MRAP-TM 9-2355-106-23-1 MaxxPro Base PDF

ARMY *TM 9-2355-106-23-1
AIR FORCE TO 36A12-1C-2400-2-1
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL

FOR
MINE RESISTANT AMBUSH PROTECTED (MRAP)
M1224
(NSN 2355-01-553-4634) (EIC 1XF)
M1224A1
(NSN 2355-01-561-0281) (EIC 1XM)
* SUPERSEDURE NOTICE – This manual supersedes TM 9-2355-106-23-1, dated 27 April 2009, including all changes.
DISCLOSURE NOTICE – This information is furnished upon the condition that it will not be released to another nation without the specific authority of the
Department of the Army of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether
patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be
provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the
document, it will not be downgraded or declassified without written approval of the originating United States agency.
DISTRIBUTION STATEMENT C – Distribution authorized to U.S. Government Agencies and their contractors only for Specific Authority as determined on
01 August 2012. Other requests for this document shall be referred to TACOM Life Cycle Management Command, ATTN: AMSTA-LCC-MMK, Warren, MI
48397–5000..
WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq) or the
Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties.
Disseminate in accordance with provisions of DoD Directive 5230.25.
DESTRUCTION NOTICE – Destroy by any method that will prevent disclosure of contents or reconstruction of contents.
HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

19 NOVEMBER 2012
TM 9-2355-106-23-1
WARNING SUMMARY
EXPLANATION OF WARNING ICONS
This warning summary contains general safety warnings and hazardous materials warnings that must
be understood and applied during operation and maintenance of this equipment. Failure to observe
these precautions could result in serious injury or death to personnel. Also included are explanations
of safety and hazardous materials icons used within the technical manual.
FIRST AID
First aid is the emergency care given to the sick, injured, or wounded before being treated by medical
personnel. First aid data can be found in FM 4-25.11. This manual contains procedures for all types of
casualties and the measures described are for use by all service members. Service members may be
able to save a life, prevent permanent disability, or reduce long periods of hospitalization by knowing
WHAT to do, WHAT NOT to do, and WHEN to seek medical assistance.
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WARNING SUMMARY – (Continued)

EXPLANATION OF GENERAL SAFETY ICONS
EAR PROTECTION – headphones over ears shows that noise level will harm ears.
ELECTRICAL – electrical wire to arm with electricity symbol running

through body shows that shock hazard is present.
ELECTRICAL – electrical wire to hand with electricity symbol running

through body shows that shock hazard is present.
FALLING PARTS – arrow bouncing off human shoulder and head shows
that failing parts present a danger to life or limb.
FLYING PARTICLES – arrows bouncing off face shows that particles

flying through air will harm face.
FLYING PARTICLES – arrows bouncing off face with face shield shows
that particles flying through the air will harm face.
HEAVY OBJECT – human figure stooping over heavy object shows physical
injury potential from improper lifting technique.
HEAVY PARTS – foot with heavy object on top shows that heavy
parts can crush and harm.
HEAVY PARTS – heavy object on human figure shows that heavy

parts present a danger to life or limb.
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HEAVY PARTS – heavy object pinning human figure against wall shows that
heavy, moving parts present a danger to life or limb.
HELMET PROTECTION – arrow bouncing of head with helmet shows

that falling parts present a danger.
HOT AREA – hand over object radiating heat shows that part is hot and can burn.
LASER LIGHT – laser light hazard symbol indicates extreme danger

for eyes from laser beams and reflections.
MOVING PARTS – human figure with an arm caught between gears shows that
the moving parts of the equipment present a danger to life or limb.
MOVING PARTS – hand with fingers caught between gears shows that the
moving parts of the equipment present a danger to life or limb.
MOVING PARTS – hand with fingers caught between rollers shows that the
moving parts of the equipment present a danger to life or limb.
SHARP OBJECT – pointed object in hand shows that a sharp object

presents a danger to life or limb.
SHARP OBJECT – pointed object in hand shows that a sharp object

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SHARP OBJECT – pointed object in foot shows that a sharp object

SLICK FLOOR – wavy line on floor with legs prone shows that
slick floor presents a danger for falling.
EYE PROTECTION – person with goggles shows that the material will injure the eyes.
GENERAL WARNINGS
WARNING
Before performing any maintenance procedure, ensure vehicle is parked on level surface,
engine is off, parking brake is applied, transmission is in NEUTRAL (N), and wheels are
chocked. Wear eye protection and stay clear of rotating parts and hot surfaces. Make sure all
electrical tools are grounded. Use extreme caution when working under vehicle. Use hydraulic
jack to raise vehicle, and place jackstands under frame rails to support axle. Keep first-aid and
fire-control equipment available during all operation and maintenance procedures. Failure to
comply may result in damage to equipment and serious injury or death to personnel.
WARNING
A/C
Do not install or remove air-conditioning testing or charging equipment while engine is

running. Failure to comply may result in serious injury or death to personnel.
WARNING
AIR DRAIN VALVES
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Air drain valves are under pressure. Wear protective goggles and do not place face in front
of air drain valves while draining air reservoirs. Open air drain valves slowly to release air
pressure gradually. Failure to comply may result in serious injury or death to personnel.
WARNING
AIR LINES
Do not disconnect any air line or fitting until system pressure has been relieved. Hoses
may whip and injure personnel, and air under pressure can penetrate skin. Failure
to comply may result in serious injury or death to personnel.
Do not operate vehicle with air pressure system loss. Vehicle has reduced or no
braking capability and may not stop. Failure to comply may result in damage to
equipment and serious injury or death to personnel.
WARNING
BATTERIES
Wear protective eye goggles, face shield, and long sleeves when working on or near batteries.
Batteries contain corrosive acid and can produce explosive gases. Batteries supply electrical
current that can cause burns and electrical shock. Always check electrolyte level with engine
off. Avoid leaning over or onto battery. Do not wear jewelry and do not smoke or have open
flame or spark near battery. Do not allow tools to contact battery box or battery terminals.
Failure to comply may result in damage to equipment and serious injury or death to personnel.
Battery acid must not contact eyes, skin, or clothing. If battery acid contacts eyes or
skin, flush area with large amounts of water for 15 minutes and seek immediate medical
care. If swallowed, do not induce vomiting. Drink large amounts of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Seek immediate medical attention.
Failure to comply may result in serious injury or death to personnel.
Disconnect battery ground cable or power source prior to working on electrical components.
If electrical shock occurs, administer first aid and seek medical assistance immediately.
Ensure batteries are disconnected before removing ESC. Failure to comply may
result in serious injury or death to personnel.
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WARNING
BRAKES (ALSO SEE HAZARDOUS MATERIALS WARNINGS)
Before working on air brake system or any auxiliary pressurized system, make
sure air pressure has been drained from all reservoirs. Failure to comply may
If springs are missing or damaged, replace with new spring hardware kit before installing
new brake shoes. Replace brake shoes if there are any signs of overheating, if step
on center wear tab of brake shoe lining is not visible, or if thickness on any part
of brake shoe is ¼ in. (6 mm) or less. Drums must be turned or replaced if there
were any signs of overheating on old brake shoes. Failure to comply may result in
damage to equipment and serious injury or death to personnel.
Do not allow grease or oil to contact brake linings. Linings can absorb grease
and oil, causing early glazing and reduced braking action. Failure to comply
may result in serious injury or death to personnel.
Before removing ABS Control Module, disconnect battery disconnect switch and
disconnect batteries. Failure to comply may result in damage to equipment
and serious injury or death to personnel.
WARNING
CAB DOOR WINCH STRAPS
Cab doors must be secured in the open position by using heavy duty winch straps
to prevent accidental closure during vehicle maintenance. Failure to comply
WARNING
COMPRESSED AIR
Do not use compressed air exceeding 30 psi (207 kPa) for cleaning purposes. Use only with
effective chip-guarding and personal protective equipment, including goggles or face shield
and gloves. Failure to comply could result in serious injury or death to personnel.
WARNING
COOLING SYSTEM/RADIATOR
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Cooling system components become pressurized and extremely hot during normal operation.
To prevent serious injury from hot coolant or scalding steam, use the following safety
procedure when removing radiator cap, surge tank cap, or deaeration cap:
• Allow engine to cool for 15 minutes.
• Wrap a thick cloth around cap to be removed.
• Loosen cap slowly one-quarter to one-half turn counterclockwise, and
pause to allow pressure to release.
• Continue to turn cap counterclockwise to remove.
Ensure all personnel stay clear of radiator while engine is running. Air in
radiator will be released, which may cause hot coolant to spray out. Failure to
comply may result in serious injury to personnel.
WARNING
DMM (DIGITAL MULTIMETER)
Ensure power is off before cutting, soldering, or removing a circuit component to insert the
Digital Multi-meter (DMM) for current measurements. Even small amounts of current can
be dangerous. Failure to comply may result in serious injury to personnel.
When routing DMM leads, do not crimp leads, run leads too close to moving parts, or let leads
touch hot engine surfaces. Failure to comply may result in serious injury to personnel.
WARNING
ELECTRICAL
Turn off ignition switch and main power switch before performing electrical system
maintenance. Failure to comply may result in serious injury or death to personnel.
Disconnect negative ground cable from batteries before removing any electrical component.
Never attempt a voltage measurement with test probe lead in current jack (10A or
300mA). Failure to comply may result in serious injury to personnel.
Shut engine down before performing voltage checks for injector solenoids. When
engine is running, injector circuits have high voltage and amperage. Failure to
comply may result in serious injury to personnel.
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Do not use a circuit breaker, fuse, or relay with higher amperage rating than listed
for a particular application. Using higher amperage will overheat the electrical circuit,
causing melted components and possible fire. Failure to comply may result in damage
to equipment and serious injury or death to personnel.
WARNING
ENGINE (ALSO SEE HAZARDOUS MATERIALS WARNINGS.)
Engine components become extremely hot during normal operation. Allow engine to cool
completely prior to performing maintenance. Use extreme care when working in close quarters
in engine compartment. Stay clear of rotating parts. Wear safety goggles, work gloves, and
long sleeves or shop coat. Failure to comply may result in serious injury or death to personnel.
Some engine components are heavy and bulky and require assistance for lifting. Use
assistance of crewmember or lifting device as required. Failure to comply may result
in damage to equipment and serious injury to personnel.
Do not rotate diesel engine when priming with oil. This may cause engine to accidentally
start. Failure to comply may result in serious injury or death to personnel.
Prior to performing work on crossmember, place wooden block between

crossmember and front engine mount. Failure to comply may result in damage
to equipment and serious injury to personnel.
WARNING
EMERGENCY HATCH
Emergency hatch door is extremely heavy. Use caution and keep arms, hands, and head
clear of hatch when opening or closing. Ensure hatch door is properly secured in both
the open or closed position. Do not operate vehicle with emergency roof hatch open.
Use lifting device capable of lifting 1000 lbs to lift emergency hatch from vehicle.
Clear all nonessential personnel from area when lifting hatch from vehicle. Do not
stand directly under hatch door while lowering to floor. Failure to comply may result
in damage to equipment and serious injury or death to personnel.
WARNING
EXHAUST
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Exhaust system components can be hot. Do not touch with bare hands or allow
contact with other skin surface. Wear protective work gloves and long sleeves.
Do not use exhaust tailpipe as a step. Failure to comply may result in damage
WARNING
FAN BLADE
Do not attempt to restrict fan blade rotation during engine operation. Improper use of
application or modification of fan drive or fan can damage fan drive. Do not operate
vehicle with malfunctioning or damaged fan drive or fan blades. Failure to comply may
result in damage to equipment and serious injury to personnel.
WARNING
FSS (FIRE SUPPRESSION SYSTEM)
Before installing FSS extinguisher, verify correct part number is being installed. Check for
visible damage to the canister, such as dents, cracked plastic, chips, or scratches where
hoses connect. If damage is visible anywhere, do not use; contact your supervisor. Failure
to comply may result in damage to equipment and serious injury or death to personnel.
Prior to servicing FSS, make sure FSS power is off, main power switch is off, unless otherwise
instructed. If damage is visible, anywhere, do not use. Contact your supervisor. Failure to
comply may result in discharging of system and serious injury or death to personnel.
Before handling extinguisher, make sure anti-recoil plug is installed in valve outlet port
and mechanical lever lockpin is installed in lever lock holes. Failure to comply may result
Some fire suppression systems have a safety pin to install before disconnecting lines. Check to
see if system uses a safety pin and install it before disconnecting lines. When disconnecting
the extinguisher lines, use extreme caution. Do not disturb the pyrotechnic actuator and
pressure switch; this will cause the extinguisher to discharge automatically. Failure to comply
may result in damage to equipment and serious injury or death to personnel.
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TM 9-2355-106-23-1

Do not drop or strike FSS extinguisher. Extinguisher can discharge accidentally and
chemical agent can escape through holes in side of ant-recoil plug. Failure to comply may
result in damage to equipment and serious injury or death to personnel.
Do not release extinguisher bottle band clamps unless anti-recoil plug is installed in
valve outlet port and mechanical lever lockpin is installed in lever lock holes. Failure to
comply may result in personal injury or death, or damage to equipment.
FSS extinguisher can move violently when discharging. Ensure extinguisher

is properly secured during use. Failure to comply may result in damage to
equipment and serious injury or death to personnel.
Replace fire extinguisher immediately after use, even if only partly used. Failure to
comply may result in serious injury or death to personnel.
Exposure to large quantities of dry chemical fire extinguisher in cab may result in temporary
breathing difficulty during and immediately after discharge. If possible, discharge fire
extinguisher from outside cab. Ventilate and wash cab thoroughly prior to reentry. If respiratory
irritation or distress occurs, move victim to fresh air. Seek medical attention if irritation persists.
Chemical fire suppression agents are refrigerants and can freeze skin. Extinguisher will
be extremely cold after discharging. Avoid contact with chemical agent and do not touch
extinguisher after use. Failure to comply may result in serious personal injury.
WARNING
FUEL LINES/PUMP
Do not loosen fuel lines at filter housing to bleed fuel system. Periodic loosening of
fittings will result in increased thread wear. Failure to comply may result in damage
Do not overtighten bolts for fuel pump or cross-thread connections on fuel lines. This
will interfere with sealing and operation of fuel pump. If seal is not complete or lines
leak due to cross-threads, fuel pump will not operate properly and vehicle may not
run. Starting vehicle without fuel pressure in lines or pump may result in damage
WARNING
GUNNER HATCH
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TM 9-2355-106-23-1

Gunner hatch is extremely heavy. Use caution when opening and closing. Wear
safety goggles when removing, installing, or working on interior of gunner hatch. Keep
arms and hands clear of gunner hatch when closing. Failure to comply may result in
Gunner sliding hatch can only be opened or closed when vehicle is stationary and on level
surface. Do not attempt to open or close the hatch when vehicle is in motion. Make sure latch
locks are secured into place in the open or closed positions before vehicle starts moving.
Ensure gunner hatch is completely locked in open position before moving vehicle with
gunner in position. Use extreme caution when standing in gunner hatch while vehicle is
in motion. Gunner should be holding onto weapon or other support to maintain stability at
all times. Failure to comply may result in serious injury or death to personnel.
WARNING
HEATSHRINK TUBING
Never use open flame to apply heat to heatshrink tubing. Allow heatshrink tubing to cool
before handling. Failure to comply may result in serious injury to personnel.
WARNING
HEAVY LIFTING
Prior to moving heavy components with lifting device, clear path of travel and clear
personnel from area. Use extreme caution if lifting objects overhead or backing up.
Stop and lower load as soon as possible. Failure to comply may result in damage
WARNING
HOOD
Hood is extremely heavy. Ensure there is adequate space to open hood completely
without pinning personnel between hood and another structure. Use extreme care
when working under hood and make sure it is properly supported. Failure to comply
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TM 9-2355-106-23-1

WARNING
INSTRUMENT PANEL
The instrument panel is bulky and heavy and cannot be removed by one person. Before
removing the side A-pillar mounting bolts, obtain assistance for remainder of removal. Failure
WARNING
JACKS
Before lifting vehicle off ground, make sure it is parked on level surface. Set parking brake
and chock wheels. Use hydraulic jack to lift vehicle. Do not use jack alone to support
vehicle. Never work under or near a vehicle supported only by jack or lifting device. Use
rated jackstands under frame rails to properly support vehicle. Do not support vehicle
under front and rear axles. Use additional jackstands as necessary to support vehicle
components during removal and installation procedures. Failure to comply may result
WARNING
LITTER
Keep personnel clear of litter-lift moving parts. Ensure litters and patients are properly
secured and clear of rear door/ramp and all other obstacles during litter-lift movement.
Hold litter stub and connector plate up while removing or installing hex-head screws from
bracket. If connector plate and stub fall and slide down stainless sliding rail, serious damage to
parts may occur. Failure to comply may result in serious injury or death to personnel.
WARNING
PITMAN ARM
Pitman arm will be extremely tight. Do not pound on pitman arm or apply heat to pitman
arm or sector shaft. Never weld pitman arm or sector shaft. Failure to comply may result
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Proper installation of pitman is critical to vehicle safety. Install pitman arm after steering gear is
mounted on vehicle so proper torque can be applied to pitman arm. Otherwise, pitman arm
could loosen and cause an accident. If pitman arm is loose, replace pitman arm and sector
shaft. Always use a new tab lock retainer. If tabs and notches do not line up, tighten beyond
specified torque value until two tabs align. Never back off retainer to align retaining tabs.
When installing new cotter pin, tighten nut until slot appears and insert cotter pin.
Never back off nut to install cotter pin. Failure to comply may result in damage
WARNING
REAR CABIN DOOR/RAMP
Rear cabin door/ramp is heavy. Make sure door/ramp /is secured so it will not move. Failure
to comply may result in serious personal injury or death to personnel.
Ensure no one is behind vehicle when lowering rear door/ramp. Use extreme caution when
using emergency rear door/ramp release, to ensure no one is struck by door as it falls open.
Keep arms and legs clear of rear door/ramp when closing. Do not operate rear door/ramp when
vehicle is in motion. Failure to comply may result in serious injury or death to personnel.
Attach a lifting device and sling to rear door/ramp prior to removing mounting bolts. Failure
Rear door/ramp is heavy. Ensure lifting device and sling are in place prior to removing rear
door/ramp mounting bolts. Failure to comply may result in serious injury or death to personnel.
WARNING
RIFLES
Remove rifles from rifle racks being worked on. Ensure rifles are not loaded and store in
safe manner. Failure to comply may result in serious injury or death to personnel.
WARNING
TOWING EYES
Do not remove both rear towing eyes at the same time, Entire rear frame crossmember
assembly will fall. Replace one towing eye at a time. Failure to comply may result in
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TM 9-2355-106-23-1

WARNING
TRANSFER CASE
During normal vehicle operation, transfer case and oil cooler can become very hot. Allow
transfer case and oil cooler to cool prior to servicing oil cooler. Wear safety goggles, work
gloves, and protective clothing. Use extreme caution when opening drain valves and
removing bolts. Failure to comply may result in serious injury to personnel.
WARNING
TRANSMISSION
Use care when working with hot transmission and fluid during maintenance procedures.
Wear protective goggles, work gloves, and long sleeves to avoid injury. Avoid contact
with hot transmission oil or sump when draining transmission oil. If transmission oil
temperature is above 220°F (104°C), allow transmission oil to cool before removing dipstick.
WARNING
WHEELS/TIRES
Wheel and tire assemblies are heavy. Do not attempt to lift wheel and tire assemblies without
assistance from crewmember. Wear safety goggles and work gloves. Failure to comply
Ensure vehicle is parked on hard, level surface before changing wheel and tire
assembly. Soft or uneven ground may cause jack or jackstand to slip, resulting in
EXPLANATION OF HAZARDOUS MATERIALS ICONS
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BIOLOGICAL – abstract symbol bug shows that a material may contain

bacteria or viruses that present a danger to life or health.
CHEMICAL – drops of liquid on hand shows that the material will cause
burns or irritation to human skin or tissue.
CRYOGENIC – hand in block of ice shows that the material is extremely

cold and can injure human skin or tissue.
EXPLOSION – rapidly expanding symbol shows that the material may explode
if subjected to high temperatures, sources of ignition or high pressure.
FIRE – flame shows that a material may ignite and cause burns.
POISON – skull and crossbones shows that a material is poi-

sonous or is a danger to life.
RADIATION – three circular wedges shows that the material emits

radioactive energy and can injure human tissue.
VAPOR – human figure in a cloud shows that material vapors

present a danger to life or health.
WARNING
ANTI-SEIZE COMPOUND
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Anti-seize compound is flammable and toxic. Container may explode from excessive heat. Vapors can
cause headache, dizziness, unconsciousness, corneal injury, and respiratory tract irritation. Use only in
well-ventilated area. Use approved respirator with dual organic vapor/mist and particulate cartridge. Wear
chemical safety goggles and full-face shield when using. Avoid contact with skin and wear rubber or plastic,
solvent-resistant gloves. In case of contact, remove contaminated clothing and immediately wash area
with soap and water. If compound contacts eyes, flush eyes with large amounts of water for at least 15
minutes and obtain immediate medical attention. If swallowed, do not induce vomiting; obtain immediate
medical attention. Failure to comply may result in serious injury or death to personnel.
WARNING
ASBESTOS
Brake dust contains asbestos, a known health hazard. Always wear safety goggles and an approved respirator
during all brake service procedures. Wear respirator during removal of wheels through assembly. Handle all brake
parts with care; brake dust covers all brake parts. Failure to comply may result in serious injury or death to personnel.
Never use compressed air or dry brushing to clean brake parts or assemblies. Use an industrial vacuum
cleaner with a HEPA filter system to clean dust from brake drums, backing plates, and other brake parts. After
vacuuming, remove any remaining dust with a rag soaked in water and wrung until nearly dry. Carefully clean
parts in a well-ventilated or open-air area. During brake disassembly, carefully place all parts on the floor to avoid
getting dust into the air. Do not use compressed air to clean clothing after working on brakes; use vacuum
with HEPA filter system. Failure to comply may result in serious injury or death to personnel.
WARNING
CARBON MONOXIDE
Carbon monoxide is a colorless, odorless, and dangerous gas that deprives the body of oxygen and
causes suffocation. Use the following precautions to avoid carbon monoxide poisoning. Failure to
comply may result in permanent brain damage or death to personnel.
• Do not idle engine for long periods of time.
• If necessary to run engine in confined area during vehicle service, use proper equipment
to vent exhaust gasses outside work area.
• Do not operate personnel heater in enclosed area without adequate ventilation.
• Turn auxiliary diesel heater switch off before filling any fuel tank on vehicle.
• Do not sleep in vehicle with heater operating or engine idling.
• Notify Field Maintenance if exhaust fumes are detected in crew compartment while operating the vehicle.
• Be alert at all times for exhaust odors and symptoms of exposure to carbon monoxide, such as
headaches, dizziness, loss of muscular control, apparent drowsiness, and coma. If symptoms are evident,
move affected personnel to fresh air, keep them warm, do not permit physical exercise, administer
artificial respiration (if necessary), and seek immediate medical attention.
WARNING
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CARC (CHEMICAL AGENT RESISTANT COATING)
Vehicles are finished with a chemical agent resistant coating (CARC). CARC contains isocyanates, which
are highly irritating to skin and respiratory system. Breathing CARC vapor or dried paint dust can cause
coughing, shortness of breath, burning sensation in throat and nose, watering of eyes, pain during
respiration, and chest tightness. Skin contact with particulates can cause itching or redness of skin.
Sensitivity to isocyanates may increase from repeated exposure. Use the following precautions to prevent
injury from exposure. Failure to comply may result in serious injury to personnel.
• Never weld or cut CARC coated surfaces. Grinding or sanding CARC coated surfaces will create harmful dust.
• Personnel who have lung or breathing problems or who have had a reaction to isocyanates must not be in
any area where CARC painting operations are performed or CARC dust particles are present.
• CARC painting operations must be performed only by qualified painters wearing protective gear and respirators
and working in fully equipped facilities. All personnel in the area must wear high-efficiency air purifying respirators,
protective goggles, gloves, and other protective clothing. Thoroughly wash all clothing before reuse.
WARNING
CLEANING SOLVENTS
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful
to skin and clothing. Wear goggles and protective clothing. Keep away from open flame and use in
well-ventilated area. If adhesive, solvent, or sealing compound get on skin or clothing, wash immediately
with soap and water. Failure to comply may result in injury or death to personnel.
WARNING
CONNECTOR LUBRICANT
Connector lubricant is harmful to skin and eyes. If lubricant contacts eyes, rinse thoroughly and
contact physician if irritation persists. If skin is contacted, wash thoroughly with soap and water.
Failure to comply may result in serious injury to personnel.
WARNING
CORROSION PREVENTIVE COMPOUND
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Corrosion preventive compound is toxic. Use only in well-ventilated area. Use approved respirator with dual
organic vapor/mist and particulate cartridge. Do not get in eyes; wear chemical safety goggles and full-face shield
when using. Avoid contact with skin and wear rubber or plastic, solvent-resistant gloves. In case of contact, remove
contaminated clothing and immediately wash area with soap and water. If compound contacts eyes, flush eyes with
large amounts of water for at least 15 minutes and get immediate medical attention. If swallowed, do not induce
vomiting; contact a physician immediately. Failure to comply may result in serious injury or death to personnel.
WARNING
DIELECTRIC GREASE
Dielectric grease is harmful to skin and eyes. If grease contacts eyes, rinse thoroughly and
WARNING
ETHER CANISTER
Ether canisters contain hazardous, combustible and flammable materials. Handle with care and dispose of in
accordance with standard operating procedures. Use approved respirator with dual organic vapor/mist and
particulate cartridge. Avoid contact with skin and eyes, and avoid breathing fumes. If swallowed, do not induce
vomiting. Obtain immediate medical attention. Failure to comply may result in serious injury or death to personnel.
Ether canisters are pressurized, combustible and flammable. Keep away from flames and sparks. Do not
incinerate or puncture canister. Do not expose to temperatures above 120°F (49°C). Do not store spare
canister in vehicle cab. Failure to comply may result in serious injury or death to personnel.
WARNING
ENGINE FLUIDS
Engine fluids (oil, fuel, and coolant) may flammable and may be hazardous to human health and the environment.
Handle all fluids and other contaminated materials (such as filters and rags) in accordance with standard operating
procedures. Recycle or dispose of engine fluids, filters, and other contaminated materials in accordance with
standard operating procedures. Failure to comply may result in environmental damage and injury to personnel.
WARNING
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FIBERGLASS
Direct contact with fiberglass materials or exposure to airborne fiberglass dust may irritate skin, eyes, nose, and
throat. Minimize exposure to fiberglass particles by wearing long sleeves and long pants, work gloves, hat, and
face shield or safety goggles with side shields. Personnel who experience irritation or have a known sensitivity
should wear an approved particulate respirator. After working with fiberglass materials, wash skin with soap and
running water and change clothing before touching eyes. Failure to comply may result in injury to personnel.
WARNING
FUEL
Fuel is flammable and can explode. Keep all open flames, flammable materials, ignition sources,
and sparks away from diesel fuel and keep fire extinguisher nearby. Do not smoke when working
with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited by hot engine.
Be alert at all times for the smell of fuel. Hot engines and components can ignite fuel. If fuel smell
is detected while operating vehicle, shut down vehicle immediately. Failure to comply may result
Store diesel fuel in an approved container clearly marked DIESEL FUEL or JP-8, accordingly.
Dispose of fuel in an approved container clearly marked DIESEL FUEL or JP-8, accordingly,
in accordance with standard operating procedures.
Never use diesel fuel or JP-8 to clean parts. Fuel is highly flammable. Failure to comply may result
WARNING
HYDRAULIC FLUID
Hydraulic fluid is flammable and harmful to skin and eyes. Wear work gloves and eye protection
when handling fluids. Do not perform maintenance while smoking or near flame or sparks. If fluid
contacts skin, wash affected area immediately. In case of eye contact, flush with water for 15 minutes
and seek medical care immediately. Dispose of hydraulic fluid in accordance with standard operating
procedures. Failure to comply may result in serious injury to personnel.
WARNING
NBC (NUCLEAR, BIOLOGICAL, and CHEMICAL) SYSTEM

NBC system maintenance procedures require at least two personnel due to risk of medical emergency
from possible exposure to NBC agents. Maintenance must be performed by properly trained, authorized
personnel with proper safety equipment and protective clothing. Make sure batteries are disconnected and
s
TM 9-2355-106-23-1

area is well ventilated. Do not smoke or allow open flame near vehicle. Never operate system with cover
or panel removed. Failure to comply may result in serious injury or death to personnel.
WARNING
REFRIGERANT
Do not expose refrigerant containers, empty or full, to open flames or temperatures above 125°F (52°C). Do
not discard empty containers where they may be subject to heat from a trash burner; containers may explode.
The temperature of liquid refrigerant is -20°F (-29°C). Wear full face shield, protective rubberized gloves, and
protective clothing when working with refrigerant. If refrigerant contacts skin, remove all contaminated clothing.
Treat skin as though it were frostbitten or frozen and seek immediate medical attention. If refrigerant contacts eyes,
do not rub them. Flush eyes with cold water for at least 15 minutes to gradually increase temperature above freezing
point. Seek immediate medical attention. Failure to comply may result in serious injury or death to personnel.
Refrigerant becomes a poisonous gas in the presence of heat. Do not smoke or allow any type of flame
in immediate area while servicing air conditioning system. Never weld, solder, steam clean, or use
excessive heat on any part of the air conditioning system while charged/pressurized. Failure to comply
R-134a refrigerant must not be mixed with air and then pressurized. When mixed with large quantities
of air and pressurized, R-134a becomes combustible. Failure to comply may result in damage to
equipment and environment, and serious injury or death to personnel.
Refrigerant evaporates very quickly and may displace oxygen surrounding work area, especially in a small or
enclosed area. This can cause suffocation or brain damage. If leak occurs, avoid breathing refrigerant vapor and
thoroughly ventilate area before continuing service. If personnel breathe refrigerant vapors, obtain immediate
medical assistance. Failure to comply may result in serious injury or death to personnel.
Federal and state laws require that refrigerant be recovered and recycled. Refrigerant must be recovered
from system with authorized recommended equipment before any work can be performed on unit. Always
use approved recycling equipment to prevent accidental discharge. Failure to comply may result in
damage to equipment and environment, and serious injury or death to personnel.
WARNING
HVAC SYSTEM
Do not check compressor oil level when HVAC system is charged with refrigerant. Never open the high side hand
valve of the manifold gauge set while HVAC system is operating. If hot, high pressure refrigerant is forced through
gauge to refrigerant supply cylinder, which could rupture. Do not disconnect HVAC lines from compressor. Release
of refrigerant may cause damage to equipment or environment and serious injury or death to personnel.
Do not use parts other than those specified for the system being serviced. Failure to comply may
result in damage to equipment and serious injury or death to personnel.
Accidental or intentional introduction of liquid contaminants into the environment is a violation of state, federal, and
military regulations. Store, install, and dispose of containers in accordance with standard operating procedures.
t
TM 9-2355-106-23-1


Refer to Army POL (para. 1-8) for information concerning storage, use, and disposal of liquid contaminants.
Failure to comply may result in damage to environment and serious injury or death to personnel.
WARNING

SILICONE GASKET MATERIAL

Silicone gasket material emits a small amount of acid vapor. Ensure work area is well ventilated.
Read and carefully follow manufacturer’s instructions before use. If silicone gasket material contacts
eyes, follow manufacturer’s emergency procedures. Seek medical assistance as soon as possible.
WARNING

SILICONE GREASE

Silicone grease is harmful to skin and eyes. If silicone grease contacts eyes, rinse thoroughly and
WARNING

THREAD SEALING COMPOUND

Thread sealing compound is harmful to skin and eyes. If thread sealing compound contacts eyes,
rinse thoroughly and contact physician if irritation persists. If skin is contacted, wash thoroughly with
soap and water. Failure to comply may result in serious injury to personnel.

u/blank
TM 9-2355-106-23-1
LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE: This manual supersedes TM 9-2355-106-23-1, Dated 27 April 2009.

Zero in the “Change No.” column indicates an original page or work package.
Date of issue for original manual is:

Original 19 November 2012
THE TOTAL NUMBER OF VOLUMES IS 5, TOTAL NUMBER OF FRONT AND REAR PAGES IS 212,
AND THE TOTAL NUMBER OF WORK PACKAGES IS 796, CONSISTING OF THE FOLLOWING:
Page/WP No. Change No. Page/WP No. Change No.
Front Cover.................................................................... 0 WP 0035 (6 pgs)............................................................ 0

Warning summary (22 pgs) ........................................... 0 WP 0036 (6 pgs)............................................................ 0
i-clxvi............................................................................ 0 WP 0037 (4 pgs)............................................................ 0
VOLUME 1 .................................................................... 0 WP 0038 (4 pgs)............................................................ 0
Chapter 1 title page ....................................................... 0 WP 0039 (2 pgs)............................................................ 0
WP 0001 (24 pgs).......................................................... 0 WP 0040 (8 pgs)............................................................ 0
WP 0002 (26 pgs).......................................................... 0 WP 0041 (6 pgs)............................................................ 0
WP 0003 (34 pgs).......................................................... 0 WP 0042 (2 pgs)............................................................ 0
Chapter 2 title page ....................................................... 0 WP 0043 (14 pgs).......................................................... 0
WP 0004 (6 pgs)............................................................ 0 WP 0044 (6 pgs)............................................................ 0
WP 0005 (2 pgs)............................................................ 0 WP 0046 (6 pgs)............................................................ 0
WP 0006 (4 pgs)............................................................ 0 WP 0047 (6 pgs)............................................................ 0
WP 0007 (14 pgs).......................................................... 0 WP 0048 (10 pgs).......................................................... 0
WP 0008 (4 pgs)............................................................ 0 WP 0049 (28 pgs).......................................................... 0
WP 0009 (6 pgs)............................................................ 0 WP 0050 (30 pgs).......................................................... 0
WP 0010 (6 pgs)............................................................ 0 WP 0051 (30 pgs).......................................................... 0
WP 0011 (2 pgs) ............................................................ 0 WP 0052 (32 pgs).......................................................... 0
WP 0012 (4 pgs)............................................................ 0 WP 0053 (2 pgs)............................................................ 0
WP 0013 (2 pgs)............................................................ 0 WP 0054 (24 pgs).......................................................... 0
WP 0014 (2 pgs)............................................................ 0 WP 0055 (6 pgs)............................................................ 0
WP 0015 (2 pgs)............................................................ 0 WP 0056 (12 pgs).......................................................... 0
WP 0016 (6 pgs)............................................................ 0 WP 0057 (20 pgs).......................................................... 0
WP 0017 (6 pgs)............................................................ 0 WP 0058 (20 pgs).......................................................... 0
WP 0018 (4 pgs)............................................................ 0 WP 0059 (2 pgs)............................................................ 0
WP 0019 (12 pgs).......................................................... 0 WP 0060 (18 pgs).......................................................... 0
WP 0020 (2 pgs)............................................................ 0 WP 0061 (18 pgs).......................................................... 0
WP 0021 (10 pgs).......................................................... 0 WP 0062 (16 pgs).......................................................... 0
WP 0022 (2 pgs)............................................................ 0 WP 0063 (16 pgs).......................................................... 0
WP 0023 (2 pgs)............................................................ 0 WP 0064 (6 pgs)............................................................ 0
WP 0024 (4 pgs)............................................................ 0 WP 0065 (24 pgs).......................................................... 0
WP 0025 (4 pgs)............................................................ 0 WP 0066 (4 pgs)............................................................ 0
WP 0026 (4 pgs)............................................................ 0 WP 0067 (56 pgs).......................................................... 0
WP 0027 (2 pgs)............................................................ 0 WP 0068 (44 pgs).......................................................... 0
WP 0028 (12 pgs).......................................................... 0 WP 0069 (10 pgs).......................................................... 0
WP 0029 (6 pgs)............................................................ 0 WP 0070 (4 pgs)............................................................ 0
WP 0030 (10 pgs).......................................................... 0 WP 0071 (10 pgs).......................................................... 0
WP 0031 (2 pgs)............................................................ 0 WP 0072 (6 pgs)............................................................ 0
WP 0032 (2 pgs)............................................................ 0 WP 0073 (2 pgs)............................................................ 0
WP 0033 (8 pgs)............................................................ 0 WP 0074 (4 pgs)............................................................ 0
WP 0034 (18 pgs).......................................................... 0 WP 0075 (2 pgs)............................................................ 0
USA
TM 9-2355-106-23-1


WP 0076 (2 pgs)............................................................ 0 WP 0126 (20 pgs).......................................................... 0
WP 0077 (12 pgs).......................................................... 0 WP 0127 (24 pgs).......................................................... 0
WP 0078 (8 pgs)............................................................ 0 WP 0128 (4 pgs)............................................................ 0
WP 0079 (4 pgs)............................................................ 0 WP 0129 (26 pgs).......................................................... 0
WP 0080 (2 pgs)............................................................ 0 WP 0130 (22 pgs).......................................................... 0
WP 0081 (2 pgs)............................................................ 0 WP 0131 (26 pgs).......................................................... 0
WP 0082 (2 pgs)............................................................ 0 WP 0132 (40 pgs).......................................................... 0
WP 0083 (2 pgs)............................................................ 0 WP 0133 (2 pgs)............................................................ 0
WP 0084 (2 pgs)............................................................ 0 WP 0134 (18 pgs).......................................................... 0
WP 0085 (12 pgs).......................................................... 0 WP 0135 (2 pgs)............................................................ 0
WP 0086 (24 pgs).......................................................... 0 WP 0136 (14 pgs).......................................................... 0
WP 0087 (24 pgs).......................................................... 0 WP 0137 (40 pgs).......................................................... 0
WP 0088 (2 pgs)............................................................ 0 WP 0138 (26 pgs).......................................................... 0
WP 0089 (14 pgs).......................................................... 0 WP 0139 (16 pgs).......................................................... 0
WP 0090 (14 pgs).......................................................... 0 WP 0140 (34 pgs).......................................................... 0
WP 0091 (18 pgs).......................................................... 0 WP 0141 (18 pgs).......................................................... 0
WP 0092 (22 pgs).......................................................... 0 WP 0142 (2 pgs)............................................................ 0
WP 0093 (26 pgs).......................................................... 0 WP 0143 (6 pgs)............................................................ 0
WP 0094 (30 pgs).......................................................... 0 WP 0144 (2 pgs)............................................................ 0
WP 0095 (32 pgs).......................................................... 0 WP 0145 (6 pgs)............................................................ 0
WP 0096 (2 pgs)............................................................ 0 WP 0146 (6 pgs)............................................................ 0
WP 0097 (30 pgs).......................................................... 0 WP 0147 (10 pgs).......................................................... 0
WP 0098 (42 pgs).......................................................... 0 WP 0148 (8 pgs)............................................................ 0
WP 0099 (12 pgs).......................................................... 0 WP 0149 (10 pgs).......................................................... 0
WP 0100 (36 pgs).......................................................... 0 WP 0150 (10 pgs).......................................................... 0
WP 0101 (56 pgs).......................................................... 0 WP 0151 (2 pgs)............................................................ 0
Glossary- 1………......................................................... 0 WP 0152 (8 pgs)............................................................ 0
Index-1 – Index-17......................................................... 0 WP 0153 (8 pgs)............................................................ 0
VOLUME 2 .................................................................... 0 WP 0154 (6 pgs)............................................................ 0
WP 0102 (24 pgs).......................................................... 0 WP 0156 (8 pgs)............................................................ 0
WP 0103 (26 pgs).......................................................... 0 WP 0157 (8 pgs)............................................................ 0
WP 0104 (26 pgs).......................................................... 0 WP 0158 (2 pgs)............................................................ 0
WP 0105 (14 pgs).......................................................... 0 WP 0159 (6 pgs)............................................................ 0
WP 0106 (2 pgs)............................................................ 0 WP 0160 (6 pgs)............................................................ 0
WP 0107 (4 pgs)............................................................ 0 WP 0161 (8 pgs)............................................................ 0
WP 0108 (4 pgs)............................................................ 0 WP 0162 (8 pgs)............................................................ 0
WP 0109 (12 pgs).......................................................... 0 WP 0163 (2 pgs)............................................................ 0
WP 0110 (8 pgs) ............................................................ 0 WP 0164 (6 pgs)............................................................ 0
WP 0111 (8 pgs) ............................................................ 0 WP 0165 (8 pgs)............................................................ 0
WP 0112 (12 pgs) .......................................................... 0 WP 0166 (2 pgs)............................................................ 0
WP 0113 (2 pgs) ............................................................ 0 WP 0167 (2 pgs)............................................................ 0
WP 0114 (14 pgs) .......................................................... 0 WP 0168 (8 pgs)............................................................ 0
WP 0115 (20 pgs) .......................................................... 0 WP 0169 (8 pgs)............................................................ 0
WP 0116 (8 pgs) ............................................................ 0 WP 0170 (4 pgs)............................................................ 0
WP 0117 (24 pgs) .......................................................... 0 WP 0171 (4 pgs)............................................................ 0
WP 0118 (10 pgs) .......................................................... 0 WP 0172 (6 pgs)............................................................ 0
WP 0119 (14 pgs) .......................................................... 0 WP 0173 (28 pgs).......................................................... 0
WP 0120 (6 pgs)............................................................ 0 WP 0174 (12 pgs).......................................................... 0
WP 0121 (20 pgs).......................................................... 0 WP 0175 (6 pgs)............................................................ 0
WP 0122 (20 pgs).......................................................... 0 WP 0176 (6 pgs)............................................................ 0
WP 0123 (34 pgs).......................................................... 0 WP 0177 (70 pgs).......................................................... 0
WP 0124 (8 pgs)............................................................ 0 WP 0178 (52 pgs).......................................................... 0
WP 0125 (20 pgs).......................................................... 0 WP 0179 (6 pgs)............................................................ 0
B
USA
TM 9-2355-106-23-1


WP 0180 (8 pgs)............................................................ 0 WP 0229 (6 pgs)............................................................ 0
WP 0181 (4 pgs)............................................................ 0 WP 0230 (6 pgs)............................................................ 0
WP 0182 (4 pgs)............................................................ 0 WP 0231 (4 pgs)............................................................ 0
WP 0183 (6 pgs)............................................................ 0 WP 0232 (4 pgs)............................................................ 0
WP 0184 (8 pgs)............................................................ 0 WP 0233 (4 pgs)............................................................ 0
WP 0185 (12 pgs).......................................................... 0 WP 0234 (8 pgs)............................................................ 0
WP 0186 (14 pgs).......................................................... 0 WP 0235 (4 pgs)............................................................ 0
WP 0187 (28 pgs).......................................................... 0 WP 0236 (6 pgs)............................................................ 0
WP 0188 (24 pgs).......................................................... 0 WP 0237 (4 pgs)............................................................ 0
WP 0189 (8 pgs)............................................................ 0 WP 0238 (6 pgs)............................................................ 0
WP 0190 (4 pgs)............................................................ 0 WP 0239 (4 pgs)............................................................ 0
WP 0191 (18 pgs).......................................................... 0 WP 0240 (4 pgs)............................................................ 0
WP 0192 (26 pgs).......................................................... 0 WP 0241 (4 pgs)............................................................ 0
WP 0193 (16 pgs).......................................................... 0 WP 0242 (2 pgs)............................................................ 0
WP 0194 (4 pgs)............................................................ 0 WP 0243 (4 pgs)............................................................ 0
WP 0195 (6 pgs)............................................................ 0 WP 0244 (4 pgs)............................................................ 0
WP 0196 (6 pgs)............................................................ 0 WP 0245 (2 pgs)............................................................ 0
WP 0197 (8 pgs)............................................................ 0 WP 0246 (6 pgs)............................................................ 0
WP 0198 (6 pgs)............................................................ 0 WP 0247 (4 pgs)............................................................ 0
WP 0199 (6 pgs)............................................................ 0 WP 0248 (6 pgs)............................................................ 0
WP 0200 (6 pgs)............................................................ 0 WP 0249 (6 pgs)............................................................ 0
WP 0201 (6 pgs)............................................................ 0 WP 0250 (10 pgs).......................................................... 0
WP 0202 (10 pgs).......................................................... 0 WP 0251 (4 pgs)............................................................ 0
WP 0203 (40 pgs).......................................................... 0 WP 0252 (8 pgs)............................................................ 0
WP 0204 (8 pgs)............................................................ 0 WP 0253 (8 pgs)............................................................ 0
WP 0205 (8 pgs)............................................................ 0 WP 0254 (8 pgs)............................................................ 0
VOLUME 3 .................................................................... 0 WP 0255 (4 pgs)............................................................ 0
WP 0206 (24 pgs).......................................................... 0 WP 0257 (6 pgs)............................................................ 0
WP 0207 (18 pgs).......................................................... 0 WP 0258 (8 pgs)............................................................ 0
WP 0208 (8 pgs)............................................................ 0 WP 0259 (4 pgs)............................................................ 0
WP 0209 (6 pgs)............................................................ 0 WP 0260 (6 pgs)............................................................ 0
WP 0210 (14 pgs).......................................................... 0 WP 0261 (6 pgs)............................................................ 0
WP 0211 (14 pgs) .......................................................... 0 WP 0262 (12 pgs).......................................................... 0
WP 0212 (10 pgs).......................................................... 0 WP 0263 (6 pgs)............................................................ 0
WP 0213 (44 pgs).......................................................... 0 WP 0264 (6 pgs)............................................................ 0
WP 0214 (14 pgs).......................................................... 0 WP 0265 (16 pgs).......................................................... 0
WP 0215 (2 pgs)............................................................ 0 WP 0267 (4 pgs)............................................................ 0
WP 0216 (38 pgs).......................................................... 0 WP 0268 (14 pgs).......................................................... 0
WP 0217 (2 pgs)............................................................ 0 WP 0270 (4 pgs)............................................................ 0
WP 0218 (22 pgs).......................................................... 0 WP 0271 (6 pgs)............................................................ 0
WP 0219 (26 pgs).......................................................... 0 WP 0272 (8 pgs)............................................................ 0
WP 0220 (6 pgs)............................................................ 0 WP 0273 (4 pgs)............................................................ 0
WP 0221 (4 pgs)............................................................ 0 WP 0274 (4 pgs)............................................................ 0
WP 0222 (18 pgs).......................................................... 0 WP 0275 (6 pgs)............................................................ 0
WP 0223 (6 pgs)............................................................ 0 WP 0276 (6 pgs)............................................................ 0
WP 0224 (6 pgs)............................................................ 0 WP 0277 (14 pgs).......................................................... 0
WP 0225 (6 pgs)............................................................ 0 WP 0278 (20 pgs).......................................................... 0
WP 0226 (2 pgs)............................................................ 0 WP 0279 (6 pgs)............................................................ 0
WP 0227 (8 pgs)............................................................ 0 WP 0280 (4 pgs)............................................................ 0
WP 0228 (8 pgs)............................................................ 0 WP 0281 (6 pgs)............................................................ 0
C
USA
TM 9-2355-106-23-1


WP 0282 (4 pgs)............................................................ 0 WP 0335 (22 pgs).......................................................... 0
WP 0283 (6 pgs)............................................................ 0 WP 0336 (22 pgs).......................................................... 0
WP 0284 (8 pgs)............................................................ 0 WP 0337 (4 pgs)............................................................ 0
WP 0285 (6 pgs)............................................................ 0 WP 0338 (4 pgs)............................................................ 0
WP 0286 (6 pgs)............................................................ 0 WP 0339 (4 pgs)............................................................ 0
WP 0287 (6 pgs)............................................................ 0 WP 0340 (4 pgs)............................................................ 0
WP 0288 (6 pgs)............................................................ 0 WP 0341 (8 pgs)............................................................ 0
WP 0289 (8 pgs)............................................................ 0 WP 0342 (4 pgs)............................................................ 0
WP 0290 (6 pgs)............................................................ 0 WP 0343 (4 pgs)............................................................ 0
WP 0291 (4 pgs)............................................................ 0 WP 0344 (4 pgs)............................................................ 0
WP 0292 (6 pgs)............................................................ 0 WP 0345 (6 pgs)............................................................ 0
WP 0293 (6 pgs)............................................................ 0 WP 0346 (4 pgs)............................................................ 0
WP 0294 (4 pgs)............................................................ 0 WP 0347 (4 pgs)............................................................ 0
WP 0295 (4 pgs)............................................................ 0 WP 0348 (6 pgs)............................................................ 0
WP 0296 (4 pgs)............................................................ 0 WP 0349 (6 pgs)............................................................ 0
WP 0297 (6 pgs)............................................................ 0 WP 0350 (4 pgs)............................................................ 0
WP 0298 (4 pgs)............................................................ 0 WP 0351 (8 pgs)............................................................ 0
WP 0299 (6 pgs)............................................................ 0 WP 0352 (6 pgs)............................................................ 0
WP 0300 (4 pgs)............................................................ 0 WP 0353 (6 pgs)............................................................ 0
WP 0301 (4 pgs)............................................................ 0 WP 0354 (6 pgs)............................................................ 0
WP 0302 (6 pgs)............................................................ 0 WP 0355 (2 pgs)............................................................ 0
WP 0303 (2 pgs)............................................................ 0 WP 0356 (4 pgs)............................................................ 0
WP 0304 (4 pgs)............................................................ 0 WP 0357 (4 pgs)............................................................ 0
WP 0305 (4 pgs)............................................................ 0 WP 0358 (6 pgs)............................................................ 0
WP 0306 (4 pgs)............................................................ 0 WP 0359 (6 pgs)............................................................ 0
WP 0307 (6 pgs)............................................................ 0 WP 0360 (10 pgs).......................................................... 0
WP 0308 (4 pgs)............................................................ 0 WP 0361 (6 pgs)............................................................ 0
WP 0309 (4 pgs)............................................................ 0 WP 0362 (4 pgs)............................................................ 0
WP 0310 (4 pgs)............................................................ 0 WP 0363 (4 pgs)............................................................ 0
WP 0311 (4 pgs) ............................................................ 0 WP 0364 (6 pgs)............................................................ 0
WP 0312 (6 pgs)............................................................ 0 WP 0365 (12 pgs).......................................................... 0
WP 0313 (4 pgs)............................................................ 0 WP 0366 (4 pgs)............................................................ 0
WP 0314 (10 pgs).......................................................... 0 WP 0367 (4 pgs)............................................................ 0
WP 0315 (4 pgs)............................................................ 0 WP 0368 (4 pgs)............................................................ 0
WP 0316 (4 pgs)............................................................ 0 WP 0369 (4 pgs)............................................................ 0
WP 0317 (6 pgs)............................................................ 0 WP 0370 (10 pgs).......................................................... 0
WP 0318 (4 pgs)............................................................ 0 WP 0371 (4 pgs)............................................................ 0
WP 0319 (28 pgs).......................................................... 0 WP 0372 (4 pgs)............................................................ 0
WP 0320 (2 pgs)............................................................ 0 WP 0373 (4 pgs)............................................................ 0
WP 0321 (6 pgs)............................................................ 0 WP 0374 (6 pgs)............................................................ 0
WP 0322 (4 pgs)............................................................ 0 WP 0375 (6 pgs)............................................................ 0
WP 0323 (4 pgs)............................................................ 0 WP 0376 (6 pgs)............................................................ 0
WP 0324 (8 pgs)............................................................ 0 WP 0377 (2 pgs)............................................................ 0
WP 0325 (6 pgs)............................................................ 0 WP 0378 (8 pgs)............................................................ 0
WP 0326 (4 pgs)............................................................ 0 WP 0379 (8 pgs)............................................................ 0
WP 0327 (4 pgs)............................................................ 0 WP 0380 (4 pgs)............................................................ 0
WP 0328 (6 pgs)............................................................ 0 WP 0381 (2 pgs)............................................................ 0
WP 0329 (6 pgs)............................................................ 0 WP 0382 (4 pgs)............................................................ 0
WP 0330 (8 pgs)............................................................ 0 WP 0383 (4 pgs)............................................................ 0
WP 0331 (4 pgs)............................................................ 0 WP 0384 (8 pgs)............................................................ 0
WP 0332 (4 pgs)............................................................ 0 WP 0385 (10 pgs).......................................................... 0
WP 0333 (6 pgs)............................................................ 0 WP 0386 (8 pgs)............................................................ 0
WP 0334 (6 pgs)............................................................ 0 WP 0387 (4 pgs)............................................................ 0
D
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TM 9-2355-106-23-1


WP 0388 (4 pgs)............................................................ 0 WP 0439 (10 pgs).......................................................... 0
WP 0389 (4 pgs)............................................................ 0 WP 0440 (10 pgs).......................................................... 0
WP 0390 (4 pgs)............................................................ 0 WP 0441 (6 pgs)............................................................ 0
WP 0391 (6 pgs)............................................................ 0 WP 0442 (10 pgs).......................................................... 0
WP 0392 (4 pgs)............................................................ 0 WP 0443 (6 pgs)............................................................ 0
WP 0393 (4 pgs)............................................................ 0 WP 0444 (6 pgs)............................................................ 0
WP 0394 (4 pgs)............................................................ 0 WP 0445 (6 pgs)............................................................ 0
VOLUME 4 .................................................................... 0 WP 0446 (6 pgs)............................................................ 0
WP 0395 (4 pgs)............................................................ 0 WP 0448 (6 pgs)............................................................ 0
WP 0396 (6 pgs)............................................................ 0 WP 0449 (6 pgs)............................................................ 0
WP 0397 (4 pgs)............................................................ 0 WP 0450 (4 pgs)............................................................ 0
WP 0398 (2 pgs)............................................................ 0 WP 0451 (12 pgs).......................................................... 0
WP 0399 (4 pgs)............................................................ 0 WP 0452 (6 pgs)............................................................ 0
WP 0400 (4 pgs)............................................................ 0 WP 0453 (6 pgs)............................................................ 0
WP 0401 (4 pgs)............................................................ 0 WP 0454 (22 pgs).......................................................... 0
WP 0402 (4 pgs)............................................................ 0 WP 0455 (4 pgs)............................................................ 0
WP 0403 (6 pgs)............................................................ 0 WP 0456 (8 pgs)............................................................ 0
WP 0404 (10 pgs).......................................................... 0 WP 0457 (4 pgs)............................................................ 0
WP 0405 (4 pgs)............................................................ 0 WP 0458 (2 pgs)............................................................ 0
WP 0406 (6 pgs)............................................................ 0 WP 0459 (4 pgs)............................................................ 0
WP 0407 (10 pgs).......................................................... 0 WP 0460 (12 pgs).......................................................... 0
WP 0408 (4 pgs)............................................................ 0 WP 0461 (6 pgs)............................................................ 0
WP 0409 (6 pgs)............................................................ 0 WP 0462 (4 pgs)............................................................ 0
WP 0410 (4 pgs)............................................................ 0 WP 0463 (8 pgs)............................................................ 0
WP 0411 (6 pgs) ............................................................ 0 WP 0464 (8 pgs)............................................................ 0
WP 0412 (6 pgs)............................................................ 0 WP 0465 (10 pgs).......................................................... 0
WP 0413 (4 pgs)............................................................ 0 WP 0466 (4 pgs)............................................................ 0
WP 0414 (4 pgs)............................................................ 0 WP 0467 (6 pgs)............................................................ 0
WP 0415 (6 pgs)............................................................ 0 WP 0468 (2 pgs)............................................................ 0
WP 0416 (6 pgs)............................................................ 0 WP 0469 (4 pgs)............................................................ 0
WP 0417 (4 pgs)............................................................ 0 WP 0470 (18 pgs).......................................................... 0
WP 0418 (6 pgs)............................................................ 0 WP 0471 (14 pgs).......................................................... 0
WP 0419 (6 pgs)............................................................ 0 WP 0472 (6 pgs)............................................................ 0
WP 0420 (6 pgs)............................................................ 0 WP 0473 (4 pgs)............................................................ 0
WP 0421 (6 pgs)............................................................ 0 WP 0474 (4 pgs)............................................................ 0
WP 0422 (6 pgs)............................................................ 0 WP 0475 (6 pgs)............................................................ 0
WP 0423 (4 pgs)............................................................ 0 WP 0476 (6 pgs)............................................................ 0
WP 0424 (16 pgs).......................................................... 0 WP 0477 (12 pgs).......................................................... 0
WP 0425 (6 pgs)............................................................ 0 WP 0478 (22 pgs).......................................................... 0
WP 0426 (10 pgs).......................................................... 0 WP 0479 (4 pgs)............................................................ 0
WP 0427 (12 pgs).......................................................... 0 WP 0480 (2 pgs)............................................................ 0
WP 0428 (4 pgs)............................................................ 0 WP 0481 (4 pgs)............................................................ 0
WP 0429 (6 pgs)............................................................ 0 WP 0482 (4 pgs)............................................................ 0
WP 0430 (6 pgs)............................................................ 0 WP 0483 (2 pgs)............................................................ 0
WP 0431 (4 pgs)............................................................ 0 WP 0484 (8 pgs)............................................................ 0
WP 0432 (12 pgs).......................................................... 0 WP 0485 (2 pgs)............................................................ 0
WP 0433 (6 pgs)............................................................ 0 WP 0486 (6 pgs)............................................................ 0
WP 0434 (6 pgs)............................................................ 0 WP 0487 (2 pgs)............................................................ 0
WP 0435 (4 pgs)............................................................ 0 WP 0488 (4 pgs)............................................................ 0
WP 0436 (4 pgs)............................................................ 0 WP 0489 (8 pgs)............................................................ 0
WP 0437 (6 pgs)............................................................ 0 WP 0490 (8 pgs)............................................................ 0
WP 0438 (4 pgs)............................................................ 0 WP 0491 (6 pgs)............................................................ 0
E
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TM 9-2355-106-23-1


WP 0492 (2 pgs)............................................................ 0 WP 0545 (2 pgs)............................................................ 0
WP 0493 (6 pgs)............................................................ 0 WP 0546 (8 pgs)............................................................ 0
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WP 0598 (4 pgs)............................................................ 0 WP 0649 (4 pgs)............................................................ 0
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VOLUME 5 .................................................................... 0 WP 0660 (4 pgs)............................................................ 0
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WP 0647 (10 pgs).......................................................... 0 WP 0700 (6 pgs)............................................................ 0
WP 0648 (4 pgs)............................................................ 0 WP 0701 (12 pgs).......................................................... 0
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WP 0702 (6 pgs)............................................................ 0 WP 0753 (6 pgs)............................................................ 0
WP 0703 (4 pgs)............................................................ 0 WP 0754 (4 pgs)............................................................ 0
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WP 0713 (12 pgs).......................................................... 0 WP 0764 (4 pgs)............................................................ 0
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WP 0727 (8 pgs)............................................................ 0 WP 0778 (4 pgs)............................................................ 0
WP 0728 (6 pgs)............................................................ 0 WP 0779 (6 pgs)............................................................ 0
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WP 0735 (4 pgs)............................................................ 0 WP 0786 (4 pgs)............................................................ 0
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WP 0747 (4 pgs)............................................................ 0 Back cover..................................................................... 0
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ARMY *TM 9-2355-106-23-1
AIR FORCE TO 36A12-1C-2400-2-1
HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

WASHINGTON, D.C., 19 NOVEMBER 2012
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL

FOR
M1224
(NSN 2355-01-553-4634) (EIC 1XF)
M1224A1
(NSN 2355-01-561-0281) (EIC 1XM)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

(A) Army - You can help improve this publication. If you find any errors, or if you would like to
recommend any improvements to the procedures in this publication, please let us know. The
preferred method is to submit your DA Form 2028 (Recommended Changes to Publications
and Blank Forms) through the Internet, on the TACOM unique Logistics Support Applications
(TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all
applications requires CAC authentication, and you must complete the Access Request form the
first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand
navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will
enable us to respond more quickly to your comments and to better manage the DA Form 2028
program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S.
Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM
Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 East 11
Mile Road, Warren, MI 48397–5000. The e-mail address is [email protected].
The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.
(F) Air Force - By Air Force AFTO Form 22 directly to Warner Robins, Tech Data Home office, 584
CBSS/GBHDE, 480 Richard Ray Blvd Ste 200, Robins AFB GA 31098-1640. You may also send
in your recommended changes via electronic mail or by fax. Our fax number is DSN 472-3104
or Commercial (478) 222-3104. Forward all electronic AFTO 22 submissions to the following
mail account: [email protected]. Recommendations concerning changes to this
manual shall be submitted in accordance with TO 00-5-1-WA-1.
* SUPERSEDURE NOTICE– This manual supersedes TM 9-2355-106-23-1, dated 27 April 2009, including all changes.
DISCLOSURE NOTICE – This information is furnished upon the condition that it will not be released to another nation without the specific authority of the
Department of the Army of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information,
whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the
information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any
other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.
DISTRIBUTION STATEMENT C – Distribution authorized to U.S. Government Agencies and their contractors only for Specific Authority as determined on
01 August 2012. Other requests for this document shall be referred to TACOM Life Cycle Management Command, ATTN: AMSTA-LCC-MMK/TECH PUBS,
Warren, MI 48397–5000.
WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq) or the Export
Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties.
Disseminate in accordance with provisions of DoD Directive 5230.25.
DESTRUCTION NOTICE – Destroy by any method that will prevent disclosure of contents or reconstruction of contents.
i/ii blank
TM 9-2355-106-23-1
TABLE OF CONTENTS
Page No.
WP Sequence No.
VOLUME 1
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clviiii
CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION, VOL 1

GENERAL INFORMATION, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001
Figure 1. M1224 MRAP, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001
Figure 2. M1224A1 MRAP, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001
Table 1. Nomenclature Cross-reference List, Vol 1 . . . . . . . . . . . . . . . . . WP 0001
EQUIPMENT DESCRIPTION AND DATA, Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 1. Powertrain., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 2. Engine., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 3. Exhaust Pipe, Muffler, and Tailpipe Assembly., Vol 1 . . . . . . . . . . . . WP 0002
Figure 4. Transmission., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 5. Transfer Case., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 6. Propeller Shaft., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 7. Front Axle., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 8. Rear Axle., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 9. Steering Gear., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 10. Electrical Components., Vol 1. . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 11. Batteries., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 12. Battery Equalizers., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 13. 110V Power Inverter, 110V Outlet, and NATO Slave Start Connector., Vol 1 . . WP 0002
Figure 14. Cabin Fuse and Relay Center and Circuit Breaker Center., Vol 1 . . . . . . WP 0002
Figure 15. Engine Compartment PDC., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 16. Starter and Alternator., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 17. ESC., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 18. Right Cabin Door Actuator., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 19. Air Brakes., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 20. Air Compressor, Below Air Filter., Vol 1 . . . . . . . . . . . . . . . . . WP 0002
Figure 21. Body and Chassis Systems – Exterior., Vol 1 . . . . . . . . . . . . . . . WP 0002
Figure 22. Body and Chassis Systems – Interior., Vol 1 . . . . . . . . . . . . . . . WP 0002
Figure 23. Fuel-Fired Heater., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 24. Rear Door/Ramp Pump Assemblies., Vol 1 . . . . . . . . . . . . . . . . WP 0002
Figure 25. FSS Cylinders., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 26. HVAC/LSS Component Locations., Vol 1 . . . . . . . . . . . . . . . . . WP 0002
Figure 27. M1224., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Figure 28. M1224A1., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 1. Differences Between Models., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0002
Table 2. Vehicle Weight., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 3. Dimensions., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 4. Performance., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 5. Capacities., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 6. Cooling System., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 7. Engine Configuration., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 8. Oil Filter., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 9. Fuel System Configuration., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 10. Electrical System., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 11. Transmission., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 12. Transmission Speeds., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0002
iii
TM 9-2355-106-23-1
TABLE OF CONTENTS – (Continued)

Page No.
WP Sequence No.
Table 13. Transfer Case., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 14. Axles., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 15. Brake System., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 16. Wheels., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 17. Tires., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 18. Towing and Lifting., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 19. Winch Cable., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Table 20. Cabin., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
THEORY OF OPERATION, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 1. Drivetrain Powerflow., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 2. ECM Inputs and Outputs., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 3. Fuel Supply System., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 4. Injection System., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 5. Transmission Control Module (TCM) Inputs and Outputs., Vol 1 . . . . . . . WP 0003
Figure 6. Brake and Pneumatic System Components., Vol 1 . . . . . . . . . . . . . WP 0003
Figure 7. Steering Components., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 8. Electrical System Components., Vol 1. . . . . . . . . . . . . . . . . . . WP 0003
Figure 9. J1939 Data Link Circuit (Chassis)., Vol 1 . . . . . . . . . . . . . . . . . WP 0003
Figure 10. J1939 Data Link Circuit (Cabin)., Vol 1 . . . . . . . . . . . . . . . . . . WP 0003
Figure 11. ESC., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 12. IPC Gauges, Digital Display, and Reset Switch., Vol 1 . . . . . . . . . . . WP 0003
Figure 13. IPC Lights., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Figure 14. HVAC/LSS System Controls., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0003
Figure 15. HVAC System Air Conditioning (A/C) Diagram., Vol 1 . . . . . . . . . . . WP 0003
Figure 16. Fire Suppression System Chassis Components., Vol 1 . . . . . . . . . . . WP 0003
Figure 17. Fire Suppression System Cabin and Hood Components., Vol 1 . . . . . . . WP 0003
Figure 18. Rear Door Ramp System Diagram., Vol 1 . . . . . . . . . . . . . . . . WP 0003
Table 1. Gauges, Digital Display, and Reset Switch., Vol 1 . . . . . . . . . . . . . . WP 0003
Table 2. Warning Lamps., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
CHAPTER 2. TROUBLESHOOTING PROCEDURES, VOL 1

Troubleshooting Index, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004

Vehicle Troubleshooting Symptom Index, Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0005
ENGINE DIAGNOSTIC TROUBLE CODE (DTC) INDEX, Vol 1 . . . . . . . . . . . . . . . WP 0006
Table 1. DTC Table., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006
ELECTRONIC SYSTEM CONTROLLER (ESC) DIAGNOSTIC TROUBLE CODE (DTC)
INDEX, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007
TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) INDEX, Vol 1 . . . . . . . . . . . WP 0008
ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) INDEX, Vol 1 . . . WP 0009
VEHICLE OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . WP 0010
CONNECTING MAINTENANCE SUPPORT DEVICE (MSD), Vol 1 . . . . . . . . . . . . . WP 0011
Figure 1. Maintenance Support Device and Power Cables., Vol 1 . . . . . . . . . . . WP 0011
Figure 2. MSD to ATA Connection., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0011
Table 1. Diagnostic Software., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0011
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DIAGNOSTIC TROUBLE CODE (DTC) ACCESS PROCEDURE, Vol 1 . . . . . . . . . . . WP 0012
Figure 1. Select/Reset Button., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0012
Figure 2. ABS Blink Switch., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0012
Figure 3. Transmission Shift Selector., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0012
CLEARING INACTIVE DIAGNOSTIC TROUBLE CODE (DTC) PROCEDURE, Vol 1. . . . . . WP 0013
HARD START/NO START OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . WP 0014
ENGINE PERFORMANCE OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . WP 0015
ENGINE MECHANICAL OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . WP 0016
ENGINE SYSTEMS OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . WP 0017
Figure 1. Connectors LAM 1016, LAM 1019, and 6007., Vol 1 . . . . . . . . . . . . WP 0017
Figure 2. Connector LAM 1011., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0017
ENGINE OIL OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . . . WP 0018
INTAKE/EXHAUST TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . WP 0019
Figure 1. Filter Minder Air Filter Restriction Gauge., Vol 1 . . . . . . . . . . . . . . WP 0019
Figure 2. Exhaust Pipes., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019
Figure 3. Muffler and Tailpipe., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . WP 0019
Figure 4. Right Side of Engine, Behind Turbocharger Area., Vol 1 . . . . . . . . . . . WP 0019
Figure 5. Right Side of Engine, Behind Turbocharger Area., Vol 1 . . . . . . . . . . . WP 0019
Figure 6. Left Side Engine Compartment., Vol 1 . . . . . . . . . . . . . . . . . . WP 0019
INJECTION CONTROL PRESSURE (ICP) NO START OPERATIONAL CHECKOUT
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020
Figure 1. ICP Breakout Tee Installed., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0020
LOW INJECTOR CONTROL PRESSURE (ICP) TROUBLESHOOTING PROCEDURE, Vol 1. . WP 0021
Figure 1. High-Pressure Oil Hose., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 2. ICP Adapter., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 3. High-Pressure Oil Hose., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 4. High-Pressure Hose at Pump., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0021
Figure 5. Injector., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 6. Fuel Injector Harness Connector., Vol 1 . . . . . . . . . . . . . . . . . . WP 0021
Figure 7. Injector., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 8. Fuel Pump Camshaft., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Figure 9. High-Pressure Pump., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0021
INJECTION CONTROL PRESSURE (ICP) OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . WP 0022
BOOST PRESSURE OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . WP 0023
CHARGE AIR COOLER (CAC) PRESSURE OPERATIONAL CHECKOUT PROCEDURE, Vol 1 WP 0024
Figure 1. CAC Tester on Cold Side of CAC., Vol 1. . . . . . . . . . . . . . . . . . WP 0024
Figure 2. CAC Tester on Hot Side of CAC., Vol 1 . . . . . . . . . . . . . . . . . . WP 0024
CRANKCASE PRESSURE OPERATIONAL CHECKOUT PROCEDURE , Vol 1 . . . . . . . . WP 0025
Figure 1. Right Side of Engine., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0025
Figure 2. Right Side of Vehicle., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0025
WASTEGATE ACTUATOR OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . WP 0026
Figure 1. Right Side of Engine., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0026
Figure 2. Pressure Test Kit ZTSE4409., Vol 1. . . . . . . . . . . . . . . . . . . . WP 0026
VALVE ADJUSTMENT TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . WP 0027
Figure 1. Valve Adjustment with No. 1 Piston and No. 6 Piston at Top Dead Center
(TDC)., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027
Figure 2. Valve Adjustment Sequence., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0027
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ENGINE OIL PRESSURE (EOP) SENSOR TROUBLESHOOTING PROCEDURE, Vol 1 . . . . WP 0028
Figure 1. Left Engine, Behind Air Compressor., Vol 1 . . . . . . . . . . . . . . . . WP 0028
Figure 2. 3-Wire Breakout Harness (ZTSE4347)., Vol 1 . . . . . . . . . . . . . . . WP 0028
Figure 4. Pressure Test Kit (ZTSE4409)., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0028
Figure 5. Connector LAM1013., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0028
Figure 6. Left Rear of Engine., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . WP 0028
Figure 10. Connector LAM1019., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0028
Figure 11. Pressure Test Kit (ZTSE4409)., Vol 1 . . . . . . . . . . . . . . . . . . WP 0028
ENGINE OIL TEMPERATURE (EOT) SENSOR TROUBLESHOOTING PROCEDURE, Vol 1 . . WP 0029
Figure 1. Left Front of Engine, Above Air Compressor., Vol 1 . . . . . . . . . . . . . WP 0029
Figure 2. Breakout Tee (ZTSE4483)., Vol 1. . . . . . . . . . . . . . . . . . . . . WP 0029
Table 1. Ambient Temperature vs Voltage., Vol 1 . . . . . . . . . . . . . . . . . . WP 0029
CAMSHAFT POSITION (CMP) SENSOR TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . WP 0030
Figure 1. CMP Sensor., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030
Figure 2. Engine Control Module (ECM)., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0030
ENGINE COOLING FAN OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . WP 0031
BATTERY POWER OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . WP 0032
BATTERY CABLE TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . . WP 0033
Figure 1. CEC Power Module Location., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0033
Figure 2. Sequence of Meter Lead Connections on Positive Side., Vol 1 . . . . . . . . WP 0033
Figure 3. Alternator Positive Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0033
Figure 4. Sequence of Meter Lead Connections on Positive Side., Vol 1 . . . . . . . . WP 0033
Figure 5. Sequence of Meter Lead Connections on Negative Side., Vol 1 . . . . . . . WP 0033
Figure 6. Starter Ground Terminal., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0033
ENGINE DOES NOT CRANK TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . . . . WP 0034
Figure 1. Battery Ground Stud Located Forward of Batteries., Vol 1 . . . . . . . . . . WP 0034
Figure 2. Starter Engine Ground Jumper., Vol 1. . . . . . . . . . . . . . . . . . . WP 0034
Figure 3. Starter Frame Ground Jumper Cable., Vol 1 . . . . . . . . . . . . . . . . WP 0034
Figure 4. Starter Motor Positive Stud., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0034
Figure 5. Starter Motor Solenoid Terminal S., Vol 1 . . . . . . . . . . . . . . . . . WP 0034
Figure 6. Power Distribution Center., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0034
Figure 8. Connector 4003., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0034
Figure 9. Left Side Engine Compartment Area., Vol 1 . . . . . . . . . . . . . . . . WP 0034
Figure 10. Connector 4003., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0034
Figure 12. Left Side Engine Compartment Area., Vol 1. . . . . . . . . . . . . . . . WP 0034
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Figure 16. Behind Dash., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0034
Figure 18. Connector 1100M., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0034
FUEL PUMP PRESSURE TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . WP 0035
Figure 1. Fuel Filter Header Air Bleed Valve., Vol 1 . . . . . . . . . . . . . . . . . WP 0035
Figure 2. Fuel Pressure Gauge Set., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0035
Figure 4. Fuel Pressure Regulator., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0035
FUEL PUMP RESTRICTION TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . WP 0036
Figure 1. Fuel Filter Header Vacuum Side Quick Connect., Vol 1 . . . . . . . . . . . WP 0036
Figure 3. Fuel Filter Inlet to Supply Pump Inlet Fuel Line., Vol 1 . . . . . . . . . . . . WP 0036
Figure 4. Fuel Supply Hose., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0036
FUEL OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . WP 0037
Figure 1. Fuel Filter Header Outlet Line, Vol 1 . . . . . . . . . . . . . . . . . . . WP 0037
Figure 2. Fuel Outlet Line, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0037
FUEL PRESSURE (FULL LOAD) TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . WP 0038
Figure 1. Fuel Filter Header Air Bleed Valve., Vol 1 . . . . . . . . . . . . . . . . . WP 0038
FUEL INJECTOR TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . . WP 0039
INJECTION CONTROL PRESSURE (ICP) SENSOR TROUBLESHOOTING PROCEDURE, Vol 1 WP 0040
Figure 1. Injection Control Pressure (ICP) Sensor., Vol 1 . . . . . . . . . . . . . . . WP 0040
INJECTOR PRESSURE REGULATOR (IPR) TROUBLESHOOTING PROCEDURE, Vol 1 . . . WP 0041
Figure 1. IPR., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0041
INJECTION PRESSURE REGULATOR (IPR) SYSTEM OPERATIONAL CHECKOUT
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0042
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FUEL/WATER SEPARATOR WITH 12V DC FUEL PRE-HEATER TROUBLESHOOTING
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0043
Figure 1. Inboard Right Front Wheel., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0043
Figure 2. Underhood Power Distribution Center (PDC)., Vol 1 . . . . . . . . . . . . WP 0043
Figure 3. Fuel Heater Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0043
Figure 12. Fuel Heater Relay 4002., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0043
EXHAUST SYSTEM OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . WP 0044
Figure 1. Tailpipe and Shield., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0044
Figure 2. Muffler and Muffler Holding Straps., Vol 1 . . . . . . . . . . . . . . . . . WP 0044
Figure 3. Exhaust Pipes and Hangers., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0044
Figure 4. Turbocharger Pipe and Clamp., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0044
Figure 5. Exhaust Brake Clamps., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0044
COOLING SYSTEM OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . WP 0045
Figure 1. Radiator Test Kit., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0045
ENGINE COOLANT LEVEL SYSTEM TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . WP 0046
Figure 1. Right Engine Compartment., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0046
ENGINE COOLANT TEMPERATURE (ECT) SENSOR TROUBLESHOOTING PROCE-
DURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0047
Figure 1. ECT Sensor., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0047
Table 1. Sensor Temperature vs Resistance., Vol 1 . . . . . . . . . . . . . . . . . WP 0047
ENGINE FAN CONTROL (EFC) TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . WP 0048
Figure 1. Left Engine Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0048
Figure 2. Air Fan Shutter Fuse, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0048
Figure 7. Connector LAM 1019., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0048
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ENGINE CONTROL MODULE (ECM) TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . WP 0049
Figure 1. Left Side of Engine On Valve Cover., Vol 1 . . . . . . . . . . . . . . . . WP 0049
Figure 2. Consolidated Engine Controller (CEC) Power Module Relay., Vol 1 . . . . . . WP 0049
Figure 4. Right Side of Battery Box Above Battery., Vol 1. . . . . . . . . . . . . . . WP 0049
Figure 6. ECM Clean Ground Battery Terminal., Vol 1 . . . . . . . . . . . . . . . . WP 0049
Figure 7. CEC Power Module Relay., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0049
Figure 9. Harness Bundle Below Air Cleaner Assembly., Vol 1 . . . . . . . . . . . . WP 0049
Figure 11. CEC Power Module Relay., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0049
Figure 12. Right Side of Battery Box Above Battery., Vol 1 . . . . . . . . . . . . . . WP 0049
Figure 15. ECM Feed Fuse., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0049
Figure 16. Under Left Front of Vehicle, Inboard Frame Rail., Vol 1. . . . . . . . . . . WP 0049
Figure 18. ECM Feed Fuse., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0049
Figure 21. Engine Control Module (ECM)., Vol 1 . . . . . . . . . . . . . . . . . . WP 0049
Figure 22. Connector 4100F., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0049
ACCELERATOR POSITION SENSOR (APS)/IDLE VALIDATION SWITCH (IVS) TROUBLESHOOTING
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 1. Accelerator Position Sensor (APS)/Idle Validation Switch (IVS)., Vol 1 . . . . . WP 0050
Figure 3. Accelerator Position Sensor (APS)/Idle Validation Switch (IVS) Breakout Harness
(ZTSE4485)., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 4. Below Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 5. Firewall Pass-Through., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 6. Below Air Filter., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 7. ECM Connectors., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 8. Connector 4100F., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 9. Below Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 11. Connector 1800., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 13. Connector 1701-Engine Side., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0050
Figure 14. ECM Connectors., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Figure 16. Below Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0050
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Figure 24. Fuse Locator., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
AMERICAN TRUCKERS ASSOCIATION (ATA) COMMUNICATIONS/DATA LINK COMMUNICATIONS (DLC)
TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Figure 1. Under Left Side of Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . WP 0051
Figure 3. IP Pass-Through Connector Near Power Distribution Center (PDC) Under
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Figure 4. Engine/Dash Connector Under Hood., Vol 1 . . . . . . . . . . . . . . . . WP 0051
Figure 5. ECM Connector on Left Side of Engine., Vol 1 . . . . . . . . . . . . . . . WP 0051
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Figure 13. Engine/Dash Connector Under Hood., Vol 1 . . . . . . . . . . . . . . . WP 0051
Figure 16. ECM Connector on Left Side of Engine., Vol 1 . . . . . . . . . . . . . . WP 0051
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
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BAROMETRIC PRESSURE SENSOR (BAP) TROUBLESHOOTING PROCEDURE, Vol 1 . . . WP 0052
Figure 1. Barometric Pressure (BAP) Sensor., Vol 1 . . . . . . . . . . . . . . . . . WP 0052
Figure 2. Below Dash., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0052
Figure 3. Dash Pass-Through., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0052
Figure 9. Engine Connector 4103., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0052
Figure 11. Below Dash., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0052
Figure 14. Engine Connector 4103., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0052
Figure 16. Engine Connector 4103., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0052
ENGINE CONTROL MODULE (ECM) SELF-DIAGNOSIS TROUBLESHOOTING PROCE-
DURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0053
INJECTOR DRIVE CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . WP 0054
Figure 1. Left Side of Engine Valve Cover., Vol 1 . . . . . . . . . . . . . . . . . . WP 0054
Figure 2. Fuel Injector Test Harness (ZTSE4401)., Vol 1 . . . . . . . . . . . . . . . WP 0054
Figure 3. Fuel Injector Disconnected From Harness., Vol 1 . . . . . . . . . . . . . . WP 0054
Figure 7. Left Side of Engine Valve Cover., Vol 1 . . . . . . . . . . . . . . . . . . WP 0054
Figure 8. Fuel Injector Test Harness (ZTSE4401)., Vol 1 . . . . . . . . . . . . . . . WP 0054
Figure 9. Fuel Injector Disconnected From Harness., Vol 1 . . . . . . . . . . . . . . WP 0054
Figure 10. Fuel Injector Harness Connector., Vol 1 . . . . . . . . . . . . . . . . . WP 0054
Figure 11. Left Rear of Engine., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0054
Figure 12. Left Side of Engine Valve Cover., Vol 1. . . . . . . . . . . . . . . . . . WP 0054
Figure 13. Fuel Injector Test Harness (ZTSE4401)., Vol 1 . . . . . . . . . . . . . . WP 0054
Figure 14. Fuel Injector Disconnected From Harness., Vol 1 . . . . . . . . . . . . . WP 0054
Figure 15. Fuel Injector Harness Connector., Vol 1 . . . . . . . . . . . . . . . . . WP 0054
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Table 1. Trouble Code and Terminal Identification., Vol 1 . . . . . . . . . . . . . . . WP 0054
Table 10. Trouble Code and Terminal Identification., Vol 1 . . . . . . . . . . . . . . WP 0054
INTAKE AIR TEMPERATURE (IAT) SENSOR TROUBLESHOOTING PROCEDURE, Vol 1 . . . WP 0055
Figure 1. Rear of Air Cleaner Housing Assembly., Vol 1 . . . . . . . . . . . . . . . WP 0055
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TROUBLESHOOTING PROCE-
DURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0056
Figure 1. Top of Engine Valve Cover, Front of Engine., Vol 1 . . . . . . . . . . . . . WP 0056
Figure 4. 500 Ohm Jumper Wire (ZTSE4497) Connected to 3-Wire Breakout Harness
(ZTSE4347)., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0056
SPEED CONTROL COMMAND SWITCHES (SCCS) TROUBLESHOOTING PROCEDURE, Vol 1WP 0057
Figure 1. Driver Floor Area., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0057
Figure 2. Speed Control Command Switches on Steering Wheel., Vol 1 . . . . . . . . WP 0057
Figure 3. Speed Control Command Switches on Steering Wheel., Vol 1 . . . . . . . . WP 0057
Figure 5. Driver Floor Area., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0057
Figure 6. Steering Wheel Clock Spring Connection., Vol 1 . . . . . . . . . . . . . . WP 0057
Figure 7. Inside Steering Wheel., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0057
Figure 8. Cruise Control Switch Terminals., Vol 1 . . . . . . . . . . . . . . . . . . WP 0057
Figure 9. Cruise Control Switch Terminals., Vol 1 . . . . . . . . . . . . . . . . . . WP 0057
Figure 11. Driver Floor Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0057
Figure 12. Steering Wheel Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0057
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Figure 14. Cruise Control Switch Terminals., Vol 1 . . . . . . . . . . . . . . . . . WP 0057
VEHICLE SPEED SENSOR (VSS) TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . WP 0058
Figure 1. VSS Connector and Sensor Location., Vol 1 . . . . . . . . . . . . . . . . WP 0058
Figure 2. VSS Connector, Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 3. VSS Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 4. VSS Harness Connector Above Transmission., Vol 1 . . . . . . . . . . . . WP 0058
Figure 5. ECM Connector 6007., Vol 1. . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 6. VSS Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 7. VSS Harness Connector Above Transmission., Vol 1 . . . . . . . . . . . . WP 0058
Figure 8. VSS Terminals, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 9. ECM Connector 6007., Vol 1. . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 11. VSS Harness Connector Above Transmission., Vol 1 . . . . . . . . . . . WP 0058
Figure 12. ECM Connector 6007., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 13. VSS Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Figure 18. ECM Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
POWER DISTRIBUTION TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . WP 0059
12V AND 24V BATTERY SWITCHES TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . WP 0060
Figure 1. Front Battery Equalizer., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0060
Figure 3. Left Engine, Above Power Distribution Center (PDC)., Vol 1 . . . . . . . . . WP 0060
Figure 4. Below Center Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . . WP 0060
Figure 5. 24V Body Feed, Right Side Dash Pass-Through., Vol 1 . . . . . . . . . . . WP 0060
Figure 7. Connector LAM1152 and LAM1187., Vol 1 . . . . . . . . . . . . . . . . . WP 0060
Figure 8. Below IP, Right of Steering Column., Vol 1 . . . . . . . . . . . . . . . . . WP 0060
Figure 11. Connector LAM1189 and 1153., Vol 1 . . . . . . . . . . . . . . . . . . WP 0060
Figure 12. Connector LAM1151., Vol 1. . . . . . . . . . . . . . . . . . . . . . . WP 0060
Figure 13. Left Engine, Above Power Distribution Center (PDC)., Vol 1 . . . . . . . . WP 0060
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CABIN FUSE BLOCK 1011 TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . WP 0061
Figure 1. Cabin Fuse Block 1011, Right Side of Instrument Panel (IP)., Vol 1 . . . . . . WP 0061
Figure 2. Cabin Fuse Block 1012, Right Side of IP., Vol 1 . . . . . . . . . . . . . . WP 0061
Figure 3. ACC RELAY Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0061
Figure 4. Fuse F5 Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061
Figure 5. Behind Lower Instrument Cluster., Vol 1 . . . . . . . . . . . . . . . . . . WP 0061
Figure 6. ACC RELAY Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0061
Figure 7. Cabin Fuse Block 1011, Right Side of IP., Vol 1. . . . . . . . . . . . . . . WP 0061
Figure 11. Keyless Ignition Switch., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0061
Figure 14. Left Side Engine Compartment Above PDC., Vol 1 . . . . . . . . . . . . WP 0061
Figure 18. 12V 100-Amp Megafuse., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0061
Figure 3. IGN RELAY Socket., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . WP 0062
Figure 4. Below IP Cluster, Right Side., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0062
Figure 6. IGN RELAY Socket., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . WP 0062
Figure 10. Cabin Fuse Block 1012 Right Side of IP., Vol 1 . . . . . . . . . . . . . . WP 0062
Figure 12. Cabin Fuse Block 1012 Right Side of IP., Vol 1 . . . . . . . . . . . . . . WP 0062
Figure 13. Underhood Power Distribution Center (PDC), Left Side Engine Compart-
ment., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062
Figure 16. Left Side of Engine Compartment Above Underhood PDC., Vol 1 . . . . . . WP 0062
Figure 3. Ignition Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0063
Figure 4. Behind Key Switch., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0063
Figure 6. Ignition Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0063
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Figure 16. Above Underhood Power Distribution Center (PDC)., Vol 1 . . . . . . . . . WP 0063
Figure 1. Below Center of Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . WP 0064
Figure 2. 24V Power Distribution Module (PDM), Below Center of IP., Vol 1. . . . . . . WP 0064
Figure 3. Right Side of 24V PDM., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0064
Figure 4. 24V Power Distribution Module (PDM), Below Center of IP., Vol 1. . . . . . . WP 0064
Figure 5. 24V PDM Connector J5., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0064
Figure 6. Right Side of 24V PDM., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0064
POWER DISTRIBUTION CENTER (PDC) MINI FUSE BLOCK 4001 TROUBLESHOOTING
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065
Figure 1. Power Distribution Center (PDC) Under Hood., Vol 1 . . . . . . . . . . . . WP 0065
Figure 2. Fuse Block 4001., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065
Figure 4. Power Distribution Center (PDC) Under Hood., Vol 1 . . . . . . . . . . . . WP 0065
Figure 5. IGN Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0065
Figure 6. 12V 100-amp Mega Fuse., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0065
Figure 7. Behind Lower Instrument Cluster., Vol 1 . . . . . . . . . . . . . . . . . . WP 0065
Figure 9. Left Side of Firewall., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0065
Figure 11. Right Side of Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . . . . WP 0065
Figure 13. Power Distribution Center (PDC) Under Hood., Vol 1 . . . . . . . . . . . WP 0065
Figure 23. Above Underhood Power Distribution Center (PDC)., Vol 1 . . . . . . . . . WP 0065
Figure 24. Left Lower Side of Engine., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0065
KEYLESS IGNITION SWITCH TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . WP 0066
Figure 1. Ignition Switch., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0066
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MULTIPLEXING DATA LINK CIRCUITS TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . WP 0067
Figure 1. ATA Connector Under Instrument Panel (IP)., Vol 1 . . . . . . . . . . . . . WP 0067
Hood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 5. Transmission Control Module (TCM) Connector Under Vehicle on Bracket., Vol 1 WP 0067
Figure 9. Chassis Terminating Resistor., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0067
Figure 11. Electronic System Controller (ESC) Connector Under IP., Vol 1 . . . . . . . WP 0067
Figure 13. IPC Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 15. Transmission Auto Shift Control Module Connector., Vol 1 . . . . . . . . . WP 0067
Figure 17. Antilock Brake System (ABS) Control Module Connector Under Right Side
IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 19. Cabin Terminating Resistor Under Right Side IP., Vol 1 . . . . . . . . . . . WP 0067
Figure 22. IP Pass-Through Connector Near Power Distribution Center Under Hood., Vol 1WP 0067
Figure 24. Chassis Terminating Resistor Above Transmission., Vol 1 . . . . . . . . . WP 0067
Figure 26. ABS Module Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 27. Shift Selector Module Connector., Vol 1 . . . . . . . . . . . . . . . . . WP 0067
Figure 29. Electronic System Controller (ESC) Connector., Vol 1 . . . . . . . . . . . WP 0067
Figure 30. Transmission Control Module (TCM) Connector., Vol 1 . . . . . . . . . . . WP 0067
Figure 31. Engine Control Module (ECM) Connector., Vol 1 . . . . . . . . . . . . . WP 0067
Figure 32. Dash/IP Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 33. Dash/Engine Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 34. ABS Module Connectors., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0067
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Figure 63. TCM Connector 7150F., Vol 1. . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 65. ESC Connector 1600., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 66. Cluster Connector 1500., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0067
Figure 67. Shift Selector Module Connector 1852., Vol 1 . . . . . . . . . . . . . . . WP 0067
Figure 68. ABS Module Connector X1., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0067
ELECTRONIC SYSTEM CONTROLLER (ESC) TROUBLESHOOTING PROCEDURE, Vol 1 . . WP 0068
Figure 1. ESC Power Cable Terminal Underhood., Vol 1 . . . . . . . . . . . . . . . WP 0068
Figure 2. Under Steering Column., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0068
Figure 3. Connector 1600 to Breakout Box Male Connector., Vol 1 . . . . . . . . . . WP 0068
Figure 4. Fuse F20 in Fuse Block 1012., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0068
Figure 6. ESC Connector Under Left Side Instrument Panel., Vol 1 . . . . . . . . . . WP 0068
Figure 8. Behind IPC., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0068
Figure 10. Behind Switch Pack., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0068
Figure 13. Fuse F5 in Fuse Block 1011., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0068
Figure 16. Breakout Box Connected to ESC and Connector 1600., Vol 1 . . . . . . . . WP 0068
Figure 18. Under Instrument Panel., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0068
Figure 21. Devices Using Zero-Volt Reference Signal., Vol 1 . . . . . . . . . . . . . WP 0068
Figure 23. Cab/DCM Connector Under Instrument Panel., Vol 1 . . . . . . . . . . . WP 0068
Figure 25. Clockspring Connector 1809., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0068
Figure 27. ESC Connector Under Left Side Instrument Panel., Vol 1. . . . . . . . . . WP 0068
Figure 28. Breakout Box Connected to ESC and Connector 4004., Vol 1 . . . . . . . . WP 0068
Figure 30. Splice Block Connector Near Power Distribution Center Underhood., Vol 1 . . WP 0068
Figure 32. Fuel Level Sender Connector Behind Fuel Tank Armor., Vol 1 . . . . . . . . WP 0068
Figure 33. Splice Block Connector 4830., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0068
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Figure 34. Dash/Center Chassis Interconnect Below Power Distribution Center
Underhood., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0068
Figure 36. Splice Block Connector 4830., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0068
Figure 37. Ground Stud Under Left Side Instrument Panel., Vol 1 . . . . . . . . . . . WP 0068
Table 1. Electronic System Controller DTCs., Vol 1 . . . . . . . . . . . . . . . . . WP 0068
SWITCH PACK MODULES TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . . . . . WP 0069
Figure 1. Behind Switch Pack., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0069
Figure 3. Below Steering Column., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0069
Figure 4. Ground Eyelet 1851., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0069
Figure 6. Cabin Fuse Panel., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0069
INSTRUMENT PANEL CLUSTER (IPC) OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . WP 0070
INSTRUMENT PANEL CLUSTER (IPC) POWER AND DATA LINK CIRCUITS TROUBLESHOOTING
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071
Figure 1. Behind IPC., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071
Figure 3. Passenger Side Fuse Box., Vol 1. . . . . . . . . . . . . . . . . . . . . WP 0071
Figure 5. Passenger Side Fuse Box., Vol 1. . . . . . . . . . . . . . . . . . . . . WP 0071
Figure 7. Fuse F19 Socket., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0071
Figure 8. Driver Side IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071
MALFUNCTIONING INSTRUMENT PANEL CLUSTER (IPC) TROUBLESHOOTING
PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0072
YELLOW ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . WP 0073
RED ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . . . WP 0074
Figure 1. Right Side of Radiator., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0074
CHECK TRANSMISSION LAMP TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . WP 0075
COOLANT LEVEL WARNING LAMP TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . WP 0076
PARK BRAKE WARNING LAMP TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . WP 0077
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DIAGNOSTIC CONNECTOR TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . WP 0078
Figure 1. Left of Steering Column., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0078
Figure 2. Firewall, Above Electronic System Controller (ESC)., Vol 1 . . . . . . . . . WP 0078
Figure 4. Right Side Instrument Panel., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0078
ANTILOCK BRAKE SYSTEM (ABS) WARNING LAMP TROUBLESHOOTING PROCE-
DURE, Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0079
12V VOLTMETER OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . WP 0080
ENGINE COOLANT TEMPERATURE GAUGE OPERATIONAL CHECKOUT PROCEDURE, Vol 1WP 0081
ENGINE OIL PRESSURE GAUGE OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . WP 0082
SPEEDOMETER OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . WP 0083
TACHOMETER OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . . WP 0084
FUEL LEVEL GAUGE TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . WP 0085
Figure 1. Left Fuel Tank., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0085
Figure 4. Left Front Cabin Area., Vol 1. . . . . . . . . . . . . . . . . . . . . . . WP 0085
AIR 1/PRIMARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE, Vol 1 . . . . WP 0086
Figure 1. Driver Side Floor Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0086
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AIR 2/SECONDARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE, Vol 1 . . WP 0087
AUDIBLE ALARM OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . . . . WP 0088
ETHER START CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . WP 0089
Figure 1. Left Rear Cylinder Head., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0089
Figure 2. Left Side of Engine Compartment., Vol 1 . . . . . . . . . . . . . . . . . WP 0089
Figure 3. Under Power Distribution Center (PDC)., Vol 1 . . . . . . . . . . . . . . . WP 0089
Figure 4. Right Side of Dash., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0089
Figure 5. Behind Instrument Panel (IP) Closeout Panel., Vol 1 . . . . . . . . . . . . WP 0089
Figure 6. Engine Compartment Under Air Cleaner., Vol 1 . . . . . . . . . . . . . . WP 0089
Figure 7. Engine Compartment Under Air Cleaner., Vol 1 . . . . . . . . . . . . . . WP 0089
Figure 10. Above Power Distribution Center (PDC) on Bulkhead., Vol 1 . . . . . . . . WP 0089
Figure 11. Left Rear Cylinder Head., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0089
EXHAUST BRAKE TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . WP 0090
Figure 2. Engine Control Module Area., Vol 1. . . . . . . . . . . . . . . . . . . . WP 0090
Figure 3. Exhaust Brake Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0090
Figure 5. Engine Control Module Area., Vol 1. . . . . . . . . . . . . . . . . . . . WP 0090
Figure 9. EXHAUST BRAKE Relay., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0090
Figure 11. Engine Control Module Area., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0090
Figure 13. Power Distribution Center., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0090
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CHARGING SYSTEM TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . WP 0091
Figure 1. Alternator, Right Side Engine., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0091
Figure 7. Relay Breakout Harness (ZTSE4674)., Vol 1. . . . . . . . . . . . . . . . WP 0091
Figure 10. Fuse Block 4001., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0091
Figure 12. Relay Breakout Harness (ZTSE4674)., Vol 1 . . . . . . . . . . . . . . . WP 0091
Figure 13. 500 Ohm Resistor Harness (ZTSE4497)., Vol 1 . . . . . . . . . . . . . . WP 0091
Figure 18. Relay Breakout Harness (ZTSE4674)., Vol 1 . . . . . . . . . . . . . . . WP 0091
MASTER VEHICLE LIGHT SWITCH (MVLS) TROUBLESHOOTING PROCEDURE, Vol 1 . . . WP 0092
Figure 1. Behind IP Center Trim Panel., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0092
Figure 2. MVLS Switch., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0092
Figure 4. Bottom of IP Center Trim Opening., Vol 1 . . . . . . . . . . . . . . . . . WP 0092
Figure 15. MVLS Switch Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0092
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FRONT TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE, Vol 1. . . . . . . . . WP 0093
Figure 1. Left Front Fender Turn Signal Bulb Socket., Vol 1 . . . . . . . . . . . . . WP 0093
Figure 2. Front Fender Turn Light Connector., Vol 1 . . . . . . . . . . . . . . . . . WP 0093
Figure 3. Left Front Turn Signal Bulb Socket (Near Headlight)., Vol 1 . . . . . . . . . WP 0093
Figure 4. Left Headlight/Turn Signal Harness Connector Near Front Spring Shackle., Vol 1 WP 0093
Figure 5. Front Bumper Light Unit Terminal Identification for Bullet Connectors Behind Front
Bumper., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093
Figure 6. Left Front Bumper/Front Chassis Connector Near Front Spring Shackle., Vol 1 . WP 0093
Figure 7. Forward Chassis/PDC Connector in Engine Compartment., Vol 1. . . . . . . WP 0093
Figure 8. Electronic System Controller (ESC) Connector., Vol 1 . . . . . . . . . . . . WP 0093
Figure 11. Right Front Fender Turn Signal Bulb Socket., Vol 1 . . . . . . . . . . . . WP 0093
Figure 12. Right Front Fender Turn Light Connector., Vol 1 . . . . . . . . . . . . . . WP 0093
Figure 13. Right Front Turn Signal Bulb Socket (Near Headlight)., Vol 1 . . . . . . . . WP 0093
Figure 14. Right Headlight/Turn Signal Harness Connector Near Front Spring
Shackle., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093
Figure 15. Front Bumper Light Unit Terminal Identification for Bullet Connectors Behind Front
Bumper., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093
Figure 16. Right Front Bumper/Front Chassis Connector Near Front Spring Shackle., Vol 1WP 0093
Figure 17. Forward Chassis/PDC Connector in Engine Compartment., Vol 1 . . . . . . WP 0093
Figure 19. Forward Chassis/PDC Connector in Engine Compartment., Vol 1 . . . . . . WP 0093
REAR TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . WP 0094
Figure 1. Circuit Identification on Rear Composite Taillamp Assembly for Turn Signal Bullet
Connectors., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094
Figure 2. Taillamp/Rear Chassis Harness Connection Inside Left Frame Rail, Near Rear
Crossmember., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094
Figure 3. Left or Right Stop/Turn Relay in Engine Compartment PDC., Vol 1 . . . . . . WP 0094
Figure 4. Stop/Turn Light Connector Near Electronic System Controller (ESC)., Vol 1 . . WP 0094
Figure 5. Left or Right Stop/Turn Relay Socket., Vol 1 . . . . . . . . . . . . . . . . WP 0094
Figure 6. Left or Right Turn Trailer Relay in Engine Compartment PDC., Vol 1 . . . . . WP 0094
Figure 7. Stoplight Relay Left or Right Socket in Right IP., Vol 1 . . . . . . . . . . . . WP 0094
Figure 8. Stop/Turn Light Connector Near ESC., Vol 1 . . . . . . . . . . . . . . . . WP 0094
Figure 9. Stop/Turn Light Connector, Near ESC., Vol 1 . . . . . . . . . . . . . . . WP 0094
Figure 10. Stoplight Relay Left or Right Socket., Vol 1 . . . . . . . . . . . . . . . . WP 0094
Figure 11. Stop/Turn Light Connector 1703M., Vol 1 . . . . . . . . . . . . . . . . . WP 0094
Figure 12. ESC Connector Under Left IP., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0094
Figure 13. Left or Right Stop/Turn Relay in Engine Compartment PDC., Vol 1. . . . . . WP 0094
Figure 14. Taillamp/Rear Chassis Harness Connector Inside Left Frame Rail, Near Rear
Figure 15. Dash/Center Chassis Harness Connector in Engine Compartment., Vol 1 . . WP 0094
Figure 16. Left or Right Stop/Turn Relay Socket., Vol 1 . . . . . . . . . . . . . . . WP 0094
Figure 17. Center/Rear Chassis Harness Connector Inside Left Frame Rail., Vol 1 . . . WP 0094
Figure 22. Circuit Identification on Composite Taillamp Assembly, and Turn Signal Bullet
Figure 23. Stoplight Relay Right in Cabin Fuse and Relay Center., Vol 1 . . . . . . . . WP 0094
Figure 24. Blackout Mode Splice Pack Connector in Center IP., Vol 1 . . . . . . . . . WP 0094
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Figure 25. Stoplight Relay Right Socket., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0094
Figure 26. IP/PDC Pass-Through Connector in Engine Compartment., Vol 1 . . . . . . WP 0094
Figure 28. Taillamp/Rear Chassis Harness Inside Left Frame Rail, Near Rear
Figure 29. Center/Rear Chassis Connector Inside Left Frame Rail., Vol 1 . . . . . . . WP 0094
Figure 30. Dash/Center Chassis Connector in Engine Compartment., Vol 1 . . . . . . WP 0094
TURN SIGNAL AND HAZARD SWITCH TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . WP 0095
Figure 1. Left Side Steering Column., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 2. IP/Steering Column Harness Connector Under Center IP., Vol 1 . . . . . . . WP 0095
Figure 3. Under Center IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 4. Under Left Side Instrument Panel., Vol 1 . . . . . . . . . . . . . . . . . WP 0095
Figure 8. Left Turn Enable Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0095
Figure 9. IP/Steering Column Harness Under Center IP., Vol 1 . . . . . . . . . . . . WP 0095
Figure 12. Under Center IP., Vol 1. . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 17. Right Turn Enable Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . WP 0095
Figure 26. Right Side IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 27. Right Side IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 28. Lower IPC., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Figure 29. IP/Dash Pass-Through Connector in Engine Compartment., Vol 1 . . . . . . WP 0095
TURN SIGNAL LIGHTS OPERATIONAL CHECKOUT PROCEDURE, Vol 1 . . . . . . . . . WP 0096
SERVICE DRIVING LIGHTS TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . WP 0097
Figure 1. Headlight Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0097
Figure 2. Blackout Harness Connector Behind IPC., Vol 1 . . . . . . . . . . . . . . WP 0097
Figure 3. MVLS Connector in IP Center., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0097
Figure 6. Dash/Forward Chassis Harness Connector Left Side Engine Compartment., Vol 1WP 0097
Figure 7. Left Headlight Connector., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0097
Figure 8. Left Headlight Harness Connector Near Front Spring Shackle., Vol 1 . . . . . WP 0097
Figure 9. Left Forward Chassis Harness Connector Near Front Spring Shackle., Vol 1 . . WP 0097
Figure 10. Dash/Forward Chassis Connector Left Side Engine Compartment., Vol 1 . . . WP 0097
Figure 11. Electronic System Controller (ESC) Connector Under Left Side IP., Vol 1 . . . WP 0097
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Figure 14. Left Headlight Connector., Vol 1. . . . . . . . . . . . . . . . . . . . . WP 0097
Figure 15. Left Headlight Harness Connector Near Front Spring Shackle., Vol 1 . . . . WP 0097
Figure 16. Left Forward Chassis Harness Connector Near Front Spring Shackle., Vol 1 . WP 0097
Figure 17. Dash/Forward Chassis Connector Left Side Engine Compartment., Vol 1 . . . WP 0097
Figure 21. Turn Signal Switch Connector at Left Side of Steering Column., Vol 1 . . . . WP 0097
Figure 22. Steering Column Harness Connector Under Center IP., Vol 1 . . . . . . . . WP 0097
Figure 23. ESC Connector Under Left Side IP., Vol 1 . . . . . . . . . . . . . . . . WP 0097
CLEARANCE AND MARKER LIGHTS TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . WP 0098
Figure 1. Left Front Fender Turn Signal Bulb Socket., Vol 1 . . . . . . . . . . . . . WP 0098
Figure 2. Right Front Fender Turn Signal Bulb Socket., Vol 1 . . . . . . . . . . . . . WP 0098
Figure 3. Front Fender Marker/Turn Signal Light Connector., Vol 1 . . . . . . . . . . WP 0098
Figure 4. Front Turn Signal Bulb Socket (Near Headlight)., Vol 1 . . . . . . . . . . . WP 0098
Figure 5. Left Headlight/Turn Signal Harness Connector Near Front Spring Shackle., Vol 1 WP 0098
Figure 6. Front Bumper Light Assembly, Right Side., Vol 1 . . . . . . . . . . . . . . WP 0098
Figure 7. Front Bumper Light Assembly Left Side., Vol 1 . . . . . . . . . . . . . . . WP 0098
Figure 8. Left Front Bumper/Front Chassis Connector Near Front Spring Shackle., Vol 1 . WP 0098
Figure 9. Right Front Bumper/Front Chassis Connector Near Front Spring Shackle., Vol 1 WP 0098
Figure 10. Front Chassis/Dash Connector in Engine Compartment., Vol 1 . . . . . . . WP 0098
Figure 11. Circuit Identification on Composite Taillamp Assembly for Turn Signal Bullet
Figure 12. Taillamp/Rear Chassis Harness Inside Left Frame Rail Near Rear
Figure 13. Center/Rear Chassis Connector Inside Left Frame Rail., Vol 1 . . . . . . . WP 0098
Figure 14. Dash/Center Chassis Connector in Engine Compartment., Vol 1 . . . . . . WP 0098
Figure 17. Behind IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098
Figure 18. MVLS., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098
Figure 19. Front Clearance Light Harness., Vol 1 . . . . . . . . . . . . . . . . . . WP 0098
Figure 20. Rear Clearance Light Harness., Vol 1 . . . . . . . . . . . . . . . . . . WP 0098
Figure 21. Above Right Side Windshield., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0098
Figure 22. Behind Right Side IP Closeout., Vol 1 . . . . . . . . . . . . . . . . . . WP 0098
Figure 23. Left Side Engine Compartment on Bulkhead., Vol 1 . . . . . . . . . . . . WP 0098
Figure 25. Left Side Engine Compartment on Bulkhead., Vol 1 . . . . . . . . . . . . WP 0098
Figure 26. Above Right Side Windshield., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0098
Figure 27. Above Rear Ramp., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0098
Figure 28. Left Side Rear Stowage Box., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0098
Figure 29. Right Side Rear Stowage Box., Vol 1 . . . . . . . . . . . . . . . . . . WP 0098
Figure 31. Truck Marker/Tail Relay Socket., Vol 1 . . . . . . . . . . . . . . . . . . WP 0098
Figure 32. Left Side Engine Compartment Bulkhead., Vol 1 . . . . . . . . . . . . . WP 0098
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BLACKOUT DRIVING LIGHT TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . WP 0099
Figure 1. Left Front Bumper Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0099
Figure 2. Left Front Bumper Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . WP 0099
Figure 3. Left Engine Compartment Area., Vol 1 . . . . . . . . . . . . . . . . . . WP 0099
Figure 6. Behind Dash Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0099
BLACKOUT MARKER LIGHTS TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . WP 0100
Figure 2. Blackout Relay Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 3. Behind Dash Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 7. Left Center Frame., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 8. Left Rear Frame., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 10. Right Front Bumper Area., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 12. Right Rear of Vehicle Behind Taillight Assembly., Vol 1 . . . . . . . . . . . WP 0100
Figure 13. Left Rear of Vehicle Behind Taillight Assembly., Vol 1 . . . . . . . . . . . WP 0100
Figure 14. Rear Frame Rail., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 16. Connector 9303A., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 17. Left Center Frame Rail., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 23. Left Front Bumper Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 26. Left Engine Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 27. Blackout Relay Terminals., Vol 1 . . . . . . . . . . . . . . . . . . . . WP 0100
Figure 29. Behind Dash Area., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . WP 0100
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STOPLIGHT TROUBLESHOOTING PROCEDURE, Vol 1 . . . . . . . . . . . . . . . . . WP 0101
Figure 1. Stoplight Bullet Connectors Inside Composite Taillamp Assembly, and Terminal Identification
on Taillamp., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101
Figure 2. MVLS Connector in Center IP., Vol 1 . . . . . . . . . . . . . . . . . . . WP 0101
Figure 3. Blackout Mode Splice Pack Connector in Center IP., Vol 1 . . . . . . . . . . WP 0101
Figure 6. Taillamp/Rear Chassis Harness Connector Inside Left Frame Rail Near Rear
Figure 7. Center/Rear Chassis Connector on Left Frame Rail., Vol 1 . . . . . . . . . WP 0101
Figure 8. Dash/Center Chassis Connector in Engine Compartment., Vol 1 . . . . . . . WP 0101
Figure 9. Blackout Mode Splice Pack Connector in Center IP., Vol 1 . . . . . . . . . . WP 0101
Figure 11. Right Stop/Turn Relay in Engine Compartment Power Distribution Center
(PDC)., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101
Figure 12. Left Stop/Turn Relay in Engine Compartment PDC., Vol 1 . . . . . . . . . WP 0101
Figure 14. IPC Connector in Left IP., Vol 1 . . . . . . . . . . . . . . . . . . . . . WP 0101
Figure 16. Left Turn Enable Relay in Center IP., Vol 1 . . . . . . . . . . . . . . . . WP 0101
Figure 17. Right Turn Enable Relay in Center IP., Vol 1 . . . . . . . . . . . . . . . WP 0101
Figure 19. Left Stoplight Relay in Cabin Fuse and Relay Center., Vol 1 . . . . . . . . WP 0101
Figure 20. Right Stoplight Relay in Cabin Fuse and Relay Center., Vol 1 . . . . . . . . WP 0101
Figure 22. Flash-to-Pass Relay in Center IP., Vol 1 . . . . . . . . . . . . . . . . . WP 0101
Figure 23. Left or Right Stoplight Relay in Cabin Fuse and Relay Center., Vol 1 . . . . . WP 0101
Figure 27. Stoplight Connectors in Composite Taillamp Assembly., Vol 1 . . . . . . . . WP 0101
Figure 28. Taillamp/Rear Chassis Harness Connector, Inside Left Frame Rail Near Rear
Figure 30. Left or Right Stoplight Relay in Cabin Relay and Fuse Center., Vol 1 . . . . . WP 0101
Figure 35. Stop/Turn Light Connector Near ESC., Vol 1 . . . . . . . . . . . . . . . WP 0101
Figure 45. Electronic System Controller (ESC) Connector Under Left Side Instrument
Panel., Vol 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101
Figure 46. Stoplight Relay Left and Right in Cabin Relay and Fuse Center., Vol 1 . . . . WP 0101
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Figure 47. Right or Left Turn Trailer Relay in Engine Compartment PDC., Vol 1 . . . . . WP 0101
Figure 48. Left and Right Stop/Turn Relay in Engine Compartment PDC., Vol 1 . . . . . WP 0101
Figure 49. Dash/Center Harness Connector in Engine Compartment., Vol 1 . . . . . . WP 0101
Figure 50. Center/Rear Harness Connector Inside Left Frame Rail., Vol 1 . . . . . . . WP 0101
Figure 53. Stop/Turn Light Connector Near ESC., Vol 1 . . . . . . . . . . . . . . . WP 0101
VOLUME 2

BLACKOUT STOPLIGHTS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . WP 0102
Figure 1. Behind Right Taillamp Assembly., Vol 2 . . . . . . . . . . . . . . . . . . WP 0102
Figure 2. Behind Left Taillamp Assembly., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0102
Figure 4. B/O STOP TRUCK Relay Socket., Vol 2. . . . . . . . . . . . . . . . . . WP 0102
Figure 5. Above Left Rear Spring., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 6. Inboard Rear of Left Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . WP 0102
Figure 7. Inboard Left Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 8. Below Air Cleaner., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 9. Behind Master Vehicle Light Switch (MVLS) Switch., Vol 2 . . . . . . . . . . WP 0102
Figure 10. B/O STOP TRUCK Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . WP 0102
Figure 12. Left Firewall., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 13. Inboard Left Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 17. Left Firewall., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102
Figure 18. B/O STOP TRUCK Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . WP 0102
Figure 19. Inboard Rear of Left Frame Rail., Vol 2. . . . . . . . . . . . . . . . . . WP 0102
BACKUP LIGHTS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . WP 0103
Figure 4. Backup Lamps Relay Terminals., Vol 2 . . . . . . . . . . . . . . . . . . WP 0103
Figure 5. Backup Lamps Relay Terminals., Vol 2 . . . . . . . . . . . . . . . . . . WP 0103
Figure 7. BACKUP LAMPS Relay Terminals., Vol 2 . . . . . . . . . . . . . . . . . WP 0103
Figure 8. Center Underbody Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 9. Connector 4705F2., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 12. Left Rear Frame Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 13. Center Rear Frame Area., Vol 2. . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 14. Left Rear Vehicle Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 15. Backup Light Intrpt Relay Terminals., Vol 2 . . . . . . . . . . . . . . . . WP 0103
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Figure 17. Backup Light Intrpt Relay Terminals., Vol 2 . . . . . . . . . . . . . . . . WP 0103
Figure 18. Rear Vehicle Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 19. Left Rear Frame Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 20. Center Rear Frame Area., Vol 2. . . . . . . . . . . . . . . . . . . . . WP 0103
Figure 21. Left Engine Compartment Area., Vol 2. . . . . . . . . . . . . . . . . . WP 0103
Figure 22. Left Rear Backup Light., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0103
INSTRUMENT PANEL (IP) LIGHTS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . WP 0104
Figure 1. MVLS Connector in IP Center., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0104
Figure 2. Panel Light Feed Bus Bar in IP Center., Vol 2 . . . . . . . . . . . . . . . WP 0104
Figure 4. Power Mirror Switch Connector in IP Center., Vol 2 . . . . . . . . . . . . . WP 0104
Figure 5. 24-Volt Meter Connector in IP Center., Vol 2 . . . . . . . . . . . . . . . . WP 0104
Figure 6. Ether Start Switch Connector in Left Side IP., Vol 2 . . . . . . . . . . . . . WP 0104
Figure 7. Shift Selector Module Connector in IP Center., Vol 2 . . . . . . . . . . . . WP 0104
Figure 8. Fuel Fired Heater Control in IP Center., Vol 2 . . . . . . . . . . . . . . . WP 0104
Figure 9. Switch Pack Connector in IP Center., Vol 2 . . . . . . . . . . . . . . . . WP 0104
Figure 10. Cluster Connector in Left Side IP., Vol 2 . . . . . . . . . . . . . . . . . WP 0104
Figure 11. Power Mirror Switch Connector in IP Center., Vol 2 . . . . . . . . . . . . WP 0104
Figure 12. 24-Volt Meter Connector in IP Center., Vol 2 . . . . . . . . . . . . . . . WP 0104
Figure 13. Ether Start Switch Connector in Left Side IP., Vol 2 . . . . . . . . . . . . WP 0104
Figure 15. Shift Selector Module Connector in IP Center., Vol 2 . . . . . . . . . . . . WP 0104
Figure 16. Fuel Fired Heater Control in IP Center., Vol 2 . . . . . . . . . . . . . . . WP 0104
Figure 17. Switch Pack Connector in IP Center., Vol 2 . . . . . . . . . . . . . . . . WP 0104
Figure 19. Cluster Connector in Left Side IP., Vol 2 . . . . . . . . . . . . . . . . . WP 0104
FLASH-TO-PASS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . WP 0105
Figure 1. Flash-to-Pass Relay in Center Instrument Panel (IP)., Vol 2 . . . . . . . . . WP 0105
Figure 2. Flash-to-Pass Relay in Center IP., Vol 2 . . . . . . . . . . . . . . . . . . WP 0105
Figure 3. Electronic System Controller (ESC) Connectors Under Left IP., Vol 2 . . . . . WP 0105
Figure 4. Steering Column/IP Harness Connector Under Center IP., Vol 2 . . . . . . . WP 0105
Figure 5. Turn Signal Switch Connector on Steering Column., Vol 2 . . . . . . . . . . WP 0105
Figure 8. ESC Connectors Under Left Side IP., Vol 2 . . . . . . . . . . . . . . . . WP 0105
CRUISE CONTROL OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . WP 0106
ELECTRIC HORNS OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . WP 0107
SINGLE ELECTRIC HORN FAULT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . WP 0108
Figure 1. Vehicle Front Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0108
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ELECTRIC HORNS SWITCH TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . WP 0109
Figure 1. Driver Controls Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0109
Figure 4. Lower Clock Spring Connector Interface., Vol 2 . . . . . . . . . . . . . . WP 0109
Figure 6. Steering Wheel Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0109
Figure 8. Lower Clock Spring Connector Interface., Vol 2 . . . . . . . . . . . . . . WP 0109
Figure 12. Driver Controls Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . . WP 0109
MASTER VEHICLE LIGHT SWITCH (MVLS) HORN ENABLE CIRCUIT TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0110
Figure 3. ELECTRIC HORN Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . . WP 0110
Figure 4. Center Instrument Panel Area., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0110
Figure 6. Instrument Panel (IP) Pass-Through Connector 1701., Vol 2 . . . . . . . . . WP 0110
ELECTRIC HORNS CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . WP 0111
Figure 5. Vehicle Front Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0111
ELECTRIC HORNS SOUND WITHOUT PRESSING HORN PAD TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0112
WINDSHIELD WIPER AND WASHER OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . WP 0113
WINDSHIELD WASHER CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . WP 0114
Figure 1. Right Side Engine Compartment Area., Vol 2 . . . . . . . . . . . . . . . WP 0114
Figure 4. Left Side Instrument Panel (IP) Area., Vol 2 . . . . . . . . . . . . . . . . WP 0114
Figure 5. Steering Column Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0114
Figure 8. Left Side Instrument Panel (IP) Area., Vol 2 . . . . . . . . . . . . . . . . WP 0114
Figure 10. Left Engine Compartment Area, Vol 2 . . . . . . . . . . . . . . . . . . WP 0114
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WINDSHIELD WIPER SWITCH INPUTS TO ELECTRONIC SYSTEM CONTROLLER (ESC)
WINDSHIELD WIPER PARK CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . WP 0116
Figure 1. Windshield Wiper Motor Cover., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0116
Figure 2. Bottom Exterior of Windshield Area., Vol 2. . . . . . . . . . . . . . . . . WP 0116
Figure 3. WIPER POWER and WIPER HIGH/LOW Relays Location., Vol 2. . . . . . . WP 0116
Figure 4. WIPER POWER Relay., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0116
Figure 5. Relay Breakout Harness Installation., Vol 2 . . . . . . . . . . . . . . . . WP 0116
Figure 7. Left Side Instrument Panel (IP) Near Floor Area., Vol 2 . . . . . . . . . . . WP 0116
Figure 8. Relay Breakout Harness Installation., Vol 2 . . . . . . . . . . . . . . . . WP 0116
WINDSHIELD WIPER MOTOR CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . WP 0117
Figure 3. Left Side Instrument Panel Near Floor Area., Vol 2 . . . . . . . . . . . . . WP 0117
Figure 9. Left Side IP Near Floor Area., Vol 2. . . . . . . . . . . . . . . . . . . . WP 0117
Figure 10. Left Side IP Near Floor Area., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0117
Figure 14. WIPER POWER Relay Breakout Harness Installation., Vol 2 . . . . . . . . WP 0117
Figure 15. WIPER POWER Relay Breakout Harness., Vol 2 . . . . . . . . . . . . . WP 0117
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Figure 17. WIPER HIGH/LOW Relay Breakout Harness Installation., Vol 2 . . . . . . . WP 0117
Figure 19. WIPER HIGH/LOW Relay Breakout Harness., Vol 2 . . . . . . . . . . . . WP 0117
NATO CONNECTOR TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . WP 0118
Figure 1. Battery Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118
Figure 2. Right Side of Forward Stowage Box., Vol 2 . . . . . . . . . . . . . . . . WP 0118
Figure 3. NATO Cables at Battery Box., Vol 2. . . . . . . . . . . . . . . . . . . . WP 0118
Figure 4. Behind NATO Connector., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0118
Figure 5. NATO Cables at Battery Box., Vol 2. . . . . . . . . . . . . . . . . . . . WP 0118
Figure 6. Right Side of Forward Stowage Box., Vol 2 . . . . . . . . . . . . . . . . WP 0118
Figure 7. NATO Connector., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118
Figure 8. NATO Connector., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118
110V INVERTER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . WP 0119
Figure 1. Right Front Stowage Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 2. Terminals LAM1076, LAM1075, LAM1074, and LAM1073., Vol 2 . . . . . . . WP 0119
Figure 3. Right Side of Right Front Stowage Box., Vol 2 . . . . . . . . . . . . . . . WP 0119
Figure 4. Terminal LAM1079., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 5. Terminals LAM1077 and LAM1078., Vol 2 . . . . . . . . . . . . . . . . . WP 0119
Figure 6. Right Side of Right Front Stowage Box., Vol 2 . . . . . . . . . . . . . . . WP 0119
Figure 7. Right Rear Stowage Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 8. 110V Harness Wires., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 9. 110V Outlet Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 10. 110V Outlet Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 11. 110V Harness Wires., Vol 2. . . . . . . . . . . . . . . . . . . . . . . WP 0119
Figure 12. 110V Harness Wires., Vol 2. . . . . . . . . . . . . . . . . . . . . . . WP 0119
BATTERY EQUALIZER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . WP 0120
Figure 1. Battery Equalizer., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0120
Figure 2. Battery Equalizer., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0120
Figure 3. Battery Equalizer Connections., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0120
Figure 4. Battery Equalizer Connections., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0120
HEATED WINDSHIELD TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . WP 0121
Figure 1. Heated Windshield Connectors Under Left and Right Windshields., Vol 2 . . . WP 0121
Figure 4. Circuit Breaker F38 at Right Side IP., Vol 2 . . . . . . . . . . . . . . . . WP 0121
Figure 5. Left Heated Windshield Relay Socket at Right Side IP., Vol 2. . . . . . . . . WP 0121
Figure 6. Left Heated Windshield Relay Socket., Vol 2 . . . . . . . . . . . . . . . . WP 0121
Figure 8. Left Heated Windshield Relay Socket at Right Side IP., Vol 2. . . . . . . . . WP 0121
Figure 9. Left Heated Windshield Relay Socket., Vol 2 . . . . . . . . . . . . . . . . WP 0121
Figure 12. ESC 1601 Connector Under Steering Column., Vol 2 . . . . . . . . . . . WP 0121
Figure 13. Left Heated Windshield Relay Socket at Right Side IP., Vol 2 . . . . . . . . WP 0121
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Figure 15. Cicuit Breaker F40 at Right Side IP., Vol 2 . . . . . . . . . . . . . . . . WP 0121
Figure 16. Right Heated Windshield Relay Socket at Right Side IP., Vol 2 . . . . . . . WP 0121
Figure 17. Right Heated Windshield Relay Socket., Vol 2 . . . . . . . . . . . . . . WP 0121
Figure 22. ESC 1601 Connector Under Steering Column., Vol 2 . . . . . . . . . . . WP 0121
SPOTLIGHT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . WP 0122
Figure 1. IP Spotlight Control Connector., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0122
Figure 2. Fuse F39., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 3. Spotlight IP Harness Connector., Vol 2 . . . . . . . . . . . . . . . . . . WP 0122
Figure 5. Spotlight Pass-Through Roof Connectors., Vol 2 . . . . . . . . . . . . . . WP 0122
Figure 6. Spotlight Bezel Removal., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 7. Spotlight Bulb Connector., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 8. Spotlight Bulb Connector., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 10. Spotlight Pass-Through Roof Connectors., Vol 2 . . . . . . . . . . . . . WP 0122
Figure 14. Connectors LAM1001 and LAM1002., Vol 2 . . . . . . . . . . . . . . . WP 0122
Figure 17. Spotlight Bulb Connector., Vol 2. . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 18. Spotlight Pass-Through Roof Connectors., Vol 2 . . . . . . . . . . . . . WP 0122
Figure 20. Top of Spotlight Mount., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 22. LAM1005., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122
Figure 24. Top of Spotlight Mount., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0122
Table 1. Connector LAM1001 and LAM1002 Terminal Pairs., Vol 2 . . . . . . . . . . WP 0122
Table 2. Connector LAM1004 and LAM1005 Terminal Pairs., Vol 2 . . . . . . . . . . WP 0122
POWER/HEATED MIRROR TROUBLESHOOTING PROCEDURE, Vol 2. . . . . . . . . . . WP 0123
Figure 1. Left Power Mirror., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 2. Right Power Mirror., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 6. Behind IP Center., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 7. Below Dash, Left of Steering Column., Vol 2 . . . . . . . . . . . . . . . . WP 0123
Figure 9. Left Power Mirror., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 10. Below Dash, Left of Steering Column., Vol 2 . . . . . . . . . . . . . . . WP 0123
Figure 12. Right Power Mirror., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 13. Below IP Fuse Block., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0123
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Figure 15. Behind IP Center., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Figure 25. Left Power Mirror., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
TRAILER CONNECTOR OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . WP 0124
Figure 1. Lower Rear Body Panel., Vol 2. . . . . . . . . . . . . . . . . . . . . . WP 0124
Figure 2. Left Side Front Bumper., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0124
TRAILER CONNECTOR LEFT, RIGHT, AND CLEARANCE BLACKOUT (B/O) CIRCUIT
Figure 5. Engine Compartment Power Distribution Center (PDC)., Vol 2 . . . . . . . . WP 0125
Figure 6. Left Rear Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0125
Figure 7. Left Side Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0125
Figure 8. Engine Compartment Under Air Cleaner Housing., Vol 2 . . . . . . . . . . WP 0125
Figure 12. Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125
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Figure 14. Left Rear Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0125
Figure 15. Engine Compartment Power Distribution Center (PDC)., Vol 2 . . . . . . . WP 0125
Figure 16. Left Side Front Bumper., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0125
Figure 19. Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125
TRAILER CONNECTOR LEFT SERVICE SIGNAL CIRCUIT TROUBLESHOOTING PROCE-
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0126
Figure 9. Engine Compartment Under Air Cleaner Assembly., Vol 2 . . . . . . . . . . WP 0126
Figure 14. Engine Compartment Under Air Cleaner Assembly., Vol 2 . . . . . . . . . WP 0126
Figure 15. Left Side Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0126
Figure 17. Lower Rear Body Panel., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0126
Figure 20. Left Turn Trailer Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . . WP 0126
TRAILER CONNECTOR RIGHT SERVICE SIGNAL CIRCUIT TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0127
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REAR TRAILER CONNECTOR GROUND CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 WP 0128
Figure 2. Left Side Center Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0128
TRAILER CONNECTOR SERVICE CLEARANCE CIRCUIT TROUBLESHOOTING PROCE-
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0129
Figure 4. TRLR MRKR Fuse Socket., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0129
Figure 7. TRLR MRKR Fuse Socket., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0129
Figure 19. TRUCK MRKR TAIL Relay Socket., Vol 2 . . . . . . . . . . . . . . . . WP 0129
Figure 20. TRUCK MRKR TAIL Relay Terminals., Vol 2 . . . . . . . . . . . . . . . WP 0129
Figure 21. TRAILER MARKER TAIL LIGHT Relay Socket Terminals., Vol 2. . . . . . . WP 0129
Figure 23. TRAILER MARKER TAIL LIGHT Relay Socket., Vol 2 . . . . . . . . . . . WP 0129
Figure 25. TRAILER MARKER TAIL LIGHT Relay Socket., Vol 2 . . . . . . . . . . . WP 0129
Figure 26. Lower Left Side Dash., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0129
Figure 27. MRKR STOP Fuse Socket., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0129
TRAILER CONNECTOR STOP BLACKOUT CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2WP 0130
Figure 6. Left Rear Frame Rail Behind Air Dryer., Vol 2 . . . . . . . . . . . . . . . WP 0130
Figure 8. Engine Compartment Below PDC., Vol 2 . . . . . . . . . . . . . . . . . WP 0130
Figure 12. Engine Compartment Under PDC., Vol 2 . . . . . . . . . . . . . . . . . WP 0130
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TRAILER CONNECTOR AUXILIARY POWER CIRCUIT TROUBLESHOOTING PROCE-
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0131
Figure 26. TRAILER ABS CENTER PIN Relay., Vol 2 . . . . . . . . . . . . . . . . WP 0131
TRAILER CONNECTOR BRAKE CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . WP 0132
Figure 9. Left Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0132
Figure 20. Behind MVLS Switch., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0132
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Figure 27. TRAILER STOP Relay Socket., Vol 2 . . . . . . . . . . . . . . . . . . WP 0132
Figure 29. Under Left Side of Dash., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0132
FRONT CREW LIGHT OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . WP 0133
FRONT CREW LIGHT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . WP 0134
Figure 1. Front Cabin Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 2. Right Side Instrument Panel Area., Vol 2 . . . . . . . . . . . . . . . . . WP 0134
Figure 3. Circuit Breaker F43 Reset Button., Vol 2 . . . . . . . . . . . . . . . . . WP 0134
Figure 4. Center of Instrument Panel Area., Vol 2 . . . . . . . . . . . . . . . . . . WP 0134
Figure 8. Right Side Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 9. Right Rear Wire Harness Channel Cover., Vol 2 . . . . . . . . . . . . . . WP 0134
Figure 10. Right Side Rear Door/Ramp Area., Vol 2 . . . . . . . . . . . . . . . . . WP 0134
Figure 12. Front Cabin Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 13. Right Side Rear Door/Ramp Area., Vol 2 . . . . . . . . . . . . . . . . . WP 0134
Figure 14. Right Side Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 16. Left Rear Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 18. Left Rear Ceiling Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0134
Figure 19. Circuit Breaker Socket F43., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0134
REAR CREW LIGHT OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . WP 0135
REAR CREW LIGHTS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . WP 0136
Figure 1. Left Rear Roof Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0136
Figure 3. Right Rear Roof Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . . WP 0136
Figure 4. Left Rear Roof Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0136
Figure 5. Right Rear Roof Area., Vol 2. . . . . . . . . . . . . . . . . . . . . . . WP 0136
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FUEL-FIRED HEATER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . WP 0137
Figure 1. Above Fuel Tank., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0137
Figure 2. Behind Right Forward Storage Compartment., Vol 2 . . . . . . . . . . . . WP 0137
Figure 3. Inboard of Right Rear Wheel., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0137
Figure 4. Above Fuel Tank., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0137
Figure 5. Inboard of Right Rear Wheel., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0137
Figure 6. Above Frame, Inboard of Left Front Wheel., Vol 2 . . . . . . . . . . . . . WP 0137
Figure 7. Underhood Power Distribution Center., Vol 2. . . . . . . . . . . . . . . . WP 0137
Figure 9. Behind Center Instrument Panel (IP)., Vol 2 . . . . . . . . . . . . . . . . WP 0137
Figure 11. Below Power Distribution Center (PDC)., Vol 2 . . . . . . . . . . . . . . WP 0137
Figure 13. Left Side Firewall., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0137
Figure 16. Behind Center Instrument Panel (IP)., Vol 2 . . . . . . . . . . . . . . . WP 0137
Figure 19. Behind Center Instrument Panel (IP)., Vol 2 . . . . . . . . . . . . . . . WP 0137
Figure 25. Behind Right Stowage Compartment., Vol 2 . . . . . . . . . . . . . . . WP 0137
Figure 26. Instrument Panel Right Side Closeout Panel., Vol 2 . . . . . . . . . . . . WP 0137
Figure 27. Instrument Panel Fuse Blocks., Vol 2 . . . . . . . . . . . . . . . . . . WP 0137
Figure 35. Instrument Panel Fuse Blocks., Vol 2 . . . . . . . . . . . . . . . . . . WP 0137
4-PACK AIR SOLENOID CIRCUITS FROM ELECTRONIC SYSTEM CONTROLLER (ESC)
Figure 1. Left Side Frame Rail Center of Vehicle., Vol 2 . . . . . . . . . . . . . . . WP 0138
Figure 2. Engine Compartment Near Left Front Wheel., Vol 2. . . . . . . . . . . . . WP 0138
Figure 8. Engine Compartment Near Left Front Wheel., Vol 2. . . . . . . . . . . . . WP 0138
Figure 12. Engine Compartment Near Left Front Wheel., Vol 2 . . . . . . . . . . . . WP 0138
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Figure 13. Under Steering Column., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0138
Figure 16. Left Side Frame Rail Center of Vehicle., Vol 2. . . . . . . . . . . . . . . WP 0138
Figure 17. Engine Compartment Near Left Front Wheel., Vol 2 . . . . . . . . . . . . WP 0138
Figure 18. Under Steering Column., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0138
Figure 22. Engine Compartment Inboard Left Wheel., Vol 2 . . . . . . . . . . . . . WP 0138
ANTILOCK BRAKE SYSTEM (ABS) J1939 SERIAL COMMUNICATIONS TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0139
Figure 1. Instrument Panel Right Side Closeout Panel., Vol 2 . . . . . . . . . . . . . WP 0139
Figure 2. Behind Right Side of Instrument Panel (IP)., Vol 2 . . . . . . . . . . . . . WP 0139
Figure 4. Left Side Lower Instrument Panel., Vol 2 . . . . . . . . . . . . . . . . . WP 0139
Figure 6. Underhood Power Distribution Center., Vol 2. . . . . . . . . . . . . . . . WP 0139
Figure 10. Underhood Power Distribution Center., Vol 2 . . . . . . . . . . . . . . . WP 0139
Figure 13. Underhood Power Distribution Center., Vol 2 . . . . . . . . . . . . . . . WP 0139
ANTILOCK BRAKE SYSTEM (ABS) PRESSURE MODULATOR VALVE (PMV) COMMON CIRCUIT
Figure 2. Behind Right Instrument Panel., Vol 2. . . . . . . . . . . . . . . . . . . WP 0140
Figure 5. Outboard Left Front Frame Rail, Inboard of Left Front Wheel., Vol 2. . . . . . WP 0140
Figure 8. Outboard Left Front Frame Rail, Inboard of Left Front Wheel., Vol 2. . . . . . WP 0140
Figure 11. Inboard Right Frame Rail, Near Right Rear Wheel., Vol 2 . . . . . . . . . . WP 0140
Figure 12. Inboard Left Frame Rail, Near Fuel Tank., Vol 2 . . . . . . . . . . . . . . WP 0140
Figure 15. Inboard Left Frame Rail, Near Left Rear Wheel., Vol 2 . . . . . . . . . . . WP 0140
Figure 19. Outboard Left Front Frame Rail, Inboard of Left Front Wheel., Vol 2 . . . . . WP 0140
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Figure 22. Outboard Frame Rail, Inboard of Right Front Wheel., Vol 2 . . . . . . . . . WP 0140
Figure 25. Inboard Right Frame Rail, Near Right Rear Wheel., Vol 2. . . . . . . . . . WP 0140
Figure 29. Inboard Left Frame Rail, Near Left Rear Wheel., Vol 2 . . . . . . . . . . . WP 0140
TRANSMISSION CIRCUIT TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . WP 0141
Figure 1. Transmission Control Unit Cover., Vol 2 . . . . . . . . . . . . . . . . . . WP 0141
Figure 3. Battery Compartment., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 5. Starter Motor Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 7. Battery Box Compartment., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 8. Left Side of Engine Starter Area., Vol 2 . . . . . . . . . . . . . . . . . . WP 0141
Figure 9. Battery Compartment., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 12. Dash Harness., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 13. Fuse Block Under Hood., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0141
Figure 15. Connector 4705F1., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0141
TRANSMISSION OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . WP 0142
TRANSMISSION FLUID OVER TEMPERATURE TROUBLESHOOTING PROCEDURE, Vol 2 . WP 0143
Figure 1. Right Side of Transmission., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0143
TRANSMISSION CONTROL MODULE (TCM) OPERATIONAL CHECKOUT PROCEDURE, Vol 2 WP 0144
TRANSMISSION HIGH SIDE DRIVER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . WP 0145
TRANSMISSION CONTROL SYSTEM ID TROUBLESHOOTING PROCEDURE, Vol 2 . . . . WP 0146
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TRANSMISSION FLUID LEVEL SENSOR TROUBLESHOOTING PROCEDURE, Vol 2 . . . . WP 0147
TRANSMISSION FLUID TEMPERATURE SENSOR TROUBLESHOOTING PROCEDURE, Vol 2 WP 0148
TRANSMISSION OUTPUT SPEED SENSOR TROUBLESHOOTING PROCEDURE, Vol 2 . . . WP 0149
Figure 1. Right Rear of Transmission., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0149
Figure 2. Right Rear of Transmission., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0149
TRANSMISSION ENGINE SPEED SENSOR TROUBLESHOOTING PROCEDURE, Vol 2 . . . WP 0150
INTERNAL TRANSMISSION OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . WP 0151
TRANSMISSION PRESSURE CONTROL SOLENOID 2 TROUBLESHOOTING PROCE-
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0152
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DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0153
TRANSMISSION PRESSURE SWITCH TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . WP 0154
Figure 4. Right Side Frame Rail., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0154
TRANSMISSION SLIPPING OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . WP 0155
TRANSMISSION PRESSURE CONTROL MAIN MOD SOLENOID TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0156
TRANSMISSION SHIFT SOLENOID 1 TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . WP 0157
TRANSMISSION LOW GEAR TROUBLESHOOTING PROCEDURE, Vol 2. . . . . . . . . . WP 0158
TRANSMISSION HIGH SIDE DRIVER 2 TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . WP 0159
TRANSMISSION HIGH SIDE DRIVER 3 TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . WP 0160
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DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0161
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0162
TRANSMISSION COMMUNICATION TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . WP 0163
TRANSFER CASE OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . WP 0164
Figure 1. Transfer Case Air Line Shift Solenoids., Vol 2 . . . . . . . . . . . . . . . WP 0164
PROPELLER SHAFT OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . WP 0165
Figure 2. Length Compensation Eccentricity Check., Vol 2 . . . . . . . . . . . . . . WP 0165
FRONT AXLE OPERATIONAL CHECKOUT PROCEDURES, Vol 2 . . . . . . . . . . . . . WP 0166
REAR AXLE OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . . . WP 0167
STOPLIGHT SWITCH CIRCUITS TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . WP 0168
Figure 1. Below Dash, Left of Steering Column., Vol 2 . . . . . . . . . . . . . . . . WP 0168
Figure 3. Electronic System Controller (ESC)., Vol 2. . . . . . . . . . . . . . . . . WP 0168
Figure 6. Electronic System Controller (ESC)., Vol 2. . . . . . . . . . . . . . . . . WP 0168
BRAKE SYSTEM OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . WP 0169
Figure 1. Left Rear Brake Chamber., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0169
BRAKE SYSTEM MECHANICAL COMPONENTS OPERATIONAL CHECKOUT PROCE-
DURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0170
Figure 1. Brake Shoe., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0170
Figure 2. Automatic Slack Adjuster Test., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0170
BRAKE SYSTEM TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . WP 0171
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AIR BRAKE SYSTEM OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . WP 0172
Figure 2. Left Front Brake Chamber., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0172
AIR BRAKE COMPONENT OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . WP 0173
Figure 1. Grease Gun Hose and Inflator Hose., Vol 2 . . . . . . . . . . . . . . . . WP 0173
Figure 2. Grease Gun Hose and Inflator Hose Connection., Vol 2 . . . . . . . . . . . WP 0173
Figure 3. Grease Gun Hose and Grease Gun Adapter., Vol 2 . . . . . . . . . . . . . WP 0173
Figure 4. Assembled Inflator Hose., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 5. Assembled Inflator Hose Attached to Rear Supply Line., Vol 2 . . . . . . . . WP 0173
Figure 6. Inflator Gauge., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 7. Spring Brake Modulating Valve., Vol 2. . . . . . . . . . . . . . . . . . . WP 0173
Figure 8. Relay Valve., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 9. Left Front Supply Line Quick-Release Valve., Vol 2 . . . . . . . . . . . . . WP 0173
Figure 10. Right Front Service Line and Rear Brake Chamber Quick-Release Valves., Vol 2WP 0173
Figure 11. Left Rear Brake Chamber., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 12. Right Front Service Line and Rear Brake Chamber Quick-Release Valves., Vol 2WP 0173
Figure 13. Rear Brake Chamber Quick-Release Valve., Vol 2 . . . . . . . . . . . . . WP 0173
Figure 14. Double Check Valves., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 15. Foot Valve., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 16. Tractor Protection Valve., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 17. Assembled Inflator Hose Attached to Rear Service Line., Vol 2 . . . . . . . WP 0173
Figure 18. Inflator Gauge., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 19. Trailer Brake Hand Control Valve., Vol 2 . . . . . . . . . . . . . . . . . WP 0173
Figure 20. In-Line Quick-Release Valve., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0173
Figure 22. Pressure Protection Valve., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 23. Front ABS Modulator Valve., Vol 2. . . . . . . . . . . . . . . . . . . . WP 0173
Figure 24. Rear ABS Modulator Valve., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 26. Trailer Brake Hand Control Valve., Vol 2 . . . . . . . . . . . . . . . . . WP 0173
Figure 27. Right Front Brake Chamber., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0173
Figure 28. Left Rear Brake Chamber., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 29. Air Dryer., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
Figure 30. Air Dryer Fittings., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0173
AIR DRYER HEATER AND THERMOSTAT TROUBLESHOOTING PROCEDURE, Vol 2. . . . WP 0174
Figure 2. Connector 9900C., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0174
Figure 5. Left Rear Engine Compartment., Vol 2 . . . . . . . . . . . . . . . . . . WP 0174
Figure 10. Left Rear Engine Compartment Chassis Ground Stud., Vol 2 . . . . . . . . WP 0174
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AIR COMPRESSOR OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . WP 0175
Figure 1. Air Compressor, Below Air Filter., Vol 2 . . . . . . . . . . . . . . . . . . WP 0175
Figure 2. Air Compressor, Below Air Filter., Vol 2 . . . . . . . . . . . . . . . . . . WP 0175
Figure 3. Air Dryer, Left Rear Tire., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0175
AIR COMPRESSOR GOVERNOR OPERATIONAL CHECKOUT, Vol 2 . . . . . . . . . . . WP 0176
Figure 1. Air Compressor Governor hose, Vol 2. . . . . . . . . . . . . . . . . . . WP 0176
Figure 2. Air Compressor Governor., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0176
Figure 3. Pressure Test Kit (ZTSE4409) Adapter., Vol 2 . . . . . . . . . . . . . . . WP 0176
Figure 4. Pressure Test Kit (ZTSE4409) Gauges., Vol 2 . . . . . . . . . . . . . . . WP 0176
Figure 5. Pressure Test Kit (ZTSE4409) Adapter., Vol 2 . . . . . . . . . . . . . . . WP 0176
ANTILOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 4. Left Front Wheel Raised., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 5. Behind Left Front Wheel., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 18. Right Front Wheel Raised., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 19. Behind Right Front Wheel., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 33. Left Rear Wheel Raised, Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 34. Left Rear Axle., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 37. Above Frame Inboard of Left Front Wheel., Vol 2 . . . . . . . . . . . . . WP 0177
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Figure 51. Right Rear Wheel Raised., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0177
Figure 52. Right Rear Axle., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . WP 0177
ANTILOCK BRAKE SYSTEM (ABS) PRESSURE MODULATOR VALVE (PMV) TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0178
Figure 13. Outboard Frame Inboard Left Front Wheel., Vol 2 . . . . . . . . . . . . . WP 0178
Figure 16. Outboard Frame Inboard Left Front Wheel., Vol 2 . . . . . . . . . . . . . WP 0178
Figure 20. Outboard Frame Inboard Right Front Wheel., Vol 2 . . . . . . . . . . . . WP 0178
Figure 23. Outboard Frame Inboard Right Front Wheel., Vol 2 . . . . . . . . . . . . WP 0178
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Figure 29. Inboard Left Frame Rail Near Left Rear Wheel., Vol 2 . . . . . . . . . . . WP 0178
Figure 33. Inboard Left Frame Rail Near Left Rear Wheel., Vol 2 . . . . . . . . . . . WP 0178
Figure 34. Inboard Left Frame Rail Near Fuel Tank., Vol 2 . . . . . . . . . . . . . . WP 0178
Figure 39. Inboard Right Frame Rail Near Right Rear Wheel., Vol 2 . . . . . . . . . . WP 0178
Figure 43. Inboard Right Frame Rail Near Right Rear Wheel., Vol 2 . . . . . . . . . . WP 0178
Figure 44. Inboard Left Frame Rail Near Fuel Tank., Vol 2 . . . . . . . . . . . . . . WP 0178
STEERING SYSTEM OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . WP 0179
Figure 1. Tie Rod Ends., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0179
Figure 2. Front Axle Raised and Supported, Vol 2 . . . . . . . . . . . . . . . . . . WP 0179
Figure 3. Steering Knuckle and King Pin., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0179
POWER STEERING OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . WP 0180
Figure 1. Power Steering Reservoir and Filter Assembly., Vol 2 . . . . . . . . . . . . WP 0180
Figure 2. Power Steering Pump., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0180
Figure 3. Power Steering Gear., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0180
Figure 4. Power Steering Gear., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0180
Figure 5. Torque Wrench Assembly to Steering Wheel., Vol 2. . . . . . . . . . . . . WP 0180
SUSPENSION TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . WP 0181
CABIN DOOR OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . . . WP 0182
Figure 1. Upper and Lower Cabin Door Lock Assemblies. Left Door Shown; Right Door
Similar., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0182
CABIN DOOR COMBAT LOCK TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . WP 0183
Figure 1. Combat Lock Handle — One Piece., Vol 2. . . . . . . . . . . . . . . . . WP 0183
Figure 2. Combat Lock Linkage Fasteners. , Vol 2 . . . . . . . . . . . . . . . . . WP 0183
Figure 3. Combat Lock Absorber., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0183
Figure 4. Combat Lock Linkage. , Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0183
CABIN DOOR LOCK ASSEMBLY TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . WP 0184
Figure 1. Cabin Door Lower Lock Assembly., Vol 2 . . . . . . . . . . . . . . . . . WP 0184
Figure 2. Cabin Door Upper Lock Assembly., Vol 2 . . . . . . . . . . . . . . . . . WP 0184
Figure 3. Cabin Door Upper Lock Assembly., Vol 2 . . . . . . . . . . . . . . . . . WP 0184
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CABIN DOOR ASSIST SYSTEM TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . WP 0185
Figure 1. Cabin Door Check Link., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0185
Figure 2. Cabin Door Actuator Air Lines., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0185
Figure 3. Cabin Doors Supply Air Line Tee., Vol 2 . . . . . . . . . . . . . . . . . . WP 0185
Figure 4. Pressure Test Kit Installed in Cabin., Vol 2 . . . . . . . . . . . . . . . . . WP 0185
Figure 5. Cabin Doors Supply Air Line Tee., Vol 2 . . . . . . . . . . . . . . . . . . WP 0185
Figure 6. Cabin Door Air Supply Line., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0185
Figure 8. Pressure Test Kit Installed in Engine Compartment., Vol 2 . . . . . . . . . . WP 0185
Figure 9. Pressure Test Kit Installed in Engine Compartment., Vol 2 . . . . . . . . . . WP 0185
Figure 11. Primary Air Tank Reservoir., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0185
WINCH TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . WP 0186
Figure 1. Remote Control Electrical Connector., Vol 2 . . . . . . . . . . . . . . . . WP 0186
Figure 2. Remote Control Cable-Out Switch., Vol 2 . . . . . . . . . . . . . . . . . WP 0186
Figure 3. Remote Control Electrical Connector., Vol 2 . . . . . . . . . . . . . . . . WP 0186
Figure 4. Remote Control Cable-In Switch., Vol 2 . . . . . . . . . . . . . . . . . . WP 0186
Figure 5. Winch Power and Ground Junction Block., Vol 2 . . . . . . . . . . . . . . WP 0186
Figure 6. Winch Ground Cable at Junction Block., Vol 2 . . . . . . . . . . . . . . . WP 0186
Figure 7. Megafuse Winch Power Feed., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0186
Figure 8. Megafuse Power Feed., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0186
Figure 9. Megafuse Power Feed Cable., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0186
Figure 10. 24V Battery Positive Terminal Test Point., Vol 2 . . . . . . . . . . . . . . WP 0186
Figure 11. Winch Power Feed Cable., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0186
Figure 12. Megafuse Power Feed., Vol 2. . . . . . . . . . . . . . . . . . . . . . WP 0186
REAR DOOR/RAMP HYDRAULIC LIFT COMPONENTS TROUBLESHOOTING PROCEDURE
(PUSH-TYPE OPERATION), Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 1. Hydraulic Cylinder., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 2. Hydraulic Ramp Springs., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 3. Manual Solenoid Valves., Vol 2. . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 4. Rear Door/Ramp Rear Switch., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0187
Figure 5. Master Rear Door/Ramp Switch., Vol 2 . . . . . . . . . . . . . . . . . . WP 0187
Figure 6. Top of Hydraulic Pump Solenoid., Vol 2 . . . . . . . . . . . . . . . . . . WP 0187
Figure 7. Ramp Circuit Breaker., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 8. Lower Right of 24V Power Distribution Center (PDC)., Vol 2 . . . . . . . . . WP 0187
Figure 9. Lower Right Corner of 24V PDC J7., Vol 2. . . . . . . . . . . . . . . . . WP 0187
Figure 10. Right Side of Hydraulic Pump., Vol 2. . . . . . . . . . . . . . . . . . . WP 0187
Figure 11. Behind Center IP Panel., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0187
Figure 12. Lower Right of 24V Power Distribution Center (PDC)., Vol 2 . . . . . . . . WP 0187
Figure 13. Lower Right of 24V PDC J7., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0187
Figure 15. Top of Hydraulic Pump Solenoid., Vol 2 . . . . . . . . . . . . . . . . . WP 0187
Figure 17. Master Rear Door/Ramp Switch., Vol 2 . . . . . . . . . . . . . . . . . WP 0187
Figure 23. Below Instrument Panel (IP) Power Distribution Center., Vol 2. . . . . . . . WP 0187
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Figure 28. Rear Door/Ramp Rear Ramp Switch., Vol 2 . . . . . . . . . . . . . . . WP 0187
REAR DOOR/RAMP HYDRAULIC LIFT COMPONENTS TROUBLESHOOTING PROCEDURE (PULL-TYPE
OPERATION), Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0188
Figure 1. Hydraulic Lines and Cylinder., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0188
Figure 2. Hydraulic Ramp Springs., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0188
Figure 3. Manual Solenoid Valve and Rear Door/Ramp Rear Switch., Vol 2. . . . . . . WP 0188
Figure 4. Master Rear/Door Ramp Switch., Vol 2 . . . . . . . . . . . . . . . . . . WP 0188
Figure 5. Sides of Hydraulic Pump Motor., Vol 2 . . . . . . . . . . . . . . . . . . WP 0188
Figure 6. Ramp Circuit Breaker., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0188
Figure 7. Lower Right of 24V Power Distribution Center (PDC)., Vol 2 . . . . . . . . . WP 0188
Figure 8. Lower Right Corner of 24V PDC J7., Vol 2. . . . . . . . . . . . . . . . . WP 0188
Figure 9. Right Side of Hydraulic Pump., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0188
Figure 10. Behind Center IP Panel., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0188
Figure 12. Lower Right of 24V PDC J7., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0188
Figure 16. Master Rear Door/Ramp Switch., Vol 2 . . . . . . . . . . . . . . . . . WP 0188
Figure 28. Rear Door/Ramp rear Ramp Switch., Vol 2 . . . . . . . . . . . . . . . . WP 0188
AIR CONDITIONING (A/C) OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . WP 0189
Figure 1. A/C Refrigerant System Diagram., Vol 2. . . . . . . . . . . . . . . . . . WP 0189
Figure 2. Recycled Air (RA) Temperature Sensor, Recycled Air (RA) Blower, and Fresh Air (FA)
Blower Locations., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0189
Figure 3. A/C Condenser Fans Location., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0189
AIR CONDITIONING (A/C) THERMAL EXPANSION VALVE (TXV) OPERATIONAL CHECKOUT
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0190
Figure 1. Thermal Expansion Valve (TXV) and Evaporator Assembly., Vol 2 . . . . . . WP 0190
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Fire Suppression System (FSS) Troubleshooting Procedure, Vol 2. . . . . . . . . . . . . . WP 0191
Figure 1. Outside Center of Right Side Frame Rail Area., Vol 2 . . . . . . . . . . . . WP 0191
Figure 2. Outside Center of Left Side Frame Rail Area., Vol 2. . . . . . . . . . . . . WP 0191
Figure 3. Backside of Left Rear Stowage Box Area., Vol 2 . . . . . . . . . . . . . . WP 0191
Figure 4. Center Cabin Floor Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0191
Figure 5. FSS Control Panel., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0191
Figure 6. Right Side Front Cabin Area., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0191
Figure 10. Backside of Hood Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0191
Figure 11. Outside Center of Right Side Frame Rail Area., Vol 2 . . . . . . . . . . . WP 0191
Figure 12. Outside Center of Left Side Frame Rail Area., Vol 2 . . . . . . . . . . . . WP 0191
Figure 13. FSS Control Panel., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0191
Figure 14. Backside of Left Rear Stowage Box Area., Vol 2 . . . . . . . . . . . . . WP 0191
FIRE SUPPRESSION SYSTEM (FSS) CONTROL PANEL POWER AND GROUND TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0192
Figure 1. Center Instrument Panel (IP) Area., Vol 2 . . . . . . . . . . . . . . . . . WP 0192
Figure 2. Center IP Near Floor Area., Vol 2. . . . . . . . . . . . . . . . . . . . . WP 0192
Figure 3. PDM Harness Electrical Storage Shield., Vol 2 . . . . . . . . . . . . . . . WP 0192
Figure 4. Center IP Near Floor Area., Vol 2. . . . . . . . . . . . . . . . . . . . . WP 0192
Figure 5. Connector C1., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0192
Figure 10. Right Side Front Cabin Area., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0192
Figure 12. Right Side Underhood Firewall Area., Vol 2 . . . . . . . . . . . . . . . . WP 0192
Figure 13. Center Instrument Panel (IP) Area., Vol 2 . . . . . . . . . . . . . . . . WP 0192
Figure 14. Center IP Near Floor Area., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0192
Figure 16. Right Side Underhood Firewall Area., Vol 2 . . . . . . . . . . . . . . . . WP 0192
Figure 18. Right Side Front Cabin Area., Vol 2 . . . . . . . . . . . . . . . . . . . WP 0192
Figure 23. Outside Center of Right Side Frame Rail Area., Vol 2 . . . . . . . . . . . WP 0192
Figure 24. Backside of Left Rear Stowage Box Area., Vol 2 . . . . . . . . . . . . . WP 0192
Figure 25. Outside Center of Left Side Frame Rail Area., Vol 2 . . . . . . . . . . . . WP 0192
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FIRE SUPPRESSION SYSTEM (FSS) EXTINGUISHER PRESSURE FAULT TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0193
Figure 2. Right Side Engine Compartment Near Firewall., Vol 2 . . . . . . . . . . . . WP 0193
Figure 11. Center Instrument Panel (IP) Area., Vol 2. . . . . . . . . . . . . . . . . WP 0193
FIRE SUPPRESSION SYSTEM (FSS) CABIN EXTINGUISHER CONTROL CIRCUIT FAULT
FIRE SUPPRESSION SYSTEM (FSS) CABIN FIRE DETECTOR POWER AND GROUND
FIRE SUPPRESSION SYSTEM (FSS) CABIN FIRE DETECTOR FIRE DETECTION CIRCUIT
FIRE SUPPRESSION SYSTEM (FSS) ENGINE EXTINGUISHER CONTROL CIRCUIT FAULT
FIRE SUPPRESSION SYSTEM (FSS) ENGINE FIRE DETECTOR POWER AND GROUND
FIRE SUPPRESSION SYSTEM (FSS) ENGINE FIRE DETECTOR FIRE DETECTION CIRCUIT
Figure 2. Backside of Hood Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0199
FIRE SUPPRESSION SYSTEM (FSS) FUEL TANK EXTINGUISHER CONTROL CIRCUIT FAULT
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FIRE SUPPRESSION SYSTEM (FSS) TIRES EXTINGUISHER CONTROL CIRCUIT FAULT
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS)
OPERATIONAL CHECKOUT PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0202
Figure 1. HVAC Service Ports., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0202
Figure 2. Recycled Air (RA) Temperature Sensor, Recycled Air (RA) Blower, and Fresh Air (FA)
Blower Locations., Vol 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0202
Figure 4. A/C Compressor Clutch Location., Vol 2. . . . . . . . . . . . . . . . . . WP 0202
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) OPERATOR
PANEL AND CLIMATE CONTROL UNIT (CCU) POWER AND GROUND TROUBLESHOOTING
PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 1. HVAC/LSS Box Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 2. CCU Case Ground., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 4. HVAC/LSS Operator Panel Area., Vol 2 . . . . . . . . . . . . . . . . . . WP 0203
Figure 6. Connector P21., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 11. HVAC/LSS Operator Panel Area., Vol 2 . . . . . . . . . . . . . . . . . WP 0203
Figure 21. HVAC/LSS Box Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 25. PDM Harness Electrical Storage Shield., Vol 2 . . . . . . . . . . . . . . WP 0203
Figure 26. HVAC/LSS Control Power Wiring Harness Connection at 24V Power Distribution
Module., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 29. HVAC/LSS Control Power Wiring Harness Connection at Climate Control Unit (CCU)
Box., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 30. PDM Harness Electrical Storage Shield., Vol 2 . . . . . . . . . . . . . . WP 0203
Figure 31. HVAC/LSS Control Power Wiring Harness Connection at 24V Power Distribution
Module., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203
Figure 33. CCU Case Ground Connector., Vol 2 . . . . . . . . . . . . . . . . . . WP 0203
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Figure 41. Connector Interface J22., Vol 2 . . . . . . . . . . . . . . . . . . . . . WP 0203
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) RECYCLED
AIR (RA) BLOWER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . WP 0204
Figure 1. HVAC Box Interior Area., Vol 2 . . . . . . . . . . . . . . . . . . . . . . WP 0204
Figure 3. Connector P8., Vol 2 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0204
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) FRESH AIR
(FA) BLOWER TROUBLESHOOTING PROCEDURE, Vol 2 . . . . . . . . . . . . . . . . WP 0205
Figure 1. HVAC Box Nuclear, Biological, and Chemical (NBC) Filter Area., Vol 2 . . . . WP 0205
Figure 2. HVAC Box NBC Filter Area., Vol 2 . . . . . . . . . . . . . . . . . . . . WP 0205
VOLUME 3

HEATING VENTILATING AND AIR CONDITIONING (HVAC) 3-WAY VALVE TROUBLESHOOTING
PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0206
Figure 1. HVAC Box Heater Hose Connections., Vol 3 . . . . . . . . . . . . . . . . WP 0206
Figure 2. HVAC Box Heater Hose Connections., Vol 3 . . . . . . . . . . . . . . . . WP 0206
Figure 3. Right Side Engine Compartment at Firewall., Vol 3 . . . . . . . . . . . . . WP 0206
Figure 4. Heater Hoses Above Battery Box., Vol 3 . . . . . . . . . . . . . . . . . WP 0206
Figure 5. 3-Way Valve Heater Hose Connections at Firewall., Vol 3 . . . . . . . . . . WP 0206
Figure 6. Right Front Cabin Area., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0206
Figure 7. HVAC Box Area., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0206
Figure 8. Heater Coolant Engine Outlet Valve., Vol 3 . . . . . . . . . . . . . . . . WP 0206
Figure 9. Heater Coolant Engine Inlet Valve., Vol 3 . . . . . . . . . . . . . . . . . WP 0206
Figure 10. Heater Hose Above Battery Box., Vol 3 . . . . . . . . . . . . . . . . . WP 0206
Figure 11. 3-Way Valve Heater Hose Connections., Vol 3 . . . . . . . . . . . . . . WP 0206
Figure 12. 24V Power Source at Left Side Engine Compartment Area., Vol 3 . . . . . . WP 0206
Figure 13. 3–Way Valve Bench Test Connections., Vol 3 . . . . . . . . . . . . . . . WP 0206
Figure 14. Right Side Engine Compartment at Firewall., Vol 3 . . . . . . . . . . . . WP 0206
Figure 15. Right Front Cabin Area., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0206
Figure 16. HVAC Box Area., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . WP 0206
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) HIGH IDLE CIRCUIT TROUBLESHOOTING
PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0207
Figure 2. AIR COND Relay Breakout Harness., Vol 3 . . . . . . . . . . . . . . . . WP 0207
Figure 12. AIR COND Relay Breakout Harness Installation., Vol 3. . . . . . . . . . . WP 0207
Figure 13. Left Front Cabin Area., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0207
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RECYCLED AIR (RA) TEMPERATURE
SENSOR TROUBLESHOOTING PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0208
Figure 3. HVAC Box Exterior Area., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0208
Table 1. Temperature vs Resistance., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0208
HEATING VENTILATING AND AIR CONDITIONING (HVAC) FREEZE SWITCH TROUBLESHOOTING
PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0209
Figure 2. HVAC Freeze Switch Terminals Location., Vol 3 . . . . . . . . . . . . . . WP 0209
HEATING VENTILATING AND AIR CONDITIONING (HVAC) LOW PRESSURE CUTOUT SWITCH
Figure 1. Low Pressure Switch Harness Connectors Location., Vol 3 . . . . . . . . . WP 0210
Figure 2. Low Pressure Switch Connector Interfaces Location., Vol 3 . . . . . . . . . WP 0210
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) TRINARY SWITCH TROUBLESHOOTING
PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0211
Figure 5. A/C Compressor Clutch Location., Vol 3. . . . . . . . . . . . . . . . . . WP 0211
Figure 6. HVAC Box Exterior., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0211
Figure 9. A/C Compressor Connector Location., Vol 3 . . . . . . . . . . . . . . . . WP 0211
Figure 11. A/C Condenser Fans Location., Vol 3 . . . . . . . . . . . . . . . . . . WP 0211
Figure 12. HVAC Box Exterior., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0211
Figure 14. HVAC Box Exterior., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0211
HEATING VENTILATING AND AIR CONDITIONING (HVAC) COMPRESSOR CONTROL
Figure 1. Engine Compartment Area., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0212
Figure 9. Connector J36 (Compressor Side)., Vol 3 . . . . . . . . . . . . . . . . . WP 0212
HEATING VENTILATING AND AIR CONDITIONING (HVAC) CONDENSER FANS TROUBLESHOOTING
PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0213
Figure 3. Left Side A/C Condenser Fans Location., Vol 3. . . . . . . . . . . . . . . WP 0213
Figure 4. Right Side A/C Condenser Fans Location., Vol 3 . . . . . . . . . . . . . . WP 0213
Figure 10. Right Side Condenser Area., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0213
Figure 11. Connector P4., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0213
Figure 15. Relay Socket 1019., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0213
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Figure 24. Right Side Condenser Fans Area., Vol 3 . . . . . . . . . . . . . . . . . WP 0213
Figure 26. Right Instrument Panel Area., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0213
Figure 30. Left Side Condenser Fans Area., Vol 3. . . . . . . . . . . . . . . . . . WP 0213
Figure 43. Left Side Condenser Fans Area., Vol 3. . . . . . . . . . . . . . . . . . WP 0213
Figure 45. Right Instrument Panel Area., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0213
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) CABIN
PRESSURE TROUBLESHOOTING PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . WP 0214
Figure 1. NBC Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 2. NBC Particle Separator Filter., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0214
Figure 3. FA Blower., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 4. Fresh Air Inlet Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 5. Fresh Air Inlet on Roof., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 6. Overpressure Relief Valve., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 7. Left Front Cabin Door Seal. Right Front Cabin Door Seal Similar., Vol 3 . . . . WP 0214
Figure 8. Rear Door/Ramp Seal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 9. Emergency Escape Hatch., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0214
Figure 10. Sliding Gunner Hatch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0214
CHAPTER 6. PREVENTIVE MAINTENANCE INSTRUCTIONS, VOL 3

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION, Vol 3 . . WP 0215
Table 1. Visual Detection of Corrosion., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0215
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PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS), Vol 3 . . . . . . . . . . WP 0216
Figure 1. Air Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 2. Batteries., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 3. 110V Outlet., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 4. NATO Jump Start Connector., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0216
Figure 5. Door Hinges., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 6. Condenser Fans., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 7. NBC Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 8. Weapon Station Turret., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 9. Compressed Air Couplers., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 10. Front Axle Components., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 11. Bearing Cone Damage., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 12. Bearing Cup Damage., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 13. Pitman Arm and Drag Link., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 14. Steering Shaft., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 15. Air Line Right Side., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 16. Air Line Left Side., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 17. Front Air Chamber., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 18. Chassis Inspection and Lubrication Points., Vol 3 . . . . . . . . . . . . . WP 0216
Figure 19. Front Axle Plugs., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 20. Engine and Transmission Pans., Vol 3 . . . . . . . . . . . . . . . . . . WP 0216
Figure 21. Cooling System., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 22. Left Side of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 23. Fuel/Water Separator., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 24. Fuel Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 25. Engine Oil Lines., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 26. Turbo Oil Lines., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 27. Alternator and Voltage Regulator., Vol 3 . . . . . . . . . . . . . . . . . WP 0216
Figure 28. Starter Motor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 29. Fuel Tank., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 30. Transmission Dipstick., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 31. Transfer Case Plugs., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 32. Transfer Case Cooling Components., Vol 3 . . . . . . . . . . . . . . . . WP 0216
Figure 33. Air Cleaner Indicator, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 34. Rear Air Chamber., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 35. Air Valve., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 36. Rear Axle Breather., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 37. Hydraulic Ramp Pump Fill Cap., Vol 3 . . . . . . . . . . . . . . . . . . WP 0216
Figure 38. Tread Depth Gauge., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 39. Tire Rotation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Figure 40. Mounting Brackets., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0216
Table 1. Mandatory Replacement Parts., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0216
CHAPTER 7. MAINTENANCE INSTRUCTIONS, VOL 3

SERVICE UPON RECEIPT, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0217
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ENGINE ASSEMBLY REMOVAL, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 1. Alternator Positive Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0218
Figure 2. Alternator Negative Cable Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0218
Figure 3. Engine Harness and A/C Pressure Hoses., Vol 3 . . . . . . . . . . . . . . WP 0218
Figure 4. O-Rings., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 5. Fan Drive Air Line., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 6. Insulated Engine Wiring Harness Retainer., Vol 3. . . . . . . . . . . . . . WP 0218
Figure 8. Engine Block Ground Stud., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 9. Transmission Dipstick Tube and Air Line., Vol 3 . . . . . . . . . . . . . . WP 0218
Figure 10. Lower Mounting Bracket on Transmission Dipstick Tube., Vol 3 . . . . . . . WP 0218
Figure 11. Power Steering Hoses., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 12. Air Compressor Connection., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0218
Figure 13. Supply Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 14. Fire Suppression System (FSS) Engine Compartment Assembly and
Brackets., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 15. Fuel Filter Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 16. Transmission Cooler Lines and Fuel Lines Bracket., Vol 3 . . . . . . . . . WP 0218
Figure 17. Transmission Oil Cooler Line Bracket on Oil Pan., Vol 3 . . . . . . . . . . WP 0218
Figure 18. Draft Tube and Transmission Oil Cooler Lines Bracket., Vol 3 . . . . . . . . WP 0218
Figure 19. Transmission and Transmission Jack., Vol 3 . . . . . . . . . . . . . . . WP 0218
Figure 20. Access Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 21. Converter Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 22. Transmission Flywheel Housing Bolts., Vol 3 . . . . . . . . . . . . . . . WP 0218
Figure 23. Transmission Mount., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 24. Engine Lifting Eyelets., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 25. Rear Engine Mount., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 26. Front Crossmember Engine Mounts., Vol 3 . . . . . . . . . . . . . . . . WP 0218
Figure 27. Turbocharger Hose., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 28. Air Compressor Fittings., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 29. Power Steering Pump Fittings., Vol 3 . . . . . . . . . . . . . . . . . . WP 0218
Figure 30. A/C Compressor Bracket., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0218
Figure 31. Exhaust Brake Solenoid and Fuel Filter Assembly Bracket., Vol 3 . . . . . . WP 0218
Figure 32. Exhaust Brake Hose and Ether Start Thermostatic Switch., Vol 3 . . . . . . WP 0218
Figure 33. Starter Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218
ENGINE ASSEMBLY INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 1. Turbocharger Hose., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 2. Air Compressor Fittings., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 3. Power Steering Pump Fittings., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0219
Figure 4. A/C Compressor Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 5. Exhaust Brake Solenoid and Fuel Filter Assembly Bracket., Vol 3. . . . . . . WP 0219
Figure 6. Exhaust Brake Hose and Ether Start Thermostatic Switch., Vol 3 . . . . . . . WP 0219
Figure 7. Engine Eyelets., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 9. Rear Engine Mount., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 11. Punch Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 12. Flywheel Housing Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 13. Punch Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 16. Transmission Mount., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0219
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Figure 17. Draft Tube and Transmission Oil Cooler Lines Bracket., Vol 3 . . . . . . . . WP 0219
Figure 18. Transmission Oil Cooler and Fuel Line Bracket on Oil Pan., Vol 3 . . . . . . WP 0219
Figure 19. Transmission Cooler Lines and Fuel Lines Retainer., Vol 3 . . . . . . . . . WP 0219
Figure 20. Fuel Line Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 21. FSS Engine Compartment Pipes and Bracket., Vol 3. . . . . . . . . . . . WP 0219
Figure 22. Supply Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 25. Lower Mounting Bracket on Transmission Dipstick Tube., Vol 3 . . . . . . . WP 0219
Figure 26. Transmission Dipstick Tube and Air Line Retainer., Vol 3 . . . . . . . . . . WP 0219
Figure 27. Engine Ground Stud., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 28. ECM., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0219
Figure 30. Insulated Engine Wiring Harness Retainer., Vol 3 . . . . . . . . . . . . . WP 0219
Figure 32. Engine Harness and A/C Pressure Hoses., Vol 3 . . . . . . . . . . . . . WP 0219
Figure 33. Alternator Negative Cable Installation., Vol 3 . . . . . . . . . . . . . . . WP 0219
Figure 34. Alternator Positive Cable Installation., Vol 3. . . . . . . . . . . . . . . . WP 0219
FRONT ENGINE MOUNT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0220
Figure 1. Front Lifting Eye., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0220
Figure 2. Front Crossmember., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0220
Figure 3. Front Engine Mount Bracket. , Vol 3 . . . . . . . . . . . . . . . . . . . WP 0220
Figure 4. Front Crossmember., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0220
REAR ENGINE MOUNT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0221
Figure 1. Engine Lifting Eyelets., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0221
CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . WP 0222
Figure 1. Coolant Line Disconnected., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 2. Cylinder Head Components Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0222
Figure 3. Cylinder Head Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 4. Cylinder Head Gasket Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0222
Figure 5. Cylinder Head Gasket Cleaning., Vol 3 . . . . . . . . . . . . . . . . . . WP 0222
Figure 6. Cylinder Head Flatness Measurement., Vol 3 . . . . . . . . . . . . . . . WP 0222
Figure 7. Cylinder Head Pressure Test., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0222
Figure 8. Pipe Plug., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 9. Test Adapter., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 10. Cylinder Head Upper Deck Inspection., Vol 3 . . . . . . . . . . . . . . . WP 0222
Figure 11. Cylinder Head Lower Deck Inspection., Vol 3 . . . . . . . . . . . . . . . WP 0222
Figure 12. Test Adapter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 13. Drain Cylinder Head., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 14. Cylinder Head Pressure Test Kit., Vol 3 . . . . . . . . . . . . . . . . . WP 0222
Figure 15. Engine Block Inspection., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 16. Cylinder Head Dowel Rings., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0222
Figure 17. Cylinder Head Gasket Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0222
Figure 18. Cylinder Head Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 19. Cylinder Head Components Installation., Vol 3 . . . . . . . . . . . . . . WP 0222
Figure 20. Engine Timing Mark Alignment., Vol 3 . . . . . . . . . . . . . . . . . . WP 0222
Figure 21. Cylinder Head Bolt Tightening Sequence., Vol 3. . . . . . . . . . . . . . WP 0222
Figure 22. Rocker Arm Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0222
Figure 23. Coolant Line Connected., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0222
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WP Sequence No.
CRANKSHAFT DAMPER AND FRONT SEAL ASSEMBLY REMOVAL AND INSTALLATION, Vol 3WP 0223
Figure 1. Crankshaft Damper and Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0223
Figure 2. Crankshaft Damper (Plate Removed)., Vol 3 . . . . . . . . . . . . . . . . WP 0223
Figure 3. Front Seal Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0223
Figure 4. Crankshaft Damper Wear Sleeve., Vol 3. . . . . . . . . . . . . . . . . . WP 0223
Figure 5. Crankshaft Damper Wear Sleeve., Vol 3. . . . . . . . . . . . . . . . . . WP 0223
Figure 6. Front Seal., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0223
Figure 7. Damper Heater., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0223
Figure 8. Crankshaft Damper Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0223
Figure 9. Crankshaft Damper., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0223
REAR CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . WP 0224
Figure 1. Rear Oil Seal Retainer Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0224
Figure 2. Rear Oil Seal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0224
Figure 3. Rear Oil Seal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0224
Figure 4. Wear Sleeve Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0224
Figure 5. Rear Oil Seal Installer Base., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0224
Figure 6. Rear Oil Seal Installation on Base., Vol 3 . . . . . . . . . . . . . . . . . WP 0224
Figure 7. Rear Seal Installer on Base., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0224
Figure 8. Rear Oil Seal Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0224
FLEX PLATE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0225
Figure 1. Crankshaft Vibration Damper., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0225
Figure 2. Flexplate Bolts Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0225
Figure 3. Guide Studs Installation., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0225
Figure 4. Flexplate Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0225
Figure 5. Crankshaft Vibration Damper., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0225
Figure 6. Flexplate Bolts Installation., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0225
STARTER RING GEAR REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0226
Figure 1. Starter Ring Gear., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0226
Figure 2. Starter Ring Gear., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0226
FRONT ENGINE COVER REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . WP 0227
Figure 1. Camshaft Position Sensor Harness., Vol 3. . . . . . . . . . . . . . . . . WP 0227
Figure 2. Front Engine Cover Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0227
Figure 3. O-Rings and Seal Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0227
Figure 4. Gasket Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0227
Figure 5. Gasket Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0227
Figure 6. O-Rings and Seal Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0227
Figure 7. Front Engine Cover Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0227
Figure 8. Camshaft Position Sensor Harness., Vol 3. . . . . . . . . . . . . . . . . WP 0227
VALVE COVER AND GASKET REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . WP 0228
Figure 1. A/C High-Pressure Switch Connectors., Vol 3 . . . . . . . . . . . . . . . WP 0228
Figure 2. A/C Compressor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 3. Engine Wiring Harness and Fan Drive Assembly Air Line. (Alternator Removed for
Clarity)., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 4. Engine Valve Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 5. Injector Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 6. Injector Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 7. Engine Valve Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 8. Engine Wiring Harness and Fan Drive Assembly Air Line. (Alternator Removed for
Clarity)., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 9. A/C Compressor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228
Figure 10. A/C High-Pressure Switch Connectors., Vol 3 . . . . . . . . . . . . . . . WP 0228
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ENGINE VALVE ADJUSTMENT, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0229
Figure 1. Crankshaft Timing Marks., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0229
Figure 2. Engine Valve Sequence., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0229
Figure 3. Engine Valve Adjustment., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0229
Figure 4. Crankshaft Timing Marks., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0229
Figure 5. Engine Valve Adjustment., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0229
OIL GAUGE TUBE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . WP 0230
Figure 1. Engine Oil Level Gauge., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0230
Figure 2. Oil Gauge Tube and Transmission Dipstick Retainer., Vol 3 . . . . . . . . . WP 0230
Figure 3. Center Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230
Figure 4. Lower Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230
Figure 6. Center Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230
Figure 8. Engine Oil Level Gauge., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0230
ENGINE OIL BREATHER TUBE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0231
Figure 1. Engine Oil Breather Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0231
Figure 2. Engine Oil Breather Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0231
ENGINE OIL FILTER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0232
Figure 1. Engine Oil Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0232
Figure 2. Engine Oil Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0232
ENGINE OIL DRAIN/FILL PROCEDURE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0233
Figure 1. Engine Oil Drain Plug., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0233
Figure 2. Engine Oil Dipstick., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0233
Figure 3. Dipstick Parameters., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0233
ENGINE OIL COOLER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0234
Figure 1. Engine Oil Cooler., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0234
Figure 2. Oil Cooler and Filter Header Disassembly., Vol 3 . . . . . . . . . . . . . . WP 0234
Figure 3. Oil Cooler and Filter Header Assembly., Vol 3 . . . . . . . . . . . . . . . WP 0234
Figure 4. Oil Cooler Locator Pin (Oil Filter Header Shown, Front Oil Cooler Header
Similar)., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0234
Figure 5. Assemble Oil Cooler., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0234
Figure 6. Oil Cooler and Filter Header Assembly., Vol 3 . . . . . . . . . . . . . . . WP 0234
Figure 7. Assembled Engine Oil Cooler., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0234
ENGINE OIL COOLER PRESSURE REGULATOR REMOVAL AND INSTALLATION , Vol 3 . . WP 0235
Figure 1. Engine Oil Cooler Pressure Regulator., Vol 3 . . . . . . . . . . . . . . . WP 0235
Figure 2. Oil Cooler Pressure Regulator O-Ring Removal. , Vol 3 . . . . . . . . . . . WP 0235
Figure 3. Oil Cooler Pressure Regulator O-Ring Installation., Vol 3 . . . . . . . . . . WP 0235
Figure 4. Engine Oil Cooler Pressure Regulator., Vol 3 . . . . . . . . . . . . . . . WP 0235
ENGINE OIL PAN REMOVAL AND INSTALLATION , Vol 3 . . . . . . . . . . . . . . . . . WP 0236
Figure 1. Oil Pan Bolt Locations., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0236
Figure 2. Engine Oil Pan., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0236
Figure 3. Bottom View of Engine Block., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0236
Figure 4. Engine Oil Pan Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0236
Figure 5. Oil Pan Bolt Locations., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0236
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ENGINE OIL PICKUP TUBE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0237
Figure 1. Engine Front Cover., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0237
Figure 2. Engine Oil Pickup Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0237
Figure 3. Engine Oil Pickup Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0237
Figure 4. Engine Front Cover., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0237
FRONT OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0238
Figure 1. Oil Pump Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 2. Oil Pump Housing., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 3. Crankshaft Front., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 4. Front Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 5. Crankshaft Front., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 6. Oil Pump Housing., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0238
Figure 7. Oil Pump Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0238
EXHAUST MANIFOLD REMOVAL AND INSTALLATION , Vol 3 . . . . . . . . . . . . . . . WP 0239
Figure 1. Exhaust Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0239
Figure 2. Exhaust Manifold. , Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0239
SERPENTINE BELT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0240
Figure 1. Serpentine Belt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0240
Figure 2. Serpentine Belt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0240
SERPENTINE BELT IDLER PULLEY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0241
Figure 1. Serpentine Belt Idler Pulley., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0241
Figure 2. Serpentine Belt Idler Pulley., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0241
SERPENTINE BELT TENSIONER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . WP 0242
Figure 1. Serpentine Belt Tensioner., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0242
Figure 2. Adapter Plate Alignment., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0242
Figure 3. Serpentine Belt Tensioner Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0242
SERPENTINE BELT UPPER IDLER PULLEY REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0243
Figure 1. Serpentine Belt Upper Idler Pulley., Vol 3 . . . . . . . . . . . . . . . . . WP 0243
Figure 2. Serpentine Belt Upper Idler Pulley., Vol 3 . . . . . . . . . . . . . . . . . WP 0243
AIR CONDITIONER (A/C) BELT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0244
Figure 1. A/C Belt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0244
Figure 2. A/C Belt Configuration., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0244
AIR CONDITIONING (A/C) BELT TENSIONER REMOVAL AND INSTALLATION, Vol 3 . . . . WP 0245
Figure 1. A/C Belt Tensioner., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0245
Figure 2. A/C Belt Tensioner., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0245
EXHAUST BRAKE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . WP 0246
Figure 1. Exhaust Brake and Turbocharger Pipe Connection., Vol 3 . . . . . . . . . . WP 0246
Figure 2. Exhaust Brake and Supply Air Line Connection., Vol 3 . . . . . . . . . . . WP 0246
Figure 3. Turbocharger Pipe Downstream Clamp., Vol 3 . . . . . . . . . . . . . . . WP 0246
Figure 4. Turbocharger Pipe Downstream Clamp., Vol 3 . . . . . . . . . . . . . . . WP 0246
Figure 5. Exhaust Brake and Supply Air Line Connection., Vol 3 . . . . . . . . . . . WP 0246
Figure 6. Exhaust Brake and Turbocharger Pipe Connection., Vol 3 . . . . . . . . . . WP 0246
EXHAUST BRAKE SOLENOID REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0247
Figure 1. Exhaust Brake Solenoid and Electrical Connector., Vol 3 . . . . . . . . . . WP 0247
Figure 2. Exhaust Brake Solenoid and Bracket., Vol 3 . . . . . . . . . . . . . . . . WP 0247
Figure 3. Exhaust Brake Solenoid and Bracket., Vol 3 . . . . . . . . . . . . . . . . WP 0247
Figure 4. Exhaust Brake Solenoid and Electrical Connector., Vol 3 . . . . . . . . . . WP 0247
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WP Sequence No.
EXHAUST BRAKE SUPPLY AIR LINE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0248
Figure 1. Exhaust Brake Supply Air Line Connection., Vol 3 . . . . . . . . . . . . . WP 0248
Figure 2. Exhaust Brake Supply Air Line Clamp., Vol 3 . . . . . . . . . . . . . . . WP 0248
Figure 4. Exhaust Brake Supply Air Line Clamp., Vol 3 . . . . . . . . . . . . . . . WP 0248
FUEL INJECTOR REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . WP 0249
Figure 1. Fuel Injector Electrical Connector., Vol 3 . . . . . . . . . . . . . . . . . WP 0249
Figure 2. Fuel Injector Harness Clip., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0249
Figure 3. Fuel Injector Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0249
Figure 4. Fuel Injector and Gaskets., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0249
Figure 5. Fuel Injector and Gaskets., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0249
Figure 6. Fuel Injector Installation., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0249
Figure 7. Fuel Injector Electrical Connector., Vol 3 . . . . . . . . . . . . . . . . . WP 0249
OIL/FUEL MANIFOLD REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0250
Figure 1. Fuel Lines Disconnected., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 2. Front of Oil/Fuel Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 3. Rear of Oil/Fuel Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 4. Oil/Fuel Manifold and Gasket., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0250
Figure 5. Oil/Fuel Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 6. Oil/Fuel Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 7. Oil/Fuel Manifold and Gasket., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0250
Figure 8. Oil/Fuel Manifold Bolt Torque Sequence., Vol 3. . . . . . . . . . . . . . . WP 0250
Figure 9. Rear Oil/Fuel Manifold Plug., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 10. Front of Oil/Fuel Manifold., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0250
Figure 11. Connect Fuel lines., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0250
FUEL PRESSURE REGULATOR REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . WP 0251
Figure 1. Fuel Pressure Regulator Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0251
Figure 2. Fuel Pressure Regulator Disassembly., Vol 3 . . . . . . . . . . . . . . . WP 0251
Figure 3. Fuel Pressure Regulator Assembly., Vol 3 . . . . . . . . . . . . . . . . . WP 0251
Figure 4. Fuel Pressure Regulator Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0251
HIGH-PRESSURE INJECTOR PUMP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0252
Figure 1. Engine Oil Temperature Sensor Removal., Vol 3 . . . . . . . . . . . . . . WP 0252
Figure 2. High-Pressure Injector Pump., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0252
Figure 5. High-Pressure Injector Pump Lines and Connector., Vol 3 . . . . . . . . . . WP 0252
Figure 6. Adding Engine Oil to Pump Reservoir., Vol 3 . . . . . . . . . . . . . . . . WP 0252
Figure 7. Engine Oil Pressure Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0252
FUEL PUMP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0253
Figure 1. Fuel Inlet Line Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0253
Figure 2. Fuel Filter Header Supply Line Removal., Vol 3 . . . . . . . . . . . . . . WP 0253
Figure 3. Fuel Pump Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0253
Figure 4. Fuel Pump Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0253
Figure 5. Fuel Filter Header Supply Line Installation., Vol 3. . . . . . . . . . . . . . WP 0253
Figure 6. Fuel Inlet Line Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0253
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WP Sequence No.
FUEL FILTER HEADER/PRIMER PUMP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0254
Figure 1. Fuel Line Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0254
Figure 2. Fuel Filter Header Assembly and Lines., Vol 3 . . . . . . . . . . . . . . . WP 0254
Figure 3. Fuel Filter Header Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0254
Figure 4. Fuel Filter Header Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0254
Figure 5. Fuel Filter Header Assembly and Lines., Vol 3 . . . . . . . . . . . . . . . WP 0254
Figure 6. Fuel Line Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0254
FUEL PRIMER SEQUENCE, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0255
Figure 1. Fuel Bleed Valve., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0255
AIR INTAKE TUBE (TO TURBO) REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0256
Figure 1. Air Intake Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0256
Figure 2. Right Side Air Intake Tube., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0256
Figure 3. Right Side Air Intake Tube., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0256
Figure 4. Air Intake Tube., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0256
AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . WP 0257
Figure 1. Air Cleaner Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0257
Figure 2. Air Cleaner Assembly Side View., Vol 3 . . . . . . . . . . . . . . . . . . WP 0257
Figure 3. Air Filters., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0257
Figure 4. Air Filters., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0257
Figure 5. Air Cleaner Assembly Side View., Vol 3 . . . . . . . . . . . . . . . . . . WP 0257
Figure 6. Air Cleaner Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0257
Figure 7. Air Filter Restriction Gauge., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0257
AIR CLEANER SUPPORT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . WP 0258
Figure 1. Air Cleaner Support., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0258
AIR FILTER RESTRICTION GAUGE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0259
Figure 1. Air Filter Restriction Gauge Viewed From Behind Instrument Panel., Vol 3. . . WP 0259
Figure 3. Air Filter Restriction Gauge Viewed From Behind Instrument Panel., Vol 3. . . WP 0259
CENTER PANEL AIR FILTER RESTRICTION GAUGE TUBING AND FITTING REMOVAL AND
INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 1. Air Line Union., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 2. Firewall Grommet., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 3. IP Center Trim Panel., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 4. Air Filter Restriction Gauge Connection., Vol 3 . . . . . . . . . . . . . . . WP 0260
Figure 5. IP Harness, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 6. IP Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 7. Air Filter Restriction Gauge Connection., Vol 3 . . . . . . . . . . . . . . . WP 0260
Figure 9. Firewall Grommet., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
Figure 10. Air Line Union., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260
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TM 9-2355-106-23-1

Page No.
WP Sequence No.
TURBOCHARGER ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0261
Figure 1. Turbocharger Hose Connections., Vol 3 . . . . . . . . . . . . . . . . . . WP 0261
Figure 2. Turbocharger Flange Nut., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0261
Figure 4. Turbocharger Mounting., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0261
Figure 5. Turbocharger Mounting., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0261
Figure 8. Turbocharger Hose Connections., Vol 3 . . . . . . . . . . . . . . . . . . WP 0261
TURBOCHARGER LUBRICANT LINES REMOVAL AND INSTALLATION, Vol 3. . . . . . . . WP 0262
Figure 1. Turbocharger Lubricant Supply Line Connection., Vol 3 . . . . . . . . . . . WP 0262
Figure 2. Turbocharger Lubricant Supply Line Connection., Vol 3 . . . . . . . . . . . WP 0262
Figure 3. Turbocharger Lubricant Supply Line Flange Gasket., Vol 3. . . . . . . . . . WP 0262
Figure 4. Turbocharger Oil Fitting., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0262
Figure 5. Turbocharger Oil Fitting O-Rings., Vol 3 . . . . . . . . . . . . . . . . . . WP 0262
Figure 6. Turbocharger Lubricant Drain Tube Connection., Vol 3 . . . . . . . . . . . WP 0262
Figure 8. Turbocharger Lubricant Drain Tube Flange Gasket., Vol 3 . . . . . . . . . . WP 0262
Figure 9. Turbocharger Lubricant Drain Tube Flange., Vol 3 . . . . . . . . . . . . . WP 0262
Figure 10. Turbocharger Lubricant Drain Tube O-Rings., Vol 3 . . . . . . . . . . . . WP 0262
Figure 11. Turbocharger Lubricant Drain Tube O-Rings., Vol 3 . . . . . . . . . . . . WP 0262
Figure 12. Turbocharger Lubricant Drain Tube Flange., Vol 3 . . . . . . . . . . . . . WP 0262
Figure 13. Turbocharger Lubricant Drain Tube Flange Gasket., Vol 3 . . . . . . . . . WP 0262
Figure 16. Turbocharger Oil Fitting O-Rings., Vol 3 . . . . . . . . . . . . . . . . . WP 0262
Figure 17. Turbocharger Oil Fitting., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0262
Figure 18. Turbocharger Lubricant Supply Line Flange Gasket., Vol 3 . . . . . . . . . WP 0262
Figure 19. Turbocharger Lubricant Supply Line Connection., Vol 3 . . . . . . . . . . WP 0262
Figure 20. Turbocharger Lubricant Supply Line Connection., Vol 3 . . . . . . . . . . WP 0262
CHARGE AIR COOLER (CAC) ASSEMBLY REMOVAL AND INSTALLATION, Vol 3. . . . . . WP 0263
Figure 1. CAC Pipes and Hoses., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0263
Figure 2. Left Side CAC Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0263
Figure 3. Right Side CAC Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0263
Figure 4. Radiator and CAC Assembly., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0263
Figure 5. Radiator and CAC Assembly., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0263
Figure 6. Right Side CAC Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0263
Figure 7. Left Side CAC Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0263
Figure 8. CAC Pipes and Hoses., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0263
CHARGE AIR COOLER (CAC) HOSE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0264
Figure 1. Charge Air Cooler Pipes and Hoses., Vol 3 . . . . . . . . . . . . . . . . WP 0264
Figure 2. Clamps., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0264
Figure 3. Charge Air Cooler Pipes and Hoses., Vol 3 . . . . . . . . . . . . . . . . WP 0264
lxv
TM 9-2355-106-23-1

Page No.
WP Sequence No.
FUEL TANK REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 1. Fuel Tank Cap., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 2. Fuel Tank Drain Plug., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 3. Fuel-Fired Heater Fuel Pump Fuel Line., Vol 3 . . . . . . . . . . . . . . . WP 0265
Figure 4. Fuel Level Sensor Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 5. Fuel Tank Feed and Return Lines., Vol 3 . . . . . . . . . . . . . . . . . WP 0265
Figure 6. Fuel Tank Mounting Straps., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 7. Fuel Tank Strap Linings., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 8. Fuel-Fired Heater Fuel Tank Outlet., Vol 3 . . . . . . . . . . . . . . . . . WP 0265
Figure 9. Fuel Tank Level Sender, Feed, Vent, and Return Line Connections., Vol 3 . . . WP 0265
Figure 10. Fuel Tank Anti-Siphon Screen., Vol 3 . . . . . . . . . . . . . . . . . . WP 0265
Figure 11. Fuel Tank Anti-Siphon Screen., Vol 3 . . . . . . . . . . . . . . . . . . WP 0265
Figure 12. Fuel Tank Level Sender, Feed, Vent, and Return Line Connections., Vol 3 . . WP 0265
Figure 13. Fuel-Fired Heater Fuel Tank Outlet., Vol 3 . . . . . . . . . . . . . . . . WP 0265
Figure 14. Fuel Tank Strap Linings., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 15. Fuel Tank Mounting Straps., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0265
Figure 16. Fuel Tank Feed and Return Lines., Vol 3 . . . . . . . . . . . . . . . . . WP 0265
Figure 17. Fuel Level Sensor Harness., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0265
Figure 18. Fuel-Fired Heater Fuel Pump Fuel Line., Vol 3 . . . . . . . . . . . . . . WP 0265
Figure 19. Fuel Tank Cap., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0265
FUEL TANK BRACKET REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0266
Figure 1. Fuel-Fired Heater Fuel Pump., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0266
Figure 2. Harness Mounting Strap., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0266
Figure 3. Fuel Tank Support., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0266
Figure 4. Fuel Tank Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0266
Figure 5. Fuel Tank Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0266
Figure 6. Fuel Tank Support., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0266
Figure 7. Harness Mounting Strap., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0266
FUEL TANK STRAP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0267
Figure 1. Fuel Tank Mounting Strap Cotter Pins., Vol 3. . . . . . . . . . . . . . . . WP 0267
Figure 2. Fuel Tank Mounting Strap Pins., Vol 3. . . . . . . . . . . . . . . . . . . WP 0267
FUEL HOSE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0268
Figure 1. Fuel Tank Draw and Return Line Hoses., Vol 3 . . . . . . . . . . . . . . . WP 0268
Figure 2. Fuel Hose Cushioned Clamp., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0268
Figure 3. Fuel Hose Retainer., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 4. Fuel Pump Fuel Hose Feed Line., Vol 3 . . . . . . . . . . . . . . . . . . WP 0268
Figure 5. Fuel Rail Fuel Hose Return Line., Vol 3 . . . . . . . . . . . . . . . . . . WP 0268
Figure 6. Fuel Hose Retainers., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 7. Fuel Hose Routing., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 8. Fuel Hose Retainers., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 9. Fuel Filter Separator Fuel Hoses., Vol 3 . . . . . . . . . . . . . . . . . . WP 0268
Figure 10. Fuel Filter Separator Fuel Hoses., Vol 3 . . . . . . . . . . . . . . . . . WP 0268
Figure 11. Fuel Hose Retainers., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 12. Fuel Hose Routing., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 13. Fuel Hose Retainers., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 14. Fuel Pump Fuel Hose Feed Line., Vol 3 . . . . . . . . . . . . . . . . . WP 0268
Figure 15. Fuel Rail Fuel Hose Return Line., Vol 3 . . . . . . . . . . . . . . . . . WP 0268
Figure 16. Fuel Hose Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 17. Fuel Hose Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0268
Figure 18. Fuel Tank Draw and Return Line Hoses., Vol 3 . . . . . . . . . . . . . . WP 0268
lxvi
TM 9-2355-106-23-1

Page No.
WP Sequence No.
FUEL FILTER AND STRAINER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0269
Figure 1. Fuel Filter and Strainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0269
Figure 2. Fuel Strainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0269
Figure 3. Fuel Filter and Strainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0269
FUEL/WATER SEPARATOR FILTER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0270
Figure 1. Fuel/Water Separator Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0270
Figure 2. Fuel/Water Separator Filter., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0270
FUEL/WATER SEPARATOR ASSEMBLY PURGE, REMOVAL, AND INSTALLATION, Vol 3. . . WP 0271
Figure 1. Purging Sediment Bowl., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0271
Figure 2. Fuel/Water Separator Assembly Connections., Vol 3 . . . . . . . . . . . . WP 0271
Figure 3. Fuel/Water Separator Assembly., Vol 3 . . . . . . . . . . . . . . . . . . WP 0271
Figure 4. Fuel/Water Separator Assembly Mounting Bracket., Vol 3 . . . . . . . . . . WP 0271
Figure 5. Fuel/Water Separator Assembly Mounting Bracket., Vol 3 . . . . . . . . . . WP 0271
Figure 7. Fuel/Water Separator Assembly Connections., Vol 3 . . . . . . . . . . . . WP 0271
ETHER (COLD) START VALVE AND ATOMIZER ASSEMBLY REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0272
Figure 1. Electrical Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0272
Figure 2. Ether (Cold) Start Valve Tubing., Vol 3 . . . . . . . . . . . . . . . . . . WP 0272
Figure 3. Ether (Cold) Start Valve Tubing and Atomizer Jet Assembly., Vol 3 . . . . . . WP 0272
Figure 4. Ether (Cold) Start Valve Assembly., Vol 3 . . . . . . . . . . . . . . . . . WP 0272
Figure 5. Ether (Cold) Start Valve Assembly Bracket., Vol 3 . . . . . . . . . . . . . WP 0272
Figure 6. Ether (Cold) Start Valve Frame Bracket., Vol 3 . . . . . . . . . . . . . . . WP 0272
Figure 7. Ether (Cold) Start Valve Frame Bracket., Vol 3 . . . . . . . . . . . . . . . WP 0272
Figure 8. Ether (Cold) Start Valve Assembly Bracket., Vol 3 . . . . . . . . . . . . . WP 0272
Figure 9. Ether (Cold) Start Valve Assembly., Vol 3 . . . . . . . . . . . . . . . . . WP 0272
Figure 10. Ether (Cold) Start Valve Tubing and Atomizer Jet Assembly., Vol 3 . . . . . WP 0272
Figure 11. Ether (Cold) Start Valve Tubing., Vol 3 . . . . . . . . . . . . . . . . . . WP 0272
Figure 12. Electrical Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0272
ETHER CANISTER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0273
Figure 1. Ether Canister., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0273
Figure 2. Ether Canister., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0273
ETHER COLD START THERMOSTATIC SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . WP 0274
Figure 1. Ether Cold Start Thermostatic Switch., Vol 3 . . . . . . . . . . . . . . . . WP 0274
Figure 2. Ether Cold Start Thermostatic Switch., Vol 3 . . . . . . . . . . . . . . . . WP 0274
EXHAUST PIPE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . WP 0275
Figure 1. Rear Exhaust Pipe Clamps., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0275
Figure 2. Rear Exhaust Pipe Hanger., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0275
Figure 3. Front Exhaust Pipe Clamps., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0275
Figure 4. Front Exhaust Pipe Mounting., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0275
Figure 5. Rear Exhaust Mounting Clamps., Vol 3 . . . . . . . . . . . . . . . . . . WP 0275
Figure 6. Rear Exhaust Hanger., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0275
Figure 7. Rear Exhaust Pipe Mounting., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0275
MUFFLER AND SHIELD REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0276
Figure 1. Tailpipe Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0276
Figure 2. Muffler and Tailpipe Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0276
Figure 3. Muffler Holding Strap., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0276
Figure 4. Muffler Holding Strap., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0276
Figure 5. Muffler and Tailpipe Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0276
Figure 6. Tail Pipe Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0276
lxvii
TM 9-2355-106-23-1

Page No.
WP Sequence No.
COOLING SYSTEM DRAIN AND FILL, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 3. Right Side of Deaeration Tank., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0277
Figure 4. Radiator Coolant Surge Overflow Tank., Vol 3 . . . . . . . . . . . . . . . WP 0277
Figure 5. Radiator — Left Side., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 7. Coolant Hoses Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 8. Coolant Hoses Installation., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 12. Radiator Drain Valve., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 13. Air Bleed Valve Opened., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 14. Right Side of Deaeration Tank., Vol 3 . . . . . . . . . . . . . . . . . . WP 0277
Figure 15. Brown Wire Disconnected., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 16. Battery Door., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 17. Jumper Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 18. Brown Wire Connected., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0277
Figure 20. Radiator Coolant Surge Overflow Tank., Vol 3. . . . . . . . . . . . . . . WP 0277
RADIATOR REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 1. Radiator Hose Connections., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 2. Transmission Cooling Lines at Radiator., Vol 3 . . . . . . . . . . . . . . . WP 0278
Figure 3. Radiator Ground Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 4. Radiator Side Support., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 5. Upper Left Rear Radiator Support Frame., Vol 3 . . . . . . . . . . . . . . WP 0278
Figure 6. Radiator Stay Rods., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 7. Lower Left Rear Radiator Support Frame., Vol 3 . . . . . . . . . . . . . . WP 0278
Figure 8. Right Side Radiator., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 9. Lower Radiator Stay Rod End., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0278
Figure 10. Radiator Hose Support Bracket., Vol 3 . . . . . . . . . . . . . . . . . . WP 0278
Figure 11. Frame Crossmember Bracket Bolts., Vol 3 . . . . . . . . . . . . . . . . WP 0278
Figure 12. Lower Radiator Support Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0278
Figure 13. Transmission Cooling Line Fittings and Drain Valve., Vol 3 . . . . . . . . . WP 0278
Figure 14. Lower Radiator Support Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0278
Figure 15. Frame Crossmember Bracket Bolts., Vol 3 . . . . . . . . . . . . . . . . WP 0278
Figure 16. Radiator Hose Support Bracket., Vol 3 . . . . . . . . . . . . . . . . . . WP 0278
Figure 17. Radiator Stay Rod Lower End., Vol 3 . . . . . . . . . . . . . . . . . . WP 0278
Figure 18. Lower Left Rear Radiator Support Frame., Vol 3 . . . . . . . . . . . . . WP 0278
Figure 19. Right Side Radiator., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 20. Radiator Stay Rods., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 21. Upper Left Rear Radiator Support Frame., Vol 3 . . . . . . . . . . . . . WP 0278
Figure 22. Side Radiator Support., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 23. Radiator Ground Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0278
Figure 24. Transmission Cooling Lines at Radiator., Vol 3 . . . . . . . . . . . . . . WP 0278
Figure 25. Radiator Hose Connections., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0278
DEAERATION TANK REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0279
Figure 1. Left Side of Deaeration Tank., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0279
Figure 3. Left Side of Deaeration Tank., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0279
lxviii
TM 9-2355-106-23-1

Page No.
WP Sequence No.
DEAERATION TANK PRESSURE CAP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0280
RADIATOR SURGE OVERFLOW TANK REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0281
Figure 1. Bottom of Surge Overflow Tank., Vol 3 . . . . . . . . . . . . . . . . . . WP 0281
Figure 2. Upper Surge Overflow Tank., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0281
Figure 3. Bottom of Surge Overflow Tank., Vol 3 . . . . . . . . . . . . . . . . . . WP 0281
Figure 4. Upper Surge Overflow Tank., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0281
RADIATOR FAN AND FAN SHROUD REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0282
Figure 1. Right Fan Shroud Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0282
Figure 2. View of Engine Compartment from Above., Vol 3 . . . . . . . . . . . . . . WP 0282
Figure 3. View of Engine Compartment from Above., Vol 3 . . . . . . . . . . . . . . WP 0282
Figure 4. Right Fan Shroud Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0282
THERMOSTAT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . WP 0283
Figure 1. Inlet Radiator Pipe Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0283
Figure 2. Thermostat and Inlet Radiator Pipe., Vol 3 . . . . . . . . . . . . . . . . . WP 0283
Figure 3. Thermostat Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0283
Figure 4. Thermostat Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0283
Figure 5. Thermostat and Inlet Radiator Pipe., Vol 3 . . . . . . . . . . . . . . . . . WP 0283
Figure 6. Inlet Radiator Pipe Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0283
WATER INLET ELBOW REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0284
Figure 1. Inlet Hose Lower Elbow Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0284
Figure 2. Water Inlet Elbow Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0284
Figure 3. Water Inlet Elbow Gasket., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0284
Figure 4. Water Inlet Elbow Engine Mount., Vol 3 . . . . . . . . . . . . . . . . . . WP 0284
Figure 5. Water Inlet Elbow., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0284
Figure 6. Water Inlet Elbow Gasket Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0284
Figure 7. Water Inlet Elbow Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0284
Figure 8. Inlet Hose Lower Elbow Installation., Vol 3. . . . . . . . . . . . . . . . . WP 0284
RADIATOR PIPES/HOSES REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . WP 0285
Figure 1. Radiator Pipes/Hoses., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0285
Figure 2. Radiator Pipes/Hoses., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0285
ENGINE WATER PUMP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0286
Figure 1. Water Pump and Pulley Assembly., Vol 3 . . . . . . . . . . . . . . . . . WP 0286
Figure 2. Water Pump and Pulley Assembly., Vol 3 . . . . . . . . . . . . . . . . . WP 0286
COOLING FAN DRIVE ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0287
Figure 2. Top of A/C Compressor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0287
Figure 3. A/C Compressor Bracket Bolts., Vol 3. . . . . . . . . . . . . . . . . . . WP 0287
Figure 4. Front of Fan Drive Assembly., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0287
Figure 5. Front of Fan Drive Assembly., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0287
Figure 6. A/C Compressor Bracket Bolts., Vol 3. . . . . . . . . . . . . . . . . . . WP 0287
Figure 8. Top of A/C Compressor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0287
COOLING FAN ACTUATOR SOLENOID REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0288
Figure 1. Fan Actuator Solenoid., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0288
Figure 2. Cooling Fan Solenoid., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0288
Figure 4. Fan Actuator Solenoid., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0288
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WP Sequence No.
ALTERNATOR REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . . . . . . WP 0289
Figure 1. Sensor Wiring Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0289
Figure 2. Alternator Positive Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0289
Figure 3. Alternator Negative Cable Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0289
Figure 4. Alternator Mounting Bolt Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0289
Figure 5. Alternator Mounting Bolt Installation, Vol 3 . . . . . . . . . . . . . . . . . WP 0289
Figure 6. Alternator Negative Cable Installation, Vol 3 . . . . . . . . . . . . . . . . WP 0289
Figure 7. Alternator Positive Cable Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0289
Figure 8. Sensor Wiring Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0289
ALTERNATOR BRACKET REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . WP 0290
Figure 1. Fuel/Water Separator Hose Bracket Mounting Bolt., Vol 3 . . . . . . . . . . WP 0290
Figure 2. Alternator Bracket and Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0290
Figure 3. Alternator Bracket Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0290
Figure 4. Alternator Bracket Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0290
Figure 5. Alternator Bracket and Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0290
Figure 6. Fuel/Water Separator Hose Bracket Mounting Bolt., Vol 3 . . . . . . . . . . WP 0290
ALTERNATOR PULLEY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0291
Figure 1. Alternator Pulley Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0291
Figure 2. Alternator Shaft., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0291
Figure 3. Alternator Pulley Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0291
STARTER MOTOR REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . . . . WP 0292
Figure 1. Starter Ground Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0292
Figure 2. Solenoid Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292
Figure 3. Helper Solenoid Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0292
Figure 4. Starter Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292
Figure 5. Helper Solenoid Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0292
Figure 6. Starter Bolts., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292
Figure 8. Starter Ground Cable Installation., Vol 3. . . . . . . . . . . . . . . . . . WP 0292
TRANSMISSION FLUID TEMPERATURE GAUGE AND HARNESS REMOVAL AND
Figure 1. Instrument Panel Cluster Back Cover Removal., Vol 3 . . . . . . . . . . . WP 0293
Figure 2. Transmission Fluid Temperature Gauge and Harness., Vol 3 . . . . . . . . . WP 0293
Figure 3. Transmission Fluid Temperature Gauge Removal., Vol 3 . . . . . . . . . . WP 0293
Figure 4. Transmission Fluid Temperature Gauge Removal., Vol 3 . . . . . . . . . . WP 0293
Figure 5. Transmission Fluid Temperature Gauge Installation., Vol 3. . . . . . . . . . WP 0293
Figure 6. Transmission Fluid Temperature Gauge Harness., Vol 3 . . . . . . . . . . . WP 0293
Figure 7. Instrument Panel Cluster Back Cover Installation., Vol 3 . . . . . . . . . . . WP 0293
AIR 1 PRESSURE GAUGE AND HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0294
Figure 2. Air 1 Pressure Gauge and Harness Removal., Vol 3 . . . . . . . . . . . . WP 0294
Figure 3. Air 1 Pressure Gauge Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0294
AIR 2 PRESSURE GAUGE AND HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0295
Figure 2. Air 2 Pressure Gauge and Harness., Vol 3. . . . . . . . . . . . . . . . . WP 0295
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MAIN POWER SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0296
Figure 1. MAIN POWER Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0296
Figure 2. MAIN POWER Switch Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0296
Figure 3. MAIN POWER Switch Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0296
Figure 4. MAIN POWER Switch Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0296
INSTRUMENT PANEL CLUSTER (IPC) REMOVAL AND INSTALLATION, Vol 3. . . . . . . . WP 0297
Figure 1. IP Cluster Mounting Screws., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0297
Figure 2. IP Cluster Harness Connections., Vol 3 . . . . . . . . . . . . . . . . . . WP 0297
Figure 3. Front View IP Cluster., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0297
Figure 6. IP Cluster., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0297
INSTRUMENT PANEL CLUSTER (IPC) RIGHT SIDE WARNING PANEL REMOVAL AND
Figure 1. Right Side Warning Panel Assembly., Vol 3 . . . . . . . . . . . . . . . . WP 0298
Figure 2. Right Side Warning Panel Assembly., Vol 3 . . . . . . . . . . . . . . . . WP 0298
INSTRUMENT PANEL (IP) LIGHT BULB REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0299
Figure 1. Warning Light Bulb Removal., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0299
Figure 3. Serviceable Gauge Bulb Identification., Vol 3 . . . . . . . . . . . . . . . WP 0299
Figure 4. Right Side Warning Panel Bulb Installation., Vol 3 . . . . . . . . . . . . . WP 0299
Figure 5. Warning Light Bulb Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0299
Figure 6. Bulb Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0299
ETHER COLD START THERMOSTATIC SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . WP 0300
Figure 1. Ether Start Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0300
Figure 2. Ether Start Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0300
ROCKER SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . WP 0301
Figure 1. Rocker Switch Panel Assembly Removal., Vol 3 . . . . . . . . . . . . . . WP 0301
Figure 2. Rocker Switch Retainers., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0301
Figure 3. Rocker Switch Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0301
Figure 4. Rocker Switch Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0301
Figure 5. Rocker Switch Panel Assembly Installation., Vol 3 . . . . . . . . . . . . . WP 0301
KEYLESS IGNITION SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0302
Figure 1. Keyless Ignition Switch Cover., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0302
Figure 2. Keyless Ignition Switch Nut., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0302
Figure 3. Keyless Ignition Switch Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0302
Figure 4. Keyless Ignition Switch Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0302
Figure 5. Keyless Ignition Switch Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0302
Figure 6. Keyless Ignition Switch Cover., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0302
MASTER VEHICLE LIGHT SWITCH (MVLS) REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0303
Figure 2. MVLS Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0303
24V GAUGE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0304
Figure 1. 24V Gauge Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0304
Figure 2. 24V Gauge Front., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0304
Figure 3. 24V Gauge Front., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0304
Figure 4. 24V Gauge Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0304
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24V GAUGE BULB REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . . . . WP 0305
Figure 1. 24V Gauge Bulb Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0305
Figure 2. 24V Gauge Bulb Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0305
MIRROR REMOTE CONTROL SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0306
Figure 1. Mirror Remote Control Switch., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0306
Figure 2. Mirror Switch Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0306
MASTER VEHICLE LIGHT SWITCH (MVLS) GROUND HARNESS REMOVAL AND
Figure 1. Instrument Panel Center Trim Panel., Vol 3 . . . . . . . . . . . . . . . . WP 0307
Figure 2. MVLS Ground Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0307
Figure 3. MVLS Ground Wire Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0307
Figure 4. MVLS Ground Wire Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0307
Figure 5. MVLS Ground Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0307
INFRARED (IR) LIGHT SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0308
Figure 1. IR Control Switch in IP Center Trim Panel., Vol 3 . . . . . . . . . . . . . . WP 0308
Figure 2. IR Control Switch in IP Center Trim Panel., Vol 3 . . . . . . . . . . . . . . WP 0308
MASTER REAR DOOR/RAMP SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0309
Figure 1. Master Rear Door/Ramp Switch Removal., Vol 3 . . . . . . . . . . . . . . WP 0309
Figure 2. Master Rear Door/Ramp Switch Connector., Vol 3 . . . . . . . . . . . . . WP 0309
Figure 3. Master Rear Door/Ramp Switch Installation., Vol 3 . . . . . . . . . . . . . WP 0309
Figure 4. Master Rear Door/Ramp Switch Connector., Vol 3 . . . . . . . . . . . . . WP 0309
MASTER REAR DOOR/RAMP SWITCH JUMPER HARNESS REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0310
Figure 2. IP Center Panel., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0310
MASTER CREW LIGHT SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . WP 0311
Figure 1. Master Crew Light Switch Removal., Vol 3. . . . . . . . . . . . . . . . . WP 0311
Figure 2. Master Crew Light Switch Connector., Vol 3 . . . . . . . . . . . . . . . . WP 0311
Figure 3. Master Crew Light Switch Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0311
Figure 4. Master Crew Light Switch Connector., Vol 3 . . . . . . . . . . . . . . . . WP 0311
MASTER CREW LIGHT SWITCH JUMPER HARNESS REMOVAL AND INSTALLATION, Vol 3 . WP 0312
Figure 1. Master Crew Light Switch Removal., Vol 3. . . . . . . . . . . . . . . . . WP 0312
Figure 4. Master Crew Light Switch Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0312
SPOTLIGHT CONTROL REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0313
Figure 1. Spotlight Control Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0313
Figure 2. Spotlight Control Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0313
Figure 3. Spotlight Control Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0313
Figure 4. Spotlight Control Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0313
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WP Sequence No.
MIRROR REMOTE CONTROL SWITCH WIRING HARNESS REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0314
Figure 1. Door Handle Trim., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0314
Figure 2. Kick Panel Power Mirror Harness Connector., Vol 3. . . . . . . . . . . . . WP 0314
Figure 3. Power Mirror Harness Connector., Vol 3. . . . . . . . . . . . . . . . . . WP 0314
Figure 4. Door Armor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0314
Figure 5. Mirror Mounting Plate., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0314
Figure 6. Mirror Harness., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0314
Figure 10. Power Mirror Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . WP 0314
Figure 11. Kick Panel Power Mirror Harness Connector., Vol 3 . . . . . . . . . . . . WP 0314
ANTILOCK BRAKE SYSTEM (ABS) BLINK CODE SWITCH REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0315
Figure 1. ABS Blink Code Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0315
Figure 2. ABS Blink Code Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0315
CRUISE CONTROL SWITCH MODULE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0316
Figure 1. Cruise Control Switch Module Removal., Vol 3 . . . . . . . . . . . . . . . WP 0316
Figure 2. Cruise Control Switch Module Wiring., Vol 3 . . . . . . . . . . . . . . . . WP 0316
Figure 3. Cruise Control Switch Module Wiring., Vol 3 . . . . . . . . . . . . . . . . WP 0316
Figure 4. Cruise Control Switch Wire Routing., Vol 3 . . . . . . . . . . . . . . . . WP 0316
Figure 5. Cruise Control Switch Module Installation., Vol 3 . . . . . . . . . . . . . . WP 0316
INSTRUMENT PANEL (IP) CIRCUIT BREAKER, FUSE, AND RELAY REMOVAL AND
Figure 1. IP Circuit Breakers, Fuses, and Relays., Vol 3 . . . . . . . . . . . . . . . WP 0317
Figure 2. Testing for Faulty Fuse., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0317
Figure 3. Testing for Faulty Circuit Breaker., Vol 3 . . . . . . . . . . . . . . . . . . WP 0317
INSTRUMENT PANEL (IP) CENTER RELAY REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0318
Figure 1. Instrument Panel Center Relays., Vol 3 . . . . . . . . . . . . . . . . . . WP 0318
Figure 2. Instrument Panel Center Relays., Vol 3 . . . . . . . . . . . . . . . . . . WP 0318
Table 1. Instrument Panel Center Relay Location., Vol 3 . . . . . . . . . . . . . . . WP 0318
INSTRUMENT PANEL (IP) HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0319
Figure 1. Anti-Lock Brake System (ABS) Control Module Connectors., Vol 3 . . . . . . WP 0319
Figure 2. Ground Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 3. IP Circuit Breaker, Fuse, and Relay Center Removal., Vol 3 . . . . . . . . . WP 0319
Figure 4. Right Side IP Harness Connector Removal., Vol 3 . . . . . . . . . . . . . WP 0319
Figure 5. Center IP Harness Connector Removal., Vol 3 . . . . . . . . . . . . . . . WP 0319
Figure 6. Keyless Switch Connector., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 7. Diagnostic Connector and Ground Leads., Vol 3 . . . . . . . . . . . . . . WP 0319
Figure 8. Electrical System Control (ESC) Module Cover Removal., Vol 3 . . . . . . . WP 0319
Figure 9. ESC Module Connectors., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 10. Stop/Turn Lighting and Drivers Door In-Line Connectors., Vol 3 . . . . . . . WP 0319
Figure 11. Left Heated Windshield Harness., Vol 3 . . . . . . . . . . . . . . . . . WP 0319
Figure 12. Mega-Fuse Ring Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0319
Figure 13. Front of Dash Pass-Through., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0319
Figure 14. Front of Dash Pass-Through Connector. , Vol 3 . . . . . . . . . . . . . . WP 0319
Figure 15. IP Harness Bulkhead Connector. , Vol 3 . . . . . . . . . . . . . . . . . WP 0319
Figure 16. Battery Feed Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0319
Figure 17. Right Side IP Harness Cable Lock Strap Removal., Vol 3. . . . . . . . . . WP 0319
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Figure 20. Left Side IP Harness Cable Lock Strap Removal., Vol 3 . . . . . . . . . . WP 0319
Figure 21. Center IP Harness Cable Lock Strap Removal., Vol 3 . . . . . . . . . . . WP 0319
Figure 22. Center IP Harness Cable Lock Strap Removal., Vol 3 . . . . . . . . . . . WP 0319
Figure 23. Center IP Harness Cable Lock Strap Installation., Vol 3 . . . . . . . . . . WP 0319
Figure 24. Center IP Harness Cable Lock Strap Installation., Vol 3 . . . . . . . . . . WP 0319
Figure 25. Left Side IP Harness Cable Lock Strap Installation., Vol 3 . . . . . . . . . WP 0319
Figure 26. Right Side IP Harness Cable Lock Strap Installation., Vol 3 . . . . . . . . . WP 0319
Figure 29. Battery Feed Cable Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0319
Figure 30. IP Harness Bulkhead Connector. , Vol 3 . . . . . . . . . . . . . . . . . WP 0319
Figure 31. Front of Dash Pass-Through Connector. , Vol 3 . . . . . . . . . . . . . . WP 0319
Figure 32. Front of Dash Pass-Through., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0319
Figure 33. Mega-Fuse Ring Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0319
Figure 34. Left Heated Windshield Harness., Vol 3 . . . . . . . . . . . . . . . . . WP 0319
Figure 35. Left Side IP In-Line Connectors., Vol 3 . . . . . . . . . . . . . . . . . . WP 0319
Figure 36. ESC Module Connectors., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 37. ESC Module Cover Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0319
Figure 38. Keyless Switch Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 39. Center IP Harness Connector Installation., Vol 3 . . . . . . . . . . . . . WP 0319
Figure 40. Right Side IP Harness Connector Installation., Vol 3 . . . . . . . . . . . . WP 0319
Figure 41. IP Circuit Breaker, Fuse, and Relay Center Installation., Vol 3 . . . . . . . . WP 0319
Figure 42. Ground Cable Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0319
Figure 43. ABS Control Module Connectors., Vol 3 . . . . . . . . . . . . . . . . . WP 0319
INSTRUMENT PANEL (IP) HARNESS TERMINATING RESISTOR REMOVAL AND
Figure 1. IP Harness Terminating Resistor Removal., Vol 3. . . . . . . . . . . . . . WP 0320
Figure 2. IP Harness Terminating Resistor Installation., Vol 3 . . . . . . . . . . . . . WP 0320
CABIN ELECTRICAL GROUND STUD PLATE REMOVAL AND INSTALLATION, Vol 3. . . . . WP 0321
Figure 1. Cabin Interior Instrument Panel (IP)Harness Ground Connections., Vol 3 . . . WP 0321
Figure 2. Cabin Exterior Harness Ground Connections., Vol 3 . . . . . . . . . . . . WP 0321
Figure 3. Exterior Ground Studs And Washers., Vol 3 . . . . . . . . . . . . . . . . WP 0321
Figure 4. Cabin Interior Electrical Ground Stud Plate. , Vol 3 . . . . . . . . . . . . . WP 0321
Figure 5. Cabin Interior Electrical Ground Stud Plate. , Vol 3 . . . . . . . . . . . . . WP 0321
Figure 6. Exterior Ground Studs And Washers., Vol 3 . . . . . . . . . . . . . . . . WP 0321
Figure 7. Cabin Exterior Harness Ground Connections., Vol 3 . . . . . . . . . . . . WP 0321
Figure 8. Cabin Interior IP Harness Ground Connections., Vol 3 . . . . . . . . . . . WP 0321
AIR GAUGE TRANSDUCER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0322
Figure 1. Air Gauge Transducers., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0322
Figure 2. Air Gauge Transducers., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0322
MULTIFUNCTION TURN SIGNAL SWITCH ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 WP 0323
Figure 1. Multifunction Turn Signal Switch Assembly., Vol 3 . . . . . . . . . . . . . WP 0323
Figure 2. Multifunction Turn Signal Switch Assembly., Vol 3 . . . . . . . . . . . . . WP 0323
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STEERING COLUMN WIRING HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . WP 0324
Figure 1. Steering Column Connectors., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0324
Figure 2. Accelerator Pedal Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0324
Figure 3. Stop Light Switch Connector., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0324
Figure 4. Transducers and IP Harness Connectors., Vol 3 . . . . . . . . . . . . . . WP 0324
Figure 5. Barometric Pressure Sensor (BAP) Connector., Vol 3 . . . . . . . . . . . . WP 0324
Figure 6. BAP Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0324
Figure 7. Transducers and IP Harness Connectors., Vol 3 . . . . . . . . . . . . . . WP 0324
Figure 8. Stop Light Switch Connector., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0324
Figure 9. Accelerator Pedal Connector., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0324
Figure 10. Steering Column Connectors., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0324
STEERING WHEEL WIRE HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0325
Figure 1. Wiring Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0325
Figure 2. Steering Wheel Switches and Wiring Harness., Vol 3 . . . . . . . . . . . . WP 0325
Figure 3. Steering Wheel Switches and Wiring Harness., Vol 3 . . . . . . . . . . . . WP 0325
Figure 4. Cruise Control Switch Wire Routing. , Vol 3 . . . . . . . . . . . . . . . . WP 0325
Figure 5. Cruise Control Switch Module Installation., Vol 3 . . . . . . . . . . . . . . WP 0325
BRAKE STOPLIGHT SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0326
Figure 1. Stoplight Switch., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0326
PARKING BRAKE LAMP TRANSDUCER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0327
Figure 1. Parking Brake Lamp Transducer., Vol 3 . . . . . . . . . . . . . . . . . . WP 0327
110V COVER, OUTLET, AND BOX REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . WP 0328
Figure 1. 110V Outlet Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0328
Figure 3. 110V Outlet Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0328
Figure 5. 110V Outlet Wire Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0328
Figure 6. 110V Outlet Wire Retainer., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0328
Figure 8. 110V Outlet Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0328
Figure 10. 110V Outlet Cover., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . WP 0328
ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0329
Figure 1. Electrical Connector Cover Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0329
Figure 2. Wiring Harness Electrical Connector Removal., Vol 3 . . . . . . . . . . . . WP 0329
Figure 3. ECM Bracket Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0329
Figure 4. ECM Bracket Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0329
Figure 5. Wiring Harness Electrical Connector Installation., Vol 3 . . . . . . . . . . . WP 0329
Figure 6. Electrical Connector Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0329
ENGINE SENSOR WIRING HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0330
Figure 1. Engine Wiring Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 2. Left Side View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 3. Top View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 4. Front View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 5. Left Side View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 6. Top View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 7. Front View of Engine., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0330
Figure 8. Engine Wiring Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0330
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FUEL INJECTOR HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0331
Figure 1. Fuel Injector Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0331
Figure 2. Fuel Injector Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0331
AIR CONDITIONING (A/C) CONDENSER FAN MOTOR RELAY REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0332
Figure 1. A/C Condenser Fan Motor Relays., Vol 3 . . . . . . . . . . . . . . . . . WP 0332
Figure 2. A/C Condenser Fan Motor Relays., Vol 3 . . . . . . . . . . . . . . . . . WP 0332
Table 1. A/C Condenser Fan Motor Relay Location., Vol 3 . . . . . . . . . . . . . . WP 0332
POWER DISTRIBUTION CENTER (PDC) FUSE AND RELAY REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0333
Figure 1. PDC Armor Plate., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0333
Figure 2. PDC Cover Cable Lock Strap., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0333
Figure 3. PDC Fuses and Relays., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0333
Figure 5. PDC Fuses and Relays., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0333
Figure 6. PDC Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0333
POWER DISTRIBUTION CENTER (PDC) JUNCTION BOX REMOVAL AND INSTALLATION, Vol 3WP 0334
Figure 4. PDC Junction Door and Junction Box., Vol 3 . . . . . . . . . . . . . . . . WP 0334
Figure 5. PDC Junction Box and Junction Door., Vol 3 . . . . . . . . . . . . . . . . WP 0334
POWER DISTRIBUTION CENTER (PDC) HARNESS REMOVAL AND INSTALLATION, Vol 3 . WP 0335
Figure 1. Washer Bottle Connector and A/C Harness Removal., Vol 3 . . . . . . . . . WP 0335
Figure 2. A/C Harness Connector Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0335
Figure 3. PDC Harness Breakout Cable Lock Strap Removal., Vol 3. . . . . . . . . . WP 0335
Figure 4. PDC Harness to Engine Harness Connectors. , Vol 3 . . . . . . . . . . . . WP 0335
Figure 5. PDC Harness Cable Lock Straps and Wiper Motor Harness., Vol 3 . . . . . . WP 0335
Figure 6. PDC Harness to Front Chassis Harness Connectors., Vol 3 . . . . . . . . . WP 0335
Figure 7. PDC Harness to Center Chassis Harness Connectors., Vol 3 . . . . . . . . WP 0335
Figure 8. PDC Harness 12/24V Cable Removal., Vol 3 . . . . . . . . . . . . . . . WP 0335
Figure 9. Front of Dash Pass-Through Connector., Vol 3 . . . . . . . . . . . . . . . WP 0335
Figure 10. Pass-Through Armor Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0335
Figure 11. Ground Wire and Electronic System Controller (ESC) Connector Access
Panel., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0335
Figure 12. ESC Cover Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0335
Figure 13. ESC Connector Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0335
Figure 14. ESC Connector Removal at Bulkhead., Vol 3 . . . . . . . . . . . . . . . WP 0335
Figure 15. ESC Connector Installation at Bulkhead., Vol 3 . . . . . . . . . . . . . . WP 0335
Figure 16. ESC Connector Installation., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0335
Figure 17. ESC Cover Installation., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0335
Figure 18. Ground Wire and ESC Connector Access Panel., Vol 3 . . . . . . . . . . WP 0335
Figure 19. Pass-Through Armor Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0335
Figure 20. Front of Dash Sealer Application., Vol 3 . . . . . . . . . . . . . . . . . WP 0335
Figure 21. Front of Dash Pass-Through Connector., Vol 3 . . . . . . . . . . . . . . WP 0335
Figure 22. PDC Harness 12/24V Cable Installation., Vol 3 . . . . . . . . . . . . . . WP 0335
Figure 23. PDC Harness to Center Chassis Harness Connectors., Vol 3 . . . . . . . . WP 0335
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Figure 24. PDC Harness to Front Chassis Harness Connectors., Vol 3. . . . . . . . . WP 0335
Figure 25. PDC Harness Cable Lock Straps and Wiper Motor Harness., Vol 3 . . . . . WP 0335
Figure 26. PDC Harness to Engine Harness Connectors. , Vol 3 . . . . . . . . . . . WP 0335
Figure 27. PDC Harness Breakout Cable Lock Strap Installation., Vol 3 . . . . . . . . WP 0335
Figure 28. A/C Harness Connector Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0335
Figure 29. Washer Bottle Connector and A/C Harness Installation., Vol 3. . . . . . . . WP 0335
ENGINE WIRING HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0336
Figure 1. Deaeration Tank Low Coolant Sensor., Vol 3 . . . . . . . . . . . . . . . . WP 0336
Figure 2. Alternator and Regulator Positive Cable Connections., Vol 3 . . . . . . . . . WP 0336
Figure 3. Alternator Negative Cable Connections., Vol 3 . . . . . . . . . . . . . . . WP 0336
Figure 4. Engine Wiring Harness-to-Engine Sensor Harness Connection., Vol 3. . . . . WP 0336
Figure 5. Fan Drive Clutch Air Line Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0336
Figure 6. Exhaust Brake Solenoid., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 8. Dash and Vehicle Interface Connectors., Vol 3 . . . . . . . . . . . . . . . WP 0336
Figure 9. ECM/CEC Connector Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 10. 24V Underhood Junction Block., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 11. Cabin Electrical Ground Plate Stud., Vol 3 . . . . . . . . . . . . . . . . WP 0336
Figure 12. Clean Battery Feed and ECM/CEC Clean Power and Ground., Vol 3. . . . . WP 0336
Figure 13. Engine Block Grounds., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 14. Transfer Case Jumper Harness., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 15. Ether Start Thermostat Sensor., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 16. Transmission Control Module (TCM) Cover., Vol 3 . . . . . . . . . . . . . WP 0336
Figure 17. TCM Harness Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 18. Transmission Output Speed Sensor and Transmission Bulkhead Connec-
tor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 19. Transmission Input Speed Sensor., Vol 3 . . . . . . . . . . . . . . . . . WP 0336
Figure 20. Transmission Input Speed Sensor., Vol 3 . . . . . . . . . . . . . . . . . WP 0336
Figure 21. Transmission Output Speed Sensor and Transmission Bulkhead Connec-
tor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 22. TCM Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 23. TCM Cover., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 24. Ether Start Thermostat Sensor., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 25. Transfer Case Jumper Harness., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 26. Engine Block Grounds., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 27. Clean Battery Feed and ECM/CEC Clean Power and Ground., Vol 3. . . . . WP 0336
Figure 28. Cabin Electrical Ground Plate Stud., Vol 3 . . . . . . . . . . . . . . . . WP 0336
Figure 29. 24V Underhood Junction Block., Vol 3 . . . . . . . . . . . . . . . . . . WP 0336
Figure 30. ECM/CEC Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 31. Dash and Vehicle Interface Connectors., Vol 3 . . . . . . . . . . . . . . WP 0336
Figure 32. Cooling Fan Solenoid., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 33. Exhaust Brake Solenoid., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0336
Figure 34. Fan Drive Clutch Air Line Installation., Vol 3 . . . . . . . . . . . . . . . WP 0336
Figure 35. Engine Wiring Harness-to-Engine Sensor Harness Connection., Vol 3 . . . . WP 0336
Figure 36. Alternator Negative Cable Connections., Vol 3 . . . . . . . . . . . . . . WP 0336
Figure 37. Alternator and Regulator Positive Cable Connections., Vol 3 . . . . . . . . WP 0336
Figure 38. Deaeration Tank Low Coolant Sensor., Vol 3 . . . . . . . . . . . . . . . WP 0336
ENGINE WIRING HARNESS TERMINATING RESISTOR REMOVAL AND INSTALLATION, Vol 3 WP 0337
Figure 1. Engine Wiring Harness Terminating Resistor Removal., Vol 3 . . . . . . . . WP 0337
Figure 2. Engine Wiring Harness Terminating Resistor Installation., Vol 3 . . . . . . . WP 0337
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STARTER MOTOR-TO-ENGINE GROUND JUMPER CABLE REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0338
Figure 1. Starter Motor-to-Engine Ground Jumper Cable., Vol 3. . . . . . . . . . . . WP 0338
STARTER MOTOR-TO-FRAME GROUND JUMPER CABLE REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0339
Figure 1. Starter Motor-to-Frame Ground Jumper Cable., Vol 3 . . . . . . . . . . . . WP 0339
ALTERNATOR INTERCONNECT POSITIVE CABLE REMOVAL AND INSTALLATION, Vol 3 . . WP 0340
Figure 1. Harness Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0340
Figure 2. Alternator Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0340
Figure 3. Alternator Cable Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0340
Figure 4. Harness Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0340
12V AND 24V BATTERY DISCONNECT SWITCH SOLENOID REMOVAL AND INSTALLA-
TION, Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0341
Figure 1. 12V and 24V Battery Disconnect Switch Solenoids (Outboard View)
Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0341
Figure 2. 12V and 24V Battery Disconnect Switch Solenoids (Inboard View) Removal., Vol 3WP 0341
Figure 3. 12V and 24V Battery Disconnect Switch Solenoids (Top View) Removal., Vol 3 . WP 0341
Figure 4. 12V and 24V Battery Disconnect Switch Solenoids (Top View) Installation., Vol 3 WP 0341
Figure 5. 12V and 24V Battery Disconnect Switch Solenoids (Inboard View) Installa-
tion., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0341
Figure 6. 12V and 24V Battery Disconnect Switch Solenoids (Outboard View)
Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0341
12V BATTERY DISCONNECT SWITCH SOLENOID FEED CABLE REMOVAL AND
Figure 1. 12V Battery Disconnect Switch Solenoid Feed Cable Removal., Vol 3 . . . . . WP 0342
Figure 2. 12V Battery Disconnect Switch Solenoid Feed Cable Installation., Vol 3 . . . . WP 0342
24V BATTERY DISCONNECT SWITCH SOLENOID FEED CABLE REMOVAL AND
Figure 1. 24V Battery Disconnect Switch Solenoid Feed Cable Removal., Vol 3 . . . . . WP 0343
Figure 2. 24V Battery Disconnect Switch Solenoid Feed Cable Installation., Vol 3 . . . . WP 0343
WINCH MEGAFUSE FEED CABLE REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0344
Figure 1. 300A Megafuse and Holder., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0344
Figure 2. Megafuse Feed Cable., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0344
INVERTER DISCONNECT BATTERY SWITCH SOLENOID HARNESS REMOVAL AND
Figure 1. Inverter Switch Solenoid Wiring., Vol 3 . . . . . . . . . . . . . . . . . . WP 0345
Figure 2. Inverter Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0345
Figure 3. Battery Switch Solenoid., Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0345
Figure 4. Inverter Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0345
Figure 5. Inverter Switch Solenoid Wiring., Vol 3 . . . . . . . . . . . . . . . . . . WP 0345
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12V TO 24V DISCONNECT BATTERY SWITCH SOLENOID FEED HARNESS REMOVAL AND
Figure 1. 12V to 24V Disconnect Battery Switch Solenoid Feed Harness Fastener
Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0346
Figure 2. 12V to 24V Disconnect Battery Switch Solenoid Feed Harness Installation., Vol 3WP 0346
Figure 3. 12V to 24V Disconnect Battery Switch Solenoid Feed Harness Fastener
12V TO 24V DISCONNECT BATTERY SWITCH SOLENOID GROUND HARNESS REMOVAL AND
Figure 1. 12V to 24V Disconnect Battery Switch Solenoid Ground Harness Removal., Vol 3WP 0347
Figure 2. 12V to 24V Disconnect Battery Switch Solenoid Ground Harness Installa-
tion., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0347
24V BODY FEED HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0348
Figure 1. 24V Body Feed Harness Connections at Solenoid., Vol 3 . . . . . . . . . . WP 0348
Figure 2. Harness Routing and Cable Lock Straps., Vol 3 . . . . . . . . . . . . . . WP 0348
Figure 3. 24V Body Feed Harness Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0348
Figure 4. 24V Body Feed Harness Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0348
Figure 5. Harness Routing and Cable Lock Straps., Vol 3 . . . . . . . . . . . . . . WP 0348
Figure 6. 24V Body Feed Harness Connections at Solenoid., Vol 3 . . . . . . . . . . WP 0348
EQUALIZER CABLES REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0349
Figure 1. Equalizer Negative Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0349
Figure 2. Equalizer Positive Cable Removal at 12/24V Solenoids., Vol 3 . . . . . . . . WP 0349
Figure 3. Equalizer Cable Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0349
Figure 4. Equalizer Cable Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0349
Figure 5. Equalizer Positive Cable Installation at 12/24V Solenoids., Vol 3 . . . . . . . WP 0349
Figure 6. Equalizer Negative Cable Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0349
BATTERY EQUALIZER REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0350
Figure 1. Battery Equalizer Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0350
Figure 2. Equalizer Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0350
Figure 3. Battery Equalizer Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0350
Figure 4. Equalizer Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0350
MASTER DISCONNECT HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0351
Figure 1. Master Disconnect Harness Removal at Solenoid., Vol 3 . . . . . . . . . . WP 0351
Figure 2. Master Disconnect Harness Removal at Transmission., Vol 3 . . . . . . . . WP 0351
Figure 3. Master Disconnect Harness at PDC Harness., Vol 3 . . . . . . . . . . . . WP 0351
Figure 4. Master Disconnect Harness at PDC Harness., Vol 3 . . . . . . . . . . . . WP 0351
Figure 5. Master Disconnect Harness Connectors at PDC Harness., Vol 3 . . . . . . . WP 0351
Figure 6. Master Disconnect Harness Installation at PDC Harness., Vol 3 . . . . . . . WP 0351
Figure 7. Master Disconnect Harness Installation at Transmission., Vol 3. . . . . . . . WP 0351
Figure 8. Master Disconnect Harness Installation at Solenoid., Vol 3. . . . . . . . . . WP 0351
110V INVERTER REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . . . . . . . . . . WP 0352
Figure 1. 110V Inverter Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 2. Inverter Circuit Connections., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 3. Positive Cable Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 4. Inverter Positive Cable., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 5. 110V Inverter Positive Cable Installation., Vol 3. . . . . . . . . . . . . . . WP 0352
Figure 6. Positive Cable Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 7. 110V Inverter Installation, Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0352
Figure 8. 110V Inverter Connections., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0352
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WP Sequence No.
ELECTRONIC SYSTEM CONTROLLER (ESC) REMOVAL AND INSTALLATION, Vol 3 . . . . WP 0353
Figure 1. ESC Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0353
Figure 2. Power Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0353
Figure 3. ESC Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0353
Figure 4. ESC Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0353
Figure 5. ESC Power Wire., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0353
Figure 6. Positive Cable to Fuse Holder., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0353
ELECTRONIC SYSTEM CONTROLLER (ESC) BRACE REMOVAL AND INSTALLATION, Vol 3 WP 0354
Figure 1. Power Distribution Center (PDC) Armor., Vol 3 . . . . . . . . . . . . . . . WP 0354
Figure 2. PDC., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0354
Figure 3. ESC Brace and Pass-Through., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0354
Figure 4. ESC Brace and Pass-Through., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0354
Figure 5. PDC., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0354
Figure 6. PDC Armor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0354
ANTILOCK BRAKE SYSTEM (ABS) CONTROL MODULE REMOVAL AND INSTALLATION, Vol 3WP 0355
Figure 1. ABS Control Module., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0355
FRONT CREW LIGHT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0356
Figure 1. Front Crew Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0356
Figure 2. Front Crew Light Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0356
Figure 3. Front Crew Light Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0356
Figure 4. Front Crew Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0356
REAR CREW LIGHT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0357
Figure 1. Rear Crew Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0357
Figure 2. Rear Crew Light Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0357
INTERIOR LIGHTS CREW LIGHT LIMIT SWITCH AND JUMPER HARNESS REMOVAL AND
Figure 1. Crew Light Limit Switch Connections., Vol 3 . . . . . . . . . . . . . . . . WP 0358
Figure 2. Right Rear Cabin Molding., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0358
Figure 3. Crew Light Limit Switch Jumper Harness Connector., Vol 3 . . . . . . . . . WP 0358
Figure 4. Crew Light Limit Switch Jumper Harness Connector., Vol 3 . . . . . . . . . WP 0358
Figure 6. Crew Light Limit Switch Connections., Vol 3 . . . . . . . . . . . . . . . . WP 0358
INTERIOR LIGHTS LEFT REAR CREW LIGHT HARNESS REMOVAL AND INSTALLATION, Vol 3WP 0359
Figure 1. Left Rear Crew Light Harness Connector., Vol 3 . . . . . . . . . . . . . . WP 0359
Figure 2. Center Headliner Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0359
Figure 3. Left Rear Crew Light Harness., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0359
Figure 6. Left Rear Crew Light Harness., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0359
Figure 7. Center Headliner Bracket., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0359
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WP Sequence No.
INTERIOR LIGHTS RIGHT REAR AND FRONT CREW LIGHTS HARNESS REMOVAL AND
Figure 1. Ramp Limit Switch Jumper Harness Connector., Vol 3 . . . . . . . . . . . WP 0360
Figure 2. Right Rear Crew Light Harness., Vol 3 . . . . . . . . . . . . . . . . . . WP 0360
Figure 3. Front Crew Light Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0360
Figure 4. Right Rear and Front Crew Lights Harness Connector., Vol 3 . . . . . . . . WP 0360
Figure 5. Right Rear and Front Crew Lights Harness Connector Removal., Vol 3 . . . . WP 0360
Figure 6. Right Rear and Front Crew Lights Harness Connector Installation., Vol 3 . . . WP 0360
Figure 7. Right Rear and Front Crew Lights Harness Connector., Vol 3 . . . . . . . . WP 0360
Figure 8. Front Crew Light Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0360
Figure 9. Right Rear Crew Light Harness., Vol 3 . . . . . . . . . . . . . . . . . . WP 0360
Figure 10. Ramp Limit Switch Jumper Harness Connector., Vol 3 . . . . . . . . . . . WP 0360
FRONT BUMPER TURN SIGNAL AND PARKING LIGHT ASSEMBLY REMOVAL AND
Figure 1. Bumper Light Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0361
Figure 2. Front Light Guard., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0361
Figure 3. Front Bumper Light Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0361
Figure 4. Front Bumper Light Installation., Vol 3. . . . . . . . . . . . . . . . . . . WP 0361
Figure 5. Front Light Guard., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0361
Figure 6. Bumper Light Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0361
SPOTLIGHT LIGHT BULB REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . WP 0362
Figure 2. Spotlight Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0362
Figure 3. Spotlight Lens Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0362
Figure 4. Spotlight Lens Assembly., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0362
Figure 6. Spotlight Bezel Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0362
SPOTLIGHT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . WP 0363
Figure 2. Spotlight Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0363
Figure 3. Spotlight Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0363
SPOTLIGHT EXTERIOR HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0364
Figure 1. Spotlight Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0364
Figure 2. Cable Lock Straps., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0364
Figure 3. Spotlight Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0364
Figure 4. Spotlight Harness Connectors., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0364
Figure 5. Spotlight Harness Connectors., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0364
Figure 6. Spotlight Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0364
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WP Sequence No.
SPOTLIGHT INTERIOR HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0365
Figure 2. Roof Pass-Through Cover Plate., Vol 3 . . . . . . . . . . . . . . . . . . WP 0365
Figure 3. Cabin Roof Cover Plate., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 4. Right Front Door Molding., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 5. Fuse Panel., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 6. Connector Wire Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 7. Contact Tool., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 9. Spotlight Switch Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 10. Spotlight Switch Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 11. IP Center Trim Panel., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 12. Connector Body., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 13. Harness Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 14. Right Front Door Molding., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 15. Cabin Roof Cover Plate., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0365
Figure 16. Roof Pass-Through Cover Plate., Vol 3 . . . . . . . . . . . . . . . . . WP 0365
BLACKOUT DRIVE LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0366
Figure 1. Blackout Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0366
Figure 2. Blackout Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0366
Figure 3. Blackout Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0366
Figure 4. Blackout Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0366
CLEARANCE AND MARKER LIGHT HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . WP 0367
Figure 1. Clearance and Marker Light Harness., Vol 3 . . . . . . . . . . . . . . . . WP 0367
Figure 2. Clearance and Marker Light Harness., Vol 3 . . . . . . . . . . . . . . . . WP 0367
INFRARED (IR) LIGHT REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0368
Figure 1. IR Light Location., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0368
Figure 2. IR Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0368
Figure 3. IR Light Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0368
FRONT CLEARANCE LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . WP 0369
Figure 1. Front Light Panel Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0369
Figure 2. Front Clearance Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0369
Figure 3. Front Clearance Light., Vol 3. . . . . . . . . . . . . . . . . . . . . . . WP 0369
Figure 4. Front Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0369
Figure 5. Front Clearance Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0369
Figure 6. Front Light Panel Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0369
FRONT CLEARANCE LIGHT BAR HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0370
Figure 1. Front Clearance Light Bar Screws Removal., Vol 3 . . . . . . . . . . . . . WP 0370
Figure 2. Front Clearance Light Bar Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0370
Figure 3. Left Side of Light Bar Lock Straps., Vol 3 . . . . . . . . . . . . . . . . . WP 0370
Figure 4. Left Side of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0370
Figure 5. Center of Light Bar Lock Straps., Vol 3 . . . . . . . . . . . . . . . . . . WP 0370
Figure 6. Center of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0370
Figure 7. Right Side of Light Bar Lock Straps., Vol 3. . . . . . . . . . . . . . . . . WP 0370
Figure 8. Right Side of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . WP 0370
Figure 9. Right Side of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . WP 0370
Figure 10. Right Side of Light Bar Lock Straps., Vol 3 . . . . . . . . . . . . . . . . WP 0370
Figure 11. Center of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0370
Figure 12. Center of Light Bar Lock Straps., Vol 3 . . . . . . . . . . . . . . . . . . WP 0370
Figure 13. Left Side of Light Bar Circuitry., Vol 3 . . . . . . . . . . . . . . . . . . WP 0370
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WP Sequence No.
Figure 14. Left Side of Light Bar Lock Straps., Vol 3 . . . . . . . . . . . . . . . . . WP 0370
Figure 15. Front Clearance Light Bar Installation., Vol 3 . . . . . . . . . . . . . . . WP 0370
Figure 16. Front Clearance Light Bar Screws Installation., Vol 3. . . . . . . . . . . . WP 0370
FRONT FENDER LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . WP 0371
Figure 1. Socket Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0371
Figure 2. Light Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0371
Figure 3. Light Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0371
FRONT FENDER LIGHT BULB REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . WP 0372
Figure 1. Bulb Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0372
FRONT TURN SIGNAL AND PARKING LIGHT BULB REMOVAL AND INSTALLATION, Vol 3 . WP 0373
Figure 1. Socket Cover., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0373
Figure 2. Bulb Removal and Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0373
Figure 3. Bulb Removal and Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0373
Figure 4. Socket Cover Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0373
FRONT BUMPER LEFT HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0374
Figure 1. Front Bumper Left Harness Lock Straps., Vol 3. . . . . . . . . . . . . . . WP 0374
Figure 2. Front Bumper Left Harness Connectors., Vol 3 . . . . . . . . . . . . . . . WP 0374
Figure 3. Front Bumper Left Harness Connectors and Ground., Vol 3 . . . . . . . . . WP 0374
Figure 4. Front Bumper Bullet Connectors., Vol 3 . . . . . . . . . . . . . . . . . . WP 0374
Figure 6. Front Bumper Left Harness Connectors and Ground., Vol 3 . . . . . . . . . WP 0374
Figure 7. Front Bumper Left Harness Connectors., Vol 3 . . . . . . . . . . . . . . . WP 0374
FRONT BUMPER RIGHT HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0375
Figure 1. Front Bumper Harness Lock Straps., Vol 3 . . . . . . . . . . . . . . . . WP 0375
Figure 2. Front Bumper Harness Connectors., Vol 3 . . . . . . . . . . . . . . . . . WP 0375
Figure 5. Front Bumper Harness Connectors., Vol 3 . . . . . . . . . . . . . . . . . WP 0375
Figure 6. Front Bumper Harness Lock Straps., Vol 3 . . . . . . . . . . . . . . . . WP 0375
HEADLAMP REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0376
Figure 1. Headlamp Bezel Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0376
Figure 2. Headlamp Retainer Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0376
Figure 3. Headlamp Connector., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0376
Figure 4. Headlamp Retainer Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0376
Figure 5. Headlamp Bezel Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0376
HEADLAMP ALIGNMENT PROCEDURE, Vol 3. . . . . . . . . . . . . . . . . . . . . . WP 0377
Figure 1. Headlamp Alignment Dimensions., Vol 3 . . . . . . . . . . . . . . . . . WP 0377
Figure 2. Headlamp Adjusting Screw Side., Vol 3 . . . . . . . . . . . . . . . . . . WP 0377
Figure 3. Headlamp Adjusting Screw Top., Vol 3 . . . . . . . . . . . . . . . . . . WP 0377
LEFT HEADLAMP AND TURN SIGNAL HARNESS REMOVAL AND INSTALLATION, Vol 3 . . WP 0378
Figure 1. Left Headlamp Harness Main Connector., Vol 3 . . . . . . . . . . . . . . WP 0378
Figure 2. Side Marker Light Harness Connector., Vol 3 . . . . . . . . . . . . . . . WP 0378
Figure 3. Headlamp Harness Clips., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0378
Figure 4. Left Headlamp Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0378
Figure 5. Left Headlamp Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . WP 0378
Figure 6. Left Light Housing Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0378
Figure 7. Side Marker Light Harness Connector Connection., Vol 3 . . . . . . . . . . WP 0378
Figure 8. Left Headlamp Harness Main Connector Connection., Vol 3 . . . . . . . . . WP 0378
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WP Sequence No.
RIGHT HEADLAMP AND TURN SIGNAL HARNESS REMOVAL AND INSTALLATION, Vol 3. . WP 0379
Figure 1. Right Headlamp Harness Main Connector., Vol 3 . . . . . . . . . . . . . . WP 0379
Figure 4. Right Headlamp Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0379
Figure 5. Right Headlamp Assembly Assembly., Vol 3 . . . . . . . . . . . . . . . . WP 0379
Figure 6. Right Headlamp Assembly Installation., Vol 3 . . . . . . . . . . . . . . . WP 0379
Figure 8. Right Headlamp Harness Main Connector., Vol 3 . . . . . . . . . . . . . . WP 0379
HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . WP 0380
Figure 2. Headlamp Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0380
Figure 3. Headlamp Harness Installation., Vol 3. . . . . . . . . . . . . . . . . . . WP 0380
Figure 4. Headlamp Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0380
HEADLAMP BEZEL REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . . WP 0381
Figure 1. Headlamp Bezel Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0381
Figure 2. Headlamp Bezel Installation., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0381
BACKUP LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . WP 0382
Figure 1. Rear Light Housing Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0382
Figure 2. Backup Light Assembly Removal., Vol 3. . . . . . . . . . . . . . . . . . WP 0382
Figure 3. Backup Light Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0382
Figure 4. Rear Light Housing Installation., Vol 3. . . . . . . . . . . . . . . . . . . WP 0382
COMPOSITE TAILLAMP ASSEMBLY REMOVAL AND INSTALLATION, Vol 3. . . . . . . . . WP 0383
Figure 1. Rear Light Housing Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0383
Figure 2. Taillamp Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0383
Figure 3. Taillamp Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0383
Figure 4. Rear Light Housing Installation., Vol 3. . . . . . . . . . . . . . . . . . . WP 0383
TAILLAMP HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . . . . . . . WP 0384
Figure 1. rear taillamp box Removal., Vol 3. . . . . . . . . . . . . . . . . . . . . WP 0384
Figure 2. Taillamp Assembly Removal., Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0384
Figure 3. Right Rear of Rear Crossmember., Vol 3 . . . . . . . . . . . . . . . . . WP 0384
Figure 4. Right Rear of Body in Front of Taillamp Housing., Vol 3 . . . . . . . . . . . WP 0384
Figure 5. Left Rear of Rear Crossmember., Vol 3 . . . . . . . . . . . . . . . . . . WP 0384
Figure 6. Front of Taillamp Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0384
Figure 7. Front of Taillamp Harness., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0384
Figure 8. Left Rear of Rear Crossmember., Vol 3 . . . . . . . . . . . . . . . . . . WP 0384
Figure 9. Right Rear of Rear Crossmember., Vol 3 . . . . . . . . . . . . . . . . . WP 0384
Figure 10. Right Rear of Body in Front of Taillamp Housing., Vol 3 . . . . . . . . . . WP 0384
Figure 11. Taillamp Assembly Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0384
Figure 12. rear taillamp box Installation., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0384
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WP Sequence No.
REAR CLEARANCE LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0385
Figure 1. Antenna Support Side., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 3. Antenna Support Upper., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 4. Left Top Step., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 5. Top Center Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 6. Right Top Step Repositioned., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0385
Figure 7. Rear Clearance Light Wiring., Vol 3. . . . . . . . . . . . . . . . . . . . WP 0385
Figure 8. Rear Light., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 9. Rear Light., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 10. Rear Clearance Light Wiring., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0385
Figure 11. Right Top Step Repositioned., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0385
Figure 12. Top Center Bolt., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 13. Left Top Step., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 14. Right Top Step., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0385
Figure 16. Antenna Support Upper Bolts., Vol 3. . . . . . . . . . . . . . . . . . . WP 0385
REAR CLEARANCE LIGHT BAR HARNESS REMOVAL AND INSTALLATION, Vol 3 . . . . . WP 0386
Figure 1. Rear Clearance Light Bar Removal., Vol 3 . . . . . . . . . . . . . . . . . WP 0386
Figure 2. Rear Armor Plate Bolt Removal., Vol 3 . . . . . . . . . . . . . . . . . . WP 0386
Figure 3. Light Bar Connector Removal., Vol 3 . . . . . . . . . . . . . . . . . . . WP 0386
Figure 4. Left Side of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 5. Center of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 6. Right Side of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 7. Right Side of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 8. Center of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 9. Left Side of Light Bar., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . WP 0386
Figure 10. Light Bar Connector Installation., Vol 3 . . . . . . . . . . . . . . . . . . WP 0386
Figure 11. Rear Armor Plate Bolt Installation., Vol 3 . . . . . . . . . . . . . . . . . WP 0386
Figure 12. Rear Clearance Light Bar Installation., Vol 3 . . . . . . . . . . . . . . . WP 0386
REAR SIDEMARKER LIGHT ASSEMBLY REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0387
Figure 1. Sidemarker Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0387
Figure 2. Sidemarker Light Housing., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0387
Figure 3. Sidemarker Light Housing., Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0387
Figure 4. Sidemarker Light., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0387
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL AND INSTALLATION, Vol 3 . WP 0388
ENGINE OIL TEMPERATURE (EOT) SENSOR REMOVAL AND INSTALLATION, Vol 3 . . . . WP 0389
Figure 1. EOT Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0389
Figure 2. EOT Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0389
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL AND INSTALLATION, Vol 3 . WP 0390
Figure 1. MAP Sensor., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0390
Figure 2. MAP Sensor., Vol 3. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0390
INJECTION CONTROL PRESSURE (ICP) SENSOR REMOVAL AND INSTALLATION, Vol 3 . . WP 0391
Figure 1. ICP Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0391
Figure 2. ICP Sensor and O-Ring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0391
Figure 3. ICP Sensor and O-Ring., Vol 3 . . . . . . . . . . . . . . . . . . . . . . WP 0391
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ENGINE OIL PRESSURE (EOP) SENSOR REMOVAL AND INSTALLATION, Vol 3 . . . . . . WP 0392
Figure 1. EOP Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0392
Figure 2. EOP Sensor., Vol 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0392
CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION, Vol 3 . . . . . . . WP 0393
Figure 1. Front View of CMP Sensor. , Vol 3 . . . . . . . . . . . . . . . . . . . . WP 0393
Figure 2. CMP Sensor and Engine Front Cover. , Vol 3 . . . . . . . . . . . . . . . WP 0393
Figure 3. CMP Sensor and O-Ring. , Vol 3 . . . . . . . . . . . . . . . . . . . . . WP 0393
Figure 4. Engine Front Cover and CMP Sensor., Vol 3 . . . . . . . . . . . . . . . . WP 0393
TRANSFER CASE MODE SWITCH REMOVAL AND INSTALLATION, Vol 3 . . . . . . . . . WP 0394
Figure 1. Transfer Case Mode Switch Removal., Vol 3 . . . . . . . . . . . . . . . . WP 0394
Figure 2. Transfer Case Mode Switch Installation., Vol 3 . . . . . . . . . . . . . . . WP 0394
VOLUME 4

TRANSFER CASE VEHICLE SPEED SENSOR (VSS) REMOVAL AND INSTALLATION, Vol 4 . WP 0395
Figure 1. Transfer Case VSS Removal., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0395
Figure 2. Transfer Case VSS Installation., Vol 4. . . . . . . . . . . . . . . . . . . WP 0395
INJECTION PRESSURE REGULATOR (IPR) SENSOR REMOVAL AND INSTALLATION, Vol 4. WP 0396
Figure 1. IPR Sensor and Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0396
Figure 2. IPR Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0396
Figure 3. IPR Sensor and O-Rings., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0396
Figure 4. IPR Sensor and O-Rings., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0396
Figure 6. IPR Sensor and Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0396
ACCELERATOR PEDAL SENSOR (APS) REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0397
Figure 1. APS., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0397
Figure 2. APS., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0397
BAROMETRIC PRESSURE SENSOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0398
Figure 1. Barometric Pressure Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0398
Figure 2. Barometric Pressure Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0398
INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0399
Figure 1. IAT Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0399
Figure 2. IAT Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0399
FUEL LEVEL SENDING UNIT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0400
Figure 1. Fuel Level Sending Unit and Gasket Removal., Vol 4 . . . . . . . . . . . . WP 0400
Figure 2. Fuel Level Sending Unit and Gasket Installation., Vol 4 . . . . . . . . . . . WP 0400
WATER SENSOR PROBE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0401
Figure 1. Fuel/Water Separator and Water Sensor Probe., Vol 4 . . . . . . . . . . . WP 0401
Figure 2. O-Ring Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0401
Figure 3. O-Ring Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0401
Figure 4. Fuel/Water Separator and Water Sensor Probe., Vol 4 . . . . . . . . . . . WP 0401
ELECTRIC HORN REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . WP 0402
Figure 1. Horn Mounting., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0402
Figure 2. Horn Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0402
Figure 3. Horn Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0402
Figure 4. Horn Mounting., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0402
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HORN BUTTON ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0403
Figure 1. Steering Wheel Assembly and Tool., Vol 4 . . . . . . . . . . . . . . . . . WP 0403
Figure 2. Horn Button Assembly and Spring., Vol 4 . . . . . . . . . . . . . . . . . WP 0403
Figure 3. Horn Button Assembly and Wiring Harness., Vol 4 . . . . . . . . . . . . . WP 0403
Figure 4. Horn Button Assembly and Electrical Connectors., Vol 4. . . . . . . . . . . WP 0403
Figure 5. Horn Button Assembly Removed., Vol 4 . . . . . . . . . . . . . . . . . . WP 0403
Figure 6. Horn Button Assembly and Electrical Connectors., Vol 4. . . . . . . . . . . WP 0403
Figure 7. Position Horn Button Assembly., Vol 4 . . . . . . . . . . . . . . . . . . WP 0403
Figure 8. Horn Button and Steering Wheel., Vol 4 . . . . . . . . . . . . . . . . . . WP 0403
BATTERY DISCONNECT PROCEDURE, Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0404
Figure 1. Battery Door., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0404
Figure 2. Battery Identification., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0404
Figure 3. Clean-Power and Clean-Ground Connections., Vol 4 . . . . . . . . . . . . WP 0404
Figure 4. Battery 1 Ground Connections., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0404
Figure 6. Battery 1 Positive Connections., Vol 4. . . . . . . . . . . . . . . . . . . WP 0404
Figure 10. Clean-Power and Clean-Ground Connections., Vol 4 . . . . . . . . . . . WP 0404
BATTERY CABLE AND CLEAN POWER HARNESS REMOVAL AND INSTALLATION, Vol 4 . . WP 0405
ENGINE CONTROL MODULE (ECM) AND TRANSMISSION CONTROL MODULE (TCM) CLEAN POWER
AND GROUND HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0406
Figure 1. Clean Power and Ground Harness Connections at Battery., Vol 4. . . . . . . WP 0406
Figure 2. ECM/TCM Clean Harness Removal., Vol 4 . . . . . . . . . . . . . . . . WP 0406
Figure 3. Clean Power and Ground Harness Connectors at Starter Motor., Vol 4 . . . . WP 0406
Figure 4. Clean Power and Ground Harness Connectors at Starter Motor., Vol 4 . . . . WP 0406
Figure 5. ECM/TCM Clean Harness Installation., Vol 4. . . . . . . . . . . . . . . . WP 0406
Figure 6. Clean Power and Ground Harness Connections at Battery., Vol 4. . . . . . . WP 0406
BATTERY CABLES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0407
Figure 2. Battery 3 Negative Connections., Vol 4 . . . . . . . . . . . . . . . . . . WP 0407
Figure 10. Battery 2 Positive Connections., Vol 4 . . . . . . . . . . . . . . . . . . WP 0407
BODY GROUND TO FIREWALL GROUND CABLE REMOVAL AND INSTALLATION, Vol 4 . . WP 0408
Figure 1. Ground Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0408
Figure 2. Firewall Ground Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0408
Figure 3. Firewall Ground Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0408
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BATTERY STUD ADAPTER TERMINAL CLAMP REMOVAL AND INSTALLATION, Vol 4. . . . WP 0409
Figure 1. Battery Stud Adapter Terminal Clamp Removal., Vol 4 . . . . . . . . . . . WP 0409
Figure 2. Battery Stud Adapter Terminal Clamp Inspection., Vol 4 . . . . . . . . . . . WP 0409
Figure 3. Battery Stud Adapter Terminal Clamp Cleaning., Vol 4 . . . . . . . . . . . WP 0409
Figure 4. Battery Terminal Cleaning., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0409
Figure 5. Battery Clamp Spreader., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0409
Figure 6. Battery Stud Adapter Terminal Clamp Installation., Vol 4. . . . . . . . . . . WP 0409
BATTERY BODY GROUND CABLE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0410
Figure 1. Battery Body Ground Cable Removal., Vol 4 . . . . . . . . . . . . . . . . WP 0410
Figure 2. Battery Body Ground Cable Installation., Vol 4 . . . . . . . . . . . . . . . WP 0410
INSTRUMENT PANEL (IP) FEED HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0411
Figure 1. IP Feed Harness Connections at 12V Solenoid., Vol 4 . . . . . . . . . . . WP 0411
Figure 2. IP Feed Harness Removal at Transmission. , Vol 4 . . . . . . . . . . . . . WP 0411
Figure 3. IP Feed Harness Connector Removal at MegaFuse Power Stud., Vol 4 . . . . WP 0411
Figure 4. IP Feed Harness Connector Installation at MegaFuse Power Stud., Vol 4 . . . WP 0411
Figure 5. IP Feed Harness Installation., Vol 4. . . . . . . . . . . . . . . . . . . . WP 0411
Figure 6. IP Feed Harness Connector Installation at 12V Solenoid., Vol 4 . . . . . . . WP 0411
ENGINE CONTROL MODULE (ECM) AND THE TRANSMISSION CONTROL MODULE (TCM) CLEAN
POWER FUSE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . WP 0412
Figure 1. Fuse Holder Identification., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0412
Figure 2. Fuse Caps., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0412
Figure 3. Fuse Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0412
Figure 4. Testing for Faulty Fuse, Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0412
Figure 5. Fuse Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0412
Figure 6. Fuse Caps., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0412
STARTER MOTOR-TO-BATTERY FEED CABLE REMOVAL AND INSTALLATION, Vol 4. . . . WP 0413
Figure 2. Solenoid Feed Cable Installation., Vol 4 . . . . . . . . . . . . . . . . . . WP 0413
STARTER MOTOR-TO-BATTERY GROUND CABLE REMOVAL AND INSTALLATION, Vol 4 . . WP 0414
Figure 1. Starter Ground Cable Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0414
Figure 2. Starter Ground Cable Installation., Vol 4. . . . . . . . . . . . . . . . . . WP 0414
WINCH BATTERY CABLE JUNCTION BLOCK AND BRACKET SUPPORT REMOVAL AND
Figure 1. Battery Cable Junction Block Support., Vol 4. . . . . . . . . . . . . . . . WP 0415
Figure 2. Battery Cables Junction Block Assembly., Vol 4 . . . . . . . . . . . . . . WP 0415
Figure 3. Junction Block., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0415
Figure 4. Battery Cable Junction Block Support., Vol 4. . . . . . . . . . . . . . . . WP 0415
Figure 5. Battery Cables Junction Block Assembly., Vol 4 . . . . . . . . . . . . . . WP 0415
WINCH FEED CABLE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0416
Figure 3. Winch Cables Along Right Side Frame Rail., Vol 4 . . . . . . . . . . . . . WP 0416
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WINCH GROUND CABLE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0417
BATTERY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0418
Figure 1. Battery Clamp Adaptor Stud., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0418
Figure 2. Battery Holddown Bracket., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0418
Figure 3. Battery Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0418
Figure 4. Battery Clamps., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0418
BATTERY BOX REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . WP 0419
Figure 1. Battery Box Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0419
Figure 2. Battery Tray Removal., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0419
Figure 3. Rear Battery Support Brackets., Vol 4. . . . . . . . . . . . . . . . . . . WP 0419
Figure 4. Rear Battery Support Brackets., Vol 4. . . . . . . . . . . . . . . . . . . WP 0419
Figure 5. Battery Tray Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0419
Figure 6. Battery Box Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0419
ELECTRICAL WIRE REPAIR PROCEDURES, Vol 4. . . . . . . . . . . . . . . . . . . . WP 0420
Figure 1. Wire Preparation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0420
Figure 2. Heatshrink Tubing., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0420
Figure 3. Splice Clip., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0420
Figure 4. Soldering., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0420
Figure 5. Heatshrink Tubing., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0420
NATO JUMP START CONNECTOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0421
Figure 1. NATO Jump Start Connector Cover., Vol 4. . . . . . . . . . . . . . . . . WP 0421
Figure 2. NATO Jump Start Connector Wiring., Vol 4 . . . . . . . . . . . . . . . . WP 0421
Figure 3. NATO Jump Start Connector Bolts., Vol 4 . . . . . . . . . . . . . . . . . WP 0421
Figure 4. NATO Jump Start Connector Exploded View., Vol 4 . . . . . . . . . . . . . WP 0421
Figure 6. NATO Jump Start Connector Cover., Vol 4. . . . . . . . . . . . . . . . . WP 0421
12V UNDERHOOD MEGAFUSE AND HOLDER REMOVAL AND INSTALLATION, Vol 4 . . . . WP 0422
Figure 1. Underhood Fuse Holder Removal., Vol 4 . . . . . . . . . . . . . . . . . WP 0422
Figure 3. Underhood Fuse Holder Installation., Vol 4 . . . . . . . . . . . . . . . . WP 0422
24V UNDERHOOD JUNCTION BLOCK REMOVAL AND INSTALLATION, Vol 4. . . . . . . . WP 0423
Figure 1. Electrical Harness Connections., Vol 4 . . . . . . . . . . . . . . . . . . WP 0423
Figure 2. 24V Underhood Junction Block Removal., Vol 4 . . . . . . . . . . . . . . WP 0423
Figure 3. 24V Underhood Junction Block Installation., Vol 4 . . . . . . . . . . . . . WP 0423
Figure 4. Electrical Harness Connections., Vol 4 . . . . . . . . . . . . . . . . . . WP 0423
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WP Sequence No.
FORWARD CHASSIS WIRING HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0424
Figure 1. Forward Chassis Harness Connectors Near Power Distribution Center
(PDC)., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 2. Left ABS Modulator Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . . WP 0424
Figure 3. Left ABS Modulator Connections., Vol 4 . . . . . . . . . . . . . . . . . . WP 0424
Figure 4. Behind Steering Gear., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 5. Front Bumper Left Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . WP 0424
Figure 6. Front Bumper Left Harness Connections., Vol 4 . . . . . . . . . . . . . . WP 0424
Figure 7. Left Horn., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 8. Right Horn., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 9. Front Bumper Right Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . WP 0424
Figure 10. Front Bumper Right Harness Connections., Vol 4 . . . . . . . . . . . . . WP 0424
Figure 11. Right Outboard Frame Rail., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 12. Right ABS Modulator Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0424
Figure 13. Right ABS Modulator Connections., Vol 4 . . . . . . . . . . . . . . . . WP 0424
Figure 14. Right ABS Modulator Connections., Vol 4 . . . . . . . . . . . . . . . . WP 0424
Figure 15. Right ABS Modulator Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0424
Figure 16. Right Outboard Frame Rail., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 17. Front Bumper Right Harness Connections., Vol 4 . . . . . . . . . . . . . WP 0424
Figure 18. Front Bumper Right Harness Cable Lock Straps., Vol 4 . . . . . . . . . . WP 0424
Figure 19. Right Horn., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 20. Left Horn., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 21. Front Bumper Left Harness Connections., Vol 4 . . . . . . . . . . . . . . WP 0424
Figure 22. Front Bumper Left Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . WP 0424
Figure 23. Behind Steering Gear., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0424
Figure 24. Left ABS Modulator Connections., Vol 4 . . . . . . . . . . . . . . . . . WP 0424
Figure 25. Left ABS Modulator Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0424
Figure 26. Forward Chassis Harness Connectors Near Power Distribution Center
(PDC)., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0424
FRONT ANTILOCK BRAKE SYSTEM (ABS) SENSOR REMOVAL AND INSTALLATION, Vol 4 . WP 0425
Figure 1. ABS Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0425
Figure 2. Sensor Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0425
Figure 5. Sensor Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0425
CENTER CHASSIS WIRING HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0426
Figure 1. Air Dryer Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0426
Figure 2. Rear of Center Chassis Harness, Inboard View., Vol 4 . . . . . . . . . . . WP 0426
Figure 3. Transfer Case Sensors Connectors., Vol 4. . . . . . . . . . . . . . . . . WP 0426
Figure 4. Four-Pack Shift Solenoids Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0426
Figure 5. Fuel Sender Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0426
Figure 6. Center Chassis Harness Ground., Vol 4 . . . . . . . . . . . . . . . . . . WP 0426
Figure 7. Five Connectors., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0426
Figure 8. Five Connectors., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0426
Figure 9. Center Chassis Harness Ground., Vol 4 . . . . . . . . . . . . . . . . . . WP 0426
Figure 10. Fuel Sender Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0426
Figure 11. Four-Pack Shift Solenoids Connector., Vol 4 . . . . . . . . . . . . . . . WP 0426
Figure 12. Transfer Case Sensors Connectors., Vol 4 . . . . . . . . . . . . . . . . WP 0426
Figure 13. Rear of Center Chassis Harness, Inboard View., Vol 4 . . . . . . . . . . . WP 0426
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WP Sequence No.
REAR CHASSIS HARNESS REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . WP 0427
Figure 1. Rear Chassis Harness, Inboard View., Vol 4 . . . . . . . . . . . . . . . . WP 0427
Figure 2. Left Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 3. Left Two-Pin Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 4. Cable Lock Straps Near Crossmember., Vol 4 . . . . . . . . . . . . . . . WP 0427
Figure 5. Cable Lock Straps on Crossmember., Vol 4 . . . . . . . . . . . . . . . . WP 0427
Figure 6. Right Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 7. Right Two-Pin Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 8. Air Dryer Support Bracket Nuts., Vol 4 . . . . . . . . . . . . . . . . . . WP 0427
Figure 9. Front of Rear Chassis Harness, Inboard View., Vol 4 . . . . . . . . . . . . WP 0427
Figure 10. Front of Rear Chassis Harness, Inboard View., Vol 4. . . . . . . . . . . . WP 0427
Figure 12. Right Two-Pin Connector., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 13. Right Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 14. Cable Lock Straps on Crossmember., Vol 4. . . . . . . . . . . . . . . . WP 0427
Figure 15. Cable Lock Straps Near Crossmember., Vol 4 . . . . . . . . . . . . . . WP 0427
Figure 16. Left Two-Pin Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 17. Left Modulator Valve., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0427
Figure 18. Rear Chassis Harness, Inboard View., Vol 4 . . . . . . . . . . . . . . . WP 0427
FRONT TRAILER HOOKUP COVER REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . WP 0428
Figure 1. Front Trailer Hookup Cover Fasteners., Vol 4 . . . . . . . . . . . . . . . WP 0428
Figure 2. Front Trailer Hookup Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0428
Figure 3. Front Trailer Hookup Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0428
Figure 4. Front Trailer Hookup Cover Fasteners., Vol 4 . . . . . . . . . . . . . . . WP 0428
FRONT TRAILER HOOKUP HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0429
Figure 1. Ground Stud Nut., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0429
Figure 2. Front Trailer Harness Connectors., Vol 4 . . . . . . . . . . . . . . . . . WP 0429
Figure 3. Front Trailer Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0429
Figure 4. Front Trailer Hookup Harness., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0429
Figure 5. Front Trailer Hookup Harness., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0429
Figure 6. Ground Stud Nut., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0429
Figure 7. Front Trailer Harness Connectors., Vol 4 . . . . . . . . . . . . . . . . . WP 0429
Figure 8. Front Trailer Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0429
REAR TRAILER HOOKUP COVER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0430
Figure 1. Rear Cover Plate Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0430
Figure 2. Rear Trailer Hookup Removal., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0430
Figure 3. Rear Trailer Hookup Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0430
Figure 4. Rear Trailer Hookup Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0430
Figure 5. Rear Trailer Hookup Installation., Vol 4 . . . . . . . . . . . . . . . . . . WP 0430
Figure 6. Rear Cover Plate Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0430
REAR TRAILER HOOKUP HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0431
Figure 1. Rear Trailer Hookup Harness Connectors., Vol 4 . . . . . . . . . . . . . . WP 0431
Figure 2. Rear Trailer Hookup Harness Connectors., Vol 4 . . . . . . . . . . . . . . WP 0431
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WP Sequence No.
REAR DOOR/RAMP HYDRAULIC SYSTEM CONTROL HARNESS REMOVAL AND INSTALLATION
, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 1. Rear Door/Ramp Control Harness Connector., Vol 4 . . . . . . . . . . . . WP 0432
Figure 2. Right Rear Cabin Molding Cover., Vol 4 . . . . . . . . . . . . . . . . . . WP 0432
Figure 3. Seat Rope Tension Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 4. Seat Rope Tension Lever., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 5. Right Center Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 6. Right Front Cabin Molding., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 9. Rear Door/Ramp Control Harness to IP Harness Connector Removal., Vol 4 . . WP 0432
Figure 10. Rear Door/Ramp Control Harness Connector Installation., Vol 4. . . . . . . WP 0432
Figure 12. Right Front Door Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 13. Right Front Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 14. Right Center Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0432
Figure 15. Seat Rope Tension Lever., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 16. Seat Rope Tension Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0432
Figure 17. Right Rear Cabin Molding Cover., Vol 4 . . . . . . . . . . . . . . . . . WP 0432
Figure 18. Rear Door/Ramp Hydraulic System Harness Connector., Vol 4 . . . . . . . WP 0432
REAR DOOR/RAMP HYDRAULIC SYSTEM HARNESS REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0433
Figure 1. Rear Door/Ramp Motor Ground and Solenoid Wires., Vol 4 . . . . . . . . . WP 0433
Figure 2. Rear Door/Ramp Control Connection., Vol 4 . . . . . . . . . . . . . . . . WP 0433
Figure 3. Rear Door/Ramp Hydraulic System Harness Connector., Vol 4 . . . . . . . . WP 0433
Figure 4. Rear Door/Ramp Hydraulic System Harness Connector., Vol 4 . . . . . . . . WP 0433
Figure 5. Rear Door/Ramp Hydraulic Valve Connectors., Vol 4 . . . . . . . . . . . . WP 0433
Figure 6. Rear Door/Ramp Battery Connection., Vol 4 . . . . . . . . . . . . . . . . WP 0433
REAR DOOR/RAMP HYDRAULIC SYSTEM HARNESS REMOVAL AND INSTALLATION (PULL-TYPE
OPERATION), Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0434
Figure 1. Rear Door/Ramp Solenoid Connections., Vol 4. . . . . . . . . . . . . . . WP 0434
Figure 2. Rear Door/Ramp Valve Harness Connectors., Vol 4. . . . . . . . . . . . . WP 0434
Figure 3. Rear Door/Ramp Hydraulic System Harness Connectors., Vol 4 . . . . . . . WP 0434
Figure 4. Rear Door/Ramp Solenoid Connections., Vol 4. . . . . . . . . . . . . . . WP 0434
110V OUTLET HARNESS REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . . WP 0435
Figure 1. 110V Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0435
Figure 2. 110V Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0435
24V INSTRUMENT PANEL (IP) FEED HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . WP 0436
Figure 1. 24V IP Feed Wiring Harness Connector., Vol 4 . . . . . . . . . . . . . . . WP 0436
Figure 2. 24V Input Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0436
Figure 3. 24V Input Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0436
Figure 4. 24V Instrument Panel (IP) Feed Wiring Harness Connector., Vol 4 . . . . . . WP 0436
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WP Sequence No.
24V POWER DISTRIBUTION MODULE (PDM) FEED HARNESS REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0437
Figure 1. Exterior Side of Pass-Through Plate., Vol 4 . . . . . . . . . . . . . . . . WP 0437
Figure 2. Interior Side of Pass-Through Plate., Vol 4. . . . . . . . . . . . . . . . . WP 0437
Figure 4. PDM Feed Wiring Harness Connector., Vol 4 . . . . . . . . . . . . . . . WP 0437
Figure 5. PDM Feed Wiring Harness Connector., Vol 4 . . . . . . . . . . . . . . . WP 0437
24V POWER DISTRIBUTION MODULE (PDM) GROUND CABLE REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0438
Figure 1. PDM Ground Cable Connection., Vol 4 . . . . . . . . . . . . . . . . . . WP 0438
Figure 2. PDM Ground Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0438
Figure 3. PDM Ground Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0438
Figure 4. PDM Ground Cable Connection., Vol 4 . . . . . . . . . . . . . . . . . . WP 0438
LEFT 12V SOCKET AND FEED HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0439
Figure 1. 12V Junction Box., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 2. Junction Box Cover Screws., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 3. Left Side Junction Box Wires., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0439
Figure 4. Junction Box., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 5. Power Distribution Module (PDM) Harness Electrical Storage Shield and Duct
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 6. 12V Power Outlet Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 7. Cable Lock Strap., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 8. Feed Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0439
Figure 12. Electrical Harness Storage Duct Center Rear Cover., Vol 4 . . . . . . . . . WP 0439
Figure 14. Left Side Junction Box Wires., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0439
Figure 15. Junction Box Cover Screws., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0439
RIGHT 12V SOCKET AND FEED HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0440
Figure 2. Junction Box Cover Screws., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0440
Figure 3. Right Side Junction Box Wires., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0440
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0440
Figure 12. Electrical Harness Storage Duct Center Rear Cover., Vol 4 . . . . . . . . . WP 0440
Figure 14. Right Side Junction Box Wires., Vol 4 . . . . . . . . . . . . . . . . . . WP 0440
Figure 15. Junction Box Cover Screws., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0440
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Page No.
WP Sequence No.
FRONT AND REAR CLEARANCE LIGHTS ROOF HARNESS REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0441
Figure 1. Front Clearance Light Bar Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0441
Figure 2. Roof Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0441
Figure 3. Rear Clearance Light Bar Connection., Vol 4. . . . . . . . . . . . . . . . WP 0441
Figure 4. Roof Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0441
Figure 5. Front Clearance Light Bar Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0441
CLEARANCE LIGHTS CABIN JUMPER HARNESS REMOVAL AND INSTALLATION, Vol 4 . . WP 0442
Figure 1. Roof Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 2. Roof Pass-Through Cover Plate., Vol 4 . . . . . . . . . . . . . . . . . . WP 0442
Figure 3. Roof Access Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 4. Door Opening Trim., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 5. Clearance Lights Jumper Harness., Vol 4 . . . . . . . . . . . . . . . . . WP 0442
Figure 6. Connector Wire Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 7. Contact Tool., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 8. Connector Pin Installation, Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 9. Clearance Lights Jumper Harness., Vol 4 . . . . . . . . . . . . . . . . . WP 0442
Figure 10. Door Opening Trim., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 11. Roof Access Plate., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0442
Figure 12. Roof Pass-Through Cover Plate., Vol 4 . . . . . . . . . . . . . . . . . WP 0442
Figure 13. Roof Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0442
24V POWER DISTRIBUTION MODULE (PDM) REMOVAL AND INSTALLATION, Vol 4 . . . . WP 0443
Figure 1. Drive Selector Console., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0443
Figure 2. Electrical Cables, Right Side of 24V PDM., Vol 4 . . . . . . . . . . . . . . WP 0443
Figure 3. Front Cable Shield., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0443
Figure 4. Electrical Cables., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0443
Figure 5. 24V PDM., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0443
Figure 6. Front Cable Shield., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0443
Figure 7. Electrical Cables, Right Side of 24V PDM., Vol 4 . . . . . . . . . . . . . . WP 0443
Figure 8. Drive Selector Console., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0443
REAR DOOR/RAMP FEED WIRING HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . WP 0444
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0444
Figure 2. Rear Door/Ramp Feed Harness Connection., Vol 4 . . . . . . . . . . . . . WP 0444
Figure 3. Rear Door/Ramp Feed Connector., Vol 4 . . . . . . . . . . . . . . . . . WP 0444
Figure 4. PDM Harness Electrical Storage Shield and Duct Covers., Vol 4 . . . . . . . WP 0444
24V GOVERNMENT FURNISHED EQUIPMENT (GFE) HARNESS REMOVAL AND
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0445
Figure 2. 24V GFE Wiring Harness Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0445
Figure 3. GFE Terminal Box Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0445
Figure 4. GFE Wiring Harness Connections., Vol 4 . . . . . . . . . . . . . . . . . WP 0445
Figure 5. GFE Wiring Harness Connections., Vol 4 . . . . . . . . . . . . . . . . . WP 0445
Figure 6. GFE Terminal Box Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0445
Figure 7. 24V GFE Wiring Harness Connector., Vol 4 . . . . . . . . . . . . . . . . WP 0445
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0445
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Page No.
WP Sequence No.
TURRET POWER FEED HARNESS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0446
Covers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0446
Figure 2. Turret Power Feed Wiring Harness Connector., Vol 4 . . . . . . . . . . . . WP 0446
Figure 3. Turret Power Feed Box Cover., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0446
Figure 4. Turret Power Feed Wiring Harness Cables., Vol 4 . . . . . . . . . . . . . WP 0446
Figure 5. Turret Power Feed Harness Connections., Vol 4 . . . . . . . . . . . . . . WP 0446
Figure 6. Turret Power Feed Box Cover., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0446
Figure 7. Turret Power Feed Wiring Harness Connector., Vol 4 . . . . . . . . . . . . WP 0446
110V INVERTER MAIN POWER SWITCH REMOVAL AND INSTALLATION, Vol 4. . . . . . . WP 0447
Figure 1. 110V Inverter MAIN POWER Switch Wiring., Vol 4 . . . . . . . . . . . . . WP 0447
Figure 2. 110V Inverter MAIN POWER Switch Installation., Vol 4 . . . . . . . . . . . WP 0447
WINCH MEGAFUSE AND HOLDER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0448
24V INVERTER MEGAFUSE AND HOLDER REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0449
Figure 1. 24V Inverter Megafuse Holder., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0449
Figure 3. 24V Inverter Megafuse Holder., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0449
NATO JUMP START CONNECTOR CABLES REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0450
Figure 1. Battery Cable Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0450
Figure 4. Battery Cable Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0450
INVERTER AND MAIN POWER SWITCH SOLENOID CABLES REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 1. 110V Inverter Wiring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 2. Inverter Circuit Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 3. Positive Cable to MAIN POWER., Vol 4 . . . . . . . . . . . . . . . . . . WP 0451
Figure 4. Inverter Mounting Nuts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 5. 110V Inverter Positive Cable., Vol 4. . . . . . . . . . . . . . . . . . . . WP 0451
Figure 6. NATO Jump Start Negative Cable., Vol 4 . . . . . . . . . . . . . . . . . WP 0451
Figure 7. Positive Cable Mega-Fuse., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 8. Mega-Fuse Cables., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 9. NATO Jump Start., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 10. NATO Jump Start., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 11. Mega-Fuse Cables., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 12. Mega-Fuse Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 13. NATO Jump Start Negative Cable., Vol 4 . . . . . . . . . . . . . . . . . WP 0451
Figure 14. 110V Inverter Positive Cable Installation., Vol 4 . . . . . . . . . . . . . . WP 0451
Figure 15. 110V Inverter Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 16. Positive Cable to MAIN POWER., Vol 4 . . . . . . . . . . . . . . . . . WP 0451
Figure 17. 110V Inverter Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0451
Figure 18. 110V Inverter Wiring., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0451
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Page No.
WP Sequence No.
TRANSMISSION AUTO SHIFT CONTROL MODULE REMOVAL AND INSTALLATION, Vol 4 . . WP 0452
Figure 1. Transmission Driver Control Assembly., Vol 4 . . . . . . . . . . . . . . . WP 0452
Figure 2. Transmission Auto Shift Control Module Harness., Vol 4. . . . . . . . . . . WP 0452
Figure 3. Transmission Driver Control Assembly Panels., Vol 4 . . . . . . . . . . . . WP 0452
Figure 4. Transmission Auto Shift Control Module. , Vol 4 . . . . . . . . . . . . . . WP 0452
Figure 5. Transmission Auto Shift Control Module. , Vol 4 . . . . . . . . . . . . . . WP 0452
Figure 6. Transmission Driver Control Assembly Panels., Vol 4 . . . . . . . . . . . . WP 0452
Figure 7. Control Module Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0452
Figure 8. Transmission Driver Control Assembly., Vol 4 . . . . . . . . . . . . . . . WP 0452
TRANSMISSION CONTROL MODULE AND BRACE REMOVAL AND INSTALLATION, Vol 4 . . WP 0453
Figure 2. Transmission Control Unit Harness., Vol 4 . . . . . . . . . . . . . . . . . WP 0453
Figure 3. Transmission Control Unit., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0453
Figure 4. Transmission Control Unit Brace., Vol 4 . . . . . . . . . . . . . . . . . . WP 0453
Figure 5. Transmission Control Unit Brace., Vol 4 . . . . . . . . . . . . . . . . . . WP 0453
Figure 6. Transmission Control Unit., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0453
Figure 7. Transmission Control Unit Harness., Vol 4 . . . . . . . . . . . . . . . . . WP 0453
TRANSMISSION ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0454
Figure 3. Upper Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 5. Cooler Hoses., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 6. Rear Transmission Electrical Connectors., Vol 4 . . . . . . . . . . . . . . WP 0454
Figure 7. Input Speed Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 8. Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 9. Access Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 11. Transmission-to-Engine Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0454
Figure 12. Upper Transmission Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 13. Dipstick Tube and Seal., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 14. Starter Ring Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 15. Transmission-to-Engine Mating Surface (Engine Shown)., Vol 4 . . . . . . . WP 0454
Figure 16. Bracket Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 17. Hose Fittings Removal., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 18. Hose Fitting Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 19. Bracket Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 20. Starter Ring Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 21. Dipstick Tube and Seal., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 22. Upper Transmission Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 23. Transmission-to-Engine Bolts., Vol 4. . . . . . . . . . . . . . . . . . . WP 0454
Figure 26. Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 27. Input Speed Sensor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 28. Rear Transmission Electrical Connectors., Vol 4. . . . . . . . . . . . . . WP 0454
Figure 29. Cooler Hoses., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
Figure 31. Retainer Mounting Plate Installation., Vol 4 . . . . . . . . . . . . . . . . WP 0454
Figure 32. Upper Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0454
xcvi
TM 9-2355-106-23-1

Page No.
WP Sequence No.
TRANSMISSION MOUNTING CROSSMEMBER REMOVAL AND INSTALLATION, Vol 4. . . . WP 0455
Figure 1. Transmission Rear Mount Frame Bracket., Vol 4 . . . . . . . . . . . . . . WP 0455
Figure 2. Transmission Mounting Crossmember Spring And Transmission Rear Mount
Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0455
Figure 3. Transmission Mounting Crossmember Spring And Transmission Rear Mount
Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0455
Figure 4. Transmission Rear Mount Frame Bracket., Vol 4 . . . . . . . . . . . . . . WP 0455
TRANSMISSION COOLER HOSE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0456
Figure 1. Lower Hoses., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 2. Flywheel Housing Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 3. Lower Retainers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 4. Upper Retainer and Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 5. Upper Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 6. Upper Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 7. Upper Retainer and Lower Hose., Vol 4 . . . . . . . . . . . . . . . . . . WP 0456
Figure 8. Flywheel Housing Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 9. Lower Retainers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
Figure 10. Lower Hoses., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0456
TRANSMISSION FLUID AND FILTER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0457
Figure 1. Drain Plug., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0457
Figure 2. Filter and Seals., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0457
Figure 3. Filter and Seals., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0457
Figure 4. Filter Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0457
TRANSMISSION BREATHER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0458
Figure 1. Breather., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0458
Figure 2. Breather., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0458
TRANSMISSION SPEED SENSORS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0459
Figure 1. Transmission Input and Output Speed Sensors., Vol 4 . . . . . . . . . . . WP 0459
Figure 2. Transmission Input and Output Speed Sensors., Vol 4 . . . . . . . . . . . WP 0459
TRANSFER CASE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0460
Figure 1. Top of Transfer Case., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 2. Front of Transfer Case., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 3. Air Line Clamp., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 4. Transfer Case Vent Tube., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 6. Rear of Transfer Case., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 7. Left Side of Transfer Case Mounting., Vol 4 . . . . . . . . . . . . . . . . WP 0460
Figure 8. Right Side of Transfer Case Mounting., Vol 4 . . . . . . . . . . . . . . . WP 0460
Figure 9. Right Side of Transfer Case Mounting., Vol 4 . . . . . . . . . . . . . . . WP 0460
Figure 10. Left Side of Transfer Case Mounting., Vol 4. . . . . . . . . . . . . . . . WP 0460
Figure 12. Rear of Transfer Case., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 13. Front of Transfer Case., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 14. Transfer Case Vent Tube., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 15. Air Line Clamp., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0460
Figure 16. Top of Transfer Case., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0460
xcvii
TM 9-2355-106-23-1

Page No.
WP Sequence No.
TRANSFER CASE MOUNT AND SUPPORT REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0461
Figure 1. Cabin Mounting Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0461
Figure 2. Transfer Case Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0461
Figure 3. Transfer Case Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0461
Figure 4. Cabin Mounting Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0461
TRANSFER CASE ARMOR REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . WP 0462
Figure 1. FSS Cylinder Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0462
Figure 2. Transfer Case Armor Mounting., Vol 4 . . . . . . . . . . . . . . . . . . WP 0462
Figure 3. Transfer Case Armor Mounting., Vol 4 . . . . . . . . . . . . . . . . . . WP 0462
Figure 4. FSS Cylinder Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0462
TRANSFER CASE AIR LINES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0463
Figure 1. Front Axle Shift Cylinder Air Line., Vol 4 . . . . . . . . . . . . . . . . . . WP 0463
Figure 2. Front Axle Shift Cylinder Air Line Bracket., Vol 4 . . . . . . . . . . . . . . WP 0463
Figure 3. Two-Speed Shift Cylinder Air Line Connections., Vol 4 . . . . . . . . . . . WP 0463
Figure 5. Transfer Case Air Line Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0463
Figure 7. Two-Speed Shift Cylinder Air Line Connections., Vol 4 . . . . . . . . . . . WP 0463
Figure 8. Transfer Case Air Line Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . WP 0463
Figure 9. Front Axle Shift Cylinder Air Line., Vol 4 . . . . . . . . . . . . . . . . . . WP 0463
Figure 10. Front Axle Shift Cylinder Air Line Bracket., Vol 4 . . . . . . . . . . . . . WP 0463
Table 1. 4-Pack Air Solenoid Module Air Line Connections., Vol 4 . . . . . . . . . . . WP 0463
4-PACK AIR SOLENOID MODULE AND SUPPORT REMOVAL AND INSTALLATION, Vol 4 . . WP 0464
Figure 1. 4-Pack Air Solenoid Module Harness Connection., Vol 4 . . . . . . . . . . WP 0464
Figure 2. 4-Pack Air Solenoid Module Air Line Connections., Vol 4 . . . . . . . . . . WP 0464
Figure 3. 4-Pack Air Solenoid Module and Support Disassembly., Vol 4 . . . . . . . . WP 0464
Figure 4. Solenoid Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0464
Figure 5. Solenoid Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0464
Figure 6. 4-Pack Air Solenoid Module and Support Assembly., Vol 4. . . . . . . . . . WP 0464
Figure 7. 4-Pack Air Solenoid Module., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0464
Figure 8. 4-Pack Air Solenoid Module Air Line Connections., Vol 4 . . . . . . . . . . WP 0464
Table 1. 4-Pack Air Solenoid Module Air Line Connections., Vol 4 . . . . . . . . . . . WP 0464
TRANSFER CASE OIL COOLER HOSE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0465
Figure 1. Transfer Case Oil Cooler Return Hose., Vol 4 . . . . . . . . . . . . . . . WP 0465
Figure 2. Transfer Case Oil Cooler Feed Hose., Vol 4 . . . . . . . . . . . . . . . . WP 0465
Figure 4. Transfer Case Oil Cooler Return Hose Routing., Vol 4. . . . . . . . . . . . WP 0465
Figure 5. Transfer Case Oil Cooler Feed Hose., Vol 4 . . . . . . . . . . . . . . . . WP 0465
Figure 6. Transfer Case Oil Cooler Hose Routing., Vol 4 . . . . . . . . . . . . . . . WP 0465
Figure 7. Transfer Case Oil Cooler Hose Routing., Vol 4 . . . . . . . . . . . . . . . WP 0465
Figure 8. Transfer Case Oil Cooler Return Hose Routing., Vol 4. . . . . . . . . . . . WP 0465
Figure 10. Transfer Case Oil Cooler Feed Hose., Vol 4 . . . . . . . . . . . . . . . WP 0465
Figure 11. Transfer Case Oil Cooler Hose Routing., Vol 4 . . . . . . . . . . . . . . WP 0465
Figure 12. Transfer Case Oil Cooler Return Hose Routing., Vol 4 . . . . . . . . . . . WP 0465
Figure 13. Transfer Case Oil Cooler Hose Routing., Vol 4 . . . . . . . . . . . . . . WP 0465
Figure 14. Transfer Case Oil Cooler Feed Hose., Vol 4 . . . . . . . . . . . . . . . WP 0465
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TM 9-2355-106-23-1

Page No.
WP Sequence No.
TRANSFER CASE DRAIN/FILL PROCEDURE, Vol 4 . . . . . . . . . . . . . . . . . . . WP 0466
Figure 1. Transfer Case Drain and Fill Locations., Vol 4 . . . . . . . . . . . . . . . WP 0466
Figure 2. Transfer Case Drain and Fill Locations., Vol 4 . . . . . . . . . . . . . . . WP 0466
Table 1. Equipment Specification Capacities Table., Vol 4 . . . . . . . . . . . . . . WP 0466
TRANSFER CASE OIL COOLER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0467
Figure 1. Transfer Case Oil Cooler and Air Brake Quick Release Valves Location., Vol 4. WP 0467
Figure 2. Air Brake Quick Release Valve Mounting Bracket., Vol 4. . . . . . . . . . . WP 0467
Figure 3. Transfer Case Oil Cooler and Hoses., Vol 4 . . . . . . . . . . . . . . . . WP 0467
Figure 4. Transfer Case Oil Cooler Mounting., Vol 4 . . . . . . . . . . . . . . . . . WP 0467
Figure 5. Transfer Case Oil Cooler Mounting., Vol 4 . . . . . . . . . . . . . . . . . WP 0467
Figure 6. Transfer Case Oil Cooler and Hoses., Vol 4 . . . . . . . . . . . . . . . . WP 0467
Figure 7. Air Brake Quick Release Valve Mounting Bracket., Vol 4. . . . . . . . . . . WP 0467
Figure 8. Rear Air Brake Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . WP 0467
PROP SHAFT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . WP 0468
Figure 1. Prop Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0468
Figure 2. Prop Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0468
TRANSMISSION TO TRANSFER CASE PROP SHAFT REMOVAL AND INSTALLATION, Vol 4. WP 0469
Figure 1. Transfer Case End of Propshaft Straps and Bolts., Vol 4. . . . . . . . . . . WP 0469
Figure 2. Transmission End of Propshaft Straps and Bolts., Vol 4 . . . . . . . . . . . WP 0469
Figure 3. Transmission End of Propshaft Straps and Bolts., Vol 4 . . . . . . . . . . . WP 0469
Figure 4. Transfer Case End of Propshaft Straps and Bolts., Vol 4. . . . . . . . . . . WP 0469
FRONT AXLE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0470
Figure 1. Raising Front Axle., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0470
Figure 2. Highboy Jackstand Right Side., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0470
Figure 3. Highboy Jackstand Left Side., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0470
Figure 4. Vent Tube Disconnection., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0470
Figure 5. Left Front Shock Absorber Lower Mount., Vol 4 . . . . . . . . . . . . . . WP 0470
Figure 6. Left Air Brake Chamber Disconnected., Vol 4 . . . . . . . . . . . . . . . WP 0470
Figure 7. Left Antilock Brake System (ABS) Sensor Disconnected., Vol 4 . . . . . . . WP 0470
Figure 8. Right Front Shock Absorber Lower Mount., Vol 4 . . . . . . . . . . . . . . WP 0470
Figure 9. Right Air Brake Chamber Disconnected., Vol 4 . . . . . . . . . . . . . . . WP 0470
Figure 10. Right Antilock Brake System (ABS) Sensor Disconnected., Vol 4 . . . . . . WP 0470
Figure 11. Front U-Bolt Plates and Axle Assembly Removal., Vol 4 . . . . . . . . . . WP 0470
Figure 12. Preparation for Wheel and Tire Removal., Vol 4 . . . . . . . . . . . . . . WP 0470
Figure 13. Preparation for Wheel and Tire Installation., Vol 4 . . . . . . . . . . . . . WP 0470
Figure 14. Front Axle Assembly Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0470
Figure 15. Front Axle Assembly Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0470
Figure 16. U-Bolt Plate Locknuts Torque Sequence., Vol 4 . . . . . . . . . . . . . . WP 0470
Figure 17. Right ABS Sensor Connected., Vol 4 . . . . . . . . . . . . . . . . . . WP 0470
Figure 18. Right Air Brake Chamber Connected., Vol 4 . . . . . . . . . . . . . . . WP 0470
Figure 19. Right Front Shock Absorber on Lower Mount., Vol 4 . . . . . . . . . . . . WP 0470
Figure 20. Left ABS Sensor Connected., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0470
Figure 21. Left Air Brake Chamber Connected., Vol 4 . . . . . . . . . . . . . . . . WP 0470
Figure 22. Left Front Shock Absorber on Lower Mount., Vol 4 . . . . . . . . . . . . WP 0470
xcix
TM 9-2355-106-23-1

Page No.
WP Sequence No.
FRONT WHEEL HUB AND BEARING REMOVAL AND INSTALLATION , Vol 4 . . . . . . . . WP 0471
Figure 1. Hubcap Removal. Brake Shoes and Hardware Removed for Clarity., Vol 4. . . WP 0471
Figure 2. Snapring Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 3. Drive Flange Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 4. Hub and Spindle, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 5. Hub, Bearing, and Seal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 6. Bearing Cone Cage Inspection., Vol 4. . . . . . . . . . . . . . . . . . . WP 0471
Figure 7. Tapered Roller Cup Inspection., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0471
Figure 8. Spindle Inspection., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 9. Antilock Brake System (ABS) Tone Ring Inspection, Vol 4 . . . . . . . . . . WP 0471
Figure 10. Two-Jaw Puller Inner Tapered Roller Cup Removal., Vol 4 . . . . . . . . . WP 0471
Figure 11. Inner Tapered Roller Cup Removal., Vol 4 . . . . . . . . . . . . . . . . WP 0471
Figure 12. Outer Tapered Roller Cup., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 13. Inner Tapered Roller Cup., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 14. Outer Tapered Roller Cup., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 15. Hub and Bearings., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 16. Hub and Spindle., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 17. Dial Indicator., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 18. Snapring Installation., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0471
Figure 19. Hubcap., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0471
FRONT AXLE ASSEMBLY ALIGNMENT PROCEDURE, Vol 4 . . . . . . . . . . . . . . . WP 0472
Figure 1. Preparing Tires., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0472
Figure 2. Positioning Wheel Alignment Gauge., Vol 4 . . . . . . . . . . . . . . . . WP 0472
Figure 3. Scribing Line on Tires., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0472
Figure 4. Toe Measurement, Viewed from Above., Vol 4 . . . . . . . . . . . . . . . WP 0472
Figure 5. Toe Adjustment., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0472
Figure 6. Toe Measurement, Viewed from Above., Vol 4 . . . . . . . . . . . . . . . WP 0472
FRONT AXLE BREATHER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0473
Figure 1. Front Axle Breather Hose Clamp Removal from Breather., Vol 4 . . . . . . . WP 0473
Figure 2. Front Axle Breather Removal from Differential Case., Vol 4 . . . . . . . . . WP 0473
Figure 3. Front Axle Breather Installation., Vol 4 . . . . . . . . . . . . . . . . . . WP 0473
Figure 4. Breather Hose Installed on Front Axle Breather., Vol 4 . . . . . . . . . . . WP 0473
FRONT AXLE DIFFERENTIAL DRAIN/FILL PROCEDURE, Vol 4 . . . . . . . . . . . . . . WP 0474
Figure 1. Front Axle Differential Case., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0474
Figure 2. Front Axle Differential Case., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0474
UPPER AND LOWER KING PIN BUSHING AND AXLE SHAFT OIL SEAL REMOVAL AND
Figure 1. Drive Shaft Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0475
Figure 2. Axle Housing., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0475
Figure 3. King Pin Socket and Bushing Removal., Vol 4 . . . . . . . . . . . . . . . WP 0475
Figure 4. Axle Shaft Oil Seal Removal., Vol 4. . . . . . . . . . . . . . . . . . . . WP 0475
Figure 5. Axle Shaft Oil Seal Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0475
Figure 6. Socket Plug Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0475
Figure 7. King Pin Bushing on Driver., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0475
Figure 8. King Pin Bushing Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0475
Figure 9. Drive Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0475
c
TM 9-2355-106-23-1

Page No.
WP Sequence No.
STEERING ARM REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . . . . . . WP 0476
Figure 1. Steering Arm Set-Up for Removal., Vol 4 . . . . . . . . . . . . . . . . . WP 0476
Figure 2. Steering Arm., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0476
Figure 3. Brake Chamber Mounting Bracket., Vol 4 . . . . . . . . . . . . . . . . . WP 0476
Figure 4. Steering Arm and Knuckle., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0476
Figure 5. Steering Arm and Knuckle., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0476
Figure 6. Brake Chamber Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0476
Figure 8. Steering Arm Set-Up for Installation., Vol 4 . . . . . . . . . . . . . . . . WP 0476
STEERING KNUCKLE AND KING PIN REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0477
Figure 1. Steering Knuckle., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . WP 0477
Figure 2. Steering Knuckle Supported by Floor Jack., Vol 4 . . . . . . . . . . . . . WP 0477
Figure 4. Cleaning Steering Knuckle., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0477
Figure 5. Inspecting Upper and Lower Steering Knuckle Caps., Vol 4 . . . . . . . . . WP 0477
Figure 6. Inspecting King Pin Bushings., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0477
Figure 7. Inspecting Upper and Lower Bearing Surfaces of Steering Knuckle., Vol 4 . . . WP 0477
Figure 8. Steering Knuckle Supported by Floor Jack., Vol 4 . . . . . . . . . . . . . WP 0477
Figure 10. Steering Knuckle End Play., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0477
Figure 11. Lower Steering Knuckle Cap and Grease Fitting. Lower Shown; Upper
Similar., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0477
Figure 12. Steering Knuckle Bearing Preload., Vol 4. . . . . . . . . . . . . . . . . WP 0477
REAR AXLE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0478
Figure 1. Air Chamber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 2. Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 3. Air Vent Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 4. Inner Air Line Hoses., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 5. Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 6. 20-Ton Floor Jack., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 8. 10-Ton Jackstands., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 10. Hoist Lever Chain., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 11. Strap., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 12. Hoist Lever., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 13. Rear Axle Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 14. 10-Ton Jackstand Removal., Vol 4. . . . . . . . . . . . . . . . . . . . WP 0478
Figure 15. Rear Axle Assembly Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0478
Figure 16. Block and Wedge., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 17. Wedge and Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 19. Hoist Lever Chain., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 20. Strap., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 22. Guide Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 23. Wedge., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 24. Rear Axle Assembly Installation., Vol 4. . . . . . . . . . . . . . . . . . WP 0478
Figure 25. Spring Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 26. 10-Ton Jackstands., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 27. Rear Axle Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
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WP Sequence No.
Figure 29. 10-Ton Vehicle Support Stand., Vol 4 . . . . . . . . . . . . . . . . . . WP 0478
Figure 30. Jackstand., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 32. Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 33. Inner Air Line Hoses., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 34. Air Vent Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 35. Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0478
Figure 36. Air Chamber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0478
REAR AXLE DIFFERENTIAL DRAIN/FILL PROCEDURE, Vol 4. . . . . . . . . . . . . . . WP 0479
Figure 1. Rear Axle Differential., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0479
Figure 2. Rear Axle Differential., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0479
REAR HUB ASSEMBLY BEARING AND BEARING CUP REMOVAL AND INSTALLATION, Vol 4 WP 0480
Figure 1. Rear Hub Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0480
Figure 2. Rear Hub Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0480
REAR AXLE OUTER HUB ASSEMBLY DRAIN/FILL PROCEDURE, Vol 4 . . . . . . . . . . WP 0481
Figure 1. Drain/Fill Plug., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0481
Figure 2. Rear Axle Outer Hub Plug., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0481
Figure 3. Rear Axle Fill Plug., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0481
REAR AXLE SHAFT AND GASKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0482
Figure 1. Rear Axle Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0482
Figure 2. Rear Axle Shaft and Gasket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0482
Figure 3. Rear Axle Shaft and Gasket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0482
FRONT AXLE ANTILOCK BRAKE SYSTEM (ABS) TONE RING REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0483
Figure 1. Tone Ring and Hub., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0483
BRAKE ADJUSTMENT PROCEDURES, Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 1. Two-Pin Slack Adjuster., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 2. One-Pin Slack Adjuster., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 3. One-Pin Slack Adjuster., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 4. Pushrod., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 5. Pushrod Travel., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 6. Pushrod., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0484
Figure 7. Pushrod Travel., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0484
FRONT BRAKE DUST SHIELD REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0485
Figure 1. Dust Shield., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0485
FRONT BRAKE SHOES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0486
Figure 1. Front Brake Shoes., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0486
Figure 2. Anchor Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0486
Figure 4. Brake Shoes., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0486
FRONT BRAKE DRUM REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0487
Figure 1. Front Brake Drum., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0487
Figure 2. Front Brake Drum., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0487
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FRONT BRAKE S-CAMSHAFT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0488
Figure 2. Horizontal Line., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0488
Figure 3. Brake S-Camshaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0488
Figure 4. Snapring Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0488
Figure 5. Outer Grease Fitting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0488
Figure 6. Inner Grease Fitting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0488
FRONT BRAKE SPIDER AND SPINDLE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . WP 0489
Figure 1. Front Brake Spider Assembly Removal., Vol 4 . . . . . . . . . . . . . . . WP 0489
Figure 2. Spindle Assembly Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0489
Figure 3. Remove Seals and Bushings., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0489
Figure 4. Spindle and ABS Sensor Sleeve and Clip., Vol 4 . . . . . . . . . . . . . . WP 0489
Figure 5. Install Seals and Bushings., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0489
Figure 6. Camshaft Bushings Alignment., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0489
Figure 7. Spindle and ABS Sensor Sleeve and Clip., Vol 4 . . . . . . . . . . . . . . WP 0489
Figure 8. Spindle Assembly Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0489
Figure 9. Front Brake Spider Assembly Installation., Vol 4 . . . . . . . . . . . . . . WP 0489
FRONT SLACK ADJUSTER ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0490
Figure 1. Two-Pin Slack Adjuster Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0490
Figure 3. One-Pin Slack Adjuster Removal., Vol 4. . . . . . . . . . . . . . . . . . WP 0490
Figure 4. Two-Pin Slack Adjuster Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0490
Figure 5. Clevis Pins Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0490
Figure 6. Grease Fitting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0490
Figure 7. One-Pin Slack Adjuster Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0490
REAR ANTILOCK BRAKE SYSTEM (ABS) SENSOR REMOVAL AND INSTALLATION, Vol 4. . WP 0491
Figure 1. ABS Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0491
Figure 3. ABS Sensor Wire Bracket Nut., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0491
Figure 5. ABS Sensor Wire Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0491
Figure 6. ABS Electrical Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0491
REAR BRAKE DUST SHIELD REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0492
REAR BRAKE SHOES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0493
Figure 1. Rear Brake Shoes., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0493
Figure 3. Spider Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0493
Figure 5. Brake Shoes., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0493
REAR BRAKE DRUM AND HUB ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . WP 0494
Figure 1. Rear Brake Drum and Hub Assembly., Vol 4 . . . . . . . . . . . . . . . . WP 0494
Figure 2. Rear Brake Drum., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0494
Figure 3. Antilock Brake System (ABS) Ring., Vol 4 . . . . . . . . . . . . . . . . . WP 0494
Figure 4. ABS Ring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0494
Figure 5. Rear Brake Drum., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0494
Figure 6. Rear Brake Drum and Hub Assembly., Vol 4 . . . . . . . . . . . . . . . . WP 0494
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BRAKE S-CAMSHAFT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0495
Figure 2. Rear Brake S-Camshaft., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0495
Figure 3. Snapring Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0495
REAR BRAKE SPIDER ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0496
Figure 1. Rear Brake Spider Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0496
Figure 2. Remove Seals and Bushings., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0496
Figure 3. Install Seals and Bushings., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0496
Figure 4. Rear Brake Spider Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0496
REAR SLACK ADJUSTER ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0497
Figure 1. Two-Pin Slack Adjuster Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0497
Figure 2. Snapring and Clevis Pin Removal., Vol 4 . . . . . . . . . . . . . . . . . WP 0497
Figure 3. One-Pin Slack Adjuster Removal., Vol 4. . . . . . . . . . . . . . . . . . WP 0497
Figure 4. Two-Pin Slack Adjuster Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0497
Figure 5. Clevis Pins Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0497
Figure 7. One-Pin Slack Adjuster Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0497
Figure 8. Slack Adjuster Nut Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0497
BRAKE S-CAMSHAFT TUBE SUPPORT BRACKET REMOVAL AND INSTALLATION, Vol 4 . . WP 0498
Figure 1. Brake S-Camshaft Tube Support Bracket., Vol 4 . . . . . . . . . . . . . . WP 0498
Figure 2. Brake S-Camshaft Tube Support Bracket., Vol 4 . . . . . . . . . . . . . . WP 0498
AIR RESERVOIR TANK REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0499
Figure 1. Secondary Tank Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 2. Secondary Tank Air Lines and Fittings., Vol 4 . . . . . . . . . . . . . . . WP 0499
Figure 3. Secondary Tank Air Drain Cable., Vol 4 . . . . . . . . . . . . . . . . . . WP 0499
Figure 4. Supply Tank Air Lines and Fittings., Vol 4 . . . . . . . . . . . . . . . . . WP 0499
Figure 5. Secondary and Supply Tank Air Lines., Vol 4. . . . . . . . . . . . . . . . WP 0499
Figure 6. Primary and Supply Tank Air Drain Cables., Vol 4 . . . . . . . . . . . . . WP 0499
Figure 7. Supply and Secondary Tank Mounting., Vol 4 . . . . . . . . . . . . . . . WP 0499
Figure 8. Air Tank Cable Fasteners., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 9. Primary Tank Air Lines and Fittings., Vol 4 . . . . . . . . . . . . . . . . . WP 0499
Figure 10. Primary Tank Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 11. Primary Tank Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 12. Primary Tank Air Lines and Fittings., Vol 4 . . . . . . . . . . . . . . . . WP 0499
Figure 13. Route Two Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 14. Supply and Secondary Tank Mounting., Vol 4 . . . . . . . . . . . . . . . WP 0499
Figure 15. Air Tank Cable Fasteners., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0499
Figure 16. Primary and Supply Tank Air Drain Cables., Vol 4 . . . . . . . . . . . . . WP 0499
Figure 17. Secondary and Supply Tank Air Lines., Vol 4 . . . . . . . . . . . . . . . WP 0499
Figure 18. Supply Tank Air Lines and Fittings., Vol 4. . . . . . . . . . . . . . . . . WP 0499
Figure 19. Secondary Tank Air Drain Cable., Vol 4 . . . . . . . . . . . . . . . . . WP 0499
Figure 20. Secondary Tank Air Lines and Fittings., Vol 4 . . . . . . . . . . . . . . . WP 0499
Figure 21. Secondary Tank Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0499
CABIN DOOR ASSIST SYSTEM LIMIT VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . WP 0500
Figure 1. Primary and Supply Tanks., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0500
Figure 2. Limit Valve Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0500
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WP Sequence No.
BRAKE PEDAL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . WP 0501
Figure 1. Brake Pedal Yoke Pin Cotter Pin., Vol 4 . . . . . . . . . . . . . . . . . . WP 0501
Figure 2. Brake Pedal Pivot Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0501
Figure 3. Brake Pedal Pivot., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0501
Figure 4. Brake Pedal Yoke Pin., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0501
Figure 5. Brake Pedal Pivot Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0501
Figure 6. Brake Pedal Yoke Pin Cotter Pin., Vol 4 . . . . . . . . . . . . . . . . . . WP 0501
FOOT BRAKE VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0502
Figure 1. Exhaust Air Line., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 2. Foot Brake Valve Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 3. Brake Pedal Cotter Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 4. Brake Pedal Yoke Pin., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 5. Foot Brake Valve and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0502
Figure 6. Foot Brake Valve, Bracket, and Yoke Assembly., Vol 4 . . . . . . . . . . . WP 0502
Figure 7. Foot Brake Valve Lower Fittings., Vol 4 . . . . . . . . . . . . . . . . . . WP 0502
Figure 8. Foot Brake Valve, Bracket, and Yoke Assembly., Vol 4 . . . . . . . . . . . WP 0502
Figure 9. Foot Brake Valve and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0502
Figure 10. Brake Pedal Yoke Pin., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 11. Brake Pedal Yoke Cotter Pin., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0502
Figure 12. Foot Brake Valve Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0502
Figure 13. Exhaust Air Line., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0502
TRACTOR PROTECTION VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0503
Figure 1. Door Actuator Air Line Supply., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0503
Figure 2. Exterior Air Lines., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . WP 0503
Figure 3. Tractor Protection Valve Upper Air Lines., Vol 4 . . . . . . . . . . . . . . WP 0503
Figure 4. Tractor Protection Valve Lower Air Lines., Vol 4 . . . . . . . . . . . . . . WP 0503
Figure 5. Tractor Protection Valve and Bracket., Vol 4 . . . . . . . . . . . . . . . . WP 0503
Figure 6. Tractor Protection Valve Bracket., Vol 4 . . . . . . . . . . . . . . . . . . WP 0503
Figure 7. Tractor Protection Valve Fittings., Vol 4 . . . . . . . . . . . . . . . . . . WP 0503
Figure 8. Tractor Protection Valve Fittings., Vol 4 . . . . . . . . . . . . . . . . . . WP 0503
Figure 9. Tractor Protection Valve Bracket., Vol 4 . . . . . . . . . . . . . . . . . . WP 0503
Figure 10. Tractor Protection Valve and Bracket., Vol 4 . . . . . . . . . . . . . . . WP 0503
Figure 12. Tractor Protection Valve Upper Air Lines., Vol 4 . . . . . . . . . . . . . . WP 0503
Figure 13. Exterior Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0503
Figure 14. Door Actuator Air Line Supply., Vol 4. . . . . . . . . . . . . . . . . . . WP 0503
UPPER AIR LINE GROMMET REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0504
Figure 1. Dual Brake Valve and Tractor Protection Valve Upper Air Lines., Vol 4 . . . . WP 0504
Figure 3. Interior Air Lines Inside Cabin View., Vol 4 . . . . . . . . . . . . . . . . . WP 0504
Figure 4. Interior Air Lines Inside Cabin View., Vol 4 . . . . . . . . . . . . . . . . . WP 0504
Figure 6. Dual Brake Valve and Tractor Protection Valve Upper Air Lines., Vol 4 . . . . WP 0504
DRIVER CONTROL MODULE (DCM) LEFT AIR LINE GROMMET REMOVAL AND
Figure 3. Interior Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0505
Figure 4. Interior Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0505
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WP Sequence No.
HAND BRAKE CONTROL VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0506
Figure 1. Instrument Panel (IP) Center Trim Panel., Vol 4 . . . . . . . . . . . . . . WP 0506
Figure 2. Hand Brake Control Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0506
Figure 3. Hand Brake Control Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0506
Table 1. Hand Brake Control Valve Tubing., Vol 4 . . . . . . . . . . . . . . . . . . WP 0506
FRONT ANTILOCK BRAKE SYSTEM (ABS) MODULATOR VALVE REMOVAL AND
Figure 2. ABS Modulator Valve Air Line., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0507
Figure 3. ABS Modulator Valve and Bolts., Vol 4 . . . . . . . . . . . . . . . . . . WP 0507
Figure 4. ABS Modulator Air Line Fittings., Vol 4 . . . . . . . . . . . . . . . . . . WP 0507
Figure 5. ABS Modulator Air Line Fittings., Vol 4 . . . . . . . . . . . . . . . . . . WP 0507
Figure 6. ABS Modulator Valve Air Line., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0507
Figure 7. ABS Modulator Valve and Bolts., Vol 4 . . . . . . . . . . . . . . . . . . WP 0507
FRONT BRAKE AIR HOSES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0508
Figure 2. Front Brake Chamber., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0508
Figure 3. Front Brake Chamber., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0508
SPRING BRAKE MODULATING VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0509
AIR BRAKE RELAY VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0510
Figure 1. Air Brake Relay Valve Connections., Vol 4 . . . . . . . . . . . . . . . . . WP 0510
Figure 2. Air Brake Relay Valve Mounting., Vol 4 . . . . . . . . . . . . . . . . . . WP 0510
Figure 3. Air Brake Relay Valve Mounting., Vol 4 . . . . . . . . . . . . . . . . . . WP 0510
Figure 4. Air Brake Relay Valve Connections., Vol 4 . . . . . . . . . . . . . . . . . WP 0510
REAR ANTILOCK BRAKE SYSTEM (ABS) MODULATOR VALVE REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0511
Figure 1. ABS Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0511
Figure 2. ABS Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0511
AIR HOSE QUICK CONNECT FITTING REMOVAL AND INSTALLATION, Vol 4. . . . . . . . WP 0512
Figure 1. Air Hose Quick Connect Fitting Replacement., Vol 4 . . . . . . . . . . . . WP 0512
Figure 2. Air Fitting Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0512
AIR HOSE FITTING REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0513
Figure 1. Air Hose Fitting Replacement., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0513
Figure 2. Air Hose Fitting Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0513
FRONT BRAKE AIR CHAMBER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0514
Figure 1. Left Air Line Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0514
Figure 2. Right Air Line Hose., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0514
Figure 3. Air Chamber – Automatic Slack Adjuster., Vol 4 . . . . . . . . . . . . . . WP 0514
Figure 4. Air Chamber – Manual Slack Adjuster., Vol 4. . . . . . . . . . . . . . . . WP 0514
Figure 7. Air Chamber – Manual Slack Adjuster., Vol 4. . . . . . . . . . . . . . . . WP 0514
Figure 8. Left Air Line Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0514
Figure 9. Right Air Line Hose., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0514
cvi
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Page No.
WP Sequence No.
REAR BRAKE AIR HOSES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0515
Figure 1. Rear Brake Chamber Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0515
Figure 2. Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0515
Figure 4. Rear Brake Chamber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0515
Figure 5. Rear Brake Chamber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0515
Figure 6. Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0515
Figure 8. Brake Chamber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0515
REAR BRAKE AIR CHAMBER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0516
Figure 2. Air Line Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0516
Figure 3. ABS Sensor Wire Bracket Nut., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0516
Figure 4. Air Chamber Slack Adjuster with Two Clevis Pins., Vol 4 . . . . . . . . . . WP 0516
Figure 5. Air Chamber Slack Adjuster with One Clevis Pin., Vol 4 . . . . . . . . . . . WP 0516
Figure 6. Air Chamber Slack Adjuster with Two Clevis Pins., Vol 4 . . . . . . . . . . WP 0516
Figure 7. Air Chamber Slack Adjuster with One Clevis Pin., Vol 4 . . . . . . . . . . . WP 0516
Figure 8. ABS Sensor Wire Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0516
Figure 9. Air Line Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0516
Figure 10. Modulator Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0516
AIR DRYER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0517
Figure 1. Air Dryer Connections., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0517
Figure 3. Air Dryer Support Bracket Bolts., Vol 4 . . . . . . . . . . . . . . . . . . WP 0517
Figure 6. Air Dryer Support Bracket Bolts., Vol 4 . . . . . . . . . . . . . . . . . . WP 0517
AIR DRYER BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0518
Figure 1. Air Dryer Lower Mounting Bracket., Vol 4 . . . . . . . . . . . . . . . . . WP 0518
Figure 2. Air Dryer Bracket Harness Retainers., Vol 4 . . . . . . . . . . . . . . . . WP 0518
Figure 3. Left Rear Gladhand Air Hose., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0518
Figure 4. Quick Disconnect Air Hose Rear of Transfer Case Oil Cooler ., Vol 4 . . . . . WP 0518
Figure 5. Air Brake Quick Release Valve Air Hose., Vol 4 . . . . . . . . . . . . . . WP 0518
Figure 6. Air Brake Relay Valve Air Hose., Vol 4 . . . . . . . . . . . . . . . . . . WP 0518
Figure 7. Transfer Case Oil Cooler Lines., Vol 4 . . . . . . . . . . . . . . . . . . WP 0518
Figure 8. Air Dryer Bracket., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . WP 0518
Figure 9. Air Dryer Bracket Frame Nuts and Bolts., Vol 4. . . . . . . . . . . . . . . WP 0518
Figure 10. Air Dryer Bracket Harness Retainers., Vol 4 . . . . . . . . . . . . . . . WP 0518
Figure 11. Air Dryer Lower Mounting Bracket., Vol 4 . . . . . . . . . . . . . . . . . WP 0518
Figure 12. Left Gladhand Air Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0518
Figure 13. Quick Connect Air Hose Rear of Transfer Case Oil Cooler., Vol 4 . . . . . . WP 0518
Figure 14. Air Brake Quick Release Valve Air Hose., Vol 4 . . . . . . . . . . . . . . WP 0518
Figure 15. Air Brake Relay Valve Air Hose., Vol 4 . . . . . . . . . . . . . . . . . . WP 0518
Figure 16. Transfer Case Oil Cooler Lines., Vol 4 . . . . . . . . . . . . . . . . . . WP 0518
AIR DRYER DESICCANT CARTRIDGE REMOVAL AND INSTALLATION, Vol 4. . . . . . . . WP 0519
Figure 1. Air Dryer Desiccant Cartridge., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0519
Figure 2. Air Dryer Cartridge Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0519
Figure 3. Air Dryer Cartridge Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0519
Figure 4. Air Dryer Desiccant Cartridge., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0519
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Page No.
WP Sequence No.
PRESSURE PROTECTION VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0520
Figure 1. Pressure Protection Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0520
Figure 2. Pressure Protection Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0520
AIR BRAKE QUICK RELEASE VALVES REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0521
Figure 1. Front Air Brake Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . WP 0521
Figure 2. Rear Air Brake Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . WP 0521
Figure 3. Front Air Brake Quick Release Valve., Vol 4 . . . . . . . . . . . . . . . . WP 0521
AIR BRAKE DOUBLE CHECK VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0522
Figure 1. Air Brake Double Check Valve., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0522
AIR COMPRESSOR SUPPLY AIR LINE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0523
Figure 1. Air Compressor Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0523
Figure 2. Air Intake Tube Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0523
Figure 3. Air Intake Tube Connection., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0523
AIR COMPRESSOR DELIVERY AIR LINE REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0524
Figure 2. Air Compressor Delivery Air Line Bracket Clamp., Vol 4 . . . . . . . . . . . WP 0524
Figure 3. Air Line Pipe and Hose Connection., Vol 4. . . . . . . . . . . . . . . . . WP 0524
Figure 4. Air Line Hose Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0524
Figure 7. Air Line Hose at Air Dryer., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0524
Figure 8. Fabricating Air Compressor Tube., Vol 4 . . . . . . . . . . . . . . . . . WP 0524
Figure 9. Making Air Compressor Tube Ends., Vol 4 . . . . . . . . . . . . . . . . . WP 0524
Figure 11. Air Compressor Delivery Air Line Bracket Clamp., Vol 4 . . . . . . . . . . WP 0524
Figure 12. Air Line Pipe and Hose Connection., Vol 4 . . . . . . . . . . . . . . . . WP 0524
Figure 13. Air Line Hose at Air Dryer., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0524
Figure 14. Air Line Hose Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . WP 0524
AIR COMPRESSOR GOVERNOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0525
Figure 1. Air Compressor Governor Connections., Vol 4 . . . . . . . . . . . . . . . WP 0525
Figure 3. Air Compressor Governor Fittings., Vol 4 . . . . . . . . . . . . . . . . . WP 0525
Figure 4. Air Compressor Governor Fittings., Vol 4 . . . . . . . . . . . . . . . . . WP 0525
Figure 6. Air Compressor Governor Connections., Vol 4 . . . . . . . . . . . . . . . WP 0525
AIR COMPRESSOR GOVERNOR ADJUSTMENT PROCEDURE, Vol 4 . . . . . . . . . . . WP 0526
Figure 1. Air Compressor Governor, Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0526
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Page No.
WP Sequence No.
AIR COMPRESSOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0527
Figure 3. Air Compressor Coolant Inlet Block Connection., Vol 4 . . . . . . . . . . . WP 0527
Figure 4. Air Compressor Coolant Outlet., Vol 4. . . . . . . . . . . . . . . . . . . WP 0527
Figure 5. Air Compressor Coolant Outlet Block Connection., Vol 4 . . . . . . . . . . WP 0527
Figure 6. Air Compressor Oil Inlet., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0527
Figure 7. Air Compressor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0527
Figure 8. Air Compressor Coolant Inlet., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0527
Figure 9. Air Compressor Front Cover Gasket., Vol 4 . . . . . . . . . . . . . . . . WP 0527
Figure 10. Air Compressor Front Cover Gasket., Vol 4 . . . . . . . . . . . . . . . . WP 0527
Figure 11. Air Compressor Coolant Inlet., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0527
Figure 12. Air Compressor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0527
Figure 13. Air Compressor Oil Inlet., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0527
Figure 14. Air Compressor Coolant Outlet Block Connection., Vol 4 . . . . . . . . . . WP 0527
Figure 15. Air Compressor Coolant Outlet., Vol 4 . . . . . . . . . . . . . . . . . . WP 0527
Figure 16. Air Compressor Coolant Inlet Block Connection., Vol 4 . . . . . . . . . . . WP 0527
GLADHANDS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . WP 0528
Figure 1. Gladhand., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0528
Figure 2. Gladhand., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0528
TRAILER CONTROL VALVE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0529
Figure 1. Trailer Control Valve Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0529
Figure 2. Trailer Control Valve Handle and Mount., Vol 4 . . . . . . . . . . . . . . . WP 0529
Figure 3. Trailer Control Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0529
Figure 4. Trailer Control Valve Handle and Mount., Vol 4 . . . . . . . . . . . . . . . WP 0529
Figure 5. Trailer Control Valve Air Lines., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0529
WHEEL AND TIRE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0530
Figure 1. Wheel and Tire Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0530
Figure 2. Wheel Nuts and Bolts., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0530
Figure 3. Wheel and Tire Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0530
TIE ROD REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0531
Figure 1. Tie Rod End to Knuckle. Right Shown, Left Similar., Vol 4 . . . . . . . . . . WP 0531
Figure 2. Tie Rod End and Knuckle., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0531
Figure 3. Tie Rod-to-Steering Knuckle Position., Vol 4 . . . . . . . . . . . . . . . . WP 0531
Figure 4. Tie Rod Clamp., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . WP 0531
STEERING SHAFT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0532
Figure 1. Steering Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0532
Figure 3. Steering Column End., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0532
Figure 4. Steering Gear End., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0532
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TM 9-2355-106-23-1

Page No.
WP Sequence No.
STEERING COLUMN REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0533
Figure 1. Steering Shaft at Column., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 2. Turn Signal Switch, Lower., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 3. Turn Signal Switch, Upper., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 4. Trailer Brake Control Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 5. Steering Column., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 6. Lower Steering Column., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 7. Lower Steering Column., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 8. Steering Column., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 9. Trailer Brake Control Valve., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 10. Turn Signal Switch, Lower., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 11. Turn Signal Switch, Upper., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0533
Figure 12. Steering Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0533
STEERING WHEEL AND CLOCK SPRING REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0534
Figure 1. Steering Wheel with Horn Button Removed., Vol 4 . . . . . . . . . . . . . WP 0534
Figure 2. Steering Wheel and Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 3. Steering Wheel Puller., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 4. Clock Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 5. Clock Spring Timing., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 6. Clock Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 7. Steering Wheel and Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0534
Figure 8. Steering Wheel with Horn Button Removed., Vol 4 . . . . . . . . . . . . . WP 0534
PITMAN ARM REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . WP 0535
Figure 2. Pitman Arm Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 3. Pitman Arm Retainer Removal., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0535
Figure 4. Pitman Arm Puller., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 5. Pitman Arm and Sector Shaft., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0535
Figure 6. Pitman Arm Retainer Kit., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 7. Pitman Arm Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 8. Pitman Arm and Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 10. Tightening Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 11. Installed Depth Measurement., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0535
Figure 12. Pitman Arm and Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 13. Tightening Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 14. Pitman Arm Retainer., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0535
Figure 15. Bending Retaining Tabs., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0535
STEERING DRAG LINK REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0536
STEERING GEAR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . WP 0537
Figure 2. Steering Gear Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0537
Figure 3. Steering Gear Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0537
BLEEDING SINGLE GEAR, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0538
Figure 1. Support Front Axle., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0538
Figure 2. Power Steering Pump Reservoir., Vol 4 . . . . . . . . . . . . . . . . . . WP 0538
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Page No.
WP Sequence No.
POWER STEERING PUMP REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0539
Figure 1. Air Compressor Support., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0539
Figure 4. Pump Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0539
Figure 5. Power Steering Pump Inlet Hose., Vol 4 . . . . . . . . . . . . . . . . . . WP 0539
Figure 6. Power Steering Pump Inlet Hose., Vol 4 . . . . . . . . . . . . . . . . . . WP 0539
Figure 7. Pump Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0539
Figure 10. Power Steering Pump Support., Vol 4 . . . . . . . . . . . . . . . . . . WP 0539
POWER STEERING TUBING AND HOSE REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0540
Figure 1. Power Steering Hoses., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0540
POWER STEERING RESERVOIR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0541
Figure 1. Power Steering Reservoir and Hoses., Vol 4 . . . . . . . . . . . . . . . . WP 0541
Figure 2. Power Steering Reservoir and Hoses., Vol 4 . . . . . . . . . . . . . . . . WP 0541
POWER STEERING FILTER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0542
Figure 1. Power Steering Reservoir., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0542
POWER STEERING RESERVOIR DRAIN/FILL PROCEDURE, Vol 4 . . . . . . . . . . . . WP 0543
FRONT BUMPER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . WP 0544
Figure 1. Right Front Towing Eye Brace., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0544
Figure 2. Right Side View of Winch Carrier Assembly., Vol 4 . . . . . . . . . . . . . WP 0544
Figure 3. Right Side Armor Grille Support., Vol 4 . . . . . . . . . . . . . . . . . . WP 0544
Figure 4. Right Side of Front Bumper., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0544
Figure 5. Right Front Turn Signal and Parking Light Panel Mount., Vol 4 . . . . . . . . WP 0544
Figure 6. Wire Harness Supports., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0544
Figure 7. Right Side Lower Bumper Brace., Vol 4 . . . . . . . . . . . . . . . . . . WP 0544
Figure 8. Upper Bumper Braces., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0544
Figure 9. Upper Bumper Braces., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0544
Figure 10. Right Side Lower Bumper Brace., Vol 4 . . . . . . . . . . . . . . . . . WP 0544
Figure 11. Right Front Turn Signal and Parking Light Panel Mount., Vol 4 . . . . . . . WP 0544
Figure 12. Right Side of Front Bumper., Vol 4. . . . . . . . . . . . . . . . . . . . WP 0544
Figure 13. Right Side Armor Grille Support., Vol 4. . . . . . . . . . . . . . . . . . WP 0544
Figure 14. Right Side View of Winch Carrier Assembly., Vol 4. . . . . . . . . . . . . WP 0544
Figure 15. Right Front Towing Eye Brace., Vol 4 . . . . . . . . . . . . . . . . . . WP 0544
Figure 16. Wire Harness Brackets., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0544
WINCH REMOTE CONTROL CONNECTOR SUPPORT REMOVAL AND INSTALLATION, Vol 4 WP 0545
Figure 1. Winch Remote Control Connector., Vol 4 . . . . . . . . . . . . . . . . . WP 0545
Figure 2. Winch Remote Control Connector., Vol 4 . . . . . . . . . . . . . . . . . WP 0545
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Page No.
WP Sequence No.
FRONT FRAME CROSSMEMBER AND RADIATOR SUPPORT REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0546
Figure 1. Lower Radiator Crossmember and Button-Head Cable Lock Straps., Vol 4. . . WP 0546
Figure 2. Radiator Support Crossmember., Vol 4 . . . . . . . . . . . . . . . . . . WP 0546
Figure 3. Cable Lock Strap Saddle Mounts on Right Side Radiator Support Crossmember
Brace., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0546
Figure 4. Radiator Support Crossmember and Radiator Support Assembly., Vol 4 . . . . WP 0546
Figure 5. Radiator Support Crossmember and Radiator Support Assembly., Vol 4 . . . . WP 0546
Figure 6. Radiator Support Crossmember., Vol 4 . . . . . . . . . . . . . . . . . . WP 0546
Figure 7. Lower Radiator Crossmember., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0546
Figure 8. Cable Lock Strap Saddle Mounts on Right Side Radiator Support Crossmember
Brace., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0546
FRONT FRAME CROSSMEMBER AND SUPPORT REMOVAL AND INSTALLATION, Vol 4 . . WP 0547
Figure 1. Front Frame Crossmember Assembly., Vol 4. . . . . . . . . . . . . . . . WP 0547
Figure 2. Front Frame Crossmember and Supports., Vol 4 . . . . . . . . . . . . . . WP 0547
Figure 3. Front Frame Crossmember., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0547
ENGINE MOUNT CROSSMEMBER ASSEMBLY REMOVAL AND INSTALLATION, Vol 4. . . . WP 0548
Figure 1. Engine Lifting Eye., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0548
Figure 3. Jackstand Placement., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0548
Figure 4. Engine Mount Insulator., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0548
Figure 5. Engine Mount Crossmember Assembly., Vol 4 . . . . . . . . . . . . . . . WP 0548
Figure 6. Engine Mount Crossmember Assembly., Vol 4 . . . . . . . . . . . . . . . WP 0548
Figure 7. Engine Mount Insulator., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0548
REAR FRAME CROSSMEMBER AND SUPPORT REMOVAL AND INSTALLATION, Vol 4 . . . WP 0549
Figure 1. Side View of Right Rear Towing Eye., Vol 4 . . . . . . . . . . . . . . . . WP 0549
Figure 2. Left Gladhand Cable Tie Location., Vol 4 . . . . . . . . . . . . . . . . . WP 0549
Figure 3. Backside of Rear Frame Crossmember and Left Support., Vol 4 . . . . . . . WP 0549
Figure 4. Backside of Rear Frame Crossmember and Left Support., Vol 4 . . . . . . . WP 0549
Figure 6. Left Gladhand Cable Tie Location., Vol 4 . . . . . . . . . . . . . . . . . WP 0549
HARNESS SUPPORT BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0550
Figure 1. Harness Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0550
Figure 2. Right Harness Support Bracket Frame Brace., Vol 4 . . . . . . . . . . . . WP 0550
Figure 3. Right Harness Support Bracket Frame Brace Bolts., Vol 4 . . . . . . . . . . WP 0550
Figure 4. Left Harness Support Bracket Frame Brace Bolts., Vol 4 . . . . . . . . . . WP 0550
Figure 5. Left Harness Support Bracket Frame Brace., Vol 4 . . . . . . . . . . . . . WP 0550
Figure 6. Left Harness Support Bracket Frame Brace., Vol 4 . . . . . . . . . . . . . WP 0550
Figure 7. Left Harness Support Bracket Frame Brace Bolts., Vol 4 . . . . . . . . . . WP 0550
Figure 8. Right Harness Support Bracket Frame Brace Bolts., Vol 4 . . . . . . . . . . WP 0550
Figure 9. Right Harness Support Bracket Frame Brace., Vol 4 . . . . . . . . . . . . WP 0550
Figure 10. Harness Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0550
REAR TOWING EYE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0551
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TOWING PINTLE HOOK REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0552
Figure 1. Towing Pintle Hook Assembly from Backside of Rear Frame Crossmember., Vol 4WP 0552
Figure 2. Towing Pintle Hook Assembly on Rear Frame Crossmember., Vol 4. . . . . . WP 0552
Figure 3. Towing Pintle Hook Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0552
Figure 4. Towing Pintle Hook Upper Jaw Assembly., Vol 4 . . . . . . . . . . . . . . WP 0552
Figure 5. Upper Jaw Release Handle Return Spring Location., Vol 4 . . . . . . . . . WP 0552
Figure 6. Upper Jaw Release Handle Return Spring Alignment., Vol 4 . . . . . . . . . WP 0552
Figure 7. Towing Pintle Hook Upper Jaw Assembly., Vol 4 . . . . . . . . . . . . . . WP 0552
Figure 8. Towing Pintle Hook Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0552
Figure 9. Towing Pintle Hook Assembly on Rear Frame Crossmember., Vol 4. . . . . . WP 0552
Figure 10. Towing Pintle Hook Assembly from Backside of Rear Frame Crossmem-
ber., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0552
Figure 11. Left Side View of Towing Pintle Hook., Vol 4 . . . . . . . . . . . . . . . WP 0552
FRONT TOWING EYE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . WP 0553
Figure 1. Side View of Right Front Towing Eye Behind Bumper., Vol 4 . . . . . . . . . WP 0553
Figure 2. Front View of Right Front Towing Eye., Vol 4 . . . . . . . . . . . . . . . . WP 0553
Figure 3. Side View of Right Front Towing Eye Behind Bumper., Vol 4 . . . . . . . . . WP 0553
FRONT AXLE BUMPER STOP REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0554
Figure 1. Front Axle Bumper Stop Removal., Vol 4 . . . . . . . . . . . . . . . . . WP 0554
Figure 2. Front Axle Bumper Stop Installation., Vol 4 . . . . . . . . . . . . . . . . WP 0554
FRONT AXLE BUMPER STOP BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0555
Figure 1. Front Axle Bumper Stop Bracket Locknut and Harness Clip Extension
Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0555
Figure 2. Front Bumper Stop Bracket Removal., Vol 4 . . . . . . . . . . . . . . . . WP 0555
Figure 3. Front Bumper Stop Bracket Installation., Vol 4 . . . . . . . . . . . . . . . WP 0555
Figure 4. Front Axle Bumper Stop Bracket Locknut and Harness Clip Extension
AUXILIARY SPRING REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . WP 0556
Figure 1. Auxiliary Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0556
Figure 2. Auxiliary Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0556
REAR SPRING ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0557
Figure 1. Rear Spring Rear Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . . . . WP 0557
Figure 2. Rear Spring Front Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . . . WP 0557
Figure 3. Rear Spring Pivot Link., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 4. Front U-Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 5. Rear U-Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 6. Rear Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 7. Rear Leaf Spring Front Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . WP 0557
Figure 8. Rear Spring., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 9. Rear Leaf Spring Front Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . WP 0557
Figure 10. Rear U-Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 11. Front U-Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 12. Rear Spring U-Bolt Tightening Sequence., Vol 4. . . . . . . . . . . . . . WP 0557
Figure 13. Rear Spring Pivot Link., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0557
Figure 14. Rear Spring Front Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . . . WP 0557
Figure 15. Rear Spring Rear Bracket Rebound Pin., Vol 4 . . . . . . . . . . . . . . WP 0557
FRONT SPRING SHACKLE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0558
Figure 1. Front Spring Shackle., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0558
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FRONT SPRING ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0559
Figure 1. Shock Absorber Lower Mount., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0559
Figure 2. Front Spring Rear Shackle., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 3. Front Spring Front Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 4. Raising Front of Vehicle., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 5. Front Spring Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 8. Front Spring Installation., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 9. Front Spring U-Bolts Installation., Vol 4 . . . . . . . . . . . . . . . . . . WP 0559
Figure 10. Front Spring and U-Bolts., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 11. Front Spring U-Bolt Tightening Sequence., Vol 4 . . . . . . . . . . . . . WP 0559
Figure 13. Front Spring Shackle., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0559
Figure 14. Shock Absorber Lower Mount., Vol 4 . . . . . . . . . . . . . . . . . . WP 0559
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0560
Figure 1. Front Shock Absorber Lower Mount Removal., Vol 4 . . . . . . . . . . . . WP 0560
Figure 2. Front Shock Absorber Upper Mount Removal., Vol 4 . . . . . . . . . . . . WP 0560
Figure 3. Front Shock Absorber Upper Mount Installation., Vol 4 . . . . . . . . . . . WP 0560
Figure 4. Front Shock Absorber Lower Mount Installation., Vol 4 . . . . . . . . . . . WP 0560
FRONT SHOCK ABSORBER LOWER MOUNTING BRACKET REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0561
Figure 1. Front Shock Absorber Lower Mounting Bracket Removal, U-Bolts, Locknuts and
Washers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0561
Figure 2. Front Shock Absorber Lower Mounting Bracket Removal., Vol 4 . . . . . . . WP 0561
Figure 3. Front Shock Absorber Lower Mounting Bracket Installation., Vol 4 . . . . . . WP 0561
Figure 4. Front Shock Absorber Lower Mounting Bracket Installation, U-Bolt Locknuts and
Washers., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0561
Figure 5. Front Spring U-Bolt Tightening Sequence., Vol 4 . . . . . . . . . . . . . . WP 0561
FRONT SHOCK ABSORBER UPPER MOUNTING BRACKET REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0562
Figure 1. Front Shock Absorber Upper Mounting Bracket Removal., Vol 4 . . . . . . . WP 0562
Figure 2. Front Shock Absorber Upper Mounting Bracket Installation., Vol 4 . . . . . . WP 0562
INSTRUMENT PANEL (IP) STORAGE BIN REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0563
Figure 1. IP Storage Bin Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0563
Figure 2. IP Storage Bin Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0563
CROSS-VEHICLE EQUIPMENT BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0564
Figure 1. Heated Windshield Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0564
Figure 2. Cross-Vehicle Equipment Bracket Bolt Exterior Locations., Vol 4 . . . . . . . WP 0564
Figure 3. Cross-Vehicle Equipment Bracket Nut Left Side Interior Locations., Vol 4 . . . WP 0564
Figure 4. Cross-Vehicle Equipment Bracket Nut Center Interior Location., Vol 4 . . . . . WP 0564
Figure 5. Cross-Vehicle Equipment Bracket Nut Right Side Interior Locations., Vol 4. . . WP 0564
Figure 6. Cross-Vehicle Equipment Bracket Bolt Exterior Locations., Vol 4 . . . . . . . WP 0564
Figure 7. Cross-Vehicle Equipment Bracket Nut Left Side Interior Locations., Vol 4 . . . WP 0564
Figure 8. Cross-Vehicle Equipment Bracket Nut Center Interior Location., Vol 4 . . . . . WP 0564
Figure 9. Cross-Vehicle Equipment Bracket Nut Right Side Interior Locations., Vol 4. . . WP 0564
Figure 10. Cross-Vehicle Equipment Bracket Bolt Exterior Locations., Vol 4 . . . . . . WP 0564
Figure 11. Heated Windshield Harness., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0564
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STEERING COLUMN COVERS REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0565
Figure 1. Steering Column Cover Upper Section Screws., Vol 4. . . . . . . . . . . . WP 0565
Figure 2. Steering Column Cover Upper Section., Vol 4 . . . . . . . . . . . . . . . WP 0565
Figure 3. Steering Column Cover Lower Section Screw., Vol 4 . . . . . . . . . . . . WP 0565
Figure 4. Steering Column Cover Wiring Harness Retainer., Vol 4 . . . . . . . . . . . WP 0565
Figure 5. Steering Column Cover Wiring Harness Retainer., Vol 4 . . . . . . . . . . . WP 0565
Figure 6. Steering Column Cover Lower Section Screw., Vol 4 . . . . . . . . . . . . WP 0565
Figure 7. Steering Column Cover Upper Section., Vol 4 . . . . . . . . . . . . . . . WP 0565
Figure 8. Steering Column Cover Upper Section Screws., Vol 4. . . . . . . . . . . . WP 0565
DRIVER CONTROL MOUNTING (DCM) BRACKET ASSEMBLY REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0566
Figure 1. DCM Bracket Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0566
Figure 2. DCM Bracket Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0566
ARMOR GRILLE REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . . . . . . WP 0567
Figure 1. Upper Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0567
Figure 2. Lower Mounting Bolts., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0567
Figure 3. Lower Mounting Bolts., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0567
Figure 4. Upper Support Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0567
ARMOR GRILLE SUPPORT AND ARMOR GRILLE SUPPORT BRACKET REMOVAL AND
Figure 1. Left Side Armor Grille Support and Bracket; Right Side Similar., Vol 4 . . . . . WP 0568
Figure 2. Left Side Armor Grille Support and Bracket; Right Side Similar., Vol 4 . . . . . WP 0568
HOOD/FENDER LATCH REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0569
Figure 1. Hood and Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0569
Figure 2. Fender and Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0569
Figure 3. Hood and Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0569
HOOD HINGE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0570
Figure 1. Hood Hinge Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0570
Figure 2. Hood Hinge Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0570
HOOD GRILLE AIR INTAKE REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . WP 0571
Figure 1. Hood Grille., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0571
Figure 2. Hood Grille., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0571
HOOD GRILLE SURROUND ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0572
Figure 1. Grille Support Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0572
Figure 2. Hood Grille Surround Assembly., Vol 4 . . . . . . . . . . . . . . . . . . WP 0572
Figure 3. Hood Grille Surround Assembly., Vol 4 . . . . . . . . . . . . . . . . . . WP 0572
Figure 4. Grille Support Installation., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0572
HOOD SAFETY CABLE ASSEMBLY REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0573
Figure 1. Hood Safety Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0573
HOOD TORSION ASSIST BAR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0574
Figure 1. Torsion Bar and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0574
Figure 2. Torsion Bar, Washer, and Clip., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0574
Figure 3. Torsion Bar, Washer, and Clip., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0574
Figure 4. Torsion Bar and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0574
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HOOD ASSEMBLY REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . . . . . . . WP 0575
Figure 1. Headlamp and Turn Signal Harness Connector., Vol 4 . . . . . . . . . . . WP 0575
Figure 2. Underside of Hood Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0575
Figure 4. Torsion Assist Bar, Washer, and Spring Clip., Vol 4 . . . . . . . . . . . . . WP 0575
Figure 5. Hood Mounting Hinge., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 6. Mirror Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 7. Hood/Fender Latch., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 9. Front Fender Light Harness., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 10. Front Turn Signal and Parking Light Assembly., Vol 4 . . . . . . . . . . . WP 0575
Figure 11. Torsion Assist Bar and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . WP 0575
Figure 13. Base Straplock Mounting., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 15. Torsion Assist Bar and Bracket., Vol 4 . . . . . . . . . . . . . . . . . . WP 0575
Figure 16. Front Turn Signal and Parking Light Assembly., Vol 4 . . . . . . . . . . . WP 0575
Figure 17. Front Fender Light Harness., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0575
Figure 18. Hood Safety Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 19. Hood/Fender Latch., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 20. Mirror Assembly., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 21. Hood Mounting Hinge., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 22. Torsion Assist Bar, Washer, and Spring Clip., Vol 4 . . . . . . . . . . . . WP 0575
Figure 23. Hood Safety Cable., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0575
Figure 25. Headlamp and Turn Signal Harness Connector., Vol 4 . . . . . . . . . . . WP 0575
HOOD MIRROR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . WP 0576
Figure 1. Mirror Trim and Glass., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0576
Figure 4. Mirror Trim and Glass., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0576
INSTRUMENT PANEL (IP) REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . WP 0577
Figure 1. IP Center Mounting Brace Bolt., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0577
Figure 2. Data Link Connector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 3. Steering Column Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 4. Ignition Switch Nut., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 5. Transmission Auto Shift Driver Control Module., Vol 4 . . . . . . . . . . . . WP 0577
Figure 6. IP Circuit Breaker, Fuse, and Relay Center., Vol 4 . . . . . . . . . . . . . WP 0577
Figure 7. Air Conditioning (A/C) Condenser Fan Relays., Vol 4 . . . . . . . . . . . . WP 0577
Figure 8. IP Wiring Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . . . WP 0577
Figure 9. IP Wiring Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . . . WP 0577
Figure 10. IP Wiring Harness Cable Lock Straps., Vol 4 . . . . . . . . . . . . . . . WP 0577
Figure 14. Left IP Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 15. Right IP Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 16. IP Center Mounting Brace., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 17. IP Center Mounting Brace., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 18. IP Center Mounting Brace Bolt., Vol 4 . . . . . . . . . . . . . . . . . . WP 0577
Figure 19. Right IP Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 20. Left IP Mounting Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0577
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Figure 21. Steering Column Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 22. Data Link Connector., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0577
Figure 23. Ignition Switch and Transmission Auto Shift Driver Control Module., Vol 4 . . WP 0577
Figure 28. A/C Condenser Fan Relays., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0577
Figure 29. IP Circuit Breaker, Fuse, and Relay Center., Vol 4 . . . . . . . . . . . . . WP 0577
INSTRUMENT PANEL (IP) CLUSTER CLOSEOUT REMOVAL AND INSTALLATION, Vol 4 . . WP 0578
Figure 1. Instrument Panel Cluster Closeout Panel., Vol 4 . . . . . . . . . . . . . . WP 0578
INSTRUMENT PANEL (IP) CENTER CLOSEOUT REMOVAL AND INSTALLATION, Vol 4 . . . WP 0579
Figure 1. Instrument Panel Cluster Closeout., Vol 4 . . . . . . . . . . . . . . . . . WP 0579
Figure 2. Instrument Panel Right Side Closeout Fuse Access Panel., Vol 4 . . . . . . . WP 0579
Figure 3. Engine Start Switch Cover., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0579
Figure 4. Instrument Panel Center Closeout Removal., Vol 4 . . . . . . . . . . . . . WP 0579
Figure 5. Instrument Panel Center Closeout Alignment Slots., Vol 4 . . . . . . . . . . WP 0579
Figure 6. Instrument Panel Center Closeout Installation., Vol 4 . . . . . . . . . . . . WP 0579
Figure 7. Instrument Panel Center Closeout Installation., Vol 4 . . . . . . . . . . . . WP 0579
Figure 8. Engine Start Switch Cover., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0579
Figure 9. Instrument Panel Cluster Closeout., Vol 4 . . . . . . . . . . . . . . . . . WP 0579
Figure 10. Instrument Panel Right Side Closeout Fuse Access Panel Engagement., Vol 4 WP 0579
INSTRUMENT PANEL (IP) RIGHT SIDE CLOSEOUT REMOVAL AND INSTALLATION, Vol 4 . WP 0580
Figure 1. IP Right Side Closeout Fuse Panel., Vol 4 . . . . . . . . . . . . . . . . . WP 0580
Figure 2. Upper IP Right Side Closeout., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0580
Figure 3. Upper IP Right Side Closeout Engagement., Vol 4 . . . . . . . . . . . . . WP 0580
Figure 4. Upper IP Right Side Closeout., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0580
Figure 5. IP Right Side Closeout Fuse Panel Engagement., Vol 4 . . . . . . . . . . . WP 0580
INSTRUMENT PANEL (IP) CENTER TRIM PANEL REMOVAL AND INSTALLATION, Vol 4 . . . WP 0581
Figure 2. Hand Brake Control., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0581
Figure 3. IP Center Trim Panel Wiring., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0581
Figure 4. IP Center Trim Panel Wiring., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0581
Figure 5. Hand Brake Control., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0581
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) GAUGE REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0582
Figure 1. NBC Gauge., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0582
Figure 2. NBC Gauge Front., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0582
Figure 3. NBC Gauge Front., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0582
Figure 4. NBC Gauge Hose., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0582
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WP Sequence No.
CABIN ROOF MOLDING REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . WP 0583
Figure 1. Right Front Windshield Molding., Vol 4 . . . . . . . . . . . . . . . . . . WP 0583
Figure 3. Right Front Cabin Molding., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0583
Figure 6. Rear Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0583
Figure 7. Rear Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0583
Figure 10. Right Front Cabin Molding., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0583
Figure 11. Right Front Door Molding., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0583
Figure 12. Right Front Windshield Molding., Vol 4 . . . . . . . . . . . . . . . . . . WP 0583
ROOF ARMOR FRONT PANEL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0584
Figure 1. Roof Armor Front Panel., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0584
Figure 2. Roof Armor Front Panel., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0584
ROOF ARMOR FRONT SPOILER REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . WP 0585
Figure 1. Roof Armor Front Spoiler., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0585
Figure 2. Roof Armor Front Spoiler., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0585
ROOF ARMOR MIDDLE FRONT PANEL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0586
Figure 1. Roof Armor Middle Front Panel., Vol 4 . . . . . . . . . . . . . . . . . . WP 0586
Figure 2. Roof Armor Middle Front Panel., Vol 4 . . . . . . . . . . . . . . . . . . WP 0586
ROOF ARMOR MIDDLE REAR PANEL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . WP 0587
Figure 1. Roof Armor Middle Rear Panel., Vol 4. . . . . . . . . . . . . . . . . . . WP 0587
Figure 2. Roof Armor Middle Rear Panel., Vol 4. . . . . . . . . . . . . . . . . . . WP 0587
ROOF ARMOR REAR SPOILER REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . WP 0588
Figure 1. Upper Ladder Step., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0588
Figure 2. Light Bar., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0588
Figure 3. Roof Armor Rear Panel., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0588
Figure 5. Light Bar., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0588
Figure 6. Upper Ladder Step., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0588
ROOF ARMOR REAR PANEL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . WP 0589
WEAPON (SLIDING) HATCH (GUNNER HATCH) REMOVAL AND INSTALLATION, Vol 4 . . . WP 0590
Figure 1. Gunner Hatch Sliders., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0590
Figure 2. Gunner Hatch Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0590
Figure 3. Gunner Hatch Brackets, Shock Absorbers, Rubber Buffer, and Handle., Vol 4 . WP 0590
Figure 4. Gunner Hatch Rails., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0590
Figure 5. Gunner Hatch Rails., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0590
Figure 6. Handle, Shock Absorbers, Rubber Buffer, and Gunner Hatch Brackets., Vol 4 . WP 0590
Figure 7. Gunner Hatch Removal., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0590
Figure 8. Gunner Hatch Sliders., Vol 4. . . . . . . . . . . . . . . . . . . . . . . WP 0590
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WP Sequence No.
WEAPON (SLIDING) HATCH (GUNNER HATCH) INNER LOCK REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0591
Figure 1. Gunner Hatch Unlatched and Upper Latch Handle in Open Position., Vol 4 . . WP 0591
Figure 2. Mounting Hardware and Lock Assembly Removal., Vol 4 . . . . . . . . . . WP 0591
Figure 3. Latch Hook Spring and Latch Hook Removal., Vol 4 . . . . . . . . . . . . WP 0591
Figure 4. Latch Pin Removed from Bracket., Vol 4 . . . . . . . . . . . . . . . . . WP 0591
Figure 5. Latch Pin Installed., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0591
Figure 6. Latch Hook Aligned with Mounting Bolt., Vol 4 . . . . . . . . . . . . . . . WP 0591
Figure 7. New Lock Assembly Aligned with Mounting Holes., Vol 4 . . . . . . . . . . WP 0591
WEAPON (SLIDING) HATCH (GUNNER HATCH) SEAL REMOVAL AND INSTALLATION, Vol 4 WP 0592
Figure 1. Weapon Hatch Seal Removal., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0592
Figure 2. Weapon Hatch Seal Installation., Vol 4 . . . . . . . . . . . . . . . . . . WP 0592
CABIN EMERGENCY HATCH AND HINGE REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0593
Figure 1. Emergency Hatch Removal from Vehicle., Vol 4 . . . . . . . . . . . . . . WP 0593
Figure 2. Emergency Hatch Hinges., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0593
Figure 3. Emergency Hatch Hinges., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0593
Figure 4. Emergency Hatch Installation on Vehicle., Vol 4 . . . . . . . . . . . . . . WP 0593
Figure 5. Emergency Hatch Closed., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0593
CABIN EMERGENCY HATCH HANDLE/LOCK ASSEMBLY REMOVAL AND INSTALLA-
TION, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0594
Figure 1. Grab Handle and Lock Assembly Removal., Vol 4 . . . . . . . . . . . . . WP 0594
Figure 2. Emergency Hatch Handle/Lock Assembly and Grab Handle Installation., Vol 4 . WP 0594
CABIN EMERGENCY HATCH SEAL REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . WP 0595
Figure 1. Attaching Chain Hoist to Hatch Handle., Vol 4 . . . . . . . . . . . . . . . WP 0595
Figure 2. Attaching Chain Hoist to Riot Guard., Vol 4 . . . . . . . . . . . . . . . . WP 0595
Figure 3. Tightening Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0595
Figure 4. Emergency Hatch Seal Removal., Vol 4 . . . . . . . . . . . . . . . . . . WP 0595
Figure 5. Emergency Hatch Seal Installation., Vol 4 . . . . . . . . . . . . . . . . . WP 0595
Figure 6. Emergency Hatch Seal Seam Adhesive Application., Vol 4 . . . . . . . . . WP 0595
Figure 7. Loosening Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0595
Figure 8. Removing Chain Hoist from Riot Guard., Vol 4 . . . . . . . . . . . . . . . WP 0595
Figure 9. Removing Chain Hoist from Hatch Handle., Vol 4. . . . . . . . . . . . . . WP 0595
HULL GUN PORT REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . WP 0596
Figure 1. Internal Gun Port in Open Position., Vol 4 . . . . . . . . . . . . . . . . . WP 0596
Figure 2. External Gun Port in Open Position., Vol 4. . . . . . . . . . . . . . . . . WP 0596
Figure 3. External Gun Port Installation., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0596
Figure 4. Internal Gun Port Installation, Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0596
LEFT ENGINE ARMOR PLATE REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . WP 0597
Figure 1. Tire Fire Suppression System (FSS) Bracket., Vol 4 . . . . . . . . . . . . WP 0597
Figure 2. Left Side Engine Armor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0597
Figure 3. Power Distribution Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0597
Figure 4. Power Distribution Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0597
Figure 5. Left Side Engine Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0597
Figure 6. Tire FSS Bracket., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . WP 0597
LEFT ENGINE ARMOR PLATE BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . . . WP 0598
Figure 1. Left Side Engine Armor Plate Bracket., Vol 4. . . . . . . . . . . . . . . . WP 0598
Figure 2. Left Side Engine Armor Plate Bracket., Vol 4. . . . . . . . . . . . . . . . WP 0598
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WP Sequence No.
RIGHT ENGINE ARMOR PLATE REMOVAL AND INSTALLATION, Vol 4. . . . . . . . . . . WP 0599
Figure 1. Right Side Engine Armor Plate., Vol 4. . . . . . . . . . . . . . . . . . . WP 0599
Figure 2. Right Side Engine Armor Plate (Mounting Bracket Hidden)., Vol 4 . . . . . . WP 0599
RIGHT ENGINE ARMOR PLATE BRACKET REMOVAL AND INSTALLATION, Vol 4. . . . . . WP 0600
Figure 1. Fuel Water Separator Assembly Connections., Vol 4 . . . . . . . . . . . . WP 0600
Figure 3. Right Side Engine Armor Plate Bracket., Vol 4 . . . . . . . . . . . . . . . WP 0600
Figure 4. Right Side Engine Armor Plate Bracket., Vol 4 . . . . . . . . . . . . . . . WP 0600
Figure 6. Fuel Water Separator Assembly Connections., Vol 4 . . . . . . . . . . . . WP 0600
INNER WHEEL DEFLECTOR ARMOR PLATE REMOVAL AND INSTALLATION, Vol 4. . . . . WP 0601
Figure 1. Lower Inner Wheel Deflector Armor Plate., Vol 4 . . . . . . . . . . . . . . WP 0601
Figure 2. Inner Wheel Deflector Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . WP 0601
Figure 3. Lower Inner Wheel Deflector Armor Plate., Vol 4 . . . . . . . . . . . . . . WP 0601
Figure 4. Inner Wheel Deflector Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . WP 0601
LEFT INNER WHEEL DEFLECTOR BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . . WP 0602
Figure 1. Front Frame Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0602
Figure 2. Rear Frame Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0602
Figure 3. Left Inner Wheel Deflector Bracket Shield., Vol 4 . . . . . . . . . . . . . . WP 0602
Figure 4. Air Line, Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0602
Figure 5. Left Inner Wheel Deflector., Vol 4. . . . . . . . . . . . . . . . . . . . . WP 0602
Figure 6. Left Inner Wheel Deflector Bracket., Vol 4 . . . . . . . . . . . . . . . . . WP 0602
Figure 7. Air Line., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0602
Figure 8. Left Inner Wheel Deflector Bracket Shield., Vol 4 . . . . . . . . . . . . . . WP 0602
Figure 10. Front Frame Bracket., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0602
RIGHT INNER WHEEL DEFLECTOR BRACKET REMOVAL AND INSTALLATION, Vol 4 . . . WP 0603
Figure 1. Wheel Deflector Ground Wires and Harness., Vol 4 . . . . . . . . . . . . . WP 0603
Figure 4. Wheel Deflector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0603
Figure 5. Wheel Deflector., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0603
Figure 8. Wheel Deflector Ground Wires and Harness., Vol 4 . . . . . . . . . . . . . WP 0603
EXTERIOR BATTERY BOX ARMOR DOOR REMOVAL AND INSTALLATION, Vol 4. . . . . . WP 0604
Figure 1. Battery Door., Vol 4. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0604
Figure 2. Battery Box Access Door., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0604
Figure 3. Battery Box Access Door., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0604
Figure 4. Exterior Battery Box Armor Door., Vol 4 . . . . . . . . . . . . . . . . . . WP 0604
EXTERIOR FUEL TANK ARMOR DOOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . WP 0605
Figure 1. Fuel Tank Access Door., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0605
Figure 2. Exterior Fuel Tank Armor Door., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0605
Figure 3. Exterior Fuel Tank Armor Door., Vol 4 . . . . . . . . . . . . . . . . . . . WP 0605
Figure 4. Fuel Tank Access Door., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0605
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WP Sequence No.
BELLY ARMOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . WP 0606
Figure 1. Left Side Rear Belly Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . WP 0606
Figure 2. Fuel Tank Cover Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 3. Battery Box Cover., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 4. Right Side Battery Box., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 5. Belly Armor Kit Support. Right side shown; left side similar., Vol 4 . . . . . . WP 0606
Figure 6. Belly Armor Kit Support Straps., Vol 4. . . . . . . . . . . . . . . . . . . WP 0606
Figure 7. Left Side Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 8. Right Side Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 9. Belly Armor Center Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 10. Right Front Belly Armor., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 11. Left Front Belly Armor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 12. Left Belly Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 13. Fuel Tank Cover and Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . WP 0606
Figure 14. Belly Armor and Fuel Tank Cover Plate., Vol 4 . . . . . . . . . . . . . . WP 0606
Figure 15. Belly Armor and Fuel Tank Cover Plate., Vol 4 . . . . . . . . . . . . . . WP 0606
Figure 16. Left Side Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 17. Right Side Chain Hoist., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 18. Wheel Deflector Bolts., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 19. Belly Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 20. Left Front Belly Armor., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 21. Right Front Belly Armor., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 22. Belly Armor Center Mount., Vol 4 . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 23. Left Side Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 24. Belly Armor Kit Support., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 25. Right Side Battery Box., Vol 4. . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 26. Fuel Tank Cover Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 27. Battery Box Cover Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0606
Figure 28. Left Side Rear Belly Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . WP 0606
CABIN DOOR REMOVAL AND INSTALLATION, Vol 4 . . . . . . . . . . . . . . . . . . . WP 0607
Figure 1. Air Line Disconnected from Door Actuator Connector (Single Piston)., Vol 4 . . WP 0607
Figure 2. Air Line Disconnected from Door Actuator Connector (Dual Piston)., Vol 4 . . . WP 0607
Figure 3. Upper and Lower Door Hinge Removal., Vol 4 . . . . . . . . . . . . . . . WP 0607
Figure 4. Installation of Upper and Lower Door Hinges., Vol 4 . . . . . . . . . . . . WP 0607
Figure 5. Air Line Secured to Door Actuator Connector (Single Piston)., Vol 4. . . . . . WP 0607
Figure 6. Air Line Secured to Door Actuator Connector (Dual Piston)., Vol 4 . . . . . . WP 0607
SECURING CABIN DOOR FOR SERVICE, Vol 4 . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 1. Door Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 2. Front Towing Eye., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 3. Chain Hoist., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 4. Door Actuator Rod., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 5. Door Actuator Rod., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 7. Front Towing Eye., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
Figure 8. Door Armor Plate., Vol 4 . . . . . . . . . . . . . . . . . . . . . . . . WP 0608
VOLUME 5
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DOOR ARMOR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0609
Figure 2. Kick Panel Power Mirror Harness Connector., Vol 5. . . . . . . . . . . . . WP 0609
Figure 3. Power Mirror Harness Connector., Vol 5. . . . . . . . . . . . . . . . . . WP 0609
Figure 5. Door Window Riot Guard., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0609
Figure 10. Mirror Mounting Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0609
Figure 11. Door Armor., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0609
Figure 12. Power Mirror Harness Connector., Vol 5 . . . . . . . . . . . . . . . . . WP 0609
Figure 13. Kick Panel Power Mirror Harness Connector., Vol 5 . . . . . . . . . . . . WP 0609
DOOR WINDOW RIOT GUARD REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . WP 0610
UPPER CABIN DOOR LOCK, SPACER, AND BRACKET REMOVAL AND INSTALLATION, Vol 5 WP 0611
Figure 1. Upper Cabin Door Lock, Spacer, and Bracket Removal., Vol 5 . . . . . . . . WP 0611
Figure 2. Upper Cabin Door Lock, Spacer, and Bracket Installation., Vol 5 . . . . . . . WP 0611
LOWER CABIN DOOR LOCK, SPACER, AND BRACKET REMOVAL AND INSTALLATION , Vol 5WP 0612
Figure 1. Lower Cabin Door Lock Retainer Clip Removal., Vol 5 . . . . . . . . . . . WP 0612
Figure 2. Lower Cabin Door Lock, Spacer, and Bracket Removal., Vol 5 . . . . . . . . WP 0612
Figure 3. Lower Cabin Door Lock, Spacer, and Bracket Installation., Vol 5 . . . . . . . WP 0612
Figure 4. Lower Cabin Door Lock Retainer Clip Installation., Vol 5. . . . . . . . . . . WP 0612
CABIN DOOR STRIKER AND CABIN DOOR CHECK STOP ASSEMBLIES REMOVAL AND
Figure 1. Cabin Door Striker Tapping Plate Cover Removal., Vol 5 . . . . . . . . . . WP 0613
Figure 2. Cabin Door Striker Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0613
Figure 3. Door Check Stop Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0613
Figure 4. Door Check Stop Installation., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0613
Figure 5. Cabin Door Striker Installation., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0613
Figure 6. Cabin Door Striker Tapping Plate Cover Installation., Vol 5. . . . . . . . . . WP 0613
CABIN DOOR SEAL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . WP 0614
Figure 1. Cabin Door Seal Removal., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0614
Figure 2. Cabin Door Seal Application., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0614
CABIN DOOR LINKAGE INSPECTION AND ADJUSTMENT PROCEDURE (LOWER INTERIOR COMBAT
DOOR LOCK-TYPE), Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0615
Figure 1. Inner Door Latch Handle Shaft in Neutral Position., Vol 5 . . . . . . . . . . WP 0615
Figure 2. Air Valve Linkage Centered on Latch Handle Shaft., Vol 5 . . . . . . . . . . WP 0615
Figure 3. Air Valve Perpendicular to Air Valve Module Face., Vol 5 . . . . . . . . . . WP 0615
Figure 4. Door Latches Set in Closed Position., Vol 5 . . . . . . . . . . . . . . . . WP 0615
Figure 5. Door Speed Stop Lock Nut and Adjustment Bolt., Vol 5 . . . . . . . . . . . WP 0615
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WP Sequence No.
CABIN DOOR LINKAGE INSPECTION AND ADJUSTMENT PROCEDURE (UPPER COMBAT DOOR LOCK
TYPE), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0616
Figure 1. Inner Door Latch Handle Shaft in Neutral Position., Vol 5 . . . . . . . . . . WP 0616
Figure 2. Air Valve Linkage Adjustment., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0616
Figure 3. Door Latch Linkage Adjustment., Vol 5 . . . . . . . . . . . . . . . . . . WP 0616
Figure 4. Cylinder Lock Shaft Linkage Adjustment., Vol 5 . . . . . . . . . . . . . . WP 0616
Figure 5. Door Latch Linkage., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0616
Figure 6. Lower Door Latch Adjustment., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0616
Figure 7. Upper Door Latch Linkage Adjustment., Vol 5 . . . . . . . . . . . . . . . WP 0616
Figure 8. Door Speed Stop Adjusting Bolts., Vol 5. . . . . . . . . . . . . . . . . . WP 0616
DUAL-PNEUMATIC DOOR ACTUATOR REMOVAL AND INSTALLATION, Vol 5 . . . . . . . WP 0617
Figure 1. Door Actuator Air Line and Pin., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0617
Figure 2. Door Actuator Latch Linkage Rod., Vol 5 . . . . . . . . . . . . . . . . . WP 0617
Figure 3. Outside Mirror Harness., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 4. Combat Lock Linkage., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 5. Door Actuator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 7. Door Actuator Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 8. Pneumatic Door Actuator Bolts., Vol 5 . . . . . . . . . . . . . . . . . . WP 0617
Figure 9. Combat Lock Linkage., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 10. Outside Mirror Harness., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0617
Figure 11. Door Actuator Latch Linkage Rod., Vol 5 . . . . . . . . . . . . . . . . . WP 0617
Figure 12. Door Actuator Air Line and Pin., Vol 5 . . . . . . . . . . . . . . . . . . WP 0617
CABIN DOOR ASSIST SYSTEM ACTUATOR AIR LINE TUBING REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0618
Figure 1. Actuator Air Lines., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0618
Figure 2. Tubing Replacement., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0618
LEFT DOOR AIR SUPPLY LINE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . WP 0619
Figure 1. Supply Air Line Tubing., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0619
Figure 2. Supply Air Line Tubing Retainers., Vol 5. . . . . . . . . . . . . . . . . . WP 0619
Figure 3. Supply Air Line Tubing Tee., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0619
Figure 4. Air Line Tubing Tee., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . WP 0619
RIGHT CABIN DOOR ASSIST SYSTEM SUPPLY AIR LINE TUBING REMOVAL AND
Figure 3. Follow Air Line To Left Side Of Vehicle., Vol 5 . . . . . . . . . . . . . . . WP 0620
Figure 4. Supply Air Line Tubing Tee, Located On Left Side Of Vehicle., Vol 5 . . . . . WP 0620
Figure 5. Air Line Tubing Tee., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . WP 0620
CABIN DOOR ASSIST SYSTEM SUPPLY PASS-THROUGH AIR LINE TUBING REMOVAL AND
Figure 1. Door Actuator Air Line Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0621
Figure 4. Air Line Union Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0621
Figure 6. Door Actuator Air Line Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0621
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WP Sequence No.
CABIN DOOR ASSIST SYSTEM SUPPLY AIR LINE TUBING REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0622
CABIN DOOR EXTERIOR HANDLE ASSEMBLY REMOVAL AND INSTALLATION (SINGLE-AND
DUAL-CYLINDER), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0623
Figure 1. Inner Door Handle Shaft Cover Plate Removal., Vol 5 . . . . . . . . . . . . WP 0623
Figure 2. Upper Hex Bolt Removal from Inner Shaft Lock Plate Bracket., Vol 5 . . . . . WP 0623
Figure 3. Combat Lock Shaft Lever and Vertical Shaft Lever Removal from Combat Lock Bell
Crank., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0623
Figure 4. Retaining Clips Removal from Door Linkage Rods., Vol 5 . . . . . . . . . . WP 0623
Figure 5. Retaining Clip Removed from Lower Linkage Rod and Door Latch Plate., Vol 5. WP 0623
Figure 6. Interior Handle Socket Head Screws Removal., Vol 5 . . . . . . . . . . . . WP 0623
Figure 7. Exterior Door Handle Positioned for Removal., Vol 5 . . . . . . . . . . . . WP 0623
Figure 8. Interior Door Handle Assembly Partial Removal., Vol 5 . . . . . . . . . . . WP 0623
Figure 9. Cabin Door Interior Handle Assembly Removal from Inner Door., Vol 5 . . . . WP 0623
Figure 10. Cabin Door Interior Handle Assembly., Vol 5 . . . . . . . . . . . . . . . WP 0623
Figure 11. Setscrew Loosened on Exterior Handle., Vol 5 . . . . . . . . . . . . . . WP 0623
Figure 12. Exterior Handle Removed from Interior Handle Assembly., Vol 5. . . . . . . WP 0623
Figure 13. Exterior Handle Installation on Interior Handle Shaft Assembly., Vol 5 . . . . WP 0623
Figure 14. Interior Handle Shaft Assembly Installation on Inner Door Frame., Vol 5 . . . WP 0623
Figure 15. New Door Exterior Handle Installation., Vol 5 . . . . . . . . . . . . . . . WP 0623
Figure 16. Door Interior Handle Shaft Assembly Partial Installation., Vol 5 . . . . . . . WP 0623
Figure 17. Door Interior Handle Assembly Secured to Inner Door., Vol 5 . . . . . . . . WP 0623
Figure 18. Retaining Clips Installed on Linkage Rods., Vol 5 . . . . . . . . . . . . . WP 0623
Figure 19. Combat Shaft Lever and Vertical Lever Installed on Bell Crank., Vol 5 . . . . WP 0623
Figure 20. Hex Bolts Installed on Inner Shaft Lock Plate Bracket., Vol 5 . . . . . . . . WP 0623
Figure 21. Inner Door Handle Shaft Cover Plate Installation., Vol 5 . . . . . . . . . . WP 0623
CABIN DOOR INTERIOR HANDLE ASSEMBLY REMOVAL AND INSTALLATION (SINGLE-PISTON,
LOWER COMBAT DOOR LOCK-TYPE), Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0624
Figure 1. Inner Door Handle Shaft Cover Plate., Vol 5 . . . . . . . . . . . . . . . . WP 0624
Figure 2. Upper Hex Bolt., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0624
Figure 3. Combat Lock Shaft Lever and Vertical Shaft Lever., Vol 5 . . . . . . . . . . WP 0624
Figure 4. Retaining Clips and Door Linkage Rods., Vol 5 . . . . . . . . . . . . . . . WP 0624
Figure 5. Cabin Door Interior Handle Socket-Head Screws., Vol 5 . . . . . . . . . . . WP 0624
Figure 6. Cabin Door Interior Handle Assembly., Vol 5 . . . . . . . . . . . . . . . . WP 0624
Figure 8. Cabin Door Interior Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0624
Figure 9. Cabin Door Interior Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0624
Figure 10. Cabin Door Interior Handle Assembly., Vol 5 . . . . . . . . . . . . . . . WP 0624
Figure 11. Retaining Clips and Door Linkage Rods., Vol 5 . . . . . . . . . . . . . . WP 0624
Figure 12. Combat Lock Shaft Lever and Vertical Shaft Lever to Combat Lock
Bellcrank., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0624
Figure 13. Hex Bolts Installed on Inner Shaft Lockplate Bracket., Vol 5. . . . . . . . . WP 0624
Figure 14. Inner Door Handle Shaft Cover Plate., Vol 5 . . . . . . . . . . . . . . . WP 0624
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WP Sequence No.
CABIN DOOR INTERIOR HANDLE ASSEMBLY REMOVAL AND INSTALLATION (DUAL PISTON UPPER
INTERIOR COMBAT DOOR LOCK-TYPE), Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0625
Figure 1. Inner Door Handle Shaft Cover Plate Removal., Vol 5 . . . . . . . . . . . . WP 0625
Figure 2. Upper Hex Bolt Removal from Inner Shaft Lockplate Bracket., Vol 5 . . . . . WP 0625
Figure 3. Combat Lock Shaft Lever and Vertical Shaft Lever Removal from Combat Lock
Bellcrank., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0625
Figure 4. Retaining Clips, Springs, and Door Linkage Rods Removal., Vol 5 . . . . . . WP 0625
Figure 5. Cabin Door Interior Handle Assembly Removal., Vol 5 . . . . . . . . . . . WP 0625
Figure 6. Cabin Door Interior Handle Assembly Removed., Vol 5 . . . . . . . . . . . WP 0625
Figure 7. Cabin Door Interior Handle Disassembly., Vol 5 . . . . . . . . . . . . . . WP 0625
Figure 9. Cabin Door Interior Handle Assembly Installation., Vol 5. . . . . . . . . . . WP 0625
Figure 10. Retaining Clips, Springs, and Door Linkage Rods Installation., Vol 5 . . . . . WP 0625
Figure 11. Combat Lock Shaft Lever and Vertical Shaft Lever Installed on Bellcrank., Vol 5 WP 0625
Figure 12. Hex Bolts Installed on Inner Shaft Lockplate Bracket., Vol 5. . . . . . . . . WP 0625
Figure 13. Inner Door Handle Shaft Cover Plate Installation., Vol 5 . . . . . . . . . . WP 0625
CABIN DOOR TRIM PANEL REMOVAL AND INSTALLATION (ONE-PIECE, LOWER COMBAT DOOR
LOCK-TYPE), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0626
Figure 1. Inside Door Combat Lock Handle Removal., Vol 5 . . . . . . . . . . . . . WP 0626
Figure 2. Cabin Door Trim Panel Fasteners Removal., Vol 5 . . . . . . . . . . . . . WP 0626
Figure 3. Cabin Door Trim Panel Fasteners Installation., Vol 5 . . . . . . . . . . . . WP 0626
Figure 4. Door Interior Combat Lock Handle Installation., Vol 5 . . . . . . . . . . . . WP 0626
CABIN DOOR TRIM PANEL REMOVAL AND INSTALLATION (TWO-PIECE, UPPER COMBAT DOOR
LOCK TYPE), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0627
Figure 1. Cabin Door Trim Panel Fasteners Removal., Vol 5 . . . . . . . . . . . . . WP 0627
Figure 2. Cabin Door Trim Panel Fasteners Installation., Vol 5 . . . . . . . . . . . . WP 0627
CABIN DOOR COMBAT LOCK ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0628
Figure 1. Cabin Door Combat Lock Removal., Vol 5 . . . . . . . . . . . . . . . . . WP 0628
Figure 2. Combat Lock Shaft in Near-Vertical Position., Vol 5 . . . . . . . . . . . . . WP 0628
Figure 3. Door Combat Lock Assembly Installation., Vol 5 . . . . . . . . . . . . . . WP 0628
EXTERIOR BODY ARMOR RIGHT FRONT PANEL REMOVAL AND INSTALLATION, Vol 5 . . WP 0629
Figure 1. Body Armor Right Front Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0629
Figure 2. Handrail and Door Grab Handle., Vol 5 . . . . . . . . . . . . . . . . . . WP 0629
Figure 3. Handrail and Door Grab Handle., Vol 5 . . . . . . . . . . . . . . . . . . WP 0629
Figure 4. Body Armor Right Front Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0629
EXTERIOR BODY ARMOR MIDDLE REAR PANEL REMOVAL AND INSTALLATION, Vol 5 . . WP 0630
Figure 1. Body Armor Middle Rear Panel., Vol 5 . . . . . . . . . . . . . . . . . . WP 0630
Figure 2. Hand Rail., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0630
Figure 4. Body Armor Middle Rear Panel., Vol 5 . . . . . . . . . . . . . . . . . . WP 0630
EXTERIOR BODY ARMOR REAR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0631
Figure 1. Body Armor Rear Panel., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0631
Figure 2. Body Armor Rear Panel., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0631
EXTERIOR BODY ARMOR RIOT GUARD REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0632
Figure 1. Exterior Body Armor Riot Guard., Vol 5 . . . . . . . . . . . . . . . . . . WP 0632
Figure 2. Exterior Body Armor Riot Guard., Vol 5 . . . . . . . . . . . . . . . . . . WP 0632
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Page No.
WP Sequence No.
EXTERIOR BODY ARMOR LEFT FRONT PANEL REMOVAL AND INSTALLATION, Vol 5 . . . WP 0633
Figure 1. Body Armor Left Front Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0633
Figure 2. Door Grab Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0633
Figure 3. Door Grab Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0633
Figure 4. Body Armor Left Front Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0633
EXTERIOR BODY ARMOR LEFT MIDDLE FRONT PANEL REMOVAL AND INSTALLATION, Vol 5WP 0634
Figure 1. Body Armor Left Middle Front Panel., Vol 5 . . . . . . . . . . . . . . . . WP 0634
Figure 4. Body Armor Left Middle Front Panel., Vol 5 . . . . . . . . . . . . . . . . WP 0634
EXTERIOR BODY ARMOR RIGHT MIDDLE FRONT PANEL REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0635
Figure 1. Body Armor Right Middle Front Panel., Vol 5. . . . . . . . . . . . . . . . WP 0635
Figure 4. Body Armor Right Middle Front Panel., Vol 5. . . . . . . . . . . . . . . . WP 0635
REAR DOOR/RAMP SEAL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . WP 0636
Figure 1. Rear Door/Ramp Assembly Lowered., Vol 5 . . . . . . . . . . . . . . . . WP 0636
Figure 2. Rear Door/Ramp Seal Seam Adhesive Cut., Vol 5 . . . . . . . . . . . . . WP 0636
Figure 3. Rear Door/Ramp Seal Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0636
Figure 4. Rear Door/Ramp Seal Installation., Vol 5 . . . . . . . . . . . . . . . . . WP 0636
Figure 5. Rear Door/Ramp Seal Seam Adhesive Application., Vol 5 . . . . . . . . . . WP 0636
Figure 6. Rear Door/Ramp Assembly Raised., Vol 5. . . . . . . . . . . . . . . . . WP 0636
BODY ARMOR REAR WALL, RIOT GUARD, AND BRACKET REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 1. Rear Ladder and Fuel/Water Cans., Vol 5 . . . . . . . . . . . . . . . . . WP 0637
Figure 2. Upper Light Bar, Above Rear Door., Vol 5 . . . . . . . . . . . . . . . . . WP 0637
Figure 3. Rear Wall Body Armor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 4. Rear Window Riot Guard., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 5. Fuel/Water Can Mount., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 6. Fuel/Water Mount., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 7. Rear Window Riot Guard., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 8. Rear Wall Body Armor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0637
Figure 9. Upper Light Bar, Above Rear Door., Vol 5 . . . . . . . . . . . . . . . . . WP 0637
Figure 10. Rear Ladder., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0637
REAR WALL OVERLAP REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . WP 0638
Figure 1. Rear Sheet Metal Panel., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0638
Figure 3. Trailer Electrical Socket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0638
Figure 4. Rear Wall Overlap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0638
Figure 5. Rear Wall Overlap Removed., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0638
Figure 6. Rear Wall Overlap Removed., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0638
Figure 7. Rear Wall Overlap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0638
Figure 9. Trailer Electrical Socket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0638
Figure 10. Rear Sheet Metal Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0638
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Page No.
WP Sequence No.
REAR DOOR/RAMP REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . WP 0639
Figure 2. Loop Lifting Sling Around Door/Ramp Left Hinge., Vol 5 . . . . . . . . . . . WP 0639
Figure 3. Loop Lifting Sling Around Door/Ramp Right Hinge., Vol 5 . . . . . . . . . . WP 0639
Figure 4. Loop Lifting Sling Around Door/Ramp Left Rear Mounting Boss., Vol 5 . . . . WP 0639
Figure 5. Loop Lifting Sling Around Door/Ramp Right Rear Mounting Boss., Vol 5 . . . . WP 0639
Figure 6. Route Ends of Slings Through a Fifth Sling., Vol 5 . . . . . . . . . . . . . WP 0639
Figure 7. Locking Safety Pin Removed from Hydraulic Cylinder., Vol 5 . . . . . . . . . WP 0639
Figure 8. Rear Door/Ramp Removed from Vehicle., Vol 5 . . . . . . . . . . . . . . WP 0639
Figure 9. Rear Door/Ramp Assembly Installed., Vol 5 . . . . . . . . . . . . . . . . WP 0639
Figure 10. Loop Lifting Sling Around Door/Ramp Right Hinge., Vol 5. . . . . . . . . . WP 0639
Figure 11. Loop Lifting Sling Around Door/Ramp Right Hinge., Vol 5 . . . . . . . . . . WP 0639
Figure 14. Rear Door/Ramp Assembly Installed., Vol 5 . . . . . . . . . . . . . . . WP 0639
Figure 15. Hydraulic Cylinder Secured with Locking Safety Pin., Vol 5 . . . . . . . . . WP 0639
Figure 16. Bottom Step Adjusted with Spacers., Vol 5 . . . . . . . . . . . . . . . . WP 0639
BOTTOM RAMP STEP REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0640
Figure 1. Bottom Ramp Step Removal from Ramp., Vol 5 . . . . . . . . . . . . . . WP 0640
Figure 2. Bottom Ramp Step Installation., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0640
REAR DOOR/RAMP LOCK ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . . . . . . . WP 0641
Figure 2. Right Side Shroud Cover Removal., Vol 5 . . . . . . . . . . . . . . . . . WP 0641
Figure 3. Left Side Shroud Cover Removal., Vol 5. . . . . . . . . . . . . . . . . . WP 0641
Figure 4. Coil Springs Removal from Door Lock Assembly., Vol 5 . . . . . . . . . . . WP 0641
Figure 5. Rear Door Lock Assembly Mounting Brackets Removal., Vol 5 . . . . . . . . WP 0641
Figure 6. Rear Door Lock Assembly Removed from Vehicle., Vol 5 . . . . . . . . . . WP 0641
Figure 7. Rear Door Lock Assembly with Mounting Brackets Removed., Vol 5 . . . . . WP 0641
Figure 8. Mounting Brackets Installed on Rear Door Lock Assembly., Vol 5 . . . . . . . WP 0641
Figure 9. Rear Door Lock Assembly Installed., Vol 5. . . . . . . . . . . . . . . . . WP 0641
Figure 10. Coil Springs Installed on Rear Door Lock Assembly and Roof-Mounted
Brackets., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0641
Figure 11. Rear Door/Ramp Assembly Lowered., Vol 5 . . . . . . . . . . . . . . . WP 0641
Figure 12. Right Side Shroud Cover Installed on Roof-Mounted Bracket., Vol 5 . . . . . WP 0641
Figure 13. Left Side Shroud Cover Installed on Roof-Mounted Bracket., Vol 5. . . . . . WP 0641
A-PILLAR COVER TRIM REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . WP 0642
Figure 1. A-Pillar Cover Trim Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0642
Figure 2. A-Pillar Cover Trim., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0642
Figure 3. A-Pillar Cover Trim., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0642
Figure 4. A-Pillar Cover Trim Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0642
A-PILLAR ASSIST HANDLE REMOVAL AND INSTALLATION, Vol 5. . . . . . . . . . . . . WP 0643
Figure 1. A-Pillar Assist Handle Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0643
Figure 2. A-Pillar Assist Handle Installation., Vol 5 . . . . . . . . . . . . . . . . . WP 0643
SIDE COWL BODY ARMOR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0644
Figure 1. Side Cowl Body Armor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0644
Figure 2. Side Cowl Body Armor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0644
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Page No.
WP Sequence No.
WINDSHIELD ARMOR REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0645
Figure 1. Antenna Brackets., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0645
Figure 2. Windshield Armor and Front Marker Bar., Vol 5. . . . . . . . . . . . . . . WP 0645
Figure 3. Windshield Armor and Front Maker Bar., Vol 5 . . . . . . . . . . . . . . . WP 0645
Figure 4. Antenna Brackets., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0645
DRIVER CONTROL MOUNTING (DCM) BRACKET ASSEMBLY EXTERIOR ARMOR REMOVAL AND
INSTALLATION (WITHOUT FRONT ACCESS PANEL), Vol 5 . . . . . . . . . . . . . . . . WP 0646
Figure 1. DCM Right Side Exterior Armor Lower Bolt., Vol 5 . . . . . . . . . . . . . WP 0646
Figure 2. DCM Right Side Exterior Armor Upper Bolts., Vol 5 . . . . . . . . . . . . . WP 0646
Figure 3. DCM Left Side Exterior Armor Lower Bolt., Vol 5 . . . . . . . . . . . . . . WP 0646
Figure 4. DCM Left Side Exterior Armor Upper Inboard Bolts., Vol 5 . . . . . . . . . . WP 0646
Figure 5. DCM Left Side Exterior Armor Upper Outboard Bolt., Vol 5 . . . . . . . . . WP 0646
Figure 6. DCM Left Side Exterior Armor Upper Outboard Bolt., Vol 5 . . . . . . . . . WP 0646
Figure 7. DCM Left Side Exterior Armor Upper Inboard Bolts., Vol 5 . . . . . . . . . . WP 0646
Figure 8. DCM Left Side Exterior Armor Lower Bolt., Vol 5 . . . . . . . . . . . . . . WP 0646
Figure 9. DCM Right Side Exterior Armor Upper Bolts., Vol 5 . . . . . . . . . . . . . WP 0646
Figure 10. DCM Right Side Exterior Armor Lower Bolt., Vol 5 . . . . . . . . . . . . . WP 0646
DRIVER CONTROL MOUNTING (DCM) BRACKET ASSEMBLY EXTERIOR ARMOR REMOVAL AND
INSTALLATION (WITH FRONT ACCESS PANEL), Vol 5 . . . . . . . . . . . . . . . . . . WP 0647
Figure 1. DCM Front Access Cover Armor Bolts., Vol 5 . . . . . . . . . . . . . . . WP 0647
Figure 2. Air Lines and Steering Column Lockbolt., Vol 5. . . . . . . . . . . . . . . WP 0647
Figure 3. Air Line., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0647
Figure 4. Exterior Armor Inboard Bolts., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0647
Figure 5. Exterior Armor Outboard Lower Bolt., Vol 5 . . . . . . . . . . . . . . . . WP 0647
Figure 6. Exterior Armor Outboard Upper Bolt., Vol 5 . . . . . . . . . . . . . . . . WP 0647
Figure 7. Exterior Armor Bottom Cover., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0647
Figure 8. Exterior Armor Bottom Cover., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0647
Figure 9. Exterior Armor Outboard Upper Bolt., Vol 5 . . . . . . . . . . . . . . . . WP 0647
Figure 10. Exterior Armor Outboard Lower Bolt., Vol 5 . . . . . . . . . . . . . . . . WP 0647
Figure 11. Exterior Armor Inboard Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0647
Figure 12. Air Line., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0647
Figure 13. Air Lines and Steering Column Pinch Bolt., Vol 5 . . . . . . . . . . . . . WP 0647
Figure 14. DCM Front Access Cover Armor Bolts., Vol 5 . . . . . . . . . . . . . . . WP 0647
DRIVER CONTROL MOUNTING (DCM) BRACKET ASSEMBLY INTERIOR ARMOR REMOVAL AND
Figure 1. Electronic System Controller (ESC) Module Connector., Vol 5 . . . . . . . . WP 0648
Figure 2. DCM Bracket Assembly Interior Armor., Vol 5 . . . . . . . . . . . . . . . WP 0648
Figure 3. DCM Bracket Assembly Interior Armor., Vol 5 . . . . . . . . . . . . . . . WP 0648
Figure 4. ESC Module Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0648
ENGINE COVER REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . WP 0649
Figure 1. Engine Cover Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0649
Figure 2. Engine Cover Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0649
COWL PANEL DRAIN TUBE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0650
Figure 1. Cowl Panel Drain Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0650
MOTOR BAFFLE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . WP 0651
Figure 1. Motor Baffle and Flat Back Cowl Seal., Vol 5 . . . . . . . . . . . . . . . . WP 0651
Figure 2. Motor Baffle and Flat Back Cowl Seal., Vol 5 . . . . . . . . . . . . . . . . WP 0651
REAR WINDOW ARMOR GLASS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0652
Figure 1. Rear Window., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0652
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Page No.
WP Sequence No.
DOOR WINDOW ARMOR GLASS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0653
Figure 1. Door Window., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0653
Figure 2. Door Window., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0653
CABIN WINDOW ARMOR GLASS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0654
Figure 1. Cabin Window., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0654
WINDSHIELD ARMOR GLASS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . WP 0655
Figure 1. Heated Windshield Electrical Connectors., Vol 5 . . . . . . . . . . . . . . WP 0655
Figure 2. Windshield., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0655
Figure 3. Windshield Removal With Sling., Vol 5 . . . . . . . . . . . . . . . . . . WP 0655
Figure 4. Windshield., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0655
Figure 5. Heated Windshield Electrical Connectors., Vol 5 . . . . . . . . . . . . . . WP 0655
STEP AND BRACKETS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . WP 0656
Figure 1. Left Side Steps, Inside Bolt., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 2. Rear Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 3. Step., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 4. Front Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 5. Rear Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 7. Front Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 8. Step., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
Figure 10. Inside Bolt., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656
FENDER AND REINFORCEMENT REMOVAL AND INSTALLATiON, Vol 5 . . . . . . . . . . WP 0657
Figure 2. Fender and Bolts., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . WP 0657
Figure 3. Fender Reinforcement., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0657
Figure 4. Fender Reinforcement., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0657
Figure 5. Fender and Rivet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0657
Figure 6. Fender and Bolts, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0657
FLOOR PANEL (FRONT) REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . WP 0658
Figure 1. Front Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0658
Figure 2. Front Floor Panel Bottom., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0658
Figure 3. Front Floor Panel Bottom., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0658
Figure 4. Front Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0658
FLOOR PANEL (FRONT CENTER) REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0659
Figure 1. Front Center Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0659
CENTER FLOOR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . WP 0660
Figure 1. Center Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0660
REAR CENTER FLOOR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . WP 0661
Figure 1. Rear Center Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0661
REAR FLOOR PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0662
Figure 1. Rear Floor Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0662
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Page No.
WP Sequence No.
DRIVER SEAT REMOVAL AND INSTALLATION, Vol 5. . . . . . . . . . . . . . . . . . . WP 0663
Figure 1. Rear Seat Hanger Safety Strap., Vol 5 . . . . . . . . . . . . . . . . . . WP 0663
Figure 2. Seat Upper Strap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 3. Suspension Lever., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 4. Seat Suspension Lever Release., Vol 5 . . . . . . . . . . . . . . . . . . WP 0663
Figure 5. Seat Suspension Retainer., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 6. Floor Anchor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 7. Driver Seat Rear Eyebolts., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 8. Driver Seat and Suspension., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 9. Driver Seat and Suspension., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 10. Driver Seat Rear Eyebolt., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 12. Seat Suspension Retainer., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0663
Figure 13. Seat Suspension Lever Release., Vol 5 . . . . . . . . . . . . . . . . . WP 0663
SEATBELT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0664
Figure 1. Seatbelt Retractor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0664
Figure 2. Seatbelt Buckle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0664
Figure 3. Seatbelt Retractor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0664
Figure 4. Seatbelt Buckle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0664
RIGHT FLOOR SEAT BRACKET REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0665
Figure 1. Seatbelt Ratchet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0665
Figure 3. HVAC Control Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0665
Figure 4. Left Front Seatbelt Retractor., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0665
Figure 5. Floor Seat Bracket Lower Mounting Bolts., Vol 5 . . . . . . . . . . . . . . WP 0665
Figure 6. Floor Seat Bracket Upper Mounting Bolts., Vol 5 . . . . . . . . . . . . . . WP 0665
Figure 7. Floor Seat Bracket Upper Mounting Bolts., Vol 5 . . . . . . . . . . . . . . WP 0665
Figure 8. Floor Seat Bracket Lower Mounting Bolts., Vol 5 . . . . . . . . . . . . . . WP 0665
Figure 9. Junction Box Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0665
Figure 10. HVAC Control Box, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0665
Figure 11. Left Front Seatbelt Retractor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0665
Figure 12. Seatbelt Ratchet Installation., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0665
CREW AND FRONT PASSENGER SEAT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . WP 0666
Figure 1. Headrest Strap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 2. Headrest Buckle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 7. Seat Suspension Retainer., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 9. Inboard Eyebolt., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 10. Floor Straps., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 11. Floor Straps., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 12. Inboard Eyebolt., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 14. Seat Suspension Retainer., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 15. Seat Suspension Lever Release., Vol 5 . . . . . . . . . . . . . . . . . WP 0666
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Page No.
WP Sequence No.
Figure 18. Rear Seat Hanger Safety Strap., Vol 5. . . . . . . . . . . . . . . . . . WP 0666
Figure 19. Headrest Buckle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
Figure 20. Headrest Strap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0666
COMMUNICATIONS RACK REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . WP 0667
Figure 1. Left Front Seat Hanger Safety Strap Tensioner., Vol 5 . . . . . . . . . . . . WP 0667
Figure 2. Left Front Seat Hanger Safety Strap Anchor Pin., Vol 5 . . . . . . . . . . . WP 0667
Figure 3. Left Front Seat Belt Retractor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0667
Figure 4. Left 12V DC Socket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0667
Figure 5. Communications Rack Top Brackets., Vol 5 . . . . . . . . . . . . . . . . WP 0667
Figure 6. Ground Straps. Front Ground Strap Shown. Rear Ground Strap Similar., Vol 5 . WP 0667
Figure 7. Fire Extinguisher and Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0667
Figure 8. Communications Rack and Left Front Floor Seat Bracket., Vol 5 . . . . . . . WP 0667
Figure 9. Communications Rack Brackets., Vol 5 . . . . . . . . . . . . . . . . . . WP 0667
Figure 10. Communications Rack., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0667
Figure 11. Communications Rack., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0667
Figure 12. Communications Rack Brackets., Vol 5 . . . . . . . . . . . . . . . . . WP 0667
Figure 13. Communications Rack and Left Front Floor Seat Bracket., Vol 5. . . . . . . WP 0667
Figure 14. Fire Extinguisher and Bracket., Vol 5 . . . . . . . . . . . . . . . . . . WP 0667
Figure 15. Communications Rack Top Brackets., Vol 5. . . . . . . . . . . . . . . . WP 0667
Figure 16. Ground Straps. Front Ground Strap Shown. Rear Ground Strap Similar., Vol 5 WP 0667
Figure 17. Left 12V DC Socket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0667
Figure 18. Left Front Seat Belt Retractor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0667
Figure 19. Seat Hanger Safety Strap Routing., Vol 5 . . . . . . . . . . . . . . . . WP 0667
Figure 20. Left Front Seat Hanger Safety Strap Anchor Pin., Vol 5 . . . . . . . . . . WP 0667
Figure 21. Left Front Seat Hanger Safety Strap Tensioner., Vol 5 . . . . . . . . . . . WP 0667
GUNNER PLATFORM/STAND REMOVAL AND INSTALLATION, Vol 5. . . . . . . . . . . . WP 0668
Figure 1. 12-Volt Junction Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0668
Figure 2. Gunner Platform Stand Floor Mounting Bolts., Vol 5 . . . . . . . . . . . . WP 0668
Figure 3. Left Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . . WP 0668
Figure 4. Right Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . WP 0668
Figure 5. Ammunition Container Assembly., Vol 5 . . . . . . . . . . . . . . . . . . WP 0668
Figure 6. 12-Volt Junction Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0668
Figure 8. Gunner Restraint Retaining Ring., Vol 5 . . . . . . . . . . . . . . . . . . WP 0668
Figure 9. Left Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . . WP 0668
Figure 10. Right Side Gunner Platform Stand Mounting Bolts., Vol 5. . . . . . . . . . WP 0668
Figure 11. Right Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . WP 0668
Figure 12. Left Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . WP 0668
Figure 13. Gunner Platform Floor Mounting Bolts., Vol 5 . . . . . . . . . . . . . . . WP 0668
Figure 14. 12-Volt Junction Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0668
Figure 15. Right Side Gunner Platform Stand Mounting Bolts., Vol 5. . . . . . . . . . WP 0668
Figure 16. Left Side Gunner Platform Stand Mounting Bolts., Vol 5 . . . . . . . . . . WP 0668
Figure 18. Gunner Restraint Retaining Ring., Vol 5 . . . . . . . . . . . . . . . . . WP 0668
Figure 19. 12-Volt Junction Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0668
Figure 20. Ammunition Container Assembly., Vol 5 . . . . . . . . . . . . . . . . . WP 0668
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Page No.
WP Sequence No.
GUNNER RESTRAINT ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0669
Figure 1. Gunner Restraint Retaining Ring., Vol 5 . . . . . . . . . . . . . . . . . . WP 0669
Figure 2. Retractor Assembly Rear Mounting Bolt., Vol 5. . . . . . . . . . . . . . . WP 0669
Figure 3. Retractor Cap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0669
Figure 4. Retractor Assembly Front Mounting Bolt., Vol 5 . . . . . . . . . . . . . . WP 0669
Figure 5. Retractor Assembly Mounting Plate., Vol 5 . . . . . . . . . . . . . . . . WP 0669
Figure 6. Retractor Assembly Mounting plate., Vol 5. . . . . . . . . . . . . . . . . WP 0669
Figure 7. Retractor Assembly Mounting Bolts., Vol 5. . . . . . . . . . . . . . . . . WP 0669
Figure 8. Retractor Cap., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0669
Figure 9. Retractor Assembly Rear Mounting Bolt., Vol 5. . . . . . . . . . . . . . . WP 0669
Figure 10. Gunner Restraint Retaining Ring., Vol 5 . . . . . . . . . . . . . . . . . WP 0669
REAR COMMUNICATION RACK REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0670
Figure 1. Rear Communication Rack Upper Tray., Vol 5 . . . . . . . . . . . . . . . WP 0670
Figure 3. Rear Communication Rack., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0670
Figure 4. Rear Communication Rack. , Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0670
Figure 6. Communications Rack Upper Tray., Vol 5 . . . . . . . . . . . . . . . . . WP 0670
RIGHT SIDE FORWARD STOWAGE BOX REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0671
Figure 1. Right Side Forward Stowage Box Removal., Vol 5 . . . . . . . . . . . . . WP 0671
Figure 2. Right Side Forward Stowage Box Installation., Vol 5 . . . . . . . . . . . . WP 0671
AIR CONDITIONING (A/C) CONDENSER PANEL REMOVAL AND INSTALLATION, Vol 5 . . . WP 0672
Figure 1. A/C Condenser Panel Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0672
Figure 2. A/C Condenser Panel Installation., Vol 5 . . . . . . . . . . . . . . . . . WP 0672
RIGHT SIDE REAR STOWAGE BOX REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0673
Figure 1. Sidemarker Harness Retainer., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0673
Figure 2. Sidemarker Harness Bolt., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0673
Figure 3. Right Rear Stowage Box Removal., Vol 5 . . . . . . . . . . . . . . . . . WP 0673
Figure 4. Sidemarker Light., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . WP 0673
Figure 5. Sidemarker Light Wiring., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0673
Figure 6. Right Side Rear Stowage Box Installation., Vol 5 . . . . . . . . . . . . . . WP 0673
Figure 7. Sidemarker Harness Bolt., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0673
LEFT SIDE FORWARD STOWAGE BOX REMOVAL AND INSTALLATION, Vol 5 . . . . . . . WP 0674
Figure 1. Left Side Forward Stowage Box Removal., Vol 5 . . . . . . . . . . . . . . WP 0674
Figure 2. Left Side Forward Stowage Box Installation., Vol 5 . . . . . . . . . . . . . WP 0674
RIGHT REAR STOWAGE BOX LATCH REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . WP 0675
Figure 1. Stowage Box Latch Removal., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0675
Figure 2. Stowage Box Latch Installation., Vol 5 . . . . . . . . . . . . . . . . . . WP 0675
LEFT REAR STOWAGE BOX REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0676
Figure 1. Left Rear Stowage Box Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0676
Figure 2. Left Rear Stowage Box Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0676
Figure 3. Left Rear Stowage Box Inside Bolts., Vol 5 . . . . . . . . . . . . . . . . WP 0676
Figure 4. Sidemarker Wiring., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0676
Figure 5. Sidemarker Wiring., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0676
Figure 6. Left Rear Stowage Box Inside Bolts., Vol 5 . . . . . . . . . . . . . . . . WP 0676
Figure 7. Left Rear Stowage Box Installation., Vol 5 . . . . . . . . . . . . . . . . . WP 0676
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Page No.
WP Sequence No.
WINCH CABLE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . WP 0677
Figure 1. Hook and Coupler., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0677
Figure 2. Winch Cable and Drum., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0677
Figure 3. Winch Cable and Drum., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0677
WINCH ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . WP 0678
Figure 2. Winch Harness Support., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 4. Winch Carrier Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 5. Front Crossmember Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 6. Winch Assembly Removal., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 7. Winch Assembly Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 8. Front Crossmember Bolt Installation., Vol 5 . . . . . . . . . . . . . . . . WP 0678
Figure 9. Winch Carrier Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 10. Hook and Coupler., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 11. Winch Harness Support., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0678
Figure 12. Junction Block., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0678
LITTER ARM STORAGE BRACKET REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0679
Figure 1. Litter Arms., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0679
Figure 2. Litter Arm Storage Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0679
Figure 3. Litter Arm Storage Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0679
Figure 4. Litter Arms., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0679
FRONT LITTER ARM MOUNT PLATE AND ARM SUPPORT REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0680
Figure 1. Front Litter Arm Mount Plate., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0680
Figure 2. Arm Support., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0680
Figure 3. Die Mark., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0680
Figure 5. Front Litter Arm Mount Plate., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0680
REAR LITTER ARM MOUNT PLATE AND ARM SUPPORT REMOVAL AND INSTALLATION, Vol 5WP 0681
Figure 1. Rear Litter Arm Mount Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0681
Figure 3. Die Mark., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0681
Figure 5. Rear Litter Arm Mount Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0681
DOOR MOUNTED MIRROR REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0682
Figure 1. Door Mounted Mirror., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0682
Figure 2. Door Mounted Mirror., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0682
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Page No.
WP Sequence No.
WIPER COWL PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0683
Figure 2. Windshield Wiper Idler Shaft Driver., Vol 5 . . . . . . . . . . . . . . . . . WP 0683
Figure 3. Windshield Wiper Idler Shaft Nut., Vol 5 . . . . . . . . . . . . . . . . . . WP 0683
Figure 4. Cowl Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0683
Figure 5. Windshield Washer Pump Hose., Vol 5 . . . . . . . . . . . . . . . . . . WP 0683
Figure 6. Underside of Cowl Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0683
Figure 7. Windshield Washer Wet Arm Adapter Nut., Vol 5 . . . . . . . . . . . . . . WP 0683
Figure 8. Windshield Washer Wet Arm Adapter and Sealing Washer., Vol 5 . . . . . . WP 0683
Figure 9. Windshield Washer Wet Arm Adapter and Sealing Washer., Vol 5 . . . . . . WP 0683
Figure 10. Windshield Washer Wet Arm Adapter Nut., Vol 5 . . . . . . . . . . . . . WP 0683
Figure 11. Windshield Washer Wet Arm Adapter Alignment., Vol 5 . . . . . . . . . . WP 0683
Figure 12. Underside of Cowl Panel., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0683
Figure 13. Windshield Washer Pump Hose., Vol 5. . . . . . . . . . . . . . . . . . WP 0683
Figure 14. Windshield Wiper Linkage and Idler Shaft Alignment., Vol 5. . . . . . . . . WP 0683
Figure 15. Windshield Wiper Idler Shaft., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0683
Figure 16. Windshield Wiper Idler Shaft Nut., Vol 5 . . . . . . . . . . . . . . . . . WP 0683
Figure 17. Windshield Wiper Washer Hose., Vol 5. . . . . . . . . . . . . . . . . . WP 0683
Figure 18. Windshield Wiper Motor Wiring Harness., Vol 5 . . . . . . . . . . . . . . WP 0683
Figure 19. Cowl Panel., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0683
Figure 20. Windshield Wiper Idler Shaft Driver., Vol 5 . . . . . . . . . . . . . . . . WP 0683
Figure 21. Windshield Wiper Motor Cover., Vol 5 . . . . . . . . . . . . . . . . . . WP 0683
WINDSHIELD WIPER MOTOR, TRANSMISSION, BRACKET, AND LINKAGE ASSEMBLY REMOVAL AND
Figure 1. Windshield Wiper Motor Harness Cable Lock Strap., Vol 5. . . . . . . . . . WP 0684
Figure 2. Windshield Wiper Motor Harness., Vol 5. . . . . . . . . . . . . . . . . . WP 0684
Figure 3. Windshield Wiper Motor Assembly Bolts., Vol 5 . . . . . . . . . . . . . . WP 0684
Figure 4. Windshield Wiper Motor Assembly., Vol 5 . . . . . . . . . . . . . . . . . WP 0684
Figure 5. Windshield Wiper Motor Assembly., Vol 5 . . . . . . . . . . . . . . . . . WP 0684
Figure 6. Windshield Wiper Motor Assembly Bolts., Vol 5 . . . . . . . . . . . . . . WP 0684
Figure 7. Windshield Wiper Motor Harness., Vol 5. . . . . . . . . . . . . . . . . . WP 0684
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . WP 0685
Figure 1. Windshield Wiper Arm Nut and Washer Hose., Vol 5 . . . . . . . . . . . . WP 0685
Figure 2. Windshield Wiper Arm Lockwasher., Vol 5 . . . . . . . . . . . . . . . . . WP 0685
Figure 3. Windshield Wiper Arm and Blade Assembly., Vol 5 . . . . . . . . . . . . . WP 0685
Figure 4. Knurled Driver on Idler Shaft., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0685
Figure 5. Windshield Wiper Arm and Blade Assembly Installation and Alignment., Vol 5 . WP 0685
Figure 6. Windshield Wiper Arm Lockwasher., Vol 5 . . . . . . . . . . . . . . . . . WP 0685
Figure 7. Windshield Wiper Arm Nut and Washer Hose., Vol 5 . . . . . . . . . . . . WP 0685
WINDSHIELD WASHER RESERVOIR AND PUMP MOTOR ASSEMBLY REMOVAL AND
Figure 1. Windshield Washer Fluid Reservoir., Vol 5 . . . . . . . . . . . . . . . . . WP 0686
Figure 2. Windshield Washer Pump Harness Connector., Vol 5 . . . . . . . . . . . . WP 0686
Figure 5. Windshield Washer Reservoir and Pump Motor., Vol 5 . . . . . . . . . . . WP 0686
Figure 6. Windshield Washer Pump Harness Connector., Vol 5 . . . . . . . . . . . . WP 0686
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WP Sequence No.
WINDSHIELD WASHER HOSE ASSEMBLY REMOVAL AND INSTALLATION, Vol 5. . . . . . WP 0687
Figure 1. Windshield Washer Pump Hose Routing., Vol 5 . . . . . . . . . . . . . . WP 0687
Figure 5. Windshield Washer Pump Hose to Washer Pump., Vol 5 . . . . . . . . . . WP 0687
Figure 6. Windshield Washer Pump Hose to Washer Pump., Vol 5 . . . . . . . . . . WP 0687
WINDSHIELD WASHER RESERVOIR BRACKET REMOVAL AND INSTALLATION, Vol 5 . . . WP 0688
Figure 1. Windshield Washer Reservoir Bracket., Vol 5 . . . . . . . . . . . . . . . WP 0688
Figure 2. Windshield Washer Reservoir Bracket., Vol 5 . . . . . . . . . . . . . . . WP 0688
WINDSHIELD WIPER MOTOR HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0689
Figure 1. Power Distribution Center (PDC) Armor Plate., Vol 5 . . . . . . . . . . . . WP 0689
Figure 2. Windshield Wiper Motor Harness Connector., Vol 5 . . . . . . . . . . . . . WP 0689
Figure 3. Windshield Wiper Motor Harness Routing On Bulkhead., Vol 5 . . . . . . . . WP 0689
Figure 4. Windshield Wiper Motor Harness Routing On Cowl., Vol 5 . . . . . . . . . . WP 0689
Figure 6. Windshield Wiper Motor Harness Connection., Vol 5 . . . . . . . . . . . . WP 0689
Figure 7. Windshield Wiper Motor Harness Connection., Vol 5 . . . . . . . . . . . . WP 0689
Figure 9. Windshield Wiper Motor Harness Routing On Cowl., Vol 5 . . . . . . . . . . WP 0689
Figure 10. Windshield Wiper Motor Harness Routing On Bulkhead., Vol 5 . . . . . . . WP 0689
Figure 11. Windshield Wiper Motor Harness Connector., Vol 5 . . . . . . . . . . . . WP 0689
REAR DOOR/RAMP HYDRAULIC PUMP COVER REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0690
Figure 1. Rear Door/Ramp Hydraulic Pump Cover., Vol 5 . . . . . . . . . . . . . . WP 0690
Figure 2. Rear Door/Ramp Hydraulic Pump Cover., Vol 5 . . . . . . . . . . . . . . WP 0690
REAR DOOR/RAMP HYDRAULIC PUMP COVER REMOVAL AND INSTALLATION (PULL-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0691
Figure 1. Removing Pump Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0691
Figure 2. Rear Door/Ramp Hydraulic Pump Cover Removal., Vol 5 . . . . . . . . . . WP 0691
Figure 3. Rear Door/Ramp Hydraulic Pump Cover Installation., Vol 5 . . . . . . . . . WP 0691
Figure 4. Installing Pump Handle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0691
REAR DOOR/RAMP HYDRAULIC PUMP REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0692
Figure 1. Hydraulic Pump and Valve Assembly Electrical Connections., Vol 5 . . . . . . WP 0692
Figure 2. Hydraulic Valve Assembly Hose Connections., Vol 5 . . . . . . . . . . . . WP 0692
Figure 3. Rear Door/Ramp Hydraulic Pump Mounting Bolts., Vol 5 . . . . . . . . . . WP 0692
Figure 4. Rear Door/Ramp Hydraulic Pump Mounting Bolts., Vol 5 . . . . . . . . . . WP 0692
Figure 5. Hydraulic Valve Assembly Hose Connections., Vol 5 . . . . . . . . . . . . WP 0692
Figure 6. Hydraulic Pump and Valve Assembly Electrical Connections., Vol 5 . . . . . . WP 0692
REAR DOOR/RAMP HYDRAULIC PUMP REMOVAL AND INSTALLATION (PULL-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0693
Figure 1. Disconnecting Hydraulic Pump Solenoid., Vol 5 . . . . . . . . . . . . . . WP 0693
Figure 2. Connecting Hydraulic Pump Solenoid., Vol 5. . . . . . . . . . . . . . . . WP 0693
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WP Sequence No.
REAR DOOR/RAMP HYDRAULIC HAND PUMP REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0694
Figure 1. Rear Door/Ramp Hand Pump., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0694
Figure 2. Rear Door/Ramp Hand Pump., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0694
REAR DOOR/RAMP HYDRAULIC POWER UNIT MANIFOLD AND MODULE REMOVAL AND
INSTALLATION (PULL-TYPE OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0695
Figure 1. Hydraulic Power Unit Manifold and Module Removal., Vol 5 . . . . . . . . . WP 0695
Figure 2. Hydraulic Power Unit Manifold and Module Installation., Vol 5 . . . . . . . . WP 0695
REAR DOOR/RAMP HYDRAULIC CYLINDER REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0696
Figure 1. Rear Door/Ramp Lowered and Supported with Jackstand., Vol 5 . . . . . . . WP 0696
Figure 2. Right Side Upper Shroud Cover., Vol 5 . . . . . . . . . . . . . . . . . . WP 0696
Figure 3. Hydraulic Transfer Block Hose Connection., Vol 5 . . . . . . . . . . . . . WP 0696
Figure 4. Hydraulic Cylinder Locking Safety Pin., Vol 5 . . . . . . . . . . . . . . . WP 0696
Figure 5. Hydraulic Cylinder Upper Lockpin Shaft and Cotter Pin., Vol 5 . . . . . . . . WP 0696
Figure 6. Hydraulic Cylinder Upper Lockpin Shaft and Cotter Pin., Vol 5 . . . . . . . . WP 0696
Figure 7. Hydraulic Cylinder Locking Safety Pin., Vol 5 . . . . . . . . . . . . . . . WP 0696
Figure 8. Hydraulic Transfer Block Hose Connection., Vol 5 . . . . . . . . . . . . . WP 0696
Figure 9. Hydraulic Reservoir Filled with Hydraulic Fluid., Vol 5 . . . . . . . . . . . . WP 0696
Figure 10. Restoration of Hydraulic Pressure in Hydraulic Pump Assembly., Vol 5 . . . . WP 0696
Figure 11. Jackstand Removed from Rear Door/Ramp., Vol 5. . . . . . . . . . . . . WP 0696
Figure 12. Right Side Upper Shroud Cover., Vol 5. . . . . . . . . . . . . . . . . . WP 0696
REAR DOOR/RAMP HYDRAULIC CYLINDER REMOVAL AND INSTALLATION (PULL-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0697
Figure 1. Manual Override Directional Valve., Vol 5 . . . . . . . . . . . . . . . . . WP 0697
Figure 3. Right Side Upper Shroud Cover Removal., Vol 5 . . . . . . . . . . . . . . WP 0697
Figure 4. Hydraulic Hose Lines Removal and Hydraulic Fluid Drained., Vol 5 . . . . . . WP 0697
Figure 5. Locking Safety Pin Removed from Hydraulic Cylinder., Vol 5 . . . . . . . . . WP 0697
Figure 6. Cotter Pin and Hydraulic Cylinder Removal., Vol 5 . . . . . . . . . . . . . WP 0697
Figure 7. Rear Door/Ramp Hydraulic Cylinder Installed in Upper Door Lock Bracket., Vol 5 WP 0697
Figure 8. Hydraulic Cylinder Installed on Rear/Door Ramp., Vol 5 . . . . . . . . . . . WP 0697
Figure 9. Hydraulic Hose Lines Connected to Transfer Block., Vol 5 . . . . . . . . . . WP 0697
Figure 10. Jackstand Removed from Rear Door/Ramp., Vol 5 . . . . . . . . . . . . WP 0697
Figure 11. Right Side Upper Shroud Cover Installed., Vol 5 . . . . . . . . . . . . . . WP 0697
REAR DOOR/RAMP GAS SPRING REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0698
Figure 2. Upper Door/Ramp Lock Bracket Front Bolts., Vol 5 . . . . . . . . . . . . . WP 0698
Figure 3. Lowering Upper Lock Bracket and Removing Gas Spring., Vol 5 . . . . . . . WP 0698
Figure 4. Rear Door/Ramp Lower Gas Spring Bracket., Vol 5 . . . . . . . . . . . . . WP 0698
Figure 5. Rear Door/Ramp Lower Gas Spring Bracket., Vol 5 . . . . . . . . . . . . . WP 0698
Figure 6. Installing Gas Spring and Securing Upper Lock Bracket., Vol 5 . . . . . . . . WP 0698
Figure 7. Upper Door Lock Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . . WP 0698
REAR DOOR/RAMP HYDRAULIC RESERVOIR FLUID FILL PROCEDURE (PULL-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0699
Figure 1. Hydraulic Reservoir Cap Removal., Vol 5 . . . . . . . . . . . . . . . . . WP 0699
Figure 2. Hydraulic Reservoir Filling., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0699
Figure 3. Hydraulic Reservoir Cap Installation., Vol 5 . . . . . . . . . . . . . . . . WP 0699
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Page No.
WP Sequence No.
REAR DOOR/RAMP HYDRAULIC HOSES REMOVAL AND INSTALLATION (PUSH-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0700
Figure 1. Hydraulic Fluid Drained from Rear Door/Ramp Hydraulic Reservoir., Vol 5 . . . WP 0700
Figure 2. Three Hydraulic Hoses Removed., Vol 5 . . . . . . . . . . . . . . . . . WP 0700
Figure 3. Three Hydraulic Hoses Installed., Vol 5 . . . . . . . . . . . . . . . . . . WP 0700
Figure 4. Hydraulic Reservoir Refilled with Hydraulic Fluid., Vol 5 . . . . . . . . . . . WP 0700
Figure 5. Restoration of Hydraulic Pressure in Hydraulic Pump Assembly., Vol 5 . . . . WP 0700
REAR DOOR/RAMP HYDRAULIC HOSES REMOVAL AND INSTALLATION (PULL-TYPE
OPERATION), Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0701
Figure 1. Manual Override Directional Valve., Vol 5 . . . . . . . . . . . . . . . . . WP 0701
Figure 3. Hydraulic Power Module-to-Hydraulic Cylinder Hose Removal., Vol 5 . . . . . WP 0701
Figure 7. Hydraulic Cylinder Short Vertical Hose Removal., Vol 5 . . . . . . . . . . . WP 0701
Figure 8. Hydraulic Cylinder Long Vertical Hose Removal., Vol 5 . . . . . . . . . . . WP 0701
Figure 9. Hydraulic Cylinder Long Vertical Hose Installation., Vol 5 . . . . . . . . . . WP 0701
Figure 10. Hydraulic Cylinder Short Vertical Hose Installation., Vol 5. . . . . . . . . . WP 0701
Figure 11. Hydraulic Power Module-to-Hydraulic Cylinder Hose Installation., Vol 5. . . . WP 0701
Figure 12. Hydraulic Power Module-to-Hydraulic Cylinder Hose Installation., Vol 5 . . . WP 0701
Figure 15. Jackstand Removed from Rear Door/Ramp., Vol 5 . . . . . . . . . . . . WP 0701
OUTSIDE GUNNER PROTECTION RISER REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0702
Figure 1. Chain Hoists and Lifting Slings., Vol 5. . . . . . . . . . . . . . . . . . . WP 0702
Figure 2. Outside Gunner Protection Riser Removal., Vol 5 . . . . . . . . . . . . . WP 0702
Figure 4. Outside Gunner Riser Bolts Installation., Vol 5 . . . . . . . . . . . . . . . WP 0702
OUTSIDE GUNNER PROTECTION ARMOR REMOVAL AND INSTALLATION, Vol 5 . . . . . WP 0703
Figure 1. Gunner Protection Armor., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0703
Figure 2. Gunner Protection Armor., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0703
GUN TURRET PLATFORM REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . WP 0704
Figure 2. Gun Turret Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0704
Figure 4. Gun Turret Platform Installation., Vol 5 . . . . . . . . . . . . . . . . . . WP 0704
TURRET MOUNTING PLATE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0705
Figure 1. Turret Mounting Plate Bolts Removal., Vol 5 . . . . . . . . . . . . . . . . WP 0705
Figure 2. Turret Mounting Plate Removal., Vol 5 . . . . . . . . . . . . . . . . . . WP 0705
Figure 3. Turret Mounting Plate Installation., Vol 5. . . . . . . . . . . . . . . . . . WP 0705
Figure 4. Turret Mounting Plate Bolts Installation., Vol 5 . . . . . . . . . . . . . . . WP 0705
RIFLE RACK REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . WP 0706
Figure 1. Rifle Rack., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0706
Figure 2. Rifle Rack., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0706
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Page No.
WP Sequence No.
HEATING VENTILATING AND AIR CONDITIONING (HVAC) SERVICE/RECHARGE
PROCEDURE, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0707
Figure 2. Recovery/Recharging Station., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0707
Table 1. R134a Refrigerant Temperature vs Pressure., Vol 5 . . . . . . . . . . . . . WP 0707
HEATING VENTILATING AND AIR CONDITIONING (HVAC) COMPRESSOR REMOVAL AND
Figure 1. HVAC Hoses At Compressor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0708
Figure 2. HVAC Compressor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0708
Figure 3. HVAC Compressor., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0708
Figure 4. HVAC Hoses At Compressor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0708
HEATING VENTILATING AND AIR CONDITIONING (HVAC) EVAPORATOR INLET HOSE REMOVAL AND
Figure 1. Right Main Duct Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0709
Figure 2. Rear Electricity Duct., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0709
Figure 3. Evaporator Inlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . . . . WP 0709
Figure 4. Evaporator Inlet Hose at Evaporator., Vol 5 . . . . . . . . . . . . . . . . WP 0709
Figure 5. HVAC Hose End with O-Ring Installed., Vol 5 . . . . . . . . . . . . . . . WP 0709
Figure 6. HVAC Hose End with O-Ring., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0709
Figure 7. Evaporator Inlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . . . . WP 0709
Figure 10. Right Main Duct Cover., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0709
HEATING VENTILATING AND AIR CONDITIONING (HVAC) EVAPORATOR OUTLET HOSE REMOVAL
AND INSTALLATION, Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0710
Figure 1. Right Main Duct Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0710
Figure 3. Penetration Dust Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0710
Figure 7. Evaporator Outlet Hose at Evaporator., Vol 5 . . . . . . . . . . . . . . . WP 0710
Figure 8. HVAC Hose End with O-Ring Installed., Vol 5 . . . . . . . . . . . . . . . WP 0710
Figure 9. HVAC Hose End with O-Ring., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0710
Figure 10. Evaporator Outlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . . . WP 0710
Figure 13. Penetration Dust Plate., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0710
Figure 14. Penetration Dust Plate., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0710
Figure 15. Rear HVAC Channel Cover., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0710
Figure 16. Right HVAC Channel Cover., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0710
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Page No.
WP Sequence No.
HEATING VENTILATING AND AIR CONDITIONING (HVAC) FILTER OUTLET HOSE REMOVAL AND
Figure 1. HVAC Filter Outlet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0711
Figure 2. HVAC Filter Outlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . . . WP 0711
Figure 3. HVAC Filter Outlet Hose O-Ring., Vol 5 . . . . . . . . . . . . . . . . . . WP 0711
Figure 4. HVAC Filter Outlet Hose O-Ring., Vol 5 . . . . . . . . . . . . . . . . . . WP 0711
Figure 5. HVAC Filter Outlet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0711
Figure 6. HVAC Filter Outlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . . . WP 0711
HEATING VENTILATING AND AIR CONDITIONING (HVAC) COMPRESSOR SUCTION HOSE REMOVAL
Figure 1. HVAC Compressor Suction Hose at Compressor Inlet., Vol 5. . . . . . . . . WP 0712
Figure 2. HVAC Compressor Suction Hose at Penetration Dust Plate., Vol 5 . . . . . . WP 0712
Figure 3. O-Rings, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0712
Figure 5. Compressor Inlet., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . WP 0712
Figure 6. HVAC Compressor Suction Hose at Penetration Dust Plate., Vol 5 . . . . . . WP 0712
HEATING VENTILATING AND AIR CONDITIONING (HVAC) LEFT-SIDE CONDENSER INLET HOSE
REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0713
Figure 1. Left HVAC Condenser Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . . WP 0713
Figure 2. Condenser Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0713
Figure 3. Left Front Opening to Cab Double-Floor., Vol 5. . . . . . . . . . . . . . . WP 0713
Figure 4. Left Condenser Hose Fitting., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0713
Figure 5. Left Rear Opening to Cab Double-Floor., Vol 5 . . . . . . . . . . . . . . . WP 0713
Figure 10. Condenser Hoses., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . WP 0713
Figure 11. Condenser Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0713
Figure 13. Left HVAC Condenser Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . WP 0713
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RIGHT-SIDE CONDENSER INLET HOSE
Figure 1. Condenser Inlet Hose Fittings., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0714
Figure 2. Condenser Inlet Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0714
Figure 3. Condenser Inlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0714
Figure 4. Cab Right-Side Double-Floor Front Opening., Vol 5 . . . . . . . . . . . . . WP 0714
Figure 6. Cab Right-Side Double-Floor Rear Opening., Vol 5 . . . . . . . . . . . . . WP 0714
Figure 9. Condenser Inlet Hose Fittings., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0714
Figure 10. Condenser Inlet Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0714
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Page No.
WP Sequence No.
HEATING VENTILATING AND AIR CONDITIONING (HVAC) LEFT-SIDE CONDENSER OUTLET HOSE
Figure 1. Left Condenser Outlet Hose Fitting at HVAC Filter., Vol 5 . . . . . . . . . . WP 0715
Figure 2. Condenser Outlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0715
Figure 4. Left Condenser Outlet Hose Fitting., Vol 5 . . . . . . . . . . . . . . . . . WP 0715
Figure 5. Left Rear Opening to Cab Double-Floor., Vol 5 . . . . . . . . . . . . . . . WP 0715
Figure 6. Condenser Outlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0715
Figure 13. Left HVAC Condenser Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . WP 0715
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RIGHT-SIDE CONDENSER OUTLET HOSE
Figure 1. Right HVAC Condenser Hose Fittings., Vol 5. . . . . . . . . . . . . . . . WP 0716
Figure 2. Right HVAC Condenser Hose at Filter., Vol 5. . . . . . . . . . . . . . . . WP 0716
Figure 3. Right Front Opening to Cab Double-Floor., Vol 5 . . . . . . . . . . . . . . WP 0716
Figure 4. Right Rear Opening to Cab Double-Floor., Vol 5 . . . . . . . . . . . . . . WP 0716
Figure 5. Right Rear Opening to Cab Double-Floor., Vol 5 . . . . . . . . . . . . . . WP 0716
Figure 7. Right HVAC Condenser Hose Fittings., Vol 5. . . . . . . . . . . . . . . . WP 0716
Figure 8. Right HVAC Condenser Hose at Tee., Vol 5 . . . . . . . . . . . . . . . . WP 0716
HEATING VENTILATING AND AIR CONDITIONING (HVAC) COMPRESSOR DISCHARGE HOSE
Figure 1. 3-Way Valve., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0717
Figure 2. Compressor Discharge Hose Heat Shrink Tubing., Vol 5. . . . . . . . . . . WP 0717
Figure 3. HVAC Compressor Discharge Hose at Compressor., Vol 5. . . . . . . . . . WP 0717
Figure 4. HVAC Compressor Discharge Hose at T-fitting., Vol 5 . . . . . . . . . . . . WP 0717
Figure 5. HVAC Compressor Discharge Hose at Compressor., Vol 5. . . . . . . . . . WP 0717
Figure 6. HVAC Compressor Discharge Hose at T-fitting., Vol 5 . . . . . . . . . . . . WP 0717
Figure 7. Compressor Discharge Outlet Heat Shrink Tubing, Vol 5 . . . . . . . . . . WP 0717
Figure 8. HVAC Compressor Discharge Hose at Tee., Vol 5 . . . . . . . . . . . . . WP 0717
HEATING VENTILATING AND AIR CONDITIONING (HVAC) SERVICE PORT/SCHRADER VALVE
Figure 1. HVAC Service Port., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0718
Figure 2. HVAC Service Port., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0718
HEATING VENTILATING AND AIR CONDITIONING (HVAC) WATER DRAINAGE HOSE REMOVAL AND
Figure 1. HVAC Water Drainage Hose Upper End., Vol 5. . . . . . . . . . . . . . . WP 0719
Figure 2. HVAC Water Drainage Hose Lower End., Vol 5. . . . . . . . . . . . . . . WP 0719
Figure 3. HVAC Water Drainage Hose Upper End., Vol 5. . . . . . . . . . . . . . . WP 0719
Figure 4. HVAC Water Drainage Hose Lower End., Vol 5. . . . . . . . . . . . . . . WP 0719
HEATING VENTILATING AND AIR CONDITIONING (HVAC) FRESH AIR INLET TUBE REMOVAL AND
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NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DUST TUBE REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0721
Figure 1. External Dust Tube at Forward Side of Heating Ventilating and Air Conditioning (HVAC)/Life
Support System (LSS) Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0721
Figure 2. Dust Tube at Forward Side of HVAC/LSS Box., Vol 5 . . . . . . . . . . . . WP 0721
Figure 3. External Dust Tube at Floor Under Right Front Seat., Vol 5 . . . . . . . . . WP 0721
Figure 4. Dust Tube at Floor Under Right Front Seat., Vol 5 . . . . . . . . . . . . . WP 0721
Figure 5. Dust Tube at Floor Under Right Front Seat., Vol 5 . . . . . . . . . . . . . WP 0721
Figure 6. External Dust Tube at Floor Under Right Front Seat., Vol 5 . . . . . . . . . WP 0721
Figure 7. Dust Tube at Forward Side of HVAC/LSS Box., Vol 5 . . . . . . . . . . . . WP 0721
Figure 8. External Dust Tube at Forward Side of HVAC/LSS Box., Vol 5 . . . . . . . . WP 0721
HEATING VENTILATING AND AIR CONDITIONING (HVAC) REFRIGERANT FILTER REMOVAL AND
Figure 1. HVAC Filter., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0722
Figure 2. O-Ring Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0722
Figure 4. HVAC Filter., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0722
HEATING VENTILATING AND AIR CONDITIONING (HVAC) CONDENSER REMOVAL AND
Figure 1. HVAC Condenser Lines., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0723
Figure 2. HVAC Condenser Unit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0723
Figure 4. HVAC Condenser Fan Assembly., Vol 5 . . . . . . . . . . . . . . . . . . WP 0723
Figure 5. HVAC Condenser Fan Assembly., Vol 5 . . . . . . . . . . . . . . . . . . WP 0723
Figure 8. HVAC Condenser Lines., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0723
AIR CONDITIONER CONDENSER FAN ASSEMBLY REMOVAL AND INSTALLATION, Vol 5 . . WP 0724
Figure 1. Condenser Fan Assembly Harness Connection., Vol 5 . . . . . . . . . . . WP 0724
Figure 2. Condenser Fan Assembly., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0724
Figure 3. Condenser Fan Assembly., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0724
Figure 4. Condenser Fan Assembly Harness Connection., Vol 5 . . . . . . . . . . . WP 0724
ENGINE WATER OUTLET PIPE AND ELBOW REMOVAL AND INSTALLATION, Vol 5 . . . . WP 0725
Figure 1. Engine Water Outlet Pipe Assembly., Vol 5 . . . . . . . . . . . . . . . . WP 0725
Figure 2. Engine Water Outlet Pipe Assembly., Vol 5 . . . . . . . . . . . . . . . . WP 0725
HEATING VENTILATING AND AIR CONDITIONING (HVAC) 3-WAY VALVE COOLANT OUTLET HOSE
Figure 3. Outlet Hose at 3-Way Valve., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0726
Figure 4. Outlet Hose at Dust Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0726
Figure 5. Outlet Hose at Dust Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0726
Figure 6. Outlet Hose at 3-Way Valve., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0726
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) 3-WAY VALVE REMOVAL AND
Figure 3. HVAC 3-Way Valve., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0727
Figure 4. 3-Way Valve Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0727
Figure 5. 3-Way Valve and Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0727
Figure 6. 3-Way Valve and Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0727
Figure 7. 3-Way Valve Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0727
Figure 8. HVAC 3-Way Valve., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0727
HEATING VENTILATING AND AIR CONDITIONING (HVAC) CABIN HEATER HOSE REMOVAL AND
Figure 3. Heater Hose Connections at Floor., Vol 5 . . . . . . . . . . . . . . . . . WP 0728
Figure 4. Heater Hose Connections at Life Support System (LSS) Box., Vol 5 . . . . . WP 0728
Figure 5. Heater Hose Connections at Floor., Vol 5 . . . . . . . . . . . . . . . . . WP 0728
Figure 6. Heater Hose Connections at LSS Box., Vol 5 . . . . . . . . . . . . . . . WP 0728
HEATING VENTILATING AND AIR CONDITIONING (HVAC) FUEL-FIRED HEATER COOLANT OUTLET
HOSE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0729
Figure 3. Hose Connections at Fuel-Fired Heater., Vol 5 . . . . . . . . . . . . . . . WP 0729
Figure 4. Fuel-Fired Heater Outlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0729
Figure 5. Fuel-Fired Heater Outlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0729
Figure 6. Hose Connections at Fuel-Fired Heater., Vol 5 . . . . . . . . . . . . . . . WP 0729
Figure 7. Heater Coolant Engine Inlet Valve Installation., Vol 5 . . . . . . . . . . . . WP 0729
HEATING VENTILATING AND AIR CONDITIONING (HVAC) 3-WAY VALVE COOLANT INLET HOSE
Figure 1. Inlet Valve To Water Pump From Heater., Vol 5. . . . . . . . . . . . . . . WP 0730
Figure 2. Inlet Hose To Engine From Heater., Vol 5 . . . . . . . . . . . . . . . . . WP 0730
Figure 5. Inlet Hose To Engine From Heater., Vol 5 . . . . . . . . . . . . . . . . . WP 0730
Figure 6. Inlet Valve To Water Pump From Heater., Vol 5. . . . . . . . . . . . . . . WP 0730
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) FUEL-FIRED HEATER COOLANT INLET
HOSE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0731
Figure 3. Fuel-Fired Heater Hose Connections., Vol 5 . . . . . . . . . . . . . . . . WP 0731
Figure 4. Fuel-Fired Heater Inlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . WP 0731
Figure 5. Fuel-Fired Heater Hose Tee., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0731
Figure 6. Fuel-Fired Hose Tee and Dust Plate., Vol 5 . . . . . . . . . . . . . . . . WP 0731
Figure 7. Fuel-Fired Heater Inlet Hose at 3-Way Valve., Vol 5. . . . . . . . . . . . . WP 0731
Figure 8. Fuel-Fired Heater Inlet Hose at 3-Way Valve., Vol 5. . . . . . . . . . . . . WP 0731
Figure 9. Fuel-Fired Heater Inlet Hose at Penetration Dust Plate., Vol 5 . . . . . . . . WP 0731
Figure 10. Fuel-Fired Heater Hose Tee., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0731
Figure 11. Fuel-Fired Heater Inlet Hose., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0731
Figure 12. Fuel-Fired Heater Hose Connections., Vol 5 . . . . . . . . . . . . . . . WP 0731
FUEL-FIRED HEATER REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . WP 0732
Figure 3. Fuel-Fired Heater Mounted., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0732
Figure 4. Fuel-Fired Heater Coolant Hoses., Vol 5 . . . . . . . . . . . . . . . . . WP 0732
Figure 7. Fuel-Fired Heater Coolant Hoses., Vol 5 . . . . . . . . . . . . . . . . . WP 0732
Figure 8. Fuel-Fired Heater Mounted., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0732
Figure 11. Fuel-Fired Heater Bleed Screw., Vol 5 . . . . . . . . . . . . . . . . . . WP 0732
FUEL-FIRED HEATER FUEL PUMP AND FUEL LINE REMOVAL AND INSTALLATION, Vol 5 . WP 0733
Figure 1. Fuel Tank Connection., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0733
Figure 3. Fuel-Fired Heater Fuel Line Connection., Vol 5. . . . . . . . . . . . . . . WP 0733
Figure 4. Fuel-Fired Heater Fuel Line Connection., Vol 5. . . . . . . . . . . . . . . WP 0733
Figure 6. Fuel Tank Connection., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0733
FUEL FIRED HEATER AND FUEL FIRED HEATER FUEL PUMP HARNESS REMOVAL AND
Figure 1. Fuel Fired Heater Connector., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0734
Figure 2. Fire Suppression System (FSS) Harness., Vol 5 . . . . . . . . . . . . . . WP 0734
Figure 3. Frame Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 4. Main Harness, Right Side., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 5. Transmission Bellhousing., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 6. Fuel Fired Heater Harness., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 7. Fuel Pump Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 8. Main Harness Near Starter., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 9. Power Distribution Center (PDC) Armor., Vol 5 . . . . . . . . . . . . . . . WP 0734
Figure 10. Fuel Fired Heater and Fuel Fired Heater Fuel Pump Harness Connectors at
PDC., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 11. Fuel Fired Heater and Fuel Fired Heater Fuel Pump Harness Connectors at
PDC., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 13. Main Harness Near Starter., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
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Figure 14. Fuel Pump Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 15. Fuel Fired Heater Harness., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 16. Transmission Bellhousing., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 17. Main Harness, Right Side., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 18. Frame Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 19. FSS Harness., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0734
Figure 20. Fuel Fired Heater Connector., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0734
FUEL-FIRED HEATER TIMER CONTROL REMOVAL AND INSTALLATION, Vol 5 . . . . . . WP 0735
Figure 1. Fuel-Fired Heater Timer Control Switch and Timer Wiring., Vol 5 . . . . . . . WP 0735
Figure 2. Fuel-Fired Heater Timer Switch and Control., Vol 5 . . . . . . . . . . . . . WP 0735
Figure 3. Fuel-Fired Heater Timer Switch and Control., Vol 5 . . . . . . . . . . . . . WP 0735
Figure 4. Fuel-Fired Heater Timer Control Switch and Timer Wiring., Vol 5 . . . . . . . WP 0735
FIRE SUPPRESSION SYSTEM (FSS) DISABLE AND ENABLE, Vol 5 . . . . . . . . . . . . WP 0736
Figure 1. Fire Suppression System (FSS) Harness Removal., Vol 5 . . . . . . . . . . WP 0736
FIRE SUPPRESSION SYSTEM (FSS) CONTROL UNIT REMOVAL AND INSTALLATION, Vol 5 WP 0737
Figure 1. FSS Control Unit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0737
FIRE SUPPRESSION SYSTEM (FSS) CONTROL UNIT BRACKET REMOVAL AND
Figure 1. Communication Bracket., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0738
Figure 2. FSS Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0738
Figure 3. FSS Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0738
Figure 4. Communication Bracket., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0738
FIRE SUPPRESSION SYSTEM (FSS) CABIN HARNESS REMOVAL AND INSTALLATION, Vol 5 WP 0739
Figure 1. Interior Pass-Through Plate Connection., Vol 5. . . . . . . . . . . . . . . WP 0739
Covers., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0739
Figure 4. FSS Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0739
Figure 5. FSS Cabin Cylinder Connection., Vol 5 . . . . . . . . . . . . . . . . . . WP 0739
Figure 6. FSS Cabin Cylinder Connection., Vol 5 . . . . . . . . . . . . . . . . . . WP 0739
Figure 7. FSS Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0739
Figure 10. Interior Pass-Through Plate Connection., Vol 5 . . . . . . . . . . . . . . WP 0739
FIRE SUPPRESSION SYSTEM (FSS) CHASSIS HARNESS REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0740
Figure 1. FSS Engine Compartment Sensor Connection., Vol 5 . . . . . . . . . . . . WP 0740
Figure 2. FSS Cylinder Connection., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0740
Figure 3. FSS Fuel Tank Extinguisher Cylinder Connection., Vol 5. . . . . . . . . . . WP 0740
Figure 4. FSS Tire Extinguisher Cylinder Connection., Vol 5 . . . . . . . . . . . . . WP 0740
Figure 9. FSS Tire Extinguisher Cylinder Connection., Vol 5 . . . . . . . . . . . . . WP 0740
Figure 10. FSS Fuel Tank Extinguisher Cylinder Connection., Vol 5 . . . . . . . . . . WP 0740
Figure 11. FSS Engine Extinguisher Cylinder Connection., Vol 5 . . . . . . . . . . . WP 0740
Figure 12. FSS Engine Compartment Sensor Connection., Vol 5 . . . . . . . . . . . WP 0740
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FIRE SUPPRESSION SYSTEM (FSS) ENGINE COMPARTMENT SENSOR REMOVAL AND
Figure 1. FSS Engine Compartment Sensor Connections., Vol 5 . . . . . . . . . . . WP 0741
FIRE SUPPRESSION SYSTEM (FSS) CABIN SENSOR REMOVAL AND INSTALLATION, Vol 5 WP 0742
Figure 1. FSS Cabin Compartment Sensor Connections., Vol 5 . . . . . . . . . . . . WP 0742
Figure 2. FSS Cabin Compartment Sensor Installation., Vol 5 . . . . . . . . . . . . WP 0742
FIRE SUPPRESSION SYSTEM (FSS) FUEL TANK CYLINDER REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0743
Figure 1. FSS Fuel Tank Cylinder Connections., Vol 5 . . . . . . . . . . . . . . . . WP 0743
Figure 2. FSS Engine Cylinder Mount., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0743
Figure 3. FSS Fuel Tank Cylinder Mount., Vol 5. . . . . . . . . . . . . . . . . . . WP 0743
Figure 4. FSS Fuel Tank Cylinder Connection., Vol 5 . . . . . . . . . . . . . . . . WP 0743
FIRE SUPPRESSION SYSTEM (FSS) FUEL TANK DISPERSION UNIT AND PIPE REMOVAL AND
Figure 1. Fuel Tank FSS Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0744
Figure 2. FSS Fuel Tank Dispersion Unit Hose., Vol 5 . . . . . . . . . . . . . . . . WP 0744
Figure 3. FSS Fuel Tank Dispersion Unit and Pipe, (Rear Nozzle Shown, Front Nozzle
Similar)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0744
Figure 4. FSS Fuel Tank Dispersion Unit and Pipe, (Rear Nozzle Shown, Front Nozzle
Similar)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0744
Figure 5. FSS Fuel Tank Dispersion Unit Hose., Vol 5 . . . . . . . . . . . . . . . . WP 0744
Figure 6. Fuel Tank FSS Bracket., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0744
FIRE SUPPRESSION SYSTEM (FSS) CABIN CYLINDER REMOVAL AND INSTALLATION, Vol 5WP 0745
Figure 2. FSS Cabin Cylinder Electrical Connector., Vol 5 . . . . . . . . . . . . . . WP 0745
Figure 3. FSS Cabin Cylinder Connections Shield., Vol 5 . . . . . . . . . . . . . . WP 0745
Figure 4. FSS Cabin Cylinder Hoses., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0745
Figure 5. FSS Cabin Cylinder Hoses., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0745
Figure 6. FSS Cabin Cylinder Connections Shield., Vol 5 . . . . . . . . . . . . . . WP 0745
Figure 7. FSS Cabin Cylinder Electrical Connector., Vol 5 . . . . . . . . . . . . . . WP 0745
FIRE SUPPRESSION SYSTEM (FSS) CABIN/CREW DISPERSION UNIT AND PIPE REMOVAL AND
Figure 1. Front FSS Cabin/Crew Dispersion Unit and Pipe., Vol 5 . . . . . . . . . . . WP 0746
Figure 2. Rear FSS Cabin/Crew Dispersion Unit and Pipe (Right Side Shown, Left Side
Similar)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0746
Figure 3. Rear FSS Cabin/Crew Dispersion Unit and Pipe (Right Side Shown, Left Side
Similar)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0746
Figure 4. Front FSS Cabin/Crew Dispersion Unit and Pipe., Vol 5 . . . . . . . . . . . WP 0746
FIRE SUPPRESSION SYSTEM (FSS) TIRE CYLINDER REMOVAL AND INSTALLATION, Vol 5 WP 0747
Figure 1. FSS Tire Cylinder Connections., Vol 5 . . . . . . . . . . . . . . . . . . WP 0747
Figure 2. FSS Tire Cylinder Connections., Vol 5 . . . . . . . . . . . . . . . . . . WP 0747
FIRE SUPPRESSION SYSTEM (FSS) FRONT TIRE DISPERSION UNIT AND PIPE REMOVAL AND
Figure 1. FSS Front Tire Dispersion Unit and Pipe., Vol 5 . . . . . . . . . . . . . . WP 0748
Figure 2. FSS Front Tire Dispersion Unit and Pipe., Vol 5 . . . . . . . . . . . . . . WP 0748
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FIRE SUPPRESSION SYSTEM (FSS) REAR TIRE DISPERSION UNIT AND PIPE REMOVAL AND
Figure 1. FSS Rear Tire Dispersion Unit and Pipe., Vol 5. . . . . . . . . . . . . . . WP 0749
Figure 2. FSS Rear Tire Dispersion Unit and Pipe., Vol 5. . . . . . . . . . . . . . . WP 0749
FIRE SUPPRESSION SYSTEM (FSS) ENGINE CYLINDER REMOVAL AND INSTALLA-
TION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0750
Figure 1. FSS Engine Cylinder Connections., Vol 5 . . . . . . . . . . . . . . . . . WP 0750
Figure 4. FSS Engine Cylinder Connections., Vol 5 . . . . . . . . . . . . . . . . . WP 0750
FIRE SUPPRESSION SYSTEM (FSS) ENGINE DISPERSION UNIT AND PIPE REMOVAL AND
Figure 1. FSS Engine Dispersion Unit and Pipe., Vol 5. . . . . . . . . . . . . . . . WP 0751
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) MAIN AIR
DUCT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 1. Rear Seat Ratchet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 2. Seat Suspension Lever Position., Vol 5 . . . . . . . . . . . . . . . . . . WP 0752
Figure 4. Fire Suppression Fitting., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 5. Wire Harness Cable Lock Strap., Vol 5 . . . . . . . . . . . . . . . . . . WP 0752
Figure 6. Main Air Duct Removal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 7. Main Air Duct Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 8. Fire Suppression Fitting., Vol 5. . . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 9. Wire Harness Cable Lock Strap., Vol 5 . . . . . . . . . . . . . . . . . . WP 0752
Figure 10. Suspension Seat Shackles., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0752
Figure 11. Seat Suspension Lever Position., Vol 5. . . . . . . . . . . . . . . . . . WP 0752
Figure 12. Seat Suspension Lever Engaged., Vol 5 . . . . . . . . . . . . . . . . . WP 0752
Figure 13. Rear Seat Ratchet., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0752
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) AIR DUCT
LOUVER REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0753
Figure 1. Forward Facing Right Side Center Louver. , Vol 5 . . . . . . . . . . . . . WP 0753
Figure 2. Rear Facing Left Side Louver., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0753
Figure 3. Rear Facing Right Side Center Louver., Vol 5 . . . . . . . . . . . . . . . WP 0753
Figure 4. Seat Suspension Mount Clevis and Pin., Vol 5 . . . . . . . . . . . . . . . WP 0753
Figure 5. Rear Facing Left Side Louver., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0753
Figure 6. Rear Facing Right Side Center Louver., Vol 5 . . . . . . . . . . . . . . . WP 0753
Figure 7. Seat Suspension Mount Clevis and Pin., Vol 5 . . . . . . . . . . . . . . . WP 0753
Figure 8. Forward Facing Right Side Center Louver., Vol 5 . . . . . . . . . . . . . . WP 0753
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) DEFOGGING
AIR DUCT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0754
Figure 1. Defogging Air Duct Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0754
Figure 2. Defogging Air Duct Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0754
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) DIFFUSER
AIR DUCT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0755
Figure 1. Diffuser Air Duct., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0755
Figure 2. Diffuser Air Duct., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0755
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WP Sequence No.
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) FRESH AIR
INLET FLANGE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . WP 0756
Figure 1. Fresh Air Inlet Flange., Vol 5. . . . . . . . . . . . . . . . . . . . . . . WP 0756
Figure 2. Fresh Air Inlet Flange., Vol 5. . . . . . . . . . . . . . . . . . . . . . . WP 0756
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS)
OVERPRESSURE RELIEF VALVE REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . WP 0757
Figure 1. Overpressure Relief Valve Mounting., Vol 5 . . . . . . . . . . . . . . . . WP 0757
Figure 2. Overpressure Relief Valve Shield Assembly Mounting., Vol 5. . . . . . . . . WP 0757
Figure 3. Overpressure Relief Valve Shield Assembly., Vol 5 . . . . . . . . . . . . . WP 0757
Figure 4. Overpressure Relief Valve O-Ring., Vol 5 . . . . . . . . . . . . . . . . . WP 0757
Figure 5. Overpressure Relief Valve Shield Assembly Mounting., Vol 5. . . . . . . . . WP 0757
Figure 6. Overpressure Relief Valve O-Ring., Vol 5 . . . . . . . . . . . . . . . . . WP 0757
Figure 7. Overpressure Relief Valve Mounting., Vol 5 . . . . . . . . . . . . . . . . WP 0757
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RECEIVER/DRIER REMOVAL AND
Figure 1. Inlet Hose at Evaporator Assembly., Vol 5 . . . . . . . . . . . . . . . . . WP 0758
Figure 2. Inlet Hose at Receiver/Drier., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0758
Figure 3. Pressure Switch Connection., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0758
Figure 4. Discharge Hose at Thermal Expansion Valve., Vol 5 . . . . . . . . . . . . WP 0758
Figure 5. Receiver/Drier Mounting Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0758
Figure 6. Discharge Hose at Receiver/Drier., Vol 5 . . . . . . . . . . . . . . . . . WP 0758
Figure 7. High Pressure Switch., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0758
Figure 8. Receiver/Drier Mounting Plate and Clamp., Vol 5 . . . . . . . . . . . . . . WP 0758
Figure 9. Receiver/Drier Mounting Plate and Clamp., Vol 5 . . . . . . . . . . . . . . WP 0758
Figure 10. High Pressure Switch., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0758
Figure 11. Discharge Hose at Receiver/Drier., Vol 5 . . . . . . . . . . . . . . . . . WP 0758
Figure 12. Receiver/Drier Mounting Bolts., Vol 5 . . . . . . . . . . . . . . . . . . WP 0758
Figure 13. Discharge Hose at Thermal Expansion Valve., Vol 5 . . . . . . . . . . . . WP 0758
Figure 14. Pressure Switch Connection., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0758
Figure 15. Inlet Hose at Receiver/Drier., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0758
Figure 16. Inlet Hose at Evaporator Assembly., Vol 5 . . . . . . . . . . . . . . . . WP 0758
HEATING VENTILATING AND AIR CONDITIONING (HVAC) MAIN EVAPORATOR ASSEMBLY REMOVAL
Figure 1. Evaporator Fittings., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0759
Figure 2. Evaporator Hose With O-Ring Installed., Vol 5 . . . . . . . . . . . . . . . WP 0759
Figure 3. HVAC Thermostat., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0759
Figure 4. Evaporator Mounting Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . WP 0759
Figure 5. Evaporator Mounting Bracket Bolts., Vol 5 . . . . . . . . . . . . . . . . . WP 0759
Figure 6. HVAC Thermostat., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0759
Figure 7. Evaporator Hose With O-Ring Removed, Vol 5 . . . . . . . . . . . . . . . WP 0759
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) HEATER RADIATOR REMOVAL AND
Figure 3. Heater Radiator Outlet Fitting., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0760
Figure 4. Heater Radiator Outlet Hose Inside LSS Box at Panel., Vol 5 . . . . . . . . WP 0760
Figure 5. Heater Radiator Inlet Fitting., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0760
Figure 6. Heater Radiator Inlet Hose Inside LSS Box at Panel., Vol 5 . . . . . . . . . WP 0760
Figure 7. Heater Radiator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0760
Figure 8. Heater Radiator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0760
Figure 9. Heater Radiator Inlet Fitting., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0760
Figure 10. Heater Radiator Inlet Hose Inside LSS Box at Panel., Vol 5 . . . . . . . . . WP 0760
Figure 11. Heater Radiator Outlet Fitting., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0760
Figure 12. Heater Radiator Outlet Hose Inside LSS Box at Panel., Vol 5 . . . . . . . . WP 0760
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) BOX
Figure 3. Heater Hoses., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0761
Figure 5. Evaporator Hose With O-Ring Installed., Vol 5 . . . . . . . . . . . . . . . WP 0761
Figure 6. HVAC/LSS Box Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0761
Figure 7. HVAC Box Seal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0761
Figure 8. HVAC/LSS Box Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0761
Figure 9. Blower Harness Routing., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0761
Figure 10. Evaporator Hose With O-Ring Removed, Vol 5 . . . . . . . . . . . . . . WP 0761
Figure 12. Heater Hoses., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0761
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) FILTER REMOVAL AND INSTALLATION, Vol 5WP 0762
Figure 1. NBC Access Door., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0762
Figure 2. NBC Filter Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0762
Figure 3. NBC Filter in NBC Filter Housing., Vol 5 . . . . . . . . . . . . . . . . . . WP 0762
Figure 4. NBC Filter Installation., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0762
Figure 6. NBC Access Door., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0762
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) FILTER COVER AND HOUSING REMOVAL AND
Figure 2. NBC Filter Housing., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0763
Figure 3. NBC Filter Outlet Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0763
Figure 4. NBC Filter Outlet Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0763
Figure 5. NBC Filter Housing., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0763
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NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) PARTICLE SEPARATOR FILTER REMOVAL AND
Figure 1. NBC Particle Separator Filter Mounting., Vol 5 . . . . . . . . . . . . . . . WP 0764
Figure 4. NBC Particle Separator Filter Mounting., Vol 5 . . . . . . . . . . . . . . . WP 0764
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) MAIN
BLOWER MOTOR AND SUPPORT REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . WP 0765
Figure 1. HVAC/LSS Main Blower Motor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0765
Figure 2. HVAC/LSS Main Blower Motor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0765
HEATING VENTILATING AND AIR CONDITIONING/LIFE SUPPORT SYSTEM (HVAC/LSS) UPPER
BLOWER REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0766
Figure 1. Blower Mounting Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0766
Figure 2. Blower Harness Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0766
Figure 3. Fan Drive Setscrew., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0766
Figure 4. Blower Motor and Mounting Panel., Vol 5 . . . . . . . . . . . . . . . . . WP 0766
Figure 5. Blower Mounting Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0766
Figure 6. Blower Harness Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0766
HEATING VENTILATING AND AIR CONDITIONING/LIFE SUPPORT SYSTEM (HVAC/LSS) UPPER PANEL
Figure 1. HVAC Cover Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0767
Figure 2. HVAC Cover Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0767
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RECIRCULATED AIR (RA) TEMPERATURE
SENSOR REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0768
Figure 1. RA Sensor Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0768
Figure 2. LSS Operator Panel Connector., Vol 5 . . . . . . . . . . . . . . . . . . WP 0768
Figure 3. RA Sensor Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0768
Figure 4. RA Sensor Bolts., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0768
Figure 5. RA Sensor Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0768
Figure 6. LSS Operator Panel Connector., Vol 5 . . . . . . . . . . . . . . . . . . WP 0768
CLIMATE CONTROL UNIT (CCU) BOX REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . WP 0769
Figure 1. CCU Box Upper Connections., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0769
Figure 2. CCU Box Lower Connections., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0769
Figure 3. CCU Box Ground., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 4. CCU Box Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 5. CCU Box Side Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 6. CCU Box Side Connector., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 7. CCU Box Mounting., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 8. CCU Box Lower Connections., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0769
Figure 9. CCU Box Ground., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0769
Figure 10. CCU Box Upper Connections., Vol 5. . . . . . . . . . . . . . . . . . . WP 0769
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) OPERATOR
PANEL REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0770
Figure 1. LSS Operator Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0770
Figure 2. LSS Operator Panel Housing., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0770
Figure 3. LSS Operator Panel Wiring Harness., Vol 5 . . . . . . . . . . . . . . . . WP 0770
Figure 4. LSS Operator Panel Wiring Harness., Vol 5 . . . . . . . . . . . . . . . . WP 0770
Figure 5. LSS Operator Panel Housing., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0770
Figure 6. LSS Operator Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0770
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) LOW PRESSURE SWITCH REMOVAL AND
Figure 1. HVAC Low Pressure Switch., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0771
Figure 2. HVAC Low Pressure Switch., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0771
HEATING VENTILATING AND AIR CONDITIONING (HVAC) LEFT CONDENSER CONTROL WIRING
HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0772
Figure 1. Left Condenser., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0772
Figure 2. Left Condenser Harness Connectors., Vol 5 . . . . . . . . . . . . . . . . WP 0772
Figure 3. Left Condenser., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0772
HEATING VENTILATING AND AIR CONDITIONING (HVAC) RIGHT CONDENSER CONTROL WIRING
HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0773
Figure 1. Right Condenser., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0773
Figure 2. Right Condenser Harness Connectors., Vol 5 . . . . . . . . . . . . . . . WP 0773
Figure 3. Right Condenser., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0773
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) ENGINE
WIRING HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 1. Interior Penetration Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0774
Figure 2. Interior HVAC/LSS Wiring Harness., Vol 5 . . . . . . . . . . . . . . . . . WP 0774
Figure 3. Penetration Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0774
Figure 4. HVAC/LSS Engine Harness O-Ring., Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 6. High Idle Request Circuit Connector., Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 7. Low Pressure Switch Connector., Vol 5 . . . . . . . . . . . . . . . . . . WP 0774
Figure 8. Low Pressure Switch Connector., Vol 5 . . . . . . . . . . . . . . . . . . WP 0774
Figure 9. High Idle Request Circuit Connector., Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 10. 3-Way Valve., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0774
Figure 11. HVAC/LSS Engine Harness O-Ring., Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 12. Penetration Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0774
Figure 13. Interior HVAC/LSS Wiring Harness., Vol 5 . . . . . . . . . . . . . . . . WP 0774
Figure 14. Interior Penetration Plate., Vol 5. . . . . . . . . . . . . . . . . . . . . WP 0774
HEATING VENTILATING AND AIR CONDITIONING (HVAC) CONTROL INPUT WIRING HARNESS
Figure 1. HVAC/LSS Control Input Wiring Harness Connections at Climate Control Unit (CCU)
Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0775
Figure 2. Right HVAC Channel Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0775
Figure 3. Rear HVAC Channel Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0775
Figure 4. HVAC Condenser Relay Harness Connector., Vol 5 . . . . . . . . . . . . . WP 0775
Figure 5. HVAC Condenser Relay Harness Connector., Vol 5 . . . . . . . . . . . . . WP 0775
Figure 7. Right HVAC Channel Cover., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0775
Figure 8. HVAC/LSS Control Input Wiring Harness Connections at Climate Control Unit (CCU)
Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0775
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HEATING VENTILATING AND AIR CONDITIONING (HVAC) CONTROL 2 WIRING HARNESS REMOVAL
Figure 1. Interior Pass-Through Plate., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0776
Figure 2. Interior HVAC Control 2 Wiring Harness Connector., Vol 5 . . . . . . . . . . WP 0776
Figure 3. Exterior Pass-Through Plate., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0776
Figure 4. HVAC Control 2 Wiring Harness O-Ring., Vol 5. . . . . . . . . . . . . . . WP 0776
Figure 7. HVAC Compressor Connector., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0776
Figure 8. HVAC Compressor Harness Connector., Vol 5 . . . . . . . . . . . . . . . WP 0776
Figure 9. Left Condenser Connectors., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0776
Figure 10. Right Condenser Connectors., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0776
Figure 11. HVAC Control 2 Harness O-Ring., Vol 5 . . . . . . . . . . . . . . . . . WP 0776
Figure 12. Exterior Pass-Through Plate., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0776
Figure 13. Interior HVAC Wiring Harness Connector., Vol 5. . . . . . . . . . . . . . WP 0776
Figure 14. Interior Pass-Through Plate., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0776
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) CONTROL
POWER WIRING HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0777
Figure 1. HVAC/LSS Control Power Wiring Harness Connection at Climate Control Unit (CCU)
Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0777
Figure 3. Electrical Harness Storage Duct Cover., Vol 5 . . . . . . . . . . . . . . . WP 0777
Figure 4. Power Distribution Module (PDM) Harness Electrical Storage Shield., Vol 5 . . WP 0777
Figure 5. HVAC/LSS Control Power Wiring Harness Connection at PDM., Vol 5 . . . . . WP 0777
Figure 6. HVAC/LSS Control Power Wiring Harness Routing with Mechanic's Wire., Vol 5 WP 0777
Figure 7. HVAC/LSS Control Power Wiring Harness Routing with Mechanic's Wire., Vol 5 WP 0777
Figure 8. HVAC/LSS Control Power Wiring Harness Connection at Circuit Breaker
Panel., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0777
Figure 9. HVAC/LSS Control Power Wiring Harness Connection at CCU Box., Vol 5 . . . WP 0777
Figure 10. Power Distribution Module (PDM) Harness Electrical Storage Shield., Vol 5. . WP 0777
Figure 11. Electrical Harness Storage Duct Cover., Vol 5 . . . . . . . . . . . . . . . WP 0777
Figure 12. Rear HVAC Channel Cover., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0777
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) MAIN
BLOWER MOTOR WIRING HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . WP 0778
Figure 1. HVAC/LSS Main Blower Motor Wiring Harness., Vol 5. . . . . . . . . . . . WP 0778
Figure 2. HVAC/LSS Main Blower Motor Wiring Harness., Vol 5. . . . . . . . . . . . WP 0778
HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) UPPER
BLOWER WIRING HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . WP 0779
Figure 1. HVAC/LSS Upper Blower Wiring Harness at Climate Control Unit (CCU)
Box., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0779
Figure 2. HVAC/LSS Upper Blower Wiring Harness at Upper HVAC/LSS Blower., Vol 5 . WP 0779
Figure 3. HVAC/LSS Upper Blower Wiring Harness Routing., Vol 5 . . . . . . . . . . WP 0779
Figure 4. HVAC/LSS Upper Blower Wiring Harness at Upper HVAC/LSS Blower., Vol 5 . WP 0779
Figure 5. HVAC/LSS Upper Blower Wiring Harness Routing., Vol 5 . . . . . . . . . . WP 0779
Figure 6. HVAC/LSS Upper Blower Wiring Harness at CCU Box., Vol 5 . . . . . . . . WP 0779
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HEATING VENTILATING AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS) CONTROL
WIRING HARNESS REMOVAL AND INSTALLATION, Vol 5 . . . . . . . . . . . . . . . . WP 0780
Figure 1. HVAC/LSS Control Wiring Harness at Climate Control Unit (CCU) Box., Vol 5 . WP 0780
Figure 2. HVAC/LSS Control Wiring Harness Mounting., Vol 5 . . . . . . . . . . . . WP 0780
Figure 3. HVAC Trinary Pressure Switch Connection., Vol 5 . . . . . . . . . . . . . WP 0780
Figure 4. HVAC/LSS Control Wiring Harness Routing., Vol 5 . . . . . . . . . . . . . WP 0780
Figure 5. HVAC/LSS Control Wiring Harness Routing., Vol 5 . . . . . . . . . . . . . WP 0780
Figure 6. HVAC Trinary Pressure Switch Connection., Vol 5 . . . . . . . . . . . . . WP 0780
Figure 7. HVAC/LSS Control Wiring Harness Mounting., Vol 5 . . . . . . . . . . . . WP 0780
Figure 8. HVAC/LSS Control Wiring Harness at CCU Box., Vol 5 . . . . . . . . . . . WP 0780
PREPARATION FOR STORAGE OR SHIPMENT, Vol 5 . . . . . . . . . . . . . . . . . . WP 0781
GENERAL MAINTENANCE, Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0782
LUBRICATION INSTRUCTIONS, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 1. Body Overview., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 2. Chassis Overview., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 3. Front Axle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 4. Oil Filter., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 5. Engine Oil Pan., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 6. Engine Oil Dipstick, Transmission Fluid Dipstick, and Power Steering
Reservoir., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 7. Transmission Drain., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 8. Drag Link., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 9. Pintle Hook., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 10. Left Upper King Pin and Inner S-Camshaft (Right Similar)., Vol 5 . . . . . . WP 0783
Figure 11. Left Lower King Pin (Right Similar)., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 12. Left Front Outer S-Camshaft (Right Similar)., Vol 5 . . . . . . . . . . . . WP 0783
Figure 13. Left Front Slack Adjuster (Right Similar)., Vol 5 . . . . . . . . . . . . . . WP 0783
Figure 14. Rear Axle., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 15. Rear Door Hydraulic Fluid Reservoir., Vol 5. . . . . . . . . . . . . . . . WP 0783
Figure 16. Rear Door Hydraulic Cylinder at Door., Vol 5 . . . . . . . . . . . . . . . WP 0783
Figure 17. Rear Door Hydraulic Cylinder Upper Pivot., Vol 5 . . . . . . . . . . . . . WP 0783
Figure 18. Left Rear Door Lock (Right Similar)., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 19. Right Rear Slack Adjuster (Left Similar)., Vol 5 . . . . . . . . . . . . . . WP 0783
Figure 20. Right Outer S-Camshaft (Left Similar)., Vol 5 . . . . . . . . . . . . . . . WP 0783
Figure 21. Intermediate Steering Shaft, Upper., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 22. Intermediate Steering Shaft, Lower., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 23. Left Tie Rod End (Right Similar)., Vol 5. . . . . . . . . . . . . . . . . . WP 0783
Figure 24. Intermediate Propeller Shaft, Rear., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 25. Intermediate Propeller Shaft, Front., Vol 5 . . . . . . . . . . . . . . . . WP 0783
Figure 26. Transfer Case., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 27. Front and Rear Propeller Shafts — Two Universals Each., Vol 5. . . . . . . WP 0783
Figure 28. Left Door Latches and Striker, Upper., Vol 5 . . . . . . . . . . . . . . . WP 0783
Figure 29. Left Door Hinge, Upper., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 30. Right Front Stowage Compartment (Left Similar)., Vol 5 . . . . . . . . . . WP 0783
Figure 31. Right Rear Stowage Compartment (Left Similar)., Vol 5 . . . . . . . . . . WP 0783
Figure 32. Winch Cable., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 33. Rear Wheel Bearings., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 34. Front Wheel Bearings., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0783
Figure 35. Engine Coolant., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783
Table 1. Lubrication Schedule., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0783
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ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION, Vol 5 . . . . . . . . . WP 0784
Table 2. Index of Manufactured Items., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0784
ILLUSTRATED LIST OF MANUFACTURED ITEMS, Vol 5 . . . . . . . . . . . . . . . . . WP 0785
Figure 1. Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 2. Conduit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 4. Insulator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 6. Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 7. Conduit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 8. Hose Insulator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 10. Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 11. Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 12. Conduit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 13. Hose Insulator., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 14. Washer Supply Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 16. Copper Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 17. Breather Hose., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 18. Nonmetallic Nylon Tube., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 19. Power Steering Hose Armor., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0785
Figure 22. Hood Seal., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 23. Foam Trim Tape., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 24. Power Mirror Harness Conduit., Vol 5 . . . . . . . . . . . . . . . . . . WP 0785
Figure 25. Fuel Line Conduit., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 26. Storage Box Door Seal., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 27. C-Channel Trim Molding., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0785
Figure 28. Fittings, Conduit, and Hose., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0785
Figure 30. Hose Sleeve., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 1. Material., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 2. Hose and Conduit Lengths., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 3. HVAC Hose Assemblies., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 10. Material., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 11. Material., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785
Table 16. Nylon Tube Lengths., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0785
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TORQUE LIMITS, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0786
Figure 1. Standard and Metric Fastener Markings., Vol 5. . . . . . . . . . . . . . . WP 0786
Figure 2. Standard Fastener Grades., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0786
Figure 3. Measuring Fastener., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0786
Table 1. Torque Limits for Dry Fasteners., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0786
Table 2. Torque Limits for Wet Fasteners., Vol 5 . . . . . . . . . . . . . . . . . . WP 0786
Table 3. Torque Limits for Metric Fasteners., Vol 5 . . . . . . . . . . . . . . . . . WP 0786
SCHEMATIC INTRODUCTION, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0787
Figure 1. Circuit Diagram Instructions., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0787
Figure 2. Circuit Identification and Location Chart (1 of 4)., Vol 5 . . . . . . . . . . . WP 0787
Figure 6. Symbols., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0787
Figure 7. Relay Functions., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . WP 0787
Figure 8. Abbreviations., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0787
CONNECTOR LOCATIONS, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0788
Table 1. Connector Locations, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . WP 0788
ELECTRICAL SYSTEM SCHEMATICS, Vol 5. . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 1. CH2_01, J1708 Data Link., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 2. CH2_02, J1939 Data Link – Cabin., Vol 5 . . . . . . . . . . . . . . . . . WP 0789
Figure 3. CH2_03, J1939 Data Link – Chassis., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 4. CH3_01, Master Power Disconnect Switch., Vol 5 . . . . . . . . . . . . . WP 0789
Figure 5. CH3_02, 12V Ignition Feed – Cabin (1 of 2)., Vol 5 . . . . . . . . . . . . . WP 0789
Figure 6. CH3_03, 12V Ignition Feed – Cabin (2 of 2). , Vol 5. . . . . . . . . . . . . WP 0789
Figure 7. CH3_04, 12V Ignition Feed – Chassis., Vol 5 . . . . . . . . . . . . . . . WP 0789
Figure 8. CH3_05, 12V Battery Feed – Cabin. , Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 9. CH3_06, 12V Battery Feed – Chassis., Vol 5 . . . . . . . . . . . . . . . WP 0789
Figure 10. CH3_07, 12V Accessory Feed., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 11. CH3_08, Grounds – Instrument Panel (IP) (1 of 2)., Vol 5 . . . . . . . . . . WP 0789
Figure 12. CH3_09, Grounds – IP (2 of 2). , Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 13. CH3_10, Grounds – Chassis., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0789
Figure 14. CH3_11, 24V Battery Feed – Cabin., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 15. CH3_12, 24V Battery Feed – Chassis., Vol 5 . . . . . . . . . . . . . . . WP 0789
Figure 16. CH3_13, 24V Power Distribution Module (PDM).., Vol 5 . . . . . . . . . . WP 0789
Figure 17. CH3_14, CEC Engine and Transmission Clean Power and Ground., Vol 5 . . WP 0789
Figure 18. CH4_01, 24V Cranking and Charging Circuits – I6 HEUI Engine., Vol 5 . . . WP 0789
Figure 19. CH4_02, 24V Alternator Ignition., Vol 5 . . . . . . . . . . . . . . . . . WP 0789
Figure 20. CH5_01, Horn – Dual Electric., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 21. CH5_02, Power and Heated Mirrors., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 22. CH5_02A, Heated Windshield., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 23. CH5_03, Windshield Wiper Motor., Vol 5 . . . . . . . . . . . . . . . . . WP 0789
Figure 24. CH5_03A, Windshield Wiper Washer Pump., Vol 5 . . . . . . . . . . . . WP 0789
Figure 25. CH5_04, Switch Pack., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0789
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Figure 26. CH5_05, 12V Power Sockets., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0789
Figure 27. CH5_06, Hydraulic Ramp Control – First Production., Vol 5 . . . . . . . . . WP 0789
Figure 28. CH5_06A, Hydraulic Ramp Control – Second Production., Vol 5. . . . . . . WP 0789
Figure 29. CH5_07, Fire Suppression System (FSS) Control., Vol 5 . . . . . . . . . . WP 0789
Figure 30. CH5_08, Government Furnished Equipment (GFE) Power., Vol 5 . . . . . . WP 0789
Figure 31. CH5_09, Turret Power., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 32. CH06_01, Instrument Panel Gauge List., Vol 5 . . . . . . . . . . . . . . WP 0789
Figure 33. CH06_02, Instrument Panel Warning Light List., Vol 5 . . . . . . . . . . . WP 0789
Figure 34. CH06_03, Warning Lights Controlled by Engine, Transmission, and Antilock Brake System
(ABS) Controller., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 35. CH6_05, Gauge Cluster., Vol 5 . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 36. CH6_06, Air Pressure Input Circuits., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 37. CH6_07, Fuel Gauge Input Circuit., Vol 5. . . . . . . . . . . . . . . . . WP 0789
Figure 38. CH6_08, Air Park Brake Warning Light., Vol 5. . . . . . . . . . . . . . . WP 0789
Figure 39. CH6_09, Warning Light – Transfer Case., Vol 5 . . . . . . . . . . . . . . WP 0789
Figure 40. CH6_10, 24V Meter., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 41. CH7_01, Air Dryer., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 42. CH7_02, Air – Antilock Brake System (1 of 2)., Vol 5. . . . . . . . . . . . WP 0789
Figure 43. CH7_03, Air – Antilock Brake System (2 of 2)., Vol 5. . . . . . . . . . . . WP 0789
Figure 44. CH7_04, Air Solenoid 4-Way Pack., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 45. CH7_05, Fuel Water Separator with 12V Fuel Pre-Heater and Water
Probe., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 46. CH7_06, Fuel-Fired Heater., Vol 5. . . . . . . . . . . . . . . . . . . . WP 0789
Figure 47. CH7_07, 110V AC Power., Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 48. CH7_08, Winch Power Cables., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 49. CH7_09, Trailer Sockets – Front and Rear., Vol 5 . . . . . . . . . . . . . WP 0789
Figure 50. CH7_10, Trailer ABS Center Pin Auxiliary Power., Vol 5 . . . . . . . . . . WP 0789
Figure 51. CH8_01, Master Vehicle Light Switch (MVLS) and Panel Light Feed., Vol 5 . . WP 0789
Figure 52. CH8_02, Service Headlights., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0789
Figure 53. CH8_03, Service Backup Lights., Vol 5 . . . . . . . . . . . . . . . . . WP 0789
Figure 54. CH8_04, Service Lights – Front Marker Lights., Vol 5 . . . . . . . . . . . WP 0789
Figure 55. CH8_04A, Service Lights – Rear Marker and Taillights with Trailer Sockets., Vol 5WP 0789
Figure 56. CH8_05, Service Lights – Clearance., Vol 5 . . . . . . . . . . . . . . . WP 0789
Figure 57. CH8_06, Service Lights – Turn Signal and Stop Light Relays and Switch., Vol 5 WP 0789
Figure 58. CH8_07, Service Lights – Front Turn Signal Lights., Vol 5 . . . . . . . . . WP 0789
Figure 59. CH8_08, Service Lights – Left Rear Turn and Stop Light with Trailer
Sockets., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 60. CH8_09, Service Lights – Right Rear Turn and Stop Light with Trailer
Sockets., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 61. CH8_10, Dome Lights., Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0789
Figure 62. CH8_11, Infrared Driving Light., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 63. CH8_12, Blackout Driving Light., Vol 5 . . . . . . . . . . . . . . . . . . WP 0789
Figure 64. CH8_13, Blackout Marker and Taillights with Trailer Sockets., Vol 5 . . . . . WP 0789
Figure 65. CH8_14, Blackout Stop Lights with Trailer Sockets., Vol 5 . . . . . . . . . WP 0789
Figure 66. CH8_15, Remote Control Spotlight Power., Vol 5 . . . . . . . . . . . . . WP 0789
Figure 67. CH8_16, Trailer Stop Lights with Trailer Sockets., Vol 5 . . . . . . . . . . WP 0789
Figure 68. CH9_01, I6 – HEUI Engine Controls., Vol 5 . . . . . . . . . . . . . . . . WP 0789
Figure 69. CH9_02, I6 - HEUI Engine Controls – Cruise Control., Vol 5 . . . . . . . . WP 0789
Figure 70. CH9_03, I6 - HEUI Engine Fan and Wiring with Air Clutch., Vol 5 . . . . . . WP 0789
Figure 71. CH9_04, I6 - HEUI Engine – Ether Start., Vol 5 . . . . . . . . . . . . . . WP 0789
Figure 72. CH10_01, Allison WTEC Transmission (1 of 3)., Vol 5 . . . . . . . . . . . WP 0789
Figure 73. CH10_02, Allison WTEC Transmission (2 of 3)., Vol 5 . . . . . . . . . . . WP 0789
Figure 74. CH10_03 Allison WTEC Transmission (3 of 3)., Vol 5 . . . . . . . . . . . WP 0789
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Figure 75. CH11_01, HVAC, Cabin (1 of 2)., Vol 5. . . . . . . . . . . . . . . . . . WP 0789
Figure 76. CH11_02, HVAC, Cabin (2 of 2)., Vol 5. . . . . . . . . . . . . . . . . . WP 0789
Figure 77. CH11_03, HVAC – Engine Compartment., Vol 5 . . . . . . . . . . . . . . WP 0789
Figure 78. I6 - HEUI Engine Controls - Injector Harness., Vol 5 . . . . . . . . . . . . WP 0789
Figure 79. I6 - HEUI Engine Controls - Engine Sensor Harness., Vol 5 . . . . . . . . . WP 0789
Figure 80. Power Distribution Function Diagram., Vol 5 . . . . . . . . . . . . . . . WP 0789
CONNECTOR COMPOSITES, Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 1. Connector Composites (254M, 1002)., Vol 5 . . . . . . . . . . . . . . . . WP 0790
Figure 2. Connector Composites (1003, 1010)., Vol 5 . . . . . . . . . . . . . . . . WP 0790
Figure 3. Connector Composites (1011)., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0790
Figure 7. Connector Composites (1018, 1019, 1050, 1051)., Vol 5 . . . . . . . . . . WP 0790
Figure 8. Connector Composites (1052, 1053, 1054, 1055, 1100M, 1101M)., Vol 5 . . . WP 0790
Figure 9. Connector Composites (1111, 1112, 1150, 1250, 1500, 1520)., Vol 5 . . . . . WP 0790
Figure 10. Connector Composites (1521, 1555M, 1600, 1601)., Vol 5 . . . . . . . . . WP 0790
Figure 11. Connector Composites (1650, 1658)., Vol 5. . . . . . . . . . . . . . . . WP 0790
Figure 12. Connector Composites (1701)., Vol 5 . . . . . . . . . . . . . . . . . . WP 0790
Figure 14. Connector Composites (1703F, 1703M, 1800, 1804)., Vol 5. . . . . . . . . WP 0790
Figure 15. Connector Composites (1805, 1808, 1809, 1810, 1811, 1812, 1813)., Vol 5 . . WP 0790
Figure 16. Connector Composites (1822, 1823, 1824, 1850, 1851, 1852, 1852B,
1862)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 17. Connector Composites (1876, 1877, 1878, 1936, 1937, 1938)., Vol 5 . . . . WP 0790
Figure 20. Connector Composites (2401, 2500, 2501, 3000M, 3003M)., Vol 5 . . . . . WP 0790
Figure 24. Connector Composites (4004, 4005, 4006, 4006A, 4007, 4008)., Vol 5 . . . . WP 0790
Figure 25. Connector Composites (4015, 4019, 4021, 4025, 4028A, 4028C, 4034, 4035,
4036)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 26. Connector Composites (4042, 4043, 4100F, 4101M)., Vol 5. . . . . . . . . WP 0790
Figure 27. Connector Composites (4103, 4105, 4111M)., Vol 5 . . . . . . . . . . . . WP 0790
Figure 28. Connector Composites (4300, 4301)., Vol 5 . . . . . . . . . . . . . . . WP 0790
Figure 29. Connector Composites (4305M, 4305F, 4705F1, 4705F2, )., Vol 5 . . . . . . WP 0790
Figure 30. Connector Composites (4811, 4830, 4840, 4900, 4910)., Vol 5 . . . . . . . WP 0790
Figure 31. Connector Composites (4953, 4954, 6007)., Vol 5 . . . . . . . . . . . . . WP 0790
Figure 32. Connector Composites (6102, 6103, 6104, 6105, 6106, 6108, 6109, 6302, 6306,
6307)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 33. Connector Composites (6308, 6309, 6316, 6321, 6322, 6323M, 6323F, 6401M,
6401F)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 34. Connector Composites (6502, 6503, 6550M, 6703, 6704, 7104F, 7104M)., Vol 5WP 0790
Figure 35. Connector Composites (7150F, 7205F, 7206M)., Vol 5 . . . . . . . . . . . WP 0790
Figure 36. Connector Composites (7208M, 7210, 7250F, 7603M, 7605M, 7611)., Vol 5 . WP 0790
Figure 37. Connector Composites (8000, 8001, 8153F, 8153FR, 8154, 8154R, 8311,
8312)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 38. Connector Composites (8400B, 8500, 8501, 8502A, 8503A, 8600, 8800,
8801)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 39. Connector Composites (8802, 8803, 9100, 9250, 9251, 9254, 9255)., Vol 5. . WP 0790
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Figure 40. Connector Composites (9256, 9257, 9260M, 9260F, 9261M, 9261F,
9303A)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 41. Connector Composites (9501, 9502, 9503, 9504, 9700)., Vol 5 . . . . . . . WP 0790
Figure 42. Connector Composites (9714, 9715, 9715M)., Vol 5 . . . . . . . . . . . . WP 0790
Figure 43. Connector Composites (9715, 9715F, 9716P, 9716F, 9716, 9716M)., Vol 5 . . WP 0790
Figure 44. Connector Composites (9717, 9717F, 9717M, 9720, 9722, 9723, 9724)., Vol 5 WP 0790
Figure 45. Connector Composites (9733, 9733P, 9736, 9750, 9754, 9755, 9778F,
9779F)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 46. Connector Composites (9780M, 9783, 9800F, 9800M)., Vol 5 . . . . . . . . WP 0790
Figure 47. Connector Composites (9900C, 9916, 9917)., Vol 5 . . . . . . . . . . . . WP 0790
Figure 48. Connector Composites (C1, C2, C3, C4, C6, C7)., Vol 5 . . . . . . . . . . WP 0790
Figure 49. Connector Composites (C8, C9, C10)., Vol 5 . . . . . . . . . . . . . . . WP 0790
Figure 50. Connector Composites (C11)., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0790
Figure 51. Connector Composites (J2, J5, J10, J19, J22, J33, J33, J33, J34)., Vol 5 . . . WP 0790
Figure 52. Connector Composites (J34, J34, J34, J36, P1, P3, P4, P4, P5)., Vol 5 . . . WP 0790
Figure 53. Connector Composites (P6, P8, P10, P12, P14, P17, P19)., Vol 5 . . . . . . WP 0790
Figure 54. Connector Composites (P20, P21, P22, P23)., Vol 5 . . . . . . . . . . . . WP 0790
Figure 55. Connector Composites (P29, P31, P33, P33, P33, P34)., Vol 5 . . . . . . . WP 0790
Figure 56. Connector Composites (P34, P34, P34, P35, P36, P37)., Vol 5 . . . . . . . WP 0790
Figure 57. Connector Composites (LAM1001, LAM1002, LAM1003, LAM1004, LAM1005, LAM1006,
LAM1007)., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
LAM1014, LAM1015, LAM1016)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0790
LAM1024, LAM1025)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
LAM1032, LAM1033, LAM1034, LAM1035)., Vol 5 . . . . . . . . . . . . . . . . . . WP 0790
LAM1073, LAM1074, LAM1075)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . WP 0790
LAM1112, LAM1113, LAM1114, LAM1115)., Vol 5 . . . . . . . . . . . . . . . . . . . WP 0790
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TM 9-2355-106-23-1

Page No.
WP Sequence No.
LAM1202, LAM1203)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
Figure 78. Connector Composites (LAM1204, LAM1205, LAM1206, LAM1207, LAM1208,
LAM1209)., Vol 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
LAM1216, LAM1217)., Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790
CHAPTER 10. SUPPORTING INFORMATION, VOL 5

REFERENCES, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0791
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION, Vol 5 . . . . . . . . . . . WP 0792
MAINTENANCE ALLOCATION CHART, Vol 5 . . . . . . . . . . . . . . . . . . . . . . WP 0793
EXPENDABLE AND DURABLE ITEMS LIST, Vol 5 . . . . . . . . . . . . . . . . . . . . WP 0794
TOOL IDENTIFICATION LIST, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0795
Mandatory Replacement Parts, Vol 5 . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0796
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TM 9-2355-106-23-1
HOW TO USE THIS MANUAL

Field Maintenance personnel shall familiarize themselves with the format and contents of this Technical
Manual (TM) prior to performing maintenance procedures. Learning how to use this TM will enable
personnel to quickly locate information, gain proper knowledge of the M1224 and M1224A1 vehicles,
and shorten the time necessary to complete a required procedure.
This manual describes in detail the Field Maintenance authorized by the Maintenance Allocation Chart (MAC) and
Repair Parts and Special Tools List (RPSTL) (TM 9-2355-106-23P). It is divided into the following ten chapters:
• Chapter 1 – General Information, Equipment Description, and Theory of Operation
• Chapters 2, 3, 4, and 5 – Troubleshooting Procedures
• Chapter 6 – Preventive Maintenance Instructions
• Chapters 7, 8, and 9– Maintenance Instructions
• Chapter 10 – Supporting Information, including publication references; tools, parts, and materials
information; and the Maintenance Allocation Chart (MAC)
A Warning Summary appears at the front of the manual. Become familiar with these warnings
before performing maintenance on the vehicle.
The Table of Contents in the front of the manual lists all chapters and work packages (WPs) by title and number.
An alphabetical index is included at the back of the manual to help locate information quickly by topic.
Three types of notations appear throughout the manual:
WARNINGS identify risk of injury or death to personnel.
CAUTIONS identify risk of damage to equipment.
NOTES provide additional explanations or helpful information for the user.
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TM 9-2355-106-23-1
HOW TO USE THIS MANUAL – (Continued)

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OR OPERATION
General Information contains information that may be useful to maintainer. For example,
equipment designations and purpose statements.
Equipment Description and Data provides a brief description and location of major parts and
components. Descriptions are supported by illustrations.
Theory of Operation describes components and systems in detail to support troubleshooting resolution.
Maintainers should review and become familiar with these sections prior to performing
maintenance procedures on the equipment.
WORK PACKAGE (WP) FEATURES
Each chapter of this TM is organized in WPs. Each WP is an independent, stand-alone data
unit. Each WP is assigned a four-digit sequence number.
In general, WP content is either information oriented or procedure oriented. System description WPs
explain system function for background information needed during repair. Troubleshooting WPs give
step-by-step instructions to locate and isolate a fault or failure in specific systems. Maintenance WPs
provide step-by-step instructions for removal and installation of components.
MAINTENANCE PROCEDURES OVERVIEW
Procedural WPs contain a section titled “Initial Setup,” which includes the following information:
• Test Equipment: Test equipment needed to complete a task. If test equipment is
not required, this heading will not be used.
• Tools and Special Tools: General Mechanic's Tool Kit, special tools, and other common tools
required to perform maintenance tasks. Torque wrenches are required for many tasks; the proper
torque wrench should be available to tighten mounting hardware.
• Materials/Parts: Mandatory replacement parts (gaskets, O-rings, etc.) as well as expendable/durable items
and materials required for the task. To replace other unserviceable parts, refer to TM 9-2355-106-23P for
requisition data. If no mandatory replacement materials/parts are required, this heading will not be used.
• Personnel Required: The number of personnel needed to perform a task. If only one
maintainer is needed, this heading will not be used.
• References: TMs and work packages needed to complete the task.
• Equipment Conditions: Conditions that must exist before starting the task. If none
are required, this heading will not be used.
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TM 9-2355-106-23-1

The Initial Setup section also includes cross-references to supporting information WPs, other
publications, and other maintenance WPs as necessary for the task.
Table . Initial Setup Example.

INITIAL SETUP: References
Test Equipment TM 9-2355-106-10
Maintenance Support Device (MSD), TM 9-2355-106-23P
(WP0697, Item 28) Equipment Condition
Tools and Special Tools Parking brake set (TM 9-2355-106-10)
General Mechanic's Tool Kit (GMTK), Transmission set in NEUTRAL (N) (TM 9-2355-106-10)
(WP0697, Item 6)
Engine off (TM 9-2355-106-10)
Materials/Parts
MAIN POWER switch off (TM 9-2355-106-10)
Grease, (WP0696, Item 14)
Wheels chocked (TM 9-2355-106-10)
Personnel Required
Engine hood open and secured (TM 9-2355-106-10)
Maintainer (2)
Belly armor removed (WP 0496)
Starter motor removed (WP 0222)
In addition to the Initial Setup information detailed above, maintenance procedures have Follow-On Maintenance
tasks to be performed at the end of the procedure before the vehicle is returned to service.
In some maintenance procedures, special torque specifications may be listed for fasteners. If a special torque is not
listed, the maintainer will be instructed to install a fastener and tighten securely. In such cases, the maintainer must
use the standard torque for the size and grade fastener. For further information, refer to Torque Limits (WP 0786).
PMCS OVERVIEW
To ensure the vehicle is ready for operation at all times, it must be inspected on a regular basis so items to be
serviced may be found before they result in serious damage, equipment failure, or injury to personnel. The PMCS
table contains systematic inspections and services to maintain the vehicle in mission-ready condition.
TROUBLESHOOTING PROCEDURES OVERVIEW
This section gives instructions on proper diagnostic techniques for all diagnostic procedures.
The troubleshooting procedures in this TM are designed to isolate one failure at a time and cannot give answers
to every possible vehicle malfunction encountered. However, the procedures do list the most common answers
to a problem in an organized, step-by-step manner. Faults are listed in the Vehicle Troubleshooting Symptom
Index (WP 0005). The Vehicle Troubleshooting Symptom Index will direct the user to WPs that include tests
and inspections to locate the source of a problem and lead to a successful correction. It is assumed that the
vehicle will be returned to operating condition at the end of the troubleshooting procedure.
Troubleshooting Guidelines
After reading this Troubleshooting Procedures Overview, begin all troubleshooting with the
Vehicle Operational Checkout Procedure (WP 0010).
When performing troubleshooting, use the following process.
VERIFY THE PROBLEM

Operate the complete system and list all symptoms, in order to:
1. Check the accuracy and completeness of the complaint.
2. Learn more that might give a clue to the nature and location of the problem.
3. Analyze which parts of the system are working.
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TM 9-2355-106-23-1

PERFORM PRELIMINARY STEPS BEFORE TESTING
1. Gather information by talking to the operator, if possible. Try to determine the exact
symptoms by gathering relevant information:
a. What happened and when?
b. Under what conditions?
c. When did the symptoms begin?
d. What else occurred at that time?
2. Verify that all operator maintenance tasks have been completed (TM 9-2355-106-10). Verify that any
operator troubleshooting tasks that apply to the current symptom have been completed (TM 9-2355-106-10).
3. Avoid preconceived ideas. Eliminate any nonelectrical causes for the problem first
(contaminated fuel, clogged air filters, etc.).
4. Ensure the vehicle batteries are at 75% State Of Charge (SOC) or higher when measuring specific
gravity. This represents an Open Circuit Voltage (OCV) of 12.4V. Batteries with an OCV of 12V or
less are considered to be either completely discharged or to have a dead cell.
5. Check any light or indicator lamp filament that is suspected of being open (burned out). This
is done to avoid unnecessary extensive circuit checks.
6. Inspect all connectors for spread-open terminals and loose, corroded, or damaged pins, wires, etc. If a fuse
is blown, locate the cause of the overload condition and repair it. The common procedure is as follows:
Isolate sections of the circuit by disconnecting connectors, and measure the resistance to ground to find the
circuit that is shorted to ground. Then locate the damaged spot in the wire or connector and replace it.
7. Inspect fuses visually for an open element when possible, and test electrically for
resistance or voltage drop across the terminals.
8. Multiple symptoms may occur when a ground stud is loose or has poor contact. When multiple symptoms
are present, inspect ground studs at engine bulkhead and starter for loose connection or corrosion.
If required, disassemble ground stud connection and clean with a wire brush.
CHECK THE INSTRUMENT PANEL CLUSTER (IPC) INDICATOR LAMPS

• Some IPC indicators provide direct indication of a fault with a specific system. Examples are
the engine oil pressure gauge and the engine coolant temperature gauge. Certain IPC indicator
lamps indicate a fault in a general system, such as the engine or transmission. Diagnosis of a
specific Diagnostic Trouble Code (DTC) for that system will isolate the fault.
• The IPC activates the RED ENGINE warning indicator when it receives a message on the drivetrain 1939
data link from the engine controller. The engine controller will send this message when warning thresholds
for coolant temperature, coolant level, or low engine oil pressure have been exceeded. The indicator lamp
will be accompanied by a message on the odometer display and the IPC alarm will sound.
• The IPC activates the YELLOW ENGINE warning indicator when it receives a message on the
drivetrain 1939 data link from the engine controller. The engine controller will send this message
when it detects certain faults in engine components, such as fuel injectors and engine sensors.
The light will be accompanied by a message on the odometer display.
• The IPC activates the CHECK TRANS lamp when it receives a message on the drivetrain 1939
data link from the Electronic System Controller (ESC). The ESC generates this message when
the transmission controller notifies it that a fault has been detected.
• The IPC activates the ABS indicator when it receives a message on the drivetrain 1939
data link from the ESC. The ESC generates this message when the ABS controller notifies
it that a fault has been detected or when ABS is activated.
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TM 9-2355-106-23-1

CHECK THE CIRCUIT DIAGRAM
Refer to the circuit diagram for possible clues to the problem. If several circuits fail at the same time,
check for a common power source or common ground connection. If part of a circuit fails, check the
connections between the part that works and the part that doesn't work.
For example, if the low-beam headlights work, but both high-beam lights and the high-beam indicator do
not work, then the power and ground paths must be good. Since the dimmer switch is the component that
switches the power to the high-beam headlights, it is the most likely cause of failure.
CHECK FOR CAUSE OF THE PROBLEM

Do the easiest things first. Look for the most obvious cause of a problem. For example, excessive
oil consumption may be the result of leaks at gaskets or loose line connections.
Double-check the diagnosis before disassembly. The source of most engine problems can
be traced to more than one part in a system. For example:
• Excessive fuel consumption may not be caused by the fuel pump alone. Instead, the trouble could
be a clogged air cleaner or a restricted exhaust passage causing severe back-pressure.
• Engines are often disassembled in search of a problem and the real evidence of the problem is
destroyed. Check again to be sure an easier solution to the problem has not been overlooked.
Before correcting a problem, diagnose the cause of the problem. Do not allow the same failure to occur again.
CIRCUIT TESTING
During circuit testing, it is expected that the specified circuit will be tested from one end to
the other, including all splices and connections in between.
When probing terminals, take care not to damage the terminal.
Schematics facilitate testing by dividing a circuit into segments.
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TM 9-2355-106-23-1
Figure 1. Connector Terminal Numbering Example.
Some work packages may reference a connector composite view that has only the outside terminals labeled.
In such cases, the maintainer must identify the correct terminal by counting terminals in the applicable row.
For example, if the desired terminal is terminal 60, the maintainer identifies row 51 through 64, and then
counts up from terminal 51 or down from terminal 64 until terminal 60 is identified. Refer to Figure
MAKE THE REPAIR

It is expected that once a fault is located, it will be repaired or replaced as required.
VERIFY THE REPAIR IS COMPLETE

Operate the system and check that the repair has eliminated all symptoms and
has not caused any new symptoms.
Troubleshooting Methods
Three troubleshooting methods are used in this TM:
• Logic process (Troubleshooting Procedure WPs)
• Operational checkout (Operational Checkout Procedure WPs)
• Symptom based (Troubleshooting Procedure WPs)
Each method is explained below.
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TM 9-2355-106-23-1

Logic Process
The logic process is used to isolate a fault through a series of tests. Each test yields an indication or condition
(result observed during the testing). The maintainer selects the corresponding answer to determine the next
action to isolate the fault. Generally, this method is referred to as a logic tree. The logic tree has various
paths (branches) that the maintainer will traverse to determine or isolate the fault. Each path or branch
has a test, a question (What did the maintainer observe?), and a choice of answers to the question. Each
answer leads the maintainer to the next appropriate test until the fault is isolated.
Logic Troubleshooting Procedure Example:
STEPS
1. Turn ignition OFF (TM 9-2355-106-10).
2. Turn MAIN POWER switch OFF (TM 9-2355-106-10).
3. Disconnect connector 1804.
4. Measure resistance between connector 1804 terminal B and ground with multimeter.
CONDITION/INDICATION
Does multimeter read more than 5 ohms?
DECISION
YES – Go to Step 8.
NO – Go to next step.
STEP
5. Measure resistance between connector 1804 terminal F and ground with multimeter.
Does multimeter read OL?
DECISION
NO – Go to Step 7.
YES – Go to next step.
MALFUNCTION
6. Steering column wiring harness is faulty.
ACTION
Replace steering column wiring harness. Refer to Steering Column Harness Removal and
Installation (WP 0192). Return vehicle to service.
Operational Checkout
An operational checkout contains an ordered set of test procedures to determine if a system is operational
or requires corrective action. Each operational test procedure leads to a condition/indication. If a normal
condition/indication is obtained, the next operational checkout step is performed. When an abnormal
condition/indication is observed, the maintainer is instructed to perform the corrective action provided or
to refer to a specified WP for detailed troubleshooting or maintenance instructions.
Operational Checkout Procedure Example:
STEPS
1. Turn ignition on (TM 9-2355-106-10).
2. Turn MAIN POWER switch on (TM 9-2355-106-10).
3. Put Master Vehicle Light Switch (MVLS) in PARK mode (TM 9-2355-106-10).
4. Firmly push on horn pad on steering wheel (TM 9-2355-106-10).
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TM 9-2355-106-23-1

5. If both horns operate, return vehicle to service.
Horns are on without pressing horn pad.
CORRECTIVE ACTION
Refer to Electric Horns Sound Without Pressing Horn Pad Troubleshooting Procedure (WP 0190).
Only one horn does not operate.
CORRECTIVE ACTION
Refer to Single Horn Fault Troubleshooting Procedure (WP 0191).
Symptom Based Procedure
A symptom based procedure lists a vehicle symptom, followed by one or more possible malfunctions. Each
malfunction lists one or more possible corrective actions, with corresponding WP references.
Symptom Based Procedure Example:
SYMPTOM
VEHICLE PULLS LEFT OR RIGHT
MALFUNCTION
Improper wheel alignment.
CORRECTIVE ACTION
Adjust as necessary. Refer to Front Axle Alignment Procedure (WP 2990).
MALFUNCTION
Loose, damaged, or leaking shock absorber.
CORRECTIVE ACTION
Replace as necessary. Refer to Front Shock Absorber Removal and Installation (WP 3660).
MALFUNCTION
Broken spring or loose spring bushings.
CORRECTIVE ACTION
Adjust as necessary. Refer to Front Spring Assembly Removal and Installation (WP 3630)
or Rear Spring Assembly Removal and Installation (WP 3640).
MALFUNCTION
Broken or loose U-bolts.
CORRECTIVE ACTION
Adjust as necessary. Refer to Front Spring Assembly Removal and Installation (WP 3630)
or Rear Spring Assembly Removal and Installation (WP 3640).
clxvi
TM 9-2355-106-23-1
CHAPTER 1
GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF

OPERATION
FOR

TM 9-2355-106-23-1 0001
FIELD MAINTENANCE
GENERAL INFORMATION
SCOPE
This Technical Manual (TM) contains Field Maintenance instructions for maintaining and servicing the M1224
MRAP and M1224A1 with MRAP with Expedient Armor Program (MEAP). It includes cautions and warnings
regarding safety for personnel and equipment, equipment description and data, and troubleshooting procedures to
be followed to identify and locate vehicle malfunctions. It also contains preventive maintenance checks and service
procedures, a Maintenance Allocation Chart, and other Field level supporting information.
• Type of Manual – Field
• Model number and equipment names:
M1224 MRAP
M1224A1 MRAP
• Purpose of equipment – These vehicles are capable of supporting multiple missions to include recon, convoy
operations, troop transport, CASEVAC, and Combat Engineer and EOD missions for maneuver units. They
provide increased survivability for personnel via an armored cabin and V-shaped blast resistant hull.
Figure 1. M1224 MRAP
Figure 2. M1224A1 MRAP
0001–1
TM 9-2355-106-23-1 0001

GENERAL INFORMATION - (CONTINUED)

MAINTENANCE FORMS RECORDS AND REPORTS

1. (A) Department of the Army forms and procedures used for equipment maintenance will be those prescribed
by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual;
DA PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation
(TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.
2. (AF) Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101 and the
applicable TO 00-20 Series Technical Orders.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your MRAP vehicle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can
tell us what you don’t like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation
Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency
Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in
DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

CORROSION PREVENTION AND CONTROL

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals.
It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion
damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or
cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation
(oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are
excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or
breaking. SF Form 368, Product Quality Deficiency Report, should be submitted to the address specified in DA
PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

For general vehicle destruction procedures, refer to TM 750-244-6, Procedures for Destruction of Tank -
Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive and Armaments Command).

PREPARATION FOR STORAGE OR SHIPMENT

No special preparation, other than maintenance, is required when MRAPs are driven under their own power to
their destination.

All doors, except the driver door, should be tied closed. All material that exceeds the width of the vehicle should be
removed and secured inside the vehicle. All antennas should be lowered and tied down.

Turn off all Government Furnished Equipment (GFE).

Vehicle Storage

The unit is responsible for adequate storage and protection of new vehicles. Maintain records for vehicles in
storage so that proper inspection and maintenance can be performed. Perform the following procedures before
storing vehicle:
0001–2
TM 9-2355-106-23-1 0001


Storage Duration Two Months or Less
NOTE

To avoid damaging the finish, avoid wiping dirt off of dry surfaces; wash vehicle when surface
is cool to the touch.

A low electrolyte level is normally the result of a broken battery case or years of usage. It
will not normally be seen on new vehicles.

1. Wash vehicle with warm water and mild soap. Dry wet surfaces with a chamois or soft cloth.
2. Inspect painted surfaces; touch up all exposed primed or raw metal areas to prevent rust.
3. Check radiator coolant reservoir for proper level and adequate freeze protection.
4. Cover open ends of exhaust and air intake for the HVAC system.
5. Check batteries state of charge. Charge batteries if open circuit voltage is below 12.6 volts.
6. Fill fuel tank to maximum level. Ventilate system by releasing filler cap. If this can’t be accomplished,
completely drain the fuel tank.
7. Inspect vehicle prior to storage by performing the next appropriate PMCS, and make any repairs necessary.
Ensure that maintenance services and lubrication are up to date.

Storage Duration Over 2 Months

NOTE

After every 3 months of additional storage, repeat items 1 through 10.

Units in storage for longer than 2 months require the following additional procedures.

1. Inspect for the following:

a. Leaks
b. Low or flat tires
c. Corrosion
d. Water in compartments
e. Other problems or shortcomings
2. Perform the next scheduled major maintenance service.
3. Start and run vehicle at fast idle until it reaches operating temperature.
4. To remove surface charge from the battery, operate heater and air conditioner and turn on headlights
and other accessories for a few minutes.
5. Drive the vehicle a short distance. Shift the transmission in various ranges; apply and release the service
and parking brake systems.
6. Turn off heater and air conditioner and any other accessories; shut off lights. Park vehicle and shut
off engine.
7. Disconnect and remove batteries and store in a cool, well-ventilated area. Recharge and clean before use.
8. Drain air brake reservoirs and close drain cocks.
9. Check radiator coolant reservoir for proper level and adequate freeze protection.
10. Lubricate all exposed components.
11. For vehicles exposed to ultraviolet rays of the sun, apply a coating of powdered cleanser or similar product to
the inside surfaces of windshield and windows to shade the interior.

0001–3
TM 9-2355-106-23-1 0001
Storage Facilities

1. Whenever possible, store vehicles indoors, protected from sunlight, in a dry, well-ventilated area. If indoor
storage is not available, select storage lots to eliminate conditions that cause deterioration.
2. Park away from transformers and/or electrical motors. When the protective wax in tire compound cracks,
ozone in the air attacks the exposed areas.
3. Park away from trees, high weeds, and grass to prevent damage from tree or weed sap and to minimize
bird and insect stains.
4. Park away from railroad tracks, paint shops, smoky industrial areas, and locations of possible road splash
contact.
5. If a vehicle is parked on an incline, block the wheels.

NOMENCLATURE CROSS-REFERENCE LIST

This listing includes nomenclature cross references used in this manual:

Table 1. Nomenclature Cross-reference List
Common Name Official Nomenclature
110V Battery Disconnect Switch Switch, Battery
110V Cover, Outlet, and Box Box, Receptacle
110V Inverter Inverter, 1800 W
110V Outlet Harness Harness, 110 Volt
12V and 24V Battery Disconnect Switch Switch, Battery Disconnect, Solenoid
12V Battery Disconnect Switch Solenoid Feed Cable Cable, Disconnect
12V to 24V Disconnect Battery Switch Solenoid Feed
Harness Cable Assembly, Positive
12V to 24V Disconnect Battery Switch Solenoid
Ground Harness Cable Assembly, Negative
12V Underhood Megafuse Fuse, Mega
12V Underhood Megafuse Holder Holder, Megafuse
24V Battery Disconnect Switch Solenoid Feed Cable Cable, Disconnect
24V Body Feed Harness Cable, 24V Body Feed
24V Gauge Gauge, Battery-Generator
24V Gauge Bulb Bulb
24V Government Furnished Equipment (GFE) Wiring
Harness Harness, IP Feed, 24-Volt
24V Instrument Panel (IP) Feed Wiring Harness Harness, IP Feed, 24-Volt
24V Inverter Megafuse Megafuse, 150A
24V Inverter Megafuse Holder Holder, Megafuse
24V Power Distribution Module (PDM) Box, Circuit Breaker Power Distribution Panel
24V Power Distribution Module (PDM) Ground Cable Cable, Ground
24V Underhood Junction Block Block, Junction
4-Pack Air Solenoid Module Solenoid, Air, Transfer Case
4-Pack Air Solenoid Module Support Support, 4-Pack, Air Solenoid
Accelerator Pedal Sensor (APS) Sensor, Throttle Position
Air 1 Pressure Gauge and Harness Gauge Electronic Air 1
Air 2 Pressure Gauge and Harness Gauge Electronic Air 2
Air Brake Double Check Valve Valve, Check
Air Brake Quick Release Valves Valve, Brake, Quick Release
Air Brake Relay Valve Valve, Relay, R-14
Air Cleaner Assembly Cleaner, Air, Assembly
Air Cleaner Support Bracket, Mounting
Air Compressor Compressor, Air
0001–4
TM 9-2355-106-23-1 0001


Air Compressor Delivery Air Line Tube, Air Compressor
Air Compressor Governor Governor, Air Compressor
Air Compressor Supply Air Line Hose, Heater, 3/4-in. ID
Air Conditioner (A/C) Belt Belt, A/C Compressor
Air Conditioner (A/C) Condenser Fan Motor Relay Relay, General Control
Air Conditioner Condenser Fan Assembly Blowers Assembly
Air Conditioning (A/C) Belt Tensioner Tensioner, Belt
Air Conditioning A/C Condenser Panel Panel, AC Condenser
Air Dryer Dryer Assembly, Air
Air Dryer Bracket Bracket, Air Dryer
Air Dryer Desiccant Cartridge Cartridge, Desiccant
Air Filter Restriction Gauge Gauge, Air Cleaner
Air Gauge Transducer Transducer, Air Pressure Gauge
Air Hose Fitting Elbow
Air Hose Quick-Connect Fitting Coupling, Air Hose
Air Intake Tube (To Turbo) Pipe, Air
Air Reservoir Tank Tank, Air Secondary
Alternator Generator, Alternator
Alternator Bracket Bracket, Alternator
Alternator Interconnect Positive Cable Cable, Alternator
Alternator Pulley Pulley, Groove
Antilock Brake System (ABS) Blink Code Switch ABS-6 Blink Code Switch
Antilock Brake System (ABS) Control Module Module, ABS Control
A-Pillar Assist Handle Handle
A-Pillar Cover Trim Cover, A-Pillar
Armor Grille Grille Assembly
Armor Grille Support and Armor Grille Support Bracket Support, Assembly Lower Grill
Auxiliary Spring Spring, Rubber, Auxiliary
Axle Shaft Oil Seal Seal, Oil Spindle
Backup Light Assembly Light, White, Backup
Barometric Pressure Sensor Sensor, Barometric Pressure
Battery Battery, Storage
Battery Body Ground Cable Cable, Negative
Battery Box Tray Module, Battery
Battery Cable and Clean Power Harness Cable Assembly, Battery
Battery Cables Cable, Positive
Battery Disconnect Switch Switch, Battery
Battery Equalizer Converter Equalizer, Battery
Belly Armor Belly Deflector, Pan
Blackout Drive Light Assembly Light, Blackout
Body Armor Rear Wall, Riot Guard, and Bracket Armor, Rear Wall
Body Ground to Firewall Ground Cable Cable, Negative
Bottom Ramp Step Steps, Welded
Brake Pedal Pedal, Brake
Brake Stoplight Switch Switch, Pressure, Stop Light
Cabin Door Door, Assembly
Cabin Door Assist System Actuator Air Line Tubing Tube, Black Nylon 1/4-In. OD.
Cabin Door Assist System Limit Valve Elbow
Cabin Door Assist System Supply Air Line Tubing Tube, Black Nylon
Cabin Door Assist System Supply Pass-Through Air
Line Tubing Tube, Black Nylon
Cabin Door Combat Lock Assembly Handle, Outside Door, Assembly
0001–5
TM 9-2355-106-23-1 0001


Cabin Door Exterior Handle Assembly Handle, Outside Door, Assembly
Cabin Door Interior Handle Assembly
Cabin Door Interior Handle Assembly Handle, Door
Cabin Door Seal Seal
Cabin Door Striker and Cabin Door Check Stop
Assemblies Cabin Door Check Stop
Cabin Electrical Ground Stud Plate Stud, M8 X 1 MM
Cabin Emergency Hatch and Hinge Emergency Hatch
Cabin Emergency Hatch Handle/Lock Assembly Emergency, Hatch, Lock
Cabin Emergency Hatch Seal Seal Ring, Escape Hatch
Cabin Roof Molding Moulding
Cabin Window Armor Glass Window, Armor Glass Assembly
Camshaft Position (CMP) Sensor Sensor, Camshaft Position
Center Chassis Harness Harness, Chassis, Center
Center Floor Panel Panel, Floating Floor Center
Center Panel Air Filter Restriction Gauge Tubing and
Fitting Tube, Black Nylon, 1/4-In. OD.
Charge Air Cooler (CAC) Assembly Cooler, Charge Air
Charge Air Cooler (CAC) Hose Pipe, Air Duct
Clearance and Marker Light Harness Harness
Clearance Lights Cabin Jumper Harness Harness, Roof
Climate Control Unit CCU Box CCU Box
Communications Rack Rack, Communications
Composite Taillamp Assembly Taillamp, Composite, Assembly
Cooling Fan Actuator Solenoid Solenoid, Air Valve
Cooling Fan Drive Assembly Drive, Fan
Cowl Panel Drain Tube Tube, Drain
Crankshaft Damper Damper, Vibration
Crew and Front Passenger Seat Seat, Front, Passenger
Cross-Vehicle Equipment Bracket Bracket, Cross Vehicle Equipment
Cruise Control Switch Module Switch, Steering Wheel
Deaeration Tank Tank, Deaeration
Deaeration Tank Pressure Cap Cap, Filler Opening
Door Armor Panel Panel, Armor
Door Mounted Mirror Mirror, Powered, Assembly
Door Window Armor Glass Glass, Door Assembly
Door Window Riot Guard Guard, Riot Protection
Driver Control Module (DCM) Left Air Line Grommet Guide, Tube Passthru Gland Low
Driver Control Mounting (DCM) Bracket Assembly DCM Base
Driver Control Mounting (DCM) Bracket Assembly
Exterior Armor Cover, DCM, Main
Driver Control Mounting (DCM) Bracket Assembly
Interior Armor Bracket, DCM Interior Armor
Driver Seat Seat, Driver
Dual-Pneumatic Door Actuator Actuation Assembly
Electric Horn Horn, W/Brackets
Electronic System Controller (ESC) Controller, Electronic System
Electronic System Controller (ESC) Brace Brace
Engine Control Module (ECM) Module, Electronic Control
Engine Control Module (ECM) and the Transmission
Control Module (TCM) Fuse Fuse, Blade Type
Engine Control Module (ECM) and Transmission
Control Module (TCM) Clean Power and Ground
Harness Cable Assembly, Battery
Engine Coolant Temperature (ECT) Sensor Sensor, Oil/Coolant Temperature
0001–6
TM 9-2355-106-23-1 0001


Engine Cover Cover, Engine
Engine Mount Crossmember Assembly Crossmember
Engine Oil Breather Tube Tube Assembly, Breather
Engine Oil Cooler Cooler Assembly, Oil
Engine Oil Cooler Pressure Regulator Valve, Regulating
Engine Oil Filter Filter, Oil
Engine Oil Pan Oil Pan Assembly
Engine Oil Pickup Tube Tube Assembly, Oil Pick Up
Engine Oil Pressure (EOP) Sensor Sensor, Engine Oil Pressure
Engine Oil Temperature (EOT) Sensor Sensor, Oil/Coolant Temperature
Engine Sensor Wiring Harness Wiring, Electronic
Engine Water Outlet Pipe Assembly, Pipe
Engine Water Outlet Pipe Elbow Elbow, Pipe, Vibralok
Engine Water Pump Pump, Water
Engine Wiring Harness Harness, Base 24-V
Equalizer Cables Cable, Converter
Ether (Cold) Start Valve and Atomizer Assembly Ether Start Assembly
Ether Start Switch Switch, Ether Start
Exhaust Brake Brake, Exhaust Compression
Exhaust Brake Solenoid Solenoid, Exhaust Brake
Exhaust Brake Supply Air Line Tube, Black Nylon
Exhaust Manifold Manifold, Exhaust, Center
Exhaust Pipe Pipe, Exhaust
Exterior Battery Box Armor Door Side Belly, Door Right
Exterior Body Armor Left Front Panel Panel, Armor, Left Side, Front
Exterior Body Armor Left Middle Front Panel Panel, Armor, Side, Front-Middle
Exterior Body Armor Middle Rear Panel Panel, Armor, Side, Rear-Middle
Exterior Body Armor Rear Panel Panel, Armor, Side, Rear
Exterior Body Armor Right Front Panel Panel, Armor, Right Side, Front
Exterior Body Armor Riot Guard Guard, Riot Protection, Side, Front
Exterior Fuel Tank Armor Door Side Belly, Fuel Tank Door, Left
Fender and Reinforcement Extension, Fender
Flexplate Assembly Plate, Flex
Floor Panel (Front Center) Panel, Floating Floor Center
Floor Panel (Front) Panel, Floating Floor Front
Foot Brake Valve Valve
Forward Chassis Harness Harness Assembly, Forward Chassis
Front and Rear Clearance Lights Roof Harness Harness, Roof
Front Antilock Brake System (ABS) Modulator Valve Valve, Air Modulator
Front Antilock Brake System (ABS) Sensor Transmitter, Speed Sensor
Front Axle Antilock Brake System (ABS) Tone Ring Ring, ABS Tone
Front Axle Assembly Axle, Front, Assembly
Front Axle Breather Breather Assembly
Front Axle Bumper Stop Bumper, Front Spring
Front Axle Bumper Stop Bracket Stop, Front Axle
Front Brake Air Chamber Chamber, Brake
Front Brake Air Hose Tubing, Nonmetallic
Front Brake Drum Drum, Brake
Front Brake Dust Shield Shield, Dust, Brake
Front Brake S-Camshaft Camshaft, Brake
Front Brake Shoes Shoe, Brake
Front Brake Spider and Spindle Assembly Spider, Brake, With Bushing
0001–7
TM 9-2355-106-23-1 0001


Front Bumper Bumper, Front
Front Bumper Right Harness Harness, Electrical, Right
Front Bumper Turn Signal and Parking Light Assembly Light, Turn Signal
Front Clearance Light Assembly Bar, Front Marker Light
Front Clearance Light Bar Harness Harness Front - Clearance Light Bar
Front Crew Light Light, Front, Crew
Front Engine Cover Front Cover, Front Half
Front Engine Mount Insulator, Engine Front Mounting
Front Fender Light Assembly Light, Turn Signal Assembly
Front Fender Light Bulb Light, Turn Signal, Amber
Front Frame Crossmember and Radiator Support Crossmember, Front
Front Frame Crossmember and Support Crossmember, Front
Front Litter Arm Mount Plate and Arm Support Forward Mounting
Front Oil Pump Assembly Rotor, Pump
Front Shock Absorber Shock Absorber
Front Shock Absorber Lower Mounting Bracket Seat, U-Bolt Front
Front Shock Absorber Upper Mounting Bracket Bracket, Front Shock Mounting
Front Slack Adjuster Assembly Adjuster, Slack
Front Spring Assembly Spring Assembly
Front Spring Shackle Shackle
Front Towing Eye Eye, Tow
Front Trailer Hookup Cover Cover, Socket
Front Trailer Hookup Harness Harness, Front Trailer
Front Turn Signal and Parking Light Bulb Light, Turn Signal, Amber
Front Wheel Hub Hub Assembly
Front Wheel Hub Bearing Bearing, Inner
FSS Cabin Cylinder Extinguisher, 9-kg
FSS Cabin Sensor Sensor, Cabin
FSS Cabin Wiring Harness Harness, Cabin
FSS Cabin/Crew Dispersion Unit and Pipe Nozzle, Water Mist, Front
FSS Chassis Harness Harness, Chassis
FSS Control Unit System, Control
FSS Control Unit Bracket Bracket, Control Box
FSS Engine Compartment Sensor Sensor, Engine
FSS Engine Cylinder Extinguisher, 2 kg
FSS Engine Dispersion Unit and Pipe Nozzle, Flood
FSS Front Tire Dispersion Unit and Pipe Nozzle, Foam
FSS Fuel Tank Cylinder Extinguisher, 6-kg
FSS Fuel Tank Dispersion Unit and Pipe Nozzle, Powder
FSS Rear Tire Dispersion Unit and Pipe Nozzle, Foam
FSS Tire Cylinder Extinguisher, 9-kg
Fuel Filter and Strainer Filter, Fuel
Fuel Filter Header/Primer Pump Assembly Header, Fuel Filter Assembly
Fuel Hose Tube Assembly, Formed Fuel Line
Fuel Injector Injector, Assembly
Fuel Injector Harness Harness, Injector
Fuel Level Sending Unit Sending Unit, Fuel
Fuel Pressure Regulator Valve, Regulator
Fuel Pump Pump, Low Pressure Fuel
Fuel Tank Tank, Fuel
Fuel/Water Separator Filter Element, Fuel Filter
Fuel-Fired Heater Heater Assembly, Fuel Fired
Fuel-Fired Heater and Fuel-Fired Heater Fuel Pump
Harness Harness, Chassis - Fuel Fired Heater
Fuel-Fired Heater Fuel Pump Pump, Fuel
0001–8
TM 9-2355-106-23-1 0001


Fuel-Fired Heater Fuel Pump Fuel Line Hose, Fuel Line
Fuel-Fired Heater Timer Control Control, Timer Fuel
Gladhands Coupling Half, Quick Disconnect
Gun Port Port, Gun Hole
Gunner Platform Stand Platform, Adjustable Gunner
Hand Brake Control Valve Valve
Headlamp Assembly Headlamp Assembly
High-Pressure Injector Pump Pump
Hood Assembly Hood Assembly, N/Access
Hood Assembly Air Intake Grille Grille, Assembly, Air
Hood Assembly/Fender Extension Latch Latch, Hood Strap
Hood Grille Surround Assembly Grille, Surround Assembly
Hood Hinge Assembly Hinge, Hood
Hood Mirror Mirror, Assembly
Hood Safety Cable Assembly Cable Hood Assembly
Hood Torsion Assist Bar Bar, Torsion
Horn Button Assembly Cap, Horn Steering
HVAC 3-Way Valve and Bracket Valve, Three-Way
HVAC 3-Way Valve Bracket Support, Three-Way Valve
HVAC 3-Way Valve Coolant Inlet Hose Hose, Heater
HVAC 3-Way Valve Coolant Outlet Hose Hose, Heater
HVAC Cabin Heater Hose Hose, Heater
HVAC Compressor Compressor, Assembly
HVAC Compressor Discharge Hose Hose, Compressor Discharge
HVAC Compressor Suction Hose Hose, Compressor Suction
HVAC Control 2 Wiring Harness Harness, Control II
HVAC Control Input Wiring Harness Harness, AC Section
HVAC Evaporator Inlet Hose Hose, Evaporator Inlet
HVAC Evaporator Outlet Hose Hose, Evaporator Outlet
HVAC Filter Outlet Hose Hose, Filter Outlet
HVAC Fresh Air Inlet Tube Tube, Inlet Air
HVAC Fuel-Fired Heater Coolant Inlet Hose Hose, Heater
HVAC Fuel-Fired Heater Coolant Outlet Hose Hose, Heater
HVAC Heater Radiator Radiator, Vehicular
HVAC Left Condenser Control Wiring Harness Harness, Left Condenser
HVAC Left-Side Condenser Inlet Hose Hose, Condenser Inlet
HVAC Left-Side Condenser Outlet Hose Hose, Condenser Exit
HVAC Main Evaporator Assembly Evaporator, Main
HVAC Pressure Gauge Gauge, Driver Control, HVAC Pressure
HVAC Receiver/Drier Receiver, Dryer
HVAC Recirculated Air RA Temperature Sensor Sensor, Recirculated Air Temperature
HVAC Refrigerant Filter Filter Unit
HVAC Right Condenser Control Wiring Harness Harness, Right Condenser
HVAC Right-Side Condenser Inlet Hose Hose, Condenser Inlet
HVAC Right-Side Condenser Outlet Hose Hose, Condenser Exit
HVAC Service Port/Schrader Valve Valve, Schrader
HVAC Water Drainage Hose Hose, Water Drainage
HVAC/LSS Air Duct Louver Louver
HVAC/LSS Box LSS Box Assembly
HVAC/LSS Control Power Wiring Harness Harness, CCU Power
HVAC/LSS Control Wiring Harness Harness, Control Input
HVAC/LSS Defogging Air Duct Duct, Air Defogging
0001–9
TM 9-2355-106-23-1 0001


HVAC/LSS Diffuser Air Duct Duct, Air Diffuser
HVAC/LSS Engine Wiring Harness Harness, AC, Engine
HVAC/LSS Fresh Air Inlet Flange Flange, Fresh Air
HVAC/LSS Main Air Duct Duct, Air
HVAC/LSS Main Blower Motor and Support Blower, Main
HVAC/LSS Main Blower Motor Wiring Harness Harness, RA Blower
HVAC/LSS Operator Panel Operating Panel Assembly
HVAC/LSS Overpressure Relief Valve Valve, Relief
HVAC/LSS Upper Blower Blower Assembly
HVAC/LSS Upper Blower Wiring Harness Harness, FA Blower
HVAC/LSS Upper Panel Cover, Housing Upper
Infrared (IR) Light Assembly Light, Infrared
Infrared (IR) Light Switch Control Assembly, IR Light
Injection Control Pressure (ICP) Sensor Sensor, Injector Control Pressure
Injection Pressure Regulator (IPR) Sensor Regulator Assembly, Injection, Pressure
Inner Wheel Deflector Armor Plate Wheel Deflector
Instrument Panel (I/P) Cluster Closeout Closeout, Instrument Panel, Cluster
Instrument Panel (IP) Carrier Assembly, Driver Control, Main
Instrument Panel (IP) Center Relay Relay, Gen Control
Instrument Panel (IP) Center Trim Panel Panel, Trim, Instrument Panel, Center
Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Breaker, Circuit
Instrument Panel (IP) Cluster Housing, IPC
Instrument Panel (IP) Feed Harness Harness, Instrument Panel Feed
Instrument Panel (IP) Harness Harness, Instrument
Instrument Panel (IP) Light Bulb Lamp, Socket
Instrument Panel (IP) Right Side Closeout Passenger Trim, Upper Assembly
Instrument Panel (IP) Storage Bin Box, Storage Bin
Instrument Panel Center Closeout Panel, Trim, Instrument Panel, Center
Instrument Panel Cluster Right Side Warning Panel Light, Instrument With Harness
Intake Air Temperature (IAT) Sensor Sensor, Temperature
Interior Lights Crew Light Limit Switch Switch, Limit
Interior Lights Crew Light Limit Switch Jumper Harness Harness, Jumper
Interior Lights Left Rear Crew Light Harness Harness, Dome Light
Interior Lights Right Rear and Front Crew Lights
Harness Harness, Dome Light
Inverter and Battery Disconnect Switch Solenoid
Cables Cable, Inverter
Inverter Disconnect Battery Switch Solenoid Harness Harness, Disconnect, Converter Equalizer
Keyless Ignition Switch Switch, Keyless
King Pin Cap, King Pin Upper
Left 12V Socket and Feed Harness Harness, Socket, 12-Volt, Right
Left Door Air Supply Line Tube, Black Nylon
Left Headlamp and Turn Signal Harness Harness, Electrical, Left
Left Inner Wheel Deflector Bracket Bracket, Wheel Left
Left Rear Stowage Box Box, Storage, Rear Left
Left Side Engine Armor Plate Armor, Engine Side, Upper
Left Side Engine Armor Plate Bracket Armor, Engine Side, Left
Left Side Forward Stowage Box Box, Storage, Middle Left
Litter Arm Storage Bracket Litter, Arm Storage
Lower Cabin Door Lock, Spacer, and Bracket Lock Mechanism, Assembly
Manifold Absolute Pressure (MAP) Sensor Sensor, Map
Master Crew Light Switch Switch, Light, Assembly
Master Crew Light Switch Jumper Harness Harness, Jumper Crew
Master Disconnect Harness Harness, Disconnect, Converter Equalizer
Master Rear Door/Ramp Switch Switch, Ramp
0001–10
TM 9-2355-106-23-1 0001


Master Rear Door/Ramp Switch Jumper Harness Harness, Jumper
Master Vehicle Light Switch (MVLS) Switch, Light Master
Master Vehicle Light Switch (MVLS) Ground Harness Cable Assembly, Jumper
Mirror Remote Control Switch Switch, Power Mirror
Mirror Remote Control Switch Wiring Harness Cable, Mirror Jumper Harness
Motor Baffle Baffle, Motor
Muffler and Shield Muffler Assembly, Exhaust
Multifunction Turn Signal Switch Assembly Switch, Turn Signal
NATO Jump Start Connector Connector, NATO Jump Start
NATO Jump Start Connector Cable Cable, Negative, NATO Jump Start
NATO Jump Start Connector Cable Cable, Positive, NATO Jump Start
NBC Dust Tube Tube, Dust
NBC Filter Filter, NBC
NBC Filter Cover and Housing Housing, NBC Filter
NBC Particle Separator Filter Separator, Particle
Oil Gauge Tube Tube, Eng Oil Fill
Oil/Fuel Manifold Manifold, High-Pressure Oil/Fuel
Outside Gunner Protection Armor Gunner Protection
Outside Gunner Protection Riser Support, Turret
Parking Brake Lamp Transducer Switch, Pressure, Park Brake
Pitman Arm Arm, Pitman Power
Power Distribution Center (PDC) Fuse Fuse
Power Distribution Center (PDC) Harness Harness, Dash Wiring
Power Distribution Center (PDC) Junction Box Box, Power Distribution Center
Power Distribution Center (PDC) Relay Relay
Power Steering Filter Filter, Oil Power
Power Steering Pump Pump Assembly, Power
Power Steering Reservoir Reservoir, Power Steering
Power Steering Tubing and Hose Hose, Power Steering
Pressure Protection Valve Valve, Reservoir Control
Prop Shaft Drive Shaft Assembly
Radiator Housed Radiator Assembly
Radiator Fan and Fan Shroud Recirc Shield Assembly
Radiator Pipes/Hoses Pipe, Radiator Upper
Radiator Surge Overflow Tank Tank, Overflow
Rear Antilock Brake System (ABS) Modulator Valve Valve, Modulator
Rear Antilock Brake System (ABS) Sensor Sensor, Transmitter, Wheel Speed
Rear Axle Assembly Axle, Rear, Assembly
Rear Axle Shaft and Gasket Axle Shaft
Rear Brake Air Chamber Chamber, Brake
Rear Brake Air Hoses Tubing, Nonmetallic
Rear Brake Drum and Hub Assembly Drum, Brake
Rear Brake Dust Shield Shields, Dust
Rear Brake S-Camshaft Camshaft, "S" Head
Rear Brake S-Camshaft Tube Support Bracket Bracket, Camshaft
Rear Brake Shoes Shoe, Brake W/Lining
Rear Brake Spider Assembly Brake Spider
Rear Center Floor Panel Panel, Floating Floor Center
Rear Chassis Harness Harness, Chassis, Rear
Rear Clearance Light Assembly Plate, Mounting, Light Bracket Retention
Rear Clearance Light Bar Harness Harness, Rear, Clearance Light Bar
Rear Communication Rack Tray, Duke Mounting
0001–11
TM 9-2355-106-23-1 0001


Rear Crankshaft Oil Seal Seal Assembly, Radial Lip
Rear Crew Light Light, Rear, Crew
Rear Door/Ramp Assembly Door, Ramp Welded
Rear Door/Ramp Feed Wiring Harness Harness, 24-Volt
Rear Door/Ramp Hydraulic Cylinder Hydraulic Cylinder
Rear Door/Ramp Hydraulic Hoses Hose Assembly, Hydraulic
Rear Door/Ramp Hydraulic Power Unit Manifold and
Module Manifold, Power Unit
Rear Door/Ramp Hydraulic Pump Hydraulic Power Unit
Rear Door/Ramp Hydraulic Pump Cover Cover Assembly, Liftgate Hydraulic Pump Access
Rear Door/Ramp Hydraulic System Control Harness Assembly, Wire Harness
Rear Door/Ramp Hydraulic System Harness Harness, Jumper
Rear Door/Ramp Lock Assembly Latch Door Assembly, Stairs
Rear Door/Ramp Seal Seal, Nonmetallic
Rear Engine Mount Insulator, Engine Rear Mounting
Rear Floor Panel Panel, Floating Floor Rear
Rear Frame Crossmember and Support Crossmember, Frame, Rear
Rear Hub Assembly Bearing and Bearing Cup Hub, Machined
Rear Litter Arm Mount Plate and Arm Support Rear Mounting Plate
Rear Sidemarker Light Assembly Marker, Red Light
Rear Slack Adjuster Assembly Adjuster, Brake Slack
Rear Spring Assembly Spring, Assy RR 31k
Rear Towing Eye Hook, Tow
Rear Trailer Hookup Harness Harness, Trailer
Rear Window Armor Glass Window, Armor Glass, Rear Wall Assembly
Rifle Rack Base, Gun
Right 12V Socket and Feed Harness Harness, Socket, 12-Volt, Left
Right Cabin Door Assist System Supply Air Line Tubing Tube, Black Nylon
Right Floor Seat Bracket Bracket, Floor Seat
Right Headlamp and Turn Signal Harness Harness, Electrical, Right
Right Inner Wheel Deflector Bracket Bracket, Wheel Right
Right Rear Stowage Box Latch Locker Assembly
Right Side Engine Armor Plate Armor, Engine Side, Right
Right Side Forward Stowage Box Storage Box, Middle, Right
Right Side Rear Stowage Box Storage Box, Rear, Right
Rocker Switch Switch, High/Neutral
Roof Armor Front Panel Armor, Add On, Front
Roof Armor Front Spoiler Front-Spoiler Assembly
Roof Armor Middle Front Panel Armor, Add-On, Middle, Left, Front
Roof Armor Middle Rear Panel Armor, Add-On, Middle, Left, Rear
Roof Armor Rear Panel Armor, Add-On, Hatch
Roof Armor Rear Spoiler Armor, Add-On, Rear
Seatbelt Restraints
Serpentine Belt Belt, V-Rib
Serpentine Belt Idler Pulley Pulley, Groove
Serpentine Belt Tensioner Tensioner, Pulley
Serpentine Belt Upper Idler Pulley Pulley, Groove
Side Cowl Body Armor Panel Armor, Cowl, Add On
Spotlight Light, Spot
Spotlight Control Control, Electronic
Spotlight Exterior Harness Harness, Exterior Spot Light
Spotlight Interior Harness Harness, Spot Light - Interior
Spotlight Light Bulb Bulb, Spotlight
Spring Brake Modulating Valve Valve, Air Modulator
Starter Motor Motor, Starter
0001–12
TM 9-2355-106-23-1 0001


Starter Motor-to-Battery Feed Cable Cable, Positive
Starter Motor-to-Battery Ground Cable Cable, Negative
Starter Motor-to-Engine Ground Jumper Cable Jumper, Engine Ground
Starter Motor-to-Frame Ground Jumper Cable Jumper, Starter Ground
Starter Ring Gear Gear, Ring
Steering Arm Arm, Steering
Steering Column Column, Steering
Steering Column Covers Covers, Steering Column
Steering Column Wiring Harness Harness, Electrical
Steering Drag Link Link, Steering Drag
Steering Gear Steering Gear Assembly
Steering Knuckle Knuckle, Steering With Bushing
Steering Shaft Shaft, Steering
Steering Wheel and Clock Spring Wheel, Steering
Step and Brackets Stair Mount
Taillamp Harness Harness, Taillamp
Towing Pintle Hook Hook, Pintle
Tractor Protection Valve Valve, Tractor Protection
Trailer Control Valve Hand Control, Valve
Transfer Case Air Lines Tube, Black Nylon
Transfer Case Armor Plate, Mounting
Transfer Case Mount and Support Bracket, Support
Transfer Case Oil Cooler Cooler, Lubricating
Transfer Case Oil Cooler Hose Hose Assembly
Transmission Assembly Transmission
Transmission Auto Shift Control Module Control, Shift
Transmission Breather
Transmission Control Module and Brace Module, Transmission Control
Transmission Control Module Brace Bracket, Transmission Control Module
Transmission Cooler Hose Hose Assembly, Oil Cooler, Transmission
Transmission Fluid and Filter Filter, Fluid
Transmission Fluid Temperature Gauge and Harness Gauge, Transmission Oil Temp
Transmission Mounting Crossmember Mounting Assembly, Rear
Transmission to Transfer Case Propshaft Driveshaft, Transmission To Transfer Case
Turbocharger Turbo, GT3782
Turbocharger Lubricant Lines Tube, Turbo Oil Inlet
Turret Mounting Plate Mounting Plate
Turret Power Feed Wiring Harness Wiring Harness
Upper Air Line Grommet Guide, Tube Passthru Gland Up
Upper and Lower King Pin Bushing Bushing, King Pin
Upper Cabin Door Lock, Spacer, and Bracket Lock Mechanism, Assembly
Valve Cover and Gasket Valve Cover Assembly
Valve Cover Gasket Parts Kit, Seal Replacement
Water Inlet Elbow Inlet, Water
Water Sensor Probe Probe, Water Sensor
Weapon (Sliding) Hatch (Gunner Hatch) Hatch, Sliding Roof
Weapon (Sliding) Hatch (Gunner Hatch) Inner Lock
Assembly Hook, Locker
Wheel and Tire Assembly Wheel Assembly
Winch Battery Cable Junction Block Block, Junction
Winch Battery Cable Junction Bracket Support
Assembly Bracket, Junction Block, Winch
0001–13
TM 9-2355-106-23-1 0001


Winch Cable Cable, Winch
Winch Ground Cable Harness, Cable Winch
Winch Megafuse Megafuse, 300 Amp
Winch Megafuse Feed Cable Cable, Battery Positive
Winch Megafuse Holder Holder, Megafuse
Winch Remote Control Connector Support Extension, Winch
Windshield Armor Armor, Front, Add On
Windshield Armor Glass Window, Windshield
Windshield Washer Hose Assembly Hose, Washer Supply
Windshield Washer Reservoir and Pump Motor
Assembly Assembly, Bottle, Washer
Windshield Washer Reservoir Bracket Support, Washer Bottle
Windshield Wiper Arm and Blade Assembly, Wiper Arm
Windshield Wiper Motor Harness Harness, Wiper
Windshield Wiper Motor, Transmission, Bracket, and
Linkage Assembly Assembly, Windshield Wiper
Wiper Cowl Panel Cover, Wiper Assembly

0001–14
TM 9-2355-106-23-1 0001
LIST OF ABBREVIATIONS/ACRONYMS

Table 2. Abbreviations/Acronyms

Abbreviations/Acronyms Definition
A or Amp Ampere
AAL Additional Authorization List
ABS Antilock Brake System
AC Alternating Current
A/C Air Conditioner
ACC Accessory
ACCEL Accelerate
ADJ Adjust
AGSP Auxiliary Gauge Switch Pack
AIC 1: Atlantic Intelligence Command; 2: Afloat Intelligence
Center
AIR Aerospace Information Reports
ALT Acquisition, Logistics, and Technology
Amb Ambient
AMF ACE (Allied Command, Europe) Mobile Force
AMP Ampere
ANSI American National Standards Institute
AOAP Army Oil Analysis Program
APS Accelerator Position Sensor
APS/IVS Accelerator Position Sensor/Idle Validation Switch
ASB Aviation Support Battalion
ASTM American Society for Testing and Materials
ATA American Trucking Association
ATC Automatic Traction Control
AUX Auxiliary
AWG American Wire Gauge
B+ or VBAT Battery Voltage
B.O B/O Blackout
BAP Barometric Pressure Sensor
BARO Barometric Absolute Pressure
BAT Battery
BATT Battery
BCP Brake Control Pressure
BCS Brake Control Pressure
BDC Bottom Dead Center
bhp Brake Horsepower
BII Basic Issue Items
BIO 1: Biotechology Industry Organization
2: BIO markers
BNO Brake Normally Open
BOI Basis of Issue
BPS Brake Pressure Switch
BRT Bright (on Instrument Panel)
BTDC Before Top Dead Center
BTRY 1: Battery; 2: Field Artillery
BTU British Thermal Unit
C-Celsius Celsius
CAC Charge Air Cooler
CAGEC Commercial and Government Entity Code
CAN Controller Area Network
CAP Cold Ambient Protection
CARC Chemical Agent Resistant Coating
0001–15
TM 9-2355-106-23-1 0001

GENERAL INFORMATION – (CONTINUED)

cc cubic centimeter
CCA Cold Cranking Ampere
CCU Climate Control Unit
CEC Consolidated Engine Controlle
cfm cubic feet per minute
cfs cubic feet per second
CID Cubic Inch Displacement
CIRC Circuit
CKP Crankshaft Position
CLS 1: Coolant Level Switch
2: Contractor Logistics Support
cm Centimeter
CMD Command
CMP Camshaft Position Sensor
CNTR Center
CNTRL Control
COO Cruise ON/OFF Switch
COTS Commercial Off the Shelf
CPC Corrosion Prevention and Control
CPU Central Processing Unit
CTA 1: Common Table of Allowance
2: Contractor Logistics Support
CTC Coolant Temperature Compensation
CTRL Control
CTRLR Controller
Cyl Cylinder
D Drive
DC Direct Current
DCL Data Communications Link
DCM Driver Control Module
DIA Diameter
DIFF Differential
DLC Data Link Connector
DME Dimethyl Ether
DMM Digital Multimeter
DOD Department of Defense
DT Diesel Turbocharged
DTC Diagnostic Trouble Code
DTRM Diesel Thermo Recirculation Module
EBP Exhaust Back Pressure
ECI Engine Crank Inhibit
ECL Engine Coolant Level
ECM Electronic Control Module
ECM PWR Electronic Control Module Power
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EFC Engine Fan Control
EFP 1: Engine Fuel Pressure
2: Explosively Forged Projectiles
EFRC Engine Family Ratings Code
EGC Electronic Gauge Cluster
EGDP Exhaust Gas Differential Pressure
EIC End Item Code
EIR Equipment Improvement Recommendation
EMP Electromagnetic Pulse

0001–16
TM 9-2355-106-23-1 0001


EOD Explosive Ordnance Disposal
EOP Engine Oil Pressure
EOT Engine Oil Temperature
EPA Environmental Protection Agency
EPG Electronic Pressure Governor
EPR Engine Pressure Regulator
ESC Electronic System Controller
ESD Electrostatic Discharge
EST Electronic Service Tool
F Fahrenheit
FA Fresh Air (Blower HVAC)
FGC Functional Group Code
FMI Failure Mode Indicator
FPC Fuel Pump Control
FPCV Fuel Pressure Control Valve
FRP Fuel Rail Pressure
FRS Forward Repair System
FSS Fire Suppression System
ft Feet
FWD Forward
GAA Grease, Automotive and Artillery
gal gallon
gal/h U.S. gallons per hour
gal/min U.S. gallons per minute
GAWR Gross Axle Weight Rating
GCW Gross Combined Weight
GCWR Gross Combined Weight Rating
GFE Government Furnished Equipment
GFCI Ground Fault Circuit Interrupter
GMTK General Mechanic’s Tool Kit
GND Ground (Electrical)
GPC Glow Plug Control
GPD Glow Plug Diagnostic
GPR Glow Plug Relay
GRND Ground
GVW Gross Vehicle Weight
H₂O Water
HC Hydrocarbons
HCI Hardness Critical Item
HDO Heavy Duty Oil (used with OE/HDO)
HEUI Hydraulically Actuated Electronically Controlled Unit
Injector(s)
Hg Mercury
Hl High
Hp Horsepower
HPU Hydraulic Power Unit
HTR Heater
HTRWIF Heater Water In Fuel
HVAC Heating Ventilating and Air Conditioning
IAHC Inlet Air Heater Control
IAHD Inlet Air Heater Diagnostic
IAHR Inlet Air Heater Relay
IAT Intake Air Temperature
IAW In Accordance With
ICP Injector Control Pressure

0001–17
TM 9-2355-106-23-1 0001


ICS Interactive Communication System
ID Inside Diameter
IDM Injector Drive Module
IED Improvised Explosive Device
IGM Ignition
in. Inch
in. H₂O inch of water
in. Hg inch of Mercury
IP Instrument Panel
IPC Instrument Panel Cluster
IPR 1: Injection Pressure Regulator
2: In Process Review
IR Infrared
ISO International Organization for Standardixation
ISS Independent Suspension System
IST 1: Idle Shutdown time 2: In-Service Training
ITP Internal Transfer Pump
IVS Idle Validation Switch
JCT Junction (Electrical)
JTA Joint Table of Allowances
kg Kilogram
km Kilometer
km/h Kilometers per hour
km/l Kilometers per liter
KOEO Key-On Engine-Off
KOER Key-On Engine-Running
kPa Kilopascal
L Liter
L/h Liters per hour
L/m Liters per minute
L/s Liters per second
lb Pound
lb-ft Pound force foot
lb-in Pound force inch
lb/s Pounds per second
LCD Liquid Crystal Display
LED Light Emitting Diode
LO Low
LSD Low Sulfur Diesel
LSS Life Support System
m Meter
m/s meters per second
MAC Maintenance Allocation Chart
MAF Mass Air Flow
MAG Magnetic
MAP Manifold Absolute Pressure (Sensor)
MAT Manifold Air Temperature
MAX Maximum
MEAP MRAP Expedient Armor Program
mi Mile
MIL Military
mm Millimeter
MOD 1: Modification 2: Module
MPa Megapascal
mpg Miles per Gallon

0001–18
TM 9-2355-106-23-1 0001


mph Miles per Hour
MPR Main Power Relay
MRAP Mine Resistant Ambush Protected
MSD Maintenance Support Device
MSG Micro Strain Gauge
MSM Multiplex System Module
MTOE Modified Table of Organization and Equipment
MVLS Master Vehicle Light Switch
N Neutral
N•m Newton Meter
NATO North Atlantic Treaty Organization
NBC Nuclear Biological and Chemical
NC Normally Closed (Electrical)
NCO Non-Commissioned Officer
NDTI Nondestructive Testing Inspection
NHA Next Higher Authority
NIIN National item Identification Number
(consists of last 9 digits of the NSN)
NSN National Stock Number
OCC Output Circuit Check
OCP Overcrank Protection
OCV Open Circuit Voltage
OD Outside Diameter
OEA Oil, Engine, Arctic
OHM unit of electrical resistance
OSHA Occupational Safety and Health Administration
OWL Oil/Water Lamp
P/N Part Number
PAG Polyalkylene Glycol (refrigerant oil)
PAM 1: Pamphlet 2: Pyrometer Ammeter Module
PDC Power Distribution Center
PDM Power Distribution Module
PID Parameter Identifier
PMCS Preventative Maintenance Checks and Services
PMV Pressure Modulator Valve
POL Petroleum Oil and Lubricants
ppm parts per million
PQDR Product Quality Deficiency Report
PRF MIL-PRF: Military Performance Specification
PROM Programmable Read Only Memory
psi Pounds per square inch
psia Pounds per square inch absolute
psig Pounds per square inch gauge
pt Pint
PTC Positive Temperature Coefficient
PTO 1: Power Takeoff 2: Preliminary Technical Order
PVC polyvinyl chloride
PWM Pulse Width Modulation
PWR Power (voltage)
qt Quart
QTY Quantity
R Reverse
RA Recirculated (Reclyed) Air (Blower HVAC)
RAM 1: Random Access Memory
2: Reliability, Availability, Maintainability
0001–19
TM 9-2355-106-23-1 0001

RAS Resume/Accelerate Switch (Speed Control)
REF Reference
rev Revolution
RFI 1: Request for Information
2: Radio Frequency Interface
RLY Relay
RMS Reliability, Maintainability, and Supportability
ROM Read-Only Memory
RPG Rocket Propelled Grenade
rpm Revolutions per minute
RPS Remote Accelerator Position Sensor
RPSTL Repair Parts and Special Tools List
RTV Room Temperature Vulcanization
(type of silicone)
SAE Society of Automotive Engineers
(developer of aerospace, automotive, and commercial
vehicle standards)
SATS Standard Automotive Tool Set
SC/SM Supply Catalogs/Supply Manuals
SCCS Speed Control Command Switches
SCS Speed Control Switch
SHD Shield (Electrical)
SID Subsystem Identifier
SIG GRD Signal Ground
SMR Source, Maintenance, and Recoverability (Codes)
SOC State of Charge (electrical)
SPAWAR Space and Naval Warfare Systems Command
SRA Specialized Repair Activity
STI Self-Test Input
SW Switch (Electrical)
SYNC Synchronization
TACH Tachometer Output
TACOM U.S. Army Tank Automotive and Armaments Command
TAMMS The Army Maintenance Management System
TASMG Theatre Aviation Sustainment Maintenance Group
TCM Transmission Control Module
TDA Tables of Distribution and Allowances
TDC Top Dead Center
TEMP Temperature
TM Technical Manual
TMDE Test Measurement and Diagnostic Equipment
TTS Transmission Tailshaft Speed
TXV Thermal Expansion Valve
U/I Unit of Issue
UOC Usable on Code
USAPPC United States Army Publications and Printing
Command
USB Universal Serial Bus
UVC Under Valve Cover
V Volt
VBAT or B+ Battery Voltage
VC Volume Control
VEPS Vehicle Electronics Programming System
VFI Valve Function Insert
VGT Variable Geometry Turbocharger

0001–20
TM 9-2355-106-23-1 0001

RAS Resume/Accelerate Switch (Speed Control)
REF Reference
rev Revolution
RFI 1: Request for Information
2: Radio Frequency Interface
RLY Relay
RMS Reliability, Maintainability, and Supportability
ROM Read-Only Memory
RPG Rocket Propelled Grenade
rpm Revolutions per minute
RPS Remote Accelerator Position Sensor
RPSTL Repair Parts and Special Tools List
RTV Room Temperature Vulcanization
(type of silicone)
SAE Society of Automotive Engineers
(developer of aerospace, automotive, and commercial
vehicle standards)
SATS Standard Automotive Tool Set
SC/SM Supply Catalogs/Supply Manuals
SCCS Speed Control Command Switches
SCS Speed Control Switch
SHD Shield (Electrical)
SID Subsystem Identifier
SIG GRD Signal Ground
SMR Source, Maintenance, and Recoverability (Codes)
SOC State of Charge (electrical)
SPAWAR Space and Naval Warfare Systems Command
SRA Specialized Repair Activity
STI Self-Test Input
SW Switch (Electrical)
SYNC Synchronization
TACH Tachometer Output
TACOM U.S. Army Tank Automotive and Armaments Command
TAMMS The Army Maintenance Management System
TASMG Theatre Aviation Sustainment Maintenance Group
TCM Transmission Control Module
TDA Tables of Distribution and Allowances
TDC Top Dead Center
TEMP Temperature
TM Technical Manual
TMDE Test Measurement and Diagnostic Equipment
TTS Transmission Tailshaft Speed
TXV Thermal Expansion Valve
U/I Unit of Issue
UOC Usable on Code
USAPPC United States Army Publications and Printing
Command
USB Universal Serial Bus
UVC Under Valve Cover
V Volt
VBAT or B+ Battery Voltage
VC Volume Control
VEPS Vehicle Electronics Programming System
VFI Valve Function Insert
VGT Variable Geometry Turbocharger

0001–21
TM 9-2355-106-23-1 0001

VIW Vehicle Interface Wiring
VLV Valve
VOP Valve Opening Pressure
VRE Vehicle Retarder Enable
VREF Reference Voltage
VSO Vehicle Speed Output
VSR Variable Speed Reversing
VSS Vehicle Speed Sensor
WCA Warranty Claim Action
WIF Water In Fuel
WP Work Package
WTEC World Transmission Electronically Controlled
Automatic Transmissions (Allison)
XFER Transfer
ZIP Zip Code
+/- ± plus or minus
> greater than
> greater than or equal to
< less than
< less than or equal to
° degrees (temperature)
® registered trademark
™ unregistered trademark

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this Field Maintenance
Manual, TM 9-2355-106-23. If quality of material requirements are not stated in this manual, the material must
meet the requirements of the drawings, standards, specifications, or approved engineering change proposals
applicable to the subject equipment.

SAFETY, CARE AND HANDLING

The following procedures should be observed when handling all ESD sensitive components and units containing
such components. Failure to observe all of these precautions can cause permanent damage to the electrostatic
device. This damage can cause the device to fail immediately or at a later date when exposed to an adverse
environment.
1. Turn off and /or disconnect all power, signal sources and loads used with the unit.
2. Place the unit on a grounded non-conductive work surface.
3. Ground the repair maintainer using a non-conductive wrist strap or other device using 1 mega-ohm series
resistor to protect the operator.
4. Ground any tools (including soldering equipment) that will contact the unit. Contact with the operator’s hand
provides sufficient ground for tools that are otherwise electrically isolated.
5. All electrostatic sensitive replacement components are shipped in non-conductive foam or tubes and must
be stored in the original shipping container until installed.
6. When these devices and assemblies are removed from the unit, they should be placed on the non-conductive
work surface or in non-conductive containers.
7. When not being worked on, place disconnected circuit boards in plastic bags that have been coated or
impregnated with a non-conductive material.
8. Do not handle these devices unnecessarily or remove them from their packages until actually used or tested.

0001–22
TM 9-2355-106-23-1 0001
COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment
(MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic
Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical
Department Expendable/Durable Items, as applicable to your unit.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL) TM 9-2355-106-23P.
Special tools: Test, Measurement, and Diagnostic Equipment (TMDE); and support equipment are listed in
Tool Identification List (WP 0795); and mandatory replacement items are listed in (WP 0796).

The Maintenance Allocation Chart (MAC) (WP 0793) designates overall authority and responsibility for the
performance of maintenance functions on the identified end item or component.

REPAIR PARTS

Repair parts are listed and illustrated in the repair parts and special tools list TM 9-2355-106-23P.

END OF WORK PACKAGE
0001–23/blank
TM 9-2355-106-23-1 0002
FIELD MAINTENANCE
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The Mine Resistant Ambush Protected (MRAP) M1224 and M1224A1 general characteristics, capabilities, and
features are described in the Operator's Manual (TM 9-2355-106-10). This work package describes the technical
features of MRAP systems.
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
POWERTRAIN SYSTEM
Figure 1. Powertrain.
The powertrain system consists of the following major components: engine, transmission, transfer case, exhaust,
prop shafts, U-joints, rear axle, front axle, and steering.
0002–1
TM 9-2355-106-23-1 0002
EQUIPMENT DESCRIPTION AND DATA - (CONTINUED)
ENGINE
Figure 2. Engine.
The vehicle is powered by a DT 530 in-line, six-cylinder fuel injected diesel engine with a 530-cubic-inch (8.7 L)
displacement. The engine firing order is 1-5-3-6-2-4. Basic engine features include two valves per cylinder, direct
injection, a wet-sleeve cylinder design, and seven main bearings. Figure 2 identifies some major components of
the engine; A/C compressor, alternator, turbocharger, oil filter, starter, and fuel pump.
EXHAUST SYSTEM
Figure 3. Exhaust Pipe, Muffler, and Tailpipe Assembly.
The exhaust system includes an exhaust pipe (Figure 3, Item 3), muffler (Figure 3, Item 1), tailpipe (Figure 3, Item
2), and exhaust brake mounted to the turbocharger exhaust port. The exhaust pipe, muffler, and tailpipe assembly
route exhaust gasses away from operator and crew, as well as reduce operating noise.
The exhaust brake system on the MRAP has been disabled. The system will provide NO braking assist. There is a
nonfunctioning exhaust brake switch on the IP. There is also a nonfunctioning exhaust brake valve directly in the
exhaust stream near the turbocharger exhaust outlet.
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TM 9-2355-106-23-1 0002
TRANSMISSION
Figure 4. Transmission.
The M1224 and M1224A1 vehicles are equipped with an Allison 3000SP series automatic transmission (Figure 4,
Item 1). The transmission is divided into four major modules:
• Input module
• Main housing and gear module
• Control module
• Output module
The input module includes the torque converter, torque converter housing, and engine adaptation ring. An input
speed sensor is mounted to the torque converter housing.
The main housing and gear module includes the oil pump charging system, three planetary gear sets, two rotating
clutches, and three stationary clutches. Gear range clutches are multiple-disc, wet-type clutches.
The control module is attached to the bottom of the transmission and is covered by the oil pan. The control module
houses both oil filters and all control solenoids, control valves, and temperature sensors. Internal electrical
wiring is routed up through the control module to a connector mounted to the transmission case. Oil filters are
cartridge style, disposable, external access type. The control system is capable of recognizing hydraulic and
electronic conditions that are not within calibrated operating limits. Some out-of-limit conditions can be corrected
by the control system. All out-of-limit condition Diagnostic Trouble Codes (DTCs) are stored in the Transmission
Control Module (TCM) for later retrieval.
The output module supports the output flange and the output speed sensor.
Features unique to Allison 3000SP series transmissions include:

• Torque converter with lockup clutch and torsional damper
• Dual internal oil filters, serviceable without complete loss of transmission fluid
• Adaptive, electronic, closed loop controls with self-diagnostic capabilities
The transmission is equipped with an oil fill tube and dipstick.
0002–3
TM 9-2355-106-23-1 0002
TRANSFER CASE
Figure 5. Transfer Case.
The M1224 and M1224A1 vehicles are equipped with a Meritor MTC-4210 series transfer case. This transfer case
is a four-shaft design with two-speed front and rear output. Gear ratios are 1:1 and 2.05:1.
The transmission provides the two-speed transfer case with power via a propshaft. Operators send inputs to the
Electronic System Controller (ESC) via rocker switches on the Instrument Panel (IP). The ESC controls air solenoids
that actuate an air-operated shift fork and collar that place the transfer case gears in LO, HIGH, or NEUTRAL.
ESC controlled air solenoids also actuate the front axle de-clutch pushrod and shift fork to connect or disconnect
the front axle and allow two wheel drive operation. Propshafts at the front and rear of the transfer case send
power to the front and rear axles.
PROPELLER SHAFTS
Figure 6. Propeller Shaft.
The vehicle is equipped with three propeller shafts:

• Transmission-to-transfer case propeller shaft
• Rear axle-to-transfer case propeller shaft
• Front axle-to-transfer case propeller shaft
0002–4
TM 9-2355-106-23-1 0002
Each propeller shaft is equipped with a universal joint (U-joint) on each end. Each propeller shaft also has a
length compensation joint and boot that compensate for propeller shaft length changes due to suspension travel
and chassis torque. Each U-joint has a grease fitting.
FRONT AXLE
Figure 7. Front Axle.
The front steering axle (Figure 7, Item 1) has an 18,000-lb Gross Axle Weight Rating (GAWR). The single-speed
differential features a 4:33:1 gear ratio. Upper and lower kingpin bushings provide pivot points for the steering
knuckles. Shock absorbers are used on the front axle only.
REAR AXLE, SUSPENSION
Figure 8. Rear Axle.
The rear drive axle (Figure 8, Item 1) has a 23,000-lb GAWR. Like the front steer axle, the rear drive axle has a
single-speed differential that provides a 4:33:1 gear ratio. The MRAP suspension uses leaf springs (Figure
8, Item 2).
0002–5
TM 9-2355-106-23-1 0002
STEERING GEAR
Figure 9. Steering Gear.
The M1224 and M1224A1 vehicles are equipped with a Sheppard M110 series steering gear (Figure 9, Item 1)
providing full-time power assist. The steering gear connects to the left steering knuckle (Figure 9, Item 2) by means
of a pitman arm (Figure 9, Item 4) and drag link (Figure 9, Item 3). Manual effort is required only as necessary
to overcome the internal torsion bar and turn the rotary valve. The power steering pump, located behind the air
compressor on the left side of the engine, uses a remote reservoir. A tie rod relays steering inputs to the right
side. Toe is adjustable.
The steering gear has the following features:
• 23.0:1 internal gear ratio
• 100-degree gear travel
• 2,175 psi (14996 kPa) rated pressure
• 2.25-inch (57.2-mm) output shaft diameter
0002–6
TM 9-2355-106-23-1 0002
ELECTRICAL SYSTEM
Figure 10. Electrical Components.
The electrical system consists of the following major components: heated windshields, windshield wipers, heated
mirrors, horns, batteries, power inverter, and 110V outlet.
BATTERIES
Figure 11. Batteries.
Four lead-acid batteries (Figure 11, Item 1), rated at 725 CCA each, are connected in series-parallel. The batteries
provide 12V and 24V power for vehicle systems.
0002–7
TM 9-2355-106-23-1 0002
BATTERY EQUALIZERS
Figure 12. Battery Equalizers.
Two battery equalizers (Figure 12, Item 1) mounted near the batteries regulate power between the 12V and 24V
sides of the system. The battery equalizers also maintain an equal state-of-charge on all batteries.
110V POWER INVERTER, 110V OUTLET, AND NATO SLAVE START CONNECTOR
Figure 13. 110V Power Inverter, 110V Outlet, and NATO Slave Start Connector.
The vehicle is equipped with an 1800 watt, 110V, alternating current (AC) inverter (Figure 13, Item 2) to provide
power for auxiliary AC equipment. A 110V outlet (Figure 13, Item 1) is located in the rear storage box. The 110V
power inverter has the following features:
• 1800 watt AC output with 2900 watt surge capacity
• True sine wave AC output
• Powersave mode draws only 1.5 watts with no load
• Over-temperature shutdown and automatic overload protection
• Over-voltage and under-voltage protection
• Short circuit and AC back-feed protection
0002–8
TM 9-2355-106-23-1 0002
The NATO slave start connector (Figure 13, Item 3) is used to jump-start a disabled vehicle with the NATO
slave start cable.
CABIN FUSE AND RELAY CENTER AND CIRCUIT BREAKER CENTER
Figure 14. Cabin Fuse and Relay Center and Circuit Breaker Center.
The cabin fuse and relay center is located behind a panel on the right side of the IP (Figure 14, Item 1). A circuit
breaker panel (Figure 14, Item 2) is located on the lower part of the IP between the front seats. Components are
identified on the circuit breaker panel and fuse and relay center.
POWER DISTRIBUTION CENTER (PDC)
Figure 15. Engine Compartment PDC.
The PDC is located under the hood on the right side of the engine compartment. The PDC contains fuse blocks
4001, 4002, and 4003. Graphics on the cover of the PDC identify components.
0002–9
TM 9-2355-106-23-1 0002
STARTER AND ALTERNATOR
Figure 16. Starter and Alternator.
A 400-amp alternator, driven by the engine accessory drivebelt, charges the batteries. The 24V starter is mounted
on the left side of the engine.
ELECTRONIC SYSTEM CONTROLLER (ESC)
Figure 17. ESC.
To manage electrical system functions, the vehicle uses an ESC, located to the left of the steering column, an
Instrument Panel Cluster (IPC), located at the left side of the IP, and a switch pack, located in the center of the IP.
The ESC and IPC are on the J1939 datalink. The ESC communicates with the switch pack via a dedicated J1708
datalink. The ESC monitors systems and receives inputs from the Engine Control Module (ECM), Transmission
Control Module (TCM), Antilock Brake System (ABS) module, and Electronic Gauge Cluster (EGC) for diagnostic
purposes. An MSD can be used to retrieve trouble codes, to monitor system operation, and to initiate tests.
0002–10
TM 9-2355-106-23-1 0002
PNEUMATIC CABIN DOOR ACTUATOR
Figure 18. Right Cabin Door Actuator.
Both cabin side doors utilize hidden pneumatic door actuators to assist in opening and closing the armored doors.
Each door has a door handle shaft. The door handle and actuator air valve linkage mount to the door handle shaft.
The actuator air valve supplies pressurized air to pneumatic cylinders attached to the door. Vehicles that have
a door with a lower interior combat lock utilize a single piston door actuator. Vehicles that have a door with
an upper interior combat lock utilize a dual piston door actuator. If single piston systems sustain damage, the
systems are replaced with dual piston units.
0002–11
TM 9-2355-106-23-1 0002
AIR BRAKES
Figure 19. Air Brakes.
The vehicle features air-operated brakes at all four wheels. Air pressure is provided by an air compressor located
on the lower left side of the engine. The compressor output is routed through an air dryer (Figure 19, Item 3),
which contains a desiccant material that removes moisture from the air. Air is then routed to the dual air tanks
(Figure 19, Item 2) on the right side of the vehicle.
The service brakes are actuated by the foot valve (Figure 19, Item 4) that is directly attached to the service
brake pedal in the cabin.
All four wheels utilize brake drums (Figure 19, Item 5) that contain S-camshaft actuated brake shoes. The
S-camshafts are actuated by air brake chambers (Figure 19, Item 1). Spring brakes on the rear wheels actuate
when air pressure falls below 25 psi (172 kPa). IP mounted controls operate the parking brake and send air
to trailer brake connectors at the rear of the vehicle.
0002–12
TM 9-2355-106-23-1 0002
The ABS relies on inputs from wheel-speed sensors (Figure 19, Item 6) installed at each wheel. The sensors
send signals to the ABS controller. The controller is located under the right side IP. The controller operates four air
pressure modulator valves that are used to hold and release air in the brake air chambers. The controller monitors
ABS components for malfunctions and can record trouble codes. Codes can be retrieved via a switch under the left
side of the IP or via ABS troubleshooting software on the Maintenance Support Device (MSD).
AIR COMPRESSOR
Figure 20. Air Compressor, Below Air Filter.
The air compressor is a gear-driven dual piston pump that supplies pressurized air to the vehicle air reservoirs.
The air reservoirs provide large volumes of pressurized air to the air brakes, door actuators, and front and rear
gladhand connections.
0002–13
TM 9-2355-106-23-1 0002
BODY AND CHASSIS SYSTEMS
Figure 21. Body and Chassis Systems – Exterior.
0002–14
TM 9-2355-106-23-1 0002
Figure 22. Body and Chassis Systems – Interior.
The body and chassis systems consist of the following major components: emergency hatch, lifting and tie-down
fixtures, electric winch, fuel fired heater, tow connections, rear door/ramp, litter rack, communications rack, gunner
hatch, interior lighting, seats, and gunner platform.
0002–15
TM 9-2355-106-23-1 0002
FUEL-FIRED HEATER
Figure 23. Fuel-Fired Heater.
A diesel-fuel-fired auxiliary heater (Figure 23, Item 1) on the right side of the vehicle warms the engine coolant.
The heater ignites a burner by means of a glow pin. An electric pump sends coolant through a heat exchanger
and circulates it through the cooling system to provide cabin heating. The auxiliary heater operation can be
programmed to occur at specific times or can be manually activated. Temperature can be regulated between
149°F (65°C) and 176°F (80°C).
REAR DOOR/RAMP
Figure 24. Rear Door/Ramp Pump Assemblies.
The rear door/ramp is operated by a hydraulic system (Figure 24, Item 1) inside the cabin at the rear of the vehicle.
There are two designs: push-type and pull-type operation. Switches on the IP and on the rear door/ramp hydraulic
assembly provide inputs for operating the rear door/ramp. The inputs operate an electric motor and hydraulic
pump, which extends and retracts the hydraulic cylinder to lower and raise the door/ramp. If the 24V electric motor
does not function, the door/ramp can be raised or lowered by a manually operated solenoid valve and pump.
0002–16
TM 9-2355-106-23-1 0002
FIRE SUPPRESSION SYSTEM (FSS)
Figure 25. FSS Cylinders.
The FSS provides automatic fire extinguishing for the engine compartment and the cabin. Manual switches are
provided for the engine compartment, cabin, tires, and fuel tanks. Each area uses a different FSS:
• Cabin fire suppression unit (Figure 25, Item 4) is located inside the cabin, under the communications
rack, and contains water.
• Engine fire suppression unit (Figure 25, Item 1) is located outside the vehicle, behind the right side air
conditioning condensers, and contains HFC 227ea agent.
• Tire fire suppression unit (Figure 25, Item 2) is located outside the vehicle, behind the left side rear stowage
box, and contains Petrotech TM25.
• Fuel tank fire suppression unit (Figure 25, Item 3) is located outside the vehicle, behind the left side air
conditioning condensers, and contains a dry chemical.
Each fire suppression unit incorporates a 24V pressure sensing transducer and a 24V dispersion solenoid. Fire
suppression units are under pressure when full. The transducers send a signal to the fire suppression control box
to indicate the state of charge. If the state of charge is low, a corresponding RED Light Emitting Diode (LED) will
illuminate on the control box for the affected system.
There are two heat detectors:
• One heat detector is located inside the vehicle, at the right front A-pillar near the floor. The sensor wire
runs from the front of the vehicle to the rear of the vehicle, along the interior roof. If a sudden increase in
temperature is detected along this wire, the heat detector will activate the cabin fire suppression unit. If the
heat detector fails to detect a fire, the CABIN switch on the control box can be used to override the heat
detector and activate the cabin fire suppression unit.
0002–17
TM 9-2355-106-23-1 0002
• The other heat detector is located in the engine compartment. The sensor wire is mounted to the engine
hood. If a sudden increase in temperature is detected along this wire, the heat detector will activate the
engine fire suppression unit. If the heat detector fails to detect fire, the ENGINE switch on the control box
can be used to override the heat detector and activate the engine fire suppression unit.
There are no heat detectors for the tires or the fuel tank. The fire suppression units are manually activated by
using the corresponding switch on the control box.
The control box manages the automatic and manual functions of the FSS and monitors the pressure in the fire
suppression units. A RED LED is provided for each fire suppression unit. An illuminated RED LED indicates
one of the following conditions:
• An automatic or manual request for fire suppression was requested and successfully delivered.
• The corresponding fire suppression unit is low on pressure or is empty.
• An open circuit has been detected between the control box and the corresponding fire suppression unit.
All four RED LEDs will illuminate when the LAMP TEST button is pushed. The GREEN light will illuminate when
the MAIN POWER switch and FSS power (FUSE) switch are turned on.
HEATING VENTILATION AND AIR CONDITIONING (HVAC)/LIFE SUPPORT SYSTEM (LSS)
Figure 26. HVAC/LSS Component Locations.
0002–18
TM 9-2355-106-23-1 0002
The M1224 and M1224A1 are equipped with a high performance HVAC/LSS system. Major components of
the system include:
• Refrigerant compressor
• Recycled Air (RA) and Fresh Air (FA) blowers
• Nuclear, Biological, and Chemical (NBC) filter
• Fresh air tube
• Heater core
• Evaporator core
• HVAC/LSS operator panel and Climate Control Unit (CCU)
• Dual A/C condensers (one on each side of vehicle)
When activated, the HVAC/LSS produces an over-pressure condition in the crew cabin to prevent entry of
outside contaminants. An FA blower draws outside air into the system through an inlet in the roof. Outside air
then passes through the NBC filter canister and across an evaporator core and heater core before being mixed
with recycled cabin air via the RA blower.
The HVAC/LSS operator panel located behind the passenger seat, has controls for mode (vent, cool, heat, and
dry), temperature, and fan speed. The CCU is located directly below the operator panel. When cool mode is
selected at the HVAC/LSS operator panel, the condenser fans activate and cool the condenser.
HEATED WINDSHIELD AND MIRRORS

Refer to TM 9-2355-106-10 for a description of the heated windshield and mirrors.
HORNS
Refer to TM 9-2355-106-10 for a description of the horns.
WINDSHIELD WIPERS
Refer to TM 9-2355-106-10 for a description of the windshield wipers.
LIGHTING SYSTEM
Refer to TM 9-2355-106-10 for location and description of lights.
INFRARED (IR) LIGHTING

Refer to TM 9-2355-106-10 for information on IR lighting.
COMPRESSED AIR STORAGE TANK

Refer to TM 9-2355-106-10 for information on the compressed air storage tank.
AIR COMPRESSOR FITTING

Refer to TM 9-2355-106-10 for information on the air compressor fitting.
EMERGENCY HATCH
Refer to TM 9-2355-106-10 for a description of the emergency hatch.
LIFTING AND TIE-DOWN FIXTURES

Refer to TM 9-2355-106-10 for a description of the lifting and tie-down fixtures.
0002–19
TM 9-2355-106-23-1 0002
ELECTRIC WINCH
Refer to TM 9-2355-106-10 for information on the electric winch.
FLAT TOWING CONNECTIONS
Refer to TM 9-2355-106-10 for a description of flat towing connections.
LITTER RACKS
Refer to TM 9-2355-106-10 for a description of the litter racks.
COMMUNICATIONS RACK
Refer to TM 9-2355-106-10 for a description of the communications rack.
GUNNER HATCH
Refer to TM 9-2355-106-10 for a description of the gunner hatch.
INTERIOR LIGHTING
Refer to TM 9-2355-106-10 for a description of the interior lighting.
SEATS
Refer to TM 9-2355-106-10 for a description of the seats.
GUNNER PLATFORM
Refer to TM 9-2355-106-10 for a description of the gunner platform.
PLATES, STENCIL, AND SERIAL NUMBERS
Refer to TM 9-2355-106-10 for warranty plate, stencil, or location of serial numbers.
DIFFERENCES BETWEEN MODELS
Figure 27. M1224.

0002–20
TM 9-2355-106-23-1 0002
Figure 28. M1224A1.
Figure 27 shows an MRAP Base vehicle (M1224). Figure 28 shows an MRAP vehicle with additional armor
installed under the MRAP Expedient Armor Program (MEAP). MEAP equipped vehicles (M1224A1) have a curb
weight of 41,000 pounds and a GVW of 46,500 pounds. The increased weight of MEAP equipped vehicles
requires that they be operated accordingly.
Table 1. Differences Between Models.

MODEL ITEM (@ gross wt) SPECIFICATION
M1224 Vehicle Weight Curb Weight: 37,850 lbs
Gross Vehicle Weight (GVW):
43,500 lbs
M1224A1 (with MEAP kit) Vehicle Weight Curb Weight: 41,000 lbs
Gross Vehicle Weight (GVW):
46,500 lbs
M1224 Width 99 in. (2.51 m)
M1224A1 (with MEAP kit) Width 119.3 in. (3.0 m)
M1224 Power to Weight Ratio 15 hp/ton
M1224A1 (with MEAP kit) Power to Weight Ratio 14.5 hp/ton
M1224 Maximum Grade (climb) 60%
M1224A1 (with MEAP kit) Maximum Grade (climb) 50%
M1224 Maximum Grade (descent) 60%
M1224A1 (with MEAP kit) Maximum Grade (descent) 50%
M1224 Maximum Grade (parking) 60%
M1224A1 (with MEAP kit) Maximum Grade (parking) 20%
0002–21
TM 9-2355-106-23-1 0002
EQUIPMENT DATA
Refer to the following tables for specific equipment data.
Table 2. Vehicle Weight.

VEHICLE CATEGORY SPECIFICATION
M1224 (without MEAP kit) Curb Weight: 37,850 lbs
Gross Vehicle Weight (GVW): 43,500 lbs
M1224A1 (with MEAP kit) Curb Weight: 41,000 lbs
Gross Vehicle Weight (GVW): 46,500 lbs
Table 3. Dimensions.
GROUND CLEARANCE SPECIFICATION
Front Axle Housing 13.0 in. (33.0 cm)
Belly Pan Armor 15.0 in. (38.1 cm)
Rear Axle Housing 10.25 in. (26.0 cm)
Table 4. Performance.
ITEM SPECIFICATION
Power to Weight Ratio (gross wt) 15 hp/ton
Power to Weight Ratio (MEAP gross wt) 14.5 hp/ton
Fuel Consumption (moving) 4.4 mpg
Angle of Approach 58 degrees
Angle of Departure 46 to 48 degrees
Maximum Grade (climb) 60%
Maximum Grade (descent) 60%
Maximum Grade (side) 30%
Ford Depth 36 in. (0.91 m)
Turning Radius, Curb to Curb 62 feet (18.9 m)
Top Speed 65 mph (105 km/h)
Vehicle Operating Temperature Range -25° to +125°F (-32° to +52°C)
Table 5. Capacities.
ITEM SPECIFICATION
Engine Oil with Filter 30 qt (28.3 L) (OE/HDO-15-40)
Cooling System 29 qt (27.6 L) (CID A-A-52624A; Type I/ A or C;
ethylene glycol) (50/50 mix with water)
Coolant Overflow Tank 4.8 qt (4.5 L)
Coolant Deaeration Tank 5.9 qt (5.6 L)
Transmission with Filter – Dry 29 qt (27.4 L) (OE/HDO-10)
Transmission with Filter – Drain and Refill 19 qt (18 L) (OE/HDO-10)
Axle – Front 13 qt (12.3 L) (SAE 80W90)
Axle – Rear 19.5 qt (18.5 L) (SAE 80W90)
Wheel Bearing – Rear 1.6 qt (1.5 L) (SAE 80W90)
Rear Door/Ramp Hydraulic Fluid 6.5 qt (6.2 L) (MIL-PRF-46170; Type I)
Power Steering 5.5 qt (5.2 L) (OE/HDO-15-40)
Transfer Case – w/ Cooler MTC4210 GCS transfer case: 6 qt (5.7 L) (SAE
80W90).
MTC4210XL-100 transfer case: 8 qt (7.6 L) (SAE
80W90)
Windshield Wiper Fluid 4 qt (3.8 L) Cleaning Compound, Windshield
A/C System 7.05 lb (3.19 kg) (R134A)
0002–22
TM 9-2355-106-23-1 0002
Table 6. Cooling System.

ITEM SPECIFICATION
Radiator Working Pressure 15 psi (103 kPa) low idle
Table 7. Engine Configuration.

ITEM SPECIFICATION
Make International®
Model DT 530 ST
Type Four-stroke, in-line
Cylinders Six
Bore 4.59 in. (116.6 mm)
Stroke 5.35 in. (135.9 mm)
Displacement 530 cu-in. (8.7 L)
Peak Torque 950 lb-ft @ 1200 rpm
Maximum Brake Horsepower (at 2,000 rpm) 330 hp
Maximum Governed Engine Speed 2,200 rpm
Table 8. Oil Filter.

ITEM SPECIFICATION
Type Full flow, spin-on
Quantity 1
Oil Pressure 40-70 psi (276-483 kPa)
Table 9. Fuel System Configuration.

ITEM SPECIFICATION
Type Diesel injection (electronically controlled)
Fuel Tank Capacity 57 gal. (216 L)
Air Cleaner Dual element
Fuel Type Diesel or JP8
Fuel Pressure 66 psi ± 5 psi (455 kPa ± 34 kPa)
Table 10. Electrical System.

ITEM SPECIFICATION
Alternator 400 amp Neihoff
Front Engine Accessory Drive Single serpentine belt
Batteries Exide lead acid (12V, 725 CCA, 4 each, connected in
series-parallel for 12V and 24V power)
Table 11. Transmission.

ITEM SPECIFICATION
Make Allison
Model 3000SP five-speed
Type Electronic Control System, WTEC III – Allison 4th
Generation
Table 12. Transmission Speeds.

ITEM SPECIFICATION
Forward Five
Reverse One
0002–23
TM 9-2355-106-23-1 0002
Table 13. Transfer Case.

ITEM SPECIFICATION
Make Meritor
Model MTC4210 GCS
MTC4210XL-100
Type Two-speed with NEUTRAL (NEUTL)
Table 14. Axles.

ITEM SPECIFICATION
Front MX-18-120/18,000 lbs – Meritor
Rear RS-23-160/23,000 lbs – Meritor
Table 15. Brake System.

ITEM SPECIFICATION
Actuation Air
Number of Brake Chambers Two per axle, rear also equipped with spring brakes
Type S-Cam
Front Bendix shoes – 16.5 x 7
Rear Bendix shoes – 16.5 x 7
Air Compressor Bendix Tu-Flo 550
Truck Air System 110-130 psi (758-896 kPa)
Table 16. Wheels.

ITEM SPECIFICATION
Type Two-piece bolt-together Hutchinson run flat
Quantity 4
Rim Size 20 x 10.00
Stud Quantity per Wheel 10
Wheel Assembly Bolt Torque 150-170 lb-ft (203-230 N•m)
Lug Nut Torque 450-500 lb-ft (610-678 N•m)
Spacer Plate Torque 175-200 lb-ft (237-271 N•m)
Table 17. Tires.

ITEM SPECIFICATION
Type Tubeless radial
Quantity 4 per vehicle
Tire Model Michelin XZL
Size 395/85R20
Load Range J
Tire Pressure: Highway (Front and Rear with 23k Rear 115 psi (793 kPa) @ 60 mph
Axle) (M1224)
Tire Pressure: Highway (Front with 25.5k Rear Axle) 115 psi (793 kPa) @ 55 mph
(M1224A1)
Tire Pressure: Highway (Rear with 25.5k Rear Axle) 127 psi (876 kPa) @ 55 mph
(M1224A1)
Tire Pressure: Cross-Country (Front and Rear – All) 77 psi (531 kPa) @ 45 mph
Tire Pressure: Mud/Sand/Snow (Front and Rear – All) 45 psi (310 kPa) @ 20 mph
Tire Pressure: Emergency (Front and Rear – All) 40 psi (276 kPa) @ 10 mph
Table 18. Towing and Lifting.

ITEM SPECIFICATION
Pintle Hook Maximum Load Capacity 49,000 lb (22,226 kg)
Front Tiedown Eyes Maximum Load Capacity 49,000 lb (22,226 kg)
0002–24
TM 9-2355-106-23-1 0002
Rear Tiedown Eyes Maximum Load Capacity 49,000 lb (22,226 kg)

Side Tiedown Eyes Maximum Load Capacity 25,000 lb (11,339 kg)
Front Tow Eyes Maximum Load Capacity 61,500 lb (27,896 kg)
Forward Lifting Eyes Maximum Load Capacity 30,500 lb (13,835 kg)
Front Hook for Towing Maximum Load Capacity 15,000 lb (6,804 kg)
Table 19. Winch Cable.

ITEM SPECIFICATION
Diameter 5/8 in. (15.9 mm)
Length 70 ft (21.3 m)
Ultimate Strength 40,000 lb (18,144 kg)
Working Load (Winch Maximum Rated Load) 18,000 lb (8,165 kg)
Table 20. Cabin.

ITEM SPECIFICATION
Windshield, Door, Side, and Rear Window Glazing Transparent armor
Personnel Capacity 6
END OF WORK PACKAGE
0002–25/blank
TM 9-2355-106-23-1 0003
FIELD MAINTENANCE
THEORY OF OPERATION
VEHICLE DESCRIPTION AND FEATURES
For a description of basic vehicle features, refer to General Information and Equipment Description and Data in the
Operator’s Manual (TM 9-2355-106-10). Additional information about the general characteristics of the M1224 and
M1224A1 can be found in Equipment Description and Data (WP 0002).
DRIVETRAIN
Figure 1. Drivetrain Powerflow.
The M1224 and M1224A1 are equipped with a DT530 in-line, six cylinder, fuel-injected, four-cycle, water-cooled
turbodiesel engine. The engine provides input power to the automatic transmission. The engine is equipped with a
turbocharger, overhead valves with replaceable valve guides, and replaceable valve seats for both intake and
exhaust. The engine is fueled by a direct injection fuel system with electronic sensors and Hydraulically actuated
Electronically controlled Unit Injectors (HEUI). The firing order is 1-5-3-6-2-4.
The front differential transfers power from the drivetrain to the front wheels and allows the front wheels to rotate
at different speeds during a turn. The front differential receives input torque from the front drive shaft when
the vehicle is in four-wheel drive mode.
The vehicles are equipped with an Allison 3000SP series automatic transmission. The transmission uses a
combination of a torque converter, three planetary gear sets, and five clutch packs to provide multiple output gear
ratios. The transmission allows the turbodiesel engine to remain within operational range while providing a wide
range of transmission output shaft speeds and vehicle speeds.
The vehicles are equipped with a Meritor MTC-4210 series transfer case. This transfer case is a four-shaft
design with two-speed front and rear output. Gear ratios are 1:1 and 2.05:1. The Electrical System Controller
(ESC) controls air solenoids that actuate an air-operated shift fork and collar that place the transfer case gears in
LO, HIGH, or NEUTRAL.
0003–1
TM 9-2355-106-23-1 0003
THEORY OF OPERATION - (CONTINUED)
The rear differential transfers power from the drivetrain to the rear wheels and allows the rear wheels to rotate at
different speeds during a turn. The rear differential receives input torque from the rear drive shaft anytime the
vehicle is moving. The rear differential can not be disengaged.
ENGINE CONTROLS SYSTEM DESCRIPTION
The Engine Control Module (ECM) is mounted on the left side of the engine below the high pressure oil rail. One
60-way connector (LAM1019) links the ECM to input and output components on the engine harness. Another
60-way connector (6007) is located lower on the side of the ECM. It links the ECM to additional engine-related
components and to the vehicle electrical system.
The ECM performs the following functions:
• Supplies input components with power and ground circuits.
• Processes signals from inputs.
• Calculates engine control strategy based on stored operating instructions.
• Controls actuators by means of output drivers and pulse width modulated signals.
ECM POWER SUPPLY
When the ignition switch is turned ON, ignition voltage is supplied to ECM connector 6007, terminal 24. This
signals the ECM to connect a battery feed to additional ECM pins by means of the ECM power relay.
One side of the ECM power relay coil (terminal 86) is provided with a battery feed. To actuate the relay, the ECM
provides a path to ground (terminal 85) for the relay coil via ECM connector 6007, terminal 25. As a result,
battery power at terminal 30 of the relay is connected to terminal 87 of the relay and to ECM connector 6007,
terminals 21, 22, and 41.
ECM terminals 23 and 42 on the 6007 connector provide the ECM with a battery ground.
The ECM monitors the power circuits and can record Diagnostic Trouble Codes if it detects a malfunction.
DTC 112 can be caused by an alternator that is overcharging or improper voltage during a jump-start.
DTC 113 can be caused by an alternator that is undercharging, weak batteries, high resistance, or poor
connections in B+ circuits.
DTC 626 will be set any time the ECM powers down due to an interruption in a power or ground circuit. When
power or ground is restored, the ECM will reboot itself. Relearning engine parameters may cause erratic engine
operation. Turning the ignition switch OFF and then ON again causes the code to change from active to inactive.
0003–2
TM 9-2355-106-23-1 0003
ECM INPUTS AND OUTPUTS
Figure 2. ECM Inputs and Outputs.
0003–3
TM 9-2355-106-23-1 0003
Engine and vehicle sensors send input signals to the ECM by:
•Changing reference voltage to produce a signal.
•Generating signal voltage.
•Switching a voltage feed on and off.
ACCELERATOR POSITION SENSOR (APS)/IDLE VALIDATION SWITCH (IVS)
The vehicle engine uses an electronic accelerator pedal assembly that includes an Accelerator Position Sensor
(APS) and an Idle Validation Switch (IVS). The APS and IVS are integrated into one component mounted
on the accelerator pedal. The ECM determines accelerator pedal position by processing input signals from
the APS and IVS.
The ECM sends a regulated 5V signal through ECM chassis connector 6007, terminal 3 to APS connector terminal
C. The APS returns a variable voltage signal (depending on pedal position) from APS connector terminal A to
ECM connector 6007, terminal 8. Terminal B of the APS connector is provided a ground by the ECM at connector
6007, terminal 11.
The ECM determines lowest and the highest pedal positions by reading and storing minimum and maximum
voltage levels from the APS during each ignition cycle. When the pedal is disconnected (or a new one is installed),
the pedal does not need calibration, since calibration occurs each time ignition switch is turned on.
The IVS receives 12V from ignition fuse. The ECM expects to receive one of two IVS signals through ECM
connector 6007, terminal 27 from APS/IVS connector terminal D: 0V when the pedal is in the idle position; 12V
when the pedal is depressed.
The APS/IVS unit can be replaced without replacing the entire accelerator pedal assembly.
BAROMETRIC ABSOLUTE PRESSURE (BAP) SENSOR
The Barometric Absolute Pressure Sensor (BAP) is located behind the instrument cluster.
The BAP sensor is a variable capacitance device that, when supplied with a 5V reference signal from ECM,
produces a linear analog voltage signal that indicates pressure.
The BAP signal is used to calculate altitude, which allows ECM to adjust timing and fuel quantity for improved
engine operation and smoke control.
A BAP signal detected Out of Range High or Out of Range Low by the ECM will cause the ECM to ignore the BAP
signal and use the Manifold Absolute Pressure (MAP) signal generated at low idle as an indication of barometric
pressure. If a MAP fault is also detected, the BAP value will default to 29.6 in. Hg (barometric pressure at sea level).
The ECM sends a regulated 5V signal from ECM connector LAM1019, terminal 3, to the BAP connector terminal
2. The BAP sensor returns a variable voltage signal (representing atmospheric pressure) from BAP connector
terminal 3 to the ECM at connector LAM1019, terminal 29. Terminal 1 of the BAP connector is provided a ground
at ECM connector LAM1019, terminal 11.
The ECM continuously monitors signals from the BAP sensor at terminal 29. If a signal is out of the expected
range, a Diagnostic Trouble Code is logged. The warning light does NOT turn on.
BRAKE SWITCH CIRCUIT
The brake switch is located on the air lines in the instrument panel. The switch signals the Electronic System
Controller (ESC) when the brakes are applied. This ESC sends this information to the ECM over the J1939 data
link circuit. It is used by the ECM to disengage cruise control functions and to enable the exhaust brake. The brake
signal will interrupt the cold ambient protection feature and reset the time interval for the idle shutdown feature.
0003–4
TM 9-2355-106-23-1 0003
CAMSHAFT POSITION (CMP) SENSOR
The engine control system includes a CMP sensor located on the front of the engine near the auto belt tensioner.
The CMP sensor, along with a timing disk at the front of the camshaft, provide the ECM with a signal that indicates
camshaft position and engine speed. A narrow vane on the disk (corresponding with a wider window) is used to
indicate the position of the number one piston.
The CMP sensor is a Hall-Effect-type device that generates a digital frequency as windows on the timing disk
pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of
selected windows, allows the ECM to detect engine speed and position. When the narrow vane passes the
CMP sensor, the signal on-time is less than when the other vanes pass the sensor. This produces a signal that
the ECM uses to indicate engine position.
The ECM uses the CMP sensor signal to synchronize piston position with injector firing sequence. The injection
sequence begins when the ECM detects the narrow vane on the timing disk indicating cylinder 1. The piston
position for each cylinder is then continuously calculated as each vane on the timing disk passes by the CMP
sensor. This information is processed by the ECM and used for injection timing and fuel delivery control. The
engine will not operate without a functioning CMP signal.
After every two crankshaft revolutions, the ECM verifies synchronization. If the ECM receives too many or too few
pulses for the number of engine revolutions, it will set a DTC. However, the ECM will attempt to determine the cause
of an invalid signal and identify it with a DTC. CMP codes that are set will become inactive codes if the ignition
switch is turned off. These codes can be retrieved using the MSD, or cruise control switches and the cluster display.
The ECM provides a 5-volt reference signal to CMP sensor terminal B via connector LAM1019, terminal 40. It
provides a ground to CMP sensor terminal A via connector LAM1019, terminal 53. The ECM receives the signal
from CMP sensor terminal C at connector LAM1019, terminal 51.
ENGINE COOLANT LEVEL SYSTEM
The engine coolant level system monitors the engine coolant level. ECM connector 6007, terminal 10 provides a
5-volt reference signal to level sensor terminal A. Terminal B is connected to the ECM signal ground. The magnetic
sensor in the coolant surge tank is open when the tank is full.
The engine coolant level sensor is used with the optional engine warning and protection feature. The coolant level
system monitors coolant level in the surge tank to protect the engine from damage due to operating the engine
when the coolant level is low. When this feature has been enabled and the engine is running, the ECM will cause
the red LOW COOLANT warning light to flash and the warning buzzer to sound if the coolant level is below the
level of the sender in the surge tank. If the system is programmed for engine shutdown, the ECM will cause
the engine to stop running after the coolant level has been depleted below the coolant level sensor and the
preprogrammed warning time has expired. If the engine stops running in this condition, it can be restarted and
run again for the warning time period, provided it is capable of restarting.
DTC 236 will be active when a low coolant situation is present, and the MSD will indicate Engine Coolant Level
Below Warning/Critical level. After the coolant has been restored to proper levels, DTC 323 will remain as an
inactive code and the ECM will log the engine hours of the occurrence.
0003–5
TM 9-2355-106-23-1 0003
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
The engine control system includes an ECT sensor located on the right side of the engine behind the alternator
mounting bracket. The ECT sensor is a thermistor-type device that modifies a 0 to 5V signal by changing
resistance in response to changes in coolant temperature. When the temperature of the coolant decreases, the
resistance of the thermistor increases, which causes the signal voltage to increase. As the temperature of the
coolant increases, the resistance of the thermistor decreases, which causes the signal voltage to decrease. The
ECT sensor is supplied a regulated 5V reference signal at terminal B from ECM connector LAM1019, terminal
13. The sensor is grounded at terminal A through the signal return at ECM connector LAM1019, terminal 19. As
the coolant temperature increases or decreases, the sensor changes resistance and provides the ECM with
the coolant temperature signal.
The ECM uses the ECT signal for engine fan control, coolant temperature compensation, and the optional high
temperature warning and shutdown systems. Coolant temperature compensation is used to protect the engine if
the coolant temperature is too high.
If the coolant reaches 214°F (101°C), the ECM will reduce the fuel delivery by 6% for each °C of temperature
increase. If the coolant temperature increases to 218°F (104°C), fuel quantity will be reduced 3% for each °C
of temperature increase. Coolant temperature compensation can be programmed to be inoperative in certain
applications where full engine performance is required over the protection of the engine. For engines equipped with
an engine warning system, the ECM will activate the audible warning alarm and illuminate the RED OIL/WATER
warning light when the engine coolant temperature reaches 225°F (107°C). For engines equipped with an engine
shutdown system, the ECM will shut the engine off when the coolant temperature reaches 235°F (112.5°C). The
vehicle operator may restart the engine by turning the ignition switch OFF and then restarting it. After restart, the
ECM will allow the engine to run for an additional 30 seconds before shutting it off again.
With the ignition switch ON, the ECM continuously monitors the ECT circuit for expected voltages. If the signal
voltage is more or less than the expected value, the ECM will set a DTC. In that case, the ECM will disregard
the signal voltage and default to a temperature of 180°F (82°C) for engine running operation and -29°F (-33.9°C)
for starting the engine. If the DTC is no longer present, the ECM will return to normal operation using the ECT
signal for processing.
ENGINE CRANK INHIBIT (ECI) SYSTEM
The engine starting system is controlled by the ECM through its control of a ground for the starter relay. The starter
relay controls the current to the helper relay and starter solenoid. While the engine is running, the ECM prevents
starter motor operation and possible damage to the starter pinion and ring gear. In addition, ECM control prevents
the starter motor from engaging unless the transmission is in NEUTRAL.
The ECI system includes the following:
• Gear position input from Transmission Control Module (TCM)
• Ignition switch
• Starter relay
• Starter motor and solenoids
• Batteries and cables
When the ECM recognizes that the engine is not running, it grounds terminal 46 on connector 6007, providing the
TCM signals that the transmission is not in gear. Grounding terminal 46 provides a current path for the starter relay
coil when the ignition switch is moved to START. When the ECM recognizes that the engine is running, the ECM
will open terminal 46. This will prevent the starter relay coil from energizing and the starter motor from engaging.
0003–6
TM 9-2355-106-23-1 0003
ENGINE FAN CONTROL (EFC)
The EFC solenoid provides ON/OFF control for the engine cooling system fan and a load for engine braking
when required. To operate the solenoid, the ECM monitors inputs from the engine coolant temperature and
the exhaust brake signal.
The AIR FAN SHUTTER fuse in the Power Distribution Center provides the fan solenoid with 12 volts when
the ignition is turned ON. The ECM controls the solenoid at connector LAM1019, terminal 8. Normal fan ON
temperature is 212°F (100°C). Normal fan OFF temperature is 207.5°F (97.5°C).
If a malfunction occurs in either the power or ground circuit, EFC is disabled and the engine fan is on all the time.
For test purposes, EFC solenoid can be turned ON/OFF through Key-On, Engine-Off Standard Test on the MSD.
During this test, the ECM performs an output circuit test that momentarily enables the EFC solenoid and measures
the voltage drop across the solenoid. DTC 246 is set only during this test.
ENGINE OIL PRESSURE (EOP) SENSOR
The EOP sensor is a variable capacitance device located near the fuel filter on the left side of the engine. When
pressure is applied to the sensor, the capacitance changes in proportion with the pressure. ECM connector
LAM1019, terminal 40, supplies a regulated 5V signal to terminal B of the EOP sensor. The EOP sensor is supplied
with a signal ground at terminal A by ECM connector LAM1019, terminal 19. The oil pressure signal from the
sensor at terminal C is sent to terminal 14 of ECM connector LAM1019. This signal increases in proportion to an
increase in pressure up to a maximum of 85.3 psi (588 kPa).
The ECM monitors the EOP signal to provide information for the oil pressure gauge and for warning lamp
operation. If the vehicle is equipped with the engine shutdown system and the oil pressure drops to 2.0 psi (14
kPa) @ 700 rpm, 5.0 psi (34 kPa) @ 1400 rpm, or 12.0 psi (83 kPa) @ 2000 rpm, the ECM will shut the engine off.
During engine operation, the ECM compares the expected oil pressure to engine speed. If the ECM detects low oil
pressure for a given engine speed, the ECM will set a DTC. If the oil pressure is lower than the critical level, the
ECM will record a DTC. The ECM automatically records this as a low oil pressure event that cannot be erased
using the MSD. This becomes a record of engine operation.
ENGINE OIL TEMPERATURE (EOT) SENSOR
The EOT sensor is a thermistor-type device which produces a 0 to 5V signal in response to changes in engine
oil temperature. It is located on the back of the front cover on the left side of the engine. The ECM uses the
EOT sensor signal to adjust fuel timing and quantity to compensate for oil viscosity changes during temperature
variations.
When oil temperature decreases, the resistance of the thermistor increases, which causes the signal voltage to
increase. As oil temperature increases, the resistance of the thermistor decreases, causing the signal voltage
to decrease. The EOT sensor is supplied a regulated 5V reference signal at terminal B from ECM connector
LAM1019, terminal 12. A ground circuit is supplied at terminal A by ECM connector LAM1019, terminal 19.
With the ignition switch ON, the ECM continuously monitors the EOT signal to determine if it is within expected
values. If the signal voltage is above or below the expected levels, the ECM will set a DTC. If the ECM detects
an EOT signal that is Out of Range High or Out of Range Low, it will ignore the EOT signal and default to the
ECT sensor. If the ECT sensor is not sending a correct signal, the ECM will default to 29°F (-1.7°C) for starting or
212°F (100°C) for engine running operation.
The AMBER ENGINE lamp is illuminated as long as the DTC condition exists.
0003–7
TM 9-2355-106-23-1 0003
INTAKE AIR TEMPERATURE (IAT) SENSOR
The IAT sensor is a thermistor-type device that modifies a 0 to 5V signal in response to changes in temperature. It
is located on the air filter housing. The IAT signal determines the timing and quantity of fuel required for starting in
cold weather to limit smoke emissions.
When intake air temperature decreases, the resistance of the thermistor increases, which causes the signal voltage
to increase. As intake air temperature increases, the resistance of the thermistor decreases, causing the signal
voltage to decrease. The IAT sensor is supplied a regulated 5V reference signal at terminal B from ECM connector
6007, terminal 11. A return circuit (ground) is supplied at terminal A from ECM connector 6007, terminal 12.
With the ignition switch ON, the ECM continuously monitors the IAT signal to determine if it is within expected
values. If the signal voltage is above or below the expected levels, the ECM will set a DTC. If the ECM detects
an IAT signal that is Out of Range High or Out of Range Low, the ECM will ignore the IAT signal and default to
77°F (25°C).
The AMBER ENGINE lamp is illuminated as long as the DTC condition exists.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The engine control system includes a MAP sensor located on the top of the intake manifold. The ECM measures
the signal from the MAP sensor to determine intake manifold (boost) pressure. From this information, the ECM can
control fuel quantity and modify injection timing for engine operating conditions.
The MAP sensor is a variable capacitance device that produces a linear analog voltage signal. Pressure applied
to the MAP sensor changes the capacitance of the sensor, which varies the signal voltage sent to the ECM. As
boost pressure increases, the signal voltage increases.
The MAP sensor is supplied 5V at sensor terminal B from ECM connector LAM1019, terminal 40. A ground circuit
is supplied to terminal A of the sensor from ECM connector LAM1019, terminal 19. MAP sensor terminal C
provides a signal to ECM connector LAM1019, terminal 30.
The ECM monitors the MAP sensor signal for expected values. If the ECM detects the MAP signal is more or less
than the desired value, it will set a DTC. If an active DTC for the MAP sensor is set, the ECM will ignore the MAP
sensor signal and operate the engine using programmed default values. Active DTCs for the MAP sensor will
cause the ECM to illuminate the amber engine warning light.
VEHICLE SPEED SENSOR (VSS)
The VSS sensor is located in the top of the transfer case.

The transfer case output speed signal is generated by a magnetic pickup that responds to the rotation of a
toothed gear installed in the transfer case. This Alternating Current (AC) sine wave signal is received by the ECM
at connector 6007, terminals 39 and 40. The signal is used with tire size and axle ratio to calculate vehicle
speed. Calculated vehicle speed is transmitted to the instrument cluster on the J1939 data link to operate the
speedometer. Calculated vehicle speed is also used in the control strategies for features such as cruise control
and road speed limiting.
When the ECM determines that the vehicle is operating at 0 mph, it performs diagnostic checks of the VSS circuit.
A voltage signal transmitted by the ECM will detect if the return voltage is Out of Range High or Out of Range Low.
An Out of Range Low DTC normally indicates an open or short to ground. An Out of Range High DTC normally
indicates a short to voltage. When a VSS DTC is detected, the ECM disables cruise control operation. If road
speed limiting is enabled, it will limit engine rpm in all gears.
FUEL SYSTEM
The fuel system consists of three major subsystems:

• Fuel supply system
• Injection Control Pressure (ICP) system
• Fuel injectors
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These subsystems work together to inject pressurized fuel into the combustion chambers. The fuel supply system
delivers fuel from the fuel tanks to the injectors. The ICP system supplies the injectors with high pressure oil, and
the fuel injectors deliver high pressure fuel to the engine in response to ECM inputs.
FUEL SUPPLY SYSTEM
Figure 3. Fuel Supply System.
The fuel supply system includes the following:

• Tank
• Supply lines
• Strainer
• Filter
• Supply pump
• Supply manifold
• Passages (within fuel supply manifold and cylinder head to feed injectors)
• Fuel pressure regulator
• Return lines
Fuel Flow
The suction side of the supply pump draws fuel from the tank to the strainer. Fuel then flows through the strainer
into the supply pump. The pump increases fuel pressure to approximately 65 psi (448 kPa). Pressurized fuel is
pumped through the filter to the supply manifold for distribution through passages in the head to the fuel injectors.
The supply manifold pressure is controlled to 65 psi (448 kPa) by a fuel pressure regulator mounted at the rear of
the manifold. After flowing through the pressure regulator, excess fuel is returned to the tank.
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INJECTION CONTROL PRESSURE (ICP) SYSTEM
Figure 4. Injection System.
The ICP system includes the following components:

• Internal reservoir (cast into the front cover)
• High pressure pump assembly
• Injection Pressure Regulator (IPR)
• High pressure supply hose
• High pressure supply rail
• Drilled passages in the cylinder head
• ICP sensor
The ICP system provides the necessary energy to actuate the injection system hydraulically. Engine lube oil is
the hydraulic fluid used for this purpose.
An oil reservoir integral to the front cover provides a constant supply of oil to a high pressure hydraulic pump
mounted on the front cover. The high pressure pump is a gear-driven, swash-plate-type pump. High pressure oil is
delivered by the high pressure pump to the high pressure oil supply manifold and into passages machined into
the cylinder head.
When the injector solenoid is energized, high pressure lube oil is used to pressurize and atomize fuel. After fuel
injection into the combustion chamber is complete, the solenoid is deactivated. Oil within the injector is vented
through the top portion of the injector and allowed to drain back to the oil pan.
ICP Sensor and IPR Valve
The ECM continuously monitors pressure using the ICP sensor and controls injection pressure by operating the
IPR. This control based on sensor feedback is known as Closed Loop.
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The ICP sensor is a variable capacitance device. When pressure is applied to the sensor, the capacitance changes
in relation to the pressure. The ECM supplies a regulated 5V signal to terminal B of the ICP sensor from ECM
connector LAM1019, terminal 40. The ICP sensor is supplied a ground at terminal A to ECM connector LAM1019,
terminal 19. During engine operation, oil pressure changes sensor capacitance; the incoming 5V reference signal
changes in relation to pressure. The oil pressure signal from the sensor at terminal C is sent to terminal 16 of ECM
connector LAM1019. This signal increases equally in proportion to an increase in pressure.
The IPR valve is sent a pulse width modulated signal by the ECM to control the pressure of the oil in the ICP
system. The pulse width is modulated between 8% and 60% to control pressure in the range of 500-3000 psi
(3.4-20 MPa). The regulator is mounted in the high pressure oil pump and maintains desired injection control
pressure by dumping excess oil through an (internal shuttle) spool valve into the front cover and back to the oil pan.
Diagnostic codes can be set by the ECM if the ICP electrical signal is out of range or if the ICP signal received
corresponds to an out-of-range value for the ICP for a given operating condition.
If these failures occur, the ECM will ignore the ICP signal and control the IPR valve from programmed default
values. This is called open loop operation.
FUEL INJECTOR OPERATION
The ECM controls:

• Correct firing sequence
• Injector timing
• Injection duration
The ECM monitors engine speed and cylinder positions by constantly monitoring the camshaft position sensor
signal. When the narrow vane of the timing sensor disc passes in front of the camshaft position sensor, the
difference in the signal it generates indicates the position of piston 1. The positions of pistons 2 through 6 are
based on the position of piston 1.
The ECM provides a constant ground path to all fuel injectors.
By using output driver transistors, the ECM supplies 115+ volts DC to each injector, following the firing order 1, 5,
3, 6, 2, 4. The ECM has an output driver for each fuel injector.
The 115+ volt DC supply is created by the ECM by making and breaking a 12-volt source across an internal coil,
based on the same principle as an automotive ignition coil.
The injection operation is divided into three stages:
1. Fill stage
During the fill stage, the injector solenoid is deactivated and the poppet valve is closed, preventing the
flow of high pressure oil to the intensifier piston. At this point, the intensifier piston is up, allowing fuel to
enter and fill the injector nozzle.
2. Injection stage
To initiate injection, the ECM energizes the solenoid. This rapidly lifts the poppet valve from its seat, allowing
high pressure oil to enter the injector. At the intensifier piston, pressure is transmitted from the high pressure
oil to the fuel and multiplied 6 to 7 times, creating fuel injection pressures of up to 21,000 psi (145 MPa).
As fuel pressure increases, check valves prevent the fuel from flowing back to the supply manifold.
When pressure is high enough to lift the needle valve, high-pressure atomized fuel is injected into the
combustion chamber.
3. End of injection
When injection is complete, the ECM deactivates the solenoid; the poppet valve and intensifier piston return
to their closed position, and the injector returns to the fill stage.
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Injector Scuff Test
The injector scuff test detects problems with injection and combustion. The test analyzes the individual contribution
of each power cylinder. Its primary function is to detect a bad injector, although it will also detect problems that
could affect the cylinder performance (i.e., valves, push rods, pistons, rings, etc.). Further diagnostic testing may
be necessary to resolve mechanical issues. During this test, the ECM controls fuel delivery and determines each
cylinder’s power contribution. If a cylinder is not performing satisfactorily, a DTC may be set.
TRANSMISSION
Figure 5. Transmission Control Module (TCM) Inputs and Outputs.
Operators select automatic or manual shifts with the shift selector module in the center instrument panel. In DRIVE
(D), the transmission automatically shifts through gears 1-5. Up and down arrows on the shift selector provide the
option of manual shifts. The shift selector is one of several inputs the TCM uses in shifting between gears. For
main transmission inputs and outputs, refer to Figure 5.
The TCM is located on a bracket mounted on the left frame rail above the transmission. The TCM communicates
with the vehicle electrical system via an 80-way connector. A 20-way connector on the back of the transmission
housing connects the TCM to the transmission internal wiring harness.
To provide 5 forward gear ratios and 1 reverse gear ratio, the transmission employs solenoids to control five
clutches, which hold or release parts of 3 planetary gear modules. In the event of electrical system failure,
transmission valves are designed to return to default hydraulic positions and provide limp-in gear ratios.
The TCM monitors transmission circuits for proper operation and records DTCs when it detects malfunctions.
DTCs can be retrieved with the MSD or by using shift selector UP and DOWN buttons and the shift selector display.
Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012) for details.
TRANSFER CASE
The switch pack in the center instrument panel provides inputs to Electronic System Controller (ESC) for transfer
case operation. The ESC then operates the solenoids that route air pressure to transfer case shift mechanisms. A
shift fork and collar connects the input shaft to low-range or high-range gears, which are coupled to an idler gear
assembly. The idler gear then turns the gear on the rear output shaft. A pushrod and shift fork connects the gear
on the rear output shaft to a gear on the front output shaft for front axle operation.
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BRAKE AND PNEUMATIC SYSTEMS
Figure 6. Brake and Pneumatic System Components.
For brake and pneumatic system component identification and location, refer to Figure 6.
The M1224 and M1224A1 vehicles are equipped with air-operated drum brakes on all four wheels and an
Antilock Brake System (ABS).
The ABS Electronic Control Unit (ECU) employs wheel speed sensors and ABS modulator valves to enhance
vehicle control during braking. The ECU uses wheel speed sensors to monitor individual wheels for locking
tendencies and for feedback during antilock braking. The ECU operates the pressure modulator valves to adjust
the brake pressure at each wheel, optimizing traction between the tire and the road surface.
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At brake actuation, air pressure in the brake chamber rotates the S-camshaft, which then pushes rollers located on
the brake shoes against the brake drum. When a brake shoe is forced into the drum, friction slows the movement
of the drum to stop the vehicle.
The ABS uses an ABS modulator valve to regulate the flow of air to the brake chambers during braking.
An air dryer removes moisture from the compressed air provided by the air compressor. The air dryer uses a
replaceable desiccant cartridge to remove moisture. The air dryer periodically purges moisture out of a purge vent.
To prevent brake lag, a relay valve is used to actuate the brakes. Brake lag is the amount of time between when
the operator actuates the foot valve and the air reaches the brake chambers. The relay valve controls the flow
of air between the brake chambers and the reservoirs. The foot valve provides air pressure to the relay valve,
and the relay valve opens and closes in proportion to the amount of pressure applied by the foot valve. Since
the relay valve can flow more air than the foot valve, brake lag is limited.
The vehicle brake pedal is connected to a foot valve that controls air pressure to the brake chambers. The
pressure is determined by the driver’s pedal stroke.
The ECU monitors ABS circuits for proper operation and records DTCs when it detects malfunctions. The DTCs
can be retrieved via the MSD or via the cluster ABS indicator lamp and an ABS blink switch to the left of the
steering column. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012) for details.
Air pressure is supplied by an engine-driven air compressor. The system has two air supply tanks. One tank
supplies air for the front (secondary) brake system. The other supplies air to the rear (primary) brakes. The rear
axle also has spring-applied parking brakes.
Pneumatic cylinders assist the opening and closing of the armor-reinforced cabin doors. Air is routed to the
cylinders by air valves connected to the latch handle assembly. M1224 models that have the lower combat
door lock type have a single-cylinder for each door. M1224 models that have the upper combat door lock type
have dual cylinders. Linkage rods feature adjustable ends for door latching and air valve operation adjustment.
Door opening and closing speed is also adjustable.
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STEERING AND SUSPENSION
Figure 7. Steering Components.
For steering and suspension component identification and location, refer to Figure 7.
The power steering pump is mounted on the left side of the engine, behind the air compressor. The pump supplies
high pressure fluid to the steering gear. A remote reservoir receives return fluid from the steering gear and
routes it back to the power steering pump.
Upper and lower king pin bushings are pressed into the axle housing and are replaceable separately. The kingpins
allow the front wheels to pivot and turn the vehicle.
The tie rod assembly consists of two tie rod ends and a connecting tube or tie rod. The length of the tie rod
assembly is adjustable to allow front wheel alignment.
The suspension on the M1224 and M1224A1 consists of front and rear leaf springs and front shock absorbers.
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The power steering fluid reservoir is located near the radiator above the left front tire. The reservoir stores and
cools fluid that is not currently being used by the power steering pump.
The steering wheel and steering column inside the cab and the steering shaft in the engine compartment provide
input to the steering gear, mounted above the left frame rail near the bumper. A pitman arm and drag link connect
the steering gear to a steering arm on the left kingpin assembly.
TIRES AND WHEELS
The M1224 is equipped with 395/85R20 tires mounted on two-piece, 20-inch forged aluminum wheels. The wheel
inner and outer pieces are bolted together and have an internal O-ring seal between them. The tire and wheel
assemblies also incorporate a Variable Function Insert (VFI) that provides run flat capability and prevents the
tire beads from excessive movement on the wheel.
ELECTRICAL SYSTEM COMPONENTS AND POWER DISTRIBUTION
Figure 8. Electrical System Components.
The vehicle has a dual electrical system with four batteries in a series-parallel configuration that provides 12V or
24V power. The batteries are located behind a cover below the right door.
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The system uses a 24V high output alternator for battery charging.
Four lead-acid batteries, rated at 725 CCA each, are connected in series-parallel. The batteries are split into two
pairs. Each pair of batteries is wired in series and has a battery equalizer to provide 12V or 24V power. The 12V
and 24V outputs from each pair of batteries are wired in parallel to the mag switches.
The battery equalizers, mounted near the batteries, regulate power between the 12V and 24V batteries. The
battery equalizer has three connections: 24V battery positive, 12V battery positive, and ground. The battery
equalizer senses the voltage of each battery. When a 12V load is activated, 12V battery voltage will begin to
drop. The equalizer will pull 24V energy from the 24V battery, convert it to 12V energy, and provide it to the 12V
battery until voltages between the two batteries are equal. In effect, the battery equalizer allows 12V loads to
pull equally from both batteries.
The vehicle is equipped with an 1800–watt, 110V, alternating current (AC) inverter to provide power for auxiliary AC
equipment. A 110V outlet is located in the rear storage box. The NATO jump start connector is also located there.
The jump start connector is wired directly to the batteries.
The 110V power inverter has the following features:
• 1800-watt AC output with 2900-watt surge capacity
• True sine wave AC output
• Powersave mode that draws only 1.5 watts with no load
• Over-temperature shutdown and automatic overload protection
• Over-voltage and under-voltage protection
• Short circuit and AC back-feed protection
The transmission control module is a microprocessor that controls the operation of the transmission.
The primary power distribution and control points in the electrical system are the MAIN POWER switch, the 12V and
two 24V mag switches, megafuses, engine compartment power distribution center, and cabin fuse and relay center.
The MAIN POWER switch provides a ground for 12V and 24V mag switches in the battery compartment. The
mag switches, in turn, supply both 12V and 24V power to the power distribution center and the cabin fuse and
relay center.
In addition, this 24V mag switch provides a feed for 24V body systems such as the remote controlled spotlight,
climate control, Fire Suppression System (FSS), and rear door pump motor. The vehicle winch is powered by the
unswitched side of this 24V mag switch and protected by a 300-amp megafuse.
Another 24V mag switch provides power to an inverter that supplies 110V AC at the right front and right rear
storage boxes. This circuit is protected by a separate 150-amp megafuse.
The 12V mag switch supplies power to a junction with a 100-amp megafuse near the power distribution center.
From the unfused side of the megafuse, power is supplied to the Electronic System Controller (ESC) and to the
12V battery feed for the chassis. From the fused side of the megafuse, power is supplied to the cabin fuse
and relay center.
24V power is supplied from the vehicle batteries to the starter motor solenoid terminal 2 on a 4/0 cable. The
negative battery terminals are connected to the starter motor ground stud. The negative battery terminals are
also connected directly to the frame rail. The engine block ground, cab, and frame are connected by ground
cables or circuits to the starter motor ground.
The engine control module is a microprocessor that control the operation of the diesel engine.
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STARTING CIRCUIT
Starting system components include the ignition switch, starter ISO and power relay, engine crank inhibit circuit,
helper relay, starter solenoid, and starter motor. In the START position, the ignition switch routes 12 volts to the
coil side of the starter ISO and power relay. As long as the engine is not running and the transmission is not in
gear, the engine crank inhibit circuit provides a ground for the coil. As a result, the ISO and power relay supplies a
24-volt feed to the helper relay. The helper relay then provides 24 volts to the starter solenoid, which supplies the
starter motor with battery power.
CHARGING CIRCUIT
When the vehicle is running, the alternator supplies 24V power through two positive alternator terminals. Wiring
and fusible links connect these terminals to the starter motor solenoid positive battery stud. From this stud, current
flows to the batteries through the positive battery cable.
Wiring connects two negative terminals on the alternator to engine block grounds above the starter motor.
DATA LINK CIRCUITS
Figure 9. J1939 Data Link Circuit (Chassis).
For a diagram of the chassis part of the J1939 data link circuit, refer to Figure 9.
For a diagram of the cabin part of the J1939 data link circuit, refer to Figure 10.
Multiplexing, in the form of data link circuits, simplifies module communication and reduces wiring complexity on
the M1224. The vehicle uses two types of data link circuits; J1708 and J1939. Both are two-wire systems. The
J1708 data link is often referred to as American Trucking Association (ATA), and J1939 is often referred to as
Controller Area Network (CAN).
There are three separate data links used on the vehicle:
• Drivetrain J1939 data link - This data link provides the main path for communication between vehicle modules:
engine controller, transmission controller, Antilock Brake System (ABS) controller, Instrument Panel Cluster
(IPC), ESC, and the shift selector module. The circuit terminates at each end with a 120-ohm resistor, one
above the transmission and the other behind the right side of the instrument panel. An additional branch of the
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J1939 data link circuit is routed to the data link connector and provides a link for the Maintenance Support
Device (MSD). The data link connector is located to the left of the steering column.
• Switch data link - This J1708 data link provides a path for communication between the center panel switch
pack and ESC.
• J1708 data link - This data link connects the ECM to the data link connector for engine diagnostics.
Figure 10. J1939 Data Link Circuit (Cabin).
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ELECTRONIC SYSTEM CONTROLLER (ESC)
Figure 11. ESC.
The ESC is mounted below the instrument panel to the left of the steering column. It connects with the vehicle
electrical system via two 36-way connectors and three 8-way connectors. Power is provided by a cable from the
unfused side of the 100-amp mega fuse in the engine compartment. The ESC receives inputs from switches and
sensors and distributes electrical power to provide the driver with control over vehicle systems and indications of
vehicle performance. It performs the following functions:
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• Communicates with the IPC on the J1939 data link to display vehicle information and system diagnostics.
• Communicates with the instrument panel switch pack through a dedicated J1708 data link.
• Receives input from the switch pack and controls power to the solenoid air pack for transfer case operation.
• Receives inputs from the switch pack and sends requests for exhaust brake operation to the ECM.
• Receives inputs from the cruise control switches and sends requests for cruise control operation to the ECM.
• Receives inputs from steering column switches and controls the horns, turn signals, and washers/wipers.
• Receives inputs from the brake switch to control the brake lights.
• Communicates with the IPC on the J1939 data link to supply the service headlights with power.
DIAGNOSTICS
The ESC monitors circuits for proper operation and records Diagnostic Trouble Codes (DTCs) when it detects
malfunctions. DTCs can be retrieved with the Maintainance Support Device (MSD) or by using the CRUISE ON
switch and the cruise RESUME/ACCEL switch and the Instrument Panel Cluster (IPC) display. Refer to Diagnostic
Trouble Code (DTC) Access Procedure (WP 0012) for details.
SWITCH PACK
The switch pack module is located in the center instrument panel. The mechanical assembly for each switch snaps
into the switch receptacle and can be released from the rear of the switch pack. The switches communicate with
the ESC over a dedicated J1708 data link. Switch positions and functions are programmed into the ESC. Based on
switch inputs, the ESC operates vehicle features or sends messages to other modules requesting operation.
Some switches will flash when a switch is malfunctioning or there is an error associated with the feature controlled
by the switch. The ESC continuously monitors switch pack communication on the switch data link. In most cases,
the switch pack will notify the ESC if one of the individual switches has failed. In addition, if a switch pack fails to
communicate with the ESC within the expected period of time, the ESC will record a DTC.
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INSTRUMENT PANEL CLUSTER (IPC)
Figure 12. IPC Gauges, Digital Display, and Reset Switch.
Table 1. Gauges, Digital Display, and Reset Switch.

LOCATION COMPONENT GAUGE MIN./GAUGE WARNING LIGHT TRIP POINT
MAX.
1 Tachometer 0-3000 rpm N/A
2 Speedometer 0-85 mph (0-137 kph) N/A
3 Engine coolant 140/260°F (60/126°C) > 230°F (> 110°C)
temperature gauge
with integral warning light
4 Transmission oil 100-400°F (38-204°C) > 250°F (121°C)
temperature gauge
with integral warning light
5 Engine oil pressure 0-100 psi (689.48 kPa) < 7 psi (48.26 kPa) and engine speed
gauge with integral > 325 rpm
warning light
5 Engine oil temperature 100-300°F (38-149°C) > 230°F (> 110°C)
gauge with integral
warning light
7 Fuel level gauge with Empty/Full < 12.8%
integral warning light
8 Primary air pressure 0-150 psi (1034 kPa) < 70 psi (482 kPa)
gauge with integral
warning light
9 Voltmeter gauge with 10/16 volts < 12V or > 15.0V DC and engine
integral warning light speed > 325 rpm
(12-volt system only)
10 Secondary air pressure 0-150 psi (1034 kPa) < 70 psi (482 kPa)
gauge with integral
warning light
11 Digital display
12 Reset switch
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Figure 13. IPC Lights.
Table 2. Warning Lamps.

LOCATION WARNING LIGHT REPRESENTATION COLOR DRIVEN BY
1 Range inhibited RANGE INHIBITED YELLOW Status transmitted on drivetrain
J1939 data link from ESC.
Input to ESC from transmission
controller.
2 Economy ECON N/A Lamp is not used.
3 Fuel filter FUEL FILTER N/A Lamp is not used.
4 Warn engine ENGINE YELLOW Status transmitted on drivetrain
J1939 data link from engine
controller.
5 Stop engine ENGINE RED Status transmitted on drivetrain
J1939 data link from engine
controller.
6 Brake warning BRAKE N/A Lamp is not used.
7 Brake fluid BRAKE FLUID N/A Lamp is not used.
8 Wait to start WAIT TO START N/A Lamp is not used.
9 Check transmission CHECK TRANS YELLOW Status transmitted on drivetrain
J1939 data link from ESC.
Input to ESC from transmission
controller.
10 Trailer ABS Trailer ABS icon YELLOW Status transmitted on drivetrain
J1939 data link from ESC. Input
to ESC from ABS controller.
11 Washer Fluid WASHER FLUID N/A Lamp is not used.
12 Left turn Left turn signal icon GREEN Status transmitted from ESC
on drivetrain J1939 data link.
Input to ESC from turn signal
switch.
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13 Traction control TRAC CTRL N/A Lamp is not used.

14 Water in fuel WATER IN FUEL YELLOW Status transmitted on drivetrain
to ESC from fuel filter. (Does
not light up during testing
procedures.)
15 Service park brake SERVICE (P) N/A Lamp is not used.
16 Check electrical CHECK ELEC SYS N/A Lamp is not used.
system
17 Park brake PARK BRAKE RED Status transmitted on drivetrain
to ESC from park brake switch.
18 Cruise control active CRUISE GREEN Active status transmitted on
drivetrain J1939 data link from
ESC. Input to ESC from cruise
switch.
19 Antilock braking ABS icon YELLOW Status transmitted on drivetrain
system J1939 data link from ESC. Input
to ESC from ABS controller.
20 Right turn Right turn signal icon GREEN Status transmitted on drivetrain
to ESC from turn signal switch.
21 Coolant level COOLANT LEVEL RED Status transmitted on drivetrain
J1939 data link from ESC. On
when coolant level < 25%.
Input to ESC from surge tank.
22 Fasten seatbelt Fasten seatbelt icon RED Status transmitted on drivetrain
J1939 data link from ESC. On
when engine on, occupants in
driver and commander seats,
and seatbelts unfastened
23 High beam High beam icon BLUE Status transmitted on drivetrain
to ESC from high beam switch.
24 Idle shut down IDLE SHUT DOWN N/A Lamp is not used.
25 Blank N/A N/A Lamp is not used.
26 Retard Overheat RETARD OVERHEAT N/A Lamp is not used.
27 Power take-off PTO N/A Lamp is not used.
28 Front axle differential FR AXLE DIFF LOCK N/A Lamp is not used.
lock
29 Rear axle differential RR AXLE DIFF LOCK N/A Lamp is not used.
lock
30 Snow valve SNOW VALVE N/A Lamp is not used.
31 Front axle engaged FR AXLE ENGAGED N/A Lamp is not used.
For IPC gauge, digital display, and reset switch location, refer to Figure 12 For IPC warning light location, refer to
Figure 13.
The IPC components include gauges, warning lamps, a digital display, a display set/reset button, an audible alarm,
and a panel dimmer switch. The IPC communicates with the Electronic System Controller (ESC) and other
controllers through the J1939 data link.
GAUGES
The IPC has nine stepper motor-driven gauges. All gauges except the speedometer and tachometer have their
own warning lights, which signal the operator when gauge readings are outside preset limits.
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GAUGE DATA
The IPC continuously monitors incoming gauge data for out-of-range or data-not-present conditions. If the data is
out of range, the cluster or gauge pack will turn on the Light Emitting Diode (LED) embedded in the respective
gauge.
If data is not available for a small gauge in the IPC, the needle will be driven clockwise to the 6 o'clock position. If
data is not available for the speedometer or tachometer, the gauge will repeat the following sequence three times:
1. Go immediately to the zero position.
2. Sweep up to the 50% position.
3. Sweep back to zero.
4. Pause.
GAUGE, WARNING LAMP, AND LCD CHECK AT KEY ON
After the ignition is turned on, the Instrument Panel Cluster (IPC) displays a gauge and lamp check sequence. All
gauges must sweep from zero to maximum to zero in unison. All of the gauge warning lights will illuminate along
with the panel warning lights that are associated with features installed on the vehicle. The alarms associated
with each gauge warning light do not sound. All of the segments of the IPC Liquid Crystal Display (LCD) should
display while the gauges sweep. At the end of the sweep, the LCD will turn off all segments for 5 seconds, display
the firmware version number, and then return to operational mode. The lights controlled by the panel dimmer in
the IPC will also come on during the gauge sweep.
If the instrument cluster experiences a system fault, it will transmit a fault message to the Electronic System
Controller (ESC).
Mode and Select/Reset Switch
The IPC includes a select/reset switch, used to control the digital display. The switch interfaces directly with
the IPC and is located on the lower right of the IPC lens. The switch allows the user to select modes within
each major area of the display and perform reset functions. Each time the switch is momentarily depressed, the
display will progress to the next mode. Depressing the switch for 3 seconds while in the odometer mode will
switch the display between miles and kilometers. Depressing the switch for 3 seconds or more in other modes
will clear the display or toggle between options, depending upon the current mode. The reset function has no
effect if the parameter cannot be reset.
AUDIBLE ALARM SYSTEM
The Instrument Panel Cluster (IPC) contains an audible alarm that is capable of producing different beep counts
and beep durations. The alarm type for each gauge is determined by the alarm code programmed for that gauge in
the Electronic Systems Controller (ESC).
Pressing and holding the top of the panel dimmer switch and the set/reset switch for 5 seconds will disable the
cluster alarm for all warning conditions until the engine speed reaches 325 rpm or the ignition is cycled.
One-Time, Five-Short-Beeps Alarm
An out-of-range value in any of the following gauges will trigger a one-time, five-short-beeps, audible alarm and
visual indicator light in the corresponding gauge. The alarm will sound only once per gauge during each ignition
cycle.
• Fuel level
• Voltmeter
• Engine oil pressure
• Engine coolant temperature
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TM 9-2355-106-23-1 0003
• Transmission oil temperature

• Engine oil temperature
Repetitive, One-Long-Beep Alarm
An out-of-range-value in either of the following gauges will trigger a repetitive, one-long-beep, audible alarm
and visual indicator light in the corresponding gauge. The alarm will stop as soon as normal conditions are
re-established.
• Primary air pressure

• Secondary air pressure
One-Time, 10-Short-Beeps Alarm
A loss of communication to the IPC from the ESC or engine controller on the J1939 data link will trigger a one-time,
10-short-beeps, audible alarm.
One-Time, Three-Long-Beeps Alarm
A sensor fault error will result in the small gauge pointer being driven clockwise to the 6 o'clock position and a
three-long-beep audible alarm. The same audible alarm accompanies the speedometer and tachometer if they are
missing data. The gauge pointers in the speedometer and tachometer will repeat the following sequence three
times and then park the pointer at the minimum position until the sensor fault is no longer active.
1. Go immediately to the zero position

2. Sweep up to a 50% position
3. Immediately sweep back to zero
4. Pause
Repetitive Short-Duration Blips
The turn signal will be accompanied by a sequence of short blips synchronized with the flashing of the lamps. This
audio indicator repeats each time the ESC requests that the IPC turn on the turn signal lights. The audio indicator
does not accompany the application of the hazard lights.
HEATING VENTILATION and AIR CONDITIONING (HVAC)
Figure 14. HVAC/LSS System Controls.

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TM 9-2355-106-23-1 0003
Figure 15. HVAC System Air Conditioning (A/C) Diagram.
For HVAC/LSS controls refer to Figure 14 For an HVAC/LSS system A/C diagram refer to Figure 15.
0003–27
TM 9-2355-106-23-1 0003
Airflow
Fresh air is drawn through the fresh air inlet tube, which is located behind the passenger seat and connected
between the roof and HVAC/LSS box. The Fresh Air (FA) blower forces air through the Nuclear, Biological, and
Chemical (NBC) filter and across the A/C evaporator and heater core. Conditioned air is then mixed with recycled
cabin air and distributed throughout the cabin by the Recycled Air (RA) blower.
The FA blower and RA blower are running anytime the LSS switch is in the ON position. The FA blower speed is
not adjustable and is limited to 100 cubic feet per minute (cfm) by the NBC filter. The RA blower speed can be
controlled with the R/A FAN SPEED control knob on the HVAC/LSS operator panel. The HVAC/LSS employs a
cabin overpressure strategy that utilizes the FA blower and an overpressure relief valve to achieve a cabin pressure
of 2.8 inch W.C. (± 0.8 inch W.C.) (700 pascal [± 200 pascal]) above atmospheric pressure. The overpressure relief
valve is located in the cabin roof, near the back of the cabin, on the left side.
Operating Modes
The HVAC/LSS operator panel offers four operating modes: VENT, COOL, HEAT, and DRY. Mode doors are not
used to control temperature. The A/C compressor is commanded on for cooling, and coolant is routed to the heater
core for heating. A manually operated mode door can redirect some air from the main air duct to the defogging air
duct to eliminate moisture from the windshield. Mode switch operation is as follows:
• VENT mode selected and LSS switch ON: FA and RA blowers will be commanded on. RA blower speed may
be changed via the R/A FAN SPEED knob. The HVAC/LSS will not heat or cool the cabin air in this mode.
• COOL mode selected, LSS switch ON: engine running. FA and RA blowers will be commanded on. RA
blower speed may be changed using the RA/FAN SPEED knob. If the transmission is in N (NEUTRAL), the
Climate Control Unit (CCU) will command an increased idle speed by sending a 24V signal through the
high idle request circuit to the AIR COND relay. The AIR COND relay will complete a ground circuit to the
Electronic Systems Controller (ESC). The ESC sends a high idle speed request via the J1939 data link to
the engine controller. The engine controller will increase engine speed to 1,300 rpm (± 800 rpm) within 10
seconds. If transmission gear selector is taken out of N (NEUTRAL) or the parking brake (YELLOW knob) is
not applied, the engine speed will immediately return to base engine idle speed.
The CCU monitors the RA temperature sensor to determine if the A/C compressor should be commanded
on. The CCU will command the A/C compressor on only when RA temperature is warmer than 67°F (± 4°F)
(19.4°C [± 2°C]). The condenser fans turn on when A/C system high-side pressure reaches 232 psi (± 25.4
psi) (1,600 kPa [± 175 kPa]). The freeze switch will signal the CCU to turn off the A/C compressor clutch if
the A/C evaporator temperature is colder than 39.2ºF (± 3.6ºF) (4ºC [± 2ºC]). It will not turn back on until A/C
evaporator temperature is warmer than 42.8ºF (± 3.6ºF) (6ºC [± 2ºC]).
• HEAT mode selected, TEMPERATURE LEVEL switch in maximum heat position, and LSS switch ON:
Engine running at operating temperature, FA and RA blowers will be commanded on. The RA blower
speed may be changed using the R/A FAN SPEED knob. The CCU monitors the RA temperature sensor
and opens or closes the 3-way valve to divert hot engine coolant to the heater core to regulate cabin
temperature. The A/C compressor will not be commanded on in this mode.
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TM 9-2355-106-23-1 0003
• DRY mode selected, LSS switch ON: engine running. FA and RA blowers will be commanded on. The
RA blower speed may be changed using the R/A FAN SPEED knob. If the transmission gear selector is
in N (NEUTRAL), the CCU will command an increased idle speed by sending a 24V signal through the
high-idle request circuit to the AIR COND relay. The AIR COND relay will complete a ground circuit to the
Electronic Systems Controller (ESC). The ESC sends a high-idle speed request via the J1939 data link
circuit to the engine controller. The engine controller will increase engine speed to 1,300 rpm (± 800
rpm) within 10 seconds. If transmission gear selector is taken out of N (NEUTRAL) or parking brake
(YELLOW knob) is not applied, the engine speed will immediately return to base engine idle speed. The A/C
compressor will be commanded on. Within about 15 seconds, the condenser fans will be commanded on. In
this mode, the compressor will continue running while the condenser fans cycle on and off to keep A/C
high-side pressure between 174 psi (± 29 psi) and 232 psi (± 25.4 psi) (1,200 kPa [± 200 kPa] and 1,600
kPa [± 175 kPa]). The CCU uses the trinary medium switch to monitor high-side refrigerant pressure to
determine condenser fan operation. The CCU will command the 3-way valve to divert hot engine coolant to
the heater core in the HVAC/LSS. The CCU monitors the RA temperature sensor and opens or closes the
3-way valve to divert hot engine coolant to the heater core to regulate cabin temperature. Air is heated and
dehumidified in DRY mode.
NOTE
In DRY mode, when the three-position TEMPERATURE LEVEL switch is cycled from cool to
warm, the A/C compressor and condenser fans may shut off for 2-8 minutes. During this time,
turning the LSS switch off, then back on, will reset the system, restarting the A/C compressor
and condenser fans. If the LSS switch is not switched off and then back on, the CCU will
automatically reset and restart the A/C compressor and condenser fans.
0003–29
TM 9-2355-106-23-1 0003
FIRE SUPPRESSION SYSTEM (FSS)
Figure 16. Fire Suppression System Chassis Components.
0003–30
TM 9-2355-106-23-1 0003
Figure 17. Fire Suppression System Cabin and Hood Components.
For fire suppression system chassis component location and identification, refer to Figure 16. For fire suppression
system cabin and hood component location and identification, refer to Figure 17.
The vehicle is equipped with a sensor-activated and crew-operated fire suppression system (FSS) with four
subsystems that protect the cabin and occupants, the engine, the tires, and the fuel tank.
The cabin protection system uses a water mist spray without chemical additives, designed to protect occupants
from extreme heat for a period of 3 minutes. There are different media for the other three areas: HFC227ea Clean
Agent for the engine, Petrotech TM25 for the tires, and Dry Powder ABC 70 for the fuel tank.
The control unit for the FSS is located between the driver and front passenger seats.
Fire suppression cylinders are under pressure when full. Each fire suppression unit incorporates a 24V
pressure-sensing transducer and a 24V dispersion solenoid. The transducers send a signal to the fire suppression
control box to indicate the state of charge. When the 24V dispersion solenoid is activated, pressure in the
suppression unit cylinder forces the fire suppression media to escape through corresponding dispersion hoses,
pipes, and nozzles.
There are two heat detector sensor modules and detection circuits. The sensor module for the cabin heat detector
is located inside the vehicle at the right front A-pillar near the floor. The sensor wire runs up the A-pillar, to the
rear of the vehicle along the interior roof, along the back of the vehicle, and then forward. If a sudden increase in
temperature is detected along this wire, the control unit will activate the cabin fire suppression unit. If the heat
detector fails to detect a fire, the CABIN switch on the control unit can be used to override the heat detector and
activate the cabin fire suppression unit.
The engine compartment heat detector sensor module and circuit are located under the hood in the engine
compartment. If a sudden increase in temperature is detected along this wire, the control unit will activate the
engine fire suppression unit. If the heat detector fails to detect fire, the ENGINE switch on the control unit can be
used to override the heat detector and activate the engine fire suppression unit.
0003–31
TM 9-2355-106-23-1 0003
There are no heat detectors for the tires or the fuel tank. The fire suppression units are manually activated by
using the corresponding switch on the control box.
The control unit manages the automatic and manual functions of the FSS and monitors the pressure in the fire
suppression units. A RED LED is provided for each fire suppression unit. An illuminated RED LED indicates
one of several conditions:
• An automatic or manual request for fire suppression was received.
• The corresponding fire suppression cylinder is low on pressure or is empty.
• An open circuit between the control box and the corresponding fire suppression unit has been detected.
All four RED LEDs will illuminate when the LAMP TEST button is pushed.
The GREEN light will illuminate when the MAIN POWER switch and FSS power switch are turned on.
REAR DOOR/RAMP
Figure 18. Rear Door Ramp System Diagram.
For rear door/ramp system component identification and location, refer to Figure 18
Hydraulic pressure controls the movement of the rear door/ramp assembly and related components. The following
components are part of the hydraulic lift system:
• The hydraulic power unit (HPU) consists of the electric motor and pump, manifold, hand pump, and, on some
HPUs, an accumulator. The HPU is fastened to vehicle-mounted brackets at the right rear corner of the crew
0003–32
TM 9-2355-106-23-1 0003
compartment. The manifold uses solenoids to direct the hydraulic fluid in the proper direction to extend or retract
the rear door/ramp hydraulic cylinder. Operator switches located on the pump cover and center instrument
panel energize the pump and solenoids. On vehicles so equipped, the accumulator stores the hydraulic fluid
necessary to operate the system. A hand pump is incorporated into the HPU to allow manual operation of the
hydraulic system if there is an electrical system failure. A hose at the bottom of the motor and pump or, on
vehicles so equipped, the accumulator transfers hydraulic fluid to the hand pump for manual system operation.
• Two hydraulic hoses connect the HPU manifold to the hydraulic cylinder manifold. Hydraulic fluid is directed
through the hoses by the solenoids on the HPU manifold.
• The hydraulic cylinder consists of a hydraulically operated cylinder with a manifold and, on some cylinders, a
counterbalance valve. In response to switch input, the manifold on the HPU directs fluid through hoses, to the
proper side of the hydraulic cylinder's manifold, to raise or lower the rear door/ramp. The hydraulic cylinder
is attached to the rear door/ramp and the roof-mounted interior bracket. Cylinder movement is dampened
by a gas spring.
END OF WORK PACKAGE
0003–33/blank
TM 9-2355-106-23-1
CHAPTER 2
TROUBLESHOOTING PROCEDURES
FOR

TM 9-2355-106-23-1 0004
FIELD MAINTENANCE
TROUBLESHOOTING INDEX
Malfunction/Symptom Troubleshooting Procedure
General Information
1. Vehicle Troubleshooting Symptom Index . . . . . . . . . . . . . . . . .WP 0005
2. Engine Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . . . . .WP 0006
3. Electronic System Controller (ESC) Diagnostic Trouble Code (DTC) Index . .WP 0007
4. Transmission Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . .WP 0008
5. Antilock Brake System (ABS) Diagnostic Trouble Code (DTC) Index . . . . .WP 0009
6. Vehicle Operational Checkout Procedure . . . . . . . . . . . . . . . . .WP 0010
7. Connecting Maintenance Support Device (MSD) . . . . . . . . . . . . . .WP 0011
8. Diagnostic Trouble Code (DTC) Access Procedure . . . . . . . . . . . . .WP 0012
9. Clearing Inactive Diagnostic Trouble Code (DTC) Procedure . . . . . . . .WP 0013
Engine
10. Engine Mechanical Operational Checkout Procedure . . . . . . . . . . .WP 0016
11. Boost Pressure Operational Checkout Procedure . . . . . . . . . . . . .WP 0023
12. Charge Air Cooler Pressure Operational Checkout Procedure . . . . . . .WP 0024
13. Crankcase Pressure Operational Checkout Procedure . . . . . . . . . . .WP 0025
14. Engine Oil Operational Checkout Procedure . . . . . . . . . . . . . . .WP 0018
15. Engine Oil Pressure (EOP) Sensor Troubleshooting Procedure . . . . . . .WP 0028
16. Engine Oil Temperature (EOT) Sensor Troubleshooting Procedure . . . . .WP 0029
17. Engine Systems Operational Checkout Procedure . . . . . . . . . . . .WP 0017
18. Injection Control Pressure (ICP) No Start Operational Checkout Procedure . .WP 0020
19. Injection Control Pressure (ICP) Operational Checkout Procedure. . . . . .WP 0022
20. Intake/Exhaust Troubleshooting Procedure. . . . . . . . . . . . . . . .WP 0019
21. Low Injector Control Pressure (ICP) Troubleshooting Procedure . . . . . .WP 0021
22. Valve Adjustment Troubleshooting Procedure . . . . . . . . . . . . . .WP 0027
23. Wastegate Actuator Operational Checkout Procedure . . . . . . . . . . .WP 0026
Cooling System
24. Cooling System Operational Checkout Procedure . . . . . . . . . . . . .WP 0045
25. Engine Cooling Fan Operational Checkout Procedure . . . . . . . . . . .WP 0031
Electrical System
26. 110V Inverter Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0119
27. 12V and 24V Battery Switches Troubleshooting Procedure . . . . . . . . .WP 0060
28. 12-Volt Voltmeter Operational Checkout Procedure . . . . . . . . . . . .WP 0080
29. 4-Pack Air Solenoid Circuits From Electronic System Controller (ESC) .WP 0138
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . .
30. Accelerator Position Sensor (APS)/Idle Validation Switch (IVS) .WP 0050
31. AIR 1/Primary Air Pressure Gauge Troubleshooting Procedure . . . . . . .WP 0086
32. Air 2/Secondary Air Pressure Gauge Troubleshooting Procedure . . . . . .WP 0087
33. American Truckers Association (ATA) Communications/Data Communications.WP 0051
Link (DLC) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . .
34. Antilock Brake System (ABS) J1939 Serial Communications Troubleshooting .WP 0139
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35. Antilock Brake System (ABS) Pressure Modulator Valve (PMV) Common .WP 0140
Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . .
36. Antilock Brake System (ABS) Warning Lamp Troubleshooting Procedure. . .WP 0079
37. Audible Alarm Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0088
38. Backup Lights Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0103
39. Barometric Pressure Sensor (BAP) Troubleshooting Procedure . . . . . . .WP 0052
40. Battery Equalizer Troubleshooting Procedure. . . . . . . . . . . . . . .WP 0120
41. Blackout Driving Light Troubleshooting Procedure. . . . . . . . . . . . .WP 0099
0004–1
TM 9-2355-106-23-1 0004
Troubleshooting Index - (CONTINUED)
42. Blackout Marker Light Troubleshooting Procedure. . . . . . . . . . . . .WP 0100

43. Blackout Stoplights Troubleshooting Procedure . . . . . . . . . . . . . .WP 0102
44. Cabin Fuse Block 1011 Troubleshooting Procedure . . . . . . . . . . . .WP 0061
48. Charging System Troubleshooting Procedure. . . . . . . . . . . . . . .WP 0091
49. Check Transmission Lamp Troubleshooting Procedure . . . . . . . . . .WP 0075
50. Clearance/Marker Lights Troubleshooting Procedure . . . . . . . . . . .WP 0098
51. Coolant Level Warning Lamp Troubleshooting Procedure . . . . . . . . .WP 0076
52. Cruise Control Operational Checkout Procedure . . . . . . . . . . . . .WP 0106
53. Diagnostic Connector Troubleshooting Procedure . . . . . . . . . . . . .WP 0078
54. Electric Horns Circuit Troubleshooting Procedure . . . . . . . . . . . . .WP 0111
55. Electric Horns Operational Checkout Procedure . . . . . . . . . . . . .WP 0107
56. Electric Horns Sound without Pressing Horn Pad Troubleshooting Procedure .WP 0112
57. Electric Horns Switch Troubleshooting Procedure . . . . . . . . . . . . .WP 0109
58. Electronic System Controller (ESC) Troubleshooting Procedure. . . . . . .WP 0068
59. Engine Control Module (ECM) Self-Diagnosis Troubleshooting Procedure . .WP 0053
60. Engine Control Module (ECM) Troubleshooting Procedure . . . . . . . . .WP 0049
61. Engine Coolant Temperature Gauge Troubleshooting Procedure . . . . . .WP 0081
62. Engine Oil Pressure Gauge Operational Checkout Procedure . . . . . . .WP 0082
63. Ether Start Circuit Troubleshooting Procedure . . . . . . . . . . . . . .WP 0089
64. Exhaust Brake Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0090
65. Flash-To-Pass Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0105
66. Front Crew Light Operatonal Checkout Procedure. . . . . . . . . . . . .WP 0133
67. Front Crew Light Troubleshooting Procedure . . . . . . . . . . . . . . .WP 0134
68. Front Turn Signal Lights Troubleshooting Procedure . . . . . . . . . . .WP 0093
69. Fuel Fired Heater Troubleshooting Procedure . . . . . . . . . . . . . .WP 0137
70. Fuel Level Gauge Troubleshooting Procedure . . . . . . . . . . . . . .WP 0085
71. Heated Windshield Troubleshooting Procedure . . . . . . . . . . . . . .WP 0121
72. Injector Drive Circuit Troubleshooting Procedure . . . . . . . . . . . . .WP 0054
73. Instrument Panel (IP) Lights Troubleshooting Procedure . . . . . . . . . .WP 0104
74. Instrument Panel Cluster (IPC) Operational Checkout Procedure . . . . . .WP 0070
75. Instrument Panel Cluster (IPC) Power and Data Link Circuits Troubleshooting.WP 0071
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76. Intake Air Temperature (IAT) Sensor Troubleshooting Procedure . . . . . .WP 0055
77. Keyless Ignition Switch Troubleshooting Procedure . . . . . . . . . . . .WP 0066
78. Malfunctioning Instrument Panel Cluster (IPC) Troubleshooting Procedure . .WP 0072
79. Manifold Absolute Pressure (MAP) Sensor Troubleshooting Procedure . . .WP 0056
80. Master Vehicle Light Switch (MVLS) Horn Enable Circuit Troubleshooting .WP 0110
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81. Master Vehicle Light Switch (MVLS) Troubleshooting Procedure . . . . . .WP 0092
82. Multiplexing Data Link Circuits Troubleshooting Procedure . . . . . . . . .WP 0067
83. NATO Connector Troubleshooting Procedure . . . . . . . . . . . . . . .WP 0118
84. Park Brake Warning Lamp Troubleshooting Procedure. . . . . . . . . . .WP 0077
85. Power Distribution Center (PDC) Mini Fuse Block 4001 Troubleshooting .WP 0065
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86. Power Distribution Troubleshooting Procedure . . . . . . . . . . . . . .WP 0059
87. Power/Heated Mirror Troubleshooting Procedure . . . . . . . . . . . . .WP 0123
88. Rear Crew Lights Operatonal Checkout Procedure . . . . . . . . . . . .WP 0135
89. Rear Crew Lights Troubleshooting Procedure . . . . . . . . . . . . . .WP 0136
90. Rear Trailer Connector Ground Circuit Troubleshooting Procedure . . . . .WP 0128
91. Rear Turn Signal Lights Troubleshooting Procedure . . . . . . . . . . . .WP 0094
92. Red Engine Warning Lamp Troubleshooting Procedure . . . . . . . . . .WP 0074
93. Service Driving Lights Troubleshooting Procedure. . . . . . . . . . . . .WP 0097
94. Single Electric Horn Fault Troubleshooting Procedure . . . . . . . . . . .WP 0108
0004–2
TM 9-2355-106-23-1 0004
95. Speed Control Command Switches (SCCS) Troubleshooting Procedure . . .WP 0057
96. Speedometer Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0083
97. Spotlight Troubleshooting Procedure . . . . . . . . . . . . . . . . . .WP 0122
98. Stoplights Troubleshooting Procedure . . . . . . . . . . . . . . . . . .WP 0101
99. Switch Pack Modules Troubleshooting Procedure . . . . . . . . . . . . .WP 0069
100. Tachometer Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0084
101. Trailer Connector Auxiliary Power Circuit Troubleshooting Procedure . . . .WP 0131
102. Trailer Connector Brake Circuit Troubleshooting Procedure . . . . . . . .WP 0132
103. Trailer Connector Left Service Signal Circuit Troubleshooting Procedure . .WP 0126
104. Trailer Connector Left, Right, and Clearance Black Out (B/O) Circuit .WP 0125
105. Trailer Connector Operational Checkout Procedure . . . . . . . . . . .WP 0124
106. Trailer Connector Right Service Signal Circuit Troubleshooting Procedure. .WP 0127
107. Trailer Connector Service Clearance Circuit Troubleshooting Procedure . .WP 0129
108. Trailer Connector Stop Black Out (B/O) Circuit Troubleshooting Procedure .WP 0130
109. Turn Signal and Hazard Switch Troubleshooting Procedure . . . . . . . .WP 0095
110. Turn Signal Lights Operational Checkout Procedure . . . . . . . . . . .WP 0096
111. Vehicle Speed Sensor (VSS) Troubleshooting Procedure . . . . . . . . .WP 0058
112. Windshield Washer Circuit Troubleshooting Procedure . . . . . . . . . .WP 0114
113. Windshield Wiper and Washer Operational Checkout Procedure . . . . . .WP 0113
114. Windshield Wiper Motor Circuit Troubleshooting Procedure . . . . . . . .WP 0117
115. Windshield Wiper Park Circuit Troubleshooting Procedure . . . . . . . .WP 0116
116. Windshield Wiper Switch Inputs to Electronic System Controller (ESC) .WP 0115
117. Yellow Engine Warning Lamp Troubleshooting Procedure . . . . . . . . .WP 0073
Transmission
118. Transmission Fluid Level Sensor Troubleshooting Procedure . . . . . . .WP 0147
119. Internal Transmission Operational Checkout Procedure . . . . . . . . . .WP 0151
120. Transfer Case Operational Checkout Procedure . . . . . . . . . . . . .WP 0164
121. Transmission Circuit Troubleshooting Procedure . . . . . . . . . . . . .WP 0141
122. Transmission Communication Troubleshooting Procedure. . . . . . . . .WP 0163
123. Transmission Control Module (TCM) Operational Checkout Procedure . . .WP 0144
124. Transmission Control System ID Troubleshooting Procedure . . . . . . .WP 0146
125. Transmission Engine Speed Sensor Troubleshooting Procedure . . . . . .WP 0150
126. Transmission Fluid Over Temperature Troubleshooting Procedure . . . . .WP 0143
127. Transmission High Side Driver 2 Troubleshooting Procedure . . . . . . .WP 0159
128. Transmission High Side Driver 3 Troubleshooting Procedure . . . . . . .WP 0160
129. Transmission High Side Driver Troubleshooting Procedure . . . . . . . .WP 0145
130. Transmission Low Gear Troubleshooting Procedure . . . . . . . . . . .WP 0158
131. Transmission Operational Checkout Procedure . . . . . . . . . . . . .WP 0142
132. Transmission Output Speed Sensor Troubleshooting Procedure . . . . . .WP 0149
133. Transmission Pressure Control Main MOD Troubleshooting Procedure . . .WP 0156
134. Transmission Pressure Control Solenoid 1 Troubleshooting Procedure . . .WP 0162
138. Transmission Pressure Switch Troubleshooting Procedure . . . . . . . .WP 0154
139. Transmission Shift Solenoid 1 Troubleshooting Procedure . . . . . . . .WP 0157
140. Transmission Slipping Operational Checkout Procedure . . . . . . . . .WP 0155
141. Transmission Temperature Sensor Troubleshooting Procedure . . . . . .WP 0148
Transfer Assembly
0004–3
TM 9-2355-106-23-1 0004
142. Transfer Case Operational Checkout Procedure . . . . . . . . . . . . .WP 0164
Propeller Shafts
143. Propeller Shaft Operational Checkout Procedure. . . . . . . . . . . . .WP 0165
Front Axle
144. Front Axle Operational Checkout Procedure. . . . . . . . . . . . . . .WP 0166
Rear Axle
145. Rear Axle Operational Checkout Procedure . . . . . . . . . . . . . . .WP 0167
Brakes
146. Air Brake Component Operational Checkout Procedure. . . . . . . . . .WP 0173
147. Air Brake System Operational Checkout Procedure . . . . . . . . . . .WP 0172
148. Air Compressor Governor Operational Checkout Procedure . . . . . . . .WP 0176
149. Air Compressor Operational Checkout Procedure . . . . . . . . . . . .WP 0175
150. Air Dryer Heater and Thermostat Troubleshooting Procedure . . . . . . .WP 0174
151. Antilock Brake System (ABS) Pressure Modulator Valve (PMV) .WP 0178
152. Antilock Brake System (ABS) Wheel Speed Sensor Troubleshooting .WP 0177
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153. Brake System Mechanical Components Operational Checkout Procedure . .WP 0170
154. Brake System Operational Checkout Procedure . . . . . . . . . . . . .WP 0169
155. Stoplight Switch Brake Switch Circuits Troubleshooting Procedure . . . . .WP 0168
156. Brake System Troubleshooting Procedure . . . . . . . . . . . . . . .WP 0171
Steering
157. Power Steering Operational Checkout Procedure . . . . . . . . . . . .WP 0180
158. Steering System Operational Checkout Procedure . . . . . . . . . . . .WP 0179
Springs and Shock Absorbers

159. Suspension Troubleshooting Procedure . . . . . . . . . . . . . . . .WP 0181
Cabin Door
160. Cabin Door Assist System Troubleshooting Procedure . . . . . . . . . .WP 0185
161. Cabin Door Combat Lock Troubleshooting Procedure . . . . . . . . . .WP 0183
162. Cabin Door Lock Assembly Troubleshooting Procedure. . . . . . . . . .WP 0184
163. Cabin Door Operational Checkout Procedure . . . . . . . . . . . . . .WP 0182
Winch
164. Winch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . .WP 0186
Hydraulic System (Rear Door)

165. Rear Door/Ramp Hydraulic Lift Components Troubleshooting Procedure .WP 0187
(Push-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166. Rear Door/Ramp Hydraulic Lift Components Troubleshooting Procedure .WP 0188
(Pull-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Ventilation and Air Conditioning (HVAC)

167. Heating Ventilating and Air Conditioning (HVAC) 3-Way Valve .WP 0206
168. Heating Ventilating and Air Conditioning (HVAC) Compressor Control .WP 0212
169. Heating Ventilating and Air Conditioning (HVAC) Condenser Fans .WP 0213
0004–4
TM 9-2355-106-23-1 0004
170. Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) .WP 0214
Cabin Pressure Troubleshooting Procedure . . . . . . . . . . . . . . . . .
Fresh Air (FA) Blower Troubleshooting Procedure . . . . . . . . . . . . . .
Recycled Air (RA) Blower Troubleshooting Procedure . . . . . . . . . . . .
173. Heating Ventilating and Air Conditioning (HVAC) Freeze Switch .WP 0209
174. Heating Ventilating and Air Conditioning (HVAC) High Idle Circuit .WP 0207
175. Heating Ventilating and Air Conditioning (HVAC) Low Pressure Cutout .WP 0210
Switch Operational Checkout Procedure . . . . . . . . . . . . . . . . . .
Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . .
177. Heating Ventilating and Air Conditioning (HVAC)/Life Support System .WP 0203
(LSS) Operator Panel and Climate Control Unit (CCU) Power and Ground
178. Heating Ventilating and Air Conditioning (HVAC) Recycled Air (RA) .WP 0208
Temperature Sensor Troubleshooting Procedure. . . . . . . . . . . . . . .
179. Heating Ventilating and Air Conditioning (HVAC) Trinary Switch .WP 0211
Fire Suppression System (FSS)

180. Fire Suppression System (FSS) Troubleshooting Procedure. . . . . . . .WP 0191
181. Fire Suppression System (FSS) Control Panel Power and Ground .WP 0192
Troubleshooting Procedure.. . . . . . . . . . . . . . . . . . . . . . . .
182. Fire Suppression System (FSS) Cabin Extinguisher Control Circuit Fault .WP 0194
183. Fire Suppression System (FSS) Cabin Fire Detector Fire Detection Circuit .WP 0196
184. Fire Suppression System (FSS) Cabin Fire Detector Power and Ground .WP 0195
185. Fire Suppression System (FSS) Control Panel Power and Ground .WP 0193
186. Fire Suppression System (FSS) Engine Extinguisher Control Circuit Fault .WP 0197
187. Fire Suppression System (FSS) Engine Fire Detector Fire Detection Circuit .WP 0199
188. Fire Suppression System (FSS) Engine Fire Detector Power and Ground .WP 0198
189. Fire Suppression System (FSS) Fuel Tank Extinguisher Control Circuit Fault .WP 0200
190. Fire Suppression System (FSS) Tires Extinguisher Control Circuit Fault .WP 0201
END OF WORK PACKAGE
0004–5/blank
TM 9-2355-106-23-1
CHAPTER 3
TROUBLESHOOTING PROCEDURES
FOR

TM 9-2355-106-23-1 0005
FIELD MAINTENANCE
VEHICLE TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting Procedure
Engine
1. Coolant in lubricating oil or lubricating oil in coolant . . . . . . . . . . . . .WP 0016
2. Engine cranks but will not start. . . . . . . . . . . . . . . . . . . . . .WP 0014
3. Engine has poor performance . . . . . . . . . . . . . . . . . . . . . .WP 0015
4. Engine oil pressure low . . . . . . . . . . . . . . . . . . . . . . . . .WP 0018
5. Engine starts but will not continue to run . . . . . . . . . . . . . . . . .WP 0014, WP 0015
6. Engine warning lamp on . . . . . . . . . . . . . . . . . . . . . . . .WP 0010
7. Engine will not crank . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0034
8. Excessive engine oil consumption . . . . . . . . . . . . . . . . . . . .WP 0016
9. Excessive exhaust smoke. . . . . . . . . . . . . . . . . . . . . . . .WP 0016
10. Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . .WP 0016
11. Excessive noise from engine . . . . . . . . . . . . . . . . . . . . . .WP 0016
12. Excessive smoke or oil discharge from engine breather tube . . . . . . . .WP 0016
13. Fuel dilution of engine oil . . . . . . . . . . . . . . . . . . . . . . .WP 0016
14. Lubricating oil in fuel . . . . . . . . . . . . . . . . . . . . . . . . .WP 0016
Cooling System
15. Engine cooling fan malfunction . . . . . . . . . . . . . . . . . . . . .WP 0031
16. Engine overheats . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0045
17. High coolant temperature or coolant loss. . . . . . . . . . . . . . . . .WP 0016
Electrical System
18. 12V circuit voltage too high or too low . . . . . . . . . . . . . . . . . .WP 0120
19. 12V voltmeter malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0080
20. AIR 1/Primary air pressure gauge malfunction . . . . . . . . . . . . . .WP 0086
21. AIR 2/Secondary air pressure gauge malfunction . . . . . . . . . . . . .WP 0087
22. Antilock brake system (ABS) warning lamp malfunction . . . . . . . . . .WP 0079
23. Audible alarm malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0088
24. Blackout driving light malfunction . . . . . . . . . . . . . . . . . . . .WP 0099
25. Blackout marker light malfunction . . . . . . . . . . . . . . . . . . . .WP 0100
26. Charging system malfunction . . . . . . . . . . . . . . . . . . . . . .WP 0091
27. Check transmission lamp malfunction . . . . . . . . . . . . . . . . . .WP 0075
28. Clearance/marker lights malfunction . . . . . . . . . . . . . . . . . .WP 0098
29. Coolant level warning lamp malfunction . . . . . . . . . . . . . . . . .WP 0076
30. Cruise control malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0106
31. Engine coolant temperature gauge malfunction . . . . . . . . . . . . .WP 0081
32. Engine oil pressure gauge malfunction . . . . . . . . . . . . . . . . .WP 0082
33. Flash-to-pass malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0105
34. Fuel level gauge malfunction . . . . . . . . . . . . . . . . . . . . . .WP 0085
35. Hazard lights malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0093
36. Horn inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0107
37. Instrument Panel Cluster (IPC) malfunction. . . . . . . . . . . . . . . .WP 0070
38. Instrument Panel Cluster (IPC) warning lamp on . . . . . . . . . . . . .WP 0070
39. Instrument panel lights malfunction . . . . . . . . . . . . . . . . . . .WP 0104
40. Maintenance Support Device (MSD) will not communicate . . . . . . . . .WP 0078
41. Master Vehicle Light Switch (MVLS) malfunction . . . . . . . . . . . . .WP 0092
42. No power to fuse box . . . . . . . . . . . . . . . . . . . . . . . . .WP 0059
43. Park brake warning lamp malfunction . . . . . . . . . . . . . . . . . .WP 0077
44. Red engine warning lamp malfunction . . . . . . . . . . . . . . . . . .WP 0074
45. Service driving lights malfunction . . . . . . . . . . . . . . . . . . . .WP 0097
46. Shift indicator display malfunction . . . . . . . . . . . . . . . . . . . .WP 0142
47. Speedometer malfunction . . . . . . . . . . . . . . . . . . . . . . .WP 0083
48. Stoplights malfunction . . . . . . . . . . . . . . . . . . . . . . . .WP 0101
0005–1
TM 9-2355-106-23-1 0005
Vehicle Troubleshooting Symptom Index - (CONTINUED)
49. Switch pack module switch malfunction . . . . . . . . . . . . . . . . .WP 0069

50. Tachometer malfunction . . . . . . . . . . . . . . . . . . . . . . . .WP 0084
51. Trailer connector lighting circuit malfunction . . . . . . . . . . . . . . .WP 0124
52. Transmission oil temperature gauge malfunction . . . . . . . . . . . . .
53. Turn signal lights malfunction . . . . . . . . . . . . . . . . . . . . .WP 0093
54. Windshield wiper malfunction. . . . . . . . . . . . . . . . . . . . . .WP 0113
55. Yellow engine warning lamp malfunction . . . . . . . . . . . . . . . .WP 0073
Transmission
56. Excessive noise from transmission . . . . . . . . . . . . . . . . . . .WP 0142
57. Vehicle will not move . . . . . . . . . . . . . . . . . . . . . . . . .WP 0142, WP 0164,
WP 0165, WP 0166,
WP 0167, WP 0172
Transfer Assembly
58. Excessive noise from transfer case . . . . . . . . . . . . . . . . . . .WP 0164
Propeller Shafts
59. Excessive noise from propeller shaft . . . . . . . . . . . . . . . . . .WP 0165
Front Axle
60. Excessive noise from front axle . . . . . . . . . . . . . . . . . . . . .WP 0166
Rear Axle
61. Excessive noise from rear axle . . . . . . . . . . . . . . . . . . . . .WP 0167
Brakes
62. Air brake pressure low. . . . . . . . . . . . . . . . . . . . . . . . .WP 0172
63. Antilock Brake System (ABS) warning lamp on . . . . . . . . . . . . . .WP 0010, WP 0009,
64. Parking brake will not release or set . . . . . . . . . . . . . . . . . . .WP 0172
65. Service brake system malfunction. . . . . . . . . . . . . . . . . . . .WP 0171
Steering
66. Steering hard to turn . . . . . . . . . . . . . . . . . . . . . . . . .WP 0179, WP 0180,
WP 0472
Springs and Shock Absorbers

67. Suspension malfunction . . . . . . . . . . . . . . . . . . . . . . . .WP 0181
Winch
68. Winch malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0186
Hydraulic System (Rear Door)

69. Rear door hydraulic lift malfunction . . . . . . . . . . . . . . . . . . .WP 0187
Heating Ventilation and Air Conditioning (HVAC)

70. Heating Ventilation and Air Conditioning (HVAC) system malfunction . . . .WP 0189
Fire Suppression System (FSS)

71. Fire Suppression System (FSS) malfunction . . . . . . . . . . . . . . .WP 0191
END OF WORK PACKAGE
0005–2
TM 9-2355-106-23-1 0006
FIELD MAINTENANCE
ENGINE DIAGNOSTIC TROUBLE CODE (DTC) INDEX
INITIAL SETUP:
NOT APPLICABLE
Table 1. DTC Table.

DTC CONDITION/DESCRIPTION REPAIR INFORMATION
*Indicates AMBER engine lamp is ON and odometer message is displayed when DTC is set.
111 No errors detected - System OK
112 Electrical system voltage B+ Out Refer to Engine Control Module (ECM) Troubleshooting
of Range HIGH. Procedure (WP 0049).
113 Electrical system voltage B+ Out Refer to Engine Control Module (ECM) Troubleshooting
of Range LOW. Procedure (WP 0049).
114* Engine Coolant Temperature Refer to Engine Coolant Temperature (ECT) Sensor
(ECT) signal Out of Range LOW. Troubleshooting Procedure (WP 0047).
115* ECT signal Out of Range HIGH. Refer to Engine Coolant Temperature (ECT) Sensor
Troubleshooting Procedure (WP 0047).
121* Intake Manifold Absolute Refer to Manifold Absolute Pressure (MAP) Sensor
Pressure (MAP) signal Out of Troubleshooting Procedure (WP 0056).
Range HIGH.
122* MAP signal Out of Range LOW. Refer to Manifold Absolute Pressure (MAP) Sensor
123* MAP in range DTC. Refer to Manifold Absolute Pressure (MAP) Sensor
124* Injection Control Pressure (ICP) Refer to Injection Control Pressure (ICP) Sensor
signal Out of Range LOW. Troubleshooting Procedure (WP 0040).
125* ICP signal Out of Range HIGH. Refer to Injection Control Pressure (ICP) Sensor
131* Accelerator Position Signal (APS) Refer to Accelerator Position Sensor (APS)/Idle Validation
Out of Range LOW. Switch (IVS) Troubleshooting Procedure (WP 0050).
132* APS Out of Range HIGH. Refer to Accelerator Position Sensor (APS)/Idle Validation
Switch (IVS) Troubleshooting Procedure (WP 0050).
133* APS in range DTC. Refer to Accelerator Position Sensor (APS)/Idle Validation
134* Accelerator position and Idle Refer to Accelerator Position Sensor (APS)/Idle Validation
Validation Switch (IVS) disagree. Switch (IVS) Troubleshooting Procedure (WP 0050).
135* IVS circuit DTC. Refer to Accelerator Position Sensor (APS)/Idle Validation
141 Vehicle Speed Signal (VSS) Out Refer to Vehicle Speed Sensor (VSS) Troubleshooting
of Range LOW. Procedure (WP 0058).
142 VSS Out of Range HIGH. Refer to Vehicle Speed Sensor (VSS) Troubleshooting
Procedure (WP 0058).
143 Wrong number of Camshaft Refer to Camshaft Position (CMP) Sensor Troubleshooting
Position (CMP) signal transitions Procedure (WP 0030).
per camshaft revolution.
144 CMP signal noise detected. Refer to Camshaft Position (CMP) Sensor Troubleshooting
145* CMP signal inactive while ICP Refer to Camshaft Position (CMP) Sensor Troubleshooting
has increased. Procedure (WP 0030).
151 Barometric Pressure Sensor Refer to Barometric Pressure Sensor (BAP) Troubleshooting
(BAP) signal Out of Range HIGH. Procedure (WP 0052).
152 BAP signal Out of Range LOW. Refer to Barometric Pressure Sensor (BAP) Troubleshooting
0006–1
TM 9-2355-106-23-1 0006
ENGINE DIAGNOSTIC TROUBLE CODE (DTC) INDEX - (CONTINUED)
154 Intake Air Temperature (IAT) Refer to Intake Air Temperature (IAT) Sensor
155 IAT signal Out of Range HIGH. Refer to Intake Air Temperature (IAT) Sensor
211* Engine Oil Pressure (EOP) signal Refer to Engine Oil Pressure (EOP) Sensor Troubleshooting
Out of Range LOW. Procedure (WP 0028).
212* EOP signal Out of Range HIGH. Refer to Engine Oil Pressure (EOP) Sensor Troubleshooting
213 Remote throttle signal Out of Vehicle not equipped with this feature.
Range LOW.
214 Remote throttle signal Out of Vehicle not equipped with this feature.
Range HIGH.
215 VSS frequency Out of Range Refer to Vehicle Speed Sensor (VSS) Troubleshooting
HIGH. Procedure (WP 0058).
216 Electronic Pressure Governor Vehicle not equipped with this feature.
(EPG) signal Out of Range LOW.
225 EOP sensor signal in-range DTC. Refer to Engine Oil Pressure (EOP) Sensor Troubleshooting
226 EPG sensor signal Out of Range Vehicle not equipped with this feature.
HIGH.
231 American Truckers Association Refer to American Truckers Association (ATA)
(ATA) data communication link Communications/Data Communications Link (DLC)
error. Troubleshooting Procedure (WP 0051).
236 Engine coolant level switch circuit Refer to Engine Coolant Level System Troubleshooting
DTC. Procedure (WP 0046).
241 Injection Pressure Regulator Refer to Injection Pressure Regulator (IPR) Troubleshooting
(IPR) regulator self-test failed. Procedure (WP 0041).
246 Engine Fan Control (EFC)- Refer to Engine Fan Control (EFC) Troubleshooting
self-test failed. Procedure (WP 0048).
256 Radiator shutter enable self-test If equipped
failed.
265 Exhaust Brake relay DTC. Refer to Exhaust Brake Troubleshooting Procedure
(WP 0090).
311* Engine Oil Temperature (EOT) Refer to Engine Oil Temperature (EOT) Sensor
312* EOT signal Out of Range HIGH. Refer to Engine Oil Temperature (EOT) Sensor
313 EOP below warning level. Refer to Engine Oil Pressure (EOP) Sensor Troubleshooting
314 EOP below critical level. Refer to Engine Oil Pressure (EOP) Sensor Troubleshooting
315* Engine speed above warning Refer to Camshaft Position (CMP) Sensor Troubleshooting
level. Procedure (WP 0030).
316 ECT unable to reach commanded Refer to Engine Coolant Temperature (ECT) Sensor
set point. Troubleshooting Procedure (WP 0047).
321 ECT above warning level. Refer to Engine Coolant Temperature (ECT) Sensor
322 ECT above critical level. Refer to Engine Coolant Temperature (ECT) Sensor
323 Engine coolant below Refer to Engine Coolant Level System Troubleshooting
warning/critical level. Procedure (WP 0046).
325 Power reduced, matched to Refer to Engine Coolant Temperature (ECT) Sensor
cooling system performance. Troubleshooting Procedure (WP 0047).
331* ICP above system working range. Refer to Injection Pressure Regulator (IPR) Troubleshooting
0006–2
TM 9-2355-106-23-1 0006
332* ICP above spec with engine off. Refer to Injection Control Pressure (ICP) Sensor
333* ICP above/below desired level. Refer to Injection Pressure Regulator (IPR) System
334 ICP unable to achieve set point in Refer to Injection Pressure Regulator (IPR) System
time (poor performance). Troubleshooting Procedure (WP 0042).
335 ICP unable to build pressure Refer to Injection Pressure Regulator (IPR) System
during cranking. Troubleshooting Procedure (WP 0042).
421-426 Injector high side to low side open Refer to Injector Drive Circuit Troubleshooting Procedure
(cyl. number indicated). (WP 0054).
431-436 Injector high side shorted to low Refer to Injector Drive Circuit Troubleshooting Procedure
side (cyl. number indicated). (WP 0054).
451-456 High side shorted to ground or V Refer to Injector Drive Circuit Troubleshooting Procedure
BAT (cyl. number indicated). (WP 0054).
461-466 Cylinder contribution test failed Refer to Diagnosing Scuffed Injectors Troubleshooting
(cyl. number indicated). Procedure (WP 0039).
513* Low side to bank 1 open. Refer to Injector Drive Circuit Troubleshooting Procedure
(WP 0054).
514* Low side to bank 2 open. Refer to Injector Drive Circuit Troubleshooting Procedure
(WP 0054).
515* Bank 1 low side short to ground Refer to Injector Drive Circuit Troubleshooting Procedure
or B+. (WP 0054).
521* Bank 2 low side short to ground Refer to Injector Drive Circuit Troubleshooting Procedure
or B+. (WP 0054).
525* Injector driver circuit DTC. Refer to Engine Control Module (ECM) Self-Diagnosis
612* Incorrect ECM installed for CMP Refer to Camshaft Position (CMP) Sensor Troubleshooting
timing wheel. Procedure (WP 0030).
614* Engine Family Rating Code Refer to Engine Control Module (ECM) Self-Diagnosis
(EFRC)/ECM configuration Troubleshooting Procedure (WP 0053).
mismatch.
621* Engine using mfg. default rating Refer to Engine Control Module (ECM) Self-Diagnosis
program engine. Troubleshooting Procedure (WP 0053).
622* Engine using field default rating. Refer to Engine Control Module (ECM) Self-Diagnosis
623* Invalid engine rating code; check Refer to Engine Control Module (ECM) Self-Diagnosis
ECM programming. Troubleshooting Procedure (WP 0053).
624 Field defaults active. Refer to Engine Control Module (ECM) Self-Diagnosis
626 ECM unexpected reset. Refer to Engine Control Module (ECM) Troubleshooting
631* Read Only Memory (ROM) Refer to Engine Control Module (ECM) Self-Diagnosis
self-test DTC. Troubleshooting Procedure (WP 0053).
632 RAM memory - CPU self-test Refer to Engine Control Module (ECM) Self-Diagnosis
DTC. Troubleshooting Procedure (WP 0053).
655 Programmable parameter list Refer to Engine Control Module (ECM) Self-Diagnosis
level incompatible. Troubleshooting Procedure (WP 0053).
661 RAM programmable parameter Refer to Engine Control Module (ECM) Self-Diagnosis
list corrupt. Troubleshooting Procedure (WP 0053).
0006–3
TM 9-2355-106-23-1 0006
664 Calibration level incompatible. Refer to Engine Control Module (ECM) Self-Diagnosis
665 Programmable parameter Refer to Engine Control Module (ECM) Self-Diagnosis
memory content corrupt. Troubleshooting Procedure (WP 0053).
END OF WORK PACKAGE
0006–4
TM 9-2355-106-23-1 0007
FIELD MAINTENANCE
ELECTRONIC SYSTEM CONTROLLER (ESC) DIAGNOSTIC TROUBLE CODE (DTC) INDEX
INITIAL SETUP:
NOT APPLICABLE
Table 1. DTC Table.

ESC CON-
NECTOR
AND PIN
DTC NUMBER CONDITION/DESCRIPTION REPAIR INFORMATION
70 14 1 0 1600/4004/ Park brake cannot be applied or Refer to Park Brake Warning Lamp
16, 32, 16 cannot be released. Troubleshooting Procedure (WP 0077).
70 14 1 1 1600/4004/ Failure in the auto apply relay Refer to Park Brake Warning Lamp
16, 32, 16 or in the air lines between the Troubleshooting Procedure (WP 0077).
auto apply relay and the park
brake switch.
597 14 1 0 Hyd or Air w/o Brake switch is stuck in the Refer to Brake Switch Circuits
4091 - 1600 open or closed position. Troubleshooting Procedure (WP 0168).
Air w/4091 -
4004/33
597 14 2 0 Hyd or Air w/o Brake switch inputs do not Refer to Brake Switch Circuits
4091 - 1600 match. Troubleshooting Procedure (WP 0168).
Air w/4091 -
4004/33
610 14 1 0 1600/12 Loss of ignition feed for 10 Refer to ESC Troubleshooting Procedure
seconds while the engine is (WP 0068).
running.
610 14 2 0 1600/2 Loss of accessory feed for 10 Refer to ESC Troubleshooting Procedure
seconds while the engine is (WP 0068).
running.
611 14 2 1 4008/A Solenoid power under-current. Refer to 4-Pack Air Solenoid Circuits
From Electronic System Controller (ESC)
611 14 2 2 4008/A Solenoid power over-current. Refer to 4-Pack Air Solenoid Circuits
From Electronic System Controller (ESC)
611 14 2 3 4008/A Solenoid power less than Refer to 4-Pack Air Solenoid Circuits
normal. From Electronic System Controller (ESC)
611 14 2 4 4008/A Solenoid power greater than Refer to 4-Pack Air Solenoid Circuits
normal. From Electronic System Controller (ESC)
611 14 2 6 4008/A Solenoid power has current flow Refer to 4-Pack Air Solenoid Circuits
when output commanded off. From Electronic System Controller (ESC)
611 14 6 1 4008/F Wiper power under-current. Refer to Windshield Wiper and Washer
Operational Checkout Procedure
(WP 0113).
611 14 6 2 4008/F Wiper power over-current. Refer to Windshield Wiper and Washer
Operational Checkout Procedure
(WP 0113).
0007–1
TM 9-2355-106-23-1 0007
ELECTRONIC SYSTEM CONTROLLER (ESC) DIAGNOSTIC TROUBLE CODE (DTC) INDEX - (CONTINUED)
611 14 6 3 4008/F Wiper power less than normal Refer to Windshield Wiper and Washer
low current but more than open Operational Checkout Procedure
circuit. (WP 0113).
611 14 6 4 4008/F Wiper power greater than Refer to Windshield Wiper and Washer
normal high current and less Operational Checkout Procedure
than fusing current. (WP 0113).
611 14 6 6 4008/F Wiper power has current flow Refer to Windshield Wiper and Washer
when output commanded off. Operational Checkout Procedure
(WP 0113).
611 14 12 1 4007/E Electric horn under-current. Refer to Electric Horns Operational
Checkout Procedure (WP 0107).
611 14 12 2 4007/E Electric horn over-current. Refer to Electric Horns Operational
611 14 12 3 4007/E Electric horn less than normal Refer to Electric Horns Operational
low current but more than open Checkout Procedure (WP 0107).
circuit.
611 14 12 4 4007/E Electric horn greater than Refer to Electric Horns Operational
normal high current and less Checkout Procedure (WP 0107).
than fusing current.
611 14 12 6 4007/E Electric horn has current flow Refer to Electric Horns Operational
when output commanded off. Checkout Procedure (WP 0107).
612 14 0 1 1600/2 Ignition out of range low. Refer to ESC Troubleshooting Procedure
(WP 0068).
612 14 0 2 1600/2 Ignition out of range high. Refer to ESC Troubleshooting Procedure
(WP 0068).
612 14 1 1 1600/33 Brake switch out of range low. Refer to Brake Switch Circuits (WP 0168).
612 14 1 2 1600/33 Brake switch out of range high. Refer to Brake Switch Circuits (WP 0168).
612 14 3 1 1600/16 Secondary air sensor out of Refer to Secondary Air Pressure Gauge
range low. Pin 16 short to Troubleshooting Procedure (WP 0087).
ground or open circuit.
612 14 3 2 1600/16 Secondary air sensor out of Refer to Secondary Air Pressure Gauge
range high. Pin 16 shorted high. Troubleshooting Procedure (WP 0087).
612 14 4 1 1600/15 Primary air sensor/auxiliary air Refer to Primary Air Pressure Gauge
sensor out of range low. Pin 15 (WP 0086).
shorted low.
612 14 4 2 1600/15 Primary air sensor/auxiliary air Refer to Primary Air Pressure Gauge
sensor out of range high. Pin Troubleshooting Procedure (WP 0086).
15 shorted high.
612 14 5 1 1600/10 Analog cruise switch input out Refer to Cruise Control Troubleshooting
of range low. Pin 10 shorted to Procedure (WP 0106).
612 14 5 2 1600/10 Analog cruise switch input out Refer to Cruise Control Troubleshooting
of range high. Pin 10 shorted Procedure (WP 0106).
high.
612 14 23 1 4004/4 Fuel level sensor out of range Refer to Fuel Level Gauge Troubleshooting
low. Pin 4 shorted to ground. Procedure (WP 0085).
high. Pin 4 shorted high or open Procedure (WP 0085).
circuit.
low. Pin 5 short to ground. Procedure (WP 0085).
high. Pin 5 shorted high or open Procedure (WP 0085).
circuit.
0007–2
TM 9-2355-106-23-1 0007
612 14 30 1 4004/27 Switched 5V sensor supply out Refer to Electronic System Controller
of range low. Pin 27 shorted to (ESC) Troubleshooting Procedure
ground or open circuit. (WP 0068).
612 14 30 2 4004/27 Switched 5V sensor supply out Refer to Electronic System Controller
of range high. Pin 27 shorted (ESC) Troubleshooting Procedure
high. (WP 0068).
612 14 33 1 4004/10 Engine oil temperature/park Refer to Engine Oil Temperature (EOT)
brake out of range low. Pin 10 Gauge Troubleshooting Procedure
short to ground. (WP 0029). Refer to Secondary Air
Pressure Gauge Troubleshooting
612 14 33 2 4004/10 Engine oil temperature/park Refer to Engine Oil Temperature (EOT)
brake out of range high. Pin 10 Gauge Troubleshooting Procedure
short high. (WP 0029). Refer to Secondary Air
Pressure Gauge Troubleshooting
612 14 35 1 4004/13 Brake application air out of Refer to AIR 1/Primary Air Pressure Gauge
range low. Pin 13 short to Troubleshooting Procedure (WP 0086).
612 14 35 2 4004/13 Brake application air out of Refer to AIR 1/Primary Air Pressure Gauge
range high. Pin 13 short high. Troubleshooting Procedure (WP 0086).
612 14 36 1 4004/3 Transmission oil temp out Refer to Malfunctioning Instrument Panel
of range low. Pin 3 short to Cluster (IPC) Troubleshooting Procedure
ground. (WP 0072).
614 14 1 1 1600/34, 35, Instrument Panel Cluster (IPC) Refer to Instrument Panel Cluster
36 / ESC communication error. (IPC) Operational Checkout Procedure
(WP 0070).
(WP 0070).
(WP 0070).
(WP 0070).
625 14 5 0 1600/29, 30 Switch pack data link fault. Refer to Electronic System Controller
(ESC) Troubleshooting Procedure
(WP 0068).
625 14 5 17 1600/29, 30 Switch Pack 4 Switch 1, micro Refer to Switch Pack Modules
switch inputs are in an invalid Troubleshooting Procedure (WP 0069).
state.
state.
state.
state.
0007–3
TM 9-2355-106-23-1 0007
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
state.
0007–4
TM 9-2355-106-23-1 0007
state.
state.
state.
state.
state.
state.
state.
state.
625 14 6 0 1600/29, 30 Switch Pack 3 not Refer to Switch Pack Modules
communicating with ESC. Troubleshooting Procedure (WP 0069).
Switch data link fault.
state.
state.
state.
625 14 6 20 1600/29, 30 Switch Pack 3 Switch 1. micro Refer to Switch Pack Modules
state.
state.
state.
state.
state.
0007–5
TM 9-2355-106-23-1 0007
state.
625 14 6 53 1600/29, 30 Switch Pack 3 Switch 3. Switch Refer to Switch Pack Modules
actuator or faulty micro switch. Troubleshooting Procedure (WP 0069).
state.
state.
state.
state.
state.
state.
state.
actuator or faulty micro switch Troubleshooting Procedure (WP 0069).
state.
state.
actuator or faulty micro switch Troubleshooting Procedure (WP 0069).
state.
state.
0007–6
TM 9-2355-106-23-1 0007
state.
state.
state.
state.
state.
627 14 11 4009/4010 ESC main power and ground Refer to Electronic System Controller
interruption (ESC) Troubleshooting Procedure
(WP 0068).
639 14 0 240 1600/34, 35, Engine brake torque not being Refer to Transmission Operational
36 communicated from the ECM Checkout Troubleshooting Procedure
or transmission retarder torque (WP 0142).
not being communicated from
transmission.
639 14 1 240 1600/34, 35, ABS controller not Refer to Antilock Brake System
36 communicating with the ESC. (ABS) J1939 Serial Communications
639 14 2 240 1600/34, 35, Electronic transmission Refer to Transmission Circuit
36 controller communication Troubleshooting Procedure (WP 0141).
has not been received.
639 14 3 240 1600/34, 35, Accelerator position not Refer to Multiplexing Data Link
36 communicated to ESC. Troubleshooting Procedure (WP 0067).
639 14 4 240 1600/34, 35, Engine speed not Refer to Multiplexing Data Link
36 communicated to ESC. Troubleshooting Procedure (WP 0067).
639 14 5 240 1600/34, 35, Current gear, range inhibit and Refer to Transmission Operational
36 check transmission lamps not Checkout Troubleshooting Procedure
communicated to ESC. (WP 0142).
639 14 8 240 1600/34, 35, Electronic pressure mode Refer to Multiplexing Data Link
36 indicator not communicated to Troubleshooting Procedure (WP 0067).
ESC.
0007–7
TM 9-2355-106-23-1 0007
639 14 33 239 1600/34, 35, IPC not communicating with Refer to Instrument Panel Cluster
36 ESC. (IPC) Power and Data Link Circuits
639 14 82 254 1600/34, 35, Pyrometer ammeter not Refer to Engine Oil Pressure Gauge
36 communicating to ESC. Operational Checkout Procedure
(WP 0082).
1542 14 11 1600/1, 2, 12 ESC main power or ground Electronic System Controller (ESC)
interruption. Troubleshooting Procedure (WP 0068).
2023 14 105 or N/A IPC gauge location 5 (oil Refer to Engine Oil Pressure Gauge
205 6 pressure) data unavailable to Operational Checkout Procedure
IPC. Data for this gauge is not (WP 0082).
being transmitted on the data
link.
2023 14 105 or N/A IPC gauge location 5 (oil Refer to Engine Oil Pressure Gauge
205 7 pressure) data missing to IPC. Operational Checkout Procedure
Data for this gauge is not being (WP 0082).
transmitted on the data link.
2023 14 106 or N/A IPC gauge location 6 sensor Refer to Instrument Panel Cluster
206 5 fault to primary IPC. There is (IPC) Operational Checkout Procedure
a problem with the sensor that (WP 0070).
provides the data for this gauge.
The gauge in this location is
optional.
2023 14 106 or N/A IPC gauge location 6 data Refer to Instrument Panel Cluster
206 6 unavailable to primary IPC. The (IPC) Operational Checkout Procedure
data that this gauge displays (WP 0070).
should be, but is not, available
at this time. The gauge in this
location is optional.
2023 14 106 or N/A IPC gauge location 6 data Refer to Instrument Panel Cluster
206 7 missing to primary IPC. The (IPC) Operational Checkout Procedure
data for this gauge is not being (WP 0070).
The gauge in this location is
optional.
2023 14 107 or N/A IPC gauge location 7 (fuel level) Refer to Fuel Level Gauge Troubleshooting
207 5 sensor fault to primary IPC. Procedure (WP 0085).
There is a problem with the
sensor that provides the data
for this gauge.
207 6 data unavailable to IPC. The Procedure (WP 0085).
data that this gauge displays
at this time.
207 7 data unavailable to IPC. The Procedure (WP 0085).
at this time.
2023 14 108 or N/A IPC gauge location 8. Primary Refer to Instrument Panel Cluster
208 5 Air Pressure Gauge sensor fault (IPC) Operational Checkout Procedure
to IPC. There is a problem with (WP 0070).
the sensor that provides the
data for this gauge.
0007–8
TM 9-2355-106-23-1 0007
to IPC. There is a problem with (WP 0070).
the sensor that provides the
data for this gauge.
to IPC. The data for this gauge (WP 0070).
is not being transmitted on the
data link.
2023 14 109 or N/A IPC gauge location 9. Voltmeter Refer to 12V Voltmeter Operational
209 5 sensor fault to IPC. There is a Checkout Procedure (WP 0080).
problem with the sensor that
209 6 data unavailable to IPC. The Checkout Procedure (WP 0080).
at this time.
209 7 data missing to IPC. The data Checkout Procedure (WP 0080).
for this gauge is not being
2023 14 110 or N/A IPC gauge location 10. Refer to IPC Operational Checkout
210 5 Secondary AirPressure Gauge Procedure (WP 0070).
sensor fault to IPC. There is a
problem with the sensor that
210 6 Secondary Air Pressure Gauge Procedure (WP 0070).
data unavailable to IPC. The
at this time.
210 7 Voltmeter data missing to Procedure (WP 0070).
IPC. The data for this gauge
is not being transmitted on the
data link.
2023 14 150 or N/A Loss of data link from ESC to Refer to Electronic System Controller
250 1 IPC. Loss of communication in (ESC) Troubleshooting Procedure
excess of 10 seconds. (WP 0068).
2023 14 150 or N/A ECM not communicating with Refer to Multiplexing Data Link
250 2 IPC. Loss of communication in Troubleshooting Procedure (WP 0067).
excess of 10 seconds.
2023 14 150 or N/A ABS warning light malfunction Refer to ABS Warning Lamp
250 8 on IPC. Troubleshooting Procedure (WP 0079).
2023 14 150 or N/A Trailer ABS warning light Refer to ABS Warning Lamp
250 9 malfunction on primary IPC. Troubleshooting Procedure (WP 0079).
2033 14 1 0 1601/A Connector 1601 pin A is drawing Refer to Electronic System Controller
current and it is configured as (ESC) Troubleshooting Procedure
unused. (WP 0068).
0007–9
TM 9-2355-106-23-1 0007
2033 14 1 1 1601/A Connector 1601 pin A current Refer to Electronic System Controller
overload. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 1 2 1601/A Connector 1601 pin A output Refer to Electronic System Controller
open circuit. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 1 3 1601/A Connector 1601 pin A output Refer to Electronic System Controller
shorted to ground. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 2 0 1601/E Connector 1601 pin E is drawing Refer to Electronic System Controller
unused. (WP 0068).
2033 14 2 1 1601/E Connector 1601 pin E (reverse Refer to Electronic System Controller
lamps) current overload. (ESC) Troubleshooting Procedure
(WP 0068).
lamps). Output open circuit. (ESC) Troubleshooting Procedure
(WP 0068).
lamps). Output shorted to (ESC) Troubleshooting Procedure
ground. (WP 0068).
2033 14 3 0 1600/11 Connector 1600 pin 11. Electric Refer to Electronic System Controller
Door Control Open Command, (ESC) Troubleshooting Procedure
is drawing current and it is (WP 0068).
configured as unused.
Door Open current overloaded. (ESC) Troubleshooting Procedure
(WP 0068).
Door Open circuit open. (ESC) Troubleshooting Procedure
(WP 0068).
Door Open shorted to ground. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 4 0 1600/6 Connector 1600 pin 6. Fog Refer to Electronic System Controller
Light Command is drawing (ESC) Troubleshooting Procedure
current and it is configured as (WP 0068).
unused.
2033 14 4 1 1600/6 Connector 1600 pin 6, Fog Refer to Electronic System Controller
Light Command Output, current (ESC) Troubleshooting Procedure
overload. (WP 0068).
2033 14 4 2 1600/6 1600 pin 6, Fog Light Command Refer to Electronic System Controller
Output, open circuit. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 4 3 1600/6 Connector 1600 pin 6, Fog Light Refer to Electronic System Controller
Command Output, shorted to (ESC) Troubleshooting Procedure
ground. (WP 0068).
2033 14 5 0 1600/4 Connector 1600 pin 4 is drawing Refer to Electronic System Controller
unused. (WP 0068).
2033 14 5 1 1600/4 Connector 1600 pin 4 (Bus Refer to Electronic System Controller
- Park Brake Relay). Output (ESC) Troubleshooting Procedure
overloaded. Connector 1600 (WP 0068).
pin 4 current overload.
0007–10
TM 9-2355-106-23-1 0007
2033 14 5 2 1600/4 Connector 1600 pin 4 open Refer to Electronic System Controller
circuit. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 5 3 1600/4 Connector 1600 pin 4 shorted Refer to Electronic System Controller
to ground. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 6 0 4004/17 Connector 4004 pin 17. There Refer to Electronic System Controller
is a load on this pin that has (ESC) Troubleshooting Procedure
been configured as unused. (WP 0068).
2033 14 6 1 4004/17 Connector 4004 pin 17. Body Refer to Electronic System Controller
Trailer Marker & Tail Lamp relay (ESC) Troubleshooting Procedure
is output overloaded. (WP 0068).
is output open circuit. (WP 0068).
is Output shorted to ground. (WP 0068).
2033 14 7 0 4004/19 Connector 4004/ pin 19. There Refer to Electronic System Controller
is a load on this pin that has (ESC) Troubleshooting Procedure
been configured as unused. (WP 0068).
2033 14 7 1 4004/19 Connector 4004/ pin 1. (Air Refer to Electronic System Controller
Solenoid Power) output (ESC) Troubleshooting Procedure
overloaded. (WP 0068).
2033 14 7 2 4004/19 Connector 4004/ pin 19 (Air Refer to Electronic System Controller
Solenoid Power) output open (ESC) Troubleshooting Procedure
circuit. (WP 0068).
2033 14 7 3 4004/19 Connector 4004/ pin 19 (Air Refer to Electronic System Controller
Solenoid Power) output shorted (ESC) Troubleshooting Procedure
to ground. (WP 0068).
2033 14 8 0 4004/20 Connector 4004/ pin 20 (Wiper Refer to Electronic System Controller
High Speed Relay). There is a (ESC) Troubleshooting Procedure
load on this pin that has been (WP 0068).
configured as unused.
High Speed Relay) output (ESC) Troubleshooting Procedure
overloaded. (WP 0068).
High Speed Relay) output open (ESC) Troubleshooting Procedure
circuit. (WP 0068).
2033 14 8 3 4004/20 Connector 4004/ pin 20 (Wiper Refer to Windshield Wiper and Washer
High Speed Relay) output Operational Checkout Procedure
shorted to ground. (WP 0113).
2033 14 9 0 4004/21 Connector 4004/ pin 21 (Stop Refer to Electronic System Controller
Relay). There is a load on this (ESC) Troubleshooting Procedure
pin that has been configured as (WP 0068).
Unused.
Relay) output overloaded. (ESC) Troubleshooting Procedure
(WP 0068).
Relay) output open circuit. (ESC) Troubleshooting Procedure
(WP 0068).
0007–11
TM 9-2355-106-23-1 0007
Relay) output shorted to ground. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 10 0 4004/22 Connector 4004/ pin 22. Refer to 4-Pack Air Solenoid Circuits
(4-Pack Air Solenoid Channel From Electronic System Controller (ESC)
3). There is a load on this pin Troubleshooting Procedure (WP 0138).
that has been configured as
unused.
2033 14 10 1 4004/22 4004/ pin 22 (4-Pack Air Refer to 4-Pack Air Solenoid Circuits
Solenoid Channel 3) current from Electronic System Controller (ESC)
overload. Defective relay, or Troubleshooting Procedure (WP 0138).
4-pack air solenoid module.
2033 14 10 2 4004/22 Connector 4004/ pin 22. Refer to 4-Pack Air Solenoid Circuits
Output open circuit (4-Pack Air from Electronic System Controller (ESC)
Solenoid Channel 3). Open Troubleshooting Procedure (WP 0138).
circuit, defective relay, or 4-pack
air solenoid module.
2033 14 10 3 4004/22 Connector 4004/ pin 22 (4-Pack Refer to 4-Pack Air Solenoid Circuits
Air Solenoid Channel 3). Output from Electronic System Controller (ESC)
shorted to ground, defective Troubleshooting Procedure (WP 0138).
relay, or 4-pack air solenoid
module.
2033 14 10 4 4004/22 Connector 4004/ pin 22 shorted Refer to 4-Pack Air Solenoid Circuits
to ground. Power to solenoid from Electronic System Controller (ESC)
pack has been disabled due Troubleshooting Procedure (WP 0138).
to solenoid 3 being shorted to
ground.
2033 14 11 0 4004/23 4004/ pin 23 is drawing current Refer to Electronic System Controller
and it is configured as unused. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 11 1 4004/23 Connector 4004/ pin 23 current Refer to Electronic System Controller
overload. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 11 2 4004/23 Connector 4004/ pin 23 output Refer to Electronic System Controller
open circuit. (ESC) Troubleshooting Procedure
(WP 0068).
2033 14 11 3 4004/23 Connector 4004/ pin 23 output Refer to Electronic System Controller
shorted to ground. (ESC) Troubleshooting Procedure
(WP 0068).
Solenoid Channel 2) is drawing from Electronic System Controller (ESC)
current and it is configured as Troubleshooting Procedure (WP 0138).
unused.
Air Solenoid Channel 2) output from Electronic System Controller (ESC)
overloaded. Troubleshooting Procedure (WP 0138).
Air Solenoid Channel 2) open from Electronic System Controller (ESC)
circuit, defective relay, or Troubleshooting Procedure (WP 0138).
4-Pack Air Solenoid Module.
Air Solenoid Channel 2) shorted from Electronic System Controller (ESC)
to ground. defective relay or Troubleshooting Procedure (WP 0138).
0007–12
TM 9-2355-106-23-1 0007
to ground. Power to the from Electronic System Controller (ESC)
solenoid pack has been turned Troubleshooting Procedure (WP 0138).
off due to a short in solenoid 2.
2033 14 13 0 4004/25 Connector 4004/ pin 25, Park Refer to 4-Pack Air Solenoid Circuits
Position Unlock solenoid. There from Electronic System Controller (ESC)
is a load on this pin and it has Troubleshooting Procedure (WP 0138).
been configured as unused.
2033 14 13 1 4004/25 Connector 4004/ pin 25. Output Refer to 4-Pack Air Solenoid Circuits
overloaded. Bus connector from Electronic System Controller (ESC)
1602 pin 25, Park Position Troubleshooting Procedure (WP 0138).
Unlock solenoid, output
overloaded.
2033 14 13 2 4004/25 Connector 4004/ pin 25. Park Refer to 4-Pack Air Solenoid Circuits
Position Unlock solenoid, from Electronic System Controller (ESC)
Output open circuit. Troubleshooting Procedure (WP 0138).
2033 14 13 3 4004/25 Connector 4004/ pin 25. Park Refer to 4-Pack Air Solenoid Circuits
Position Unlock solenoid, output from Electronic System Controller (ESC)
shorted to ground. Troubleshooting Procedure (WP 0138).
2033 14 14 0 4004/29 Connector 4004/ pin 29 is Refer to Windshield Wiper and Washer
drawing current and it is Operational Checkout Procedure
configured as unused. (WP 0113).
2033 14 14 1 4004/29 Connector 4004/ pin 29 current Refer to Windshield Wiper and Washer
overload. Operational Checkout Procedure
(WP 0113).
2033 14 14 2 4004/29 Connector 4004/ pin 29 open Refer to Windshield Wiper and Washer
circuit. Operational Checkout Procedure
(WP 0113).
2033 14 14 3 4004/29 Connector 4004/ pin 29 shorted Refer to Windshield Wiper and Washer
to ground. Operational Checkout Procedure
(WP 0113).
Solenoid Channel 4) is drawing from Electronic System Controller (ESC)
current and it is configured as Troubleshooting Procedure (WP 0138).
unused.
Air Solenoid Channel 4) current from Electronic System Controller (ESC)
overload. Troubleshooting Procedure (WP 0138).
Air Solenoid Channel 4) open from Electronic System Controller (ESC)
circuit. Troubleshooting Procedure (WP 0138).
Air Solenoid Channel 4) shorted from Electronic System Controller (ESC)
to ground, defective relay, or Troubleshooting Procedure (WP 0138).
4-pack air solenoid module.
2033 14 16 0 4004/31 Connector 4004/ pin 31 is Refer to 4-Pack Air Solenoid Circuits
drawing current and it is from Electronic System Controller (ESC)
configured as unused. Troubleshooting Procedure (WP 0138).
0007–13
TM 9-2355-106-23-1 0007
2033 14 16 1 4004/31 . Connector 4004/ pin 31 Refer to 4-Pack Air Solenoid Circuits
(4-Pack Air Solenoid Channel from Electronic System Controller (ESC)
1). Current overload, defective Troubleshooting Procedure (WP 0138).
relay, or 4-Pack Air Solenoid
Module.
Air Solenoid Channel 1). Open from Electronic System Controller (ESC)
circuit, defective relay, or Troubleshooting Procedure (WP 0138).
Air Solenoid Channel 1). from Electronic System Controller (ESC)
Shorted to ground, defective Troubleshooting Procedure (WP 0138).
relay, or 4-Pack Air Solenoid
Module.
END OF WORK PACKAGE
0007–14
TM 9-2355-106-23-1 0008
FIELD MAINTENANCE
TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) INDEX
INITIAL SETUP:
NOT APPLICABLE
Table 1. DTC Table.

DTC CONDITION/DESCRIPTION REPAIR INFORMATION
*Indicates AMBER CHECK TRANS lamp is ON when DTC is set.
P0121 Pedal Position Sensor, Low Refer to Accelerator Position Sensor (APS)/Idle Validation
Voltage. Switch (IVS) Troubleshooting Procedure (WP 0050).
P0123 Pedal Position Sensor, High Refer to Accelerator Pedal Sensor/Idle Validation
Voltage. Troubleshooting Procedure (WP 0050).
P0218 Transmission Fluid Over Refer to Transmission Fluid Over Temperature
Temperature. Troubleshooting Procedure (WP 0143).
P0602* Transmission Control Module Refer to Transmission Control Module (TCM) Operational
(TCM) Not Programmed. Checkout Procedure (WP 0144).
(TCM) Vehicle Options (TRANS Checkout Procedure (WP 0144).
ID) Error.
(TCM) Processor. Checkout Procedure (WP 0144).
P0614* Torque Control Data Mismatch Refer to Transmission Control Module (TCM) Operational
– Engine Control Module Checkout Procedure (WP 0144).
(ECM)/Transmission Control
Module (TCM).
(TCM) Internal Temperature Too Checkout Procedure (WP 0144).
High.
P063E* Auto Configuration Throttle Input Refer to Transmission Control Module (TCM) Operational
Not Present. Checkout Procedure (WP 0144).
P063F Auto Configuration Engine Refer to Transmission Control Module (TCM) Operational
Coolant Temp Input Not Present. Checkout Procedure (WP 0144).
P0658* Actuator Supply Voltage 1 Refer to Transmission High Side Driver Troubleshooting
(HSD1) Low. Procedures (WP 0145).
P0659* Actuator Supply Voltage 1 Refer to Transmission High Side Driver Troubleshooting
(HSD1) High. Procedures (WP 0145).
P0702* Transmission Control System Refer to Transmission Control System ID Troubleshooting
Electrical (Trans ID). Procedures (WP 0146).
P070C Transmission Fluid Level Refer to Transmission Fluid Level Sensor Troubleshooting
Sensor, Low. Procedures (WP 0147).
P070D Transmission Fluid Level Refer to Transmission Fluid Level Sensor Troubleshooting
Sensor, High. Procedures (WP 0147).
P0711* Transmission Fluid Temperature Refer to Transmission Temperature Sensor Troubleshooting
Sensor Performance. Procedures (WP 0148).
Sensor, Low. Procedures (WP 0148).
Sensor, High. Procedures (WP 0148).
P0721* Output Speed Sensor Refer to Transmission Control Module (TCM) Operational
Performance. Checkout Procedure (WP 0149).
P0722* Output Speed Sensor, No Refer to Transmission Control Module (TCM) Operational
Signal. Checkout Procedure (WP 0149).
P0726 Engine Speed Sensor Refer to Transmission High Side Driver Troubleshooting
Performance. Procedures (WP 0150).
0008–1
TM 9-2355-106-23-1 0008
TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) INDEX - (CONTINUED)
P0727 Engine Speed Sensor, No Refer to Transmission High Side Driver Troubleshooting
Signal. Procedures (WP 0150).
P0731* Incorrect 1st Gear Ratio. Refer to Internal Transmission Operational Checkout
P0732* Incorrect 2nd Gear Ratio. Refer to Internal Transmission Operational Checkout
P0733* Incorrect 3rd Gear Ratio. Refer to Internal Transmission Operational Checkout
P0734* Incorrect 4th Gear Ratio. Refer to Internal Transmission Operational Checkout
P0735* Incorrect 5th Gear Ratio. Refer to Internal Transmission Operational Checkout
P0736* Incorrect Reverse Gear Ratio. Refer to Internal Transmission Operational Checkout
P0776* Pressure Control Solenoid 2, Refer to Transmission Pressure Control Solenoid 2
Stuck Off. Troubleshooting Procedures (WP 0152).
Stuck On. Troubleshooting Procedures (WP 0152).
Stuck Off. Troubleshooting Procedure (WP 0153).
Stuck On. Troubleshooting Procedure (WP 0153).
P0842* Transmission Pressure Switch Refer to Transmission Pressure Switch Troubleshooting
1, Low. Procedures (WP 0154).
P0843* Transmission Pressure Switch Refer to Transmission Pressure Switch Troubleshooting
1, High. Procedures (WP 0154).
P0880 Transmission Control Module Refer to Transmission Circuit Troubleshooting Procedure
(TCM) Power Input Signal. (WP 0141).
(TCM) Power Input Signal (WP 0141).
Performance.
(TCM) Power Input Signal, Low. (WP 0141).
(TCM) Power Input Signal, High. (WP 0141).
P0894* Transmission Component Refer to Transmission Slipping Operational Checkout
Slipping. Procedure (WP 0155).
P0960* Pressure Control Solenoid Main Refer to Transmission Pressure Control Main MOD
Modulation Control, Open. Troubleshooting Procedures (WP 0156).
Mod Control, Low. Troubleshooting Procedures (WP 0156).
Mod Control, High. Troubleshooting Procedures (WP 0156).
P0964* Pressure Control Solenoid 2 Refer to Transmission Pressure Control Solenoid 2
Control, Open. Troubleshooting Procedures (WP 0152).
Control, Low. Troubleshooting Procedures (WP 0152).
Control, High. Troubleshooting Procedures (WP 0152).
0008–2
TM 9-2355-106-23-1 0008
P0973* Shift Solenoid 1 Control, Low. Refer to Transmission Shift Solenoid 1 Troubleshooting
Procedures (WP 0153).
P0974* Shift Solenoid 1 Control, High. Refer to Transmission Shift Solenoid 1 Troubleshooting
P1739* Incorrect Low Gear Ratio. Refer to Transmission Low Gear Troubleshooting Procedures
(WP 0158).
P2670* Actuator Supply Voltage 2 Refer to Transmission High Side Driver 2 Troubleshooting
(HSD2), Low. Procedures (WP 0159).
(HSD2), High. Procedures (WP 0159).
(HSD3), Low. Procedures (WP 0160).
(HSD3), High. Procedures (WP 0160).
Control, Low Troubleshooting Procedures (WP 0162).
U0010 Controller Area Network (CAN) Refer to Transmission Communication Troubleshooting
Bus Reset Counter Overrun. Procedures (WP 0163).
U0100* Lost Communication with Engine Refer to Transmission Communication Troubleshooting
Cotrol Module (ECM) (J1587). Procedures (WP 0163).
U0103* Lost Communication with Gear Refer to Transmission Communication Troubleshooting
Shift Module (Shift Selector) 1. Procedures (WP 0163).
U0115* Lost Communication With Refer to Transmission Communication Troubleshooting
Engine Control Module (ECM). Procedures (WP 0163).
U0291* Lost Communication with Gear Refer to Transmission Communication Troubleshooting
U0304* Incompatible Gear Shift Module Refer to Transmission Communication Troubleshooting
1 (Shift Selector ID). Procedures (WP 0163).
U0333* Incompatible Gear Shift Module Refer to Transmission Communication Troubleshooting
2 (Shift Selector ID). Procedures (WP 0163).
0008–3
TM 9-2355-106-23-1 0008
U0404* Invalid Data Received from Gear Refer to Transmission Communication Troubleshooting
U0592* Invalid Data Received from Gear Refer to Transmission Communication Troubleshooting
END OF WORK PACKAGE
0008–4
TM 9-2355-106-23-1 0009
FIELD MAINTENANCE
ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) INDEX
INITIAL SETUP:
NOT APPLICABLE
NOTE
Sequences of blinks illuminate the ABS indicator lamp for half a second, with half-second
pauses between them. Pauses between blink code digits are 1.5 seconds. Pauses between
blink code messages are 2.5 seconds. The lamp remains on for 5 seconds at the end of
messages.
Once the ABS indicator lamp begins displaying a sequence of codes, it continues until all blink
code messages have been displayed and then returns to the normal operating mode. During
this time, the ABS control module will ignore any additional blink code switch activation.
Table 1. DTC Table.

1st 2nd CONDITION/DESCRIPTION REPAIR INFORMATION
BLINK BLINK
CODE CODE
2 1 Left Steer Axle Sensor Excessive Refer to Antilock Brake System (ABS) Wheel Speed
Air Gap. Sensor Troubleshooting Procedure (WP 0177).
2 2 Left Steer Axle Sensor Output Refer to Antilock Brake System (ABS) Wheel Speed
Low at Drive-Off. Sensor Troubleshooting Procedure (WP 0177).
2 3 Left Steer Axle Sensor Open or Refer to Antilock Brake System (ABS) Wheel Speed
Shorted. Sensor Troubleshooting Procedure (WP 0177).
2 4 Left Steer Axle Sensor Loss of Refer to Antilock Brake System (ABS) Wheel Speed
Sensor Signal. Sensor Troubleshooting Procedure (WP 0177).
2 5 Left Steer Axle Sensor Wheel Refer to Antilock Brake System (ABS) Wheel Speed
End. Sensor Troubleshooting Procedure (WP 0177).
2 6 Left Steer Axle Sensor Erratic Refer to Antilock Brake System (ABS) Wheel Speed
2 7 Left Steer Axle Sensor Tire Size Refer to Antilock Brake System (ABS) Wheel Speed
Calibration. Sensor Troubleshooting Procedure (WP 0177).
2 10 Left Steer Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
Configuration Error. Sensor Troubleshooting Procedure (WP 0177).
3 1 Right Steer Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
Excessive Air Gap. Sensor Troubleshooting Procedure (WP 0177).
3 2 Right Steer Axle Sensor Output Refer to Antilock Brake System (ABS) Wheel Speed
3 3 Right Steer Axle Sensor Open or Refer to Antilock Brake System (ABS) Wheel Speed
3 4 Right Steer Axle Sensor Loss of Refer to Antilock Brake System (ABS) Wheel Speed
3 5 Right Steer Axle Sensor Wheel Refer to Antilock Brake System (ABS) Wheel Speed
3 6 Right Steer Axle Sensor Erratic Refer to Antilock Brake System (ABS) Wheel Speed
3 7 Right Steer Axle Sensor Tire Size Refer to Antilock Brake System (ABS) Wheel Speed
3 10 Right Steer Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
4 1 Left Drive Axle Sensor Excessive Refer to Antilock Brake System (ABS) Wheel Speed
Air Gap. Sensor Troubleshooting Procedure (WP 0177).
0009–1
TM 9-2355-106-23-1 0009
ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE (DTC) INDEX - (CONTINUED)
4 2 Left Drive Axle Sensor Output Refer to Antilock Brake System (ABS) Wheel Speed
4 3 Left Drive Axle Sensor Open or Refer to Antilock Brake System (ABS) Wheel Speed
4 4 Left Drive Axle Sensor Loss of Refer to Antilock Brake System (ABS) Wheel Speed
4 5 Left Drive Axle Sensor Wheel Refer to Antilock Brake System (ABS) Wheel Speed
4 6 Left Drive Axle Sensor Erratic Refer to Antilock Brake System (ABS) Wheel Speed
4 7 Left Drive Axle Sensor Tire Size Refer to Antilock Brake System (ABS) Wheel Speed
4 10 Left Drive Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
5 1 Right Drive Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
Excessive Air Gap. Sensor Troubleshooting Procedure (WP 0177).
5 2 Right Drive Axle Sensor Output Refer to Antilock Brake System (ABS) Wheel Speed
5 3 Right Drive Axle Sensor Open or Refer to Antilock Brake System (ABS) Wheel Speed
5 4 Right Drive Axle Sensor Loss of Refer to Antilock Brake System (ABS) Wheel Speed
5 5 Right Drive Axle Sensor Wheel Refer to Antilock Brake System (ABS) Wheel Speed
5 6 Right Drive Axle Sensor Erratic Refer to Antilock Brake System (ABS) Wheel Speed
5 7 Right Drive Axle Sensor Tire Size Refer to Antilock Brake System (ABS) Wheel Speed
5 10 Right Drive Axle Sensor Refer to Antilock Brake System (ABS) Wheel Speed
6 1 Power Supply Battery Voltage Refer to Antilock Brake System (ABS) J1939 Serial
Too Low. Communications Troubleshooting Procedure (WP 0139)
Too High. Communications Troubleshooting Procedure (WP 0139)
Too Low During ABS. Communications Troubleshooting Procedure (WP 0139)
Open Circuit. Communications Troubleshooting Procedure (WP 0139)
6 5 Power Supply Ignition Voltage Refer to Antilock Brake System (ABS) J1939 Serial
Too Low. Communications Troubleshooting Procedure (WP 0139)
Too High. Communications Troubleshooting Procedure (WP 0139)
Too Low During ABS. Communications Troubleshooting Procedure (WP 0139)
6 8 Power Supply Input Voltage Has Refer to Antilock Brake System (ABS) J1939 Serial
Excessive Noise (Temporary). Communications Troubleshooting Procedure (WP 0139)
6 9 Power Supply Input Voltage Has Refer to Antilock Brake System (ABS) J1939 Serial
Excessive Noise. Communications Troubleshooting Procedure (WP 0139)
7 1 Left Steer Axle Release Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
Shorted to Ground. Valve (PMV) Troubleshooting Procedure (WP 0178).
Shorted to Voltage. Valve (PMV) Troubleshooting Procedure (WP 0178).
Open Circuit. Valve (PMV) Troubleshooting Procedure (WP 0178).
7 4 Left Steer Axle Hold Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
0009–2
TM 9-2355-106-23-1 0009
7 7 Left Steer Axle Common Circuit Refer to Antilock Brake System (ABS) Pressure Modulator
7 8 Left Steer Axle Configuration If this DTC sets, ABS control module is faulty. Refer to
Error. Antilock Brake System (ABS) Control Module Removal
and Installation (WP 0355).
8 1 Right Steer Axle Release Refer to Antilock Brake System (ABS) Pressure Modulator
Solenoid Shorted to Ground. Valve (PMV) Troubleshooting Procedure (WP 0178).
Solenoid Shorted to Voltage. Valve (PMV) Troubleshooting Procedure (WP 0178).
Solenoid Open Circuit. Valve (PMV) Troubleshooting Procedure (WP 0178).
8 4 Right Steer Axle Hold Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
8 7 Right Steer Axle Common Circuit Refer to Antilock Brake System (ABS) Pressure Modulator
8 8 Right Steer Axle Configuration If this DTC sets, ABS control module is faulty. Refer to
9 1 Left Drive Axle Release Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
9 4 Left Drive Axle Hold Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
9 7 Left Drive Axle Common Circuit Refer to Antilock Brake System (ABS) Pressure Modulator
9 8 Left Drive Axle Configuration If this DTC sets, ABS control module is faulty. Refer to
10 1 Right Drive Axle Release Refer to Antilock Brake System (ABS) Pressure Modulator
Solenoid Shorted to Ground. Valve (PMV) Troubleshooting Procedure (WP 0178).
Solenoid Shorted to Voltage. Valve (PMV) Troubleshooting Procedure (WP 0178).
Solenoid Open Circuit. Valve (PMV) Troubleshooting Procedure (WP 0178).
10 4 Right Drive Axle Hold Solenoid Refer to Antilock Brake System (ABS) Pressure Modulator
0009–3
TM 9-2355-106-23-1 0009
10 7 Right Drive Axle Common Circuit Refer to Antilock Brake System (ABS) Pressure Modulator
10 8 Right Drive Axle Configuration If this DTC sets, ABS control module is faulty. Refer to
11 1 J1939 Serial Communications Refer to Antilock Brake System (ABS) J1939 Serial
Error. Communications Troubleshooting Procedure (WP 0139).
11 2 J1939 Retarder Communications Refer to Antilock Brake System (ABS) J1939 Serial
11 3 J1939 Engine Communications Refer to Antilock Brake System (ABS) J1939 Serial
12 1 Stop Lamp Switch Not Detected. Vehicle is not equipped with this feature. If this DTC sets,
ABS control module is faulty. Refer to Antilock Brake
System (ABS) Control Module Removal and Installation
(WP 0355).
12 2 Stop Lamp Switch Defective. Vehicle is not equipped with this feature. If this DTC sets,
(WP 0355).
12 3 Automatic Traction Control (ATC) ABS control module has been placed in the dynamometer
Disabled or Dynamometer Test test mode by either the diagnostic blink code switch or a
Mode Active. hand-held or PC-based diagnostic tool. ATC is disabled.
If this DTC sets, ABS control module is faulty. Refer to
Antilock Brake System (ABS) Control Module Removal
12 7 PMV Common Shorted to Refer to Antilock Brake System (ABS) Pressure Modulator
Ground. Valve (PMV) Common Circuit Troubleshooting Procedure
(WP 0140).
12 8 PMV Common Shorted to Refer to Antilock Brake System (ABS) Pressure Modulator
Voltage. Valve (PMV) Common Circuit Troubleshooting Procedure
(WP 0140).
12 9 ATC Disabled to Prevent Brake ATC is temporarily disabled to prevent excessive heating
Fade. of the foundation brakes. Informational DTC, no repair
required.
12 10 Tire Size Out of Range (Front to Verify proper tire inflation (TM 9-2355-106-10).Verify
Rear). tire tread wear is not excessive. Refer to Preventive
Maintenance Checks And Services (PMCS) Including
Lubrication Instructions (WP 0216). Verify tone ring
teeth are not damaged. Refer to Front Axle Antilock
Brake System (ABS) Tone Ring Removal and Installation
(WP 0483).
12 11 Wheel Speed Sensors Reversed Sensors are reversed (left to right) on one of the axles.
on an Axle. Verify proper installation, connection, and wiring of the
sensors. Refer to Front Antilock Brake System (ABS)
Sensor Removal and Installation (WP 0425).
12 12 Differential Lock Solenoid Vehicle is not equipped with this feature. If this DTC sets,
Shorted to Ground or Open ABS control module is faulty. Refer to Antilock Brake
Circuit. System (ABS) Control Module Removal and Installation
(WP 0355).
12 13 Differential Lock Solenoid Vehicle is not equipped with this feature. If this DTC sets,
Shorted to Voltage. ABS control module is faulty. Refer to Antilock Brake
(WP 0355).
0009–4
TM 9-2355-106-23-1 0009
12 23 I/O 2 or I/O 3 Shorted High. Check for short circuit condition between voltage and the
I/O 2 and I/O 3 circuits.
13 2 ABS control module circuit failure Check for damaged or corroded connectors. Check for
(10). damaged wiring. Clear trouble codes. If DTCs return,
replace the ABS control module. Refer to Antilock Brake
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(WP 0355).
(1A). damaged wiring. Clear trouble codes. If DTCs return,
(WP 0355).
0009–5
TM 9-2355-106-23-1 0009
(1B). damaged wiring. Clear trouble codes. If DTCs return,
(WP 0355).
(WP 0355).
18 1 Traction Control Valve (TCV) Vehicle is not equipped with this feature. If this DTC sets,
Solenoid Shorted to Ground. ABS control module is faulty. Refer to Antilock Brake
(WP 0355).
18 2 TCV Solenoid Shorted to Voltage. Vehicle is not equipped with this feature. If this DTC sets,
(WP 0355).
18 3 TCV Solenoid Open Circuit. Vehicle is not equipped with this feature. If this DTC sets,
(WP 0355).
18 4 TCV Configuration Error. Vehicle is not equipped with this feature. If this DTC sets,
(WP 0355).
END OF WORK PACKAGE
0009–6
TM 9-2355-106-23-1 0010
FIELD MAINTENANCE
VEHICLE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Test Equipment WP 0014
Maintenance Support Device (MSD) (WP 0795, Item WP 0011
70) WP 0078
WP 0005
Tools and Special Tools
WP 0012
General Mechanic's Tool Kit (GMTK)
WP 0006
(WP 0795, Item 37)
WP 0172
References WP 0174
TM 9-2355-106-10 WP 0173
TM 9-2355-106-23P WP 0009
WP 0032 WP 0782
WP 0409
WP 0412 Equipment Condition
WP 0317 Parking brake set (TM 9-2355-106-10)
WP 0333 Transmission set in NEUTRAL (N) (TM
WP 0448 9-2355-106-10)
WP 0449 Engine off (TM 9-2355-106-10)
WP 0422 MAIN POWER switch off (TM 9-2355-106-10)
WP 0034 Wheels chocked (TM 9-2355-106-10)
TROUBLESHOOTING PROCEDURE
NOTE
Personnel must read and understand the Troubleshooting Procedures Overview in How to Use
This Manual before performing any troubleshooting procedures.
It is assumed that if a fault is found, the technician will correct it.
STEP
1. Perform following preliminary inspections:

2. Ensure that battery is fully charged. Refer to Battery Power Troubleshooting Procedure (WP 0032).
3. Ensure that battery cables are clean and tight. Refer to Battery Stud Adapter Terminal Clamp Removal and
Installation (WP 0409).
4. Inspect for open fuses at following locations:
• Engine Control Module (ECM) and Transmission Control Module (TCM) Clean Power Fuse (WP 0412)
• Instrument Panel Circuit Breaker, Fuse, and Relay (WP 0317)
• Power Distribution Center (PDC) Fuse and Relay (WP 0333)
• Winch Mega Fuse and Holder (WP 0448)
• 24V Inverter Megafuse and Fuse Holder (WP 0449)
• 12V Underhood Megafuse and Holder (WP 0422)
5. Inspect easily accessible systems or visible system components for obvious damage or conditions that
could cause symptom.
0010–1
TM 9-2355-106-23-1 0010
VEHICLE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Was condition found and corrected?
DECISION
YES Return vehicle to service.

NO Go to next step.
STEP
6. Note which vehicle system symptom is related to.
Is symptom related to engine?
DECISION
NO Go to Step 13.
YES Go to next step.
STEP
7. Perform engine start procedure (TM 9-2355-106-10).
Does engine crank?
DECISION
NO Go to Engine Does Not Crank Troubleshooting Procedure (WP 0034).

STEP
8. Refer to results from Step 7.
Does engine start and run?
DECISION
NO Go to Hard Start/No Start Operational Checkout Procedure (WP 0014).

STEP
9. Perform engine shutdown procedure (TM 9-2355-106-10).

10. Connect MSD. Refer to Connecting Maintenance Support Device (MSD) (WP 0011).
Does MSD communicate with Transmission Control Module (TCM) or Electronic System Controller (ESC)?
DECISION
NO Go to Diagnostic Connector Troubleshooting Procedure (WP 0078).

0010–2
TM 9-2355-106-23-1 0010
STEP
11. Refer to results from Step 10.
Does MSD communicate with ECM?
DECISION
NO Go to Engine Control Module (ECM) Troubleshooting Procedure (WP 0049).

STEP
12. Obtain Diagnostic Trouble Codes (DTCs) for ECM with MSD. Refer to Diagnostic Trouble Code (DTC) Access
Does MSD display current DTCs?
DECISION
NO Go to Vehicle Troubleshooting Symptom Index (WP 0005).

YES Go to Engine DTC Index (WP 0006).
STEP
Is symptom related to transmission?
DECISION
NO Go to Step 16.
STEP
Does MSD communicate with TCM?
DECISION
NO Go to Transmission Control Module (TCM) Power Operational Checkout Procedure (WP 0142).
STEP
15. Obtain DTCs for TCM with MSD. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
0010–3
TM 9-2355-106-23-1 0010
DECISION

YES Go to Transmission DTC Index (WP 0008).
STEP
Is symptom related to chassis?
DECISION
NO Go to Step 19.
STEP
Does MSD communicate with ESC?
DECISION
NO Go to Electronic System Controller (ESC) Troubleshooting Procedure (WP 0068).

STEP
18. Obtain DTCs for ESC with MSD. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
DECISION

YES Go to ESC DTC Index (WP 0007).
STEP
Is symptom related to antilock brakes?
DECISION
NO Go to Step 22.
0010–4
TM 9-2355-106-23-1 0010
STEP
Does MSD communicate with antilock brake control module?
DECISION
NO Go to American Truckers Association (ATA) Communications/Data Communications Link (DLC)

Troubleshooting Procedure(WP 0051).
STEP
21. Obtain DTCs for antilock brake module. Refer to Diagnostic Trouble Code (DTC) Access Procedure
(WP 0012).
Does antilock brake module display DTCs?
DECISION

YES Go to Antilock Brake Diagnostic Trouble Code (DTC) Index (WP 0009).
STEP
Is symptom related to transfer case?
DECISION
YES Go to Vehicle Troubleshooting Symptom Index (WP 0005).

NO Go to next step.
STEP
Is symptom is related to service brakes?
DECISION

YES Go to Air Brake System Operational Checkout Procedure (WP 0172), Air Dryer Heater and Thermostat
Troubleshooting Procedure (WP 0174), and Air Brake Component Operational Checkout Procedure (WP 0173).
END OF WORK PACKAGE
0010–5/blank
TM 9-2355-106-23-1 0011
FIELD MAINTENANCE
CONNECTING MAINTENANCE SUPPORT DEVICE (MSD)
INITIAL SETUP:
Test Equipment Equipment Condition
Maintenance Support Device (MSD) (WP 0795, Item Parking brake set (TM 9-2355-106-10)
70) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
References
Engine off (TM 9-2355-106-10)
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0782
MAINTENANCE SUPPORT DEVICE
Figure 1. Maintenance Support Device and Power Cables.
The MSD laptop computer, along with troubleshooting software, is used to diagnose vehicle systems. The MSD
communicates with vehicle control modules by means of an interface cable. The cable connects to the 9-pin
American Trucking Association (ATA) diagnostic connector, located to the left of the steering column.
0011–1
TM 9-2355-106-23-1 0011
CONNECTING MAINTENANCE SUPPORT DEVICE (MSD) - (CONTINUED)
CONNECTING MSD TO VEHICLE
Figure 2. MSD to ATA Connection.
1. Connect 9-pin connector of truck interface cable (Figure 2, Item 4) to ATA 9-pin connector (Figure 2, Item
5) to left of steering column.
2. Connect USB connector on truck interface cable (Figure 2, Item 4) to USB port (Figure 2, Item 1) on back of
MSD (Figure 2, Item 3).
3. To operate from external power, connect power cable or power pack to MSD power port (Figure 2, Item 2).
4. Turn MAIN POWER switch ON (TM 9-2355-106-10).
5. Turn ignition switch on.
6. Power up MSD (Figure 2, Item 3).
Table 1. Diagnostic Software.

System Software
Engine Service Assistant™
Transmission Allision-DOC™ for PC-Service Tool
Antilock Brake System (ABS) ACom™ Diagnostics
Body, Electronic System Controller (ESC), Instrument Diamond Logic® Builder
Panel Cluster (IPC), Switch Pack, J1939 Data Link
Circuit
7. Double-click icon for appropriate diagnostic software. Refer to Table 1.
END OF WORK PACKAGE
0011–2
TM 9-2355-106-23-1 0012
FIELD MAINTENANCE
DIAGNOSTIC TROUBLE CODE (DTC) ACCESS PROCEDURE
INITIAL SETUP:
Test Equipment TM 9-2355-106-23P

70) WP 0782
References
TM 9-2355-106-10
This procedure covers retrieval of stored DTCs for the following control modules:
• Electronic System Controller (ESC)
• Engine Control Module (ECM)
• Antilock Brake System (ABS)
• Transmission Control Module (TCM)
MSD AVAILABLE
The MSD is capable of retrieving stored DTCs from each control module listed above. If available, use the
MSD to retrieve DTCs.
DTC Retrieval Using MSD

1. Set transmission in NEUTRAL (N) (TM 9-2355-106-10).
2. Set parking brake (TM 9-2355-106-10).
3. Shut engine off (TM 9-2355-106-10).
4. Turn MAIN POWER switch off (TM 9-2355-106-10).
5. Chock wheels (TM 9-2355-106-10).
6. Connect MSD to vehicle. Refer to Connecting Maintenance Support Device (MSD) (WP 0011).
8. Turn ignition switch ON (TM 9-2355-106-10).
9. Record stored DTCs using MSD.
MSD UNAVAILABLE
If the MSD is unavailable, use the off-line diagnostic mode to retrieve DTCs by performing the following steps. The
mode is specific to each control module.
ESC
6. Press and release CRUISE ON and RESUME/ACCEL buttons simultaneously during Instrument Panel
(IP) gauge sweep.
7. Observe odometer display.
a. The display will show the number of stored DTCs.
b. After 10 seconds, the first DTC displays for 10 seconds before displaying the next DTC in the list. The
cycle continues for all stored DTCs.
0012–1
TM 9-2355-106-23-1 0012
DIAGNOSTIC TROUBLE CODE (DTC) ACCESS PROCEDURE - (CONTINUED)
Figure 1. Select/Reset Button.
8. To manually cycle through the DTC list, press and release the cluster select/reset button (Figure 1, Item 1).
9. Record DTCs.
ECM
NOTE
All ECM DTCs are three digits. The IP uses the RED and AMBER ENGINE lamps to display
DTCs. Code 111 indicates no stored ECM DTCs.

6. Press and release CRUISE ON and RESUME/ACCEL buttons simultaneously during IP gauge sweep.
7. Observe RED ENGINE lamp. Lamp will flash once to indicate start of active DTC retrieval.
8. Count each time AMBER ENGINE lamp flashes. A slight pause will occur between each series of flashes. A
sequence of three series of flashes and pauses represents the DTC. The following is an example:
Two flashes, pause, three flashes, pause, and two flashes indicate DTC 232 is set.
9. Record each active DTC.
10. Observe RED ENGINE lamp after AMBER ENGINE lamp flashes. RED ENGINE lamp indicates the following
conditions:
a. If there is more than one DTC, the RED ENGINE lamp will flash one time to indicate the beginning of a
new DTC.
Continue recording active DTCs.
b. RED ENGINE lamp will flash two times to indicate beginning of inactive DTCs.
(1) Count each time the AMBER ENGINE lamp flashes.
(2) Record each inactive DTC.
c. RED ENGINE lamp will flash three times after retrieval of all active and inactive DTCs.
0012–2
TM 9-2355-106-23-1 0012
ABS Module
Figure 2. ABS Blink Switch.

6. Depress and release ABS blink switch one time. Refer to Figure 2.
7. Observe ABS indicator lamp.
8. Count each time ABS lamp flashes. Lamp will flash for 0.5 seconds, with 0.5-second pauses between
flashes. A pause of 1.5 seconds indicates the end of each digit of the DTC. A 2.5-second pause between
flashes occurs between DTCs.
9. Record each DTC.
10. Observe ABS lamp. Lamp will remain on for 5 seconds after retrieval of all ABS DTCs.
0012–3
TM 9-2355-106-23-1 0012
TCM
Figure 3. Transmission Shift Selector.

6. Press shift selector UP and DOWN arrows simultaneously two times. Refer to Figure 3.
7. Record DTCs displayed on shift selector.
END OF WORK PACKAGE
0012–4
TM 9-2355-106-23-1 0013
FIELD MAINTENANCE
CLEARING INACTIVE DIAGNOSTIC TROUBLE CODE (DTC) PROCEDURE
INITIAL SETUP:

9-2355-106-10)
References Engine shut off (TM 9-2355-106-10)
TM 9-2355-106-10 MAIN POWER switch off (TM 9-2355-106-10)
TM 9-2355-106-23P Wheels chocked (TM 9-2355-106-10)
WP 0011
WP 0782
This procedure covers clearing inactive DTCs for the following control modules:
• Engine Control Module (ECM)
• Electronic System Controller (ESC)
• Antilock Brake System (ABS) Control Module
• Transmission Control Module (TCM)
Procedure With MSD
NOTE
Clearing inactive DTCs stored in the ECM requires use of MSD.
1. Connect MSD to vehicle. Refer to Connecting Maintenance Support Device (MSD) WP 0011.
2. Clear inactive DTCs stored in specific control module, using MSD.
ESC Procedure Without MSD

3. Press and release CRUISE ON and RESUME/ACCEL buttons simultaneously during Instrument Panel
(IP) gauge sweep.
4. Press SER. DRIVE on Master Vehicle Light Switch (MVLS) two times (TM 9-2355-106-10).
5. Press ENTER on Master Vehicle Light Switch (MVLS) (TM 9-2355-106-10).
6. Place turn signal switch in left turn position (TM 9-2355-106-10).
7. Press CRUISE ON and SET/CRUISE buttons simultaneously (TM 9-2355-106-10).
8. Release cruise control buttons (TM 9-2355-106-10).
ABS Blink Switch Procedure Without MSD

3. Wait two seconds after turning ignition switch on.
4. Depress and release blink switch three times.
TCM Without MSD

3. Press shift selector UP and DOWN arrows simultaneously two times.
0013–1
TM 9-2355-106-23-1 0013
CLEARING INACTIVE DIAGNOSTIC TROUBLE CODE (DTC) PROCEDURE - (CONTINUED)
4. Press and hold shift selector MODE button for 10 seconds.
END OF WORK PACKAGE
0013–2
TM 9-2355-106-23-1 0014
FIELD MAINTENANCE
HARD START/NO START OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
References WP 0032
TM 9-2355-106-10 WP 0066
TM 9-2355-106-23P WP 0782
WP 0037
WP 0049 9-2355-106-10)
WP 0020 Engine off (TM 9-2355-106-10)
NOTE
STEP
1. Perform engine startup procedure (TM 9 2355–106–10).
Vehicle cranks but will not start or is difficult to start.
CORRECTIVE ACTION
Perform the following diagnostic procedures in order listed.
1. Battery Power Operational Checkout Procedure (WP 0032)
2. Keyless Ignition Switch Troubleshooting Procedure (WP 0066)
3. Fuel Operational Checkout Procedure (WP 0037)
4. Engine Systems Operational Checkout Procedure (WP 0017)
5. Engine Oil Operational Checkout Procedure (WP 0018)
6. Intake/Exhaust Troubleshooting Procedure (WP 0019)
7. Engine Control Module (ECM) Troubleshooting Procedure (WP 0049)
8. Injection Control Pressure (ICP) No Start Operational Checkout Procedure (WP 0020)
1. Return vehicle to service.
END OF WORK PACKAGE
0014–1/blank
TM 9-2355-106-23-1 0015
FIELD MAINTENANCE
ENGINE PERFORMANCE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
References WP 0024
TM 9-2355-106-10 WP 0027
TM 9-2355-106-23P WP 0782
WP 0018
Equipment Condition
WP 0035
Parking brake set (TM 9-2355-106-10)
WP 0036
Transmission set in NEUTRAL (N) (TM
WP 0019
9-2355-106-10)
WP 0038
Engine off (TM 9-2355-106-10)
WP 0022
WP 0023
WP 0025
WP 0026
NOTE
STEP
1. Start vehicle and evaluate engine performance.
Engine runs but has performance issues.
CORRECTIVE ACTION
Perform the following diagnostic procedures in the order listed.
1. Engine Oil Operational Checkout Procedure (WP 0018)
2. Fuel Pump Pressure Troubleshooting Procedure (WP 0035)
3. Fuel Pump Restriction Troubleshooting Procedure (WP 0036)
4. Intake/Exhaust Troubleshooting Procedure (WP 0019)
5. Fuel Pressure (Full Load) Troubleshooting Procedure (WP 0038)
6. Injection Control Pressure (ICP) Troubleshooting Procedure (WP 0022)
7. Boost Pressure Troubleshooting Procedure (WP 0023)
8. Crankcase Pressure Troubleshooting Procedure (WP 0025)
9. Wastegate Actuator Troubleshooting Procedure (WP 0026)
10. Charge Air Cooler Pressure Operational Checkout Procedure (WP 0024)
11. Valve Adjustment Troubleshooting Procedure (WP 0027)
1. Return vehicle to service.
END OF WORK PACKAGE
0015–1/blank
TM 9-2355-106-23-1 0016
FIELD MAINTENANCE
ENGINE MECHANICAL OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70) WP 0233
WP 0236
Tools and Special Tools WP 0234
General Mechanic's Tool Kit (GMTK) WP 0253
(WP 0795, Item 37) WP 0261
WP 0277
References
WP 0283
WP 0011
WP 0527
WP 0019
WP 0782
WP 0014
WP 0045 9-2355-106-10)
WP 0218 Engine off (TM 9-2355-106-10)
WP 0228 Engine hood open and secured (TM 9-2355-106-10)
EXCESSIVE OIL CONSUMPTION
WARNING
Use extreme caution when testing or working on electrical circuits. Always assume that
electrical circuits are live. Electrical shock can occur upon contact with voltage high enough
to cause current flow through muscles or nerves. On Direct Current (DC) systems, generally
1 milliamp of current can be felt, 5 milliamps can cause severe pain, 15 milliamps can cause
loss of muscle control, and 70 milliamps can be fatal. Wear protective clothing; ensure skin,
clothing, and surrounding areas are dry; do not wear jewelry; and touch only the insulated,
nonmetallic parts of electrical components and testing equipment. To prevent electrical arcing,
avoid shorting electrical test probes and jumper wires. Electrical arcing can cause bright
flashes of light, capable of causing temporary blindness. If electrical injury occurs, immediately
shut off power supply and seek medical assistance. Failure to comply may result in serious
injury or death to personnel.
Engine hood is extremely heavy and requires two-person lift. Ensure that there is adequate
space in front of the vehicle to open hood completely without pinning or pinching personnel
between hood and any other structure. Use extreme care when working under hood and make
sure it is properly supported. Failure to comply may result in serious injury or death to personnel.
NOTE
0016–1
TM 9-2355-106-23-1 0016
ENGINE MECHANICAL OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
STEP
1. Visually inspect for external oil leaks.
External oil leaks are detected.
CORRECTIVE ACTION
Perform necessary repairs to correct external oil leaks. Refer to Chapter 4 Index for required removal and
replacement procedures.
1. Inspect engine air filter (TM 9-2355-106–10).
Air filter is restricted.
Replace air filter. Refer to (TM 9-2355-106–10). Return vehicle to service.
1. Visually inspect engine air induction system for damage and leaks. Refer to Intake/Exhaust Restriction
Inspection of engine air induction system reveals damage or leaks.
Perform necessary repairs to correct engine air induction system leaks or damage. Refer to Alphabetical Index for
required removal and installation procedures.
1. Verify crankcase pressure is not excessive. Refer to Crankcase Pressure Troubleshooting Procedure
(WP 0025).
Crankcase pressure is excessive.
Replace engine. Refer to Engine Assembly Removal (WP 0218) and Engine Assembly Installation (WP 0219).
Return vehicle to service.
1. Remove air dryer governor supply air line from air dryer. Refer to Air Compressor Supply Air Line Removal
Oil in air line.
Replace air compressor. Refer to Air Compressor Removal and Installation (WP 0527). Return vehicle to service.
1. Check engine oil level (TM 9-2355-106-10).
Engine oil level is excessive.
Change engine oil. Fill with recommended amount and viscosity of new engine oil. Refer to Engine Oil Drain/Fill
Procedure (WP 0233). Return vehicle to service.
1. Verify engine oil is recommended viscosity. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
Unable to verify engine oil is recommended viscosity.
Change engine oil. Fill with recommended amount and viscosity of new engine oil. Refer to Engine Oil Drain/Fill
Procedure (WP 0233). Return vehicle to service.
1. Verify vehicle is not moving over-rated loads. Refer to (TM 9-2355-106-10).
Vehicle is moving over-rated loads.
Reduce load. Return vehicle to service.
1. Verify vehicle is not operated in incorrect gear range that lugs the engine.
Vehicle is operated in incorrect gear range that lugs engine.
Operate vehicle in correct gear or transfer case range. Refer to (TM 9-2355-106-10). Return vehicle to service.
1. Inspect turbocharger inlets and outlets. Refer to Turbocharger Removal and Installation (WP 0261).
Turbocharger compressor inlet is clean while outlet is oily, turbocharger turbine outlet is coked while inlet is not or
turbocharger shows other visible signs of oil leakage.
Replace turbocharger. Refer to Turbocharger Removal and Installation (WP 0261). Return vehicle to service.
0016–2
TM 9-2355-106-23-1 0016
1. Verify fuel injector O-rings and injectors are not leaking engine oil. Refer to Injection Control Pressure (ICP)
Fuel injector O-rings or injectors leak engine oil.
Replace fuel injector O-rings or fuel injectors. Refer to Fuel Injector Removal and Installation (WP 0249). Return
vehicle to service.
EXCESSIVE FUEL CONSUMPTION
STEP
1. Visually inspect for fuel leaks.
Fuel leaks are detected.
CORRECTIVE ACTION
Refer to Chapter 4 Index for replacement procedures to repair fuel leak.
1. Check engine oil level regularly.
Engine oil level is increasing.
STEP 1. Connect MSD. Refer to Connecting Maintenance Support Device (MSD) (WP 0011).
STEP 2. Perform injector tests with MSD. Replace injectors operating incorrectly. Refer to Fuel Injector Removal
and Installation (WP 0249). Return vehicle to service.
1. Monitor engine speed during use.
Engine speed is too high or too low.
Adjust driving practices to operate engine in correct speed range for operating conditions. Refer to (TM
9-2355-106-10). Return vehicle to service.
1. Monitor idle time.
Idle time is excessive.
Reduce idle time.
1. Monitor actual fuel used during specific operating periods and conditions. Compare to another vehicle during
similar operating periods and conditions.
Fuel use is excessive when compared to another vehicle.
Perform all performance and hard start/no start diagnostics. Refer to Engine Performance Operational Checkout
Procedure (WP 0015), and Hard Start/No Start Operational Checkout Procedure (WP 0014).
HIGH COOLANT TEMPERATURE OR COOLANT LOSS
STEP
1. Verify engine cooling system overheats.
Cooling system overheats.
CORRECTIVE ACTION
Refer to Cooling System Troubleshooting Procedure (WP 0045).
0016–3
TM 9-2355-106-23-1 0016
EXCESSIVE EXHAUST SMOKE

STEP
1. Visually inspect air filter for restriction (TM 9-2355-106-10).
Air filter is restricted.
CORRECTIVE ACTION
Replace air filter (TM 9-2355-106-10). Return vehicle to service.
1. Visually inspect air induction system for restriction. Refer to Intake/Exhaust Restriction Troubleshooting
Induction system is restricted.
Remove restriction or replace restricted components. Refer to Chapter 4 Index for applicable replacement
procedures.
1. Inspect turbocharger compressor housing for engine oil leakage. Refer to Turbocharger Removal and
Inspection of turbocharger compressor housing indicates engine oil leakage.
Replace Turbocharger. Refer to Turbocharger Removal and Installation (WP 0261). Return vehicle to service.
1. Verify engine operating temperature is correct (TM 9-2355-106-10).
Engine operating temperature is below normal.
Replace thermostat. Refer to Thermostat Removal and Installation (WP 0283). Return vehicle to service.
1. Check engine oil regularly (TM 9-2355-106-10).
Engine oil level is decreasing.
Refer to Excessive Oil Consumption in this work package.
FUEL DILUTION OF ENGINE OIL
STEP
1. Visually inspect fuel pump for indication of fuel leaks. Refer to Fuel Pump Removal and Installation
(WP 0253).
Fuel leaks are indicated.
CORRECTIVE ACTION
Replace fuel pump. Refer to Fuel Pump Removal and Installation (WP 0253). Return vehicle to service.
1. Perform injector tests in Performance and Hard Start/No Start. Refer to Hard Start/No Start Operational
One or more fuel injectors fail tests.
Replace fuel injector. Refer to Fuel Injector Removal and Installation (WP 0249). Return vehicle to service.
1. Visually inspect fuel injector O-rings for damage and deterioration. Refer to Fuel Injector Removal and
Damaged or deteriorated fuel injector O-rings are indicated.
Replace damaged or deteriorated O-rings. Refer to Fuel Injector Removal and Installation (WP 0249). Return
vehicle to service.
0016–4
TM 9-2355-106-23-1 0016
COOLANT IN LUBRICATING OIL OR LUBRICATING OIL IN COOLANT

STEP
1. Visually inspect engine oil dipstick for WHITE or milky oil (TM 9-2355-106-10).
2. Visually inspect radiator surge overflow tank for engine oil (TM 9-2355-106-10).
Engine oil is milky WHITE or engine oil is in overflow tank.
CORRECTIVE ACTION
Replace engine. Refer to Engine Assembly Removal (WP 0218)and Engine Assembly Installation (WP 0219).
EXCESSIVE SMOKE OR OIL DISCHARGE FROM ENGINE OIL BREATHER TUBE
STEP
1. Inspect turbocharger compressor housing for engine oil leakage. Refer to turbocharger removal and
installation (WP 0261).
Inspection of turbocharger compressor housing indicates engine oil leakage.
CORRECTIVE ACTION
Replace Turbocharger. Refer to Turbocharger Removal and Installation (WP 0261). Return vehicle to service.
1. Inspect engine oil breather tube for engine oil leakage. Refer to engine oil breather tube removal and
installation (WP 0231).
Inspection of engine oil breather tube indicates engine oil leakage.
Replace air compressor. Refer to Air Compressor Removal and Installation (WP 0527). Return vehicle to service.
1. Perform Crankcase Pressure Troubleshooting Procedure. Refer to Crankcase Pressure Test Troubleshooting
Crankcase Pressure Troubleshooting Procedure results are out of specification.
LUBE OIL IN FUEL
STEP
2. Perform fuel injector balance test with MSD.
One or more fuel injectors indicate faults.
CORRECTIVE ACTION
STEP 1. Inspect fuel injector O-rings for faults. Refer to Fuel Injector Removal and Installation (WP 0249).
STEP 2. Replace faulty fuel injector O-rings. Refer to Fuel Injector Removal and Installation (WP 0249).
STEP 3. If no O-rings appear faulty, replace suspect fuel injector. Refer to Fuel Injector Removal and Installation
(WP 0249). Return vehicle to service.
1. Inspect fuel/oil manifold gasket for leaks. Refer to Oil/Fuel Manifold Removal and Installation (WP 0250).
Leaking fuel/oil manifold gasket is indicated.
0016–5
TM 9-2355-106-23-1 0016
Replace fuel/oil manifold. Refer to Oil/Fuel Manifold Removal and Installation (WP 0250). Return vehicle
to service.
1. Inspect for cracked or porous fuel/manifold. Refer to Oil/Fuel Manifold Removal and Installation (WP 0250).
Cracked or porous fuel/oil manifold is indicated.
Replace fuel/oil manifold. Refer to Oil/Fuel Manifold Removal and Installation (WP 0250). Return vehicle
to service.
1. Inspect for cracked or porous cylinder head. Refer to Cylinder Head and Gasket Removal and Installation
(WP 0222).
Cracked or porous cylinder head is indicated. Refer to Cylinder Head and Gasket Removal and Installation
(WP 0222).
Replace cylinder head. Refer to Cylinder Head and Gasket Removal and Installation (WP 0222). Return vehicle
to service.
END OF WORK PACKAGE
0016–6
TM 9-2355-106-23-1 0017
FIELD MAINTENANCE
ENGINE SYSTEMS OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0330
WP 0407
References
TM 9-2355-106-10
WP 0014
TM 9-2355-106-23P
WP 0045
WP 0782
WP 0033
WP 0263 9-2355-106-10)
WP 0264 Engine off (TM 9-2355-106-10)
0017–1
TM 9-2355-106-23-1 0017
ENGINE SYSTEMS OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
WARNING
Fuel is flammable and can explode. Keep all open flames, flammable materials, ignition
sources, and sparks away from diesel fuel and keep fire extinguisher nearby. Do not smoke
when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited by
hot engine. Failure to comply may result in serious injury or death to personnel.
Be alert at all times for the smell of fuel. Hot engines and components can ignite fuel. If fuel
smell is detected while operating vehicle, shut down vehicle immediately. Failure to comply
Store diesel fuel in an approved container clearly marked DIESEL FUEL. Dispose of fuel in
an approved container clearly marked DIESEL FUEL in accordance with standard operating
procedures.
NOTE
Engine will not start with Injection Pressure Regulator (IPR) or Camshaft Position Sensor
(CMP) disconnected.
STEP
0017–2
TM 9-2355-106-23-1 0017
1. Inspect engine electrical connections. Refer to Figure 1.
Figure 1. Connectors LAM 1016, LAM 1019, and 6007.
Injector Pressure Regulator (IPR) or Engine Control Module (ECM) connections loose, damaged, or corroded.
CORRECTIVE ACTION
Replace engine sensor wiring harness or replace engine wiring harness. Refer to Engine Sensor Wiring Harness
Removal and Installation (WP 0330) or Engine Wiring Harness Removal and Installation (WP 0336). Return
vehicle to service.
0017–3
TM 9-2355-106-23-1 0017
Figure 2. Connector LAM 1011.
1. Inspect Camshaft Position Sensor electrical connector. Refer to Figure 2.

Camshaft Position Sensor connector loose, damaged, or corroded.
Replace engine sensor wiring harness or replace engine wiring harness. Refer to Engine Sensor Wiring Harness
Removal and Installation (WP 0330) or Engine Wiring Harness Removal and Installation (WP 0336). Return
vehicle to service.
1. Inspect Power Distribution Center (PDC) electrical connections. Refer to Power Distribution Center (PDC)
Fuse and Relay Removal and Installation (WP 0333).
Fuse or relay connections loose, damaged, or corroded.
Replace PDC. Refer to Power Distribution Center (PDC) Junction Box Removal and Installation (WP 0334).
1. Inspect battery electrical connections. Refer to Battery Cable Troubleshooting Procedure (WP 0033).
Battery connections loose, damaged, or corroded.
Replace or tighten battery cables. Refer to Battery Cables Removal and Installation (WP 0407). Return vehicle
to service.
1. Visually inspect engine sensor wiring harnesses.
Engine sensor wiring harnesses are pinched or chafed.
Replace engine sensor harness. Refer to Engine Sensor Wiring Harness Removal and Installation (WP 0330).
1. Visually inspect fuel system for leaks.
Leaks in fuel lines or tank is present.
Damage to fuel lines or tank is present.
Replace fuel hoses. Refer to Fuel Hose Removal and Installation (WP 0268). Replace fuel tank. Refer to Fuel
Tank and Bracket Removal and Installation (WP 0265). Return vehicle to service.
1. Visually inspect cooling system for leaks.
0017–4
TM 9-2355-106-23-1 0017
Cooling system leaks are present.

Repair as required. Refer to Cooling System Operational Checkout Procedure (WP 0045). Return vehicle
to service.
1. Visually inspect engine oil, system for leaks.
Oil line and supply manifold leaks are present.
Repair as required. Refer to Oil and Fuel Manifold Removal and Installation (WP 0250). Return vehicle to service.
1. Visually inspect air induction system for leaks.
Air cleaner housing damage or distortion that could allow unfiltered air into engine.
Replace air cleaner housing. Refer to Air Cleaner Assembly Removal and Installation (WP 0257). Return vehicle
to service.
Air filter element has holes, damaged end cap or seals, or is plugged with dirt/debris.
Replace air cleaner housing. Refer to Air Cleaner Assembly Removal and Installation (WP 0257). Return vehicle
to service.
Air intake hoses and clamps are loose or not properly positioned over sealing beads.
Properly install hoses and tighten clamps. Refer to Air Intake Tube (To Turbo) Removal and Installation (WP 0256)
and Charge Air Cooler (CAC) Hose Removal and Installation (WP 0264). Return vehicle to service.
Charge air cooler and hoses are leaking or damaged.
Replace charge air cooler or hoses. Refer to Charge Air Cooler (CAC) Assembly Removal and Installation
(WP 0263) or Charge Air Cooler (CAC) Hose Removal and Installation (WP 0264). Return vehicle to service.
1. Return to Hard Start/No Start Toubleshooting Procedure (WP 0014).
END OF WORK PACKAGE
0017–5/blank
TM 9-2355-106-23-1 0018
FIELD MAINTENANCE
ENGINE OIL OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Materials/Parts WP 0597
Rags - (2) (WP 0794, Item 39) WP 0598
Lubricating oil (WP 0794, Item 27) WP 0599
WP 0606
References
WP 0782
TM 9-2355-106-10
TM 9-2355-106-23P Equipment Condition
WP 0014 Vehicle positioned on level surface
WP 0216 9-2355-106-10)
WP 0222 Engine off (TM 9-2355-106-10)
WP 0253 Belly armor removed (WP 0606)
WP 0261 Left side engine armor removed (WP 0597)
WP 0264 Left engine armor plate bracket removed (WP 0598)
WP 0527 Right side engine armor removed (WP 0599)
WP 0524 Right side engine armor plate removed (WP 0599)
WARNING
Use caution when working under hood with ignition ON. Failure to comply may result in damage
NOTE
Personnel must read and understand the Troubleshooting Procedure Overview in How to Use
STEP
1. Remove oil fill cap. Refer to TM 9-2355-106-10.
2. Check bottom of oil fill cap for milky-white residue or smell of antifreeze.
0018–1
TM 9-2355-106-23-1 0018
ENGINE OIL OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
1. Oil fill cap has milky-white residue or smells like antifreeze.

CORRECTIVE ACTION
STEP 1. Engine coolant is leaking into crankcase. Perform the following inspections:
a. Remove air compressor and gasket. Refer to Air Compressor Removal and Installation (WP 0527). Inspect
gasket and air compressor for cracks and evidence of coolant leak. Replace faulty component as necessary.
If a fault is found, change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
b. Remove engine cylinder head and gasket. Refer to Engine Cylinder Head and Gasket Removal and
Installation (WP 0222). Inspect cylinder head gasket and cylinder head for cracks and evidence of coolant
leaking into crankcase. Replace faulty component as necessary. If a fault is found, change engine oil.
Refer to Engine Oil Drain/Fill Procedure (WP 0233).
1. Compare sample of oil from this vehicle to sample of known-good oil for this vehicle. Verify color and odor
of samples are similar.
Engine contains incorrect oil.
STEP 1. Change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
NOTE
Ensure engine has been off for at least 1 minute.
1. Check engine oil level. Refer to TM 9-2355-106-10.

Engine oil level is too low.
NOTE
Excessive oil consumption can be caused by towing abnormally heavy loads, driving in an
incorrect gear causing the engine to lug, over-revving the engine, and other improper operation.
Refer to TM 9-2355-106-10 for proper vehicle operation.
STEP 1. Visually inspect engine and vehicle undercarriage for external engine oil leaks. If oil leak is present,
visually follow oil trail to source of leak. If oil leak is found, refer to Chapter 4, Maintenance Instructions, index for
repair procedures. If oil leak is present but source cannot be found, perform the following steps:
a. Clean oil residue from engine and undercarriage.
b. Top-off engine oil level (TM 9-2355-106-10).
c. Turn MAIN POWER switch ON (TM 9-2355-106-10).
d. Start engine and let idle for 10 minutes. Do not let engine run out of oil. Turn engine off immediately if
oil leak is severe.
e. Turn engine off (TM 9-2355-106-10).
f. Inspect engine and vehicle undercarriage for external engine oil leaks.
STEP 2. Observe engine intake air filter restriction gauge (TM 9-2355-106-10). If restriction gauge indicates
restriction, refer to Intake Restriction Test Troubleshooting Procedure (WP 0259).
STEP 3. Compare sample of oil from this vehicle to sample of known-good oil for this vehicle. Verify that color,
odor, and thickness of samples are similar. If incorrect oil viscosity was used, change engine oil. Refer to Engine
Oil Drain/Fill Procedure (WP 0233).
STEP 4. Ensure air brake compressor is not leaking engine oil internally by inspecting air dryer desiccant
cartridge for oil residue. Refer to Air Dryer Desiccant Cartridge Removal and Installation (WP 0519). If oil is found
in desiccant cartridge, replace air compressor and desiccant cartridge. Refer to Air Compressor Removal and
Installation (WP 0527) and Air Dryer Desiccant Cartridge Removal and Installation (WP 0519).
0018–2
TM 9-2355-106-23-1 0018
STEP 5. Ensure turbocharger is not leaking internally by inspecting charge air cooler inlet pipe for oil residue.
Refer to Charge Air Cooler (CAC) Hose Removal and Installation (WP 0264) to remove piping between
turbocharger and charge air cooler for inspection. If oil residue is found, replace turbocharger. Refer to
Turbocharger Removal and Installation (WP 0261).
NOTE
Fuel injector O-rings and seals must be replaced anytime the fuel injectors are removed. After
inspecting the injector seals and O-rings during the next step, install new O-rings and seals as
instructed in the injector installation procedure.
Engine could be consuming oil due to an internal engine mechanical fault.
STEP 6. Remove fuel injectors, refer to Fuel Injector Removal and Installation (WP 0249) and inspect O-rings
and seals for damage.
STEP 7. To determine if an internal engine mechanical fault is present. Refer to Crankcase Pressure Test
STEP 8. Perform the following steps to determine if valve guides and seals are worn.
a. Top-off engine oil level (TM 9-2355-106-10).
b. Turn MAIN POWER switch ON (TM 9-2355-106-10).
c. Start the engine and let idle for 10 minutes (TM 9-2355-106-10).
d. Test drive vehicle for 10 miles (TM 9-2355-106-10).
e. Turn engine OFF (TM 9-2355-106-10).
f. Turn MAIN POWER switch off (TM 9-2355-106-10).
g. Keep engine off for at least 4 hours (TM 9-2355-106-10).
h. Turn MAIN POWER switch ON (TM 9-2355-106-10).
i. Start engine and observe tailpipe (TM 9-2355-106-10).
j. If unusual blue smoke comes from tailpipe upon startup, replace engine cylinder head and gasket. Refer to
Engine Cylinder Head and Gasket Removal and Installation (WP 0222).
Engine oil level is too high.

STEP 1. Drain enough oil to bring oil level to recommended level. Refer to Engine Oil Drain/Fill Procedure
(WP 0233).
STEP 2. Capture sample of engine oil in container for inspection. Refer to Engine Oil Drain/Fill Procedure
(WP 0233).
STEP 3. Compare oil sample with used oil from another vehicle. Comparison sample should be taken from
vehicle with same engine model that does not exhibit same symptoms as vehicle being checked.
STEP 4. If engine oil is milky-white in color or smells like antifreeze, engine coolant is leaking into crankcase.
Perform the following inspections:
a. Remove air compressor and gasket. Refer to Air Compressor Removal and Installation (WP 0527). Inspect
gasket and air compressor for cracks and evidence of a coolant leak. Replace faulty component as
necessary. If a fault is found, change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
b. Remove engine cylinder head and gasket. Refer to Engine Cylinder Head and Gasket Removal and
Installation (WP 0222). Inspect cylinder head gasket and cylinder head for cracks and evidence of coolant
leaking into crankcase. Replace faulty component as necessary. If a fault is found, change engine oil.
Refer to Engine Oil Drain/Fill Procedure (WP 0233).
0018–3
TM 9-2355-106-23-1 0018
STEP 5. If engine oil smells of fuel, oil is contaminated with diesel fuel. Perform the following inspections:
a. Remove fuel pump. Refer to Fuel Pump Removal and Installation (WP 0253). Inspect gasket and fuel pump
for evidence of fuel leaking into crankcase. Replace faulty component as necessary. If a fault is found,
change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
b. Remove oil/fuel manifold. Refer to Oil/Fuel Manifold Removal and Installation (WP 0250), replace gasket
and change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
1. If oil meets specification, return to Hard Start/No Start Troubleshooting Procedure (WP 0014).
END OF WORK PACKAGE
0018–4
TM 9-2355-106-23-1 0019
FIELD MAINTENANCE
INTAKE/EXHAUST TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0275
Terminal Test Kit (WP 0795, Item 122) WP 0276
WP 0335
Materials/Parts
WP 0336
Goggles (WP 0794, Item 20)
WP 0247
Gloves (WP 0794, Item 19)
WP 0597
References WP 0782
TM 9-2355-106-10
WP 0024 9-2355-106-10)
WP 0056 Engine off (TM 9-2355-106-10)
0019–1
TM 9-2355-106-23-1 0019
INTAKE/EXHAUST TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
WARNING
Use extreme caution when testing or working on or around electrical circuits. Always assume
that electrical circuits are live. Electrical shock can occur upon contact with voltage high
enough to cause current flow through muscles or nerves. On Direct Current (DC) systems,
generally 1 milliamp of current can be felt, 5 milliamps can cause severe pain, 15 milliamps
can cause loss of muscle control, and 70 milliamps can be fatal. Wear protective clothing;
ensure skin, clothing, and surrounding areas are dry; do not wear jewelry; and touch only
the insulated, nonmetallic parts of electrical components and testing equipment. To prevent
electrical arcing, avoid shorting electrical test probes and jumper wires. Electrical arcing can
cause bright flashes of light, capable of causing temporary blindness. If electrical injury occurs,
immediately shut off power supply and seek medical assistance. Failure to comply may result
in serious injury or death to personnel.
CAUTION
Use light contact when probing connector terminals. Do not force test probe into connector
terminal. Failure to comply may result in damage to connector terminal.
NOTE
1. Observe FILTER MINDER (Figure 1, Item 1) air filter restriction gauge located in center of Instrument Panel
(IP). Refer to TM 9-2355-106-10.
0019–2
TM 9-2355-106-23-1 0019
Figure 1. Filter Minder Air Filter Restriction Gauge.
Does FILTER MINDER air filter restriction gauge read 22 in. H2O (5.5 kPa) or more?
DECISION
NO Go to Step 3.
STEP
2. Remove engine air filter and inspect. Refer to TM 9-2355-106-10. Air filter should be clean and undamaged.
Is air filter dirty or damaged?
DECISION
YES Go to Step 23.

NO Go to Step 24.
STEP
3. Remove air cleaner housing, refer to Air Cleaner Assembly Removal and Installation (WP 0257). Inspect air
cleaner housing for debris, damage, and restrictions.
Is air filter housing damaged or restricted?
DECISION
YES Go to Step 24.

NO Go to next step.
0019–3
TM 9-2355-106-23-1 0019
STEP
4. Remove air intake tube between air filter housing and turbo fresh air inlet, refer to Air Intake Tube (To Turbo)
Removal and Installation (WP 0256). Inspect intake tube for debris, damage, and restrictions.
Is intake tube damaged or restricted?
DECISION
YES Go to Step 25.

NO Go to next step.
STEP
5. Inspect Charge Air Cooler (CAC) hoses, pipes, and clamps for damage, restrictions, or looseness. Refer to
Charge Air Cooler (CAC) Hose Removal and Installation (WP 0264).
Are any CAC hoses, pipes, or clamps damaged, restricted, or loose?
DECISION
YES Go to Step 26.

NO Go to next step.
STEP
6. Perform CAC pressure test. Refer to Charge Air Cooler Pressure Operational Checkout Procedure (WP 0024).
Did CAC pressure test pass?
DECISION
NO Go to Step 27.
STEP
7. Visually inspect exhaust pipes (Figure 2, Item 1), muffler (Figure 3, Item 2), and tailpipe (Figure 3, Item
1) for damage or restrictions.
Figure 2. Exhaust Pipes.

0019–4
TM 9-2355-106-23-1 0019
Figure 3. Muffler and Tailpipe.
Are exhaust pipes, muffler, or tailpipe damaged or restricted?
DECISION
YES Go to Step 28.

NO Go to next step.
STEP
8. Remove muffler. Refer to Muffler and Shield Removal and Installation (WP 0276).
10. Start engine (TM 9-2355-106-10).
Does engine start normally?
DECISION
YES Go to Step 29.

NO Go to next step.
STEP
11. Inspect exhaust brake valve actuator arm (Figure 4, Item 1). Arm should be in position shown in illustration.
0019–5
TM 9-2355-106-23-1 0019
Figure 4. Right Side of Engine, Behind Turbocharger Area.
Is exhaust brake valve actuator arm in position indicated?
DECISION

NO Go to Step 18.
STEP
12. Turn ignition switch OFF (TM 9-2355-106-10).

14. Remove exhaust brake. Refer to Exhaust Brake Removal and Installation (WP 0246).
15. Turn MAIN POWER switch on (TM 9-2355-106-10).
16. Start engine (TM 9-2355-106-10).
Does engine start normally?
DECISION
YES Go to Step 30.

NO Go to next step.
STEP
17. Start engine (TM 9-2355-106-10).
Does a hard start or no start condition still exist?
DECISION
YES Proceed to Hard Start/No Start Operational Checkout Procedure (WP 0014) or Engine Performance
Troubleshooting Procedures (WP 0015)
NO Return vehicle to service.
0019–6
TM 9-2355-106-23-1 0019
STEP
WARNING
Wear eye protection when working on or around air systems. Air lines, fittings, and components
contain air under pressure. Failure to comply may result in injury or death to personnel.
18. Disconnect air line (Figure 5, Item 2) from exhausted brake valve actuator while observing actuator arm
(Figure 5, Item 1) for movement. Actuator arm should move back to position indicated in illustration.
Figure 5. Right Side of Engine, Behind Turbocharger Area.
Did actuator arm move to position indicted?
DECISION

NO Go to Step 30.
STEP
19. Remove left side engine armor. Refer to Left Side Engine Armor Plate Removal and Installation (WP 0597).
20. Disconnect connector 4100F/4103 (connector with 18 wires). Refer to Figure 6.
0019–7
TM 9-2355-106-23-1 0019
Figure 6. Left Side Engine Compartment.
21. Measure resistance between connector 4103 terminal 15 and all other terminals on connector 4103 with
multimeter. Refer to Figure 6.
Did multimeter read OL for all terminals?
DECISION

NO Go to Step 32.
STEP
22. Measure resistance between connector 4100F terminal 15 and all other terminals on connector 4100F with
DECISION
YES Go to Step 33.

NO Go to Step 31.
0019–8
TM 9-2355-106-23-1 0019
MALFUNCTION
- 23. Air filter is faulty.
ACTION
Replace air filter. Refer to TM 9-2355-106-10. Return vehicle to service.
END OF TEST
MALFUNCTION
- 24. Air cleaner housing is faulty.
ACTION
Replace air cleaner housing. Refer to Air Cleaner Assembly Removal and Installation (WP 0257). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 25. Air intake tube is faulty.
ACTION
Replace air intake tube. Refer to Air Intake Tube (To Turbo) Removal and Installation (WP 0056). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 26. Hoses, pipes, or clamps are damaged, restricted, or loose.
ACTION
Repair as necessary. Refer to Charge Air Cooler (CAC) Hose Removal and Installation (WP 0264). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 27. CAC is faulty.
ACTION
Replace CAC. Refer to Charge Air Cooler (CAC) Removal and Installation (WP 0263). Return vehicle to service.
END OF TEST
0019–9
TM 9-2355-106-23-1 0019
MALFUNCTION
- 28. Exhaust pipes, muffler, or tailpipe is faulty.
ACTION
Replace exhaust pipes, muffler, or tailpipe. Refer to Exhaust Pipe Removal and Installation (WP 0275) or
Muffler and Shield Removal and Installation (WP 0276). Return vehicle to service.
END OF TEST
MALFUNCTION
- 29. Muffler is faulty.
ACTION
Replace muffler. Refer to Muffler and Shield Removal and Installation (WP 0276). Return vehicle to service.
END OF TEST
MALFUNCTION
- 30. Exhaust brake is faulty.
ACTION
Replace exhaust brake. Refer to Exhaust Brake Removal and Installation (WP 0246). Return vehicle to service.
END OF TEST
MALFUNCTION
- 31. Engine wiring harness is faulty.
ACTION
Replace engine wiring harness. Refer to Engine Wiring Harness Removal and Installation (WP 0336). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 32. PDC harness is faulty.
ACTION
Replace PDC harness. Refer to Power Distribution Center (PDC) Harness Removal and Installation (WP 0335).
END OF TEST
MALFUNCTION
- 33. Exhaust brake solenoid is faulty.
ACTION
Replace exhaust brake solenoid. Refer to Exhaust Brake Solenoid Removal and Installation (WP 0247).
0019–10
TM 9-2355-106-23-1 0019
END OF TEST
END OF WORK PACKAGE
0019–11/blank
TM 9-2355-106-23-1 0020
FIELD MAINTENANCE
INJECTION CONTROL PRESSURE (ICP) NO START OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Equipment Condition
(WP 0795, Item 37)
Tee, 3-wire pressure sensor breakout (ZTSE4347)
(WP 0795, Item 116)
9-2355-106-10)
References Engine off (TM 9-2355-106-10)
WP 0035
WARNING
NOTE
STEP
0020–1
TM 9-2355-106-23-1 0020
INJECTION CONTROL PRESSURE (ICP) NO START OPERATIONAL CHECKOUT PROCEDURE -

(CONTINUED)
1. Install 3-wire breakout tee between ICP sensor (Figure 1, Item 1) and harness connector. Refer to Figure 1.
Figure 1. ICP Breakout Tee Installed.

4. Measure DC voltage between breakout tee GREEN SIG CIRC test lead and BLACK SIG GRND test lead with
5. Observe multimeter while cranking engine and record ICP voltage. A minimum of 1.0V is necessary to
start engine.
ICP voltage less than 1.0V.
CORRECTIVE ACTION
Refer to Low Injection Control Pressure (ICP) Pressure Troubleshooting Procedure (WP 0021).
ICP voltage more than 1.0V.
CORRECTIVE ACTION
Refer to Fuel Pump Pressure Troubleshooting Procedure (WP 0035).
END OF WORK PACKAGE
0020–2
TM 9-2355-106-23-1 0021
FIELD MAINTENANCE
LOW INJECTOR CONTROL PRESSURE (ICP) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0228
70) WP 0233
Tee, Injection Control Pressure (ICP) adapter WP 0252
(ZTSE4594) (WP 0795, Item 119) WP 0253
Gun, air (WP 0795, Item 43) WP 0389
WP 0391
Sealing compound (WP 0794, Item 44) WP 0782
Goggles, industrial (WP 0794, Item 20) Equipment Condition
Personnel Required Transmission set in NEUTRAL (N) (TM
Maintainer - (2) 9-2355-106-10)
Engine off (TM 9-2355-106-10)
References MAIN POWER switch off (TM 9-2355-106-10)
TM 9-2355-106-10 Wheels chocked (TM 9-2355-106-10)
TM 9-2355-106-23P Engine hood open and secured (TM 9-2355-106-10)
0021–1
TM 9-2355-106-23-1 0021
LOW INJECTOR CONTROL PRESSURE (ICP) TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
If Diagnostic Trouble Codes (DTCs) were detected, perform those diagnostics first (WP 0007).
STEP
1. Remove Engine Oil Temperature (EOT) sensor. Refer to Engine Oil Temperature (EOT) Sensor Removal and
0021–2
TM 9-2355-106-23-1 0021
2. Oil should come out of EOT opening on front cover. Install EOT sensor when complete. Refer to Engine Oil
Temperature (EOT) Sensor Removal and Installation (WP 0389).
Did oil come out of EOT sensor opening on front cover?
DECISION
NO Go to Step 26.
STEP
Figure 1. High-Pressure Oil Hose.
3. Disconnect high-pressure oil hose (Figure 1, Item 3) from elbow fitting (Figure 1, Item 2) on high-pressure
oil manifold (Figure 1, Item 1).
0021–3
TM 9-2355-106-23-1 0021
Figure 2. ICP Adapter.
4. Install ICP adapter (Figure 2, Item 4) into end of high-pressure hose (Figure 2, Item 5).
5. Install new ICP sensor (Figure 2, Item 3) into ICP adapter (Figure 2, Item 4).
6. Transfer ICP harness connector (Figure 2, Item 2) from original ICP sensor (Figure 2, Item 1) on high-pressure
oil manifold (Figure 2, Item 6) to new ICP sensor (Figure 2, Item 3) in high-pressure hose (Figure 2, Item 5).
Leave original ICP sensor (Figure 2, Item 1) in high-pressure oil manifold (Figure 2, Item 6).
8. Observe ICP on MSD while cranking engine (TM 9–2355–106–10).
Is ICP more than 500 psi (3,447 kPa)?
DECISION
NO Go to Step 20.
0021–4
TM 9-2355-106-23-1 0021
STEP
9. Remove ICP harness connector (Figure 2, Item 2), new ICP sensor (Figure 2, Item 3), and ICP adapter (Figure
2, Item 4) from high-pressure hose (Figure 2, Item 5).
10. Install ICP harness connector (Figure 2, Item 2) on original ICP sensor (Figure 2, Item 1).
Figure 3. High-Pressure Oil Hose.
11. Install high-pressure hose (Figure 3, Item 3) to fitting (Figure 3, Item 2) on high-pressure oil manifold (Figure 3,
Item 1). Tighten hose securely.
12. Remove valve cover. Refer to Valve Cover Removal and Installation (WP 0228).
0021–5
TM 9-2355-106-23-1 0021
Figure 4. High-Pressure Hose at Pump.
13. Remove high-pressure hose (Figure 4, Item 2) from high-pressure injector pump (Figure 4, Item 1).
NOTE
Regulate shop air to 100 psi (689 kPa).
14. Apply more than 100 psi (689 kPa) of shop air into high-pressure hose (Figure 4, Item 2) using air gun.
Figure 5. Injector.
15. Inspect for leakage around base of each fuel injector (Figure 5, Item 1). Some leakage around top of fuel
injector is normal. One injector shown (Figure 5, Item 1).
Are any fuel injectors leaking?
DECISION
YES Go to Step 27.

NO Go to next step.
0021–6
TM 9-2355-106-23-1 0021
STEP
Figure 6. Fuel Injector Harness Connector.
16. With valve cover still off, connect fuel injector harness connector (Figure 6, Item 1) to harness on fuel injectors.
18. With air pressure still applied, command injectors ON using MSD.
0021–7
TM 9-2355-106-23-1 0021
Figure 7. Injector.
19. Check for oil discharge from each injector (Figure 7, Item 1). Oil discharge should be equal. Excess oil
discharge indicates faulty fuel injector. One injector shown. (Figure 7, Item 1).
Did any fuel injectors have excessive oil discharge?
DECISION
YES Go to Step 28.

NO Go to Step 27.
STEP
20. Remove fuel pump from high-pressure injector pump. Refer to Fuel Pump Removal and Installation
(WP 0253).
21. Disconnect fuel injector harness connector (Figure 7, Item 2).
Figure 8. Fuel Pump Camshaft.
22. With assistant, crank engine and check for rotation of fuel pump camshaft (Figure 8, Item 2) inside
high-pressure injector pump housing (Figure 8, Item 1).
0021–8
TM 9-2355-106-23-1 0021
Is camshaft rotating?
DECISION
YES Go to Step 29.

NO Go to next step.
STEP
23. Remove high-pressure injector pump. Refer to High-Pressure Injector Pump Removal and Installation
(WP 0252).
Figure 9. High-Pressure Pump.
24. Check drive gear (Figure 9, Item 1) on high-pressure pump (Figure 9, Item 2) for tightness.
Is drive gear tight?
DECISION
YES Go to Step 30.

NO Go to next step.
MALFUNCTION
- 25. Drive gear is loose.
ACTION
Tighten drive gear mounting bolt. Return vehicle to service.
END OF TEST
MALFUNCTION
- 26. Lubrication system low on oil.
0021–9
TM 9-2355-106-23-1 0021
ACTION
Go to Engine Oil Drain/Fill Procedure (WP 0233). Return vehicle to service.
END OF TEST
MALFUNCTION
- 27. Fuel injector O-rings faulty.
ACTION
Replace fuel injector O-rings. Go to Fuel Injector Removal and Installation (WP 0249). Return vehicle to service.
END OF TEST
MALFUNCTION
- 28. Fuel injector faulty.
ACTION
Replace fuel injector. Go to Fuel Injector Removal and Installation (WP 0249). Return vehicle to service.
END OF TEST
MALFUNCTION
- 29. Injection pressure regulator faulty.
ACTION
Replace injection pressure regulator. Go to Injection Pressure Regulator Removal and Installation (WP 0396).
END OF TEST
MALFUNCTION
- 30. High-pressure injector pump faulty.
ACTION
Replace high-pressure injector pump. Go to High-Pressure Injector Pump Removal and Installation (WP 0252).
END OF TEST
END OF WORK PACKAGE
0021–10
TM 9-2355-106-23-1 0022
FIELD MAINTENANCE
INJECTION CONTROL PRESSURE (ICP) OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Maintenance Support Device (MSD) (WP 0795, Item
Equipment Condition
70)
References Transmission set in NEUTRAL (N) (TM
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0021
WARNING
NOTE
STEP
2. Start engine (TM 9-2355-106-10).
3. Observe ICP voltage on MSD while driving vehicle.
NOTE
Vehicle can be driven uphill or fully loaded to reach 100% engine load.
4. Drive vehicle on road until engine reaches operating temperature. On an open section of road, select suitable
gear. Press accelerator pedal to floor and accelerate to 100% load.
5. Record ICP voltage at full load.
6. Stop vehicle and record ICP voltage at 1200 rpm.
7. Record ICP voltage at idle.
0022–1
TM 9-2355-106-23-1 0022
INJECTION CONTROL PRESSURE (ICP) OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
8. Turn engine OFF (TM 9-2355-106-10).

ICP voltages do not meet the following specifications:
Full load – 3.54V and 3.74V
1200 rpm – 1.87V and 2.07V
Idle – 0.38V and 0.58V
CORRECTIVE ACTION
Proceed to Low ICP Pressure Test Troubleshooting Procedure (WP 0021).
1. Return to next step in Engine Performance Operational Checkout Procedure (WP 0015).
END OF WORK PACKAGE
0022–2
TM 9-2355-106-23-1 0023
FIELD MAINTENANCE
BOOST PRESSURE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70)
Equipment Condition
Tools and Special Tools Parking brake set (TM 9-2355-106-10)
General Mechanic's Tool Kit (GMTK) Transmission set in NEUTRAL (N) (TM
(WP 0795, Item 37) 9-2355-106-10)
Engine shut off (TM 9-2355-106-10)
WP 0011
WARNING
NOTE
STEP
2. Turn ignition switch to the START position (TM 9-2355-106-10).
3. Start engine (TM 9-2355-106-10).
4. Verify correct engine performance. Refer to Engine Performance Operational Checkout Procedure
(WP 0015).
0023–1
TM 9-2355-106-23-1 0023
BOOST PRESSURE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
NOTE
Insufficient boost pressure may result in poor engine performance at full load.
Engine does not perform correctly at full load.

CORRECTIVE ACTION
STEP 1. Turn all accessories and ignition OFF (TM 9-2355-106-10).
STEP 2. Connect MSD to American Trucking Association (ATA) diagnostic connector. Refer to Connecting
Maintenance Support Device (MSD) (WP 0011).
STEP 3. Drive vehicle on road until engine reaches operating temperature. Find open section of road and select
suitable gear. Depress accelerator pedal (full depression) to floor and accelerate to rated speed and 100% load.
Drive vehicle uphill or fully loaded to reach correct engine loading at rated engine speed (TM 9-2355-106-10).
STEP 4. Record intake manifold boost pressure from the MSD at full load and rated engine speed.
Pressure equals 4.13V/32 psi (1.5 kPa).
CORRECTIVE ACTION
Return to next step in Vehicle Operational Checkout Procedure (WP 0010).
Pressure does not equal 4.13V/32 psi (1.5 kPa).
CORRECTIVE ACTION
Perform Wastegate Actuator test. Refer to Wastegate Actuator Operational Checkout Procedure (WP 0026).
END OF WORK PACKAGE
0023–2
TM 9-2355-106-23-1 0024
FIELD MAINTENANCE
CHARGE AIR COOLER (CAC) PRESSURE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
General Mechanic's Tool Kit (GMTK) (Item 37)
Equipment Condition
Charge air cooler tester (ZTSE4341) (WP 0795, Item
124)
Materials/Parts 9-2355-106-10)
Gloves, leather (WP 0794, Item 19) Engine off (TM 9-2355-106-10)
Goggles (WP 0794, Item 20) MAIN POWER switch off (TM 9-2355-106-10)
References Engine hood open and secured (TM 9-2355-106-10)
TM 9-2355-106-10 Left side engine armor plate removed (WP 0597)
TM 9-2355-106-23P Right side engine armor plate removed (WP 0599)
WARNING
To prevent coupler from blowing off charge air cooler hose during test, connect safety chain
before applying air pressure to system. Increase air pressure slowly to prevent adapters
from blowing off. After testing, relieve pressure slowly through bleed valve before removing
test equipment. Failure to comply may result in damage to equipment and serious injury or
death to personnel.
CAUTION
To prevent foreign matter from entering the engine, cover the turbocharger exhaust and intake
piping while the charge air cooler is disconnected. Failure to comply may result in damage
to equipment.
NOTE
Charge air coolers are not required to be leak-proof. Do not test the cooler core for leaks by
submerging it in a radiator test tank. Almost all charge air cooler units will show leakage if
they are submerged.
It is not necessary to remove charge air cooler from the vehicle to perform the test in this
work package.
0024–1
TM 9-2355-106-23-1 0024
CHARGE AIR COOLER (CAC) PRESSURE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
STEP
NOTE
End seal movement is indicated by a polished area at seal contact area in air cleaner housing.
1. Inspect air induction system components.

• Air cleaner housing damage or distortion that could allow unfiltered air into engine.
• Air filter end seal movement inside housing.
• Air filter element end cap dents, holes, damaged seals, or soot.
• Air intake hoses and clamps loose or not properly positioned over sealing beads.
CORRECTIVE ACTION
Replace air cleaner assembly. Refer to Air Cleaner Assembly Removal and Installation (WP 0257).
Chassis-mounted CAC and piping damaged.
CORRECTIVE ACTION
Replace CAC hose. Refer to Charge Air Cooler (CAC) Hose Removal and Installation (WP 0251).
NOTE
An instruction manual accompanies the CAC tester.
1. Install CAC tester bleed-off coupler at CAC cold side rubber hose (Figure 1, Item 1).
0024–2
TM 9-2355-106-23-1 0024
Figure 1. CAC Tester on Cold Side of CAC.
0024–3
TM 9-2355-106-23-1 0024
2. Install CAC tester gauge and regulator assembly (Figure 2, Item 2) at CAC hot side rubber hose (Figure
2, Item 3).
Figure 2. CAC Tester on Hot Side of CAC.
3. Connect filtered air supply (Figure 2, Item 4) to quick disconnect fitting (Figure 2, Item 5) on CAC tester
gauge and regulator assembly (Figure 2, Item 2).
4. Open air valve (Figure 2, Item 6) and adjust regulator (Figure 2, Item 7) to 30 psi (206.9 kPa), and then shut off
air valve and monitor gauge (Figure 2, Item 1). Note decrease in air pressure.
Air pressure drop is 5 psi (34.5 kPa) or less in 15 seconds.
Go to Engine Performance Operational Checkout Procedure (WP 0015).
1. Coat following areas with soapy water:
• All pipe and hose surfaces.
• All pipes to and from charge air cooler.
2. Open air valve (Figure 2, Item 6) and adjust regulator (Figure 2, Item 7) to 30 psi (206.9 kPa), and then
shut off air valve.
Bubbles from soapy water indicate presence of leaks.
Replace CAC hose. Refer to Charge Air Cooler (CAC) Hose Removal and Installation (WP 0251). Return vehicle
to service.
END OF WORK PACKAGE
0024–4
TM 9-2355-106-23-1 0025
FIELD MAINTENANCE
CRANKCASE PRESSURE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Pressure Test Kit (ZTSE4409) (WP 0795, Item 77) WP 0782
Equipment Condition
(WP 0795, Item 37)
Adapter, crankcase pressure test (WP 0795, Item 1)
9-2355-106-10)
WARNING
NOTE
Excessive crankcase pressure may indicate engine mechanical faults that result in poor
engine performance.
STEP
1. Park vehicle on level ground (TM 9-2355-106-10).
2. Verify engine oil level is not above full mark and oil dipstick is secured (TM 9-2355-106-10).
3. Verify intake manifold gasket is not leaking. Refer to Engine Systems Operational Checkout Procedures
(WP 0017).
4. Verify breather tube is clean and valve rocker cover is tight. Refer to Engine Systems Operational Checkout
5. Verify air compressor does not affect test results by disconnecting air compressor delivery line. Refer to Air
Compressor Delivery Air Line Removal and Installation (WP 0524).
Engine does not perform correctly.
CORRECTIVE ACTION
0025–1
TM 9-2355-106-23-1 0025
CRANKCASE PRESSURE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Figure 1. Right Side of Engine.
NOTE
If engine has a breather extension tube, remove extension tube before installing the crankcase
breather tool.
STEP 1. Install crankcase breather tool (Figure 1).
0025–2
TM 9-2355-106-23-1 0025
Figure 2. Right Side of Vehicle.
STEP 2. Connect a line from the crankcase breather tool to position 4 of magnehelic gauge (Figure 2).
STEP 3. Turn MAIN POWER switch on (TM 9-2355-106-10) .
STEP 4. Start engine (TM 9-2355-106-10).
STEP 5. Run engine to reach normal operating temperature (TM 9-2355-106-10).
STEP 6. Run engine at high idle (no load) rpm.
NOTE
Allow the gauge reading to stabilize before taking the pressure reading.
STEP 7. Record crankcase pressure.

STEP 8. Turn engine off (TM 9-2355-106-10).
STEP 9. Turn MAIN POWER switch off (TM 9-2355-106-10).
Recorded pressure is less than 6.0 in. H2O.
CORRECTIVE ACTION
Recorded pressure is more than 6.0 in. H2O.
0025–3
TM 9-2355-106-23-1 0025
CORRECTIVE ACTION
END OF WORK PACKAGE
0025–4
TM 9-2355-106-23-1 0026
FIELD MAINTENANCE
WASTEGATE ACTUATOR OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:

WP 0261
(WP 0795, Item 37) WP 0782
Soapstone (WP 0795, Item 93)
Materials/Parts Equipment Condition
Goggles, industrial (WP 0794, Item 20) Parking brake set (TM 9-2355-106-10)
Face shield, industrial (WP 0794, Item 16) Transmission set in NEUTRAL (N) (TM
Gloves (WP 0794, Item 19) 9-2355-106-10)
WARNING
NOTE
This Manual before performing any troubleshooting.
STEP
0026–1
TM 9-2355-106-23-1 0026
WASTEGATE ACTUATOR OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
1. Verify correct engine performance. Refer to Engine Performance Operational Checkout Procedure
(WP 0015).
NOTE
Incorrect wastegate operation may cause poor engine performance.
Engine does not perform correctly.

CORRECTIVE ACTION
STEP 1. Remove right side engine armor plate. Refer to Right Side Engine Armor Plate Removal and Installation
(WP 0599).
STEP 2. Remove right engine armor plate bracket. Refer to Right Engine Armor Plate Bracket Removal and
STEP 3. Remove air intake tube. Refer to Air Intake Tube (to Turbo) Removal and Installation (WP 0256).
Figure 1. Right Side of Engine.
STEP 4. Remove actuator boost line (Figure 1, Item 2) from turbocharger housing (Figure 1, Item 1).
0026–2
TM 9-2355-106-23-1 0026
WASTEGATE ACTUATOR OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Figure 2. Pressure Test Kit ZTSE4409.
STEP 5. Connect air regulator with 0-60 psi gauge (Figure 2, Item 1) to actuator boost line (Figure 2, Item 2).
STEP 6. Mark actuator shaft (Figure 2, Item 3) at wastegate actuator bracket (Figure 2, Item 4) with soapstone
marker. Spray leak detector or soap solution around actuator housing.
STEP 7. Slowly apply air pressure to actuator. Movement of actuator shaft (Figure 2, Item 3) (indicated by
position of soapstone mark) should start at 26-30 psi (179-207 kPa).
STEP 8. Measure movement of actuator shaft (Figure 2, Item 3) between soapstone mark and wastegate
actuator bracket (Figure 2, Item 4) with ruler.
Actuator shaft does not move at 26-30 psi (179-207 kPa).
CORRECTIVE ACTION
Actuator shaft does not move more than 0.25 in. (6.35 mm).
CORRECTIVE ACTION
Actuator housing leaks.
CORRECTIVE ACTION
END OF WORK PACKAGE
0026–3/blank
TM 9-2355-106-23-1 0027
FIELD MAINTENANCE
VALVE ADJUSTMENT TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Tools and Special Tools Equipment Condition
General Mechanic's Tool Kit (GMTK) Parking brake set (TM 9-2355-106-10)
(WP 0795, Item 37) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
References
Engine off (TM 9-2355-106-10)
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0015
WP 0229
Engine valve cover removed (WP 0228)
WP 0228
WP 0782
WARNING
NOTE
NOTE
Perform engine valve clearance check on cold engine.
SYMPTOM
Engine performance is poor.
MALFUNCTION
Engine valve adjustment may be incorrect.
CORRECTIVE ACTION
0027–1
TM 9-2355-106-23-1 0027
VALVE ADJUSTMENT TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP 1. Rotate crankshaft until piston number 1 is on compression stroke and timing mark on damper pulley is
aligned with TDC mark on front cover. Refer to Engine Valve Adjustment (WP 0229).
Figure 1. Valve Adjustment with No. 1 Piston and No. 6 Piston at Top Dead Center (TDC).
Figure 2. Valve Adjustment Sequence.
STEP 2. Check valve adjustment for valves 1, 2, 3, 6, 7, and 10 by inserting a 0.025-inch (0.64-mm) feeler gauge
between rocker arm and valve stem tip. A light drag on feeler gauge indicates correct valve clearance. Refer to
Figure 1 and Figure 2. If valve clearance is incorrect, refer to Engine Valve Adjustment (WP 0229).
STEP 3. Position piston number six at TDC in the compression stroke. Refer to Engine Valve Adjustment
(WP 0229).
STEP 4. Check valve adjustment for valves 4, 5, 8, 9, 11, and 12 by inserting a 0.025-inch (0.64-mm) feeler
gauge between rocker arm and valve stem tip. A light drag on feeler gauge indicates correct valve clearance.
Refer to Figure 1 and Figure 2. If valve clearance is incorrect refer, to Engine Valve Adjustment (WP 0229).
STEP 5. Return to next step in Engine Performance Operational Checkout Procedure (WP 0015).
END OF WORK PACKAGE
0027–2
TM 9-2355-106-23-1 0028
FIELD MAINTENANCE
ENGINE OIL PRESSURE (EOP) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
WP 0782
General Mechanic's Tool Kit (GMTK) Equipment Condition
(WP 0795, Item 37) Parking brake set (TM 9-2355-106-10)
Tee, 3-wire pressure sensor breakout (ZTSE4347) Transmission set in NEUTRAL (N) (TM
(WP 0795, Item 116) 9-2355-106-10)
Personnel Required Engine off (TM 9-2355-106-10)
Maintainer - (2) MAIN POWER switch off (TM 9-2355-106-10)
References Engine hood open and secured (TM 9-2355-106-10)
TM 9-2355-106-10 Left side engine armor plate removed (WP 0597)
TM 9-2355-106-23P Left engine armor plate bracket removed (WP 0598)
WP 0392
WP 0238 Drawings Required
WP 0393 WP 0789, Figure 79
This procedure covers the following Diagnostic Trouble Codes (DTCs):

• 211
• 212
• 225
• 313
• 314
0028–1
TM 9-2355-106-23-1 0028
ENGINE OIL PRESSURE (EOP) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
Keep hands and clothing clear of moving parts in the engine compartment. Rotating parts
can cause severe injury to personnel. Ensure that all guards are in place and do not wear
loose clothing when conducting maintenance. Always check to ensure that the area is clear
of personnel and obstructions before starting the engine. Failure to comply may result in
injury to personnel.
CAUTION
NOTE
Make sure engine oil is at the proper level before performing the work package.
0028–2
TM 9-2355-106-23-1 0028
STEP
1. Disconnect harness connector LAM1013. Refer to Figure 1.
Figure 1. Left Engine, Behind Air Compressor.
2. Install 3-wire breakout harness between EOP sensor and harness connector LAM1013. Refer to Figure 2
and Figure 1.
Figure 2. 3-Wire Breakout Harness (ZTSE4347).
0028–3
TM 9-2355-106-23-1 0028

5. Measure DC voltage between breakout harness SIG CIRC and ground with multimeter. Refer to Figure 2.
Does multimeter read between 0.039V and 1.49V?
DECISION
NO Go to Step 14.
STEP
6. Measure DC voltage between breakout harness SIG CIRC and ground with multimeter. Refer to Figure 3.
7. Observe multimeter while assistant operates engine at 700 rpm, 1400 rpm, and 2000 rpm.
Does multimeter read more than 1V at 700 rpm, 1.2V at 1400 rpm, and 1.7V at 2000 rpm?
DECISION

NO Go to next step.
STEP

10. Remove 3-wire breakout harness (ZTSE4347) from EOP sensor and harness connector LAM1013. Refer
to Figure 3.
11. Remove EOP sensor. Refer to Engine Oil Pressure (EOP) Sensor Removal and Installation (WP 0392).
12. Install pressure test kit (ZTSE4409) mechanical gauge 5 to EOP sensor location on engine. Refer to Figure 4.
0028–4
TM 9-2355-106-23-1 0028
Figure 4. Pressure Test Kit (ZTSE4409).
Does mechanical gauge 5 read more than 5 psi at 700 rpm, 10 psi at 1400 rpm, and 20 psi at 2000 rpm?
DECISION
NO Go to Step 45.
YES Go to Step 50.
STEP

16. Measure resistance between connector LAM1013 terminal A and ground with multimeter. Refer to Figure 5.
Figure 5. Connector LAM1013.
0028–5
TM 9-2355-106-23-1 0028
Does multimeter read less than 5 ohms?
DECISION
NO Go to Step 20.
STEP

19. Measure DC voltage between connector LAM1013 terminal B and ground with multimeter. Refer to Figure 5.
DECISION
NO Go to Step 22.
YES Go to Step 33.
0028–6
TM 9-2355-106-23-1 0028
STEP
20. Disconnect connector LAM1019. Refer to Engine Control Module (ECM) Removal and Installation (WP 0329).
Refer to Figure 6.
Figure 6. Left Rear of Engine.
21. Measure resistance between connector LAM1013 terminal A and connector LAM1019 terminal 19 with
multimeter. Refer to Figure 5 and Figure 6.
DECISION
YES Go to Step 51.

NO Go to Step 49.
STEP

Refer to Figure 6.
Does multimeter read more than 0V?
DECISION
YES Go to Step 49.

NO Go to next step.
0028–7
TM 9-2355-106-23-1 0028
STEP

30. Measure resistance between connector LAM1013 terminal B and ground with multimeter. Refer to Figure 7.
DECISION
NO Go to Step 49.
STEP
31. Measure resistance between connector LAM1013 terminals B and A with multimeter. Refer to Figure 7.
DECISION
NO Go to Step 49.
STEP
32. Measure resistance between connector LAM1013 terminal B and connector LAM1019 terminal 40 with
DECISION
YES Go to Step 51.

NO Go to Step 49.
0028–8
TM 9-2355-106-23-1 0028
STEP

Refer to Figure 8.

38. Measure DC voltage between connector LAM1013 terminal C and ground with multimeter. Refer to Figure 7.
DECISION
YES Go to Step 49.

NO Go to next step.
STEP

41. Measure resistance between connector LAM1013 terminals C and B with multimeter. Refer to Figure 7.
DECISION
NO Go to Step 49.
0028–9
TM 9-2355-106-23-1 0028
STEP
42. Measure resistance between connector LAM1013 terminal C and ground with multimeter. Refer to Figure 9.
DECISION
NO Go to Step 49.
STEP
43. Measure resistance between connector LAM1013 terminals C and A with multimeter. Refer to Figure 9.
DECISION
NO Go to Step 49.
STEP
44. Measure resistance between connector LAM1013 terminal C and connector LAM1019 terminal 14 with
0028–10
TM 9-2355-106-23-1 0028
DECISION
YES Go to Step 51.

NO Go to Step 49.
STEP
45. Replace engine oil pump. Refer to Front Oil Pump Assembly Removal and Installation (WP 0238).
46. Install pressure test kit (ZTSE4409) mechanical gauge 5 to EOP sensor location on engine. Refer to Figure 11.
Figure 11. Pressure Test Kit (ZTSE4409).
47. Turn ignition switch ON, with engine running (TM 9-2355-106-10).
Does mechanical gauge 5 read more than 5 psi at 700 rpm, 10 psi at 1400 rpm, and 20 psi at 2000 rpm?
DECISION
NO Go to Step 52.
0028–11
TM 9-2355-106-23-1 0028
MALFUNCTION
- 49. Engine sensor harness is faulty.
ACTION
END OF TEST
MALFUNCTION
- 50. EOP sensor is faulty.
ACTION
Replace EOP sensor. Refer to Engine Oil Pressure (EOP) Sensor Removal and Installation (WP 0393).
END OF TEST
MALFUNCTION
- 51. ECM is faulty.
ACTION
Replace ECM. Refer to Engine Control Module (ECM) Removal and Installation (WP 0329). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 52. An engine mechanical fault is present.
ACTION
Replace engine. Refer to Engine Assembly Removal and Installation (WP 0215). Return the vehicle to service.
END OF TEST
END OF WORK PACKAGE
0028–12
TM 9-2355-106-23-1 0029
FIELD MAINTENANCE
ENGINE OIL TEMPERATURE (EOT) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Tee, 2-way breakout (WP 0795, Item 115) 9-2355-106-10)
Engine off (TM 9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0329
WP 0330 Schematic (WP 0789, Figure 79)
WP 0782
This procedure covers the following Diagnostic Trouble Code (DTCs):

• DTC 311
• DTC 312
WARNING
CAUTION
0029–1
TM 9-2355-106-23-1 0029
ENGINE OIL TEMPERATURE (EOT) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
NOTE
STEP
1. Disconnect harness connector LAM1015 from EOT sensor. Refer to Figure 1.
Figure 1. Left Front of Engine, Above Air Compressor.
DECISION
YES Go to Step 11.

NO Go to next step.
STEP

4. Turn ignition switch ON (TN 9-2355-106-10).
5. Measure DC voltage between EOT signal circuit terminal B and ground with multimeter. Refer to Figure 1.
0029–2
TM 9-2355-106-23-1 0029
DECISION
NO Go to Step 13.
STEP
Figure 2. Breakout Tee (ZTSE4483).

8. Install breakout tee (ZTSE4483) between EOT harness and EOT sensor. Refer to Figure 2.
10. Measure DC voltage between breakout tee (ZTSE4483) terminals SIGNAL and SIGNAL GROUND with
multimeter.
Table 1. Ambient Temperature vs Voltage.

VOLTAGE TEMPERATURE °F TEMPERATURE °C
0.82-0.89V 212 100
3.78-3.86V 68 20
4.35-4.39V 32 0
Does multimeter read voltage corresponding to specifications in Table 1?
DECISION
NO Go to Step 19.
YES Go to Step 18.
0029–3
TM 9-2355-106-23-1 0029
STEP
11. Disconnect harness connector LAM1019. Refer to Figure 3. Refer to Engine Control Module (ECM) Removal
12. Measure resistance between harness connector LAM1015 terminal A and harness connector LAM1019
terminal 19 with multimeter. Refer to Figure 3 and Figure 4.
DECISION
NO Go to Step 18.
YES Go to Step 20.
0029–4
TM 9-2355-106-23-1 0029
STEP

14. Disconnect harness connector LAM1019. Refer to Engine Control Module (ECM) Removal and Installation
(WP 0329). Refer to Figure 3.
15. Measure resistance between harness connector LAM1015 terminal B and ground with multimeter. Refer
to Figure 4.
DECISION
NO Go to Step 20.
STEP
16. Measure resistance between harness connector LAM1015 terminal B and harness connector LAM1019
DECISION
YES Go to Step 20.

NO Go to next step.
STEP
17. Measure resistance between harness connector LAM1019 terminal 12 and all other harness connector
LAM1019 terminals. Multimeter should read OL for each test. Refer to Figure 3.
Does multimeter read OL for each test?
DECISION
YES Go to Step 18.

NO Go to Step 20.
0029–5
TM 9-2355-106-23-1 0029
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 19. EOT sensor is faulty.
ACTION
Replace EOT sensor. Refer to Engine Oil Temperature (EOT) sensor removal and installation(WP 0330).
END OF TEST
MALFUNCTION
- 20. Sensor wiring harness is faulty.
ACTION
Replace engine sensor harness. Refer to Engine Sensor Harness Removal and Installation (WP 0317).
END OF TEST
END OF WORK PACKAGE
0029–6
TM 9-2355-106-23-1 0030
FIELD MAINTENANCE
CAMSHAFT POSITION (CMP) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
9-2355-106-10)
References
Engine off (TM 9-2355-106-10)
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0329
WP 0317
WP 0782 WP 0789, Figure 79

• 143
• 144
• 145
• 315
• 612
0030–1
TM 9-2355-106-23-1 0030
CAMSHAFT POSITION (CMP) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0030–2
TM 9-2355-106-23-1 0030
STEP
Figure 1. CMP Sensor.
2. Measure resistance between connector LAM1011 terminal A and ground with multimeter. Refer to Figure 1
DECISION
NO Go to Step 12.
STEP

DECISION
NO Go to Step 14.
0030–3
TM 9-2355-106-23-1 0030
STEP
DECISION
NO Go to Step 25.
STEP
7. Measure DC amperage between connector LAM1011 terminal B and ground with multimeter. Refer to
Figure 3.
Does multimeter read between 2 milliamps and 10 milliamps?
DECISION
YES Go to Step 37.

NO Go to next step.
STEP

10. Disconnect connector LAM1019. Refer to Figure 2 Refer to Engine Control Module (ECM) Removal and
Figure 2. Engine Control Module (ECM).
11. Measure resistance between connector LAM1011 terminals B and C with multimeter. Refer to Figure 3.

0030–4
TM 9-2355-106-23-1 0030
DECISION
YES Go to Step 38.

NO Go to Step 36.
STEP
12. Disconnect connector LAM1019. Refer to Figure 2. Refer to Engine Control Module (ECM) Removal and
DECISION
YES Go to Step 38.

NO Go to Step 36.
STEP

DECISION
YES Go to Step 36.

NO Go to next step.
STEP

0030–5
TM 9-2355-106-23-1 0030
DECISION
NO Go to Step 36.
STEP
DECISION
NO Go to Step 36.
STEP
DECISION
YES Go to Step 38.

NO Go to Step 36.
STEP

0030–6
TM 9-2355-106-23-1 0030
DECISION
YES Go to Step 36.

NO Go to next step.
STEP

DECISION
NO Go to Step 36.
STEP
0030–7
TM 9-2355-106-23-1 0030
DECISION
NO Go to Step 36.
STEP
DECISION
YES Go to Step 38.

NO Go to Step 36.
MALFUNCTION
- 36. Engine sensor wiring harness is faulty.
ACTION
Replace engine sensor wiring harness. Refer to Engine Sensor Wiring Harness Removal and Installation
END OF TEST
MALFUNCTION
- 37. CMP sensor is faulty.

0030–8
TM 9-2355-106-23-1 0030
ACTION
Replace CMP sensor. Refer to Camshaft Position (CMP) Sensor Removal and Installation (WP 0393). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0030–9/blank
TM 9-2355-106-23-1 0031
FIELD MAINTENANCE
ENGINE COOLING FAN OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70) WP 0288
WP 0499
(WP 0795, Item 37) Equipment Condition
Materials/Parts Transmission set in NEUTRAL (N) (TM
Goggles, industrial (WP 0794, Item 20) 9-2355-106-10)
WARNING
Do not attempt to restrict fan blade rotation during engine operation. Improper use of
application or modification of fan drive or fan can damage fan drive. Do not operate vehicle with
malfunctioning or damaged fan drive or fan blades. Failure to comply may result in damage to
equipment and serious injury to personnel.
Air drain valves are under pressure. Wear protective goggles and do not place face in front
of air drain valves while draining air reservoirs. Open air drain valves slowly to release air
pressure gradually. Failure to comply may result in serious injury or death to personnel.
Do not disconnect any air line or fitting until system pressure has been relieved. Hoses may
whip and injure personnel, and air under pressure can penetrate skin. Failure to comply may
Do not operate vehicle with air pressure system loss. Vehicle has reduced or no braking
capability and may not stop. Failure to comply may result in damage to equipment and serious
0031–1
TM 9-2355-106-23-1 0031
ENGINE COOLING FAN OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Let air pressure build in both tanks to 100 psi (689 kPa) before releasing the parking brake.
Low air pressure may affect vehicle braking capability. Failure to comply may result in injury or
death to personnel.
NOTE
STEP
1. Connect Maintenance Support Device (MSD) to vehicle. Refer to Connecting Maintenance Support Device
(MSD) (WP 0011).
2. Read Diagnostic Trouble Codes (DTCs).
DTC 246 is set.
CORRECTIVE ACTION
Refer to Engine Diagnostic Trouble Code (DTC) Index (WP 0006).
1. Verify no other engine DTCs are set.
Other engine DTCs set.
Refer to Engine Diagnostic Trouble Code (DTC) Index (WP 0006).
1. Check fan clutch air hose for damage and leaks. Refer to Cooling Fan Actuator Solenoid Removal and
Fan clutch air hose damaged or leaking.
Replace fan clutch air hose. Refer to Cooling Fan Actuator Solenoid Removal and Installation (WP 0288). Return
vehicle to service.
1. Drain air supply in secondary and supply tanks. Refer to Air Reservoir Tank Removal and Installation
(WP 0499).
2. Remove outlet side air hose to engine cooling fan from cooling fan actuator solenoid. Refer to Cooling Fan
Actuator Solenoid Removal and Installation (WP 0288).
3. Start engine (TM 9-2355-106-10) and build air pressure in Air 2 pressure gauge to 30 psi (207 kPa).
6. Check for air leaking from cooling fan actuator solenoid. Refer to Cooling Fan Actuator Solenoid Removal and
Air leaking from solenoid.
Replace cooling fan actuator solenoid. Refer to Cooling Fan Actuator Solenoid Removal and Installation
1. Start engine (TM 9-2355-106-10) and build air pressure to more than 70 psi (483 kPa).
4. With engine off, attempt to spin fan blades.
Fan blades spin.
Replace cooling fan drive assembly. Refer to Cooling Fan Drive Assembly Removal and Installation (WP 0287).
END OF WORK PACKAGE

0031–2
TM 9-2355-106-23-1 0032
FIELD MAINTENANCE
BATTERY POWER OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Tools and Special Tools References
General Mechanic's Tool Kit (GMTK) TM 9-2355-106-10
(WP 0795, Item 37) TM 9-2355-106-23P
Battery filler, gravity (WP 0795, Item 14) WP 0418
Battery Service Kit (WP 0795, Item 15) WP 0782
Analyzer, battery and charging system
Equipment Condition
(WP 0795, Item 7)
Tester, antifreeze solution/battery specific gravity
(WP 0795, Item 123)
9-2355-106-10)
Materials/Parts Engine shut off (TM 9-2355-106-10)
Water, distilled (WP 0794, Item 15) MAIN POWER switch off (TM 9-2355-106-10)
Batteries removed (WP 0418)
WARNING
Battery acid must not contact eyes, skin, or clothing. If battery acid contacts eyes or skin,
flush area with large amounts of water for 15 minutes and seek immediate medical care. If
swallowed, do not induce vomiting. Drink large amounts of water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil. Seek immediate medical attention. Failure to comply
NOTE
NOTE
Before beginning these test procedures, make sure the vehicle batteries are at 75% state of
charge (SOC) or higher. This represents an open circuit voltage (OCV) of 12.4 volts. Verify
accessories have not been left on for an extended period.
STEP
1. Check for proper electrolyte level in each cell of all batteries as indicated on batteries (TM 9-2355-106-10).
2. Verify specific gravity in each cell of all batteries with gravity tester.
3. Verify all battery terminals are free of corrosion (TM 9-2355-106-10).
0032–1
TM 9-2355-106-23-1 0032
BATTERY POWER OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
NOTE
When the battery analyzer is connected to the battery, instructions appear on the analyzer
screen. Follow instructions to perform the test. An instruction manual accompanies the
analyzer.
4. Connect battery analyzer to battery and test each battery with battery and charging analyzer.
Electrolyte level low.
CORRECTIVE ACTION
Fill low cell as indicated on battery with distilled water (TM 9-2355-106-10). Charge batteries after adding distilled
water.
Battery terminals are corroded.
CORRECTIVE ACTION
Clean battery terminals (TM 9-2355-106-10).
Battery fails specific gravity test per tester. Specific gravity results must be within 0.05 units between each cell.
CORRECTIVE ACTION
Replace battery. Refer to Battery Removal and Installation (WP 0418).
Battery fails test per analyzer.
CORRECTIVE ACTION
Replace battery. Refer to Battery Removal and Installation (WP 0418).
END OF WORK PACKAGE
0032–2
TM 9-2355-106-23-1 0033
FIELD MAINTENANCE
BATTERY CABLE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
WP 0333
WP 0336
WP 0407
(WP 0795, Item 37)
WP 0782
Gloves, rubber (WP 0795, Item 38)
Face shield, industrial (WP 0794, Item 16) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
Personnel Required
Maintainer - (2)
References Wheels chocked (TM 9-2355-106-10)
TM 9-2355-106-10 Engine hood open and secured (TM 9-2355-106-10)
TM 9-2355-106-23P
WP 0032 WP 0789, Figure 28
BATTERY CABLE TESTING
NOTE
Battery condition and state of charge must be confirmed before any load tests can be
performed. Refer to Battery Power Troubleshooting Procedure (WP 0032).
Ensure nuts holding battery cables to starter solenoid and starter terminals are tight.
Slow cranking is often caused by high resistance in the battery cables or connections, especially in cold weather.
After all batteries check good and terminals are clean and tight, check the battery cables using the sequence
of measurements described in this test.
The voltage loss on the positive side plus the voltage loss on the negative side equals the difference between the
voltage available in the batteries and the voltage available at the starter. A multimeter reading of more than 0.5V
indicates a faulty cable.
0033–1
TM 9-2355-106-23-1 0033
BATTERY CABLE TROUBLESHOOTING PROCEDURE - (CONTINUED)
BATTERY CABLE TEST
WARNING
0033–2
TM 9-2355-106-23-1 0033
NOTE
The starter solenoid B+ terminal is at battery voltage (24V) when batteries are connected.
STEP
Figure 1. CEC Power Module Location.
1. To prevent engine from starting during test, remove CEC Power Module relay (Figure 1, Item 2) from Power
Distribution Center (Figure 1, Item 1) at rear of engine compartment on driver side. Refer to Power Distribution
Center (PDC) Fuse and Relay Removal and Installation (WP 0333).
0033–3
TM 9-2355-106-23-1 0033
2. Connect multimeter from either alternator B+ terminal to battery positive post as shown by meter 1. Refer to
Figure 2. Measure voltage from battery post, not cable end.
Figure 2. Sequence of Meter Lead Connections on Positive Side.

4. Have assistant crank engine. Note reading on multimeter while engine is cranking.
Does multimeter read more than 0.5V?
DECISION
YES Go to Step 9.
NO Go to next step.
0033–4
TM 9-2355-106-23-1 0033
STEP
Figure 3. Alternator Positive Terminals.
5. Move test lead connected to one B+ terminal on alternator to other B+ terminal on alternator (Figure 3,
Item 1). Repeat Steps 3 and 4.
DECISION
YES Go to Step 9.
NO Go to next step.
0033–5
TM 9-2355-106-23-1 0033
STEP
Figure 4. Sequence of Meter Lead Connections on Positive Side.
6. Connect meter leads as shown by meters 2, 3, and 4. Refer to Figure 4. Repeat Steps 3 and 4 for each
meter connection.
Does multimeter read more than 0.5V for one or more tests?
DECISION
YES Go to Step 9.
NO Go to next step.
0033–6
TM 9-2355-106-23-1 0033
STEP
Figure 5. Sequence of Meter Lead Connections on Negative Side.
7. Connect meter leads as shown by meters 5 and 6. Refer to Figure 5. Repeat Steps 3 and 4 for each meter
connection.
Does multimeter read more than 0.5V for one or more tests?
DECISION
YES Go to Step 9.
NO Go to next step.
0033–7
TM 9-2355-106-23-1 0033
STEP
Figure 6. Starter Ground Terminal.
8. Connect multimeter between negative battery post and starter ground terminal as shown by meter 7. Refer to
Figure 5. Attach lead directly to starter ground stud (Figure 6, Item 1), not cable end. Repeat Steps 3 and 4.
DECISION
YES Go to Step 9.
NO Refer to next step in Hard Start/No Start Troubleshooting Procedures (List) Operational Checkout Procedure
(WP 0014).
MALFUNCTION
- 9. Faulty cables.
ACTION
Replace battery cable or cables that failed test. For cables on alternator, refer to Engine Wiring Harness
Removal and Installation (WP 0336). For cable on starter, refer to Starter Motor to Battery Ground Cable
Removal and Installation (WP 0414). For all other cables, refer to Battery Cables Removal and Installation
END OF TEST
END OF WORK PACKAGE
0033–8
TM 9-2355-106-23-1 0034
FIELD MAINTENANCE
ENGINE DOES NOT CRANK TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0336
WP 0407
(WP 0795, Item 37) WP 0419
Personnel Required WP 0782
Maintainer - (2) Equipment Condition
References
TM 9-2355-106-10
9-2355-106-10)
TM 9-2355-106-23P
WP 0067
WP 0032
WP 0034
WP 0257
Battery box removed (WP 0419)
WP 0292
Belly armor removed (WP 0606)
WP 0302
WP 0317 WP 0789, Figure 18
0034–1
TM 9-2355-106-23-1 0034
ENGINE DOES NOT CRANK TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
NOTE
STEP
1. Verify battery ground stud connections (Figure 1, Item 1) are clean and tight.
Figure 1. Battery Ground Stud Located Forward of Batteries.
2. Verify starter engine ground jumper cable terminals are clean and tight at engine stud (Figure 2, Item 1) and
starter ground stud (Figure 2, Item 2).
0034–2
TM 9-2355-106-23-1 0034
Figure 2. Starter Engine Ground Jumper.
3. Verify starter frame ground jumper cable terminal is clean and tight at frame. Refer to Figure 3.
Figure 3. Starter Frame Ground Jumper Cable.
4. Verify batteries are fully charged. Refer to Battery Power Troubleshooting Procedure (WP 0032).
Are batteries fully charged?
DECISION
YES Go to Step 11.

NO Go to next step.
0034–3
TM 9-2355-106-23-1 0034
STEP
5. Charge batteries.
6. Test batteries to verify batteries are good. Refer to Battery Power Troubleshooting Procedure (WP 0032).
Replace batteries found to be faulty. Refer to Battery Removal and Installation (WP 0418).
9. Verify transmission is in Neutral (N) (TM 9-2355-106-10).
10. Attempt to start engine (TM 9-2355-106-10).
Does engine crank?
DECISION
NO Go to Step 15.
STEP

13. Verify transmission is in Neutral (N) (TM 9-2355-106-10).
14. Attempt to start engine (TM 9-2355-106-10).
Does engine crank?
DECISION

NO Go to next step.
0034–4
TM 9-2355-106-23-1 0034
STEP
15. Measure DC voltage between starter solenoid positive stud (Figure 4, Item 1) and ground with multimeter.
Figure 4. Starter Motor Positive Stud.
DECISION
NO Go to Step 50.
0034–5
TM 9-2355-106-23-1 0034
STEP
16. Measure DC voltage between starter motor solenoid terminal S (Figure 5, Item 1) and ground with multimeter.
Figure 5. Starter Motor Solenoid Terminal S.
17. Have assistant hold ignition switch in START position (TM 9-2355-106-10) while observing multimeter.
DECISION
YES Go to Step 51.

NO Go to next step.
0034–6
TM 9-2355-106-23-1 0034
STEP
18. Remove starter relay from power distribution center. Refer to Figure 6. Refer to Power Distribution Center
(PDC) Fuse and Relay Removal and Installation (WP 0333).
Figure 6. Power Distribution Center.
WARNING
Engine may start when testing or jumpering terminals. Always check to ensure that area is clear
of personnel and obstructions before testing. Failure to comply may result in injury to personnel.
19. Install a jumper wire between starter relay terminal 30 and terminal 87. Refer to Figure 6.
Does engine crank?
DECISION
NO Go to Step 31.
0034–7
TM 9-2355-106-23-1 0034
STEP
20. Measure DC voltage between starter relay terminal 86 and ground with a multimeter. Refer to Figure 6.
21. Have assistant hold ignition switch in START position (TM 9-2355-106-10) while observing multimeter.
DECISION
NO Go to Step 40.
STEP
22. With assistance, measure resistance between starter relay terminal 85 and ground with multimeter. Refer
to Figure 6.
23. Have an assistant turn ignition switch to START position (TM 9-2355-106-10) while observing multimeter.
DECISION
NO Go to Step 49.
STEP
24. Turn ignition switch OFF.

25. Turn MAIN POWER switch OFF.
26. Disconnect BLACK engine control module connector 6007. Refer to Figure 7. Refer to ECM Removal and
27. With assistant, measure resistance between connector 6007 terminal 46 and connector 4003 terminal 85
with multimeter. Refer to Figure 7 and Figure 8.
0034–8
TM 9-2355-106-23-1 0034
Figure 8. Connector 4003.
DECISION
NO Go to Step 46.
STEP
28. Remove air cleaner assembly. Refer to Air Cleaner Assembly Removal and Installation (WP 0257).
29. Disconnect connector 4103. Refer to Figure 9.
Figure 9. Left Side Engine Compartment Area.
0034–9
TM 9-2355-106-23-1 0034
30. Measure resistance between connector 4103 terminal 17 and connector 4003 terminal 85 with multimeter.
Refer to Figure 9 and Figure 10.
DECISION
YES Go to Step 52.

NO Go to Step 53.
STEP
31. Measure voltage between connector 4003 terminal 30 and ground with multimeter. Refer to Figure 10.
DECISION
YES Go to Step 33.

NO Go to next step.
0034–10
TM 9-2355-106-23-1 0034
STEP
32. Measure voltage between connector 4025 and ground with multimeter. Refer to Figure 11.
DECISION
YES Go to Step 52.

NO Go to Step 54.
0034–11
TM 9-2355-106-23-1 0034
STEP
33. Turn ignition switch OFF.

34. Turn MAIN POWER switch OFF.
36. Disconnect connector 4101M. Refer to Figure 12.
37. Install starter relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
38. Measure DC voltage between connector 4101M terminal A and ground. Refer to Figure 12.
39. Have an assistant turn ignition switch to START position (TM 9-2355-106-10) while observing multimeter.
DECISION
NO Go to Step 52.
YES Go to Step 53.
0034–12
TM 9-2355-106-23-1 0034
STEP
41. Measure resistance between connector 1701 (engine harness side) terminal 8 and ground with multimeter.
Refer to Figure 13.
DECISION
YES Go to Step 52.

NO Go to next step.
0034–13
TM 9-2355-106-23-1 0034
STEP
42. Measure resistance between relay connector 4003 terminal 86 and connector 1701 (engine side) terminal
8. Refer to Figure 14 and Figure 15.
Is resistance more than 5 ohms?
DECISION
YES Go to Step 52.

NO Go to next step.
0034–14
TM 9-2355-106-23-1 0034
STEP
43. Disconnect ignition switch connector 1100M. Refer to Figure 16. Refer to Keyless Ignition Switch Removal
Figure 16. Behind Dash.
44. Measure resistance between connector 1701 terminal 8 (cabin side) and ground with multimeter. Refer to
Figure 17.
0034–15
TM 9-2355-106-23-1 0034
DECISION
YES Go to Step 55.

NO Go to next step.
STEP
45. Measure resistance between connector 1100M terminal B and connector 1701 terminal 8 with multimeter.
Figure 18. Connector 1100M.
DECISION
YES Go to Step 55.

NO Go to Step 56.
STEP
47. Verify MSD indicates vehicle is in neutral.
Does MSD indicate vehicle is in NEUTRAL (N)?
DECISION
YES Go to Step 57.

NO Go to next step.
0034–16
TM 9-2355-106-23-1 0034
MALFUNCTION
- 48. Data links are faulty.
ACTION
Diagnose and repair/replace data links. Refer to Multiplexing Data Link Circuits Troubleshooting Procedure
(WP 0067).
END OF TEST
MALFUNCTION
- 49. Start relay is faulty.
ACTION
Replace start relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
END OF TEST
MALFUNCTION
- 50. Battery cable between batteries and starter motor solenoid is faulty.
ACTION
Replace battery cable. Refer to Battery Cable Removal and Installation (WP 0407). Return vehicle to service.
END OF TEST
MALFUNCTION
- 51. Starter motor is faulty.
ACTION
Replace starter motor. Refer to Starter Motor Removal and Installation (WP 0292). Return vehicle to service.
END OF TEST
MALFUNCTION
- 52. PDC wiring harness is faulty.
ACTION
Replace PDC wiring harness. Refer to PDC Harness Removal and Installation (WP 0335). Return vehicle
to service.
END OF TEST
0034–17
TM 9-2355-106-23-1 0034
MALFUNCTION
ACTION
Replace engine wiring harness. Refer to Engine Harness Removal and Installation (WP 0336). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 54. Battery cable is faulty.
ACTION
Replace battery cable between starter motor and 24 volt stud. Refer to Battery Cable Removal and Installation
END OF TEST
MALFUNCTION
- 55. IP wiring harness is faulty.
ACTION
Replace IP wiring harness. Refer to Instrument Panel (IP) Feed Harness Removal and Installation (WP 0411).
END OF TEST
MALFUNCTION
- 56. Ignition switch is faulty.
ACTION
Replace ignition switch. Refer to Keyless Ignition Switch Removal and Installation (WP 0302). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 57. Engine Control Module (ECM) is faulty.
ACTION
to service.
END OF TEST
END OF WORK PACKAGE

0034–18
TM 9-2355-106-23-1 0035
FIELD MAINTENANCE
FUEL PUMP PRESSURE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0036
Cap and plug set (WP 0795, Item 23)
Equipment Condition
Personnel Required Parking brake set (TM 9-2355-106-10)
Maintainer (2) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
References Engine shut off (TM 9-2355-106-10)
WARNING
Hood is extremely heavy. Ensure there is adequate space to open hood completely without
pinning personnel between hood and another structure. Use extreme care when working
under hood and make sure it is properly supported. Failure to comply may result in serious
NOTE
0035–1
TM 9-2355-106-23-1 0035
FUEL PUMP PRESSURE TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Remove cap (Figure 1, Item 2) and air bleed valve (Figure 1, Item 3) from fuel filter header (Figure 1, Item 1).
Figure 1. Fuel Filter Header Air Bleed Valve.
2. Install adapter (Figure 2, Item 3) from fuel Pressure Test Kit into air bleed valve opening on fuel filter header
(Figure 2, Item 2).
Figure 2. Fuel Pressure Gauge Set.
3. Install fuel pressure gauge set by connecting line (Figure 2, Item 1), contained in fuel Pressure Test Kit, from
adapter (Figure 2, Item 3) to fuel pressure gauge 5 on gauge bar (Figure 2, Item 4).
NOTE
Cranking engine with fuel injector harness connector disconnected will prevent the engine from
starting and cause additional Diagnostic Trouble codes (DTC) to set.
4. Disconnect fuel injector harness connector (Figure 3, Item 1) from valve cover (Figure 3, Item 2).
0035–2
TM 9-2355-106-23-1 0035
5. Record maximum pressure shown on fuel pressure gauge 5, while assistant cranks engine for 20 seconds.
Is fuel pressure more than 35 psi (241.3 kPa)?
DECISION
YES Remove test equipment and install air bleed valve and cap. Connect fuel injector harness connector (Figure
3, Item 1) to valve cover (Figure 3, Item 2) and go to Vehicle Troubleshooting Symptom Index (WP 0005).
NO Go to next step.
STEP
6. Replace fuel filter (WP 0269).

7. Clean fuel strainer (WP 0269).
Is fuel pressure more than 35 psi (241.3 kPa)?
DECISION
YES Remove test equipment and install air bleed valve and cap. Connect fuel injector harness connector
(Figure 3, Item 1) to valve cover (Figure 3, Item 2) and return vehicle to service.
NO Go to next step.
0035–3
TM 9-2355-106-23-1 0035
STEP
9. Disconnect fuel pressure regulator connector (Figure 4, Item 2) from fuel pressure regulator valve (Figure
4, Item 3).
Figure 4. Fuel Pressure Regulator.
10. Remove fuel pressure regulator valve (Figure 4, Item 3) from rear of fuel/oil supply manifold (Figure 4, Item 1).
11. Install new fuel pressure regulator valve (Figure 4, Item 3) on fuel/oil supply manifold (Figure 4, Item 1).
Tighten fuel pressure regulator valve securely.
12. Install fuel pressure regulator connector (Figure 4, Item 2) on fuel pressure regulator valve (Figure 4, Item 3).
NOTE
Cranking engine with fuel injector harness connector disconnected will prevent the engine from
starting and cause additional Diagnostic Trouble codes (DTC) to set.
13. Ensure fuel injector harness connector (Figure 5, Item 1) is still disconnected from valve cover (Figure
5, Item 2).
0035–4
TM 9-2355-106-23-1 0035
Is maximum pressure more than previously recorded pressure?
DECISION
NO Go to Step 16.
STEP
15. Verify correct engine performance.
Does engine perform correctly?
DECISION
YES Connect fuel injector harness connector to valve cover (Figure 5, Item 2) and return vehicle to service.
NO Go to Engine Performance Check (WP 0015).
MALFUNCTION
- 16. Fuel pump restriction.
0035–5
TM 9-2355-106-23-1 0035
ACTION
Perform fuel pump restriction troubleshooting procedure. Refer to Fuel Pump Restriction Troubleshooting
END OF TEST
END OF WORK PACKAGE
0035–6
TM 9-2355-106-23-1 0036
FIELD MAINTENANCE
FUEL PUMP RESTRICTION TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
WP 0270
Cap and Plug kit (WP 0795, Item 23) Parking brake set (TM 9-2355-106-10)
Personnel Required 9-2355-106-10)
Maintainer (2) Engine off (TM 9-2355-106-10)
TM 9-2355-106-23P Left side engine armor removed (WP 0597)
WARNING
NOTE
0036–1
TM 9-2355-106-23-1 0036
FUEL PUMP RESTRICTION TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Remove cap (Figure 1, Item 3) and vacuum side quick connect fitting (Figure 1, Item 2) from fuel filter header
(Figure 1, Item 1).
Figure 1. Fuel Filter Header Vacuum Side Quick Connect.
2. Install adapter (Figure 2, Item 2) from Fuel Pressure Test Kit into vacuum side quick connect opening on fuel
filter header (Figure 2, Item 3).
3. Install fuel pressure gauge set by connecting Fuel Pressure Test Kit line (Figure 2, Item 4) from adapter (Figure
2, Item 2) on fuel filter header (Figure 2, Item 3) to gauge 2 on gauge bar (Figure 2, Item 1).
4. Have assistant start engine (TM 9-2355-106-10).
5. Check for fuel leaks in line (Figure 2, Item 4) to gauge 2 on gauge bar (Figure 2, Item 1)
6. Measure vacuum at 1200 rpm and record reading.
0036–2
TM 9-2355-106-23-1 0036
Is vacuum more than 8 in.Hg (203 mm Hg)?
DECISION
NO Go to Step 10
STEP
7. Replace fuel/water separator filter. Refer to Fuel/Water Separator Filter Removal and Installation (WP 0270).
Is vacuum more than 8 in.Hg (203 mm Hg)?
DECISION
YES Go to Step 17.

STEP
10. Check fuel filter outlet to supply pump inlet fuel line (Figure 3, Item 1) for damage, rust, or kinks.
Figure 3. Fuel Filter Inlet to Supply Pump Inlet Fuel Line.
Does the fuel filter outlet to supply pump inlet fuel line have any damage, rust, or kinks?
DECISION
YES Go to Step 19.

NO Go to next step.
0036–3
TM 9-2355-106-23-1 0036
STEP
11. Turn off engine (TM 9-2355-106-10).

12. Remove fuel supply hose (Figure 4, Item 1) from fuel filter header (Figure 4, Item 2).
Figure 4. Fuel Supply Hose.
13. Install plug to seal off fuel supply hose opening at fuel filter header (Figure 4, Item 2).
Is recorded reading more than 17 in.Hg (431 mm Hg)?
DECISION
YES Go to Step 18.

NO Go to next step.
MALFUNCTION
- 16. Fuel pump is faulty.
ACTION
Replace fuel pump. Refer to Fuel Pump Removal and Installation (WP 0253). Return vehicle to service.
END OF TEST
0036–4
TM 9-2355-106-23-1 0036
MALFUNCTION
- 17. Fuel supply hose restricted.
ACTION
Replace fuel supply hose. Refer to Fuel Hose Removal and Installation (WP 0268). Return vehicle to service.
END OF TEST
MALFUNCTION
- 18. Fuel supply hose leaking.
ACTION
Replace fuel supply hose. Refer to Fuel Hose Removal and Installation (WP 0268). Return vehicle to service.
END OF TEST
MALFUNCTION
- 19. Damaged fuel filter outlet to supply pump inlet fuel line.
ACTION
Replace fuel filter outlet to supply pump inlet fuel line. Refer to Fuel Pump Removal and Installation (WP 0253).
END OF TEST
END OF WORK PACKAGE
0036–5/blank
TM 9-2355-106-23-1 0037
FIELD MAINTENANCE
FUEL OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:

(WP 0795, Item 37) WP 0265
Pressure Test Kit (WP 0795, Item 77) WP 0268
WP 0271
Hose (WP 0794, Item 24) WP 0782
Measure, liquid (WP 0794, Item 34)
Personnel Required Equipment Condition
Maintainer (2) Parking brake set (TM 9-2355-106-10)
References 9-2355-106-10)
TM 9-2355-106-10 Engine off (TM 9-2355-106-10)
TM 9-2355-106-23P MAIN POWER switch off (TM 9-2355-106-10)
WARNING
Store diesel fuel in an approved container clearly marked DIESEL FUEL. Dispose of fuel in
an approved container clearly marked DIESEL FUEL in accordance with standard operating
procedures.
Do not fill fuel tank with engine running. Do not overfill fuel tank. Clean fuel spills immediately.
Ensure fuel nozzle is grounded to filler neck to prevent sparks. Failure to comply may result in
injury or death to personnel and damage to equipment.
NOTE
0037–1
TM 9-2355-106-23-1 0037
FUEL OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
STEP
1. Remove fuel cap and visually inspect fuel level in fuel tank (TM 9-2355-106-10).
Fuel is very low or empty.
CORRECTIVE ACTION
Add fuel and follow priming procedure. Refer to Fuel Primer Sequence (WP 0255).
1. Take fuel sample at water separator. Refer to Fuel/Water Separator Assembly Purge, Removal, and
Water is present in fuel sample.
Drain separator. Refer to Fuel/Water Separator Assembly Purge, Removal and Installation (WP 0271). Drain
and replace fuel. Refer to Fuel Tank and Bracket Removal and Installation (WP 0265). Move vehicle to a warm
building and allow time for vehicle to warm up to ensure there is no ice in lines.
1. Inspect fuel sample for gelling.
Fuel sample is gelled.
Move vehicle to a warm building and allow it time for vehicle to warm up. Flush fuel system, replace fuel filter, and
replace fuel. Refer to Fuel Filter and Strainer Removal and Installation (WP 0269).
1. Compare fuel sample to known good fuel supply.
Fuel sample is much darker than known good fuel.
Dark color may indicate oil contaminated fuel. Refer to Engine Mechanical Operations Checkout Procedure
– Lube Oil in Fuel (WP 0016).
Fuel sample is lighter than known good fuel or has gasoline smell.
1. Replace fuel filter. Refer to Fuel Filter and Strainer Removal and Installation (WP 0269).
2. Drain and replace fuel. Refer to Fuel Tank and Bracket Removal and Installation (WP 0265).
1. Disconnect fuel outlet line (Figure 1, Item 2) at fuel rail (Figure 1, Item 1) and fuel filter header outlet (Figure
1, Item 3).
0037–2
TM 9-2355-106-23-1 0037
Figure 1. Fuel Filter Header Outlet Line
2. Remove outlet line (Figure 1, Item 2).

3. Reposition and install fuel outlet line (Figure 2, Item 1) on fuel filter outlet port (Figure 2, Item 2).
0037–3
TM 9-2355-106-23-1 0037
Figure 2. Fuel Outlet Line
4. Install an 18-inch section of 3/8-in. ID fuel hose (Figure 2, Item 3) on fuel outlet line (Figure 2, Item 1), and
place open end of hose into measuring cup (Figure 2, Item 4).
5. Take fuel sample from fuel filter outlet header while assistant cranks engine.
Less than 8 oz fuel is delivered during 15 seconds of cranking.
Replace fuel filter and clean filter inlet screen. Refer to Fuel Filter and Strainer Removal and Installation (WP 0269).
1. Visually inspect for damaged or crimped fuel hoses (TM 9-2355-106-10).
Damaged or crimped fuel hoses are detected.
Replace damaged or crimped fuel hoses or pickup. Refer to Fuel Hose Removal and Installation (WP 0268).
1. Verify fuel sending unit is not crimped. Refer to Fuel Tank and Bracket Removal and Installation (WP 0265).
Fuel sending unit is crimped or damaged.
Replace fuel sending unit. Refer to Fuel Tank and Bracket Removal and Installation (WP 0265).
1. Test fuel pressure. Refer to Fuel Pump Pressure Test Troubleshooting Procedure (WP 0035).
END OF WORK PACKAGE
0037–4
TM 9-2355-106-23-1 0038
FIELD MAINTENANCE
FUEL PRESSURE (FULL LOAD) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
WP 0269
WP 0782
Personnel Required
Maintainer - (2)
9-2355-106-10)
WARNING
NOTE
0038–1
TM 9-2355-106-23-1 0038
FUEL PRESSURE (FULL LOAD) TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Remove cap (Figure 1, Item 2) and air bleed valve (Figure 1, Item 3) from fuel filter header (Figure 1, Item 1).
Figure 1. Fuel Filter Header Air Bleed Valve.
2. Install adapter (Figure 2, Item 3) from Fuel Pressure Test Kit into air bleed valve opening on fuel filter header
(Figure 2, Item 2).
3. Install fuel pressure gauge set by connecting Fuel Pressure Test Kit line (Figure 2, Item 1) from adapter (Figure
2, Item 3) on fuel filter header (Figure 2, Item 2) to fuel pressure gauge 5 on gauge bar (Figure 2, Item 4).
4. Bleed air from fuel line to ensure accurate reading by loosening line at gauge and priming fuel system
(WP 0255). Tighten line securely after bleeding fuel system.
5. Start engine and run at idle to check for fuel leaks in line (Figure 2, Item 1) to pressure gauge.
0038–2
TM 9-2355-106-23-1 0038
NOTE
Ensure gauge set is secured to right side windshield, outside of vehicle in position viewable by
assistant during road test.
6. Drive vehicle on road until engine reaches operating temperature. Find open section of road and select
suitable gear. Press accelerator pedal to floor and accelerate to 100% load. Drive vehicle uphill or fully loaded
to reach correct engine loading at rated engine speed.
7. With assistant, measure and record fuel pressure.
Is recorded fuel pressure more than 45 psi (310 kPa)?
DECISION
YES Refer to Engine Performance Operational Checkout Procedure (WP 0015).

NO Go to next step.
STEP
8. Replace fuel filter (WP 0269).

9. Clean fuel strainer (WP 0269).
10. Drive vehicle on road until engine reaches operating temperature. Find open section of road and select
suitable gear. Press accelerator pedal to floor and accelerate to 100% load. Drive vehicle uphill or fully loaded
to reach correct engine loading at rated engine speed.
11. With assistant, measure and record fuel pressure.
Is recorded fuel pressure more than 45 psi (310 kPa)?
DECISION

NO Go to Step 13.
STEP
12. Verify correct engine performance.
Does engine perform correctly?
DECISION

NO Refer to next step in Engine Performance Operational Checkout Procedure (WP 0015).
0038–3
TM 9-2355-106-23-1 0038
MALFUNCTION
- 13. Restriction in fuel pump.
ACTION
Perform fuel pump restriction troubleshooting procedure. Refer to Fuel Pump Restriction Troubleshooting
END OF TEST
END OF WORK PACKAGE
0038–4
TM 9-2355-106-23-1 0039
FIELD MAINTENANCE
FUEL INJECTOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0782
References Equipment Condition
TM 9-2355-106-10 Parking brake set (TM 9-2355-106-10)
TM 9-2355-106-23P Transmission set in NEUTRAL (N) (TM
WP 0011 9-2355-106-10)
WP 0218 Engine shut off (TM 9-2355-106-10)
WP 0265

• 461
• 462
• 463
• 464
• 465
• 466
WARNING
NOTE
SYMPTOM
Yellow engine warning lamp is on.
MALFUNCTION
One or more of the following DTCs are set: 461, 462, 463, 464, 465, or 466.
0039–1
TM 9-2355-106-23-1 0039
FUEL INJECTOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
SYMPTOM
Fuel injectors show signs of rust or corrosion.
MALFUNCTION
Fuel system has water or other foreign contamination found during fuel injector replacement.
CORRECTIVE ACTION
Remove any water or other foreign contamination from entire fuel system, including fuel tanks,
fuel filter housings, strainers, and fuel supply manifold. Replace all injectors that show signs of
rust or corrosion. Refer to one or more of the following procedures:
• Fuel Injector Removal and Installation (WP 0249).
• Fuel Tank and Bracket Removal and Installation (WP 0265).
• Fuel/Water Separator Filter Removal and Installation (WP 0270).
• Fuel Filter and Strainer Removal and Installation (WP 0269).
• Oil/Fuel Manifold Removal and Installation (WP 0250).
SYMPTOM
Fuel injector has been replaced and one or more of the following DTCs returns: 461, 462, 463, 464, 465,
or 466.
MALFUNCTION
Internal engine malfunction causing one or more of the following DTCs to set: 461, 462, 463, 464,
465, or 466.
CORRECTIVE ACTION
Replace engine. Refer to Engine Assembly Removal (WP 0218) and Engine Assembly
END OF WORK PACKAGE
0039–2
TM 9-2355-106-23-1 0040
FIELD MAINTENANCE
INJECTION CONTROL PRESSURE (ICP) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Terminal Test Kit (WP 0795, Item 122) 9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0329
Air cleaner assembly removed (WP 0257)
WP 0317

• 124
• 125
• 332
WARNING
0040–1
TM 9-2355-106-23-1 0040
INJECTION CONTROL PRESSURE (ICP) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP
Figure 1. Injection Control Pressure (ICP) Sensor.
DECISION
NO Go to Step 7.
STEP

0040–2
TM 9-2355-106-23-1 0040
DECISION
NO Go to Step 9.
STEP
DECISION
YES Go to Step 32.

NO Go to Step 20.
STEP
Refer to Figure 3.
0040–3
TM 9-2355-106-23-1 0040
DECISION
YES Go to Step 33.

NO Go to Step 31.
STEP

Refer to Figure 3.
DECISION
YES Go to Step 31.

NO Go to next step.
STEP

DECISION
NO Go to Step 31.
STEP
DECISION
NO Go to Step 31.
STEP
0040–4
TM 9-2355-106-23-1 0040
DECISION
YES Go to Step 33.

NO Go to Step 31.
STEP

Refer to Figure 5.

0040–5
TM 9-2355-106-23-1 0040
DECISION
YES Go to Step 31.

NO Go to next step.
STEP

DECISION
NO Go to Step 31.
STEP
DECISION
NO Go to Step 31.
0040–6
TM 9-2355-106-23-1 0040
STEP
DECISION
YES Go to Step 33.

NO Go to nest step.
MALFUNCTION
ACTION
END OF TEST
0040–7
TM 9-2355-106-23-1 0040
MALFUNCTION
- 32. ICP sensor is faulty.
ACTION
Replace ICP sensor. Refer to Injection Control Pressure (ICP) Sensor Removal and Installation (WP 0391).
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0040–8
TM 9-2355-106-23-1 0041
FIELD MAINTENANCE
INJECTOR PRESSURE REGULATOR (IPR) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:

70) WP 0782
WP 0012 Left engine armor plate removed (WP 0597)
WP 0257 Air cleaner assembly removed (WP 0257)
WP 0329
WP 0330 WP 0789, Figure 79

• 241*
• 331
* DTC does not illuminate engine warning lamp.
WARNING
Use caution when working under hood with ignition ON. Failure to comply may result in damage
0041–1
TM 9-2355-106-23-1 0041
INJECTOR PRESSURE REGULATOR (IPR) TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP
1. Retrieve engine DTCs manually or with MSD. Refer to Diagnostic Trouble Code (DTC) Access Procedure
(WP 0012).
Do DTCs 231 or 331 display?
DECISION

STEP
NOTE
Engine will not run with DTC 241 active or IPR disconnected.

4. Disconnect connector LAM1016. Refer to Figure 1.
Figure 1. IPR.
0041–2
TM 9-2355-106-23-1 0041

7. Measure DC voltage between connector LAM1016 terminals A and B with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 21.

NO Go to next step.
STEP
8. Measure DC voltage between connector LAM1016 terminal A and ground with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 16.

NO Go to next step.
STEP

0041–3
TM 9-2355-106-23-1 0041
DECISION
NO Go to Step 27.
STEP
13. Measure resistance between connector LAM1016 terminal A and all other terminals on connector LAM1019
DECISION
NO Go to Step 27.
STEP
14. Connect connector LAM1016. Refer to Figure 3.

15. Measure resistance between connector LAM1019 terminal 17 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 26.
YES Go to Step 28.
STEP

Does multimeter read between 0 and 3 ohms?
0041–4
TM 9-2355-106-23-1 0041
DECISION
NO Go to Step 27.
STEP
20. Measure resistance between connector LAM1016 terminal B and all other terminals on connector LAM1019
DECISION
YES Go to Step 28.

NO Go to Step 27.
STEP

0041–5
TM 9-2355-106-23-1 0041
DECISION
NO Go to Step 27.
STEP
25. Measure resistance between connector LAM1016 terminal B and all other terminals on connector LAM1019
DECISION
YES Go to Step 28.

NO Go to Step 27.
MALFUNCTION
- 26. Faulty ECM.
ACTION
to service.
END OF TEST
MALFUNCTION
- 27. Faulty engine sensor wiring harness.
ACTION
END OF TEST
MALFUNCTION
- 28. Faulty IPR.
ACTION
Replace IPR. Refer to Injector Pressure Regulator (IPR) Valve Removal and Installation (WP 0396). Return
vehicle to service.
END OF TEST
END OF WORK PACKAGE

0041–6
TM 9-2355-106-23-1 0042
FIELD MAINTENANCE
INJECTION PRESSURE REGULATOR (IPR) SYSTEM OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70) WP 0396
WP 0597
General Mechanics Tool Kit (GMTK) (WP 0795, Item WP 0782
37)
Equipment Condition
References Parking brake set (TM 9-2355-106-10)
TM 9-2355-106-10 Transmission set in NEUTRAL (N) (TM
TM 9-2355-106-23P 9-2355-106-10)
WP 0040 Left side engine armor plate removed (WP 0597)
WARNING
CAUTION
NOTE
0042–1
TM 9-2355-106-23-1 0042
INJECTION PRESSURE REGULATOR (IPR) SYSTEM OPERATIONAL CHECKOUT PROCEDURE -

(CONTINUED)
STEP
1. Retrieve DTCs manually or with MSD. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
DTCs 124, 125, or 332 set.
CORRECTIVE ACTION
Refer to Injection Control Pressure (ICP) No Start Operational Checkout Procedure (WP 0020).
1. Check engine oil for contamination, correct grade, and correct oil level. Refer to Engine Oil Operational
2. Check Injection Control Pressure (ICP) sensor for proper function. Refer to Injection Control Pressure (ICP)
Sensor Troubleshooting Procedure (WP 0040).
3. Check Injection Pressure Regulator (IPR) for proper function. Refer to Injection Pressure Regulator (IPR)
Wrong oil grade used or oil contamination.
Change engine oil. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
Vehicle driven less than 20 miles (32 kilometers) after oil change.
Drive vehicle 15 to 20 miles, (24 to 32 kilometers) to eliminate air bubbles from oil reservoir and high pressure
system.
Engine oil level is too high or low.
Fill or drain engine oil to proper level. Refer to Engine Oil Drain/Fill Procedure (WP 0233).
Injection Control Pressure (ICP) sensor faulty.
Replace ICP sensor. Refer to (WP 0391).
Injection Pressure Regulator (IPR) valve faulty.
Replace IPR valve. Refer to (WP 0396).
END OF WORK PACKAGE
0042–2
TM 9-2355-106-23-1 0043
FIELD MAINTENANCE
FUEL/WATER SEPARATOR WITH 12V DC FUEL PRE-HEATER TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Terminal Test Kit (WP 0795, Item 122) Equipment Condition
Materials/Parts
Cable lock strap (WP 0796, Item 155)
9-2355-106-10)
WP 0333 Air filter removed (WP 0258)
WP 0335 Right engine armor plate removed (WP 0599)
WARNING
0043–1
TM 9-2355-106-23-1 0043
FUEL/WATER SEPARATOR WITH 12V DC FUEL PRE-HEATER TROUBLESHOOTING PROCEDURE -

(CONTINUED)
NOTE
Remove cable lock straps as necessary to perform procedure. Note position and size of cable
lock straps to aid installation.
Fuel/water separator temperature must be below 50°F (10°C).
STEP

2. Turn ignition switch ON (TM 9-2355-106-10). Fuel/water separator should begin to feel warm to touch within
5 minutes.
Is fuel/water separator warm?
DECISION

NO Go to next step.
STEP

5. Disconnect connector 4042 from fuel/water separator heater terminal. Refer to Figure 1.
Figure 1. Inboard Right Front Wheel.

8. Measure DC voltage between fuel/water separator heater harness connector 4042 terminal and ground with
0043–2
TM 9-2355-106-23-1 0043

(CONTINUED)
DECISION
YES Go to Step 36.

NO Go to next step.
STEP
Figure 2. Underhood Power Distribution Center (PDC).

11. Remove fuel heater relay 4002. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
12. Measure resistance between relay socket terminal 85 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 37.
0043–3
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP

14. Turn Ignition switch ON (TM 9-2355-106-10).
15. Measure DC voltage between relay 4002 socket terminals 85 and 86 with multimeter. Refer to Figure 3.
Figure 3. Fuel Heater Relay Socket.
DECISION
NO Go to Step 21.
STEP
16. Measure DC voltage between relay 4002 socket terminals 85 and 87 with multimeter. Refer to Figure 3.
DECISION
NO Go to Step 26.
0043–4
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP
17. Install jumper wire between relay 4002 socket terminals 30 and 86. Refer to Figure 3.
18. Measure DC voltage between fuel/water separator heater harness connector 4042 terminal and ground with
DECISION
YES Go to Step 38.

NO Go to next step.
0043–5
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP
19. Disconnect connector 4305F/4305M. Refer to Figure 5.
20. Measure DC voltage between connector 4305F terminal E and ground with multimeter. Refer to Figure 5.
DECISION
YES Go to Step 39.

NO Go toStep 37.
0043–6
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP
21. Remove and inspect 10A IGNITION BUS fuse. Refer to Power Distribution Center (PDC) Fuse and Relay
Removal and Installation (WP 0333).
Is fuse open?
DECISION
YES Go to Step 23.

NO Go to next step.
STEP
22. Measure DC voltage between each fuse socket terminal C3 and D3 to ground with multimeter. Refer
to Figure 6.
Does multimeter read between 10.5V and 13.5V for either test?
DECISION
NO Go to Step 40.
YES Go to Step 37.
0043–7
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP

25. Measure resistance between relay 4002 socket terminal 86 and ground with multimeter. Refer to Figure 7.
DECISION
NO Go to Step 37.
YES Go to Step 38.
0043–8
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP
26. Remove and inspect 20A FUEL HTR WIF fuse. Refer to Power Distribution Center (PDC) Fuse and Relay
Is fuse open?
DECISION
YES Go to Step 28.

NO Go to next step.
STEP
27. Measure DC voltage between each fuse socket terminal G3 and H3 to ground with multimeter. Refer
to Figure 8.
DECISION
NO Go to Step 40.
YES Go to Step 37.
0043–9
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP

DECISION
NO Go to Step 37.
STEP
DECISION
YES Go to Step 34.

NO Go to next step.
STEP
32. Disconnect connector 4305F/4305M. Refer to Figure 10.

0043–10
TM 9-2355-106-23-1 0043

(CONTINUED)
DECISION
YES Go to Step 37.

NO Go to Step 39.
0043–11
TM 9-2355-106-23-1 0043

(CONTINUED)
STEP
NOTE
Fuel/water separator must be below 50°F (10°C) for following test.
34. Connect fuel/water separator heater harness connector 4042. Refer to Figure 11.
Figure 12. Fuel Heater Relay 4002.
Does multimeter read more than 1 ohm?
DECISION
NO Go to Step 36.
YES Go to Step 38.
0043–12
TM 9-2355-106-23-1 0043

(CONTINUED)
MALFUNCTION
- 36. Fuel/water separator is faulty.
ACTION
Replace fuel/water separator. Refer to Fuel/Water Separator Assembly Purge, Removal, and Installation
END OF TEST
MALFUNCTION
- 37. Power Distribution Center (PDC) harness is faulty.
ACTION
END OF TEST
MALFUNCTION
- 38. Fuel heater relay is faulty.
ACTION
Replace fuel heater relay. Refer to Power Distribution Center (PDC) Fuel and Relay Removal and Installation
END OF TEST
MALFUNCTION
- 39. Forward chassis harness is faulty.
ACTION
Replace forward chassis harness. Refer to Forward Chassis Harness Removal and Installation (WP 0424).
END OF TEST
MALFUNCTION
- 40. Power Distribution Center (PDC) is faulty.
ACTION
Refer to Power Distribution Troubleshooting Procedure (WP 0059).
END OF TEST
END OF WORK PACKAGE
0043–13/blank
TM 9-2355-106-23-1 0044
FIELD MAINTENANCE
EXHAUST SYSTEM OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Equipment Condition
Materials/Parts Parking brake set (TM 9-2355-106-10)
Gloves, leather (WP 0794, Item 19) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
WARNING
Exhaust system components can be hot. Do not touch with bare hands or allow contact
with other skin surface. Wear protective work gloves and long sleeves. Do not use exhaust
tailpipe as a step. Failure to comply may result in damage to equipment and serious injury or
death to personnel.
Do not remove hot exhaust system from vehicle. Bolts can stretch, crack, and break when hot.
Allow exhaust system to cool before loosening bolts on C-clamps. Failure to comply may result
in damage to equipment and injury or death to personnel.
NOTE
STEP
0044–1
TM 9-2355-106-23-1 0044
EXHAUST SYSTEM OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
1. Inspect tailpipe (Figure 1, Item 3), shield assembly (Figure 1, Item 2), tailpipe bracket (Figure 1, Item 1) and
C-clamp (Figure 1, Item 4) for looseness, damage, or rust.
Figure 1. Tailpipe and Shield.
Tail pipe rattling, contacting body, or rusted.

CORRECTIVE ACTION
1. Tighten tailpipe connection at C-clamp.

2. Replace C-clamp if unable to tighten, rusted, or damaged. Refer to Muffler and Shield Removal and
3. Replace tailpipe if damaged or rusted. Refer to Muffler and Shield Removal and Installation (WP 0276).
Shield assembly loose, damaged, or rusted.

CORRECTIVE ACTION
1. Tighten shield assembly.

2. Replace shield assembly if unable to tighten, damaged, or rusted. Refer to Muffler and Shield Removal and
Tailpipe bracket loose or damaged.

CORRECTIVE ACTION
1. Tighten tailpipe bracket.

2. Replace tailpipe bracket if damaged. Refer to Muffler and Shield Removal and Installation (WP 0276).
1. Inspect muffler (Figure 2, Item 2), C-clamp (Figure 2, Item 3), and muffler holding straps (Figure 2, Item 1)
for looseness, damage, or rust.
0044–2
TM 9-2355-106-23-1 0044
Figure 2. Muffler and Muffler Holding Straps.
Muffler noisy or exhaust smell inside vehicle.

1. Tighten muffler connection at C-clamp. Replace C-clamp if unable to tighten, damaged, or rusted. Refer to
Muffler and Shield Removal and Installation (WP 0276). Return vehicle to service.
2. If muffler is damaged, has holes, or rust-through areas, replace muffler. Refer to Muffler and Shield Removal
Muffler loose, rattling, or hanging low under vehicle.
1. Inspect muffler holding straps for looseness, damage, or rusted.
2. Tighten loose components.
3. Replace damaged or rusted components. Refer to Muffler and Shield Removal and Installation (WP 0276).
1. Inspect exhaust pipes (Figure 3, Item 3 and 5), pipe coupling (Figure 3, Item 4), loop clamps (Figure 3,
Item 1) and hangers (Figure 3, Item 2).
Figure 3. Exhaust Pipes and Hangers.
0044–3
TM 9-2355-106-23-1 0044
Excessive exhaust noise or exhaust smell inside vehicle.

1. Inspect front and rear exhaust pipes for damage, holes, or rust-through areas.
2. Replace defective exhaust pipes. Refer to Exhaust Pipe Removal and Installation (WP 0275). Return
vehicle to service.
3. Inspect exhaust pipe coupling. Tighten if loose.
4. If unable to tighten coupling, or if damaged or rusted, replace coupling. Refer to Exhaust Pipe Removal and
Rattling or banging noise under vehicle during operation.
1. Inspect front exhaust hangers and rear exhaust hangers for looseness, damage, or rust.
2. Inspect loop clamps for looseness, damage, or rust.
3. Tighten loose components.
4. Replace damaged or rusted components. Refer to Exhaust Pipe Removal and Installation (WP 0275).
1. Inspect turbocharger pipe (Figure 4, Item 1) and pipe clamp (Figure 4, Item 2).
Figure 4. Turbocharger Pipe and Clamp.
0044–4
TM 9-2355-106-23-1 0044
Excessive exhaust noise or exhaust smell inside vehicle.

1. Inspect turbocharger pipe for leaking, damage, or rust-through areas. Replace pipe if defective. Refer to
Exhaust Pipe Removal and Installation (WP 0275). Return vehicle to service.
2. Inspect for leaking, damage, or rust-through areas of pipe clamp. Replace pipe clamp if found defective.
Refer to Exhaust Pipe Removal and Installation (WP 0275). Return vehicle to service.
1. Inspect exhaust brake clamps (Figure 5, Item 1 and 2) for leaks.
Figure 5. Exhaust Brake Clamps.
Excessive exhaust noise, exhaust brake not operating properly, or exhaust smell inside vehicle.
1. Inspect exhaust brake-to-turbocharger clamp for leaking or damage. If found defective, replace clamp.
Refer to Exhaust Brake Removal and Installation (WP 0246). Return vehicle to service.
2. Inspect exhaust brake-to-turbocharger pipe clamp for leaking or damage. If found defective, replace clamp.
Refer to Exhaust Brake Removal and Installation (WP 0246). Return vehicle to service.
END OF WORK PACKAGE
0044–5/blank
TM 9-2355-106-23-1 0045
FIELD MAINTENANCE
COOLING SYSTEM OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70) WP 0283
Radiator Test Kit (SVTS262KIT) (WP 0795, Item 83)
Equipment Condition
Materials/Parts Parking brake set (TM 9-2355-106-10)
Gloves, leather (WP 0794, Item 19) Transmission set in NEUTRAL (N) (TM
Goggles (WP 0794, Item 20) 9-2355-106-10)
Engine off (TM 9-2355-106-10)
WARNING
NOTE
STEP
1. Verify coolant level is not low (TM 9-2355-106-10).
Coolant level is low.
CORRECTIVE ACTION
Fill to proper level and verify that vehicle achieves proper operating temperature (TM 9-2355-106-10).
2. Retrieve DTCs. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
DTCs associated with engine cooling are set.
Diagnose DTCs. Refer to Engine Diagnostic Trouble Code (DTC) Index (WP 0006).
0045–1
TM 9-2355-106-23-1 0045
COOLING SYSTEM OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
WARNING
Cooling system components become pressurized and extremely hot during normal operation.
To prevent serious injury from hot coolant or scalding steam, use the following safety procedure
when removing radiator cap, surge tank cap, or deaeration cap:
Allow engine to cool for 15 minutes.
Wrap a thick cloth around cap to be removed.
Loosen cap slowly one-quarter to one-half turn counterclockwise, and pause to allow pressure
to release.
Continue to turn cap counterclockwise to remove.
1. Carefully remove cap from deaeration tank. Refer to Deaeration Tank Pressure Cap Removal and Installation
(WP 0280). Test cooling system for leaks. Perform the following steps:
a. Connect Radiator Test Kit SVTS262KIT.
Figure 1. Radiator Test Kit.
b. Apply 16 psi (110.3 kPa) to cooling system. System should maintain 16 psi (110.3 kPa) for 10 minutes.
System does not maintain 16 psi (110.3 kPa) for 10 minutes.
• Visually inspect engine, water pump, and all cooling system components for leaks and repair or replace as
necessary. Refer to Chapter 4 Work Package Index, for relevant repair procedures.
• Inspect cabin heater components and hoses for coolant leaks and repair or replace as necessary. Refer to
Chapter 4 Work Package Index, for relevant repair procedures.
• Inspect for coolant in engine oil. Refer to Engine Mechanical Troubleshooting Procedure (WP 0016).
1. Verify fan, clutch, and drive belt are operating correctly. Refer to Engine Cooling Fan Operational Checkout
0045–2
TM 9-2355-106-23-1 0045
COOLING SYSTEM OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Fan, clutch, or drive belt is not operating correctly.

Refer to Chapter 4 Work Package Index, for relevant repair procedures.
1. Observe temperature gauge to verify engine reaches operating temperature (TM 9-2355-106-10).
Engine does not reach operating temperature.
Replace thermostat. Refer to Thermostat Removal and Installation (WP 0283). Return vehicle to service.
END OF WORK PACKAGE
0045–3/blank
TM 9-2355-106-23-1 0046
FIELD MAINTENANCE
ENGINE COOLANT LEVEL SYSTEM TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0281
WP 0329
WP 0782 WP 0789, Figure 68
This procedure covers the following DTCs:

• 236
• 323
WARNING
NOTE
0046–1
TM 9-2355-106-23-1 0046
ENGINE COOLANT LEVEL SYSTEM TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
Figure 1. Right Engine Compartment.
2. Measure resistance between connector 6401M terminal B and ground with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 13.
0046–2
TM 9-2355-106-23-1 0046
STEP

5. Measure DC voltage between connector 6401M terminal A and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 12.

NO Go to next step.
STEP

8. Disconnect connector 6007. Refer to Figure 3. Refer to Engine Control Module (ECM) Removal and
0046–3
TM 9-2355-106-23-1 0046
9. Measure resistance between connector 6401M terminal A and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 13.
STEP
10. Measure resistance between connector 6401M terminal A and connector 6007 terminal 10 with multimeter.
0046–4
TM 9-2355-106-23-1 0046
DECISION
NO Go to Step 13.
STEP
11. Measure resistance between connector 6007 terminal 10 and all other terminals in connector 6007. Multimeter
should read OL for each test. Refer to Figure 7.
DECISION
NO Go to Step 13.
YES Go to Step 14.
MALFUNCTION
- 12. Coolant level sensor is faulty.
ACTION
Replace deaeration tank. Refer to Deaeration Tank Removal and Installation (WP 0279). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 13. Engine harness is faulty.
ACTION
vehicle to service.
0046–5
TM 9-2355-106-23-1 0046
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0046–6
TM 9-2355-106-23-1 0047
FIELD MAINTENANCE
ENGINE COOLANT TEMPERATURE (ECT) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0336
Tee, 2-way breakout (ZTSE4483) (WP 0795, Item WP 0388
115) WP 0782

Tape (WP 0794, Item 52) Parking brake set (TM 9-2355-106-10)
Personnel Required 9-2355-106-10)
Maintainer - (2) Engine off (TM 9-2355-106-10)
TM 9-2355-106-23P Alternator removed (WP 0289)
WP 0289 Alternator bracket removed (WP 0290)

• DTC 114
• DTC 115
• DTC 316
• DTC 321
• DTC 322
• DTC 325
WARNING
0047–1
TM 9-2355-106-23-1 0047
ENGINE COOLANT TEMPERATURE (ECT) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
After removing the alternator and prior to connecting vehicle batteries, wrap the terminal ends
of the alternator battery cables with electrical tape to prevent accidental contact with ground.
Failure to comply may result in damage to system components.
NOTE
STEP
Figure 1. ECT Sensor.
DECISION
YES Go to Step 13.

NO Go to next step.
0047–2
TM 9-2355-106-23-1 0047
STEP
3. Connect vehicle batteries. Refer to MAIN POWER Procedure (WP 0404).

6. Measure DC voltage between harness connector LAM1040 terminal B and ground with multimeter. Refer
to Figure 1.
Does multimeter read between than 4.5 volts and 5.5 volts?
DECISION
NO Go to Step 15.
STEP

9. Install breakout tee (ZTSE4483) between ECT sensor and harness connector LAM1040. Refer to Figure 2.

12. Measure and record DC voltage between breakout tee (ZTSE4483) terminals SIGNAL and SIGNAL GROUND.
0047–3
TM 9-2355-106-23-1 0047
Table 1. Sensor Temperature vs Resistance.

VOLTAGE TEMPERATURE °F TEMPERATURE °C SENSOR RESISTANCE
0.356V 230 110 1.19k ohms
3.87V 32 0 69.2k ohms
4.33V 5 -20 131k ohms
Does multimeter read voltage corresponding to specifications in Table 1?
DECISION
NO Go to Step 21.
YES Go to Step 20.
STEP
13. Disconnect harness connector LAM1019 . Refer to Engine Control Module (ECM) Removal and Installation
14. With assistance, measure resistance between sensor connector LAM1040 terminal A and harness connector
LAM1019 terminal 19 with multimeter. Refer to Figure 4 and Figure 3.
DECISION
NO Go to Step 20.
0047–4
TM 9-2355-106-23-1 0047
YES Go to Step 22.
STEP

to Figure 4.
DECISION
NO Go to Step 22.
STEP
18. With assistance, measure resistance between harness connector LAM1040 terminal B and harness connector
LAM1019 terminal 13 with multimeter. Refer to Figure 4 and Figure 3.
DECISION
YES Go to Step 22.

NO Go to next step.
0047–5
TM 9-2355-106-23-1 0047
STEP
19. With assitance, measure resistance between harness connector LAM1019 terminal 13 and all other harness
connector LAM1019 terminals. Multimeter should read OL for each test. Refer to Figure 3.
DECISION
YES Go to Step 20.

NO Go to Step 22.
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 21. ECT sensor is faulty.
ACTION
Replace ECT sensor. Refer to Engine Coolant Temperature (ECT) Sensor Removal and Installation(WP 0388).
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0047–6
TM 9-2355-106-23-1 0048
FIELD MAINTENANCE
ENGINE FAN CONTROL (EFC) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0335
WP 0597 WP 0789, Figure 70
WARNING
NOTE
0048–1
TM 9-2355-106-23-1 0048
ENGINE FAN CONTROL (EFC) TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Disconnect EFC solenoid connector 4111M. Refer to Figure 1.
Figure 1. Left Engine Area.

Does multimeter read between 10.5 volts and 13.5 volts?
DECISION
NO Go to Step 11.
0048–2
TM 9-2355-106-23-1 0048
STEP

Does multimeter read less than 1,000 ohms?
DECISION
YES Go to Step 20.

NO Go to next step.
STEP

10. Measure DC voltage connector 4111M terminals A and B with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 18.

NO Go to Step 29.
0048–3
TM 9-2355-106-23-1 0048
STEP
11. Remove and inspect AIR FAN SHUTTER fuse. Refer to Power Distribution Center (PDC) Fuse and Relay
Removal and Installation (WP 0333). Refer to Figure 2.
Figure 2. Air Fan Shutter Fuse
Is AIR FAN SHUTTER fuse open?
DECISION
YES Go to Step 24.

NO Go to next step.
STEP
12. Measure DC voltage between each AIR FAN SHUTTER fuse socket terminals and ground with multimeter.
Refer to Figure 2.
Does multimeter read between 10.5 volts and 13.5 volts for either test?
DECISION
NO Go to Power Distribution Troubleshooting (WP 0059).

STEP
13. Install AIR FAN SHUTTER fuse. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
0048–4
TM 9-2355-106-23-1 0048

16. Disconnect Connector 4103. Refer to .Figure 3
17. Measure resistance between connector 4111M terminal A and connector 4103 terminal 14 with multimeter.
Refer to Figure 4. Refer to Figure 3.
0048–5
TM 9-2355-106-23-1 0048
DECISION
NO Go to Step 30.
YES Go to Step 31.
STEP

20. Disconnect LAM 1019 harness connector. Refer to Figure 5. Refer to Engine Control Module (ECM)
DECISION
NO Go to Step 30.
0048–6
TM 9-2355-106-23-1 0048
STEP
22. Measure resistance between connector 4111M terminal B and connector LAM 1019 terminal 8 with multimeter.
Figure 7. Connector LAM 1019.
DECISION
NO Go to Step 30.
0048–7
TM 9-2355-106-23-1 0048
STEP
23. Measure resistance between connector LAM 1019 terminal 8 and all other terminals in ECM GRAY LAM 1019
connector with multimeter. Multimeter should read OL for each test. Refer to Figure 7.
DECISION
NO Go to Step 30.
YES Go to Step 32.
STEP
24. Turn ignition switch OFF (TM 9–2355–106–10).

25. Turn MAIN POWER switch OFF (TM 9–2355–106–10).
DECISION
YES Go to Step 29.

NO Go to next step.
0048–8
TM 9-2355-106-23-1 0048
STEP
DECISION
NO Go to Step 30.
YES Go to Step 31.
MALFUNCTION
- 29. EFC Solenoid is faulty.
0048–9
TM 9-2355-106-23-1 0048
ACTION
Replace EFC solenoid. Refer to Cooling Fan Actuator Solenoid Removal and Installation (WP 0288). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 31. Power Distribution Center (PDC) wiring harness is faulty.
ACTION
Replace PDC wiring harness. Refer to Power Distribution Center (PDC) Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0048–10
TM 9-2355-106-23-1 0049
FIELD MAINTENANCE
ENGINE CONTROL MODULE (ECM) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0412
WP 0405
WP 0598
WP 0606
(WP 0795, Item 37)
WP 0789
Terminal Test Kit (WP 0795, Item 122)
WP 0782
Gloves, rubber (WP 0795, Item 38)
Faceshield, industrial (WP 0794, Item 16) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
Personnel Required
Maintainer - (2)
TM 9-2355-106-23P Belly armor removed (WP 0606)
WP 0011 Left side engine armor plate bracket removed
WP 0014 (WP 0598)
WP 0051
WP 0329 WP 0789, Figure 17
WP 0334 WP 0789, Figure 68
This procedure covers the following ECM Diagnostic Trouble Codes (DTCs):
• 112
• 113
• 626
These DTCs will not illuminate amber engine warning lamp.
0049–1
TM 9-2355-106-23-1 0049
ENGINE CONTROL MODULE (ECM) TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0049–2
TM 9-2355-106-23-1 0049
STEP
Does engine start and run?
DECISION
YES Go to Step 9.
NO Go to next step.
STEP
Does MSD communicate with the Engine Control Module (ECM)?
DECISION
NO Go to American Truckers Association (ATA) Communications/Data Communications Link (DLC)

0049–3
TM 9-2355-106-23-1 0049
STEP

5. Disconnect fuel injector harness. Refer to Figure 1.
Figure 1. Left Side of Engine On Valve Cover.

8. With MSD, check voltage on ECM while cranking engine (TM 9-2355-106-10). A minimum of 7 volts is
necessary to start engine.
Does MSD read more than 7V?
DECISION
YES Go to Step 59.

NO Go to Step 10.
STEP
9. Retrieve ECM DTCs. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
0049–4
TM 9-2355-106-23-1 0049
Are DTCs 112, 113, or 626 displayed?
DECISION
NO Go to Step 60.
STEP

12. Remove Power Distribution Center (PDC) armor and cover. Refer to Power Distribution Center (PDC)
13. Remove Consolidated Engine Controller (CEC) power module relay. Refer to Figure 2.
Figure 2. Consolidated Engine Controller (CEC) Power Module Relay.

16. Turn all accessories off (TM 9-2355-106-10).
17. Measure DC voltage between ground and CEC POWER MODULE relay terminals 86 and 30 with multimeter.
Refer to Figure 2.
Does multimeter read between 10.5V and 13.8V for each test?
0049–5
TM 9-2355-106-23-1 0049
DECISION
NO Go to Step 30.
STEP
18. Install and remove CEC power module relay two or three times while listening and feeling for CEC power
module relay click.
Does CEC power module relay click?
DECISION
YES Go to Step 21.

NO Go to next step.
STEP
19. Substitute known-good CEC power module relay.

20. Install and remove known-good CEC power module relay two or three times while listening and feeling for
known-good CEC power module relay click.
Does known-good CEC power module relay click?
DECISION
NO Go to Step 41.
YES Go to Step 65.
STEP

24. Disconnect connector 9260F from 9260M. Refer to Figure 4.

0049–6
TM 9-2355-106-23-1 0049
Figure 4. Right Side of Battery Box Above Battery.
25. Measure resistance between connector 9260F terminal A and connector 6007 terminals 1, 2, 23, and 42
Does multimeter read less than 3 ohms for each test?
DECISION
NO Go to Step 48.
STEP
26. Measure resistance between connector 9260M terminal A and ground terminal (Figure 6, Item 1) with
0049–7
TM 9-2355-106-23-1 0049
Figure 6. ECM Clean Ground Battery Terminal.
DECISION
NO Go to Step 61.
STEP
27. Measure resistance between CEC power module relay terminal 87 and connector 6007 terminals 21, 22, and
41 with multimeter. Refer to Figure 7 and Figure 8.
0049–8
TM 9-2355-106-23-1 0049
Figure 7. CEC Power Module Relay.
Did multimeter read less than 3 ohms for each test?
DECISION
YES Go to Step 65.

NO Go to next step.
0049–9
TM 9-2355-106-23-1 0049
STEP
28. Disconnect connectors 4105/4101M. Refer to Figure 9.
Figure 9. Harness Bundle Below Air Cleaner Assembly.
29. Measure resistance between connector 4101M terminal A and connector 6007 terminals 21, 22, and 41
DECISION
NO Go to Step 69.
YES Go to Step 70.
0049–10
TM 9-2355-106-23-1 0049
STEP

32. Measure resistance between CEC power module relay terminals 86 and 30 with multimeter. Refer to Figure 11.
DECISION
NO Go to Step 70.
0049–11
TM 9-2355-106-23-1 0049
STEP
33. Remove and test engine ECM feed 40A fuse (Figure 12, Item 1). Refer to Engine Control Module (ECM) and
Transmission Control Module (TCM) Clean Power and Ground Fuse Removal and Installation (WP 0412).
Is fuse good?
DECISION
NO Go to Step 50.
0049–12
TM 9-2355-106-23-1 0049
STEP
34. With assistant, measure resistance between CEC power module relay terminal 86 and ECM feed 40A fuse
terminal B with multimeter. Refer to Figure 13 and Figure 12.
DECISION
YES Go to Step 61.

NO Go to next step.
0049–13
TM 9-2355-106-23-1 0049
STEP
36. With assistant, measure resistance between engine ECM feed fuse terminal B and connector 4101M terminal
B with multimeter. Refer to Figure 14 and Figure 15.
Figure 15. ECM Feed Fuse.
Does multimeter read between 0 ohms and 3 ohms?
DECISION
YES Go to Step 70.

NO Go to next step.
0049–14
TM 9-2355-106-23-1 0049
STEP
NOTE
There are two connectors in this area. Each connector contains two wires. Connector
6323M/6323F is the larger of the two connectors and contains the larger wires.
Figure 16. Under Left Front of Vehicle, Inboard Frame Rail.
38. With assistance, measure resistance between engine ECM feed fuse terminal B and connector 6323M
terminal A with multimeter. Refer to Figure 16 and Figure 15.
Does the multimeter read between 0 ohms and 3 ohms?
DECISION
YES Go to Step 69.

NO Go to next step.
0049–15
TM 9-2355-106-23-1 0049
STEP
39. Disconnect connectors 9261F/9261M. Refer to Figure 17.
40. Measure resistance between engine ECM feed fuse terminal B and connector 9261F terminal A with
Figure 18. ECM Feed Fuse.
Does the multimeter read between 0 ohms and 3 ohms?
DECISION
NO Go to Step 61.
YES Go to Step 66.
STEP

0049–16
TM 9-2355-106-23-1 0049

43. Disconnect connector 4103/4100F. Refer to Figure 19.
44. Measure resistance between CEC power module relay terminal 85 and connector 4103 terminal 18 with
DECISION
NO Go to Step 70.
0049–17
TM 9-2355-106-23-1 0049
STEP
46. Measure resistance between connector 4100F terminal 18 and connector 6007 terminal 25 with multimeter.
Figure 22. Connector 4100F.
DECISION
NO Go to Step 69.
STEP
47. Measure resistance between ground and connector 6007 terminals 1, 2, 23, and 42 with multimeter. Refer to
Figure 23.
0049–18
TM 9-2355-106-23-1 0049
DECISION
YES Go to Step 63.

NO Go to next step.
0049–19
TM 9-2355-106-23-1 0049
STEP
NOTE
There are two connectors in this area. Each connector contains two wires. Connector
6323M/6323F is the larger of the two connectors and contains the larger wires.
48. Disconnect connector 6323F. Refer to Figure 24.
49. Measure resistance between connector 6323F terminal B and connector 6007 terminals 1, 2, 23, and 42
Did multimeter read less than 3 ohms for each test?

0049–20
TM 9-2355-106-23-1 0049
DECISION
NO Go to Step 69.
YES Go to Step 66.
STEP
50. Disconnect connectors 9261M/9261F. Refer to Figure 26.
51. Measure resistance between connector 9261F terminal A and ground with multimeter. Refer to Figure 26.
DECISION
NO Go to Step 62.
0049–21
TM 9-2355-106-23-1 0049
STEP
52. Disconnect connectors 6323M/6323F. Refer to Figure 27.
53. Measure resistance between connect 6323M terminal A and ground with multimeter. Refer to Figure 27.
DECISION
NO Go to Step 67.
0049–22
TM 9-2355-106-23-1 0049
STEP
54. Disconnect connector 4105 from 4101M. Refer to Figure 28.
55. Measure resistance between ground and connector 4105 terminals A and B with multimeter. Refer to
Figure 28.
DECISION
NO Go to Step 71.
0049–23
TM 9-2355-106-23-1 0049
STEP
DECISION
NO Go to Step 68.
STEP
0049–24
TM 9-2355-106-23-1 0049
DECISION
NO Go to Step 68.
YES Go to Step 64.
MALFUNCTION
- 59. ECM cranking voltage is sufficient to allow engine to start.
ACTION
Return to Hard Start/No Start Toubleshooting Procedure (WP 0014).
END OF TEST
MALFUNCTION
- 60. ECM voltage is currently within specifications.
ACTION
END OF TEST
MALFUNCTION
- 61. Battery cable and clean power harness faulty.
ACTION
Replace battery cable and clean power harness. Refer to Battery Cable and Clean Power Harness Removal
END OF TEST
MALFUNCTION
- 62. Battery cable and clean ground harness faulty.
ACTION
Replace battery cable and clean ground harness. Refer to Battery Disconnect Procedure (WP 0404).
END OF TEST
0049–25
TM 9-2355-106-23-1 0049
MALFUNCTION
- 63. ECM faulty.
ACTION
Replace ECM. Refer to ECM Removal and Installation (WP 0329). Return vehicle to service.
END OF TEST
MALFUNCTION
- 64. ECM faulty.
ACTION
Replace 40A engine ECM feed fuse and ECM. Refer to Engine Control Module (ECM) and Transmission Control
Module (TCM) Clean Power and Ground Fuse Removal and Installation (WP 0412). Refer to ECM Removal
END OF TEST
MALFUNCTION
- 65. Relay faulty.
ACTION
Replace relay. Return vehicle to service.
END OF TEST
MALFUNCTION
- 66. ECM and Transmission Control Module (TCM) clean power and ground harness faulty.
ACTION
Replace ECM and TCM clean power and ground harness. Refer to ECM and TCM Clean Power and Ground
Harness Removal and Installation (WP 0406). Return vehicle to service.
END OF TEST
MALFUNCTION
- 67. ECM and Transmission Control Module (TCM) clean power and ground harness faulty.
ACTION
Replace 40A fuse and ECM and Transmission Control Module (TCM) clean power and ground harness. Refer
to Refer to ECM and TCM Clean Power and Ground Harness Removal and Installation (WP 0406). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 68. Engine wire harness faulty.

0049–26
TM 9-2355-106-23-1 0049
ACTION
Replace 40A fuse. Refer to Engine Control Module (ECM) and Transmission Control Module (TCM) Clean
Power and Ground Fuse Removal and Installation (WP 0412). Refer to Replace engine wire harness. Refer to
Engine Wire Harness Removal and Installation (WP 0336). Return vehicle to service.
END OF TEST
MALFUNCTION
- 69. Engine wire harness faulty.
ACTION
Replace engine wire harness. Refer to Engine Wire Harness Removal and Installation (WP 0336). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 70. Power Distribution Center (PDC) harness faulty.
ACTION
END OF TEST
MALFUNCTION
- 71. Power Distribution Center (PDC) harness faulty.
ACTION
Replace 40A fuse and PDC harness. Refer to Engine Control Module (ECM) and Transmission Control Module
(TCM) Clean Power and Ground Fuse Removal and Installation (WP 0412). Refer to Power Distribution Center
(PDC) Harness Removal and Installation (WP 0335). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0049–27/blank
TM 9-2355-106-23-1 0050
FIELD MAINTENANCE

PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0062
Tee, Accelerator Position Sensor (APS)/Idle WP 0782
Validation Switch (IVS), Sensor Breakout
Equipment Condition
(ZTSE4485) (WP 0795, Item 117)
Personnel Required Transmission set in NEUTRAL (N) (TM
Maintainer - (2) 9-2355-106-10)
Engine off (TM 9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0324
Left side engine armor plate removed (WP 0598)
WP 0329
Left cabin door open and secured (WP 0608)
WP 0319
WP 0336 WP 0789, Figure 68

• 131
• 132
• 133
• 134
• 135
0050–1
TM 9-2355-106-23-1 0050

PROCEDURE - (CONTINUED)
WARNING
Cabin door must be secured in the open position by using heavy duty straps to prevent
accidental closure during vehicle maintenance. Pull check link retaining pin prior to securing
door open. Failure to comply may result in serious injury or death to personnel.
CAUTION
NOTE
STEP
1. Disconnect harness connector 1804. Refer to Figure 1.
0050–2
TM 9-2355-106-23-1 0050

Figure 1. Accelerator Position Sensor (APS)/Idle Validation Switch (IVS).
2. Measure resistance between harness connector 1804 terminal B and ground with multimeter. Refer to
Figure 1.
DECISION
YES Go to Step 24.

NO Go to next step.
0050–3
TM 9-2355-106-23-1 0050

STEP

5. Measure DC voltage between harness connector 1804 terminal C and ground with multimeter. Refer to
Figure 2.
DECISION
NO Go to Step 33.
STEP

7. Turn MAIN POWER switch OFF (TM 9-2355-106-10)..
8. Measure resistance between harness connector 1804 terminal A and ground with multimeter. Refer to
Figure 2.
Does multimeter read between 300,000 ohms and 400,000 ohms?
DECISION
NO Go to Step 54.
STEP
9. Measure resistance between harness connector 1804 terminal D and ground with multimeter. Refer to
Figure 2.
DECISION
NO Go to Step 65.
0050–4
TM 9-2355-106-23-1 0050

STEP

12. Measure DC voltage between harness connector 1804 terminal F and ground. Refer to Figure 2.
DECISION
NO Go to Step 76.
STEP

15. Measure resistance between harness connector 1804 terminal E and ground. Refer to Figure 2.
DECISION
NO Go to Step 91.
STEP
16. Measure resistance between harness connector 1804 terminal E and all other terminals in harness connector
1804. Refer to Figure 2. Multimeter should read OL for each test.
DECISION
NO Go to Step 91.
STEP
17. Install APS-IVS breakout harness (ZTSE4485) between APS-IVS sensor and harness connector 1804.
Refer to Figure 3.
0050–5
TM 9-2355-106-23-1 0050

Figure 3. Accelerator Position Sensor (APS)/Idle Validation Switch (IVS) Breakout Harness (ZTSE4485).

20. Measure DC voltage between APS-IVS breakout harness (ZTSE4485) GREEN APS SIGNAL test lead and
ground with multimeter. Refer to Figure 3.
21. Observe multimeter while slowly depressing accelerator pedal.
Does voltage transition smoothly from 0.6V to 4.0V?
DECISION
NO Go to Step 95.
STEP
22. Measure DC voltage between APS-IVS breakout harness (ZTSE4485) WHITE IVS SIGNAL test lead and
23. Observe multimeter while slowly depressing accelerator pedal.
Does multimeter read between 10.5V and 13.5V from just off idle to wide-open throttle?
DECISION
YES Go to Step 96.

NO Go to Step 95.
0050–6
TM 9-2355-106-23-1 0050

STEP
24. Disconnect harness connector 1800/1805. Refer to Figure 4.
Figure 4. Below Instrument Panel (IP).
25. Measure resistance between harness connector 1800 terminal B4 and ground with multimeter. Refer
to Figure 4.
DECISION
NO Go to Step 91.
STEP
0050–7
TM 9-2355-106-23-1 0050

Figure 5. Firewall Pass-Through.
27. Measure resistance between connector 1701 terminal 2 (engine harness side) and ground with multimeter.
Refer to Figure 5.
DECISION
NO Go to Step 94.
0050–8
TM 9-2355-106-23-1 0050

STEP
Figure 6. Below Air Filter.
29. Disconnect 18-wire harness connector 4100F/4103. Refer to Figure 6.

30. Measure resistance between harness connector 4100F terminal 6 and ground with multimeter. Refer to
Figure 6.
DECISION
NO Go to Step 92.
0050–9
TM 9-2355-106-23-1 0050

STEP
31. Disconnect ECM connector 6007. Refer to Figure 7. Refer to Engine Control Module (ECM) Removal and
Figure 7. ECM Connectors.
32. Measure resistance between connector 4100F terminal 6 and connector 6007 terminal 11 with multimeter.
DECISION
NO Go to Step 96.
YES Go to Step 93.
STEP

0050–10
TM 9-2355-106-23-1 0050



38. Measure DC voltage between harness connector 1800 terminal C5 and ground with multimeter. Refer
to Figure 9.
DECISION
YES Go to Step 91.

NO Go to next step.
STEP

0050–11
TM 9-2355-106-23-1 0050

42. Measure resistance between harness connector 1800 terminal C5 and ground with multimeter. Refer to
Figure 11.
DECISION
NO Go to Step 94.
0050–12
TM 9-2355-106-23-1 0050

STEP
43. Measure resistance between harness connector 1800 terminal C5 and connector 1701 terminal 5 (cabin side)
DECISION
NO Go to Step 94.
STEP
44. Measure resistance between connector 1701 terminal 5 (cabin side) and all other connector 1701 (cabin side)
terminals with multimeter. Multimeter should read OL for each test. Refer to Figure 10.
DECISION
NO Go to Step 94.
0050–13
TM 9-2355-106-23-1 0050

STEP

47. Measure resistance between harness connector 4103 terminal 4 and ground with multimeter. Refer to
Figure 12.
DECISION
NO Go to Step 92.
STEP
48. Measure resistance between harness connector 4103 terminal 4 and harness connector 1701 (engine harness
side) terminal 5 with multimeter. Refer to Figure 12 and Figure 13.
0050–14
TM 9-2355-106-23-1 0050

Figure 13. Connector 1701-Engine Side.
DECISION
NO Go to Step 92.
STEP
49. Measure resistance between harness connector 4103 terminal 4 and all other harness connector 4103
terminals. Multimeter should read OL for each test. Refer to Figure 12.
DECISION
NO Go to Step 92.
0050–15
TM 9-2355-106-23-1 0050

STEP
50. Disconnect Engine Control Module (ECM) connector 6007. Refer to Figure 14. Refer to Engine Control
Module (ECM) Removal and Installation (WP 0329).
Figure 15.
DECISION
NO Go to Step 93.
STEP
52. Measure resistance between harness connector 4100F terminal 4 and harness connector 6007 terminal 3
0050–16
TM 9-2355-106-23-1 0050

DECISION
NO Go to Step 93.
STEP
53. Measure resistance between harness connector 6007 terminal 3 and all other terminals in harness connector
6007 with multimeter. Multimeter should read OL for each test. Refer to Figure 14.
DECISION
NO Go to Step 93.
YES Go to Step 96.
0050–17
TM 9-2355-106-23-1 0050

STEP
Figure 16.
DECISION
YES Go to Step 91.

NO Go to next step.
0050–18
TM 9-2355-106-23-1 0050

STEP
57. Measure resistance between harness connector 1701 (engine harness side) terminal 1 and ground with
DECISION
YES Go to Step 94.

NO Go to next step.
0050–19
TM 9-2355-106-23-1 0050

STEP
Figure 18.
DECISION
YES Go to Step 92.

NO Go to next step.
0050–20
TM 9-2355-106-23-1 0050

STEP
Figure 18.
DECISION
NO Go to Step 93.
STEP
DECISION
NO Go to Step 93.
STEP
0050–21
TM 9-2355-106-23-1 0050

DECISION
NO Go to Step 93.
YES Go to Step 96.
STEP
66. Measure resistance between harness connector 1800 terminal B5 and ground with multimeter. Refer to
Figure 20.
DECISION
YES Go to Step 91.

NO Go to next step.
STEP

0050–22
TM 9-2355-106-23-1 0050

68. Measure resistance between harness connector 1701 (engine harness side) terminal 4 and ground with
DECISION
YES Go to Step 94.

NO Go to next step.
0050–23
TM 9-2355-106-23-1 0050

STEP
Figure 22.
DECISION
YES Go to Step 92.

NO Go to next step.
0050–24
TM 9-2355-106-23-1 0050

STEP
Figure 22.
DECISION
NO Go to Step 93.
STEP
DECISION
NO Go to Step 93.
STEP
0050–25
TM 9-2355-106-23-1 0050

DECISION
NO Go to Step 93.
YES Go to Step 96.
STEP

78. Remove and Inspect fuse F24. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal
and Installation (WP 0317). Refer to Figure 24.
Figure 24. Fuse Locator.
Is fuse F24 open?
DECISION
YES Go to Step 86.

NO Go to next step.
STEP

81. Measure DC voltage between ground and fuse block 1012 terminals A2 and B2 with multimeter. Refer to
Figure 24.
DECISION
NO Go to Cabin Fuse Block 1012 Troubleshooting Procedure (WP 0062).

STEP

0050–26
TM 9-2355-106-23-1 0050

85. Measure resistance between harness connector 1800 terminal C6 and accelerator fuse (F24) terminal B2
DECISION
YES Go to Step 94.

NO Go to Step 91.
STEP

88. Measure resistance between harness connector 1804 terminal F and ground with multimeter. Refer to
Figure 26.
0050–27
TM 9-2355-106-23-1 0050

DECISION
YES Go to Step 95.

NO Go to next step.
STEP

0050–28
TM 9-2355-106-23-1 0050

90. Measure resistance between harness connector 1804 terminal F and ground with multimeter. Refer to
Figure 26.
DECISION
NO Go to Step 91.
YES Go to Step 94.
MALFUNCTION
- 91. Steering column wiring harness is faulty.
ACTION
Replace steering column wiring harness. Refer to Steering Column Harness Removal and Installation
END OF TEST
MALFUNCTION
- 92. Power distribution center harness is faulty.
ACTION
Replace power distribution center harness. Refer to Power Distribution Center (PDC) Harness Removal and
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 94. Instrument panel wiring harness is faulty.
ACTION
Replace instrument panel wiring harness. Refer to Instrument Panel Harness Removal and Installation
0050–29
TM 9-2355-106-23-1 0050

END OF TEST
MALFUNCTION
- 95. APS/IVS sensor is faulty.
ACTION
Replace APS/IVS sensor. Refer to APS/IVS Sensor Removal and Installation (WP 0397). Return vehicle
to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0050–30
TM 9-2355-106-23-1 0051
FIELD MAINTENANCE

INITIAL SETUP:
Terminal Test Kit (WP 0795, Item 122) Parking brake set (TM 9-2355-106-10)
TM 9-2355-106-10 Engine shut off (TM 9-2355-106-10)
WP 0319
WP 0336 WP 0789, Figure 1
DIAGNOSTIC TROUBLE CODES AND SYMPTOMS.

• 231
This procedure covers the following symptoms:
• No ATA data communication
• DTCs will not display or MSD will not power up
• Instrument cluster display for speedometer, tachometer, oil pressure, coolant temperature, and battery
voltage does not function
0051–1
TM 9-2355-106-23-1 0051

TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
terminal. Failure to comply may result in damage to connector terminal
NOTE
STEP

3. Measure DC voltage between connector 1650 terminal F and ground with multimeter. Refer to Figure 1.
0051–2
TM 9-2355-106-23-1 0051

Figure 1. Under Left Side of Instrument Panel (IP).
DECISION
YES Go to Step 17.

NO Go to next step.
STEP
Does multimeter read less than 2.5V?
DECISION
YES Go to Step 24.

NO Go to next step.
STEP
5. Measure DC voltage between connector 1650 terminal G and ground with multimeter. Refer to Figure 1.
0051–3
TM 9-2355-106-23-1 0051

DECISION
YES Go to Step 34.

NO Go to next step.
STEP
6. Measure DC voltage between connector 1650 terminal G and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 41.

NO Go to next step.
STEP

9. Measure resistance between connector 1650 terminal G and terminal F with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 66.
0051–4
TM 9-2355-106-23-1 0051

STEP
Figure 3. IP Pass-Through Connector Near Power Distribution Center (PDC) Under Hood.
12. Measure resistance between connector 1701 terminal 40 and 41 with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 65.

NO Go to next step.
0051–5
TM 9-2355-106-23-1 0051

STEP
13. Disconnect connector 4100F (connector with 18 wires). Refer to Figure 4.
Figure 4. Engine/Dash Connector Under Hood.
14. Measure resistance between connector 4100F terminal 10 and 11 with multimeter. Refer to Figure 4.
DECISION
YES Go to Step 64.

NO Go to next step.
0051–6
TM 9-2355-106-23-1 0051

STEP
Figure 5. ECM Connector on Left Side of Engine.
DECISION
YES Go to Step 66.

NO Go to Step 63.
0051–7
TM 9-2355-106-23-1 0051

STEP
19. Measure resistance between connector 1701 terminal 40 and all other connector 1701 terminals with
DECISION
YES Go to Step 65.

NO Go to next step.
0051–8
TM 9-2355-106-23-1 0051

STEP
20. Disconnect connector 4103/4100F (connector with 18 wires). Refer to Figure 7.
Does multimeter read less than 5 ohms for any terminal?
DECISION
YES Go to Step 64.

NO Go to next step.
0051–9
TM 9-2355-106-23-1 0051

STEP
23. Measure resistance between connector 4100F terminal 10 and all other connector 4100F terminals with
0051–10
TM 9-2355-106-23-1 0051

DECISION
YES Go to Step 63.

NO Go to Step 61.
STEP

26. Measure resistance between connector 1650 terminal F and ground with multimeter. Refer to Figure 10.
DECISION
YES Go to Step 47.

NO Go to next step.
0051–11
TM 9-2355-106-23-1 0051

STEP
29. Measure resistance between connector 1701 terminal 40 and connector 1650 terminal F with multimeter.

0051–12
TM 9-2355-106-23-1 0051

DECISION
YES Go to Step 65.

NO Go to next step.
STEP
0051–13
TM 9-2355-106-23-1 0051

DECISION
YES Go to Step 64.

NO Go to next step.
0051–14
TM 9-2355-106-23-1 0051

STEP
33. Measure resistance between connector 6007 terminal 16 and connector 4100F terminal 10 with multimeter.
DECISION
YES Go to Step 63.

NO Go to Step 66.
0051–15
TM 9-2355-106-23-1 0051

STEP
DECISION
YES Go to Step 65.

NO Go to next step.
0051–16
TM 9-2355-106-23-1 0051

STEP
Does multimeter less than 5 ohms for any terminal?
DECISION
YES Go to Step 64.

NO Go to next step.
0051–17
TM 9-2355-106-23-1 0051

STEP
40. Measure resistance between connector 4100F terminal 11 and all other connector 4100F terminals with
DECISION
YES Go to Step 63.

NO Go to Step 62.
0051–18
TM 9-2355-106-23-1 0051

STEP

43. Measure resistance between connector 1650 terminal G and ground with multimeter. Refer to Figure 22.
DECISION
YES Go to Step 54.

NO Go to next step.
0051–19
TM 9-2355-106-23-1 0051

STEP
44. Measure resistance between connector 1650 terminal G and connector 1701 terminal 41 with multimeter.
DECISION
YES Go to Step 65.

NO Go to next step.
STEP
0051–20
TM 9-2355-106-23-1 0051

DECISION
YES Go to Step 64.

NO Go to next step.
0051–21
TM 9-2355-106-23-1 0051

STEP
46. Measure resistance between connector 6007 terminal 17 and connector 4100F terminal 11 with multimeter.
DECISION
YES Go to Step 63.

NO Go to Step 66.
STEP
0051–22
TM 9-2355-106-23-1 0051

49. Measure resistance between connector 1701 terminal 40 and ground with multimeter. Refer to Figure 29.
DECISION
YES Go to Step 65.

NO Go to next step.
0051–23
TM 9-2355-106-23-1 0051

STEP
50. Disconnect connector 4103 (connector with 18 wires). Refer to Figure 30.
DECISION
YES Go to Step 64.

NO Go to next step.
0051–24
TM 9-2355-106-23-1 0051

STEP
DECISION
YES Go to Step 63.

NO Go to Step 66.
0051–25
TM 9-2355-106-23-1 0051

STEP
DECISION
YES Go to Step 65.

NO Go to next step.
0051–26
TM 9-2355-106-23-1 0051

STEP
DECISION
YES Go to Step 64.

NO Go to next step.
0051–27
TM 9-2355-106-23-1 0051

STEP
DECISION
YES Go to Step 63.

NO Go to Step 66.
STEP
DECISION
YES Go to Step 63.

NO Go to Step 66.
STEP
DECISION
YES Go to Step 63.

NO Go to Step 66.
0051–28
TM 9-2355-106-23-1 0051

MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
Replace IP wiring harness. Refer to Instrument Panel (IP) Harness Removal and Installation (WP 0319).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
END OF WORK PACKAGE
0051–29/blank
TM 9-2355-106-23-1 0052
FIELD MAINTENANCE
BAROMETRIC PRESSURE SENSOR (BAP) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
9-2355-106-10)
WP 0398 Instrument Panel Cluster (IPC) removed (WP 0297)
WP 0319
WP 0336 WP 0789, Figure 68
WP 0324
WP 0782

• 151
• 152
WARNING
CAUTION
0052–1
TM 9-2355-106-23-1 0052
BAROMETRIC PRESSURE SENSOR (BAP) TROUBLESHOOTING PROCEDURE - (CONTINUED)
NOTE
STEP
1. Disconnect harness connector 1808 at BAP sensor. Refer to Figure 1.
Figure 1. Barometric Pressure (BAP) Sensor.
DECISION
YES Go to Step 7.
NO Go to next step.
STEP

5. Measure DC voltage between connector 1808 terminal 2 and ground with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 15.
STEP
0052–2
TM 9-2355-106-23-1 0052
DECISION
YES Go to Step 91.

NO Go to Step 53.
STEP
Figure 2. Below Dash.
8. Measure resistance between connector 1800 terminal B4 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 92.
0052–3
TM 9-2355-106-23-1 0052
STEP
9. Disconnect dash pass-through connector 1701. Refer to Figure 3.
Figure 3. Dash Pass-Through.
10. Measure resistance between dash pass-through connector 1701 terminal 2 and ground with multimeter.
Refer to Figure 3.
DECISION
NO Go to Step 93.
0052–4
TM 9-2355-106-23-1 0052
STEP
11. Disconnect 18-wire harness connector 4100F. Refer to Figure 4.
12. Measure resistance between connector 4100F terminal 6 and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 93.
0052–5
TM 9-2355-106-23-1 0052
STEP
Refer to Figure 5.
14. Measure resistance between connector 4100F terminal 6 and connector LAM1019 terminal 11 with multimeter.
DECISION
YES Go to Step 95.

NO Go to Step 96.
STEP

17. Disconnect 18-wire harness connector 4103. Refer to Figure 6.

0052–6
TM 9-2355-106-23-1 0052

DECISION
NO Go to Step 33.
STEP


26. Measure DC voltage between connector 1800 terminal C5 and ground with multimeter. Refer to Figure 7.
0052–7
TM 9-2355-106-23-1 0052
DECISION
NO Go to Step 92.
0052–8
TM 9-2355-106-23-1 0052
STEP


32. Measure DC voltage between dash pass-through connector 1701 terminal 5 and ground with multimeter.
Refer to Figure 8.
DECISION
NO Go to Step 93.
YES Go to Step 94.
0052–9
TM 9-2355-106-23-1 0052
STEP

35. Measure resistance between connector 4103 terminals 4 and 6, and connector 4103 terminal 4 and ground
with multimeter. Refer to Figure 9.
Does multimeter read OL in each test?
DECISION
NO Go to Step 37.
STEP
Figure 9. Engine Connector 4103.
0052–10
TM 9-2355-106-23-1 0052
DECISION
NO Go to Step 41.
YES Go to Step 45.
STEP
38. Measure resistance between connector 1800 terminals C5 and B4, and connector 1800 terminal C5 and
DECISION
YES Go to Step 92.

NO Go to next step.
0052–11
TM 9-2355-106-23-1 0052
STEP
40. Measure resistance between dash pass-through 1701 terminals 5 and 2, and dash pass-through 1701 terminal
5 and ground with multimeter. Refer to Figure 12.
DECISION
YES Go to Step 93.

NO Go to Step 94.
0052–12
TM 9-2355-106-23-1 0052
STEP
42. Measure resistance between connector 4103 terminal 4 and connector 1800 terminal C5 with multimeter.
0052–13
TM 9-2355-106-23-1 0052
DECISION
YES Go to Step 92.

NO Go to next step.
STEP
0052–14
TM 9-2355-106-23-1 0052
44. Measure resistance between dash pass-through connector 1701 terminal 5 and connector 4103 terminal 4
0052–15
TM 9-2355-106-23-1 0052
DECISION
YES Go to Step 93.

NO Go to Step 94.
STEP

48. Measure DC voltage between 18-wire connector 4100F terminal 4 and ground with multimeter. Refer to
Figure 18.
0052–16
TM 9-2355-106-23-1 0052
DECISION
YES Go to Step 95.

NO Go to next step.
STEP

51. Measure resistance between connector 4100F terminals 4 and 6, and connector 4100F terminal 4 and
DECISION
NO Go to Step 95.
STEP
DECISION
NO Go to Step 95.
YES Go to Step 96.
STEP

55. Disconnect 18-wire harness connector 4103. Refer to Figure 20.
0052–17
TM 9-2355-106-23-1 0052

DECISION
NO Go to Step 71.
STEP

0052–18
TM 9-2355-106-23-1 0052
61. Disconnect harness connector 1800. Refer to Figure 21

0052–19
TM 9-2355-106-23-1 0052
DECISION
NO Go to Step 92.
STEP

0052–20
TM 9-2355-106-23-1 0052

70. Measure DC voltage between instrument panel connector 1701 terminal 7 and ground with multimeter.
Refer to Figure 23.
DECISION
NO Go to Step 94.
YES Go to Step 93.
0052–21
TM 9-2355-106-23-1 0052
STEP

73. Measure resistance between connector 4103 terminals 3 and 6, and 4103 terminal 3 and ground with
DECISION
NO Go to Step 75.
0052–22
TM 9-2355-106-23-1 0052
STEP
74. Measure resistance between connector 4103 terminal 3 and connector 1808 terminal 3 with multimeter. Refer
to Figure 24 and Figure 25.
DECISION
NO Go to Step 79.
YES Go to Step 83.
0052–23
TM 9-2355-106-23-1 0052
STEP
76. Measure resistance between connector 1800 terminals C10 and B4, and connector 1800 terminal C10
and ground with multimeter. Refer to Figure 26.
DECISION
YES Go to Step 92.

NO Go to next step.
0052–24
TM 9-2355-106-23-1 0052
STEP
78. Measure resistance between dash pass-through 1701 terminals 7 and 2, and dash pass-through 1701 terminal
7 and ground with multimeter. Refer to Figure 27.
DECISION
YES Go to Step 93.

NO Go to Step 94.
0052–25
TM 9-2355-106-23-1 0052
STEP
80. Measure resistance between connector 4103 terminal 3 and connector 1800 terminal C10 with multimeter.

0052–26
TM 9-2355-106-23-1 0052
DECISION
YES Go to Step 92.

NO Go to next step.
0052–27
TM 9-2355-106-23-1 0052
STEP
82. Measure resistance between dash pass-through connector 1701 terminal 7 and connector 4103 terminal 3
DECISION
YES Go to Step 93.

NO Go to Step 94.
0052–28
TM 9-2355-106-23-1 0052
STEP
Refer to Figure 31.

86. Measure DC voltage between connector 4100F terminal 3 and ground with multimeter. Refer to Figure 32.
DECISION
YES Go to Step 95.

NO Go to next step.
0052–29
TM 9-2355-106-23-1 0052
STEP

89. Measure resistance between connector 4100F terminals 3 and 6, and connector 4100F terminal 3 and
DECISION
NO Go to Step 95.
STEP
DECISION
NO Go to Step 95.
YES Go to Step 96.
MALFUNCTION
- 91. Barometric Pressure (BAP) Sensor is faulty.
ACTION
Replace Barometric Pressure (BAP) Sensor. Refer to Barometric Pressure Sensor Removal and Installation
END OF TEST
MALFUNCTION
ACTION
Replace steering column wiring harness. Refer to Steering Column Wiring Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
0052–30
TM 9-2355-106-23-1 0052
END OF TEST
MALFUNCTION
- 94. Power distribution center harness is faulty.
ACTION
Replace power distribution center harness. Refer to Power Distribution Center (PDC) Harness Removal and
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0052–31/blank
TM 9-2355-106-23-1 0053
FIELD MAINTENANCE
ENGINE CONTROL MODULE (ECM) SELF-DIAGNOSIS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
MAIN POWER switch on (TM 9-2355-106-10)
WP 0011
Ignition switch on (TM 9-2355-106-10)
WP 0329
WP 0782

• 525
• 614
• 621
• 622
• 623
• 624
• 631
• 632
• 655
• 661
• 664
• 665
NOTE
STEP
1. Retrieve DTCs manually or with MSD. Refer to Diagnostic Trouble Code (DTC) Access Procedure (WP 0012).
One or more of the following DTCs are set:
• 525
• 614
• 621
• 622
• 623
• 624
• 631
• 632
• 655
0053–1
TM 9-2355-106-23-1 0053
ENGINE CONTROL MODULE (ECM) SELF-DIAGNOSIS TROUBLESHOOTING PROCEDURE - (CONTINUED)
• 661
• 664
• 665
CORRECTIVE ACTION
to service.
END OF WORK PACKAGE
0053–2
TM 9-2355-106-23-1 0054
FIELD MAINTENANCE
INJECTOR DRIVE CIRCUIT TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0782
Equipment Condition
(WP 0795, Item 37)
Harness, fuel injector test (ZTSE4401)
9-2355-106-10)
(WP 0795, Item 50)
Engine off (TM 9-2355-106-10)
WP 0228
WP 0329 WP 0789, Figure 79

• 421–426
• 431–436
• 451–456
• 513
• 514
• 515
• 521
NOTE
For DTCs 421-426, 431-436, 451-456, the last digit refers to affected cylinder number. For
example, code 421 indicates cylinder 1 has an open circuit between the ECM high side driver
and the low side (signal return) to ECM.

• Engine will not start.
• Engine runs rough.
• Engine warning lamp is ON.
0054–1
TM 9-2355-106-23-1 0054
INJECTOR DRIVE CIRCUIT TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
STEP
Are DTCs 421, 422, 423, 424, 425, or 426 present?
DECISION
YES Go to Step 5.
NO Go to next step.
STEP
2. Refer to results in Step 1.
0054–2
TM 9-2355-106-23-1 0054
DECISION
YES Go to Step 32.

NO Go to next step.
STEP
DECISION
YES Go to Step 18.

NO Go to next step.
STEP
Is trouble code 513 or 514 present?
DECISION
YES Go to Step 44.

NO Go to Step 51.
STEP

0054–3
TM 9-2355-106-23-1 0054
7. Disconnect harness connector LAM1020 at valve cover. Refer to Figure 1.
Figure 1. Left Side of Engine Valve Cover.
8. Connect fuel injector test harness (ZTSE4401) (Figure 2, Item 1) to valve cover side of LAM1020.
Figure 2. Fuel Injector Test Harness (ZTSE4401).
9. Measure resistance between high side and common terminal on test harness with multimeter. To match the
trouble code to the test harness terminal colors, refer to Table 1.
Table 1. Trouble Code and Terminal Identification.

Trouble Code Test Harness High Side Terminal Test Harness Common Terminal
Color Color
421 Black Brown
422 Blue Brown
423 Red Brown
424 Violet Yellow
425 Green Yellow
426 Orange Yellow
0054–4
TM 9-2355-106-23-1 0054
DECISION
YES Go to Step 16.

NO Go to next step.
STEP
10. Remove fuel injector test harness (ZTSE4401) (Figure 2, Item 1) from valve cover side of LAM1020.
11. Remove rocker cover. Refer to Rocker Cover and Gasket Removal and Installation (WP 0228).
12. Disconnect fuel injector harness connectors (Figure 3, Item 2) from fuel injectors (Figure 3, Item 1).
Figure 3. Fuel Injector Disconnected From Harness.
0054–5
TM 9-2355-106-23-1 0054
13. Install fuel injector test harness (ZTSE4401) to fuel injector harness connector (Figure 4, Item 1).
14. Measure resistance between high side terminal on test harness and the injector connector terminal with the
same color wire with multimeter. To match the trouble code to the test harness terminal colors, refer to Table 2.

Trouble Code Test Harness Terminal Color and Injector Connector
Terminal Wire Color
421 Black
422 Blue
423 Red
424 Violet
425 Green
426 Orange
DECISION
NO Go to Step 61.
0054–6
TM 9-2355-106-23-1 0054
STEP
15. Measure resistance between low side terminal on test harness and injector connector terminal with same color
wire with multimeter. To match the trouble code to the test harness terminal color, refer to Table 3.

Trouble Code Test Harness Terminal Color and Injector Connector
Terminal Wire Color
421 Brown
422 Brown
423 Brown
424 Yellow
425 Yellow
426 Yellow
DECISION
YES Go to Step 60.

NO Go to Step 61.
STEP
0054–7
TM 9-2355-106-23-1 0054
17. Measure resistance between sensor harness side injector harness connector terminal and ECM connector
LAM1019 terminal with multimeter. Refer to Figure 7 and Figure 6 To match the trouble code to the terminals,
refer to Table 4.

Trouble Code Injector Harness Connector Terminal ECM Terminal
(Sensor Harness Side)
421 B 43
422 C 21
423 D 41
424 M 46
425 N 25
426 P 44
DECISION
YES Go to Step 62.

NO Go to Step 63.
STEP

0054–8
TM 9-2355-106-23-1 0054
20. Disconnect harness connector LAM1020 at valve cover. Refer to Figure 7.
0054–9
TM 9-2355-106-23-1 0054
22. Measure resistance between injector high side terminal on test harness and ground with multimeter. To match
the trouble code to the terminal, refer to Table 5.

Trouble Code High Side Test Harness Terminal Color
451 Black
452 Blue
453 Red
454 Violet
455 Green
456 Orange
DECISION
NO Go to Step 30.
STEP
25. Inspect fuel injector harness for bare or pinched wires.
Are any wires bare or pinched?
DECISION
YES Go to Step 61.

NO Go to next step.
0054–10
TM 9-2355-106-23-1 0054
STEP
26. Disconnect fuel injector harness connectors (Figure 9, Item 2) from fuel injectors (Figure 9, Item 1).
27. Connect fuel injector test harness (ZTSE4401) to fuel injector harness connector (Figure 10, Item 1).
0054–11
TM 9-2355-106-23-1 0054
28. Measure resistance between injector high side terminal on test harness and ground with multimeter. To match
the trouble code to the terminal color, refer to Table 6.

Trouble Code High Side Test Harness Terminal Color
451 Black
452 Blue
453 Red
454 Violet
455 Green
456 Orange
DECISION
YES Go to Step 61.

NO Go to next step.
STEP
29. Measure resistance between low side test terminal and ground with multimeter. To match the trouble code to
the terminal, refer to Table 7.

Trouble Code Test Harness Color
451 Brown
452 Brown
453 Brown
454 Yellow
455 Yellow
456 Yellow
DECISION
YES Go to Step 61.

NO Go to Step 60.
0054–12
TM 9-2355-106-23-1 0054
STEP
30. Disconnect ECM connector LAM1019. Refer to Engine Control Module (ECM) Removal and Installation
31. Measure resistance between (sensor harness side) connector LAM1020 high side terminals and ground with
multimeter. Refer to Figure 12. To match the trouble code to the terminal, refer to Table 8.

Trouble Code Fuel Injector Connector LAM1020 Terminals (Sensor
Harness Side)
451 B
452 C
453 D
454 M
455 N
456 P
DECISION
YES Go to Step 62.

NO Go to Step 63.
STEP

0054–13
TM 9-2355-106-23-1 0054
34. Disconnect fuel injector harness connector LAM1020 at valve cover. Refer to Figure 12.
36. Measure resistance between high side and common terminal on test harness with multimeter. To match
the trouble code to the terminals, refer to Table 9.

Trouble Code High Side Terminal Color Common Terminal Color
431 Black Brown
432 Blue Brown
433 Red Brown
434 Violet Yellow
435 Green Yellow
436 Orange Yellow
0054–14
TM 9-2355-106-23-1 0054
Does multimeter read between 2.5 and 3.5 ohms?
DECISION
YES Go to Step 42.

NO Go to next step.
STEP
39. Disconnect fuel injector harness connectors. Refer to Figure 14.
40. Connect fuel injector test harness (ZTSE4401) to fuel injector harness connector (Figure 15, Item 1).
0054–15
TM 9-2355-106-23-1 0054
41. Measure resistance between high side and common terminals on test harness with multimeter. To match the
trouble code to the terminal color, refer to Table 10.

Trouble Code High Side Terminal Color Common Terminal Color
431 Black Brown
432 Blue Brown
433 Red Brown
434 Violet Yellow
435 Green Yellow
436 Orange Yellow
DECISION
NO Go to Step 61.
YES Go to Step 60.
0054–16
TM 9-2355-106-23-1 0054
STEP
43. Measure resistance between (sensor harness side) connector LAM1020 high side and low side terminal with
multimeter. Refer to Figure 17. To match the trouble code to the terminals, refer to Table 11.

Trouble Code Connector LAM1020 High Side Connector LAM1020 Low Side
Terminal (Sensor Harness Side) Terminal (Sensor Harness Side)
431 B A
432 C A
433 D A
434 M L
435 N L
436 P L
DECISION
YES Go to Step 62.

NO Go to Step 63.
STEP

0054–17
TM 9-2355-106-23-1 0054
46. Disconnect fuel injector harness connector LAM1020 at valve cover. Refer to Figure 17.
48. Measure resistance between high side and common terminals on test harness with multimeter. To match the
trouble code to the terminal color, refer to Table 12.

Trouble Code High Side Terminal Common Terminal
513 Black Brown
514 Violet Yellow

0054–18
TM 9-2355-106-23-1 0054
DECISION
YES Go to Step 61.

NO Go to next step.
STEP
50. Measure resistance between ECM connector LAM1019 low side terminal and sensor harness side connector
LAM1020 low side terminal with multimeter. Refer to Figure 19 and Figure 20. To match the trouble code to
the terminals, refer to Table 13.

Trouble Code ECM Connector Low Side Terminal Connector LAM1020 Low Side
Terminal (Sensor Harness Side)
513 42 A
514 26 L
DECISION
YES Go to Step 62.

NO Go to Step 63.
STEP

0054–19
TM 9-2355-106-23-1 0054
55. Measure resistance between common terminal on test harness and ground with multimeter. To match the
trouble code to the terminal, refer to Table 14.

Trouble Code ZTSE4401 Test Harness Common Terminal
515 Brown
521 Yellow
0054–20
TM 9-2355-106-23-1 0054
DECISION
YES Go to Step 61.

NO Go to next step.
STEP
57. Measure resistance between sensor harness side connector LAM1020 low side terminal and ground with
multimeter. To match the trouble code to the terminal, refer to Table 15.

Trouble Code Connector LAM1020 Low Side Terminal (Sensor Harness
Side)
515 A
521 L
DECISION
YES Go to Step 62.

NO Go to next step.
STEP
58. Measure resistance between ECM connector LAM1019 terminal 42 and all other LAM1019 terminals with
0054–21
TM 9-2355-106-23-1 0054
DECISION
YES Go to Step 62.

NO Go to next step.
STEP
59. Measure resistance between ECM connector LAM1019 terminal 26 and all other LAM1019 terminals with
DECISION
YES Go to Step 62.

NO Go to Step 63.
MALFUNCTION
- 60. Fuel injector is faulty.
ACTION
Replace fuel injector indicated by DTC. Refer to Fuel Injector Removal and Installation (WP 0249). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 61. Fuel injector wiring harness is faulty.
ACTION
Replace fuel injector wiring harness. Refer to Fuel Injector Wiring Harness Removal and Installation (WP 0336).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 63.ECM is faulty.
ACTION
to service.
0054–22
TM 9-2355-106-23-1 0054
END OF TEST
END OF WORK PACKAGE
0054–23/blank
TM 9-2355-106-23-1 0055
FIELD MAINTENANCE
INTAKE AIR TEMPERATURE (IAT) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Test Equipment TM 9-2355-106-23P
70) WP 0329
WP 0782
Tee, 2-way breakout (ZTSE4483) (WP 0795, Item Transmission set in NEUTRAL (N) (TM
115) 9-2355-106-10)
Terminal Test Kit (ZTSE4435C) (WP 0795, Item Engine off (TM 9-2355-106-10)
122) MAIN POWER switch off (TM 9-2355-106-10)
Personnel Required
Maintainer - (2)
References
TM 9-2355-106-10

• DTC 154
• DTC 155
WARNING
0055–1
TM 9-2355-106-23-1 0055
INTAKE AIR TEMPERATURE (IAT) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP
1. Disconnect harness connector 6703 from IAT sensor. Refer to Figure 1.
Figure 1. Rear of Air Cleaner Housing Assembly.
Figure 1.
DECISION
YES Go to Step 13.

NO Go to next step.
STEP

5. Measure DC voltage between IAT signal circuit terminal A and ground with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 15.
0055–2
TM 9-2355-106-23-1 0055
STEP
7. Install breakout tee (ZTSE4483) in harness connector 6703. Refer to Figure 2.

11. Connect jumper wire from Terminal Test Kit (ZTSE4435C) between breakout tee (ZTSE4483) terminals
SIGNAL and SIGNAL GROUND. Refer to Figure 2.
12. Observe IAT signal voltage in continuous monitoring mode with MSD.
Does IAT signal voltage read 0V?
DECISION
NO Go to Step 20.
YES Go to Step 21.
0055–3
TM 9-2355-106-23-1 0055
STEP
13. Disconnect harness connector 6007. Refer to Engine Control Module (ECM) Removal and Installation
14. Measure resistance between harness connector 6703 terminal B and harness connector 6007 terminal 11
DECISION
NO Go to Step 20.
YES Go to Step 22.
STEP

16. Disconnect harness connector 6007. Refer to Engine Control Module (ECM) Removal and Installation
Figure 4.
0055–4
TM 9-2355-106-23-1 0055
DECISION
NO Go to Step 22.
STEP
18. Measure resistance between harness connector 6703 terminal A and harness connector 6007 terminal 12
DECISION
YES Go to Step 22.

NO Go to next step.
STEP
19. Measure resistance between harness connector 6007 terminal 12 and all other harness connector 6007
terminals. Refer to Figure 3.
DECISION
YES Go to Step 20.

NO Go to Step 22.
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 21. IAT sensor is faulty.
ACTION
Replace IAT sensor. Refer to Air Cleaner Assembly Removal and Installation (WP 0257). Return vehicle
to service.
END OF TEST
MALFUNCTION
0055–5
TM 9-2355-106-23-1 0055
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0055–6
TM 9-2355-106-23-1 0056
FIELD MAINTENANCE
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0390
WP 0782
Tee, 3-wire pressure sensor breakout (ZTSE4347) Transmission set in NEUTRAL (N) (TM
(WP 0795, Item 116) 9-2355-106-10)
Harness, 500 ohm resistor (ZTSE4497) Engine off (TM 9-2355-106-10)
(WP 0795, Item 48) MAIN POWER switch off (TM 9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P Drawings Required
WP 0011 WP 0789, Figure 79

• 121
• 122
• 123
WARNING
CAUTION
0056–1
TM 9-2355-106-23-1 0056
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
NOTE
STEP
Figure 1. Top of Engine Valve Cover, Front of Engine.
2. Measure resistance between harness connector LAM1014 terminal A and ground with multimeter. Refer
to Figure 1.
DECISION
NO Go to Step 11.
STEP

0056–2
TM 9-2355-106-23-1 0056
to Figure 2.
DECISION
NO Go to Step 13.
STEP
7. Observe MAP signal voltage in continuous monitoring mode with MSD.
Does MAP signal voltage read 0V?
DECISION
NO Go to Step 24.
0056–3
TM 9-2355-106-23-1 0056
STEP
8. Connect 3-wire breakout harness to MAP sensor harness connector LAM1014. Refer to Figure 3.
0056–4
TM 9-2355-106-23-1 0056
9. Connect 500 ohm jumper wire (ZTSE4497) between 3-wire breakout harness (ZTSE4347) terminals VREF
(+5) and SIG CIRC. Refer to Figure 4.
Figure 4. 500 Ohm Jumper Wire (ZTSE4497) Connected to 3-Wire Breakout Harness (ZTSE4347).
10. Observe MAP signal voltage in continuous monitoring mode with MSD.
Does MAP signal voltage read between 4.5V and 5.5V?
DECISION
NO Go to Step 33.
YES Go to Step 41.
0056–5
TM 9-2355-106-23-1 0056
STEP
12. Measure resistance between harness connector LAM1014 terminal A and harness connector LAM1019
DECISION
YES Go to Step 42.

NO Go to Step 40.
STEP

0056–6
TM 9-2355-106-23-1 0056

to Figure 8.
DECISION
YES Go to Step 40.

NO Go to next step.
STEP

to Figure 8.
0056–7
TM 9-2355-106-23-1 0056
DECISION
NO Go to Step 40.
STEP
22. Measure resistance between harness connector LAM1014 terminals B and A with multimeter. Refer to
Figure 8.
DECISION
NO Go to Step 40.
STEP
23. Measure resistance between harness connector LAM1014 terminal B and harness connector LAM1019
DECISION
YES Go to Step 42.

NO Go to Step 40.
STEP

29. Measure DC voltage between harness connector LAM1014 terminal C and ground with multimeter. Refer
to Figure 8.
DECISION
YES Go to Step 40.

NO Go to next step.
STEP

0056–8
TM 9-2355-106-23-1 0056

32. Measure resistance between harness connector LAM1014 terminals B and C with multimeter. Refer to
Figure 10.
DECISION
NO Go to Step 40.
YES Go to Step 42.
STEP

35. Disconnect 500 ohm jumper wire (ZTSE4497) and 3-wire breakout harness (ZTSE4347) from harness
connector LAM1014.
36. Measure resistance between harness connector LAM1014 terminal C and ground with multimeter. Refer to
Figure 10.
DECISION
NO Go to Step 40.
STEP
38. Measure resistance between harness connector LAM1014 terminals C and A with multimeter. Refer to
Figure 10 Refer to Figure 9.
0056–9
TM 9-2355-106-23-1 0056
DECISION
NO Go to Step 40.
STEP
39. Measure resistance between harness connector LAM1014 terminal C and harness connector LAM1019
DECISION
YES Go to Step 42.

NO Go to Step 40.
MALFUNCTION
ACTION
Replace ECM engine harness. Refer to Engine Sensor Wiring Harness Removal and Installation (WP 0330).
END OF TEST
MALFUNCTION
- 41. MAP sensor is faulty.
ACTION
Replace MAP sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Removal and Installation (WP 0390).
END OF TEST
MALFUNCTION

0056–10
TM 9-2355-106-23-1 0056
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0056–11/blank
TM 9-2355-106-23-1 0057
FIELD MAINTENANCE
SPEED CONTROL COMMAND SWITCHES (SCCS) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Equipment Condition
TM 9-2355-106-23P 9-2355-106-10)
WP 0565 Engine off (TM 9-2355-106-10)
WP 0353
WP 0324 WP 0789, Figure 69

• 221
WARNING
CAUTION
NOTE
0057–1
TM 9-2355-106-23-1 0057
SPEED CONTROL COMMAND SWITCHES (SCCS) TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Disconnect Electronic System Controller (ESC) connector 1600. Refer to Figure 1.
Figure 1. Driver Floor Area.
Does multimeter read more than 100,000 ohms?
DECISION
NO Go to Step 11.
0057–2
TM 9-2355-106-23-1 0057
STEP
3. Press and hold CRUISE/THROTTLE ON/OFF switch ON. Refer to Figure 2.
Figure 2. Speed Control Command Switches on Steering Wheel.
4. Measure resistance between connector 1600 terminals 3 and 10 with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 24.
STEP
5. Press and hold CRUISE/THROTTLE ON/OFF switch OFF. Refer to Figure 2.

DECISION
YES Go to Step 38.

NO Go to next step.
0057–3
TM 9-2355-106-23-1 0057
STEP
7. Press and hold cruise control SET/CRUISE switch. Refer to Figure 3.
Figure 3. Speed Control Command Switches on Steering Wheel.
DECISION
NO Go to Step 48.
STEP
9. Press and hold cruise control RESUME/ACCEL switch. Refer to Figure 3.

0057–4
TM 9-2355-106-23-1 0057
DECISION
NO Go to Step 62.
YES Go to Step 76.
STEP
12. Measure resistance between connector 1805 terminals A4 and B12 with multimeter. Refer to Figure 5.
DECISION
YES Go to Step 77.

NO Go to next step.
0057–5
TM 9-2355-106-23-1 0057
STEP
13. Remove steering column covers. Refer to Steering Column Covers Removal and Installation (WP 0565).
Figure 6. Steering Wheel Clock Spring Connection.
15. Measure resistance between connector 1809 terminals A and B with multimeter. Refer to Figure 6.
DECISION
YES Go to Step 78.

NO Go to next step.
STEP
16. Remove horn pad. Refer to Horn Button Assembly Removal and Installation (WP 0403).
Figure 7. Inside Steering Wheel.
18. Measure resistance between harness connector LAM1179 terminals A and B with multimeter. Refer to
Figure 7.
0057–6
TM 9-2355-106-23-1 0057
DECISION
YES Go to Step 79.

NO Go to next step.
STEP
19. Remove SET/RESUME switch. Refer to Cruise Control Switch Module Removal and Installation (WP 0316).
20. Measure resistance between SET/RESUME switch terminals 1 and 2 with multimeter. Refer to Figure 8.
Figure 8. Cruise Control Switch Terminals.
DECISION
NO Go to Step 80.
STEP
21. Remove CRUISE/THROTTLE ON/OFF switch. Refer to Cruise Control Switch Module Removal and
22. Measure resistance between CRUISE/THROTTLE ON/OFF switch terminals 2 and 5 with multimeter. Refer
to Figure 9.
0057–7
TM 9-2355-106-23-1 0057
DECISION
NO Go to Step 80.
STEP
23. Measure resistance between connector LAM1179 terminals A and B with multimeter. Refer to Figure 10.
DECISION
NO Go to Step 77.
NO Go to Step 76.
0057–8
TM 9-2355-106-23-1 0057
STEP
25. Press and hold CRUISE/THROTTLE ON/OFF switch ON.

DECISION
YES Go to Step 77.

NO Go to next step.
0057–9
TM 9-2355-106-23-1 0057
STEP
Figure 12. Steering Wheel Area.

30. Measure resistance between connector 1809 terminal A and B with multimeter. Refer to Figure 12.
DECISION
YES Go to Step 78.

NO Go to next step.
STEP
32. Disconnect clock spring upper connector and steering wheel harness LAM1179. Refer to Figure 13.

34. Measure resistance between connector LAM1179 terminals A and B. Refer to Figure 13.
0057–10
TM 9-2355-106-23-1 0057
DECISION
YES Go to Step 79.

NO Go to next step.
STEP
37. Measure resistance between CRUISE/THROTTLE ON/OFF switch terminals 2 and 5 with multimeter. Refer to
Figure 14.
DECISION
NO Go to Step 80.
YES Go to Step 81.
0057–11
TM 9-2355-106-23-1 0057
STEP
39. Press and hold CRUISE/THROTTLE ON/OFF switch OFF.

DECISION
YES Go to Step 77.

NO Go to next step.
STEP
0057–12
TM 9-2355-106-23-1 0057

DECISION
YES Go to Step 78.

NO Go to next step.
STEP
47. Measure resistance between CRUISE/THROTTLE ON/OFF switch terminals 2 and 5 with multimeter. Refer to
Figure 17.
0057–13
TM 9-2355-106-23-1 0057
DECISION
NO Go to Step 80.
YES Go to Step 81.
STEP
49. Press and hold SET/CRUISE switch.

DECISION
YES Go to Step 77.

NO Go to next step.
STEP
0057–14
TM 9-2355-106-23-1 0057

DECISION
YES Go to Step 78.

NO Go to next step.
STEP

0057–15
TM 9-2355-106-23-1 0057
DECISION
YES Go to Step 79.

NO Go to next step.
STEP
DECISION
NO Go to Step 80.
YES Go toStep 81.
STEP
0057–16
TM 9-2355-106-23-1 0057
63. Press and hold RESUME/ACCEL switch.

DECISION
YES Go to Step 77.

NO Go to next step.
STEP
0057–17
TM 9-2355-106-23-1 0057

DECISION
YES Go to Step 78.

NO Go to next step.
STEP

0057–18
TM 9-2355-106-23-1 0057
DECISION
YES Go to Step 79.

NO Go to next step.
STEP
DECISION
NO Go to Step 80.
YES Go to Step 81.
MALFUNCTION
- 76. ESC is faulty.
ACTION
Replace ESC. Refer to Electronic System Controller (ESC) Removal and Installation (WP 0353). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 77. Instrument panel harness is faulty.
ACTION
Replace instrument panel harness. Refer to Instrument Panel Harness Removal and Installation (WP 0319).
END OF TEST
MALFUNCTION
- 78. Steering column harness is faulty.
0057–19
TM 9-2355-106-23-1 0057
ACTION
Replace steering column harness. Refer to Steering Column Wiring Harness Removal and Installation
END OF TEST
MALFUNCTION
- 79. Clock spring harness is faulty.
ACTION
Replace steering wheel. Refer to Steering Wheel and Clock Spring Removal and Installation (WP 0534).
END OF TEST
MALFUNCTION
- 80. Switch is faulty.
ACTION
Replace switch. Refer to Cruise Control Switch Module Removal and Installation (WP 0316). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 81. Steering wheel harness is faulty.
ACTION
Replace steering wheel harness. Refer to Steering Wheel Wire Harness Removal and Installation (WP 0325).
END OF TEST
END OF WORK PACKAGE
0057–20
TM 9-2355-106-23-1 0058
FIELD MAINTENANCE
VEHICLE SPEED SENSOR (VSS) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine shut off (TM 9-2355-106-10)
WP 0395

• 141
• 142
• 215
Speedometer is inoperative.
STEP
WARNING
0058–1
TM 9-2355-106-23-1 0058
VEHICLE SPEED SENSOR (VSS) TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
1. Disconnect VSS connector 9755. Refer to Figure 1.
Figure 1. VSS Connector and Sensor Location.
0058–2
TM 9-2355-106-23-1 0058
2. Measure resistance between VSS sensor terminals A and B with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 58.
STEP
3. Measure resistance between VSS sensor terminal A and ground with multimeter. Refer to Figure 1.
DECISION
NO Go to Step 58.
STEP
4. Measure resistance between VSS sensor terminal B and ground with multimeter. Refer to Figure 2.
Figure 2. VSS Connector
DECISION
NO Go to Step 58.
0058–3
TM 9-2355-106-23-1 0058
STEP

7. Measure DC voltage between connector 9755 terminal A and ground with multimeter. Refer to Figure 3.
Figure 3. VSS Terminals.
DECISION
YES Go to Step 15.

NO Go to next step.
STEP
DECISION
YES Go to Step 21.

NO Go to next step.
STEP
9. Measure DC voltage between connector 9755 terminal B and ground with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 28.

NO Go to next step.
STEP
0058–4
TM 9-2355-106-23-1 0058
DECISION
YES Go to Step 35.

NO Go to next step.
STEP

DECISION
YES Go to Step 43.

NO Go to next step.
STEP
14. Remove vehicle speed sensor from transfer case and inspect surface facing tone wheel for damage. Refer to
Vehicle Speed Sensor Removal and Installation (WP 0395).
Is the speed sensor surface damaged?
DECISION
YES Go to Step 62.

NO Go to Step 61.
STEP
15. Remove belly armor. Refer to Belly Armor Removal and Installation (WP 0606).
0058–5
TM 9-2355-106-23-1 0058
Figure 4. VSS Harness Connector Above Transmission.
16. Disconnect VSS harness connector 9750/7611. Refer to Figure 4.

DECISION
NO Go to Step 60.
STEP
18. Perform engine shut down procedure (TM 9-2355-106-10).
Figure 5. ECM Connector 6007.
19. Disconnect ECM connector 6007. Refer to Engine Control Module (ECM) Removal and Installation (WP 0329).
20. Measure resistance between connector 6007 terminal 39 and remaining terminals with multimeter. Refer
to Figure 5.
0058–6
TM 9-2355-106-23-1 0058
DECISION
YES Go to Step 59.

NO Go to Step 61.
STEP
21. Perform engine shut down procedure (TM-9-2355-106-10).
22. Measure resistance between connector 9755 terminal A and ground with multimeter. Refer to Figure 6.
DECISION
YES Go to Step 48.

NO Go to next step.
0058–7
TM 9-2355-106-23-1 0058
STEP
Figure 8. VSS Terminals

25. Measure resistance between connector 9750 terminal A and connector 9755 terminal A with multimeter.
DECISION
YES Go to Step 60.

NO Go to next step.
0058–8
TM 9-2355-106-23-1 0058
STEP
27. Measure resistance between connector 6007 terminal 39 and connector 7611 terminal A with multimeter.
DECISION
YES Go to Step 61.

NO Go to Step 59.
0058–9
TM 9-2355-106-23-1 0058
STEP

DECISION
NO Go to Step 60.
0058–10
TM 9-2355-106-23-1 0058
STEP

34. Measure resistance between connector 6007 terminal 40 and remaining terminals with multimeter. Refer to
Figure 12.
DECISION
YES Go to Step 59.

NO Go to Step 61.
STEP
35. Turn ignition switch OFF (TM-9-2355-106-10).

36. Turn MAIN POWER switch OFF (TM-9-2355-106-10).
37. Measure resistance between connector 9755 terminal B and ground with multimeter. Refer to Figure 13.
0058–11
TM 9-2355-106-23-1 0058
DECISION
YES Go to Step 53.

NO Go to next step.
STEP

40. Measure resistance between connector 9755 terminal B and connector 9750 terminal B with multimeter. Refer
DECISION
YES Go to Step 60.

NO Go to next step.
0058–12
TM 9-2355-106-23-1 0058
STEP
42. Measure resistance between connector 6007 terminal 40 and connector 7611 terminal B with multimeter.
DECISION
YES Go to Step 61.

NO Go to Step 59.
0058–13
TM 9-2355-106-23-1 0058
STEP
DECISION
NO Go to Step 60.
0058–14
TM 9-2355-106-23-1 0058
STEP
Figure 18. ECM Terminals.
DECISION
YES Go to Step 59.

NO Go to Step 61.
0058–15
TM 9-2355-106-23-1 0058
STEP
DECISION
YES Go to Step 60.

NO Go to next step.
0058–16
TM 9-2355-106-23-1 0058
STEP
DECISION
YES Go to Step 59.

NO Go to Step 61.
0058–17
TM 9-2355-106-23-1 0058
STEP
DECISION
YES Go to Step 60.

NO Go to next step.
0058–18
TM 9-2355-106-23-1 0058
STEP
DECISION
YES Go to Step 59.

NO Go to Step 61.
MALFUNCTION
- 58. VSS is faulty.
ACTION
Replace VSS. Refer to Vehicle Speed Sensor Removal and Installation (WP 0395). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
0058–19
TM 9-2355-106-23-1 0058
MALFUNCTION
- 60. Transfer case wiring from sensor to engine wiring harness is faulty.
ACTION
Replace center chassis wiring harness. Refer Center Chassis Harness Removal and Installation (WP 0426).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 62. Transfer case is faulty.
ACTION
Replace transfer case and vehicle speed sensor. Refer to Transfer Case Assembly Removal and Installation
(WP 0460) and Vehicle Speed Sensor Removal and Installation (WP 0395). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0058–20
TM 9-2355-106-23-1 0059
FIELD MAINTENANCE
POWER DISTRIBUTION TROUBLESHOOTING PROCEDURE
INITIAL SETUP:

WP 0061 9-2355-106-10)
WP 0065
WP 0782
NOTE
SYMPTOM
Power not available at Instrument Panel Distribution Center fuse block.
MALFUNCTION
No power at one or more sockets in fuse block 1011.
CORRECTIVE ACTION
Go to Cabin Fuse Block 1011 Troubleshooting Procedure (WP 0061).

MALFUNCTION
CORRECTIVE ACTION

MALFUNCTION
CORRECTIVE ACTION

MALFUNCTION
CORRECTIVE ACTION
SYMPTOM
Power not available at Power Distribution Center (PDC).
MALFUNCTION
CORRECTIVE ACTION
0059–1
TM 9-2355-106-23-1 0059
POWER DISTRIBUTION TROUBLESHOOTING PROCEDURE - (CONTINUED)
Go to Power Distribution Center (PDC) Mini Fuse Block 4001 Troubleshooting Procedure
(WP 0065).
END OF WORK PACKAGE
0059–2
TM 9-2355-106-23-1 0060
FIELD MAINTENANCE
12V AND 24V BATTERY SWITCHES TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0411
WP 0353
Materials/Parts
WP 0782
Goggles, industrial (WP 0794, Item 20)
Face shield, industrial (WP 0794, Item 16) Equipment Condition
References
TM 9-2355-106-10
9-2355-106-10)
TM 9-2355-106-23P
WP 0443
WP 0348
WP 0437
WP 0341
Exterior battery box armor door removed
WP 0407
(WP 0604)
WP 0346
WP 0319 WP 0789,
WP 0296 WP 0789, Figure 16
0060–1
TM 9-2355-106-23-1 0060
12V AND 24V BATTERY SWITCHES TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
NOTE
0060–2
TM 9-2355-106-23-1 0060
STEP

3. Measure DC voltage between connector LAM1163 12V terminal (Figure 1, Item 1) and ground with multimeter.
Figure 1. Front Battery Equalizer.
DECISION
NO Go to Step 18.
0060–3
TM 9-2355-106-23-1 0060
STEP
DECISION
NO Go to Step 28.
0060–4
TM 9-2355-106-23-1 0060
STEP
5. Measure DC voltage between 12V megafuse (Figure 3, Item 1) terminal (battery side) and ground with
multimeter.
Figure 3. Left Engine, Above Power Distribution Center (PDC).
DECISION
NO Go to Step 31.
0060–5
TM 9-2355-106-23-1 0060
STEP
Figure 4. Below Center Instrument Panel (IP).

8. Disconnect 24V Power Distribution Module (PDM) connector P4. Refer to Figure 4.
11. Measure DC voltage between ground and PDM connector P4 terminals A and B with multimeter. Refer
to Figure 4.
Does multimeter read between 22.5V and 25.5V at each terminal?
DECISION
YES Go to Step 37.

NO Go to next step.
0060–6
TM 9-2355-106-23-1 0060
STEP

14. Disconnect 24V body feed harness connector LAM1044. Refer to Figure 5.
Figure 5. 24V Body Feed, Right Side Dash Pass-Through.

17. Measure DC voltage between ground and connector LAM1044 terminals A and B with multimeter. Refer
to Figure 5.
DECISION
NO Go to Step 38.
YES Go to Step 39.
0060–7
TM 9-2355-106-23-1 0060
STEP
DECISION
YES Go to Step 40.

NO Go to next step.
STEP
19. Measure DC voltage between connector LAM1152 terminal (Figure 7, Item 1) and ground with multimeter.
Figure 7. Connector LAM1152 and LAM1187.
DECISION
YES Go to Step 21.

NO Go to next step.
0060–8
TM 9-2355-106-23-1 0060
STEP
DECISION
NO Go to Step 42.
YES Go to Step 43.
STEP

Figure 8. Below IP, Right of Steering Column.
24. Measure resistance between connector 1150 terminal B and ground with multimeter.
0060–9
TM 9-2355-106-23-1 0060
DECISION
NO Go to Step 45.
STEP
DECISION
YES Go to Step 46.

NO Go to next step.
STEP
26. Disconnect dash pass-through harness connector 1701. Refer to Figure 10.

0060–10
TM 9-2355-106-23-1 0060
DECISION
YES Go to Step 45.

NO Go to Step 47.
0060–11
TM 9-2355-106-23-1 0060
STEP
Figure 11. Connector LAM1189 and 1153.
DECISION
NO Go to Step 41.
STEP
DECISION
NO Go to Step 43.
0060–12
TM 9-2355-106-23-1 0060
STEP
DECISION
NO Go to Step 48.
YES Go to Step 44.
0060–13
TM 9-2355-106-23-1 0060
STEP
NOTE
Three heavy gauge wires connect to the battery side of the 12V megafuse. The wire marked
M14Z supplies battery power from the 12V MAIN POWER switch to the megafuse. The wire
marked J14H supplies power to fuse block 4001 in the Power Distribution Center (PDC). The
wire that supplies power to the Electronic System Controller (ESC) does not have a circuit label.

33. Disconnect the B+ supply harnesses from the 12V megafuse (Figure 13, Item 1) terminal.
Figure 13. Left Engine, Above Power Distribution Center (PDC).
34. Measure the resistance between B+ supply harness M14Z and ground with multimeter. Refer to Figure 13.
DECISION
NO Go to Step 49.
STEP
36. Measure resistance between ESC B+ terminal and ground with multimeter. Refer to Figure 13.
0060–14
TM 9-2355-106-23-1 0060
DECISION
YES Go to Step 51.

NO Go to Step 50.
MALFUNCTION
- 37. 24V Power Distribution Module (PDM) is faulty.
ACTION
Replace 24V PDM. Refer to 24V Power Distribution Module (PDM) Center Removal and Installation (WP 0443).
END OF TEST
MALFUNCTION
- 38. 24V body feed harness is faulty.
ACTION
Replace 24V body feed harness. Refer to 24V Body Feed Harness Removal and Installation (WP 0348).
END OF TEST
MALFUNCTION
- 39. 24V PDM feed harness is faulty.
ACTION
Replace PDC feed harness. Refer to 24V Power Distribution Module (PDM) Feed Harness and Ground Cable
Removal and Installation (WP 0437). Return vehicle to service.
END OF TEST
MALFUNCTION
- 40. 12V MAIN POWER switch is faulty.
ACTION
Replace 12V MAIN POWER switch. Refer to 12V and 24V MAIN POWER Switch Removal and Installation
END OF TEST
MALFUNCTION
- 41. Battery cable to 24V MAIN POWER switch is faulty.
ACTION
Replace battery cable. Refer to Battery Cables Removal and Installation (WP 0407). Return vehicle to service.
0060–15
TM 9-2355-106-23-1 0060
END OF TEST
MALFUNCTION
- 42. Battery cable to 12V MAIN POWER switch is faulty.
ACTION
Replace battery cable. Refer to Battery Cables Removal and Installation (WP 0407). Return vehicle to service.
END OF TEST
MALFUNCTION
- 43. 12V to 24V MAIN POWER switch solenoid feed harness is faulty.
ACTION
Replace V12 to 24V MAIN POWER switch solenoid feed harness. Refer to 12V to 24V Disconnect Battery
Switch Solenoid Feed Harness Removal and Installation (WP 0346). Return vehicle to service.
END OF TEST
MALFUNCTION
- 44. 12V to 24V MAIN POWER switch solenoid ground harness is faulty.
ACTION
Replace V12 to 24V disconnect battery switch solenoid ground harness. Refer to 12V to 24V Disconnect Battery
Switch Solenoid Ground Harness Removal and Installation (WP 0347). Return vehicle to service.
END OF TEST
MALFUNCTION
- 45. IP harness is faulty.
ACTION
Replace IP harness. Refer to Instrument Panel Harness Removal and Installation (WP 0319). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 46. MAIN POWER switch is faulty.
ACTION
Replace MAIN POWER switch. Refer to MAIN POWER Switch Removal and Installation (WP 0296). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 47. Master disconnect harness is faulty.

0060–16
TM 9-2355-106-23-1 0060
ACTION
Replace master disconnect harness. Refer to Master Disconnect Harness Removal and Installation (WP 0351).
END OF TEST
MALFUNCTION
- 48. 24V MAIN POWER switch is faulty.
ACTION
Replace 24V MAIN POWER switch. Refer to 12V and 24V MAIN POWER Switch Removal and Installation
END OF TEST
MALFUNCTION
- 49. IP feed harness is faulty.
ACTION
Replace IP feed harness. Refer to Instrument Panel (IP) Feed Harness Removal and Installation (WP 0411).
END OF TEST
0060–17
TM 9-2355-106-23-1 0060
MALFUNCTION
- 50. PDC and IP feed harnesses are faulty.
ACTION
Replace PDC and IP feed harnesses. Refer to Power Distribution Center (PDC) Harness Removal and
Installation (WP 0335) and Instrument Panel (IP) Feed Harness Removal and Installation (WP 0411). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 51. ESC and IP feed harness are faulty.
ACTION
Replace ESC and IP Feed harness. Refer to Electronic System Controller (ESC) Removal and Installation
(WP 0353) and Instrument Panel (IP) Feed Harness Removal and Installation (WP 0411). Return vehicle
to service.
END OF TEST
END OF WORK PACKAGE
0060–18
TM 9-2355-106-23-1 0061
FIELD MAINTENANCE
CABIN FUSE BLOCK 1011 TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0060
Instrument panel (IP) right side closeout removed
WP 0302
(WP 0580)
WP 0317
WP 0782 WP 0789, Figure 10
WARNING
0061–1
TM 9-2355-106-23-1 0061
CABIN FUSE BLOCK 1011 TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
This procedure assumes that cabin fuse block 1011 lacks voltage at a buss bar with MAIN
POWER and ignition switches ON.
STEP
1. Remove fuse F5 from cabin fuse block 1011. Refer to Figure 1. Refer to Instrument Panel (IP) Circuit Breaker,
Fuse, and Relay Removal and Installation (WP 0317).
Figure 1. Cabin Fuse Block 1011, Right Side of Instrument Panel (IP).

4. Measure DC voltage between fuse F5 socket terminal E1 and ground with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 47.

NO Go to next step.
0061–2
TM 9-2355-106-23-1 0061
STEP

7. Remove ACC RELAY from cabin fuse block 1012. Refer to Figure 2. Refer to Instrument Panel (IP) Circuit
Breaker, Fuse, and Relay Removal and Installation (WP 0317).
Figure 2. Cabin Fuse Block 1012, Right Side of IP.
8. Measure resistance between ACC RELAY socket terminal 87A and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 47.
STEP
9. Measure resistance between ACC RELAY socket terminal 85 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 47.
0061–3
TM 9-2355-106-23-1 0061
STEP
10. Measure resistance between ACC RELAY terminal 30 and fuse F5 socket terminal E1 with multimeter.
Figure 3. ACC RELAY Socket.
Figure 4. Fuse F5 Socket.
DECISION
NO Go to Step 47.
0061–4
TM 9-2355-106-23-1 0061
STEP

13. Measure DC voltage between ACC RELAY socket terminal 86 and ground with multimeter. Refer to Figure 3.
DECISION
NO Go to Step 15.
STEP
DECISION
NO Go to Step 42.
YES Go to Step 44.
STEP

0061–5
TM 9-2355-106-23-1 0061
17. Disconnect keyless ignition switch connector 1100M. Refer to Figure 5.
Figure 5. Behind Lower Instrument Cluster.

0061–6
TM 9-2355-106-23-1 0061
DECISION
NO Go to Step 24.
STEP

21. Connect jumper wire between connector 1100M terminals A and C. Refer to .
Figure 6. ACC RELAY Socket.
DECISION
NO Go to Step 47.
YES Go to Step 48.
0061–7
TM 9-2355-106-23-1 0061
STEP

25. Remove and inspect fuse F6. Refer to Figure 7. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and
Relay Removal and Installation (WP 0317).
Is fuse open?
DECISION
YES Go to Step 28.

NO Go to next step.
STEP

27. Measure DC voltage between ground and fuse F6 socket terminals F2 and E2 with multimeter. Refer
to Figure 7.
DECISION
YES Go to Step 47.

NO Go to Step 42.
0061–8
TM 9-2355-106-23-1 0061
STEP
DECISION
NO Go to Step 33.
0061–9
TM 9-2355-106-23-1 0061
STEP
29. Install ACC RELAY in cabin fuse block 1012. Refer to Figure 9. Refer to Instrument Panel (IP) Circuit Breaker,
30. Measure resistance between connector 1100M terminal C and ground with multimeter. Refer to Figure 10.
DECISION
NO Go to Step 38.
STEP
31. Measure resistance between connector 1100M terminal D and ground with multimeter. Refer to Figure 10.
0061–10
TM 9-2355-106-23-1 0061
DECISION
NO Go to Step 40.
STEP
32. Measure resistance between keyless ignition switch terminal BAT and ground with multimeter. Refer to
Figure 11.
Figure 11. Keyless Ignition Switch.
DECISION
YES Go to Step 47.

NO Go to Step 48.
STEP
33. Remove left side engine armor plate. Refer to Left Side Engine Armor Plate Removal and Installation
(WP 0597).
34. Remove STARTER relay from underhood PDC. Refer to Figure 12. Refer to Power Distribution Center (PDC)
0061–11
TM 9-2355-106-23-1 0061
DECISION
YES Go to Step 45.

NO Go to next step.
0061–12
TM 9-2355-106-23-1 0061
STEP
Figure 14. Left Side Engine Compartment Above PDC.
DECISION
NO Go to Step 50.
YES Go to Step 47.
0061–13
TM 9-2355-106-23-1 0061
STEP
DECISION
NO Go to Step 47.
YES Go to Step 44.
0061–14
TM 9-2355-106-23-1 0061
STEP
40. Remove IGN RELAY from cabin fuse block 1012. Refer to Figure 17. Refer to Instrument Panel (IP) Circuit
DECISION
YES Go to Step 46.

NO Go to Step 47.
0061–15
TM 9-2355-106-23-1 0061
STEP
42. Measure DC voltage between ground and each terminal in 12V 100-amp megafuse (Figure 18, Item 1).
Figure 18. 12V 100-Amp Megafuse.
DECISION
YES Go to Step 47.

NO Go to next step.
STEP
43. Refer to results of Step 42.
DECISION
NO Go to Step 49.
YES Go to Step 51.
0061–16
TM 9-2355-106-23-1 0061
MALFUNCTION
- 44. ACC RELAY is faulty.
ACTION
Replace ACC RELAY. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
(WP 0317).
END OF TEST
MALFUNCTION
- 45. STARTER relay is faulty.
ACTION
Replace STARTER relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
END OF TEST
MALFUNCTION
- 46. IGN RELAY is faulty.
ACTION
Replace IGN RELAY. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
END OF TEST
MALFUNCTION
ACTION
Replace IP harness. Refer to Instrument Panel (IP) Harness Removal and Installation (WP 0319).
END OF TEST
0061–17
TM 9-2355-106-23-1 0061
MALFUNCTION
- 48. Keyless ignition switch is faulty.
ACTION
Replace keyless ignition switch. Refer to Keyless Ignition Switch Removal and Installation (WP 0302).
END OF TEST
MALFUNCTION
- 49. MAIN POWER switches system is faulty.
ACTION
Diagnose MAIN POWER switches system fault. Refer to 12V and 24V Battery Switches Troubleshooting
END OF TEST
MALFUNCTION
- 50. PDC or harness is faulty.
ACTION
Replace PDC. Refer to Power Distribution Center (PDC) Harness Removal and Installation (WP 0335).
END OF TEST
MALFUNCTION
ACTION
Replace IP harness and 12V 100-amp megafuse. Refer to Instrument Panel (IP) Harness Removal and
Installation (WP 0319). Refer to 12V Underhood Megafuse and Holder Removal and Installation (WP 0422).
END OF TEST
END OF WORK PACKAGE
0061–18
TM 9-2355-106-23-1 0062
FIELD MAINTENANCE
INITIAL SETUP:
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0060
Instrument panel (IP) right side closeout removed
WP 0302
(WP 0580)
WP 0317
WP 0782 WP 0789, Figure 10
WARNING
0062–1
TM 9-2355-106-23-1 0062
CAUTION
NOTE
STEP
1. Remove fuse F20 from cabin fuse block 1012. Refer to Figure 1. Refer to Instrument Panel (IP) Circuit

4. Measure DC voltage between fuse F20 socket terminal E2 and ground. Refer to Figure 1.
DECISION
YES Go to Step 44.

NO Go to next step.
0062–2
TM 9-2355-106-23-1 0062
STEP

8. Measure resistance between IGN RELAY socket terminal 85 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 44.
STEP

11. Measure DC voltage between IGN RELAY socket terminal 86 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 14.
0062–3
TM 9-2355-106-23-1 0062
STEP
Figure 3. IGN RELAY Socket.
DECISION
NO Go to Step 42.
STEP
13. Measure DC voltage between IGN RELAY socket terminals 87 and 30 with multimeter. Refer to Figure 3.
DECISION
NO Go to Step 44.
YES Go to Step 45.
0062–4
TM 9-2355-106-23-1 0062
STEP

16. Disconnect ignition switch connector 1100M. Refer to Figure 4.
Figure 4. Below IP Cluster, Right Side.

DECISION
NO Go to Step 23.
0062–5
TM 9-2355-106-23-1 0062
STEP

20. Connect jumper wire between connector 1100M terminals A and D. Refer to Figure 5.

Figure 6. IGN RELAY Socket.
DECISION
NO Go to Step 44.
YES Go to Step 46.
0062–6
TM 9-2355-106-23-1 0062
STEP

24. Remove and inspect fuse F6. Refer to Figure 7. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and
Relay Removal and Installation (WP 0317).
Is fuse open?
DECISION
YES Go to Step 27.

NO Go to next step.
STEP

DECISION
NO Go to Step 42.
YES Go to Step 44.
0062–7
TM 9-2355-106-23-1 0062
STEP
DECISION
YES Go to Step 37.

NO Go to next step.
STEP
DECISION
YES Go to Step 40.

NO Go to next step.
STEP
DECISION
YES Go to Step 44.

NO Go to next step.
STEP
0062–8
TM 9-2355-106-23-1 0062
DECISION
NO Go to Step 35.
STEP
DECISION
NO Go to Step 45.
0062–9
TM 9-2355-106-23-1 0062
STEP
Figure 10. Cabin Fuse Block 1012 Right Side of IP.
DECISION
NO Go to Step 45.
YES Go to Step 44.
0062–10
TM 9-2355-106-23-1 0062
STEP
35. Install IGN RELAY in cabin fuse block 1012. Refer to Figure 12. Refer to Instrument Panel (IP) Circuit
Figure 12. Cabin Fuse Block 1012 Right Side of IP.
DECISION
NO Go to Step 46.
YES Go to Step 45.
0062–11
TM 9-2355-106-23-1 0062
STEP
37. Remove Power Distribution Center (PDC) armor plate. Refer to Left Side Engine Armor Plate Removal and
38. Remove STARTER relay from underhood PDC. Refer to Figure 13 Refer to Power Distribution Center (PDC)
Figure 13. Underhood Power Distribution Center (PDC), Left Side Engine Compartment.
0062–12
TM 9-2355-106-23-1 0062
DECISION
NO Go to Step 44.
YES Go to Step 48.
STEP
DECISION
NO Go to Step 44.
YES Go to Step 49.
0062–13
TM 9-2355-106-23-1 0062
STEP
42. Measure voltage between ground and each terminal in 12V 100-amp megafuse (Figure 16, Item 1) with
multimeter.
Figure 16. Left Side of Engine Compartment Above Underhood PDC.
DECISION
YES Go to Step 44.

NO Go to next step.
STEP
43. Refer to results of previous test.
DECISION
NO Go to Step 50.
YES Go to Step 47.
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 45. IGN RELAY is faulty.

0062–14
TM 9-2355-106-23-1 0062
ACTION
Replace IGN RELAY. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
(WP 0317).
END OF TEST
MALFUNCTION
- 46. Keyless iIgnition switch is faulty.
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
(WP 0333).
END OF TEST
MALFUNCTION
- 49. ACC RELAY is faulty.
ACTION
Replace ACC RELAY. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
(WP 0317).
END OF TEST
MALFUNCTION
- 50. Power supply from 12V and 24V battery switches is faulty.
ACTION
Isolate fault with 12V and 24V battery switches. Refer to 12V and 24V Battery Switches Troubleshooting
0062–15
TM 9-2355-106-23-1 0062
END OF TEST
END OF WORK PACKAGE
0062–16
TM 9-2355-106-23-1 0063
FIELD MAINTENANCE
INITIAL SETUP:
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0060
Instrument panel right side closeout removed
WP 0302
(WP 0580)
WP 0317
WP 0782
This procedure assumes that cabin fuse block 1013 lacks voltage at one or more buss bars with MAIN POWER
and ignition switches ON.
WARNING
0063–1
TM 9-2355-106-23-1 0063
CAUTION
NOTE
STEP
1. Remove ETHER START circuit breaker from cabin fuse block 1013. Refer to Instrument Panel (IP) Circuit
Breaker, Fuse, and Relay Removal and Installation (WP 0317). Refer to Figure 1.

4. Measure DC voltage between ground and fuse socket terminal A1 with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 39.

NO Go to next step.
0063–2
TM 9-2355-106-23-1 0063
STEP

7. Remove IGN RELAY from cabin fuse block 1013. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and
Relay Removal and Installation (WP 0317). Refer to Figure 2.
8. Measure resistance between relay socket terminal 85 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 39.
STEP

11. Measure DC voltage between relay socket terminal 86 and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 14.
0063–3
TM 9-2355-106-23-1 0063
STEP
Figure 3. Ignition Relay Socket.
DECISION
NO Go to Step 37.
STEP
13. Measure DC voltage between relay socket terminals 87 and 30 with multimeter. Refer to Figure 3.
DECISION
NO Go to Step 39.
YES Go to Step 40.
0063–4
TM 9-2355-106-23-1 0063
STEP

Figure 4. Behind Key Switch.

DECISION
NO Go to Step 21.
0063–5
TM 9-2355-106-23-1 0063
STEP
Figure 6. Ignition Relay Socket.
DECISION
NO Go to Step 39.
YES Go to Step 42.
0063–6
TM 9-2355-106-23-1 0063
STEP

22. Remove and inspect KEY SWITCH/DIAGNOSTIC CONNECTOR fuse from cabin fuse block 1011. Refer
to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation (WP 0317). Refer
to Figure 7.
Is fuse open?
DECISION
YES Go to Step 25.

NO Go to next step.
STEP

DECISION
YES Go to Step 39.

NO Go to Step 37.
0063–7
TM 9-2355-106-23-1 0063
STEP
DECISION
NO Go to Step 30.
STEP
DECISION
NO Go to Step 33.
STEP
27. Install IGN RELAY in cabin fuse block 1013. Refer to Figure 9.

0063–8
TM 9-2355-106-23-1 0063
DECISION
NO Go to Step 35.
STEP
29. Measure resistance between ignition switch, not harness connector 1100M, terminal BAT and ground with
DECISION
NO Go to Step 39.
YES Go to Step 42.
STEP
30. Remove left engine armor upper plate. Refer to Left Side Engine Armor Plate Removal and Installation
(WP 0597).
31. Remove STARTER relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
0063–9
TM 9-2355-106-23-1 0063
0063–10
TM 9-2355-106-23-1 0063
DECISION
NO Go to Step 39.
YES Go to Step 41.
STEP
33. Remove ACC RELAY. Refer to Figure 13.
DECISION
NO Go to Step 39.
YES Go to Step 40.
0063–11
TM 9-2355-106-23-1 0063
STEP
35. Remove IGN RELAY. Refer to Figure 14.
DECISION
NO Go to Step 39.
YES Go to Step 40.
0063–12
TM 9-2355-106-23-1 0063
STEP
37. Measure DC voltage between ground and each 12V 100-amp megafuse terminal (Figure 16, Item 1) with
multimeter.
Figure 16. Above Underhood Power Distribution Center (PDC).
DECISION
YES Go to Step 39.

NO Go to next step.
STEP
38. Refer to results of test just performed.
DECISION
NO Go to Step 43.
YES Go to Step 44.
0063–13
TM 9-2355-106-23-1 0063
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 40. IGN RELAY (H3) is faulty.
ACTION
Replace IGN RELAY (H3). Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and
END OF TEST
MALFUNCTION
ACTION
(WP 0333).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 43. Power supply from 12V and 24V battery switches is faulty.
ACTION
Isolate fault with 12V and 24V battery switches. Refer to 12V and 24V Battery Switches Troubleshooting
END OF TEST
0063–14
TM 9-2355-106-23-1 0063
MALFUNCTION
ACTION
END OF TEST
END OF WORK PACKAGE
0063–15/blank
TM 9-2355-106-23-1 0064
FIELD MAINTENANCE
INITIAL SETUP:
Engine off (TM 9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
Instrument panel right side closeout removed
WP 0319
(WP 0580)
WP 0436
WP 0443 WP 0789, Figure 14
WP 0060
WP 0782
WARNING
CAUTION
NOTE
0064–1
TM 9-2355-106-23-1 0064
STEP
Figure 1. Below Center of Instrument Panel (IP).
2. Reset 70-amp 24V VDC I.P. POWER circuit breaker (Figure 2, Item 1) in 24V PDM.
Figure 2. 24V Power Distribution Module (PDM), Below Center of IP.

5. Measure DC voltage between ground and connector LAM1041 terminals A and B with multimeter. Refer
to Figure 1.
0064–2
TM 9-2355-106-23-1 0064
Does multimeter read between 21V and 27V for each test?
DECISION
YES Go to Step 19.

NO Go to next step.
STEP

8. Disconnect 24V PDM connector J5 (Figure 3, Item 1).
Figure 3. Right Side of 24V PDM.
9. Reset 70-amp 24V VDC I.P. POWER circuit breaker (Figure 4, Item 1) in 24V PDM.
0064–3
TM 9-2355-106-23-1 0064
Figure 4. 24V Power Distribution Module (PDM), Below Center of IP.

12. Measure DC voltage between ground and 24V PDM connector J5 (connector on PDM) terminals B and
C with multimeter. Refer to Figure 5.
Figure 5. 24V PDM Connector J5.
DECISION
YES Go to Step 20.

NO Go to next step.
0064–4
TM 9-2355-106-23-1 0064
STEP

15. Disconnect connector P4. Refer to Figure 6.
Figure 6. Right Side of 24V PDM.

18. Measure DC voltage between ground and connector P4 terminals A and B with multimeter. Refer to Figure 6.
DECISION
YES Go to Step 21.

NO Go to Step 22.
0064–5
TM 9-2355-106-23-1 0064
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 20. 24V IP feed harness is faulty.
ACTION
Replace 24V IP feed harness. Refer to 24V Instrument Panel (IP) Feed Harness Removal and Installation
(WP 0436).
END OF TEST
MALFUNCTION
- 21. 24V PDM is faulty.
ACTION
Replace 24V PDM. Refer to 24V Power Distribution Module (PDM) Removal and Installation (WP 0443).
END OF TEST
MALFUNCTION
- 22. 24V MAIN POWER system is faulty.
ACTION
Diagnose fault in 24V MAIN POWER system. Refer to 12V and 24V Battery Switches Troubleshooting
END OF TEST
END OF WORK PACKAGE
0064–6
TM 9-2355-106-23-1 0065
FIELD MAINTENANCE
POWER DISTRIBUTION CENTER (PDC) MINI FUSE BLOCK 4001 TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0060
Left side engine armor plate removed (WP 0597)
WP 0302
WP 0319 WP 0789, Figure 9, WP 0789, Figure 7,
WP 0333 WP 0789, Figure 15
WP 0335
WP 0782
WARNING
0065–1
TM 9-2355-106-23-1 0065
POWER DISTRIBUTION CENTER (PDC) MINI FUSE BLOCK 4001 TROUBLESHOOTING PROCEDURE -
(CONTINUED)
CAUTION
NOTE
This procedure assumes that Mini Fuse Block 4001 lacks voltage at a buss bar with MAIN
STEP
1. Remove the following fuses:

• Fuse 11, 5A REMOTE PWR MDL
• Fuse 15, 30A AIR ABS
Refer to Figure 1. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
Figure 1. Power Distribution Center (PDC) Under Hood.

0065–2
TM 9-2355-106-23-1 0065
(CONTINUED)

5. Measure DC voltage between ground and each of the following fuse socket terminals with multimeter:
• E3
• E4
Refer to Figure 1.
DECISION
NO Go to Step 26.
STEP

• Fuse 19, 5A ENGINE IGN
• Fuse 23, 5A AIR ABS
• Fuse 27, 20A AIR DRYER & DRN VLV
(WP 0333).
Figure 2. Fuse Block 4001.

• E1
• E2
• E3
Refer to Figure 2.
0065–3
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
NO Go to Step 16.
STEP

• Fuse 2, 10A B/O STOP
• Fuse 6, 15A AUX PWR
(WP 0333).
• C1
• C2
Refer to Figure 3.
Does multimeter read between 21V and 27V at each terminal?
DECISION
NO Go to Step 58.
YES Go to Step 65.
0065–4
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP

18. Remove IGN relay. Refer to Figure 4. Refer to Power Distribution Center (PDC) Fuse and Relay Removal
19. Measure resistance between IGN relay socket terminal 85 and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 65.
0065–5
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
20. Measure resistance between IGN relay socket terminal 87A and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 65.
STEP

23. Measure DC voltage between IGN relay socket terminal 86 and ground with multimeter. Refer to Figure 5.
Figure 5. IGN Relay Socket.
DECISION
NO Go to Step 27.
0065–6
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
DECISION
NO Go to Step 65.
STEP
25. Measure DC voltage between IGN relay socket terminals 87 and 30 with multimeter. Refer to Figure 5.
DECISION
NO Go to Step 65.
YES Go to Step 60.
STEP
26. Measure DC voltage between ground and each 12-volt 100-amp mega fuse terminal (Figure 6, Item 1) with
multimeter.
Figure 6. 12V 100-amp Mega Fuse.
DECISION
NO Go to Step 66.
0065–7
TM 9-2355-106-23-1 0065
(CONTINUED)
YES Go to Step 65.
STEP

Figure 7. Behind Lower Instrument Cluster.

DECISION
NO Go to Step 39.
0065–8
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP

DECISION
YES Go to Step 67.

NO Go to next step.
0065–9
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP

Figure 9. Left Side of Firewall.
38. Measure resistance between connector 1701 (engine side) terminal 11 and IGN relay socket terminal 86 with
multimeter. Refer to Figure 10. Refer to Figure 9.
0065–10
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
NO Go to Step 65.
YES Go to Step 68.
STEP

40. Remove IP closeout. Refer to Instrument Panel (IP) Right Side Closeout Removal and Installation (WP 0580).
41. Remove and inspect 5A fuse F6. Refer to Figure 11. Refer to Instrument Panel (IP) Circuit Breaker, Fuse,
and Relay Removal and Installation (WP 0317).
Figure 11. Right Side of Instrument Panel (IP).
Is fuse open?
DECISION
NO Go to Step 68.
0065–11
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
DECISION
NO Go to Step 48.
STEP
DECISION
NO Go to Step 50.
0065–12
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
44. Install IGN relay. Refer to Figure 13. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
DECISION
NO Go to Step 52.
0065–13
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
46. Remove keyless ignition switch. Refer to Engine Start Keyless Ignition Switch Removal and Installation
(WP 0302).
47. Measure resistance between keyless ignition switch terminal BAT and ground with multimeter. Refer to
Figure 14.
DECISION
YES Go to Step 68.

NO Go to Step 67.
STEP
48. Remove STARTER relay. Refer to Figure 15. Refer to Power Distribution Center (PDC) Fuse and Relay
0065–14
TM 9-2355-106-23-1 0065
(CONTINUED)
0065–15
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
NO Go to Step 68.
YES Go to Step 63.
STEP
50. Remove ACC RELAY. Refer to Figure 17. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay
0065–16
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
NO Go to Step 68.
YES Go to Step 64.
STEP
52. Remove relay IGN from fuse block 4003. Refer to Figure 19. Refer to Power Distribution Center (PDC) Fuse
0065–17
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
YES Go to Step 60.

NO Go to next step.
STEP
0065–18
TM 9-2355-106-23-1 0065
(CONTINUED)
DECISION
YES Go to Step 61.

NO Go to next step.
STEP
56. Remove IGN RELAY from fuse block 1012. Refer to Figure 22. Refer to Instrument Panel (IP) Circuit Breaker,
DECISION
NO Go to Step 68.
YES Go to Step 62.
0065–19
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
58. Measure DC voltage between 24V feed stud and ground with multimeter. Refer to Figure 23.
Figure 23. Above Underhood Power Distribution Center (PDC).
Does multimeter read between 21V and 27V?
DECISION
YES Go to Step 65.

NO Go to next step.
0065–20
TM 9-2355-106-23-1 0065
(CONTINUED)
STEP
59. Measure DC voltage between starter solenoid (Figure 24, Item 2) 24V feed stud (Figure 24, Item 1) and
ground with multimeter.
Figure 24. Left Lower Side of Engine.
DECISION
NO Go to Step 70.
YES Go to Step 69.
MALFUNCTION
- 60. IGN relay from fuse panel 4003 is faulty.
ACTION
Replace IGN relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
(WP 0333).
END OF TEST
MALFUNCTION
- 61. IGN RELAY from fuse panel 1013 is faulty.
ACTION
(WP 0317).
0065–21
TM 9-2355-106-23-1 0065
(CONTINUED)
END OF TEST
MALFUNCTION
- 62. IGN RELAY from fuse panel 1012 is faulty.
ACTION
(WP 0317).
END OF TEST
MALFUNCTION
ACTION
(WP 0333).
END OF TEST
MALFUNCTION
- 64. ACC relay is faulty.
ACTION
Replace ACC relay. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
(WP 0317).
END OF TEST
MALFUNCTION
- 65. Power Distribution Center (PDC) or harness is faulty.
ACTION
Replace PDC. Refer to Power Distribution Center (PDC) Harness Removal and Installation (WP 0335).
END OF TEST
MALFUNCTION
- 66. MAIN POWER switches system is faulty.
ACTION
Diagnose MAIN POWER switches system fault. Refer to 12V and 24V Battery Switches Troubleshooting
END OF TEST
0065–22
TM 9-2355-106-23-1 0065
(CONTINUED)
MALFUNCTION
ACTION
Replace ignition switch. Refer to Keyless Ignition Switch Removal and Installation (WP 0302).
END OF TEST
MALFUNCTION
- 68. Instrument Panel (IP) harness is faulty.
ACTION
END OF TEST
MALFUNCTION
- 69. Engine harness is faulty.
ACTION
Replace engine harness. Refer to Engine Wiring Harness Removal and Installation (WP 0336).
END OF TEST
MALFUNCTION
- 70. Starter motor feed cable is faulty.
ACTION
Replace starter motor feed cable. Refer to Starter Motor Feed Cable Removal and Installation (WP 0413).
END OF TEST
END OF WORK PACKAGE
0065–23/blank
TM 9-2355-106-23-1 0066
FIELD MAINTENANCE
KEYLESS IGNITION SWITCH TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
9-2355-106-10)
References
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0302
Keyless ignition switch removed (WP 0302)
WP 0782
WARNING
CAUTION
NOTE
0066–1
TM 9-2355-106-23-1 0066
KEYLESS IGNITION SWITCH TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
Figure 1. Ignition Switch.
1. While turning switch to START position, measure resistance between switch terminal BAT and all other
switch terminals. Refer to Figure 1 and Figure 2.
Does multimeter read less than 5 ohms between BAT and STA, and BAT and IGN only?
DECISION
NO Go to Step 5.
STEP
2. Turn key to RUN position and measure resistance between switch terminal BAT and all other terminals.
Does multimeter read less than 5 ohms between terminals BAT and IGN, and BAT and ACC only?
DECISION
NO Go to Step 5.
0066–2
TM 9-2355-106-23-1 0066
STEP
3. Turn key to ACCESSORY (ACC) position and measure resistance between switch terminal BAT and all
other terminals. Refer to Figure 1 and Figure 2.
Does multimeter read less 5 ohms between BAT and ACC only?
DECISION
NO Go to Step 5.
STEP
4. Turn key to OFF position and measure resistance between switch terminal BAT and all other terminals.
Does multimeter read OL for all tests?
0066–3
TM 9-2355-106-23-1 0066
DECISION
NO Go to next step.
YES Go to Step 6.
MALFUNCTION
- 5. Ignition switch is faulty.
ACTION
Replace ignition switch. Refer to Keyless Ignition Switch Removal and Installation (WP 0302). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 6. No malfunction at this time.
ACTION
Return to next step in Hard Start/No Start Operational Checkout Procedure (WP 0014).
END OF TEST
END OF WORK PACKAGE
0066–4
TM 9-2355-106-23-1 0067
FIELD MAINTENANCE
MULTIPLEXING DATA LINK CIRCUITS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0355
WP 0578
WP 0580
WP 0597
(WP 0795, Item 37)
WP 0782
References
TM 9-2355-106-10 Equipment Condition
TM 9-2355-106-23P Parking brake set (TM 9-2355-106-10)
WP 0078 9-2355-106-10)
WP 0320

• No Instrument Panel Cluster (IPC) information available.
• No communication between modules.
0067–1
TM 9-2355-106-23-1 0067
MULTIPLEXING DATA LINK CIRCUITS TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0067–2
TM 9-2355-106-23-1 0067
STEP

Figure 1. ATA Connector Under Instrument Panel (IP).
3. Measure DC voltage between ATA connector terminal C and ground with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 45.

NO Go to next step.
0067–3
TM 9-2355-106-23-1 0067
STEP
4. Measure voltage between ATA connector terminal C and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 69.

NO Go to next step.
STEP
5. Measure DC voltage between ATA connector terminal D and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 57.

NO Go to next step.
STEP
6. Measure voltage between ATA connector terminal D and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 33.

NO Go to next step.
0067–4
TM 9-2355-106-23-1 0067
STEP

9. Measure resistance between ATA connector terminal C and D with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 147.

NO Go to next step.
STEP

11. Measure resistance between IP harness side of connector 1701 terminal 15 and terminal 16 with multimeter.
Refer to Figure 3.
0067–5
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 22.

NO Go to next step.
STEP
12. Remove left side engine armor. Refer to Left Side Engine Armor Removal and Installation (WP 0597).

DECISION
YES Go to Step 136.

NO Go to next step.
0067–6
TM 9-2355-106-23-1 0067
STEP
Figure 5. Transmission Control Module (TCM) Connector Under Vehicle on Bracket.
16. Disconnect TCM connector 7150F. Refer to Figure 5. Refer to Transmission Control Unit and Brace Removal
DECISION
YES Go to Step 140.

NO Go to next step.
0067–7
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 139.

NO Go to next step.
0067–8
TM 9-2355-106-23-1 0067
STEP
Figure 9. Chassis Terminating Resistor.
20. Disconnect chassis terminating resistor above transmission. Refer to Figure 9.
0067–9
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 146.

NO Go to Step 137.
STEP
Figure 11. Electronic System Controller (ESC) Connector Under IP.
22. Disconnect ESC connector 1600. Refer to Figure 11.
23. Measure resistance between connector cabin side 1701 terminal 15 and 16 with multimeter. Refer to
Figure 12.
DECISION
YES Go to Step 141.

NO Go to next step.
0067–10
TM 9-2355-106-23-1 0067
STEP
24. Remove IPC. Refer to Instrument Panel Cluster (IPC) Removal and Installation (WP 0297).
Figure 13. IPC Connector.
25. Disconnect IPC connector 1500. Refer to Figure 13.
Figure 14.
0067–11
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 142.

NO Go to next step.
STEP
Figure 15. Transmission Auto Shift Control Module Connector.
27. Disconnect transmission auto shift control module connector. Refer to Figure 15. Refer to Transmission Auto
Shift Control Module Removal and Installation (WP 0452).
Figure 16.
0067–12
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 143.

NO Go to next step.
STEP
Figure 17. Antilock Brake System (ABS) Control Module Connector Under Right Side IP.
29. Disconnect ABS control module connector X1. Refer to Figure 17.
Figure 18.
0067–13
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 144.

NO Go to next step.
STEP
Figure 19. Cabin Terminating Resistor Under Right Side IP.
31. Disconnect cabin terminating resistor under right side IP. Refer to Figure 19.
0067–14
TM 9-2355-106-23-1 0067
32. Measure resistance between IP side connector 1701 terminal 15 and 16 with multimeter. Refer to Figure 20.
DECISION
YES Go to Step 145.

NO Go to Step 138.
STEP

35. Measure resistance between ATA connector terminal D and ground with multimeter. Refer to Figure 21.
0067–15
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 86.

NO Go to next step.
STEP
Figure 22. IP Pass-Through Connector Near Power Distribution Center Under Hood.

37. Measure resistance between IP harness side connector 1701 terminal 15 and 16 with multimeter. Refer to
Figure 22.
DECISION
YES Go to Step 43.

NO Go to next step.
0067–16
TM 9-2355-106-23-1 0067
STEP
39. Disconnect connector 4100F (connector with 18 wires). Refer to Figure 23.
DECISION
NO Go to Step 136.
0067–17
TM 9-2355-106-23-1 0067
STEP
Figure 24. Chassis Terminating Resistor Above Transmission.
41. Disconnect chassis terminating resistor above transmission. Refer to Figure 24. Refer to Belly Armor
42. Measure resistance between terminating resistor terminal A and C with multimeter. Refer to Figure 24.
DECISION
YES Go to Step 146.

NO Go to Step 137.
0067–18
TM 9-2355-106-23-1 0067
STEP
43. Disconnect cabin terminating resistor under right side IP. Refer to Figure 25. Refer to Instrument Panel (IP)
Right Side Closeout Removal and Installation (WP 0580).
44. Measure resistance between terminating resistor terminal A and C with multimeter. Refer to Figure 25.
DECISION
YES Go to Step 145.

NO Go to Step 138.
0067–19
TM 9-2355-106-23-1 0067
STEP
46. Disconnect and reconnect modules one at a time while observing MSD for communication recovery.
Figure 26. ABS Module Connector.
47. Disconnect and reconnect ABS module connector X1. Refer to Figure 26.
Does MSD indicate that communication was restored when module was disconnected?
DECISION
YES Go to Step 130.

NO Go to next step.
STEP
Figure 27. Shift Selector Module Connector.
48. Disconnect and reconnect shift selector module connector 1852. Refer to Figure 27. Refer to Transmission
Auto Shift Control Module Removal and Installation (WP 0452).
0067–20
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 124.

NO Go to next step.
STEP
49. Disconnect and reconnect IPC connector 1500. Refer to Figure 28. Refer to Instrument Panel Cluster (IPC)
DECISION
YES Go to Step 118.

NO Go to next step.
0067–21
TM 9-2355-106-23-1 0067
STEP
Figure 29. Electronic System Controller (ESC) Connector.
50. Disconnect and reconnect ESC connector 1600. Refer to Figure 29.
DECISION
YES Go to Step 112.

NO Go to next step.
STEP
Figure 30. Transmission Control Module (TCM) Connector.
51. Disconnect and reconnect TCM connector 7150F. Refer to Figure 30. Refer to Transmission Control Unit
and Brace Removal and Installation (WP 0453).
0067–22
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 100.

NO Go to next step.
STEP
Figure 31. Engine Control Module (ECM) Connector.
52. Disconnect and reconnect ECM connector 6007. Refer to Figure 31. Refer to Engine Control Module (ECM)
DECISION
YES Go to Step 106.

NO Go to next step.
0067–23
TM 9-2355-106-23-1 0067
STEP
Figure 32. Dash/IP Connector.

54. Measure resistance between IP side connector 1701 terminal 15 and all other terminals with multimeter.
Refer to Figure 32.
DECISION
YES Go to Step 138.

NO Go to next step.
0067–24
TM 9-2355-106-23-1 0067
STEP
Figure 33. Dash/Engine Connector.
56. Measure resistance between connector 4100F terminal 7 and all other terminals with multimeter. Refer to
Figure 33.
DECISION
YES Go to Step 137.

NO Go to Step 136.
0067–25
TM 9-2355-106-23-1 0067
STEP
58. Disconnect and reconnect modules one at a time while observing MSD for communication recovery.
59. Disconnect and reconnect ABS module connector X1. Refer to Figure 34. Refer to Antilock Brake System
(ABS) Control Module Removal and Installation (WP 0355).
Figure 34. ABS Module Connectors.
DECISION
YES Go to Step 133.

NO Go to next step.
0067–26
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 127.

NO Go to next step.
0067–27
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 121.

NO Go to next step.
STEP
0067–28
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 115.

NO Go to next step.
STEP
DECISION
YES Go to Step 103.

NO Go to next step.
STEP
0067–29
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 109.

NO Go to next step.
STEP

66. Measure resistance between IP side connector 1701 terminal 16 and all other terminals with multimeter.
Refer to Figure 40.
DECISION
YES Go to Step 138.

NO Go to next step.
0067–30
TM 9-2355-106-23-1 0067
STEP
68. Measure resistance between connector 4100F terminal 8 and all other terminals with multimeter. Refer to
Figure 41.
DECISION
YES Go to Step 137.

NO Go to Step 136.
STEP

71. Measure resistance between connector 1650 terminal C and ground with multimeter. Refer to Figure 42.
0067–31
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 36.

NO Go to next step.
STEP
73. Disconnect and reconnect modules and resistors one at a time while observing MSD for communication
recovery.
DECISION
YES Go to Step 144.

NO Go to next step.
0067–32
TM 9-2355-106-23-1 0067
STEP
75. Disconnect cabin terminating resistor above transmission. Refer to Figure 44. Refer to Instrument Panel (IP)
Does MSD indicate that communication was restored when resistor was disconnected?
DECISION
YES Go to Step 145.

NO Go to next step.
0067–33
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 143.

NO Go to next step.
0067–34
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 142.

NO Go to next step.
STEP
0067–35
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 142.

NO Go to next step.
STEP
DECISION
YES Go to Step 141.

NO Go to next step.
STEP

0067–36
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 139.

NO Go to next step.
STEP
DECISION
YES Go to Step 146.

NO Go to next step.
0067–37
TM 9-2355-106-23-1 0067
STEP

83. Measure resistance between IP side connector 1701 terminal 15 and ground with multimeter. Refer to
Figure 51.
DECISION
YES Go to Step 138.

NO Go to next step.
0067–38
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 137.

NO Go to Step 136.
0067–39
TM 9-2355-106-23-1 0067
STEP
87. Disconnect and reconnect modules and resistors one at a time while observing MSD for communication
recovery.
DECISION
YES Go to Step 144.

NO Go to next step.
0067–40
TM 9-2355-106-23-1 0067
STEP
89. Disconnect cabin terminating resistor above transmission. Refer to Figure 54. Refer to Instrument Panel (IP)
DECISION
YES Go to Step 145.

NO Go to next step.
0067–41
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 143.

NO Go to next step.
0067–42
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 142.

NO Go to next step.
STEP
0067–43
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 141.

NO Go to next step.
STEP
DECISION
YES Go to Step 140.

NO Go to next step.
STEP

0067–44
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 139.

NO Go to next step.
STEP
DECISION
YES Go to Step 146.

NO Go to next step.
0067–45
TM 9-2355-106-23-1 0067
STEP

97. Measure resistance between IP side connector 1701 terminal 16 and ground with multimeter. Refer to
Figure 61.
DECISION
YES Go to Step 138.

NO Go to next step.
0067–46
TM 9-2355-106-23-1 0067
STEP
DECISION
YES Go to Step 137.

NO Go to Step 136.
0067–47
TM 9-2355-106-23-1 0067
STEP
100.Turn ignition switch OFF (TM 9-2355-106-10).

101.Turn MAIN POWER switch OFF (TM 9-2355-106-10).
Figure 63. TCM Connector 7150F.
102.Measure resistance between connector 7150F terminal 28 and all other connector 7150F terminals with
DECISION
YES Go to Step 137.

NO Go to Step 140.
STEP

105.Measure resistance between connector 7150F terminal 8 and all other connector 7150F terminals with
DECISION
YES Go to Step 137.

NO Go to Step 140.
0067–48
TM 9-2355-106-23-1 0067
STEP

108.Measure resistance between connector 6007 terminal 19 and all other connector 6007 terminals with
DECISION
YES Go to Step 137.

NO Go to Step 139.
STEP

DECISION
YES Go to Step 137.

NO Go to Step 139.
0067–49
TM 9-2355-106-23-1 0067
STEP

Figure 65. ESC Connector 1600.
DECISION
YES Go to Step 138.

NO Go to Step 141.
0067–50
TM 9-2355-106-23-1 0067
STEP

DECISION
YES Go to Step 138.

NO Go to Step 141.
STEP

Figure 66. Cluster Connector 1500.
DECISION
YES Go to Step 138.

NO Go to Step 142.
STEP

0067–51
TM 9-2355-106-23-1 0067
DECISION
YES Go to Step 138.

NO Go to Step 142.
STEP

Figure 67. Shift Selector Module Connector 1852.
DECISION
YES Go to Step 138.

NO Go to Step 143.
STEP

DECISION
YES Go to Step 138.

NO Go to Step 143.
0067–52
TM 9-2355-106-23-1 0067
STEP

Figure 68. ABS Module Connector X1.
132.Measure resistance between connector X1 terminal 8 and all other connector X1 terminals with multimeter.
Refer to Figure 68.
DECISION
YES Go to Step 138.

NO Go to Step 144.
STEP
133.Turn ignition switch OFF (TM TM 9-2355-106-10).

134.Turn MAIN POWER switch OFF (TM TM 9-2355-106-10).
135.Measure resistance between connector X1 terminal 7 and all other connector X1 terminals with multimeter.
Refer to Figure 68.
DECISION
YES Go to Step 138.

NO Go to Step 144.
0067–53
TM 9-2355-106-23-1 0067
MALFUNCTION
- 136. Dash wiring harness is faulty.
ACTION
Replace dash harness. Refer to Power Distribution Harness Removal and Installation (WP 0335). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace IP wiring harness. Refer to Instrument Panel (IP) Harness Removal and Installation (WP 0319).
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 140. TCM is faulty.
ACTION
Replace TCM. Refer to Transmission Control Unit and Brace Removal and Installation (WP 0453). Return
vehicle to service.
END OF TEST
MALFUNCTION

0067–54
TM 9-2355-106-23-1 0067
ACTION
Replace ESC. Refer to Electronic Sytem Controller (ESC) Removal and Installation (WP 0353). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 142. IPC is faulty.
ACTION
Replace IPC. Refer to Instrument Panel Cluster (IPC) Removal and Installation (WP 0578). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 143. Shift selector module is faulty.
ACTION
Replace shift selector module. Refer to Transmission Auto Shift Control Module Removal and Installation
END OF TEST
MALFUNCTION
- 144. ABS module is faulty.
ACTION
Replace ABS module. Refer to Antilock Brake System (ABS) Control Module Removal and Installation
END OF TEST
0067–55
TM 9-2355-106-23-1 0067
MALFUNCTION
- 145. Cabin terminating resistor is faulty.
ACTION
Replace cabin terminating resistor. Refer to Instrument Panel (IP) Harness Terminating Resistor Removal and
END OF TEST
MALFUNCTION
- 146. Chassis terminating resistor is faulty.
ACTION
Replace chassis terminating resistor. Refer to Engine Wiring Harness Terminating Resistor Removal and
END OF TEST
MALFUNCTION
- 147. Datalink circuits are operating as designed. Recheck diagnostic connector power and ground (WP 0078).
Check MSD connector for missing, corroded, or damaged terminals. If communication failure persists, substitute
a known good ECM and ESC and retest.
ACTION
END OF TEST
END OF WORK PACKAGE
0067–56
TM 9-2355-106-23-1 0068
FIELD MAINTENANCE
ELECTRONIC SYSTEM CONTROLLER (ESC) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0319
WP 0335
(WP 0795, Item 37) WP 0426
Box, breakout, Electronic System Controller (ESC) WP 0598
(ZTSE4477) (WP 0795, Item 21) WP 0580
Personnel Required WP 0605
Maintainer - (2) WP 0782
Equipment Condition
References
TM 9-2355-106-10
TM 9-2355-106-23P
9-2355-106-10)
WP 0012
Engine off (TM 9-2355-106-10)
WP 0059
WP 0067
WP 0086
WP 0087
Cabin doors open and secured (TM 9-2355-106-10)
WP 0106
WP 0257 WP 0789, Figure 35
WP 0297 WP 0789, Figure 37
WP 0301 WP 0789, Figure 44

This procedure addresses the following Diagnostic Trouble Codes (DTCs):
Table 1. Electronic System Controller DTCs.

FAULT CODE FAULT DESCRIPTION
610 14 1 0 Loss of ignition feed for 10 seconds while the engine is running.
610 14 2 0 Loss of accessory feed for 10 seconds while the engine is running.
612 14 0 1 Ignition out of range low. Short to ground or open circuit.
612 14 0 2 Ignition out of range high. Shorted high.
612 14 30 1 Switched 5V sensor supply out of range low. Short to ground or open circuit.
612 14 30 2 Switched 5V sensor supply out of range high. Shorted high.
625 14 5 0 Switch pack data link fault.
627 14 11 ESC main power and ground interruption.
1542 14 11 ESC main power and ground interruption.
1557 0 1 1 ESC internal fault software main loop time exceeded.
1705 14 150 1 ESC not communicating with the IPC (IPC Version 8.7).
2023 14 150 1 Loss of data link from ESC to primary IPC (150) (IPC Version 9.3 and later).
2023 14 250 1 Loss of data link from ESC to secondary IPC (250) (IPC Version 9.3 and later).
This procedure addresses the following symptoms:

• All ESC features are inoperative. ESC controlled features include:
• Windshield and mirror heaters
• Windshield wipers
0068–1
TM 9-2355-106-23-1 0068
ELECTRONIC SYSTEM CONTROLLER (ESC) TROUBLESHOOTING PROCEDURE - (CONTINUED)
• Park lamps
• Turn signals
• Headlights
• Brake lamps
• Transfer case mode
• Electric horns
• Water-in-fuel warning lamp
• Park brake warning lamp
• Fasten seatbelts warning lamp
• High beam headlight indicator lamp
• Turn signal indicator lamps
• Primary air pressure gauge
• Secondary air pressure gauge
• Transmission temperature gauge
• Fuel level gauge
• Front axle disconnect
• All ESC dependent Electronic Gauge Cluster (EGC) lamps and gauges are inoperative. ESC dependent
EGC lamps and gauges include:
• All ESC 5-volt reference dependent features are inoperative. ESC 5-volt reference dependent features
include:
• Primary air pressure gauge pressure transducer
• Secondary air pressure gauge pressure transducer
• All ESC zero-volt reference dependent features are inoperative. ESC zero-volt reference feature include:
• Park brake switch
• Primary air pressure gauge pressure transducer
• Secondary air pressure gauge pressure transducer
• Electric horn switch
• Windshield wiper switch
• Fuel level sending unit
• Air conditioner relay AC ON signal to ESC connector 4004
• All switch pack module controlled functions are inoperative. Switch pack module controlled functions include:
• Mirror and windshield heaters
0068–2
TM 9-2355-106-23-1 0068
0068–3
TM 9-2355-106-23-1 0068
STEP
WARNING
CAUTION
NOTE
Is DTC 1557 0 1 1 set?
DECISION
YES Go to Step 146.

NO Go to next step.
STEP
2. Refer to previously accessed DTCs.

0068–4
TM 9-2355-106-23-1 0068
Is DTC 625 14 5 0 set?
DECISION
YES Go to Step 47.

NO Go to next step.
STEP
Is the DTC any of the following:
• 1705 14 150 1
• 2023 14 150 1
• 2023 14 250 1
DECISION
YES Go to Step 30.

NO Go to next step.
STEP
• 610 14 1 0
• 610 14 2 0
• 612 14 0 1
• 612 14 0 2
• 627 14 11
• 1542 14 11
DECISION
YES Go to Step 12.

NO Go to next step.
0068–5
TM 9-2355-106-23-1 0068
STEP
• 612 14 30 1
• 612 14 30 2
DECISION
YES Go to Primary Air Pressure Gauge Troubleshooting Procedure (WP 0086) and Secondary Air Pressure
Gauge Troubleshooting Procedure (WP 0087).
NO Go to next step.
STEP
6. Operate the following features and observe the response:

• Windshield and mirror heaters
• Windshield wipers
• Park lamps
• Turn signals
• Headlights
• Brake lamps
• Electric horns
Do all features fail to operate?
DECISION
YES Go to Step 12.

NO Go to next step.
STEP
7. Operate the following features and observe the response:

• Mirror and windshield heaters
0068–6
TM 9-2355-106-23-1 0068

Do all of the features fail to operate?
DECISION
YES Go to Step 47.

NO Go to next step.
STEP
8. Operate the vehicle and observe the following EGC lamps and gauges:
Do all EGC lamps and gauges fail to operate?
DECISION
YES Go to Step 30.

NO Go to next step.
0068–7
TM 9-2355-106-23-1 0068
STEP
9. Operate the vehicle and observe the following gauges:

Do the primary and secondary air pressure gauges fail to operate correctly?
DECISION
YES Go to Primary Air Pressure Gauge Troubleshooting Procedure (WP 0086) and Secondary Air Pressure
Gauge Troubleshooting Procedure (WP 0087).
NO Go to next step.
STEP
10. Operate vehicle and observe the following features:

• Electric horn switch
• Park brake switch
• Windshield wiper switch
Do all features fail to operate correctly?
DECISION
YES Go to Step 69.

NO Go to next step.
STEP
11. Observe the fuel level gauge.
Does the fuel level gauge operate correctly?
DECISION
YES Go to Step 149.

NO Go to Step 102.
0068–8
TM 9-2355-106-23-1 0068
STEP
12. Measure voltage between ESC power cable terminal (left) at megafuse and ground with multimeter. Refer
to Figure 1.
Figure 1. ESC Power Cable Terminal Underhood.
DECISION

NO Go to Power Distribution Troubleshooting Procedure (WP 0059).
STEP

15. Disconnect connector 1600 from ESC. Refer to Figure 2.
0068–9
TM 9-2355-106-23-1 0068
Figure 2. Under Steering Column.
Figure 3. Connector 1600 to Breakout Box Male Connector.
16. Install connector 1600 on ZTSE4477 breakout box male connector. Refer to Figure 3.
19. Measure voltage between ZTSE4477 breakout box pin 12 and ground with multimeter. Refer to Figure 3.

0068–10
TM 9-2355-106-23-1 0068
DECISION
NO Go to Step 22.
STEP
DECISION
NO Go to Step 63.
STEP
21. Measure voltage between ZTSE4477 breakout box pin 2 and pin 1 with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 146.

NO Go to Step 138.
0068–11
TM 9-2355-106-23-1 0068
STEP
22. Remove IP right side closeout. Refer to Instrument Panel (IP) Right Side Closeout Removal and Installation
(WP 0580).
Figure 4. Fuse F20 in Fuse Block 1012.

25. Remove and inspect fuse F20. Refer to Figure 4. Refer to Instrument Panel (IP) Circuit Breaker, Fuse,
Is fuse F20 open?
DECISION
YES Go to Step 29.

NO Go to next step.
STEP

28. Measure voltage between fuse F20 socket terminal F2 and ground, and fuse F20 socket terminal E2 and
Does multimeter read between 10.5 volts and 13.5 volts at either terminal?
DECISION
YES Go to Step 142.

0068–12
TM 9-2355-106-23-1 0068
STEP
29. Measure resistance between ZTSE4477 breakout box pin 12 and ground with multimeter. Refer to Figure 5.
DECISION
YES Go to Step 142.

NO Go to Step 146.
0068–13
TM 9-2355-106-23-1 0068
STEP

Figure 6. ESC Connector Under Left Side Instrument Panel.
0068–14
TM 9-2355-106-23-1 0068
33. Install connector 1600 on ZTSE4477 breakout box male connector. Refer to Figure 7.

DECISION

NO Go to Step 63.
STEP
37. Measure voltage between ZTSE4477 breakout box pin 2 and pin 1 with multimeter. Refer to Figure 7.
DECISION

NO Go to Step 138.
0068–15
TM 9-2355-106-23-1 0068
STEP
39. Disconnect connector 1500 from IPC.
42. Measure voltage between connector 1500 terminal 4 and ground with multimeter. Refer to Figure 8.
Figure 8. Behind IPC.
DECISION

NO Go to Multiplexing Data Link Circuits Troubleshooting Procedure (WP 0067).
0068–16
TM 9-2355-106-23-1 0068
STEP
43. Measure voltage between connector 1500 terminals 5 and ground with multimeter. Refer to Figure 9.
Does multimeter read between 1.0 and 5.0 volts?
DECISION

STEP

DECISION
YES Go to Step 148.

0068–17
TM 9-2355-106-23-1 0068
STEP
47. Remove switch pack from Instrument Panel (IP). Refer to Rocker Switch Removal and Installation (WP 0301).
48. Disconnect connector 1101M from switch pack module. Refer to Figure 10.
Figure 10. Behind Switch Pack.
49. Turn MAIN POWER switch ON(TM 9-2355-106-10).

51. Measure voltage between connector 1101M terminal D and ground with multimeter. Refer to Figure 10.
DECISION

NO Go to Step 53.
0068–18
TM 9-2355-106-23-1 0068
STEP
52. Measure voltage between connector 1101M terminal E and ground with multimeter. Refer to Figure 10.
DECISION
YES Go to Step 141.

NO Go to Step 58.
STEP

56. With assistant, measure resistance between connector 1600 terminal 29 and connector 1101M terminal D
0068–19
TM 9-2355-106-23-1 0068
DECISION

NO Go to Step 142
STEP
57. Measure resistance between ESC connector 1600 terminal 29 and all other terminals in connector 1600 with
Does multimeter read OL for every terminal?
DECISION
YES Go to Step 146.

NO Go to Step 142
STEP

61. Measure resistance between connector 1600 terminal 30 and connector 1101M terminal E with multimeter.
DECISION

NO Go to Step 142
STEP
62. Measure resistance between ESC connector 1600 terminal 30 and all other terminals in connector 1600 with
Does multimeter read OL for every terminal?
DECISION
YES Go to Step 146.

NO Go to Step 142
STEP
63. Remove IP right side closeout. Refer to Instrument Panel (IP) Right Side Closeout Removal and Installation
(WP 0580).
64. Remove and inspect fuse F5. Refer to Figure 13.
0068–20
TM 9-2355-106-23-1 0068
Figure 13. Fuse F5 in Fuse Block 1011.
Is fuse F5 open?
DECISION
YES Go to Step 68.

NO Go to next step.
STEP

67. Measure voltage between fuse F5 socket terminal F1 and ground, and fuse F5 socket terminal E1 and
ground with multimeter. Refer to Figure 13. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay
Does multimeter read between 10.5 volts and 13.5 volts at either terminal?
DECISION
YES Go to Step 142.

0068–21
TM 9-2355-106-23-1 0068
STEP
68. Measure resistance between ZTSE4477 breakout box pin 2 and ground with multimeter. Refer to Figure 14.
DECISION
YES Go to Step 146.

NO Go to Step 142.
0068–22
TM 9-2355-106-23-1 0068
STEP

Figure 15. ESC Connector 1600.
72. Install connector 1600 on ZTSE4477 breakout box male connector. Install ZTSE4477 breakout box female
connector on ESC. Refer to Figure 16.
0068–23
TM 9-2355-106-23-1 0068
Figure 16. Breakout Box Connected to ESC and Connector 1600.

Does multimeter read more than 0 volts?
DECISION
NO Go to Step 94.
STEP

78. Disconnect ZTSE4477 breakout box female connector from ESC. Refer to Figure 17.
0068–24
TM 9-2355-106-23-1 0068

DECISION
NO Go to Step 146.
0068–25
TM 9-2355-106-23-1 0068
STEP

84. Disconnect connector 1800/1805 under instrument panel. Refer to Figure 18.
Figure 18. Under Instrument Panel.


0068–26
TM 9-2355-106-23-1 0068
DECISION
YES Go to Step 142.

NO Go to next step.
0068–27
TM 9-2355-106-23-1 0068
STEP
Figure 21. Devices Using Zero-Volt Reference Signal.

91. Observe and record voltage between connector 1805 pin A4 and ground with multimeter while disconnecting
the following connectors: primary and secondary air pressure transducers (1811 and 1812), clockspring
(1809), park brake switch (1813), and wiper control (1810). Refer to Figure 21 and Figure 20.
Did multimeter read 0 volts when any device was disconnected?
DECISION
NO Go to Step 144.
0068–28
TM 9-2355-106-23-1 0068
STEP
92. Refer to recorded results.
Did multimeter read 0 volts when connectors 1811 or 1812 were disconnected?
DECISION
YES Go to AIR 1/Primary Air Pressure Gauge Troubleshooting Procedure (WP 0086).
NO Go to next step.
STEP
93. Refer to recorded results.
Did multimeter read 0 volts when connectors 1809 or 1813 were disconnected?
DECISION
YES Go to Cruise Control Operational Checkout Procedure (WP 0106).

NO Go to Windshield Wiper Switch Inputs to Electronic System Controller (ESC) Troubleshooting Procedure
(WP 0115).
0068–29
TM 9-2355-106-23-1 0068
STEP

97. Disconnect connector 1800 from 1805 under instrument panel. Refer to Figure 23.
Figure 23. Cab/DCM Connector Under Instrument Panel.
98. Measure resistance between ZTSE4477 breakout box pin 3 and connector 1800 terminal A4 with multimeter.
0068–30
TM 9-2355-106-23-1 0068
DECISION
YES Go to Step 142.

NO Go to next step.
0068–31
TM 9-2355-106-23-1 0068
STEP
100.Disconnect clockspring connector 1809 under instrument panel. Refer to Figure 25.
Figure 25. Clockspring Connector 1809.
101.Measure resistance between connector 1805 terminal A4 and connector 1809 terminal A with multimeter.
DECISION
YES Go to Step 144.

NO Go to Step 146.
0068–32
TM 9-2355-106-23-1 0068
STEP

104.Disconnect connector 4004 at ESC. Refer to Figure 27.
Figure 27. ESC Connector Under Left Side Instrument Panel.
0068–33
TM 9-2355-106-23-1 0068
105.Install connector 4004 on ZTSE4477 breakout box male connector. Install ZTSE4477 breakout box female
connector on ESC. Refer to Figure 28.
Figure 28. Breakout Box Connected to ESC and Connector 4004.
106.Turn MAIN POWER switch ON (TM 9-2355-106-10).

107.Turn ignition switch ON (TM 9-2355-106-10).
108.Measure voltage between ZTSE4477 breakout box pin 26 and ground with multimeter. Refer to Figure 28.
DECISION
NO Go to Step 133.
0068–34
TM 9-2355-106-23-1 0068
STEP


DECISION
NO Go to Step 146.
0068–35
TM 9-2355-106-23-1 0068
STEP
116. Remove left engine armor bracket. Refer to Left Engine Armor Plate Bracket Removal and Installation
(WP 0598).
117. Disconnect splice block connector 4830 under power distribution center in engine compartment. Refer to
Figure 30.
Figure 30. Splice Block Connector Near Power Distribution Center Underhood.

0068–36
TM 9-2355-106-23-1 0068
120.Measure voltage between ZTSE4477 breakout box pin 26 and ground with multimeter. Refer to Figure 31.
DECISION
YES Go to Step 143.

NO Go to next step.
STEP
121.Measure voltage between splice block connector 4830 terminal C and ground with multimeter. Refer to
Figure 30.
Did multimeter read more than 0 volts?
DECISION
YES Go to Step 143.

NO Go to next step.
0068–37
TM 9-2355-106-23-1 0068
STEP
122.Remove fuel tank armor. Refer to Exterior Fuel Tank Armor Door Removal and Installation (WP 0605).
123.Disconnect fuel level sensor connector 9100 at fuel tank. Refer to Figure 32.
Figure 32. Fuel Level Sender Connector Behind Fuel Tank Armor.

126.Measure voltage between splice block connector 4830 terminal A and ground with multimeter. Refer to
Figure 33.
Figure 33. Splice Block Connector 4830.
DECISION
NO Go to Step 147.
0068–38
TM 9-2355-106-23-1 0068
STEP

129.Disconnect connector 9700/9714 located below power distribution center. Refer to Figure 34.
Figure 34. Dash/Center Chassis Interconnect Below Power Distribution Center Underhood.

132.Measure voltage between connector 4830 terminal A and ground with multimeter. Refer to Figure 33.
DECISION
YES Go to Step 143.

NO Go to Step 145.
0068–39
TM 9-2355-106-23-1 0068
STEP
133.Remove air cleaner assembly. Refer to Air Cleaner Assembly Removal and Installation (WP 0257).
134.Remove left engine armor bracket. Refer to Left Engine Armor Plate Bracket Removal and Installation
(WP 0598).
135.Disconnect ZTSE4477 breakout box female connector from ESC. Refer to Figure 35.
136.Disconnect electronic ground splice connector 4830. Refer to Figure 36.
Figure 36. Splice Block Connector 4830.
0068–40
TM 9-2355-106-23-1 0068
137.With assistant, measure resistance between ZTSE4477 breakout box pin 26 and connector 4830 terminal B
with multimeter. Refer to Figure 35. Refer to Figure 36.
DECISION
YES Go to Step 146.

NO Go to Step 143.
STEP

140.Inspect the connections at ground stud 1851 for corrosion or looseness. Refer to Figure 37.
Figure 37. Ground Stud Under Left Side Instrument Panel.
Are connections corrosion-free and secure?
DECISION
YES Go to Step 142.

NO Clean and secure connections. Return vehicle to service.
0068–41
TM 9-2355-106-23-1 0068
MALFUNCTION
- 141. Switch pack is faulty.
ACTION
Replace switch pack. Refer to Rocker Switch Removal and Installation (WP 0301). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace instrument panel wiring harness. Refer to Instrument Panel Wiring Harness Removal and Installation
END OF TEST
MALFUNCTION
- 143. Power distribution center (PDC) wiring harness is faulty.
ACTION
Replace power distribution center wiring harness. Refer to Power Distribution Center (PDC) Harness Removal
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 145. Center chassis wiring harness is faulty.
ACTION
Replace center chassis wiring harness. Refer to Center Chassis Wiring Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
Replace ESC. Refer to ESC Removal and Installation (WP 0353). Return vehicle to service.
0068–42
TM 9-2355-106-23-1 0068
END OF TEST
MALFUNCTION
- 147. Fuel level sending unit is faulty.
ACTION
Replace fuel level sender. Refer to Fuel Level Sending Unit Removal and Installation (WP 0299). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 149. Condition that resulted in symptom or DTC not present.
ACTION
END OF TEST
END OF WORK PACKAGE
0068–43/blank
TM 9-2355-106-23-1 0069
FIELD MAINTENANCE
SWITCH PACK MODULES TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0782
Equipment Condition
(WP 0795, Item 37)
TM 9-2355-106-10 Engine off (TM 9-2355-106-10)
WP 0006
WP 0068 WP 0789, Figure 57
WARNING
NOTE
0069–1
TM 9-2355-106-23-1 0069
SWITCH PACK MODULES TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP

2. Turn ignition ON (TM 9-2355-106-10).
3. Turn each rocker switch in switch pack ON and OFF while observing rocker switch lights (TM 9-2355-106-10).
Does each rocker switch light illuminate while switch is ON and go out while switch is OFF?
DECISION
NO Go to Step 8.
STEP
Are switch pack DTCs set?
DECISION
NO Go to troubleshooting procedure applicable to feature controlled by inoperative switch. Refer to Vehicle

Troubleshooting Symptom Index (WP 0005).
STEP
5. Refer to DTCs retrieved in last test.
Are switch pack communication DTCs set?
DECISION
YES Go to Step 8.
NO Go to next step.
STEP
6. Refer to DTCs retrieved in last test.
Are individual switch fault DTCs set?
DECISION
YES Go to Step 26.

NO Go to next step.
STEP
7. Observe switch pack switches.
Is any rocker switch indicator flashing?
0069–2
TM 9-2355-106-23-1 0069
DECISION
YES Go to troubleshooting procedure applicable to feature controlled by flashing switch. Refer to Vehicle
Troubleshooting Symptom Index (WP 0005).
STEP
8. Remove switch pack from instrument panel. Refer to (WP 0301).

Figure 1. Behind Switch Pack.
0069–3
TM 9-2355-106-23-1 0069
DECISION
NO Go to Step 19.
STEP

13. Measure DC voltage between connector 1101M terminal B and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 21.
STEP
14. Measure DC voltage between connector 1101M terminal D and ground with multimeter. Refer to Figure 2.
DECISION

0069–4
TM 9-2355-106-23-1 0069
STEP
15. Measure DC voltage between connector 1101M terminal E and ground with multimeter. Refer to Figure 2.
DECISION

STEP
16. Turn headlights ON (TM 9-2355-106-10).

17. Adjust panel lights to full brightness (TM 9-2355-106-10).
18. Measure DC voltage between connector 1101M terminal C and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 27.
YES Go to Step 28.
0069–5
TM 9-2355-106-23-1 0069
STEP
19. Disconnect ground eyelet 1851 circuit A11–GA from ground stud. Refer to Figure 3.
Figure 3. Below Steering Column.
20. Measure resistance between ground eyelet 1851 circuit A11–GA and connector 1101M terminal A with
Figure 4. Ground Eyelet 1851.
0069–6
TM 9-2355-106-23-1 0069
DECISION
NO Go to Step 27.
YES Clean ground eyelet 1851 and connect to ground stud. Return vehicle to service.
STEP
21. Remove and visually inspect fuse F5. Refer to Figure 6.
Figure 6. Cabin Fuse Panel.
0069–7
TM 9-2355-106-23-1 0069
Is fuse F5 open?
DECISION
YES Go to Step 25.

NO Go to next step.
STEP

24. Measure resistance between fuse F5 socket terminal F1 and connector 1101M terminal B, and fuse F5 socket
terminal E1 and connector 1101M terminal B with multimeter. Refer to Figure 5 and Figure 6.
Does multimeter read less than 5 ohms for either test?
DECISION
NO Go to Step 27.
YES Go to Power Distribution Troubleshooting Procedure (WP 0059).
STEP
DECISION
NO Go to Step 29.
YES Go to Step 30.
MALFUNCTION
- 26. Individual switch is faulty.
ACTION
Replace switch. Refer to Rocker Switch Removal and Installation (WP 0301). Return vehicle to service.
0069–8
TM 9-2355-106-23-1 0069
END OF TEST
MALFUNCTION
- 27. Instrument Panel (IP) wiring harness is faulty.
ACTION
Replace IP wiring harness. Refer to Instrument Panel Harness Removal and Installation (WP 0319). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace switch pack. Refer to Rocker Switch Removal and Installation (WP 0301). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace fuse and IP harness. Refer to Instrument Panel Harness Removal and Installation (WP 0319). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace fuse and switch pack. Refer to Rocker Switch Removal and Installation (WP 0301). Return vehicle
to service.
END OF TEST
END OF WORK PACKAGE
0069–9/blank
TM 9-2355-106-23-1 0070
FIELD MAINTENANCE
INSTRUMENT PANEL CLUSTER (IPC) OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
References WP 0782
TM 9-2355-106-10
Equipment Condition
TM 9-2355-106-23P
WP 0005
WP 0071
9-2355-106-10)
WP 0072
WP 0088
WP 0092
WP 0097
WP 0297
Problems with IPC operation can be caused by a lack of power, a malfunctioning IPC, a malfunctioning Electronic
System Controller (ESC), a malfunctioning data link, problems in the engine controller, problems in the Antilock
Brake System (ABS) controller, problems in the transmission controller, or problems with wiring or sensors feeding
the electronic controllers throughout the system.
IPC PRELIMINARY SYSTEM CHECK
WARNING
CAUTION
NOTE
STEP
2. Turn ignition switch ON (TM 9-2355-106-10) while observing IPC. Verify IPC responds to ignition ON.
0070–1
TM 9-2355-106-23-1 0070
INSTRUMENT PANEL CLUSTER (IPC) OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
IPC does not respond to ignition ON.

CORRECTIVE ACTION
Go to Instrument Panel Cluster (IPC) Power and Data Link Circuits Troubleshooting (WP 0071).
NOTE
A correct gauge sweep is as follows:
After the ignition is turned on, a gauge sweep of the IPC will be performed. Each gauge must
sweep from zero to maximum to zero in unison. All gauge warning lights will illuminate along
with panel warning lights applicable to features installed on the vehicle. The YELLOW and RED
ENGINE warning lamps should also illuminate. The lights controlled by the panel dimmer in
the IPC will also come on during the gauge sweep. Alarms associated with gauge warning
lights will not sound. All segments of the IPC Liquid Quartz Display (LCD) should display while
the gauges sweep. At the end of the sweep, the LCD will turn off all segments for 5 seconds,
display the firmware version number, and then return to operational mode.
1. Turn ignition OFF then ON while observing IPC (TM 9-2355-106-10). Verify IPC gauge sweep.
IPC gauge sweep performs with errors.
Go to Malfunctioning Instrument Panel Cluster (IPC) Troubleshooting Procedure (WP 0072).
1. Turn ignition OFF then ON (TM 9-2355-106-10). Observe IPC after gauge sweep concludes. Verify warning
lamps are not illuminated.
Warning lamps are illuminated.
Go to troubleshooting symptom index for specific warning light (WP 0005).
1. Turn ignition OFF then ON (TM 9-2355-106-10). Observe IPC after gauge sweep concludes.
A gauge points to the 6 o'clock position or provides an incorrect reading.
Go to troubleshooting symptom index for specific gauge (WP 0005).
NOTE
Correct Select/Reset button function is as follows:
The Select/Reset switch controls the digital display. The switch allows the user to select modes
within each major functional area of the display and perform reset functions. Each time the
switch is momentarily depressed, it will scan through a different mode. Depressing the switch
for 3 seconds or more will clear the display or toggle between options, depending upon the
current mode. The Reset function has no effect if the parameter cannot be reset.
1. Verify Select/Reset button functions correctly.

Select/Reset button functions incorrectly.
Replace IPC. Refer to Instrument Panel Cluster (IPC) Removal and Installation (WP 0297).
1. Turn headlights ON (TM 9-2355-106-10). Verify headlight high/low beam indicator and MVLS panel dimmer
controls work correctly (TM 9-2355-106-10).
Headlight indicator or MVLS panel dimmer controls work incorrectly.
Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedure (WP 0092) and Service Headlights
1. Verify odometer backlight dimmer control works correctly (TM 9-2355-106-10).
Odometer backlight dimmer control does not work correctly.
0070–2
TM 9-2355-106-23-1 0070
INSTRUMENT PANEL CLUSTER (IPC) OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
1. Turn ignition OFF then ON (TM 9-2355-106-10). Turn headlights ON (TM 9-2355-106-10). Pump brakes to
reduce air pressure below 70 psi (482.6 kPa). Verify alarm sounds when air pressure is below 70 psi (482.6
kPa).
Alarm does not sound when air pressure is below 70 psi (482.6 kPa).
Go to Audible Alarm Troubleshooting Procedure (WP 0088).
END OF WORK PACKAGE
0070–3/blank
TM 9-2355-106-23-1 0071
FIELD MAINTENANCE
PROCEDURE
INITIAL SETUP:
Equipment Condition
(WP 0795, Item 37)
Materials/Parts 9-2355-106-10)
Grease (WP 0794, Item 22) Engine off (TM 9-2355-106-10)
Lockwasher (WP 0796, Item 17) MAIN POWER switch off (TM 9-2355-106-10)
References
Cabin doors open and secured (TM 9-2355-106-10)
TM 9-2355-106-10
IPC removed (WP 0297)
TM 9-2355-106-23P
WARNING
CAUTION
NOTE
0071–1
TM 9-2355-106-23-1 0071
STEP

Figure 1. Behind IPC.
DECISION
NO Go to Step 8.
STEP
DECISION
NO Go to Step 15.
0071–2
TM 9-2355-106-23-1 0071
STEP

DECISION
NO Go to Step 22.
YES Go to Step 26.
STEP

Figure 3. Passenger Side Fuse Box.
0071–3
TM 9-2355-106-23-1 0071
Is fuse F2 open?
DECISION
NO Go to Step 12.
STEP
DECISION
YES Go to Step 30.

NO Go to Step 31.
STEP

14. Measure DC voltage between fuse F2 socket terminal H2 and ground, and fuse F2 socket terminal G2 and
DECISION
NO Go to Power Distribution Troubleshooting (WP 0059).

YES Go to Step 31.
STEP

0071–4
TM 9-2355-106-23-1 0071

Figure 5. Passenger Side Fuse Box.
Is fuse F19 open?
DECISION
NO Go to Step 19.
0071–5
TM 9-2355-106-23-1 0071
STEP
DECISION
YES Go to Step 30.

NO Go to Step 31.
0071–6
TM 9-2355-106-23-1 0071
STEP

21. Measure DC voltage between fuse F19 socket terminal F1 and ground, and fuse socket F19 terminal E1 and
Figure 7. Fuse F19 Socket.
DECISION

YES Go to Step 31.
0071–7
TM 9-2355-106-23-1 0071
STEP
22. Remove nut (Figure 8, Item 1) and lockwasher (Figure 8, Item 7) from upper interior cabin IP ground stud
(Figure 8, Item 2). Discard lockwasher.
Figure 8. Driver Side IP.
23. Clean four ground wires (Figure 8, Item 3, 4, 5, and 6) at upper interior cabin IP ground stud (Figure 8, Item 2).
24. Secure four ground wires (Figure 8, Item 3, 4, 5, and 6) on ground stud (Figure 8, Item 2) with new lockwasher
(Figure 8, Item 7) and nut (Figure 8, Item 1).
DECISION
NO Go to Step 31.
0071–8
TM 9-2355-106-23-1 0071
STEP

DECISION

STEP
DECISION

MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
Replace IP harness. Refer to Instrument Panel (IP) Harness Removal and Installation (WP 0319). Return
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0071–9/blank
TM 9-2355-106-23-1 0072
FIELD MAINTENANCE
MALFUNCTIONING INSTRUMENT PANEL CLUSTER (IPC) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0299
WP 0782
Equipment Condition
(WP 0795, Item 37)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off
WARNING
CAUTION
0072–1
TM 9-2355-106-23-1 0072
MALFUNCTIONING INSTRUMENT PANEL CLUSTER (IPC) TROUBLESHOOTING PROCEDURE -

(CONTINUED)
NOTE
A correct gauge sweep is as follows:
After the ignition is turned on, a gauge sweep of the Instrument Panel Cluster (IPC) will be
performed. Each gauge must sweep from zero to maximum to zero in unison. All gauge
warning lights will illuminate along with panel warning lights applicable to features installed on
the vehicle. The YELLOW and RED ENGINE warning lamps should also illuminate. Alarms
associated with gauge warning lights will not sound. All segments of the IPC Liquid Crystal
Display (LCD) should display while the gauges sweep. At the end of the sweep, the LCD will
turn off all segments for 5 seconds, display the firmware version number, and then return
to operational mode.
STEP

2. Turn ignition switch ON while observing gauges (TM 9-2355-106-10).
Do all gauges sweep correctly?
DECISION
NO Go to Step 13.
STEP
3. Press PANEL BRT. and then ENTER on the Master Vehicle Light Switch (MVLS) while observing panel lights.
The following panel lights should light:
• Fuel level gauge light
• Speedometer light
• Tachometer light
• Water temperature gauge light
• Transmission fluid temperature gauge light
• Oil pressure gauge light
• Primary air pressure gauge light
• Secondary air pressure gauge light
• Voltmeter light
Do all panel lights illuminate?
DECISION
YES Go to Step 9.
NO Go to next step.
0072–2
TM 9-2355-106-23-1 0072

(CONTINUED)
STEP

5. Replace the suspect panel light bulb. Refer to Instrument Panel (IP) Light Bulb Removal and Installation
(WP 0299).
8. Press PANEL BRT. and then ENTER on the MVLS while observing panel lights.
Does previously malfunctioning panel light illuminate?
DECISION
NO Go to Step 22.
STEP

10. Turn ignition switch ON while observing IPC LCD (TM 9-2355-106-10).
Does IPC LCD function properly during gauge sweep?
DECISION
NO Go to Step 22.
STEP

12. Turn ignition switch ON while observing warning lamps (TM 9-2355-106-10).
Are all warning lamps for installed features illuminated during gauge sweep?
DECISION
NO Go to Step 19.
0072–3
TM 9-2355-106-23-1 0072

(CONTINUED)
STEP
13. Note which gauge malfunctioned.
Do transmission fluid temperature gauge, primary air pressure gauge, and secondary air pressure gauge
sweep correctly?
DECISION
YES Go to Step 22.

NO Go to next step.
STEP
14. Note which gauge malfunctioned.
Is transmission fluid temperature gauge malfunctioning?
DECISION
YES Go to Step 17.

NO Go to next step.
STEP
15. Swap air pressure gauges and jumper harnesses with known good air pressure gauges and harnesses.
Refer to Air 1 Pressure Gauge and Harness Removal and Installation (WP 0294) and Air 2 Pressure Gauge
and Harness Removal and Installation (WP 0295).
16. Turn ignition switch OFF then ON while observing IPC.
Does previously working gauge also work in new position?
DECISION
NO Go to Step 22.
YES Go to Step 23.
STEP
17. Swap transmission fluid temperature gauge with known-good transmission fluid temperature gauge. Refer to
Transmission Fluid Temperature Gauge and Harness Removal and Installation (WP 0293).
18. Turn ignition switch OFF then ON while observing IPC (TM 9-2355-106-10).
0072–4
TM 9-2355-106-23-1 0072

(CONTINUED)
Does transmission fluid temperature gauge sweep correctly?
DECISION
NO Go to Step 22.
STEP
19. Replace inoperative warning lamp bulb. Refer to Instrument Panel (IP) Light Bulb Removal and Installation
(WP 0299).
21. Turn ignition switch ON while observing warning lamps (TM 9-2355-106-10).
Are all warning lamps for installed features illuminated during gauge sweep?
DECISION
NO Go to Step 22.
MALFUNCTION
ACTION
Replace IPC. Go to Instrument Panel Cluster (IPC) Removal and Installation (WP 0297). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 23. Gauge is faulty.
ACTION
Replace faulty gauge and jumper harness. Refer to Transmission Fluid Temperature Gauge and Harness
Removal and Installation (WP 0293), Air 1 Pressure Gauge and Harness Removal and Installation (WP 0294),
or Air 2 Pressure Gauge and Harness Removal and Installation (WP 0295). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0072–5/blank
TM 9-2355-106-23-1 0073
FIELD MAINTENANCE
YELLOW ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:

Equipment Condition
70)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353
WARNING
NOTE
STEP

2. Turn ignition switch ON while observing YELLOW ENGINE warning lamp (TM 9-2355-106-10).
Does YELLOW ENGINE warning lamp illuminate during gauge sweep?
DECISION
NO Go to Step 4.
0073–1
TM 9-2355-106-23-1 0073
YELLOW ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
3. Place vehicle in diagnostic mode while observing YELLOW ENGINE warning lamp. Refer to Diagnostic
Trouble Code (DTC) Access Procedure (WP 0012).
Does YELLOW ENGINE warning lamp illuminate while vehicle is in diagnostic mode?
DECISION
NO Go to Step 5.
MALFUNCTION
- 4. Instrument Panel Cluster (IPC) is faulty.
ACTION
END OF TEST
MALFUNCTION
- 5. Electronic System Controller (ESC) is faulty.
ACTION
Replace ESC. Refer to Electronic System Controller (ESC) Removal and Installation (WP 0353).
END OF TEST
END OF WORK PACKAGE
0073–2
TM 9-2355-106-23-1 0074
FIELD MAINTENANCE
RED ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Equipment Condition
70)
TM 9-2355-106-10 Engine off (TM 9-2355-106-10)
WP 0006 Cabin doors open and secured (TM 9-2355-106-10)
WP 0329
WARNING
NOTE
0074–1
TM 9-2355-106-23-1 0074
RED ENGINE WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
4. Retrieve DTCs with MSD.
Are engine DTCs set?
DECISION
YES Go to Engine Diagnostic Trouble Code (DTC) Index (WP 0006).

NO Go to next step.
STEP

6. Turn ignition switch ON while observing RED ENGINE warning lamp (TM 9-2355-106-10).
Does RED ENGINE warning lamp illuminate during gauge sweep?
DECISION
NO Go to Step 12.
STEP
7. Disconnect coolant level sensor connector. Refer to Figure 1.
0074–2
TM 9-2355-106-23-1 0074
Figure 1. Right Side of Radiator.
8. Install jumper wire between terminal A and B of connector 6401M. Refer to Figure 1.
9. Start engine and let idle (TM 9-2355-106-10).
Does RED ENGINE warning lamp flash?
DECISION

NO Go to next step.
STEP
10. With MSD, verify Engine Control Module (ECM) sends request to flash RED ENGINE warning lamp.
Does ECM send request to flash RED ENGINE warning lamp?
DECISION
NO Go to next step.
YES Go to Step 12.
0074–3
TM 9-2355-106-23-1 0074
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0074–4
TM 9-2355-106-23-1 0075
FIELD MAINTENANCE
CHECK TRANSMISSION LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70)
Equipment Condition
TM 9-2355-106-23P 9-2355-106-10)
WP 0011 Engine off (TM 9-2355-106-10)
WARNING
NOTE
STEP
4. Retrieve Diagnostic Trouble Code (DTC) data with MSD.
Are transmission DTCs set?
DECISION
YES Go to Transmission Operational Checkout Procedure (WP 0142).

NO Go to next step.
0075–1
TM 9-2355-106-23-1 0075
CHECK TRANSMISSION LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP

6. Turn ignition switch ON while observing check transmission warning lamp in Instrument Panel Cluster (IPC)
(TM 9-2355-106-10).
Does check transmission warning lamp illuminate during gauge sweep and go out after gauge sweep (TM
9-2355-106-10)?
DECISION
NO Go to Step 9.
STEP
7. Command check transmission warning lamp ON and OFF with MSD.
Does check transmission lamp turn ON and OFF when commanded with MSD?
DECISION

NO Go to next step Step 8.
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 9. IPC is faulty.
ACTION
Replace IPC. Refer to Instrument Panel Cluster Removal and Installation (WP 0297). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0075–2
TM 9-2355-106-23-1 0076
FIELD MAINTENANCE
COOLANT LEVEL WARNING LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
Equipment Condition
WARNING
NOTE
STEP

2. Turn ignition switch ON while observing COOLANT LEVEL warning lamp (TM 9-2355-106-10).
Does COOLANT LEVEL warning lamp illuminate during gauge sweep and turn off after gauge sweep?
DECISION
NO Go to Step 3.
0076–1
TM 9-2355-106-23-1 0076
COOLANT LEVEL WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
MALFUNCTION
- 3. IPC is faulty.
ACTION
Replace Instrument Panel Cluster (IPC). Refer to Instrument Panel Cluster (IPC) Removal and Installation
END OF TEST
END OF WORK PACKAGE
0076–2
TM 9-2355-106-23-1 0077
FIELD MAINTENANCE
PARK BRAKE WARNING LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0327
WP 0782
Equipment Condition
(WP 0795, Item 37)
Terminal Test Kit (ZTSE 4435C) (WP 0795, Item
122)
9-2355-106-10)
WP 0011
WP 0319 Schematic (WP 0789, Figure 38),
LAMP FUNCTION
The park brake lamp should light during the IPC gauge sweep after the ignition is turned ON. The lamp will go out
when the park brake is released. If the park brake is not engaged when the ignition is turned ON, the lamp should
go out after approximately 5 seconds. The light should go out when the park brake is released.
WARNING
CAUTION
NOTE
0077–1
TM 9-2355-106-23-1 0077
PARK BRAKE WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
1. Connect MSD. Refer to Connecting MSD (WP 0011).

Does park brake warning lamp illuminate during gauge sweep?
DECISION
NO Go to Step 28.
STEP
4. Activate park brake warning lamp with MSD.
Does park brake warning lamp illuminate when activated with MSD?
DECISION
NO Go to Step 29.
STEP
5. Start vehicle and build air pressure to at least 80 psi (3.83 kPa) (TM 9-2355-106-10).
6. Monitor park brake transducer inputs to ESC with MSD.
7. Move park brake control in and out while observing MSD (TM 9-2355-106-10).
Do inputs to MSD correspond correctly with park brake control position?
DECISION

NO Go to next step.
0077–2
TM 9-2355-106-23-1 0077
STEP
8. Disconnect Park Brake connector 1813. Refer to Figure 1.
9. Connect and disconnect jumper wire between connector 1813 terminals C and D while observing MSD.
Refer to Figure 1.
Do MSD inputs change as jumper wire is connected and disconnected?
DECISION
YES Go to Step 30.

NO Go to next step.
STEP

12. Measure resistance between connector 1813 terminal D and ground with multimeter. Refer to Figure 1.
0077–3
TM 9-2355-106-23-1 0077
DECISION
NO Go to Step 23.
STEP

15. Measure DC voltage between connector 1813 terminal C and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 29.

NO Go to next step.
STEP
16. Disconnect Cabin (CAB)/Driver Control Module (DCM) connector 1800. Refer to Figure 3.
0077–4
TM 9-2355-106-23-1 0077
17. Measure DC voltage between connector 1800 terminal B7 and ground with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 31.

NO Go to next step.
0077–5
TM 9-2355-106-23-1 0077
STEP

20. Disconnect Electronic System Controller (ESC) connector 1600. Refer to Figure 4.
DECISION
NO Go to Step 27.
0077–6
TM 9-2355-106-23-1 0077
STEP
22. Measure resistance between connector 1600 terminal 32 and connector 1800 terminal B7 with multimeter.
DECISION
NO Go to Step 27.
YES Go to Step 29.
0077–7
TM 9-2355-106-23-1 0077
STEP
24. Measure resistance between connector 1813 terminal D and connector 1600 terminal 3 with multimeter.
0077–8
TM 9-2355-106-23-1 0077
DECISION
YES Go to Step 29.

NO Go to next step.
STEP
26. Measure resistance between connector 1805 terminal A4 and connector 1813 terminal D with multimeter.
0077–9
TM 9-2355-106-23-1 0077
DECISION
YES Go to Step 27.

NO Go to Step 31.
MALFUNCTION
ACTION
Replace instrument panel wiring harness. Refer to Instrument Panel (IP) Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
0077–10
TM 9-2355-106-23-1 0077
MALFUNCTION
- 30. Park brake switch is faulty.
ACTION
Replace park brake switch. Refer to Park Brake Lamp Transducer Removal and Installation (WP 0327).
END OF TEST
MALFUNCTION
ACTION
Replace steering column wiring harness. Refer to Steering Column Harness Removal and Installation
END OF TEST
END OF WORK PACKAGE
0077–11/blank
TM 9-2355-106-23-1 0078
FIELD MAINTENANCE
DIAGNOSTIC CONNECTOR TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Equipment Condition
Personnel Required Parking brake set (TM 9-2355-106-10)
Maintainer - (2) Transmission set in NEUTRAL (N) (TM
9-2355-106-10)
References
Engine off (TM 9-2355-106-10)
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0321
DIAGNOSTIC TROUBLE CODES (DTCS)

There are no DTCs associated with the diagnostic connector circuits. A fault with the diagnostic connector data link
circuits will prevent DTCs from being read.
WARNING
0078–1
TM 9-2355-106-23-1 0078
DIAGNOSTIC CONNECTOR TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP
1. Measure resistance between connector 1650 terminal A and cabin ground stud with multimeter. Refer to
Figure 1. Refer to Figure 2.
Figure 1. Left of Steering Column.
0078–2
TM 9-2355-106-23-1 0078
Figure 2. Firewall, Above Electronic System Controller (ESC).
DECISION
YES Go to Step 6.
NO Go to next step.
STEP
2. Disconnect all ground terminal connectors at ground stud. Refer to Cabin Electrical Ground Stud Plate
3. Clean all connections between ground terminal connectors and ground stud.
4. Connect ground terminal connections at ground stud.
0078–3
TM 9-2355-106-23-1 0078
5. Measure resistance between connector 1650 terminal A and ground stud. Refer to Figure 3.
DECISION
NO Go to Step 33.
STEP

DECISION
NO Go to Step 13.
STEP
9. Measure DC voltage between 1650 terminals C and A with multimeter. Refer to Figure 3.
DECISION
NO Refer to Multiplexing Data Link Circuits Troubleshooting Procedure (WP 0067).

0078–4
TM 9-2355-106-23-1 0078
STEP
10. Measure DC voltage between connector 1650 terminals D and A with multimeter. Refer to Figure 3.
Does multimeter read DC voltage between 1V and 4V?
DECISION
NO Refer to Multiplexing Data Link Circuits Troubleshooting Procedure (WP 0067).

STEP
11. Measure DC voltage between connector 1650 terminals F and A with multimeter. Refer to Figure 3.
Does multimeter read DC voltage between 2.5V and 4.5V?
DECISION
NO Refer to American Truckers Association (ATA) Communications/Data Communications Link (DLC)

STEP
12. Measure DC voltage between connector 1650 terminals G and A with multimeter. Refer to Figure 3.
DECISION
NO Refer to American Truckers Association (ATA) Communications/Data Communications Link (DLC)

0078–5
TM 9-2355-106-23-1 0078
STEP

15. Remove and inspect fuse F6. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and
Installation (WP 0317). Refer to Figure 4.
Figure 4. Right Side Instrument Panel.
Is fuse blown?
DECISION
NO Go to Step 23.
STEP
16. Measure resistance between fuse block 1011 terminal F2 and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 33.
STEP
17. Install new fuse in fuse block 1011 circuit F6. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay
22. Remove and inspect fuse F6 for blown fuse. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay
Is fuse blown?
0078–6
TM 9-2355-106-23-1 0078
DECISION
YES Go to Step 33.

NO Return to service.
STEP

25. Measure DC voltage between fuse block 1011 terminal E2 and ground with multimeter. Refer to Figure 4.
DECISION
NO Go to Step 33.
STEP

27. Turn MAIN POWER OFF (TM 9-2355-106-10).
28. With assistance, measure resistance between fuse block 1011 terminal F2 and connector 1650 terminal B with
0078–7
TM 9-2355-106-23-1 0078
DECISION
NO Go to Step 33.
STEP
29. Install fuse F6 in fuse block 1011. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal
32. Measure DC voltage between connector 1650 terminals B and A with multimeter. Refer to Figure 6.
DECISION

NO Go to Step 33.
MALFUNCTION
ACTION
END OF TEST
END OF WORK PACKAGE
0078–8
TM 9-2355-106-23-1 0079
FIELD MAINTENANCE
ANTILOCK BRAKE SYSTEM (ABS) WARNING LAMP TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Equipment Condition
70)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353

• 2023 14 150 8
• 2023 14 250 8
WARNING
NOTE
0079–1
TM 9-2355-106-23-1 0079
ANTILOCK BRAKE SYSTEM (ABS) WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
Does ABS warning lamp illuminate during gauge sweep?
DECISION
NO Go to Step 11.
STEP
4. Activate ABS warning lamp with MSD.
Does ABS warning lamp illuminate?
DECISION

NO Go to next step.
STEP

7. Substitute known-good Instrument Panel Cluster (IPC). Refer to Instrument Panel Cluster (IPC) Removal and
10. Activate ABS warning lamp with MSD.
Does ABS warning lamp illuminate when activated with MSD?
DECISION
YES Go to Step 11.

NO Go to Step 12.
0079–2
TM 9-2355-106-23-1 0079
ANTILOCK BRAKE SYSTEM (ABS) WARNING LAMP TROUBLESHOOTING PROCEDURE - (CONTINUED)
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0079–3/blank
TM 9-2355-106-23-1 0080
FIELD MAINTENANCE
12V VOLTMETER OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70) WP 0782

General Mechanic's Tool Kit (GMTK) (Item 37) Parking brake set (TM 9-2355-106-10)
TM 9-2355-106-10 Engine off (TM 9-2355-106-10)
TM 9-2355-106-23P MAIN POWER switch OFF (TM 9-2355-106-10)

• 1705 14 109 3
• 1705 14 109 4
• 1705 14 109 5
• 1705 14 109 6
• 2023 14 109 5 or 2023 14 209 5
• 2023 14 109 6 or 2023 14 209 6
• 2023 14 109 7 or 2023 14 209 7
WARNING
NOTE
STEP
1. Turn MAIN POWER switch ON while observing 12-volt gauge (TM 9-2355-106-10). 12-volt gauge should
sweep from 10 volts to 16 volts and back to 10 volts.
0080–1
TM 9-2355-106-23-1 0080
12V VOLTMETER OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
12-volt gauge does not sweep correctly during gauge sweep.

CORRECTIVE ACTION
2. Activate 12-volt gauge with MSD.
12-volt gauge does not perform correctly when activated with MSD.
Replace Electronic System Controller (ESC). Refer to Electronic System Controller (ESC) Removal and Installation
END OF WORK PACKAGE
0080–2
TM 9-2355-106-23-1 0081
FIELD MAINTENANCE
ENGINE COOLANT TEMPERATURE GAUGE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
70)
Equipment Condition
TM 9-2355-106-23P 9-2355-106-10)
WP 0011 Engine off (TM 9-2355-106-10)

• DTC 1705 14 103 3
• DTC 1705 14 103 4
• DTC 1705 14 103 5
• DTC 1705 14 103 6
• DTC 2023 14 103 5 or 2023 14 203 5
• DTC 2023 14 103 6 or 2023 14 203 6
• DTC 2023 14 103 7 or 2023 14 203 7
WARNING
NOTE
STEP
2. Turn ignition switch ON while observing engine coolant temperature gauge (TM 9-2355-106-10). Engine
coolant temperature gauge should sweep from 140°F to 260°F and back to 140°F.
0081–1
TM 9-2355-106-23-1 0081
ENGINE COOLANT TEMPERATURE GAUGE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Engine coolant temperature gauge does not sweep correctly during gauge sweep.
CORRECTIVE ACTION
Replace instrument panel cluster. Refer to Instrument Panel Cluster (IPC) Removal and Installation (WP 0297).
2. Activate engine coolant temperature gauge with MSD.
Engine coolant temperature gauge does not perform correctly when activated with MSD.
Replace Electronic System Controller. Refer to Electronic System Controller (ESC) Removal and Installation
(WP 0353).
END OF WORK PACKAGE
0081–2
TM 9-2355-106-23-1 0082
FIELD MAINTENANCE
ENGINE OIL PRESSURE GAUGE OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Equipment Condition
70)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0577

• 1705 14 105 3
• 1705 14 105 4
• 1705 14 105 5
• 1705 14 105 6
• 2023 14 105 5 or 2023 14 205 5
• 2023 14 105 6 or 2023 14 205 6
• 2023 14 105 7 or 2023 14 205 7
0082–1
TM 9-2355-106-23-1 0082
ENGINE OIL PRESSURE GAUGE OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
WARNING
NOTE
STEP
2. Turn ignition switch ON while observing oil pressure gauge (TM 9-2355-106-10). Oil pressure gauge should
sweep from 0 psi to 100 psi and back to 0 psi.
Engine oil pressure gauge does not sweep correctly during gauge sweep.
CORRECTIVE ACTION
2. Activate engine oil pressure gauge with MSD.
Engine oil pressure gauge does not perform correctly when activated with MSD.
END OF WORK PACKAGE
0082–2
TM 9-2355-106-23-1 0083
FIELD MAINTENANCE
SPEEDOMETER OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Equipment Condition
70)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353

• 1705 14 102 3
• 1705 14 102 4
• 1705 14 102 5
• 1705 14 102 6
• 2023 14 102 5 or 2023 14 202 5
• 2023 14 102 6 or 2023 14 202 6
• 2023 14 102 7 or 2023 14 202 7
0083–1
TM 9-2355-106-23-1 0083
SPEEDOMETER OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
WARNING
NOTE
STEP
2. Turn ignition switch ON while observing speedometer (TM 9-2355-106-10). Speedometer should sweep from
0 mph (0 km/h) to 85 mph (137 km/h) and back to 0 mph (0 km/h).
Speedometer does not sweep correctly during gauge sweep.
CORRECTIVE ACTION
1. Connect Maintenance Support Device (MSD). Refer to Connecting Maintenance Support Device (MSD)
(WP 0011).
2. Activate speedometer with MSD.
Speedometer does not perform correctly when activated with MSD.
Replace electronic system controller. Refer to Electronic System Controller (ESC) Removal and Installation
(WP 0353).
END OF WORK PACKAGE
0083–2
TM 9-2355-106-23-1 0084
FIELD MAINTENANCE
TACHOMETER OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
Equipment Condition
70)
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353

• 1705 14 101 3
• 1705 14 101 4
• 1705 14 101 5
• 1705 14 101 6
• 2023 14 101 5 or 2023 14 201 5
• 2023 14 101 6 or 2023 14 201 6
• 2023 14 101 7 or 2023 14 201 7
0084–1
TM 9-2355-106-23-1 0084
TACHOMETER OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
WARNING
NOTE
STEP
2. Turn ignition switch ON while observing tachometer (TM 9-2355-106-10). Tachometer should sweep from
0 rpm to 4,000 rpm and back to 0 rpm.
Tachometer does not sweep correctly during gauge sweep.
CORRECTIVE ACTION
(WP 0297).
2. Activate tachometer with MSD.
Tachometer does not perform correctly when activated with MSD.
(WP 0353).
END OF WORK PACKAGE
0084–2
TM 9-2355-106-23-1 0085
FIELD MAINTENANCE
FUEL LEVEL GAUGE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0597
WP 0605
WP 0782
References
TM 9-2355-106-10
9-2355-106-10)
TM 9-2355-106-23P
Engine off (TM 9-2355-106-10)
WP 0011
WP 0071
WP 0085
WP 0297
Exterior fuel tank armor door removed (WP 0605)
WP 0335
WP 0400 WP 0789, Figure 37

• 612 14 25 1
• 612 14 25 2
• 612 14 23 1
• 612 14 23 2
• 1705 14 107 3
• 1705 14 107 4
• 1705 14 107 5
• 1705 14 107 6
• 2023 14 107 5 or 2023 207 5
• 2023 14 107 6 or 2023 207 6
• 2023 14 107 7 or 2023 207 7
0085–1
TM 9-2355-106-23-1 0085
FUEL LEVEL GAUGE TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
STEP
NOTE
1. Turn MAIN POWER switch ON while observing fuel level gauge (TM 9-2355-106-10).
Does fuel level gauge sweep from empty to full and back to empty?
DECISION
NO Go to Step 28.
STEP
3. Activate fuel level gauge with MSD.
0085–2
TM 9-2355-106-23-1 0085
Does fuel level gauge perform correctly when activated with MSD?
DECISION
NO Go to Step 29.
STEP

6. Open fuel door (TM 9-2355-106-10).
7. Disconnect left fuel sender connector 9100. Refer to Figure 1.
Figure 1. Left Fuel Tank.
DECISION
NO Go to Step 12.
0085–3
TM 9-2355-106-23-1 0085
STEP

DECISION
NO Go to Step 17.
YES Go to Step 30.
STEP
(WP 0597).
13. Disconnect chassis/dash center connector 9700. Refer to Figure 3.

0085–4
TM 9-2355-106-23-1 0085
14. Measure resistance between connector 9700 terminal D8 and ground with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 31.

NO Go to next step.
0085–5
TM 9-2355-106-23-1 0085
STEP
Figure 4. Left Front Cabin Area.
16. Measure resistance between connector 9700 Electronic System Controller (ESC) side terminal D8 and
connector 4004 terminal 26 with multimeter. Refer to Figure 4 and Figure 5.

0085–6
TM 9-2355-106-23-1 0085
DECISION
NO Go to Step 32.
YES Go to Step 29.
STEP
(WP 0597).
18. Disconnect chassis/dash center connector 9700. Refer to Figure 6.

20. Turn ignition ON (TM 9-2355-106-10).
21. Measure DC voltage between connector 9700 (ESC side) terminal B11 and ground with multimeter. Refer
to Figure 6.
DECISION
YES Go to Step 31.

NO Go to next step.
0085–7
TM 9-2355-106-23-1 0085
STEP

Figure 7. Left Front Cabin Area.
25. Measure resistance between connector 9700 (ESC side) terminal B11 and ground with multimeter. Refer
to Figure 8.
0085–8
TM 9-2355-106-23-1 0085
DECISION
NO Go to Step 32.
STEP
26. Measure resistance between connector 9700 (ESC side) terminal B11 and connector 4004 terminal 5 with
0085–9
TM 9-2355-106-23-1 0085
DECISION
NO Go to Step 32.
STEP
27. Measure resistance between connector 4004 terminal 5 and all other terminals in connector 4004 with
DECISION
NO Go to Step 32.
YES Go to Step 29.
MALFUNCTION
- 28. Instrument panel cluster is faulty.
ACTION
END OF TEST
0085–10
TM 9-2355-106-23-1 0085
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 30. Fuel level sensor is faulty.
ACTION
Replace fuel level sensor. Refer to Fuel Level Sensor Removal and Installation (WP 0397). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 31. Center chassis harness is faulty.
ACTION
Replace center chassis harness. Refer to Center Chassis Harness Removal and Installation (WP 0426).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
END OF WORK PACKAGE
0085–11/blank
TM 9-2355-106-23-1 0086
FIELD MAINTENANCE
AIR 1/PRIMARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0324
WP 0319
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353 Left cabin door open and secured (WP 0608)
This procedure covers the following Electronic System Controller (ESC) Diagnostic Trouble Codes (DTCs):
• 612 14 4 1
• 612 14 4 2
• 612 14 30 1
• 612 14 30 2
• 2023 14 108 5
• 2023 14 110 5 or 2023 14 210 5
• 2023 14 110 6 or 2023 14 210 6
• 2023 14 110 7 or 2023 14 210 7
0086–1
TM 9-2355-106-23-1 0086
AIR 1/PRIMARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0086–2
TM 9-2355-106-23-1 0086
STEP

2. Turn ignition ON (TM 9-2355-106-10) while observing primary air pressure gauge.
Does primary air pressure gauge sweep from 0 psi to 150 psi and back to 0 psi?
DECISION
NO Go to Step 63.
STEP
3. Connect MSD. Refer to Connecting Maintenance Support Device (WP 0011).

4. Activate primary air pressure gauge with MSD.
Does primary air pressure gauge perform correctly when activated with MSD?
DECISION
NO Go to Step 66.
0086–3
TM 9-2355-106-23-1 0086
STEP

7. Disconnect primary air pressure transducer harness connector 1811. Refer to Figure 1.
Figure 1. Driver Side Floor Area.
Figure 1.
DECISION
NO Go to Step 13.
0086–4
TM 9-2355-106-23-1 0086
STEP

11. Measure DC voltage between harness connector 1811 terminal B and ground with multimeter. Refer to
Figure 1.
DECISION
NO Go to Step 17.
STEP
12. Measure DC voltage between harness connector 1811 terminals B and C with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 40.
YES Go to Step 67.
0086–5
TM 9-2355-106-23-1 0086
STEP
14. Measure resistance between harness connector 1800 terminal A4 and ground with multimeter. Refer
to Figure 3.
Does multimeter read less then 5 ohms?
DECISION
YES Go to Step 69.

NO Go to next step.
0086–6
TM 9-2355-106-23-1 0086
STEP
16. Measure resistance between harness connector 1800 terminal A4 and harness connector 1600 terminal 3
0086–7
TM 9-2355-106-23-1 0086
DECISION
NO Go to Step 70.
YES Go to Step 66.
STEP

Figure 6.
DECISION
YES Go to Step 34.

NO Go to next step.
STEP

Figure 6.
DECISION
YES Go to Step 28.

NO Go to next step.
0086–8
TM 9-2355-106-23-1 0086
STEP
to Figure 7.
DECISION
YES Go to Step 69.

NO Go to Step 70.
0086–9
TM 9-2355-106-23-1 0086
STEP
1600 with multimeter. Refer to Figure 8.
DECISION
NO Go to Step 32.
STEP
0086–10
TM 9-2355-106-23-1 0086
DECISION
YES Go to Step 66.

NO Go to next step.
STEP
31. Measure resistance between harness connector 1800 terminal B3 and harness connector 1600 terminal 27
0086–11
TM 9-2355-106-23-1 0086
DECISION
YES Go to Step 69.

NO Go to Step 70.
STEP

33. Measure resistance between ESC harness connector 1600 terminal 27 and all other terminals in harness
connector 1600 with multimeter. Refer to Figure 11.
DECISION
NO Go to Step 70.
YES Go to Step 69.
0086–12
TM 9-2355-106-23-1 0086
STEP


39. Measure DC voltage between harness connector 1800 terminal B3 and ground with multimeter. Refer to
Figure 12.
DECISION
NO Go to Step 69.
YES Go to Step 70.
STEP

0086–13
TM 9-2355-106-23-1 0086

Figure 14.
DECISION
YES Go to Step 57.

NO Go to next step.
0086–14
TM 9-2355-106-23-1 0086
STEP

48. Measure resistance between harness connector 1811 terminal C and ground with multimeter. Refer to
Figure 15.
DECISION
YES Go to Step 51.

NO Go to next step.
0086–15
TM 9-2355-106-23-1 0086
STEP
Figure 16.
DECISION
NO Go to Step 70.
YES Go to Step 69.
0086–16
TM 9-2355-106-23-1 0086
STEP
DECISION
YES Go to Step 54.

NO Go to next step.
0086–17
TM 9-2355-106-23-1 0086
STEP
DECISION
YES Go to Step 69.

NO Go to Step 70.
0086–18
TM 9-2355-106-23-1 0086
STEP
54. Measure resistance between harness connector 1811 terminal C and harness connector 1600 terminal 15
DECISION
YES Go to Step 66.

NO Go to next step.
0086–19
TM 9-2355-106-23-1 0086
STEP
56. Measure resistance between harness connector 1800 terminal C12 and harness connector 1600 terminal 15
DECISION
NO Go to Step 70.
YES Go to Step 69.
0086–20
TM 9-2355-106-23-1 0086
STEP


62. Measure DC voltage between harness connector 1800 terminal C12 and ground with multimeter. Refer to
Figure 22.
DECISION
NO Go to Step 69.
YES Go to Step 70.
STEP
63. Substitute known good primary air pressure gauge. Refer to Air 1 Pressure Gauge and Harness Removal and
0086–21
TM 9-2355-106-23-1 0086

65. Turn ignition switch ON while observing primary air pressure gauge (TM 9-2355-106-10). Primary air pressure
gauge should sweep from 0 psi to 150 psi and back to 0 psi.
Does primary air pressure gauge sweep correctly during gauge sweep?
DECISION
NO Go to Step 68.
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 67. Primary air pressure transducer is faulty.
ACTION
Replace primary air pressure transducer. Refer to Air Gauge Transducer Removal and Installation (WP 0322).
END OF TEST
MALFUNCTION
- 68. Instrument panel cluster (IPC) is faulty.
ACTION
END OF TEST
0086–22
TM 9-2355-106-23-1 0086
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 70. Instrument panel (IP) harness is faulty.
ACTION
Replace instrument panel harness. Refer to Instrument Panel (IP) Harness Removal and Installation
END OF TEST
END OF WORK PACKAGE
0086–23/blank
TM 9-2355-106-23-1 0087
FIELD MAINTENANCE
AIR 2/SECONDARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0324
WP 0319
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0353 Left cabin door open and secured (WP 0608)
This procedure covers the following Electronic System Controller (ESC) Diagnostic Trouble Codes (DTCs):
• 612 14 3 1
• 612 14 3 2
• 612 14 30 1
• 612 14 30 2
• 2023 14 108 5
• 2023 14 110 5 or 2023 14 210 5
• 2023 14 110 6 or 2023 14 210 6
• 2023 14 110 7 or 2023 14 210 7
0087–1
TM 9-2355-106-23-1 0087
AIR 2/SECONDARY AIR PRESSURE GAUGE TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
STEP

2. Turn ignition ON (TM 9-2355-106-10) while observing secondary air pressure gauge.
Does secondary air pressure gauge sweep from 0 psi to 150 psi and back to 0 psi?
DECISION
NO Go to Step 63.
STEP
3. Connect MSD. Refer to Connecting Maintenance Support Device (WP 0011).

4. Activate secondary air pressure gauge with MSD.
Does secondary air pressure gauge perform correctly when activated with MSD?
0087–2
TM 9-2355-106-23-1 0087
DECISION
NO Go to Step 66.
STEP

7. Disconnect secondary air pressure transducer harness connector 1812. Refer to Figure 1.
Figure 1.
DECISION
NO Go to Step 13.
STEP
0087–3
TM 9-2355-106-23-1 0087

Figure 1.
DECISION
NO Go to Step 17.
STEP
12. Measure DC voltage between harness connector 1812 terminals B and C with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 40.
YES Go to Step 67.
0087–4
TM 9-2355-106-23-1 0087
STEP
14. Measure resistance between harness connector 1800 terminal A4 and ground with multimeter. Refer
to Figure 3.
DECISION
YES Go to Step 69.

NO Go to next step.
0087–5
TM 9-2355-106-23-1 0087
STEP
16. Measure resistance between harness connector 1800 terminal A4 and harness connector 1600 terminal 3
DECISION
NO Go to Step 70.
0087–6
TM 9-2355-106-23-1 0087
YES Go to Step 66.
STEP

Figure 6.
DECISION
YES Go to Step 34.

NO Go to next step.
STEP

Figure 6.
DECISION
YES Go to Step 28.

NO Go to next step.
0087–7
TM 9-2355-106-23-1 0087
STEP
to Figure 7.
DECISION
YES Go to Step 69.

NO Go to Step 70.
0087–8
TM 9-2355-106-23-1 0087
STEP
DECISION
NO Go to Step 32.
0087–9
TM 9-2355-106-23-1 0087
STEP
DECISION
YES Go to Step 66.

NO Go to next step.
STEP
0087–10
TM 9-2355-106-23-1 0087
0087–11
TM 9-2355-106-23-1 0087
DECISION
YES Go to Step 69.

NO Go to Step 70.
STEP

DECISION
NO Go to Step 70.
YES Go to Step 69.
STEP

0087–12
TM 9-2355-106-23-1 0087

Figure 12.
DECISION
NO Go to Step 69.
YES Go to Step 70.
0087–13
TM 9-2355-106-23-1 0087
STEP


0087–14
TM 9-2355-106-23-1 0087
Figure 14.
DECISION
YES Go to Step 57.

NO Go to next step.
STEP

48. Measure resistance between harness connector 1812 terminal C and ground with multimeter. Refer to
Figure 15.
DECISION
YES Go to Step 51.

NO Go to next step.
0087–15
TM 9-2355-106-23-1 0087
STEP
50. Measure resistance between harness connector 1800 terminal B2 and ground with multimeter. Refer to
Figure 16.
DECISION
NO Go to Step 70.
YES Go to Step 69.
0087–16
TM 9-2355-106-23-1 0087
STEP
DECISION
YES Go to Step 54.

NO Go to next step.
0087–17
TM 9-2355-106-23-1 0087
STEP
DECISION
YES Go to Step 69.

NO Go to Step 70.
0087–18
TM 9-2355-106-23-1 0087
STEP
54. Measure resistance between harness connector 1812 terminal C and harness connector 1600 terminal 16
DECISION
YES Go to Step 66.

NO Go to next step.
0087–19
TM 9-2355-106-23-1 0087
STEP
DECISION
NO Go to Step 70.
YES Go to Step 69.
0087–20
TM 9-2355-106-23-1 0087
STEP


Figure 22.
DECISION
NO Go to Step 69.
YES Go to Step 70.
0087–21
TM 9-2355-106-23-1 0087
STEP
63. Substitute known good secondary air pressure gauge. Refer to Air 2 Pressure Gauge and Harness Removal
65. Turn ignition switch ON while observing secondary air pressure gauge (TM 9-2355-106-10). Secondary air
pressure gauge should sweep from 0 psi to 150 psi and back to 0 psi.
Does secondary air pressure gauge sweep correctly during gauge sweep?
DECISION
NO Go to Step 68.
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 67. Secondary air pressure transducer is faulty.
ACTION
Replace secondary air pressure transducer. Refer to Air Gauge Transducer Removal and Installation
END OF TEST
MALFUNCTION
- 68. Instrument panel cluster (IPC) is faulty.
ACTION
END OF TEST
MALFUNCTION
ACTION
0087–22
TM 9-2355-106-23-1 0087
END OF TEST
MALFUNCTION
ACTION
Replace instrument panel harness. Refer to Instrument Panel (IP) Harness Removal and Installation
END OF TEST
END OF WORK PACKAGE
0087–23/blank
TM 9-2355-106-23-1 0088
FIELD MAINTENANCE
AUDIBLE ALARM OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
Equipment Condition
NOTE
STEP
3. Turn service drive lights ON (TM 9-2355-106-10).
4. Push brake pedal repeatedly until air pressure gauges read below 70 psi (TM 9-2355-106-10).
Alarm does not sound.
CORRECTIVE ACTION
2. Idle engine until air pressure gauges read over 70 psi (TM 9-2355-106-10).
Alarm does not stop sounding.
END OF WORK PACKAGE
0088-1/blank
TM 9-2355-106-23-1 0089
FIELD MAINTENANCE
ETHER START CIRCUIT TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0336
WP 0597
Materials/Parts
WP 0782
Maintainer - (2) Vehicle parking brake set (TM 9-2355-106-10)
TM 9-2355-106-10 Engine off (TM 9-2355-106-10)
WP 0272 Left side engine armor plate removed (WP 0597)
WP 0274
WP 0317 WP 0789, Figure 71
0089–1
TM 9-2355-106-23-1 0089
ETHER START CIRCUIT TROUBLESHOOTING PROCEDURE - (CONTINUED)
STEP
WARNING
Ether canisters contain hazardous, combustible and flammable materials. Handle with care and
dispose of in accordance with standard operating procedures. Use approved respirator with
dual organic vapor/mist and particulate cartridge. Avoid contact with skin and eyes, and avoid
breathing fumes. If swallowed, do not induce vomiting. Obtain immediate medical attention.
Ether canisters are pressurized, combustible and flammable. Keep away from flames and
sparks. Do not incinerate or puncture canister. Do not expose to temperatures above 120°F
(49°C). Do not store spare canister in vehicle cab. Failure to comply may result in serious
CAUTION
NOTE
0089–2
TM 9-2355-106-23-1 0089
1. Install new ether canister and verify system operation (TM 9-2355-106-10). Refer to Ether Canister Removal
Is ether start operational (TM 9-2355-106-10)?
DECISION

NO Go to next step.
STEP

4. Disconnect connectors 6550M/thermostatic switch. Refer to Figure 1.
Figure 1. Left Rear Cylinder Head.
5. Install jumper wire between connector 6550M terminals A and B. Refer to Figure 1.
6. Disconnect connector 8400B. Refer to Figure 2.
0089–3
TM 9-2355-106-23-1 0089
Figure 2. Left Side of Engine Compartment.

9. With assistance, measure DC voltage between connector 8400B terminal B and ground with multimeter while
ether start switch is activated. Refer to Figure 2.
DECISION
NO Go to Step 11.
STEP
10. With assistance, measure DC voltage between connector 8400B terminal B and terminal A with multimeter
while ether start switch is activated. Refer to Figure 2.
DECISION
YES Go to Step 40.

NO Go to Step 29.
STEP

0089–4
TM 9-2355-106-23-1 0089

13. Disconnect connector 4301 from 4300 (22 wires). Refer to Figure 3.
Figure 3. Under Power Distribution Center (PDC).

16. With assistance, measure DC voltage between connector 4301 terminal 19 and ground with multimeter while
ether start switch is activated. Refer to Figure 3.
DECISION
YES Go to Step 47.

NO Go to next step.
STEP
0089–5
TM 9-2355-106-23-1 0089

Figure 4. Right Side of Dash.

22. Measure DC voltage between connector 1010 terminal 2B and ground with multimeter. Refer to Figure 4.
DECISION
YES Go to Step 35.

NO Go to next step.
0089–6
TM 9-2355-106-23-1 0089
STEP

25. Remove and inspect F33 circuit breaker. Refer to Figure 5. Refer to Instrument Panel (IP) Circuit Breaker,
Figure 5. Behind Instrument Panel (IP) Closeout Panel.
Is circuit breaker tripped?
DECISION
YES Go to Step 43.

NO Go to next step.
STEP

28. With circuit breaker removed, measure DC voltage between F33 terminal A1 and ground with multimeter.
Refer to Figure 5.
DECISION
NO Refer to Power Distribution Troubleshooting Procedure (WP 0059).

YES Go to Step 48.
0089–7
TM 9-2355-106-23-1 0089
STEP

31. Disconnect connector 4301 from 4300 (22 wires). Refer to Figure 6.
Figure 6. Engine Compartment Under Air Cleaner.
DECISION
YES Go to Step 47.

NO Go to next step.
0089–8
TM 9-2355-106-23-1 0089
STEP
33. Disconnect connector 4100F (18 wires). Refer to Figure 7.
Figure 7. Engine Compartment Under Air Cleaner.
DECISION
YES Go to Step 47.

NO Go to Step 52.
0089–9
TM 9-2355-106-23-1 0089
STEP

37. With assistance, measure resistance between connector 1010 terminal 3 and connector 4301 terminal 19 with
DECISION
YES Go to Step 50.

NO Go to next step.
0089–10
TM 9-2355-106-23-1 0089
STEP
Figure 10. Above Power Distribution Center (PDC) on Bulkhead.
39. With assistance, measure resistance between connector 1701 terminal 29 and connector 1010 terminal 3
DECISION
NO Go to Step 48.
YES Go to Step 49.
0089–11
TM 9-2355-106-23-1 0089
STEP
NOTE
Thermal switch must be cooled or ambient temperature must be below 40°F (4.4°C) before
test can be performed.

42. Measure resistance between thermostatic switch connector terminals A and B with multimeter. Refer to
Figure 11.
Figure 11. Left Rear Cylinder Head.
DECISION
NO Go to Step 46.
YES Go to Step 51.
0089–12
TM 9-2355-106-23-1 0089
STEP
43. Reset and install breaker. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and
Did breaker trip?
DECISION

MALFUNCTION
- 46. Ether (cold) start valve is faulty.
ACTION
Replace ether (cold) start valve. Refer to Ether (COLD) Start Valve Removal and Installation (WP 0272).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 49. Power distribution center (PDC) harness is faulty.
ACTION
0089–13
TM 9-2355-106-23-1 0089
END OF TEST
MALFUNCTION
- 50. Ether start switch is faulty.
ACTION
Replace ether start switch. Refer to Ether Start Switch Removal and Installation (WP 0300). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 51. Ether thermal switch is faulty.
ACTION
Replace ether thermal switch. Refer to Ether Thermal Switch Removal and Installation (WP 0274). Return
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0089–14
TM 9-2355-106-23-1 0090
FIELD MAINTENANCE
EXHAUST BRAKE TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
Terminal Test Kit (WP 0795, Item 122) Parking brake set (TM 9-2355-106-10)
WP 0059 Engine off (TM 9-2355-106-10)
WP 0335
WP 0597 WP 0789, Figure 68
This procedure covers the following Diagnostic Trouble Code (DTC):

• 265
0090–1
TM 9-2355-106-23-1 0090
EXHAUST BRAKE TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
When the exhaust brake switch is turned on, switch will light but no braking assist is available.
The exhaust brake system is disabled and cannot be activated via the switch. Service brake
must be primarily used when descending long grades. Use hard pressure braking with
applications of 3 to 5 seconds' duration, instead of long, continuous applications. This type
of brake application minimizes temperature rise, brake fade, and air consumption by the air
brake system. Failure to comply may result in loss of braking ability and serious injury or
death to personnel.
CAUTION
NOTE
STEP
1. Remove EXHAUST BRAKE relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal
and Installation (WP 0334) and Figure 1.
0090–2
TM 9-2355-106-23-1 0090

4. Measure DC voltage between EXHAUST BRAKE relay socket terminal 86 and ground with multimeter.
Refer to Figure 1.
DECISION

NO Go to Step 25.
STEP
5. Measure DC voltage between EXHAUST BRAKE relay socket terminal 85 and ground with multimeter.
Refer to Figure 1.
0090–3
TM 9-2355-106-23-1 0090
Does multimeter read 0V?
DECISION

NO Go to Step 13.
STEP
6. Disconnect connector 6007 from ECM. Refer to Engine Control Module (ECM) Removal and Installation
(WP 0329) and Figure 2.
Figure 2. Engine Control Module Area.
7. Measure resistance between EXHAUST BRAKE relay socket terminal 85 and ground with multimeter. Refer
to Figure 3.
Figure 3. Exhaust Brake Relay Socket.
DECISION

NO Go to Step 22.
0090–4
TM 9-2355-106-23-1 0090
STEP
8. Measure resistance between EXHAUST BRAKE relay socket terminal 85 and connector 6007 terminal 47
0090–5
TM 9-2355-106-23-1 0090
DECISION
YES Go to Step 12.

NO Go to next step.
STEP
10. Disconnect connector 4103 from 4100F (connector with 18 wires). Refer to Figure 6.
0090–6
TM 9-2355-106-23-1 0090
11. Measure resistance between connector 4103 terminal 16 and EXHAUST BRAKE relay socket terminal 85
DECISION
YES Go to Step 32.

NO Go to Step 30.
STEP
0090–7
TM 9-2355-106-23-1 0090
12. Measure resistance between EXHAUST BRAKE relay terminals 85 and 86 with multimeter. Refer to Figure 9.
Figure 9. EXHAUST BRAKE Relay.
DECISION
YES Go to Step 33.

NO Go to Step 31.
STEP


19. Measure DC voltage between connector 4100F terminal 16 and ground with multimeter. Refer to Figure 10.
0090–8
TM 9-2355-106-23-1 0090
Does multimeter read 0V?
DECISION
YES Go to Step 30.

NO Go to next step.
STEP
20. Disconnect connector 6007 from ECM. Refer to Engine Control Module (ECM) Removal and Installation
(WP 0329) and Figure 11.
21. Measure resistance between connector 6007 terminal 47 and all other terminals on connector 6007 with
DECISION
YES Go to Step 33.

NO Go to Step 32.
0090–9
TM 9-2355-106-23-1 0090
STEP
DECISION
YES Go to Step 32.

NO Go to Step 30.
STEP
25. Remove and test 5-amp EXHAUST BRAKE fuse. Refer to Power Distribution Center (PDC) Fuse and Relay
Removal and Installation (WP 0333) and Figure 13.
0090–10
TM 9-2355-106-23-1 0090
Is fuse open?
DECISION
YES Go to Step 29.

NO Go to next step.
STEP

28. Measure DC voltage between ground and each EXHAUST BRAKE fuse socket terminal (A2 and B2) with
Does multimeter read between 10.5V and 13.5V for either terminal?
0090–11
TM 9-2355-106-23-1 0090
DECISION
YES Go to Step 30.

NO Refer to Power Distribution Troubleshooting (WP 0059).
STEP
29. Measure resistance between EXHAUST BRAKE relay socket terminal 86 and ground with multimeter. Refer to
Figure 14.
DECISION
YES Go to Step 31.

NO Go to Step 30.
MALFUNCTION
- 30. Harness is faulty.
ACTION
Replace harness. Refer to Power Distribution Center (PDC) Harness Removal and Installation (WP 0335).
END OF TEST
MALFUNCTION
- 31. Exhaust brake relay is faulty.
ACTION
Replace exhaust brake relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
0090–12
TM 9-2355-106-23-1 0090
END OF TEST
MALFUNCTION
- 32. Harness is faulty.
ACTION
Replace harness. Refer to Engine Wiring Harness Removal and Installation (WP 0336). Return vehicle
to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
END OF WORK PACKAGE
0090–13/blank
TM 9-2355-106-23-1 0091
FIELD MAINTENANCE
CHARGING SYSTEM TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0240
Harness, 500 ohm resistor (ZTSE4497) WP 0782
(WP 0795, Item 4)
Equipment Condition
Materials/Parts
Goggles, industrial (WP 0794, Item 20)
Faceshield, industrial (WP 0794, Item 16)
9-2355-106-10)
Lockwasher (WP 0796, Item 9)
Engine off (TM 9-2355-106-10)
WP 0032 Perform Battery Operational Checkout Procedure
WP 0059 (WP 0032)
WP 0257
WP 0336 WP 0789, Figure 18
0091–1
TM 9-2355-106-23-1 0091
CHARGING SYSTEM TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
NOTE
0091–2
TM 9-2355-106-23-1 0091
STEP
1. Inspect for loose, worn, or damaged serpentine belt (TM 9-2355-106-10).
Did inspection reveal defective serpentine belt?
DECISION
YES Go to Serpentine Belt Removal and Installation (WP 0240).

NO Go to next step.
STEP
2. Measure DC voltage between the alternator B+ terminals (Figure 1, Item 1 and 2) and ground with multimeter.
Figure 1. Alternator, Right Side Engine.
DECISION
NO Go to Step 53.
0091–3
TM 9-2355-106-23-1 0091
STEP
3. Measure resistance between engine ground and each alternator ground terminal (Figure 2, Item 3 and
4) with multimeter.
DECISION
NO Go to Step 53.
STEP
4. Start and idle engine (TM 9-2355-106-10).

5. Measure DC voltage between alternator B+ terminal (Figure 2, Item 1 or 2) and ground with multimeter.
DECISION
NO Go to Step 7.
0091–4
TM 9-2355-106-23-1 0091
STEP
6. Measure AC voltage between alternator B+ terminal (Figure 2, Item 1 or 2) and ground with multimeter.
DECISION
NO Fault is not present. Return vehicle to service.

YES Go to Step 56.
STEP

8. Restart and idle engine (TM 9-2355-106-10).
9. Measure DC voltage between alternator B+ terminal (Figure 2, Item 1 or 2) and ground with multimeter.
DECISION
YES Go to Step 55.

NO Go to next step.
STEP
10. Recall results from test just performed.
DECISION
YES Go to Step 56.

NO Go to next step.
0091–5
TM 9-2355-106-23-1 0091
STEP
11. Measure DC voltage between alternator regulator IGN terminal (Figure 3, Item 1) and ground with multimeter.
DECISION
YES Go to Step 56.

NO Go to next step.
STEP

0091–6
TM 9-2355-106-23-1 0091
14. Remove and inspect fuse 4 from fuse block 4001. Refer to Power Distribution Center (PDC) Fuse and Relay
Removal and Installation (WP 0333). Refer to Figure 4 and Figure 5.
Is fuse open?
DECISION
NO Go to Step 24.
0091–7
TM 9-2355-106-23-1 0091
STEP
15. Remove relay 1 from fuse block 4002. Refer to Power Distribution Center (PDC) Fuse and Relay Removal
16. Install relay breakout harness (ZTSE4674) (Figure 7, Item 1) in place of relay 1 (Figure 7, Item 2) in fuse
block 4002.
Figure 7. Relay Breakout Harness (ZTSE4674).
17. Install relay 1 (Figure 7, Item 3) in connector of relay breakout harness (ZTSE4674) (Figure 7, Item 1).
18. Measure resistance between relay breakout harness terminal 30 and ground with multimeter. Refer to
Figure 7.
0091–8
TM 9-2355-106-23-1 0091
DECISION
NO Go to Step 52.
STEP
19. Remove nut, lockwasher, and alternator regulator IGN terminal (Figure 8, Item 1) from voltage regulator.
Discard lockwasher.
20. Measure resistance between IGN terminal (Figure 8, Item 1) and ground with multimeter.
DECISION
YES Go to Step 56.

NO Go to next step.
0091–9
TM 9-2355-106-23-1 0091
STEP
22. Disconnect harness connector 4103 (connector with 18 wires). Refer to Figure 9.
DECISION
NO Go to Step 52.
YES Go to Step 53.
0091–10
TM 9-2355-106-23-1 0091
STEP
24. Install fuse 4 in fuse block 4001. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
25. Remove relay 1 from fuse block 4002. Refer to Power Distribution Center (PDC) Fuse and Relay Removal
0091–11
TM 9-2355-106-23-1 0091
26. Install relay breakout harness (ZTSE4674) (Figure 12, Item 1) in place of relay 1 (Figure 12, Item 2) in
fuse block 4002.
27. Install relay 1 (Figure 12, Item 3) in connector of relay breakout harness (ZTSE4674) (Figure 12, Item 1).
30. Measure DC voltage between relay breakout harness (ZTSE4674) terminal 30 and ground with multimeter.
Refer to Figure 12.
DECISION
NO Go to Step 48.
STEP
31. Measure DC voltage between relay breakout harness (ZTSE4674) terminal 85 and ground with multimeter.
Refer to Figure 12.
DECISION

STEP

34. Measure resistance between relay breakout harness (ZTSE4674) terminal 86 and ground with multimeter.
Refer to Figure 12.
0091–12
TM 9-2355-106-23-1 0091
DECISION
NO Go to Step 52.
STEP
35. Connect 500 ohm resistor harness (ZTSE4497) between relay breakout harness (ZTSE4674) terminals 30
and 87. Refer to Figure 13 and Figure 12.
Figure 13. 500 Ohm Resistor Harness (ZTSE4497).

0091–13
TM 9-2355-106-23-1 0091
DECISION
NO Go to Step 41.
STEP
39. Start and idle engine (TM 9-2355-106-10).

DECISION
NO Go to Step 56.
YES Go to Step 54.
0091–14
TM 9-2355-106-23-1 0091
STEP

44. Disconnect harness connector 4103 (connector with 18 wires). Refer to Figure 16.

DECISION
NO Go to Step 52.
YES Go to Step 53.
0091–15
TM 9-2355-106-23-1 0091
STEP

50. Remove fuse 4 from fuse block 4001. Refer to Power Distribution Center (PDC) Fuse and Relay Removal
51. Measure resistance between relay breakout harness (ZTSE4674) terminal 30 and fuse block 4001 terminal
F2H1 with multimeter. Refer to Figure 18 and Figure 19.
0091–16
TM 9-2355-106-23-1 0091
DECISION
NO Go to Step 52.
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 54. 24V relay is faulty.
0091–17
TM 9-2355-106-23-1 0091
ACTION
Replace 24V relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
END OF TEST
MALFUNCTION
- 55. Alternator regulator responded to overvoltage condition.
ACTION
If condition continues, replace alternator. Refer to Alternator Removal and Installation (WP 0289). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 56. Alternator is faulty.
ACTION
Replace alternator. Refer to Alternator Removal and Installation (WP 0289). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0091–18
TM 9-2355-106-23-1 0092
FIELD MAINTENANCE
MASTER VEHICLE LIGHT SWITCH (MVLS) TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Equipment Condition
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0100 Instrument Panel (IP) center trim panel removed
WP 0101 (WP 0581)
WP 0104
Drawings Required
WP 0303
WP 0789, Figure 51
WP 0307
WP 0411
WARNING
CAUTION
0092–1
TM 9-2355-106-23-1 0092
MASTER VEHICLE LIGHT SWITCH (MVLS) TROUBLESHOOTING PROCEDURE - (CONTINUED)
NOTE
STEP

3. Press each button on MVLS switch while observing MVLS indicator lights (TM 9-2355-106-10).
Does each light, except for PANEL DIM, PANEL BRT, and ENTER, illuminate momentarily as the corresponding
button is pressed?
DECISION
NO Go to Step 30.
STEP
4. Press STOPLIGHT button and then press ENTER button within 5 seconds.
Do stoplights illuminate (TM 9-2355-106-10)?
DECISION
NO Go to Step 38.
STEP
5. Press SER. DRIVE button and then press ENTER button within 5 seconds.
Do driving lights illuminate (TM 9-2355-106-10)?
DECISION
NO Go to Step 46.
0092–2
TM 9-2355-106-23-1 0092
STEP
6. Press PARK button and then press ENTER button within 5 seconds.
Do park lights illuminate (TM 9-2355-106-10)?
DECISION
NO Go to Step 58.
STEP
7. Press B.O. DRIVE button and then press ENTER button within 5 seconds.
Do blackout driving lights operate correctly (TM 9-2355-106-10)?
DECISION
NO Go to Step 66.
STEP
8. Press B.O. MARKER button and then press ENTER button within 5 seconds on MVLS switch.
Do blackout marker lights operate correctly (TM 9-2355-106-10)?
DECISION
NO Go to Step 78.
STEP
9. Press PARK button and then press ENTER button within 5 seconds.
10. Press PANEL DIM button and observe instrument panel dimming.
11. Press PANEL BRT button and observe instrument panel brightness.
Does panel light dimming correspond to inputs?
DECISION
YES MVLS is operating correctly.

NO Go to next step.
0092–3
TM 9-2355-106-23-1 0092
STEP

14. Disconnect MVLS switch connector 1954. Refer to Figure 1.
Figure 1. Behind IP Center Trim Panel.
15. Connect jumper wire between connector 1954 terminal F and MVLS switch terminal F. Refer to Figure 1
and Figure 2.
Figure 2. MVLS Switch.
0092–4
TM 9-2355-106-23-1 0092

18. Press PANEL DIM button and then press the ENTER button within 5 seconds on MVLS switch.
19. Measure DC voltage between MVLS switch terminal B and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 90.
STEP
20. Press PANEL BRT button and then press the ENTER button within 5 seconds on MVLS switch.
21. Measure DC voltage between MVLS switch terminal B and ground with multimeter. Refer to Figure 2.
DECISION
NO Go to Step 90.
0092–5
TM 9-2355-106-23-1 0092
STEP

24. Remove jumper wire.
25. Connect MVLS switch connector 1954. Refer to Figure 3.
0092–6
TM 9-2355-106-23-1 0092
26. Disconnect panel light adapter splice pack 1002. Refer to Figure 4.
Figure 4. Bottom of IP Center Trim Opening.

29. Measure DC voltage from connector 1002 terminal D and ground with multimeter. Refer to Figure 4.
DECISION
YES Refer to Instrument Panel Lights Troubleshooting Procedure (WP 0104).

NO Go to Step 91.
STEP
30. Refer to results of test just performed.
Do any MVLS indicator lights illuminate?
DECISION
YES Go to Step 90.

NO Go to next step.
0092–7
TM 9-2355-106-23-1 0092
STEP

32. Turn battery switch OFF (TM 9-2355-106-10).
33. Measure resistance between LAM1111 and ground with multimeter. Refer to Figure 5.
Does multimeter read less than 1 ohm?
DECISION
NO Go to Step 88.
0092–8
TM 9-2355-106-23-1 0092
STEP
34. Disconnect MVLS connector 1954. Refer to Figure 6.

DECISION
NO Go to Step 91.
YES Go to Step 90.
0092–9
TM 9-2355-106-23-1 0092
STEP

41. Connect jumper wire between connector 1954 terminal F and MVLS switch terminal F. Refer to Figure 7
and Figure 8.

44. Press STOPLIGHT switch and then press ENTER within 5 seconds.
0092–10
TM 9-2355-106-23-1 0092
45. Measure DC voltage between connector 1954 terminals H and J to ground with multimeter. Refer to Figure 7.
DECISION
YES Refer to Stoplights Troubleshooting Procedures (WP 0101).

NO Go to Step 90.
STEP

49. Connect jumper wire between connector 1954 terminal F and MVLS switch terminal F. Refer to Figure 9 and
Figure 10.
0092–11
TM 9-2355-106-23-1 0092

52. Press SER DRIVE and then press ENTER within 5 seconds.
53. Measure DC voltage between connector 1954 terminal M and ground with multimeter. Refer to Figure 9.
DECISION
NO Go to Step 90.
STEP
54. Press PARK and then press ENTER within 5 seconds.

DECISION
NO Go to Step 90.
0092–12
TM 9-2355-106-23-1 0092
STEP
56. Press STOPLIGHT and then press ENTER within 5 seconds.

DECISION
NO Go to Step 90.
YES Refer to Service Driving Lights Troubleshooting Procedure (WP 0097) or Stoplights Troubleshooting
0092–13
TM 9-2355-106-23-1 0092
STEP

Figure 13.

64. Press SER DRIVE and then press ENTER within 5 seconds.
0092–14
TM 9-2355-106-23-1 0092
65. Measure DC voltage between connector 1954 terminals H and J and ground with multimeter. Refer to
Figure 14.
DECISION
NO Go to Step 90.
YES Refer to Clearance/Marker Lights Troubleshooting Procedure (WP 0098).
0092–15
TM 9-2355-106-23-1 0092
STEP

Figure 15. MVLS Switch Connector.
Figure 16.

72. Press B.O. DRIVE and then press ENTER within 5 seconds.
0092–16
TM 9-2355-106-23-1 0092
73. Measure DC voltage between connector 1954 terminal D and ground with multimeter. Refer to Figure 17.
DECISION
NO Go to Step 90
STEP
74. Press B.O. MARKER and then press ENTER within 5 seconds.
75. Measure DC voltage between connector 1954 terminal E and ground with multimeter. Refer to Figure 17.
DECISION
NO Go to Step 90.
0092–17
TM 9-2355-106-23-1 0092
STEP
76. Press SER DRIVE and then press ENTER within 5 seconds on the MVLS switch.
DECISION
NO Go to Step 90.
YES Refer to Blackout Driving Lights Troubleshooting Procedure (WP 0099).
STEP

0092–18
TM 9-2355-106-23-1 0092
Figure 19.

83. Turn battery ignition switch ON (TM 9-2355-106-10).
84. Press B.O. MARKER and then press ENTER within 5 seconds.
85. Measure DC voltage between connector 1954 terminal E and ground with multimeter. Refer to Figure 18.
DECISION
NO Go to Step 90.
STEP
86. Press SER DRIVE and then press ENTER within 5 seconds on the MVLS switch.
DECISION
NO Go to Step 90.
YES Refer to Blackout Marker Lights Troubleshooting Procedure (WP 0100).
0092–19
TM 9-2355-106-23-1 0092
STEP
89. Measure resistance between connector LAM1112 and ground with multimeter. Refer to Figure 20.
Does multimeter read less than 1 ohm?
DECISION
YES Go to Step 91.

NO Go to Step 92.
MALFUNCTION
- 90. Faulty MVLS.
ACTION
Replace MVLS. Refer to Master Vehicle Light Switch (MVLS) Removal and Installation (WP 0303). Return
vehicle to service.
END OF TEST
0092–20
TM 9-2355-106-23-1 0092
MALFUNCTION
- 91. Faulty harness.
ACTION
Replace IP wiring harness. Refer to Instrument Panel (IP) Feed Harness Removal and Installation (WP 0411).
END OF TEST
MALFUNCTION
- 92. Faulty harness.
ACTION
Replace harness. Refer to Master Vehicle Light Switch (MVLS) Ground Harness Removal and Installation
(WP 0307).
END OF TEST
END OF WORK PACKAGE
0092–21/blank
TM 9-2355-106-23-1 0093
FIELD MAINTENANCE
FRONT TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0367
WP 0580
Wire tags (WP 0794, Item 33) WP 0782
WP 0011 9-2355-106-10)
WP 0092 Engine off (TM 9-2355-106-10)
WP 0317 MAIN POWER switch OFF (TM 9-2355-106-10)
WP 0372
WP 0373 WP 0789, Figure 58
WP 0374 WP 0789, Figure 13
Before Beginning This Troubleshooting Procedure

Successful diagnosis of turn signal lights depends on performing various procedures in correct sequence. Failure
to comply will lead to misdiagnosis. Perform Turn Signal Lights Operational Checkout Procedure (WP 0096)
before performing tests in this troubleshooting procedure.
WARNING
0093–1
TM 9-2355-106-23-1 0093
FRONT TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP

3. Press SER. DRIVE on Master Vehicle Light Switch (MVLS) and then press ENTER within 5 seconds (TM
9-2355-106-10).
4. Activate left turn signals (TM 9-2355-106-10).
5. Observe left front turn signal lights.
6. Activate right turn signals (TM 9-2355-106-10).
7. Observe right front turn signal lights.
Are all front turn signal lights inoperative?
DECISION
YES Go to Step 123.

NO Go to next step.
STEP
8. Activate left turn signals (TM 9-2355-106-10).

Are all 3 left front turn signal lights inoperative?
DECISION
YES Go to Step 50.

NO Go to next step.
0093–2
TM 9-2355-106-23-1 0093
STEP
Are turn signal light on left front fender and turn signal light next to left headlight inoperative?
DECISION
YES Go to Step 36.

NO Go to next step.
STEP
Is turn signal light on left front fender inoperative?
DECISION
YES Go to Step 19.

NO Go to next step.
STEP
Is turn signal light next to left front headlight inoperative?
DECISION
YES Go to Step 31.

NO Go to next step.
STEP
Is turn signal light in left front bumper inoperative?
DECISION
YES Go to Step 43.

NO Go to next step.
STEP
14. Activate right turn signals (TM 9-2355-106-10).

0093–3
TM 9-2355-106-23-1 0093
Are all 3 right front turn signal lights inoperative?
DECISION
YES Go to Step 102.

NO Go to next step.
STEP
Are turn signal light on right front fender and turn signal light next to right headlight inoperative?
DECISION
YES Go to Step 88.

NO Go to next step.
STEP
Is turn signal light on right front fender inoperative?
DECISION
YES Go to Step 71.

NO Go to next step.
0093–4
TM 9-2355-106-23-1 0093
STEP
Is turn signal light next to right headlight inoperative?
DECISION
YES Go to Step 83.

NO Go to Step 95.
STEP
19. Remove turn signal bulb from socket 8154. Refer to Front Fender Light Bulb Removal and Installation
Figure 1. Left Front Fender Turn Signal Bulb Socket.

22. Press SER. DRIVE on MVLS and then press ENTER within 5 seconds (TM 9-2355-106-10).
23. Measure DC voltage between bulb socket 8154 terminal A and terminal G with multimeter. Refer to Figure 1.
Does multimeter display alternate between voltage readings and OL?
DECISION
YES Go to Step 127.

NO Go to next step.
0093–5
TM 9-2355-106-23-1 0093
STEP

26. Disconnect connector LAM1061 from connector 8153F under left front fender. Refer to Figure 2.
Figure 2. Front Fender Turn Light Connector.

30. Measure DC voltage between harness connector LAM1061 terminal C and A with multimeter. Refer to
Figure 2.
DECISION
YES Go to Step 133.

NO Go to Step 134.
0093–6
TM 9-2355-106-23-1 0093
STEP
31. Remove turn signal bulb from socket LAM1203. Refer to Front Turn Signal and Parking Light Bulb Removal
Figure 3. Left Front Turn Signal Bulb Socket (Near Headlight).

35. Measure DC voltage between bulb socket LAM1203 terminal A and G with multimeter. Refer to Figure 3.
DECISION
YES Go to Step 126.

NO Go to Step 134.
0093–7
TM 9-2355-106-23-1 0093
STEP

38. Follow wiring harness down from headlight and disconnect first 5-way harness connector LAM1046. Refer
to Figure 4.
Figure 4. Left Headlight/Turn Signal Harness Connector Near Front Spring Shackle.

42. Measure DC voltage between harness connector LAM1046 terminal B and terminal D with multimeter. Refer
to Figure 4.
DECISION
YES Go to Step 134.

NO Go to Step 131.
STEP

NOTE
Label bullet connectors before disconnecting.
45. Disconnect bullet connectors LAM1103 leading to 460/461 and GND terminals. Refer to Figure 5.
0093–8
TM 9-2355-106-23-1 0093
Figure 5. Front Bumper Light Unit Terminal Identification for Bullet Connectors Behind Front Bumper.

49. Measure DC voltage between harness side bullet connector LAM1103 for terminals 460/461 and GND with
DECISION
YES Go to Step 128.

NO Go to Step 131.
0093–9
TM 9-2355-106-23-1 0093
STEP

52. Follow wiring harness down from headlight and disconnect second 5-way harness connector LAM1101.
Refer to Figure 6.
Figure 6. Left Front Bumper/Front Chassis Connector Near Front Spring Shackle.

to Figure 6.
DECISION
YES Go to Step 131.

NO Go to next step.
STEP

DECISION

0093–10
TM 9-2355-106-23-1 0093
NO Go to Step 130.
STEP
60. Remove left side engine armor plate bracket. Refer to Left Side Engine Armor Plate Bracket Removal and
61. Disconnect connector 4301/4300 (24 cavities with 22 wires). Refer to Figure 7.
Figure 7. Forward Chassis/PDC Connector in Engine Compartment.

65. Measure DC voltage between harness connector 4301 terminal 9 and 13 with multimeter. Refer to Figure 7.
0093–11
TM 9-2355-106-23-1 0093
DECISION
YES Go to Step 130.

NO Go to next step.
STEP

0093–12
TM 9-2355-106-23-1 0093
69. Measure resistance between connector 4301 terminal 9 and ESC connector 4007 terminal C with multimeter.
DECISION

NO Go to Step 129.
STEP
0093–13
TM 9-2355-106-23-1 0093
DECISION
YES Go to Step 136.

NO Go to Step 129.
STEP
71. Remove turn signal bulb from socket 8154R. Refer to Front Fender Light Bulb Removal and Installation
(WP 0372). Refer to Figure 11,
Figure 11. Right Front Fender Turn Signal Bulb Socket.

75. Measure DC voltage between bulb socket 8154R terminal A and terminal G with multimeter. Refer to
Figure 11.
DECISION
YES Go to Step 127.

NO Go to next step.
0093–14
TM 9-2355-106-23-1 0093
STEP

78. Disconnect connector LAM1062 from connector 8153FR under right front fender. Refer to Figure 12.
Figure 12. Right Front Fender Turn Light Connector.

82. Measure DC voltage between harness connector LAM1062 terminal C and A with multimeter. Refer to
Figure 12.
DECISION
YES Go to Step 133.

NO Go to Step 135.
0093–15
TM 9-2355-106-23-1 0093
STEP
83. Remove turn signal bulb from socket LAM1204. Refer to Front Turn Signal and Parking Light Bulb Removal
Figure 13. Right Front Turn Signal Bulb Socket (Near Headlight).

87. Measure DC voltage between bulb socket LAM1204 terminal A and G with multimeter. Refer to Figure 13.
DECISION
YES Go to Step 126.

NO Go to Step 135.
0093–16
TM 9-2355-106-23-1 0093
STEP

90. Follow wiring harness down from headlight and disconnect first 5-way harness connector LAM1047. Refer to
Figure 14.
Figure 14. Right Headlight/Turn Signal Harness Connector Near Front Spring Shackle.

to Figure 14.
DECISION
YES Go to Step 135.

NO Go to Step 132.
STEP

0093–17
TM 9-2355-106-23-1 0093
NOTE
97. Disconnect bullet connectors LAM1104 leading to 460/461 and GND terminals. Refer to Figure 15.
Figure 15. Front Bumper Light Unit Terminal Identification for Bullet Connectors Behind Front Bumper.

100.Press SER. DRIVE on MVLS and then press ENTER within 5 seconds (TM 9-2355-106-10).
101.Measure DC voltage between harness side bullet connector LAM1104 for terminals 460/461 and GND with
DECISION
YES Go to Step 128.

NO Go to Step 132.
STEP

104.Follow wiring harness down from headlight and disconnect second 5-way harness connector LAM1107.
Refer to Figure 16.
0093–18
TM 9-2355-106-23-1 0093
Figure 16. Right Front Bumper/Front Chassis Connector Near Front Spring Shackle.

108.Measure DC voltage between harness connector LAM1107 terminal B and terminal D with multimeter. Refer
to Figure 16.
DECISION
YES Go to Step 132.

NO Go to next step.
STEP

DECISION

NO Go to Step 130.
STEP
112. Remove left side engine armor plate bracket. Refer to Left Side Engine Armor Plate Bracket Removal and
113. Disconnect connector 4301/4300 (24 cavities with 22 wires). Refer to Figure 17.
0093–19
TM 9-2355-106-23-1 0093

DECISION
YES Go to Step 130.

NO Go to next step.
0093–20
TM 9-2355-106-23-1 0093
STEP

120.Disconnect ESC connector 4007. Refer to Figure 18.
121.With assistance, measure resistance between connector 4301 terminal 11 and ESC connector 4007 terminal
B with multimeter. Refer to Figure 18 and Figure 17.
DECISION

NO Go to Step 129.
0093–21
TM 9-2355-106-23-1 0093
STEP
122.Measure resistance between connector 4301 terminal 11 and ground with multimeter. Refer to Figure 19.
DECISION
YES Go to Step 136.

NO Go to Step 129.
0093–22
TM 9-2355-106-23-1 0093
STEP
123.Remove left side engine armor plate bracket. Refer to Left Side Engine Armor Plate Bracket Removal and
124.Disconnect connector 4301/4300 (24 cavities with 22 wires). Refer to Figure 19.
DECISION
YES Go to Step 130.

NO Go to Step 129.
MALFUNCTION
- 126. Front turn signal and parking light bulb is faulty.
ACTION
Replace bulb. Refer to Front Turn Signal and Parking Light Bulb Removal and Installation (WP 0373). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 127. Front fender light bulb is faulty.
ACTION
Replace bulb. Refer to Front Fender Light Bulb Removal and Installation (WP 0372). Return vehicle to service.
END OF TEST
MALFUNCTION
- 128. Front bumper lamp unit is faulty.
ACTION
Replace front bumper lamp unit. Refer to Front Bumper Turn Signal and Parking Light Assembly Removal and
END OF TEST
0093–23
TM 9-2355-106-23-1 0093
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 131. Front bumper harness is faulty.
ACTION
Replace front bumper harness. Refer to Front Bumper Left Harness Removal and Installation (WP 0374).
END OF TEST
MALFUNCTION
ACTION
Replace front bumper harness. Refer to Front Bumper Right Harness Removal and Installation (WP 0375).
END OF TEST
MALFUNCTION
- 133. Clearance and marker light harness is faulty.
ACTION
Replace clearance and marker light harness. Refer to Clearance and Marker Light Harness Removal and
END OF TEST
MALFUNCTION
- 134. Headlight and turn signal harness is faulty.

0093–24
TM 9-2355-106-23-1 0093
ACTION
Replace headlight and turn signal harness. Refer to Left Headlamp and Turn Signal Harness Removal and
END OF TEST
MALFUNCTION
ACTION
Replace headlight and turn signal harness. Refer to Right Headlamp and Turn Signal Harness Removal and
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0093–25/blank
TM 9-2355-106-23-1 0094
FIELD MAINTENANCE
REAR TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0427
WP 0581
Wire tags (WP 0794, Item 33) WP 0782
Maintainer - (2) Parking brake set (TM 9-2355-106-10)
References
9-2355-106-10)
TM 9-2355-106-10
Engine off (TM 9-2355-106-10)
TM 9-2355-106-23P
WP 0257
WP 0317
WP 0319
WP 0335 WP 0789, Figure 59
WP 0353 WP 0789, Figure 60
WP 0383 WP 0789, Figure 51

WARNING
0094–1
TM 9-2355-106-23-1 0094
REAR TURN SIGNAL LIGHTS TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP

3. Press SER. DRIVE on master vehicle light switch (MVLS) and then press ENTER within 5 seconds (TM
9-2355-106-10).
4. Activate left and then right turn signals (TM 9-2355-106-10).
5. Observe rear turn signal lights.
Are both rear turn signal lights inoperative?
DECISION
YES Go to Step 76
NO Go to next step.
STEP
NOTE
Right taillamp shown, left taillamp similar.
6. Remove inoperative rear composite taillamp. Refer to Composite Taillamp Assembly Removal and Installation
(WP 0383).
NOTE
7. Disconnect bullet connectors leading to terminals 22 and GND on inoperative turn signal stoplight. Refer
to Figure 1.
0094–2
TM 9-2355-106-23-1 0094
Figure 1. Circuit Identification on Rear Composite Taillamp Assembly for Turn Signal Bullet Connectors.

11. Position turn signal lever to inoperative side (TM 9-2355-106-10).
12. Measure DC voltage between harness side bullet connectors for terminals 22 and GND with multimeter.
Refer to Figure 1.
DECISION
YES Go to Step 95.

NO Go to next step.
STEP

15. Measure resistance between harness side bullet connector terminal GND and ground with multimeter. Refer
to Figure 1.
0094–3
TM 9-2355-106-23-1 0094
DECISION

NO Go to Step 103.
STEP
16. Disconnect rear chassis harness 5-pin connector 9303A from taillamp harness 5-pin connector LAM1086.
Refer to Figure 2.
Figure 2. Taillamp/Rear Chassis Harness Connection Inside Left Frame Rail, Near Rear Crossmember.

20. Measure DC voltage between connector 9303A terminal B for left turn signal, or terminal C for right turn
signal, and ground with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 103.

NO Go to next step.
STEP
21. Remove LEFT STOP TURN relay if left turn signals are inoperative, or RIGHT STOP TURN relay if right turn
signals are inoperative, from Power Distribution Center (PDC). Refer to Power Distribution Center (PDC) Fuse
25. Measure DC voltage between left or right relay socket terminal 87 and ground with multimeter. Refer
to Figure 3.
0094–4
TM 9-2355-106-23-1 0094
Figure 3. Left or Right Stop/Turn Relay in Engine Compartment PDC.
DECISION
YES Go to Step 56.

NO Go to next step.
0094–5
TM 9-2355-106-23-1 0094
STEP

Figure 4. Stop/Turn Light Connector Near Electronic System Controller (ESC).
29. Measure resistance between left or right relay socket terminal 87 and connector 1703M terminal D for left side
or terminal A for right side with mutimeter. Refer to Figure 4 and Figure 5.
Figure 5. Left or Right Stop/Turn Relay Socket.
DECISION

NO Go to Step 98.
0094–6
TM 9-2355-106-23-1 0094
STEP
30. Remove LEFT TURN TRAILER relay or RIGHT TURN TRAILER relay. Refer to Power Distribution Center
(PDC) Fuse and Relay Removal and Installation (WP 0333). Refer to Figure 6.
Figure 6. Left or Right Turn Trailer Relay in Engine Compartment PDC.
31. Measure resistance between LEFT or RIGHT STOP TURN relay socket terminal 87 and ground with
mutimeter. Refer to Figure 5.
DECISION

NO Go to Step 98.
0094–7
TM 9-2355-106-23-1 0094
STEP
32. Remove STOPLIGHT RELAY RIGHT or STOPLIGHT RELAY LEFT for inoperative turn signal from cabin relay
and fuse center. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
Figure 7. Stoplight Relay Left or Right Socket in Right IP.
33. Measure resistance between left or right relay socket terminal 30 and connector 1703F terminal D for left side
or terminal A for right side with multimeter. Refer to Figure 7 and Figure 8.
0094–8
TM 9-2355-106-23-1 0094
Figure 8. Stop/Turn Light Connector Near ESC.
DECISION

NO Go to Step 96.
STEP
34. Measure resistance between left or right relay socket terminal 30 and ground with multimeter. Refer to
Figure 7.
DECISION

NO Go to Step 96.
0094–9
TM 9-2355-106-23-1 0094
STEP
35. Connect connector 1703F to 1703M. Refer to Figure 9.
Figure 9. Stop/Turn Light Connector, Near ESC.

39. Measure DC voltage between left or right relay socket terminal 87 and ground with multimeter. Refer to
Figure 10.
Figure 10. Stoplight Relay Left or Right Socket.
DECISION

NO Go to Step 44.
0094–10
TM 9-2355-106-23-1 0094
STEP
40. Measure DC voltage between left or right stoplight relay socket terminal 85 and ground with multimeter.
Refer to Figure 10.
Does multimeter read 10.5V to 13.5V?
DECISION

NO Go to Step 96.
STEP

43. Measure resistance between left or right stoplight relay socket terminal 86 and ground with multimeter.
Refer to Figure 10.
DECISION
YES Go to Step 100.

NO Go to Step 96.
STEP

0094–11
TM 9-2355-106-23-1 0094
50. Measure DC voltage between connector 1703M terminal C for left side or terminal B for right side and ground
Figure 11. Stop/Turn Light Connector 1703M.
DECISION
YES Go to Step 96.

NO Go to next step.
STEP

0094–12
TM 9-2355-106-23-1 0094
Figure 12. ESC Connector Under Left IP.
54. Measure resistance between connector 1703M terminal C for left side or terminal B for right side and connector
4008 terminal C for left side or terminal B for right side with multimeter. Refer to Figure 12 and Figure 11.
DECISION

NO Go to Step 98.
STEP
55. Measure resistance between connector 1703M terminal C for left side or terminal B for right side and ground
DECISION
YES Go to Step 97.

NO Go to Step 98.
0094–13
TM 9-2355-106-23-1 0094
STEP
56. Measure DC voltage between RIGHT or LEFT STOP TURN relay socket terminal 86 and ground with
DECISION

NO Go to Step 98.
STEP

59. Measure resistance between RIGHT or LEFT STOP TURN relay socket terminal 85 and ground with
0094–14
TM 9-2355-106-23-1 0094
DECISION
NO Go to Step 98.
STEP
60. Measure resistance between RIGHT or LEFT STOP TURN socket terminal 30 and ground with multimeter.
Refer to Figure 13.
DECISION

NO Go to Step 69.
STEP
61. With assistance, measure resistance between RIGHT or LEFT STOP TURN relay socket terminal 30 and
connector 9303A terminal B for left side or terminal C for right side with multimeter. Refer to Figure 13 and
Figure 14.
Figure 14. Taillamp/Rear Chassis Harness Connector Inside Left Frame Rail, Near Rear Crossmember.
DECISION
YES Go to Step 99.

NO Go to next step.
STEP
62. Remove air cleaner. Refer to Air Cleaner Assembly Removal and Installation (WP 0257).
0094–15
TM 9-2355-106-23-1 0094
63. Remove left side engine armor bracket. Refer to Left Engine Armor Plate Bracket Removal and Installation
(WP 0598).
64. Disconnect dash/center harness connector 9714/9700 in engine compartment. Refer to Figure 15.
Figure 15. Dash/Center Chassis Harness Connector in Engine Compartment.
65. Measure resistance between RIGHT or LEFT STOP TURN relay socket terminal 30 and connector 9714
terminal A5 for left turn signal or terminal B6 for right turn signal with multimeter. Refer to Figure 15 and
Figure 16.

0094–16
TM 9-2355-106-23-1 0094
DECISION

NO Go to Step 98.
STEP
66. Loosen air dryer mounting bolts and move air dryer to one side to access connectors on left frame rail. Refer
to Air Dryer Removal and Installation (WP 0517).
67. Disconnect center chassis harness connector 9800F from rear chassis harness connector 9800M. Refer to
Figure 17.
Figure 17. Center/Rear Chassis Harness Connector Inside Left Frame Rail.
68. Measure resistance between connector 9700 terminal A5 for left side or terminal B6 for right side and connector
9800F terminal 2 for left side or terminal 3 for right side with multimeter. Refer to Figure 18 and Figure 17.
DECISION
YES Go to Step 102.
0094–17
TM 9-2355-106-23-1 0094
NO Go to Step 101.
STEP
Figure 19.
0094–18
TM 9-2355-106-23-1 0094
DECISION
NO Go to next step.
YES Go to Step 102.
0094–19
TM 9-2355-106-23-1 0094
STEP
(WP 0598).
74. Disconnect dash/center chassis harness connector 9714/9700. Refer to Figure 21.
DECISION
YES Go to Step 101.

NO Go to Step 98.
0094–20
TM 9-2355-106-23-1 0094
STEP
76. Remove right rear composite taillamp. Refer to Composite Taillamp Assembly Removal and Installation
(WP 0383).
NOTE
77. Disconnect bullet connector leading to GND terminal on right turn signal. Refer to Figure 22.
Figure 22. Circuit Identification on Composite Taillamp Assembly, and Turn Signal Bullet Connectors.
78. Measure resistance between harness side bullet connector GND terminal and ground with multimeter.
DECISION

NO Go to Step 86.
0094–21
TM 9-2355-106-23-1 0094
STEP
79. Remove STOPLIGHT RELAY RIGHT from right side IP. Refer to Figure 23. Refer to Instrument Panel (IP)
Circuit Breaker, Fuse, and Relay Removal and Installation (WP 0317).
Figure 23. Stoplight Relay Right in Cabin Fuse and Relay Center.
80. Remove IP center trim panel. Refer to IP Center Trim panel Removal and Installation (WP 0581).
81. Remove cap and metal bus bar from blackout mode splice pack connector 1050. Refer to Figure 24.
Figure 24. Blackout Mode Splice Pack Connector in Center IP.
82. Measure resistance between STOPLIGHT RELAY RIGHT socket terminal 85 and connector 1050 terminal D
DECISION
NO Go to Step 96.
0094–22
TM 9-2355-106-23-1 0094
STEP
83. Measure resistance between STOPLIGHT RELAY RIGHT socket 86 and ground with multimeter. Refer to
Figure 25.
Figure 25. Stoplight Relay Right Socket.
DECISION
NO Go to Step 96.
0094–23
TM 9-2355-106-23-1 0094
STEP
Figure 26. IP/PDC Pass-Through Connector in Engine Compartment.

85. With assistance, measure resistance between connector 1701 (cabin side) terminal 27 and connector 1050
terminal H with multimeter. Refer to Figure 26 and Figure 27.
DECISION
NO Go to Step 96.
YES Go to Step 98.
0094–24
TM 9-2355-106-23-1 0094
STEP
86. Disconnect rear chassis harness 5-pin connector 9303A from taillamp harness 5-pin connector LAM1086.
Refer to Figure 28.
Figure 28. Taillamp/Rear Chassis Harness Inside Left Frame Rail, Near Rear Crossmember.
87. Measure resistance between connector 9303A terminal E and ground with multimeter. Refer to Figure 28.
DECISION
YES Go to Step 103.

NO Go to next step.
0094–25
TM 9-2355-106-23-1 0094
STEP
Figure 29.
Figure 29. Center/Rear Chassis Connector Inside Left Frame Rail.
DECISION
YES Go to Step 102.

NO Go to next step.
STEP
(WP 0598).
0094–26
TM 9-2355-106-23-1 0094
93. Disconnect PDC harness connector 9714 from center chassis harness connector 9700 in engine compartment.
Refer to Figure 30.
Figure 30. Dash/Center Chassis Connector in Engine Compartment.
94. Measure resistance between connector 9714 terminal C6 and ground with multimeter. Refer to Figure 30.
DECISION
YES Go to Step 101.

NO Go to Step 98.
MALFUNCTION
- 95. Taillamp is faulty.
ACTION
Replace taillamp. Refer to Composite Taillamp Assembly Removal and Installation (WP 0383). Return vehicle
to service.
0094–27
TM 9-2355-106-23-1 0094
END OF TEST
MALFUNCTION
ACTION
Replace instrument panel wiring harness. Refer to Instrument Panel (IP) Wiring Harness Removal and
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 99. Power distribution center relay is faulty.
ACTION
Replace power distribution center relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
END OF TEST
MALFUNCTION
- 100. Instrument panel relay is faulty.
ACTION
Replace instrument panel relay. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and
END OF TEST
MALFUNCTION

0094–28
TM 9-2355-106-23-1 0094
ACTION
END OF TEST
MALFUNCTION
- 102. Rear chassis harness is faulty.
ACTION
Replace rear chassis harness. Refer to Rear Chassis Harness Removal and Installation (WP 0427). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 103. Taillamp harness is faulty.
ACTION
Replace taillamp harness. Refer to Taillamp Harness Removal and Installation (WP 0384). Return vehicle
to service.
END OF TEST
END OF WORK PACKAGE
0094–29/blank
TM 9-2355-106-23-1 0095
FIELD MAINTENANCE
TURN SIGNAL AND HAZARD SWITCH TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37)
Equipment Condition
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0319
Drawings Required
WP 0333
WP 0789, Figure 57
WP 0335
WP 0789, Figure 11
WP 0323
WP 0789, Figure 51
WP 0324
WP 0353

0095–1
TM 9-2355-106-23-1 0095
TURN SIGNAL AND HAZARD SWITCH TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0095–2
TM 9-2355-106-23-1 0095
STEP

3. Press SER.DRIVE on Master Vehicle Light Switch (MVLS) and then press ENTER within five seconds (TM
9-2355-106-10).
4. Activate hazard lights (TM 9-2355-106-10).
5. Observe all turn signal lights.
6. Deactivate hazard lights (TM 9-2355-106-10).
7. Activate left and then right turn signal lights (TM 9-2355-106-10).
Are all turn signal lights inoperative?
DECISION
YES Go to Step 72.

NO Go to next step.
STEP
9. Activate left turn signal lights (TM 9-2355-106-10).
Are all turn signal lights on left side inoperative?
DECISION

NO Go to Step 41.
0095–3
TM 9-2355-106-23-1 0095
STEP
11. Disconnect connector 1810 from multifunction turn signal switch. Refer to Figure 1.
Figure 1. Left Side Steering Column.

14. Press SER. DRIVE on MVLS and then press ENTER within five seconds (TM 9-2355-106-10).
DECISION
YES Go to Step 102.

NO Go to next step.
0095–4
TM 9-2355-106-23-1 0095
STEP

18. Disconnect IP/steering column harness connector 1800 under center instrument panel. Refer to Figure 2.
Figure 2. IP/Steering Column Harness Connector Under Center IP.

22. Measure DC voltage between harness connector 1800 terminal A1 and A4 with multimeter. Refer to Figure 2.
DECISION
YES Go to Step 98.

NO Go to next step.
0095–5
TM 9-2355-106-23-1 0095
STEP
23. Remove left turn enable relay from center instrument panel relay block. Refer to IP Center Relay Removal and
27. Measure DC voltage between left turn enable relay socket terminal 30 and ground with multimeter. Refer
to Figure 3.
Figure 3. Under Center IP.
DECISION
YES Go to Step 34.

NO Go to next step.
0095–6
TM 9-2355-106-23-1 0095
STEP

Figure 4. Under Left Side Instrument Panel.
DECISION

NO Go to Step 99.
0095–7
TM 9-2355-106-23-1 0095
STEP
32. Measure resistance between connector 1600 terminal 19 and left turn enable relay socket terminal 30 with
DECISION

NO Go to Step 99.
0095–8
TM 9-2355-106-23-1 0095
STEP
33. Measure resistance between connector 1600 terminal 19 and all other terminals in connector with multimeter.
Refer to Figure 6.
DECISION
YES Go to Step 100.

NO Go to Step 99.
0095–9
TM 9-2355-106-23-1 0095
STEP
34. Measure DC voltage between left turn enable relay socket terminal 86 and ground with multimeter. Refer
to Figure 7.
DECISION

NO Go to Step 99.
0095–10
TM 9-2355-106-23-1 0095
STEP

37. Measure resistance between left turn enable relay socket terminal 85 and ground with multimeter. Refer
to Figure 7.
DECISION

NO Go to Step 99.
STEP
38. Measure resistance between left turn enable relay socket terminal 87 and ground with multimeter. Refer
to Figure 8.
Figure 8. Left Turn Enable Relay Socket.
DECISION

NO Go to Step 99.
0095–11
TM 9-2355-106-23-1 0095
STEP
39. Measure resistance between left turn enable relay socket terminal 87 and connector 1800 terminal A1 with
Figure 9. IP/Steering Column Harness Under Center IP.
DECISION

NO Go to Step 99.
STEP
40. Measure resistance between connector 1800 terminal A1 and all other terminals in connector with multimeter.
Refer to Figure 9.
0095–12
TM 9-2355-106-23-1 0095
DECISION
YES Go to Step 101.

NO Go to Step 99.
STEP

0095–13
TM 9-2355-106-23-1 0095
DECISION
YES Go to Step 102.

NO Go to next step.
STEP


52. Press SER. DRIVE on MVLS switch and then press ENTER within five seconds (TM 9-2355-106-10).
53. Measure DC voltage between harness connector 1800 terminal A2 and A4 with multimeter. Refer to Figure 11.
0095–14
TM 9-2355-106-23-1 0095
DECISION
YES Go to Step 98.

NO Go to next step.
STEP
54. Remove right turn enable relay from center instrument panel relay block. Refer to IP Center Relay Removal

58. Measure DC voltage between right turn enable relay socket terminal 30 and ground with multimeter. Refer to
Figure 12.
0095–15
TM 9-2355-106-23-1 0095
DECISION
YES Go to Step 65.

NO Go to next step.
STEP

0095–16
TM 9-2355-106-23-1 0095
DECISION

NO Go to Step 99.
STEP
63. Measure resistance between connector 1600 terminal 18 and right turn enable relay socket terminal 30 with
0095–17
TM 9-2355-106-23-1 0095
DECISION

NO Go to Step 99.
STEP
64. Measure resistance between connector 1600 terminal 18 and all other terminals in connector with multimeter.
Refer to Figure 15.
DECISION
YES Go to Step 100.

NO Go to Step 99.
0095–18
TM 9-2355-106-23-1 0095
STEP
65. Measure DC voltage between right turn enable relay socket terminal 86 and ground with multimeter. Refer to
Figure 16.
DECISION

NO Go to Step 99.
0095–19
TM 9-2355-106-23-1 0095
STEP

68. Measure resistance between right turn enable relay socket terminal 85 and ground with multimeter. Refer to
Figure 16.
DECISION

NO Go to Step 99.
STEP
69. Measure resistance between right turn enable relay socket terminal 87 and ground with multimeter. Refer to
Figure 16.
DECISION

NO Go to Step 99.
STEP
70. Measure resistance between right turn enable relay socket terminal 87 and connector 1800 terminal A2 with
Figure 17. Right Turn Enable Relay Socket.

0095–20
TM 9-2355-106-23-1 0095
DECISION

NO Go to Step 99.
STEP
71. Measure resistance between connector 1800 terminal A2 and all other terminals in connector with multimeter.
Refer to Figure 18.
DECISION
YES Go to Step 101.

NO Go to Step 99.
0095–21
TM 9-2355-106-23-1 0095
STEP
72. Remove left turn enable relay from center instrument panel relay block. Refer to IP Center Relay Removal

76. Measure DC voltage between left turn enable relay socket terminal 86 and ground with multimeter. Refer to
Figure 19.
DECISION

NO Go to Step 87.
STEP

79. Measure resistance between left turn enable relay socket terminal 85 and ground with multimeter. Refer to
Figure 19.
0095–22
TM 9-2355-106-23-1 0095
DECISION

NO Go to Step 99.
STEP
DECISION
YES Go to Step 102.

NO Go to next step.
0095–23
TM 9-2355-106-23-1 0095
STEP
84. Measure resistance between connector 1800 terminal A4 and ground with multimeter. Refer to Figure 21.
DECISION
YES Go to Step 98.

NO Go to next step.
STEP
85. Disconnect ESC connector 1600. Refer to Figure 22
0095–24
TM 9-2355-106-23-1 0095
86. Measure resistance between connector 1600 terminal 3 and connector 1800 terminal A4 with multimeter.
DECISION
YES Go to Step 100.

NO Go to Step 99.
0095–25
TM 9-2355-106-23-1 0095
STEP

89. Disconnect Master Vehicle Light Switch (MVLS). Refer to Figure 23.
0095–26
TM 9-2355-106-23-1 0095
90. Measure resistance between connector 1954 terminal J and left turn enable relay socket terminal 86 with
DECISION

NO Go to Step 99.
0095–27
TM 9-2355-106-23-1 0095
STEP
91. Remove RIGHT TURN ENABLE relay and FLASH TO PASS relay from center instrument panel relay block.
Refer to Figure 25. Refer to IP Center Relay Removal and Installation (WP 0318).
92. Remove STOPLIGHT RELAY LEFT from right side instrument panel. Refer to Figure 26. Refer to Instrument
Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation (WP 0317).
Figure 26. Right Side IP.
93. Remove STOPLIGHT RELAY RIGHT from right side instrument panel. Refer to Figure 27. Refer to Instrument
Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation (WP 0317).
0095–28
TM 9-2355-106-23-1 0095
Figure 27. Right Side IP.
NOTE
Instrument panel cluster (IPC) does not need to be removed to access connector 1520.
Illustration only shows IPC removed for clarity.
94. Disconnect connector 1520 from instrument panel cluster. Refer to Figure 28.
Figure 28. Lower IPC.
0095–29
TM 9-2355-106-23-1 0095
Figure 29. IP/Dash Pass-Through Connector in Engine Compartment.
97. Measure resistance between connector 1050 terminals A, B, C, D, H, J and ground with multimeter. Refer to
Figure 30.
0095–30
TM 9-2355-106-23-1 0095
DECISION
YES Go to Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedures (WP 0092).
NO Go to Step 99.
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
Replace ESC. Refer to Electronic System Controller Removal and Installation (WP 0353). Return vehicle
to service.
END OF TEST
0095–31
TM 9-2355-106-23-1 0095
MALFUNCTION
- 101. Center instrument panel relay is faulty.
ACTION
Replace center instrument panel relay. Refer to Instrument Panel Center Relay Removal and Installation
END OF TEST
MALFUNCTION
- 102. Turn signal switch is faulty.
ACTION
Replace turn signal switch. Refer to Multifunction Turn Signal Switch Assembly Removal and Installation
END OF TEST
END OF WORK PACKAGE
0095–32
TM 9-2355-106-23-1 0096
FIELD MAINTENANCE
TURN SIGNAL LIGHTS OPERATIONAL CHECKOUT PROCEDURE
INITIAL SETUP:
WP 0093 9-2355-106-10)
WP 0094 Engine off (TM 9-2355-106-10)
WARNING
NOTE
STEP
3. Press SER. DRIVE on master vehicle light switch (MVLS) and then press ENTER within 5 seconds (TM
9-2355-106-10).
4. Activate left turn signal lights (TM 9-2355-106-10).
5. Observe left side turn signal lights.
6. Activate right turn signal lights (TM 9-2355-106-10).
7. Observe right side turn signal lights.
8. Activate hazard lights (TM 9-2355-106-10).
All hazard or turn signal lights are inoperative.
CORRECTIVE ACTION
0096–1
TM 9-2355-106-23-1 0096
TURN SIGNAL LIGHTS OPERATIONAL CHECKOUT PROCEDURE - (CONTINUED)
Go to Turn Signal and Hazard Switch Troubleshooting Procedure (WP 0095).

All front turn signal lights are inoperative.
CORRECTIVE ACTION
Go to Front Turn Signal Lights Troubleshooting Procedure (WP 0093).
Both rear turn signal lights are inoperative.
CORRECTIVE ACTION
Go to Rear Turn Signal Lights Troubleshooting Procedure (WP 0094).
All left side turn signal lights are inoperative.
CORRECTIVE ACTION
All right side turn signal lights are inoperative.
CORRECTIVE ACTION
Any or all left front turn signal lights are inoperative.
CORRECTIVE ACTION
Any or all right front turn signal lights are inoperative.
CORRECTIVE ACTION
Left rear turn signal light is inoperative.
CORRECTIVE ACTION
Right rear turn signal light is inoperative.
CORRECTIVE ACTION
END OF WORK PACKAGE
0096–2
TM 9-2355-106-23-1 0097
FIELD MAINTENANCE
SERVICE DRIVING LIGHTS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0424
WP 0565
WP 0581
WP 0597
(WP 0795, Item 37)
WP 0655
References WP 0782
TM 9-2355-106-10
WP 0297 9-2355-106-10)
WP 0319 Engine off (TM 9-2355-106-10)
WP 0353
WP 0375 WP 0789, Figure 52
WP 0376 WP 0789, Figure 51

• Low-beam driving lights are inoperative.
• High-beam driving lights are inoperative.
• Both low- and high-beam driving lights are inoperative.
0097–1
TM 9-2355-106-23-1 0097
SERVICE DRIVING LIGHTS TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
STEP

9-2355-106-10).
4. Activate low- and high-beam driving lights while observing driving lights (TM 9-2355-106-10).
Are both low- and high-beam driving lights inoperative?
DECISION
YES Go to Step 9.
NO Go to next step.
STEP
5. Activate low-beam driving lights (TM 9-2355-106-10).

0097–2
TM 9-2355-106-23-1 0097
6. Observe service driving lights.
Are both low-beam driving lights illuminated?
DECISION
NO Go to Step 39.
STEP
7. Activate high-beam driving lights (TM 9-2355-106-10).

8. Observe service driving lights.
Are both high-beam driving lights illuminated?
DECISION
NO Go to Step 77.
YES Service lights are operating normally. Return vehicle to service.
0097–3
TM 9-2355-106-23-1 0097
STEP
9. Remove headlights. Refer to Headlight Assembly Removal and Installation (WP 0376).
10. Disconnect either headlight connector LAM1048 or LAM1049 (LAM1048 shown). Refer to Figure 1.
Figure 1. Headlight Connector.
11. Measure resistance between connector LAM1048 or LAM1049 terminal B and ground with multimeter. Refer
to Figure 1.
DECISION
NO Go to Step 29.
STEP
Is Electronic System Controller (ESC) receiving service lamps input?
DECISION
YES Go to Step 32.

NO Go to next step.
0097–4
TM 9-2355-106-23-1 0097
STEP
16. Remove instrument panel cluster. Refer to Instrument Panel Cluster (IPC) Removal and Installation
(WP 0297).
17. Disconnect IPC blackout harness connector 1520. Refer to Figure 2.
Figure 2. Blackout Harness Connector Behind IPC.

21. Measure DC voltage between connector 1520 terminal A and ground. Refer to Figure 2.
DECISION
YES Go to Step 137.

NO Go to next step.
0097–5
TM 9-2355-106-23-1 0097
STEP

24. Remove IP center trim panel. Refer to Instrument Panel (IP) Center Trim Panel Removal and Installation
(WP 0581).
Figure 3. MVLS Connector in IP Center.

0097–6
TM 9-2355-106-23-1 0097
DECISION
NO Go to Step 135.
STEP
27. Measure resistance between connector 1520 terminal A and connector 1954 terminal M with multimeter.
DECISION
YES Go to Step 135.

NO Go to next step.
STEP
28. Measure resistance between connector 1954 terminal M and all other connector 1954 terminals with
multimeter. Multimeter should read OL for each test. Refer to Figure 5.
DECISION
NO Go to Step 135.
YES Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedures (WP 0092).
0097–7
TM 9-2355-106-23-1 0097
STEP
(WP 0597).
30. Disconnect dash/forward chassis harness connector 4301/4300. Refer to Figure 6.
Figure 6. Dash/Forward Chassis Harness Connector Left Side Engine Compartment.
DECISION
YES Go to Step 139.

NO Go to Step 138.
STEP
32. Press SER.DRIVE on MVLS switch and then press ENTER within 5 seconds.
Is ESC activating service lamps output?
0097–8
TM 9-2355-106-23-1 0097
DECISION
NO Go to Step 137.
STEP
(WP 0597).
38. Measure DC voltage between connector 4300 terminals 4 and 5 and ground with multimeter. Refer to Figure 6.
DECISION
YES Go to Step 139.

NO Go to Step 138.
0097–9
TM 9-2355-106-23-1 0097
STEP
39. Remove headlight. Refer to Headlight Assembly Removal and Installation (WP 0376).
40. Disconnect inoperative headlight connector LAM1048 or LAM 1049 (LAM1048 shown). Refer to Figure 7.
Figure 7. Left Headlight Connector.

44. Measure DC voltage between connector LAM1048 or LAM1049 terminal C and terminal B with multimeter.
Refer to Figure 7.
DECISION
YES Go to Step 134.

NO Go to next step.
0097–10
TM 9-2355-106-23-1 0097
STEP

47. Disconnect inoperative headlight harness connector LAM1046 or LAM 1047 (LAM1046 shown). Refer
to Figure 8.
Figure 8. Left Headlight Harness Connector Near Front Spring Shackle.

51. Measure DC voltage between LAM1046 or LAM1047 terminal C and terminal B with multimeter. Refer
to Figure 8.
DECISION
YES Go to Step 141.

NO Go to next step.
0097–11
TM 9-2355-106-23-1 0097
STEP

54. Disconnect inoperative headlight forward chassis harness connector LAM1101 or LAM1107 (LAM1101
shown). Refer to Figure 9.
Figure 9. Left Forward Chassis Harness Connector Near Front Spring Shackle.

58. Measure DC voltage between LAM1101 or LAM1107 terminal C and terminal B with multimeter. Refer
to Figure 9.
DECISION
YES Go to Step 140.

NO Go to next step.
0097–12
TM 9-2355-106-23-1 0097
STEP
(WP 0597).
Figure 10. Dash/Forward Chassis Connector Left Side Engine Compartment.

64. Measure DC voltage between connector 4300 terminal 5 and terminal 13 with multimeter. Refer to Figure 10.
DECISION
YES Go to Step 139.

NO Go to next step.
0097–13
TM 9-2355-106-23-1 0097
STEP

Figure 11. Electronic System Controller (ESC) Connector Under Left Side IP.

0097–14
TM 9-2355-106-23-1 0097
DECISION
NO Go to Step 139.
STEP
DECISION
NO Go to Step 138.
STEP
70. Measure resistance between connector 4300 terminal 5 and connector 4007 terminal D with multimeter. Refer
DECISION
NO Go to Step 138.
STEP
71. Measure resistance between connector 4007 terminal D and all other terminals in connector 4007 with
0097–15
TM 9-2355-106-23-1 0097
DECISION
NO Go to Step 138.
STEP
72. Connect connector 4007.

(WP 0011).
75. Toggle turn signal switch between high- and low-beam headlights while observing MSD.
76. Verify ESC receives high- and low-beam headlight request from turn signal switch with MSD.
Does ESC receive low headlight request?
DECISION
YES Go to Step 137.

NO Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedures (WP 0092).
0097–16
TM 9-2355-106-23-1 0097
STEP
77. Remove left headlight. Refer to Headlight Assembly Removal and Installation (WP 0376).
78. Disconnect inoperative headlight connector LAM1048 or LAM1049 (LAM1048 shown). Refer to Figure 14.
Figure 14. Left Headlight Connector.

82. Measure DC voltage between connector LAM1048 or LAM1049 terminal A and terminal B with multimeter.
Refer to Figure 14.
DECISION
YES Go to Step 134.

NO Go to next step.
0097–17
TM 9-2355-106-23-1 0097
STEP

85. Disconnect inoperative headlight harness connector LAM1046 or LAM1047 (LAM1046 shown). Refer to
Figure 15.
Figure 15. Left Headlight Harness Connector Near Front Spring Shackle.

89. Measure DC voltage between LAM1046 or LAM1047 terminal C and terminal A with multimeter. Refer to
Figure 15.
DECISION
YES Go to Step 141.

NO Go to next step.
0097–18
TM 9-2355-106-23-1 0097
STEP

92. Disconnect inoperative headlight forward chassis harness connector LAM1101 or LAM1107 (LAM1101
shown). Refer to Figure 16.
Figure 16. Left Forward Chassis Harness Connector Near Front Spring Shackle.

96. Measure DC voltage between LAM1101 or LAM1107 terminal C and terminal A with multimeter. Refer to
Figure 16.
DECISION
YES Go to Step 140.

NO Go to next step.
0097–19
TM 9-2355-106-23-1 0097
STEP
97. Remove left side engine armor. Refer to Left Side Engine Armor Plate Removal and Installation (WP 0597).
Figure 17. Dash/Forward Chassis Connector Left Side Engine Compartment.

102.Measure DC voltage between connector 4300 terminal 4 and terminal 13 with multimeter. Refer to Figure 17.
DECISION
YES Go to Step 139.

NO Go to next step.
0097–20
TM 9-2355-106-23-1 0097
STEP

0097–21
TM 9-2355-106-23-1 0097
DECISION
NO Go to Step 139.
STEP
DECISION
NO Go to Step 138.
0097–22
TM 9-2355-106-23-1 0097
STEP
108.Measure resistance between connector 4300 terminal 4 and connector 4007 terminal G with multimeter. Refer
DECISION
NO Go to Step 138.
STEP
109.Measure resistance between connector 4007 terminal G and all other terminals in connector 4007 with
multimeter. Refer to Figure 20. Multimeter should read OL for each test.
DECISION
NO Go to Step 138.
STEP
110. Connect connector 4007.

(WP 0011).
113. Toggle turn signal switch between high- and low-beam headlights while observing MSD.
114. Verify ESC receives high- and low-beam headlight request from turn signal switch with MSD.
Does ESC receive low-beam headlight request?
0097–23
TM 9-2355-106-23-1 0097
DECISION
YES Go to Step 137.

NO Go to next step.
STEP
116. Disconnect turn signal switch connector 1810. Refer to Figure 21.
Figure 21. Turn Signal Switch Connector at Left Side of Steering Column.

120.Measure DC voltage between connector 1810 terminals 3 and 7 with multimeter. Refer to Figure 21.
DECISION
YES Go to Step 142.

NO Go to next step.
STEP

123.Disconnect steering column harness connector 1800/1805. Refer to Figure 22.
0097–24
TM 9-2355-106-23-1 0097
Figure 22. Steering Column Harness Connector Under Center IP.

127.Measure DC voltage between connector 1800 terminal A7 and A4 with multimeter. Refer to Figure 22.
DECISION
YES Go to Step 136.

NO Go to next step.
STEP

0097–25
TM 9-2355-106-23-1 0097
Figure 23. ESC Connector Under Left Side IP.
131.Measure resistance between connector 1800 terminal A4 and connector 1600 terminal 3 with multimeter.
Refer to Figure 24.
DECISION
NO Go to Step 135.
0097–26
TM 9-2355-106-23-1 0097
STEP
132.Measure resistance between connector 1800 terminal A7 and ground with multimeter. Refer to Figure 24.
DECISION
NO Go to Step 135.
STEP
133.Measure resistance between connector 1800 terminal A7 and connector 1600 terminal 20 with multimeter.
Refer to Figure 25.
DECISION
NO Go to Step 135.
YES Go to Step 137.
MALFUNCTION
- 134. Headlamp is faulty.
ACTION
Replace headlamp. Refer to Headlamp Removal and Installation (WP 0655). Return vehicle to service.
0097–27
TM 9-2355-106-23-1 0097
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 138. Dash harness is faulty.
ACTION
Replace dash harness. Refer to Dash Harness Removal and Installation (WP 0335). Return vehicle to service.
END OF TEST
0097–28
TM 9-2355-106-23-1 0097
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
Replace front bumper harness. Refer to Front Bumper Left Harness Removal and Installation (WP 0375) or
Front Bumper Right Harness Removal and Installation (WP 0374). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace headlight and turn signal harness. Refer to Left Headlight and Turn Signal Harness Removal and
Installation (WP 0378). Refer to Right Headlight and Turn Signal Harness Removal and Installation (WP 0379).
END OF TEST
MALFUNCTION
- 142. Turn signal switch is faulty.
ACTION
Replace turn signal switch. Refer to Multifunction Turn Signal Switch Removal and Installation (WP 0323).
END OF TEST
END OF WORK PACKAGE
0097–29/blank
TM 9-2355-106-23-1 0098
FIELD MAINTENANCE
CLEARANCE AND MARKER LIGHTS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0370
WP 0441
References
WP 0442
TM 9-2355-106-10
WP 0424
TM 9-2355-106-23P
WP 0426
WP 0059
WP 0427
WP 0092
WP 0517
WP 0257
WP 0580
WP 0303
WP 0597
WP 0297
WP 0598
WP 0333
WP 0782
WP 0335
WP 0324 Vehicle parking brake set (TM 9-2355-106-10)
WP 0372 9-2355-106-10)
WP 0361 Engine off (TM 9-2355-106-10)
WP 0374
WP 0378 (WP 0789, Figure 58)
WP 0379 (WP 0789, Figure 59)
WP 0367 (WP 0789, Figure 60)
WP 0385 (WP 0789, Figure 14)
0098–1
TM 9-2355-106-23-1 0098
CLEARANCE AND MARKER LIGHTS TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
STEP

3. Enable lights by pressing SER. DRIVE on Master Vehicle Light Switch (MVLS) and then press ENTER
within 5 seconds (TM 9-2355-106-10).
Is one fender marker/turn signal light inoperative?
DECISION
YES Go to Step 18.

NO Go to next step.
STEP
4. Observe marker/turn signal lights next to front headlights.

0098–2
TM 9-2355-106-23-1 0098
Is one marker/turn signal light next to front headlight inoperative?
DECISION
YES Go to Step 32.

NO Go to next step.
STEP
5. Observe marker/turn signal lights next to front headlights and fender marker/turn signal light.
Are marker/turn signal light next to front headlight, and fender marker/turn signal light on one side, inoperative?
DECISION
YES Go to Step 37.

NO Go to next step.
STEP
6. Observe front bumper marker/turn signal lights.
Is one front bumper marker/turn signal light inoperative?
DECISION
YES Go to Step 44.

NO Go to next step.
STEP
7. Observe front marker/turn signal lights.
Are all front marker/turn signal lights on one side inoperative?
DECISION
YES Go to Step 51.

NO Go to next step.
STEP
8. Observe all marker/turn signal lights.
Are all front marker/turn signals inoperative?
DECISION
YES Go to Step 58.
0098–3
TM 9-2355-106-23-1 0098
NO Go to next step.
STEP
9. Observe rear marker/turn signal lights.
Is one rear marker/turn signal light inoperative?
DECISION
YES Go to Step 64.

NO Go to next step.
STEP
10. Observe rear side marker lights.
Is one rear side marker light inoperative?
DECISION
YES Go to Step 145.

NO Go to next step.
STEP
11. Observe rear marker/turn signal lights.
Are all rear marker/turn signal lights inoperative?
DECISION
YES Go to Step 70.

NO Go to next step.
STEP
12. Observe all marker/turn signal lights at front and rear.
Are all marker/turn signals lights and clearance lights at front and rear inoperative?
DECISION
YES Go to Step 92.

NO Go to next step.
STEP
13. Observe all marker/turn signal lights at front and rear.
Are rear marker/turn signals lights and all clearance lights inoperative?
0098–4
TM 9-2355-106-23-1 0098
DECISION
YES Go to Step 152.

NO Go to next step.
STEP
14. Observe clearance lights at front and rear.
Is one clearance light inoperative?
DECISION
YES Go to Step 104.

NO Go to next step.
STEP
Are both front and rear clearance lights inoperative?
DECISION
YES Go to Step 109.

NO Go to next step.
STEP
Are front clearance lights inoperative?
DECISION
YES Go to Step 131.

NO Go to next step.
STEP
Are rear clearance lights inoperative?
DECISION
YES Go to Step 138.

NO Marker and clearance lights are operating normally. Return vehicle to service.
0098–5
TM 9-2355-106-23-1 0098
STEP

20. Remove inoperative fender marker/turn signal bulb from socket by disconnecting connector 8154 for left front
fender marker/turn signal light, or 8154R for right front fender marker/turn signal light. Refer to Figure 1 or
Figure 2. Refer to Front Fender Light Bulb Removal and Installation (WP 0372).
Figure 1. Left Front Fender Turn Signal Bulb Socket.
Figure 2. Right Front Fender Turn Signal Bulb Socket.

23. Enable lights by pressing SER. DRIVE on MVLS and then press ENTER within 5 seconds (TM 9-2355-106-10).
24. Measure DC voltage between connector 8154 or 8154R terminal B and terminal G with multimeter. Refer to
Figure 1 or Figure 2.
DECISION
YES Go to Step 184.

NO Go to next step.
STEP

0098–6
TM 9-2355-106-23-1 0098
27. Disconnect connector LAM1061 for left front fender marker/turn signal light or LAM1062 for right front fender
marker/turn signal light. Refer to Figure 3.
Figure 3. Front Fender Marker/Turn Signal Light Connector.

31. Measure DC voltage between harness connector LAM1061 or LAM1062 terminal C and terminal B with
DECISION
YES Go to Step 192.

NO Go to Step 193.
0098–7
TM 9-2355-106-23-1 0098
STEP
32. Remove inoperative marker/turn signal bulb from socket. Refer to Front Turn Signal and Parking Light Bulb
Figure 4. Front Turn Signal Bulb Socket (Near Headlight).

36. Measure DC voltage between bulb socket connector LAM1203 or bulb socket connector LAM1204 terminals B
and G with multimeter. Refer to Figure 4.
DECISION
YES Go to Step 183.

NO Go to Step 193.
0098–8
TM 9-2355-106-23-1 0098
STEP

39. Follow wiring harness down from headlight and disconnect first 5-way harness connector LAM1046 for left
marker/turn signal or LAM1047 for right marker/turn signal. Refer to Figure 5. Right side similar.
Figure 5. Left Headlight/Turn Signal Harness Connector Near Front Spring Shackle.

43. Measure DC voltage between harness connector LAM1046 or LAM1047 terminal B and terminal E with
multimeter. Refer to Figure 5. Right side similar.
DECISION
YES Go to Step 193.

NO Go to Step 191.
0098–9
TM 9-2355-106-23-1 0098
STEP

46. Disconnect connectors LAM1104 for right side or LAM1103 for left side leading to 491 and GND terminals on
inoperative front bumper light assembly. Refer to Figure 6 or Figure 7.
Figure 6. Front Bumper Light Assembly, Right Side.
0098–10
TM 9-2355-106-23-1 0098
Figure 7. Front Bumper Light Assembly Left Side.

50. Measure DC voltage between harness side connector LAM1104 for right side or LAM1103 for left side for
terminals leading to 491 and GND on front bumper light assembly with multimeter. Refer to Figure 6 or
Figure 7.
DECISION
YES Go to Step 185.

NO Go to Step 191.
0098–11
TM 9-2355-106-23-1 0098
STEP

53. Follow wiring harness down from headlight and disconnect second 5-way harness connector LAM1101 for left
marker/turn signal, or LAM1107 for right marker/turn signal. Refer to Figure 8 or Figure 9.
Figure 8. Left Front Bumper/Front Chassis Connector Near Front Spring Shackle.
Figure 9. Right Front Bumper/Front Chassis Connector Near Front Spring Shackle.

57. Measure DC voltage between harness connector LAM1101 or LAM1107 terminal E and B with multimeter.
Refer to Figure 8 or Figure 9.
0098–12
TM 9-2355-106-23-1 0098
DECISION
YES Go to Step 191.

NO Go to Step 190.
STEP
58. Remove left side engine armor plate bracket. Refer to Left Engine Armor Plate Bracket Removal and
59. Disconnect 24-way connector 4301 from 24-way connector 4300. Refer to Figure 10.
Figure 10. Front Chassis/Dash Connector in Engine Compartment.

62. Enable lights by pressing SER. DRIVE on MVLS switch and then press ENTER within 5 seconds (TM
9-2355-106-10).
0098–13
TM 9-2355-106-23-1 0098
63. Measure DC voltage between harness connector 4301 terminal 12 and terminal 13 with multimeter. Refer to
Figure 10.
DECISION
YES Go to Step 190.

NO Go to Step 189.
STEP
64. Remove taillamp assembly. Refer to Composite Taillamp Assembly Removal and Installation (WP 0383).
65. Disconnect connectors leading to 21 and GND terminals on inoperative light. Refer to Figure 11. Right
side shown; left side similar.
Figure 11. Circuit Identification on Composite Taillamp Assembly for Turn Signal Bullet Connectors.

9-2355-106-10).
69. Measure DC voltage between harness side connectors for terminals 21 and GND with multimeter. Refer to
Figure 11.
0098–14
TM 9-2355-106-23-1 0098
DECISION
YES Go to Step 186.

NO Go to Step 197.
STEP

72. Follow wiring harness down from taillamp and disconnect 5-way harness connector 9303A. Refer to Figure 12.
Figure 12. Taillamp/Rear Chassis Harness Inside Left Frame Rail Near Rear Crossmember.

9-2355-106-10).
76. Measure DC voltage between connector 9303A terminals E and D with multimeter. Refer to Figure 12.
DECISION
YES Go to Step 197.

NO Go to next step.
STEP

80. Disconnect center/rear chassis connector 9800M. Refer to Figure 13.
0098–15
TM 9-2355-106-23-1 0098
Figure 13. Center/Rear Chassis Connector Inside Left Frame Rail.

9-2355-106-10).
84. Measure DC voltage between connector 9800M terminals 4 and 12 with multimeter. Refer to Figure 13.
DECISION
YES Go to Step 196.

NO Go to next step.
STEP
(WP 0597).
87. Disconnect connector 9714 from connector 9700 in engine compartment. Refer to Figure 14.
0098–16
TM 9-2355-106-23-1 0098

9-2355-106-10).
91. Measure DC voltage between dash side connector 9714 terminal B7 and C6 with multimeter. Refer to
Figure 14.
DECISION
YES Go to Step 195.

NO Go to Step 189.
0098–17
TM 9-2355-106-23-1 0098
STEP
92. Remove TRUCK MARKER TAIL relay from center instrument panel relay block. Refer to Power Distribution
Center (PDC) Fuse and Relay Removal and Installation (WP 0333). Refer to Figure 15.
0098–18
TM 9-2355-106-23-1 0098
94. Measure resistance between relay socket terminal 87 and connector 4007 terminal H with multimeter. Refer
DECISION
YES Go to Step 189.

NO Go to next step.
0098–19
TM 9-2355-106-23-1 0098
STEP
95. Disconnect connector 1520. Refer to Instrument Panel Cluster (IPC) Removal and Installation (WP 0297).
Refer to Figure 17.
Figure 17. Behind IP.

DECISION
YES Go to Step 188.

NO Go to next step.
STEP

102.Disconnect connector 1954 at MVLS switch. Refer to Master Vehicle Light Switch (MVLS) Removal and
0098–20
TM 9-2355-106-23-1 0098
Figure 18. MVLS.
103.Measure resistance between connector 1520 terminal B and connector 1954 terminal H with multimeter. Refer
DECISION
YES Go to Step 187.

NO Go to Step 198.
0098–21
TM 9-2355-106-23-1 0098
STEP
104.Remove inoperative clearance light from mounting bar. Refer to Rear Clearance Light Assembly Removal and
Installation (WP 0385) or Front Clearance Light Assembly Removal and Installation (WP 0369).
107.Enable lights by pressing SER. DRIVE on MVLS and then press ENTER within 5 seconds (TM 9-2355-106-10).
108.Measure DC voltage between inoperative clearance light terminal and ground stud with multimeter. For front
clearance lights, refer to Figure 19. For rear clearance lights, refer to Figure 20.
Figure 19. Front Clearance Light Harness.
0098–22
TM 9-2355-106-23-1 0098
Figure 20. Rear Clearance Light Harness.
DECISION
YES Go to Step 204.

NO Go to Step 206.
0098–23
TM 9-2355-106-23-1 0098
STEP

Figure 21. Above Right Side Windshield.

115. Measure DC voltage between connector LAM1171 terminals A and B with multimeter. Refer to Figure 21.
DECISION
YES Go to Step 202.

NO Go to next step.
STEP
116. Remove instrument panel (IP) right side closeout. Refer to Instrument Panel (IP) Right Side Closeout
0098–24
TM 9-2355-106-23-1 0098
Figure 22. Behind Right Side IP Closeout.

121.Measure DC voltage between connector LAM1039 terminal A and B with multimeter. Refer to Figure 22.
DECISION
YES Go to Step 201.

NO Go to next step.
STEP
122.Measure DC voltage between connector LAM1039 terminal A and ground with multimeter. Refer to Figure 22.
DECISION
YES Go to Step 203.

NO Go to next step.
STEP

125.Measure resistance between connector LAM1039 (engine side) terminal A and ground with multimeter.
Refer to Figure 22.
0098–25
TM 9-2355-106-23-1 0098
DECISION
YES Go to Step 128.

NO Go to next step.
STEP
126.Disconnect connector 1701. Refer to Figure 23.
Figure 23. Left Side Engine Compartment on Bulkhead.
127.Measure resistance between connector 1701 (cabin side) terminal 21 and ground with multimeter. Refer to
Figure 23.
DECISION
NO Go to Step 189.
YES Go to Step 203.
STEP
128.Remove TRUCK MARKER TAIL relay. Refer to Power Distribution Center Fuse and Relay Removal and
0098–26
TM 9-2355-106-23-1 0098
0098–27
TM 9-2355-106-23-1 0098
Figure 25. Left Side Engine Compartment on Bulkhead.
130.Measure resistance between connector 1701 (engine side) terminal 21 and relay socket terminal 30 with
DECISION
YES Go to Step 187.

NO Go to Step 189.
STEP

133.Disconnect connector LAM1138. Refer to Figure 26.
0098–28
TM 9-2355-106-23-1 0098
Figure 26. Above Right Side Windshield.

137.Measure DC voltage between connector LAM1138 terminals A and B with multimeter. Refer to Figure 26.
DECISION
YES Go to Step 199.

NO Go to Step 202.
0098–29
TM 9-2355-106-23-1 0098
STEP

140.Disconnect connector LAM1137. Refer to Figure 27.
Figure 27. Above Rear Ramp.

143.Enable lights by pressing SER. DRIVE on MVLS and then pressing ENTER within 5 seconds (TM
9-2355-106-10).
144.Measure DC voltage between connector LAM1137 terminals A and B with multimeter. Refer to Figure 27.
DECISION
YES Go to Step 200.

NO Go to Step 202.
STEP

147.Disconnect connector LAM1089 for left side or LAM1090 for right side. Refer to Figure 28 or Figure 29.
0098–30
TM 9-2355-106-23-1 0098
Figure 28. Left Side Rear Stowage Box.
Figure 29. Right Side Rear Stowage Box.

9-2355-106-10).
151.Measure DC voltage between connector terminal for inoperative light, LAM1089 or LAM1090, and ground
with multimeter. Refer to Figure 28 or Figure 29.
DECISION
YES Go to Step 205.

NO Go to Step 197.
0098–31
TM 9-2355-106-23-1 0098
STEP
152.Remove TRUCK MARKER/TAIL relay from center instrument panel relay block. Refer to Power Distribution
Center (PDC) Fuse and Relay Removal and Installation (WP 0333). Refer to Figure 30.

9-2355-106-10).
156.Measure DC voltage between TRUCK MARKER/TAIL relay socket terminal 87 and ground with multimeter.
Refer to Figure 30.
DECISION
NO Go to Step 189.
STEP

159.Measure resistance between TRUCK MARKER/TAIL relay socket terminal 86 and ground with multimeter.
Refer to Figure 31.
0098–32
TM 9-2355-106-23-1 0098
Figure 31. Truck Marker/Tail Relay Socket.
DECISION
NO Go to Step 189.
STEP

9-2355-106-10).
163.Measure DC voltage between relay socket terminal 85 and ground with multimeter. Refer to Figure 31.
DECISION
YES Go to Step 177.

NO Go to next step.
0098–33
TM 9-2355-106-23-1 0098
STEP

Figure 32. Left Side Engine Compartment Bulkhead.

9-2355-106-10).
170.Measure DC voltage between connector 1701 (cabin side) terminal 27 and ground with multimeter. Refer to
Figure 32.
DECISION
YES Go to Step 203.

NO Go to next step.
STEP

173.Disconnect connector 1954. Refer to Figure 33. Refer to Master Vehicle Light Switch (MVLS) Removal and
0098–34
TM 9-2355-106-23-1 0098
Figure 33. MVLS.
0098–35
TM 9-2355-106-23-1 0098
174.Measure resistance between connector 1701 (cabin side) terminal 27 and ground with multimeter. Refer to
Figure 34.
DECISION
YES Go to Step 203.

NO Go to next step.
STEP
175.Measure resistance between connector 1701 (cabin side) terminal 27 and connector 1954 terminal H with
DECISION
NO Go to Step 203.
STEP
176.Measure resistance between connector 1954 terminal H and all other connector 1954 terminals with
0098–36
TM 9-2355-106-23-1 0098
DECISION
NO Go to Step 203.
YES Go to Step 198.
STEP

179.Connect a jumper wire from relay socket terminal 87 to terminal 30. Refer to Figure 35.

9-2355-106-10).
Are rear marker/turn signals lights and all clearance lights ON?
DECISION
YES Go to Step 194.

NO Go to Step 189.
0098–37
TM 9-2355-106-23-1 0098
MALFUNCTION
- 183. Front marker/turn signal bulb is faulty.
ACTION
Replace bulb. Refer to Front Turn Signal and Parking Light Bulb Removal and Installation (WP 0373). Return
vehicle to service.
END OF TEST
MALFUNCTION
- 184. Front fender light bulb is faulty.
ACTION
Replace bulb. Refer to Front Fender Light Bulb Removal and Installation (WP 0372). Return vehicle to service.
END OF TEST
MALFUNCTION
- 185. Front bumper lamp unit is faulty.
ACTION
Replace front bumper lamp unit. Refer to Front Bumper Turn Signal and Parking Light Assembly Removal and
END OF TEST
MALFUNCTION
- 186. Taillamp is faulty.
ACTION
Replace taillamp. Refer to Composite Taillamp Assembly Removal and Installation (WP 0383). Return vehicle
to service.
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
to service.
0098–38
TM 9-2355-106-23-1 0098
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
Replace front bumper harness. Refer to Front Bumper Right Harness Removal and Installation (WP 0375) or
Front Bumper Left Harness Removal and Installation (WP 0374). Return vehicle to service.
END OF TEST
MALFUNCTION
- 192. Front fender jumper harness is faulty.
ACTION
Replace front fender jumper harness. Refer to Front Fender Jumper Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
Replace headlight and turn signal harness. Refer to Left Headlight and Turn Signal Harness Removal and
Installation (WP 0378). Refer to Right Headlight and Turn Signal Harness Removal and Installation (WP 0379).
0098–39
TM 9-2355-106-23-1 0098
END OF TEST
MALFUNCTION
- 194. TRUCK MARKER TAIL relay is faulty.
ACTION
Replace TRUCK MARKER TAIL relay. Refer to Power Distribution Center Fuse and Relay Removal and
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
to service.
END OF TEST
MALFUNCTION
- 198. MVLS switch is faulty.
ACTION
Refer to Master Vehicle Light Switch (MVLS) Troubleshooting Procedures (WP 0092). Return vehicle to service.
END OF TEST
MALFUNCTION
- 199. Front clearance light bar harness is faulty.

0098–40
TM 9-2355-106-23-1 0098
ACTION
Replace front clearance light bar harness. Refer to Front Clearance Light Bar Harness Removal and Installation
END OF TEST
MALFUNCTION
- 200. Rear clearance harness is faulty.
ACTION
Replace rear clearance harness. Refer to Rear Clearance Light Bar Harness Removal and Installation
END OF TEST
MALFUNCTION
- 201. Clearance lights cabin jumper harness is faulty.
ACTION
Replace clearance lights cabin jumper harness. Refer to Clearance Lights Cabin Jumper Harness Removal and
END OF TEST
MALFUNCTION
- 202. Front and rear clearance lights harness is faulty.
ACTION
Replace front and rear clearance lights harness. Refer to Front and Rear Clearance Lights Harness Removal
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 204. Clearance light assembly is faulty.
ACTION
Replace front rear clearance light assembly. Refer to Rear Clearance Light Assembly Removal and Installation
(WP 0386) or Front Clearance Light Assembly Removal and Installation (WP 0369).
0098–41
TM 9-2355-106-23-1 0098
END OF TEST
MALFUNCTION
- 205. Rear side marker light assembly is faulty.
ACTION
Replace rear sidemarker light assembly. Refer to Rear Sidemarker Light Assembly Removal and Installation
(WP 0387).
END OF TEST
MALFUNCTION
- 206. Front or rear clearance light bar harness is faulty.
ACTION
Replace front clearance light bar harness with inoperative light or rear clearance light bar harness with
inoperative light. Refer to Rear Clearance Light Bar Harness Removal and Installation (WP 0386) or Front
Clearance Light Bar Harness Removal and Installation (WP 0370). Return vehicle to service.
END OF TEST
END OF WORK PACKAGE
0098–42
TM 9-2355-106-23-1 0099
FIELD MAINTENANCE
BLACKOUT DRIVING LIGHT TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0366
WP 0597 (WP 0789, Figure 63)
WARNING
0099–1
TM 9-2355-106-23-1 0099
BLACKOUT DRIVING LIGHT TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP
1. Disconnect blackout driving light connector LAM1099. Refer to Figure 1.
Figure 1. Left Front Bumper Area.

4. Press Master Vehicle Light Switch (MVLS) B.O. DRIVE button and then press ENTER within 5 seconds (TM
9-2355-106-10).
5. Measure DC voltage between connector LAM1099 and LAM1102 with multimeter. Refer to Figure 1.
DECISION
YES Go to Step 29.

NO Go to next step.
0099–2
TM 9-2355-106-23-1 0099
STEP

8. Disconnect blackout lighting connector 9916. Refer to Figure 2.

DECISION
YES Go to Step 30.

NO Go to next step.
STEP

(WP 0597).
0099–3
TM 9-2355-106-23-1 0099
16. Disconnect harness connector 4300/4301 (22 wire). Refer to Figure 3.
Figure 3. Left Engine Compartment Area.

DECISION
YES Go to Step 31.

NO Go to next step.
0099–4
TM 9-2355-106-23-1 0099
STEP

23. Measure resistance between connector 1701 (engine side) terminal 37 and ground with multimeter. Refer
to Figure 4.
DECISION
NO Go to Step 32.
0099–5
TM 9-2355-106-23-1 0099
STEP
24. Measure resistance between connector 1701 terminal 37 (engine side) and connector 4301 terminal 21.
DECISION
NO Go to Step 32.
0099–6
TM 9-2355-106-23-1 0099
STEP
25. Disconnect MVLS connector 1954. Refer to Figure 6. Refer to Master Vehicle Light Switch (MVLS) Removal
Figure 6. Behind Dash Area.
26. Measure resistance between connector 1701 (cabin side) terminal 37 and ground with multimeter. Refer
to Figure 7.
0099–7
TM 9-2355-106-23-1 0099
DECISION
NO Go to Step 33.
STEP
27. With assistance, measure resistance between connector 1701 (cabin side) terminal 37 and connector 1954
terminal D with multimeter. Refer to Figure 7. Refer to Figure 8.
0099–8
TM 9-2355-106-23-1 0099
DECISION
NO Go to Step 33.
0099–9
TM 9-2355-106-23-1 0099
STEP
28. Measure resistance between connector 1954 terminal D and all other connector 1954 terminals with
DECISION
NO Go to Step 33.
YES Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedure (WP 0092).
MALFUNCTION
- 29. Blackout light is faulty.
ACTION
Replace blackout light. Refer to Blackout Drive Light Assembly Removal and Installation (WP 0366). Return
vehicle to service.
END OF TEST
0099–10
TM 9-2355-106-23-1 0099
MALFUNCTION
- 30. Left bumper wiring harness is faulty.
ACTION
Replace left bumper wiring harness. Refer to Front Bumper Left and Right Harness Removal and Installation
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
END OF WORK PACKAGE
0099–11/blank
TM 9-2355-106-23-1 0100
FIELD MAINTENANCE
BLACKOUT MARKER LIGHTS TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
(WP 0795, Item 37) WP 0424
WP 0427
Personnel Required
WP 0598
Maintainer - (2)
WP 0782
References
Equipment Condition
TM 9-2355-106-10
TM 9-2355-106-23P
WP 0092
9-2355-106-10)
WP 0303
Engine off (TM 9-2355-106-10)
WP 0319
WP 0333
WP 0335
WP 0361
WP 0384 (WP 0789, Figure 64)
WARNING
0100–1
TM 9-2355-106-23-1 0100
BLACKOUT MARKER LIGHTS TROUBLESHOOTING PROCEDURE - (CONTINUED)
CAUTION
NOTE
STEP

3. Press Master Vehicle Light Switch (MVLS) ALL OFF button, then press ENTER within 5 seconds (TM
9-2355-106-10).
4. Observe blackout marker lights (TM 9-2355-106-10).
Are all blackout marker lights off?
DECISION
NO Go to Step 23.
0100–2
TM 9-2355-106-23-1 0100
STEP
5. Press MVLS B.O. MARKER button, then press ENTER within 5 seconds.
6. Observe blackout marker lights.
Are all blackout marker lights on?
DECISION

NO Go to next step.
STEP
Are any blackout marker lights on?
DECISION
YES Go to Step 64.

NO Go to next step.
STEP

0100–3
TM 9-2355-106-23-1 0100
10. Remove B/O MRKR TRUCK 4003 relay. Refer to Figure 1. Refer to Power Distribution Center (PDC) Fuse

13. Press B.O. MARKER then enter within 5 seconds on MVLS switch.
14. Measure DC voltage between B/O MARKER TRUCK relay socket terminal 86 and ground with multimeter.
Refer to Figure 1.
DECISION
NO Go to Step 128.
STEP
0100–4
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 128.
STEP
16. Measure DC voltage between relay socket terminal 87 and 85 with multimeter. Refer to Figure 2.
Figure 2. Blackout Relay Terminals.
DECISION
NO Go to Step 150.
STEP

19. Install jumper wire between relay socket terminals 30 and 87. Refer to Figure 2.
Are any blackout marker lights on?
DECISION
YES Go to Step 151.

NO Go to Step 150.
0100–5
TM 9-2355-106-23-1 0100
STEP
23. Disconnect MVLS connector 1954. Refer to Figure 3. Refer to Master Vehicle Light Switch (MVLS) Removal
Are blackout marker lights off?
DECISION
YES Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedure (WP 0092).
NO Go to next step.
0100–6
TM 9-2355-106-23-1 0100
STEP
25. Remove B/O MRKR TRUCK 4003 relay. Refer to Figure 4. Refer to Power Distribution Center (PDC) Fuse
Are blackout marker lights off?
DECISION
NO Go to Step 28.
STEP
27. Measure DC voltage between B/O MARKER TRUCK relay socket terminal 86 and ground with multimeter.
Refer to Figure 4.
0100–7
TM 9-2355-106-23-1 0100
DECISION
YES Go to Step 54.

NO Go to Step 151.
STEP

32. Disconnect harness connector 4301 from 4300 (22-wire). Refer to Figure 5.

35. Measure DC voltage between connector 4301 (22-wire, relay side) terminal 23 and ground with multimeter.
Refer to Figure 5.
0100–8
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 58.
STEP

38. Disconnect harness connector 9700 from 9714. Refer to Figure 6.

41. Measure DC voltage between connector 9700 (relay side) terminal D1 and ground with multimeter. Refer
to Figure 6.
DECISION
YES Go to Step 150.

NO Go to next step.
0100–9
TM 9-2355-106-23-1 0100
STEP

44. Disconnect harness connector 9800M from 9800F. Refer to Figure 7.
Figure 7. Left Center Frame.

47. Measure DC voltage between connector 9800M terminal 5 and ground with multimeter. Refer to Figure 7.
DECISION
NO Go to Step 152.
0100–10
TM 9-2355-106-23-1 0100
STEP

50. Disconnect harness connector 9720 from LAM1085. Refer to Figure 8.
Figure 8. Left Rear Frame.

DECISION
NO Go to Step 153.
YES Go to Step 154.
0100–11
TM 9-2355-106-23-1 0100
STEP

57. Measure resistance between connector 1701 (cabin side) terminal 24 and all other connector 1701 terminals
with multimeter. Multimeter should read OL for each test. Refer to Figure 9.
DECISION
YES Go to Step 150.

NO Go to Step 155.
STEP

0100–12
TM 9-2355-106-23-1 0100
Figure 10. Right Front Bumper Area.
60. Disconnect connector LAM1104 wire 483. Refer to Figure 10.

63. Measure voltage between connector 4300 (22-wire) terminal 23 and ground. Refer to Figure 11.
0100–13
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 157.
YES Go to Step 137.
STEP
Are all front blackout marker lights on?
DECISION
NO Go to Step 97.
STEP

67. Remove inoperative taillight assembly. Refer to Composite Taillamp Assembly Removal and Installation
(WP 0383).
68. Disconnect inoperative rear blackout (wire 24) connector. Refer to Figure 12 and Figure 13.
Figure 12. Right Rear of Vehicle Behind Taillight Assembly.

0100–14
TM 9-2355-106-23-1 0100
Figure 13. Left Rear of Vehicle Behind Taillight Assembly.

71. Turn B/O lights ON (TM 9-2355-106-10).
72. Measure DC voltage between connector LAM1088 or LAM1087 and ground with multimeter. Refer to
Figure 12 and Figure 13.
Does multimeter read between 10.5V and 13.5V at inoperative rear blackout light connectors?
DECISION
YES Go to Step 156.

NO Go to next step.
0100–15
TM 9-2355-106-23-1 0100
STEP

75. Disconnect connector 9303A. Refer to Figure 14.
Figure 14. Rear Frame Rail.
Figure 15. Rear Frame Rail.

80. Measure DC voltage between connector 9303A terminal E and connector 9720 terminal B with multimeter.
0100–16
TM 9-2355-106-23-1 0100
Figure 16. Connector 9303A.
DECISION
YES Go to Step 154.

NO Go to next step.
0100–17
TM 9-2355-106-23-1 0100
STEP

83. Disconnect harness connector 9800F from 9800M. Refer to Figure 17.
Figure 17. Left Center Frame Rail.

87. Measure DC voltage between connector 9800F terminals 5 and 12 with multimeter. Refer to Figure 17.
DECISION
YES Go to Step 153.

NO Go to next step.
0100–18
TM 9-2355-106-23-1 0100
STEP

92. Disconnect connectors 9714 from 9700. Refer to Figure 18.

96. Measure DC voltage between connector 9714 terminals C6 and D1 with multimeter. Refer to Figure 18.
DECISION
YES Go to Step 152.

NO Go to Step 150.
0100–19
TM 9-2355-106-23-1 0100
STEP
97. Observe front blackout marker lights.
Is right front marker light on?
DECISION
YES Go to Step 113.

NO Go to next step.
STEP

100.Disconnect right front blackout marker light connector LAM1104 wires 483 and GND. Refer to Figure 19.
0100–20
TM 9-2355-106-23-1 0100

103.Turn B/O marker lights ON (TM 9-2355-106-10).
104.Measure DC voltage between connector LAM1104 wires 483 and GND with multimeter. Refer to Figure 19.
DECISION
YES Go to Step 157.

NO Go to next step.
STEP

107.Disconnect connector LAM1107 (follow wires from the B/O MARKER light to inline). Refer to Figure 20.
0100–21
TM 9-2355-106-23-1 0100

111. Press MVLS B.O. MARKER button, then press ENTER within 5 seconds.
112. Measure DC voltage between connector LAM1107 terminal B and connector 9917 terminal A with multimeter.
DECISION
YES Go to Step 158.

NO Go to Step 159.
0100–22
TM 9-2355-106-23-1 0100
STEP

115. Disconnect left front blackout marker light connector LAM1103 wires 483 and GND. Refer to Figure 23.

118. Turn B/O marker lights ON (TM 9-2355-106-10).
119. Measure DC voltage between connector LAM1103 wires 483 and GND with multimeter. Refer to Figure 23.
DECISION
YES Go to Step 160.

NO Go to next step.
0100–23
TM 9-2355-106-23-1 0100
STEP

122.Disconnect connector LAM1101 (follow wire harness from B/O MARKER light to inline). Refer to Figure 24.

0100–24
TM 9-2355-106-23-1 0100
126.Turn B/O marker lights ON (TM 9-2355-106-10).

127.Measure DC voltage between connector LAM1101 terminal B and connector 9916 terminal A with multimeter.
DECISION
YES Go to Step 161.

NO Go to Step 159.
STEP

130.Disconnect pass-through connector 1701. Refer to Figure 26.
131.Measure resistance between connector 1701 (engine side) terminal 24 and ground with multimeter. Refer to
Figure 26.
0100–25
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 150.
STEP
132.Measure resistance between connector 1701 (engine side) terminal 24 and B/O relay socket terminal 86.
Figure 27. Blackout Relay Terminals.
DECISION
NO Go to Step 150.
0100–26
TM 9-2355-106-23-1 0100
STEP
133.Disconnect MVLS connector 1954. Refer to Figure 29. Refer to Master Vehicle Light Switch (MVLS)
0100–27
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 155.
STEP
135.With assistance, measure resistance between connector 1701 terminal 24 and connector 1954 terminal E
DECISION
NO Go to Step 155.
0100–28
TM 9-2355-106-23-1 0100
STEP
DECISION
NO Go to Step 155.
YES Go to Master Vehicle Light Switch (MVLS) Troubleshooting Procedures (WP 0092).
STEP
137.Measure voltage between connector 4301 terminal 23 and ground with multimeter. Refer to Figure 31.
DECISION
NO Go to Step 158.
0100–29
TM 9-2355-106-23-1 0100
STEP

140.Disconnect connector LAM1103 wires 483. Refer to Figure 32.

143.Measure voltage between connector 4300 (22-wire) terminal 23 and ground with multimeter. Refer to
Figure 33.
0100–30
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 160.
STEP

0100–31
TM 9-2355-106-23-1 0100

149.Measure voltage between connector 4300 (24-cavity 22-wire connector) terminal 23 and ground with

0100–32
TM 9-2355-106-23-1 0100
DECISION
NO Go to Step 161.
YES Go to Step 159.
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 151. B/O MARKER TRUCK relay is faulty.
ACTION
Replace B/O MARKER TRUCK relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and
END OF TEST
MALFUNCTION
ACTION
Replace center chassis wiring harness. Refer to Center Chassis Harness Removal and Installation (WP 0426).
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
to service.
0100–33
TM 9-2355-106-23-1 0100
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
- 156. Rear blackout light is faulty.
ACTION
Replace inoperative rear blackout light. Refer to Composite Taillamp Assembly Removal and Installation
END OF TEST
MALFUNCTION
- 157. Right front blackout marker light is faulty.
ACTION
Replace blackout light. Refer to Front Bumper Turn Signal and Parking Light Assembly Removal and Installation
END OF TEST
MALFUNCTION
- 158. Right front bumper harness is faulty.
ACTION
Replace right front bumper harness. Refer to Front Bumper Right Harness Removal and Installation (WP 0375).
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
- 160. Left front blackout marker light is faulty.

0100–34
TM 9-2355-106-23-1 0100
ACTION
Replace blackout light. Refer to Front Bumper Turn Signal and Parking Light Assembly Removal and Installation
END OF TEST
MALFUNCTION
- 161. Left front bumper harness is faulty.
ACTION
Replace left front bumper harness. Refer to Front Bumper Left Harness Removal and Installation (WP 0374).
END OF TEST
END OF WORK PACKAGE
0100–35/blank
TM 9-2355-106-23-1 0101
FIELD MAINTENANCE
STOPLIGHT TROUBLESHOOTING PROCEDURE
INITIAL SETUP:
70) WP 0427
WP 0517
WP 0581
WP 0597
(WP 0795, Item 37)
WP 0655
WP 0782
Personnel Required
Maintainer - (2) Equipment Condition
TM 9-2355-106-10 9-2355-106-10)
TM 9-2355-106-23P Engine off (TM 9-2355-106-10)
WP 0297
WP 0318 (WP 0789, Figure 59)
WP 0319 (WP 0789, Figure 60)
WP 0333 (WP 0789, Figure 57)
WP 0335 (WP 0789, Figure 12)
WP 0353 (WP 0789, Figure 13)
WP 0384 (WP 0789, Figure 51)
DIAGNOSTIC TROUBLE CODES AND SYMPTOMS

• Both right and left stoplights are inoperative.
• Right stoplight is inoperative.
• Left stoplight is inoperative.
• One stoplight stays on.
• Both stoplights stay on.
0101–1
TM 9-2355-106-23-1 0101
STOPLIGHT TROUBLESHOOTING PROCEDURE - (CONTINUED)
WARNING
CAUTION
NOTE
0101–2
TM 9-2355-106-23-1 0101
STEP
1. Start engine (TM 9-2355-106-10).

2. Observe Instrument Panel Cluster (IPC) air pressure gauges and allow air pressure to build to 100 psi (689
kPa).
3. Turn engine OFF (TM 9-2355-106-10).
9-2355-106-10).
6. With assistance, press down brake pedal and observe stoplights.
Are both right and left stoplights inoperative?
DECISION
YES Go to Step 10.

NO Go to next step.
STEP
7. Press down brake pedal and observe stoplights.
Is left or right stoplight inoperative?
DECISION
YES Go to Step 71.

NO Go to next step.
STEP
8. Press and release brake pedal and observe stoplights.
Do both stoplights remain on after pedal is released?
DECISION
YES Go to Step 175.

NO Go to next step.
0101–3
TM 9-2355-106-23-1 0101
STEP
9. Press and release brake pedal and observe stoplights.
Does left or right stoplight remain on after pedal is released?
DECISION
YES Go to Step 140.

NO Stoplights are operating normally. Return vehicle to service.
STEP
10. Remove left or right taillight. Refer to Composite Taillamp Assembly Removal and Installation (WP 0383).
11. Disconnect bullet connector leading to terminal GND on left or right stoplight. Refer to Figure 1.
Figure 1. Stoplight Bullet Connectors Inside Composite Taillamp Assembly, and Terminal Identification on
Taillamp.
to Figure 1.
0101–4
TM 9-2355-106-23-1 0101
DECISION

NO Go to Step 32.
STEP
13. Connect Maintenance Support Device (MSD) to vehicle. Refer to Connecting Maintenance Support Device
(MSD) (WP 0011).
14. Press SER. DRIVE on MVLS and then press ENTER within 5 seconds.
15. Ensure air pressure is sufficient to operate brakes.
16. Press brake pedal down and observe ESC inputs.
17. With MSD, verify ESC receives brake switch input.
Does Electronic System Controller (ESC) receive brake pressure switch request?
DECISION
NO Go to Brake Pressure Switch Troubleshooting Procedure (WP 0168).

STEP
18. Press brake pedal down and observe ESC outputs with MSD.
Does ESC activate brake outputs?
DECISION
NO Go to Step 179.
0101–5
TM 9-2355-106-23-1 0101
STEP
19. Remove IP center trim panel. Refer to Instrument Panel (IP) Center Trim Panel Removal and Installation
(WP 0581).
Figure 2. MVLS Connector in Center IP.
21. Measure resistance between connector 1954 terminal J and ground with multimeter. Refer to Figure 2.
Does multimeter read less than 0.8 ohms?
DECISION
YES Go to Step 40.

NO Go to next step.
0101–6
TM 9-2355-106-23-1 0101
STEP
22. Connect MVLS connector 1954.


DECISION
YES Go to Step 66.

NO Go to next step.
0101–7
TM 9-2355-106-23-1 0101
STEP
28. Turn ignition switch OFF (TM-9-2355-106-10).

29. Turn MAIN POWER switch OFF (TM-9-2355-106-10).
Figure 4. MVLS Connector in Center IP.
31. Measure resistance between connector 1050 terminal A and MVLS connector 1954 terminal J with multimeter.

0101–8
TM 9-2355-106-23-1 0101
DECISION
YES Go to Step 187.

NO Go to Step 178.
STEP
32. Disconnect taillamp/rear chassis connector 9303A. Refer to Figure 6.
Figure 6. Taillamp/Rear Chassis Harness Connector Inside Left Frame Rail Near Rear Crossmember.
33. Measure resistance between connector 9303A terminal E and ground with multimeter. Refer to Figure 6.
DECISION
YES Go to Step 186.

NO Go to next step.
STEP
0101–9
TM 9-2355-106-23-1 0101
Figure 7. Center/Rear Chassis Connector on Left Frame Rail.
DECISION
YES Go to Step 185.

NO Go to next step.
0101–10
TM 9-2355-106-23-1 0101
STEP
(WP 0597).
39. Measure resistance between dash side connector 9714 terminal C6 and ground with multimeter. Refer
to Figure 8.
DECISION
YES Go to Step 184.

NO Go to Step 183.
0101–11
TM 9-2355-106-23-1 0101
STEP
DECISION
YES Go to Step 178.

NO Go to next step.
STEP
42. Measure resistance between connector 1050 terminal H and ground with multimeter. Refer to Figure 9.
DECISION
YES Go to Step 46.

NO Go to next step.
0101–12
TM 9-2355-106-23-1 0101
STEP
DECISION
YES Go to Step 52.

NO Go to next step.
STEP
DECISION
YES Go to Step 55.

NO Go to next step.
STEP
DECISION
YES Go to Step 57.

NO Go to Step 59.
0101–13
TM 9-2355-106-23-1 0101
STEP
46. Disconnect IP/Dash connector 1701. Refer to Figure 10.
47. Measure resistance between engine side connector 1701 terminal 27 and ground with multimeter. Refer to
Figure 10.
DECISION
NO Go to Step 178.
0101–14
TM 9-2355-106-23-1 0101
STEP
48. Remove right stop/turn relay. Refer to Figure 11 Refer to Power Distribution Center (PDC) Fuse and Relay
Figure 11. Right Stop/Turn Relay in Engine Compartment Power Distribution Center (PDC).
DECISION
NO Go to Step 182.
0101–15
TM 9-2355-106-23-1 0101
STEP
50. Remove LEFT STOP TURN relay. Refer to Figure 12. Refer to Power Distribution Center (PDC) Fuse
Figure 12. Left Stop/Turn Relay in Engine Compartment PDC.
0101–16
TM 9-2355-106-23-1 0101
DECISION
NO Go to Step 182.
YES Go to Step 183.
0101–17
TM 9-2355-106-23-1 0101
STEP
53. Disconnect IPC connector 1500. Refer to Figure 14.
Figure 14. IPC Connector in Left IP.
DECISION
NO Go to Step 188.
YES Go to Step 178.
STEP
55. Remove left turn enable relay. Refer to Figure 16.

0101–18
TM 9-2355-106-23-1 0101
Figure 16. Left Turn Enable Relay in Center IP.
DECISION
NO Go to Step 181.
YES Go to Step 178.
0101–19
TM 9-2355-106-23-1 0101
STEP
57. Remove right turn enable relay. Refer to Figure 17.
Figure 17. Right Turn Enable Relay in Center IP.
0101–20
TM 9-2355-106-23-1 0101
DECISION
NO Go to Step 181.
YES Go to Step 178.
STEP
59. Remove STOPLIGHT RELAY LEFT. Refer to Figure 19.
Figure 19. Left Stoplight Relay in Cabin Fuse and Relay Center.
DECISION
NO Go to Step 180.
0101–21
TM 9-2355-106-23-1 0101
STEP
61. Remove STOPLIGHT RELAY RIGHT. Refer to Figure 20.
Figure 20. Right Stoplight Relay in Cabin Fuse and Relay Center.
DECISION
NO Go to Step 180.
STEP
63. Remove FLASH-TO-PASS relay. Refer to Figure 22.

0101–22
TM 9-2355-106-23-1 0101
Figure 22. Flash-to-Pass Relay in Center IP.
DECISION
NO Go to Step 181.
YES Go to Step 178.
0101–23
TM 9-2355-106-23-1 0101
STEP
65. Remove right side IP closeout panel. Refer to Instrument Panel (IP) Right Side Closeout Removal and
66. Remove STOPLIGHT RELAY LEFT or RIGHT. Refer to Figure 23.
Figure 23. Left or Right Stoplight Relay in Cabin Fuse and Relay Center.
67. Measure resistance between STOPLIGHT RELAY LEFT or RIGHT socket terminal 85 and connector 1050
terminal D with multimeter. Refer to Figure 23. Refer to Figure 21.
DECISION
NO Go to Step 178
0101–24
TM 9-2355-106-23-1 0101
STEP
68. Measure resistance between STOPLIGHT RELAY LEFT or RIGHT relay socket terminal 86 and ground with
DECISION
NO Go to Step 178.
STEP
69. Disconnect IP/Dash connector 1701. Refer to Figure 25.
0101–25
TM 9-2355-106-23-1 0101
70. Measure resistance between connector 1701 terminal 27 and connector 1050 terminal H with multimeter.
DECISION
NO Go to Step 178.
0101–26
TM 9-2355-106-23-1 0101
YES Go to Step 183.
STEP

0101–27
TM 9-2355-106-23-1 0101
73. Disconnect bullet connectors leading to stoplight terminals 22 and GND on inoperative stoplight. Refer to
Figure 27.
Figure 27. Stoplight Connectors in Composite Taillamp Assembly.

77. Ensure sufficient air pressure to close brake switch.
78. Have assistant press down on brake pedal.
79. Measure DC voltage between harness terminal 22 and GND with multimeter. Refer to Figure 27.
DECISION
YES Go to Step 177.

NO Go to next step.
STEP

to Figure 27.
0101–28
TM 9-2355-106-23-1 0101
DECISION
YES Go to Step 186.

NO Go to next step.
STEP
83. Disconnect taillamp/rear chassis harness connector 9303A. Refer to Figure 28.
Figure 28. Taillamp/Rear Chassis Harness Connector, Inside Left Frame Rail Near Rear Crossmember.

87. Ensure sufficient air pressure to close brake switch.
89. Measure DC voltage between connector 9303A terminal B for left stoplight or terminal C for right stoplight
and ground with multimeter. Refer to Figure 28.
DECISION
YES Go to Step 186.

NO Go to next step.
0101–29
TM 9-2355-106-23-1 0101
STEP

92. Remove relay for inoperative stoplight from PDC. Refer to Figure 29.

96. Ensure sufficient air pressure to close brake pressure switch.
98. Measure DC voltage between LEFT or RIGHT STOP TURN relay socket terminal 87 and ground with
DECISION
YES Go to Step 122.

NO Go to next step.
0101–30
TM 9-2355-106-23-1 0101
STEP
99. Remove right side IP closeout panel. Refer to Instrument Panel (IP) Right Side Closeout Removal and
100.Remove relay for inoperative stoplight. Refer to Figure 30.
Figure 30. Left or Right Stoplight Relay in Cabin Relay and Fuse Center.

103.Press SER. DRIVE on MVLS and then press ENTER within 5 seconds.
104.Ensure sufficient air pressure to close brake pressure switch.
105.Have assistant press down on brake pedal.
106.Measure DC voltage between STOPLIGHT RELAY LEFT or RIGHT socket terminal 87 and ground with
DECISION
NO Go to Step 113.
0101–31
TM 9-2355-106-23-1 0101
STEP
107.Measure DC voltage between STOPLIGHT RELAY LEFT or RIGHT socket terminal 85 and ground with
DECISION
NO Go to Step 178.
STEP

110. Measure resistance between STOPLIGHT RELAY LEFT or RIGHT socket terminal 86 and ground with
multimeter. Refer to Figure 31 .
DECISION
NO Go to Step 178.
STEP
DECISION
YES Go to Step 120.

NO Go to next step.
0101–32
TM 9-2355-106-23-1 0101
STEP
112. Measure resistance between STOPLIGHT RELAY LEFT or RIGHT socket terminal 30 and LEFT or RIGHT
STOP TURN relay socket terminal 87 with multimeter. Refer to Figure 31 and refer to Figure 32.
DECISION
NO Go to Step 118.
YES Go to Step 180.
0101–33
TM 9-2355-106-23-1 0101
STEP

116. Measure resistance between STOPLIGHT RELAY RIGHT socket terminal 87 and connector 4008 terminal B
or between STOPLIGHT RELAY LEFT socket terminal 87 and connector 4008 terminal C with multimeter.
0101–34
TM 9-2355-106-23-1 0101
DECISION
NO Go to Step 178.
STEP
DECISION
NO Go to Step 179.
YES Go to Step 178.
0101–35
TM 9-2355-106-23-1 0101
STEP

119. Measure resistance between STOPLIGHT RELAY LEFT or RIGHT socket terminal 30 and connector 1703F
terminal A for right stoplight, or 1703F terminal D for left stoplight, with multimeter. Refer to Figure 35 and
Figure 36.
0101–36
TM 9-2355-106-23-1 0101
DECISION
NO Go to Step 178.
YES Go to Step 183.
STEP
120.Disconnect connector 1703F/1703M. Refer to Figure 35

121.Measure resistance between STOPLIGHT RELAY LEFT or RIGHT socket terminal 30 and ground with
DECISION
YES Go to Step 178.

NO Go to Step 183.
0101–37
TM 9-2355-106-23-1 0101
STEP
122.Measure DC voltage between LEFT or RIGHT STOP TURN relay socket terminal 86 and ground with
DECISION
NO Go to Step 183.
0101–38
TM 9-2355-106-23-1 0101
STEP

125.Measure resistance between LEFT or RIGHT STOP TURN relay socket terminal 85 and ground with
DECISION
NO Go to Step 183.
STEP
DECISION
YES Go to Step 134.

NO Go to next step.
0101–39
TM 9-2355-106-23-1 0101
STEP
127.Measure resistance between LEFT or RIGHT STOP TURN relay socket terminal 30 and connector 9303A
terminal B for left stoplight, or terminal C for right stoplight, with multimeter. Refer to Figure 38 and refer to
Figure 39.
DECISION
YES Go to Step 182.

NO Go to next step.
STEP
128.Remove left side engine armor plate. Refer to Left Side Engine Armor Plate (WP 0597).
129.Disconnect connector 9714 from 9700. Refer to Figure 40.
0101–40
TM 9-2355-106-23-1 0101
130.Measure resistance between LEFT or RIGHT STOP TURN relay socket terminal 30 and dash side connector
9714 terminal A5 for left stoplight, or terminal B6 for right stoplight, with multimeter. Refer to Figure 40
and refer to Figure 41.
DECISION
NO Go to Step 183.
0101–41
TM 9-2355-106-23-1 0101
STEP
131.Loosen air dryer mounting bolts and move air dryer to one side to access connectors on left frame rail. Refer
132.Disconnect connector 9800F from 9800M. Refer to Figure 42.
133.Measure resistance between chassis side connector 9700 terminal A5 for left stoplight, or terminal B6 for right
stoplight, and center/rear chassis connector 9800F terminal 2 for left stoplight, or terminal 3 for right stoplight,
with multimeter. Refer to Figure 40. Refer to Figure 42.
DECISION
YES Go to Step 185.

NO Go to Step 184.
STEP
135.Disconnect connector 9800M/9800F. Refer to Figure 42.
0101–42
TM 9-2355-106-23-1 0101
DECISION
NO Go to Step 185.
0101–43
TM 9-2355-106-23-1 0101
STEP
137.Remove left side engine armor plate. Refer to Left Side Engine Armor Plate Removal and Installation
(WP 0597).
138.Disconnect connector 9700 from 9714. Refer to Figure 44
DECISION
YES Go to Step 183.

NO Go to Step 184.
0101–44
TM 9-2355-106-23-1 0101
STEP
Figure 45. Electronic System Controller (ESC) Connector Under Left Side Instrument Panel.
Does stoplight go out?
DECISION
YES Go to Step 179.

NO Go to next step.
0101–45
TM 9-2355-106-23-1 0101
STEP
141.Remove STOPLIGHT RELAY LEFT or RIGHT for stoplight that remains on. Refer to Figure 46. Refer to
Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation (WP 0317).
Figure 46. Stoplight Relay Left and Right in Cabin Relay and Fuse Center.
Does taillamp go out?
DECISION
YES Go to Step 166.

NO Go to next step.
0101–46
TM 9-2355-106-23-1 0101
STEP
142.Remove RIGHT or LEFT TURN TRAILER relay for stoplight that remains on. Refer to Figure 47.
Figure 47. Right or Left Turn Trailer Relay in Engine Compartment PDC.
Does stop lamp go out?
DECISION
YES Go to Front and Rear Trailer Connector Operational Checkout Procedure (WP 0124).
NO Go to next step.
0101–47
TM 9-2355-106-23-1 0101
STEP
143.Remove LEFT or RIGHT STOP TURN relay for stoplight that remains on. Refer to Figure 48. Refer to Power
Distribution Center (PDC) Fuse and Relay Removal and Installation (WP 0333).
Figure 48. Left and Right Stop/Turn Relay in Engine Compartment PDC.
Does stop lamp go out?
DECISION
YES Go to Step 167.

NO Go to next step.
0101–48
TM 9-2355-106-23-1 0101
STEP
144.Remove left side engine armor. Refer to Left Side Engine Armor Removal and Installation (WP 0597).
145.Disconnect connector 9714 from 9700. Refer to Figure 49.
Figure 49. Dash/Center Harness Connector in Engine Compartment.

149.Measure DC voltage between dash side connector 9714 terminal B6 for right stoplight, or terminal A5 for left
stoplight, and ground with multimeter. Refer to Figure 49.
DECISION
YES Go to Step 183.

NO Go to next step.
0101–49
TM 9-2355-106-23-1 0101
STEP

152.Connect connector 9700 to 9714. Refer to Figure 49.
154.Disconnect connector 9800F from 9800M. Refer to Figure 50.
Figure 50. Center/Rear Harness Connector Inside Left Frame Rail.

158.Measure DC voltage between center chassis side connector 9800F terminal 3 for right stoplight, or terminal 2
for left stoplight, and ground with multimeter. Refer to Figure 50.
DECISION
YES Go to Step 184.

NO Go to next step.
0101–50
TM 9-2355-106-23-1 0101
STEP

161.Disconnect harness connector 9303A from LAM1086. Refer to Figure 51.

165.Measure DC voltage between connector 9303A terminal B for left stoplight, or C for right stoplight, and
ground. Refer to Figure 51.
DECISION
YES Go to Step 185.

NO Go to Step 186.
0101–51
TM 9-2355-106-23-1 0101
STEP
166.Measure voltage at STOPLIGHT RELAY LEFT or RIGHT socket terminal 87 of stoplight that was on. Refer to
Figure 52.
DECISION
YES Go to Step 178.

NO Go to Step 180.
0101–52
TM 9-2355-106-23-1 0101
STEP

169.Disconnect dash/IP connector 1703F/1703M. Refer to Figure 53.

173.Measure voltage on IP side connector 1703F terminal A for right stoplight or D for left stoplight. Refer to
Figure 53.
DECISION
YES Go to Step 178.
0101–53
TM 9-2355-106-23-1 0101
NO Go to next step.
STEP
174.Measure voltage on dash side connector 1703M terminal A for right stoplight or D for left stoplight. Refer to
Figure 53.
DECISION
YES Go to Step 183.

NO Go to Step 182.
STEP
175.Connect MSD to vehicle. Refer to Connecting Maintenance Support Device (MSD) (WP 0011).
176.Observe brake switch input to MSD with brake pedal released.
Does input show brake switch activated?
DECISION
YES Go to Brake Switch Troubleshooting Procedure (WP 0168).

NO Go to Step 179.
MALFUNCTION
- 177. Taillamp unit is faulty.
ACTION
Replace taillamp unit. Refer to Taillamp Removal and Installation (WP 0655). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
0101–54
TM 9-2355-106-23-1 0101
END OF TEST
MALFUNCTION
- 180. Instrument panel (IP) relay is faulty.
ACTION
Replace IP relay. Refer to Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation
END OF TEST
MALFUNCTION
- 181. Instrument panel center relay is faulty.
ACTION
Replace instrument panel center relay. Refer to Instrument Panel Center Relay Removal and Installation
END OF TEST
MALFUNCTION
- 182. Power Distribution Center (PDC) relay is faulty.
ACTION
Replace PDC relay. Refer to Power Distribution Center (PDC) Fuse and Relay Removal and Installation
END OF TEST
MALFUNCTION
ACTION
END OF TEST
MALFUNCTION
ACTION
0101–55
TM 9-2355-106-23-1 0101
END OF TEST
MALFUNCTION
ACTION
vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace Taillamp harness. Refer to Taillamp Harness Removal and Installation (WP 0384). Return vehicle
to service.
END OF TEST
MALFUNCTION
- 187. MVLS is faulty.
ACTION
Replace MVLS. Refer to MVLS Removal and Installation (WP 0427). Return vehicle to service.
END OF TEST
MALFUNCTION
ACTION
Replace IPC. Refer to Instrument Panel Cluster (IPC) Removal and Installation(WP 0297). Return vehicle
to service.
END OF TEST
END OF WORK PACKAGE
0101–56

TM 9-2355-106-23-1

GLOSSARY
GLOSSARY

ATA Data Link A serial datalink specified by the American Trucking Association and the SAE.
Continuous Test A function of the ECM in which ECM inputs and outputs are continuously monitored
to ensure that the readings are within set limits.
Drive Train Data Primary communication link for the ECM, ESC, and instrument cluster.
Link J1939
Driver A transistor in the output section of the ECM to turn various actuators in the system on or off.
Duty Cycle Signal A type of control signal that has a controlled on/off time measure from 0%
to 100%. Normally used to control solenoids.
Fault Detection/ An alternate control strategy devised to reduce adverse effects of a system failure. Should a
Management sensor fail, the ECM substitutes a good sensor signal or assumed sensor value in its place.

The AMBER light illuminates to alert the driver that the vehicle requires servicing.
Injection Control High lube oil pressure generated by a high pressure pump/pressure regulator
Pressure to hydraulically actuate the fuel injectors.
Input Conditioner A device or circuit that conditions or prepares an input signal for use by the microprocessor.
Low Speed Digital Switched sensor inputs that generate an on/off (high/low) signal to the ECM. The
Inputs input supplied to the ECM from the sensor could be from a high input source switch
(usually 12 or 5 volts) or a grounding-type switch, which grounds the signal from a
current-limiting resistor internal to the ECM, creating a low signal (0 volts).
Normally Closed Refers to a switch solenoid that remains closed when no control force is acting on it.
Normally Open Refers to a switch that remains open when no control force is acting on it.
On Demand Test A self-test the technician initiates that is run from a program in the processor.
Output State Check An "On Demand" test selected by the technician that forces the processor to
activate actuators "High or Low" for additional diagnostics.
Pulse Width The length of time an actuator, such as an injector, remains energized.
Switch Sensors Switch sensors are used to indicate position, levels, or pressures. Switch sensors produce a
digital signal created by opening or closing a switch. The on or off signal can indicate position
as in the case of a clutch switch, level as in the case of a coolant level switch, or pressure as
in the case of a low oil pressure switch. A switch sensor normally has two connectors: signal
return (grd) and signal. A switch sensor is considered a low speed digital signal input.

Glossary–1/blank

TM 9-2355-106-23-1

INDEX
Subject WP Sequence No.–Page No.
A
Accelerator Pedal Sensor (APS) Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0397–1
Accelerator Position Sensor (APS)/Idle Validation Switch (IVS) Troubleshooting Procedure . . . . WP 0050–1
AIR 1 Pressure Gauge and Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0294–1
AIR 1/Primary Air Pressure Gauge Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0086–1
AIR 2 Pressure Gauge and Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0295–1
AIR 2/Secondary Air Pressure Gauge Troubleshooting Procedure . . . . . . . . . . . . . . . WP 0087–1
Air Brake Component Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0173–1
Air Brake Double Check Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0522–1
Air Brake Quick Release Valves Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0521–1
Air Brake Relay Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0510–1
Air Brake System Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0172–1
Air Cleaner Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0257–1
Air Cleaner Support Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0258–1
Air Compressor Delivery Air Line Removal and Installation . . . . . . . . . . . . . . . . . . WP 0524–1
Air Compressor Governor Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0526–1
Air Compressor Governor Operational Checkout Procedure . . . . . . . . . . . . . . . . . . WP 0176–1
Air Compressor Governor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0525–1
Air Compressor Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0175–1
Air Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0527–1
Air Compressor Supply Air Line Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0523–1
Air Conditioner (A/C) Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0244–1
Air Conditioning (A/C) Condenser Fan Motor Relay Removal and Installation . . . . . . . . . . WP 0332–1
Air Conditioner Condenser Fan Assembly Removal and Installation . . . . . . . . . . . . . . . WP 0724–1
Air Conditioning (A/C) Belt Tensioner Removal and Installation . . . . . . . . . . . . . . . . . WP 0245–1
Air Conditioning (A/C) Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0189–1
Air Conditioning (A/C) Thermal Expansion Valve Operational Checkout Procedure . . . . . . . . WP 0190–1
Air Conditioning A/C Condenser Panel Removal and Installation . . . . . . . . . . . . . . . . WP 0672–1
Air Dryer Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0518–1
Air Dryer Desiccant Cartridge Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0519–1
Air Dryer Heater and Thermostat Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0174–1
Air Dryer Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0517–1
Air Filter Restriction Gauge Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0259–1
Air Filter Restriction Gauge Tubing and Fitting Removal and Installation . . . . . . . . . . . . . WP 0260–1
Air Gauge Transducer Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0322–1
Air Hose Fitting Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0513–1
Air Hose Quick Connect Fitting Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0512–1
Air Intake Tube (To Turbo) Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0256–1
Air Reservoir Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0499–1
Alternator Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0290–1
Alternator Interconnect Positive Cable Removal and Installation . . . . . . . . . . . . . . . . WP 0340–1
Alternator Pulley Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0291–1
Alternator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0289–1
American Truckers Association (ATA) Communications/Data Communications Link (DLC) Troubleshooting
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051–1
Antilock Brake System (ABS) Blink Code Switch Removal and Installation . . . . . . . . . . . . WP 0315–1
Antilock Brake System (ABS) Control Module Removal and Installation . . . . . . . . . . . . . WP 0355–1
Antilock Brake System (ABS) Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . . . . WP 0009–1
Antilock Brake System (ABS) J1939 Serial Communications Troubleshooting Procedure . . . . . WP 0139–1
Antilock Brake System (ABS) Pressure Modulator Valve (PMV) Common Circuit Troubleshooting Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0140–1
Antilock Brake System (ABS) Pressure Modulator Valve (PMV) Troubleshooting Procedure . . . . WP 0178–1
Antilock Brake System (ABS) Warning Lamp Troubleshooting Procedure . . . . . . . . . . . . WP 0079–1
Antilock Brake System (ABS) Wheel Speed Sensor Troubleshooting Procedure . . . . . . . . . WP 0177–1
Index–1
TM 9-2355-106-23-1

INDEX – (Continued)
A-Pillar Assist Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0643–1
A-Pillar Cover Trim Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0642–1
Armor Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0567–1
Armor Grille Support and Armor Grille Support Bracket Removal and Installation . . . . . . . . . WP 0568–1
Audible Alarm Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088–1
Auxiliary Spring Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0556–1

B
Backup Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0382–1
Backup Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0103–1
Barometric Pressure Sensor (BAP) Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0052–1
Barometric Pressure Sensor Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0398–1
Battery Body Ground Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0410–1
Battery Box Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0419–1
Battery Cable and Clean Power Harness Removal and Installation . . . . . . . . . . . . . . . WP 0405–1
Battery Cable Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0033–1
Battery Cables Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0407–1
Battery Disconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0404–1
Battery Disconnect Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0296–1
Battery Equalizer Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0350–1
Battery Equalizer Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0120–1
Battery Power Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0032–1
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0418–1
Battery Stud Adapter Terminal Clamp Removal and Installation . . . . . . . . . . . . . . . . WP 0409–1
Belly Armor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0606–1
Blackout Drive Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0366–1
Blackout Driving Light Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0099–1
Blackout Marker Light Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0100–1
Blackout Stoplights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0102–1
Bleeding Single Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0538–1
Body Armor Rear Wall, Riot Guard, and Bracket Removal and Installation . . . . . . . . . . . . WP 0637–1
Body Ground to Firewall Ground Cable Removal and Installation . . . . . . . . . . . . . . . . WP 0408–1
Boost Pressure Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0023–1
Bottom Ramp Step Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0640–1
Brake Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0484–1
Brake Pedal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0501–1
Brake Stoplight Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0326–1
Brake System Mechanical Components Operational Checkout Procedure . . . . . . . . . . . . WP 0170–1
Brake System Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0169–1
Brake System Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0171–1

C
Cabin Door Assist System Actuator Air Line Tubing Removal and Installation . . . . . . . . . . WP 0618–1
Cabin Door Assist System Limit Valve Removal and Installation . . . . . . . . . . . . . . . . WP 0500–1
Cabin Door Assist System Supply Air Line Tubing Removal and Installation . . . . . . . . . . . WP 0622–1
Cabin Door Assist System Supply Pass-Through Air Line Tubing Removal and Installation . . . . . WP 0621–1
Cabin Door Assist System Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0185–1
Cabin Door Combat Lock Assembly Removal and Installation . . . . . . . . . . . . . . . . . WP 0628–1
Cabin Door Combat Lock Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0183–1
Cabin Door Exterior Handle Assembly Removal and Installation (Single-and Dual-Cylinder) . . . . WP 0623–1
Cabin Door Interior Handle Assembly Removal and Installation (Dual Piston Upper Interior Combat Door
Lock-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0625–1
Cabin Door Interior Handle Assembly Removal and Installation (Single-Piston, Lower Combat Door Lock-Type)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0624–1
Index–2
TM 9-2355-106-23-1


Cabin Door Linkage Inspection and Adjustment Procedure (Lower Interior Combat Door Lock-Type) WP 0615–1
Cabin Door Linkage Inspection and Adjustment Procedure (Upper Combat Door Lock Type-Operation) WP 0616–1
Cabin Door Lock Assembly Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0184–1
Cabin Door Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0182–1
Cabin Door Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0607–1
Cabin Door Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0614–1
Cabin Door Striker and Cabin Door Check Stop Assemblies Removal and Installation . . . . . . . WP 0613–1
Cabin Door Trim Panel Removal and Installation (One-Piece, Lower Combat Door Lock-Type) . . . WP 0626–1
Cabin Door Trim Panel Removal and Installation (Two-Piece, Upper Combat Door Lock Type) . . . WP 0627–1
Cabin Electrical Ground Stud Plate Removal and Installation . . . . . . . . . . . . . . . . . . WP 0321–1
Cabin Emergency Hatch and Hinge Removal and Installation . . . . . . . . . . . . . . . . . WP 0593–1
Cabin Emergency Hatch Handle/Lock Assembly Removal and Installation . . . . . . . . . . . . WP 0594–1
Cabin Emergency Hatch Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0595–1
Cabin Fuse Block 1011 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0061–1
Cabin Roof Molding Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0583–1
Cabin Window Armor Glass Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0654–1
Camshaft Position (CMP) Sensor Removal and Installation . . . . . . . . . . . . . . . . . . WP 0393–1
Camshaft Position (CMP) Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0030–1
Center Chassis Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0426–1
Center Floor Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0660–1
Center Panel Air Filter Restriction Gauge Tubing and Fitting Removal and Installation . . . . . . . WP 0260–1
Charge Air Cooler (CAC) Assembly Removal and Installation . . . . . . . . . . . . . . . . . WP 0263–1
Charge Air Cooler (CAC) Hose Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0264–1
Charge Air Cooler Pressure Operational Checkout Procedure . . . . . . . . . . . . . . . . . WP 0024–1
Charging System Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0091–1
Check Transmission Lamp Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0075–1
Clearance and Marker Light Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0367–1
Clearance Lights Cabin Jumper Harness Removal and Installation . . . . . . . . . . . . . . . WP 0442–1
Clearance/Marker Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0098–1
Clearing Inactive Diagnostic Trouble Code (DTC) Procedure . . . . . . . . . . . . . . . . . . WP 0013–1
Climate Control Unit (CCU) Box Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0769–1
Communications Rack Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0667–1
Composite Taillamp Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0383–1
Connecting Maintenance Support Device (MSD) . . . . . . . . . . . . . . . . . . . . . . . WP 0011–1
Connector Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0790–1
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0788–1
Coolant Level Warning Lamp Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0076–1
Cooling Fan Actuator Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0288–1
Cooling Fan Drive Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0287–1
Cooling System Drain and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0277–1
Cooling System Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0045–1
Cowl Panel Drain Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0650–1
Crankcase Pressure Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0025–1
Crankshaft Damper and Front Seal Assembly Removal and Installation . . . . . . . . . . . . . WP 0223–1
Crew and Front Passenger Seat Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0666–1
Cross-Vehicle Equipment Bracket Removal and Installation . . . . . . . . . . . . . . . . . . WP 0564–1
Cruise Control Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0106–1
Cruise Control Switch Module Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0316–1
Cylinder Head and Gasket Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0222–1

Index–3
TM 9-2355-106-23-1


Deaeration Tank Pressure Cap Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0280–1
Deaeration Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0279–1
Diagnostic Connector Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0078–1
Diagnostic Trouble Code (DTC) Access Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0012–1
Door Armor Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0609–1
Door Mounted Mirror Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0682–1
Door Window Armor Glass Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0653–1
Door Window Riot Guard Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0610–1
Driver Control Module (DCM) Left Air Line Grommet Removal and Installation . . . . . . . . . . WP 0505–1
Driver Control Mounting (DCM) Bracket Assembly Exterior Armor Removal and Installation (Without Front Access
Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0646–1
Driver Control Mounting (DCM) Bracket Assembly Exterior Armor Removal and Installation (With Front Access
Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0647–1
Driver Control Mounting (DCM) Bracket Assembly Interior Armor Removal and Installation . . . . . WP 0648–1
Driver Control Mounting (DCM) Bracket Assembly Removal and Installation . . . . . . . . . . . WP 0566–1
Driver Seat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0663–1
Dual-Pneumatic Door Actuator Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0617–1

E
Electric Horn Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0402–1
Electric Horns Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0111–1
Electric Horns Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0107–1
Electric Horns Sound Without Pressing Horn Pad Troubleshooting Procedure . . . . . . . . . . WP 0112–1
Electric Horns Switch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0109–1
Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0789–1
Electrical Wire Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0420–1
Electronic System Controller (ESC) Brace Removal and Installation . . . . . . . . . . . . . . WP 0354–1
Electronic System Controller (ESC) Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . . WP 0007–1
Electronic System Controller (ESC) Removal and Installation . . . . . . . . . . . . . . . . . WP 0353–1
Electronic System Controller (ESC) Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0068–1
Engine Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0219–1
Engine Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218–1
Engine Control Module (ECM) and Transmission Control Module (TCM) Clean Power Fuse Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0412–1
Engine Control Module (ECM) and Transmission Control Module (TCM) Clean Power and Ground Harness
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0406–1
Engine Control Module (ECM) Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0329–1
Engine Control Module (ECM) Self-Diagnosis Troubleshooting Procedure . . . . . . . . . . . . WP 0053–1
Engine Control Module (ECM) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0049–1
Engine Coolant Level System Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0046–1
Engine Coolant Temperature (ECT) Sensor Removal and Installation . . . . . . . . . . . . . . WP 0388–1
Engine Coolant Temperature (ECT) Sensor Troubleshooting Procedure . . . . . . . . . . . . . WP 0047–1
Engine Coolant Temperature Gauge Operational Checkout Procedure . . . . . . . . . . . . . WP 0081–1
Engine Cooling Fan Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . WP 0031–1
Engine Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0649–1
Engine Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . . . . . . . . . . . . . . WP 0006–1
Engine Does Not Crank Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0034–1
Engine Fan Control (EFC) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0048–1
Engine Mechanical Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . WP 0016–1
Engine Mount Crossmember Assembly Removal and Installation . . . . . . . . . . . . . . . . WP 0548–1
Engine Oil Breather Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0231–1
Engine Oil Cooler Pressure Regulator Removal and Installation . . . . . . . . . . . . . . . . WP 0235–1
Engine Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0234–1
Engine Oil Drain/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0233–1
Index–4
TM 9-2355-106-23-1

Engine Oil Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0232–1
Engine Oil Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018–1
Engine Oil Pan Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0236–1
Engine Oil Pickup Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0237–1
Engine Oil Pressure (EOP) Sensor Removal and Installation . . . . . . . . . . . . . . . . . . WP 0392–1
Engine Oil Pressure (EOP) Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0028–1
Engine Oil Pressure Gauge Operational Checkout Procedure . . . . . . . . . . . . . . . . . WP 0082–1
Engine Oil Temperature (EOT) Sensor Removal and Installation . . . . . . . . . . . . . . . . WP 0389–1
Engine Oil Temperature (EOT) Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . WP 0029–1
Engine Performance Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0015–1
Engine Sensor Wiring Harness Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0330–1
Engine Systems Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0017–1
Engine Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0229–1
Engine Water Outlet Pipe and Elbow Removal and Installation . . . . . . . . . . . . . . . . . WP 0725–1
Engine Water Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0286–1
Engine Wiring Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0336–1
Engine Wiring Harness Terminating Resistor Removal and Installation . . . . . . . . . . . . . WP 0337–1
Equalizer Cables Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0349–1
Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002–1
Ether (Cold) Start Valve and Atomizer Assembly Removal and Installation . . . . . . . . . . . . WP 0272–1
Ether Canister Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0273–1
Ether Cold Start Thermostatic Switch Removal and Installation . . . . . . . . . . . . . . . . . WP 0274–1
Ether Start Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0089–1
Ether Start Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0300–1
Exhaust Brake Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0246–1
Exhaust Brake Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0247–1
Exhaust Brake Supply Air Line Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0248–1
Exhaust Brake Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0090–1
Exhaust Manifold Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0239–1
Exhaust Pipe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0275–1
Exhaust System Operational Checkout Troubleshooting Procedure . . . . . . . . . . . . . . . WP 0044–1
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0794–1
Exterior Battery Box Armor Door Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0604–1
Exterior Body Armor Left Front Panel Removal and Installation . . . . . . . . . . . . . . . . . WP 0633–1
Exterior Body Armor Left Middle Front Panel Removal and Installation . . . . . . . . . . . . . WP 0634–1
Exterior Body Armor Middle Rear Panel Removal and Installation . . . . . . . . . . . . . . . WP 0630–1
Exterior Body Armor Rear Panel Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0631–1
Exterior Body Armor Right Front Panel Removal and Installation . . . . . . . . . . . . . . . . WP 0629–1
Exterior Body Armor Right Middle Front Panel Removal and Installation . . . . . . . . . . . . . WP 0635–1
Exterior Body Armor Riot Guard Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0632–1
Exterior Fuel Tank Armor Door Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0605–1

F
Fender and Reinforcement Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0657–1
Fire Suppression System (FSS) Cabin Cylinder Removal and Installation . . . . . . . . . . . . WP 0745–1
Fire Suppression System (FSS) Cabin Extinguisher Control Circuit Fault Troubleshooting Procedure WP 0194–1
Fire Suppression System (FSS) Cabin Fire Detector Fire Detection Circuit Troubleshooting Procedure WP 0196–1
Fire Suppression System (FSS) Cabin Fire Detector Power and Ground Troubleshooting Procedure WP 0195–1
Fire Suppression System (FSS) Cabin Harness Removal and Installation . . . . . . . . . . . . WP 0739–1
Fire Suppression System (FSS) Cabin Sensor Removal and Installation . . . . . . . . . . . . . WP 0742–1
Fire Suppression System (FSS) Cabin/Crew Dispersion Unit and Pipe Removal and Installation . . WP 0746–1
Fire Suppression System (FSS) Chassis Harness Removal and Installation . . . . . . . . . . . WP 0740–1
Fire Suppression System (FSS) Control Panel Power and Ground Troubleshooting Procedure. . . WP 0192–1
Fire Suppression System (FSS) Control Unit Bracket Removal and Installation . . . . . . . . . . WP 0738–1
Index–5
TM 9-2355-106-23-1

Fire Suppression System (FSS) Control Unit Removal and Installation . . . . . . . . . . . . . WP 0737–1
Fire Suppression System (FSS) Disable and Enable . . . . . . . . . . . . . . . . . . . . . WP 0736–1
Fire Suppression System (FSS) Engine Compartment Sensor Removal and Installation . . . . . . WP 0741–1
Fire Suppression System (FSS) Engine Cylinder Removal and Installation . . . . . . . . . . . . WP 0750–1
Fire Suppression System (FSS) Engine Dispersion Unit and Pipe Removal and Installation . . . . WP 0751–1
Fire Suppression System (FSS) Engine Extinguisher Control Circuit Fault Troubleshooting Procedure WP 0197–1
Fire Suppression System (FSS) Engine Fire Detector Fire Detection Circuit Troubleshooting Procedure WP 0199–1
Fire Suppression System (FSS) Engine Fire Detector Power and Ground Troubleshooting Procedure WP 0198–1
Fire Suppression System (FSS) Extinguisher Pressure Fault Troubleshooting Procedure. . . . . . WP 0193–1
Fire Suppression System (FSS) Front Tire Dispersion Unit and Pipe Removal and Installation . . . WP 0748–1
Fire Suppression System (FSS) Fuel Tank Cylinder Removal and Installation . . . . . . . . . . WP 0743–1
Fire Suppression System (FSS) Fuel Tank Dispersion Unit and Pipe Removal and Installation . . . WP 0744–1
Fire Suppression System (FSS) Fuel Tank Extinguisher Control Circuit Fault Troubleshooting Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0200–1
Fire Suppression System (FSS) Rear Tire Dispersion Unit and Pipe Removal and Installation . . . WP 0749–1
Fire Suppression System (FSS) Tire Cylinder Removal and Installation . . . . . . . . . . . . . WP 0747–1
Fire Suppression System (FSS) Tires Extinguisher Control Circuit Fault Troubleshooting Procedure . WP 0201–1
Fire Suppression System (FSS) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0191–1
Flash-To-Pass Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105–1
Flexplate Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0225–1
Floor Panel (Front Center) Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0659–1
Floor Panel (Front) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0658–1
Floor Panel (Rear Center) Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0661–1
Foot Brake Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0502–1
Forward Chassis Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0424–1
Front and Rear Clearance Lights Roof Harness Removal and Installation . . . . . . . . . . . . WP 0441–1
Front Antilock Braking System (ABS) Modulator Valve Removal and Installation . . . . . . . . . WP 0507–1
Front Antilock Braking System (ABS) Sensor Removal and Installation . . . . . . . . . . . . . WP 0425–1
Front Axle Antilock Braking System (ABS) Tone Ring Removal and Installation . . . . . . . . . . WP 0483–1
Front Axle Assembly Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0472–1
Front Axle Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0470–1
Front Axle Breather Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0473–1
Front Axle Bumper Stop Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0555–1
Front Axle Bumper Stop Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0554–1
Front Axle Differential Drain/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0474–1
Front Axle Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0166–1
Front Brake Air Chamber Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0514–1
Front Brake Air Hose Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0508–1
Front Brake Drum Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0487–1
Front Brake Dust Shield Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0485–1
Front Brake S-Camshaft Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0488–1
Front Brake Shoes Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0486–1
Front Brake Spider and Spindle Assembly Removal and Installation . . . . . . . . . . . . . . WP 0489–1
Front Bumper Left Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0374–1
Front Bumper Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0544–1
Front Bumper Right Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0375–1
Front Bumper Turn Signal and Parking Light Assembly Removal and Installation . . . . . . . . . WP 0361–1
Front Clearance Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0369–1
Front Clearance Light Bar Harness Removal and Installation . . . . . . . . . . . . . . . . . . WP 0370–1
Front Crew Light Operatonal Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0133–1
Front Crew Light Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0356–1
Front Crew Light Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0134–1
Front Engine Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0227–1
Front Engine Mount Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0220–1
Index–6
TM 9-2355-106-23-1

Front Fender Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0371–1
Front Fender Light Bulb Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0372–1
Front Frame Crossmember and Radiator Support Removal and Installation . . . . . . . . . . . WP 0546–1
Front Frame Crossmember and Support Removal and Installation . . . . . . . . . . . . . . . WP 0547–1
Front Litter Arm Mount Plate and Arm Support Removal and Installation . . . . . . . . . . . . . WP 0680–1
Front Oil Pump Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0238–1
Front Shock Absorber Lower Mounting Bracket Removal and Installation . . . . . . . . . . . . WP 0561–1
Front Shock Absorber Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0560–1
Front Shock Absorber Upper Mounting Bracket Removal and Installation . . . . . . . . . . . . WP 0562–1
Front Slack Adjuster Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0490–1
Front Spring Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0559–1
Front Spring Shackle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0558–1
Front Towing Eye Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0553–1
Front Trailer Hookup Cover Removal and Installa tion . . . . . . . . . . . . . . . . . . . . . WP 0428–1
Front Trailer Hookup Harness Removal and Insta llati on . . . . . . . . . . . . . . . . . . . . WP 0429–1
Front Turn Signal and Parking Light Bulb Removal and Installation . . . . . . . . . . . . . . . WP 0373–1
Front Turn Signal Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0093–1
Front Wheel Hub and Bearing Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0471–1
Fuel Filter and Strainer Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0269–1
Fuel Filter Header/Primer Pump Assembly Removal and Installation . . . . . . . . . . . . . . WP 0254–1
Fuel-Fired Heater Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0137–1
Fuel Hose Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0268–1
Fuel Injector Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0331–1
Fuel Injector Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0249–1
Fuel Injector Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0039–1
Fuel Level Gauge Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0085–1
Fuel Level Sending Unit Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0400–1
Fuel Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0037–1
Fuel Pressure (Full Load) Troubleshooting Proce dure . . . . . . . . . . . . . . . . . . . . . WP 0038–1
Fuel Pressure Regulator Removal and Installatio n . . . . . . . . . . . . . . . . . . . . . . WP 0251–1
Fuel Primer Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0255–1
Fuel Pump Pressure Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0035–1
Fuel Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0253–1
Fuel Pump Restriction Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0036–1
Fuel Tank Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0266–1
Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0265–1
Fuel Tank Strap Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0267–1
Fuel/Water Separator Assembly Purge, Removal, and Installation . . . . . . . . . . . . . . . WP 0271–1
Fuel/Water Separator Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0270–1
Fuel/Water Separator with 12V DC Fuel Pre-Heater Troubleshooting Procedure . . . . . . . . . WP 0043–1
Fuel-Fired Heater and Fuel-Fired Heater Fuel Pump Harness Removal and Installation . . . . . . WP 0734–1
Fuel-Fired Heater Fuel Pump and Fuel Line Removal and Installation . . . . . . . . . . . . . . WP 0733–1
Fuel-Fired Heater Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0732–1
Fuel-Fired Heater Timer Control Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0735–1

G
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001–1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0782–1
Gladhands Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0528–1
Gun Port Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0596–1
Gun Turret Platform Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0704–1
Gunner Platform Stand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0668–1
Gunner Restraint Assembly Removal and Inst alla tio n . . . . . . . . . . . . . . . . . . . . . WP 0669–1
Index–7
TM 9-2355-106-23-1


H
Hand Brake Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0506–1
Hard Start/No Start Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . WP 0014–1
Harness Support Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0550–1
Headlamp Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0377–1
Headlamp Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0380–1
Headlamp Bezel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0381–1
Headlamp Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0376–1
Heated Windshield Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0121–1
Heating Ventilating and Air Conditioning (HVAC) 3-Way Valve and Bracket Removal and Installation WP 0727–1
Heating Ventilating and Air Conditioning (HVAC) 3-Way Valve Coolant Inlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0730–1
Heating Ventilating and Air Conditioning (HVAC) 3-Way Valve Coolant Outlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0726–1
Heating Ventilating and Air Conditioning (HVAC) 3-Way Valve Troubleshooting Procedure . . . . . WP 0206–1
Heating Ventilating and Air Conditioning (HVAC) Cabin Heater Hose Removal and Installation . . . WP 0728–1
Heating Ventilating and Air Conditioning (HVAC) Compressor Control Troubleshooting Procedure . WP 0212–1
Heating Ventilating and Air Conditioning (HVAC) Compressor Discharge Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0717–1
Heating Ventilating and Air Conditioning (HVAC) Compressor Removal and Installation . . . . . . WP 0708–1
Heating Ventilating and Air Conditioning (HVAC) Compressor Suction Hose Removal and Installation WP 0712–1
Heating Ventilating and Air Conditioning (HVAC) Condenser Assembly Removal and Installation . . WP 0723–1
Heating Ventilating and Air Conditioning (HVAC) Condenser Fans Troubleshooting Procedure . . . WP 0213–1
Heating Ventilating and Air Conditioning (HVAC) Control 2 Wiring Harness Removal and Installation WP 0776–1
Heating Ventilating and Air Conditioning (HVAC) Control Input Wiring Harness Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0775–1
Heating Ventilating and Air Conditioning (HVAC) Evaporator Inlet Hose Removal and Installation . . WP 0709–1
Heating Ventilating and Air Conditioning (HVAC) Evaporator Outlet Hose Removal and Installation . WP 0710–1
Heating Ventilating and Air Conditioning (HVAC) Filter Outlet Hose Removal and Installation . . . . WP 0711–1
Heating Ventilating and Air Conditioning (HVAC) Freeze Switch Troubleshooting Procedure . . . . WP 0209–1
Heating Ventilating and Air Conditioning (HVAC) Fresh Air Inlet Tube Removal and Installation . . . WP 0720–1
Heating Ventilating and Air Conditioning (HVAC) Fuel-Fired Heater Coolant Inlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0731–1
Heating Ventilating and Air Conditioning (HVAC) Fuel-Fired Heater Coolant Outlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0729–1
Heating Ventilating and Air Conditioning (HVAC) Heater Radiator Removal and Installation . . . . WP 0760–1
Heating Ventilating and Air Conditioning (HVAC) High Idle Circuit Troubleshooting Procedure . . . WP 0207–1
Heating Ventilating and Air Conditioning (HVAC) Left Condenser Control Wiring Harness Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0772–1
Heating Ventilating and Air Conditioning (HVAC) Left-Side Condenser Inlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0713–1
Heating Ventilating and Air Conditioning (HVAC) Left-Side Condenser Outlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0715–1
Heating Ventilating and Air Conditioning (HVAC) Life Support System (LSS) Control Power Wiring Harness
Heating Ventilating and Air Conditioning (HVAC) Low Pressure Cutout Switch Operational Checkout Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0210–1
Heating Ventilating and Air Conditioning (HVAC) Low Pressure Switch Removal and Installation . . WP 0771–1
Heating Ventilating and Air Conditioning (HVAC) Main Evaporator Assembly Removal and Installation WP 0759–1
Heating Ventilating and Air Conditioning (HVAC) Receiver/Drier Removal and Installation . . . . . WP 0758–1
Heating Ventilating and Air Conditioning (HVAC) Recirculated Air (RA) Temperature Sensor Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0768–1
Index–8
TM 9-2355-106-23-1


Heating Ventilating and Air Conditioning (HVAC) Recirculated Air (RA) Temperature Sensor Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0768–1
Heating Ventilating and Air Conditioning (HVAC) Recycled Air (RA) Temperature Sensor Troubleshooting
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0208–1
Heating Ventilating and Air Conditioning (HVAC) Refrigerant Filter Removal and Installation . . . . WP 0722–1
Heating Ventilating and Air Conditioning (HVAC) Right Condenser Control Wiring Harness Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0773–1
Heating Ventilating and Air Conditioning (HVAC) Right-Side Condenser Inlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0714–1
Heating Ventilating and Air Conditioning (HVAC) Right-Side Condenser Outlet Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0716–1
Heating Ventilating and Air Conditioning (HVAC) Service Port/Schrader Valve Removal and Installation WP 0718–1
Heating Ventilating and Air Conditioning (HVAC) Service/Recharge Procedure . . . . . . . . . . WP 0707–1
Heating Ventilating and Air Conditioning (HVAC) Trinary Switch Troubleshooting Procedure . . . . WP 0211–1
Heating Ventilating and Air Conditioning (HVAC) Water Drainage Hose Removal and Installation . . WP 0719–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Air Duct Louver Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0753–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Box Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0761–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Cabin Pressure Troubleshooting
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0214–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Control Wiring Harness Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0780–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Defogging Air Duct Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0754–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Diffuser Air Duct Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0755–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Engine Wiring Harness Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0774–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Fresh Air (FA) Blower Troubleshooting
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0205–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Fresh Air Inlet Flange Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0756–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Main Air Duct Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0752–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Main Blower Motor and Support
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Main Blower Motor Wiring Harness
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Operational Checkout Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0202–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Operator Panel and Climate Control
Unit (CCU) Power and Ground Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0203–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Operator Panel Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0770–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Overpressure Relief Valve Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0757–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Recycled Air (RA) Blower
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0204–1
Heating Ventilating and Air Conditioning (HVAC)/Life Support System (LSS) Upper Blower Wiring Harness
Heating Ventilating and Air Conditioning/Life Support System (HVAC/LSS) Upper Blower Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0766–1
Index–9
TM 9-2355-106-23-1


Heating Ventilating and Air Conditioning/Life Support System (HVAC/LSS) Upper Panel Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0767–1
Heating, Ventilating, and Air Conditioning (HVAC) Compressor Discharge Hose Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0717–1
High-Pressure Injector Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0252–1
Hood Air Intake Grille Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0571–1
Hood Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0575–1
Hood/Fender Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0569–1
Hood Grille Surround Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0572–1
Hood Hinge Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0570–1
Hood Mirror Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0576–1
Hood Safety Cable Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0573–1
Hood Torsion Assist Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0574–1
Horn Button Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0403–1

I
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0785–1
Illustrated List Of Manufactured Items Introduction . . . . . . . . . . . . . . . . . . . . . . WP 0784–1
Infrared (IR) Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0368–1
Infrared (IR) Light Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0308–1
Injection Control Pressure (ICP) No Start Operational Checkout Procedure . . . . . . . . . . . WP 0020–1
Injection Control Pressure (ICP) Operational Checkout Procedure . . . . . . . . . . . . . . . WP 0022–1
Injection Control Pressure (ICP) Sensor Removal and Installation . . . . . . . . . . . . . . . WP 0391–1
Injection Control Pressure (ICP) Sensor Troubleshooting Procedure . . . . . . . . . . . . . . WP 0040–1
Injection Pressure Regulator (IPR) Sensor Removal and Installation . . . . . . . . . . . . . . WP 0396–1
Injection Pressure Regulator (IPR) System Troubleshooting Operational Checkout Procedure . . . WP 0042–1
Injection Pressure Regulator (IPR) Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0041–1
Injector Drive Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0054–1
Inner Wheel Deflector Armor Plate Removal and Installation . . . . . . . . . . . . . . . . . . WP 0601–1
Instrument Panel (I/P) Cluster Closeout Removal and Installation . . . . . . . . . . . . . . . . WP 0578–1
Instrument Panel (IP) Center Relay Removal and Installation . . . . . . . . . . . . . . . . . WP 0318–1
Instrument Panel (IP) Center Trim Panel Removal and Installation . . . . . . . . . . . . . . . WP 0581–1
Instrument Panel (IP) Circuit Breaker, Fuse, and Relay Removal and Installation . . . . . . . . . WP 0317–1
Instrument Panel (IP) Cluster Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0297–1
Instrument Panel (IP) Feed Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0411–1
Instrument Panel (IP) Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0319–1
Instrument Panel (IP) Harness Terminating Resistor Removal and Installation . . . . . . . . . . WP 0320–1
Instrument Panel (IP) Light Bulb Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0299–1
Instrument Panel (IP) Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0104–1
Instrument Panel (IP) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0577–1
Instrument Panel (IP) Right Side Closeout Removal and Installation . . . . . . . . . . . . . . WP 0580–1
Instrument Panel (IP) Storage Bin Removal and Installation . . . . . . . . . . . . . . . . . . WP 0563–1
Instrument Panel Center Closeout Removal and Installation . . . . . . . . . . . . . . . . . . WP 0579–1
Instrument Panel Cluster (IPC) Operational Checkout Procedure . . . . . . . . . . . . . . . . WP 0070–1
Instrument Panel Cluster (IPC) Power and Data Link Circuits Troubleshooting Procedure . . . . . WP 0071–1
Instrument Panel Cluster Right Side Warning Panel Removal and Installation . . . . . . . . . . WP 0298–1
Intake Air Temperature (IAT) Sensor Removal and Installation . . . . . . . . . . . . . . . . . WP 0399–1
Intake Air Temperature (IAT) Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0055–1
Intake/Exhaust Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019–1
Interior Lights Crew Light Limit Switch and Jumper Harness Removal and Installation . . . . . . . WP 0358–1
Interior Lights Left Rear Crew Light Harness Removal and Installation . . . . . . . . . . . . . WP 0359–1
Interior Lights Right Rear and Front Crew Lights Harness Removal and Installation . . . . . . . . WP 0360–1
Internal Transmission Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0151–1
Inverter and Battery Disconnect Switch Solenoid Cables Removal and Installation . . . . . . . . WP 0451–1
Index–10
TM 9-2355-106-23-1

Inverter Disconnect Battery Switch Solenoid Harness Removal and Installation . . . . . . . . . . WP 0345–1

K
Keyless Ignition Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0302–1
Keyless Ignition Switch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0066–1

L
Left 12V Socket and Feed Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0439–1
Left Door Air Supply Line Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0619–1
Left Headlamp and Turn Signal Harness Removal and Installation . . . . . . . . . . . . . . . WP 0378–1
Left Inner Wheel Deflector Bracket Removal and Installation . . . . . . . . . . . . . . . . . . WP 0602–1
Left Rear Stowage Box Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0676–1
Left Side Engine Armor Plate Bracket Removal and Installation . . . . . . . . . . . . . . . . WP 0598–1
Left Side Engine Armor Plate Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0597–1
Left Side Forward Stowage Box Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0674–1
Litter Arm Storage Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0679–1
Low Injector Control Pressure (ICP) Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0021–1
Lower Cabin Door Lock, Spacer, and Bracket Removal and Installation . . . . . . . . . . . . . WP 0612–1
Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0783–1

M
Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0793–1
Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . WP 0792–1
Malfunctioning Instrument Panel Cluster (IPC) Troubleshooting Proced ure . . . . . . . . . . . . WP 0072–1
Mandatory Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0796–1
Manifold Absolute Pressure (MAP) Sensor Removal and Installation . . . . . . . . . . . . . . WP 0390–1
Manifold Absolute Pressure (MAP) Sensor Troubleshooting Procedure . . . . . . . . . . . . . WP 0056–1
Master Crew Light Switch Jumper Harness Removal and Installation . . . . . . . . . . . . . . WP 0312–1
Master Crew Light Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0311–1
Master Disconnect Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0351–1
Master Rear Door/Ramp Switch Jumper Harness Removal and Installation . . . . . . . . . . . WP 0310–1
Master Rear Door/Ramp Switch Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0309–1
Master Vehicle Light Switch (MVLS) Ground Harness Removal and Installation . . . . . . . . . WP 0307–1
Master Vehicle Light Switch (MVLS) Horn Enable Circuit Troubleshooting Procedure . . . . . . . WP 0110–1
Master Vehicle Light Switch (MVLS) Removal and Installation . . . . . . . . . . . . . . . . . WP 0303–1
Master Vehicle Light Switch (MVLS) Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0092–1
Mirror Remote Control Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0306–1
Mirror Remote Control Switch Wiring Harness Removal and Installation . . . . . . . . . . . . . WP 0314–1
Motor Baffle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0651–1
Muffler and Shield Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0276–1
Multifunction Turn Signal Switch Assembly Removal and Installation . . . . . . . . . . . . . . WP 0323–1
Multiplexing Data Link Circuits Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0067–1

N
NATO Connector Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0118–1
NATO Jump Start Connector Cables Removal and Installation . . . . . . . . . . . . . . . . . WP 0450–1
NATO Jump Start Connector Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0421–1
Nuclear, Biological, and Chemical (NBC) Dust Tube Removal and Installation . . . . . . . . . . WP 0721–1
Nuclear, Biological, and Chemical (NBC) Filter Cover and Housing Removal and Installation . . . . WP 0763–1
Nuclear, Biological, and Chemical (NBC) Filter Removal and Installation . . . . . . . . . . . . . WP 0762–1
Nuclear, Biological, and Chemical (NBC) Gauge Removal and Installation . . . . . . . . . . . . WP 0582–1
Nuclear, Biological, and Chemical (NBC) Particle Separator Filter Removal and Installation . . . . WP 0764–1
Nuclear, Chemical, and Biological (NBC) Gauge Removal and Installation . . . . . . . . . . . . WP 0582–1
Index–11
TM 9-2355-106-23-1


O
Oil Gauge Tube Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230–1
Oil/Fuel Manifold Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0250–1
Outside Gunner Protection Armor Removal and Installation . . . . . . . . . . . . . . . . . . WP 0703–1
Outside Gunner Protection Riser Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0702–1

P
Park Brake Warning Lamp Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0077–1
Parking Brake Lamp Transducer Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0327–1
Pitman Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0535–1
Power Distribution Center (PDC) Fuse and Relay Removal and Installation . . . . . . . . . . . WP 0333–1
Power Distribution Center (PDC) Harness Removal and Installation . . . . . . . . . . . . . . . WP 0335–1
Power Distribution Center (PDC) Junction Box Removal and Installation . . . . . . . . . . . . . WP 0334–1
Power Distribution Center (PDC) Mini Fuse Block 4001 Troubleshooting Procedure . . . . . . . . WP 0065–1
Power Distribution Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0059–1
Power Steering Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0542–1
Power Steering Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0180–1
Power Steering Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0539–1
Power Steering Reservoir Drain/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0543–1
Power Steering Reservoir Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0541–1
Power Steering Tubing and Hose Removal and Installation . . . . . . . . . . . . . . . . . . WP 0540–1
Power/Heated Mirror Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0123–1
Preparation For Storage Or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0781–1
Pressure Protection Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0520–1
Preventive Maintenance Checks And Services (PMCS) . . . . . . . . . . . . . . . . . . . . WP 0216–1
Preventive Maintenance Checks And Services (PMCS) Introduction . . . . . . . . . . . . . . WP 0215–1
Prop Shaft Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0468–1
Propeller Shaft Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0165–1

R
Radiator Fan and Fan Shroud Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0282–1
Radiator Pipes/Hoses Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0285–1
Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0278–1
Radiator Surge Overflow Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0281–1
Rear Antilock Brake System (ABS) Modulator Valve Removal and Installation . . . . . . . . . . WP 0511–1
Rear Antilock Brake System (ABS) Sensor Removal and Installation . . . . . . . . . . . . . . WP 0491–1
Rear Axle Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0478–1
Rear Axle Differential Drain and Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0479–1
Rear Axle Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . WP 0167–1
Rear Axle Outer Hub Assembly Drain and Fill Procedure . . . . . . . . . . . . . . . . . . . WP 0481–1
Rear Axle Shaft and Gasket Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0482–1
Rear Brake Air Chamber Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0516–1
Rear Brake Air Hoses Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0515–1
Rear Brake Drum and Hub Assembly Removal and Installation . . . . . . . . . . . . . . . . . WP 0494–1
Rear Brake Dust Shield Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0492–1
Rear Brake S-Camshaft Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0495–1
Rear Brake S-Camshaft Tube Support Bracket Removal and Installation . . . . . . . . . . . . WP 0498–1
Rear Brake Shoes Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0493–1
Rear Brake Spider Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0496–1
Rear Center Floor Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0661–1
Rear Chassis Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0427–1
Rear Clearance Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0385–1
Index–12
TM 9-2355-106-23-1

Rear Clearance Light Bar Harness Removal and Installation . . . . . . . . . . . . . . . . . . WP 0386–1
Rear Communication Rack Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0670–1
Rear Crankshaft Oil Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0224–1
Rear Crew Light Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0357–1
Rear Crew Lights Operatonal Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0135–1
Rear Crew Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0136–1
Rear Door/Ramp Hydraulic System Harness Removal and Installation (Pull-Type Operation) . . . . WP 0434–1
Rear Door/Ramp Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0639–1
Rear Door/Ramp Feed Wiring Harness Removal and Installation . . . . . . . . . . . . . . . . WP 0444–1
Rear Door/Ramp Gas Spring Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0698–1
Rear Door/Ramp Hydraulic Cylinder Removal and Installation (Push-Type Operation) . . . . . . . WP 0696–1
Rear Door/Ramp Hydraulic Cylinder Removal and Installation (Pull-Type Operation) . . . . . . . WP 0697–1
Rear Door/Ramp Hydraulic Hand Pump Removal and Installation (Push-Type Operation) . . . . . WP 0694–1
Rear Door/Ramp Hydraulic Hoses Removal and Installation (Push-Type Operation) . . . . . . . WP 0700–1
Rear Door/Ramp Hydraulic Hoses Removal and Installation (Pull-Type Operation) . . . . . . . . WP 0701–1
Rear Door/Ramp Hydraulic Lift Components Troubleshooting Procedure (Push-Type Operation) . . WP 0187–1
Rear Door/Ramp Hydraulic Lift Components Troubleshooting Procedure (Pull-Type Operation) . . . WP 0188–1
Rear Door/Ramp Hydraulic Power Unit Manifold and Module Removal and Installation (Pull-Type Operation)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0695–1
Rear Door/Ramp Hydraulic Pump Cover Removal and Installation . . . . . . . . . . . . . . . WP 0690–1
Rear Door/Ramp Hydraulic Pump Cover Removal and Installation (Pull-Type Operation) . . . . . WP 0691–1
Rear Door/Ramp Hydraulic Pump Removal and Installation (Push-Type Operation) . . . . . . . . WP 0692–1
Rear Door/Ramp Hydraulic Pump Removal and Installation (Pull-Type Operation) . . . . . . . . WP 0693–1
Rear Door/Ramp Hydraulic Reservoir Fluid Fill Procedure (Pull-Type Operation) . . . . . . . . . WP 0699–1
Rear Door/Ramp Hydraulic System Control Harness Removal and Installation . . . . . . . . . . WP 0432–1
Rear Door/Ramp Hydraulic System Harness Removal and Installation (Push-Type Operation) . . . WP 0433–1
Rear Door/Ramp Lock Assembly Removal and Installation . . . . . . . . . . . . . . . . . . WP 0641–1
Rear Door/Ramp Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0636–1
Rear Engine Mount Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0221–1
Rear Floor Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0662–1
Rear Frame Crossmember and Support Removal and Installation . . . . . . . . . . . . . . . WP 0549–1
Rear Hub Assembly Bearing and Bearing Cup Removal and Installation . . . . . . . . . . . . . WP 0480–1
Rear Litter Arm Mount Plate and Arm Support Removal and Installation . . . . . . . . . . . . . WP 0681–1
Rear Sidemarker Light Assembly Removal and Installation . . . . . . . . . . . . . . . . . . WP 0387–1
Rear Slack Adjuster Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0497–1
Rear Spring Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0557–1
Rear Towing Eye Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0551–1
Rear Trailer Connector Ground Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . WP 0128–1
Rear Trailer Hookup Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0430–1
Rear Trailer Hookup Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0431–1
Rear Turn Signal Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0094–1
Rear Wall Overlap Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0638–1
Rear Window Armor Glass Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0652–1
Red Engine Warning Lamp Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0074–1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0791–1
Rifle Rack Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0706–1
Right 12V Socket and Feed Harness Removal and Installation . . . . . . . . . . . . . . . . . WP 0440–1
Right Cabin Door Assist System Supply Air Line Tubing Removal and Installation . . . . . . . . WP 0620–1
Right Engine Armor Plate Bracket Removal and Installation . . . . . . . . . . . . . . . . . . WP 0600–1
Right Floor Seat Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0665–1
Right Headlamp and Turn Signal Harness Removal and Installation . . . . . . . . . . . . . . . WP 0379–1
Right Inner Wheel Deflector Bracket Removal and Installation . . . . . . . . . . . . . . . . . WP 0603–1
Right Rear Stowage Box Latch Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0675–1
Right Side Engine Armor Plate Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0599–1
Index–13
TM 9-2355-106-23-1

Right Side Forward Stowage Box Removal and Installation . . . . . . . . . . . . . . . . . . WP 0671–1
Right Side Rear Stowage Box Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0673–1
Rocker Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0301–1
Roof Armor Front Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0584–1
Roof Armor Front Spoiler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0585–1
Roof Armor Middle Front Panel Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0586–1
Roof Armor Middle Rear Panel Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0587–1
Roof Armor Rear Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0589–1
Roof Armor Rear Spoiler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0588–1

S
Schematic Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0787–1
Seatbelt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0664–1
Securing Cabin Door For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0608–1
Serpentine Belt Idler Pulley Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0241–1
Serpentine Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0240–1
Serpentine Belt Tensioner Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0242–1
Serpentine Belt Upper Idler Pulley Removal and Installation . . . . . . . . . . . . . . . . . . WP 0243–1
Service Driving Lights Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0097–1
Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0217–1
Side Cowl Body Armor Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0644–1
Single Electric Horn Fault Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0108–1
Speed Control Command Switches (SCCS) Troubleshooting Procedure . . . . . . . . . . . . . WP 0057–1
Speedometer Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0083–1
Spotlight Control Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0313–1
Spotlight Exterior Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0364–1
Spotlight Interior Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0365–1
Spotlight Light Bulb Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0362–1
Spotlight Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0363–1
Spotlight Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122–1
Spring Brake Modulating Valve Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0509–1
Starter Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292–1
Starter Motor-to-Battery Feed Cable Removal and Installation . . . . . . . . . . . . . . . . . WP 0413–1
Starter Motor-to-Battery Ground Cable Removal and Installation . . . . . . . . . . . . . . . . WP 0414–1
Starter Motor-to-Engine Ground Jumper Cable Removal and Installation . . . . . . . . . . . . WP 0338–1
Starter Motor-to-Frame Ground Jumper Cable Removal and Installation . . . . . . . . . . . . . WP 0339–1
Starter Ring Gear Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0226–1
Steering Arm Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0476–1
Steering Column Covers Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0565–1
Steering Column Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0533–1
Steering Column Wiring Harness Removal and Installation . . . . . . . . . . . . . . . . . . WP 0324–1
Steering Drag Link Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0536–1
Steering Gear Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0537–1
Steering Knuckle and King Pin Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0477–1
Steering Shaft Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0532–1
Steering System Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0179–1
Steering Wheel and Clock Spring Removal and Installation . . . . . . . . . . . . . . . . . . WP 0534–1
Steering Wheel Wire Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0325–1
Step and Brackets Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0656–1
Stoplight Switch Circuits Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0168–1
Stoplight Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101–1
Suspension Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0181–1
Switch Pack Modules Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0069–1
Index–14
TM 9-2355-106-23-1


T
Tachometer Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0084–1
Taillamp Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0384–1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003–1
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0283–1
Tie Rod Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0531–1
Tool Identification List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0795–1
Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0786–1
Towing Pintle Hook Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0552–1
Tractor Protection Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0503–1
Trailer Connector Auxiliary Power Circuit Troubleshooting Procedure . . . . . . . . . . . . . . WP 0131–1
Trailer Connector Brake Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0132–1
Trailer Connector Left Service Signal Circuit Troubleshooting Procedure . . . . . . . . . . . . . WP 0126–1
Trailer Connector Left, Right, and Clearance Black Out (B/O) Circuit Troubleshooting Procedure . . WP 0125–1
Trailer Connector Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0124–1
Trailer Connector Right Service Signal Circuit Troubleshooting Procedure . . . . . . . . . . . . WP 0127–1
Trailer Connector Service Clearance Circuit Troubleshooting Procedure . . . . . . . . . . . . . WP 0129–1
Trailer Connector Stop Blackout (B/O) Circuit Troubleshooting Procedure . . . . . . . . . . . . WP 0130–1
Trailer Control Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0529–1
Transfer Case Air Lines Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0463–1
Transfer Case Armor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0462–1
Transfer Case Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0460–1
Transfer Case Drain/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0466–1
Transfer Case Mode Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0394–1
Transfer Case Mount and Support Removal and Installation . . . . . . . . . . . . . . . . . . WP 0461–1
Transfer Case Oil Cooler Hose Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0465–1
Transfer Case Oil Cooler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0467–1
Transfer Case Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0164–1
Transfer Case Vehicle Speed Sensor (VSS) Removal and Installation . . . . . . . . . . . . . . WP 0395–1
Transmission Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0454–1
Transmission Auto Shift Control Module Removal and Installation . . . . . . . . . . . . . . . WP 0452–1
Transmission Breather Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0458–1
Transmission Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0141–1
Transmission Communication Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0163–1
Transmission Control Module (TCM) Operational Checkout Procedure . . . . . . . . . . . . . WP 0144–1
Transmission Control Module and Brace Removal and Installation . . . . . . . . . . . . . . . WP 0453–1
Transmission Control System ID Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0146–1
Transmission Cooler Hose Removal and Installation . . . . . . . . . . . . . . . . . . . . . WP 0456–1
Transmission Diagnostic Trouble Code (DTC) Index . . . . . . . . . . . . . . . . . . . . . WP 0008–1
Transmission Engine Speed Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0150–1
Transmission Fluid and Filter Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0457–1
Transmission Fluid Level Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . . WP 0147–1
Transmission Fluid Over Temperature Troubleshooting Procedure . . . . . . . . . . . . . . . WP 0143–1
Transmission Fluid Temperature Gauge and Harness Removal and Installation . . . . . . . . . . WP 0293–1
Transmission Fluid Temperature Sensor Troubleshooting Procedure . . . . . . . . . . . . . . WP 0148–1
Transmission High Side Driver 2 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0159–1
Transmission High Side Driver 3 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0160–1
Transmission High Side Driver Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0145–1
Transmission Low Gear Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . WP 0158–1
Transmission Mounting Crossmember Removal and Installation . . . . . . . . . . . . . . . . WP 0455–1
Transmission Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . WP 0142–1
Transmission Output Speed Sensor Troubleshooting Procedure . . . . . . . . . . . . . . . . WP 0149–1
Transmission Pressure Control Main MOD Troubleshooting Procedure . . . . . . . . . . . . . WP 0156–1
Index–15
TM 9-2355-106-23-1

Transmission Pressure Control Solenoid 1 Troubleshooting Procedure . . . . . . . . . . . . . WP 0162–1
Transmission Pressure Switch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0154–1
Transmission Shift Solenoid 1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0157–1
Transmission Slipping Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . WP 0155–1
Transmission Speed Sensors Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0459–1
Transmission to Transfer Case Propshaft Removal and Installation . . . . . . . . . . . . . . . WP 0469–1
Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004–1
Turbocharger Lubricant Lines Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0262–1
Turbocharger Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0261–1
Turn Signal and Hazard Switch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0095–1
Turn Signal Lights Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . WP 0096–1
Turret Mounting Plate Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . WP 0705–1
Turret Power Feed Wiring Harness Removal and Installation . . . . . . . . . . . . . . . . . . WP 0446–1

U
Upper Air Line Grommet Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0504–1
Upper and Lower King Pin Bushing and Axle Shaft Oil Seal Removal and Installation . . . . . . . WP 0475–1
Upper Cabin Door Lock, Spacer, and Bracket Removal and Installation . . . . . . . . . . . . . WP 0611–1

V
Valve Adjustment Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . WP 0027–1
Valve Cover and Gasket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0228–1
Vehicle Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010–1
Vehicle Speed Sensor (VSS) Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0058–1
Vehicle Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005–1

W
Wastegate Actuator Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . WP 0026–1
Water Inlet Elbow Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0284–1
Water Sensor Probe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0401–1
Weapon (Sliding) Hatch (Gunner Hatch) Inner Lock Assembly Removal and Installation . . . . . . WP 0591–1
Weapon (Sliding) Hatch (Gunner Hatch) Removal and Installation . . . . . . . . . . . . . . . WP 0590–1
Weapon Hatch Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0592–1
Wheel and Tire Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0530–1
Winch Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0678–1
Winch Battery Cable Junction Block and Bracket Support Assembly Removal and Installation . . . WP 0415–1
Winch Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0677–1
Winch Feed Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0416–1
Winch Ground Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0417–1
Winch Megafuse and Holder Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0448–1
Winch Megafuse Feed Cable Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0344–1
Winch Remote Control Connector Support Removal and Installation . . . . . . . . . . . . . . WP 0545–1
Winch Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0186–1
Windshield Armor Glass Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0655–1
Windshield Armor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0645–1
Windshield Washer Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . WP 0114–1
Windshield Washer Hose Assembly Removal and Installation . . . . . . . . . . . . . . . . . WP 0687–1
Windshield Washer Reservoir and Pump Motor Assembly Removal and Installation . . . . . . . . WP 0686–1
Windshield Washer Reservoir Bracket Removal and Installation . . . . . . . . . . . . . . . . WP 0688–1
Windshield Wiper and Washer Operational Checkout Procedure . . . . . . . . . . . . . . . . WP 0113–1
Index–16
TM 9-2355-106-23-1

Windshield Wiper Arm and Blade Removal and Installation . . . . . . . . . . . . . . . . . . WP 0685–1
Windshield Wiper Motor Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0117–1
Windshield Wiper Motor Harness Removal and Installation . . . . . . . . . . . . . . . . . . WP 0689–1
Windshield Wiper Motor, Transmission, Bracket, and Linkage Assembly Removal and Installation . WP 0684–1
Windshield Wiper Park Circuit Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0116–1
Windshield Wiper Switch Inputs to Electronic System Controller (ESC) Troubleshooting Procedure . WP 0115–1
Wiper Cowl Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . WP 0683–1

Y
Yellow Engine Warning Lamp Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . WP 0073–1
110V Cover, Outlet, and Box Removal and Installation . . . . . . . . . . . . . . . . . . . . WP 0328–1
110V Inverter Battery Disconnect Switch Removal and Installation . . . . . . . . . . . . . . . WP 0447–1
110V Inverter Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0352–1
110V Inverter Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0119–1
110V Outlet Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . WP 0435–1
12V and 24V Battery Disconnect Switch Removal and Installation . . . . . . . . . . . . . . . WP 0341–1
12V and 24V Battery Switches Troubleshooting Procedure . . . . . . . . . . . . . . . . . . WP 0060–1
12V Battery Disconnect Switch Solenoid Feed Cable Removal and Installation . . . . . . . . . . WP 0342–1
12V to 24V Disconnect Battery Switch Solenoid Feed Harness Removal and Installation . . . . . WP 0346–1
12V to 24V Disconnect Battery Switch Solenoid Ground Harness Removal and Installation . . . . WP 0347–1
12V Underhood Megafuse and Holder Removal and Installation . . . . . . . . . . . . . . . . WP 0422–1
12-Volt Voltmeter Operational Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . WP 0080–1
24V Battery Disconnect Switch Solenoid Feed Cable Removal and Installation . . . . . . . . . . WP 0343–1
24V Body Feed Harness Removal and Installation . . . . . . . . . . . . . . . . . . . . . . WP 0348–1
24V Gauge Bulb Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0305–1
24V Gauge Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0304–1
24V Government Furnished Equipment (GFE) Wiring Harness Removal and Installation . . . . . . WP 0445–1
24V Instrument Panel (IP) Feed Wiring Harness Removal and Installation . . . . . . . . . . . . WP 0436–1
24V Inverter Megafuse and Holder Removal and Installation . . . . . . . . . . . . . . . . . . WP 0449–1
24V Power Distribution Module (PDM) Feed Harness Removal and Installation . . . . . . . . . . WP 0437–1
24V Power Distribution Module (PDM) Ground Cable Removal and Installation . . . . . . . . . . WP 0438–1
24V Power Distribution Module (PDM) Removal and Installation . . . . . . . . . . . . . . . . WP 0443–1
24V Underhood Junction Block Removal and Installation . . . . . . . . . . . . . . . . . . . WP 0423–1
4-Pack Air Solenoid Circuits From Electronic System Controller (ESC) Troubleshooting Procedure . WP 0138–1
4-Pack Air Solenoid Module and Support Removal and Installation . . . . . . . . . . . . . . . WP 0464–1
Index–17/blank

RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts DATE
and Special Tool Lists (RPSTL) and
BLANK FORMS Supply Catalogs/Supply Manuals
Date you filled out this form.
For use of this form, see AR 25-30; the proponent agency is OAASA. (SC/SM).
TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command Your mailing address
ATTN: AMSTA‐LCL‐MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397‐5000
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
TM Number Date of the TM Title of the TM
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO. (Exact wording of recommended change must be given)
0007-3 Figure 2, Item 9 should show a lockwasher. Currently shows a

flat washer.
0018-2 Cleaning and inspection, Step 6, reference to governor support

pin (14) is wrong reference. Reference should be change to
(12).
SAMPLE
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION
Your Name Your Phone Number Your Signature
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00
TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command Date you filled out
ATTN: AMSTA‐LCL‐MPP/TECH PUBS Your Address this form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TM Number Date of the TM Title of the TM
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED
SAMPLE
PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

PLUS EXTENSION
Your Name Your Signature
Your Phone Number
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts and Special
DATE
BLANK FORMS Tool Lists (RPSTL) and Supply Catalogs/Supply
Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA
U.S. Army TACOM Life Cycle Management Command
MAINTENANCE MANUAL FOR MINE RESISTANT AMBUSH
TM 9‐2355‐106‐23‐1 19 November 2012 PROTECTED VEHICLE
PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON

GRAPH NO.

PLUS EXTENSION
MAINTENANCE MANUAL FOR MINE RESISTANT
TM 9‐2355‐106‐23‐1 19 November 2012 AMBUSH PROTECTED VEHICLE
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED
PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and

PLUS EXTENSION
APD V4.00
DATE
Manuals (SC/SM).
GRAPH NO.

PLUS EXTENSION
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED
PART III – REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and

PLUS EXTENSION
APD V4.00
DATE
Manuals (SC/SM).
GRAPH NO.

PLUS EXTENSION
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED
PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and

PLUS EXTENSION
APD V4.00
By Order of the Secretary of the Army:
RAYMOND T. ODIERNO
General, United States Army
Official: Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1229003
By Order of the Secretary of the Air Force:
JANET C. WOLFENBARGER MARK A. WELSH, III

General, United States Air Force General, United States Air Force
Commander, AFMC Chief of Staff
Distribution:
To be distributed in accordance with the initial distribution number (IDN) 381168

requirements for TM 9-2355-106-23-1.

THE METRIC SYSTEM AND EQUIVALENTS

Linear Measure Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Pounds 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Temperature
Liquid Measure
9/5 C° +32 = F°
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 5/9 (°F - 32) = °C
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius
90° Fahrenheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0° Celsius

APPROXIMATE CONVERSION FACTORS

To Change To Multiply By To Change To Multiply By
Inches Centimeters 2.540 Centimeters Inches 0.394
Feet Meters 0.305 Meters Feet 3.280
Yards Meters 0.914 Meters Yards 1.094
Miles Kilometers 1.609 Kilometers Miles 0.621
Sq Inches Sq Centimeters 6.451 Sq Centimeters Sq Inches 0.155
Sq Feet Sq Meters 0.093 Sq Meters Sq Feet 10.764
Sq Yards Sq Meters 0.836 Sq Meters Sq Yards 1.196
Sq Miles Sq Kilometers 2.590 Sq Kilometers Sq Miles 0.386
Acres Sq Hectometers 0.405 Sq Hectometers Acres 2.471
Cubic Feet Cubic Meters 0.028 Cubic Meters Cubic Feet 35.315
Cubic Yards Cubic Meters 0.765 Cubic Meters Cubic Yards 1.308
Fluid Ounces Milliliters 29.573 Milliliters Fluid Ounces 0.034
Pints Liters 0.473 Liters Pints 2.113
Quarts Liters 0.946 Liters Quarts 1.057
Gallons Liters 3.785 Liters Gallons 0.264
Ounces Grams 28.349 Grams Ounces 0.035
Pounds Kilograms 0.454 Kilograms Pounds 2.205
Short Tons Metric Tons 0.907 Metric Tons Short Tons 1.102
Pound-Feet Newton-Meters 1.356 Newton-Meters Pound-Feet 0.738
Pounds per Sq Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch
Miles per Gallon Kilometers per Liter 0.425 Kilometers per Liter Miles per Gallon 2.354
Miles per Hour Kilometers per Hour 1.609 Kilometers per Hour Miles per Hour 0.621

PIN: 084302-000

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ARMY *TM 9-2355-106-23-1

AIR FORCE TO 36A12-1C-2400-2-1

FIELD MAINTENANCE MANUAL

MINE RESISTANT AMBUSH PROTECTED (MRAP)

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

WARNING SUMMARY – (Continued)

ELECTRICAL – electrical wire to arm with electricity symbol running

ELECTRICAL – electrical wire to hand with electricity symbol running

FLYING PARTICLES – arrows bouncing off face shows that particles

HEAVY PARTS – heavy object on human figure shows that heavy

WARNING SUMMARY – (Continued)

HELMET PROTECTION – arrow bouncing of head with helmet shows

LASER LIGHT – laser light hazard symbol indicates extreme danger

SHARP OBJECT – pointed object in hand shows that a sharp object

SHARP OBJECT – pointed object in hand shows that a sharp object

WARNING SUMMARY – (Continued)

SHARP OBJECT – pointed object in foot shows that a sharp object

Do not install or remove air-conditioning testing or charging equipment while engine is

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

Prior to performing work on crossmember, place wooden block between

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

FSS extinguisher can move violently when discharging. Ensure extinguisher

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

EXPLANATION OF HAZARDOUS MATERIALS ICONS

WARNING SUMMARY – (Continued)

BIOLOGICAL – abstract symbol bug shows that a material may contain

CRYOGENIC – hand in block of ice shows that the material is extremely

POISON – skull and crossbones shows that a material is poi-

RADIATION – three circular wedges shows that the material emits

VAPOR – human figure in a cloud shows that material vapors

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

CARC (CHEMICAL AGENT RESISTANT COATING)

CORROSION PREVENTIVE COMPOUND

WARNING SUMMARY – (Continued)

WARNING SUMMARY – (Continued)

NBC (NUCLEAR, BIOLOGICAL, and CHEMICAL) SYSTEM

WARNING SUMMARY – (Continued)

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes TM 9-2355-106-23-1, Dated 27 April 2009.

Date of issue for original manual is:

Page/WP No. Change No. Page/WP No. Change No.

Front Cover.................................................................... 0 WP 0035 (6 pgs)............................................................ 0

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

FIELD MAINTENANCE MANUAL

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clviiii

CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION, VOL 1

TABLE OF CONTENTS – (Continued)

CHAPTER 2. TROUBLESHOOTING PROCEDURES, VOL 1

CHAPTER 3. TROUBLESHOOTING PROCEDURES, VOL 1

TABLE OF CONTENTS – (Continued)