator tube must be fully seated or oil leaks can occur.
2. Position the oil level indicator tube (2) and install it in the crankcase.
3. Install the bolt (1) in the cylinder head cover and tighten to 10 N·m (89 in. lbs.).
4. Position the wire harness loom at the oil level indicator tube and fasten with new cable tie (3).
OIL
DESCRIPTION
For complete engine oil type and capacity specifications, see fluid types in the lubrication and maintenance section.
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it has sat overnight. Or if the engine has been running, allow the
engine to be shut off for at least 5 minutes before checking the oil level.
Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add only
when the level is at or below the ADD mark.
STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE

Change the engine oil at the mileage and time intervals described in the maintenance section of the Owners Man-
ual.
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTER-
NAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH
SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS,
HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CON-
AREA.
TO CHANGE ENGINE OIL

1. Run the engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn the engine off.
3. Remove the oil filler cap (1).
5. Remove the lower splash shield screws (1) and the shield.
6. Place a suitable drain pan under the crankcase drain.
7. Remove the drain plug from the crankcase and allow the oil
to drain into the pan. Inspect the drain plug threads for
stretching or other damage. Replace the drain plug and
gasket if damaged.
8. Remove the oil filter. Refer to Page 9-666.
9. Install the drain plug (1) and tighten to 30 N·m (22 ft. lbs.).
10. Install the lower splash shield. Tighten to 7 N·m (5 ft. lbs.).
11. Lower the vehicle and fill the crankcase with specified type
and amount of engine oil.
12. Install a new oil filter. Refer to Page 9-666.
13. Install the oil filler cap.
14. Start the engine and inspect for leaks.
15. Turn off the engine and inspect the oil level.
USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after
it has been drained from a vehicle engine. See the warning
above for common practices and recommendations.
OIL FILTER
DESCRIPTION
The oil filter is mounted on the upper side of the front of the engine. It uses a replaceable element that can be
incinerated.
REMOVAL
1. Use an oil filter wrench if necessary to remove the oil filter
cap (1).
2. Remove oil filter cap with the filter.

3. Remove the oil filter.
INSTALLATION
1. Replace the oil filter cap seal.
2. Install a new filter (1) in the cap.
3. Install the filter and cap (1) and tighten to 25 N·m (18 ft.
lbs.).
OIL PAN
REMOVAL
LOWER OIL PAN
shield.
3. Remove the transmission oil cooler line retainer bolts (1).

Position the cooler lines aside.
4. Remove the lower oil pan retaining bolts and the lower oil
pan (1).
REMOVAL - UPPER OIL PAN

1. Remove the engine. Refer to Page 9-592.
2. Separate the transmission from the engine. Refer to Page
21-210 or Refer to Page 21-344.
4. Mount the engine on an engine stand.
5. Remove the lower oil pan. Refer to Page 9-663.
6. Remove the 24 upper oil pan bolts (1).
7. Separate the upper oil pan from the engine block.
INSTALLATION
LOWER OIL PAN
Note: The components using sealant must be assembled
within ten minutes of sealant application.
1. Clean the lower oil pan and the lower portion of the upper
oil pan gasket surfaces thoroughly.
2. Apply a 1.5 mm to 2 mm bead of Loctite 5203 sealant or
equivalent to the lower oil pan sealing surface (1) as
shown.
3. Install the lower oil pan and oil pan bolts. Tighten the lower
oil pan bolts to 14 N·m (10 ft. lbs.).
4. Position and install the transmission cooler lines and retain-

ers (1). Tighten the bolts to 10 N·m (7 ft. lbs.).
5. Install and tighten the oil pan drain plug to 30 N·m (22 ft
lbs.).
6. Install the lower splash shield and screws (1). Tighten the
screws to 5 N·m (44 in. lbs.).
8. Fill the crankcase to the specified oil level.
INSTALLATION - UPPER OIL PAN

1. Clean the gasket surfaces thoroughly.
Note: The components using sealant must be assembled

within ten minutes of sealant application.
2. Apply a 1.5 to 2 mm. bead of Loctite 5203 sealant (1) or

equivalent to the oil pan sealing surface as shown.
3. Position the upper oil pan on the engine block.

4. Install the oil pan bolts with the proper size and length bolt
in the correct bolt hole.
• (1) M6 X 20
• (2) M6 X 40
• (3) M6 X 90
• (4) M8 X 30
5. Tighten the M6 size bolts to 10 N·m (89 in. lbs). Follow the
tightening sequence diagram.
6. Tighten the M8 size bolts to 20 N·m (15 ft. lbs.). Follow the
tightening sequence diagram.
7. Install the lower oil pan. Refer to Page 9-663.
9. Install the transmission to the engine. Refer to Page
10. Install the engine. Refer to Page 9-597.
OIL LEVEL/TEMPERATURE SENSOR

REMOVAL
2. Disconnect the oil level/temperature sensor harness con-
nector (1).
3. Remove the two oil level/temperature sensor screws (1).

4. Remove the two harness retainer screws (2) and the oil
level/temperature sensor.
INSTALLATION
1. Position the oil level/temperature sensor in the upper oil
pan with the screws (1).
2. Position the harness retainer in the upper oil pan with the
screws (2).
3. Tighten all screws for the oil level/temperature sensor to 10
N·m (89 in. lbs.).
4. Connect the oil level/temperature sensor harness connector

(1).
OIL SPRAY NOZZLES

REMOVAL
1. Remove the upper oil pan. Refer to Page 9-663.
2. If necessary, rotate the crankshaft slightly at the vibration
damper.
3. Remove the oil spray nozzle bolts (1) and the oil spray noz-
zles.
Note: Do not use hard objects to clean the oil spray noz-
zles. Replace the oil spray nozzles if they are blocked.
4. Use compressed air only in the oil flow direction to clean

the oil spray nozzles.
INSTALLATION
Note: Ensure the jet pipes of the oil spray nozzles are not damaged or bent during installation.
1. Position the oil spray nozzles and bolts in the engine block.
2. Tighten the oil spray nozzle bolts to 15 N·m (11 ft. lbs.).
3. Install the upper oil pan. Refer to Page 9-663.
OIL PUMP
DESCRIPTION
The gear-type oil pump is located below the crankshaft and is driven from the crankshaft by a separate roller chain.
REMOVAL
2. Remove the oil pump bolts (1).
3. Release the oil pump chain tensioner (1) and remove the
oil pump from the oil pump drive chain (2).
CLEANING
1. Clean all of the parts thoroughly in a suitable solvent.
INSTALLATION
1. Inspect the oil pump check valve. Remove any debris or
sealant. Check the operation of the check valve by pressing
and releasing the plunger (1).
2. Fill the oil pump with engine oil.

3. Check the oil pump drive chain for wear. Replace any worn
or damaged parts.
4. Position the oil pump driven sprocket in the drive chain.
Position and install the oil pump and bolts. Tighten the bolts
to 20 N·m (15 ft. lbs.).
6. Refill the engine with motor oil to specified level.
OIL PUMP DRIVE CHAIN

REMOVAL
1. Remove the timing chain cover. Refer to Page 9-685.
2. Remove the oil pump. Refer to Page 9-674.
3. Remove the oil pump drive chain (2) and disgard. Inspect
the oil pump drive chain tensioner spring for wear and
replace as necessary.
INSTALLATION
1. Check the oil pump drive chain guide for wear and replace
as necessary.
2. Install the new oil pump drive chain and the oil pump.
3. Install the timing chain cover. Refer to Page 9-688.
OIL PRESSURE RELIEF VALVE

DESCRIPTION
The oil pressure relief valve cannot be adjusted or repaired. If faulty, worn, or damaged, the entire oil pump assem-
bly must be replaced.
INTAKE MANIFOLD
DESCRIPTION
A magnesium two-stage resonance intake manifold has long runners to enhance low-speed torque and shorter run-
ners for added horsepower. The runners, and the plenum chamber that feeds them, nest between the cylinder
banks. Complex components of the multi-piece die-cast manifold are adhesive bonded together.
OPERATION
A variable intake manifold provides a marked supercharging effect to air flow entering the cylinders as the intake
valve closes. Long individual tubes for each cylinder that enhance low-speed torque have a tuned length of 32.9
inches (835 mm). This length is achieved by coiling the tubes in the valley of the cylinder block. In these tubes, the
air rotates 450 degrees from entry to cylinder head. To achieve a similar effect at higher speeds, a tube length of
18.3 inches (465 mm) is used. Butterfly valves in the walls of the long tubes, operated by the engine control com-
puter, switch the flow between long and short flow paths at approximately 3700 rpm. The engine speed for switcho-
ver to the short tubes provides an imperceptible change in engine torque, because the maximum supercharging
effect is consistent throughout the 2000 to 5000-rpm speed range.
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may
not be functioning.
WARNING: USE EXTREME CAUTION 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 THE FAN. DO NOT WEAR
LOOSE CLOTHING.
1. Start the engine.

2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM’S change, the area of the suspected leak has been found.
4. Repair as required.
REMOVAL
3. Remove the mass air flow sensor. Refer to Page 14-37.
4. Remove the fuel rail with fuel injectors. Refer to Page
14-33.
5. Disconnect the vacuum lines to the EGR valve, brake
booster, crankcase ventilator and purge valve from the
intake manifold.
6. Disconnect the engine harness connectors.
7. Disconnect the EGR pipe (1) at the EGR valve (2).
8. Remove the air pump switchover valves (4).

9. Remove the bolts, the intake manifold (1) and the gaskets
(2).
INSTALLATION
1. Clean the gasket surfaces of the cylinder heads and the
intake manifold.
2. Position the intake manifold (1) on the cylinder heads with
new gaskets (2) in place.
3. Install the intake manifold bolts and tighten to 20 N·m (15
ft. lbs.).
4. Install the air pump switchover valves (4). Tighten the bolts
to 20 N·m (15 ft. lbs.).
5. Connect the EGR pipe fitting (1) to the EGR valve (2).
Tighten the EGR pipe fitting to 40 N·m (30 ft. lbs.).
6. Install the mass air flow sensor. Refer to Page 14-39.
7. Connect the engine harness connectors.
8. Connect the vacuum lines at the crankcase ventilator,
purge valve, EGR valve, and the brake booster.
9. Install the fuel rail with fuel injectors. Refer to Page 14-34.
EXHAUST MANIFOLD
DESCRIPTION
Thin-wall air-gap construction for the exhaust manifolds reduces underhood temperature by keeping heat in the
exhaust stream. This also allows the catalytic converter to be mounted in a more advantageous position for pack-
aging, under the floor instead of close to the engine. Stainless steel inner manifolds, separated by an air space from
two-piece stainless steel outer shells, reduce heat loss to the air in much the same way thermo-pane glass reduces
heat loss through windows. Hydro-formed inner manifolds, through which the exhaust flows, provide precise dimen-
sional control. They are assembled to the cylinder head flanges, exhaust pipe flanges and the outer shells by laser
welding.
REMOVAL
LEFT SIDE
shield.
5. Remove the left side catalytic converter. Refer to Page

11-7.
6. Remove the exhaust manifold nuts (3).
8. Remove the left side exhaust manifold (1) and gaskets (2)
from the engine compartment.
REMOVAL- RIGHT SIDE

shield.
5. Remove the right side catalytic converter. Refer to Page

11-5.
6. Remove exhaust manifold nuts (3), the exhaust manifold
(2), and the gaskets (1) from below the vehicle.
INSTALLATION
LEFT SIDE
1. Position the manifold (1) and gaskets (2) on the cylinder
head. Install the manifold nuts (3) and tighten to 35 N·m
(26 ft. lbs.).
2. Install the left side catalytic converter. Refer to Page 11-7.
screws to 5 N·m (44 in. lbs).
7. Start the engine and check for exhaust leaks.
INSTALLATION - RIGHT SIDE

1. Position the manifold (2) and gaskets (1) on the cylinder
head.
2. Install the manifold nuts (3) and tighten to 35 N·m (26 ft.
lbs.).
3. Install the right side catalytic converter. Refer to Page 11-7.
TIMING CHAIN TENSIONER

REMOVAL
1. Remove the generator. Refer to Page 8F-28.
INSTALLATION
1. Install the timing chain tensioner. Tighten the timing chain tensioner to 80 N·m (59 ft. lbs.).
2. Install the generator. Refer to Page 8F-29.
TIMING CHAIN COVER

REMOVAL
1. Remove the engine from the vehicle. Refer to Page 9-592.
2. Separate the engine from the transmission. For manual
Refer to Page 21-344, for automatic Refer to Page
21-210.
3. Remove the clutch cover (1) and the clutch (2) if equipped.
Refer to Page 6-9.
4. Mount the engine on a stand.
6. Remove the lower oil pan. Remove the bolts (1) and
remove the upper oil pan. Refer to Page 9-663.
7. Remove the power steering pump. Refer to Page 19-52.
8. Remove the idler pulley.
9. Remove the bolt (1) and remove the vibration damper (2).
10. Remove the generator. Refer to Page 8F-28.
11. Rotate the crankshaft to 40° ATDC.

13. Using Special Tool 9102 (1) Flywheel Locking Tool, lock
the flywheel by inserting the tool into the starter opening.
14. Remove the cylinder head bolts (1) and remove the cylin-
der heads. Refer to Page 9-611.
15. Remove the timing chain tensioner. Refer to Page 9-684.
16. Remove the timing chain cover bolts as shown. Remove

the timing chain cover.
INSTALLATION
Note: Ensure all sealing surfaces have been cleaned and
prepared properly for effective repair. Multi-Layer Steel
(MLS) gaskets require a scratch free sealing surface.
1. Install the cylinder heads, and install the bolts (1). Refer to
Page 9-614.
2. Align the basic valve timing to 40 deg. ATDC. Refer to

Page 9-695.
Note: Apply sealer ONLY to the area marked (1) as shown.

If porous points are visible at the cylinder heads or at the
rear of the engine near the sealing surface of the cylinder
head gasket, apply sealant at these points. The sealant
must be applied only as a 2.0 mm ± 0.5 mm bead, assem-
bled within 10 minutes, and not be flattened or spread.
Note:
3. Apply a 1.5 to 2.0 mm bead of Loctite 5203 or equivalent

sealer to the area marked (1) as shown.
4. Position the timing chain cover on the front of the engine.
Note: Ensure that the bolts indicated by the arrows are

installed with thread sealer prior to assembly.
5. Install the timing chain cover bolts and tighten to 20 N·m

(15 ft. lbs.).
6. Install the timing chain tensioner (1), tighten to 80 N·m (59

ft. lbs.). Refer to Page 9-685.
7. Remove Special Tool 9102 Flywheel Locking Tool (1) from

the engine.
9. Install a new front crankshaft radial oil seal. Refer to Page
9-636.
10. Install the generator. Refer to Page 8F-29.
11. Install the vibration damper. Refer to Page 9-652.

12. Install the idler pulley. Refer to Page 7-48.
13. Install the power steering pump, return hose (1), and pres-
sure hose (2). Refer to Page 19-53.
14. Install the upper and lower (1) oil pan. Refer to Page
9-663.
15. Install the accesory drive belt. Refer to Page 7-46.
16. Remove the engine from the stand.

18. Install the transmission on the engine. Refer to Page
19. Install the engine in the vehicle. Refer to Page 9-597.
TIMING CHAIN
REMOVAL
2. Remove the oil pump drive chain (2) and tensioner (1).
3. Remove the left and right camshaft sprocket bolts (1).

4. Remove the timing chain and camshaft sprockets.
5. Remove the timing chain crankshaft sprocket (2).

6. Clean and inspect all gasket surfaces, chain guides, and
sprockets for wear or damage. Repair or replace as
necessary.
INSTALLATION
1. Invert the engine on the engine stand.
2. Install the crankshaft sprocket (2).
3. Ensure the crankshaft has maintained 40 degrees ATDC. If

not, rotate until aligned with 40 degree marking.
4. Align the balance shaft sprocket with the timing mark (3)
and the copper teeth (1) of the timing chain.
5. Insert the camshaft sprockets (6) into the timing chain and
align the camshaft sprocket timing marks (4) and (5) with
the copper teeth (1) of the timing chain.
6. Install the timing chain with the sprockets and route within
in the timing chain guides (1).

Plates, lock the camshaft sprockets.
8. Install the oil pump, the oil pump drive chain (2) and the oil
pump drive chain tensioner (1). Refer to Page 9-676.
9. Rotate the engine to the upright position.

10. Install the timing chain cover. Tighten the bolts to 20 N·m
(15 ft. lbs.). Refer to Page 9-688.
Plates from the camshaft sprockets.
BALANCE SHAFT
DESCRIPTION
A balance shaft is used to compensate for the rocking motion
inherent in a 90-degree V-6 engine. It rotates at engine speed
in the opposite direction. Mounted above the crankshaft in the
cylinder block, it is driven by the timing chain.
REMOVAL
2. Rotate the crankshaft and align the basic valve timing to 40

degrees ATDC.

flywheel.

6. Remove the rear crankshaft oil seal. Refer to Page 9-634.
7. Hold the balance shaft rear counter weight (1) with a drift,
remove the rear retaining bolt (2).
8. Remove the balance shaft rear counter weight (1) from the
balance shaft.
1 - CAMSHAFT POSITION SENSOR 4 - REAR RETAINING BOLT

2 - BALANCE SHAFT FRONT COUNTER WEIGHT 5 - BALANCE SHAFT
3 - BALANCE SHAFT REAR COUNTER WEIGHT 6 - LOCKING PLATE BOLT
9. Remove the balance shaft locking plate bolt (6) and locking
plate at the front of the engine block.
10. Remove the balance shaft (5) from the front of the engine.
INSTALLATION
1 - CAMSHAFT POSITION SENSOR 4 - REAR RETAINING BOLT

2 - BALANCE SHAFT FRONT COUNTER WEIGHT 5 - BALANCE SHAFT
3 - BALANCE SHAFT REAR COUNTER WEIGHT 6 - LOCKING PLATE BOLT
1. Position the balance shaft (5) into the engine balance shaft
bore from the front.
Note: Balance shaft rear retaining bolt (4) must be

replaced if length exceeds 50 mm.
2. Install the balance shaft rear counter weight (3) onto the
balance shaft (5) and install the rear retaining bolt (4).
Tighten the bolt to 20 N·m (15 ft. lbs.). Rotate the bolt (4)
an additional 90°.
3. Install the balance shaft locking plate and locking plate bolt
(6). Tighten the balance shaft locking plate bolt to 20 N·m
(15 ft. lbs.).
4. Install the crankshaft rear radial oil seal. Refer to Page
9-634.
6. Install the timing chain cover. Refer to Page 9-688.
7. Remove the Special Tool 9102 Flywheel Locking Tool (1)

from the engine and install the starter. Refer to Page
8F-44.
TIMING CHAIN GUIDES

REMOVAL
1. Remove the timing chain (1). Refer to Page 9-693.
2. Remove the timing chain guides (1) off of the mounting

pins. Inspect and replace worn or damaged guides as
required.
INSTALLATION
1. Install the timing chain guides on the mounting pins. Lubricate surface with engine oil.
ENGINE TIMING
OPERATION
The crankshaft driven timing chain maintains camshaft (6) and
balance shaft (3) operation and timing. Timing marks on the
crankshaft (2) , balance shaft (3) and camshafts (5) are
aligned with copper links (1) in the timing chain to keep
symetrical valve and ignition performance.
ZH EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM REMOVAL - REAR HEAT SHIELD . . . . . . . . . . 8

DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......2 INSTALLATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . ......2 INSTALLATION - FRONT HEAT SHIELD .....9
DIAGNOSIS AND TESTING - EXHAUST INSTALLATION - REAR HEAT SHIELD ......9
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ......3 MUFFLER
INSPECTION . . . . . . . . . . . . . . . . . . . . . ......3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
EXHAUST SYSTEM ALIGNMENT .... ......4 SUPPORT BRACKET AND ISOLATOR
SPECIFICATIONS - TORQUE . . . . . . . . . ......4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CATALYTIC CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL - FRONT EXHAUST PIPES . . ......5
INSTALLATION - FRONT EXHAUST PIPES .....7
HEAT SHIELDS
REMOVAL
REMOVAL - FRONT HEAT SHIELD . . . ......8
11 - 2 EXHAUST SYSTEM ZH
EXHAUST SYSTEM
DESCRIPTION
1 - CENTER EXHAUST FLANGE 8 - LEFT SIDE MANIFOLD FLANGE

2 - NUTS 9 - RIGHT SIDE MANIFOLD FLANGE
3 - RETAINING BOLTS 10 - RIGHT EXHAUST PIPE
4 - EXHAUST SEAL 11 - RETAINING BOLTS
5 - LEFT EXHAUST PIPE 12 - EXHAUST SEAL
6 - LEFT SIDE O2 SENSOR CONNECTOR 13 - NUTS
7 - RIGHT SIDE O2 SENSOR CONNECTOR
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system
floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will
result in excessive floor pan temperatures and objectionable fumes.
A thin-wall air-gap insulated exhaust pipe leads to the three-way catalytic converter, which has an air-gap insulated
housing. The air-gap insulation, whereby a steel shell is wrapped around the component, limits heat loss to hasten
the catalytic converter action. The insulation also minimizes the need for insulation to protect the passenger com-
partment from excessive temperatures. A large - 812 cu. in., (13.3 L) - muffler is tuned to produce a sporty tone that
meets pass-by noise levels in all markets. The rear-mounted muffler terminates in dual bright exhaust tips.
OPERATION
The exhaust emission control system is calibrated to meet ULEV I emission standards in California, Tier 2, BIN 8
emission standards in other U.S. states and Stage IV emission standards in Europe. The engine control computer
and other hardware are the same for all markets, but there is some difference in the software depending on local
emissions requirements. Dual ignition reduces hydrocarbon emissions (unburned fuel) released by the engine to the
catalytic converter by 20 percent compared to single ignition systems. This reduction is especially beneficial during
the cold start and warm up phases of operation, which is when a majority of the tailpipe emissions occur on today’s
cars because the catalytic converter has not yet reached its operating temperature. The exhaust system channels
exhaust gases from the engine and away from the vehicle.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps to specified

torque at leaking joints.
2. Burned or blown out muffler. 2. Replace muffler assembly..

3. Burned or rusted-out exhaust 3. Replace exhaust pipe.
pipe.
4. Exhaust pipe leaking at manifold 4. Tighten connection attaching
flange. nuts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten exhaust manifold to
and cylinder head. cylinder head stud nuts or bolts.
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting body 8. Re-align exhaust system to clear
or chassis. surrounding components.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking

joints.
INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corro-
sion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for
cracks and corrosion damage.
ADJUSTMENTS
EXHAUST SYSTEM ALIGNMENT
A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system com-
ponents. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system for
broken or loose clamps, heat shields, insulators, and brackets. Replace or tighten as necessary. It is important that
exhaust system clearances and alignment be maintained.
Perform the following procedures to align the exhaust system.
1. Loosen clamps and support brackets.
2. Align the exhaust system starting at the front, working rearward.
3. Tighten all clamps and brackets once alignment and clearances are achieved.

Exhaust Flanges - Bolts(All) 20 15 —
Muffler Hanger - Bolts 20 15 —
Muffler Ground - Bolt 10 — 89
Heat Shield - Nuts (All) 10 — 89
Stiffener - Bolts 20 15 —
CATALYTIC CONVERTER
REMOVAL - FRONT EXHAUST PIPES
WARNING: THE NORMAL OPERATING TEMPERATURE OF
THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE,
NEVER ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE
SHOULD BE TAKEN WHEN WORKING NEAR THE CATA-
LYTIC CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.


2. Disconnect the oxygen sensor harness connectors (6 and
7).
3. Support the exhaust system.
4. Remove the bolts at the left and right side exhaust manifold
flanges (8 and 9).
5. Remove the center exhaust flange bolts (3).
6. Remove the left and right side exhaust pipes from the vehi-
cle (5 and 10).
7. Remove the bolts (1) at the right side exhaust pipe flange.
INSTALLATION - FRONT EXHAUST PIPES

Note: Inspect the exhaust manifold flange surface. Replace as required.
EXHAUST
1. Install bolts at right side exhaust pipe flange (11). Tighten to 20 N·m (15 ft. lbs.).
2. Position and support the front exhaust pipes in the vehicle.
3. Install bolts at the left and right exhaust manifold (8 and 9) flanges.
4. Install bolts at the center exhaust manifold flange (3).
5. Tighten exhaust manifold flange bolts to 20 N·m (15 ft. lbs.).
6. Tighten bolts at the center exhaust pipe flange to 20 N·m (15 ft. lbs.).
7. Connect oxygen sensor wiring harness connectors (6 and 7).
8. Route oxygen sensor wire harness in harness retainer.
9. Remove exhaust system support.
HEAT SHIELDS
REMOVAL
REMOVAL - FRONT HEAT SHIELD
1. Remove front exhaust section. Refer to Page 11-5.
2. Remove the heat shield nuts (1) and the heat shield.
REMOVAL - REAR HEAT SHIELD

2. Remove the heat shield nuts (1) and the heat shield.
INSTALLATION
INSTALLATION - FRONT HEAT SHIELD
1. Position the heat shield on the floor pan.
2. Install the heat shield nuts (1). Tighten the nuts to 10 N·m
(89 in. lbs.).
3. Install the front exhaust section. Refer to Page 11-7.
INSTALLATION - REAR HEAT SHIELD

1. Install the heat shield and the nuts (1). Tighten the nuts to
10 N·m (89 in. lbs.).
2.
MUFFLER
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERATURE OF
THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE,
NEVER ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE
SHOULD BE TAKEN WHEN WORKING NEAR THE CATA-
LYTIC CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.

2. Support the rear section of the exhaust system.
3. Remove bolts (1) from the center connection flange.
4. Disconnect the ground (1) strap at the muffler.

5. Remove the pipe (1) from the exhaust hanger (2).
6. Pry off rubber the exhaust hangers (1) and remove the
muffler with the pipe.
INSTALLATION
1. Position the muffler section in rubber exhaust hangers.
2. Install the bolts in the center exhaust flange (2). Tighten the
3. Connect the ground strap (1) at the muffler and tail pipe.
Tighten the ground strap bolt to 10 N·m (89 in. lbs.).
4. Remove the support.

SUPPORT BRACKET AND ISOLATOR

REMOVAL
2. Remove the bracket bolt (1).
3. Remove the bracket and the isolator (2) from the exhaust
hanger.
4. Remove the isolator from the bracket.
INSTALLATION
1. Position the bracket and bolt on the vehicle.
2. Tighten the bolt to 20 N·m (15 ft. lbs.).
3. Install the isolator and hanger.
ZH FRAME & BUMPERS 13 - 1
FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT FASCIA INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

REMOVAL .............................1 FRAME
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS - FRAME DIMENSIONS . . . . . 9
REAR FASCIA
REMOVAL .............................7
FRONT FASCIA
REMOVAL
2. Remove the lower splash shield retaining screws (1) and
the lower splash shield (2).
13 - 2 FRAME & BUMPERS ZH
Note: Left side shown, right side similar.
3. Remove the left and right front fascia access panel retain-
ing nuts and screws (1).
4. Remove access panels from the vehicle.
5. Disconnect the fog lamp wire harness connectors (1).
6. Disconnect the ambient air temperature sensor wire har-

ness connector (2).
Note: The front marker lamp harness connector can be

reached through the access hole in the inner fender well.
7. Disconnect the front marker lamp wire harness connectors

(1).
8. Remove the lower fascia retaining nuts (1).

9. Remove the left and right front fender to fascia retaining
nuts and bolts. Refer to Page 23-112.
11. Remove the front grille assembly retaining bolts (1).

12. Remove the upper fascia retaining bolts (1).

13. Remove the fascia from the vehicle.
INSTALLATION
1. Position the fascia on the vehicle and install the upper facia
retaining bolts (1).
2. Position the front grille assembly and install the retaining

bolts (1).
4. Install the left and right front fender to fascia retaining nuts
and bolts. Refer to Page 23-113.
5. Install the lower fascia retaining nuts (1).

6. Connect the ambient air temp sensor wire harness connec-
tor (2).
7. Connect the front marker lamp wire harness connector (1).

8. Connect the fog lamp wire harness connectors (1).
9. Install the left and right front fascia access panel retaining
nuts and screws (1).
10. Install the lower splash shield and the retaining screws
(1).
REAR FASCIA
REMOVAL
1. Remove the rear fascia assembly retaining screws (1, 2,

and 3).
3. Remove the right and left lower fascia trim retaining screws
(1).
4. Remove the rear fascia from the vehicle.
INSTALLATION
1. Position the rear fascia on the vehicle and install the retain-
ing screws (1, 2, and 3).
2. Install the lower fascia trim and the retaining screws (1).
FRAME
SPECIFICATIONS - FRAME DIMENSIONS
ENGINE COMPARTMENT DIMENSIONS

FRAME DIMENSIONS
ZH FUEL SYSTEM 14 - 1
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY ..........................1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY DIAGNOSIS AND TESTING - FUEL LEVEL

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - FUEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE LEAK DOWN TEST ...........4 FUEL LINES
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - FUEL SYSTEM FUEL PUMP
PRESSURE RELEASE PROCEDURE . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDARD PROCEDURE - DRAINING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIAGNOSIS AND TESTING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS ........................7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL FILL CHECK VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL RAIL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL FILTER/PRESSURE REGULATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FUEL TANK
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL LEVEL SENDING UNIT / SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL LEVEL SENDING UNIT/SENSOR . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION FUEL TANK FILLER TUBE
FUEL LEVEL SENDING UNIT/SENSOR . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
14 - 2 FUEL DELIVERY ZH
FUEL DELIVERY
DESCRIPTION
The aluminum fuel tank (7) is located in the cargo area behind a metal partition.
The fuel delivery system consists of the following items:
• Fuel injector rail
• Fuel tank filler tube cap
• Fuel tank/filler vent tube assembly
• Fuel tubes/lines/hoses (3)
• In-line electric fuel pump (5)
• In-line fuel filter/pressure regulator (4)
• In-tank fuel strainer
ZH FUEL DELIVERY 14 - 3
OPERATION
1 - TANK VENT/ROLLOVER VALVES 6 - EVAP PURGE SOLENOID

2 - FUEL TANK 7 - EVAP CANISTER
3 - FUEL FILLER TUBE 8 - FUEL VAPOR PRESSURE RELIEF VALVE
4 - FUEL FILLER TUBE CHECK VALVE 9 - CHARCOAL CANISTER SHUTOFF VALVE
5 - FUEL TANK OVERFILL CHECK VALVE
The fuel system provides fuel pressure by an external fuel pump mounted under the vehicle near the fuel tank
outlet. The PCM controls the operation of the fuel system by providing battery voltage to the fuel pump through the
fuel pump relay. The PCM requires only three inputs and a good ground to operate the fuel pump relay. The three
inputs are:
• Ignition voltage
• Crankshaft Position (CKP) sensor
• Camshaft Position (CMP) sensor
The fuel pressure regulator and main fuel filter are combined into a single unit. A strainer inside the fuel tank also
provides a means of preliminary filtering of the fuel before it leaves the bottom of the fuel tank.
The fuel tank filler tube assembly, which is permanently fixed to the fuel tank, uses a pressure/vacuum 1/4 turn fuel
filler cap.
The evaporation control and Onboard Refueling Vapor Recovery (ORVR) systems should also be considered part of
the fuel system. They are designed to reduce the emission of the fuel vapors into the atmosphere. For complete
operation and function of these systems, see operation in the emissions control section. Refer to Page 25-12.
There are a total of four check-type valves within the fuel tank/fuel filler tube assembly. Two tank vent/rollover valves
(1) are inside and near the top of the fuel tank. They provide a means for vapors to vent, yet can close to prevent
fuel from entering the evaporative system in the event of a rollover. The fuel tank overfill check valve (5) uses a float
and closes the opening at the bottom of the fuel filler tube (3) as the level of the fuel reaches capacity to prevent
an overfill condition. The fuel filler tube check valve (4), located below the narrow portion of the tube, has a dual
purpose. It also prevents fuel from exiting the fuel tank through the fuel filler tube in the event of a rollover and
eliminates fuel from splashing back on the customer during refueling.
DIAGNOSIS AND TESTING - FUEL PRESSURE LEAK DOWN TEST

Use this test in conjunction with the Fuel Pump Pressure Test and the Fuel Pump Capacity Test.
CHECK VALVE OPERATION

The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank, and to maintain
fuel supply line pressure (engine warm) when the pump is not operational. It also is used to keep the fuel supply
line full of gasoline when the pump is not operational. After 30 minutes the fuel pressure may drop to 2.5 bar (36
psi), but the liquid gasoline will remain in the fuel supply line between the check valve and fuel injectors. When the
fuel pump is activated, the fuel pressure should immediately (1-2 seconds) rise to specification.
Abnormally long periods of cranking to restart a hot engine that has been shut down for a shout period of time may
be caused by either fuel pressure bleeding past a fuel injector(s), or fuel pressure bleeding past the check valve in
the fuel pump. To determine the cause of this condition:
1. Remove the engine cover for access and disconnect the fuel inlet line at the fuel rail.
2. Connect the correct fuel line pressure test adapter tool between the disconnected fuel inlet line and fuel rail.
3. Connect Special Tool C-4799-B or equivalent to the test port on the test adapter tool.
4. Start the engine and bring to normal operating temperature.
5. Observe the test gauge. Normal operating pressure should be 3.7 - 4.2 bar (54 - 61 psi).
6. Shut engine off.
7. Pressure should not fall below 2.5 bar (36 psi) after 30 minutes.
8. If pressure falls below 2.5 bar (36 psi) within 30 minutes, it must be determined if a fuel injector, the check valve
within the fuel pump, or a fuel tube/line is leaking.
9. Again, start the engine. After bringing to normal operating temperature, shut engine off.
TESTING FOR FUEL INJECTOR OR FUEL RAIL LEAKAGE

Clamp off the rubber hose portion of the adaptor tool between the fuel rail and the test port “T”. If the pressure now
holds at or above 2.5 bar (36 psi) for 30 minutes, a fuel injector or the fuel rail is leaking.
TESTING FOR FUEL PUMP CHECK VALVE, FILTER/REGULATOR CHECK VALVE, OR FUEL
TUBE/LINE LEAKAGE
Clamp off the rubber hose portion of the adaptor tool between the vehicle fuel line and the test port “T”. If the
pressure now holds at or above 2.5 bar (36 psi) for 30 minutes, a leak may be found in the fuel tubes or lines or
one of the check valves. Note: A quick loss of pressure usually indicates a defective check valve in the pressure
regulator. A slow loss of pressure usually indicates a defective check valve in the fuel pump. These valves are not
serviced separately. If found defective, the entire component that the valve is a part of must be replaced as an
assembly.
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE

1. Remove the fuel filler tube cap.

2. Remove the fuel pump fuse from the relay control module (3) located next to the PCM.
3. Start and run engine until it stalls.
4. Attempt restarting engine until it will no longer run.
5. Turn ignition key to OFF position.
6. Return the fuel pump fuse to the relay control module.
7. One or more Diagnostic Trouble Codes may have been stored in PCM memory due to fuel pump fuse removal.
The DRB IIIT scan tool must be used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL TANK

Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool).
The quickest draining procedure involves lowering the fuel tank.
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SER-
VICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail con-
nection. Refer to DRBIIIT scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pressure Release Procedure in this group for procedures. Discon-
nect the fuel line at the fuel rail and remove the plastic retainer from the fuel rail. Take plastic retainer and install it
back into the fuel line from body. Attach end of special test hose tool number 6539 at fuel line connection from the
body line. Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and
drain tank until empty. When done, remove the special test hose tool number 6539 from the body line. Remove the
plastic retainer from the special test hose tool number 6539 and reinstall it into the fuel line from the body. Install the
fuel line to the fuel rail.
If electric fuel pump is not operating, tank must be lowered for fuel draining. Refer to following procedures.
1. Remove fuel filler cap.
2. Perform the Fuel System Pressure Release procedure. Refer to Page 14-5.
3. Disconnect negative cable from battery.
4. Raise vehicle and support.
5. Certain models are equipped with a separate grounding wire (strap) connecting the fuel fill tube assembly to the
body. Disconnect wire by removing screw.
6. Open fuel fill door and remove screws mounting fuel filler tube assembly to body. Do not disconnect rubber fuel
fill or vent hoses from tank at this time.
7. Place a transmission jack under center of fuel tank. Apply a slight amount of pressure to fuel tank with trans-
mission jack.
Note: Lower the tank just enough so that the filler tube fitting is the highest point of the fuel tank.
8. Remove fuel tank mounting strap nuts from mounting strap studs.
9. Remove filler tube from fuel tank. Tank will be drained through this fitting.
WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
10. Drain fuel tank into holding tank or a properly labeled Gasoline safety container.
CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or
explosion.
11. If fuel pump module removal is necessary. Refer to Page 14-17.
SPECIFICATIONS
FUEL DELIVERY
TORQUE

Fuel strainer to fuel tank 40 30 —
Fuel tank retaining nuts 10 7 89
Fuel feed hose to fuel 30 22 —
strainer
Fuel tank partition 10 7 89
retaining bolts
Fuel rail to intake manifold 9 — 80
bolts
Fuel feed line to fuel rail 38 28 —
FUEL SYSTEM
Nominal working pressure is 3.7 - 4.2 bar (54 - 61 psi).
Allowable leak down (engine off) pressure after 30 minutes is 2.5 bar (36 psi).
Minimum fuel delivery rate is 1 liter (1.05 qt.) in a maximum of 35 seconds.
Fuel pump amperage draw range is 4 - 9 amps.
FUEL CAPACITY
CAPACITY LITERS U.S. GALLONS

Total 60 15.8
Reserve 8 2.1
Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing
tolerance and refill procedures.
SPECIAL TOOLS
9240 PIN WRENCH
FUEL FILL CHECK VALVE

DESCRIPTION
All vehicles are equipped with an inlet check valve on the inside of the fuel tank at the filler tube.
The check valve prevents fuel from splashing back during vehicle refueling. The valve cannot be adjusted or
repaired. If faulty, worn, or damaged, the entire fuel tank must be replaced as an assembly.
OPERATION
When the fuel tank is full, a float closes a flap at the bottom insert. The fuel filler neck is filled rapidly and the
gasoline pump nozzle switches off.

DESCRIPTION
FUEL FILTER
The combination fuel filter/fuel pressure regulator (4) consists
of a housing with an integrated filter element. The fuel flows
through the filter from the outside to the inside. As a result,
any impurities are trapped inside the filter.
FUEL PRESSURE REGULATOR

The combination fuel filter/fuel pressure regulator (2) is located
along side of the fuel pump as part of the fuel filter assembly.
It is transversely mounted to a chassis crossmember
(left-to-right).
OPERATION
FUEL PRESSURE REGULATOR
1 - FILTER 6 - DIAPHRAGM
2 - DIAPHRAGM PRESSURE REGULATOR 7 - VALVE
3 - AIR LINE 8 - FUEL FILTER / PRESSURE REGULATOR
4 - COMPRESSION SPRING 9 - FEED FROM FUEL PUMP
5 - TO ENGINE 10 - RETURN FLOW TO FUEL TANK
The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of
between 3.7 - 4.2 bar (54 - 61 psi) at the fuel injectors.
Fuel is supplied to the fuel filter/fuel pressure regulator by the electric fuel pump directly.
The fuel pump assembly contains a check valve to maintain some fuel pressure in the system when the engine is
not operating.
If fuel pressure at the pressure regulator exceeds a set amount, an internal diaphragm closes and excess fuel pres-
sure is routed back into the tank through the pressure regulator.
The diaphragm pressure regulator (2) regulates the fuel pressure by means of the return flow (10) quantity to the
fuel tank.
If the pressure rises above the set pressure, the diaphragm (6) is pressed further against the compression spring
(4).
The valve (7) attached to the diaphragm opens the passage for the return flow further. If the pressure drops below
the set pressure, the valve is closed again by the compression spring (4).
FUEL FILTER
The fuel flows through the filter (1) trapping any fuel impurities that may lie in the bottom of the tank.
The fuel filter can not be serviced separately from the pressure regulator, the entire fuel filter/fuel pressure regulator
must be replaced as an assembly. For complete fuel filter/fuel pressure regulator removal procedures, see fuel filter/
fuel pressure regulator removal in this section.
REMOVAL
2. Remove the splash shield.
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT

FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE
DISCONNECTING ANY FUEL LINES, THIS PRESSURE
MUST BE RELEASED.
3. Release the fuel system pressure. Refer to Page 14-5.
Note: Place a shop towel around fuel lines to catch any

excess fuel during disassembly.
4. Remove the fuel filter/pressure regulator degassing line (1).

5. Remove the fuel rail supply line (3) at the fuel filter/pres-
sure regulator.
6. Remove the fuel delivery hose.
7. Remove the fuel return hose at the fuel filter/pressure reg-
ulator.
8. Remove the clamp retaining screw and remove the fuel fil-
ter/pressure regulator.
INSTALLATION
1. Position the fuel filter/pressure regulator into the clamp,
install the retaining screw and tighten.
2. Install the following hoses/lines in order:
1. The fuel return hose.
2. The fuel delivery hose.
3. The fuel rail supply line (3).
4. The degaussing line (1).
3. Tighten the hoses/lines to the fuel filter/pressure regulator.
4. Install the splash shield.
FUEL LEVEL SENDING UNIT / SENSOR

DESCRIPTION
FUEL LEVEL SENDING UNIT/SENSOR
1 - ELECTRICAL CONNECTOR 4 - FUEL TANK

2 - FUEL LEVEL SENDING UNIT 5 - SPECIAL TOOL 9240
3 - SEAL
The fuel level sending unit (2) is combined with a fuel tank pressure sensor and is mounted at the top of the fuel
tank (4) extending downward inside. The sending unit is a lever-type sensor with sliding contacts (potentiometer).
OPERATION
FUEL LEVEL SENDING UNIT/SENSOR
The fuel level sender produces a resistance value and changes it with the amount of fuel in the fuel tank. The float
arm attached to the sender moves as the fuel level changes. The fuel pressure sensor uses a transducer to deter-
mine a resistance value for the emission control system.
DIAGNOSIS AND TESTING - FUEL LEVEL SENDING UNIT
1 - FUEL LEVEL SENDER 4 - POTENTIOMETER

2 - LEVEL SENSOR 5 - PRESSURE SENSOR
3 - CONTACTS
The fuel level sending unit (1) contains a variable resistor (3) (track). As the float (2) moves up or down, electrical
resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending
unit only, it must be removed from vehicle. The sending unit is a part of the fuel level sending unit/sensor, located
and accessible at the top of the fuel tank. Measure the resistance across the sending unit terminals. With float (2)
in up position, resistance should be 20 ohms (+/- 5%). With float (2) in down position, resistance should be 270
ohms (+/- 5%).
REMOVAL
1 - ELECTRICAL CONNECTOR 4 - FUEL TANK

2 - FUEL LEVEL SENDING UNIT 5 - SPECIAL TOOL 9240
3 - SEAL

2. Drain the fuel tank. Refer to Page 14-5.
3. Remove the cargo area interior trim panels.
4. Remove the fuel tank partition retaining bolts and remove the fuel tank partition.
5. Disconnect the fuel level sending unit/sensor harness connector (1).
Note: Place a shop towel around the fuel level sending unit/sensor to catch any excess fuel during disas-
sembly.
6. Install Special Tool 9240 (5) and rotate the fuel level sending unit/sensor (2) counterclockwise.
7. Remove the fuel level sending unit/sensor (2) from the fuel tank (4).
INSTALLATION
1. Install the fuel level sending unit/sensor into the fuel tank.
2. Install Special Tool 9240 and rotate the fuel level sending unit/sensor clockwise fully to stop. Remove the Special Tool.
3. Connect the fuel level sending unit/sensor harness connector.
4. Install the fuel tank partition into the cargo area, then install the retaining bolts and torque to 10 N·m (7 ft. lbs.).
5. Install the cargo area interior trim panels.
6. Restore the fuel level.
FUEL LINES
DESCRIPTION
1 - TO CHARCOAL CANISTER 5 - FUEL PUMP

2 - FUEL LEVEL SENDER 6 - TO FUEL RAIL
3 - AIR LINE FROM FOR PRESSURE REGULATOR 7 - FUEL TANK
4 - FUEL FILTER 8 - FUEL TANK PRESSURE SENSOR
WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS, LINES, OR MOST COMPONENTS, FUEL SYS-
TEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel
pressures and the possibility of contamination in the fuel system. If it is necessary to replace these lines/tubes/
hoses, only those designed for this vehicle may be used.
The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction.
This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type
clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel
leaks. Use new, original equipment type hose clamps as replacements when necessary.
FUEL PUMP
DESCRIPTION
The fuel pump is a rotating spindle-type pump. The fuel pump moves fuel from the fuel tank through the fuel filter
to the engine’s fuel injectors.
OPERATION
Note: Check valve maintains volume of fuel in the rail and lines, not pressure.
The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains a check
valve. The valve in the pump outlet maintains the volume of fuel during engine off conditions for a short while. It is
normal for fuel pressure to drop to zero after cool down. The fuel pump relay provides voltage to the fuel pump. The
fuel pump has a maximum deadheaded pressure output of approximately 9.0 kPa (130 psi). The regulator adjusts
fuel system pressure to approximately 3.7 - 4.2 bar (54 - 61 psi).

FUEL PUMP TEST
FUEL PUMP PRESSURE TEST
Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump
Amperage Test.
The fuel pump contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gas-
oline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop (cold fluid contracts),
but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. When the electric fuel
pump is activated, fuel pressure should immediately (1–2 seconds) rise to specification.
The fuel system is equipped with a separate fuel pump mounted to the chassis along side of the fuel filter/pressure
regulator. The fuel filter/pressure regulator is not controlled by engine vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF.
BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO
THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.
1. Remove the protective cap and connect the 0–6.9 bar fuel
pressure gauge (2) to the fuel rail service test port pressure
fitting (1) on the fuel rail (3). The DRBT III Scan Tool
along with the PEP module, the 34.4 bar pressure
transducer, and the transducer-to-test port adapter may
also be used in place of the fuel pressure gauge.
2. Start and warm engine and note pressure gauge reading.
Fuel pressure should be 3.7 - 4.2 bar (54 - 61 psi) at idle.
3. If engine runs, but pressure is below 3.7 bar (54 psi), check
for a kinked fuel supply line somewhere between fuel rail
(3) and fuel pump. If line is not kinked, but specifications for
either the Fuel Pump Capacity, Fuel Pump Amperage or
Fuel Pressure Leak Down Tests were not met, replace the
fuel pump. Refer to Fuel Pump Removal/Installation.
4. If operating pressure is above 3.7 bar (54 psi), electric fuel pump is OK, but fuel filter/pressure regulator is defec-
tive. Replace fuel filter/pressure regulator. Refer to Fuel Filter/Pressure Regulator Removal/Installation.
5. Install the protective cap to the service test port pressure fitting (1) on the fuel rail.
FUEL PUMP CAPACITY TEST

Before performing this test, verify fuel pump pressure. Refer to Fuel Pump Pressure Test. Use this test in
conjunction with the Fuel Pressure Leak Down Test.
1. Release fuel system pressure. Refer to Page 14-5.
2. Disconnect fuel supply line at fuel rail.
3. Obtain the correct Fuel Line Pressure Test Adapter Tool Hose.
4. Connect the correct Fuel Line Pressure Test Adapter Tool Hose into disconnected fuel supply line. Insert other
end of Adaptor Tool Hose into a graduated container.
5. Remove fuel tank filler tube cap.
7. A good fuel pump will deliver 1 liter (1.05 qt.) of fuel in a maximum of 35 seconds.
a. If capacity is lower than specification, but fuel pump can be heard operating, check for a kinked/dam-
aged fuel supply line somewhere between fuel rail and fuel pump.
b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/pressure
regulator assembly. Refer to Page 14-10.
c. If both fuel pressure and capacity are low, replace both fuel pump Refer to Page 14-17, and fuel filter/
pressure regulator assemblies Refer to Page 14-10.
FUEL PUMP AMPERAGE TEST

This amperage (current draw) test is to be done in conjunction with the Fuel Pump Pressure Test, Fuel Pump
Capacity Test and Fuel Pressure Leak Down Test. Before performing the amperage test, be sure the temperature of
the fuel tank is above 10° C (50° F).
The DRBT Scan Tool along with the DRB Low Current Shunt
(LCS) adapter, and its test leads, will be used to check fuel
pump amperage specifications.
1. Be sure fuel tank contains fuel before starting test. If tank is
empty or near empty, amperage readings will be incorrect.
2. Obtain LCS adapter (1).
3. Plug cable from LCS adapter (2) into DRB scan tool at SET
1 receptacle.
4. Plug DRB into vehicle 16–way connector (data link connec-
tor).
5. Connect (-) and (+) test cable leads into LCS adapter
receptacles (3). Use 10 amp (10A +) receptacle and com-
mon (-) receptacles.
6. Gain access to MAIN MENU on DRB screen.

7. Press DVOM button on DRB.
8. Using left/right arrow keys, highlight CHANNEL 1 function on DRB screen.
9. Press ENTER three times.
10. Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale).
11. Press ENTER to change 2 amp scale to 10 amp scale. This step must be done to prevent damage to DRB
scan tool or LCS adapter (blown fuse).
12. Remove cover from Control Module Box and remove the fuel pump relay fuse (Refer to label on Control Module
Box cover for fuse location).
WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND SYS-
TEM PRESSURE WILL BE PRESENT. THIS WILL OCCUR AFTER CONNECTING TEST LEADS FROM LCS
ADAPTER INTO FUEL PUMP FUSE CAVITIES. THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY
IN OFF POSITION. BEFORE ATTACHING TEST LEADS, BE SURE ALL FUEL LINES AND FUEL SYSTEM COM-
PONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehicle electrical system and LCS adapter, the test leads must
be connected into fuse cavities.
13. Attach the test leads from LCS adapter into the fuel relay fuse cavities. For location of these cavities, refer to
component locator views.
14. When the LCS adapter test leads are attached to the fuel pump relay fuse cavities, the fuel pump will be
activated. Determine fuel pump amperage on DRB screen. Amperage should be below 9.0 amps. If amperage
is below 9.0 amps, and specifications for the Fuel Pump Pressure, Fuel Pump Capacity and Fuel Pressure
Leak Down tests were met, the fuel pump is OK.
15. If amperage is more than 9.0 amps, replace the fuel pump assembly. The electric fuel pump is serviced sep-
arately.
16. Disconnect test leads from relay fuse cavities immediately after testing.
REMOVAL

2. Lift the vehicle and support.
WARNING: PLACE A SHOP TOWEL AROUND THE FUEL LINES TO CATCH ANY EXCESS FUEL DURING DIS-
ASSEMBLY.
4. Pinch off the fuel suction hose (6) and the fuel delivery hose (2), then disconnect the hoses from the fuel pump
(4).
5. Disconnect the fuel pump harness connectors (3).
6. Remove the clamp retaining screw (1) and remove the fuel pump from the vehicle.
INSTALLATION
1. Install the fuel pump into the clamp, install the clamp
retaining screw and tighten.
2. Install the fuel pump harness connectors.
3. Install both the fuel suction hose (4) and the fuel delivery
hose to the fuel pump and tighten.
FUEL RAIL
DESCRIPTION
The fuel rail is used to mount the fuel injectors to the engine and is itself mounted to the intake manifold. It also
supplies the necessary fuel to each individual fuel injector and is located above the intake manifold and fuel injec-
tors.
OPERATION
The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank
mounted fuel pump module. Refer to Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this
group for information. The fuel rail is not repairable.
REMOVAL
1 - FUEL RAIL TRIM PANEL 5 - FUEL INJECTOR RETAINING CLIP

2 - FUEL RAIL 6 - FUEL INJECTOR HARNESS CONNECTOR
3 - FUEL LINE 7 - FUEL RAIL SERVICE VALVE
4 - FUEL INJECTOR 8 - FUEL RAIL BOLT
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH ENGINE OFF. THIS
PRESSURE MUST BE RELEASED BEFORE SERVICING THE FUEL RAIL.

2. Remove the fuel rail trim panel screw and then remove the fuel rail trim panel (1).
WARNING: PLACE A SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL.
3. Release the fuel pressure through the fuel rail service valve (7).
4. Disconnect the fuel feed line (3) at the fuel rail.
5. Remove the fuel injector harness connector retaining clips (5), then disconnect the fuel injector harness connec-
tors (6) from the fuel injectors (4).
6. Remove the fuel rail bolts (8) attaching the fuel rail (2) to the intake manifold.
7. Remove the fuel rail (2) with the fuel injectors (4) by moving the fuel rail (2) side to side and lifting gently upward.
INSTALLATION

1. Install the fuel rail (2) with the fuel injectors (4) by moving the fuel rail (2) side to side and pushing gently inward
towards the intake.
2. Install the fuel rail bolts (8) attaching the fuel rail (2) to the intake. Tighten to 9 N·m (80 in. lbs.).
3. Install the fuel injector harness (6) to the fuel injectors (4) then install the fuel injector harness connector retaining
clips (5).
4. Connect the fuel feed line (3) to the fuel rail and torque to 38 N·m (28 ft. lbs.).
5. Install the fuel rail trim panel (1), then install the fuel rail trim panel screw.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of sheet steel. Its main functions are for fuel storage. The tank is made from steel. It
is equipped with a ORVR (Onboard Refueling Vapor Recovery) this is used to control refueling vapor emissions.
OPERATION
This model passes a full 360 degree roll over test without fuel leakage. To accomplish this, fuel and vapor flow
controls are required for all fuel tank connections.
An evaporation control system is connected to the roll over valve(s)/control valve to reduce emissions of fuel vapors
into the atmosphere, when the tank is vented due to vapor expansion in the tank. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to a charcoal canister where they are temporarily held. When
the engine is running, the vapors are drawn into the intake manifold. In addition, fuel vapors produced during vehicle
refueling are allowed to pass through the vent hoses/tubes to the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). This is equipped with a self-diagnosing system using a Natural Vacuum
Leak Detection (NVLD). Refer to the Emission Control System for additional information.
REMOVAL
2. Raise the vehicle and support.
4. Drain the fuel tank. Refer to Page 14-5.
5. Disconnect the fuel feed hose (4) from the bottom of the
fuel tank.
6. Disconnect the fuel return hose from the bottom of the fuel
tank.
7. Remove the cargo area trim panels.
8. Remove the fuel tank partition retaining bolts (2) and

remove the fuel tank partition.
9. Disconnect the fuel tank level and pressure sensor connec-
tors (1) from the fuel sending unit.
10. Disconnect the fuel tank filler neck cup seals from the
body.
11. Remove the fuel tank.
Note: Inspect the strainer and o-ring for damage and

replace as necessary.
12. Remove the fuel strainer from the bottom of the fuel tank
and inspect.
INSTALLATION
1. Install the fuel strainer (6) into the bottom of the fuel tank
(4) and torque to 40 N·m (30 ft. lbs.).
Note: Be sure to position the splash bowl inside the tank

when installing the fuel strainer. The fuel strainer holds
the splash bowl in place.
2. Install the fuel tank (4) into the cargo area. Install the fuel
tank retaining nuts (3) and torque to 10 N·m (7 ft. lbs.).
3. Position the fuel tank filler neck cup seal (9) around the
filler neck.
4. Connect the fuel tank level and pressure sensor connectors

(1) to the fuel tank sending unit.
5. Install the fuel tank partition into the cargo area. Install the
fuel tank partition retaining bolts (2) and torque to 10 N·m
(7 ft. lbs.).
6. Install the cargo area trim panels.
7. Connect the fuel feed hose (4) to the fuel strainer at the
bottom of the fuel tank. Tighten the hose to 30 N·m (22 ft.
lbs.)
8. Connect the fuel return hose to the fuel tank.
FUEL TANK FILLER TUBE

DESCRIPTION
The fuel tank filler tube (1) is an integral part of the fuel tank
assembly and cannot be adjusted or repaired. If faulty, worn,
or damaged, the entire fuel tank assembly must be replaced
as a complete unit.
ZH FUEL INJECTION 14 - 25
FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 25 MANIFOLD TUNE VALVE
ACCELERATOR PEDAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ACCELERATOR PEDAL POSITION SENSOR MAP SENSOR
CRANKSHAFT POSITION SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 O2 SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FUEL INJECTOR REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31 UPSTREAM O2 SENSOR . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REMOVAL - DOWNSTREAM O2 . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34 UPSTREAM O2 . . . . . . . . . . . . . . . . . . . . . . . 46
FUEL PUMP RELAY INSTALLATION - DOWNSTREAM O2 . . . . . . . 47
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35 THROTTLE BODY
INTAKE AIR TEMPERATURE SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
MANIFOLD AIR FLOW (MAF) SENSOR THROTTLE POSITION SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL INJECTION
SPECIFICATIONS

Accelerator Pedal Nut 15 11 133
Crankshaft Position
8 6 71
Sensor Bolt
Fuel Rail Bolt 9 7 80
Oxygen Sensor 55 41 487
Throttle Body Bolts 20 15 177
Tune Valve Rod Nut 6 4 44
14 - 26 FUEL INJECTION ZH
ACCELERATOR PEDAL
DESCRIPTION
The accelerator pedal houses the accelerator pedal position
sensor. The accelerator pedal is replaced as a unit.
REMOVAL
2. Remove the accelerator pedal upper nut (1).
3. Remove the lower accelerator nut cover (1) and the nut.
4. Lift the accelerator pedal off of the welded stud and out of
the bracket.
5. Disconnect the accelerator pedal harness connector from
the accelerator pedal.
INSTALLATION
1. Connect the accelerator pedal harness connector.
2. Slide the accelerator pedal into the bracket and onto the
welded stud.
3. Install the accelerator pedal lower nut (1). Tighten to 15
N·m (11 ft. lbs.).
4. Install the plastic nut cover.
5. Install the accelerator pedal upper nut (1). Tighten to 15

N·m (11 ft. lbs.).

DESCRIPTION
The accelerator pedal position sensor (1) is located inside the
accelerator pedal. The accelerator pedal position sensor (1)
can not be serviced by itself. The accelerator pedal must be
replaced as a unit. Refer to Page 14-26.
OPERATION
1 - ACCELERATOR PEDAL POSITION SENSOR 4 - KICKDOWN SIMULATOR

2 - ACCELERATOR PEDAL 5 - BASE PLATE
3 - PEDAL LEVER
The PCM recognizes how the accelerator pedal is being pressed and switches between a few characteristic curves.
Eighty percent of the engine’s power is achieved for a pedal travel of about 50% for an aggressive driver and about
40% for a conservative driver. There is no further difference felt above a pedal travel of about 90%.
The characteristic curve for a conservative driver is active after a long drive. Then the accelerator pedal must be
pressed down unusually hard to obtain a higher acceleration level.
The accelerator pedal position sensor in the accelerator pedal determines the opening angle of the throttle valve in
the throttle body. The data transfers over the CAN data bus.
Further functions are: Idle speed control, cruise control, engine torque for ESP operation and short performance
limitation; for example, for a higher coolant temperature.
The opening angle of the throttle valve will only be determined by the accelerator pedal signal when no limiting
functions are active.
The accelerator pedal position sensor is detected by the nominal value potentiometer or hall sensor in the pedal
value sensor and information is released to the PCM. The PCM determines the position of the throttle valve and
actuates the throttle valve motor.
The actual value potentiometer in the actuator signals the throttle valve position back to the PCM.
The second potentiometer in the actuator and the second signal from the pedal value sensor (potentiometer or hall
sensor) supplies a reference value for the plausibility check. The system switches over to the second potentiometer
or the hall sensor if the first potentiometer or hall sensor fails (emergency mode).
The accelerator pedal position sensor on the accelerator pedal works according to the hall principal. the sensor is
integrated into the pedal lever axis. It consists of a shaft with a ring magnet. This rotates in a printed circuit board
with a stator in the fixed hall elements. This produces a change in the voltage.
The accelerator pedal position sensor is supplied with 5 volts from the PCM. The information regarding accelerator
position is supplied to the PCM by means of two voltages (pin 4: approximately 0 up to 2.25 volts and pin 5: approx-
imately 0 up to 4.5 volts).
The kickdown simulator is not used as a “kickdown switch”. Wide Open Throttle (WOT) recognition takes place over
the signal from the accelerator pedal position sensors pressure point, which is located in the pedal assembly. WOT
position is simulated before achieving the full load position.
CRANKSHAFT POSITION SENSOR

DESCRIPTION
The crankshaft position sensor (1) is located on the left side of
the engine just forward of the transmission housing. The bot-
tom of the sensor is positioned above the flywheel.
The sensor is a hall effect device combined with an internal
magnet.
OPERATION
The crankshaft position sensor generates pulses that are the signal sent to the powertrain control module (PCM).
The PCM interprets the sensor signal to determine the crankshaft position. The PCM then uses this position, along
with other inputs, to determine injector sequence and ignition timing.
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots.
Two sets contain 4 slots and one set contains 5 slots, for a total of 13 slots. Basic timing is set by the position of
the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines which
piston will be next at TDC from the camshaft position sensor input. It may take the PCM one engine revolution to
determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence and ignition timing. Once the PCM
determines crankshaft position, it begins energizing the injectors and coils in sequence.
The PCM uses the crankshaft position sensor to calculate the following:
• Engine rpm
• TDC
• Ignition coil synchronization
• Injector synchronization
• Camshaft-to-crankshaft misalignment
REMOVAL
3. Disconnect the crankshaft position sensor harness connec-
tor.
4. Remove the retaining bolt and the crankshaft position sen-
sor (1).
INSTALLATION
1. Install the crankshaft position sensor to the engine tighten to 8 N·m (71 in. lbs.).
2. Connect the crankshaft position sensor harness connector.
FUEL INJECTOR
DESCRIPTION
The injectors are positioned in the cylinder heads with the noz-
zle ends directly above the intake valve port. The fuel injectors
are electrical solenoids.
OPERATION
The fuel injector employs the following devices.
• Fuel distribution pipe (1)
• Retaining clip (3)
• Magnetic coil (4)
• Nozzle needle (6)
• Magnetic anchor (7)
The fuel injectors are 12 volt electrical solenoids. The injector
contains a pintle that closes off an orifice at the nozzle end.
When electric current is supplied to the injector, the armature
and needle move a short distance against a spring, allowing
fuel to flow out the orifice. Because the fuel is under high pres-
sure, a fine spray is developed in the shape of a hollow cone
or two streams. The spraying action atomizes the fuel, adding
it to the air entering the combustion chamber.
The engine control relay which is contained in the relay control
module provides battery voltage to each injector. Injector oper-
ation is controlled by a ground path provided for each injector
by the PCM. Injector on-time (pulse-width) is variable, and is
determined by the PCM processing all the data previously dis-
cussed to obtain the optimum injector pulse width for each
operating condition. The pulse width is controlled by the dura-
tion of the ground path provided.
REMOVAL


3. Remove the fuel rail trim panel screw and then remove the fuel rail trim panel (1).
4. Release the fuel pressure through the fuel rail service valve (7) using a fuel pressure tester. Collect the fuel in a
suitable container.
5. Disconnect the fuel feed line (3).
6. Remove the fuel injector wire harness connector retaining clips and then disconnect the fuel injector harness (6)
from the fuel injectors (4).
7. Remove the fuel rail retaining bolts (8).
8. Remove the fuel rail (2) with the fuel injectors (4) by moving the fuel rail (2) side to side while lifting upward.
9. Remove the fuel injector retaining clips and the fuel injectors (4) from the fuel rail (2).
INSTALLATION

1. Install the fuel injectors (4) to the fuel rail (2) by gently pushing the fuel injector into the fuel rail (2). Install the
retaining clips.
2. Install the fuel rail (2) with the fuel injectors (4) by moving the fuel rail (2) side to side and pushing downward
towards the intake manifold.
3. Install the fuel rail retaining bolts. Tighten to 9 N·m (80 in. lbs.).
4. Install the fuel injector harness (6) to the fuel injectors (4) then install the fuel injector electrical connector retain-
ing clips (5).
5. Connect the fuel feed line (3). Tighten to 38 N·m (28 ft. lbs.).
6. Install the fuel rail trim panel (1) and screw.
FUEL PUMP RELAY

DESCRIPTION
The fuel pump relay is housed within the relay control module
(1) located inside the control module box (3) in the engine
compartment. The relay control module also contains the fuses
(2) for the fuel pump relay circuitry. The relays in the relay
control module cannot be adjusted or repaired. If faulty or
damaged, the entire module unit must be replaced as an
assembly.
OPERATION
The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit contains a fuse.
The fuse is located in the relay control module. Refer to the Wiring Diagrams for circuit information.
The PCM controls the fuel pump relay by switching the ground path for the coil side of the relay on and off. The
PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On
position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the
PCM de-energizes the relay.

DESCRIPTION
The Intake Air Temperature sensor (IAT) (1,6,2) is integrated
into the Mass Air Flow sensor (MAF). The IAT cannot be ser-
viced separately. Refer to the MAF service procedures for
removal. Refer to Page 14-37.
The IAT senses the inlet air temperature to the engine. The
IAT then sends a signal to the Powertrain Control Module
(PCM).
OPERATION
The Intake Air Temperature sensor (IAT) has a Negative Temperature Coefficient (NTC) integrated into the IAT. The
IAT alters its electrical resistance in line with the intake air temperature. When the temperature increases, the resis-
tance reading drops. As the temperature drops the resistance increases. The IAT sends this resistance reading to
the PCM to help calculate the amount of fuel that is needed. The IAT is integrated into the Mass Air Flow sensor
(MAF) and cannot be serviced individually. Refer to the MAF service procedures for removal and installation of the
IAT/MAF.
MANIFOLD AIR FLOW (MAF) SENSOR

DESCRIPTION
The Mass Air Flow sensor (MAF) is located on the rear of the engine attached to the throttle body, under the air
cleaner housing. The MAF is constructed from plastic and also houses the Intake Air Temperature sensor (IAT).
OPERATION
The Mass Air Flow sensor (MAF) employs the following:
• (1) Temperature resistor
• (2) Sensor resistor
• (3) Hot film resistor
• (4) Electronics housing
• (5) MAF housing
• (6) Heating resistor
The MAF controls the temperature of the heating resistor (6)
by means of a variable voltage so its temperature is 160°C
(320°F) above the intake air temperature detected by the tem-
perature resistor (1).
The temperature of the heating resistor (6) is detected by the
sensor resistor (2). If a temperature change occurs as a result
of an increased or reduced air flow, the PCM adapts the volt-
age at the heating resistor (6) until the temperature difference
is again achieved.
This control voltage is used by the PCM as a measure for the
metered air mass. The intake air temperature is detected by
an additional Negative Temperature Coefficient (NTC) resistor.
REMOVAL
3. Disconnect the MAF/IAT harness connector (1).
4. Remove the vent hose (2).
5. Disengage the lock ring (1) that attaches the MAF to the
intake by inserting a suitable tool into the locking ring (1)
and moving the tabs on the intake (2) away from their
locked position.
6. Press the locking tab (1) on the bottom right of the MAF
down with a suitable tool unlocking it from the intake. Press
the locking tab on the upper left of the MAF upward with a
suitable tool, unlocking it from the intake manifold.
7. Remove the MAF from the intake manifold.
8. Inspect the sealing ring and replace if necessary.
9. Inspect the sealing ring between the air inlet and the MAF
and replace if necessary.
10. Inspect the locking tabs on the MAF and replace if
necessary.
INSTALLATION
1. Install the MAF onto the intake by securely pushing the
MAF onto the throttle body.
2. Lock the lower locking tab (1) to the intake manifold. Lock
the upper locking tab to the intake manifold.
3. Push the MAF so the upper locking ring (1) and tabs (2)
are inline with the tabs on the intake, then squeeze the
locking ring (1) to lock the MAF onto the intake.
4. Install the vent hose (2) to the MAF sensor.

5. Connect the MAF/IAT harness connector (1).
MANIFOLD TUNE VALVE

DESCRIPTION
The manifold tune valve (2) opens a crossover passage in that
it connects both sides of the intake manifold plenum. It is con-
trolled by a vacuum solenoid (1).
OPERATION
The PCM controls the MTV solenoid. The manifold tune valve optimizes acoustical tuning of the intake system dur-
ing wide open throttle operation throughout the RPM range to increase torque.
REMOVAL
3. Remove the air injection pump. Refer to Page 25-32.
4. Disconnect the manifold tune valve harness connector at
the manifold tune valve solenoid.
5. Disconnect the vacuum line.
6. Remove the left hand air pump switch over valve. Refer to
Page 25-36.
7. Remove the nut retaining the manifold tune valve to the
valve rod.
8. Remove the manifold tune valve (2) and the solenoid (1)
from the intake.
INSTALLATION
1. Install the intake manifold tune valve (2) to the intake man-
ifold.
2. Install the tune valve arm retaining nut the valve rod.
Tighten the nut to 5 N·m (44 in. lbs.).
3. Install the left hand air pump switch over valve and bolts.
Tighten the bolts to 20 N·m (15 lb. ft.).
4. Connect the vacuum line and the manifold tune valve har-
ness connector at the manifold tune valve solenoid.
5. Install the air injection pump. Refer to Page 25-33.
MAP SENSOR
DESCRIPTION
The Manifold Absolute Pressure (MAP) sensor, is mounted to
the front of the engine on the right side next to the air pump.
OPERATION
The MAP sensor monitors the pressure in the intake manifold. The pressure in the manifold moves a diaphragm
connected to piezo resistors which alter their resistance values. The output voltage of the resistors serves as infor-
mation to the PCM about the pressure in the intake manifold.
REMOVAL
3. Disconnect the Manifold Absolute Pressure (MAP) harness
connector.
4. Remove the retaining bolt (1).
5. Remove the (MAP) sensor.
INSTALLATION
1. Install the MAP sensor.
2. Install the bolt (1).
3. Connect the Manifold Absolute Pressure (MAP) harness
connector.
O2 SENSOR
DESCRIPTION
The oxygen sensor threads into the outlet flange of the
exhaust manifold.
OPERATION
1 - ELECTRICAL CONNECTION 6 - PROTECTIVE TUBE

2 - SENSOR HOUSING 7 - INNER, OPEN COMBUSTION CHAMBER
3 - ACTIVE CERAMIC PROBE BODY 8 - ELECTRODE (OUTER)
4 - MATING SURFACE 9 - ELECTRODE (INNER)
5 - HEATING ELEMENT
A single sensor ground is used for all O2 sensors.

As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient cat-
alyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One
sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from
the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM
uses the upstream heated oxygen sensor input when adjusting injector pulse width.
When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code
and illuminates the malfunction indicator lamp (MIL).
The O2 sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas. When
a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust
leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich
air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen
content and converting it to electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature
during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into
closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of
extended idle.
In Closed Loop operation the PCM monitors the O2 sensors input (along with other inputs) and adjusts the injector
pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injec-
tor pulse width based on preprogrammed (fixed) values and inputs from other sensors.
The engine control relay located in the relay control module supplies battery voltage to both the upstream and
downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating ele-
ments reduce the time required for the sensors to reach operating temperature. The PCM uses pulse width mod-
ulation to control the ground side of the heater to regulate the temperature.
UPSTREAM OXYGEN SENSOR

The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on
this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width.
The sensor output varies from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust
manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces volt-
age as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces
a voltage as high as 1.0 volt. By monitoring the oxygen content in the exhaust gases and comparing that to the
oxygen content in ambient air and converting it to electrical voltage, the sensor acts as a rich-lean switch.
The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the
system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation
during periods of extended idle.
In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with
other signals. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and
inputs from other sensors.
DOWNSTREAM OXYGEN SENSOR

The downstream heated oxygen sensor signal is used to detect catalytic convertor deterioration. As the convertor
deteriorates, the signal from the downstream sensor begins to match the upstream sensor signal except for a slight
time delay. By comparing the downstream heated oxygen sensor signal to the signal from the upstream sensor, the
PCM calculates catalytic convertor efficiency. This calculation is also used to establish the upstream O2 goal voltage
(switching point).
REMOVAL
UPSTREAM O2 SENSOR
Note: The left side O2 sensor is shown. The right side is
similar.

3. Disconnect the O2 sensor harness connector.
4. Remove the O2 sensor (1).
REMOVAL - DOWNSTREAM O2
Note: The left side O2 sensor is shown. The right side is

similar.

3. Disconnect the O2 sensor harness connector.
4. Remove the O2 sensor (1).
INSTALLATION
UPSTREAM O2
1. Apply anti-sieze compound to the threaded portion of the
O2 sensor.
2. Install the O2 sensor (1). Tighten to 50 N·m (37 ft. lbs.).
3. Connect the O2 sensor harness connector.
INSTALLATION - DOWNSTREAM O2
1. Apply anti-sieze compound to the threaded portion of the
O2 sensor.
2. Install the O2 sensor (1). Tighten to 50 N·m (37 ft. lbs.).
3. Connect the O2 sensor harness connector.
THROTTLE BODY
DESCRIPTION
The throttle body is located on the intake manifold. The throttle
body meters air into the intake manifold. Fuel does not enter
the intake manifold through the throttle body. Fuel is sprayed
into the manifold by the fuel injectors.
OPERATION
Filtered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve (plate) is used
to supply air for idle and driving conditions.
The throttle position sensor is part the throttle body. The throttle position sensor signal is used by the PCM to deter-
mine throttle position. The PCM controls the electronic throttle control to meter air into the engine. This regulates
engine power. The vehicle is in sense a “Drive by Wire” system.
REMOVAL
3. Remove the Mass Air Flow sensor with the intake tube.
4. Remove the crankcase vent tube (1) from the intake.
5. Disconnect the throttle body harness conector (3).
6. Remove the four bolts (4) attaching the throttle body (5) to
the intake.
7. Remove the O-ring (2) from the throttle body (5) and
discard.
INSTALLATION
1. Install the new O-ring (2) to the throttle body (5).
2. Install the throttle body (5) to the intake. Tighten to 9 N·m
(80 in lbs.).
3. Connect the throttle body harness connector (3).
4. Install the crankcase vent tube (1) to the intake.
5. Install the MAF sensor. Refer to Page 14-39.
THROTTLE POSITION SENSOR

DESCRIPTION
1 - THROTTLE VALVE 5 - THROTTLE VALVE DRIVE SHAFT

2 - MECHANICAL STOP SPRING CAPSULE 6 - THROTTLE VALVE ACTUAL VALUE (POTENTIOMETER 1)
3 - ELECTRONIC THROTTLE CONTROL 7 - THROTTLE VALVE ACTUAL VALUE (POTENTIOMETER 2)
4 - GEAR 8 - SPRING
The throttle position sensor (TPS) is a part of the throttle body.

The TPS cannot be removed separately. Refer to the throttle body removal and installation procedures. Refer to
Page 14-48.
OPERATION
1 - THROTTLE VALVE 5 - THROTTLE VALVE DRIVE SHAFT

2 - MECHANICAL STOP SPRING CAPSULE 6 - THROTTLE VALVE ACTUAL VALUE (POTENTIOMETER 1)
3 - ELECTRONIC THROTTLE CONTROL 7 - THROTTLE VALVE ACTUAL VALUE (POTENTIOMETER 2)
4 - GEAR 8 - SPRING
The Throttle Position Sensor (TPS) contains two actual value potentiometers for detecting the position of the throttle
valve. The second potentiometer is designed to form a reference value. The system will switch over to the second
potentiometer if the first one fails. The TPS cannot be serviced separately. If the TPS fails, the throttle body must be
replaced. Refer to the throttle body service procedures. Refer to Page 14-48.
ZH STEERING 19 - 1
STEERING
TABLE OF CONTENTS
page page
STEERING SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 6

DESCRIPTION SPECIAL TOOLS
STEERING SYSTEM . . . . . . . . . . . . . . ......1 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . ......2 COLUMN ...............................8
DIAGNOSIS AND TESTING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER STEERING SYSTEM . . . . . . . ......2 LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FLOW AND PRESSURE . . . . . . . . . . . ......5
STEERING
DESCRIPTION
STEERING SYSTEM
1 - ACCESSORY DRIVE BELT 4 - C-CLIP

2 - HIGH PRESSURE HOSE 5 - RESERVOIR
3 - POWER STEERING PUMP BOLTS 6 - SUPPLY LINE
The power steering pump is a constant flow rate and displacement vane type pump. The pump reservoir is attached
to the pump body. The pump is connected to the steering by the pressure and return hoses. The steering gear used
is a recirculating ball type gear. A column provides steering input.
19 - 2 STEERING ZH
The power steering system consists of the following: Steering gear, Pressure hose, Pump, Return hose and
Reservoir.
OPERATION
1 - STEERING GEAR 5 - TIE ROD

2 - STEERING SHAFT 6 - DRAG LINK
3 - PINCH BOLT 7 - PRESSURE HOSE
4 - STEERING GEAR MOUNTING BOLTS 8 - RETURN HOSE
The rack piston balls act as a rolling thread between the worm shaft and rack piston. The worm shaft is supported
by a thrust bearing at the lower end and a bearing assembly at the upper end. When the worm shaft is turned from
the steering column the rack piston moves. The rack piston teeth mesh with the pitman shaft. Turning the worm
shaft turns the pitman shaft, which moves the steering linkage.

POWER STEERING SYSTEM
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a stand-
still or at park with the engine running. Or when the steering wheel is at the end of its travel. Hiss is a high fre-
quency noise similar to that of a water tap being closed slowly. The noise is present in all valves that have a high
velocity fluid passing through an orifice. There is no relationship between this noise and steering performance.
ZH STEERING 19 - 3
STEERING NOISE
HISS OR WHISTLE 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
seal. panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension 2. Inspect and repair suspension.

components.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other 5. Reposition hose.
components.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
2. Belt routing. 2. Verify belt routing is correct.
1. Low fluid level. 1. Fill to proper level.

2. Pressure hose in contact with other 2. Reposition hose.
WHINE OR GROWL
components.
3. Internal pump noise. 3. Replace pump.
4. Air in the system. 4. Perform pump initial operation.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose 2. Replace o-ring.

fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.

KNOCKING 2. Wrong gear. 2. Verify gear.
19 - 4 STEERING ZH
BINDING AND STICKING
DIFFICULT TO TURN WHEEL 1. Low fluid level. 1. Fill to proper level.

STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of 7. Repair or replace gear.
adjustment.
8. Ball joints binding. 8. Inspect and repair as necessary.
INSUFFICIENT ASSISTANCE. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY 1. Tire pressure. 1. Adjust tire pressure.

INCREASE IN TURNING EFFORT 2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Inspect and lubricate steering and
4. Lack of lubrication.
5. Pressure and flow test and repair
5. Low pump pressure or flow.
as necessary.
6. Pressure and flow test, and repair
6. Internal gear leak.
as necessary.
STEERING WHEEL 1. Tire pressure. 1. Adjust tire pressure.

DOES NOT WANT TO RETURN TO 2. Wheel alignment. 2. Align front end.
CENTER POSITION
3. Inspect and lubricate steering and
3. Lack of lubrication.
4. High friction in steering gear. 4. Test and adjust as necessary.
5. Ball joints binding. 5. Inspect and repair as necessary.
Note:
Some roads will cause a vehicle to drift, due to the crown in the road.
ZH STEERING 19 - 5
LOOSE STEERING AND VEHICLE LEADS/DRIFTS
EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Repair as necessary.

WHEEL steering components.
2. Worn or loose wheel bearings. 2. Repair as necessary.

3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS TO ONE SIDE 1. Tire Pressure. 1. Adjust tire pressure.

DURING BRAKING
2. Air in brake hydraulics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.
VEHICLE LEADS OR DRIFTS 1. Tire pressure. 1. Adjust tire pressure.

FROM STRAIGHT AHEAD 2. Radial tire lead. 2. Cross front tires.
DIRECTION ON UNCROWNED
3. Brakes dragging. 3. Repair as necessary.
ROAD.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering/ 6. Repair as necessary.
DIAGNOSIS AND TESTING - STEERING FLOW AND PRESSURE

The following procedure is used to test the operation of the power steering system on the vehicle. This test will
provide the gallons per minute (GPM) or flow rate of the power steering pump along with the maximum relief pres-
sure. Perform the test any time a power steering system problem is present. This test will determine if the power
steering pump or the power steering gear is functioning properly. The following pressure and flow test is performed
using the standard shop tool “Power Steering Analyzer Tool Kit #6815” and the “Adapter Kit #6893”.
FLOW AND PRESSURE TEST

1. Check the accessory drive belt to ensure it is in good con-
dition and adjusted properly.
2. Connect the pressure gauge hose (4) from the “Power
Steering Analyzer” to the Tube 6865.
3. Connect the Adapter (1) 6826 to the Power Steering Ana-
lyzer test valve end.
4. Disconnect the high pressure hose from the power steering
pump.
5. Connect the Tube 6865 onto the pump hose fitting.
6. Connect the power steering hose from the steering gear to
the Adapter 6826.
7. Open the test valve completely.
8. Start the engine and let it idle long enough to circulate
power steering fluid through the flow/pressure test gauge.
9. Shut the engine off and check the fluid level, add fluid as
necessary. Start the engine again and let it idle.
19 - 6 STEERING ZH
10. The initial pressure reading should be 345-552 kPa (50-80 psi). If the pressure is higher inspect the hoses for
restrictions and repair as necessary.
11. Increase the engine speed to 1500 RPM and read the flow meter. The reading should be 2.4 - 2.8 GPM. If the
reading is below this specification, the pump should be replaced.
CAUTION: This next step involves testing maximum pump pressure output and flow control valve operation.
Do not leave the valve closed for more than three seconds as the pump could be damaged.
12. Close the valve fully three times for three seconds and record the highest pressure indicated each time. All
three readings must be at pump relief pressure specifications and within 345 kPa (50 psi) of each other.
• If pressure is above the specifications but not within 345 kPa (50 psi) of each other, replace the pump.
• If pressure is within 345 kPa (50 psi) of each other but below the specifications, replace the pump.
CAUTION: Do not force the pump to operate against the stops for more than 2 to 4 seconds at a time. Pump
damage could result.
13. Open the test valve and turn the steering wheel to the extreme left and right positions against the stops. Record
the highest pressure reading at each position. Compare readings to the pump specifications chart. If the pres-
sure readings are not within 50 psi. of each other, the gear is leaking internally and must be repaired.
PUMP FLOW SPECIFICATIONS
DESRIPTION SPECIFICATION
FLOW RATE (GPM) 107-115

Drag Link to Idler Arm Nut 50 37 444
Drag Link to Pittman Arm Nut 50 37 444
Engine Mount Bolts 25 18 216
Idler Arm Mounting Nut and Bolt 50 37 444
Idler Arm Pinch Bolt 30 22 264
Outer Tie Rod to Steering Knuckle Nut 50 37 444
Pittman Arm Pinch Bolt 55 41 492
Power Steering High Pressure Hose 30 22 264
Power Steering Pump Mounting Bolts 20 15 180
Power Steering Return Hose 40 30 360
Steering Column Lower Nuts 8 5.9 71
Steering Column Pinch Bolt 30 22 264
Steering Column Upper Bolts 20 15 180
Steering Coupling Pinch Bolt 30 22 264
Steering Damper Bracket Nut and Bolt 40 29 348
Steering Damper to Drag Link Nut and Bolt 40 29 348
Steering Gear Lock Nut 60 44 528
Steering Gear Mounting Bolts 60 44 528
ZH STEERING 19 - 7
SPECIAL TOOLS
STEER
ING
9159 Steering Seal Installer
C-3894-A Tie Rod Puller
9168 Ball Joint Puller

19 - 8 COLUMN ZH
COLUMN
TABLE OF CONTENTS
page page
COLUMN IGNITION SWITCH

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 13 STEERING WHEEL
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING COLUMN . . . . . . . . . . . . . . . . . . . 15 KEY/LOCK CYLINDER
IGNITION LOCK CABLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
COLUMN
DESCRIPTION
1 - STEERING LOCK 6 - LOWER STEERING COLUMN NUTS

2 - UPPER STEERING COLUMN BOLTS 7 - STEERING SHAFT
3 - STEERING WHEEL 8 - STEERING GEAR
4 - CLOCKSPRING 9 - PINCH BOLT
5 - MULTIFUNCTION/SPEED CONTROL SWITCH 10 - RETAINING CLAMP
ZH COLUMN 19 - 9
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE

ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MIN-
UTES FOR THE SYSTEM CAPACITOR TO DISCHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDEN-
TAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND
BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COATINGS AND ARE SPE-
CIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTI-
TUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED
IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Safety goggles should be worn at all times when working on steering columns.
The steering column has been designed so that the wiring, switches, shrouds and steering wheel can be serviced
without removing the steering column from the vehicle.
To service the steering wheel, switches or airbag refer to the appropriate procedure.
REMOVAL

19 - 10 COLUMN ZH
WARNING: BEFORE SERVICING THE STEERING COLUMN

THE AIRBAG SYSTEM MUST BE DISARMED. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.

2. Remove the left lower instrument panel (2) from under the
steering column. Refer to Page 23-149.
3. Remove the driver airbag screws (1). Refer to Page

8O-100.
4. Position the front wheels in the straight-ahead position.
5. Remove the steering wheel bolt (1) and remove the steer-
ing wheel. Refer to Page 19-25.
ZH COLUMN 19 - 11
6. Remove the clockspring screws (1). Refer to Page 8O-94.
7. Remove the instrument cluster (1). Refer to Page 8J-83.

8. Remove the steering lock. Refer to Page 19-19.
9. Remove the speed control switch (1). Refer to Page 8P-4.

19 - 12 COLUMN ZH
10. Remove the multi-function switch screws (1-2). Refer to

Page 8L-112.
11. Remove the column trim ring.
12. Remove the pinch bolt (1) attaching the steering column
to the steering gear.
13. Remove the lower nuts on the steering column attaching
the steering column to the lower mounting surface.
14. Remove the upper bolts (1) on the steering column attach-
ing it to the instrument panel support.
CAUTION: DO NOT use force as the intermediate shaft is

sensitive to the effects of side force.
15. Pull the steering column out away from the instrument
panel.
ZH COLUMN 19 - 13
DISASSEMBLY
1 - OUTER COLUMN TUBE 11 - LOCKING RING

2 - PLASTIC BEARING 12 - DISK SPRING
3 - STEERING SHAFT NUT 13 - LOCKING RING
4 - DISK SPRING 14 - COUPLER FLANGE SEAL
5 - THRUST RING 15 - CUP SEAL
6 - RETAINING RING 16 - PINCH BOLT
7 - PLASTIC BEARING 17 - FLANGE
8 - INNER COLUMN TUBE 18 - INTERMEDIATE SHAFT NUT
9 - INTERMEDIATE SHAFT 19 - ADJUSTING LEVER
10 - THRUST RING 20 - STEERING WHEEL
1. Remove the pinch bolt (16) from the intermediate shaft (9), remove intermediate shaft (9).
2. Remove the retaining ring (6), disk spring (4) and the thrust ring (5).
3. Push the intermediate shaft (9) out slightly, remove the locking ring (13) and the thrust ring (10).
4. Press the ball bearing out of the steering column using the intermediate shaft (9).
19 - 14 COLUMN ZH
ASSEMBLY
1 - OUTER COLUMN TUBE 11 - LOCKING RING

2 - PLASTIC BEARING 12 - DISK SPRING
3 - STEERING SHAFT NUT 13 - LOCKING RING
4 - DISK SPRING 14 - COUPLER FLANGE SEAL
5 - THRUST RING 15 - CUP SEAL
6 - RETAINING RING 16 - PINCH BOLT
7 - PLASTIC BEARING 17 - FLANGE
8 - INNER COLUMN TUBE 18 - INTERMEDIATE SHAFT NUT
9 - INTERMEDIATE SHAFT 19 - ADJUSTING LEVER
10 - THRUST RING 20 - STEERING WHEEL
1. Using a suitable tool, press the new bearing (7) in up to the stop in the steering column.
2. Slide the intermediate shaft in and press the second bearing in.
Note: Ensure that the locking ring locks in position correctly in the groove of the upper steering shaft. Two
locking rings are fitted on vehicles with contact spirals.
3. Push the thrust ring and locking ring (13) together onto the intermediate shaft (9).
4. Slide on the thrust ring (5) and the disk spring (4).
Note: The disk spring must be preloaded fully; preload fully using the lower steering shaft, if necessary.
Note: If the preload is too high, the upper steering shaft can only be turned very unevenly or it sticks. The
ball bearings are pressed into the bearing shells excessively.
Note: If the preload is too low, play is detectable at the steering wheel when the jacket tube is installed.
5. Mount the retaining ring (6) on the intermediate shaft (9) and, using a suitable tool, push on until the disk spring
(4) is fully preloaded.
ZH COLUMN 19 - 15
6. Attach the lower tube (1) to the upper tube by screwing in the countersunk screw to protect the splines.
7. Slide the lower intermediate shaft onto the upper intermediate shaft and install bolt and nut.
8. Use a suitable tool to protect the lower intermediate shaft.
9. Using a press, slide the lower intermediate shaft onto the upper intermediate shaft until the disc spring is fully
preloaded. Check the steering column for ease of movement by turning it at the same time, tighten the nut and
bolt in this position.
INSTALLATION
STEERING COLUMN

19 - 16 COLUMN ZH
WARNING: BEFORE SERVICING THE STEERING COLUMN

THE AIRBAG SYSTEM MUST BE DISARMED. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: DO NOT use force as the intermediate shaft is

sensitive to the effects of side force.
1. Install the steering column.

2. Install the lower nuts on the steering column attaching the
steering column to the lower mounting surface. Tighten to 8
N·m (71 in. lbs.).
3. Install the upper bolts (1) on the steering column attaching
it to the instrument panel support. Tighten to 20 N·m (15 ft.
lbs.).
4. Install the pinch bolt (1) attaching the upper steering col-
umn to the steering gear. Tighten to 30 N·m (22 ft. lbs.).
5. Connect the clockspring electrical connector.
6. Install the column trim ring.
7. Install the speed control switch screws (1).

ZH COLUMN 19 - 17
8. Install the multi-function switch screws (1-2).

9. Reconnect the ignition switch connector.
10. Install the instrument cluster (1). Refer to Page 8J-84.
11. Install the clockspring screws (1). Refer to Page 8O-96.

19 - 18 COLUMN ZH
12. Install the steering wheel bolt (1). Refer to Page 19-26.
13. Install the driver airbag screws (1). Refer to Page

8O-100.
14. Install the left lower instrument panel (2) under the steer-
ing column. Refer to Page 23-155.
ZH COLUMN 19 - 19
IGNITION LOCK CABLE

REMOVAL
2. Remove the ashtray (2) at front of center console. Refer to
Page 23-173.
3. Remove the lower instrument panel (2). Refer to Page

23-149.
19 - 20 COLUMN ZH
4. Press the locking tabs together and push the ignition lock
cable (1) out of ignition / starter switch in the direction of
the arrows.
5. Remove the shifter bezel (1). Refer to Page 23-173.
6. Remove the ignition lock cable (1) from electronic selector

lever module by turning it 90° to the left and then pulling it
straight out.
ZH COLUMN 19 - 21
INSTALLATION
1. Install the ignition lock cable (1) to the ignition / starter
switch by sliding it into the retaining slot until the tabs click.
2. Install the ignition lock cable (1) to the shift lever assembly
by inserting it into the mounting hole and then turning it 90°
to the right.
3. Turn the ignition switch to the off/lock position. It should
only be possible to move the shift lever out of the Park
position when the ignition switch is in the on/run position
and the brake pedal is depressed. It should only be possi-
ble to remove the ignition key when the shift lever is in the
Park position and the ignition switch is in the off/lock
position.
19 - 22 COLUMN ZH
4. Install the lower instrument panel (2). Refer to Page

23-155.
5. Install the ash tray (2) in the front center console.
6. Install the shifter cover (1). Refer to Page 23-183.

ZH COLUMN 19 - 23
IGNITION SWITCH
REMOVAL
1 - IGNITION SWITCH CONNECTOR 6 - STEERING LOCK

2 - IGNITION SWITCH 7 - PARK/BRAKE INTERLOCK CABLE
3 - WASHER 8 - BUZZER
4 - PARKING LOCK VALVE 9 - RELEASE CLAMP
5 - CAM
1. Remove the lower instrument panel cover. Refer to Page 23-149.

3. Remove the transponder coil from the lock cylinder by removing the top section of the instrument panel. Refer to
Page 23-149.
4. Insert a plastic wedge directly between the ignition switch cover sleeve and the transponder coil. Press the tran-
sponder coil off of the ignition switch cover sleeve with a plastic wedge.
5. Disconnect the 2-pin connector for the transponder coil from the RKE control module.
CAUTION: The steering lock and lock cylinder can only be fitted in lock cylinder position (1(. NEVER turn
the steering lock when the ignition/starter switch is not fitted.
6. Remove the key cylinder. Refer to Page 19-23.

7. Disconnect the connector (8) from the warning buzzer contact.
8. Disconnect the connector (1) from the ignition/starter switch.
Note: Vehicles with automatic transmission

19 - 24 COLUMN ZH
9. Remove the parking lock interlock cable (7).

10. Release the clamp (9), press in locking pin and pull the steering lock (6) out of the steering column.
Note: The ignition switch must not be turned out of position (1( when the ignition/starter switch is not fitted,
otherwise the steering lock is locked permanently
11. Remove the ignition switch (2).

12. Remove the washer (3) and parking lock valve (4).
13. Remove the warning buzzer (8) contact and switch.
INSTALLATION
1 - IGNITION SWITCH CONNECTOR 6 - STEERING LOCK

2 - IGNITION SWITCH 7 - PARK/BRAKE INTERLOCK CABLE
3 - WASHER 8 - BUZZER
4 - PARKING LOCK VALVE 9 - RELEASE CLAMP
5 - CAM
1. Install the warning buzzer contact switch (8).
CAUTION: The steering lock and lock cylinder can only be fitted in lock cylinder position (1(. Never turn the
steering lock when the ignition/starter switch is not fitted.
2. Install the washer (3) and the parking lock valve (4).
Note: The ignition switch must not be turned out of position (1( when the ignition/starter switch is not fitted,
otherwise the steering lock is locked permanently.
3. Install the ignition switch (2).

ZH COLUMN 19 - 25
4. Install the clamp (9), press in locking pin to install the steering lock (6) to the steering column.
5. Install the parking lock interlock cable (7).
6. Install the connector from the ignition/starter switch (1).
7. Install the connector from the warning buzzer contact (10).
8. Install the key cylinder. Refer to Page 19-21.
9. Install the transponder coil.
11. Install the lower instrument panel cover. Refer to Page 23-149.
STEERING WHEEL
REMOVAL
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIRBAG,

RUBBER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE
DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTE-
RIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS
MAY CAUSE IRRITATION TO THE SKIN AND EYES.
19 - 26 COLUMN ZH

2. Push in the adjustable steering column fully.
3. Position the steering wheel so that the front wheels are in
the straight-ahead position.
4. Remove the ignition key and allow the steering to lock into
position.
5. Remove the airbag screws (1) on the steering wheel. Refer
to Page 8O-100.
6. Using a long hex tool (2), remove the countersunk screw

(1) while steadying the steering wheel.
7. Carefully pass the connector from the airbag through the
hole in the steering wheel. Remove the steering wheel from
the vehicle.
8. Check the horn/airbag and clock spring contacts for any
damage. Replace if necessary. Refer to Page 8O-94.
INSTALLATION
PERSONAL INJURY.
ZH COLUMN 19 - 27
WARNING: WHEN REMOVING A DEPLOYED AIRBAG,

RUBBER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE
DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTE-
RIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS
MAY CAUSE IRRITATION TO THE SKIN AND EYES.
CAUTION: If the steering wheel is offset by more than 1

tooth, the turn signal indicator is no longer properly
aligned.
CAUTION: The SRS malfunction indicator lamp must not

come on at full steering lock in either direction.
CAUTION: If the steering wheel is not on straight, offset it

by a maximum of 1 tooth, if the difference is greater,
check and adjust the front wheel toe-in. Refer to Page
2-13.
1. Align the recesses of the splines in the steering wheel with

the markings on the steering shaft.
2. Install the countersunk bolt (1). Tighten to 80 N·m (60 ft.
lbs.).
19 - 28 COLUMN ZH
3. Install the airbag screws (1) on the steering wheel. Refer to

Page 8O-100.
KEY/LOCK CYLINDER
REMOVAL
Note: If the lock cylinder/key is notched or jamming, spray
the lock cylinder with lock cylinder grease. If it is not pos-
sible to eliminate the complaint, replace the lock cylinder
and key.
1. Press out the escutcheon (2) with a suitable tool.

ZH COLUMN 19 - 29
2. Pull the transponder coil (3) off the lock cylinder (2) with a
plastic wedge (1).
3. Push the sleeve onto the cap and turn the lock cylinder to
position 919 with the key.
4. Unlock the lock cylinder (1) by turning the cap counter-

clockwise through 90° and then remove.
19 - 30 COLUMN ZH
INSTALLATION
1. Spray the outside of the lock cylinder (1) with lock cylinder
grease and insert it into the cap.
2. Push the key through the cap as far as the stop in the lock
cylinder (1).
3. Turn the cap clockwise approx. 90° until it can be felt or
heard “lock” into position.
4. Turn the key to position 909.

5. Press in the escutcheon (2).
ZH COLUMN 19 - 31
6. Install the transponder coil (3) on the lock cylinder.

19 - 32 GEAR ZH
GEAR
TABLE OF CONTENTS
page page
GEAR ADJUSTMENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32 STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . .. . . . . . . . . . . . . . . . . . . . . . . . . 32 PITMAN SHAFT SEAL
REMOVAL . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GEAR
DESCRIPTION
The power steering gear is a recirculating ball type gear. The steering gear is securely mounted to the driver’s side
of the vehicle. The steering linkage is attached to the pitman arm then attached to the idler arm.

OPERATION
The steering gear acts as a rolling thread between the worm shaft and rack piston. The worm shaft is supported by
a thrust bearing at the lower end and a bearing assembly at the upper end. When the worm shaft is turned the rack
piston moves. The rack piston teeth mesh with the pitman shaft. Turning the worm shaft turns the pitman shaft,
which turns the steering linkage.
ZH GEAR 19 - 33

REMOVAL
1. Draw off the fluid from the power steering pump reservoir.
3. Remove the drag link / tie rod (1) from the pitman arm.
4. Remove the left front cross brace.
19 - 34 GEAR ZH
5. Remove the power steering return line (3) and the high-
pressure line (2).
WARNING: ON VEHICLES WITH HORN/AIRBAG CLOCK

SPRING CONTACT, THE STEERING WHEEL MUST NOT BE
TURNED WHEN THE STEERING GEAR IS REMOVED, OTH-
ERWISE THE CLOCK SPRING CONTACT WILL BE DAM-
AGED BEYOND REPAIR.
6. Remove the ignition key and allow the steering wheel to

lock.
7. Remove the pinch bolt (1) from the steering coupling.

8. Remove the steering shaft from the steering gear.
9. Remove the engine ground strap from the frame member.
10. Remove the lower engine mounting bolts (1) on the left
and right of the engine mounts.
ZH GEAR 19 - 35
11. Safely install a support jack (1), under the left side of the
engine. Raise the engine (2) approx. 40 mm (2 in.).
CAUTION: DO NOT use force, otherwise the lower steering

shaft will be damaged on vehicles with a rigid steering
column.
12. Remove the three bolts (1) attaching the steering gear to
the body of the vehicle, carefully move steering gear out
of the steering shaft then remove the steering gear from
the vehicle.
19 - 36 GEAR ZH
INSTALLATION
1. Turn the steering gear to the center position by aligning the
marking lines on the steering shaft and the housing cover.
CAUTION: DO NOT use force, otherwise the lower steering

shaft (collapsible tubing) will be damaged. Ensure that the
connection is assembled correctly.
2. Carefully install the steering gear coupling onto the steering

shaft.
3. Push the lower steering shaft into the steering coupling
then bolt steering gear onto the vehicle. Tighten to 60 N·m
(44 ft. lbs.).
4. Lower the engine and tighten the engine mounts (1).

5. Install the ground strap to the frame.
ZH GEAR 19 - 37
6. Install the pinch bolt (1) to the steering coupling. Tighten to

30 N·m (22 ft. lbs.).
7. Install the high-pressure hose (2). Tighten to 30 N·m (22 ft.

lbs.).
8. Install the return line (3). Tighten to 40 N·m (30 ft. lbs.).
9. Install the drag link / tie rod. Refer to Page 19-49.
10. Install the left front cross brace.
11. Fill and bleed the power steering pump. Refer to Page
19-51.
19 - 38 GEAR ZH
ADJUSTMENTS
STEERING GEAR
1. Using Special Tool 9168 Ball Joint Puller (2) remove the tie
rod / drag link at the pitman arm (1). Refer to Page 19-47.
2. Determine the friction torque of the steering gear by slowly
turning the steering wheel from stop to stop several times.
3. Adjust the steering gear by loosening the lock nut.
4. Turn the adjusting screw 1/4 revolutions in stages.
• Counterclockwise = less play = increased coefficient of
friction.
• Clockwise = more play = reduced coefficient of friction.
5. Tighten the lock nut to 60 N·m (44 ft. lbs.).
6. Check the adjustment after tightening the lock nut, repeat
adjustment, if necessary.
PITMAN SHAFT SEAL

REMOVAL
1. Measure the distance of point “A” between the pitman arm
(2) and the steering gear (1) using a caliper gauge.
ZH GEAR 19 - 39
2. Remove the lower snap ring (4) from the pitman shaft.
3. Remove the pitman arm (3) from the pitman shaft.
4. Remove the upper locking ring (2).
5. Remove the pitman shaft seal (1) from the steering gear
housing using a suitable prying tool.
INSTALLATION
CAUTION: DO NOT damage the sealing lip of the pitman
shaft seal when sliding it on over the pitman shaft splines.
1. Using Special Tool 9159 Steering Seal Installer (1) install a

new pitman shaft seal into the steering gear.
19 - 40 GEAR ZH
2. Install the upper snap ring (2).

3. Remove any oil and grease from the splined section of the
pitman arm, and the pitman arm shaft.
4. Install the lower snap ring (4).
5. Install the pitman arm to the previously measured depth of

measurement 9A9. Tighten the pinch bolt to 55 N·m (41 ft.
lbs.).
6. Check the steering gear for any leaks.
7. Check for correct power steering fluid level.
ZH LINKAGE 19 - 41
LINKAGE
TABLE OF CONTENTS
page page
IDLER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DRAG LINK
PITMAN ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 TIE ROD END
DAMPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
IDLER ARM
REMOVAL
1 - BEARING BUSHING, NUT, AND BOLT 3 - DRAG LINK

2 - HEAT SHIELD, NUT, AND BOLT 4 - IDLER ARM
1. Remove drag link (3) from the idler arm (4) by removing the idler arm nut.
2. Remove the heat shield (2).
3. Remove the nut and bolt and remove the idler arm (4) from the vehicle.
4. Loosen the pinch-bolt on the idler arm (4).
5. Remove the idler arm bushing from the idler arm (4).
6. Inspect the idler arm bushing. Replace as necessary.
19 - 42 LINKAGE ZH
INSTALLATION
1 - BEARING BUSHING, NUT, AND BOLT 3 - DRAG LINK

2 - HEAT SHIELD, NUT, AND BOLT 4 - IDLER ARM
1. Install the idler arm bushing to the idler arm (4).

2. Adjust the idler arm bushing to the reference dimension.
3. Install the idler arm pinch bolt. Tighten to 30 N·m (22 ft. lbs.).
4. Install the idler arm to the vehicle.
5. Install the nut and bolt on the idler arm. Tighten to 50 N·m (37 ft. lbs.).
6. Install the heat shield (2).
7. Install the drag link to the idler arm. Tighten to 50 N·m (37 ft. lbs.).
ZH LINKAGE 19 - 43
PITMAN ARM
REMOVAL
1. Using Special Tool 9168 Ball Joint Puller remove the drag
link from the pitman arm.
2. Measure the distance of point 9A9 between the pitman arm

(2) and the steering gear (1) using a caliper gauge.
19 - 44 LINKAGE ZH
3. Remove the snap ring (2) that holds the pitman arm (1) on
the shaft.
4. Remove the pitman arm by loosening the pinch bolt (1).

With a prying device, remove the pitman arm from the pit-
man arm shaft (2).
ZH LINKAGE 19 - 45
INSTALLATION
1. Remove any oil and grease from the splined section of the
pitman arm shaft and the pitman arm.
2. Install the pitman arm (1) to the pitman arm shaft (2).
3. Install the snap ring (2).

19 - 46 LINKAGE ZH
4. Install the pitman arm to the previously measured depth of

measurement 9A9. Tighten the pinch bolt to 55 N·m (41 ft.
lbs.).
DAMPER
REMOVAL
1. Remove the nut and bolt (1) from the steering damper
mounting bracket.
2. Remove the nut and bolt from the drag link.
3. Remove the steering damper from the vehicle.
ZH LINKAGE 19 - 47
INSTALLATION
1. Install the steering damper into the vehicle.
2. Install the nut and bolt to the drag link. Tighten to 40 N·m
(29 ft. lbs.).
3. Install the bolt and nut (1) to the steering damper bracket.
DRAG LINK
REMOVAL
1. Remove the steering dampener from the drag link. Refer to
Page 19-46.
2. Remove the nuts attaching the drag link (1) to the pitman
arm and the idler arm.
19 - 48 LINKAGE ZH
3. Remove the nuts attaching the tie rod ends to the steering
knuckles.
4. Using Special Tool C-3894-A (2) Two Jaw Puller remove
the tie rod ends (1) from the steering knuckles.
5. Using Special Tool 9168 (2) Ball Joint Puller remove the
drag link (1) from the pitman arm and the idler arm.
Note: The right-hand drag link joint is a pivot joint with a

swivelling range of max. 2°. This prevents the drag link
from tilting.
6. Inspect the tie rod ends for play or damage. Repair as

necessary.
ZH LINKAGE 19 - 49
INSTALLATION
1. Clean any grease or debris from the tie rod ends, and the
drag link attaching points (1).
2. Install the drag link and the attaching nuts (1) to the idler
arm and pitman arm. Tighten the drag link nuts to 50 N·m
(37 ft. lbs.).
3. Install the tie rod ends into the steering knuckles.
4. Install the nuts on the tie rod ends. Tighten to 50 N·m (37
ft. lbs.).
5. Install the steering dampener. Tighten to 40 N·m (29 ft.
lbs.).
6. Adjust the front toe setting on the vehicle. Refer to Page
2-6.
TIE ROD END

REMOVAL
1. Loosen the tie rod end jam nut (1).
2. Remove nut from the tie rod end at the steering knuckle.
3. Using Special Tool C-3894-A (2) two jaw puller remove the
tie rod end (1) from the steering knuckle.
4. Unscrew the tie rod end from the drag link.
19 - 50 LINKAGE ZH
INSTALLATION
1. Clean the tapered surfaces, and remove any grease or
debris from the tie rod end.
2. Thread the tie rod end onto the drag link.
3. Install the tie rod end to the steering knuckle.
4. Install the attaching nut on the tie rod end. Tighten to 50
N·m (37 ft. lbs.).
5. Thread the jam nut down far enough to hold the tie rod end
in place. Do not tighten the jam nut.
6. Adjust the front toe setting on the vehicle. Refer to Page
2-6.
ZH PUMP 19 - 51
PUMP
TABLE OF CONTENTS
page page
PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
STEERING PUMP INITIAL OPERATION . . . . . 51
PUMP
STANDARD PROCEDURE
STEERING PUMP INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOV-
ING COMPONENTS.
CAUTION: Use MOPART power steering fluid or equivalent. Do not use automatic transmission fluid and do
not overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.
2. Start the engine and let run for a few seconds then turn engine off.
3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine.
4. Raise the front wheels off the ground.
5. Slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times.
6. Check the fluid level and add if necessary.
7. Lower the vehicle, start the engine and turn the steering wheel slowly from lock to lock.
8. Stop the engine and check the fluid level and refill as required.
CAUTION: DO NOT run a vehicle with foamy fluid for an extended period. This may cause pump damage.
9. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the proce-
dure.
19 - 52 PUMP ZH
REMOVAL

1. Remove the accessory drive belt (1). Refer to Page 7-45.

2. Remove the oil in the power steering reservoir (5).
3. Remove the power steering supply line (6) from the reservoir.
4. Remove the return hose from the power steering pump.
5. Remove the high-pressure hose (2) from the power steering pump.
6. Remove the power steering pump by removing the two bolts (3) attaching it to the engine block.
7. Remove the reservoir if necessary, by pressing out the c-clip (4) using a suitable tool.
ZH PUMP 19 - 53
INSTALLATION

1. Install the reservoir if it was removed, by inserting the c-clip using a suitable tool.
2. Install the power steering pump and bolts (3) to the engine block. Tighten to 20 N·m (15 ft. lbs.).
3. Install the high-pressure hose (2) on the pump.
4. Install the return hose on the pump.
5. Install the power steering supply line (6) to the reservoir.
6. Install the accessory drive belt (1). Refer to Page 7-46.
7. Fill the power steering pump reservoir and then bleed the system by performing the initial operation. Refer to
Page 19-51.
ZH TRANSMISSION 21 - 1
TRANSMISSION
TABLE OF CONTENTS
page page
NAG1 - ELECTRICAL DIAGNOSTICS . . . . . . . . . . 1 MANUAL - SERVICE INFORMATION . . . . . . . . . 342

AUTOMATIC - NAG1 SERVICE INFORMATION . 183
NAG1 - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
NAG1 - ELECTRICAL DIAGNOSTICS (P0702) INTERNAL CONTROLLER . . . . . . . . 76

DIAGNOSIS AND TESTING (P0702) INVALID CONTROL MODULE
(P0219) ENGINE OVERSPEED . . . . . . . . . . . . 3 VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
(P0562) SYSTEM UNDERVOLTAGE ........6 (P0702) SOLENOID SUPPLY/WATCHDOG . . . 80
(PO563) SYSTEM OVERVOLTAGE . . . . . . . . . 9 (P0710) TRANS TEMP SENSOR SHORTED . 83
(P0600) ABS BRAKE MESSAGE . . . . . . . . . . 12 (P0714) TRANS TEMP SENSOR ERRATIC . . 87
(P0600) ABS CAN MESSAGE INCORRECT . . 15 (P0715) INPUT SENSOR MISMATCH . . . . . . . 90
(P0600) ABS CAN MESSAGE MISSING . . . . . 18 (P0715) INPUT SENSOR OVERSPEED . . . . . 94
(P0600) ABS LEFT FRONT SENSOR (P0715) N2 INPUT SPEED SENSOR
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
(P0600) ABS LEFT REAR SENSOR (P0715) N3 INPUT SPEED SENSOR
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
(P0600) ABS RIGHT FRONT SENSOR (P0720) CAN BUS CIRCUIT . . . . . . . . . . . . . 109
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 (P0730) IMPROPER GEAR . . . . . . . . . . . . . 113
(P0600) ABS RIGHT REAR SENSOR (P0730) IMPROPER RATIO . . . . . . . . . . . . . 116
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 (P0740) TCC OVERTEMP . . . . . . . . . . . . . . 119
(P0600) ACCEL PEDAL SENSOR CAN (P0740) TCC STUCK ON . . . . . . . . . . . . . . . 121
MESSAGE INCORRECT . . . . . . . . . . . . . . . . 34 (P0743) TCC SOLENOID CIRCUIT . . . . . . . . 124
(P0600) CAN MESSAGE FROM ECM FROM (P0748) MODULATING PRESSURE
SLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 128
(P0600) ENGINE CAN MESSAGE (P0753) 1-2/4-5 SOLENOID CIRCUIT . . . . . . 132
INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . 41 (P0753) 1–2/4–5 SOLENOID CIRCUIT
(P0600) ENGINE CAN MESSAGE MISSING . . 44 SHORT TO GROUND . . . . . . . . . . . . . . . . . . 136
(P0600) ENGINE RPM MESSAGE . . . . . . . . . 48 (P0758) 2-3 SOLENOID CIRCUIT . . . . . . . . . 138
(P0600) ENGINE TEMPERATURE MESSAGE . 51 (P0758) 2–3 SOLENOID CIRCUIT SHORT
(P0600) ENGINE TORQUE MESSAGE TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . 142
INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . 54 (P0763) 3-4 SOLENOID CIRCUIT . . . . . . . . . 144
(P0600) IC CAN MESSAGE INCORRECT . . . 57 (P0763) 3–4 SOLENOID CIRCUIT SHORT
(P0600) IC/HVAC CAN MESSAGE MISSING . 60 TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . 148
(P0600) SLA CAN MESSAGE INCORRECT . . 64 (P0778) SHIFT PRESSURE SOLENOID
(P0700) SENSOR SUPPLY VOLTAGE . . . . . . 67 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
(P0700) TRANSMISSION SLIPPING . . . . . . . . 71 (P0778) SOLENOID SUPPLY VOLTAGE . . . . 154
(P0702) CONTROL MODULE TCM IS NOT (P0850) TRANS TEMP SENSOR - P/N
CODED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . 158
21 - 2 NAG1 - ELECTRICAL DIAGNOSTICS ZH
(P1793) ENGINE TORQUE REDUCTION . . . 163 RR WHEEL SPIN CAN MESSAGE NOT
CAN BUS CIRCUIT . . . . . . . . . . . . . . . . . . . 167 VALID . . . . . . . . . . . . . . . . . . . . . . . . . .... . 175
INCORRECT CAN MESSAGE FROM ABS . . 169 OVERVOLTAGE . . . . . . . . . . . . . . . . . .... . 177
INTERNAL CONTROLLER . . . . . . . . . . . . . . 171 UNDERVOLTAGE . . . . . . . . . . . . . . . . .... . 179
LR WHEEL SPIN CAN MESSAGE NOT TRANSMISSION VERIFICATION TEST ... . 181
VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 SCHEMATICS AND DIAGRAMS . . . . . . . .... . 182
NAG1 - ELECTRICAL DIAGNOSTICS

ZH NAG1 - ELECTRICAL DIAGNOSTICS 21 - 3
(P0219) ENGINE OVERSPEED
(P0219) ENGINE OVERSPEED — CONTINUED
• When Monitored: Valid Engine RPM message received at least once, the CAN Bus Circuit and Engine CAN
Message Missing are not active.
• Set Condition: If the engine speed increases above 5100 RPM.
POSSIBLE CAUSES
ENGINE - MECHANICAL PROBLEM

TRANSMISSION - MECHANICAL PROBLEM
For a complete Transmission Control Module Circuit Diagram Refer to Page 21-182.
Diagnostic Test

Note: Low fluid level can be the cause of many transmission prob-
lems. If the fluid level is low, locate and repair the leak then check
and adjust the fluid level in accordance with the Service Information.
Note: Always perform diagnostics with a fully charged battery to
avoid false symptoms.
With the DRB IIIT, read the engine DTCs. Check and repair all engine
DTCs prior to performing transmission symptom diagnostics.
With the DRB IIIT, read and record all Transmission DTCs.
Most DTCs set on start up but some must be set by driving the vehicle
such that all diagnostic monitors have run.
Note: Verify flash level of transmission controller. Some problems are
corrected by software upgrades to the transmission controller.
Perform this procedure prior to Symptom diagnosis.

Continue
Go To 2
2. ENGINE - MECHANICAL PROBLEM

Determine if any Engine Mechanical problems are present.
Are any Engine Mechanical problems present?

Yes >> Refer to the Engine - Service Information section for the
proper repair procedure.
No >> Go To 3
(P0219) ENGINE OVERSPEED — CONTINUED
3. TRANSMISSION - MECHANICAL PROBLEM
Determine if there are any Transmission Mechanical problems present.
Remove the Transmission Oil Pan and inspect for debris or a plugged
Transmission Oil Filter.
Is there any debris, plugged Transmission Oil Filter, or signs of an

internal transmission problem?
Yes >> Refer to the Transmission - Service Information for the
proper repair procedure.
No >> Go To 4
4. PCM - ENGINE OVERSPEED

Note: The Engine and Transmission must not have mechanical prob-
lems and be operating normally before proceeding with this test.
Replace and program the Powertrain Control Module. Refer to Page
8E-56
With the DRB IIIT, erase Transmission DTCs.
Road test the vehicle.
With the DRB IIIT, read Transmission DTCs.
Did DTC (P0219) ENGINE OVERSPEED set again?

Yes >> Replace the Transmission Control Module. Refer to Page
8E-60.
(P0562) SYSTEM UNDERVOLTAGE
(P0562) SYSTEM UNDERVOLTAGE — CONTINUED
• When Monitored: Always monitored with system active at each ignition cycle.
• Set Condition: System voltage falls below 8.5 volts with the engine RPM greater than 2000 RPM for 60
seconds.
POSSIBLE CAUSES
ENGINE CHARGING SYSTEM DTCS PRESENT

TRACTION SYSTEM RELAY OUTPUT VOLTAGE LOW
Diagnostic Test


Continue
Go To 2
(P0562) SYSTEM UNDERVOLTAGE — CONTINUED
2. ENGINE CHARGING SYSTEM DTCS PRESENT
With the DRB IIIT, read Engine DTCs.
Are any Engine Charging System DTCs present?

Yes >> Refer to the Engine - Electrical Diagnostics category and
perform the appropriate symptom.
No >> Go To 3
3. TRACTION SYSTEM RELAY OUTPUT VOLTAGE LOW AT TCM

Start the engine.
Increase the engine speed to 1500 RPM.
TCM C1 harness connector.

Yes >> Repair the Traction System Relay Output circuit for an
open.
Page 8E-60.
TEST.
(PO563) SYSTEM OVERVOLTAGE
(PO563) SYSTEM OVERVOLTAGE — CONTINUED
• Set Condition: System voltage above 16.9 volts with the engine and transmission input speed sensors
above 2000 RPM for 60 seconds.
POSSIBLE CAUSES
VEHICLE JUMP STARTED IMPROPERLY

TRACTION SYSTEM RELAY OUTPUT VOLTAGE HIGH
Diagnostic Test


Continue
Go To 2
2. VEHICLE JUMP STARTED IMPROPERLY

Determine if the vehicle was jump started improperly.
Note: If the battery was jump started with the batteries in series, the
System Overvoltage DTC will be set.
Was the vehicle jump started improperly?

Yes >> Erase the DTC if the vehicle was jump started improperly.
No >> Go To 3
(PO563) SYSTEM OVERVOLTAGE — CONTINUED
With the DRB IIIT, read the Engine DTCs.

No >> Go To 4
4. TRACTION SYSTEM RELAY OUTPUT VOLTAGE HIGH AT TCM

Start the engine.
Increase the engine speed to 1500 RPM.
Measure the voltage of the Traction System Relay Output circuit in the
TCM C1 harness connector.

8E-60.
No >> Refer to the Engine - Electrical Diagnostics category
and perform the appropriate symptom.
(P0600) ABS BRAKE MESSAGE
(P0600) ABS BRAKE MESSAGE — CONTINUED
• When Monitored: Valid ABS CAN Bus message received at least once and CAN Bus Circuit, ABS CAN
Message Missing, ABS CAN Message Incorrect are not active.
• Set Condition: Brake light switch signal not valid - CAB sending invalid value.
POSSIBLE CAUSES
CAN BUS CIRCUIT DTC PRESENT

ABS DTCS PRESENT
For a complete CAN BUS Circuit Diagram Refer to Page 8E-45.
Diagnostic Test


Continue
Go To 2
(P0600) ABS BRAKE MESSAGE — CONTINUED
2. (P0720) CAN BUS CIRCUIT DTC PRESENT
Is DTC (P0720) CAN BUS CIRCUIT present?

Yes >> Refer to the Transmission - Electrical Diagnostics category
No >> Go To 3
3. CHECK TO SEE IF ABS DTCS ARE PRESENT

With the DRB IIIT, read ABS DTCs.
Are any ABS or Bus related DTCs present?

Yes >> Refer to the Brakes - ABS Electrical Diagnostics category
No >> Go To 4
4. CAB - BRAKE MESSAGE ERROR

Replace the Controller Antilock Brake Module. Refer to Page 8E-63.
With the DRB IIIT, erase ABS DTCs.
Start the engine.
With the brakes firmly applied, shift the gear selector into drive.
Did DTC (P0600) ABS BRAKE MESSAGE set again?

8E-60.
(P0600) ABS CAN MESSAGE INCORRECT
(P0600) ABS CAN MESSAGE INCORRECT — CONTINUED
• When Monitored: ABS CAN messages received at least once and CAN Bus Circuit is not active.
• Set Condition: DTC Detected if the number of bytes incorrect for CAN ID.
POSSIBLE CAUSES
Diagnostic Test


Continue
Go To 2
(P0600) ABS CAN MESSAGE INCORRECT — CONTINUED
2. CAB - INTERNAL
Start the engine and with the brakes firmly applied place the gear selector
into Drive.
Did DTC (P0600) ABS CAN MESSAGE INCORRECT set again?

8E-60.
(P0600) ABS CAN MESSAGE MISSING
(P0600) ABS CAN MESSAGE MISSING — CONTINUED
• When Monitored: CAN Bus Circuit error not present, 1 second after ignition on and not in Park or Neutral,
no System Overvoltage or System Undervoltage conditions present, or transmission in Park or Neutral and
engine RPM greater than 850 RPM.
• Set Condition: This DTC is set when a CAN ID was not received in the required time are not being sent
from the CAB. NOTE: The CAB is powered by the run only ignition feed. This means that this DTC will be
set if the key is placed in the start position with the transmission in gear or if in Park or Neutral and the
engine RPM is greater than 850 RPM.
POSSIBLE CAUSES
VEHICLE STARTED IN GEAR

ABS DTCS PRESENT
CAN C BUS +/- CIRCUIT OPEN
Diagnostic Test


Continue
Go To 2
2. ABS DTC SET WHEN VEHICLE STARTED IN GEAR OTHER THAN
PARK OR NEUTRAL
Note: This DTC can be erroneously set if the vehicle was started in
gear or with the engine running.
With the DRB IIIT, erase this DTC.
Did DTC (P0600) ABS CAN MESSAGE MISSING set again?

Yes >> Go To 3
Note: If the ignition switch is moved to the RUN/START position with
the shift lever not in the Park or Neutral position or the RUN/START
position with the engine RPM >850, a (P0600) ABS CAN MESSAGE
MISSING DTC will set. Erase DTC and return to customer.

Note: If DTC (P0720) CAN BUS CIRCUIT is present, perform diagnos-
tics on that symptom first.

No >> Go To 4

Are any performance or bus related ABS DTCs present?

No >> Go To 5
5. CAN C BUS +/- CIRCUIT OPEN
ness connector to the TCM C3 harness connector.
connector to the TCM C3 harness connector.
Is the resistance above 5.0 ohms on either circuit?

Yes >> Repair the faulty CAN C Bus circuit for an open.
No >> Go To 6
6. CAB - BRAKE MESSAGE MISSING

Replace and program the Controller Antilock Brake Module. Refer to
Page 8E-63.
Start the engine.
Did DTC (P0600) ABS CAN MESSAGE MISSING set again?

8E-60.
(P0600) ABS LEFT FRONT SENSOR MESSAGE
(P0600) ABS LEFT FRONT SENSOR MESSAGE — CONTINUED
• When Monitored: Valid ABS CAN messages received at least once and the CAN Bus Circuit, ABS CAN
• Set Condition: Wheel Speed Front Left signal not valid or CAB has detected a sensor failure.
POSSIBLE CAUSES

ABS DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0600) ABS LEFT FRONT SENSOR MESSAGE — CONTINUED

No >> Go To 3

Are any ABS DTCs present?

No >> Go To 4
4. CONTROLLER ANTILOCK BRAKE MODULE

Did DTC (P0600) ABS LEFT FRONT SENSOR MESSAGE set again?
8E-60.
(P0600) ABS LEFT REAR SENSOR MESSAGE
(P0600) ABS LEFT REAR SENSOR MESSAGE — CONTINUED
• Set Condition: Wheel Speed Rear Left signal not valid or CAB has detected a sensor failure.
POSSIBLE CAUSES

ABS DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0600) ABS LEFT REAR SENSOR MESSAGE — CONTINUED

No >> Go To 3


No >> Go To 4

Did DTC (P0600) ABS LEFT REAR SENSOR MESSAGE set again?
8E-60.
(P0600) ABS RIGHT FRONT SENSOR MESSAGE
(P0600) ABS RIGHT FRONT SENSOR MESSAGE — CONTINUED
• Set Condition: Wheel Speed Front Right signal not valid or CAB has detected a sensor failure.
POSSIBLE CAUSES

ABS DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0600) ABS RIGHT FRONT SENSOR MESSAGE — CONTINUED

No >> Go To 3


No >> Go To 4

Did DTC (P0600) ABS RIGHT FRONT SENSOR MESSAGE set

again?
8E-60.
(P0600) ABS RIGHT REAR SENSOR MESSAGE
(P0600) ABS RIGHT REAR SENSOR MESSAGE — CONTINUED
• Set Condition: Wheel Speed Rear Right signal not valid or CAB has detected a sensor failure.
POSSIBLE CAUSES

ABS DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0600) ABS RIGHT REAR SENSOR MESSAGE — CONTINUED

No >> Go To 3


No >> Go To 4

Did DTC (P0600) ABS RIGHT REAR SENSOR MESSAGE set again?
8E-60.
(P0600) ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT
(P0600) ACCEL PEDAL SENSOR CAN MESSAGE INCORRECT — CONTINUED
• When Monitored: When a valid Accelerator Pedal Position Sensor (APPS) or Throttle Position Sensor (TPS)
CAN Message Received at least once and the DTCs, CAN Bus Circuit, Engine CAN Message Missing and
Engine CAN Message Incorrect are not active.
• Set Condition: Accelerator Pedal Position Sensor (APPS) or Throttle Position Sensor (TPS) Message not
valid or a PCM Engine Sensor DTC detected.
POSSIBLE CAUSES

ENGINE APP OR TPS DTCS PRESENT
ENGINE COMMUNICATION DTCS PRESENT
Diagnostic Test


Continue
Go To 2

No >> Go To 3

Note: If the TCM detects and stores a DTC, the TCM also stores the
active DTC.
With the DRB IIIT, erase TCM DTCs.
With the DRB IIIT, read the TCM DTCs.

Yes >> Go To 4
No >> Go To 7
4. CHECK TO SEE IF ENGINE COMMUNICATION DTCS ARE PRESENT

Are any Engine Bus related DTCs present?

No >> Go To 5
5. CHECK TO SEE IF ENGINE DTCS ARE PRESENT
Are any Engine APPS or TPS DTCs present?

No >> Go To 6
6. TCM - ENGINE TPS MESSAGE

Replace the Transmission Control Module. Refer to Page 8E-60.
Did DTC (P0600) ACCEL PEDAL SENSOR CAN MESSAGE INCOR-

RECT set again?
to Page 8E-56.

Using the schematics as a guide, inspect the wiring and connectors spe-
cific to this circuit.

(P0600) CAN MESSAGE FROM ECM FROM SLA
(P0600) CAN MESSAGE FROM ECM FROM SLA — CONTINUED
• When Monitored: SLA CAN-ID received at least once by the PCM and CAN Bus Circuit DTC is not active.
• Set Condition: CAN message received by the PCM from the Shift Lever Assembly is incorrect.
POSSIBLE CAUSES

SHIFT LEVER DTCS PRESENT
CAN C BUS CIRCUIT(S) OPEN
Diagnostic Test
1. PRE-DIAGNOSTIC CHECKOUT
lems. If the fluid level is low, locate and repair the leak, then check
Note: Check connectors – Clean/Repair as necessary. Poor pin to ter-
connectors.
Repair as necessary.
Most DTCs set on startup but some must be set by driving the vehicle
Note: Verify flash level of the transmission controller. Some problems
are corrected by software upgrades to the transmission controller.

Continue
Go To 2
(P0600) CAN MESSAGE FROM ECM FROM SLA — CONTINUED
2. CHECK TO SEE IF (P0720) CAN BUS CIRCUIT DTC PRESENT
Note: If the DTC, (P0720) CAN BUS CIRCUIT, is present, perform
diagnostics on that symptom first.
Is the DTC, (P0720) CAN BUS CIRCUIT, present?

No >> Go To 3
3. CHECK TO SEE IF SHIFT LEVER DTC PRESENT

With the DRB IIIT, read Shift Lever DTCs.
Are any Shift Lever DTCs present?

Yes >> Refer to the Shift Lever Assembly category in this section
No >> Go To 4
4. CAN C BUS (+) OR (-) CIRCUIT(S) OPEN

Disconnect the Shift Lever Assembly harness connector.
Measure the resistance between the CAN C Bus (+) circuit and the CAN
C Bus (-) circuit in the Shift Lever Assembly harness connector.
Is the resistance 60 ohms ± 3.0 ohms?

Yes >> Replace the Shift Lever Assembly. Refer to Page 21-340.
No >> Repair the faulty CAN C Bus circuit for an open.
TEST.
(P0600) ENGINE CAN MESSAGE INCORRECT
(P0600) ENGINE CAN MESSAGE INCORRECT — CONTINUED
• When Monitored: CAN-ID received at least once and CAN Bus Circuit is not active.
• Set Condition: DTC Detected if the number of bytes is incorrect for CAN ID.
POSSIBLE CAUSES
ENGINE DTCS PRESENT



Continue
Go To 2
(P0600) ENGINE CAN MESSAGE INCORRECT — CONTINUED
Are any performance or bus related Engine DTCs present?

No >> Go To 3
3. PCM - ENGINE CAN MESSAGE INCORRECT

8E-56.
Start the engine.
Did DTC (P0600) ENGINE CAN MESSAGE INCORRECT set again?

8E-60.
(P0600) ENGINE CAN MESSAGE MISSING
(P0600) ENGINE CAN MESSAGE MISSING — CONTINUED
• When Monitored: CAN Bus Circuit error not present 1 second after ignition on and not in Park or Neutral, no
System Overvoltage or System Undervoltage conditions present, or transmission in Park or Neutral and engine
RPM greater than 850 RPM.
• Set Condition: This DTC is set if a CAN ID was not received in the required time, from the Powertrain
Controller.
POSSIBLE CAUSES

ENGINE DTCS PRESENT
CAN C BUS +/- CIRCUIT OPEN
For a complete Transmission Control Module Circuit Diagram Refer to Page 8E-45.
For a complete CAN BUS Circuit Diagram Refer to Page 21-182.
Diagnostic Test


Continue
Go To 2

No >> Go To 3

Are any performance or bus related Engine DTCs present?

No >> Go To 4
4. CAN C BUS +/- CIRCUIT OPEN

harness connector to the TCM C3 harness connector.
Measure the resistance of the CAN C Bus (-) circuit from the PCM C4
Is the resistance above 5.0 ohms on either circuit?

Yes >> Repair the faulty CAN C Bus circuit for an open.
No >> Go To 5
5. PCM - ENGINE CAN MESSAGE MISSING
Reconnect the TCM C3 harness connector.
8E-56.
Start the engine.
With the brakes firmly applied, shift the gear selector into Drive.
Did DTC (P0600) ENGINE CAN MESSAGE MISSING set again?

Yes >> Replace the Transmission Control Module in accordance
with the Service Information. Refer to Page 8E-60.
(P0600) ENGINE RPM MESSAGE
(P0600) ENGINE RPM MESSAGE — CONTINUED
• When Monitored: Valid TPS CAN message received at least once and CAN Bus Circuit, Engine CAN Mes-
sage Missing and Engine CAN Message Incorrect are not active.
• Set Condition: Engine Speed signal not valid or PCM error.
POSSIBLE CAUSES

ENGINE DTCS PRESENT
Diagnostic Test

lems. If the fluid level is low locate and repair the leak then check
Note: Check for any Technical Service bulletins that may apply.

Continue
Go To 2
(P0600) ENGINE RPM MESSAGE — CONTINUED

No >> Go To 3

Are any performance or Bus related Engine DTCs present?

No >> Go To 4
4. PCM - ENGINE RPM MESSAGE

8E-56.
Start the engine.
Did DTC (P0600) ENGINE RPM MESSAGE set again?

8E-60.
(P0600) ENGINE TEMPERATURE MESSAGE
(P0600) ENGINE TEMPERATURE MESSAGE — CONTINUED
• When Monitored: Valid Engine Temperature CAN message received at least once and CAN Bus Circuit
error, Engine CAN Message Missing and Engine CAN Message Incorrect are not active.
• Set Condition: Engine coolant temperature signal is not valid - indicates possible coolant temperature
sensor error.
POSSIBLE CAUSES

ENGINE DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0600) ENGINE TEMPERATURE MESSAGE — CONTINUED

No >> Go To 3

Are any Engine Coolant Temperature Sensor DTCs present?

No >> Go To 4
4. PCM - ENGINE TEMP MESSAGE

8E-56.
Start the engine.
Did DTC (P0600) ENGINE TEMPERATURE MESSAGE set again?

8E-60.
(P0600) ENGINE TORQUE MESSAGE INCORRECT
(P0600) ENGINE TORQUE MESSAGE INCORRECT — CONTINUED
• When Monitored: Valid Torque CAN message received at least once and CAN Bus Circuit, Engine CAN
Message Missing and Engine CAN Message Incorrect are not active.
• Set Condition: Engine torque message not valid or Powertrain Control Module error.
POSSIBLE CAUSES
ENGINE DTCS PRESENT

Diagnostic Test


Continue
Go To 2
(P0600) ENGINE TORQUE MESSAGE INCORRECT — CONTINUED

No >> Go To 3
3. PCM - ENGINE TORQUE MESSAGE INCORRECT

8E-56.
Drive the vehicle performing multiple aggressive upshifts and downshifts.
Did DTC (P0600) ENGINE TORQUE MESSAGE INCORRECT set

again?
8E-60.
(P0600) IC CAN MESSAGE INCORRECT
(P0600) IC CAN MESSAGE INCORRECT — CONTINUED
• When Monitored: IC CAN-ID received at least once and CAN Bus Circuit DTC is not active.
• Set Condition: CAN message received from the Instrument Cluster is incorrect.
POSSIBLE CAUSES

INSTRUMENT CLUSTER DTCS PRESENT
CAN C BUS CIRCUIT OPEN
INSTRUMENT CLUSTER
Diagnostic Test

connectors.

Continue
Go To 2
(P0600) IC CAN MESSAGE INCORRECT — CONTINUED

No >> Go To 3
3. CHECK TO SEE IF INSTRUMENT CLUSTER DTC PRESENT

Are any Instrument Cluster DTCs present?

Yes >> Refer to the Instrument Cluster - Electrical Diagnostics cat-
egory and perform the appropriate symptom.
No >> Go To 4

C Bus (-) circuit in the Instrument Cluster C1 harness connector.

TEST.
(P0600) IC/HVAC CAN MESSAGE MISSING
(P0600) IC/HVAC CAN MESSAGE MISSING — CONTINUED
• When Monitored: IC CAN-ID received at least once and CAN Bus Circuit DTC is not active.
• Set Condition: CAN message received from the Instrument Cluster is missing or the IC reports over the
CAN C Bus an SCI Bus message missing from the A/C Heater Control Module.
POSSIBLE CAUSES

INSTRUMENT CLUSTER DTC PRESENT
A/C HEATER CONTROL MODULE DTC PRESENT
CAN C BUS CIRCUIT OPEN
SERIAL COMMUNICATION CIRCUIT OPEN
INSTRUMENT CLUSTER
Diagnostic Test

connectors.

Continue
Go To 2

No >> Go To 3
3. CHECK TO SEE IF INSTRUMENT CLUSTER DTC PRESENT

Are any Instrument Cluster DTCs present?

Yes >> Refer to the Instrument Cluster - Electrical Diagnostics cat-
egory and perform the appropriate symptom.
No >> Go To 4
4. CHECK TO SEE IF A/C HEATER CONTROL MODULE DTC

PRESENT

With the DRB IIIT, read A/C Heater Control Module DTCs.
Are any A/C Heater Control Module DTCs present?

Yes >> Refer to the Heating & Air Conditioning - Electrical Diagnos-
tics category and perform the appropriate symptom.
No >> Go To 5
C Bus (-) circuit in the Instrument Cluster C1 harness connector.

Yes >> Go To 6
TEST.
6. SERIAL COMMUNICATION K1 OR K2 CIRCUIT OPEN

Measure the resistance of the Serial Communication K1 and K2 circuits
from the Instrument Cluster C1 harness connector to the A/C Heater Con-
trol Module harness connector.
Is the resistance below 5 ohms for both circuits?

Yes >> Go To 7
No >> Repair the Serial Communication circuit(s) for an open.
TEST.
7. MODULE REPLACEMENT
Replace the A/C Heater Control Module. Refer to Page 24-79.

(P0600) SLA CAN MESSAGE INCORRECT
(P0600) SLA CAN MESSAGE INCORRECT — CONTINUED
• When Monitored: SLA CAN-ID received at least once and CAN Bus Circuit DTC is not active.
• Set Condition: CAN message received from the Shift Lever Assembly is incorrect.
POSSIBLE CAUSES

SHIFT LEVER ASSEMBLY DTCS PRESENT
CAN BUS CIRCUIT OPEN
Diagnostic Test

connectors.

Continue
Go To 2
(P0600) SLA CAN MESSAGE INCORRECT — CONTINUED

No >> Go To 3
3. CHECK TO SEE IF SHIFT LEVER DTC PRESENT

With the DRB IIIT, read Shift Lever Assembly DTCs.
Are any Shift Lever Assembly DTCs present?

Yes >> Refer to the Shift Lever Assembly category and perform the
appropriate symptom.
No >> Go To 4

Measure the resistance from the CAN C Bus (+) circuit to the CAN C Bus
(-) circuit at the Shift Lever Assembly harness connector.

TEST.
(P0700) SENSOR SUPPLY VOLTAGE
(P0700) SENSOR SUPPLY VOLTAGE — CONTINUED
• When Monitored: Always monitored with system active at each ignition cycle and no undervoltage condition
exists.
• Set Condition: If measured sensor voltage is not within specified limits 4.8-7.2 volts or if a failed regulator,
Sensor Supply Voltage circuit shorted to ground, Sensor Supply Voltage circuit shorted to voltage is
detected.
POSSIBLE CAUSES
SENSOR SUPPLY VOLTAGE CIRCUIT SHORTED TO ANOTHER CIRCUIT

SENSOR SUPPLY VOLTAGE CIRCUIT SHORTED TO GROUND
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 5
3. SENSOR SUPPLY VOLTAGE CIRCUIT SHORT TO OTHER CIRCUITS

Disconnect the Transmission Solenoid Assembly harness connector.
Measure the resistance from the Sensor Supply Voltage circuit to all other
circuits in the Transmission Solenoid harness connector.
Is the resistance below 100 kohms between any other circuit?

Yes >> Repair the Sensor Supply Voltage circuit for a short to other
circuit(s).
No >> Go To 4
4. SENSOR SUPPLY VOLTAGE CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the Sensor Supply Voltage
circuit at the Transmission Solenoid Assembly harness connector.

Yes >> Repair the Sensor Supply Voltage circuit for a short to
ground.
Page 8E-60.
TEST.

Yes >> Repair as necessary
(P0700) TRANSMISSION SLIPPING
(P0700) TRANSMISSION SLIPPING — CONTINUED
• When Monitored: Engine RPM greater than 450 RPM, output speed greater than 180 RPM, no N2 - N3
input speed sensor errors present, no gear selector lever errors present, no ABS system errors, and all wheel
speeds between 70 - 380 RPM with no wheel slip detected.
• Set Condition: Calculated ratio not within allowable range for the engaged gear. No shifting operation.
The TCM constantly calculates the transmission ratio based on the N2 - N3 input speed signals and the
calculated output shaft speed (CAN message from the ABS). The TCM will detect if the transmission is
slipping or an invalid gear ratio is present.
POSSIBLE CAUSES
OTHER DTCS PRESENT

AXLE - MECHANICAL - GEAR RATIO
INTERNAL TRANSMISSION
Diagnostic Test

lems. If the fluid level is low locate and repair the leak then check
Note: Check for any Technical Service Bulletin that may apply.

Continue
Go To 2
(P0700) TRANSMISSION SLIPPING — CONTINUED
2. OTHER DTCS PRESENT
Are any Improper Gear and/or Improper Ratio DTCs present?

No >> Go To 3
3. AXLE - MECHANICAL - GEAR RATIO

Verify the correct axle gear ratio and make sure there are no mechanical
problems. Refer to the Differential & Driveline category for the proper pro-
cedures.

Yes >> Refer to the Differential & Driveline category for proper
repair procedures.
No >> Go To 4
4. INTERNAL TRANSMISSION
Determine if the Transmission is mechanically slipping.
Is the transmission slipping?

Yes >> Repair internal transmission as necessary. Refer to the Ser-
vice Information for the proper repair procedure.
Page 8E-60.
TEST.
(P0702) CONTROL MODULE TCM IS NOT CODED
(P0702) CONTROL MODULE TCM IS NOT CODED — CONTINUED
• Set Condition: The TCM has not been flashed.
POSSIBLE CAUSES
TRANSMISSION CONTROL MODULE NOT FLASHED
Diagnostic Test
1. TRANSMISSION CONTROL MODULE NOT FLASHED

View repair.
Repair >> Flash the Transmission Control Module to the proper level.
(P0702) INTERNAL CONTROLLER
(P0702) INTERNAL CONTROLLER — CONTINUED
• Set Condition: This code is set whenever Transmission Control Module (TCM) senses an internal error. If
the Internal Controller DTC is set with any Solenoid DTCs, repair the Solenoid DTCs first, erase all DTCs,
then verify the Internal Controller DTC sets again before replacing the TCM.
POSSIBLE CAUSES
Diagnostic Test
1. TRANSMISSION CONTROL MODULE

The Transmission Control Module is reporting internal errors and must be
replaced.
View repair.
Repair >> Replace the Transmission Control Module. Refer to Page
8E-60.
(P0702) INVALID CONTROL MODULE VERSION
(P0702) INVALID CONTROL MODULE VERSION — CONTINUED
• Set Condition: The TCM is not the correct one for the vehicle or has not been flashed properly.
POSSIBLE CAUSES
Diagnostic Test

connectors.

Continue
Go To 2
2. VALIDATE PART NUMBER AND FLASH

Validate if the TCM part number and flash is correct for the vehicle.
Is the TCM part number and flash correct for the vehicle?
8E-60.
No >> Flash the controller as applicable. If the controller has
the wrong part number or cannot be flashed, replace
the Transmission Control Module. Refer to Page
8E-60.
TEST.
(P0702) SOLENOID SUPPLY/WATCHDOG
(P0702) SOLENOID SUPPLY/WATCHDOG — CONTINUED
• Set Condition: During the power up of the TCM, it tests the ability of the external watchdog to shut down
the Solenoid Supply Voltage driver.
POSSIBLE CAUSES
SOLENOID DTCS PRESENT

SOLENOID SUPPLY CIRCUIT SHORTED TO ANOTHER CIRCUIT
Diagnostic Test


Continue
Go To 2
(P0702) SOLENOID SUPPLY/WATCHDOG — CONTINUED
2. SOLENOID DTCS PRESENT
Are any Solenoid DTCs present?

Yes >> Repair all Solenoid DTCs before proceeding with test.
No >> Go To 3
3. SOLENOID SUPPLY VOLTAGE CIRCUIT SHORTED TO ANOTHER

CIRCUIT

Check the resistance from the Solenoid Supply Voltage circuit to all other
circuits at the Transmission Solenoid Assembly harness connector.
Is the resistance below 100 kohms between the Solenoid Supply

Voltage circuit and any other circuit?
Yes >> Repair the Solenoid Supply Voltage circuit for a short to
another circuit.
Page 8E-60
TEST.
(P0710) TRANS TEMP SENSOR SHORTED
(P0710) TRANS TEMP SENSOR SHORTED — CONTINUED
• When Monitored: Always monitored with system active.
• Set Condition: Temperature sensor input below a threshold, failed temperature sensor, short to ground,
TCM.
POSSIBLE CAUSES
TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO GROUND

TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO OTHER CIRCUITS
TRANSMISSION TEMP SENSOR - P/N SWITCH
Diagnostic Test


Continue
Go To 2
2. CHECK TO SEE IF ENGINE STARTS

Attempt to start the engine in Park and Neutral.
Does the engine start in either position, Park or Neutral?

Yes >> Go To 3
No >> Go To 4
3. TRANSMISSION TEMPERATURE SENSOR
Place the gear selector in Drive.
Measure the resistance of the Transmission Temperature Sensor from the
Temp Sensor - P/N Switch circuit to the Sensor Ground circuit at the TCM
Is the resistance between 500 ohms and 2500 ohms?

8E-60.
No >> Check for a poor terminal to pin connections at the
Transmission Solenoid Assembly harness connector
and repair as necessary. If no problems are found in
the connector, replace the Transmission Temperature
Sensor - P/N Switch. Refer to Page 21-281.
TEST.
4. TRANSMISSION TEMP SENSOR - P/N SWITCH

Note: This procedure may set several DTCs in both the PCM and
TCM. Disregard and erase DTCs after this procedure.
With the gear selector in park, attempt to start the engine.
Does the engine start?

Yes >> Replace the Transmission Temperature Sensor - P/N Switch
Assembly. Refer to Page 21-281.
No >> Go To 5
5. TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the Temp Sensor - P/N
Switch circuit.

Yes >> Repair the Temp Sensor - P/N Switch circuit for a short to
ground.
No >> Go To 6
6. TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO OTHER
CIRCUITS

Measure the resistance from the Temp Sensor - P/N Switch circuit to all
other circuits in the TCM C1 and C2 harness connectors.

other circuit(s).
Page 8E-60.
TEST.
(P0714) TRANS TEMP SENSOR ERRATIC
(P0714) TRANS TEMP SENSOR ERRATIC — CONTINUED
• When Monitored: When transmission temperature is below 170°C (338°F).
• Set Condition: When there is a 10°C (18°F) variation between each transmission temperature sensor
read. If the DTC is reset (after an ignition cycle), the DTC will be set to Stored (Intermittent) status.
POSSIBLE CAUSES
TRANSMISSION TEMP SENSOR CIRCUITS
Diagnostic Test


Continue
Go To 2
2. TRANSMISSION TEMP SENSOR CIRCUITS

With the DRB IIIT, monitor the Transmission Temperature.
With the brakes firmly applied, place the gear selector in Drive.
While monitoring the DRB IIIT, wiggle the wires and connectors from the
TCM to the Transmission Solenoid Assembly.
Did the transmission temperature fluctuate while wiggling the

wires?
Yes >> Repair the wiring and/or connectors as necessary.
No >> Go To 3
(P0714) TRANS TEMP SENSOR ERRATIC — CONTINUED
3. TRANS TEMP SENSOR - PARK NEUTRAL SWITCH
Replace the Transmission Temp Sensor - P/N Switch. Refer to Page
21-281.
Did DTC (P0714) TRANS TEMP SENSOR ERRATIC set again?

8E-60.
(P0715) INPUT SENSOR MISMATCH
(P0715) INPUT SENSOR MISMATCH — CONTINUED
• When Monitored: Engine speed greater than 450 RPM, no engine speed DTCs, no TCM undervoltage sys-
tem operation, no output speed sensor DTCs (signal from the ABS system), all wheel speeds above 250 RPM
(signal from the ABS system), no rear wheel speed DTCs (signal from the ABS system), and no wheel slip
detected (signal from the ABS system), no shifting operation, N3 input speed sensor greater than 800 RPM
and N2 input speed sensor greater than 0 RPM and the TCM not in reset.
• Set Condition: If the speed difference between the N2 and N3 input speed sensors is greater than 150
RPM.
POSSIBLE CAUSES
SPEED SENSOR DTCS PRESENT

Diagnostic Test


Continue
Go To 2
2. SPEED SENSOR DTCS PRESENT
Are any Speed Sensor or Sensor Supply DTCs present?

Yes >> Repair any Speed Sensor and/or Sensor Supply DTCs
before proceeding with test.
No >> Go To 3
3. CHECK TO SEE IF INPUT SENSOR MISMATCH IS CURRENT

Start the engine.
Drive the vehicle at speeds to allow multiple 2-3 and 3-4 upshifts.
Did DTC (P0715) INPUT SENSOR MISMATCH set again?

Yes >> Go To 4
No >> Go To 5
Is there any debris, plugged Transmission Oil Filter, or sign of an

Yes >> Repair the internal transmission as necessary. Refer to the
Transmission - Service Information for proper repair proce-
dures.
Page 8E-60.
TEST.

(P0715) INPUT SENSOR OVERSPEED
(P0715) INPUT SENSOR OVERSPEED — CONTINUED
• When Monitored: Whenever the N2 input speed sensor is greater than 0 RPM.
• Set Condition: If the RPM of the N2 or N3 input speed sensor is greater than 7700 RPM.
POSSIBLE CAUSES
Diagnostic Test


Continue
Go To 2
(P0715) INPUT SENSOR OVERSPEED — CONTINUED
2. CHECK TO SEE IF INPUT SENSOR OVERSPEED IS CURRENT
Raise the vehicle on the hoist.
Start the engine.
Note: This DTC indicates a catastrophic transmission failure.
With the DRB IIIT in Sensors, monitor the N2 and N3 Speed Sensors.
Firmly apply the brakes and place the gear selector in Drive.
Release the brakes and raise the engine RPM to allow the transmission to
upshift to the 2-3 and 3-4 shift schedule.
WARNING: BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTAT-
ING WHEELS.
Did either the N2 or N3 Speed Sensors display an RPM above

7700?
Yes >> Go To 3
No >> Go To 4

Transmission - Service Information for proper repair proce-
dures.
Page 8E-60.
TEST.


(P0715) N2 INPUT SPEED SENSOR CIRCUIT
(P0715) N2 INPUT SPEED SENSOR CIRCUIT — CONTINUED
detected (signal from the ABS system).
• Set Condition: If the N2 input speed sensor signal is equal to 0 RPM, signal circuit shorted to ground,
shorted to battery, an open input speed sensor, a faulty input speed sensor, or an open sensor supply cir-
cuit.
POSSIBLE CAUSES
SENSOR SUPPLY VOLTAGE CIRCUIT OPEN

N2 INPUT SPEED SENSOR SIGNAL CIRCUIT OPEN
N2 SPEED SENSOR SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
SENSOR GROUND CIRCUIT SHORTED TO OTHER CIRCUIT
N2 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
N2 INPUT SPEED SENSOR
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 11
3. SENSOR SUPPLY VOLTAGE CIRCUIT OPEN

Measure the resistance of the Sensor Supply Voltage circuit from the TCM
C2 harness connector to the Transmission Solenoid Assembly harness
connector.

Yes >> Go To 4
No >> Repair the Sensor Supply Voltage circuit for an open.
4. N2 INPUT SPEED SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the N2 Input Speed Sensor Signal circuit from
the TCM C2 harness connector to the Transmission Solenoid Assembly
harness connector.

Yes >> Go To 5
No >> Repair the N2 Input Speed Sensor Signal circuit for an
open.
Measure the resistance of the Sensor Ground circuit from the TCM C2
harness connector to the Transmission Solenoid Assembly harness con-
nector.

Yes >> Go To 6
6. N2 SPEED SENSOR SIGNAL CIRCUIT SHORT TO OTHER CIRCUITS

Measure the resistance from the N2 Speed Sensor Signal circuit to all
other circuits in the Transmission Solenoid Assembly harness connector.

Yes >> Repair the N2 Speed Sensor Signal circuit for a short to
other circuit(s).
No >> Go To 7
7. N2 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the N2 Input Speed Sensor
Signal circuit.

Yes >> Repair the N2 Input Speed Sensor Signal circuit for a short
to ground.
No >> Go To 8
8. SENSOR GROUND CIRCUIT SHORT TO OTHER CIRCUITS
Measure the resistance from the Sensor Ground circuit to all other circuits
in the Transmission Solenoid Assembly harness connector.

Yes >> Repair the Sensor Ground circuit for a short to other cir-
cuit(s).
No >> Go To 9
9. SENSOR GROUND CIRCUIT SHORT TO GROUND


No >> Go To 10
10. CHECKING N2 INPUT SPEED SENSOR W/ LAB SCOPE
Reconnect the Transmission Solenoid Assembly harness connector.
with Special Tool #6801, backprobe N2 Input Speed Sensor Signal circuit
using Channel 1 at the TCM C2 harness connector.
WARNING: PROPERLY SUPPORT VEHICLE.
Raise all drive wheels off the ground.
Start the engine.
ING WHEELS.
Place gear selector in drive and increase vehicle speed to engage 2nd
gear.
Compare the scope pattern on the DRB IIIT with a typical 5 volt square
wave pattern.
Does the scope pattern match a typical 5 volt square wave signal
scope pattern?
8E-60.
No >> Replace the N2 Input Speed Sensor. Refer to Page
21-281.
TEST.


(P0715) N3 INPUT SPEED SENSOR CIRCUIT
detected (signal from the ABS system), no shifting operation, detected gear is 3rd or 4th and the detected gear
is the actual vehicle gear.
• Set Condition: If the N3 input speed sensor signal is equal to 0 RPM, short signal circuit to ground,
shorted to battery, an open input speed sensor, a faulty input speed sensor, or an open sensor supply cir-
cuit.
POSSIBLE CAUSES
SENSOR SUPPLY VOLTAGE CIRCUIT OPEN

N3 INPUT SPEED SENSOR SIGNAL CIRCUIT OPEN
N3 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
N3 SPEED SENSOR SIGNAL CIRCUIT SHORTED TO ANOTHER CIRCUIT
SENSOR GROUND CIRCUIT SHORTED TO ANOTHER CIRCUIT
N3 INPUT SPEED SENSOR
For a complete Transmission Control Module Circuit Diagram, Refer to Page 21-182.
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 11
3. SENSOR SUPPLY VOLTAGE CIRCUIT OPEN

Measure the resistance of the Sensor Supply Voltage circuit from the TCM
connector.

Yes >> Go To 4
No >> Repair the Sensor Supply Voltage circuit for an open.
4. N3 INPUT SPEED SENSOR SIGNAL CIRCUIT OPEN

Measure the resistance of the N3 Input Speed Sensor Signal circuit from
harness connector.

Yes >> Go To 5
No >> Repair the N3 Input Speed Sensor Signal circuit for an
open.
nector.

Yes >> Go To 6
6. N3 SPEED SENSOR SIGNAL CIRCUIT SHORT TO OTHER CIRCUITS

Measure the resistance from the N3 Speed Sensor Signal circuit to all

Yes >> Repair the N3 Speed Sensor Signal circuit for a short to
other circuit(s).
No >> Go To 7
7. N3 INPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the N3 Input Speed Sensor
Signal circuit.

Yes >> Repair the N3 Input Speed Sensor Signal circuit for a short
to ground.
No >> Go To 8
in the Transmission Solenoid harness connector.

cuits.
No >> Go To 9
9. SENSOR GROUND CIRCUIT SHORT TO GROUND


No >> Go To 10
10. CHECKING N3 INPUT SPEED SENSOR W/ LAB SCOPE
with Miller special tool #6801, backprobe N3 Input Speed Sensor Signal
circuit using Channel 1 at the TCM C2 harness connector.
WARNING: PROPERLY SUPPORT THE VEHICLE.
Raise all drive wheels off the ground.
Start the engine.
ING WHEELS.
Place gear selector in drive and increase vehicle speed to engage 2nd
gear.
Compare the scope pattern on the DRB IIIT with a typical 5 volt square
wave pattern.
Does the scope pattern match a typical 5 volt square wave signal
scope pattern?
8E-60.
No >> Replace the N3 Input Speed Sensor. Refer to Page
21-281.
TEST.


(P0720) CAN BUS CIRCUIT
(P0720) CAN BUS CIRCUIT — CONTINUED
• Set Condition: Open circuit in the CAN C Bus (+) circuit or CAN C Bus (-) circuit, short to ground of CAN
C Bus (+) circuit or CAN C Bus (-) circuit, short to voltage of CAN C Bus (+) circuit or CAN C Bus (-) circuit,
CAN C Bus (+) circuit shorted to CAN C Bus (-) circuit, or a TCM failure. Note: All CAN message missing
DTCs will also be present, which indicates a complete Bus failure.
POSSIBLE CAUSES
CAN C BUS(+) SHORTED TO CAN C BUS (-)

CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT OPEN
CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT SHORTED TO GROUND
CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT SHORTED TO ANOTHER CIRCUIT
Diagnostic Test


Continue
Go To 2
2. CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT OPEN
Note: If the CAN BUS CIRCUIT DTC is present, all the CAN MESSAGE
MISSING DTCs will be set also. Ignore the Missing Message DTCs
and perform the CAN BUS CIRCUIT DTC test.
Measure the resistance of both the CAN C Bus (+) circuit and the CAN C
Bus (-) circuit from the TCM C3 harness connector and to both the PCM
harness connector and to the CAB harness connector.
Is the resistance of both Bus circuits below 5.0 ohms?

Yes >> Go To 3
3. CAN C BUS (+) SHORT TO CAN C BUS (-)

(-) circuit.

Yes >> Repair the CAN C Bus (+) circuit for a short to the CAN C
Bus (-) circuit.
No >> Go To 4
4. CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT SHORT TO

GROUND

Measure the resistance between ground and both the CAN C Bus (+) cir-
cuit and the CAN C Bus (-) circuit.
Is the resistance below 5.0 ohms on either Bus circuit?

Yes >> Repair the faulty CAN C Bus circuit for a short to ground.
No >> Go To 5
5. CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT SHORTED TO
ANOTHER CIRCUIT

Measure the resistance from both the CAN C Bus (+) circuit and the CAN
C Bus (-) circuit to all other circuits in the TCM C3 and C2 harness con-
nector.
Is the resistance below 5.0 ohms between any other circuit?

Yes >> Repair the CAN C Bus (+) and/or CAN C Bus (-) circuit for
a short to other circuits.
No >> Go To 6
6. PCM - CAN BUS CIRCUIT

(-) circuit at the PCM harness connector.
Is the resistance 60.0 ohms, ± 3.0 ohms?

to Page 8E-56.
No >> Go To 7
7. CAB - TERMINATING RESISTOR

Reconnect the PCM harness connector.
(-) circuit at the CAB harness connector.
Is the resistance 120 ohms, ± 2.0 ohms?

Yes >> Replace the Controller Antilock Brake Module. Refer to
Page 8E-63.
Page 8E-60.
TEST.
(P0730) IMPROPER GEAR
(P0730) IMPROPER GEAR — CONTINUED
• When Monitored: Engine RPM greater than 450 and output speed (ABS) greater than 180 RPM. No Input
Speed sensor N2 - N3, Shift lever, and/or ABS wheel speed DTCs present.
• Set Condition: The TCM compares the calculated gear with the gear the transmission has actually
engaged. If the actual gear differs from the gear calculated by the TCM, the TCM value is adjusted to the
engaged gear and a counter is increased by 2. If after a shift the engaged gear and the calculated gear still
match, the counter is decreased by 1 point. A DTC is detected as soon as the counter exceeds a threshold.
If the fault is detected 3 consecutive ignition cycles, the transmission will be placed in Limp-in and the MIL
activated.
POSSIBLE CAUSES
ABS DTCS PRESENT

SOLENOID DTCS PRESENT
Diagnostic Test


Continue
Go To 2
(P0730) IMPROPER GEAR — CONTINUED
2. SOLENOID DTCS PRESENT
Are any Transmission Solenoid DTCs present?

No >> Go To 3
3. ABS DTCS PRESENT


No >> Go To 4
Remove and inspect the Transmission Valve Body and Solenoid Assembly
in accordance with the Service Information.
Note: This DTC is usually set due to an internal transmission prob-
lem such as but not limited to: stuck solenoid, valve and/or contam-
ination in the valve body, broken springs, leaking clutch seals,
dislodged or broken snap ring.
Inspect the internal transmission in accordance with the Service Informa-
tion.
Where any problems found?

Transmission - Service Information for the proper repair
procedure.
Page 8E-60.
TEST.
(P0730) IMPROPER RATIO
(P0730) IMPROPER RATIO — CONTINUED
• When Monitored: Engine RPM greater than 450 RPM, output speed greater than 180 RPM, no N2 - N3
input speed sensor errors present, no gear selector lever errors present, no ABS system errors, and all wheel
speeds above 450 RPM.
• Set Condition: No shifting operation and detected gear is not the actual gear. No shifting operation -
detected (calculated) gear is less than actual (expected) gear, no plausible gear is calculated, actual turbine
speed - calculated turbine speed >300 RPM or calculated transmission ratio is above threshold. During an
Upshift - detected (calculated) gear is less than actual (expected) gear-1. During Downshift - detected (cal-
culated) gear is less than actual (expected) gear.
POSSIBLE CAUSES
Diagnostic Test


Continue
Go To 2
(P0730) IMPROPER RATIO — CONTINUED
2. TRANSMISSION MECHANICAL PROBLEM
Determine if there are any Transmission Mechanical problems present.
Refer to the Service Information for proper removal and inspection proce-
dures.

Yes >> Refer to the Transmission - Service Information for the
proper repair procedure. Pay particular attention to the
valve body components and stuck solenoids.
Page 8E-60.
TEST.
(P0740) TCC OVERTEMP
(P0740) TCC OVERTEMP — CONTINUED
• When Monitored: Solenoid supply active. No Input Speed Sensor N2 - N3, CAN Bus, PCM, CAN Engine,
CAN Engine Speed DTCs present. Torque Converter Clutch in slip mode.
• Set Condition: Friction loss factor reaches threshold.
POSSIBLE CAUSES
Diagnostic Test


Continue
Go To 2
This DTC is an informational DTC.
Check for any Technical Service Bulletins or Controller updates that may
apply.
This is usually a sign of TCC failure or internal transmission problems.
Check the Engine and Transmission Cooling Systems for proper opera-
tion.
View repair.
Repair >> Repair internal Transmission as necessary. Refer to the
Service Information for proper repair procedure.
(P0740) TCC STUCK ON
(P0740) TCC STUCK ON — CONTINUED
• When Monitored: No Input Speed Sensor N2 - N3, CAN Bus Circuit, PCM, CAN Engine, No CAN Engine
Torque and/or Shift in progress DTCs present. Must be in a valid forward gear.
• Set Condition: Engine RPM (turbine speed) is greater than 30 RPM when the engine torque is less than
100 N·m for 1.0 second.
POSSIBLE CAUSES
TCC SOLENOID CONTROL CIRCUIT SHORTED TO GROUND

TCC SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
Diagnostic Test


Continue
Go To 2
(P0740) TCC STUCK ON — CONTINUED
Start the engine.
With the brakes firmly applied, shift the gear selector into Drive.
Did the engine stall or stumble?

Yes >> Repair the internal transmission. Pay particular attention to
the components related to the TCC. Refer to the Transmis-
sion - Service Information for the proper repair procedure.
No >> Go To 3
3. TCC SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the TCC Solenoid Control
circuit.

Yes >> Repair the TCC Solenoid Control circuit for a short to
ground.
No >> Go To 4
4. TCC SOLENOID CONTROL CIRCUIT SHORT TO OTHER CIRCUITS

Measure the resistance from the TCC Solenoid Control circuit to all other
Is the resistance below 100 kohms on any circuit?

Yes >> Repair the TCC Solenoid Control circuit for a short to other
circuit(s).
Page 8E-60.
TEST.
(P0743) TCC SOLENOID CIRCUIT
(P0743) TCC SOLENOID CIRCUIT — CONTINUED
• Set Condition: If the TCM detects a short to ground or battery on the solenoid control circuit, shorted
solenoid, open solenoid, or an open or shorted solenoid control circuit driver in the TCM.
POSSIBLE CAUSES
TCC SOLENOID CONTROL CIRCUIT OPEN

TCC SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
TCC SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
TCC SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. TCC SOLENOID CONTROL CIRCUIT OPEN

Disconnect the Transmission Control Module C2 harness connector.
Disconnect the Transmission Solenoid Assembly harness connector
Measure the resistance of the TCC Solenoid Control circuit from the TCM
connector.

Yes >> Go To 4
No >> Repair the TCC Solenoid Control circuit for an open.
4. TCC SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the TCC Solenoid Control
circuit.

Yes >> Repair the TCC Solenoid Control circuit for a short to
ground.
No >> Go To 5
5. TCC SOLENOID CONTROL CIRCUIT SHORT TO OTHER CIRCUITS
Measure the resistance from the TCC Solenoid Control circuit to all other

Yes >> Repair the TCC Solenoid Control circuit for a short to other
circuit(s).
No >> Go To 6
6. TCC SOLENOID RESISTANCE OUT OF TOLERANCE

Measure the resistance from the TCC Solenoid Control circuit to the Sole-
noid Supply Voltage circuit at the Transmission Control Module C2 har-
ness connector.
Is the resistance between 2.0 and 4.0 ohms?

8E-60.
No >> Replace the TCC Solenoid. Refer to Page 21-281.
TEST.

Note: Check for Technical Service Bulletins that may apply.

(P0748) MODULATING PRESSURE SOLENOID CIRCUIT
(P0748) MODULATING PRESSURE SOLENOID CIRCUIT — CONTINUED
• Set Condition: If the TCM detects a short to ground, a short to voltage on the solenoid control circuit, a
shorted solenoid, an open solenoid, or an open or shorted solenoid control circuit driver in the TCM.
POSSIBLE CAUSES
MODULATING PRESSURE SOLENOID CONTROL CIRCUIT OPEN

MODULATING PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
MODULATING PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
MODULATING PRESSURE SOLENOID
Diagnostic Test

and adjust the fluid level in accordance with the service information.

Continue
Go to 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. MODULATING PRESSURE SOLENOID CONTROL CIRCUIT OPEN

Measure the resistance of the Modulating Pressure Solenoid Control cir-
cuit from the TCM C2 harness connector to the Transmission Solenoid
Assembly harness connector.

Yes >> Go To 4
No >> Repair the Modulating Pressure Solenoid Control circuit for
an open.
4. MODULATING PRESSURE SOLENOID CONTROL CIRCUIT SHORT

TO GROUND

Measure the resistance between ground and the Modulating Pressure
Solenoid Control circuit.

Yes >> Repair the Modulating Pressure Solenoid Control circuit for
a short to ground.
No >> Go To 5
5. MODULATING PRESSURE SOLENOID CONTROL CIRCUIT SHORT
TO OTHER CIRCUITS

Measure the resistance from the Modulating Pressure Solenoid Control
circuit to all other circuits in the Transmission Solenoid Assembly harness
connector.

Yes >> Repair the Modulating Pressure Solenoid Control circuit for
a short to other circuits.
No >> Go To 6
6. MODULATING PRESSURE SOLENOID RESISTANCE OUT OF

TOLERANCE

Measure the resistance from the Modulating Pressure Solenoid Control
circuit to the Solenoid Supply Voltage circuit at the Transmission Control
Module C2 harness connector.

8E-60.
No >> Replace the Modulating Pressure Solenoid. Refer to
Page 21-281.
TEST.


Yes >> Repair as necessary
(P0753) 1-2/4-5 SOLENOID CIRCUIT
(P0753) 1-2/4-5 SOLENOID CIRCUIT — CONTINUED
• Set Condition: If the TCM detects a short to battery on the solenoid control circuit, shorted solenoid, open
solenoid, or an open or shorted solenoid control circuit in the TCM.
POSSIBLE CAUSES
1-2/4-5 SOLENOID CONTROL CIRCUIT OPEN

1-2/4-5 SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
1-2/4-5 SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
1-2/4-5 SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. 1-2/4-5 SOLENOID CONTROL CIRCUIT OPEN

Measure the resistance of the 1-2/4-5 Solenoid Control circuit from the
TCM harness connector to the Transmission Solenoid Assembly harness
connector.

Yes >> Go To 4
No >> Repair the 1-2/4-5 Solenoid Control circuit for an open.
4. Test 1-2/4-5 SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the 1-2/4-5 Solenoid Control
circuit.

Yes >> Repair the 1-2/4-5 Solenoid Control circuit for a short to
ground.
No >> Go To 5
5. 1-2/4-5 SOLENOID CONTROL CIRCUIT SHORT TO OTHER
CIRCUITS

Measure the resistance from the 1-2/4-5 Solenoid Control circuit to all

Yes >> Repair the 1-2/4-5 Solenoid Control circuit for a short to
other circuit(s).
No >> Go To 6
6. 1-2/4-5 SOLENOID RESISTANCE OUT OF TOLERANCE

Measure the resistance from the 1-2/4-5 Solenoid Control circuit to the
Solenoid Supply Voltage circuit at the Transmission Control Module C2
harness connector.

8E-60.
No >> Replace the 1-2/4-5 Solenoid. Refer to Page 21-281.
TEST.


(P0753) 1–2/4–5 SOLENOID CIRCUIT SHORT TO GROUND
(P0753) 1–2/4–5 SOLENOID CIRCUIT SHORT TO GROUND — CONTINUED
• Set Condition: If the TCM detects a short to ground on the solenoid control circuit or solenoid control
circuit shorted to ground in the TCM.
POSSIBLE CAUSES
1-2/4-5 SOLENOID CONTROL CIRCUIT SHORTED TO GROUND

1-2/4-5 SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
1-2/4-5 SOLENOID
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0753) 1–2/
4–5 SOLENOID CIRCUIT.
No >> Go To 2


(P0758) 2-3 SOLENOID CIRCUIT
(P0758) 2-3 SOLENOID CIRCUIT — CONTINUED
POSSIBLE CAUSES
2-3 SOLENOID CONTROL CIRCUIT OPEN

2-3 SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
2-3 SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
2-3 SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. 2-3 SOLENOID CONTROL CIRCUIT OPEN

Measure the resistance of the 2-3 Solenoid Control circuit from the TCM
connector.

Yes >> Go To 4
No >> Repair the 2-3 Solenoid Control circuit for an open.
4. 2-3 SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the 2-3 Solenoid Control cir-
cuit.

Yes >> Repair the 2-3 Solenoid Control circuit for a short to ground.
No >> Go To 5
5. 2-3 SOLENOID CONTROL CIRCUIT SHORT TO OTHER CIRCUITS
Measure the resistance of the 2-3 Solenoid Control circuit to all other cir-
cuits in the Transmission Solenoid Assembly harness connector.

Yes >> Repair the 2-3 Solenoid Control circuit for a short to the
other circuit(s).
No >> Go To 6
6. 2-3 SOLENOID RESISTANCE OUT OF TOLERANCE

Measure the resistance from the 2-3 Solenoid Control circuit to the Sole-
noid Supply Voltage circuit in the Transmission Control Module C2 har-
ness connector.

8E-60.
No >> Replace the 2-3 Solenoid. Refer to Page 21-281.
TEST.

The conditions that caused this DTC to set is currently not present.

(P0758) 2–3 SOLENOID CIRCUIT SHORT TO GROUND
(P0758) 2–3 SOLENOID CIRCUIT SHORT TO GROUND — CONTINUED
• Set Condition: If the TCM detects a short to ground on the solenoid control circuit or solenoid control
POSSIBLE CAUSES

2-3 SOLENOID
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0758) 2–3
SOLENOID CIRCUIT.
No >> Go To 2

and open circuits.

(P0763) 3-4 SOLENOID CIRCUIT
POSSIBLE CAUSES
3-4 SOLENOID CONTROL CIRCUIT OPEN

3-4 SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. 3-4 SOLENOID CONTROL CIRCUIT OPEN

Measure the resistance of the 3-4 Solenoid Control circuit from the TCM
connector.

Yes >> Go To 4
No >> Repair the 3-4 Solenoid Control circuit for an open.
4. 3-4 SOLENOID CONTROL CIRCUIT SHORT TO GROUND

Measure the resistance between ground and the 3-4 Solenoid Control cir-
cuit.

Yes >> Repair the 3-4 Solenoid Control circuit for a short to ground.
No >> Go To 5
5. 3-4 SOLENOID CONTROL CIRCUIT SHORT TO OTHER CIRCUITS
Measure the resistance of the 3-4 Solenoid Control circuit between all

Yes >> Repair the 3-4 Solenoid Control circuit for a short to other
circuits.
No >> Go To 6
6. 3-4 SOLENOID RESISTANCE OUT OF TOLERANCE

Measure the resistance from the 3-4 Solenoid Control circuit to the Sole-
noid Supply Voltage circuit at the Transmission Control Module C2 har-
ness connector.

8E-60.
No >> Replace the 3-4 Solenoid. Refer to Page 21-281.
TEST.


(P0763) 3–4 SOLENOID CIRCUIT SHORT TO GROUND
(P0763) 3–4 SOLENOID CIRCUIT SHORT TO GROUND — CONTINUED
• Set Condition: If the TCM detects a short to ground on the solenoid control circuit or a solenoid control
POSSIBLE CAUSES

3-4 SOLENOID
Diagnostic Test

Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to (P0763) 3–4
SOLENOID CIRCUIT.
No >> Go To 2


(P0778) SHIFT PRESSURE SOLENOID CIRCUIT
(P0778) SHIFT PRESSURE SOLENOID CIRCUIT — CONTINUED
• When Monitored: When the solenoid is off, solenoid active with 25-75% duty cycle and/or the solenoid sup-
ply is active.
• Set Condition: If the TCM detects a short to ground or battery on the solenoid control circuit, shorted
solenoid, open solenoid, or an open or shorted solenoid control circuit in the TCM.
POSSIBLE CAUSES
SHIFT PRESSURE SOLENOID CONTROL CIRCUIT OPEN

SHIFT PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
SHIFT PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO ANOTHER CIRCUIT
SHIFT PRESSURE SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 7
3. SHIFT PRESSURE SOLENOID CONTROL CIRCUIT OPEN

Measure the resistance of the Shift Pressure Solenoid Control circuit from
harness connector.

Yes >> Go To 4
No >> Repair the Shift Pressure Solenoid Control circuit for an
open.
4. SHIFT PRESSURE SOLENOID CONTROL CIRCUIT SHORT TO

GROUND

Measure the resistance between ground and the Shift Pressure Solenoid
Control circuit.

Yes >> Repair the Shift Pressure Solenoid Control circuit for a short
to ground.
No >> Go To 5
5. SHIFT PRESSURE SOLENOID CONTROL CIRCUIT SHORT TO
OTHER CIRCUITS

Measure the resistance from the Shift Pressure Solenoid Control circuit to
all other circuits at the Transmission Solenoid Assembly harness connec-
tor.

Yes >> Repair the Shift Pressure Solenoid Control circuit for a short
to other circuits.
No >> Go To 6
6. SHIFT PRESSURE SOLENOID RESISTANCE OUT OF TOLERANCE

Measure the resistance from the Shift Pressure Solenoid Control circuit to
the Solenoid Supply Voltage circuit at the Transmission Control Module C2
harness connector.

8E-60.
No >> Replace the Shift Pressure Solenoid. Refer to Page
21-281.
TEST.


(P0778) SOLENOID SUPPLY VOLTAGE
(P0778) SOLENOID SUPPLY VOLTAGE — CONTINUED
• When Monitored: When the solenoid is active or not active and no undervoltage condition exists.
• Set Condition: If voltage is present when the output is off or the measured supply voltage and measured
battery voltage differ by 3.6 volts.
POSSIBLE CAUSES
SOLENOID SUPPLY CIRCUIT SHORTED TO ANOTHER CIRCUIT

SOLENOID SUPPLY VOLTAGE CIRCUIT SHORTED TO GROUND
SOLENOID
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 6
3. SOLENOID SUPPLY CIRCUIT SHORTED TO ANOTHER CIRCUIT

Measure the resistance from the Solenoid Supply Voltage circuit to all

another circuit.
No >> Go To 4
4. SOLENOID SUPPLY CIRCUIT SHORTED TO GROUND

Measure the resistance between ground and the Solenoid Supply Voltage
circuit at the Transmission Solenoid Assembly harness connector.

ground.
No >> Go To 5
5. SOLENOID ASSEMBLY SHORTED TO GROUND
Measure the resistance between ground and all Solenoid Control circuits
at the Transmission Control Module C2 harness connector.

Yes >> Replace the Solenoid that is shorted to ground in accor-
dance with the Service Information.
Page 8E-60.
TEST.


(P0850) TRANS TEMP SENSOR - P/N SWITCH CIRCUIT
(P0850) TRANS TEMP SENSOR - P/N SWITCH CIRCUIT — CONTINUED
• Set Condition: Temp sensor is open while in forward gears (1-5), temp sensor, open Temp Sensor- P/N
Switch circuit, P/N Switch.
POSSIBLE CAUSES
SHIFT LEVER ASSEMBLY ADJUSTMENT

TEMP SENSOR - P/N SWITCH CIRCUIT OPEN
TEMP SENSOR - P/N SWITCH CIRCUIT SHORTED TO GROUND
SENSOR GROUND CIRCUIT SHORTED TO ANOTHER CIRCUIT
TEMP SENSOR- P/N SWITCH CIRCUIT SHORTED TO ANOTHER CIRCUIT
TEMP SENSOR - P/N SWITCH
Diagnostic Test


Continue
Go To 2
active DTC.

Yes >> Go To 3
No >> Go To 9

nector.

Yes >> Repair the Sensor Ground circuit for an open.
No >> Go To 4
4. TEMP SENSOR - P/N SWITCH CIRCUIT OPEN

Measure the resistance of the Temp Sensor - P/N Switch circuit from the
TCM C2 harness connector to the Transmission Solenoid Assembly har-
ness connector.

Yes >> Go To 5
No >> Repair the Temp Sensor - P/N Switch circuit for an open.
5. TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO GROUND
Measure the resistance between ground and the Temp Sensor - P/N
Switch circuit.

ground.
No >> Go To 6

at the TCM C1 and C2 harness connectors.
Is the resistance below 100 kohms on any of the circuits?

cuit(s).
No >> Go To 7
7. TEMP SENSOR - P/N SWITCH CIRCUIT SHORT TO OTHER

CIRCUITS

Measure the resistance from the Temp Sensor - P/N Switch circuit to all
other circuits at the TCM C1 and C2 harness connectors.
Is the resistance below 100 kohms on any circuit?

other circuit(s).
No >> Go To 8
8. TEMP SENSOR - P/N SWITCH
With the brakes firmly applied, place the gear selector in Drive.
Measure the resistance between the Temp Sensor - P/N Switch circuit and
the Sensor Ground circuit in the TCM C2 harness connector.

8E-60.
No >> Replace the Temp Sensor - P/N Switch. Refer to
Page 21-281.
TEST.


(P1793) ENGINE TORQUE REDUCTION
(P1793) ENGINE TORQUE REDUCTION — CONTINUED
• When Monitored: Engine intervention active for at least 20 ms, no engine torque errors, engine torque
demand is greater than 0.
• Set Condition: Torque Reduction acknowledge bit - not set, no shift aborts, the error flag Torque Reduc-
tion Acknowledge is not set, Powertrain controller not supporting torque requests.
POSSIBLE CAUSES

ENGINE DTCS PRESENT
CAN C BUS (+) / (-) CIRCUIT OPEN
Diagnostic Test


Continue
Go To 2

No >> Go To 3


No >> Go To 4
4. CAN C BUS (+) / (-) CIRCUIT OPEN

Measure the resistance of the CAN C Bus (-) circuit from the PCM C4
Is the resistance of both CAN C Bus circuits below 5 ohms?

Yes >> Go To 5
No >> Repair the faulty CAN C Bus circuit(s) for an open.
5. PCM - ENGINE TORQUE REDUCTION
8E-56.
Start the engine.
Did DTC (P1793) ENGINE TORQUE REDUCTION set again?

8E-60.
CAN BUS CIRCUIT
CAN BUS CIRCUIT — CONTINUED
POSSIBLE CAUSES
CAN COMMUNICATION FAILURE

CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT OPEN
For a complete Shift Lever Assembly Circuit Diagram Refer to Page 21-182 .
Diagnostic Test
1. CHECK FOR CAN DTCS IN OTHER MODULES

With the DRB IIIT, read the stored and active DTCs for all modules on the
CAN C Bus.
Are other modules reporting CAN Bus DTCs?

Yes >> Refer to the reporting category and perform the appropriate
symptom. If the PCM is reporting a CAN Bus failure, refer
to the PCM tests first.
No >> Go To2
2. CAN C BUS (+) AND/OR CAN C BUS (-) CIRCUIT OPEN

Measure the resistance of both the CAN C Bus (+) circuit and the CAN C
Bus (-) circuit from the PCM harness connector to the SLA harness con-
nector.
Is the resistance of both CAN C Bus circuits below 5.0 ohms?

TEST.
INCORRECT CAN MESSAGE FROM ABS
INCORRECT CAN MESSAGE FROM ABS — CONTINUED
POSSIBLE CAUSES
For a complete Shift Lever Assembly Circuit Diagram, Refer to Page 21-182.
Diagnostic Test
1. CAB - INTERNAL
With the DRB IIIT, erase SLA DTCs.
Start the engine.
With the brakes firmly applied, place the shift lever into Drive.
With the DRB IIIT, read SLA DTCs.
Did DTC INCORRECT CAN MESSAGE FROM ABS set again?

INTERNAL CONTROLLER
INTERNAL CONTROLLER — CONTINUED
POSSIBLE CAUSES
Diagnostic Test
1. SLA - INTERNAL ERROR

The Shift Lever Assembly is reporting internal errors.
View repair.
Repair >> Replace the Shift Lever Assembly. Refer to Page 21-340.
LR WHEEL SPIN CAN MESSAGE NOT VALID
LR WHEEL SPIN CAN MESSAGE NOT VALID — CONTINUED
POSSIBLE CAUSES
ABS WHEEL SPEED SENSOR DTC PRESENT

Diagnostic Test
1. CAN BUS OR ABS DTC PRESENT

With the DRB IIIT, read the ABS DTCs.
Are any CAN Bus or Wheel Speed Sensor DTCs present?

No >> Go To 2
2. CAB – ABS LR SENSOR MESSAGE

Start the engine.
Did DTC LR WHEEL SPIN CAN MESSAGE NOT VALID set again?
RR WHEEL SPIN CAN MESSAGE NOT VALID
RR WHEEL SPIN CAN MESSAGE NOT VALID — CONTINUED
POSSIBLE CAUSES
ABS WHEEL SPEED SENSOR DTC PRESENT

Diagnostic Test
1. CAN BUS OR ABS DTC PRESENT

With the DRB IIIT, read the ABS DTCs.
Are any CAN Bus or Wheel Speed Sensor DTCs present?

No >> Go To2
2. CAB – ABS RR SENSOR MESSAGE

Start the engine.
Did DTC RR WHEEL SPIN CAN MESSAGE NOT VALID set again?
OVERVOLTAGE
OVERVOLTAGE — CONTINUED
POSSIBLE CAUSES

FUSED IGNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY OUTPUT CIRCUITS HIGH AT SLA
Diagnostic Test

With the DRB IIIT, read the engine DTCs.

No >> Go To 2
2. FUSED IGNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY

OUTPUT CIRCUITS OVERVOLTAGE

Start the engine and raise the engine speed to 1500 RPM.
Measure the voltage of the Fused Ignition Switch Output and Traction Sys-
tem Relay Output circuits at the SLA harness connector.
Is the voltage above 16.0 volts ± 0.3 volt?

Yes >> Repair the Fused Ignition Switch Output and Traction Sys-
tem Relay Output circuits for an overvoltage condition.
21-340.
TEST.
UNDERVOLTAGE
UNDERVOLTAGE — CONTINUED
POSSIBLE CAUSES

FUSED IGNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY OUTPUT LOW AT SLA
Diagnostic Test

With the DRB IIIT, read the engine DTCs.

No >> Go To 2
2. FUSED IGNITION SWITCH OUTPUT OR TRACTION SYSTEM RELAY

OUTPUT LOW AT SLA

Start the engine and raise the engine speed to 1500 RPM.
Measure the voltage of the Fused Ignition Switch Output or Traction Sys-
tem Relay Output circuits at the SLA harness connector.

Yes >> Repair the Fused Ignition Switch Output or Traction System
Relay Output circuit for an open.
21-340.
TEST.
TRANSMISSION VERIFICATION TEST
1.
Reconnect any disconnected components.
Connect the DRB IIIT to the Data Link Connector.
With the DRB IIIT, erase ABS DTCs.
With the DRB IIIT, display the Transmission temperature. Start and run the
engine until the Transmission temperature is above 43°C (110°F).
Check the Transmission fluid and adjust if necessary. Refer to the Service
Information for the proper Fluid Fill procedure.
Note: If internal repairs were performed and the shift quality is still
poor, it may be necessary to check the internal repair.
ROAD TEST PROCEDURE
Road test the vehicle. Make fifteen to twenty 1–2, 2–3, 3–4, and 4–5
upshifts.
Perform these shifts from a standing start to 72 km/h (45 MPH) with a
constant throttle opening of 20 to 25 degrees.
With speeds below 40 km/h (25 MPH), make five to eight wide open throt-
tle kickdowns to 1st gear. Allow at least 5 seconds each in 2nd and 3rd
gear between each kickdown.
Were any Diagnostic Trouble Codes set?

Yes >> Repair is not complete, refer to appropriate symptom.
No >> Repair is complete.
AUTOMATIC TRANSMISSION CIRCUIT DIAGRAM

ZH AUTOMATIC - NAG1 SERVICE INFORMATION 21 - 183
AUTOMATIC - NAG1 SERVICE INFORMATION
TABLE OF CONTENTS
page page
AUTOMATIC - NAG1 SERVICE INFORMATION STANDARD PROCEDURE

DESCRIPTION ...................... . . 184 CHECK OIL LEVEL . . . . . . . . . . . . . . . . . . . 294
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 186 STANDARD PROCEDURE - TRANSMISSION
DIAGNOSIS AND TESTING FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
AUTOMATIC TRANSMISSION . . . . . . . . . . . 206 STANDARD PROCEDURE - FILTER
DIAGNOSIS AND TESTING - PRELIMINARY . . 206 CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
DIAGNOSIS AND TESTING - ROAD FREEWHEELING CLUTCH
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 298
DIAGNOSIS AND TESTING - AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 298
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 207 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 299
STANDARD PROCEDURE - ALUMINUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 210 HOLDING CLUTCHES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 302
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 213 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 303
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 HOLDING CLUTCH B1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 227 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 304
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 230 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
SPECIFICATIONS - NAG1 AUTOMATIC HOLDING CLUTCH B2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 251 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 307
SPECIAL TOOLS - NAG1 AUTOMATIC ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 252 SPEED SENSOR
DRIVING CLUTCHES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 311
DESCRIPTION ...................... . . 255 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 311
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 256 OIL PUMP
DRIVING CLUTCH K1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 312
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 257 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 312
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 312
DRIVING CLUTCH K2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 261 OUTPUT SHAFT BEARING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
DRIVING CLUTCH K3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 316
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 266 OUTPUT SHAFT SEAL
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
ELECTROHYDRAULIC UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 318
DESCRIPTION ...................... . . 268 PISTONS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 282 PLANETARY GEARTRAIN
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 321
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 290 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 321
FLUID AND FILTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 322
DESCRIPTION ...................... . . 292 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 292 SHIFT INTERLOCK SOLENOID
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 324
EFFECTS OF INCORRECT FLUID LEVEL . . 293 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 326
DIAGNOSIS AND TESTING - CAUSES OF TEMP SENSOR/PARK-NEUTRAL SWITCH
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 293 DESCRIPTION
DIAGNOSIS AND TESTING - FLUID PARK/NEUTRAL CONTACT . . . . . . . . . . . . . 327
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 293
21 - 184 AUTOMATIC - NAG1 SERVICE INFORMATION ZH
DESCRIPTION - TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 337

TEMPERATURE SENSOR . . . . . . . . . . . . . . 327 SHIFT INTERLOCK SOLENOID
OPERATION DESCRIPTION ................ . . . . . . . . 338
PARK/NEUTRAL CONTACT . . . . . . . . . . . . . 328 ADJUSTMENTS - SHIFT INTERLOCK
OPERATION - TRANSMISSION SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 338
TEMPERATURE SENSOR . . . . . . . . . . . . . . 328 SHIFT LEVER ASSEMBLY
TORQUE CONVERTER DESCRIPTION ................ . . . . . . . . 339
DESCRIPTION .............. . . . . . . . . . . 330 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 339
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 336 GEAR SHIFT ROD
TORQUE CONVERTER HUB SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
AUTOMATIC - NAG1 SERVICE INFORMATION

DESCRIPTION
The NAG1 automatic transmission is an electronically controlled 5-speed transmission with a lock-up clutch in the
torque converter. The ratios for the gear stages are obtained by 3 planetary gear sets. Fifth gear is designed as an
overdrive with a high-speed ratio.
The gears are actuated electronically/hydraulically. The gears are shifted by means of an appropriate combination of
three multi-disc holding clutches, three multi-disc driving clutches, and two freewheeling clutches.
Electronic transmission control enables precise adaptation of pressures to the respective operating conditions and to
the engine output during the shift phase which results in a significant improvement in shift quality.
Furthermore, it offers the advantage of a flexible adaptation to various vehicles and engines.
Basically, the automatic transmission with electronic control offers the following advantages:
• Reduces fuel consumption.
• Improved shift comfort.
• More favorable step-up through the five gears.
• Increased service life and reliability.
• Lower maintenance costs.
1 - TORQUE CONVERTER 11 - PARKING LOCK GEAR

2 - OIL PUMP 12 - INTERMEDIATE SHAFT
3 - DRIVESHAFT 13 - FREEWHEEL F2
4 - MULTI-DISC HOLDING CLUTCH B1 14 - REAR PLANETARY GEAR SET
5 - DRIVING CLUTCH K1 15 - CENTER PLANETARY GEAR SET
6 - DRIVING CLUTCH K2 16 - ELECTROHYDRAULIC CONTROL UNIT
7 - MULTI-DISC HOLDING CLUTCH B3 17 - FRONT PLANETARY GEAR SET
8 - DRIVING CLUTCH K3 18 - FREEWHEEL F1
9 - MULTI-DISC HOLDING CLUTCH B2 19 - STATOR SHAFT
10 - OUTPUT SHAFT 20 - TORQUE CONVERTER LOCK-UP CLUTCH
TRANSMISSION IDENTIFICATION
The transmission name, NAG1, means New Automatic Gearbox, generation 1.
The transmission can be generically identified visually by the presence of a round 13-way connector located near
the front corner of the transmission oil pan, on the right side. Specific transmission information can be found
stamped into a pad on the left side of the transmission, above the oil pan rail.
TRANSMISSION GEAR RATIOS

The gear ratios for the NAG1 automatic transmission are as follows:
1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59:1

2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19:1
3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41:1
4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16:1
TRANSMISSION HOUSING
The converter housing and transmission are made from a light alloy. These are bolted together and centered via the
outer multi-disc carrier of multi-disc holding clutch, B1 (4). A coated intermediate plate provides the sealing. The oil
pump (2) and the outer multi-disc carrier of the multi-disc holding clutch, B1 (4), are bolted to the converter housing.
The stator shaft (19) is pressed into it and prevented from rotating by splines. The electrohydraulic control unit (16)
is bolted to the transmission housing from underneath. A sheet metal steel oil pan forms the closure.
MECHANICAL SECTION
The mechanical section consists of a driveshaft (3), output shaft (10), a sun gear shaft, and three planetary gear
sets (14, 15 and 17) which are coupled to each other. The planetary gear sets each have four planetary pinion
gears. The oil pressure for the torque converter lock-up clutch (20) and driving clutch K2 (6) is supplied through
bores in the drive shaft (3). The oil pressure to driving clutch K3 (8) is transmitted through the output shaft (10). The
lubricating oil is distributed through additional bores in both shafts. All the bearing points of the gear sets, as well as
the freewheeling clutches and actuators, are supplied with lubricating oil. The parking lock gear (11) is connected to
the output shaft (10) via splines.
Freewheel F1 (18) and F2 (13) are used to optimize the shifts. The front freewheel, F1 (18), is supported on the
extension of the stator shaft (19) on the transmission side and, in the locking direction, connects the sun gear of the
front planetary gear set (17) to the transmission housing. In the locking direction, the rear freewheel, F2 (13), con-
nects the sun gear of the center planetary gear set (15) to the sun gear of the rear planetary gear set (14).
ELECTROHYDRAULIC CONTROL UNIT

The electrohydraulic control unit (16) comprises the shift plate made from light alloy for the hydraulic control and an
electrical control unit. The electrical control unit comprises of a supporting body made of plastic, into which the
electrical components are assembled. The supporting body is mounted on the shift plate and screwed to it.
Strip conductors inserted into the supporting body make the connection between the electrical components and a
plug connector. The connection to the wiring harness on the vehicle and the transmission control module (TCM) is
produced via this 13-pin plug connector with a bayonet lock.
SHIFT GROUPS
The hydraulic control components (including actuators), which are responsible for the pressure distribution before,
during, and after a gear change are described as a shift group. Each shift group contains a command valve, a
holding pressure shift valve, a shift pressure shift valve, overlap regulating valve, and a solenoid.
The hydraulic system contains three shift groups: 1-2/4-5, 2-3, and 3-4. Each shift group can also be described as
being in one of two possible states. The active shift group is described as being in the shift phase when it is actively
engaging/disengaging a clutch combination. The 1-2/4-5 shift group control the B1 (4) and K1 (5) clutches. The 2-3
shift group controls the K2 (6) and K3 (8) clutches. The 3-4 shift group controls the K3 (8) and B2 (9) clutches.
OPERATION
The transmission control is divided into the electronic and hydraulic transmission control functions. While the elec-
tronic transmission control is responsible for gear selection and for matching the pressures to the torque to be trans-
mitted, the transmission’s power supply control occurs via hydraulic elements in the electrohydraulic control module.
The oil supply to the hydraulic elements, such as the hydrodynamic torque converter, the shift elements and the
hydraulic transmission control, is provided by way of an oil pump connected with the torque converter.
The Transmission Control Module (TCM) allows for the precise adaptation of pressures to the corresponding oper-
ating conditions and to the engine output during the gearshift phase, resulting in a noticeable improvement in shift
quality. The engine speed limit can be reached in the individual gears at full throttle and kickdown. The shift range
can be changed in the forward gears while driving, but the TCM employs a downshift safeguard to prevent over-
revving the engine. The system offers the additional advantage of flexible adaptation to different vehicle and engine
variants.
EMERGENCY RUNNING FUNCTION

In order to ensure a safe driving state and to prevent damage to the automatic transmission, the TCM control mod-
ule switches to limp-home mode in the event of critical faults. A DTC assigned to the fault is stored in memory. All
solenoid and regulating valves are thus de-energized.
The net effect is:
• The last engaged gear remains engaged.
• The modulating pressure and shift pressures rise to the maximum levels.
• The torque converter lockup clutch is deactivated.
In order to preserve the operability of the vehicle to some extent, the hydraulic control can be used to engage 2nd
gear or reverse using the following procedure:
• Stop the vehicle.
• Switch off engine.
• Move selector lever to “P”.
• Wait at least 10 seconds.
• Start engine.
• Move selector lever to D: 2nd gear.
• Move selector lever to R: Reverse gear.
The limp-home function remains active until the DTC is rectified or the stored DTC is erased with the DRBIIIT tool.
Sporadic faults can be reset via ignition OFF/ON.
CLUTCH APPLICATION
Refer to the following table for which shift elements are applied in each gear position.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N X X
R 3.16 X* X X X
* = The shift components required during coast.
FIRST GEAR POWERFLOW

Torque from the torque converter is increased via the driveshaft (25) and all three planetary gearsets and trans-
ferred to the output shaft (26).
1 - TORQUE CONVERTER LOCK-UP CLUTCH 17 - FRONT PLANETARY PINION GEARS

2 - TORQUE CONVERTER TURBINE 18 - CENTER PLANETARY PINION GEARS
3 - TORQUE CONVERTER IMPELLER 19 - REAR PLANETARY PINION GEARS
4 - MULTI-DISC HOLDING CLUTCH B1 20 - FREEWHEEL F1
5 - MULTI-DISC HOLDING CLUTCH B3 21 - FRONT PLANETARY SUN GEAR
6 - MULTI-DISC HOLDING CLUTCH B2 22 - CENTER PLANETARY SUN GEAR
7 - DRIVING CLUTCH K1 23 - REAR PLANETARY SUN GEAR
8 - FRONT PLANETARY ANNULUS GEAR 24 - FREEWHEEL F2
9 - DRIVING CLUTCH K2 25 - DRIVE SHAFT
10 - CENTER PLANETARY ANNULUS GEAR 26 - OUTPUT SHAFT
11 - REAR PLANETARY ANNULUS GEAR A - ENGINE SPEED
12 - DRIVING CLUTCH K3 B - TRANSMISSION INPUT SPEED
13 - FRONT PLANETARY CARRIER C - FIRST GEAR RATIO
14 - CENTER PLANETARY CARRIER D - SECOND GEAR RATIO
15 - REAR PLANETARY CARRIER E - THIRD GEAR RATIO
16 - TORQUE CONVERTER STATOR F - FIXED PARTS
1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER

2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - MULTI-DISC HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - MULTI-DISC HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - MULTI-DISC HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEEL F2
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS
Front Planetary Gear Set
The annulus gear (8) is driven by the driveshaft (25). The sun gear (21) is held against the housing by the locked
freewheel F1 (20) during acceleration and via the engaged multi-disc holding clutch B1 (4) during deceleration. The
planetary pinion gears (17) turn on the fixed sun gear (21) and increase the torque from the annulus gear (8) to the
planetary carrier (13). The planetary carrier (13) moves at a reduced speed in the running direction of the engine.
Center Planetary Gear Set
The annulus gear (10) is driven at the same speed as the rear planetary carrier (15) as a result of a mechanical
connection. The sun gear (22) is held against the housing by the multi-disc holding clutch B2 (6). The planetary
pinion gears (18) turn on the fixed sun gear (22) and increase the torque from the annulus gear (10) to the plan-
etary carrier. The output shaft (26) connected to the center planetary carrier (14) turns at a reduced speed in the
running direction of the engine.
Rear Planetary Gear Set
The annulus gear (11) turns at a reduced speed due to the mechanical connection to the front planetary carrier (15).
The sun gear (23) is held against the housing by the engaged multi-disc holding clutch B2 (6), by the locked free-
wheel F2 (24) during acceleration and by the engaged driving clutch K3 (12) during deceleration. The rear planetary
gears (19) turn on the fixed sun gear (23) and increase the torque from the annulus gear (11) to the planetary
carrier (15). The planetary carrier (15) moves at a reduced speed in the running direction of the engine.
SECOND GEAR POWERFLOW

Torque from the torque converter is increased via the driveshaft (25) and the center and rear planetary gearset and
transferred to the output shaft (26).

B - TRANSMISSION INPUT SPEED E - FIXED PARTS
C - FIRST GEAR RATIO

B - TRANSMISSION INPUT SPEED E - FIXED PARTS
C - FIRST GEAR RATIO
The planetary carrier (13) and sun gear (21) are connected via the engaged driving clutch K1 (7). The planetary
gearset is therefore blocked and turns as a closed unit at the input speed due to the mechanical connection of the
annulus gear (8) and driveshaft (25).
The annulus gear (10) is driven at the same speed as the rear planetary carrier (15) as a result of a mechanical
connection. The sun gear (22) is held against the housing by the multi-disc holding clutch B2 (6). The planetary
pinion gears (18) turn on the fixed sun gear (22) and increase the torque from the annulus gear (10) to the plan-
etary carrier (14). The output shaft (26) connected to the planetary carrier (14) turns at a reduced speed in the
running direction of the engine.
The annulus gear (11) turns at the input speed as a result of the mechanical connection to the front planetary carrier
(13). The sun gear (23) is held against the housing by the engaged multi-disc holding clutch B2 (6), by the locked
freewheel F2 (24) during acceleration and by the engaged driving clutch K3 (12) during deceleration. The rear plan-
etary pinion gears (19) turn on the fixed sun gear (23) and increase the torque from the annulus gear (11) to the
THIRD GEAR POWERFLOW

Torque from the torque converter is increased via the driveshaft (25) and the center planetary gearset and trans-

A - ENGINE SPEED C - FIRST GEAR RATIO
B - TRANSMISSION INPUT SPEED D - FIXED PARTS

A - ENGINE SPEED C - FIRST GEAR RATIO
B - TRANSMISSION INPUT SPEED D - FIXED PARTS
gearset is therefore locked and turns as a closed unit at the input speed due to the mechanical connection of the
annulus gear (8) and driveshaft (25).
The annulus gear (10) turns at the input speed as a result of the engaged driving clutch K2 (9). The sun gear (22)
is held against the housing by the multi-disc holding clutch B2 (6). The planetary pinion gears (18) turn on the fixed
sun gear (22) and increase the torque from the annulus gear (10) to the planetary carrier (14). The output shaft (26)
connected to the planetary carrier (14) turns at a reduced speed in the running direction of the engine.
The driving clutch K2 (9) is engaged and transfers the input speed of the driveshaft (25) to the planetary carrier (15)
via the annulus gear (10). The annulus gear (11) turns in the same way as the planetary carrier (15) due to the
mechanical connection with the locked front planetary gearset. This planetary gearset is therefore locked and turns
as a closed unit.
FOURTH GEAR POWERFLOW

Speed and torque are not converted by the direct gear ratio of the 4th gear. Power is transferred from the driveshaft
(25) to the output shaft (26) via three locked planetary gearsets.

A - ENGINE SPEED B - TRANSMISSION INPUT SPEED

A - ENGINE SPEED B - TRANSMISSION INPUT SPEED
gearset is therefore locked and turns as a closed unit at the input speed due to the mechanical connection of the
annulus gear (8) and the driveshaft (25).
The annulus gear (10) turns at the input speed as a result of the engaged driving clutch K2 (9). The driving clutch
K3 (12) connects the sun gears (22) and (23) of the rear and center planetary gearset. The planetary gearset is
locked by the same speeds of the annulus gear (10) and the sun gear (22) and it turns as a closed unit.
via the annulus gear (10). The annulus gear (11) turns in the same way as the planetary carrier (15) due to the
mechanical connection with the locked front planetary gearset. The planetary gearset is therefore locked and turns
as a closed unit.
FIFTH GEAR POWERFLOW



The annulus gear (10) turns at the input speed as a result of the engaged driving clutch K2 (9). The driving clutch
K3 (12) transfers an increased speed to the center planetary sun gear (22) due to the connection with the rear
planetary sun gear (23). The planetary pinion gears (18) turn between the annulus gear (10) and the sun gear (22).
The speed of the center planetary carrier (14) and the output shaft (26) connected to the center planetary carrier
lies between that of the annulus gear (10) and the sun gear (22). This provides a step-up ratio.
via the annulus gear (10). The annulus gear (11) turns at a reduced speed due to the mechanical connection with
the front planetary carrier (13). The rear planetary pinion gears (19) turn between the annulus gear (11) and the sun
gear (23). The sun gear (23) moves at an increased speed in the running direction of the engine.
REVERSE GEAR POWERFLOW

ferred with reversed direction of rotation to the output shaft (26).


The annulus gear (10) is held against the housing by the multi-disc holding clutch B3 (5) via the mechanical con-
nection to the planetary carrier (15). The sun gear (22) turns backwards due to the engaged driving clutch K3 (12).
The planetary gears (18) turn on the fixed annulus gear (10) and increase the torque from the sun gear (22) to the
planetary carrier (14). The output shaft (26) connected to the planetary carrier (14) turns at a reduced speed in the
opposite direction to the running direction of the engine.
The planetary carrier (15) is held against the housing by the engaged multi-disc holding clutch B3 (5). The annulus
gear (11) turns at a reduced speed due to the mechanical connection to the front planetary carrier (13). The rear
planetary gears (19) turn between the annulus gear (11) and the sun gear (23). The direction is reversed by the held
planetary carrier (15) so that the sun gear (23) turns in the opposite direction to the running direction of the engine.
SHIFT GROUPS/SHIFT SEQUENCE

1-2 Shift - First Gear Engaged
The end face of the command valve (5) is kept unpressurized via the solenoid valve for 1-2 and 4-5 shift (1). Via the
holding pressure shift valve (4), the working pressure (p-A) is present at the multi-disc holding clutch B1 (7). Clutch
K1 (6) is unpressurized.
1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE

2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - MULTI-DISC HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE
Shift Phase
Via the 1-2 and 4-5 shift solenoid (1), the shift valve pressure (p-SV) is directed onto the end face of the command
valve (5). The command valve (5) is moved and the shift pressure (p-S) coming from the shift pressure shift valve
(3) is directed via the command valve (5) onto driving clutch K1 (6). Simultaneously the multi-disc holding clutch B1
(7) is subjected to overlap pressure by the overlap valve (2).

The multi-disc holding clutch B1 (7) pressure acting on the end face of the shift pressure shift valve (3) is replaced
by the working pressure (p-A). The rising shift pressure (p-S) at driving clutch K1 (6) acts on the annular face of the
overlap regulating valve (2) and reduces the overlap pressure regulated by the overlap regulating valve (2). When
a corresponding pressure level is reached at the holding pressure shift valve (4), this valve switches over.
Second Gear Engaged
After the gearchange is complete, the pressure on the end face of the command valve (5) is reduced via the 1-2
and 4-5 shift solenoid valve (1), and the command valve (5) is pushed back to its basic position. Via the holding
pressure shift valve (4) the working pressure (p-A) now passes via the command valve (5) to driving clutch K1 (6).
The multi-disc holding clutch B1 (7) is deactivated (unpressurized). The spring of the shift pressure shift valve (3)
pushes the valve back to its basic position.

Gear Shift N to D (1st gear) - Engine Started
With the engine started and the gearshift lever in the NEUTRAL or PARK positions, holding clutch B1 (1) and driving
clutch K3 (4) are applied and the various valves in the 1-2/4-5 shift group are positioned to apply pressure to the
multi-disc holding clutch B2.
1 - MULTI-DISC HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE

2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE
3 - MULTI-DISC HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE
4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE
5 - MULTI-DISC HOLDING CLUTCH B2 PISTON 15 - 3-4 OVERLAP REGULATING VALVE
6 - MULTI-DISC HOLDING CLUTCH B2 PISTON OPPOSING FACE 16 - BALL VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID 17 - 1-2/4-5 COMMAND VALVE
8 - SHIFT PRESSURE REGULATING VALVE 18 - 1-2/4-5 COMMAND VALVE
9 - SHIFT VALVE B2 19 - BALL VALVE
10 - 3-4 SHIFT SOLENOID
Activation Sequence
The selector valve opens the shift pressure (p-S) feed connection from the ball valve (19) with the shift valve B2 (9).
With the shift valve B2 (9) in the upper position, shift pressure (p-S) travels behind the piston B2 (5) and simulta-
neously to the opposing face of the piston B2 (6). The multi-disc holding clutch B2 begins to close.
The pressure on the opposing face of the piston B2 (6) ensures a soft activation of the multi-disc holding clutch B2.

First Gear Engaged
The TCM monitors the activation sequence via the speed of the input shaft, which slows down as the frictional
connection in the multiple-disc holding clutch increases. When the speed drops to the specified level, the TCM shuts
off the power to the 3-4 shift solenoid (10). The spring chamber of the shift valve B2 (9) is depressurized and
switches downwards. This connects the line to the opposing face of the piston B2 (6) with the pressure holding
valve (11). The pressure on the opposing face of the piston B2 (6) drops to a residual pressure.

The working pressure (p-A) is formed and travels via the 2-3 holding pressure shift valve, the 2-3 command valve
and the ball valve (16) to driving clutch K3 (4) and via the 3-4 command valve (13) to the end face of the 3-4 shift
pressure shift valve (14). The 3-4 shift pressure shift valve (14) is moved against the force of the spring towards the
right. At the same time the 3-4 solenoid valve (10) is energized. This allows shift valve pressure (p-SV) to enter the
spring chamber of the shift valve B2 (9) and to reach the end face of the 3-4 command valve (13). The shift valve
B2 (9) is held in the upper position and the 3-4 command valve (13) switches towards the right. At the end face of
the 3-4 shift pressure shift valve (14) the working pressure (p-A) is replaced by shift valve pressure (p-SV).
The 3-4 command valve (13) moves to the left. Working pressure (p-A) travels via the holding pressure shift valve
(12) and the 3-4 command valve (13) to the piston of multi-disc holding clutch B2 (5).

AUTOMATIC TRANSMISSION
CAUTION: Before attempting any repair on a NAG1 automatic transmission, check for Diagnostic Trouble
Codes with the DRBIIIT scan tool.
Transmission malfunctions may be caused by these general conditions:

• Poor engine performance.
• Improper adjustments.
• Hydraulic malfunctions.
• Mechanical malfunctions.
• Electronic malfunctions.
• Transfer case performance.
Diagnosis of these problems should always begin by checking the easily accessible variables: fluid level and con-
dition, gearshift cable adjustment. Then perform a road test to determine if the problem has been corrected or if
more diagnosis is necessary.
DIAGNOSIS AND TESTING - PRELIMINARY

IF VEHICLE IS DRIVEABLE
1. Check for transmission fault codes using the DRBIIIT scan tool.
2. Check the fluid level and its condition.
3. Adjust the gearshift cable if the complaint was based on delayed, erratic, or harsh shifts.
4. Road test the vehicle and note how the transmission upshifts, downshifts, and engages.
IF VEHICLE IS DISABLED
1. Check the fluid level and its condition.
2. Check for a broken or disconnected gearshift cable.
3. Check for a cracked or leaking cooler line, loose or missing pressure-port plugs.
4. Raise and support the vehicle on safety stands, start the engine, shift the transmission into gear, and note the
following:
a. If the propeller shaft turns but the wheels do not, inspect the differential and axle shafts.
b. If the propeller shaft does not turn and the transmission is noisy, stop the engine. Remove the trans-
mission oil pan, and check for debris. If the pan is clear, remove the transmission and check for a dam-
aged flexplate, torque converter, oil pump, or input shaft.
c. If the propeller shaft does not turn and the transmission is not noisy, perform the hydraulic-pressure test
to determine if the concern is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING

Before road testing the vehicle, be sure that the fluid level and the control cable adjustments have been checked
and adjusted if necessary. Verify that all the diagnostic trouble codes have been resolved.
Observe the engine’s performance during the road test. A poorly tuned engine will not allow an accurate analysis of
the transmission’s operation.
Operate the transmission in all gear ranges. Check for shift variations and engine flare which indicates slippage.
Note if shifts are harsh, spongy, delayed, early, or if part throttle downshifts are sensitive.
Slippage is indicated by engine flare, this usually means that the transmission has a clutch concern an overrunning
clutch or a possible line pressure problem.
A slipping clutch can often be determined by comparing which internal units are applied in various gear ranges. The
clutch application chart provides a basis for analyzing road test results.
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N X X
R 3.16 X* X X X
* = The shift components required during coast.
DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION

MAXIMUM SPEED 30 km/h 1. Speed Control 30 Actuated. 1. Instruct Customer.
ENGINE DIES WHEN 1. PWM Valve Blocked. 1. Replace Valve.
TRANSMISSION IS
SHIFTED INTO GEAR, 2. Torque Converter Lock Up Control 2. Enable Movement of Valve,
ALSO NOISES IN N Valve Locked. Remove Particle.
AND/OR P
LEVER IN 9P9 POSITION 1. No Vacuum Brake Booster After 1. Check Vacuum/ Tightness of
BLOCKED (BRAKE Long Immobilization, Brake Pedal Brake Booster.
ACTIVATED) Not Fully Applied/Hard Pedal.
2. No Stoplamp Switch Signal (no 2. Check Contact to Stoplamp

DTC IN PCM). Switch. Replace Switch if
Necessary.
GRUMBLING, DRONING, 1. Slip Speed TCC too Low. 1. Switch Off Torque Converter
JERKING WHEN TCC IS Lock Up Using DRBIIIT. If
ENGAGED Complaint is Not Reproduced
Afterwards, Replace PWM
Valve, Set Adaption Values to
Zero.
HOWLING, HUMMING 1. Oil Filter Blocked. 1. Replace Oil Filter.
ABOVE 4000 RPM IN
EACH GEAR 2. Oil Pump. 2. Replace Oil Pump.
WHINING, SINGING 1. Gear Set Noises in 1st, 2nd and 1. Replace Transmission.
5th Gear.
2. Intermediate Bearing of the Drive 2. Replace Intermediate

Shaft at 0 km/h, Only When Cold. Bearing of the Drive Shaft.
9CLACK9 NOISE FROM 1. Park Lock Solenoid. 1. Replace Shift Lever
CENTER SHIFT AREA Assembly.
WHEN STOPPING OR
STARTING
CRACKING NOISE WHEN 1. Stick - Slip Between Joint Flange 1. Install Zinc Coated Collar Nut
LOAD CYCLE and Collar Nut. Together with Washer.

CHATTERING IN CENTER 1. Bushing Shift Shaft has too Much 1. Replace Shifter Lever and
CONSOLE SHIFT WHILE Clearance. Cover Plate.
ACCELERATING
HARD 2-3 UPSHIFT WHEN 1. Response Characteristic Control 1. Install K2 Disc Spring.
STEPPING OFF THE Loop.
ACCELERATOR PEDAL
UPSHIFT 2-3, 3-4 1. Spring of Regulating Valve 1. Replace Spring.
SLIPPING Pressure control Valve Broken.
HARD 2-1 DOWNSHIFT 1. Transmission (2-1 downshift) not 1. Re-adapt Transmission.
WHEN COMING TO A Adapted.
STOP
2. TCM Software Data. 2. Flash TCM.
3. Freewheel F1 Defective. 3. Replace Freewheel F1.
HARD 3-2 DOWNSHIFT 1. K3 Idles. 1. Install TCM and/or
WHEN DECELERATION Electrohydraulic Control Unit.
EVEN AFTER
READAPTION
NO RESP. DELAYED 1. Different Tire Sizes are Mounted 1. Mount Uniform Tire Sizes on
UPSHIFT, NO DTC on the Front Axle. the Front Axle.
NO UPSHIFT 3-4, 4-5 1. Upshift Prevention to Realize 1. Instruct Customer.
AFTER FAST OFF Dynamical Drivestyle.
(ACCELERATOR)
NO UPSHIFT OF 1ST 1. Gear Recognition Switch. 1. Replace Gear Recognition
GEAR BELOW 5000 RPM Switch.
NO UPSHIFT INTO 5TH 1. The Upshift 4-5 at Full Throttle or 1. Instruct Customer.
GEAR WHEN FULL Kick Down Never Occurs Until
THROTTLE OR KICK Reaching Cut Off Speed. Under
DOWN ACTIVATION These Conditions, the High Powered
Vehicle Will Never Shift Into 5th
Gear Below 250 km/h.
NO KICK DOWN 1. Accelerator Pedal Value < 95%. 1. Check Engine Control. Adjust
SHIFTING as Necessary.
ENGINE TURNS UP 1. Oil Level too Low. 1. Check Oil Level. Add if
WHILE 2-3 UPSHIFT Necessary.
AND/OR HARD 3-2
DOWNSHIFT 2. Oil Filter not Installed. 2. Install Oil Filter.
3. Freewheel F2 Defective. 3. Replace Freewheel F2,
Hollow Shaft, and Rear Sun
Gear/Inner Disc Carrier K3.
GRABBING 2-3 COASTING 1. Oil Level too Low. 1. Check Oil Level. Add if
UPSHIFT AND/OR BRAKE Necessary.
DOWNSHIFT
2. Oil Filter not Installed. 2. Install Oil Filter.
3. Control Shift or Command Valve 3. Check Each Slide Valve for
Blocked. Base Position and Ease of
Movement, Remove Particle.
4. K3 Disc Burnt, Hot Spots or 4. Replace Inner and Outer
Rubbed Down. Disc Carrier K3 and Control
Valve.

DELAYED ENGAGEMENT, 1. Oil Level too Low. 1. Check Oil Level. Add if
NO TRANSFER OF Necessary.
POWER IN R AND/OR D,
ALSO AT TIMES 2. Recognition Switch - Selector 2. Replace Recognition Switch
Lever Position. Only When Intermediate
Position or Fault is Indicated.
3. Oil Filter not Installed. 3. Install Oil Filter.
4. AEV, Delayed Pressure Build Up 4. Install New Shifting
on Piston B2/B3. Procedure (TCM,
Electrohydraulic Control Unit or
Repair Set).
5. Wrong Combination TCM/ 5. Check Combination
Electrohydraulic Control Unit. TCM/Electrohydraulic Control
Unit. Replace TCM Resp.
Electrohydraulic Control Unit, if
necessary.
NO UPSHIFT OF 1ST 1. Connector Ballast Unit. Output 1. Check Connectors, Replace
GEAR AT TIMES Speed Sensor Loose, Incorrectly Output Speed Sensor if
Contacted. Necessary.
2. Output Speed Sensor Defective 2. Replace Output Speed

Sensor.
LEAKAGE AT THE AREA 1. Deformation O-rings. 1. Replace O-rings.
OF THE ELECTRICAL
PLUG TO THE 2. Deformation Adapter. 2. Replace Adaptor.
CONDUCTOR PLATE 3. The Conductor Plate is not Fitted 3. Remove Nose of Conductor
Surface to Surface on the Valve Plate.
Body in One Corner, the Plug Is not
Centered in the Socket and the
O-ring Will Not Seal.
4. Contacting At The Conductor Plate 4. Replace Conductor Plate.
Leaky. Oil In Harness, Sometimes In
The Control Module.
LEAKAGE AT THE AREA 1. Bolts (Torx M6) Outer Disc Carrier 1. Clean Thread and Install the
OF BELL HOUSING/ B1. Bolts Using Sealer.
TORQUE CONVERTER
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter 1. Clean Thread and Install the
Housing. Bolts Using Sealer.
2. Oil Drain Plug Converter Loose 2. Install Drain Plug Correctly.
Resp. No Seal Ring Installed.
3. Weld Seam of Torque Converter 3. Replace Torque Converter.
Leaky.
4. Radial Sealing Ring Oil Pump 4. Replace Sealing Ring.
Defective.
5. O-ring Oil Pump Defective or not 5. Install O-ring.
Installed.
6. Bushing of Oil Pump Loose, 6. Install Fit Bolt if Necessary.
caused by Missing Fit Bolt at
Transmission/Engine Flange.
STANDARD PROCEDURE - ALUMINUM THREAD REPAIR

Damaged or worn threads in the aluminum transmission case and valve body can be repaired by the use of Heli-
Coils™, or equivalent. This repair consists of drilling out the worn-out damaged threads. Then tap the hole with a
special Heli-Coil™ tap, or equivalent, and installing a Heli-Coil™ insert, or equivalent, into the hole. This brings the
hole back to its original thread size.
Heli-Coil™, or equivalent, tools and inserts are readily available from most automotive parts suppliers.
REMOVAL
3. Remove the lower splash shield screws (1) and the lower
splash shield.
4. Remove the transmission ground bolt (1) and cable.

5. Place a suitable drain pan beneath the transmission drain.

6. Remove the transmission drain plug (2) and drain the
transmission.
7. Disconnect the transmission shift selector rod (1).
8. Disconnect the transmission oil cooler line banjo fittings (1)

from the left and right sides of the tranmission housing.
9. Remove the transmission oil cooler line retainer bolts (1)

from the left and right side of the engine lower oil pan.
10. Remove the torque converter access cover (1).
Note: Rotate the engine at the vibration damper bolt.
11. Remove the torque converter bolts (2).
12. Disconnect and remove the oxygen sensor harness con-

nectors (1)
13. Remove the heat shield bolts (2) and the heat shield
14. Disconnect the transmission control harness connector

(2).
15. Position a transmission jack under the transmission oil
pan rail.
17. Remove the transmission to engine retaining bolts.
18. Lower and remove the transmission from the vehicle.
DISASSEMBLY
1. Remove the torque converter (1). Refer to Page 21-335.
2. Place the transmission in a vertical position.

3. Measure the input shaft end play as follows.
a. Attach the Special Tool 8266-18 (2) to Special Tool
8266-8 (1).
b. Attach the Special Tool C-3339 (3) and the Special
Tool 8266-8 (1).
c. Install the assembled tool onto the input shaft of
the transmission and tighten the retaining screw on
Special Tool 8266-18 (2) to secure it to the input
shaft.
d. Position the dial indicator plunger against a flat
spot on the oil pump and zero the dial indicator.
e. Move the input shaft in and out. Record the maxi-
mum travel for assembly reference.
4. Loosen the guide bushing (12) and remove it from the

transmission housing.
5. Remove the oil pan (5).
6. Remove the oil filter (4).
7. Unscrew the bolts (3) and remove the electrohydraulic unit
(2).
8. Place the transmission in the PARK position before attempt-
ing to remove the output shaft nut.
9. Remove the output shaft nut holding the propeller shaft
flange to the output shaft.
10. Remove the propeller shaft flange.
11. Remove the transmission rear oil seal with a suitable slide
hammer and screw.
12. Remove the transmission output shaft washer. Be sure to
tag the washer since it is very similar to the geartrain end-
play shim and they must not be interchanged.
13. Remove the transmission rear output shaft bearing retain-
ing ring (1).
14. Position Special Tool 9082 (1) over the inner race of the
output shaft bearing (3).
15. Slide the collar (3) on Special Tool 9082 (1) downward
over the fingers of the tool (4).
16. Remove the output shaft bearing (3).

17. Remove the geartrain end-play shim from the output shaft.
Be sure to tag the shim since it is very similar to the out-
put shaft washer and they must not be interchanged.
18. Remove the bolts holding the transmission housing to the
torque converter housing from inside the converter hous-
ing.
19. Stand the transmission upright on the converter housing.
Be sure to use suitable spacers between the bench sur-
face and the torque converter housing since the input
shaft protrudes past the front surface of the housing.
20. Remove the remaining bolts holding the transmission
housing to the torque converter housing.
21. Remove the transmission housing from the torque con-
verter housing.
1 - DRIVING CLUTCH K1 5 - THRUST WASHER

2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, CLUTCH K2
3 - DRIVING CLUTCH K3, OUTPUT SHAFT, AND CENTER AND 7 - TEFLON RINGS
REAR PLANETARY GEAR SETS
4 - THRUST NEEDLE BEARING
22. Remove the output shaft with the center and rear gear set and clutch K3 (3).
23. Remove the thrust needle bearing (4) and the thrust washer (5).
24. Remove the drive shaft with driving clutch K2 and front planetary gear set (6).
25. Remove the driving clutch K1 (1).
1 - BOLTS - M6X32 4 - BOLTS - M8X35

2 - CONVERTER HOUSING 5 - MULTI-DISC HOLDING CLUTCH B1
3 - INTERMEDIATE PLATE 6 - OIL PUMP
26. Unscrew the bolts (4) and remove the oil pump (6). Screw two opposed bolts into the oil pump housing and
press the oil pump out of the converter housing by applying light blows with a plastic hammer.
27. Remove and discard the torque converter hub seal and the oil pump outer o-ring seal from the oil pump.
28. Unscrew the bolts (1) and remove the multi-disc brake B1 (5) from the torque converter housing. Screw two
opposed bolts into the multi-disc brake B1 (5) and separate from the torque converter housing by applying light
blows with a plastic hammer.
29. Detach the intermediate plate (3) from torque converter housing (2).
1 - SNAP-RING 5 - PARKING LOCK GEAR

2 - MULTI-DISC HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING
3 - SPRING WASHER 7 - BOLTS - M8X60
4 - MULTI-DISC HOLDING CLUTCH B2
30. Unscrew the bolts (7).

31. Remove the snap-ring (1), then remove the multi-disc holding clutch B3 discs (2) from the transmission housing
(6). The externally toothed disc carrier for the multi-disc holding clutch B2 (4) is also the piston for the multi-disc
holding clutch B3 discs (2).
32. Remove the parking lock gear (5).
ASSEMBLY
1 - SNAP-RING 5 - PARKING LOCK GEAR

2 - MULTI-DISC HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING
3 - SPRING WASHER 7 - BOLTS - M8X60
4 - MULTI-DISC HOLDING CLUTCH B2
1. Insert the parking lock gear (5).

2. Install the multi-disc holding clutch B2 (4) in the transmission housing (6).
3. Screw in the bolts (7). Tighten the bolts to 16 N·m (141 in. lbs.).
Note: During the measurement the snap ring (7) must con-
tact the upper bearing surface of the groove in the outer
multi-disc carrier (8).
Note: Pay attention to the sequence of discs. Place new fric-

tion multi-discs in ATF fluid for one hour before installing.
4. Insert and measure the spring washer (4) and multi-disc

holding clutch pack B3 (2, 6).
a. Put the multi-discs for multi-disc holding clutch B3
together in the sequence shown in the illustration
and insert individually.
b. Using a feeler gauge, determine the play “L” at three
points between the snap-ring (7) and outer multi-disc
(1). B3 clutch clearance should be 1.0-1.4 mm (0.039-
0.055 in.). Adjust the clearance as necessary.
c. Adjust with snap-ring (7), if necessary. Snap-rings are
available in thicknesses of 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), 4.1 mm (0.162 in.), 4.4
mm (0.173 in.), and 4.7 mm (0.185 in.).
5. Place the intermediate plate (3) on the converter housing (2) and align.
Note: The intermediate plate can generally be used several times. The plate must not be coated with sealant
6. Check that the driving clutch K1 feed hole (1) in the inner
hub of multi-disc holding clutch B1 is free before installing
multi-disc holding clutch B1.
1 - BOLTS - M6X32 4 - BOLTS - M8X35

2 - CONVERTER HOUSING 5 - MULTI-DISC HOLDING CLUTCH B1
3 - INTERMEDIATE PLATE 6 - OIL PUMP
7. Install the multi-disc holding clutch B1 (5) onto the converter housing (2) and intermediate plate (3). Installed
position of clutch B1 (5) in relation to converter housing (2) is specified by a plain dowel pin (arrow) in clutch B1
(5).
8. Install the bolts to multi-disc holding clutch B1 (5) to the converter housing (2).
9. Securely tighten the multi-disc holding clutch B1 (5) on the converter housing (2) to 10 N·m (88.5 in. lbs.).
10. Install a new torque converter hub seal (1) into the oil
pump using Special Tool 8902A.
11. Install a new oil pump outer o-ring seal (2) onto the oil
pump.
12. Install the oil pump (6) and securely tighten. Tighten the
oil pump bolts to 20 N·m (177 in. lbs.).
1 - DRIVING CLUTCH K1 5 - THRUST WASHER

2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, CLUTCH K2
3 - DRIVING CLUTCH K3, OUTPUT SHAFT, AND CENTER AND 7 - TEFLON RINGS
REAR PLANETARY GEAR SETS
4 - THRUST NEEDLE BEARING
13. Using grease, insert the teflon rings (7) in the groove so that the joint remains together.
14. Install the driving clutch K1 (1) onto multi-disc holding clutch B1.
15. Install the drive shaft with driving clutch K2 (6) and front planetary gear set (1).
16. Install the front washer (5) and the thrust needle bearing (4).
17. Install the output shaft with the center and rear planetary gear set and driving clutch K3 (3).
18. Using grease, install both the teflon rings (7) in the groove at the rear of the output shaft so that the joint stays
together.
19. Mount the transmission housing on the torque converter housing.
20. Screw in the bolts through the transmission housing into the torque converter housing. Tighten the bolts to 20
N·m (177 in. lbs.).
21. Measure the end-play between the parking lock gear and the grooved ball bearing in order to select the proper
geartrain end-play shim.
a. Place Special Tool 6311 (1) on the transmission

housing. Using a depth gauge, measure from the
gauge bar (1) to the parking lock gear (2).
b. Using a depth gauge, measure from the Special

Tool 6311 (1) to the contact surface of the output
shaft bearing (2) in the transmission housing.
c. Subtract the first figure from the second figure to
determine the current end-play of the transmission.
Select a shim such that the end-play will be 0.3-0.5
mm (0.012-0.020 in.). Shims are available in thick-
nesses of 0.2 mm (0.008 in.), 0.3 mm (0.012 in.),
0.4 mm (0.016 in.), and 0.5 mm (0.020 in.).
d. Install the selected end-play shim.
22. Screw in the bolts through the converter housing into the
transmission housing. Tighten the bolts to 20 N·m (177 in.
lbs.)
.
23. Install the output shaft bearing in the rear transmission

housing.
a. Using Special Tool 9287 (1), install the output shaft
bearing (2) into the transmission housing (3). The
closed side of the plastic cage must point
towards the parking lock gear.
b. Install the retaining ring (1). Ensure that the retain-

ing ring (1) is seated correctly in the groove.
c. Check that there is no play between the bearing (2)
and the retaining ring (1) using a feeler gauge.
d. There must be no play between the retaining ring
(1) and the bearing (2). If the ring cannot be
installed, a thinner ring must be used. If there is
play between the ring (1) and the bearing (2), a
thicker ring must be installed. Retaining rings are
available in thicknesses of 2.0 mm (0.079 in.), 2.1
mm (0.083 in.), and 2.2 mm (0.087 in.).
24. Rotate the transmission so that the bellhousing is pointed
upward and ensuring that the output shaft is allowed to
move freely.
25. Measure the input shaft end-play.
Note: If the end-play is incorrect, the transmission is

incorrectly assembled, or the geartrain end-play shim is
incorrect. The geartrain end-play shim is selective.
a. Attach Special Tool 8266-18 (2) to Special Tool

8266-8 (1).
b. Attach Special Tool C-3339 (3) to Special Tool
8266-8 (1).
c. Install the assembled tool onto the input shaft of
the transmission and tighten the retaining screw on
Special Tool 8266-18 (2) to secure it to the input
shaft.
d. Position the dial indicator plunger against a flat
spot on the oil pump and zero the dial indicator.
e. Move the input shaft in and out and record reading.
End play should be 0.3-0.5 mm (0.012-0.020 in.).
Adjust as necessary.
26. Install the output shaft washer onto the output shaft.
27. Install a new transmission rear seal into the transmission

case (2) with Special Tool 8902A (1).
28. Install the propeller shaft flange onto the output shaft.
29. Place the transmission in the PARK position before
attempting to tighten the output shaft nut.
30. Install a new output shaft nut. Tighten the output shaft nut
to 120 N·m (88.5 ft. lbs.).
31. Stake the output shaft nut to the output shaft as follows.
a. Place the Special Tool 9078 (2) Special Tool
C-4171 onto the output shaft.
b. Rotate the Special Tool 9078 (2) until the alignment
pin (3) engages the output shaft notch (4).
c. Press downward on the staking tool (1) until the

staking pin (3) contacts the output shaft nut flange
(2).
d. Strike Special Tool C-4171 with a suitable hammer
until the output shaft nut is securely staked to the
output shaft.
32. Install the electrohydraulic unit (2). Tighten the bolts to 8

N·m (71 in. lbs.).
33. Install the oil filter (4).
34. Install the oil pan (5). Tighten the bolts to 8 N·m (71 in.
lbs.).
35. Install the guide bushing (12).
36. Install the torque converter (1). Refer to Page 21-336.

INSTALLATION
1. Inspect the rear crankshaft seal area for signs of leakage.
Replace the seal if required. Refer to Page 9-634.
2. Ensure the torque converter is fully seated in the transmis-
sion. Mount the transmission on the transmission jack.
3. Position the transmission in the vehicle on the engine block
dowels.
4. Install the transmission retaining bolts and the ground
cable. Tighten the bolts to 38 N·m (28 ft. lbs.).
Note: Rotate the engine at the vibration damper bolt.
5. Install the torque converter bolts. Tighten the bolts to 50

N·m (37 ft. lbs.).
6. Install the torque converter access cover (1).
8. Check the seal on the bayonet retainer (1). Replace as

required. Connect the transmission controller harness con-
nector (2).
9. Install the heat shield and harness retainer with bolts (2).
10. Route the oxygen sensor wire harness in the retainer and
connect the oxygen sensors (1).
11. Install the transmission oil cooler line banjo bolt fittings (1)
through the washers and into the transmission oil cooler
lines. Install the fittings on the left and right sides of the
transmission case. Tighten the fittings to 34 N·m (25 ft.
lbs.).
12. Install the transmission oil cooler line retainers and bolts
at the left and right sides of the oil pan. Tighten the bolts
to 20 N·m (15 ft. lbs.).
13. Attach the shift rod to the transmission shift arm and
install the retaining clip (1).
14. Install the transmission drain plug (2) with a new gasket
(1). Tighten the drain plug to 20 N·m (15 ft. lbs.).
19. Fill the transmission to the specified level with the speci-
fied transmission fluid.
21. Check the transmission fluid level using Special Tool
8863–A.
HYDRAULIC FLOW IN PARK

HYDRAULIC FLOW IN REVERSE - FAILSAFE

HYDRAULIC FLOW IN REVERSE

HYDRAULIC FLOW IN NEUTRAL - DEFAULT

HYDRAULIC FLOW IN NEUTRAL

HYDRAULIC FLOW IN NEUTRAL TO DRIVE

HYDRAULIC FLOW IN DRIVE - FAILSAFE

HYDRAULIC FLOW IN DRIVE - FIRST

HYDRAULIC FLOW IN DRIVE - FIRST

HYDRAULIC FLOW IN DRIVE - SECOND


HYDRAULIC FLOW IN DRIVE - THIRD


HYDRAULIC FLOW IN DRIVE - FOURTH


HYDRAULIC FLOW IN DRIVE - FIFTH






SPECIFICATIONS - NAG1 AUTOMATIC TRANSMISSION

GEAR RATIOS
1ST 3.59:1
2ND 2.19:1
3RD 1.41:1
4TH 1.00:1
5TH 0.83:1
REVERSE 3.16:1
SPECIFICATIONS
COMPONENT METRIC (mm) INCH (in.)

Geartrain End-play 0.3-0.5 0.012-0.020
Geartrain End-play Shim 0.2, 0.3, 0.4, and 0.5 0.008, 0.012, 0.016, 0.020
Rear Planetary Gear Set End-play 0.15-0.6 0.006-0.024
Rear Planetary Gear Set Snap-rings 3.0, 3.4, and 3.7 0.118, 0.134, 0.146
B1 Clutch Clearance 2 Disc 2.3-2.7 0.091-0.106
3 Disc 2.7-3.1 0.106-0.122
4 Disc 3.0-3.4 0.118-0.134
B1 Clutch Snap-rings 2.6, 2.9, 3.2, 3.5, 3.8, and 0.102, 0.114, 0.126, 0.138,
4.1 0.150, 0.162
B2 Clutch Clearance 4 Disc 1.9-2.3 0.075-0.091
5 Disc 2.0-2.4 0.079-0.095
B2 Clutch Snap-rings 2.9, 3.2, 3.5, 3.8, and 4.1 0.114, 0.126, 0.138, 0.150,
0.162
B3 Clutch Clearance 1.0-1.4 0.039-0.055
B3 Clutch Snap-rings 3.2, 3.5, 3.8, 4.1, 4.4, and 0.126, 0.138, 0.150,
4.7 0.162, 0.173, 0.185
K1 Clutch Clearance 3 Disc 2.7-3.1 0.106-0.122
4 Disc 3.0-3.4 0.118-0.134
5 Disc 3.3-3.7 0.13-0.146
6 Disc 3.6-4.0 0.142-0.158
K1 Clutch Snap-rings 2.6, 2.9, 3.2, 3.5, 3.8, and 0.102, 0.114, 0.126, 0.138,
4.1 0.150, 0.162
4 Disc 2.4-2.8 0.095-0.110
5 Disc 2.5-2.9 0.099-0.114
6 Disc 2.7-3.1 0.106-0.122
3.8 0.138, 0.150
4 Disc 2.4-2.8 0.095-0.110
5 Disc 2.5-2.9 0.099-0.114
3.5 0.126, 0.138

Bolt, B2 Clutch Carrier 16 - 141
Bolt, B1 Carrier to Converter Housing 10 - 88.5
Nut, Propeller Flange 120 88.5 -
Bolt, Electrohydraulic Unit 8 - 71
Bolt, Transmission Housing to Converter Housing 20 - 177
Bolts, Oil Pan 8 - 71
Screws, Valve Body/Housing Side Cover 4 - 35
Bolt, Shift Plate 8 - 71
Bolt, Solenoid Leaf Spring 8 - 71
Plug, Oil Pan Drain 20 - 177
Nut, Shifter Mechanism to Floor Pan 7 - 65
SPECIAL TOOLS - NAG1 AUTOMATIC

TRANSMISSION
6311 BAR, GAUGE
C-3339 DIAL INDICATOR
C-4171 HANDLE
8266 END PLAY SET

8901 TOOL, PRESSING

82 ADAPTER, GEARTRAIN END-PLAY
8863A DIPSTICK
8902A INSTALLER, SEAL
8900 Compressor, Multi-use Spring
9078 TOOL, STAKING

9082 REMOVER, BEARING 9287 INSTALLER, BEARING

DRIVING CLUTCHES
DESCRIPTION
Three multi-plate driving clutches the front, middle and rear multi-plate clutches K1 (1), K2 (2) and K3 (5), are
located in the planetary gear sets in the transmission housing.
1 - K1 DRIVING CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR

2 - K2 DRIVING CLUTCH 13 - K2 DRIVING CLUTCH EXTERNAL TOOTH DISC CARRIER
3 - EXTERNAL TOOTHED DISC 14 - K2 DRIVING CLUTCH PISTON
4 - INTERNAL TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 DRIVING CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 DRIVING CLUTCH EXTERNAL TOOTH DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 PISTON 18 - K1 DRIVING CLUTCH INTERNAL TOOTH DISC CARRIER
8 - K3 DRIVING CLUTCH INTERNAL TOOTH DISC CARRIER 19 - K1 DRIVING CLUTCH EXTERNAL TOOTH DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 DRIVING CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
A multi-plate driving clutch consists of a number of internally toothed discs (4) on an internally toothed disc carrier
and externally toothed discs (3) on an externally toothed disc carrier.
OPERATION
The driving clutches (1, 2 and 5) produce a non-positive locking connection between two elements of a planetary
gear set or between one element from each of two planetary gear sets in order to transmit the drive torque.
1 - K1 DRIVING CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR

2 - K2 DRIVING CLUTCH 13 - K2 DRIVING CLUTCH EXTERNALLY TOOTHED DISC
CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 DRIVING CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 DRIVING CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 DRIVING CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 DRIVING CLUTCH PISTON 18 - K1 DRIVING CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 DRIVING CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 DRIVING CLUTCH EXTERNALLY TOOTHED DISC
CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 DRIVING CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR
If the piston (20) on driving clutch K1 (1) is subjected to oil pressure, it presses the internal and external discs of the
disc set together. The sun gear (17) is locked with the planetary carrier (15) via the externally toothed disc carrier
(19) and the internally toothed disc carrier (18). The front planetary gear set is thus locked and turns as a closed
unit.
If the driving clutch K2 (2) is actuated via the piston (14), the piston compresses the disc set. The annulus gear (16)
of the front planetary gear set is locked with the annulus gear (11) of the center planetary gear set via the externally
toothed disc carrier (13) and the center planetary carrier (10) on which the internally toothed discs are seated. Annu-
lus gear (16) and annulus gear (11) turn at the same speed as the input shaft (21)
If the driving clutch K3 (5) is actuated via the piston (7), the piston compresses the disc set. The sun gear (12) of
the center planetary gear set is locked with the sun gear (9) of the rear planetary gear set via the externally toothed
disc carrier (6) and the internally toothed disc carrier (8). Sun gear (12) and sun gear (9) turn at the same speed.
DRIVING CLUTCH K1
DISASSEMBLY
1 - K1 OUTER DISC CARRIER 7 - DISC SPRING

2 - FREEWHEEL F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK
1. Remove the snap-ring (11) from the K1 outer disc carrier (1).
2. Take the multiple-disc pack (12) out of the K1 outer disc carrier (1).
3. Place Special Tool 8900 on the spring plate (8) and compress the spring until the snap-ring (10) is exposed.
4. Remove the snap-ring (10).
5. Take out the disc spring (7) and remove the piston (6) by carefully blowing compressed air into the bore.
6. Remove the snap-ring (3) and take out the freewheel F1 (2).
ASSEMBLY

1. Install the piston (6) in the K1 outer disc carrier (1). Check the sealing rings (4 and 5) and replace if necessary.
The rounded off edges of the sealing rings must point outwards.
2. Insert the disc spring (7). Insert the disc spring with the curvature towards the piston.
3. Insert the spring plate (8). Insert the spring plate with the curvature towards the sun gear. Check the sealing ring
(9), replace if necessary.
4. Place Special Tool 8900 on spring plate (8) and compress the spring until the groove of the snap-ring is exposed.
5. Insert the snap-ring (10). After installing, check the snap-ring for correct seat.
Note: Pay attention to the sequence of the discs. Place new friction multiple-discs in ATF fluid for one hour
before installing.
6. Insert the multiple disc pack (12) in the K1 outer disc carrier (1).
7. Insert the snap-ring (11).
8. Measure the K1 clutch pack clearance.
a. Mount Special Tool 8901 (1) on the K1 outer disc

carrier (2).
b. Using a lever press, compress the pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).
c. Using a feeler gauge, determine the play “L” at

three points between the snap-ring (6) and outer
multiple-disc (3).
d. During the measurement, the snap-ring (6) must
contact the upper bearing surface of the groove in
the outer multiple-disc carrier.
e. The correct clutch clearance is 2.7-3.1 mm (0.106-
0.122 in.) for three friction disc versions, 3.0-3.4
mm (0.118-0.134 in.) for four disc versions, 3.3-3.7
mm (0.130-0.146 in.) for five disc versions, and
3.6-4.0 mm (0.142-0.158 in.) for six disc versions.
f. Adjust with snap-ring (6), if necessary. Snap-rings
are available in thicknesses of 2.6 mm (0.102 in.),
2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).

9. Insert the front freewheel F1 (2) and fit the snap-ring (3). The freewheel F1 (2) must be installed in the direction
of the arrow.
DRIVING CLUTCH K2
DISASSEMBLY
1 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR 9 - SPRING RETAINER

SET
2 - THRUST BEARING 10 - SNAP-RING
3 - INPUT SHAFT AND K2 CLUTCH 11 - DISC SPRING
4 - PISTON OUTER SEAL RING 12 - MULTIPLE DISC PACK
5 - PISTON INNER SEAL RING 13 - SNAP-RING
6 - PISTON 14 - HOLLOW GEAR
7 - DISC SPRING 15 - SNAP-RING
8 - SPRING RETAINER SEAL
1. Remove the snap-ring (15) from the K1 inner disc carrier with integrated front gear set (1) and take off the hollow
gear (14).
2. Remove the input shaft and K2 clutch (3).
3. Remove the thrust bearing (2).
4. Remove the snap-ring (13) from K2 outer multiple-disc carrier.
5. Take out the multiple-disc pack (12).
6. Take out the disc spring (11).
7. Fit Special Tool 8900 (1) onto spring retainer and press
until snap-ring (2) is released.

SET

9. Take out the disc spring (7) and pull the piston (6) out of the outer multiple-disc carrier.
ASSEMBLY

SET
1. Install the piston (6) in the outer multiple-disc carrier. Inspect the seals (4 and 5), replace if necessary. The
rounded edges of the seals must point to the outside.
2. Insert the disc spring (7) and the spring retainer (9). Insert the disc spring (7) with the curved side pointing
toward the spring retainer (9). Inspect the seal (8), replace if necessary.
3. Place Special Tool 8900 on the spring plate (1) and press
until the groove of the snap-ring is exposed.
5. Insert the disc spring.
Note: Pay attention to the sequence of the discs. Place

new friction multiple-discs in ATF fluid for one hour before
installing.
6. Insert the multiple-disk set into the outer multiple-disk car-

rier.
7. Fit the snap-ring.
8. Measure the K2 clutch clearance.

a. Mount Special Tool 8901 (1) on the outer multiple
disc (2).
see small arrow).

multiple-disc (4).
d. During the measurement the snap-ring (6) must
contact the upper bearing surface of the groove in
the outer multiple-disc carrier.
mm (0.095-0.110 in.) for four disc versions, 2.5-2.9
mm (0.099-0.114 in.) for five disc versions, and
2.7-3.1 mm (0.106-0.122 in.) for six disc versions.
f. Adjust with snap-ring (6), if necessary. Snap-rings
2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm
(0.126 in.), 3.5 mm (0.138 in.), and 3.8 mm (0.150
in.).

SET
9. Insert the thrust bearing (2) into the K1 inner disc carrier. Insert the thrust bearing (2) with a little grease to
prevent it from slipping.
10. Install the input shaft and k2 clutch in the K1 inner disc carrier with integrated front gear set (1).
11. Fit the hollow gear (14). Pay attention to the installation position.
DRIVING CLUTCH K3
DISASSEMBLY
1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE
1. Remove the snap-ring (1) from the outer disc carrier (8).
2. Remove the multiple disc pack (2) and the disc spring (3) from the outer disc carrier.
3. Place Special Tool 8900 (9) on the spring plate (5) and compress the spring until the snap-ring (4) is exposed.
5. Remove the spring plate (5) and the piston (6) from the outer disc carrier (8).
ASSEMBLY
1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE
1. Install the piston (6) in the outer disc carrier (8). Check the sealing ring (7) and replace if necessary. The
rounded off edges of the sealing ring must point outwards.
2. Insert the spring plate (5). Insert the spring plate (5) with the curvature towards the piston.
3. Mount Special Tool 8900 (9) on the spring plate (5) and clamp until the snap-ring groove is exposed.
4. Insert the snap-ring (4). The collar of the snap-ring (4) must point towards the disc pack (2).
before installing.
5. Install the disc spring (3) and the multiple disc pack (2) in the outer disc carrier (8).
7. Measure the K3 clutch clearance.
a. Mount Special Tool 8901 (1) on the outer disc car-

rier.
see small arrow).

multiple-disc (2).
d. During the measurement, the snap-ring must con-
tact the upper bearing surface of the groove in the
outer multiple-disc carrier.
mm (0.095-0.110 in.) for four disc versions, and
2.5-2.9 mm (0.099-0.114 in.) for five disc versions.
f. Adjust with snap-ring, if necessary. Snap-rings are
available in thicknesses of 2.0 mm (0.079 in.), 2.3
mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm (0.114
in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138 in.).
ELECTROHYDRAULIC UNIT
DESCRIPTION
The electrohydraulic control unit comprises the shift plate made from light alloy for the hydraulic control and an
electrical control unit. The electrical control unit comprises of a supporting body made of plastic, into which the
electrical components are assembled. The supporting body is mounted on the shift plate and screwed to it.
Strip conductors inserted into the supporting body make the connection between the electrical components and a
plug connector. The connection to the wiring harness on the vehicle and the transmission control module (TCM) is
produced via this 13-pin plug connector with a bayonet lock.
ELECTRICAL CONTROL UNIT

The electrical control unit (7) consists of a plastic shell which
houses the RPM sensors (1,12), regulating solenoid valves (3,
4), solenoid valves (5, 6, 10), the TCC solenoid valve (11), the
park/neutral contact (9), and the transmission oil temperature
sensor (8). Conductor tracks integrated into the shell connect
the electric components to a plug connection (2). This 13-pin
plug connection (2) establishes the connection to the vehicle-
side cable harness and to the transmission control module
(TCM). With the exception of the solenoid valves, all other
electric components are fixed to the conductor tracks.
HYDRAULIC CONTROL UNIT

Working Pressure (Operating Pressure) (p-A)
The working pressure provides the pressure supply to the hydraulic control and the transmission shift elements. It is
the highest hydraulic pressure in the entire hydraulic system. The working pressure is regulated at the working pres-
sure regulating valve in relation to the load and gear. All other pressures required for the transmission control are
derived from the working pressure.
Lubrication Pressure (p-Sm)
At the working pressure regulating valve, surplus oil is diverted to the lubrication pressure regulating valve, from
where it is used in regulated amounts to lubricate and cool the mechanical transmission components and the torque
converter. Furthermore, the lubrication pressure (p-Sm) is also used to limit the pressure in the torque converter.
Shift Pressure (p-S)
The shift pressure is determined by the shift pressure regulating solenoid valve and the shift pressure regulating
valve. The shift pressure:
• Regulates the pressure in the activating shift element during the shift phase.
• Determines, together with the modulating pressure, the pressure reduction at the deactivating shift element
as regulated by the overlap regulating valve.
• Initializes 2nd gear in limp-home mode.
Modulating Pressure (p-Mod)
The modulating pressure influences the size of the working pressure and determines, together with the shift pres-
sure, the pressure regulated at the overlap regulating valve. The modulating pressure is regulated at the modulating
pressure regulating solenoid valve, which is under regulating valve pressure. The modulating pressure is variable
and relative to the engine load.
Regulating Valve Pressure (p-RV)
The regulating valve pressure is regulated at the regulating valve pressure regulating valve in relation to the working
pressure (p-A) up to a maximum pressure of 8 bar (116 psi). It supplies the modulating pressure regulating solenoid
valve, the shift pressure regulating solenoid valve and the shift valve pressure regulating valve.
Shift Valve Pressure (p-SV)
The shift valve pressure (p-SV) is derived from the regulating valve pressure (p-RV), is regulated at the shift valve
pressure regulating valve and is then present at the:
• 1-2 and 4-5 shift solenoid valve.
• 3-4 shift solenoid valve.
• 2-3 shift solenoid valve.
• Torque converter lockup solenoid valve.
• 3-4 and 2-3 shift pressure shift valve.
The shift valve pressure (p-SV) controls the command valves via the upshift/downshift solenoid valves.
Overlap Pressure (p-Ü)
The overlap pressure controls the shift component pressure reduction during a shift phase. The pressure in a shift
element as it disengages is controlled during the shift phase depending on engine load (modulating pressure) and
the pressure in the shift element as it engages. The adjusted pressure is inversely proportional to the transmission
capability of the shift element being engaged (controlled overlap).
Working Pressure Regulating Valve (Operating Pressure)
The working pressure regulating valve (4) is located in the

valve housing of the shift plate. It regulates the primary pres-
sure of the hydraulic system.
Torque Converter Lockup Clutch Regulating Valve
The torque converter lock-up clutch regulating valve (6) is

located in the valve housing of the electrohydraulic control
module. The valve is responsible for the hydraulic control of
the torque converter lockup clutch and distribution of the lubri-
cating oil.
Overlap Regulating Valve
Each shift group is assigned one overlap regulating valve (1).

The 1-2 / 4-5 overlap regulating valve is installed in the shift
valve housing; the 2-3 and 3-4 overlap regulating valves are
installed in the valve housing. The overlap regulating valve
regulates the pressure reduction during a shift phase.
Command Valve
1 - HOLDING CLUTCH B1 3 - 1-2/4-5 COMMAND VALVE

2 - DRIVING CLUTCH K1
Each shift group possesses one command valve (3). The 1-2 / 4-5 and 2-3 command valves are installed in the shift
valve housing; the 3-4 command valve is installed in the valve housing. The command valve switches the shift
group from the stationary phase to the shift phase and back again.
Holding Pressure Shift Valve
1 - HOLDING PRESSURE SHIFT VALVE
Each shift group possesses one holding pressure shift valve (1). The 1-2 / 4-5 and 2-3 holding pressure shift valves
are installed in the shift valve housing; the 3-4 holding pressure shift valve is installed in the valve housing. The
holding pressure shift valve allocates the working pressure to one actuator of a shift group.
Shift Pressure Shift Valve
1 - 1-2/4-5 COMMAND VALVE 3 - HOLDING CLUTCH B1

2 - DRIVING CLUTCH K1 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE
Each shift group possesses one shift pressure shift valve (4). The 1-2 / 4-5 and 2-3 shift pressure shift valves are
installed in the shift valve housing; the 3-4 shift pressure shift valve is installed in the valve housing. It assigns the
shift pressure (p-S) to the activating actuator and the overlap pressure (p-Ü) regulated by the overlap regulating
valve to the deactivating actuator.
Lubrication Pressure Regulating Valve
The lubrication pressure regulating valve (1) is located in the

valve housing of the electrohydraulic control module. The valve
controls the fluid to lubricate and cool the mechanical part of
the transmission, and limits the pressure in the torque
converter.
Shift Pressure Regulating Valve
The shift pressure regulating valve (3) is located in the valve

housing of the shift plate. It regulates the shift pressure (p-S).
Regulating Valve Pressure Regulating Valve
The regulating valve pressure regulating valve (1) is located in

the valve housing of the electrohydraulic control module. It
regulates the regulating valve pressure (p-RV).
Shift Valve Pressure Regulating Valve
The shift valve pressure regulating valve (1) is located in the

valve housing of the electrohydraulic control module. It regu-
lates the shift valve pressure (p-SV).
OPERATION
ELECTRICAL CONTROL UNIT
Signals from the transmission control module (TCM) are con-
verted into hydraulic functions in the electrical control unit (7).
The RPM sensors (1, 12), starter interlock contact (9), and
transmission oil temperature sensor (8) of the electrical control
unit (7) supply the TCM with input signals. The solenoid valves
are controlled by the TCM and trigger the hydraulic functions.
HYDRAULIC CONTROL UNIT

Working Pressure Regulating Valve (Operating Pressure)
The working pressure (p-A) is regulated at the working pres-

sure regulating valve (4) in relation to load (modulating pres-
sure) and gear (K1 or K2 pressure). The spring in the working
pressure regulating valve sets a minimum pressure level
(basic pressure).
Torque Converter Lockup Clutch Regulating Valve
The torque converter lockup clutch regulating valve (6) regu-

lates the torque converter lock-up clutch working pressure in
relation to the torque converter clutch control pressure.
According to the size of the working pressure, the torque con-
verter lockup clutch is either Engaged, Disengaged, or Slip-
ping. When the regulating valve (6) is in the lower position,
lubricating oil flows through the torque converter and oil cooler
(8) into the transmission (torque converter lockup clutch
unpressurized). In its regulating position (slipping, torque con-
verter lockup clutch pressurized), a reduced volume of lubricat-
ing oil flows through the annular passage (7) bypassing the
torque converter and passing direct through the oil cooler into
the transmission. The rest of the lubricating oil is directed via
the throttle “a” into the torque converter in order to cool the
torque converter lockup clutch.
Overlap Regulating Valve
During the shift phase, the pressure in the deactivating shift

actuator is regulated in relation to the engine load (modulating
pressure) and the pressure in the activating actuator. The reg-
ulated pressure is inversely proportional to the transfer capac-
ity of the activating shift actuator (regulated overlap).
Command Valve
1 - HOLDING CLUTCH B1 3 - 1-2/4-5 COMMAND VALVE

2 - DRIVING CLUTCH K1
When the end face is unpressurized (stationary phase), the working pressure is directed to the actuated shift ele-
ment. If the end face of the command valve is subjected to the shift valve pressure (p-SV) (shift phase), then the
shift pressure is switched to the activating element and the overlap pressure is switched to the deactivating element.
Shift Valve Holding Pressure
1 - HOLDING PRESSURE SHIFT VALVE
The holding pressure shift valve is actuated by the pressures present at the end face in the actuators and a spring.
It assigns the working pressure to the actuator with the higher pressure (taking into account the spring force and the
effective surface area). The other element of the shift group is then unpressurized. The valve switches over only
during the shift phase and only at a certain pressure ratio between the overlap pressure (p-Ü) and the shift pressure
(p-S).
Shift Pressure Shift Valve
1 - 1-2/4-5 COMMAND VALVE 3 - HOLDING CLUTCH B1

2 - DRIVING CLUTCH K1 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE
When the multiple-disc brake B1 (3) is activated, the working pressure (pa) is applied to the end face of the 1-2 /
4-5 shift pressure shift valve (4) via the command valve (1). Its shift state is maintained during the shift phase by
substituting the shift element pressure acting on its end face (and which is variable during the shift phase) with a
corresponding constant pressure. When the multi-plate clutch K1 (2) is activated, the end face of the shift valve is
unpressurized during the stationary and shift phases, so the shift state is maintained during the shift phase in this
case too.
Lubrication Pressure Regulating Valve
At the working pressure, regulating valve surplus oil is diverted

to the lubrication pressure regulating valve (1), from where the
lubrication pressure (p-Sm) is used in regulated amounts to
supply the transmission lubrication system including the torque
converter.
Shift Pressure Regulating Valve
The shift pressure is determined by the shift pressure regulat-

ing solenoid valve and the shift pressure regulating valve (3).
In addition, pressure from the driving clutch K2 (1) is also
present at the annular surface (2) of the shift pressure regu-
lating valve (3). This reduces the shift pressure in 2nd gear.
Regulating Valve Pressure Regulating Valve
The regulating valve pressure (p-RV) is set at the regulating

valve pressure regulating valve (1) in relation to the working
pressure (p-A) as far as the maximum pressure.
Shift Valve Pressure Regulating Valve
The non-constant regulating valve pressure (p-RV) is regulated

to a constant shift valve pressure (p-SV) at the shift valve
pressure regulating valve (1) and is used to supply the 1-2 and
4-5 / 3-4 / 2-3 solenoid valves and the torque converter lockup
clutch PWM solenoid valve.
REMOVAL
1. Move selector lever to position “P”.
3. Remove the bolt (3) and screw (1) holding the heat shield
(2) to the transmission.
4. Loosen the guide bushing and remove it from the transmis-
sion housing.
5. Disconnect the 13-pin plug connector (1). Turn the bayonet

lock of the guide bushing (2) anti-clockwise.
Note: If the transmission fluid is burnt or contains

abraded particles, the oil cooler lines and oil cooler must
be flushed out.
6. Remove the transmission filter. Refer to Page 21-294.

7. Unscrew the bolts (3) and remove electrohydraulic control

module (2).
DISASSEMBLY
1. Remove the electrohydraulic control unit from the vehicle.
2. Remove the solenoid caps (1, 2).
3. Unscrew the bolts (3, 4).
Note: Pay attention to the different lengths of the Torx

socket bolts.
4. Remove the leaf springs (5).

5. Withdraw the solenoid valves (6 - 11) from the shift plate
(13).
Note: Check O-rings on solenoid valves for damage and

replace if necessary.
6. Bend away the retaining lug on the stiffening rib on the

transmission oil temperature sensor.
7. Remove the electrohydraulic control module (12) from the
shift plate (13).
Note: Pay great attention to cleanliness for all work on the shift plate. Fluffy cloths must not be used.
Leather cloths are particularly good. After dismantling, all parts must be washed and blown out with com-
pressed-air, noting that parts may be blown away.
8. Unbolt the leaf spring (5).

9. Unscrew the bolts (1).
10. Remove the valve housing (2) from the valve body (4).
11. Remove the strainers (1) for the modulating pressure and
shift pressure control solenoid valves from the valve hous-
ing.
12. Note the locations of the major shift valve group compo-
nents for assembly reference.
13. Remove the strainer in the inlet to torque converter

lock-up control solenoid valve (1).
14. Remove the sealing plate (3).
Note: A total of 12 valve balls are located in the valve

body, four made from plastic (4) and eight from steel (1,
3).
15. Note the location of all check balls (1, 3, 4) and the cen-
tral strainer (2) for re-installation. Remove all check balls
(1, 3, 4) and the central strainer (2).
16. Remove the screws holding the side covers to the valve
body and valve housing.
1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE

2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE
3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE
5 - 1-2/4-5 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 12 - 2-3 SHIFT PRESSURE SHIFT VALVE
6 - SHIFT PRESSURE REGULATING VALVE 13 - TCC LOCK-UP REGULATING VALVE
7 - REGULATING VALVE PRESSURE REGULATING VALVE
17. Remove all the valves and springs from the valve body (1). Check all valves for ease of movement and
shavings.
1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE
2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON
3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE
4 - 3-4 HOLDING PRESSURE SHIFT VALVE 9 - LUBRICATING PRESSURE REGULATING VALVE
5 - 3-4 COMMAND VALVE
18. Remove all of the valves and springs from the valve housing (2). Check all valves for ease of movement and
shavings.
Note: The sleeves and pistons of the overlap regulating valves must not be mixed up.
19. Remove the pressure supply valve from the valve body.
ASSEMBLY
1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE

2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE
3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE
5 - 1-2/4-5 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 12 - 2-3 SHIFT PRESSURE SHIFT VALVE
6 - SHIFT PRESSURE REGULATING VALVE 13 - TCC LOCK-UP REGULATING VALVE
7 - REGULATING VALVE PRESSURE REGULATING VALVE
1. Install all of the valves and springs from the valve body (1). Check all valves for ease of movement and
shavings.
Note: Pay great attention to cleanliness for all work on the

shift plate. Fluffy cloths must not be used. Leather cloths
are particularly good. After dismantling, all parts must be
washed and blown out with compressed-air, noting that
parts may be blown away.
2. Install the pressure supply valve (1) into the valve body.
Note: The sleeves and pistons of the overlap regulating valves must not be mixed up.
1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE
2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON
3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE
4 - 3-4 HOLDING PRESSURE SHIFT VALVE 9 - LUBRICATING PRESSURE REGULATING VALVE
5 - 3-4 COMMAND VALVE
3. Install all of the valves and springs into the valve housing (2). Check all valves for ease of movement and shav-
ings.
4. Install the screws to hold the side covers to the valve body and valve housing. Tighten the screws to 4 N·m (35
in. lbs.).
Note: A total of 12 valve balls are located in the valve

body, four made from plastic (4) and eight from steel (1,
3).
5. Install all of the check balls (1, 3, 4) and the central strainer
(2).
6. Install the strainer in the inlet to the torque converter

lock-up control solenoid valve (1).
7. Position the sealing plate (3) onto the valve body (4).
8. Install the valve housing (2) onto the valve body (4) and
sealing plate (3).
9. Install the shift plate bolts (1). Tighten the bolts to 8 N·m
(71 in. lbs.).
10. Install the leaf spring (5).
11. Install the strainers (1) for the modulating pressure and
shift pressure control solenoid valves into the valve
housing.
12. Install the electrohydraulic control module (12) onto the

shift plate (13).
13. Bend the retaining lug on the stiffening rib on the trans-
mission oil temperature sensor to retain the electrohydrau-
lic control module.
14. Install the solenoid valves (6 - 11) into the shift plate (13).
Note: Check the O-rings on the solenoid valves for dam-

age and replace if necessary.
15. Install the leaf springs (5).

16. Install the bolts (3, 4). Tighten the bolts to 8 N·m (71 in.
lbs.).
Note: Pay attention to the different lengths of the bolts.
17. Install the solenoid caps (1, 2).

18. Install the electrohydraulic unit into the vehicle. Refer to
Page 21-290.
INSTALLATION
1. Position the electrohydraulic unit in the transmission hous-
ing.
2. Insert the selector valve (1) in the driver of the detent plate
(2). When installing the electrohydraulic control module in
the transmission housing, the plastic part of the selector
valve (1) must engage in the driver of the detent plate (2).
3. Install the bolts (3) and tighten to 8 N·m (71 in. lbs.).
4. Install a new oil filter..
5. Install the oil pan (5) and torque the oil pan bolts to 8 N·m
(71 in. lbs.).
6. Install the oil drain plug (8) with a new drain plug gasket
(9). Torque the drain plug to 20 N·m (177 in. lbs.).
7. Install the guide bushing (12) into the transmission housing
and install the bolt (11) to hold the guide bushing in place.
8. Check the O-ring on the plug connector (1), and replace if

necessary.
9. Install the plug connector (1) into the guide bushing (2).
Turn the bayonet lock of the guide bushing (2) clockwise to
connect plug connector (1).
10. Position the heat shield (2) onto the transmission housing
and install the screw (1) and bolt (3) to hold the shield in
place.
11. Fill the transmission with specified fluid. Refer to Page
21-294.
FLUID AND FILTER

DESCRIPTION
The oil level control is located on the electrohydraulic unit and
consists of the float (5) which is integrated into the electrohy-
draulic control unit. The float is positioned to plug the opening
between the oil gallery and gearset chamber so that the rotat-
ing gearsets do not splash about in oil as the oil level rises.
The oil level control reduces power loss and prevents oil from
being thrown out of the transmission housing at high oil
temperatures.
OPERATION
With low oil levels, the lubricating oil which flows constantly
out of the gearset, flows back to oil galley (2) though the open-
ing (6). If the oil level rises, the oil presses the float (5) against
the housing opening (6). The float (5) therefore separates the
oil gallery (2) from the gearset chamber (1). The lubricating oil
which continues to flow out of the gearsets is thrown against
the housing wall, incorporated by the rotating parts and flows
back into the oil galley (2) through the upper opening (arrow).

EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be
low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aer-
ates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid
overheating, oxidation and varnish buildup which interferes with valve and clutch operation. Foaming also causes
fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be
mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID

Burnt, discolored fluid is a result of overheating which has four primary causes.
1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal
failure.
2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a
faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and
lines caused by debris or kinked lines.
3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high
load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should
have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination
needed to handle heavy loads.
4. Low fluid level.
DIAGNOSIS AND TESTING - FLUID CONTAMINATION

Transmission fluid contamination is generally a result of:
• adding incorrect fluid
• failure to clean dipstick and fill tube when checking level
• engine coolant entering the fluid
• internal failure that generates debris
• overheat that generates sludge (fluid breakdown)
• failure to replace contaminated converter after repair
The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage,
abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using rec-
ommended fluids only.
The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign mate-
rial on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube
clean before withdrawing the dipstick.
Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace
the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission,
an overhaul is necessary.
The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary
because normal converter flushing procedures will not remove all contaminants.
STANDARD PROCEDURE
CHECK OIL LEVEL
1. Verify that the vehicle is parked on a level surface.
2. Remove locking pin (1). Remove the plate of the locking
pin with a suitable tool and press out the pin remaining in
the cap downwards.
3. Remove the cap (2) from the fill tube (3).
WARNING: RISK OF ACCIDENT FROM VEHICLE START-

ING OFF BY ITSELF WHEN ENGINE RUNNING. RISK OF
INJURY FROM CONTUSIONS AND BURNS IF YOU INSERT
YOUR HANDS INTO THE ENGINE WHEN IT IS STARTED
OR WHEN IT IS RUNNING. SECURE VEHICLE TO PRE-
VENT IT FROM MOVING OFF BY ITSELF. WEAR PROP-
ERLY FASTENED AND CLOSE-FITTING WORK CLOTHES.
DO NOT TOUCH HOT OR ROTATING PARTS.
4. Actuate the parking brake. Start engine and let it run at idle speed in selector lever position “P”.
5. Shift through the transmission modes several times with the vehicle stationary and the engine idling
6. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the
Special Tool 8863A (1) in up to the stop and pull out again, read off oil level, repeat if necessary.
7. Check the transmission oil temperature.
Note: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward
gear position.
8. The transmission Special Tool 8863A has indicator marks every 10mm. Determine the height of the oil level on
the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if
the transmission oil level is correct.
9. Add or remove oil as necessary and recheck the oil level.
10. Once the oil level is correct, install a new dipstick tube
cap (2) and lock pin (1).
STANDARD PROCEDURE - TRANSMISSION FILL

To avoid overfilling transmission after a fluid change or over-
haul, perform the following procedure:
1. Verify that the vehicle is parked on a level surface.
2. Remove the locking pin (1). Remove the plate of the lock-
ing pin with a suitable tool and press out the pin remaining
in the cap downwards.
3. Remove the cap (2) from the fill tube (3).
4. Add the following initial quantity of ShellT 3403 to transmis-
sion:
a. If only the fluid and filter were changed, add 5.0 L
(10.6 pts.) of transmission fluid to the transmission.
b. If the transmission was completely overhauled, the
torque converter was replaced or drained, and the
cooler was flushed, add 7.7 L (16.3 pts.) of trans-
mission fluid to the transmission.
5. Check the transmission fluid level. Refer to Page 21-294,
and adjust as required.
STANDARD PROCEDURE - FILTER CHANGE

2. Position a drain pan under the transmission drain plug. Remove the plug (2) and the gasket (1). Allow the trans-
mission to drain thoroughly.
3. Remove the oxygen sensor wire harness (1) from the heat
shield.
4. Remove the screws (2) from the heat shield and position it
out of the way.
5. Remove the remaining screws (3) and the transmission pan

(1).
6. Remove and discard the transmission filter (6) from the
valve body.
7. Clean the transmission oil pan and the gasket surface of
the transmission.
8. Install a new transmission filter (6).
9. Replace the transmission pan gasket if damaged or swol-
len.
10. Install the transmission pan (1) and bolts (3). Tighten the
bolts to 8 N·m (71 in. lbs.).
11. Install the drain plug (2) with a new gasket (1). Tighten the
drain plug to 20 N·m (15 lbs.ft.).
12. Install the heat shield and the bolts (2). Tighten the bolts
to 8 N·m (71 in. lbs.).
13. Route the oxygen sensor wire harness (1) in the heat
shield. Connect the oxygen sensor wire harness connec-
tors.
15. Fill the transmission with the specified fluid.
FREEWHEELING CLUTCH
DESCRIPTION
Freewheeling clutches are installed in the front planetary gear
set between the sun gear and the stator shaft, and in the rear
planetary gear set between the sun gear and the intermediate
shaft.
The freewheel consists of an outer race (4), an inner race (7),
a number of locking elements (3) and a cage (6) for these
locking elements.
OPERATION
The freewheel optimizes individual gearshifts. They lock indi-
vidual elements of a planetary gear set together or against the
transmission housing in one direction of rotation to allow the
torque to be transmitted.
If the inner race (7) of the freewheeling clutch is locked and
the outer race (4) turns counter clockwise (1), the locking ele-
ments (3) adopt a diagonal position on account of their special
contours, allowing the freewheel function. The outer race (4)
slides over the locking elements (3) with negligible friction. If
the rotation of the outer race (4) changes to clockwise (2), the
locking elements (3) stand up and lock the outer and inner
races (4, 7) together.
DISASSEMBLY
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - SNAP-RING 5 - RETAINING RING
3 - FREEWHEEL F2 6 - O-RINGS
1. Remove the retaining ring (5) from the hollow shaft (1).
2. Remove the K3 inner disc carrier and rear planetary sun gear (4) with the K3 internally toothed disk carrier and
the rear freewheel F2 (3).
3. Remove the snap-ring (2) for freewheel.
4. Press the freewheel out of the K3 inner disc carrier and rear planetary sun gear (4).
5. Check the O-rings (6), replace if necessary.
6. Check the anti-friction bearing (2) in the K3 inner disc car-

rier and rear planetary sun gear for damage. Replace as
necessary.
ASSEMBLY
1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - SNAP-RING 5 - RETAINING RING
3 - FREEWHEEL F2 6 - O-RINGS
1. Press the freewheel F2 (3) into the K3 inner disc carrier and rear planetary sun gear (4).
2. Install the snap-ring (2) for the freewheel.
3. Check the O-rings (6) on the hollow shaft (1), replace if necessary.
4. Install the K3 inner disc carrier and rear planetary sun gear (4) with the K3 internally toothed disc carrier and the
freewheel (3) onto the hollow shaft (1).
5. Install the retaining ring (5) onto the hollow shaft (1).
HOLDING CLUTCHES
DESCRIPTION
1 - B1 10 - CENTER PLANETARY GEARSET ANNULUS GEAR

2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 PISTON 15 - B1 INTERNALLY TOOTHED DISC CARRIER
7 - B2 PISTON 16 - B1 PISTON
8 - B2 INTERNALLY TOOTHED DISC CARRIER 17 - B1 EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
Three multi-disc holding clutches, the front, middle and rear multi-disc holding clutches B1 (1), B3 (4) and B2 (5),
are located in the planetary gear sets in the transmission housing.
A multi-disc holding clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier
and externally toothed discs (9) on an externally toothed disc carrier, which is rigidly connected to the transmission
housing.
OPERATION
1 - B1 10 - CENTER PLANETARY GEARSET ANNULUS GEAR

2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 PISTON 15 - B1 INTERNALLY TOOTHED DISC CARRIER
7 - B2 PISTON 16 - B1 PISTON
8 - B2 INTERNALLY TOOTHED DISC CARRIER 17 - B1 EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER
The multi-disc holding clutches (1, 4 and 5) connect the annulus gear, sun gear, or planetary carrier of a planetary
gear set against the transmission housing in order to transmit the drive torque.
If the piston (16) on multi-disc holding clutch B1 (1) is subjected to oil pressure, it presses the internal (3) and
external discs (2) of the disc set together. The internally toothed disc carrier (15) locks the sun gear (14) against the
housing. The planetary pinion gears (13) turn on the sun gear (14).
If the multi-disc holding clutch B2 (5) is actuated via the piston (7), the piston compresses the disc set. The inter-
nally toothed disc carrier (8) locks the sun gear (12) against the housing. The planetary pinion gears (11) turn on the
sun gear (12).
If the multi-disc holding clutch B3 (4) is actuated via the piston (6), the planetary carrier (9) and the annulus gear
(10) are locked. When the multi-disc clutch B3 (4) is actuated, the direction of rotation is reversed.
HOLDING CLUTCH B1
DISASSEMBLY
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING

4 - SNAP-RING

2. Remove the multiple-disc pack (6) and the disc spring (5) from the multi-disc holding clutch B1 outer carrier.
3. Place Special Tool 8900 on the disc spring and compress the spring until the snap-ring (4) is exposed.
5. Remove the piston (2) from the multi-disc holding clutch B1 carrier by carefully blowing compressed air into the
bore.
ASSEMBLY
1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING

4 - SNAP-RING
1. Install the piston (2) in the outer multiple-disc carrier (1). Press in the piston using the disc spring (3) and Special
Tool 8900. Place Special Tool 8900 on the disc spring (3) and compress until the groove of the snap-ring (4) is
exposed
Note: Check the vulcanized gasket, replace if necessary.
Note: The collar of the snap-ring must point towards the multiple-disc pack. After installing, check the snap-
ring for correct seat.
3. Insert the disc spring (5) and the multiple-disc pack (6) in the multi-disc holding clutch B1 outer carrier.
Note: Pay attention to the sequence of discs. Place the new friction multiple-discs in ATF fluid for one hour
before installing.
5. Measure the multi-disc holding clutch B1 clearance.

a. Mount Special Tool 8901 (1) multi-disc holding

clutch B1 outer carrier (2).
see small arrow).

multiple-disc (4). During the measurement, the
snap-ring (6) must contact the upper bearing sur-
face of the groove in the outer multiple-disc carrier
(5). The correct clearance is 2.3-2.7 mm
(0.091-0.106 in.) for 2 friction disc versions, 2.7-3.1
mm (0.106-0.122 in.) for 3 disc versions, and 3.0-
3.4 mm (0.118-0.134 in.) for 4 disc versions.
d. Adjust with snap-ring (6), if necessary. Snap-rings
2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).
HOLDING CLUTCH B2
DISASSEMBLY
1 - SNAP-RING 9 - B3 PISTON SEALING RING

2 - MULTIPLE DISC PACK 10 - B2 PISTON
3 - DISC SPRING 11 - PISTON GUIDE SEALING RING
4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING
5 - O-RING 13 - PISTON GUIDE RING
6 - B3 PISTON SEALING RING 14 - PISTON BACK PRESSURE DISC SPRING
7 - B3 PISTON SEALING RING 15 - SPRING PLATE
8 - B3 PISTON/B2 OUTER DISC CARRIER 16 - SNAP-RING
1. Remove the snap ring (1).

2. Take the multi-disc pack (2) and the disc spring (3) out of the B3 piston/B2 outer disc carrier (8). The B3 pis-
ton/B2 outer disc carrier (8) for the multi-disc holding clutch B2 is the piston for the multiple-disc holding clutch
B3 at the same time.
3. Place Special Tool 8900 on the piston back pressure spring disc (14) and compress the spring until the groove
for the snap-ring is exposed.
5. Remove the spring plate (15) and the piston back pressure disc spring (14).
6. Separate the piston guide ring (13) and the B2 piston (10) from the B3 piston/B2 outer disc carrier (8) by blowing
compressed air into the bore.
7. Press the piston guide ring (13) out of the B2 piston (10).
8. Separate the B2 and B3 piston guide (4) from the B3 piston/B2 outer disc carrier (8) by blowing compressed air
into the bore.
ASSEMBLY

1. Assemble the B2 and B3 piston guide (4) and the B3 piston/B2 outer disc carrier (8) in the correct position.
2. Check all of the sealing rings, replace if necessary. The rounded off edges on the sealing rings (6), (11), and (12)
must point outwards. The rounded off edges on the sealing ring (9) must point inwards.
3. Insert the B2 piston (10) in B3 piston/B2 outer disc carrier (8).
4. Insert the piston guide ring (2). The valve (1) in the piston
guide ring must be on top.

5. Insert the piston back pressure disc spring (14) and the spring plate (15). Insert the disc spring with the curvature
towards the spring plate.
6. Place Special Tool 8900 on the disc spring (14) and compress the spring until the groove for the snap-ring is
exposed.
before installing.
8. Insert the disc spring (3) and the multi-disc pack (2) in the B3 piston/B2 outer disc carrier (8).
Note: During the measurement the snap-ring (1) must contact the upper bearing surface of the groove in the
outer multiple-disc carrier.
10. Measure the B2 clutch pack clearance.

a. Mount Special Tool 8901 (1) on the B3/B2 outer
disc carrier (2).
see small arrow).

multiple-disc (7).
d. The correct clutch clearance is 1.9-2.3 mm (0.075-
0.091 in.) for the four friction disc versions and 2.0-
2.4 mm (0.079-0.095 in.) for the five disc versions.
e. Adjust with snap-ring (8), if necessary. Snap-rings
3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm
(0.150 in.), and 4.1 mm (0.162 in.).
SPEED SENSOR
DESCRIPTION
The input speed sensors (6, 8) are fixed to the shell of the
control unit via contact blades. The speed sensors are pressed
against the transmission housing (2) by a spring (7) which is
held against the valve housing of the shift plate (5). This
ensures a defined distance between the speed sensors and
the exciter ring (4).
OPERATION
Signals from the input speed sensors (6, 8) are recorded in
the transmission control module (TCM) together with the wheel
and engine speeds and other information and are processed
into an input signal for electronic control.
Input speed sensor N2 (6) records the speed of the front sun
gear via the externally toothed disc carrier of the multiple-disc
clutch K1 (10) and input speed sensor N3 (8) records the
speed of the front planet carrier via the internally toothed disc
carrier of driving clutch K1 (3).
OIL PUMP
DESCRIPTION
The oil pump (crescent-type pump) is installed in the torque converter casing behind the torque converter and is
driven by the drive flange of the torque converter. The pump creates the oil pressure required for the hydraulic
procedures.
OPERATION
When the engine is running, the oil is pumped through the
inlet chamber (5) along the upper and lower side of the cres-
cent to the pressure chamber (6) of the housing. The meshing
of the teeth prevents oil flowing from the delivery side to the
intake side. An external gear (3), eccentrically mounted in the
pump housing, is located on the internal gear (4) which is con-
nected to the drive flange. The crescent (1) drives the external
wheel.
DISASSEMBLY
1. Remove the pump gears (1 and 2) from the pump housing.
2. Remove the inner oil pump seal (1).

3. Remove the outer oil pump o-ring (2).
ASSEMBLY
1. Install a new inner oil pump seal (1) with Special Tool
8902-A.
2. Replace the outer oil pump o-ring (2).
3. Lubricate the pump gears with transmission fluid and place

in the pump housing. Insert the pump gear (1) so that the
chamfer (arrow) points towards the pump housing.
OUTPUT SHAFT BEARING

REMOVAL
attempting to remove the output shaft nut.
4. Remove the output shaft nut holding the propeller shaft
flange to the output shaft.
6. Remove the transmission rear oil seal with a suitable slide
hammer and screw.
7. Remove the transmission output shaft washer. Be sure to
tag the washer since it is very similar to the geartrain end-
play shim and they must not be interchanged.
8. Remove the transmission rear output shaft bearing retain-
ing ring (1).
9. Position Special Tool 9082 (1) over the inner race of the
output shaft bearing (3).
10. Slide the collar (3) on the Special Tool 9082 (1) downward
over the fingers (4) of the tool.
11. Remove the output shaft bearing (3).

CAUTION: Verify that the geartrain end-play shim has

remained on the output shaft and against the park gear.
The shim may be adhered to the bearing inner race.
Retrieve the shim from the bearing and install over the
output shaft and against the park gear.
INSTALLATION
CAUTION: Verify that the geartrain end-play shim is prop-
erly installed over the output shaft and against the park
gear.
1. Install the output shaft bearing in the rear transmission

housing.
a. Using Special Tool 9287 (1), install the output shaft
bearing (2) into the transmission housing (3). The
closed side of the plastic cage must point
towards the parking lock gear.
b. Install the retaining ring (1). Ensure that the retain-

ing ring is seated correctly in the groove.
c. Check that there is no play between the bearing (2)
and the retaining ring (1) using feeler gauge.
d. There must be no play between the retaining ring
and the bearing. If the ring cannot be installed, a
thinner ring must be used. If there is play between
the ring and the bearing, a thicker ring must be
installed. Retaining rings are available in thick-
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.),
and 2.2 mm (0.087 in.).
2. Install the output shaft washer onto the output shaft.
3. Install a new transmission rear seal into the transmission

case (2) with Special Tool 8902A (1).
to 120 N·m (88.5 ft. lbs.).

a. Place Special Tool 9078 (2) and Special Tool
b. Rotate Special Tool 9078 (2) until the alignment pin
(3) engages the output shaft notch (4).
c. Press downward on Special Tool 9078 (1) until the

(2).
d. Strike the Special Tool C-4171 with a suitable ham-
mer until the output shaft nut is securely staked to
the output shaft.
OUTPUT SHAFT SEAL

REMOVAL
1. Remove the propeller shaft. Refer to Page 3-26. Move propeller shaft to the right and tie up.
2. Place the transmission in the PARK position before attempting to remove the output shaft nut.
3. Remove the output shaft nut holding the propeller shaft flange to the output shaft.
5. Remove the output shaft seal with suitable screw and slide hammer.
INSTALLATION
1. Position the new output shaft seal over the output shaft and
against the transmission case (2).
2. Use Special Tool 8902A (1) to install the seal.
to 120 N·m (88.5 ft. lbs.).

a. Place the Special Tool 9078 (2) and Special Tool
b. Rotate the Special Tool 9078 (2) until the alignment
pin (3) engages the output shaft notch (4).
c. Press downward on the Special Tool 9078 (1) until

the staking pin (3) contacts the output shaft nut
flange.
d. Strike the Special Tool C-4171 with a suitable ham-
mer until the output shaft nut is securely staked to
the output shaft.
PISTONS
DESCRIPTION
There are several sizes and types of pistons used in an automatic transmission. Some pistons are used to apply
clutches. They all have in common the fact that they are round or circular in shape, located within a smooth walled
cylinder, which is closed at one end and converts fluid pressure into mechanical movement. The fluid pressure
exerted on the piston is contained within the system through the use of piston rings or seals.
OPERATION
The principal which makes this operation possible is known as Pascal’s Law. Pascal’s Law can be stated as: “Pres-
sure on a confined fluid is transmitted equally in all directions and acts with equal force on equal areas.”
PRESSURE
Pressure is nothing more than force (lbs.) divided by area (in
or ft.), or force per unit area. Given a 100 lb. block and an
area of 100 sq. in. on the floor, the pressure exerted by the
block is: 100 lbs. 100 in or 1 pound per square inch, or PSI as
it is commonly referred to.
PRESSURE ON A CONFINED FLUID

Pressure is exerted on a confined fluid by applying a force to
some given area in contact with the fluid. A good example of
this is a cylinder filled with fluid and equipped with a piston
that is closely fitted to the cylinder wall. If a force is applied to
the piston, pressure will be developed in the fluid. Of course,
no pressure will be created if the fluid is not confined. It will
simply “leak” past the piston. There must be a resistance to
flow in order to create pressure. Piston sealing is extremely
important in hydraulic operation. Several kinds of seals are
used to accomplish this within a transmission. These include
but are not limited to O-rings, D-rings, lip seals, sealing rings,
or extremely close tolerances between the piston and the cyl-
inder wall. The force exerted is downward (gravity), however,
the principle remains the same no matter which direction is
taken. The pressure created in the fluid is equal to the force
applied, divided by the piston area. If the force is 100 lbs., and
the piston area is 10 sq. in., then the pressure created equals
10 PSI. Another interpretation of Pascal’s Law is that regard-
less of container shape or size, the pressure will be main-
tained throughout, as long as the fluid is confined. In other
words, the pressure in the fluid is the same everywhere within
the container.
FORCE MULTIPLICATION
Using the 10 PSI example used in the illustration, a force of
1000 lbs. can be moved with a force of only 100 lbs. The
secret of force multiplication in hydraulic systems is the total
fluid contact area employed. The illustration shows an area
that is ten times larger than the original area. The pressure
created with the smaller 100 lb. input is 10 PSI. The concept
“pressure is the same everywhere” means that the pressure
underneath the larger piston is also 10 PSI. Pressure is equal
to the force applied divided by the contact area. Therefore, by
means of simple algebra, the output force may be found. This
concept is extremely important, as it is also used in the design
and operation of all shift valves and limiting valves in the valve
body, as well as the pistons, of the transmission, which acti-
vate the clutches and bands. It is nothing more than using a
difference of area to create a difference in pressure to move
an object.
PISTON TRAVEL
The relationship between hydraulic lever and a mechanical
lever is the same. With a mechanical lever, it’s a weight-to-dis-
tance output rather than a pressure-to-area output. Using the
same forces and areas as in the previous example, the
smaller piston has to move ten times the distance required to
move the larger piston one inch. Therefore, for every inch the
larger piston moves, the smaller piston moves ten inches. This
principle is true in other instances also. A common garage
floor jack is a good example. To raise a car weighing 2000
lbs., an effort of only 100 lbs. may be required. For every inch
the car moves upward, the input piston at the jack handle
must move 20 inches downward.
PLANETARY GEARTRAIN
DESCRIPTION
Three planetary gear sets are used to produce the different gear ratios. These are located in the mechanical part of
the transmission as the front, middle and rear planetary gear sets.
OPERATION
The annulus gear (1) and sun gear (3) elements of a planetary
gear system are alternately driven and braked by the actuating
elements of the multi-plate clutch and multiple-disc brake. The
planetary pinion gears (2) can turn on the internal gearing of
the annulus gear (1) and on the external gearing of the sun
gear (3). This allows for a variety of gear ratios and the rever-
sal of the rotation direction without the need for moving gear
wheels or shift collars. When two components of the planetary
gear set are locked together, the planetary gear set is locked
and turns as a closed unit.
The torque and engine speed are converted according to the
lever ratios and the ratio of the number of teeth on the driven
gears to that on the drive gears, and is referred to as the gear
ratio. The overall ratio of a number of planetary gear sets con-
nected in series is obtained by multiplying the partial ratios.
DISASSEMBLY
1 - TEFLON RINGS 7 - DRIVING CLUTCH K3

2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER
3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING
4 - THRUST WASHER 10 - SHIM
5 - REAR PLANETARY GEAR SET 11 - RETAINING RING
6 - REAR HOLLOW SHAFT/FREEWHEEL F2
1. Remove the upper two visible teflon rings (1) from the output shaft with center planetary carrier (2).
2. Remove the retaining ring (11), shim (10), axial needle bearing (9) and thrust washer (8) from the output shaft
with center planetary carrier (2).
3. Remove the driving clutch K3 (7).
4. Remove the rear hollow shaft/freewheel F2 (6) from the output shaft with center planetary carrier (2).
5. Remove the rear planetary gear set (5) with integrated tubular shaft of center gear set from the output shaft with
center planetary carrier (2).
6. Remove the thrust washer (4).
ASSEMBLY
1 - TEFLON RINGS 7 - DRIVING CLUTCH K3

2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER
3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING
4 - THRUST WASHER 10 - SHIM
5 - REAR PLANETARY GEAR SET 11 - RETAINING RING
6 - REAR HOLLOW SHAFT/FREEWHEEL F2
1. Mount the thrust washer (4) with the collar pointing towards the planet carrier.
2. Mount the rear planetary gear set (5) with the integrated tubular shaft of the center gear set on the output shaft
with center planetary carrier (2).
3. Using grease, install the lower three teflon rings (1) in the groove so that the joint stays together.
4. Put the rear hollow shaft/freewheel F2 (6) onto the output shaft.
5. Install the clutch K3 (7).
6. Mount the retaining ring (11), shim, axial needle bearing (9) and thrust washer (8).
7. Using grease, insert the upper two teflon rings (1) in the groove so that the joint remains together.
8. Inspect for axial play between shim (10) and retaining ring (11). Check axial play “S” between shim (10) and
retaining ring (1) using a feeler gauge. Clearance should be 0.15-0.6 mm (0.006-0.024 in.). Shims are available
in thicknesses of 3.0 mm (0.118 in.), 3.4 mm (0.134 in.), and 3.7 mm (0.146 in.). Adjust as necessary.
Note: During the test, apply a contact force by hand to K3 in the direction of the output shaft.
SHIFT INTERLOCK SOLENOID

DESCRIPTION
The typical electrical solenoid used in automotive applications is a linear actuator. It is a device that produces
motion in a straight line. This straight line motion can be either forward or backward in direction, and short or long
distance.
A solenoid is an electromechanical device that uses a magnetic force to perform work. It consists of a coil of wire,
wrapped around a magnetic core made from steel or iron, and a spring loaded, movable plunger, which performs
the work, or straight line motion.
The solenoids used in transmission applications are attached to valves which can be classified as normally open
or normally closed. The normally open solenoid valve is defined as a valve which allows hydraulic flow when no
current or voltage is applied to the solenoid. The normally closed solenoid valve is defined as a valve which does
not allow hydraulic flow when no current or voltage is applied to the solenoid. These valves perform hydraulic con-
trol functions for the transmission and must therefore be durable and tolerant of dirt particles. For these reasons, the
valves have hardened steel poppets and ball valves. The solenoids operate the valves directly, which means that
the solenoids must have very high outputs to close the valves against the sizable flow areas and line pressures
found in current transmissions. Fast response time is also necessary to ensure accurate control of the transmission.
The strength of the magnetic field is the primary force that determines the speed of operation in a particular sole-
noid design. A stronger magnetic field will cause the plunger to move at a greater speed than a weaker one. There
are basically two ways to increase the force of the magnetic field:
1. Increase the amount of current applied to the coil or
2. Increase the number of turns of wire in the coil.
The most common practice is to increase the number of turns by using thin wire that can completely fill the available
space within the solenoid housing. The strength of the spring and the length of the plunger also contribute to the
response speed possible by a particular solenoid design.
A solenoid can also be described by the method by which it is controlled. Some of the possibilities include variable
force, pulse-width modulated, constant ON, or duty cycle. The variable force and pulse-width modulated versions
utilize similar methods to control the current flow through the solenoid to position the solenoid plunger at a desired
position somewhere between full ON and full OFF. The constant ON and duty cycled versions control the voltage
across the solenoid to allow either full flow or no flow through the solenoid’s valve.
UPSHIFT/DOWNSHIFT SOLENOID VALVES

The solenoid valves for upshifts and downshifts are located in
the shell of the electric control unit and pressed against the
shift plate with a spring.
The solenoid valves (1) initiate the upshift and downshift pro-
cedures in the shift plate.
The solenoid valves (1) are sealed off from the valve housing
of the shift plate (5) by two O-rings (4, 6). The contact springs
(8) at the solenoid valve engage in a slot in the conductor
tracks (7). The force of the contact spring (8) ensures safe
contacts.
MODULATING PRESSURE CONTROL SOLENOID VALVE

The modulating pressure control solenoid valve is located in
the shell of the electric valve control unit and pressed against
the shift plate by a spring.
Its purpose is to control the modulating pressure, depending
on the continuously changing operating conditions, such as
load and gear change.
The modulating pressure regulating solenoid valve (1) has an
interference fit and is sealed off to the valve body of the shift
plate (4) by a seal (arrow). The contact springs (2) at the sole-
noid valve engage in a slot in the conductor tracks (3). The
force of the contact springs (2) ensures secure contacts.
TORQUE CONVERTER LOCKUP CLUTCH PWM

SOLENOID VALVE
The torque converter lockup clutch PWM solenoid valve (1) is
located in the shell of the electric valve control unit and is
pressed against the shift plate by a spring.
The PWM solenoid valve (1) for the torque converter lockup
controls the pressure for the torque converter lockup clutch.
The torque converter lockup PWM solenoid valve (1) is sealed
off to the valve body of the shift plate (4) by an O-ring (5) and
a seal (arrow). The contact springs (2) at the solenoid valve
engage in a slot in the conductor tracks (3). The force of the
contact springs (2) ensures secure contacts.
SHIFT PRESSURE CONTROL SOLENOID VALVE

The shift pressure control solenoid valve (1) is located in the
shell of the electric valve control unit and is pressed against
the shift plate by a spring.
Its purpose is to control the shift pressure depending on the
continuously changing operating conditions, such as load and
gear change.
The shift pressure regulating solenoid valve (1) has an inter-
ference fit and is sealed off to the valve body of the shift plate
(4) by a seal (arrow). The contact springs (2) at the solenoid
valve engage in a slot in the conductor tracks (3). The force of
the contact springs (2) ensures secure contacts.
OPERATION
When an electrical current is applied to the solenoid coil, a magnetic field is created which produces an attraction
to the plunger, causing the plunger to move and work against the spring pressure and the load applied by the fluid
the valve is controlling. The plunger is normally directly attached to the valve which it is to operate. When the cur-
rent is removed from the coil, the attraction is removed and the plunger will return to its original position due to
spring pressure.
The plunger is made of a conductive material and accomplishes this movement by providing a path for the magnetic
field to flow. By keeping the air gap between the plunger and the coil to the minimum necessary to allow free move-
ment of the plunger, the magnetic field is maximized.
UPSHIFT/DOWNSHIFT SOLENOID VALVES

If a solenoid valve is actuated by the TCM, it opens and guides the control pressure (p-SV) to the assigned com-
mand valve. The solenoid valve remains actuated and therefore open until the shifting process is complete. The shift
pressure (p-SV) to the command valve is reduced to zero as soon as the power supply to the solenoid valve is
interrupted.
SHIFT PRESSURE CONTROL SOLENOID VALVE

The shift pressure regulating solenoid valve (1) assigns a proportional pressure to the current which is controlled by
the TCM according to the load.
TEMP SENSOR/PARK-NEUTRAL SWITCH

DESCRIPTION
PARK/NEUTRAL CONTACT
The park/neutral contact (4) is located in the shell of the elec-
tric control unit and is fixed to the conductor tracks.
Its purpose is to recognize selector valve and selector lever
positions “P” and “N”. The park/neutral contact consists of:
• the plunger (2).
• the permanent magnet (3).
• the dry-reed contact (4).
DESCRIPTION - TRANSMISSION
TEMPERATURE SENSOR
The transmission oil temperature sensor (1) is located in the
shell of the electric valve control unit and is fixed to the con-
ductor tracks.
Its purpose is to measure the temperature of the transmission
oil and pass the temperature to the TCM as an input signal. It
is a temperature-dependent resistor (PTC).
OPERATION
PARK/NEUTRAL CONTACT
In selector lever positions “P” and “N” the park/neutral contact
(4) is actuated by a cam track which is located on the detent
plate. The permanent magnet (3) is moved away from the dry-
reed contact (4). The dry-reed contact (4) is opened. The TCM
receives an electric signal. The circuit to the starter in the
selector lever positions “P” and “N” is closed.
OPERATION - TRANSMISSION
TEMPERATURE SENSOR
The temperature of the transmission oil has a considerable
effect on the shifting time and therefore the shift quality. By
measuring the oil temperature, shift operations can be opti-
mized in all temperature ranges. The transmission oil temper-
ature sensor (1) is switched in series with the park/neutral
contact. The temperature signal is transferred to the TCM only
when the dry-reed contact of the park/neutral contact is closed
in REVERSE or a forward gear position.
Refer to the Transmission Temperature Sensor Specifications
table for the relationship between transmission temperature,
sensor voltage, and sensor resistance.
TRANSMISSION TEMP SENSOR SPECIFICATIONS
TEMPERATURE (C) TEMPERATURE (F) VOLTAGE RESISTANCE

-50 -58 0.73 506.0
-45 -49 0.77 534.0
-40 -40 0.80 564.0
-35 -31 0.84 593.0
-30 -22 0.88 624.0
-25 -13 0.91 654.0
-20 -4 0.95 686.0
-15 5 0.98 718.0
-10 14 1.02 750.0
-5 23 1.05 783.0
0 32 1.09 817.0
5 41 1.12 851.0
10 50 1.16 886.0
15 59 1.19 921.0
20 68 1.23 957.0
25 77 1.26 994.0
30 86 1.30 1032.0
35 95 1.33 1070.0
40 104 1.37 1109.0
45 113 1.40 1149.0
50 122 1.44 1189.0
55 131 1.48 1231.0
60 140 1.51 1273.0
65 149 1.55 1316.0
70 158 1.58 1360.0
75 167 1.62 1405.0
80 176 1.65 1450.0
85 185 1.69 1497.0
90 194 1.72 1545.0
95 203 1.76 1594.0
100 212 1.79 1644.0
105 221 1.83 1695.0
110 230 1.86 1747.0
115 239 1.90 1800.0
120 248 1.93 1855.0
125 257 1.97 1911.0
130 266 2.00 1968.0
135 275 2.04 2027.0
140 284 2.08 2087.0
145 293 2.11 2148.0
150 302 2.15 2211.0
TEMPERATURE (C) TEMPERATURE (F) VOLTAGE RESISTANCE

155 311 2.18 2276.0
160 320 2.22 2342.0
165 329 2.25 2410.0
170 338 2.29 2479.0
175 347 2.32 2551.0
TORQUE CONVERTER
DESCRIPTION
The torque converter is a hydraulic device that couples the
engine crankshaft to the transmission. The torque converter
consists of an outer shell with an internal turbine (1), a stator
(3), an overrunning clutch, an impeller (2) and an electronically
applied converter clutch. The converter clutch provides
reduced engine speed and greater fuel economy when
engaged. Clutch engagement also provides reduced transmis-
sion fluid temperatures. The converter clutch engages in third
gear. The torque converter hub drives the transmission oil
(fluid) pump.
The torque converter is a sealed, welded unit that is not
repairable and is serviced as an assembly.
CAUTION: The torque converter must be replaced if a

transmission failure resulted in large amounts of metal or
fiber contamination in the fluid.
IMPELLER
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION

2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 - ENGINE ROTATION
SECTION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially
along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the
engine, so is the impeller, because they are one and the same and are the driving members of the system.
TURBINE
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER

2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite
the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and
splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are
curved in the opposite direction.
STATOR
The stator assembly is mounted on a stationary shaft which is
an integral part of the oil pump. The stator (1) is located
between the impeller (2) and turbine (4) within the torque con-
verter case. The stator contains a freewheeling clutch, which
allows the stator to rotate only in a clockwise direction. When
the stator is locked against the freewheeling clutch, the torque
multiplication feature of the torque converter is operational.
TORQUE CONVERTER CLUTCH (TCC)

The TCC was installed to improve the efficiency of the torque
converter that is lost to the slippage of the fluid coupling.
Although the fluid coupling provides smooth, shock-free power
transfer, it is natural for all fluid couplings to slip. If the impeller
and turbine were mechanically locked together, a zero slip-
page condition could be obtained. A hydraulic piston with fric-
tion material was added to the turbine assembly to provide this
mechanical lock-up.
In order to reduce heat build-up in the transmission and buffer
the powertrain against torsional vibrations, the TCM can duty
cycle the torque converter lock-up solenoid to achieve a
smooth application of the torque converter clutch. This func-
tion, referred to as Electronically Modulated Converter Clutch
(EMCC) can occur at various times depending on the following
variables:
• Shift lever position
• Current gear range
• Transmission fluid temperature
• Engine coolant temperature
• Input speed
• Throttle angle
• Engine speed
OPERATION
The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive
plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated
by the impeller, rotates and turns the transmission input shaft.
TURBINE
As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and
rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft)
to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine’s
blades, it continues in a “hindering” direction back toward the impeller. If the fluid is not redirected before it strikes
the impeller, it will strike the impeller in such a direction that it would tend to slow it down.
STATOR
Torque multiplication is achieved by locking the stator’s over-
running clutch to its shaft. Under stall conditions (the turbine is
stationary), the oil leaving the turbine blades strikes the face of
the stator blades and tries to rotate them in a counterclockwise
direction (3). When this happens the over-running clutch of the
stator locks and holds the stator from rotating. With the stator
locked, the oil strikes the stator blades and is redirected into a
“helping” direction before it enters the impeller. This circulation
of oil from impeller to turbine, turbine to stator, and stator to
impeller, can produce a maximum torque multiplication of
about 2.0:1. As the turbine begins to match the speed of the
impeller, the fluid that was hitting the stator in such as way as
to cause it to lock-up is no longer doing so. In this condition of
operation, the stator begins to free wheel and the converter
acts as a fluid coupling.
TORQUE CONVERTER CLUTCH (TCC)

In a standard torque converter, the impeller and turbine are
rotating at about the same speed and the stator is freewheel-
ing, providing no torque multiplication. By applying the tur-
bine’s piston and friction material to the front cover, a total
converter engagement can be obtained. The result of this
engagement is a direct 1:1 mechanical link between the
engine and the transmission.
The clutch can be engaged in second, third, fourth, and fifth
gear ranges.
The TCM controls the torque converter by way of internal logic
software. The programming of the software provides the TCM
with control over the torque converter solenoid. There are four
output logic states that can be applied as follows:
• No EMCC
• Partial EMCC
• Full EMCC
• Gradual-to-no EMCC
NO EMCC
Under No EMCC conditions, the TCC Solenoid is OFF. There are several conditions that can result in NO EMCC
operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need
for EMCC under current driving conditions.
PARTIAL EMCC
Partial EMCC operation modulates the TCC Solenoid (duty cycle) to obtain partial torque converter clutch applica-
tion. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some
slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations.
FULL EMCC
During Full EMCC operation, the TCM increases the TCC Solenoid duty cycle to full ON after Partial EMCC control
brings the engine speed within the desired slip range of transmission input speed relative to engine rpm.
GRADUAL-TO-NO EMCC
This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by
decreasing the TCC Solenoid duty cycle.
REMOVAL
1. Remove transmission and torque converter from vehicle.
Refer to Page 21-210
2. Place a suitable drain pan under the converter housing end
of the transmission.
CAUTION: Verify that transmission is secure on the lifting

device or work surface; the center of gravity of the trans-
mission will shift when the torque converter is removed
creating an unstable condition. The torque converter is a
heavy unit. Use caution when separating the torque con-
verter from the transmission.
3. Pull the torque converter (1) forward until the center hub
clears the oil pump seal.
4. Separate the torque converter from the transmission (2).
INSTALLATION
Check the converter hub and drive flats for sharp edges, burrs,
scratches, or nicks. Polish the hub and flats with 320/400 grit
paper or crocus cloth if necessary. The hub must be smooth to
avoid damaging the pump seal at installation.
1. Lubricate the oil pump seal lip with transmission fluid.
2. Place the torque converter in position on the transmission.
CAUTION: Do not damage oil pump seal or converter hub

while inserting torque converter into the front of the trans-
mission.
3. Align the torque converter to oil pump seal opening.

4. Insert the torque converter hub into the oil pump.
5. While pushing the torque converter inward, rotate converter
until converter is fully seated in the oil pump gears.
6. Check the converter seating with a scale and straightedge.
Surface of the converter lugs should be at least 19 mm (3/4
in.) (3) to the rear of the straightedge when converter is
fully seated.
7. If necessary, temporarily secure the converter with a
C-clamp attached to the converter housing.
8. Install the transmission in the vehicle. Refer to Page
21-227.
9. Fill the transmission with the recommended fluid.
TORQUE CONVERTER HUB SEAL

REMOVAL
1. Remove the torque converter. Refer to Page 21-335.
2. Remove the torque converter hub seal with suitable screw and slide hammer.
INSTALLATION
1. Position the torque converter hub seal (1) over the input
shaft (2) and against the transmission oil pump.
2. Using Special Tool 8902A (2), install a new torque con-

verter hub seal.
3. Install the torque converter. Refer to Page 21-336.
SHIFT INTERLOCK SOLENOID

DESCRIPTION
The shift interlock solenoid is not serviced separately. If the shift interlock solenoid becomes inoperable, the shift
mechanism must be replaced.
ADJUSTMENTS - SHIFT INTERLOCK SOLENOID
1. Set the parking brake.

2. Remove the front center console. Refer to Page 23-173.
3. Remove the shifter outer cover.
4. Set the selector lever to nuetral. Lever must be touching the slot (arrow).
5. Energize the interlock solenoid (3).
6. Loosen the bolts (1).
7. Adjust the gap between the locking lever (4) and the cam plate (5) to .02 mm using the adjusting screw (2).
8. Tighten the bolts (1) to 3.5 N·m (31 in. lbs.).
9. Install the shifter outer cover.
10. Install the console. Refer to Page 23-183.

DESCRIPTION
In vehicles equipped with an automatic transmission, the Shift
Lever Assembly (2) is located at the front of the center console
(1).
The Shift Lever Assembly provides four shift positions which
are:
• Park (P)
• Reverse (R)
• Neutral (N)
• Drive (D)
In the Drive (D) position, five forward gears are available. On
the Shift Lever Assembly next to the “D” is a “+” symbol and a
“–” symbol. While in the Drive position, pushing the shift lever
to the right toward the “+” on the Shift Lever Assembly will
upshift one range at a time. Conversely, pushing the shift lever
to the left toward the “–” on the Shift Lever Assembly will
downshift one range at a time. This enables the other forward
gears to be accessed (engine speed permitting). Also, pushing
and holding the shift lever to the left or right will change the
transmission gear that is accessed when the shift lever is put
into the Drive (D) position.
Also located on the Shift Lever Assembly is the transmission mode switch (W/S). In Standard (S) mode, the vehicle
transmission starts off in first gear at all times. In Winter (W) mode, the vehicle transmission starts off in second
gear unless manually downshifted and the forward gears have a reduced RPM range. In Winter mode, if transmis-
sion kickdown occurs, transmission upshifts and downshifts are the same as Standard mode operation.
OPERATION
The Shift Lever Assembly consists of a printed circuit board, an opti-electronic switch for program selection recog-
nition at the “W/S” program selector, contacts at the shift lever for recognizing the selected shift range, two plugs,
and four light emitting diodes (LEDs) to illuminate the shift gate. The shift lever printed circuit board receives digital
and analog input signals, controls various components and transfers information to various modules via the Con-
troller Area Network (CAN) bus. The Shift Lever Assembly has input and output signals to the Data Link Connector.
The Shift Lever Assembly receives input signals from the selector lever, the W/S switch, the upshift/downshift (+/-)
Autostick switch, the shift gate illumination, the kickdown switch, and the brake lamp switch. The Shift Lever Assem-
bly sends output signals to the reverse/park lock and the reverse lamps. A safety mechanism is built into the Shift
Lever Assembly to prevent mechanical damage to the automatic transmission. The rear wheel speed is measured
through the Controller Antilock Brake (CAB) and delivered to the Shift Lever Assembly. As a result, shifting the
selector lever from Neutral to Reverse above approximately 8 km/h (5 MPH) is not allowed.
The ignition lock control cable attached to the Shift Lever Assembly prevents the driver from removing the ignition
key if the selector lever is not in the Park position.
Brake Transmission Shift Interlock

BTSI is a safety feature that enables the shift selector lever to stay locked in the Park position when the brake pedal
is not depressed (ignition on) or when there is no current present in the Shift Lever Assembly. If the Shift Lever
Assembly selector lever cannot be shifted from the Park position due to a mechanical or electrical failure, the selec-
tor lever can be released from the Park position using the shift lock override procedure. To do this, insert a long
screwdriver into the notch just below the “-D+” symbol on the Shift Lever Assembly and depress the lock button
while moving the selector lever out of the Park position at the same time. This will allow the shift lever to be man-
ually moved out of the Park position in order to move the vehicle.
REMOVAL
1. Remove the front center console. Refer to Page 23-173.
2. Remove the gear shift lever handle.
3. Disconnect the wire harness connectors (2) at the rear of
the shift mechanism.
4. Remove the retaining bolts (3).
5. Lift the shift mechanim up and disconnect the shift rod.
Remove the shift mechanism from the vehicle.
INSTALLATION
1. Connect the shift rod to the shift mechanism and install the retainer clip.
2. Position the shift mechanism (1) in the vehicle.
3. Install the retaining bolts (3). Tighten the bolts to 7 N·m (65 in. lbs.).
4. Connect the wire harness (2) connectors at the rear of the shift mechanism.
5. Install the front center console. Refer to Page 23-183.
6. Install the gear shift lever handle.
GEAR SHIFT ROD

REMOVAL
2. Remove the retaining clip at the shifter (1).
3. Remove the retaining clip at the transmission shift arm and

remove the shift rod from the vehicle.
INSTALLATION
1. Position the shift rod on the transmission shift arm an install the clip.
2. Position the shift rod on the shifter and install the clip.
3. Lower the vehicle and check the operation of the shift mechanism.
21 - 342 MANUAL - SERVICE INFORMATION ZH
MANUAL - SERVICE INFORMATION
TABLE OF CONTENTS
page page
MANUAL - SERVICE INFORMATION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 342 REAR SECTION HOUSING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 343 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 362
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 344 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 REVERSE SHAFT
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 363
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 347 GEARTRAIN HOUSING
SPECIFICATIONS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 363
SPECIFICATIONS - GEAR RATIOS . . . . . . . 349 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 350 MAINSHAFT W/INPUT SHAFT
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 351 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 368
FLUID DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 369
STANDARD PROCEDURE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
STANDARD PROCEDURE - FLUID DRAIN COUNTERSHAFT
AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 380
STANDARD PROCEDURE - CHECKING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 353 SYNCHRONIZER
BACKUP LAMP SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 386
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 354 GEAR SHIFT LEVER HANDLE
OUTPUT FLANGE SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 356 REVERSE LOCKOUT CABLE
DETENT PLUG DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 388
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 SHIFT MECHANISM
INPUT SHAFT SEAL STANDARD PROCEDURE - SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 389
TRANSMISSION FRONT SECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 392
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 361
MANUAL - SERVICE INFORMATION

DESCRIPTION
The manual transmission is a fully synchronized two-shaft transmission with six forward gears and one reverse
gear. The 6th gear is used to save fuel and reduce engine speed. The manual transmission is equipped with a
conventional dry clutch with automatic wear adjuster which is operated by a central clutch operator. The transmis-
sion is maintenance-free and has a permanent oil fill. A precise and light shift with short shifting travels is achieved
by the following measures:
• Transmission of the shift lever movement to the transmission by the shift rod and control cable
• Central shift shaft supported on needle bearings
• Multiple-cone synchronization in 1st, 2nd, 3rd and 4th gear
• Fully-synchronized reverse gear
ZH MANUAL - SERVICE INFORMATION 21 - 343
OPERATION
1 - FRONT TRANSMISSION HOUSING 11 - MAIN SHAFT

2 - 2ND GEAR 12 - CENTRAL SHIFT SHAFT
3 - MULTIPLE-CONE SYNCHRONIZATION 1ST/2ND GEAR 13 - 4TH GEAR
4 - 1ST GEAR 14 - MULTIPLE-CONE SYNCHRONIZATION 1ST/2ND GEAR
5 - REVERSE GEAR 15 - THIRD GEAR
6 - MAIN SHAFT 16 - 6TH GEAR
7 - CENTRAL SHIFT SHAFT 17 - 5TH GEAR
8 - INNER SHIFT MODULE 18 - INPUT SHAFT
9 - COUNTER SHAFT 19 - RELEASE BEARING/SLAVE CYLINDER
10 - REVERSE GEAR IDLER GEAR
The gear assemblies and shafts are located between two bearing planes. The divided transmission housing is made
up of a light metal alloy, the housing parts of which are sealed with liquid sealing agent. The input shaft is supported
by a pilot bearing in the flywheel and by a deep-groove ball bearing in the transmission housing. The main shaft and
input shaft are inserted into each other on a common shaft plane in the transmission housing and are supported by
deep-groove ball bearings. The countershaft is designed as a hollow shaft to reduce weight and is supported by a
deep-groove ball bearing and a roller sleeve. The shaft play does not have to be adjusted due to the very tight
production tolerances of the gear wheels and housing halves, as well as the use of roller sleeves.

LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant
level check.
Leaks can occur at the mating surfaces of the gear case and adaptor or from the front/rear seals. A suspected leak
could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating
surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening, or use of a
non–recommended sealer.
A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may
be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the
clutch disc causing the disc to slip, grab, and/or chatter.
A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a
minute or so before checking. These recommendations will ensure an accurate check and avoid an underfill or over-
fill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant level, improper, or contaminated lubricants. The consequence of
using non–recommended lubricants is noise, excessive wear, internal bind, and hard shifting. Substantial lubricant
leaks can result in gear, shift rail, synchronizer, and bearing damage. If a leak goes undetected for an extended
period, the first indications of component damage are usually hard shifting and noise.
Shift component damage, incorrect clutch adjustment, or a damaged clutch pressure plate or disc are additional
probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause
incorrect release. If the clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro
rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new syn-
chronizer rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as
the rings wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is
audible, but generally only at extreme speeds.
Severe, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient,
improper, or contaminated lubricant will promote rapid wear of gears, synchronizers, shift rails, forks and bearings.
The overheating caused by a lubricant problem can also lead to gear and bearing damage.
REMOVAL
4. Support the transmission with a jack.
5. Remove the rear transmission mount bolts (1) and the rear
crossmember bolts (2). Remove the rear transmission
mount together, with the crossmember, from the vehicle.
6. Disconnect the backup lamp switch harness connector (1).
7. Disconnect the pressure line (1) at the clutch slave cylin-

der. Remove the retaining bolt (2) and the pressure line (1)
from the transmission.
8. Disconnect the reverse lockout cable (1) by turning the

locking nut counter clockwise. Remove the cable end from
the ball stud and position the cable aside.
9. Disconnect the shift rod (1) from the ball stud (2). Position
the shift rod (1) aside.
10. Disconnect the ground cable (1) at the transmission.

11. Remove the transmission to engine retaining bolts.
12. Lower the transmission down and out of vehicle.
CLEANING
Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not
use acid or corrosive base solvents. Dry all parts except bearings with compressed air.
Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk or similar solvents. Do not dry
the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
INSTALLATION
1. Position the transmission on the jack.
2. Install the transmission to the rear of the engine block.
Align the transmission dowels to the engine block dowel
holes.
3. Connect the ground cable (1) to the transmission. Tighten
the bolt to 40 N·m (30 ft. lbs.).
4. Install the transmission to engine block retaining bolts.
5. Raise the rear of the transmission.
6. Install the rear crossmember together with the transmission

mount and install the bolts. Tighten the transmission mount
bolts (1) to the transmission to 30 N·m (22 ft. lbs.). Tighten
the rear crossmember retaining bolts (2) to the body to 40
N·m (30 ft. lbs.).
7. Connect the shift rod (1) to the transmission ball stud (2).
8. Connect the reverse lockout cable (1) and turn the nut
clockwise to lock in place. Connect the cable end to the
ball stud.
9. Connect the backup lamp switch harness connector (1).

10. Connect the pressure line (1) to the slave cylinder. Install
the retaining bolt (2) to the transmission. Tighten the
retaining bolt to 10 N·m (89 in. lbs.).
12. Fill the transmission. Refer to Page 21-352.
14. Check the brake fluid level in master cylinder fluid reser-
voir.
15. Bleed the clutch slave cylinder. Refer to Page 6-7.
16. Recheck the brake fluid level.
19. Check for proper clutch operation.
SPECIFICATIONS
SPECIFICATIONS - GEAR RATIOS
GEAR RATIOS
1st Gear 4.46
2nd Gear 2.61
3rd Gear 1.72
4th Gear 1.25
5th Gear 1.00
6th Gear 0.84
Reverse Gear 4.06
SPECIFICATIONS

Backup Lamp Switch Bolt 8 6 71
Camshaft Position Sensor 8 6 71
Countershaft Bolt 90 66 797
Front Section To Rear 28 21 248
Section Bolts
Locking Plate Bolts 9 7 80
Oil Drain Plug 60 44 531
Oil Fill Plug 50 37 443
Pinion Flange Collared 180 133 1593
Nut
Rear Crossmember Bolts 40 30 354
Release Bearing/Slave 9 7 80
Cylinder Bolts
Reverse Idler Shaft 23 17 204
Retaining Bolt
Reverse Lockout Cable 20 15 177
Bracket Bolts
Slave Cylinder Pressure 10 7.3 89
Line Bolt
Transmission To Engine 40 30 354
Bolts
Transmission Ground Bolt 40 30 354
Transmission Mount Bolts 30 22 266
SPECIAL TOOLS
PULLER 1026
DRIFT 9123
Wrench C-3281
DRIFT 9122
SLIDE HAMMER C-3752
SPLITTER 1126
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID DRAIN
AND FILL
2. Remove the fill plug (1).
3. Place a suitable drain pan below the drain plug (2).
Remove the drain plug (2) and allow the transmission to
drain completely.
4. Install the drain plug (2) and tighten to 60 N·m (44 ft. lbs.).
5. Remove the drain pan. Fill the transmission with the spec-
ified fluid.
6. Install and tighten the fill plug (1) to 50 N·m (37 ft. lbs.).
ADAPTOR 8870
STANDARD PROCEDURE - CHECKING FLUID LEVEL

2. Remove the transmission fill plug (1).
3. The full fluid level should be at the base of the fill plug
threaded hole. If the fluid is low, check for visible transmis-
sion fluid leaks and top off the fluid level.
4. Install and tighten the fill plug (1) to 50 N·m (37 ft. lbs.).
BACKUP LAMP SWITCH

REMOVAL
2. Put the transmission in reverse.
4. Disconnect the backup lamp switch harness connector (1).
5. Remove the backup lamp switch retaining bolt (1).

6. Remove the backup lamp switch (2) and o-ring seal from
the
. transmission.
INSTALLATION
1. Install the backup lamp switch (2) with a new o-ring seal.
2. Install the backup lamp switch retaining bolt (1). Tighten the
bolt to 10 N·m (89 in. lbs.).
3. Connect the backup lamp switch harness connector (1).

6. Check the operation of the backup lamps.
OUTPUT FLANGE SEAL

REMOVAL
1. Support the transmission.
3. Hold the output flange (3) with Special Tool C-3281 (2)
Flange Wrench while removing the collared nut (1).
4. Remove the output flange (3) from output shaft (1).
Note: Do not score the transmission seal bore.
5. Pry out transmission output flange seal (2) with a

screwdriver.
INSTALLATION
1. Install the new output flange seal (1) using Special Tool
9122 Drift (2) and a mallet.
2. Install the output flange (3) and nut. Hold the flange (3) with
Special Tool C-3281 Flange Wrench (2). Tighten the nut to
180 N·m (133 ft. lbs.).
Note: The Special Tool 9078 has two possible locations

for the beveled staking pin. The pin must be installed in
the hole labeled “Transmission” for this operation. This
hole is located directly across from the spring loaded
alignment pin.

a. Place the Special Tool 9078 Staking Tool (2) onto
the output shaft.
b. Rotate the Special Tool 9078 Staking Tool (2) until
the alignment pin (3) engages the output shaft
notch (4).
c. Press downward on the staking tool (1) until the

(2).
d. Strike Special Tool 9078 Staking Tool with a suit-
able hammer until the output shaft nut is securely
staked to the output shaft.

5. Check the transmission fluid level. Refer to Page 21-352.
DETENT PLUG
REMOVAL
1. Remove the transmission. Refer to Page 21-344.
2. Mount the transmission on a holding fixture.
3. Use Special Tool C–3752 Slide Hammer and 8870 Adaptor
to remove the detent plug (1).
INSTALLATION
1. Smooth any burrs or nicks in the detent plug bore.
2. Use a plastic mallet to drive in and fully seat the detent
plug (1).
3. Remove the transmission from the holding fixture.
21-347.
INPUT SHAFT SEAL

REMOVAL
2. Mount the transmission on a holding fixture.
3. Remove the clutch release bearing/slave cylinder. Refer to
Page 6-20.
4. Use a screwdriver (1) to pry out the input shaft seal (2).
INSTALLATION
1. Use Special Tool 9123 Drift (1) and a mallet to drive in the
new seal (2).
2. Install the clutch release bearing/slave cylinder. Refer to
Page 6-20.
3. Remove the transmission from the holding fixture.
21-347.
TRANSMISSION FRONT SECTION

DISASSEMBLY
1 - SHIFT SHAFT BEARING 4 - LOCKING PLATE BOLTS

2 - INPUT SHAFT BEARING 5 - LOCKING PLATES
3 - COUNTERSHAFT BEARING 6 - GUIDE SLEEVE

2. Separate the front and rear transmission sections. Refer to Page 21-363.
3. Remove the locking plate bolts (4) and the locking plates (5).
4. Drive out the input shaft bearing (2) and the countershaft bearing (3).
5. Remove the shift shaft bearing (1).
6. Remove the guide sleeves (6).
ASSEMBLY
1. Drive in the sleeves (6) using a mallet.
2. Install the shift shaft bearing (1).
Note: The input and counter shaft bearings must be fully seated before installing the locking plates.
3. Install the input shaft bearing (2) and the countershaft bearing (3).
4. Install the locking plates (5) and bolts (4). Tighten the bolts to 9 N·m (7 ft. lbs.).
5. Assemble the front and rear transmission sections. Refer to Page 21-365.
6. Install the transmission. Refer to Page 21-347.
REAR SECTION HOUSING

DISASSEMBLY
1 - REVERSE IDLER SHAFT RETAINING BOLT 7 - MAINSHAFT BEARING

2 - BEARING SHELL 8 - COUNTERSHAFT BEARING
3 - REVERSE IDLER SHAFT 9 - LOCKING PLATE RETAINING BOLTS
4 - CYLINDRICAL ROLLER BEARING 10 - LOCKING PLATES
5 - REVERSE GEAR 11 - SHIFT SHAFT BEARING
6 - WASHER 12 - OUTPUT FLANGE SEAL

2. Disassemble the geartrain housing. Refer to Page 21-363.
3. Remove the retainer bolt (1).
4. Remove the bearing shell (2), reverse idler shaft (3) with the bearings (4), reverse gear (5) and the washer (6).
5. Drive out the countershaft bearing (8) using a drift punch.
6. Remove the retaining bolts (9), locking plates (10), and the mainshaft bearing (7).
7. Remove the shift shaft bearing (11).
8. Drive out the output flange seal (12).
ASSEMBLY
1. Install a new output flange seal (12) using Special Tool 9123 Drift.
2. Use a suitable deep socket to drive in the shift shaft bearing (11).
3. Install the mainshaft bearing (7), locking plates (10), and retaining bolts (9). Tighten the bolts to 9 N·m (7 ft. lbs.).
4. Drive in the countershaft bearing (8).
5. Install the reverse gear idler shaft (3).
6. Install the bearing shell (2).
7. Install the bearings (4), reverse gear (5), and the washer (6).
8. Align the retainer bolt (1) in the shell and the idler shaft and install. Tighten the bolt to 20 N·m (15 ft. lbs.).
9. Assemble the geartrain housing. Refer to Page 21-365.
REVERSE SHAFT
DESCRIPTION
The reverse shaft and reverse idler gear are housed in the rear gear train housing. Refer to Gear Train Housing in
this section.
GEARTRAIN HOUSING
DISASSEMBLY
1 - INPUT SHAFT SEAL 4 - COUNTERSHAFT

2 - SNAP RING 5 - COUNTERSHAFT BOLT
3 - INPUT SHAFT 6 - SEALING RING

2. Remove the alignment dowels from the transmission front mounting surface.
3. Mount the transmission in a holding fixture.
4. Remove the clutch release bearing/slave cylinder. Refer to Page 6-20.
5. Remove the sealing ring (6) from countershaft bore (4) using a screwdriver.
6. Remove the input shaft seal (1) using a screw driver.
7. Remove the countershaft bolt (5).
8. Remove the input shaft snap ring (2).
9. Rotate the transmission to a vertical position in the fixture.

10. Remove the output shaft collared nut (5) and the output
flange (6).
11. Drive out the roll pin (8) with a suitable roll pin punch and
remove the shift actuator (7).
12. Remove the reverse gear detent plug (1). Refer to Page
21-358.
13. Remove the rear section retaining bolts (4).
14. Separate the rear section from the front section.
Note: The countershaft, input shaft, and shift unit can only
be removed as an assembly from the rear section.
15. Use a two jaw puller (1) to press the shafts and shift unit
out of the rear section of the transmission.
16. Mount the mainshaft and countershaft together (1) in a

vise with protective jaws. Remove the shifter (2).
17. Disassemble the rear section housing. Refer to Page
21-362.
ASSEMBLY
1. Assemble the rear section housing. Refer to Page 21-362.
Note: Be certain that the shift forks are aligned in the

shifting sleeves on the shafts.
2. Fit the shifter assembly (2) on to the main and counter

shafts (1).
3. Fit the rear section of the transmission (4) over the main
shaft and shift shaft. Align the reverse gear (1) to the gear
sets as shown.
4. Use the output flange (3) and the collared nut (1) to draw in
the output shaft. Remove the nut and flange when the rear
section is in place.
5. Install the shifter plate bolts. Tighten the bolts to 28 N·m
(21 ft. lbs.).
6. Install the counter shaft bolt (5). Tighten the bolt to 90 N·m
(66 ft. lbs.).
7. Install the snap ring (2) on the input shaft.
8. Use Special Tool 9123 Drift to drive in a new input shaft
seal.
9. Install a new sealing ring (6) in the counter shaft bolt open-
ing (4).
10. Install the clutch release bearing/slave cylinder. Refer to
Page 6-20.
11. Remove the front section of the transmission from the
holding fixture and install the alignment dowels.
12. Apply a 1.5 to 2mm. bead of Loctite 5203 sealer or equiv-

alent to the front section as shown.
13. Fit the front and rear transmission sections together.

14. Install the bolts (4) and tighten to 28 N·m (21 ft. lbs.).
15. Install the shift actuator (7) and drive the roll pin (8) in
until flush.
16. Drive the reverse gear detent (1) in until fully seated.
17. Install the oil filler plug (2). Tighten the plug to 50 N·m (37
ft. lbs.).
18. Install the oil drain plug (3). Tighten the plug to 60 N·m
(44 ft. lbs.).
19. Install the output flange (6) and collared nut (5). Tighten
the nut to 180 N·m (133 ft. lbs.).
MAINSHAFT W/INPUT SHAFT

DESCRIPTION
1 - BALL 22 - CONE RING

2 - SLIDER (NARROW) 23 - FRICTION RING
3 - COMPRESSION SPRING 24 - IDLER GEAR FOR 2ND GEAR
4 - SLIDING SLEEVE 25 - 2ND GEAR NEEDLE BEARING
5 - SYNCHRONIZER RING 26 - SLIDING SLEEVE
6 - CLUTCH BODY 27 - REVERSE GEAR SYNCHRONIZER BODY
7 - SNAP RING 28 - COMPRESSION SPRING
8 - CYLINDRICAL ROLLER BEARING 29 - SLIDER (NARROW)
9 - INPUT SHAFT 30 - BALL
10 - IDLER GEAR FOR 1ST GEAR 31 - SYNCHRONIZER RING
11 - 1ST GEAR NEEDLE BEARING 32.- IDLER GEAR FOR REVERSE GEAR
12 - FRICTION RING 33 - REVERSE GEAR NEEDLE BEARING
13 - CONE RING 34 - SLEEVE
14 - SYNCHRONIZER RING 35 - THRUST WASHER
15 - SNAP RING 36 - MAINSHAFT
16 - SLIDING SLEEVE 37 - 6TH GEAR NEEDLE BEARING
17 - 1ST/2ND GEAR SYNCHRONIZER BODY 38 - IDLER GEAR FOR 6TH GEAR
18 - COMPRESSION SPRING 39 - CLUTCH BODY
19 - SLIDER (WIDE) 40 - SYNCHRONIZER RING
20 - BALL 41 - 5TH/6TH GEAR SYNCHRONIZER BODY
21 - SYNCHRONIZER RING
DISASSEMBLY
2. Mount the main shaft in a vise with protective jaws.
3. Remove first gear idler gear (2) using a jaw puller (1).
4. Remove the reverse gear synchronizer assembly (1).

5. Remove the synchronizer ring (1) and idler gear (2) for
reverse gear.
6. Remove first gear needle bearing (1) and sleeve (2).
7. Remove the thrust washer (1), first gear idler gear (2), and
first gear idler needle bearing (3).
8. Remove the friction ring (1), cone ring (2), and the synchro-
nizer ring (3).
9. Remove the locking ring (1) using pliers. Remove the 1st/
2nd gear synchronizer using the jaw puller.
10. Remove the synchronizer ring (1), cone ring (2), and fric-
tion ring (3).
11. Remove the second gear idler gear (1) and needle bearing
(2).
12. Remove the main shaft (1) from the input shaft (2).
13. Remove the synchronizer ring (5) and the clutch body (4).
14. Remove the cylindrical roller bearing (3) from the input
shaft (2).
15. Remove the input shaft (2) from the vise.
16. Clamp the main shaft (3) in the vise with input end up.
17. Remove the locking ring (1), pull off the synchronizer cone
(2) and the clutch body using the jaw puller.
18. Remove the synchronizer ring (1) and the clutch body (2).
19. Remove the 6th gear idler gear (1) and needle bearing
(2).
20. Remove the main shaft (3) from the vise.
ASSEMBLY
1. Install the 6th gear needle bearing (2) and gear (1) on the
mainshaft (3).
2. Install the clutch body (2) and the synchronizer ring (1).
Note: The inscription on the synchronizer body must face

upwards (towards the input end). The drivers on the syn-
chronizer ring must engage in the grooves in the synchro-
nizer body.
3. Assemble the synchronizer if it is not being replaced. Refer

to Page 21-386.
4. Press on the 5th/6th gear synchronizer assembly (1).
Note: Snap rings that are bent or otherwise damaged

must be replaced.
5. Install the snap ring (1) on the mainshaft (2). Check that it
is fully seated.
6. Install the synchronizer ring (2). Be sure the drivers on the

synchronizer ring are engaged in the grooves of the syn-
chronizer body.
7. Oil the cylindrical bearing (2) and place it in the input shaft
(1).
8. Place the input shaft (1) on the mainshaft.
9. Invert the mainshaft with input shaft in the vise. Use pro-
tected vise jaws.
10. Install the second gear needle bearing (3), and second
gear (2) on the mainshaft (1) with the collar facing
upwards.
11. Install the friction ring (4), the cone ring (3), and the syn-
chronizer ring (2). The lobes in the friction ring (4) must
engage in the recesses of the synchronizer ring (3).
12. Assemble the 1st/2nd gear synchronizer if it is not being

replaced. Refer to Page 21-386.
13. Install the 1st/2nd gear synchronizer assembly (1).
Note: Do not over expand the snap ring.
14. Install the snap ring (1).
Note: The lobes on the friction ring (1) must engage in the
recesses in the synchronizer ring (3).
15. Install the synchronizer ring (3), the cone ring (2), and the
friction ring (1).
16. Install the first gear needle bearing (3), first gear (2), and
press on the 1st gear thrust washer (1).
17. Press on the sleeve (2), and the reverse gear needle
bearing (1).
Note: The reverse gear collar must face upwards.
18. Install the reverse gear (2), and the synchronizer ring (1).
19. Press on the reverse gear synchronizer assembly (1).

20. Remove the input shaft together with the mainshaft from
the vise.
21. Assemble the geartrain housing. Refer to Page 21-365.
COUNTERSHAFT
DISASSEMBLY
1 - 4TH GEAR IDLER GEAR 13 - CONSTANT MESH GEAR

2 - 4TH GEAR NEEDLE BEARING 14 - SNAP RING
3 - COUNTERSHAFT 15 - SNAP RING
4 - SLIDING SLEEVE 16 - BALL BEARING
5 - BLOCKING PIECE 17 - SLIDING BLOCK
6 - SYNCHRONIZER RING 18 - COMPRESSION SPRING
7 - SYNCHRONIZER CONE RING 19 - 3RD/4TH GEAR SYNCHRONIZER BODY
8 - FRICTION RING 20 - SYNCHRONIZER RING
9 - CLUTCH BODY 21 - SYNCHRONIZER CONE RING
10 - 3RD GEAR NEEDLE BEARING 22 - FRICTION RING
11 - 3RD GEAR IDLER GEAR 23 - CLUTCH BODY
12 - 6TH GEAR DRIVE GEAR

3. Remove the snap ring (1).

4. Press off the constant mesh gear (2) and the 6th gear drive
gear (3).
5. Clamp the countershaft in a vise with protective jaws with
the output end pointing downwards.
6. Remove the 3rd gear idler gear (1) and needle bearing (2).
7. Remove the 3rd/4th gear clutch body (1) and the friction
ring (2).
8. Remove the 3rd/4th gear cone ring (1), the synchronizer

ring (2), and the locking ring (3) using pliers.
9. Use the jaw puller to remove the 4th gear (2) together with
the 3rd/4th gear synchronizer (1).
10. Remove the 4th gear synchronizer ring (1), cone ring (2),
and friction ring (3).
11. Remove the 4th gear clutch body (1), gear (2), and needle
bearing (3).
12. Release the countershaft from the vise.
ASSEMBLY
1. Clamp the countershaft in a vise with input end up.
2. Install the 4th gear needle bearing (3), gear (2), and clutch
body (1).
3. Install 4th gear friction ring (3), cone ring (2), and synchro-
nizer ring (1).
4. Unless a new synchronizer is being used, the synchronizer
unit must be properly assembled. Refer to Page 21-386.
5. Install the 4th gear (2) and the 3rd/4th gear synchronizer
unit (1).
6. Install the snap ring (3), the 3rd/4th gear synchronizer ring
(2), and cone ring (1).
7. Install the friction ring (2), and clutch body (1).
8. Install the 3rd gear needle bearing (2), and 3rd gear idler
gear (1).
9. Install the 6th gear drive gear (3) and press onto the coun-
tershaft.
10. Install the constant mesh gear (2) and press onto the
countershaft.
11. Install a new snap ring (1).
12. Remove the countershaft from the vise.
13. Assemble the gear train housing. Refer to Page 21-365.
SYNCHRONIZER
DESCRIPTION
When shifting, high torque transmission and frequent shift work with a reduced shift force at the same time require
a powerful synchronization unit. The multiple-cone synchronization in gears 1 to 6 meets these requirements and
therefore offers the following advantages during the shift process:
• Fast synchronization
• High level of shift comfort
• Low shift forces
ASSEMBLY
1. SLIDING SLEEVE 4. SPRING

2. STEEL BALL 5. SYNCHRONIZER BODY
3. SLIDER
GEAR SHIFT LEVER HANDLE

REMOVAL
1. Lift the shift boot (2) to expose the retainer nut (3).
2. Rotate the retainer nut (3) clockwise and down to remove
the shift handle (1).
3. Pull straight up on the handle (1).
INSTALLATION
1. Install the shift handle (1) on the shift rod (4).
2. Tighten the retainer nut (3) counterclockwise (upward) until
it is snug.
3. Push the shifter cover (2) down over the retainer and shift
rod (4).
REVERSE LOCKOUT CABLE

DESCRIPTION
Reverse gear, which is selected by moving the lever to the left and back (toward the driver) from first gear is pro-
tected against accidental selection by the lockout cable. The lockout cable requires that the knob must be lifted
before selecting reverse or the movement will be blocked. The reverse gear lockout cable is serviced only with the
shift mechanism. If the cable becomes inoperable, the shift mechanism must be replaced. Refer to Page 21-391.
SHIFT MECHANISM
DESCRIPTION
1 - SHIFT ROD 8 - REVERSE GEAR SHIFT FORK

2 - FLOOR SHIFT 9 - 1ST/2ND GEAR SHIFT FORK
3 - SWIVEL LEVER 10 - 3RD/4TH GEAR SHIFT FORK
4 - SELECTOR CABLE 11 - 5TH/6TH GEAR SHIFT FORK
5 - BRACKET 12 - INNER SHIFT MODULE
6 - SELECTOR ROD 13 - COUPLING MODULE
7 - BRACKET 14 - CENTRAL SHIFT SHAFT
The floor shift (2) is connected to the transmission by a coupling module (13) and supported on the body tunnel so
that it can move via a swivel lever (3). This prevents transmission of vibrations and noise to the floor shift and to the
tunnel by means of rubber mounts on the coupling rod, shift rod and the two swivel levers. The selector movement
is transmitted from the shift lever to the inner shift module (12) in the transmission by the selector cable (4) and the
shift movement is transmitted by the shift rod (1). Both transmission components are maintenance-free.
This type of shift mechanism has the following advantages:

• Precise and easy to operate shift.
• No transmission of component movements to the shift lever and tunnel. The swivel lever (3) and rubber
mounts allow the engine/transmission joint to move in all directions.
STANDARD PROCEDURE - SHIFT LEVER ADJUSTMENT

1. Move the shift lever (1) to the right position and pull up on
the shift lever.
2. Insert the Special Tool 9120 (2) into the shifter alignment
slot with the recess of the tool facing upwards.
3. Slide the adjustment tool (2) forward until it contacts the

plastic ring (1) at the front of the shifter.
4. Ensure the adjustment tool (2) is properly placed at the
front and the rear of the shifter housing (3).
5. Move the shift lever the the left position.
Note: Hold the shift lever in place until adjustment proce-

dure is complete.
6. Depress the detent tab (1) on the reverse lockout cable.
7. Depress the release button (1) on the reverse lockout

cable.
8. Adjustment procedure is now complete.
9. Move the shift lever (1) to the right position and pull up on
the shift lever (1).
10. Remove the Special Tool 9120 (2) from the shifter align-
ment slot.
REMOVAL
2. Remove the shift lever handle. Refer to Page 21-387.
3. Press down on the retainer spring (5) and remove the lock
pin (2) from the shift lever (1). Remove the shift lever (1),
the washer (6) and spring (5), the cover (4) and the boot
(3) from the shift mechanism.

5. Lower the engine and transmission slightly with the support.
6. Loosen the cable lock nut (2) and press In on the release
button (3) to remove the reverse lockout cable (1) from the
bracket.
7. Remove the shift rod (2) from the ball stud. Remove the
retaining pin (1) from the shift mechanism.
8. Lower and remove the shift mechanism (3) from the
vehicle.
INSTALLATION
Note: Be sure that the foam insulation remains in position
around the opening in the floor pan.
1. Position the shift mechanism (3) in the vehicle above the

transmission and install the retaining pin (1). Connect the
shift rod (2) to the ball stud.
2. Press the release button (3) and install the reverse lockout
cable (1) in the bracket. Tighten the lock nut (2).

5. Install the boot (3), the cover (4), the spring (5) and washer
(6) on the shift mechanism.
6. Press down on the washer (6) and install the retaining pin
(2).
7. Install the gear shift lever handle (1). Refer to Page

21-387.
ZH TIRES/WHEELS 22 - 1
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS - ELECTRICAL DIAGNOSTICS. . . . 1 TIRES/WHEELS - SERVICE INFORMATION . . . . . 37
TIRES/WHEELS - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
TIRES/WHEELS - ELECTRICAL DIAGNOSTICS TIRE PRESSURE SENSOR/TRANSMITTER . 19

DIAGNOSIS AND TESTING TRANSMITTER FAILURE . . . . . . . . . . . . . . . . 22
NO TIRES TRAINED . . . . . . . . . . . . . . . . . . . . 2 LEFT FRONT TIRE PRESSURE SENSOR/
TIRE PRESSURE MONITOR MODULE TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 24
FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LEFT REAR TIRE PRESSURE SENSOR/
TIRE PRESSURE SENSOR/TRANSMITTER TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 26
SIGNAL JAMMED . . . . . . . . . . . . . . . . . . . . . . 6 RIGHT FRONT TIRE PRESSURE SENSOR/
SIGNAL JAMMED . . . . . . . . . . . . . . . . . . . . . . 9 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 28
LEFT FRONT TIRE PRESSURE SENSOR/ RIGHT REAR TIRE PRESSURE SENSOR/
TRANSMITTER SIGNAL JAMMED . . . . . . . . . 11 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 30
LEFT REAR TIRE PRESSURE SENSOR/ TIRE PRESSURE SENSOR/TRANSMITTER
TRANSMITTER SIGNAL JAMMED . . . . . . . . . 13 LOW BATTERY . . . . . . . . . . . . . . . . . . . . . . . 32
RIGHT FRONT TIRE PRESSURE SENSOR/ TIRE PRESSURE VERIFICATION TEST . . . . 35
TRANSMITTER SIGNAL JAMMED . . . . . . . . . 15 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 36
RIGHT REAR TIRE PRESSURE SENSOR/
TRANSMITTER SIGNAL JAMMED . . . . . . . . . 17
TIRES/WHEELS - ELECTRICAL DIAGNOSTICS

22 - 2 TIRES/WHEELS - ELECTRICAL DIAGNOSTICS ZH
NO TIRES TRAINED
ZH TIRES/WHEELS - ELECTRICAL DIAGNOSTICS 22 - 3
NO TIRES TRAINED — CONTINUED
When Monitored And Set Condition
• When Monitored: With the ignition on, the Tire Pressure Monitor (TPM) monitors the tire pressure sensor/
transmitters approximately once a minute (60 – 68 seconds) when the vehicle speed is above 33 km/h (20
MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module does not receive a signal from any tire pressure
sensor/transmitter, the DTC will be set.
POSSIBLE CAUSES
INITIALIZATION FAILURE
TIRE TRAINING TIMEOUT
For a complete Tire Pressure Monitor Circuit Diagram Refer to Page 22-36
Diagnostic Test
1. PROGRAMMING TIRE PRESSURE MONITOR

With the DRB IIIT and a calibration magnet, program the Tire Pressure
Monitor module for all four tire pressure sensor/transmitters.
Disconnect the DRB IIIT and prepare the vehicle for a road test.
Road test the vehicle above 33 km/h (20 MPH) for a minimum of two min-
utes.
With the DRB IIIT read the last 32 transmissions received by the Tire
Pressure Monitor.
Does the DRB IIIT display any of the tire pressure transmitter IDs in
the last 32 transmissions?
Yes >> Repair is complete.
Perform TIRE PRESSURE MONITOR VERIFICATION
TEST.
No >> Replace and program the Tire Pressure Monitor mod-
ule. Refer to Page 22-51
Perform TIRE PRESSURE MONITOR VERIFICA-
TION TEST.
TIRE PRESSURE MONITOR MODULE FAILURE
TIRE PRESSURE MONITOR MODULE FAILURE — CONTINUED
transmitters approximately once a minute. The TPM module stores the last 32 transmissions from the four tire
pressure sensor/transmitters.
• Set Condition: If the Tire Pressure Monitor (TPM) module does not receive a transmission from any of the
four tire pressure/transmitters for six consecutive ignition cycles lasting at least 15 minutes, the DTC will be
set.
POSSIBLE CAUSES
NO TIRE PRESSURE SENSOR/TRANSMITTERS

TIRE PRESSURE SENSOR/TRANSMITTERS NOT PROGRAMMED
TIRE PRESSURE MONITOR MODULE
For a complete Tire Pressure Monitor Circuit Diagram Refer to Page 22-36.
Diagnostic Test
1. INSPECT TIRE PRESSURE SENSOR/TRANSMITTERS

Inspect all four vehicle wheels for the Tire Pressure Sensor/Transmitters
being present.
Do all the wheels have tire pressure sensor/transmitters?

Yes >> Go to 2
No >> Install the Tire Pressure Sensor/Transmitters and pro-
gram module. Refer to Page 22-55
TEST.
2. PROGRAMMING TIRE PRESSURE MONITOR

With the DRB IIIT and a calibration magnet, program the Tire Pressure
Monitor module for all four sensor/transmitters.
Disconnect the DRB IIIT and prepare the vehicle for a road test.
Road test the vehicle above 33 km/h (20 MPH) for a minimum of two min-
utes.
With the DRB IIIT read the last 32 transmissions received by the Tire
Pressure Monitor.
Does the DRB IIIT display any of the tire pressure transmitter IDs in
the last 32 transmissions?
Yes >> Repair is complete.
TEST.
No >> Replace and program the Tire Pressure Monitor mod-
ule. Refer to Page 22-51
TION TEST.
TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives an undetectable frequency transmis-
sion from the left front tire pressure sensor/transmitter, the DTC will be set.
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED

MPH).
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED

MPH).
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED

MPH).
SIGNAL JAMMED
MPH).
sion from a tire pressure sensor/transmitter, the DTC will be set.
POSSIBLE CAUSES
OUTSIDE RADIO FREQUENCY INTERFERENCE
For a complete Tire Pressure Monitor Circuit Diagram Refer to Page 22-36
TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
Diagnostic Test

Does the DRB IIIT display a Sensor/Transmitter Signal Jammed

DTC?
Yes >> Replace the Tire Pressure Sensor/Transmitter at the
affected wheel. Refer to Page 22-53
TEST.
No >> The condition that caused this DTC is currently not
present. Inspect the related wiring harness for a pos-
sible intermittent condition.
TION TEST.
SIGNAL JAMMED
SIGNAL JAMMED — CONTINUED
MPH).
sion from a tire pressure sensor/transmitter, the DTC will be set.
POSSIBLE CAUSES
Diagnostic Test

With the DRB IIIT, read the TPM DTCs.
Is this DTC preset?

Yes >> For complete diagnosis of this DTC, refer to TIRE PRES-
SURE SENSOR/TRANSMITTER SIGNAL JAMMED.
No >> Go To 2


Perform TIRE PRESSURE VERIFICATION TEST.
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER SIGNAL JAMMED — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


TIRE PRESSURE SENSOR/TRANSMITTER
TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER
MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives a transmission from the left front tire
pressure sensor/transmitter that the battery is low, the DTC will be set.
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER

MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives a transmission from the left rear tire
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER

MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives a transmission from the right front tire
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER

MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives a transmission from the right rear tire
TRANSMITTER FAILURE
MPH).
• Set Condition: If the Tire Pressure Monitor (TPM) module receives a transmission from a tire pressure
sensor/transmitter that the battery is low, the DTC will be set.
POSSIBLE CAUSES
For a complete Tire Pressure Monitor Circuit Diagram. Refer to Page 22-36
TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
Diagnostic Test

Does the DRB IIIT display a Tire Pressure Sensor/Transmitter DTC?

affected wheel.
TEST.
TION TEST.
TRANSMITTER FAILURE
TRANSMITTER FAILURE — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

SURE SENSOR/TRANSMITTER.
No >> Go To 2


LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER — CONTINUED
MPH).
POSSIBLE CAUSES
Diagnostic Test

Is this DTC preset?

No >> Go To 2


TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY
TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY — CONTINUED
LEFT FRONT TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY
MPH).
LEFT REAR TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY

MPH).
RIGHT FRONT TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY

MPH).
RIGHT REAR TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY

MPH).
LOW BATTERY
MPH).
POSSIBLE CAUSES
TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY
For a complete Tire Pressure Monitor Circuit Diagram Refer to Page 22-36.
TIRE PRESSURE SENSOR/TRANSMITTER LOW BATTERY — CONTINUED
Diagnostic Test

Does the DRB IIIT display a Sensor/Transmitter Low Battery DTC?

affected wheel. Refer to Page 22-53
TEST.
TION TEST.
TIRE PRESSURE VERIFICATION TEST
1.
Drive the vehicle at 40 km/h (25 MPH) for at least 2 minutes.
responding symptom.

TIRE PRESSURE MONITOR CIRCUIT DIAGRAM

ZH TIRES/WHEELS - SERVICE INFORMATION 22 - 37
TIRES/WHEELS - SERVICE INFORMATION
TABLE OF CONTENTS
page page
TIRES/WHEELS - SERVICE INFORMATION TIRES

DIAGNOSIS AND TESTING - TIRE AND DESCRIPTION
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . 38 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
STANDARD PROCEDURE RADIAL - PLY TIRES . . . . . . . . . . . . . . . . . . . 57
TIRE AND WHEEL BALANCE .......... . . 42 TIRE INFLATION PRESSURES . . . . . . . . . . . 57
STANDARD PROCEDURE - MATCH TIRE PRESSURE FOR HIGH SPEED .... . . 58
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . 43 REPLACEMENT TIRES . . . . . . . . . . . . . . . . . 58
STANDARD PROCEDURE - TIRE ROTATION . 45 DIAGNOSIS AND TESTING
STANDARD PROCEDURE - TIRE AND DIAGNOSIS AND TESTING - TREAD WEAR
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . 46 INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . 59
TIRE PRESSURE MONITORING DIAGNOSIS AND TESTING - TIRE WEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46 PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DIAGNOSIS AND TESTING - TIRE NOISE
DIAGNOSIS AND TESTING - TIRE PRESSURE OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . . 59
MONITORING SYSTEM . . . . . . . . . . . . . . . . . 48 DIAGNOSIS AND TESTING - TIRE/VEHICLE
SPECIFICATIONS LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TIRE PRESSURE MONITORING SYSTEM . . . 49 STANDARD PROCEDURE
MODULE REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . 60
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49 STANDARD PROCEDURE - DRAINING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIREFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
STANDARD PROCEDURE - TPM MODULE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 50 SPECIFICATIONS - TIRES .............. . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 WHEELS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 DESCRIPTION
SENSOR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52 DIAGNOSIS AND TESTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 WHEEL INSPECTION ................ . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 STANDARD PROCEDURE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55 WHEEL REPLACEMENT . . . . . . . . . . . . . . . . 63
22 - 38 TIRES/WHEELS - SERVICE INFORMATION ZH
TIRES/WHEELS - SERVICE INFORMATION

DIAGNOSIS AND TESTING - TIRE AND WHEEL RUNOUT
WHEELS
Radial runout (1) is the difference between the high and low
points on the wheel. This is measured by using a dial indicator
(1) on the inner portion of the wheel (6).
Lateral runout (2) is the side to side movement of the wheel.

This is measured by using a dial indicator (1) on the inner por-
tion of the wheel (6) rim.
TIRES
• Radial runout (1) of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause the
vehicle to shake.
• Lateral runout (2) of more than 1.0 mm (.040 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate the wheel
and tire assembly on the mounting bolts (See Method 1). If
this does not reduce runout to an acceptable level, the tire can
be rotated on the wheel. (See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)

1. Drive the vehicle a short distance to eliminate tire flat spotting from a parked position.
2. Check the wheel bearings and adjust or replace if necessary.
• Front wheel bearings (2).
• Rear wheel bearings (5).

3. Check the wheel mounting surface (1) of the wheel hub.
4. Relocate the wheel on the mounting surface of the wheel
hub (1), two bolts over from the original position.
5. Tighten wheel bolts until all are properly torqued, to elimi-
nate brake distortion 110 N·m (81 ft. lbs.).
6. Check the radial runout (1). If it is still excessive, mark the

tire sidewall, wheel, and bolt at the point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)

Note: Rotating the tire on wheel is particularly effective when there is runout in both tire and wheel.
1. Remove the tire from the wheel and mount the wheel on a service dynamic balance machine.
2. Check the wheel radial runout and the lateral runout.
• Radial runout (1). This is measured by using a dial indicator (1) on the inner portion of the wheel (6).
• Lateral runout (1). This is measured by using a dial

indicator (1) on the inner portion of the wheel (6) rim.
3. If the point of the greatest wheel lateral runout is near the
original mark, remount the tire 180 degrees. Recheck the
runout or match mount.
STANDARD PROCEDURE
TIRE AND WHEEL BALANCE
It is recommended that a two plane service dynamic balancer be used when a tire and wheel assembly require
balancing. Refer to balancer operation instructions for proper cone mounting procedures. Typically aluminum wheels
use the back cone mounting method without a cone spring.
Note: Static should be used only when a two plane balancer is not available.
Note: Aluminum wheels require coated balance weights and special alignment equipment.
Wheel balancing can be accomplished with either on or off vehicle equipment. When using on-vehicle balancing
equipment, remove the opposite wheel/tire. Off-vehicle balancing is recommended.
For static balancing, find the location of the heavy spot (1)
causing the imbalance. Counter balance wheel directly oppo-
site the heavy spot. Determine weight required to counter bal-
ance the area of imbalance. Place half of this weight (3) on
the inner rim flange and the other half on the outer rim
flange.
For dynamic balancing, the balancing equipment is designed

to locate the amount of weight (2) to be applied to both the
inner and outer rim flange.
STANDARD PROCEDURE - MATCH MOUNTING

Tires and wheels are not match mounted at the factory. Match mounting is a technique used to reduce runout in the
wheel/tire assembly. This means that the high spot of the tire is aligned with the low spot on the wheel rim. The high
spot on the tire is marked with a paint mark or a bright colored adhesive label on the outboard sidewall. The low
spot on the rim is identified with a label on the outside of the rim and a dot on the inside of the rim. If the outside
label has been removed the tire will have to be removed to locate the dot on the inside of the rim.
Before dismounting a tire from its wheel, a reference mark should be placed on the tire at the valve stem location.
This reference will ensure that it is remounted in the original position on the wheel.
1. Use a dial indicator to locate the high spot of the tire on the
center tread rib. Record the indicator reading and mark the
high spot on the tire.
2. Place a mark (1) on the tire at the valve stem (4) location.
3. Break down the tire and remount it so that the valve stem
(1) is 180 degrees from the mark (2) on the tire.
4. Measure the total runout again and mark the tire to indicate
the high spot (2).
5. If runout is still excessive use the following procedures.
• If the high spot is within 101.6 mm (4.0 in.) of the first
spot and is still excessive, replace the tire.
• If the high spot is within 101.6 mm (4.0 in.) of the first
spot on the wheel, the wheel may be out of specifications
Refer to Page 22-1.
• If the high spot is NOT within 101.6 mm (4.0 in.) of
either high spot, draw an arrow on the tread from second
high spot to first. Break down the tire and remount it 90
degrees on rim in that direction. This procedure will nor-
mally reduce the runout to an acceptable amount.
STANDARD PROCEDURE - TIRE ROTATION

WARNING: DO NOT ROTATE TIRES IN A FRONT TO BACK FASHION. THE FRONT AND REAR TIRES ARE
DIFFERENT SIZES AND WILL CAUSE VEHICLE MALFUNCTION.
The only method of tire rotation is from the rear right side to rear left side and from the front right side to
the front left side.
Tires on the front and rear of the vehicle operate at different loads and perform different steering, driving, and brak-
ing functions. For these reasons they wear at unequal rates and tend to develop irregular wear patterns. These
effects can be reduced by rotating the tires at regular intervals. The benefits of tire rotation are:
• Increase tread life
• Maintain traction levels
• A smooth, quiet ride
STANDARD PROCEDURE - TIRE AND WHEEL INSTALLATION

The wheel bolts are designed for specific applications. They must be replaced with equivalent parts. Do not use
replacement parts of lesser quality or a substitute design.
Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure
wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of wheel bolts.
This could affect the safety and handling of your vehicle.
To install the wheel, first position it properly on the mounting
surface. All wheel bolts should then be tightened just snug.
Gradually tighten them in sequence 1, 2, 3, 4, 5 to 110 N·m
(81 ft. lbs.). Never use oil or grease on bolts.
TIRE PRESSURE MONITORING

DESCRIPTION
This vehicle has a tire pressure monitoring (TPM) system. It is
there to alert the driver when air pressure in any of the vehi-
cle’s four tires falls below a predetermined threshold. It alerts
the driver with a lamp in the instrument cluster.
The garage door opener/tire pressure monitor module (1) is

located in the headliner near the inside rear view mirror (2).
The tire pressure monitoring (TPM) system utilizes a control
module to control the system. The control module also has a
garage door opener control module integrated along with it.
The tire pressure monitoring system utilizes transmitters that

are located in the valve stem (1) of each tire (2) to communi-
cate the tire pressure condition to the module. If a tire has low
air pressure, an indicator light on the instrument cluster is illu-
minated. The vehicle operator must check the tire pressure of
each tire in order to determine which tire has a low pressure
condition.
The low tire pressure warning system utilizes these main com-
ponents:
• Tire Pressure Monitoring Module
• Tire Pressure Sensors/Transmitters
• Tire Pressure Indicator Lamp
For information on specific components, refer to that individual
component.
OPERATION
The garage door opener/tire pressure monitoring (TPM) mod-
ule (1) has a microprocessor controller that can monitor the
transmissions from the sensor/transmitters anytime the ignition
is on. It can store the last 32 transmissions. There are two
important values included in these transmissions. They are:
• Why the transmission was sent,
• Low Tire Pressure
The module compares the transmitted tire pressure from the
sensor (2) to the two pressure thresholds (low pressure or crit-
ical pressure).
If the module determines that the tire pressure transmitted is

below the low or critical pressure thresholds, it will signal for
the “Low Tire” pressure warning lamp to come on.
The TPM module performs diagnostic routines, stores diagnos-
tic trouble codes and provides the appropriate lamp status to
the body control module (BCM).
When the module determines there is a fault, the low tire pres-
sure indicator lamp circuit is grounded and the BCM turns on
the “Low Tire” pressure indicator lamp.
The TPM module also stores its own identification number,
module version and the date of manufacture.
DIAGNOSIS AND TESTING - TIRE PRESSURE MONITORING SYSTEM

Diagnostics for the electronic components of the tire pressure monitoring system can be done using the DRBIIIT
scan tool and Appropriate Diagnostic Information.
The tire pressure sensors/transmitters and TPM module are not repairable components. If either of these compo-
nents are found to be at fault or damaged, the component must be replaced. Refer to Page 22-51.
SPECIFICATIONS
TIRE PRESSURE MONITORING SYSTEM
Low Pressure Threshold 26 psi
Pressure Sensor/Transmitter Mounting Nut Torque 4 N·m (35 in. Lbs.)
MODULE
DESCRIPTION
The tire pressure monitoring (TPM) system utilizes a control
module (1) to control the system. The TPM module (1) is
located in the headliner between the dome lamp and the rear
view mirror.
OPERATION
The tire pressure monitoring (TPM) module has a microprocessor controller that can monitor the transmissions from
the sensor/transmitters anytime the ignition is on. It can store the last 32 transmissions. There are three important
values included in these transmissions. They are:
• Why the transmission was sent,
• Pressure
The module compares the transmitted tire pressure to the two pressure thresholds (low pressure or critical pres-
sure). If the module determines that the tire pressure transmitted is below the low or critical pressure thresholds, it
will signal for the “Low Tire” pressure warning lamp to come on.
The TPM module (1) performs diagnostic routines, stores diag-
nostic trouble codes and provides the appropriate lamp status
to the body control module (BCM). When the module deter-
mines there is a fault, the low tire pressure indicator lamp cir-
cuit is grounded and the BCM turns on the “Low Tire” pressure
indicator lamp.
The TPM module (1) also stores its own identification number,
each of the four sensor/transmitter identification numbers,
module version and the date of manufacture.
STANDARD PROCEDURE - TPM MODULE PROGRAMMING

If a TPM module fails, or one or more tire pressure sensor/transmitters fail, after replacement, the TPM module’s
diagnostic memory must be cleared and reprogrammed. This is necessary for the module to detect which wheel is
sending the signal.
Refer to the following procedure to program the module for identification of one new or all tire pressure sensor/
transmitters.
Note: The vehicle’s tires must not have been rotated above 8 km/h (5 mph) in the last two minutes prior to
programming.
1. Connect a DRBIIIT scan tool to the vehicle’s diagnostic connector beneath the instrument panel, to the left of the
steering column.
2. Access the Chassis System using the DRBIIIT.
3. Once in the Chassis System, select Tire Pressure Monitor.
4. Select the appropriate function from the next screen displaying the following options:
• Program LF Pressure Sensor
• Program RF Pressure Sensor
• Program RR Pressure Sensor
• Program LR Pressure Sensor
• Program Module (4 Sensors)
5. Place a magnet, special tool 8821, at the valve stem for that wheel as directed by the DRBIIIT. If the Program
Module function has been chosen, the DRBIIIT will direct you to the left front wheel pressure sensor/transmitter
first.
6. When that wheel’s pressure sensor/transmitter has been programmed, the DRBIIIT will display Program Trans-
mitter Complete or will automatically direct you to the next wheel sensor/transmitter to be programmed.
Note: When programming the module (all four sensor/transmitters), the magnet should be moved from
wheel to wheel in a clockwise direction starting at the left front wheel.
7. Remove the magnet and if programming the entire module, move the magnet to each of the remaining wheels as
directed by the DRBIIIT. Each sensor/transmitter will automatically sense the presence of the magnet and begin
programming.
8. Once Program Transmitter Complete is displayed, exit the program function screen.
9. Verify that the module programming is complete by looking at the tire pressure sensor/transmitter ID’s in the
Sensor Display using the DRBIIIT.
REMOVAL
1. Using a plastic wedge. Slide the wedge under the TPM
(Tire Pressure Module) module (1) and the headliner and
pry the TPM (1) away from the headliner.
INSTALLATION
1. Install the TPM (1) by snapping it into the headliner.
SENSOR
DESCRIPTION
CAUTION: Be sure that an original equipment valve stem cap or a valve stem cap of the same sealing capa-
bility is always used if the valve stem cap requires replacement.
A tire pressure sensor/transmitter is installed in each wheel of this vehicle as part of the tire pressure monitoring
system. A special valve stem incorporated into each tire pressure sensor/transmitter attaches it to the wheel.
VALVE STEM CORE AND CAP

On this vehicle, the valve stem is part of the tire pressure sensor/transmitter and is used as its antenna. If corrosion
were to develop in the valve stem, it would affect the ability of the tire pressure sensor/transmitter to send the radio
frequency signal to the TPM module.
The valve stem used on this vehicle is made from aluminum. Corrosion of aluminum will be caused by putting a
dissimilar metal in contact with it. To prevent this type of corrosion from developing within the valve stem, the core
of the valve stem is made of a compatible metal and is specially coated.
For this reason, a standard valve stem core must never be installed in this valve stem. If the core of the valve stem
is removed when servicing the tire, the original valve stem core must be reinstalled. If the valve stem core needs to
be replaced, it must be replaced with an original equipment valve stem core.
The valve stem caps used on this vehicle are specially designed for their use on the valve stem of the tire pressure
sensor/transmitter. Each valve stem cap has an O-ring in the upper end of the valve stem cap to provide a positive
seal at the end of the valve stem. This keeps dirt contamination and corrosion out of the valve stem caused by
moisture. As listed earlier, these conditions can affect the ability of the tire pressure transmitter to send the radio
frequency signal to the TPM module.
OPERATION
Each tire pressure sensor/transmitter serves three functions:
• It is used as a valve stem to inflate and deflate the tire.
• It periodically measures tire pressure. (Approximately every 30 seconds.)
• It transmits the tire pressure value to the low tire pressure warning module in the vehicle. (Approximately
every 60 seconds or if tire pressure changes by one psi or more between transmissions.)
The system operates by monitoring a radio frequency transmission from the sensor/transmitters located in each
wheel. When the vehicle reaches a speed of approximately 32 km/h (20 mph), centrifugal force created by the rotat-
ing wheels closes a roll switch inside each sensor/transmitter, powering up the circuitry.
The sensor/transmitters will only send out information when vehicle speed is above 32 km/h (20 mph). To facilitate
transmitting the radio signal to the TPM module, the valve stem acts as the antenna for the tire pressure sensor/
transmitter. When the TPM module senses that pressure is below one of two calibrated thresholds, (low pressure or
critical pressure) the TPM system will set a diagnostic trouble code and indirectly operate the “Low Tire” pressure
indicator lamp and the chime tone through the body control module (BCM).
The tire pressure sensor/transmitter is powered by an internal battery. The battery is not replaceable separately. In
the event of battery failure, the entire tire pressure sensor/transmitter at that wheel will require replacement. To
extend the life of the battery, the sensor/transmitter is not activated until the vehicle reaches a speed of approxi-
mately 32 km/h (20 mph) as stated earlier.
Each tire pressure sensor/transmitter has a unique identity code. This will allow the TPM system to indicate to a
technician, through diagnostic trouble codes in the module, which tire of the vehicle has lost air pressure. This code
is also used to identify to a technician which pressure sensor/transmitter has set a diagnostic trouble code. For this
reason, if a tire pressure sensor/transmitter needs to be replaced, the new sensor/transmitter must be programmed
to have its identity code recognized by the receiver.
REMOVAL
1. Remove the tire/wheel from the vehicle.
CAUTION: When removing the stick-on balancing weights

from the wheel, do not use an abrasive cleaner or a
cleaner which will damage the protective finish on the
wheel.
2. Remove the balancing weights from the wheel (1).
Note: The cap used on this valve stem contains an O-ring

seal to prevent contamination and moisture from entering
the valve stem. Retain this valve stem cap for reuse. Do
not substitute a regular valve stem cap in its place.
3. Remove the cap from the valve stem (2).
Note: The valve stem used on this vehicle is made of alu-

minum and the core is nickel plated brass. The original
valve stem core must be reinstalled and not substituted
for a valve stem core made of a different material. This is
required to prevent corrosion in the valve stem caused by
the different metals.
4. Using the appropriate tool, remove the core (4) from the
valve stem (2).
5. Let the tire fully deflate.
CAUTION: The pressure transmitter must be removed

from the wheel and dropped into the tire prior to breaking
the bead and dismounting the tire. Failure to do this will
greatly increase the risk of damaging the pressure trans-
ducer when servicing the tire.
6. Remove the nut (1) mounting the valve stem (4) of the
pressure sensor/transmitter to the wheel (2). Drop sensor/
transmitter into the tire (3).
CAUTION: When breaking the top and bottom bead of the

tire off the wheel, care must be used so the bead breaking
mechanism on the tire changer does not damage the
wheel. This includes the surface of the wheel flange on
the inside of the wheel.
7. Using the tire changer manufacturer’s procedure, first break

down the upper bead of the tire. Then break down the bot-
tom bead of the tire.
CAUTION: When dismounting the upper tire bead from the

wheel, the proper procedure must be used. Not using the
proper procedure will result in damage to the wheel and
tire.
8. Dismount the upper bead of the tire(1) from the wheel(2).

The upper bead must be fully dismounted from the
wheel to remove the tire pressure transmitter from the
inside of the tire. The bottom bead of the tire does not
need to be removed from the wheel.
9. Pull upward on the tire(1). Reach inside the tire and
remove the pressure sensor/transmitter(3).
INSTALLATION
Note: When installing the tire pressure sensor/transmitter,
replace the sealing grommet at the valve stem base before
installing the pressure transmitter in the wheel. Also, be
sure that the surface of the wheel that the grommet seals
are against is clean and not damaged.
1. Install the tire pressure sensor/transmitter (1) on the wheel

(2).
2. Install the special sensor mounting nut (3). When tightening
the tire pressure sensor/transmitter nut, hold the sensor so
it does not rotate. Once tightened, the gap between the
sensor and the wheel must be even on both sides as
shown. If the sensor/transmitter rotates (clocks), damage to
the sensor/transmitter can occur when mounting the tire.
Tighten the nut (3) to 4 N·m (35 in. lbs.).
CAUTION: When mounting the upper bead of the extended

mobility tire, the proper procedure must be used. Not
using the proper procedure will result in damage to the
wheel and tire.
3. Mount the upper bead of the tire on the wheel.

4. Inflate the tire(s) to the proper specification.
5. Install the original or an OEM replacement valve stem cap
on the valve stem.
6. Using a soap solution, check that no air leak is present
where the valve stem mounts to the wheel.
7. Balance the tire/wheel assembly using the correct proce-
dure for using wheel flange mount and stick-on wheel
weights. For balancing information and wheel weight posi-
tioning, Refer to Page 22-42.
8. Install the tire/wheel on the vehicle. Refer to Page 22-42.
9. Program the identification code for the new tire pressure
sensor/transmitter into the TPM module.
10. Verify that the TPM module has been programmed with
the identification code from the new tire pressure sensor/
transmitter using the DRBIIIT scan tool. If the identification
code and tire pressure thresholds from the new tire pres-
sure transmitter are present in the receivers memory the
new tire pressure transmitter has been correctly pro-
grammed to the receiver.
TIRES
DESCRIPTION
TIRES
Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal
operation. The ride and handling characteristics match the vehicle’s requirements. With proper care they will give
excellent reliability, traction, skid resistance, and tread life.
Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much
greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire
are:
• Rapid acceleration
• Severe brake applications
• High speed driving
• Excessive speeds on turns
• Striking curbs and other obstacles
Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown in the
section on Tire Rotation. This will help to achieve a greater tread life.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are encoded in
the letters and numbers imprinted on the side wall of the tire.
In a metric sire size as P185/80R13. The first letter of the tire
size tells if the tire is used for passenger (P), temporary (T), or
commercial (C) use. The second designation tells the section
width (1) of the tire. The section width is the distance in milli-
meters from one side of the tire to the other when it is inflated
normally. The third designation tells the aspect ratio (2). The
aspect ratio (2) is found by dividing the section height (2) by
the section width (1). The aspect ratio means the tire’s height
is 80% of the width. This is called the profile of the tire. Lower
profile tires make the vehicle closer to the road and reduce
wind drag underneath the vehicle body. The next designation
tells the construction type. R means radial tire, B means
belted, and D means diagonal (bias). The last designation
gives the wheel rim in inches. The most common car rim sizes
are 13, 14, 15. Some rims are as large as 20 inches in diam-
eter.
Performance tires have a speed rating letter after the aspect
ratio number. The speed rating is not always printed on the tire
sidewall. These ratings are:
• Q up to 100 mph
• S up to 112 mph
• T up to 118 mph
• U up to 124 mph
• H up to 130 mph
• V up to 149 mph
• Z more than 149 mph (consult the tire manufacturer for the specific speed rating)
An All Season type tire will have either M + S, M & S or M–S (indicating mud and snow traction) imprinted on the
side wall.
RADIAL - PLY TIRES

Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance.
Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only.
They may be mixed with temporary spare tires when necessary.
Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the
same recommended inflation pressures.
The use of tires from different manufacture’s on the same vehicle is NOT recommended. The proper tire pressure
should be maintained on all four tires.
Z-rated tires are optimized for performance driving and may provide slightly reduced ride comfort, increased tire
noise and substantially increased tread wear compared to all-season tires.
TIRE INFLATION PRESSURES

WARNING: OVER- OR UNDER-INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL.
Under-inflation will cause rapid shoulder wear (1), tire flexing,

and possible tire failure.
Over-inflation will cause rapid center wear (1) and loss of the
tire’s ability to cushion shocks.
Improper inflation can cause:

• Uneven wear patterns
• Reduced tread life

• Reduced fuel economy
• Unsatisfactory ride
• Vehicle drift
For proper tire pressure specification refer to the Tire Inflation Pressure Chart provided with the vehicle’s Owner’s
Manual. A Certification Label on the driver’s side door pillar provides the minimum tire and rim size for the vehicle.
The label also lists the cold inflation pressure for these tires at full load operation.
Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure
should be checked cold once a month. Tire pressure decreases as the ambient temperature drops. Check tire pres-
sure frequently when ambient temperature varies widely.
Tire inflation pressures are cold inflation pressure. The vehicle must sit for at least 3 hours to obtain the correct cold
inflation pressure reading, or be driven less than one mile after sitting for 3 hours. Tire inflation pressures may
increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up.
TIRE PRESSURE FOR HIGH SPEED

Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. For
speeds up to and including 120 km/h (75 mph), tires must be inflated to the pressures shown on the tire placard.
For continuous speeds in excess of 120 km/h (75 mph), tires must be inflated to the maximum pressure specified
on the tire sidewall.
Vehicles loaded to the maximum capacity should not be driven at continuous speeds above 75 mph (120 km/h).
For emergency vehicles that are driven at speeds over 90 mph (144 km/h), special high speed tires must be used.
Consult tire manufacturer for correct inflation pressure recommendations.
REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN
RESULT IN SUDDEN TIRE FAILURE.
The original equipment tires provide a proper balance of many characteristics such as:
• Ride
• Noise
• Handling
• Durability
• Tread life
• Traction
• Rolling resistance
• Speed capability
It is recommended that tires equivalent to the original equipment tires be used when replacement is needed.
Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle.

DIAGNOSIS AND TESTING - TREAD WEAR INDICATORS
Tread wear indicators (3) are molded into the bottom of the
tread grooves.
Tire replacement is necessary when indicators appear in two
or more grooves or if localized balding occurs.
DIAGNOSIS AND TESTING - TIRE WEAR

PATTERNS
Under-inflation will cause wear on the shoulders of tire. Over-inflation will cause wear at the center of tire.
Excessive camber causes the tire to run at an angle to the
road. One side of tread is then worn more than the other.
Excessive toe-in or toe-out causes wear on the tread edges
and a feathered effect across the tread.
DIAGNOSIS AND TESTING - TIRE NOISE OR

VIBRATION
Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly
tire imbalance.
To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note
the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as
speed varies, while the tire noise will usually remain constant.
DIAGNOSIS AND TESTING - TIRE/VEHICLE LEAD

Use the following vehicle lead diagnosis and correction procedure to diagnose and correct a vehicle lead or drift
problem.
VEHICLE LEAD DIAGNOSIS AND CORRECTION

1. Adjust tire pressure to correct OK?
Road test
specifications. If vehicle still leads, go to step 2.
OK?
2. Cross switch front tire and wheel Vehicle leads same direction. Go to
Road test
assemblies. step 3.
Vehicle leads opposite direction. Go
to step 4.
3. Probable Cause - Vehicle. Check
If alignment is OK go to step 4.
front alignment toe - caster - Adjust alignment to correct settings.
If alignment is not OK.
camber.
WARNING:
4. Probable Cause - Tires. Replace DO NOT SWITCH FRONT AND REAR TIRE ASSEMBLIES. THEY ARE
front tires. DIFFERENT WHEEL SIZES AND WILL CAUSE DAMAGE TO THE
VEHICLE
STANDARD PROCEDURE
REPAIRING LEAKS
CAUTION: Ensure that the tire has been drained of all
TIREFIT tire sealant. If not the tire will have to be properly
drained before any tire service may be performed. Refer to
Page 22-60.
For proper repairing, a radial tire must be removed from the

wheel. Repairs should only be made if the defect, or puncture,
is in the tread area (1). The tire should be replaced if the
puncture is located in the sidewall.
Deflate the tire completely before removing the tire from the
wheel. Use lubrication such as a mild soap solution when dis-
mounting or mounting tire. Use tools free of burrs or sharp
edges which could damage the tire or wheel rim.
Before mounting tire on wheel, make sure all rust is removed
from the rim bead and repaint if necessary.
Install wheel on vehicle, and tighten to proper torque specifi-
cation, 110 N·m (89 ft. lbs.).
STANDARD PROCEDURE - DRAINING

TIREFIT
WARNING: KEEP AWAY FROM FIRE, SPARKS OR NAKED FLAME. DO NOT SMOKE WHILE HANDLING A
TIRE THAT HAS BEEN INFLATED USING TIREFIT. DO NOT INHALE VAPORS. CALL A PHYSICIAN IMMEDI-
ATELY IF AN ALLERGIC REACTION OCCURS. KEEP TIREFIT AWAY FROM CHILDREN. IF SWALLOWED,
INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. THE TIRE SEALANT MUST NOT COME INTO
CONTACT WITH THE SKIN, EYES OR CLOTHING, RINSE IMMEDIATELY WITH CLEAN WATER.
TIREFIT sealant can be used on the roadside to seal minor punctures, in particular in the tread. The tire can then
continue to be used to a limited extent until it can be replaced. After using TIREFIT tire sealant the customer is
required to find the nearest authorized DaimlerChryslerT service center immediately and replace the damaged tire
with a new one. Tires which have been treated with TIREFIT tire sealant must not be repaired. They must always
be replaced with new tires of the same make and manufacturer. Refer to Page 22-61. To avoid an odor due to
TIREFIT, relieve the tire pressure out in the open.
2. Remove the wheel and tire assembly from the vehicle.
Note: Raise the wheel off the ground approximately 8 to 10 inches off the ground to allow the TIREFIT to be
forced by gravity.
3. Position the wheel and tire assembly so that the air valve is pointing downwards for approximately ten minutes.
WARNING: THE TIRE SEALANT MUST NOT COME INTO CONTACT WITH THE SKIN, EYES OR CLOTHING,
RINSE IMMEDIATELY WITH CLEAN WATER.
4. Remove the valve stem with the appropriate tool, allow the tire pressure to escape from the tire.
5. Remove the valve from the wheel.
6. Attach the hose from the TIREFIT container to the plastic bottle.
7. Squeeze the container and immerse the hose as deep as possible in the tire sealant through the valve bore in
the wheel.
8. Remove the sealant by sucking it out of the tire with the container until all of the TIREFIT sealant is removed.
This will generally remove 90% of the TIREFIT sealant.
9. Remove the tire from the wheel.
10. Clean the wheel making sure it is free of the TIREFIT sealant.
11. Install a new tire to the wheel.
12. Install the wheel and tire assembly to the vehicle. Refer to Page 22-63.
CLEANING
Note: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning.
Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the
tires.
To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating
away with a soft bristle brush. Steam cleaning may also be used to remove the coating.
SPECIFICATIONS - TIRES
SPECIFICATIONS
FRONT TIRES 225/40ZR18
REAR TIRES 255/35ZR19
WHEELS
DESCRIPTION
WHEELS
The rim size is on the vehicle safety certification label located on the driver’s door shut face. The size of the rim is
determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified
maximum vehicle capacity.
This vehicle has aluminum wheels. Every wheel has raised
sections between the rim flanges (1) and rim drop well (3)
called safety humps.
Initial inflation of the tire forces the bead over these raised
sections. In case of rapid loss of air pressure, the raised sec-
tions help hold the tire on the wheel.
The wheel bolts are designed for specific applications. All alu-
minum wheels have wheel bolts with an enlarged head. This
enlarged head is necessary to ensure proper retention of the
wheels. Do not use replacement bolts with a different design
or lesser quality.

WHEEL INSPECTION
WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE
SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HIS-
TORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM
COULD FAIL WITHOUT WARNING.
Inspect wheels for:

• Excessive run out
• Dents or cracks
• Damaged wheel bolt holes
• Air leaks from any area or surface of the rim
Note: Do not attempt to repair a wheel by hammering, heating or welding.
If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement
wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of
the wheel should be the same as the original wheel.
STANDARD PROCEDURE
WHEEL REPLACEMENT
The wheel bolts are designed for specific applications. They must be replaced with equivalent parts. Do not use
replacement parts of lesser quality or a substitute design. All aluminum wheels have wheel bolts which feature an
enlarged head. This enlarged head is necessary to ensure proper retention of the aluminum wheels.
Note: Do not use chrome plated lug bolts with chrome plated wheels.
Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure
wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of the wheel
bolts. This could affect the safety and handling of your vehicle.
To install the wheel, first position it properly on the mounting
surface. All wheel bolts should then be tightened just snug.
Gradually tighten them in sequence (1-5) to the proper torque
specification. Never use oil or grease on the bolts.
Wheels must be replaced if they have:

• Excessive runout
• Bent or dented
• Leak air through welds
• Have damaged bolt holes
Wheel repairs employing hammering, heating, or welding are not allowed.
Original equipment wheels are available through your dealer. Replacement wheels from any other source should be
equivalent in:
• Load carrying capacity
• Diameter
• Width
• Offset
• Mounting configuration
Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with
used wheels is not recommended. Their service history may have included severe treatment.
ZH BODY 23 - 1
BODY
TABLE OF CONTENTS
page page
BODY - ELECTRICAL DIAGNOSTICS . . . . . . . . . . . 1 BODY - SERVICE INFORMATION . . . . . . . . . . . . . 29
BODY - ELECTRICAL DIAGNOSTICS
TABLE OF CONTENTS
page page
BODY - ELECTRICAL DIAGNOSTICS REAR SPOILER DRIVER (UP) CIRCUIT . . . . 13

DIAGNOSIS AND TESTING REAR SPOILER DRIVER (DOWN) CIRCUIT . 16
BODY CONTROL MODULE INTERNAL REAR SPOILER LIMIT SWITCH FAILURE . . . 19
FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REAR SPOILER MOTOR FAILURE . . . . . . . . 23
REAR SPOILER SWITCH SENSE CIRCUIT . . . 4 REAR SPOILER VERIFICATION TEST . . . . . . 27
SPOILER LIMIT SWITCH SIGNAL (UP) SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 28
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPOILER LIMIT SWITCH SIGNAL (DOWN)
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BODY - ELECTRICAL DIAGNOSTICS

23 - 2 BODY - ELECTRICAL DIAGNOSTICS ZH
ZH BODY - ELECTRICAL DIAGNOSTICS 23 - 3
• Set Condition: If the Body Control Module (BCM) detects an internal malfunction, the DTC is set.
POSSIBLE CAUSES
NO POWER TO BODY CONTROL MODULE
BODY CONTROL MODULE
For a complete Rear Spoiler Circuit Diagram. Refer to Page 23-28.
Diagnostic Test

harness connector.

Perform REAR SPOILER VERIFICATION TEST.
REAR SPOILER SWITCH SENSE CIRCUIT
REAR SPOILER SWITCH SENSE CIRCUIT — CONTINUED
• Set Condition: The Body Control Module (BCM) reports a short to power, ground, or an open circuit fail-
ure on the Rear Spoiler Switch Sense circuit.
POSSIBLE CAUSES
REAR SPOILER SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

REAR SPOILER SWITCH SENSE CIRCUIT SHORTED TO GROUND
REAR SPOILER SWITCH SENSE CIRCUIT OPEN
BODY CONTROL MODULE
For a complete Rear Spoiler Circuit Diagram, Refer to Page 23-28.
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE REAR SPOILER SWITCH

SENSE CIRCUIT

Disconnect the Rear Spoiler Switch harness connector.
Measure the resistance of the Rear Spoiler Switch Sense circuit from the
BCM harness connector to the Rear Spoiler Switch harness connector.

Yes >> Go to 2
No >> Repair the Rear Spoiler Switch Sense circuit for an open.
2. MEASURE THE VOLTAGE OF THE REAR SPOILER SWITCH SENSE

CIRCUIT

Measure the voltage of the Rear Spoiler Switch Sense circuit at the Rear
Spoiler Switch harness connector.
Is voltage present?
Yes >> Repair the Rear Spoiler Switch Sense circuit for a short to
voltage.
No >> Go to 3
REAR SPOILER SWITCH SENSE CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE REAR SPOILER SWITCH
SENSE CIRCUIT

Measure the resistance between ground and the Rear Spoiler Switch
Sense circuit at the Rear Spoiler Switch harness connector.

Yes >> Repair the Rear Spoiler Switch Sense circuit for a short to
ground.
8E-72.
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT — CONTINUED
ure on the Spoiler Limit Switch Signal (Up) circuit.
POSSIBLE CAUSES
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT SHORTED TO VOLTAGE

SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT SHORTED TO GROUND
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT OPEN
BODY CONTROL MODULE
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE SPOILER LIMIT SWITCH

SIGNAL (UP) CIRCUIT

Disconnect the Rear Spoiler Limit Switch harness connector.
Measure the resistance of the Spoiler Limit Switch Signal (Up) circuit from
the BCM harness connector to the Rear Spoiler Limit Switch harness con-
nector.

Yes >> Go to 2
No >> Repair the Spoiler Limit Switch Signal (Up) circuit for an
open.
2. MEASURE THE VOLTAGE OF THE SPOILER LIMIT SWITCH SIGNAL

(UP) CIRCUIT

Measure the voltage of the Spoiler Limit Switch Signal (Up) circuit at the
Rear Spoiler Limit Switch harness connector.
Is voltage present?
Yes >> Repair the Spoiler Limit Switch Signal (Up) circuit for a
short to voltage.
No >> Go to 3
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT — CONTINUED
SIGNAL (UP) CIRCUIT

Measure the resistance between ground and the Spoiler Limit Switch Sig-
nal (Up) circuit at the Rear Spoiler Limit Switch harness connector.

short to ground.
8E-72.
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT — CONTINUED
ure on the Spoiler Limit Switch Signal (Down) circuit.
POSSIBLE CAUSES
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT SHORTED TO VOLTAGE

SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT SHORTED TO GROUND
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT OPEN
BODY CONTROL MODULE
Diagnostic Test

SIGNAL (DOWN) CIRCUIT

Measure the resistance of the Spoiler Limit Switch Signal (Down) circuit
from the BCM harness connector to the Rear Spoiler Limit Switch harness
connector.

Yes >> Go to 2
No >> Repair the Spoiler Limit Switch Signal (Down) circuit for
an open.

(DOWN) CIRCUIT

Measure the voltage of the Spoiler Limit Switch Signal (Down) circuit at
the Rear Spoiler Limit Switch harness connector.
Is voltage present?
Yes >> Repair the Spoiler Limit Switch Signal (Down) circuit for a
short to voltage.
No >> Go to 3
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT — CONTINUED

nal (Down) circuit at the Rear Spoiler Limit Switch harness connector.

short to ground.
8E-72.
REAR SPOILER DRIVER (UP) CIRCUIT
REAR SPOILER DRIVER (UP) CIRCUIT — CONTINUED
ure on the Rear Spoiler Driver (Up) circuit.
POSSIBLE CAUSES
REAR SPOILER DRIVER (UP) CIRCUIT SHORTED TO VOLTAGE

REAR SPOILER DRIVER (UP) CIRCUIT SHORTED TO GROUND
REAR SPOILER DRIVER (UP) CIRCUIT OPEN
BODY CONTROL MODULE
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE REAR SPOILER DRIVER (UP)

CIRCUIT

Disconnect the Rear Spoiler Motor harness connector.
Measure the resistance of the Rear Spoiler Driver (Up) circuit from the
BCM harness connector to the Rear Spoiler Motor harness connector.

Yes >> Go to 2
No >> Repair the Rear Spoiler Driver (Up) circuit for an open.
2. MEASURE THE VOLTAGE OF THE REAR SPOILER DRIVER (UP)

CIRCUIT

Measure the voltage of the Rear Spoiler Driver (Up) circuit at the Rear
Spoiler Motor harness connector.
Is voltage present?
Yes >> Repair the Rear Spoiler Driver (Up) circuit for a short to
voltage.
No >> Go to 3
REAR SPOILER DRIVER (UP) CIRCUIT — CONTINUED
CIRCUIT

Measure the resistance between ground and the Rear Spoiler Driver (Up)
circuit at the Rear Spoiler Motor harness connector.

ground.
8E-72.
REAR SPOILER DRIVER (DOWN) CIRCUIT
REAR SPOILER DRIVER (DOWN) CIRCUIT — CONTINUED
ure on the Rear Spoiler Driver (Down) circuit.
POSSIBLE CAUSES
REAR SPOILER DRIVER (DOWN) CIRCUIT SHORTED TO VOLTAGE

REAR SPOILER DRIVER (DOWN) CIRCUIT SHORTED TO GROUND
REAR SPOILER DRIVER (DOWN) CIRCUIT OPEN
BODY CONTROL MODULE
Diagnostic Test
1. MEASURE THE RESISTANCE OF THE REAR SPOILER DRIVER

(DOWN) CIRCUIT

Measure the resistance of the Rear Spoiler Driver (Down) circuit from the

Yes >> Go to 2
No >> Repair the Rear Spoiler Driver (Down) circuit for an
open.
2. MEASURE THE VOLTAGE OF THE REAR SPOILER DRIVER

(DOWN) CIRCUIT

Measure the voltage of the Rear Spoiler Driver (Down) circuit at the Rear
Is voltage present?
Yes >> Repair the Rear Spoiler Driver (Down) circuit for a short to
voltage.
No >> Go to 3
REAR SPOILER DRIVER (DOWN) CIRCUIT — CONTINUED
(DOWN) CIRCUIT

Measure the resistance between ground and the Rear Spoiler Driver
(Down) circuit at the Rear Spoiler Motor harness connector.

ground.
8E-72.
REAR SPOILER LIMIT SWITCH FAILURE
REAR SPOILER LIMIT SWITCH FAILURE — CONTINUED
• Set Condition: The Body Control Module (BCM) reports a Rear Spoiler Limit Switch failure.
POSSIBLE CAUSES
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT SHORTED TO VOLTAGE

SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT SHORTED TO VOLTAGE
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT SHORTED TO GROUND
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT SHORTED TO GROUND
SPOILER LIMIT SWITCH SIGNAL (UP) CIRCUIT OPEN
SPOILER LIMIT SWITCH SIGNAL (DOWN) CIRCUIT OPEN
REAR SPOILER LIMIT SWITCH GROUND CIRCUIT OPEN
REAR SPOILER LIMIT SWITCH
Diagnostic Test

SIGNAL (UP) CIRCUIT

Measure the resistance of the Spoiler Limit Switch Signal (Up) circuit from
the BCM harness connector to the Rear Spoiler Limit Switch harness con-
nector.

Yes >> Go to 2
No >> Repair the Spoiler Limit Switch Signal (Up) circuit for an
open.

Measure the resistance of the Spoiler Limit Switch (Down) circuit from the
BCM harness connector to the Rear Spoiler Limit Switch harness connec-
tor.

Yes >> Go to 3
No >> Repair the Spoiler Limit Switch Signal (Down) circuit for
an open.
(UP) CIRCUIT

Measure the voltage of the Spoiler Limit Switch Signal (Up) circuit at the
Rear Spoiler Limit Switch harness connector.
Is voltage present?
short to voltage.
No >> Go to 4

(DOWN) CIRCUIT
Measure the voltage of the Spoiler Limit Switch Signal (Down) circuit at
the Rear Spoiler Limit Switch harness connector.
Is voltage present?
short to voltage.
No >> Go to 5

SIGNAL (UP) CIRCUIT

nal (Up) circuit at the Rear Spoiler Limit Switch harness connector.

short to ground.
No >> Go to 6
nal (Down) circuit at the Rear Spoiler Limit Switch harness connector.

short to ground.
No >> Go to 7
7. MEASURE THE RESISTANCE OF THE REAR SPOILER LIMIT

SWITCH GROUND CIRCUIT
Measure the resistance between ground and the Rear Spoiler Limit Switch
Ground circuit.

Yes >> Replace the Rear Spoiler Limit Switch.
No >> Repair the Rear Spoiler Limit Switch Ground circuit for
an open.
REAR SPOILER MOTOR FAILURE
REAR SPOILER MOTOR FAILURE — CONTINUED
• Set Condition: The Body Control Module (BCM) reports a Rear Spoiler Motor failure.
POSSIBLE CAUSES
REAR SPOILER DRIVER (UP) CIRCUIT SHORTED TO VOLTAGE

REAR SPOILER DRIVER (DOWN) CIRCUIT SHORTED TO VOLTAGE
REAR SPOILER DRIVER (UP) CIRCUIT SHORTED TO GROUND
REAR SPOILER DRIVER (DOWN) CIRCUIT SHORTED TO GROUND
REAR SPOILER DRIVER (UP) CIRCUIT OPEN
REAR SPOILER DRIVER (DOWN) CIRCUIT OPEN
REAR SPOILER MOTOR
Diagnostic Test

CIRCUIT

Measure the resistance of the Rear Spoiler Driver (Up) circuit from the

Yes >> Go to 2
No >> Repair the Rear Spoiler Driver (Up) circuit for an open.

(DOWN) CIRCUIT
Measure the resistance of the Rear Spoiler Driver (Down) circuit from the

Yes >> Go to 3
No >> Repair the Rear Spoiler Driver (Down) circuit for an
open.
3. MEASURE THE VOLTAGE OF THE REAR SPOILER DRIVER (UP)
CIRCUIT

Measure the voltage of the Rear Spoiler Driver (Up) circuit at the Rear
Is voltage present?
voltage.
No >> Go to 4
4. MEASURE THE VOLTAGE OF THE REAR SPOILER DRIVER

(DOWN) CIRCUIT
Measure the voltage of the Rear Spoiler Driver (Down) circuit at the Rear
Is voltage present?
voltage.
No >> Go to 5

CIRCUIT

Measure the resistance between ground and the Rear Spoiler Driver (Up)
circuit at the Rear Spoiler Motor harness connector.

ground.
No >> Go to 6
(DOWN) CIRCUIT
Measure the resistance between ground and the Rear Spoiler Driver
(Down) circuit at the Rear Spoiler Motor harness connector.

ground.
No >> Replace the Rear Spoiler Motor. Refer to Page
23-117.
REAR SPOILER VERIFICATION TEST
1.
Operate the Spoiler Switch to fully extend the spoiler.
Operate the Spoiler Switch to fully retract the spoiler.
Drive the vehicle at 89 km/h (55 MPH) and verify the spoiler operation.
responding symptom.

REAR SPOILER CIRCUIT DIAGRAM

ZH BODY - SERVICE INFORMATION 23 - 29
BODY - SERVICE INFORMATION
TABLE OF CONTENTS
page page
BODY - SERVICE INFORMATION LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DIAGNOSIS AND TESTING BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . 52
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . 29 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 30 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
STANDARD PROCEDURE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . 31 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 141
DRILLING AND WELDING . . . . . . . . . . . . . . . 31 INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
SPECIFICATIONS PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
SPECIFICATIONS - BODY LUBRICATION . . . 32 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
SPECIFICATIONS - TORQUE ........ . . . . 33
BODY - SERVICE INFORMATION

WATER LEAKS
Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing
plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a location away from
the actual leak point, making leak detection difficult. All body sealing points should be water tight in normal wet-
driving conditions. Water flowing downward from the front of the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not always seal water tight under all conditions. At times, side glass or
door seals will allow water to enter the passenger compartment during high pressure washing or hard driving rain
(severe) conditions. Over-compensating on door or glass adjustments to stop a water leak that occurs under severe
conditions can cause premature seal wear and excessive closing or latching effort. After completing a repair, water
test vehicle to verify leak has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS

Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned and
sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper
procedures.
WATER LEAK TESTS

WARNING: DO NOT USE ELECTRIC SHOP LIGHTS OR TOOLS IN WATER TEST AREA. PERSONAL INJURY
CAN RESULT.
When the conditions causing a water leak have been determined, simulate the conditions as closely as possible.
• If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an open-ended garden
hose.
• If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable veloc-
ity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions.
• If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this
condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the
leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the
vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist
the right side of the vehicle.
23 - 30 BODY - SERVICE INFORMATION ZH
WATER LEAK DETECTION

To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of
the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose
cannot be positioned without being held, have someone help do the water test.
Some water leaks must be tested for a considerable length of time to become apparent. When a leak appears, find
the highest point of the water track or drop. The highest point usually will show the point of entry. After leak point
has been found, repair the leak and water test to verify that the leak has stopped.
Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped water may
splash or run from the cavity, often at a distance from the entry point. Most water leaks of this type become appar-
ent after accelerating, stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD

When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can also be used
to deflect light to a limited-access area to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD

Some water leaks in the luggage compartment can be detected without water testing. Position the vehicle in a
brightly lit area. From inside the darkened luggage compartment inspect around seals and body seams. If neces-
sary, have a helper direct a shop light over the suspected leak areas around the luggage compartment. If light is
visible through a normally sealed location, water could enter through the opening.
PRESSURIZED LEAK TEST METHOD

When a water leak into the passenger compartment cannot be detected by water testing, pressurize the passenger
compartment and soap test exterior of the vehicle. To pressurize the passenger compartment, close all doors and
windows, start engine, and set heater control to high blower in HEAT position. If engine can not be started, connect
a charger to the battery to ensure adequate voltage to the blower. With interior pressurized, apply dish detergent
solution to suspected leak area on the exterior of the vehicle. Apply detergent solution with spray device or soft
bristle brush. If soap bubbles occur at a body seam, joint, seal or gasket, the leak entry point could be at that
location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component
alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body
sealing points should be air tight in normal driving conditions. Moving sealing surfaces will not always seal airtight
under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger com-
partment during high cross winds. Over-compensating on door or glass adjustments to stop wind noise that occurs
under severe conditions can cause premature seal wear and excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted exterior moldings or body ornamentation. Loose moldings can
flutter, creating a buzzing or chattering noise. An open cavity or protruding edge can create a whistling or howling
noise. Inspect the exterior of the vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS

Verify that floor and body plugs are in place and body components are aligned and sealed. If component alignment
or sealing is necessary, refer to the appropriate section of this group for proper procedures.
ROAD TESTING WIND NOISE

1. Drive the vehicle to verify the general location of the wind noise.
2. Apply a 50 mm (2 in.) piece of masking tape in 150 mm (6 in.) lengths along the weatherstrips, weld seams or
moldings. After each length is applied, drive the vehicle. If noise goes away after the piece of tape is applied,
remove the tape, locate, and repair the concern.
POSSIBLE CAUSE OF WIND NOISE

• Moldings standing away from the body surface can catch the wind and whistle.
• Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds.
• Misaligned movable components.
• Missing or improperly installed plugs in pillars.
• Weld burn through holes.
STANDARD PROCEDURE
BODY LUBRICATION
All mechanisms and linkages should be lubricated when necessary. This will maintain ease of operation and provide
protection against rust and excessive wear. The weatherstrip seals should be lubricated to prolong their life as well
as to improve door sealing.
All applicable exterior and interior vehicle operating mechanisms should be inspected and cleaned. Pivot/sliding con-
tact areas on the mechanisms should then be lubricated.
1. When necessary, lubricate the operating mechanisms with the specified lubricants.
2. Apply silicone lubricant to a cloth and wipe it on door seals to avoid over-spray that can soil passenger’s cloth-
ing.
3. Before applying lubricant, the component should be wiped clean. After lubrication, any excess lubricant should be
removed.
4. The hood latch, latch release mechanism, latch striker, and safety latch should be lubricated periodically.
5. The door lock cylinders should be lubricated twice each year (preferably autumn and spring).
a. Spray a small amount of lock cylinder lubricant directly into the lock cylinder.
b. Apply a small amount to the key and insert it into the lock cylinder.
c. Rotate it to the locked position and then back to the unlocked position several times.
d. Remove the key. Wipe the lubricant from it with a clean cloth to avoid soiling of clothing.
DRILLING AND WELDING

When holes must be drilled or punched in an inner body panel, verify depth of space to the outer body panel,
electrical wiring, or other components. Damage to vehicle can result.
Do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area.
Fire or hazardous conditions can result.
Always have a fire extinguisher ready for use when welding.
23 - 32 BODY - SERVICE INFORMATION ZH
SPECIFICATIONS
SPECIFICATIONS - BODY LUBRICATION
COMPONENT SERVICE INTERVAL LUBRICANT

Multi-Purpose Grease NLGI GC-LB
Door Hinges As Required
(Water Resistant) (1)
Multi-Purpose Grease NLGI GC-LB
Door Latches As Required
(Water Resistant) (1)
As Required
Hood Latch, Release Mechanism and Multi-Purpose Grease NLGI GC-LB 2
(When Performing Other
Safety Latch EP (2)
Underhood Service)
Hood Hinges As Required Engine Oil
Multi-Purpose Grease NLGI GC-LB 2
Seat Track and Release Mechanism As Required
EP (2)
Liftgate Hinge As Required
EP (2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot and Slide Multi-Purpose Grease NLGI GC-LB 2
As Required
Contact Surfaces) EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice a Year Lock-Cylinder Lubricant (4)
Parking Brake Mechanism As Required
EP (1)
1 = MoparT Wheel Bearing Grease (High Temp)
2 = MoparT Multi-Mileage Lubricant
3 = MoparT Spray White Lube
4 = MoparT Lock Cylinder Lubricant

Door Check Strap to Body 30 22 266
Door Check Strap to Door 10 7 88
Door Hinge to A-pillar 32 24 283
Door Hinge to Body 30 22 266
Door Lock to Door 8 6 71
Door Striker to Body 28 21 248
Hood Hinge to Body 8 6 71
Hood Hinge to Hood 10 7 88
Hood Latch to Body 8 6 71
Hood Striker to Hood 10 7 88
Liftgate Hinge to Body 25 18 221
Liftgate Hinge to Liftgate 25 18 221
Liftgate Latch to Liftgate 8 6 71
Liftgate Striker to Frame 10 7 88
Power Window Motor to
13 10 115
Door
Liftgate Release Handle
8 6 71
Retaining Bolt
Liftgate Latch Assembly to
8 6 71
Liftgate
Rear Cross Strut to Frame 60 44 531
Seat Adjustment Motor 4 3 35
Seat Height Adjustment to
24 18 212
Frame
Seat Rail to Seat 50 37 443
Seat Track to Floor 50 37 443
Seatback to Frame 35 26 310
Seatbelt End Fitting 35 26 310
Spoiler Blade to Mounting
8 6 71
Plate
Spoiler Mounting Plate to
8 6 71
Liftgate
23 - 34 LIFTGATE ZH
LIFTGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE LATCH STRIKER

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GAS PROP LIFTGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
HINGE TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
LATCH BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EXTERIOR HANDLE
REMOVAL
2. Remove the rear liftgate trim panel. Refer to Page 23-48.
3. Disconnect the rear spoiler harness connectors (1).
ZH LIFTGATE 23 - 35
4. Remove the seven rear latch support bracket retaining nuts

and bolts (1).
5. Remove the bracket from vehicle.
6. Remove the four rear latch retaining bolts (1) and remove
the latch assembly from the rear liftgate.
7. Disconnect the pneumatic harness connector (1) and the

harness connector (2) from the rear latch assembly.
23 - 36 LIFTGATE ZH
DISASSEMBLY
1. Disconnect the rear liftgate release handle linkage by push-
ing the arm (1) up off the linkage and then pulling the link-
age out of the latch.
2. Remove the remaining handle retaining bolt (1) and remove

the handle assembly from the latch assembly bracket.
ZH LIFTGATE 23 - 37
INSTALLATION
ASSEMBLY
1. Install the liftgate release handle assembly on the latch
bracket. Install the retaining bolt (1). Tighten to 8 N·m (71
in. lbs.).
2. Connect the rear liftgate release handle linkage (1).

23 - 38 LIFTGATE ZH
INSTALLATION
1. Connect the pneumatic harness connector (2) and the har-
ness connector (1) to the rear latch assembly.
2. Install the rear latch assembly into the rear liftgate. Install
the retaining bolts (1). Tighten to 8 N·m (71 in. lbs.).
ZH LIFTGATE 23 - 39
3. Install the rear latch assembly bracket and then install the
seven retaining nuts and bolts (1). Tighten to 8 N·m (71 in.
lbs.).
4. Connect the rear spoiler harness connectors (1).

5. Install the rear liftgate trim panel. Refer to Page 23-49.
23 - 40 LIFTGATE ZH
GAS PROP
REMOVAL
1. Open the rear liftgate.
2. Support the liftgate with a suitable propping device.
3. Remove the gas prop lock cap (1) on the upper end. Then
pull the gas prop (2) off of its mounting point.
4. Remove the gas prop lock cap (1) on the lower end. Then
pull the gas prop (2) off of its mounting point.
ZH LIFTGATE 23 - 41
INSTALLATION
1. Place the gas prop on its upper and lower mounting points
and push it in until it clicks.
2. Install the upper lock cap (1) on the gas prop (2).
3. Install the lower lock cap (1) on the gas prop (2).
4. Verify the rear liftgate operation.
23 - 42 LIFTGATE ZH
HINGE
REMOVAL
1. Remove the liftgate. Refer to Page 23-44.
2. Remove the remaining two bolts (1) from the hinges and
then remove the hinges from the liftgate.
INSTALLATION
1. Install the hinges onto the liftgate lining them up with the
witness marks in the paint.
2. Install the two bolts (1) attaching the hinges to the liftgate.
3. Install the liftgate. Refer to Page 23-46.
ZH LIFTGATE 23 - 43
LATCH
REMOVAL
1. For removal of the latch, Refer to Page 23-34.
INSTALLATION
For installation of the latch, Refer to Page 23-37.
LATCH STRIKER
REMOVAL
1. Remove the trunk rear trim panel. Refer to Page 23-48.
2. Remove the bolts (1) attaching the striker (2) to the vehicle.
INSTALLATION
1. Align the striker (2) to the witness marks in the paint then
install the striker’s bolts (1). Tighten to 10 N·m (88 in. lbs.).
2. Install the trunk rear trim panel. Refer to Page 23-49.
23 - 44 LIFTGATE ZH
LIFTGATE
REMOVAL
1. Open the liftgate.
2. Remove the trim panels (1) from the liftgate. The liftgate
has two trim panels, an upper and a lower. Both trim panels
must be removed to access the liftgate’s harness connec-
tors. Refer to Page 23-48.
3. Disconnect the following harness connections:
• Right and left defroster harness connections.
• Right and left license plate lamp harness connections.
• Ground lug G302.
• Antenna amplifier harness connector.
• Rear liftgate lock switch.
• Pneumatic lock air line.
• Center High Mounted Stop Lamp (CHMSL) harness
connector.
• Rear spoiler limit switch and motor harness
connectors.
4. Remove the rubber grommet (1) from the liftgate. Then pull
the harness through the access hole.
5. Remove the headliner. Refer to Page 23-194.
ZH LIFTGATE 23 - 45
6. Using a suitable propping device, prop the liftgate up and

remove the gas prop (2) from its mount point (1).
7. Have a helper hold the liftgate and remove the two bolts (2)
from each hinge under the roof of the vehicle, leaving the
hinge bolts (1) attached to the liftgate.
8. Carefully lift the liftgate off the body and then set it down on
a clean dry surface.
23 - 46 LIFTGATE ZH
INSTALLATION
1. Have a helper lift the liftgate and install the two bolts (1) for
each hinge from inside the roof panel. Tighten to 25 N·m
(18 ft. lbs.).
2. Using a suitable propping device, prop the rear liftgate up

and install the gas prop (2) to its mount point. The install
the upper lock cap (1) on the gas prop.
3. Connect the following harness connections:
• Right and left defroster harness connections.
• Right and left license plate lamp harness connections.
• Ground lug G302.
• Antenna amplifier harness connector.
• Rear liftgate lock switch.
• Pneumatic lock air line.
• Center High Mounted Stop Lamp (CHMSL) harness
connector.
• Rear spoiler limit switch and motor harness
connectors.
ZH LIFTGATE 23 - 47
4. Install the rubber grommet (1) to the liftgate.
5. Install the trim panel to the liftgate. Refer to Page 23-49.

6. Align the liftgate. Refer to Page 23-53.
23 - 48 LIFTGATE ZH
TRIM PANEL
REMOVAL
LOWER LIFTGATE TRIM PANEL
1. Remove the handle trim screw (1).
2. Pull down on the lower liftgate trim panel (1) to release it

from the liftgate.
ZH LIFTGATE 23 - 49
UPPER LIFTGATE TRIM PANEL

1. Remove the lower trim panel. Refer to Lower Liftgate Trim
Panel.
2. Remove the two screws (1) attaching the upper liftgate trim
panel (2) to the liftgate.
3. Pull down on the upper liftgate trim panel (2) to release it
from the liftgate.
INSTALLATION
UPPER LIFTGATE TRIM PANEL
1. Push up on the upper liftgate trim panel (2) to attach it to
the liftgate.
2. Install the two screws (1) attaching the upper liftgate trim
panel (2) to the liftgate.
3. Install the lower trim panel. Refer to Lower Liftgate Trim
Panel.
23 - 50 LIFTGATE ZH
LOWER LIFTGATE TRIM PANEL

1. Push on the lower liftgate trim panel (1) to attach the retain-
ers to the liftgate.
2. Install the handle trim screw (1).

ZH LIFTGATE 23 - 51
BUMPER
REMOVAL
1. Open the liftgate.
2. Remove the bolt (1) attaching the bumper to the liftgate.
INSTALLATION
1. Position the bumper, then install the bolt attaching the bumper to the liftgate. Do not tighten the bolt at this time.
2. Close the liftgate and align it with the quarter panels. Refer to Page 23-53.
3. Tighten the liftgate bumper bolt.
23 - 52 BODY STRUCTURE ZH
BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH WELD LOCATIONS

SPECIFICATIONS - BODY GAP SPECIFICATIONS - WELD LOCATIONS . . . . . . 74
MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . 53 STRUCTURAL ADHESIVE LOCATIONS
OPENING DIMENSIONS SPECIFICATIONS - STRUCTURAL
SPECIFICATIONS - BODY DIMENSIONS . . . . . 55 ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SEALER LOCATIONS
SPECIFICATIONS - SEALER LOCATIONS . . . . 57
ZH BODY STRUCTURE 23 - 53
GAP AND FLUSH

SPECIFICATIONS - BODY GAP MEASUREMENTS
FRONT AND SIDE GAP DIMENSIONS
LOCATION GAP
1 WINDSHIELD SURROUND FRAME TO BODY 0.9 +/- 0.5
2 WINDSHIELD SURROUND FRAME TO CROSS MEMBER PANEL 2 +/- 1
DOOR GLASS TO OUTER QUARTER PANEL 7 +/- 1.5
3 OUTER QUARTER PANEL TO ROOF PANEL PART / RAIL INNER GAP 1 +/- 0.5
OUTER GAP 1 +/- 0.2
4 DOOR GLASS TO REAR WINDOW BRACKET SEAL 8 +/- 2.5
5 OUTER DOOR SKIN TO OUTER QUARTER PANEL 4 +/- 0.5
6 DOOR GLASS TO WINDSHIELD SURROUND FRAME 7 +/- 1.5
7 OUTER MIRROR TRIANGLE TO WINDSHIELD SURROUND FRAME 2 +/- 1.5
8 OUTER DOOR PANEL TO ROCKER PANEL VERTICAL 7 +/- 1.5
HORIZONTAL 5 +/- 1.5
9 SIDE LOUVER TO FRONT FENDER 0.5 +0.5 -0.1
SIDE LOUVER TO OUTER DOOR SKIN 0.5 +0.5 -0.1
10 FRONT FENDER TO OUTER DOOR SKIN 4.4 +/- 0.5
11 FRONT FENDER TO ROCKER PANEL 0 + 0.5
12 FRONT FENDER TO LOUVER (UPPER SECTION) 1.2 +/- 0.5
FRONT FENDER TO LOUVER (LOWER SECTION) 1.2 +/- 0.5
13 LOWER GRILLE TO FRONT FASCIA 0.5 +0.5 -0.2
14 HOOD TO FRONT FASCIA 4 +/- 1.5
15 HOOD TO GRILLE 6 +/- 1.5
REAR AND SIDE GAP AND FLUSH DIMENSIONS
LOCATION GAP
1 ROOF PANEL TO REAR WINDOW 6 +1.5 -2
2 OUTSIDE HATCH PANEL TO SPOILER WING UPPER 6 +/- 1
LOWER 4.5 +/- 1
3 OUTER QUARTER PANEL TO HATCH 4 +/- 1
4 OUTER QUARTER PANEL TO REAR FASCIA 0.7 +/- 0.5
5 OUTER QUARTER PANEL TO REAR FASCIA 0 + 0.5
6 OUTER QUARTER PANEL TO OUTER WHEELHOUSE 0 + 0.5
7 FUEL FILLER DOOR TO OUTER QUARTER PANEL UPPER 3 +/- 0.5
LOWER 0.1
8 OUTER QUARTER PANEL TO REAR WINDOW 7 +/- 1.5
OPENING DIMENSIONS
SPECIFICATIONS - BODY DIMENSIONS
DOOR OPENING
LIFTGATE OPENING
WINDSHIELD OPENING
SEALER LOCATIONS
SPECIFICATIONS - SEALER LOCATIONS
A-PILLAR - TRUNK
BULKHEAD - FRAME
BULKHEAD - ROCKER
BULKHEAD
BUMPER FRAME
ENGINE COMPARTMENT
FENDER - ROCKER
FRONT INNER FENDER

FRONT SPRING MOUNT

INTERIOR BULKHEAD
REAR - WHEELHOUSE
REAR FASCIA - HEADLAMP

REAR QUARTER
ROCKER
TUNNEL
UNDERSIDE
UNDERSIDE REAR
WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS
A - PILLAR
FRONT - REAR FLOOR

INNER A-PILLAR
INNER PANEL
INNER ROOF
INNER WHEELHOUSE
REAR BODY PANEL

REAR TRUNK FLOOR

ROCKER PANEL
ROOF - HATCH
TUNNEL - FLOOR
WHEELHOUSE 2
WHEELHOUSE
STRUCTURAL ADHESIVE LOCATIONS

SPECIFICATIONS - STRUCTURAL ADHESIVES
BODY SIDE
ROOF PANEL
23 - 88 DOOR ZH
DOOR
TABLE OF CONTENTS
page page
CHECK STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 WINDOW REGULATOR
DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 LATCH
ADJUSTMENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 92 LOCK CYLINDER
DOOR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95 TRIM PANEL
ADJUSTMENTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 96 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CHECK STRAP
REMOVAL
2. Remove the door speaker by removing the screws (1)
attaching it to the door.
3. Remove the door foil from the inner door panel front area.
Replace any damaged door foil.
ZH DOOR 23 - 89
4. Remove the plastic seal located over the check strap bolt
(6).
CAUTION: Avoid damaging the vehicle’s paint.
5. Remove the torx screw (4) and then remove the retaining
plate (3).
6. Remove the bolts (1) attaching the check strap to the door.
7. Remove the seal from the door check strap.
8. Remove the door check strap through the installation open-
ing in the inner door panel.
INSTALLATION
Note: Lubricate the door check strap below the plastic
cover.
1. Install the door check strap through the installation opening

in the inner door panel.
2. Install the screw (3), then install the seal (5) to the door
check strap.
Note: Tighten the bolts on the end first.
3. Install the two bolts (1) attaching the door check strap (2) to
the door. Tighten to 10 N·m (88 in. lbs.).
4. Install the torx screw (4) and install the retaining plate.
23 - 90 DOOR ZH
5. Install the door foil to the inner door panel front area.
6. Install the door speaker by installing the screws (1) attach-
ing it to the door.
7. Install the door trim panel on the front door. Refer to Page
23-109.
DOOR
REMOVAL
1. Remove the check strap. Refer to Page 23-88.
2. Disconnect and remove the lock air line (1) from the door
lock. Then remove the air line from the door.
ZH DOOR 23 - 91
CAUTION: Have a helper hold the door for you to avoid

damaging the paint.
3. Disconnect the side view mirror (1) and the power window
motor connector (5).
4. Remove the bolts from the bottom and top hinge and then
slowly pull door away from A-pillar.
5. Remove the protective hose (3) from the front door and pull
out all electrical leads as well as the lock air line.
6. Remove the front door and lay down on secure clean area.
INSTALLATION
CAUTION: Have a helper hold the door for you to avoid
damaging the paint.
1. Install the protective hose on the front door and thread all
electrical leads as well as the air line lead into the door.
2. Slowly position the door onto the A-pillar then install the
bolts to the bottom and top hinge. Tighten to 32 Nm (24 ft.
lb.).
3. Connect the rearview mirror (1) and the power window
motor (4) electrical connector.
4. Install the door check strap to the A-pillar. Refer to Page

23-89.
23 - 92 DOOR ZH
5. Connect and install the lock air line (1) to the door.
6. Adjust the door for fit and function. Refer to Page 23-92.
ADJUSTMENTS
ADJUSTMENT
Test and adjustment values for gaps on hoods, doors and lids
Front Door to Front Fender 4.0 ±0.5 mm
Front Door to Rear Quarter Panel 4.0 ±0.5 mm
Roof to Windshield Frame 9.0 (+0/-2) mm
CAUTION: Avoid damaging the vehicle’s paint.
1. Remove the lock striker.

2. Inspect the gap sizes of the door in accordance to the table.
3. Loosen the bolts on the door side, then adjust the gap dimensions by moving the front door up, down; front and
back, then tighten to 32 N·m (24 ft. lbs.).
4. Loosen the bolts on the hinge side, adjust, then tighten with the centering screw on the hinge;adjust contour of
driver’s door at the hinge side. Tighten to 32 N·m (24 ft. lbs.).
5. Install the lock striker. Tighten to 28 N·m (21 ft. lbs.).
6. Insert a centering gauge into the door lock until lock completely catches (catch stage 2).
7. Position a depth stop at the height of the striker on the outside of the door and then close the door until the
depth stop makes contact on both sides.
8. Press the striker into the center gauge from the inside through the open window and then tighten the bolts.
9. Pull the outer door handle and then remove the centering gauge.
10. Check the door for easy motion.
11. Check the window for proper adjustment. If necessary adjust the window. Refer to Page 23-96.
ZH DOOR 23 - 93
DOOR GLASS
REMOVAL
WARNING: WHEN WORKING ON THE POWER WINDOWS
OR THE WINDOWS IN THE VEHICLE DOORS, THE UNSE-
CURED WINDOW CAN FALL DOWN AND CAN CAUSE
INJURY BY PINCHING HANDS.
CAUTION: Secure the window against falling down.
Note: Move the plastic wedge directly into the clips.
2. Remove the inner window sealing rail by opening the win-

dow, then press the sealing rail off of the inner door with a
plastic wedge and remove from the door. Check the clips
for wear or damage (5 each).
3. Remove the outer window sealing rail by removing the two
chrome cover screws (1), then pull the rubber door seal off
at the separation point which is about 3-4 inches down the
back of the door seal.
4. Remove the cover on the door escutcheon with a plastic
wedge, then remove the expanding anchor clip.
5. Press the sealing rail off of the window shaft uniformly with
a wedge and remove from the door.
23 - 94 DOOR ZH
6. Remove the door speakers by removing the screws (1).

7. Remove the door foil from the inner door.
8. Lower the window until the mounting screws (2-4) are

accessible through the assembly openings in the door.
9. Disconnect the connector for the power window motor (3).
Note: The slider is fastened to the window and cannot be

removed.
10. Loosen the mounting bolt only until the window (5) can be
lifted out of the slider.
11. Remove the window by pulling it upward while guiding the
slider through the opening in the door shaft.
12. Put the window down on a secure and dry surface.
ZH DOOR 23 - 95
INSTALLATION
WARNING: WHEN WORKING ON THE POWER WINDOWS
OR THE WINDOWS IN THE VEHICLE DOORS, THE UNSE-
CURED WINDOW CAN FALL DOWN AND CAN CAUSE
INJURY BY PINCHING HANDS.
CAUTION: Secure the window against falling down.
1. Install the window (5) by inserting it downward while guid-

ing the slider through the opening in door shaft.
2. Tighten the mounting bolts (2-4).
3. Connect the connector for the power window motor (3).
4. Install the door foil on the inner door.
5. Install the door speaker (1).

23 - 96 DOOR ZH
6. Install the outer window sealing rail by pressing the sealing

rail onto the window shaft uniformly. Then install the
expanding anchor clip. Install the plastic cover on the
escutcheon,then install the rubber door seal. Install the
chrome cover by installing the two screws (1).
7. Install the inner window sealing rail by pressing the sealing
rail on the inner door.
8. Adjust the door glass and clean. Refer to Page 23-96.
9. Install the door trim panel. Refer to Page 23-109.
ADJUSTMENTS
ADJUSTMENT
1. Check the front door adjustment and adjust if necessary.
2. Remove the door trim panel on the front door. Refer to
Page 23-108.
3. Remove the door speaker (1).
4. Remove the door foil from the door.
5. Loosen the nuts from both of the window stop brackets
(2-4) located in the middle portion of the door.
6. Close the window (5) until it is flush with the front edge of
the door eschutcheon.
ZH DOOR 23 - 97
7. Remove the plug on the underside of the door (2) covering

the bolt (3), loosen the bolt until the guide rail can be
moved.
Note: In the second detent stage of the door lock, the

edge of the window glass must disappear completely
below the rubber seal. If necessary, the inclination of the
window can be corrected by loosening the bolts, and the
longitudinal direction of the window can be corrected by
loosening the bolt. In addition, the inclination of the win-
dow relative to the weatherstrip can be increased or
reduced by loosening the nut;the sliding jaw must be
moved for this purpose.
8. Adjust the window so that the upper glass edge makes

contact with the inner rubber sealing lip (1) over the entire
length when the door lock is in the first catch position, then
tighten bolts and nuts (3) on the guide rail.
9. Tighten the bolts and nut if they were loosened.
10. Install the bolt plug.
Note: Grease the sliding jaws and guide rail as well as the window lift rail.
11. Check the window for ease of movement.

12. Install door foil on the door.
13. Install the door speaker.
14. Install the door trim panel on the front door. Refer to Page 23-109.
23 - 98 DOOR ZH
EXTERIOR HANDLE
REMOVAL
1 - LOCK CYLINDER 4 - HANDLE RETAINER

2 - DOOR HANDLE 5 - SCREW
3 - BACKING PLATES 6 - SCREW
1. Remove the door weather seal (2) from the door in the
area of the door lock.
2. Loosen the screw (1), pull door handle out to the stop and
hold it in place. Retighten the screw (1) lightly with the han-
dle in this position. Left front door: Right-hand thread.
Right front door: Left-hand thread.
ZH DOOR 23 - 99
Note: The screw will not fall out.
3. Remove the 4 mm Allen screw (1) on the face of the door.

4. Remove the lock cylinder.
INSTALLATION

23 - 100 DOOR ZH
1. Install the lock cylinder and install the screw (1).
2. Loosen the screw (1) and retighten without pulling or hold-

ing the door handle.
3. Check the door lock release for proper function by closing
the catch in the door latch with a suitable tool and releasing
it with the door handle.
4. Insert the door weather strip (2) into the channel.
5. Check for proper door and handle function.
ZH DOOR 23 - 101
WINDOW REGULATOR
REMOVAL
1 - UPPER WINDOW REGULATOR NUT 5 - WINDOW REGULATOR

2 - RIVET 6 - WINDOW MOTOR
3 - LOWER DOOR 7 - UPPER REGULATOR BOLT
4 - LOWER DOOR NUT 8 - BRACKET
1. Remove the door glass. Refer to Page 23-93.
Note: Remove the rivet residue and any metal chips from the door.
2. Drill out the rivets (2).
Note: Loosen the bolt only until window lift mechanism can be moved out of bracket.
3. Loosen the upper regulator bolt (7) which is between the inner and outer door panel on the face of the door.
4. Remove the upper window regulator nut (1).
5. Remove the lower door nuts (4) from the door bottom. Nuts are located behind the rubber plugs.
6. Unclip power window motor cable from the door.
7. Lift the window regulator up, then turn it and lift the regulator out through the assembly opening in the door.
23 - 102 DOOR ZH
INSTALLATION
1 - UPPER WINDOW REGULATOR NUT 5 - WINDOW REGULATOR

2 - RIVET 6 - WINDOW MOTOR
3 - LOWER DOOR 7 - UPPER REGULATOR BOLT
4 - LOWER DOOR NUT 8 - BRACKET
1. Install the window regulator (5) through the assembly opening in the door.
2. Fasten the power window motor with three rivets (2).
3. Connect the power window motor (6).
4. Install the lower door nuts (4) in the door bottom (3), then install the rubber plugs.
5. Install the upper window regulator nut (1).
6. Install the upper window regulator nut (1) between the inner and outer door panels.
7. Install the door glass in the front door. Refer to Page 23-95.
ZH DOOR 23 - 103
LATCH
REMOVAL
1 - WINDOW RUN CHANNEL 6 - DOOR LOCK MODULE

2 - WINDOW RUN CHANNEL BOLTS 7 - ASSEMBLY SCREW
3 - RUBBER PLUG 8 - LATCH CABLE
4 - SCREW 9 - LATCH AIR LINE
5 - RETAINER
1. Remove the door trim panel on the front door. Refer to Page 23-108.
2. Remove the exterior door handle on the front door. Refer to Page 23-98.
3. Remove the foil from the door.
4. Remove the rubber plug (3), remove the window channel bolts (2) and remove the window run channel (1) down-
ward through installation opening.
5. Remove the latch cable (8) from the clip.
6. Disconnect the latch air line (9).
7. Remove the assembly screw (7) and remove the door lock module (6).
23 - 104 DOOR ZH
INSTALLATION
1 - WINDOW RUN CHANNEL 6 - DOOR LOCK MODULE

2 - WINDOW RUN CHANNEL BOLTS 7 - ASSEMBLY SCREW
3 - RUBBER PLUG 8 - LATCH CABLE
4 - SCREW 9 - LATCH AIR LINE
5 - RETAINER
1. Install the door lock module (6) through installation opening then tighten the screws.
2. Connect the line (9) to the vacuum element on door lock.
3. Install the lock control cable (8) to the clip.
4. Install the nuts (2) and window run channel (1) through installation opening then install the rubber plug (3).
5. Install the foil on the front door.
6. Install the exterior door handle on the front door. Refer to Page 23-99
7. Install the door trim panel on the front door. Refer to Page 23-109
ZH DOOR 23 - 105
LOCK CYLINDER
REMOVAL

1. Remove the door weather seal (2) from the door in the
area of the door lock.
2. Loosen the screw (1), pull door handle out to the stop and
hold it in place. Retighten the screw (1) lightly with the han-
dle in this position. Left front door: Right-hand thread.
Right front door: Left-hand thread.
23 - 106 DOOR ZH
Note: The screw will not fall out.
3. Remove the 4 mm Allen screw (1) on the face of the door.

4. Remove the lock cylinder.
INSTALLATION

ZH DOOR 23 - 107
1. Install the lock cylinder and install the screw (1).
2. Loosen the screw (1) and retighten without pulling or hold-

ing the door handle.
3. Check the door lock release for proper function by closing
the catch in the door latch with a suitable tool and releasing
it with the door handle.
4. Insert the door weather strip (2) into the channel.
5. Check for proper door and handle function.
23 - 108 DOOR ZH
TRIM PANEL
REMOVAL
1 - ESCUTCHEON COVER 7 - SCREW

2 - DOOR 8 - SRS COVER
3 - SHEET METAL CLIP NUTS 9 - SCREW
4 - DOOR TRIM PANEL 10 - CLIP
5 - SCREW 11 - SCREWS
6 - PULL HANDLE COVER 12 - CHROME DOOR END COVER
1. Open the window.

2. Remove the pull handle cover (6) from the trim panel (4) by pressing out the cover from the bottom using a
plastic wedge.
3. Remove the screw (5) behind the upper portion of the door handle pull (6).
4. Remove the escutcheon cover (1) using a plastic wedge.
5. Remove the door end cover (12) by removing the two screws (11) attaching it to the door frame.
6. Remove the SRS cover (8) and remove the screw (7) behind the cover.
7. Remove the door trim panel (4) off inner door from the bottom, front and back using a plastic wedge.
8. Lift the top of the door trim panel upwards and out of the clips at the sealing rail using a plastic wedge and at
the same time pull away from the inner door.
9. Disconnect the front door speaker connector.
10. Disconnect the door lock cable from the plastic retainer clip located on the back side of the inside of the trim
panel.
11. Remove the door trim panel (4) and place in a clean dry place.
ZH DOOR 23 - 109
12. Check the sheet-metal clip nuts (3) on the door trim panel. If necessary replace any damaged sheet-metal clip
nuts.
13. Check the door foil on the door and the clips on the door lining. If necessary replace any damaged door foil or
clips.
INSTALLATION
1 - ESCUTCHEON COVER 7 - SCREW

2 - DOOR 8 - SRS COVER
3 - SHEET METAL CLIP NUTS 9 - SCREW
4 - DOOR TRIM PANEL 10 - CLIP
5 - SCREW 11 - SCREWS
6 - PULL HANDLE COVER 12 - CHROME DOOR END COVER
1. Connect the door lock cable to the plastic retainer clip located on the back side of the inside of the trim panel.
2. Connect the front door speaker connector.
3. Install the door trim panel (4) by tilting it outwards and clipping the upper door panel clips. Then swing the door
trim panel down and push in the clips on the bottom of the door panel.
4. Install the screw (7) behind the the SRS cover (8) and then install the cover.
5. Install the two screws (11) attaching the chrome door end cover (12) it to the door frame.
6. Install the escutcheon cover (1).
7. Install the screw (5) behind the upper portion of the door handle pull (6).
8. Install the pull handle cover (6).
23 - 110 EXTERIOR ZH
EXTERIOR
TABLE OF CONTENTS
page page
GRILLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 REAR SPOILER
FRONT FENDERS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113 SPOILER WING . . . . . . . . . . . . . . . . . . . . . . 117
COWL GRILLE REMOVAL - MOUNTING PLATE . . . . . . . . . . 118
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 REMOVAL - MOTOR . . . . . . . . . . . . . . . . . . 120
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114 INSTALLATION
EXTERIOR NAME PLATES SPOILER WING . . . . . . . . . . . . . . . . . . . . . . 121
REMOVAL INSTALLATION - MOUNTING PLATE . . . . . . 122
DOUBLE SIDED TAPE . . . . . . . . . . . . . . . . . 114 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 125
REMOVAL - ADHESIVES . . . . . . . . . . . . . . . 114 ROCKER PANEL MOLDING
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
DOUBLE SIDED TAPE . . . . . . . . . . . . . . . . . 115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION - ADHESIVES . . . . . . . . . . . 115
FUEL FILL DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
GRILLE
REMOVAL
1. Raise the hood.
2. Remove the four grille retaining screws (1).
3. Pull the grille assembly from the bottom to disengage the
bottom retaining clips, and then remove the grille.
ZH EXTERIOR 23 - 111
INSTALLATION
1. Align the bottom grille retainer and snap it into place.
2. Install the four upper retaining screws (1).
3. Close the hood.
FRONT FENDERS
REMOVAL
1 - FENDER TO INNER SUPPORT BOLTS 5 - HEADLAMP SCREW

2 - FENDER TO A-PILLAR BOLTS 6 - FRONT FASCIA
3 - LOWER FENDER BOLTS 7 - HOOD
4 - LEFT FRONT FENDER (RIGHT SIDE SIMILAR)
1. Open the hood (7) and raise it to its upright position. Refer to Page 23-130.
2. Remove the front fascia (6). Refer to Page 13-1.
3. Remove the bolts (2) on the fender attaching it to the A-pillar.
4. Remove the bolts (3) on the lower rear portion of the fender.
5. Remove the screw (5) on the top front of the fender.
6. Remove the four bolts (1) attaching the fender to the inner support.
7. Remove the front fender (4).
INSTALLATION
1 - FENDER TO INNER SUPPORT BOLTS 5 - HEADLAMP SCREW

2 - FENDER TO A-PILLAR BOLTS 6 - FRONT FASCIA
3 - LOWER FENDER BOLTS 7 - HOOD
4 - LEFT FRONT FENDER (RIGHT SIDE SIMILAR)
1. Position the front fender (4).

2. Install the four bolts (1) attaching the fender to the inner support.
3. Install the screw (5) on the top front of the fender.
4. Install the bolts (3) on the lower portion of the rear of the fender.
5. Install the bolts (2) on the fender attaching it to the A-pillar.
6. Install the front fascia (6). Refer to Page 13-4.
7. Close the hood (7).
8. Align the fender. Refer to Page 23-53.
COWL GRILLE
REMOVAL
1. Remove the windshield wiper arm plastic caps, then
remove the nuts (1) and the wiper arms.
2. Remove the seven screws (2) from the cowl grille.
3. Pull back on the cowl grille to release the clips (3) and
remove the hoses and connections from the underside of
the cowl grille, then remove the cowl grille from the vehicle.
INSTALLATION
1. Install the hoses and connections to the underside of the cowl grille, then install the cowl grille to the vehicle,
engaging the clips on the back side of the cowl grille.
2. Install the seven screws to the front of the cowl grille.
3. Install the windshield wiper arms, nuts and plastic caps.
EXTERIOR NAME PLATES

REMOVAL
DOUBLE SIDED TAPE
1. Mark the reference points before removing the name plate.
2. Using a heat gun, gently apply heat in a circular motion to loosen the adhesive bond.
3. Using a nonmetallic prying device, such as a plastic or wood trim stick, gently pry up at the corners and remove.
4. Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover.
REMOVAL - ADHESIVES
1. Mark the reference points before removing.
2. Using a heat gun, gently apply heat in a circular motion to loosen the adhesive bond.
3. With your fingernail lift up and peel away badging/tape from the panel, using a heat gun as you go.
4. Clean off all traces of adhesive from the panel(s) with a general purpose adhesive remover.
INSTALLATION
DOUBLE SIDED TAPE
1. Clean the panel surface with isopropyl alcohol.
2. Align the badging to it’s reference points.
3. Install and press securely to assure full adhesive contact.
4. Clean away any reference points from the panel.
INSTALLATION - ADHESIVES
1. Clean the panel surface with isopropyl alcohol.
2. Remove the paper carrier and align the badging/tape to the reference points or an adjacent panel.
3. Install and press securely, using a plastic spreader to eliminate all air bubbles.
4. Remove the top protective carrier.
5. Clean away any reference points.
FUEL FILL DOOR

REMOVAL
1. Open the fuel filler door (1).
2. Remove the two bolts (2).
3. Remove the fuel filler door.
INSTALLATION
1. Install the fuel filler door (1) to the vehicle.
2. Install the two bolts (2).
3. Verify correct alignment of the fuel filler door and the body. Refer to Page 23-53.
REAR SPOILER
DESCRIPTION
A deployable rear spoiler enhances the vehicle’s stability. Pow-
ered by an electric motor, it deploys automatically when the
vehicle speed reaches 50 mph (80 km/h) to provide 40 Lbs.
(356 Newtons) of aerodynamic downforce to the rear of the
vehicle at 80 mph (129 km/h).
OPERATION
The rear spoiler is powered by an electric motor located
directly below the spoiler wing in the spoiler assembly. When
the vehicle reaches 50 mph (80 km/h), the rear spoiler
deploys, giving the vehicle 40 Lbs. (356 Newtons) of down-
force at 80 mph (129 km/h). As the vehicle decelerates, the
rear spoiler starts to retract at a speed of 25 mph (40 km/h).
When retracted, the spoiler nestles between the rear quarter
panels and the rear liftgate window.
The spoiler can be manually deployed at lower speed using

the override switch mounted in the center console. Pushing
the switch up raises the rear spoiler. Pushing the switch down
lowers the rear spoiler.
To prevent injury, the rear spoiler retracts in defined steps to
allow time to pull any hands or foreign objects that may be in
the path of the rear spoiler before it is all the way down. If the
rear spoiler gets disturbed while retracting automatically or
while retracting manually, the rear spoiler is automatically
driven up again and will lock in the up position. During manual
retraction, if you let up on the switch, the rear spoiler will be
driven to its up position. When retracting the rear spoiler man-
ually, a single audible chime is produced to indicate to the
driver that the rear spoiler is in the fully retracted position. A
warning signal (LED) on the spoiler override switch illuminates,
indicating a malfunction to the driver. A malfunction that pre-
vents the spoiler from deploying illuminates a red warning
lamp in the override switch.
REMOVAL
SPOILER WING
1. If the rear spoiler is not already in the up position, raise the
rear spoiler by pushing the top of the manual override
switch (1).
2. Remove the four screws (1) then remove the rear spoiler
wing (2) from the rear spoiler linkage.
REMOVAL - MOUNTING PLATE

1. Remove the spoiler wing (2) from the linkage. Refer to
Page 23-117.
2. Open the rear hatch.

3. Remove the lower trim panel (1). Refer to Page 23-48.
4. Disconnect the spoiler electrical connections (1).
5. Remove the two drain tubes from the mounting plate.

6. Remove the sixteen mounting plate nuts (1) from the rear
hatch.
7. Lower the hatch down and pull the mounting plate out of
the rear hatch.
8. Remove the mounting bracket from the mounting plate by

removing the two bolts (1).
REMOVAL - MOTOR
1 - LINKAGE BOLTS 5 - GEAR DRIVE

2 - LINKAGE 6 - FINAL REDUCTION GEAR
3 - TORQUE SHAFT 7 - MOTOR BRACKET
4 - MOTOR 8 - SPOILER WING
CAUTION: The spoiler must be in its up position to

remove the motor. If the spoiler cannot be put in its up
position the entire spoiler assembly must be replaced.
1. Remove the spoiler wing (8). Refer to Page 23-117.

2. Remove the lower hatch trim panel. Refer to Page 23-48.
3. Remove the mounting plate. Refer to Page 23-117.

4. Disconnect the electrical connectors.
5. Remove the three screws (1) attaching the motor to the
bracket.
INSTALLATION
SPOILER WING
1. Install the rear spoiler wing (2) onto the spoiler linkage.
Tighten to 8 N·m (71 in. lbs.).
2. Install the four screws (1) attaching the rear spoiler wing
the linkage.
3. Move the spoiler to its down position verifying the spoiler

wings alignment to the vehicle’s body.
INSTALLATION - MOUNTING PLATE

1. Install the mounting bracket to the mounting plate. Tighten
to 8 N·m (71 in. lbs.).
2. Install the mounting plate to the rear hatch.

3. Install the sixteen mounting nuts (1) attaching the mounting
plate to the rear hatch. Tighten to 8 N·m (71 in. lbs.).
4. Install the two drain tubes.
5. Connect the spoiler electrical connections (1).
6. Install the lower trim panel (1). Refer to Page 23-49.

7. Install the spoiler wing (2) to the linkage (1). Refer to Page
23-121.
8. Verify the rear spoiler operation by using the manual over-

ride switch to operate the spoiler making sure there is
smooth operation and proper alignment.
INSTALLATION
1. Install the three screws (1) attaching the motor to the
bracket.
2. Connect the electrical connectors.
3. Install the mounting plate. Refer to Page 23-121.
4. Install the spoiler wing. Refer to Page 23-121.
ROCKER PANEL MOLDING

REMOVAL
2. Remove the front wheel liner.
4. Remove the screws attaching the rocker panel (2) to the
vehicle
5. Remove the screws attaching the lift pads (1) to the vehicle
6. Remove the rocker panel (2).
INSTALLATION
1. Install the rocker panel.
2. Install the screws attaching the lift pads to the vehicle.
3. Install the screws attaching the rocker panel to the vehicle.
5. Install the front wheel liner.
23 - 126 HOOD ZH
HOOD
TABLE OF CONTENTS
page page
GAS PROP INSULATION

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HINGE LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
HOOD LATCH RELEASE CABLE
STANDARD PROCEDURE - MOVING THE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
HOOD TO ITS FULLY UPRIGHT POSITION . 130 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 LATCH STRIKER
ADJUSTMENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
ADJUSTMENT - HOOD . . . . . . . . . . . . . . . . 134
GAS PROP
REMOVAL
1. Open the hood.
2. Support the hood with a suitable prop device.
3. Remove the gas prop lock (1) on the upper end (2).
ZH HOOD 23 - 127
4. Remove the gas prop lock (1) on the lower end (2).
5. Remove gas prop from vehicle.
INSTALLATION
1. Place gas prop (2) in position on the vehicle.
2. Install the lower lock cap (1) on the gas prop (2).
23 - 128 HOOD ZH
3. Install the upper lock caps (1) on the gas prop (2).
4. Verify hood lid operation.
HINGE
REMOVAL
1. Remove the hood from the hinge by removing the upper
bolts (1) then the lower bolts (2). Refer to Page 23-131.
ZH HOOD 23 - 129
2. Remove the inner front fender (1).

3. Mark the position of the hood hinge on the inner panel.
4. Remove the bolts (2) and then remove the hood hinge.
INSTALLATION
1. Install the hood hinge, then install the bolts (2). Tighten to 8
N·m (70 in. lbs.).
2. Install the inner front fender (1).
23 - 130 HOOD ZH
3. Install the hood by installing the lower bolts (2), then install-
ing the upper bolts (1). Tighten to 10 N·m (88 in. lbs.).
HOOD
STANDARD PROCEDURE - MOVING THE HOOD TO ITS FULLY UPRIGHT POSITION
OPENING
CAUTION: The locking button symbol “PRESS” must be
completely visible in the opening of the gas prop rod
cover tube.
1. Press the gas prop rod locking button in the opening of the
gas prop rod cover tube and then move the hood to its fully
upright position until locking button catches on the detent.
ZH HOOD 23 - 131
CLOSING
CAUTION: The locking button symbol “PRESS” must be
completely visible in the opening of the gas prop rod
cover tube.
1. Press the gas prop rod locking button in the opening of the
gas prop rod cover tube and then slowly allow the hood to
come down against the pressure of the gas pressure strut.
REMOVAL
1. Open the hood by pulling the handle (1) and move it to the
full upright position.
23 - 132 HOOD ZH
Note: The hood is held in place by the safety hooks on

the hood hinges.
2. Remove the two lower bolts (2) from the left and right hood
hinges.
3. Remove the gas prop rod retainer (1) and remove the gas
prop rod (2) from the hood at the top retaining hook (3).
4. Remove the upper bolt (1) from the left and right hood
hinges.
5. Remove the hood with the help of a second person. Set the
hood down on a suitable flat surface.
ZH HOOD 23 - 133
INSTALLATION
1. Position the hood on the safety hooks on the hood hinges.
2. Install the lower bolts (2) on the hood.
3. Install the upper bolts (1) on the hood.
4. Move the bolts (1,2) to coincide with the impressions in the
paint. Have a second person tighten the bolts (1,2) to the
hood. Tighten to 10 N·m (88 in. lbs.).
5. Install the gas prop rod (2) to the hood at the top then
install the gas prop rod retainer (1).
6. Shut the hood and make sure that the hood shuts properly
and securely and that there is a uniform gap around the
hood to the front fenders and grille. If not the hood may
need to be adjusted. Refer to Page 23-134
23 - 134 HOOD ZH
ADJUSTMENTS
ADJUSTMENT - HOOD
ADJUSTING IN LONGITUDINAL AND VERTICAL DIRECTIONS
Note: For minor adjustment in longitudinal and vertical
directions; for larger adjustment path see steps 4 - 10.
1. Open the hood.

2. Loosen the bolts (1,2) on the hood hinges and adjust the
hood.
3. Tighten the bolts. Tighten to 10 N·m (88 in. lbs.).
4. Move the hood to its fully upright position. Refer to Page
23-130
5. Remove the gas prop rod from the hood at the top and lay
it down in the engine compartment.
6. Close the hood.
7. Remove the inner fender from the front fender.
8. Loosen the bolts on the hood hinges in the front fender.
Note: For larger adjustment path loosen the top section of

the hood latch, adjust and retighten.
9. Adjust the hood so that the front edge of the front fender coincides with the hood and the top edges are flush.
10. Tighten the bolts on the engine hood hinges. Tighten to 10
N·m (88 in. lbs.).
Note: If necessary install a spacer below the top section

of engine hood latch. Raise/lower the upper frame cross
member.
11. Adjust the height of the stop bumper so that the top edges
of the front fenders are flush with the hood.
12. Install the gas prop rod.
ZH HOOD 23 - 135
ADJUSTING IN LATERAL DIRECTION

1. Loosen the bolts (1) on the top section of hood latch (2).
2. Adjust the gaps on the left and right of the hood.
3. Center the top section of hood latch (2) in the lateral and
longitudinal directions in relation to the bottom section of
the hood latch and then tighten the bolts (2). Tighten to 8
N·m (70 in. lbs.).
4. Install the inner fender in the front fender.
Note: For this purpose close the hood, release and ensure
that hook is caught in upper frame cross member.
5. Check the function of the safety hook.

6. Close the hood.
7. Check the locking function of the hood latch and the safety
hook.
GAP DIMENSIONS
Hood and front fender 4.0 mm (±0.5 mm)

Hood and front headlamps 6.0 mm (+1/-0.5 mm)
Hood and radiator grille 7.0 mm (+1/-0.5 mm)
Radiator grille and front headlamp 5.0 mm (+1/-0.5 mm)
INSULATION
REMOVAL
1. Open the hood.
2. Remove the twelve plastic anchors (1).
3. Remove the insulation.
23 - 136 HOOD ZH
INSTALLATION
1. Install the insulation to the hood.
2. Install the twelve plastic anchors (1) to the hood.
3. Close the hood.
LATCH
REMOVAL
1. Open the hood
2. Remove the bolts (1) and then remove hood latch (2) lower
section.
3. Remove the hood pull cable (2) from the hood striker (3).
Note: Mark installation position of the hood catch upper

section on the hood.
4. Remove the hood latch (3).

ZH HOOD 23 - 137
INSTALLATION
1. Grease the hood latch (3).
2. Connect the hood latch (3) to the hood latch release cable
(2).
3. Note the correct routing of hood latch release cable (2).
4. Install the hood latch release cable (2) to the hood latch
(3).
5. Position the bolts (1) and install the hood latch (2). Tighten
to 8 N·m (71 in. lbs.).
6. Close the hood and test for proper alignment and fit.
23 - 138 HOOD ZH
LATCH RELEASE CABLE

REMOVAL
1. Open the hood and move it to the upright position.
2. Remove the screw on the pull handle (1).
3. Pull the handle (1) out of the arresting mechanism in the
cover and then remove the hood pull cable from the handle
(1).
4. Remove the cable grommet from the bulkhead just below

the fuse box.
5. Remove the upper frame cross member.
6. Remove the clip on the frame cross member.
7. Remove the cover.
8. Remove the hood latch (6).
9. Remove the hood latch release cable (1) from between the
headlamp and the upper frame cross member.
ZH HOOD 23 - 139
INSTALLATION
Note: Pay particular attention to the routing of the hood
latch release cable.
1. Install the hood latch release cable (1) between the head-
lamp and the upper frame cross member.
2. Install the hood latch (6).
3. Install the cover.
4. Install the clip on the frame cross member
5. Install the upper frame cross member.
6. Install the wire to the grommet (3) on the hood latch
release cable (2).
Note: Ensure that hood latch release cable grommet is

properly seated in the bulkhead.
7. Push the cable grommet into the bulkhead below the fuse
box.
8. Install the handle (1) to the arresting mechanism in the
cover and hook the hood latch release cable to the handle.
9. Install the screw on handle (1).
10. Close the hood and check for proper operation.
23 - 140 HOOD ZH
LATCH STRIKER
REMOVAL
1. Remove the two bolts (2) attaching the latch striker (1) to
the hood.
2. Remove the latch striker (1) from the hood.
INSTALLATION
1. Install the latch striker (1) to the hood.
2. Install the two bolts (2) attaching the latch striker (1) to the
hood. Tighten to 10 N·m (88 in. lbs.).
ZH INSTRUMENT PANEL 23 - 141
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
GLOVE COMPARTMENT REMOVAL - LOWER INSTRUMENT PANEL

STANDARD PROCEDURE (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
ADJUSTING THE GLOVE REMOVAL - INSTRUMENT CLUSTER
COMPARTMENT . . . . . . . . . . . . . . . . . . . . . 141 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
REMOVAL INSTALLATION
GLOVE COMPARTMENT . . . . . . . . . . . . . . . 143 INSTALLATION - INSTRUMENT PANEL (TOP
REMOVAL - DRAWER . . . . . . . . . . . . . . . . . 144 SECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSTALLATION INSTALLATION - LOWER INSTRUMENT
GLOVE COMPARTMENT . . . . . . . . . . . . . . . 146 PANEL (LEFT) . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION - DRAWER ........... . . 147 INSTALLATION - LOWER INSTRUMENT
INSTRUMENT PANEL ASSEMBLY PANEL (RIGHT) . . . . . . . . . . . . . . . . . . . . . . 160
REMOVAL INSTALLATION - INSTRUMENT CLUSTER
INSTRUMENT PANEL (TOP SECTION) . . . . 149 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
REMOVAL - LOWER INSTRUMENT PANEL
(LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
GLOVE COMPARTMENT
STANDARD PROCEDURE
ADJUSTING THE GLOVE COMPARTMENT
Note: Close attention must be paid to the uniform transi-
tion and gap width of the glove compartment lid in rela-
tion to the instrument panel.
1. Screw in the stop buffer on the closing surface (1).

23 - 142 INSTRUMENT PANEL ZH
2. Loosen the screw (4) to the striker latch. Adjust the gap
width and transition at the top.
3. Loosen the hinge screws (2) and adjust the gap width and
transition at the bottom and sides.
4. Unscrew both stop buffers until the glove compartment lid
makes contact and can still be closed easily.
5. Check for easy motion and proper function.
REMOVAL
GLOVE COMPARTMENT
1. Remove the side air nozzle.
23-149
3. Open the glove compartment.
4. Remove the cover at the top of the glove compartment

opening (2).
5. Remove the glove compartment lamp (1) and disconnect
the electrical connection.
6. Remove the screws (1, 2, 4, and 5) around the opening

and the screw (3) on the side of the instrument panel.
7. Remove the glove compartment from the vehicle.
REMOVAL - DRAWER
1. Open the glove compartment drawer (3).
2. Disconnect the retaining rail for the interior covering (1) at
the top with a plastic wedge.
3. Disconnect the insert clip from the damper shock (2).
4. Remove the damper shock.
5. Remove the screws (2) from both of the hinges.
6. Pull the glove compartment drawer out of the hinges (2).

7. Remove the clip at the bottom of the retaining strap and
unhook the retaining strap (3).
8. Remove the glove compartment drawer from the vehicle.
INSTALLATION
GLOVE COMPARTMENT
Note: When installing the air duct, check the clips and
exposed electrical connections for the glove compartment
illumination and route through the opening.
1. Install glove compartment.

2. Install the screws (1, 2, 4 and 5) around the opening.
3. Connect the glove compartment lamp electrical connector

and install.
4. Install the cover (2) at the top of the glove compartment
opening.

23-155.
6. Install the side air nozzle.
INSTALLATION - DRAWER
1. Install the glove compartment drawer on the hinges (2).
2. Install the clip at the bottom of the retaining strap (3) and
hook the retaining strap.
3. Install the damper shock (1).
4. Install the insert clip to the damper shock (1).
5. Connect the retaining rail (1) for the interior covering at the
top.
6. Close the glove compartment door.

7. Check the adjustment of the glove compartment door and
adjust, if necessary. Refer to Page 23-141.
INSTRUMENT PANEL ASSEMBLY

REMOVAL
INSTRUMENT PANEL (TOP SECTION)
1. Remove the A-pillar trim (1).
Note: A plastic wedge or a suitable coin can be used to

turn the fuse cover locks.
2. Remove the fuse covers (1) on the left and right.

3. Remove the screw located in the right and left air nozzles
(2) by pushing the deflector up to reveal the screw.
4. Remove the screws (1) on left and right of the instrument
panel located on the inside of the fuse cover.
5. Remove the screws attaching the front center console to
the top section on the instrument panel.
6. Open the glove compartment and remove the screws (1)

attaching it the top section of the instrument panel.
7. Remove the defroster grille screws (1) and the defroster

grille pulling it outwards.
8. Remove the bolts (1) on left and right under the defroster
grille.
CAUTION: Damage to the top section of instrument panel

can occur if the A-pillar sheet metal clips are not removed
when removing and installing the top section of the
instrument panel.
9. Remove the sheet metal clips (1) on left and right A-pillars.
10. Lift the top section (1) of the instrument panel and remove
toward rear.
11. Lay the top section of instrument panel down on a suitable
surface.
REMOVAL - LOWER INSTRUMENT PANEL (LEFT)

1. Remove the air nozzle.
2. Remove the screw (3) attaching the cover under the steer-
ing column then remove the cover (2).
3. Remove the fuse panel cover.
4. Remove the screws (1) attaching the lower instrument
cover (5) to the illumination control module (4) and the side
of the instrument panel to the support bar (6).
5. Remove the illumination control module (7).
Note: Do not unscrew pedal cover (1).
6. Remove the screws (arrows) in the under side cover (2).

7. Pull the lower instrument cover (2) off of the upper instru-
ment panel cover.
8. Remove the screw (2) attaching the hood latch release

handle bezel to the lower instrument panel and then guide
the handle through the lower cover (1).
9. Separate the lower panel (2) from the upper panel (1) and
then remove the lower instrument panel.
REMOVAL - LOWER INSTRUMENT PANEL (RIGHT)

1. Fold back the carpet (3).
2. Remove the screws (2) attaching the lower instrument
panel to the glove compartment.
3. Pull the lower instrument panel (1) out.
REMOVAL - INSTRUMENT CLUSTER COVER

3. Remove the sentry key antenna ring from the key cylinder.
4. Remove the screws attaching the instrument cluster cover
to the lower instrument panel.
5. Disconnect the instrument cluster cover (1) from the top
with a plastic wedge.
6. Tip the instrument cluster cover toward the rear at the top.
Lift it over the jacket tube covering and simultaneously
guide the adjustment knobs through the cover.
INSTALLATION
INSTALLATION - INSTRUMENT PANEL (TOP SECTION)
Note: Pay good attention to the uniform gap in relation to
the driver and passenger door trim panels.
Note: When installing, check for proper installation of the

insulating mat, sheet metal clips and expanding anchors.
1. Install the top section (1) of instrument panel.
2. Install the sheet metal clips (1) on left and right A-pillars.
3. Install the bolts (1) on left and right under the defroster
grille.
4. Position the defroster grille (2) and install the screws (1).
5. Install the screws (1) to the glove compartment attaching it

to the top section of the instrument panel.
6. Install the screws (1) attaching the front center console to

the top section on the instrument panel.
7. Install the screws (1) on left and right of the instrument

panel located on the inside of the fuse cover.
8. Install the screws (2) located in the air nozzles.
9. Install the fuse covers (1) on the left and right.

10. Install the A-pillar trim (1).
INSTALLATION - LOWER INSTRUMENT

PANEL (LEFT)
Note: When installing, insert the front tabs on the pedal
lower instrument panel below the floor covering.
1. Install the lower instrument panel (2) upward and toward

the front.
2. Guide the hood latch release handle (2) through the lower
instrument panel (1) then install the screw attaching it to
the lower instrument panel (1).
3. Install the lower instrument panel onto the upper instrument

panel.
4. Install the screw in the lower instrument panel.
5. Install the illumination control module (7).
6. Install the screws attaching the illumination control module
(7) to the instrument panel and to the support bar (6) on
the side.
7. Install the cover (2) under the steering column. Then install
the screw (3).
8. Install the side air nozzle.
INSTALLATION - LOWER INSTRUMENT PANEL (RIGHT)

1. Install the lower instrument panel (3) in toward the front.
2. Install the screws attaching the lower instrument panel to
the glove compartment.
3. Fold back the carpet.
INSTALLATION - INSTRUMENT CLUSTER

COVER
1. Tip the instrument cluster cover toward the rear at the top,
then lift it over the jacket tube covering and simultaneously
guide the adjustment knobs through the cover.
2. Connect the instrument cluster cover (1) to the instrument
panel top section.
3. Install the screws attaching the instrument cluster cover to
the lower instrument panel.
4. Install the sentry key antenna ring to the key cylinder.
5. Install the lower instrument panel. Refer to Page 23-155
6. Install the steering wheel. Refer to Page 19-26
ZH INTERIOR 23 - 161
INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR TRIM INSTALLATION

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 CENTER CONSOLE (FRONT) . . . . . . . . . . . 183
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 162 INSTALLATION - CENTER CONSOLE
CARPET COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
REMOVAL INSTALLATION - REAR CENTER
CARPET (LEFT) .................. . . . 163 CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . 188
CARPET (RIGHT) ................. . . . 166 INSTALLATION - ASH TRAY . . . . . . . . . . . . . 190
INSTALLATION INSTALLATION - SHIFT LEVER ASSEMBLY
CARPET (LEFT) .................. . . . 168 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
INSTALLATION - CARPET (RIGHT) . . . . . . . 171 DOOR SILL TRIM PLATE
CENTER CONSOLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 193
CENTER CONSOLE (FRONT) . . . . . . . . .. . 173 HEADLINER
REMOVAL - CENTER CONSOLE COVER . . 176 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
REMOVAL - REAR CENTER CONSOLE . .. . 178 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 196
REMOVAL - ASHTRAY . . . . . . . . . . . . . . .. . 180
REMOVAL - SHIFT LEVER ASSEMBLY
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
A-PILLAR TRIM
REMOVAL
1. Press the A-pillar (1) out of the retaining clips (3 each) with
a plastic wedge starting at the top.
2. Remove the A-pillar (1) toward the middle of the vehicle.
23 - 162 INTERIOR ZH
3. Remove the retaining clips (1) if doing any service to the

instrument panel.
INSTALLATION
1. Install the retaining clips on the A-pillar and attach the elec-
tric wire.
2. Position the A-pillar (1) flush on top of the section of the

instrument panel and press it into the retaining clips.
3. Lift the rubber lip on the A-pillar seal over the A-pillar trim
with a plastic wedge.
CARPET
REMOVAL
CARPET (LEFT)
3. Remove the cover on center console. Refer to Page
23-173.
4. Remove the ashtray housing with the stowage compart-
ment in the front of the center console. Refer to Page
23-173.
5. Remove the air outlet cover in the footwell.
6. Remove the door sill trim plate (4). Refer to Page 23-193.
7. Remove the kick panel (2) in the left footwell by pulling the
edge guard (1) off in the area of the kick panel (2). Remove
the cap (3) with a small screwdriver, then remove the
screw.
8. Remove the pedal cover.
9. Remove nut (1) attaching the accelerator pedal to the

instrument panel structural duct.
10. Remove the nut (1) attaching the accelerator pedal to the
floor. Disconnect the electrical connector and remove the
pedal from the welded stud.
11. Unhook the storage pocket (1) and remove it from the
vehicle.
12. Disconnect the electrical connector from the parking brake
switch (4).
13. Remove the plugs (3) and then remove the rear edge
guard (2) in the lower area.
Note: Cut the single-piece carpet (1) along dotted lines in

order to avoid time-consuming removal of the heater or
air conditioning systems.
CAUTION: Do not damage the electrical and pneumatic

lines!
14. Cut the carpet (1) in the transmission tunnel area along
the dotted lines with a sharp knife.

lines!
15. Cut the carpet (1) in the shift lever assembly area.

lines!
16. Cut the carpet (1) in the footwell area under the front cen-
ter console.
17. Lift at the rear while removing the carpet (1) from below
the center console and then remove it from the vehicle.
CARPET (RIGHT)
23-173.
4. Remove the ashtray housing with the stowage compart-
ment in the front center console. Refer to Page 23-173.
5. Remove the air outlet cover in the footwell.
6. Remove lower instrument panel (right). Refer to Page
23-149.
7. Removing the door sill trim plate (4). Refer to Page 23-193
8. Remove the kick panel (2) in the right footwell. Pull the
edge guard (1) off in the area of the kick panel (2). Remove
the cap (3) with a suitable tool, then remove the screw.
9. Unhook the storage pocket and remove it from the vehicle.

10. Disconnect the connector from the parking brake switch
(1).
11. Remove the plugs and pull off the edge protector at the
rear in the lower area.
CAUTION: Do not damage electrical and pneumatic lines!
12. Cut the carpet (1) in the transmission tunnel area along
the dotted lines with a sharp knife.
13. Cut the carpet (1) in the shift lever module.
14. Cut the carpet (1) in the footwell area under the front cen-
ter console.
15. Remove the carpet (1) below the center console, then lift
at the rear and then remove it from vehicle.
INSTALLATION
CARPET (LEFT)
Note: Before installing the carpet (1), clean the vehicle
passenger compartment in the area of the floor covering.
1. Prepare the carpet (1) for installation by cutting the new

carpet along the dotted line with a suitable cutting device
and remove the section below the heater (cross-hatched).
2. Install the section of carpet (1) below the heater

(cross-hatched).
3. Install the carpet by inserting the cut edge in the front area
below the center console, while simultaneously guiding the
parking brake lever, kick-down switch, welded pin for the
accelerator pedal and the electrical leads for the driver’s
seat through the carpet (arrows).
4. Expose the lines in the area of the center console and then
attach the two halves of the carpet at the front and rear
with clips (1) along the cutting line. For this purpose, cut
slits in both carpet halves (2) with a blade and then insert
the clips (1).
5. Install the plugs (3) and then install the rear edge guard (2)
in the lower area.
6. Connect the electrical connector (4) to the parking brake (5)
switch.
7. Install the storage pocket (1).
8. Install the nut (1) attaching the accelerator pedal to the

floor, then install the electrical connector.
9. Install nut (1) attaching the accelerator pedal to the instru-

ment panel structural duct.
10. Install the pedal cover.
11. Install the paneling (2) in the left footwell.

12. Install the door sill trim plate (4). Refer to Page 23-193.
Install the edge guard (1) in the area of the paneling (2).
Install the screw (3), then install the cap.
13. Install the air outlet cover in the footwell.
14. Install the ashtray housing with the stowage compartment
in the front of the center console. Refer to Page 23-183.
15. Install the cover on center console. Refer to Page 23-183.
INSTALLATION - CARPET (RIGHT)

Note: Before installing floor covering, clean vehicle pas-
senger compartment in area of floor covering.
1. Prepare the carpet (1) for installation. Cut the new carpet
(1) along the dotted line with a suitable tool and remove the
section below the heater (cross-hatched).
2. Install the new section in the heater box area

(cross-hatched).
3. Install the carpet by inserting the cut edge in the front area
below the center console while simultaneously guiding the
parking brake lever (2) and the electrical leads (1) for the
passenger’s seat through the carpet.
4. Expose the lines in the area of the center console and

attach the two halves of the floor covering at the front and
rear with clips (1) along the cutting line. For this purpose
cut slits in both of the carpet halves with a blade and then
insert the clips (1).
5. Install the plugs and the edge protector at the rear in the
lower area.
6. Connect the electrical connector to the parking brake
switch.
7. Install the storage pocket.
8. Install the paneling (2) in the left footwell.

9. Install the door sill trim plate (4). Refer to Page 23-193.
Install the edge guard (1) in the area of the paneling (2).
Install the screw (3) then install the cap.
10. Install the cover below instrument panel. Refer to Page
23-155.
11. Install the air outlet cover in the footwell.
12. Install the ashtray housing with the stowage compartment
in the front center console. Refer to Page 23-183.
13. Install the cover on the center console. Refer to Page
23-183.
CENTER CONSOLE
REMOVAL
CENTER CONSOLE (FRONT)
23-149 and Refer to Page 23-149.
2. Remove the instrument cluster cover (1). Refer to Page

23-149.
3. Remove the rear center console (2). Refer to Page 23-173.
4. Remove the center console cover (1). Refer to Page

23-173.
5. Remove the ashtray with stowage compartment (1) on the

center console. Refer to Page 23-173.
6. Remove the glove compartment from the hinges (2). Refer

to Page 23-143.
7. Remove the A/C heater control module (2). Refer to Page

24-79.
8. Remove the screws (3) attaching the center console to the

rear center console, air duct (2) and the instrument panel
top section (1).
9. Remove the center console (2) downward from the top sec-
tion (1) of the instrument panel.
10. Remove the center console (2) from the vehicle.
REMOVAL - CENTER CONSOLE COVER

1. Remove the radio.
2. Remove the screws (1) in the radio cutout attaching it to

the center console cover.
3. Pull the cover (1) toward the rear and pull it out at the top
of the instrument panel (2 hooks).
4. Disconnect the console switch group at the catch lugs (2).

5. Remove the console switch group (1) from the cover.
REMOVAL - REAR CENTER CONSOLE

1. Remove the cover (1) around the shift lever. Refer to Page
23-173.
2. Pull the handle (1) off the parking brake lever.

3. Remove the screws (1) attaching the center console to the

rear center console.
4. Open the lid on the rear stowage compartment.
Note: The carpet flap is approximately 2 in. wide and is

attached with Velcro© to the stowage compartment.
5. Lift the carpeting (2) at the rear of the rear stowage com-
partment.
6. Remove the nuts (1).
7. Lift the rear center console (2) up uniformly while moving it

out at the front, disconnecting it from the arresting hook at
the separating point of the front (1) and rear center con-
soles (2).
8. Guide the parking brake handle through the opening in the
retractable cover.
9. Disconnect all electrical connectors.
10. Remove the rear center console (2) from the vehicle.
REMOVAL - ASHTRAY
1. Remove the cover (1) on the center console. Refer to
Page 23-173
2. Remove the screws (1-3) attaching the ashtray (2) to the

center console.
3. Press the ashtray housing (1) to the left and remove it

toward the right (arrows).
4. Disconnect the ashtray harness connector for the courtesy

light (1).
REMOVAL - SHIFT LEVER ASSEMBLY COVER

1. Remove the chrome plastic frame (1) with a plastic wedge.
2. Press the cover (1) out of the catch in the center console at
the rear and side with a plastic wedge.
3. Disconnect the electrical connectors (1) to the power win-

dow switches.
INSTALLATION
CENTER CONSOLE (FRONT)
Note: When installing, insert the insulating mat, expose
the electric wires and insert the panel into the side insert
tabs on the center console.
1. Install the center console (4) upward into the top section of
the instrument panel.
2. Install the screws attaching the center console to the rear
center console (3), air duct (2) and instrument panel top
section (1).
3. Install the A/C heater control module (2). Refer to Page

24-81,
4. Install the glove compartment to the hinges (2). Refer to

Page 23-146.
5. Install the ashtray with the stowage compartment (1) on the

center console. Refer to Page 23-183.
6. Install the center console cover (1). Refer to Page 23-183.
7. Install the rear center console (2). Refer to Page 23-183.
8. Install the instrument cluster cover (1). Refer to Page

23-155.

23-155.
INSTALLATION - CENTER CONSOLE COVER
1. Install the console switch group (1) to the cover.

2. Connect the cockpit switch group to the catch lugs (2).
3. Push the cover (2) toward the front at top on the instrument
panel top section.
4. Install the screws (1) in the radio cutout.
5. Install the radio.

INSTALLATION - REAR CENTER CONSOLE

1. Connect the electrical connectors.
2. Guide the parking brake handle through opening in the
retractable cover.
3. Install the rear center console (2) uniformly while moving in
at front (1) arresting hook at the separating point.
4. Install the nuts (1).

5. Install the carpeting (2).
6. Close the cover on the stowage compartment.
7. Install the screws (1) attaching the front and the rear center
consoles.
8. Instal the handle on the parking brake lever.
9. Install the cover (1) around the shift lever. Refer to Page
23-183.
INSTALLATION - ASH TRAY

1. Connect the ashtray courtesy light harness connector (1).
2. Install the ashtray housing (1) to the right and push it

toward the left.
3. Install the screws (1-3) attaching the ashtray (2) to the cen-
ter console.
4. Install the cover (1) on the center console. Refer to Page

23-183.
5. Install the cover around the shift lever. Refer to Page

23-183.
INSTALLATION - SHIFT LEVER ASSEMBLY COVER

1. Connect the electrical connectors (1) to the power window
switches.
2. Press cover (1) into the catch in the center console at the
rear and the side.
3. Install the chrome plastic frame (1).
DOOR SILL TRIM PLATE

REMOVAL
1. Pull up on the door sill trim plate releasing it from the body
clips.
INSTALLATION
1. Push the door sill trim down until it locks into place.
HEADLINER
REMOVAL
1. Remove the dome lamp assembly (2) by gently prying off
the lens using a trim stick (1) or equivalent.
2. Remove the two retaining screws (1) and pull the dome
lamp assembly from the headliner.
3. Disconnect the dome lamp assembly harness connector (1)

and remove the dome lamp assembly.
4. Remove the garage door opener/TPM module (1) from the

headliner using a trim stick or equivalent. Pull the module
from the headliner and disconnect the harness connector.
5. Remove both the right and left sun visor assemblies.
6. Remove the right and left A-pillar trim panels.

7. Tilt both seats all the way forward and all the way down.
8. Disengage rear interior trim panel (2) retaining clips near

headliner.
9. Remove the rear headliner retaining clips (1).
10. Remove the headliner from the passenger door opening.
INSTALLATION
1. Install the headliner through the passenger door opening.
2. Install the sun visor assemblies. This will hold the headliner
into the correct position.
3. Install the rear headliner retainers (2).
4. Connect the rear interior trim panel retaining clips (1) near
headliner.
5. Install the right and left A-pillar trim panels (1).

6. Using a trim stick, reinstall head liner into upper window
weather strips.
7. Connect the garage door opener/TPM module (1) harness

connector and install into the headliner.
8. Connect the dome lamp assembly harness connector (1)

and install into the headliner.
9. Install the retaining screws (1).

10. Install the dome lamp assembly lens.
ZH PAINT 23 - 199
PAINT
TABLE OF CONTENTS
page page
PAINT PAINT TOUCH - UP

SPECIFICATIONS - PAINT CODE . . . . . . . . . . 199 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 200
PAINT CODE WET SANDING/BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 199 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 200
BASE COAT/CLEAR COAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 199
PAINT
SPECIFICATIONS - PAINT CODE
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER CODE

Sapphire Silver Metallic Clear Coat BS3
Graphite Metallic Clear Coat ZDR
Alabaster Clear Coat 960
Black Clear Coat 040
Blaze Red Crystal Pearl Coat ARH
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER CODE

Dark Slate Gray and Cedar two-tone XDV/ARK
Dark Slate Gray and Medium Slate Gray two-tone XDV/BD5
Dark Slate Gray monotone XDV
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the Body Code plate. The plate is located on the in the engine com-
partment and attached to the top of the right frame rail. Refer to the Introduction section at the front of this manual
for body code plate description. The first digit of the paint code listed on the vehicle indicates the sequence of
application, i.e.: P = primary coat, Q = secondary coat.
BASE COAT/CLEAR COAT FINISH

DESCRIPTION
The original equipment finish is a multi-step process that involves cleaning, electrodeposition (e-coat), base coat,
and clear coat steps. Additionally, selected areas of the vehicle may be coated with an anti-chip finish.
23 - 200 PAINT ZH
PAINT TOUCH - UP
DESCRIPTION
WARNING: USE AN OSHA APPROVED BREATHING FILTER WHEN SPRAYING PAINT OR SOLVENTS IN A
CONFINED AREA. PERSONAL INJURY CAN RESULT.
When a painted metal surface has been scratched or chipped, it should be touched-up as soon as possible to avoid
corrosion. For best results, use MoparT Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. Refer to Intro-
duction group of this manual for Body Code Plate information.
OPERATION
WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL – BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR
ALCOHOL – BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT.
1. Scrape any loose paint and corrosion from the inside of the scratch or chip.
2. Clean the affected area with MoparT Tar/Road Oil Remover, and allow to dry.
3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap the primer onto a good surface
finish. The applicator brush should be wet enough to puddle-fill the defect without running. Do not stroke the
brush applicator on the body surface. Allow the filler/primer to dry hard.
4. Cover the filler/primer with color touch-up paint. Do not overlap the touch-up color onto the original color coat
around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke the applicator brush
on the body surface. Allow the touch-up paint to dry hard.
5. On vehicles without clear coat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with
rubbing compound.
6. On vehicles with clear coat, apply clear top coat to touch-up paint with the same technique as described in Base
Coat/Clear Coat Finish, Refer to Page 23-199. Allow clear top coat to dry hard. If desired, finesse sanding can
be performed on clear top coat.
WET SANDING/BUFFING & POLISHING

DESCRIPTION
CAUTION: Do not remove more than .5 mils of clearcoat finish, if equipped. Basecoat paint must retain
clearcoat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine film thickness before and after the
repair.
Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse
sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated.
Finesse sanding operation should be performed by a trained automotive paint technician.
ZH SEATS 23 - 201
SEATS
TABLE OF CONTENTS
page page
SEATS INSTALLATION - PLASTIC BACK COVER . . 205

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 201 SEAT BACK COVER
SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 INSTALLATION - SEAT BACK COVER . . . . . . . 208
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 203 SEAT CUSHION
SEAT BACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 213
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . . 204 SEAT CUSHION COVER
REMOVAL - PLASTIC BACK COVER . . . . . . 204 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . . 205
SEATS
DESCRIPTION
Leather high-back bucket seats are standard. Both seats feature eight-way power adjustment - horizontal, vertical,
cushion tilt, and back angle. Ergonomic power seat switches with tabs resembling the cushion and back in profile
and placement mount on the outboard seat cushion side shields. Movement of the seats correlates with the direc-
tion of switch travel. Seat adjustment is allowed with the ignition switch in the 9off9 position or when the key is
removed only when the door is open. The power adjuster provides 7.6 inches (194 mm) of longitudinal adjustment
and 1.7 inches (43 mm) of vertical adjustment.
Standard heated seats have two heating levels and a timed automatic shutoff. Separate rocker switches for the
driver and passenger heaters mount in the center console. Pressing the top of the switch turns on the normal heat-
ing level and pressing to bottom of the switch turns on the rapid heating level. Two lamps in each switch indicate
the level of heat selected: one lamp illuminates for normal heating and both for rapid heating. Without user inter-
vention, the timer automatically switches from rapid heating to normal heating after five minutes. Normal heating
continues without manual intervention for approximately 30 minutes. The heaters may automatically switch off due
to high electrical system demand or a low battery. When this occurs, one or both indicator lamps will blink (depend-
ing on selected heating level) until sufficient voltage is available.
23 - 202 SEATS ZH
SEAT
REMOVAL
1. Move the seat (1) all the way back to its lock position.
2. Pull the plastic front covering (3) from the seat tracks.
3. Remove the two front seat track bolts (2).
4. Move the seat all the way forward to its lock position.
5. Remove the bolt (2) on the seat track for the seat belt
mounting.
6. Remove the belt end from the seat adjuster.
7. Remove the rear two bolts (1) attaching the seat track to
the floor.
8. Disconnect the electrical connectors for the seat heater and
the electrical seat adjustment.
9. Move the seat backward, lift up and then remove from the
vehicle.
ZH SEATS 23 - 203
INSTALLATION
1. Install the seats into the vehicle.
2. Connect the electrical connectors for the seat heater and
the electrical seat adjustment.
3. Insert the bolts (1) in the bolt holes in the rear of the seat
track.
4. Tighten the two rear seat track bolts (1). Tighten to 50 N·m
(37 ft. lbs.).
5. Install the belt end fitting to the seat adjuster.
Note: Tighten the bolt for the belt end fitting only so that
it can be moved.
6. Install the bolt (2) at the belt end fitting. Tighten to 35 N·m
(26 ft. lbs.).
7. Move the seat all the way backwards.
8. Install the two front seat track bolts (2). Tighten to 50 N·m
(37 ft. lbs.).
9. Install the plastic covering (3) to the seat tracks.
23 - 204 SEATS ZH
SEAT BACK
REMOVAL
SEAT BACK
2. Remove the seat cushion. Refer to Page 23-211.
3. Loosen the bolt on the seat height adjustment by removing
the left and right bolts (2).
4. Remove the bolts (1) from the seat back.
5. Disconnect the seat back heater and adjustment electrical
connectors.
6. Remove the seat back from the frame.
REMOVAL - PLASTIC BACK COVER

1. Remove the cover on the seat back (only down to step 6).
Note: Use T25 Torx socket.
2. Remove the screws (1) on left and right sides.

3. Unhook the plastic back cover at the top of the seat back
frame (2) and remove it from the seat back frame.
ZH SEATS 23 - 205
INSTALLATION
SEAT BACK
1. Install the seat back to the frame.
2. Connect the seat back heater and adjustment electrical
connectors.
3. Install the bolts (1) to the seat back. Tighten to 35 N·m (26
ft. lbs.).
4. Install the seat height adjustment by installing the left and
right bolts (2). Tighten to 24 N·m (18 ft. lbs.).
5. Install the seat cushion. Refer to Page 23-213.
INSTALLATION - PLASTIC BACK COVER

1. Install the plastic back cover on the top of the seat back
frame (2).
2. Install the screws (1) on left and right sides.
3. Install the cover on the seat back. Refer to Page 23-208.
23 - 206 SEATS ZH
SEAT BACK COVER

REMOVAL
1. Remove the front seat back. Refer to Page 23-204.
2. Lay the seat back (1) down on a suitable surface with the
cover (2) down.
3. Unhook the cover (2) all the way around on the clip groove
in the rear shell.
4. Remove seat back frame (3) from the foam rubber pad (2).
ZH SEATS 23 - 207
5. Remove the cover (2) from the VelcroT strip in area of seat
back (1) hinge area.
6. Pull the cover (1) over the foam rubber pad (3) in the upper
area.
7. Remove the longitudinal retainers by turning the upholstery
clips (2) 90°.
8. Remove the cover (1) from the foam rubber pad (3).
9. Pull the upholstery wires (2) out of the fabric sleeves (3) in
the cover (1).
23 - 208 SEATS ZH
10. Remove the upholstery clips (2) on the rear of the foam
rubber pad (1).
INSTALLATION - SEAT BACK COVER

1. Insert the upholstery wires (2) into the fabric sleeves (3) in
the cover (1).
ZH SEATS 23 - 209
2. Attach the upholstery clips (2) to the rear of the foam rub-
ber pad (1).
3. Fold over the cover (1) and position it on the front of the
foam rubber pad (4).
4. Connect the upholstery clips (2) with the upholstery wires
starting with the center upholstery wire (3).
5. Draw the cover (2) over the foam rubber pad (1).
6. Attach the cover to the Velcro strip in the area of the seat
back hinge area.
23 - 210 SEATS ZH
7. Position the seat back frame (3) on the foam rubber pad
(2).
8. Hook in the cover (2) all the way around in the clip groove
in the seat back shell and align.
9. Install the front seat back (1).
ZH SEATS 23 - 211
SEAT CUSHION
REMOVAL
1. Remove the seat. Refer to Page 23-202.
2. Remove the bolt (2) on the front seat (1) to the frame (3).
3. Remove the panel (2).

23 - 212 SEATS ZH
4. Pull the two expanding anchors (2) out of the front left and
right bearing brackets (1).
5. Remove the bearing brackets (1) from the seat cushion (2).
6. Disconnect the heated seat cushion from the 4-pin connec-

tor.
7. Lift the seat cushion at the front and remove from seat
frame (2), then remove the two springs (1) on the rear of
the seat frame.
ZH SEATS 23 - 213
INSTALLATION
1. Install both springs (1) into the plate springs with the nar-
row coils pointing downward at an angle and insert into
humps on cushion shell (2). Push the seat cushion toward
the rear below the seat back.
2. Install the seat cushion at front and install to the seat
frame.
Note: Insert the connection leads into connector with

present leads.
3. Connect the leads for the heated seat cushion to the 4-pin
connector.
Note: The expanding anchors and bearing brackets are

deleted parts and must be reordered for installation.
4. Install the two expanding anchors (2) into the front left and
right bearing bracket (1).
23 - 214 SEATS ZH
5. Install the front bolt (2).

SEAT CUSHION COVER

REMOVAL
1. Remove the front seat cushion. Refer to Page 23-211
2. Lay the seat cushion on a suitable surface with the cover
facing down.
3. Unhook the two fabric tabs on the cushion shell (1).
ZH SEATS 23 - 215
4. Unhook the cover (2) all the way around the clip groove in
the seat cushion shell (1).
5. Remove the cushion shell from the foam rubber pad.

6. Fold the cover (1) to the side and unhook the upholstery
straps from the wire insert in the foam rubber pad (2).
7. Pull the lateral upholstery wire (2) out of the fabric sleeve in
the cover (6) and unhook the upholstery straps (1,5) from
the foam rubber pad (4).
23 - 216 SEATS ZH
8. Fold the cover (1) to the side and unhook the middle uphol-
stery straps (2) from the wire insert (3) in the foam rubber
pad (4).
9. Remove the cover (1) from the foam rubber pad (2).
10. Unhook the upholstery straps and pull the longitudinal
upholstery wires out of the fabric sleeves in the cover (1).
ZH SEATS 23 - 217
INSTALLATION
1. Insert the longitudinal upholstery wires into the fabric
sleeves in the cover (3).
2. Fold the cover over and position it on the foam rubber pad
(1).
3. Hook the middle longitudinal upholstery wire onto the wire,
insert it in the foam rubber pad (1) with the fabric straps
(2).
4. Pull the rear lateral upholstery wire into the fabric sleeve in
the cover (3).
5. Install the side longitudinal retainers and the rear lateral
retainers.
6. Pull the cover (3) to the side over the foam rubber pad (1).
Note: Insert one additional retaining clip in clip groove at

front center (arrow)
7. Position the seat cushion shell (1), align the cover (2) and
hook the cover into the cushion shell (1) all the way
around.
8. Hook fabric tabs on the left and right into the cushion shell.
Trim the seam on cover in this area.
23 - 218 SEATS ZH
9. Ensure that the contour of the cover is positioned correctly.

10. Install the seat cushion (1). Refer to Page 23-213.
ZH HEATING & AIR CONDITIONING 24 - 1
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING - ELECTRICAL HEATING & AIR CONDITIONING - SERVICE
HEATING & AIR CONDITIONING - ELECTRICAL

DIAGNOSTICS
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING - ELECTRICAL A/C PRESSURE SENSOR CIRCUIT ..... . . 28
DIAGNOSTICS COOLANT CIRCULATION PUMP CIRCUIT . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 LEFT COOLANT CIRCULATION VALVE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING RIGHT COOLANT CIRCULATION VALVE
AMBIENT TEMPERATURE SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 A/C COMPRESSOR CLUTCH CIRCUIT . . . . . 43
LEFT HEATER CORE TEMPERATURE RECIRCULATED AIR SWITCHOVER VALVE
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 8 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
RIGHT HEATER CORE TEMPERATURE NO COMMUNICATION FROM INSTRUMENT
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . 13 CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
EVAPORATOR TEMPERATURE SENSOR NO COMMUNICATION TO INSTRUMENT
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENGINE COOLANT TEMPERATURE BODY VERIFICATION TEST . . . . . . . . . . . . . 53
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . 23 SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 54
HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS

DESCRIPTION
To maintain the performance level of the heating-air conditioning system, the engine cooling system must be prop-
erly maintained. Any obstructions in front of the radiator or condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The heating system includes the radiator, heater core and the heater hoses. Refer to Cooling for more information
before opening, or attempting any service to the engine cooling system.
A manual dual-zone temperature control type heating-air conditioning system is factory-installed on this model.
This vehicle is equipped with a common HVAC housing assembly. The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing mounted under the instrument panel.
24 - 2 HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS ZH
OPERATION
Outside fresh air enters the vehicle through the cowl top opening at the base of the windshield, and passes through
a plenum chamber to the HVAC system blower housing. Air flow velocity can then be adjusted with the blower motor
speed selector switch on the A/C heater control panel. The air intake openings must be kept free of snow, ice,
leaves, and other obstructions for the HVAC system to receive a sufficient volume of outside air.
It is also important to keep the air intake openings clear of debris because leaf particles and other debris that is
small enough to pass through the cowl plenum screen can accumulate within the HVAC housing. The closed, warm,
damp and dark environment in the HVAC housing is ideal for the growth of certain molds, mildews and other fungi.
Any accumulation of decaying plant matter provides an additional food source for fungal spores, which enter the
housing with the fresh air. Excess debris, as well as objectionable odors created by decaying plant matter and grow-
ing fungi can be discharged into the passenger compartment during HVAC system operation.
In a blend-air system, a blend door controls the amount of unconditioned air (or cooled air from the evaporator) that
is allowed to flow through and around, the heater core. A temperature control on the A/C heater control panel deter-
mines the discharge air temperature by energizing the blend door actuator, which operates the blend door. This
allows an almost immediate control of the output air temperature of the system.
The mode control on the A/C heater control panel is used to direct the conditioned air to the selected system out-
lets. The mode control uses engine vacuum to control the mode doors, which are operated by vacuum actuators.
The outside air intake can be shut off on manual temperature control systems by selecting the Recirculation Mode
with the mode control. This will operate the recirculation door that closes off the outside fresh air intake and recir-
culates the air that is already inside the vehicle.
The air conditioner is designed for the use of non-CFC, R-134a refrigerant. The air conditioning system has an
evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. This air conditioning
system uses a thermal expansion valve to meter refrigerant flow to the evaporator coil. To maintain minimum evap-
orator temperature and prevent evaporator freezing, the system utilizes an evaporator thermister probe with the
appropriate operating logic located in the A/C Heater Control Module.

ZH HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS 24 - 3
AMBIENT TEMPERATURE SENSOR CIRCUIT
• Set Condition: The A/C Heater Control Module reports an abnormally high or low voltage that is detected
by the Instrument Cluster on the Ambient Temperature Sensor Signal circuit.
POSSIBLE CAUSES
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

AMBIENT TEMPERATURE SENSOR OPEN
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
AMBIENT TEMPERATURE SENSOR GROUND CIRCUIT OPEN
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
INSTRUMENT CLUSTER
For a complete HVAC Circuit Diagram, Refer to Page 24-54.
Diagnostic Test

Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE AMBIENT TEMPERATURE


Measure the voltage of the Ambient Temperature Sensor Signal circuit at
the Ambient Temperature Sensor harness connector.

short to voltage.
No >> Go to 3
Connect a jumper wire between the Ambient Temperature Sensor Signal
circuit and the Sensor Ground circuit.
Yes >> Go to 4
No >> Replace the Ambient Temperature Sensor. Refer to
Page 24-82
4. MEASURE THE RESISTANCE OF THE AMBIENT TEMPERATURE


Measure the resistance of the Ambient Temperature Sensor Signal circuit
from the Instrument Cluster harness connector to the Ambient Tempera-
ture Sensor harness connector.

Yes >> Go to 5
No >> Repair the Ambient Temperature Sensor Signal circuit for
an open.

Measure the resistance of the Sensor Ground circuit from the Instrument
Cluster harness connector to the Ambient Temperature Sensor harness
connector.

Yes >> Replace the Instrument Cluster. Refer to Page 8J-83
Yes >> Go to 7
No >> Go to 9

Reconnect the Ambient Temperature Sensor connector.
Wait two minutes.

DTC?
24-82
No >> Go to 8

Ensure the Ambient Temperature Sensor is connected at this time.
Start the engine.

DTC?
Yes >> Replace the Ambient Temperature Sensor.
Perform BODY VERIFICATION TEST. Refer to Page
24-2.
AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the Ambient Temperature
Signal circuit.

short to ground.
No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE AMBIENT


Measure the resistance from the Ambient Temperature Sensor Signal cir-
cuit to the Sensor Ground circuit at the Ambient Temperature Sensor con-
nector.

short to the Sensor Ground circuit.
No >> Replace the Instrument Cluster. Refer to Page 8J-83
LEFT HEATER CORE TEMPERATURE SENSOR CIRCUIT
LEFT HEATER CORE TEMPERATURE SENSOR CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormally high or low voltage on the Left
Heater Core Temperature Sensor Signal circuit.
POSSIBLE CAUSES
LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

LEFT HEATER CORE TEMPERATURE SENSOR OPEN
LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
LEFT HEATER CORE TEMPERATURE SENSOR GROUND OPEN
LEFT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
Diagnostic Test
1. READ LEFT HEATER CORE TEMPERATURE SENSOR VOLTAGE

WITH DRB IIIT

With the DRB IIIT, read the Left Heater Core Temperature Sensor voltage.
Does the DRB IIIT display LEFT HEATER CORE TEMP: 5.0 VOLTS
or greater?
Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE LEFT HEATER CORE

TEMPERATURE SENSOR SIGNAL CIRCUIT

Disconnect the Heater Core Temperature Sensor harness connector.
Measure the voltage of the Left Heater Core Temperature Sensor Signal
circuit at the Heater Core Temperature Sensor harness connector.

Yes >> Repair the Left Heater Core Temperature Sensor Signal cir-
cuit for a short to voltage.
No >> Go to 3
WITH DRB III

Connect a jumper wire between the Left Heater Core Temperature Sensor
Signal circuit and the Sensor Ground circuit.
or greater?
Yes >> Go to 4
No >> Replace the Heater Core Temperature Sensor. Refer to
Page 24-85
4. MEASURE THE RESISTANCE OF THE LEFT HEATER CORE


Measure the resistance of the Left Heater Core Temperature Sensor Sig-
nal circuit from the A/C Heater Control Module harness connector to the
Heater Core Temperature Sensor harness connector.

Yes >> Go to 5
No >> Repair the Left Heater Core Temperature Sensor Signal

Measure the resistance of the Sensor Ground circuit from the A/C Heater
Control Module harness connector to the Heater Core Temperature Sensor
harness connector.

Yes >> Replace the A/C Heater Control Module. Refer to Page
24-79
WITH DRB IIIT

or greater?
Yes >> Go to 7
No >> Go to 9

Reconnect the Heater Core Temperature Sensor connector.
Wait two minutes.
Does the DRB IIIT display Left Heater Core Temperature Sensor
Failure DTC?
Yes >> Replace the Heater Core Temperature Sensor. Refer to
Page 24-85
No >> Go to 8

Ensure the Heater Core Temperature Sensor is connected at this time.
Start the engine.
Turn the A/C system on.
Does the DRB IIIT display Left Heater Core Temperature Sensor
Failure DTC?
Page 24-85
HEATER CORE TEMPERATURE SENSOR SIGNAL
CIRCUIT

Measure the resistance between ground and the Left Heater Core Tem-
perature Signal circuit.

cuit for a short to ground.
No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE LEFT HEATER CORE


Measure the resistance from the Left Heater Core Temperature Sensor
Signal circuit to the Sensor Ground circuit at the Heater Core Temperature
Sensor connector.

cuit for a short to the Sensor Ground circuit.
Page 24-79
RIGHT HEATER CORE TEMPERATURE SENSOR CIRCUIT
RIGHT HEATER CORE TEMPERATURE SENSOR CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormally high or low voltage on the Right
Heater Core Temperature Sensor Signal circuit.
POSSIBLE CAUSES
RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

RIGHT HEATER CORE TEMPERATURE SENSOR OPEN
RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
RIGHT HEATER CORE TEMPERATURE SENSOR GROUND OPEN
RIGHT HEATER CORE TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
Diagnostic Test
1. READ RIGHT HEATER CORE TEMPERATURE SENSOR VOLTAGE

WITH DRB IIIT

With the DRB IIIT, read the Right Heater Core Temperature Sensor volt-
age.
Does the DRB IIIT display Right HEATER CORE TEMP: 5.0 VOLTS
or greater?
Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE RIGHT HEATER CORE


Measure the voltage of the Right Heater Core Temperature Sensor Signal
circuit at the Heater Core Temperature Sensor harness connector.

Yes >> Repair the Right Heater Core Temperature Sensor Signal
No >> Go to 3
WITH DRB IIIT

Connect a jumper wire between the Right Heater Core Temperature Sen-
sor Signal circuit and the Sensor Ground circuit.
age.
Does the DRB IIIT display RIGHT HEATER CORE TEMP: 4.5 VOLTS
or greater?
Yes >> Go to 4
No >> Replace the Heater Core Temperature Sensor. Refer to
Page 24-85.
4. MEASURE THE RESISTANCE OF THE RIGHT HEATER CORE


Measure the resistance of the Right Heater Core Temperature Sensor Sig-
nal circuit from the A/C Heater Control Module harness connector to the
Heater Core Temperature Sensor harness connector.

Yes >> Go to 5
No >> Repair the Right Heater Core Temperature Sensor Signal

Control Module harness connector to the Heater Core Temperature Sensor
harness connector.

24-79.
WITH DRB IIIT

age.
Does the DRB IIIT display RIGHT HEATER CORE TEMP: 4.5 VOLTS
or greater?
Yes >> Go to 7
No >> Go to 9

Reconnect the Heater Core Temperature Sensor connector.
Wait two minutes.
Does the DRB IIIT display Right Heater Core Temperature Sensor
Failure DTC?
Page 24-85.
No >> Go to 8

Ensure the Heater Core Temperature Sensor is connected at this time.
Start the engine.
Turn the A/C system on.
Does the DRB IIIT display Right Heater Core Temperature Sensor
Failure DTC?
Page 24-85.
HEATER CORE TEMPERATURE SENSOR SIGNAL
CIRCUIT

Measure the resistance between ground and the Right Heater Core Tem-
perature Signal circuit.

No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE RIGHT HEATER CORE


Measure the resistance from the Right Heater Core Temperature Sensor
Signal circuit to the Sensor Ground circuit at the Heater Core Temperature
Sensor connector.

circuit for a short to the Sensor Ground circuit.
Page 24-79.
EVAPORATOR TEMPERATURE SENSOR CIRCUIT
EVAPORATOR TEMPERATURE SENSOR CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormally high or low voltage on the Evap-
orator Temperature Sensor Signal circuit.
POSSIBLE CAUSES
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

EVAPORATOR TEMPERATURE SENSOR OPEN
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
EVAPORATOR TEMPERATURE SENSOR GROUND OPEN
EVAPORATOR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
Diagnostic Test
1. READ EVAPORATOR TEMPERATURE SENSOR VOLTAGE WITH

DRB IIIT

With the DRB IIIT, read the Evaporator Temperature Sensor voltage.
Does the DRB IIIT display EVAP TEMP: 5.0 VOLTS or greater?
Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE EVAPORATOR TEMPERATURE


Disconnect the Evaporator Temperature Sensor harness connector.
Measure the voltage of the Evaporator Temperature Sensor Signal circuit
at the Evaporator Temperature Sensor harness connector.

Yes >> Repair the Evaporator Temperature Sensor Signal circuit for
a short to voltage.
No >> Go to 3
DRB IIIT

Connect a jumper wire between the Evaporator Temperature Sensor Sig-
nal circuit and the Sensor Ground circuit.
Yes >> Go to 4
No >> Replace the Evaporator Temperature Sensor. Refer to
Page 24-84.
4. MEASURE THE RESISTANCE OF THE EVAPORATOR


Measure the resistance of the Evaporator Temperature Sensor Signal cir-
cuit from the A/C Heater Control Module harness connector to the Evap-
orator Temperature Sensor harness connector.

Yes >> Go to 5
No >> Repair the Evaporator Temperature Sensor Signal circuit
for an open.

Control Module harness connector to the Evaporator Temperature Sensor
harness connector.

24-79.
DRB IIIT

Disconnect the Evaporator Temperature Sensor harness connector.
Yes >> Go to 7
No >> Go to 9

Reconnect the Evaporator Temperature Sensor connector.
Wait two minutes.
Does the DRB IIIT display Evaporator Temperature Sensor Failure

DTC?
Yes >> Replace the Evaporator Temperature Sensor. Refer to
Page 24-84.
No >> Go to 8

Ensure the Evaporator Temperature Sensor is connected at this time.
Start the engine.
Turn the A/C system on and run for at least five minutes (so water will
form on the Evaporator Temperature Sensor).
Does the DRB IIIT display an Evaporator Temperature Sensor Fail-

ure DTC?
Yes >> Replace the Evaporator Temperature Sensor. Refer to
Page 24-84.
EVAPORATOR TEMPERATURE SENSOR SIGNAL
CIRCUIT

Measure the resistance between ground and the Evaporator Temperature
Signal circuit.

a short to ground.
No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE EVAPORATOR


Measure the resistance from the Evaporator Temperature Sensor Signal
circuit to the Sensor Ground circuit at the Evaporator Temperature Sensor
harness connector.

Page 24-79
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module reports an abnormally high or low voltage that is detected
by the Instrument Cluster. The abnormal condition is at the Powertrain Control Module (PCM) on the Engine
Coolant Temperature Sensor Signal circuit. The abnormal condition is communicated from the PCM to the
Instrument Cluster by the CAN bus.
POSSIBLE CAUSES
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

ENGINE COOLANT TEMPERATURE SENSOR OPEN
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN
ENGINE COOLANT TEMPERATURE SENSOR GROUND OPEN
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORT TO GROUND
Diagnostic Test
1. READ ENGINE COOLANT TEMPERATURE SENSOR VOLTAGE

WITH DRB IIIT

With the DRB IIIT, read the Engine Coolant Temperature Sensor voltage.
Does the DRB IIIT display ENGINE COOLANT TEMP: 5.0 VOLTS or
greater?
Yes >> Go to 2
No >> Go to 6
2. MEASURE THE VOLTAGE OF THE ENGINE COOLANT


Disconnect the Engine Coolant Temperature Sensor harness connector.
Measure the voltage of the Engine Coolant Temperature Sensor Signal
Circuit at the Engine Coolant Temperature Sensor harness connector.

Yes >> Repair the Engine Coolant Temperature Sensor Signal cir-
cuit for a short to voltage.
No >> Go to 3
WITH DRB IIIT

Connect a jumper wire between the Engine Coolant Temperature Sensor
Signal circuit and the Sensor Ground circuit.
greater?
Yes >> Go to 4
to Page 7-29.
4. MEASURE THE RESISTANCE OF THE ENGINE COOLANT


Disconnect the Powertrain Control Module harness connector.
Measure the resistance of the Engine Coolant Temperature Sensor Signal
circuit from the Powertrain Control Module harness connector to the
Engine Coolant Temperature Sensor harness connector.

Yes >> Go to 5
No >> Repair the Engine Coolant Temperature Sensor Signal

Measure the resistance of the Sensor Ground circuit from the Powertrain
Control Module harness connector to the Engine Coolant Temperature

8E-56.
WITH DRB IIIT

Disconnect the Engine Coolant Temperature Sensor harness connector.
greater?
Yes >> Go to 7
No >> Go to 9

Reconnect the Engine Coolant Temperature Sensor connector.
Wait two minutes.
Does the DRB IIIT display an Engine Coolant Temperature Sensor

Failure DTC?
Yes >> Replace the Engine Coolant Temperature Sensor. Refer to
Page 7-29.
No >> Go to 8

Ensure the Engine Coolant Temperature Sensor is connected at this time.
Start the engine.
Does the DRB IIIT display an Engine Coolant Temperature Sensor

Failure DTC?
Yes >> Replace the Engine Coolant Temperature Sensor. Refer to
Page 7-29.
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
CIRCUIT

Disconnect the Powertrain Control Module harness connector.
Measure the resistance between ground and the Engine Coolant Temper-
ature Signal circuit at the Powertrain Control Module connector.

cuit for a short to ground.
No >> Go to 10
10. MEASURE THE RESISTANCE FROM THE ENGINE COOLANT


Measure the resistance from the Engine Coolant Temperature Sensor Sig-
nal circuit to the Sensor Ground circuit at the Engine Coolant Temperature

cuit for a short to the Sensor Ground circuit.
No >> Replace the Powertrain Control Module. Refer to
Page 8E-56.
A/C PRESSURE SENSOR CIRCUIT
A/C PRESSURE SENSOR CIRCUIT — CONTINUED
• When Monitored: Engine Running with the A/C on.
• Set Condition: The A/C Heater Control Module detects an abnormally high or low voltage on the A/C
Pressure Sensor Signal circuit.
POSSIBLE CAUSES
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE

A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO 5-VOLT SUPPLY CIRCUIT
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
A/C PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT
A/C PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT OPEN
A/C PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
A/C PRESSURE SENSOR
A/C PRESSURE SENSOR SIGNAL CIRCUIT OPEN
A/C PRESSURE SENSOR GROUND CIRCUIT OPEN
Diagnostic Test
1. READ A/C PRESSURE SENSOR VOLTAGE WITH DRB IIIT

Note: Ensure the A/C refrigerant system is properly charged to spec-
ifications.
With the DRB IIIT, read the A/C Pressure Sensor voltage.

Yes >> Go to 2
No >> Go to 7
2. MEASURE THE RESISTANCE FROM THE A/C PRESSURE SENSOR
SIGNAL CIRCUIT TO THE 5-VOLT SUPPLY CIRCUIT

Disconnect the A/C Pressure Sensor harness connector.
Measure the resistance from the A/C Pressure Sensor Signal circuit to the
5-Volt supply circuit at the A/C Pressure Sensor harness connector.

Yes >> Repair the A/C Pressure Sensor Signal circuit for a short to
the 5-Volt Supply circuit.
No >> Go to 3
3. MEASURE THE VOLTAGE ON THE A/C PRESSURE SENSOR

SIGNAL CIRCUIT

Measure the voltage on the A/C Pressure Sensor Signal circuit at the A/C
Pressure Sensor harness connector.

battery voltage.
No >> Go to 4
4. MONITOR A/C PRESSURE SENSOR VOLTAGE WITH DRB IIIT

Connect a jumper wire between the A/C Pressure Sensor Signal circuit
and the Sensor ground circuit.
With the DRB IIIT, monitor the A/C Pressure Sensor voltage.

Yes >> Replace the A/C Pressure Sensor. Refer to Page 24-86.
No >> Go to 5
5. MEASURE THE RESISTANCE OF THE A/C PRESSURE SENSOR
SIGNAL CIRCUIT

Measure the resistance of the A/C Pressure Sensor Signal circuit from the
A/C Heater Control Module harness connector to the A/C Pressure Sensor
harness connector.

Yes >> Go to 6
No >> Repair the A/C Pressure Sensor Signal circuit for an
open.
6. MEASURE THE RESISTANCE BETWEEN GROUND AND THE A/C

PRESSURE SENSOR GROUND CIRCUIT

Measure the resistance between ground and the A/C Pressure Sensor
Ground circuit at the A/C Pressure Sensor harness connector.

24-79.
No >> Repair the A/C Pressure Sensor ground circuit for an
open.
7. READ A/C PRESSURE SENSOR VOLTAGE WITH DRB IIIT

With the DRB IIIT, read the A/C Pressure Sensor voltage.
Is the voltage below 0.5 of a volt?

Yes >> Go to 8
Disconnect the A/C Pressure Sensor harness connector.
Measure the voltage of the 5-Volt Supply circuit at the A/C Pressure Sen-

Yes >> Go to 9
No >> Go to 12
9. MONITOR A/C PRESSURE SENSOR VOLTAGE WITH DRB IIIT

With the DRB IIIT, monitor the A/C Pressure Sensor voltage.
Is the voltage above 0.5 of a volt?

Yes >> Replace the A/C Pressure Sensor. Refer to Page 24-86
No >> Go to 10

PRESSURE SENSOR SIGNAL CIRCUIT

Measure the resistance between ground and the A/C Pressure Sensor
Signal circuit in the A/C Pressure Sensor harness connector.

ground.
No >> Go to 11
11. MEASURE THE RESISTANCE FROM THE A/C PRESSURE
SENSOR SIGNAL CIRCUIT TO THE SENSOR GROUND
CIRCUIT

Measure the resistance from the A/C Pressure Sensor Signal circuit to the
Sensor Ground circuit at the A/C Pressure Sensor harness connector.

the Sensor Ground circuit.
Page 24-79.

PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT

Measure the resistance between ground and the 5-Volt Supply circuit at
the A/C Pressure Sensor harness connector.

No >> Go to 13
13. MEASURE THE RESISTANCE OF THE A/C PRESSURE SENSOR


Measure the resistance of the 5-Volt Supply circuit from the A/C Pressure
Sensor harness connector to the A/C Heater Control Module harness con-
nector.

24-79.
No >> Repair the A/C Pressure Sensor 5-Volt Supply circuit
for an open.
COOLANT CIRCULATION PUMP CIRCUIT
COOLANT CIRCULATION PUMP CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormal condition on the Coolant Circulation
Pump Control circuit.
POSSIBLE CAUSES

COOLANT CIRCULATION PUMP CONTROL CIRCUIT OPEN
COOLANT CIRCULATION PUMP
Diagnostic Test
1. MEASURE COOLANT CIRCULATION PUMP VOLTAGE

continuing.
Disconnect the Coolant Circulation Pump harness connector.
Measure the voltage of the Fused B(+) circuit at the Coolant Circulation
Pump harness connector.

Yes >> Go to 2
No >> Repair the Coolant Circulation Pump Fused B(+) circuit.
2. MEASURE THE VOLTAGE OF THE COOLANT CIRCULATION PUMP

CONTROL CIRCUIT

Connect a jumper wire between the terminals in the Coolant Circulation
Pump harness connector.
Measure the voltage of the Coolant Circulation Pump Control circuit at the

Yes >> Go to 3
No >> Repair the Coolant Circulation Pump Control circuit for
an open.
COOLANT CIRCULATION PUMP CIRCUIT — CONTINUED
3. MEASURE THE VOLTAGE OF THE COOLANT CIRCULATION PUMP
CONTROL CIRCUIT

Reconnect the Coolant Circulation Pump harness connector.
Measure the voltage of the Coolant Circulation Pump Control circuit at the

24-79.
No >> Replace the Coolant Circulation Pump. Refer to Page
24-123.
LEFT COOLANT CIRCULATION VALVE CIRCUIT
LEFT COOLANT CIRCULATION VALVE CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormal condition on the Left Coolant Circu-
lation Valve Control circuit.
POSSIBLE CAUSES

LEFT COOLANT CIRCULATION VALVE CONTROL CIRCUIT OPEN
LEFT COOLANT CIRCULATION VALVE
Diagnostic Test
1. MEASURE COOLANT CIRCULATION VALVE VOLTAGE

continuing.
Disconnect the Coolant Circulation Valve harness connector.

Yes >> Go to 2
No >> Repair the Coolant Circulation Valve Fused B(+) circuit.
2. MEASURE THE VOLTAGE OF THE LEFT COOLANT CIRCULATION

VALVE CONTROL CIRCUIT

Connect a jumper wire between the Left Coolant Circulation Valve termi-
nals in the Coolant Circulation Valve harness connector.
Measure the voltage of the Left Coolant Circulation Valve Control circuit at
the A/C Heater Control Module harness connector.

Yes >> Go to 3
No >> Repair the Left Coolant Circulation Valve Control circuit
for an open.
LEFT COOLANT CIRCULATION VALVE CIRCUIT — CONTINUED
3. MEASURE THE VOLTAGE OF THE LEFT COOLANT CIRCULATION

Reconnect the Coolant Circulation Valve harness connector.
Measure the voltage of the Left Coolant Circulation Valve Control circuit at
the A/C Heater Control Module harness connector.

24-79.
No >> Replace the Coolant Circulation Valve. Refer to Page
24-140.
RIGHT COOLANT CIRCULATION VALVE CIRCUIT
RIGHT COOLANT CIRCULATION VALVE CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormal condition on the Right Coolant Cir-
culation Valve Control circuit.
POSSIBLE CAUSES

RIGHT COOLANT CIRCULATION VALVE CONTROL CIRCUIT OPEN
RIGHT COOLANT CIRCULATION VALVE
Diagnostic Test
1. MEASURE COOLANT CIRCULATION VALVE VOLTAGE

continuing.
Disconnect the Coolant Circulation Valve harness connector.

Yes >> Go to 2
No >> Repair the Coolant Circulation Valve Fused B(+) circuit.
2. MEASURE THE VOLTAGE OF THE RIGHT COOLANT CIRCULATION


Connect a jumper wire between the Right Coolant Circulation Valve termi-
nals in the Coolant Circulation Valve harness connector.
Measure the voltage of the Right Coolant Circulation Valve Control circuit
at the A/C Heater Control Module harness connector.

Yes >> Go to 3
No >> Repair the Right Coolant Circulation Valve Control circuit
for an open.
RIGHT COOLANT CIRCULATION VALVE CIRCUIT — CONTINUED
3. MEASURE THE VOLTAGE OF THE RIGHT COOLANT CIRCULATION

Reconnect the Coolant Circulation Valve harness connector.
Measure the voltage of the Right Coolant Circulation Valve Control circuit
at the A/C Heater Control Module harness connector.

24-79
No >> Replace the Coolant Circulation Valve. Refer to Page
24-140.
A/C COMPRESSOR CLUTCH CIRCUIT
A/C COMPRESSOR CLUTCH CIRCUIT — CONTINUED
• When Monitored: Engine Running with the A/C on.
• Set Condition: The A/C Heater Control Module detects an A/C Compressor malfunction.
POSSIBLE CAUSES
A/C COMPRESSOR CLUTCH SIGNAL CIRCUIT OPEN

A/C COMPRESSOR CLUTCH
For a complete HVAC Circuit Diagram Refer to Page 24-54.
Diagnostic Test
1. TEST THE A/C COMPRESSOR CLUTCH

Disconnect the inline connector C106 in the underhood relay control mod-
ule compartment.
Using a jumper wire to battery power, energize the A/C Compressor
clutch.
Does the A/C Compressor clutch energize?

Yes >> Go to 2
No >> Go to 3
2. MEASURE THE RESISTANCE OF THE A/C COMPRESSOR CLUTCH

SIGNAL CIRCUIT

Measure the resistance of the A/C Compressor Clutch signal circuit from
the inline connector C106 to the A/C Heater Control Module harness con-
nector.

24-79.
No >> Repair the A/C Compressor Clutch signal circuit for an
open.
A/C COMPRESSOR CLUTCH CIRCUIT — CONTINUED
3. MEASURE THE RESISTANCE OF THE A/C COMPRESSOR CLUTCH
SIGNAL CIRCUIT

Disconnect the A/C Compressor Clutch connector.
Measure the resistance of the A/C Compressor Clutch signal circuit from
the inline connector C106 to the A/C Compressor Clutch connector.

Yes >> Replace the A/C Compressor Clutch. Refer to Page
24-121.
No >> Repair the A/C Compressor Clutch signal circuit for an
open.
RECIRCULATED AIR SWITCHOVER VALVE CIRCUIT
RECIRCULATED AIR SWITCHOVER VALVE CIRCUIT — CONTINUED
• Set Condition: The A/C Heater Control Module detects an abnormal condition on the Recirculated Air
Switchover Valve Control circuit.
POSSIBLE CAUSES

RECIRCULATED AIR SWITCHOVER VALVE CONTROL CIRCUIT OPEN
RECIRCULATED AIR SWITCHOVER VALVE
Diagnostic Test
1. MEASURE RECIRCULATED AIR SWITCHOVER VALVE VOLTAGE

continuing.
Disconnect the Recirculated Air Switchover Valve harness connector.
Measure the voltage of the Fused B(+) circuit at the Recirculated Air
Switchover Valve harness connector.

Yes >> Go to 2
No >> Repair the Recirculated Air Switchover Valve Fused B(+)
circuit.
2. MEASURE THE RESISTANCE OF THE RECIRCULATED AIR

SWITCHOVER VALVE CONTROL CIRCUIT

Disconnect the Recirculated Air Switchover Valve harness connector.
Measure the resistance of the Recirculated Air Switchover Valve Control
circuit from the Recirculated Air Switchover Valve harness connector to the

Yes >> Go to 3
No >> Repair the Recirculated Air Switchover Valve Control cir-
cuit for an open.
RECIRCULATED AIR SWITCHOVER VALVE CIRCUIT — CONTINUED
3. MEASURE THE VOLTAGE OF THE RECIRCULATED AIR
SWITCHOVER VALVE CONTROL CIRCUIT
Reconnect the Recirculated Air Switchover Valve connector.

Measure the voltage of the Recirculated Air Switchover Valve Control cir-
cuit at the A/C Heater Control Module harness connector.

24-79.
No >> Replace the Recirculated Air Switchover Valve. Refer
to Page 24-87.
NO COMMUNICATION FROM INSTRUMENT CLUSTER
NO COMMUNICATION FROM INSTRUMENT CLUSTER — CONTINUED
ment Cluster.
POSSIBLE CAUSES

INSTRUMENT CLUSTER
Diagnostic Test

K1 CIRCUIT

harness connector.

24-79.
open.
NO COMMUNICATION TO INSTRUMENT CLUSTER
NO COMMUNICATION TO INSTRUMENT CLUSTER — CONTINUED
ment Cluster.
POSSIBLE CAUSES

INSTRUMENT CLUSTER
Diagnostic Test

K2 CIRCUIT

harness connector.

24-79.
open.
1.

HVAC SYSTEM CIRCUIT DIAGRAM

ZH HEATING & AIR CONDITIONING - SERVICE INFORMATION 24 - 55
HEATING & AIR CONDITIONING - SERVICE INFORMATION
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING - SERVICE OPERATION - REST SYSTEM . . . . . . . . . . . . 64

INFORMATION DIAGNOSIS AND TESTING
DESCRIPTION A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . 64
COOLING SYSTEM REQUIREMENTS . . . . . . 55 DIAGNOSIS AND TESTING - HEATER
DESCRIPTION - HEATER AND AIR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 68
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . 55 SPECIFICATIONS
DESCRIPTION - RESIDUAL ENGINE HEAT A/C APPLICATION TABLE . . . . . . . . . . . . . . . 70
SYSTEM (REST) . . . . . . . . . . . . . . . . . . . . . . 57 SPECIFICATIONS - CHARGE CAPACITY . . . . 70
DESCRIPTION - REFRIGERANT SYSTEM SPECIFICATIONS - TORQUE . . . . . . . . . . . . 70
SERVICE PORT . . . . . . . . . . . . . . . . . . . . . . . 58 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 88
HEATER AND AIR CONDITIONER . . . . . . . . . 59 PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
HEATING & AIR CONDITIONING - SERVICE INFORMATION

DESCRIPTION
COOLING SYSTEM REQUIREMENTS
To maintain the performance level of the heating-air conditioning system, the engine cooling system must be prop-
erly maintained. Any obstructions in front of the radiator or condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The engine cooling system includes the heater core and the heater hoses. Refer to Cooling for more information
before opening, or attempting any service to the engine cooling system.
DESCRIPTION - HEATER AND AIR CONDITIONER

WARNING: THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE
PERFORMED BY QUALIFIED SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRI-
TATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDI-
TIONING REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE
REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGER-
ANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SER-
VICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL
FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE
REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DAN-
GEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.
24 - 56 HEATING & AIR CONDITIONING - SERVICE INFORMATION ZH
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with
the service equipment being used.
Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can
cause noise and system failure.
Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after
the system has been discharged. Never open or loosen a connection before recovering the refrigerant.
The refrigerant system must always be evacuated before charging.
Do not open the refrigerant system or uncap a replacement component until you are ready to service the
system. This will prevent contamination in the system.
Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination
from entering the refrigerant system.
Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap
or plug.
Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal
with clean refrigerant oil before connecting.
Do not remove the sealing caps from a replacement component until it is to be installed.
When installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. Position the refrig-
erant lines away from exhaust system components or any sharp edges, which may damage the line.
Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refrigerant system
will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a wrench on both halves of the fitting. This will prevent twist-
ing of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrig-
erant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store
refrigerant oil only in a clean, airtight, and moisture-free container.
Keep service tools and the work area clean. Contamination of the refrigerant system through careless work
habits must be avoided.
A manual dual-zone temperature control type heating-air conditioning system is standard on this model.
1 - INLET AIR DUCT 4 - FLOOR VENT OUTLET

2 - BLOWER MOTOR 5 - HEATER CORE
3 - SIDE VENT OUTLET 6 - EVAPORATOR
This vehicle is equipped with a common HVAC housing assembly. The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing mounted under the instrument panel.
DESCRIPTION - RESIDUAL ENGINE HEAT SYSTEM (REST)

The Residual Engine Heat System (REST) system enables the
vehicle to be heated with the ignition “OFF”. A switch (4) in the
heater-A/C controls activates this system.
DESCRIPTION - REFRIGERANT SYSTEM SERVICE PORT

The two refrigerant system service ports are used to charge,
recover/recycle, evacuate, and test the air conditioning refrig-
erant system.
Note:
Unique service port coupler sizes are used on the R-134a
system to ensure that the refrigerant system is not acci-
dentally contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
The high pressure service port (1) is located on the liquid line
near the front of the engine compartment behind the front
grille.
The low pressure service port (1) is located on the suction line
on the left side of the engine compartment near the shock
mounting.
OPERATION
HEATER AND AIR CONDITIONER

Outside fresh air enters the vehicle through the cowl top opening at the base of the windshield (1), and passes
through a plenum chamber to the HVAC housing. Air flow can then be adjusted by the blower motor (2) speed
switch on the A/C heater control panel. The fresh air then travels through the evaporator (6) and the heater core (5)
then out into the vehicle through the side and floor vents (3-4).
It is also important to keep the air intake openings clear of debris because leaf particles and other debris that is
small enough to pass through the cowl plenum screen can accumulate within the HVAC housing. This closed, warm,
damp and dark environment created within the HVAC housing is ideal for the growth of certain molds, mildews and
other fungi. Any accumulation of decaying plant matter provides an additional food source for fungal spores, which
can enter the housing with the fresh air. Excess debris, as well as objectionable odors created by decaying plant
matter and growing fungi can be discharged into the passenger compartment during HVAC system operation.
AIR CONDITIONING
The A/C compressor (8) is driven by the engines accessory
drive belt. The A/C compressor (8) compresses the gaseous
refrigerant (7) which heats up and flows into the condenser
(6). The heat resulting from the compression is absorbed from
the refrigerant by the surface of the condenser (6). As the
refrigerant cools down it liquefies becoming a high-pressure
liquid (4). As the refrigerant (4) flows through the receiver/drier
(5) it is purified of chemical and mechanical impurities. It then
travels to the expansion valve (3) which sprays the cooled, low
pressure liquid (4) into the evaporator (1), located in the fresh
air flow. The refrigerant (4) evaporates in the evaporator (1).
This evaporation process absorbs heat from the fresh air flow-
ing across the system of tubes and honeycombs, therefore
cooling the air that is blown into the passenger compartment.
The low pressure gas then returns to the A/C compressor.
The moisture in the fresh air is condensed out and the condensation drained to the outside through a drain in the
HVAC housing. The air is dried. The A/C compressor sucks in the refrigerant which has become gaseous due to the
absorption of heat and compresses it again. When the engine is running and with blower switched on, cooled air
can flow into the passenger compartment through various outlet openings. The intensity of cooling depends on the
passenger compartment temperature set and the blower output.
The mode control on the A/C heater control panel is used to

direct the conditioned air to the selected system outlets. The
mode control switches directs engine vacuum to control the
mode doors, which are operated by vacuum actuators. The
mode control switches electrical current to control the mode
doors, which are operated by actuators.
• Mode Control (1)
• Passenger Temperature Control (2)
• Air Conditioning Button (3)
• REST Button (4)
• Driver’s Temperature Control (5)
• Fan Control (6)
• Rear Defogger Button (7)
HEATER SYSTEM
1 - RESERVOIR 5 - COOLANT CIRCULATION PUMP

2 - THERMOSTAT 6 - COOLANT CIRCULATION VALVE
3 - ENGINE 7 - WATER PUMP
The water pump (7) pumps coolant through the engine (3). There the coolant absorbs heat from the engine (3),
heating up the coolant. Then the heated coolant flows through into the heater core (4) where the heat is transferred
to the air in the passenger compartment. The coolant flowing through the heater core (4) is controlled by a coolant
circulation valve (6) located in the coolant return. The coolant can be controlled separately for the left and right
sides.
The coolant returns to the water pump (7) via the coolant return hose. A coolant circulation pump (5) is installed
between the coolant circulation valve (6) and the water pump (7). The coolant circulation pump (5) serves for main-
taining a uniform flow of heating water through the heater core (4) even at low engine speeds and in the residual
engine heat utilization mode (REST). The major portion of the coolant flows from the engine (3) to the thermostat (2)
instead of flowing through the heater core (4). The thermostat (2) routes the water through the radiator (8) or directly
to the water pump (7) depending on the temperature.
1 - INLET AIR DUCT 3 - HEATER CORE

2 - BLOWER MOTOR
In a blend-air system, a blend door controls the amount of unconditioned air (or cooled air from the evaporator) that
is allowed to flow through, or around, the heater core (3). A temperature control knob on the A/C heater control
panel determines the discharge air temperature by energizing the blend door actuator, which operates the blend
door. This allows an almost immediate control of the output air temperature of the system.
R.E.S.T. SYSTEM
1 - RESERVOIR 5 - COOLANT CIRCULATION PUMP

2 - THERMOSTAT 6 - COOLANT CIRCULATION VALVE
3 - ENGINE 7 - WATER PUMP
The coolant circulation pump pumps the heated coolant to the

heater core when the engine is off. When the REST button (4)
is pressed the temperature is controlled by the A/C heater con-
trol module (in the same manner as when the ignition is ON).
The A/C heater control module switches the coolant circulation
pump on which drives the impeller via a magnetic clutch. A
light in the switch will illuminate indicating that the REST sys-
tem is active.
OPERATION - REST SYSTEM

The REST system is activated by a switch in the heater-A/C controls when the ignition is turned “OFF”. This system
circulates residual heat from the engine to the heater core. The coolant is recirculated by an auxiliary coolant pump
mounted below the right front headlamp. The temperature is automatically adjusted according to the temperature
setting in the heater-A/C controls. The REST system will automatically be shut off when:
• The ignition key is turned “ON”.
• After approximately 30 minutes of operation.
• If the battery voltage falls below 11.5 volts.

A/C PERFORMANCE

The air conditioning system is designed to provide the passenger compartment with low temperature and low
humidity air. The evaporator (6), located in the HVAC housing behind the instrument panel, is cooled to tempera-
tures near the freezing point. As warm damp air passes through the cooled evaporator (6), the air transfers its heat
to the refrigerant in the evaporator (6) and the moisture in the air condenses on the evaporator fins.
Humidity has an important bearing on the temperature of the air delivered to the interior of the vehicle. It is impor-
tant to understand the effect that humidity has on the performance of the air conditioning system. When humidity is
high, the evaporator has to perform a double duty. It must lower the air temperature, and it must lower the temper-
ature of the moisture in the air that condenses on the evaporator fins. Condensing the moisture in the air transfers
heat energy into the evaporator fins and tubing. This reduces the amount of heat the evaporator can absorb from
the air. High humidity greatly reduces the ability of the evaporator to lower the temperature of the air.
However, evaporator capacity used to reduce the amount of moisture in the air is not wasted. Wringing some of the
moisture out of the air entering the vehicle adds to the comfort of the passengers. Although, an owner may expect
too much from their air conditioning system on humid days. A performance test is the best way to determine
whether the system is performing up to standard. This test also provides valuable clues as to the possible cause of
trouble with the air conditioning system.
The air temperature in the test room and in the vehicle must be a minimum of 21° C (70° F) for this test.
1. Connect a manifold gauge set.
2. Set the A/C Heater mode control switch knob (2) in the
Panel position, the temperature control knob (7) in the full
cool position, the A/C button in the On position, and the
blower motor switch knob (6) in the highest speed position.
3. Start the engine and hold the idle at 1,300 rpm with the
compressor clutch engaged.
4. The engine should be at operating temperature. The doors
and windows must be open.
5. Insert a thermometer in the driver side center A/C (panel)
outlet. Operate the engine for five minutes.
6. The compressor clutch may cycle, depending upon the
ambient temperature and humidity.
7. With the compressor clutch engaged, record the discharge
air temperature and the compressor discharge pressure.
8. Compare the discharge air temperature to the Performance
Temperature and Pressure chart.
Performance Temperature and Pressure

Ambient Air 21° C 27° C 32° C 38° C 43° C
Temperature (70° F @ 80% (80° F @ 80% (90° F @ 80% (100° F @ (110° F @ 20%
and Humidity humidity) humidity) humidity) 50% humidity) humidity)
Air Temperature
10 to 13° C 14 to 17° C 15 to 18° C 17 to 20° C 14 to 17° C
at Center Panel
(50 to 55° F) (58 to 63° F) (60 to 65° F) (63 to 68° F) (58 to 63° F)
Outlet
Evaporator Inlet 241 to 276 262 to 290 269 to 296 275 to 303 262 to 290
Pressure at kPa kPa kPa kPa kPa
Charge Port (35 to 40 psi) (38 to 42 psi) (39 to 43 psi) (40 to 44 psi) (38 to 42 psi)
1241 to 1792 1380 to 1930 1380 to 1930 1655 to 2206
Compressor 1567 to 2068
kPa kPa kPa kPa
Discharge kPa
(180 to 260 (200 to 280 (200 to 280 (240 to 320
Pressure (220 to 300 psi)
psi) psi) psi) psi)
Note: The discharge air temperatures will be lower if the humidity is less than the percentages shown.
9. Compare the compressor discharge pressure to the Performance Temperature and Pressure chart. If the com-
pressor discharge pressure is high, see the Pressure Diagnosis chart.
Pressure Diagnosis
Rapid compressor clutch cycling 1. Low refrigerant system charge. 1. Test the A/C system for leaks.
(ten or more cycles per minute). Repair, evacuate and charge the
refrigerant system, if required.
Equal pressures, but the 1. No refrigerant in the refrigerant 1. Test the A/C system for leaks.
compressor clutch does not engage. system. Repair, evacuate and charge the
A/C, if required.
2. Faulty A/C compressor clutch 2. Test the compressor clutch coil
coil. and replace, if required.
3. Faulty A/C pressure transducer. 3. Test the A/C high pressure
transducer and replace, if required.
4. Faulty A/C Heater Control 4. Test the A/C Heater Control
Module. Module and replace, if required.
Normal pressures, but A/C 1. Excessive refrigerant oil in 1. Recover the refrigerant from the
Performance Test air temperatures system. refrigerant system and inspect the
at center panel outlet are too high. refrigerant oil content. Restore the
refrigerant oil to the proper level, if
required.
2. Blend door inoperative or sealing 2. Inspect the blend door for proper
improperly. operation and sealing and correct, if
required.
3. Blend door actuator faulty or 3. Replace if faulty.
inoperative.
The low side pressure is normal or 1. Low refrigerant system charge. 1. Test the refrigerant system for
slightly low, and the high side leaks. Repair, evacuate and charge
pressure is too low. the refrigerant system, if required.
2. Refrigerant flow through the 2. Replace the restricted receiver/
receiver/dryer is restricted. drier, if required.
3. Refrigerant flow through the Replace the restricted evaporator
evaporator is restricted. coil, if required.
4. Faulty compressor. Replace the compressor, if required.
The low side pressure is normal or 1. Condenser air flow restricted. 1. Check the condenser for
slightly high, and the high side damaged fins, foreign objects
pressure is too high. obstructing air flow through the
condenser fins, and missing or
improperly installed air seals. Clean,
repair, or replace components as
required.
2. Inoperative cooling fan. 2. Test the cooling fan and replace,
if required.
3. Refrigerant system overcharged. 3. Recover the refrigerant from the
refrigerant system. Charge the
refrigerant system to the proper
level, if required.
Pressure Diagnosis
4. Air in the refrigerant system. 4. Test the refrigerant system for

leaks. Repair, evacuate and charge
the refrigerant system, if required.
5. Engine overheating. 5. Test the cooling system and
repair, if required.
The low side pressure is too high, 1. Accessory drive belt slipping. 1. Inspect the accessory drive belt
and the high side pressure is too condition and tension. Tighten or
low. replace the accessory drive belt, if
required.
2. Faulty compressor. 2. Replace the compressor, if
required.
The low side pressure is too low, 1. Restricted refrigerant flow 1. Inspect the refrigerant lines for
and the high side pressure is too through the refrigerant lines. kinks, tight bends or improper
high. routing. Correct the routing or
replace the refrigerant line, if
required.
2. Restricted refrigerant flow 2. Replace the Expansion Valve if
through the A/C Expansion Valve. restricted.
3. Restricted refrigerant flow 3. Replace the restricted condenser,
through the condenser. if required.
DIAGNOSIS AND TESTING - HEATER PERFORMANCE

Before performing the following tests, refer to Cooling for the procedures to check the radiator coolant level, ser-
pentine drive belt tension, radiator air flow and the radiator fan operation. Also be certain that the accessory vacuum
supply line is connected at the engine intake manifold for the manual temperature control system.
MAXIMUM HEATER OUTPUT

Engine coolant is delivered to the heater core through two
heater hoses. With the engine idling at normal operating tem-
perature, set the temperature control knob (2 and 5) in the full
hot position, the mode control switch knob (1) in the floor heat
position, and the blower motor switch knob (6) in the highest
speed position. Using a test thermometer, check the tempera-
ture of the air being discharged at the HVAC housing floor out-
lets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
15.5° C 21.1° C 26.6° C 32.2° C
Ambient Air Temperature
(60° F) (70° F) (80° F) (90° F)
Minimum Air Temperature at 62.2° C 63.8° C 65.5° C 67.2° C
Floor Outlet (144° F) (147° F) (150° F) (153° F)
If the floor outlet air temperature is too low, refer to Cooling to check the engine coolant temperature specifications.
Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than
the coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine
coolant flow obstruction in the cooling system. Refer to the Cooling section for the procedures.
OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow:
• Pinched or kinked heater hoses.
• Improper heater hose routing.
• Plugged heater hoses or supply and return ports at the cooling system connections.
• A plugged heater core.
If proper coolant flow through the cooling system is verified, and heater outlet air temperature is still low, a mechan-
ical problem may exist.
MECHANICAL PROBLEMS
Possible locations or causes of insufficient heat:
• An obstructed cowl air intake.
• Obstructed heater system outlets.
• A blend door not functioning properly.
• An air-bound system.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the A/C Heater con-
trol panel, the following could require service:
• The A/C heater control.
• The blend door actuator(s).
• The wire harness circuits for the A/C heater control or the blend door actuator(s).
• The blend door(s).
• Improper engine coolant temperature.
SPECIFICATIONS
A/C APPLICATION TABLE
ITEM DESCRIPTION NOTES

SYSTEM R134a w/ expansion valve 1.97 lbs. (.88 kg.)
COMPRESSOR Nippendenso ND-8 PAG oil
FREEZE UP CONTROL —
At a coolant temperature >123 °C the duty factor is reduced by 50 %. In
this case the A/C compressor is switched on in cycles, i.e. off approx. 20
STAGE 1
sec. and on approx. 20 sec. If the coolant temperature drops to below
123 °C the A/C compressor is switched on again permanently.
At a coolant temperature >127 °C the A/C compressor is switched off
STAGE 2 completely. When the coolant temperature drops to below 127 °C the A/C
compressor is switched back on in the cycled mode (stage 1).
Refrigerant pressure < 2 bar = A/C compressor off
A/C PRESSURE TRANSDUCER
Refrigerant pressure >28 bar = A/C compressor off
CONTROL HEAD Manual type DRB IIIT
MODE DOORS Vacuum —
BLEND DOOR Vacuum —
BLOWER MOTOR — Resistor block
CLUTCH Electromagnetic Coil —
DRAW — —
DRB IIIT —
SPECIFICATIONS - CHARGE CAPACITY

The R-134a refrigerant system charge capacity for this vehicle is 0.88 kilograms (1.97 lbs.).

Expansion Valve Nut 10 7 88
Expansion Valve Bolt 8 6 71
Reservoir Fluid Lines 17 12 150
Compressor to Condensor Fluid Line 22 16 195
Condensor to Reservoir Fluid Line 17 12 150
Refrigerant Pressure Sensor 12 9 106
Refrigerant Temperature Sensor 6 5 53
High Pressure Line to Condensor 33 24 292
ZH CONTROLS 24 - 71
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH CONTROLS

DIAGNOSIS AND TESTING - COMPRESSOR EVAPORATOR TEMPERATURE SENSOR
CLUTCH COIL . . . . . . . . . . . . . . . . . . . . . . . . 73 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
STANDARD PROCEDURE - COMPRESSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
CLUTCH BREAK-IN . . . . . . . . . . . . . . . . . . . . 74 HEATER CORE TEMPERATURE SENSOR
BLOWER MOTOR REGULATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76 A/C PRESSURE TRANSDUCER
A/C HEATER CONTROL MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 RECIRC AIR SWITCHOVER VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
24 - 72 CONTROLS ZH
A/C COMPRESSOR CLUTCH

DESCRIPTION
1 - PULLEY 5 - SOLENOID
2 - MELTING FUSE 6 - PRESSURE PLATE
3 - BEARING 7 - RUBBER INSERT
4 - INPUT SHAFT 8 - SPLINES
The pulley (1) on the A/C compressor drive shaft (4) is driven by the poly-V-belt. The clutch turns on the ball bearing
(3) around the magnetic coil (5) fastened to the A/C compressor housing. The pressure plate (6) with rubber insert
(7) is connected to the A/C compressor drive shaft (4) by splines (8) allowing it to move in the axial direction.
ZH CONTROLS 24 - 73
OPERATION
1 - PULLEY 5 - SOLENOID
2 - MELTING FUSE 6 - PRESSURE PLATE
3 - BEARING 7 - RUBBER INSERT
4 - INPUT SHAFT 8 - SPLINES
In order to start operating the refrigerant compressor, the heater A/C control module actuates the electromagnetic
clutch and the solenoid (5) is supplied with electrical current. The magnetic force attracts the pressure plate (6)
against the rubber insert (7) and holds it securely. This creates the connection between the engine and the com-
pressor. If the solenoid (5) is de-energized, then the pressure plate (6) is pressed back by the rubber insert (7) into
its rest position and the connection is interrupted.
The clutch also preforms a safety shutoff of the compressor. To prevent a mechanical defect in the compressor from
causing the accessory drive belt to jump loose, the electromagnetic clutch releases itself automatically. With a
mechanical defect, the compressor rotates more sluggishly or even locks completely. The heat generated at the
friction surface causes the melting fuse (2) in the solenoid (5) to melt. The current supply to the solenoid (5) is
interrupted and the frictional connection is released.
The A/C compressor clutch is not serviced separately. The A/C compressor clutch must be replaced as a unit with
the A/C compressor.
DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH COIL

For circuit descriptions and diagrams, refer to the appropriate wiring diagrams. The battery must be fully-charged
before performing the following tests. Refer to Battery for more information.
1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt
scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil.
2. With the a/c heater mode control switch in any a/c mode, the a/c heater control a/c switch in the ON position,
and the blower motor switch in the lowest speed position, start the engine and run it at normal idle.
3. The compressor clutch coil voltage should read within 0.2 volts of the battery voltage. If there is voltage at the
clutch coil, but the reading is not within 0.2 volts of the battery voltage, test the clutch coil feed circuit for exces-
sive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRBIIIT scan tool
24 - 74 CONTROLS ZH
and the appropriate diagnostic information for testing of the compressor clutch circuit. The following components
must be checked and repaired as required before you can complete testing of the clutch coil:
• A/C heater control module mode control switch
• A/C pressure transducer
• A/C evaporator temperature sensor
4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes
with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temper-
ature at 21° C (70° F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical
accessories until the system voltage drops below 12.5 volts.
a. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced.
b. If the clutch coil current reading is zero, the coil is open and should be replaced.
STANDARD PROCEDURE - COMPRESSOR CLUTCH BREAK-IN

After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five
seconds on, then five seconds off). During this procedure, set the A/C Heater control in the Recirculation Mode, the
A/C button in the on position, the blower motor switch in the highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor
clutch torque capability.
BLOWER MOTOR REGULATOR

REMOVAL
1. Remove the lower instrument panel cover (2) from the
instrument panel (1). Refer to Page 23-149.
ZH CONTROLS 24 - 75
2. Disconnect the blower motor electrical connector (1) from

the relief in the blower motor door.
3. Slide the motor door catch mounts (1) to the sides.

4. Swing the blower motor door down.
Note: The electrical leads are a one-way connection to the

blower motor.
5. Disconnect the electrical leads blue (2) and red (3).

6. Remove the screws (1) attaching the blower motor regula-
tor (4) to the blower motor assembly.
7. Remove the electronic blower motor (4) regulator from the
assembly.
24 - 76 CONTROLS ZH
INSTALLATION
1. Install the electronic blower motor regulator assembly (4) to
the heater case.
2. Install the screws (1) attaching the blower motor regulator
to the blower motor assembly.
Note: The electrical leads are a one-way connection to the

blower motor.
3. Connect the electrical leads blue (2) and red (3).

4. Swing the blower motor door up.
5. Slide the motor door catch mounts (1) to the inside.

ZH CONTROLS 24 - 77
6. Connect the blower motor electrical connector (1).
7. Install the lower instrument panel cover. Refer to Page

23-155.
24 - 78 CONTROLS ZH

DESCRIPTION
The manual temperature control HVAC system uses a combi-
nation of electrical, and vacuum controls. These controls pro-
vide the vehicle operator with a number of setting options to
help control the climate and comfort within the vehicle. Refer
to the owner’s manual in the vehicle glove box for more infor-
mation on the suggested operation and use of these controls.
Both A/C heater control module panels are located on the
instrument panel inboard of the steering column and above the
radio. The A/C heater control panel contains two rotary-type
temperature control knobs (2 and 5), a rotary-type mode con-
trol switch knob (1), a rotary-type blower motor speed switch
knob (6) and an air conditioning compressor push button
switch (3).
OPERATION
Dual zone temperature control provides a side-to-side variation in comfort temperatures to exceed the needs of
either front seat occupant.
The A/C Heater Control Module panels are serviced only as complete units and cannot be repaired. If faulty or
damaged, the entire A/C Heater Control Module must be replaced.
The A/C Heater Control Module makes it possible to make adjustments coming from the driver such as:
• “Temperature” by setting the temperature thumb-
wheels. (2 and 5)
• “Air quantity” by adjusting the blower switch setting. (6)
• “Air distribution” by setting the air distribution switch.
(1)
• “Recirculating air” by pressing the recirculating air
push-button. (4)
• Activating the residual engine heat utilization system
with the ignition switched off by pressing the REST but-
ton. (4)
• Switching off the A/C by pressing the EC button (3).
ZH CONTROLS 24 - 79
The A/C Heater Control Module integrated in the push-button control module looks after all system regulation and
control functions, such as:
• Automatic switchover from fresh air to recirculated air mode.
• Electrical control of the A/C compressor.
• Control of the electric fan for the engine/air conditioning system.
REMOVAL
COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

2. Remove the radio. Refer to Page 8A-27.
3. Remove the center console panel screws (1). Refer to

Page 23-173.
24 - 80 CONTROLS ZH
4. Pull out the A/C heater control module by pressing in the

catch lugs (1) at the sides.
5. Disconnect the electrical connector (1) by swinging the

retaining bow down.
6. Remove the A/C heater control module.
ZH CONTROLS 24 - 81
INSTALLATION
CONNECT AND ISOLATE THE BATTERY NEGATIVE
1. Connect the electrical connector (1) by swinging the retain-

ing bow up.
2. Install the A/C heater control module (2) by pressing in the

catch lugs (1) at the sides.
24 - 82 CONTROLS ZH
3. Install the center console panel screws (1-2). Refer to

Page 23-183.
4. Install the radio. Refer to Page 8A-28.
CONTROLS
REMOVAL
2. Remove the engine compartment lower panel.
3. Open the installation flap for left fog lamp located in the left
inner fenderwell towards the front.
4. Disconnect the ambient air temperature harness connector
(2) located next to the front fascia mount (1).
ZH CONTROLS 24 - 83
5. Unclip the ambient air temperature from the front bumper

support.
INSTALLATION
1. Clip the ambient air temperature to the front bumper sup-
port.
2. Connect the ambient air temperature harness connector
(2).
3. Close the installation flap for left fog lamp located in the left
inner fenderwell.
4. Install the engine compartment lower panel.
24 - 84 CONTROLS ZH
EVAPORATOR TEMPERATURE SENSOR

REMOVAL
2. Remove the evaporator temperature sensor located on the
left side of the heater A/C case.
3. Disconnect the evaporator temperature sensor harness
connector from the sensor.
INSTALLATION
1. Connect the evaporator temperature sensor harness to the
evaporator temperature sensor (1).
2. Push the evaporator temperature sensor (1) into the A/C
heater case.
ZH CONTROLS 24 - 85
HEATER CORE TEMPERATURE SENSOR

REMOVAL
2. Remove the heater core temperature sensor (1) located on
the front of the heater A/C case (2).
3. Disconnect the heater core temperature sensor harness
connector from the sensor.
INSTALLATION
1. Connect the heater core temperature sensor harness con-
nector to the sensor.
2. Install the heater core temperature sensor (1) to the front of
the heater A/C case (2).
24 - 86 CONTROLS ZH
A/C PRESSURE TRANSDUCER

REMOVAL
1. Evacuate the A/C system. Refer to Page 24-116.
2. Disconnect the A/C pressure transducer harness connector
(2).
3. Remove the A/C pressure transducer from the receiver/
dryer (1).
INSTALLATION
1. Install the A/C pressure transducer to the receiver/dryer (1).
2. Connect the A/C pressure transducer harness connector
(2).
3. Charge the A/C system. Refer to Page 24-116.
ZH CONTROLS 24 - 87
RECIRC AIR SWITCHOVER VALVE

REMOVAL
1. Remove the glove compartment. Refer to Page 23-143.
2. Disconnect the vacuum lines (1) from the recirculation
switchover valve.
3. Disconnect the recirculation switchover valve harness con-
nector from the recirculation switchover valve.
4. Remove the recirculation switchover valve.
INSTALLATION
1. Install the recirculation switchover valve.
2. Connect the recirculation switchover valve harness connec-
tor to the recirculation switchover valve.
3. Connect the vacuum lines (1) to the recirculation switchover
valve.
4. Install the glove compartment. Refer to Page 23-146.
24 - 88 DISTRIBUTION ZH
DISTRIBUTION
TABLE OF CONTENTS
page page
BLOWER MOTOR INSTALLATION - CENTER AIR NOZZLE . . . 108

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 DEFROSTER DUCTS
HVAC HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 FLOOR DISTRIBUTION DUCTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 REMOVAL - FOOTWELL AIR OUTLET
AIR OUTLETS COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
REMOVAL INSTALLATION - FOOTWELL AIR OUTLET
SIDE AIR NOZZLE . . . . . . . . . . . . . . . . . . . . 107 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
REMOVAL - CENTER AIR NOZZLE . . . . . . . 107
INSTALLATION
SIDE AIR NOZZLE . . . . . . . . . . . . . . . . . . . . 108
BLOWER MOTOR
REMOVAL
1. Remove the lower instrument panel cover (2) from the
instrument panel (1). Refer to Page 23-149.
ZH DISTRIBUTION 24 - 89
2. Disconnect the blower motor electrical connector (1) from

the relief in the blower motor door.
3. Slide the blower motor door catch mounts (1) to the sides.
4. Swing the blower motor door down.
5. Remove the screws (1) attaching the blower motor to the

heater housing.
6. Remove the blower motor and squirrel cage as an
assembly.
INSTALLATION
1. Install the blower motor and squirrel cage as an assembly.
2. Install the screws (1) attaching the blower motor to the
heater housing.
3. Swing the blower motor door up.
4. Install the blower motor door catch mounts (1) by sliding

them over to the detents.
5. Connect the blower motor electrical connector (1).
6. Install the lower instrument panel cover (2). Refer to Page

23-155.
HVAC HOUSING
REMOVAL
WARNING: THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE PER-
SONAL INJURY MAY RESULT FROM IMPROPER SERVICE
PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED
BY QUALIFIED SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND REFRIGER-
ANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE
EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION
WHEN SERVICING THE AIR CONDITIONING REFRIGER-
ANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM
DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMMEDI-
ATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME.
POISONOUS GAS IS CREATED WHEN REFRIGERANT IS
BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOM-
MENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTI-
LATE THE WORK AREA BEFORE RESUMING SERVICE.
LARGE AMOUNTS OF REFRIGERANT RELEASED IN A
CLOSED WORK AREA WILL DISPLACE THE OXYGEN
AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY
HIGH. AS A RESULT, ANYTHING THAT COMES IN CON-
TACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS
PROTECT THE SKIN OR DELICATE OBJECTS FROM
DIRECT CONTACT WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHICLE
REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED AIR.
SOME MIXTURES OF AIR AND R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED PRES-
SURES. THESE MIXTURES ARE POTENTIALLY DANGER-
OUS, AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.

PERSONAL INJURY.
WARNING: AN AIRBAG INFLATOR UNIT MAY CONTAIN

SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATE-
RIALS ARE POISONOUS AND EXTREMELY FLAMMABLE.
CONTACT WITH ACID, WATER, OR HEAVY METALS MAY
PRODUCE HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF MOIS-
TURE) OR COMBUSTIBLE COMPOUNDS. AN AIRBAG
INFLATOR UNIT MAY ALSO CONTAIN A GAS CANISTER
PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO
DISMANTLE AN AIRBAG UNIT OR TAMPER WITH ITS
INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURES EXCEEDING 93° C (200° F).
WARNING: THE FASTENERS, SCREWS, AND BOLTS

ORIGINALLY USED FOR THE RESTRAINT SYSTEM COM-
PONENTS HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE RESTRAINT SYSTEM. THEY
MUST NEVER BE REPLACED WITH ANY SUBSTITUTES.
ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT
WITH THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN AIRBAG

UNIT ATTACHED, NEVER PLACE THE COLUMN ON THE
FLOOR OR ANY OTHER SURFACE WITH THE STEERING
WHEEL OR AIRBAG UNIT FACE DOWN.
CAUTION: Liquid refrigerant is corrosive to metal sur-

faces. Follow the operating instructions supplied with the
service equipment being used.
Never add R-12 to a refrigerant system designed to use
R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a refrig-
erant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a sys-
tem. Damage to the system will result.
Do not overcharge the refrigerant system. This will cause
excessive compressor head pressure and can cause noise
and system failure.
Recover the refrigerant before opening any fitting or con-
nection. Open the fittings with caution, even after the sys-
tem has been discharged. Never open or loosen a
connection before recovering the refrigerant.
The refrigerant system must always be evacuated before
charging.
Do not open the refrigerant system or uncap a replace-
ment component until you are ready to service the sys-
tem. This will prevent contamination in the system.
Before disconnecting a component, clean the outside of
the fittings thoroughly to prevent contamination from
entering the refrigerant system.
Immediately after disconnecting a component from the
refrigerant system, seal the open fittings with a cap or
plug.
Before connecting an open refrigerant fitting, always
install a new seal or gasket. Coat the fitting and seal with
clean refrigerant oil before connecting.
Do not remove the sealing caps from a replacement com-
ponent until it is to be installed.
When installing a refrigerant line, avoid sharp bends that
may restrict refrigerant flow. Position the refrigerant lines
away from exhaust system components or any sharp
edges, which may damage the line.
Tighten refrigerant fittings only to the specified torque.
The aluminum fittings used in the refrigerant system will
not tolerate overtightening.
When disconnecting a refrigerant fitting, use a wrench on
both halves of the fitting. This will prevent twisting of the
refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmosphere
if left uncapped. Do not open a container of refrigerant oil
until you are ready to use it. Replace the cap on the oil
container immediately after using. Store refrigerant oil
only in a clean, airtight, and moisture-free container.
Keep service tools and the work area clean. Contamina-
tion of the refrigerant system through careless work hab-
its must be avoided.

2. Evacuate the refrigerant from the A/C system. Refer to
Page 24-116.
CAUTION: Do not open cooling system unless coolant

temperature is below 90° C. Open cap slowly and release
the pressure. Do not pour coolant into beverage bottles.
Wear protective gloves, protective clothing and eye pro-
tection.
3. Relieve the pressure in the cooling system by turning the

cap on supply reservoir to catch “1” and then tightening it
back to its rest position.
4. Drain the coolant from the engine cooling system. Refer to
Page 7-18.
5. Remove the hot water hose clamp (1) located inboard from
the brake booster on the bulkhead, then remove and plug
off the hot water hose.
6. Remove the two hot water hose clamps (1) from hot water
hoses located on the right side of the bulkhead, then
remove the two hot water hoses.
7. Remove the instrument panel top section (1). Refer to

Page 23-149.

23-149.

23-149.
10. Remove the instrument cluster cover (1). Refer to Page

23-149.
11. Remove the green insulating mats.
12. Remove the nuts for the instrument cluster holder then
remove instrument cluster. Refer to Page 8J-83.
13. Remove the Sentry Key Remote Entry Module (SKREM)

by:
• Disconnect the 2-pin CAN harness connector from the
SKREM (1).
• Disconnect the 2-pin harness connector for the tran-
sponder coil (1).
• Disconnect the 18-pin harness connector (1).
• Press the retaining tabs apart (1).
• Remove the SKREM control module from the base
plate.
Note: This is necessary to remove the instrument panel

support from the vehicle.
14. Remove all of the wiring harness nylon ties attaching the
wiring harnesses on the instrument panel support.
15. Remove any harness connectors (1) or electric leads on

the body transmission tunnel.
16. Remove the bolts and nuts (1) attaching the steering col-
umn to the instrument panel support.
Note: It is not necessary to fully remove the steering col-

umn from the vehicle.
17. Relocate the steering column out of the working area.

WARNING: BE SURE YOU HAVE TAKEN THE NECESSARY

PRECAUTIONS TO DISENGAGE THE AIRBAG SYSTEM.
18. Remove the electrical harness connector (1) on passenger

airbag module.
19. Remove the heater ducts on left and right side of the
instrument panel support.
20. Remove the nuts (1) on the heater case attaching it to the
21. Remove the bolts from the instrument panel support
attaching it to the body transmission tunnel.
22. Remove the bolts (1) attaching the instrument panel sup-
port to the front of the vehicle bulkhead.
23. Remove the bolts (1) attaching the instrument panel sup-
port to the A-pillars.
24. Disconnect the connectors (1) from the vacuum reservoir.
CAUTION: To avoid any damage to the vehicle a helper

may be required to aid in the removal of the instrument
panel support.
25. Remove the instrument panel support.

26. Remove the electrical harness connector on heater core

temperature sensor located on the front of the heater
housing and the evaporator temperature sensor (1)
located on the left side of the heater case.
27. Disconnect the electrical harness connector from the fresh

air/recirculating air flap switchover valve (1) located on the
right front of the heater housing where the vacuum lines
for the reservoir where removed.
28. Remove all the nylon ties on the heater housing attaching
any wiring harnesses.

panel support.
CAUTION: Be sure not to spill any residual coolant from

the heater housing into the passenger compartment of the
vehicle.
29. Remove the heater housing from the vehicle by tipping it

forward and removing through the passenger side door.
INSTALLATION
1. Install the HVAC housing to the vehicle.
2. Install any wiring harnesses associated with the HVAC
housing with nylon ties in their respected routing positions.
3. Connect the harness connector (1) to the fresh air/recircu-
lating air flap switchover valve located on the right side of
the heater housing.
4. Install the harness connector on heater core temperature

sensor located on the front of the HVAC housing. Then
install the evaporator temperature sensor (1) to the HVAC
case.

panel support.
5. Install the instrument panel support to the vehicle.

6. Install the bolts (1) attaching the instrument panel support

to the A-pillars.
7. Connect the connectors (1) to the vacuum reservoir switch

over valve.
8. Install the bolts (1) attaching the instrument panel support

to the front of the vehicle bulkhead.
9. Install the nuts to the instrument panel support attaching it

to the body transmission tunnel.
10. Install the nuts on the heater housing (1) attaching it to
the instrument panel support.
11. Install the heater ducts on left and right side of the instru-
ment panel support.
12. Install the harness connector (1) on passenger airbag

module.
13. Locate the steering column to its mounting position on the

14. Install the bolts and nuts (1) attaching the steering column
to the instrument panel support.
15. Install the connection (1) for electric leads on body tunnel.
16. Install all of the wiring harnesses to their respected routing
positions attaching them with nylon ties on the instrument
panel support.
17. Install the Sentry Key Remote Entry Module (SKREM) by:
• Connecting the 2-pin CAN harness connector to the
SKREM module.
• Connecting the 2-pin harness connector for the tran-
sponder coil.
• Connecting the 18-pin connector.
• Installing the SKREM control module to the base plate.
18. Install instrument cluster holder to the vehicle then install
the nuts for the instrument cluster holder.
19. Install the green insulating mats.
20. Install the instrument panel top section (1). Refer to Page
23-155.
21. Install the left lower instrument panel (2). Refer to Page
23-155.
22. Install the lower right instrument panel (2). Refer to Page
23-155.
23. Install the instrument cluster cover (1). Refer to Page

8J-84.
24. Install the two hot water hoses (1) then install the two hot
water hose clamps to hot water hoses located on the right
side of the bulkhead.
25. Install the hot water hose (1) the install the hot water hose
clamp located inboard to the brake booster on the bulk-
head.
26. Fill the coolant to the engine cooling system. Refer to
Page 7-18.
AIR OUTLETS
REMOVAL
SIDE AIR NOZZLE
Note: Open and close catches with a plastic wedge or a
suitable coin.
1. Turn the plugs (1) 90° to the left and remove the fuse cover
(3).
2. Remove the screw located in the upper bezel of the air
nozzle (2), tilt the deflector up to reveal the screw (arrow).
3. Pull the air nozzle out toward the rear.
REMOVAL - CENTER AIR NOZZLE

23-173.
2. Remove the screws attaching the center air nozzle to the
center console cover (2).
3. Disconnect the air nozzle catch clips (3).
4. Remove the air nozzle from the center console cover (4).
INSTALLATION
SIDE AIR NOZZLE
Note: When installing connect the air nozzle to the air
duct.
1. Install the side air nozzle to the vehicle.

2. Install the screw located in the upper bezel of the air nozzle
(2), tilt the deflector up to reveal the screw hole.
3. Turn the plugs (1) 90° to the right to install the fuse cover.
INSTALLATION - CENTER AIR NOZZLE

1. Connect the air nozzles catch clips (3).
2. Install the screws (2) attaching the center air nozzle (1) to
the center console cover (4).
3. Install the cover on the center console. Refer to Page
23-183.
DEFROSTER DUCTS
REMOVAL
1. The defroster duct is part of the upper top section of the
instrument panel. There are plastic trim pieces which make
up the final duct distribution. These trim pieces can be
removed by, removing the screws (1) in the outside edge of
the trim piece the inner edge is held into place by a tab slid
under the top section of the instrument panel.
INSTALLATION
1. Install the defroster duct trim piece into the top section of
the instrument panel. Then install the screw (1).
FLOOR DISTRIBUTION DUCTS

REMOVAL - FOOTWELL AIR OUTLET COVER
1. Turn the screw 90° (1) on the vent (4) to the left and
remove the front cover (3) away from the rear portion (2).
2. Remove the screw (1) attaching the footwell air outlet cover
to the center console (2).
3. Slide the panel (2) forward to release the hooks and then
remove from the center console (1).
INSTALLATION - FOOTWELL AIR OUTLET COVER

1. Install the cover by sliding the panel rearward.
2. Install the screw attaching the footwell air outlet cover to

the center console.
3. Install the cover then turn the screw 90° to the right.
ZH PLUMBING 24 - 113
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132

DESCRIPTION - REFRIGERANT LINES/ LIQUID LINE
HOSES/TUBES . . . . . . . . . . . . . . . . . . . . . . 114 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 135
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 SUCTION LINE
DIAGNOSIS AND TESTING - REFRIGERANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . 116 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
STANDARD PROCEDURE A/C EXPANSION VALVE
REFRIGERANT SYSTEM SERVICE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 138
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . 116 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 139
STANDARD PROCEDURE - REFRIGERANT DIAGNOSIS AND TESTING - A/C EXPANSION
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . 117 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
STANDARD PROCEDURE - REFRIGERANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . 117 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
STANDARD PROCEDURE - REFRIGERANT HEATER CORE
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . 118 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 141
A/C COMPRESSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 141
DESCRIPTION - A/C COMPRESSOR . . . . . . . 119 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
OPERATION - A/C COMPRESSOR . . . . . . . . . 120 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
DIAGNOSIS AND TESTING - COMPRESSOR RECEIVER / DRIER
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 145
PLUMBING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122 REFRIGERANT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124 REFRIGERANT OIL
A/C CONDENSER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 148
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 149
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 125 STANDARD PROCEDURE - REFRIGERANT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 127 COOLANT CIRCULATION VALVE
A/C EVAPORATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 150
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 130 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 151
24 - 114 PLUMBING ZH
PLUMBING
DESCRIPTION - REFRIGERANT LINES/HOSES/TUBES
The refrigerant lines and hoses are used to carry the refriger-
ant between the various air conditioning system components.
• Evaporator (1)
• Expansion Valve (3)
• Receiver/Drier (5)
• Condensor (6)
• A/C Compressor (8)
A barrier hose design with a nylon tube, which is sandwiched
between rubber layers, is used for the R-134a air conditioning
systems. This nylon tube helps to further contain the R-134a
refrigerant, which has a smaller molecular structure than R-12
refrigerant. The ends of the refrigerant hoses are made from
lightweight aluminum or steel, and commonly use braze-less
fittings.
Any kinks or sharp bends in the refrigerant plumbing will
reduce the capacity of the entire air conditioning system. Kinks
and sharp bends reduce the flow of refrigerant in the system.
A good rule for the flexible hose refrigerant lines is to keep the
radius of all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should be routed
so they are at least 80 millimeters (3 inches) from the exhaust
manifold.
There are two types of refrigerant fittings:
• All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are
the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak.
• Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable
and new gaskets do not require lubrication before installing.
Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper
use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube
fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side
of the connection with a second wrench.
The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the
fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened,
tighten the fitting and recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets
SAE Standard J2210.
The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refriger-
ant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can
occur if foreign material is present in the refrigerant system.
When it is necessary to open the refrigerant system, have everything needed to service the system ready. The
refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and
fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts
stock should be capped or sealed until they are to be installed.
All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean
and dry. All tools and equipment must be designed for R-134a refrigerant.
WARNING
WARNING: THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE
PERFORMED BY QUALIFIED SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRI-
TATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDI-
TIONING REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE
REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGER-
ANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SER-
VICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL
FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE
REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DAN-
GEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.
CAUTION
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with
the service equipment being used.
Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can
cause noise and system failure.
Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after
the system has been discharged. Never open or loosen a connection before recovering the refrigerant.
The refrigerant system must always be evacuated before charging.
Do not open the refrigerant system or uncap a replacement component until you are ready to service the
system. This will prevent contamination in the system.
Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination
from entering the refrigerant system.
Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap
or plug.
Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal
with clean refrigerant oil before connecting.
Do not remove the sealing caps from a replacement component until it is to be installed.
When installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. Position the refrig-
erant lines away from exhaust system components or any sharp edges, which may damage the line.
Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refrigerant system
will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a wrench on both halves of the fitting. This will prevent twist-
ing of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrig-
erant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store
refrigerant oil only in a clean, airtight, and moisture-free container.
Keep service tools and the work area clean. Contamination of the refrigerant system through careless work
habits must be avoided.
DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PER-
FORMING THE FOLLOWING OPERATION. Refer to Page 24-115.
If the air conditioning system is not cooling properly, determine if the refrigerant system is fully-charged. Refer to
Page 24-2.
An electronic leak detector designed for R-134a refrigerant is recommended for locating and confirming refrigerant
system leaks. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use
of this equipment.
An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate
the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an
electronic leak detector prior to component repair or replacement.
To detect a leak in the refrigerant system, perform one of the following procedures:
SYSTEM EMPTY
1. Evacuate the refrigerant system. Refer to Page 24-116.
2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated
refrigerant system. Refer to Page 24-116.
3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
4. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a
refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrig-
erant lines, connector fittings and components.
5. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel
outlet. Set the blower motor switch to the lowest speed position, the A/C button in the On position, and select the
Recirculation Mode.
SYSTEM LOW
1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run
with the air conditioning system turned on for five minutes.
3. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a
refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrig-
erant lines, connector fittings and components.
4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel
outlet. Set the blower motor switch to the lowest speed position, the A/C button in the On position, and select the
Recirculation Mode.
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING AN AIR CONDITIONING REFRIGERANT
SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED, BEFORE
CONNECTING TO OR DISCONNECTING FROM THE REFRIGERANT SYSTEM. FAILURE TO OBSERVE THESE
WARNINGS MAY RESULT IN PERSONAL INJURY.
When servicing the air conditioning system, a R-134a refrigerant recovery/recycling/charging station that meets SAE
Standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/
charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and
use of this equipment.
A manifold gauge set may be needed with some recovery/recycling/charging equipment. The service hoses on the
gauge set being used should have manual (turn wheel), or automatic back-flow valves at the service port connector
ends. This will prevent refrigerant from being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS

CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible
and system damage will result.
LOW PRESSURE GAUGE HOSE The low pressure hose (Blue with Black stripe) attaches to the suction service
port. This port is located on the suction line near the driver side of the engine compartment.
HIGH PRESSURE GAUGE HOSE The high pressure hose (Red with Black stripe) attaches to the discharge service
port. This port is located on the discharge line between the compressor and the condenser inlet behind the front
grille.
RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE The center manifold hose (Yellow, or White, with Black
stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on
the manifold gauge set are opened, the refrigerant in the system will escape through this hose.
STANDARD PROCEDURE - REFRIGERANT RECOVERY

A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover
the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment
manufacturer for the proper care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be
charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pres-
sure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage
the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at
near room temperature. To evacuate the refrigerant system, use the following procedure:
1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold
gauge set to the refrigerant system of the vehicle.
2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads
88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn off the vacuum pump.
a. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be cor-
rected. Refer to Page 24-116.
b. If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open
the suction and discharge valves and evacuate the system for an additional ten minutes.
3. Close all of the valves, and turn off the charging station vacuum pump.
4. The refrigerant system is now ready to be charged with R-134a refrigerant. Refer to Page 24-116.
STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE

After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the
system.
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge
the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment man-
ufacturer for proper care and use of this equipment.
PARTIAL CHARGE METHOD

The partial charge method is used to add a partial charge to a refrigerant system that is low on refrigerant. To
perform this procedure the evaporator inlet and outlet tube temperatures are measured. The temperature difference
is measured with a temperature meter with one or two clamp-on thermocouple probes. The difference between the
evaporator inlet and outlet tube temperatures will determine the amount of refrigerant needed.
Before adding a partial refrigerant charge, check for refrigerant system leaks. Refer to Page 24-116. If a leak is
found, make the necessary repairs before attempting a full or partial refrigerant charge.
1. Attach a manifold gauge set to the refrigerant system service ports.
2. Attach the two clamp-on thermocouple probes to the inlet and outlet tubes of the evaporator coil.
• If a single thermocouple probe is used, attach the probe to the evaporator inlet tube just before the collar of
the refrigerant line connector fitting. The probe must make contact with the bottom surface of the evaporator
inlet tube.
• If dual thermocouple probes are used, attach probe 1 to the evaporator inlet tube, and probe 2 to the evap-
orator outlet tube. Attach both probes to the evaporator tubes just before the collar of the refrigerant line con-
nector fittings. The probes must make contact with the bottom surfaces of the evaporator inlet and outlet tubes.
3. Open all of the windows or doors of the passenger compartment.
4. Set the A/C button on the A/C Heater controls to the on position, the temperature control knob in the full cool
position, select Recirculation Mode, and place the blower motor switch in the highest speed position.
5. Start the engine and hold the engine idle speed at 1,000 rpm. Allow the engine to warm up to normal operating
temperature.
6. The compressor clutch may cycle, depending upon ambient temperature, humidity, and the refrigerant system
charge level.
7. Hold the engine idle speed at 1,000 rpm.
8. Allow three to five minutes for the refrigerant system to stabilize, then record the temperatures of the evaporator
inlet and outlet tubes.
• If a single probe is used, record the temperature of the evaporator inlet tube. Then remove the probe from
the inlet tube and attach it to the evaporator outlet tube just before the collar of the refrigerant line connector
fitting. The probe must make contact with the bottom surface of the evaporator outlet tube. Allow the thermo-
couple and meter time to stabilize, then record the temperature of the evaporator outlet tube. Subtract the inlet
tube temperature reading from the outlet tube temperature reading.
• If dual probes are used, record the temperatures of both the evaporator inlet and outlet tubes. Then subtract
the inlet tube temperature reading from the outlet tube temperature reading.
9. If the measured temperature differential is higher than 22° C to 26° C (40° F to 47° F), add 0.4 kilograms (14
ounces) of refrigerant.
10. Allow three to five minutes for the refrigerant system to stabilize, then take a second set of thermocouple mea-
surements. Record the temperature difference to determine if an additional charge is required.
11. Record the compressor discharge pressure. If the reading is higher than the pressure shown in the Compressor
Discharge Pressure Chart, the system could be overcharged. If the reading is equal to, or lower than the pres-
sure shown in the chart, continue with this procedure.
Compressor Discharge Pressure Chart

Ambient 16°C 21°C 27°C 32°C 38°C 43°C
Temperature (60°F) (70°F) (80°F) (90°F) (100°F) (110°F)
Compressor 1378 kPa 1516 kPa 1723 kPa 1930 kPa 2206 kPa 2413 kPa
Discharge (200 psi) (220 psi) (250psi) (280 psi) (320 psi) (350 psi)
Pressure
EXAMPLE: The ambient temperature is 21° C (70° F). The evaporator inlet tube temperature is 12° C (54° F) and
the evaporator outlet tube temperature is 10° C (50° F). Subtract the inlet tube temperature from the outlet tube
temperature. The difference is -2° C (-4° F). With a -2° C (-4° F) temperature differential at 21° C (70° F) ambient
temperature, the system is fully charged.
12. Add enough refrigerant to bring the refrigerant system up to a full charge.
13. Remove the jumper wire from the low pressure cycling clutch switch wire harness connector and plug the con-
nector back into the switch.
A/C COMPRESSOR
DESCRIPTION - A/C COMPRESSOR
The air conditioning system uses a Nippondenso, double-acting swash plate-type compressor. This compressor has
a fixed displacement of 170 cubic centimeters (10.374 cubic inches). A label identifying the use of R-134a refrigerant
is located on the underhood fuse panel cover.
The A/C system uses 1.97 Lbs. (0.88 Kg.) of R-134a type refrigerant.
OPERATION - A/C COMPRESSOR
1 - DRIVE SHAFT 7 - OUTLET VALVE

2 - CRANKCASE 8 - REGULATION VALVE
3 - SWASH PLATE 9 - SPRING
4 - PISTON 10 - CONNECTION DUCT
5 - VALVE PLATE 11 - CONNECTION PLATE
6 - INTAKE VALVE
After the electromagnetic clutch has produced the frictional connection between the engine and the compressor, the
drive shaft (1) drives the swash plate (3). The rotation of the inclined swash plate (3) causes the pistons (4) to move
in strokes. During the intake stroke, refrigerant vapor is sucked in via the inlet valve (6). If the piston (4) moves in
the counter direction, it delivers the refrigerant vapor via the pressure control valve (7), with the vapor being com-
pressed and heating up, into the refrigerant line to the condenser.
DIAGNOSIS AND TESTING - COMPRESSOR NOISE

When investigating an air conditioning related noise, you must first know the conditions under which the noise
occurs. These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed, engine
temperature, and any other special conditions. Noises that develop during air conditioning operation can often be
misleading. For example: What sounds like a failed front bearing or connecting rod, may be caused by loose bolts,
nuts, mounting brackets, or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and depending upon belt tension, belts can develop
noises that are mistaken for a compressor noise. Improper belt tension can cause a misleading noise when the
compressor clutch is engaged, which may not occur when the compressor clutch is disengaged. Check the acces-
sory drive belt condition and tension as described in the Cooling section before beginning this procedure. Refer to
Page 7-43.
1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Switch the compressor
on and off several times to clearly identify the compressor noise. Listen to the compressor while the clutch is
engaged and disengaged. Probe the compressor with an engine stethoscope or a long screwdriver with the han-
dle held to your ear to better localize the source of the noise.
2. Loosen all of the compressor mounting hardware and

retighten. Tighten the compressor clutch mounting nut. Be
certain that the clutch coil is mounted securely to the com-
pressor, and that the clutch plate and pulley are properly
aligned and have the correct air gap.
3. To duplicate a high-ambient temperature condition (high

head pressure), restrict the air flow through the condenser.
Install a manifold gauge set to be certain that the discharge
pressure does not exceed 2760 kPa (400 psi).
4. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual
noises. Also check the refrigerant lines for kinks or sharp bends that will restrict refrigerant flow, which can cause
noises.
5. If the noise is from opening and closing of the high pressure relief valve, reclaim, evacuate, and recharge the
refrigerant system. If the high pressure relief valve still does not seat properly, replace the a/c compressor. Refer
to Page 24-121.
6. If the noise is from liquid slugging on the suction line, check the refrigerant oil level and the refrigerant system
charge.
7. If the noise continues, replace the compressor and repeat. Refer to Page 24-121.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAUTIONS IN
THE FRONT OF THIS SECTION BEFORE PERFORMING
THE FOLLOWING OPERATION.
1. Evacuate the refrigerant from the system. Refer to Page

24-116.
5. Remove the lower engine compartment panel.
6. Remove the three compressor bolts (1) attaching it to the
engine block.
7. Remove the bolts on the high side and the low side pres-
sure lines.
8. Disconnect the A/C harness connector from the
compressor.
INSTALLATION
1. Connect the A/C harness connector to the compressor.
2. Install the bolts on the high side and the low side pressure
lines. Tighten to 23 N·m (17 ft. lbs.).
3. Install the A/C compressor then install the three bolts (1).
4. Install the lower engine compartment panel.
7. Charge the refrigerant to the system. Refer to Page
24-116.
PLUMBING
DESCRIPTION
The coolant circulation pump is used to maintain a uniform flow of coolant through the heater core even at low
engine speeds and in the residual engine heat utilization mode (R.E.S.T.).
OPERATION
FUNCTION IN HEATING MODE
The quantity of coolant pumped into the heater core with the engine running depends on the coolant pump. The
coolant circulation pump ensures that the water flows through the heater core uniformly without bubbles even at low
speeds. The coolant circulation pump is controlled by the A/C heater control module.
FUNCTION WITH RESIDUAL ENGINE HEAT UTILIZATION

The coolant circulation pump, pumps the heated coolant to the heater core when the engine is OFF. When the
R.E.S.T. button is pressed the temperature is controlled by the A/C heater control module (in the same manner as
when the ignition is ON). The A/C heater control module switches the electric motor for the coolant circulation pump
which drives the impeller via a magnetic clutch.
REMOVAL
1. Drain the coolant system. Refer to Page 7-18.

2. Remove the headlamp assembly (4) from the right side of the vehicle. Refer to Page 8L-108.
3. Disconnect the coolant circulation pump harness connector from the coolant circulation pump (3).
4. Disconnect the two hoses (2) from the coolant circulation pump (3).
5. Remove the two bolts (1) from the coolant circulation pump (3).
6. Remove the coolant circulation pump (3).
INSTALLATION
1. Install the coolant circulation pump (3) into the vehicle.

2. Install the two bolts (1) attaching the coolant circulation pump (3) to the vehicle.
3. Install the coolant circulation pump harness connector to the coolant circulation pump (3).
4. Install the two hoses (2) the coolant circulation pump (3).
5. Install the headlamp assembly to the vehicle. Refer to Page 8L-108.
6. Fill the coolant system. Refer to Page 7-18.
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of the engine
cooling radiator. The condenser transforms the refrigerant from
gaseous into liquid. It is attached to the vehicle with two bolts
(1) and to the A/C lines with fittings.
OPERATION
When the refrigerant gas (7) gives up its heat, it condenses.
When the refrigerant leaves the condenser (6), it has become
a high-pressure liquid refrigerant (4). The volume of air flowing
over the condenser fins (6) is critical to the proper cooling per-
formance of the air conditioning system. Therefore, it is impor-
tant that there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign material on
the condenser fins (6) that might obstruct proper air flow. Also,
any factory-installed air seals or shrouds must be properly
reinstalled following radiator or condenser service.
The condenser (6) cannot be repaired and, if faulty or dam-
aged, it must be replaced. Refer to Page 24-126.
REMOVAL
CAUTION: Before removing the condenser, note the loca-
tion of each of the radiator and condenser air seals. These
seals are used to direct air through the condenser and
radiator. The air seals must be reinstalled in their proper
locations in order for the air conditioning and engine cool-
ing systems to perform as designed.

2. Evacuate the refrigerant from the A/C system. Refer to
Page 24-116.
WARNING: OPEN THE COOLING SYSTEM ONLY WHEN

THE COOLANT TEMPERATURE IS BELOW 90°C. OPEN
THE CAP SLOWLY AND REDUCE THE PRESSURE. WEAR
PROTECTIVE GLOVES, PROTECTIVE CLOTHING AND
PROTECTIVE GOGGLES.
3. Relieve pressure in cooling system by turning the radiator

cap on the reservoir to catch “1”.
5. Remove the coolant reservoir (1). Refer to Page 7-24.
6. Remove the refrigerant lines (1) from the condenser.
7. Loosen the mount for the condenser connection fittings

(1-2).
8. Tilt the radiator forward and remove the condensor.
INSTALLATION
1. Install the condenser.
2. Tighten the mount for the condenser connection fittings
(1-2).
3. Install the refrigerant lines (1) to the condenser. Tighten to

24 N·m (18 ft. lbs.).
4. Install the radiator. Refer to Page 7-35.

5. Install the lower radiator hose to the radiator.
6. Install the upper radiator hose (1) to the radiator.

7. Install the radiator fan (1). Refer to Page 7-27.
8. Install the coolant reservoir (1). Refer to Page 7-24.

9. Fill the coolant. Refer to Page 7-18.
10. Charge the refrigerant in the refrigerant system. Refer to
Page 24-116.
A/C EVAPORATOR
DESCRIPTION
The evaporator coil is located in the HVAC housing, under the instrument panel. The evaporator coil is positioned in
the HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is
distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be
conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes.
OPERATION
Refrigerant enters the evaporator from the orifice tube as a low-temperature, low-pressure liquid. As air flows over
the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by
the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure
gas before it leaves the evaporator.
The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Page 24-130.
REMOVAL
1. Remove the HVAC housing. Refer to Page 24-92.

2. Remove the heater core. Refer to Page 24-142.
3. Remove the valve strip on the top of the HVAC housing by
removing the four screws and removing the aluminum lines
from the housing.
4. Disconnect the vacuum lines from the vacuum element (2).
5. Separate the blower housing from air distribution housing,
unclip the two sliding clips (1).
6. Remove the four spring clips.
7. Remove the screw (1) behind the expansion valve.

8. Remove the foam gasket.
9. Remove the air distribution housing upper section by

removing the spring clips.
10. Remove the evaporator from the housing.
INSTALLATION
1. Install the evaporator to the housing.
2. Install the air distribution housing upper section by installing
the spring clips.
3. Install the foam gasket.

4. Install the screw (1) behind the expansion valve.
5. Connect the blower housing to air distribution housing, clip

the two sliding clips (1).
6. Install the four spring clips.

7. Connect the vacuum lines to the vacuum element.
8. Install the valve strip.
9. Install the heater core. Refer to Page 24-144.

10. Install the HVAC housing. Refer to Page 24-101.
LIQUID LINE
REMOVAL
1. Evacuate the A/C system. Refer to Page 24-116.

3. Remove the left front wheel and tire assembly.
4. Remove the front inner wheel well panel.
5. Remove the liquid line (1) from the receiver/dryer.
6. Remove the liquid line (1) from the condenser.

INSTALLATION
Any kinks or sharp bends in the refrigerant plumbing will

reduce the capacity of the entire air conditioning system. Kinks
and sharp bends reduce the flow of refrigerant in the system.
A good rule for the flexible hose refrigerant lines is to keep the
radius of all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should be routed
so they are at least 80 millimeters (3 inches) from the exhaust
manifold.
High pressures are produced in the refrigerant system when
the air conditioning compressor is operating. Extreme care
must be exercised to make sure that each of the refrigerant
system connections is pressure-tight and leak free. It is a good
practice to inspect all flexible hose refrigerant lines at least
once a year to make sure they are in good condition and prop-
erly routed.
1. Install the liquid line (1) to the condenser. Tighten to 24
N·m (18 ft. lbs.).
2. Install the liquid line (1) to the receiver/dryer. Tighten to 17

N·m (12 ft. lbs.).
3. Install the front inner wheel well panel.
4. Install the left front wheel and tire assembly.
5. Charge the A/C system. Refer to Page 24-116.
SUCTION LINE
REMOVAL

2. Recover the refrigerant from the refrigerant system. Refer
to Page 24-116.
3. Remove the retainer nut (1) from the expansion valve (3).
4. Slide the suction line off the stud and liquid line. Remove
the lines from the clip.

6. Remove the A/C compressor bolts (1).
7. Remove the suction line from the compressor.
8. Remove the suction line assembly from the vehicle.
INSTALLATION
WARNING:
ANY KINKS OR SHARP BENDS IN THE REFRIGERANT
PLUMBING WILL REDUCE THE CAPACITY OF THE
ENTIRE AIR CONDITIONING SYSTEM. KINKS AND SHARP
BENDS REDUCE THE FLOW OF REFRIGERANT IN THE
SYSTEM. A GOOD RULE FOR THE FLEXIBLE HOSE
REFRIGERANT LINES IS TO KEEP THE RADIUS OF ALL
BENDS AT LEAST TEN TIMES THE DIAMETER OF THE
HOSE. IN ADDITION, THE FLEXIBLE HOSE REFRIGERANT
LINES SHOULD BE ROUTED SO THEY ARE AT LEAST 80
MILLIMETERS (3 INCHES) FROM THE EXHAUST MANI-
FOLD.
WARNING:
HIGH PRESSURES ARE PRODUCED IN THE REFRIGER-
ANT SYSTEM WHEN THE AIR CONDITIONING COMPRES-
SOR IS OPERATING. EXTREME CARE MUST BE
EXERCISED TO MAKE SURE THAT EACH OF THE
REFRIGERANT SYSTEM CONNECTIONS IS PRESSURE-
TIGHT AND LEAK FREE. IT IS A GOOD PRACTICE TO
INSPECT ALL FLEXIBLE HOSE REFRIGERANT LINES AT
LEAST ONCE A YEAR TO MAKE SURE THEY ARE IN
GOOD CONDITION AND PROPERLY ROUTED.
1. Install the suction line to the compressor. Tighten the

mounting bolt to 23 N·m (18 ft. lbs.).
2. Install the A/C compressor bolts (1). Refer to Page 24-122.
3. Slide the suction line and the liquid line over the expansion
valve stud. Tighten the nut (1) to 10 N·m (88 in. lbs.).
5. Evacuate the refrigerant system. Refer to Page 24-116.
6. Charge the refrigerant system. Refer to Page 24-116.
A/C EXPANSION VALVE

DESCRIPTION
The expansion valve is located at the front of the heater-A/C housing between the liquid and suction lines and the
evaporator coil. The expansion valve sprays the refrigerant into the evaporator.
The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expan-
sion valve must be replaced. Refer to Page 24-140.
OPERATION
1 - DIAPHRAGM 4 - VALVE BALL

2 - EXPANSION VALVE BODY 5 - SPRING
3 - TAPPET
When the A/C compressor is switched on the pressure in the evaporator decreases causing the diaphragm (1) to
flex downward in an arch. The tappet (3) follows the motion of the diaphragm and presses the valve ball (4) away
from its seat against the force of the spring (5). The refrigerant is sprayed into the evaporator through the open
valve. Since the motion of the diaphragm (1) is dependent on the intake pressure as well as the temperature at the
evaporator output, only the quantity of refrigerant which can be evaporated optimally is injected.
DIAGNOSIS AND TESTING - A/C EXPANSION VALVE

The expansion valve is located on the engine side of the dash panel near the shock tower.
The expansion valve can fail in three different positions (open, closed or restricted).
In an Open Position: this will result in a noisy compressor or no cooling. The cause can be a broken spring, broken
ball or excessive moisture in the A/C system. If the spring or ball are found to be defective, replace the expansion
valve. If excessive moisture is found in the A/C system, recycle the refrigerant.
In a Closed Position: There will be low suction pressure and no cooling. This may be caused by a failed power
dome or excessive moisture in the A/C system. If the power dome on the expansion valve is found to be defective
replace the expansion valve. If excessive moisture is found recycle the refrigerant.
A Restricted Orifice: There will be low suction pressure and no cooling. This may be caused by debris in the
refrigerant system. If debris is believed to be the cause, recycle the refrigerant and replace the expansion valve and
the receiver/drier.
REMOVAL

24-116.
2. Remove the nut (1).
3. Pull the pressure lines off.
4. Remove the screws (2).
5. Remove the expansion valve (3) off of the pressure lines.
INSTALLATION
1. Install the expansion valve (3) to the pressure lines.
Note: Tighten the screws evenly to avoid canting.
2. Install the bolts (2). Tighten to 8 N·m (71 in. lb.).

3. Replace the O-rings. Install the pressure lines.
4. Install the nut (1). Tighten to 10 N·m (88 in. lb.).
5. Charge the air conditioning, check for any leakage. Refer
to Page 24-116.
HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows
of tubes and fins.
OPERATION
1 - INLET AIR DUCT 3 - HEATER CORE

2 - BLOWER MOTOR
Engine coolant is circulated through heater hoses to the heater core (3) at all times. As the coolant flows through
the heater core (3), heat removed from the engine is transferred to the heater core fins and tubes. Air directed
through the heater core picks up the heat from the heater core fins. The temperature control door allows control of
the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed
through the heater core (3). The blower motor (2) speed controls the volume of air flowing through the HVAC hous-
ing.
The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Refer to Page 24-142. Refer to
Cooling for more information on the engine cooling system.
REMOVAL

1. Remove HVAC housing. Refer to Page 24-92.

2. Remove the bolts on the cover (1).
3. Unclip the spring clamps.
4. Remove the cover.
5. Remove the guide for the heating water flow pipe (2).
6. Remove the heating water return line (1).
7. Remove the heater core together with the heating water

pipes.
8. Remove the retainer clip (1) and remove the pipe from the
heater core.
INSTALLATION
1. Install the heating water pipes on the heater core then
install the clip (1).
2. Install the heat exchanger together with the heating water
pipes.
3. Connect the socket yoke for heating water flow pipe.
4. Install the heating water return line (1).

5. Install the guide (2) for the heating water flow pipe.
6. Install the cover (1).
7. Clip the spring clamps.
8. Install the bolts on the cover.
9. Install HVAC housing. Refer to Page 24-101.
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in the engine compartment
between the condenser and is part of the liquid line (1) assem-
bly. The filter/drier cannot be repaired, if the filter/drier is faulty,
damaged, left open to the atmosphere or contaminated the
line assembly must be replaced. Refer to Page 24-146.
OPERATION
The receiver/drier (5) performs a filtering action to prevent for-
eign material in the refrigerant from contaminating the expan-
sion valve (3). A desiccant bag is mounted inside the receiver/
drier canister (5) to absorb any moisture which may have
entered and become trapped within the refrigerant system. In
addition, during periods of high demand A/C operation, the
receiver/drier (5) acts as a reservoir to store surplus refriger-
ant. Refrigerant enters the receiver/drier (5) as a high-pres-
sure, low-temperature liquid from the condenser (6).
REMOVAL

24-116.
2. Disconnect the electrical connector (2).
3. Remove the upper pressure line (1).
4. Remove the refrigerant pressure sensor (2).
7. Remove left inner fender (front section) by removing the
plastic nuts and the screws attaching the panel to the inner
fenderwell.
8. Remove the pressure line (1).

9. Remove the mounting nuts (2).
10. Remove the receiver/drier from the vehicle.
INSTALLATION
1. Install the receiver/drier to the vehicle.
2. Install the mounting nuts (2).
3. Install the lower pressure line (1). Tighten to 17 N·m (12 ft.
lbs.).
4. Install left inner fender (front section).
6. Install the refrigerant pressure sensor (2).

7. Install the upper pressure line (1). Tighten to 17 N·m (12 ft.
lbs.).
8. Connect the electrical connector (2).
9. Charge the refrigerant the system.
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which
is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is
a non-toxic, non-flammable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants.
This is because R-134a is a greenhouse gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of
R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air condi-
tioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a
refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong
refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the compressor
identifying to service technicians that the air conditioning system is equipped with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG), wax-free
lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to
an R-134a refrigerant system.
There are different PAG oils available, and each contains a different additive package. The 10PA17 compressor
used in this vehicle is designed to use an ND8 PAG refrigerant oil. Use only refrigerant oil of this same type to
service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the
same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause compressor
damage, and too much can reduce air conditioning system performance.
PAG refrigerant oil is much more hygroscopic than mineral oil, and will absorb any moisture it comes into contact
with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be
used. After use, recap the oil container immediately to prevent moisture contamination.
STANDARD PROCEDURE - REFRIGERANT OIL LEVEL

When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant
oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dis-
persed throughout the refrigerant system. The accumulator, evaporator, condenser, and compressor will each retain
a significant amount of the needed refrigerant oil.
It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the
compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the
air conditioning system.
It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An
oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component
seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has
been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when a accumulator, evaporator coil, or condenser are replaced. See the Refrigerant
Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor
and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the old compressor.
Refrigerant Oil Capacities

Component ml fl oz
A/C System 130 4.40
Receiver Drier 70 2.37
Condenser 10 0.34
Evaporator 50 1.69
Drain and measure the oil from the old
Compressor
compressor - see text.
COOLANT CIRCULATION VALVE

DESCRIPTION
The coolant circulation valve (3) regulates the quantity of cool-
ant flowing through the heater hoses (1-2) to the heater core.
OPERATION
When the temperature dial is set to 9MIN9 the A/C heater control module switches the coolant circulation valve (3)

solenoid to ground, the solenoid pulls in and blocks the coolant flow through the heater core (2) separately on the
left and right sides. If the temperature dial is set to 9MAX9 the A/C heater control module interrupts the ground
connection, current does not flow through the solenoid and the maximum quantity of coolant flows through the
heater core (2).
In normal operation the A/C heater control module switches the ground connection intermittently. The locking and
closing times of the coolant circulation valve are subject to deviations between the actual temperature and set tem-
perature.
RESIDUAL ENGINE HEAT UTILIZATION

In the residual engine heat utilization mode the interior temperature is controlled in the same manner as while driv-
ing; the coolant is circulated by the coolant circulation pump.
REMOVAL
WARNING: Open the cooling system only when the cool-
ant temperature is below 90° C. Open the cap slowly and
reduce the pressure. Wear protective gloves, protective
clothing and protective goggles.
1. Relieve the pressure in the cooling system by, turning the

radiator cap on the reservoir to catch “1”.
2. Loosen the top screw for the heat shield. Then remove the
heat shield.
3. Clamp off the hot water hoses.
4. Loosen the hose clamps on heater water hoses (2).
5. Remove the heater water hose.
6. Disconnect the electrical connector (1) on the coolant circu-

lation valve.
7. Remove the rubber mounts (6) from the mounting points on
the body side.
8. Remove the coolant circulation valve.
INSTALLATION
1. Install the coolant circulation valve.
2. Install the rubber mounts to the mounting points on the
body side.
3. Connect the electrical connector (1) on the coolant circula-
tion valve.
4. Install the heater water hose (2).

5. Tighten the hose clamps on heater water hose.
6. Unclamp the hot water hose.
7. Tighten the top screw for the heat shield.
8. Top off the cooling system. Refer to Page 7-18.
ZH EMISSIONS CONTROL 25 - 1
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL DESCRIPTION - HIGH AND LOW LIMITS . . . . 11

DESCRIPTION DESCRIPTION - TRIP DEFINITION . . . . . . . . 12
DESCRIPTION - MONITORED DESCRIPTION - VEHICLE EMISSION
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTROL INFORMATION LABEL . . . . . . . . . 12
DESCRIPTION - MONITORED SYSTEMS . . . . 6 OPERATION - SYSTEM ............. . . . . . 12
DESCRIPTION - NON-MONITORED EVAPORATIVE EMISSIONS ........... . . . . . 14
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 EXHAUST GAS RECIRCULATION ...... . . . . . 23
DESCRIPTION - DRB IIIT STATE DISPLAY AIR INJECTION .................... . . . . . 30
TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . 11 ON-BOARD DIAGNOSTICS ........... . . . . . 37
25 - 2 EMISSIONS CONTROL ZH
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - MONITORED COMPONENTS
There are several components that will affect vehicle emissions if they malfunction. If one of these components
1 - MASS AIR FLOW/INTAKE AIR TEMPERATURE SENSOR 10 - CAMSHAFT POSITION SENSOR

2 - THROTTLE BODY (INCLUDES ELECTRONIC THROTTLE 11 - AIR PUMP SWITCHOVER SOLENOID
CONTROL AND THROTTLE POSITION SENSOR) 12 - MANIFOLD ABSOLUTE PRESSURE SENSOR
3 - FUEL INJECTOR 13 - RIGHT AIR PUMP SWITCHOVER VALVE
4 - CRANKSHAFT POSITION SENSOR 14 - LEFT AIR PUMP SWITCHOVER VALVE
5 - IGNITION COIL 15 - EXHAUST GAS RECIRCULATION SOLENOID
6 - SHORT RUNNER VALVE SOLENOID 16 - EXHAUST GAS RECIRCULATION VALVE
7 - SHORT RUNNER VALVE 17 - RIGHT KNOCK SENSOR
8 - AIR PUMP 18 - LEFT KNOCK SENSOR
9 - COOLANT TEMPERATURE SENSOR
malfunctions, the Malfunction Indicator Lamp (MIL) will illuminate.

Some of the component monitors are checking for proper operation of the part. Electrically operated components
now have input (rationality) and output (functionality) checks as well as continuity tests (opens/shorts). Previously, a
component like the Throttle Position Sensor (TPS) was checked by the Powertrain Control Module (PCM) for an
open or shorted circuit. If one of these conditions occurred, a Diagnostic Trouble Code (DTC) was set. Now there
is a check to ensure that the component is working. This is done by watching for a TPS indication of a greater or
lesser throttle opening than Manifold Absolute Pressure (MAP) and engine rpm indicate. In the case of the TPS, if
engine vacuum is high and engine rpm is 1600 or greater and the TPS indicates a large throttle opening, a DTC will
be set. The same applies to low vacuum and 1600 rpm.
Any component that has an associated limp-in will set a fault after 1 trip with the malfunction present.
Refer to the appropriate Powertrain Diagnostic Procedure Manual for diagnostic procedures.
The following is a list of the monitored components:
• Catalyst Monitor
• Comprehensive Components
• Exhaust Gas Recirculation (EGR)
• Fuel Control (rich/lean)
• Oxygen Sensor Monitor
• Oxygen Sensor Heater Monitor
• Purge
• Misfire
• Evaporative Vacuum Leak Detection (EVLD)
COMPREHENSIVE COMPONENTS
Along with the major monitors, OBD II requires that the diagnostic system monitor any component that could affect
emissions levels. In many cases, these components were being tested under OBD I. The OBD I requirements
focused mainly on testing emissions-related components for electrical opens and shorts.
However, OBD II also requires that inputs from powertrain components to the PCM be tested for rationality and
that outputs to powertrain components from the PCM be tested for functionality. Methods for monitoring the vari-
ous Comprehensive Component monitoring include:
• Circuit Continuity
• Open
• Shorted to Voltage
• Shorted to Ground
• Rationality and Functionality
• Outputs Tested for functionality
Note: Comprehensive component monitors are continuous. Therefore, enabling conditions do not apply. All
will set a DTC and illuminate the MIL in 1 trip.
Input Rationality - While input signals to the PCM are constantly being monitored for electrical opens and shorts,
they are also tested for rationality. This means that the input signal is compared against other inputs and information
to see if it makes sense under the current conditions.
PCM sensor and CAN Bus inputs that are checked for rationality include:
• Manifold Absolute Pressure (MAP) Sensor
• Oxygen Sensor (O2S) (slow response)
• Engine Coolant Temperature (ECT) Sensor
• Camshaft Position (CMP) Sensor
• Vehicle Speed from the Controller Antilock Brake (CAB)
• Crankshaft Position (CKP) Sensor
• Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor
• Accelerator Pedal Position Sensor (APPS)
• Throttle Position Sensor (TPS)
• Knock Sensors
• Oxygen Sensor Heater
• Engine Controller
• Brake Switch
• Evaporative Vacuum Leak Detection (EVLD)
• P/N Switch
• Transmission Controls
Output Functionality - PCM outputs are tested for functionality in addition to testing for opens and shorts. When
the PCM provides a voltage to an output component, it can verify that the command was carried out by monitoring
specific input signals for expected changes. For example, when the PCM commands the Electronic Throttle Control
(ETC) Motor to a specific position under certain operating conditions, it expects to see a specific (target) idle speed
(rpm). If it does not, it stores a DTC.
PCM outputs monitored for functionality include:
• Fuel Injectors
• Air Pump Switchover Solenoid
• Short Runner Valve Solenoid
• Ignition Coils
• Throttle Body (Electronic Throttle Control/Throttle Position Sensor)
• Purge Solenoid
• EGR Solenoid
• Radiator Fan Control
• Transmission Controls
OXYGEN SENSOR (O2S) MONITOR
DESCRIPTION - Effective control of exhaust emissions is achieved by an oxygen feedback system. The most
important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches
operating temperature 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional
to the amount of oxygen in the exhaust. When there is a large amount of oxygen in the exhaust caused by a lean
condition, misfire or exhaust leak, the sensor produces a low voltage, below 450mV. When the oxygen content is
lower, caused by a rich condition, the sensor produces a higher voltage, above 450mV.
The information obtained by the sensor is used to calculate the fuel injector pulse width. The PCM is programmed
to maintain the optimum air/fuel ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the EGR, Purge System, and Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following manners:
• Slow response rate (Big Slope)
• Reduced output voltage (Half Cycle)
• Heater Performance
• Dynamic shift
• Shorted or open circuits
Slow Response Rate (Big Slope) - Response rate is the time required for the sensor to switch from lean to rich
signal output once it is exposed to a richer than optimum air/fuel mixture or vice versa. As the PCM adjusts the
air/fuel ratio, the sensor must be able to rapidly detect the change. As the sensor ages, it could take longer to detect
the changes in the oxygen content of the exhaust gas. The rate of change that an oxygen sensor experiences is
called ’Big Slope’. The PCM checks the oxygen sensor voltage in increments of a few milliseconds.
Reduced Output Voltage (Half Cycle) - The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can
easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a
shift in the air/fuel mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunc-
tioning sensor could have difficulty changing beyond the threshold value. Many times, the condition is only tempo-
rary and the sensor will recover. Under normal conditions, the voltage signal surpasses the threshold and a counter
is incremented by one. This is called the Half Cycle Counter.
OPERATION - As the Oxygen Sensor signal switches, the PCM monitors the half cycle and big slope signals from
the oxygen sensor. If during the test neither counter reaches a predetermined value, a malfunction is entered and a
Freeze Frame is stored. Only one counter reaching its predetermined value is needed for the monitor to pass.
The Oxygen Sensor Signal Monitor is a 2 trip monitor that is tested only once per trip. When the Oxygen Sensor
fails the test in two consecutive trips, the MIL is illuminated and a DTC is set. The MIL is extinguished when the
Oxygen Sensor monitor passes in three consecutive trips. The DTC is erased from memory after 40 consecutive
warm-up cycles without test failure.
OXYGEN SENSOR HEATER MONITOR
DESCRIPTION - If the Oxygen sensor (O2S) DTC as well as a O2S heater DTC is present, the O2S Heater DTC
MUST be repaired first. After the O2S Heater is repaired, verify that the sensor circuit is operating correctly.
Note: The O2S Heaters are kept off at coolant temperatures below 20°C (68°F) and at high engine rpm in
order to avoid damaging the heaters. The voltage reading taken from the O2S are very temperature sensitive.
The readings taken from the O2S are not accurate below 300°C (572°F). Heating the O2S is done to allow the
engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must
be tested to ensure that it is heating the sensor properly. The heater resistance is checked by the PCM almost
immediately after the engine is started. The same O2S heater return pin used to read the heater resistance is capa-
ble of detecting an open, shorted high or shorted low circuit.
OPERATION - The Oxygen Sensor Heater Monitor begins after the ignition has been turned OFF and the O2 sen-
sors have cooled. As the sensor cools down, the resistance increases and the PCM reads the increase in voltage.
Once voltage has increased to a predetermined amount, higher than when the test started, the oxygen sensor is
cool enough to test heater operation.
When the oxygen sensor is cool enough, the PCM provides a ground path for the O2S heater circuit. Voltage to the
O2 sensor begins to increase the temperature. As the sensor temperature increases, the internal resistance
decreases.
The heater elements are tested each time the engine is turned OFF if all the enabling conditions are met. If the
monitor fails, the PCM stores a maturing fault and a Freeze Frame is entered. If two consecutive tests fail, a DTC
is stored. Because the ignition is OFF, the MIL is illuminated at the beginning of the next key cycle, after the 2nd
failure.
CATALYST MONITOR
DESCRIPTION - To comply with clean air regulations, vehicles are equipped with catalytic converters. These con-
verters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a
restriction of the exhaust. This can increase vehicle emissions and deteriorate engine performance, driveability and
fuel economy.
The catalyst monitor uses dual oxygen sensors (O2Ss) to monitor the efficiency of the converter. The dual O2S
strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both
reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The
upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic con-
verter. The PCM calculates the air/fuel mixture from the output of the O2S. A low voltage indicates high oxygen
content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture).
When the upstream O2S detects a high oxygen condition, there is an abundance of oxygen in the exhaust gas. A
functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter
absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S
will indicate limited activity in this condition.
As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the down-
stream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen
will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the
upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2Ss.
To monitor the system, the number of lean-to-rich switches of upstream and downstream O2Ss is counted. The ratio
of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An
effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For
a totally ineffective catalyst, this ratio will be one-to-one, indicating that no oxidation occurs in the device.
The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over
the legal limit, the MIL will be illuminated.
OPERATION - To monitor catalyst efficiency, the PCM expands the rich and lean switch points of the heated oxygen
sensor. With extended switch points, the air/fuel mixture runs richer and leaner to overburden the catalytic converter.
Once the test is started, the air/fuel mixture runs rich and lean and the O2S switches are counted. A switch is
counted when an oxygen sensor signal goes from below the lean threshold to above the rich threshold. The number
of Rear O2S switches is divided by the number of Front O2S switches to determine the switching ratio.
The test runs for 20 seconds. As catalyst efficiency deteriorates over the life of the vehicle, the switch rate at the
downstream sensor approaches that of the upstream sensor. If at any point during the test period the switch ratio
reaches a predetermined value, a counter is incremented by one. The monitor is enabled to run another test during
that trip. When the test fails three times, the counter increments to three, a malfunction is entered, and a Freeze
Frame is stored. When the counter increments to three during the next trip, the code is matured and the MIL is
illuminated. If the test passes the first, no further testing is conducted during that trip.
The MIL is extinguished after three consecutive good trips.
DESCRIPTION - MONITORED SYSTEMS

There are new electronic circuit monitors that check fuel, emission, engine and ignition performance. These monitors
use information from various sensor circuits to indicate the overall operation of the fuel, engine, ignition and emis-
sion systems and thus the emissions performance of the vehicle.
The fuel, engine, ignition and emission system monitors do not indicate a specific component problem. They do
indicate that there is an implied problem within one of the systems and that a specific problem must be diagnosed.
If any of these monitors detect a problem affecting vehicle emissions, the Malfunction Indicator Lamp (MIL) will be
illuminated. These monitors generate Diagnostic Trouble Codes that can be displayed with the a DRBIIIT scan tool.
The following is a list of the system monitors:
• EGR Monitor
• Misfire Monitor
• Fuel System Monitor
• Oxygen Sensor Monitor
• Oxygen Sensor Heater Monitor
• Catalyst Monitor
• Evaporative Vacuum Leak Detection System Monitor
Following is a description of each system monitor and its DTC.
Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnostic procedures.
OXYGEN SENSOR (O2S) MONITOR
DESCRIPTION - Effective control of exhaust emissions is achieved by an oxygen feedback system. The most
important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches
operating temperature 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional
to the amount of oxygen in the exhaust. When there is a large amount of oxygen in the exhaust caused by a lean
condition, misfire or exhaust leak, the sensor produces a low voltage, below 450mV. When the oxygen content is
lower, caused by a rich condition, the sensor produces a higher voltage, above 450mV.
The information obtained by the sensor is used to calculate the fuel injector pulse width. The PCM is programmed
to maintain the optimum air/fuel ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the EGR, Purge System, and Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following manners:
• Slow response rate (Big Slope)
• Reduced output voltage (Half Cycle)
• Heater Performance
• Dynamic shift
• Shorted or open circuits
Slow Response Rate (Big Slope) - Response rate is the time required for the sensor to switch from lean to rich
signal output once it is exposed to a richer than optimum air/fuel mixture or vice versa. As the PCM adjusts the
air/fuel ratio, the sensor must be able to rapidly detect the change. As the sensor ages, it could take longer to detect
the changes in the oxygen content of the exhaust gas. The rate of change that an oxygen sensor experiences is
called ’Big Slope’. The PCM checks the oxygen sensor voltage in increments of a few milliseconds.
Reduced Output Voltage (Half Cycle) - The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can
easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a
shift in the air/fuel mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunc-
tioning sensor could have difficulty changing beyond the threshold value. Many times, the condition is only tempo-
rary and the sensor will recover. Under normal conditions the voltage signal surpasses the threshold and a counter
is incremented by one. This is called the Half Cycle Counter.
OPERATION - As the Oxygen Sensor signal switches, the PCM monitors the half cycle and big slope signals from
the oxygen sensor. If during the test neither counter reaches a predetermined value, a malfunction is entered and a
Freeze Frame is stored. Only one counter reaching its predetermined value is needed for the monitor to pass.
The Oxygen Sensor Signal Monitor is a 2 trip monitor that is tested only once per trip. When the Oxygen Sensor
fails the test in two consecutive trips, the MIL is illuminated and a DTC is set. The MIL is extinguished when the
Oxygen Sensor monitor passes in three consecutive trips. The DTC is erased from memory after 40 consecutive
warm-up cycles without test failure.
OXYGEN SENSOR HEATER MONITOR
DESCRIPTION - If the Oxygen sensor (O2S) DTC as well as a O2S heater DTC is present, the O2S Heater DTC
MUST be repaired first. After the O2S Heater is repaired, verify that the sensor circuit is operating correctly.
Note: The O2S Heaters are kept off at coolant temperatures below 20°C (68°F) and at high engine rpm in
order to avoid damaging the heaters. The voltage reading taken from the O2S are very temperature sensitive.
The readings taken from the O2S are not accurate below 300°C (572°F). Heating the O2S is done to allow the
engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must
be tested to ensure that it is heating the sensor properly. The heater resistance is checked by the PCM almost
immediately after the engine is started. The same O2S heater return pin used to read the heater resistance is capa-
ble of detecting an open, shorted high or shorted low circuit.
OPERATION - The Oxygen Sensor Heater Monitor begins after the ignition has been turned OFF and the O2 sen-
sors have cooled. As the sensor cools down, the resistance increases and the PCM reads the increase in voltage.
Once voltage has increased to a predetermined amount, higher than when the test started, the oxygen sensor is
cool enough to test heater operation.
When the oxygen sensor is cool enough, the PCM provides a ground path for the O2S heater circuit. Voltage to the
O2 sensor begins to increase the temperature. As the sensor temperature increases, the internal resistance
decreases.
The heater elements are tested each time the engine is turned OFF if all the enabling conditions are met. If the
monitor fails, the PCM stores a maturing fault and a Freeze Frame is entered. If two consecutive tests fail, a DTC
is stored. Because the ignition is OFF, the MIL is illuminated at the beginning of the next key cycle, after the 2nd
failure.
EGR MONITOR
The Powertrain Control Module (PCM) performs an on-board diagnostic check of the EGR system.
The EGR monitor is used to test whether the EGR system is operating within specifications. The diagnostic check
activates only during selected engine/driving conditions. When the conditions are met, the EGR is turned off (sole-
noid de-energized) and the O2S compensation control is monitored. Turning off the EGR shifts the air/fuel ratio in
the lean direction. The O2S data should indicate an increase in the O2 concentration in the combustion chamber
when the exhaust gases are no longer recirculated. While this test does not directly measure the operation of the
EGR system, it can be inferred from the shift in the O2S data whether the EGR system is operating correctly.
Because the O2S is being used, the O2S test must pass its test before the EGR test. This monitor also looks at
EGR linear potentiometer for feedback.
MISFIRE MONITOR
Excessive engine misfire results in increased catalyst temperature and causes an increase in HC emissions. Severe
misfires could cause catalyst damage. To prevent catalytic convertor damage, the PCM monitors engine misfire.
The Powertrain Control Module (PCM) monitors for misfire during most engine operating conditions (positive torque)
by looking at changes in the crankshaft speed. If a misfire occurs, the speed of the crankshaft will vary more than
normal.
FUEL SYSTEM MONITOR
The PCM is programmed to maintain the optimum air/fuel ratio. This is done by making short term corrections in the
fuel injector pulse width based on the O2S output. The programmed memory acts as a self–calibration tool that the
engine controller uses to compensate for variations in engine specifications, sensor tolerances and engine fatigue
over the life span of the engine. By monitoring the actual air/fuel ratio with the O2S (short term) and multiplying that
with the program long term (adaptive) memory calculation, then comparing that to the limit, it can be determined
whether it will pass an emissions test. If a malfunction occurs such that the PCM cannot maintain the optimum
air/fuel ratio, then the MIL will be illuminated.
CATALYST MONITOR
DESCRIPTION - To comply with clean air regulations, vehicles are equipped with catalytic converters. These con-
verters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a
restriction of the exhaust. This can increase vehicle emissions and deteriorate engine performance, driveability and
fuel economy.
The catalyst monitor uses dual oxygen sensors (O2Ss) to monitor the efficiency of the converter. The dual O2S
strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both
reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The
upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic con-
verter. The PCM calculates the air/fuel mixture from the output of the O2S. A low voltage indicates high oxygen
content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture).
When the upstream O2S detects a high oxygen condition, there is an abundance of oxygen in the exhaust gas. A
functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter
absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S
will indicate limited activity in this condition.
As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the down-
stream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen
will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the
upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2Ss.
To monitor the system, the number of lean-to-rich switches of upstream and downstream O2Ss is counted. The ratio
of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An
effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For
a totally ineffective catalyst, this ratio will be one-to-one, indicating that no oxidation occurs in the device.
The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over
the legal limit, the MIL will be illuminated.
OPERATION - To monitor catalyst efficiency, the PCM expands the rich and lean switch points of the heated oxygen
sensor. With extended switch points, the air/fuel mixture runs richer and leaner to overburden the catalytic converter.
Once the test is started, the air/fuel mixture runs rich and lean and the O2S switches are counted. A switch is
counted when an oxygen sensor signal goes from below the lean threshold to above the rich threshold. The number
of Rear O2S switches is divided by the number of Front O2S switches to determine the switching ratio.
The test runs for 20 seconds. As catalyst efficiency deteriorates over the life of the vehicle, the switch rate at the
downstream sensor approaches that of the upstream sensor. If at any point during the test period the switch ratio
reaches a predetermined value, a counter is incremented by one. The monitor is enabled to run another test during
that trip. When the test fails three times, the counter increments to three, a malfunction is entered, and a Freeze
Frame is stored. When the counter increments to three during the next trip, the code is matured and the MIL is
illuminated. If the test passes the first, no further testing is conducted during that trip.
The MIL is extinguished after three consecutive good trips.
EVAPORATIVE VACUUM LEAK DETECTION SYSTEM
1 - FUEL LEVEL SENDING UNIT/PRESSURE SENSOR 8 - FUEL PUMP

2 - FUEL WARNING INDICATOR 9 - FUEL TANK
3 - INSTRUMENT CLUSTER 10 - FUEL VAPOR PRESSURE RELIEF VALVE
4 - MALFUNCTION INDICATOR LAMP 11 - EVAP PURGE SOLENOID
5 - POWERTRAIN CONTROL MODULE 12 - EVAP CANISTER
6 - FUEL PUMP RELAY 13 - CHARCOAL CANISTER SHUTOFF VALVE
7 - FUEL FILTER/PRESSURE REGULATOR 14 - FUEL FILLER CAP
The Evaporative Vacuum Leak Detection (EVLD) system has replaced the leak detection pump as the method of
evaporative system leak detection. This is to detect a leak equivalent to a 0.5 mm (0.020 in.) hole. This system has
the capability to detect holes of this size very dependably. In addition to the detection of very small leaks, this sys-
tem has the capability of detecting medium as well as large evaporative system leaks.
The EVLD system incorporates the EVAP Purge Hoses, EVAP Canister, fuel tank, fuel filler neck and fuel filler cap
with the Charcoal Canister Shutoff Valve, EVAP Purge Solenoid, PCM and engine vacuum to detect a leak in the
purge system.
The PCM seals the Charcoal Canister Shutoff Valve and opens the EVAP Purge Solenoid to perform the 3–stage
leak test after the following conditions have been met:
• Battery voltage > 11 volts
• Engine running for approximately 16 minutes
• Engine idling
• Vehicle at rest
• Emission controls in closed loop
• Intake air temperature less than 45°C (113°F)
• Engine coolant temperature at startup < 100°C (212°F)
• Engine load < 35%
• Transmission in Drive or Reverse
• Secondary air injection not active
• Atmospheric pressure > 780 hPa (11.31 psi) i.e., altitude > 8200 feet
• Low purge canister activity
• Fuel tank level between 1/4 and 3/4
• No excessive fuel slosh in the fuel tank
• No fault in the Charcoal Canister Shutoff Valve, EVAP Purge Solenoid, or Fuel Tank Pressure Sensor
• No leak in the ORVR Pressure Relief Valve
The leak test consists of three successive tests that are dependent on the previous test passing. If one test fails, the
next test will not be run. The major leak test begins by closing the Charcoal Canister Shutoff Valve and opening the
EVAP Purge Solenoid to allow engine vacuum to build to 6 mbar (2.4 inH2O), as measured by the Fuel Tank Pres-
sure Sensor, in the fuel tank within approximately 12 seconds. If there is no vacuum buildup in the fuel tank, there
is a major leak present, the leak test is aborted, the Low Fuel Warning Indicator is illuminated in the instrument
cluster and a DTC is stored in the PCM.
If the major leak test passes, the EVAP Purge Solenoid is closed when vacuum inside the fuel tank reaches approx-
imately 6 mbar (2.4 inH2O) and the vacuum is analyzed for approximately 30 seconds. The vacuum must not drop
by more than 0.3 to 0.5 mbar (0.12 to 0.2 inH2O), depending on the fuel level in the fuel tank, during the 30 second
time period. If there is a minor leak, the leak test is aborted and a DTC is stored in the PCM. The leak test will be
aborted if an excessive lean correction occurs during vacuum buildup.
If the minor leak test passes, the micro leak test initiates by again bringing the vacuum in the fuel tank up to approx-
imately 6 mbar (2.4 inH2O). Once the vacuum in the fuel tank is re-established, the EVAP Purge Solenoid is closed.
The vacuum must not drop by more than 0.1 to 0.15 mbar (0.04 to 0.06 inH2O), depending on the fuel level in the
fuel tank, per second. If the vacuum drops more rapidly, a DTC is stored in the PCM. The leak test will be aborted
if an excessive lean correction occurs during vacuum buildup.
When the leak test is complete, the EVAP Purge Solenoid is opened and the purge control system returns to normal
operation.
DESCRIPTION - NON-MONITORED CIRCUITS

The PCM does not monitor all circuits, systems and conditions that could have malfunctions causing driveability
problems. However, malfunctions in these systems may cause the PCM to store diagnostic trouble codes for other
systems or components. For example, a fuel pressure problem will not register a fault directly but could cause a
rich/lean condition or misfire. This could cause the PCM to store an oxygen sensor or misfire diagnostic trouble
code.
The major non-monitored circuits are listed below along with examples of failure modes that do not directly cause
the PCM to set a DTC, but instead for a system that is monitored.
FUEL PRESSURE
The fuel pressure regulator controls fuel system pressure. The PCM cannot detect a clogged fuel pump inlet filter,
clogged in-line fuel filter, or a pinched fuel supply or return line. However, these could result in a rich or lean con-
dition causing the PCM to store an oxygen sensor, fuel system, or misfire diagnostic trouble code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an inoperative ignition coil, fouled or worn spark plugs, ignition cross firing, or open spark
plug cables. The misfire will, however, increase the oxygen content in the exhaust, deceiving the PCM into thinking
the fuel system is too lean. Also see misfire detection.
CYLINDER COMPRESSION
The PCM cannot detect uneven, low, or high engine cylinder compression. Low compression lowers O2 content in
the exhaust, leading to a fuel system, oxygen sensor or misfire detection fault.
EXHAUST SYSTEM
The PCM cannot detect a plugged, restricted or leaking exhaust system. It may set an EGR, Fuel system or O2S
fault.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determine if a fuel injector is clogged, the needle is sticking or if the wrong injector is installed.
However, these could result in a rich or lean condition causing the PCM to store a diagnostic trouble code for either
misfire, an oxygen sensor or the fuel system.
EXCESSIVE OIL CONSUMPTION
Although the PCM monitors engine exhaust oxygen content when the system is in closed loop, it cannot determine
excessive oil consumption.
THROTTLE BODY AIR FLOW
The PCM cannot detect a clogged or restricted air cleaner inlet or filter element.
VACUUM ASSIST
The PCM cannot detect leaks or restrictions in the vacuum circuits of vacuum assisted engine control system
devices or vacuum assisted accessories. However, these could cause the PCM to store a MAP sensor diagnostic
trouble code and cause a high idle condition.
PCM SYSTEM GROUND
The PCM cannot determine a poor system ground. However, one or more diagnostic trouble codes may be gener-
ated as a result of this condition.
PCM CONNECTOR ENGAGEMENT
The PCM may not be able to determine spread or damaged connector pins. However, it might store diagnostic
trouble codes as a result of pins not making good contact.
DESCRIPTION - DRB IIIT STATE DISPLAY TEST MODE

The switch (component) inputs to the Powertrain Control Module (PCM) have two recognized states; HIGH and
LOW. The PCM cannot recognize the difference between a selected switch position versus an open circuit, a short
circuit or a defective switch. If the State Display screen shows the change from HIGH to LOW or LOW to HIGH,
assume the entire switch circuit to the PCM functions properly. From the state display screen, access either State
Display Inputs and Outputs or State Display Sensors.
DESCRIPTION - HIGH AND LOW LIMITS

The PCM compares input signal voltages from each input device with established high and low limits for the device.
If the input voltage is not within limits and other criteria are met, the PCM stores a diagnostic trouble code in mem-
ory. Other diagnostic trouble code criteria might include engine RPM limits or input voltages from other sensors or
switches that must be present before verifying a diagnostic trouble code condition.
DESCRIPTION - TRIP DEFINITION

A “Trip” means vehicle operation (following an engine-off period) of duration and driving mode such that all compo-
nents and systems are monitored at least once by the diagnostic system. The monitors must successfully pass
before the PCM can verify that a previously malfunctioning component is meeting the normal operating conditions of
that component. For misfire or fuel system malfunction, the MIL may be extinguished if the fault does not recur
when monitored during three subsequent sequential driving cycles in which conditions are similar to those under
which the malfunction was first determined.
Anytime the MIL is illuminated, a DTC is stored. The DTC can self erase only after the MIL has been extinguished.
Once the MIL is extinguished, the PCM must pass the diagnostic test for the most recent DTC for 40 warm-up
cycles (80 warm-up cycles for the Fuel System Monitor and the Misfire Monitor). A warm-up cycle can best be
described by the following:
• The engine must be running
• A rise of 4.4°C (40°F) in engine temperature must occur from the time engine was started
• Engine coolant temperature must crossover 71°C (160°F)
• A “driving cycle” that consists of engine start up and engine shut off.
Once the above conditions occur, the PCM is considered to have passed a warm-up cycle. Due to the conditions
required to extinguish the MIL and erase the DTC, it is most important that after a repair has been made, all DTCs
be erased and the repair verified by running 1 good trip.
DESCRIPTION - VEHICLE EMISSION CONTROL INFORMATION LABEL

All models have a Vehicle Emission Control Information (VECI) Label. DaimlerChrysler permanently attaches the
label in the engine compartment. It cannot be removed without defacing information and destroying the label.
The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected
and routed according to the label.
OPERATION - SYSTEM
The Powertrain Control Module (PCM) monitors many different circuits in the fuel injection, ignition, emission and
engine systems. If the PCM senses a problem with a monitored circuit often enough to indicate an actual problem,
it stores a Diagnostic Trouble Code (DTC) in the PCM’s memory. If the code applies to a non-emissions related
component or system and the problem is repaired or ceases to exist, the PCM cancels the code after 40 warmup
cycles. Diagnostic trouble codes that affect vehicle emissions illuminate the Malfunction Indicator Lamp (MIL).
Certain criteria must be met before the PCM stores a DTC in memory. The criteria may be a specific range of
engine RPM, engine temperature, and/or input voltage to the PCM.
The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred. This may happen
because one of the DTC criteria for the circuit has not been met. For example , assume the diagnostic trouble code
criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 rpm. Suppose
the sensor’s output circuit shorts to ground when the engine operates above 2400 rpm (resulting in 0 volt input to
the PCM). Because the condition happens at an engine speed above the maximum threshold (2000 rpm), the PCM
will not store a DTC.
There are several operating conditions for which the PCM monitors and sets DTCs. Refer to Monitored Systems,
Monitored Components, and Non-Monitored Circuits in this section.
Note: Various diagnostic procedures may actually cause a diagnostic monitor to set a DTC. For instance,
pulling a spark plug wire to perform a spark test may set the misfire code. When a repair is completed and
verified, use the DRB IIIT scan tool to erase all DTCs and extinguish the MIL.
Technicians can retrieve stored DTCs. For obtaining the DTC

information, use the Data Link Connector(2) with the DRB IIIT
scan tool.
25 - 14 EVAPORATIVE EMISSIONS ZH
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DESCRIPTION - EVAPORATION CONTROL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FUEL FILLER CAP
CHARCOAL CANISTER SHUTOFF VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ORVR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CRANKCASE VENT HOSE VAPOR CANISTER
EVAP PURGE SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ZH EVAPORATIVE EMISSIONS 25 - 15
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAPORATION CONTROL SYSTEM
1 - FUEL LEVEL SENDING UNIT/PRESSURE SENSOR 8 - FUEL PUMP

2 - FUEL WARNING INDICATOR 9 - FUEL TANK
3 - INSTRUMENT CLUSTER 10 - FUEL VAPOR PRESSURE RELIEF VALVE
4 - MALFUNCTION INDICATOR LAMP 11 - EVAP PURGE SOLENOID
5 - POWERTRAIN CONTROL MODULE 12 - EVAP CANISTER
6 - FUEL PUMP RELAY 13 - CHARCOAL CANISTER SHUTOFF VALVE
7 - FUEL FILTER/PRESSURE REGULATOR 14 - FUEL FILLER CAP
The evaporation control system prevents the emission of fuel tank vapors into the atmosphere. When fuel evapo-
rates in the fuel tank, the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister.
The canister temporarily holds the vapors. The Powertrain Control Module (PCM) allows intake manifold vacuum to
draw vapors into the combustion chambers during certain operating conditions.
This vehicle uses a pulse-width modulated purge solenoid system. The PCM controls vapor flow by operating the
purge solenoid. Refer to EVAP Purge Solenoid in this section.
Note: The evaporative system uses specially manufactured hoses. If they need replacement, only use fuel
resistant hose. Also the hoses must be able to pass an Ozone compliance test.
Note: For more information on Onboard Refueling Vapor Recovery (ORVR), refer to the Fuel Delivery sec-
tion.
CHARCOAL CANISTER SHUTOFF VALVE

DESCRIPTION
The Charcoal Canister Shutoff Valve is part of the Evaporative Vacuum Leak Detection (EVLD) system. The Char-
coal Canister Shutoff Valve is mounted on the EVAP Canister. This assembly is located above a splash shield in
front of the right rear axleshaft.
OPERATION
The Charcoal Canister Shutoff Valve is actuated by the PCM to isolate the EVAP purge system in order to deter-
mine if a leak exists in any of the purge system components.
REMOVAL
For removal procedure, Refer to Page 25-20.
INSTALLATION
For installation procedure, Refer to Page 25-21.
CRANKCASE VENT HOSE

DESCRIPTION
The PCV system consists of a draft-tube style throttle body insert (2) and hoses (1 and 3) connected between the
cylinder head covers and the throttle body insert (2).
Crankcase ventilation is accomplished by means of a draft-

tube style insert (2) protruding through the throttle body into
the intake airstream (4). The crankcase gases are drawn into
the intake manifold when air passing the tube insert creates a
vacuum in the Crankcase Vent Hoses (1 and 3).
EVAP PURGE SOLENOID

DESCRIPTION
This vehicle uses a pulse-width modulated purge solenoid. The solenoid regulates the rate of vapor flow from the
EVAP canister to the throttle body. The PCM controls the frequency at which the solenoid operates in order to cus-
tomize the vapor volume for each cylinder.
OPERATION
The PCM will only energize the solenoid when the engine is at operating temperature, but will de-energize it during
periods of deceleration. When de-energized, no vapors are purged.
The pulse-width modulated purge solenoid controls the fuel vapor purge rate from the vapor canister and fuel tank
to the engine intake manifold.
REMOVAL
1. Disconnect harness connector from solenoid (2).
2. Disconnect vapor hoses (1 and 4) from solenoid (3).
3. Remove solenoid (3) from bracket (5).
INSTALLATION
1. Install solenoid (3) on bracket (5).
2. Connect vapor hoses (1 and 4) to solenoid (3).
3. Connect connector (2) to solenoid (3).
FUEL FILLER CAP

DESCRIPTION
The plastic/metal fuel filler cap is installed with a quarter turn onto the end of the fuel filler tube. Its purpose is to
retain vapors and fuel in the fuel tank.
OPERATION
The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal operating condi-
tions. The relief valve is calibrated to open when a pressure of 172 mbar (2.5 psi) or vacuum of 20 mbar (8 inH2O)
occurs in the fuel tank. When the pressure or vacuum is relieved, the valve returns to the normally closed position.
WARNING: REMOVE THE FUEL FILLER CAP TO RELEASE FUEL TANK PRESSURE BEFORE DISCONNECT-
ING ANY FUEL SYSTEM COMPONENT.
ORVR
DESCRIPTION
The Onboard Refueling Vapor Recovery (ORVR) System is used to remove excess vapors in the fuel tank during
refueling.
OPERATION
1 - TANK VENT/ROLLOVER VALVES 6 - EVAP PURGE SOLENOID

2 - FUEL TANK 7 - EVAP CANISTER
3 - FUEL FILLER TUBE 8 - FUEL VAPOR PRESSURE RELIEF VALVE
4 - FUEL FILLER TUBE CHECK VALVE 9 - CHARCOAL CANISTER SHUTOFF VALVE
5 - FUEL TANK OVERFILL CHECK VALVE
The emission control principle used in the ORVR system is that the fuel flowing into the fuel filler tube (3) creates
an aspiration effect which draws air into the fuel filler tube (3). During refueling, the fuel tank (2) is vented to the
EVAP canister (7) to capture escaping vapors. With air flowing into the fuel filler tube (3), there are no fuel vapors
escaping to the atmosphere. Once the refueling vapors are captured by the EVAP Canister (7), the vehicle’s com-
puter controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by
the EVAP purge solenoid (6) so that there is minimal or no impact on driveability or tailpipe emissions.
As fuel starts to flow through the Fuel Filler Tube (3), it opens the normally closed Fuel Filler Tube Check Valve (4)
and enters the fuel tank (2). Vapor or air is expelled from the tank through the tank vent/rollover valves (1) to the
EVAP canister (7). Vapor is absorbed in the canister (7) until vapor flow in the lines stops, either following refueling
shut-off or by having the fuel level in the tank rise high enough to close the check valves in the tank vent/rollover
valves (1). The fuel filler tube (3) also incorporates a fuel tank overfill check valve (5). As fuel level rises, the fuel
tank overfill check valve (5) seals the in-tank end of the fuel filler tube (3). This largely prevents overfilling of the fuel
tank (2). At this point in the fueling of the vehicle, the tank pressure increases, the fuel filler tube check valve (4)
closes (preventing tank fuel from spitting back at the operator), and fuel then rises up the filler tube (3) to shut-off
the dispensing nozzle.
VAPOR CANISTER
DESCRIPTION
The EVAP Canister is located above a splash shield in front of the right rear axleshaft.
OPERATION
This vehicle uses a maintenance-free, evaporative (EVAP) canister filled with activated carbon granules. Fuel tank
vapors are vented into the canister where they are absorbed by the activated carbon granules. The canister tem-
porarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Power-
train Control Module (PCM) purges the canister through the pulse-width modulated purge solenoid. The PCM purges
the canister at predetermined intervals and engine conditions.
REMOVAL
3. Remove the shield retaining nuts from splash shield.
5. Carefully disconnect the vapor/vacuum/vent hoses (2).
6. Slide the EVAP canister (4) to the left, off of mounting
bracket.
7. Disconnect the charcoal canister shutoff valve harness con-
nector (1).
8. Depress the locking tab (2) to release charcoal canister

shutoff valve (1).
9. While holding the lock tab (2) in release position, turn char-
coal canister shutoff valve (1) clockwise and remove from
EVAP canister.
10. Discard the old o-ring (3).
INSTALLATION
1. Install the charcoal canister shutoff valve (1) to EVAP can-
ister (2) using new o-ring (3).
2. Connect the charcoal canister shutoff valve harness con-

nector (1).
3. Connect the hoses (2).
4. Slide the EVAP canister to the right, on to mounting
bracket.
5. Install the splash shield and retaining nuts.

ZH EXHAUST GAS RECIRCULATION 25 - 23
EXHAUST GAS RECIRCULATION
TABLE OF CONTENTS
page page
EXHAUST GAS RECIRCULATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26

SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . 23 VALVE
SOLENOID DESCRIPTION .. . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 OPERATION . ... . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 REMOVAL . . . ... . . . . . . . . . . . . . . . . . . . . . . . 27
TUBE INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EXHAUST GAS RECIRCULATION


EGR VALVE TO 31 23 275
CYLINDER HEAD
EGR TUBE TO EGR 11 — 95
VALVE
EGR TUBE TO INTAKE 11 — 95
MANIFOLD
EGR SOLENOID TO EGR 11 — 95
VALVE
25 - 24 EXHAUST GAS RECIRCULATION ZH
SOLENOID
REMOVAL
3. Disconnect the solenoid harness connector (1).
4. Disconnect the solenoid vacuum lines (2).
5. Remove the solenoid to valve mounting bolt (2).

6. Remove the valve to cylinder head mounting bolt (1).
7. Clean the gasket surfaces. Discard the old gasket. Clean
the EGR passages as necessary.
INSTALLATION
1. Position the solenoid to valve and loosely install solenoid to
valve bolt (2).
2. Install the valve bolt (1) to cylinder head and tighten to 31
N·m (23 ft. lbs.).
3. Tighten the solenoid to valve bolt (2) to 11 N·m (95 in. lbs.).
4. Connect the vacuum hoses (2).

5. Connect the EGR solenoid harness connector (1).
TUBE
REMOVAL
2. Remove the EGR tube mounting bolts (1) at intake mani-
fold.
3. Remove the EGR tube flange nut (2) at EGR valve.
4. Remove the EGR tube.
5. Clean the gasket surfaces on the EGR tube and intake
manifold. Discard old gasket. Note that any loose dirt can
lodge between the tube and manifold and cause vacuum
leakage that will give a rough idle and reduced manifold
vacuum.
INSTALLATION
1. Loosely install the EGR tube flange nut (2) to the EGR
valve.
2. Position the new gasket between tube and intake manifold.
3. Install the tube bolts (1) to intake manifold and tighten to 31
N·m (23 ft. lbs.).
4. Tighten the EGR tube flange nut (2) to 11 N·m (95 in. lbs.).
VALVE
DESCRIPTION
The EGR valve consists of three major components; the EGR
tube (1), the EGR solenoid (2), and the EGR valve (3). The
EGR valve (3) is located at the right rear of the engine and is
attached to the right cylinder head, to the right of the throttle
body (4). The EGR solenoid (2) is attached to the EGR valve
(3) on the throttle body side of the valve. The EGR tube (1)
connects the EGR valve (3) to the rear of the intake manifold
(5).
OPERATION
The exhaust gas recirculation flow is determined by the powertrain control module (PCM). For a given set of con-
ditions, the PCM calulates the ideal exhaust gas recirculation flow to minimize NOx emissions and maximize fuel
economy by adjusting the pintle position. Pintle position is controlled by the EGR solenoid. The PCM adjusts the
duty cycle of the power supplied to the solenoid coil to obtain the correct position.
REMOVAL
3. Disconnect the solenoid harness connector (1).
4. Disconnect the solenoid to valve vacuum line (2).
5. Remove the EGR tube flange nut (2) at valve.

6. Remove the solenoid to valve mounting bolt (3).
7. Remove the valve to cylinder head mounting bolts (1).
8. Clean the gasket surfaces. Discard the old gasket. Clean
the EGR passages as necessary.
INSTALLATION
1. Position new gasket between the valve and cylinder head.
2. Loosely install valve front bolt (1) to cylinder head, do not
tighten bolt.
3. Position solenoid to valve and loosely install solenoid (3) to
valve bolt.
4. Loosely install valve rear bolt (2) to cylinder head, do not
tighten bolt.
5. Loosely install the EGR tube flange nut (2) to valve.

6. Tighten the valve to cylinder head bolts (1) to 31 N·m (23 ft.
lbs.).
7. Tighten the flange nut (2) to 11 N·m (95 in. lbs.).
8. Tighten the solenoid to valve bolt (3) to 11 N·m (95 in. lbs.).
9. Connect the solenoid harness connector (1).

10. Connect the vacuum hose (2).
25 - 30 AIR INJECTION ZH
AIR INJECTION
TABLE OF CONTENTS
page page
AIR INJECTION SWITCHOVER SOLENOID

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 31 SWITCHOVER VALVE
AIR PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
AIR INJECTION
DESCRIPTION
1 - AIR PUMP SWITCHOVER VALVE (LH) 4 - AIR PUMP

2 - MANIFOLD ABSOLUTE PRESSURE SENSOR 5 - VACUUM CHECK VALVE
3 - AIR PUMP SWITCHOVER SOLENOID 6 - AIR PUMP SWITCHOVER VALVE (RH)
ZH AIR INJECTION 25 - 31
This vehicle is equipped with an air pump that injects air into the exhaust to reduce the emissions during engine
warmup. The air injected into the exhaust will cause the catalytic converters to heat up more quickly. This will
improve the emission levels during a cold start. The air pump switchover system incorporates an air pump (4) with
two air pump switchover valves (1 and 6), an air pump switchover solenoid (3), an air pump relay, a vacuum check
valve (5) and the PCM.
The air pump relay is located in the relay control module and can be easily identified by referring to the relay control
module label. The air pump is mounted to the top center of the engine timing cover. The air pump switchover valves
(1 and 6) are located at the front, top of the engine, mounted just in front of the left and right cylinder covers. The
air pump switchover solenoid (3) is mounted on the right front of the engine, just below the air pump switchover
valve RH (6).
OPERATION
Air is allowed to enter the exhaust when the PCM simulta-
neously actuates the air pump relay, air pump (1), and air
pump switchover solenoid (4) after engine startup for up to 2
1/2 minutes. The following conditions must also be met in
order for the system to become active:
• Coolant temperature >10°C (50°F) but <60°C (140°F)
• Engine speed <3000 rpm
• Throttle valve not wide open
After an actuation, the air injection system will remain deacti-
vated until the coolant temperature drops from >60°C (140°F)
to <40°C (104°F).
The air pump (1) draws in air through a maintenance-free filter

and pumps it to the air pump switchover valves (3 and 6). The
air pump switchover valves (3 and 6) prevent exhaust gases
from flowing back into the air pump (1).
The air pump switchover solenoid (4) is supplied with vacuum from the intake manifold through a check valve (5).
When the air pump switchover solenoid (4) is activated, it passes engine vacuum to the air pump switchover valves
(3 and 6). The air which is delivered via the air pump switchover tube (2) is forced through the valves into the
cylinder head openings to the exhaust. The injected air reacts with the hot exhaust gases in the outlet port. An
oxidation of carbon monoxides (CO) and hydrocarbons (HC) takes place and results in an additional increase in the
exhaust temperature.
SPECIFICATIONS
TORQUE

AIR PUMP RETAINING 20 — 177
BRACKET
AIR PUMP
REMOVAL
3. Disconnect the air pump switchover tube (1).
4. Disconnect the air pump harness connector (2).
5. Remove the air pump retaining bolt (2).

6. Remove the air pump (1) from the air pump retaining
bracket (3).
INSTALLATION
1. Position the air pump (1) into the air pump retaining bracket
(3).
2. Install the air pump retaining bolt (2) and tighten to 20 N·m
(177 in. lbs.) torque.
3. Connect the air pump harness connector (2).

4. Connect the air pump switchover tube (1).
SWITCHOVER SOLENOID
REMOVAL
3. Disconnect the air pump switchover solenoid harness con-
nector (2).
4. Disconnect the vacuum lines (1).
5. Pull the air pump switchover solenoid locking tab (1) away
from air pump switchover solenoid (2).
6. Remove the air pump switchover solenoid (2) from air
pump switchover solenoid retaining bracket (3).
INSTALLATION
1. Position the air pump switchover solenoid (2) above air
pump switchover solenoid mounting bracket (3) and lower
until air pump switchover solenoid locking tab (1) snaps into
place.
2. Connect the vacuum lines (1).

3. Connect the air pump switchover solenoid harness connec-
tor (2).
SWITCHOVER VALVE
REMOVAL
3. Disconnect the vacuum line (3).
4. Disconnect the air pump switchover tube (2).
5. Remove the air pump switchover valve retaining bolt (4).
6. Remove the air pump switchover valve (1) discard the old
gasket.
INSTALLATION
1. Position the new gasket between intake manifold and air
pump switchover valve (1).
2. Install the retaining bolt (4) and tighten to 20 N·m (177 in.
lbs.).
3. Connect the vacuum line (3).
4. Connect the air pump switchover tube (2).
ZH ON-BOARD DIAGNOSTICS 25 - 37
ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
page page
TASK MANAGER OPERATION - TASK MANAGER . . . . . . . . . . . . 37

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
TASK MANAGER
DESCRIPTION
The PCM is responsible for efficiently coordinating the operation of all the emissions-related components. The PCM
is also responsible for determining if the diagnostic systems are operating properly. The software designed to carry
out these responsibilities is called the Task Manager.
OPERATION - TASK MANAGER

The Task Manager determines which tests happen when and which functions occur when. Many of the diagnostic
steps required by OBD II must be performed under specific operating conditions. The Task Manager software orga-
nizes and prioritizes the diagnostic procedures. The job of the Task Manager is to determine if conditions are appro-
priate for tests to be run, monitor the parameters for a trip for each test, and record the results of the test. Following
are the responsibilities of the Task Manager software:
• Test Sequence
• MIL Illumination
• Diagnostic Trouble Codes (DTCs)
• Trip Indicator
• Freeze Frame Data Storage
• Similar Conditions Window
Test Sequence
In many instances, emissions systems must fail diagnostic tests more than once before the PCM illuminates the
MIL. These tests are know as ’two trip monitors.’ Other tests that turn the MIL lamp on after a single failure are
known as ’one trip monitors.’ A trip is defined as ’start the vehicle and operate it to meet the criteria necessary to
run the given monitor.’
Many of the diagnostic tests must be performed under certain operating conditions. However, there are times when
tests cannot be run because another test is in progress (conflict), another test has failed (pending) or the Task
Manager has set a fault that may cause a failure of the test (suspend).
• Pending
Under some situations, the Task Manager will not run a monitor if the MIL is illuminated and a fault is stored
from another monitor. In these situations, the Task Manager postpones monitors pending resolution of the
original fault. The Task Manager does not run the test until the problem is remedied.
For example, when the MIL is illuminated for an Oxygen Sensor fault, the Task Manager does not run the
Catalyst Monitor until the Oxygen Sensor fault is remedied. Since the Catalyst Monitor is based on signals
from the Oxygen Sensor, running the test would produce inaccurate results.
• Conflict
There are situations when the Task Manager does not run a test if another monitor is in progress. In these
situations, the effects of another monitor running could result in an erroneous failure. If this conflict is present,
the monitor is not run until the conflicting condition passes. Most likely the monitor will run later after the con-
flicting monitor has passed.
For example, if the Fuel System Monitor is in progress, the Task Manager does not run the EGR Monitor.
Since both tests monitor changes in air/fuel ratio and adaptive fuel compensation, the monitors will conflict with
each other.
25 - 38 ON-BOARD DIAGNOSTICS ZH
• Suspend
Occasionally the Task Manager may not allow a two trip fault to mature. The Task Manager will suspend the
maturing of a fault if a condition exists that may induce an erroneous failure. This prevents illuminating the MIL
for the wrong fault and allows more precise diagnosis.
For example, if the PCM is storing a one trip fault for the Oxygen Sensor and the EGR monitor, the Task
Manager may still run the EGR Monitor but will suspend the results until the Oxygen Sensor Monitor either
passes or fails. At that point the Task Manager can determine if the EGR system is actually failing or if an
Oxygen Sensor is failing.
MIL Illumination
The PCM Task Manager carries out the illumination of the MIL. The Task Manager triggers MIL illumination upon
test failure, depending on monitor failure criteria.
The Task Manager Screen shows both a Requested MIL state and an Actual MIL state. When the MIL is illuminated
upon completion of a test for a third trip, the Requested MIL state changes to OFF. However, the MIL remains
illuminated until the next key cycle. During the key cycle for the third good trip, the Requested MIL state is OFF,
while the Actual MIL state is ON. After the next key cycle, the MIL is not illuminated and both MIL states read OFF.
Diagnostic Trouble Codes (DTCs)

With OBD II, different DTC faults have different priorities according to regulations. As a result, the priorities deter-
mine MIL illumination and DTC erasure. DTCs are entered according to individual priority. DTCs with a higher pri-
ority overwrite lower priority DTCs.
Priorities
• Priority 0 - Non-emissions related trouble codes
• Priority 1 - One trip failure of a two trip fault for non-fuel system and non-misfire.
• Priority 2 - One trip failure of a two trip fault for fuel system (rich/lean) or misfire.
• Priority 3 - Two trip failure for a non-fuel system and non-misfire or matured one trip comprehensive com-
ponent fault.
• Priority 4 — Two trip failure or matured fault for fuel system (rich/lean) and misfire or one trip catalyst dam-
aging misfire.
Non-emissions related failures have no priority. One trip failures of two trip faults have low priority. Two trip failures
or matured faults have higher priority. One and two trip failures of fuel system and misfire monitor take precedence
over non-fuel system and non-misfire failures.
DTC Self Erasure

With one trip components or systems, the MIL is illuminated upon test failure and DTCs are stored.
Two trip monitors are components requiring failure in two consecutive trips for MIL illumination. Upon failure of the
first test, the Task Manager enters a maturing code. If the component fails the test for a second time the code
matures and a DTC is set.
After three good trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a
warm-up cycle counter. DTCs are automatically erased following 40 warm-up cycles if the component does not fail
again.
For misfire and fuel system monitors, the component must pass the test under a Similar Conditions Window in order
to record a good trip. A Similar Conditions Window is when engine RPM is within ±375 rpm and load is within ±10%
of when the fault occurred.
Note: It is important to understand that a component does not have to fail under a similar window of oper-
ation to mature. It must pass the test under a Similar Conditions Window when it failed to record a Good
Trip for DTC erasure for misfire and fuel system monitors.
DTCs can be erased anytime with a DRB IIIT. Erasing the DTC with the DRB IIIT erases all OBD II information. The
DRB IIIT automatically displays a warning that erasing the DTC will also erase all OBD II monitor data. This includes
all counter information for warmup cycles, trips and Freeze Frame.
ZH ON-BOARD DIAGNOSTICS 25 - 39
Trip Indicator
The Trip is essential for running monitors and extinguishing the MIL. In OBD II terms, a trip is a set of vehicle
operating conditions that must be met for a specific monitor to run. All trips begin with a key cycle.
Good Trip
The Good Trip counters are as follows:
• Specific Good Trip
• Fuel System Good Trip
• Misfire Good Trip
• Alternate Good Trip (appears as a Global Good Trip on DRB IIIT)
• Comprehensive Components
• Major Monitor
• Warmup Cycles
Specific Good Trip
The term Good Trip has different meanings depending on the circumstances:
• If the MIL is OFF, a trip is defined as when the Oxygen Sensor Monitor and the Catalyst Monitor have been
completed in the same drive cycle.
• If the MIL is ON and a DTC was set by the Fuel Monitor or Misfire Monitor (both continuous monitors), the
vehicle must be operated in the Similar Condition Window for a specified amount of time.
• If the MIL is ON and a DTC was set by a Task Manager commanded once-per-trip monitor (such as the
Oxygen Sensor Monitor, Catalyst Monitor, Purge Flow Monitor, Leak Detection Pump Monitor, EGR Monitor or
Oxygen Sensor Heater Monitor), a good trip is when the monitor is passed on the next start-up.
• If the MIL is ON and any other emissions DTC was set (not an OBD II monitor), a good trip occurs when the
Oxygen Sensor Monitor and Catalyst Monitor have been completed, or two minutes of engine run time if the
Oxygen Sensor Monitor and Catalyst Monitor have been stopped from running.
Fuel System Good Trip
To count a good trip (three required) and turn off the MIL, the following conditions must occur:
• Engine in closed loop
• Operating in Similar Conditions Window
• Short Term multiplied by Long Term less than threshold
• Less than threshold for a predetermined time
If all of the previous criteria are met, the PCM will count a good trip (three required) and turn off the MIL.
Misfire Good Trip
If the following conditions are met the PCM will count one good trip (three required) in order to turn off the MIL:
• Operating in Similar Condition Window
• 1000 engine revolutions with no misfire
Warmup Cycles
Once the MIL has been extinguished by the Good Trip Counter, the PCM automatically switches to a Warmup Cycle
Counter that can be viewed on the DRB IIIT. Warmup Cycles are used to erase DTCs and Freeze Frames. Forty
Warmup cycles must occur in order for the PCM to self-erase a DTC and Freeze Frame. A Warmup Cycle is defined
as follows:
• Engine coolant temperature must start below and rise above 71°C (160°F)
• Engine coolant temperature must rise by 4.4°C (40°F)
• No further faults occur
Freeze Frame Data Storage

Once a failure occurs, the Task Manager records several engine operating conditions and stores it in a Freeze
Frame. The Freeze Frame is considered one frame of information taken by an onboard data recorder. When a fault
occurs, the PCM stores the input data from various sensors so that technicians can determine under what vehicle
operating conditions the failure occurred.
25 - 40 ON-BOARD DIAGNOSTICS ZH
The data stored in Freeze Frame is usually recorded when a system fails the first time for two trip faults. Freeze
Frame data will only be overwritten by a different fault with a higher priority.
Note: Erasing DTCs, either with the DRB IIIT or by disconnecting the battery, also clears all Freeze Frame
data.
Similar Conditions Window

The Similar Conditions Window displays information about engine operation during a monitor. Absolute MAP (engine
load) and Engine RPM are stored in this window when a failure occurs. There are two different Similar conditions
Windows: Fuel System and Misfire.
FUEL SYSTEM
• Fuel System Similar Conditions Window — An indicator that ’Absolute MAP When Fuel Sys Fail’ and
’RPM When Fuel Sys Failed’ are all in the same range when the failure occurred. Indicated by switching from
’NO’ to ’YES’.
• Absolute MAP When Fuel Sys Fail — The stored MAP reading at the time of failure. Informs the user at
what engine load the failure occurred.
• Absolute MAP — A live reading of engine load to aid the user in accessing the Similar Conditions Window.
• RPM When Fuel Sys Fail — The stored RPM reading at the time of failure. Informs the user at what
engine RPM the failure occurred.
• Engine RPM — A live reading of engine RPM to aid the user in accessing the Similar Conditions Window.
• Adaptive Memory Factor — The PCM utilizes both Short Term Compensation and Long Term Adaptive to
calculate the Adaptive Memory Factor for total fuel correction.
• Upstream O2S Volts — A live reading of the Oxygen Sensor to indicate its performance. For example,
stuck lean, stuck rich, etc.
• SCW Time in Window (Similar Conditions Window Time in Window) — A timer used by the PCM that
indicates that, after all Similar Conditions have been met, if there has been enough good engine running time
in the SCW without failure detected. This timer is used to increment a Good Trip.
• Fuel System Good Trip Counter — A Trip Counter used to turn OFF the MIL for Fuel System DTCs. To
increment a Fuel System Good Trip, the engine must be in the Similar Conditions Window, Adaptive Memory
Factor must be less than the calibrated threshold and the Adaptive Memory Factor must stay below that
threshold for a calibrated amount of time.
• Test Done This Trip — Indicates that the monitor has already been run and completed during the current
trip.
MISFIRE
• Same Misfire Warm-Up State — Indicates if the misfire occurred when the engine was warmed up above
71°C (160°F).
• In Similar Misfire Window — An indicator that ’Absolute MAP When Misfire Occurred’ and ’RPM When
Misfire Occurred’ are all in the same range when the failure occurred. Indicated by switching from ’NO’ to
’YES’.
• Absolute MAP When Misfire Occurred — The stored MAP reading at the time of failure. Informs the user
at what engine load the failure occurred.
• Absolute MAP — A live reading of engine load to aid the user in accessing the Similar Conditions Window.
• RPM When Misfire Occurred — The stored RPM reading at the time of failure. Informs the user at what
engine RPM the failure occurred.
• Engine RPM — A live reading of engine RPM to aid the user in accessing the Similar Conditions Window.
• Adaptive Memory Factor — The PCM utilizes both Short Term Compensation and Long Term Adaptive to
calculate the Adaptive Memory Factor for total fuel correction.
• 200 Rev Counter — Counts 0–100 720 degree cycles.
• SCW Cat 200 Rev Counter — Counts when in similar conditions.
• SCW FTP 1000 Rev Counter — Counts 0–4 when in similar conditions.
• Misfire Good Trip Counter — Counts up to three to turn OFF the MIL.
• Misfire Data— Data collected during test.
• Test Done This Trip— Indicates YES when the test is done.
ZH INDEX 1
Description Group-Page Description Group-Page Description Group-Page

INDEX
ABS BRAKE MESSAGE, DIAGNOSIS AND ACCESSORY DRIVE - SPECIFICATIONS- AIR FLOW (MAF) SENSOR - REMOVAL,
TESTING - (P0600) . . . . . . . . . . . . . . . . . . . 21-12 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
ABS BRAKE SYSTEM - STANDARD ACCESSORY DRIVE BELT - DIAGNOSIS AIR INJECTION - DESCRIPTION . . . . . . . . . 25-30
PROCEDURE, BLEEDING . . . . . . . . . . . . . . . 5-203 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-43 AIR INJECTION - OPERATION . . . . . . . . . . . 25-31
ABS CAN MESSAGE INCORRECT, ACCESSORY FUSE BLOCK - AIR INJECTION - SPECIFICATIONS . . . . . . . 25-31
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-15 DESCRIPTION, UNDERHOOD . . . . . . . . . 8W-97-5 AIR INJECTION RELAY CIRCUIT,
ABS CAN MESSAGE MISSING, ACCESSORY FUSE BLOCK - DIAGNOSIS AND TESTING - (P0410)
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-18 INSTALLATION, UNDERHOOD . . . . . . . . . 8W-97-5 SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . 9-362
ABS, DIAGNOSIS AND TESTING - ACCESSORY FUSE BLOCK - OPERATION, AIR INJECTION SWITCHOVER SOLENOID
INCORRECT CAN MESSAGE FROM . . . . . . 21-169 UNDERHOOD . . . . . . . . . . . . . . . . . . . . . 8W-97-5 CIRCUIT, DIAGNOSIS AND TESTING -
ABS LEFT FRONT SENSOR MESSAGE, ACCESSORY FUSE BLOCK - REMOVAL, (P0412) SECONDARY . . . . . . . . . . . . . . . . . 9-365
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-22 UNDERHOOD . . . . . . . . . . . . . . . . . . . . . 8W-97-5 AIR INJECTION SYSTEM, DIAGNOSIS
ABS LEFT REAR SENSOR MESSAGE, ACCIDENT REPORT DRIVER CIRCUIT AND TESTING - (P0410) SECONDARY . . . . 9-356
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-25 HIGH, DIAGNOSIS AND TESTING - AIR NOZZLE - INSTALLATION, CENTER . . 24-108
ABS RIGHT FRONT SENSOR MESSAGE, (P2513) ENHANCED . . . . . . . . . . . . . . . . . . 9-499 AIR NOZZLE - REMOVAL, CENTER . . . . . . 24-107
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-28 ACCIDENT REPORT DRIVER CIRCUIT AIR NOZZLE, INSTALLATION - SIDE . . . . . 24-108
ABS RIGHT REAR SENSOR MESSAGE, LOW, DIAGNOSIS AND TESTING - AIR NOZZLE, REMOVAL - SIDE . . . . . . . . . 24-107
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-31 (P2513) ENHANCED . . . . . . . . . . . . . . . . . . 9-504 AIR OUTLET COVER - INSTALLATION,
ABS VERIFICATION TEST, DIAGNOSIS ACTUATOR - INSTALLATION, FUEL DOOR FOOTWELL . . . . . . . . . . . . . . . . . . . . . . . . 24-111
AND TESTING . . . . . . . . . . . . . . . . . . 5-148,5-185 LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-45 AIR OUTLET COVER - REMOVAL,
A/C APPLICATION TABLE, ACTUATOR - INSTALLATION, LIFTGATE FOOTWELL . . . . . . . . . . . . . . . . . . . . . . . . 24-110
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 24-70 LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-46 AIR PUMP - INSTALLATION . . . . . . . . . . . . 25-33
A/C COMPRESSOR - DESCRIPTION . . . . . 24-119 ACTUATOR - REMOVAL, FUEL DOOR AIR PUMP - REMOVAL . . . . . . . . . . . . . . . . 25-32
A/C COMPRESSOR - INSTALLATION . . . . . 24-122 LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-44 AIR SWITCHOVER VALVE -
A/C COMPRESSOR - OPERATION . . . . . . . 24-120 ACTUATOR - REMOVAL, LIFTGATE LOCK . . 8N-46 INSTALLATION, RECIRC . . . . . . . . . . . . . . . 24-87
A/C COMPRESSOR - REMOVAL . . . . . . . . 24-121 ACTUATOR SLOW RESPONSE, AIR SWITCHOVER VALVE - REMOVAL,
A/C COMPRESSOR CLUTCH - DIAGNOSIS AND TESTING - DRIVER RECIRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-87
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-72 DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-2 AIR SWITCHOVER VALVE CIRCUIT,
A/C COMPRESSOR CLUTCH - ACTUATOR SLOW RESPONSE, DIAGNOSIS AND TESTING -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-73 DIAGNOSIS AND TESTING - FUEL RECIRCULATED . . . . . . . . . . . . . . . . . . . . . . 24-46
A/C COMPRESSOR CLUTCH CIRCUIT, DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5 AIR TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-43 ACTUATOR SLOW RESPONSE, DESCRIPTION, INTAKE.. . . . . . . . . . . . . . . . . 14-36
A/C CONDENSER - DESCRIPTION . . . . . . . 24-125 DIAGNOSIS AND TESTING - AIR TEMPERATURE SENSOR -
A/C CONDENSER - INSTALLATION . . . . . . 24-127 PASSENGER DOOR/LIFTGATE LOCK . . . . . . . 8N-8 OPERATION, INTAKE . . . . . . . . . . . . . . . . . . 14-36
A/C CONDENSER - OPERATION . . . . . . . . . 24-125 ACTUATOR STUCK, DIAGNOSIS AND AIR TEMPERATURE SENSOR CIRCUIT
A/C CONDENSER - REMOVAL . . . . . . . . . . 24-126 TESTING - (P0211) THROTTLE . . . . . 9-252,9-257 HIGH, DIAGNOSIS AND TESTING -
A/C EVAPORATOR - DESCRIPTION . . . . . . 24-130 ADHESIVES - INSTALLATION . . . . . . . . . . 23-115 (P0113) INTAKE . . . . . . . . . . . . . . . . . . . . . . . 9-36
A/C EVAPORATOR - INSTALLATION . . . . . 24-132 ADHESIVES - REMOVAL . . . . . . . . . . . . . . 23-114 AIR TEMPERATURE SENSOR CIRCUIT
A/C EVAPORATOR - OPERATION . . . . . . . . 24-130 ADHESIVES - SPECIFICATIONS, LOW, DIAGNOSIS AND TESTING -
A/C EVAPORATOR - REMOVAL . . . . . . . . . 24-130 STRUCTURAL . . . . . . . . . . . . . . . . . . . . . . . 23-87 (P0112) INTAKE . . . . . . . . . . . . . . . . . . . . . . . 9-31
A/C EXPANSION VALVE - DESCRIPTION . . 24-138 ADJUSTING FRONT AXLE CAMBER AND AIRBAG - DESCRIPTION, DRIVER . . . . . . . . 8O-97
A/C EXPANSION VALVE - DIAGNOSIS CASTER, STANDARD PROCEDURE - AIRBAG - DESCRIPTION, PASSENGER . . . 8O-101
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 24-139 CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 AIRBAG - DESCRIPTION, SIDE IMPACT . . 8O-112
A/C EXPANSION VALVE - INSTALLATION . 24-140 ADJUSTING FRONT TOE-IN - STANDARD AIRBAG - INSTALLATION, DRIVER . . . . . . 8O-100
A/C EXPANSION VALVE - OPERATION . . . . 24-139 PROCEDURE, CHECKING . . . . . . . . . . . . . . . . 2-10 AIRBAG - INSTALLATION, PASSENGER . . 8O-103
A/C EXPANSION VALVE - REMOVAL . . . . . 24-140 ADJUSTING REAR AXLE TOE - AIRBAG - INSTALLATION, SIDE IMPACT . . 8O-114
A/C HEATER CONTROL MODULE - STANDARD PROCEDURE, CHECKING . . . . . . 2-12 AIRBAG - OPERATION, DRIVER . . . . . . . . . 8O-98
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-78 ADJUSTING THE GLOVE COMPARTMENT, AIRBAG - OPERATION, PASSENGER . . . . . 8O-101
A/C HEATER CONTROL MODULE - STANDARD PROCEDURE . . . . . . . . . . . . . . 23-141 AIRBAG - OPERATION, SIDE IMPACT . . . . 8O-113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-81 ADJUSTING VEHICLE LEVEL AT FRONT AIRBAG - REMOVAL, DRIVER . . . . . . . . . . 8O-100
A/C HEATER CONTROL MODULE - AND REAR AXLES, STANDARD AIRBAG - REMOVAL, PASSENGER . . . . . . 8O-102
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-78 PROCEDURE - INSPECTING . . . . . . . . . . . . . . 2-8 AIRBAG - REMOVAL, SIDE IMPACT . . . . . 8O-114
A/C HEATER CONTROL MODULE - ADJUSTING VEHICLE LEVEL AT FRONT AIRBAG ON/OFF SWITCH SIGNAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-79 AND REAR AXLES WITH AN CIRCUIT, DIAGNOSIS AND TESTING -
A/C HEATER CONTROL MODULE, ELECTRONIC INCLINOMETER, PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-49
DIAGNOSIS AND TESTING - NO STANDARD PROCEDURE - INSPECTING . . . . . 2-8 AIRBAG SQUIB CIRCUIT, DIAGNOSIS
RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-21 ADJUSTING WHEEL BEARING, AND TESTING - DRIVER . . . . . . . . . . . . . . . . 8O-4
A/C PERFORMANCE, DIAGNOSIS AND DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 2-24 AIRBAG SQUIB CIRCUIT, DIAGNOSIS
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-64 AFTER A SUPPLEMENTAL RESTRAINT AND TESTING - LEFT SIDE . . . . . . . . . . . . . 8O-29
A/C PRESSURE SENSOR CIRCUIT, DEPLOYMENT - STANDARD AIRBAG SQUIB CIRCUIT, DIAGNOSIS
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-28 PROCEDURE, SERVICE . . . . . . . . . . . . . . . . 8O-84 AND TESTING - PASSENGER . . . . . . . . . . . 8O-23
A/C PRESSURE TRANSDUCER - AFTER AN OIL CHANGE, STANDARD AIRBAG SQUIB CIRCUIT, DIAGNOSIS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-86 PROCEDURE - RESETTING THE FSS AND TESTING - RIGHT SIDE . . . . . . . . . . . 8O-35
A/C PRESSURE TRANSDUCER - MAINTENANCE INDICATOR . . . . . . . . . . . . . 8J-78 AIRBAG VERIFICATION TEST, DIAGNOSIS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-86 AIMING - STANDARD PROCEDURE, AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8O-67
ACCEL PEDAL SENSOR CAN MESSAGE WASHER NOZZLE . . . . . . . . . . . . . . . . . . . . 8R-28 AIRBAG WARNING INDICATOR CIRCUIT,
INCORRECT, DIAGNOSIS AND TESTING AIR CLEANER ELEMENT - INSTALLATION . . 9-609 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-46
- (P0600) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-34 AIR CLEANER ELEMENT - REMOVAL . . . . . 9-609 AJAR SWITCH - DESCRIPTION, DOOR . . . 8L-144
ACCELERATION SENSOR - AIR CLEANER HOUSING - INSTALLATION . . 9-608 AJAR SWITCH - INSTALLATION, HOOD . . . 8Q-50
DESCRIPTION, LATERAL . . . . . . . . . . . . . . . 5-199 AIR CLEANER HOUSING - REMOVAL . . . . . 9-608 AJAR SWITCH - INSTALLATION,
ACCELERATION SENSOR - AIR CONDITIONER - DESCRIPTION, LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-146
INSTALLATION, LATERAL . . . . . . . . . . . . . . 5-200 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-55 AJAR SWITCH - OPERATION, DOOR . . . . . 8L-144
ACCELERATION SENSOR - OPERATION, AIR CONDITIONER, OPERATION - AJAR SWITCH - REMOVAL, HOOD . . . . . . . 8Q-50
LATERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-199 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-59 AJAR SWITCH - REMOVAL, LIFTGATE . . . 8L-145
ACCELERATION SENSOR - REMOVAL, AIR CONDITIONING - ELECTRICAL AJAR SWITCH, INSTALLATION - DOOR . . 8L-146
LATERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 DIAGNOSTICS - DESCRIPTION, AJAR SWITCH, REMOVAL - DOOR . . . . . . 8L-145
ACCELERATION SENSOR CIRCUIT, HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1 ALARM SWITCH - INSTALLATION,
DIAGNOSIS AND TESTING - ESP AIR CONDITIONING - ELECTRICAL TOW-AWAY . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-59
LATERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138 DIAGNOSTICS - OPERATION, HEATING . . . . . 24-2 ALARM SWITCH - REMOVAL, TOW-
ACCELERATOR PEDAL - DESCRIPTION . . . . 14-26 AIR FLOW CIRCUIT, DIAGNOSIS AND AWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-59
ACCELERATOR PEDAL - INSTALLATION . . . 14-27 TESTING - (P0102) MASS . . . . . . . . . . . . . . . 9-10 ALARM TRIPS ON ITS OWN, DIAGNOSIS
ACCELERATOR PEDAL - REMOVAL . . . . . . . 14-26 AIR FLOW (MAF) SENSOR - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8Q-32
ACCELERATOR PEDAL POSITION DESCRIPTION, MANIFOLD . . . . . . . . . . . . . 14-37 ALIGNMENT - DESCRIPTION, WHEEL . . . . . . . 2-4
SENSOR - DESCRIPTION . . . . . . . . . . . . . . . 14-28 AIR FLOW (MAF) SENSOR - ALIGNMENT - OPERATION, WHEEL . . . . . . . . 2-5
ACCELERATOR PEDAL POSITION INSTALLATION, MANIFOLD . . . . . . . . . . . . . 14-39 ALIGNMENT - SPECIFICATIONS, WHEEL . . . . 2-13
SENSOR - OPERATION . . . . . . . . . . . . . . . . 14-29 AIR FLOW (MAF) SENSOR - OPERATION, ALIGNMENT, ADJUSTMENTS - EXHAUST
ACCESSORY DRIVE - DESCRIPTION . . . . . . . 7-42 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
ACCESSORY DRIVE - OPERATION . . . . . . . . 7-42
2 INDEX ZH

ALIGNMENT INSPECTION - STANDARD ARM - INSTALLATION, LOWER CONTROL . . 2-37, BACKUP LAMP SWITCH - REMOVAL . . . . 21-353
PROCEDURE, CHASSIS . . . . . . . . . . . . . . . . . . 2-7 2-55 BALANCE SHAFT - DESCRIPTION . . . . . . . . 9-698
ALIGNMENT INSPECTION - STANDARD ARM - INSTALLATION, PITMAN . . . . . . . . . 19-45 BALANCE SHAFT - INSTALLATION . . . . . . . 9-701
PROCEDURE, WHEEL . . . . . . . . . . . . . . . . . . . 2-6 ARM - INSTALLATION, UPPER CONTROL . . . 2-39 BALANCE SHAFT - REMOVAL . . . . . . . . . . . 9-698
ALIGNMENT, STANDARD PROCEDURE - ARM - REMOVAL, IDLER . . . . . . . . . . . . . . . 19-41 BALANCE, STANDARD PROCEDURE -
WINDSHIELD WIPER BLADE . . . . . . . . . . . 8R-36 ARM - REMOVAL, LOWER CONTROL . . 2-34,2-53 TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . 22-42
ALUMINUM THREAD REPAIR - ARM - REMOVAL, PITMAN . . . . . . . . . . . . . 19-43 BALL JOINT - INSTALLATION, LOWER . . . . . 2-32
STANDARD PROCEDURE . . . . . . . . . . . . . . 21-210 ARM - REMOVAL, UPPER CONTROL . . . . . . 2-39 BALL JOINT - REMOVAL, LOWER . . . . . . . . . 2-29
ALWAYS ON, DIAGNOSIS AND TESTING - ARMS - ADJUSTMENT, WIPER . . . . . . . . . . 8R-36 BAR - INSTALLATION, STABILIZER . . . . 2-47,2-76
HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-5 ARMS - DESCRIPTION, WIPER . . . . . . . . . . 8R-33 BAR - INSTALLATION, TRACK . . . . . . . . . . . . 2-53
ALWAYS ON, DIAGNOSIS AND TESTING - ARMS - INSTALLATION, WIPER . . . . . . . . . 8R-34 BAR - REMOVAL, STABILIZER . . . . . . . 2-46,2-72
RADIATOR COOLING FAN . . . . . . . . . . . . . . . . 7-6 ARMS - REMOVAL, WIPER . . . . . . . . . . . . . 8R-33 BAR - REMOVAL, TRACK . . . . . . . . . . . . . . . 2-52
AMBIENT TEMPERATURE SENSOR ASH RECEIVER LAMP - INSTALLATION . . 8L-153 BAS RELEASE SWITCH CIRCUIT,
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . 24-3 ASH RECEIVER LAMP - REMOVAL . . . . . . 8L-151 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 5-166
AMBIENT TEMPERATURE SENSOR ASH RECEIVER LAMP INOPERATIVE, BAS SOLENOID VALVE CIRCUIT,
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . 8J-9 DIAGNOSIS AND TESTING . . . . . . . . . . . . 8L-130 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 5-181
AMPLIFIER - INSTALLATION . . . . . . . . . . . . 8A-22 ASH TRAY - INSTALLATION . . . . . . . . . . . 23-190 BAS TRAVEL SENSOR CIRCUIT,
AMPLIFIER - REMOVAL . . . . . . . . . . . . . . . 8A-20 ASHTRAY - REMOVAL . . . . . . . . . . . . . . . . 23-180 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 5-171
AN ELECTRONIC INCLINOMETER, AUDIO - SERVICE INFORMATION - BASE - DESCRIPTION, BRAKES . . . . . . . . . . . 5-3
STANDARD PROCEDURE - INSPECTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8A-19 BASE - WARNING, BRAKES . . . . . . . . . . . . . . 5-4
AND ADJUSTING VEHICLE LEVEL AT AUDIO - SERVICE INFORMATION - BASE BRAKE SYSTEM, DIAGNOSIS AND
FRONT AND REAR AXLES WITH . . . . . . . . . . . 2-8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8A-20 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
AN OIL CHANGE, STANDARD AUDIO - SERVICE INFORMATION - BASE COAT/CLEAR COAT FINISH -
PROCEDURE - RESETTING THE FSS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 8A-20 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 23-199
MAINTENANCE INDICATOR AFTER . . . . . . . 8J-78 AUDIO SYSTEM - DIAGNOSIS AND BATTERY - DESCRIPTION . . . . . . . . . . . . . . . 8F-7
ANGLE AND SPEED, DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-20 BATTERY - DIAGNOSIS AND TESTING . . . . . 8F-9
TESTING - (P0104) MAF SENSOR AUTOMATIC - NAG1 SERVICE BATTERY - INSTALLATION . . . . . . . . . . . . . . 8F-18
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 INFORMATION - DESCRIPTION . . . . . . . . . 21-184 BATTERY - OPERATION . . . . . . . . . . . . . . . . . 8F-8
ANGLE SENSOR - DESCRIPTION, AUTOMATIC - NAG1 SERVICE BATTERY - REMOVAL . . . . . . . . . . . . . . . . . 8F-17
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 INFORMATION - OPERATION . . . . . . . . . . . 21-186 BATTERY CABLES - DIAGNOSIS AND
ANGLE SENSOR - INSTALLATION, AUTOMATIC DAY / NIGHT MIRROR - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-68 BATTERY, DIAGNOSIS AND TESTING -
ANGLE SENSOR - OPERATION, AUTOMATIC DAY / NIGHT MIRROR - TIRE PRESSURE SENSOR/
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8N-68 TRANSMITTER LOW . . . . . . . . . . . . . . . . . . 22-32
ANGLE SENSOR - REMOVAL, STEERING . . 5-200 AUTOMATIC DAY / NIGHT MIRROR - BATTERY ELECTROLYTE LEVEL -
ANGLE SENSOR CIRCUIT, DIAGNOSIS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-68 STANDARD PROCEDURE, CHECKING . . . . . 8F-16
AND TESTING - STEERING . . . . . . . . . . . . . 5-124 AUTOMATIC DAY/NIGHT MIRROR BATTERY, STANDARD PROCEDURE -
ANTENNA - DESCRIPTION, REAR INOPERATIVE, DIAGNOSIS AND CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-10
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-24 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-59 BATTERY SYSTEM - CLEANING . . . . . . . . . . . 8F-5
ANTENNA - INSTALLATION, REAR AUTOMATIC TRANSMISSION - BATTERY SYSTEM - DESCRIPTION . . . . . . . . 8F-2
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-26 DIAGNOSIS AND TESTING . . . . . . . . . . . . 21-207 BATTERY SYSTEM - DIAGNOSIS AND
ANTENNA - REMOVAL, REAR WINDOW . . . 8A-25 AUTOMATIC TRANSMISSION - SPECIAL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
ANTENNA CIRCUIT, DIAGNOSIS AND TOOLS, NAG1 . . . . . . . . . . . . . . . . . . . . . . 21-252 BATTERY SYSTEM - INSPECTION . . . . . . . . . 8F-6
TESTING - SENTRY KEY . . . . . . . . . . . . . . . 8Q-38 AUTOMATIC TRANSMISSION - BATTERY SYSTEM - OPERATION . . . . . . . . . 8F-2
ANTENNA GRID REPAIR - STANDARD SPECIFICATIONS, NAG1 . . . . . . . . . . . . . . 21-251 BATTERY SYSTEM - SPECIAL TOOLS . . . . . . 8F-7
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8A-24 AUTOMATIC TRANSMISSION, BATTERY SYSTEM - SPECIFICATIONS . . . . . . 8F-6
ANTENNA MODULE - INSTALLATION, DIAGNOSIS AND TESTING . . . . . . . . . . . . 21-206 BATTERY SYSTEM HIGH, DIAGNOSIS
REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . 8A-23 AUTOMATIC TRANSMISSION FLUID - AND TESTING - (P0563) . . . . . . . . . . . . . . . 9-419
ANTENNA MODULE - REMOVAL, REAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 BATTERY SYSTEM LOW, DIAGNOSIS
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-23 AXLE CAMBER - STANDARD AND TESTING - (P0562) . . . . . . . . . . . . . . . 9-417
ANTENNA RING - INSTALLATION, PROCEDURE, CHECKING REAR . . . . . . . . . . . 2-11 BATTERY SYSTEM VOLTAGE, DIAGNOSIS
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8Q-55 AXLE CAMBER AND CASTER, STANDARD AND TESTING - (P0561) . . . . . . . . . . . . . . . 9-414
ANTENNA RING - REMOVAL, SENTRY PROCEDURE - CHECKING AND BATTERY TESTER - STANDARD
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-54 ADJUSTING FRONT . . . . . . . . . . . . . . . . . . . . . 2-8 PROCEDURE, USING MICRO 420 . . . . . . . . 8F-12
ANTILOCK BRAKE - DESCRIPTION, AXLE CARRIER - INSTALLATION, REAR . . . . 2-93 BATTERY VOLTAGE INDICATOR
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-62 AXLE CARRIER - REMOVAL, REAR . . . . . . . . 2-87 INOPERATIVE, DIAGNOSIS AND
ANTILOCK BRAKE - INSTALLATION, AXLE TOE - STANDARD PROCEDURE, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-46
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-64 CHECKING AND ADJUSTING REAR . . . . . . . . 2-12 BCM AND CENTRAL LOCKING
ANTILOCK BRAKE - OPERATION, AXLES, STANDARD PROCEDURE - PUMP/SECURITY SYSTEM MODULE,
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-62 INSPECTING AND ADJUSTING VEHICLE DIAGNOSIS AND TESTING - NO
ANTILOCK BRAKE - REMOVAL, LEVEL AT FRONT AND REAR . . . . . . . . . . . . . 2-8 COMMUNICATION WITH . . . . . . . . . . . . . . . . 8Q-8
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-63 AXLES WITH AN ELECTRONIC BEAM BULB - INSTALLATION, HIGH . . . . . 8L-105
ANTILOCK BRAKE, DIAGNOSIS AND INCLINOMETER, STANDARD BEAM BULB - REMOVAL, HIGH . . . . . . . . 8L-103
TESTING - NO RESPONSE FROM PROCEDURE - INSPECTING AND BEAM BULB, INSTALLATION - LOW . . . . . 8L-104
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-25 ADJUSTING VEHICLE LEVEL AT FRONT BEAM BULB, REMOVAL - LOW . . . . . . . . . 8L-103
ANTI-THEFT TOW SENSOR - AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 BEAM HEADLAMP INOPERATIVE,
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-58 B BUS (-) CIRCUIT FAILURE, DIAGNOSIS DIAGNOSIS AND TESTING - LEFT HIGH . . . 8L-23
ANTI-THEFT TOW SENSOR - REMOVAL . . . 8Q-57 AND TESTING - CAN . . . . . . . . . . . . . . . . . . 8Q-10 BEAM HEADLAMP INOPERATIVE,
ANTI-THEFT TOW SENSOR SIGNAL B BUS (+) CIRCUIT FAILURE, DIAGNOSIS DIAGNOSIS AND TESTING - LEFT LOW . . . 8L-20
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 8Q-22 AND TESTING - CAN . . . . . . . . . . . . . . . . . . 8Q-13 BEAM HEADLAMP INOPERATIVE,
A-PILLAR TRIM - INSTALLATION . . . . . . . 23-162 BACK COVER - INSTALLATION, PLASTIC . 23-205 DIAGNOSIS AND TESTING - RIGHT
A-PILLAR TRIM - REMOVAL . . . . . . . . . . . 23-161 BACK COVER - INSTALLATION, SEAT . . . . 23-208 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-29
APPLICATION TABLE, SPECIFICATIONS - BACK COVER - REMOVAL, PLASTIC . . . . . 23-204 BEAM HEADLAMP INOPERATIVE,
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-70 BACK COVER - REMOVAL, SEAT . . . . . . . . 23-206 DIAGNOSIS AND TESTING - RIGHT
APPS 5-VOLT SUPPLY CIRCUIT, BACK ELEMENT - INSTALLATION, LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-26
DIAGNOSIS AND TESTING - (P0121) . . . . . . 9-61 HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-41 BEAM INDICATOR INOPERATIVE,
APPS SENSOR #1 AND #2 VOLTAGE BACK ELEMENT - REMOVAL, HEATED DIAGNOSIS AND TESTING - HIGH . . . . . . . 8J-42
CORRELATION, DIAGNOSIS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 BEARING - DESCRIPTION, HUB . . . . . . . . . . 2-23
TESTING - (P0221) . . . . . . . . . . . . . . . . . . . 9-262 BACK, INSTALLATION - SEAT . . . . . . . . . . 23-205 BEARING - INSTALLATION, CENTER . . . . . . . 3-32
APPS SIGNAL #1 CIRCUIT HIGH, BACK, REMOVAL - SEAT . . . . . . . . . . . . . . 23-204 BEARING - INSTALLATION, HUB . . . . . . . . . . 2-70
DIAGNOSIS AND TESTING - (P0123) . . . . . . 9-70 BACK UP LAMP INOPERATIVE, BEARING - INSTALLATION, OUTPUT
APPS SIGNAL #1 CIRCUIT LOW, DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8L-50 SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-316
DIAGNOSIS AND TESTING - (P0122) . . . . . . 9-65 BACK UP LAMP INOPERATIVE, BEARING - INSTALLATION, PILOT . . . . . . . . 6-23
APPS SIGNAL #2 CIRCUIT HIGH, DIAGNOSIS AND TESTING - RIGHT . . . . . . 8L-62 BEARING - REMOVAL, CENTER . . . . . . . . . . . 3-31
DIAGNOSIS AND TESTING - (P0223) . . . . . 9-279 BACKUP LAMP - INSTALLATION . . . . . . . . . 8L-88 BEARING - REMOVAL, HUB . . . . . . . . . . . . . 2-67
APPS SIGNAL #2 CIRCUIT LOW, BACKUP LAMP - REMOVAL . . . . . . . . . . . . 8L-88 BEARING - REMOVAL, OUTPUT SHAFT . . . 21-314
DIAGNOSIS AND TESTING - (P0222) . . . . . 9-274 BACKUP LAMP SWITCH - DESCRIPTION . . 8L-89 BEARING - REMOVAL, PILOT . . . . . . . . . . . . 6-23
ARM - INSTALLATION, IDLER . . . . . . . . . . . 19-42 BACKUP LAMP SWITCH - INSTALLATION . 21-354
ZH INDEX 3

BEARING BRIDGE - INSTALLATION, BLOCK - DESCRIPTION, ENGINE FUSE . . 8W-97-2 BRACKET AND ISOLATOR -
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 9-622 BLOCK - DESCRIPTION, FUSE . . . . . . . . 8W-97-6 INSTALLATION, SUPPORT . . . . . . . . . . . . . . 11-14
BEARING BRIDGE - REMOVAL, BLOCK - DESCRIPTION, UNDERHOOD BRACKET AND ISOLATOR - REMOVAL,
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 9-619 ACCESSORY FUSE . . . . . . . . . . . . . . . . . 8W-97-5 SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
BEARING CLEARANCE USING BLOCK - INSPECTION, ENGINE . . . . . . . . . . 9-633 BRACKETS - INSTALLATION, ENGINE
PLASTIGAGET - STANDARD BLOCK - INSTALLATION, ENGINE FUSE . 8W-97-3 MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-656
PROCEDURE, MEASURING . . . . . . . . . . . . . 9-591 BLOCK - INSTALLATION, UNDERHOOD BRACKETS - REMOVAL, ENGINE MOUNT . . 9-655
BEARING, DIAGNOSIS AND TESTING - ACCESSORY FUSE . . . . . . . . . . . . . . . . . 8W-97-5 BRAKE - DESCRIPTION, CONTROLLER
ADJUSTING WHEEL . . . . . . . . . . . . . . . . . . . 2-24 BLOCK - OPERATION, ENGINE FUSE . . . 8W-97-2 ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-62
BEARINGS - DESCRIPTION, BLOCK - OPERATION, FUSE . . . . . . . . . . 8W-97-6 BRAKE - INSTALLATION, CONTROLLER
CONNECTING ROD . . . . . . . . . . . . . . . . . . . 9-638 BLOCK - OPERATION, UNDERHOOD ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-64
BEARINGS - DESCRIPTION, ACCESSORY FUSE . . . . . . . . . . . . . . . . . 8W-97-5 BRAKE - OPERATION, CONTROLLER
CRANKSHAFT AND MAIN . . . . . . . . . . . . . . 9-647 BLOCK - REMOVAL, ENGINE FUSE . . . . . 8W-97-2 ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-62
BEARINGS - INSTALLATION, BLOCK - REMOVAL, UNDERHOOD BRAKE - OPERATION, PARKING . . . . . . . . . . 5-57
CRANKSHAFT AND MAIN . . . . . . . . . . . . . . 9-650 ACCESSORY FUSE . . . . . . . . . . . . . . . . . 8W-97-5 BRAKE - REMOVAL, CONTROLLER
BEARINGS - OPERATION, CRANKSHAFT BLOWER MOTOR - INSTALLATION . . . . . . . 24-90 ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-63
AND MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 9-647 BLOWER MOTOR - REMOVAL . . . . . . . . . . . 24-88 BRAKE BOOSTER - DESCRIPTION,
BEARINGS - REMOVAL, CRANKSHAFT BLOWER MOTOR REGULATOR - POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
AND MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 9-647 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-76 BRAKE BOOSTER - INSTALLATION,
BEARINGS - STANDARD PROCEDURE, BLOWER MOTOR REGULATOR - POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
CONNECTING RODS . . . . . . . . . . . . . . . . . . 9-638 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-74 BRAKE BOOSTER - OPERATION, POWER . . . 5-49
BEARING/SLAVE CYLINDER - BODY - DESCRIPTION, THROTTLE . . . . . . . 14-47 BRAKE BOOSTER - REMOVAL, POWER . . . . 5-50
DESCRIPTION, RELEASE . . . . . . . . . . . . . . . . 6-19 BODY - INSTALLATION, THROTTLE . . . . . . . 14-48 BRAKE CALIPER - ASSEMBLY, FRONT
BEARING/SLAVE CYLINDER - BODY - OPERATION, THROTTLE . . . . . . . . . 14-47 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
INSTALLATION, RELEASE . . . . . . . . . . . . . . . 6-20 BODY - REMOVAL, THROTTLE . . . . . . . . . . 14-48 BRAKE CALIPER - CLEANING, DISC . . . . . . . 5-30
BEARING/SLAVE CYLINDER - BODY CONTROL MODULE - BRAKE CALIPER - DISASSEMBLY, FRONT
OPERATION, RELEASE . . . . . . . . . . . . . . . . . 6-19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-71 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
BEARING/SLAVE CYLINDER - REMOVAL, BODY CONTROL MODULE - BRAKE CALIPER - INSPECTION, DISC . . . . . 5-30
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8E-73 BRAKE CALIPER - INSTALLATION, REAR
BELT - CLEANING, DRIVE . . . . . . . . . . . . . . . 7-45 BODY CONTROL MODULE - OPERATION . . 8E-71 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
BELT - DIAGNOSIS AND TESTING, BODY CONTROL MODULE - REMOVAL . . . . 8E-72 BRAKE CALIPER - REMOVAL, REAR . . . . . . . 5-28
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . 7-43 BODY CONTROL MODULE AND CENTRAL BRAKE CALIPER, INSTALLATION -
BELT - INSPECTION, DRIVE . . . . . . . . . . . . . 7-45 LOCKING PUMP/SECURITY SYSTEM FRONT DISC . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
BELT - INSTALLATION, DRIVE . . . . . . . . . . . . 7-46 MODULE, DIAGNOSIS AND TESTING - BRAKE CALIPER, REMOVAL - FRONT
BELT - REMOVAL, DRIVE . . . . . . . . . . . . . . . 7-45 NO COMMUNICATION WITH . . . . . . . . . . . . 8N-20 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
BELT & SEAT BELT TENSIONER - BODY CONTROL MODULE, DIAGNOSIS BRAKE CALIPERS - DESCRIPTION, DISC . . . 5-24
DESCRIPTION, SEAT . . . . . . . . . . . . . . . . . 8O-119 AND TESTING - NO RESPONSE FROM . . . . 8E-36 BRAKE CALIPERS - OPERATION, DISC . . . . . 5-24
BELT & SEAT BELT TENSIONER - BODY CONTROL MODULE INTERNAL BRAKE COMPONENTS, SPECIFICATIONS . . . 5-10
INSPECTION, SEAT . . . . . . . . . . . . . . . . . . 8O-125 FAILURE, DIAGNOSIS AND TESTING . . . . . . . 23-2 BRAKE, DIAGNOSIS AND TESTING - NO
BELT & SEAT BELT TENSIONER - BODY CONTROL MODULE INTERNAL RESPONSE FROM CONTROLLER
INSTALLATION, SEAT . . . . . . . . . . . . . . . . 8O-125 FAILURE, DIAGNOSIS AND TESTING . . . . . 8N-11 ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-25
BELT & SEAT BELT TENSIONER - BODY DIMENSIONS - SPECIFICATIONS . . . 23-55 BRAKE, DIAGNOSIS AND TESTING -
OPERATION, SEAT . . . . . . . . . . . . . . . . . . . 8O-120 BODY GAP MEASUREMENTS - PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
BELT & SEAT BELT TENSIONER - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 23-53 BRAKE FLUID CONTAMINATION,
REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . 8O-122 BODY LUBRICATION - SPECIFICATIONS . . . 23-32 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-42
BELT BUCKLE - DESCRIPTION, SEAT . . . . 8O-115 BODY LUBRICATION, STANDARD BRAKE FLUID LEVEL SENSOR -
BELT BUCKLE - INSTALLATION, SEAT . . . 8O-117 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 23-31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-75
BELT BUCKLE - REMOVAL, SEAT . . . . . . . 8O-116 BODY VERIFICATION TEST, DIAGNOSIS BRAKE FLUID LEVEL SENSOR -
BELT INDICATOR INOPERATIVE, AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8A-16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
DIAGNOSIS AND TESTING - SEAT . . . . . . . . 8J-48 BODY VERIFICATION TEST, DIAGNOSIS BRAKE FLUID, SPECIFICATIONS . . . . . . . . . . 5-43
BELT TENSIONER - DESCRIPTION, SEAT AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8E-44 BRAKE HOSE - INSTALLATION, REAR . . . . . . 5-16
BELT & SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-119 BODY VERIFICATION TEST, DIAGNOSIS BRAKE HOSE, INSTALLATION - FRONT . . . . . 5-14
BELT TENSIONER - INSPECTION, SEAT AND TESTING . . . . . . . . . . . . . 8G-20,8G-34,8G-8 BRAKE HOSE, REMOVAL - FRONT . . . . . . . . 5-12
BELT & SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-125 BODY VERIFICATION TEST, DIAGNOSIS BRAKE HOSE, REMOVAL - REAR . . . . . . . . . 5-13
BELT TENSIONER - INSTALLATION . . . . . . . . 7-44 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-53 BRAKE HOSES AND LINES, DIAGNOSIS
BELT TENSIONER - INSTALLATION, SEAT BODY VERIFICATION TEST, DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 5-10
BELT & SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-125 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8H-7 BRAKE LAMP RELAY - DESCRIPTION . . . . . 8L-90
BELT TENSIONER - OPERATION, SEAT BODY VERIFICATION TEST, DIAGNOSIS BRAKE LAMP RELAY - INSTALLATION . . . . 8L-90
BELT & SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-120 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8J-52 BRAKE LAMP RELAY - OPERATION . . . . . . 8L-90
BELT TENSIONER - REMOVAL . . . . . . . . . . . 7-44 BODY VERIFICATION TEST, DIAGNOSIS BRAKE LAMP RELAY - REMOVAL . . . . . . . . 8L-90
BELT TENSIONER - REMOVAL, SEAT AND TESTING . . . . . . . . . . . . . . . . . 8L-133,8L-77 BRAKE LAMP SWITCH - DESCRIPTION . . . 8L-91
BELT & SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-122 BODY VERIFICATION TEST, DIAGNOSIS BRAKE LAMP SWITCH - INSTALLATION . . . 8L-92
BELT TENSIONER CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 8N-119,8N-28,8N-62,8N-93 BRAKE LAMP SWITCH - OPERATION . . . . . 8L-91
AND TESTING - DRIVER SEAT . . . . . . . . . . 8O-53 BOOSTER - DESCRIPTION, POWER BRAKE LAMP SWITCH - REMOVAL . . . . . . 8L-91
BELT TENSIONER CIRCUIT, DIAGNOSIS BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 BRAKE LAMP SWITCH CIRCUIT,
AND TESTING - PASSENGER SEAT . . . . . . . 8O-56 BOOSTER - INSTALLATION, POWER DIAGNOSIS AND TESTING . . . . . . . . 5-143,5-176
BELT TENSIONER SQUIB CIRCUIT, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 BRAKE LINES - DESCRIPTION . . . . . . . . . . . 5-10
DIAGNOSIS AND TESTING - DRIVER BOOSTER - OPERATION, POWER BRAKE . . . 5-49 BRAKE MESSAGE, DIAGNOSIS AND
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10 BOOSTER - REMOVAL, POWER BRAKE . . . . 5-50 TESTING - (P0600) ABS . . . . . . . . . . . . . . . 21-12
BELT TENSIONER SQUIB CIRCUIT, BOOSTER, DIAGNOSIS AND TESTING - BRAKE PADS - INSTALLATION, REAR
DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER . . . . . . . . . . . . . 5-44 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
PASSENGER SEAT . . . . . . . . . . . . . . . . . . . . 8O-17 BOOT - INNER - INSTALLATION, CV . . . . . . . . 3-9 BRAKE PADS - REMOVAL, REAR DISC . . . . . 5-19
BLADE ALIGNMENT, STANDARD BOOT - INNER - REMOVAL, CV . . . . . . . . . . . 3-7 BRAKE PADS, INSTALLATION - FRONT
PROCEDURE - WINDSHIELD WIPER . . . . . 8R-36 BOOT - OUTER - INSTALLATION, CV . . . . . . 3-12 DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
BLADES - DESCRIPTION, WIPER . . . . . . . . 8R-36 BOOT - OUTER - REMOVAL, CV . . . . . . . . . . 3-11 BRAKE PADS, REMOVAL - FRONT DISC . . . . 5-17
BLADES - OPERATION, WIPER . . . . . . . . . . 8R-36 BOX LAMP - INSTALLATION, GLOVE . . . . 8L-147 BRAKE PRESSURE SENSOR -
BLEEDING - STANDARD PROCEDURE, BOX LAMP - REMOVAL, GLOVE . . . . . . . . 8L-146 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-201
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BOX LAMP INOPERATIVE, DIAGNOSIS BRAKE PRESSURE SENSOR -
BLEEDING ABS BRAKE SYSTEM - AND TESTING - GLOVE . . . . . . . . . . . . . . . 8L-127 INSTALLATION . . . . . . . . . . . . . . . . . . . 5-201,5-77
STANDARD PROCEDURE . . . . . . . . . . . . . . . 5-203 BOX LAMP/SWITCH - DESCRIPTION, BRAKE PRESSURE SENSOR -
BLEEDING PROCEDURE, STANDARD GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-148 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-201
PROCEDURE - MASTER CYLINDER . . . . . . . 5-46 BOX LAMP/SWITCH - INSTALLATION, BRAKE PRESSURE SENSOR - REMOVAL . . 5-201,
BLEEDING, STANDARD PROCEDURE - GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-149 5-76
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 BOX LAMP/SWITCH - OPERATION, BRAKE PRESSURE SENSOR 1 CIRCUIT,
BLEEDING, STANDARD PROCEDURE - GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-148 DIAGNOSIS AND TESTING - ESP . . . . . . . . 5-128
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . 6-7 BOX LAMP/SWITCH - REMOVAL, GLOVE . 8L-148 BRAKE PRESSURE SENSOR 2 CIRCUIT,
BLOCK - CLEANING, ENGINE . . . . . . . . . . . 9-633 BRACKET - INSTALLATION, REARVIEW DIAGNOSIS AND TESTING - ESP . . . . . . . . 5-133
BLOCK - DESCRIPTION, ENGINE . . . . . . . . . 9-633 MIRROR SUPPORT . . . . . . . . . . . . . . . . . . . 8N-69
4 INDEX ZH

BRAKE ROTOR - INSTALLATION, REAR CALIPER - CLEANING, DISC BRAKE . . . . . . . 5-30 CAN MESSAGE INCORRECT, DIAGNOSIS
DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 CALIPER - DISASSEMBLY, FRONT DISC AND TESTING - (P0600) IC . . . . . . . . . . . . . 21-57
BRAKE ROTOR - REMOVAL, REAR DISC . . . 5-39 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 CAN MESSAGE INCORRECT, DIAGNOSIS
BRAKE ROTOR, INSTALLATION - FRONT CALIPER - INSPECTION, DISC BRAKE . . . . . 5-30 AND TESTING - (P0600) SLA . . . . . . . . . . . 21-64
DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 CALIPER - INSTALLATION, REAR DISC CAN MESSAGE MISSING, DIAGNOSIS
BRAKE ROTOR MACHINING, STANDARD BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 AND TESTING - (P0600) ABS . . . . . . . . . . . 21-18
PROCEDURE - DISC . . . . . . . . . . . . . . . . . . . 5-38 CALIPER - REMOVAL, REAR BRAKE . . . . . . . 5-28 CAN MESSAGE MISSING, DIAGNOSIS
BRAKE ROTOR, REMOVAL - FRONT DISC . . 5-38 CALIPER, INSTALLATION - FRONT DISC AND TESTING - (P0600) ENGINE . . . . . . . . 21-44
BRAKE ROTORS, DIAGNOSIS AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 CAN MESSAGE MISSING, DIAGNOSIS
TESTING - DISC . . . . . . . . . . . . . . . . . . . . . . 5-36 CALIPER, REMOVAL - FRONT DISC AND TESTING - (P0600) IC/HVAC . . . . . . . . 21-60
BRAKE SYSTEM - STANDARD BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 CAN MESSAGE NOT VALID, DIAGNOSIS
PROCEDURE, BLEEDING ABS . . . . . . . . . . . 5-203 CALIPERS - DESCRIPTION, DISC BRAKE . . . 5-24 AND TESTING - LR WHEEL SPIN . . . . . . . 21-173
BRAKE SYSTEM, DIAGNOSIS AND CALIPERS - OPERATION, DISC BRAKE . . . . . 5-24 CAN MESSAGE NOT VALID, DIAGNOSIS
TESTING - BASE . . . . . . . . . . . . . . . . . . . . . . . 5-5 CAMBER - STANDARD PROCEDURE, AND TESTING - RR WHEEL SPIN . . . . . . . 21-175
BRAKE WARNING INDICATOR CHECKING REAR AXLE . . . . . . . . . . . . . . . . . 2-11 CAN SIGNAL LOST TO TRANS
INOPERATIVE, DIAGNOSIS AND CAMBER AND CASTER, STANDARD PERFORMANCE, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-44 PROCEDURE - CHECKING AND TESTING - (P0571) STOP LAMP
BRAKES - BASE - DESCRIPTION . . . . . . . . . . . 5-3 ADJUSTING FRONT AXLE . . . . . . . . . . . . . . . . 2-8 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-421
BRAKES - BASE - WARNING . . . . . . . . . . . . . . 5-4 CAMBER STRUT - INSTALLATION . . . . . . . . . 2-50 CANISTER - DESCRIPTION, VAPOR . . . . . . 25-20
BRAKES - ESP SERVICE INFORMATION - CAMBER STRUT - REMOVAL . . . . . . . . . . . . 2-49 CANISTER - INSTALLATION, VAPOR . . . . . . 25-21
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-188 CAMSHAFT - CLEANING . . . . . . . . . . . . . . . 9-626 CANISTER - OPERATION, VAPOR . . . . . . . . 25-20
BREAK-IN - STANDARD PROCEDURE, CAMSHAFT - DESCRIPTION . . . . . . . . . . . . 9-625 CANISTER - REMOVAL, VAPOR . . . . . . . . . . 25-20
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-74 CAMSHAFT - INSPECTION . . . . . . . . . . . . . . 9-626 CANISTER SHUTOFF VALVE -
BRIDGE - INSTALLATION, CAMSHAFT CAMSHAFT - INSTALLATION . . . . . . . . . . . . 9-626 DESCRIPTION, CHARCOAL . . . . . . . . . . . . . 25-16
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-622 CAMSHAFT - OPERATION . . . . . . . . . . . . . . 9-625 CANISTER SHUTOFF VALVE -
BRIDGE - REMOVAL, CAMSHAFT CAMSHAFT - REMOVAL . . . . . . . . . . . . . . . 9-626 INSTALLATION, CHARCOAL . . . . . . . . . . . . . 25-16
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-619 CAMSHAFT BEARING BRIDGE - CANISTER SHUTOFF VALVE -
BUCKLE - DESCRIPTION, SEAT BELT . . . . 8O-115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-622 OPERATION, CHARCOAL . . . . . . . . . . . . . . . 25-16
BUCKLE - INSTALLATION, SEAT BELT . . . 8O-117 CAMSHAFT BEARING BRIDGE - CANISTER SHUTOFF VALVE - REMOVAL,
BUCKLE - REMOVAL, SEAT BELT . . . . . . . 8O-116 REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-619 CHARCOAL . . . . . . . . . . . . . . . . . . . . . . . . . 25-16
BULB - INSTALLATION, HIGH BEAM . . . . . 8L-105 CAMSHAFT POSITION SENSOR - CANISTER SHUTOFF VALVE, DIAGNOSIS
BULB - REMOVAL, HIGH BEAM . . . . . . . . 8L-103 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 8I-5 AND TESTING - (P0446) CHARCOAL . . . . . 9-384
BULB, INSTALLATION - LOW BEAM . . . . . 8L-104 CAMSHAFT POSITION SENSOR - CAP - CLEANING, PRESSURE . . . . . . . . . . . . . 7-36
BULB, REMOVAL - LOW BEAM . . . . . . . . . 8L-103 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4 CAP - DESCRIPTION, FUEL FILLER . . . . . . . 25-18
BULBS - STANDARD PROCEDURE, CAMSHAFT POSITION SENSOR - CAP - OPERATION, FUEL FILLER . . . . . . . . 25-18
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 8J-81 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4 CAP - OPERATION, PRESSURE . . . . . . . . . . . 7-36
BUMPER - INSTALLATION . . . . . . . . . . . . . . 23-51 CAMSHAFT POSITION SENSOR CAP - WARNING, PRESSURE . . . . . . . . . . . . 7-36
BUMPER - REMOVAL . . . . . . . . . . . . . . . . . 23-51 PERFORMANCE, DIAGNOSIS AND CAPACITIES - SPECIFICATIONS, FLUID . . . . . . 0-1
BURNT FLUID - DIAGNOSIS AND TESTING - (P0341) . . . . . . . . . . . . . . . . . . . 9-346 CAPACITY - SPECIFICATIONS, CHARGE . . . 24-70
TESTING, CAUSES OF . . . . . . . . . . . . . . . . 21-293 CAMSHAFT POSITION TIMING CARDAN UNIVERSAL JOINTS -
BUS (-) CIRCUIT FAILURE, DIAGNOSIS OVER-ADVANCED, DIAGNOSIS AND ASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . . . . 3-33
AND TESTING - CAN B . . . . . . . . . . . . . . . . 8Q-10 TESTING - (P0341) . . . . . . . . . . . . . . . . . . . 9-344 CARDAN UNIVERSAL JOINTS -
BUS (+) CIRCUIT FAILURE, DIAGNOSIS CAMSHAFT POSITION TIMING DISASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . 3-32
AND TESTING - CAN B . . . . . . . . . . . . . . . . 8Q-13 OVER-RETARDED, DIAGNOSIS AND CARGO LAMP - INSTALLATION . . . . . . . . . 8L-138
BUS CIRCUIT, DIAGNOSIS AND TESTING TESTING - (P0341) . . . . . . . . . . . . . . . . . . . 9-340 CARGO LAMP - REMOVAL . . . . . . . . . . . . 8L-137
- CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-167 CAN B BUS (-) CIRCUIT FAILURE, CARGO LAMP INOPERATIVE, DIAGNOSIS
BUS CIRCUIT, DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-10 AND TESTING . . . . . . . . . . . . . . . . . . . . . . 8L-124
- (P0720) CAN . . . . . . . . . . . . . . . . . . . . . . 21-109 CAN B BUS (+) CIRCUIT FAILURE, CARGO LAMP UNIT - INSTALLATION . . . . 8L-140
BUS COMMUNICATION GENERAL DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-13 CARGO LAMP UNIT - REMOVAL . . . . . . . . 8L-139
MALFUNCTION, DIAGNOSIS AND CAN BUS CIRCUIT, DIAGNOSIS AND CARPET (LEFT), INSTALLATION . . . . . . . . 23-168
TESTING - CAN . . . . . . . . . . . . . . . . . . 5-162,5-88 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-167 CARPET (LEFT), REMOVAL . . . . . . . . . . . . 23-163
BUS COMMUNICATION GENERAL CAN BUS CIRCUIT, DIAGNOSIS AND CARPET (RIGHT) - INSTALLATION . . . . . . 23-171
MALFUNCTION, DIAGNOSIS AND TESTING - (P0720) . . . . . . . . . . . . . . . . . . 21-109 CARPET (RIGHT), REMOVAL . . . . . . . . . . . 23-166
TESTING - CAN . . . . . . . . . . . . . . . . . . . . . . 8J-36 CAN BUS COMMUNICATION GENERAL CARRIER - INSTALLATION, REAR AXLE . . . . 2-93
BUS MESSAGE, DIAGNOSIS AND MALFUNCTION, DIAGNOSIS AND CARRIER - REMOVAL, REAR AXLE . . . . . . . . 2-87
TESTING - (P0600) NO CLUSTER . . . . . . . . 9-445 TESTING . . . . . . . . . . . . . . . . . . . . . . . 5-162,5-88 CASTER, STANDARD PROCEDURE -
BUS MESSAGE, DIAGNOSIS AND CAN BUS COMMUNICATION GENERAL CHECKING AND ADJUSTING FRONT
TESTING - (P0600) NO MALFUNCTION, DIAGNOSIS AND AXLE CAMBER . . . . . . . . . . . . . . . . . . . . . . . . 2-8
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-433 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-36 CATALYTIC 1/1 EFFICIENCY, DIAGNOSIS
BUT DOES NOT START, DIAGNOSIS AND CAN COMMUNICATIONS WITH CAB, AND TESTING - (P0422) . . . . . . . . . . . . . . . 9-369
TESTING - ENGINE CRANKS . . . . . . . . . . . . 9-563 DIAGNOSIS AND TESTING - NO . . . . . . . . . 8J-24 CATALYTIC 2/1 EFFICIENCY, DIAGNOSIS
CAB, DIAGNOSIS AND TESTING - NO CAN COMMUNICATIONS WITH PCM, AND TESTING - (P0432) . . . . . . . . . . . . . . . 9-372
CAN COMMUNICATIONS WITH . . . . . . . . . . 8J-24 DIAGNOSIS AND TESTING - NO . . . . . 5-164,5-90 CAUSES OF BURNT FLUID - DIAGNOSIS
CAB INTERNAL FAILURE, DIAGNOSIS CAN COMMUNICATIONS WITH PCM, AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-293
AND TESTING . . . . . . . . . . . . . . . . . . . 5-153,5-80 DIAGNOSIS AND TESTING - NO . . . . . . . . . 8J-18 CAUTION, PLUMBING . . . . . . . . . . . . . . . . 24-115
CAB MODULE, DIAGNOSIS AND TESTING CAN COMMUNICATIONS WITH PCM, CENTER AIR NOZZLE - INSTALLATION . . . 24-108
- (P0600) NO CAN MESSAGE FROM . . . . . . 9-427 DIAGNOSIS AND TESTING - NO . . . . . . . . . 8Q-25 CENTER AIR NOZZLE - REMOVAL . . . . . . . 24-107
CAB SYSTEM OVERVOLTAGE, CAN COMMUNICATIONS WITH TCM, CENTER BEARING - INSTALLATION . . . . . . . 3-32
DIAGNOSIS AND TESTING . . . . . . . . . 5-158,5-85 DIAGNOSIS AND TESTING - NO . . . . . . . . . . 5-92 CENTER BEARING - REMOVAL . . . . . . . . . . . 3-31
CAB SYSTEM UNDERVOLTAGE, CAN COMMUNICATIONS WITH TCM, CENTER CONSOLE - INSTALLATION,
DIAGNOSIS AND TESTING . . . . . . . . . 5-155,5-82 DIAGNOSIS AND TESTING - NO . . . . . . . . . 8J-30 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-188
CABLE - DESCRIPTION, REVERSE CAN MESSAGE FROM ABS, DIAGNOSIS CENTER CONSOLE - REMOVAL, REAR . . . 23-178
LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . 21-388 AND TESTING - INCORRECT . . . . . . . . . . . 21-169 CENTER CONSOLE COVER -
CABLE - DESCRIPTION, SPARK PLUG . . . . . 8I-13 CAN MESSAGE FROM CAB MODULE, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-186
CABLE - INSTALLATION, IGNITION LOCK . . 19-21 DIAGNOSIS AND TESTING - (P0600) CENTER CONSOLE COVER - REMOVAL . . 23-176
CABLE - INSTALLATION, LATCH RELEASE . 23-139 NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-427 CENTER CONSOLE (FRONT),
CABLE - INSTALLATION, SPARK PLUG . . . . 8I-13 CAN MESSAGE FROM ECM FROM SLA, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-183
CABLE - REMOVAL, IGNITION LOCK . . . . . . 19-19 DIAGNOSIS AND TESTING - (P0600) . . . . . 21-38 CENTER CONSOLE (FRONT), REMOVAL . . 23-173
CABLE - REMOVAL, LATCH RELEASE . . . . 23-138 CAN MESSAGE FROM EIS CONTROL CENTER HIGH MOUNTED STOP LAMP -
CABLE - REMOVAL, SPARK PLUG . . . . . . . . 8I-13 MODULE, DIAGNOSIS AND TESTING - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-92
CABLES - DESCRIPTION . . . . . . . . . . . . . . . 8F-19 (P0600) INCORRECT . . . . . . . . . . . . . . . . . . 9-425 CENTER HIGH MOUNTED STOP LAMP -
CABLES - DIAGNOSIS AND TESTING, CAN MESSAGE INCORRECT, DIAGNOSIS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8L-93
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19 AND TESTING - (P0600) ABS . . . . . . . . . . . 21-15 CENTER HIGH MOUNTED STOP LAMP -
CABLES - INSTALLATION . . . . . . . . . . . . . . . 5-64 CAN MESSAGE INCORRECT, DIAGNOSIS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-92
CABLES - OPERATION . . . . . . . . . . . . . . . . . 8F-19 AND TESTING - (P0600) ACCEL PEDAL CENTER HIGH MOUNTED STOP LAMP
CABLES - REMOVAL . . . . . . . . . . . . . . . . . . . 5-61 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-34 INOPERATIVE, DIAGNOSIS AND
CALIPER - ASSEMBLY, FRONT DISC CAN MESSAGE INCORRECT, DIAGNOSIS TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-68
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 AND TESTING - (P0600) ENGINE . . . . . . . . 21-41
ZH INDEX 5

CENTERING - STANDARD PROCEDURE, CHECK VALVE - OPERATION, FUEL FILL . . . . 14-7 CIRCUIT, DIAGNOSIS AND TESTING -
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-93 CHECKING AND ADJUSTING FRONT LAMP OUTAGE INDICATOR . . . . . . . . . . . . . . 8J-5
CENTERING SLEEVES - INSTALLATION . . . . . 3-36 AXLE CAMBER AND CASTER, CIRCUIT, DIAGNOSIS AND TESTING -
CENTERING SLEEVES - REMOVAL . . . . . . . . 3-35 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 2-8 LEFT COOLANT CIRCULATION VALVE . . . . . 24-37
CENTERING SLEEVES - SPECIFICATIONS . . . 3-30 CHECKING AND ADJUSTING FRONT CIRCUIT, DIAGNOSIS AND TESTING -
CENTRAL LOCKING PUMP - TOE-IN - STANDARD PROCEDURE . . . . . . . . 2-10 LEFT FRONT WHEEL SPEED SENSOR . . . . . . 5-95
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-36 CHECKING AND ADJUSTING REAR AXLE CIRCUIT, DIAGNOSIS AND TESTING -
CENTRAL LOCKING PUMP - DIAGNOSIS TOE - STANDARD PROCEDURE . . . . . . . . . . 2-12 LEFT HEATER CORE TEMPERATURE
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-36 CHECKING BATTERY ELECTROLYTE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8
CENTRAL LOCKING PUMP/SECURITY LEVEL - STANDARD PROCEDURE . . . . . . . . 8F-16 CIRCUIT, DIAGNOSIS AND TESTING -
SYSTEM MODULE, DIAGNOSIS AND CHECKING ENGINE OIL PRESSURE - LEFT REAR WHEEL SPEED SENSOR . . . . . . 5-107
TESTING - NO COMMUNICATION WITH DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-662 CIRCUIT, DIAGNOSIS AND TESTING -
BCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8 CHECKING FLUID LEVEL - STANDARD LEFT SIDE AIRBAG SQUIB . . . . . . . . . . . . . 8O-29
CENTRAL LOCKING PUMP/SECURITY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-353 CIRCUIT, DIAGNOSIS AND TESTING -
SYSTEM MODULE, DIAGNOSIS AND CHECKING FUEL DELIVERY, DIAGNOSIS LEFT SIDE IMPACT SENSOR SIGNAL . . . . . 8O-59
TESTING - NO COMMUNICATION WITH AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 9-556 CIRCUIT, DIAGNOSIS AND TESTING -
BODY CONTROL MODULE . . . . . . . . . . . . . 8N-20 CHECKING HARD START (FUEL (P0102) MASS AIR FLOW . . . . . . . . . . . . . . . 9-10
CENTRAL LOCKING PUMP/SECURITY SYSTEM), DIAGNOSIS AND TESTING . . . . . 9-560 CIRCUIT, DIAGNOSIS AND TESTING -
SYSTEM MODULE INTERNAL FAILURE, CHECKING REAR AXLE CAMBER - (P0116) ENGINE COOLANT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-26 STANDARD PROCEDURE . . . . . . . . . . . . . . . . 2-11 TEMPERATURE SENSOR SHORT . . . . . . . . . . 9-47
CENTRAL LOCKING PUMP/SECURITY CHECKING TOE-OUT ON TURNS - CIRCUIT, DIAGNOSIS AND TESTING -
SYSTEM MODULE INTERNAL FAILURE, STANDARD PROCEDURE . . . . . . . . . . . . . . . . 2-11 (P0121) APPS 5-VOLT SUPPLY . . . . . . . . . . . 9-61
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-30 CHIME WARNING SYSTEM - DIAGNOSIS CIRCUIT, DIAGNOSIS AND TESTING -
CENTRAL LOCKING PUMP/SECURITY AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8B-4 (P0200) FUEL INJECTOR . . . . . . . . . . . . . . . 9-236
SYSTEM MODULE SYSTEM CHIME/BUZZER - ELECTRICAL CIRCUIT, DIAGNOSIS AND TESTING -
OVERVOLTAGE, DIAGNOSIS AND DIAGNOSTICS - SCHEMATICS AND (P0201) FUEL INJECTOR #1 . . . . . . . . . . . . 9-238
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-5 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 CIRCUIT, DIAGNOSIS AND TESTING -
CENTRAL LOCKING PUMP/SECURITY CIRCUIT - (P0850) TRANS TEMP (P0202) FUEL INJECTOR #2 . . . . . . . . . . . . 9-242
SYSTEM MODULE SYSTEM SENSOR, P/N SWITCH . . . . . . . . . . . . . . . 21-158 CIRCUIT, DIAGNOSIS AND TESTING -
UNDERVOLTAGE, DIAGNOSIS AND CIRCUIT, DIAGNOSIS AND TESTING - (P0203) FUEL INJECTOR #3 . . . . . . . . . . . . 9-244
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2 A/C COMPRESSOR CLUTCH . . . . . . . . . . . . 24-43 CIRCUIT, DIAGNOSIS AND TESTING -
CERT LABEL - DESCRIPTION, VEHICLE CIRCUIT, DIAGNOSIS AND TESTING - (P0204) FUEL INJECTOR #4 . . . . . . . . . . . . 9-246
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 A/C PRESSURE SENSOR . . . . . . . . . . . . . . . 24-28 CIRCUIT, DIAGNOSIS AND TESTING -
CHAIN - INSTALLATION, OIL PUMP CIRCUIT, DIAGNOSIS AND TESTING - (P0205) FUEL INJECTOR #5 . . . . . . . . . . . . 9-248
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-677 AIRBAG WARNING INDICATOR . . . . . . . . . . 8O-46 CIRCUIT, DIAGNOSIS AND TESTING -
CHAIN - INSTALLATION, TIMING . . . . . . . . . . 9-695 CIRCUIT, DIAGNOSIS AND TESTING - (P0206) FUEL INJECTOR #6 . . . . . . . . . . . . 9-250
CHAIN - REMOVAL, OIL PUMP DRIVE . . . . 9-677 AMBIENT TEMPERATURE SENSOR . . . . . . . . 24-3 CIRCUIT, DIAGNOSIS AND TESTING -
CHAIN - REMOVAL, TIMING . . . . . . . . . . . . 9-693 CIRCUIT, DIAGNOSIS AND TESTING - (P0335) CRANKSHAFT POSITION
CHAIN COVER - INSTALLATION, TIMING . . 9-688 AMBIENT TEMPERATURE SENSOR . . . . . . . . 8J-9 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-334
CHAIN COVER - REMOVAL, TIMING . . . . . . 9-685 CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
CHAIN GUIDES - INSTALLATION, TIMING . . 9-703 ANTI-THEFT TOW SENSOR SIGNAL . . . . . . 8Q-22 (P0403) EGR CONTROL . . . . . . . . . . . . . . . 9-354
CHAIN GUIDES - REMOVAL, TIMING . . . . . 9-703 CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
CHAIN TENSIONER - INSTALLATION, BAS RELEASE SWITCH . . . . . . . . . . . . . . . . 5-166 (P0410) SECONDARY AIR INJECTION
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-685 CIRCUIT, DIAGNOSIS AND TESTING - RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-362
CHAIN TENSIONER - REMOVAL, TIMING . . 9-684 BAS SOLENOID VALVE . . . . . . . . . . . . . . . . 5-181 CIRCUIT, DIAGNOSIS AND TESTING -
CHANGE - STANDARD PROCEDURE, CIRCUIT, DIAGNOSIS AND TESTING - (P0412) SECONDARY AIR INJECTION
ENGINE OIL AND FILTER . . . . . . . . . . . . . . . 9-664 BAS TRAVEL SENSOR . . . . . . . . . . . . . . . . . 5-171 SWITCHOVER SOLENOID . . . . . . . . . . . . . . 9-365
CHANGE - STANDARD PROCEDURE, CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-296 BRAKE LAMP SWITCH . . . . . . . . . . . 5-143,5-176 (P0445) EVAP PURGE SOLENOID . . . . . . . . 9-380
CHANGE, STANDARD PROCEDURE - CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
RESETTING THE FSS MAINTENANCE CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . . 21-167 (P0460) FUEL LEVEL SENSOR . . . . . . . . . . 9-408
INDICATOR AFTER AN OIL . . . . . . . . . . . . . 8J-78 CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER SHUTOFF VALVE - COOLANT CIRCULATION PUMP . . . . . . . . . 24-34 (P0715) N2 INPUT SPEED SENSOR . . . . . . 21-97
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-16 CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER SHUTOFF VALVE - COOLANT LEVEL SENSOR/WASHER (P0715) N3 INPUT SPEED SENSOR . . . . . 21-103
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 25-16 FLUID LEVEL SWITCH . . . . . . . . . . . . . . . . . . 8J-2 CIRCUIT, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER SHUTOFF VALVE - CIRCUIT, DIAGNOSIS AND TESTING - (P0720) CAN BUS . . . . . . . . . . . . . . . . . . . 21-109
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 25-16 DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . 8L-121 CIRCUIT, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER SHUTOFF VALVE - CIRCUIT, DIAGNOSIS AND TESTING - (P0743) TCC SOLENOID . . . . . . . . . . . . . . 21-124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 25-16 DOOR LOCK SWITCH SENSE . . . . . . . . . . . 8Q-16 CIRCUIT, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER SHUTOFF VALVE, CIRCUIT, DIAGNOSIS AND TESTING - (P0748) MODULATING PRESSURE
DIAGNOSIS AND TESTING - (P0446) . . . . . 9-384 DOOR LOCK/DOOR UNLOCK SWITCH SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . 21-128
CHARGE - STANDARD PROCEDURE, SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22 CIRCUIT, DIAGNOSIS AND TESTING -
REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-118 CIRCUIT, DIAGNOSIS AND TESTING - (P0753) 1-2/4-5 SOLENOID . . . . . . . . . . . . 21-132
CHARGE CAPACITY - SPECIFICATIONS . . . . 24-70 DOOR UNLOCK SWITCH SENSE . . . . . . . . . 8Q-19 CIRCUIT, DIAGNOSIS AND TESTING -
CHARGING BATTERY, STANDARD CIRCUIT, DIAGNOSIS AND TESTING - (P0758) 2-3 SOLENOID . . . . . . . . . . . . . . . 21-138
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-10 DRIVER AIRBAG SQUIB . . . . . . . . . . . . . . . . 8O-4 CIRCUIT, DIAGNOSIS AND TESTING -
CHARGING SYSTEM - DESCRIPTION . . . . . 8F-24 CIRCUIT, DIAGNOSIS AND TESTING - (P0763) 3-4 SOLENOID . . . . . . . . . . . . . . . 21-144
CHARGING SYSTEM - DIAGNOSIS AND DRIVER SEAT BELT TENSIONER . . . . . . . . . 8O-53 CIRCUIT, DIAGNOSIS AND TESTING -
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24 CIRCUIT, DIAGNOSIS AND TESTING - (P0778) SHIFT PRESSURE SOLENOID . . . 21-150
CHARGING SYSTEM - OPERATION . . . . . . . 8F-24 DRIVER SEAT BELT TENSIONER SQUIB . . . 8O-10 CIRCUIT, DIAGNOSIS AND TESTING -
CHARGING SYSTEM - SCHEMATICS AND CIRCUIT, DIAGNOSIS AND TESTING - PASSENGER AIRBAG ON/OFF SWITCH
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 8F-26 ENGINE COOLANT TEMPERATURE SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-49
CHART - SPECIFICATIONS, TORQUE . . . . . . 5-192 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 CIRCUIT, DIAGNOSIS AND TESTING -
CHART, FRONT SUSPENSION - TORQUE . . . 2-14 CIRCUIT, DIAGNOSIS AND TESTING - PASSENGER AIRBAG SQUIB . . . . . . . . . . . . 8O-23
CHART, RESTRAINTS - TORQUE . . . . . . . . . 8O-87 ESP BRAKE PRESSURE SENSOR 1 . . . . . . . 5-128 CIRCUIT, DIAGNOSIS AND TESTING -
CHASSIS ALIGNMENT INSPECTION - CIRCUIT, DIAGNOSIS AND TESTING - PASSENGER SEAT BELT TENSIONER . . . . . 8O-56
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 2-7 ESP BRAKE PRESSURE SENSOR 2 . . . . . . . 5-133 CIRCUIT, DIAGNOSIS AND TESTING -
CHECK - DIAGNOSIS AND TESTING, CIRCUIT, DIAGNOSIS AND TESTING - PASSENGER SEAT BELT TENSIONER
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-73 ESP LATERAL ACCELERATION SENSOR . . . 5-138 SQUIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17
CHECK OIL LEVEL, STANDARD CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-294 ESP YAW RATE SENSOR . . . . . . . . . . . . . . . 5-119 REAR DEFOGGER SWITCH SENSE . . . . . . . . 8G-2
CHECK, STANDARD PROCEDURE - CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . 9-664 EVAPORATOR TEMPERATURE SENSOR . . . 24-18 REAR SPOILER DRIVER (DOWN) . . . . . . . . 23-16
CHECK STRAP - INSTALLATION . . . . . . . . . 23-89 CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
CHECK STRAP - REMOVAL . . . . . . . . . . . . . 23-88 FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . 8J-7 REAR SPOILER DRIVER (UP) . . . . . . . . . . . 23-13
CHECK VALVE - DESCRIPTION, FUEL CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT, DIAGNOSIS AND TESTING -
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7 HAZARD SWITCH . . . . . . . . . . . . . . . . . . . 8L-118 REAR SPOILER SWITCH SENSE . . . . . . . . . . 23-4
6 INDEX ZH

CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT LOW, DIAGNOSIS AND TESTING CIRCULATION VALVE CIRCUIT,
RECIRCULATED AIR SWITCHOVER - (P0103) MAF SENSOR . . . . . . . . . . . . . . . . 9-17 DIAGNOSIS AND TESTING - RIGHT
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-46 CIRCUIT LOW, DIAGNOSIS AND TESTING COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-40
CIRCUIT, DIAGNOSIS AND TESTING - - (P0107) MAP SENSOR . . . . . . . . . . . . . . . . 9-24 CLEARANCE USING PLASTIGAGET -
REMOTE KEYLESS ENTRY RELAY CIRCUIT LOW, DIAGNOSIS AND TESTING STANDARD PROCEDURE, MEASURING
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 - (P0112) INTAKE AIR TEMPERATURE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-591
CIRCUIT, DIAGNOSIS AND TESTING - SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31 CLOCKSPRING - DESCRIPTION . . . . . . . . . 8O-92
RIGHT COOLANT CIRCULATION VALVE . . . . 24-40 CIRCUIT LOW, DIAGNOSIS AND TESTING CLOCKSPRING - INSTALLATION . . . . . . . . . 8O-96
CIRCUIT, DIAGNOSIS AND TESTING - - (P0117) ENGINE COOLANT CLOCKSPRING - OPERATION . . . . . . . . . . . 8O-92
RIGHT FRONT WHEEL SPEED SENSOR . . . 5-101 TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9-49 CLOCKSPRING - REMOVAL . . . . . . . . . . . . 8O-94
CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT LOW, DIAGNOSIS AND TESTING CLOCKSPRING CENTERING - STANDARD
RIGHT HEATER CORE TEMPERATURE - (P0122) APPS SIGNAL #1 . . . . . . . . . . . . . 9-65 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8O-93
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13 CIRCUIT LOW, DIAGNOSIS AND TESTING CLP/SSM SYSTEM OVERVOLTAGE,
CIRCUIT, DIAGNOSIS AND TESTING - - (P0131) O2 SENSOR 1/1 . . . . . . . . . . . . . . 9-86 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-17
RIGHT REAR WHEEL SPEED SENSOR . . . . 5-113 CIRCUIT LOW, DIAGNOSIS AND TESTING CLP/SSM SYSTEM UNDERVOLTAGE,
CIRCUIT, DIAGNOSIS AND TESTING - - (P0135) O2 SENSOR 1/1 HEATER . . . . . . 9-107 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-14
RIGHT SIDE AIRBAG SQUIB . . . . . . . . . . . . 8O-35 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER - INSTALLATION, INSTRUMENT . 8J-84
CIRCUIT, DIAGNOSIS AND TESTING - - (P0138) O2 SENSOR 2/2 . . . . . . . . . . . . . 9-133 CLUSTER - REMOVAL, INSTRUMENT . . . . . 8J-83
RIGHT SIDE IMPACT SENSOR SIGNAL . . . . 8O-63 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER - SERVICE INFORMATION -
CIRCUIT, DIAGNOSIS AND TESTING - - (P0140) O2 SENSOR 1/2 . . . . . . . . . . . . . 9-137 DESCRIPTION, INSTRUMENT . . . . . . . . . . . 8J-56
SENTRY KEY ANTENNA . . . . . . . . . . . . . . . 8Q-38 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER - SERVICE INFORMATION -
CIRCUIT, DIAGNOSIS AND TESTING - - (P0141) O2 SENSOR 1/2 HEATER . . . . . . 9-141 OPERATION, INSTRUMENT . . . . . . . . . . . . . 8J-59
SHORT RUNNER SOLENOID . . . . . . . . . . . . 9-551 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER BULBS - STANDARD
CIRCUIT, DIAGNOSIS AND TESTING - - (P0151) O2 SENSOR 2/1 . . . . . . . . . . . . . 9-149 PROCEDURE, INSTRUMENT . . . . . . . . . . . . 8J-81
SIREN SIGNAL OUTPUT . . . . . . . . . . . . . . . 8Q-27 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER BUS MESSAGE, DIAGNOSIS
CIRCUIT, DIAGNOSIS AND TESTING - - (P0155) O2 SENSOR 2/1 HEATER . . . . . . 9-163 AND TESTING - (P0600) NO . . . . . . . . . . . . 9-445
SPEED CONTROL SWITCH INPUT . . . . . . . . 9-553 CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER COVER - INSTALLATION,
CIRCUIT, DIAGNOSIS AND TESTING - - (P0161) O2 SENSOR 2/2 HEATER . . . . . . 9-173 INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-160
SPOILER LIMIT SWITCH SIGNAL CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER COVER - REMOVAL,
(DOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10 - (P0222) APPS SIGNAL #2 . . . . . . . . . . . . 9-274 INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154
CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT LOW, DIAGNOSIS AND TESTING CLUSTER, DIAGNOSIS AND TESTING -
SPOILER LIMIT SWITCH SIGNAL (UP) . . . . . 23-7 - (P0325) KNOCK SENSOR #1 . . . . . . . . . . 9-324 NO COMMUNICATION FROM
CIRCUIT, DIAGNOSIS AND TESTING - CIRCUIT LOW, DIAGNOSIS AND TESTING INSTRUMENT. . . . . . . . . . . . . . . . . . . . . . . . . 24-49
STEERING ANGLE SENSOR . . . . . . . . . . . . . 5-124 - (P0330) KNOCK SENSOR #2 . . . . . . . . . . 9-332 CLUSTER, DIAGNOSIS AND TESTING -
CIRCUIT FAILURE, DIAGNOSIS AND CIRCUIT LOW, DIAGNOSIS AND TESTING NO COMMUNICATION FROM
TESTING - CAN B BUS (-) . . . . . . . . . . . . . 8Q-10 - (P0452) FUEL TANK PRESSURE INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8J-14
CIRCUIT FAILURE, DIAGNOSIS AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-395 CLUSTER, DIAGNOSIS AND TESTING -
TESTING - CAN B BUS (+) . . . . . . . . . . . . . 8Q-13 CIRCUIT LOW, DIAGNOSIS AND TESTING NO COMMUNICATION TO
CIRCUIT HIGH, DIAGNOSIS AND - (P2513) ENHANCED ACCIDENT INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 24-51
TESTING - COOLING FAN CONTROL . . . . . . 9-517 REPORT DRIVER . . . . . . . . . . . . . . . . . . . . . 9-504 CLUSTER, DIAGNOSIS AND TESTING -
CIRCUIT HIGH, DIAGNOSIS AND CIRCUIT LOW, DIAGNOSIS AND TESTING NO COMMUNICATION TO
TESTING - (P0108) MAP SENSOR . . . . . . . . 9-29 - SHORT RUNNER SOLENOID . . . . . . . . . . . 9-549 INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8J-16
CIRCUIT HIGH, DIAGNOSIS AND CIRCUIT OPEN, DIAGNOSIS AND CLUSTER, DIAGNOSIS AND TESTING -
TESTING - (P0113) INTAKE AIR TESTING - COOLING FAN CONTROL . . . . . . 9-514 NO RESPONSE FROM INSTRUMENT . . . . . . 8E-13
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9-36 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - ASSEMBLY, FREEWHEELING . . 21-301
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0134) O2 SENSOR 1/1 . . . . . . 9-105 CLUTCH - DESCRIPTION . . . . . . . . . . . . . . . . . 6-1
TESTING - (P0118) ENGINE COOLANT CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - DESCRIPTION, A/C
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9-51 TESTING - (P0135) O2 SENSOR 1/1 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-72
CIRCUIT HIGH, DIAGNOSIS AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-117 CLUTCH - DESCRIPTION,
TESTING - (P0123) APPS SIGNAL #1 . . . . . . 9-70 CIRCUIT OPEN, DIAGNOSIS AND FREEWHEELING . . . . . . . . . . . . . . . . . . . . . 21-298
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0138) O2 SENSOR 1/2 . . . . . . 9-131 CLUTCH - DIAGNOSIS AND TESTING . . . . . . . 6-2
TESTING - (P0132) O2 SENSOR 1/1 . . . . . . . 9-93 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - DISASSEMBLY,
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0138) O2 SENSOR 2/2 . . . . . . 9-135 FREEWHEELING . . . . . . . . . . . . . . . . . . . . . 21-299
TESTING - (P0135) O2 SENSOR 1/1 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - INSTALLATION, MASTER
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-113 TESTING - (P0141) O2 SENSOR 1/2 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
CIRCUIT HIGH, DIAGNOSIS AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-143 CLUTCH - OPERATION . . . . . . . . . . . . . . . . . . 6-2
TESTING - (P0138) O2 SENSOR 1/2 . . . . . . 9-129 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - OPERATION, A/C
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0154) O2 SENSOR 2/1 . . . . . . 9-161 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 24-73
TESTING - (P0140) O2 SENSOR 2/2 . . . . . . 9-139 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - OPERATION, FREEWHEELING . . 21-298
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0155) O2 SENSOR 2/1 CLUTCH - REMOVAL, MASTER
TESTING - (P0141) O2 SENSOR 1/2 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145 CIRCUIT OPEN, DIAGNOSIS AND CLUTCH - WARNING . . . . . . . . . . . . . . . . . . . . 6-2
CIRCUIT HIGH, DIAGNOSIS AND TESTING - (P0161) O2 SENSOR 2/2 CLUTCH B1 - ASSEMBLY, HOLDING . . . . . 21-305
TESTING - (P0152) O2 SENSOR 2/1 . . . . . . 9-151 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-175 CLUTCH B1 - DISASSEMBLY, HOLDING . . 21-304
CIRCUIT HIGH, DIAGNOSIS AND CIRCUIT OPEN, DIAGNOSIS AND CLUTCH B2 - ASSEMBLY, HOLDING . . . . . 21-308
TESTING - (P0155) O2 SENSOR 2/1 TESTING - VOLTAGE SUPPLY . . . . . . . . . . . . 8R-2 CLUTCH B2 - DISASSEMBLY, HOLDING . . 21-307
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-165 CIRCUIT SHORT TO GROUND - (P0753) CLUTCH BREAK-IN - STANDARD
CIRCUIT HIGH, DIAGNOSIS AND 1, 2/4-5 SOLENOID . . . . . . . . . . . . . . . . . . 21-136 PROCEDURE, COMPRESSOR . . . . . . . . . . . 24-74
TESTING - (P0161) O2 SENSOR 2/2 CIRCUIT SHORT TO GROUND - (P0758) CLUTCH CIRCUIT, DIAGNOSIS AND
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-177 2, 3 SOLENOID . . . . . . . . . . . . . . . . . . . . . 21-142 TESTING - A/C COMPRESSOR . . . . . . . . . . 24-43
CIRCUIT HIGH, DIAGNOSIS AND CIRCUIT SHORT TO GROUND - (P0763) CLUTCH COIL - DIAGNOSIS AND
TESTING - (P0223) APPS SIGNAL #2 . . . . . 9-279 3, 4 SOLENOID . . . . . . . . . . . . . . . . . . . . . 21-148 TESTING, COMPRESSOR . . . . . . . . . . . . . . . 24-73
CIRCUIT HIGH, DIAGNOSIS AND CIRCUITS - DESCRIPTION, NON- CLUTCH COVER - DESCRIPTION . . . . . . . . . . 6-12
TESTING - (P0325) KNOCK SENSOR #1 . . . 9-328 MONITORED . . . . . . . . . . . . . . . . . . . . . . . . 25-10 CLUTCH COVER - INSTALLATION . . . . . . . . . 6-13
CIRCUIT HIGH, DIAGNOSIS AND CIRCULATION PUMP CIRCUIT, CLUTCH COVER - OPERATION . . . . . . . . . . . 6-12
TESTING - (P0330) KNOCK SENSOR #2 . . . 9-330 DIAGNOSIS AND TESTING - COOLANT . . . . 24-34 CLUTCH COVER - REMOVAL . . . . . . . . . . . . . 6-12
CIRCUIT HIGH, DIAGNOSIS AND CIRCULATION VALVE - DESCRIPTION, CLUTCH DISC - INSTALLATION . . . . . . . . . . . 6-10
TESTING - (P0453) FUEL TANK COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . 24-150 CLUTCH DISC - REMOVAL . . . . . . . . . . . . . . . 6-9
PRESSURE SENSOR . . . . . . . . . . . . . . . . . . 9-397 CIRCULATION VALVE - INSTALLATION, CLUTCH K1 - ASSEMBLY, DRIVING . . . . . . 21-258
CIRCUIT HIGH, DIAGNOSIS AND COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . 24-153 CLUTCH K1 - DISASSEMBLY, DRIVING . . . 21-257
TESTING - (P2513) ENHANCED CIRCULATION VALVE - OPERATION, CLUTCH K2 - ASSEMBLY, DRIVING . . . . . . 21-263
ACCIDENT REPORT DRIVER . . . . . . . . . . . . 9-499 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . 24-151 CLUTCH K2 - DISASSEMBLY, DRIVING . . . 21-261
CIRCUIT HIGH, DIAGNOSIS AND CIRCULATION VALVE - REMOVAL, CLUTCH K3 - ASSEMBLY, DRIVING . . . . . . 21-267
TESTING - SHORT RUNNER SOLENOID . . . 9-545 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . 24-152 CLUTCH K3 - DISASSEMBLY, DRIVING . . . 21-266
CIRCUIT INFORMATION - DESCRIPTION . 8W-01-5 CIRCULATION VALVE CIRCUIT, CLUTCH PEDAL - INSTALLATION . . . . . . . . . 6-25
CIRCUIT LOW, DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - LEFT CLUTCH PEDAL - REMOVAL . . . . . . . . . . . . . 6-24
- COOLING FAN CONTROL . . . . . . . . . . . . . 9-519 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-37 CLUTCHES - DESCRIPTION, DRIVING . . . . 21-255
CLUTCHES - DESCRIPTION, HOLDING . . . 21-302
ZH INDEX 7

CLUTCHES - OPERATION, DRIVING . . . . . 21-256 CONDITIONER, OPERATION - HEATER CONTROL MODULE - DESCRIPTION, A/C
CLUTCHES - OPERATION, HOLDING . . . . . 21-303 AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-59 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-78
COAT FINISH - DESCRIPTION, BASE CONDITIONING - ELECTRICAL CONTROL MODULE - DESCRIPTION,
COAT/CLEAR . . . . . . . . . . . . . . . . . . . . . . . 23-199 DIAGNOSTICS - DESCRIPTION, BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-71
COAT/CLEAR COAT FINISH - HEATING & AIR . . . . . . . . . . . . . . . . . . . . . . . 24-1 CONTROL MODULE - DESCRIPTION,
DESCRIPTION, BASE . . . . . . . . . . . . . . . . . 23-199 CONDITIONING - ELECTRICAL POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 8E-54
CODE - DESCRIPTION, PAINT . . . . . . . . . . 23-199 DIAGNOSTICS - OPERATION, HEATING CONTROL MODULE - DESCRIPTION,
CODE - SPECIFICATIONS, PAINT . . . . . . . . 23-199 & AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-3
COIL - DESCRIPTION, IGNITION . . . . . . . . . . 8I-5 CONDITIONS - DIAGNOSIS AND CONTROL MODULE - DESCRIPTION,
COIL - DIAGNOSIS AND TESTING, TESTING, SPARK PLUG . . . . . . . . . . . . . . . . . 8I-8 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8E-58
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-73 CONNECTING FLANGE SEAL - CONTROL MODULE - INSTALLATION, A/C
COIL - INSTALLATION, IGNITION . . . . . . . . . . 8I-5 INSTALLATION, DIFFERENTIAL . . . . . . . . . . . 3-47 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-81
COIL - REMOVAL, IGNITION . . . . . . . . . . . . . 8I-5 CONNECTING FLANGE SEAL - REMOVAL, CONTROL MODULE - INSTALLATION,
COLUMN - ASSEMBLY . . . . . . . . . . . . . . . . 19-14 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 3-46 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-73
COLUMN - DESCRIPTION . . . . . . . . . . . . . . . 19-8 CONNECTING ROD - DESCRIPTION, CONTROL MODULE - INSTALLATION,
COLUMN - DISASSEMBLY . . . . . . . . . . . . . . 19-13 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-639 POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 8E-57
COLUMN - REMOVAL . . . . . . . . . . . . . . . . . . 19-9 CONNECTING ROD BEARINGS - CONTROL MODULE - INSTALLATION,
COLUMN, INSTALLATION - STEERING . . . . 19-15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-638 RADIATOR FAN . . . . . . . . . . . . . . . . . . . . . . . 7-29
COMBUSTION PRESSURE LEAKAGE CONNECTING RODS AND BEARINGS - CONTROL MODULE - INSTALLATION,
TEST - DIAGNOSIS AND TESTING, STANDARD PROCEDURE . . . . . . . . . . . . . . . 9-638 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 9-588 CONNECTOR - DESCRIPTION, DATA LINK . 8E-53 CONTROL MODULE - INSTALLATION,
COMMUNICATION - DESCRIPTION . . . . . . . 8E-52 CONNECTOR - INSTALLATION . . . . . . . 8W-01-11 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8E-61
COMMUNICATION - OPERATION . . . . . . . . . 8E-52 CONNECTOR - OPERATION, DATA LINK . . . 8E-53 CONTROL MODULE - OPERATION, A/C
COMMUNICATION FROM INSTRUMENT CONNECTOR - REMOVAL . . . . . . . . . . . 8W-01-11 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-78
CLUSTER, DIAGNOSIS AND TESTING - CONNECTOR, GROUND AND SPLICE CONTROL MODULE - OPERATION, BODY . . 8E-71
NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-14 INFORMATION - DESCRIPTION . . . . . . . . 8W-01-6 CONTROL MODULE - OPERATION,
COMMUNICATION GENERAL CONNECTOR/GROUND/SPLICE LOCATION POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 8E-54
MALFUNCTION, DIAGNOSIS AND - DESCRIPTION . . . . . . . . . . . . . . . . . . . . 8W-91-1 CONTROL MODULE - OPERATION,
TESTING - CAN BUS . . . . . . . . . . . . . . 5-162,5-88 CONNECTORS REVERSED, DIAGNOSIS RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-3
COMMUNICATION GENERAL AND TESTING - (P0040) 1/1 AND 2/1 CONTROL MODULE - OPERATION,
MALFUNCTION, DIAGNOSIS AND O2 SENSOR HARNESS . . . . . . . . . . . . . . . . . . 9-5 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8E-58
TESTING - CAN BUS . . . . . . . . . . . . . . . . . . 8J-36 CONSOLE - INSTALLATION, REAR CONTROL MODULE - REMOVAL, A/C
COMMUNICATION TO INSTRUMENT CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-188 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-79
CLUSTER, DIAGNOSIS AND TESTING - CONSOLE - REMOVAL, REAR CENTER . . . 23-178 CONTROL MODULE - REMOVAL, BODY . . . 8E-72
NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-51 CONSOLE COVER - INSTALLATION, CONTROL MODULE - REMOVAL,
COMMUNICATION TO INSTRUMENT CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186 POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 8E-56
CLUSTER, DIAGNOSIS AND TESTING - CONSOLE COVER - REMOVAL, CENTER . . 23-176 CONTROL MODULE - REMOVAL,
NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-16 CONSOLE (FRONT), INSTALLATION - RADIATOR FAN . . . . . . . . . . . . . . . . . . . . . . . 7-29
COMMUNICATION WITH BCM AND CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-183 CONTROL MODULE - REMOVAL, RELAY . 8W-97-4
CENTRAL LOCKING PUMP/SECURITY CONSOLE (FRONT), REMOVAL - CENTER . 23-173 CONTROL MODULE - REMOVAL,
SYSTEM MODULE, DIAGNOSIS AND CONTACT, DESCRIPTION - PARK/ TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8E-60
TESTING - NO . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8 NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-327 CONTROL MODULE AND CENTRAL
COMMUNICATION WITH BODY CONTROL CONTACT, OPERATION - PARK/NEUTRAL . 21-328 LOCKING PUMP/SECURITY SYSTEM
MODULE AND CENTRAL LOCKING CONTAMINATION - DIAGNOSIS AND MODULE, DIAGNOSIS AND TESTING -
PUMP/SECURITY SYSTEM MODULE, TESTING, FLUID . . . . . . . . . . . . . . . . . . . . 21-293 NO COMMUNICATION WITH BODY . . . . . . . 8N-20
DIAGNOSIS AND TESTING - NO . . . . . . . . . 8N-20 CONTAMINATION, DIAGNOSIS AND CONTROL MODULE, DIAGNOSIS AND
COMMUNICATIONS WITH CAB, TESTING - BRAKE FLUID . . . . . . . . . . . . . . . 5-42 TESTING - NO RESPONSE FROM A/C
DIAGNOSIS AND TESTING - NO CAN . . . . . 8J-24 CONTAMINATION, DIAGNOSIS AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
COMMUNICATIONS WITH PCM, TESTING - ENGINE OIL SENSOR CONTROL MODULE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - NO CAN . 5-164,5-90 WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-538 TESTING - NO RESPONSE FROM BODY . . . 8E-36
COMMUNICATIONS WITH PCM, CONTINUITY - STANDARD PROCEDURE, CONTROL MODULE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - NO CAN . . . . . 8J-18 TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10 TESTING - NO RESPONSE FROM
COMMUNICATIONS WITH PCM, CONTINUOUSLY WITH IGNITION ON, POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . 8E-4
DIAGNOSIS AND TESTING - NO CAN . . . . . 8Q-25 DIAGNOSIS AND TESTING - WASHERS CONTROL MODULE, DIAGNOSIS AND
COMMUNICATIONS WITH TCM, RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-6 TESTING - NO RESPONSE FROM
DIAGNOSIS AND TESTING - NO CAN . . . . . . 5-92 CONTINUOUSLY WITH IGNITION ON, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8E-33
COMMUNICATIONS WITH TCM, DIAGNOSIS AND TESTING - WIPERS CONTROL MODULE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - NO CAN . . . . . 8J-30 RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17 TESTING - (P0600) INCORRECT CAN
COMPARTMENT, INSTALLATION - GLOVE . 23-146 CONTROL ARM - INSTALLATION, LOWER . . 2-37, MESSAGE FROM EIS . . . . . . . . . . . . . . . . . . 9-425
COMPARTMENT, REMOVAL - GLOVE . . . . 23-143 2-55 CONTROL MODULE INTERNAL FAILURE,
COMPARTMENT, STANDARD CONTROL ARM - INSTALLATION, UPPER . . . 2-39 DIAGNOSIS AND TESTING - BODY . . . . . . . . 23-2
PROCEDURE - ADJUSTING THE GLOVE . . 23-141 CONTROL ARM - REMOVAL, LOWER . . 2-34,2-53 CONTROL MODULE INTERNAL FAILURE,
COMPRESSION PRESSURE TEST - CONTROL ARM - REMOVAL, UPPER . . . . . . 2-39 DIAGNOSIS AND TESTING - BODY . . . . . . . 8N-11
DIAGNOSIS AND TESTING, CYLINDER . . . . 9-587 CONTROL BELOW LIMIT (AT IDLE), CONTROL MODULE LOW VOLTAGE,
COMPRESSOR - DESCRIPTION, A/C . . . . . 24-119 DIAGNOSIS AND TESTING - (P0172) DIAGNOSIS AND TESTING - (P0702)
COMPRESSOR - INSTALLATION, A/C . . . . 24-122 FUEL SYSTEM 1/1 LEAN . . . . . . . . . . . . . . . 9-207 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-455
COMPRESSOR - OPERATION, A/C . . . . . . . 24-120 CONTROL BELOW LIMIT (AT IDLE), CONTROL MODULE PERFORMANCE,
COMPRESSOR - REMOVAL, A/C . . . . . . . . 24-121 DIAGNOSIS AND TESTING - (P0175) DIAGNOSIS AND TESTING - (P0221)
COMPRESSOR CLUTCH - DESCRIPTION, FUEL SYSTEM 2/1 LEAN . . . . . . . . . . . . . . . 9-233 ELECTRONIC THROTTLE . . . . . . . . . . . . . . . 9-270
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-72 CONTROL BELOW LIMIT (AT LOAD), CONTROL MODULE PROCESSOR,
COMPRESSOR CLUTCH - OPERATION, DIAGNOSIS AND TESTING - (P0172) DIAGNOSIS AND TESTING - (P0221)
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-73 FUEL SYSTEM 1/1 LEAN . . . . . . . . . . . . . . . 9-199 ELECTRONIC THROTTLE . . . . . . . . . . . . . . . 9-272
COMPRESSOR CLUTCH BREAK-IN - CONTROL BELOW LIMIT (AT LOAD), CONTROL MODULE REQUESTED MIL
STANDARD PROCEDURE . . . . . . . . . . . . . . . 24-74 DIAGNOSIS AND TESTING - (P0174) ILLUMINATION, DIAGNOSIS AND
COMPRESSOR CLUTCH CIRCUIT, FUEL SYSTEM 2/1 LEAN . . . . . . . . . . . . . . . 9-224 TESTING - (P2561) HVAC . . . . . . . . . . . . . . 9-512
DIAGNOSIS AND TESTING - A/C . . . . . . . . . 24-43 CONTROL CIRCUIT, DIAGNOSIS AND CONTROL MODULE TCM IS NOT CODED,
COMPRESSOR CLUTCH COIL - TESTING - (P0403) EGR . . . . . . . . . . . . . . . 9-354 DIAGNOSIS AND TESTING - (P0702) . . . . . 21-74
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-73 CONTROL CIRCUIT, DIAGNOSIS AND CONTROL MODULE VERSION,
COMPRESSOR NOISE - DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY DIAGNOSIS AND TESTING - (P0702)
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 24-120 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 INVALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-78
CONCENTRATION TESTING - DIAGNOSIS CONTROL CIRCUIT HIGH, DIAGNOSIS CONTROL MOTOR PERFORMANCE,
AND TESTING, COOLANT . . . . . . . . . . . . . . . 7-17 AND TESTING - COOLING FAN . . . . . . . . . . 9-517 DIAGNOSIS AND TESTING - (P0120)
CONDENSER - DESCRIPTION, A/C . . . . . . 24-125 CONTROL CIRCUIT LOW, DIAGNOSIS ELECTRONIC THROTTLE . . . . . . . . . . . . . . . . 9-53
CONDENSER - INSTALLATION, A/C . . . . . . 24-127 AND TESTING - COOLING FAN . . . . . . . . . . 9-519 CONTROL OVER LIMIT (AT IDLE),
CONDENSER - OPERATION, A/C . . . . . . . . 24-125 CONTROL CIRCUIT OPEN, DIAGNOSIS DIAGNOSIS AND TESTING - (P0171)
CONDENSER - REMOVAL, A/C . . . . . . . . . 24-126 AND TESTING - COOLING FAN . . . . . . . . . . 9-514 FUEL SYSTEM 1/1 RICH . . . . . . . . . . . . . . . 9-183
CONDITIONER - DESCRIPTION, HEATER CONTROL INFORMATION LABEL -
AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-55 DESCRIPTION, VEHICLE EMISSION . . . . . . 25-12
8 INDEX ZH

CONTROL OVER LIMIT (AT IDLE), CONVERTER HUB SEAL - INSTALLATION, COOLING FAN INOPERATIVE, DIAGNOSIS
DIAGNOSIS AND TESTING - (P0174) TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-337 AND TESTING - RADIATOR . . . . . . . . . . . . . . . 7-2
FUEL SYSTEM 2/1 RICH . . . . . . . . . . . . . . . 9-218 CONVERTER HUB SEAL - REMOVAL, COOLING SYSTEM - STANDARD
CONTROL OVER LIMIT (AT LOAD), TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-337 PROCEDURE, REFILLING . . . . . . . . . . . . . . . . 7-18
DIAGNOSIS AND TESTING - (P0171) COOLANT - DESCRIPTION, HOAT . . . . . . . . . 7-16 COOLING SYSTEM LEAK, DIAGNOSIS
FUEL SYSTEM 1/1 RICH . . . . . . . . . . . . . . . 9-187 COOLANT - DESCRIPTION, HOAT . . . . . . . . . . 0-4 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-13
CONTROL OVER LIMIT (AT LOAD), COOLANT - OPERATION . . . . . . . . . . . . . . . . 7-17 COOLING SYSTEM, OPERATION -
DIAGNOSIS AND TESTING - (P0173) COOLANT CIRCULATION PUMP CIRCUIT, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
FUEL SYSTEM 2/1 RICH . . . . . . . . . . . . . . . 9-211 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-34 COOLING SYSTEM OVERHEATING,
CONTROL OVER LIMIT (AT LOAD), COOLANT CIRCULATION VALVE - DIAGNOSIS AND TESTING - ENGINE . . . . . . 7-12
DIAGNOSIS AND TESTING - (P0174) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 24-150 COOLING SYSTEM REQUIREMENTS,
FUEL SYSTEM 2/1 RICH . . . . . . . . . . . . . . . 9-221 COOLANT CIRCULATION VALVE - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-55
CONTROL SWITCH INPUT CIRCUIT, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 24-153 COOLING SYSTEM REVERSE FLUSHING
DIAGNOSIS AND TESTING - SPEED . . . . . . 9-553 COOLANT CIRCULATION VALVE - - STANDARD PROCEDURE . . . . . . . . . . . . . . 7-19
CONTROL SYSTEM - DESCRIPTION, OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 24-151 COOLING SYSTEM, STANDARD
EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . 25-15 COOLANT CIRCULATION VALVE - PROCEDURE - DRAINING . . . . . . . . . . . . . . . 7-18
CONTROL SYSTEM (MIL REQUEST), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 24-152 CORE - DESCRIPTION, HEATER . . . . . . . . 24-141
DIAGNOSIS AND TESTING - (P0700) COOLANT CIRCULATION VALVE CIRCUIT, CORE - INSTALLATION, HEATER . . . . . . . . 24-144
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-453 DIAGNOSIS AND TESTING - LEFT . . . . . . . . 24-37 CORE - OPERATION, HEATER . . . . . . . . . . 24-141
CONTROL SYSTEM (MIL REQUEST), COOLANT CIRCULATION VALVE CIRCUIT, CORE - REMOVAL, HEATER . . . . . . . . . . . 24-142
DIAGNOSIS AND TESTING - (P0702) DIAGNOSIS AND TESTING - RIGHT . . . . . . 24-40 CORE AND OIL GALLERY PLUGS -
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-457 COOLANT CONCENTRATION TESTING - STANDARD PROCEDURE, ENGINE . . . . . . . 9-591
CONTROL SYSTEM (MIL REQUEST), DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 7-17 CORE TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING - (P0705) COOLANT LEVEL SENSOR - INSTALLATION, HEATER . . . . . . . . . . . . . . . 24-85
SLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-463 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-20 CORE TEMPERATURE SENSOR -
CONTROL SYSTEM (MIL REQUEST), COOLANT LEVEL SENSOR - REMOVAL . . . . . 7-20 REMOVAL, HEATER . . . . . . . . . . . . . . . . . . . 24-85
DIAGNOSIS AND TESTING - (P0705) COOLANT LEVEL SENSOR/WASHER CORE TEMPERATURE SENSOR CIRCUIT,
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-465 FLUID LEVEL SWITCH CIRCUIT, DIAGNOSIS AND TESTING - LEFT
CONTROL SYSTEM (MIL REQUEST), DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8J-2 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8
DIAGNOSIS AND TESTING - (P0715) COOLANT RECOVERY RESERVOIR - CORE TEMPERATURE SENSOR CIRCUIT,
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-467 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-25 DIAGNOSIS AND TESTING - RIGHT
CONTROL SYSTEM (MIL REQUEST), COOLANT RECOVERY RESERVOIR - HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13
DIAGNOSIS AND TESTING - (P0720) OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 CORRELATION, DIAGNOSIS AND
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-475 COOLANT RECOVERY RESERVOIR - TESTING - (P0120) THROTTLE
CONTROL SYSTEM (MIL REQUEST), REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 POSITION SENSOR 1/2 . . . . . . . . . . . . . . . . . 9-59
DIAGNOSIS AND TESTING - (P0730) COOLANT TEMP, DIAGNOSIS AND CORRELATION, DIAGNOSIS AND
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-477 TESTING - (P0128) FORCED LIMITED TESTING - (P0221) APPS SENSOR #1
CONTROL SYSTEM (MIL REQUEST), POWER EXCESSIVE HIGH . . . . . . . . . . . . . . . 9-74 AND #2 VOLTAGE . . . . . . . . . . . . . . . . . . . . 9-262
DIAGNOSIS AND TESTING - (P0740) COOLANT TEMPERATURE SENSOR - CORRESPOND TO THE VEHICLE
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-479 INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-31 EQUIPMENT, DIAGNOSIS AND TESTING
CONTROL SYSTEM (MIL REQUEST), COOLANT TEMPERATURE SENSOR - - PROGRAMMING DOES NOT . . . . . . . . . . . 8O-41
DIAGNOSIS AND TESTING - (P0743) OPERATION, ENGINE . . . . . . . . . . . . . . . . . . . 7-29 COUNTERSHAFT - ASSEMBLY . . . . . . . . . . 21-383
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-481 COOLANT TEMPERATURE SENSOR - COUNTERSHAFT - DISASSEMBLY . . . . . . . 21-380
CONTROL SYSTEM (MIL REQUEST), REMOVAL, ENGINE . . . . . . . . . . . . . . . . . . . . 7-29 COURTESY LAMP - INSTALLATION . . . . . . 8L-141
DIAGNOSIS AND TESTING - (P0748) COOLANT TEMPERATURE SENSOR COURTESY LAMP - REMOVAL . . . . . . . . . 8L-140
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-483 CIRCUIT, DIAGNOSIS AND TESTING - COURTESY LAMP DEFEAT SWITCH -
CONTROL SYSTEM (MIL REQUEST), ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8L-141
DIAGNOSIS AND TESTING - (P0753) COOLANT TEMPERATURE SENSOR COURTESY LAMP SWITCH/UNIT -
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-485 CIRCUIT HIGH, DIAGNOSIS AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8L-142
CONTROL SYSTEM (MIL REQUEST), TESTING - (P0118) ENGINE . . . . . . . . . . . . . 9-51 COURTESY LAMP SWITCH/UNIT -
DIAGNOSIS AND TESTING - (P0758) COOLANT TEMPERATURE SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8L-143
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-487 CIRCUIT LOW, DIAGNOSIS AND COURTESY LAMP SWITCH/UNIT -
CONTROL SYSTEM (MIL REQUEST), TESTING - (P0117) ENGINE . . . . . . . . . . . . . 9-49 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-142
DIAGNOSIS AND TESTING - (P0763) COOLANT TEMPERATURE SENSOR COURTESY LAMP SWITCH/UNIT -
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 9-489 PERFORMANCE, DIAGNOSIS AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142
CONTROLLER - DESCRIPTION, TESTING - (P0116) ENGINE . . . . . . . . . . . . . 9-40 COVER - DESCRIPTION, CLUTCH . . . . . . . . . 6-12
OCCUPANT RESTRAINT . . . . . . . . . . . . . . . 8O-87 COOLANT TEMPERATURE SENSOR COVER - DESCRIPTION, CYLINDER HEAD . 9-617
CONTROLLER - INSTALLATION, SHORT CIRCUIT, DIAGNOSIS AND COVER - INSTALLATION, CENTER
OCCUPANT RESTRAINT . . . . . . . . . . . . . . . 8O-91 TESTING - (P0116) ENGINE . . . . . . . . . . . . . 9-47 CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
CONTROLLER - OPERATION, OCCUPANT COOLANT THERMOSTAT - DESCRIPTION, COVER - INSTALLATION, CLUTCH . . . . . . . . 6-13
RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-88 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 COVER - INSTALLATION, CYLINDER
CONTROLLER - REMOVAL, OCCUPANT COOLANT THERMOSTAT - DIAGNOSIS HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-618
RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-89 AND TESTING, ENGINE . . . . . . . . . . . . . . . . . 7-22 COVER - INSTALLATION, FOOTWELL AIR
CONTROLLER ANTILOCK BRAKE - COOLANT THERMOSTAT - OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-111
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-62 INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-23 COVER - INSTALLATION, INSTRUMENT
CONTROLLER ANTILOCK BRAKE - COOLANT THERMOSTAT - OPERATION, CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8E-64 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 COVER - INSTALLATION, PLASTIC BACK . 23-205
CONTROLLER ANTILOCK BRAKE - COOLANT THERMOSTAT - REMOVAL, COVER - INSTALLATION, SEAT BACK . . . . 23-208
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-62 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 COVER - INSTALLATION, SEAT CUSHION . 23-217
CONTROLLER ANTILOCK BRAKE - COOLER LINES - INSTALLATION, COVER - INSTALLATION, SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-63 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 7-50 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23-192
CONTROLLER ANTILOCK BRAKE, COOLER LINES - REMOVAL, COVER - INSTALLATION, TIMING CHAIN . . 9-688
DIAGNOSIS AND TESTING - NO TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 7-49 COVER - OPERATION, CLUTCH . . . . . . . . . . . 6-12
RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-25 COOLING - ELECTRICAL DIAGNOSTICS - COVER - REMOVAL, CENTER CONSOLE . . 23-176
CONTROLLER, DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 COVER - REMOVAL, CLUTCH . . . . . . . . . . . . 6-12
- INTERNAL . . . . . . . . . . . . . . . . . . . . . . . . 21-171 COOLING - ELECTRICAL DIAGNOSTICS - COVER - REMOVAL, CYLINDER HEAD . . . . 9-617
CONTROLLER, DIAGNOSIS AND TESTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 COVER - REMOVAL, FOOTWELL AIR
- NO RESPONSE FROM OCCUPANT COOLING - SERVICE INFORMATION - OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-110
RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-11 COVER - REMOVAL, INSTRUMENT
CONTROLLER, DIAGNOSIS AND TESTING COOLING FAN ALWAYS ON, DIAGNOSIS CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-154
- (P0702) INTERNAL . . . . . . . . . . . . . . . . . . 21-76 AND TESTING - RADIATOR . . . . . . . . . . . . . . . 7-6 COVER - REMOVAL, PLASTIC BACK . . . . . 23-204
CONTROLS - INSTALLATION . . . . . . . . . . . . 24-83 COOLING FAN CONTROL CIRCUIT HIGH, COVER - REMOVAL, SEAT BACK . . . . . . . . 23-206
CONTROLS - REMOVAL . . . . . . . . . . . . . . . 24-82 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-517 COVER - REMOVAL, SEAT CUSHION . . . . . 23-214
CONVERTER - DESCRIPTION, TORQUE . . . 21-330 COOLING FAN CONTROL CIRCUIT LOW, COVER - REMOVAL, SHIFT LEVER
CONVERTER - INSTALLATION, TORQUE . . 21-336 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-519 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23-182
CONVERTER - OPERATION, TORQUE . . . . 21-333 COOLING FAN CONTROL CIRCUIT OPEN, COVER - REMOVAL, TIMING CHAIN . . . . . . 9-685
CONVERTER - REMOVAL, TORQUE . . . . . . 21-335 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-514 COWL GRILLE - INSTALLATION . . . . . . . . 23-114
COWL GRILLE - REMOVAL . . . . . . . . . . . . 23-114
ZH INDEX 9

CRANKCASE VENT HOSE - DESCRIPTION . 25-16 CYLINDER FLUID LOSS - DIAGNOSIS DIAGRAMS, CHARGING SYSTEM -
CRANKS BUT DOES NOT START, AND TESTING, MASTER . . . . . . . . . . . . . . . . 5-45 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
DIAGNOSIS AND TESTING - ENGINE . . . . . 9-563 CYLINDER HEAD - CLEANING . . . . . . . . . . . 9-614 DIAGRAMS, CHIME/BUZZER -
CRANKSHAFT AND MAIN BEARINGS - CYLINDER HEAD - DESCRIPTION . . . . . . . . 9-610 ELECTRICAL DIAGNOSTICS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-647 CYLINDER HEAD - INSPECTION . . . . . . . . . 9-614 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
CRANKSHAFT AND MAIN BEARINGS - CYLINDER HEAD - INSTALLATION . . . . . . . 9-614 DIAGRAMS, DIAGNOSIS AND TESTING -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-650 CYLINDER HEAD - OPERATION . . . . . . . . . . 9-610 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8A-17
CRANKSHAFT AND MAIN BEARINGS - CYLINDER HEAD - REMOVAL . . . . . . . . . . . 9-611 DIAGRAMS, DIAGNOSIS AND TESTING -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 9-647 CYLINDER HEAD COVER - DESCRIPTION . . 9-617 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 23-28
CRANKSHAFT AND MAIN BEARINGS - CYLINDER HEAD COVER - DIAGRAMS, DIAGNOSIS AND TESTING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-647 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-618 SCHEMATICS . . . . . . . . . . . . . . . . . . . 5-149,5-186
CRANKSHAFT OIL SEAL - FRONT - CYLINDER HEAD COVER - REMOVAL . . . . . 9-617 DIAGRAMS, DIAGNOSIS AND TESTING -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-636 CYLINDER HEAD GASKET - DIAGNOSIS SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
CRANKSHAFT OIL SEAL - FRONT - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 9-610 DIAGRAMS, DIAGNOSIS AND TESTING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-636 CYLINDER LOCK SWITCH - SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8E-45
CRANKSHAFT OIL SEAL - REAR - INSTALLATION, DRIVER . . . . . . . . . . . . . . . 8Q-57 DIAGRAMS, DIAGNOSIS AND TESTING -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-635 CYLINDER LOCK SWITCH - REMOVAL, SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 9-574
CRANKSHAFT OIL SEAL - REAR - DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-56 DIAGRAMS, DIAGNOSIS AND TESTING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-634 CYLINDER MISFIRE, DIAGNOSIS AND SCHEMATICS . . . . . . . . . . . . . . 8G-21,8G-35,8G-9
CRANKSHAFT POSITION SENSOR - TESTING - (P0300) MULTIPLE . . . . . . . . . . 9-283 DIAGRAMS, DIAGNOSIS AND TESTING -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-30 CYLINDER, OPERATION - MASTER . . . . . . . . 5-44 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 24-54
CRANKSHAFT POSITION SENSOR - CYLINDER/POWER BOOSTER, DIAGRAMS, DIAGNOSIS AND TESTING -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14-31 DIAGNOSIS AND TESTING - MASTER . . . . . . 5-44 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8H-8
CRANKSHAFT POSITION SENSOR - DAMAGED OR WORN THREADS - DIAGRAMS, DIAGNOSIS AND TESTING -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-30 STANDARD PROCEDURE, REPAIR OF . . . . . 9-589 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8J-53
CRANKSHAFT POSITION SENSOR - DAMPER - INSTALLATION . . . . . . . . . . . . . . 19-47 DIAGRAMS, DIAGNOSIS AND TESTING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31 DAMPER - INSTALLATION, VIBRATION . . . . 9-652 SCHEMATICS . . . . . . . . . . . . . . . . . . 8L-134,8L-78
CRANKSHAFT POSITION SENSOR DAMPER - REMOVAL . . . . . . . . . . . . . . . . . 19-46 DIAGRAMS, DIAGNOSIS AND TESTING -
CIRCUIT, DIAGNOSIS AND TESTING - DAMPER - REMOVAL, VIBRATION . . . . . . . 9-651 SCHEMATICS . . . . . . . 8N-120,8N-29,8N-63,8N-94
(P0335) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-334 DATA LINK CONNECTOR - DESCRIPTION . . 8E-53 DIAGRAMS, DIAGNOSIS AND TESTING -
CUSHION - INSTALLATION, SEAT . . . . . . . 23-213 DATA LINK CONNECTOR - OPERATION . . . . 8E-53 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 8O-68
CUSHION - REMOVAL, SEAT . . . . . . . . . . . 23-211 DAY / NIGHT MIRROR - DESCRIPTION, DIAGRAMS, DIAGNOSIS AND TESTING -
CUSHION COVER - INSTALLATION, SEAT . . 23-217 AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . 8N-68 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 22-36
CUSHION COVER - REMOVAL, SEAT . . . . . 23-214 DAY / NIGHT MIRROR - OPERATION, DIAGRAMS, DIAGNOSIS AND TESTING -
CUSHION ELEMENT, INSTALLATION - AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . 8N-68 SCHEMATICS . . . . . . . . . . . . . . . . . 21-182,21-230
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-41 DAY / NIGHT MIRROR - REMOVAL, DIAGRAMS, DIAGNOSIS AND TESTING -
CUSHION ELEMENT, REMOVAL - HEATED AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . 8N-68 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 8Q-44
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 DAY/NIGHT MIRROR INOPERATIVE, DIAGRAMS, DIAGNOSIS AND TESTING -
CUSTOMER PREFERENCES - STANDARD DIAGNOSIS AND TESTING - SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 8R-20
PROCEDURE, TOGGLING . . . . . . . . . . . . . . 8N-35 AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . 8N-59 DIAGRAMS, IGNITION SYSTEM -
CV BOOT - INNER - INSTALLATION . . . . . . . . 3-9 DEFEAT SWITCH - DESCRIPTION, ELECTRICAL DIAGNOSTICS -
CV BOOT - INNER - REMOVAL . . . . . . . . . . . . 3-7 COURTESY LAMP . . . . . . . . . . . . . . . . . . . 8L-141 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
CV BOOT - OUTER - INSTALLATION . . . . . . . 3-12 DEFINITION - DESCRIPTION, TRIP . . . . . . . 25-12 DIAGRAMS, SPEED CONTROL -
CV BOOT - OUTER - REMOVAL . . . . . . . . . . . 3-11 DEFOGGER GRID - DIAGNOSIS AND ELECTRICAL DIAGNOSTICS -
CV JOINT - INSPECTION . . . . . . . . . . . . . . . . 3-16 TESTING, REAR WINDOW . . . . . . . . . . . . . 8G-12 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2
CV JOINT - INSTALLATION . . . . . . . . . . . . . . 3-19 DEFOGGER INOPERATIVE, DIAGNOSIS DIAGRAMS, STARTING SYSTEM -
CV JOINT - REMOVAL . . . . . . . . . . . . . . . . . . 3-14 AND TESTING - REAR WINDOW . . . . . . . . . . 8G-5 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 8F-39
CYLINDER - CLUTCH - INSTALLATION, DEFOGGER SWITCH - INSTALLATION, DIFFERENTIAL - DESCRIPTION, REAR . . . . . 3-37
MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . 8G-12 DIFFERENTIAL - DIAGNOSIS AND
CYLINDER - CLUTCH - REMOVAL, DEFOGGER SWITCH - REMOVAL, REAR TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 3-37
MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12 DIFFERENTIAL - OPERATION, REAR . . . . . . . 3-37
CYLINDER - DESCRIPTION, RELEASE DEFOGGER SWITCH SENSE CIRCUIT, DIFFERENTIAL - SPECIAL TOOLS, REAR . . . 3-41
BEARING/SLAVE . . . . . . . . . . . . . . . . . . . . . . 6-19 DIAGNOSIS AND TESTING - REAR . . . . . . . . 8G-2 DIFFERENTIAL CONNECTING FLANGE
CYLINDER - INSTALLATION, KEY/LOCK . . . 19-30 DEFOGGER SYSTEM - DIAGNOSIS AND SEAL - INSTALLATION . . . . . . . . . . . . . . . . . . 3-47
CYLINDER - INSTALLATION, LOCK . . . . . . 23-106 TESTING, REAR WINDOW . . . . . . . . . . . . . 8G-11 DIFFERENTIAL CONNECTING FLANGE
CYLINDER - INSTALLATION, RELEASE DEFROSTER DUCTS - INSTALLATION . . . . 24-109 SEAL - REMOVAL . . . . . . . . . . . . . . . . . . . . . 3-46
BEARING/SLAVE . . . . . . . . . . . . . . . . . . . . . . 6-20 DEFROSTER DUCTS - REMOVAL . . . . . . . . 24-109 DIFFERENTIAL HOUSING -
CYLINDER - OPERATION, RELEASE DEPLOYMENT - STANDARD INSTALLATION, REAR . . . . . . . . . . . . . . . . . . 3-42
BEARING/SLAVE . . . . . . . . . . . . . . . . . . . . . . 6-19 PROCEDURE, SERVICE AFTER A DIFFERENTIAL HOUSING - REMOVAL,
CYLINDER - REMOVAL, KEY/LOCK . . . . . . . 19-28 SUPPLEMENTAL RESTRAINT . . . . . . . . . . . 8O-84 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
CYLINDER - REMOVAL, LOCK . . . . . . . . . . 23-105 DETECTED, DIAGNOSIS AND TESTING - DIFFERENTIAL LUBRICANT -
CYLINDER - REMOVAL, RELEASE (P1600) ROUGH ROAD . . . . . . . . . . . . . . . . 9-493 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
BEARING/SLAVE . . . . . . . . . . . . . . . . . . . . . . 6-20 DETECTED, DIAGNOSIS AND TESTING - DIMENSIONS - SPECIFICATIONS, BODY . . . 23-55
CYLINDER #1 MISFIRE, DIAGNOSIS AND SAFETY FUEL SHUT OFF . . . . . . . . . . . . . . . 9-540 DIMENSIONS - SPECIFICATIONS, FRAME . . . 13-9
TESTING - (P0301) . . . . . . . . . . . . . . . . . . . 9-294 DETENT PLUG - INSTALLATION . . . . . . . . 21-359 DIMMER SWITCH - DESCRIPTION . . . . . . 8L-144
CYLINDER #2 MISFIRE, DIAGNOSIS AND DETENT PLUG - REMOVAL . . . . . . . . . . . . 21-358 DIODE - INSTALLATION . . . . . . . . . . . . 8W-01-12
TESTING - (P0302) . . . . . . . . . . . . . . . . . . . 9-304 DEVICES - STANDARD PROCEDURE, DIODE - REMOVAL . . . . . . . . . . . . . . . . 8W-01-12
CYLINDER #3 MISFIRE, DIAGNOSIS AND ELECTROSTATIC DISCHARGE (ESD) DISC - INSTALLATION, CLUTCH . . . . . . . . . . 6-10
TESTING - (P0303) . . . . . . . . . . . . . . . . . . . 9-308 SENSITIVE . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9 DISC - REMOVAL, CLUTCH . . . . . . . . . . . . . . . 6-9
CYLINDER #4 MISFIRE, DIAGNOSIS AND DIAGNOSTICS - DESCRIPTION, COOLING DISC BRAKE CALIPER - ASSEMBLY,
TESTING - (P0304) . . . . . . . . . . . . . . . . . . . 9-312 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
CYLINDER #5 MISFIRE, DIAGNOSIS AND DIAGNOSTICS - DESCRIPTION, HEATING DISC BRAKE CALIPER - CLEANING . . . . . . . 5-30
TESTING - (P0305) . . . . . . . . . . . . . . . . . . . 9-316 & AIR CONDITIONING - ELECTRICAL . . . . . . 24-1 DISC BRAKE CALIPER - DISASSEMBLY,
CYLINDER #6 MISFIRE, DIAGNOSIS AND DIAGNOSTICS - OPERATION, COOLING - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
TESTING - (P0306) . . . . . . . . . . . . . . . . . . . 9-320 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 DISC BRAKE CALIPER - INSPECTION . . . . . . 5-30
CYLINDER BLEEDING PROCEDURE, DIAGNOSTICS - OPERATION, HEATING & DISC BRAKE CALIPER - INSTALLATION,
STANDARD PROCEDURE - MASTER . . . . . . . 5-46 AIR CONDITIONING - ELECTRICAL . . . . . . . . 24-2 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
CYLINDER BLEEDING, STANDARD DIAGNOSTICS - SCHEMATICS AND DISC BRAKE CALIPER, INSTALLATION -
PROCEDURE - MASTER . . . . . . . . . . . . . . . . . 6-7 DIAGRAMS, CHIME/BUZZER - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
CYLINDER COMBUSTION PRESSURE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2 DISC BRAKE CALIPER, REMOVAL -
LEAKAGE TEST - DIAGNOSIS AND DIAGNOSTICS - SCHEMATICS AND FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-588 DIAGRAMS, IGNITION SYSTEM - DISC BRAKE CALIPERS - DESCRIPTION . . . . 5-24
CYLINDER COMPRESSION PRESSURE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2 DISC BRAKE CALIPERS - OPERATION . . . . . 5-24
TEST - DIAGNOSIS AND TESTING . . . . . . . 9-587 DIAGNOSTICS - SCHEMATICS AND DISC BRAKE PADS - INSTALLATION,
CYLINDER, DESCRIPTION - MASTER . . . . . . 5-44 DIAGRAMS, SPEED CONTROL - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
CYLINDER FLUID LEVEL, STANDARD ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 DISC BRAKE PADS - REMOVAL, REAR . . . . . 5-19
PROCEDURE - MASTER . . . . . . . . . . . . . . . . 5-43 DIAGRAMS - DESCRIPTION, HOW TO DISC BRAKE PADS, INSTALLATION -
USE WIRING . . . . . . . . . . . . . . . . . . . . . . 8W-01-1 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
10 INDEX ZH

DISC BRAKE PADS, REMOVAL - FRONT . . . . 5-17 DRAIN AND REFILL - STANDARD DRIVING CLUTCHES - OPERATION . . . . . . 21-256
DISC BRAKE ROTOR - INSTALLATION, PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 DROP - STANDARD PROCEDURE,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 DRAINING COOLING SYSTEM, TESTING FOR A VOLTAGE . . . . . . . . . . . 8W-01-11
DISC BRAKE ROTOR - REMOVAL, REAR . . . 5-39 STANDARD PROCEDURE . . . . . . . . . . . . . . . . 7-18 DUCTS - INSTALLATION, DEFROSTER . . . 24-109
DISC BRAKE ROTOR, INSTALLATION - DRAINING FUEL TANK - STANDARD DUCTS - REMOVAL, DEFROSTER . . . . . . . 24-109
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 ECM FROM SLA, DIAGNOSIS AND
DISC BRAKE ROTOR MACHINING, DRAINING TIREFIT - STANDARD TESTING - (P0600) CAN MESSAGE
STANDARD PROCEDURE . . . . . . . . . . . . . . . . 5-38 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-60 FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-38
DISC BRAKE ROTOR, REMOVAL - FRONT . . 5-38 DRAW TEST - STANDARD PROCEDURE, EGR CONTROL CIRCUIT, DIAGNOSIS
DISC BRAKE ROTORS, DIAGNOSIS AND IGNITION-OFF . . . . . . . . . . . . . . . . . . . . . . . 8F-14 AND TESTING - (P0403) . . . . . . . . . . . . . . . 9-354
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 DRAWER - INSTALLATION . . . . . . . . . . . . . 23-147 EGR SYSTEM PERFORMANCE,
DISCHARGE (ESD) SENSITIVE DEVICES - DRAWER - REMOVAL . . . . . . . . . . . . . . . . 23-144 DIAGNOSIS AND TESTING - (P0400) . . . . . 9-350
STANDARD PROCEDURE, DRB IIIT DOES NOT POWER UP, EIS CONTROL MODULE, DIAGNOSIS
ELECTROSTATIC . . . . . . . . . . . . . . . . . . . 8W-01-9 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8E-2 AND TESTING - (P0600) INCORRECT
DISPLAY OF REMAINING FSS MILEAGE DRB IIIT STATE DISPLAY TEST MODE - CAN MESSAGE FROM . . . . . . . . . . . . . . . . . 9-425
AT DRIVER’S REQUEST, STANDARD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-11 ELECTRIC GEAR SHIFT MODULE (SLA),
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8J-75 DRIER - DESCRIPTION, RECEIVER . . . . . . 24-145 DIAGNOSIS AND TESTING - (P0600)
DISPLAY TEST MODE - DESCRIPTION, DRIER - INSTALLATION, RECEIVER . . . . . 24-147 LOST COMM WITH . . . . . . . . . . . . . . . . . . . 9-439
DRB IIIT STATE . . . . . . . . . . . . . . . . . . . . . . 25-11 DRIER - OPERATION, RECEIVER . . . . . . . . 24-146 ELECTRICAL DIAGNOSTICS -
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1 DRIER - REMOVAL, RECEIVER . . . . . . . . . 24-146 DESCRIPTION, COOLING . . . . . . . . . . . . . . . . . 7-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1 DRILLING AND WELDING, STANDARD ELECTRICAL DIAGNOSTICS -
DOES NOT START, DIAGNOSIS AND PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 23-31 DESCRIPTION, HEATING & AIR
TESTING - ENGINE CRANKS BUT . . . . . . . . 9-563 DRIVE - DESCRIPTION, ACCESSORY . . . . . . 7-42 CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-1
DOME LAMP CIRCUIT, DIAGNOSIS AND DRIVE - OPERATION, ACCESSORY . . . . . . . . 7-42 ELECTRICAL DIAGNOSTICS -
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-121 DRIVE - SPECIFICATIONS-TORQUE, OPERATION, COOLING . . . . . . . . . . . . . . . . . . 7-1
DOOR - INSTALLATION . . . . . . . . . . . . . . . . 23-91 ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 ELECTRICAL DIAGNOSTICS -
DOOR - INSTALLATION, FUEL FILL . . . . . . 23-115 DRIVE BELT - CLEANING . . . . . . . . . . . . . . . . 7-45 OPERATION, HEATING & AIR
DOOR - REMOVAL . . . . . . . . . . . . . . . . . . . . 23-90 DRIVE BELT - DIAGNOSIS AND TESTING, CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-2
DOOR - REMOVAL, FUEL FILL . . . . . . . . . 23-115 ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 ELECTRICAL DIAGNOSTICS -
DOOR AJAR SWITCH - DESCRIPTION . . . 8L-144 DRIVE BELT - INSPECTION . . . . . . . . . . . . . . 7-45 SCHEMATICS AND DIAGRAMS,
DOOR AJAR SWITCH - OPERATION . . . . . . . 8L-144 DRIVE BELT - INSTALLATION . . . . . . . . . . . . 7-46 CHIME/BUZZER . . . . . . . . . . . . . . . . . . . . . . . 8B-2
DOOR AJAR SWITCH, INSTALLATION . . . . 8L-146 DRIVE BELT - REMOVAL . . . . . . . . . . . . . . . . 7-45 ELECTRICAL DIAGNOSTICS -
DOOR AJAR SWITCH, REMOVAL . . . . . . . 8L-145 DRIVE CHAIN - INSTALLATION, OIL SCHEMATICS AND DIAGRAMS,
DOOR CYLINDER LOCK SWITCH - PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-677 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . 8I-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-56 DRIVE CHAIN - REMOVAL, OIL PUMP . . . . 9-677 ELECTRICAL DIAGNOSTICS -
DOOR GLASS - INSTALLATION . . . . . . . . . . 23-95 DRIVELINE - DIAGNOSIS AND TESTING . . . . . 3-3 SCHEMATICS AND DIAGRAMS, SPEED
DOOR GLASS - REMOVAL . . . . . . . . . . . . . 23-93 DRIVER AIRBAG - DESCRIPTION . . . . . . . . 8O-97 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2
DOOR LATCH ASSEMBLY - DRIVER AIRBAG - INSTALLATION . . . . . . 8O-100 ELECTROHYDRAULIC UNIT - ASSEMBLY . 21-287
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-42 DRIVER AIRBAG - OPERATION . . . . . . . . . . 8O-98 ELECTROHYDRAULIC UNIT -
DOOR LATCH ASSEMBLY - REMOVAL . . . . 8N-40 DRIVER AIRBAG - REMOVAL . . . . . . . . . . 8O-100 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-268
DOOR LOCK ACTUATOR - DRIVER AIRBAG SQUIB CIRCUIT, ELECTROHYDRAULIC UNIT -
INSTALLATION, FUEL . . . . . . . . . . . . . . . . . 8N-45 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8O-4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-282
DOOR LOCK ACTUATOR - REMOVAL, DRIVER CIRCUIT HIGH, DIAGNOSIS AND ELECTROHYDRAULIC UNIT -
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-44 TESTING - (P2513) ENHANCED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21-290
DOOR LOCK ACTUATOR SLOW ACCIDENT REPORT . . . . . . . . . . . . . . . . . . . 9-499 ELECTROHYDRAULIC UNIT - OPERATION . 21-275
RESPONSE, DIAGNOSIS AND TESTING DRIVER CIRCUIT LOW, DIAGNOSIS AND ELECTROHYDRAULIC UNIT - REMOVAL . . 21-281
- DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-2 TESTING - (P2513) ENHANCED ELECTROLYTE LEVEL - STANDARD
DOOR LOCK ACTUATOR SLOW ACCIDENT REPORT . . . . . . . . . . . . . . . . . . . 9-504 PROCEDURE, CHECKING BATTERY . . . . . . . 8F-16
RESPONSE, DIAGNOSIS AND TESTING DRIVER CYLINDER LOCK SWITCH - ELECTRONIC INCLINOMETER,
- FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-57 STANDARD PROCEDURE - INSPECTING
DOOR LOCK SWITCH - INSTALLATION, DRIVER DOOR LOCK ACTUATOR SLOW AND ADJUSTING VEHICLE LEVEL AT
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43 RESPONSE, DIAGNOSIS AND TESTING . . . . 8N-2 FRONT AND REAR AXLES WITH AN . . . . . . . . 2-8
DOOR LOCK SWITCH - REMOVAL, DRIVER DOOR LOCK SWITCH - ELECTRONIC STABILITY PROGRAM
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-43 (ESP) - OPERATION . . . . . . . . . . . . . . . . . . . 5-189
DOOR LOCK SWITCH SENSE CIRCUIT, DRIVER DOOR LOCK SWITCH - ELECTRONIC THROTTLE CONTROL
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43 MODULE PERFORMANCE, DIAGNOSIS
DOOR LOCK/DOOR UNLOCK SWITCH DRIVER (DOWN) CIRCUIT, DIAGNOSIS AND TESTING - (P0221) . . . . . . . . . . . . . . . 9-270
SENSE CIRCUIT, DIAGNOSIS AND AND TESTING - REAR SPOILER . . . . . . . . . 23-16 ELECTRONIC THROTTLE CONTROL
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22 DRIVER POWER SEAT FRONT RISER MODULE PROCESSOR, DIAGNOSIS
DOOR OPENER/TIRE PRESSURE MOTOR INOPERATIVE, DIAGNOSIS AND TESTING - (P0221) . . . . . . . . . . . . . . . 9-272
MONITOR, DIAGNOSIS AND TESTING - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-85 ELECTRONIC THROTTLE CONTROL
NO RESPONSE FROM UNIVERSAL DRIVER POWER SEAT HORIZONTAL MOTOR PERFORMANCE, DIAGNOSIS
GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17 MOTOR INOPERATIVE, DIAGNOSIS AND TESTING - (P0120) . . . . . . . . . . . . . . . . 9-53
DOOR SILL TRIM PLATE - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-83 ELECTROSTATIC DISCHARGE (ESD)
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-193 DRIVER POWER SEAT INOPERATIVE, SENSITIVE DEVICES - STANDARD
DOOR SILL TRIM PLATE - REMOVAL . . . . 23-193 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-74 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
DOOR SPEAKER, INSTALLATION - DRIVER POWER SEAT REAR RISER ELEMENT - DESCRIPTION, HEATED SEAT . 8G-39
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-31 MOTOR INOPERATIVE, DIAGNOSIS ELEMENT - INSTALLATION, AIR
DOOR SPEAKER, REMOVAL - LOWER . . . . 8A-29 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-87 CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-609
DOOR SPEAKERS, DIAGNOSIS AND DRIVER POWER SEAT RECLINER ELEMENT - INSTALLATION, HEATED
TESTING - NO SOUND FROM LEFT . . . . . . . 8A-8 MOTOR INOPERATIVE, DIAGNOSIS SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . . 8G-41
DOOR SPEAKERS, DIAGNOSIS AND AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-81 ELEMENT - REMOVAL, AIR CLEANER . . . . . 9-609
TESTING - NO SOUND FROM RIGHT . . . . . 8A-10 DRIVER SEAT BELT TENSIONER CIRCUIT, ELEMENT - REMOVAL, HEATED SEAT
DOOR UNLOCK SWITCH SENSE CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-53 BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-19 DRIVER SEAT BELT TENSIONER SQUIB ELEMENT, INSTALLATION - HEATED
DOOR/LIFTGATE LOCK ACTUATOR SLOW CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 8O-10 SEAT CUSHION . . . . . . . . . . . . . . . . . . . . . . 8G-41
RESPONSE, DIAGNOSIS AND TESTING DRIVER (UP) CIRCUIT, DIAGNOSIS AND ELEMENT, REMOVAL - HEATED SEAT
- PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8N-8 TESTING - REAR SPOILER . . . . . . . . . . . . . 23-13 CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40
DOUBLE INVERTED FLARING, DRIVER’S REQUEST, STANDARD EMERGENCY TOW HOOKS -
STANDARD PROCEDURE . . . . . . . . . . . . . . . . 5-11 PROCEDURE - DISPLAY OF DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 0-14
DOUBLE SIDED TAPE, INSTALLATION . . . . 23-115 REMAINING FSS MILEAGE AT . . . . . . . . . . . 8J-75 EMISSION CONTROL INFORMATION
DOUBLE SIDED TAPE, REMOVAL . . . . . . . 23-114 DRIVING CLUTCH K1 - ASSEMBLY . . . . . . 21-258 LABEL - DESCRIPTION, VEHICLE . . . . . . . . 25-12
DOWNSTREAM O2 - INSTALLATION . . . . . . 14-47 DRIVING CLUTCH K1 - DISASSEMBLY . . . 21-257 ENGINE - SERVICE INFORMATION -
DOWNSTREAM O2 - REMOVAL . . . . . . . . . 14-46 DRIVING CLUTCH K2 - ASSEMBLY . . . . . . 21-263 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-583
DRAG LINK - INSTALLATION . . . . . . . . . . . . 19-49 DRIVING CLUTCH K2 - DISASSEMBLY . . . 21-261 ENGINE - SERVICE INFORMATION -
DRAG LINK - REMOVAL . . . . . . . . . . . . . . . 19-47 DRIVING CLUTCH K3 - ASSEMBLY . . . . . . 21-267 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 9-583
DRAIN AND FILL - STANDARD DRIVING CLUTCH K3 - DISASSEMBLY . . . 21-266 ENGINE - SPECIFICATIONS . . . . . . . . . . . . . 9-602
PROCEDURE, FLUID . . . . . . . . . . . . . . . . . 21-352 DRIVING CLUTCHES - DESCRIPTION . . . . 21-255 ENGINE BLOCK - CLEANING . . . . . . . . . . . . 9-633
ZH INDEX 11

ENGINE BLOCK - DESCRIPTION . . . . . . . . . 9-633 ENGINE RPM MESSAGE, DIAGNOSIS EVAPORATION CONTROL SYSTEM -
ENGINE BLOCK - INSPECTION . . . . . . . . . . 9-633 AND TESTING - (P0600) . . . . . . . . . . . . . . . 21-48 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-15
ENGINE CAN MESSAGE INCORRECT, ENGINE, STANDARD PROCEDURE - EVAPORATOR - DESCRIPTION, A/C . . . . . . 24-130
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-41 HYDROSTATIC LOCKED . . . . . . . . . . . . . . . . 9-588 EVAPORATOR - INSTALLATION, A/C . . . . . 24-132
ENGINE CAN MESSAGE MISSING, ENGINE TEMPERATURE MESSAGE, EVAPORATOR - OPERATION, A/C . . . . . . . 24-130
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-44 DIAGNOSIS AND TESTING - (P0600) . . . . . 21-51 EVAPORATOR - REMOVAL, A/C . . . . . . . . . 24-130
ENGINE COOLANT TEMPERATURE ENGINE TIMING - OPERATION . . . . . . . . . . 9-704 EVAPORATOR TEMPERATURE SENSOR -
SENSOR - INSTALLATION . . . . . . . . . . . . . . . 7-31 ENGINE TORQUE MESSAGE INCORRECT, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-84
ENGINE COOLANT TEMPERATURE DIAGNOSIS AND TESTING - (P0600) . . . . . 21-54 EVAPORATOR TEMPERATURE SENSOR -
SENSOR - OPERATION . . . . . . . . . . . . . . . . . 7-29 ENGINE TORQUE REDUCTION, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-84
ENGINE COOLANT TEMPERATURE DIAGNOSIS AND TESTING - (P1793) . . . . 21-163 EVAPORATOR TEMPERATURE SENSOR
SENSOR - REMOVAL . . . . . . . . . . . . . . . . . . . 7-29 ENHANCED ACCIDENT REPORT DRIVER CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 24-18
ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, DIAGNOSIS AND EXCESSIVE HIGH COOLANT TEMP,
SENSOR CIRCUIT, DIAGNOSIS AND TESTING - (P2513) . . . . . . . . . . . . . . . . . . . 9-499 DIAGNOSIS AND TESTING - (P0128)
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 ENHANCED ACCIDENT REPORT DRIVER FORCED LIMITED POWER . . . . . . . . . . . . . . . 9-74
ENGINE COOLANT TEMPERATURE CIRCUIT LOW, DIAGNOSIS AND EXHAUST MANIFOLD - DESCRIPTION . . . . 9-680
SENSOR CIRCUIT HIGH, DIAGNOSIS TESTING - (P2513) . . . . . . . . . . . . . . . . . . . 9-504 EXHAUST PIPES - INSTALLATION,
AND TESTING - (P0118) . . . . . . . . . . . . . . . . 9-51 ENTRY MODULE - DESCRIPTION, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
ENGINE COOLANT TEMPERATURE SENTRY KEY REMOTE . . . . . . . . . . . . . . . . 8E-69 EXHAUST PIPES - REMOVAL, FRONT . . . . . . 11-5
SENSOR CIRCUIT LOW, DIAGNOSIS ENTRY MODULE - DESCRIPTION, EXHAUST SYSTEM - DESCRIPTION . . . . . . . 11-2
AND TESTING - (P0117) . . . . . . . . . . . . . . . . 9-49 SENTRY KEY REMOTE . . . . . . . . . . . . . . . . 8N-46 EXHAUST SYSTEM - DIAGNOSIS AND
ENGINE COOLANT TEMPERATURE ENTRY MODULE - DESCRIPTION, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE . . . . . . . . . . . . . . . . 8Q-52 EXHAUST SYSTEM - INSPECTION . . . . . . . . 11-3
AND TESTING - (P0116) . . . . . . . . . . . . . . . . 9-40 ENTRY MODULE - DIAGNOSIS AND EXHAUST SYSTEM - OPERATION . . . . . . . . . 11-2
ENGINE COOLANT TEMPERATURE TESTING, SENTRY KEY REMOTE . . . . . . . . 8N-47 EXHAUST SYSTEM ALIGNMENT,
SENSOR SHORT CIRCUIT, DIAGNOSIS ENTRY MODULE - INSTALLATION, ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 11-4
AND TESTING - (P0116) . . . . . . . . . . . . . . . . 9-47 SENTRY KEY REMOTE . . . . . . . . . . . . . . . . 8Q-55 EXPANSION VALVE - DESCRIPTION, A/C . 24-138
ENGINE COOLANT THERMOSTAT - ENTRY MODULE - OPERATION, SENTRY EXPANSION VALVE - DIAGNOSIS AND
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-21 KEY REMOTE . . . . . . . . . . . . . . . . . . . . . . . . 8E-69 TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . 24-139
ENGINE COOLANT THERMOSTAT - ENTRY MODULE - OPERATION, SENTRY EXPANSION VALVE - INSTALLATION, A/C . 24-140
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 7-22 KEY REMOTE . . . . . . . . . . . . . . . . . . . . . . . 8Q-52 EXPANSION VALVE - OPERATION, A/C . . . 24-139
ENGINE COOLANT THERMOSTAT - ENTRY MODULE - REMOVAL, SENTRY EXPANSION VALVE - REMOVAL, A/C . . . . . 24-140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-23 KEY REMOTE . . . . . . . . . . . . . . . . . . . . . . . 8Q-53 EXTERIOR - LAMPS/LIGHTING . . . . . . . . . . 8L-86
ENGINE COOLANT THERMOSTAT - ENTRY MODULE, DIAGNOSIS AND EXTERIOR - SERVICE INFORMATION -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 TESTING - NO RESPONSE FROM DESCRIPTION, LAMPS/LIGHTING . . . . . . . . 8L-85
ENGINE COOLANT THERMOSTAT - SENTRY KEY REMOTE . . . . . . . . . . . . . . . . 8E-40 EXTERIOR - SERVICE INFORMATION -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 ENTRY MODULE INTERNAL FAILURE, OPERATION, LAMPS/LIGHTING . . . . . . . . . . 8L-85
ENGINE COOLING SYSTEM, OPERATION . . . 7-12 DIAGNOSIS AND TESTING - SENTRY EXTERIOR HANDLE - INSTALLATION . . . . . 23-37,
ENGINE COOLING SYSTEM KEY REMOTE . . . . . . . . . . . . . . . . . . . . . . . 8Q-34 23-99
OVERHEATING, DIAGNOSIS AND ENTRY RELAY CONTROL CIRCUIT, EXTERIOR HANDLE - REMOVAL . . . . 23-34,23-98
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 DIAGNOSIS AND TESTING - REMOTE EXTERIOR LAMPS - SPECIFICATIONS . . . . . 8L-87
ENGINE CORE AND OIL GALLERY PLUGS KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 FAILURE, DIAGNOSIS AND TESTING -
- STANDARD PROCEDURE . . . . . . . . . . . . . 9-591 ENTRY TRANSMITTER - DIAGNOSIS AND BODY CONTROL MODULE INTERNAL . . . . . . 23-2
ENGINE CRANKS BUT DOES NOT START, TESTING, KEYLESS . . . . . . . . . . . . . . . . . . . 8N-37 FAILURE, DIAGNOSIS AND TESTING -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-563 EQUIPMENT, DIAGNOSIS AND TESTING - BODY CONTROL MODULE INTERNAL . . . . . 8N-11
ENGINE DIAGNOSIS - MECHANICAL - PROGRAMMING DOES NOT FAILURE, DIAGNOSIS AND TESTING -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-584 CORRESPOND TO THE VEHICLE . . . . . . . . . 8O-41 CAB INTERNAL . . . . . . . . . . . . . . . . . . 5-153,5-80
ENGINE DIAGNOSIS, INTRODUCTION . . . . . 9-583 ERRATIC, DIAGNOSIS AND TESTING - FAILURE, DIAGNOSIS AND TESTING -
ENGINE DIAGNOSIS, PERFORMANCE . . . . . 9-586 (P0714) TRANS TEMP SENSOR . . . . . . . . . 21-87 CAN B BUS (-) CIRCUIT . . . . . . . . . . . . . . . 8Q-10
ENGINE FUSE BLOCK - DESCRIPTION . . 8W-97-2 ESP BRAKE PRESSURE SENSOR 1 FAILURE, DIAGNOSIS AND TESTING -
ENGINE FUSE BLOCK - INSTALLATION . . 8W-97-3 CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 5-128 CAN B BUS (+) CIRCUIT . . . . . . . . . . . . . . . 8Q-13
ENGINE FUSE BLOCK - OPERATION . . . . 8W-97-2 ESP BRAKE PRESSURE SENSOR 2 FAILURE, DIAGNOSIS AND TESTING -
ENGINE FUSE BLOCK - REMOVAL . . . . . 8W-97-2 CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 5-133 CENTRAL LOCKING PUMP/SECURITY
ENGINE GASKET SURFACE ESP, DIAGNOSIS AND TESTING - SYSTEM MODULE INTERNAL . . . . . . . . . . . 8N-26
PREPARATION - STANDARD (P0720) TRANSMISSION INCORRECT FAILURE, DIAGNOSIS AND TESTING -
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 9-590 TORQUE REQUEST FROM . . . . . . . . . . . . . . 9-469 CENTRAL LOCKING PUMP/SECURITY
ENGINE HEAT SYSTEM (REST) - ESP LATERAL ACCELERATION SENSOR SYSTEM MODULE INTERNAL . . . . . . . . . . . 8Q-30
DESCRIPTION, RESIDUAL . . . . . . . . . . . . . . 24-57 CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 5-138 FAILURE, DIAGNOSIS AND TESTING -
ENGINE MOUNT BRACKETS - ESP MIL REQUEST, DIAGNOSIS AND ORC INTERNAL . . . . . . . . . . . . . . . . . . . . . . . 8O-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-656 TESTING - (P0500) VEHICLE SPEED FAILURE, DIAGNOSIS AND TESTING -
ENGINE MOUNT BRACKETS - REMOVAL . . 9-655 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 9-412 SENTRY KEY REMOTE ENTRY MODULE
ENGINE OIL AND FILTER CHANGE - ESP SERVICE INFORMATION - INTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-34
STANDARD PROCEDURE . . . . . . . . . . . . . . . 9-664 DESCRIPTION, BRAKES . . . . . . . . . . . . . . . . 5-188 FAN - INSTALLATION, RADIATOR . . . . . . . . . 7-27
ENGINE OIL AND LUBRICANTS, ESP TORQUE MANAGEMENT REQUEST FAN - REMOVAL, RADIATOR . . . . . . . . . . . . . 7-26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 PERFORMANCE, DIAGNOSIS AND FAN ALWAYS ON, DIAGNOSIS AND
ENGINE OIL LEAK INSPECTION, TESTING - (P2545) . . . . . . . . . . . . . . . . . . . 9-506 TESTING - RADIATOR COOLING . . . . . . . . . . . 7-6
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-660 ESP YAW RATE SENSOR CIRCUIT, FAN CONTROL CIRCUIT HIGH,
ENGINE OIL LEVEL CHECK, STANDARD DIAGNOSIS AND TESTING . . . . . . . . . . . . . 5-119 DIAGNOSIS AND TESTING - COOLING . . . . 9-517
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 9-664 EVACUATE - STANDARD PROCEDURE, FAN CONTROL CIRCUIT LOW,
ENGINE OIL PRESSURE - DIAGNOSIS REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-117 DIAGNOSIS AND TESTING - COOLING . . . . 9-519
AND TESTING, CHECKING . . . . . . . . . . . . . . 9-662 EVAP PURGE SOLENOID - DESCRIPTION . . 25-17 FAN CONTROL CIRCUIT OPEN,
ENGINE OIL SENSOR LEVEL EVAP PURGE SOLENOID - INSTALLATION . 25-18 DIAGNOSIS AND TESTING - COOLING . . . . 9-514
PERFORMANCE, DIAGNOSIS AND EVAP PURGE SOLENOID - OPERATION . . . . 25-17 FAN CONTROL MODULE -
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-521 EVAP PURGE SOLENOID - REMOVAL . . . . . 25-17 INSTALLATION, RADIATOR . . . . . . . . . . . . . . 7-29
ENGINE OIL SENSOR OVER EVAP PURGE SOLENOID CIRCUIT, FAN CONTROL MODULE - REMOVAL,
TEMPERATURE, DIAGNOSIS AND DIAGNOSIS AND TESTING - (P0445) . . . . . 9-380 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-526 EVAP PURGE SOLENOID STUCK OPEN, FAN INOPERATIVE, DIAGNOSIS AND
ENGINE OIL SENSOR PERFORMANCE, DIAGNOSIS AND TESTING - (P0446) . . . . . 9-387 TESTING - RADIATOR COOLING . . . . . . . . . . . 7-2
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-531 EVAP PURGE VALVE, DIAGNOSIS AND FASCIA - INSTALLATION, FRONT . . . . . . . . . 13-4
ENGINE OIL SENSOR QUALITY TESTING - (P0441) . . . . . . . . . . . . . . . . . . . 9-376 FASCIA - INSTALLATION, REAR . . . . . . . . . . 13-8
PERFORMANCE, DIAGNOSIS AND EVAP PURGE VALVE LEAKING, FASCIA - REMOVAL, FRONT . . . . . . . . . . . . . 13-1
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-533 DIAGNOSIS AND TESTING - (P0457) . . . . . 9-406 FASCIA - REMOVAL, REAR . . . . . . . . . . . . . . 13-7
ENGINE OIL SENSOR WATER EVAP SYSTEM FAILURE, DIAGNOSIS FASTENER IDENTIFICATION -
CONTAMINATION, DIAGNOSIS AND AND TESTING - (P0440) GENERAL . . . . . . . 9-374 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-3
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-538 EVAP SYSTEM LARGE LEAK, DIAGNOSIS FASTENER USAGE, DESCRIPTION . . . . . . Intro.-6
ENGINE OVERSPEED, DIAGNOSIS AND AND TESTING - (P0455) . . . . . . . . . . . . . . . 9-399 FENDERS - INSTALLATION, FRONT . . . . . . 23-113
TESTING - (P0219) . . . . . . . . . . . . . . . . . . . . 21-3 EVAP SYSTEM SMALL LEAK, DIAGNOSIS FENDERS - REMOVAL, FRONT . . . . . . . . . 23-112
AND TESTING - (P0442) . . . . . . . . . . . . . . . 9-378
12 INDEX ZH

FILL - STANDARD PROCEDURE, FLUID FLUID LEVEL SENSOR - REMOVAL, FROM TRANSMISSION CONTROL
DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-352 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 MODULE, DIAGNOSIS AND TESTING -
FILL - STANDARD PROCEDURE, FLUID LEVEL, STANDARD PROCEDURE - NO RESPONSE . . . . . . . . . . . . . . . . . . . . . . 8E-33
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-296 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-43 FROM UNIVERSAL GARAGE DOOR
FILL CHECK VALVE - DESCRIPTION, FLUID LEVEL SWITCH - INSTALLATION, OPENER/TIRE PRESSURE MONITOR,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26 DIAGNOSIS AND TESTING - NO
FILL CHECK VALVE - OPERATION, FUEL . . . . 14-7 FLUID LEVEL SWITCH - REMOVAL, RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
FILL DOOR - INSTALLATION, FUEL . . . . . . 23-115 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26 FRONT - INSTALLATION, CRANKSHAFT
FILL DOOR - REMOVAL, FUEL . . . . . . . . . 23-115 FLUID LEVEL SWITCH CIRCUIT, OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-636
FILL/CHECK LOCATIONS - DESCRIPTION, DIAGNOSIS AND TESTING - COOLANT FRONT - REMOVAL, CRANKSHAFT OIL
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 LEVEL SENSOR/WASHER . . . . . . . . . . . . . . . 8J-2 SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-636
FILLER CAP - DESCRIPTION, FUEL . . . . . . . 25-18 FLUID LOSS - DIAGNOSIS AND TESTING, FRONT AND REAR AXLES, STANDARD
FILLER CAP - OPERATION, FUEL . . . . . . . . 25-18 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-45 PROCEDURE - INSPECTING AND
FILLER TUBE - DESCRIPTION, FUEL FLUID, SPECIFICATIONS - BRAKE . . . . . . . . . 5-43 ADJUSTING VEHICLE LEVEL AT . . . . . . . . . . . 2-8
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24 FLUSHING - STANDARD PROCEDURE, FRONT AND REAR AXLES WITH AN
FILTER - DESCRIPTION, FLUID . . . . . . . . . 21-292 COOLING SYSTEM REVERSE . . . . . . . . . . . . 7-19 ELECTRONIC INCLINOMETER,
FILTER - DESCRIPTION, OIL . . . . . . . . . . . . 9-666 FLYWHEEL - DESCRIPTION . . . . . . . . . . . . . . 6-21 STANDARD PROCEDURE - INSPECTING
FILTER - INSTALLATION, OIL . . . . . . . . . . . 9-666 FLYWHEEL - DIAGNOSIS AND TESTING . . . . 6-21 AND ADJUSTING VEHICLE LEVEL AT . . . . . . . 2-8
FILTER - OPERATION, FLUID . . . . . . . . . . . 21-292 FLYWHEEL - INSTALLATION . . . . . . . . . . . . . 6-23 FRONT AXLE CAMBER AND CASTER,
FILTER - REMOVAL, OIL . . . . . . . . . . . . . . . 9-666 FLYWHEEL - INSTALLATION, FLEX PLATE . . 9-654 STANDARD PROCEDURE - CHECKING
FILTER CHANGE - STANDARD FLYWHEEL - OPERATION . . . . . . . . . . . . . . . 6-21 AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . 2-8
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-296 FLYWHEEL - REMOVAL . . . . . . . . . . . . . . . . . 6-22 FRONT BRAKE HOSE, INSTALLATION . . . . . . 5-14
FILTER CHANGE - STANDARD FLYWHEEL - REMOVAL, FLEX PLATE . . . . . 9-653 FRONT BRAKE HOSE, REMOVAL . . . . . . . . . . 5-12
PROCEDURE, ENGINE OIL . . . . . . . . . . . . . . 9-664 FOG LAMP - INSTALLATION . . . . . . . . . . . . 8L-94 FRONT DISC BRAKE CALIPER -
FILTER/PRESSURE REGULATOR - FOG LAMP - REMOVAL . . . . . . . . . . . . . . . . 8L-93 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
DESCRIPTION, FUEL . . . . . . . . . . . . . . . . . . . 14-8 FOG LAMP INOPERATIVE, DIAGNOSIS FRONT DISC BRAKE CALIPER -
FILTER/PRESSURE REGULATOR - AND TESTING - LEFT . . . . . . . . . . . . . . . . . . 8L-2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 5-29
INSTALLATION, FUEL . . . . . . . . . . . . . . . . . 14-10 FOG LAMP INOPERATIVE, DIAGNOSIS FRONT DISC BRAKE CALIPER,
FILTER/PRESSURE REGULATOR - AND TESTING - RIGHT . . . . . . . . . . . . . . . . . 8L-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-32
OPERATION, FUEL . . . . . . . . . . . . . . . . . . . . . 14-9 FOG LAMP UNIT - INSTALLATION . . . . . . . . 8L-96 FRONT DISC BRAKE CALIPER, REMOVAL . . 5-25
FILTER/PRESSURE REGULATOR - FOG LAMP UNIT - REMOVAL . . . . . . . . . . . 8L-95 FRONT DISC BRAKE PADS,
REMOVAL, FUEL . . . . . . . . . . . . . . . . . . . . . 14-10 FOOTWELL AIR OUTLET COVER - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-20
FINISH - DESCRIPTION, BASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 24-111 FRONT DISC BRAKE PADS, REMOVAL . . . . . 5-17
COAT/CLEAR COAT . . . . . . . . . . . . . . . . . . 23-199 FOOTWELL AIR OUTLET COVER - FRONT DISC BRAKE ROTOR,
FITTED SLEEVES - INSTALLATION . . . . . . . . 3-36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 24-110 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 5-40
FITTED SLEEVES - REMOVAL . . . . . . . . . . . . 3-35 FORCED LIMITED POWER EXCESSIVE FRONT DISC BRAKE ROTOR, REMOVAL . . . . 5-38
FITTING, STANDARD PROCEDURE - HIGH COOLANT TEMP, DIAGNOSIS FRONT EXHAUST PIPES - INSTALLATION . . . 11-7
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-640 AND TESTING - (P0128) . . . . . . . . . . . . . . . . 9-74 FRONT EXHAUST PIPES - REMOVAL . . . . . . 11-5
FLANGE SEAL - INSTALLATION, FORM-IN-PLACE GASKETS AND FRONT FASCIA - INSTALLATION . . . . . . . . . . 13-4
DIFFERENTIAL CONNECTING . . . . . . . . . . . . . 3-47 SEALERS - STANDARD PROCEDURE . . . . . 9-589 FRONT FASCIA - REMOVAL . . . . . . . . . . . . . . 13-1
FLANGE SEAL - INSTALLATION, OUTPUT . 21-356 FRAME DIMENSIONS - SPECIFICATIONS . . . 13-9 FRONT FENDERS - INSTALLATION . . . . . . 23-113
FLANGE SEAL - INSTALLATION, PINION . . . . 3-45 FREEWHEELING CLUTCH - ASSEMBLY . . . 21-301 FRONT FENDERS - REMOVAL . . . . . . . . . . 23-112
FLANGE SEAL - REMOVAL, FREEWHEELING CLUTCH - DESCRIPTION . 21-298 FRONT HEAT SHIELD - INSTALLATION . . . . . 11-9
DIFFERENTIAL CONNECTING . . . . . . . . . . . . . 3-46 FREEWHEELING CLUTCH - FRONT HEAT SHIELD - REMOVAL . . . . . . . . . 11-8
FLANGE SEAL - REMOVAL, OUTPUT . . . . . 21-355 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-299 FRONT MARKER LAMP - INSTALLATION . 8L-111
FLANGE SEAL - REMOVAL, PINION . . . . . . . 3-43 FREEWHEELING CLUTCH - OPERATION . . 21-298 FRONT MARKER LAMP - REMOVAL . . . . . 8L-110
FLARING - STANDARD PROCEDURE, ISO . . . 5-11 FROM A/C HEATER CONTROL MODULE, FRONT MOUNT - INSTALLATION . . . . . . . . . 9-658
FLARING, STANDARD PROCEDURE - DIAGNOSIS AND TESTING - NO FRONT MOUNT - REMOVAL . . . . . . . . . . . . 9-657
DOUBLE INVERTED . . . . . . . . . . . . . . . . . . . . 5-11 RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 FRONT POSITION LAMP - DESCRIPTION . . 8L-97
FLASHER - DESCRIPTION, HAZARD . . . . . . 8L-99 FROM ALL SPEAKERS, DIAGNOSIS AND FRONT POSITION LAMP - INSTALLATION . . 8L-98
FLEX PLATE / FLYWHEEL - TESTING - NO SOUND . . . . . . . . . . . . . . . . . 8A-5 FRONT POSITION LAMP - OPERATION . . . . 8L-97
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-654 FROM BODY CONTROL MODULE, FRONT POSITION LAMP - REMOVAL . . . . . 8L-97
FLEX PLATE / FLYWHEEL - REMOVAL . . . . 9-653 DIAGNOSIS AND TESTING - NO FRONT POWER WINDOW INOPERATIVE,
FLEXIBLE SERVICE SYSTEM (FSS) - RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-36 DIAGNOSIS AND TESTING - LEFT . . . . . . 8N-110
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 0-11 FROM CONTROLLER ANTILOCK BRAKE, FRONT POWER WINDOW INOPERATIVE,
FLOW AND PRESSURE - DIAGNOSIS DIAGNOSIS AND TESTING - NO DIAGNOSIS AND TESTING - RIGHT . . . . . 8N-113
AND TESTING, STEERING . . . . . . . . . . . . . . . 19-5 RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-25 FRONT RISER MOTOR - INSTALLATION . . 8N-102
FLOW CIRCUIT, DIAGNOSIS AND FROM INSTRUMENT CLUSTER, FRONT RISER MOTOR - REMOVAL . . . . . 8N-102
TESTING - (P0102) MASS AIR . . . . . . . . . . . 9-10 DIAGNOSIS AND TESTING - NO FRONT RISER MOTOR INOPERATIVE,
FLOW (MAF) SENSOR - DESCRIPTION, COMMUNICATION . . . . . . . . . . . . . . . . . . . . 8J-14 DIAGNOSIS AND TESTING - DRIVER
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-37 FROM INSTRUMENT CLUSTER, POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8N-85
FLOW (MAF) SENSOR - INSTALLATION, DIAGNOSIS AND TESTING - NO FRONT SECTION - ASSEMBLY,
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-39 RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-13 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-361
FLOW (MAF) SENSOR - OPERATION, FROM LEFT DOOR SPEAKERS, FRONT SECTION - DISASSEMBLY,
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-37 DIAGNOSIS AND TESTING - NO TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-361
FLOW (MAF) SENSOR - REMOVAL, SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8 FRONT SENSOR MESSAGE, DIAGNOSIS
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-37 FROM LEFT REAR SPEAKER, DIAGNOSIS AND TESTING - (P0600) ABS LEFT . . . . . . . 21-22
FLUID - DESCRIPTION, AUTOMATIC AND TESTING - NO SOUND . . . . . . . . . . . . 8A-12 FRONT SENSOR MESSAGE, DIAGNOSIS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 0-5 FROM OCCUPANT RESTRAINT AND TESTING - (P0600) ABS RIGHT . . . . . 21-28
FLUID - DIAGNOSIS AND TESTING, CONTROLLER, DIAGNOSIS AND FRONT SIDE MARKER LAMP
CAUSES OF BURNT . . . . . . . . . . . . . . . . . . 21-293 TESTING - NO RESPONSE . . . . . . . . . . . . . . 8E-10 INOPERATIVE, DIAGNOSIS AND
FLUID AND FILTER - DESCRIPTION . . . . . 21-292 FROM POWERTRAIN CONTROL TESTING - LEFT . . . . . . . . . . . . . . . . . . . . . . 8L-32
FLUID AND FILTER - OPERATION . . . . . . . 21-292 MODULE, DIAGNOSIS AND TESTING - FRONT SIDE MARKER LAMP
FLUID CAPACITIES - SPECIFICATIONS . . . . . . 0-1 NO RESPONSE . . . . . . . . . . . . . . . . . . . . . . . 8E-4 INOPERATIVE, DIAGNOSIS AND
FLUID CONTAMINATION - DIAGNOSIS FROM RIGHT DOOR SPEAKERS, TESTING - RIGHT . . . . . . . . . . . . . . . . . . . . 8L-35
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-293 DIAGNOSIS AND TESTING - NO FRONT SUSPENSION - TORQUE CHART . . . . 2-14
FLUID CONTAMINATION, DIAGNOSIS SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-10 FRONT TIRE PRESSURE SENSOR/
AND TESTING - BRAKE . . . . . . . . . . . . . . . . . 5-42 FROM RIGHT REAR SPEAKER, TRANSMITTER, DIAGNOSIS AND
FLUID DRAIN AND FILL - STANDARD DIAGNOSIS AND TESTING - NO TESTING - LEFT . . . . . . . . . . . . . . . . . . . . . . 22-24
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-352 SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-14 FRONT TIRE PRESSURE SENSOR/
FLUID FILL/CHECK LOCATIONS - FROM SENTRY KEY REMOTE ENTRY TRANSMITTER, DIAGNOSIS AND
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 MODULE, DIAGNOSIS AND TESTING - TESTING - RIGHT . . . . . . . . . . . . . . . . . . . . 22-28
FLUID LEVEL - STANDARD PROCEDURE, NO RESPONSE . . . . . . . . . . . . . . . . . . . . . . 8E-40 FRONT TIRE PRESSURE SENSOR/
CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . 21-353 FROM SHIFT LEVER ASSEMBLY, TRANSMITTER SIGNAL JAMMED,
FLUID LEVEL, DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - NO DIAGNOSIS AND TESTING - LEFT . . . . . . . . 22-11
- EFFECTS OF INCORRECT . . . . . . . . . . . . 21-293 RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-29 FRONT TIRE PRESSURE SENSOR/
FLUID LEVEL SENSOR - INSTALLATION, TRANSMITTER SIGNAL JAMMED,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 DIAGNOSIS AND TESTING - RIGHT . . . . . . 22-15
ZH INDEX 13

FRONT TOE-IN - STANDARD FUEL MIXTURE (OFF IDLE), DIAGNOSIS FUSE BLOCK - INSTALLATION,
PROCEDURE, CHECKING AND AND TESTING - (P0171) FUEL SYSTEM UNDERHOOD ACCESSORY . . . . . . . . . . . 8W-97-5
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 1/1 UNDERCORRECTION OF . . . . . . . . . . . . 9-179 FUSE BLOCK - OPERATION . . . . . . . . . . . 8W-97-6
FRONT TURN LAMP INOPERATIVE, FUEL MIXTURE (OFF IDLE), DIAGNOSIS FUSE BLOCK - OPERATION, ENGINE . . . 8W-97-2
DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8L-11 AND TESTING - (P0174) FUEL SYSTEM FUSE BLOCK - OPERATION,
FRONT TURN LAMP INOPERATIVE, 2/1 UNDERCORRECTION OF . . . . . . . . . . . . 9-227 UNDERHOOD ACCESSORY . . . . . . . . . . . 8W-97-5
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8L-17 FUEL MIXTURE (OFF IDLE), DIAGNOSIS FUSE BLOCK - REMOVAL, ENGINE . . . . . 8W-97-2
FRONT TURN SIGNAL LAMP - AND TESTING - (P0175) FUEL SYSTEM FUSE BLOCK - REMOVAL, UNDERHOOD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8L-99 2/1 OVERCORRECTION OF . . . . . . . . . . . . . 9-230 ACCESSORY . . . . . . . . . . . . . . . . . . . . . . 8W-97-5
FRONT TURN SIGNAL LAMP - REMOVAL . . 8L-98 FUEL PRESSURE LEAK DOWN TEST - FUSES POWERING SEVERAL LOADS -
FRONT WHEEL SPEED SENSOR - DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 14-4 STANDARD PROCEDURE, TESTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-193 FUEL PUMP - DESCRIPTION . . . . . . . . . . . . 14-15 FOR A SHORT TO GROUND ON . . . . . . 8W-01-10
FRONT WHEEL SPEED SENSOR - FUEL PUMP - OPERATION . . . . . . . . . . . . . 14-15 GALLERY PLUGS - STANDARD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5-195 FUEL PUMP RELAY - DESCRIPTION . . . . . . 14-35 PROCEDURE, ENGINE CORE AND OIL . . . . 9-591
FRONT WHEEL SPEED SENSOR - FUEL PUMP RELAY - OPERATION . . . . . . . . 14-35 GAP MEASUREMENTS -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-193 FUEL PUMP TEST, DIAGNOSIS AND SPECIFICATIONS, BODY . . . . . . . . . . . . . . . 23-53
FRONT WHEEL SPEED SENSOR - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 GARAGE DOOR OPENER/TIRE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194 FUEL RAIL - DESCRIPTION . . . . . . . . . . . . . 14-18 PRESSURE MONITOR, DIAGNOSIS
FRONT WHEEL SPEED SENSOR CIRCUIT, FUEL RAIL - INSTALLATION . . . . . . . . . . . . 14-20 AND TESTING - NO RESPONSE FROM
DIAGNOSIS AND TESTING - LEFT . . . . . . . . . 5-95 FUEL RAIL - OPERATION . . . . . . . . . . . . . . . 14-18 UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
FRONT WHEEL SPEED SENSOR CIRCUIT, FUEL RAIL - REMOVAL . . . . . . . . . . . . . . . . 14-19 GAS PROP - INSTALLATION . . . . . . 23-127,23-41
DIAGNOSIS AND TESTING - RIGHT . . . . . . 5-101 FUEL SHUT OFF DETECTED, DIAGNOSIS GAS PROP - REMOVAL . . . . . . . . . . 23-126,23-40
FSS MAINTENANCE INDICATOR AFTER AND TESTING - SAFETY . . . . . . . . . . . . . . . 9-540 GASKET - DIAGNOSIS AND TESTING,
AN OIL CHANGE, STANDARD FUEL SYSTEM 1/1 LEAN CONTROL CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . 9-610
PROCEDURE - RESETTING THE . . . . . . . . . 8J-78 BELOW LIMIT (AT IDLE), DIAGNOSIS GASKET SURFACE PREPARATION -
FSS MAINTENANCE INDICATOR, AND TESTING - (P0172) . . . . . . . . . . . . . . . 9-207 STANDARD PROCEDURE, ENGINE . . . . . . . 9-590
STANDARD PROCEDURE - RESETTING FUEL SYSTEM 1/1 LEAN CONTROL GASKETS AND SEALERS - STANDARD
THE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-76 BELOW LIMIT (AT LOAD), DIAGNOSIS PROCEDURE, FORM-IN-PLACE . . . . . . . . . . 9-589
FSS MILEAGE AT DRIVER’S REQUEST, AND TESTING - (P0172) . . . . . . . . . . . . . . . 9-199 GEAR - DESCRIPTION . . . . . . . . . . . . . . . . . 19-32
STANDARD PROCEDURE - DISPLAY OF FUEL SYSTEM 1/1 OVERCORRECTION OF GEAR - INSTALLATION . . . . . . . . . . . . . . . . 19-36
REMAINING . . . . . . . . . . . . . . . . . . . . . . . . . 8J-75 FUEL MIXTURE (AT IDLE), DIAGNOSIS GEAR - OPERATION . . . . . . . . . . . . . . . . . . . 19-32
FUEL DELIVERY - DESCRIPTION . . . . . . . . . . 14-2 AND TESTING - (P0172) . . . . . . . . . . . . . . . 9-195 GEAR - REMOVAL . . . . . . . . . . . . . . . . . . . . . 19-33
FUEL DELIVERY - OPERATION . . . . . . . . . . . 14-3 FUEL SYSTEM 1/1 RICH CONTROL OVER GEAR, ADJUSTMENTS - STEERING . . . . . . 19-38
FUEL DELIVERY, DIAGNOSIS AND LIMIT (AT IDLE), DIAGNOSIS AND GEAR, DIAGNOSIS AND TESTING -
TESTING - CHECKING . . . . . . . . . . . . . . . . . 9-556 TESTING - (P0171) . . . . . . . . . . . . . . . . . . . 9-183 (P0730) IMPROPER . . . . . . . . . . . . . . . . . . 21-113
FUEL DOOR LOCK ACTUATOR - FUEL SYSTEM 1/1 RICH CONTROL OVER GEAR RATIOS - SPECIFICATIONS . . . . . . . 21-349
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-45 LIMIT (AT LOAD), DIAGNOSIS AND GEAR SHIFT LEVER HANDLE -
FUEL DOOR LOCK ACTUATOR - TESTING - (P0171) . . . . . . . . . . . . . . . . . . . 9-187 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21-387
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-44 FUEL SYSTEM 1/1 UNDERCORRECTION GEAR SHIFT LEVER HANDLE - REMOVAL . 21-387
FUEL DOOR LOCK ACTUATOR SLOW OF FUEL MIXTURE (OFF IDLE), GEAR SHIFT MODULE (SLA), DIAGNOSIS
RESPONSE, DIAGNOSIS AND TESTING . . . . 8N-5 DIAGNOSIS AND TESTING - (P0171) . . . . . 9-179 AND TESTING - (P0600) LOST COMM
FUEL FILL CHECK VALVE - DESCRIPTION . . 14-7 FUEL SYSTEM 2/1 LEAN CONTROL WITH ELECTRIC . . . . . . . . . . . . . . . . . . . . . 9-439
FUEL FILL CHECK VALVE - OPERATION . . . . 14-7 BELOW LIMIT (AT IDLE), DIAGNOSIS GEAR SHIFT ROD - INSTALLATION . . . . . . 21-341
FUEL FILL DOOR - INSTALLATION . . . . . . 23-115 AND TESTING - (P0175) . . . . . . . . . . . . . . . 9-233 GEAR SHIFT ROD - REMOVAL . . . . . . . . . 21-341
FUEL FILL DOOR - REMOVAL . . . . . . . . . . 23-115 FUEL SYSTEM 2/1 LEAN CONTROL GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-323
FUEL FILLER CAP - DESCRIPTION . . . . . . . 25-18 BELOW LIMIT (AT LOAD), DIAGNOSIS GEARTRAIN - DESCRIPTION,
FUEL FILLER CAP - OPERATION . . . . . . . . . 25-18 AND TESTING - (P0174) . . . . . . . . . . . . . . . 9-224 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-321
FUEL FILTER/PRESSURE REGULATOR - FUEL SYSTEM 2/1 OVERCORRECTION OF GEARTRAIN - DISASSEMBLY,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14-8 FUEL MIXTURE (OFF IDLE), PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-322
FUEL FILTER/PRESSURE REGULATOR - DIAGNOSIS AND TESTING - (P0175) . . . . . 9-230 GEARTRAIN - OPERATION, PLANETARY . . 21-321
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14-10 FUEL SYSTEM 2/1 RICH CONTROL OVER GEARTRAIN HOUSING - ASSEMBLY . . . . . 21-365
FUEL FILTER/PRESSURE REGULATOR - LIMIT (AT IDLE), DIAGNOSIS AND GEARTRAIN HOUSING - DISASSEMBLY . . 21-363
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 TESTING - (P0174) . . . . . . . . . . . . . . . . . . . 9-218 GENERAL - WARNINGS . . . . . . . . . . . . . 8W-01-7
FUEL FILTER/PRESSURE REGULATOR - FUEL SYSTEM 2/1 RICH CONTROL OVER GENERAL EVAP SYSTEM FAILURE,
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10 LIMIT (AT LOAD), DIAGNOSIS AND DIAGNOSIS AND TESTING - (P0440) . . . . . 9-374
FUEL INJECTION - SPECIFICATIONS . . . . . . 14-25 TESTING - (P0173) . . . . . . . . . . . . . . . . . . . 9-211 GENERAL MALFUNCTION, DIAGNOSIS
FUEL INJECTOR - DESCRIPTION . . . . . . . . . 14-31 FUEL SYSTEM 2/1 RICH CONTROL OVER AND TESTING - CAN BUS
FUEL INJECTOR - INSTALLATION . . . . . . . . 14-34 LIMIT (AT LOAD), DIAGNOSIS AND COMMUNICATION . . . . . . . . . . . . . . . . 5-162,5-88
FUEL INJECTOR - OPERATION . . . . . . . . . . 14-32 TESTING - (P0174) . . . . . . . . . . . . . . . . . . . 9-221 GENERAL MALFUNCTION, DIAGNOSIS
FUEL INJECTOR - REMOVAL . . . . . . . . . . . . 14-33 FUEL SYSTEM 2/1 UNDERCORRECTION AND TESTING - CAN BUS
FUEL INJECTOR #1 CIRCUIT, DIAGNOSIS OF FUEL MIXTURE (OFF IDLE), COMMUNICATION . . . . . . . . . . . . . . . . . . . . 8J-36
AND TESTING - (P0201) . . . . . . . . . . . . . . . 9-238 DIAGNOSIS AND TESTING - (P0174) . . . . . 9-227 GENERATOR - DESCRIPTION . . . . . . . . . . . 8F-27
FUEL INJECTOR #2 CIRCUIT, DIAGNOSIS FUEL SYSTEM PRESSURE RELEASE GENERATOR - INSTALLATION . . . . . . . . . . . 8F-29
AND TESTING - (P0202) . . . . . . . . . . . . . . . 9-242 PROCEDURE - STANDARD GENERATOR - OPERATION . . . . . . . . . . . . . 8F-27
FUEL INJECTOR #3 CIRCUIT, DIAGNOSIS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 GENERATOR - REMOVAL . . . . . . . . . . . . . . . 8F-28
AND TESTING - (P0203) . . . . . . . . . . . . . . . 9-244 FUEL TANK - DESCRIPTION . . . . . . . . . . . . 14-20 GENERATOR - SPECIFICATIONS . . . . . . . . . 8F-27
FUEL INJECTOR #4 CIRCUIT, DIAGNOSIS FUEL TANK - INSTALLATION . . . . . . . . . . . . 14-22 GLASS - INSTALLATION, DOOR . . . . . . . . . 23-95
AND TESTING - (P0204) . . . . . . . . . . . . . . . 9-246 FUEL TANK - OPERATION . . . . . . . . . . . . . . 14-20 GLASS - REMOVAL, DOOR . . . . . . . . . . . . . 23-93
FUEL INJECTOR #5 CIRCUIT, DIAGNOSIS FUEL TANK - REMOVAL . . . . . . . . . . . . . . . 14-21 GLASS - SERVICE INFORMATION -
AND TESTING - (P0205) . . . . . . . . . . . . . . . 9-248 FUEL TANK - STANDARD PROCEDURE, DESCRIPTION, HEATED . . . . . . . . . . . . . . . . 8G-10
FUEL INJECTOR #6 CIRCUIT, DIAGNOSIS DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 GLASS - SERVICE INFORMATION -
AND TESTING - (P0206) . . . . . . . . . . . . . . . 9-250 FUEL TANK FILLER TUBE - DESCRIPTION . 14-24 OPERATION, HEATED . . . . . . . . . . . . . . . . . 8G-11
FUEL INJECTOR CIRCUIT, DIAGNOSIS FUEL TANK PRESSURE SENSOR CIRCUIT GLASS HEATING GRID REPAIR -
AND TESTING - (P0200) . . . . . . . . . . . . . . . 9-236 HIGH, DIAGNOSIS AND TESTING - STANDARD PROCEDURE, REAR . . . . . . . . . 8G-13
FUEL LEVEL SENDING UNIT - (P0453) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-397 GLOVE BOX LAMP - INSTALLATION . . . . . 8L-147
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 14-12 FUEL TANK PRESSURE SENSOR CIRCUIT GLOVE BOX LAMP - REMOVAL . . . . . . . . . 8L-146
FUEL LEVEL SENDING UNIT/SENSOR, LOW, DIAGNOSIS AND TESTING - GLOVE BOX LAMP INOPERATIVE,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-11 (P0452) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-395 DIAGNOSIS AND TESTING . . . . . . . . . . . . 8L-127
FUEL LEVEL SENDING UNIT/SENSOR, FUEL TANK PRESSURE SENSOR GLOVE BOX LAMP/SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-11 PERFORMANCE, DIAGNOSIS AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8L-148
FUEL LEVEL SENSOR CIRCUIT, TESTING - (P0451) . . . . . . . . . . . . . . . . . . . 9-390 GLOVE BOX LAMP/SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8J-7 FUNCTION CHECK - DIAGNOSIS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8L-149
FUEL LEVEL SENSOR CIRCUIT, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-73 GLOVE BOX LAMP/SWITCH -
DIAGNOSIS AND TESTING - (P0460) . . . . . 9-408 FUSE BLOCK - DESCRIPTION . . . . . . . . . 8W-97-6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-148
FUEL LINES - DESCRIPTION . . . . . . . . . . . . 14-14 FUSE BLOCK - DESCRIPTION, ENGINE . . 8W-97-2 GLOVE BOX LAMP/SWITCH - REMOVAL . . 8L-148
FUEL MIXTURE (AT IDLE), DIAGNOSIS FUSE BLOCK - DESCRIPTION, GLOVE COMPARTMENT, INSTALLATION . . 23-146
AND TESTING - (P0172) FUEL SYSTEM UNDERHOOD ACCESSORY . . . . . . . . . . . 8W-97-5 GLOVE COMPARTMENT, REMOVAL . . . . . . 23-143
1/1 OVERCORRECTION OF . . . . . . . . . . . . . 9-195 FUSE BLOCK - INSTALLATION, ENGINE . 8W-97-3
14 INDEX ZH

GLOVE COMPARTMENT, STANDARD HEADLAMP SWITCH - REMOVAL . . . . . . . 8L-105 HEATER CONTROL MODULE - REMOVAL,
PROCEDURE - ADJUSTING THE . . . . . . . . 23-141 HEADLAMP UNIT - DESCRIPTION . . . . . . . 8L-107 A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-79
GRID - DESCRIPTION, HEATED MIRROR . . 8G-23 HEADLAMP UNIT - INSTALLATION . . . . . . 8L-108 HEATER CONTROL MODULE, DIAGNOSIS
GRID - DIAGNOSIS AND TESTING, REAR HEADLAMP UNIT - REMOVAL . . . . . . . . . . 8L-108 AND TESTING - NO RESPONSE FROM
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . 8G-12 HEADLINER - INSTALLATION . . . . . . . . . . 23-196 A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
GRID REPAIR - STANDARD PROCEDURE, HEADLINER - REMOVAL . . . . . . . . . . . . . . 23-194 HEATER CORE - DESCRIPTION . . . . . . . . . 24-141
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-24 HEAT SHIELD - INSTALLATION, FRONT . . . . 11-9 HEATER CORE - INSTALLATION . . . . . . . . 24-144
GRID REPAIR - STANDARD PROCEDURE, HEAT SHIELD - INSTALLATION, REAR . . . . . 11-9 HEATER CORE - OPERATION . . . . . . . . . . . 24-141
REAR GLASS HEATING . . . . . . . . . . . . . . . . 8G-13 HEAT SHIELD - REMOVAL, FRONT . . . . . . . . 11-8 HEATER CORE - REMOVAL . . . . . . . . . . . . 24-142
GRILLE - INSTALLATION . . . . . . . . . . . . . . 23-111 HEAT SHIELD - REMOVAL, REAR . . . . . . . . . 11-8 HEATER CORE TEMPERATURE SENSOR -
GRILLE - INSTALLATION, COWL . . . . . . . . 23-114 HEAT SYSTEM (REST) - DESCRIPTION, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-85
GRILLE - REMOVAL . . . . . . . . . . . . . . . . . . 23-110 RESIDUAL ENGINE . . . . . . . . . . . . . . . . . . . 24-57 HEATER CORE TEMPERATURE SENSOR -
GRILLE - REMOVAL, COWL . . . . . . . . . . . 23-114 HEATED GLASS - SERVICE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-85
GROUND - (P0753) 1, 2/4-5 SOLENOID INFORMATION - DESCRIPTION . . . . . . . . . . 8G-10 HEATER CORE TEMPERATURE SENSOR
CIRCUIT SHORT TO . . . . . . . . . . . . . . . . . . 21-136 HEATED GLASS - SERVICE CIRCUIT, DIAGNOSIS AND TESTING -
GROUND - (P0758) 2, 3 SOLENOID INFORMATION - OPERATION . . . . . . . . . . . 8G-11 LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8
CIRCUIT SHORT TO . . . . . . . . . . . . . . . . . . 21-142 HEATED MIRROR GRID - DESCRIPTION . . 8G-23 HEATER CORE TEMPERATURE SENSOR
GROUND - (P0763) 3, 4 SOLENOID HEATED MIRROR INOPERATIVE, CIRCUIT, DIAGNOSIS AND TESTING -
CIRCUIT SHORT TO . . . . . . . . . . . . . . . . . . 21-148 DIAGNOSIS AND TESTING - LEFT . . . . . . . 8G-16 RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13
GROUND - STANDARD PROCEDURE, HEATED MIRROR INOPERATIVE, HEATER PERFORMANCE - DIAGNOSIS
TESTING FOR A SHORT TO . . . . . . . . . 8W-01-10 DIAGNOSIS AND TESTING - RIGHT . . . . . . 8G-18 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-68
GROUND AND SPLICE INFORMATION - HEATED MIRRORS - SERVICE HEATER PERFORMANCE, DIAGNOSIS
DESCRIPTION, CONNECTOR . . . . . . . . . . 8W-01-6 INFORMATION - DESCRIPTION . . . . . . . . . . 8G-22 AND TESTING - (P0135) O2 SENSOR
GROUND ON FUSES POWERING HEATED MIRRORS - SERVICE 1/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109
SEVERAL LOADS - STANDARD INFORMATION - DIAGNOSIS AND HEATER PERFORMANCE, DIAGNOSIS
PROCEDURE, TESTING FOR A SHORT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-22 AND TESTING - (P0141) O2 SENSOR
TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10 HEATED MIRRORS - SERVICE 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-147
GUIDES - INSTALLATION, TIMING CHAIN . . 9-703 INFORMATION - OPERATION . . . . . . . . . . . 8G-22 HEATER PERFORMANCE, DIAGNOSIS
GUIDES - REMOVAL, TIMING CHAIN . . . . . 9-703 HEATED SEAT BACK ELEMENT - AND TESTING - (P0155) O2 SENSOR
HALFSHAFTS - DESCRIPTION . . . . . . . . . . . . . 3-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-41 2/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-169
HALFSHAFTS - INSTALLATION . . . . . . . . . . . . 3-5 HEATED SEAT BACK ELEMENT - HEATER PERFORMANCE, DIAGNOSIS
HALFSHAFTS - OPERATION . . . . . . . . . . . . . . . 3-3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 AND TESTING - (P0161) O2 SENSOR
HALFSHAFTS - REMOVAL . . . . . . . . . . . . . . . . 3-4 HEATED SEAT CUSHION ELEMENT, 2/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-171
HANDLE - INSTALLATION, EXTERIOR . . . . 23-37, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-41 HEATER SWITCH ILLUMINATION -
23-99 HEATED SEAT CUSHION ELEMENT, DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8L-150
HANDLE - INSTALLATION, GEAR SHIFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 HEATING & AIR CONDITIONING -
LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387 HEATED SEAT ELEMENT - DESCRIPTION . . 8G-39 ELECTRICAL DIAGNOSTICS -
HANDLE - REMOVAL, EXTERIOR . . . 23-34,23-98 HEATED SEAT INOPERATIVE, DIAGNOSIS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-1
HANDLE - REMOVAL, GEAR SHIFT AND TESTING - LEFT . . . . . . . . . . . . . . . . . 8G-26 HEATING & AIR CONDITIONING -
LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387 HEATED SEAT INOPERATIVE, DIAGNOSIS ELECTRICAL DIAGNOSTICS -
HANDLING NON-DEPLOYED AND TESTING - RIGHT . . . . . . . . . . . . . . . . 8G-29 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
SUPPLEMENTAL RESTRAINTS - HEATED SEAT MODULE - INSTALLATION . . 8G-42 HEATING GRID REPAIR - STANDARD
STANDARD PROCEDURE . . . . . . . . . . . . . . 8O-83 HEATED SEAT MODULE - REMOVAL . . . . . 8G-41 PROCEDURE, REAR GLASS . . . . . . . . . . . . 8G-13
HARNESS - DIAGNOSIS AND TESTING, HEATED SEAT SWITCH - INSTALLATION . . 8G-38 HIGH BEAM BULB - INSTALLATION . . . . . 8L-105
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7 HEATED SEAT SWITCH - REMOVAL . . . . . . 8G-37 HIGH BEAM BULB - REMOVAL . . . . . . . . . 8L-103
HARNESS CONNECTORS REVERSED, HEATED SEATS - SERVICE INFORMATION HIGH BEAM HEADLAMP INOPERATIVE,
DIAGNOSIS AND TESTING - (P0040) - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8G-36 DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8L-23
1/1 AND 2/1 O2 SENSOR . . . . . . . . . . . . . . . . 9-5 HEATED SEATS - SERVICE INFORMATION HIGH BEAM HEADLAMP INOPERATIVE,
HAZARD FLASHER - DESCRIPTION . . . . . . 8L-99 - DIAGNOSIS AND TESTING . . . . . . . . . . . . 8G-37 DIAGNOSIS AND TESTING - RIGHT . . . . . . 8L-29
HAZARD SWITCH - DESCRIPTION . . . . . . 8L-100 HEATED SEATS - SERVICE INFORMATION HIGH BEAM INDICATOR INOPERATIVE,
HAZARD SWITCH - INSTALLATION . . . . . . 8L-102 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8G-36 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8J-42
HAZARD SWITCH - OPERATION . . . . . . . . 8L-100 HEATED SEATS INOPERATIVE, HIGH MOUNTED STOP LAMP -
HAZARD SWITCH - REMOVAL . . . . . . . . . 8L-100 DIAGNOSIS AND TESTING - BOTH . . . . . . . 8G-32 DESCRIPTION, CENTER . . . . . . . . . . . . . . . . 8L-92
HAZARD SWITCH CIRCUIT, DIAGNOSIS HEATER AND AIR CONDITIONER - HIGH MOUNTED STOP LAMP -
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 8L-118 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-55 INSTALLATION, CENTER . . . . . . . . . . . . . . . 8L-93
HCU (HYDRAULIC CONTROL UNIT) - HEATER AND AIR CONDITIONER, HIGH MOUNTED STOP LAMP -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-204 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-59 REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8L-92
HCU (HYDRAULIC CONTROL UNIT) - HEATER CIRCUIT HIGH, DIAGNOSIS AND HIGH MOUNTED STOP LAMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5-206 TESTING - (P0135) O2 SENSOR 1/1 . . . . . . 9-113 INOPERATIVE, DIAGNOSIS AND
HCU (HYDRAULIC CONTROL UNIT) - HEATER CIRCUIT HIGH, DIAGNOSIS AND TESTING - CENTER . . . . . . . . . . . . . . . . . . . 8L-68
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-204 TESTING - (P0141) O2 SENSOR 1/2 . . . . . . 9-145 HIGH SPEED, DESCRIPTION - TIRE
HCU (HYDRAULIC CONTROL UNIT) - HEATER CIRCUIT HIGH, DIAGNOSIS AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5-205 TESTING - (P0155) O2 SENSOR 2/1 . . . . . . 9-165 HIGH SPEED INOPERATIVE, DIAGNOSIS
HEAD - CLEANING, CYLINDER . . . . . . . . . . 9-614 HEATER CIRCUIT HIGH, DIAGNOSIS AND AND TESTING - WIPERS . . . . . . . . . . . . . . . 8R-11
HEAD - DESCRIPTION, CYLINDER . . . . . . . 9-610 TESTING - (P0161) O2 SENSOR 2/2 . . . . . . 9-177 HINGE - INSTALLATION . . . . . . . . . . 23-129,23-42
HEAD - INSPECTION, CYLINDER . . . . . . . . . 9-614 HEATER CIRCUIT LOW, DIAGNOSIS AND HINGE - REMOVAL . . . . . . . . . . . . . 23-128,23-42
HEAD - INSTALLATION, CYLINDER . . . . . . . 9-614 TESTING - (P0135) O2 SENSOR 1/1 . . . . . . 9-107 HOAT COOLANT - DESCRIPTION . . . . . . . . . . 7-16
HEAD - OPERATION, CYLINDER . . . . . . . . . 9-610 HEATER CIRCUIT LOW, DIAGNOSIS AND HOAT COOLANT - DESCRIPTION . . . . . . . . . . 0-4
HEAD - REMOVAL, CYLINDER . . . . . . . . . . . 9-611 TESTING - (P0141) O2 SENSOR 1/2 . . . . . . 9-141 HOISTING - STANDARD PROCEDURE . . . . . . 0-10
HEAD COVER - DESCRIPTION, CYLINDER . 9-617 HEATER CIRCUIT LOW, DIAGNOSIS AND HOLDING CLUTCH B1 - ASSEMBLY . . . . . 21-305
HEAD COVER - INSTALLATION, TESTING - (P0155) O2 SENSOR 2/1 . . . . . . 9-163 HOLDING CLUTCH B1 - DISASSEMBLY . . 21-304
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 9-618 HEATER CIRCUIT LOW, DIAGNOSIS AND HOLDING CLUTCH B2 - ASSEMBLY . . . . . 21-308
HEAD COVER - REMOVAL, CYLINDER . . . . 9-617 TESTING - (P0161) O2 SENSOR 2/2 . . . . . . 9-173 HOLDING CLUTCH B2 - DISASSEMBLY . . 21-307
HEAD GASKET - DIAGNOSIS AND HEATER CIRCUIT OPEN, DIAGNOSIS AND HOLDING CLUTCHES - DESCRIPTION . . . . 21-302
TESTING, CYLINDER . . . . . . . . . . . . . . . . . . 9-610 TESTING - (P0135) O2 SENSOR 1/1 . . . . . . 9-117 HOLDING CLUTCHES - OPERATION . . . . . 21-303
HEADLAMP - DESCRIPTION . . . . . . . . . . . 8L-103 HEATER CIRCUIT OPEN, DIAGNOSIS AND HOLE REPAIR, DESCRIPTION -
HEADLAMP - OPERATION . . . . . . . . . . . . . 8L-103 TESTING - (P0141) O2 SENSOR 1/2 . . . . . . 9-143 THREADED . . . . . . . . . . . . . . . . . . . . . . . . Intro.-6
HEADLAMP INOPERATIVE, DIAGNOSIS HEATER CIRCUIT OPEN, DIAGNOSIS AND HOOD - ADJUSTMENT . . . . . . . . . . . . . . . 23-134
AND TESTING - LEFT HIGH BEAM . . . . . . . 8L-23 TESTING - (P0155) O2 SENSOR 2/1 . . . . . . 9-167 HOOD - INSTALLATION . . . . . . . . . . . . . . . 23-133
HEADLAMP INOPERATIVE, DIAGNOSIS HEATER CIRCUIT OPEN, DIAGNOSIS AND HOOD - REMOVAL . . . . . . . . . . . . . . . . . . . 23-131
AND TESTING - LEFT LOW BEAM . . . . . . . . 8L-20 TESTING - (P0161) O2 SENSOR 2/2 . . . . . . 9-175 HOOD AJAR SWITCH - INSTALLATION . . . . 8Q-50
HEADLAMP INOPERATIVE, DIAGNOSIS HEATER CONTROL MODULE - HOOD AJAR SWITCH - REMOVAL . . . . . . . 8Q-50
AND TESTING - RIGHT HIGH BEAM . . . . . . 8L-29 DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-78 HOOD TO ITS FULLY UPRIGHT POSITION
HEADLAMP INOPERATIVE, DIAGNOSIS HEATER CONTROL MODULE - - STANDARD PROCEDURE, MOVING
AND TESTING - RIGHT LOW BEAM . . . . . . 8L-26 INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-81 THE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-130
HEADLAMP SWITCH - DESCRIPTION . . . . 8L-105 HEATER CONTROL MODULE - HOOKS - DESCRIPTION, EMERGENCY
HEADLAMP SWITCH - INSTALLATION . . . 8L-106 OPERATION, A/C . . . . . . . . . . . . . . . . . . . . . 24-78 TOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14
HEADLAMP SWITCH - OPERATION . . . . . . 8L-105
ZH INDEX 15

HORIZONTAL MOTOR INOPERATIVE, IGNITION LOCK CABLE - INSTALLATION . . 19-21 INJECTION - DESCRIPTION, AIR . . . . . . . . . 25-30
DIAGNOSIS AND TESTING - DRIVER IGNITION LOCK CABLE - REMOVAL . . . . . . 19-19 INJECTION - OPERATION, AIR . . . . . . . . . . 25-31
POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8N-83 IGNITION ON, DIAGNOSIS AND TESTING INJECTION - SPECIFICATIONS, AIR . . . . . . . 25-31
HORIZONTAL MOTOR INOPERATIVE, - WASHERS RUN CONTINUOUSLY INJECTION - SPECIFICATIONS, FUEL . . . . . 14-25
DIAGNOSIS AND TESTING - WITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-6 INJECTION RELAY CIRCUIT, DIAGNOSIS
PASSENGER POWER SEAT . . . . . . . . . . . . . 8N-91 IGNITION ON, DIAGNOSIS AND TESTING AND TESTING - (P0410) SECONDARY
HORIZONTAL MOTOR, INSTALLATION . . . 8N-102 - WIPERS RUN CONTINUOUSLY WITH . . . . 8R-17 AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-362
HORIZONTAL MOTOR, REMOVAL . . . . . . . 8N-101 IGNITION SWITCH - INSTALLATION . . . . . . 19-24 INJECTION SWITCHOVER SOLENOID
HORN - INSTALLATION . . . . . . . . . . . . . . . . 8H-12 IGNITION SWITCH - REMOVAL . . . . . . . . . . 19-23 CIRCUIT, DIAGNOSIS AND TESTING -
HORN - REMOVAL . . . . . . . . . . . . . . . . . . . 8H-11 IGNITION SYSTEM - ELECTRICAL (P0412) SECONDARY AIR . . . . . . . . . . . . . . 9-365
HORN - SERVICE INFORMATION - DIAGNOSTICS - SCHEMATICS AND INJECTION SYSTEM, DIAGNOSIS AND
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8H-9 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2 TESTING - (P0410) SECONDARY AIR . . . . . 9-356
HORN - SERVICE INFORMATION - IGNITION SYSTEM - SERVICE INJECTOR - DESCRIPTION, FUEL . . . . . . . . 14-31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-9 INFORMATION - DESCRIPTION . . . . . . . . . . . 8I-3 INJECTOR - INSTALLATION, FUEL . . . . . . . . 14-34
HORN - SPECIFICATIONS . . . . . . . . . . . . . . 8H-10 IGNITION SYSTEM - SERVICE INJECTOR - OPERATION, FUEL . . . . . . . . . . 14-32
HORN RELAY - DESCRIPTION . . . . . . . . . . 8H-14 INFORMATION - OPERATION . . . . . . . . . . . . . 8I-3 INJECTOR - REMOVAL, FUEL . . . . . . . . . . . 14-33
HORN SWITCH - DIAGNOSIS AND IGNITION-OFF DRAW TEST - STANDARD INJECTOR #1 CIRCUIT, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-12 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-14 TESTING - (P0201) FUEL . . . . . . . . . . . . . . 9-238
HORN SWITCH - INSTALLATION . . . . . . . . . 8H-13 IIIT DOES NOT POWER UP, DIAGNOSIS INJECTOR #2 CIRCUIT, DIAGNOSIS AND
HORN SWITCH - REMOVAL . . . . . . . . . . . . 8H-13 AND TESTING - DRB . . . . . . . . . . . . . . . . . . . 8E-2 TESTING - (P0202) FUEL . . . . . . . . . . . . . . 9-242
HORN SYSTEM - DIAGNOSIS AND IIIT STATE DISPLAY TEST MODE - INJECTOR #3 CIRCUIT, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-10 DESCRIPTION, DRB . . . . . . . . . . . . . . . . . . . 25-11 TESTING - (P0203) FUEL . . . . . . . . . . . . . . 9-244
HORNS ALWAYS ON, DIAGNOSIS AND ILLUMINATION - DESCRIPTION, HEATER INJECTOR #4 CIRCUIT, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-5 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-150 TESTING - (P0204) FUEL . . . . . . . . . . . . . . 9-246
HORNS INOPERATIVE, DIAGNOSIS AND ILLUMINATION - DESCRIPTION, T/C INJECTOR #5 CIRCUIT, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-2 RANGE INDICATOR . . . . . . . . . . . . . . . . . . 8L-150 TESTING - (P0205) FUEL . . . . . . . . . . . . . . 9-248
HOSE - DESCRIPTION, CRANKCASE ILLUMINATION, DIAGNOSIS AND INJECTOR #6 CIRCUIT, DIAGNOSIS AND
VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-16 TESTING - (P2561) HVAC CONTROL TESTING - (P0206) FUEL . . . . . . . . . . . . . . 9-250
HOSE - INSTALLATION, REAR BRAKE . . . . . . 5-16 MODULE REQUESTED MIL . . . . . . . . . . . . . 9-512 INJECTOR CIRCUIT, DIAGNOSIS AND
HOSE, INSTALLATION - FRONT BRAKE . . . . . 5-14 IMPACT AIRBAG - DESCRIPTION, SIDE . . 8O-112 TESTING - (P0200) FUEL . . . . . . . . . . . . . . 9-236
HOSE, REMOVAL - FRONT BRAKE . . . . . . . . . . 5-12 IMPACT AIRBAG - INSTALLATION, SIDE . . 8O-114 INNER - INSTALLATION, CV BOOT . . . . . . . . . 3-9
HOSE, REMOVAL - REAR BRAKE . . . . . . . . . 5-13 IMPACT AIRBAG - OPERATION, SIDE . . . . 8O-113 INNER - REMOVAL, CV BOOT . . . . . . . . . . . . . 3-7
HOSES / TUBES - INSTALLATION, IMPACT AIRBAG - REMOVAL, SIDE . . . . . 8O-114 INOPERATIVE, DIAGNOSIS AND TESTING
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-27 IMPACT SENSOR - DESCRIPTION, SIDE . . 8O-107 - ASH RECEIVER LAMP . . . . . . . . . . . . . . . 8L-130
HOSES / TUBES - REMOVAL, WASHER . . . 8R-26 IMPACT SENSOR - INSTALLATION, SIDE . 8O-110 INOPERATIVE, DIAGNOSIS AND TESTING
HOSES AND LINES, DIAGNOSIS AND IMPACT SENSOR - OPERATION, SIDE . . . 8O-107 - AUTOMATIC DAY/NIGHT MIRROR . . . . . . 8N-59
TESTING - BRAKE . . . . . . . . . . . . . . . . . . . . . 5-10 IMPACT SENSOR - REMOVAL, SIDE . . . . . 8O-108 INOPERATIVE, DIAGNOSIS AND TESTING
HOUSING - ASSEMBLY, GEARTRAIN . . . . . 21-365 IMPACT SENSOR SIGNAL CIRCUIT, - BATTERY VOLTAGE INDICATOR . . . . . . . . 8J-46
HOUSING - ASSEMBLY, REAR SECTION . . 21-362 DIAGNOSIS AND TESTING - LEFT SIDE . . . 8O-59 INOPERATIVE, DIAGNOSIS AND TESTING
HOUSING - DISASSEMBLY, GEARTRAIN . . 21-363 IMPACT SENSOR SIGNAL CIRCUIT, - BOTH HEATED SEATS . . . . . . . . . . . . . . . . 8G-32
HOUSING - DISASSEMBLY, REAR DIAGNOSIS AND TESTING - RIGHT INOPERATIVE, DIAGNOSIS AND TESTING
SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 21-362 SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-63 - BOTH POWER MIRRORS . . . . . . . . . . . . . 8N-57
HOUSING - INSTALLATION, AIR INCLINOMETER, STANDARD INOPERATIVE, DIAGNOSIS AND TESTING
CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-608 PROCEDURE - INSPECTING AND - BOTH POWER SEATS . . . . . . . . . . . . . . . . 8N-78
HOUSING - INSTALLATION, HVAC . . . . . . . 24-101 ADJUSTING VEHICLE LEVEL AT FRONT INOPERATIVE, DIAGNOSIS AND TESTING
HOUSING - INSTALLATION, REAR AND REAR AXLES WITH AN - BOTH POWER WINDOWS . . . . . . . . . . . 8N-116
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 3-42 ELECTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 INOPERATIVE, DIAGNOSIS AND TESTING
HOUSING - REMOVAL, AIR CLEANER . . . . . 9-608 INCORRECT, DIAGNOSIS AND TESTING - - BRAKE WARNING INDICATOR . . . . . . . . . 8J-44
HOUSING - REMOVAL, HVAC . . . . . . . . . . . 24-92 PCM NOT IDENTIFIED OR . . . . . . . . . . 5-161,5-94 INOPERATIVE, DIAGNOSIS AND TESTING
HOUSING - REMOVAL, REAR INDICATOR AFTER AN OIL CHANGE, - CARGO LAMP . . . . . . . . . . . . . . . . . . . . . 8L-124
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 3-41 STANDARD PROCEDURE - RESETTING INOPERATIVE, DIAGNOSIS AND TESTING
HOW TO USE WIRING DIAGRAMS - THE FSS MAINTENANCE . . . . . . . . . . . . . . . 8J-78 - CENTER HIGH MOUNTED STOP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-01-1 INDICATOR CIRCUIT, DIAGNOSIS AND LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-68
HUB / BEARING - DESCRIPTION . . . . . . . . . . 2-23 TESTING - AIRBAG WARNING . . . . . . . . . . 8O-46 INOPERATIVE, DIAGNOSIS AND TESTING
HUB / BEARING - INSTALLATION . . . . . . . . . 2-70 INDICATOR CIRCUIT, DIAGNOSIS AND - DRIVER POWER SEAT . . . . . . . . . . . . . . . 8N-74
HUB / BEARING - REMOVAL . . . . . . . . . . . . . 2-67 TESTING - LAMP OUTAGE . . . . . . . . . . . . . . . 8J-5 INOPERATIVE, DIAGNOSIS AND TESTING
HUB SEAL - INSTALLATION, TORQUE INDICATOR ILLUMINATION - - DRIVER POWER SEAT FRONT RISER
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-337 DESCRIPTION, T/C RANGE . . . . . . . . . . . . 8L-150 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-85
HUB SEAL - REMOVAL, TORQUE INDICATOR INOPERATIVE, DIAGNOSIS INOPERATIVE, DIAGNOSIS AND TESTING
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-337 AND TESTING - BATTERY VOLTAGE . . . . . . 8J-46 - DRIVER POWER SEAT HORIZONTAL
HVAC CONTROL MODULE REQUESTED INDICATOR INOPERATIVE, DIAGNOSIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-83
MIL ILLUMINATION, DIAGNOSIS AND AND TESTING - BRAKE WARNING . . . . . . . 8J-44 INOPERATIVE, DIAGNOSIS AND TESTING
TESTING - (P2561) . . . . . . . . . . . . . . . . . . . 9-512 INDICATOR INOPERATIVE, DIAGNOSIS - DRIVER POWER SEAT REAR RISER
HVAC HOUSING - INSTALLATION . . . . . . . 24-101 AND TESTING - HIGH BEAM . . . . . . . . . . . . 8J-42 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-87
HVAC HOUSING - REMOVAL . . . . . . . . . . . . 24-92 INDICATOR INOPERATIVE, DIAGNOSIS INOPERATIVE, DIAGNOSIS AND TESTING
HYDROSTATIC LOCKED ENGINE, AND TESTING - LEFT TURN SIGNAL . . . . . . 8J-38 - DRIVER POWER SEAT RECLINER
STANDARD PROCEDURE . . . . . . . . . . . . . . . 9-588 INDICATOR INOPERATIVE, DIAGNOSIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-81
IC CAN MESSAGE INCORRECT, AND TESTING - RIGHT TURN SIGNAL . . . . 8J-40 INOPERATIVE, DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-57 INDICATOR INOPERATIVE, DIAGNOSIS - GLOVE BOX LAMP . . . . . . . . . . . . . . . . . 8L-127
IC/HVAC CAN MESSAGE MISSING, AND TESTING - SEAT BELT . . . . . . . . . . . . . 8J-48 INOPERATIVE, DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - (P0600) . . . . . 21-60 INDICATOR INOPERATIVE, DIAGNOSIS - HIGH BEAM INDICATOR . . . . . . . . . . . . . . 8J-42
IDENTIFICATION - DESCRIPTION, AND TESTING - TELESCOPING WHEEL . . . . 8J-50 INOPERATIVE, DIAGNOSIS AND TESTING
FASTENER . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-3 INDICATOR MODULE - INSTALLATION, - HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-2
IDENTIFICATION AND INFORMATION - ON / OFF SWITCH . . . . . . . . . . . . . . . . . . . 8O-106 INOPERATIVE, DIAGNOSIS AND TESTING
DESCRIPTION, SECTION . . . . . . . . . . . . . 8W-01-5 INDICATOR MODULE - REMOVAL, ON / - LEFT BACK UP LAMP . . . . . . . . . . . . . . . . 8L-50
IDENTIFICATION NUMBER - OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8O-105 INOPERATIVE, DIAGNOSIS AND TESTING
DESCRIPTION, VEHICLE . . . . . . . . . . . . . . Intro.-2 INDICATOR, STANDARD PROCEDURE - - LEFT FOG LAMP . . . . . . . . . . . . . . . . . . . . . 8L-2
IDENTIFIED OR INCORRECT, DIAGNOSIS RESETTING THE FSS MAINTENANCE . . . . . 8J-76 INOPERATIVE, DIAGNOSIS AND TESTING
AND TESTING - PCM NOT . . . . . . . . . 5-161,5-94 INDICATOR TUBE - INSTALLATION, OIL - LEFT FRONT POWER WINDOW . . . . . . . 8N-110
IDLE SPEED PERFORMANCE, DIAGNOSIS LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-663 INOPERATIVE, DIAGNOSIS AND TESTING
AND TESTING - (P0221) . . . . . . . . . . . . . . . 9-266 INDICATOR TUBE - REMOVAL, OIL - LEFT FRONT SIDE MARKER LAMP . . . . . . 8L-32
IDLER ARM - INSTALLATION . . . . . . . . . . . 19-42 LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-663 INOPERATIVE, DIAGNOSIS AND TESTING
IDLER ARM - REMOVAL . . . . . . . . . . . . . . . 19-41 INDICATORS - DIAGNOSIS AND - LEFT FRONT TURN LAMP . . . . . . . . . . . . . 8L-11
IDLER PULLEY - INSTALLATION . . . . . . . . . . 7-48 TESTING, TREAD WEAR . . . . . . . . . . . . . . . 22-59 INOPERATIVE, DIAGNOSIS AND TESTING
IDLER PULLEY - REMOVAL . . . . . . . . . . . . . 7-47 INFLATION PRESSURES, DESCRIPTION - - LEFT HEATED MIRROR . . . . . . . . . . . . . . . 8G-16
IGNITION COIL - DESCRIPTION . . . . . . . . . . . 8I-5 TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-57 INOPERATIVE, DIAGNOSIS AND TESTING
IGNITION COIL - INSTALLATION . . . . . . . . . . 8I-5 INITIAL OPERATION, STANDARD - LEFT HEATED SEAT . . . . . . . . . . . . . . . . . 8G-26
IGNITION COIL - REMOVAL . . . . . . . . . . . . . . 8I-5 PROCEDURE - STEERING PUMP . . . . . . . . . 19-51
16 INDEX ZH

INOPERATIVE, DIAGNOSIS AND TESTING INPUT SHAFT SEAL - INSTALLATION . . . . 21-360 INTERLOCK SOLENOID - OPERATION,
- LEFT HIGH BEAM HEADLAMP . . . . . . . . . 8L-23 INPUT SHAFT SEAL - REMOVAL . . . . . . . . 21-359 SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-326
INOPERATIVE, DIAGNOSIS AND TESTING INPUT SPEED SENSOR CIRCUIT, INTERMITTENT NO CRANK, DIAGNOSIS
- LEFT LOW BEAM HEADLAMP . . . . . . . . . . 8L-20 DIAGNOSIS AND TESTING - (P0715) AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 9-567
INOPERATIVE, DIAGNOSIS AND TESTING N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-97 INTERMITTENT SPEED INOPERATIVE,
- LEFT PARK LAMP . . . . . . . . . . . . . . . . . . . . 8L-8 INPUT SPEED SENSOR CIRCUIT, DIAGNOSIS AND TESTING - WIPERS . . . . . 8R-15
INOPERATIVE, DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - (P0715) INTERNAL CONTROLLER, DIAGNOSIS
- LEFT POWER MIRROR . . . . . . . . . . . . . . . 8N-53 N3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-103 AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-171
INOPERATIVE, DIAGNOSIS AND TESTING INSPECTING AND ADJUSTING VEHICLE INTERNAL CONTROLLER, DIAGNOSIS
- LEFT REAR SIDE MARKER LAMP . . . . . . . 8L-38 LEVEL AT FRONT AND REAR AXLES, AND TESTING - (P0702) . . . . . . . . . . . . . . . 21-76
INOPERATIVE, DIAGNOSIS AND TESTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 2-8 INTERNAL FAILURE, DIAGNOSIS AND
- LEFT REAR TURN LAMP . . . . . . . . . . . . . . 8L-53 INSPECTING AND ADJUSTING VEHICLE TESTING - BODY CONTROL MODULE . . . . . . 23-2
INOPERATIVE, DIAGNOSIS AND TESTING LEVEL AT FRONT AND REAR AXLES INTERNAL FAILURE, DIAGNOSIS AND
- LEFT STOP LAMP . . . . . . . . . . . . . . . . . . . 8L-47 WITH AN ELECTRONIC TESTING - BODY CONTROL MODULE . . . . 8N-11
INOPERATIVE, DIAGNOSIS AND TESTING INCLINOMETER, STANDARD INTERNAL FAILURE, DIAGNOSIS AND
- LEFT TAIL LAMP . . . . . . . . . . . . . . . . . . . . 8L-44 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 TESTING - CAB . . . . . . . . . . . . . . . . . . 5-153,5-80
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER - INSTALLATION . . 8J-84 INTERNAL FAILURE, DIAGNOSIS AND
- LEFT TURN SIGNAL INDICATOR . . . . . . . . 8J-38 INSTRUMENT CLUSTER - REMOVAL . . . . . 8J-83 TESTING - CENTRAL LOCKING
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER - SERVICE PUMP/SECURITY SYSTEM MODULE . . . . . 8N-26
- LICENSE LAMP NO.1 . . . . . . . . . . . . . . . . 8L-71 INFORMATION - DESCRIPTION . . . . . . . . . . 8J-56 INTERNAL FAILURE, DIAGNOSIS AND
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER - SERVICE TESTING - CENTRAL LOCKING
- LICENSE LAMP NO.2 . . . . . . . . . . . . . . . . 8L-74 INFORMATION - OPERATION . . . . . . . . . . . . 8J-59 PUMP/SECURITY SYSTEM MODULE . . . . . 8Q-30
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER BULBS - INTERNAL FAILURE, DIAGNOSIS AND
- PASSENGER POWER SEAT . . . . . . . . . . . . 8N-76 STANDARD PROCEDURE . . . . . . . . . . . . . . . 8J-81 TESTING - ORC . . . . . . . . . . . . . . . . . . . . . . . 8O-2
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER COVER - INTERNAL FAILURE, DIAGNOSIS AND
- PASSENGER POWER SEAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-160 TESTING - SENTRY KEY REMOTE
HORIZONTAL MOTOR . . . . . . . . . . . . . . . . . 8N-91 INSTRUMENT CLUSTER COVER - ENTRY MODULE . . . . . . . . . . . . . . . . . . . . . 8Q-34
INOPERATIVE, DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-154 INTERNATIONAL SYMBOLS -
- PASSENGER POWER SEAT RECLINER INSTRUMENT CLUSTER, DIAGNOSIS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-2
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-89 AND TESTING - NO COMMUNICATION INTERNATIONAL SYMBOLS -
INOPERATIVE, DIAGNOSIS AND TESTING FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-49 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
- RADIATOR COOLING FAN . . . . . . . . . . . . . . . 7-2 INSTRUMENT CLUSTER, DIAGNOSIS INTRODUCTION - ENGINE DIAGNOSIS . . . . 9-583
INOPERATIVE, DIAGNOSIS AND TESTING AND TESTING - NO COMMUNICATION INVALID CONTROL MODULE VERSION,
- RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-14 DIAGNOSIS AND TESTING - (P0702) . . . . . 21-78
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER, DIAGNOSIS INVALID TRANSMITTER, DIAGNOSIS
- REAR WINDOW DEFOGGER . . . . . . . . . . . . 8G-5 AND TESTING - NO COMMUNICATION AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8Q-36
INOPERATIVE, DIAGNOSIS AND TESTING TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-51 INVERTED FLARING, STANDARD
- RIGHT BACK UP LAMP . . . . . . . . . . . . . . . 8L-62 INSTRUMENT CLUSTER, DIAGNOSIS PROCEDURE - DOUBLE . . . . . . . . . . . . . . . . . 5-11
INOPERATIVE, DIAGNOSIS AND TESTING AND TESTING - NO COMMUNICATION IS NOT CODED, DIAGNOSIS AND
- RIGHT FOG LAMP . . . . . . . . . . . . . . . . . . . . 8L-5 TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-16 TESTING - (P0702) CONTROL MODULE
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT CLUSTER, DIAGNOSIS TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
- RIGHT FRONT POWER WINDOW . . . . . . 8N-113 AND TESTING - NO RESPONSE FROM . . . . 8E-13 ISO FLARING - STANDARD PROCEDURE . . . 5-11
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (LEFT) - ISOLATOR - INSTALLATION, SUPPORT
- RIGHT FRONT SIDE MARKER LAMP . . . . 8L-35 INSTALLATION, LOWER . . . . . . . . . . . . . . . 23-158 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (LEFT) - REMOVAL, ISOLATOR - REMOVAL, SUPPORT
- RIGHT FRONT TURN LAMP . . . . . . . . . . . 8L-17 LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-152 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (RIGHT) - JOINT - INSPECTION, CV . . . . . . . . . . . . . . . 3-16
- RIGHT HEATED MIRROR . . . . . . . . . . . . . 8G-18 INSTALLATION, LOWER . . . . . . . . . . . . . . . 23-160 JOINT - INSTALLATION, CV . . . . . . . . . . . . . . 3-19
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (RIGHT) - JOINT - INSTALLATION, LOWER BALL . . . . . 2-32
- RIGHT HEATED SEAT . . . . . . . . . . . . . . . . 8G-29 REMOVAL, LOWER . . . . . . . . . . . . . . . . . . 23-154 JOINT - REMOVAL, CV . . . . . . . . . . . . . . . . . 3-14
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (TOP SECTION) - JOINT - REMOVAL, LOWER BALL . . . . . . . . . 2-29
- RIGHT HIGH BEAM HEADLAMP . . . . . . . . 8L-29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-155 JOINTS - ASSEMBLY, SINGLE CARDAN
INOPERATIVE, DIAGNOSIS AND TESTING INSTRUMENT PANEL (TOP SECTION), UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
- RIGHT LOW BEAM HEADLAMP . . . . . . . . 8L-26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-149 JOINTS - DISASSEMBLY, SINGLE
INOPERATIVE, DIAGNOSIS AND TESTING INSULATION - INSTALLATION . . . . . . . . . . 23-136 CARDAN UNIVERSAL . . . . . . . . . . . . . . . . . . 3-32
- RIGHT PARK LAMP . . . . . . . . . . . . . . . . . . 8L-14 INSULATION - REMOVAL . . . . . . . . . . . . . 23-135 JUMP STARTING, STANDARD
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE AIR TEMPERATURE SENSOR - PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
- RIGHT POWER MIRROR . . . . . . . . . . . . . 8N-55 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-36 KEY ANTENNA CIRCUIT, DIAGNOSIS AND
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE AIR TEMPERATURE SENSOR - TESTING - SENTRY . . . . . . . . . . . . . . . . . . . 8Q-38
- RIGHT REAR SIDE MARKER LAMP . . . . . 8L-41 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-36 KEY ANTENNA RING - INSTALLATION,
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE AIR TEMPERATURE SENSOR SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-55
- RIGHT REAR TURN LAMP . . . . . . . . . . . . 8L-65 CIRCUIT HIGH, DIAGNOSIS AND KEY ANTENNA RING - REMOVAL,
INOPERATIVE, DIAGNOSIS AND TESTING TESTING - (P0113) . . . . . . . . . . . . . . . . . . . . 9-36 SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-54
- RIGHT STOP LAMP . . . . . . . . . . . . . . . . . . 8L-59 INTAKE AIR TEMPERATURE SENSOR KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING CIRCUIT LOW, DIAGNOSIS AND DESCRIPTION, SENTRY . . . . . . . . . . . . . . . . 8E-69
- RIGHT TAIL LAMP . . . . . . . . . . . . . . . . . . 8L-56 TESTING - (P0112) . . . . . . . . . . . . . . . . . . . . 9-31 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE MANIFOLD - DESCRIPTION . . . . . . 9-678 DESCRIPTION, SENTRY . . . . . . . . . . . . . . . 8N-46
- RIGHT TURN SIGNAL INDICATOR . . . . . . 8J-40 INTAKE MANIFOLD - INSTALLATION . . . . . . 9-680 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE MANIFOLD - OPERATION . . . . . . . . 9-678 DESCRIPTION, SENTRY . . . . . . . . . . . . . . . 8Q-52
- SEAT BELT INDICATOR . . . . . . . . . . . . . . . 8J-48 INTAKE MANIFOLD - REMOVAL . . . . . . . . . 9-678 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKS - DIAGNOSIS DIAGNOSIS AND TESTING, SENTRY . . . . . . 8N-47
- TELESCOPING WHEEL INDICATOR . . . . . . 8J-50 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 9-678 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE/EXHAUST VALVES AND SEALS - INSTALLATION, SENTRY . . . . . . . . . . . . . . . 8Q-55
- WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . 8R-4 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-632 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE/EXHAUST VALVES AND SEALS - OPERATION, SENTRY . . . . . . . . . . . . . . . . . 8E-69
- WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-630 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE/EXHAUST VALVES AND SEALS - OPERATION, SENTRY . . . . . . . . . . . . . . . . . 8Q-52
- WIPERS HIGH SPEED . . . . . . . . . . . . . . . 8R-11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-632 KEY REMOTE ENTRY MODULE -
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE/EXHAUST VALVES AND SEALS - REMOVAL, SENTRY . . . . . . . . . . . . . . . . . . 8Q-53
- WIPERS INTERMITTENT SPEED . . . . . . . . 8R-15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 9-630 KEY REMOTE ENTRY MODULE,
INOPERATIVE, DIAGNOSIS AND TESTING INTAKE/EXHAUST VALVES AND SEALS - DIAGNOSIS AND TESTING - NO
- WIPERS LOW SPEED . . . . . . . . . . . . . . . . 8R-13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-630 RESPONSE FROM SENTRY . . . . . . . . . . . . . 8E-40
INPUT CIRCUIT, DIAGNOSIS AND INTERIOR LAMPS - SPECIFICATIONS . . . . 8L-137 KEY REMOTE ENTRY MODULE
TESTING - SPEED CONTROL SWITCH . . . . 9-553 INTERLOCK SOLENOID - ADJUSTMENTS, INTERNAL FAILURE, DIAGNOSIS AND
INPUT SENSOR MISMATCH, DIAGNOSIS SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-338 TESTING - SENTRY . . . . . . . . . . . . . . . . . . . 8Q-34
AND TESTING - (P0715) . . . . . . . . . . . . . . . 21-90 INTERLOCK SOLENOID - DESCRIPTION, KEY VERIFICATION TEST, DIAGNOSIS
INPUT SENSOR OVERSPEED, DIAGNOSIS SHIFT . . . . . . . . . . . . . . . . . . . . . . . 21-324,21-338 AND TESTING - SENTRY . . . . . . . . . . . . . . . 8Q-43
AND TESTING - (P0715) . . . . . . . . . . . . . . . 21-94
ZH INDEX 17

KEYLESS ENTRY RELAY CONTROL LAMP INOPERATIVE, DIAGNOSIS AND LATCH RELEASE CABLE - REMOVAL . . . . 23-138
CIRCUIT, DIAGNOSIS AND TESTING - TESTING - LEFT STOP . . . . . . . . . . . . . . . . . 8L-47 LATCH STRIKER - INSTALLATION . . 23-140,23-43
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 LAMP INOPERATIVE, DIAGNOSIS AND LATCH STRIKER - REMOVAL . . . . . 23-140,23-43
KEYLESS ENTRY TRANSMITTER - TESTING - LEFT TAIL . . . . . . . . . . . . . . . . . 8L-44 LATERAL ACCELERATION SENSOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-37 LAMP INOPERATIVE, DIAGNOSIS AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-199
KEY/LOCK CYLINDER - INSTALLATION . . . . 19-30 TESTING - RIGHT BACK UP . . . . . . . . . . . . 8L-62 LATERAL ACCELERATION SENSOR -
KEY/LOCK CYLINDER - REMOVAL . . . . . . . 19-28 LAMP INOPERATIVE, DIAGNOSIS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5-200
KNOCK SENSOR - DESCRIPTION . . . . . . . . . . 8I-6 TESTING - RIGHT FOG . . . . . . . . . . . . . . . . . 8L-5 LATERAL ACCELERATION SENSOR -
KNOCK SENSOR - INSTALLATION . . . . . . . . . 8I-6 LAMP INOPERATIVE, DIAGNOSIS AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-199
KNOCK SENSOR - OPERATION . . . . . . . . . . . 8I-6 TESTING - RIGHT FRONT SIDE LATERAL ACCELERATION SENSOR -
KNOCK SENSOR - REMOVAL . . . . . . . . . . . . . 8I-6 MARKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
KNOCK SENSOR #1 CIRCUIT HIGH, LAMP INOPERATIVE, DIAGNOSIS AND LATERAL ACCELERATION SENSOR
DIAGNOSIS AND TESTING - (P0325) . . . . . 9-328 TESTING - RIGHT FRONT TURN . . . . . . . . . 8L-17 CIRCUIT, DIAGNOSIS AND TESTING -
KNOCK SENSOR #1 CIRCUIT LOW, LAMP INOPERATIVE, DIAGNOSIS AND ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
DIAGNOSIS AND TESTING - (P0325) . . . . . 9-324 TESTING - RIGHT PARK . . . . . . . . . . . . . . . 8L-14 LATERAL LINK - INSTALLATION . . . . . . . . . . 2-52
KNOCK SENSOR #2 CIRCUIT HIGH, LAMP INOPERATIVE, DIAGNOSIS AND LATERAL LINK - REMOVAL . . . . . . . . . . . . . . 2-51
DIAGNOSIS AND TESTING - (P0330) . . . . . 9-330 TESTING - RIGHT REAR SIDE MARKER . . . 8L-41 LEAD - DIAGNOSIS AND TESTING,
KNOCK SENSOR #2 CIRCUIT LOW, LAMP INOPERATIVE, DIAGNOSIS AND TIRE/VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 22-60
DIAGNOSIS AND TESTING - (P0330) . . . . . 9-332 TESTING - RIGHT REAR TURN . . . . . . . . . . 8L-65 LEAK, DIAGNOSIS AND TESTING -
KNOCK SENSOR SYSTEM FAILURE, LAMP INOPERATIVE, DIAGNOSIS AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 7-13
DIAGNOSIS AND TESTING - (P1386) . . . . . 9-491 TESTING - RIGHT STOP . . . . . . . . . . . . . . . 8L-59 LEAK, DIAGNOSIS AND TESTING -
KNUCKLE - DESCRIPTION . . . . . . . . . . . . . . . 2-15 LAMP INOPERATIVE, DIAGNOSIS AND (P0442) EVAP SYSTEM SMALL . . . . . . . . . 9-378
KNUCKLE - INSTALLATION . . . . . . . . . . 2-20,2-63 TESTING - RIGHT TAIL . . . . . . . . . . . . . . . . 8L-56 LEAK, DIAGNOSIS AND TESTING -
KNUCKLE - REMOVAL . . . . . . . . . . . . . . 2-16,2-58 LAMP, INSTALLATION - REAR MARKER . . 8L-111 (P0455) EVAP SYSTEM LARGE . . . . . . . . . . 9-399
LABEL - DESCRIPTION, VECI . . . . . . . . . . Intro.-9 LAMP NO.1 INOPERATIVE, DIAGNOSIS LEAK DOWN TEST - DIAGNOSIS AND
LABEL - DESCRIPTION, VEHICLE AND TESTING - LICENSE . . . . . . . . . . . . . . 8L-71 TESTING, FUEL PRESSURE . . . . . . . . . . . . . . 14-4
EMISSION CONTROL INFORMATION . . . . . . 25-12 LAMP NO.2 INOPERATIVE, DIAGNOSIS LEAK INSPECTION, DIAGNOSIS AND
LABEL - DESCRIPTION, VEHICLE SAFETY AND TESTING - LICENSE . . . . . . . . . . . . . . 8L-74 TESTING - ENGINE OIL . . . . . . . . . . . . . . . . 9-660
CERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 LAMP OUTAGE INDICATOR CIRCUIT, LEAKAGE TEST - DIAGNOSIS AND
LAMP - DESCRIPTION, CENTER HIGH DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8J-5 TESTING, CYLINDER COMBUSTION
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . . . 8L-92 LAMP RELAY - DESCRIPTION, BRAKE . . . . 8L-90 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-588
LAMP - DESCRIPTION, FRONT POSITION . . 8L-97 LAMP RELAY - INSTALLATION, BRAKE . . . . 8L-90 LEAKING, DIAGNOSIS AND TESTING -
LAMP - INSTALLATION, ASH RECEIVER . . 8L-153 LAMP RELAY - OPERATION, BRAKE . . . . . . . 8L-90 (P0457) EVAP PURGE VALVE . . . . . . . . . . . . . 9-406
LAMP - INSTALLATION, BACKUP . . . . . . . . 8L-88 LAMP RELAY - REMOVAL, BRAKE . . . . . . . 8L-90 LEAKS - DIAGNOSIS AND TESTING,
LAMP - INSTALLATION, CARGO . . . . . . . . 8L-138 LAMP, REMOVAL - REAR MARKER . . . . . . 8L-110 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . 9-678
LAMP - INSTALLATION, CENTER HIGH LAMP SWITCH - DESCRIPTION, BACKUP . . 8L-89 LEAKS - DIAGNOSIS AND TESTING,
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-93 LAMP SWITCH - DESCRIPTION, BRAKE . . . 8L-91 REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-116
LAMP - INSTALLATION, COURTESY . . . . . 8L-141 LAMP SWITCH - INSTALLATION, LEAKS, DIAGNOSIS AND TESTING -
LAMP - INSTALLATION, FOG . . . . . . . . . . . . 8L-94 BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-354 WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-29
LAMP - INSTALLATION, FRONT MARKER . 8L-111 LAMP SWITCH - INSTALLATION, BRAKE . . 8L-92 LEAKS, STANDARD PROCEDURE -
LAMP - INSTALLATION, FRONT LAMP SWITCH - OPERATION, BRAKE . . . . . 8L-91 REPAIRING . . . . . . . . . . . . . . . . . . . . . . . . . 22-60
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-98 LAMP SWITCH - REMOVAL, BACKUP . . . . 21-353 LEAN CONTROL BELOW LIMIT (AT
LAMP - INSTALLATION, FRONT TURN LAMP SWITCH - REMOVAL, BRAKE . . . . . . 8L-91 IDLE), DIAGNOSIS AND TESTING -
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-99 LAMP SWITCH CAN SIGNAL LOST TO (P0172) FUEL SYSTEM 1/1 . . . . . . . . . . . . . 9-207
LAMP - INSTALLATION, GLOVE BOX . . . . 8L-147 TRANS PERFORMANCE, DIAGNOSIS LEAN CONTROL BELOW LIMIT (AT
LAMP - INSTALLATION, LICENSE PLATE . 8L-109 AND TESTING - (P0571) STOP . . . . . . . . . . 9-421 IDLE), DIAGNOSIS AND TESTING -
LAMP - OPERATION, FRONT POSITION . . . 8L-97 LAMP SWITCH CIRCUIT, DIAGNOSIS (P0175) FUEL SYSTEM 2/1 . . . . . . . . . . . . . 9-233
LAMP - REMOVAL, ASH RECEIVER . . . . . . 8L-151 AND TESTING - BRAKE . . . . . . . . . . . 5-143,5-176 LEAN CONTROL BELOW LIMIT (AT
LAMP - REMOVAL, BACKUP . . . . . . . . . . . . 8L-88 LAMP SWITCH SIGNAL PERFORMANCE, LOAD), DIAGNOSIS AND TESTING -
LAMP - REMOVAL, CARGO . . . . . . . . . . . . 8L-137 DIAGNOSIS AND TESTING - (P0571) (P0172) FUEL SYSTEM 1/1 . . . . . . . . . . . . . 9-199
LAMP - REMOVAL, CENTER HIGH STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-423 LEAN CONTROL BELOW LIMIT (AT
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-92 LAMP SWITCH/UNIT - DESCRIPTION, LOAD), DIAGNOSIS AND TESTING -
LAMP - REMOVAL, COURTESY . . . . . . . . . 8L-140 COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142 (P0174) FUEL SYSTEM 2/1 . . . . . . . . . . . . . 9-224
LAMP - REMOVAL, FOG . . . . . . . . . . . . . . . 8L-93 LAMP SWITCH/UNIT - INSTALLATION, LEARN - STANDARD PROCEDURE, TCM
LAMP - REMOVAL, FRONT MARKER . . . . 8L-110 COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-143 QUICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-59
LAMP - REMOVAL, FRONT POSITION . . . . . 8L-97 LAMP SWITCH/UNIT - OPERATION, LEFT BACK UP LAMP INOPERATIVE,
LAMP - REMOVAL, FRONT TURN COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-50
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-98 LAMP SWITCH/UNIT - REMOVAL, LEFT DOOR SPEAKERS, DIAGNOSIS AND
LAMP - REMOVAL, GLOVE BOX . . . . . . . . 8L-146 COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142 TESTING - NO SOUND FROM . . . . . . . . . . . . 8A-8
LAMP - REMOVAL, LICENSE PLATE . . . . . 8L-109 LAMP UNIT - INSTALLATION, CARGO . . . . 8L-140 LEFT FOG LAMP INOPERATIVE,
LAMP CIRCUIT, DIAGNOSIS AND LAMP UNIT - INSTALLATION, FOG . . . . . . . 8L-96 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8L-2
TESTING - DOME . . . . . . . . . . . . . . . . . . . 8L-121 LAMP UNIT - REMOVAL, CARGO . . . . . . . 8L-139 LEFT FRONT POWER WINDOW
LAMP DEFEAT SWITCH - DESCRIPTION, LAMP UNIT - REMOVAL, FOG . . . . . . . . . . . 8L-95 INOPERATIVE, DIAGNOSIS AND
COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-141 LAMP UNIT, INSTALLATION - TAIL . . . . . . 8L-115 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-110
LAMP INOPERATIVE, DIAGNOSIS AND LAMP UNIT, REMOVAL - TAIL . . . . . . . . . . 8L-113 LEFT FRONT SIDE MARKER LAMP
TESTING - ASH RECEIVER . . . . . . . . . . . . 8L-130 LAMPS - SPECIFICATIONS, EXTERIOR . . . . 8L-87 INOPERATIVE, DIAGNOSIS AND
LAMP INOPERATIVE, DIAGNOSIS AND LAMPS - SPECIFICATIONS, INTERIOR . . . 8L-137 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-32
TESTING - CARGO . . . . . . . . . . . . . . . . . . . 8L-124 LAMPS/LIGHTING - EXTERIOR - LEFT FRONT TURN LAMP INOPERATIVE,
LAMP INOPERATIVE, DIAGNOSIS AND SERVICE INFORMATION - DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-11
TESTING - CENTER HIGH MOUNTED DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-85 LEFT FRONT WHEEL SPEED SENSOR
STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-68 LAMPS/LIGHTING - EXTERIOR - CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . 5-95
LAMP INOPERATIVE, DIAGNOSIS AND SERVICE INFORMATION - OPERATION . . . . 8L-85 LEFT HEATED MIRROR INOPERATIVE,
TESTING - GLOVE BOX . . . . . . . . . . . . . . . 8L-127 LAMPS/LIGHTING, EXTERIOR . . . . . . . . . . . 8L-86 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8G-16
LAMP INOPERATIVE, DIAGNOSIS AND LAMPS/LIGHTING-INTERIOR - LEFT HEATED SEAT INOPERATIVE,
TESTING - LEFT BACK UP . . . . . . . . . . . . . . 8L-50 DIAGNOSIS AND TESTING . . . . . . . . . . . . 8L-136 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8G-26
LAMP INOPERATIVE, DIAGNOSIS AND LAMP/SWITCH - DESCRIPTION, GLOVE LEFT HIGH BEAM HEADLAMP
TESTING - LEFT FOG . . . . . . . . . . . . . . . . . . . 8L-2 BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-148 INOPERATIVE, DIAGNOSIS AND
LAMP INOPERATIVE, DIAGNOSIS AND LAMP/SWITCH - INSTALLATION, GLOVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-23
TESTING - LEFT FRONT SIDE MARKER . . . 8L-32 BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-149 LEFT LOW BEAM HEADLAMP
LAMP INOPERATIVE, DIAGNOSIS AND LAMP/SWITCH - OPERATION, GLOVE INOPERATIVE, DIAGNOSIS AND
TESTING - LEFT FRONT TURN . . . . . . . . . . 8L-11 BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-148 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
LAMP INOPERATIVE, DIAGNOSIS AND LAMP/SWITCH - REMOVAL, GLOVE BOX . 8L-148 LEFT PARK LAMP INOPERATIVE,
TESTING - LEFT PARK . . . . . . . . . . . . . . . . . . 8L-8 LATCH - INSTALLATION . . . 23-104,23-137,23-43 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8L-8
LAMP INOPERATIVE, DIAGNOSIS AND LATCH - REMOVAL . . . . . . . 23-103,23-136,23-43 LEFT POWER MIRROR INOPERATIVE,
TESTING - LEFT REAR SIDE MARKER . . . . 8L-38 LATCH ASSEMBLY - INSTALLATION, DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-53
LAMP INOPERATIVE, DIAGNOSIS AND DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-42 LEFT REAR SIDE MARKER LAMP
TESTING - LEFT REAR TURN . . . . . . . . . . . 8L-53 LATCH ASSEMBLY - REMOVAL, DOOR . . . . 8N-40 INOPERATIVE, DIAGNOSIS AND
LATCH RELEASE CABLE - INSTALLATION . 23-139 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
18 INDEX ZH

LEFT REAR SPEAKER, DIAGNOSIS AND LEVER ASSEMBLY COVER - REMOVAL, LOADS - STANDARD PROCEDURE,
TESTING - NO SOUND FROM . . . . . . . . . . . 8A-12 SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-182 TESTING FOR A SHORT TO GROUND
LEFT REAR TURN LAMP INOPERATIVE, LEVER ASSEMBLY, DIAGNOSIS AND ON FUSES POWERING SEVERAL . . . . . 8W-01-10
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-53 TESTING - NO RESPONSE FROM SHIFT . . . 8E-29 LOCATION - DESCRIPTION, CONNECTOR/
LEFT REAR WHEEL SPEED SENSOR LEVER HANDLE - INSTALLATION, GEAR GROUND/SPLICE . . . . . . . . . . . . . . . . . . . 8W-91-1
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 5-107 SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387 LOCATIONS - DESCRIPTION, FLUID
LEFT SIDE AIRBAG SQUIB CIRCUIT, LEVER HANDLE - REMOVAL, GEAR FILL/CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-29 SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387 LOCATIONS - SPECIFICATIONS, SEALER . . 23-57
LEFT SIDE IMPACT SENSOR SIGNAL LICENSE LAMP NO.1 INOPERATIVE, LOCATIONS - SPECIFICATIONS, WELD . . . . 23-74
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 8O-59 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-71 LOCK ACTUATOR - INSTALLATION, FUEL
LEFT STOP LAMP INOPERATIVE, LICENSE LAMP NO.2 INOPERATIVE, DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-45
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-47 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-74 LOCK ACTUATOR - INSTALLATION,
LEFT TAIL LAMP INOPERATIVE, LICENSE PLATE LAMP - INSTALLATION . . 8L-109 LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-46
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-44 LICENSE PLATE LAMP - REMOVAL . . . . . . 8L-109 LOCK ACTUATOR - REMOVAL, FUEL
LEFT TURN SIGNAL INDICATOR LIFTGATE - INSTALLATION . . . . . . . . . . . . . 23-46 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-44
INOPERATIVE, DIAGNOSIS AND LIFTGATE - REMOVAL . . . . . . . . . . . . . . . . . 23-44 LOCK ACTUATOR - REMOVAL, LIFTGATE . . 8N-46
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-38 LIFTGATE AJAR SWITCH - LOCK ACTUATOR SLOW RESPONSE,
LEVEL - STANDARD PROCEDURE, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8L-146 DIAGNOSIS AND TESTING - DRIVER
CHECKING BATTERY ELECTROLYTE . . . . . . 8F-16 LIFTGATE AJAR SWITCH - REMOVAL . . . . 8L-145 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-2
LEVEL - STANDARD PROCEDURE, LIFTGATE LOCK ACTUATOR - LOCK ACTUATOR SLOW RESPONSE,
CHECKING FLUID . . . . . . . . . . . . . . . . . . . 21-353 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-46 DIAGNOSIS AND TESTING - FUEL
LEVEL - STANDARD PROCEDURE, LIFTGATE LOCK ACTUATOR - REMOVAL . . 8N-46 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . 24-149 LIFTGATE LOCK SWITCH - LOCK ACTUATOR SLOW RESPONSE,
LEVEL AT FRONT AND REAR AXLES, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-45 DIAGNOSIS AND TESTING -
STANDARD PROCEDURE - INSPECTING LIFTGATE LOCK SWITCH - REMOVAL . . . . . 8N-45 PASSENGER DOOR/LIFTGATE . . . . . . . . . . . . 8N-8
AND ADJUSTING VEHICLE . . . . . . . . . . . . . . . 2-8 LIMIT (AT IDLE), DIAGNOSIS AND LOCK CABLE - INSTALLATION, IGNITION . . 19-21
LEVEL AT FRONT AND REAR AXLES TESTING - (P0171) FUEL SYSTEM 1/1 LOCK CABLE - REMOVAL, IGNITION . . . . . . 19-19
WITH AN ELECTRONIC RICH CONTROL OVER . . . . . . . . . . . . . . . . . 9-183 LOCK CYLINDER - INSTALLATION . . . . . . 23-106
INCLINOMETER, STANDARD LIMIT (AT IDLE), DIAGNOSIS AND LOCK CYLINDER - REMOVAL . . . . . . . . . . 23-105
PROCEDURE - INSPECTING AND TESTING - (P0172) FUEL SYSTEM 1/1 LOCK SWITCH - DESCRIPTION, POWER . . 8N-38
ADJUSTING VEHICLE . . . . . . . . . . . . . . . . . . . 2-8 LEAN CONTROL BELOW . . . . . . . . . . . . . . . 9-207 LOCK SWITCH - INSTALLATION, DRIVER
LEVEL CHECK, STANDARD PROCEDURE LIMIT (AT IDLE), DIAGNOSIS AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-57
- ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . 9-664 TESTING - (P0174) FUEL SYSTEM 2/1 LOCK SWITCH - INSTALLATION, DRIVER
LEVEL, DIAGNOSIS AND TESTING - RICH CONTROL OVER . . . . . . . . . . . . . . . . . 9-218 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43
EFFECTS OF INCORRECT FLUID . . . . . . . . 21-293 LIMIT (AT IDLE), DIAGNOSIS AND LOCK SWITCH - INSTALLATION,
LEVEL INDICATOR TUBE - TESTING - (P0175) FUEL SYSTEM 2/1 LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-45
INSTALLATION, OIL . . . . . . . . . . . . . . . . . . . 9-663 LEAN CONTROL BELOW . . . . . . . . . . . . . . . 9-233 LOCK SWITCH - INSTALLATION, POWER . . 8N-39
LEVEL INDICATOR TUBE - REMOVAL, LIMIT (AT LOAD), DIAGNOSIS AND LOCK SWITCH - REMOVAL, DOOR
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-663 TESTING - (P0171) FUEL SYSTEM 1/1 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-56
LEVEL PERFORMANCE, DIAGNOSIS AND RICH CONTROL OVER . . . . . . . . . . . . . . . . . 9-187 LOCK SWITCH - REMOVAL, DRIVER
TESTING - ENGINE OIL SENSOR . . . . . . . . . 9-521 LIMIT (AT LOAD), DIAGNOSIS AND DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43
LEVEL SENDING UNIT - DIAGNOSIS AND TESTING - (P0172) FUEL SYSTEM 1/1 LOCK SWITCH - REMOVAL, LIFTGATE . . . . 8N-45
TESTING, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-12 LEAN CONTROL BELOW . . . . . . . . . . . . . . . 9-199 LOCK SWITCH - REMOVAL, POWER . . . . . 8N-39
LEVEL SENDING UNIT/SENSOR, LIMIT (AT LOAD), DIAGNOSIS AND LOCK SWITCH SENSE CIRCUIT,
DESCRIPTION - FUEL . . . . . . . . . . . . . . . . . 14-11 TESTING - (P0173) FUEL SYSTEM 2/1 DIAGNOSIS AND TESTING - DOOR . . . . . . 8Q-16
LEVEL SENDING UNIT/SENSOR, RICH CONTROL OVER . . . . . . . . . . . . . . . . . 9-211 LOCK/DOOR UNLOCK SWITCH SENSE
OPERATION - FUEL . . . . . . . . . . . . . . . . . . . 14-11 LIMIT (AT LOAD), DIAGNOSIS AND CIRCUIT, DIAGNOSIS AND TESTING -
LEVEL SENSOR - INSTALLATION, BRAKE TESTING - (P0174) FUEL SYSTEM 2/1 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 LEAN CONTROL BELOW . . . . . . . . . . . . . . . 9-224 LOCKED ENGINE, STANDARD
LEVEL SENSOR - INSTALLATION, LIMIT (AT LOAD), DIAGNOSIS AND PROCEDURE - HYDROSTATIC . . . . . . . . . . . 9-588
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 TESTING - (P0174) FUEL SYSTEM 2/1 LOCKING PUMP - DESCRIPTION,
LEVEL SENSOR - REMOVAL, BRAKE RICH CONTROL OVER . . . . . . . . . . . . . . . . . 9-221 CENTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-36
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 LIMIT SWITCH FAILURE, DIAGNOSIS LOCKING PUMP - DIAGNOSIS AND
LEVEL SENSOR - REMOVAL, COOLANT . . . . 7-20 AND TESTING - REAR SPOILER . . . . . . . . . 23-19 TESTING, CENTRAL . . . . . . . . . . . . . . . . . . 8N-36
LEVEL SENSOR CIRCUIT, DIAGNOSIS LIMIT SWITCH SIGNAL (DOWN) LOCKING PUMP/SECURITY SYSTEM
AND TESTING - FUEL . . . . . . . . . . . . . . . . . . 8J-7 CIRCUIT, DIAGNOSIS AND TESTING - MODULE, DIAGNOSIS AND TESTING -
LEVEL SENSOR CIRCUIT, DIAGNOSIS SPOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10 NO COMMUNICATION WITH BCM AND
AND TESTING - (P0460) FUEL . . . . . . . . . . 9-408 LIMIT SWITCH SIGNAL (UP) CIRCUIT, CENTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8
LEVEL SENSOR/WASHER FLUID LEVEL DIAGNOSIS AND TESTING - SPOILER . . . . . 23-7 LOCKING PUMP/SECURITY SYSTEM
SWITCH CIRCUIT, DIAGNOSIS AND LIMITED POWER EXCESSIVE HIGH MODULE, DIAGNOSIS AND TESTING -
TESTING - COOLANT . . . . . . . . . . . . . . . . . . . 8J-2 COOLANT TEMP, DIAGNOSIS AND NO COMMUNICATION WITH BODY
LEVEL, STANDARD PROCEDURE - TESTING - (P0128) FORCED . . . . . . . . . . . . . 9-74 CONTROL MODULE AND CENTRAL . . . . . . 8N-20
CHECK OIL . . . . . . . . . . . . . . . . . . . . . . . . 21-294 LIMITS - DESCRIPTION, HIGH AND LOW . . 25-11 LOCKING PUMP/SECURITY SYSTEM
LEVEL, STANDARD PROCEDURE - LINE - INSTALLATION, LIQUID . . . . . . . . . 24-135 MODULE INTERNAL FAILURE,
MASTER CYLINDER FLUID . . . . . . . . . . . . . . 5-43 LINE - INSTALLATION, SUCTION . . . . . . . . 24-137 DIAGNOSIS AND TESTING - CENTRAL . . . . 8N-26
LEVEL SWITCH - INSTALLATION, LINE - REMOVAL, LIQUID . . . . . . . . . . . . . 24-134 LOCKING PUMP/SECURITY SYSTEM
WASHER FLUID . . . . . . . . . . . . . . . . . . . . . 8R-26 LINE - REMOVAL, SUCTION . . . . . . . . . . . 24-136 MODULE INTERNAL FAILURE,
LEVEL SWITCH - REMOVAL, WASHER LINES - DESCRIPTION, BRAKE . . . . . . . . . . . 5-10 DIAGNOSIS AND TESTING - CENTRAL . . . . 8Q-30
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26 LINES - DESCRIPTION, FUEL . . . . . . . . . . . 14-14 LOCKING PUMP/SECURITY SYSTEM
LEVEL SWITCH CIRCUIT, DIAGNOSIS LINES - INSTALLATION, TRANSMISSION MODULE SYSTEM OVERVOLTAGE,
AND TESTING - COOLANT LEVEL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 DIAGNOSIS AND TESTING - CENTRAL . . . . . 8Q-5
SENSOR/WASHER FLUID . . . . . . . . . . . . . . . . 8J-2 LINES - REMOVAL, TRANSMISSION LOCKING PUMP/SECURITY SYSTEM
LEVEL/TEMPERATURE SENSOR - COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 MODULE SYSTEM UNDERVOLTAGE,
INSTALLATION, OIL . . . . . . . . . . . . . . . . . . . 9-673 LINES, DIAGNOSIS AND TESTING - DIAGNOSIS AND TESTING - CENTRAL . . . . . 8Q-2
LEVEL/TEMPERATURE SENSOR - BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . 5-10 LOCKOUT CABLE - DESCRIPTION,
REMOVAL, OIL . . . . . . . . . . . . . . . . . . . . . . 9-672 LINES/HOSES/TUBES - DESCRIPTION, REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-388
LEVER - INSTALLATION . . . . . . . . . . . . . . . . 5-68 REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . 24-114 LOCKS - DIAGNOSIS AND TESTING,
LEVER - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-66 LINK - INSTALLATION, DRAG . . . . . . . . . . . 19-49 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-32
LEVER ADJUSTMENT - STANDARD LINK - INSTALLATION, LATERAL . . . . . . . . . . 2-52 LOCKS - SERVICE INFORMATION -
PROCEDURE, SHIFT . . . . . . . . . . . . . . . . . 21-389 LINK - INSTALLATION, TRAILING . . . . . . . . . 2-51 DESCRIPTION, POWER . . . . . . . . . . . . . . . . 8N-30
LEVER ASSEMBLY - DESCRIPTION, LINK - REMOVAL, DRAG . . . . . . . . . . . . . . . 19-47 LOCKS - SERVICE INFORMATION -
SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-339 LINK - REMOVAL, LATERAL . . . . . . . . . . . . . 2-51 OPERATION, POWER . . . . . . . . . . . . . . . . . 8N-31
LEVER ASSEMBLY - INSTALLATION, LINK - REMOVAL, TRAILING . . . . . . . . . . . . . 2-50 LOCKS - SPECIFICATIONS, POWER . . . . . . 8N-35
SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-340 LINK CONNECTOR - DESCRIPTION, DATA . 8E-53 LOW BATTERY, DIAGNOSIS AND
LEVER ASSEMBLY - OPERATION, SHIFT . . 21-339 LINK CONNECTOR - OPERATION, DATA . . . 8E-53 TESTING - TIRE PRESSURE
LEVER ASSEMBLY - REMOVAL, SHIFT . . . 21-340 LINKAGE - DESCRIPTION, WIPER . . . . . . . 8R-42 SENSOR/TRANSMITTER . . . . . . . . . . . . . . . 22-32
LEVER ASSEMBLY COVER - LIQUID LINE - INSTALLATION . . . . . . . . . . 24-135 LOW BEAM BULB, INSTALLATION . . . . . . 8L-104
INSTALLATION, SHIFT . . . . . . . . . . . . . . . . 23-192 LIQUID LINE - REMOVAL . . . . . . . . . . . . . 24-134 LOW BEAM BULB, REMOVAL . . . . . . . . . . 8L-103
ZH INDEX 19

LOW BEAM HEADLAMP INOPERATIVE, MACHINING, STANDARD PROCEDURE - MARKER LAMP INOPERATIVE,
DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8L-20 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . 5-38 DIAGNOSIS AND TESTING - RIGHT
LOW BEAM HEADLAMP INOPERATIVE, MAF SENSOR CIRCUIT LOW, DIAGNOSIS REAR SIDE . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8L-26 AND TESTING - (P0103) . . . . . . . . . . . . . . . . 9-17 MARKER LAMP, INSTALLATION - REAR . . 8L-111
LOW, DIAGNOSIS AND TESTING - MAF SENSOR PERFORMANCE, MARKER LAMP, REMOVAL - REAR . . . . . . 8L-110
COOLING FAN CONTROL CIRCUIT . . . . . . . 9-519 DIAGNOSIS AND TESTING - (P0101) . . . . . . . 9-8 MASS AIR FLOW CIRCUIT, DIAGNOSIS
LOW, DIAGNOSIS AND TESTING - MAF SENSOR THROTTLE ANGLE AND AND TESTING - (P0102) . . . . . . . . . . . . . . . . 9-10
(P0103) MAF SENSOR CIRCUIT . . . . . . . . . . 9-17 SPEED, DIAGNOSIS AND TESTING - MASTER CYLINDER - CLUTCH -
LOW, DIAGNOSIS AND TESTING - (P0104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6-17
(P0107) MAP SENSOR CIRCUIT . . . . . . . . . . 9-24 MAIN BEARINGS - DESCRIPTION, MASTER CYLINDER - CLUTCH -
LOW, DIAGNOSIS AND TESTING - CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-647 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
(P0112) INTAKE AIR TEMPERATURE MAIN BEARINGS - INSTALLATION, MASTER CYLINDER BLEEDING
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . 9-31 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-650 PROCEDURE, STANDARD PROCEDURE . . . . 5-46
LOW, DIAGNOSIS AND TESTING - MAIN BEARINGS - OPERATION, MASTER CYLINDER BLEEDING,
(P0117) ENGINE COOLANT CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-647 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 6-7
TEMPERATURE SENSOR CIRCUIT . . . . . . . . . 9-49 MAIN BEARINGS - REMOVAL, MASTER CYLINDER, DESCRIPTION . . . . . . . 5-44
LOW, DIAGNOSIS AND TESTING - CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-647 MASTER CYLINDER FLUID LEVEL,
(P0122) APPS SIGNAL #1 CIRCUIT . . . . . . . 9-65 MAINSHAFT W/INPUT SHAFT - STANDARD PROCEDURE . . . . . . . . . . . . . . . . 5-43
LOW, DIAGNOSIS AND TESTING - ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 21-374 MASTER CYLINDER FLUID LOSS -
(P0131) O2 SENSOR 1/1 CIRCUIT . . . . . . . . 9-86 MAINSHAFT W/INPUT SHAFT - DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-45
LOW, DIAGNOSIS AND TESTING - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-368 MASTER CYLINDER, OPERATION . . . . . . . . . 5-44
(P0135) O2 SENSOR 1/1 HEATER MAINSHAFT W/INPUT SHAFT - MASTER CYLINDER/POWER BOOSTER,
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-369 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-44
LOW, DIAGNOSIS AND TESTING - MAINTENANCE INDICATOR AFTER AN MATCH MOUNTING - STANDARD
(P0138) O2 SENSOR 2/2 CIRCUIT . . . . . . . 9-133 OIL CHANGE, STANDARD PROCEDURE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-43
LOW, DIAGNOSIS AND TESTING - - RESETTING THE FSS . . . . . . . . . . . . . . . . 8J-78 MEASUREMENTS - SPECIFICATIONS,
(P0140) O2 SENSOR 1/2 CIRCUIT . . . . . . . 9-137 MAINTENANCE INDICATOR, STANDARD BODY GAP . . . . . . . . . . . . . . . . . . . . . . . . . . 23-53
LOW, DIAGNOSIS AND TESTING - PROCEDURE - RESETTING THE FSS . . . . . . 8J-76 MEASURING BEARING CLEARANCE
(P0141) O2 SENSOR 1/2 HEATER MALFUNCTION, DIAGNOSIS AND USING PLASTIGAGET - STANDARD
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-141 TESTING - CAN BUS COMMUNICATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 9-591
LOW, DIAGNOSIS AND TESTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . 5-162,5-88 MECHANICAL - DIAGNOSIS AND
(P0151) O2 SENSOR 2/1 CIRCUIT . . . . . . . 9-149 MALFUNCTION, DIAGNOSIS AND TESTING, ENGINE DIAGNOSIS . . . . . . . . . . 9-584
LOW, DIAGNOSIS AND TESTING - TESTING - CAN BUS COMMUNICATION MECHANISM - DESCRIPTION, SHIFT . . . . . . 21-388
(P0155) O2 SENSOR 2/1 HEATER GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-36 MECHANISM - INSTALLATION, SHIFT . . . . 21-392
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-163 MANAGEMENT REQUEST MECHANISM - REMOVAL, SHIFT . . . . . . . 21-391
LOW, DIAGNOSIS AND TESTING - PERFORMANCE, DIAGNOSIS AND METRIC SYSTEM - DESCRIPTION . . . . . . Intro.-6
(P0161) O2 SENSOR 2/2 HEATER TESTING - (P0702) TCM TORQUE . . . . . . . 9-461 MICRO 420 BATTERY TESTER -
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173 MANAGEMENT REQUEST STANDARD PROCEDURE, USING . . . . . . . . 8F-12
LOW, DIAGNOSIS AND TESTING - PERFORMANCE, DIAGNOSIS AND MIL ILLUMINATION, DIAGNOSIS AND
(P0222) APPS SIGNAL #2 CIRCUIT . . . . . . 9-274 TESTING - (P2545) ESP TORQUE . . . . . . . . 9-506 TESTING - (P2561) HVAC CONTROL
LOW, DIAGNOSIS AND TESTING - MANAGEMENT SIGNAL, DIAGNOSIS AND MODULE REQUESTED . . . . . . . . . . . . . . . . . 9-512
(P0325) KNOCK SENSOR #1 CIRCUIT . . . . 9-324 TESTING - (P0702) LOSS OF TORQUE . . . . 9-459 MIL REQUEST, DIAGNOSIS AND
LOW, DIAGNOSIS AND TESTING - MANAGER - DESCRIPTION, TASK . . . . . . . . 25-37 TESTING - (P0500) VEHICLE SPEED
(P0330) KNOCK SENSOR #2 CIRCUIT . . . . 9-332 MANAGER - OPERATION, TASK . . . . . . . . . 25-37 PERFORMANCE ESP . . . . . . . . . . . . . . . . . . 9-412
LOW, DIAGNOSIS AND TESTING - MANIFOLD - DESCRIPTION, EXHAUST . . . . 9-680 MIRROR - DESCRIPTION, AUTOMATIC
(P0452) FUEL TANK PRESSURE MANIFOLD - DESCRIPTION, INTAKE . . . . . . 9-678 DAY / NIGHT . . . . . . . . . . . . . . . . . . . . . . . . 8N-68
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . 9-395 MANIFOLD - INSTALLATION, INTAKE . . . . . 9-680 MIRROR - INSTALLATION, SIDEVIEW . . . . 8N-72
LOW, DIAGNOSIS AND TESTING - MANIFOLD - OPERATION, INTAKE . . . . . . . . 9-678 MIRROR - OPERATION, AUTOMATIC DAY
(P0562) BATTERY SYSTEM . . . . . . . . . . . . . 9-417 MANIFOLD - REMOVAL, INTAKE . . . . . . . . . 9-678 / NIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-68
LOW, DIAGNOSIS AND TESTING - MANIFOLD AIR FLOW (MAF) SENSOR - MIRROR - REMOVAL, AUTOMATIC DAY /
(P2513) ENHANCED ACCIDENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-37 NIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-68
REPORT DRIVER CIRCUIT . . . . . . . . . . . . . . 9-504 MANIFOLD AIR FLOW (MAF) SENSOR - MIRROR - REMOVAL, SIDEVIEW . . . . . . . . 8N-72
LOW, DIAGNOSIS AND TESTING - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14-39 MIRROR GRID - DESCRIPTION, HEATED . . 8G-23
SHORT RUNNER SOLENOID CIRCUIT . . . . . 9-549 MANIFOLD AIR FLOW (MAF) SENSOR - MIRROR INOPERATIVE, DIAGNOSIS AND
LOW LIMITS - DESCRIPTION, HIGH . . . . . . 25-11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-37 TESTING - AUTOMATIC DAY/NIGHT . . . . . . 8N-59
LOW SPEED INOPERATIVE, DIAGNOSIS MANIFOLD AIR FLOW (MAF) SENSOR - MIRROR INOPERATIVE, DIAGNOSIS AND
AND TESTING - WIPERS . . . . . . . . . . . . . . . 8R-13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37 TESTING - LEFT HEATED . . . . . . . . . . . . . . 8G-16
LOW VOLTAGE, DIAGNOSIS AND MANIFOLD LEAKS - DIAGNOSIS AND MIRROR INOPERATIVE, DIAGNOSIS AND
TESTING - (P0702) TRANSMISSION TESTING, INTAKE . . . . . . . . . . . . . . . . . . . . 9-678 TESTING - LEFT POWER . . . . . . . . . . . . . . . 8N-53
CONTROL MODULE . . . . . . . . . . . . . . . . . . . 9-455 MANIFOLD TUNE VALVE - DESCRIPTION . . 14-40 MIRROR INOPERATIVE, DIAGNOSIS AND
LOWER BALL JOINT - INSTALLATION . . . . . . 2-32 MANIFOLD TUNE VALVE - INSTALLATION . . 14-41 TESTING - RIGHT HEATED . . . . . . . . . . . . . 8G-18
LOWER BALL JOINT - REMOVAL . . . . . . . . . 2-29 MANIFOLD TUNE VALVE - OPERATION . . . . 14-40 MIRROR INOPERATIVE, DIAGNOSIS AND
LOWER CONTROL ARM - INSTALLATION . . 2-37, MANIFOLD TUNE VALVE - REMOVAL . . . . . 14-41 TESTING - RIGHT POWER . . . . . . . . . . . . . 8N-55
2-55 MANUAL BLEEDING, STANDARD MIRROR, INSTALLATION - REARVIEW . . . . 8N-69
LOWER CONTROL ARM - REMOVAL . . 2-34,2-53 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 MIRROR SUPPORT BRACKET -
LOWER DOOR SPEAKER, INSTALLATION . . 8A-31 MAP SENSOR - DESCRIPTION . . . . . . . . . . 14-42 INSTALLATION, REARVIEW . . . . . . . . . . . . . 8N-69
LOWER DOOR SPEAKER, REMOVAL . . . . . . 8A-29 MAP SENSOR - INSTALLATION . . . . . . . . . . 14-43 MIRROR SWITCH - INSTALLATION,
LOWER INSTRUMENT PANEL (LEFT) - MAP SENSOR - OPERATION . . . . . . . . . . . . 14-42 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-158 MAP SENSOR - REMOVAL . . . . . . . . . . . . . 14-42 MIRROR SWITCH - REMOVAL, POWER . . . 8N-71
LOWER INSTRUMENT PANEL (LEFT) - MAP SENSOR CIRCUIT HIGH, MIRRORS - SERVICE INFORMATION -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-152 DIAGNOSIS AND TESTING - (P0108) . . . . . . 9-29 DESCRIPTION, HEATED . . . . . . . . . . . . . . . . 8G-22
LOWER INSTRUMENT PANEL (RIGHT) - MAP SENSOR CIRCUIT LOW, DIAGNOSIS MIRRORS - SERVICE INFORMATION -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-160 AND TESTING - (P0107) . . . . . . . . . . . . . . . . 9-24 DESCRIPTION, POWER . . . . . . . . . . . . . . . . 8N-66
LOWER INSTRUMENT PANEL (RIGHT) - MAP SENSOR PERFORMANCE, MIRRORS - SERVICE INFORMATION -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-154 DIAGNOSIS AND TESTING - (P0106) . . . . . . 9-21 DIAGNOSIS AND TESTING, HEATED . . . . . . 8G-22
LOWER OIL PAN, INSTALLATION . . . . . . . . 9-669 MARKER LAMP - INSTALLATION, FRONT . 8L-111 MIRRORS - SERVICE INFORMATION -
LOWER OIL PAN, REMOVAL . . . . . . . . . . . . 9-667 MARKER LAMP - REMOVAL, FRONT . . . . 8L-110 DIAGNOSIS AND TESTING, POWER . . . . . . 8N-66
LR WHEEL SPIN CAN MESSAGE NOT MARKER LAMP INOPERATIVE, MIRRORS - SERVICE INFORMATION -
VALID, DIAGNOSIS AND TESTING . . . . . . . 21-173 DIAGNOSIS AND TESTING - LEFT OPERATION, HEATED . . . . . . . . . . . . . . . . . 8G-22
LUBRICANT - DESCRIPTION, FRONT SIDE . . . . . . . . . . . . . . . . . . . . . . . . 8L-32 MIRRORS - SERVICE INFORMATION -
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 MARKER LAMP INOPERATIVE, OPERATION, POWER . . . . . . . . . . . . . . . . . 8N-66
LUBRICANTS, DESCRIPTION - ENGINE DIAGNOSIS AND TESTING - LEFT MIRRORS INOPERATIVE, DIAGNOSIS
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 REAR SIDE . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38 AND TESTING - BOTH POWER . . . . . . . . . . 8N-57
LUBRICATION - DESCRIPTION . . . . . . . . . . 9-660 MARKER LAMP INOPERATIVE, MODE - DESCRIPTION, DRB IIIT STATE
LUBRICATION - SPECIFICATIONS, BODY . . 23-32 DIAGNOSIS AND TESTING - RIGHT DISPLAY TEST . . . . . . . . . . . . . . . . . . . . . . . 25-11
LUBRICATION POINTS - DESCRIPTION . . . . . 0-14 FRONT SIDE . . . . . . . . . . . . . . . . . . . . . . . . 8L-35 MODULATING PRESSURE SOLENOID
LUBRICATION, STANDARD PROCEDURE - CIRCUIT, DIAGNOSIS AND TESTING -
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-31 (P0748) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-128
20 INDEX ZH

MODULE - DESCRIPTION . . . . . . . . . . . . . . 22-49 MODULE AND CENTRAL LOCKING MONITORED COMPONENTS -
MODULE - DESCRIPTION, A/C HEATER PUMP/SECURITY SYSTEM MODULE, DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-2
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-78 DIAGNOSIS AND TESTING - NO MONITORED SYSTEMS - DESCRIPTION . . . . 25-6
MODULE - DESCRIPTION, BODY COMMUNICATION WITH BODY MOTOR - DESCRIPTION, STARTER . . . . . . . 8F-41
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-71 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20 MOTOR - DIAGNOSIS AND TESTING,
MODULE - DESCRIPTION, POWERTRAIN MODULE, DIAGNOSIS AND TESTING - STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-54 NO COMMUNICATION WITH BCM AND MOTOR - INSTALLATION, BLOWER . . . . . . 24-90
MODULE - DESCRIPTION, RELAY CENTRAL LOCKING PUMP/SECURITY MOTOR - INSTALLATION, FRONT RISER . 8N-102
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-3 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8 MOTOR - INSTALLATION, REAR RISER . . 8N-100
MODULE - DESCRIPTION, SECURITY MODULE, DIAGNOSIS AND TESTING - MOTOR - INSTALLATION, RECLINER . . . . 8N-104
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-65 NO COMMUNICATION WITH BODY MOTOR - INSTALLATION, STARTER . . . . . . 8F-44
MODULE - DESCRIPTION, SENTRY KEY CONTROL MODULE AND CENTRAL MOTOR - INSTALLATION, WASHER
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8E-69 LOCKING PUMP/SECURITY SYSTEM . . . . . 8N-20 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-31
MODULE - DESCRIPTION, SENTRY KEY MODULE, DIAGNOSIS AND TESTING - MOTOR - INSTALLATION, WINDOW . . . . . 8N-123
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8N-46 NO RESPONSE FROM A/C HEATER MOTOR - INSTALLATION, WIPER . . . . . . . . 8R-48
MODULE - DESCRIPTION, SENTRY KEY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 MOTOR - OPERATION, STARTER . . . . . . . . . 8F-41
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8Q-52 MODULE, DIAGNOSIS AND TESTING - MOTOR - REMOVAL . . . . . . . . . . . . . . . . . 23-120
MODULE - DESCRIPTION, NO RESPONSE FROM BODY CONTROL . . . 8E-36 MOTOR - REMOVAL, BLOWER . . . . . . . . . . 24-88
TRANSMISSION CONTROL . . . . . . . . . . . . . 8E-58 MODULE, DIAGNOSIS AND TESTING - MOTOR - REMOVAL, FRONT RISER . . . . . 8N-102
MODULE - DESCRIPTION, WIPER . . . . . . . 8R-42 NO RESPONSE FROM POWERTRAIN MOTOR - REMOVAL, REAR RISER . . . . . . . 8N-99
MODULE - DIAGNOSIS AND TESTING, CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-4 MOTOR - REMOVAL, RECLINER . . . . . . . . 8N-103
SENTRY KEY REMOTE ENTRY . . . . . . . . . . 8N-47 MODULE, DIAGNOSIS AND TESTING - MOTOR - REMOVAL, STARTER . . . . . . . . . . 8F-43
MODULE - INSTALLATION . . . . . . . . . . . . . . 22-52 NO RESPONSE FROM SENTRY KEY MOTOR - REMOVAL, WASHER PUMP . . . . 8R-31
MODULE - INSTALLATION, A/C HEATER REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8E-40 MOTOR - REMOVAL, WINDOW . . . . . . . . . 8N-122
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-81 MODULE, DIAGNOSIS AND TESTING - MOTOR - REMOVAL, WIPER . . . . . . . . . . . 8R-47
MODULE - INSTALLATION, BODY NO RESPONSE FROM TRANSMISSION MOTOR FAILURE, DIAGNOSIS AND
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-73 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-33 TESTING - REAR SPOILER . . . . . . . . . . . . . 23-23
MODULE - INSTALLATION, HEATED SEAT . 8G-42 MODULE, DIAGNOSIS AND TESTING - MOTOR INOPERATIVE, DIAGNOSIS AND
MODULE - INSTALLATION, ON / OFF (P0600) INCORRECT CAN MESSAGE TESTING - DRIVER POWER SEAT
SWITCH INDICATOR . . . . . . . . . . . . . . . . . 8O-106 FROM EIS CONTROL . . . . . . . . . . . . . . . . . . 9-425 FRONT RISER . . . . . . . . . . . . . . . . . . . . . . . 8N-85
MODULE - INSTALLATION, POWERTRAIN MODULE, DIAGNOSIS AND TESTING - MOTOR INOPERATIVE, DIAGNOSIS AND
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-57 (P0600) NO CAN MESSAGE FROM CAB . . . 9-427 TESTING - DRIVER POWER SEAT
MODULE - INSTALLATION, RADIATOR MODULE FAILURE, DIAGNOSIS AND HORIZONTAL . . . . . . . . . . . . . . . . . . . . . . . . 8N-83
FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 7-29 TESTING - TIRE PRESSURE MONITOR . . . . . 22-4 MOTOR INOPERATIVE, DIAGNOSIS AND
MODULE - INSTALLATION, REAR MODULE INTERNAL FAILURE, TESTING - DRIVER POWER SEAT
WINDOW ANTENNA . . . . . . . . . . . . . . . . . . 8A-23 DIAGNOSIS AND TESTING - BODY REAR RISER . . . . . . . . . . . . . . . . . . . . . . . . 8N-87
MODULE - INSTALLATION, RELAY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2 MOTOR INOPERATIVE, DIAGNOSIS AND
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4 MODULE INTERNAL FAILURE, TESTING - DRIVER POWER SEAT
MODULE - INSTALLATION, SECURITY DIAGNOSIS AND TESTING - BODY RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-81
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-68 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-11 MOTOR INOPERATIVE, DIAGNOSIS AND
MODULE - INSTALLATION, SECURITY MODULE INTERNAL FAILURE, TESTING - PASSENGER POWER SEAT
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-49 DIAGNOSIS AND TESTING - CENTRAL HORIZONTAL . . . . . . . . . . . . . . . . . . . . . . . . 8N-91
MODULE - INSTALLATION, SENTRY KEY LOCKING PUMP/SECURITY SYSTEM . . . . . 8N-26 MOTOR INOPERATIVE, DIAGNOSIS AND
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8Q-55 MODULE INTERNAL FAILURE, TESTING - PASSENGER POWER SEAT
MODULE - INSTALLATION, DIAGNOSIS AND TESTING - CENTRAL RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-89
TRANSMISSION CONTROL . . . . . . . . . . . . . 8E-61 LOCKING PUMP/SECURITY SYSTEM . . . . . 8Q-30 MOTOR, INSTALLATION - HORIZONTAL . . 8N-102
MODULE - INSTALLATION, WIPER . . . . . . . 8R-44 MODULE INTERNAL FAILURE, MOTOR PERFORMANCE, DIAGNOSIS
MODULE - OPERATION . . . . . . . . . . . . . . . . 22-50 DIAGNOSIS AND TESTING - SENTRY AND TESTING - (P0120) ELECTRONIC
MODULE - OPERATION, A/C HEATER KEY REMOTE ENTRY . . . . . . . . . . . . . . . . . 8Q-34 THROTTLE CONTROL . . . . . . . . . . . . . . . . . . 9-53
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-78 MODULE LOW VOLTAGE, DIAGNOSIS MOTOR REGULATOR - INSTALLATION,
MODULE - OPERATION, BODY CONTROL . . 8E-71 AND TESTING - (P0702) BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-76
MODULE - OPERATION, POWERTRAIN TRANSMISSION CONTROL . . . . . . . . . . . . . 9-455 MOTOR REGULATOR - REMOVAL,
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-54 MODULE PERFORMANCE, DIAGNOSIS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-74
MODULE - OPERATION, RELAY AND TESTING - (P0221) ELECTRONIC MOTOR, REMOVAL - HORIZONTAL . . . . . . 8N-101
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-3 THROTTLE CONTROL . . . . . . . . . . . . . . . . . 9-270 MOTOR, SPECIFICATIONS - STARTER . . . . . 8F-40
MODULE - OPERATION, SECURITY MODULE PROCESSOR, DIAGNOSIS AND MOTOR SYNCHRONIZE - STANDARD
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-65 TESTING - (P0221) ELECTRONIC PROCEDURE, WIPER . . . . . . . . . . . . . . . . . 8R-46
MODULE - OPERATION, SENTRY KEY THROTTLE CONTROL . . . . . . . . . . . . . . . . . 9-272 MOUNT - INSTALLATION, FRONT . . . . . . . . 9-658
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8E-69 MODULE PROGRAMMING - STANDARD MOUNT - INSTALLATION, REAR . . . . . . . . . 9-660
MODULE - OPERATION, SENTRY KEY PROCEDURE, TPM . . . . . . . . . . . . . . . . . . . 22-50 MOUNT - REMOVAL, FRONT . . . . . . . . . . . . 9-657
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8Q-52 MODULE REQUESTED MIL MOUNT - REMOVAL, REAR . . . . . . . . . . . . . 9-659
MODULE - OPERATION, TRANSMISSION ILLUMINATION, DIAGNOSIS AND MOUNT BRACKETS - INSTALLATION,
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-58 TESTING - (P2561) HVAC CONTROL . . . . . . 9-512 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-656
MODULE - REMOVAL . . . . . . . . . . . . . . . . . 22-51 MODULE (SLA), DIAGNOSIS AND MOUNT BRACKETS - REMOVAL, ENGINE . . 9-655
MODULE - REMOVAL, A/C HEATER TESTING - (P0600) LOST COMM WITH MOUNTED STOP LAMP - DESCRIPTION,
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-79 ELECTRIC GEAR SHIFT . . . . . . . . . . . . . . . . 9-439 CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-92
MODULE - REMOVAL, BODY CONTROL . . . 8E-72 MODULE SYSTEM OVERVOLTAGE, MOUNTED STOP LAMP - INSTALLATION,
MODULE - REMOVAL, HEATED SEAT . . . . . 8G-41 DIAGNOSIS AND TESTING - CENTRAL CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-93
MODULE - REMOVAL, ON / OFF SWITCH LOCKING PUMP/SECURITY SYSTEM . . . . . . 8Q-5 MOUNTED STOP LAMP - REMOVAL,
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . 8O-105 MODULE SYSTEM UNDERVOLTAGE, CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-92
MODULE - REMOVAL, POWERTRAIN DIAGNOSIS AND TESTING - CENTRAL MOUNTED STOP LAMP INOPERATIVE,
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-56 LOCKING PUMP/SECURITY SYSTEM . . . . . . 8Q-2 DIAGNOSIS AND TESTING - CENTER
MODULE - REMOVAL, RADIATOR FAN MODULE TCM IS NOT CODED, HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-68
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 DIAGNOSIS AND TESTING - (P0702) MOUNTING - STANDARD PROCEDURE,
MODULE - REMOVAL, REAR WINDOW CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74 MATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-43
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-23 MODULE VERSION, DIAGNOSIS AND MOUNTING PLATE - INSTALLATION . . . . . 23-122
MODULE - REMOVAL, RELAY CONTROL . 8W-97-4 TESTING - (P0702) INVALID CONTROL . . . 21-78 MOUNTING PLATE - REMOVAL . . . . . . . . . 23-118
MODULE - REMOVAL, SECURITY MOLDING - INSTALLATION, ROCKER MUFFLER - INSTALLATION . . . . . . . . . . . . . 11-12
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-67 PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-125 MUFFLER - REMOVAL . . . . . . . . . . . . . . . . . 11-10
MODULE - REMOVAL, SECURITY MOLDING - REMOVAL, ROCKER PANEL . . 23-125 MULTI-FUNCTION SWITCH -
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-48 MONITOR, DIAGNOSIS AND TESTING - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-25
MODULE - REMOVAL, SENTRY KEY NO RESPONSE FROM UNIVERSAL MULTI-FUNCTION SWITCH -
REMOTE ENTRY . . . . . . . . . . . . . . . . . . . . . 8Q-53 GARAGE DOOR OPENER/TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8L-113
MODULE - REMOVAL, TRANSMISSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17 MULTI-FUNCTION SWITCH - REMOVAL . . 8L-112
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-60 MONITOR MODULE FAILURE, MULTIPLE CYLINDER MISFIRE,
MODULE - REMOVAL, WIPER . . . . . . . . . . . 8R-42 DIAGNOSIS AND TESTING - TIRE DIAGNOSIS AND TESTING - (P0300) . . . . . 9-283
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4 NIGHT MIRROR - DESCRIPTION,
AUTOMATIC DAY . . . . . . . . . . . . . . . . . . . . . 8N-68
ZH INDEX 21

NIGHT MIRROR - OPERATION, O2 SENSOR 2/1 HEATER CIRCUIT HIGH, OIL PAN, REMOVAL - LOWER . . . . . . . . . . . 9-667
AUTOMATIC DAY . . . . . . . . . . . . . . . . . . . . . 8N-68 DIAGNOSIS AND TESTING - (P0155) . . . . . 9-165 OIL PRESSURE - DIAGNOSIS AND
NIGHT MIRROR - REMOVAL, O2 SENSOR 2/1 HEATER CIRCUIT LOW, TESTING, CHECKING ENGINE . . . . . . . . . . . 9-662
AUTOMATIC DAY . . . . . . . . . . . . . . . . . . . . . 8N-68 DIAGNOSIS AND TESTING - (P0155) . . . . . 9-163 OIL PRESSURE RELIEF VALVE -
NOISE - DIAGNOSIS AND TESTING, O2 SENSOR 2/1 HEATER CIRCUIT OPEN, DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-677
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . 24-120 DIAGNOSIS AND TESTING - (P0155) . . . . . 9-167 OIL PUMP - ASSEMBLY . . . . . . . . . . . . . . 21-313
NOISE, DIAGNOSIS AND TESTING - O2 SENSOR 2/1 HEATER OIL PUMP - CLEANING . . . . . . . . . . . . . . . . 9-675
WIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-30 PERFORMANCE, DIAGNOSIS AND OIL PUMP - DESCRIPTION . . . . . . . . . . . . . 9-674
NOISE OR VIBRATION - DIAGNOSIS AND TESTING - (P0155) . . . . . . . . . . . . . . . . . . . 9-169 OIL PUMP - DESCRIPTION . . . . . . . . . . . . 21-312
TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . 22-59 O2 SENSOR 2/1 LONG DELAY TIME, OIL PUMP - DISASSEMBLY . . . . . . . . . . . . 21-312
NON-DEPLOYED SUPPLEMENTAL DIAGNOSIS AND TESTING - (P0153) . . . . . 9-155 OIL PUMP - INSTALLATION . . . . . . . . . . . . 9-676
RESTRAINTS - STANDARD O2 SENSOR 2/1 LONG PERFORMANCE, OIL PUMP - OPERATION . . . . . . . . . . . . . . 21-312
PROCEDURE, HANDLING . . . . . . . . . . . . . . 8O-83 DIAGNOSIS AND TESTING - (P0153) . . . . . 9-153 OIL PUMP - REMOVAL . . . . . . . . . . . . . . . . 9-674
NON-MONITORED CIRCUITS - O2 SENSOR 2/1 SHORT DELAY TIME, OIL PUMP DRIVE CHAIN -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-10 DIAGNOSIS AND TESTING - (P0153) . . . . . 9-157 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-677
NOT CODED, DIAGNOSIS AND TESTING - O2 SENSOR 2/1 SHORT PERFORMANCE, OIL PUMP DRIVE CHAIN - REMOVAL . . . . . 9-677
(P0702) CONTROL MODULE TCM IS . . . . . 21-74 DIAGNOSIS AND TESTING - (P0153) . . . . . 9-159 OIL SEAL - FRONT - INSTALLATION,
NOT START, DIAGNOSIS AND TESTING - O2 SENSOR 2/2 BELOW THRESHOLD, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-636
ENGINE CRANKS BUT DOES . . . . . . . . . . . . 9-563 DIAGNOSIS AND TESTING - (P0137) . . . . . 9-127 OIL SEAL - FRONT - REMOVAL,
NOT VALID, DIAGNOSIS AND TESTING - O2 SENSOR 2/2 CIRCUIT HIGH, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-636
LR WHEEL SPIN CAN MESSAGE . . . . . . . . 21-173 DIAGNOSIS AND TESTING - (P0140) . . . . . 9-139 OIL SEAL - REAR - INSTALLATION,
NOT VALID, DIAGNOSIS AND TESTING - O2 SENSOR 2/2 CIRCUIT LOW, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-635
RR WHEEL SPIN CAN MESSAGE . . . . . . . 21-175 DIAGNOSIS AND TESTING - (P0138) . . . . . 9-133 OIL SEAL - REAR - REMOVAL,
NOZZLE - INSTALLATION, CENTER AIR . . 24-108 O2 SENSOR 2/2 CIRCUIT OPEN, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 9-634
NOZZLE - INSTALLATION, WASHER . . . . . . 8R-30 DIAGNOSIS AND TESTING - (P0138) . . . . . 9-135 OIL SENSOR LEVEL PERFORMANCE,
NOZZLE - REMOVAL, CENTER AIR . . . . . . 24-107 O2 SENSOR 2/2 HEATER CIRCUIT HIGH, DIAGNOSIS AND TESTING - ENGINE . . . . . 9-521
NOZZLE - REMOVAL, WASHER . . . . . . . . . . 8R-29 DIAGNOSIS AND TESTING - (P0161) . . . . . 9-177 OIL SENSOR OVER TEMPERATURE,
NOZZLE AIMING - STANDARD O2 SENSOR 2/2 HEATER CIRCUIT LOW, DIAGNOSIS AND TESTING - ENGINE . . . . . 9-526
PROCEDURE, WASHER . . . . . . . . . . . . . . . . 8R-28 DIAGNOSIS AND TESTING - (P0161) . . . . . 9-173 OIL SENSOR PERFORMANCE,
NOZZLE, INSTALLATION - SIDE AIR . . . . . 24-108 O2 SENSOR 2/2 HEATER CIRCUIT OPEN, DIAGNOSIS AND TESTING - ENGINE . . . . . 9-531
NOZZLE, REMOVAL - SIDE AIR . . . . . . . . . 24-107 DIAGNOSIS AND TESTING - (P0161) . . . . . 9-175 OIL SENSOR QUALITY PERFORMANCE,
NOZZLES - INSTALLATION, OIL SPRAY . . . . . 9-674 O2 SENSOR 2/2 HEATER DIAGNOSIS AND TESTING - ENGINE . . . . . 9-533
NOZZLES - REMOVAL, OIL SPRAY . . . . . . . 9-674 PERFORMANCE, DIAGNOSIS AND OIL SENSOR WATER CONTAMINATION,
NUMBER - DESCRIPTION, VEHICLE TESTING - (P0161) . . . . . . . . . . . . . . . . . . . 9-171 DIAGNOSIS AND TESTING - ENGINE . . . . . 9-538
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . Intro.-2 O2 SENSOR HARNESS CONNECTORS OIL SPRAY NOZZLES - INSTALLATION . . . . 9-674
O2 - INSTALLATION, DOWNSTREAM . . . . . 14-47 REVERSED, DIAGNOSIS AND TESTING OIL SPRAY NOZZLES - REMOVAL . . . . . . . . 9-674
O2 - REMOVAL, DOWNSTREAM . . . . . . . . . 14-46 - (P0040) 1/1 AND 2/1 . . . . . . . . . . . . . . . . . . 9-5 ON/OFF SWITCH SIGNAL CIRCUIT,
O2, INSTALLATION - UPSTREAM . . . . . . . . 14-46 O2 SENSOR, REMOVAL - UPSTREAM . . . . . 14-45 DIAGNOSIS AND TESTING -
O2 SENSOR - DESCRIPTION . . . . . . . . . . . . 14-43 OCCUPANT RESTRAINT CONTROLLER - PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-49
O2 SENSOR - OPERATION . . . . . . . . . . . . . 14-44 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8O-87 OPEN, DIAGNOSIS AND TESTING -
O2 SENSOR 1/1 CIRCUIT HIGH, OCCUPANT RESTRAINT CONTROLLER - VOLTAGE SUPPLY CIRCUIT . . . . . . . . . . . . . . 8R-2
DIAGNOSIS AND TESTING - (P0132) . . . . . . 9-93 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-91 OPEN-CIRCUIT VOLTAGE TEST -
O2 SENSOR 1/1 CIRCUIT LOW, OCCUPANT RESTRAINT CONTROLLER - STANDARD PROCEDURE . . . . . . . . . . . . . . . 8F-13
DIAGNOSIS AND TESTING - (P0131) . . . . . . 9-86 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8O-88 ORC INTERNAL FAILURE, DIAGNOSIS
O2 SENSOR 1/1 CIRCUIT OPEN, OCCUPANT RESTRAINT CONTROLLER - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8O-2
DIAGNOSIS AND TESTING - (P0134) . . . . . 9-105 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-89 ORC PROGRAMMING - STANDARD
O2 SENSOR 1/1 HEATER CIRCUIT HIGH, OCCUPANT RESTRAINT CONTROLLER, PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8O-89
DIAGNOSIS AND TESTING - (P0135) . . . . . 9-113 DIAGNOSIS AND TESTING - NO ORC SYSTEM UNDERVOLTAGE,
O2 SENSOR 1/1 HEATER CIRCUIT LOW, RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-10 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-43
DIAGNOSIS AND TESTING - (P0135) . . . . . 9-107 OFF DETECTED, DIAGNOSIS AND ORVR - DESCRIPTION . . . . . . . . . . . . . . . . . 25-18
O2 SENSOR 1/1 HEATER CIRCUIT OPEN, TESTING - SAFETY FUEL SHUT . . . . . . . . . . 9-540 ORVR - OPERATION . . . . . . . . . . . . . . . . . . 25-19
DIAGNOSIS AND TESTING - (P0135) . . . . . 9-117 OFF SWITCH INDICATOR MODULE - OUTAGE INDICATOR CIRCUIT,
O2 SENSOR 1/1 HEATER INSTALLATION, ON . . . . . . . . . . . . . . . . . . 8O-106 DIAGNOSIS AND TESTING - LAMP . . . . . . . . 8J-5
PERFORMANCE, DIAGNOSIS AND OFF SWITCH INDICATOR MODULE - OUTER - INSTALLATION, CV BOOT . . . . . . . . 3-12
TESTING - (P0135) . . . . . . . . . . . . . . . . . . . 9-109 REMOVAL, ON . . . . . . . . . . . . . . . . . . . . . . 8O-105 OUTER - REMOVAL, CV BOOT . . . . . . . . . . . 3-11
O2 SENSOR 1/1 LONG DELAY TIME, OIL - DESCRIPTION . . . . . . . . . . . . . . . . . . . 9-664 OUTLET COVER - INSTALLATION,
DIAGNOSIS AND TESTING - (P0133) . . . . . 9-101 OIL - DESCRIPTION, REFRIGERANT . . . . . 24-148 FOOTWELL AIR . . . . . . . . . . . . . . . . . . . . . 24-111
O2 SENSOR 1/1 LONG PERFORMANCE, OIL - OPERATION, REFRIGERANT . . . . . . . 24-149 OUTLET COVER - REMOVAL, FOOTWELL
DIAGNOSIS AND TESTING - (P0133) . . . . . . 9-99 OIL AND FILTER CHANGE - STANDARD AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-110
O2 SENSOR 1/1 SHORT DELAY TIME, PROCEDURE, ENGINE . . . . . . . . . . . . . . . . . 9-664 OUTPUT CIRCUIT, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0133) . . . . . . 9-95 OIL AND LUBRICANTS, DESCRIPTION - TESTING - SIREN SIGNAL . . . . . . . . . . . . . 8Q-27
O2 SENSOR 1/1 SHORT PERFORMANCE, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 OUTPUT FLANGE SEAL - INSTALLATION . 21-356
DIAGNOSIS AND TESTING - (P0133) . . . . . 9-103 OIL CHANGE, STANDARD PROCEDURE - OUTPUT FLANGE SEAL - REMOVAL . . . . . 21-355
O2 SENSOR 1/2 ABOVE THRESHOLD, RESETTING THE FSS MAINTENANCE OUTPUT SHAFT BEARING -
DIAGNOSIS AND TESTING - (P0137) . . . . . 9-121 INDICATOR AFTER AN . . . . . . . . . . . . . . . . . 8J-78 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21-316
O2 SENSOR 1/2 BELOW THRESHOLD, OIL FILTER - DESCRIPTION . . . . . . . . . . . . 9-666 OUTPUT SHAFT BEARING - REMOVAL . . . 21-314
DIAGNOSIS AND TESTING - (P0137) . . . . . 9-119 OIL FILTER - INSTALLATION . . . . . . . . . . . . 9-666 OUTPUT SHAFT SEAL - INSTALLATION . . 21-318
O2 SENSOR 1/2 CIRCUIT HIGH, OIL FILTER - REMOVAL . . . . . . . . . . . . . . . . 9-666 OUTPUT SHAFT SEAL - REMOVAL . . . . . . 21-318
DIAGNOSIS AND TESTING - (P0138) . . . . . 9-129 OIL GALLERY PLUGS - STANDARD OVER LIMIT (AT LOAD), DIAGNOSIS AND
O2 SENSOR 1/2 CIRCUIT LOW, PROCEDURE, ENGINE CORE . . . . . . . . . . . . 9-591 TESTING - (P0174) FUEL SYSTEM 2/1
DIAGNOSIS AND TESTING - (P0140) . . . . . 9-137 OIL LEAK INSPECTION, DIAGNOSIS AND RICH CONTROL . . . . . . . . . . . . . . . . . . . . . . 9-221
O2 SENSOR 1/2 CIRCUIT OPEN, TESTING - ENGINE . . . . . . . . . . . . . . . . . . . 9-660 OVER TEMPERATURE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0138) . . . . . 9-131 OIL LEVEL - STANDARD PROCEDURE, TESTING - ENGINE OIL SENSOR . . . . . . . . . 9-526
O2 SENSOR 1/2 HEATER CIRCUIT HIGH, REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . 24-149 OVER-ADVANCED, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0141) . . . . . 9-145 OIL LEVEL CHECK, STANDARD TESTING - (P0341) CAMSHAFT
O2 SENSOR 1/2 HEATER CIRCUIT LOW, PROCEDURE - ENGINE . . . . . . . . . . . . . . . . 9-664 POSITION TIMING . . . . . . . . . . . . . . . . . . . . 9-344
DIAGNOSIS AND TESTING - (P0141) . . . . . 9-141 OIL LEVEL INDICATOR TUBE - OVERCORRECTION OF FUEL MIXTURE
O2 SENSOR 1/2 HEATER CIRCUIT OPEN, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-663 (AT IDLE), DIAGNOSIS AND TESTING -
DIAGNOSIS AND TESTING - (P0141) . . . . . 9-143 OIL LEVEL INDICATOR TUBE - REMOVAL . . 9-663 (P0172) FUEL SYSTEM 1/1 . . . . . . . . . . . . . 9-195
O2 SENSOR 1/2 HEATER OIL LEVEL, STANDARD PROCEDURE - OVERCORRECTION OF FUEL MIXTURE
PERFORMANCE, DIAGNOSIS AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-294 (OFF IDLE), DIAGNOSIS AND TESTING
TESTING - (P0141) . . . . . . . . . . . . . . . . . . . 9-147 OIL LEVEL/TEMPERATURE SENSOR - - (P0175) FUEL SYSTEM 2/1 . . . . . . . . . . . 9-230
O2 SENSOR 2/1 CIRCUIT HIGH, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9-673 OVERHEATING, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0152) . . . . . 9-151 OIL LEVEL/TEMPERATURE SENSOR - TESTING - ENGINE COOLING SYSTEM . . . . . 7-12
O2 SENSOR 2/1 CIRCUIT LOW, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-672 OVER-RETARDED, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0151) . . . . . 9-149 OIL PAN - INSTALLATION, UPPER . . . . . . . 9-671 TESTING - (P0341) CAMSHAFT
O2 SENSOR 2/1 CIRCUIT OPEN, OIL PAN - REMOVAL, UPPER . . . . . . . . . . . 9-669 POSITION TIMING . . . . . . . . . . . . . . . . . . . . 9-340
DIAGNOSIS AND TESTING - (P0154) . . . . . 9-161 OIL PAN, INSTALLATION - LOWER . . . . . . . 9-669
22 INDEX ZH

OVERSPEED, DIAGNOSIS AND TESTING - PATTERNS - DIAGNOSIS AND TESTING, PLATE - REMOVAL, DOOR SILL TRIM . . . 23-193
(P0219) ENGINE . . . . . . . . . . . . . . . . . . . . . . 21-3 TIRE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . 22-59 PLATE - REMOVAL, MOUNTING . . . . . . . . 23-118
OVERSPEED, DIAGNOSIS AND TESTING - PCM, DIAGNOSIS AND TESTING - NO PLATE LAMP - INSTALLATION, LICENSE . 8L-109
(P0715) INPUT SENSOR . . . . . . . . . . . . . . . 21-94 CAN COMMUNICATIONS WITH . . . . . . 5-164,5-90 PLATE LAMP - REMOVAL, LICENSE . . . . . 8L-109
OVERTEMP, DIAGNOSIS AND TESTING - PCM, DIAGNOSIS AND TESTING - NO PLATINUM PLUGS - DESCRIPTION . . . . . . . . 8I-7
(P0740) TCC . . . . . . . . . . . . . . . . . . . . . . . 21-119 CAN COMMUNICATIONS WITH . . . . . . . . . . 8J-18 PLUG - INSTALLATION, DETENT . . . . . . . . 21-359
OVERVOLTAGE, DIAGNOSIS AND PCM, DIAGNOSIS AND TESTING - NO PLUG - INSTALLATION, SPARK . . . . . . . . . . 8I-12
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-177 CAN COMMUNICATIONS WITH . . . . . . . . . . 8Q-25 PLUG - OPERATION, SPARK . . . . . . . . . . . . . 8I-7
OVERVOLTAGE, DIAGNOSIS AND PCM NOT IDENTIFIED OR INCORRECT, PLUG - REMOVAL, DETENT . . . . . . . . . . . 21-358
TESTING - CAB SYSTEM . . . . . . . . . . . 5-158,5-85 DIAGNOSIS AND TESTING . . . . . . . . . 5-161,5-94 PLUG - REMOVAL, SPARK . . . . . . . . . . . . . . 8I-11
OVERVOLTAGE, DIAGNOSIS AND PCM PROGRAMMED INCORRECT PLUG CABLE - DESCRIPTION, SPARK . . . . . 8I-13
TESTING - CENTRAL LOCKING TRANS/NO COMM FROM TCM, PLUG CABLE - INSTALLATION, SPARK . . . . 8I-13
PUMP/SECURITY SYSTEM MODULE DIAGNOSIS AND TESTING - (P0602) . . . . . 9-451 PLUG CABLE - REMOVAL, SPARK . . . . . . . . 8I-13
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-5 PCM/SKREEM PROGRAMMING - PLUG CONDITIONS - DIAGNOSIS AND
OVERVOLTAGE, DIAGNOSIS AND STANDARD PROCEDURE . . . . . . . . . . . . . . . 8E-54 TESTING, SPARK . . . . . . . . . . . . . . . . . . . . . . 8I-8
TESTING - CLP/SSM SYSTEM . . . . . . . . . . 8N-17 PEDAL - DESCRIPTION . . . . . . . . . . . . . . . . . 5-53 PLUGS - DESCRIPTION, PLATINUM . . . . . . . . 8I-7
OVERVOLTAGE, DIAGNOSIS AND PEDAL - DESCRIPTION, ACCELERATOR . . . 14-26 PLUGS - SPECIFICATIONS, SPARK . . . . . . . . 8I-4
TESTING - (PO563) SYSTEM . . . . . . . . . . . . 21-9 PEDAL - INSTALLATION . . . . . . . . . . . . . . . . 5-55 PLUGS - STANDARD PROCEDURE,
OWN, DIAGNOSIS AND TESTING - PEDAL - INSTALLATION, ACCELERATOR . . . 14-27 ENGINE CORE AND OIL GALLERY . . . . . . . . 9-591
ALARM TRIPS ON ITS . . . . . . . . . . . . . . . . 8Q-32 PEDAL - INSTALLATION, CLUTCH . . . . . . . . . 6-25 PLUMBING - CAUTION . . . . . . . . . . . . . . . 24-115
PADS - INSTALLATION, REAR DISC PEDAL - OPERATION . . . . . . . . . . . . . . . . . . . 5-53 PLUMBING - DESCRIPTION . . . . . . . . . . . 24-122
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 PEDAL - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-54 PLUMBING - INSTALLATION . . . . . . . . . . . 24-124
PADS - REMOVAL, REAR DISC BRAKE . . . . . 5-19 PEDAL - REMOVAL, ACCELERATOR . . . . . . 14-26 PLUMBING - OPERATION . . . . . . . . . . . . . 24-122
PADS, INSTALLATION - FRONT DISC PEDAL - REMOVAL, CLUTCH . . . . . . . . . . . . 6-24 PLUMBING - REMOVAL . . . . . . . . . . . . . . . 24-123
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 PEDAL POSITION SENSOR - PLUMBING - WARNING . . . . . . . . . . . . . . . 24-115
PADS, REMOVAL - FRONT DISC BRAKE . . . . 5-17 DESCRIPTION, ACCELERATOR . . . . . . . . . . 14-28 PLY TIRES - RADIAL . . . . . . . . . . . . . . . . . . 22-57
PAINT CODE - DESCRIPTION . . . . . . . . . . 23-199 PEDAL POSITION SENSOR - OPERATION, POINTS - DESCRIPTION, LUBRICATION . . . . 0-14
PAINT CODE - SPECIFICATIONS . . . . . . . . 23-199 ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . 14-29 POLISHING - DESCRIPTION, WET
PAINT TOUCH - UP - DESCRIPTION . . . . . 23-200 PEDAL SENSOR CAN MESSAGE SANDING/BUFFING . . . . . . . . . . . . . . . . . . 23-200
PAN - INSTALLATION, UPPER OIL . . . . . . . 9-671 INCORRECT, DIAGNOSIS AND TESTING PORT - DESCRIPTION, REFRIGERANT
PAN - REMOVAL, UPPER OIL . . . . . . . . . . . 9-669 - (P0600) ACCEL . . . . . . . . . . . . . . . . . . . . . 21-34 SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . 24-58
PAN, INSTALLATION - LOWER OIL . . . . . . . . 9-669 PERFORMANCE - DIAGNOSIS AND POSITION - STANDARD PROCEDURE,
PAN, REMOVAL - LOWER OIL . . . . . . . . . . . 9-667 TESTING, HEATER . . . . . . . . . . . . . . . . . . . . 24-68 MOVING THE HOOD TO ITS FULLY
PANEL - INSTALLATION, TRIM . . . . 23-109,23-49 PERFORMANCE - ENGINE DIAGNOSIS . . . . 9-586 UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . 23-130
PANEL - REMOVAL, TRIM . . . . . . . . 23-108,23-48 PERFORMANCE, DIAGNOSIS AND POSITION LAMP - DESCRIPTION, FRONT . . 8L-97
PANEL (LEFT) - INSTALLATION, LOWER TESTING - A/C . . . . . . . . . . . . . . . . . . . . . . . 24-64 POSITION LAMP - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-158 PERFORMANCE, DIAGNOSIS AND FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-98
PANEL (LEFT) - REMOVAL, LOWER TESTING - ENGINE OIL SENSOR . . . . . . . . . 9-531 POSITION LAMP - OPERATION, FRONT . . . 8L-97
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-152 PERFORMANCE, DIAGNOSIS AND POSITION LAMP - REMOVAL, FRONT . . . . . 8L-97
PANEL MOLDING - INSTALLATION, TESTING - ENGINE OIL SENSOR LEVEL . . . 9-521 POSITION SENSOR - DESCRIPTION,
ROCKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-125 PERFORMANCE, DIAGNOSIS AND ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-28
PANEL MOLDING - REMOVAL, ROCKER . . 23-125 TESTING - ENGINE OIL SENSOR POSITION SENSOR - DESCRIPTION,
PANEL (RIGHT) - INSTALLATION, LOWER QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-533 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-30
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-160 PERFORMANCE, DIAGNOSIS AND POSITION SENSOR - DESCRIPTION,
PANEL (RIGHT) - REMOVAL, LOWER TESTING - (P0101) MAF SENSOR . . . . . . . . . . 9-8 THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154 PERFORMANCE, DIAGNOSIS AND POSITION SENSOR - INSTALLATION,
PANEL SPEAKER - INSTALLATION, REAR . . 8A-33 TESTING - (P0106) MAP SENSOR . . . . . . . . 9-21 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-5
PANEL SPEAKER - REMOVAL, REAR . . . . . 8A-29 PERFORMANCE, DIAGNOSIS AND POSITION SENSOR - INSTALLATION,
PANEL (TOP SECTION) - INSTALLATION, TESTING - (P0116) ENGINE COOLANT CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-155 TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9-40 POSITION SENSOR - OPERATION,
PANEL (TOP SECTION), REMOVAL - PERFORMANCE, DIAGNOSIS AND ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-29
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-149 TESTING - (P0120) ELECTRONIC POSITION SENSOR - OPERATION,
PARK LAMP INOPERATIVE, DIAGNOSIS THROTTLE CONTROL MOTOR . . . . . . . . . . . . 9-53 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4
AND TESTING - LEFT . . . . . . . . . . . . . . . . . . 8L-8 PILOT BEARING - INSTALLATION . . . . . . . . . 6-23 POSITION SENSOR - OPERATION,
PARK LAMP INOPERATIVE, DIAGNOSIS PILOT BEARING - REMOVAL . . . . . . . . . . . . . 6-23 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-30
AND TESTING - RIGHT . . . . . . . . . . . . . . . . 8L-14 PINION FLANGE SEAL - INSTALLATION . . . . 3-45 POSITION SENSOR - OPERATION,
PARKING BRAKE - OPERATION . . . . . . . . . . . 5-57 PINION FLANGE SEAL - REMOVAL . . . . . . . . 3-43 THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
PARKING BRAKE, DIAGNOSIS AND PIPES - INSTALLATION, FRONT POSITION SENSOR - REMOVAL,
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4
PARK/NEUTRAL CONTACT, DESCRIPTION . 21-327 PIPES - REMOVAL, FRONT EXHAUST . . . . . . 11-5 POSITION SENSOR - REMOVAL,
PARK/NEUTRAL CONTACT, OPERATION . . 21-328 PISTON AND CONNECTING ROD - CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
PASSENGER AIRBAG - DESCRIPTION . . . 8O-101 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 9-639 POSITION SENSOR 1/2 CORRELATION,
PASSENGER AIRBAG - INSTALLATION . . . 8O-103 PISTON FITTING, STANDARD DIAGNOSIS AND TESTING - (P0120)
PASSENGER AIRBAG - OPERATION . . . . . 8O-101 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 9-640 THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59
PASSENGER AIRBAG - REMOVAL . . . . . . . 8O-102 PISTON RINGS - INSTALLATION . . . . . . . . . 9-645 POSITION SENSOR CIRCUIT, DIAGNOSIS
PASSENGER AIRBAG ON/OFF SWITCH PISTON RINGS - REMOVAL . . . . . . . . . . . . 9-645 AND TESTING - (P0335) CRANKSHAFT . . . 9-334
SIGNAL CIRCUIT, DIAGNOSIS AND PISTONS - DESCRIPTION . . . . . . . . . . . . . 21-319 POSITION SENSOR PERFORMANCE,
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-49 PISTONS - OPERATION . . . . . . . . . . . . . . . 21-319 DIAGNOSIS AND TESTING - (P0341)
PASSENGER AIRBAG SQUIB CIRCUIT, PITMAN ARM - INSTALLATION . . . . . . . . . . 19-45 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 9-346
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-23 PITMAN ARM - REMOVAL . . . . . . . . . . . . . 19-43 POSITION TIMING OVER-ADVANCED,
PASSENGER DOOR/LIFTGATE LOCK PITMAN SHAFT SEAL - INSTALLATION . . . . 19-39 DIAGNOSIS AND TESTING - (P0341)
ACTUATOR SLOW RESPONSE, PITMAN SHAFT SEAL - REMOVAL . . . . . . . 19-38 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 9-344
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-8 PLANETARY GEARTRAIN - ASSEMBLY . . . 21-323 POSITION TIMING OVER-RETARDED,
PASSENGER POWER SEAT HORIZONTAL PLANETARY GEARTRAIN - DESCRIPTION . 21-321 DIAGNOSIS AND TESTING - (P0341)
MOTOR INOPERATIVE, DIAGNOSIS PLANETARY GEARTRAIN - CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 9-340
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-91 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-322 POTENTIAL - STANDARD PROCEDURE,
PASSENGER POWER SEAT PLANETARY GEARTRAIN - OPERATION . . 21-321 TESTING OF VOLTAGE . . . . . . . . . . . . . . 8W-01-9
INOPERATIVE, DIAGNOSIS AND PLASTIC BACK COVER - INSTALLATION . . 23-205 POWER BRAKE BOOSTER -
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-76 PLASTIC BACK COVER - REMOVAL . . . . . 23-204 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5-48
PASSENGER POWER SEAT RECLINER PLASTIGAGET - STANDARD POWER BRAKE BOOSTER -
MOTOR INOPERATIVE, DIAGNOSIS PROCEDURE, MEASURING BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-51
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-89 CLEARANCE USING . . . . . . . . . . . . . . . . . . . 9-591 POWER BRAKE BOOSTER - OPERATION . . . 5-49
PASSENGER SEAT BELT TENSIONER PLATE / FLYWHEEL - INSTALLATION, POWER BRAKE BOOSTER - REMOVAL . . . . . 5-50
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 8O-56 FLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-654 POWER DISTRIBUTION - DESCRIPTION . 8W-97-1
PASSENGER SEAT BELT TENSIONER PLATE / FLYWHEEL - REMOVAL, FLEX . . . . 9-653 POWER DISTRIBUTION - OPERATION . . 8W-97-1
SQUIB CIRCUIT, DIAGNOSIS AND PLATE - INSTALLATION, DOOR SILL POWER EXCESSIVE HIGH COOLANT
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17 TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-193 TEMP, DIAGNOSIS AND TESTING -
PLATE - INSTALLATION, MOUNTING . . . . . 23-122 (P0128) FORCED LIMITED . . . . . . . . . . . . . . 9-74
ZH INDEX 23

POWER LOCK SWITCH - DESCRIPTION . . . 8N-38 POWERING SEVERAL LOADS - PRESSURE SENSOR CIRCUIT LOW,
POWER LOCK SWITCH - INSTALLATION . . 8N-39 STANDARD PROCEDURE, TESTING DIAGNOSIS AND TESTING - (P0452)
POWER LOCK SWITCH - REMOVAL . . . . . . 8N-39 FOR A SHORT TO GROUND ON FUSES . 8W-01-10 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 9-395
POWER LOCKS - DIAGNOSIS AND POWERTRAIN CONTROL MODULE - PRESSURE SENSOR PERFORMANCE,
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-54 DIAGNOSIS AND TESTING - (P0451)
POWER LOCKS - SERVICE POWERTRAIN CONTROL MODULE - FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 9-390
INFORMATION - DESCRIPTION . . . . . . . . . . 8N-30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8E-57 PRESSURE SENSOR/TRANSMITTER,
POWER LOCKS - SERVICE POWERTRAIN CONTROL MODULE - DIAGNOSIS AND TESTING - LEFT
INFORMATION - OPERATION . . . . . . . . . . . 8N-31 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-54 FRONT TIRE . . . . . . . . . . . . . . . . . . . . . . . . 22-24
POWER LOCKS - SPECIFICATIONS . . . . . . . 8N-35 POWERTRAIN CONTROL MODULE - PRESSURE SENSOR/TRANSMITTER,
POWER MIRROR INOPERATIVE, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-56 DIAGNOSIS AND TESTING - LEFT
DIAGNOSIS AND TESTING - LEFT . . . . . . . 8N-53 POWERTRAIN CONTROL MODULE, REAR TIRE . . . . . . . . . . . . . . . . . . . . . . . . . 22-26
POWER MIRROR INOPERATIVE, DIAGNOSIS AND TESTING - NO PRESSURE SENSOR/TRANSMITTER,
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8N-55 RESPONSE FROM . . . . . . . . . . . . . . . . . . . . . 8E-4 DIAGNOSIS AND TESTING - RIGHT
POWER MIRROR SWITCH - POWERTRAIN VERIFICATION TEST, FRONT TIRE . . . . . . . . . . . . . . . . . . . . . . . . 22-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-71 VER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-569 PRESSURE SENSOR/TRANSMITTER,
POWER MIRROR SWITCH - REMOVAL . . . 8N-71 POWERTRAIN VERIFICATION TEST, DIAGNOSIS AND TESTING - RIGHT
POWER MIRRORS - SERVICE VER 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-570 REAR TIRE . . . . . . . . . . . . . . . . . . . . . . . . . 22-30
INFORMATION - DESCRIPTION . . . . . . . . . . 8N-66 POWERTRAIN VERIFICATION TEST, PRESSURE SENSOR/TRANSMITTER,
POWER MIRRORS - SERVICE VER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 DIAGNOSIS AND TESTING - TIRE . . . . . . . . 22-19
INFORMATION - DIAGNOSIS AND POWERTRAIN VERIFICATION TEST, PRESSURE SENSOR/TRANSMITTER LOW
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-66 VER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-571 BATTERY, DIAGNOSIS AND TESTING -
POWER MIRRORS - SERVICE POWERTRAIN VERIFICATION TEST, TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-32
INFORMATION - OPERATION . . . . . . . . . . . 8N-66 VER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-572 PRESSURE SENSOR/TRANSMITTER
POWER MIRRORS INOPERATIVE, POWERTRAIN VERIFICATION TEST, SIGNAL JAMMED, DIAGNOSIS AND
DIAGNOSIS AND TESTING - BOTH . . . . . . . 8N-57 VER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-573 TESTING - LEFT FRONT TIRE . . . . . . . . . . . 22-11
POWER SEAT FRONT RISER MOTOR PREFERENCES - STANDARD PRESSURE SENSOR/TRANSMITTER
INOPERATIVE, DIAGNOSIS AND PROCEDURE, TOGGLING CUSTOMER . . . . 8N-35 SIGNAL JAMMED, DIAGNOSIS AND
TESTING - DRIVER . . . . . . . . . . . . . . . . . . . 8N-85 PRELIMINARY - DIAGNOSIS AND TESTING - LEFT REAR TIRE . . . . . . . . . . . . 22-13
POWER SEAT HORIZONTAL MOTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-206 PRESSURE SENSOR/TRANSMITTER
INOPERATIVE, DIAGNOSIS AND PREPARATION - STANDARD SIGNAL JAMMED, DIAGNOSIS AND
TESTING - DRIVER . . . . . . . . . . . . . . . . . . . 8N-83 PROCEDURE, ENGINE GASKET TESTING - RIGHT FRONT TIRE . . . . . . . . . . 22-15
POWER SEAT HORIZONTAL MOTOR SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-590 PRESSURE SENSOR/TRANSMITTER
INOPERATIVE, DIAGNOSIS AND PRESSURE - DIAGNOSIS AND TESTING, SIGNAL JAMMED, DIAGNOSIS AND
TESTING - PASSENGER . . . . . . . . . . . . . . . 8N-91 CHECKING ENGINE OIL. . . . . . . . . . . . . . . . . 9-662 TESTING - RIGHT REAR TIRE . . . . . . . . . . . 22-17
POWER SEAT INOPERATIVE, DIAGNOSIS PRESSURE - DIAGNOSIS AND TESTING, PRESSURE SENSOR/TRANSMITTER
AND TESTING - DRIVER . . . . . . . . . . . . . . . 8N-74 STEERING FLOW . . . . . . . . . . . . . . . . . . . . . . 19-5 SIGNAL JAMMED, DIAGNOSIS AND
POWER SEAT INOPERATIVE, DIAGNOSIS PRESSURE BLEEDING - STANDARD TESTING - TIRE. . . . . . . . . . . . . . . . . . . . . . . . 22-6
AND TESTING - PASSENGER . . . . . . . . . . . 8N-76 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 PRESSURE SOLENOID CIRCUIT,
POWER SEAT REAR RISER MOTOR PRESSURE CAP - CLEANING . . . . . . . . . . . . 7-36 DIAGNOSIS AND TESTING - (P0748)
INOPERATIVE, DIAGNOSIS AND PRESSURE CAP - OPERATION . . . . . . . . . . . 7-36 MODULATING . . . . . . . . . . . . . . . . . . . . . . 21-128
TESTING - DRIVER . . . . . . . . . . . . . . . . . . . 8N-87 PRESSURE CAP - WARNING . . . . . . . . . . . . . 7-36 PRESSURE SOLENOID CIRCUIT,
POWER SEAT RECLINER MOTOR PRESSURE FOR HIGH SPEED, DIAGNOSIS AND TESTING - (P0778)
INOPERATIVE, DIAGNOSIS AND DESCRIPTION - TIRE . . . . . . . . . . . . . . . . . . 22-58 SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-150
TESTING - DRIVER . . . . . . . . . . . . . . . . . . . 8N-81 PRESSURE LEAK DOWN TEST - PRESSURE TEST - DIAGNOSIS AND
POWER SEAT RECLINER MOTOR DIAGNOSIS AND TESTING, FUEL . . . . . . . . . 14-4 TESTING, CYLINDER COMPRESSION . . . . . 9-587
INOPERATIVE, DIAGNOSIS AND PRESSURE LEAKAGE TEST - DIAGNOSIS PRESSURE TRANSDUCER -
TESTING - PASSENGER . . . . . . . . . . . . . . . 8N-89 AND TESTING, CYLINDER INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-86
POWER SEAT SWITCH - DIAGNOSIS COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . 9-588 PRESSURE TRANSDUCER - REMOVAL,
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-96 PRESSURE MONITOR, DIAGNOSIS AND A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-86
POWER SEAT SWITCH - INSTALLATION . . . 8N-98 TESTING - NO RESPONSE FROM PRESSURE VERIFICATION TEST,
POWER SEAT SWITCH - REMOVAL . . . . . . 8N-96 UNIVERSAL GARAGE DOOR DIAGNOSIS AND TESTING - TIRE . . . . . . . . 22-35
POWER SEAT TRACK - INSTALLATION . . . 8N-107 OPENER/TIRE . . . . . . . . . . . . . . . . . . . . . . . 8E-17 PRESSURES, DESCRIPTION - TIRE
POWER SEAT TRACK - REMOVAL . . . . . . 8N-105 PRESSURE MONITOR MODULE FAILURE, INFLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 22-57
POWER SEATS - SERVICE INFORMATION DIAGNOSIS AND TESTING - TIRE . . . . . . . . . 22-4 PROCESSOR, DIAGNOSIS AND TESTING
- DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8N-95 PRESSURE MONITORING - - (P0221) ELECTRONIC THROTTLE
POWER SEATS - SERVICE INFORMATION DESCRIPTION, TIRE . . . . . . . . . . . . . . . . . . 22-46 CONTROL MODULE . . . . . . . . . . . . . . . . . . . 9-272
- DIAGNOSIS AND TESTING . . . . . . . . . . . . 8N-96 PRESSURE MONITORING - OPERATION, PROGRAM (ESP) - OPERATION,
POWER SEATS - SERVICE INFORMATION TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-48 ELECTRONIC STABILITY . . . . . . . . . . . . . . . 5-189
- OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8N-95 PRESSURE MONITORING SYSTEM - PROGRAMMING - STANDARD
POWER SEATS - SERVICE INFORMATION DIAGNOSIS AND TESTING, TIRE . . . . . . . . . 22-48 PROCEDURE, ORC . . . . . . . . . . . . . . . . . . . 8O-89
- SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 8N-96 PRESSURE MONITORING SYSTEM, PROGRAMMING - STANDARD
POWER SEATS INOPERATIVE, SPECIFICATIONS - TIRE . . . . . . . . . . . . . . . 22-49 PROCEDURE, PCM/SKREEM . . . . . . . . . . . . 8E-54
DIAGNOSIS AND TESTING - BOTH . . . . . . . 8N-78 PRESSURE RELEASE PROCEDURE - PROGRAMMING - STANDARD
POWER STEERING SYSTEM, DIAGNOSIS STANDARD PROCEDURE, FUEL PROCEDURE, TPM MODULE . . . . . . . . . . . . 22-50
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 19-2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 PROGRAMMING - STANDARD
POWER UP, DIAGNOSIS AND TESTING - PRESSURE RELIEF VALVE - PROCEDURE, TRANSMITTER . . . . . . . . . . . 8N-37
DRB IIIT DOES NOT . . . . . . . . . . . . . . . . . . . 8E-2 DESCRIPTION, OIL . . . . . . . . . . . . . . . . . . . 9-677 PROGRAMMING - STANDARD
POWER WINDOW INOPERATIVE, PRESSURE SENSOR - DESCRIPTION, PROCEDURE, UNIVERSAL
DIAGNOSIS AND TESTING - LEFT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-201 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 8M-3
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-110 PRESSURE SENSOR - INSTALLATION, PROGRAMMING DOES NOT
POWER WINDOW INOPERATIVE, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-201,5-77 CORRESPOND TO THE VEHICLE
DIAGNOSIS AND TESTING - RIGHT PRESSURE SENSOR - OPERATION, EQUIPMENT, DIAGNOSIS AND TESTING . . . 8O-41
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-113 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-201 PROP - INSTALLATION, GAS . . . . . . 23-127,23-41
POWER WINDOW SWITCH - PRESSURE SENSOR - REMOVAL, BRAKE . 5-201, PROP - REMOVAL, GAS . . . . . . . . . 23-126,23-40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . 8N-124 5-76 PROPELLER SHAFT - DESCRIPTION . . . . . . . 3-23
POWER WINDOW SWITCH - REMOVAL . . 8N-124 PRESSURE SENSOR 1 CIRCUIT, PROPELLER SHAFT - DIAGNOSIS AND
POWER WINDOWS - SERVICE DIAGNOSIS AND TESTING - ESP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
INFORMATION - DESCRIPTION . . . . . . . . . 8N-121 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128 PROPELLER SHAFT - INSTALLATION . . . . . . 3-28
POWER WINDOWS - SERVICE PRESSURE SENSOR 2 CIRCUIT, PROPELLER SHAFT - REMOVAL . . . . . . . . . . 3-26
INFORMATION - DIAGNOSIS AND DIAGNOSIS AND TESTING - ESP PROPELLER SHAFT - WARNING . . . . . . . . . . 3-23
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-121 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133 PULLEY - INSTALLATION, IDLER . . . . . . . . . 7-48
POWER WINDOWS - SERVICE PRESSURE SENSOR CIRCUIT, PULLEY - REMOVAL, IDLER . . . . . . . . . . . . . 7-47
INFORMATION - OPERATION . . . . . . . . . . 8N-121 DIAGNOSIS AND TESTING - A/C . . . . . . . . . 24-28 PUMP - ASSEMBLY, OIL . . . . . . . . . . . . . . 21-313
POWER WINDOWS INOPERATIVE, PRESSURE SENSOR CIRCUIT HIGH, PUMP - CLEANING, OIL . . . . . . . . . . . . . . . 9-675
DIAGNOSIS AND TESTING - BOTH . . . . . . 8N-116 DIAGNOSIS AND TESTING - (P0453) PUMP - DESCRIPTION, CENTRAL
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 9-397 LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-36
PUMP - DESCRIPTION, FUEL . . . . . . . . . . . 14-15
24 INDEX ZH

PUMP - DESCRIPTION, OIL . . . . . . . . . . . . . 9-674 RAIL - OPERATION, FUEL . . . . . . . . . . . . . . 14-18 REAR SPEAKER, DIAGNOSIS AND
PUMP - DESCRIPTION, OIL . . . . . . . . . . . . 21-312 RAIL - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-19 TESTING - NO SOUND FROM RIGHT . . . . . 8A-14
PUMP - DESCRIPTION, WATER . . . . . . . . . . 7-36 RANGE INDICATOR ILLUMINATION - REAR SPOILER - DESCRIPTION . . . . . . . . 23-116
PUMP - DIAGNOSIS AND TESTING, DESCRIPTION, T/C . . . . . . . . . . . . . . . . . . 8L-150 REAR SPOILER - OPERATION . . . . . . . . . . 23-116
CENTRAL LOCKING . . . . . . . . . . . . . . . . . . . 8N-36 RATE SENSOR - DESCRIPTION, YAW . . . . . 5-201 REAR SPOILER DRIVER (DOWN)
PUMP - DISASSEMBLY, OIL . . . . . . . . . . . 21-312 RATE SENSOR - INSTALLATION, YAW . . . . 5-201 CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 23-16
PUMP - INSPECTION, WATER . . . . . . . . . . . . 7-38 RATE SENSOR - OPERATION, YAW . . . . . . . 5-201 REAR SPOILER DRIVER (UP) CIRCUIT,
PUMP - INSTALLATION, AIR . . . . . . . . . . . . 25-33 RATE SENSOR - REMOVAL, YAW . . . . . . . . 5-201 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 23-13
PUMP - INSTALLATION, OIL . . . . . . . . . . . . 9-676 RATE SENSOR CIRCUIT, DIAGNOSIS AND REAR SPOILER LIMIT SWITCH FAILURE,
PUMP - INSTALLATION, WATER . . . . . . . . . . 7-40 TESTING - ESP YAW . . . . . . . . . . . . . . . . . . 5-119 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 23-19
PUMP - OPERATION, FUEL . . . . . . . . . . . . . 14-15 RATIO, DIAGNOSIS AND TESTING - REAR SPOILER MOTOR FAILURE,
PUMP - OPERATION, OIL . . . . . . . . . . . . . 21-312 (P0730) IMPROPER . . . . . . . . . . . . . . . . . . 21-116 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 23-23
PUMP - REMOVAL, AIR . . . . . . . . . . . . . . . . 25-32 RATIOS - SPECIFICATIONS, GEAR . . . . . . . 21-349 REAR SPOILER SWITCH SENSE CIRCUIT,
PUMP - REMOVAL, OIL . . . . . . . . . . . . . . . . 9-674 REAR - INSTALLATION, CRANKSHAFT DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 23-4
PUMP - REMOVAL, WATER . . . . . . . . . . . . . . 7-37 OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-635 REAR SPOILER VERIFICATION TEST,
PUMP CIRCUIT, DIAGNOSIS AND REAR - REMOVAL, CRANKSHAFT OIL DIAGNOSIS AND TESTING . . . . . . . . . . . . . 23-27
TESTING - COOLANT CIRCULATION . . . . . . 24-34 SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-634 REAR SUSPENSION - SPECIFICATIONS . . . . 2-48
PUMP DRIVE CHAIN - INSTALLATION, REAR AXLE CAMBER - STANDARD REAR TIRE PRESSURE SENSOR/
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-677 PROCEDURE, CHECKING . . . . . . . . . . . . . . . . 2-11 TRANSMITTER, DIAGNOSIS AND
PUMP DRIVE CHAIN - REMOVAL, OIL . . . . 9-677 REAR AXLE CARRIER - INSTALLATION . . . . . 2-93 TESTING - LEFT . . . . . . . . . . . . . . . . . . . . . . 22-26
PUMP INITIAL OPERATION, STANDARD REAR AXLE CARRIER - REMOVAL . . . . . . . . 2-87 REAR TIRE PRESSURE SENSOR/
PROCEDURE - STEERING . . . . . . . . . . . . . . 19-51 REAR AXLE TOE - STANDARD TRANSMITTER, DIAGNOSIS AND
PUMP MOTOR - INSTALLATION, PROCEDURE, CHECKING AND TESTING - RIGHT . . . . . . . . . . . . . . . . . . . . 22-30
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-31 ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 REAR TIRE PRESSURE SENSOR/
PUMP MOTOR - REMOVAL, WASHER . . . . 8R-31 REAR AXLES, STANDARD PROCEDURE - TRANSMITTER SIGNAL JAMMED,
PUMP RELAY - DESCRIPTION, FUEL . . . . . 14-35 INSPECTING AND ADJUSTING VEHICLE DIAGNOSIS AND TESTING - LEFT . . . . . . . . 22-13
PUMP RELAY - OPERATION, FUEL . . . . . . . 14-35 LEVEL AT FRONT . . . . . . . . . . . . . . . . . . . . . . . 2-8 REAR TIRE PRESSURE SENSOR/
PUMP TEST, DIAGNOSIS AND TESTING - REAR AXLES WITH AN ELECTRONIC TRANSMITTER SIGNAL JAMMED,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 INCLINOMETER, STANDARD DIAGNOSIS AND TESTING - RIGHT . . . . . . 22-17
PUMP/SECURITY SYSTEM MODULE, PROCEDURE - INSPECTING AND REAR TURN LAMP INOPERATIVE,
DIAGNOSIS AND TESTING - NO ADJUSTING VEHICLE LEVEL AT FRONT . . . . . 2-8 DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8L-53
COMMUNICATION WITH BCM AND REAR BRAKE CALIPER - REMOVAL . . . . . . . . . 5-28 REAR TURN LAMP INOPERATIVE,
CENTRAL LOCKING . . . . . . . . . . . . . . . . . . . . 8Q-8 REAR BRAKE HOSE - INSTALLATION . . . . . . 5-16 DIAGNOSIS AND TESTING - RIGHT . . . . . . 8L-65
PUMP/SECURITY SYSTEM MODULE, REAR BRAKE HOSE, REMOVAL . . . . . . . . . . . 5-13 REAR WHEEL SPEED SENSOR -
DIAGNOSIS AND TESTING - NO REAR CENTER CONSOLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-196
COMMUNICATION WITH BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-188 REAR WHEEL SPEED SENSOR -
CONTROL MODULE AND CENTRAL REAR CENTER CONSOLE - REMOVAL . . . . 23-178 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5-198
LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20 REAR DEFOGGER SWITCH SENSE REAR WHEEL SPEED SENSOR -
PUMP/SECURITY SYSTEM MODULE CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . 8G-2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
INTERNAL FAILURE, DIAGNOSIS AND REAR DIFFERENTIAL - DESCRIPTION . . . . . . 3-37 REAR WHEEL SPEED SENSOR -
TESTING - CENTRAL LOCKING . . . . . . . . . . 8N-26 REAR DIFFERENTIAL - DIAGNOSIS AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
PUMP/SECURITY SYSTEM MODULE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 REAR WHEEL SPEED SENSOR CIRCUIT,
INTERNAL FAILURE, DIAGNOSIS AND REAR DIFFERENTIAL - OPERATION . . . . . . . 3-37 DIAGNOSIS AND TESTING - LEFT . . . . . . . . 5-107
TESTING - CENTRAL LOCKING . . . . . . . . . . 8Q-30 REAR DIFFERENTIAL - SPECIAL TOOLS . . . . 3-41 REAR WHEEL SPEED SENSOR CIRCUIT,
PUMP/SECURITY SYSTEM MODULE REAR DIFFERENTIAL HOUSING - DIAGNOSIS AND TESTING - RIGHT . . . . . . 5-113
SYSTEM OVERVOLTAGE, DIAGNOSIS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-42 REAR WINDOW ANTENNA -
AND TESTING - CENTRAL LOCKING . . . . . . . 8Q-5 REAR DIFFERENTIAL HOUSING - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8A-24
PUMP/SECURITY SYSTEM MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 REAR WINDOW ANTENNA -
SYSTEM UNDERVOLTAGE, DIAGNOSIS REAR DISC BRAKE CALIPER - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-26
AND TESTING - CENTRAL LOCKING . . . . . . . 8Q-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-35 REAR WINDOW ANTENNA - REMOVAL . . . 8A-25
PURGE SOLENOID - DESCRIPTION, EVAP . 25-17 REAR DISC BRAKE PADS - REAR WINDOW ANTENNA MODULE -
PURGE SOLENOID - INSTALLATION, INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-23
EVAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 REAR DISC BRAKE PADS - REMOVAL . . . . . 5-19 REAR WINDOW ANTENNA MODULE -
PURGE SOLENOID - OPERATION, EVAP . . . 25-17 REAR DISC BRAKE ROTOR - REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-23
PURGE SOLENOID - REMOVAL, EVAP . . . . 25-17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-42 REAR WINDOW DEFOGGER GRID -
PURGE SOLENOID CIRCUIT, DIAGNOSIS REAR DISC BRAKE ROTOR - REMOVAL . . . . 5-39 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8G-12
AND TESTING - (P0445) EVAP . . . . . . . . . . 9-380 REAR FASCIA - INSTALLATION . . . . . . . . . . . 13-8 REAR WINDOW DEFOGGER
PURGE SOLENOID STUCK OPEN, REAR FASCIA - REMOVAL . . . . . . . . . . . . . . . 13-7 INOPERATIVE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - (P0446) REAR GLASS HEATING GRID REPAIR - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
EVAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-387 STANDARD PROCEDURE . . . . . . . . . . . . . . 8G-13 REAR WINDOW DEFOGGER SWITCH -
PURGE VALVE, DIAGNOSIS AND REAR HEAT SHIELD - INSTALLATION . . . . . . 11-9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-12
TESTING - (P0441) EVAP . . . . . . . . . . . . . . 9-376 REAR HEAT SHIELD - REMOVAL . . . . . . . . . 11-8 REAR WINDOW DEFOGGER SWITCH -
PURGE VALVE LEAKING, DIAGNOSIS REAR MARKER LAMP, INSTALLATION . . . 8L-111 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
AND TESTING - (P0457) EVAP . . . . . . . . . . 9-406 REAR MARKER LAMP, REMOVAL . . . . . . . 8L-110 REAR WINDOW DEFOGGER SYSTEM -
QUICK LEARN - STANDARD REAR MOUNT - INSTALLATION . . . . . . . . . . 9-660 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8G-11
PROCEDURE, TCM . . . . . . . . . . . . . . . . . . . 8E-59 REAR MOUNT - REMOVAL . . . . . . . . . . . . . 9-659 REARVIEW MIRROR, INSTALLATION . . . . . 8N-69
RADIAL, PLY TIRES . . . . . . . . . . . . . . . . . . . 22-57 REAR PANEL SPEAKER - INSTALLATION . . 8A-33 REARVIEW MIRROR SUPPORT BRACKET
RADIATOR - CLEANING . . . . . . . . . . . . . . . . . 7-34 REAR PANEL SPEAKER - REMOVAL . . . . . . 8A-29 - INSTALLATION . . . . . . . . . . . . . . . . . . . . . 8N-69
RADIATOR - DESCRIPTION . . . . . . . . . . . . . . 7-32 REAR RISER MOTOR - INSTALLATION . . . 8N-100 RECEIVER / DRIER - DESCRIPTION . . . . . 24-145
RADIATOR - INSPECTION . . . . . . . . . . . . . . . 7-34 REAR RISER MOTOR - REMOVAL . . . . . . . 8N-99 RECEIVER / DRIER - INSTALLATION . . . . . 24-147
RADIATOR - INSTALLATION . . . . . . . . . . . . . 7-35 REAR RISER MOTOR INOPERATIVE, RECEIVER / DRIER - OPERATION . . . . . . . 24-146
RADIATOR - REMOVAL . . . . . . . . . . . . . . . . . 7-33 DIAGNOSIS AND TESTING - DRIVER RECEIVER / DRIER - REMOVAL . . . . . . . . 24-146
RADIATOR COOLING FAN ALWAYS ON, POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8N-87 RECEIVER LAMP - INSTALLATION, ASH . . 8L-153
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 7-6 REAR SECTION HOUSING - ASSEMBLY . . 21-362 RECEIVER LAMP - REMOVAL, ASH . . . . . . 8L-151
RADIATOR COOLING FAN INOPERATIVE, REAR SECTION HOUSING - RECEIVER LAMP INOPERATIVE,
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 7-2 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-362 DIAGNOSIS AND TESTING - ASH . . . . . . . 8L-130
RADIATOR FAN - INSTALLATION . . . . . . . . . . 7-27 REAR SENSOR MESSAGE, DIAGNOSIS RECIRC AIR SWITCHOVER VALVE -
RADIATOR FAN - REMOVAL . . . . . . . . . . . . . 7-26 AND TESTING - (P0600) ABS LEFT . . . . . . . 21-25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24-87
RADIATOR FAN CONTROL MODULE - REAR SENSOR MESSAGE, DIAGNOSIS RECIRC AIR SWITCHOVER VALVE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-29 AND TESTING - (P0600) ABS RIGHT . . . . . 21-31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-87
RADIATOR FAN CONTROL MODULE - REAR SIDE MARKER LAMP RECIRCULATED AIR SWITCHOVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 INOPERATIVE, DIAGNOSIS AND VALVE CIRCUIT, DIAGNOSIS AND
RADIO - INSTALLATION . . . . . . . . . . . . . . . 8A-28 TESTING - LEFT . . . . . . . . . . . . . . . . . . . . . . 8L-38 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-46
RADIO - REMOVAL . . . . . . . . . . . . . . . . . . . 8A-27 REAR SIDE MARKER LAMP RECLINER MOTOR - INSTALLATION . . . . . 8N-104
RADIO INOPERATIVE, DIAGNOSIS AND INOPERATIVE, DIAGNOSIS AND RECLINER MOTOR - REMOVAL . . . . . . . . 8N-103
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 TESTING - RIGHT . . . . . . . . . . . . . . . . . . . . 8L-41 RECLINER MOTOR INOPERATIVE,
RAIL - DESCRIPTION, FUEL . . . . . . . . . . . . 14-18 REAR SPEAKER, DIAGNOSIS AND DIAGNOSIS AND TESTING - DRIVER
RAIL - INSTALLATION, FUEL . . . . . . . . . . . . 14-20 TESTING - NO SOUND FROM LEFT . . . . . . 8A-12 POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8N-81
ZH INDEX 25

RECLINER MOTOR INOPERATIVE, RELEASE SWITCH - INSTALLATION . . . . . . 5-203 REVERSE LOCKOUT CABLE -
DIAGNOSIS AND TESTING - RELEASE SWITCH - OPERATION . . . . . . . . . 5-203 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-388
PASSENGER POWER SEAT . . . . . . . . . . . . . 8N-89 RELEASE SWITCH - REMOVAL . . . . . . . . . . 5-203 REVERSE SHAFT - DESCRIPTION . . . . . . . 21-363
RECOVERY - STANDARD PROCEDURE, RELEASE SWITCH CIRCUIT, DIAGNOSIS REVERSED, DIAGNOSIS AND TESTING -
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . 24-117 AND TESTING - BAS . . . . . . . . . . . . . . . . . . 5-166 (P0040) 1/1 AND 2/1 O2 SENSOR
RECOVERY RESERVOIR - INSTALLATION, RELIEF VALVE - DESCRIPTION, OIL HARNESS CONNECTORS . . . . . . . . . . . . . . . . . 9-5
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-677 RICH CONTROL OVER LIMIT (AT IDLE),
RECOVERY RESERVOIR - OPERATION, REMAINING FSS MILEAGE AT DRIVER’S DIAGNOSIS AND TESTING - (P0171)
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 REQUEST, STANDARD PROCEDURE - FUEL SYSTEM 1/1 . . . . . . . . . . . . . . . . . . . . 9-183
RECOVERY RESERVOIR - REMOVAL, DISPLAY OF . . . . . . . . . . . . . . . . . . . . . . . . . 8J-75 RICH CONTROL OVER LIMIT (AT IDLE),
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 REMOTE ENTRY MODULE - DIAGNOSIS AND TESTING - (P0174)
REDUCTION, DIAGNOSIS AND TESTING - DESCRIPTION, SENTRY KEY . . . . . . . . . . . . 8E-69 FUEL SYSTEM 2/1 . . . . . . . . . . . . . . . . . . . . 9-218
(P1793) ENGINE TORQUE . . . . . . . . . . . . . 21-163 REMOTE ENTRY MODULE - RICH CONTROL OVER LIMIT (AT LOAD),
REFILL - STANDARD PROCEDURE, DESCRIPTION, SENTRY KEY . . . . . . . . . . . . 8N-46 DIAGNOSIS AND TESTING - (P0171)
DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 REMOTE ENTRY MODULE - FUEL SYSTEM 1/1 . . . . . . . . . . . . . . . . . . . . 9-187
REFILLING COOLING SYSTEM - DESCRIPTION, SENTRY KEY . . . . . . . . . . . . 8Q-52 RICH CONTROL OVER LIMIT (AT LOAD),
STANDARD PROCEDURE . . . . . . . . . . . . . . . . 7-18 REMOTE ENTRY MODULE - DIAGNOSIS DIAGNOSIS AND TESTING - (P0173)
REFRIGERANT - DESCRIPTION . . . . . . . . . 24-148 AND TESTING, SENTRY KEY . . . . . . . . . . . . 8N-47 FUEL SYSTEM 2/1 . . . . . . . . . . . . . . . . . . . . 9-211
REFRIGERANT - OPERATION . . . . . . . . . . . 24-148 REMOTE ENTRY MODULE - RICH CONTROL OVER LIMIT (AT LOAD),
REFRIGERANT LINES/HOSES/TUBES - INSTALLATION, SENTRY KEY . . . . . . . . . . . 8Q-55 DIAGNOSIS AND TESTING - (P0174)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 24-114 REMOTE ENTRY MODULE - OPERATION, FUEL SYSTEM 2/1 . . . . . . . . . . . . . . . . . . . . 9-221
REFRIGERANT OIL - DESCRIPTION . . . . . . 24-148 SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-69 RING - INSTALLATION, SENTRY KEY
REFRIGERANT OIL - OPERATION . . . . . . . 24-149 REMOTE ENTRY MODULE - OPERATION, ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-55
REFRIGERANT OIL LEVEL - STANDARD SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8Q-52 RING - REMOVAL, SENTRY KEY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 24-149 REMOTE ENTRY MODULE - REMOVAL, ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-54
REFRIGERANT RECOVERY - STANDARD SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8Q-53 RINGS - INSTALLATION, PISTON . . . . . . . . 9-645
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 24-117 REMOTE ENTRY MODULE, DIAGNOSIS RINGS - REMOVAL, PISTON . . . . . . . . . . . . 9-645
REFRIGERANT SYSTEM CHARGE - AND TESTING - NO RESPONSE FROM RISER MOTOR - INSTALLATION, FRONT . 8N-102
STANDARD PROCEDURE . . . . . . . . . . . . . . 24-118 SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-40 RISER MOTOR - INSTALLATION, REAR . . 8N-100
REFRIGERANT SYSTEM EVACUATE - REMOTE ENTRY MODULE INTERNAL RISER MOTOR - REMOVAL, FRONT . . . . . 8N-102
STANDARD PROCEDURE . . . . . . . . . . . . . . 24-117 FAILURE, DIAGNOSIS AND TESTING - RISER MOTOR - REMOVAL, REAR . . . . . . . 8N-99
REFRIGERANT SYSTEM LEAKS - SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8Q-34 RISER MOTOR INOPERATIVE,
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . 24-116 REMOTE KEYLESS ENTRY RELAY DIAGNOSIS AND TESTING - DRIVER
REFRIGERANT SYSTEM SERVICE CONTROL CIRCUIT, DIAGNOSIS AND POWER SEAT FRONT . . . . . . . . . . . . . . . . . . . 8N-85
EQUIPMENT, STANDARD PROCEDURE . . . 24-116 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 RISER MOTOR INOPERATIVE,
REFRIGERANT SYSTEM SERVICE PORT - REPAIR - STANDARD PROCEDURE, DIAGNOSIS AND TESTING - DRIVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-58 ANTENNA GRID . . . . . . . . . . . . . . . . . . . . . . 8A-24 POWER SEAT REAR . . . . . . . . . . . . . . . . . . 8N-87
REGULATOR - DESCRIPTION, FUEL REPAIR - STANDARD PROCEDURE, ROAD DETECTED, DIAGNOSIS AND
FILTER/PRESSURE . . . . . . . . . . . . . . . . . . . . . 14-8 REAR GLASS HEATING GRID . . . . . . . . . . . 8G-13 TESTING - (P1600) ROUGH . . . . . . . . . . . . 9-493
REGULATOR - DESCRIPTION, VOLTAGE . . . 8F-30 REPAIR, DESCRIPTION - THREADED ROAD TEST - DIAGNOSIS AND TESTING,
REGULATOR - INSTALLATION, BLOWER HOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5-191
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-76 RESERVOIR - INSTALLATION, COOLANT ROAD TESTING - DIAGNOSIS AND
REGULATOR - INSTALLATION, FUEL RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-206
FILTER/PRESSURE . . . . . . . . . . . . . . . . . . . . 14-10 RESERVOIR - INSTALLATION, WASHER . . . 8R-32 ROCKER PANEL MOLDING -
REGULATOR - INSTALLATION, WINDOW . 23-102 RESERVOIR - OPERATION, COOLANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-125
REGULATOR - OPERATION, FUEL RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 ROCKER PANEL MOLDING - REMOVAL . . 23-125
FILTER/PRESSURE . . . . . . . . . . . . . . . . . . . . . 14-9 RESERVOIR - REMOVAL, COOLANT ROD - DESCRIPTION, PISTON AND
REGULATOR - REMOVAL, BLOWER RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . 9-639
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-74 RESERVOIR - REMOVAL, WASHER . . . . . . 8R-32 ROD - INSTALLATION, GEAR SHIFT . . . . . 21-341
REGULATOR - REMOVAL, FUEL RESETTING THE FSS MAINTENANCE ROD - REMOVAL, GEAR SHIFT . . . . . . . . . 21-341
FILTER/PRESSURE . . . . . . . . . . . . . . . . . . . . 14-10 INDICATOR AFTER AN OIL CHANGE, ROD BEARINGS - DESCRIPTION,
REGULATOR - REMOVAL, WINDOW . . . . . 23-101 STANDARD PROCEDURE . . . . . . . . . . . . . . . 8J-78 CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . 9-638
RELAY - DESCRIPTION, BRAKE LAMP . . . . 8L-90 RESETTING THE FSS MAINTENANCE ROD END - INSTALLATION, TIE . . . . . . . . . 19-50
RELAY - DESCRIPTION, FUEL PUMP . . . . . 14-35 INDICATOR, STANDARD PROCEDURE . . . . . 8J-76 ROD END - REMOVAL, TIE . . . . . . . . . . . . . 19-49
RELAY - DESCRIPTION, HORN . . . . . . . . . . 8H-14 RESIDUAL ENGINE HEAT SYSTEM RODS AND BEARINGS - STANDARD
RELAY - INSTALLATION . . . . . . . . . . . . . . . 8N-50 (REST) - DESCRIPTION . . . . . . . . . . . . . . . . 24-57 PROCEDURE, CONNECTING . . . . . . . . . . . . 9-638
RELAY - INSTALLATION, BRAKE LAMP . . . . 8L-90 REST SYSTEM - OPERATION . . . . . . . . . . . 24-64 ROTATION - STANDARD PROCEDURE,
RELAY - OPERATION, BRAKE LAMP . . . . . . 8L-90 RESTRAINT CONTROLLER - TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-45
RELAY - OPERATION, FUEL PUMP . . . . . . . 14-35 DESCRIPTION, OCCUPANT . . . . . . . . . . . . . 8O-87 ROTOR - INSTALLATION, REAR DISC
RELAY - REMOVAL . . . . . . . . . . . . . . . . . . . 8N-48 RESTRAINT CONTROLLER - BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
RELAY - REMOVAL, BRAKE LAMP . . . . . . . 8L-90 INSTALLATION, OCCUPANT . . . . . . . . . . . . 8O-91 ROTOR - REMOVAL, REAR DISC BRAKE . . . 5-39
RELAY CIRCUIT, DIAGNOSIS AND RESTRAINT CONTROLLER - OPERATION, ROTOR, INSTALLATION - FRONT DISC
TESTING - (P0410) SECONDARY AIR OCCUPANT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-88 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-362 RESTRAINT CONTROLLER - REMOVAL, ROTOR MACHINING, STANDARD
RELAY CONTROL CIRCUIT, DIAGNOSIS OCCUPANT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-89 PROCEDURE - DISC BRAKE . . . . . . . . . . . . . 5-38
AND TESTING - REMOTE KEYLESS RESTRAINT CONTROLLER, DIAGNOSIS ROTOR, REMOVAL - FRONT DISC BRAKE . . 5-38
ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-40 AND TESTING - NO RESPONSE FROM ROTORS, DIAGNOSIS AND TESTING -
RELAY CONTROL MODULE - OCCUPANT . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10 DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-3 RESTRAINT DEPLOYMENT - STANDARD RUNNER SOLENOID CIRCUIT,
RELAY CONTROL MODULE - PROCEDURE, SERVICE AFTER A DIAGNOSIS AND TESTING - SHORT . . . . . . 9-551
INSTALLATION . . . . . . . . . . . . . . . . . . . . 8W-97-4 SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . 8O-84 RUNNER SOLENOID CIRCUIT HIGH,
RELAY CONTROL MODULE - RESTRAINT SYSTEM - DIAGNOSIS AND DIAGNOSIS AND TESTING - SHORT . . . . . . 9-545
OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8W-97-3 TESTING, SUPPLEMENTAL . . . . . . . . . . . . . 8O-83 RUNNER SOLENOID CIRCUIT LOW,
RELAY CONTROL MODULE - REMOVAL . 8W-97-4 RESTRAINT SYSTEM (SRS) - DIAGNOSIS AND TESTING - SHORT . . . . . . 9-549
RELEASE BEARING/SLAVE CYLINDER - VERIFICATION TEST - STANDARD RUNOUT - DIAGNOSIS AND TESTING,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6-19 PROCEDURE, SUPPLEMENTAL . . . . . . . . . . 8O-86 TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . 22-38
RELEASE BEARING/SLAVE CYLINDER - RESTRAINTS - SERVICE INFORMATION - RUNOUT - SPECIFICATION . . . . . . . . . . . . . . 3-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6-20 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8O-70 SAFETY CERT LABEL - DESCRIPTION,
RELEASE BEARING/SLAVE CYLINDER - RESTRAINTS - SERVICE INFORMATION - VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8O-76 SAFETY FUEL SHUT OFF DETECTED,
RELEASE BEARING/SLAVE CYLINDER - RESTRAINTS - SERVICE INFORMATION - DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-540
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-82 SCHEMATICS AND DIAGRAMS,
RELEASE CABLE - INSTALLATION, LATCH . 23-139 RESTRAINTS - STANDARD PROCEDURE, CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8F-26
RELEASE CABLE - REMOVAL, LATCH . . . . 23-138 HANDLING NON-DEPLOYED SCHEMATICS AND DIAGRAMS,
RELEASE PROCEDURE - STANDARD SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . 8O-83 CHIME/BUZZER - ELECTRICAL
PROCEDURE, FUEL SYSTEM RESTRAINTS - TORQUE CHART . . . . . . . . . 8O-87 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 REVERSE FLUSHING - STANDARD SCHEMATICS AND DIAGRAMS,
RELEASE SWITCH - DESCRIPTION . . . . . . . 5-203 PROCEDURE, COOLING SYSTEM . . . . . . . . . 7-19 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8A-17
26 INDEX ZH

SCHEMATICS AND DIAGRAMS, SEAT BELT & SEAT BELT TENSIONER - SEATS INOPERATIVE, DIAGNOSIS AND
DIAGNOSIS AND TESTING . . . . . . . . 5-149,5-186 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 8O-122 TESTING - BOTH HEATED . . . . . . . . . . . . . . 8G-32
SCHEMATICS AND DIAGRAMS, SEAT BELT BUCKLE - DESCRIPTION . . . . 8O-115 SEATS INOPERATIVE, DIAGNOSIS AND
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 7-10 SEAT BELT BUCKLE - INSTALLATION . . . . 8O-117 TESTING - BOTH POWER . . . . . . . . . . . . . . 8N-78
SCHEMATICS AND DIAGRAMS, SEAT BELT BUCKLE - REMOVAL . . . . . . . . 8O-116 SECONDARY AIR INJECTION RELAY
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8E-45 SEAT BELT INDICATOR INOPERATIVE, CIRCUIT, DIAGNOSIS AND TESTING -
SCHEMATICS AND DIAGRAMS, DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8J-48 (P0410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-362
DIAGNOSIS AND TESTING . . . . 8G-21,8G-35,8G-9 SEAT BELT TENSIONER - DESCRIPTION, SECONDARY AIR INJECTION
SCHEMATICS AND DIAGRAMS, SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-119 SWITCHOVER SOLENOID CIRCUIT,
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8H-8 SEAT BELT TENSIONER - INSPECTION, DIAGNOSIS AND TESTING - (P0412) . . . . . 9-365
SCHEMATICS AND DIAGRAMS, SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-125 SECONDARY AIR INJECTION SYSTEM,
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8J-53 SEAT BELT TENSIONER - INSTALLATION, DIAGNOSIS AND TESTING - (P0410) . . . . . 9-356
SCHEMATICS AND DIAGRAMS, SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-125 SECTION - ASSEMBLY, TRANSMISSION
DIAGNOSIS AND TESTING . . . . . . . 8L-134,8L-78 SEAT BELT TENSIONER - OPERATION, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-361
SCHEMATICS AND DIAGRAMS, SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-120 SECTION HOUSING - ASSEMBLY, REAR . . 21-362
DIAGNOSIS AND SEAT BELT TENSIONER - REMOVAL, SECTION HOUSING - DISASSEMBLY,
TESTING . . . . . . . . . . 8N-120,8N-29,8N-63,8N-94 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-122 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-362
SCHEMATICS AND DIAGRAMS, SEAT BELT TENSIONER CIRCUIT, SECTION IDENTIFICATION AND
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-68 DIAGNOSIS AND TESTING - DRIVER . . . . . 8O-53 INFORMATION - DESCRIPTION . . . . . . . . 8W-01-5
SCHEMATICS AND DIAGRAMS, SEAT BELT TENSIONER CIRCUIT, SECURITY - SERVICE INFORMATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-44 DIAGNOSIS AND TESTING - DESCRIPTION, VEHICLE THEFT . . . . . . . . . 8Q-46
SCHEMATICS AND DIAGRAMS, PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-56 SECURITY - SERVICE INFORMATION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-20 SEAT BELT TENSIONER SQUIB CIRCUIT, OPERATION, VEHICLE THEFT . . . . . . . . . . . 8Q-47
SCHEMATICS AND DIAGRAMS, IGNITION DIAGNOSIS AND TESTING - DRIVER . . . . . 8O-10 SECURITY SYSTEM MODULE -
SYSTEM - ELECTRICAL DIAGNOSTICS . . . . . 8I-2 SEAT BELT TENSIONER SQUIB CIRCUIT, DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-65
SCHEMATICS AND DIAGRAMS, SPEED DIAGNOSIS AND TESTING - SECURITY SYSTEM MODULE -
CONTROL - ELECTRICAL DIAGNOSTICS . . . . 8P-2 PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8E-68
SCHEMATICS AND DIAGRAMS, SEAT CUSHION - INSTALLATION . . . . . . . . 23-213 SECURITY SYSTEM MODULE -
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 8F-39 SEAT CUSHION - REMOVAL . . . . . . . . . . . 23-211 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-49
SEAL - FRONT - INSTALLATION, SEAT CUSHION COVER - INSTALLATION . 23-217 SECURITY SYSTEM MODULE -
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . 9-636 SEAT CUSHION COVER - REMOVAL . . . . . 23-214 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-65
SEAL - FRONT - REMOVAL, SEAT CUSHION ELEMENT, INSTALLATION SECURITY SYSTEM MODULE -
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . 9-636 - HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-41 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-67
SEAL - INSTALLATION, DIFFERENTIAL SEAT CUSHION ELEMENT, REMOVAL - SECURITY SYSTEM MODULE -
CONNECTING FLANGE . . . . . . . . . . . . . . . . . . 3-47 HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-48
SEAL - INSTALLATION, INPUT SHAFT . . . . 21-360 SEAT ELEMENT - DESCRIPTION, HEATED . 8G-39 SENDING UNIT - DIAGNOSIS AND
SEAL - INSTALLATION, OUTPUT FLANGE . 21-356 SEAT FRONT RISER MOTOR TESTING, FUEL LEVEL . . . . . . . . . . . . . . . . . 14-12
SEAL - INSTALLATION, OUTPUT SHAFT . . 21-318 INOPERATIVE, DIAGNOSIS AND SENDING UNIT/SENSOR, DESCRIPTION -
SEAL - INSTALLATION, PINION FLANGE . . . . 3-45 TESTING - DRIVER POWER . . . . . . . . . . . . 8N-85 FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
SEAL - INSTALLATION, PITMAN SHAFT . . . 19-39 SEAT HORIZONTAL MOTOR SENDING UNIT/SENSOR, OPERATION -
SEAL - INSTALLATION, TORQUE INOPERATIVE, DIAGNOSIS AND FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
CONVERTER HUB . . . . . . . . . . . . . . . . . . . 21-337 TESTING - DRIVER POWER . . . . . . . . . . . . 8N-83 SENSE CIRCUIT, DIAGNOSIS AND
SEAL - INSTALLATION, VALVE STEM . . . . . 9-628 SEAT HORIZONTAL MOTOR TESTING - DOOR LOCK SWITCH . . . . . . . . 8Q-16
SEAL - REAR - INSTALLATION, INOPERATIVE, DIAGNOSIS AND SENSE CIRCUIT, DIAGNOSIS AND
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . 9-635 TESTING - PASSENGER POWER . . . . . . . . . 8N-91 TESTING - DOOR LOCK/DOOR UNLOCK
SEAL - REAR - REMOVAL, CRANKSHAFT SEAT INOPERATIVE, DIAGNOSIS AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-634 TESTING - DRIVER POWER . . . . . . . . . . . . 8N-74 SENSE CIRCUIT, DIAGNOSIS AND
SEAL - REMOVAL, DIFFERENTIAL SEAT INOPERATIVE, DIAGNOSIS AND TESTING - DOOR UNLOCK SWITCH . . . . . . 8Q-19
CONNECTING FLANGE . . . . . . . . . . . . . . . . . . 3-46 TESTING - LEFT HEATED . . . . . . . . . . . . . . 8G-26 SENSE CIRCUIT, DIAGNOSIS AND
SEAL - REMOVAL, INPUT SHAFT . . . . . . . 21-359 SEAT INOPERATIVE, DIAGNOSIS AND TESTING - REAR DEFOGGER SWITCH . . . . . 8G-2
SEAL - REMOVAL, OUTPUT FLANGE . . . . . 21-355 TESTING - PASSENGER POWER . . . . . . . . . 8N-76 SENSE CIRCUIT, DIAGNOSIS AND
SEAL - REMOVAL, OUTPUT SHAFT . . . . . . 21-318 SEAT INOPERATIVE, DIAGNOSIS AND TESTING - REAR SPOILER SWITCH . . . . . . . 23-4
SEAL - REMOVAL, PINION FLANGE . . . . . . . 3-43 TESTING - RIGHT HEATED . . . . . . . . . . . . . 8G-29 SENSITIVE DEVICES - STANDARD
SEAL - REMOVAL, PITMAN SHAFT . . . . . . . 19-38 SEAT MODULE - INSTALLATION, HEATED . 8G-42 PROCEDURE, ELECTROSTATIC
SEAL - REMOVAL, TORQUE CONVERTER SEAT MODULE - REMOVAL, HEATED . . . . . 8G-41 DISCHARGE (ESD) . . . . . . . . . . . . . . . . . 8W-01-9
HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-337 SEAT REAR RISER MOTOR SENSOR - DESCRIPTION . . . . . . . . . . . . . . . 22-52
SEAL - REMOVAL, VALVE STEM . . . . . . . . . 9-627 INOPERATIVE, DIAGNOSIS AND SENSOR - DESCRIPTION, ACCELERATOR
SEALER LOCATIONS - SPECIFICATIONS . . . 23-57 TESTING - DRIVER POWER . . . . . . . . . . . . 8N-87 PEDAL POSITION . . . . . . . . . . . . . . . . . . . . 14-28
SEALERS - STANDARD PROCEDURE, SEAT RECLINER MOTOR INOPERATIVE, SENSOR - DESCRIPTION, BRAKE
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . 9-589 DIAGNOSIS AND TESTING - DRIVER PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-201
SEALS - CLEANING, INTAKE/EXHAUST POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-81 SENSOR - DESCRIPTION, CRANKSHAFT
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-632 SEAT RECLINER MOTOR INOPERATIVE, POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
SEALS - DESCRIPTION, INTAKE/ DIAGNOSIS AND TESTING - SENSOR - DESCRIPTION, FRONT WHEEL
EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . 9-630 PASSENGER POWER . . . . . . . . . . . . . . . . . . 8N-89 SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193
SEALS - INSTALLATION, INTAKE/ SEAT SWITCH - DIAGNOSIS AND SENSOR - DESCRIPTION, INTAKE AIR
EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . 9-632 TESTING, POWER . . . . . . . . . . . . . . . . . . . . 8N-96 TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36
SEALS - OPERATION, INTAKE/EXHAUST SEAT SWITCH - INSTALLATION, HEATED . . 8G-38 SENSOR - DESCRIPTION, KNOCK . . . . . . . . . 8I-6
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-630 SEAT SWITCH - INSTALLATION, POWER . . 8N-98 SENSOR - DESCRIPTION, LATERAL
SEALS - REMOVAL, INTAKE/EXHAUST SEAT SWITCH - REMOVAL, HEATED . . . . . . 8G-37 ACCELERATION . . . . . . . . . . . . . . . . . . . . . . 5-199
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-630 SEAT SWITCH - REMOVAL, POWER . . . . . . 8N-96 SENSOR - DESCRIPTION, MANIFOLD AIR
SEAT - INSTALLATION . . . . . . . . . . . . . . . . 23-203 SEAT TRACK - INSTALLATION, POWER . . 8N-107 FLOW (MAF) . . . . . . . . . . . . . . . . . . . . . . . . 14-37
SEAT - REMOVAL . . . . . . . . . . . . . . . . . . . 23-202 SEAT TRACK - REMOVAL, POWER . . . . . . 8N-105 SENSOR - DESCRIPTION, MAP . . . . . . . . . . 14-42
SEAT BACK COVER - INSTALLATION . . . . . 23-208 SEATS - DESCRIPTION . . . . . . . . . . . . . . . 23-201 SENSOR - DESCRIPTION, O2 . . . . . . . . . . . 14-43
SEAT BACK COVER - REMOVAL . . . . . . . . 23-206 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION, REAR WHEEL
SEAT BACK ELEMENT - INSTALLATION, DESCRIPTION, HEATED . . . . . . . . . . . . . . . . 8G-36 SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-41 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION, SIDE IMPACT . . 8O-107
SEAT BACK ELEMENT - REMOVAL, DESCRIPTION, POWER . . . . . . . . . . . . . . . . 8N-95 SENSOR - DESCRIPTION, SPEED . . . . . . . 21-311
HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-40 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION, STEERING
SEAT BACK, INSTALLATION . . . . . . . . . . . . 23-205 DIAGNOSIS AND TESTING, HEATED . . . . . . 8G-37 ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200
SEAT BACK, REMOVAL . . . . . . . . . . . . . . . 23-204 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION, THROTTLE
SEAT BELT & SEAT BELT TENSIONER - DIAGNOSIS AND TESTING, POWER . . . . . . 8N-96 POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8O-119 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION,
SEAT BELT & SEAT BELT TENSIONER - OPERATION, HEATED . . . . . . . . . . . . . . . . . 8G-36 TRANSMISSION TEMPERATURE . . . . . . . . 21-327
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 8O-125 SEATS - SERVICE INFORMATION - SENSOR - DESCRIPTION, TRAVEL . . . . . . . 5-201
SEAT BELT & SEAT BELT TENSIONER - OPERATION, POWER . . . . . . . . . . . . . . . . . 8N-95 SENSOR - DESCRIPTION, YAW RATE . . . . . 5-201
INSTALLATION . . . . . . . . . . . . . . . . . . . . . 8O-125 SEATS - SERVICE INFORMATION - SENSOR - INSTALLATION . . . . . . . . . . . . . . 22-55
SEAT BELT & SEAT BELT TENSIONER - SPECIFICATIONS, POWER . . . . . . . . . . . . . . 8N-96 SENSOR - INSTALLATION, ANTI-THEFT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 8O-120 TOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-58
ZH INDEX 27

SENSOR - INSTALLATION, BRAKE FLUID SENSOR - REMOVAL, LATERAL SENSOR 2/1 CIRCUIT LOW, DIAGNOSIS
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 ACCELERATION . . . . . . . . . . . . . . . . . . . . . . 5-200 AND TESTING - (P0151) O2 . . . . . . . . . . . . 9-149
SENSOR - INSTALLATION, BRAKE SENSOR - REMOVAL, MANIFOLD AIR SENSOR 2/1 CIRCUIT OPEN, DIAGNOSIS
PRESSURE . . . . . . . . . . . . . . . . . . . . . 5-201,5-77 FLOW (MAF) . . . . . . . . . . . . . . . . . . . . . . . . 14-37 AND TESTING - (P0154) O2 . . . . . . . . . . . . 9-161
SENSOR - INSTALLATION, CAMSHAFT SENSOR - REMOVAL, MAP . . . . . . . . . . . . . 14-42 SENSOR 2/1 HEATER CIRCUIT HIGH,
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-5 SENSOR - REMOVAL, OIL LEVEL/ DIAGNOSIS AND TESTING - (P0155)
SENSOR - INSTALLATION, COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 9-672 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-165
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 SENSOR - REMOVAL, REAR WHEEL SENSOR 2/1 HEATER CIRCUIT LOW,
SENSOR - INSTALLATION, CRANKSHAFT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197 DIAGNOSIS AND TESTING - (P0155)
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31 SENSOR - REMOVAL, SIDE IMPACT . . . . . 8O-108 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-163
SENSOR - INSTALLATION, ENGINE SENSOR - REMOVAL, STEERING ANGLE . . 5-200 SENSOR 2/1 HEATER CIRCUIT OPEN,
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-31 SENSOR - REMOVAL, TRAVEL . . . . . . 5-202,5-78 DIAGNOSIS AND TESTING - (P0155)
SENSOR - INSTALLATION, EVAPORATOR SENSOR - REMOVAL, YAW RATE . . . . . . . . 5-201 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-84 SENSOR #1 AND #2 VOLTAGE SENSOR 2/1 HEATER PERFORMANCE,
SENSOR - INSTALLATION, FRONT CORRELATION, DIAGNOSIS AND DIAGNOSIS AND TESTING - (P0155)
WHEEL SPEED . . . . . . . . . . . . . . . . . . . . . . . 5-195 TESTING - (P0221) APPS . . . . . . . . . . . . . . 9-262 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-169
SENSOR - INSTALLATION, HEATER CORE SENSOR 1 CIRCUIT, DIAGNOSIS AND SENSOR 2/1 LONG DELAY TIME,
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-85 TESTING - ESP BRAKE PRESSURE . . . . . . . 5-128 DIAGNOSIS AND TESTING - (P0153)
SENSOR - INSTALLATION, KNOCK . . . . . . . . . 8I-6 SENSOR #1 CIRCUIT HIGH, DIAGNOSIS O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-155
SENSOR - INSTALLATION, LATERAL AND TESTING - (P0325) KNOCK . . . . . . . . . 9-328 SENSOR 2/1 LONG PERFORMANCE,
ACCELERATION . . . . . . . . . . . . . . . . . . . . . . 5-200 SENSOR #1 CIRCUIT LOW, DIAGNOSIS DIAGNOSIS AND TESTING - (P0153)
SENSOR - INSTALLATION, MANIFOLD AND TESTING - (P0325) KNOCK . . . . . . . . . 9-324 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-153
AIR FLOW (MAF) . . . . . . . . . . . . . . . . . . . . . 14-39 SENSOR 1/1 CIRCUIT HIGH, DIAGNOSIS SENSOR 2/1 SHORT DELAY TIME,
SENSOR - INSTALLATION, MAP . . . . . . . . . 14-43 AND TESTING - (P0132) O2 . . . . . . . . . . . . . 9-93 DIAGNOSIS AND TESTING - (P0153)
SENSOR - INSTALLATION, OIL SENSOR 1/1 CIRCUIT LOW, DIAGNOSIS O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-157
LEVEL/TEMPERATURE . . . . . . . . . . . . . . . . . 9-673 AND TESTING - (P0131) O2 . . . . . . . . . . . . . 9-86 SENSOR 2/1 SHORT PERFORMANCE,
SENSOR - INSTALLATION, REAR WHEEL SENSOR 1/1 CIRCUIT OPEN, DIAGNOSIS DIAGNOSIS AND TESTING - (P0153)
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-198 AND TESTING - (P0134) O2 . . . . . . . . . . . . 9-105 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-159
SENSOR - INSTALLATION, SIDE IMPACT . 8O-110 SENSOR 1/1 HEATER CIRCUIT HIGH, SENSOR 2/2 BELOW THRESHOLD,
SENSOR - INSTALLATION, STEERING DIAGNOSIS AND TESTING - (P0135) DIAGNOSIS AND TESTING - (P0137)
ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-113 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-127
SENSOR - INSTALLATION, TRAVEL . . . 5-202,5-78 SENSOR 1/1 HEATER CIRCUIT LOW, SENSOR 2/2 CIRCUIT HIGH, DIAGNOSIS
SENSOR - INSTALLATION, YAW RATE . . . . 5-201 DIAGNOSIS AND TESTING - (P0135) AND TESTING - (P0140) O2 . . . . . . . . . . . . 9-139
SENSOR - OPERATION . . . . . . . . . . . . . . . . 22-53 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107 SENSOR 2/2 CIRCUIT LOW, DIAGNOSIS
SENSOR - OPERATION, ACCELERATOR SENSOR 1/1 HEATER CIRCUIT OPEN, AND TESTING - (P0138) O2 . . . . . . . . . . . . 9-133
PEDAL POSITION . . . . . . . . . . . . . . . . . . . . 14-29 DIAGNOSIS AND TESTING - (P0135) SENSOR 2/2 CIRCUIT OPEN, DIAGNOSIS
SENSOR - OPERATION, BRAKE O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-117 AND TESTING - (P0138) O2 . . . . . . . . . . . . . . 9-135
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-201 SENSOR 1/1 HEATER PERFORMANCE, SENSOR 2/2 HEATER CIRCUIT HIGH,
SENSOR - OPERATION, CAMSHAFT DIAGNOSIS AND TESTING - (P0135) DIAGNOSIS AND TESTING - (P0161)
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-177
SENSOR - OPERATION, CRANKSHAFT SENSOR 1/1 LONG DELAY TIME, SENSOR 2/2 HEATER CIRCUIT LOW,
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30 DIAGNOSIS AND TESTING - (P0133) DIAGNOSIS AND TESTING - (P0161)
SENSOR - OPERATION, ENGINE O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-101 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-29 SENSOR 1/1 LONG PERFORMANCE, SENSOR 2/2 HEATER CIRCUIT OPEN,
SENSOR - OPERATION, FRONT WHEEL DIAGNOSIS AND TESTING - (P0133) DIAGNOSIS AND TESTING - (P0161)
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-175
SENSOR - OPERATION, INTAKE AIR SENSOR 1/1 SHORT DELAY TIME, SENSOR 2/2 HEATER PERFORMANCE,
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36 DIAGNOSIS AND TESTING - (P0133) DIAGNOSIS AND TESTING - (P0161)
SENSOR - OPERATION, KNOCK . . . . . . . . . . . 8I-6 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-95 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-171
SENSOR - OPERATION, LATERAL SENSOR 1/1 SHORT PERFORMANCE, SENSOR CAN MESSAGE INCORRECT,
ACCELERATION . . . . . . . . . . . . . . . . . . . . . . 5-199 DIAGNOSIS AND TESTING - (P0133) DIAGNOSIS AND TESTING - (P0600)
SENSOR - OPERATION, MANIFOLD AIR O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-103 ACCEL PEDAL . . . . . . . . . . . . . . . . . . . . . . . 21-34
FLOW (MAF) . . . . . . . . . . . . . . . . . . . . . . . . 14-37 SENSOR 1/2 ABOVE THRESHOLD, SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - OPERATION, MAP . . . . . . . . . . . 14-42 DIAGNOSIS AND TESTING - (P0137) TESTING - A/C PRESSURE . . . . . . . . . . . . . 24-28
SENSOR - OPERATION, O2 . . . . . . . . . . . . . 14-44 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-121 SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - OPERATION, REAR WHEEL SENSOR 1/2 BELOW THRESHOLD, TESTING - AMBIENT TEMPERATURE . . . . . . 24-3
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196 DIAGNOSIS AND TESTING - (P0137) SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - OPERATION, SIDE IMPACT . . . 8O-107 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-119 TESTING - AMBIENT TEMPERATURE . . . . . . 8J-9
SENSOR - OPERATION, SPEED . . . . . . . . . 21-311 SENSOR 1/2 CIRCUIT HIGH, DIAGNOSIS SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - OPERATION, STEERING AND TESTING - (P0138) O2 . . . . . . . . . . . . 9-129 TESTING - BAS TRAVEL . . . . . . . . . . . . . . . 5-171
ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-200 SENSOR 1/2 CIRCUIT LOW, DIAGNOSIS SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - OPERATION, THROTTLE AND TESTING - (P0140) O2 . . . . . . . . . . . . 9-137 TESTING - ENGINE COOLANT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 SENSOR 1/2 CIRCUIT OPEN, DIAGNOSIS TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-23
SENSOR - OPERATION, TRANSMISSION AND TESTING - (P0138) O2 . . . . . . . . . . . . 9-131 SENSOR CIRCUIT, DIAGNOSIS AND
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . 21-328 SENSOR 1/2 CORRELATION, DIAGNOSIS TESTING - ESP LATERAL
SENSOR - OPERATION, TRAVEL . . . . . . . . . 5-202 AND TESTING - (P0120) THROTTLE ACCELERATION . . . . . . . . . . . . . . . . . . . . . . 5-138
SENSOR - OPERATION, YAW RATE . . . . . . . 5-201 POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59 SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - REMOVAL . . . . . . . . . . . . . . . . . . 22-53 SENSOR 1/2 HEATER CIRCUIT HIGH, TESTING - ESP YAW RATE . . . . . . . . . . . . . 5-119
SENSOR - REMOVAL, ANTI-THEFT TOW . . 8Q-57 DIAGNOSIS AND TESTING - (P0141) SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - REMOVAL, BRAKE FLUID O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-145 TESTING - EVAPORATOR
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 SENSOR 1/2 HEATER CIRCUIT LOW, TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-18
SENSOR - REMOVAL, BRAKE PRESSURE . 5-201, DIAGNOSIS AND TESTING - (P0141) SENSOR CIRCUIT, DIAGNOSIS AND
5-76 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-141 TESTING - FUEL LEVEL . . . . . . . . . . . . . . . . . 8J-7
SENSOR - REMOVAL, CAMSHAFT SENSOR 1/2 HEATER CIRCUIT OPEN, SENSOR CIRCUIT, DIAGNOSIS AND
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-4 DIAGNOSIS AND TESTING - (P0141) TESTING - LEFT FRONT WHEEL SPEED . . . . 5-95
SENSOR - REMOVAL, COOLANT LEVEL . . . . 7-20 O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-143 SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - REMOVAL, CRANKSHAFT SENSOR 1/2 HEATER PERFORMANCE, TESTING - LEFT HEATER CORE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31 DIAGNOSIS AND TESTING - (P0141) TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 24-8
SENSOR - REMOVAL, ENGINE COOLANT O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-147 SENSOR CIRCUIT, DIAGNOSIS AND
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 7-29 SENSOR 2 CIRCUIT, DIAGNOSIS AND TESTING - LEFT REAR WHEEL SPEED . . . . 5-107
SENSOR - REMOVAL, EVAPORATOR TESTING - ESP BRAKE PRESSURE . . . . . . . 5-133 SENSOR CIRCUIT, DIAGNOSIS AND
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-84 SENSOR #2 CIRCUIT HIGH, DIAGNOSIS TESTING - (P0335) CRANKSHAFT
SENSOR - REMOVAL, FRONT WHEEL AND TESTING - (P0330) KNOCK . . . . . . . . . 9-330 POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-334
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194 SENSOR #2 CIRCUIT LOW, DIAGNOSIS SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - REMOVAL, HEATER CORE AND TESTING - (P0330) KNOCK . . . . . . . . . 9-332 TESTING - (P0460) FUEL LEVEL . . . . . . . . . 9-408
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-85 SENSOR 2/1 CIRCUIT HIGH, DIAGNOSIS SENSOR CIRCUIT, DIAGNOSIS AND
SENSOR - REMOVAL, KNOCK . . . . . . . . . . . . 8I-6 AND TESTING - (P0152) O2 . . . . . . . . . . . . 9-151 TESTING - (P0715) N2 INPUT SPEED . . . . . 21-97
28 INDEX ZH

SENSOR CIRCUIT, DIAGNOSIS AND SENSOR SIGNAL CIRCUIT, DIAGNOSIS SHAFT - DESCRIPTION, PROPELLER . . . . . . 3-23
TESTING - (P0715) N3 INPUT SPEED . . . . 21-103 AND TESTING - LEFT SIDE IMPACT . . . . . . 8O-59 SHAFT - DESCRIPTION, REVERSE . . . . . . 21-363
SENSOR CIRCUIT, DIAGNOSIS AND SENSOR SIGNAL CIRCUIT, DIAGNOSIS SHAFT - DIAGNOSIS AND TESTING,
TESTING - RIGHT FRONT WHEEL AND TESTING - RIGHT SIDE IMPACT . . . . . 8O-63 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101 SENSOR SUPPLY VOLTAGE, DIAGNOSIS SHAFT - DISASSEMBLY, MAINSHAFT
SENSOR CIRCUIT, DIAGNOSIS AND AND TESTING - (P0700) . . . . . . . . . . . . . . . 21-67 W/INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . 21-369
TESTING - RIGHT HEATER CORE SENSOR SYSTEM FAILURE, DIAGNOSIS SHAFT - INSTALLATION, BALANCE . . . . . . . 9-701
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 24-13 AND TESTING - (P1386) KNOCK . . . . . . . . . 9-491 SHAFT - INSTALLATION, PROPELLER . . . . . . 3-28
SENSOR CIRCUIT, DIAGNOSIS AND SENSOR THROTTLE ANGLE AND SPEED, SHAFT - REMOVAL, BALANCE . . . . . . . . . . . 9-698
TESTING - RIGHT REAR WHEEL SPEED . . . 5-113 DIAGNOSIS AND TESTING - (P0104) SHAFT - REMOVAL, PROPELLER . . . . . . . . . 3-26
SENSOR CIRCUIT, DIAGNOSIS AND MAF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 SHAFT - WARNING, PROPELLER . . . . . . . . . 3-23
TESTING - STEERING ANGLE . . . . . . . . . . . 5-124 SENSOR WATER CONTAMINATION, SHAFT BEARING - INSTALLATION,
SENSOR CIRCUIT HIGH, DIAGNOSIS DIAGNOSIS AND TESTING - ENGINE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-316
AND TESTING - (P0108) MAP . . . . . . . . . . . . 9-29 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-538 SHAFT BEARING - REMOVAL, OUTPUT . . . 21-314
SENSOR CIRCUIT HIGH, DIAGNOSIS SENSOR/TRANSMITTER, DIAGNOSIS SHAFT SEAL - INSTALLATION, INPUT . . . . 21-360
AND TESTING - (P0113) INTAKE AIR AND TESTING - LEFT FRONT TIRE SHAFT SEAL - INSTALLATION, OUTPUT . . 21-318
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 9-36 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-24 SHAFT SEAL - INSTALLATION, PITMAN . . . 19-39
SENSOR CIRCUIT HIGH, DIAGNOSIS SENSOR/TRANSMITTER, DIAGNOSIS SHAFT SEAL - REMOVAL, INPUT . . . . . . . 21-359
AND TESTING - (P0118) ENGINE AND TESTING - LEFT REAR TIRE SHAFT SEAL - REMOVAL, OUTPUT . . . . . . 21-318
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 9-51 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-26 SHAFT SEAL - REMOVAL, PITMAN . . . . . . . 19-38
SENSOR CIRCUIT HIGH, DIAGNOSIS SENSOR/TRANSMITTER, DIAGNOSIS SHIELD - INSTALLATION, FRONT HEAT . . . . 11-9
AND TESTING - (P0453) FUEL TANK AND TESTING - RIGHT FRONT TIRE SHIELD - INSTALLATION, REAR HEAT . . . . . 11-9
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-397 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-28 SHIELD - REMOVAL, FRONT HEAT . . . . . . . . 11-8
SENSOR CIRCUIT LOW, DIAGNOSIS AND SENSOR/TRANSMITTER, DIAGNOSIS SHIELD - REMOVAL, REAR HEAT . . . . . . . . . 11-8
TESTING - (P0103) MAF . . . . . . . . . . . . . . . . 9-17 AND TESTING - RIGHT REAR TIRE SHIFT INTERLOCK SOLENOID -
SENSOR CIRCUIT LOW, DIAGNOSIS AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-30 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . 21-338
TESTING - (P0107) MAP . . . . . . . . . . . . . . . . 9-24 SENSOR/TRANSMITTER, DIAGNOSIS SHIFT INTERLOCK SOLENOID -
SENSOR CIRCUIT LOW, DIAGNOSIS AND AND TESTING - TIRE PRESSURE . . . . . . . . 22-19 DESCRIPTION . . . . . . . . . . . . . . . . . . 21-324,21-338
TESTING - (P0112) INTAKE AIR SENSOR/TRANSMITTER LOW BATTERY, SHIFT INTERLOCK SOLENOID -
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 9-31 DIAGNOSIS AND TESTING - TIRE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-326
SENSOR CIRCUIT LOW, DIAGNOSIS AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-32 SHIFT LEVER ADJUSTMENT -
TESTING - (P0117) ENGINE COOLANT SENSOR/TRANSMITTER SIGNAL STANDARD PROCEDURE . . . . . . . . . . . . . . 21-389
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 9-49 JAMMED, DIAGNOSIS AND TESTING - SHIFT LEVER ASSEMBLY - DESCRIPTION . 21-339
SENSOR CIRCUIT LOW, DIAGNOSIS AND LEFT FRONT TIRE PRESSURE . . . . . . . . . . . 22-11 SHIFT LEVER ASSEMBLY -
TESTING - (P0452) FUEL TANK SENSOR/TRANSMITTER SIGNAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21-340
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-395 JAMMED, DIAGNOSIS AND TESTING - SHIFT LEVER ASSEMBLY - OPERATION . . 21-339
SENSOR ERRATIC, DIAGNOSIS AND LEFT REAR TIRE PRESSURE. . . . . . . . . . . . . 22-13 SHIFT LEVER ASSEMBLY - REMOVAL . . . 21-340
TESTING - (P0714) TRANS TEMP . . . . . . . . 21-87 SENSOR/TRANSMITTER SIGNAL SHIFT LEVER ASSEMBLY COVER -
SENSOR HARNESS CONNECTORS JAMMED, DIAGNOSIS AND TESTING - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23-192
REVERSED, DIAGNOSIS AND TESTING RIGHT FRONT TIRE PRESSURE . . . . . . . . . 22-15 SHIFT LEVER ASSEMBLY COVER -
- (P0040) 1/1 AND 2/1 O2 . . . . . . . . . . . . . . . 9-5 SENSOR/TRANSMITTER SIGNAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-182
SENSOR LEVEL PERFORMANCE, JAMMED, DIAGNOSIS AND TESTING - SHIFT LEVER ASSEMBLY, DIAGNOSIS
DIAGNOSIS AND TESTING - ENGINE RIGHT REAR TIRE PRESSURE . . . . . . . . . . 22-17 AND TESTING - NO RESPONSE FROM . . . . 8E-29
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-521 SENSOR/TRANSMITTER SIGNAL SHIFT LEVER HANDLE - INSTALLATION,
SENSOR MESSAGE, DIAGNOSIS AND JAMMED, DIAGNOSIS AND TESTING - GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
TESTING - (P0600) ABS LEFT FRONT . . . . . 21-22 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . 22-6 SHIFT LEVER HANDLE - REMOVAL,
SENSOR MESSAGE, DIAGNOSIS AND SENSOR/WASHER FLUID LEVEL SWITCH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-387
TESTING - (P0600) ABS LEFT REAR . . . . . . 21-25 CIRCUIT, DIAGNOSIS AND TESTING - SHIFT MECHANISM - DESCRIPTION . . . . . 21-388
SENSOR MESSAGE, DIAGNOSIS AND COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . 8J-2 SHIFT MECHANISM - INSTALLATION . . . . 21-392
TESTING - (P0600) ABS RIGHT FRONT . . . 21-28 SENTRY KEY ANTENNA CIRCUIT, SHIFT MECHANISM - REMOVAL . . . . . . . . 21-391
SENSOR MESSAGE, DIAGNOSIS AND DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-38 SHIFT MODULE (SLA), DIAGNOSIS AND
TESTING - (P0600) ABS RIGHT REAR . . . . 21-31 SENTRY KEY ANTENNA RING - TESTING - (P0600) LOST COMM WITH
SENSOR MISMATCH, DIAGNOSIS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-55 ELECTRIC GEAR . . . . . . . . . . . . . . . . . . . . . 9-439
TESTING - (P0715) INPUT . . . . . . . . . . . . . 21-90 SENTRY KEY ANTENNA RING - SHIFT PRESSURE SOLENOID CIRCUIT,
SENSOR OVER TEMPERATURE, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-54 DIAGNOSIS AND TESTING - (P0778) . . . . 21-150
DIAGNOSIS AND TESTING - ENGINE SENTRY KEY REMOTE ENTRY MODULE - SHIFT ROD - INSTALLATION, GEAR . . . . . 21-341
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-526 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-69 SHIFT ROD - REMOVAL, GEAR . . . . . . . . . 21-341
SENSOR OVERSPEED, DIAGNOSIS AND SENTRY KEY REMOTE ENTRY MODULE - SHOCK - INSTALLATION . . . . . . . . . . . . 2-41,2-81
TESTING - (P0715) INPUT . . . . . . . . . . . . . 21-94 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-46 SHOCK - REMOVAL . . . . . . . . . . . . . . . . 2-40,2-80
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE ENTRY MODULE - SHOES - INSTALLATION . . . . . . . . . . . . . . . . 5-73
AND TESTING - ENGINE OIL . . . . . . . . . . . . 9-531 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8Q-52 SHOES - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-70
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE ENTRY MODULE - SHORT CIRCUIT, DIAGNOSIS AND
AND TESTING - (P0101) MAF . . . . . . . . . . . . . 9-8 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-47 TESTING - (P0116) ENGINE COOLANT
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE ENTRY MODULE - TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9-47
AND TESTING - (P0106) MAP . . . . . . . . . . . . 9-21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-55 SHORT DELAY TIME, DIAGNOSIS AND
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE ENTRY MODULE - TESTING - (P0133) O2 SENSOR 1/1 . . . . . . . 9-95
AND TESTING - (P0116) ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-69 SHORT DELAY TIME, DIAGNOSIS AND
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 9-40 SENTRY KEY REMOTE ENTRY MODULE - TESTING - (P0153) O2 SENSOR 2/1 . . . . . . 9-157
SENSOR PERFORMANCE, DIAGNOSIS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-52 SHORT PERFORMANCE, DIAGNOSIS AND
AND TESTING - (P0341) CAMSHAFT SENTRY KEY REMOTE ENTRY MODULE - TESTING - (P0133) O2 SENSOR 1/1 . . . . . . 9-103
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-346 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-53 SHORT PERFORMANCE, DIAGNOSIS AND
SENSOR PERFORMANCE, DIAGNOSIS SENTRY KEY REMOTE ENTRY MODULE, TESTING - (P0153) O2 SENSOR 2/1 . . . . . . 9-159
AND TESTING - (P0451) FUEL TANK DIAGNOSIS AND TESTING - NO SHORT RUNNER SOLENOID CIRCUIT,
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-390 RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-40 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 9-551
SENSOR, P/N SWITCH CIRCUIT - SENTRY KEY REMOTE ENTRY MODULE SHORT RUNNER SOLENOID CIRCUIT
(P0850) TRANS TEMP . . . . . . . . . . . . . . . . 21-158 INTERNAL FAILURE, DIAGNOSIS AND HIGH, DIAGNOSIS AND TESTING . . . . . . . . 9-545
SENSOR QUALITY PERFORMANCE, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-34 SHORT RUNNER SOLENOID CIRCUIT
DIAGNOSIS AND TESTING - ENGINE SENTRY KEY VERIFICATION TEST, LOW, DIAGNOSIS AND TESTING . . . . . . . . . 9-549
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-533 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-43 SHORT TO GROUND - (P0753) 1, 2/4-5
SENSOR, REMOVAL - UPSTREAM O2 . . . . . 14-45 SEVERAL LOADS - STANDARD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 21-136
SENSOR SHORT CIRCUIT, DIAGNOSIS PROCEDURE, TESTING FOR A SHORT SHORT TO GROUND - (P0758) 2, 3
AND TESTING - (P0116) ENGINE TO GROUND ON FUSES POWERING . . . 8W-01-10 SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 21-142
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 9-47 SHAFT - ASSEMBLY, MAINSHAFT SHORT TO GROUND - (P0763) 3, 4
SENSOR SHORTED, DIAGNOSIS AND W/INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . 21-374 SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . 21-148
TESTING - (P0710) TRANS TEMP . . . . . . . . 21-83 SHAFT - DESCRIPTION, BALANCE . . . . . . . 9-698 SHORT TO GROUND - STANDARD
SENSOR SIGNAL CIRCUIT, DIAGNOSIS SHAFT - DESCRIPTION, MAINSHAFT PROCEDURE, TESTING FOR A . . . . . . . 8W-01-10
AND TESTING - ANTI-THEFT TOW . . . . . . . 8Q-22 W/INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . 21-368
ZH INDEX 29

SHORT TO GROUND ON FUSES SLA CAN MESSAGE INCORRECT, SPARK PLUG CABLE - REMOVAL . . . . . . . . 8I-13
POWERING SEVERAL LOADS - DIAGNOSIS AND TESTING - (P0600) . . . . . 21-64 SPARK PLUG CONDITIONS - DIAGNOSIS
STANDARD PROCEDURE, TESTING SLA CONTROL SYSTEM (MIL REQUEST), AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8I-8
FOR A . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10 DIAGNOSIS AND TESTING - (P0705) . . . . . 9-463 SPARK PLUGS - SPECIFICATIONS . . . . . . . . . 8I-4
SHORTED, DIAGNOSIS AND TESTING - SLA, DIAGNOSIS AND TESTING - SPEAKER - INSTALLATION, REAR PANEL . . 8A-33
(P0710) TRANS TEMP SENSOR . . . . . . . . . 21-83 (P0600) CAN MESSAGE FROM ECM SPEAKER - INSTALLATION, TWEETER . . . . 8A-34
SHUT OFF DETECTED, DIAGNOSIS AND FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-38 SPEAKER - REMOVAL, REAR PANEL . . . . . 8A-29
TESTING - SAFETY FUEL . . . . . . . . . . . . . . . 9-540 SLEEVES - INSTALLATION, CENTERING . . . . 3-36 SPEAKER - REMOVAL, TWEETER . . . . . . . . 8A-30
SHUTOFF VALVE - DESCRIPTION, SLEEVES - INSTALLATION, FITTED . . . . . . . . 3-36 SPEAKER, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER . . . . . . . . . . . . . . . . . 25-16 SLEEVES - REMOVAL, CENTERING . . . . . . . . 3-35 NO SOUND FROM LEFT REAR . . . . . . . . . . 8A-12
SHUTOFF VALVE - INSTALLATION, SLEEVES - REMOVAL, FITTED . . . . . . . . . . . 3-35 SPEAKER, DIAGNOSIS AND TESTING -
CHARCOAL CANISTER . . . . . . . . . . . . . . . . . 25-16 SLEEVES - SPECIFICATIONS, CENTERING . . 3-30 NO SOUND FROM RIGHT REAR . . . . . . . . . 8A-14
SHUTOFF VALVE - OPERATION, SLIPPING, DIAGNOSIS AND TESTING - SPEAKER, INSTALLATION - LOWER
CHARCOAL CANISTER . . . . . . . . . . . . . . . . . 25-16 (P0700) TRANSMISSION . . . . . . . . . . . . . . . 21-71 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-31
SHUTOFF VALVE - REMOVAL, CHARCOAL SLOW RESPONSE, DIAGNOSIS AND SPEAKER, REMOVAL - LOWER DOOR . . . . 8A-29
CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . 25-16 TESTING - DRIVER DOOR LOCK SPEAKERS, DIAGNOSIS AND TESTING -
SHUTOFF VALVE, DIAGNOSIS AND ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-2 NO SOUND FROM ALL . . . . . . . . . . . . . . . . . 8A-5
TESTING - (P0446) CHARCOAL SLOW RESPONSE, DIAGNOSIS AND SPEAKERS, DIAGNOSIS AND TESTING -
CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . 9-384 TESTING - FUEL DOOR LOCK NO SOUND FROM LEFT DOOR . . . . . . . . . . . 8A-8
SIDE AIRBAG SQUIB CIRCUIT, ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5 SPEAKERS, DIAGNOSIS AND TESTING -
DIAGNOSIS AND TESTING - LEFT . . . . . . . 8O-29 SLOW RESPONSE, DIAGNOSIS AND NO SOUND FROM RIGHT DOOR . . . . . . . . . 8A-10
SIDE AIRBAG SQUIB CIRCUIT, TESTING - PASSENGER DOOR/ SPECIFICATION, RUNOUT . . . . . . . . . . . . . . . 3-30
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8O-35 LIFTGATE LOCK ACTUATOR . . . . . . . . . . . . . 8N-8 SPEED CONTROL - ELECTRICAL
SIDE IMPACT AIRBAG - DESCRIPTION . . . 8O-112 SMALL LEAK, DIAGNOSIS AND TESTING DIAGNOSTICS - SCHEMATICS AND
SIDE IMPACT AIRBAG - INSTALLATION . . 8O-114 - (P0442) EVAP SYSTEM . . . . . . . . . . . . . . 9-378 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2
SIDE IMPACT AIRBAG - OPERATION . . . . 8O-113 SOLENOID - ADJUSTMENTS, SHIFT SPEED CONTROL - SERVICE
SIDE IMPACT AIRBAG - REMOVAL . . . . . . 8O-114 INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-338 INFORMATION - DESCRIPTION . . . . . . . . . . . 8P-3
SIDE IMPACT SENSOR - DESCRIPTION . . 8O-107 SOLENOID - DESCRIPTION, EVAP PURGE . 25-17 SPEED CONTROL - SERVICE
SIDE IMPACT SENSOR - INSTALLATION . 8O-110 SOLENOID - DESCRIPTION, SHIFT INFORMATION - OPERATION . . . . . . . . . . . . 8P-3
SIDE IMPACT SENSOR - OPERATION . . . . 8O-107 INTERLOCK . . . . . . . . . . . . . . . . . . 21-324,21-338 SPEED CONTROL SWITCH INPUT
SIDE IMPACT SENSOR - REMOVAL . . . . . 8O-108 SOLENOID - INSTALLATION . . . . . . . . . . . . 25-25 CIRCUIT, DIAGNOSIS AND TESTING . . . . . . 9-553
SIDE IMPACT SENSOR SIGNAL CIRCUIT, SOLENOID - INSTALLATION, EVAP SPEED, DESCRIPTION - TIRE PRESSURE
DIAGNOSIS AND TESTING - LEFT . . . . . . . 8O-59 PURGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 FOR HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . 22-58
SIDE IMPACT SENSOR SIGNAL CIRCUIT, SOLENOID - INSTALLATION, SPEED, DIAGNOSIS AND TESTING -
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8O-63 SWITCHOVER . . . . . . . . . . . . . . . . . . . . . . . 25-35 (P0104) MAF SENSOR THROTTLE
SIDE MARKER LAMP INOPERATIVE, SOLENOID - OPERATION, EVAP PURGE . . . 25-17 ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
DIAGNOSIS AND TESTING - LEFT SOLENOID - OPERATION, SHIFT SPEED INOPERATIVE, DIAGNOSIS AND
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-32 INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-326 TESTING - WIPERS HIGH . . . . . . . . . . . . . . 8R-11
SIDE MARKER LAMP INOPERATIVE, SOLENOID - REMOVAL . . . . . . . . . . . . . . . . 25-24 SPEED INOPERATIVE, DIAGNOSIS AND
DIAGNOSIS AND TESTING - LEFT SOLENOID - REMOVAL, EVAP PURGE . . . . 25-17 TESTING - WIPERS INTERMITTENT . . . . . . 8R-15
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38 SOLENOID - REMOVAL, SWITCHOVER . . . . 25-34 SPEED INOPERATIVE, DIAGNOSIS AND
SIDE MARKER LAMP INOPERATIVE, SOLENOID CIRCUIT, DIAGNOSIS AND TESTING - WIPERS LOW . . . . . . . . . . . . . . 8R-13
DIAGNOSIS AND TESTING - RIGHT TESTING - (P0412) SECONDARY AIR SPEED PERFORMANCE, DIAGNOSIS AND
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35 INJECTION SWITCHOVER . . . . . . . . . . . . . . 9-365 TESTING - (P0221) IDLE . . . . . . . . . . . . . . . 9-266
SIDE MARKER LAMP INOPERATIVE, SOLENOID CIRCUIT, DIAGNOSIS AND SPEED PERFORMANCE ESP MIL
DIAGNOSIS AND TESTING - RIGHT TESTING - (P0445) EVAP PURGE . . . . . . . . 9-380 REQUEST, DIAGNOSIS AND TESTING -
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41 SOLENOID CIRCUIT, DIAGNOSIS AND (P0500) VEHICLE . . . . . . . . . . . . . . . . . . . . 9-412
SIDEVIEW MIRROR - INSTALLATION . . . . . 8N-72 TESTING - (P0743) TCC . . . . . . . . . . . . . . 21-124 SPEED SENSOR - DESCRIPTION . . . . . . . . 21-311
SIDEVIEW MIRROR - REMOVAL . . . . . . . . . 8N-72 SOLENOID CIRCUIT, DIAGNOSIS AND SPEED SENSOR - DESCRIPTION, FRONT
SIGNAL - INSTALLATION, TURN . . . . . . . . 8L-116 TESTING - (P0748) MODULATING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193
SIGNAL - REMOVAL, TURN . . . . . . . . . . . . 8L-114 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 21-128 SPEED SENSOR - DESCRIPTION, REAR
SIGNAL CIRCUIT, DIAGNOSIS AND SOLENOID CIRCUIT, DIAGNOSIS AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
TESTING - ANTI-THEFT TOW SENSOR . . . . 8Q-22 TESTING - (P0753) 1-2/4-5 . . . . . . . . . . . . 21-132 SPEED SENSOR - INSTALLATION, FRONT
TESTING - LEFT SIDE IMPACT SENSOR . . . 8O-59 TESTING - (P0758) 2-3 . . . . . . . . . . . . . . . 21-138 SPEED SENSOR - INSTALLATION, REAR
TESTING - PASSENGER AIRBAG TESTING - (P0763) 3-4 . . . . . . . . . . . . . . . 21-144 SPEED SENSOR - OPERATION . . . . . . . . . 21-311
ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . 8O-49 SOLENOID CIRCUIT, DIAGNOSIS AND SPEED SENSOR - OPERATION, FRONT
SIGNAL CIRCUIT, DIAGNOSIS AND TESTING - (P0778) SHIFT PRESSURE . . . 21-150 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193
TESTING - RIGHT SIDE IMPACT SOLENOID CIRCUIT, DIAGNOSIS AND SPEED SENSOR - OPERATION, REAR
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-63 TESTING - SHORT RUNNER . . . . . . . . . . . . 9-551 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196
SIGNAL INDICATOR INOPERATIVE, SOLENOID CIRCUIT HIGH, DIAGNOSIS SPEED SENSOR - REMOVAL, FRONT
DIAGNOSIS AND TESTING - LEFT AND TESTING - SHORT RUNNER . . . . . . . . 9-545 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-38 SOLENOID CIRCUIT LOW, DIAGNOSIS SPEED SENSOR - REMOVAL, REAR
SIGNAL INDICATOR INOPERATIVE, AND TESTING - SHORT RUNNER . . . . . . . . 9-549 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197
DIAGNOSIS AND TESTING - RIGHT SOLENOID CIRCUIT SHORT TO GROUND SPEED SENSOR CIRCUIT, DIAGNOSIS
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-40 - (P0753) 1, 2/4-5 . . . . . . . . . . . . . . . . . . . 21-136 AND TESTING - LEFT FRONT WHEEL . . . . . . 5-95
SIGNAL LAMP - INSTALLATION, FRONT SOLENOID CIRCUIT SHORT TO GROUND SPEED SENSOR CIRCUIT, DIAGNOSIS
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-99 - (P0758) 2, 3 . . . . . . . . . . . . . . . . . . . . . . 21-142 AND TESTING - LEFT REAR WHEEL . . . . . . 5-107
SIGNAL LAMP - REMOVAL, FRONT SOLENOID CIRCUIT SHORT TO GROUND SPEED SENSOR CIRCUIT, DIAGNOSIS
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-98 - (P0763) 3, 4 . . . . . . . . . . . . . . . . . . . . . . 21-148 AND TESTING - (P0715) N2 INPUT . . . . . . 21-97
SIGNAL OUTPUT CIRCUIT, DIAGNOSIS SOLENOID STUCK OPEN, DIAGNOSIS SPEED SENSOR CIRCUIT, DIAGNOSIS
AND TESTING - SIREN . . . . . . . . . . . . . . . . 8Q-27 AND TESTING - (P0446) EVAP PURGE . . . . 9-387 AND TESTING - (P0715) N3 INPUT . . . . . . 21-103
SILL TRIM PLATE - INSTALLATION, SOLENOID SUPPLY VOLTAGE, SPEED SENSOR CIRCUIT, DIAGNOSIS
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-193 DIAGNOSIS AND TESTING - (P0778) . . . . 21-154 AND TESTING - RIGHT FRONT WHEEL . . . . 5-101
SILL TRIM PLATE - REMOVAL, DOOR . . . 23-193 SOLENOID SUPPLY/WATCHDOG, SPEED SENSOR CIRCUIT, DIAGNOSIS
SINGLE CARDAN UNIVERSAL JOINTS - DIAGNOSIS AND TESTING - (P0702) . . . . . 21-80 AND TESTING - RIGHT REAR WHEEL . . . . . 5-113
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 SOLENOID VALVE - DESCRIPTION . . . . . . . 5-202 SPLICE INFORMATION - DESCRIPTION,
SINGLE CARDAN UNIVERSAL JOINTS - SOLENOID VALVE - INSTALLATION . . . . . . . 5-202 CONNECTOR, GROUND . . . . . . . . . . . . . . 8W-01-6
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 3-32 SOLENOID VALVE - OPERATION . . . . . . . . . 5-202 SPLICING - STANDARD PROCEDURE,
SIREN - INSTALLATION . . . . . . . . . . . . . . . 8Q-51 SOLENOID VALVE - REMOVAL . . . . . . . . . . 5-202 WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-13
SIREN - REMOVAL . . . . . . . . . . . . . . . . . . . 8Q-50 SOLENOID VALVE CIRCUIT, DIAGNOSIS SPOILER - DESCRIPTION, REAR . . . . . . . . 23-116
SIREN SIGNAL OUTPUT CIRCUIT, AND TESTING - BAS . . . . . . . . . . . . . . . . . . 5-181 SPOILER - OPERATION, REAR . . . . . . . . . 23-116
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-27 SPARK PLUG - INSTALLATION . . . . . . . . . . . 8I-12 SPOILER DRIVER (DOWN) CIRCUIT,
SKREEM, INSTALLATION . . . . . . . . . . . . . . . 8E-70 SPARK PLUG - OPERATION . . . . . . . . . . . . . . 8I-7 DIAGNOSIS AND TESTING - REAR . . . . . . . 23-16
SKREEM, INSTALLATION . . . . . . . . . . . . . . 8N-49 SPARK PLUG - REMOVAL . . . . . . . . . . . . . . 8I-11 SPOILER DRIVER (UP) CIRCUIT,
SKREEM, REMOVAL . . . . . . . . . . . . . . . . . . 8E-70 SPARK PLUG CABLE - DESCRIPTION . . . . . 8I-13 DIAGNOSIS AND TESTING - REAR . . . . . . . 23-13
SKREEM, REMOVAL . . . . . . . . . . . . . . . . . . 8N-47 SPARK PLUG CABLE - INSTALLATION . . . . . 8I-13
30 INDEX ZH

SPOILER LIMIT SWITCH FAILURE, STOP LAMP INOPERATIVE, DIAGNOSIS SWITCH - INSTALLATION, LIFTGATE
DIAGNOSIS AND TESTING - REAR . . . . . . . 23-19 AND TESTING - LEFT . . . . . . . . . . . . . . . . . 8L-47 LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-45
SPOILER LIMIT SWITCH SIGNAL STOP LAMP INOPERATIVE, DIAGNOSIS SWITCH - INSTALLATION, MULTI-
(DOWN) CIRCUIT, DIAGNOSIS AND AND TESTING - RIGHT . . . . . . . . . . . . . . . . 8L-59 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-113
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10 STOP LAMP SWITCH CAN SIGNAL LOST SWITCH - INSTALLATION, POWER LOCK . . 8N-39
SPOILER LIMIT SWITCH SIGNAL (UP) TO TRANS PERFORMANCE, SWITCH - INSTALLATION, POWER
CIRCUIT, DIAGNOSIS AND TESTING . . . . . . . 23-7 DIAGNOSIS AND TESTING - (P0571) . . . . . 9-421 MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-71
SPOILER MOTOR FAILURE, DIAGNOSIS STOP LAMP SWITCH SIGNAL SWITCH - INSTALLATION, POWER SEAT . . 8N-98
AND TESTING - REAR . . . . . . . . . . . . . . . . . 23-23 PERFORMANCE, DIAGNOSIS AND SWITCH - INSTALLATION, POWER
SPOILER SWITCH SENSE CIRCUIT, TESTING - (P0571) . . . . . . . . . . . . . . . . . . . 9-423 WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-124
DIAGNOSIS AND TESTING - REAR . . . . . . . . 23-4 STRAP - INSTALLATION, CHECK . . . . . . . . . 23-89 SWITCH - INSTALLATION, REAR
SPOILER VERIFICATION TEST, STRAP - REMOVAL, CHECK . . . . . . . . . . . . 23-88 WINDOW DEFOGGER . . . . . . . . . . . . . . . . . 8G-12
DIAGNOSIS AND TESTING - REAR . . . . . . . 23-27 STRIKER - INSTALLATION, LATCH . 23-140,23-43 SWITCH - INSTALLATION, RELEASE . . . . . . 5-203
SPOILER WING, INSTALLATION . . . . . . . . 23-121 STRIKER - REMOVAL, LATCH . . . . . 23-140,23-43 SWITCH - INSTALLATION, TOW-AWAY
SPOILER WING, REMOVAL . . . . . . . . . . . . 23-117 STRUCTURAL ADHESIVES - ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-59
SPRAY NOZZLES - INSTALLATION, OIL . . . 9-674 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 23-87 SWITCH - INSTALLATION, WASHER
SPRAY NOZZLES - REMOVAL, OIL . . . . . . . 9-674 STRUT - INSTALLATION, CAMBER . . . . . . . . 2-50 FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 8R-26
SPRING - INSTALLATION . . . . . . . . . . . 2-44,2-85 STRUT - REMOVAL, CAMBER . . . . . . . . . . . . 2-49 SWITCH - OPERATION, BRAKE LAMP . . . . . 8L-91
SPRING - REMOVAL . . . . . . . . . . . . . . . 2-42,2-83 SUCTION LINE - INSTALLATION . . . . . . . . 24-137 SWITCH - OPERATION, DOOR AJAR . . . . . 8L-144
SPRINGS - DESCRIPTION, VALVE . . . . . . . . 9-633 SUCTION LINE - REMOVAL . . . . . . . . . . . . 24-136 SWITCH - OPERATION, HAZARD . . . . . . . . 8L-100
SPRINGS - OPERATION, VALVE . . . . . . . . . 9-633 SUPPLEMENTAL RESTRAINT SWITCH - OPERATION, HEADLAMP . . . . . 8L-105
SQUIB CIRCUIT, DIAGNOSIS AND DEPLOYMENT - STANDARD SWITCH - OPERATION, RELEASE . . . . . . . . 5-203
TESTING - DRIVER AIRBAG . . . . . . . . . . . . . 8O-4 PROCEDURE, SERVICE AFTER A . . . . . . . . 8O-84 SWITCH - REMOVAL . . . . . . . . . . . . . . . . . . . 8P-4
SQUIB CIRCUIT, DIAGNOSIS AND SUPPLEMENTAL RESTRAINT SYSTEM - SWITCH - REMOVAL, BACKUP LAMP . . . . 21-353
TESTING - DRIVER SEAT BELT DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8O-83 SWITCH - REMOVAL, BRAKE LAMP . . . . . . 8L-91
TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10 SUPPLEMENTAL RESTRAINT SYSTEM SWITCH - REMOVAL, DOOR CYLINDER
SQUIB CIRCUIT, DIAGNOSIS AND (SRS) - VERIFICATION TEST - LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-56
TESTING - LEFT SIDE AIRBAG . . . . . . . . . . 8O-29 STANDARD PROCEDURE . . . . . . . . . . . . . . 8O-86 SWITCH - REMOVAL, DRIVER DOOR
SQUIB CIRCUIT, DIAGNOSIS AND SUPPLEMENTAL RESTRAINTS - LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43
TESTING - PASSENGER AIRBAG . . . . . . . . . 8O-23 STANDARD PROCEDURE, HANDLING SWITCH - REMOVAL, HAZARD . . . . . . . . . . . 8L-100
SQUIB CIRCUIT, DIAGNOSIS AND NON-DEPLOYED . . . . . . . . . . . . . . . . . . . . . 8O-83 SWITCH - REMOVAL, HEADLAMP . . . . . . . 8L-105
TESTING - PASSENGER SEAT BELT SUPPLY CIRCUIT, DIAGNOSIS AND SWITCH - REMOVAL, HEATED SEAT . . . . . . 8G-37
TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17 TESTING - (P0121) APPS 5-VOLT. . . . . . . . . . 9-61 SWITCH - REMOVAL, HOOD AJAR . . . . . . . 8Q-50
SQUIB CIRCUIT, DIAGNOSIS AND SUPPLY CIRCUIT OPEN, DIAGNOSIS SWITCH - REMOVAL, HORN . . . . . . . . . . . . 8H-13
TESTING - RIGHT SIDE AIRBAG . . . . . . . . . 8O-35 AND TESTING - VOLTAGE . . . . . . . . . . . . . . . 8R-2 SWITCH - REMOVAL, IGNITION . . . . . . . . . 19-23
STABILITY PROGRAM (ESP) - SUPPLY VOLTAGE, DIAGNOSIS AND SWITCH - REMOVAL, LIFTGATE AJAR . . . 8L-145
OPERATION, ELECTRONIC . . . . . . . . . . . . . . 5-189 TESTING - (P0700) SENSOR . . . . . . . . . . . . 21-67 SWITCH - REMOVAL, LIFTGATE LOCK . . . . 8N-45
STABILIZER BAR - INSTALLATION . . . . 2-47,2-76 SUPPLY VOLTAGE, DIAGNOSIS AND SWITCH - REMOVAL, MULTI-FUNCTION . . 8L-112
STABILIZER BAR - REMOVAL . . . . . . . . 2-46,2-72 TESTING - (P0778) SOLENOID . . . . . . . . . 21-154 SWITCH - REMOVAL, POWER LOCK . . . . . 8N-39
STARTER MOTOR - DESCRIPTION . . . . . . . 8F-41 SUPPLY/WATCHDOG, DIAGNOSIS AND SWITCH - REMOVAL, POWER MIRROR . . . 8N-71
STARTER MOTOR - DIAGNOSIS AND TESTING - (P0702) SOLENOID . . . . . . . . . . 21-80 SWITCH - REMOVAL, POWER SEAT . . . . . . 8N-96
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41 SUPPORT BRACKET - INSTALLATION, SWITCH - REMOVAL, POWER WINDOW . 8N-124
STARTER MOTOR - INSTALLATION . . . . . . . 8F-44 REARVIEW MIRROR . . . . . . . . . . . . . . . . . . 8N-69 SWITCH - REMOVAL, REAR WINDOW
STARTER MOTOR - OPERATION . . . . . . . . . 8F-41 SUPPORT BRACKET AND ISOLATOR - DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
STARTER MOTOR - REMOVAL . . . . . . . . . . 8F-43 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 11-14 SWITCH - REMOVAL, RELEASE . . . . . . . . . 5-203
STARTER MOTOR, SPECIFICATIONS . . . . . . 8F-40 SUPPORT BRACKET AND ISOLATOR - SWITCH - REMOVAL, TOW-AWAY
STARTING, STANDARD PROCEDURE - REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-59
JUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 SURFACE PREPARATION - STANDARD SWITCH - REMOVAL, WASHER FLUID
STARTING SYSTEM - DESCRIPTION . . . . . . 8F-32 PROCEDURE, ENGINE GASKET . . . . . . . . . . 9-590 LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26
STARTING SYSTEM - DIAGNOSIS AND SUSPENSION - SPECIFICATIONS . . . . . . . . . 2-13 SWITCH CAN SIGNAL LOST TO TRANS
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-33 SUSPENSION - SPECIFICATIONS, REAR . . . . 2-48 PERFORMANCE, DIAGNOSIS AND
STARTING SYSTEM - OPERATION . . . . . . . . 8F-33 SUSPENSION - TORQUE CHART, FRONT . . . 2-14 TESTING - (P0571) STOP LAMP . . . . . . . . . 9-421
STARTING SYSTEM - SCHEMATICS AND SUSPENSION AND STEERING SYSTEM - SWITCH CIRCUIT - (P0850) TRANS
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 8F-39 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 2-1 TEMP SENSOR, P/N . . . . . . . . . . . . . . . . . 21-158
STEER, SPECIAL TOOLS . . . . . . . . . . . . . . . . 19-7 SUSPENSION, SPECIAL TOOLS . . . . . . . . . . . . 2-2 SWITCH CIRCUIT, DIAGNOSIS AND
STEERING ANGLE SENSOR - SWITCH - DESCRIPTION, BACKUP LAMP . . 8L-89 TESTING - BAS RELEASE . . . . . . . . . . . . . . 5-166
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 5-200 SWITCH - DESCRIPTION, BRAKE LAMP . . . 8L-91 SWITCH CIRCUIT, DIAGNOSIS AND
STEERING ANGLE SENSOR - SWITCH - DESCRIPTION, COURTESY TESTING - BRAKE LAMP . . . . . . . . . . 5-143,5-176
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5-200 LAMP DEFEAT . . . . . . . . . . . . . . . . . . . . . . 8L-141 SWITCH CIRCUIT, DIAGNOSIS AND
STEERING ANGLE SENSOR - OPERATION . 5-200 SWITCH - DESCRIPTION, DIMMER . . . . . . 8L-144 TESTING - COOLANT LEVEL
STEERING ANGLE SENSOR - REMOVAL . . . 5-200 SWITCH - DESCRIPTION, DOOR AJAR . . . 8L-144 SENSOR/WASHER FLUID LEVEL . . . . . . . . . . 8J-2
STEERING ANGLE SENSOR CIRCUIT, SWITCH - DESCRIPTION, HAZARD . . . . . . 8L-100 SWITCH CIRCUIT, DIAGNOSIS AND
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 5-124 SWITCH - DESCRIPTION, HEADLAMP . . . . 8L-105 TESTING - HAZARD . . . . . . . . . . . . . . . . . . 8L-118
STEERING COLUMN, INSTALLATION . . . . . . 19-15 SWITCH - DESCRIPTION, MULTI- SWITCH FAILURE, DIAGNOSIS AND
STEERING FLOW AND PRESSURE - FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-25 TESTING - REAR SPOILER LIMIT . . . . . . . . 23-19
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 19-5 SWITCH - DESCRIPTION, POWER LOCK . . 8N-38 SWITCH ILLUMINATION - DESCRIPTION,
STEERING GEAR, ADJUSTMENTS . . . . . . . . 19-38 SWITCH - DESCRIPTION, RELEASE . . . . . . 5-203 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-150
STEERING PUMP INITIAL OPERATION, SWITCH - DIAGNOSIS AND TESTING, SWITCH INDICATOR MODULE -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 19-51 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-12 INSTALLATION, ON / OFF . . . . . . . . . . . . . 8O-106
STEERING SYSTEM - DIAGNOSIS AND SWITCH - DIAGNOSIS AND TESTING, SWITCH INDICATOR MODULE -
TESTING, SUSPENSION . . . . . . . . . . . . . . . . . 2-1 POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8N-96 REMOVAL, ON / OFF . . . . . . . . . . . . . . . . . 8O-105
STEERING SYSTEM, DESCRIPTION . . . . . . . . 19-1 SWITCH - INSTALLATION . . . . . . . . . . . . . . . 8P-5 SWITCH INPUT CIRCUIT, DIAGNOSIS
STEERING SYSTEM, DIAGNOSIS AND SWITCH - INSTALLATION, BACKUP AND TESTING - SPEED CONTROL . . . . . . . 9-553
TESTING - POWER . . . . . . . . . . . . . . . . . . . . 19-2 LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-354 SWITCH, INSTALLATION - DOOR AJAR . . 8L-146
STEERING WHEEL - INSTALLATION . . . . . . 19-26 SWITCH - INSTALLATION, BRAKE LAMP . . 8L-92 SWITCH, REMOVAL - DOOR AJAR . . . . . . 8L-145
STEERING WHEEL - REMOVAL . . . . . . . . . . 19-25 SWITCH - INSTALLATION, DRIVER SWITCH SENSE CIRCUIT, DIAGNOSIS
STEM SEAL - INSTALLATION, VALVE . . . . . 9-628 CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8Q-57 AND TESTING - DOOR LOCK . . . . . . . . . . . 8Q-16
STEM SEAL - REMOVAL, VALVE . . . . . . . . . 9-627 SWITCH - INSTALLATION, DRIVER DOOR SWITCH SENSE CIRCUIT, DIAGNOSIS
STOP LAMP - DESCRIPTION, CENTER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-43 AND TESTING - DOOR LOCK/DOOR
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-92 SWITCH - INSTALLATION, HAZARD . . . . . 8L-102 UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
STOP LAMP - INSTALLATION, CENTER SWITCH - INSTALLATION, HEADLAMP . . . 8L-106 SWITCH SENSE CIRCUIT, DIAGNOSIS
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-93 SWITCH - INSTALLATION, HEATED SEAT . . 8G-38 AND TESTING - DOOR UNLOCK . . . . . . . . . 8Q-19
STOP LAMP - REMOVAL, CENTER HIGH SWITCH - INSTALLATION, HOOD AJAR . . . 8Q-50 SWITCH SENSE CIRCUIT, DIAGNOSIS
MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-92 SWITCH - INSTALLATION, HORN . . . . . . . . 8H-13 AND TESTING - REAR DEFOGGER . . . . . . . . 8G-2
STOP LAMP INOPERATIVE, DIAGNOSIS SWITCH - INSTALLATION, IGNITION . . . . . . 19-24 SWITCH SENSE CIRCUIT, DIAGNOSIS
AND TESTING - CENTER HIGH SWITCH - INSTALLATION, LIFTGATE AND TESTING - REAR SPOILER . . . . . . . . . . 23-4
MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-68 AJAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-146
ZH INDEX 31

SWITCH SIGNAL CIRCUIT, DIAGNOSIS TCM, DIAGNOSIS AND TESTING - TENSIONER - INSTALLATION, SEAT BELT
AND TESTING - PASSENGER AIRBAG (P0602) PCM PROGRAMMED & SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . 8O-125
ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-49 INCORRECT TRANS/NO COMM FROM . . . . 9-451 TENSIONER - INSTALLATION, TIMING
SWITCH SIGNAL (DOWN) CIRCUIT, TCM IS NOT CODED, DIAGNOSIS AND CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-685
DIAGNOSIS AND TESTING - SPOILER TESTING - (P0702) CONTROL MODULE . . . 21-74 TENSIONER - OPERATION, SEAT BELT &
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10 TCM QUICK LEARN - STANDARD SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-120
SWITCH SIGNAL PERFORMANCE, PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8E-59 TENSIONER - REMOVAL, BELT . . . . . . . . . . . 7-44
DIAGNOSIS AND TESTING - (P0571) TCM TORQUE MANAGEMENT REQUEST TENSIONER - REMOVAL, SEAT BELT &
STOP LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 9-423 PERFORMANCE, DIAGNOSIS AND SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-122
SWITCH SIGNAL (UP) CIRCUIT, TESTING - (P0702) . . . . . . . . . . . . . . . . . . . 9-461 TENSIONER - REMOVAL, TIMING CHAIN . . 9-684
DIAGNOSIS AND TESTING - SPOILER TELESCOPING WHEEL INDICATOR TENSIONER CIRCUIT, DIAGNOSIS AND
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7 INOPERATIVE, DIAGNOSIS AND TESTING - DRIVER SEAT BELT . . . . . . . . . . 8O-53
SWITCHOVER SOLENOID - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-50 TENSIONER CIRCUIT, DIAGNOSIS AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 25-35 TEMP, DIAGNOSIS AND TESTING - TESTING - PASSENGER SEAT BELT . . . . . . 8O-56
SWITCHOVER SOLENOID - REMOVAL . . . . 25-34 (P0128) FORCED LIMITED POWER TENSIONER SQUIB CIRCUIT, DIAGNOSIS
SWITCHOVER SOLENOID CIRCUIT, EXCESSIVE HIGH COOLANT . . . . . . . . . . . . . 9-74 AND TESTING - DRIVER SEAT BELT . . . . . . 8O-10
DIAGNOSIS AND TESTING - (P0412) TEMP SENSOR ERRATIC, DIAGNOSIS TENSIONER SQUIB CIRCUIT, DIAGNOSIS
SECONDARY AIR INJECTION . . . . . . . . . . . . 9-365 AND TESTING - (P0714) TRANS . . . . . . . . . 21-87 AND TESTING - PASSENGER SEAT
SWITCHOVER VALVE - INSTALLATION . . . . 25-36 TEMP SENSOR, P/N SWITCH CIRCUIT - BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17
SWITCHOVER VALVE - INSTALLATION, (P0850) TRANS . . . . . . . . . . . . . . . . . . . . . 21-158 TERMINAL - INSTALLATION . . . . . . . . . 8W-01-12
RECIRC AIR . . . . . . . . . . . . . . . . . . . . . . . . . 24-87 TEMP SENSOR SHORTED, DIAGNOSIS TERMINAL - REMOVAL . . . . . . . . . . . . . 8W-01-12
SWITCHOVER VALVE - REMOVAL . . . . . . . . 25-36 AND TESTING - (P0710) TRANS . . . . . . . . . 21-83 TEST - DIAGNOSIS AND TESTING,
SWITCHOVER VALVE - REMOVAL, TEMPERATURE, DIAGNOSIS AND INSPECTION AND ROAD . . . . . . . . . . . . . . . 5-191
RECIRC AIR . . . . . . . . . . . . . . . . . . . . . . . . . 24-87 TESTING - ENGINE OIL SENSOR OVER . . . 9-526 TEST - STANDARD PROCEDURE,
SWITCHOVER VALVE CIRCUIT, TEMPERATURE MESSAGE, DIAGNOSIS IGNITION-OFF DRAW . . . . . . . . . . . . . . . . . . 8F-14
DIAGNOSIS AND TESTING - AND TESTING - (P0600) ENGINE . . . . . . . . 21-51 TEST - STANDARD PROCEDURE,
RECIRCULATED AIR . . . . . . . . . . . . . . . . . . 24-46 TEMPERATURE SENSOR - DESCRIPTION, OPEN-CIRCUIT VOLTAGE . . . . . . . . . . . . . . . 8F-13
SWITCH/UNIT - DESCRIPTION, INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36 TEST - STANDARD PROCEDURE,
COURTESY LAMP . . . . . . . . . . . . . . . . . . . 8L-142 TEMPERATURE SENSOR - DESCRIPTION, SUPPLEMENTAL RESTRAINT SYSTEM
SWITCH/UNIT - INSTALLATION, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-327 (SRS) - VERIFICATION . . . . . . . . . . . . . . . . 8O-86
COURTESY LAMP . . . . . . . . . . . . . . . . . . . 8L-143 TEMPERATURE SENSOR - TEST, DIAGNOSIS AND TESTING - ABS
SWITCH/UNIT - OPERATION, COURTESY INSTALLATION, ENGINE COOLANT . . . . . . . . 7-31 VERIFICATION . . . . . . . . . . . . . . . . . . 5-148,5-185
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142 TEMPERATURE SENSOR - TEST, DIAGNOSIS AND TESTING -
SWITCH/UNIT - REMOVAL, COURTESY INSTALLATION, EVAPORATOR . . . . . . . . . . . 24-84 AIRBAG VERIFICATION . . . . . . . . . . . . . . . . 8O-67
LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-142 TEMPERATURE SENSOR - TEST, DIAGNOSIS AND TESTING - BODY
SYMBOLS - DESCRIPTION, INSTALLATION, HEATER CORE . . . . . . . . . . 24-85 VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 8A-16
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . Intro.-2 TEMPERATURE SENSOR - OPERATION, TEST, DIAGNOSIS AND TESTING - BODY
SYMBOLS - DESCRIPTION, ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-29 VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 8E-44
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . 0-6 TEMPERATURE SENSOR - OPERATION, TEST, DIAGNOSIS AND TESTING - BODY
SYNCHRONIZE - STANDARD INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36 VERIFICATION . . . . . . . . . . . . . 8G-20,8G-34,8G-8
PROCEDURE, WIPER MOTOR . . . . . . . . . . . 8R-46 TEMPERATURE SENSOR - OPERATION, TEST, DIAGNOSIS AND TESTING - BODY
SYNCHRONIZER - ASSEMBLY . . . . . . . . . . 21-386 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-328 VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 8H-7
SYNCHRONIZER - DESCRIPTION . . . . . . . 21-386 TEMPERATURE SENSOR - REMOVAL, TEST, DIAGNOSIS AND TESTING - BODY
TABLE, SPECIFICATIONS - A/C ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-29 VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 8J-52
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . 24-70 TEMPERATURE SENSOR - REMOVAL, TEST, DIAGNOSIS AND TESTING - BODY
TAIL LAMP INOPERATIVE, DIAGNOSIS EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . 24-84 VERIFICATION . . . . . . . . . . . . . . . . . 8L-133,8L-77
AND TESTING - LEFT . . . . . . . . . . . . . . . . . 8L-44 TEMPERATURE SENSOR - REMOVAL, TEST, DIAGNOSIS AND TESTING - BODY
TAIL LAMP INOPERATIVE, DIAGNOSIS HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-85 VERIFICATION . . . . . . 8N-119,8N-28,8N-62,8N-93
AND TESTING - RIGHT . . . . . . . . . . . . . . . . 8L-56 TEMPERATURE SENSOR CIRCUIT, TEST, DIAGNOSIS AND TESTING -
TAIL LAMP UNIT, INSTALLATION . . . . . . . 8L-115 DIAGNOSIS AND TESTING - AMBIENT . . . . . 24-3 SENTRY KEY VERIFICATION . . . . . . . . . . . . 8Q-43
TAIL LAMP UNIT, REMOVAL . . . . . . . . . . . 8L-113 TEMPERATURE SENSOR CIRCUIT, TEST, DIAGNOSIS AND TESTING - VTSS
TAIL/STOP - INSTALLATION . . . . . . . . . . . 8L-115 DIAGNOSIS AND TESTING - AMBIENT . . . . . 8J-9 VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 8Q-33
TAIL/STOP - REMOVAL . . . . . . . . . . . . . . . 8L-114 TEMPERATURE SENSOR CIRCUIT, TESTER - STANDARD PROCEDURE,
TANK - DESCRIPTION, FUEL . . . . . . . . . . . . 14-20 DIAGNOSIS AND TESTING - ENGINE USING MICRO 420 BATTERY . . . . . . . . . . . . 8F-12
TANK - INSTALLATION, FUEL . . . . . . . . . . . 14-22 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 THEFT SECURITY - SERVICE
TANK - OPERATION, FUEL . . . . . . . . . . . . . . 14-20 TEMPERATURE SENSOR CIRCUIT, INFORMATION - DESCRIPTION,
TANK - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-21 DIAGNOSIS AND TESTING - VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-46
TANK - STANDARD PROCEDURE, EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . 24-18 THEFT SECURITY - SERVICE
DRAINING FUEL . . . . . . . . . . . . . . . . . . . . . . 14-5 TEMPERATURE SENSOR CIRCUIT, INFORMATION - OPERATION, VEHICLE . . . 8Q-47
TANK FILLER TUBE - DESCRIPTION, DIAGNOSIS AND TESTING - LEFT THERMOSTAT - DESCRIPTION, ENGINE
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24 HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . 24-8 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
TANK PRESSURE SENSOR CIRCUIT TEMPERATURE SENSOR CIRCUIT, THERMOSTAT - DIAGNOSIS AND
HIGH, DIAGNOSIS AND TESTING - DIAGNOSIS AND TESTING - RIGHT TESTING, ENGINE COOLANT . . . . . . . . . . . . . 7-22
(P0453) FUEL . . . . . . . . . . . . . . . . . . . . . . . 9-397 HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-13 THERMOSTAT - INSTALLATION, ENGINE
TANK PRESSURE SENSOR CIRCUIT TEMPERATURE SENSOR CIRCUIT HIGH, COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
LOW, DIAGNOSIS AND TESTING - DIAGNOSIS AND TESTING - (P0113) THERMOSTAT - OPERATION, ENGINE
(P0452) FUEL . . . . . . . . . . . . . . . . . . . . . . . 9-395 INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
TANK PRESSURE SENSOR TEMPERATURE SENSOR CIRCUIT HIGH, THERMOSTAT - REMOVAL, ENGINE
PERFORMANCE, DIAGNOSIS AND DIAGNOSIS AND TESTING - (P0118) COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
TESTING - (P0451) FUEL . . . . . . . . . . . . . . 9-390 ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 9-51 THERMOSTAT RATIONALITY, DIAGNOSIS
TAPE, INSTALLATION - DOUBLE SIDED . . 23-115 TEMPERATURE SENSOR CIRCUIT LOW, AND TESTING - (P0128) . . . . . . . . . . . . . . . . 9-78
TAPE, REMOVAL - DOUBLE SIDED . . . . . . 23-114 DIAGNOSIS AND TESTING - (P0112) THREAD REPAIR - STANDARD
TASK MANAGER - DESCRIPTION . . . . . . . . 25-37 INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31 PROCEDURE, ALUMINUM . . . . . . . . . . . . . 21-210
TASK MANAGER - OPERATION . . . . . . . . . . 25-37 TEMPERATURE SENSOR CIRCUIT LOW, THREADED HOLE REPAIR, DESCRIPTION . Intro.-6
T/C RANGE INDICATOR ILLUMINATION - DIAGNOSIS AND TESTING - (P0117) THREADS - STANDARD PROCEDURE,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 8L-150 ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 9-49 REPAIR OF DAMAGED OR WORN . . . . . . . . 9-589
TCC OVERTEMP, DIAGNOSIS AND TEMPERATURE SENSOR PERFORMANCE, THRESHOLD, DIAGNOSIS AND TESTING
TESTING - (P0740) . . . . . . . . . . . . . . . . . . 21-119 DIAGNOSIS AND TESTING - (P0116) - (P0137) O2 SENSOR 1/2 ABOVE . . . . . . . 9-121
TCC SOLENOID CIRCUIT, DIAGNOSIS ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 9-40 THRESHOLD, DIAGNOSIS AND TESTING
AND TESTING - (P0743) . . . . . . . . . . . . . . 21-124 TEMPERATURE SENSOR SHORT - (P0137) O2 SENSOR 1/2 BELOW . . . . . . . 9-119
TCC STUCK ON, DIAGNOSIS AND CIRCUIT, DIAGNOSIS AND TESTING - THRESHOLD, DIAGNOSIS AND TESTING
TESTING - (P0740) . . . . . . . . . . . . . . . . . . 21-121 (P0116) ENGINE COOLANT . . . . . . . . . . . . . . 9-47 - (P0137) O2 SENSOR 2/2 BELOW . . . . . . . 9-127
TCM, DIAGNOSIS AND TESTING - NO TENSIONER - DESCRIPTION, SEAT BELT THROTTLE ACTUATOR STUCK,
CAN COMMUNICATIONS WITH . . . . . . . . . . . 5-92 & SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . 8O-119 DIAGNOSIS AND TESTING - (P0211) . . . . . 9-252,
TCM, DIAGNOSIS AND TESTING - NO TENSIONER - INSPECTION, SEAT BELT & 9-257
CAN COMMUNICATIONS WITH . . . . . . . . . . 8J-30 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-125 THROTTLE ANGLE AND SPEED,
TENSIONER - INSTALLATION, BELT . . . . . . . 7-44 DIAGNOSIS AND TESTING - (P0104)
MAF SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 9-19
32 INDEX ZH

THROTTLE BODY - DESCRIPTION . . . . . . . . 14-47 TIRE PRESSURE SENSOR/TRANSMITTER TRANSMISSION CONTROL MODULE
THROTTLE BODY - INSTALLATION . . . . . . . 14-48 SIGNAL JAMMED, DIAGNOSIS AND LOW VOLTAGE, DIAGNOSIS AND
THROTTLE BODY - OPERATION . . . . . . . . . 14-47 TESTING - RIGHT FRONT . . . . . . . . . . . . . . 22-15 TESTING - (P0702) . . . . . . . . . . . . . . . . . . . 9-455
THROTTLE BODY - REMOVAL . . . . . . . . . . . 14-48 TIRE PRESSURE SENSOR/TRANSMITTER TRANSMISSION CONTROL SYSTEM (MIL
THROTTLE CONTROL MODULE SIGNAL JAMMED, DIAGNOSIS AND REQUEST), DIAGNOSIS AND TESTING -
PERFORMANCE, DIAGNOSIS AND TESTING - RIGHT REAR . . . . . . . . . . . . . . . 22-17 (P0700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-453
TESTING - (P0221) ELECTRONIC . . . . . . . . 9-270 TIRE PRESSURE VERIFICATION TEST, TRANSMISSION CONTROL SYSTEM (MIL
THROTTLE CONTROL MODULE DIAGNOSIS AND TESTING . . . . . . . . . . . . . 22-35 REQUEST), DIAGNOSIS AND TESTING -
PROCESSOR, DIAGNOSIS AND TIRE ROTATION - STANDARD (P0702) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-457
TESTING - (P0221) ELECTRONIC . . . . . . . . 9-272 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-45 TRANSMISSION CONTROL SYSTEM (MIL
THROTTLE CONTROL MOTOR TIRE WEAR PATTERNS - DIAGNOSIS REQUEST), DIAGNOSIS AND TESTING -
PERFORMANCE, DIAGNOSIS AND AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 22-59 (P0705) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-465
TESTING - (P0120) ELECTRONIC . . . . . . . . . 9-53 TIREFIT - STANDARD PROCEDURE, TRANSMISSION CONTROL SYSTEM (MIL
THROTTLE POSITION SENSOR - DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . 22-60 REQUEST), DIAGNOSIS AND TESTING -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-49 TIRES - RADIAL, PLY . . . . . . . . . . . . . . . . . 22-57 (P0715) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-467
THROTTLE POSITION SENSOR - TIRES - SPECIFICATIONS . . . . . . . . . . . . . . 22-61 TRANSMISSION CONTROL SYSTEM (MIL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 TIRES, DESCRIPTION . . . . . . . . . . . . . . . . . 22-56 REQUEST), DIAGNOSIS AND TESTING -
THROTTLE POSITION SENSOR 1/2 TIRES, DESCRIPTION - REPLACEMENT . . . 22-58 (P0720) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-475
CORRELATION, DIAGNOSIS AND TIRES TRAINED, DIAGNOSIS AND TRANSMISSION CONTROL SYSTEM (MIL
TESTING - (P0120) . . . . . . . . . . . . . . . . . . . . 9-59 TESTING - NO . . . . . . . . . . . . . . . . . . . . . . . . 22-2 REQUEST), DIAGNOSIS AND TESTING -
TIE ROD END - INSTALLATION . . . . . . . . . . 19-50 TIRE/VEHICLE LEAD - DIAGNOSIS AND (P0730) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-477
TIE ROD END - REMOVAL . . . . . . . . . . . . . . 19-49 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-60 TRANSMISSION CONTROL SYSTEM (MIL
TIMING - OPERATION, ENGINE . . . . . . . . . . 9-704 TOE - STANDARD PROCEDURE, REQUEST), DIAGNOSIS AND TESTING -
TIMING CHAIN - INSTALLATION . . . . . . . . . 9-695 CHECKING AND ADJUSTING REAR (P0740) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-479
TIMING CHAIN - REMOVAL . . . . . . . . . . . . . 9-693 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 TRANSMISSION CONTROL SYSTEM (MIL
TIMING CHAIN COVER - INSTALLATION . . . 9-688 TOE-IN - STANDARD PROCEDURE, REQUEST), DIAGNOSIS AND TESTING -
TIMING CHAIN COVER - REMOVAL . . . . . . 9-685 CHECKING AND ADJUSTING FRONT . . . . . . . 2-10 (P0743) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-481
TIMING CHAIN GUIDES - INSTALLATION . . 9-703 TOE-OUT ON TURNS - STANDARD TRANSMISSION CONTROL SYSTEM (MIL
TIMING CHAIN GUIDES - REMOVAL . . . . . . 9-703 PROCEDURE, CHECKING . . . . . . . . . . . . . . . . 2-11 REQUEST), DIAGNOSIS AND TESTING -
TIMING CHAIN TENSIONER - TOGGLING CUSTOMER PREFERENCES - (P0748) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-483
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-685 STANDARD PROCEDURE . . . . . . . . . . . . . . 8N-35 TRANSMISSION CONTROL SYSTEM (MIL
TIMING CHAIN TENSIONER - REMOVAL . . . 9-684 TOUCH - UP - DESCRIPTION, PAINT . . . . 23-200 REQUEST), DIAGNOSIS AND TESTING -
TIMING OVER-ADVANCED, DIAGNOSIS TOW HOOKS - DESCRIPTION, (P0753) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-485
AND TESTING - (P0341) CAMSHAFT EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . 0-14 TRANSMISSION CONTROL SYSTEM (MIL
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-344 TOW SENSOR - INSTALLATION, REQUEST), DIAGNOSIS AND TESTING -
TIMING OVER-RETARDED, DIAGNOSIS ANTI-THEFT . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-58 (P0758) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-487
AND TESTING - (P0341) CAMSHAFT TOW SENSOR - REMOVAL, ANTI-THEFT . . 8Q-57 TRANSMISSION CONTROL SYSTEM (MIL
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-340 TOW SENSOR SIGNAL CIRCUIT, REQUEST), DIAGNOSIS AND TESTING -
TIRE AND WHEEL BALANCE, STANDARD DIAGNOSIS AND TESTING - (P0763) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-489
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-42 ANTI-THEFT . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-22 TRANSMISSION COOLER LINES -
TIRE AND WHEEL INSTALLATION - TOW-AWAY ALARM SWITCH - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-50
STANDARD PROCEDURE . . . . . . . . . . . . . . . 22-46 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-59 TRANSMISSION COOLER LINES -
TIRE AND WHEEL RUNOUT - DIAGNOSIS TOW-AWAY ALARM SWITCH - REMOVAL . 8Q-59 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 22-38 TOWING - STANDARD PROCEDURE . . . . . . . . 0-6 TRANSMISSION, DIAGNOSIS AND
TIRE INFLATION PRESSURES, TPM MODULE PROGRAMMING - TESTING - AUTOMATIC . . . . . . . . . . . . . . . 21-206
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 22-57 STANDARD PROCEDURE . . . . . . . . . . . . . . . 22-50 TRANSMISSION FILL - STANDARD
TIRE NOISE OR VIBRATION - DIAGNOSIS TRACK - INSTALLATION, POWER SEAT . . 8N-107 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-296
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 22-59 TRACK - REMOVAL, POWER SEAT . . . . . . 8N-105 TRANSMISSION FLUID - DESCRIPTION,
TIRE PRESSURE FOR HIGH SPEED, TRACK BAR - INSTALLATION . . . . . . . . . . . . 2-53 AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 22-58 TRACK BAR - REMOVAL . . . . . . . . . . . . . . . . 2-52 TRANSMISSION FRONT SECTION -
TIRE PRESSURE MONITOR MODULE TRAILING LINK - INSTALLATION . . . . . . . . . . 2-51 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 21-361
FAILURE, DIAGNOSIS AND TESTING . . . . . . . 22-4 TRAILING LINK - REMOVAL . . . . . . . . . . . . . 2-50 TRANSMISSION FRONT SECTION -
TIRE PRESSURE MONITORING - TRAINED, DIAGNOSIS AND TESTING - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-361
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 22-46 NO TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2 TRANSMISSION INCORRECT TORQUE
TIRE PRESSURE MONITORING - TRANS PERFORMANCE, DIAGNOSIS AND REQUEST FROM ESP, DIAGNOSIS AND
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 22-48 TESTING - (P0571) STOP LAMP TESTING - (P0720) . . . . . . . . . . . . . . . . . . . 9-469
TIRE PRESSURE MONITORING SYSTEM SWITCH CAN SIGNAL LOST TO . . . . . . . . . 9-421 TRANSMISSION SLIPPING, DIAGNOSIS
- DIAGNOSIS AND TESTING . . . . . . . . . . . . 22-48 TRANS TEMP SENSOR ERRATIC, AND TESTING - (P0700) . . . . . . . . . . . . . . . 21-71
TIRE PRESSURE MONITORING SYSTEM, DIAGNOSIS AND TESTING - (P0714) . . . . . 21-87 TRANSMISSION TEMPERATURE SENSOR
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 22-49 TRANS TEMP SENSOR, P/N SWITCH - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 21-327
TIRE PRESSURE SENSOR/ CIRCUIT - (P0850) . . . . . . . . . . . . . . . . . . 21-158 TRANSMISSION TEMPERATURE SENSOR
TRANSMITTER, DIAGNOSIS AND TRANS TEMP SENSOR SHORTED, - OPERATION . . . . . . . . . . . . . . . . . . . . . . . 21-328
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-19 DIAGNOSIS AND TESTING - (P0710) . . . . . 21-83 TRANSMISSION VERIFICATION TEST,
TIRE PRESSURE SENSOR/ TRANSDUCER - INSTALLATION, A/C DIAGNOSIS AND TESTING . . . . . . . . . . . . 21-181
TRANSMITTER, DIAGNOSIS AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-86 TRANSMITTER - DESCRIPTION,
TESTING - LEFT FRONT . . . . . . . . . . . . . . . 22-24 TRANSDUCER - REMOVAL, A/C UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-1
TIRE PRESSURE SENSOR/ PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-86 TRANSMITTER - DIAGNOSIS AND
TRANSMITTER, DIAGNOSIS AND TRANSMISSION - DIAGNOSIS AND TESTING, KEYLESS ENTRY . . . . . . . . . . . . . 8N-37
TESTING - LEFT REAR . . . . . . . . . . . . . . . . 22-26 TESTING, AUTOMATIC . . . . . . . . . . . . . . . . 21-207 TRANSMITTER - DIAGNOSIS AND
TIRE PRESSURE SENSOR/ TRANSMISSION - SPECIAL TOOLS, TESTING, UNIVERSAL . . . . . . . . . . . . . . . . . 8M-2
TRANSMITTER, DIAGNOSIS AND NAG1 AUTOMATIC . . . . . . . . . . . . . . . . . . . 21-252 TRANSMITTER - INSTALLATION,
TESTING - RIGHT FRONT . . . . . . . . . . . . . . 22-28 TRANSMISSION - SPECIFICATIONS, UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-4
TIRE PRESSURE SENSOR/ NAG1 AUTOMATIC . . . . . . . . . . . . . . . . . . . 21-251 TRANSMITTER - OPERATION,
TRANSMITTER, DIAGNOSIS AND TRANSMISSION BUS MESSAGE, UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
TESTING - RIGHT REAR . . . . . . . . . . . . . . . 22-30 DIAGNOSIS AND TESTING - (P0600) TRANSMITTER - REMOVAL, UNIVERSAL . . . 8M-3
TIRE PRESSURE SENSOR/TRANSMITTER NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-433 TRANSMITTER, DIAGNOSIS AND
LOW BATTERY, DIAGNOSIS AND TRANSMISSION CONTROL MODULE - TESTING - INVALID . . . . . . . . . . . . . . . . . . . 8Q-36
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-58 TRANSMITTER FAILURE, DIAGNOSIS
TIRE PRESSURE SENSOR/TRANSMITTER TRANSMISSION CONTROL MODULE - AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 22-22
SIGNAL JAMMED, DIAGNOSIS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8E-61 TRANSMITTER PROGRAMMING -
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6 TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE . . . . . . . . . . . . . . 8N-37
TIRE PRESSURE SENSOR/TRANSMITTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-58 TRANSMITTER PROGRAMMING -
SIGNAL JAMMED, DIAGNOSIS AND TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE, UNIVERSAL . . . . . 8M-3
TESTING - LEFT FRONT . . . . . . . . . . . . . . . 22-11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-60 TRANSMITTER, SPECIFICATIONS . . . . . . . . 8N-37
TIRE PRESSURE SENSOR/TRANSMITTER TRANSMISSION CONTROL MODULE, TRANS/NO COMM FROM TCM,
SIGNAL JAMMED, DIAGNOSIS AND DIAGNOSIS AND TESTING - NO DIAGNOSIS AND TESTING - (P0602)
TESTING - LEFT REAR . . . . . . . . . . . . . . . . 22-13 RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-33 PCM PROGRAMMED INCORRECT . . . . . . . . 9-451
TRAVEL SENSOR - DESCRIPTION . . . . . . . . 5-201
ZH INDEX 33

TRAVEL SENSOR - INSTALLATION . . . 5-202,5-78 UNIT - DISASSEMBLY, VALVE - INSTALLATION, SOLENOID . . . . . . 5-202
TRAVEL SENSOR - OPERATION . . . . . . . . . 5-202 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . 21-282 VALVE - INSTALLATION, SWITCHOVER . . . . 25-36
TRAVEL SENSOR - REMOVAL . . . . . . . 5-202,5-78 UNIT - INSTALLATION, CARGO LAMP . . . . 8L-140 VALVE - OPERATION . . . . . . . . . . . . . . . . . . 25-27
TRAVEL SENSOR CIRCUIT, DIAGNOSIS UNIT - INSTALLATION, VALVE - OPERATION, A/C EXPANSION . . . 24-139
AND TESTING - BAS . . . . . . . . . . . . . . . . . . 5-171 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . 21-290 VALVE - OPERATION, CHARCOAL
TRAY - DESCRIPTION . . . . . . . . . . . . . . . . . 8F-22 UNIT - INSTALLATION, FOG LAMP . . . . . . . 8L-96 CANISTER SHUTOFF . . . . . . . . . . . . . . . . . . 25-16
TRAY - INSTALLATION . . . . . . . . . . . . . . . . . 8F-23 UNIT - INSTALLATION, HEADLAMP . . . . . . 8L-108 VALVE - OPERATION, COOLANT
TRAY - INSTALLATION, ASH . . . . . . . . . . . 23-190 UNIT - OPERATION, CIRCULATION . . . . . . . . . . . . . . . . . . . . . . 24-151
TRAY - OPERATION . . . . . . . . . . . . . . . . . . . 8F-22 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . 21-275 VALVE - OPERATION, FUEL FILL CHECK . . . . 14-7
TRAY - REMOVAL . . . . . . . . . . . . . . . . . . . . 8F-23 UNIT - REMOVAL, CARGO LAMP . . . . . . . 8L-139 VALVE - OPERATION, MANIFOLD TUNE . . . 14-40
TREAD WEAR INDICATORS - DIAGNOSIS UNIT - REMOVAL, ELECTROHYDRAULIC . 21-281 VALVE - OPERATION, SOLENOID . . . . . . . . 5-202
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 22-59 UNIT - REMOVAL, FOG LAMP . . . . . . . . . . . 8L-95 VALVE - REMOVAL . . . . . . . . . . . . . . . . . . . 25-27
TRIM - INSTALLATION, A-PILLAR . . . . . . . 23-162 UNIT - REMOVAL, HEADLAMP . . . . . . . . . 8L-108 VALVE - REMOVAL, A/C EXPANSION . . . . . 24-140
TRIM - REMOVAL, A-PILLAR . . . . . . . . . . 23-161 UNIT, INSTALLATION - TAIL LAMP . . . . . . 8L-115 VALVE - REMOVAL, CHARCOAL
TRIM PANEL - INSTALLATION . . . . . 23-109,23-49 UNIT, REMOVAL - TAIL LAMP . . . . . . . . . . 8L-113 CANISTER SHUTOFF . . . . . . . . . . . . . . . . . . 25-16
TRIM PANEL - REMOVAL . . . . . . . . 23-108,23-48 UNIT/SENSOR, DESCRIPTION - FUEL VALVE - REMOVAL, COOLANT
TRIM PLATE - INSTALLATION, DOOR LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . 14-11 CIRCULATION . . . . . . . . . . . . . . . . . . . . . . 24-152
SILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-193 UNIT/SENSOR, OPERATION - FUEL VALVE - REMOVAL, MANIFOLD TUNE . . . . . 14-41
TRIM PLATE - REMOVAL, DOOR SILL . . . 23-193 LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . 14-11 VALVE - REMOVAL, RECIRC AIR
TRIP DEFINITION - DESCRIPTION . . . . . . . . 25-12 UNIVERSAL GARAGE DOOR OPENER/ SWITCHOVER . . . . . . . . . . . . . . . . . . . . . . . 24-87
TRIPS ON ITS OWN, DIAGNOSIS AND TIRE PRESSURE MONITOR, VALVE - REMOVAL, SOLENOID . . . . . . . . . . 5-202
TESTING - ALARM . . . . . . . . . . . . . . . . . . . 8Q-32 DIAGNOSIS AND TESTING - NO VALVE - REMOVAL, SWITCHOVER . . . . . . . 25-36
TUBE - DESCRIPTION, FUEL TANK RESPONSE FROM . . . . . . . . . . . . . . . . . . . . 8E-17 VALVE CIRCUIT, DIAGNOSIS AND
FILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24 UNIVERSAL JOINTS - ASSEMBLY, TESTING - BAS SOLENOID . . . . . . . . . . . . . 5-181
TUBE - INSTALLATION . . . . . . . . . . . . . . . . 25-26 SINGLE CARDAN . . . . . . . . . . . . . . . . . . . . . . 3-33 VALVE CIRCUIT, DIAGNOSIS AND
TUBE - INSTALLATION, OIL LEVEL UNIVERSAL JOINTS - DISASSEMBLY, TESTING - LEFT COOLANT
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . 9-663 SINGLE CARDAN . . . . . . . . . . . . . . . . . . . . . . 3-32 CIRCULATION . . . . . . . . . . . . . . . . . . . . . . . 24-37
TUBE - REMOVAL . . . . . . . . . . . . . . . . . . . . 25-26 UNIVERSAL TRANSMITTER - VALVE CIRCUIT, DIAGNOSIS AND
TUBE - REMOVAL, OIL LEVEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8M-1 TESTING - RECIRCULATED AIR
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . 9-663 UNIVERSAL TRANSMITTER - DIAGNOSIS SWITCHOVER . . . . . . . . . . . . . . . . . . . . . . . 24-46
TUBES - INSTALLATION, WASHER AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8M-2 VALVE CIRCUIT, DIAGNOSIS AND
HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-27 UNIVERSAL TRANSMITTER - TESTING - RIGHT COOLANT
TUBES - REMOVAL, WASHER HOSES . . . . 8R-26 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8M-4 CIRCULATION . . . . . . . . . . . . . . . . . . . . . . . 24-40
TUNE VALVE - DESCRIPTION, MANIFOLD . . 14-40 UNIVERSAL TRANSMITTER - OPERATION . . 8M-2 VALVE, DIAGNOSIS AND TESTING -
TUNE VALVE - INSTALLATION, UNIVERSAL TRANSMITTER - REMOVAL . . . 8M-3 (P0441) EVAP PURGE . . . . . . . . . . . . . . . . . 9-376
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41 UNIVERSAL TRANSMITTER VALVE, DIAGNOSIS AND TESTING -
TUNE VALVE - OPERATION, MANIFOLD . . . 14-40 PROGRAMMING - STANDARD (P0446) CHARCOAL CANISTER
TUNE VALVE - REMOVAL, MANIFOLD . . . . . 14-41 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8M-3 SHUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-384
TURN LAMP INOPERATIVE, DIAGNOSIS UNLOCK SWITCH SENSE CIRCUIT, VALVE LEAKING, DIAGNOSIS AND
AND TESTING - LEFT FRONT . . . . . . . . . . . 8L-11 DIAGNOSIS AND TESTING - DOOR . . . . . . 8Q-19 TESTING - (P0457) EVAP PURGE . . . . . . . . 9-406
TURN LAMP INOPERATIVE, DIAGNOSIS UNLOCK SWITCH SENSE CIRCUIT, VALVE SPRINGS - DESCRIPTION . . . . . . . . 9-633
AND TESTING - LEFT REAR . . . . . . . . . . . . 8L-53 DIAGNOSIS AND TESTING - DOOR VALVE SPRINGS - OPERATION . . . . . . . . . . 9-633
TURN LAMP INOPERATIVE, DIAGNOSIS LOCK/DOOR . . . . . . . . . . . . . . . . . . . . . . . . 8N-22 VALVE STEM SEAL - INSTALLATION . . . . . . 9-628
AND TESTING - RIGHT FRONT . . . . . . . . . . 8L-17 UP - DESCRIPTION, PAINT TOUCH . . . . . . 23-200 VALVE STEM SEAL - REMOVAL . . . . . . . . . 9-627
TURN LAMP INOPERATIVE, DIAGNOSIS UP, DIAGNOSIS AND TESTING - DRB IIIT VALVES AND SEALS - CLEANING,
AND TESTING - RIGHT REAR . . . . . . . . . . . 8L-65 DOES NOT POWER . . . . . . . . . . . . . . . . . . . . 8E-2 INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . 9-632
TURN SIGNAL - INSTALLATION . . . . . . . . 8L-116 UP LAMP INOPERATIVE, DIAGNOSIS VALVES AND SEALS - DESCRIPTION,
TURN SIGNAL - REMOVAL . . . . . . . . . . . . 8L-114 AND TESTING - LEFT BACK . . . . . . . . . . . . 8L-50 INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . 9-630
TURN SIGNAL INDICATOR INOPERATIVE, UP LAMP INOPERATIVE, DIAGNOSIS VALVES AND SEALS - INSTALLATION,
DIAGNOSIS AND TESTING - LEFT . . . . . . . . 8J-38 AND TESTING - RIGHT BACK . . . . . . . . . . . 8L-62 INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . 9-632
TURN SIGNAL INDICATOR INOPERATIVE, UPPER CONTROL ARM - INSTALLATION . . . 2-39 VALVES AND SEALS - OPERATION,
DIAGNOSIS AND TESTING - RIGHT . . . . . . 8J-40 UPPER CONTROL ARM - REMOVAL . . . . . . . 2-39 INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . 9-630
TURN SIGNAL LAMP - INSTALLATION, UPPER OIL PAN - INSTALLATION . . . . . . . . 9-671 VALVES AND SEALS - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-99 UPPER OIL PAN - REMOVAL . . . . . . . . . . . . 9-669 INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . 9-630
TURN SIGNAL LAMP - REMOVAL, UPRIGHT POSITION - STANDARD VAPOR CANISTER - DESCRIPTION . . . . . . . 25-20
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-98 PROCEDURE, MOVING THE HOOD TO VAPOR CANISTER - INSTALLATION . . . . . . 25-21
TURNS - STANDARD PROCEDURE, ITS FULLY . . . . . . . . . . . . . . . . . . . . . . . . . 23-130 VAPOR CANISTER - OPERATION . . . . . . . . . 25-20
CHECKING TOE-OUT ON . . . . . . . . . . . . . . . . 2-11 UPSTREAM O2, INSTALLATION . . . . . . . . . . 14-46 VAPOR CANISTER - REMOVAL . . . . . . . . . . 25-20
TWEETER SPEAKER - INSTALLATION . . . . . 8A-34 UPSTREAM O2 SENSOR, REMOVAL . . . . . . 14-45 VECI LABEL - DESCRIPTION . . . . . . . . . . . Intro.-9
TWEETER SPEAKER - REMOVAL . . . . . . . . 8A-30 USAGE, DESCRIPTION - FASTENER . . . . . Intro.-6 VEHICLE EMISSION CONTROL
UNDERHOOD ACCESSORY FUSE BLOCK USE WIRING DIAGRAMS - INFORMATION LABEL - DESCRIPTION . . . . 25-12
- DESCRIPTION . . . . . . . . . . . . . . . . . . . . 8W-97-5 DESCRIPTION, HOW TO . . . . . . . . . . . . . 8W-01-1 VEHICLE EQUIPMENT, DIAGNOSIS AND
UNDERHOOD ACCESSORY FUSE BLOCK USING MICRO 420 BATTERY TESTER - TESTING - PROGRAMMING DOES NOT
- INSTALLATION . . . . . . . . . . . . . . . . . . . 8W-97-5 STANDARD PROCEDURE . . . . . . . . . . . . . . . 8F-12 CORRESPOND TO THE . . . . . . . . . . . . . . . . 8O-41
UNDERHOOD ACCESSORY FUSE BLOCK VALVE - DESCRIPTION . . . . . . . . . . . . . . . . 25-27 VEHICLE IDENTIFICATION NUMBER -
- OPERATION . . . . . . . . . . . . . . . . . . . . . 8W-97-5 VALVE - DESCRIPTION, A/C EXPANSION . 24-138 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-2
UNDERHOOD ACCESSORY FUSE BLOCK VALVE - DESCRIPTION, CHARCOAL VEHICLE LEVEL AT FRONT AND REAR
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 8W-97-5 CANISTER SHUTOFF . . . . . . . . . . . . . . . . . . 25-16 AXLES, STANDARD PROCEDURE -
UNDERVOLTAGE, DIAGNOSIS AND VALVE - DESCRIPTION, COOLANT INSPECTING AND ADJUSTING . . . . . . . . . . . . 2-8
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-179 CIRCULATION . . . . . . . . . . . . . . . . . . . . . . 24-150 VEHICLE LEVEL AT FRONT AND REAR
UNDERVOLTAGE, DIAGNOSIS AND VALVE - DESCRIPTION, FUEL FILL AXLES WITH AN ELECTRONIC
TESTING - CAB SYSTEM . . . . . . . . . . . 5-155,5-82 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7 INCLINOMETER, STANDARD
UNDERVOLTAGE, DIAGNOSIS AND VALVE - DESCRIPTION, MANIFOLD TUNE . . 14-40 PROCEDURE - INSPECTING AND
TESTING - CENTRAL LOCKING VALVE - DESCRIPTION, OIL PRESSURE ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PUMP/SECURITY SYSTEM MODULE RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-677 VEHICLE SAFETY CERT LABEL -
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2 VALVE - DESCRIPTION, SOLENOID . . . . . . . 5-202 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-1
UNDERVOLTAGE, DIAGNOSIS AND VALVE - DIAGNOSIS AND TESTING, A/C VEHICLE SPEED PERFORMANCE ESP
TESTING - CLP/SSM SYSTEM . . . . . . . . . . 8N-14 EXPANSION . . . . . . . . . . . . . . . . . . . . . . . . 24-139 MIL REQUEST, DIAGNOSIS AND
UNDERVOLTAGE, DIAGNOSIS AND VALVE - INSTALLATION . . . . . . . . . . . . . . . . 25-28 TESTING - (P0500) . . . . . . . . . . . . . . . . . . . 9-412
TESTING - ORC SYSTEM . . . . . . . . . . . . . . 8O-43 VALVE - INSTALLATION, A/C EXPANSION . 24-140 VEHICLE SPEED SIGNAL (CAB CAN
UNDERVOLTAGE, DIAGNOSIS AND VALVE - INSTALLATION, CHARCOAL MESSAGE), DIAGNOSIS AND TESTING
TESTING - (P0562) SYSTEM . . . . . . . . . . . . . 21-6 CANISTER SHUTOFF . . . . . . . . . . . . . . . . . . 25-16 - (P0500) NO . . . . . . . . . . . . . . . . . . . . . . . . 9-410
UNIT - ASSEMBLY, ELECTROHYDRAULIC . 21-287 VALVE - INSTALLATION, COOLANT VEHICLE THEFT SECURITY - SERVICE
UNIT - DESCRIPTION, CIRCULATION . . . . . . . . . . . . . . . . . . . . . . 24-153 INFORMATION - DESCRIPTION . . . . . . . . . . 8Q-46
ELECTROHYDRAULIC . . . . . . . . . . . . . . . . 21-268 VALVE - INSTALLATION, MANIFOLD VEHICLE THEFT SECURITY - SERVICE
UNIT - DESCRIPTION, HEADLAMP . . . . . . 8L-107 TUNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-41 INFORMATION - OPERATION . . . . . . . . . . . 8Q-47
UNIT - DIAGNOSIS AND TESTING, FUEL VALVE - INSTALLATION, RECIRC AIR VENT HOSE - DESCRIPTION,
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . 14-12 SWITCHOVER . . . . . . . . . . . . . . . . . . . . . . . 24-87 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 25-16
34 INDEX ZH

VERIFICATION TEST - STANDARD WASHER HOSES / TUBES - REMOVAL . . . . 8R-26 WINDOW ANTENNA MODULE -
PROCEDURE, SUPPLEMENTAL WASHER NOZZLE - INSTALLATION . . . . . . 8R-30 INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8A-23
RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . 8O-86 WASHER NOZZLE - REMOVAL . . . . . . . . . . 8R-29 WINDOW ANTENNA MODULE -
VERIFICATION TEST, DIAGNOSIS AND WASHER NOZZLE AIMING - STANDARD REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . . 8A-23
TESTING - ABS . . . . . . . . . . . . . . . . . 5-148,5-185 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8R-28 WINDOW DEFOGGER GRID - DIAGNOSIS
VERIFICATION TEST, DIAGNOSIS AND WASHER PUMP MOTOR - INSTALLATION . 8R-31 AND TESTING, REAR . . . . . . . . . . . . . . . . . 8G-12
TESTING - AIRBAG . . . . . . . . . . . . . . . . . . . 8O-67 WASHER PUMP MOTOR - REMOVAL . . . . . 8R-31 WINDOW DEFOGGER INOPERATIVE,
VERIFICATION TEST, DIAGNOSIS AND WASHER RESERVOIR - INSTALLATION . . . 8R-32 DIAGNOSIS AND TESTING - REAR . . . . . . . . 8G-5
TESTING - BODY . . . . . . . . . . . . . . . . . . . . . 8A-16 WASHER RESERVOIR - REMOVAL . . . . . . . 8R-32 WINDOW DEFOGGER SWITCH -
VERIFICATION TEST, DIAGNOSIS AND WASHERS INOPERATIVE, DIAGNOSIS INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8G-12
TESTING - BODY . . . . . . . . . . . . . . . . . . . . . 8E-44 AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8R-4 WINDOW DEFOGGER SWITCH -
VERIFICATION TEST, DIAGNOSIS AND WASHERS RUN CONTINUOUSLY WITH REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8G-12
TESTING - BODY . . . . . . . . . . . 8G-20,8G-34,8G-8 IGNITION ON, DIAGNOSIS AND WINDOW DEFOGGER SYSTEM -
VERIFICATION TEST, DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-6 DIAGNOSIS AND TESTING, REAR . . . . . . . . 8G-11
TESTING - BODY . . . . . . . . . . . . . . . . . . . . . 24-53 WATER CONTAMINATION, DIAGNOSIS WINDOW INOPERATIVE, DIAGNOSIS
VERIFICATION TEST, DIAGNOSIS AND AND TESTING - ENGINE OIL SENSOR . . . . 9-538 AND TESTING - LEFT FRONT POWER . . . 8N-110
TESTING - BODY . . . . . . . . . . . . . . . . . . . . . . 8H-7 WATER LEAKS, DIAGNOSIS AND WINDOW INOPERATIVE, DIAGNOSIS
VERIFICATION TEST, DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-29 AND TESTING - RIGHT FRONT POWER . . 8N-113
TESTING - BODY . . . . . . . . . . . . . . . . . . . . . 8J-52 WATER PUMP - DESCRIPTION . . . . . . . . . . . 7-36 WINDOW MOTOR - INSTALLATION . . . . . 8N-123
VERIFICATION TEST, DIAGNOSIS AND WATER PUMP - INSPECTION . . . . . . . . . . . . 7-38 WINDOW MOTOR - REMOVAL . . . . . . . . . 8N-122
TESTING - BODY . . . . . . . . . . . . . . . 8L-133,8L-77 WATER PUMP - INSTALLATION . . . . . . . . . . 7-40 WINDOW REGULATOR - INSTALLATION . . 23-102
VERIFICATION TEST, DIAGNOSIS AND WATER PUMP - REMOVAL . . . . . . . . . . . . . . 7-37 WINDOW REGULATOR - REMOVAL . . . . . 23-101
TESTING - BODY . . . . 8N-119,8N-28,8N-62,8N-93 WEAR INDICATORS - DIAGNOSIS AND WINDOW SWITCH - INSTALLATION,
VERIFICATION TEST, DIAGNOSIS AND TESTING, TREAD . . . . . . . . . . . . . . . . . . . . . 22-59 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-124
TESTING - REAR SPOILER . . . . . . . . . . . . . 23-27 WEAR PATTERNS - DIAGNOSIS AND WINDOW SWITCH - REMOVAL, POWER . 8N-124
VERIFICATION TEST, DIAGNOSIS AND TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . 22-59 WINDOWS - SERVICE INFORMATION -
TESTING - SENTRY KEY . . . . . . . . . . . . . . . 8Q-43 WELD LOCATIONS - SPECIFICATIONS . . . . 23-74 DESCRIPTION, POWER . . . . . . . . . . . . . . . 8N-121
VERIFICATION TEST, DIAGNOSIS AND WELDING, STANDARD PROCEDURE - WINDOWS - SERVICE INFORMATION -
TESTING - TIRE PRESSURE . . . . . . . . . . . . 22-35 DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-31 DIAGNOSIS AND TESTING, POWER . . . . . 8N-121
VERIFICATION TEST, DIAGNOSIS AND WET SANDING/BUFFING & POLISHING - WINDOWS - SERVICE INFORMATION -
TESTING - TRANSMISSION . . . . . . . . . . . . 21-181 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 23-200 OPERATION, POWER . . . . . . . . . . . . . . . . . 8N-121
VERIFICATION TEST, DIAGNOSIS AND WHEEL - INSTALLATION, STEERING . . . . . . 19-26 WINDOWS INOPERATIVE, DIAGNOSIS
TESTING - VTSS . . . . . . . . . . . . . . . . . . . . . 8Q-33 WHEEL - REMOVAL, STEERING . . . . . . . . . 19-25 AND TESTING - BOTH POWER . . . . . . . . . 8N-116
VERIFICATION TEST, VER 1 - WHEEL ALIGNMENT - DESCRIPTION . . . . . . . 2-4 WINDSHIELD WIPER BLADE
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 9-569 WHEEL ALIGNMENT - OPERATION . . . . . . . . . 2-5 ALIGNMENT, STANDARD PROCEDURE . . . . 8R-36
VERIFICATION TEST, VER 2 - WHEEL ALIGNMENT - SPECIFICATIONS . . . . 2-13 WINDSHIELD WIPER/WASHER SYSTEM,
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 9-570 WHEEL ALIGNMENT INSPECTION - DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-23
VERIFICATION TEST, VER 3 - STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 2-6 WING, INSTALLATION - SPOILER . . . . . . . 23-121
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 WHEEL BALANCE, STANDARD WING, REMOVAL - SPOILER . . . . . . . . . . . 23-117
VERIFICATION TEST, VER 3 - PROCEDURE - TIRE . . . . . . . . . . . . . . . . . . . 22-42 WIPER ARMS - ADJUSTMENT . . . . . . . . . . 8R-36
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 9-571 WHEEL BEARING, DIAGNOSIS AND WIPER ARMS - DESCRIPTION . . . . . . . . . . 8R-33
VERIFICATION TEST, VER 4 - TESTING - ADJUSTING . . . . . . . . . . . . . . . . . 2-24 WIPER ARMS - INSTALLATION . . . . . . . . . . 8R-34
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 9-572 WHEEL INDICATOR INOPERATIVE, WIPER ARMS - REMOVAL . . . . . . . . . . . . . 8R-33
VERIFICATION TEST, VER 5 - DIAGNOSIS AND TESTING - WIPER BLADE ALIGNMENT, STANDARD
POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 9-573 TELESCOPING . . . . . . . . . . . . . . . . . . . . . . . 8J-50 PROCEDURE - WINDSHIELD . . . . . . . . . . . 8R-36
VERSION, DIAGNOSIS AND TESTING - WHEEL INSPECTION, DIAGNOSIS AND WIPER BLADES - DESCRIPTION . . . . . . . . . 8R-36
(P0702) INVALID CONTROL MODULE . . . . . 21-78 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-62 WIPER BLADES - OPERATION . . . . . . . . . . 8R-36
VIBRATION - DIAGNOSIS AND TESTING, WHEEL INSTALLATION - STANDARD WIPER LINKAGE - DESCRIPTION . . . . . . . . 8R-42
TIRE NOISE OR . . . . . . . . . . . . . . . . . . . . . . 22-59 PROCEDURE, TIRE . . . . . . . . . . . . . . . . . . . 22-46 WIPER MODULE - DESCRIPTION . . . . . . . . 8R-42
VIBRATION DAMPER - INSTALLATION . . . . 9-652 WHEEL REPLACEMENT, STANDARD WIPER MODULE - INSTALLATION . . . . . . . 8R-44
VIBRATION DAMPER - REMOVAL . . . . . . . . 9-651 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-63 WIPER MODULE - REMOVAL . . . . . . . . . . . 8R-42
VOLTAGE CORRELATION, DIAGNOSIS WHEEL RUNOUT - DIAGNOSIS AND WIPER MOTOR - INSTALLATION . . . . . . . . 8R-48
AND TESTING - (P0221) APPS TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . 22-38 WIPER MOTOR - REMOVAL . . . . . . . . . . . . 8R-47
SENSOR #1 AND #2 . . . . . . . . . . . . . . . . . . 9-262 WHEEL SPEED SENSOR - DESCRIPTION, WIPER MOTOR SYNCHRONIZE -
VOLTAGE, DIAGNOSIS AND TESTING - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193 STANDARD PROCEDURE . . . . . . . . . . . . . . 8R-46
(P0561) BATTERY SYSTEM . . . . . . . . . . . . . 9-414 WHEEL SPEED SENSOR - DESCRIPTION, WIPERS HIGH SPEED INOPERATIVE,
VOLTAGE, DIAGNOSIS AND TESTING - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196 DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-11
(P0700) SENSOR SUPPLY . . . . . . . . . . . . . . 21-67 WHEEL SPEED SENSOR - WIPERS INOPERATIVE, DIAGNOSIS AND
VOLTAGE, DIAGNOSIS AND TESTING - INSTALLATION, FRONT . . . . . . . . . . . . . . . . 5-195 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-8
(P0702) TRANSMISSION CONTROL WHEEL SPEED SENSOR - WIPERS INTERMITTENT SPEED
MODULE LOW . . . . . . . . . . . . . . . . . . . . . . . 9-455 INSTALLATION, REAR . . . . . . . . . . . . . . . . . 5-198 INOPERATIVE, DIAGNOSIS AND
VOLTAGE, DIAGNOSIS AND TESTING - WHEEL SPEED SENSOR - OPERATION, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-15
(P0778) SOLENOID SUPPLY . . . . . . . . . . . 21-154 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-193 WIPERS LOW SPEED INOPERATIVE,
VOLTAGE DROP - STANDARD WHEEL SPEED SENSOR - OPERATION, DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-13
PROCEDURE, TESTING FOR A . . . . . . . 8W-01-11 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-196 WIPERS RUN CONTINUOUSLY WITH
VOLTAGE INDICATOR INOPERATIVE, WHEEL SPEED SENSOR - REMOVAL, IGNITION ON, DIAGNOSIS AND
DIAGNOSIS AND TESTING - BATTERY . . . . 8J-46 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-194 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
VOLTAGE POTENTIAL - STANDARD WHEEL SPEED SENSOR - REMOVAL, WIPERS/WASHERS - SERVICE
PROCEDURE, TESTING OF . . . . . . . . . . . 8W-01-9 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-197 INFORMATION - DESCRIPTION . . . . . . . . . . 8R-21
VOLTAGE REGULATOR - DESCRIPTION . . . . 8F-30 WHEEL SPEED SENSOR CIRCUIT, WIPERS/WASHERS - SERVICE
VOLTAGE SUPPLY CIRCUIT OPEN, DIAGNOSIS AND TESTING - LEFT INFORMATION - OPERATION . . . . . . . . . . . 8R-22
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8R-2 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95 WIPER/WASHER SYSTEM, DIAGNOSIS
VOLTAGE TEST - STANDARD WHEEL SPEED SENSOR CIRCUIT, AND TESTING - WINDSHIELD . . . . . . . . . . . 8R-23
PROCEDURE, OPEN-CIRCUIT . . . . . . . . . . . 8F-13 DIAGNOSIS AND TESTING - LEFT WIRE SPLICING - STANDARD
VTSS VERIFICATION TEST, DIAGNOSIS REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107 PROCEDURE . . . . . . . . . . . . . . . . . . . . . 8W-01-13
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8Q-33 WHEEL SPEED SENSOR CIRCUIT, WIRING DIAGRAMS - DESCRIPTION,
WARNING INDICATOR CIRCUIT, DIAGNOSIS AND TESTING - RIGHT HOW TO USE . . . . . . . . . . . . . . . . . . . . . 8W-01-1
DIAGNOSIS AND TESTING - AIRBAG . . . . . 8O-46 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101 WIRING HARNESS - DIAGNOSIS AND
WARNING INDICATOR INOPERATIVE, WHEEL SPEED SENSOR CIRCUIT, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7
DIAGNOSIS AND TESTING - BRAKE . . . . . . 8J-44 DIAGNOSIS AND TESTING - RIGHT WORN THREADS - STANDARD
WARNING SYSTEM - DIAGNOSIS AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113 PROCEDURE, REPAIR OF DAMAGED
TESTING, CHIME . . . . . . . . . . . . . . . . . . . . . . 8B-4 WHEELS, DESCRIPTION . . . . . . . . . . . . . . . 22-62 OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-589
WASHER FLUID LEVEL SWITCH - WIND NOISE, DIAGNOSIS AND TESTING . . 23-30 YAW RATE SENSOR - DESCRIPTION . . . . . 5-201
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-26 WINDOW ANTENNA - DESCRIPTION, YAW RATE SENSOR - INSTALLATION . . . . . 5-201
WASHER FLUID LEVEL SWITCH - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-24 YAW RATE SENSOR - OPERATION . . . . . . . 5-201
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26 WINDOW ANTENNA - INSTALLATION, YAW RATE SENSOR - REMOVAL . . . . . . . . . 5-201
WASHER HOSES / TUBES - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-26 YAW RATE SENSOR CIRCUIT,
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-27 WINDOW ANTENNA - REMOVAL, REAR . . . 8A-25 DIAGNOSIS AND TESTING - ESP . . . . . . . . 5-119
ZH P CODE INDEX 1
BODY DIAGNOSITCS FUEL LEVEL SENSOR CIRCUIT . . . . . . . . . . . . . .8J-7 RIGHT FRONT TIRE PRESSURE
HAZARD SWITCH CIRCUIT . . . . . . . . . . . . . .8L-118 SENSOR/TRANSMITTER SIGNAL
A/C COMPRESSOR CLUTCH CIRCUIT . . . . . . . .24-43 JAMMED. . . . . . . . . . . . . . . . . . . . . . . . . . . .22-15
INVALID TRANSMITTER . . . . . . . . . . . . . . . . . .8Q-36
A/C PRESSURE SENSOR CIRCUIT . . . . . . . . . .24-28 RIGHT FRONT TIRE PRESSURE
LAMP OUTAGE INDICATOR CIRCUIT . . . . . . . . . .8J-5 SENSOR/TRANSMITTER . . . . . . . . . . . . . . . .22-28
AIRBAG VERIFICATION TEST . . . . . . . . . . . . . .8O-67
LEFT COOLANT CIRCULATION VALVE RIGHT HEATER CORE TEMPERATURE
AIRBAG WARNING INDICATOR CIRCUIT . . . . . .8O-46 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-37 SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . .24-13
AMBIENT TEMPERATURE SENSOR LEFT FRONT TIRE PRESSURE SENSOR/
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-3 RIGHT REAR TIRE PRESSURE SENSOR/
TRANSMITTER SIGNAL JAMMED. . . . . . . . . .22-11 TRANSMITTER SIGNAL JAMMED. . . . . . . . . .22-17
AMBIENT TEMPERATURE SENSOR LEFT FRONT TIRE PRESSURE SENSOR/
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8J-9 RIGHT REAR TIRE PRESSURE SENSOR/
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . .22-24 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . .22-30
ANTI-THEFT TOW SENSOR SIGNAL LEFT HEATER CORE TEMPERATURE
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Q-22 RIGHT SIDE AIRBAG SQUIB CIRCUIT . . . . . . . .8O-35
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . .24-8
BODY CONTROL MODULE INTERNAL RIGHT SIDE IMPACT SENSOR SIGNAL
LEFT REAR TIRE PRESSURE SENSOR/ CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8O-63
FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-2 TRANSMITTER SIGNAL JAMMED. . . . . . . . . .22-13
BODY CONTROL MODULE INTERNAL SENTRY KEY ANTENNA CIRCUIT . . . . . . . . . .8Q-38
LEFT REAR TIRE PRESSURE SENSOR/
FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . .8N-11 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . .22-26 SENTRY KEY REMOTE ENTRY MODULE
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .24-53 INTERNAL FAILURE. . . . . . . . . . . . . . . . . . . .8Q-34
LEFT SIDE AIRBAG SQUIB CIRCUIT . . . . . . . .8O-29
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8A-16 SENTRY KEY VERIFICATION TEST . . . . . . . . . .8Q-43
LEFT SIDE IMPACT SENSOR SIGNAL
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8E-44 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8O-59 SIGNAL JAMMED . . . . . . . . . . . . . . . . . . . . . . . .22-9
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8G-20 NO CAN COMMUNICATIONS WITH CAB . . . . . .8J-24 SIREN SIGNAL OUTPUT CIRCUIT . . . . . . . . . .8Q-27
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8G-34 NO CAN COMMUNICATIONS WITH PCM . . . . . .8J-18 SPOILER LIMIT SWITCH SIGNAL (DOWN)
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-10
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8G-8 NO CAN COMMUNICATIONS WITH PCM . . . . . .8Q-25
SPOILER LIMIT SWITCH SIGNAL (UP)
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8H-7 NO CAN COMMUNICATIONS WITH TCM . . . . . .8J-30 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-7
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8J-52 NO COMMUNICATION FROM TIRE PRESSURE MONITOR MODULE
BODY VERIFICATION TEST . . . . . . . . . . . . . .8L-133 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . .24-49 FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-4
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8L-77 NO COMMUNICATION FROM TIRE PRESSURE SENSOR/TRANSMITTER
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . .8J-14 LOW BATTERY. . . . . . . . . . . . . . . . . . . . . . . .22-32
BODY VERIFICATION TEST . . . . . . . . . . . . . .8N-119
NO COMMUNICATION TO INSTRUMENT TIRE PRESSURE SENSOR/TRANSMITTER
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8N-28 CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . .24-51 SIGNAL JAMMED . . . . . . . . . . . . . . . . . . . . . .22-6
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8N-62 NO COMMUNICATION TO INSTRUMENT TIRE PRESSURE SENSOR/TRANSMITTER . . . .22-19
BODY VERIFICATION TEST . . . . . . . . . . . . . . . .8N-93 CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . .8J-16
TIRE PRESSURE VERIFICATION TEST . . . . . . . .22-35
CAN B BUS (+) CIRCUIT FAILURE . . . . . . . . . .8Q-13 NO COMMUNICATION WITH BCM AND
CENTRAL LOCKING PUMP/SECURITY TRANSMITTER FAILURE . . . . . . . . . . . . . . . . . .22-22
CAN B BUS (-) CIRCUIT FAILURE . . . . . . . . . .8Q-10
SYSTEM MODULE. . . . . . . . . . . . . . . . . . . . . .8Q-8 VOLTAGE SUPPLY CIRCUIT OPEN . . . . . . . . . .8R-2
CAN BUS COMMUNICATION GENERAL
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . .8J-36 NO COMMUNICATION WITH BODY VTSS VERIFICATION TEST . . . . . . . . . . . . . . . .8Q-33
CONTROL MODULE AND CENTRAL *ALARM TRIPS ON ITS OWN . . . . . . . . . . . . . .8Q-32
CENTRAL LOCKING PUMP/SECURITY LOCKING PUMP/SECURITY SYSTEM
SYSTEM MODULE INTERNAL FAILURE . . . .8N-26 MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . .8N-20 *ASH RECEIVER LAMP INOPERATIVE . . . . . .8L-130
CENTRAL LOCKING PUMP/SECURITY NO TIRES TRAINED . . . . . . . . . . . . . . . . . . . . . .22-2 *AUTOMATIC DAY/NIGHT MIRROR
SYSTEM MODULE INTERNAL FAILURE . . . .8Q-30 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8N-59
ORC INTERNAL FAILURE . . . . . . . . . . . . . . . . . .8O-2
CENTRAL LOCKING PUMP/SECURITY *BATTERY VOLTAGE INDICATOR
SYSTEM MODULE SYSTEM ORC SYSTEM UNDERVOLTAGE . . . . . . . . . . . .8O-43 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8J-46
OVERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . . .8Q-5 PASSENGER AIRBAG ON/OFF SWITCH *BOTH HEATED SEATS INOPERATIVE . . . . . . . .8G-32
CENTRAL LOCKING PUMP/SECURITY SIGNAL CIRCUIT. . . . . . . . . . . . . . . . . . . . . .8O-49
*BOTH POWER MIRRORS INOPERATIVE . . . .8N-57
SYSTEM MODULE SYSTEM PASSENGER AIRBAG SQUIB CIRCUIT . . . . . . . .8O-23
UNDERVOLTAGE . . . . . . . . . . . . . . . . . . . . . .8Q-2 *BOTH POWER SEATS INOPERATIVE . . . . . . . .8N-78
PASSENGER DOOR/LIFTGATE LOCK
CLP/SSM SYSTEM OVERVOLTAGE . . . . . . . . . .8N-17 ACTUATOR SLOW RESPONSE . . . . . . . . . . . .8N-8 *BOTH POWER WINDOWS INOPERATIVE . . . .8N-116
CLP/SSM SYSTEM UNDERVOLTAGE . . . . . . . .8N-14 PASSENGER SEAT BELT TENSIONER *BRAKE WARNING INDICATOR
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8O-56 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8J-44
COOLANT CIRCULATION PUMP CIRCUIT . . . .24-34
PASSENGER SEAT BELT TENSIONER *CARGO LAMP INOPERATIVE . . . . . . . . . . . .8L-124
COOLANT LEVEL SENSOR/WASHER FLUID
LEVEL SWITCH CIRCUIT . . . . . . . . . . . . . . . .8J-2 SQUIB CIRCUIT . . . . . . . . . . . . . . . . . . . . . .8O-17 *CENTER HIGH MOUNTED STOP LAMP
PROGRAMMING DOES NOT INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-68
DOME LAMP CIRCUIT . . . . . . . . . . . . . . . . . .8L-121
CORRESPOND TO THE VEHICLE *DRB IIIT DOES NOT POWER UP . . . . . . . . . . . .8E-2
DOOR LOCK SWITCH SENSE CIRCUIT . . . . . .8Q-16 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . .8O-41
*DRIVER POWER SEAT FRONT RISER
DOOR LOCK/DOOR UNLOCK SWITCH REAR DEFOGGER SWITCH SENSE MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-85
SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . .8N-22 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8G-2 *DRIVER POWER SEAT HORIZONTAL
DOOR UNLOCK SWITCH SENSE CIRCUIT . . . .8Q-19 REAR SPOILER DRIVER (DOWN) CIRCUIT . . . .23-16 MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-83
DRIVER AIRBAG SQUIB CIRCUIT . . . . . . . . . . . .8O-4 REAR SPOILER DRIVER (UP) CIRCUIT . . . . . .23-13 *DRIVER POWER SEAT INOPERATIVE . . . . . .8N-74
DRIVER DOOR LOCK ACTUATOR SLOW REAR SPOILER LIMIT SWITCH FAILURE . . . . . .23-19 *DRIVER POWER SEAT REAR RISER
RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . .8N-2 MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-87
REAR SPOILER MOTOR FAILURE . . . . . . . . . .23-23
DRIVER SEAT BELT TENSIONER CIRCUIT . . . .8O-53 *DRIVER POWER SEAT RECLINER
REAR SPOILER SWITCH SENSE CIRCUIT . . . . . .23-4
DRIVER SEAT BELT TENSIONER SQUIB MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-81
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .8O-10 REAR SPOILER VERIFICATION TEST . . . . . . . .23-27
*GLOVE BOX LAMP INOPERATIVE . . . . . . . .8L-127
ENGINE COOLANT TEMPERATURE RECIRCULATED AIR SWITCHOVER VALVE
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-46 *HIGH BEAM INDICATOR INOPERATIVE . . . . . .8J-42
SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . .24-23
REMOTE KEYLESS ENTRY RELAY *HORNS ALWAYS ON . . . . . . . . . . . . . . . . . . . .8H-5
EVAPORATOR TEMPERATURE SENSOR
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-18 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . .8Q-40 *HORNS INOPERATIVE . . . . . . . . . . . . . . . . . .8H-2
FUEL DOOR LOCK ACTUATOR SLOW RIGHT COOLANT CIRCULATION VALVE *LEFT BACK UP LAMP INOPERATIVE . . . . . . . .8L-50
RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . .8N-5 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-40 *LEFT FOG LAMP INOPERATIVE . . . . . . . . . . . .8L-2
2 P CODE INDEX ZH

*LEFT FRONT POWER WINDOW *RIGHT HEATED SEAT INOPERATIVE . . . . . . . .8G-29 RIGHT REAR WHEEL SPEED SENSOR
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . .8N-110 *RIGHT HIGH BEAM HEADLAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-113
*LEFT FRONT SIDE MARKER LAMP INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-29 STEERING ANGLE SENSOR CIRCUIT . . . . . . . .5-124
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-32 *RIGHT LOW BEAM HEADLAMP
*LEFT FRONT TURN LAMP INOPERATIVE . . . .8L-11 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-26 POWERTRAIN DIAGNOSITCS
*LEFT HEATED MIRROR INOPERATIVE . . . . . .8G-16 *RIGHT PARK LAMP INOPERATIVE . . . . . . . . . .8L-14 (P0040) 1/1 AND 2/1 O2 SENSOR
*LEFT HEATED SEAT INOPERATIVE . . . . . . . .8G-26 *RIGHT POWER MIRROR INOPERATIVE . . . . . .8N-55 HARNESS CONNECTORS REVERSED . . . . . . . .9-5
*LEFT HIGH BEAM HEADLAMP *RIGHT REAR SIDE MARKER LAMP (P0101) MAF SENSOR PERFORMANCE . . . . . . . .9-8
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-23 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-41 (P0102) MASS AIR FLOW CIRCUIT . . . . . . . . . .9-10
*LEFT LOW BEAM HEADLAMP *RIGHT REAR TURN LAMP INOPERATIVE . . . .8L-65 (P0103) MAF SENSOR CIRCUIT LOW . . . . . . . .9-17
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-20 *RIGHT STOP LAMP INOPERATIVE . . . . . . . . . .8L-59 (P0104) MAF SENSOR THROTTLE ANGLE
*LEFT PARK LAMP INOPERATIVE . . . . . . . . . . . .8L-8 *RIGHT TAIL LAMP INOPERATIVE . . . . . . . . . .8L-56 AND SPEED . . . . . . . . . . . . . . . . . . . . . . . . . .9-19
*LEFT POWER MIRROR INOPERATIVE . . . . . .8N-53 *RIGHT TURN SIGNAL INDICATOR (P0106) MAP SENSOR PERFORMANCE . . . . . .9-21
*LEFT REAR SIDE MARKER LAMP INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8J-40 (P0107) MAP SENSOR CIRCUIT LOW . . . . . . . .9-24
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-38 *SEAT BELT INDICATOR INOPERATIVE . . . . . .8J-48 (P0108) MAP SENSOR CIRCUIT HIGH . . . . . . . .9-29
*LEFT REAR TURN LAMP INOPERATIVE . . . . . .8L-53 *TELESCOPING WHEEL INDICATOR (P0112) INTAKE AIR TEMPERATURE
*LEFT STOP LAMP INOPERATIVE . . . . . . . . . .8L-47 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8J-50 SENSOR CIRCUIT LOW. . . . . . . . . . . . . . . . . .9-31
*LEFT TAIL LAMP INOPERATIVE . . . . . . . . . . . .8L-44 *WASHERS INOPERATIVE . . . . . . . . . . . . . . . .8R-4 (P0113) INTAKE AIR TEMPERATURE
*LEFT TURN SIGNAL INDICATOR *WASHERS RUN CONTINUOUSLY WITH SENSOR CIRCUIT HIGH. . . . . . . . . . . . . . . . . .9-36
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8J-38 IGNITION ON . . . . . . . . . . . . . . . . . . . . . . . .8R-6 (P0116) ENGINE COOLANT
*LICENSE LAMP NO.1 INOPERATIVE . . . . . . . .8L-71 *WIPERS HIGH SPEED INOPERATIVE . . . . . . . .8R-11 TEMPERATURE SENSOR
*LICENSE LAMP NO.2 INOPERATIVE . . . . . . . .8L-74 *WIPERS INOPERATIVE . . . . . . . . . . . . . . . . . .8R-8 PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . .9-40
*NO RESPONSE FROM A/C HEATER *WIPERS INTERMITTENT SPEED (P0116) ENGINE COOLANT
CONTROL MODULE. . . . . . . . . . . . . . . . . . . .8E-21 INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8R-15 TEMPERATURE SENSOR SHORT
CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47
*NO RESPONSE FROM BODY CONTROL *WIPERS LOW SPEED INOPERATIVE . . . . . . . .8R-13
MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . .8E-36 (P0117) ENGINE COOLANT
*WIPERS RUN CONTINUOUSLY WITH TEMPERATURE SENSOR CIRCUIT LOW. . . . . .9-49
*NO RESPONSE FROM CONTROLLER IGNITION ON . . . . . . . . . . . . . . . . . . . . . . . .8R-17
ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . .8E-25 (P0118) ENGINE COOLANT
TEMPERATURE SENSOR CIRCUIT HIGH. . . . . .9-51
*NO RESPONSE FROM INSTRUMENT CHASSIS DIAGNOSITCS (P0120) ELECTRONIC THROTTLE
CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . .8E-13
ABS VERIFICATION TEST . . . . . . . . . . . . . . . .5-148 CONTROL MOTOR PERFORMANCE . . . . . . . .9-53
*NO RESPONSE FROM OCCUPANT
RESTRAINT CONTROLLER . . . . . . . . . . . . . .8E-10 ABS VERIFICATION TEST . . . . . . . . . . . . . . . .5-185 (P0120) THROTTLE POSITION SENSOR
1/2 CORRELATION. . . . . . . . . . . . . . . . . . . . . .9-59
*NO RESPONSE FROM POWERTRAIN BAS RELEASE SWITCH CIRCUIT . . . . . . . . . . . .5-166
CONTROL MODULE . . . . . . . . . . . . . . . . . . . .8E-4 BAS SOLENOID VALVE CIRCUIT . . . . . . . . . . . .5-181 (P0121) APPS 5-VOLT SUPPLY CIRCUIT . . . . . .9-61
*NO RESPONSE FROM SENTRY KEY BAS TRAVEL SENSOR CIRCUIT . . . . . . . . . . . .5-171 (P0122) APPS SIGNAL #1 CIRCUIT LOW . . . . . .9-65
REMOTE ENTRY MODULE . . . . . . . . . . . . . .8E-40 (P0123) APPS SIGNAL #1 CIRCUIT HIGH . . . . . .9-70
BRAKE LAMP SWITCH CIRCUIT . . . . . . . . . . . .5-143
*NO RESPONSE FROM SHIFT LEVER (P0128) FORCED LIMITED POWER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .8E-29 BRAKE LAMP SWITCH CIRCUIT . . . . . . . . . . . .5-176 EXCESSIVE HIGH COOLANT TEMP. . . . . . . . . .9-74
*NO RESPONSE FROM TRANSMISSION CAB INTERNAL FAILURE . . . . . . . . . . . . . . . . . .5-153
(P0128) THERMOSTAT RATIONALITY . . . . . . . .9-78
CONTROL MODULE. . . . . . . . . . . . . . . . . . . .8E-33 CAB INTERNAL FAILURE . . . . . . . . . . . . . . . . . .5-80 (P0131) O2 SENSOR 1/1 CIRCUIT LOW . . . . . .9-86
*NO RESPONSE FROM UNIVERSAL CAB SYSTEM OVERVOLTAGE . . . . . . . . . . . . . .5-158
(P0132) O2 SENSOR 1/1 CIRCUIT HIGH . . . . . .9-93
GARAGE DOOR OPENER/TIRE CAB SYSTEM OVERVOLTAGE . . . . . . . . . . . . . .5-85
PRESSURE MONITOR . . . . . . . . . . . . . . . . . .8E-17 (P0133) O2 SENSOR 1/1 LONG DELAY
CAB SYSTEM UNDERVOLTAGE . . . . . . . . . . . .5-155 TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-101
*NO SOUND FROM ALL SPEAKERS . . . . . . . . . .8A-5
CAB SYSTEM UNDERVOLTAGE . . . . . . . . . . . . . .5-82 (P0133) O2 SENSOR 1/1 LONG
*NO SOUND FROM LEFT DOOR PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . .9-99
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . .8A-8 CAN BUS COMMUNICATION GENERAL
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . .5-162 (P0133) O2 SENSOR 1/1 SHORT DELAY
*NO SOUND FROM LEFT REAR SPEAKER . . . .8A-12 TIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-95
CAN BUS COMMUNICATION GENERAL
*NO SOUND FROM RIGHT DOOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . .5-88 (P0133) O2 SENSOR 1/1 SHORT
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . .8A-10 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-103
ESP BRAKE PRESSURE SENSOR 1
*NO SOUND FROM RIGHT REAR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-128 (P0134) O2 SENSOR 1/1 CIRCUIT OPEN . . . . . .9-105
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . .8A-14
ESP BRAKE PRESSURE SENSOR 2 (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
*PASSENGER POWER SEAT HORIZONTAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-133 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-113
MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-91
ESP LATERAL ACCELERATION SENSOR (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
*PASSENGER POWER SEAT INOPERATIVE . . . .8N-76 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-138 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-107
*PASSENGER POWER SEAT RECLINER ESP YAW RATE SENSOR CIRCUIT . . . . . . . . . .5-119 (P0135) O2 SENSOR 1/1 HEATER CIRCUIT
MOTOR INOPERATIVE. . . . . . . . . . . . . . . . . .8N-89 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-117
LEFT FRONT WHEEL SPEED SENSOR
*RADIO INOPERATIVE . . . . . . . . . . . . . . . . . . . .8A-2 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-95 (P0135) O2 SENSOR 1/1 HEATER
*REAR WINDOW DEFOGGER LEFT REAR WHEEL SPEED SENSOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-109
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8G-5 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107 (P0137 O2 SENSOR 2/2 ABOVE
*RIGHT BACK UP LAMP INOPERATIVE . . . . . .8L-62 NO CAN COMMUNICATIONS WITH PCM . . . . . .5-164 THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . .9-123
*RIGHT FOG LAMP INOPERATIVE . . . . . . . . . . . .8L-5 NO CAN COMMUNICATIONS WITH PCM . . . . . .5-90 (P0137) O2 SENSOR 1/2 ABOVE
*RIGHT FRONT POWER WINDOW THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . .9-121
NO CAN COMMUNICATIONS WITH TCM . . . . . .5-92
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . .8N-113 (P0137) O2 SENSOR 1/2 BELOW
PCM NOT IDENTIFIED OR INCORRECT . . . . . .5-161 THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . .9-119
*RIGHT FRONT SIDE MARKER LAMP
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-35 PCM NOT IDENTIFIED OR INCORRECT . . . . . . . .5-94 (P0137) O2 SENSOR 2/2 BELOW
*RIGHT FRONT TURN LAMP RIGHT FRONT WHEEL SPEED SENSOR THRESHOLD . . . . . . . . . . . . . . . . . . . . . . . .9-127
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . .8L-17 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-101 (P0138) O2 SENSOR 1/2 CIRCUIT HIGH . . . . . .9-129
*RIGHT HEATED MIRROR INOPERATIVE . . . .8G-18 (P0138) O2 SENSOR 1/2 CIRCUIT OPEN . . . . . .9-131
ZH P CODE INDEX 3

(P0138) O2 SENSOR 2/2 CIRCUIT LOW . . . . . .9-133 (P0200) FUEL INJECTOR CIRCUIT . . . . . . . . . .9-236 (P0455) EVAP SYSTEM LARGE LEAK . . . . . . . .9-399
(P0138) O2 SENSOR 2/2 CIRCUIT OPEN . . . . . .9-135 (P0201) FUEL INJECTOR #1 CIRCUIT . . . . . . . .9-238 (P0457) EVAP PURGE VALVE LEAKING . . . . . .9-406
(P0140) O2 SENSOR 1/2 CIRCUIT LOW . . . . . .9-137 (P0202) FUEL INJECTOR #2 CIRCUIT . . . . . . . .9-242 (P0460) FUEL LEVEL SENSOR CIRCUIT . . . . . .9-408
(P0140) O2 SENSOR 2/2 CIRCUIT HIGH . . . . . .9-139 (P0203) FUEL INJECTOR #3 CIRCUIT . . . . . . . .9-244 (P0500) NO VEHICLE SPEED SIGNAL
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT (P0204) FUEL INJECTOR #4 CIRCUIT . . . . . . . .9-246 (CAB CAN MESSAGE) . . . . . . . . . . . . . . . . . .9-410
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-145 (P0205) FUEL INJECTOR #5 CIRCUIT . . . . . . . .9-248 (P0500) VEHICLE SPEED PERFORMANCE
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT ESP MIL REQUEST . . . . . . . . . . . . . . . . . . . .9-412
(P0206) FUEL INJECTOR #6 CIRCUIT . . . . . . . .9-250
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-141 (P0561) BATTERY SYSTEM VOLTAGE . . . . . . . .9-414
(P0211) THROTTLE ACTUATOR STUCK . . . . . .9-252
(P0141) O2 SENSOR 1/2 HEATER CIRCUIT (P0562) BATTERY SYSTEM LOW . . . . . . . . . .9-417
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-143 (P0211) THROTTLE ACTUATOR STUCK . . . . . .9-257
(P0563) BATTERY SYSTEM HIGH . . . . . . . . . .9-419
(P0141) O2 SENSOR 1/2 HEATER (P0221) APPS SENSOR #1 AND #2
VOLTAGE CORRELATION . . . . . . . . . . . . . . . .9-262 (P0571) STOP LAMP SWITCH CAN
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-147 SIGNAL LOST TO TRANS
(P0151) O2 SENSOR 2/1 CIRCUIT LOW . . . . . .9-149 (P0221) ELECTRONIC THROTTLE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-421
CONTROL MODULE PERFORMANCE . . . . . .9-270
(P0152) O2 SENSOR 2/1 CIRCUIT HIGH . . . . . .9-151 (P0571) STOP LAMP SWITCH SIGNAL
(P0221) ELECTRONIC THROTTLE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-423
(P0153) O2 SENSOR 2/1 LONG DELAY CONTROL MODULE PROCESSOR. . . . . . . . . .9-272
TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-155 (P0600) INCORRECT CAN MESSAGE
(P0221) IDLE SPEED PERFORMANCE . . . . . . . .9-266 FROM EIS CONTROL MODULE. . . . . . . . . . . .9-425
(P0153) O2 SENSOR 2/1 LONG
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-153 (P0222) APPS SIGNAL #2 CIRCUIT LOW . . . .9-274 (P0600) LOST COMM WITH ELECTRIC
(P0153) O2 SENSOR 2/1 SHORT DELAY (P0223) APPS SIGNAL #2 CIRCUIT HIGH . . . .9-279 GEAR SHIFT MODULE (SLA) . . . . . . . . . . . .9-439
TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-157 (P0300) MULTIPLE CYLINDER MISFIRE . . . . . .9-283 (P0600) NO CAN MESSAGE FROM CAB
(P0153) O2 SENSOR 2/1 SHORT MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . .9-427
(P0301) CYLINDER #1 MISFIRE . . . . . . . . . . . .9-294
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-159 (P0302) CYLINDER #2 MISFIRE . . . . . . . . . . . .9-304 (P0600) NO CLUSTER BUS MESSAGE . . . . . .9-445
(P0154) O2 SENSOR 2/1 CIRCUIT OPEN . . . . . .9-161 (P0303) CYLINDER #3 MISFIRE . . . . . . . . . . . .9-308 (P0600) NO TRANSMISSION BUS
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .9-433
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-165 (P0304) CYLINDER #4 MISFIRE . . . . . . . . . . . .9-312 (P0602) PCM PROGRAMMED INCORRECT
(P0305) CYLINDER #5 MISFIRE . . . . . . . . . . . .9-316 TRANS/NO COMM FROM TCM. . . . . . . . . . . .9-451
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-163 (P0306) CYLINDER #6 MISFIRE . . . . . . . . . . . .9-320 (P0700) TRANSMISSION CONTROL
(P0155) O2 SENSOR 2/1 HEATER CIRCUIT (P0325) KNOCK SENSOR #1 CIRCUIT SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-453
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-167 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-328 (P0702) LOSS OF TORQUE MANAGEMENT
(P0155) O2 SENSOR 2/1 HEATER (P0325) KNOCK SENSOR #1 CIRCUIT SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-459
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-169 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-324 (P0702) TCM TORQUE MANAGEMENT
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT (P0330) KNOCK SENSOR #2 CIRCUIT REQUEST PERFORMANCE . . . . . . . . . . . . . .9-461
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-177 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-330 (P0702) TRANSMISSION CONTROL
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT (P0330) KNOCK SENSOR #2 CIRCUIT MODULE LOW VOLTAGE . . . . . . . . . . . . . . . .9-455
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-173 LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-332 (P0702) TRANSMISSION CONTROL
(P0161) O2 SENSOR 2/2 HEATER CIRCUIT (P0335) CRANKSHAFT POSITION SENSOR SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-457
OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-175 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-334 (P0705) SLA CONTROL SYSTEM (MIL
(P0161) O2 SENSOR 2/2 HEATER (P0341) CAMSHAFT POSITION SENSOR REQUEST) . . . . . . . . . . . . . . . . . . . . . . . . . .9-463
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-171 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-346 (P0705) TRANSMISSION CONTROL
(P0171) FUEL SYSTEM 1/1 RICH (P0341) CAMSHAFT POSITION TIMING SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-465
CONTROL OVER LIMIT (AT IDLE) . . . . . . . .9-183 OVER-ADVANCED . . . . . . . . . . . . . . . . . . . .9-344 (P0715) TRANSMISSION CONTROL
(P0171) FUEL SYSTEM 1/1 RICH (P0341) CAMSHAFT POSITION TIMING SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-467
CONTROL OVER LIMIT (AT LOAD) . . . . . . . .9-187 OVER-RETARDED. . . . . . . . . . . . . . . . . . . . . .9-340 (P0720) TRANSMISSION CONTROL
(P0171) FUEL SYSTEM 1/1 (P0400) EGR SYSTEM PERFORMANCE . . . . . .9-350 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-475
UNDERCORRECTION OF FUEL (P0403) EGR CONTROL CIRCUIT . . . . . . . . . .9-354 (P0720) TRANSMISSION INCORRECT
MIXTURE (OFF IDLE) . . . . . . . . . . . . . . . . . .9-179 TORQUE REQUEST FROM ESP. . . . . . . . . . . .9-469
(P0410) SECONDARY AIR INJECTION
(P0172) FUEL SYSTEM 1/1 LEAN RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . .9-362 (P0730) TRANSMISSION CONTROL
CONTROL BELOW LIMIT (AT IDLE). . . . . . . .9-207 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-477
(P0172) FUEL SYSTEM 1/1 LEAN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-356 (P0740) TRANSMISSION CONTROL
CONTROL BELOW LIMIT (AT LOAD) . . . . . .9-199 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-479
(P0172) FUEL SYSTEM 1/1 SWITCHOVER SOLENOID CIRCUIT . . . . . . . .9-365 (P0743) TRANSMISSION CONTROL
OVERCORRECTION OF FUEL MIXTURE SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-481
(AT IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . .9-195 (P0422) CATALYTIC 1/1 EFFICIENCY . . . . . . . .9-369
(P0748) TRANSMISSION CONTROL
(P0173) FUEL SYSTEM 2/1 RICH (P0432) CATALYTIC 2/1 EFFICIENCY . . . . . . . .9-372 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-483
CONTROL OVER LIMIT (AT LOAD) . . . . . . . .9-211 (P0440) GENERAL EVAP SYSTEM (P0753) TRANSMISSION CONTROL
(P0174) FUEL SYSTEM 2/1 LEAN FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-374 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-485
CONTROL BELOW LIMIT (AT LOAD) . . . . . .9-224 (P0441) EVAP PURGE VALVE . . . . . . . . . . . . . .9-376 (P0758) TRANSMISSION CONTROL
(P0174) FUEL SYSTEM 2/1 RICH (P0442) EVAP SYSTEM SMALL LEAK . . . . . . . .9-378 SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-487
CONTROL OVER LIMIT (AT IDLE) . . . . . . . .9-218 (P0445) EVAP PURGE SOLENOID CIRCUIT . . . .9-380 (P0763) TRANSMISSION CONTROL
(P0174) FUEL SYSTEM 2/1 RICH (P0446) CHARCOAL CANISTER SHUTOFF SYSTEM (MIL REQUEST). . . . . . . . . . . . . . . .9-489
CONTROL OVER LIMIT (AT LOAD) . . . . . . . .9-221 VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-384 (P1386) KNOCK SENSOR SYSTEM
(P0174) FUEL SYSTEM 2/1 (P0446) EVAP PURGE SOLENOID STUCK FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-491
UNDERCORRECTION OF FUEL OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-387 (P1600) ROUGH ROAD DETECTED . . . . . . . . . .9-493
MIXTURE (OFF IDLE) . . . . . . . . . . . . . . . . . .9-227
(P0451) FUEL TANK PRESSURE SENSOR (P2513) ENHANCED ACCIDENT REPORT
(P0175) FUEL SYSTEM 2/1 LEAN PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-390 DRIVER CIRCUIT HIGH . . . . . . . . . . . . . . . .9-499
CONTROL BELOW LIMIT (AT IDLE). . . . . . . .9-233
(P0452) FUEL TANK PRESSURE SENSOR (P2513) ENHANCED ACCIDENT REPORT
(P0175) FUEL SYSTEM 2/1 CIRCUIT LOW. . . . . . . . . . . . . . . . . . . . . . . .9-395 DRIVER CIRCUIT LOW. . . . . . . . . . . . . . . . . .9-504
OVERCORRECTION OF FUEL MIXTURE
(OFF IDLE) . . . . . . . . . . . . . . . . . . . . . . . . . .9-230 (P0453) FUEL TANK PRESSURE SENSOR (P2545) ESP TORQUE MANAGEMENT
CIRCUIT HIGH. . . . . . . . . . . . . . . . . . . . . . . .9-397 REQUEST PERFORMANCE . . . . . . . . . . . . . .9-506
4 P CODE INDEX ZH

(P2561) HVAC CONTROL MODULE TRANSMISSION DIAGNOSITCS (P0715) INPUT SENSOR OVERSPEED . . . . . . . .21-94
REQUESTED MIL ILLUMINATION. . . . . . . . . .9-512 (P0715) N2 INPUT SPEED SENSOR
COOLING FAN CONTROL CIRCUIT HIGH . . . . . .9-517 (P0219) ENGINE OVERSPEED . . . . . . . . . . . . . .21-3 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-97
COOLING FAN CONTROL CIRCUIT LOW . . . . . .9-519 (P0562) SYSTEM UNDERVOLTAGE . . . . . . . . . .21-6 (P0715) N3 INPUT SPEED SENSOR
COOLING FAN CONTROL CIRCUIT OPEN . . . . . .9-514 (P0600) ABS BRAKE MESSAGE . . . . . . . . . . . .21-12 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .21-103
ENGINE OIL SENSOR LEVEL (P0600) ABS CAN MESSAGE INCORRECT . . . .21-15 (P0720) CAN BUS CIRCUIT . . . . . . . . . . . . . .21-109
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-521 (P0600) ABS CAN MESSAGE MISSING . . . . . .21-18 (P0730) IMPROPER GEAR . . . . . . . . . . . . . .21-113
ENGINE OIL SENSOR OVER (P0600) ABS LEFT FRONT SENSOR (P0730) IMPROPER RATIO . . . . . . . . . . . . . .21-116
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . .9-526 MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .21-22 (P0740) TCC OVERTEMP . . . . . . . . . . . . . . . .21-119
ENGINE OIL SENSOR PERFORMANCE . . . . . . . .9-531 (P0600) ABS LEFT REAR SENSOR (P0740) TCC STUCK ON . . . . . . . . . . . . . . . .21-121
ENGINE OIL SENSOR QUALITY MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .21-25
(P0743) TCC SOLENOID CIRCUIT . . . . . . . . . .21-124
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . .9-533 (P0600) ABS RIGHT FRONT SENSOR
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .21-28 (P0748) MODULATING PRESSURE
ENGINE OIL SENSOR WATER SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . .21-128
CONTAMINATION. . . . . . . . . . . . . . . . . . . . . .9-538 (P0600) ABS RIGHT REAR SENSOR
MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .21-31 (P0753) 1-2/4-5 SOLENOID CIRCUIT . . . . . .21-132
POWERTRAIN VERIFICATION TEST –
VER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-569 (P0600) ACCEL PEDAL SENSOR CAN (P0753) 1–2/4–5 SOLENOID CIRCUIT
MESSAGE INCORRECT . . . . . . . . . . . . . . . .21-34 SHORT TO GROUND . . . . . . . . . . . . . . . . . .21-136
POWERTRAIN VERIFICATION TEST –
VER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-570 (P0600) CAN MESSAGE FROM ECM (P0758) 2-3 SOLENOID CIRCUIT . . . . . . . . . .21-138
POWERTRAIN VERIFICATION TEST – FROM SLA . . . . . . . . . . . . . . . . . . . . . . . . . .21-38 (P0758) 2–3 SOLENOID CIRCUIT SHORT
VER 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 (P0600) ENGINE CAN MESSAGE TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .21-142
POWERTRAIN VERIFICATION TEST – INCORRECT. . . . . . . . . . . . . . . . . . . . . . . . . .21-41 (P0763) 3-4 SOLENOID CIRCUIT . . . . . . . . . .21-144
VER 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-571 (P0600) ENGINE CAN MESSAGE MISSING . . . .21-44 (P0763) 3–4 SOLENOID CIRCUIT SHORT
POWERTRAIN VERIFICATION TEST – (P0600) ENGINE RPM MESSAGE . . . . . . . . . .21-48 TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .21-148
VER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-572 (P0600) ENGINE TEMPERATURE (P0778) SHIFT PRESSURE SOLENOID
POWERTRAIN VERIFICATION TEST – MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . .21-51 CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .21-150
VER 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-573 (P0600) ENGINE TORQUE MESSAGE (P0778) SOLENOID SUPPLY VOLTAGE . . . . . .21-154
SAFETY FUEL SHUT OFF DETECTED . . . . . . . .9-540 INCORRECT. . . . . . . . . . . . . . . . . . . . . . . . . .21-54 (P0850) TRANS TEMP SENSOR - P/N
SHORT RUNNER SOLENOID CIRCUIT (P0600) IC CAN MESSAGE INCORRECT . . . . . .21-57 SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . .21-158
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-545 (P0600) IC/HVAC CAN MESSAGE (P1793) ENGINE TORQUE REDUCTION . . . . . .21-163
SHORT RUNNER SOLENOID CIRCUIT MISSING. . . . . . . . . . . . . . . . . . . . . . . . . . . .21-60 (PO563) SYSTEM OVERVOLTAGE . . . . . . . . . . . .21-9
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-549 (P0600) SLA CAN MESSAGE INCORRECT . . . .21-64 CAN BUS CIRCUIT . . . . . . . . . . . . . . . . . . . .21-167
SHORT RUNNER SOLENOID CIRCUIT . . . . . . . .9-551 (P0700) SENSOR SUPPLY VOLTAGE . . . . . . . .21-67 INCORRECT CAN MESSAGE FROM ABS . . . .21-169
SPEED CONTROL SWITCH INPUT CIRCUIT . . . .9-553 (P0700) TRANSMISSION SLIPPING . . . . . . . .21-71 INTERNAL CONTROLLER . . . . . . . . . . . . . . . .21-171
*CHECKING FUEL DELIVERY . . . . . . . . . . . . . .9-556 (P0702) CONTROL MODULE TCM IS NOT LR WHEEL SPIN CAN MESSAGE NOT
*CHECKING HARD START (FUEL SYSTEM) . . . .9-560 CODED . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-74 VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-173
*ENGINE CRANKS BUT DOES NOT START . . . .9-563 (P0702) INTERNAL CONTROLLER . . . . . . . . . .21-76 OVERVOLTAGE . . . . . . . . . . . . . . . . . . . . . . . .21-177
*INTERMITTENT NO CRANK . . . . . . . . . . . . . .9-567 (P0702) INVALID CONTROL MODULE RR WHEEL SPIN CAN MESSAGE NOT
*RADIATOR COOLING FAN ALWAYS ON . . . . . . . .7-6 VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . .21-78 VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-175
*RADIATOR COOLING FAN INOPERATIVE . . . . . .7-2 (P0702) SOLENOID SUPPLY/WATCHDOG . . . .21-80 TRANSMISSION VERIFICATION TEST . . . . . .21-181
(P0710) TRANS TEMP SENSOR SHORTED . . . .21-83 UNDERVOLTAGE . . . . . . . . . . . . . . . . . . . . . .21-179
(P0714) TRANS TEMP SENSOR ERRATIC . . . .21-87
(P0715) INPUT SENSOR MISMATCH . . . . . . . .21-90
SERVICE MANUAL COMMENTS
What errors(s) have you found?

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□ Dealership Technician
Dealer Code:
Retail Customer □
Manual Title, Year, Number and Page: _________________________________________________

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Address: ________________________________________________________________________
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All comments become property of DaimlerChrysler and may be used without compensation.
8
DaimlerChrysler Corporation
Attn. Publications Dept.
CIMS 486-02-70
800 Chrysler Drive
Auburn Hills, MI 48326-2757

Crossfire 2004 Service Manual

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Crossfire 2004 Service Manual

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GROUP TAB LOCATOR

0 Lubrication & Maintenance

3 Differential & Driveline

8E Electronic Control Modules

8Q Vehicle Theft Security

13 Frame & Bumpers

24 Heating & Air Conditioning

Component and System Index

Service Manual Comment Forms (Rear of Manual)

VEHICLE SAFETY CERT LABEL THREADED HOLE REPAIR ...............6

VEHICLE SAFETY CERT LABEL

VEHICLE IDENTIFICATION NUMBER

CROSSFIRE VIN CODE BREAKDOWN

POSITION INTERPRETATION CODE = DESCRIPTION

1 HIGH BEAM 13 REAR WINDOW WASHER

THREADED HOLE REPAIR

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

LUBRICATION & MAINTENANCE

LUBRICATION & MAINTENANCE TOWING

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES

PARTS AND LUBRICANT RECOMMENDATIONS

AUTOMATIC TRANSMISSION FLUID

FLUID CHECK/FILL POINTS AND LUBRICATION LOCATIONS

API SERVICE GRADE CERTIFIED

ENERGY CONSERVING OIL

LUBRICANTS AND GREASES

SPECIALIZED LUBRICANTS AND OILS

DESCRIPTION - HOAT COOLANT

COOLANT SELECTION AND ADDITIVES

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID

Note: For fluid level checking procedures, Refer to Page 21-294 .

DESCRIPTION - DIFFERENTIAL LUBRICANT

FLUID FILL/CHECK LOCATIONS

TO JUMP START A DISABLED VEHICLE:

2. When using another vehicle as a booster source, park the

CAUTION: Do not crank starter motor on disabled vehicle

DISCONNECT CABLE CLAMPS AS FOLLOWS:

The vehicle can be lifted with:

CAUTION: Do not lift vehicle with a floor jack positioned under:

TRIP ODOMETER, FSS INDICATOR

This symbol represents Service A.

The second symbol represents Service B.

Depending on operating conditions throughout the year, the

The next service may be calculated and displayed next to this

EMERGENCY TOW HOOKS

The tow hooks should be used for EMERGENCY purposes only.

SUSPENSION WHEEL ALIGNMENT ......................4

DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

2. Loose or worn steering or 2. Tighten or replace components as

2. Loose or worn steering or 2. Tighten or replace components as

2. Loose or worn steering or 2. Tighten or replace components as

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.

VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

9150 Rear Spring Compressor

C-3894–A Tie Rod Puller

9150 Rear Spring Compressor 9168 Ball Joint Puller

9152 Spring Compressor Plates 9199 Bearing Tool