2000 Hummer Service Manual

2000 SERVICE MANUAL
TABLE OF CONTENTS
General Information 1
Engine
Fuel, Emissions and Exhaust
Cooling System
COMMERCIAL HUMMER
Transmission/Transfer Case
Wheels and Tires/ Central Tire Ination System
Brake System
Steering System
Axles/Suspension and Frame
Body
10
Heating/Ventilation/ Air Conditioning (HVAC)
11
AM GENERAL CORPORATION
408 South Byrkit Avenue P Box 728 .O. Mishawaka, Indiana 46546-0728
Electrical
12
Accessories
AM General Number 05745159 Copyright 1999 All Rights Reserved. Printed in U.S.A.
13
Index
14
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Section 1 General Information, Lubrication and Maintenance

TABLE OF CONTENTS
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Bolt Identification and Torque Limits (Dry*) . . . . . . . . . . . . . . .1-13 Bolt Identification and Torque Limits (Wet*). . . . . . . . . . . . . . .1-14 Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 Emission Control information Label . . . . . . . . . . . . . . . . . . . . . .1-3 Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 EPA Noise Emission Control Information Label. . . . . . . . . . . . .1-5 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 Hummer Service Hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Lubrication and Maintenance Items. . . . . . . . . . . . . . . . . . . . . .1-25 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21 Miscellaneous essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . .1-33 Paint and Trim Colors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Recommended Fuel/Fluids/Lubricants/Capacities . . . . . . . . . 1-24 Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Safety Certification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Scheduled Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Service Manual Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 Towing, Lifting, Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Transfer Case Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 U.S./Metric Conversions and Equivalents . . . . . . . . . . . . . . . . 1-15 Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . . 1-5 Vehicle Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
SAFETY SUMMARY
Individuals who decide to perform their own repairs should have proper training and limit repairs to components which will not affect the safety of the vehicle or its occupants. When replacement parts are required, it is strongly recommended that they are purchased through an authorized HUMMER dealer. It is essential that replacement parts meet or exceed manufacturers specifications. Vehicle performance and personal safety may be impaired if other than original factory components are installed. The installation of nonapproved accessories or conversions is not recommended as they could affect the vehicles driving characteristics and personal safety. AM General Corporation will not be liable for personal injury or damage to property resulting from the installation of nonapproved accessories or conversions to the HUMMER. Following the safety precautions as prescribed throughout this manual may greatly reduce the risks of personal injury and damage to the vehicle. However, it is unlikely that AM General Corporation will account for all possibilities. Warnings, cautions, and notes are used throughout this service manual to assist service personnel in the performance of maintenance actions. These statements are designed as reminders for trained and experienced service personnel. WARNINGS Indicate potential safety hazards and must be followed to avoid personal injury. Warnings appear as follows:
WARNING: To avoid injury, do not remove surge tank ller cap before depressurizing cooling system when engine temperature is above 190 F (88 C).
CAUTIONS Indicate potential equipment damage, and must be followed to avoid damage to components or systems. An example of a caution is shown below: CAUTION: To avoid starter damage, do not operate starter continuously for more than 15 seconds. Wait 10 to 15 seconds between periods of operation. NOTES Indicate methods or actions that may simplify vehicle maintenance or help maintain vehicle performance. An example of a note is shown below: NOTE: Clean all components, examine for wear or damage, and replace if necessary.
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General Information, Lubrication and Maintenance
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CARBON MONOXIDE
WARNING: Carbon monoxide (exhaust gases) can be fatal. WARNING: Brain damage or death can result from heavy exposure to carbon monoxide. The following precautions must be followed to ensure personal safety.
1. Do not operate vehicle engine in enclosed areas. Do not idle the vehicle engine with vehicle windows closed. Be alert at all times for exhaust odors. Be alert for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness Loss of muscular control If you see another person with exhaust poisoning symptoms: Remove person from area Expose to open air
AM General Corporation Commercial Publications Department 408 S. Byrkit St. P.O. Box 728 Mishawaka, IN 46546-0728 Forms are furnished at the end of this manual.
Service Manual Revisions

In order to receive future revisions to this service manual, please write to: AM General Corporation Service Parts Logistics Operations Commercial Publications/Customer Service 408 South Byrkit Avenue P.O. Box 728 Mishawaka, Indiana 46546-0728 Be sure to specify publication number.
2.
HUMMER SERVICE HOTLINE

On occasion, an unusual service problem can arise that is not covered in the manual. For this reason, AM General Corporation has established a service hotline for dealership assistance. The hotline number is: 1-800-638-8303
Keep person warm Do not permit physical exercise Administer artificial respiration, if necessary Notify medical personnel The best defense against exhaust poisoning is adequate ventilation.
Transfer Case Hotline

If you have questions that are not answered in Section 5 of this Service Manual, you can call the Transfer Case Hotline at 1-800-945-4327 (in the U.S.) for more information. International and Canadian customers and dealers should call 1-315-432-4110.
ABOUT THIS MANUAL

This service manual contains instructions for maintaining the 1999 commercial HUMMER. Spend some time looking through this manual. Features to improve the usefulness of this manual and increase your efficiency are: Accessing Information - These include: tabulated sections for quick reference, extensive troubleshooting guides for specific systems, and step-by-step directions for service repairs. Illustrations - A variety of methods are used to make locating and repairing components easy. Locator illustrations, exploded views, and cut-away diagrams make the information in this manual easy to understand. The service manual is the best source available for providing information and data critical to vehicle operation and maintenance. In this manual you will find the following information: Safety Summary General Information General Service Procedures Detailed Service Procedures Torque Ranges Wiring Diagrams and Schematics HUMMER owners and dealership service personnel can submit service manual suggestions and comments in writing to:
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EMISSION CONTROL INFORMATION LABEL

The vehicle emission control label contains engine information such as curb idle rpm, engine displacement, catalytic converter type, fuel rate, and vacuum hose routing. This label is affixed to the air cleaner housing (Figure 1-1).
Figure 1-1: Emission Control Information Label Information
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SAFETY CERTIFICATION LABEL

The safety certification label is located on the driver side Bpillar (door latch post) (Figures 1-2, 1-3, and 1-4). The label is required by the National Highway Traffic Safety Administration and includes a tamper-proof feature. If the label is tampered with, a void pattern will appear across the label. The label contains the name of the manufacturer, the month and year the vehicle was manufactured, the certification statement, the vehicle identification number (VIN), and the vehicle model type. It also contains the Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Ratings (GAWR), and wheel and tire information. For more information on the GVWR and GAWR, refer to VEHICLE LOADING INFORMATION in the Hummer Owners Manual.
Figure 1-3: Safety Certification Label for 10,300 lb GVWR Vehicles
Figure 1-4: Safety Certification Label for 10,800 lb GVWR Vehicles
TRANSMISSION IDENTIFICATION
The 4L80-E automatic transmission serial number is located on a plate at the right side of the transmission (Figure 1-5).
Figure 1-2: Safety Certification Label for Fleet Vehicles (12,100 lb. GVW vehicles)
TRANSMISSION I.D. PLATE
Figure 1-5: Transmission I.D. Plate Location
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EPA NOISE EMISSION CONTROL INFORMATION LABEL

The EPA noise emission control information label is located on the passenger side B-pillar (door latch post). The label is required by the EPA and includes a tamper-proof feature. If the label is tampered with, a void pattern will appear across the label. Notify the dealer or the manufacturer if the label is missing or displays a void pattern (Figure 1-6). The label contains the name of the manufacturer, the month and year the vehicle was manufactured, a statement regarding vehicle conformance to applicable U.S. EPA regulations, and a description of acts prohibited by the Noise Control Act of 1972.
TRANSFER CASE SERIAL NUMBER (ON ID PLATE)
Figure 1-7: Transfer Case I.D. Plate Location
ENGINE IDENTIFICATION
The engine serial number label is located at the rear of the left cylinder head (Figure 1-8).
ENGINE SERIAL NUMBER LABEL
Figure 1-8: Engine I.D. Label Location
VEHICLE IDENTIFICATION NUMBER (VIN)

The VIN plate is located at the upper left front corner of the dashpad (Figure 1-9).
Figure 1-6: EPA Noise Emission Control Information Label Location
TRANSFER CASE IDENTIFICATION

The transfer case serial and assembly numbers are located on a tag attached to the rear case (Figure 1-7).
VIN PLATE
Figure 1-9: VIN Plate Location

The first twelve digits of the seventeen digit VIN are explained in the chart on the following page. 05745159
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89
000001
Digit 1 Manufacturing Country
Digit 12 through 17 Sequential, Assigned Serial Number
Digit 2 Company/Make Digit 11 Plant Code Digit 3 Vehicle Type Digit 10 Model Year Digit 4 Engine Type Digit 9 Check Digit Digit 5 Transmission/Drive Digit 8 GVWR Digit 6 and 7 Truck Line Series Model, Body Type
Vehicle Identication Number Decoding Chart

Digit 1 2 3 5 6&7 Code 1 3 7 Z A 83 84 89 90 8 9 10 11 12-17 3-1-01 3 Y E Code Denition United States AM General Corporation Commercial Vehicles 6.5L (395 in.3),Turbocharged Diesel, GM, 8 cyl., 195 hp 4-Speed, Automatic/LHD 1-1/4 ton 1-1/4 ton 1-1/4 ton 1-1/4 ton Check Digit 2000 Mishawaka, Indiana Sequential Serial Number 4-door Station wagon 2-door enlarged cab Open body w/full hard doors Truck, utility HMC4 Truck, utility HMCS Truck, utility XLC2 Truck, utility HMCO
Class 3, 10,001 lb - 14,000 lb (4,541 kg - 6,356 kg)
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COMPONENT DATA
Engine:
Manufacturer ................................................................................................................................................................. GM Powertrain Model ........................................................................................................................................................................... 6.5 L (395 in.3) Type.........................................................................................................................Four Cycle, Turbocharged Diesel, Liquid-Cooled Power Output: ..................................................................................................... 195 HP @ 3400 rpm/430 ft lb. Torque @ 1800 rpm
Engine Dimensions:
Length.............................................................................................................................................................................. 35 in. (89 cm) Width ............................................................................................................................................................................... 28 in. (71 cm) Height .............................................................................................................................................................................. 28 in. (71 cm) Net Weight, Dry ............................................................................................................................................................701 lb (318 kg)
Governed Speed:
Full Load ............................................................................................................................................................................ 3,400 RPM No Load.............................................................................................................................................................................. 3,650 RPM Idle Speed ............................................................................................................................................................................... 700 RPM Operating Speed ........................................................................................................................................................1,500-2,600 RPM
Cylinders:
Number.................................................................................................................................................................................................8 Arrangement................................................................................................................................................................................. 90 V Firing Order..............................................................................................................................................1-8-7-2-6-5-4-3 (Clockwise) Bore ......................................................................................................................................................................4.06 in. (103.12 mm) Stroke ......................................................................................................................................................................... 3.82 in. (9.7 cm) Displacement .................................................................................................................................................................6.5 L (395 in.3) Compression Ratio: ......................................................................................................................................................................20.2:1
Lubricating System:
Type................................................................................................................................................................................. Pressure Feed Operating Pressure: (Minimum)................................................................................................................................. 30 psi (206.8 kPa) @ 2000 RPM (Idle Minimum)..................................................................................................................................................... 6 psi (41.3 kPa) System Capacity (Filter Included)...................................................................................................................................... 8 qt (7.6 L) Operating Temperature (Normal)................................................................................................................. 180-275 F (82-135 C) Oil Pump ............................................................................................................................................................................High Output Filter ................................................................................................................................................................ Paper Element, Spin On
Fuel/Air System:
Fuel Supply Pump Type ....................................................................................................................................................... Electronic Fuel Filter Type ...................................................................................................................... Two Stage Fuel Filter /Water Separator Glow Plug Type ...........................................................................................................................................................(11G) Fast Start
Starter:
Manufacturer ...........................................................................................................................................................................Prestolite Model ...........................................................................................................................................................................................MMO Capacity (Peak) ........................................................................................................................................................................... 6.0 hp Voltage ...........................................................................................................................................................................................12 V
Cooling System:
Type........................................................................................................................................................... Liquid w/Fan and Radiator Operating Temperature. ............................................................................................................................... 190-235 F (88-113 C) Filler Cap Pressure ...................................................................................................................................................... 15 psi (103 kPa) Radiator Type .................................................................................................................................................. 4 Row Core Downflow Fan Type..............................................................................................................................................8 Blade,suction w/viscous drive Fan Diameter ............................................................................................................................................................ 19.5 in. (49.5 cm) 05745159
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Thermostat: Starts to Open ..........................................................................................................................................................190 F (88 C) Fully Open.............................................................................................................................................................212 F (100 C)
Generator:
Manufacturer ................................................................................................................................................................................Delco Output ................................................................................................................................................. 124 AMP @ 1842 Engine RPM Rated Voltage .................................................................................................................................................................. 13.35 -15.9 V
Batteries:
Manufacturer ..............................................................................................................................................................Johnson Controls Type.......................................................................................................................................................................... Low Maintenance Number ............................................................................................................................................................................................... 2 Voltage ...........................................................................................................................................................................................12 V Amperage @ 0 F ...............................................................................................................................800 Cold Cranking amps Each Battery 32 F ...............................................................................................................................1000 Cold Cranking amps Each Battery 80 F ............................................................................................................................................110 Reserve Capacity (Minutes)
Transmission:
Manufacturer ................................................................................................................................................................ GM Powertrain Model......................................................................................................................................................................................... 4L80-E Type...................................................................................................................................................................... 4-Speed, Automatic Converter Torque Ratio................................................................................................................................................................ 2.2:1 Gear Ratios: First...................................................................................................................................................................................... 2.48:1 Second ................................................................................................................................................................................. 1.48:1 Third .................................................................................................................................................................................... 1.00:1 Fourth .................................................................................................................................................................................. 0.75:1 Reverse ....................................................................................................................................................................................... 2.08:1 Oil Type.............................................................................................................................................................................. Dexron III Oil Pressure .............................................................................................................................................. 35-324 psi (241-2,234 kPa)
Transfer Case:
Manufacturer ........................................................................................................................................................... New Venture Gear Model................................................................................................................................................................................................242 Type......................................................................................................................................................... Full Time Four-Wheel Drive Gear Ratios High and High Lock ..........................................................................................................................................................................1:1 Low Range................................................................................................................................................................................... 2.72:1 Oil Type.............................................................................................................................................................................. Dexron III
Geared Hub:
Manufacturer ......................................................................................................... AM General Corporation design, made by Tremec Type......................................................................................................................................................................................Spur Gears Gear Ratio.....................................................................................................................................................................................1.92:1 Oil Type................................................................................................................................................................................SAE 80-90
Axle/Differential:
Manufacturer .............................................................................................................AM General Corporation design, made by Dana Type: Axle ......................................................................................................Fixed Mounted Differential W/ Independent Half Shafts Differential .............................................................................................................Hypoid Torque Biasing (Paired Worm Gears) Gear Ratio: 10,300 and 10,800:................................................................................................................................................................2.56:1 12,100:...................................................................................................................................................................................3.08:1
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Service Brake Caliper (Front):

Manufacturer ................................................................................................................................................................... Kelsey-Hayes Piston Diameter ............................................................................................................................................................ 2.6 in. (6.6 cm)
Service/Parking Brake Caliper (Rear):

Manufacturer ................................................................................................................................................................... Kelsey-Hayes Piston Diameter ............................................................................................................................................................ 2.6 in. (6.6 cm)
Service/Parking Brake Rotor:

Manufacturer ................................................................................................................................................................... Kelsey-Hayes Diameter ................................................................................................................................................................ 10.5 in. (266.7 mm) Thickness.................................................................................................................................................................... 0.87 in. (22 mm) Minimum Thickness................................................................................................................................................. 0.81 in. (20.7 mm)
Steering System:
Steering Gear: Manufacturer ..................................................................................................................................................................... Saginaw Type .........................................................................................................................................Recirculating Ball, Worm and Nut Ratio ................................................................................................................................................................................... 13/16:1 Power Steering Pump: Manufacturer ..................................................................................................................................................................... Saginaw Output Pressure (Max) .................................................................................................... 1,465 - 1,515 psi (10,101 - 10,446 kPa) Flow Rate (Max)........................................................................................................................................... 2.6 gpm (9.8 Lpm) Capacity (@ 1500 RPM) .............................................................................................................................. 2.6 gpm (9.8 Lpm) Reservoir ............................................................................................................................................................................ Remote Frame: Manufacturer ............................................................................................................. AM General Corporation design, made by Dana Type........................................................................................................................................................................................ Steel Box No. of Crossmembers ...........................................................................................................................................................................5
Air Conditioner:
Manufacturer (Compressor) ............................................................................................................................................. GM-Harrison Model ............................................................................................................................................................................................HD-6 Field (Coil) ..................................................................................................................................................................................... 12 V Oil Capacity.................................................................................................................................................................. 8 fl oz (237 ml) Refrigerant.................................................................................................................................................................................. R-134a Capacity (system + 2 oz. of oil) .................................................................................................................................. 3.2 lb. (1.45 kg)
Winch:
Manufacturer ................................................................................................................................................................................. Warn Model ................................................................................................................................................... 12,000 lb., 12VDC HUMMER Type.......................................................................................................................................... Electric Drive, Thermal Cutoff Switch Capacity................................................................................................................................................................. 12,000 lb (5,448 kg)
Wheels and Tires:

Manufacturer ..........................................................................................................................Goodyear Tire Size 37 in. X 12.5R-16.5 Wheel Type: Standard ......................................................................................................................................................................... One-Piece Size...........................................................................................................................................................................16.5 x 8.25 in.
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General Information, Lubrication and Maintenance ________________
FLUID CAPACITIES
Cooling System .................................................................................................................................................................. 26 qt (25 L) Engine: Crankcase (oil pan) only .............................................................................................................................................. 7 qt (6.6 L) Crankcase and Filter..................................................................................................................................................... 8 qt (7.6 L) Fuel Tank...................................................................................................................................................................25 gal. (95 L) Auxiliary Fuel Tank ...............................................................................................................................................17 gal. (64.3 L) Axle (front/rear) ........................................................................................................................................................... 2 qt (1.9 L) Transmission: Drain and Refill (with Pan Removed) ....................................................................................................................... 7.7 qt (7.3 L) W/Dry Converter ................................................................................................................................................... 13.5 qt (12.8 L) Transfer Case.................................................................................................................................................................... 3.5 qt (3.3 L) Geared Hub........................................................................................................................................................................ 1 pt (0.47 L) Steering System ................................................................................................................................................................ 1 qt (0.95 L) Brake Hydraulic System (DOT 3) Master Cylinder ................................................................................................................................................. 1.64 pt (0.78 L) Total System ....................................................................................................................................................... 3.12 pt. (1.5 L) Windshield Washer Reservoir........................................................................................................................................2.5 gal. (9.5 L)
VEHICLE WEIGHTS
Curb Weight (10,300/10,800 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 6,460 lb (2,930 kg) Four Door Open Top (w/ full doors) (HMCO) ................................................................................................ 6,710 lb (3,044 kg) Four Door Hard Top (HMC4) .......................................................................................................................... 6,860 lb (3,112 kg) Four-Door Station Wagon (HMCS) ................................................................................................................. 7,050 lb (3,198 kg) Payload (10,300 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 3,840 lb (1,742 kg) Four-Door Open Top (w/ full doors) (HMCO) ................................................................................................ 3,590 lb (1,628 kg) Four Door Hard Top (HMC4) .......................................................................................................................... 3,440 lb (1,560 kg) Four-Door Station Wagon (HMCS) ................................................................................................................. 3,250 lb (1,474 kg) Payload (10,800 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 4,340 lb (1,968 kg) Four-Door Open Top (w/ full doors) (HMCO) ................................................................................................ 4,090 lb (1,855 kg) Four Door Hard Top (HMC4) .......................................................................................................................... 3,940 lb (1,768 kg) Four-Door Station Wagon (HMCS) ................................................................................................................. 3,750 lb (1,700 kg) Gross Vehicle Weight (GVW) ............................................................................................ 10,300 lb (4,676 kg)/10,800 lb (4,899 kg) Gross Axle Weight Rating (GAWR): Front.............................................................................................................................................................. 4,100 lb (1,860 kg) Rear............................................................................................................................................................... 6,800 lb (3,084 kg) Gross Combination Weight (GCW) ...................................................................................................................... 14,800 lb (6,719 kg) Maximum Towed Load: Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 8,340 lb (3,783 kg) Four-Door Open Top (w/ full doors) (HMCO) ................................................................................................ 8,090 lb (3,670 kg) Four-Door Hard Top (HMC4).......................................................................................................................... 7,940 lb (3,602 kg) Four-Door Station Wagon (HMCS) ................................................................................................................. 7,750 lb (3,515 kg)
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Turbo Diesel Engine -- (12,100 lb. (5,489 kg) GVWR Vehicles -- Fleet Vehicles Only
Curb Weight (12,100 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 6,720 lb (3,048 kg) Four Door Hard Top (HMC4).......................................................................................................................... 7,120 lb (3,230 kg) Four-Door Station Wagon (HMCS)................................................................................................................. 7,310 lb (3,316 kg) Payload (12,100 GVWR): Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 5,380 lb (2,440 kg) Four Door Hard Top (HMC4).......................................................................................................................... 4,980 lb (2,258 kg) Four-Door Station Wagon (HMCS)................................................................................................................. 4,790 lb (2,172 kg) Gross Vehicle Weight (GVW) .............................................................................................................................. 12,100 lb (5,488 kg) Gross Axle Weight Rating (GAWR): Front ............................................................................................................................................................. 4,400 lb (1,995 kg) Rear .............................................................................................................................................................. 7,700 lb (3,492 kg) Gross Combination Weight (GCW) ...................................................................................................................... 16,500 lb (6,719 kg) Maximum Towed Load: Two-Door Enlarged Cab (Hard Top) (XLC2) ................................................................................................. 9,780 lb (4,436 kg) Four-Door Hard Top (HMC4) ......................................................................................................................... 9,380 lb (4,254 kg) Four-Door Station Wagon (HMCS)................................................................................................................. 9,190 lb (4,168 kg)
VEHICLE DIMENSIONS
Length (see Note)184.5 in. (4,68.6 mm): Height ................................................................................................................................................................ 75 in. (190.5 mm) Width (without mirrors) ................................................................................................................................ 86.50 in. (219.7 mm) Ground Clearance ................................................................................................................................... 16 in. (41 cm) (at GVW) Wheelbase ............................................................................................................................................................. 130 in (330 cm) Track Width ............................................................................................................................................................. 72 in. (183 m) NOTE: The vehicle weight and dimensions data applies to models without a winch.
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ABBREVIATIONS
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Brake System A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternating Current AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ampere CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carbon Monoxide C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Celsius (centigrade) cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter CTIS . . . . . . . . . . . . . . . . . . . . . . Central Tire Inflation System CDR. . . . . . . . . . . . . . . . . . . Crankcase Depression Regulator cm3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Centimeter in.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Inch cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . Degree (angle or temperature) DTC . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter d.c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current EPA. . . . . . . . . . . . . . . . . . . Environmental Protection Agency F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feet ft/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feet Per Minute fl oz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid Ounce gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gram GAWR . . . . . . . . . . . . . . . . . . . . . . Gross Axle Weight Rating GVW. . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight GVWR . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower HVAC. . . . . . . . . . . . . Heat, Ventilation, and Air Conditioning in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch INC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Include ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Diameter kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilograms km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer km/h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers Per Hour kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascals lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Hand L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter mpg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles Per Gallon mph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles Per Hour mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ohms oz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ounce O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Diameter P/N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Number %. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Percentage pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pint + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plus + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-feet lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-inch psi . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds Per Square Inch qt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quart : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratio ref. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference RPM. . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions Per Minute rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right-Hand cm2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square Centimeters in2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square Inches TT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Trac 4 VIN . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watts UNC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unified Coarse UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unified Fine
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BOLT IDENTIFICATION AND TORQUE LIMITS (DRY*)

* A phosphate and oil bolt is considered dry
Bolt Head ID Marks and SAE GRADE
BOLT SIZE DIA. INCHES 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/4 1-3/8 1-1/2 MILLIMETERS 6 6 8 8 10 10 11 11 13 13 14 14 16 16 19 19 22 22 25 25 29 32 35 38 THREADS PER INCH 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 14
SAE GRADE NO. 1 OR 2 POUND FEET (NEWTONMETERS) 5(7) 6(8) 11(15) 13(18) 18(24) 20(27) 28(38) 30(41) 39(53) 41(56) 51(69) 55(75) 63(85) 95(129) 105(142) 115(156) 160(217) 175(237) 235(319) 250(339)
SAE GRADE NO. 5 POUND FEET (NEWTONMETERS) 8(11) 10(14) 17(23) 19(26) 31(42) 35(47) 49(66) 55(75) 75(102) 85(115) 110(149) 120(163) 150(203) 170(231) 270(366) 295(400) 395(536) 435(590) 590(800) 660(895) 800 - 880 (1085 - 1193) 1460 - 1680 (1980 - 2278) 1940 - 2200 (2631 - 2983)
SAE GRADE NO. 6 OR 7 POUND FEET (NEWTONMETERS) 10(14) 19(26) 34(46) 55(75) 85(115) 120(163) 167(226) 280(380) 440(597) 660(895)
SAE GRADE NO. 8 POUND FEET (NEWTONMETERS) 12(16) 14(19) 24(33) 27(37) 44(60) 49(66) 70(95) 78(106) 105(142) 120(163) 155(210) 170(231) 210(285) 240(325) 375(509) 420(570) 605(820) 675(915) 910(1234) 990(1342) 1280 - 1440 (1736 - 1953) 1820 - 2000 (2468 - 2712) 2380 - 2720 (3227 - 3688) 3160 - 3560 (4285 - 4827)
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BOLT IDENTIFICATION AND TORQUE LIMITS (WET*)

*A cadmium plated bolt is considered wet.
Bolt Head ID Marks and SAE Grade
BOLT SIZE DIA. INCHES 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/4 1-3/8 1-1/2 MILLIMETERS 6 6 8 8 10 10 11 11 13 13 14 14 16 16 19 19 22 22 25 25 29 32 35 39 THREADS PER INCH 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 14
SAE GRADE NO. 1 OR 2 POUND FEET (NEWTONMETERS) 4(5) 5(7) 10(14) 12(16) 16(22) 18(24) 25(34) 27(37) 35(48) 37(50) 46(62) 50(67) 57(77) 85(115) 95(129) 104(141) 144(195) 158(214) 212(287) 225(305)
SAE GRADE NO. 6 OR 7 POUND FEET (NEWTONMETERS) 9(12) 17(23) 31(42) 50(68) 77(104) 108(146) 150(203) 252(342) 396(537) 594(805)
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U.S./METRIC CONVERSIONS AND EQUIVALENTS Metric Conversions

MULTIPLY INCHES FEET MILES SQUARE INCHES CUBIC INCHES FLUID OUNCES PINTS QUARTS GALLON POUNDS SHORT TONS POUND-INCHES POUND-FEET POUNDS PER SQUARE INCH MILES PER GALLON MILES PER HOUR BY 2.54 0.305 1.609 6.451 16.39 29.573 0.473 0.946 3.785 0.454 0.907 0.113 1.356 6.895 0.425 1.609 TO GET CENTIMETERS METERS KILOMETERS SQUARE CENTIMETERS CUBIC CENTIMETERS MILLILITERS LITERS LITERS LITERS KILOGRAMS METRIC TONS NEWTON-METERS NEWTON-METERS KILOPASCALS KILOMETERS PER LITER KILOMETERS PER HOUR
U.S. Standard Conversions

MULTIPLY CENTIMETERS/MILLIMETERS METERS KILOMETERS SQUARE CENTIMETERS CUBIC CENTIMETERS MILLILITERS LITERS LITERS LITERS KILOGRAMS METRIC TONS NEWTON-METERS NEWTON-METERS KILOPASCALS BY 0.3937 3.280 0.621 0.155 0.061 0.034 2.113 1.057 0.264 2.205 1.102 0.738 8.851 0.145 KILOMETERS PER LITER KILOMETERS PER HOUR TO GET INCHES FEET MILES SQUARE INCHES CUBIC INCHES FLUID OUNCES PINTS QUARTS GALLONS POUNDS SHORT TONS POUND-FEET POUND-INCHES POUNDS PER SQUARE INCH 2.354MILES PER GALLON 0.621MILES PER HOUR
Temperature
32 FAHRENHEIT = 0 CELSIUS CELSIUS = 0.556 X (F -32) 212 FAHRENHEIT = 100 CELSIUS FAHRENHEIT = (1.8 X C) +32
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PAINT AND TRIM COLORS

Interior trim colors are tan and gray. Seating materials are available in cloth and vinyl. Soft top colors and codes are: Tan (T) and Black (B). Exterior paint colors and codes are outlined in the following chart.
Top Coat Description
AM General Code
Candy Apple Red White Gloss Black Gloss Competition Yellow Burgundy Metallic Bright White Silver Metallic Mesa Dusk Carmel Metallic Pewter Woodland Green REPLACEMENT KEYS
R19 W8 B9 Y20 P17 W14 S15 C22 P33 G23
Replacement keys can be cut using Briggs and Stratton or Curtis key cutting tools. Key codes are provided on an identificaion tag included with each key set (Figure 1-10).
Figure 1-10: Key Code Location
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TOWING, LIFTING, JUMP STARTING Vehicle Lifting/Jacking Points

Vehicle jacking points are shown in Figure 1-11. The vehicle can be raised with a floor jack at any of the indicated positions. Jacking can be performed at the front, rear, or at any one wheel. In cases where the entire vehicle must be raised, use jack stands at equidistant points on the frame rails. Use a minimum of four stands to support the vehicle. Suggested capacity for individual jack stands is 3 ton, with a vertical reach of 19 in. (49 cm). Typical jack stand placement for raising one side of the vehicle is shown in Figure 1-12. Always be sure the jack stand saddle is securely engaged and the stand is level.
Vehicle Hoisting
Hummer vehicles can be raised on a hoist for service access. Drive-on and swivel arm hoists are both acceptable. Hoist capacity and width are important. The greater width and weight of Hummer vehicles require a larger hoisting platform. Do not use an under capacity hoist, or modify an existing hoist for use; this practice is neither safe nor recommended.
REAR BUMPER FRONT LOWER CONTROL ARMS FRAME RAIL
FRONT CROSSMEMBER
REAR CROSSMEMBER
FRAME RAIL
REAR LOWER CONTROL ARMS
Figure 1-11: Vehicle Jacking Points
JACK STANDS POSITIONED UNDER FRAME RAIL
Figure 1-12: Typical Jack Stand Placement
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Towing Recommendations
Hummer vehicles can be towed with wheel lift, sling-type, or flat bed tow equipment. Flat bed and wheel lift equipment is recommended over sling type or A-frame equipment. Towing Cautions: Remove or secure loads in the towed vehicle Never use the shackles on the front bumpers as tie down points Always use safety chains on sling towed vehicles Always follow the transmission/transfer case shift position recommendations (Transfer Case in N (Neutral); Transmission in P (Park). Use a low vehicle trailer for recreational towing (behind an RV or other vehicle) when possible. Never put chains, cables or straps on any steering components.
Flat Bed/Wheel Lift Towing Procedures

Flat bed/wheel lift tow vehicles are highly recommended. They keep all of the towed vehicle wheels off the pavement. This is important with full time four wheel drive vehicles. Loading only requires that the towed vehicle be raised or winched onto the towing platform. A further advantage of this type equipment is that tow speed and distance are not limited. Once the towed vehicle is loaded, set the parking brake, shift the transmission into Park and install the vehicle tie downs. Tie down attachment points are shown in Figure 1-13.
LOOPS FRAME RAIL/ CROSSMEMBER LOOP
Figure 1-13: Vehicle Tie-Down Points
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Conventional Towing Procedures

Front Towing
1. 2. 3. 4. 5. 6. Loop chains around lower control arms and secure to tow sling (Figure 1-14). Insert 4 x 4 x 48 length of wood between bumper and sling chains (Figure 1-14). Raise front end and verify that sling is firmly positioned against front bumper. Release parking brakes. Shift transmission into Park and transfer case into Neutral. Position tow dollies under rear wheels. Proceed with towing operations.
SLING ASSEMBLY
SLING CHAINS
SLING ASSEMBLY FRAME RAIL WOOD BLOCK CROSSMEMBER
CHAIN ASSEMBLY
Figure 1-15: Rear Towing with Conventional Equipment
Conventional Towing When Keys are not Available

If the vehicle doors are locked and the keys are not available you cannot determine that the transmission is in Park and the transfer case is in N (Neutral). In these situations, you must use one of the following towing methods: a. Use tow dollies at all wheels and flat tow, or b. Raise the vehicle front or rear and use tow dollies under the wheels not raised.
LOWER CONTROL ARM
WOOD CROSSBEAM
Figure 1-14: Front Towing With Conventional Equipment
Rear Towing
1. 2. 3. 4. 5. 6. Loop sling chain around frame rails adjacent to rear crossmember and secure to tow sling (Figure 1-15). Insert 4 x 4 x 48 length of wood between bumper and sling chains (Figure 1-15). Raise rear end and verify that sling is firmly positioned against rear bumper. Release parking brakes. Shift transmission into Park and transfer case into Neutral. Position tow dollies under front wheels. Proceed with towing operations.
Recreational Towing
Hummer vehicles can be towed behind an RV if desired. A low-boy style vehicle trailer is best for this purpose. Flat towing is not recommended.
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Jump Starting
Hummer vehicles can be jump started when necessary. Starting can be performed with a portable starting unit, separate booster batteries, or the battery in another vehicle. Certain Cautions and Warnings must be observed when jump starting a vehicle. They are: If the battery in another vehicle is being used for jump starting, do not allow the two vehicles to touch. Contact can result in damage to the electrical system in both vehicles. Always connect negative to ground and positive to positive. Never jump start a vehicle with a frozen battery. This practice could lead to personal injury. Never jump start a battery when electrolyte level is below the top of the cell plates. Do not allow jumper cable clamps to touch after connecting them to the booster battery. Never allow open flame near batteries, especially during jump start operations or when batteries are charging. Personal injury could occur in either case. Never use 24 volt booster equipment, or equipment that is NOT negative ground. Either will seriously damage the vehicle electrical system. Remove all jewelry from hands and wrists to avoid arcing caused by accidental contact with battery current source.
BATTERY POSITIVE TERMINAL
JUMPER POSITIVE (+) CABLE
JUMPER NEGATIVE (-) CABLE GENERATOR MOUNTING BRACKET
Jump Start Procedure

1. 2. Set parking brake and shift transmission into Park. Do not jump start if low or dead battery is: frozen, cracked, has loose terminal socket, electrolyte level is below cell plates, or indicates less than 9 volts across terminals. Install temporary or replacement battery instead. However, if battery is only low on charge and is OK otherwise, proceed with jump starting. Connect positive (+) jumper cable to battery positive terminal (Figure 1-16).
3.
NOTE: An adapter may be required to connect the cables to some side mount terminals. 4. Connect negative (-) jumper cable to generator mounting bracket (Figure 1-16). Be sure cable clamp is securely attached. If portable booster machine is being used, verify that machine is at 12 volt setting. Higher volt/amp settings can damage vehicle electrical system. Start vehicle. Disconnect jumper cables immediately after engine startup.
Figure 1-16: Jumper Cable Connections
5.
6.
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MAINTENANCE SCHEDULE Recommended Maintenance

Maintenance recommendations in this section were developed to maintain satisfactory vehicle operation. Items described in Maintenance Inspection Groups A, B, and C are important to proper operation, performance, and safety. It is important that maintenance items outlined in the schedules be performed at suggested intervals. Regular maintenance will greatly improve vehicle reliability and longevity.
Normal Maintenance
The vehicle maintenance schedules reflect services required for normal operation. Normal operation includes city/highway driving on hard surface roads with only minimal operation on unpaved road surfaces.
water contamination is evident. If water contamination proves extensive, it will also be necessary to replace the transmission uid lter, and ush the transmission uid cooler and lines. Lubricate the steering linkage, ball joints, propeller shaft, and body lubrication points. Check the brake and power steering uid levels and top off as needed. Examine the engine air lter. Replace the lter element if necessary and clean the air lter housing and dust unloader. Change engine oil and replace engine oil lter.
Maintenance Inspection Groups A-B-C

The inspection groups outline additional components to be checked at stated mileage intervals. The intervals are described in your maintenance booklet. Perform necessary service repair, replacement, or adjustments as each inspection item is checked.
Maintenance After Severe Operation

Severe operation includes extensive off-road driving, salt water fording, commercial use, sustained operation in high ambient temperatures, and trailer towing. This type of vehicle operation requires additional and more frequent service. If the vehicle is going to be used frequently in severe operating situations, maintenance should be done on an hourly rather than a mileage schedule, as shown in the Scheduled Maintenance Chart on page 122 . To keep track of the hours of severe operation, an optional hourmeter can be installed at your Hummer dealer. Commercial use involves regular operation as a delivery or service type vehicle. Severe off-road use involves extended operation on rough terrain, stream fording, salt water fording, or sustained operation in sand, mud, snow, or dirt surfaces. Severe operation also includes prolonged daily operation in heavy trafc when ambient temperatures are high. The additional maintenance required immediately after severe off-road operation is as follows: Wash the vehicle underbody, driveline and brake components, and all steering linkage and suspension parts with a low pressure fresh water spray. If vehicle was driven over rough terrain, examine the underbody and driveline components for impact damage. Also check for leaks and loose parts. If the vehicle was driven through deep water, examine geared hub, axle and vent lines for water contamination. If the lines have become disconnected, these components may become water contaminated. Also inspect the axle and hub vents if required. Check the front/rear brake pads for contamination by dirt, mud, sand, etc. Replace the pads if foreign material has become embedded in the lining. However, if the pads are only wet from water, allow them to air dry, or drive the vehicle about a block with the brakes lightly applied to heat and dry the pads. Check transmission and transfer case uid levels and condition. Drain and replace the uid in either assembly if 05745159
Maintenance Inspection Group A:

Check uid levels and condition for power steering pump, cooling system (reservoir and surge tank), brakes, transmission, transfer case, geared hubs, and axles. Check CDR valve for oil saturation. Inspect condition of control arms, springs, and shock absorbers. Check tire wear and condition. Lubricate all grease ttings and body lubrication points. Inspect geared hubs for leaking seals or damage. Inspect service brakes and parking brake. Check axles for leaks or damage. Check torque of wheel half nuts and lug nuts. Inspect condition of geared hub and axle vent lines. Inspect condition of transmission and transfer case vent lines. Inspect U-joints for wear or missing/damaged grease ttings. Inspect condition of engine mounts and insulators. Inspect transmission/transfer case shift linkage for wear, binding, distortion. Check fuel lter and drain/clean if necessary. Check CTIS operation. Verify that system inates/deates tires. Check winch operation and cable condition (if equipped). Free-spool out and pay-in at least 30 feet of cable. Check ball joints for wear. Test drive vehicle and complete a functional check of all systems. Check air cleaner.
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Maintenance Inspection Group B: Inspect fuel injection pump, lines, and ttings for leaks or damage. Check battery voltage and condition. Inspect serpentine belt condition. Inspect exhaust system and shields. Inspect and rotate tires. Inspect halfshaft boots and ball joint seals. Inspect condition of steering column, U-joints, tie rods, steering arm, center link, and idler arm. Check fuel tank vent line lter. Inspect condition of frame rails and crossmembers. Check A/C system operation. Check wheel alignment. Maintenance Inspection Group C: Inspect surge tank, radiator and shroud, A/C condenser, power steering and transmission coolers, and all hoses and ttings for security of mounting, leaks, obstructions, or damage. Inspect fuel tank, lines, and cap. Inspect all wiring harnesses for frays, splits, missing insulation, poor connections. Inspect power steering pump, power steering gear, hoses, lines, and ttings for leaks or damage.
SCHEDULED MAINTENANCE CHART

3,000 Miles (4,800 km) 100 hrs normal use or 50 hrs severe operation
Change engine oil and replace lter. Check items in Maintenance Group A.
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Check items in Maintenance Groups A and B.
NOTES
Clean all dirt from caps and surrounding areas before opening to check uids.
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Change geared hub oil. Change axle oil. Change engine coolant. Change transmission and transfer case uid. Change transmission lter. Check items in Maintenance Groups A, B, and C.
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Change engine coolant. Change transmission and transfer case uid.
3-1-01
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1-23
Change transmission lter. Check items in Maintenance Groups A, B, and C. Change geared hub oil. Change axle oil. Inspect brake uid for moisture contamination.
45,000 Miles (72,400 km) 1,500 hrs normal use or 750 hrs severe operation
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Change engine coolant. Change transmission and transfer case uid. Change transmission lter. Check items in Maintenance Groups A, B, and C. Change geared hub oil. Change axle oil. Inspect brake uid for moisture contamination.
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Change engine coolant. Change transmission and transfer case uid. Change transmission lter. Check items in Maintenance Groups A, B, and C. Change geared hub oil. Change axle oil.
Change engine oil and replace lter. Clean or replace air lter. Replace fuel lter element. Check items in maintenance Groups A and B.
57, 000 Miles (91,700 km) 1,900 hrs normal use or 950 hrs severe operation
60,000 Miles (96,500 km) 2,000 hrs normal use or 1,000 hrs severe operation
Change engine oil and replace lter. Check items in Maintenance Groups A.
Change engine oil and replace lter. Clean or replace air lters. Replace fuel lter element. Change engine coolant. Change transmission and transfer case uid. Inspect fuel tank, fuel cap and fuel lines. Change transmission lter. Check items in Maintenance Groups A, B, and C. Change geared hub oil. Change axle oil. Drain & replace brake uid.
NOTE: Some maintenance requires specialized knowledge or equipment and may be best handled by qualied service technicians at your nearest HUMMER dealer. NOTE:
After your vehicle has been driven for 63,000 miles (101,400 km) repeat the schedule indicated in this section, starting at 3,000 miles (4,800 km).
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RECOMMENDED FUEL/FLUIDS/LUBRICANTS/ CAPACITIES Recommended Fuel

Recommended fuel for 6.5L diesel engines is #2 diesel. Do not use any other type fuel.
Transmission/Transfer Case/Steering Gear and Pump Fluid

Recommended lubricant for the transmission, transfer case, and steering system is Dexron III automatic transmission fluid. Approximate fluid capacities are: 1 qt (0.95L) for the steering gear and pump 3.5 qts (3.3L) for the transfer case 13.5 qts (12.8L) for the transmission, converter, and cooler 7.7 qts (7.3L) for the transmission (during fluid drain/refill)
Engine Oil
HOT WEATHER
F C
Brake Fluid
+100 +36
+60 +32 0
+16 0
Recommended brake fluid for all Hummer vehicles is DOT 3 brake fluid. Master cylinder approximate capacity is 1.64 pints (0.78L). Brake system approximate capacity is 3.1 pints (1.5L).
SAE 30W
-18
Front/Rear Axle and Geared Hub Lubricant

Recommended lubricant for axles and hubs is a heavy duty, multipurpose, API GL-5 gear lubricant, with viscosity ratings of 80W-90 or 75W-90. The 80W-90 is an all purpose lubricant. The 75W-90 lubricant is suggested for use in areas where winter temperatures are consistently below freezing.
-20
SAE 15W-40 PREFERRED

-29
SAE 10W-30
COLD WEATHER
CG-4/SJ QUALITY PREFERRED CF-4/SH QUALITY ACCEPTABLE DO NOT USE SAE 10W-40 GRADE OIL, OR ANY OTHER GRADE NOT RECOMMENDED
Steering Linkage and Suspension Lubricant

Recommended lubricant for steering and driveline components is an NLGI LB, or GC-LB grade multipurpose chassis grease. Use only those lubricants that display the NLGI certification symbol.
Figure 1-17: Oil Viscosity Chart

Diesel engine oil capacities are: 7.0 qts (6.6L) without filter change 8.0 qts (7.6L) with filter change 2.0 qts (1.9L) for engine oil cooler Refer to Section 2 for more information regarding engine oil.
Body Lubrication
Door hinges, linkage parts, cables, and other body components can be lubricated with a number of different lubricants. Suggested lubricants and applications are: Window regulator mechanisms spray white grease Window slides silicone spray lube Door hinges engine oil, ATF, or LPS brand spray lube Linkage/cables LPS brand silicone spray lube Lock strikers chassis grease, white grease, or LPS #3. Seat track multipurpose chassis grease (NLGI-LB) Lock mechanisms ATF, silicone spray lube, graphite lube
Engine Coolant
Recommended engine coolant is a mixture of ethylene glycol antifreeze and water. Use a mixture containing 50% antifreeze and 50% water. Radiator capacity is 7 qts (6.6L). System capacity is approximately 26 qts (25L).
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Engine Oil and Filter Change
1-25
A/C Refrigerant and Compressor Oil

The only refrigerant that can be used is R-134a. No other refrigerant is recommended. The only compressor oil recommended is PAG (polyalkylene glycol). It is the only oil compatible with refrigerant R-134a. No other oil is recommended. Any PAG oil used should be compatible with General Motors specifications. A/C system capacities are: 11 fluid ounces (325 ml) of PAG oil 3.2 lb (1.45 kg) refrigerant
LUBRICATION AND MAINTENANCE ITEMS Engine Oil Level

The engine oil dipstick is at the driver side of the engine (Figure 1-18). Correct oil level is to the FULL mark. Acceptable level is in the crosshatch area below the FULL mark. Check oil level only when the engine is shut down and the vehicle is on a level surface. Wait one minute after shut down to check. Never overfill the engine. The excess oil will be churned into foam causing oil film breakdown and consequent engine damage.
OIL DIPSTICK
The oil filter is located on the driver side of the engine (Figure 1-19). A front mounted fill tube is used. The spin-on oil filter is only removed with a standard bandtype tool. Coat the seal on a new filter with oil and clean the adapter surface before installation. Tighten the filter by hand. Replace filter every 3,000 mi (4,800 km). The oil pan drain plug has a gasket that should be replaced if cut, cracked, or distorted. Check the gasket seating surface on the oil pan. Burrs or nicks can be smoothed with a fine tooth file. Also replace the drain plug if the threads are worn or damaged. Be sure the plug is tightened to required torque of 16 lbft (22 Nm).
OIL FILTER
ADAPTER
OIL PAN DRAIN PLUG
Figure 1-19: Oil Filter/Drain Plug Location
OIL FILLER CAP
Figure 1-18: Oil Dipstick Location
Figure 1-20: Engine Oil Fill Location
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Fuel Filter Service

Replace the filter element every 6,000 mi (9,600 km), or annually, whichever occurs first (Figure 1-21). See Purging Air From Diesel Filter (Section 3).
FUEL FILTER
Check transmission fluid level at least once each month. Procedure is as follows: 1. Drive vehicle until transmission uid is at normal operating temperature. Fluid must be hot to obtain accurate reading. 2. Position vehicle on level surface. 3. Shift transmission into Park. 4. Operate engine at curb idle speed. 5. Remove transmission dipstick and check level (Figure 1-22). Correct level is within crosshatch marks on dipstick. 6. If fluid level is too high, remove excess through fill tube using suction gun and 3/16-in. teflon tubing. If level is low, check for leaks and, if OK, add fluid in 1-2 ounce increments until level is correct. CAUTION: Do not overfill the transmission. The excess fluid will be churned into foam resulting in overflow from the fill and vent tubes, slip and flare during upshifts, fluid breakdown and eventual clutch failure. 7. Check fluid color and condition. Normal color ranges from dark red to light pink. Fluid that is dark brown, black, or orange and full of bubbles indicates a problem that may require overhaul.
Figure 1-21: Fuel Filter Location
Transmission Fluid
TRANSMISSION DIPSTICK AND FILL TUBE
Transfer Case Fluid

Check transfer case fluid level every 3,000 mi (4 900 km), or semiannually, whichever comes first. Remove fill plug and gasket. Level should be within 1/2 in. (12.7 mm) of fill plug opening when transfer case is level. Install fill plug and gasket, and tighten to 15-25 lb-ft (20-33 Nm). Change fluid every 12,000 mi (19 000 km) or annually, whichever occurs first (Figure 1-23). Inspect rubber plug in the shift rail roll pin access passage located near the shift lever for leakage. Replace plug if leakage is present.
Figure 1-22: Transmission Dipstick Location

Replace the transmission fluid filter each time the fluid is changed. Refill the transmission with Dexron III afterward.
FILL PLUG
DRAIN PLUG
Figure 1-23: Transfer Case Fill/Drain Plug Location
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Universal and Slip Joint Lubrication
1-27
Axle and Geared Hub

Check axle and hub lubricant condition and level every 3,000 mi (4,800 km) or semiannually, whichever occurs first. Geared hub level should be within 1/2 in. (12.7 mm) of fill plug opening when lubricant is cold, or to plug level when hot. Axle level should be within 1/4 in. (6.4 mm) of fill plug opening when lubricant is cold, or to plug level when hot (Figures 1-24 and 1-25). Change axle and hub lubricant when contaminated by water or foreign material. Use GL-5, SAE 80W-90 or 75W-90 gear lubricant only.
LUBRICATION POINT
Lubricate U-joints with a multipurpose, NLGI-LB grade chassis grease. Lubricate propeller shaft universal and slip joints every 3,000 mi (4,800 km), or semiannually, whichever occurs first. Use a hand operated or low-pressure air powered lubrication gun. If operating conditions are severe service at 1,000 mi. (1,600 km) intervals. The rear propeller shaft U-joints have two grease fitting locations (Figure 1-26). The front shaft has four fitting locations (Figure 1-27)
FILL PLUG U-JOINT LUBE FITTINGS
Figure 1-26: Propeller Shaft Lube Points
LUBE FITTING LOCATIONS DRAINPLUG LUBRICATION POINT
Figure 1-24: Geared Hub Fill/Drain Plug Locations
FILL PLUG
LUBE FITTING LOCATIONS
Figure 1-27: Front Propeller Shaft Lube Points
DRAINPLUG
Figure 1-25: Axle Fill/Drain Plug Locations

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Steering and Suspension Lubrication Points

Lubricate steering and suspension components every 3,000 mi. (4 800 km), or semiannually, whichever occurs first. If operating conditions are severe, service at 1,000 mi. (1 600 km) intervals.
IDLER ARM FITTINGS
RADIUS ROD LUBE FITTING UPPER BALL JOINT FITTING
TIE ROD END FITTING (2)
Figure 1-29: Idler Arm and Tie Rod Lube Points
STEERING ARM FITTING
LOWER BALL JOINT FITTING
Figure 1-28: Ball Joint/Radius Rod Lube Points
Suspension lube points include the upper and lower ball joints and the rear suspension radius rods (Figure 1-28). Steering lube points include the tie rod ends, idler arm, steering arm, and intermediate steering shaft ( Figure 1-29 through Figure 1-31). Use a hand operated or low pressure air powered lube gun filled with a multipurpose chassis grease. NLGI-LB classification lubricating grease is recommended.
TIE ROD END FITTINGS
Figure 1-30: Tie Rod and Steering Arm Lube Points
LUBE FITTINGS
Figure 1-31: Intermediate Steering Shaft Lube Points
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Master Cylinder Fluid Level Check
1-29
Power Steering Fluid

Check the fluid level in the power steering reservoir monthly and adjust level as necessary. If fluid is hot, level should be between HOT and COLD marks on the cap indicator. If fluid is cool, level should be between ADD and COLD marks. In either condition, level must be above ADD mark. NOTE: Power steering fluid does not require periodic replacement.
CAUTION: Use DOT 3 brake fluid only. Failure to use the proper fluid may affect brake performance or damage brake components. Check master cylinder fluid level monthly. Correct fluid level is to within 1/2 in. (13 mm) from the MAX indicator. Clean the master cylinder cap and exterior before checking fluid level. Dirt on the cap must not be allowed to enter the reservoirs. Add DOT 3 fluid if necessary and reinstall the cap (Figure 1-34).
MASTER CYLINDER CAP
MAX FLUID LEVEL INDICATOR
Figure 1-32: Power Steering Pump Reservoir
Cooling System Fluid Level Check

Check coolant level at the surge tank monthly and adjust level as necessary. Level should be at, or above, the cold fill line (Figure 1-33).
FILLER CAP SURGE TANK
Figure 1-34: Master Cylinder Cap Location
Wheels/Tires/CTIS
Inspect tire and wheel condition. Look for loose wheel nuts and rim stud nuts, or dented, deformed wheel rims. Note tire tread wear and sidewall condition. If the vehicle is used for extensive off road operation, check the sidewalls for bulges, bead damage, cuts, fabric breaks. If the tire treads are worn, note type of wear. If wear is only on one shoulder, toe setting or camber may be incorrect. If tires are scalloped or worn at crown only, or both shoulders, inflation pressures are probably incorrect. If the vehicle is equipped with CTIS, cycle the system and check operation. Verify tire inflation pressures with an accurate gauge.
Serpentine Belt
COLD FILL LINE
Replace the belt if frayed, cut, or torn. Minor, small surface cracks within the belt grooves are normal. Do not replace the belt unless cracks extend all the way through or across the belt face.
Figure 1-33: Surge Tank Coolant Level Indicator Location
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CDR Valve
Clean the CDR valve with parts solvent and allow to dry. Replace the valve if oil soaked, or if it wont sustain vacuum/atmospheric pressure testing, see CDR Valve in Section 3 for pressure testing instructions. Also replace the valve hose if cracked, brittle and hard.
Body Lubrication Points

Every 6 months or 3,000 mi (4 800 km), whichever occurs first, lubricate the: hood hinges, hood stops, tailgate hinges, door hinges, door handles, parking brake lever, service brake pedal push rod stud, transfer case shift linkage, and transmission shift linkage (Figure 1-35). Suggested lubricants include engine oil or ATF for hinges; LPS silicone lube for linkages, handles, and brake push rod; white grease for seat tracks, window regulators and park brake lever. Door locks should use a graphite based lubricant such as Lock-Eze. Refer to the Recommended Fuel/Fluids/Lubricants/Capacities section for more detailed lube information. Check condition of the spare tire and swing away carrier mechanism, if equipped. Be sure the spare is properly inflated and the carrier operates smoothly, without bind.
DOOR HINGE HOOD STOP (GREASE) TRANSMISSION SHIFT LINKAGE
DOOR LOCKS
DOOR HINGE SWING AWAY TIRE CARRIER (IF EQUIPPED)
HOOD HINGE CENTER HOOD STOP (GREASE) WAGON DOOR HINGES AND LOCKS
TAILGATE HINGE
SERVICE BRAKE PEDAL PUSH ROD STUD
HOOD STOP (GREASE) PARKING BRAKE LEVER
SEAT TRACKS
TRANSFER CASE SHIFT LINKAGE DOOR HANDLE
Figure 1-35: Body Lubrication Points
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1-31
ESSENTIAL TOOLS
NOTE: See page 1-1 of the 1999 Service Parts Catalog for information on ordering Kent-Moore tools.
Engine
Tool No. J23523-F J26999-30 J22102 J26999 J39084 J33139 J23951 J35555 J8001 J23129 J41613 J41515-A J41240-1 J41240-5A Description Harmonic Balancer Remover/Installer Set Compression Gauge Adapter Front Crankshaft Seal Installer Compression Gauge Rear Main Seal Installer Engine Lifting Sling and Bracket Water Manometer Vacuum (MITY-VAC) Pump Dial Indicator Set Universal Seal Remover, use with slide hammer J6125-1B Turbocharger Inlet Guard Glow Plug Socket Spanner, Fan Clutch Wrench, Fan Clutch

Tool No. J29075-AMG J29872-A J29873 J29698-A J28552-A J38641-B J34151 J41711 J28552-100 Description Fuel Injector Pressure Test Tool Injection Pump Adjusting Tool (used with ratchet handle) Fuel Injector Socket (30mm) Injection Line (are nut) Wrench, 3/4 Fuel Pressure Gauge Diesel Fuel Hydrometer Housing Pressure Adapter Injection Pump Timing Wrench, 6.5 Turbo Adapter, Fuel Line
Tool No. J39544-AMG J35944-500 J8614-01 J8092 J25025-B J39775 J21867 J33831 J33835 J38869 J41623 J42543 J38694 J-8614-5 Description Transmission Oil Cooler Flush Kit Cooler Line Adapters Yoke Holding Tool Universal Driver Handle Dial Indicator and Guide Pin Set Transmission Test Jumper Harness Pressure Gauge and Hose Assembly Input Seal Installer Pump Housing Seal Installer Output Shaft Seal Installer Oil Cooler Release Tool Selector Shaft Seal Remover/Installer Installer, Oil Pump to Converter Seal Bolt Kit, Yoke Holding Tool
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1-32
Wheels, Tires and CTIS

Tool No. J42557 Description Cam Socket
Brakes
Tool No. J42553 Disc Brake Tool Kit Description
Steering
Tool No. J24319-B J25033-C J33141 J25034-C J25323 J42548 J8092 Description Steering Linkage and Tie-Rod Puller Pump Pulley Installer Adapter Fittings (used with J-25323) Pump Pulley Remover Power Steering System Analyzer Puller, Pitman Arm Universal Driver Handle

Tool No. J8092 J24319-B J8001 J29162 J33143 J8614-O1 J42545 J35184 J38869 J35910 J42546 J42547 J42591 Description Universal Driver Handle Steering Linkage and Tie Rod Puller Dial Indicator Rear Retainer Seal Installer Input Seal Installer Yoke Holding Tool (includes J8614-5 bolt kit) Clampnut Socket Spindle Seal Installer Seal Installer Axle Boot Crimping Tool 1/4 in. Drive Torque Wrench (Preset) 3/8 in. Drive Torque Wrench (Preset) Steering Cover Seal Installer
HVAC
Tool No. J42549 J42550 J42551 Description HVAC Anemometer HVAC Flow Meter Adapter Kit Leak Detector, A/C R134a
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1-33
Electrical
Tool No. TKOA TA1151 TA1152 TA1190-A J35616-A J42645-C J43160 7000041 J44237 J24538-B J35592 J42645-99SW J42645-C Description Tech 1 Diagnostic Scanner Tech 1 Adapter, part of TK-O-A Tech 1 Test Lead, part of TK-O-A Tech 1 Operators Manual, part of TK-O-A Connector Test Adapter Set HUMMER Mass Storage Cartridge Kit Adapter Cable, Tech 1A (14/16 pin) Vehicle Interface Module (VIM) ABS, DLC Jumper Tester, Gauge Pinout Box, ABS Software Package Mass Storage Cartridge, HUMMER
Electrical Troubleshooting
Tool No. J35689-A J39200 J38125-A Description Micro-Pack Extract Tool Fluke 87 DVOM Electrical Terminal
MISCELLANEOUS ESSENTIAL TOOLS

Tool No. J26900-13 J8092 J8001 J6125-1B J23129 J35910 J44238 J42183 J6125-1B J-29532 Description Magnetic Base Driver Handle Dial Indicator Set Slide Hammer Seal Remover Axle Boot Crimping Tool Adapter, Brake Bleeder Handle, Seal Driver (short) Slide Hammer Brake Pressure Bleeder
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1-34
SPECIAL TOOLS Engine

Tool No. J29834 J8080 J6098-10 J8062 J33042 J33049 J24270 J29134-8 J8087 J39507 J8089 J8358 J25087-C J8037 J8101 J42525 J6098-O1 Description Valve Lifter Removal Tool Main Bearing Shell Remover/Installer (In-Vehicle) Camshaft Bearing Remover/Installer (use with J33049) Valve Spring Compressor Static Timing Mark Gauge Camshaft Bearing Replacement Set (Universal) Ridge Reamer Piston Pin Retaining Ring Compression Sleeve Cylinder Bore Gauge Piston Retaining Ring Installer Set Carbon Remover Brush, for cast iron and steel Carbon Remover Brush, for aluminum Oil Pressure Tester/Pump Primer Cylinder Bore Gauge Valve Guide Cleaner Piston Ring Expander Camshaft Bearing Remover/Installer, use with J6098-10 and J33049

Tool No. J26925 Description Mag-Tac Engine Tachometer
Tool No. J2619-01 J29369 J33839 J33829 J33833 J33832 J29170 Description Slide Hammer and Adapter Bushing/Bearing Remover Kit Rear Output Bushing Remover (use with J8092) Pilot Bearing Installer (use with J8092) Output Shaft Main Bearing Installer (use with J8092) Front Output Shaft Rear Bearing Installer (use with J8092) Input Gear Bearing Remover (use with J8092)
Wheels, Tires and CTIS

Tool No. 05710216 05710215 05744619 Description Internal Tubeless Tire Repair Kit External Tubeless Tire Repair Kit Video, One-piece Wheel Service
Steering
Tool No. J6219 J6221 J6278 (or J21551) J7624 J7754-C J21552 Description Pitman Shaft Seal Installer Stub Shaft Bearing and Seal Remover/Installer Pitman Shaft Bearing Remover/Installer Spanner Wrench (Adjuster Plug) Inch-Pound Torque Wrench (Over-Center Preload) Rack Piston Arbor
_______________
1-35

Tool No. J33142 J21786 J21787 J8611-01 J29162 J8608 J39524 J24385-01 J35237 J3409-01 Part of J3409-01 J22610 Description Axle Shaft and Seal Installer Pinion Rear Bearing Cup Remover Pinion Front Bearing Cup Remover Rear Pinion Bearing Race Installer Rear Retaining Seal Installer Rear Pinion Bearing Race Installer Pinion Depth Gauge Set Axle Housing Spreader Bearing Installer Stand, with Holding Fixtures Axle Holding Fixture Adapter Keystone Clamp Pliers
HVAC
Tool No. J39500-A J34021-A J39500-20A J39500-24A J39183-C J6742-03 J36847 J24182-2A Description A/C Recovery, Recycle, Evacuate and Discharge Service Cart (from Robinaire) Compressor Cluch Pulley, Core and Bearing Replacement Tool Set High Side Coupler Adapter (Compact Prole) Low Side Coupler Adapter (Compact Prole) Manifold Gauge Set Thermometer Condenser Fin Straightener Tool Schrader Valve Core Tool
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________________________________________________________________________________
2-1
Section 2 Engine
INTRODUCTION
This section contains general information, diesel engine diagnosis, turbocharger service, and diesel engine repair and overhaul. A table of contents is provided that lists the various repair items and the section page number where repair information is located. Use the contents tables to avoid random searches for needed information. Specifications for diesel engines are located at the end of this section for quick reference. Service tool information can be found at the end of the Engine section.
TABLE OF CONTENTS
A/C Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 Boost Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Camshaft Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59 Timing Chain, Sprocket and Drive Gears . . . . . . . . . . . . .2-71 Crankshaft Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42 Connecting Rod Journal Diameter. . . . . . . . . . . . . . . . . . .2-97 Crankshaft and Main Bearings Removal . . . . . . . . . . . . . .2-60 End Play Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81 Main Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97 Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Cylinder Block Cylinder Bore and Piston Measurement . . . . . . . . . . . . . .2-62 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Cylinder Head Cylinder Head And Gasket Service . . . . . . . . . . . . . . . . . .2-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55 Damper and Flywheel Service . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 Engine Assembly and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .2-80 Block, Camshaft and Bearing Sizes. . . . . . . . . . . . . . . . . .2-98 Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 Engine Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 Mounting Bracket/Insulator . . . . . . . . . . . . . . . . . . . . . . . .2-19 Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45 Scan Tool Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Service Piston and Cylinder Bore . . . . . . . . . . . . . . . . . . .2-97 Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96 Engine Assembly and Adjustment Crankshaft and Main Bearing Installation. . . . . . . . . . . . . 2-80 Crankshaft Main Bearing Selection . . . . . . . . . . . . . . . . . . 2-80 Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Fan-Pulley-Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Flushing Engine Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Front Cover and Baffle Installation . . . . . . . . . . . . . . . . . . . . . . 2-86 Front Cover and Oil Filler Tube . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Front Cover And Timing Chain . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Front Cover Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . 2-22 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Fuel Filter Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Fuel Injection Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Fuel Injection Pump Fuel Supply and Return Line Removal . . . . . . . . . . . . . . . 2-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Glow Plug Glow Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Glow Plug and Injection Nozzle . . . . . . . . . . . . . . . . . . . . . 2-90 Operation and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Intake and Exhaust Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 In-Vehicle Service, Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . 2-19 Lifter, Pushrod, Rocker Arm Service . . . . . . . . . . . . . . . . . . . 2-76 Lubricants/Sealants/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Oil Filter Adapter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Filter, Adapter, Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Oil Filter/Adapter/Oil Pressure Sending Unit . . . . . . . . . . . . . . 2-57 Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
05745159
2-2
Engine
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Oil Pump Oil Pump and Drive Removal . . . . . . . . . . . . . . . . . . . . . . .2-58 Oil Pump and Pump Drive Service. . . . . . . . . . . . . . . . . . .2-77 Oil Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Oil Pump Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . Test 2-7 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Oil Pump, Oil Pan, Flywheel Installation . . . . . . . . . . . . . . . . . .2-84 Piston/Connecting Rod Installation and Bearing Fit. . . . . . . . . . . . . . . . . . . . . . . . .2-83 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59 Piston/Connecting Rod Overhaul . . . . . . . . . . . . . . . . . . . . . . .2-67 Piston and Connecting Rod Assembly . . . . . . . . . . . . . . .2-69 Piston Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 Piston Selection and Fit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68 Power Steering Pump and Bracket . . . . . . . . . . . . . . . . . . . . . .2-50 Pushrod, Rocker Arm and Shaft Installation . . . . . . . . . . . . . .2-90 Rear Main Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . .2-29 Rear Main Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82 Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Rocker Arm Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54 Cover Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Shaft and Pushrod Removal. . . . . . . . . . . . . . . . . . . . . . . .2-54 Shaft and Pushrod Service . . . . . . . . . . . . . . . . . . . . . . . . .2-33 Rocker Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
Serpentine Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Timing Chain/Drive Sprockets/Drive Gear . . . . . . . . . . . . . . . . 2-57 Timing Chain-Sprocket-Gear Installation . . . . . . . . . . . . . . . . . 2-85 Torsional Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Torsional Damper/Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . 2-93 Turbocharger Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Service and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Turbocharger and Center Manifold Removal . . . . . . . . . . . . . . 2-52 Turbocharger and Intake Manifold . . . . . . . . . . . . . . . . . . . . . . 2-93 Vacuum Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Water Crossover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Water Pump and Adapter Plate Installation . . . . . . . . . . . . . . . 2-87 Water Pump and Adapter Plate Removal . . . . . . . . . . . . . . . . . 2-56
ENGINE DESCRIPTION
A turbocharged diesel engine is used in Hummer vehicles. It is a liquid cooled, four-stroke, 90 V8 engine with a displacement of 6.5L (395 cu. in.) (Figure 2-1). The engine is manufactured by General Motors Corporation. dead center on the intake and power strokes. The extra oil pressure and volume needed for piston cooling is provided by a high output oil pump. The pump has a working pressure of 80 psi (552 kPa). Oil feed for piston spray is through galleries and oil tubes located in the main bearing saddles and webs. The crankshaft is supported by five insert style main bearings. Thrust is taken by the number 3 main. The camshaft is also supported by five bearings; plain type bearings are used. The engine is equipped with three ring aluminum pistons. Connecting rods are forged steel. The pistons are attached to the rods with hardened steel piston pins. Each piston pin is retained by two snap rings; one at each end of the pin. The pin is a floating fit in the rod and piston. A single chain driven camshaft operates the overhead valve train. Roller lifters and tubular push rods actuate the rocker arms. The arms are mounted on shafts bolted to each cylinder head. The cylinder heads are equipped with glow plugs for each cylinder and a prechamber for each combustion chamber. One plug and one prechamber are used in each combustion chamber. The glow plugs heat air entering the prechambers. This aids the combustion process and improves cold weather starting and operation. The glow plugs are activated only when ambient temperatures fall below a pre-set value. On the turbo diesel engine the glow plug relay is mounted on the intake manifold and is controlled by the PCM.
Figure 2-1: 6.5L Turbo Diesel Engine
Engine Components
The engine block and cylinder heads are cast iron. Turbo engines are equipped with a three-piece aluminum intake manifold and cast iron exhaust manifolds. The oil cooling system for turbo diesel pistons provides for oil spray onto the underside of the piston crown. This is accomplished by additional oil feed orifice tubes and galleries in the block. Oil spray occurs when the piston is approaching bottom
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Engine
2-3
The turbocharged diesel engine is equipped with a Warner Gear turbocharger. A wastegate, in the turbine housing, controls boost. The wastegate is operated by an externally mounted vacuum actuator. The actuator opens the gate to decrease boost, or closes it to increase boost. Waste gate position is controlled by the PCM. The turbocharger increases the amount of air entering the combustion chambers. This allows a proportionate increase in fuel injected into the cylinders. The result is a much denser cylinder charge and greater power output. The turbocharger turbine and compressor impellers are the mechanisms that pump additional air into the combustion chambers. The impeller wheels are operated by the high speed gas flow through the engine exhaust system. Engine lubrication is through a conventional mechanical pump located at the rear of the crankcase. The pump is shaft driven by the oil pump drive unit which in turn, is driven off the camshaft. A belt driven vacuum pump is used on both engines. Both versions of the 6.5L diesel are equipped with a high pressure fuel injection system. The system consists of an electric fuel supply pump, an injection pump, a separate injector nozzle for each cylinder, and the necessary injector feed lines. The rotary type injection pump pressurizes, meters, and distributes fuel to the individual injectors. System working pressure is 1750 psi (120 bar) for turbocharged engines. The pump is gear driven through matching gears on the pump and camshaft.
LUBRICANTS/SEALANTS/COOLANT Engine Oil

Recommended engine oil for diesel engines used in HUMMER vehicles is API classification CG-4 (Figure 2-3). Synthetic oils are equally acceptable. Oil viscosity recommendations are: Use 15W-40 at ambient temperatures from 0F (-18C) to above 100F (36C). Use 30W at ambient temperatures above 32F (0C). Use 10W-30 at ambient temperatures below 32F (0C). Do not use 10W-40, or any other oil that is not specifically recommended. Use recommended oils only for lubrication purposes during repair and overhaul.
SAE 30W
ENGINE IDENTIFICATION
The diesel engine I.D. decal is located on the forward face of the passenger side cylinder head (Figure 2-2). The decal provides the engine assembly/serial number and a bar code. Similar decals are placed on the driver side cylinder head and passenger side of the oil pan.
SAE 10W-30
SAE 15W-40 PREFERRED
API CG-4, CH-4 QUALITY PREFERRED DO NOT USE SAE 10W-40 GRADE OIL, OR ANY OTHER GRADE NOT RECOMMENDED
Figure 2-3: Oil Viscosity Chart

ENGINE SERIAL NUMBER BAR CODE DECAL
Figure 2-2: Diesel Engine I.D. Tag Location
Service Tools
The special service tools described in this section are available through the dealer tool program.
Specications
Engine specifications for overhaul, adjustment, inspection and torque requirements are provided at the end of this section. 05745159 3-1-02
2-4
Engine
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Sealants
Anerobic, RTV, and standard sealants are all used for various repairs. RTV (room temperature vulcanizing) sealers are used when a non-rigid part is attached to a rigid part (e.g. oil pan to engine block). Typical RTV sealers would be Permatex High Temp, Ultra Copper, Ultra Black, or Loctite 599. Anerobic (gasket eliminator) sealants are used where two rigid parts are being assembled. This type of sealant cures in the absence of air. Typical anerobic sealers are Loctite 510 and 518. Standard type sealers are used primarily as gasket dressing or thread sealants. Typical examples would be Permatex #2, or Perfect Seal spray sealer. Thread locking sealants are frequently recommended for fasteners subject to heat and vibration. Recommended products are: Loctite 242 for all purpose use Loctite Stud and Bearing Mount for semi-permanent attachment
3.
4.
5.
Thread adapter J26999-30 into glow plug hole of first cylinder to be tested. Then attach compression gauge J26999 to adapter. Have helper crank engine through six cycles (to generate six compression strokes). Note and record gauge pressure. Repeat procedure at remaining cylinders. Minimum acceptable cylinder pressure is 380 psi (2626 kPa). In addition, lowest cylinder should be at least 80% of highest; this is maximum allowable cylinder variance.
CAUTION: Never inject oil into the diesel engine cylinders for any reason. This could result in piston and rod damage because of the minimal clearances in a high compression diesel combustion chamber.
Coolant
Recommended engine coolant is an ethylene glycol base, all weather coolant with corrosion and anti-foaming inhibitors. All of the major brands are acceptable (i.e. Prestone, Peak, Zerex, etc.). Do not use coolants other than ethylene glycol based. Recycle coolant according to EPA regulations. Do not use pure coolant in the cooling system, especially in cold-climate regions. Recommended mix is 50% antifreeze, 50% water.
COMPRESSION GAUGE J26999
ADAPTER J26999-30
CLEANING MATERIALS
Normal parts cleaning solvents can be used for most purposes. Use brake or contact cleaner, to clean surfaces where anaerobic or RTV sealants will be applied. This type of solvent does not leave a residue that interferes with sealer cure or adhesion. Carbon deposits can be emulsified by some spray type gasket removers. Permatex and 3M both have effective products. Avoid using diesel fuel, gasoline, paint and lacquer thinners or kerosene for parts cleaning purposes. These products can leave an undesirable residue. Cylinder and lifter bores should be cleaned with a liquid detergent and warm water mixture after honing or polishing. A bristle brush or cotton towel can be used to wash the bores until clean and free of oil, dirt, and abrasive grit. Figure 2-4: Compression Test Tools
FUEL FILTER WARNING LAMP

All Hummer models are equipped with a fuel filter warning lamp. The lamp is in circuit with a sensor mounted in the filter. The purpose of the lamp is to alert the driver when water, ice, or wax buildup occurs in the filter. Lamp illumination can be intermittent or continuous depending on the severity of water or wax buildup. In most cases, continuous illumination of the lamp simply means it is time to drain the filter. However, a continuous lamp plus engine stall or restart problems may indicate a plugged filter or fuel lines. Intermittent illumination of the lamp indicates that water is accumulating in the filter. In this instance, it is only necessary to drain off the water at the wheel house draincock.
COMPRESSION TEST
1. 2. Disconnect fuel solenoid wire at injection pump. Disconnect and remove all glow plugs.
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Engine
2-5
ROAD TESTING
The purpose of road testing is basically to confirm or deny the existence of an engine fault. Procedure is as follows: 1. Note condition of wheels/tires before test. Worn, damaged tires or wheels can cause vibration or noise. 2. Check and adjust lube levels in engine and transmission and top off engine coolant if necessary. 3. Turn off A/C system. 4. Start and run engine at idle speed with transmission in neutral. Record any noise or vibration that may be present. Rev engine and note any noise/vibration plus any change in magnitude or frequency. 5. Drive vehicle at legal speed and note any evidence of noise, vibration, low power, miss, etc. a. If vibration was noted, drive vehicle above vibration speed. Then shift into neutral and coast down through problem range. If vibration still occurs, problem is with chassis component. However, if vibration ceases, problem is with driveline component. b. If noise is noted, shift into neutral at about 35 mph and note if noise changes in pitch, frequency, or stops altogether. 6. Operate A/C system and note effect. If noise or vibration begins, problem is related to A/C compressor, clutch, accessory mounting bracket, or belt. However, if noise/ vibration is absent, note this and proceed to next step. 7. Connect compound gauge to manifold air intake tube fitting. Then press accelerator pedal to wide open position and record boost reading which should be 2 psi or greater.
seems to make a greater frequency noise. This is because the bearing may knock at both ends of piston travel.
Piston and Connecting Rod

Piston slap is usually caused by severely worn cylinder bores and pistons, partially collapsed piston skirts, worn pin bores, severely worn rings, or an undersized piston. An incorrectly assembled, or installed connecting rod and piston assembly will also produce slap. Slap always occurs at crankshaft speeds. In severe cases, slap may occur in both directions of piston travel. Although fairly common on high mileage engines, slap can be difficult to hear on low mileage engines. As the term implies, piston slap is appropriate for the sound generated. It occurs when a piston begins to rock within the cylinder as it travels up and down. This action causes the skirt to slap the cylinder wall as it straightens, then rocks away from the direction of thrust.
Valvetrain and Camshaft

Rocker arm and hydraulic lifter noise is probably the most easily identifiable. Both make tapping (or clicking) noises that only differ in pitch and volume. Although damaged valve springs or pushrods are more difficult to hear, they usually cause a power loss or rough engine condition and require inspection to locate. A worn, missing, or incorrect thickness camshaft thrust washer will cause excessive cam end play. The most frequent result is an audible knocking sound localized at the rear of the block. Timing gear and chain noise is not always audible, even when the chain and gears are severely worn. These components, when failed, are usually discovered during timing checks prompted by a low power or no-start condition. NOTE: Valvetrain noise can also be the result (or first indicator) of low oil pressure.
ENGINE NOISE DIAGNOSIS

Engine noises are usually sensitive to changes in rpm and load. For example, a collapsed lifter will make an audible ticking noise that increases in frequency as rpm goes up. Engine noises can also be determined according to speed of the related rotating component. For instance, valvetrain noises will be at a frequency that is one half crankshaft speed.
Starter Noise
The starter bendix can hang and prevent quick disengagement after startup. The resulting noise can be misdiagnosed as engine related. A mechanics stethoscope is fairly effective at differentiating engine and starter noise.
Accessories
Noise caused by engine accessories such as the vacuum pump alternator, power steering pump, A/C clutch, or drive pulleys is speed sensitive. An increase or decrease in engine rpm will generally change pitch and frequency, or even cause it to stop. A mechanics stethoscope will generally help pinpoint a noise source. Removing the accessory drivebelt will also help verify an accessory generated noise.
Knocking Noise At Idle

Knocking noises can be from connecting rod bearings, a cracked flywheel, converter touching the housing or cover, A/ C compressor, or loose exhaust component. Look for exhaust components grounding against the body, frame, or driveline component. Remove the converter access cover and visually inspect the flywheel and converter. Check the cover and converter housing for signs of contact. A flywheel cracked at the hub will allow the converter to wobble slightly. Test the A/C system for incorrect charge levels which can produce compressor knock.
Bearings
Bearing noise can be differentiated by pitch. A damaged connecting rod bearing makes a higher pitched, metallic knocking sound. This as opposed to the lower pitch thump of a worn, or spun main bearing. A failed rod bearing can be confusing as it 05745159
2-6
Engine
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Diesel Fuel Knock or Rattle

The rattling sound unique to diesel engine is normal. It is a function of high compression ratio, injector nozzle spray pattern and pressure, and compression ignition. However, incorrect injection pump timing, low quality fuel, or injector nozzle faults can make the normal sound much more pronounced. If the normal rattling is accompanied by, or becomes a knocking sound, the fuel injectors, injection pump, pump timing, and fuel quality must all be tested.
DIAGNOSIS EQUIPMENT
Diagnosing engine mechanical problems can be performed with normal shop equipment. Compression testing with a good quality gauge will reveal condition of the engine rings, pistons, cylinder bores, valves, and guides. Vacuum diaphragm operation is quickly tested with a hand operated vacuum pump. These pumps are available from companies such as Kent-Moore, Snap-On, RobinAire and Lisle. A digital or analog multimeter is used for many tasks such as checking wire continuity, shorted-open circuits and components, ground connections, battery condition, glow plug current levels, and so on. A tachometer is required for checking/setting idle speeds. On diesel engines, an especially accurate tachometer is needed to check cranking speeds of 100-180 rpm. An oil pressure gauge is necessary in order to accurately test engine oil pressure. The best gauges are mineral oil filled to avoid indicator needle bounce. The gauge should have a dial range up to 100 psi in 2 psi increments. Necessary adapters to connect the gauge are available from either the gauge manufacturer, or Kent-Moore Tool Corp. An all purpose dial indicator set such as J8001, is also needed. Accurate measurement of clearances, component wear, chain deflection, and overhaul dimensional settings is only possible with a dial indicator. A good quality vernier caliper and micrometer set are also needed to check part tolerances.
just below the injector nozzle (Figure 2-5). The tip of each plug extends into a pre-chamber which concentrates the fuel/air mixture prior to combustion. The glow plugs are operated by a relay mounted on a bracket attached to the right side intake manifold. The relay is in circuit with the ignition switch and is energized only when the switch is in the start and run positions. Turning the ignition switch to the start position allows current to flow through the switch to the relay and the PCM. Once energized, the PCM uses information from the coolant temperature sensor and the intake air temperature sensor to determine glow plug on time. The PCM commands the relay to allow current to flow through it and to the individual glow plugs and monitors each glow plug circuit voltage individually. If a glow plug failure is detected, a DTC P0380 will be set.
GLOW PLUG TEST

1. 2. 3. 4. Check all glow plug connections. They should be tight and corrosion free. Verify that engine temperature is at or below 95F (35C). Turn multimeter to amps or current flow setting. Check current at each glow plug (Figure 2-6). Place ammeter clamp around glow plug wire. Current should be 13-14 amps. If current at glow plug is less than 13-14 amps, further diagnosis is required. If current is zero check fuses and circuit for shorts, grounds and opens. Check the fusible link between the starter and the glow plug relay.
CYLINDER HEAD VALVE FUEL INJECTOR
5.
GLOW PLUG BLOCK
SCAN TOOL USE

The Tech 2 scan tool is primarily designed to test/interrogate PCM/TCM circuits. The tool is extremely useful in locating sensor, switch, or computer faults that affect engine performance. However, the tool is not really designed to replace vacuum gauges, compression testers, multimeters, or 12 volt test lamps.
PRE-CHAMBER
PISTON
COMBUSTION CHAMBER
GLOW PLUG OPERATION AND TESTING

The engine glow plugs are used to heat air entering the combustion chamber. Heating the air results in improved cold temperature starting and engine warm-up. A total of eight glow plugs are used; one for each cylinder. Each glow plug is threaded into a cylinder head port located
Figure 2-5: Glow Plug Location In Cylinder Head and Pre-Chamber
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Engine
2-7
WAIT
FUSE
LAMP CONTROL FEEDBACK SIGNAL RELAY CONTROL
TO IGNITION SWITCH
AMMETER
13-14
POWER TRAIN CONTROL MODULE (PCM)
FUSE
TO IGNITION SWITCH
PK PP BL PP
PK BL YL BK PP BL G1 PP PK
#2
#4
#6
#8
#3
#1
#7
#5
GLOW PLUGS RH GLOW PLUG RELAY
GLOW PLUGS LH
00-S02-001
FUSIBLE LINK
TO STARTER POS. STUD
Figure 2-6: Checking Current at Each Glow Plug
OIL PUMP PRESSURE TEST

Connect the pressure test gauge to the transmitter fitting in the valley of the block. Pressure should be a minimum of 6 psi (41 kPa) at hot idle and increase to 30 psi (207 kPa) at 2000 rpm. Low pressures at both test ranges with correct oil level indicate: Pump pickup strainer or tube loose Pump pressure relief valve or spring problem Pump gears worn, chipped Pump shaft worn, slipping Oil galley plug loose, missing Main bearings severely worn Cam bearing turned (spun) or misaligned
ENGINE DIAGNOSIS General Information

The diagnosis charts describe common faults that may occur. Potential causes are listed in order of probability. Although the charts list frequent causes for specific engine related problems, they do not cover every possible cause. The charts are intended to serve as guides only. The diagnosis information in this section is aimed at solving engine mechanical problems with normal shop diagnostic equipment.
05745159
2-8
Engine
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Engine Diagnosis
PROBLEM Hard Starting 1. POTENTIAL CAUSE Insufcient cranking speed (below 100 rpm cold or 180 rpm hot). Caused by: Low batteries Bad cable connections Serpentine belt or alternator problem Starter problem Poor connections Relay Solenoid Brushes Armature Starter drive damage Insufcient fuel to injectors, or start switch has fault. Check run solenoid also. CORRECTION 1. Check, repair cables or connections. Recharge batteries if low. Replace batteries if shorted, sulphated, damaged. Replace belt or tensioner if damaged. Test alternator output and repair or replace if low.
2.
2. Check/repair cable and solenoid connections if needed. Check starter draw; overhaul if draw exceeds 450-475 amps. Remove and overhaul starter if brushes, starter drive, or armature are faulty.
3.
3. Check fuel volume at supply pump and injectors while cranking engine. If volume is low, check for restrictions in lines or at lter. If volume is OK, check pressure at pumps and injectors and repair as needed. 4. Drain off water at fuel lter draincock. Then crank engine with draincock open for 5-10 seconds to purge remaining water. If water continues to appear in fuel coming out draincock, purge fuel tank and lines, and refuel vehicle. 5. Check fuse and wiring harness to plugs. Correct open or short as required. Refer to diagnosis in Section 12 if required. 6. Check for loose fuel line connections at pump and injectors. Correct if necessary then bleed any remaining air at injectors. 7. Check return lines (from engine to tank) and correct restrictions, kinks, plugged lines. Make sure tank vent is OK. Repair as necessary. 8. Remove and clean air intake components. Replace lter element if plugged or restricted. 9. Check timing marks on pump and front cover. If aligned, check marks on pump gears and cam sprockets. Re-time if necessary.
4.
Water in fuel (lter indicator light NOT on).
5.
Glow plugs inoperative (most noticeable at cold ambient temperatures).
6.
Air in fuel delivery lines.
7.
Fuel return lines restricted or tank vent inoperative.
8.
Air cleaner plugged (after extended off-road operation). Injection pump timing or camshaft timing may be off if pump, cam, or timing chain/ sprockets/gears were removed/replaced during service.
9.
10. Vehicle misfueled.
10. Drain sample at lter draincock. Replace fuel load if fuel contains gasoline, kerosene, fuel oil, or low quality fuel.
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Engine
2-9
Engine Diagnosis
PROBLEM Hard Starting When Hot 1. POTENTIAL CAUSE Wrong fuel or poor quality fuel. CORRECTION 1. Drain and rell tank. Purge rest of fuel system and bleed injectors. 2. Check lines at fuel pump and injectors for leaks, or loose ttings. Tighten or replace lines as needed. 3. Clear or replace either line if restricted, pinched, or damaged. 4. Replace fuel supply pump if pressure is less than 5 1/2 psi. 5. Test and replace switch or solenoid if necessary.
2.
Air leaks in fuel supply (suction) lines.
3.
Fuel return or vent line restricted.
4.
Low fuel pressure to injector pump.
5.
Engine shut-off solenoid problem.
6. Hard Starting When Cold 1.
Low compression due to rings, pistons, valves. Incorrect grade of diesel fuel.
6. Check compression and overhaul engine if necessary. 1. Drain and rell fuel tank and lter. Bleed injectors and purge lines as needed. 2. Drain water. Remove and clean lter and lines if wax formation has occurred. 3. Check current ow at relay. Minimum current is 55 amps. If OK, check current ow at each glow plug. Current should be 14 amp. Repair wiring or replace faulty glow plug(s). 4. Check for pump operation, if inoperative check fuses and wiring. If pump operates, check ow. 1. Check and correct linkage adjustment as needed.
2.
Water in fuel or wax buildup in lter.
3.
Glow plugs inoperative.
4. Engine Will Not Crank 1.
Fuel lift pump inoperative. Shift lever not entirely in Park (or Neutral position). Insufcient battery voltage due to: Low charge Corroded connections Damaged Cables or solenoid wires
2.
2. Check batteries and cable connections. Charge low batteries and check generator and belt. Replace failed battery(s). Clean corrosion from cables connections. Replace or repair cables or terminals as needed. 3. Check fuse condition at fuse boxes. If blown fuse is found, check circuit for shorts, grounds. 4. Test switch continuity with ohmmeter. Replace switch if open/shorted.
3.
Blown fuse.
4. Park/Neutral position switch problem.
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Engine _____________________________________________________________________
Engine Diagnosis
PROBLEM Engine Will Not Crank (Continued) POTENTIAL CAUSE 5. Starter or solenoid problem. CORRECTION 5. Check for bad or loose connections at starter and solenoid. If OK, note if starter surges when current is applied. Problem may be with Bendix or armature. 6. Test and replace injectors that are stuck open. Replace blown head gasket or replace head if cracked.
6. Hydrostatic lock. Combustion chambers lled with fuel, or coolant due to faulty injectors, or blown head gasket. (Remove glow plugs, crank engine and note uid coming out of plug holes). 7. Flywheel ring gear teeth or starter Bendix damaged. Engine Stalling 1. Air leaks in fuel lines.
7. Remove transmission access cover and inspect ring gear and bendix. Replace ywheel or starter Bendix as necessary. 1. Check lines from fuel pump to injectors. Replace lines that leak or have damaged ttings. Tighten loose injectors. Bleed injectors afterward. 2. Drain off lter contents at draincock. Clean out fuel tank and lines if lter contained sludge. Clean out lter if full of wax or dirt. 3. Drain and rell tank. Drain fuel lter and bleed injectors. 4. Replace lter if necessary. Remove and clean out air cleaner body, intake duct, cap, hoses, and dust unloader.
2. Fuel lter partially plugged by wax formation, dirt/sludge, or partially water lled.
3. Misfueled, wrong fuel, or low quality fuel.
4. Restricted air intake due to plugged lter element, air cleaner, intake duct. Generally caused by extended off -road operation in dusty areas. 5. Fuel supply pump problem or restriction in fuel lines, injector pump, or injectors.
5. Check fuel ow at pump and injectors. Supply pump minimum pressure is 5 1/2 psi. Replace worn, damaged, or failed parts.
6. Fuel drain back or return lines restricted/ damaged.
6. Inspect and repair or replace lines, clamps as needed.
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Engine
2-11
Engine Diagnosis
PROBLEM Low Power, Poor Acceleration POTENTIAL CAUSE 1. Vehicle overloaded. 2. Low grade diesel fuel. 3. Sludge or wax buildup in fuel lter (low fuel supply). 4. Air in fuel supply system. CORRECTION 1. Lighten vehicle load. 2. Drain tank and refuel. 3. Drain and clean lter.
5.
Fuel supply pump failed.
4. Check lines from fuel supply pump and to injectors. Replace leaking, damaged lines as needed. Bleed air at injector fuel line ttings. 5. Check and replace pump if output is less than 5 1/2 psi. 6. Check and correct as needed. 7. Check air intake cap, duct, air cleaner, hoses, and air horn. Clean/repair as needed. Replace lter if plugged. 8. Replace pump if inoperative. 9. Check wiring and solenoid. Repair wiring and connectors. Replace solenoid if failed.
6. 7.
Mistimed injection pump. Restriction in air intake system.
8. 9.
Vacuum pump failure. Engine shut-off solenoid has intermittent open or short.
10. Turbocharger, related wiring, or wastegate actuator fault may have occurred. May also be caused by exhaust gasket failure.
10. Check wiring, wastegate vacuum actuator, and PCM with Tech I scan tool. Run vacuum check on actuator and vacuum pump with vacuum tool. Check for intake/exhaust leaks. Replace turbocharger, or related components as indicated by diagnosis. 11. Diagnose and replace pump as needed. Replace damaged injectors. 12. Check compression and timing. Then disassemble engine and repair as needed. Remove engine completely if diagnosis indicates crankshaft, rod, or piston problem.
11. Injection pump, or injector failure.
12. Engine problem: Timing chain and gears worn. Cam and injection pump gears mistimed. Piston, ring, or valve wear. Worn cam lobes. Damaged piston(s). Exhaust Smoke: Blue Smoke 1. CDR valve faulty.
1. Check valve operation with manometer or vacuum hand pump. Clean or replace valve and hose if necessary. 2. Remove glow plugs and check compression. Then repair valve train and cylinder heads, or perform piston ring replacement.
2.
Worn piston rings, valve stem seals, or valve guides.
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Engine _____________________________________________________________________
Engine Diagnosis
PROBLEM White Smoke 1. 2. POTENTIAL CAUSE Low quality fuel. Injection pump/engine timing is retarded. CORRECTION 1. Drain and rell tank with better quality fuel. 2. Check and correct timing. 3. Verify problem and repair as necessary. Replace cracked head, block, or head gasket.
3. Engine coolant entering combustion chamber through blown gasket, cracked head, loose/ damaged head bolts. May be accompanied by low coolant level and overheating.
4. Low ambient temperatures (below freezing). Black Smoke 1. Low grade diesel fuel. 2. Overrich fuel mixture: Drain/return lines restricted. Injector(s) stuck open. Engine speed or throttle sensor fault. 3 Black smoke at wide open throttle.
4. Normal condition caused primarily by water vapor. Not a concern unless it continues after warmup. 1. Drain and rell tank. 2. Test, diagnose and repair as required.
3. Restriction in air intake system, no vacuum to wastegate actuator, damaged wastegate, or air leak at intake or exhaust manifold. 1. Try to avoid prolonged idling. 2. Add proper quality fuel. (not necessary to drain and rell tank). 3. Clear vent and line. 4. Clear restriction. Replace line if kinked or pinched. 5. Diagnose and repair as indicated.
Gray Smoke
1. Long idle periods. 2. Low grade fuel.
3. Fuel tank vent restricted. 4. Fuel return line restricted. 5. Engine problem (low compression excessive blowby, worn rings or valve stem seals).
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Engine
2-13
Engine Diagnosis
PROBLEM Excessive Oil Consumption POTENTIAL CAUSE 1. Prolonged high speed, high load, or overload operation. 2. Incorrect oil grade used for high ambient temperature operation. CORRECTION 1. Reduce overload, or speed as needed.
2. Switch to SG, SH-CD oil with SAE viscosity rating of 15W-40, 20W-50, or 30W.
3. Oil leaks at: Rocker covers Oil pan Rear main seal Oil lter Timing chain cover or seal Cooler hoses/lines 4. CDR valve or hose faulty. 5. Engine problem: Worn broken piston rings Worn valve seats or guides
3. Locate and correct leaks as needed.
4. Check valve and hose and replace if necessary. 5. Run compression test to verify ring problem. Overhaul cylinder heads if guides, seals, valves are worn. If wear is premature, check injectors and injection pump. Excessive fuel will wash oil off walls/guides causing ring and valve wear. 1. Check and repair as needed. Replace damaged missing bolts and apply Loctite 242 to loose bolt threads. Replace serpentine belt if damaged. Replace bent, broken pulleys.
Engine Vibration NOTE: See road test information in this section.
1. Loose engine accessories: Alternator A/C compressor Power steering pump Mounting brackets Pulleys Belt tensioner Serpentine belt Drive pulleys 2. 3. Torsional damper damaged or loose. Flywheel (driveplate) cracked or loose.
2. Replace damper if damaged, worn, loose. 3. Replace ywheel and also check for ballooned or damaged converter. 4. Replace converter. 1. Remove and clear ns with compressed air, soft bristle brush, or water stream. 2. Add coolant and check for leaks (hoses, surge tank, hose connections, water pump, radiator). 3. Replace belt and/or tensioner if either part has failed or is worn beyond limit. 4. If this type operation cannot be avoided, have driver turn on heater and rev engine when stopped in trafc. This will help dissipate some heat and get more air through radiator (from fan).
4. Torque converter imbalance caused by internal damage or missing balance weight. Overheating 1. Dirt, debris blocking air ow through coolers, condenser, and radiator. Low coolant level.
2.
3.
Serpentine belt loose, worn, or tensioner inoperative. Prolonged idling/slow speed operation in heavy trafc when ambient temperatures are high.
4.
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Engine _____________________________________________________________________
Engine Diagnosis
PROBLEM Overheating (continued) 5. POTENTIAL CAUSE Failed thermostat or radiator cap. CORRECTION 5. Check thermostat and cap operation. Replace either part if inoperative. 6. Replace clutch. 7. Check coolant ow and replace pump if necessary. 8. Verify that coolant is leaking into combustion chamber and replace gasket. 9. Replace corroded freeze plugs. Replace block if cracked. 10. Test and replace gauges or sensors as needed.
6. 7. 8.
Fan clutch inoperative. Water pump inoperative. Blown head gasket.
9.
Crack in block, or leaking freeze plug.
10. Coolant temperature gauge or sensor faulty.
High Fuel Consumption
1. Prolonged high speed - high load operation.
1. Normal with this type of operation. Have driver reduce speed or load if possible. 2. Remove and clean air horn, intake hose, air cleaner. Replace lter. 3. Locate and repair as needed. 4. Inspect and replace bent, kinked, damaged components. 5. Correct leaks. Replace actuator or turbocharger if inoperative.
2. Air cleaner/lter partially plugged.
3. Fuel leaks in lines, hoses at connections. 4. Restriction in exhaust system (should also be accompanied by drop in power). 5. Decrease in boost on turbocharged models, caused by vacuum leak at actuator, manifold leak, or turbo damage. 6. Brake drag 7. Converter one way clutch failure. 8. Injection pump internal problem. 9. Power loss due to worn rings, valve guides, cylinder bores, valves, etc.
6. Repair stuck/seized calipers. 7. Replace converter. 8. Diagnose and replace as necessary. 9. Overhaul engine.
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Engine
2-15
TURBOCHARGER SERVICE AND DIAGNOSIS Description

The turbocharger used on 6.5L diesel engines is a BorgWarner model 1H1 (Figure 2-7). Lubrication is by engine oil from the engine lubrication system. Boost is monitored by the PCM and controlled by the wastegate and electronic accelerator pedal. The pedal assembly consists of a bracket, pedal and arm, and the pedal position sensor (potentiometer); a conventional throttle linkage is not used. The turbocharger is mounted in the lifter valley at the rear of the engine block. It is positioned between the two halves of the intake manifold. A turbocharger is fundamentally an air pump used to generate additional engine power. This is accomplished by increasing volume and pressure of air entering the engine combustion chambers. An increase in air volume allows a proportional increase in fuel injected into the cylinders. The net result is a denser fuel/air mixture. A denser mixture produces more power when compressed and burned in the combustion chamber. A turbocharger feature concerns the method of operation. The turbocharger turbine and compressor impellers are rotated by the flow of engine exhaust gases. As a result, separate drive belts and pulleys are not needed.
WASTEGATE VACUUM ACTUATOR MANIFOLD CROSSOVER HOUSING
TURBOCHARGER
Figure 2-7: Turbocharger and Vacuum Actuator Mounting

The turbocharger used on 6.5L engines consists of a turbine impeller and housing, a compressor impeller and housing, a wastegate, a wastegate actuator and an impeller connectingshaft (Figure 2-8). A separate, belt driven vacuum pump supplies vacuum for wastegate actuator operation.
TURBINE HOUSING AND IMPELLER
AIR OUTLET (TO MANIFOLD)
EXHAUST OUTLET ROD
COMPRESSOR HOUSING AND IMPELLER
FRESH AIR INLET (FROM AIR CLEANER) LEVER
WASTEGATE VALVE
TURBINE/COMPRESSOR SHAFT
WASTEGATE VACUUM ACTUATOR
Figure 2-8: Turbocharger Components (Typical)
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Engine _____________________________________________________________________
TURBOCHARGER OPERATION
The wastegate valve controls boost. It is operated by the vacuum actuator. Opening the valve stops boost and closing the valve generates boost. Boost levels are continuously monitored by the PCM. In the operation, an increase in accelerator pedal sensor angle to boost detent, causes the pedal sensor to signal the PCM that engine load is increasing. At this point, the PCM closes the wastegate valve with the actuator and increases fuel flow to the injectors. Closing the wastegate valve allows full exhaust gas flow into the turbine housing. As the gas enters the housing, it acts against the blades on the turbine impeller causing it to rotate. Since the turbine and compressor impellers are fixed to the same shaft, the turbine impeller causes the compressor impeller to rotate as well. Once the compressor impeller begins rotating, it draws fresh air into the compressor housing. The air is then compressed and pumped into the intake manifold. Fresh air source for the compressor section is through the air cleaner and related ducting. A decrease in pedal sensor angle signals the PCM that boost can be reduced or stopped entirely. The PCM then opens the wastegate valve by reducing vacuum to the actuator. Once open, the wastegate causes exhaust gas to bypass the turbine housing and impeller.
The position sensor is a potentiometer that operates like a TPS. It signals pedal position to the PCM. At boost detent position, the potentiometer signal causes the PCM to close the wastegate valve and generate boost.
Turbocharger Service
The turbocharger is not a repairable component. It must be replaced as an assembly when diagnosis indicates this is necessary.
Wastegate Actuator Test

The actuator is tested with a hand operated vacuum pump. Testing is performed with the engine off (not running) as follows: 1. Operate wastegate lever by hand. Lever should move back and forth freely without bind or drag. 2. Disconnect vacuum line at actuator and connect vacuum pump to actuator. 3. Apply 5 inches vacuum to actuator and note action. Actuator rod should close wastegate smoothly. If rod fails to move, release vacuum and proceed to next step. 4. Disconnect actuator rod at wastegate lever. Apply 5 inches vacuum to actuator, and note rod operation. If rod fails to move replace actuator. But if rod does move wastegate valve or lever is binding. Free up lever with heat valve lubricant. Replace turbocharger if wastegate valve is seized or binding.
Electronic Accelerator Pedal

The electronic pedal is unique to models equipped with a turbocharged engine. It consists of a pedal, arm, and position sensor (potentiometer), attached to a mounting bracket (Figure 2-9).
Boost Pressure Test

Boost pressure is checked with a compound vacuum/pressure gauge. A road test under boost conditions is required. Procedure is as follows: 1. Attach compound gauge hose to tting on air inlet tube, air horn, or turbocharger outlet. 2. Route hose to passenger side-window and into vehicle interior. 3. Road test vehicle. Have helper either drive or observe test gauge. Press accelerator pedal to wide open position and note gauge reading. A gauge reading of 2 psi (14 kPa) or more indicates normal operation. NOTE: During deceleration, boost level may decrease, this is normal. 4. If gauge reading is zero, or well below 2 psi (14 kPa), check complete air intake and exhaust system for leaks and repair as needed. Also check vacuum actuator, and accelerator pedal potentiometer. Run electrical check with Tech 2 scan tool if electrical system problems are suspected.
POSITION SENSOR (POTENTIOMETER)
PEDAL AND ARM
MOUNTING BRACKET
Vacuum Pump Test

The pump can be checked with a standard vacuum gauge. Output should be minimum of 20-21 inches vacuum.
Figure 2-9: Electronic Accelerator Pedal
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Engine
2-17
Turbocharger Removal
1. 2. 3. Remove front console, rear console, engine cover, and disconnect related wiring and A/C ducting. Remove turbocharger heat shielding. Loosen clamps attaching turbocharger inlet tubes to exhaust manifolds and turbocharger. Then work tubes loose and remove them. Remove air duct and hoses connecting turbocharger to air cleaner. Disconnect vacuum hose at wastegate vacuum actuator. Loosen bolts that attach manifold crossover to left and right manifold halves. Prop manifold crossover up with blocks. Lift, turn and tilt turbocharger to remove it (Figure 2-10). Do not pry or force it off the engine.
Turbocharger Installation
1. 2. 3. 4. 5. 6. Install new O-ring seal on turbocharger manifold outlet. Do not reuse old O-ring as leakage may occur. Clean gasket surfaces of intake manifold and crossover housing. Mount turbocharger on engine and install bolts that secure it to engine block. Tighten crossover housing bolts. Install air inlet duct and hose and connect vacuum pump to actuator. Install turbocharger inlet tubes. Tighten flange clamps that secure tubes to manifolds and turbocharger to 71 lb. in. (8 Nm) torque. Install turbocharger and exhaust pipe heat shielding. Install engine cover, console, and ducting
VACUUM ACTUATOR TURBOCHARGER OIL SEAL PIPE CLAMP INLET PIPE INLET PIPE
4. 5. 6. 7. 8.
7. 8.
.
PIPE CLAMP PIPE CLAMP
Figure 2-10: Turbocharger Mounting
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Engine _____________________________________________________________________
Turbocharger Diagnosis
PROBLEM Low Power Poor Acceleration (Black smoke not evident at 1/2 to wide open throttle) Low Power, Poor Acceleration (Black smoke evident at 3/4 to wide open throttle) 1. POTENTIAL CAUSE Lean fuel mixture caused by insufcient fuel volume or pressure. CORRECTION 1. Problem is in fuel delivery system. Check fuel supply pump pressure, look for leaks in lines and at ttings, plugged fuel lter, accelerator cable problem, injection pump problem. Refer to low power information in guides for standard diagnosis. 1. Replace lter. 2. Remove and inspect duct components. Remove/ repair any restrictions. 3. Disassemble, inspect, repair worn, damaged, loose parts.
1. 2.
Air lter plugged. Restriction in air intake duct to turbocharger compressor wheel. Air leak in turbocharger compressor inlet and outlet ducts. May be accompanied by high pitch whine indicating system air leak. Loss of vacuum to wastegate actuator, or actuator is damaged.
3.
4.
4. Check vacuum supply. Replace hose and ttings if necessary. If OK, use hand operated vacuum tester to check actuator operation. Replace actuator or vacuum pump, as required. 5. Tighten loose bolts. Or, remove manifold and replace gaskets if necessary. 6. Check exhaust manifolds pipes, and turbocharger connections for leaks. Replace damaged components, tighten loose fasteners. 7. Remove and inspect turbocharger. Replace if compressor/turbine wheels, or other internal components are damaged. 8. Refer to low power information in standard diagnosis. 1. Disassemble and clear blockage, or restriction.
5.
Air leak at intake manifold.
6.
Exhaust leak between cylinder head ports and turbine inlet of turbocharger.
7.
Turbocharger damaged internally.
8. Turbocharger Noise 1.
Fuel system problem (over-rich mixture). Obstruction in air intake or outlet systems may cause high pitch whine. Compressor/turbine impeller contacting housing, or other internal damage. May be accompanied by vibration. Insufcient intake air volume.
2.
2. Replace turbocharger.
Blue Exhaust Smoke with Warm Engine Only
1.
1. Disassemble, inspect, and clear any restrictions. Replace damaged, worn ducting parts. 2. Remove and clear tube. Replace tube if fully plugged, pinched, or kinked. 3. Replace turbocharger.
2.
Partially plugged oil drain tube.
3.
Oil Leaking past worn compressor or turbine side seals. Engine problem caused by worn rings, or valve seals.
4.
4. Overhaul cylinder heads or engine as needed.
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Engine
2-19
DIESEL ENGINE IN-VEHICLE SERVICE General Information

The repair procedures described in this section cover engine service that can be performed in the vehicle. Engine removal is not required.
10. Remove nut securing engine bracket to stud on starter motor (Figure 2-12). 11. Raise engine enough to remove insulator, or bracket (Figure 2-12).
Left/Right Orientation
Left/right orientation throughout this section is from the driver seat. A left side location refers to the driver side of the vehicle and a right side location to the passenger side.
INSULATOR STUD AND NUT STARTER BRACKET ENGINE BRACKET
ENGINE MOUNTING BRACKET/INSULATOR

Removal
1. 2. 3. Remove fan and clutch as assembly. Remove nuts/bolts attaching front propeller shaft center bearing to bracket. Mark front propeller shaft U-joint and yoke position with paint or chalk. Then remove front propeller shaft and center bearing as assembly. Remove bolts attaching starter cable bracket to engine. Move bracket aside for working clearance. Remove bolts/nuts attaching transmission and mount to transmission crossmember (Figure 2-11).
TRANSMISSION
4. 5.
STARTER FRAME BRACKET
Figure 2-12: Engine Mounting Bracket and Insulator (Driver Side)
TRANSMISSION MOUNT TRANSMISSION CROSSMEMBER
Figure 2-11: Transmission-To-Crossmember Mounting

6. 7. 8. Disconnect transmission and transfer case shift rods at shift lever arms. Disconnect exhaust pipes, brackets, or hangers as needed. Support engine with floor jack and wood block, or safety stand if vehicle is on hoist. Position block or stand under pan rail at rear main. Remove nuts/bolts attaching insulators, or brackets to engine and frame.
9.
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Engine _____________________________________________________________________
CRANKSHAFT PULLEY
ENGINE BRACKET
Removal
1. 2. Loosen (but do not remove) crankshaft pulley bolts (Figure 2-14). Remove serpentine accessory drive belt as follows: a. Loosen drive belt by rotating belt tensioner in counterclockwise direction (Figure 2-15). Use 1/2 in. drive breaker bar to rotate pulley. b. Slide belt off tensioner and other pulleys. Then remove belt. Remove crankshaft pulley bolt and remove pulley.
3.
INSULATOR
Figure 2-13: Engine Bracket and Insulator Assembly
Installation
12. Position insulator on engine bracket (Figure 2-13). 13. Install engine bracket and insulator. Tighten engine bracket-to-block bolts to 30 lb-ft (41 Nm) torque. Tighten insulator stud nuts to 90 lb-ft (122 Nm) torque. 14. Install nut that secures engine bracket to stud on starter motor (Figure 2-12). Tighten nut to 24 lb-ft (33 Nm) torque. 15. Align and install bolts/nuts that attach transmission to transmission crossmember (Figure 2-11). 16. Connect transmission and transfer case shift rods to floor shift levers. Use new cotter pins to secure shift rod trunnions to shift lever arms. 17. Align and install front propeller shaft and center bearing. Tighten center bearing attaching bolts to 60 lb-ft (81 Nm) torque. Tighten U-joint clamp strap nuts to 13-18 lb-ft (1824 Nm) torque. 18. Install starter cable bracket. 19. Connect exhaust pipes, brackets, or hangers if loosened/ removed for service access. 20. Install fan and clutch.
PULLEY BOLT (4) CRANKSHAFT PULLEY
TORSIONAL DAMPER
Figure 2-14: Crankshaft Pulley Mounting

BELT TENSIONER
SERPENTINE BELT
Figure 2-15: Serpentine Belt Tensioner Location
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Engine
2-21
Installation
1. 2. 3. Clean face of torsional damper with brake cleaner. Smooth surface with le, or 280 grit paper, if necessary. Install pulley on damper and install pulley bolts. Tighten bolts until snug. Install serpentine belt on all pulleys except belt tensioner (Figure 2-16). Turn tensioner counterclockwise with breaker bar and slide belt onto tensioner. Then release breaker bar so tensioner can rotate clockwise to adjust belt. Tighten crankshaft pulley bolts to 48 lb-ft (65 Nm) torque.
TORSIONAL DAMPER CRANKSHAFT KEY PULLEY CRANKSHAFT DAMPER SEAL SURFACE DAMPER BOLT AND WASHER
4.
ALTERNATOR PULLEY
TENSIONER PULLEY
A/C COMPRESSOR OR IDLER PULLEY
Figure 2-17: Torsional Damper and Crankshaft Pulley Mounting
WATER PUMP PULLEY SERPENTINE BELT VACUUM PUMP PULLEY
TOOL J23523-F
POWER STEERING PUMP PULLEY
Figure 2-18: Torsional Damper Removal

CRANKSHAFT PULLEY
Installation
1. Check seal contact surface of damper. Surface must be clean and smooth to avoid damaging timing cover seal. Smooth surface with 180 grit emery if necessary. Then polish surface with 220 grit emery coated with engine oil. Inspect condition of front cover seal. Replace seal if worn, cut, cracked, or hardened. Use pry tool to remove oil seal and tool J22102 to install new seal. Install damper drive key in crankshaft. Be sure keys are fully seated in crankshaft key slots. Lubricate crankshaft nose, front cover seal, and seal surface of torsional damper with engine oil. Install torsional damper on crankshaft. Be sure drive key is not displaced during damper installation. Install damper washer and bolt. Tighten bolt to 160-200 lb-ft (217-270 Nm) torque. Install crankshaft pulley. Tighten pulley bolts to 48 lb-ft (65 Nm) torque. Install serpentine belt (Figure 2-16).
Figure 2-16: Serpentine Belt Installation
TORSIONAL DAMPER
Removal
1. 2. 3. 4. Remove crankshaft pulley and serpentine belt. Refer to procedure in this section. Remove damper bolt and washer (Figure 2-17). Remove torsional damper with tool J23523-F (Figure 2-18). Remove and inspect crankshaft keys. Replace keys if worn, chipped, or distorted. 2.
3. 4. 5. 6. 7. 8.
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Engine _____________________________________________________________________
FRONT COVER OIL SEAL REPLACEMENT

1. 2. 3. Remove crankshaft pulley and torsional damper. Refer to procedures in this section. Remove oil seal front cover with tool J22102 or pry tool (Figure 2-19). Clean seal contact surface of torsional damper. Smooth surface, if necessary, with 180 grit emery. Then polish with 220 grit emery coated with engine oil. Seal surface must be smooth to avoid damaging new seal. Install new seal in cover with tool J22102. Open end of seal goes toward interior of cover. Lubricate new seal and seal surface of torsional damper, with engine oil. Install keys in crankshaft. Then align and install torsional damper. Install damper belt and washer. Tighten bolt to 140-160 lb-ft (190-217 Nm). Install crankshaft pulley and serpentine belt. Refer to procedure in this section.
OIL PUMP DRIVE

Removal
1. 2. 3. 4. 5. 6. 7. Remove engine cover/console for access to rear of engine. Remove the turbocharger as described in this section. Clean surface of drive, block and drive clamp with carb cleaner. Remove bolt that secures oil pump drive clamp to block (Figure 2-20). Remove oil pump drive with turn and lift motion. Use channel lock or use grip pliers to remove drive. Remove gasket from block or drive. Cover pump drive opening in block to prevent dirt entry.
4. 5. 6.
Installation
1. 2. 3. 4. 5. Install new gasket on oil pump drive. Position and insert oil pump drive in block. Turn drive back and forth to seat it as needed. Install drive clamp and bolt. Tighten bolt to 25-37 lb-ft (34-50 Nm) torque. Install turbocharger as described in this section. Install engine console/cover.
7.
CLAMP
ENGINE SPEED SENSOR OIL PUMP DRIVE
FRONT COVER TOOL J22102 OIL SEAL
GASKET
Figure 2-19: Front Cover Oil Seal Location
S02-012.2
Figure 2-20: Oil Pump Drive Removal/Installation
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Engine
2-23
FRONT COVER AND TIMING CHAIN

Cover Removal
1. 2. 3. 4. 5. 6. Disconnect and remove batteries and tray. Drain engine coolant. Remove radiator upper and lower hoses. Loosen crankshaft pulley belts. Remove left and right splash shields. Disconnect hood harness then remove hood with aid of helper. Place hinge pins in hinges after removal to avoid losing them. 7. Remove A/C condenser oil coolers, radiator, and fan shroud as assembly (Figure 2-21). 8. Loosen and remove serpentine drive belt. Use 1/2 in. drive breaker bar to rotate belt tensioner counterclockwise to loosen belt (Figure 2-15). 9. Disconnect heater, bypass and inlet hoses at water pump and coolant crossover (Figure 2-22). 10. Remove oil filler neck and coolant crossover (Figure 2-22).
OIL COOLERS
RADIATOR
CONDENSER
REAR SUPPORT BRACKET
LOWER MOUNT FAN SHROUD
RIGHT SIDE AIR LIFT BRACKET
FRAME BRACKET
Figure 2-21: Condenser, Oil Coolers, Radiator and Fan Shroud Removal as an Assembly
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Engine _____________________________________________________________________
CROSSOVER
HOSE
19. Remove injection pump driven gear (Figure 2-24). 20. Remove baffle from front cover (Figure 2-24). 21. Remove nuts and washers attaching fuel injection pump to studs on front cover (Figure 2-24). NOTE: There are timing marks on the front cover and injection pump. Note position of these marks for installation reference. 22. Remove bolts that attach front cover to engine block. Then break sealer bead with putty knife and remove cover. 23. Cover oil pan opening to prevent dirt entry. 24. Check timing chain deflection with dial indicator. Measure deflection mid-way between crankshaft and cam sprockets. Maximum allowable deflection is 0.810 in. (20.5 mm). Replace chain and sprockets if deflection is greater than specified. 25. Check camshaft end play with dial indicator. Maximum allowable end play is 0.012 in. (0.3 mm). Replace cam thrust plate and spacer if end play is greater than specified. NOTE: Note position of timing marks on drive gear and crank and cam sprocket for installation reference. 26. Remove bolt and washer attaching injection pump drive gear to camshaft. Then remove gear (Figure 2-25). 27. Slide timing chain and sprockets off camshaft and crankshaft (Figure 2-25). 28. Remove drive keys from camshaft and crankshaft. Replace keys if chipped, cracked, or distorted. Minor burrs can be removed with a stone or fine tooth file. 29. Clean all old sealer off engine block, front cover, and water pump/adapter plate with scraper.
OIL FILLER NECK
Figure 2-22: Upper Radiator Hose Connections

11. Remove fan and fan clutch. 12. Remove crankshaft pulley (Figure 2-14). 13. Remove torsional damper attaching bolt and washer (Figure 2-17). 14. Remove torsional (Figure 2-18). damper with tool J23523-F
15. Remove drive keys from crankshaft. Replace keys if worn, chipped, or distorted. 16. Remove water pump and adapter plate as assembly (Figure 2-23). 17. Remove bolts that attach front cover to oil pan (Figure 2-24). 18. Rotate crankshaft by hand until timing marks on sprockets and gears are aligned and number one piston is at TDC.
ADAPTER PLATE
FRONT COVER
WATER PUMP
Figure 2-23: Water Pump and Adapter Plate Removal/Installation
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Engine
2-25
INJECTION PUMP DRIVE GEAR FRONT COVER PUMP GASKET
FUEL INJECTION PUMP
INJECTION PUMP DRIVEN GEAR
BAFFLE
FRONT SEAL
Figure 2-24: Drive Gear, Baffle, and Front Cover Removal
CAMSHAFT KEY TIMING CHAIN CAMSHAFT INJECTION PUMP DRIVE GEAR CAMSHAFT SPROCKET
CRANKSHAFT TIMING MARKS CRANKSHAFT SPROCKET CRANKSHAFT KEYS
Figure 2-25: Drive Gear, Timing Chain, and Sprocket Removal

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Engine _____________________________________________________________________
Front Cover Installation

1. 2. 3. 4. Install new camshaft thrust plate and spacer if required. Clean front cover and engine block sealing surfaces with carb cleaner and wipe dry. Install drive keys in camshaft and crankshaft. Be sure keys are seated. Assemble and install timing chain and sprockets (Figure 2-26). Check timing mark alignment before proceeding. Install injection pump drive gear on camshaft (Figure 2-26). Timing mark on gear should be facing upward (12 oclock position). Then install drive gear attaching washer and bolt. Tighten bolt to 55-60 lb-ft (7581 Nm) torque.
THRUST PLATE AND SPACER DRIVE KEYS INJECTION PUMP DRIVE GEAR
6. 7.
Install new seal in front cover with tool J22102. Apply sealer to front cover as follows: Use anerobic sealer, such as Loctite 510, on cover surfaces that contact engine block. Use RTV-type sealer, such as Loctite 592, on oil pan and oil pan contact surface of front cover. Refer to sealer application diagram (Figure 2-27).
5.
FRONT COVER
USE ANEROBIC SEALER HERE
USE RTV TYPE SEALANT HERE (OIL PAN CONTACT SURFACE) TIMING CHAIN CRANKSHAFT SPROCKET
Figure 2-27: Front Cover Sealer Application Diagram

CAMSHAFT SPROCKET CAMSHAFT CRANKSHAFT
8.
Figure 2-26: Timing Chain, Sprockets, and Drive Gear Installation
Install front cover on engine block (Figure 2-28). Be sure cover is fully seated on engine block dowels, engine block, and oil pan, before installing cover bolts. 9. Install front cover attaching bolts. Then tighten bolts as follows: Tighten cover-to-engine block bolts to 33 lb-ft (45 Nm) torque. Tighten oil pan-to-front cover bolts to 4-10 lb-ft (5-14 Nm) torque. 10. Install injection pump gasket on front cover studs (Figure 2-28:).
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Engine
2-27
INJECTION PUMP DOWEL FRONT COVER PUMP GASKET BAFFLE INJECTION PUMP DRIVEN GEAR
FRONT COVER
TIMING MARK
DOWEL
Figure 2-29: Baffle and Pump Driven Gear Installation

17. Install torsional damper. Then install damper attaching washer and bolt. Tighten bolt to 140-160 lb-ft (190-217 Nm) torque. 18. Install crankshaft pulley. Tighten pulley bolts to 48 lb-ft (65 Nm) torque. 19. Install coolant crossover and oil filler neck. Tighten crossover bolts to 31 lb-ft (42 Nm) torque and filler neck attaching nut to 13-20 lb-ft (18-27 Nm) torque. 20. Apply bead of anaerobic sealer, such as Loctite 510, to water pump and adapter plate. Refer to Figure 2-36 for sealer application. 21. Install water pump and adapter plate. Apply Permatex/ Loctite pipe sealing compound, to fastener that goes in hole A (Figure 2-30). Tighten pump/adapter bolts to 1320 lb-ft (18-27 Nm) torque.
Figure 2-28: Front Cover Mounting

11. Install baffle in front cover (Figure 2-29). Maintain minimum clearance of 0.040 in. (1.02 mm) between baffle and injection pump drive gear. Tighten baffle attaching bolts/nuts to 33 lb-ft (45 Nm) torque. 12. Install fuel injection pump driven gear on pump shaft as follows: a. Align timing marks on drive and driven gears and install driven gear on pump shaft. b. Verify timing mark alignment. Drive gear mark should be at 12 oclock position and driven gear mark at 6 oclock position. NOTE: If timing marks are not perfectly aligned, turn the pump shaft to correct alignment. Do not turn the gears. c. 13. Install and tighten driven gear attaching bolts to 13-20 lb-ft (18-27 Nm) torque. Check alignment of timing marks on front cover and injection pump flange. Rotate pump to align if necessary. Then install pump attaching nuts. Secure fuel injection pump to front cover. Tighten pump attaching nuts to 13-20 lb-ft (18-27 Nm) torque. Lubricate front cover seal lip with engine oil, or petroleum jelly. Then lubricate seal contact surface of torsional damper with engine oil. Be sure seal contact surface of damper is smooth and free of burrs, nicks, or corrosion. Install damper drive key in crankshaft slot. Be sure key is fully seated.
APPLY SEALANT HERE
APPLY SEALANT HERE
14. 15.
FASTENER HOLE A
16.
Figure 2-30: Water Pump Adapter Plate Sealer Application Diagram
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22. Install fan pulley, fan, and fan clutch. Tighten attaching nuts to 15-20 lb-ft (20-27 Nm). 23. Install serpentine drive belt. 24. Connect heater and bypass hoses at water pump and crossover. Then attach radiator upper inlet hoses to inlet tube. 25. Install radiator and shroud (Figure 2-21). Then install air conditioning condenser and power steering fluid cooler. 26. Connect radiator upper and lower hoses. 27. Fill cooling system. 28. Connect battery negative cables. 29. Evacuate and recharge air conditioning system if necessary. 30. Start and run engine to verify proper operation. Purge air from cooling system (if necessary), and top off coolant level at surge tank. 31. On turbo diesel, reprogram TDC offset. Refer to procedure at end of this section.
PUMP SHAFT
BRACKET TUBE STRAINER
OIL PUMP PUMP MOUNTING STUD
OIL PUMP SERVICE

Removal
1. 2. 3. Drain engine oil and remove oil lter. Remove oil pan bolts. Tap oil pan with rubber mallet to break sealer bead. Use putty knife to help separate sealer bead if necessary. Then remove pan. Loosen screw that secures bracket on oil pump pickup tube. Remove nut that secures tube bracket to oil pump mounting stud (Figure 2-31). Then rotate bracket off stud. Remove oil pump mounting stud (Figure 2-31). Remove oil pump and pump shaft.
Figure 2-31: Oil Pump Mounting
Installation
1. Prime oil pump. Pour about four ounces of engine oil into pump through strainer and rotate shaft to coat gears. 2. Insert pump shaft into block. Then align and seat pump. 3. Install and tighten pump mounting stud to 59-74 lb-ft (80100 Nm) torque. 4. Rotate pickup tube bracket onto pump mounting stud. Then install and tighten bracket retaining nut to 35 lb-ft (47 Nm). 5. Tighten clamp screw on pickup tube bracket to 12 lb-ft (16 Nm) torque. 6. Clean oil pan and engine block sealing surfaces with scraper and solvent. Final clean surfaces with brake or electrical contact cleaner to remove all residue. Otherwise, RTV sealer will not adhere properly. 7. Apply RTV-type sealer to front cover, oil pan, and engine pan rail surfaces. Sealers such as Permatex ultra copper, or black are equally acceptable. 8. Install rear seal in oil pan. 9. Position oil pan on engine and front cover. Then install and tighten oil pan bolts as follows: Tighten rear two bolts to 89 lb-in (10 Nm) torque. Tighten remaining bolts to 17 lb-ft (23 Nm) torque. 10. Install oil filter and refill with recommended grade engine oil.
4. 5. 6. 7.
Inspection And Replacement

The oil pump can be disassembled for inspection but not repaired. The oil pump is only serviced as an assembly. Individual parts are not available. Replace the pump if the oil pickup strainer and tube are loose, cracked, or distorted. Also replace the pump if the housing is damaged or the pump gears are worn, chipped, or cracked. Check the pump shaft and pressure relief valve and spring. Replace the pump if the spring is collapsed or broken, the valve is damaged, the retaining pin is loose, or damaged, or the pump shaft is worn or damaged. The oil pickup strainer can be cleaned with spray-type carb cleaner if necessary. However, replace the pump if heavy accumulations of oil sludge, grit, foreign material, or metal chips are present.
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REAR MAIN OIL SEAL REPLACEMENT

1. 2. Remove transmission and transfer case assembly. Remove flywheel.
CAUTION: Do not nick or scratch crankshaft seal surface when removing old seal (Figure 2-32). 3. 4. Using small screwdriver or seal puller, remove old seal from cylinder block and main bearing cap cavity. Clean old sealant or oil build-up from seal cavity. Check for excess wear in crank. Lightly coat crankshaft and inner lip of seal with engine oil. Lube oil and I.D. of seal. Position seal on crankshaft with seal lip toward block. Ensure seal lip does not flip on installation. Position seal installer J39084 on crankshaft, press seal into cavity in block, then remove installer tool (Figure 2-33). Install flywheel on crankshaft. Tighten bolts to 66 lb-ft (90 Nm). Install transmission and transfer case assembly.
BLOCK
5. 6. 7. 8. 9.
CRANKSHAFT SEAL
10. Run engine and check for leaks after assembly.
BEARING CAP
CAVITY
Figure 2-32: Rear Main Oil Seal Removal
BLOCK SEAT SEAL FLUSH WITH BLOCK AND BEARING CAP CRANKSHAFT
BLOCK
CRANKSHAFT SEAL SEAL INSTALLER J39084 MAIN BEARING CAP MAIN BEARING CAP SEAL
Figure 2-33: Rear Main Oil Seal Installation

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ROCKER ARM COVER SERVICE

Right Side Cover Removal
1. 2. Remove front console and engine cover. Remove air horn and inlet hose. Then remove air cleaner assembly. 3. Drain radiator. 4. Remove surge tank. 5. Disconnect and remove water control valve, hoses, and bracket. 6. Remove CDR valve and hose. 7. Remove bolt that attaches transmission fill tube to cylinder head. 8. Remove brackets attaching electrical wire harnesses and sensors to intake manifold. 9. Remove nuts attaching fuel injector line clamps to intake manifold studs. 10. Remove intake manifold and gaskets. Cover cylinder head intake ports to prevent dirt entry. 11. Disconnect lines at fuel injectors. Cover injectors and cap lines immediately to prevent dirt entry. 12. Loosen lines at fuel injection pump. 13. Remove studs and bolts attaching rocker arm cover to cylinder head (Figure 2-34). 14. Tap rocker arm cover with rubber mallet to break sealer bead and loosen cover. Do not pry cover loose. 15. Move fuel injector lines aside (rotate them out of way). Or, remove necessary injector lines if unable to move aside. CAUTION: Do not bend the fuel lines. The internal coating could fracture, peel off, and clog the injectors. 16. Remove rocker arm cover. 17. Scrape old silicone sealer off cover. Then clean cover with parts cleaning solvent. Final-clean sealing surfaces with brake or electrical contact cleaner. This is necessary to remove residue left from cleaning solvent and ensure proper adhesion of new sealer. 18. Clean gasket surfaces of intake manifold and cylinder head. Be sure surfaces are clean and smooth. Remove minor nicks or scratches with 220 grit emery cloth.
ROCKER ARM COVER
FASTENER INSTALLATION DIAGRAM
BOLT (2) STUD (6)
CYLINDER HEAD
Figure 2-34: Rocker Arm Cover Removal/Installation (Right Side)
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2-31
Right Side Cover Installation

1. Clean cover mounting surface of cylinder head with brake or contact cleaner and shop towels. This product will remove residue from the surface and ensure proper adhesion of new sealer. If new rocker arm cover is being installed, clean seal surface with brake or contact cleaner. Apply sealer to rocker arm cover sealing surface. Make sealer bead 3/16 in. wide by 1/16 in. thick. Use Loctite 599, Permatex Ultra Copper, or similar quality silicone sealer. Allow sealer to cure slightly (skin over) before installation. Align and install rocker arm cover on cylinder head. Install rocker arm cover attaching studs and bolts (Figure 2-34). Tighten cover fasteners evenly to 13-25 lbft (18-34 Nm) torque. Start at center and work toward ends when tightening. Remove protective covering from injectors and lines. Then connect lines to injectors and to pump, if removed. Tighten line fittings to 20-22 lb-ft (27-30 Nm) torque. Install intake manifold and new gaskets. A gasket dressing such as, perfect seal, or Permatex High Tack, can be used to hold gaskets in place. Tighten manifold bolts and studs to 31 lb-ft (42 Nm) torque in sequence (Figure 2-35). Install fuel injector line clamps and wire harness brackets on manifold studs. Tighten retaining nuts to 26 lb-ft (35 Nm) torque. Install CDR valve and hose. Install bolt that secures transmission fill tube to cylinder head. Install water control valve and hoses. Install surge tank. Refill cooling system Start engine and check cover for leaks. Then bleed each injector by loosening fuel line fitting (at injector), just enough to purge any trapped air. Stop engine when complete. Install air cleaner, inlet hose, and air horn. Install engine cover and front console. Top off engine coolant and oil levels if required.
Left Side Cover Removal

1. 2. 3. 4. 5. Remove front console and engine cover. Drain engine coolant. Remove driver side splash shield. Remove air inlet hose and air horn. Disconnect radiator upper hoses at thermostat housing and radiator. Then remove hoses and inlet tube as assembly. 6. Disconnect fuel pump, remove it from clamp and move pump aside for working clearance. 7. Remove nuts attaching harness and sensor brackets to intake manifold studs. 8. Remove nuts attaching water valve and bracket. Then move valve and bracket aside for working clearance. 9. Remove nuts and washers attaching fuel injection line clamps to manifold studs. Remove and retain clamps and fasteners. 10. Remove studs and bolts attaching intake manifold to cylinder heads. Remove manifold and gaskets. Cover cylinder head intake ports with shop towels to prevent dirt entry (Figure 2-35). 11. Remove screws attaching oil dipstick and tube to cover. Then rotate tube away from engine for working clearance. 12. Disconnect fuel lines at driver side injectors. Then loosen (or remove) lines at pump. Rotate lines aside for working clearance. Cover lines and injectors to prevent dirt entry. CAUTION: Do not bend the fuel injector lines. The internal coating could fracture, peel off, and clog the injectors. 13. Remove rocker arm cover attaching bolts and studs. Then tap cover with rubber mallet to break sealer bead. Do not pry cover loose. 14. Remove rocker arm cover. 15. Clean cover in parts cleaning solvent and scrape all traces of old silicone sealer off cover seal surfaces. Final clean cover seal surfaces with brake or contact cleaner. This is necessary to remove residue from cleaning solvent, and ensure proper adhesion of new sealer. 16. Clean gasket surfaces of intake manifold and cylinder heads. Be sure surfaces are clean and smooth. Remove minor nicks or scratches with 220 grit emery cloth.
2. 3.
4. 5.
6.
7.
8.
9. 10. 11. 12. 13. 14.
15. 16. 17.
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Left Side Cover Installation

1. Clean cover mounting rails on cylinder head with brake or contact cleaner and shop towels. This product will remove residue from surface and ensure proper adhesion of new sealer. If new rocker arm cover is being installed, clean seal surface with brake or contact cleaner. Apply sealer to rocker arm cover sealing surface. Make sealer bead 3/16 in. wide by 1/16 in. thick. Use Loctite 599, Permatex Ultra Copper, or similar quality silicone sealer. Allow sealer to cure slightly (skin over) before installation. Align and install rocker arm cover on cylinder head. Install rocker arm cover attaching bolts and studs (Figure 2-34). Tighten cover fasteners evenly to 13-25 lbft (18-34 Nm) torque (Figure 2-35). Remove protective covering from injectors and lines. Then connect lines to pump and injectors. Tighten line fittings to 20-22 lb-ft (27-30 Nm) torque. Install intake manifold and new gaskets. A gasket dressing such as Perfect Seal, or Permatex High Tack, can be used to hold gaskets in place. Tighten manifold bolts and studs to 31 lb-ft (42 Nm) torque. 8. Install fuel injector line clamps and harness and sensor brackets on manifold studs. Tighten retaining nuts to 26 lb-ft (35 Nm) torque. Attach oil dipstick and tube to cover bracket. Attach water control valve bracket to manifold. Install and connect fuel pump. Connect radiator upper hoses and inlet tube. Refill engine cooling system. Install air inlet hose and air horn. Start engine and check cover for leaks. Then bleed each injector by loosening fuel line fitting (at injector), just enough to purge trapped air. Stop engine when complete. Install engine cover and console. Top engine coolant and oil levels if required.
2. 3.
9. 10. 11. 12. 13. 14. 15.
4. 5.
16. 17.
6.
7.
FUEL DRAINBACK LINE
ROCKER ARM COVER
CYLINDER HEAD
Figure 2-35: Left Side Rocker Arm Cover
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ROCKER ARM, SHAFT, AND PUSHROD SERVICE

Removal
1. 2. Remove one or both rocker arm covers as needed. Refer to procedures in this section. Remove bolts and retainers that attach rocker arm shafts to cylinder head (Figure 2-36). Note position of bolts for installation reference. Bolts must be reinstalled in same threaded holes. 3. Lift and remove each rocker arm and shaft assembly (Figure 2-36). Do not intermix assemblies if they will be reused. Each assembly must be reinstalled in same position. Remove pushrods in sequence. Keep them in order of removal. Also note which end of push rod goes in rocker arm. This end of rod is heat treated and usually identified with a paint mark
4.
PUSHROD SHAFT ATTACHING BOLT RETAINER ROCKER ARM AND SHAFT ASSEMBLIES
Figure 2-36: Rocker Arm Shafts and Pushrods
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Cleaning and Inspection

Clean the valve train components in parts cleaning solvent. Carb cleaner or a spray type gasket remover can be used to remove stubborn deposits. Mark position of the rocker arms on the shafts. Remove the rocker arm retainers with pliers. Then remove the arms and examine the shafts for wear, grooving, or surface cracks. Check the rocker arms for cracks at the shaft bores and for wear at the valve and push rod contact points. Replace worn, or damaged parts as needed. Check the pushrods for wear, or distortion. Replace any push rod exhibiting wear (at either end), or if bent, or kinked. NOTE: The rocker arm end of each pushrod is identified with a paint stripe. The ball at this end is also coated or heat treated giving it a distinctive copper color. 8. Install rocker covers and intake manifold as described in this section.
COATED/TREATED END PAINT MARK
Installation
1. 2. Lubricate all parts with engine oil, or with a quality assembly lube. Install pushrods in same sequence as when removed. Verify that heat treated or coated end is facing up toward rocker arm. Assemble rocker arms and shaft if necessary. Secure arms with new retainers but be sure reused arms are installed on same shafts and in same position. Do not intermix parts. Index crankshaft and pistons for rocker arm shaft installation as follows: a. Position breaker bar and socket on crankshaft damper bolt. Do not use starter to rotate crankshaft. Turn shaft with hand tools only. b. Rotate crankshaft counterclockwise, and align mark on torsional damper with O mark on front cover timing tab. c. Rotate engine counterclockwise an additional 3 1/2 inches (89 mm), measured at mark on torsional damper. Damper mark should align with water pump first, lower attaching bolt at this point (Figure 2-43). Align and install rocker arm and shaft assemblies (Figure 2-36). Be very sure pushrods are seated in lifters and in rocker arms. Install rocker arm shaft retainers and bolts. Tighten bolts in small increments until snug, with socket and ratchet or nut runner.
Figure 2-37: Pushrod I.D.
3.
4.
5.
6.
CAUTION: Do not use an air wrench to tighten the bolts. In addition, stop tightening if the bolts become hard to turn before they are seated. If this condition occurs, the crankshaft and pistons are not properly indexed, allowing the valves to contact the pistons. 7. Verify that pushrods are properly seated in rocker arms and lifters. Then final-tighten rocker arm shaft bolts to 41 lb-ft (56 Nm) torque.
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EXHAUST MANIFOLD SERVICE Right Exhaust Manifold Heat Shield Replacement

Removal
1. 2. 3. 4. Remove console and engine access cover. Remove right exhaust manifold rear heat shield screws and locknuts (Figure 2-38). Remove shield attaching screws and remove heat shield. Position heat shield on crossover pipe and exhaust manifold.
CYLINDER HEAD
5. 6. 7.
Install heat shield and exhaust manifold on cylinder head and tighten capscrews to 25 lb-ft (34 Nm). Install right exhaust manifold rear heat shield. Install engine access cover and console.
TRANSMISSION FILL TUBE
EXHAUST MANIFOLD
REAR HEAT SHIELD
HEAT SHIELD
Figure 2-38: Right Exhaust Manifold Heat Shield
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Right Exhaust Manifold Rear Heat Shield Replacement

1. 2. 3. 4. 5. 6. Remove console and engine access cover. Detach rear heat shield from transmission fill tube clamp (Figure 2-39). Remove rear heat shield. Install rear heat shield. Attach rear heat shield to transmission fill tube clamp. Install engine access cover and console.
CYLINDER HEAD
TRANSMISSION FILL TUBE
EXHAUST MANIFOLD
REAR HEAT SHIELD
HEAT SHIELD
Figure 2-39: Right Rear Heat Shield
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CYLINDER HEAD AND GASKET SERVICE Cylinder Head (Left Side)

Removal
1. Remove hood with aid of helper as follows: Disconnect hood harness Remove harness clips at driver side frame rail bracket Remove bolts that attach prop rod bracket to driver side frame bracket Remove hood hinge pins Lift and remove hood 2. Remove front console and engine cover. 3. Drain radiator and disconnect batteries. 4. Disconnect and cover fluid cooler lines at transmission and power steering coolers. 5. Remove driver side splash shield. 6. Remove serpentine belt. 7. Remove air intake hose and air horn. 8. Remove A/C compressor, power steering pump, and mounting bracket as assembly. Position A/C compressor to side to allow access to rocker cover and cylinder head. 9. Remove oil dipstick tube, water crossover, thermostat housing, coolant hoses, and radiator upper hose inlet tube. 10. Disconnect or remove (Figure 2-40): Heater water valve bracket Wire harness clips and brackets Ground wires/cables at rear of cylinder head Temperature sender wire Fuel pump Glow plugs 11. Remove fuel injector line clamps. Retain clamps and attaching washers and nuts.
12. Remove intake manifold and gaskets. Note attaching stud and bolt locations for reinstallation reference. 13. Disconnect driver side fuel injector lines at pump and injectors and remove lines. Cover injectors with duct tape to prevent dirt entry. 14. Remove bolts/nuts attaching crossover pipe to exhaust manifold. 15. Remove rocker arm cover. Tap cover with rubber mallet to loosen. Do not pry on cover to remove. 16. Remove rocker arm shaft bolts and retainers. Remove arm and shaft assemblies individually. Note original position for assembly reference. 17. Remove pushrods. Note position of rods for installation reference as they must be installed in original position. 18. Remove cylinder head bolts. Discard bolts as they are not reusable. 19. Remove cylinder head (Figure 2-41) with aid of helper, or use chain hoist, portable hoist, or similar device to lift and remove cylinder head.
CYLINDER HEAD
COOLANT TEMPERATURE SENDER
DOWEL DOWEL
Figure 2-41: Cylinder Head and Gasket Removal/Installation

20. Remove cylinder head gasket. Discard gasket; it is not reusable. 21. Refer to overhaul section if head, valves, valve seats, springs, or seals require service. Check for warpage. If head was only removed to replace blown gasket, proceed to installation procedure. 22. Cover cylinder bores and lifter valleys with shop towels.
Figure 2-40: Ground Connections at Rear of Cylinder Head
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Engine _____________________________________________________________________
Cylinder Head (Left Side)

Installation 1. Clean gasket surface of cylinder block with scraper if necessary. Then remove protective covering from cylinder and lifter valleys. 2. Wipe cylinder block surface clean with solvent and cloth. 3. Position new head gasket on cylinder block. Be sure gasket is aligned on cylinder block dowels. CAUTION: Install the new gasket dry. Do not use any type of sealer on the gasket. Sealer can prevent proper seating and result in coolant leaks. 4. 5. Install cylinder head with aid of helper or with hoist. Be sure head is properly seated on cylinder block dowels. Install and tighten new cylinder head bolts as follows: Apply light coat of Teflon Pipe Sealant (PST) to threads and under heads of new bolts. b. Install and tighten bolts to initial torque of 20 lb-ft (27 Nm). Follow tightening sequence (Figure 2-42). c. Tighten bolts to 50 lb-ft (68 Nm) torque evenly and in sequence shown (Figure 2-42). d. Final-tighten bolts an additional 90 (1/4-turn). Install pushrods. Verify that they are in same sequence as when removed. Also be sure heat treated (copper color) end is toward rocker arm. a.
8.
Install rocker arm and shaft assemblies. Be sure pushrods are properly seated in lifter and rocker arms. Do this before tightening shaft retainer bolts. Install shaft retainers and bolts. Tighten bolts evenly to 41 lb-ft (56 Nm) torque.
CAUTION: Stop tightening the shaft bolts if they become hard to turn before fully seated.
WATER PUMP FIRST LOWER BOLT
3 1/2 IN. (89 MM)
6.
O (TDC) MARK ON TIMING TAB
Figure 2-43: Crankshaft Indexing Position

9. Clean cylinder head and rocker cover sealing surfaces thoroughly. Then finish-clean with brake or contact cleaner and shop towels to remove cleaning residue. This is necessary to ensure proper adhesion of sealer. 10. Apply sealer to rocker arm cover (Figure 2-44). Make sealer bead 3/16 inch wide by 1/16 inch thick. Use RTVtype silicone, adhesive-sealer such as Loctite 592, or Permatex High Temp, Ultra Copper, or Ultra Blue. Allow sealer to cure slightly (skin over) before installing cover.
Figure 2-42: Cylinder Head Bolt Tightening Sequence

7. Index crankshaft and pistons for rocker arm and shaft installation as follows: a. Position breaker bar and socket on crankshaft damper bolt. Do not use starter motor to rotate crankshaft. Use socket and wrench on damper bolt only. b. Rotate crankshaft counterclockwise and align mark on torsional damper with O (TDC) mark on front cover timing tab. c. Index crankshaft by rotating it counterclockwise an additional 3-1/2 inches (89 mm). At this point, mark on damper will be roughly aligned with first lower water pump bolt (Figure 2-43).
Figure 2-44: Applying Sealer to Rocker Arm Cover

11. Align and install rocker cover. Tighten cover bolts to 16 lb-ft (22 Nm) torque.
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12. Install fuel injector lines. Tighten line fittings at pump and injector to 19 lb-ft (26 Nm) torque. 13. Install intake manifold and gaskets. Tighten manifold studs/bolts to 31 lb-ft (42 Nm) torque. Also install turbocharger, if equipped. 14. Install engine oil dipstick tube, if removed, and connect tube to rocker cover bracket. 15. Install water crossover and thermostat housing. Use new gaskets on crossover and tighten attaching bolts to 2537 lb-ft (34-50 Nm) torque. 16. Install fuel injector line clamps, washers, and nuts. Tighten nuts to 26 lb-ft (35 Nm) torque. 17. Install or connect: glow plugs fuel pump temperature sender wire (at head) ground wires/cables (at rear of head) wire harness clips and brackets water valve and bracket 18. Install A/C compressor, power steering pump, and pump mounting bracket. 19. Install serpentine belt. 20. Install air intake hose and air horn. Be sure gasket is seated on manifold before tightening air horn bolts. 21. Connect radiator hoses, inlet tube, A/C lines, and fluid cooler lines. 22. Refill engine cooling system. 23. Connect batteries. 24. Start and run engine. Bleed injectors by loosening line fittings just enough to purge air. Then tighten fittings and stop engine. 25. Check and top off engine coolant, engine oil, and transmission fluid as required. 26. Clear codes and test drive.
11. 12. 13.
14. 15. 16.
17. 18. 19.
20.
Glow plug relay and bracket Engine wire harness clips and ground wires Passenger side glow plugs and glow plug relay Remove fuel injector line clamps, washers, nuts Remove intake manifold and gaskets. Note attaching stud and bolt locations for installation reference. Disconnect passenger side fuel injector lines at pump and injectors, and remove lines. Cover injectors with duct tape to prevent dirt entry. Remove heat shield and guard. Then remove bolts/nuts attaching crossover pipe to exhaust manifold. Remove rocker arm cover. Tap cover with rubber mallet to loosen. Do not pry on cover to remove. Remove rocker arm shaft bolts and retainers. Remove arm and shaft assemblies individually. Note original position for assembly reference. Remove pushrods. Note position or rods for installation reference as they must be installed in original position. Remove cylinder head bolts. Discard bolts as they are not reusable. Remove cylinder head with aid of helper. Or use chain hoist, portable hoist, or similar device to lift and remove cylinder head. Remove cylinder head gasket. Discard gasket; it is not reusable.
CYLINDER HEAD
Cylinder Head (Right Side)

Removal
1. 2. 3. 4. 5. 6. 7. Remove front console and engine cover. Drain radiator and disconnect batteries. Remove batteries and battery tray. Remove passenger side splash shield. Remove air cleaner, inlet hose, and air horn. Remove surge tank and water valve and hoses. Remove crossover and thermostat housing, inlet tube, and radiator upper hoses as assembly. 8. Remove serpentine belt. 9. Disconnect and remove alternator, brackets, idler pulley, and tensioner. 10. Disconnect or remove: 05745159
GASKET DOWEL DOWEL
Figure 2-45: Right Side Cylinder Head Removal/ Installation

21. Refer to cylinder head cleaning and inspection information if head, valves, valve seats, springs, or seals require service. Check for warpage. If head was only removed to replace blown gasket, proceed to installation procedure. 22. Cover cylinder bores and lifter valleys with shop towels.
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Engine _____________________________________________________________________
Cylinder Head (Right Side)

Installation
1. Clean gasket surface of cylinder block with scraper if necessary. Scuff sand surface with 180 grit emery or paper to provide better surface for gasket seating. Then remove protective covering from cylinders and lifter valleys. Wipe cylinder block surface clean with solvent and cloth. Position new head gasket on cylinder block. Be sure gasket is aligned on cylinder block dowels.
2. 3.
CAUTION: Install the new gasket dry. Do not use any type of sealer on the gasket. Sealer can prevent proper seating and result in coolant leaks. 4. 5. Install cylinder head with aid of helper or with hoist. Install and tighten new cylinder head bolts as follows: a. Apply light coat of sealer, such as Loctite Pipe Sealant w/Teflon, to thread and under heads of new bolts. b. Install and tighten bolts to initial torque 20 lb-ft (27 Nm). Follow tightening sequence shown (Figure 2-42). c. Tighten bolts to 50 lb-ft (68 Nm) torque evenly and in sequence shown (Figure 2-42). d. Final-tighten bolts an additional 90 (1/4-turn). Install pushrods. Verify that they are in same sequence as when removed. Also be sure heat treated end is toward rocker arm. Index crankshaft and pistons for rocker arm and shaft installation as follows: a. Position breaker bar and socket on crankshaft damper bolt. Do not use starter motor to rotate crankshaft. Use hand tools only. b. Rotate crankshaft counterclockwise and align mark on torsional damper with O (TDC) mark on front cover timing tab (Figure 2-43). c. Index crankshaft by rotating it counterclockwise an additional 3-1/2 inches (89 mm). At this point, mark on damper will be roughly aligned with first lower water pump bolt (Figure 2-43). Install rocker arm and shaft assemblies. Be sure pushrods are properly seated in lifters and rocker arms. Do this before tightening shaft retainer bolts. Install shaft retainers and bolts. Tighten bolts evenly to 41 lb-ft (56 Nm) torque.
6.
7.
10. Apply sealer to rocker arm cover. Make sealer bead 3/16 inch wide by 1/16 inch thick. Use RTV-type silicone, adhesive-sealer such as Loctite 592, or Permatex High Temp, Ultra Copper, or Ultra Blue. Allow sealer to cure slightly (skin over) before installing cover. 11. Align and install rocker cover. Tighten cover bolts to 16 lb-ft (22 Nm) torque. 12. Install fuel injector lines. Tighten line fittings at pump and injector to 19 lb-ft (26 Nm) torque. 13. Install intake manifold and gaskets. Tighten manifold studs/bolts to 31 lb-ft (42 Nm) torque. 14. Install water crossover and thermostat housing. Use new gaskets on crossover and tighten attaching bolts to 25-37 lb-ft (34-50 Nm) torque. 15. Install or connect: Glow plugs and glow plug relay and bracket Engine harness wires, clips, and brackets Water valve bracket 16. Install and attach transmission fill tube. 17. Install heat shield and shield guard. Tighten heat shield bolts to 25 lb-ft (34 Nm) torque. 18. Install support bracket on rear of alternator and mounting bracket. Then install alternator, bracket, and tensioner as assembly. Connect alternator wires afterward. 19. Install vacuum pump. 20. Install serpentine belt. 21. Install surge tank. 22. Install air cleaner, air horn, inlet hose, and shield. 23. Assemble radiator upper hoses and tube and connect to thermostat housing. NOTE: Check condition of the O-rings on the A/C and oil cooler fittings. Replace the O-rings if cut, worn, or distorted. 24. Connect radiator upper hose, heater hoses, and surge tank hoses. 25. Refill cooling system. 26. Install passenger side splash shield. Then install battery tray and horns (if removed). 27. Install and connect batteries. 28. Top off engine oil and transmission fluid as needed. 29. Start and run engine. Bleed injectors by loosening line fittings just enough to purge any air. Then tighten fittings and stop engine. 30. Top off engine coolant, oil, and transmission fluid as required. 31. Clear codes and test drive.
8.
CAUTION: Stop tightening the shaft bolts if they become hard to turn before they are fully seated. Check for misalignment or unseated push rods. 9. Clean cylinder head and rocker cover sealing surfaces thoroughly. Then finish-clean with brake or contact cleaner and shop towels to remove residue. This is necessary to ensure proper seal adhesion.
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Engine
BODY
2-41
VALVE LIFTER REPLACEMENT

The 6.5L diesel engines are equipped with roller-type hydraulic lifters. The lifters are not repairable. A failed lifter must be replaced as an assembly. Service access to the lifters requires removal of one or both cylinder heads. Once the head is removed, the lifters can be removed with tool J29834.
ROLLER
Removal
1. 2. Remove one or both cylinder heads as needed. Refer to procedures in this section. Remove bolt attaching guide plate clamp to block and remove clamp (Figure 2-15).
LIFTER TOOL J29834 GUIDE PLATE CLAMP AND BOLT LIFTER GUIDE PLATE VALVE LIFTER PLUNGER
6-SO2-069
Figure 2-47: Lifter Inspection Points

4. Remove necessary lifters with tool J29834. Insert tool in lifter and push tool plunger downward to expand tool lugs and grip lifter. Then remove lifter with a pull and turn motion.

CYLINDER BLOCK
Figure 2-46: Valve Lifter Removal

3. Remove lifter guide plate. Use magnet and long hand held gripper tool to unseat and remove plate.
NOTE: If more than one lifter will be removed, keep the lifters in sequence of removal. It is important that original lifters be re-installed in the same bore. This ensures that the lifter and cam lobe wear-in patterns will match.
Clean each lifter with a standard parts cleaning solvent. Dry the lifter with low pressure compressed air after cleaning. Check the lifter body for scoring and wear. Then turn the lifter over and check condition of the roller (Figure 2-47). Replace the lifter if the body is worn or scored, or the roller is scuffed, chipped, loose, or the roller bearings are worn. Press the lifter plunger down with a push rod and note if the plunger is collapsed. Replace collapsed lifters; they are not salvageable.
Installation
WARNING: The following procedural step requires the use of kerosene or diesel fuel for lifter priming. Since both liquids are ammable, do not prime the lifter near sparks, or an open ame. This is essential to ensure personal safety and injury avoidance.
1. Prime lifters as follows: a. Place lifter in container deep enough to submerge lifter. Pad container bottom to avoid damaging roller. b. Fill container with clean fresh kerosene or diesel fuel.
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c.
Engine _____________________________________________________________________
2. 3.
Stroke lifter plunger with pushrod to pump fluid through lifter. d. Remove lifter from container and wipe it dry with lint free cloth or paper. e. Re-prime lifter with clean engine oil. Apply cam lube to lifter roller and bearings. Install lifters as follows: a. b. Insert lifter in bore with tool J29834. Align lifter and install guide plate on lifters. Be sure lifters and plates are aligned. c. Install guide plate clamp and bolt. Tighten bolt to 19 lb-ft (26 Nm) torque. Install cylinder head(s) as described in this section.
7.
and reinstall rod cap. Tighten new cap nuts to 44-52 lb-ft (60-71 Nm) torque. Replace main bearings as follows: a. Loosen bearing cap bolts at adjacent bearings. b. Remove bearing cap bolts at first bearing to be replaced, and remove cap and bearing lower half (mark cap for reference before removal). c.
4.
CRANKSHAFT BEARING
Replacement In-Vehicle
The crankshaft main and rod bearings can be replaced without having to remove and completely disassemble the engine. The rod bearings only require that the piston be at or near bottom dead center for access. The main bearings are rotated out of the bearing saddles with a 1/8 in. cotter pin or with equivalent. Procedure is as follows: 1. Disconnect battery cables at batteries. 2. Remove skid plate/underbody protector, if equipped. 3. Drain engine oil from oil pan. 4. Remove oil pan. 5. Remove oil pump. 6. Replace rod bearings as follows: a. Rotate crankshaft in counterclockwise direction until connecting rod cap attaching nuts are accessible. b. Remove rod cap nuts. Note position of rod cap for installation reference. c. Remove rod cap and lower half of bearing. Then push piston upward slightly and remove upper half of bearing. NOTE: Connecting rod bearings are select fit parts. Record the color code markings on each bearing half for parts ordering and installation reference. Also note if cap was marked with OS code which indicates oversize bearings are required. d. e. Clean connecting rod and crankshaft bearing surfaces and dry with lint free shop towels. Install bearing halves in rod cap and in rod. Be sure bearing locating tangs are seated in cap and rod notches. Check bearing clearance with plastigauge. Clearance should be 0.0017-0.0039 in. (0.045-0.100 mm). Then remove rod cap, clean plastigauge off surfaces, lubricate crankshaft and bearing surfaces with engine oil
Insert tool J8080 into oil hole in crankshaft bearing journal. Position T-end of tool against bearing upper half. Rotate crankshaft counterclockwise until tool pushes upper half of main bearing out of bearing saddle in block (Figure 2-48). d. Clean main cap, crankshaft journal, and bearing saddle in block with solvent. Refer to overhaul section for bearing specifications and select fitting. e. Start plain end of new upper bearing half into place by hand. Then push bearing into position with tool J8080. Be sure bearing tang is seated in notch in bearing saddle of block (Figure 2-48). f. Check bearing clearance with plastigauge. Clearance should be 0.0017-0.003 in. (0.045-0.083 mm) for bearings one through four and 0.002-0.0036 in. (0.055-0.093 mm). Remove main cap, clean plastigauge off surfaces, lubricate bearing halves and crank journal with engine oil. Tighten new main bearing cap bolts as follows: inner bolts to 111 lb-ft (150 Nm) outer bolts to 100 lb-ft (136 Nm) 8. Install oil pump. 9. Apply RTV-type sealer to oil pan sealing surfaces and install pan. Tighten all but two rear pan bolts to 89 lb-in. (10 Nm) torque. Tighten two rear pan bolts to 17 lb-ft (23 Nm) torque. 10. Install new oil filter and refill with engine oil. Use SAE 10W-30 for temperatures under 40F and 15W-40 for temperatures above that figure. 11. Connect battery cable and reinstall skidplate. 12. Test run. Test for leaks.
f.
Section 2 Engine
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Engine
2-43
INTAKE MANIFOLD
BEARING TANG CRANKSHAFT MAIN BEARING JOURNAL MAIN BEARING UPPER HALF (IN BLOCK)
Service
A three-piece intake manifold is used on turbocharged diesel engines (Figure 2-49). It consists of left and right manifold halves and a center manifold. The center manifold joins the other manifold halves to the turbocharger. Gaskets and an O-ring seal are required at the manifold-to-cylinder head and manifold joints. A single O-ring is used to seal the center manifold-to-turbocharger flange joint.
Removal
1. 2. Remove turbocharger. Refer to procedure in this section under Turbocharger Service and Diagnosis. Remove center manifold bolts. Remove manifold from intake manifold halves and turbocharger. Discard manifold gaskets and O-ring seal. Remove brackets/clamps securing wire harnesses to rocker covers and intake manifold halves. Remove bolts/nuts/studs attaching intake manifold halves to cylinder heads. Tap manifolds with rawhide mallet to loosen and remove. Discard gaskets after removal.
3.
TOOL J8080 INSERTED IN OIL HOLE
4.
Installation
1. Clean manifold and cylinder head gasket surfaces. Apply light coat of Permatex High Tack, or #2 sealer to gaskets and position gaskets on heads. Install left and right manifold halves. Tighten attaching bolts and studs to 25-37 lb-ft (34-50 Nm) torque. Install turbocharger and center manifold as described in this section.
Figure 2-48: Removing/Installing Main Bearing Upper Half with Cotter Pin or Equivalent
2. 3.
CENTER MANIFOLD
RIGHT SIDE MANIFOLD (LEFT SIDE SIMILAR)
GASKET GASKET O-RING GASKET LEFT/RIGHT MANIFOLDS
Figure 2-49: Intake Manifold Attachment
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EXHAUST MANIFOLDS
Removal
1. Remove consoles and engine cover for access to turbocharger inlet pipes. For information regarding inlet pipes, refer to Section 3. Loosen flange clamps that secure left inlet pipe to exhaust manifold and turbocharger. On right side, loosen flange clamp and remove nuts that attach inlet pipe to exhaust manifold. Then disconnect pipe and move aside for working clearance. Remove heat shield attaching nuts/bolts and remove shield, if equipped. Disconnect glow plug wires. Remove manifold attaching bolts and remove manifold (Figure 2-50). Remove and discard manifold gasket. 7. Clean old gasket material off cylinder head and manifold with scraper and wire brush.
Installation
1. 2. 3. 4. Place new gasket on manifold, position manifold on cylinder head, and install 1-2 bolts to hold manifold in place. Install heat shield and remaining manifold bolts. Tighten bolts to 18-25 lb-ft (24-34 Nm) torque. Connect glow plug wires. Install flange clamps and turbocharger inlet pipes. If installing right side manifold, tighten inlet pipe-tomanifold attaching nuts to 37 lb-ft (50 Nm) torque. Tighten exhaust flange clamps to 71 lb-in (8 Nm) torque. Install turbocharger heat shields. Install engine cover and consoles.
2.
3. 4. 5. 6.
5. 6.
DRIVER SIDE MANIFOLD
PASSENGER SIDE MANIFOLD
Figure 2-50: Exhaust Manifold Attachment
DIESEL VACUUM PUMP SERVICE

A vacuum pump is used on all diesel models. The pump is located on the passenger side of the engine just below the alternator (Figure 2-51). This supplies vacuum for wastegate actuator operation on turbo models and for A/C and heater operation on diesel models. The pump is belt driven and has a removable pulley. The pump is tested with a standard vacuum gauge. Output should be a minimum of 20-21 inches vacuum. Pump removal only requires loosening the serpentine belt, disconnecting the vacuum output hose, and removing the pump attaching bolts.
ALTERNATOR
SERPENTINE BELT
PUMP PULLEY
VACUUM PUMP
Figure 2-51: Vacuum Pump Location
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Engine
2-45
OVERHAUL SERVICE INFORMATION

Anaerobic and RTV type sealers are both used during engine re-assembly. Anaerobic sealer such as Loctite gasket maker (515 or 510) is used on the timing chain cover. RTV sealers such as Permatex Ultra Copper, Ultra Blue, or Loctite 599, are used on the oil pan and rocker covers. Thread locking chemicals such as Loctite 242 are specified wherever necessary. In addition, Permatex dielectric compound can be used on electrical connections to prevent corrosion. Do not use substitute fasteners unless they are of the correct size and hardness grade. When replacement bolts/nuts are required, it is recommended that parts catalog items be used. This ensures that correct grade fasteners are used.
17. Remove bolts attaching radiator and shroud assembly to frame and brackets. Then (with aid of helper), remove radiator, shroud, condenser, and oil coolers as an assembly Figure 2-53.
.
ENGINE REMOVAL
1. Remove front console attaching screws. Move console rearward and disconnect console harness connector and radio harness. Then remove console. Disconnect Digital Ratio Adapter and Keyless Entry Module. Remove inner engine cover. Remove hood with aid of helper as follows: Unlatch and lower brushguard, if equipped. Unlatch and raise hood. Remove clip that attaches hood harness to driver side of frame. Disconnect hood harness from cowl top harness. Remove bolts attaching prop and bracket to driver side air lift bracket. Do not remove prop rod from hood. Leave rod attached. Tape rod to hood if desired. Remove hood hinge pins. Remove hood with aid of helper. Disconnect and remove batteries and cables. Remove battery tray. Remove driver and passenger side splash shields. Drain engine coolant and engine oil. Discharge A/C system with recovery machine set in recovery mode. Disconnect radiator upper and lower hoses at the radiator. Drain fluid in power steering pump using a suction gun. Disconnect oil lines at transmission and power steering coolers. Cap lines to prevent dirt entry Figure 2-52. Disconnect engine cooler lines for engine oil cooler. Cap lines to prevent dirt entry. Disconnect A/C lines at condenser. Cap or tape lines and fittings to prevent dirt entry. Remove rubber/sponge pads from air lift brackets. Remove return hoses from power steering pump. Remove surge tank hose from radiator.
COVER OPEN ENDS OF ALL COOLER LINES WITH DUCT TAPE
2. 3.
Figure 2-52: Covering Open Ends of Oil Cooler Lines
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
6-S02-009
Figure 2-53: Radiator, Cooler, Fan Shroud Removal/Installation

18. Remove air horn from turbocharger and air cleaner hose (Figure 2-54). 19. Disconnect radiator hose at thermostat housing and at radiator upper and lower outlets. 20. Remove the engine oil dipstick and tube 21. Loosen tensioner and remove serpentine belt. 22. Using the spanner wrench and ratchet adapter, remove cooling fan and clutch from water pump.
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23. Disconnect A/C hoses at compressor. Move hoses aside for working clearance. Cap open ends to prevent dirt entry (Figure 2-55).
ALTERNATOR/ IDLER/TENSIONER AND BRACKET ASSEMBLY
SUPPORT BRACKET
AIR HORN
AIR CLEANER HOSE
Figure 2-56: Alternator, Pulleys, and Bracket Removal/Installation

27. Remove brackets/retainers that secure wire harnesses to intake manifold and heads. 28. Disconnect AMG wiring harness from starter, glow plug controller and cowl top harness, then remove. 29. Disconnect wires at all glow plugs. 30. Remove fuel pump from retaining clamp. 31. Disconnect fuel hose from injector pump line at underside of manifold. Cap all open hose ends. 32. Disconnect injection pump and engine harness connectors. Move wire harnesses aside for removal clearance. 33. Disconnect glow plug relay wires and cables. 34. Disconnect exhaust pipe at the turbocharger. 35. Remove any remaining brackets and clips securing wire harnesses to engine. 36. Disconnect oil lines from power steering pump to hydro boost at hydro boost housing. Cap lines and hydro boost outlets to prevent dirt entry. Move lines aside for clearance. 37. Remove turbocharger heat shield and disconnect vacuum actuator hose. 38. Remove air intake manifold crossover. Tape openings to prevent dirt entry. 39. Remove intake manifold runners.
9-S03-002
Figure 2-54: Air Horn and Hose Removal/Installation

SUCTION/ DISCHARGE HOSE ASSEMBLY
SEAL WASHER (2)
COMPRESSOR
Figure 2-55: Suction/Discharge Hose Assembly Mounting

24. Disconnect bypass hose at water crossover. 25. Disconnect heater hoses at water crossover and water pump. 26. Disconnect and remove generator, belt tensioner, idler pulley and bracket as assembly (Figure 2-56).
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Engine
2-47
40. Working under vehicle, loosen, disconnect, or remove following: Remove skid plate. Remove starter and shield (with aid of helper). Remove exhaust pipe. Also loosen and move heat shield aside. Remove converter housing access cover and gasket. Remove oil filter and disconnect lines to oil cooler. Remove transmission fill tube Figure 2-58. Remove torque converter attaching bolts Figure 2-57. Remove nuts attaching engine mount insulators to frame brackets. 41. Remove turbocharger. 42. Support transmission with floor jack. Position wood blocks between transmission and jack saddle.
43. Remove bolts/studs attaching transmission to engine block. 44. Attach lifting sling to engine (Figure 2-59).
FRONT OF SLING LIFTING BRACKET
LIFTING SLING J33139
RIGHT SIDE CYLINDER HEAD (FRONT)
PIN
CONVERTER FLYWHEEL BOLT
TORQUE CONVERTER LEFT SIDE CYLINDER HEAD LIFTING BRACKET
Figure 2-57: Converter Bolt Removal/Installation
TRANSMISSION FILL/DIPSTICK TUBE
Figure 2-59: Lifting Bracket to Cylinder Head Attachment

45. Raise engine with hoist and remove it from engine bay. CAUTION: Make sure all electrical wires, harnesses, and fluid lines are disconnected and clear of engine assembly. Do this before removal to avoid damage. 46. Mount engine on heavy duty engine stand or cradle. Engine stand should have minimum capacity of 1500 lb (680 kg).
SEAL TRANSMISSION
Figure 2-58: Transmission Dipstick Tube

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Engine _____________________________________________________________________
LIFTING SLING AND BRACKET J33139 PIN
ENGINE INSTALLATION
1. If new engine is being installed, transfer mounting brackets and insulators, generator, power steering pump, A/C compressor, drive plate (ywheel), turbocharger, and necessary mounting brackets, shields, damper pulleys, sensors and ttings, from old to new engine. Attach lifting bracket to engine. Attach hoist to lifting bracket. Raise engine and guide it into engine bay with aid of helper. Align and seat engine on transmission. Be sure converter pilot hub is seated in crankshaft and that transmission is seated on engine block dowels. Install 2-3 transmission attaching bolts (finger tight) to hold engine and transmission in place. Align and seat engine mounting bracket insulators on frame brackets. Be sure insulator studs are fully seated in frame brackets before proceeding. Apply Loctite 242 to transmission, converter, and engine mount nuts/bolts. Then install and tighten nuts and bolts to following torque: Converter bolts to 32 lb-ft (43 Nm) Transmission bolts to 35 lb-ft (47 Nm) Insulator stud nuts to 90 lb-ft (122 Nm) Install converter housing access cover. Tighten cover attaching screws to 60 lb-in. (7 Nm) torque. Connect engine oil cooler lines to fittings at rear of engine block. Install turbocharger. Install starter motor and shield with aid of helper. Tighten starter mounting bolts to 30-40 lb-ft (41-54 Nm) torque. Do not connect cable and solenoid wire to starter at this time. Install exhaust pipe and heat shield, if removed and connect exhaust pipe to turbocharger. Tighten attaching nuts to 37 lb-ft (50 Nm) torque. Install new oil filter. Install intake manifolds and crossover. Install/connect following: Wire harness brackets and clamps Injection pump, engine harness, sensor wires Turbocharger actuator vacuum hose Torbocharger heat shield Transmission and engine dipstick tubes AMG engine harness Install fuel pump in clamp at driver side of engine bay. Connect fuel lines to injection pump. Install CDR valve and hose if removed. Route hydraulic lines from power steering pump to hydroboost unit and connect lines. Be sure lines are clear of hot or rotating components and are not kinked at any spot.
2. 3. 4.
5.
6.
LEFT CYLINDER HEAD
7-S02-015
Figure 2-60: Engine Mounted on Repair Stand
7. 8. 9. 10.
11.
12. 13. 14.
15. 16. 17. 18.
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Engine
2-49
19. Remove protective tape from A/C suction/discharge hose adapter and connect it to compressor. Install new seal washers.
HOSE ADAPTER SEAL WASHERS COMPRESSOR PORTS
36. Install battery tray and batteries. Connect positive and negative cables to batteries. 37. Install seals and cover plates on air lift brackets. Notched side of seals face engine. 38. Refill engine cooling system, refill engine crankcase with recommended oil, and top off transmission and power steering fluids. 39. Evacuate A/C system for 30 minutes, and recharge. 40. Leakcheck A/C system. 41. Start and run engine. Bleed injectors at line fittings if necessary. Then stop engine, recheck coolant and lubricant levels, and add as necessary. 42. Bleed cooling system with air bleeds on engine and radiator. 43. Test drive vehicle and check for leaks or vibrations.
Figure 2-61: Suction/Discharge Hose Connection

20. Connect glow relay cable and wires. 21. Position support on back of alternator. Then install generator, mounting bracket, idler pulley, support, and tensioner assembly. 22. Position remaining cables for battery installation. 23. Connect heater hoses to water pump and water crossover. Mount idler pulley on generator bracket. 24. Install fan and clutch assembly. 25. Install serpentine belt. 26. Connect air inlet hose to turbocharger. 27. Attach radiator upper hoses and tube to thermostat housing. 28. Connect battery positive cable and solenoid wire to starter motor. 29. Position radiator, shroud, condenser, and oil cooler assembly on frame and between air lift brackets, with aid of helper. Then secure assembly and supports to frame and air lift brackets. Tighten support bolts to 26 lb-ft (35 Nm) torque. Tighten frame mount bracket bolt to 30 lb-ft (41 Nm) torque. NOTE: Verify that fan-to-shroud clearance is at least 1/4 inch (3.18 mm) at all points around shroud before proceeding. Loosen bolts and adjust position if necessary. 30. 31. 32. 33. 34. Connect radiator upper and lower hoses. Connect surge tank hose to radiator. Install return lines onto power steering pump. Connect power steering pump return lines to oil cooler. Remove protective wrapping or caps and connect hoses to A/C condenser and oil coolers. Use new O-rings on cooler and A/C hoses (Figure 2-61). 35. Install passenger and driver side splash shields.
ENGINE DISASSEMBLY Serpentine Belt Removal

1. 2. Rotate belt tensioner counterclockwise with 1/2 in. drive breaker bar. Slide belt off tensioner pulley and remove belt.
CLUTCH WRENCH FAN
SPANNER
PUMP WATER PULLEY PUMP
PULLEY BOLT (4) CRANKSHAFT PULLEY

7-S02-017.2
Figure 2-62: Fan and Pulley Removal
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Fan and Pulley Removal

1. 2. 3. 4. 5. 6. 7. 8. Insert spanner J41240-1 in holes in water pump pulley (Figure 2-62). Use spanner to hold water pump shaft and wrench J 41240-5A to loosen nut securing fan clutch to water pump. Remove bolts attaching fan to fan clutch. Remove fan and clutch from water pump. Remove crankshaft pulley attaching bolts and remove pulley (Figure 2-62). Remove torsional damper bolt with socket and impact wrench. Retain damper bolt and washer. Loosen torsional damper with tool J23523-F (Figure 2-63). Remove damper and woodruff keys from crankshaft.
ALTERNATOR OIL FILLER NECK
REAR SUPPORT BRACKET MOUNTING BRACKET AND PULLEYS
DAMPER TOOL J23523-F
Figure 2-65: Alternator and Bracket Removal
A/C Compressor Removal

1. 2. Remove A/C compressor braces. Remove bolts/nuts attaching compressor to mounting bracket and remove compressor (Figure 2-66).
Figure 2-63: Torsional Damper Removal

A/C COMPRESSOR DAMPER KEY
BOLT AND WASHER
CRANKSHAFT
Figure 2-64: Torsional Damper Attachment
Alternator and Bracket Removal

1. 2. 3. Remove alternator mounting bolts and remove alternator. Remove alternator mounting and support bracket bolts and remove both brackets (Figure 2-65). Remove filler neck strap bolts and remove filler neck if desired (Figure 2-65).
ENGINE BRACKET
Figure 2-66: A/C Compressor Removal
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Engine
2-51
Power Steering Pump and Bracket Removal

1. Remove bolts/nuts attaching pump mounting bracket to block and cylinder head and remove pump and bracket as assembly. If pump requires service, remove pump attaching bolts and remove pump from bracket (Figure 2-67).
2.
MOUNTING BRACKET
PUMP PULLEY
POWER STEERING PUMP
SUPPORT BRACKET
Figure 2-67: Power Steering Pump and Bracket Removal.
Exhaust Manifold Removal

1. 2. 3. 4. 5. 6. Loosen turbocharger left side inlet pipe ange clamps. Remove left side inlet pipe. Remove left side manifold attaching bolts and remove manifold and gasket. Discard gasket (Figure 2-68). Loosen turbocharger right side inlet pipe flange clamps. Remove right side manifold bolts and remove manifold and gasket. Discard gasket (Figure 2-69). Remove inlet tube.
MANIFOLD BOLT (TYPICAL) PIPE CLAMP PASSENGER SIDE EXHAUST MANIFOLD
Figure 2-69: Right Side Exhaust Manifold Removal.
SHIELD
DRIVER SIDE EXHAUST MANIFOLD
Figure 2-68: Left Side Exhaust Manifold Removal

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Intake Manifold Removal

1. 2. 3. Remove bolts and studs attaching each manifold half to cylinder head. Tap each manifold half with rawhide mallet to loosen it. Lift and remove manifold halves and gaskets (Figures 2-70 and 2-71). Discard gaskets.
INTAKE MANIFOLD HALF GASKET O-RING
CENTER MANIFOLD
GASKET GASKET
TURBOCHARGER
Figure 2-72: Center Manifold
Water Crossover Removal

1. Loosen clamp and disconnect bypass hose at water crossover (Figures 2-73 and 2-74).
DUAL THERMOSTAT COVER WATER CROSSOVER CROSSING
Figure 2-70: Left Side Intake Manifolds Removal/ Installation

INTAKE MANIFOLD HALF
GASKET
Figure 2-73: Water Crossover Location

2. 3.
.
Remove crossover attaching bolts/studs and remove crossover. Discard crossover gaskets (Figure 2-74). Remove thermostat housing and thermostats if required. Note that turbo diesel has two thermostats (Figure 2-74).
THERMOSTAT HOUSING TWIN THERMOSTATS WATER GASKETS CROSSOVER
Figure 2-71: Right Side Intake Manifold Removal/Installation
Turbocharger and Center Manifold Removal

1. 2. 3. 4. 5. Remove turbocharger inlet and outlet pipes. Remove bolts attaching turbocharger to engine. Remove bolts attaching vacuum actuator to turbocharger and engine block. Remove turbocharger and actuator. Remove center manifold and gaskets (Figure 2-72).
Figure 2-74: Water Crossover Mounting
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Fuel Injection Line Removal

NOTE: Mark or tag fuel injection lines for installation reference. 1. 2. 3. Disconnect lines at injector nozzles (Figure 2-75). Remove clamp and boot from lines at injection pump if equipped. Disconnect and remove injection lines.
INJECTION PUMP INJECTION LINES
Fuel Supply and Return Line Removal

1. 2. 3. 4. 5. Loosen clamp and remove fuel supply hose from fuel injection pump (Figure 2-76). Loosen clamps and remove fuel return hose from injection pump and return line (Figure 2-76). Remove fuel return line clamps at right and left valve covers. Loosen clamps securing fuel return hoses to fuel injectors. Remove fuel return jumper hoses and plugs at fuel injectors.
CLAMP
Figure 2-75: Fuel Injection Line Removal
FUEL INJECTION FUEL PUMP SUPPLY HOSE PLUG FUEL RETURN HOSE CLAMP FUEL RETURN HOSE FUEL RETURN LINE
VALVE COVER STUD FUEL RETURN HOSE FUEL RETURN HOSE
Figure 2-76: Fuel Supply and Return Line Routing
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Rocker Arm Cover Removal

1. 2. 3. 4.
.
Fuel Injector Removal

1. 2. Remove fuel return hoses and clamps from injectors (Figure 2-79). Remove fuel injectors and gaskets (Figure 2-79).
FUEL INJECTOR
Remove injection line support bracket from studs (Figure 2-77). Remove cover attaching bolts and studs. Remove rocker arm cover. Tap cover with rubber mallet and twist it to remove. Do not pry on cover. Repeat procedure for opposite cover.
INJECTION LINE SUPPORT BRACKET ROCKER ARM COVER
GASKET
RETURN HOSES
STUD HOSE PLUG
CYLINDER HEAD
S02-084
Figure 2-77: Rocker Arm Cover Removal
Figure 2-79: Fuel Injector Removal
Rocker Arm Shaft and Pushrod Removal

1. 2. 3. 4. 5. Remove rocker arm retainers and bolts (Figure 2-78). Mark or tag position of each rocker arm and shaft set before removal. Remove rocker arm and shaft sets from cylinder head. Remove pushrods. Keep pushrods in removal order. Do not intermix them. Repeat procedure for opposite rocker sets.
PUSHROD RETAINER AND BOLT ROCKER ARM AND SHAFT SET (2 PER SIDE)
Glow Plug Removal

Remove glow plugs from cylinder heads (Figure 2-80). Discard any damaged plugs.
GLOW PLUG
Figure 2-80: Glow Plug Removal Figure 2-78: Rocker Arm and Shaft Removal
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Cylinder Head Removal

1. 2. 3. 4. Remove cylinder head bolts (Figure 2-81). Remove cylinder head from block. Remove cylinder head gasket. Discard gasket afterward. Repeat procedure for opposite cylinder head.
CYLINDER HEAD GUIDE PLATES CLAMP PLATE LIFTER REMOVER J29834
VALVE LIFTER
HEAD BOLTS (17 PER HEAD)
GASKET
Figure 2-82: Valve Lifters

ENGINE BLOCK
Figure 2-81: Cylinder Head and Gasket Removal
Valve Lifter Removal

1. 2. Remove lifter clamp plates from cylinder block (Figure 2-82). Remove lifter guide plates from block.
NOTE: Mark or tag lifters for installation reference. Keep them in order of removal. 3. Remove lifters from block with tool J29834 (Figure 2-82).
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Water Pump/Adapter Plate/Oil Fill Tube Removal

1. Remove oil ll tube from adapter plate (Figure 2-83).
OIL FILL TUBE ADAPTER PLATE
GASKET WATER PUMP
ADAPTER PLATE
WATER PUMP
Figure 2-85: Water Pump, Adapter Plate, and Gasket Disassembly
Fuel Injection Pump Removal

1. Remove electrical connections, fuel inlet and return lines from pump. Remove driven gear attaching bolts and remove gear from fuel injection pump (Figure 2-86). Remove injection pump attaching nuts and washers from front cover studs. Remove fuel injection pump and gasket from timing gear cover. Discard gasket.
Figure 2-83: Oil Fill Tube Removal

2. Remove water pump and adapter plate from timing gear cover (Figure 2-84). Note location of attaching studs and bolts for installation reference.
2. 3. 4.
WATER PUMP AND ADAPTER PLATE ASSEMBLY
DRIVEN GEAR
FRONT COVER STUD ELECTRONIC INJECTION PUMP
GASKET
Figure 2-84: Water Pump and Adapter Plate Removal

6-S02-187.1
3. 4.
Remove water pump, attaching bolts, and separate pump from adapter plate (Figure 2-85). Remove and discard gasket.
Figure 2-86: Fuel Injection Pump and Driven Gear Removal
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Front Cover Removal

1. 2. 3. 4. 5. Remove bafe from front cover (Figure 2-87). Remove bolts attaching front cover to oil pan. Remove bolts attaching front cover to engine block. Remove front cover. Use mallet to loosen cover. Do not pry cover loose. Remove oil seal from cover.
CYLINDER BLOCK BAFFLE INJECTION PUMP DRIVE GEAR DRIVE KEYS CRANKSHAFT
TIMING CHAIN CAMSHAFT SPROCKET CRANKSHAFT SPROCKET CAMSHAFT
Figure 2-88: Timing Chain, Drive Sprocket, Drive Gear Removal

COVER OIL SEAL FRONT COVER OIL PAN
5.
Remove drive keys from camshaft and crankshaft.
Figure 2-87: Front Cover and Baffle Removal
Timing Chain, Drive Sprockets, Drive Gear Removal

1. 2. Measure timing chain deection. Deection must not exceed 0.810 in. (21 mm). Use dial indicator J8001 (Figure 2-89). Measure camshaft end play. End play should not exceed 0.012 in. (0.3 mm). If end play exceeds 0.012 in. (0.3 mm), camshaft sprocket, thrust plate, or spacer is worn and will have to be replaced. Remove injection pump drive gear bolt and remove drive gear from camshaft. Remove crankshaft sprocket, camshaft sprocket, and timing chain as assembly (Figure 2-88).
3. 4.
DIAL INDICATOR J8001
CHAIN
Figure 2-89: Measuring Timing Chain Deflection
Oil Filter, Adapter, and Oil Pressure Sending Unit Removal

1. 2. 3. Remove oil lter from adapter (Figure 2-89). Discard oil lter. Remove adapter bolt, washer, seals and adapter. Unplug electrical connector and remove oil pressure sending unit from engine valley (Figure 2-91).
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STUDS DRAINPLUG GASKET SEAL
SEAL ADAPTER SEALS WASHER BOLT OIL FILTER OIL PAN
Figure 2-92: Oil Pan Removal
Figure 2-90: Oil Filter and Adapter Removal
Oil Pump and Drive Removal

1. 2. 3. 4. 5. 6. 7. Remove nut from pump mounting stud (Figure 2-93). Loosen bracket clamp screw and rotate bracket off mounting stud. Remove pump mounting stud. Lift and remove pump and pump shaft. Remove oil pump drive clamp. Lift and remove oil pump drive from block (Figure 2-94). Remove and discard pump drive gasket.
MOUNTING BOLT OIL PUMP SHAFT RETAINER
OIL PRESSURE SENDING UNIT
PUMP DRIVE SHAFT
Figure 2-91: Oil Pressure Sending Unit Location
Oil Pan Removal

1. 2. 3. 4. Drain oil from pan if not previously done. Remove pan bolts. Tap pan with rubber mallet to loosen. Then remove pan. Remove pan rear seal (Figure 2-92). Discard seal.
Figure 2-93: Oil Pump Removal/Installation
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CLAMP
OIL PUMP DRIVE
CYLINDER BLOCK THRUST PLATE CAMSHAFT
GASKET
SPACER
Figure 2-95: Camshaft Removal
Piston and Connecting Rod Removal

1. 2. 3. 4. Remove ridge at top of each cylinder bore with ridge reamer J24270. Remove shavings - chips afterward. Paint mark pistons for assembly reference. Mark connecting rod caps with punch, if caps do not have factory marks. Remove each piston - connecting rod assembly as follows (Figure 2-96): a. Remove number one piston connecting rod cap nuts. b. Remove rod cap and bearing half. Retain bearing for select fit reference. c. Slide lengths of appropriate size rubber hose over
Figure 2-94: Oil Pump Drive Removal
Camshaft Removal
1. Remove thrust plate and spacer (Figure 2-95).
CAUTION: Support camshaft during removal to avoid damaging bearings. 2. Remove camshaft from cylinder block.
CONNECTING ROD ROD BOLT CRANKSHAFT BEARING BEARING
NUTS ROD CAP PISTON ROD CAP
Figure 2-96: Piston and Connecting Rod Removal
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Flywheel Removal
1. 2. 3. Remove six capscrews and ywheel from crankshaft (Figure 2-97). Remove flywheel attaching bolts with impact wrench and suitable size socket. Work flywheel off crankshaft flange with rocking motion.
FLYWHEEL NO. 4 NO. 5 (REAR MAIN) CAP CAP REAR MAIN OIL SEAL NO. 3 (THRUST) NO. 2 CAP CAP NO.1 (FRONT) CAP
BEARING INSERTS
CRANKSHAFT FLANGE
Figure 2-97: Flywheel Removal
Crankshaft and Main Bearings Removal

1. Inspect main bearing caps. Note if caps have factory I.D. markings on them. However, if caps do not have factory marks, it will be necessary to mark each cap with a center punch, or scriber. Main caps must be reinstalled in same location and direction, to maintain bore alignment for crankshaft journals (Figure 2-98). Remove rear main oil seal. Remove main bearing cap bolts. Discard bolts. Tap main bearing caps with rawhide mallet to loosen. Then lift and remove caps. Keep them in order of removal (Figure 2-99). Lift crankshaft out of bearing saddles in block. Place crankshaft on bench for cleaning and inspection. Remove main bearing upper halves from block. Keep bearing halves for inspection and select fit reference.
MAIN BEARING CAPS
BEARING INSERTS
CRANKSHAFT
2. 3. 4.
Figure 2-99: Crankshaft and Bearing Removal
CYLINDER BLOCK SERVICE

Cleaning
The block can be cleaned with standard parts cleaning equipment. However, if the crankcase and bores are heavily coated with varnish, gum, carbon, sludge, or rust deposits in the coolant passages, hot tanking will be necessary. Clean out all oil galleys and water passages with wire brushes designed for this purpose.
5. 6.
CAP LOCATION AND I.D. MARKS
CAP BOLTS (4 EACH)
WARNING: The cam bearings (Figure 2-100) must be replaced if the block is hot tanked. The caustic solution used for this type of cleaning, will etch and weaken bearing surfaces. The expansion plugs and oil lter pressure regulating valve must also be removed before hot tank cleaning.
Coat the block with a light solvent after cleaning to prevent rust formation. Useful solvents are available from LPS Corp., Solder Seal, WD-40 and similar firms.
Figure 2-98: Main Bearing Cap I.D. Marks
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NOTE: Be sure to inspect the piston cooling oil tubes in turbo diesel blocks. Verify that the tubes are clear (Figure 2-101).
CAM BEARING AND BORE LOCATIONS #5 #4 #3 #2 #1
Inspection
Check all of the block surfaces for nicks, scratches, cracks, damaged threads, or evidence of porosity at any point. Minor nicks and scratches can be smoothed with a fine tooth file or 180 grit emery. Damaged threads can be either chased, or repaired with Helicoil stainless steel thread inserts. Replace the block if cracked, or if porous spots are evident. Light discoloration of gasket surfaces and cylinder bores is normal and not a cause for replacement. However, evidence of severe overheating and heat checking will require closer attention to dimensional checks. Check condition of the expansion plugs (Figure 2-102), and camshaft plug. Replace the plugs if corroded, rusted, loose, or coolant leakage is evident. Refer to the procedure in this section if plug replacement is required.
SMALL EXPANSION PLUG
Figure 2-100: Camshaft Bearing Locations
FEED ORIFICE
FEED ORIFICE
PIPE PLUG
EXPANSION PLUGS
Figure 2-102: Cylinder Block Expansion Plug Locations

Check the cam bearings. Locations in the block are shown (Figure 2-100). It is not necessary to replace the bearings if they only have a burnished, or polished appearance, and wear is very minimal. However, replace all of the bearings if one or more are scored, flaking, distorted, etched, pitted, loose, or misaligned. Also replace the bearings if the block was hot tank cleaned with the bearings in place. Refer to the bearing replacement procedure in this section. On turbocharged engines, check the oil feed holes at the rear of the block near the oil pump drive. Make sure the feed holes are clear and not plugged. This is important as any restrictions will result in turbocharger failure. Remove and inspect the oil pressure regulator and safety valves. Replace the regulator valve plug; do not reuse it. Replace the two valves if seized, binding, or plugged. Do not try to salvage the valves.
OIL SPRAY TUBES
Figure 2-101: Piston Oil Cooling Feed and Spray Orifice Locations
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Check the pipe plugs at the sides and front of the block (Figure 2-103). Replace any plugs that are loose or leaking. Coat replacement plug threads with Permatex #2, or high temp silicone sealant before installation.
OIL SAFETY VALVE BLOCK PLUG PLUG OIL PRESSURE REGULATOR VALVE
PIPE PLUGS
Check condition of the cylinder head and front cover dowel pins (Figure 2-104). Remove and replace any pins that are loose. Inspect the main bearing saddles, bearing caps, front cover surface, block webs, and pan rails (Figure 2-105). Replace the block if cracks, severe scoring, or distortion is evident at any point. Measure degree of wear and taper in each cylinder bore with bore gauge J8087 (Figure 2-106). a. Refer to the Service Piston and Cylinder Bore Specifications data at the end of this section for bore dimensions. b. Center the bore gauge in the cylinder and zero the dial indicator (Figure 2-106). c. Work the gauge slowly up and down the cylinder from top to bottom. Take measurements at cylinder axis points A and B (Figure 2-107). Note that most wear occurs in the top 2 1/2 in. (63.5 mm) of the cylinder.
BEARING CAP PAN RAIL
Figure 2-103: Cylinder Block Valve and Plug Locations
Cylinder Bore and Piston Measurement

Check surface flatness of the cylinder block deck with a straightedge and feeler gauge (Figure 2-104). Deck surface flatness must not vary by more than 0.002 in. (0.05 mm) in any six inch (15 cm) length, or 0.006 in. (0.15 mm) overall. Replace the cylinder block if deck flatness is not within stated limits. Do not attempt to salvage a block by machining the deck surface. This practice will result in valve-to-piston contact.
WEB STRAIGHTEDGE DOWEL PIN BEARING SADDLES
FRONT COVER SURFACES CAMSHAFT THRUST PLATE SURFACE
Figure 2-105: Rail, Web, Bearing Inspection Points

NOTE: Cylinder number 7 and 8 require an additional 0.0005 in. (0.013 mm) for piston clearance. Take this into account when checking bore wear. d.
DOWEL PIN CYLINDER BLOCK DECK
e.
Maximum allowable service wear and taper is 0.005 in. (0.013 mm). Rebore the cylinder and replace the pistons if wear and taper exceed allowable service limits.
Figure 2-104: Checking Deck Flatness
NOTE: Replace the cylinder block if bore diameter exceeds 4.075 in. (103.521 mm) on cylinder 1-6 and 4.076 in. (103.534 mm) on cylinders 7 and 8.
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BORE GAUGE J8087
Figure 2-106: Measuring Cylinder Taper and Wear with Bore Gauge
Measure piston skirt diameter at the centerline of the piston pin but at a right angle (opposite) to the pin. Refer to the Service Piston and Cylinder Bore Specifications data at the end of this section for dimensions. Remove the piston rings, insert the piston in the bore, and check piston-to-bore clearance with a feeler gauge. Clearance should not exceed 0.004 in. (0.120 mm) on cylinders 1 through 6, and 0.005 in. (0.133 mm) on cylinders 7 and 8. Replace the piston if the skirt is severely scored, collapsed, or worn below specied limits. Reuse the piston if in good condition and wear is minimal. However, if the cylinder bore is worn and requires reboring, the piston must be replaced, even if its in good condition. Replace the piston if the bore is OK but piston-tobore clearance is greater than specied. Remove all the expansion/freeze plugs with a punch and hammer. Coat the edges of replacement plugs with Permatex #2, or a high temp RTV sealer. Seat the new plugs in the block with a suitable size socket and hammer. Be very sure each plug is firmly seated. Replace any plug that becomes distorted during installation; do not salvage it.
CYLINDER BORE
AXIS A
AXIS B
Figure 2-107: Cylinder Bore Measuring Points
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Cylinder Boring and Honing Information

Check the ID letters stamped on the cylinder block pan rails. These letters identify the production standard piston grade size and cylinder bore. The letters used are J, K, G, and T. Grade and sizes are listed in the service piston and bore chart at the end of this section. Use this information as a check - before ordering parts or performing any machining operations. Production and oversize pistons from the factory are all the same weight, therefore engine balance is not affected. This means that a low mileage block does not have to have all the cylinders rebored if only one or two require this. However, on high mileage blocks, it is better to rebore all the cylinders to maintain equal cylinder pressures. The main bearing caps should be installed and tightened to specified torque before commencing boring operations. The block decks should also be clean, smooth, and free of nicks and burrs. The boring bar must rest on a flat, even surface to avoid an offcenter bore. Boring and honing plates are also recommended. Keep boring bar cutting tool speed and feed rates within the tool manufacturers recommendations. Excessive feed or speed rates can produce unwanted tool marks. Extra honing operations will be required to correct this. Boring should be a two step operation consisting of: a rough bore to remove about 90% of the required stock, and a finish bore to within 0.003-0.005 in. (0.0762-0.1270 mm) of the desired final size. The final bore size, including required pistonto-bore clearance, will be achieved during honing operations. Cylinder honing is required to break the glaze, or to achieve final surface finish and piston clearance after boring operations. Glaze breaking hones are designed for hand operation in a drill motor. This type of honing only requires breaking through the varnish buildup on the walls. Machine operated cylinder hones, such as those built by the Sunnen Corp., are required for achieving final finish and size. Honing operations on rebored cylinders should also be a two step procedure. A rough hone to within 0.0005 in. (0.13 mm) followed by a finish hone to size. The rough honing establishes size while finish honing generates the required 45 cross-hatch pattern. The crosshatch pattern provides a surface that will retain oil for proper wall lubrication. Perfectly smooth finishes are to be avoided. NOTE: Service oversize pistons are available in one size only which is 0.020 in. (0.50 mm) over. This is the maximum allowable cylinder oversize. Note this before initiating boring operations.
PISTON SKIRT
CAMSHAFT BEARING REPLACEMENT

Camshaft bearing tool set J33049 plus adapters J6098-11 and J6098-12 and tool set J6098-01 are required for bearing replacement. During removal, bearings 1 and 5 are removed last because they must be in place to support the pilot tool. For this reason, these bearings must be installed first during replacement. The front (no. 1) bearing has two oil feed holes. The remaining bearings have a single oil feed hole. All of the bearing feed holes must be aligned with the oil feed holes in the bearing bores. Cam bearings 1, 2, 3, and 4 are the same size. However, bearing number 5 is a different diameter. Be sure the correct bearing is installed in each bore. Replacement bearings are numbered to help avoid incorrect placement. The front (no. 1) bearing has a notch in it. This notch must face out toward the block front. Each of the bearings also has an oil groove. Install the bearings so the groove is at the top of the bore toward the upper part of the block.
Bearing Replacement Procedure

1. Remove camshaft plug at rear of block (Figure 2-109). Use long wood dowel or pipe tool and hammer to tap plug out rear of block. Discard plug afterward. It is not reusable. Remove No. 2 bearing as follows: a. Insert pilot from tool set J33049 in No. 1 bearing (Figure 2-109). b. Slide puller screw from tool set J33049 through pilot and through No. 2 bearing. c. Install adapter J6098-11 on puller screw and seat adapter in No. 2 bearing. d. Tighten nut on puller screw to remove bearing. Remove bearings 3 and 4 as described in step 2. Remove bearing No. 5 with driver handle from tool set J6098-01 and adapter J6098-12 (Figure 2-110). Remove bearing No. 1 with driver handle and J33049 (Figure 2-110).
ADAPTER J6098-11
2.
3. 4. 5.
PILOT FROM J33049
NO. 4 NO. 3 NO. 2 MICROMETER PULLER SCREW FROM J33049
Figure 2-108: Measuring Piston Skirt Diameter
Figure 2-109: Removing Cam Bearings 2, 3, and 4
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J6098-01 DRIVER HANDLE
J6098-01 DRIVER HANDLE ADAPTER J6098-12 NO. 1
ADAPTER J6098-12 NO. 5 BEARING
OIL HOLE (1) NO. 1BEARING
NO. 5 ADAPTER FROM J33049
ADAPTER FROM SET J33049
Figure 2-110: Removing Cam Bearings 1 and 5

CAUTION: It is extremely important that the cam bearings be properly aligned during installation. Failure to align the oil feed holes in the bearings and oil feed slots in the bearing bores, will result in engine failure. 6. Note ID numbers on new bearings. Place bearings in order to maintain correct installation sequence. 7. Mark center position of oil slot in each bearing bore with grease pencil or chalk. Place marks adjacent to each bearing bore so it is easily viewed. Make two marks for no. 1 bearing to ensure that both oil holes will be aligned. 8. Align oil hole in new No. 5 bearing with J6098-01 alignment mark on block. Seat bearing in block with driver handle and adapter J6098-12 (Figure 2-111). 9. Align both oil holes in new No. 1 bearing with oil holes in block (Figure 2-111). Bearing notch should be facing out and seam at 11 Oclock position. Seat bearing in block with driver handle and adapter J33049 (Figure 2-111). 10. Check installation of bearing number 1 and 5. Verify that bearing oil holes are centered on slots in bores and that bearings are flush with edges of bearing bores. The small groove in each bearing should be towards upper part of block. Remove and reposition either bearing if misaligned (Figure 2-111). 11. Install remaining bearings, starting with No. 2, as follows: a. Insert pilot in No. 1 bearing. b. Slide puller screw through pilot and No. 2 bearing bore (Figure 2-112). c. Position new bearing on adapter J33049 (Figure 2-112). d. Secure adapter to puller screw. e. Align bearing oil hole with paint mark on block. f. Tighten puller screw to draw bearing into place. g. Verify that bearing oil hole is properly aligned. h. Install bearings 3 and 4 in same manner. 05745159
BEARING SEAM AT 11 OCLOCK
OIL HOLE AT 4:30 POSITION
OIL HOLE AT 1 OCLOCK POSITION
Figure 2-111: Installing Cam Bearings 1 and 5
CAMSHAFT PLUG
ADAPTER J6098-11 NO. 2 BEARING
BEARING BORE
PILOT FROM J33049
PULLER SCREW FROM J33049
Figure 2-112: Installing Cam Bearings 2,3, and 4
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CRANKSHAFT SERVICE
Clean the crankshaft with solvent and clear the journal oil holes with a wire brush if necessary. Dry the crankshaft with compressed air or lint free shop towels. Inspect condition of rod and main journals (Figure 2-113). The journals must be smooth and free from scoring, grooves, taper, cracks, and checking/galling. Minor nicks and burrs can be removed with an oil stone and 380 grit emery. Minor scratches, or scoring on journal surfaces can be smoothed with 320 grit emery followed by polishing with crocus cloth. Check for cracks on all surfaces including the counterweights. Also check the threads in the crankshaft flange and nose. Rusty, rough threads can be cleaned up with a tap. However, replace the shaft if the threads are seriously damaged. Magnaflux or Zyglo the crankshaft if cracks are suspected. Although the crankshaft journals can be machine polished to restore surface finish, replace the crankshaft if damaged, distorted, worn, or scored. Do not attempt to salvage it.
Crankshaft runout should not exceed 0.0002 - 0.0008 in. (0.005 - 0.020 mm). Replace the crankshaft if runout is greater than specified. Do not attempt to straighten a cast iron crankshaft.
MICROMETER
Figure 2-114: Measuring Journal Diameter
COUNTERWEIGHT NOSE
SEAL SURFACE CENTER MAIN JOURNAL
MAIN JOURNAL
ROD JOURNAL OIL HOLES HOLDING FIXTURE DIAL INDICATOR J8001
Figure 2-113: Crankshaft Inspection Points
Checking Crankshaft Journal Diameter and Runout

There are three main journal diameter ranges. These ranges are identified by a color code paint mark near one of the journals. The three size range color codes are blue, orange/red, and white. Note the code on the crankshaft and refer to the specification charts at the end of this section for size ranges. Use a micrometer to check journal diameter. Measure both ends of each journal to check for taper along with wear (Figure 2-114). Journal wear or taper must not exceed 0.0002-0.001 in. (0.050.025 mm). Mount the crankshaft in a holding fixture and check runout at center (#3) main bearing journal (Figure 2-115).
Figure 2-115: Measuring Crankshaft Runout
Section 2 Engine
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PISTON/CONNECTING ROD OVERHAUL

Remove and discard the old piston rings. Use a remover/installer tool similar to parallel jaw type tool shown (Figure 2-116). Discard rings after removal. Use a ring groove tool to remove carbon and oil deposits from the ring grooves. Using a section from an old piston ring is not recommended for this purpose. Disassembly the piston, and rod as follows: a. Note piston-to-rod position for assembly reference. b. Remove retaining rings that secure piston pin. Discard rings; they are not reusable. c. Push piston pin out of piston and rod. d. Separate piston, and rod, and pin (Figure 2-117). Clean the piston, rod, and pin with solvent and carb cleaner if needed. Do not use a wire brush or any type of abrasive on the piston. Inspect piston condition. Replace the piston if cracked, severely scuffed or scored, the ring lands are worn or damaged, or the skirt is collapsed (Figure 2-118). Measure pin bore diameter in the piston (Figure 2-119). Then measure diameter of the piston pin (Figure 2-119). The difference between pin diameter and bore diameter, should be 0.0004 - 0.0006 in. (0.010-0.0153 mm). This figure represents the required pin-to-bore clearance. Replace the piston and pin as a set if clearance is greater than specified. NOTE: Turbo diesel and NA diesel piston and rod assemblies are different. Do not interchange them.
TOP COMPRESSION RING
BOTTOM COMPRESSION RING OIL RING ASSEMBLY PISTON RETAINING RING
PISTON PIN RETAINING RING ROD BOLT
PIN BUSHING
CONNECTING ROD
ROD CAP
Figure 2-117: Connecting Rod and Piston Assembly
CROWN
GROOVE LAND PISTON RING REMOVER/INSTALLER TOOL
PIN BORE SKIRT
Figure 2-118: Piston Inspection Points Figure 2-116: Piston Ring Removal/Installation Tool
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the pin bore centerline as shown. Replace the pistons if wear is such that piston-to-bore clearance would be greater than: 0.004 in. (0.120 mm) for cylinder 1-6 and 0.005 in. (0.133 mm) for cylinder 7 and 8
2.57 in. (65.3 mm) MICROMETER PISTON SKIRT
PISTON PIN
Figure 2-119: Measuring Piston Pin Diameter

Measure pin bushing diameter in connecting rod with small bore gauge or inside micrometer (Figure 2-120). Record bushing diameter and compare it to diameter of new or known good piston pin. The difference between the two measurements represents the piston pin-to-connecting rod pin bushing clearance. Required clearance is 0.0003-0.001 in. (0.0081-0.0309 mm). Replace the connecting rod if the bushing is worn oversize. The bushing is not serviced separately.
MICROMETER
Figure 2-121: Measuring Piston Skirt Diameter at Gauge Point
Piston Selection and Fit

Production engines are equipped with different grade size pistons. The different grades allow factory select fitting of pistons. Correctly, three grades are used with the ID letters JT, KT, and GT or J, K, G, or T. The different grades are to accommodate minor variances in bore size. The ID letters are on the cylinder block pan rails adjacent to each cylinder bore, or the piston itself. The grade sizes are described in the piston and bore size chart at the end of this section. Some general selection recommendations are: If an original piston is in good condition and meets all specifications, it can be reused. If the cylinder bore is OK but the piston was damaged, just use a new piston of the same grade size. If the piston grade size is not marked on the piston or pan rail, and the original piston is not reusable, select a piston that will provide the required piston-to-wall clearance. It is only necessary to know the actual bore size. The largest oversize piston available is 0.020 in. (0.50 mm). It is not necessary to rebore all the cylinders on a low mileage engine. Only the damaged cylinder needs to be repaired. This is permissible because factory service replacement and original pistons are all the same weight. Balance is not affected. However, it is recommended that all the pistons be replaced and the cyliners be rebored on high mileage engines.
CONNECTING ROD PIN BUSHING BORE GAUGE (OR INSIDE MICROMETER)
Figure 2-120: Checking Connecting Rod Pin Bushing Diameter

Check connecting rod straightness in a rod fixture, or on a surface plate or sheet of glass. The rod can be straightened if distortion is less than 0.002 in. (0.05 mm) end-to-end. Replace the rod if severely bent, twisted, or cracked. Measure piston skirt diameter at, or just below the pin bore centerline. The correct gauge point is approximately 2.57 in. (65.3 mm) down from the piston crown (Figure 2-121). Be sure measurement is taken at a point opposite (at right angle to)
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If a cylinder bore only requires honing to correct a problem, use the next grade size piston. Avoid going to the largest oversize piston unless absolutely necessary. Verify that a new piston is properly aligned on the connecting rod. The rod ID mark and the relief (combustion chamber) in the piston crown should be on the same side.
INSTALLER TOOL J39507
Piston and Connecting Rod Assembly

1. 2. 3. 4. 5. 6. Lubricate piston pin, pin bore in piston, and bushing in rod with engine oil. Install new bolts in rod and install rod cap. Start pin and piston bore. Position piston on rod. Relief in piston crown and rod bearing tangs/notches must be aligned (Figure 2-122). Push piston pin through rod to secure it to piston. Install piston pin retaining rings as follows: a. Place piston/rod assembly on clean section of workbench. b. Install tool J39507 on one end of piston pin (Figure 2-123). c. Start first retaining ring in piston pin bore (Figure 2-124). Position open end of ring downward toward bottom of piston. d. Use plastic or tape covered pry tool to work ring into pin bore. e. Insert tool J39507 into piston pin (Figure 2-122). Place tool tab on retaining ring. Seat ring by pressing downward and rotating tool in arc. Tool tab will press ring into place as it is rotated (Figure 2-125). f. Remove pin tools and install opposite retaining ring as described in steps c through e.
PISTON PIN RETAINING RING
TOOL J39507 (ON PIN)
Figure 2-123: Positioning Pin for Installation of First Retaining Ring
PISTON CROWN RELIEF
RETAINING RING (MUST EXTEND BEYOND NOTCH AND OPEN END DOWN)
PISTON PIN BORE
LOCATION OF ROD BEARING TANGS/NOTCHES
Figure 2-124: Starting Retaining Ring in Piston Pin Bore
Figure 2-122: Piston and Connecting Rod Alignment
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PISTON RING FEELER GAUGE INSTALLER TOOL J39507
TOOL TAB
RETAINING RING
Figure 2-126: Checking Piston Ring End Gap Figure 2-125: Seating Piston Pin Retainer Ring
3. Install rings in sequence: oil ring first, bottom compression ring second, and top compression ring last. Use ring expander tool J42525 to install the rings. Position ring end gaps as shown (Figure 2-127). This avoids ring gap alignment which will cause loss of compression, blow by, and oil consumption. Cover and store the piston and rod assemblies on a workbench prior to installation.
A
Piston Ring Installation

1. Check end gap of all rings. Insert ring in bore and push it down until its about 1-2 inches (2.5-5 cm) below top edge of bore. Verify that ring is level, then check end gap with feeler gauge (Figure 2-126). Correct end gaps are: Oil ring is 0.009-0.020 in. (0.25-0.51 mm) Bottom compression ring is 0.029-0.039 in. (0.75 -1.00 mm) Top compression ring is 0.010-0.020 in. (0.26-0.51 mm) If ring end gap is correct, proceed to step 3. But if gap is incorrect proceed as follows: a. If gap is only a few thousandths/mm too small, file or grind one ring end to obtain specified gap. b. If gap is almost non-existent, or ring ends overlap, rings are wrong size. c. If end gap is larger than specified by only a few thousands/mm, this indicates bore is slightly worn. Rings may be retained. 4.
5.
2.
A - OIL CONTROL RING EXPANDER GAP B - BOTTOM COMPRESSION RING GAP C - OIL CONTROL RING GAP D - TOP COMPRESSION RING GAP
Figure 2-127: Recommended Positioning of Piston Ring Gaps
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CAMSHAFT, TIMING CHAIN, SPROCKET, AND DRIVE GEAR SERVICE

Clean the camshaft and geartrain parts in solvent. Wipe the cam dry with shop towels only. Compressor can be used to dry the other parts. Inspect the cam bearing journals for wear, scoring, scuffing, or discoloration from overheating. Replace camshaft if damaged or discolored (Figure 2-128). Inspect oil pump drive gear on camshaft for damage. Replace camshaft if gear teeth are worn, chipped, or broken. Measure bearing journal wear. Journals 1, 2, 3, and 4 should be 2.164-2.166 in. (54.975-55.025 mm). Journal 5 should be 2.007-2.009 in. (50.975-51.025 mm). Mount the camshaft on V blocks and measure lift. Lift for both intake and exhaust valve lobes should be 0.281 0.002 in. (7.133 0.050 mm). Replace camshaft if any lobe is worn below specified range. Inspect both sprockets for cracks, or chipped, broken teeth. Replace sprockets as a matched set if either one is damaged. Inspect the timing chain for distortion, stretch, or binding. Replace the chain if damaged. Inspect the fuel injection pump drive and driven gears for cracks, chipped or broken teeth, and wear. Replace both gears as a set if either one is damaged. Inspect the thrust plate and spacer for wear. Replace either part if damaged or worn.
INJECTION PUMP DRIVEN GEAR CAMSHAFT SPROCKET TIMING CHAIN THRUST PLATE SPACER
FRONT COVER AND OIL FILLER TUBE

Inspect the cover for cracks, scratches/nicks on the sealing surfaces, or damaged threads. Remove minor scratches/nicks with 180 grit emery. Repair thread damage with helicoil inserts. Replace part if damaged (Figure 2-129). Inspect the adapter plate for cracks, scratches on mating and sealing surfaces, dents, pitting, and corrosion. Repair minor scratches with 180 grit emery. Replace the plate if cracked or bent.
REAR SEALING SURFACE
THREADED HOLES FRONT SEALING SURFACE
Figure 2-129: Front Cover Inspection Points

Inspect the oil filler tube grommet. Replace the grommet if cracked, brittle, or loose (Figure 2-130). Inspect the oil filler tube. Replace the tube if cracked or distorted (Figure 2-131). Inspect the filler cap sealing gasket. Replace the cap if the gasket is missing or damaged. Replace the cap if damaged.
ADAPTER PLATE OIL FILLER TUBE GROMMET CRANKSHAFT SPROCKET CAMSHAFT REAR SEALING SURFACE
INJECTION PUMP DRIVE GEAR
LOBE
JOURNAL OIL PUMP DRIVE GEAR FRONT SEALING SURFACE
Figure 2-130: Adapter Plate Inspection Points Figure 2-128: Camshaft and Geartrain
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CAP OIL FILLER TUBE
d. e. f. g. h. i.
Remove valve retainer, shield and spring. Remove stem seal from valve and slide valve out of guide and head. Remove shim. On exhaust valve, also remove nylon stem and guide seal (Figure 2-134). Remove remaining valve assemblies in same manner. Keep valve parts together on workbench or use yardstick with drilled holes to keep valve assemblies separate.
Figure 2-131: Oil Filler Tube and Cap
CYLINDER HEAD OVERHAUL

Disassembly
1. 2. Remove glow plugs and injectors if not previously removed. Remove temperature sender from left side head (Figure 2-132).
NOTE: Do not intermix the valve parts as intake and exhaust valve are different. In addition, the exhaust valves have two stem seals and a rotator style spring retainer.
VALVE SPRING COMPRESSOR TOOL J8062
TEMPERATURE SENDER
Figure 2-133: Compressing Valve Spring (to Remove Locks)

5. Mark position of pre-combustion chambers in each cylinder head (Figure 2-135). Ideally, chambers (if reused), should be installed in same location in head. Remove prechambers from cylinder heads (Figure 2-135). Use a round pry tool to loosen and start each chamber out of seat in cylinder head. Remove cover and gasket from right side head (Figure 2-136).
Figure 2-132: Temperature Sender Removal/ Installation

3. Clean valve faces with wire brush and measure amount valves are recessed in head with dial indicator. Intake valves should be recessed approximately 0.001 in. (0.034 mm) and exhaust valves approximately 0.002 in. (0.048 mm). Recessing means valve faces are positioned below cylinder head combustion chamber surface. If valves extend or protrude above chamber surface, engine is equipped with wrong valves, or heads have been mismachined. If valves are recessed to at least the stated values, continue with disassembly. Remove valve assembly in sequence as follows: a. Compress valve spring with compressor tool J8062 (Figure 2-133). b. Remove valve locks (Figure 2-134). c. Release and remove compressor tool.
6.
7.
4.
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Engine
2-73
INTAKE VALVE VALVE STEM SEAL SHIM
VALVE SPRING AND DAMPER ASSEMBLY SHIELD RETAINER
VALVE STEM SEAL
LOCKS
EXHAUST VALVE VALVE STEM AND GUIDE SEAL SHIM VALVE SPRING AND DAMPER ASSEMBLY SHIELD RETAINER/ROTATOR
Figure 2-134: Intake and Exhaust Valve Components

PRE-COMBUSTION CHAMBER CYLINDER HEAD
Clean the cylinder heads and valve components in parts cleaning solvent. Use carb cleaner and a wire brush to remove stubborn carbon deposits on the heads valves and prechambers. Check flatness of intake/exhaust manifold seating surfaces with straightedge. Surfaces must be flat to within 0.006 in. (0.15 mm). Check cylinder head flatness with straightedge and feeler gauge (Figure 2-137). Overall (end-to-end) flatness should not vary by more than 0.006 in. (0.152 mm). Replace the head if warped or distorted. Do not machine the head.
STRAIGHT EDGE
Figure 2-135: Pre-combustion Chamber Removal
COVER
GASKET FEELER GAUGE
Figure 2-137: Checking Cylinder Head Flatness

Inspect the combustion prechambers (Figure 2-138). Minor cracks under 3/16 in. (0.48 mm) in length are not cause for replacement. Install new chambers only when cracks extend beyond the indicated length (Figure 2-138).
Figure 2-136: Cover Removal/Installation

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ACCEPTABLE CRACK LENGTH NOT OVER 3/16 IN (5 MM) A B
Check the valve stems for wear, scoring, or distortion. Inspect the faces for pitting, cracks, or burnt segments. Also inspect the lock grooves at the stem top. Be sure the grooves are free of cracks, worn or broken lands, or chipped spots. Replace any valve exhibiting the foregoing conditions. Grind the valve faces only lightly to obtain the required 45 face angle (Figure 2-141). Take care to avoid cutting into the valve margin. Quik Way, Van Norman, Sioux or similar quality equipment is recommended.
UNACCEPTABLE CRACK LENGTH OVER 3/16 (5 MM) 90
C A B A. HEAD GASKET SEALING BEAD MARK B. FIRE SLOT S02-240 D B
Figure 2-138: Prechamber Inspection Points

Check fit of each pre-chamber in the cylinder head. Replace loose (or cracked) chambers. Oversize chambers are available when needed. The oversize parts are marked with ID code 08. The code numerals appear on the chamber crown, side, or interior (Figure 2-139)
.
A-SEAT WIDTH = INTAKE 0.035-0.060 in. (0.089-1.524 mm) EXHAUST (0.060-0.093 in. (1.524-2.36 mm) B-FACE ANGLE (INTAKE & EXHAUST) = 45 C-SEAT ANGLE (INTAKE & EXHAUST) = 46 D-VALVE FACE CONTACT AREA
SIZE CODE LOCATIONS
Figure 2-141: Valve Refacing Angles and Widths

Grind the valve seats to the required 46 angle with the previously recommended equipment. Or, use a 4-6 blade carbide cutter to dress the seat. Lightly lap the valves and seats with a fine grit compound. Clean the valves and seats and inspect the lap marks. The lap marks, which represent the actual contact areas on the valves and seats, should be concentric, and equal in width throughout. Ideal seat width is 0.063 in. (1.6 mm). If the lap marks are thick-thin or eccentric, the valves or guides are worn beyond tolerance. Verify by rechecking valve stem clearance and valve seat runout with a dial indicator.
Figure 2-139: Oversize Prechamber I.D.

Measure valve stem clearance with a dial indicator. Required clearance is 0.001-0.003 in. (0.026-0.069 mm) for intake and exhaust valves. If clearance is beyond limits, ream the valve guide with reamer (Figure 2-140) and install new valve with 0.0035 in. (0.089 mm) larger stem.
REAMER HANDLE
REAMER J5830-1
Figure 2-140: Typical Method of Reaming Valve Guides
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Engine
LOCKS (2)
2-75
Cylinder Head Reassembly

1. 2. 3. Scuff sand all gasket surfaces with 180 grit paper. Clean the valvetrain parts and cylinder head with solvent and dry with compressed air. Install new freeze plugs in heads if necessary. Apply Permatex #2 or high temp adhesive/sealer to edges of plugs before installation. Be sure plugs are properly seated. Install combustion prechambers in cylinder heads (Figure 2-142). Chambers should be flush to no more than 0.002 in. (0.05 mm) above head surface. Install new nylon stem and guide seals on exhaust valve guides. Lubricate valve stems and guides with 30w engine oil, or assembly lube.
INTAKE VALVE
RETAINER RETAINER/ ROTATOR SHIELD SPRING AND DAMPER SHIM STEM SEAL
4.
5. 6. 7.
Install valves as follows (Figure 2-142): a. Insert valve into guide and through nylon seal on exhaust valves. b. Install shim. c. Lubricate and install stem seal on valve. d. Position valve spring and damper on shim. e. Install shield followed by retainer on valve spring. f. Compress spring with spring compressor tool (Figure 2-133). g. Install valve locks. Be sure locks are fully seated before proceeding. Use petroleum jelly to hold locks in place during installation. h. Release and remove compressor tool. 8. Check valve spring installed height: a. Use dividers and micrometer or vernier caliper (Figure 2-143). b. Measure height from bottom of spring to top of shield as shown. c. Correct height is 46 mm (1.81 in.). Height can exceed specified figure by 0.127 mm (0.005 in.) but must never be lower than specified. d. Use thicker shim to decrease height, or thinner shim to increase height Replace any valve spring that cannot be set to specified height. 9. Apply Permatex #2, or high temp sealant to threads of coolant temperature sender. Then install the switch in the left head (Figures 2-132 ). 10. Install access cover and gasket, if removed. Use Permatex #2 or high temp sealant on gasket. 11. Cover assembled heads if they will not be installed immediately.
EXHAUST VALVE
Figure 2-142: Valvetrain Installation Sequence
SHIELD DESIRED SPRING HEIGHT IS 1.81 in. (46 mm) SHIM
Figure 2-143: Installed Height of Valve Spring
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LIFTER, PUSHROD, ROCKER ARM SERVICE

Clean the rocker arms, shafts, pushrods, guides, clamps, and lifters in parts cleaning solvent. Immerse the lifters in solvent and use a pushrod to stroke the lifter plunger. Replace any lifter that is collapsed, or if fluid cannot be pumped out oil hole when plunger is stroked. Inspect the lifter roller and bearings. Replace any lifter that exhibits wear on the body, roller, or bearings. Turn the roller and note action. Replace the lifter if the roller binds, or is seized. Check each pushrod (Figure 2-144) for distortion and wear. Replace any pushrod that is bent. Check the pushrod ball ends. Replace the pushrod if either ball end is flattened, scored, or loose. Inspect the lifter guide plates and clamps (Figure 2-144). Replace the plates and clamps if worn, or distorted. Also make sure the guide plates are a proper slip fit on the lifters. Inspect the rocker arms and shafts for wear, cracks, scoring/ grooving, or distortion. Check the pushrod contact area on each arm for wear, or scoring. Replace the rocker arms, or shaft as needed. Discard the rocker arm retainers (Figure 2-145). Also discard the rocker shaft retainers if bent, distorted, or cracked.
ROCKER SHAFT RETAINER AND BOLT ROCKER ARM RETAINER ROCKER ARMS
ROCKER ARM SHAFT
Figure 2-145: Rocker Arm and Shaft Components
DAMPER AND FLYWHEEL SERVICE

The flywheel can be immersed in cleaning solvent. However, the torsional damper should only be wiped clean with a cloth wetted with parts cleaner. The damper has a rubber composite insulator (Figure 2-146). This insulator can be damaged by immersion in some cleaning solutions. Inspect the damper insulator ring (Figure 2-146). Replace the damper if the ring is cracked, distorted, protruding, or loose (hub can be turned independently of outer shell). Also check the hub bore, keyway, and seal surface. Minor nicks or scratches can be smoothed with 320 grit emery but replace the damper if these surfaces are severely scored, or cracked. Clean the bolt hole threads with a tap if necessary. CAUTION: 6.5L diesel engines are externally balanced. The torsional damper is an integral part of the balancing mechanism. Never use a solid, or similar non-recommended damper as this practice can result in a broken crankshaft. Use factory replacement dampers only. Inspect the flywheel carefully (Figure 2-147). Look for worn, chipped, or broken ring gear teeth and check the hub for cracks at the mounting bolt holes. Place the flywheel on a flat surface and check the body for warping, distortion, or cracks at the converter attaching bolt holes. Replace the flywheel if it exhibits any of the foregoing conditions.
GUIDE CLAMP
GUIDE PLATE
PUSHROD
ROLLER LIFTER
NOTE: The ring gear is not serviced separately. It is only available as part of a new flywheel.
Figure 2-144: Lifter and Pushrod Components
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Engine
2-77
OIL PUMP AND PUMP DRIVE SERVICE

The oil pump can be disassembled for inspection if desired but not overhauled. The pump is serviced only as a complete assembly. Individual pump parts are not available. The pump shaft, pickup tube clamp and bolt, and pump mounting stud are all available as service parts (Figure 2-148). Replace the oil pump under the following conditions: Pressure test indicates low or no pump pressure High mileage overhaul Overhaul cause by oil pump failure Overhaul to correct problem that generated sludge, varnish Overhaul due to failure that produced chips, debris Repair caused by insufficient oil in engine Inspect the oil pump drive gear and housing. Replace the drive as an assembly if damaged in any way; only the drive O-ring seal is replaceable. The sensor on the oil pump drive is not serviceable. It is available only as part of the drive assembly.
PUMP SHAFT HUB CLAMP
HUB BORE
KEYWAY INSULATOR SEAL SURFACE BOLT HOLES
Figure 2-146: Torsional Damper Inspection Points

BODY RING GEAR TEETH
OIL PUMP (ASSEMBLY ONLY) MOUNTING STUD
Figure 2-147: Flywheel Inspection Points
Figure 2-148: Oil Pump Serviceable Parts
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OIL FILTER ADAPTER AND BYPASS VALVE SERVICE Oil Filter Adapter
Inspect the adapter fitting and bolt for damaged threads (Figure 2-149). Replace either fitting if damaged. Inspect the filter adapter for stripped or crossed threads, cracks, and chipped sealing surfaces. Replace the adapter if damaged. Remove and discard the old O-rings and gasket from the bolts (Figure 2-149). Install new O-rings and seal on the bolt and lubricate them with engine oil.
OIL FILTER ADAPTER
Bypass Valve
Remove the two bypass valves (Figure 2-149), and inspect them carefully. Replace either valve if damaged, or filled with shavings and/or debris. NOTE: The filter bypass and cooler bypass valves can be removed with a small hook tool.
FLUSHING ENGINE COOLER

Flush the engine oil cooler whenever a component failure contaminates the oil with metal or similar particles. The oil and filter should also be changed.
Cooler Flushing Procedure

1. 2. Remove oil cooler lines at engine and allow oil to drain into suitable container. With one line positioned in container, introduce air pressure (no more than 20 psi (140 kPa)) into the other line to force oil and contaminates out of cooler. When cooler is clear of oil, use pump or vacuum unit to then either pump or draw solvent followed by fresh oil through cooler. Continue until oil coming from cooler is free of contaminants. Reconnect cooler lines to engine adapter fittings. Change engine oil and filter.
3.
O-RINGS ADAPTER FITTING ADAPTER BOLT GASKET
4. 5.
ROCKER COVER AND OIL PAN SERVICE

CUP PLUG OIL FILTER BYPASS VALVE COOLER BYPASS VALVE
Clean the pan and covers in cleaning solvent. Use carb cleaner on stubborn deposits if necessary. Inspect rocker covers and oil pan for cracks, sealing surface distortion, and dents. Repair minor dents. Replace either cover if damaged (Figure 2-150).
OIL GALLERY PLUG
ROCKER ARM COVER
FLANGE SEALING SURFACE
Figure 2-149: Filter Adapter and Bypass Valves Figure 2-150: Rocker Arm Cover
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Engine
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Inspect the oil pan for cracks, sealing surface distortion, dents, and damaged threads (Figure 2-151). Small dents, not involving stretched metal, are not a cause for replacement. Larger dents involving stretched or creased metal will result in leaks. Inspect the drainplug and pan for crossed or stripped threads and burred flats. Discard the plug gasket. Replace the drainplug if damaged.
INTAKE AND EXHAUST MANIFOLDS

The manifolds can all be immersed in parts cleaning solvent. Carbon buildup in the exhaust manifolds can be removed with carb cleaner, wire brushing, or glass beading. Check the manifold flange and gasket surfaces with a straightedge. Replace any manifold with warped, distorted surfaces. Do not machine either type manifold in an attempt to salvage it. Minor scratches and nicks on gasket surfaces can be smoothed with 80 grit emery cloth, an oil stone, or fine tooth file. Inspect the manifolds for cracks on all surfaces. Check the exhaust manifolds and exhaust inlet pipes for splitting and flange or joint separation. Although seriously damaged parts should be replaced, minor damage on low mileage steel exhaust parts can be repaired by welding. Inspect manifold fittings and threads. Replace loose damaged fittings and repair thread damage with a tap or helicoil insert.
DRAIN PLUG
GASKET
PAN SEALING SURFACES
Figure 2-151: Oil Pan Inspection Points

A B
B A A. MAIN BEARING JOURNAL MARKINGS (BLUE, ORANGE/RED, OR WHITE) B. ROD BEARING JOURNAL MARKINGS (YELLOW OR GREEN)
Figure 2-152: Crankshaft Journal Size Identification

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ENGINE ASSEMBLY AND ADJUSTMENT

CRANKSHAFT
Crankshaft Main Bearing Selection

Main bearings are available in standard and two undersizes for select fit purposes. Required bearing clearances are: 0.0017-0.003 in. (0.045-0.083 mm) at bearings 1 through 4 0.002-0.0036 in. (0.055-0.093 mm) at number 5 rear main There are three main journal diameter ranges. The ranges are identified by a color code paint mark near one of the journals. The size range color codes are blue, orange/red, and white. Rod bearing journals are marked yellow or green. The color codes indicate journal diameter and correspond to the Main Bearing Selection Chart at the end of this section. The main bearing bores in the block are also coded for size. There are three ranges identified by the numbers 1, 2, or 3. These numbers are stamped in the cylinder block pan rail. Refer to the Main Bearing Selection chart at the end of this section. NOTE: Different bearings are used in turbo and NA diesel engines. Do not interchange the main or rod bearings.
TANG
BEARING SADDLES
MAIN BEARING UPPER HALVES (GROOVED)
Figure 2-153: Installing Crankshaft and Main Bearing Upper Halves
Crankshaft and Main Bearing Installation

1. Measure main journal diameters, note color code on crankshaft, and size letter on engine pan rail. Select bearings as needed. 0.0005 in. (0.013 mm) bearings are standard while 0.001 in. (0.026 mm) bearings are undersize. Identify and separate bearing halves before proceeding. Bearing upper halves have oil grooves while lower halves do not. Upper halves go in block while lower halves go in bearing cap. Extra wide bearing is thrust bearing and is installed in number 3 position. Install main bearing upper halves in block (Figure 2-153). Install bearing halves dry. Do not lubricate bearing saddle in block or back of bearing. Be sure each bearing locating tab is properly seated in notch machined in block. Also be sure oil holes in bearing and block are aligned. Thrust bearing half goes in #3 main bearing saddle. Install main bearing lower halves in bearing caps (Figure 2-154). Install bearings dry and be sure each bearing locating tang is seated in bearing cap notch. Thrust bearing half goes in #3 main cap. Position crankshaft in block. Do not turn the shaft. Just carefully seat it in bearing upper halves. Position length of plastigauge on each main bearing journal (Figure 2-155). Cut plastigauge so it extends across three quarters of journal. Position plastigauge so it is parallel to crankshaft center line as shown.
MAIN CAPS
2.
3.
MAIN BEARING LOWER HALVES (PLAIN)
TANG
4.
Figure 2-154: Assembling Main Caps and Bearing Lower Halves
5. 6.
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Engine
2-81
CRANKSHAFT MAIN BEARING JOURNAL GAUGING PLASTIC
COMPRESSED GAUGING PLASTIC
Figure 2-155: Gauging Plastic Position on Crankshaft Main journal

7. Install main bearing caps and old bolts retained from disassembly operations. Tighten inner cap bolts to 55 lb-ft (75 Nm), outer bolts on main caps 1 and 5 to 48 lb-ft (65 Nm) and main caps 2, 3, and 4 to 30 lb-ft (40 Nm) to compress gauging plastic. 8. Remove main bearing caps and measure plastigauge with graduated scale on gauge envelope (Figure 2-156). Measure widest point of compressed plastic. If clearances are correct, proceed to next step. If clearances are insufficient, try standard bearings. Or, if clearances are too large, try undersize bearings. In some cases, a combination of standard and undersize bearings will be needed to obtain required clearance. Note that under size bearings refer to crankshaft diameter. 9. Carefully remove crankshaft and clean plastic off journals. Then lubricate main bearings and crankshaft with 40W engine oil or a quality assembly lube, and reinstall crankshaft. 10. Reinstall main bearing caps. Be sure caps are properly aligned. Bearing notches should be aligned and direction arrows toward front. 11. Apply Permatex High Temp silicone sealer to rear main bearing cap seat in block (Figure 2-157). 12. Install new inner and outer bearing cap bolts finger tight only. Bolts will not be tightened until after crankshaft end play check.
ENVELOPE SCALE
Figure 2-156: Measuring Gauging Plastic to Determine Bearing Clearance
APPLY RTV-TYPE SEALER HERE
REAR MAIN BEARING CAP SEAT (IN BLOCK)
Figure 2-157: Sealer Application Points in Rear Main Bearing Cap Seat
CRANKSHAFT END PLAY CHECK

1. 2. Tighten bolts in main cap number 3 to approximately 10 lb-ft (14 Nm) torque. Tap crankshaft rearward then forward to align thrust bearing. Use lead hammer or rawhide mallet to tap crankshaft. Tighten long inner number 3 main cap bolts to 55 lb-ft (75 Nm) and shorter outer bolts to 30 lb-ft (40 Nm) torque. Verify that crankshaft can be rotated freely without bind or drag. Pry and hold crankshaft forward. Measure clearance between crankshaft and number 3 main bearing with feeler gauge (Figure 2-158). Clearance should be 0.004-0.010 in. (0.10-0.25 mm). If clearance is incorrect, thrust bearing is incorrect size or not seated, or crankshaft thrust surface is worn. Correct as necessary. If clearance is OK, continue with assembly.
3. 4. 5.
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CRANKSHAFT MAIN CAP TORQUE SEQUENCE

1. 2. 3. 4. 5. 6. 7. Tighten the inner 12 mm bolts to 55 lb-ft (75 N.m). Retighten the inner 12 mm bolts to 55 lb-ft (75 N.m). Tighten the inner 12 mm bolts an additional 90 degrees. Tighten the outer 12 mm bolts (crankshaft bearing caps 1 and 5) to 48 lb-ft (65 N.m). Retighten the outer 12 mm bolts (crankshaft bearing caps 1 and 5) to 48 lb-ft (65 N.m). Tighten the outer 12 mm (crankshaft bearing caps 1 and 5) an additional 90 degrees. Tighten the outer 10 mm bolts (bearing caps 2, 3, and 4) to 30 lb-ft (40 N.m).
#3 MAIN CAP
FEELER GAUGE
CAUTION: DO NOT tighten the outer 10 mm bolts an additional 90 degrees! 8. Check the crankshaft for proper rotation.
Figure 2-158: Measuring Crankshaft End Play
NOTE: If crankshaft does not rotate freely or binds in spots, problem may be: misaligned main caps, bearing incorrectly installed, foreign material on bearing or journal, wrong bearing size.
REAR MAIN SEAL INSTALLATION

1. 2. 3. Lubricate new rear main seal lip with chassis grease or petroleum jelly. Apply sealer such as Permatex #2 to outer circumference of new seal. Install seal with tool J39084 (Figure 2-159). Be sure seal is flush with block and bearing cap as shown
BLOCK SEAT SEAL FLUSH WITH BLOCK AND BEARING CAP CRANKSHAFT BLOCK
CRANKSHAFT SEAL
SEAL
MAIN BEARING CAP MAIN BEARING CAP
SEAL INSTALLER J39084
Figure 2-159: Rear Main Seal Installation
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Engine
2-83
PISTON/CONNECTING ROD INSTALLATION AND BEARING FIT

Verify correct piston and rod assembly. Be sure piston crown relief and notches in rod for bearing inserts are aligned (Figure 2-160). Install only one piston and connecting rod assembly at a time. This is necessary because rod bearing clearance must be checked with the bearing inserts dry. Check bearing clearance at each rod as it is installed. Make sure the connecting rod caps are matched to their respective rods and are properly aligned. Failure to match and align the rod caps can result in premature bearing failure. Standard and undersize bearing inserts can be combined in one rod to obtain desired clearance. Just be sure to install the undersize insert in the rod cap. CAUTION: Rod bearing clearance must be checked with the bearings dry (no lubrication). For this reason, the crankshaft must not be rotated during the measuring procedure. Otherwise, bearing damage will occur. 1. 2. 3. Lubricate cylinder wall, piston rings, and all surfaces of piston (except crown), with engine oil. Verify that piston ring ends are properly spaced. Refer to spacing diagram (Figure 2-127). Insert rod bearing halves in rod end and bearing cap. Install bearing dry. They will not be lubricated until after clearance check with plastic gauging material. Install lengths of rubber hose on each connecting rod bolt. Hose will prevent cylinder wall scratches and nicks during piston installation (Figure 2-160). Compress piston rings on #1 piston with compressor tool (Figure 2-161). Rotate crankshaft until rod journal for number one piston is accessible. Start number one piston in cylinder. Position rod end so it is aligned with crankshaft journal. Also be sure relief in piston crown is toward outside of engine. Press piston downward into cylinder with hammer handle (Figure 2-161). Guide rod end onto crankshaft journal at same time. Check rod bearing clearance as follows: a. Place strip of plastic gauging material on crankshaft rod journal (Figure 2-162). b. Install rod cap and bearing and tighten rod bolt nuts to 65 Nm (48 lb-ft). c. Remove rod cap and measure gauging material with graduated scale on plastigauge envelope (Figure 2-162). Clearance should be 0.0017-0.0039 in. (0.045-0.100 mm). d. If clearance is OK, proceed to next step. If clearance is not OK, use new standard or undersize rod bearings to obtain correct clearance. If combination of standard and undersize bearing inserts are required, install undersize insert in rod cap. Note that standard bearings provide more clearance than under size bearings.
10. Remove rod cap. Clean gauging material off crankshaft journal. Lubricate rod bearing halves and crankshaft journal with engine oil or assembly lube. Then reinstall rod cap and tighten new rod cap nuts to 48 lb-ft (65 Nm) torque. 11. Install remaining piston and connecting rod assemblies as described in steps 1. through 10.
PISTON AND ROD ASSEMBLY
ROD BOLT BEARING SHELL PROTECTIVE RUBBER HOSE (ON ROD BOLTS)
4.
5. 6. 7.
BEARING SHELL BEARING CAP
ROD NUT
Figure 2-160: Piston and Rod Assembly
8.
9.
RING COMPRESSOR TOOL
HAMMER HANDLE
Figure 2-161: Piston Installation
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Engine _____________________________________________________________________
ROD CAP AND BEARING INSERT
OIL PUMP, OIL PAN, FLYWHEEL INSTALLATION

1. 2. 3. Pour 2-3 ounces engine oil into pump and rotate pump shaft to lubricate pump gears. Install retainer and pump shaft in oil pump. Apply high temp bearing grease to upper end of shaft. Install oil pump. Be sure pump is seated on rear main cap. Refer to Oil Pump Drive Removal in this section for more information. Install pump mounting stud. Tighten stud to 59-74 lb-ft (80-100 Nm). Seat pump pickup tube bracket on mounting stud. Tighten bracket nut to 35 lb-ft (47 Nm) torque. Tighten screw that secures bracket to pump pickup tube to 12 lb-ft (16 Nm) torque. Apply silicone sealer, such as Permatex High Temp, Ultra Blue, or Ultra Black to surfaces of oil pan mounting flange surfaces (Figure 2-164). Apply sealer to pan rear seal (Figure 2-164). Then press seal into place on oil pan. Coat seal ends with sealer as well. Apply silicone sealer around two holes in right side panel rail on block (Figure 2-164). Align and position oil pan on engine block pan rails. Tighten larger diameter bolts at rear of pan to 17 lb-ft (23 Nm) torque. Tighten remaining bolts/studs to 89 lb-in. (10 Nm) torque.
DRAINPLUG GASKET PAN REAR SEAL
PLACE GAUGING STRIP ON ROD JOURNAL AS SHOWN
4. 5.
6.
7.
CONNECTING ROD MEASURE WIDEST POINT OF COMPRESSED GAUGING STRIP WITH SCALE ON ENVELOPE
8. 9.
Figure 2-162: Measuring Connecting Rod Bearing Clearance with Plastic Gauging material
12. Check connecting rod side play with feeler gauge (Figure 2-163). Insert gauge between connecting rods on same journal. Clearance should be 0.007-0.025 in. (0.170.63 mm). NOTE: If side clearance is incorrect, rod caps or rod and piston may be installed in wrong position.
FEELER GAUGE
OIL PAN MOUNTING FLANGE
PAN RAIL HOLES
Figure 2-164: Oil Pan and Seal Installation

NOTE: Be sure pan rear seal was not displaced during pan installation. 10. Clean crankshaft flange and flywheel mounting surfaces. 11. Install flywheel on flange (Figure 2-165). Be sure converter bolt pads are facing out and away from engine. 12. Apply 1-2 drops Loctite 242 to new flywheel bolts (but only if new bolts do not have pre-applied thread locker). Then install and tighten bolts 65 lb-ft (88 Nm) torque.
Figure 2-163: Checking Connecting Rod Side Clearance
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Engine
2-85
CONVERTER BOLT PADS FLYWHEEL
TIMING CHAIN-SPROCKET-GEAR INSTALLATION

1. 2. Rotate crankshaft so #1 piston is at TDC. Install sprocket drive keys in camshaft and crankshaft (Figure 2-167).
THRUST WASHER AND BOLT TIMING MARK LOCATIONS CRANKSHAFT SPROCKET INJECTION PUMP DRIVE GEAR
FLYWHEEL BOLTS (6)
CRANKSHAFT FLANGE CYLINDER BLOCK
CAMSHAFT SPROCKET
Figure 2-165: Flywheel Installation
CAMSHAFT INSTALLATION
1. 2. 3. 4. Place engine in upright position so cam bearing bores are vertical. Lubricate camshaft bearing journals with engine oil. Then lubricate cam bearings with long nozzle oil can. Lubricate camshaft lobes with assembly lube. Install 8-10 in. (20 -25 cm) long bolt or threaded rod on cam sprocket bolt hole. Bolt will serve as handle and make cam installation easier. Install camshaft. Lower and guide cam carefully through and into bearings (Figure 2-166). Lubricate and install camshaft spacer and thrust plate. Beveled edge of spacer faces toward cam. Apply 1-2 drops Loctite 242 to thrust plate bolt threads. Then install and tighten bolts 17 lb-ft (23 Nm) torque. Remove bolt or rod from camshaft.
BOLTS (2) THRUST PLATE SPACER CAM LOBES CAM JOURNALS
SPROCKET DRIVE KEYS
TIMING CHAIN
5. 6. 7. 8.
6-S02-075
Figure 2-167: Timing Chain - Sprocket Gear Installation

3. 4. 5. Place block in upright position so cam is facing up. Then rotate camshaft so drive key is toward top of block. Assemble timing chain and sprockets. Make sure sprocket timing marks are aligned as shown (Figure 2-167). Align sprockets with drive keys in crankshaft and camshaft. Then install chain and sprockets as assembly (Figure 2-167). Turn camshaft to align sprockets if necessary. Do not turn sprockets. Check chain deflection with dial indicator. If deflection is greater than 0.51 in. (13 mm), chain is stretched and will have to be replaced. Install injection pump drive gear, thrust washer, flat washer (if equipped), and bolt (Figure 2-167). Tighten bolt to 126 lb-ft (171 Nm) torque. Apply 1-2 drops Loctite 242 to bolt threads before installation. Position gear so timing marks is at 12 oclock position. Lubricate chain, sprockets, and gear with engine oil.
6.
7.
6-S02-075
Figure 2-166: Camshaft Installation

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Engine _____________________________________________________________________
FRONT COVER AND BAFFLE INSTALLATION

1. 2. Install new seal in front cover with installer tool J22102. Apply sealer to front cover as follows: Use anaerobic sealer such as Loctite 510 on cover surfaces that contact block (Figure 2-168). Use RTV-type sealer such as Permatex High Temp, Ultra Blue, or Loctite 599 (gray) to oil pan contact surface of cover (Figure 2-168). Install front cover on engine block (Figure 2-168). Be sure cover is seated on dowels, block face, and oil pan. Install and tighten front cover bolts as follows: Tighten cover-to-engine block bolts to 33 lb-ft (45 Nm) Tighten cover-to-oil pan bolts to 4-10 lb-ft (5-14 Nm) Install baffle on front cover. Maintain minimum clearance of 0.040 in. (1.02 mm) between baffle and injection pump gear. Tighten baffle attaching bolts/nuts to 33 lb-ft (45 Nm) torque.
3. 4.
5.
FRONT COVER BAFFLE
SEALANT APPLICATION DIAGRAM
ANAEROBIC SEALER HERE
SEAL RTV SEALANT HERE
RTV SEALANT HERE
Figure 2-168: Front Cover Installation
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Engine
2-87
FUEL INJECTION PUMP INSTALLATION

1. 2. 3. 4. Install injection pump gasket on front cover studs. Mount injection pump on front cover studs (Figure 2-169). Install retaining nuts finger tighten. Rotate crankshaft if necessary, to place timing mark on injection pump drive gear at 12 oclock position. Install pump driven gear into fron cover so the timing mark on the driven gear aligns with the timing mark on the drive gear. Turn pump shaft (not gear), until shaft pin aligns with slot in driven gear. Then slide pump into place and secure it with gear attaching bolts. Apply 1-2 drops Loctite 242 to bolt threads beforehand and tighten bolts to 13-20 lb-ft (18-27 Nm) torque. Tighten pump retaining nuts to 31 lbft (42 Nm) torque. Perform Timing Setting Procedure to adjust injection pump timing. Pump may also require TDC offset adjustment if front cover was replaced, or PCM was replaced with the fuel injection pump.
WATER PUMP AND ADAPTER PLATE INSTALLATION

1. Apply Permatex #2 to both sides of gasket and install gasket and water pump on adapter plate (Figure 2-171). Tighten adapter plate bolts to 13-20 lb-ft (18-27 Nm).
ADAPTER PLATE WATER PUMP GASKET
5.
6.
FRONT COVER TIMING MARK
PUMP GASKET PUMP TIMING MARK INJECTION PUMP
Figure 2-171: Assembling Water Pump and Adapter Plate

2. Apply Loctite gasket maker or 510 to contact area of adapter plate as shown (Figure 2-172).
SEALER BEAD
ADAPTER PLATE
6-S02-050.1
Figure 2-169: Injection Pump Installation
DRIVEN GEAR
Figure 2-172: Adapter Plate Sealer Application

3.
CAMSHAFT PIN DRIVE GEAR
Install adapter plate and water pump on front cover. Tighten all studs and short bolts marked A to 13-20 lb-ft (18-27 Nm). Tighten large studs and large bolt marked B to 25-37 lb -ft (34-50 Nm) (Figure 2-173).
Figure 2-170: Pump Driven Gear Installation
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Engine _____________________________________________________________________
VALVE LIFTER INSTALLATION

1.
ADAPTER PLATE FRONT COVER
2. 3.
A
4.
A
Prime valve lifters in kerosene then engine oil. Immerse lifter in kerosene rst and oil last. Then pump plunger with pushrod to force solution through lifter. Lubricate lifters with oil and install in cylinder block. Position guide plates on lifters. Then install guide clamps and bolts. Tighten bolts to 15-20 lb-ft (20 -27 Nm) (Figure 2-175). Rotate crankshaft several turns to ensure lifters move freely.
GUIDE CLAMP
WATER PUMP VALVE LIFTERS
Figure 2-173: Adapter Plate and Water Pump Installation

4. Install oil fill tube on adapter plate with two washers and nuts. Tighten nuts to 13-20 lb-ft (18-27 Nm) (Figure 2-174). Install pulley on water pump shaft flange.
GUIDE PLATES BLOCK
5.
ADAPTER PLATE
CRANKSHAFT
Figure 2-175: Valve Lifter Installation
OIL FILL TUBE
Figure 2-174: Oil Fill Tube Installation
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Engine
2-89
CYLINDER HEAD INSTALLATION Important:

Make sure that the block and head gasket surfaces are clean. The head gasket material is soft. Handle the gasket with care and make sure the gasket surface is not creased or dented. CAUTION: Do not apply any type of sealant to the head gaskets. The head gasket is made with sealant on the gasket surface. Additional sealer may cause leakage and engine damage. 1. 2. Place each head gasket on block deck and dowels (Figure 2-176). Carefully position each cylinder head on gasket and on dowels (Figure 2-176).
HEAD BOLT CYLINDER HEAD
HEAD GASKET
CAUTION: Follow torque sequence for head bolts. This is necessary for correct compression of head gasket. Failure to do so will cause leaks. NOTE: Use the correct fastener in the correct location. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install cylinder head bolts as follows: a. Apply Loctite 592 pipe thread sealant to bolt threads and under bolt heads. b. Tighten bolts in sequence (Figure 2-177), to 20 lb-ft (25 Nm) torque. c. Repeat bolt tightening sequence to a torque of 55 lb-ft (75 Nm). d. Retighten bolts in sequence to 55 lb-ft (75 Nm). e. Tighten bolts an additional 90-100 degrees (1/4 plus turn).
DOWELS
Figure 2-176: Cylinder Head and Gasket Installation
Figure 2-177: Cylinder Head Bolt Tightening Sequence
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Engine _____________________________________________________________________
GLOW PLUG AND INJECTION NOZZLE INSTALLATION

1. Install glow plugs in each cylinder head (Figure 2-178). Tighten plugs to 8-12 lb-ft (11-16 Nm).
GLOW PLUG
PUSHROD, ROCKER ARM AND SHAFT INSTALLATION

NOTE: The rocker arm end of each pushrod is identified with a paint stripe. In addition, the ball at this end of the pushrod is heat treated/coated giving it a distinctive color. Be sure the pushrods are installed with the correct end up and toward the rocker arm. 1. 2. Insert pushrods in roller lifters. Verify that all pushrods are correctly installed. Index crankshaft and pistons for rocker arm shaft installation as follows: a. Position breaker bar and socket on crankshaft damper bolt. Do not use starter to rotate crankshaft. Turn shaft with hand tools only. b. Rotate crankshaft counterclockwise, and align mark on torsional damper with O mark on front cover timing tab (Figure 2-180). c. Rotate engine counterclockwise an additional 3 1/2 inches (89 mm), measured at mark on torsional damper. Damper mark should align with water pump first, lower attaching bolt at this point (Figure 2-176). Align and install rocker arm and shaft assemblies (Figure 2-181). Be very sure pushrods are seated in lifter and in rocker arms. Also be sure rocker arm retainers are in place and seated. Install rocker arm shaft retainers and bolts. Tighten bolts in small increments until snug, with socket and ratchet or nut runner.
Figure 2-178: Glow Plug Installation

2. 3. 4. 5. 6. Install gasket on each injector nozzle (Figure 2-179). Install injector nozzles in cylinder heads finger tight. Tighten nozzles to 44-60 lb-ft (60-81 Nm) torque with installer tool J29873. Connect return hoses between nozzles and install hose clamps. Install plug on rear nozzle and install hose clamp.
INJECTOR NOZZLE GASKET HOSE CLAMPS
3.
4.
CAUTION: Do not use an air wrench to tighten the bolts. In addition, stop tightening if the bolts become hard to turn before they are seated. If this condition occurs, the crankshaft and pistons are not properly indexed, allowing the valves to contact the pistons. 5. Verify that pushrods are properly seated in rocker arms and lifters. Then final-tighten rocker arm shafts bolts to 41-lb-ft (56 Nm) torque.
PLUG RETURN HOSES
Figure 2-179: Fuel Injector Nozzle Installation
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Engine
RETAINER
2-91
ROCKER COVER INSTALLATION

PUSHROD
1.
2. 3. 4.
5.
Clean mounting anges on both rocker covers and cylinder heads. Wipe ange sealing surfaces off with isopropyl alcohol to prepare surface for sealer application. Apply RTV-type sealer to cover sealing surfaces. Align and install covers on cylinder heads (Figure 2-182). Install cover attaching bolts and studs and tighten to 13-25 lb-ft (18-34 Nm). Tighten fasteners starting at center and working toward each end. Install all necessary fuel line and wire harness brackets on covers.
ROCKER ARM AND SHAFT ASSEMBLY
WATER PUMP FIRST LOWER BOLT
Figure 2-181: Rocker Arm and Shaft Installation

FUEL LINE SUPPORT BRACKET ROCKER COVER
3.5 in. (89 mm)
O(TDC) MARK ON TIMING TAB
Figure 2-180: Crankshaft Index Position for Rocker Arm Installation

S02-084
Figure 2-182: Rocker Cover Installation
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Engine _____________________________________________________________________
FUEL INJECTOR LINE INSTALLATION

1. 2. 3. 4. 5. 6. Flush injector lines with fresh diesel fuel and compressed air. Attach fuel lines to injectors and pump. Verify line routing and connection (Figures 2-183 and 2-184). Tighten fuel line fittings at injectors and at pump to 19 lbft (25 Nm) torque. Install clips on injector lines (if removed). Attach injector line clips to rocker covers. Install boot over injection line fittings at pump.
CYL NO. 7
WATER CROSSOVER INSTALLATION

1. 2. 3. 4. 5. 6. Apply Permatex #2 to crossover gaskets and position gaskets on cylinder heads (Figure 2-185). If new crossover is being installed, transfer hose fittings to new crossover. Use Loctite PST on fitting threads. Connect bypass hose to water pump (Figure 2-185). Install crossover. Tighten cross-to-cylinder head bolts/ studs to 25-37 lb-ft (34-50 Nm). Connect bypass hose to crossover hose fittings on crossover (Figure 2-185). Install thermostat, gasket and housing on water crossover. Apply Permatex #2 to gasket before installation and tighten housing bolts to 31 lb-ft (42 Nm) torque.
CYL NO. 8
CYL NO. 6 CYL NO. 4
CYL NO. 5 CYL NO. 3
WATER CROSSOVER
CYL NO. 2
CYL NO. 1 GASKET GASKET
Figure 2-183: Fuel Injector Line Layout
CYL NO. 8 CYL NO. 1
CYL NO. 7 CYL NO. 2
CYL NO. 3 CYL NO. 4
CYL NO. 6 CYL NO. 5
Figure 2-184: Fuel Connections at Pump

BYPASS HOSE
Figure 2-185: Water Crossover Installation
EXHAUST MANIFOLD INSTALLATION

1. 2. 3. Position gasket on manifold. Then insert 1-2 bolts through manifold to hold gasket in place. Install manifold attaching bolts finger tight. Verify that gaskets are properly aligned. Tighten manifold bolts to 18-25 lb-ft (24-34 Nm) torque.
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Engine
2-93
TORSIONAL DAMPER AND CRANKSHAFT PULLEY INSTALLATION

1. 2. 3. 4. Install damper key in crankshaft (Figure 2-186). Lubricate crankshaft hub, damper seal contact surface, and damper hub bore with engine oil or chassis grease. Align and install damper on crankshaft. Install washer and damper bolt. Tighten bolt 200 lb-ft (270 Nm) torque. Have helper prevent crankshaft from turning with holding tool installed on flywheel.
DAMPER KEY
TURBOCHARGER AND INTAKE MANIFOLD INSTALLATION

1. 2. 3. Apply Permatex High Tack to manifold gaskets and position gaskets on cylinder heads. Install left/right side manifold halves. Tighten attaching bolts/studs to 31 lb-ft (42 Nm) torque. Mount turbocharger or cylinder block, and install attaching bolts, nuts, and brackets. Tighten attaching bolts/ nuts to 43 lb-ft (58 Nm) torque. Connect exhaust inlet tubes to exhaust manifolds and turbocharger (Figures 2-8 and 2-9). Tighten exhaust tube flange clamps to 7 lb-ft (10 Nm) torque.
4.
TORSIONAL DAMPER
NOTE: Do not install the intake manifold crossover housing at this time. The housing will not be installed until after the engine is installed in the vehicle. 5. 6. 7. 8. 9. 10. 11. 12. 13. Install alternator mounting brackets, and idlers on right side cylinder head. Install power steering pump and mounting brackets. Install A/C compressor and braces. Install crankshaft pulley. Tighten pulley attaching bolts to 48 lb-ft (65 Nm) torque. Install water pump pulley, if not installed before this. Install fan and clutch assembly. Tighten attaching bolts/ nuts to 15-20 lb-ft (20-27 Nm) torque. Install serpentine belt. Install glow plugs, if not previously installed. Tighten plugs to 13 lb-ft (18 Nm) torque. Install wire harness and hose brackets.
CRANKSHAFT SEAL SURFACE
Figure 2-186: Torsional Damper Installation
Fan and Pulley Installation

1. 2. 3. 4. Install crankshaft pulley and bolts (Figure 2-187). Slide fan onto clutch and install bolts finger tight. Install fan and clutch assembly on water pump shaft. Hold water pump shaft with spanner J41240-1 and tighten clutch nut to 80-100 lb-ft (108-135 Nm) with wrench J41240-5A. Torque fan bolts to 15-20 lb-ft (20-27 Nm).
WRENCH FAN SPANNER CLUTCH
5.
PULLEY
Figure 2-187: Fan and Pulley Installation.

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Engine _____________________________________________________________________
REPROGRAMMING TDC OFFSET

TDC offset must be reprogrammed whenever the PCM, front cover, timing gears, timing chain, crankshaft position sensor, or other components affecting timing are replaced. The procedure for reprogramming TDC offset is as follows: 1. Verify that vehicle batteries are fully charged. 2. Start and run engine at curb idle speed. 3. Continue running engine at curb idle speed until coolant reaches normal operating temperature. 4. Connect Tech 1 scan tool to data link/diagnostic connector. 5. Select FO: OUTPUT TESTS from Miscellaneous Test menu. 6. 7. 8. Select FO: INJ PUMP. Select TDC OFFSET LEARN. Press Up Arrow key and PCM will learn engine top dead center offset value. This requires approximately 20 seconds. Correct learned TDC Offset value should be between minus 0.25 and minus 0.75. If value is not within specified range, loosen injection pump and rotate it to correct value as follows: If value is between plus 1.0 and minus 0.25, rotate pump toward driver side to achieve specified value. If value is between minus 0.75 and minus 2.0, rotate pump toward passenger to achieve specified value.
9.
NOTE: 1 mm pump movement in either direction results in approximately 2 degrees change.

+1.0 +.5 0 -.25 -.75 -1.0 -1.5 -2.0
When the timing is in this region, rotate pump toward driver side to achieve target zone.
Target Zone
When the timing is in this region, rotate pump toward passenger side to achieve target zone.
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Engine
2-95
TORQUE SPECIFICATIONS
Item Block drainplugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant crossover/thermostat housing bolts . . . . . . . . . . . . . . . . . . . Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front cover bolts/studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic lifter guide plate and clamp bolts. . . . . . . . . . . . . . . . . . . Intake manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection line ttings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump driven gear bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil lter adapter bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing cap bolts Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer 12 mm . . . . . . . . . . . . . . . . . . . . . Outer 10 mm . . . . . . . . . . . . . . . . . . . . . Oil pan bolts (all except rear two bolts) . . . . . . . . . . . . . . . . . . . . . . (rear two bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump mounting stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pan drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump drive, clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker shaft bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsional damper bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air horn bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil ller neck nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water pump-to-adapter bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water pump-to-front cover bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger mounting bolts/nuts . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger inlet tube clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splash shield screws: 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose/wire harness brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine mount-to-block bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust U-bolt clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Tighten bolts in sequence an additional 1/4 turn. Lb-Ft. 16 126 17 48 31 30 55* 25 66 33 13 19 31 19 59 17 31 47 55* 48* 30 17 66 20 31 16 41 200 17 20 20 43 35 12 30-40 5 90 Lb-In. 89 45-65 90 90-130 45-65 Nm 22 171 23 65 42 41 75 34 89 45 18 26 42 26 80 23 42 64 75 65 40 10 23 89 27 42 22 56 270 5-7 23 28 28 58 10 47 10-15 5-7 16 41-54 7 122
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Engine _____________________________________________________________________
ENGINE SPECIFICATIONS
General Data:
Displacement Type Bore Stroke Compression Ratio Firing Order Oil Pressure 6.5L/395 c.i.d. 4 Cycle, Diesel, Liquid-Cooled 4.06 in. (103 mm) 3.82 in. (97 mm) 20.2:1 1-8-7-2-6-5-4-3 6 psi (69 kPa) at idle (hot); 30 psi (552 kPa) at 2000 RPM
Camshaft:
Lobe Lift 0.05 Intake. . . . . . . . . . . . . . . . . . . . . . . . .0.281 in. (7.133 mm) Exhaust . . . . . . . . . . . . . . . . . . . . . . .0.281 in. (7.133 mm) Camshaft End Play . . . 0.002-0.012 in. (0.051-0.305 mm) Journal Diameter (Refer to Camshaft Specifications Chart)
1NOTE:
Cylinder Bore
Diameter (Refer to Service Piston and Bore Specifications) Out-of-Round (Maximum) . . . . . . . .0.0008 in. (0.02 mm) Taper (Thrust Side) (Maximum) . . . .0.0008 in. (0.02 mm) Piston to Bore Clearance1: Bores 1 through 6 . . 0.0037-0.0047 in. (0.094-0.120 mm) Bores 7 and 8. . . . . . . . 0.004-0.005 in. (0.107-0.133 mm)
Add 0.0005 in. (0.013 mm) to cylinder bore diameters to determine proper bore size for cylinders no. 7 and no. 8. 2NOTE: Ring end gap specifications are for new bores; worn bores will generate larger ring end gaps.
Valve Train:
Lifter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Roller Rocker Arm Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5:1 Valve Lash (Intake and Exhaust) . . . . . . . . . . . Not Adjustable Valve Recess Depth: Intake. . . . . . . . . . . . . . . . . . . . . . . .0.0013 in. (0.034 mm) Exhaust . . . . . . . . . . . . . . . . . . . . . .0.0018 in. (0.048 mm) Face Angle (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . 45 Seat Angle (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . 46 Seat Runout (Intake and Exhaust) . . . . . .0.0019 in. (0.05 mm) Seat Width Intake. . . . . . . . . . . . . . . . 0.035-0.060 in. (0.89-1.53 mm) Exhaust . . . . . . . . . . . . . . 0.062-0.093 in. (1.57-2.36 mm) Stem Clearance Intake. . . . . . . . . . . . . 0.001-0.0027 in. (0.026-0.069 mm) Exhaust . . . . . . . . . . . 0.001-0.0027 in. (0.026-0.069 mm) Valve Spring Pressure Closed . . . . . . . . . . . 80 lb at 1.81 in. (356 N @ 46.0 mm) Open . . . . . . . . . . 230 lb at 1.39 in. (1025 N @ 35.3 mm) Installed Height . . . . . . . . . . . . . . . . . . . . . . . . 1.8 in. (46 mm) Timing Chain Free Play New Chain. . . . . . . . . . . . . . . . . . . . . .0.500 in. (12.7 mm) Used Chain . . . . . . . . . . . . . . . . . . . . .0.800 in. (20.3 mm)
Piston Ring:
Groove Clearance: Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keystone Ring Second . . . . . . . . . . . . 0.0015-0.0031 in. (0.039-0.079mm) Oil . . . . . . . . . . . . . . 0.0016-0.0035 in. (0.040-0.090 mm) End Gap2: Top . . . . . . . . . . . . . . . . . 0.010-0.020 in. (0.26-0.51 mm) Second . . . . . . . . . . . . . . . 0.029-0.039 in. (0.75-1.00 mm) Oil . . . . . . . . . . . . . . . . . . 0.010-0.020 in. (0.25-0.51 mm)
Piston Pin:
Diameter Fit in Piston Fit in Rod 1.220-1.221 in. (30.9961-31.0039 mm) 0.00039-0.0006 in. (0.010-0.0153 mm) 0.0003-0.001 in. (0.0081-0.0309 mm)
Crankshaft:
Journal Diameter (Refer to Main and Rod Journal Specification Charts) Journal Taper (Maximum). . . . . . . .0.0002 in. (0.005 mm) Journal Out-of-Round (Maximum) .0.0002 in. (0.005 mm) Main Bearing Clearance No. 1, 2, 3, 4 . . . . . . . 0.0018-0.003 in. (0.045-0.083 mm) No. 5 . . . . . . . . . . . . . 0.002-0.0037 in. (0.055-0.093 mm) Crankshaft End Play 0.0039-0.0098 in. (0.10-0.25 mm) Rod Bearing Clearance (Select Fit) 0.0017-0.0039 in. (0.045-0.100 mm) Rod Side Clearance 0.007-0.025 in. (0.17-0.63 mm)
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Engine
2-97
SERVICE PISTON AND CYLINDER BORE SPECIFICATIONS (MM)

NOTE: Cylinders #7 and #8 require 0.013 mm (0.005 in.) additional clearance (piston to bore). Engine Displacement 6.5L Piston Grade Production Std.JT Production Rework S or ST Service Std.JT Service Hi LimitGT 0.50 MM Oversize Skirt Diameter 102.865-102.880 103.008-103.026 102.865-102.883 102.904-102.922 103.339-103.417 Bore Diameter 1 thru 6 102.972-102.987 103.117-103.130 102.972-102.990 103.013-103.026 103.508-103.512 Bore Diameter 7&8 102.985-103.003 103.130-103.143 102.985-103.003 103.026-103.039 103.521-103.525
CRANKSHAFT MAIN JOURNAL DIAMETER AND BEARING SELECTION (MM)

6.5L Engines Crankshaft Main Journal Diameter #1 to #4 74.917 74.925 Blue 74.925 74.933 Orange or Red 74.933 74.942 White #5 74.912 74.920 Blue 74.920 74.928 Orange or Red 74.928 74.936 White Cylinder Main Bearing Bore Diameters 79.850 79.842 Stamp 3 1-.026 U.S. in Case 1-.026 U.S. in Cap 1-.026 U.S. in Case 1-.013 U.S. in Cap 1-.026 U.S. in Case 1-STD in Cap 79.842 79.834 Stamp 2 1-.013 U.S. in Case 1-.026 U.S. in Cap 1-.013 U.S. in Case 1-.013 U.S. in Cap 1-.013 in Case 1-STD in Cap 79.834 79.826 Stamp 1 1-STD in Case 1-.026 U.S. in Cap 1-STD in Case 1-.013 in Cap 1-STD Case 1-STD in Cap
NOTE: U.S. indicates undersize bearing. Bearing sizes are in millimeters. To convert from metric to U.S. sizes, multiply metric (mm) figure by 0.03937.
CRANKSHAFT CONNECTING ROD JOURNAL DIAMETER AND BEARING SELECTION (MM)

Crankshaft Pin Journal Diameter 60.913 mm 60.926 mm Green 60.926 mm 60.939 mm Yellow Connecting Rod Bearings Standard in rod .026 U.S. in cap Standard in rod Standard in cap Rod & Cap Bearings Color Codes .026 U.S. (Green) Standard (Yellow) Connecting Rod ID 64.150 mm 64.124 mm
NOTE: To convert metric to U.S. sizes, multiply metric (mm) figure by 0.03937.
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Engine _____________________________________________________________________
BLOCK, CAMSHAFT AND BEARING SIZES (MM)

6.5L Engines #1 Camshaft Journal Diameter O.D (Diameter Tolerance 0.55 mm) Finished Cam Bearing ID (Diameter tolerance 0.038 mm) Camshaft Bearing Clearance Cam Bore Diameter (Block) Cam Bearing O.D. Press Fit (Bearing to Block) 55.025 54.970 55.088 55.050 .118 .025 59.17 59.12 59.30 59.25 .18 .08 #2 55.025 54.970 55.088 55.050 .118 .025 58.92 58.87 59.05 59.00 .18 .08 #3 55.025 54.970 55.088 55.050 .118 .025 58.67 58.62 58.80 58.75 .18 .08 #4 55.025 54.970 55.088 55.050 .118 .025 58.42 58.37 58.55 58.50 .18 .08 #5 51.025 50.970 51.083 51.045 .113 .020 50.42 50.37 50.55 50.50 .18 .08
NOTE: To convert metric to U.S. sizes, multiply metric (mm) amount by 0.03937.
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Engine
2-99
ESSENTIAL TOOLS
J26999-30 J23523-F J22102 J26999
J23951 J39084
J34116
J33139
J41240-5A J35555 J41240-1
Tool No. J23523-F J26999-30 J22102 J26999 J39084 J33139 J23951 J35555 J8001 J23129 J41613 J41415-A J41240-1 J41240-5A
Description Harmonic Balancer Remover/Installer Set Compression Gauge Adapter Front Crankshaft Seal Installer Compression Gauge Rear Main Seal Installer Engine Lifting Sling and Bracket Water Manometer Vacuum (MITY-VAC) Pump Dial Indicator Set (not shown) Universal Seal Remover, use with slide hammer J6125-1B (not shown) Turbocharger Inlet Guard (not shown) Glow Plug Socket (not shown) Spanner, Fan Clutch (not shown) Wrench, Fan Clutch (not shown)
Procure from Kent-Moore.
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SPECIAL TOOLS
J8062 J29834 J8080 J6098-10
J33042
J33049
J24270
J29134-8
J8087
J39507
J8089 or J8358
J25087-C
J8037
Tool No. J29834 J8080 J6098-10 J8062 J33042 J33049 J24270 J29134-8 J8087 J39507 J8089 J8358 J25087-C J8037 J8101 J42525 J6098-O1
Description Valve Lifter Removal Tool Main Bearing Shell Remover/Installer (In-Vehicle) Camshaft Bearing Remover/Installer (use with J33049) Valve Spring Compressor Static Timing Mark Gauge Camshaft Bearing Replacement Set (Universal) Ridge Reamer Piston Pin Retaining Ring Compression Sleeve Cylinder Bore Gauge Piston Retaining Ring Installer Set Carbon Remover Brush, for cast iron and steel Carbon Remover Brush, for aluminum Oil Pressure Tester/Pump Primer Piston Ring Compressor Valve Guide Cleaner (not shown) Piston Ring Expander (not shown) Camshaft Bearing Remover/Installer, use with J6098-10 and J33049 (not shown)
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PCM/Tech 2 Scan Tool

TABLE OF CONTENTS
Basic Symptom Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cuts Out, Misses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Engine Cranks but Does Not Run . . . . . . . . . . . . . . . . . . . . 15 Excessive Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuel Knock/Combustion Noise . . . . . . . . . . . . . . . . . . . . . . 20 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hesitation, Sag, Stumble . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Intermittent Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lack of Power, Sluggishness, or Sponginess . . . . . . . . . . 19 Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Surges/Chugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Connectors 24 Way PCM-Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 32 Way PCM-Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 32 Way PCM-Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 40 Way GM Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 56 Way Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 141 76 Way Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Diagnostic System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OBD II Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . 23 P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 P0121 Accelerator Pedal Position (APP) Sensor 1 Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 P0122 Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 P0123 Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 P0126 Engine Coolant Temperature Insufficient For Stable Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 P0182 Fuel Temperature Sensor Circuit Low Voltage . . . . 50 P0183 Fuel Temperature Sensor Circuit High Voltage . . . 52 P0215 Engine Shutoff Solenoid Control Circuit . . . . . . . . . 54 P0216 Injection Timing Control System . . . . . . . . . . . . . . . 56 P0219 Engine Overspeed Condition . . . . . . . . . . . . . . . . . . 59 P0220 Accelerator Pedal Position (APP) Sensor 2 Circuit 60 P0221 Accelerator Pedal Position (APP) Sensor 2 Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 P0222 Accelerator Pedal Position (APP) Sensor 2 Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 P0223 Accelerator Pedal Position (APP) Sensor 2 Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 P0225 Accelerator Pedal Position (APP) Sensor 3 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 5745159 P0226 Accelerator Pedal Position (APP) Sensor 3 Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 71 P0227 Accelerator Pedal Position (APP) Sensor 3 Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 P0228 Accelerator Pedal Position (APP) Sensor 3 Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 P0231 Fuel Lift Pump Secondary Circuit Low Voltage . . . 76 P0236 Turbocharger (TC) Boost System . . . . . . . . . . . . . . 79 P0237 Turbocharger (TC) Boost Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 P0238 Turbocharger (TC) Boost Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 P0251 Injection Pump Cam System . . . . . . . . . . . . . . . . . . 87 P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults . . . . . . . . . . . . . . . 90 P0300 Engine Misfire Detected . . . . . . . . . . . . . . . . . . . . . . 92 P0301-P0308 Specific Cylinder Misfire Detected . . . . . . . 94 P0335 Crankshaft Position (CKP) Sensor Circuit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 P0370 Timing Reference High Resolution . . . . . . . . . . . . . 99 P0380 Glow Plug Circuit Performance . . . . . . . . . . . . . . . 102 P0501 Vehicle Speed Sensor Circuit . . . . . . . . . . . . . . . . 106 P0567 Cruise Resume Circuit . . . . . . . . . . . . . . . . . . . . . . 109 P0568 Cruise Set Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 111 P0571 Cruise Brake Switch Circuit . . . . . . . . . . . . . . . . . . 113 P0601, P0602 and P0606 Internal PCM Errors . . . . . . . . . 116 P1125 Accelerator Pedal Position (APP) System . . . . . . 117 P1214 Injection Pump Timing Offset Error . . . . . . . . . . . 119 P1216 Fuel Solenoid Response Time Too Short . . . . . . . 120 P1217 Fuel Solenoid Response Time Too Long . . . . . . . 122 P1218 Injection Pump Calibration Circuit . . . . . . . . . . . . 124 P1627 Analog to Digital Performance . . . . . . . . . . . . . . . 126 P1635 PCM 5 Volt Reference Low . . . . . . . . . . . . . . . . . . . 127 P1641 Malfunction Indicator Lamp (MIL) Control Circuit 129 P1643 Wait to Start Lamp Control Circuit . . . . . . . . . . . . 131 P1654 Check Throttle Circuit . . . . . . . . . . . . . . . . . . . . . . 133 P1656 Wastegate Solenoid Control Circuit . . . . . . . . . . . 135 Powertrain Control Module (PCM) . . . . . . . . . . . . . . . . . . . . . . . . 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Reprogramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TDC Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Verifying Vehicle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tech 2 Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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POWERTRAIN CONTROL MODULE (PCM)

The Powertrain Control Module (PCM) is located in the passenger compartment under the center console. It is the control center for the fuel and emissions system. The PCM constantly looks at the information from various sensors, and controls the systems that affect vehicle performance. Through periodic system checks the PCM can recognize operational problems and alert the driver through the Malfunction Indicator Light (MIL). Problems are stored as Diagnostic Trouble Codes (DTCs), which identify the problem areas to aid the technician in making repairs. The Powertrain Control Module, monitors a number of engine and vehicle functions and controls the following operations: Fuel control Fuel injection timing Speed Control Turbocharger Boost Transmission shift and shift quality functions. Specific transmission control diagnostics are covered in Section 5 of this service manual.
3. 4. 5.
Gain access to the PCM from the center console. Unplug the connectors from the PCM. Remove the PCM mounting hardware and the PCM.
Installation
1. 2. 3. 4. Install the mounting hardware to the new PCM. Secure the connectors to PCM. Relocate the PCM in the center console and tighten hardware. Reconnect the negative battery cables.
NOTE: NOTE: The MIL, and Check Throttle lamp will continue to be enabled until the PCM is programmed. Once the programming is complete, the lamps will be turned OFF and normal operation will resume. 5. Reprogram the new PCM.
Verifying Vehicle Repair

Verification of vehicle repair is more comprehensive for vehicles with OBD II system diagnostics. Following a repair, the technician should perform the following steps: 1. Review and record the failure records and/or Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL has been illuminated). 2. Clear DTC(s). 3. Operate the vehicle within conditions noted in the failure records and/or Freeze Frame data. 4. Monitor the DTC status information for the specific DTC which has been diagnosed until the diagnostic test associated with that DTC runs and passes. Following these steps is very important in verifying repairs on OBD II systems. Failure to follow these steps could result in unnecessary repairs.
PCM Repair
The only accepted repair to the PCM is replacement. If the diagnostic procedures call for the PCM to be replaced, it will be necessary to program the new PCM. Important When replacing the production PCM with a service PCM, a DTC P1214 will be stored. It is important to program TDC Offset into the service PCM. Refer to PCM Programming (TDC Offset). When a PCM has been replaced, a short glow plug duration will exist during the first ignition cycle (less than 2 seconds). After the first ignition cycle, the glow plug system will operate properly. When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label (do not record on PCM case). This will allow positive identification of PCM parts throughout the service life of the vehicle. To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM (for example, battery cable, PCM pigtail, PCM fuse, etc.). The ignition should be OFF for at least 30 seconds before disconnecting power to the PCM.
Reprogramming of the PCM

The PCM can be reprogrammed with the use of the Tech 2 and the GM Technical Information System (TIS). Follow the steps outlined on the TIS.
PCM Replacement
Removal
1. 2. Allow 30 seconds to elapse, after the ignition is turned to the off position, before disconnecting the battery cables. Disconnect the negative battery cables.
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PCM Programming TDC Offset

The PCM will automatically activate the TDC Offset program when the engine coolant is greater than 170 F (77C). If the PCM is not programmed with a TDC Offset, a P1214 will set. If the PCM and fuel injection pump are replaced together, or the front cover of the engine is replaced, the TDC offset will have to be cleared to allow the PCM to relearn the new value.
Clearing and learning TDC Offset

1. 2. 3. 4. 5. Install the scan tool. Starting the engine and operate the engine coolant is greater than 170 F (77 C). Clear all of the DTCs. Turn the ignition to the ON position with the vehicle OFF Hold the accelerator pedal in the wide open throttle position for a minimum of 45 seconds. This step prepares the PCM to activate the offset learn (internal). Turn the ignition to the OFF position for a minimum of 30 seconds. In this step the PCM is being powered down. Start the engine and verify that the ECT is greater than 170 (77C). Once the coolant is at the proper temperature, the PCM automatically learns a new TDC Offset. A new offset will overwrite the previous one. The offset should be between -0.25 and -0.75. If the offset is within the specified value, the procedure is complete. If the offset is not within the specified value, continue to the next step. Turn the engine OFF and loosen the injection pump mounting nuts. Slightly rotate the injection pump and tighten the nuts. Rotate the pump toward the driver side to achieve a move negative number and toward the passenger side to achieve a more positive 1mm pump movement = approximately 2.
TDC Offset Adjustment

It is necessary to reprogram TDC Offset when replacing a PCM to correct the DTC 1214 that will be stored in the memory.
6. NOTE: Note: The TDC Offset specification is only to be used after the Clear and Learn procedure is performed. 1. 2. 3. Start and run the engine at curb idle speed until the coolant reaches normal operating temperature. Connect a scan tool to the data link/diagnostic connector. Activate TDC LEARN in OUTPUT CONTROLS/ INJ. PUMP section of the scan tool. 8. 7.
NOTE: NOTE: If the engine stalls during TDC offset activation, loosen the injection pump mounting nuts and rotate the pump slightly towards the driver side of the vehicle, tighten the mounting nuts and repeat the step above. 4. If the learned TDC OFFSET is between -0.25 and -0.75 degrees, the procedure is complete. If the learned offset is not within the specifications, proceed to Clearing and Learning TDC Offset.
9.
+1.0
+.5
-.25
Target zone
-.75
-1.0
-1.5
-2.0
When the timing is in this region, rotate pump toward driver side to achieve target zone.
When the timing is in this region, rotate pump toward passenger side to achieve target zone.
02-S03-001
NOTE: Note: If you are unable to achieve the correct TDC Offset, repeat steps 2 through 9. It is possible that the injection pump may need to be adjusted multiple times until the specified value is achieved.
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TECH 2 INFORMATION
The On-Board diagnostic (OBD) System Check is an organized approach to identifying a problem created by a control module system malfunction. It must be the starting point for any driveability complaint diagnosis, this will direct the service technician to the next logical step in diagnosing the complaint. Understanding the chart and using it properly will reduce diagnostic time and prevent the unnecessary replacement of good parts.
Malfunction Indicator Lamp (MIL) Check Engine

This light is on the instrument panel and has the following functions. It informs the driver that a problem has occurred and that the vehicle should be taken in for service as soon as reasonably possible. As a bulb and system check, the light will come ON with the key ON and the engine not running. When the engine is started, the light will turn OFF. If the light remains ON, the self-diagnostic system has detected a problem. If the problem goes away, the light will go out in most cases after 10 seconds, but a DTC will remain stored in the PCM. When the light remains ON while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, an On-Board Diagnostic (OBD) System Check must be performed. This check will expose malfunctions which may not be detected if other diagnostics are performed prematurely.
Tech 2 Diagnosis
The Tech 2 (Figure 1) checks function of the solenoids, sensors, and PCM. The Tech 2 connector is attached to the vehicle data link connector (Figure 2). The Tech 2 provides data on individual circuits, or on all the related electrical components in snap shot mode. The PCM memory and circuits are interrogated by the Tech 2. The tool reads diagnostic trouble codes (DTC) and displays fault and performance parameters.
Check Throttle Lamp

This light is on the instrument panel and has the following functions: It informs the driver that a problem has occurred in the Accelerator Pedal Position (APP) circuit and the vehicle should be taken in for service as soon as reasonably possible. As a bulb and system check, the light will come ON with the key ON for 2 seconds. If the light remains ON, the self-diagnostic system has detected a problem. If the problem goes away, the light will go out in most cases after 10 seconds, but a DTC will remain stored in the PCM. When the light remains ON while the engine is running, or when a malfunction is suspected, an On-Board Diagnostic (OBD) System Check must be performed. This check will expose malfunctions which may not be detected if other diagnostics are performed prematurely.
Figure PCM-1: TECH 2 The recommended method for reading DTC(s) stored in memory is by using a Tech 2 plugged into the DLC (Figure 2).
DATA LINK CONNECTOR
01-S05-001
I.P. CLOSEOUT PANEL
Figure PCM-2: Data Link Connector
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DIAGNOSTIC SYSTEM CHECK Circuit Description

The Diagnostic System Check is an organized approach to identifying a condition that is created by a malfunction in the powertrain control system. The Diagnostic system check must be the starting point for any driveability concern. Understanding and correctly using the diagnostic table reduces diagnostic time, and prevents the replacement of good parts.
Test Description
The numbers below refer to the step number in the diagnostic table. 3.This step stores the powertrain control module (PCM) diagnostic trouble code (DTC) information into the Tech 2 memory. After you complete the diagnostic procedure, review the
captured information in order to catch the next DTC if the control module stores multiple DTCs. Review the Freeze Frame data and the Failure Records data. Use this information in order to determine how frequently and how recently the DTC set. This information may help diagnose an intermittent condition. Information about the operating conditions at the time that the DTC set may also help diagnose an intermittent condition. Capturing the stored information saves the data that the PCM loses during the following conditions: When a diagnostic procedure instructs you to clear the DTCs. When a diagnostic procedure instructs you to disconnect the PCM connectors. When a diagnostic procedure instructs you to replace the PCM.
Diagnostic System Check

Step 1 Action Connect the Tech 2 to the vehicle data link connector (DLC) and turn on. Does the Tech 2 Power up? Attempt to start the engine. Does the engine Start and Idle? Select the DTC display function for the PCM. Does the Tech 2 display any DTCs? Value(s) Yes Go to step 2. No Go to No Scan Tool Data. Go to Engine Cranks but Does Not Run. Go to step 6 Go to diagnostic trouble code (DTC) list.
2 3 4 5
Go to step 3. Go to step 4. Go to step 5. Go to DTC P0601, P0602, P0604, P0606, P01621 or P01627. Refer to section 5 for the appropriate repair procedures. System OK
With a Tech 2, select Captured Info in order to store the powertrain DTC information. Did you complete the action? Does the Tech 2 display DTC P0601, P0602, P0604, P0606 P1621 or P1627.
Is the customers concern with the automatic transmission?
Go to step 7.
Review the following symptoms. Refer to the application symptom diagnostic table: Hard Start. Surges/Chugs. Lack of Power, Sluggishness, or sponginess. Hesitation, Sag, Stumble. Cuts Out, Misses. Poor Fuel Economy. Excessive Smoke.
Go to the Intermittent Conditions.
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Tech 2 Data List

Use the Tech 2 data listed in this table for comparison after the Diagnostic System Check and finding the on-board Diagnostics function properly with no diagnostic codes displayed. The Typical Data Values are an average of display values recorded from normally operating vehicles. The Typical Data Values are intended to represent what a normally functioning system would display. The values you get may vary due to a low battery charge or other reasons, but they should be very close. Do not use a Tech 2 that displays incorrect data. Report the problem to the manufacturer. The use of an improperly functioning Tech 2 can result in misdiagnosis and unnecessary parts replacement. Use only the parameters listed in the tables for diagnosis. If the Tech 2 reads other parameters, the values are not recommended by AM General for use in diagnosis. If all values are within the range illustrated, refer to Symptoms Diagnostic Charts.
Typical Engine Data Values

Idle / Upper Radiator Hose Hot / Closed Throttle / Park or Neutral / A/C OFF Tech 2 Parameter A/C Compressor A/C Relay A/C Request APP 1 APP 2 APP 3 Act. Inj. Timing APP Angle Baro Boost Pressure Brake Switch Calc. A/C Load Crank Ref Missed Cruise Active Cruise Brake Sw. Cruise Switch Desired Idle Des. Inj Timing DTC Set This Ign. ECT Units Displayed Engaged/Disengaged On/Off Yes/No Volts Volts Volts Degrees % kPa/Volts kPa Open/Closed lb-ft # On/Off Open/Closed On/Off RPM Degrees Yes/No C/F Typical Data Value Disengaged Off no .45 - .95 volts 3.9-4.5 volts 3.6 - 4.1 volts 3.5-6 0% 3-5 volts (varies with altitude and baro pressure) 60 - 170 kPa varies with altitude Open 0 lb-ft 0 (missed) Off Closed Off 630-650 3.5 - 6.0 No 85C - 105C (185F - 221F) varies with coolant temp. 1.7-2.2 volts (varies with coolant temp.) 4 - 6% Varies 100 RPM from desired
ECT Sensor Engine Load Engine Run Time Engine Speed
Volts % Hours/Minutes/Seconds RPM
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Typical Engine Data Values

Idle / Upper Radiator Hose Hot / Closed Throttle / Park or Neutral / A/C OFF Tech 2 Parameter Engine Torque ESO Solenoid Fuel Rate Fuel Temp Units Displayed ft-lb On/Off Millimeters cubed C/F Typical Data Value 7 - 10 ft-lb On 7 - 12 mm3 60C - 80C (140F - 176F) Varies with fuel temp. 0 volts Enabled/Disable 60C - 80C (140F - 177F) Varies with incoming air 12 - 14 volts 0 (missed) 1.70 - 1.90 ms 12 - 15 volts Enabled Off 0 Off Off Off Varies (depends on start up ECT) -.25 to -.75 50C - 70C (122F - 158F) varies Park 00 Inactive Inactive No 50-70% On/Off On/Off
Glow Plug Glow Plug System Type IAT
Volts Federal/California C/F
Ignition Volts Inj. Pump Cam Reference Missed Inj. Pump Sol. Closure Time Lift Pump Lift Pump System MIL Lamp # of Current DTCs Resume Switch Service Throttle Soon Lamp Set Switch Start Up ECT TDC Offset TFT
Volts # Milliseconds Volts Disabled/Enabled On/Off # On/Off On/Off On/Off C/F Degrees C/F
TR Switch Vehicle Speed *VTD Auto Learn *VTD Fuel Disable *VTD Fuel Disable Until Ignition Off Wastegate Solenoid 1-2 Sol 2-3 Sol.
Park-Neutral, Reverse, Drive Ranges MPH kp/h Active/Inactive Active/Inactive Yes/No % On/Off On/Off
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Scan Tool Data Denitions

A list of each data message display on the scan tool will be explained in two groups: engine or transmission. This information will assist in emission or driveability problems. The displays can be viewed while the vehicle is being driven. Always perform the Engine Controls Diagnostic System Check first The Diagnostic System Check will confirm proper system operation. A/C Compressor -Range Engaged/Disengaged Boost Pressure - Range Open/Closed Indicates weather or not the air conditioning (A/C) compressor The amount of turbo boost pressure in the intake manifold.This is engaged. The output test function in the scan tool can only is measured in kPa and volts. True boost pressure is deterbe activated with the key ON and the engine OFF. mined by subtracting the barometric pressure from the actual reading. A/C Relay - Range Disabled/Enabled Crank Reference Missed - Range 0-8 Represents the commanded state of the air conditioning (A/C) clutch control relay. The A/C clutch should be engaged with The scan tool will display the numbers of crank pulses missed. ON displayed. At idle, the crank reference missed range should be 0. A/C Request - Range ON/OFF Cruise Active - Range ON/OFF Represents the state of the air conditioning (A/C) request input Indicates if the vehicle is in cruise control. from the control head. Cruise Brake Switch _ Range Open/Closed Act. Inj. Timing - Range 0 - 25 When the brake pedal is applied, the switch sends a signal to Current actual injection timing. the powertrain control module to disengage the cruise. APP Angle - Range 0 - 100 Percent Cruise Switch - Range ON/OFF Computed by the powertrain control module (PCM) from acIndicates if the cruise switch on the turn signal lever is in the celerator pedal position (APP) module voltage, or the throttle ON position. position, and should display 0 percent at idle and 100 percent Desired Idle - Range 0-3187 RPM at wide open throttle (WOT). The idle speed that is requested by the PCM. The PCM will APP 1 - Range 0-5 Volts compensate for various engine loads based on engine coolant The powertrain control module (PCM) uses the accelerator temperature to keep the engine at the desired speed. pedal position (APP) sensors to control fuel delivery as reDes. Inj Timing - Range 0-25 quested by the driver. Three APP sensors are located in a modThe amount of injection timing requested by the PCM. ule at the base of the accelerator pedal. The PCM only requires DTC Sent this ignition Range # information from one sensor, the other two serve as fail-safes. APP 1 should read approximately 0.35-0.95 volts at idle to Indicates the total number of current DTCs set this ignition cycle. above 4 volts at WOT. ECT - Range -40 to +151C (-40 to 304F) APP 2 - Range 0-5 Volts The engine coolant temperature (ECT) sensor sends a signal to The powertrain control module (PCM) uses the accelerator the PCM relative to the engine coolant temperature. The sensor pedal position (APP) sensors to control fuel delivery as reis a thermistor which changes internal resistance as temperaquested by the driver. Three APP sensors are located in a modture changes. When the sensor is cold and the internal resisule at the base of the accelerator pedal. APP 2 should read tance is high, the PCM monitors and interprets a high signal approximately 4.5 volts at idle and should steadily decrease to voltage as a cold engine. As the sensor warms and the internal approximately 1 volts at WOT. resistance decreases, the voltage signal will decrease and the PCM will interpret the lower voltage as a warm engine. APP 3 - Range 0-5 Volts Engine Load _ Range 0-100 Percent The powertrain control module (PCM) used the accelerator pedal position sensor in order to control the fuel delivery as reThe amount of load on the engine. quested by the driver. Three APP sensors are located in a modEngine Run Time - Range 00:00:00 (HRS/MIN/SEC) ule at the base of the accelerator pedal. APP 3 should read A measure of how long the engine has been operating. When approximately 2.5 volts at WOT. the ignition is cycled to OFF, the value is reset to zero. BARO - Range 10-105 kPa Engine Shutoff Solenoid - Range ON/OFF The barometric pressure reading is determined form the boost The engine shout-off solenoid (ESO) is located on the fuel insensor at ignition ON, engine OFF. The BARO reading jecting pump. When the ignition switch is OFF, the ESO is display represents barometric pressure and it is used to comin the NO FUEL position. The ESO prevents fuel from enterpensate for altitude differences. ing the fuel injection pump. Brake switch - Range Open/Closed Engine Torque - Range 0-999 lb-ft Is used for stop light and a redundant cruise control disengageThe amount of engine torque. ment switch. 1-1-02
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Engine Speed - Range 0-9999 RPM The engine speed is computed by the PCM from the crankshaft position sensor (CKP). If the CKP is inoperative, an RPM reading is taken from the injection pump cam signal. The RPM reading should remain closed to the desired idle during various engine loads with engine idling. The engine speed value is very accurate. Fuel Rate - Range 0-80 mm3 This reading is displayed in millimeters cubed (MM3). This is the amount of fuel the PCM is requesting. Fuel Temperature - Range -28 to +140C (-18 to +285F) There is a thermistor located in the optical sensor that determines fuel temperature. When the sensor is cold and the internal resistance is high, the PCM will interpret the low voltage as warm fuel. Glow Plug - Range 0-25.5 volts The amount of voltage applied to the glow plug system. The scan tool can be used to indicate if the glow plugs actually turn on by monitoring the voltage drop. Also, a good functional check of the glow plug relay. Glow Plug System - Range Enabled/Disabled Indicates whether or not the PCM has requested the glow plugs be turned on. IAT - Range -40 to +151C (-40 to +304) The intake air temperature sensor sends a signal to the PCM relative to the incoming air. The IAT is used by the PCM to adjust the fuel delivery. Ignition volts - Range 0-25.5 Volts This represents the system voltage measured by the PCM at its ignition feed circuit Ignition voltage is only present when the vehicle is running. Inj. Pump Cam Reference Missed - 0-8 The Tech 2 will display the number of cam pulses missed. At idle, the inj. pump cam reference missed. At idle, the inj.pump cam reference Missed range should read 0. Inj. Pump Sol. Closure Time - Range 0.0-4.0 milliseconds. Indicates the amount of time the fuel solenoid takes to close. When engine lode is increased, the closure time will fluctuate. Lift Pump - Range 0.0-25.5 Volts The amount of voltage the lift pump system is drawing. Also, a good functional check of the lift pump relay and the oil pressure switch. MIL - Range ON/OFF Represents the commanded state of the Service Engine Soon Light Number or DTCs - Range # Indicates the total number of current DTCs set, but does not necessarily mean that the MIL is illuminated.
Resume Switch - Range ON/OFF Indicates if the cruise control resume switch is activated. The scan tool may be used in order to determine if the cruise control resume set switch is functioning properly. Service Throttle Soon Lamp - Range ON/OFF Represents the commanded state of the service throttle soon lamp. Set Switch - Range ON/OFF Indicates if the cruise control set switch is activated. The scan tool may be used to dete4rmine if the cruise control set switch is functioning properly. Startup Cooling - Range -40 to +151C (-40 to +304F) A reading of the vehicles coolant temperature at start-up. This will change with every key cycle. TDC Offset - Range -2.50 to +2.50 The PCM has the ability to determine the amount of offset that is needed to bring the engine to top dead center.This is used by the PCM in order to determine the proper injection timing and the fuel delivery. This value may be displayed as a positive or negative number. Trans. Fluid Temp. - Range -40 to 151C (-40 to 304F) This value represents the input signal of the transmission fluid temperature sensor. Vehicle Speed - Range 0-98 Vehicle speed is a PCM internal parameter. The vehicle speed is computed by timing pulses coming from the vehicle speed sensor. Vehicle speed is used to check the torque converter clutch lock-up speed or speedometer accuracy. the speed is displayed in both kilometers per hour and miles per hour. Wastegate Solenoid - Range 0-100 Percent The PCM cycles the boost solenoid ON and OFF. The on time, or duty cycle, of the solenoid valve is expressed as a percent. The boost solenoid meters the vacuum level at the wastegate valve actuator as commanded by the PCM.
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PCM/Tech 2 Scan Tool _____________________________________________________
No Malfunction Indicator Lamp (MIL) Check Engine

Step 8 9 10 11 Action Was the On-Board Diagnostic (OBD) System Check performed? Attempt to start the engine. Does the engine start? Check the fuse number 4B of the interior fuse box. Is the fuse OK? Turn the ignition ON, probe the ignition feed circuit at the cluster connector with a test light to ground. Is the test light ON? 1. 2. 3. 4. Turn the ignition OFF. Disconnect the black PCM connector. Turn the ignition ON. Connect a fused jumper to the MIL control circuit at the PCM connector. 5. Observe the MIL. Is the MIL ON? Check the PCM ignition Feed and Battery Feed fuses. Are both of the fuses OK? 1. 2. 3. 4. Turn the ignition OFF. Disconnect the PCM connectors. Turn the ignition ON. Probe the PCM harness ignition and battery feed circuits with a test light to ground. Is the test light ON both circuit? 1. Check for a faulty PCM ground or a poor PCM ground connection. 2. If a problem is found, repair as necessary. Was a problem found? 1. Check for a poor connection at the PCM. 2. If a poor connection is found, repair as necessary. Was a problem found? 1. 2. Check the MIL control circuit for an open. If the MIL control circuit is open, repair as necessary. Was a problem found? Value(s)

Yes Go to step 2. Go to step 3. Go to step 4. Go to step 5.
No Go to OBD system check. Go to step 6. Go to step 14. Go to step 11.
12
Go to step 9.
Go to step 10.
13 14
Go to step 7. Go to step 8.
15
Go to step 18.
Go to step 9.
16
Go to step 18.
Go to step 15.
17
Go to step 18.
Go to step 16.
18 19
Repair open in the ignition feed circuit to connector C3. Is the action complete? Locate and repair open in the PCM battery feed circuit or the PCM ignition feed circuit as necessary. Is the action complete? Locate and repair short to ground in the PCM Ignition Feed circuit or the PCM Battery Feed circuit as necessary. Is the action complete?
20
Go to step 18.
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No Malfunction Indicator Lamp (MIL) Check Engine

Step 21 Action Locate and repair short to ground in the volt/oil module Ignition Feed circuit. Is the action complete? Replace the PCM. NOTE: If the PCM is faulty, then PCM must be programmed. Go to PCM Replacement and Programming Procedures. Is the action complete? 23 Check the MIL control circuit for a poor connection at the volt/oil module connector. 2. If a problem is found, repair as necessary. Was a problem found? Replace the Volt/Oil module. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Attempt to start the engine. Does the engine start and continue to run? 1. Allow engine to idle until normal operating temperature is reached. 2. Select DTC, Failed This Ign. Are any DTCs displayed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1.
Value(s)
Yes Go to step 18.
No
22
Go to step 18.
Go to step 18.
Go to step 17.
24 25
Go to step 18. Go to Step 19
Go to step 2.
26
Go to Applicable DTC Table
Go to step 20.
27
Go to Applicable DTC Table
System OK
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No Scan Tool Data

Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition OFF for 30 seconds. 10. Ignition ON, Engine OFF. Is the MIL ON? Can the Scan Tool communicate with the PCM? With the Scan Tool, command the MIL ON and OFF. 1. Ignition OFF. 2. Disconnect the PCM connectors. 3. Ignition ON. Is the MIL OFF? With the Scan Tool, check Engine Cal ID. Is the proper CAL ID present? With a test light to ground, probe the DLC connector (pin 16). Is the test light ON? With a test light to B+, probe the DLC connector (pins 4 and 5). Is the test light ON for both circuits? Check for proper operation of the cigar lighter. Does the cigar lighter operate properly? Verify proper operation of the Scan Tool with a known good vehicle with the same equipment/controller. Does the Scan Tool communicate with known good vehicle? 1. 2. Disconnect the Scan Tool. With the DVM connected to ground, check the PCM serial data line at the DLC connector (pin 2). Is voltage on the serial data line less than the specified value? With the DVM connected to ground, again check the PCM serial data line at the DLC connector (pin 2). Is voltage on the serial data line less than the specied value? 1. 2. Ignition OFF. With the DVM connected to ground, check resistance of the serial data line at the DLC connector (pin 2). Is resistance less than the specied value? 1. 2. Disconnect the PCM connectors. With the DVM connected to ground check resistance of the serial data line at the DLC connector (pin 2). Is resistance less than the specied value? Value(s) Yes Go to step 2. Go to step 3. No Go to OBD system check. Go to Chart A-1.
3 4 5
Go to step 4. Go to step 17. Go to step 6.
6 7
Go to step 9.
Go to step 21.
9 10
11
7v
Go to step 12.
Go to step 15.
12
1v
Go to step 13.
Go to step 16.
13
10 Ohms
Go to step 14.
Go to step 27.
14
10 Ohms
Go to step 24.
Go to step 28.
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No Scan Tool Data

Step 15 Action 1. Ignition OFF. 2. Disconnect the PCM Connectors. 3. Ignition ON. 4. Check voltage on the DLC connector (pin 2). Is voltage at the specied value? Reprogram the EEPROM and retest. Is serial data present? System OK. Repair short to ground on the MIL control circuit. Reprogram the EEPROM and retest. 1. 2. 3. 21 22 23 24 25 26 27 Check fuse number 1H or the interior fuse box. If fuse is blown, repair short to ground in the battery feed circuit to the DLC connector (pin 16). If the fuse is OK, repair open in the battery feed circuit to the DLC connector (pin 16). Value(s) 0v Yes Go to step 28. No Go to step 25.
16 17 18 19 20
Go to step 26.
Go to step 28.
Repair open in circuit that did not light the test light. Refer to Section 12 for ground distribution. Refer to Section 12 for cigar lighter repair. Faulty Scan Tool and/or cable. Repair short to ground in the serial data line. Repair short to voltage in the serial data line. System OK. 1. 2. 3. Check serial data line for an open. If OK, check PCM and DLC connections. If OK, replace the PCM.
Go to OBD system check.
NOTE: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 28 Replace the faulty PCM. NOTE: If the PCM is faulty, the new PCM must be programmed. Go the PCM replacement and programming procedures. Is the action complete? Go to OBD system check.
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BASIC SYMPTOM CHECKS

Before using this section, you should perform the Diagnostic System Check that determines that: The control module and the malfunction indicator lamp (MIL) are operating correctly. There are no diagnostic trouble codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The checks can lead to correcting a problem without further checks which may save valuable time.
3.
Scan Tool serial data transmitted by the control module. This involves displaying the information available on the serial data stream with a Scan Tool or one of the tools available for that purpose. Information on these tools and the meaning of the various displays can be found in this section. Normal readings under a particular operating condition can be found below the chart On-Board Diagnostic (OBD) System Check.
Tech 2 Use With Intermittents

In some situations the Tech 2 data update rate makes the tool less effective than a voltmeter, such as when trying to detect an intermittent problem which lasts for a very short time. However, the Tech 2 allows manipulation of wiring harnesses or components under the hood with the engine not running, while observing the Tech 2 readout. The Tech 2 can be plugged in and observed while driving the vehicle under the condition when the MIL Service Engine Soon light turns ON momentarily or when the engine driveability is momentarily poor. If the problem seems to be related to certain parameters that can be checked on the Tech 2, they should be checked while driving the vehicle. If there does not seem to be any correlation between the problem and any specific circuit, the Tech 2 can be checked on each position, watching for a period of time to see if there is any change in the reading that indicates intermittent operation. The Tech 2 is also an easy way to compare the operating parameters of a poorly operating engine with those of a known good one. For example, a sensor may shift in value but not set a DTC. Comparing the sensors readings with those of a known good vehicle may uncover the problem. The Tech 2 has the ability to save time in diagnosis and prevent the replacement of good parts. The key to using the Tech 2 successfully for diagnosis lies in the technicians ability to understand the system he is trying to diagnose as well as understanding of the Tech 2 operation and limitations.
Visual and Physical Checks

Check to ensure that the control module grounds are clean, tight, and in their proper location. Check the vacuum hose for splits, kinks, and proper connections, as shown on the Vehicle Emission Control Information label. Check thoroughly for any type of leak or restriction. Check for air leaks at all of the mounting areas of the intake manifold sealing surfaces. Check the wiring for the following conditions: Proper connections Pinches Cuts The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan tool readings do not indicate the conditions, then proceed in a logical order, easiest to check or most likely to cause first.
On-Board Diagnostic (OBD) System Check

After the visual/physical under hood inspection, the OnBoard Diagnostic (OBD) System Check is the starting point for all diagnostic procedures and for locating the cause of an emissions test failure. The correct procedure to diagnose a fault is to follow three basic steps. 1. Are the on-board diagnostics working? This is determined by performing the On-Board Diagnostic (OBD) System Check. If the on-board diagnostics are not working, refer to diagnostic charts in this section. If the on-board diagnostics are working properly, the next step will be: 2. Is there a DTC stored? If a DTC is stored, go directly to the numbered DTC chart in this section. This will determine if the fault is still present. If no DTC is stored, the next step will be:
Symptoms
Verify the customer complaint. Locate the correct symptom table. Check the items indicated under that symptom from the following symptom tables: Engine Cranks but Does Not Run Intermittent Conditions Hard Start Surges/Chugs Lack of Power, Sluggishness, or Sponginess Fuel Knock/Combustion Noise Hesitation, Sag, Stumble Cuts Out, Misses Poor Fuel Economy Excessive Smoke
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Symptom Engine Cranks But Does Not Run

Circuit Description
This table verifies that all the basic engine systems are operating properly. This includes the battery condition, the engine cranking speed, the glow plugs, and the fuel delivery system. If the crank shaft position sensor and the optical/fuel temperature are disconnected or malfunctioning at the same time, an engine cranks but does not run condition will exist.
Test Description
This step checks for proper cranking speed (see Diagnostic aids) 8. This step will check the ground wire on the injection pump (wire located on top of the pump. 12. This step will determine if the injection pump or wiring is at fault. 13. This step will determine if the fuel injection control voltage is present by probing at the black/gray 4 wire connector jumper harness, instead of at the 6 wire pump connector. 6.
Diagnostic Aids
If no trouble is found and the cause of an engine cranking but not running has not been found, check for the following conditions: Proper cranking speed, 100 RPM cold 180 RPM hot (a scan tool can be used to check cranking speed by pulling the ENG 1 fuse and monitoring engine speed on a scan tool while cranking). Water or foreign material in the fuel system. Basic engine condition.
Engine Cranks But Does Not Run

Step 1 Action NOTE: Before clearing DTC(s) use the Scan Tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic System Check performed? 2 3 4 5 6 7 8 Check for proper condition of batteries. Is condition of batteries OK? Check for adequate fuel in tank. Is fuel at an adequate level? Check the quality of fuel. Is fuel quality OK? Check glow plug system operation. Are glow plugs operating OK? Check for proper cranking speed. Is cranking speed OK? Check for a restriction in the fuel return system. Does the fuel return system operate properly? Check injection pump ground wire (located on top of the injection pump). Is ground OK? Ignition ON. Does MIL come ON? 100 RPM cold 180 RPM hot Go to step 23. Go to step 23. Go to step 23. Go to step 23. Go to step 23. Go to step 23. Go to step 23. Go to step 3. Go to step 4. Go to step 5. Go to step 5. Go to step 7. Go to step 8. Go to step 9. Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 10.
Go to No Malfunction Indicator Lamp on page 10 . Go to No Scan Tool Data on page 12 .
10
Install scan tool. Does scan tool display data?
Go to step 11.
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Engine Cranks But Does Not Run

Step 11 Action 1. Loosen injector line at injector. 2. Crank engine. 3. Repeat for the remaining injectors. Is there fuel coming out of injection line? Disconnect Optical/Fuel temperature sensor. Does vehicle start? 1. 2. 3. Reconnect Optical/Fuel temperature sensor. Disconnect fuel solenoid driver. With a DVOM connected to ground, probe fuel inject control circuit at harness terminal (terminal A). 4. Crank engine. Is voltage greater than or equal specied value? 1. 2. Fuel solenoid driver still disconnected. Jumper closure ground circuit (terminal C) with a test light connected to B+ at the harness terminal. Is test light ON? Turn the ignition ON, engine OFF. Verify the fuel solenoid is still disconnected. Probe ignition feed circuit (term. C) at the fuel solenoid harness connector with a test light connected to ground. Is test light ON? Value(s) Yes Go to SymptomsEngine Controls No Go to step 12.
12 13
1.2v
14
Go to step 15.
Go to step 18.
15
1. 2. 3.
Go to step 16.
Go to step 20.
16 17
Replace fuel injection pump. Is the action complete? Check the fuel inject control circuit for an open or ground between the fuel solenoid driver and the PCM. Was a problem found? Check the closure ground circuit for an open between the fuel solenoid driver and the PCM. Was a problem found? Inspect the fuel solenoid driver connector and PCM connector for proper connection. Was a problem found? Repair the open in the ignition feed circuit. Is action complete? Repair the circuit as necessary. Is the action complete? Replace the faulty PCM. Is the action complete? 1. Clear the DTCs and attempt to start engine. Does the engine start and continue to run? 1. Allow engine to reach normal operating temperature. 2. Select DCT, Fail this Ign. Are any DTCs displayed?
Go to step 23. go to step 21.
Go to step 19.
18
Go to step 21.
Go to step 19.
19
Go to step 21.
Go to step 22.
20 21 22 23 24
Go to step 23. Go to step 23. Go to step 23. Go to step 24. Go to the applicable DTC table.
Go to step 2. System OK
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Symptom Intermittent Condition

NOTE: Definition: The problem may or may not turn the MIL on or store a diagnostic trouble code. Checks Preliminary Checks Actions Refer to Basic Symptom Checks ( page 14 ).
Electrical Connections or Wiring. Poor electrical connections or wiring can cause most intermittent problems. Perform a careful check of the suspected circuit for the following conditions. Poor mating of the connector halves Backed out terminals - Terminals not fully seated in the connector body. Improperly formed or damaged terminals - Carefully reform or replace all the connector terminals in the problem circuit to ensure the proper contact tension. Poor terminal to wire contact - Check for poor terminal to wire connections by removing the terminal from the connector body and inspecting the terminals. Road Test. If a visual and physical check does not locate the cause of the problem, drive the vehicle with a DVOM connected to the suspected circuit, or use a scan tool. An abnormal voltage or scan reading, when the problem occurs, indicates the problem. The following can cause an intermittent MIL and no DTCs: Electrical system interference caused by a malfunctioning relay, powertrain control module (PCM) driven solenoid, or switch - All of these can cause a sharp electrical surge. Normally, the problem will occur when the malfunctioning component is operating. The improper installation of electrical devices, such as lights, 2-way radios, cell phones, etc. The malfunction indicator lamp (MIL) circuit intermittently shorted to ground. Poor PCM grounds. Check for loss of DTC memory by disconnecting the engine coolant temperature (ECT) sensor and idling the engine until the MIL turns ON. An engine coolant temperature (ECT) DTC should store and remain in memory when turning OFF the ignition for at least 10 seconds. If not, the PCM is malfunctioning. Check for an open diode across the A/C compressor clutch and for other open diodes.
Intermittent Malfunction Indicator Lamp (MIL).
Loss of DTC Memory.
Additional checks
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Symptom Hard Start

NOTE: Definition: the engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately die. Checks Preliminary checks. Sensor checks. Action Refer to Basic Symptom Checks ( page 14 ). Make sure that the driver is using the correct starting procedure. Check the engine coolant temperature sensor. Use the scan tool in order to compare the engine coolant temperature with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 more or less than the ambient air temperature on a cold engine, check for a high resistance in the coolant sensor circuit or the sensor itself. Check the supply to the injection pump. Check for air in the fuel system. Check the fuel return from the injection pump. Check the engine shut-off solenoid operation. Check the fuel injection nozzles. Check the fuel tank cap vent. Check for an internal injection pump problem.
Fuel system checks.
Electrical system check. Air intake system checks.
Check the glow plug operation. Check for a slow cranking speed. Check the air cleaner and the air intake ducts for a restriction. Check For a restriction in the turbo charger inlet duct. Check for a restriction in the intake manifold. Check the exhaust system for a possible restriction. Check the engine for the following conditions: Improper valve timing. Low compression. Worn rocker arms. Broken or weak valve springs. Worn camshaft lobes. Check for a no crank signal. Check the service bulletins for a control module software update.
Exhaust system check. Engine mechanical checks.
Additional checks.
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Symptom Surges/Chugs
NOTE: Definition: The engine has a power variation under a steady throttle or cruise. the vehicle seems to speed up and slow down without a change in pressure on the accelerator. Checks Preliminary checks. Action Refer to Basic Symptom Checks ( page 14 ). Be sure the driver understands the torque converter clutch operation. Be sure the driver understands the A/C compressor operation. Use the scan tool in order to ensure the reading of VSS matches the vehicle speedometer.
Fuel system checks. Additional checks.
Check the fuel pressure while the condition exists. Check the control module grounds for being clean, tight, and in their proper locations. Check the generator output voltage. Repair if less than 9 or more than 16 volts. Check the vacuum lines for kinks or links. Check the TCC operation.
Symptom Lack of Power, Sluggishness, or Sponginess

NOTE: Definition: The engine delivers less than the expected power. There is less on no increase in speed when partially applying the accelerator pedal. Checks Preliminary checks. Actions Refer to Basic Symptom Checks ( page 14 ). Compare the vehicle with a similar unit. make sure that the vehicle has an actual problem. Remove the air filter. Check for dirt, or for air ducts being plugged. Clean and replace if necessary. Inspect the transmission shift pattern and the down shift operation. Check the fuel quality. Check the engine oil level and quality.
Fuel systems checks.
Check the fuel supply to the injection pump and the fuel return from the injection pump. Check the fuel pump operation. Check for malfunction fuel injection nozzles. Check the exhaust system for a possible restriction. Inspect the exhaust system for damaged or collapsed pipes. Check for an air leakage or a restriction in the air inlet ducts or the intake manifold. Check for a worn or a damaged turbo charger turbine wheel, shaft, or compressor wheel. Check the engine for the following: Low compression. Improper valve timing. Improper or worn camshaft. Check the control module grounds for being clean, tight, and in their proper location. Check the torque converter clutch operation. Check the A/C operation. Check the generator output voltage. Repair if voltage is less than 9v and more than 16v.
Exhaust system checks. Air intake system checks. Engine mechanical check
Additional checks.
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Symptom - Fuel Knock/Combustion Noise

NOTE: Definition: A mild to severe ping which is usually worse upon acceleration. The engine makes sharp metallic knocks which change with the throttle opening. Checks Preliminary checks. Action Refer to Basic Symptom Checks ( page 14 ). Make sure that the vehicle has an actual problem. Check the fuel quality. Check fro obvious overheating problems. Check for a low engine coolant level. Check for a loose water pump belt. Check for restricted air flow through the radiator, or restricted coolant flow. Check for a malfunctioning or incorrect thermostat. Check for a correct coolant solution. The solution should be a 50/50 mix of anti-freeze and water.
Cooling system checks.
Sensor check.
Check the engine coolant temperature sensor. use the scan tool in order to compare the engine coolant temperature with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 more or less than the ambient air temperature on a cold engine, check for a high resistance in the coolant sensor circuit or the sensor itself. Check for air leaks in the fuel supply to the injection pump. Check the injection pump static timing. Check the injection nozzles. Check for incorrect basic engine parts such as the cam, the heads, the pistons, etc. Check for an excessive oil entering the combustion chamber. Check the service bulletins for control module software updates.
Fuel system checks.
Engine mechanical checks. Additional checks.
Symptom - Hesitation, Sag, Stumble

NOTE: Definition: The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur at any vehicle speed. The condition is usually most severe when trying to make the vehicle move from a stop. The condition may cause the engine to stall, if severe enough. Checks Preliminary check. Fuel system checks. Action Refer to Basic Symptom Checks ( page 14 ). Check the fuel pressure. Check for water contamination in the fuel. Perform the injector balance test. Check for a low fuel pressure after a cold start or during a moderate or a full throttle acceleration. If the fuel pressure drops below specification, there is possibly a malfunctioning fuel pump or a restriction in the fuel system.
D
Additional checks.
Check the service bulletins for any control module software updates. Check the generator output voltage.
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Symptom - Cuts Out, Misses

NOTE: Definition: A steady jerking that follows the engine speed, usually more pronounced as the engine load increased. The vibration is not normally felt above 1500 RPM or 48 km/h (30 mph). The exhaust has a steady spitting sound during idle, low speed, or hard acceleration due to the fuel starvation that can cause the engine to cut-out. Checks Preliminary check. Ignition system checks. Action Refer to Basic Symptom Checks ( page 14 ). Check for a cylinder misre: Start the engine. Allow the engine to stabilize. Perform the injector balance test. If there is no RPM drop on one or more of the cylinders, or if there is an excessive variation in drop, refer to Engine mechanical checks. Perform a cylinder compression check. Check the engine for the following conditions: Improper valve timing. Bent pushrods. Worn rocker arms. Worn camshaft lobes. Broken or weak valve springs. Check the intake and exhaust manifold passages for a casting flash. Check the fuel system for a plugged fuel filter, low fuel pressure,. etc. Check for water contamination in the fuel. Check for electromagnetic interference- The EMI on the reference circuit can cause a missing condition. Monitoring the engine RPM with the Tech 2 can detect an EMI. A sudden increase in the RPM with little change in the actual engine RPM will indicate that an EMI is present.
Engine mechanical checks
Fuel system checks. Additional checks.
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Symptom - Poor Fuel Economy

NOTE: Definition: The fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, the economy is noticeably lower than previously shown by an actual road test on this vehicle. Checks Preliminary Checks Action Refer to Basic Symptom Checks ( page 14 ). Check the air cleaner filter for dirt or being plugged. Visually or physically inspect the vacuum hoses for splits, kinks, and proper connections. Perform the Diagnostic System Check. Check the driving habits of the owner. Is the A/C ON full time? Is the defroster mode ON? Are the tires at the correct pressure? Are any excessively heavy loads being carried? Is the acceleration too much, too often? Suggest to the owner to fill the tank and recheck the fuel economy
Fuel system checks. Cooling system checks. Additional checks.
Check the fuel type and quality. Check the fuel pressure. Check the engine coolant level. Check the engine thermostat for the wrong heat range or possible being stuck open. Check the transmission shift pattern. Check the torque converter clutch operation. When the TCC is commanded ON, the Tech 2 should indicate an RPM drop. Check the service bulletins for any control module software updates. Check for dragging brakes.
Symptom - Excessive Smoke

NOTE: Definition: White, black, gray or blue smoke under load, idle or start up hot or cold. Checks Preliminary check Action Refer to Basic Symptom Checks ( page 14 ). Make sure the vehicle has an actual problem. Check the fuel quality. Check the injection pump. Check the injection pump timing. Check the injection nozzles. Check the engine coolant temperature sensor by using the Tech 2 in order to compare the engine coolant temperature with the ambient air temperature on a cold engine. If the coolant temperature reading is more than 5 more or less than ambient air temperature on a cold engine, check for a high resistance in the coolant sensor circuit or the sensor itself. Check the glow plug system operation. Check the air cleaner and the air intake ducts for a restriction. Check for a restriction in the turbo charger inlet duct. Check for a restriction in the intake manifold. Check for incorrect basic engine parts such as the cam, the heads, the pistons, etc. Check for any excessive oil entering the combustion chamber.
Fuel system checks.
Sensor Check
Air intake system check.
Engine mechanical check.
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23
OBD II DIAGNOSTIC TROUBLE CODES DTC Identication

OBD II requires that the automotive industry use a standardized Diagnostic Trouble Code (DTC) structure (Figure 3). This code structure is very different from OBD I DTC structure. The OBD II DTCs contains a letter and a four-digit number. The letter identifies the function of the device that has the fault: B = Body C = Chassis P = Powertrain U = Network or data link code The first digit of the number indicates if the DTC is generic or manufacturer-specific (0=generic, 1=specific). The second number indicates the specific vehicle system that has the fault. Below are the powertrain system identifiers: 1 = Fuel and Air Metering 2 = Fuel and Air Metering (injector circuit malfunction). 3 = Ignition System or Misfire 4 = Auxiliary Emission Controls 5 = Vehicle Speed Control and Idle Control System 6 = Computer Output Circuit 7 = Transmission 8 = Transmission The last two digits indicate the component or section of the system that has the fault.
Type A
Emissions related. Requests illumination of the MIL on the first trip with a failure. Stores a HISTORY DTC on the first trip with a failure. Stores a Freeze Frame on the first trip with a failure. Stores a failure Record. Updates the Failure Record the first time the test fails each ignition cycle.
Type B
Emission related. Armed after one trip with a failure. Disarmed after one trip with a pass. Requests illumination of the MIL on the second consecutive trip with a failure. Stores a HISTORY DTC on the second consecutive trip with a failure (the DTC is armed after the first failure). Stores a Freeze Frame on the second consecutive trip with a failure. Stores a Failure Record when the first test fails (not dependent on consecutive trip fails). Updates the Failure Record the first time the test fails each ignition cycle.
Type C
EXAMPLE: P0117 ECT SENSOR CIRCUIT LOW VOLTAGE
P0117
B - BODY C - CHASSIS P - POWERTRAIN U - NETWORK 0 - GENERIC (SAE) 1 - MANUFACTURER SPECIFIC SPECIFIC FAULT DESIGNATION SPECIFIC VEHICLE SYSTEM
Non-emission related. Request illumination of the service lamp (such as the CHECK THROTTLE not the MIL) on the first trip with a failure. Stores a HISTORY DTC on the first trip with a failure. Does not store a Freeze Frame. Stores Failure records when the test fails. Updates the Failure Record the first time the test fails each ignition cycle.
Figure PCM-3: OBD II Code Structure
Type D
Non-emission related. Does not request illumination of any lamps. Stores a History DTC on the first trip with a failure. Does not store a Freeze Frame. Stores a Failure Record when the test fails. Updates the Failure Record the first time the test fails each ignition cycle.
Code Type
Each DTC is directly related to a diagnostic test. The Diagnostic Management System sets DTCs based on the failure of the tests during a trip or trips. Certain tests must fail two consecutive trips before the DTC is set. The following are the four types of DTCs and the characteristic of those codes:
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DTC Information
The status of the test and the related DTC messages can be viewed by using the Tech 2. The combination of messages is dependent on the status of the test.The following is a list of DTC information message (some applications do not display all messages listed below): LAST TEST FAILED: This message indicates that the last diagnostic test failed. If the DTC is a type A or B this test could have occurred in a previous ignition cycle. This message remains until the test passes or the DTCs are cleared. If the DTC is a type C or D, this message clears when the ignition is turned OFF. TEST FAILED SINCE CODE CLEARED: This message indicates that the test has failed at least once since the DTCs were cleared. FAILED THIS IGNITION: This message indicates that the diagnostic test related to the DTC has failed this ignition cycle. HISTORY: This message indicates that the DTC has been stored in memory as a valid fault. Type B DTCs are not stored as history DTCs until the test has failed two consecutive trips. MIL REQUEST: This message indicates that the DTC has requested illumination of the MIL. Only type A and B DTCs can request illumination of the MIL. NOT RAN SINCE CODE CLEARED: This message indicates that the test related to this DTC has not been run uncertain of the status of the system this ignition cycle. A trip must be completed for the PCM to run the test and know the status of the system. LAST TEST PASSSED: This message indicates that the Diagnostic test that failed previously has passed the latest diagnostic test. This does not indicate that the failed is gone. It only indicates that the fault was not present during the latest test. TEST RAN AND PASSED: This message indicates that the latest test passed. The test ran and passed this ignition cycle, and ran and passed since DTCs were cleared. The test has not failed since the DTCs were cleared. FREEZE FRAME: The Diagnostic Executive in the PCM records certain vehicle operating conditions when a type A or B (emission related) DTC is stored as a history DTC. The PCM only store one Freeze Frame record. Freeze Frame data is stored for the first failed test that sets the DTC and illuminates the MIL. Freeze Frame is not updated (refreshed) if the test fails a second time. However, fuel trim and misfire DTCs take priority over all other DTCs. Fuel trim and misfire DTCs always overwrite the Freeze Frame record unless a fuel trim or misfire DTC is already stored. Any previous information related to DTCs stored in the Freeze Frame that are overwritten due to a priority DTC setting is lost. DTC FAIL RECORDS: Due to the limitations of the Freeze Frame, Failure Records was created. Failure Records assist the technicians when multiple DTCs have been set or when the DTC is non-emission related. Failure Records have similar data parameters to those that are stored in the Freeze Frame. However, the PCM has the ability to store multiple Failure Records. Failure records are stored any time a diagnostic test fails. Failure Records are only updated (refreshed) the first time the test fails during each ignition cycle. This includes type B DTCs that fail only one trip. Unlike Freeze Frame, Failure Records are not limited to emission DTCs. Type C and D Diagnostic Trouble Codes store Failure Records. The PCM can store up to Five individual DTC Failure Records. When a diagnostic test fails, Failure Records are stored in the PCM memory and assigned to the first Failure Record position. If a different diagnostic test fails, a second Failure record related to that DTC is stored in memory. Additional failed diagnostic tests for different DTCs also store Failure Records until Fail Record memory is full. If more than the maximum number of DTCs are stored, the failure records are replaced on a first in, first out basis.
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Diagnostic Trouble Code (DTC) Identification

DTC P0112 P0113 P0117 P0118 P0121 P0122 P0123 P0126 P0182 P0183 P0215 P0216 P0219 P0220 P0221 P0222 P0223 P0225 P0226 P0227 P0228 P0231 P0236 P0237 P0238 P0251 P0263 P0266 P0269 P0272 P0275 P0278 P0281 P0284 P0300 P0301 P0302 P0303 P0304 P0305 5745159 IAT Sensor Circuit Low Voltage IAT Sensor Circuit High Voltage ECT Sensor Circuit Low Voltage ECT Sensor Circuit High Voltage APP Sensor 1 Circuit Performance APP Sensor 1 Circuit Low Voltage APP Sensor 1 Circuit High Voltage Engine Coolant Temperature (ECT) Insufcient for Stable Operation Fuel Temperature Sensor Circuit Low Voltage Fuel Temperature Sensor Circuit High Voltage Engine Shutoff Control Circuit Injection Timing Control System Engine Overspeed Condition APP Sensor 2 Circuit APP Sensor 2 Circuit Performance APP Sensor 2 Circuit Low Voltage APP Sensor 2 Circuit High Voltage APP Sensor 3 Circuit APP Sensor 3 Circuit Performance APP Sensor 3 Circuit Low Voltage APP Sensor 3 Circuit High Voltage Lift Pump Secondary Circuit Low Voltage TC Boost System TC Boost Sensor Circuit Low Voltage TC Boost Sensor Circuit High Voltage Injection Pump Cam System Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Cylinder Balance System Fault Engine Misre Detected Cylinder 1 misre Detected Cylinder 2 misre Detected Cylinder 3 misre Detected Cylinder 4 misre Detected Cylinder 5 misre Detected Description Type B B B B C C C B B B D B D C C C C C C C C B B B B A D D D D D D D D B B B B B B Illuminate MIL Yes Yes Yes Yes No No No Yes Yes Yes No Yes No No No No No No No No No Yes Yes Yes Yes Yes No No No No No No No No Yes Yes Yes Yes Yes Yes 1-1-02
26
Diagnostic Trouble Code (DTC) Identification (Contd)

DTC P0306 P0307 P0308 P0335 P0370 P0380 P0501 P0567 P0568 P0571 P0601 P0602 P0606 P1125 P1214 P1216 P1217 P1218 P1627 P1635 P1641 P1643 P1654 P1656 Cylinder 6 misre Detected Cylinder 7 misre Detected Cylinder 8 misre Detected CKP Sensor Circuit Performance Timing Reference High Resolution Glow Plug Circuit Performance Vehicle Speed Sensor Circuit Cruise Resume Circuit Cruise Set Circuit Cruise Brake Switch Circuit PCM Memory PCM Not Programmed PCM Internal Communication Interrupted APP System Injection Pump Timing Offset Fuel Solenoid Response Time Too Short Fuel Solenoid Response Time Too Long Injection Pump Calibration Circuit A/D Performance 5 Volt Reference Low Malfunction Indicator Lamp (MIL) Control Circuit Wait to Start Lamp Control Circuit Service Throttle Soon (STS) Lamp Control Circuit Wastegate Solenoid Control Circuit Description Type B B B A A B D D D D A A A C B C C B B C D B D B Illuminate MIL Yes Yes Yes Yes Yes Yes No No No No Yes Yes Yes No Yes No No Yes Yes No No Yes No Yes
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PCM SCHEMATICS
FUEL PUMP RELAY R-3 EXTERIOR FUSE BOX
87 85 86 238 DG D8
C27
INTERIOR FUSE BOX

537 OR TO IGNITION FUSE 2D 20 AMP G2 59 BK
87A
30 787 GY
PCM
FUEL PUMP RELAY CONTROL FUEL LIFT PUMP SENSE SIGNAL
787 GY 787 GY
787 GY D5 C1-11 C3-M8 3 786 RD
G1
FUEL LIFT PUMP

59 BK 5B G4
2B
C55-14
COOLANT/ FUEL MODULE MAIN TANK FUEL LEVEL SENDING UNIT
C55-5
29 PK
FUEL SELECTOR SWITCH
G4 4 6 1
673 DB
789 BR
C3
P7 C26-A 675 YL 35 75 9 M6 M7
C1
AUX. TANK FUEL LEVEL SENDING UNIT

C38-C A G2 A
C2
35 37 36
C26
B B C E E D D
C67
SELECTOR VALVE ASSEMBLY
ENGINE SUPPLY
RETURN FROM INJECTION PUMP
MAIN TANK SUPPLY
MAIN TANK RETURN
AUX. TANK SUPPLY
AUX. TANK RETURN
02-S02-003
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TO BATTERY
TO BATTERY
FUSE 4D 15 AMP 291 PK 10 OR
FUSE 6B 5 AMP
INTERIOR FUSE BOX
STOP LAMP SWITCH B
TCC CRUISE BRAKE SWITCH C
BRAKE LIGHT SWITCH
22 RD
TO TURN SIGNAL SWITCH
31 C1
810 PP 40 B10 B9 TCC/ CRUISE BRAKE SIGNAL

02-S02-002
C29
STOP LAMP SIGNAL
22 RD
PCM
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29
ACCELERATOR PEDAL POSITION SENSOR

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
C27-C5 APP 2 SIGNAL C29-B1
53
719 BR
GROUND
1 E
17
718 DB
C29-B2 APP 1 SIGNAL C27-D6
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
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30 GY C9-J WATER IN FUEL LIGHT LEFT HAND STATUS CENTER C3-N7 FUSE 4B 5AMP INTERIOR FUSE BOX
HOT IN RUN AND START
HOT IN RUN AND START FUEL SOLENOID A
DRAIN FILTER
FUSE 3B 20AMP EXTERIOR FUSE BOX
FUSE 3A 20AMP EXTERIOR FUSE BOX C5-A4 239 PK A
B C9-D C3-F4 C1-45 327 YL 291 PK B A WATER IN FUEL SENSOR A C 701 DB FUEL HEATER FUEL SOLENOID FUEL DRIVER SOLENOID CONTROL A CLOSURE SIGNAL E CLOSURE GROUND C ENGINE SHUTOFF SOLENOID TO IGNITION SWITCH
D IGN
B FUEL SOLENOID HIGH
F FUEL SOLENOID LOW
C 713 RD A 57 BK 57 BK 491 BK C27-C13 CLOSURE SIGNAL C29-A1 CLOSURE GROUND 712 LG C28-C15 POWER CONTROL MODULE 9-S12-056 G2 ESO SOLENOID CONTROL C28-D3 C28-C3 FUEL INJECT CONTROL
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HOT AT ALL TIMES FUSE 2D 20 AMP INTERIOR
HOT IN RUN AND START FUSE 3A 20 AMP EXTERIOR
HOT IN RUN AND START FUSE 4B 5 AMP INTERIOR GRY C10-J STATUS CENTER POWERTRAIN CONTROL MODULE 914 PP 4 G4 554 GRY 9-S12-064 16 2 DLC 30
C1-10 STS LAMP 537 OR 239 PK MIL LAMP
TO C29-B3 714 RD
C10-H C3-G5 658 BR C1-25
C10-C C3-F3
C1-28 C28-C14 MIL CONTROL
C28-C13 C28-D13 BATT BATT
C28-C12 C28-C11 IGN IGN
C28-D11 STS LAMP CONTROL
GROUND GROUND C28-D6 C28-D7 570 BK HOT AT ALL TIMES 59 BK 570 BK FUSE 1H 5 AMP INTERIOR G2
SERIAL DATA CLASS II C28-C8
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5 VOLT REFERNCE
CKP SENSOR SIGNAL

A
CRANK SHAFT POSITION SENSOR (CKP)
BOOST/ BARO PRESSURE SENSOR
ENGINE COOLANT TEMP SENSOR (ECT) INTAKE AIR TEMPERATURE A SENSOR (IAT)
SENSOR GROUND
B B A B
651 BK 651 BK 359 PP C5
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4 651 PP
B5 357 TN
C27-C4
C5
C29-A5 CKP SENSOR SIGNAL
C29-B12 SENSOR GROUND
C27-D13 5 VOLT REFERENCE
C27-C14 BOOST SENSOR SIGNAL
C27-C11
C27-C1 SENSOR GROUND
ECT SENSOR SIGNAL
IAT SENSOR SIGNAL
POWERTRAIN CONTROL MODULE
9-S12-066
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A
5 VOLT REFERENCE
E
OPTICAL/ FUEL TEMP SENSOR
INJECTION TIMING STEPPEN MOTOR (ITS)
M
PUMP CAM HIGH SENSOR RESOLUTION SIGNAL SIGNAL SENSOR GROUND
C5
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
703 OR
375 GY
C27-D14
C29-A4 C29-A2
CAM HIGH SENSOR RES SIGNAL SIGNAL
C27-D9
SENSOR GROUND
C27-C8 C29
FUEL TEMP SIGNAL
A7
ITS HI
A8
ITS LO
A9
ITS LO
710 OR
442 BR
156 PK
708 TN
225 YL
A10
ITS HI
5 VOLT REFERENCE

9-S12-070
5745159
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34
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
C C
5 VOLT REFERNCE
CKP SENSOR SIGNAL

A
ENGINE COOLANT TEMP SENSOR (ECT) INTAKE AIR TEMPERATURE SENSOR (IAT)
SENSOR GROUND
B B A B
651 BK 651 BK 359 PP C5
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4 651 PP
B5 357 TN
C27-C4
C5
C29-A5 CKP SENSOR SIGNAL
C29-B12 SENSOR GROUND
C27-D13 5 VOLT REFERENCE
C27-C14 BOOST SENSOR SIGNAL
C27-C11
C27-C1 SENSOR GROUND
ECT SENSOR SIGNAL
IAT SENSOR SIGNAL
9-S12-066
Circuit Description
The Intake Air Temperature (IAT) sensor is a thermistor that controls signal voltage to the PCM. When the air is cold, the sensor resistance is high, therefore the PCM will see a high signal voltage. As air warms, sensor resistance becomes less and voltage drops.
Conditions for Clearing the MIL/DTC

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are recorded by this or any other emission related diagnostic. Use of a Scan Tool
Conditions for Setting the DTC

Engine coolant temperature less than 42.5C (109F). Intake air temperature greater than or equal to 151C (303F). Conditions met for 2 seconds.
Diagnostic Aids
Check harness routing for a potential short to ground in the signal circuit. Scan Tool displays intake air temperature in degrees centigrade. A skewed sensor could result in poor driveability complaints.
Action Taken When the DTC Sets

The control module illuminates the malfunction indicator lamp on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the freeze Frame and updates the Failure Record.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Table. 2.This step determines if P0112 is a hard failure or an intermittent condition. 3.This test will determine if the PCM can recognize an open sensor. 4.This step will determine if the condition is a malfunctioning PCM or if the signal wire is shorted to ground. The normal resistance across the IAT sensor connector harness is 4,000 5,000 ohms.
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DTC P0112 - Intake Air Temperature (IAT) Sensor Circuit Low Voltage
Step 1 Action NOTE: Before clearing DTC(s) use the Scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Scan tool connected. 2. Start the engine. 3. Monitor the IAT display on Scan Tool. Is the IAT display greater than or equal to the specied value? 1. Turn the engine OFF. 2. Turn the ignition ON. 3. Disconnect the IAT sensor connector. Is the IAT display less than or equal to the specied value? 1. 2. 3. Turn the ignition OFF. Disconnect the PCM connector C27. Using a DVOM measure the resistance across the IAT sensor connector. Is the resistance at the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those table(s). Are additional DTCs stored? Repair the short to ground in the IAT signal circuit. Is the action complete? Replace the IAT sensor. Is the action complete? Replace the faulty PCM. NOTE: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 9 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Go to step 10. Go to step 2. 151C (303F) Go to step 3. Go to step 5. Value(s) Yes Go to step 2. No Go to OBD System Check.
-30C (-22F)
Go to step 7.
Go to step 4.
Innite
Go to step 8.
Go to step 6.
Go to the applicable DTC Table. Go to step 9. Go to step 9. Go to step 9.
Go to Diagnostic Aids.
6 7 8
10
Go to the applicable DTC table.
System OK.
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DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B
651 BK 350 GY 651 BK 394 LG 359 PP 357 TN B5 651 PP 357 TN

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
5V CKP SENSOR SIGNAL SENSOR GROUND 5 VOLT REFERENCE A BOOST SENSOR SIGNAL
5V ECT SENSOR SIGNAL SENSOR GROUND
5V IAT SENSOR SIGNAL
02-S02-005
Circuit Description
The intake air temperature sensor is a thermistor that controls signal voltage to the PCM. When the air is cold, the sensor resistance is high, therefore the PCM will see a high signal voltage. As air warms, sensor resistance becomes less and voltage decreases. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, Clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Use of a scan tool.

IAT less than or equal to -40C (-40F). Conditions met for 2 seconds.

The control module illuminates the malfunction indicator lamp on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions on the Freeze Frame and updates the Failure Records.
Test Description
Number(s) below refer to the step number(s) on the diagnostic Table. 2. This step determines if P0113 is a hard failure or an intermittent condition. 3. This step will determine if there is a wiring problem or a faulty PCM.
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37
DTC P0113 - Intake Air Temperature (IAT) Sensor Circuit High Voltage
Step 1 Action NOTE: Before clearing DTC(s) use the Scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Start the engine. 3. Monitor the IAT display on Scan Tool. Is the IAT display colder than or equal to the specied value? 1. Turn the engine OFF. 2. Turn the ignition ON. 3. Disconnect the IAT sensor connector. 4. Jumper the IAT harness terminals together. Does the scan tool display IAT greater than or equal to the specified value? Jumper the IAT sensor signal circuit to a known good ground. Does the scan tool display an IAT greater than or equal to the specified value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. Are additional DTCs stored? Inspect the sensor connector and PCM connector for a proper connection. If a condition is found, repair as necessary. Did you complete the repair? Check the IAT sensor ground circuit for an open between the IAT sensor and the PCM. If a condition is found, repair as necessary. Did you complete the repair? Check the IAT sensor signal circuit for an open between the IAT sensor and the PCM. If a condition is found, repair as necessary. Did you complete the repair? With a DVOM, set to the mA scale, measure the current at the IAT connector. Is the current less than the specied value? Repair the short to voltage on the IAT signal circuit. Did you complete the repair? Inspect the PCM connectors for faulty connections and repair as necessary. Is the repair complete? Replace the faulty IAT sensor. Is the action complete? Replace the faulty PCM. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
-30C (-22F)
Go to step 3.
Go to step 5.
151C (303F)
Go to step 6.
Go to step 4.
4 5
151C (303F)
Go to step 7. Go to the applicable DTC Table. Go to step 14.
Go to step 8. Go to Diagnostic Aids. Go to step 9.
Go to step 14.
Go to step 11
Go to step 14.
Go to step 11.
9 10 11
50mA _ _
Go to step 10
Go to step 13.
12 13 14
15
System OK.
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DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
The engine coolant Temperature (ECT) sensor is a thermistor that controls signal voltage to the PCM. When the engine is cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As the engine warms, sensor resistance becomes less and voltage drops. The voltage measured across the thermistor is interpreted as a temperature. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last test failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycle, If no failures are reported by this or any other emission related diagnostic. Use of a Scan Tool.

The engine coolant temperatures is more than or equal to 151C (303F). All of the diagnostic set conditions met for 2 seconds.
Diagnostic Aids
Check harness routing for a potential short to ground. After engine is started, the coolant temperature should rise steadily to about 85C (185F). A skewed sensor could result in poor driveability complaints.

The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the failure happens a second time on a consecutive ignition cycle the control module will write the operating conditions to the Freeze Frame and updates the Failure Records. 1-1-02
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Table. 2. This step determines if P0117 is a hard failure or an intermittent condition. 4. This test will check the PCM and the wiring.
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39
DTC P0117 - Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
Step 1 Action NOTE: Before clearing DTC(s) use the Scan tool Capture Info to record Freeze Frame and Failure Record for reference. This data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Scan tool connected. 2. Start the engine. 3. Monitor the ECT display on Scan Tool. Does the scan tool display ECT greater than or equal to the specified value? 1. Turn the engine OFF. 2. Turn the ignition ON. 3. Disconnect the ECT sensor connector. Does the scan tool display ECT less than or equal to the specied value? 1. 2. 3. Turn the ignition OFF. Disconnect the PCM connector C27. Using a DVOM, check the resistance across the ECT sensor harness connector at the sensor. Is the resistance at the specied value? DCT is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those table(s) rst. Are any additional DTCs stored? Repair the short to ground in the ECT signal circuit. Is the action complete? Replace the faulty ECT sensor. Is the action complete? Replace the faulty PCM. NOTE: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 9 Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. Go to step 10. Go to step 2. 151C (303F) Go to step 3. Go to step 5. Value(s) Yes Go to step 2. No Go to OBD System Check.
-30C (-22F)
Go to step 7.
Go to step 4.
Innite
Go to step 8.
Go to step 6.
Go to the applicable DTC Table. Go to step 9. Go to step 9. Go to step 9.
6 7 8
10
Go to the applicable DTC table
System OK
5745159
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40
DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
The Engine Coolant Temperature (ECT) sensor is a thermistor that controls signal voltage to the PCM. When the engine is cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As the engine warms, the sensor resistance becomes less and the voltage drops. The voltage measured across the thermistor is interpreted as a temperature. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, last test failed, clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail Use of a scan tool.

Engine running for at least 8 minutes. ECT less than -30C (-22F). Conditions met for 2 seconds
Diagnostic Aids
Check harness routing for a potential short to voltage. After engine is started, the ECT temperature should rise steady to about 85C (185F). A mis-scaled sensor could result in poor driveability complaints.

The control module illuminates the malfunction indicator lamp on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails, the control module stores this information in the failure records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions to the Freeze Frame and updates the Failure Records. 1-1-02
Test Description
Number(s) below refer to number(s) on the diagnostic tables. 2. This test determines if PO 118 is an intermittent condition. 5. This test will determine if signal circuit is open, or a faulty PCM.
__________________________________________________
41
DTC P0118 - Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
Step 1 Action Note: Before clearing DTC(s) use the scan tool to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info is used. Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Scan tool connected. 2. Start the engine. 3. Monitor the ECT display on Scan Tool. Is the ECT display less than or equal to the specied value? 1. Turn the engine OFF. 2. Turn the ignition ON. 3. Disconnect the ECT sensor connector. 4. Jumper the ECT harness terminals together. Does the scan tool display ECT greater than or equal to the specified value? Jumper the ECT sensor signal circuit to a known good ground. Does the scan tool display a ECT greater than the specied value? DCT is intermittent. If no other DTC(s) are stored, go to Diagnostic Aids. Are there other DTCs stored? Inspect the sensor connector and PCM connector for a proper connection. If a problem is found repair as necessary. Is the action complete? Check the ECT sensor ground circuit for an open between the ECT sensor and the PCM. If a problem is found repair as necessary. Is the action complete? Check the ECT sensor signal circuit for an open between the ECT sensor and the PCM.Repair as necessary. Is the action complete? With a DVOM set to mA scale, measure the current at the ECT harness connector terminals. Is the current value less than the specied value? Repair the short to voltage on the ECT signal circuit. Is the repair complete? Inspect the PCM connectors for faulty connections and replace the terminals, If necessary. Is the action complete? Replace the faulty ECT sensor. Is the action complete? Replace the faulty PCM. Is the action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. -30C (-22F) Go to step 3. Go to step 5. Value(s) Yes Go to step 2. No Go to OBD System Check.
151C (303F)
Go to step 6.
Go to step 4.
4 5 6 7
151C (303F)
Go to step 7. Go to DTC Table. Go to step 14. Go to step 14.
Go to step 8. Go to Diagnostic Aids. Go to step 9. Go to step 11.
Go to step 14.
Go to step 11.
48 mA
Go to step 12.
Go to step 10.
10 11
__ __
Go to step 14 Go to step 14.
__ __
12 13 14
15
Go to DTC table.
System OK
5745159
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42
DTC P0121 Accelerator Pedal Position (APP) Sensor 1 Circuit Performance

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
The Accelerator Pedal Position (APP) module provides a voltage signal that changes relative to accelerator pedal position. There are three sensors located within the APP module that are scaled differently. This is a type C DTC.

A current DTC last Test Failed clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other nonemission related diagnostic. Use a scan tool in order to clear the DTC.

Ignition voltage greater than 6.4 volts. Engine speed greater than 300 RPM. The difference between APP 1 and APP 2 is greater than 0.23 volts (PCM compares pre-scaled voltage internal to PCM). The difference between APP 1 and APP 3 is greater than 0.50 volts (PCM compares pre-scaled voltage internal to PCM). No in range faults for APP 2 or APP 3 (PCM checks for high and low voltage faults). Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads APP 1 position in volts. It should read about .45 to .95 volt with throttle closed and ignition ON or at idle. Voltage should increase at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Scan APP 1 sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about .74 volt when throttle was closed to over about 3.7 volts when throttle is held at Wide Open Throttle (WOT) position. The following chart will check voltages on all APP circuits to see if they fall in normal ranges. The PCM compares pre-scaled voltages (these are voltages that the scan tool cant read). The scan tool reads only output voltages.

The control module stores the DTC information into memory when the diagnostic runs and fails. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records. The Check Throttle lamp will illuminate.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 4. This step determines if there is a good 5 volt reference. 6. This step will check for an open in the ground circuit.
1-1-02
__________________________________________________
43
DTC P0121 - Accelerator Pedal Position (APP) Sensor 1 Circuit Performance

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP voltages on the scan tool. Are APP voltages at specied values? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, probe APP sensor 5 volt reference circuits at APP harness terminals G, D and E. Is voltage at the specied value on all circuits? Ignition ON, engine OFF. With a test light connected to B+, probe APP sensor ground circuits at the APP sensor harness terminals A, B and J. Is Test light ON (all circuits)? 1. 2. Ignition OFF. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair as necessary. Was the 5 volt reference circuit open or shorted to ground? Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. 2. Ignition OFF. Disconnect the PCM, and check for an open sensor ground circuit to the PCM. 3. If problem is found, repair as necessary. Was APP sensor ground circuit open? Replace the APP module. Is Action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. 1. 2. 1. 2. 3. Value(s) Yes No
Go to step 2. Go to OBD System Check.
.45-.95v 4.0-4.5v 3.6-4.0v
Go to step 3.
Go to step 4.
Go to the applicable DTC table. Go to step 5.
Go to Diagnostic Aids. Go to step 6.
4.75v
Go to step 9.
Go to step 8.
Go to step 11.
Go to step 8.
9 10
11
Go to step 12.
Go to step 2.
12
System OK.
5745159
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44
DTC P0122 Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
The Accelerator Pedal Position (APP) module provides a voltage signal that changes relative to accelerator position. There are three sensors located within the APP module that are scaled differently. This is a type C DTC.

A current DTC last Test Failed clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other nonemission related diagnostic. Use a scan tool to clear codes.

Voltage is less than 0.25 volts on APP 1. Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads APP 1 position in volts. It should read about .45 to .95 volt with throttle closed and ignition ON or at idle. Voltage should increase at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Scan APP sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about .74 volt when throttle is closed to about 3.7 volts when throttle is held at Wide Open Throttle (WOT) position. A DTC P0122 will result if the signal or reference circuit are open.

The control module stores the DTC information into memory when the diagnostic runs and fails. The malfunction indicator lamp (MIL) will not illuminate. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records. The Check Throttle lamp will illuminate.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step determines if P0122 is the result of a hard failure or an intermittent condition. 4. This step checks the PCM and wiring.
1-1-02
__________________________________________________
45
DTC P0122 - Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage
Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 1 voltages on the scan tool. Is APP 1 voltages less than or equal to specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those table(s) rst. Are additional DTCs stored? 1. Disconnect the APP sensor electrical connector. 2. Jumper the APP 1 signal circuit and the 5 volt reference circuit together at the APP sensor harness connector. 3. Observe the APP 1 voltage on the Scan Tool. Is APP 1 voltage greater than the specied value? 1. Connect a test light between B+ and the APP 1 sensor signal circuit at the APP sensor harness connector. 2. Observe the APP 1 voltage on the Scan Tool. Is APP 1 voltage greater than the specied value? 1. Ignition OFF. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair as necessary. Was the 5 volt reference circuit open or shorted to ground? Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. Ignition OFF. 2. Disconnect the PCM, and check the APP 1 signal circuit for an open, short to ground. 3. If the APP 1 sensor signal circuit is open or shorted to ground, repair as necessary. Was APP 1 signal circuit open or shorted to ground? Check the APP 1 sensor signal circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? Check for a poor electrical connection at the APP module and repair if necessary. Was a problem found? Replace the APP module. Is Action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
0.25v
4.75v
Go to the Go to applicable Diagnostic DTC table. Aids. Go to step 10. Go to step 5.
4.75v
7 8
Go to step 13. Go to step 12. Go to step 13. Go to step 9.
9 10 11 12
Go to step 13. Go to step 12. Go to step 13. Go to step 11. Go to step 13. Go to step 13.
13
14
System OK.
5745159
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46
DTC P0123 Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description

A current DTC Last Test Failed clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other nonemission related diagnostic. Use a scan tool.

Voltage is greater than 4.75 volts on APP 1 sensor. Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads APP 1 position in volts. It should read about 0.45 to 0.95 volt with throttle closed and ignition ON or at idle. Voltage should increase at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Scan APP 1 sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about 0.74 volt when throttle is closed to about 3.7 volts when throttle is held at Wide Open Throttle (WOT) position. A P0123 will result if the ground circuit is open or the signal circuit is shorted to voltage. Refer to Intermittents in Section 2.

The control module stores the DTC information into memory when the diagnostic runs and fails. The malfunction indicator lamp (MIL) will not illuminate The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records. The Check Throttle lamp will illuminate.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step determines if DTC P0123 is the result of a hard failure or an intermittent condition. 3. This step checks the PCM and wiring.
1-1-02
__________________________________________________
47
DTC P0123 - Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage
Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 1 display on the scan tool. Is APP 1 above the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Are any additional DTCs stored? 1. Disconnect the APP sensor electrical connector. 2. Observe the APP 1 display on the Scan Tool. Is APP 1 less than the specied value? Probe APP 1 sensor ground circuit at the APP sensor harness connector with a test light connected to B+. Is the test light ON? 1. Check for a short to voltage on the APP 1 sensor signal circuit. 2. If the APP 1 sensor signal circuit is shorted, repair it as necessary. Was the APP 1 sensor signal circuit shorted? 1. The 5-volt reference circuit for APP 1 is shorted to battery voltage. 2. Repair the circuit as necessary. Did you nd and correct the condition? 1. Check for a faulty connection at the APP sensor. 2. If a problem is found, repair the circuit as necessary. Was the problem found and corrected? 1. Check for an open sensor ground circuit. 2. If a problem is found, repair as necessary. Was APP 1 sensor ground circuit open? Replace the APP module. Is Action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
4.75v
Go to step 4.
Go to step 3.
0.25v
Go to step 7.
Go to step 8.
Go to step 12.
Go to step 12.
Go to step 9.
10 11
12
Go to step 13.
Go to step 2.
13
System OK.
5745159
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48
DTC P0126 Engine Coolant Temperature Insufcient For Stable Operation

C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
While the engine is warming, the powertrain control module (PCM) monitors the engine coolant temperature sensor (ECT) to determine how long the engine takes to reach the coolant temperature that is required for Closed Loop temperature in a specified amount of time. This test will not run if either the intake air or the engine coolant temperature is too low at start-up. The PCM will only run this DTC on a cold start and only once per cold start. This is a class B code.
Actions Taken When the DTC Sets

The control module illuminates the malfunction indicator lamp on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores the information in the Failure Records. If the diagnosis reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
Conditions for Running the DTC

The PCM performs this DTC diagnostic test once per ignition cycle until pass or fail condition exists. The engine operation time is more than 600 seconds. DTCs P0112, P0113, P0117, or P0118 are not set. The engine coolant temperature is less than 56C (133F). The intake air temperature is more than -7C (20F). OR The engine operation time is more than 300 seconds. DTCs P0112, P0113, P0117, or P0118 are not set. The engine coolant temperature is less than 56C (133F). The intake air temperature is more than -7C (20F).
Diagnostic Aids
If other DTCs are set that share the same ground and/or 5 volt reference circuit, check for faulty connections and for faulty wiring. If the engine has been allowed to sit overnight, the engine coolant temperature and the intake air temperature values should display within a few degrees of each other. If the engine coolant temperature exceeds 60C (140F), this indicates that the engine is capable of reaching the proper temperature, but not necessarily in the correct amount of time. This diagnostic table must be repeated on a cold engine, The time required to reach the temperature threshold must be measured. When starting a cold engine, measure the amount of time the engine takes to reach the specified temperature. The engine should reach the specified temperature within 8 minutes. If the specified temperate is not reached within 7 minutes, check the coolant level, thermostat operation and the cooling fan.

The fuel burned since start-up is more than 1,000,000 cu. mm. The total idle time since start-up is less than 450 seconds. or The fuel burned since start-up is more than 468,120 cu. mm. The total idle time since start-up is less than 225 seconds. 1-1-02
__________________________________________________
49
DTC P0126 Engine Coolant Temperate Insufficient for Stable Operation

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Are any engine coolant temperature DTCs set? Connect the Tech 2, Turn the ignition switch to the ON position but dont start the engine. Disconnect the ECT sensor. Does the Tech 2 indicate that the ECT sensor is at a temperature that is colder than the specied value? Using a jumper wire, jumper thee terminals at the ECT sensor harness connector together. Does the scan tool indicate the ECT is at a temperature that is more the specied value? Values Yes Go to step 2. No Go to OBD System Check.
2 3
-35C (-31F)
Go to the specic DTC chart. Go to step 4.
Go to step 3. Go to DTC P0117.
150C (302F)
Go to step 5.
Go to DTC P0118.
Reconnect the ECT sensor. 60C (140F) Start and idle the engine. With the engine idling, observe the ECT sensor display on the Engine 1 Data List of the scan tool. WARNING: Allow time for the engine to warm up if the engine has not already reached the specied temperature. Seven minutes should be the maximum time needed to warm a cold engine. Does the scan tool indicate that the engine coolant temperature has reached the specied value? Use a DVOM in order to measure the resistance of the ECT sensor. Is the ECT resistance close to the value indicated in the Temperature Vs. Resistance table? For an engine cooling system condition, check for the following conditions: Thermostat operation. Coolant level. Coolant to water ratio., Cooling fan operation etc. Did you nd any correct the condition? Replace the ECT sensor. Did you complete the replacement?
Go to Diagnostic Aids
Go to step 6.
Go to step 7.
Go to step 8.
Go to step 9.
8 9
Go to step 2.
Use the Tech 2 in order to clear the DTCs. Start the engine and idle until normal operating temps. are reached. Select DTC specific, then enter the DTC number that was set. Operate the vehicle within the conditions for setting this DTC until the scan tool indicates the diagnostic ran. Does the scan tool indicate the diagnostic passed? Does the scan tool display any additional undiagnosed DTCs?
10
Go the specic DTC chart.
System OK.
5745159
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50
DTC P0182 Fuel Temperature Sensor Circuit Low Voltage

A
5 VOLT REFERENCE
E
COIL 1
M
B
COIL 2
PUMP CAM HIGH SENSOR RESOLUTION SIGNAL SIGNAL
SENSOR GROUND
D F
C5 375 GY
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
703 OR
C27-D14
C29-A4 C29-A2
C27-D9
C27-C8 C29
A7
A8
A9
710 OR
442 BR
156 PK
708 TN
225 YL
A10
5V
5 VOLT REFERENCE CAM HIGH SENSOR RES SIGNAL SIGNAL SENSOR GROUND
5V
FUEL TEMP SIGNAL
5V
ITS HIGH ITS LOW ITS LOW

02-S12-012
Circuit Description
The fuel temperature sensor is a thermistor that controls signal voltage to the PCM. When the fuel is cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As fuel warms, sensor resistance becomes less and voltage drops. The fuel temperature sensor is integrated with the optical sensor. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC. Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Use a scan tool.

Fuel temperature greater than 102C (215F). Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads fuel temperature in degrees centigrade. After engine is started, the fuel temperature should rise steadily.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. 1-1-02
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step determines if DTC P0182 is a hard failure or an intermittent condition. 3. This step will determine if signal circuit is shorted to ground.
711 YL
5V
ITS HIGH
__________________________________________________
51
DTC P0182 - Fuel Temperature Sensor Circuit Low Voltage

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Start the engine. 3. Monitor the Fuel Temp display on the scan tool. Is Fuel Temp greater than the specied value? 1. Engine OFF. 2. Ignition ON. 3. Disconnect the Optical/Fuel Temperature sensor connector. Is Fuel Temp less than or equal to the specied value? 1. 2. 3. Ignition OFF. Disconnect harness connector C27 Using a DVOM, check resistance to ground on circuit 225 YL at the sensor. Is the resistance at the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer those chart(s). Repair the short to ground in the Fuel Temp signal circuit. Is the action complete? Replace the fuel injection pump. Notice: If fuel injection pump is faulty, the new injection pump must be timed. Is the action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
102C (215F)
Go to step 3.
Go to step 5.
17C (63F)
Go to step 7.
Go to step 4.
Innite
Go to step 8.
Go to step 6.
Go to the applicable DTC table Go to step 9. Go to step 9.
6 7
Go to step 9.
Go to step 10.
Go to step 2.
10
System OK.
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DTC P0183 Fuel Temperature Sensor Circuit High Voltage

A
5 VOLT REFERENCE
E
COIL 1
M
B
COIL 2
SENSOR GROUND
D F
C5 375 GY
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
708 TN
703 OR
C27-D14
C29-A4 C29-A2
C27-D9
C27-C8 C29
A7
A8
A9
710 OR
442 BR
156 PK
225 YL
A10
5V
5V
FUEL TEMP SIGNAL
5V

02-S12-012
Circuit Description
The fuel temperature sensor is a thermistor that controls signal voltage to the PCM. When the fuel is cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As fuel warms, sensor resistance becomes less and voltage drops. The fuel temperature sensor is integrated with the optical sensor. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Use of a Scan Tool.

Engine operating for 8 minutes. Fuel temperature less than or equal to 17C (63F). Conditions met for 2 seconds.
Diagnostic Aids
A Tech 2 reads fuel temperature in degrees centigrade. A failure to detect an increase in fuel temperature could be the result of a faulty connection or an open in the signal circuit.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycles, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Record.
Test Description.
2 This step determines if DTC P0183 is a hard failure. 3 This step stimulates a DTC P0182. If the PCM recognizes the low signal voltage (high temp) the PCM and wiring are OK. 4 This test will determine if signal circuit is open. There should be 5 volts at sensor connector if measured with a DVOM. This will determine if there is a wiring problem or a faulty PCM. 9 This test determines if a short to voltage increases current flow through the sensor thus overwhelming the sensor. This keeps the sensor from pulling down the circuit to the correct voltage and displaying the correct temperature.
1-1-02
711 YL
5V
ITS HIGH
__________________________________________________
53
DTC P0183 - Fuel Temperature Sensor Circuit High Voltage

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Start and idle engine. 3. Monitor the Fuel Temp display on the scan tool. Is Fuel Temp less than the specied value? 1. Ignition ON. Engine OFF. 2. Disconnect the Optical/Fuel Temperature sensor connector. 3. Jumper the Fuel Temperature harness terminals together. Does the Scan Tool display fuel temperature greater than the specified value? Jumper the Fuel Temperature sensor signal circuit to a known good ground. Does the Scan Tool display a Fuel Temp greater than the specied value? DTC is intermittent. Are any other DTCs stored? Inspect the sensor connector and PCM connector for proper connection. If a problem is found repair the circuit as necessary. Did you complete the repair? Check the Fuel Temperature sensor ground circuit for an open between the Fuel Temp sensor and the PCM. If a problem is found repair as necessary. Did you complete the repair? Check the Fuel Sensor signal circuit for an open between the Fuel Temp sensor and the PCM. If a problem is found repair as necessary. Did you complete the repair? With a DVOM set to the mA scale, measure the current across the fuel temperature signal and the sensor ground circuit at the sensor harness connector. Is the current less than the specied value.? Repair the short to voltage on the fuel temperature signal circuit. Did you complete the repair? Inspect the PCM connectors for proper connections and replace the terminals, if necessary. Did you complete the repair? Replace the injection pump. Is the action complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
18C (64F)
Go to step 3.
Go to step 5.
105C (221F)
Go to step 6.
Go to step 4.
4 5
105C (221F)
Go to step 7. Go to the applicable DTC table Go to step 14.
Go to step 8. Go to Diagnostic Aids. Go to step 9.
50 mA
Go to step 12
Go to step 10
10 11 12 13 14
Go to step 14.
Go to step 14. Go to step 13 Go to step 14. Go to step 14. Go to step 15. Go to step 2.
15
System OK.
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DTC P0215 Engine Shutoff Solenoid Control Circuit

30 GY C9-J WATER IN FUEL LIGHT LEFT HAND STATUS CENTER C3-N7 FUSE 4B 5AMP INTERIOR FUSE BOX FUSE 3B 20AMP EXTERIOR FUSE BOX FUSE 3A 20AMP EXTERIOR FUSE BOX C5-A4 239 PK A C1-45 327 YL 291 PK B A WATER IN FUEL SENSOR A C 701 DB FUEL HEATER FUEL SOLENOID FUEL DRIVER SOLENOID CONTROL A CLOSURE SIGNAL E CLOSURE GROUND C ENGINE SHUTOFF SOLENOID D IGN B FUEL SOLENOID HIGH F FUEL SOLENOID LOW FUEL SOLENOID HOT IN RUN AND START HOT IN RUN AND START A
DRAIN FILTER
B C9-D C3-F4 TO IGNITION SWITCH
Circuit Description
The injection fuel supply line has a solenoid controlled shutoff located in the injection pump. When the solenoid is energized (key in the run position), the valve is open and fuel is supplied to the injection pump. By providing a ground path, the PCM energizes the solenoid. This is a type D DTC.

A current DTC Last Test Failed clears when the Diagnostic runs and passes. A history DTC clears after 40 consecutive warm up cycles, if no failures are recorded by this or any other nonemission related diagnostic. Use the scan tool.

PCM requested ESO ON. (test 1) Control circuit voltage at the PCM is greater than 8 volts. Conditions met for 2 seconds. or PCM requested ESO OFF. Control circuit voltage at the PCM is less than 8 volts. Conditions met for 2 seconds.
Diagnostic Aids
An open in the control circuit or the ignition feed circuit will cause a P0215. Also a no start condition will exist. The Scan Tool has the ability to turn the engine shutoff solenoid ON and OFF. This can be used as a quick operational check.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 3. This step will check the ESO circuit for an open. 4. After repairing the circuit for a short to voltage, check the solenoid for proper operation.

The control module stores the DTC information into memory when the diagnostics runs and fails. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. in the Failure Records.
1-1-02
__________________________________________________
55
DTC P0215 - Engine Shutoff Solenoid Circuit Malfunction

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. 4. Turn the ignition OFF. Disconnect the ESO harness connector. Turn the ignition to the RUN position leave the engine OFF. With a test light connected to ground, probe the ESO ignition feed circuit at the engine harness connector. Does the test light illuminate? 1. Ignition OFF. 2. With the test light jumper the ESO engine harness terminals. 3. Turn the ignition switch to the Run position. Is test light ON. 1. 2. 3. Turn the ignition to the Run position. With a test light, connected to B+, probe the ESO command circuit. With the TECH 2 command the ESO solenoid ON and OFF. Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 6.
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 8.
Check the ESO control circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? Check the ESO control circuit for: an open faulty fuse 2. If the ESO control circuit was faulty, repair it as necessary. Was repair performed? 1. 2. Turn the ignition to the Run position. With the test light connected to ground, probe the ESO condition is found repair the circuit as necessary. Does the test lamp illuminate? 1.
Go to step 13.
Go to step 11.
Go to Step 13.
Go to step 10.
Go to step 9.
8 9
Repair the short to ground on the ESO control circuit. Is the repair complete? Check the ESO control circuit for an open wire or a faulty connection at the PCM 2. If an ESO control circuit condition is found repair the circuit as necessary. Is the repair complete? Check the ESO control circuit for a short to voltage. Repair as necessary. Is the repair complete? Replace the engine shut-off solenoid. Is the repair complete? Replace the faulty PCM. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC until the test has run. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1.
10 11 12 13
Go to step 12.
Go to step 2.
14
Go to the DTC table
Go to step 2.
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DTC P0216 Injection Timing Control System

A
5 VOLT REFERENCE
E
COIL 1
M
B
COIL 2
SENSOR GROUND
D F
C5 375 GY
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
703 OR
C27-D14
C29-A4 C29-A2
C27-D9
C27-C8 C29
A7
A8
A9
710 OR
442 BR
156 PK
708 TN
225 YL
A10
5V
5V
FUEL TEMP SIGNAL
5V

02-S12-012
Circuit Description
Timing of the combustion event is accomplished by controlling the beginning of the injection measured in degrees of crankshaft rotation before top dead center (TDC). This test compares the desired timing to the measured timing when certain conditions have been met. In order to retard the injection timing, the powertrain control module (PCM) extends the stepper motor. In order to advance the injection timing, the PCM retracts the stepper motor. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if on failures are reported by this or any other emission related diagnostic. Use of a Scan Tool.

Engine speed has not changed more than 56 rpm for 5 seconds. A 5 difference between Act. Inj. Time and Des. Inj. Time. DTCs P0251, P0335, or P0370 are not set.
Diagnostic Aids
A hard start and possible poor performance condition might exist. Act. Inj. Time will freeze at the point of the fault. DTC P0216 will set if injection timing is not set correctly.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycles, the control module record s the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
Test Description
2.This step determines if DTC P0216 is a hard failure. 4.This step checks for an open or short in the injection timing coil circuit 1. 5.This step checks for an open or short in the injection timing coil circuit 2. 6.The important thing in this step is that the PCM is sending a varying voltage The voltage may vary between 1 and 12 usually you will see voltage vary between 5 and 6 when engine is idling. This indicates that the PCM is OK and that there is a problem with the injection timing stepper motor. If there is a steady voltage present on any circuit, this will indicate a problem with the PCM or a circuit shorted to voltage.
1-1-02
711 YL
5V
ITS HIGH
__________________________________________________
57
DTC P0216 - Injection Timing Control System

Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info Was the On-Board Diagnostic (OBD) System Check performed? 1. Engine at operating temperature. 2. Scan injection timing at idle and at 1500 rpm. Does the scan tool display a difference that is more than or equal to the specic value between the Actual Inj. Time and the Desired Inj. Time at idle or at 1500 RPM? DTC is intermittent. An additional DTCs are stored. 1. 2. 3. Ignition OFF. Disconnect PCM. Measure resistance between coil 1 low and coil 1 high at PCM harness. Is resistance between specied value? Measure resistance between coil 2 low and coil 2 high at PCM harness. Is resistance between specied value? 1. 2. 3. 4. 5. 1. 2. Reconnect PCM. Disconnect Injection Timing Stepper motor. Start and idle engine. Using scan tool, command Time Set ON. Check for varying voltage on all terminals at injection timing stepper motor electrical harness. Does voltage vary? Disconnect crankshaft position sensor. Measure resistance between crankshaft position sensor signal and 5 volt reference circuit at sensor pigtail. Is resistance between specied value? Value(s) 5 Yes Go to step 2. Go to step 4. No Go to OBD System Check. Go to step 3.
3 4
10-60 Ohms
Go to the DTC table Go to step 5.
Go to Diagnostic Aids Go to step 9.
5 6
10-60 Ohms
950-1050 Ohms
Go to step 8.
Go to step 13.
Reconnect all of the sensors and check for one of the following conditions: Incorrectly set ignition timing. A sheared camshaft driven key. If a condition is found, repair it. Did you complete the repair? 1. 2. 3. Ignition OFF. Disconnect the stepper motor. Check for an open or a short to ground in one of the following: The coil 1 low circuit. The coil 1 high circuit. If a problem is found, repair it. Did you complete the repair? 1. 2. 3. Ignition OFF. Disconnect the stepper motor. Check for an open or a short to ground in one of the following: The coil 2 low circuit. The coil 2 high circuit. If a problem is found, repair it. Did you complete the repair?
Go to step 17.
Go to step 15.
Go to step 17.
Go to step 15.
10
Go to step 18.
Go to step 16.
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DTC P0216 - Injection Timing Control System (Contd)

Step 11 12 13 14 15 16 17 Action Check for poor electrical connection at the injection timing stepper motor. Was a repair performed? Check the circuit for a short to ground or a poor connection at the PCM. Was a repair performed? Check crankshaft sensor pigtail for a short to ground. Repair it as necessary. Did you complete the repair? Replace crankshaft position sensor. Is action complete? Replace injection pump. Is action complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate the vehicle within the Conditions for Setting this DTC until the scan tool indicates the diagnostic ran. Does the Scan Tool indicate that this diagnostic Ran and Passed? Value(s) Yes Go to step 17. Go to step 17. Go to step 17. Go to step 17. Go to step 17. Go to step 17. Go to step 18. No Go to step 15. Go to step 16. Go to step 14. Go to step 2.
18
Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
Go to the DTC table
System OK.
1-1-02
__________________________________________________
59
DTC P0219 ENGINE OVERSPEED CONDITION

5 ESO cycles with an rpm drop.

DRAIN FILTER
The control module stores the DTC information into memory when the diagnostics runs and fails. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. in the Failure Records.

A current DTC Last Test Failed clears when the Diagnostic runs and passes. A history DTC clears after 40 consecutive warm up cycles, if no failures are recorded by this or any other nonemission related diagnostic. Use the scan tool.
C 713 RD A 57 BK 57 BK 491 BK C27-C13 CLOSURE SIGNAL C29-A1 CLOSURE GROUND 712 LG C28-C15 POWER CONTROL MODULE 9-S12-056 G2 ESO SOLENOID CONTROL C28-D3 C28-C3
Diagnostic Aids
This DTC will not set if an external fuel source is causing an overspeed condition. A DTC P1216 will set along with DTC P0219
FUEL INJECT CONTROL
Test Description Circuit Description

The PCM has the ability to put the vehicle in an ESO controlled idle if an engine overspeed condition has been detected. This is a type D DTC. Number(s) below refer to the number(s) on the diagnostic table. 2. The injection pump is being replaced in this step.
DTC P0219 - Engine Overspeed Condition

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? Yes Go to step 2. No Go to OBD System Check.
Replace injection pump. Notice: If injection pump is faulty, the new injection pump must be timed. Go to Checking and Adjusting Injection Timing in section 4. Is action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4.
Go to step 3.
Go to step 4.
Go to step 2.
Go to Applicable DTC table
System OK.
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DTC P0220 Accelerator Pedal Position (APP) Sensor 2 Circuit

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
Diagnostic Aids
There are no driveability issues associated with the APP module unless a DTC is present. The most likely causes of this DTC are faulty connections or the sensor itself. The least likely cause is a PCM condition. All 5-volt reference circuits must be checked for a proper reference voltage. Voltmeter accuracy is important.

Reference voltage on APP 2 less than 4.8 volts. Condition met for 2 seconds.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step will determine if there is a good voltage reference.

The PCM stores the DTC information into memory when the Diagnostic runs and fails. The MIL will not illuminate. The Control module records the operating conditions at the time the diagnostic fails. This information is stored as a Failure record. The Check Throttle light will illuminate.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use the Tech 2. A current DTC Last Test Failed clears when the diagnostic runs and passes.
1-1-02
__________________________________________________
61
DTC P0220 - Accelerator Pedal Position (APP) Sensor 2 Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, check all APP 5 volt reference circuits at APP harness. Is voltage less than specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). 1. 2. Ignition OFF. Disconnect the PCM and check the 5 volt reference circuit for a short to ground. 3. If the 5 volt reference circuit is shorted to ground, repair as necessary Was the 5 volt reference circuit shorted to ground? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
4.8v
Go to step 4.
Go to step 3.
Go to step 6.
Go to step 7.
Go to step 2.
System OK.
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D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description


Ignition voltage is greater than 6.4 volts. Engine speed greater than 300 rpm. The difference between APP 2 and APP 1 is greater than.23 volts. The difference between APP 2 and APP 3 is greater than.50 volts. No in range faults for APP 1 or APP 3. Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads APP 2 position in volts and should read about 4.5 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Refer to Section 2 for Intermittents. Scan APP 2 sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about 4.5 volts when throttle was closed to about 1.5 volts when throttle is held at Wide Open Throttle (WOT) position.

1-1-02
__________________________________________________
63
DTC P0221 - Accelerator Pedal Position (APP) Sensor 2 Circuit Performance

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP voltages on the scan tool. Are APP at specied values? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, probe APP sensor 5 volt reference circuits at APP harness terminals G, D and E. Is voltage at the specied value on all circuits? Ignition ON, engine OFF. With a test light connected to B+, probe APP sensor ground circuits at the APP sensor harness terminals A, B and J. Is the test light ON (all circuits)? 1. 2. Ignition OFF Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair it as necessary. Was the 5 volt reference circuit open or shorted to ground? 1. 2. 1. 2. 3. Value(s) Yes No
.45-.95v 4.0-4.5v 3.6-4.0v
Go to step 3.
Go to step 4.
4.75v
Go to step 9.
Go to step 8.
Go to step 11.
Go to step 7.
Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. 2. Ignition OFF Disconnect the PCM and check for an open sensor ground circuit to the PCM. 3. If problem is found, repair as necessary. Was APP sensor ground circuit open?
9 10
Replace the APP module. Is Action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
11
Go to step 12.
Go to step 2.
12
System OK.
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64
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
Diagnostic Aids
A scan tool reads APP 2 position in volts and should read about 4.5 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). An open or short to ground in CKT 721 or 720 will result in a P0222. Refer to Section 2 for Intermittents. Scan APP 2 sensor while depressing accelerator pedal with engine stopped and ignition ON, The display should vary from about 4.5 volts when throttle was closed to about 1.5 volts when throttle is held at WOT position.

Voltage is less than.25 volts on APP 2 sensor. Conditions met for 2 seconds.


1-1-02
__________________________________________________
65
Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 2 voltages on the scan tool. Is APP 2 voltage less than or equal to the specied value? DTC is intermittent. Are additional DTCs stored? 1. 2. Disconnect the APP sensor electrical connector. Jumper APP 2, 5 volt reference circuit and the APP 2 signal together at the APP sensor harness connector. 3. Observe the APP 2 voltage on the Scan Tool. Is APP 2 voltage greater than the specied value? Use the DVOM in order to probe the APP 2 sensor signal circuit at thee APP sensor harness. Is APP 2 voltage greater than the specied value? 1. 2. Ignition OFF. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair as necessary. Was the 5 volt reference circuit open or shorted to ground? Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. Ignition OFF. 2. Disconnect PCM, and check APP 2 signal circuit for short to ground. 3. Repair as necessary. Was APP 2 signal circuit open or shorted to ground? Check the APP 2 sensor signal circuit for a poor connection at the module and replace terminal if necessary. Did the terminal require replacement? Replace the APP module. Is Action complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) .25v Yes No
Go to step 2. Go to OBD System Check. Go to step 3. Go to step 4.
Go to the DTC table. Go to step 5.
4.75v
4.75v
Go to step 9.
Go to step 8.
Go to step 12.
Go to step 7.
7 8
9 10 11 12
13
Go to the DTC table
System OK
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66
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
Diagnostic Aids
A scan tool reads APP 2 position in volts and should read about 4.5 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Scan APP 2 sensor while depressing accelerator pedal with engine stopped and ignition ON, The display should vary from about 4.5 volts when throttle was closed to about 1.5 volts when throttle is held at WOT position.

Voltage is greater than 4.75 volts on APP 2. Conditions met for 2 seconds.


1-1-02
__________________________________________________
67
Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 2 display on the scan tool. Is APP 2 greater than or equal to the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Probe APP 2 sensor ground circuit at the APP sensor harness connector with a test light connected to B+. Is the test light ON? Use a fused jumper wire in order to jump the APP 2 signal circuit to the APP 2 ground circuit at the APP harness connector. Does the Tech 2 display an APP 2 voltage less then the specied value? 1. Check for an open on the APP 2 sensor signal circuit. 2. If the APP 2 sensor signal circuit is open, repair it as necessary. Was the APP 2 sensor signal circuit open? 1. Check for an open sensor ground circuit. 2. Repair as necessary. Is the repair complete? 1. 2. 3. Verify the ignition is ON with the engine OFF. Verify the APP harness is still disconnected from the APP module. With a DVOM, set to the mA scale measure the current between the APP 2 signal circuit and a good ground. Does the current measure more than the specied value? Repair the short to voltage on the APP 2 signal circuit. Is the repair complete? 1. Check for a faulty electrical connection at the APP sensor. 2. Repair as necessary. Is the repair complete? Replace the APP module. Is Action complete? 1. Check for a faulty electrical connection at the PCM. 2. Repair the connection as necessary. Is the repair complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
4.75v
Go to step 4.
Go to step 3.
Go to Diagnostic Aids. Go to Step 7.
0.25v
Go to step 8.
Go to step 6.
Go to Step 14. Go to Step 12.
30 mA
Go to step 9.
Go to step 10.
9 10
Go to step 14.
11 12
Go to step 14.
13 14
Go to step 2.
15
System OK.
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68
DTC P0225 Accelerator Pedal Position (APP) Sensor 3 Circuit

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description


Reference voltage on APP 3 less than 4.8 volts. Condition met for 2 seconds.
Diagnostic Aids
All 5 volt reference circuits must be checked for proper reference voltage. Volt meter accuracy is important.

1-1-02
__________________________________________________
69
DTC P0225 - Accelerator Pedal Position (APP) Sensor 3 Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, check all APP 5 volt reference circuits at APP harness. Is voltage less than specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). 1. 2. Ignition OFF. Disconnect the PCM and check the 5 volt reference circuit for a short to ground. 3. If the 5 volt reference circuit is shorted to ground, repair as necessary Was the 5 volt reference circuit shorted to ground? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
4.8v
Go to step 4.
Go to step 3.
Go to step 6.
Go to step 7.
Go to step 2.
System OK.
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70

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description


Ignition voltage is greater than 6.4 volts. Engine speed greater than 300 rpm. The difference between APP 3 and APP 1 is greater than.23 volts PCM compares pre-scaled voltage that is internal to the PCM. The difference between APP 3 and APP 2 is greater than.50 volts PCM compares pre-scaled voltage that is internal to the PCM. No in range faults for APP 1 or APP 2. Conditions met for 2 seconds.
Diagnostic Aids
A scan tool reads APP 3 position in volts and should read about 4.0 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Scan APP 3 sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about 4.0 volts when throttle was closed to about 2.0 volts when throttle is held at WOT position.

1-1-02
__________________________________________________
71

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP voltages on the scan tool. Are APP at specied values? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, probe APP sensor 5 volt reference circuits at APP harness terminals G, D and E. Is voltage at the specied value on all circuits? Ignition ON, engine OFF. With a test light connected to B+, probe APP sensor ground circuits at the APP sensor harness terminals A, B and J. Is the test light ON (all circuits)? 1. 2. Ignition OFF Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair it as necessary. Was the 5 volt reference circuit open or shorted to ground? 1. 2. 1. 2. 3. Value(s) Yes Go to step 2. No Go to OBD System Check.
.45-.95v 4.0-4.5v 3.6-4.0v
Go to step 3.
Go to step 4.
4.75v
Go to step 9.
Go to step 8.
Go to step 11.
Go to step 7.
Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. 2. Ignition OFF Disconnect the PCM and check for an open sensor ground circuit to the PCM. 3. If problem is found, repair as necessary. Was APP sensor ground circuit open?
Go to step 11.
Go to step 10.
Go to step 11.
Go to step 10.
9 10
Replace the APP module. Is Action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4.
11
Go to step 12.
Go to step 2.
12
System OK.
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72
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
Diagnostic Aids
A scan tool reads APP 3 position in volts and should read about 4.0 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also 90% pedal travel is acceptable for correct APP operation. Scan APP 3 sensor while depressing accelerator pedal with engine stopped and ignition ON, Display should vary from about 4.0 volts when throttle was closed to about 2.0 volts when throttle is held at Wide Open Throttle (WOT) position.

Voltage is less than.25 volts on APP 3 sensor. Conditions met for 2 seconds.


1-1-02
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73
Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 3 voltages on the scan tool. Is APP 3 voltage less than or equal to the specied value? DTC is intermittent. Are additional DTCs stored? Disconnect the APP sensor electrical connector. Jumper APP 3, 5 volt reference circuit and the APP 3 signal together at the APP sensor harness connector. 3. Observe the APP 3 voltage on the Scan Tool. Is APP 3 voltage greater than the specied value? Use the DVOM in order to probe the APP 3 sensor signal circuit at thee APP sensor harness. Is APP 3 voltage greater than the specied value? 1. Ignition OFF. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair as necessary. Was the 5 volt reference circuit open or shorted to ground? Check the 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. Ignition OFF. 2. Disconnect PCM, and check APP 3 signal circuit for short to ground. 3. Repair as necessary. Was APP 3 signal circuit open or shorted to ground? Check the APP 3 sensor signal circuit for a poor connection at the module and replace terminal if necessary. Did the terminal require replacement? Replace the APP module. Is Action complete? Replace the faulty PCM. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. Value(s) .25v Yes Go to step 2. No Go to OBD System Check. Go to step 3. Go to step 4.
4.75v
4.75v
Go to step 9.
Go to step 8.
7 8
9 10 11 12
13
Go to the DTC table
System OK
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74
D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description
Diagnostic Aids
A scan tool reads APP 3 position in volts and should read about 4.0 volts with throttle closed and ignition ON or at idle. Voltage should decrease at a steady rate as throttle is moved toward Wide Open Throttle (WOT). Also, 90% pedal travel is acceptable for correct APP operation. Scan APP 3 sensor while depressing accelerator pedal with engine stopped and ignition ON. Display should vary from about 4.0 volts when throttle is closed to about 2.0 volts when throttle is held at WOT position.

Voltage is greater than 4.75 volts on APP 3 sensor. Conditions met for 2 seconds.


1-1-02
__________________________________________________
75
Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record Freeze Frame and Failure Record for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Ignition ON, engine OFF. 2. With the throttle closed, observe APP 2 display on the scan tool. Is APP 2 greater than or equal to the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored, refer to those chart(s). Probe APP 2 sensor ground circuit at the APP sensor harness connector with a test light connected to B+. Is the test light ON? Use a fused jumper wire in order to jump the APP 2 signal circuit to the APP 2 ground circuit at the APP harness connector. Does the Tech 2 display an APP 2 voltage less then the specied value? 1. Check for an open on the APP 2 sensor signal circuit. 2. If the APP 2 sensor signal circuit is open, repair it as necessary. Was the APP 2 sensor signal circuit open? 1. Check for an open sensor ground circuit. 2. Repair as necessary. Is the repair complete? 1. 2. 3. Verify the ignition is ON with the engine OFF. Verify the APP harness is still disconnected from the APP module. With a DVOM, set to the mA scale measure the current between the APP 2 signal circuit and a good ground. Does the current measure more than the specied value? Repair the short to voltage on the APP 2 signal circuit. Is the repair complete? 1. Check for a faulty electrical connection at the APP sensor. 2. Repair as necessary. Is the repair complete? Replace the APP module. Is Action complete? 1. Check for a faulty electrical connection at the PCM. 2. Repair the connection as necessary. Is the repair complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes No
4.75v
Go to step 4.
Go to step 3.
Go to Diagnostic Aids. Go to Step 7.
0.25v
Go to step 8.
Go to step 6.
30 mA
Go to step 9.
Go to step 10.
9 10
Go to step 14.
11 12
Go to step 14.
13 14
Go to step 2.
15
System OK.
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76
DTC P0231 Fuel Lift Pump Secondary Circuit Low Voltage

FUEL PUMP RELAY R-3 EXTERIOR FUSE BOX
87 85 86 238 DG
D8
C27
INTERIOR FUSE BOX

537 OR TO IGNITION FUSE 2D 20 AMP G2 59 BK
87A
30 787 GY
PCM
FUEL PUMP RELAY CONTROL FUEL LIFT PUMP SENSE SIGNAL
787 GY
787 GY
787 GY
D5
G1
FUEL LIFT PUMP

59 BK 5B G4
C1-11 C3-M8 2B
C55-14
COOLANT/ FUEL MODULE MAIN TANK FUEL LEVEL SENDING UNIT
C55-5
29 PK
FUEL SELECTOR SWITCH
G4 4 6 1 3
673 DB
789 BR
786 RD
C3
P7 C26-A 675 YL 35 75 9 M6 M7
C1
AUX. TANK FUEL LEVEL SENDING UNIT

C38-C A G2 A
C2
35 37 36
C26
B B C E E D D
C67
SELECTOR VALVE ASSEMBLY
ENGINE SUPPLY
RETURN FROM INJECTION PUMP
MAIN TANK SUPPLY
MAIN TANK RETURN
AUX. TANK SUPPLY
AUX. TANK RETURN
02-S02-003
9-S12-051
Circuit Description
The status of the lift pump is monitored by the PCM. This signal is also used to store a DTC if the fuel pump relay is defective or fuel pump voltage is lost while the engine is running. There should be about 12 volts on circuit 787 during glow plug cycle. This is a Type B DTC.
operating condition to the Freeze Frame and updates the Failure Records.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic passes. A history DTC clears after 40 consecutive warm up cycles, if no failures are reported by this or any other emission related diagnostic, Use of a Scan Tool

Fuel lift pump commanded ON. The difference between the ignition voltage and the fuel lift pump voltage is more than 4 volts. Conditions met for 2 seconds.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. the first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module writes the 1-1-02
Diagnostic Aids
This DTC will not check the fuel pump operation.
Test Description
2. This step determines if the fuel lift pump is working. 9. This step checks if the PCM is sending a signal to turn the fuel lift pump ON.
__________________________________________________
77
DTC P0231 - Fuel Lift Pump Secondary Circuit Low Voltage

Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the ignition ON. 2. With the scan tool command the fuel lift pump ON. Does the scan tool indicate the fuel lift pump voltage is near the specified value? 1. 2. 3. 4 1. 2. 3. 1. Remove the fuel pump relay. With the fuel pump relay removed probe terminal 30 with a fused jumper to battery positive. Does the scan tool indicate voltage at the specied value? Connect an unpowered test light to ground. With the fuel pump relay removed probe terminal 87. Does the test lamp illuminate? Value(s) > 12.6v Yes No Go to step 2. Go to OBD System Check. Go to Diagnostic Aids. Go to step 4. Go to step 3.
> 12.6v
Go to step 5.
Go to step 6.
Go to step 8.
Check for an open or short to ground on the fuel lift pump signal circuit. 2. If a problem is found, repair the problem as necessary. Did you perform a repair? Connect a test light between terminal 85 and terminal 87. Does the test lamp illuminate? Repair the open fuel pump relay ground circuit. Did you complete the repair? Repair the open in the battery feed circuit to the fuel pump relay. Did you complete the repair? Turn the ignition switch OFF. Connect a test light between terminal 86 of the fuel pump relay and ground. 3. Monitor the test lamp. 4. Turn the ignition switch ON. Does the test light come ON during the glow plug cycle and then go OFF after the glow plug cycle is complete? 1. Turn the ignition switch OFF. 2. Connect a test light to ground. 3. Back probe the fuel lift pump signal circuit at the PCM. 4. Monitor the test lamp. 5. Turn the ignition switch ON. Does the test light come ON during the glow plug cycle and then go OFF after the glow plug cycle is complete? Check fro an open or short to ground in the control circuit from the fuel pump relay harness connector terminal number 86 and the PCM. Was a problem found? Repair the open or short to ground in the fuel pump relay control circuit. Did you complete the repair? 1. Check for faulty connections at the PCM. 2. If you nd a problem, repair the problem as necessary. Did you perform a repair? Replace the PCM. Did you complete the replacement? 1. 2.
6 7 8 9
Go to step 7.
10
11
12 13
Go to step 17.
14
Go to step 17.
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DTC P0231 - Fuel Lift Pump Secondary Circuit Low Voltage

Step 15 Action Check for faulty connections at the fuel pump relay connector. Repair as necessary. Did you perform a repair? Replace the fuel pump relay. Did you complete the replacement? Use the scan tool in order to clear the DTCs. Start the engine. Allow the engine to idle until the normal operating temperature is reached. 4. Select DTC and the Specic DTC function. 5. Enter the DTC number that was set. 6. Operate the vehicle within the conditions for setting this DTC until the scan tool indicates the diagnostic ran. Does the scan tool indicate the diagnostic passed? Does the scan tool display any additional undiagnosed DTCs? 1. 2. 3. Value(s) Yes No Go to step 17. Go to step 16.
16 17
Go to step 2.
18
Go to the DTC List.
System OK.
1-1-02
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79
DTC P0236 Turbocharger (TC) Boost System

C C
5 VOLT REFERNCE

D B 44

722 PP C29-A12
SENSOR SIGNAL
A
SENSOR GROUND
B B A B
GROUND
C 2 G
B
32
721 LB
53
719 BR
GROUND
651 BK 350 GY 651 BK 394 LG 359 PP 357 TN 349 YL 354 YL
1 E
C5
17
718 DB
J K
60
725 GY
GROUND
C5
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4 651 PP
B5 357 TN
15
724 DG
C27-D4 APP 3 SIGNAL
14
C29-A5 C29-B12 C27-D13 C27-C14 C27-C11 C27-C1 C27-C4
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22
5V CKP SENSOR SIGNAL SENSOR GROUND 5 VOLT REFERENCE A BOOST SENSOR SIGNAL 5V ECT SENSOR SIGNAL SENSOR GROUND 5V IAT SENSOR SIGNAL
720 TN
C28-C2
C1
02-S02-005
02-S02-004
Circuit Description
The PCM operates a solenoid to control the boost. This solenoid is normally open. By providing a ground path the PCM energizes the solenoid which then allows a vacuum to pass to the wastegate valve. During normal operation, the PCM compares the wastegate duty cycle signal with the boost signal and makes corrections in the duty cycle accordingly. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up, if no failures are reported by this or any other emission related diagnostic. Use of a Scan Tool.

Engine speed greater than 2400 RPM. Boost pressure less than or equal to 20 kPa from desired (internal to PCM). Conditions met for 10 seconds. or Engine speed greater than 1800 but less than 2400 RPM. Boost pressure less than or equal to (110 kPa) - ((100 kPa - Baro)/2) (internal to PCM). Conditions met for 2 seconds.
Diagnostic Aids
A vacuum leak or a pinched vacuum line may cause a DTC P0236. Check all vacuum lines and components connected to the hoses for leaks or sharp bends. Check vacuum source. A possible EGR DTC will store if there is a problem with the vacuum source. Also check for proper vacuum line routing. This diagnostic checks for a skewed sensor.
Test Description
3. This will check the wastegate solenoid and the filter. A plugged filter will not allow the solenoid to vent, which will cause an over-boost condition. 5.This step checks the turbocharger wastegate actuator for vacuum leaks. The actuator must hold a vacuum. 6.This step will check for vacuum leaks at the lines. 7.This step will check for a skewed boost pressure sensor.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores the information in the Failure Records. If the diagnostic records a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
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DTC P0236 - Turbocharger (TC) Boost System

Step 1 2 3 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? Is DTC P1656 set? 1. Disconnect the vacuum line at the turbocharger wastegate actuator. 2. Install a vacuum gauge in place of the turbocharger wastegate actuator. 3. Start the engine. 4. Observe the vacuum at idle. Is the vacuum greater than or equal to the specied value? 1. Disconnect wastegate solenoid electrical connector with engine running. 2. With the vacuum gauge still in place, observe the vacuum at idle. Is the vacuum greater than the specied value? 1. Turn the engine OFF. 2. Connect a hand held vacuum pump to the turbocharger wastegate actuator. 3. Apply 5 in. Hg of vacuum. Does the turbocharger wastegate actuator hold vacuum? 1. Check all vacuum lines from vacuum pump to turbocharger wastegate actuator: leaks deformities and pinches If a problem is found, repair as necessary. Was a problem found? Value(s) Yes Go to step 2. Go to DTC P1656. No Go to OBD System Check. Go to step 3. Go to step 6
15 in. Hg Go to step 4.
1 in. Hg Go to step 12. Go to step 5.
2. 7
1. Verify the engine if OFF. 2. Disconnect all vacuum lines to the wastegate actuator. 3. Grip the wastegate actuator rod with a pair of pliers. 4. Attempt to move the wastegate actuator rod back and forth. Does the turbocharger wastegate actuator rod move freely? Check the vacuum pump for proper output. Is the action complete? 1. Access engine data with a scan tool 2. Start the engine and bring to a steady idle. 3. Observe the Boost Pressured display on the scan tool. 4. Increase the engine RPM to 1,500 then back to idle. Does the scan tool display a change in the boost pressure?
8 9
Go to step 15.
Go to step 9.
10 DTC is intermittent. If no additional DTCs are stored, refer to diagnostic Aids. Are any additional DTCs stored? 11 Replace the boost sensor. Refer to the Boost Sensor Replacement. Is the sensor installed? 12 Check for a plugged wastegate solenoid lter. Is the wastegate solenoid lter plugged? 13 Replace the wastegate solenoid. Is the action complete? 14 Replace the turbocharger wastegate actuator. Is the action complete? 15 Replace the vacuum pump. Is the pump installed?
Go to step 13. Go to step 16. Go to step 16. Go to step 16. Go to step 16.
1-1-02
__________________________________________________
81
DTC P0236 - Turbocharger (TC) Boost System

Step Action Value(s) Yes No 16 1. Using the Scan Tool, select DTC, clear info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate the vehicle until the Scan Tool indicates that the diagnostic ran. Does the Scan Tool indicate that this diagnostic Passed? 17 Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Go to step 17. Go to step 2.
Go to the DTC Table
System OK
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DTC P0237 Turbocharger (TC) Boost Sensor Circuit Low Voltage

C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
The PCM operates a solenoid to the control boost. This solenoid is normally open. By providing a ground path, the PCM energizes the solenoid which allows vacuum to pass the wastegate valve. During normal, operation, the PCM monitors the boost sensor signal for high and low limits. This is a type B DTC.


Boost pressure less than 40 kPa. Conditions met for 2 seconds.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Record.
Diagnostic Aids
With the ignition ON and the engine stopped, boost pressure is equal to atmospheric pressure. Comparison of this reading with known good vehicle using the same sensor is a good way to check accuracy of a suspect sensor. Readings should be the same +.4 volt. Very little boost can be attained by revving the engine in neutral. If the Boost sensor signal circuit is open or shorted to ground, Boost solenoid will show a zero duty cycle. A J39200 can be used to measure (actual) signal voltage at the PCM harness connector.
Test Description
2. 3. This step will determine if DTC P0237 is the result of a hard failure or an intermittent condition. This step simulates conditions for a DTC P0237. If the PCM recognizes the change, the PCM and signal circuit are OK.
1-1-02
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83
DTC P0237 - Turbocharger (TC) Boost Sensor Circuit Low Voltage

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Engine idling. Does the scan tool display the specied value? Turn the ignition OFF. Disconnect the Boost sensor electrical connector. Jumper the Boost sensor 5 volt reference to the Boost sensor signal circuit at the harness. 4. Turn the ignition ON. Does the scan tool display a Pressure greater than specied value? Turn the ignition OFF. Boost sensor still disconnected. Remove the jumper wire. Jumper the Boost sensor signal circuit at the harness with a test light connected to B+. 5. Turn the ignition ON. Does the scan tool display a Pressure greater than specied value? DTC is intermittent. Are additional DTCs stored? Check for a faulty connection at the Boost sensor. Was a problem found? Check for an open or short to ground in Boost sensor signal circuit. Was a problem found? Check for an open in the Boost sensor 5 volt reference circuit. Was a problem found? Check for a short to ground in Boost sensor 5 volt reference circuit. Was a problem found? Replace the faulty Boost sensor. Is the action complete? Check the terminal connectors at the PCM for a poor connections and repair if necessary. Was a problem found? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. 1. 2. 3. Value(s) Yes Go to step 2. No Go to OBD System Check.
< 5.8 psi (40 kPa) 202 kPa
Go to step 3.
Go to step 5.
Go to step 6.
Go to step 4.
202 kPa (29.3 psi)
Go to step 8.
Go to step 7.
5 6 7 8 9 10 11 12
Go to DTC table.
See Diagnostic Aids
13
Go to step 14.
Go to step 2.
14
Go to the DTC table
System OK.
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DTC P0238 Turbocharger (TC) Boost Sensor Circuit High Voltage

C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
The PCM operates a solenoid in order to control boost. This solenoid is normally open. By providing a ground path, the PCM energizes the solenoid, which allows vacuum to pass to the wastegate valve. During normal operating, the PCM compares the wastegate duty cycle signal with the boost signal, and makes corrections to the duty cycle accordingly. This is a type B DTC.


Boost Pressure greater than or equal to 4.8 volts (202 kPa). Engine Speed less than 3506 RPM.
Diagnostic Aids
With the ignition ON and the engine stopped, boost pressure is approximately equal to Baro. Comparison of this reading with known good vehicle using the same sensor is a good way to check accuracy of a suspect sensor. Readings should be the same +.4 volt. Very little boost can be attained by revving the engine in neutral. A DVOM can be used to measure (actual) signal voltage at the PCM harness connector.

The control module illuminates the MIL on the second consecutive ignition cycled that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
Test Description
3.This step will make sure the PCM is responding to a low signal voltage. This will indicate that the PCM is OK. 9.If the scan display is still < 9kPa by disconnecting the PCM the short to voltage is in the wiring. 10.If the DVOM value is the same by disconnecting the PCM the short to battery voltage is in the wiring.
1-1-02
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85
DTC P0238 - Turbocharger (TC) Boost Sensor Circuit High Voltage

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Engine idling. Does the scan tool display a Boost Pressure greater than or equal to the specied value? 1. Turn the ignition OFF. 2. Disconnect the Boost sensor electrical connector. 3. Using a fused jumper, ground the boost sensor signal to ground. 4. Turn the ignition to the RUN position. Does the scan tool display a Boost Pressure < the specied value? 1. 2. 3. 4. Verify the boost sensor is disconnected. Turn the ignition to the RUN position. Set the DVOM to the mA scale. Measure the current across the boost sensor signal and at the sensor ground circuit at the harness connector. Does the voltage measure more than the specied value? Value(s) Yes Go to step 2. No Go to OBD System Check.
202 kPa (4.8v)
Go to step 3.
Go to step 4.
10 kPa (1.45psi)
Go to step 6.
Go to step 4.
10mA
Go to step 6.
Go to step 11.
DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those chart(s). Are additional DTCs stored? 1. 2. Turn the ignition to the RUN position. With a DVOM connected to ground, probe the 5 volt reference circuit at the boost sensor harness. Is voltage greater than the specied value?
Go to the Applicable DTC table. Go to step 12.
5.2v
1. 2.
Boost sensor disconnected. Using a DVOM measure the voltage across the boost sensor5-volt reference circuit to the sensor ground at the harness connector. Does the voltage measure more than the specied value? 1. 2. 3. Check for an open or faulty sensor signal terminal connection at the PCM or the boost sensor. If you nd a problem repair as necessary. Did you complete the repair?
4.8-5.2v
Go to step 8.
Go to step 13.
Go to step 15.
Go to step 9.
9 10 11 12 13
Check the Boost sensor for a restriction. Was a problem found and repaired? Replace the faulty Boost sensor. Is the action complete? Check for a short to voltage in the Boost sensor signal circuit. Was a problem found and repaired? Check for a short to battery voltage in the boost sensor 5-volt reference circuit. Was a problem found and repaired? Check for and open or a faulty sensor ground terminal connection at the PCM or a boost sensor. Was a problem found and repaired? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete?
Go to step 15. Go to step 14 Go to step 15. Go to step 14. Go to step 15. Go to step 14.
14
Go to step 15.
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DTC P0238 - Turbocharger (TC) Boost Sensor Circuit High Voltage

Step 15 1. 2. 3. 4. Action Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Value(s) Yes Go to step 16. No Go to step 2.
16
System OK.
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87
DTC P0251 Injection Pump Cam System

C C
5 VOLT REFERNCE
SENSOR SIGNAL
A
SENSOR GROUND
B B A B

C27-C4
349 YL
C5
354 YL
B9 359 BK 349 YL
B11 350 GY
B12 394 LG
B10 354 YL
C4
C5
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
02-S02-005
Circuit Description
The optical sensor provides a pump cam signal to the PCM by counting pulses on the sensor disk located in the injection pump. The pump cam is one of the most important inputs by the PCM for fuel control and timing. This test monitors the number of crankshaft position pulses that have occurred since the last cam pulse. The physical one to one correspondence between the pump cam and the crankshaft implies if more crank pulses are detected than cam pulses, cam pulses have been missed. This is a type A DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Use of a Scan Tool (ignition must be cycled before DTC is cleared).

8 consecutive cam pulses missing for 8 #1 cylinder. or 8 consecutive cam pulses missing for 32 #1 cylinder.
Diagnostic Aids
Intermittent DTCs P0251, P0370, and p1216 may be caused by air entering the fuel system when fuel levels are less than 1/8of a tank while the driver is performing hard acceleration or turning maneuvers. a DTC P0251, P0370, and P1216 may set if the vehicle has run out of fuel. Verify the customers driving habits to determine if the vehicle has been performing in these manners. If the vehicle has been performing in these conditions, bleed the fuel system of all air and test drive the vehicle.

The PCM reverts to backup fuel. The control module illuminates the MIL when the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records.
Test Description
3.This step will determine if this is a hard or intermittent DTC. 5.This step will determine if there is a 5 volt reference. 7.This step will check to see if the sensor is sending a signal back to the PCM. 11.This step determines if the 5 volt reference signal is present, not present, or if it is too much. 1-1-02
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DTC P0251 - Injection Pump Cam System

Step 1 2 3 4 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? Is DTC P0370 set also? Start and idle engine. With the throttle closed, observe the Cam Ref Missed display on scan tool. Does scan tool display specied value? DTC is intermittent. Are additional DTCs stored? 1. 2. 3. 4. Ignition OFF. Disconnect the Optical/Fuel temperature sensor electrical connector. Turn the ignition to the run position. Measure voltage between Optical/Sensor 5 volt circuit and chassis ground at harness connector. Is voltage at specied value? Value(s) 8 Yes Go to step 2. Go to DTC P0370 Go to step 5. Go to DTC table. Go to step 6. No Go to OBD System Check. Go to step 3. Go to step 4. Go to Diagnostic Aids. Go to step 8.
4.8-5.2v
6 7
Probe the sensor ground circuit with a test light connected to B+ at the harness connector. Is test light ON? 1. 2. 3. 4. Reconnect the Optical/Fuel temperature sensor. Start and idle engine. With scan tool, command the engine to 900 rpm. With a DVOM set on Hertz (Hz) scale, back probe Cam signal circuit at PCM. Is Hertz reading at specied value? 1. 2. Ignition OFF. Disconnect the PCM and check the Optical/Sensor 5 volt circuit for an open, short to ground, or short to the sensor ground circuit. 3. If Optical/Sensor 5 volt circuit is open or shorted to ground, repair it as necessary. Was 5 volt circuit open or shorted to ground? 1. Check for open or poor sensor ground terminal connection at PCM. 2. If a problem is found, repair as necessary. Was a repair performed? Check the Optical/Fuel Temperature 5 volt reference circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? 1. Turn the ignition switch to the RUN position. 2. Disconnect the optical/fuel temperature sensor electrical connector. 3. With a DVOM connected to ground, probe the CAM signal circuit. Does the voltage measure within the specied range? Does the voltage measure more than the specied value? Repair the short to battery/ignition voltage on the CAM signal circuit. Is the repair complete? 1. Turn the ignition OFF. 2. Check the CAM signal circuit for an open or short to ground. 3. Repair the circuit as necessary. Is the repair complete? Check for a proper connection at the PCM harness terminal and replace the terminal if necessary. Is the repair complete?
60 Hz ( 3 Hz)
Go to step 7.
Go to step 9.
10
11
4.8-5.2v
12 13 14
5.2v
15
1-1-02
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89
DTC P0251 - Injection Pump Cam System

Step 16 Action With a DVOM set to the mA scale, measure the current between the CAM signal circuit and the ground circuit at the optical/fuel temperature sensor electrical connector. Does the current measure less than the specied value? Repair the short to reference voltage on the CAM signal circuit. Is the repair complete? 1. Check for a faulty connection at the injection pump. 2. If you nd a problem, repair the problem as necessary. Did you perform a repair? Replace injection pump. Is action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) 35 mA Yes No
17 18
Go to step 21.
19 20 21
Go to step 2.
22
Go to DTC table
System OK.
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DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults
DRAIN FILTER
Circuit Description
The PCM has the ability to increase and decrease the amount of fuel to each cylinder to provide smooth idle operation. If the fuel correction exceeds define limits, this DTC will set. This is a type D DTC.
Diagnostic Aids
Injector balance test on scan tool should be used to confirm faulty cylinder. Scan tool will cutout specific cylinder requested. Its possible that if a cylinder balance fault has been detected and engine has been running for a long time, the PCM will try to increase or decrease fuel in other cylinders to compensate for a rough idle which will cause multiple cylinder balance DTCs to set. The scan tool snap shot mode can be used to properly identify the suspected cylinder. The most likely cause of cylinder balance DTCs are faulty nozzles. Inspect the following areas also: A pinched or restricted fuel feed line between the fuel tank and the fuel injection pump. A restricted fuel filter.

Engine at idle. Engine coolant at normal temperatures. Cylinder fault must be constant. Fuel correction amount exceeds limits (internal to PCM). Conditions met for 2 seconds.

This control module stores the DTC information into memory when the diagnostic runs and fails. The MIL will not illuminate. The control module stores this information into Failure Records.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step will properly identify a suspected cylinder by looking for a RPM drop. If RPM drops, cylinder is contributing, if not, cylinder is not contributing.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail Use of a Scan Tool.
1-1-02
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91
DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults
Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Connect the Tech 2. 2. Start and idle engine. 3. Engine at operating temperature. 4. Make sure all DTCs are cleared. 5. Using the scan tool, cutout (Inj. Balance) the suspected cylinder. Is there an RPM drop in the suspected cylinder? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those table(s). Are additional DTCs stored? Check for the following engine mechanical or fuel delivery problem in that cylinder. An injection nozzle malfunction. An intake manifold restriction. Repair as necessary. Was a repair performed? Replace the fuel injection pump. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
5 6
Go to step 2.
System OK.
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DTC P0300 Engine Misre Detected Circuit Description

The PCM times the intervals between each pulse of the crankshaft position sensor and compares each time interval with the other 78 to determine when an excessive change in crankshaft speed has occurred. This pulse is generated from a 4X reluctor wheel located on the front of the crankshaft. If the crankshaft speed is less than an expected amount, the PCM will increase the amount of fuel needed to correct the misfire. If the amount of fuel exceeds the calibrated value, the PCM will interpret this as a misfire and set the DTC. The misfire diagnostic is used only to identify a weak cylinder needing additional fuel. This is a class B code.
Conditions for clearing the DTC

The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the DTC with a scan tool.
Diagnostic Aids
The scan tool can be sued to control the suspected cylinder. Use the Injector Balance Test option on the Tech 2. The most likely cause for this DTC is the following conditions: A mechanical failure causing low cylinder compression in more than one cylinder. A fuel leak at the high pressure fuel injection lines or injection nozzles. A fuel injection nozzle stuck closed. After the repair has been performed, the vehicle may take approximately 30 seconds to return to a stable idle.

The engine coolant temperature (ECT) is more than 56C (132F) The engine is idling for a total of 90 seconds. The fuel adjustment is more than the calibrated value (internal to PCM).
Conditions for setting the DTC

Multiple misfires detected.

The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions tat the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
Test Description
2. This step helps identify a suspected cylinder. 4. This step identifies an area with the most likely cause of failure.
1-1-02
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93
DTC P0300 Engine Misfire Detected

Step 1 2 Action Did you perform the Diagnostic System Check-Engine Controls? 1. Connect the Tech 2. 2. Start the engine and allow it to reach normal operating conditions. 3. Using the Tech 2 cut out the suspected cylinder (Injection Balance). Is there an RPM drop in the suspected cylinder? The DTC is intermittent. Are any additional DTCs stored? Yes Go to step 2. Go to step 3. No Go to Diagnostic System Check. Go to step 4.
Go to the specic DTC trouble code chart. Go to step 6.
Go to diagnostic aids. Go to step 5.
1.
Inspect for basic engine mechanical or fuel delivery problems in the suspected cylinder. Look for: Low compression or valve train problems, an injection nozzle stuck closed, or restricted high pressure fuel injection lines. 2. Repair the condition as needed. Did you perform a repair?
5 6
Replace the fuel injection pump. Refer to Fuel Injection Pump Replacement. Did you complete the repair? Use the scan tool in order to clear the DTCs. Start the engine. Allow the engine to idle until the engine reaches normal operating temperature. 4. Select DTC and the Specic DTC function options on the Tech 2. 5. Enter the DTC number that was set. 6. Operate the vehicle within the conditions for setting this DTC until the scan tool indicates the diagnostic ran. Does the scan tool indicate the diagnostic passed? Does the scan tool display any additional undiagnosed DTCs. 1. 2. 3.
Go to step 2.
Go to the specic DTC trouble code chart.
System OK.
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DTC P0301-P0308 Specic Cylinder Misre Detected Circuit Description

The PCM times the intervals between each pulse of the crankshaft position sensor and compares each time interval with the other 78 to determine when an excessive change in crankshaft speed has occurred. This pulse is generated from a 4X reluctor wheel located on the front of the crankshaft. If the crankshaft speed is less than an expected amount, the PCM will increase the amount of fuel needed to correct the misfire. If the amount of fuel exceeds the calibrated value, the PCM will interpret this as a misfire and set the DTC. The misfire diagnostic is used only to identify a weak cylinder needing additional fuel. This diagnostic will only run once per ignition cycle. This is a class B code.

The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the DTC with a scan tool.
Diagnostic Aids
The scan tool can be sued to control the suspected cylinder. Use the Injector Balance Test option on the Tech 2. The most likely cause for this DTC is the following conditions: A mechanical failure causing low cylinder compression in more than one cylinder. A fuel leak at the high pressure fuel injection lines or injection nozzles. A fuel injection nozzle stuck closed. After the repair has been performed, the vehicle may take approximately 30 seconds to return to a stable idle.

The engine coolant temperature (ECT) is more than 56C (132F) The engine is idling for a total of 90 seconds. The fuel adjustment is more than the calibrated value (internal to PCM).
Conditions for setting the DTC

The fuel adjustment is more than the calibrated value (internal to PCM). Multiple misfires detected.
Test Description
2. This step helps identify a suspected cylinder. 4. This step identifies an area with the most likely cause of failure.

The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions tat the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
1-1-02
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95
DTC P0301 - P0308 Specific Cylinder Misfire Detected

Step 1 2 Action Did you perform the Diagnostic System Check-Engine Controls? 1. Connect the Tech 2. 2. Start the engine and allow it to reach normal operating conditions. 3. Using the Tech 2 cut out the suspected cylinder (Injection Balance). Is there an RPM drop in the suspected cylinder? The DTC is intermittent. Are any additional DTCs stored? Yes Go to step 2. Go to step 3. No Go to Diagnostic System Check. Go to step 4.
Go to the specic DTC trouble code chart. Go to step 6.
Go to diagnostic aids. Go to step 5.
Inspect for basic engine mechanical or fuel delivery problems in the suspected cylinder. Look for: Low compression or valve train problems, an injection nozzle stuck closed, or restricted high pressure fuel injection lines. 2. Repair the condition as needed. Did you perform a repair? Replace the fuel injection pump. Refer to Fuel Injection Pump Replacement. Did you complete the repair? Use the scan tool in order to clear the DTCs. Start the engine. Allow the engine to idle until the engine reaches normal operating temperature. 4. Select DTC and the Specic DTC function options on the Tech 2. 5. Enter the DTC number that was set. 6. Operate the vehicle within the conditions for setting this DTC until the scan tool indicates the diagnostic ran. Does the scan tool indicate the diagnostic passed? Does the scan tool display any additional undiagnosed DTCs. 1. 2. 3.
1.
5 6
Go to step 2.
Go to the specic DTC trouble code chart.
System OK.
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DTC P0335 Crankshaft Position (CKP) Sensor Circuit Performance

A
5 VOLT REFERENCE
E
M
HIGH PUMP CAM SENSOR RESOLUTION SIGNAL SIGNAL SENSOR GROUND
C5
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
708 TN
703 OR
375 GY
C27-D14
C29-A4 C29-A2
C27-D9
SENSOR GROUND
C27-C8 C29
FUEL TEMP SIGNAL
A7
ITS HI
A8
ITS LO
A9
ITS LO
710 OR
442 BR
156 PK
225 YL
A10
ITS HI
5 VOLT REFERENCE

9-S12-070
Circuit Description
The crankshaft position sensor is a Hall-effect type sensor that monitors crankshaft position and speed. There are four teeth 90 degrees apart on the front of the crankshaft sprocket that induce a pulse in the sensor which is transmitted to the PCM. This signal allows the PCM to determine top dead center (TDC) and RPM. This is a type A DTC.


RPM less than 300. Eight consecutive crank pulses are missing. or RPM greater than or equal to 300. An average of 8 consecutive crank pulses are missing
Diagnostic Aids
When PCM is in backup fuel, long crank times, fast idle and poor performance conditions will exist. Check for good connection at crankshaft position sensor and at PCM. Many intermittent problems are caused by faulty electrical connections or wiring. When attempting to diagnose an intermittent problem, always begin by trying to reproduce the conditions under which the failure occurs. This usually involves raising the engine to a higher temperature or operating it near RPM that the problem occurs. Since heat and vibration are often the cause of intermittent, this may bring out the failure.

The control module illuminates the MIL light when the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the freeze frame/failure records.
Test Description
2. 4. 5. This step will determine if DTC P0335 is the result of a hard failure or an intermittent condition. This step checks the 5 volt reference circuit (the 5 volt reference may vary slightly). This step checks the ground circuit.
1-1-02
711 YL
__________________________________________________
97
DTC P0335 - Crankshaft Position Sensor Circuit Performance

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? Start and idle engine. Observe Crank Ref. Missed display on scan tool. Does scan tool display specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer those table(s). Are additional DTCs stored? 1. 2. 3. 4. Ignition OFF. Disconnect the CKP sensor electrical connector. Ignition ON engine OFF. Using a DVOM, measure voltage between the CKP 5 volt reference and ground. Is voltage at specied value? Probe sensor ground circuit with a test light connected to B+. Is test light ON? 1. 2. Value(s) Yes Go to step 2. No Go to OBD System Check. Go to step 3.
Go to step 4.
4.8 - 5.2v
5 6
Go to step 6.
Go to step 9.
Reconnect the CKP sensor. 4.2 - 4.5v Go to step 14. Go to step 7. Back probe the CKP sensor signal circuit at the PCM with a DVOM connected to ground and crank the engine. Is voltage at the specied value? 4.2 - 4.5v Go to step 12. Go to step 11. Go to step 17. Go to step 10. Ignition OFF. Disconnect PCM and check the CKP 5 volt reference circuit for open, or short to ground. 3. If the CKP 5 volt reference circuit is open or shorted to ground, repair as necessary. Was the circuit open or shorted to ground? Check for open or poor sensor ground terminal connection at the PCM. If a problem is found, repair it. Was a repair performed? Check the CKP 5 volt reference circuit for a poor connection at PCM and replace terminal if necessary. Did the terminal require replacement? 1. 2. Turn the ignition OFF. Disconnect PCM and check CKP signal circuit for open, or short to ground. 3. If the CKP signal circuit is open or shorted to ground, repair it. Was the CKP signal circuit open or shorted to ground? 1. 2. 3. Disconnect the CKP sensor connector. Turn the ignition to the RUN position. With a DVOM connected to ground back probe the signal wire at the engine harness. Is there voltage present at the CKP sensor signal circuit? Repair the short to voltage on the CKP sensor signal circuit. Did you complete the repair? Check the CKP signal circuit for a poor connection at the PCM and replace the terminal if necessary. Did you perform a repair?
7 8
Does the voltage measure more than the specied value? 1. 2.
9 10
11
12
13 14
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98
DTC P0335 - Crankshaft Position Sensor Circuit Performance

Step 15 Action Replace the Crankshaft position sensor. After replacing the sensor, the PCM must be programmed with a new TDC OFFset. Refer to the Service Manual for more information on the Crankshaft Position Sensor or reprogramming the PCM. Is the action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. 5. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC. Does the Scan Tool indicate that this diagnostic Ran and Passed? Value(s) Yes Go to step 17. No
16 17
Go to step 17.
18
Go to the DTC table
System OK.
1-1-02
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99
DTC P0370 Timing Reference High Resolution

INJECTION TIMING STEPPEN MOTOR (ITS) OPTICAL/ FUEL TEMP SENSOR
A
5 VOLT REFERENCE
M
C5
C3
B8
C1
C12
C2
A3
A2
A6
A7
709 RD
708 TN
703 OR
375 GY
C27-D14
C29-A4 C29-A2
C27-D9
SENSOR GROUND
C27-C8 C29
FUEL TEMP SIGNAL
A7
ITS HI
A8
ITS LO
A9
ITS LO
710 OR
442 BR
156 PK
225 YL
A10
ITS HI
5 VOLT REFERENCE

9-S12-070
Circuit Description
The optical sensor provides a high resolution signal to the PCM by counting pulses on the sensor disk located in the injection pump. The high resolution is one of the most important inputs by the PCM for fuel control and timing. This test monitors the number of high resolution pulses which have been missed (not detected). Its based on a comparison between the number of pulses that were detected since the last pump cam pulse and the number of the pulses that should have occurred. This is a type A DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan Tool.
Diagnostic Aids
When PCM is in backup fuel, fast idle and poor performance problems will exist. If P0251 is also stored, the snap shot mode on the scan tool should be used to properly identify fault. It is possible P0370 may set if there is air in fuel system (vehicle running out of fuel). The least likely cause of failure is the PCM.

A number of High Resolution pulses missing (internal to PCM) per every 8 cam reference pulses.

The control module illuminates the MIL when the diagnostic runs. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Record.
Test Description
2. 3. This step will determine if there is a 5 volt reference. This step checks the ground circuit.
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100
___________________________________________________
DTC P0370 - Timing Reference High Resolution

Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info. Was the On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. 4. Turn the ignition to the OFF position. Disconnect the Optical/Fuel temperature sensor electrical connector. Ignition ON engine OFF. Using a DVOM, measure voltage between the Optical/Fuel temperature 5 volt reference circuit at harness connector and ground. Is voltage at the specied value? 1. 2. Verify the optical sensor is disconnected. Probe the sensor ground circuit with a test light connected to B+ at the harness connector. Is the test light ON? Reconnect the optical/fuel temperature sensor connector. Start the engine. Operate the engine close to the conditions saved in the Freeze Frame/ Failure Records. 4. Use the scan tool in order to select the DTC and its specic DTC function. 5. Enter the DTC number that was set. Does the scan tool display the term Last Test Failed? NOTE: The scan tool must display Last Test Failed (under DTC, Specific). This ensures that fault is active while performing this test. 1. Maintain the engine speed at the point of failure, per the conditions saved in the Freeze Frame/Failure Records. 2. With the DVOM on the Hertz scale, back probe the high resolution signal circuit at the PCM. Referring to the Engine Speed vs. Hertz table does the Hertz reading in the table correspond with the Hertz reading on the DVOM at the designated RPM (+ 100 Hz)? 6 1. 2. 3. Turn the ignition off. Disconnect the PCM. Check the Optical sensor 5 volts reference circuit for and open, or short to ground. 4. If the Optical/Fuel temperature 5 volt reference circuit is open or shorted to ground, repair as necessary. Was a repair performed? 1. Check for and open or a poor sensor ground terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a repair performed? Check the Optical/Fuel temperature 5 volt reference circuit for a poor connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? 1. 2. 3. Disconnect the optical sensor connector. Turn the ignition to the RUN position. With a DVOM connected to ground, probe the high resolution signal circuit at the connector. Does the voltage measure within the specied value? Go to step 19. Go to step 8. 1. 2. 3. Value(s) 4.8 - 5.2v Yes Go to step 2. Go to step 3. No Go to OBD System Check. Go to step 6.
Go to step 4.
Go to step 7.
Go to step 5. Go to diagnostic aids.
Go to step 16.
Go to step 9.
4.8 - 5.2v
10 1-1-02
Does the voltage measure more than the specied value?
4.8 - 5.2v
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101
DTC P0370 - Timing Reference High Resolution

Step 11 12 Action Repair the short to battery voltage on the high resolution signal circuit. Is the repair complete? 1. 2. 3. 4. 5. 13 Turn the ignition OFF. Disconnect the PCM. Check the high resolution signal circuit for and open, short to ground, or short to the sensor ground circuit. If the high resolution signal circuit is open or shorted to ground, repair as necessary. Was the high resolution signal circuit open or shorted to ground? Value(s) Yes Go to step 19. No
With a DVOM set to the mA scale, measure the current between the high resolution signal circuit and the ground circuit at the Optical sensor electrical connector. Does the current measure less than the specied value? Repair the short to reference voltage on the high resolution signal circuit. Is the repair complete? 1. 2. 3. Check for a poor connection at the injection pump. If a problem is found repair the problem as necessary. Is the repair complete?
20 mA
14 15
Go to step 19.
16
Check the high resolution signal circuit for a poor connection at the PCM and replace terminal if necessary. Did the terminal require replacement? Replace the injection pump. Important: If injection pump is malfunctioning, the new injection pump must be timed. Is the action complete? Replace the PCM. Important: The new PCM must be programmed. Is the action complete? 1. Using the Scan Tool, select DTC, Clear Info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
17
Go to step 19.
18
Go to step 19.
19
Go to step 20.
Go to step 2.
20
Go to the DTC table
System OK.
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DTC P0380 Glow Plug Circuit Performance

C9-J
C3-N7 #1 #3 #5 #7
FUSE 3A 20 AMP EXTERIOR

C5-A4
239 PK
FUSE 4B 5 AMP INTERIOR FUSE BOX

30 GY
FUSIBLE LINK
GLOW PLUGS LH
D IGN POWER BATT +
TO IGNITION SWITCH
LEFT BANK OUTPUT
A B
RH STATUS CENTER
C
WAIT
RIGHT BANK OUTPUT
GLOW PLUG RELAY
D
#2 #4 #6 #8
C
C9-A
C3-D1
GLOW PLUGS RH
C5-C11
C5-B4
C1-27
506 LB
466 YL
G1
C28-C7
338 DB
C27-D7 5V GLOWPLUG FEEDBACK SIGNAL
C27-C6 GLOW PLUG RELAY CONTROL B+ POWERTRAIN CONTROL MODULE (PCM)
WAIT TO START LAMP CONTROL
BK
00-S12-011
Circuit Description
The glow plug system is used to assist in providing the heat required to begin combustion during engine starting at cold ambient temperatures. The glow plugs are heated before and during cranking, as well as initial engine operation. The PCM controls the glow plug ON times by monitoring coolant temperatures and glow plug voltage. The PCM also monitors glow plugs individually to detect a failure. Once a failure has been detected, a diagnostic signal is sent to the PCM so the diagnostic code and MIL can be activated. This is a type B code.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan Tool.
Diagnostic Aids
If a P0380 DTC sets after the PCM has been flashed, the glow plug system must be relearned. If glow plug relay is stuck in the ON position, check for proper operation of glow plugs. When glow plugs are commanded ON by the Scan Tool, an internal PCM timer protects the glow plugs from damage by cycling them ON for 3 seconds and then OFF for 12 seconds. The glow plug relay battery feed wire nut should be tested for proper torque.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic records a failure on the second consecutive ignition cycle, the control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
1-1-02
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103
The California glow plug system will send the following voltages.
Test Description
3-This step will determine if P0380 is a hard failure. 4-This step will determine if there is a short to voltage on the signal circuit. 8-This step will determine if there is ignition voltage at the glow plug relay. 10-This step will determine if the glow plug control circuit and the PCM are working properly. 11-This step will determine if there is a short to voltage an the relay control circuit. 13-This step will determine if the glow plugs or the glow plug harness is causing the P0380 DTC.
Signal Voltage
Glow Plugs
3.5-6.0 2.0-3.5 1.0-2.0 0.8-1.7 Less than 1.3
None 1 2 3 4 or more
DTC P0380 - Glow Plug Circuit Performance

Step 1 Action Before clearing any DTCs, use the scan tool Capture Info to save the Freeze Frame and Failure Records for reference. The PCMs data is deleted once the Clear Info function is used. Did you perform the On-Board Diagnostic (OBD) System Check? If DTC P0380 set after a PCM reash. 1. Connect a scan tool. 2. Turn the ignition ON leaving the engine OFF. 3. Observe the Glow Plug System Type parameter on the scan tool. Does the scan tool display the Glow Plug System Type as California? 1. Connect a scan tool. 2. Turn the ignition to the RUN position. 3. Use the scan tool to command the glow plugs ON and OFF. 4. Observe the Glow Plug System Type parameter on the scan tool. Does the scan tool display the glow plug parameter is within the specified ranges? Does the scan tool display a glow plug voltage greater than the specied value? Does the scan tool display a glow plug voltage greater than the specied value? 1. 2. Turn the ignition ON leaving the engine OFF. Touch the battery feed stud on the glow plug controller with an unpowered test lamp connected to ground. Is the test light ON? The DTC is intermittent. If any additional DTCs were stored, refer to those table(s). Were there any additional DTCs stored? 1. 2. 3. Disconnect the glow plug relay middle connector. Turn the ignition ON with the engine OFF. With an unpowered test lamp connected to ground, probe the glow plug relay harness ignition feed circuit (CKT 239 PK). Is the test light ON? 1. 2. Turn the ignition ON with the engine OFF. Connect an unpowered test lamp to B+, probe the glow plug relay ground circuit (BK). Is the test light ON? Value Yes Go to step 2. No
Go to step 3.
Go to Glow Plug System Type Relearn.
Go to step 7. Go to step 4. ON 5.0-5.6v OFF 0.9-1.5v 5.6v Go to step 20. Go to step 5. Go to step 8. Go to step 23. 0.45v Go to step 10. Go to step 6.
4 5 6
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Step 10 1. 2. 3. Action Turn the ignition ON with the engine OFF. Verify that the glow plug relay control harness is disconnected. With a test light connected to ground probe the glow plug relay control circuit (CKT 466 YL) at the glow plug relay harness connector. 4. Use a scan tool to command the glow plugs ON and OFF. Does the test light respond accordingly with glow plug activation and deactivation? Does the test light remain illuminated regardless of glow plug activation or deactivation? 1. 2. 3. Value Yes No
11 12
Verify that the glow plug relay is still disconnected. 12.6v Go to step 13. Go to step 19. Turn the ignition to the RUN position. Jumper the glow plug control circuit (CKT 466 YL) to the glow plug signal circuit (CKT 506 LB). 4. With the scan tool command the glow plugs on and observe the feedback voltage. Does the glow plug feedback voltage represent battery voltage? 1. Turn the ignition OFF. 2. Disconnect the bank glow plug output circuit connectors at the glow plug relay. 3. With an unpowered test lamp connected to B+, probe each circuit. Does each circuit turn ON the test lamp? 1. 2. Turn the ignition OFF. Disconnect each glow plug connector at the glow plug that did not illuminate the test lamp. 3. With an unpowered test lamp connected to B+, probe the terminal on the glow plug. Does each glow plug illuminate the test lamp? Repair an open or a short to ground in the glow plug relay ignition feed circuit (CKT 239 PK). Did you complete the repair? Repair any opens or poor connections in the glow plug relay ground circuit (BK). Did you complete the repair? Inspect the glow plug relay control circuit (466 YL) for an open or short to ground. If the glow plug relay control circuit is open or shorted to ground, repair as necessary. Did you nd and correct the condition? Inspect the glow plug relay control circuit (CKT 466 YL) for a proper connection at the PCM and replace the terminal if necessary. Did you nd an improper connection and make the necessary repair? Inspect the glow plug relay signal circuit (CKT 506 LB) for an open or short to ground. Repair as necessary. Did you nd and correct the condition? Inspect the glow plug relay signal circuit (CKT 506 LB) for a proper connection at the PCM and replace the terminal if necessary. Did you nd an improper connection and make the necessary repair? Test for a short to voltage in the glow plug relay signal circuit (CKT 506 LB). Did you nd the improper condition? Test for a short to voltage in the glow plug relay control circuit (CKT 466 YL). Did you nd and correct the condition? Repair the open or poor connection on the battery feed circuit. Did you complete the repair? Replace any glow plug that did not illuminate the test lamp. Did you complete the repair? Go to step 25. Go to step 14.
13
14
15
Go to step 28.
16 17
18
19
20
21 22 23 24
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Step 25 26 27 28 Action Repair the open or poor connections in the glow plug harness. Did you complete the repair? Replace the glow plug relay. Did you complete the repair? Replace the PCM. THE NEW PCM MUST BE PROGRAMMED. Did you complete the repair? Use a scan tool to clear the DTCs. Start the engine. Allow the engine to idle until the engine reaches normal operating temperature. Select the DTC and the specic DTC function. Enter the DTC number which was set. Operate the vehicle, with the Conditions for Setting this DTC, until the scan tool indicates the diagnostic Ran. Does the scan tool indicate the diagnostic Passed? Does the scan tool display any addition undiagnosed DTCs? Value Yes Go to step 28. Go to step 28. Go to step 28. Go to step 29. Go to step 2. No
29
System OK.
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DTC P0501 VEHICLE SPEED SENSOR CIRCUIT

VEHICLE SPEED SENSOR (VSS) TO IGNITION EXTERIOR FUSE BOX SPEEDO / TACH MODULE
FUSE 1D 15 AMP
TWISTED PAIR
POWERTRAIN CONTROL MODULE ( PCM )

C29
GROUND 570 BK
A6
C33
G2
OVER-SPEED WARNING BUZZER (GULF COAST ONLY)
GROUND
570 BK
A7 C3-P9
C28
40 PULSE OUTPUT SHAFT REVOLUTION SIGNAL TO PCM 4000 PPM CRUISE CONTROL REFERENCE SIGNAL 565 BR
D6 C1-18
D9
223 DB
570 BR
565 BR
679 LG
239 PK
676 PP
136 TN
12
13
14
353 YL
15
CRUISE CONTROL REFERENCE SIGNAL 4000 PPM
VEHICLE SPEED SENSOR RETURN
GROUND
+12 VOLT IGNITION SIGNAL
VEHICLE OUTPUT SHAFT OVERSPEEDO SPEED REVOLUTION SPEED REFERENCE SIGNAL WARNING SIGNAL SIGNAL
DIGITAL RATIO ADAPTOR

01-S12-020
Circuit Description
The speed sensor circuit consists of a magnetic induction type sensor, a Digital Ratio Adaptor (DRA) and wiring. Geared teeth pressed on the output shaft induce an alternating current in the sensor. This A/C signal is transmitted to the DRA. The DRA compensates for various axle ratios and converts the signal into a digital signal for use by the speedometer, cruise control, and the PCM. The DRA sends two different signal to the PCM. The VSS signal An output shaft speed signal for the transmission. This is a type D DTC.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of the Tech 2.
Diagnostic Aids
Check connections at VSS buffer and PCM.

Vehicle speed greater than 20 m.p.h. Four wheel low not selected. VSS buffer calculated speed is less than half the transmission calculated speed. OR VSS buffer calculated speed is greater than transmission calculated speed by 20 m.p.h. All conditions met for 2 seconds.

The PCM will not illuminate the MIL The PCM records the operating conditions at the time the diagnostic fails. This information stores in the Failure Records. 1-1-02
_________________________________________________
107
DTC P0501 - Vehicle Speed Sensor Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Install scan tool. 2. Raise drive wheels. 3. Engine operating. 4. Transmission in any drive range. With drive wheels rotating, does vehicle speed increase with drive wheel speed increase? 1. 2. Transmission in park. Back probe the DRA module ignition feed circuit with a test light connected to ground. Is the test light ON? With a DVOM check the ground on terminal 8 of the digital ratio adaptor. Is a good ground present? With a DVOM set to AC voltage backprobe the VSS input circuit at terminals 7 and 12 of the DRA. 2. Transmission in any drive range with drive wheels rotating. Does voltage increase on the DVOM with drive wheel speed increase? Does scan tool display a trans output speed (MPH) increase with drive wheel increase? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. Are additional DTCs stored? Repair the open in the ignition feed circuit. Is action complete? Repair the open in the ground circuit. Is action complete? Check the complete VSS input circuit for an open or short to ground. Was a repair performed? Check VSS output circuits (676 and 679) for an open or short to ground. Was a repair performed? Back probe the DRA module at the VSS output circuit 353 with a DVOM connected to ground. 2. Put the transmission in drive and start the wheels rotating. Is voltage present? Check the VSS output circuit for an open or short to ground. Was a repair made? Check VSS output circuit for a poor connection at DRA module and PCM. Was a repair performed? Replace the Vehicle Speed Sensor. Replace DRA module. Is action complete? Replace the faulty PCM. Is the action complete? 1. 1. Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 7.
Go to step 3.
Go to step 4.
Go to step 8.
4 5
6 7 8 9 10 11 12
Go to step 7. Go to DTC table. Go to step 18. Go to step 18. Go to step 18.
Go to step 12. Go to Diagnostic Aids
13 14 15 16 17
Go to step 18. Go to step 14. Go to step 18. Go to step 17. Go to step 18. Go to step 18. Go to step 18.
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DTC P0501 - Vehicle Speed Sensor Circuit

Step 18 1. 2. 3. 4. Action Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Value(s) Yes Go to step 18. No Go to step 2.
19
Go to the DTC table.
System OK.
1-1-02
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109
DTC P0567 CRUISE RESUME CIRCUIT

CRUISE CONTROL SWITCH
YL
C69
C1
PCM
C27-D10 RESUME / ACCEL SIGNAL
153 LG
37
GN
152 DB
42
B11
SET / COAST SIGNAL
RD
151 GY
29
A11
ON / OFF SIGNAL
BR
B 295 BR
FUSE 5C 10 AMP
C29
INTERIOR FUSE BOX
TO IGNITION
02-S12-014
Circuit Description
The cruise Resume/Accel switch is an input to the fuel control portion of the PCM. These inputs allow the PCM to control and hold a requested speed. Cruise Resume/Accel switch sends ignition voltage to the PCM when the switch is closed (ON). This is a type D DTC.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan Tool.
Diagnostic Aids
Check for a resume/accel switch stuck in the engage position or the signal circuit is shorted to voltage.

Cruise switch OFF. Ignition voltage on Resume switch signal circuit. OR Cruise switch ON. Resume switch ON for longer than 25.5 seconds
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step determines if the signal circuit is shorted to voltage. 3. This step determines if the PCM or switch is at fault.

Will not turn on the MIL. The PCM will disallow all cruise inputs. TCC shift schedules may be affected.
5745159
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110
___________________________________________________
DTC P0567 - Cruise Resume Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Ignition ON, engine OFF. 3. Cruise switch OFF. Does scan tool display Resume Switch ON? 1. 2. 3. Ignition ON. Disconnect the PCM connector C27. Probe the Resume switch signal circuit at the PCM harness with a test light connected to chassis ground. Is the test light ON? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 7.
DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? 1. Resume switch signal circuit is shorted to voltage. 2. Repair as necessary. Is action complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
Go to the applicable DTC table Go to step 8.
6 7
Go to step 2.
System OK..
1-1-02
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111
DTC P0568 CRUISE SET CIRCUIT

YL
C69
C1
PCM
153 LG
37
GN
152 DB
42
B11
SET / COAST SIGNAL
RD
151 GY
29
A11
ON / OFF SIGNAL
BR
B 295 BR
FUSE 5C 10 AMP
C29
INTERIOR FUSE BOX
TO IGNITION
02-S12-014
Circuit Description
The cruise Set/Coast switch is an input to the fuel control portion of the PCM. These inputs allow the PCM to control and hold a requested speed. Cruise Set/Coast switch sends an ignition voltage signal to the PCM when the Set/Coast switch is ON. This is a type D DTC.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan Tool.
Diagnostic Aids
If the Set/Coast switch stuck in the ON position or the driver is holding the Set/Coast switch ON for longer than 25.5 seconds, DTC P0569 will set. DTC P0568 only checks the signal circuit for a short to voltage.

Cruise switch OFF. Ignition voltage on Set switch signal circuit. OR Cruise switch ON. Set switch ON for longer than 25.5 seconds
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This step determines if the signal circuit is shorted to voltage. 3. This step determines if the PCM or switch is at fault.

The PCM will disallow all cruise inputs. The PCM will not illuminate the MIL. TCC shift schedules may be affected.
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DTC P0568 - Cruise Set Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool connected. 2. Ignition ON, engine OFF. 3. Cruise switch OFF. Does scan tool display Set switch ON? 1. 2. 3. Ignition ON. Disconnect the PCM connector C29. Probe the Set switch signal circuit at the PCM harness with a test light connected to chassis ground. Is the test light ON? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 7.
DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? 1. The Set switch signal circuit is shorted to voltage. 2. Repair as necessary. Is action complete? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
6 7
Go to step 2.
System OK.
1-1-02
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113
DTC P0571 CRUISE BRAKE SWITCH CIRCUIT

TO BATTERY TO BATTERY
FUSE 6B 5 AMP
INTERIOR FUSE BOX
STOP LAMP SWITCH B
BRAKE LIGHT SWITCH
22 RD
31 C1

02-S02-002
C29
STOP LAMP SIGNAL
22 RD
PCM
Circuit Description
The TCC normally closed brake switch supplies a B+ signal on CKT 810 to the PCM. The circuit is opened when the brakes are applied. The stop lamp/cruise control normally open brake switch supplies a B+ signal on CKT 22 to the PCM when the brake is applied. This is a type D DTC.
Diagnostic Aids
Refer to PCM Intermittent Diagnostic Trouble Codes or Performance. Check customer driving habits and/or unusual traffic conditions (i.e. stop and go, expressway traffic). Use of any other type of bulb, such as LED replacement bulbs, in the stop light sockets may cause a false code.

Switches disagree for 10 consecutive minutes. OR TCC and cruise control brake switches are not toggling open and closed during 6 brake applications on same ignition cycle.

The PCM will not illuminate the MIL. The PCM records the operating conditions at the time the diagnostic fails. This is stored as a Failure Record.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of the Tech 2.
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DTC P0571 - Cruise Brake Switch Circuit

Step 1 2 Action Important: Before clearing DTC(s) use the scan tool Capture Info Was the On-Board Diagnostic (OBD) System Check performed? 1. Install the Tech 2. 2. Ignition ON, engine OFF. 3. Apply brakes. Does the TCC Cruise switch change status from closed to open? Apply brakes again. Does the Brake switch change status from open to closed? 1. Ignition ON, engine OFF. 2. Stop lamp switch disconnected. 3. With test light connected to ground, probe circuit 10OR, terminal A. Is the test light ON? 1. Turn the ignition ON but leave the engine OFF. 2. Verify the stop lamp switch is disconnected. 3. Turn the head lamp switch ON. 4. With a test light connected to ground, probe circuit 22RD, terminal B. Is the test light ON? 1. Disconnect stop lamp switch. 2. Jumper circuits 10OR (A) and 22RD (B) together. Does scan tool display Cruise Brake switch Closed? 1. Turn the ignition ON but leave the engine OFF. 2. Disconnect the stop light switch. 3. With test light connected to ground, probe circuit 291PK (D). Is the test light ON? 1. Stop lamp switch disconnected. 2. Jumper circuit 291PK (D) and circuit 810 PP (C) together. Does scan tool display Cruise Brake switch Closed? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? Check circuit 10OR (A) for an open or short to ground. Is action complete? 1. Check the stop lamp switch signal circuit for a short to B+ 2. Repair as necessary. Is the action complete? Check circuit 22RD for an open or short to ground. Was a repair performed? Check circuit 22RD for a poor connection at PCM. Was a repair performed? Check circuit 291PK (D) for an open or short to ground. Is action complete? Check circuit 10PP for an open or short to ground. Was a repair performed? Check circuit 810PP for a poor connection at PCM. Is action complete? Replace stop lamp switch. Is action complete? Value(s) Yes Go to step 2. Go to step 3. No Go to OBD System Check. Go to step 7.
3 4
Go to step 11.
Go to step 6.
Go to step 8.
Go to step 14.
Go to applicable DTC table. Go to step 19.
10 11
12 13 14 15 16 17
1-1-02
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115
DTC P0571 - Cruise Brake Switch Circuit

Step 18 19 Replace the faulty PCM. Is the action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. Action Value(s) Yes Go to step 19. Go to step 20. No Go to step 2.
20
System OK.
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DTC P0601, P0602 and P0606 Internal PCM Errors

P0601 PCM Memory Check Type A Code P0602 PCM Programming Type A Code P0606 PCM Internal Communication Interrupted Type A Code
Description
This diagnostic applies to internal microprocessor integrity conditions within the control module. This diagnostic also addresses if the control module is not programmed.
DTC P0601, P0602 AND P0606

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Does DTC P0602 set? Reash the PCM with new software. Does DTC P0602 set? 1. 2. 3. 4. 5. Ensure that all tool connections are secure. Ensure the programming equipment is operating correctly. Ensure that correct software/calibration package is used. Attempt to program the PCM. Does DTC P0602 reset? Value(s) Yes Go to step 2. No Go to OBD System Check.
2 3 4
Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. Use the Tech 2 in order to clear DTCs. 2. Turn the Ignition OFF for 30 seconds. 3. Start the engine? Does the DTC run and pass? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
Go to step 6.
Go to step 7.
Go to step 2
System OK.
1-1-02
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117
DTC P1125 ACCELERATOR PEDAL POSITION (APP) SYSTEM

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004
Circuit Description

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Tech 2. A current DTC Last Test Failed clears when the diagnostic runs and passes.

PCM has recognized an intermittent APP fault and there are no current APP faults stored.
Diagnostic Aids
There are no driveability issues associated with the APP module unless the DTC is present. The most likely cause of this DTC is a poor connection or a malfunctioning sensor. The least likely is a PCM problem. This DTC will set with other DTCs. All other DTCs should be diagnosed first.

The PCM stores the DTC information into memory when the diagnostic runs and fails. The MIL will not illuminate. The PCM records the operating conditions at the time the diagnostic fails. The PCM stores this information in the Failure Records. The Check Throttle lamp will illuminate.
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DTC P1125 - Accelerator Pedal Position (APP) System

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. Disconnect the APP sensor electrical connector. Ignition ON, engine OFF. With a DVOM connected to ground, check all APP 5 volt reference circuits at the APP harness. Is the voltage less than specified value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? 1. 2. Ignition OFF. Disconnect the PCM and check the 5 volt reference circuit for a short to ground. 3. If the 5 volt reference circuit is shorted to ground, repair it as necessary. Was the 5 volt reference circuit is shorted to ground? Replace the faulty PCM. Is the action complete? Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? 1. 2. 3. 4. Value(s) Yes Go to step 2. No Go to OBD System Check.
4.8v
Go to step 4.
Go to step 3.
5 6
Go to step 2.
System OK.
1-1-02
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119
DTC P1214 INJECTION PUMP TIMING OFFSET ERROR Circuit Description

The PCM has the ability to determine the amount of offset needed to bring the engine to top dead center. This is used by the PCM to determine proper injection time. This is a type B code. tic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.

TDC offset greater than 2.5 degrees. OR TDC Offset less than -2.5 degrees.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Tech 2.

The control module illuminates MIL on the second consecutive ignition cycles that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnos-
Diagnostic Aids
The PCM will only run the diagnostic test if the TDC offset adjustment procedure has been activated. The vehicle will most likely not be brought in with this DTC set.
DTC P1214 - Injection Pump Timing Offset Error

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Are there any other DTCs set? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Clear all codes and reset injection timing until TDC Offset is between specied values. Refer to TDC Offset. Is timing within specied value? 1. Check the crankshaft position sensor for the following conditions: Proper installation A loose or broken sensor mounting tab. 2. Repair the condition as necessary. Is the repair complete? Replace the injection pump. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
- 0.25 to - 0.75
Go to step 4.
Go to step 6.
Go to step 5.
5 6
Go to step 2.
System OK.
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DTC P1216 Fuel Solenoid Response Time Too Short

SPEEDO/TACH MODULE C53-4 C53-7
TO IGNITION TO IGNITION
913 WH
See detail in Power/Ground Schematic
INTERIOR FUSE FUSE BOX 4B 5 AMP
30 GY
C3-N7
FUSE 3B 20AMP
FUSE 3A 20AMP
EXTERIOR FUSE BOX
C54-13
TO IGNITION VOLT/OIL MODULE See detail in Volt/Oil Module Schematic
FUEL SOLENOID
DRAIN FILTER
B C5-A4 239 PK
C54-7
C3-F4
327 YL
A ENGINE SHUTOFF SOLENOID 291 PK A WATER IN FUEL SENSOR A C 701 DB FUEL HEATER FUEL SOLENOID FUEL DRIVER SOLENOID CONTROL A CLOSURE SIGNAL E CLOSURE GROUND C D IGN B FUEL SOLENOID HIGH F FUEL SOLENOID LOW
C1-45
B
C 713 RD A 57 BK 57 BK 491 BK C27-C13 CLOSURE SIGNAL C29-A1 CLOSURE GROUND 712 LG C28-C15 POWER CONTROL MODULE ESO SOLENOID CONTROL C28-D3 C28-C3 FUEL INJECT CONTROL
01-S12-025
G2
Circuit Description
The injection pump delivers fuel to individual cylinders by opening and closing a solenoid control fuel valve. The PCM monitors the amount of time it takes for the fuel solenoid valve to physically close after commanded to close. Closure time out of range is seen as a fault. This response time is measured in milliseconds. This is a type C DTC.

A current DTC Last Test Failed clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a scan.

Battery voltage greater than 10 volts and less than 16 volts. Engine coolant temperature greater than -1C (34F). Engine speed greater than 506 RPM. Requested fuel rate is greater than 0.0 mm. Inj. Pump Closure Time less than 0.75 ms.
Diagnostic Aids
Intermittent DTCs P0251, P0370 and P1216 may be caused by air entering the fuel system when the fuel levels get below 1/8 of a tank while performing hard acceleration or turning maneuvers. These DTCs may also set if the vehicle has run out of fuel. If DTC P1216 is set with any other codes, diagnose those codes first.

The control module stores the DCTC information into memory when the diagnostic runs and fails. The MIL will not illuminate The control module records the operating conditions at the time the diagnosed fails. The control module stores this information in the failure records. 1-1-02
Test Description
2. 3. This step will determine if the ground circuit is open which causes the vehicle not to start. This step will determine if the signal circuit is open or an injection pump (fuel solenoid) is a fault.
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121
DTC P1216 - Fuel Solenoid Response Time Too Short

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Is DTC P0219 set? Will engine start? 1. Engine at operating temperature. 2. Observe Inj. Pump Closure Time on scan tool. Is the scan tool display less than the specified value? 1. Engine running. 2. Again, observe Inj. Pump Closure Time on scan tool. Does Inj. Pump Closure Time display the specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? 1. Check the Closure ground circuit for an open. 2. If the Closure circuit is open, repair as necessary. Was a repair performed? 1. 2. Check the Closure signal circuit for an open or short to ground. If the Closure signal circuit is open or shorted to ground, repair as necessary. Was a repair performed? Check the Closure signal circuit for a poor connection at PCM and replace terminal if necessary. Is action complete? Replace injection pump. Notice: If injection pump is faulty, the new injection pump must be timed. Refer to Checking and Adjusting Injection Timing in Section 4. Is the action complete? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
2 3 4
0.75 ms
Go to DTC P0219 Go to step 4. Go to step 5.
0.1 ms
Go to step 8.
Go to step 10.
Go to applicable DTC table.
Go to step 12.
Go to step 9.
10
Go to step 12.
11
Go to step 12.
12
Go to step 13.
Go to step 2.
13
System OK.
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DTC P1217 Fuel Solenoid Response Time Too Long
DRAIN FILTER
D IGN
F FUEL SOLENOID LOW
Circuit Description
The injection pump delivers fuel to individual cylinders by opening and closing a solenoid control fuel valve. The PCM monitors the amount of time it takes for the fuel solenoid valve to physically close after commanded to close. Closure time out of range is seen as a fault. This response time is measured in milliseconds. This is a type C DTC.

A current DTC Last test failed clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a scan.

Battery voltage greater than 10 volts and less than 16 volts. Engine coolant temperature greater than -1C (34F). Engine speed greater than 506 RPM. Requested fuel rate is greater than 0.0 mm. Inj. Pump Closure Time less than 2.5 ms.
Diagnostic Aids
A weak (mechanical failure) fuel solenoid will result in a DTC P1217. If DTC P1217 is set with any other DTCs, diagnose them first. If the vehicle is running close to the DTC setting closure time, vehicle should be checked during cold start ups and during hot conditions.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 3.This step will determine if DTC P1217 is a hard failure or an intermittent. 6.This step will determine if the solenoid is at fault, or if there is a problem with the PCM or wiring.

The control module stores the DTC information into memory when the diagnostic runs and fails. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records. 1-1-02
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123
DTC P1217 - Fuel Solenoid Response Time Too Long

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Is DTC P0370 set? 1. Start the engine and idle until operating temperature is reached. 2. Observe Inj. Pump Closure Time on scan tool. Is the scan tool display greater than or equal to the specied value? 1. 2. 3. 4. All accessories on (includes aftermarket add-ons). Engine idling. All post glow plug cycles completed. With a DVOM connected to ground, measure voltage at fuse 3A in the external fuse box. Is voltage between specied value? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? Repair the fuel solenoid driver ignition feed circuit poor connections or aftermarket add-ons. Was a repair performed? Replace injection pump. Notice: If injection pump is faulty, the new injection pump must be timed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
2 3
2.4 ms
Refer to DTC P0370 Go to step 5.
12 - 15v
Go to step 7.
Go to step 6.
Go to applicable DTC table. Go to step 8.
Go to step 8.
Go to step 9.
Go to step 2.
System OK.
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DTC P1218 Injection Pump Calibration Circuit
DRAIN FILTER
D IGN
F FUEL SOLENOID LOW
Circuit Description
The PCM uses a calibrated resistor mounted internally in the injection pump to determine fuel rates. The resistor value is stored in the PCM memory. If the PCM memory has been disturbed or the PCM has been replaced, the PCM will relearn the resistor value on the next ignition cycle. This is a type B DTC.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a scan.

PCM currently does not have a valid resistor valve. PCM is unable to read a resistor value.
Diagnostic Aids
Check connection at fuel injector driver. Clear DTC, and cycle ignition. If DTC clears, treat condition as intermittent.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the failure Records. If the diagnostic reports a failure on the second consecutive ignition cycles, the control module records the operating conditions at the time of the failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records. 1-1-02
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 3. This step will determine if there is a problem with the connection at the fuel solenoid driver or faulty injection pump.
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125
DTC P1218 Injection Pump Calibration Circuit

Step 1 Action Important: Before clearing DTCs use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the Power train On-Board Diagnostic (OBD) System Check performed? Are than any other DTCs set? Value(s) Yes Go to step 2. No Go to Powertrain OBD System Check.
Refer to Applicable DTC Table Go to step 5.
Go to step 3.
Check connection at Fuel Solenoid Driver. Clear DTC, and cycle ignition. Start and idle engine. Activate Time set procedure (the diagnostic will only run when a Time Set procedure is performed). 5. Exit out of Time set procedure and Select DTC, Specic, then enter the DTC number. Does the Scan Tool indicate that the diagnostic Passed? Replace injection pump. Important: The new injection pump must be timed. Refer to Fuel Injection Pump. Is the action complete? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored refer to those table(s). Are any additional DTC(s) stored? Operate the vehicle under the conditions for running and setting. Does the scan tool indicate the diagnostic has passed. Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed?
1. 2. 3. 4.
Go to step 4.
Go to step 6.
Go to Appli- Go to Diagnoscable DTC tic Aids. Table. Go to step 7. Go to Applicable DTC Table. Go to step 2. System OK.
6 7
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DTC P1627 Analog to Digital Performance

Circuit Description
The PCM monitors internal circuits for performance problems. If a problem is detected in the analog to digital converter circuits, DTC P1627 will set. This is a class B code.

The control module turns the MIL OFF after 3 consecutive ignitions cycles that the diagnostic runs and does not fail. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. Clear the MIL using the Tech 2.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of failure. The control module writes the operating conditions to the Freeze Frame and updates the Failure Records.
DTC P1627 - A/D Performance

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? Replace the faulty PCM. Notice: If the PCM is faulty, the new PCM must be programmed. Go to PCM replacement and programming procedures. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
Go to step 2.
System OK.
1-1-02
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127
DTC P1635 PCM 5 Volt Reference Low
5 VOLT REFERNCE
A
5 VOLT REFERENCE
E
SENSOR SIGNAL
A
SENSOR GROUND
B B A B
M
651 BK
350 GY 651 BK 394 LG 359 PP 357 TN 349 YL 354 YL
C5 C3 B8 C1 C12 C2 A3 A2 A6 A7
C5
B9
359 BK 349 YL
B11
350 GY
B12
394 LG
B10
354 YL
C4
651 PP
B5
357 TN
C5
709 RD 708 TN 703 OR 375 GY 710 OR 442 BR 156 PK 225 YL 711 YL A10
ITS HI
C29-A5
C29-B12
C27-D13
C27-C14
C27-C11
C27-C1
C27-C4
C27-D14
C29-A4 C29-A2
C27-D9
SENSOR GROUND
C27-C8 C29
FUEL TEMP SIGNAL
A7
ITS HI
A8
ITS LO
A9
ITS LO
5 VOLT REFERENCE

02-S02-005
9-S12-070
Circuit Description
The PCM provides a 5 volt supply for use in powering up sensors. This test monitors the voltage present at C27D13 (shared by Boost and Crankshaft Position sensors) and C27D14 (Optical/Fuel temperature sensor (Cam/HI Res). This is a type C DTC.
Diagnostic Aids
During the time the failure is present, the setting of additional DTCs that share a 5 volt reference may also set.
Test Description
2.Checks to confirm that a DTC is still present. 3.Checks to determine if there is a 5 volt reference from the PCM. 4.Checks to determine if there is a short-to-ground in CKT 350 or CKT 375, or a short-to-ground in the PCM. 7.This step determines if the short is being caused by one of the sensors the short is in the wiring harness.

5 volt reference is less than 1 volt.

The control module stores the DTC information into memory when the diagnostic runs and fails. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records.

A current DTC Last Test Failed clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a scan.
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DTC P1635 - PCM 5 Volt Reference Low

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Scan tool installed. 2. Crank engine for 15 seconds or start up. Does DTC reset? 1. Ignition ON, engine OFF. 2. Disconnect boost sensor. 3. With a DVOM, check the 5 volt reference circuit at harness connector. Is voltage less than the specied value? 1. Disconnect PCM connector with the boost sensor 5 volt reference circuit. 2. With test light connected to B+, probe the 5 volt reference circuit at PCM harness. Is test light ON? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs are stored, refer to those charts(s) rst. Are additional DTCs stored? Replace Boost/BARO sensor. With a test lamp probe the boost sensor 5-volt reference circuit at the PCM, disconnect each sensor, one at a time, that is common to the 5-volt circuit. Does the test lamp turn OFF when one of the sensors is disconnected? 1. Disconnect the PCM connector with the fuel temperature sensor 5-volt reference circuit. 2. With a test light connected to B+, probe the fuel temperature 5 volt reference circuit at the PCM harness. Does the test lamp illuminate? Replace the sensor that caused the test light to turn OFF. Is the repair complete? Repair short to ground in 5 volt reference circuit. Is the action complete? Replace the faulty PCM. Notice: The new PCM must be programmed. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 5.
4.0v
Go to step 4.
Go to step 6.
Go to step 7.
Go to step 8.
Go to applicable DTC table. Go to step 8. Go to step 9.
Go to Diagnostic Aids Go to step 10.
6 7
9 10 11 12
Go to step 12. Go to step 12. Go to step 12 Go to step 13.
Go to Step 2.
13
System OK.
1-1-02
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129
DTC P1641 Malfunction Indicator Lamp (MIL) Control Circuit

HOT AT ALL TIMES FUSE 2D 20 AMP INTERIOR HOT IN RUN AND START FUSE 3A 20 AMP EXTERIOR 30 C1-10 STS LAMP 537 OR 239 PK MIL LAMP STATUS CENTER TO C29-B3 714 RD C10-H C3-G5 658 BR C1-25 C28-C13 C28-D13 BATT BATT C28-C12 C28-C11 IGN IGN C28-D11 STS LAMP CONTROL C28-C14 MIL CONTROL GROUND GROUND C28-D6 C28-D7 570 BK HOT AT ALL TIMES 59 BK 570 BK FUSE 1H 5 AMP INTERIOR G2 554 GRY 9-S12-064 4 G4 16 HOT IN RUN AND START FUSE 4B 5 AMP INTERIOR GRY C10-J POWERTRAIN CONTROL MODULE 914 PP 2 DLC
C10-C C3-F3
C1-28
Circuit Description
A dash light is illuminated by the PCM when the ignition is ON with the engine OFF, or if the diagnositcs have detected certin errors related to the engine performance or the engine sensor status. When the PCM is commanding the MIL ON, the woltage potential of the circuit will be low, near 0 volts. When the PCM is commanding the MIL OFF, the voltage potential of the circuit will be high, near the battery voltage. The primary function of the PCM in this circuit is to supply the ground for the MIL circuit.

Will not turn ON the MIL. The PCM sotres the DTC information into memory. The control module stores this information into Freeze Frame Records.

A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Tech 2.

MIL requested ON. Voltage at the MIL control circuit is high (near battery). OR MIL requested OFF. Voltage at the MIL control circuit is is low, near 0 volts.
Diagnostic Aids
A faulty bulb or the control circuit shorted to ground will cause a P1641 to set.
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DTC P1641 - Malfunction Indicator Lamp (MIL) Control Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the ignition ON but leave the engine OFF. 2. Use the scan tool to command the MIL ON and OFF. Does the MIL illuminate when commanded ON? The DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic aids. If any additional DTCs are stored refer to those tables. Are any additional DTCs stored? 1. Ignition OFF. 2. Disconnect connector C28. 3. Ignition ON engine OFF. Is the MIL ON? 1. 2. With the ignition ON and the engine OFF and connector C28 disconnected. With a fused jumper wire connected to ground, probe the lamp control circuit on the PCM harness connector. Does the lamp illuminate? 1. Check for poor connection at the PCM. 2. If a problem is found, repair as necessary. Is the repair complete? Inspect the MIL control circuit for a short to ground. Repair as necessary. Was a repair made? Check the MIL control circuit for the following: A control circuit either open or shorted to B+. A malfunctioning bulb. Was a problem found? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
Go to the DTC list. Go to step 7.
Go to the Diagnostic aids. Go to step 5.
Go to step 6.
Go to step 8.
Go to step 10.
Go to step 9.
7 8
9 10
Go to step 2.
11
System OK.
1-1-02
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131
DTC P1643 Wait to Start Lamp Control Circuit

C9-J
C3-N7 #1 #3 #5 #7

C5-A4
239 PK

30 GY
FUSIBLE LINK
GLOW PLUGS LH
D IGN POWER BATT +
TO IGNITION SWITCH
LEFT BANK OUTPUT
A B
RH STATUS CENTER
C
WAIT
RIGHT BANK OUTPUT
GLOW PLUG RELAY
D
#2 #4 #6 #8
C
C9-A
C3-D1
GLOW PLUGS RH
C5-C11
C5-B4
C1-27
506 LB
466 YL
G1
338 DB
C28-C7
BK
00-S12-011
Circuit Description
The Wait is illuminated by the PCM when the glow plugs are commanded ON. When the PCM is commanding the Wait lamp ON, the voltage potential of the circuit will be low (near 0 volts). When the PCM is commanding the Wait lamp OFF, the voltage potential of the circuit will be high (near battery volts). The primary function of the PCM is to supply the ground for the Wait To Start lamp circuit. This is a type B DTC.
module writes the operating conditions to the Freeze Frame and updates the Failure Records.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan tool.

Wait To Start lamp requested ON. Voltage on Wait lamp circuit is near battery volts. or Wait To Start lamp requested OFF. Voltage on Wait lamp control circuit is near 0 volts.
Diagnostic Aids
A control circuit shorted to ground will cause a P1643 to set.
Test Description
2.Repeat the command as many times as necessary (when glow plugs are commanded ON by the scan tool, an internal PCM timer protects the glow plugs from damage by cycling them ON for 3 seconds and OFF for 12 seconds. After the 12 seconds has elapsed, the glow plugs can be commanded ON again).

The control module turns the MIL ON the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycle, the control module records the operating conditions at the time of the failure. The control
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DTC P1643 Wait to Start Lamp Control Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the ignition ON leaving the engine OFF. 2. Using a scan tool, command the Glow Plug system ON and OFF. Does the lamp turn ON and OFF when commanded by the Tech 2? The DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored refer to those tables. Are additional DTCs stored? 1. Turn the ignition OFF. 2. Disconnect the PCM connector C28. 3. Turn the ignition ON leaving the engine OFF. Is the lamp OFF? With a fused jumper wire connected to ground, probe the Wait lamp control circuit in the PCM harness connector. Is the lamp ON? Check the connections at the PCM. Was a repair performed? The Wait To Start lamp control circuit is shorted to ground, repair as necessary. Is the action complete? Check the connections at the speedo/tach module. Repair as necessary. Was a problem found and corrected? Replace the speedo/tach module. Is the action complete? Replace the PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Does the Scan tool display any additional undiagnosed DTCs? Value(s) Yes Go to step 2. No Go to Powertrain OBD System Check. Go to step 4.
Go to step 3.
Go to step 6.
Go to step 8.
6 7
Go to step 10.
8 9 10 11
Go to step 9.
Go to step 2.
12
Go to the Applicable DTC table.
System OK.
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133
DTC P1654 Check Throttle Circuit

C10-C C3-F3
C1-28
Circuit Description
A dash light is illuminated by the PCM if diagnostics have detected certain errors related to the Accelerator Pedal Position (APP) sensor. When the PCM is commanding the service throttle soon lamp ON, the voltage potential of the circuit will be low, near 0 volts. When the PCM is commanding the service throttle soon lamp OFF, the voltage potential of the circuit will be high, near the battery voltage. The primary function of the PCM in this circuit is to supply the ground for the service throttle soon lamp. This is a type D code.

The PCM stores the DTC information in memory. The MIL will not illuminate. The control module records the operating conditions at the time the diagnostic fails. This information is stored as a Failure Record.

A current DTC Last Test Failed clears when the diagnostic runs and passes. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other nonemission related diagnostic. Clear the DTC with the Tech 2.

Check Throttle lamp requested ON. Voltage at the Check Throttle control circuit is high near battery voltage. OR Check Throttle lamp requested OFF. Voltage at the Check Throttle control circuit is low, near 0 volts.
Diagnostic Aids
A faulty bulb or the control circuit shorted to ground will cause a P1654 to set.
Test Description
Number(s) below refer to the number(s) on the diagnostic table. 2. This test checks the ability of the PCM to command the Check Throttle lamp on during the bulb check.
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DTC P1654 - Check Throttle Circuit

Step 1 Action Important: Before clearing DTC(s) use the scan tool Capture Info to record freeze frame and failure records for reference, as data will be lost when Clear Info function is used. Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the ignition ON but leave the engine OFF. 2. Use the scan tool to command the Check Throttle lamp ON and OFF. Does the MIL illuminate when commanded ON? The DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic aids. If any additional DTCs are stored refer to those tables. Are any additional DTCs stored? 1. Ignition OFF. 2. Disconnect connector C28. 3. Ignition ON engine OFF. Is the MIL ON? 1. 2. With the ignition ON and the engine OFF and connector C28 disconnected. With a fused jumper wire connected to ground, probe the lamp control circuit on the PCM harness connector. Does the lamp illuminate? 1. Check for poor connection at the PCM. 2. If a problem is found, repair as necessary. Is the repair complete? Inspect the Check Throttle control circuit for a short to ground. Repair as necessary. Was a repair made? Check the MIL control circuit for the following: A control circuit either open or shorted to B+. A malfunctioning bulb. Was a problem found? Replace the faulty PCM. Is the action complete? 1. 2. 3. 4. Using the Scan Tool, select DTC, Clear Info. Start engine and idle at normal operating temperature. Select DTC, Specic, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC as specied in the supporting text. Does the Scan Tool indicate that this diagnostic Ran and Passed? Using the Scan Tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 2. No Go to OBD System Check.
Go to step 3.
Go to step 4.
Go to the DTC list. Go to step 7.
Go to the Diagnostic aids. Go to step 5.
Go to step 6.
Go to step 8.
Go to step 10.
Go to step 9.
Go to step 10.
Go to step 10.
9 10
Go to step 2.
11
System OK.
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135
DTC P1656 Wastegate Solenoid Control Circuit

239 PK A B 154 YL
A4
WASTEGATE SOLENOID
C5
D3 154 TN C28-D14
FUSE 5C 10 AMP
EXTERNAL FUSE BOX
PCM
WASTEGATE SOLENOID CONROL
TO IGNITION
02-S12-013
Circuit Description
The turbocharger wastegate is a vacuum actuated valve used to control the exhaust gas heat sent to the turbo. The wastegate pulse width modulated solenoid meters the vacuum level at the wastegate valve actuator as commanded by the PCM. When the PCM is commanding the Wastegate solenoid ON, the voltage potential of the circuit will be near 0 volts. When the PCM is commanding the wastegate solenoid OFF, the voltage potential of the circuit will be near battery volts. The primary function of the PCM in this circuit is to supply the ground for the wastegate solenoid. This is a type B code.

The PCM will turn the MIL off after three consecutive trips without a fault condition. A current DTC, Last Test Failed, Clears when the diagnostic runs and passes. A History DTC will clear when forty consecutive warmup cycles that the diagnostic does not fail. Use of a Scan Tool.
Diagnostic Aids
This diagnostic will set when control circuit does not follow the PCM command. When the solenoid is requested ON voltage will drop, when the solenoid is OFF ignition voltage will be present. The scan tool has a 5 second ON time abort. The wastegate solenoid can be commanded ON for as many times as needed, in 5 second intervals. Its possible DTC P0236 may set along with DTC P1656. This diagnostic can be checked during key up. The engine will not respond to scan tool commands at idle. The engine is unable to achieve boost pressures greater than BARO at idle or at any engine speed greater than idle. The PCM control abort to prevent engine damage.

This code will set if either of the test fails. TEST 1 PCM requested Wastegate solenoid ON. Voltage on the wastegate solenoid control circuit is near battery voltage. 2 consecutive faults detected. Conditions met for 2 seconds. TEST 2 PCM requested Wastegate solenoid OFF. Voltage on the wastegate solenoid control circuit near 0 volts. 2 consecutive faults detected. Conditions met for 2 seconds.
Test Description
2. 3. This step will determine if this DTC is a current. This check can detect a partially shorted coil which would cause excessive current flow. Leaving the circuit energized for 2 minutes allows the coil to warm up. When warm, the coil may open, the amps drop to zero, or short an amp draw greater than 0.75A.

The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails. The control module records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic reports a failure on the second consecutive ignition cycled the control module records the operating conditions at the time of the failure. This control module writes the operating conditions to the Freeze Frame and updates the Failure Records. 5745159
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.
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Step 1 2 Action Important: Before clearing DTCs use the scan tool Capture Info Was the Powertrain On-Board Diagnostic (OBD) System Check performed? 1. 2. 3. Scan tool connected. Ignition ON, engine OFF. With scan tool, command the wastegate solenoid ON and OFF and listen for an audible click. Does the solenoid turn ON and OFF (audible click) with each command? 1. 2. Ignition OFF. Disconnect the PCM connector containing the wastegate solenoid control circuit. 3. Ignition ON. 4. Using a DVOM on a 10-amp scale, measure current from the solenoid control circuit in the PCM harness connector to ground for 2 minutes. Is current draw less then the specied value, but not zero?. 1. 2. 3. Ignition OFF. PCM connector still disconnected, disconnect wastegate solenoid. Using a DVOM, measure resistance from the solenoid control circuit in the PCM harness connector to ground. Does DVM display innite resistance? 1. 2. 3. Disconnect wastegate solenoid. Ignition ON, engine OFF. Connect a test light between the wastegate solenoid control circuit and an ignition feed. 4. Using a scan tool. command the solenoid ON and OFF. Does test light turn ON and OFF with each command? 1. Ignition ON engine OFF. 2. With a test light connected to ground, probe the ignition feed circuit at the Boost solenoid harness connector. Is the test light ON? 1. Ignition OFF. 2. Reconnect solenoid. 3. Disconnect the PCM harness containing the solenoid control circuit. 4. Ignition ON. 5. With a fused jumper wire connected to ground, probe the solenoid control circuit in the PCM harness connector. Does the solenoid operate (audible click)? DTC is intermittent. If no additional DTCs are stored, refer to Diagnostic Aids. If additional DTCs were stored refer to the applicable DTC table(s) first. Are any additional DTCs stored? Check for a poor connection at the wastegate solenoid and replace terminals as necessary. Did the terminals require replacement? Repair wastegate solenoid control circuit. Is the action complete? Check for a poor connection at the PCM, wastegate solenoid control circuit. Was a problem found? Value(s) Yes Go to step 2. Go to step 3. No Go to OBD System Check. Go to step 5.
0.75A
Go to step 8.
Go to step 4.
Go to step 9.
Go to step 6.
Go to step 7.
Go to step 12.
10 11
Go to step 15.
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Step 12 13 14 Action Repair the open in the ignition feed circuit. Is the action complete? Replace the wastegate solenoid. Refer to Wastegate Solenoid. Is the action complete? Replace the PCM. Important: The new PCM must be programmed. Is the action complete? 1. Using the scan tool, select DTC, Clear info. 2. Start engine and idle at normal operating temperature. 3. Select DTC, Specic, then enter the DTC number which was set. 4. Operate vehicle until the Scan Tool indicates that the diagnostic ran. Does the scan tool indicate that this diagnostic passed? Using the scan tool, select Capture Info, Review Info. Are any DTCs displayed that have not been diagnosed? Value(s) Yes Go to step 15. Go to step 15. Go to step 15. No
15
Go to step 16.
Go to step 2.
16
System OK.
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CONNECTOR LEGEND
76 WAY BULKHEAD LOCATION: LEFT SIDE FIREWALL
PIN 1 PIN 13 PIN 27 PIN39 PIN 51 PIN 65
PIN 12 PIN 26 PIN 38 PIN 50 PIN 64 PIN 76
C1 MALE
9-S12-048
CAV 12 CAV 26 CAV 38 CAV 50 CAV 64 CAV 76
C1 FEMALE
PIN CKT 400 739 740 43 962 33 37E 37D 786 537 787 37 1-1-02 COLOR LG PP YL DB BR WH YL YL RD OR GY RD Ignition Feed + Left heated windshield power + Right heated windshield power + Trailer Brake activation Trailer lights neutral safety switch feed start relay feed Ignition switch feed Fuel selector valve control Battery Fuel pump + to selector valve Ignition relay feed
9-S12-047
DESCRIPTION
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139
PIN
CKT 688 723 724 17 718 353 607 717 961 720 640 92 714 37 338 658 151 31 22 721 580 606 29 39 153 42 198 810 2 152 298 722 327 80 3 914 644 210 195 603 719
COLOR RD YL DG PP DB YL TN WH PP TN OR GY DB RD DB BR GY TN RD LB BR OR PK DG LG BR TN PP LG DB BR PP YL WH LB PP YL DG YL DG BR Rear window defrost feed APP 3 5volt reference APP 3 signal + From dimmer module APP 1 signal Speedometer signal ABS module diagnostic line APP 1 5volt reference TT4 lamp activation APP 2 5volt reference IGN+ CTIS warning circuits CTIS rear inate solenoid activation Check throttle lamp activation Battery feed to interior accessories Wait lamp activation Check engine lamp activation Cruise control ON/OFF signal Oil pressure signal Brake switch signal rest APP 2 sensor signal Not Used for 99 ABS diagnostic line Fuel gauge signal Engine temperature signal Cruise resume/accelerate signal Low brake uid lamp activation A/C request TCC brake switch signal Right front turn signal Cruise set/coast signal Backup light switch feed APP 2 ground Water-in-fuel lamp activation Under hood lamp power Left front turn signal
DESCRIPTION
PCM class 2 communication line to DLC Tachometer signal Low washer uid level lamp activation Headlight switch feed ABS lamp activation APP 1 ground 1-1-02
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PIN

CKT 793 794 41 428 47 46 725 767 1 91 37 12 13 38 16 175 943 5 9 20 21 789 941 COLOR YL RD TN PK LG WH GY BR DB TN RD OR TN RD LG LB BR DG YL RD GY BR TN
___________________________________________________
DESCRIPTION Low coolant lamp activation Low air warning lamp activation Brake uid level sensor feed CTIS buzzer activation Deate solenoid activation CTIS compressor relay activation APP 3 Ground Compass mirror temperature signal Horn relay activation CTIS front inate solenoid activation Battery feed to interior fuse box Head lamp high beam feed Head lamp low beam feed Head lamp switch feed Ignition supply to exterior fuse box fuses 2A, 2B, and 3B Power window relay feed Upper windshield washer pump activation Right rear turn signal Left rear turn signal Front park lamps Rear tail lamp feed Fuel selector valve control Lower windshield washer pump activation
1-1-02
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141
56 WAY INSTRUMENT PANEL LOCATION: BEHIND INSTRUMENT PANEL
C3 MALE
P N M L K J H PIN H6
10
1 G F E D C B A PIN A1
9-S12-050
C3 FEMALE
G F E D C B A CAV A1
10 9
6 P N M L K J H CAV H6
9-S12-049
PIN
CKT 195 54 53 67 38 15 640 46 450 47 91 92 338 2 961
COLOR YL DG DB BR RD WH OR WH PK LG TN GY DB LG PP
DESCRIPTION
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2
C3 C4 D1 D2 D3 5745159
Headlight switch feed Dome lamp switch feed Dome lamps feed Rear wiper relay activation (not used 99) Head lamp switch feed Head lamp feed to dimmer module CTIS switch ignition feed CTIS compressor indicator lamp activation Seat belt lamp activation Deate solenoid activation
Front inate solenoid activation Rear inate solenoid activation Glow plug wait lamp activation Right turn indicator lamp activation TT4 indicator lamp activation 1-1-02
142
PIN E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 G5 H6 H7 H8 H9 J6 J7 J8 J9 K6 K7 K8 K9 L6 L7 L8 M6 M7 M8 M9 N6 N7 N8 N9 P6 P7 P8 P9 P10 1-1-02

CKT 42 603 793 943 12 3 658 327 517 210 794 428 714 14 65 61 17 63 27 948 947 942 19 944 644 476 31 952 789 786 787 953 59 30 941 945 55 29 39 353 59 COLOR BR RD YL TN OR LB BR YL PK DG RD PK DB LB YL RD PP DG OR DG/YL DB/YL OR/BK YL OR YL GY TN DB BR RD GY DG BK GY TN BR OR PK DG YL BK
___________________________________________________
DESCRIPTION Brake indicator lamp activation ABS indicator lamp activation Low washer uid activation Rear Wiper feed (not used 99) High Beam indicator lamp activation Left turn indicator lamp activation Check engine lamp activation Drain Filter lamp activation Power mirror switch battery feed Transfer case lock lamp activation Low coolant lamp activation Low tire air lamp activation Check throttle lamp activation Head lamp switch feed Ignition feed to intermittent wiper switch High speed windshield wiper signal + from dimmer module Low speed windshield wiper signal Intermittent wiper signal Left hand power mirror up/down signal Left hand power mirror left/right signal Left hand power mirror common +/ Power supply to dimmer module Right hand power mirror common +/ Tachometer signal Clock battery feed Oil pressure signal to gauge Right hand power mirror left/right signal Fuel selector valve control Fuel selector valve control Fuel selector switch feed from fuel pump relay Right hand power mirror up/down signal Ground Ignition feed to gauges Windshield wiper washer pump activation Intermittent wiper relay activation Rear cargo lamp activation Fuel gauge signal Engine temperature gauge signal Speedometer signal Ground
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143
40 WAY GM ENGINE LOCATION: LEFT INTAKE MANIFOLD
PIN A1 PIN B1 PIN C1 PIN D1

9-S12-019
CAV A8 CAV B12 CAV C12 CAV D8

9-S12-020
C5 MALE
PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 5745159 31 TN Oil pressure signal to gauge 442 349 394 359 350 703 225 375 354 357 BR YL LG BK GY OR YL GY YL TN CAM signal Crankshaft position signal Boost Pressure Signal Sensor ground Sensor 5 volt reference High resolution signal Fuel temperature signal Optical Sensor 5 volt reference Engine coolant temperature signal Intake air temperature signal CKT 39 708 709 239 291 710 711 713 712 491 701 466 651 57 COLOR DG TN RD PK PK OR YL RD LG BK DB YL PP BK Engine temperature signal to gauge Injection timing stepper motor LO Injection timing stepper motor HI Engine ignition feed Engine ignition feed Injection timing stepper motor LO Injection timing stepper motor HI Closure signal to solenoid driver Fuel inject signal to solenoid driver Closure ground to solenoid driver Engine shutoff solenoid enable Glow plug controller enable Crankshaft position sensor ground Ground
C5 FEMALE
DESCRIPTION
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144
PIN C11 C12 D1 D2 D3 D4 D5 D6 D7 D8

CKT 506 156 COLOR LB PK
___________________________________________________
DESCRIPTION Glow plug feedback signal Optical sensor ground
154
YL
Wastegate solenoid control
3-1-02
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145
32 WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM

D1 C1
D16
C16
9-S12-042
C27 MALE
PIN C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 5745159 495 784 723 724 787 725 506 238 156 153 496 DB DB YL DG GY GY LB DG PK LG GY Transmission input speed sensor (lo) 4wd low switch signal APP sensor (3) 5 volt ref. APP (3) signal Lift pump feedback signal APP (3) ground Glow plug feedback signal Lift pump relay enable + Optical sensor ground Cruise control resume/accelerate Transmission input speed signal (hi) 1-1-02 713 394 265 RD LG LB Closure signal Boost pressure sensor signal Pressure Control Solenoid (Lo) 354 YL Engine coolant temp signal 357 721 466 264 225 923 TN LB YL RD YL BR Intake air temp sensor signal APP sensor (2) signal Glow plug enable + Pressure Control Solenoid (Hi) Fuel temperature signal Transmission uid temp signal CKT 651 439 COLOR PP YL Crankshaft position sensor ground A/C request+ DESCRIPTION
146
PIN D12 D13 D14 D15 D16

CKT 717 350 375 COLOR WH GY GY
___________________________________________________
DESCRIPTION APP (1) 5 volt ref. Boost sensor/crankshaft position sensor 5 volt ref. Optical sensor 5 volt reference
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147
32 WAY PCM-BLUE LOCATION: CENTER CONSOLE, PCM

D1 C1
D16
C16
9-S12-042
C28 MALE
PIN C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 5745159 714 RD Check throttle lamp control 1-1-02 440 570 570 RD BK BK Compressor clutch enable Ground Ground 239 239 537 658 701 PK PK OR BR DB Ignition / axle switch jumper Ignition Battery Malfunction indicator lamp control Engine shutoff solenoid control 720 712 237 924 315 338 914 TN LG LG TN YL DB PP APP (2) 5 volt ref. Fuel inject signal 1-2 shift solenoid control Torque converter clutch solenoid control 2-3 shift solenoid control A/C clutch control? Class 2 communications (dlc) CKT COLOR DESCRIPTION
148
PIN D12 D13 D14 D15 D16

CKT 537 154 COLOR OR TN Battery
___________________________________________________
DESCRIPTION
Waste gate solenoid control
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149

B1 A1
A12
A12
9-S12-028
C29 MALE
PIN A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 810 22 152 359 PP RD DB BK CKT 491 703 565 442 349 223 709 708 710 711 151 722 719 718 351 764 763 762 CKT BK OR BR BR YL DB DB TN OR YL GY PP BR DB PK PP DB OR PTO (1360 rpm) user installed PTO (1070 rpm) user installed Cruise control brake switch TCC brake switch Cruise control set/coast signal Boost, engine temp, intake air temp, trans temp sensor ground Closure ground High resolution sensor signal Transmission output speed sensor/VSS Cam sensor signal Crankshaft position sensor signal Vehicle speed sensor Injection timing stepper motor (HI) Injection timing stepper motor (LO) Injection timing stepper motor (LO) Injection timing stepper motor (HI) Cruise control on/off signal APP (2) ground APP (1) ground APP (1) signal Front axle switch signal + from jumper DESCRIPTION
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3-1
Section 3 Fuel, Emissions, and Exhaust

TABLE OF CONTENTS
Air Cleaner Assembly Air Cleaner Filter Element Service . . . . . . . . . . . . . . . . . . .3-21 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Air Induction Hose Replacement . . . . . . . . . . . . . . . . . . . .3-22 Air Intake Vent Line Replacement . . . . . . . . . . . . . . . . . . . . . . .3-23 Diesel Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 Drainage Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . .3-23 Engine Temperature Sender Replacement . . . . . . . . . . . . . . . .3-40 Exhaust System Catalytic Converter Replacement. . . . . . . . . . . . . . . . . . . .3-44 Crossover Pipe Replacement . . . . . . . . . . . . . . . . . . . . . . .3-44 Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42 Fuel Filter Drain Hose and Valve Replacement. . . . . . . . . . . . . . . . . .3-32 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Fuel Injection Pump Boot Replacement . . . . . . . . . . . . . . . . . .3-33 Fuel Injection System Injection Line Bracket and Clamp . . . . . . . . . . . . . . . . . . .3-36 Fuel Lift Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Fuel System Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Electronic Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . .3-4 Electronic Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45 Fuel Filter-Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Fuel Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Fuel Tanks, Lines, and Valves . . . . . . . . . . . . . . . . . . . . . . . 3-4 Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fuel Tank Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Fuel Level Transmitter and Tank Access Plate Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Fuel Tank Vent Line Service. . . . . . . . . . . . . . . . . . . . . . . . 3-29 Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Main/Auxiliary Tank Fuel Line . . . . . . . . . . . . . . . . . . . . . . 3-29 Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Glow Plug Relay/Controller Replacement . . . . . . . . . . . . . . . . . . . . . 3-40 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Main Fuel Tank Fuel Level Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Tank Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Powertrain Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Scan Tool Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Sensor and Switch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Sensor, Oil Pressure Switch, and Transmitter . . . . . . . . . . . . . 3-40 Weathercap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
FUEL SYSTEM
The fuel system components include: A 25 gallon (94.6 liter) fuel tank Fuel tank supply and return lines An electric fuel-lift pump A fuel filter-water separator assembly A gear driven fuel injection pump Individual fuel injector nozzles for each cylinder Fuel line check valves on the filtered side of the fuel system Fuel level transmitter (in fuel tank) Fuel drain back lines (at pump and injectors) A 17 gallon (64.3 liter) auxiliary fuel tank and selector switch Glow plugs (all cylinders) The fuel supply and return lines are attached with quick connect fittings.
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3-2
Fuel, Emissions, and Exhaust _____________________________________________
FUEL INJECTION PUMP INJECTORS
TANK SELECTOR
FUEL LINES
FUEL FILTER/ WATER SEPARATOR
ELECTRIC FUEL LIFT PUMP
TANK MAIN
AUXILIARY TANK
Figure 3-1: Fuel Supply System
Fuel Lift Pump

The fuel lift pump is located on the firewall near the drivers side of the engine. The electric fuel lift pump has a hollow plunger that slides in a bore located in the center passage between the inlet and outlet ports (Figure 3-2). An inlet valve is mounted on one end of the hollow plunger, and an outlet valve is positioned at the outlet end of the center passage. Both valves are closed by spring force. The lift pump is designed to move fuel under a low (suction) pressure from the fuel tank and deliver it through the filter to the transfer pump, inside the fuel injection pump. To operate correctly, the injection pump must have fuel at the correct pressure and without air bubbles. The lift pump is checked as part of the fuel supply system diagnosis. The lift pump should deliver fuel with a minimum volume of one half pint (0.24 liter) in 15 seconds and tee'd in at the injection pump fuel inlet connection running at idle, with a pressure of 5.8 to 8.7 psi (40 to 60 kPa). The lift pump suction line from the fuel tank must be air tight for correct operation of the injection pump. Any air present in the fuel system will cause runability problems and possible diagnostic trouble codes (DTCs) to be set in PCM memory.
The electrical circuit for the lift pump involves several main components (Figure 3-3). A relay mounted in the exterior fuse box, and the lift pump itself, mounted near the lter on the left side of the engine compartment. When the driver moves the ignition switch to the RUN position, the lift pump relay is energized by the PCM for 5 to 20 sec., depending on PCM time out. As soon as the PCM receives RPM signals from the EFI pump the relay is energized again. The lift pump remains running as long as the engine runs.
FUSE 2D 20A INTERIOR C1-10
537 OR
FUEL PUMP RELAY EXTERIOR FUSE BOX
TO FUEL SELECTOR SWITCH
787 GY G2
787 GY
787 GY
C27-D5
FUEL LIFT PUMP SIGNAL
57 BK
C27-D8
FUEL PUMP RELAY CONTROL
B FUEL LIFT PUMP
A
57 BK
9-S12-051 G2
Figure 3-2: Fuel Lift Pump Construction
Figure 3-3: Fuel Lift Pump Electrical Circuit
238 DG
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Fuel, Emissions, and Exhaust
3-3
Fuel Filter-Water Separator

The filter-water separator is located at the driver side of the engine compartment firewall (Figure 3-4). It performs five functions which are: Fuel filtering (2-stage) Water separation Water detection Water drain Fuel heater Fuel filtering and water separation is through a 2-stage, replaceable filter element. The filter second stage causes water to separate from the fuel in the form of droplets. These droplets are collected in a reservoir at the bottom of the filter element housing. Water is then drained off through a drain valve and hose. The drain valve is located in the driver side wheel well. Water detection and fuel heating are controlled by sensors in the filter housing. Water build-up causes the water sensor to activate the instrument panel drain filter warning light. Fuel heating occurs during cold ambient temperatures. It is controlled by a sensor in the fuel inlet port that monitors incoming fuel temperature. When temperature falls to a point where wax build-up could occur, the sensor activates the heat element within the filter housing. The heater will continue to operate until incoming fuel temperature is at or above 46 F (8 C).
RETAINING NUT AIR BLEED VALVE
Electronic Injection Pump

The turbo diesel injection pump (Figure 3-5) is controlled by the powertrain control module based on inputs from the electronic accelerator pedal and various engine sensors. The drive mechanism for the pump consists of a drive gear on the camshaft, and a driven gear on the pump. The pump is operated at camshaft speed in the opposite direction of rotation. A rotary type pump mechanism pressurizes fuel to the injectors. Pressure at the injector nozzles is approximately 2000 psi (138 bar). Residual pressure in the injector lines is maintained at 500 psi (3447 kPa) during operation. Fuel distribution to individual nozzles occurs at the pump head and rotor assembly and is activated by the fuel solenoid driver. High strength, plated steel lines are used to connect each injector to the pump. The powertrain control module controls injection timing and fuel mixture according to input signals from various sensors. A crankshaft position sensor and optical sensors are used to provide engine and injection pump position and speed signals. These signals are transmitted to the PCM and used as reference for fuel flow and timing. The injection pump is equipped with a shut off solenoid controlled by the PCM. The purpose of the solenoid, is to close and stop fuel flow within the pump. This occurs when the ignition switch is moved to the Off position. At this point, loss of PCM hold-open voltage de-energizes the solenoid causing it to close.
OPTICAL/FUEL TEMPERATURE SENSOR SOLENOID DRIVER SHUT-OFF SOLENOID PUMP SHAFT
FILTER ELEMENT
FUEL SOLENOID
HOUSING
INJECTION TIMING STEPPER MOTOR
SENSOR O-RING SCREEN SPRING
Figure 3-5:
Electronic Fuel Injection Pump
SEAL
HEATER
Figure 3-4: Fuel Filter Breakdown

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Fuel Injectors
An identical fuel injector nozzle is used for each cylinder. The nozzle is threaded into the cylinder head and positioned so the injector nozzle extends into the combustion prechamber. The injectors are a spring loaded, valve and pintle design (Figure 3-6). The pintle forms the injector nozzle and the valve seats in the nozzle tip opening. Fuel is supplied to each nozzle and in the necessary sequence, by the fuel injection pump. The high pressure fuel pulse overcomes spring pressure lifting the valve off its seat. Pressurized fuel then enters the prechamber through the nozzle in the form of a highly atomized spray. A small amount of fuel travels around the nozzle and valve for lubrication purposes. This fuel cycles back to the fuel return system through the fuel return ports at the upper end of each nozzle. The fuel injection nozzles are not repairable and are serviced only as an assembly. However, they may be cleaned to remove contamination.
FUEL INLET PORT FUEL RETURN PORT FUEL RETURN PORT
Fuel Tanks, Lines, and Valves

The main and auxiliary fuel tanks are made of high density polyethylene. Auxiliary fuel tank capacity is 17 gallons (64.3 liters). Main tank capacity is 25 gallons (94.6 liters). Quick connect fittings are used at most of the fuel line connection points. Fuel level transmitters for main and auxiliary tanks are mounted within the tanks. A selector valve, mounted on the passenger side of the frame, controls tank flow and selection. A check valve is used in the supply and return lines to prevent backflow. Vent lines are used at both tanks to avoid internal pressure buildup. Fuel return lines are used to send unused fuel from the nozzles and the injection pump back to the fuel tanks.
Glow Plugs
The diesel engine glow plugs are threaded into the cylinder head and extend into the combustion prechamber. The purpose of the plugs is to heat air entering the combustion chambers to help start the combustion process when the engine is cold. The glow plugs are used as an aid to starting; especially when ambient temperatures are low. The plugs are cycled on/off for short time periods prior to engine cranking and during initial start-up. The plugs are not on continuously, as plug damage can occur after 6-7 seconds. Turbo diesel engines use a glow plug relay that is controlled by the PCM based on inputs from engine temperature sensors. The glow plugs will cycle after the engine has started to maintain good combustion.
VALVE SPRING
INJECTOR BODY
Electronic Accelerator Pedal

Turbo diesel models are equipped with an electronic accelerator pedal assembly (Figure 3-7). The assembly consists of a pedal and arm, mounting bracket, and potentiometer module. The pedal assembly mounts in a conventional location. The pedal potentiometer module contains three potentiometers that send varying voltage signals to the PCM. By comparing the different voltage signals against a standard, the PCM can determine fuel delivery rate based on accelerator pedal position. A check throttle warning light is used to alert the driver of a problem with the pedal assembly. Some faults in the pedal potentiometer module or related wiring will trigger the check throttle warning light. The light is located in the status center. Some faults will cause loss of cruise control only and multiple faults in the APP circuit can result in decreased performance or engine idle only.
NOZZLE
PINTLE
Figure 3-6: Fuel Injector Components
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3-5
PEDAL AND ARM
Electronic Fuel Injection Pump Operation

The electronic fuel injection pump is operated by the powertrain control module. The pump contains a fuel solenoid driver, an optical and fuel temperature sensor, a shut off solenoid, a stepper motor, and a fuel solenoid. Additional signal sources that affect pump operation are: crankshaft position sensor, boost sensor, coolant temperature sensor, intake air temperature sensor, and electronic accelerator pedal. At initial engine start, the fuel/lift pump continuously supplies fuel to the injection pump. A change in accelerator pedal position to part throttle, causes an equivalent change in pedal potentiometer voltage output. The PCM then signals the solenoid driver to increase fuel flow. Flow rates are further refined based on various signals from engine sensors. The boost/baro sensor monitors changes in intake manifold pressure. Pressure changes are converted into a voltage signal transmitted to the PCM. High voltage readings indicate high manifold pressures and low voltage indicates low pressure. The intake air temperature sensor monitors incoming air temperature. Cold air generates high sensor resistance readings while warm air generates lower readings. The resistance signals are transmitted to the PCM which richens or leans the fuel mixture as needed. Barometric pressure is monitored by the baro sensor. The sensor signal is used by the PCM to adjust injection pump timing and fuel mixture for different altitudes. The stepper motor advances/retards injection timing on command by the PCM. Signals from the optical, air temperature, crankshaft position, coolant temperature, and fuel temperature sensors, are all utilized by the PCM to optimize settings. Fuel injector cycles are monitored by the PCM (which controls injection). The fuel solenoid driver returns a pulse width signal to the PCM every time it seats the fuel solenoid. This signal indicates injection has occurred at one of the injectors, and the length of the injection cycle.
POTENTIOMETER MODULE
BRACKET
Figure 3-7: Electronic Accelerator Pedal Components
CONNECTOR
FRONT OF VEHICLE
ACCELERATOR PEDAL
Figure 3-8: Electronic Accelerator Pedal (Location)

CONNECTOR CLIP
Figure 3-9: Accelerator Pedal Connector Clip
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The PCM controls operation of all of the engine and transmission outputs. It is on a bracket attached to floor under the center console. The data link connector is the access point for the scan tool. The connector is under the instrument panel at the left side of the steering column. It is a multi-pin connector with integral mounting bracket. Signal inputs used by the PCM include: Coolant temperature Intake air temperature Boost/baro pressure Optical/fuel temperature sensor Crankshaft position sensor Accelerator pedal position sensors (APP) Cruise control A/C request Vehicle speed sensor Automatic transmission fluid pressure manual valve position switch Transmission input speed sensor Transfer case low range switch Transmission fluid temperature sensor Diagnostic request
8.
Check exhaust system components for damage, loose joint connections, or grounding against body. 9. Inspect transmission linkage and wiring connections, especially if vehicle is used for off road operation. 10. If vehicle is drivable, and no obvious problems are found, road test vehicle. If vehicle is not drivable, refer to diagnosis charts and scan tool diagnosis.
Road Test
1. Note battery voltage. Low voltage can cause PCM powerup and initialization problems. Battery voltage should be no lower than 11.5 volts for satisfactory operation. Connect scan tool to diagnostic link connector. Set tool to record fault codes, or have helper use tool to interrogate system during test. Start engine and check idle operation. Note any faults such as rough idle, stalling, excessive smoke. Apply service brake and shift transmission into drive range. Note if engine stalls, runs rough, or another fault occurs. Drive vehicle on road at posted limits. Note operation under light and heavy acceleration, and at normal cruise speeds. Note faults such as surge, miss, vibration, noise, low power, smoke (blue, black, white). Shift into neutral at cruise speed and note engine operation. If vibration or noise was experienced but it now stops, problem may be with drive belt, engine mount, accessory, U-joint, or torque converter. Return to shop and note fault codes recorded by PCM . If a fuel system fault was noted during road test, refer to diagnosis charts, perform fuel system tests, and check system electrical components with scan tool.
2.
3. 4.
5.
6.
FUEL SYSTEM DIAGNOSIS General Information

Fuel system diagnosis should begin with a preliminary inspection followed by a road test to confirm existence of a problem. Preliminary inspection consists of visual checks designed to rule out faults caused by leaks, fuel line damage, or loose electrical connections. 7.
Preliminary Inspection
1. 2. Check fuel gauge readings for main and auxiliary tanks. Visually inspect fuel lines at tanks, selector valve, fuel pump, and at engine. Look for loose, damaged, leaking lines. Check vacuum actuator hose on turbo diesel models. Check wiring for fuel lift pump. Check glow plug and relay wiring. Also check electronic accelerator pedal wiring on turbo diesel. Look for loose connections at all points (including battery), or for damaged, pinched wires. Check serpentine drive belt tension and condition. Note if any indicator lights are on. If engine runs, also check voltage, oil pressure, and coolant temperature readings.
3. 4. 5.
6. 7.
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3-7
Fuel System DiagnosisDiesel Engine

PROBLEM Hard Starting 1. 2. POTENTIAL CAUSE Driver/owner not following recommended start procedure. Fuel contaminated, low quality, or wrong fuel. 1. 2. CORRECTION Remind driver/owner of required procedure. Demonstrate procedure if necessary. Drain off sample at fuel filter drain plug. Flush tank, lines, and filter if fuel is contaminated, wrong grade or type, suspect quality, or shows wax buildup. Remove and clean filter, housing, air horn and inlet hose. Replace filter if plugged. Drain off water at drain plug. Then remove, clean, and reinstall filter. Check fuel pump circuit fuse, relay, wiring. Test pump pressure at pump outlet. Replace pump if pressure is below 5.8 psi (40 kPa). Check lines for damage. Verify flow with compressed air. Repair or replace lines as necessary. Repair wiring or replace sensor if temperature readings are 5 greater or less than actual ambient air temperature. High resistance in sensor or circuit wiring will cause this. Test voltage to and from relay/controller, and at plugs. Repair wiring, replace relay/controller, or replace glow plug(s) as needed. Refer to test procedures in this section and in sections 2 and 12.
3. 4. 5. 6. 7. 8.
Air lter plugged. Excessive water in fuel lter. Fuel pump intermittent or not energized by relay. Fuel-lift pump fault. Fuel return, drain, or vent line restricted, plugged, or damaged. Coolant temperature sensor fault.
3. 4. 5. 6. 7. 8.
9.
Glow plug fault.
9.
10. Shut-off solenoid fault.
10. Test and replace solenoid if necessary. Be sure solenoid fuse and wiring are OK beforehand. Look for bad connections if problem is intermittent. 11. Test with scan tool. Look for bad ground, connections, or damaged/failed crankshaft position sensor. 12. Look for damaged pipes, muffler, converter, especially on vehicles used off road. 13. Check state of charge of batteries, load test and check connections. Refer to test procedures in Section 12. Check engine oil viscosity to ensure it is correct for the ambient temperature. Refer to specifications in Section 1. Check starter draw to determine if starter is dragging. Refer to test procedure in Section 12.
11. No cranking signal to PCM
12. Exhaust system restriction. 13. Low engine cranking speed.
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PROBLEM No Start Condition (engine cranks but will not run) 1. POTENTIAL CAUSE Excessive amount of water or wax buildup in system. 1. CORRECTION Draw off sample at drain plug. Drain and ush system if necessary.
2. 3.
Blown fuse. No fuel to injection pump.
2. 3.
Replace fuse. Check for shorts-grounds in affected circuit. Test fuel-lift pump output. Replace pump if pressure is below 5.8 psi (40 kPa). Check lines and filter for restrictions if pump output is OK. Also test pump relay. Be sure pump relay is being energized when ignition switch is in crank or start position. Check fuel level in tanks Check shut off solenoid. Check fuel solenoid driver feed (terminal A) and ground (terminal C) circuits. Inspect and repair as needed.
4.
No fuel to injectors.
4.
5.
Engine fault: broken camshaft damaged injection pump gears timing chain or gear failure Fuel tank select valve problem.
5.
6.
6.
Replace valve if it wont switch from main to auxiliary and back. NOTE: the valve will only operate if the fuel lift pump is energized! Run scan tool test and replace failed sensor, harness wire, or connector. Replace pump but only if failure is indicated by scan tool and pressure test. Confirm with scan tool. Use multimeter to locate fault.
7. 8. 9.
No inject signal from PCM. Injection pump failure. PCM ground or feed circuit fault (on ground or ignition voltage reference signal).
7. 8. 9.
10. PCM fault. Engine Starts then Stalls 1. 2. 3. 4. Air leak in fuel feed line. Glow plug fault (cold ambient temperature). Restriction in fuel tank vent or return lines. Fuel-lift pump pressure below 2 psi (14 kPa) at injection pump, or 5.8 psi (40 kPa) at fuel pump outlet. Idle rpm too low. No injection signal to PCM (turbo diesel).
10. Confirm with scan tool before replacement. 1. 2. 3. 4. Inspect lines and repair as needed. Bleed injectors afterward. Test and repair wiring, or replace failed glow plugs or relay/controller. Inspect and clear restriction. Replace cap vent, or lines as needed. Replace pump but only if fuel lines to pump are not blocked, plugged, or restricted. Also be sure flow through 2-stage filter is not restricted as well. Adjust idle to required rpm. Test with scan tool and replace failed sensor or harness.
5. 6.
5. 6.
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3-9

PROBLEM Low Power, Sluggish Acceleration 1. 2. 3. 4. 5. POTENTIAL CAUSE Contaminated or low-quality fuel. High fuel temperature. Restriction in air intake system. Fuel tank vent or return line restriction. Exhaust system restriction. 1. 2. 3. 4. 5. CORRECTION Drain, ush, and rell fuel system. Normal condition in high ambient. Remove and clean lter, housing, weathercap, hose, air horn. Clear restrictions, replace lines. Inspect entire system for damage and repair as needed. If vehicle is used for off-road operation, look for kinking, bent, or flattened pipes or muffler. Tighten loose fittings or replace lines if necessary. Inspect brake components. Look for seized or binding caliper piston, master cylinder problem, or failed hydro-boost. Test operation with scan tool. Use snapshot mode to record maximum data. Replace converter if either clutch is damaged.
6. 7.
Air leak at injector or line. Brake drag.
6. 7.
8.
Torque converter problem. Overrunning clutch failure, or converter clutch binding, or slipping. Either fault will cause high fuel consumption and require more than normal throttle opening for acceleration. Engine compression low.
8.
9.
9.
Run compression test. Repair valves, cam, chain, rings as needed.
10. Injection pump mistimed. 11. Turbo diesel electronic accelerator fault such as short, ground, loose connection indicate potentiometer failure. 12. One or more injectors failing. 13. Air leak at intake manifold.
10. Check and correct pump timing. Replace either pump gear if damaged. 11. Check pedal potentiometer wires and connections. Test with scan tool if check throttle light is on. Repair wiring, or replace pedal assembly. 12. Remove and test injectors. Replace faulty injectors as needed. 13. Locate with soap and water solution (or oil). Tighten bolts, replace gaskets, or replace manifold if required. 14. Check boost output. Replace wastegate actuator if leaking. Repair vacuum line if damaged. Replace turbocharger if compressor or turbine wheel vanes are broken, chipped, or if compressor shaft is seized/broken. 15. Locate with scan tool. Test with multimeter and replace as needed. 16. Check battery voltage and generator output. Repair or replace parts as needed if voltage is below 10, or above 16. 17. Replace pump.
14. Turbocharger inoperative or no boost.
15. Sensor failure (coolant or air temp, baro or boost sensors, etc.). 16. PCM signal voltage too low.
17. Injection pump fault.
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PROBLEM Knock-Ping Under Acceleration. 1. 2. POTENTIAL CAUSE Contaminated, incorrect, or low quality fuel. Air leak in fuel delivery system. 1. 2. CORRECTION Drain, ush, and rell fuel system. Inspect injector line fittings. Bleed injectors and tighten any loose fittings. Check all fuel supply lines for leaks. Add coolant. Repair leaks. Check with scan tool and replace as needed. Check and correct as needed. Repair engine as required. Use combustion chamber conditioner to break down carbon. Engine disassembly will be necessary if conditioner is not effective. Drain and rell tanks with correct fuel. Test and replace failed plugs, wires, or relay/ controller. Repair guides, replace seals, or replace rings as needed.
3. 4. 5. 6. 7.
Engine overheat caused by low coolant level. Coolant and/or air temperature sensor fault. Injection pump timing off. Worn valve seals or guides allowing oil into combustion chambers. Carbon buildup on pistons and in chambers as result of substandard fuel, additives, or oil entering chamber past worn rings or through valve guides. Incorrect or substandard fuel. Glow plug fault (white smoke at cold startup). Worn piston rings, valve guides or stem seals (blue smoke) allowing oil into combustion chamber. High oil consumption may also be noted by owner. Overrich mixture (black smoke) caused by stuck injector. Low fuel pump pressure (at pump). Timing advanced (white smoke at cold idle, black smoke under load when hot). Cold advance solenoid or switch fault (white smoke). Substandard fuel.
3. 4. 5. 6. 7.
Black, White, or Blue Smoke at Idle and/or Under Load
1. 2.
1. 2.
3.
3.
4. 5. 6. 7. Rough Idle and/ or Hesitation Under Acceleration 1.
4. 5. 6. 7. 1.
Test and replace any injectors that fail pressure leak test. Replace fuel-lift pump if pressure is below 5.8 psi (40 kPa) at pump. Check and adjust as necessary. Test and replace solenoid/switch as required. Drain and replace fuel.
2. 3. 4. 5.
Air leak in fuel line or injector. Fuel lter cap or tank vent restriction. Injector fault. Intake manifold leak.
2. 3. 4. 5.
Locate and correct leak. Bleed all injectors afterward. Replace cap or vent hose as required. Locate and replace faulty injector. Replace manifold or gaskets as needed.
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3-11
SCAN TOOL DIAGNOSIS

The scan tool is needed for operational testing of electronic components such as the PCM, electronic accelerator pedal potentiometer, and engine sensors. The scan tool is connected to the vehicle electrical system through the diagnostic/data link connector. The connector is a black 16-way connector. It is located under the instrument panel near the steering column. Refer to Section 2 for detailed information on scan tool use.
INJECTOR
FITTING AND LINE
PART OF J29079-125 ADAPTER KIT
NOZZLE PRESSURE GAUGE SHUTOFF VALVE KNOB
Fuel Pump Pressure Test

Fuel pump pressure should be 5.8-8.7 psi (40-60 kPa) at idle. 1. Disconnect fuel line at fuel lter inlet port. 2. Install a tee adapter in fuel line between pump and filter inlet port. 3. 4. 5. 6. Connect test gauge to tee adapter. Gauge should have pressure capacity up to 20 psi (138 kPa). Start and run engine and record fuel pump pressure. If pump pressure is less than 5.8 psi (40 kPa), replace pump and retest pressure. Remove pressure gauge and tee adapter. Reconnect fuel line to filter inlet.
PUMP HANDLE
NOZZLE TESTER J29075-AMG
Diesel Fuel Injector Test

WARNING: Nozzle tester tool J29075-AMG duplicates normal injector operating pressures which can exceed 1700 psi (117 bar). Never place hands or arms near the injector nozzle during the test. The high pressure, nely atomized spray from the nozzle can penetrate esh, destroy tissue, and result in blood poisoning. It is recommended that a clear protective receptacle be positioned around the injector to contain the spray. A receptacle can be fabricated from 3/16 to 1/4 in. clear plastic for test purposes.
The test requires a nozzle tester tool J29075-AMG, injector adapter kit J29079-125, a length of clear plastic 1/8 or 3/16 I.D. tubing, and a drip pan. 1. Locate faulty injector by loosening fuel line tting momentarily at each injector. Faulty injector will not have much affect on engine operation. 2. Remove suspect injector(s) from engine. 3. Install clear plastic tube on fuel drain/return ports on injector. 4. Attach injector to fitting and line on test tool (Figure 3-10). 5. Close shutoff valve on tool (Figure 3-10).
Figure 3-10: Pressure Testing Diesel Fuel Injector

6. 7. 8. Position drip pan under injector. Place protective receptacle or box around injector. Pump test tool handle to fill line, fitting, and injector with test fluid. 9. Test injector nozzle opening pressure as follows: a. Open test tool shutoff valve 1/4 turn. b. Press tool pump handle slowly downward and note pressure where test gauge needle stops. c. Maximum observed pressure represents injector opening pressure. Compare values to Fuel Injection Nozzle table on page 312. d. Replace injector if opening pressure is less than specified. e. Replace injector if it does not have a uniform conical spray pattern. 10. Test injector nozzle leakage as follows: a. Open test tool shutoff valve an additional 1/2 to 1 1/2 turns. b. Press tool pump handle slowly downward until test tool gauge is at 1400 psi (95 bar) and observe injector nozzle tip.
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c.
___________________________________________
A drop of fluid should form and remain on nozzle tip for at least 10 seconds. d. Replace nozzle if fluid falls off tip in less than 10 seconds. 11. Test injector chatter as follows: a. Close test tool shutoff valve. b. Press tool pump handle slowly downward and listen for a chatter like noise. c. If noise is not produced, pump handle faster and check for chatter noise again. d. If injector produces a chatter, or hissing, squealing sound, injector is OK. Noise indicates nozzle needle valve is moving freely and that seat, guide, and pintle are also OK. e. Replace nozzle if it does not produce noise. Lack of noise indicates failure of valve, spring, or seat.
Fuel Injection Nozzle COLOR RING Orange OPENING PRESSURE NEW 6.5L TD 96-99 L65 (VIN Z) 2030-2204 psi 140-152 bar USED 1700-2204 psi 117-152 bar
PART NO.
APPLICATION
(05743223)
Engine Coolant Temperature Sensor Test

The coolant temperature sensor is a thermistor that provides a temperature signal to the PCM (Figure 3-11). The signal is in the form of a voltage that changes according to sensor resistance. At low temperatures, resistance and voltage are both high. As temperature increases, resistance and voltage both decrease. A sensor fault will cause the check engine light to illuminate and the torque converter clutch to apply early. If the sensor fails in a cold mode, it can produce overrich operation and rough idle.
High TemperatureLow Resistance Test

1. 2. Allow engine to cool down. Coolant should be at ambient temperature for test. Connect scan tool, start engine, and note sensor temperature. If indicated temperature is 266 F (130 C) or above, continue test. If indicated temperature agrees with ambient, sensor is OK. Disconnect sensor and note temperature indicated on scan tool: If indicated temperature drops to -22 F (-30 C), sensor has failed and should be replaced. If indicated temperature does not drop, problem is with sensor wiring or connections.
3.
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3-13
Low TemperatureHigh Resistance Test

1. 2. Connect scan tool and start engine. Note indicated temperature: If temperature is normal, problem is with sensor wires and connections. If temperature is at or above 266 F (130 C), continue with test. Disconnect sensor wires and note scan tool reading: If temperature now reads -22 F (-30 C), sensor has failed. If temperature is OK, problem is faulty sensor ground, reference wire shorted to ground, or PCM has fault.
4. 5.
If the solenoid does not activate, perform wiring tests with a DVOM (Figure 3-12). If the wiring tests OK, replace the solenoid.
ENGINE SHUTOFF SOLENOID
F/SOL TO IGNITION SWITCH 20 AMP TO FUEL SOLENOID DRIVER PCM
SOLENOID CONTROL
COOLANT TEMPERATURE SENSOR
Figure 3-12: Engine Shut-Off Solenoid Circuit

PCM
Engine Shut-Off Solenoid Replacement

Removal
1. Disconnect the electrical connector from the ESO solenoid (Figure 3-13).
NOTE: Remove any debris from the ESO mounting surface on the injection pump before servicing the ESO solenoid. This will prevent contaminants from getting into and damaging the injection pump. 2. Remove the solenoid (style may vary) and O-ring from the injection pump housing.
Figure 3-11: Coolant Temperature Sensor Circuit
Baro Sensor
The baro sensor on turbo diesel models is used to send a barometric pressure signal to the PCM. The signal is in the form of a voltage that is interpreted by the PCM. The sensor signal is to adjust fuel metering and timing at different altitudes. The scan tool is used for baro sensor testing.
ESO SOLENOID TO HARNESS CONNECTION
Engine Shut-Off Solenoid Test

A shut-off solenoid failure can result in run-on, or a no start condition. The failure may be with the solenoid, or with the related wiring (Figure 3-12). 1. Connect the scan tool. 2. Select Miscellaneous Tests, Engine Outputs, Injection Pump, then Engine Shutoff. 3. Use the arrow keys to toggle the solenoid Off/On and listen for the solenoid to activate or click.
INJECTION PUMP
Figure 3-13: ESO Solenoid Replacement
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Installation
3. 4. 5. 6. Install the O-ring seal above the threads at the bottom of the new solenoid (Figure 3-14). Install the replacement solenoid into the injector pump housing and torque to 19 lb-ft (25 Nm). Connect the electrical connector to the ESO solenoid. Start the engine and check for leaks.
WIRE HARNESS
PCM determine pump advance or retard requirements and fuel flow. The sensor is located at the top of the injection pump adjacent to the fuel shut-off solenoid. A fault in the optical sensor or related wiring will produce fast idle and performance problems. A problem will cause a high resolution circuit fault, or a cam reference pulse error fault. The sensor can be checked with a scan tool and a voltmeter as follows:
High Resolution Fault Test

1. 2. 3. 4. Turn ignition off. Disconnect sensor harness connector. Turn ignition on. Connect voltmeter to sensor terminal A, of the harness, and to ground (Figure ). If meter indicates 5 volts, continue with test. If meter indicates zero voltage, look for open/short in wire to PCM 5 volt reference terminal, connector, or PCM. Connect volt/ohmmeter to a good engine ground and to sensor ground terminal D: If resistance is .2 W or less, proceed to next test step. If resistance is greater than .2 W, problem is with ground wire, connector, or sensor.
5.
O-RING
Fuel Solenoid and Solenoid Driver

The solenoid and driver provide the fuel injection metering to the individual injectors. The driver receives the PCM command and transmits it to the solenoid which controls the actual injection process. The solenoid driver also returns a pulse width signal back to the PCM. This signal informs the PCM that injection has taken place. The pulse width signal time is in milliseconds. A fault in either component will cause an injection pulse width
Figure 3-14: Two Styles Of Solenoids
Optical/Fuel Temperature Sensor Tests

The optical/fuel temperature sensor supplies three signals to the PCM for fuel control and timing. A high resolution signal helps determine injection timing and fuel control. A pump cam signal provides reference pulses that monitor and help determine injection timing. The fuel temperature signal helps the
Figure 3-15: Optical/Fuel Temperature Sensor Circuit
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3-15
Fuel Solenoid Driver Replacement

Removal
1. 2. Drain the engine coolant and remove the upper radiator hose from the thermostat housing. Remove the left intake manifold runner to gain access to the Fuel Solenoid Driver (on the left side of the injection pump). Refer to Section 2 (Engine) for all model years. Scribe a reference mark on the engine front cover and the injection pump housing to assist in correctly locating the Injection Pump during reassembly. Loosen the Injection Pump retaining nuts approximately 1/2 turn, using Injection Pump Timing Wrench J41711 (do not remove the nuts). Rotate the Injection Pump toward the passenger side of the vehicle until it stops, using Injection Pump Adjusting tool J 33042, and re-tighten the top Injection Pump retaining nut. Disconnect the wiring connector at the Fuel Solenoid Driver (Figure 3-16).
FUEL SOLENOID DRIVER WIRE CONNECTOR INDEX NOTCH
3.
ID NO.
4
4.
REMOVAL HOLES
5.
8-P03-002
6.
Figure 3-17: Calibrating Resister Transfer
Installation
1. 2. Install the calibrating resistor in the new Fuel Solenoid Driver using the special pliers (Figure 3-17). Place the new heat transfer pad on the side of the Fuel Solenoid Driver and insert the mounting screws through the driver and the pad. Align the Fuel Solenoid Driver mounting screws with the holes in the pump housing and tighten to 23 lb-in (2.75 Nm).
3.
Figure 3-16: Fuel Solenoid Driver Replacement

7. Loosen the four Fuel Solenoid Driver mounting screws untill they are free of the injection pump housing, using a T 15 Torx bit. Remove the mounting screws, Fuel Solenoid Driver and the heat transfer pad from the Injection Pump. Discard the heat transfer pad and the mounting screws. Remove the calibrating resistor (Figure 3-17) from the Fuel Solenoid Driver using special pliers (Klein D319B or Stanadyne 30858).
CAUTION: Do not install the Fuel Solenoid Driver without the heat transfer pad. Do not reuse a heat transfer pad. Use a new heat transfer pad only. The heat transfer pad is required to prevent overheating and rapid failure of the Fuel Solenoid Driver. CAUTION: Do not overtighten the Fuel Solenoid Driver mounting screws. Damage to the Fuel Solenoid Driver will result. 4. 5. 6. Connect the Fuel Solenoid Driver wiring harness connector. Loosen the upper Injection Pump retaining nut approximately 1/2 turn (do not remove the nut). Rotate the Injection Pump back to its original position, using the reference marks made previously and tighten the Injection Pump retaining nuts. Install the intake manifold runner. Connect the upper radiator hose to the thermostat housing and fill the coolant system. Perform the Injection Timing Adjustment Procedure below.
8.
9.
CAUTION: The Calibrating Resistor is specific to the injection pump. Do not damage the resistor. The calibrating resistor identification number is located on the front of the Calibrating Resistor (Figure 3-17). CAUTION: If the Calibrating Resistor is damaged or lost, the Injection Pump must be removed for replacement or taken to a Stanadyne dealer for calibration. If the Calibrating Resistor is missing a DTC P1218 will set.
7. 8. 9.
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___________________________________________
Injection Timing Stepper Motor

The stepper motor is used to advance or retard timing of the electronic injection pump. The motor is controlled by the PCM and is actuated by input signals primarily from the coolant, air, and fuel temperature sensors. A stepper motor fault will affect desired and measured injection timing degree readings on the scan tool. A difference of 5 or more between the readings indicates a motor fault.
TORX SCREWS STEPPER MOTOR INJECTION PUMP
Stepper Motor Test

1. 2. 3. Connect the scan tool to the diagnostic/data link connector. Start and run the engine until it reaches the normal operating temperature. Note injection timing readings on the scan tool. If desired and actual injection timing readings differ by 5 or more, continue the test. If readings are no more than 3-4 apart, but a trouble code was set, the problem is intermitent and probably caused by a bad connection between the PCM and the motor. Stop the engine and turn ignition to Off. Check the resistance between terminals A7 and A8 of the brown 24 pin PCM harness connector (C29) for coil 1 low (A8), and coil 1 high (A7) (Figure 3-19). If the resistance is between 10 and 50 ohms, continue test. If the resistance is not within the specified range, the problem is an open wire, a bad connection, or a failed stepper motor. Check the resistance between terminals A9 and A10 of the brown 24 pin PCM harness connector (C29) coil 2 low (A9), and coil 2 high (A10) (Figure 3-19). If the resistance is 10-50 ohms, the problem is in the PCM connection, or the PCM. If the resistance is other than specified, the problem is in the wires to the PCM coil 2 terminals, a bad connection, or the PCM has a fault.
STA NA DY NE
NE DY NA STA
SPRING
8-P03-001.4
ACTUATOR ARM
Figure 3-18: Stepper Motor Replacement
4. 5.
Installation
3. Place the stepper motor on the injection pump while aligning the notch in the actuating arm with the spring on the pump. Install the two torx screws and torque to 40 lb-in (4.5 Nm). Connect the wire connection to the stepper motor.
4. 5.
6.
INJECTION TIMING STEPPER MOTOR (ITS)
M
MOTOR HARNESS CONNECTOR
D A B C
Stepper Motor Replacement

709 RED
A3 708 TAN
A2 710 ORG
A6 711 YEL A10
A7
D C B A
Removal
1. 2. Disconnect the wire connector at the stepper motor. Remove the two torx screws retaining the stepper motor, disconnect the actuator arm from the spring and remove the stepper motor from the injection pump (Figure 3-18).
C29
A7
A8
ITS LO
A9
ITS LO
LEGEND
ITS HI
ITS HI
9-S03-003
Figure 3-19: Injection Timing Stepper Motor Circuit
___________________________________________
3-17
Crankshaft Position Sensor

The crankshaft position sensor is a Hall-effect device that monitors crankshaft position and rpm. Four reference teeth 90 apart, on the crankshaft timing sprocket cause the devise to turn ON or OFF producing a digital signal. This occurs as each tooth passes near the sensor magnetic field turning the sensor ON. The sensor transmits information to the PCM in the form of a 5 volt digital signal. A sensor fault will cause a crank reference missed reading to occur. The scan tool will display the number of reference pulses missed. Normal reading is zero. If a sensor fault occurs, check the sensor wiring and connectors for shorts, opens, grounds, or loose connectors (Figure 3-20).
Sensor Test
1. 2. Disconnect wires at fuel shut-off solenoid. Connect voltmeter between PCM terminal BRA5 and ground and crank engine. If meter indicates 5 volts, sensor is OK. If meter indicates less than 5 volts or zero volts, check 5 volt reference at PCM terminal BRD13. If 5 volt reference is OK, problem is bad connection or failed sensor.
Boost Sensor
The PCM supplies the boost sensor with a 5 volt reference signal (Figure 3-21). Changes in intake manifold pressure will cause a change in boost sensor resistance values and voltage. The PCM determines turbocharger boost by comparing changing sensor voltage to the original reference voltage. A sensor failure will result in loss of turbocharger boost and consequent power decrease. Trouble code P0237 or P0238 will be set.
Figure 3-20: Crankshaft Position Sensor Circuit
Figure 3-21: Boost Sensor Circuit

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Boost Sensor Circuit Test

1. 2. 3. Connect scan tool to diagnostic/data link connector. Start and run engine at idle speed. Record boost sensor voltage. If voltage is 4.0 volts or more, continue test. If voltage is less than specified, compare sensor to known good one. Voltage should not vary by more than plus or minus 0.4 volt. If sensor voltage compares favorably with known good sensor, problem is in wiring or connections. Turn ignition off and disconnect boost sensor wires. Turn ignition switch back on (engine off), and note scan tool voltage reading. If boost voltage is 1 volt or less, continue test. If voltage is less than specified, problem is in wiring or connections between sensor and PCM. Connect 12 volt test lamp between sensor terminal C and battery positive post. If lamp illuminates, problem is with sensor, connectors, or fitting. If lamp does not illuminate, problem is open wire.
Boost pressure readings are opposite what you would read for vacuum. For example, as throttle opening increases, sensor pressure readings will also increase. Vacuum readings on the other hand, will decrease as throttle opening increases.
Electronic Accelerator Pedal Tests

The pedal module contains three potentiometer-type sensors that provide voltage signals to the PCM. Each potentiometer is scaled differently to provide varying voltage signals. The PCM compares the voltage variance between them to determine throttle position (Figure 3-22). A fault in only one of the potentiometer sensors will not cause a trouble code to set. Two or more sensors must develop a fault before the check throttle light will illuminate. A fault in two sensors will cause the warning light to illuminate and engine power will be limited by the PCM. A fault in all three sensors, will cause the PCM to illuminate the light and limit engine speed idle rpm only. Trouble codes will set under the following circumstances: Two sensors generate voltage of 4.75 volts or more for a minimum of two seconds. Two sensors generate a voltage of 0.25 volts or less for a minimum of two seconds. Voltage difference between sensors 1 and 2 of 6% or more. Voltage difference of 10% or more, between sensors 1, 2, and 3. Fault in all three sensors (above or below normal signal voltage). The Tech 1 scan tool is required for accurate sensor diagnosis. However, the sensor circuit wires can be tested for shorts, opens, grounds with 12 volt test lamp and/or multimeter.
4. 5.
6.
Boost Sensor Performance Check

This check requires the scan tool to be connected, the engine running at curb idle rpm, and the transmission in Park. At idle or at closed throttle decel, a properly functioning sensor will indicate a pressure reading about the same as barometric pressure. Sensor voltage (if any), should be low. Sensor pressure readings should increase as throttle opening is increased. Voltage readings should also increase.
Figure 3-22: Electronic Accelerator Pedal Module Circuitry
___________________________________________
3-19
AIR CLEANER SERVICE

Removal
NOTE: To remove dust unloader only, perform steps 1 and 2. 1. 2. 3. 4. 5. 6. 7. 8. Remove air cleaner (Figure 3-23). Loosen clamp and remove dust unloader from air cleaner assembly. Loosen clamp and disconnect elbow from engine side of air cleaner assembly. Disconnect vent line from fitting. Loosen clamp and remove weathercap from air intake duct. Remove three capscrews and washers from air intake duct. Loosen three strap clamps around air cleaner assembly.
Installation
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install tube, adapter, and tting on air cleaner assembly (Figure 3-23). Install dust unloader on air cleaner. Tighten clamp to 4453 lb-in. (5-6 Nm). Install elbow and clamp on air cleaner. Do not tighten clamp at this time. Position air cleaner assembly on air intake support and align elbow with top of support. Align air cleaner and tighten clamp on elbow to 44-53 lbin. (5-6 Nm). Position air cleaner and strap clamps on support brackets. Then rotate until elbow clears air intake support. Install air intake duct and clamp on elbow. Align bolt holes of air intake duct with holes of air intake support. Install air intake duct on air intake support. Tighten clamp to 45-53 lb-in. (5-6 Nm). Install air cleaner assembly on support brackets and tighten strap clamps. Connect inlet hose to air horn and air cleaner. Connect vent line to fitting on air cleaner. Install weathercap on air intake duct and tighten clamp to 45-53 lb-in. (5-6 Nm). Install air cleaner shield. Install hood seal on air intake support (if removed).
Raise air intake duct from air intake support. Loosen clamp and remove air intake duct and gasket from elbow and support. Discard gasket. 9. Remove air cleaner assembly. 10. Remove clamps from air cleaner assembly. 11. Remove fitting, adapter, and tube from air cleaner assembly. 12. Remove seal from air intake support.

Replace air filter if plugged or saturated with dirt. Clean hose and dust unloader with shop towels. Clean other components with solvent and examine for wear or damage. Replace worn, damaged parts if necessary.
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WEATHERCAP
AIR INTAKE DUCT HOOD SEAL
VENT LINE GASKET AIR HORN
AIR CLEANER ASSEMBLY
AIR INTAKE SUPPORT
AIR INDUCTION HOSE
DUST UNLOADER SEAL
ELBOW AIR CLEANER ASSEMBLY
VENT FITTING ADAPTER TUBE AIR CLEANER SHIELD
Figure 3-23: Air Cleaner Assembly and Dust Unloader
___________________________________________
3-21
Air Cleaner Filter Element Service

Removal
1. 2. Remove ring clamp, cover, and gasket from air cleaner (Figure 3-24). Remove nut and washer assembly and filter element from air cleaner stud.
AIR CLEANER
AIR HORN
Removal
1. Loosen clamp and remove air induction hose from air horn (Figure 3-25).
CTIS AIR INLET ELBOW TUBRO CHARGER INLET HOSE
FILTER ELEMENT RING CLAMP GASKET CDR HOSE
AIR CLEANER STUD COVER
Figure 3-24: Air Cleaner Filter Element Removal/Installation
AIR INDUCTION HOSE

9-S03-002
Inspection
1. 2. 3. Clean components with compressed air, examine for wear or damage, and replace if necessary. Remove dust or sand by gently tapping around filter element. Remove dirt and dust from filter element by directing flow of compressed air from inside to outside of filter element.
Figure 3-25: Air Horn Mounting

2. 3. 4. 5. Remove CTIS air inlet hose and elbow from air horn. Loosen clamps that secure the air horn to the CDR valve and turbo charger inlet hose. Remove air horn. Cover turbo charger opening to prevent dirt entry.
Installation
1. Slide lter element onto air cleaner stud and install nut and washer. Tighten nut and washer to 18-35 lb-in. (2-4 Nm) (Figure 3-24).
Installation
1. 2. 3. 4. 5. Connect air induction hose to air horn (Figure 3-25). Connect air horn to turbo inlet. Tighten clamp to 44 lb-in (5 Nm). Tighten air induction clamp to air horn. Tighten clamp to 44-53 lb-in (5-6 Nm). Connect CDR hose to CDR tube on air horn. Tighten to 44 lb-in (5 Nm). Apply sealant to CTIS air inlet elbow and install into coupling on air horn. Tighten hose clamp.
NOTE: To avoid damage to hood, ensure ring clamp bolt is between the three and six oclock positions. 2. Install gasket, cover, and ring clamp on air cleaner assembly. Tighten ring clamp bolt to 27-35 lb-in. (3-4 Nm).
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Air Induction Hose Replacement

Removal
1. 2. Loosen induction hose clamps. Remove hose from air horn and air cleaner (Figure 3-26).
AIR HORN
WEATHERCAP REPLACEMENT
Removal
Remove clamp and weathercap from air intake duct (Figure 3-27).
WEATHERCAP
AIR INTAKE DUCT
AIR INDUCTION HOSE
S03-007
Figure 3-27: Weathercap Mounting
Installation
Figure 3-26: Air Induction Hose Attachment
Installation
1. 2. Install induction hose on air horn and air cleaner. Tighten hose clamps to 44 lb-in. (5 Nm) (Figure 3-26).
Install weathercap on air intake duct. Tighten clamp to 44-53 lb-in. (5-6 Nm).
FUEL TANK DRAINING

The fuel tank should only be drained with portable air powered drain equipment. This type of equipment is OSHA approved and will drain the tank through the filler neck. The tank should be drained prior to removal. Follow the drain equipment manufacturers instructions explicitly.
FILLER HOUSING
FUEL TANK FILLER CAP
Figure 3-28: Fuel Tank Filler Cap
___________________________________________
3-23
DRAINAGE BRACKET REPLACEMENT

Removal
1. 2. Remove air cleaner assembly. Remove three screws and drainage bracket from body (Figure 3-29).
DRAINAGE BRACKET AIR INTAKE SUPPORT
AIR INTAKE VENT LINE REPLACEMENT

Removal
Remove air intake vent line from tee fitting and air cleaner fitting (Figures 3-27 and 3-29)
.
AIR INTAKE VENT LINE
TEE FITTING
Figure 3-30: Air Intake Vent Line Routing
Installation
Install air intake vent line on tee fitting and air cleaner fitting (Figures 3-27 and 3-29)
.
Figure 3-29: Drainage Bracket Location
VENT LINE FITTING
Installation
1. 2. Position drainage bracket on body and install bracket screws (Figure 3-29). Install air cleaner assembly.
AIR INTAKE VENT LINE
Figure 3-31: Air Cleaner Vent Line Fitting Location

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MAIN FUEL TANK

Removal
1. 2. 3. 4. 5. 6. Drain tank with recommended equipment. Remove bolts attaching fuel filler housing to body. Remove vapor canister shield and bracket. Then disconnect tank vent lines, and hoses at branch tee in fuel filler housing. Remove clamps attaching filler tube to vent line or body. Disconnect filler housing ground strap. Loosen clamps securing connecting hose to filler tube and housing (Figure 3-32).
FUEL TANK SUPPORT STRAP STRAP BRACKET UPPER STRAP
LOWER STRAP
LOWER STRAP FILLER TUBE HOUSING CLAMP
Figure 3-32: Filler Tube-to-Tank Attachment

7. 8. 9. 10. Remove fuel filler housing and filler neck. Raise vehicle. Remove rear propeller shaft. Rotate rear axle yoke to a vertical position. Tank may not clear yoke otherwise. 11. Support tank with transmission jack or other suitable support device. 12. Remove bolts and nuts attaching front and rear upper straps to lower straps (Figure 3-33).
Figure 3-33: Fuel Tank Mounting Strap Attachment 13. Disconnect vent lines at fuel tank. 14. Lower tank enough for access to transmitter wires and fuel lines. 15. Disconnect transmitter wires. 16. Disconnect but do not remove rollover valve line. 17. Lower and remove fuel tank.
___________________________________________
3-25
Fuel Level Transmitter/Pump/Vents/ Access Plate Replacement

The fuel level transmitter, vents, and access plate can all be serviced once the tank is out of the vehicle (Figure 3-34). If the fuel tank requires replacement, be sure to replace all necessary gaskets, O-rings, seals, and strainer with new parts. Coat fitting threads with Loctite PST before installation.
Tank Cleaning
In cases where the tank was removed for correction of contamination, remove the transmitter, fuel pump, and access plate for maximum access. Use a soap and water solution and low pressure steam gun. Be sure to clean out the fuel supply and return lines as well. The tank can be dried with compressed air or allowed to air dry as desired.
FUEL LINE SUPPORT BRACKET
FUEL TANK ACCESS PLATE
FUEL LEVEL TRANSMITTER
GASKET FUEL STRAINER TANK JUMPER HARNESS
VENT LINE FITTING
ACCESS PLATE GASKET
SPACER
INNER REAR STRAP AND INSULATOR
OUTER REAR STRAP
SHIELD INSULATORS SPACER
VENT FITTING
BOTTOM STRAP O-RING (12) MAIN FUEL TANK PLUG ACCESS PLATE RETAINER OUTER FRONT STRAP BOTTOM FRONT STRAP SHIELD INSULATOR INNER FRONT STRAP AND INSULATOR
Figure 3-34: Fuel Tank and Components

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Main Fuel Tank Installation

NOTE: If tank was replaced, or if transmitter, pump, fitting, or access plate was replaced, verify that components are properly seated and secured. Refer to Fuel Level Transmitter and Tank Access Plate Service procedure in this section. 1. 2. Position tank on jack and raise tank just enough to permit installation of wires and lines. Connect fuel lines as follows: a. Push lines onto tank supply and return tubes. Note that fuel supply tube is larger in diameter than the return tube. b. Push line onto tank tube until it snaps or clicks into place. c. Pull on lines to verify secure attachment. Connect wiring and vent lines. Also connect rollover valve line. Install filler neck-to-tank hose on fuel tank. Secure hose with new clamp if required. Position tank and install bolts and nuts that attach tank upper to lower retaining straps. Tighten strap bolts to 2327 lb-in. (3 Nm) torque.
AUXILIARY FUEL TANK

Removal
1. 2. 3. 4. 5. Drain auxiliary fuel tank. Drain tank with air powered portable drain equipment. Remove tank filler neck housing from wheel house. Remove bolts attaching auxiliary tank fuel filler neck and housing to body. Disconnect filler neck at tank and vent line at housing. Support auxiliary tank with floor jack positioned under tank skid plate.
NOTE: Do not loosen or remove the bolts attaching the tank to the skid plate. The tank and skid plate will be removed as an assembly. 6. 7. Remove bolts and nuts attaching tank skid plate to left and right frame brackets and rear crossmember. Lower tank enough to reach fuel lines. Then disconnect fuel lines, fuel level transmitter wires, and vent line. Mark lines and wires for assembly reference.
3. 4. 5.
NOTE: If the upper and lower straps touch after bolt tightening, replace the straps. They are stretched or distorted and will not adequately secure the tank. 6. 7. 8. 9. 10. 11. 12. Install propeller shaft. Connect tank vent lines. Lower vehicle Install filler neck and connect ground strap. Install filler neck housing and connect vent line. Refill tank. Start engine and verify proper operation. Repair any leaks if necessary.
NOTE: The fuel supply and return lines are equipped with quick connect fittings. To disconnect, first lift and remove the fitting retainer from each fitting. Then pull the fittings free of the tank fuel tubes. 8. 9. Lower the jack and remove the tank from under the vehicle. Replace fuel level transmitter and access plate (Figure 3-34). Refer to next procedure in this section.
Installation
1. If new tank is being installed, transfer tank skid plate to new tank. 2. Place tank on floor jack and position it under vehicle. 3. Raise tank enough to reach feed lines. 4. Attach vent line and fuel level transmitter wires. 5. Connect fuel lines. Push each line onto tank tube. Secure lines with retainers. Be sure retainers are firmly seated in line fittings. 6. Raise and align tank skid plate with frame brackets and rear crossmember. 7. Install tank attaching bolts and nuts and tighten securely. 8. Install filler tube housing and fuel filler cap. 9. Install filler tube shield in wheelhouse. 10. Refill fuel tank. 11. Verify tank operation and fuel level reading.
___________________________________________
3-27
TANK ACCESS PLATE
FUEL LEVEL TRANSMITTER
GASKET FUEL STRAINER ACCESS PLATE GASKET JUMPER HARNESS
ROLLOVER VALVE AUXILIARY FUEL TANK
O-RING (8)
ACCESS PLATE RETAINER SKID PLATE
FRAME MOUNTING BRACKETS
Figure 3-35: Auxiliary Fuel Tank Components
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FUEL LEVEL TRANSMITTER AND TANK ACCESS PLATE SERVICE

Removal
1. Remove screws, lockwashers and fuel level transmitter from tank access plate (Figures 3-34 and 3-35). 2. Remove locknuts, washers, access plate and gasket from tank. 3. Remove access plate retainer and O-rings from tank. Discard O-rings. Check fuel level transmitter operation as follows: 1. Hold transmitter in the upright or empty position (Figure 3-36). 2. Using an ohmmeter, check resistance value at terminals. Resistance should be 268 20W. 3. Hold transmitter in the inverted position simulating a full tank. Resistance should fall to 19.3 8W.
SCREW LOCKWASHER FLATWASHER
6. 7. 8.
Apply liquid teflon thread sealant to transmitter mounting screws. Secure gasket and transmitter to access plate using same method as indicated for access plate above. Cap all tank fittings and perform leak check. Apply leak check solution or soapy water around access plate and transmitter gaskets and fasteners. Pump 3 p.s.i. of compressed air into tank and verify absence of leaks.
Quick Connect Fittings

Quick connect fittings are used at the main tank fuel tubes, auxiliary tank fuel tubes, and at the fuel tank selector valve. Two types of fittings are used. One type is an all plastic push on style with removable retainer. The second style is a metal, one-piece fitting with an internal tension clip to retain it. The plastic fitting retainer only requires a screwdriver and needlenose pliers to remove. The metal fitting requires a release tool, such as J37088-A, in order to disconnect it. The metal fittings are used at the main tank. The plastic, twopiece fittings are used at the auxiliary tank and fuel selector valve.
Metal Fittings
1. To disconnect, slide the release tool onto the line and into the tting. Press the tool inward to unseat the internal clip and pull the line off the fuel tube. To reconnect, just push the fitting onto the line until it snaps or clicks into place. Pull on the fitting afterward to verify proper seating.
TRANSMITTER
2. 3. 4.
GASKET
Plastic Fittings
1. 2. To disconnect, raise the retainer tab with a small at blade screwdriver and remove the retainer with needlenose pliers. To reconnect, push the fitting onto the tube, insert the retainer through the fitting sides, and seat it firmly. Be sure the retainer seats behind the fuel tube flange. Pull on the fitting afterward to verify proper seating.
Figure 3-36: Fuel Level Transmitter in Upright or Empty Position
3. 4.
Installation
CAUTION: Do not overtighten access plate or transmitter fasteners. Gasket damage and improper sealing could result. 1. 2. Thoroughly clean all gasket surfaces. Place new O-rings on access plate retainer studs and position access plate retainer in tank (Figures 3-34 and 3-35). Set gasket and access plate over studs and onto tank. Apply liquid teflon thread sealant to studs and loosely install washers and locknuts until no clearance exists between access plate, gasket and tank. Snug access plate locknuts in small increments and in a systematic circular pattern. Tighten locknuts until gasket bulges or until maximum torque of 72 lb-in. is obtained.
3. 4.
5.
___________________________________________

FUEL TANK VENT LINE
3-29
ELBOW
FUEL TANK VENT LINE
FUEL LINES
VENT LINE FILTER
VENT LINE BODY BRACKET
Figure 3-38: Fuel Tank Vent Filter Location

BRACKETS
MAIN OR AUXILIARY TANK FUEL LINE REPLACEMENT (ALL)

Removal
Figure 3-37: Fuel Tank Vent Line Locations (Typical)
1. 2. 3. 4. 5. 6. 7. 8. 9. Drain tank with portable, air powered equipment. Remove main or auxiliary fuel tank as described in this section. Disconnect any electrical wires, linkage parts, cables, or lines as needed if insufficient slack exists. Disconnect fuel lines at main tank tubes. Remove line clamps and tie straps. Disconnect lines at fuel tank selector valve and remove lines. Disconnect supply line at fuel pump. On all models, if front lines are to be replaced, disconnect lines at fuel pump and return fittings. Remove supply and/or return lines as needed (Figure 3-39).
Fuel Tank Vent Line Service

Removal
1. 2. 3. 4. 5. Remove fuel tank. Refer to procedure in this section. Remove clip and fuel tank vent line hose from vent line (Figure 3-37). Remove vent line clamps and disenagage lines. Remove tie strap securing vent line to fuel lines. Discard tie strap. Disconnect fuel tank vent lines at tank fittings.
Installation
1. 2. 3. 4. Connect vent lines to tank tting. Secure vent line to fuel lines with new tie strap (Figure 3-37). Secure vent lines in brackets with clamps and bolts. Install fuel tank. 1. 2. 3. 4. 5. 6. 7. 8.
Installation
Route new lines as needed (Figure 3-39). Be sure lines are not kinked, pinched, or touching hot or rotating parts. Connect front fuel lines to fuel pump and return fitting at injection pump. Then connect lines to fuel selector valve. Secure lines to frame clamps, brackets, P-clips, and tie straps as needed. Connect rear lines to auxiliary or main tank as required. Install main or auxiliary fuel tank as described in this section. Verify that fuel lines are securely connected and properly routed. Refill fuel tank. Check tank operation. Verify proper transmitter operation and selector switch function.
FUEL TANK VENT FILTER REPLACEMENT

The fuel tank vent filter is located just above the surge tank at the passenger side of the engine compartment (Figure 3-37). The filter is serviced as an assembly and should be replaced if restricted or damaged. To replace the filter, remove the filter retaining clamp bolt, pull the filter out of the clamp, and disconnect it from the vent line. Be sure the replacement filter is properly secured in the clamp afterward. Also, use a new vent line clamp if the original is worn, or distorted. 5745159
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FUEL SELECTOR VALVE

The selector valve is used on models equipped with an auxiliary fuel tank (Figure 3-39). The valve is electrically operated by a switch in the passenger compartment. The switch will be mounted on the instrument panel. Valve function is to switch fuel supply from main to auxiliary tank (and back) when needed. Quick connect fittings are used to attach each of the six fuel lines to the valve. The plastic, two-piece style fittings are used. The valve is mounted on a bracket attached to the passenger side frame rail. Valve position is forward of the fuel tank and B-pillar area. The valve is not a serviceable part and must be replaced when diagnosis indicates this is necessary.
Selector Valve Replacement

The valve is accessible from under the vehicle. Disconnect the battery and remove the valve-to-bracket bolts first. Then disconnect the fuel lines one at a time and tag them for reference. Last, disconnect the valve-to-switch harness and remove the valve. Reverse the process to install the valve.
VALVE-TO-PUMP AND INJECTOR LINES
FUEL SELECTOR VALVE TIE STRAP TANK-TO-VALVE LINES
VALVE MOUNTING BRACKET
RETURN LINE (AUXILIARY TANK)
FUEL LINE BRACKET
SUPPLY LINE (AUXILIARY TANK) S-CLIP (TYPICAL)
CLAMP (TYPICAL)
FUEL LINE BRACKET
FUEL LINE BRACKET
Figure 3-39: Fuel Lines, Connections, and Attachment
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3-31
FUEL FILTER SERVICE Fuel Filter Replacement

Removal
1. Loosen the hose clamps securing the CTIS compressor (if equipped) to its mounting bracket and slide the compressor forward to gain access to the fuel lter. Disconnect fuel inlet and outlet hoses from filter (Figure 3-40:). Disconnect drain hose from fuel filter. Disconnect filter harness connectors. Remove filter attaching bolts and remove fuel filter from bracket.
Installation
1. 2. 3. 4. 5. Install fuel lter on bracket and secure with washers and bolts (Figure 3-40:). Connect sensor and fuel heater harnesses to body harness connectors. Connect drain hose to fuel filter. Connect inlet and outlet hoses to fuel filter. Slide the CTIS compressor rearward into place and tighten the hose clamps securing the compressor to the mounting bracket.
2. 3. 4. 5.
Purging Air From Fuel Filter

1. 2. 3. Loosen fuel lter air bleed valve one-half turn (Figure 3-41). Run engine until fuel exits from air valve. Tighten air valve.
ELEMENT RETAINING NUT
Disassembly
1. 2. 3. Remove retaining nut and lter element from header. Remove sensor and O-ring. Loosen cap nut and remove fuel heater, seal, spring, and screen.
Assembly
1. 2. 3. Install screen, spring, cap seal, and fuel heater and tighten cap nut. Install O-ring and sensor. Install filter element and retaining nut.
INLET HOSE FUEL FILTER
AIR BLEED VALVE
FILTER ELEMENT
FILTER HOUSING OUTLET HOSE SENSOR HARNESS SCREEN SENSOR (WATER IN FUEL) O-RING SPRING
DRAIN HOSE FUEL HEATER HARNESS MOUNTING BRACKET
CAP SEAL CAP NUT
FUEL HEATER
Figure 3-40: Fuel Filter Mounting
Figure 3-41: Fuel Filter Components
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Fuel Filter Drain Hose and Valve Replacement

NOTE: To remove fuel filter drain valve only, perform steps 3 and 4.
Removal
1. 2. 3. 4. 5. Disconnect fuel lter drain hose from fuel lter (Figure 3-42). Remove two tie straps and separate drain hose from transmission oil cooler lines. Remove two tie straps and separate drain hose from transmission oil cooler lines. Disconnect drain hose at drain valve. Remove nut and drain valve from body
Installation
1. 2. 3. 4. 5. Install drain valve on body and tighten nut. Connect drain hose to valve. Connect drain hose to fuel filter. Secure drain hose to transmission oil cooler lines with two tie straps. Start engine and check for leaks.
FUEL FILTER FUEL FILTER DRAIN HOSE
BODY
DRAIN VALVE
TIE STRAPS TRANSMISSION OIL COOLER LINES
Figure 3-42: Fuel Filter Drain Hose And Valve Location
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3-33
FUEL LIFT PUMP SERVICE Fuel Lift Pump Replacement

Removal
1. 2. 3. 4. Disconnect fuel pump wiring harness (Figure 3-43). Disconnect fuel pump hoses. Loosen clamp and remove pump. Remove adapters and O-rings from fuel pump. Discard Orings.
Fuel Tank-To-Filler Neck Hose Replacement

Removal
1. 2. 3. 4. Drain fuel tank. Remove filler tube housing bolts. Disconnect filler tube vent hose. Loosen clamps and remove hose from tank and filler (Figure 3-44).
BRACKET FUEL PUMP TANK INLET TUBE WIRING HARNESS FILLER TUBE
HOSE
FILLER TUBE -TOTANK HOSE
Figure 3-44: Filler Tube-To-Tank Attachment
Installation
1. 2. 3.
ADAPTER
00-S13-003
Install hose on tank and ller tube and tighten hose clamps. Install filler tube and housing. Fill fuel tank and check for leaks.
O-RING
ADAPTER HOSE
CONNECTOR
Figure 3-43: Fuel Pump Attachment
Installation
1. 2. 3. 4. 5. Install O-rings and adapters on fuel pump (Figure 3-43). Use new O-rings. Install fuel pump in clamp and tighten clamp securely. Connect hoses to fuel pump. Connect wiring harness to pump. Start engine and check fuel pump and hoses for leaks.
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Diesel Injection Pump Fuel Hose or Tube Replacement

Removal
1. 2. 3. 4. 5. Remove supply hose. Remove return hose from injection pump and tube (Figure 3-45). Remove tube-to-injector hose. Remove injector connecting hoses (Figure 3-46). Remove nozzle cap from rear nozzle nipple.
Installation
1. 2. 3. 4. 5. 6. Install cap on rear injector nipple (Figure 3-46). Install injector connecting hose. Install tube-to-injector hose (Figure 3-45). Install fuel return hoses on tube and injection pump. Install supply hose. Start engine and check for fuel leaks.
DRAIN RETURN HOSE
SUPPLY HOSE INJECTION PUMP
RETURN TUBE INJECTOR RETURN HOSE
RETURN HOSES
Figure 3-45: Diesel Fuel Injection Return Hose and Tube Routing
NIPPLE INJECTORS
CAP
CONNECTING HOSE (TYPICAL)
Figure 3-46: Injector-To- Injector Return Hose Connection
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3-35
GLOW PLUG SERVICE Glow Plug Tip Removal (Damaged or Broken)

1. 2. 3. Remove fuel injector from necessary cylinder. Using torsional damper bolt (Figure 3-47),rotate crankshaft to bring affected piston to TDC position. Using pliers, reach through injector nozzle port (Figure 3-48), break off expanded tip, and remove from prechamber. Remove glow plug.
INJECTOR PORT
4.
GLOW PLUG PORT
Figure 3-48: Glow Plug and Injector Port Locations
Glow Plug Replacement

Removal
1. 2. Disconnect wire from glow plug with tool J39083. Remove glow plug from cylinder head (Figure 3-49).
TORSIONAL DAMPER BOLT
Figure 3-47: Torsional Damper Bolt Location

5. Direct stream of low-pressure compressed air into glow plug port. This will expel any remaining pieces of broken tip through injector port.
WIRE
NOTE: If the preceding methods fail to remove glow plug tip remains from the prechamber, the cylinder head must be removed to clear the broken pieces. 6. 7. Install new glow plug. Install fuel injector.
GLOW PLUG
Figure 3-49:
Glow Plug Removal/Installation
Installation
1. 2. Install glow plug in cylinder head. Tighten plug to 8-12 lbft (11-16 Nm) torque. Connect wire to glow plug.
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DIESEL FUEL INJECTION SYSTEM Diesel Injection Line Bracket And Clamp
Removal
1. 2. 3. 4. 5. Remove console and engine covers. Remove air horn. Remove bracket (Figure 3-50). Remove bracket from valve cover studs. Remove line clamps if necessary.
LINE CLAMP INJECTOR LINE BRACKET
Installation
1. 2. 3. 4. Install clamps on lines if removed. Install bracket on valve cover studs (Figure 3-51). Tighten bracket nuts to 13-20 lb-ft (18-27 Nm). Install air horn. Install console and engine cover.
INJECTOR LINE BRACKET
LINE CLAMP OIL DIPSTICK TUBE
VALVE COVER STUDS
Figure 3-51: Injection Line Bracket Removal/ Installation (Driver-Side)

VALVE COVER STUDS
Figure 3-50: Injection Line Bracket Removal/ Installation
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INJECTOR GASKET INJECTOR LINES
3-37
Fuel Injector Replacement

Removal
1. If removing rear injector, remove console and engine cover. Remove fuel return hose and cap from injector (Figure 3-52). Disconnect fuel return hoses from necessary injector (Figure 3-53). Remove clamp, and fuel injector line bracket and clamp. Disconnect fuel line at injector (Figure 3-53). Using socket J29873, remove injector and gasket from cylinder head.
CAP REAR INJECTOR FUEL INJECTOR
2. 3. 4. 5.
Figure 3-53: Fuel Injector and Gasket Removal/ Installation
Injection Line Replacement

Removal
FUEL RETURN HOSE
1. 2.
Remove injection pump boot. Disconnect injection lines at injectors (Figure 3-54).
INJECTION PUMP INJECTOR LINES CLAMP
Figure 3-52: Rear Injector Fuel Cap Location
Installation
1. 2. 3. 4. 5. 6. 7. 8. Apply antiseize compound to threads of new injector. Install gasket and fuel injector in cylinder head. Tighten injector to 44-60 lb-ft (60-81 Nm). Connect fuel line to injector. Tighten fuel line to 20 lb-ft (27 Nm). Install injection line bracket and clamp. Install fuel drain hose and cap. Connect drain hoses to injectors. Start engine and bleed injectors. Install console and cover.
FUEL INJECTORS
Figure 3-54: Fuel Injection Line Routing (Typical)

3. Remove injection line brackets.
NOTE: Tag fuel injection lines by cylinder number for installation reference. 4. 5. 5745159 Disconnect injection lines at pump. Remove fuel line clamps.
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Installation
1. 2. 3. Install clamps on injection lines (Figure 3-54). Connect injection lines to pump (Figure 3-55). Connect lines to injectors.
Service
The turbo diesel electronic injection pump is not serviceable. Only the pump solenoids, sensors, gaskets, and drive gears are serviceable. The pump should be replaced as an assembly if an internal fault occurs.
FRONT COVER PUMP DRIVEN GEAR PUMP DRIVE GEAR INJECTION PUMP
CYL. NO. 8 CYL. NO. 1 CYL. NO. 3
CYL. NO. 7 CYL. NO. 2 CYL. NO. 6 CYL. NO. 5
CYL. NO. 4
Figure 3-55: Fuel Injection Pump Line Connection

4. 5. 6. 7. 8. Tighten injection line nuts to 20 lb-ft (27 Nm). Install injection line brackets. Install intake manifold. Start and run engine. Bleed all injectors.
Figure 3-56: Fuel Injection Pump
Installation
1. 2. Install gasket and fuel injection pump on timing gear cover (Figure 3-57) Align pin on pump drive shaft with elongated hole in pump driven gear. Align timing marks on injection pump and front cover. Tighten injection pump attaching nuts. Align and install pump driven gear. Tighten gear attaching bolts to 13-20 lb-ft (18-27 Nm). Install hose adapter on injection pump if equipped. Install accelerator cable and bracket. Connect throttle return spring to throttle shaft lever and accelerator cable mounting bracket. Connect fuel line to pump. Install TPS. Connect fuel lines to injectors. Install injector line clamps and brackets. Install engine oil filler tube. Install fuel injector lines. Install fast idle solenoid and mounting bracket, if equipped. Adjust accelerator linkage on NA diesel models. Connect fuel return hose. Connect solenoid and sensor wires. Reprogram TDC offset.
Fuel Injection Pump

Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove engine oil ller neck and cap. Disconnect intake hoses at intake manifold. Disconnect fuel lines at injectors. Then remove fuel line clamps. Remove clip attaching accelerator cable to pump lever. Disconnect all solenoid and harness wires at injection pump. Remove throttle position sensor. Disconnect fuel hoses at injection pump. Disconnect injector fuel lines at pump. Tag lines for assembly reference if desired. Remove throttle return spring from throttle shaft lever. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: Rotate engine to gain access to driven gear-to-injection pump capscrews through oil filler tube opening 10. Remove bolts attaching pump driven gear. 11. Remove nuts and washers, attaching pump and gasket to timing gear cover. 12. Remove pump (Figure 3-56).
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3-39
Reprogramming TDC Offset

TDC offset must be reprogrammed whenever the PCM, front cover, timing gears, timing chain, crankshaft position sensor, or other components affecting timing are replaced. The procedure for reprogramming TDC offset is as follows: 1. Verify that vehicle batteries are fully charged. 2. Start and run engine at curb idle speed 3. Continue running engine at curb idle speed until coolant reaches normal operating temperature. 4. Connect Tech 1 scan tool to data link/diagnostic connector. 5. Select FO: OUTPUT TESTS from Miscellaneous Tests menu. 6. 7. 8. Select FO: INJ PUMP. Select TDC OFFSET LEARN>. Press Up Arrow key and PCM will learn engine top dead center offset value. This requires approximately 20 seconds. 9. Correct learned TDC offset value should be between minus 0.25 and minus 0.75. If value is not within specified range, loosen injection pump and rotate it to correct value as follows:
NOTE: The engines should be off before the injection pump is loosened and adjusted. If value is between plus 1.0 and minus 0.25, rotate pump toward driver side to achieve specified value. If value is between minus 0.75 and minus 2.0, rotate pump toward passenger to achieve specified value. NOTE: 1 mm pump movement in either direction results in approximately 2 degrees change.
+1.0
+.5
-.25
-.75
-1.0 -1.5
-2.0
WHEN THE TIMING IS IN THIS REGION, ROTATE PUMP TOWARD DRIVER SIDE TO ACHIEVE TARGET ZONE.
TARGET ZONE
WHEN THE TIMING IS IN THIS REGION, ROTATE PUMP TOWARD PASSENGER SIDE TO ACHIEVE TARGET ZONE
FUEL INJECTION PUMP
GASKET
TIMING GEAR COVER
Figure 3-57: Injection Pump Removal/Installation

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ENGINE TEMPERATURE SENDER REPLACEMENT

1. 2. Remove nut, lockwasher, lead, and sender from engine (Figure 3-58). Apply teflon sealant to sender threads, and install sender, lead, lockwasher, and nut on engine (Figure 3-58).
GLOW PLUG RELAY/CONTROLLER REPLACEMENT

1. 2. 3.
.
Disconnect battery ground cable. Remove console and engine cover. Disconnect power cable at relay/controller (Figure 3-59)
LOCK PIN BOLT POWER CABLE CONNECTOR
CONTROLLER
SENDER
SENDER WIRE
Figure 3-58:
Engine Temperature Sender
00-S12-010
Figure 3-59: Glow Plug Relay/Controller Location

4. 5. 6. Disengage three connectors from glow plug controller. Remove retaining bolt and remove relay. Position relay/controller on bracket and install attaching hardware. 7. Engage connectors in relay/controller. 8. Connect power cable to relay/controller stud. 9. Install engine cover and console. 10. Connect battery ground cable.
SENSOR AND SWITCH SERVICE

The sensors and switches on turbo diesel engines are serviceable parts. The boost pressure switch is on the passenger side valve cover. The coolant temperature switch is in the water crossover. The oil pressure switch is in the valley between the heads. The MAP and air temperature sensors are at the passenger side of the intake manifold.
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FUEL SYSTEM CONTAMINATION Organic Contamination

Diesel fuel systems are susceptible to fungi and other micro-organism infestation when water is present. These fungi can grow into long strings or large globules anywhere in the fuel system. Due to the amount of water, the most prevalent location for fungi is the fuel tank. The growths appear slimy and may be black, green, or brown. They are introduced by refueling with an unfiltered or aged fuel source. Fungi feed on the fuel and need only trace amounts of minerals and water. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is a loss of performance due to fuel filter clogging. Infestation can also show up as corrosion of metal parts such as injectors, fuel pumps, and steel lines.
A quick check on fuel quality can be performed with tool J38641B. NOTE: The fuel quality hydrometer provides a general indication of fuel quality and should not be considered to be scientifically accurate. 1. Drain the fuel lter housing as follows: Stop engine. Place container under drain valve hose at left front side of vehicle. Open drain valve. Start engine and run it at curb idle speed until clear fuel appears at drain valve exit hose. Fill a 1-liter (0.946 quart) container with sample of clean fuel. Close drain valve and stop engine. NOTE: Visually inspect the fuel sample for obvious contaminants such as water or sediment. Check the odor of the sample for the presence of gasoline or other foriegn solvents before testing for specific gravity. 2. Fill hydrometer tool J38641-B with fuel sample as follows: Squeeze hydrometer bulb Immerse hydrometer tip in fuel sample Release bulb and allow fuel to enter glass tube until indicator floats freely. Gently spin hydrometer to relieve surface tension of fuel sample. Read the scale on the glass bulb at the point where the top of the fuel sample contacts it: Reading this scale will indicate an approximate fuel oil specific gravity. Refer to tool instructions on how to determine API specific gravity. Refer to Fuel Oil Specific Gravity Requirements table. If the correct fuel is being used in the conditions listed in Fuel Quality (below) and meets the fuel oil specific gravity requirements for Diesel No. 1 or Diesel No. 2, the fuel is OK. If not, the fuel should be replaced.
WARNING: To avoid personal injury do not come into physical contact with biocide agents, cleaners, or additives used to remove fungi or micro-organisms.
If fungi have caused fuel system problems, sterilize the system with a diesel fuel system biocide or cleaning agent. Follow the manufacturers instructions. Use of biocides while operating under heavy loads such as towing a trailer is not recommended. Such use is permissible, but no additional biocide should be used when refueling during such operations. Contamination that is severe or does not respond to biocides may require tank removal, disassembly, and steam-cleaning.
Water or Wax Contamination

1. 2. 3. 4. 5. Remove fuel cap from ller tube. Drain fuel into portable tank with air powered pumping mechanism. Drain filter, fuel pump, and fuel lines. Refill tank with fresh fuel. Start engine and bleed lines, filter, and injectors.
3.
4.
Checking Fuel Quality

The fuel quality may cause driveability problems such as hesitation, lack of power, stalling, the inability to start, etc. For best results, use Diesel fuel No. 2 year-round (above and below freezing conditions) as the oil companies blend Diesel fuel No. 2 to address climatic differences. Diesel fuel No. 1 may be used in very cold temperatures ( when it stays below 0 F (-18 C); however; it will produce a loss in power and fuel economy. CAUTION: The use of Diesel fuel No. 1 in warm or hot climates may result in stalling, poor starting when the engine is hot, and may damage the fuel injection system.
Fuel Oil Specic Gravity Requirements:

Diesel No. 2 API Gravity 30-39 Diesel No. 1 39-44 Special Tool J38641B
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MUFFLER REPLACEMENT
1. 2. 3. 4. 5. 6. 7. Remove fasteners attaching mufer and gasket to catalytic converter (Figure 3-60). Remove fasteners attaching muffler to tailpipe. Remove fasteners attaching muffler to frame bracket and insulator. Loosen tailpipe and transfer case exhaust pipe brackets. Remove old muffler and install new muffler and gasket. Align all pipes and tighten frame/body bracket fasteners. Tighten muffler flange bolts to 26 lb-ft. (35 Nm).
Figure 3-60: Turbo Diesel
4-1-00
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3-43
HEATSHIELD
HEATSHIELD INSULATOR CROSSOVER PIPE GASKET
CUSHIONED LOOP ASSEMBLY TRANSFER CASE AND EXHAUST PIPE BRACKETS AND U-BOLT
CATALYTIC CONVERTER MUFFLER
FRONT TAILPIPE BRACKET CUSHIONED LOOP ASSEMBLY
TAILPIPE
CUSHIONED LOOP ASSEMBLY
BRACKET
Figure 3-61: Exhaust System
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CROSSOVER PIPE REPLACEMENT

Remove console and engine cover. Remove passenger side exhaust manifold rear heat shield. Loosen transfer case exhaust pipe bracket U-bolt (Figure 3-62). 4. Disconnect crossover pipe at manifolds and at catalytic converter. 5. Position new crossover pipe on manifolds. Tighten flange bolts to 26 lb-ft. (35 Nm). 6. Connect crossover pipe to catalytic converter and tighten flange bolts to 26 lb-ft. (35 Nm). 7. Tighten exhaust bracket U-bolt nuts at transfer case to 26 lb-ft. (35 Nm). 8. Install heat shield. 9. Install engine cover and console. 10. Start and run engine. Verify that exhaust components are clear of body, frame, and driveline parts.
U-BOLT CROSSOVER-TO-CONVERTER PIPE CLAMP
CATALYTIC CONVERTER REPLACEMENT

1. Loosen or remove necessary frame brackets and clamps that retain converter and pipe (Figures 3-61 and 3-62). 2. Remove bolts attaching converter to crossover or head pipe. 3. Remove flange bolts attaching converter to muffler and crossover or head pipe. 4. Remove U-bolt at transfer case bracket. 5. Remove converter. 6. Position new single or dual converter assembly in vehicle and loosely install flange bolts. 7. Connect necessary exhaust brackets and clamps to frame or body as required. 8. Tighten exhaust flange bolts to 26 lb-ft. (35 Nm). 9. Tighten frame bracket bolts. 10. Tighten transfer case exhaust bracket U-bolt nuts to 26 lbft. (35 Nm).
1. 2. 3.
SUPPORT BRACKET TRANSFER CASE
Figure 3-62: Transfer Case Exhaust Bracket Mounting
4-1-00
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3-45
ESSENTIAL TOOLS
J29872-A J29873 J29075-AMG
J41089 J29079-125 J41516-A
J29698-A
J28552-A
J38641-B
J34151
Tool No. J29075-AMG J29872-A J29873 J29698-A J28552-A J38641-B J34151 J41711 J28552-100 Procure from Kent-Moore.
Description Fuel Injector Pressure Test Tool Injection Pump Adjusting Tool (used with ratchet handle) Fuel Injector Socket (30mm) Injection Line (are nut) Wrench, 3/4 Fuel Pressure Gauge Diesel Fuel Hydrometer Housing Pressure Adapter Injection Pump Timing Wrench, 6.5 Turbo (not shown) Adapter, Fuel Line
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SPECIAL TOOLS
J26925
Tool No. J26925 Mag-Tac Engine Tachometer
Description
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4-1
Section 4 Cooling System

TABLE OF CONTENTS
Engine Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Diagnosis and Troubleshooting. . . . . . . . . . . . . . . . . . . . . .4-3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Fan and Clutch Assembly Service . . . . . . . . . . . . . . . . . . . . . . .4-16 Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Radiator Lower Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Lower Tube Assembly Replacement . . . . . . . . . . . . . . . . .4-10 Rear Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Shroud Shield Assembly Replacement . . . . . . . . . . . . . . . .4-7 Upper Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Radiator and Fan Shroud Assembly . . . . . . . . . . . . . . . . . . . . . .4-4 Serpentine Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Surge Tank Overflow Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Tank-to-Lower Radiator Tube Hose. . . . . . . . . . . . . . . . . . 4-12 Tank-to-Radiator Vent Hose . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Thermostat Bypass Hose Replacement . . . . . . . . . . . . . . . . . . . 4-8 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Water Crossover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Water Pump Inlet Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Water Pump and Adapter Plate . . . . . . . . . . . . . . . . . . . . 4-13, 4-14
ENGINE COOLING SYSTEM DESCRIPTION

The cooling system removes excess heat from the engine, engine oil, power steering fluid, transfer case fluid, and transmission fluid. Some engine heat is beneficial, but excess heat can cause engine oil to break down. If lubrication is significantly reduced, engine damage may result. To keep the oil at the proper temperature, the cooling system dissipates some of the heat produced by the engine. A serpentine belt drives the water pump which pumps coolant through the cooling system. Proper belt tension must be maintained at all times for the proper operation of the cooling system. This is accomplished by an automatic belt tensioner located at the front of the engine next to the generator (Figure 4-1). The amount of belt stretch may be determined with the scale located on the arm or the belt tensioner. If the arrow on the arm exceeds the parameters indicated, replacement is required. NOTE: Inspection of a multiple ribbed serpentine belt may reveal cracks in the belt ribs. These cracks will not impair belt performance and are not a basis for belt replacement. If any belt ribs are missing, the belt should be replaced. The cooling system is a closed continuous flow system with a pressure cap rated at 15 psi. Coolant travels through the engine block and circulates around the parts of the engine which generate heat: the cylinders, cylinder heads, combustion chambers, valve guides, valve seats, etc. As coolant is routed through the engine block, heat is transferred from the engine to the coolant. The water crossover on diesel engines collects coolant from the cylinder heads and channels it to the thermostat housing. To prevent the engine from being over-cooled, the thermostat monitors the temperature of the coolant and prevents it from being routed to the radiator until it has reached a temperature high enough to require cooling (Figures 4-2 and 4-3). The thermostat begins to open at 190F (88C) and is fully open at 212 F (100C).
ARROW
SCALE
Figure 4-1: Automatic Belt Tensioner and Belt Length Scale
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Cooling System ____________________________________________________________
ENGINE TEMPERATURE SENDING UNIT
THERMOSTAT
WATER CROSSOVER OIL COOLER
TRANSFER CASE OIL COOLER
TRANSMISSION OIL COOLER BYPASS VALVE SURGE TANK
RADIATOR
HEATER
Figure 4-2: Cooling System Routing

When the thermostat detects the coolant is hot, the thermostat opens allowing coolant to be pumped to the radiator where it is routed through a series of fins and tubes. A fan draws in outside air to help dissipate the heat before the coolant is recirculated back through the engine (Figure 4-3).
AIR CONDITIONING CONDENSER (IF EQUIPPED) ENGINE OIL/ TRANSMISSION OIL COOLER
gauge on the instrument panel to let the driver know that the system should be serviced as soon as possible. Engine coolant is added to the system through the filler cap in the surge tank. After adding or refilling the diesel engine cooling system, open the valve on the water crossover and bleed the air from the system. Like the radiator, the oil cooler also uses a series of fins and tubes to dissipate heat from fluid. The lower half of the oil cooler dissipates heat from the engine oil while the upper half cools transmission fluid. Engine oil flows from the left rear of the engine block to the bottom half of the oil cooler, then returns to the engine block. NOTE: To ensure an accurate engine oil level measurement check the engine oil within 1 to 2 minutes after shut down. The transmission fluid is cooled by the top half of the split oil cooler. Transmission fluid flows from the transmission oil outlet to the top half of the oil cooler, then to the inside of the transfer case, where it returns to the transmission (Figures 4-2 and 4-3). The transmission fluid that passes through the transfer case does not mix with the transfer case fluid, but flows through a separate oil (secondary) cooler located within the transfer case. A transmission cooler bypass valve is positioned between the transmission and transfer case cooler in the fluid line. The unit is rigidly mounted to the frame rail and is connected in parallel by hoses to the transmission cooler. The valve consists of a housing with inlet and outlet fittings, and an internal flow control valve, spring loaded in the closed position. The valve is designed to begin opening at approximately 20 psi and be fully open by 30 psi allowing fluid to bypass the transmission cooler and regulate fluid pressure in the cooler. At low temperatures, fluid viscosity and pressure are typically high. By allowing fluid to bypass the cooler at low temperatures the transmission warms to normal operating temperature
POWER STEERING OIL COOLER
WATER PUMP RADIATOR SHROUD FAN DRAINCOCK
Figure 4-3: Cooling System

The heater provides heat to warm the interior of the vehicle for passenger comfort. Hot coolant leaves the engine and passes through a heater coil. A fan draws air through the heated coil which heats the air. The air is then channeled through a plenum chamber that directs the flow of the heated air into the passenger compartment. If the engine is generating more heat than the cooling system can effectively dissipate, there may be a coolant or cooling system problem. The engine temperature sending unit transmits a signal indicating the coolant temperature to the temperature
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Cooling System
4-3
quicker. At high temperatures, fluid viscosity decreases and more fluid circulates through the cooler maintaining an even operating temperature and a constant pressure in the cooler (see Section 1 for service procedures). A separate smaller oil cooler, mounted to the fan shroud, is used to cool the power steering fluid. Two fluid returns are used: one from the hydro-boost and one from the power steering gear. Fluid flow through the hydroboost is never completely restricted during braking. The hydroboost incorporates a fluid return to release the hydraulic pressures used when applying the brakes (see Section 8 for service procedures).
ENGINE COOLING SYSTEM DIAGNOSIS AND TROUBLESHOOTING

WARNING: Do not release surge tank cap when engine is hot. Steam and/or coolant may cause serious injury.
Loss of Coolant
1. Pressurize system and check for leaks at all cooling system hoses. a. Tighten loose clamps, fasteners, or fittings. b. Replace leaking hoses. Pressurize coolant system and check for leaks at water pump or around cylinder heads. If any leakage is present, replace cylinder head gaskets, cylinder heads, or water pump. Check cylinder block for cracks. Replace if cylinder block is cracked. Check expansion plugs and block heater for leaks. Check radiator and surge tank. Remove surge tank cap. With engine running, check for excessive bubbles in surge tank that may indicate leaking head gaskets or cracked cylinder heads. If bubbles are present, remove cylinder heads and check for defective head gaskets, cracked cylinder heads, or cracked cylinder block. Replace cylinder heads if damaged. Replace engine if cylinder block is cracked.
2.
3. 4. 5. 6.
NOTE: Off-road driving in extremely dusty conditions may result in debris entrapment between the radiator and oil cooler. Trapped debris may increase coolant temperature. 3. Check for clogged or blocked radiator system. Clean and flush as required. Cleaning requires the separation of the oil cooler from the radiator and both units must be thoroughly flushed with water and compressed air. 4. Check thermostat for proper operation. Remove thermostat and place thermostat in container of water known to be 190F (88C). Observe valve. If valve does not open, replace thermostat. 5. Check radiator for bent fins. Straighten fins or replace radiator if damaged beyond repair. 6. Check operation of temperature gauge. Refer to Electrical Troubleshooting (Section 12). 7. Inspect fan blades for damage. Replace fan if damaged. 8. Check fan clutch operation. a. Check for excessive bearing play. Using fingers only, press tip of fan blade toward and away from engine. Tip of blade total movement should not exceed 0.20 in. (5.1 mm). If movement is more, replace fan drive. b. With engine off and ambient temperature of 50F (10 C) or higher, fan should turn evenly with noticeable drag. If fan turns hard, very easily, or with uneven resistance, replace fan drive. c. Fan noise is sometimes evident under the following normal conditions: When the drive is engaged for maximum cooling. During the rst 15 seconds to one minute after startup, until the drive can redistribute the silicone uid back to its normal disengage operating condition (after overnight settling). Fan noise or an excessive roar will generally occur continuously under all engine high speed conditions (2400 RPM and up) if the drive assembly is locked-up due to an internal failure. If the fan cannot be rotated by hand or there is a rough, grating feel as the fan is turned, replace the fan drive. 9. Check for leaking or defective water pump. Replace leaking or defective water pump.
Engine Coolant Temperature Gauge Above 255F (124C), Engine Overheats

1. Inspect for low coolant. Verify low coolant sensor is operating properly. (Refer to Electrical Troubleshooting, Section 12). Inspect the drivebelt and pulleys for damage. a. Replace any damaged parts. b. Check belt tension. Replace if necessary.
Fan Runs Continuously (Noisy)

1. 2. 3. 4. Check that all fan bolts are present and tightened to 45 lbft (61 Nm). Perform steps 8a and 8b on preceding page. Check for fan cut off (disengagement). Observe fan drive disengagement after 1 to 1-1/2 minutes. If fan speed does not drop and coolant temperature remains below 190 F (88 C), replace fan drive.
2.
WARNING: Use caution when testing thermostat. Hot engine coolant will cause burns.
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Cooling System ____________________________________________________________
RADIATOR AND FAN SHROUD ASSEMBLY SERVICE

Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove hood (Section 10). Drain cooling system. Remove oil cooler (Section 1). Disconnect upper hose from radiator (Figure 4-4). If equipped with air conditioner, discharge system and remove condenser (Section 11). Remove power steering cooler mounting bolts and position cooler aside. Disconnect ambient temperature switch, if equipped (Section 11). Disconnect surge tank-to-radiator vent hose from adapter.

NOTE: Clean all components, examine for wear or damage, and replace if necessary. 1. 2. 3. Remove debris embedded in radiator ns using water and compressed air (Figure 4-5). Inspect radiator for breaks, punctures, cracks, or splits. Inspect adapters and fan shroud (Figure 4-4).
Installation
CAUTION: To avoid equipment damage, upper edge of fan shroud must align with radiator top tank seam to ensure proper engine cooling. NOTE: Ensure fan shroud edge aligns with tank seam on radiator. 1. Secure fan shroud to radiator with retaining strips, lockwashers, and bolts. Tighten bolts to 6 lb-ft (8 Nm) (Figure 4-5). Secure rear support brackets and insulators to radiator with washers and locknuts. Tighten locknuts to 26 lb-ft (35 Nm). Align radiator with frame bracket, and rear support brackets with airlift brackets (Figures 4-5 and 4-6). Fasten rear support brackets to air lift brackets with bolts, washers, and locknuts. Do not tighten locknuts (Figure 4-4).
9. Disconnect lower radiator hose from radiator. 10. Remove strap securing fan shroud to radiator. 11. Remove lower mount from radiator and frame bracket (Figure 4-5). 12. Detach rear support brackets from airlift brackets (Figure 4-4). 13. Remove battery tray, and left splash shield. (Sections 10 and 12). 14. Remove the radiator from vehicle (Figure 4-5). 15. Remove retaining strips, and fan shroud from radiator. 16. Remove rear support brackets and insulators from radiator.
2.
3. 4.
HOSE FITTING WITH BLEED VALVE SURGE TANK-TO-RADIATOR VENT HOSE STRAP RADIATOR UPPER RADIATOR HOSE AIRLIFT BRACKET ADAPTER
REAR SUPPORT BRACKET FAN SHROUD LOWER RADIATOR HOSE
Figure 4-4: Radiator and Fan Shroud Assembly Mounting
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Cooling System
4-5
5. 6.
7.
8. 9.
Attach lower mount and radiator to frame bracket with washers, and locknut. Do not tighten (Figure 4-5). Align fan shroud by sliding the radiator/shroud assembly to maintain 1 1/2 1/8 in. (38.1 3 mm) from edge of shroud ring and rear edge of fan. Measure at the 2, 4, 8, and 10 oclock positions. The distance between the top of the fan blade and fan shroud must not be less than 1/4 in. (6 mm) at any position (Figure 4-6). Tighten rear support bracket locknuts to 26 lb-ft (35 Nm). Tighten frame bracket bolt to 30 lb-ft (41 Nm) (Figures 4-4 and 4-5). Install left splash shield and battery tray (Section 12). Install strap on radiator and shroud (Figure 4-4).
10. Connect upper and lower radiator hoses to radiator. 11. Use bolts to attach power steering cooler to brackets. 12. Connect ambient temperature switch, if equipped (Section 11). 13. If equipped with air conditioner, install condenser and charge system (Section 11). 14. Connect surge tank-to-radiator vent hose to adapter. 15. Fill cooling system (Section 4). 16. Install oil cooler (Section 1). 17. Start engine and check cooling system for leaks. 18. Install hood (Section 10).
RADIATOR
OIL COOLERS
CONDENSER
FRAME BRACKET
Figure 4-5: Radiator and Fan Shroud Assembly Breakdown
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Cooling System ____________________________________________________________
ENGINE COOLING SYSTEM SERVICE

Depressurizing/Draining
WARNING: To avoid injury, do not remove surge tank ller cap before depressurizing cooling system when engine temperature is above 190F (88C).
1. If engine is hot, place a thick cloth over surge tank ller cap. Turn counterclockwise to rst stop to release internal pressure (Figure 4-8). After pressure has vented, remove cap. Open drain valve and drain system (Figure 4-7). Close drain valve.
2. 3. 4.
Replenishing
NOTE: Ensure surge tank coolant level is 3/4 full before securing filler cap. 1. 2. 3. 4. Ensure drain valve is closed and heater control valve is open (Figure 4-7).
SURGE TANK FILLER CAP DRAIN VALVE
Figure 4-7: Drain Valve
Fill system with proper antifreeze solution (Table 4-1). Install filler cap on surge tank (Figure 4-8). Start engine and run at fast idle (1500 rpm) until engine temperature reaches 190 F (88 C). Stop engine. 5. Depressurize system. 6. Fill with proper antifreeze solution until surge tank is 3/4 full (Table 4-1). 7. Install filler cap on surge tank (Figure 4-8). 8. Start engine and run at fast idle (1500 RPM) until engine temperature reaches 190 F (88 C). Stop engine. 9. Depressurize system. Use tester to ensure proper coolant protection is provided. 10. Install filler cap on surge tank. 11. Start engine and check cooling system for leaks.
10 OCLOCK POSITION 2 OCLOCK POSITION
SURGE TANK
Figure 4-8: Surge Tank and Filler Cap Location

FAN SHROUD
Expected Ambient Temperature 120 to -32 F (49 to -36 C)

Antifreeze/ Water Mixture 50% antifreeze/ 50% water
Table 4-1: Antifreeze Preparation Guide Figure 4-6: Fan Shroud Clearance Check Points
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Cooling System
4-7
SHROUD SHIELD ASSEMBLY REPLACEMENT

Removal
1. 2. Remove radiator and fan shroud. Remove screws and shroud shield assembly from airlift bracket (Figure 4-9).
INSULATOR RADIATOR
AIRLIFT BRACKET
SHROUD SHIELD ASSEMBLY REAR SUPPORT BRACKET
Figure 4-10: Insulator and Rear Support Bracket Location
SURGE TANK REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Drain cooling system. Disconnect radiator vent hose from surge tank (Figure 4-12). Disconnect surge tank-to-lower radiator hose from surge tank. Disconnect overflow hose from surge tank. Disconnect low coolant sensor wiring harness. Loosen clamps and remove surge tank from bracket.
Figure 4-9: Shroud Shield Assembly Replacement
Installation
1. 2. Secure shroud shield assembly to airlift bracket with screws (Figure 4-9). Install radiator and fan shroud.
RADIATOR REAR SUPPORT BRACKET REPLACEMENT

Removal
1. 2. 3. 4. Remove left splash shield (Section 10). Remove battery tray and right splash shield (Section 12). Remove radiator rear support bracket and insulator from radiator (Figure 4-10). Remove support bracket from airlift bracket (Figure 4-11).
AIRLIFT BRACKET
Installation
1. Fasten radiator rear support bracket to airlift bracket with bolts, washers, and locknuts. Do not tighten locknuts (Figure 4-11). Secure insulator and support bracket to radiator with washers and locknut (Figure 4-10). Tighten all locknuts to 26 lb-ft (35 Nm). Install left splash shield (Section 10). Install battery tray and right splash shield (Section 12).
2. 3. 4. 5.
Figure 4-11:
Rear Support Bracket Mounting
Installation
1. 2. Secure surge tank to bracket with clamps (Figure 4-12). Connect low coolant sensor wiring harness.
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3. 4. 5. 6.
Cooling System ____________________________________________________________
Connect surge tank-to-lower radiator hose to surge tank. Connect radiator vent hose to surge tank. Connect overflow hose to surge tank. Fill and purge cooling system.
SURGE TANK VENT HOSE RADIATOR
SURGE TANK BRACKET OVERFLOW HOSE
LOW COOLANT SENSOR SURGE TANK-TO-LOWER RADIATOR HOSE VENT HOSE FITTING (HOSE NOT SHOWN)
Figure 4-13: Surge Tank-to-Radiator Vent Hose Location
THERMOSTAT BYPASS HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen two clamps and remove bypass hose from nipples on water pump and water crossover (Figure 4-14).
Figure 4-12: Surge Tank Replacement
SURGE TANK-TO-RADIATOR VENT HOSE REPLACEMENT

Removal
1. 2. 3. Depressurize cooling system. Loosen two clamps and remove radiator vent hose from radiator and surge tank (Figure 4-13). Reclaim coolant.
Installation
1. 2. Secure bypass hose to nipples on water pump and water crossover with two clamps (Figure 4-14). Fill cooling system.
BLEEDER VALVE WATER CROSSOVER
Installation
1. 2. 3. Secure radiator vent hose to surge tank and radiator with two clamps (Figure 4-13). Tighten coolant filler cap. Replace coolant.
NIPPLES
BYPASS HOSE
WATER PUMP
Figure 4-14: Thermostat Bypass Hose Replacement
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Cooling System
4-9
UPPER RADIATOR HOSE REPLACEMENT

Removal
1. 2. 3. Drain cooling system as necessary. Depressurize cooling system. Loosen clamps and remove hose from thermostat housing and radiator (Figure 4-15).
LOWER RADIATOR HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove lower radiator hose from radiator and lower tube assembly (Figure 4-16).
Installation
1. 2. Secure lower radiator hose to lower tube assembly and radiator with clamps (Figure 4-16). Fill cooling system.
RADIATOR
Installation
1. 2. Secure upper radiator hose to thermostat housing and radiator with clamps (Figure 4-15). Fill cooling system.
THERMOSTAT HOUSING
UPPER RADIATOR HOSE LOWER RADIATOR HOSE
CLAMP RADIATOR LOWER TUBE ASSEMBLY
Figure 4-16: Lower Radiator Hose Location Figure 4-15: Upper Radiator Hose Location
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RADIATOR LOWER TUBE ASSEMBLY REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. Drain cooling system. Remove drain valve from lower tube assembly (Figure 4-17). Disconnect radiator lower tube assembly from frame bracket. Loosen clamp and disconnect water pump inlet hose from lower tube assembly. Loosen clamp and disconnect surge tank-to-lower radiator hose from lower tube assembly. Loosen clamp and disconnect lower radiator hose from lower tube assembly. Remove lower tube assembly.
Installation
1. Secure lower tube assembly to frame bracket with bolts, washers, and locknuts. Tighten locknuts to 6 lb-ft (8 Nm) (Figure 4-17). Connect lower radiator hose to lower tube assembly and tighten clamp. Connect surge tank-to-lower radiator hose to lower tube assembly and tighten clamp. Connect water pump inlet hose to lower tube assembly and tighten clamp. Apply sealant tape to threads of drain valve and screw drain valve into lower tube assembly. Fill cooling system.
2. 3. 4. 5. 6.
FRAME BRACKET
WATER PUMP INLET HOSE
SURGE TANK-TOLOWER RADIATOR HOSE
LOWER TUBE ASSEMBLY LOWER RADIATOR HOSE
DRAIN VALVE
Figure 4-17: Radiator Lower Tube Assembly Location
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Cooling System
4-11
WATER PUMP INLET HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove water pump inlet hose from water pump and lower tube assembly (Figure 4-18).
SURGE TANK OVERFLOW HOSE REPLACEMENT

Removal
1. 2. Remove overow hose from surge tank ller neck (Figure 4-19). Remove screw, clamp, and overflow hose from body.
Installation
1. 2. Connect water pump inlet hose to lower tube assembly and water pump and tighten clamps (Figure 4-18). Fill cooling system.
Installation
1. 2. Connect overow hose to surge tank ller neck (Figure 4-19). Secure overflow hose to body with clamp and screw.
SURGE TANK FILLER NECK
WATER PUMP BODY OVERFLOW HOSE WATER PUMP INLET HOSE
Figure 4-19: Surge Tank Overflow Hose Mounting
LOWER TUBE ASSEMBLY
Figure 4-18: Water Pump Inlet Hose Location
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SURGE TANK-TO-LOWER RADIATOR TUBE HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove hose from surge tank and lower tube assembly (Figure 4-20).
LOW COOLANT SENSOR

The coolant level sensor is a solid-state semi-conductor device. The sensors resistance varies as a function of its temperature. As voltage/current flows through the sensor, sensor temperature increases. In the presence of a liquid, in this case engine coolant, the temperature of the sensor is controlled by transferring heat to the coolant. Should the coolant level drop below the sensor, the heat and resistance of the sensor will rise. The Low Coolant warning light will then illuminate in response to the increased resistance at the sensor.
Installation
1. 2. Install hose on lower tube assembly and surge tank and tighten clamps (Figure 4-20). Fill cooling system.
SURGE TANK
Removal
1. 2. 3. Drain and collect coolant from surge tank. Disconnect the low coolant sensor electrical connector from the engine harness connector. Remove the sensor and O-ring from the surge tank (Figure 4-21)
ELECTRICAL CONNECTOR
SURGE TANK O-RING LOWER TUBE ASSEMBLY
SURGE TANK-TO-LOWER TUBE ASSEMBLY HOSE
LOW COOLANT SENSOR
Figure 4-20: Surge Tank-to-Lower Tube Assembly Hose Location
Figure 4-21: Low Coolant Sensor
Installation
1. 2. 3. Position O-ring on sensor and thread sensor into surge tank (Figure 4-21). Plug the low coolant sensor electrical connector into the engine harness connector Fill surge tank with coolant.
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Cooling System
THERMOSTAT SEATS AND COUNTER BORES
4-13
THERMOSTAT REPLACEMENT
1. 2. 3. 4. 5. Drain engine coolant below level of water crossover. Remove bolts attaching thermostat cover to crossover housing. Remove thermostat cover and gasket (Figure 4-22). Remove both thermostats (Figure 4-23). Position new thermostats in crossover housing (Figure 4-24). Be sure thermostat seals are seated in counterbores. Wax pellet end of each thermostat goes toward engine. Apply Permatex no. 2 to both sides of thermostat housing gasket. If gasket is not used, apply 3/16 in. (5 mm) bead of Loctite 599, or Permatex Ultra Copper, or Ultra Black to cover or crossover mounting surface. Install thermostat cover and tighten cover bolts securely. Fill and bleed cooling system.
WATER CROSSOVER
6.
Figure 4-24: Thermostat Location in Crossover
7. 8.
WATER PUMP AND ADAPTER PLATE

Removal
1. Drain engine coolant. Loosen and remove serpentine drive belt. Remove fan and fan clutch (Figure 4-25). Disconnect hoses at water pump. Remove water pump and backing plate attaching bolts/ studs and remove pump and plate as assembly (Figure 4-26). Remove water pump and gasket from plate (Figure 4-27). Clean all gasket material and sealer from plate.
8-BLADE FAN FAN CLUTCH
THERMOSTAT HOUSING TWIN THERMOSTATS GASKETS WATER CROSSOVER
2. 3. 4. 5.
6. 7.
Figure 4-22: Thermostat and Cover Removal and Installation

THERMOSTAT
SERPENTINE DRIVE BELT
SEAL WAX PELLET
Figure 4-25: Fan and Clutch Mounting
Installation
1. Figure 4-23: Turbo Diesel Thermostat If new pump is being installed, transfer hose adapter ttings to new pump. Apply Loctite PST to tting threads before hand.
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2.
Cooling System
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3.
4.
Apply coat of Permatex no. 2, Ultra Black, or Ultra Copper to each side of water pump gasket. Then position gasket on pump. Apply 1/8 - 3/16 in. (3.3-5 mm) wide bead of sealer to backing plate (Figure 4-28). Encircle bolt hole at bottom of plate with sealer as shown. Also apply sealer to threads of bolt or stud used in this hole to avoid leaks. Install adapter plate and water pump on front cover. Tighten all studs and short bolts marked A to 13-20 lb-ft
5. 6. 7. 8. 9.
(18-27 Nm). Tighten large studs and large bolt marked B to 25-37 lb-ft (34-50 Nm) (Figure 4-26). Attach hoses to water pump. Install fan and clutch. Install and adjust serpentine drive belt. Refill engine cooling system. Start engine, bleed air from cooling system, and top off coolant level.
ADAPTER PLATE
FRONT COVER
A
A
WATER PUMP
BYPASS ADAPTER
BACKING PLATE
GASKET
WATER PUMP
Figure 4-27: Water Pump
3-1-02
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Cooling System
4-15
BACKING PLATE
A/C COMPRESSOR COMPRESSOR CLUTCH CONNECTOR
COMPRESSOR BOLT (4)
SEALER BEAD
ENCIRCLE THIS BOLT HOLE WITH SEALER
Figure 4-28: Backing Plate Sealer Application
WATER CROSSOVER SERVICE

Removal
1. 2. 3. Drain engine coolant to below level of crossover. Disconnect heater, surge tank, and radiator hoses at crossover. Disconnect coolant temperature sensor wires (Figure 4-29).
COOLANT TEMPERATURE SENSOR CROSSOVER
Figure 4-30: Compressor Clutch Bolt and Connector Location

WATER CROSSOVER
OIL FILLER CAP AND TUBE
STUD NUT
Figure 4-31: Water Crossover Attaching Hardware
Installation
Figure 4-29: Filler Tube and Temperature Sensor Locations
4. 5. 6. Remove oil filler tube attaching nuts and remove filler tube (Figure 4-29). Disconnect A/C compressor clutch wires (Figure 4-30). Remove compressor clutch mounting bolts. Lift compressor out of bracket and move it aside for access to crossover bolts and nuts. Remove water crossover attaching bolts/nuts (Figure 4-31). Remove crossover and gaskets. If crossover will be replaced, transfer air bleed valve and coolant temperature sensor to new crossover. Also transfer thermostats if necessary. Use Loctite PST on valve and sensor threads to ensure proper seal. 1. Apply Permatex Ultra Black or no. 2 sealer to both sides of crossover gaskets. Then position gaskets on cylinder heads. Align and install crossover. Tighten crossover nuts/bolts to 25-37 lb. ft. (34-50 Nm) torque. Install oil filler tube. Tighten attaching nuts to 13-20 lb. ft. (18-27 Nm) torque. Connect hoses to water crossover. Install A/C compressor in bracket and tighten bolts. Connect wires to coolant temperature sensor. Refill and bleed engine cooling system.
2. 3. 4. 5. 6. 7.
7. 8. 9.
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Cooling System
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SERPENTINE BELT REPLACEMENT

1. Insert square lug of half-inch drive breaker bar in belt tensioner. Then move tensioner counterclockwise to loosen belt (Figure 4-32). Remove belt from pulleys (Figure 4-33). Position half-inch drive breaker bar in belt tensioner and move tensioner counterclockwise and position serpentine belt on pulleys as shown (Figure 4-33). Release belt tensioner. Tensioner will automatically set belt tension when released.
GENERATOR BELT TENSIONER PULLEY AND PULLEY A/C COMPRESSOR (OR IDLER PULLEY WITHOUT A/C)
FAN AND CLUTCH ASSEMBLY SERVICE

Removal
1. 2. Insert spanner J41240-1 in holes in water pump pulley (Figure 4-34). Use the spanner to hold the water pump shaft and wrench J41240-5A to break the nut loose securing the fan clutch to the water pump. Remove bolts attaching fan to fan clutch. Remove fan clutch-to-water pump nut. Remove fan and clutch from water pump.
2. 3.
4.
3. 4. 5.
Installation
6. 7. 8. Slide fan onto clutch and install bolts finger tight. Install fan and clutch assembly on water pump shaft (Figure 4-34). Hold water pump shaft with spanner J41240-1 and tighten clutch nut to 80-100 lb-ft (108-135 Nm) with wrench J41240-5A. Torque fan bolts to 15-20 lb-ft (20-27 Nm).
WRENCH FAN
9.
WATER PUMP PULLEY VACUUM PUMP
SERPENTINE BELT SPANNER
CRANKSHAFT PULLEY
POWER STEERING PUMP PULLEY CLUTCH

GENERATOR PULLEY TENSIONER PULLEY A/C COMPRESSOR OR IDLER PULLEY
SERPENTINE BELT WATER PUMP PULLEY POWER STEERING PUMP PULLEY
WATER PUMP PULLEY
Figure 4-34: Fan and Clutch Assembly

VACUUM PUMP CRANKSHAFT PULLEY
Figure 4-33: Serpentine Belt Routing
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4-1
Section 4 Cooling System

TABLE OF CONTENTS
Engine Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Diagnosis and Troubleshooting. . . . . . . . . . . . . . . . . . . . . .4-3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Fan and Clutch Assembly Service . . . . . . . . . . . . . . . . . . . . . . .4-16 Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Radiator Lower Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Lower Tube Assembly Replacement . . . . . . . . . . . . . . . . .4-10 Rear Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Shroud Shield Assembly Replacement . . . . . . . . . . . . . . . .4-7 Upper Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Radiator and Fan Shroud Assembly . . . . . . . . . . . . . . . . . . . . . .4-4 Serpentine Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Surge Tank Overflow Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Tank-to-Lower Radiator Tube Hose. . . . . . . . . . . . . . . . . . 4-12 Tank-to-Radiator Vent Hose . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Thermostat Bypass Hose Replacement . . . . . . . . . . . . . . . . . . . 4-8 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Water Crossover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Water Pump Inlet Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Water Pump and Adapter Plate . . . . . . . . . . . . . . . . . . . . 4-13, 4-14
ENGINE COOLING SYSTEM DESCRIPTION

The cooling system removes excess heat from the engine, engine oil, power steering fluid, transfer case fluid, and transmission fluid. Some engine heat is beneficial, but excess heat can cause engine oil to break down. If lubrication is significantly reduced, engine damage may result. To keep the oil at the proper temperature, the cooling system dissipates some of the heat produced by the engine. A serpentine belt drives the water pump which pumps coolant through the cooling system. Proper belt tension must be maintained at all times for the proper operation of the cooling system. This is accomplished by an automatic belt tensioner located at the front of the engine next to the generator (Figure 4-1). The amount of belt stretch may be determined with the scale located on the arm or the belt tensioner. If the arrow on the arm exceeds the parameters indicated, replacement is required. NOTE: Inspection of a multiple ribbed serpentine belt may reveal cracks in the belt ribs. These cracks will not impair belt performance and are not a basis for belt replacement. If any belt ribs are missing, the belt should be replaced. The cooling system is a closed continuous flow system with a pressure cap rated at 15 psi. Coolant travels through the engine block and circulates around the parts of the engine which generate heat: the cylinders, cylinder heads, combustion chambers, valve guides, valve seats, etc. As coolant is routed through the engine block, heat is transferred from the engine to the coolant. The water crossover on diesel engines collects coolant from the cylinder heads and channels it to the thermostat housing. To prevent the engine from being over-cooled, the thermostat monitors the temperature of the coolant and prevents it from being routed to the radiator until it has reached a temperature high enough to require cooling (Figures 4-2 and 4-3). The thermostat begins to open at 190F (88C) and is fully open at 212 F (100C).
ARROW
SCALE
Figure 4-1: Automatic Belt Tensioner and Belt Length Scale
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ENGINE TEMPERATURE SENDING UNIT
THERMOSTAT
WATER CROSSOVER OIL COOLER
TRANSMISSION OIL COOLER BYPASS VALVE SURGE TANK
RADIATOR
HEATER
Figure 4-2: Cooling System Routing

When the thermostat detects the coolant is hot, the thermostat opens allowing coolant to be pumped to the radiator where it is routed through a series of fins and tubes. A fan draws in outside air to help dissipate the heat before the coolant is recirculated back through the engine (Figure 4-3).
AIR CONDITIONING CONDENSER (IF EQUIPPED) ENGINE OIL/ TRANSMISSION OIL COOLER
gauge on the instrument panel to let the driver know that the system should be serviced as soon as possible. Engine coolant is added to the system through the filler cap in the surge tank. After adding or refilling the diesel engine cooling system, open the valve on the water crossover and bleed the air from the system. Like the radiator, the oil cooler also uses a series of fins and tubes to dissipate heat from fluid. The lower half of the oil cooler dissipates heat from the engine oil while the upper half cools transmission fluid. Engine oil flows from the left rear of the engine block to the bottom half of the oil cooler, then returns to the engine block. NOTE: To ensure an accurate engine oil level measurement check the engine oil within 1 to 2 minutes after shut down. The transmission fluid is cooled by the top half of the split oil cooler. Transmission fluid flows from the transmission oil outlet to the top half of the oil cooler, then to the inside of the transfer case, where it returns to the transmission (Figures 4-2 and 4-3). The transmission fluid that passes through the transfer case does not mix with the transfer case fluid, but flows through a separate oil (secondary) cooler located within the transfer case. A transmission cooler bypass valve is positioned between the transmission and transfer case cooler in the fluid line. The unit is rigidly mounted to the frame rail and is connected in parallel by hoses to the transmission cooler. The valve consists of a housing with inlet and outlet fittings, and an internal flow control valve, spring loaded in the closed position. The valve is designed to begin opening at approximately 20 psi and be fully open by 30 psi allowing fluid to bypass the transmission cooler and regulate fluid pressure in the cooler. At low temperatures, fluid viscosity and pressure are typically high. By allowing fluid to bypass the cooler at low temperatures the transmission warms to normal operating temperature
POWER STEERING OIL COOLER
WATER PUMP RADIATOR SHROUD FAN DRAINCOCK
Figure 4-3: Cooling System

The heater provides heat to warm the interior of the vehicle for passenger comfort. Hot coolant leaves the engine and passes through a heater coil. A fan draws air through the heated coil which heats the air. The air is then channeled through a plenum chamber that directs the flow of the heated air into the passenger compartment. If the engine is generating more heat than the cooling system can effectively dissipate, there may be a coolant or cooling system problem. The engine temperature sending unit transmits a signal indicating the coolant temperature to the temperature
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Cooling System
4-3
quicker. At high temperatures, fluid viscosity decreases and more fluid circulates through the cooler maintaining an even operating temperature and a constant pressure in the cooler (see Section 1 for service procedures). A separate smaller oil cooler, mounted to the fan shroud, is used to cool the power steering fluid. Two fluid returns are used: one from the hydro-boost and one from the power steering gear. Fluid flow through the hydroboost is never completely restricted during braking. The hydroboost incorporates a fluid return to release the hydraulic pressures used when applying the brakes (see Section 8 for service procedures).
ENGINE COOLING SYSTEM DIAGNOSIS AND TROUBLESHOOTING

Loss of Coolant
1. Pressurize system and check for leaks at all cooling system hoses. a. Tighten loose clamps, fasteners, or fittings. b. Replace leaking hoses. Pressurize coolant system and check for leaks at water pump or around cylinder heads. If any leakage is present, replace cylinder head gaskets, cylinder heads, or water pump. Check cylinder block for cracks. Replace if cylinder block is cracked. Check expansion plugs and block heater for leaks. Check radiator and surge tank. Remove surge tank cap. With engine running, check for excessive bubbles in surge tank that may indicate leaking head gaskets or cracked cylinder heads. If bubbles are present, remove cylinder heads and check for defective head gaskets, cracked cylinder heads, or cracked cylinder block. Replace cylinder heads if damaged. Replace engine if cylinder block is cracked.
2.
3. 4. 5. 6.
NOTE: Off-road driving in extremely dusty conditions may result in debris entrapment between the radiator and oil cooler. Trapped debris may increase coolant temperature. 3. Check for clogged or blocked radiator system. Clean and flush as required. Cleaning requires the separation of the oil cooler from the radiator and both units must be thoroughly flushed with water and compressed air. 4. Check thermostat for proper operation. Remove thermostat and place thermostat in container of water known to be 190F (88C). Observe valve. If valve does not open, replace thermostat. 5. Check radiator for bent fins. Straighten fins or replace radiator if damaged beyond repair. 6. Check operation of temperature gauge. Refer to Electrical Troubleshooting (Section 12). 7. Inspect fan blades for damage. Replace fan if damaged. 8. Check fan clutch operation. a. Check for excessive bearing play. Using fingers only, press tip of fan blade toward and away from engine. Tip of blade total movement should not exceed 0.20 in. (5.1 mm). If movement is more, replace fan drive. b. With engine off and ambient temperature of 50F (10 C) or higher, fan should turn evenly with noticeable drag. If fan turns hard, very easily, or with uneven resistance, replace fan drive. c. Fan noise is sometimes evident under the following normal conditions: When the drive is engaged for maximum cooling. During the rst 15 seconds to one minute after startup, until the drive can redistribute the silicone uid back to its normal disengage operating condition (after overnight settling). Fan noise or an excessive roar will generally occur continuously under all engine high speed conditions (2400 RPM and up) if the drive assembly is locked-up due to an internal failure. If the fan cannot be rotated by hand or there is a rough, grating feel as the fan is turned, replace the fan drive. 9. Check for leaking or defective water pump. Replace leaking or defective water pump.
Engine Coolant Temperature Gauge Above 255F (124C), Engine Overheats

1. Inspect for low coolant. Verify low coolant sensor is operating properly. (Refer to Electrical Troubleshooting, Section 12). Inspect the drivebelt and pulleys for damage. a. Replace any damaged parts. b. Check belt tension. Replace if necessary.
Fan Runs Continuously (Noisy)

1. 2. 3. 4. Check that all fan bolts are present and tightened to 45 lbft (61 Nm). Perform steps 8a and 8b on preceding page. Check for fan cut off (disengagement). Observe fan drive disengagement after 1 to 1-1/2 minutes. If fan speed does not drop and coolant temperature remains below 190 F (88 C), replace fan drive.
2.
WARNING: Use caution when testing thermostat. Hot engine coolant will cause burns.
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Cooling System ____________________________________________________________
RADIATOR AND FAN SHROUD ASSEMBLY SERVICE

Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove hood (Section 10). Drain cooling system. Remove oil cooler (Section 1). Disconnect upper hose from radiator (Figure 4-4). If equipped with air conditioner, discharge system and remove condenser (Section 11). Remove power steering cooler mounting bolts and position cooler aside. Disconnect ambient temperature switch, if equipped (Section 11). Disconnect surge tank-to-radiator vent hose from adapter.

NOTE: Clean all components, examine for wear or damage, and replace if necessary. 1. 2. 3. Remove debris embedded in radiator ns using water and compressed air (Figure 4-5). Inspect radiator for breaks, punctures, cracks, or splits. Inspect adapters and fan shroud (Figure 4-4).
Installation
CAUTION: To avoid equipment damage, upper edge of fan shroud must align with radiator top tank seam to ensure proper engine cooling. NOTE: Ensure fan shroud edge aligns with tank seam on radiator. 1. Secure fan shroud to radiator with retaining strips, lockwashers, and bolts. Tighten bolts to 6 lb-ft (8 Nm) (Figure 4-5). Secure rear support brackets and insulators to radiator with washers and locknuts. Tighten locknuts to 26 lb-ft (35 Nm). Align radiator with frame bracket, and rear support brackets with airlift brackets (Figures 4-5 and 4-6). Fasten rear support brackets to air lift brackets with bolts, washers, and locknuts. Do not tighten locknuts (Figure 4-4).
9. Disconnect lower radiator hose from radiator. 10. Remove strap securing fan shroud to radiator. 11. Remove lower mount from radiator and frame bracket (Figure 4-5). 12. Detach rear support brackets from airlift brackets (Figure 4-4). 13. Remove battery tray, and left splash shield. (Sections 10 and 12). 14. Remove the radiator from vehicle (Figure 4-5). 15. Remove retaining strips, and fan shroud from radiator. 16. Remove rear support brackets and insulators from radiator.
2.
3. 4.
HOSE FITTING WITH BLEED VALVE SURGE TANK-TO-RADIATOR VENT HOSE STRAP RADIATOR UPPER RADIATOR HOSE AIRLIFT BRACKET ADAPTER
REAR SUPPORT BRACKET FAN SHROUD LOWER RADIATOR HOSE
Figure 4-4: Radiator and Fan Shroud Assembly Mounting
___________________________________________________________
Cooling System
4-5
5. 6.
7.
8. 9.
Attach lower mount and radiator to frame bracket with washers, and locknut. Do not tighten (Figure 4-5). Align fan shroud by sliding the radiator/shroud assembly to maintain 1 1/2 1/8 in. (38.1 3 mm) from edge of shroud ring and rear edge of fan. Measure at the 2, 4, 8, and 10 oclock positions. The distance between the top of the fan blade and fan shroud must not be less than 1/4 in. (6 mm) at any position (Figure 4-6). Tighten rear support bracket locknuts to 26 lb-ft (35 Nm). Tighten frame bracket bolt to 30 lb-ft (41 Nm) (Figures 4-4 and 4-5). Install left splash shield and battery tray (Section 12). Install strap on radiator and shroud (Figure 4-4).
10. Connect upper and lower radiator hoses to radiator. 11. Use bolts to attach power steering cooler to brackets. 12. Connect ambient temperature switch, if equipped (Section 11). 13. If equipped with air conditioner, install condenser and charge system (Section 11). 14. Connect surge tank-to-radiator vent hose to adapter. 15. Fill cooling system (Section 4). 16. Install oil cooler (Section 1). 17. Start engine and check cooling system for leaks. 18. Install hood (Section 10).
RADIATOR
OIL COOLERS
CONDENSER
FRAME BRACKET
Figure 4-5: Radiator and Fan Shroud Assembly Breakdown
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Cooling System ____________________________________________________________
ENGINE COOLING SYSTEM SERVICE

Depressurizing/Draining
WARNING: To avoid injury, do not remove surge tank ller cap before depressurizing cooling system when engine temperature is above 190F (88C).
1. If engine is hot, place a thick cloth over surge tank ller cap. Turn counterclockwise to rst stop to release internal pressure (Figure 4-8). After pressure has vented, remove cap. Open drain valve and drain system (Figure 4-7). Close drain valve.
2. 3. 4.
Replenishing
NOTE: Ensure surge tank coolant level is 3/4 full before securing filler cap. 1. 2. 3. 4. Ensure drain valve is closed and heater control valve is open (Figure 4-7).
SURGE TANK FILLER CAP DRAIN VALVE
Figure 4-7: Drain Valve
Fill system with proper antifreeze solution (Table 4-1). Install filler cap on surge tank (Figure 4-8). Start engine and run at fast idle (1500 rpm) until engine temperature reaches 190 F (88 C). Stop engine. 5. Depressurize system. 6. Fill with proper antifreeze solution until surge tank is 3/4 full (Table 4-1). 7. Install filler cap on surge tank (Figure 4-8). 8. Start engine and run at fast idle (1500 RPM) until engine temperature reaches 190 F (88 C). Stop engine. 9. Depressurize system. Use tester to ensure proper coolant protection is provided. 10. Install filler cap on surge tank. 11. Start engine and check cooling system for leaks.
SURGE TANK
Figure 4-8: Surge Tank and Filler Cap Location

FAN SHROUD
Expected Ambient Temperature 120 to -32 F (49 to -36 C)

Antifreeze/ Water Mixture 50% antifreeze/ 50% water
Table 4-1: Antifreeze Preparation Guide Figure 4-6: Fan Shroud Clearance Check Points
___________________________________________________________
Cooling System
4-7
SHROUD SHIELD ASSEMBLY REPLACEMENT

Removal
1. 2. Remove radiator and fan shroud. Remove screws and shroud shield assembly from airlift bracket (Figure 4-9).
INSULATOR RADIATOR
AIRLIFT BRACKET
SHROUD SHIELD ASSEMBLY REAR SUPPORT BRACKET
Figure 4-10: Insulator and Rear Support Bracket Location
SURGE TANK REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Drain cooling system. Disconnect radiator vent hose from surge tank (Figure 4-12). Disconnect surge tank-to-lower radiator hose from surge tank. Disconnect overflow hose from surge tank. Disconnect low coolant sensor wiring harness. Loosen clamps and remove surge tank from bracket.
Figure 4-9: Shroud Shield Assembly Replacement
Installation
1. 2. Secure shroud shield assembly to airlift bracket with screws (Figure 4-9). Install radiator and fan shroud.
RADIATOR REAR SUPPORT BRACKET REPLACEMENT

Removal
1. 2. 3. 4. Remove left splash shield (Section 10). Remove battery tray and right splash shield (Section 12). Remove radiator rear support bracket and insulator from radiator (Figure 4-10). Remove support bracket from airlift bracket (Figure 4-11).
AIRLIFT BRACKET
Installation
1. Fasten radiator rear support bracket to airlift bracket with bolts, washers, and locknuts. Do not tighten locknuts (Figure 4-11). Secure insulator and support bracket to radiator with washers and locknut (Figure 4-10). Tighten all locknuts to 26 lb-ft (35 Nm). Install left splash shield (Section 10). Install battery tray and right splash shield (Section 12).
2. 3. 4. 5.
Figure 4-11:
Rear Support Bracket Mounting
Installation
1. 2. Secure surge tank to bracket with clamps (Figure 4-12). Connect low coolant sensor wiring harness.
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4-8
3. 4. 5. 6.
Cooling System ____________________________________________________________
Connect surge tank-to-lower radiator hose to surge tank. Connect radiator vent hose to surge tank. Connect overflow hose to surge tank. Fill and purge cooling system.
SURGE TANK VENT HOSE RADIATOR
SURGE TANK BRACKET OVERFLOW HOSE
LOW COOLANT SENSOR SURGE TANK-TO-LOWER RADIATOR HOSE VENT HOSE FITTING (HOSE NOT SHOWN)
Figure 4-13: Surge Tank-to-Radiator Vent Hose Location
THERMOSTAT BYPASS HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen two clamps and remove bypass hose from nipples on water pump and water crossover (Figure 4-14).
Figure 4-12: Surge Tank Replacement
SURGE TANK-TO-RADIATOR VENT HOSE REPLACEMENT

Removal
1. 2. 3. Depressurize cooling system. Loosen two clamps and remove radiator vent hose from radiator and surge tank (Figure 4-13). Reclaim coolant.
Installation
1. 2. Secure bypass hose to nipples on water pump and water crossover with two clamps (Figure 4-14). Fill cooling system.
BLEEDER VALVE WATER CROSSOVER
Installation
1. 2. 3. Secure radiator vent hose to surge tank and radiator with two clamps (Figure 4-13). Tighten coolant filler cap. Replace coolant.
NIPPLES
BYPASS HOSE
WATER PUMP
Figure 4-14: Thermostat Bypass Hose Replacement
___________________________________________________________
Cooling System
4-9
UPPER RADIATOR HOSE REPLACEMENT

Removal
1. 2. 3. Drain cooling system as necessary. Depressurize cooling system. Loosen clamps and remove hose from thermostat housing and radiator (Figure 4-15).
LOWER RADIATOR HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove lower radiator hose from radiator and lower tube assembly (Figure 4-16).
Installation
1. 2. Secure lower radiator hose to lower tube assembly and radiator with clamps (Figure 4-16). Fill cooling system.
RADIATOR
Installation
1. 2. Secure upper radiator hose to thermostat housing and radiator with clamps (Figure 4-15). Fill cooling system.
THERMOSTAT HOUSING
UPPER RADIATOR HOSE LOWER RADIATOR HOSE
CLAMP RADIATOR LOWER TUBE ASSEMBLY
Figure 4-16: Lower Radiator Hose Location Figure 4-15: Upper Radiator Hose Location
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Cooling System
__________________________________________________________
RADIATOR LOWER TUBE ASSEMBLY REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. Drain cooling system. Remove drain valve from lower tube assembly (Figure 4-17). Disconnect radiator lower tube assembly from frame bracket. Loosen clamp and disconnect water pump inlet hose from lower tube assembly. Loosen clamp and disconnect surge tank-to-lower radiator hose from lower tube assembly. Loosen clamp and disconnect lower radiator hose from lower tube assembly. Remove lower tube assembly.
Installation
1. Secure lower tube assembly to frame bracket with bolts, washers, and locknuts. Tighten locknuts to 6 lb-ft (8 Nm) (Figure 4-17). Connect lower radiator hose to lower tube assembly and tighten clamp. Connect surge tank-to-lower radiator hose to lower tube assembly and tighten clamp. Connect water pump inlet hose to lower tube assembly and tighten clamp. Apply sealant tape to threads of drain valve and screw drain valve into lower tube assembly. Fill cooling system.
2. 3. 4. 5. 6.
FRAME BRACKET
WATER PUMP INLET HOSE
SURGE TANK-TOLOWER RADIATOR HOSE
LOWER TUBE ASSEMBLY LOWER RADIATOR HOSE
DRAIN VALVE
Figure 4-17: Radiator Lower Tube Assembly Location
_________________________________________________________
Cooling System
4-11
WATER PUMP INLET HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove water pump inlet hose from water pump and lower tube assembly (Figure 4-18).
SURGE TANK OVERFLOW HOSE REPLACEMENT

Removal
1. 2. Remove overow hose from surge tank ller neck (Figure 4-19). Remove screw, clamp, and overflow hose from body.
Installation
1. 2. Connect water pump inlet hose to lower tube assembly and water pump and tighten clamps (Figure 4-18). Fill cooling system.
Installation
1. 2. Connect overow hose to surge tank ller neck (Figure 4-19). Secure overflow hose to body with clamp and screw.
SURGE TANK FILLER NECK
WATER PUMP BODY OVERFLOW HOSE WATER PUMP INLET HOSE
Figure 4-19: Surge Tank Overflow Hose Mounting
LOWER TUBE ASSEMBLY
Figure 4-18: Water Pump Inlet Hose Location
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Cooling System
__________________________________________________________
SURGE TANK-TO-LOWER RADIATOR TUBE HOSE REPLACEMENT

Removal
1. 2. Drain cooling system. Loosen clamps and remove hose from surge tank and lower tube assembly (Figure 4-20).
LOW COOLANT SENSOR

Installation
1. 2. Install hose on lower tube assembly and surge tank and tighten clamps (Figure 4-20). Fill cooling system.
SURGE TANK
Removal
1. 2. 3. Drain and collect coolant from surge tank. Disconnect the low coolant sensor electrical connector from the engine harness connector. Remove the sensor and O-ring from the surge tank (Figure 4-21)
SURGE TANK O-RING LOWER TUBE ASSEMBLY
SURGE TANK-TO-LOWER TUBE ASSEMBLY HOSE
LOW COOLANT SENSOR
Figure 4-20: Surge Tank-to-Lower Tube Assembly Hose Location
Figure 4-21: Low Coolant Sensor
Installation
1. 2. 3. Position O-ring on sensor and thread sensor into surge tank (Figure 4-21). Plug the low coolant sensor electrical connector into the engine harness connector Fill surge tank with coolant.
_________________________________________________________
Cooling System
THERMOSTAT SEATS AND COUNTER BORES
4-13
THERMOSTAT REPLACEMENT
1. 2. 3. 4. 5. Drain engine coolant below level of water crossover. Remove bolts attaching thermostat cover to crossover housing. Remove thermostat cover and gasket (Figure 4-22). Remove both thermostats (Figure 4-23). Position new thermostats in crossover housing (Figure 4-24). Be sure thermostat seals are seated in counterbores. Wax pellet end of each thermostat goes toward engine. Apply Permatex no. 2 to both sides of thermostat housing gasket. If gasket is not used, apply 3/16 in. (5 mm) bead of Loctite 599, or Permatex Ultra Copper, or Ultra Black to cover or crossover mounting surface. Install thermostat cover and tighten cover bolts securely. Fill and bleed cooling system.
WATER CROSSOVER
6.
Figure 4-24: Thermostat Location in Crossover
7. 8.
WATER PUMP AND ADAPTER PLATE

Removal
1. Drain engine coolant. Loosen and remove serpentine drive belt. Remove fan and fan clutch (Figure 4-25). Disconnect hoses at water pump. Remove water pump and backing plate attaching bolts/ studs and remove pump and plate as assembly (Figure 4-26). Remove water pump and gasket from plate (Figure 4-27). Clean all gasket material and sealer from plate.
8-BLADE FAN FAN CLUTCH
THERMOSTAT HOUSING TWIN THERMOSTATS GASKETS WATER CROSSOVER
2. 3. 4. 5.
6. 7.
Figure 4-22: Thermostat and Cover Removal and Installation

THERMOSTAT
SERPENTINE DRIVE BELT
SEAL WAX PELLET
Figure 4-25: Fan and Clutch Mounting
Installation
1. Figure 4-23: Turbo Diesel Thermostat If new pump is being installed, transfer hose adapter ttings to new pump. Apply Loctite PST to tting threads before hand.
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3-1-02
4-14
2.
Cooling System
__________________________________________________________
3.
4.
Apply coat of Permatex no. 2, Ultra Black, or Ultra Copper to each side of water pump gasket. Then position gasket on pump. Apply 1/8 - 3/16 in. (3.3-5 mm) wide bead of sealer to backing plate (Figure 4-28). Encircle bolt hole at bottom of plate with sealer as shown. Also apply sealer to threads of bolt or stud used in this hole to avoid leaks. Install adapter plate and water pump on front cover. Tighten all studs and short bolts marked A to 13-20 lb-ft
5. 6. 7. 8. 9.
(18-27 Nm). Tighten large studs and large bolt marked B to 25-37 lb-ft (34-50 Nm) (Figure 4-26). Attach hoses to water pump. Install fan and clutch. Install and adjust serpentine drive belt. Refill engine cooling system. Start engine, bleed air from cooling system, and top off coolant level.
ADAPTER PLATE
FRONT COVER
A
A
WATER PUMP
BYPASS ADAPTER
BACKING PLATE
GASKET
WATER PUMP
Figure 4-27: Water Pump
3-1-02
_________________________________________________________
Cooling System
4-15
BACKING PLATE
A/C COMPRESSOR COMPRESSOR CLUTCH CONNECTOR
COMPRESSOR BOLT (4)
SEALER BEAD
ENCIRCLE THIS BOLT HOLE WITH SEALER
Figure 4-28: Backing Plate Sealer Application
WATER CROSSOVER SERVICE

Removal
1. 2. 3. Drain engine coolant to below level of crossover. Disconnect heater, surge tank, and radiator hoses at crossover. Disconnect coolant temperature sensor wires (Figure 4-29).
COOLANT TEMPERATURE SENSOR CROSSOVER
Figure 4-30: Compressor Clutch Bolt and Connector Location

WATER CROSSOVER
OIL FILLER CAP AND TUBE
STUD NUT
Figure 4-31: Water Crossover Attaching Hardware
Installation
Figure 4-29: Filler Tube and Temperature Sensor Locations
4. 5. 6. Remove oil filler tube attaching nuts and remove filler tube (Figure 4-29). Disconnect A/C compressor clutch wires (Figure 4-30). Remove compressor clutch mounting bolts. Lift compressor out of bracket and move it aside for access to crossover bolts and nuts. Remove water crossover attaching bolts/nuts (Figure 4-31). Remove crossover and gaskets. If crossover will be replaced, transfer air bleed valve and coolant temperature sensor to new crossover. Also transfer thermostats if necessary. Use Loctite PST on valve and sensor threads to ensure proper seal. 1. Apply Permatex Ultra Black or no. 2 sealer to both sides of crossover gaskets. Then position gaskets on cylinder heads. Align and install crossover. Tighten crossover nuts/bolts to 25-37 lb. ft. (34-50 Nm) torque. Install oil filler tube. Tighten attaching nuts to 13-20 lb. ft. (18-27 Nm) torque. Connect hoses to water crossover. Install A/C compressor in bracket and tighten bolts. Connect wires to coolant temperature sensor. Refill and bleed engine cooling system.
2. 3. 4. 5. 6. 7.
7. 8. 9.
05745159
4-16
Cooling System
__________________________________________________________
SERPENTINE BELT REPLACEMENT

1. Insert square lug of half-inch drive breaker bar in belt tensioner. Then move tensioner counterclockwise to loosen belt (Figure 4-32). Remove belt from pulleys (Figure 4-33). Position half-inch drive breaker bar in belt tensioner and move tensioner counterclockwise and position serpentine belt on pulleys as shown (Figure 4-33). Release belt tensioner. Tensioner will automatically set belt tension when released.
GENERATOR BELT TENSIONER PULLEY AND PULLEY A/C COMPRESSOR (OR IDLER PULLEY WITHOUT A/C)
FAN AND CLUTCH ASSEMBLY SERVICE

Removal
1. 2. Insert spanner J41240-1 in holes in water pump pulley (Figure 4-34). Use the spanner to hold the water pump shaft and wrench J41240-5A to break the nut loose securing the fan clutch to the water pump. Remove bolts attaching fan to fan clutch. Remove fan clutch-to-water pump nut. Remove fan and clutch from water pump.
2. 3.
4.
3. 4. 5.
Installation
6. 7. 8. Slide fan onto clutch and install bolts finger tight. Install fan and clutch assembly on water pump shaft (Figure 4-34). Hold water pump shaft with spanner J41240-1 and tighten clutch nut to 80-100 lb-ft (108-135 Nm) with wrench J41240-5A. Torque fan bolts to 15-20 lb-ft (20-27 Nm).
WRENCH FAN
9.
WATER PUMP PULLEY VACUUM PUMP
SERPENTINE BELT SPANNER
CRANKSHAFT PULLEY
POWER STEERING PUMP PULLEY CLUTCH

GENERATOR PULLEY TENSIONER PULLEY A/C COMPRESSOR OR IDLER PULLEY
SERPENTINE BELT WATER PUMP PULLEY POWER STEERING PUMP PULLEY
WATER PUMP PULLEY
Figure 4-34: Fan and Clutch Assembly

VACUUM PUMP CRANKSHAFT PULLEY
Figure 4-33: Serpentine Belt Routing
________________________________________________________________________________
5-1
Section 5 Transmission/Transfer Case

TABLE OF CONTENTS
Bulkhead, 76 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 Converter Housing Lower Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . .5-123 Upper Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . .5-123 Extension Housing Bushing and Seal . . . . . . . . . . . . . . . . . .5-157 Flexplate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-127 Front Output Shaft Bearing and Seal Replacement . . . . . . . . . . . . . . . . . . . .5-154 Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-143 Input Gear Bearing Replacement . . . . . . . . . . . . . . . . . . . . . .5-156 Instrument Panel, 56 way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Mainshaft Pilot Bearing Replacement . . . . . . . . . . . . . . . . . .5-156 PCM, 24 Way, Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38 PCM, 32 Way, Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36 PCM, 32 Way, Brown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 Propeller Shaft Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .5-169 Shift Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-135 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-131 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-132 Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-136 Torque Converter/Oil Pump Seal . . . . . . . . . . . . . . . . . . . . . .5-127 Transfer Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-158 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . .5-153 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-137 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-139 Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . .5-145 Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-143 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-138 Guide Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . .5-142 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-138 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-144 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-138 Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-139 Recommended Lubricant . . . . . . . . . . . . . . . . . . . . . . . . .5-138 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-144 Shift Rod Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-141 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-139 Speed Sensor and Switch Replacement . . . . . . . . . . . . .5-142 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-169 Vent Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141 Transmission Cooler Line and Bypass Valve Service . . . . . . . . . . . . . 5-121 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Line Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Pressure Control Solenoid Test . . . . . . . . . . . . . . . . . . 5-15 Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Electronic Shift Control Components . . . . . . . . . . . . . . . . 5-3 Engine Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-170 Fill Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121 Fluid And Filter Replacement . . . . . . . . . . . . . . . . . . . . . 5-120 Fluid Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Gear Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Input and Output Speed Sensors . . . . . . . . . . . . . . . . . . . . 5-6 Input Speed Sensor Replacement . . . . . . . . . . . . . . . . . 5-136 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130 Park Lock Component Service . . . . . . . . . . . . . . . . . . . 5-125 Park/Neutral Position Switch Replacement . . . . . . . . . . 5-133 Pressure Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Rear Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5-136 Recommended Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127 Scan Tool Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Shift Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135 Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Shifter Boot Cover Replacement . . . . . . . . . . . . . . . . . . 5-134 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-171 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Torque Converter Clutch Solenoid . . . . . . . . . . . . . . . . . . . 5-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-169 Valve Body Switch and Solenoid Service . . . . . . . . . . . 5-124 Vent Line Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-122 Warning Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Transmission Passthrough, 20 way . . . . . . . . . . . . . . . . . . . . . 5-41 Transmission, 10 Way, Black . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Transmission, 10 Way, Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 internal clutch (Figure ).Transmission shift controls include the control module and sensors for fluid temperature and output shaft speed. Solenoids are used to actuate the shift valves and apply the converter clutch. A pressure control solenoid is used to boost operating pressure. The control module energizes, or de-energizes the transmission shift solenoids and pressure control solenoid motor. The module controls shift points and sequence based on signals from engine/transmission sensors.
TRANSMISSION DESCRIPTION
The Hydra-matic, model 4L80-E is used for all engine applications in Hummer vehicles. The 4L80-E is a four-speed, automatic transmission with fully electronic shift control. Fourth gear is an overdrive range. Major transmission drive and apply components consist of: five multiple disc clutches, three roller/sprag clutches, three planetary gear sets, two bands, a control valve, band servos, accumulators, park lock mechanism, and torque converter with 5745159
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TORQUE CONVERTER OIL PUMP OVERDRIVE PLANETARY
REACTION PLANETARY
OUTPUT PLANETARY
FOURTH CLUTCH
PARK PAWL LO ROLLER CLUTCH FRONT BAND OVERDRIVE ROLLER CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH REAR BAND
OVERRUN CLUTCH
INTERMEDIATE SPRAG CLUTCH
Figure 5-1: Transmission Drive and Apply Elements
TRANSMISSION GEAR RANGES

The 4L80-E gear ranges consist of: Park, Reverse, Neutral, Overdrive D range, manual D range, manual 2 range and Manual 1 range. In Park (P) range, none of the clutches and bands are applied. In addition, the transmission output shaft is locked by a pawl that engages gear teeth on the output carrier. The pawl is actuated by a rod and detent operated by the manual lever. Park range (along with Neutral), is used for engine starting. In Reverse (R) range, the direct clutch and rear band are applied and the overdrive roller clutch is holding. The vehicle will backup (move rearward) only in this range. In Neutral (N) range, none of the clutches or bands are applied. Vehicle movement is not provided for. Neutral is used primarily for engine starting, or when the vehicle must be moved while the engine is not running. In Overdrive D range, the transmission will shift from first through fourth gear. This range is used for all normal driving conditions and also provides maximum fuel economy. Overdrive range is not, however, recommended for use on extremely steep terrain, or when pulling heavy loads. Manual D range should be used under these conditions. In manual D range, the transmission will shift from first to third gear only. This range is recommended for high load, steep terrain driving. Manual D range also provides some engine braking when descending slight grades. In manual second (2) range, the transmission will only shift from first to second. This range is useful on steep terrain or when pulling loads up an incline. Manual 2 range also provides overrun braking which is helpful on mild grades. In manual low (1) range, the transmission remains in first gear. Upshifts will not occur. This range is useful for pulling heavy loads at low speed, or when ascending steep inclines. Overrun braking is also provided which is helpful when descending steep terrain.
TRANSMISSION GEAR RATIOS

Transmission gear ratios are: First gear 2.48:1 Second gear 1.48:1 Third gear 1.00:1 Overdrive Fourth .75:1 Reverse 2.08:1
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TRANSMISSION IDENTIFICATION
An I.D. plate is attached to the passenger side of each Hydramatic Transmission (Figure 5-2). The plate contains the model, Hydra-matic type, model year, calendar year, and Julian calendar date. The I.D. plate information is required for correct service parts ordering.
ELECTRONIC SHIFT CONTROL COMPONENTS

Upshifts and downshifts in overdrive and manual D ranges are electronically controlled. Transmission electronic components include (Figure 5-3): Automatic Transmission Fluid Temperature Sensor Automatic Transmission Fluid Pressure Manual Valve Position switch Automatic Transmission Input (shaft) Speed Sensor Automatic Transmission Output(shaft) Speed Sensor (Vehicle Speed Sensor) 1-2 and 2-3 shift solenoids Pressure Control Solenoid Valve Torque Converter Clutch Pulse Width Modulated Solenoid PCM (powertrain control module) Additional inputs to the transmission PCM are provided by: the engine coolant temperature sensor, Cruise Control, A/C request, electronic accelerator pedal, crankshaft position sensor, and brake switch.
TRANSMISSION I.D. PLATE
MODEL
HYDRA-MATIC 4L80-E/4L80-EHD
Adapt Function
The 4L80-E transmission uses a line pressure control system, which has the ability to continuously adapt the systems line pressure. This compensates for normal wear and break in of the following parts. The clutch fiber plates The seals The springs The PCM maintains the following adapt parameters for the transmission: Upshift Adapt - The PCM monitors the Automatic Transmission Input (Shaft) Speed Sensor (A/T ISS) and the Output or Vehicle Speed Sensor (VSS) during commanded shifts in order to determine if a shift is occurring too fast or too slow. The PCM adjusts the signal to the transmission pressure control solenoid valve in order to maintain a set shift feel. Reset the Transmission Adapt functions when the transmission is overhauled or replaced. To reset the Transmission Adapt functions, use the Tech 2 Scan Tool.
XX
98
MODEL YEAR (98 = 1998)
0 000
CALENDAR YEAR JULIAN DATE
Figure 5-2: Transmission I.D. Plate Information (Example Plate)
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FLUID TEMPERATURE SENSOR
INPUT SPEED SENSOR
CONVERTER CLUTCH SOLENOID
PRESSURE CONTROL SOLENOID
PRESSURE SWITCH ASSEMBLY
SHIFT SOLENOIDS
Figure 5-3: Transmission Shift Control Components
TRANSMISSION FLUID PRESSURE MANUAL VALVE POSITION SWITCH

The pressure switch assembly is mounted on the valve body. It contains five pressure switches in circuit with the PCM (Figure 5-4). The switches are used to signal the PCM which gear range has been selected. Each pressure switch is activated by fluid pressure (Figure 5-5). Fluid flow through the manifold is controlled by the valve body manual valve (Figure 5-6). The five pressure switches are closed only when fluid pressure is applied. Fluid flow into the switch cavity presses the diaphragm downward against the contact element and switch contact (Figure 5-4). Once the switch closes, it completes the ground circuit to the PCM through one of the connector pins (Figure 5-4). The hydraulic and electrical schematics in Figure 5-6 illustrate switch activation and fluid flow in third gear. The Drive and PRND 4/3 switches are pressurized closing the circuit to connector pin C (Figure 5-4). This changes the digital logic at Pin C to O and the logic at Pins A and B to 1 (Figure 5-6). The PCM reads this as third gear.
THREE PIN CONNECTOR REVERSE SWITCH PRND 4/3 SWITCH LO (1-2) SWITCH
PRESSURE SWITCH ASSEMBLY
PRND 4 SWITCH
DRIVE SWITCH
Figure 5-4: Pressure Switch and Connector Identification
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BODY
FLUID O-RING
CONTACT DIAPHRAGM
CONTACT ELEMENT
SWITCH CONTACT BODY FLUID
GROUND
O-RING DIAPHRAGM
CONTACT
CONTACT ELEMENT
SWITCH CONTACT
GROUND
Figure 5-5: Pressure Switch Actuation
Figure 5-6: Hydraulic/Electrical Circuitry for Pressure Switch Assembly (Third Gear Shown)
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AUTOMATIC TRANSMISSION INPUT (SHAFT) SPEED SENSOR AND OUTPUT (SHAFT) SPEED SENSOR (VEHICLE SPEED SENSOR)
The input and vehicle speed sensors are variable reluctance, magnetic pickup units (Figure 5-7). They consist of a permanent magnet surrounded by a wire coil. The sensors are mounted in the driver side of the transmission case and the top of the transfer case at the rear. The vehicle speed sensor is positioned opposite the speedometer tone wheel in the rear of the transfer case. The input sensor is opposite the machined teeth on the forward clutch housing in the transmission (Figure 5-7). The tone wheel and gear teeth interrupt the sensor magnetic field as they rotate. This induces an AC current in each sensor coil. The vehicle sensor provides a voltage signal proportional to vehicle speed. The input sensor signal indicates transmission shaft/turbine speed. Both sensor signals are used by the PCM to determine shift speed, pattern, and converter clutch apply. Sensor signals reaching the PCM are converted to a square wave form (Figure 5-7). The wave forms correspond to the teeth on the speedometer tone wheel and forward clutch. The increase in shaft speed will cause more teeth to interrupt the sensor magnetic field in a given time. This is reflected in an increase in the number of wave forms sent to the PCM. The wave forms are compared to a fixed signal voltage in the PCM to determine speeds.
TRANSMISSION FLUID TEMPERATURE SENSOR

The fluid temperature sensor is mounted on the internal transmission harness. Failure of the sensor constitutes wiring harness replacement. It is a temperature sensitive resistor more commonly known as a thermister (Figure 5-8). Low fluid temperature produces high resistance. The PCM controls torque converter clutch apply based on sensor input signals. The PCM will not allow converter clutch apply when fluid temperature is below 68F (20C). At higher fluid temperatures, the PCM will apply or release the converter clutch as follows: Apply the clutch in second, third, fourth when fluid temperature exceeds 250F (122C). Release the clutch and prevent apply in any gear range when fluid temperature reaches or exceeds 300F (150C). Prevent converter clutch apply and set a-fault code when fluid temperature reaches 310F (154C).
SENSOR ELEMENT
O-RING
16,000
SPEED SENSOR
TEMPERATURE SENSOR
MAGNETIC PICKUP (MAGNET AND COIL) FORWARD CLUTCH GEAR TEETH OR SPEEDOMETER TONE WHEEL 5.0 SIGNAL VOLTS LOW SPEED HIGH SPEED
133 -10C +16F 110C 230F
Figure 5-8: Temperature Sensor
TIME
CONDITIONED SQUARE WAVE SIGNAL
Figure 5-7: Transmission Speed Sensor Signal Form
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SHIFT SOLENOIDS
Two solenoids are used to control upshifts and downshifts in the forward gear ranges. Solenoid A controls the 1-2 shift valve while Solenoid B controls the 2-3 shift valve. Both solenoids are mounted on the valve body and operated by the PCM. The solenoids are energized or de-energized separately and in combination to control shifts. The following chart outlines solenoid activities in the various gear ranges.
SIGNAL FLUID INLET PORT CONNECTOR EXHAUST PORT COIL
Gear Range Park, Reverse, Neutral First Second Third Fourth
1-2 Solenoid A ON ON OFF OFF ON
2-3 Solenoid B OFF OFF OFF ON ON
O-RING METERING BALL PLUNGER FRAME
Figure 5-9: Shift Solenoid Cross Section
The solenoids are de-energized when the PCM completes the solenoid ground circuit. Incoming fluid passes around the check ball and exits through the exhaust port (Figure 5-9). Energizing the solenoid causes the coil to extend the plunger blocking off the exhaust port. Incoming fluid is then routed back to the 1-2 or 2-3 shift valve, overcomes spring pressure, and moves the valve to required shift position. An example of solenoid actuation is provided in Figure 5-10 which illustrates third gear flow. Solenoid A is de-energized (off) causing signal A fluid to exhaust through the outlet port. The 1-2 shift valve remains in position through normal valve spring pressure. Energizing solenoid B, blocks the exhaust port causing signal B and actuator feed pressure to act against the 23 valve and spring. The two fluid pressures overcome spring pressure moving the 2-3 valve into Upshift position. However, in manual 1 and 2 ranges D21 fluid pressure prevents the 2-3 valve from moving to upshift position despite solenoid B energized state.
Figure 5-10: Shift Solenoid Actuation (Third Gear Shown)
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TORQUE CONVERTER CLUTCH PULSE WIDTH MODULATED SOLENOID

The torque converter clutch (TCC) solenoid is located on the transmission valve body and is energized by the PCM. The TCC solenoid acts on the TCC apply valve to control torque converter clutch application. The TCC solenoid is pulse width modulated by the PCM. This means that the PCM pulses the solenoid so that the hydraulic pressure against the torque converter clutch modulates. This modulated pressure allows the TCC to slip slightly thus keeping the TCC balanced just at the point of engagement. In operation, energizing the solenoid allows converter clutch signal fluid and 2-3 drive fluid, to act on the ball and plunger (Figure 5-11).
FRAME SIGNAL FLUID EXHAUST PORT COIL CORE METERING BALL O-RINGS
Torque signal fluid from the solenoid, also affects the torque signal compensator valve in the accumulator, and the accumulator valve in the valve body. At low throttle openings, the PCM applies a maximum of 1.1 amps current to the solenoid. This keeps the motor armature and coil energized holding the plunger away from the valve. The valve is moved inward by torque signal fluid pressure blocking the filtered actuator feed port and exposing the exhaust port. Torque signal fluid then exits through the exhaust port and returns to the system. Pressure on the reverse boost valve is minimal or at zero. At higher throttle openings, PCM current flow to the solenoid decreases to zero. At this point, the solenoid armature and coil are de-energized (Figure 5-12). The plunger and valve are moved outward by spring force closing the exhaust port. Once the exhaust port is closed, torque signal fluid is directed to the boost valve. The combination of torque signal fluid and regulator valve spring pressure, then moves the pressure regulator valve to a higher pressure setting. The solenoid replaces the vacuum modulator used on previous transmissions. Torque signal fluid acts much like throttle pressure fluid in prior transmissions.
FILTERED ACTUATOR FEED FLUID
ARMATURE EXHAUST PORT SPRING
PLUNGER FILTERED 2-3 DRIVE FLUID CONNECTOR
CONVERTER CLUTCH SIGNAL FLUID INLET
VALVE
Figure 5-11: Converter Clutch Solenoid Cross Section
PRESSURE CONTROL SOLENOID VALVE

The solenoid (Figure 5-12) uses filtered actuator fluid to regulate torque signal fluid pressure. The solenoid is controlled by the PCM and is located on the valve body. Torque signal fluid increases line pressure when required. Fluid is directed by the control solenoid against the reverse/ boost valve (Figure 5-13). Pressure on the boost valve forces it against the pressure regulator valve adding to regulator valve spring pressure. This action moves the pressure regulator valve upward allowing greater flow into the line pressure feed passage. The PCM energizes the control solenoid when throttle opening decreases. Torque signal fluid pressure then falls off and the regulator valve returns to normal position. Line pressures are boosted at high throttle openings and during reverse gear operation only. A failure in the transmission electrical circuit will also cause higher line pressures. This is a protective feature designed to prevent clutch slip.
TORQUE SIGNAL FLUID DAMPER SPRING
PLUNGER
COIL ASSEMBLY
Figure 5-12: Pressure Control Solenoid In Energized (Closed) State
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ENGINE SENSOR INPUTS

PRESSURE REGULATOR VALVE
REVERSE/ BOOST VALVE EXHAUST PORT
The electronic accelerator pedal, coolant temperature sensor, A/C switch, brake switch, and crankshaft position sensor, all affect transmission operation. The electronic accelerator pedal input signals inform the PCM of throttle position. This input affects pressure control solenoid operation and transmission line pressure. The solenoid increases line pressure at higher throttle openings. The coolant temperature sensor input affects transmission shifting. The sensor signal can prevent shifts into overdrive fourth gear when coolant temperatures are low or extremely high. Crankshaft position sensor inputs are used by the PCM to adjust shift points and fluid pressures. A signal from the A/C switch informs the PCM when the A/C switch and compressor are engaged. This signal affects transmission shift points to compensate for increased engine load and idle rpm. The brake switch signal is used by the PCM to control downshift points and torque converter release. Brake application completes the switch circuit to the PCM which then downshifts the transmission as needed.
TORQUE CONVERTER
The torque converter consists of a cover, clutch pressure plate and damper, turbine, stator, and pump (Figure 5-14). A roller clutch in the stator hub prevents stator freewheeling until coupling speed is reached. The clutch maintains torque multiplication until this point. The converter clutch, located between the cover/impeller and the stator, eliminates normal internal slippage at cruise speeds. The clutch pressure plate has friction material bonded to it that engages the cover/impeller when applied. Clutch applied at normal cruise speeds improves fuel economy and reduces fluid temperature. The converter is not a repairable part. It is serviced only by replacement.
Figure 5-13: Pressure Control Solenoid Boost Schematics
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Transmission/Transfer Case _____________________________________________
CONVERTER COVER/ IMPELLER
TURBINE
CONVERTER PUMP
CLUTCH PRESSURE PLATE AND DAMPER
ROLLER CLUTCH
STATOR SHAFT (PART OF OIL PUMP COVER)
TURBINE SHAFT
HUB
STATOR
Figure 5-14: Torque Converter Components
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b.
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TRANSMISSION SERVICEABILITY
The Hydra-matic transmission used in Hummer vehicles is serviced at two levels. Only external parts are serviced during the warranty period. A transmission internal component failure will require transmission replacement. Service replacement transmissions are available through the DCS. External repairs include replacement of the following: oil pan, gasket, magnet and filter converter housing access covers shift solenoids pressure switch speed sensors pressure control solenoid converter clutch solenoid park lock detent, actuator, pawl, pin, spring shift, plug, and bracket torque converter and seal fill tube, seal, and dipstick adapter and gasket rear mount insulator and bracket transmission wiring harness vent lines and cooler lines PCM
c. d.
Start engine, apply brakes, shift through all gear ranges and back to Park. Run engine at curb idle speed. Remove dipstick and check fluid level. Fluid should be in crosshatch area of dipstick. If level is low, add fluid in 1/4 pint/liter increments if necessary. If fluid level is high, draw-off excess with suction gun and plastic tubing inserted in filler tube.
CAUTION: Do not overfill the transmission. Excess fluid will be churned into foam aerating the fluid. The result will be fluid overheat, shift problems and clutch wear. 4. 5. If fluid level was low, check for leaks at the oil pump seal, cooler and lines, filler tube and oil pan. Check shift linkage adjustment. If vehicle starts only in Park and Neutral, linkage is OK. Linkage needs adjustment when engine wont start in one of the ranges, or if shift indicator in bezel is seriously misaligned. Inspect transmission harness and case connector. Repair loose connections or damaged wiring as needed and proceed to next step. If leaks, linkage, or fluid problems are not encountered, proceed to road test.
6.
7.
Preliminary Inspection - Vehicle Is Disabled

1. Check uid level and condition as described in procedure for driveable vehicles. Check for fluid leaks or broken shift linkage. Check driveline as follows: Raise vehicle so wheels are free to rotate. Then start engine, shift transmission and transfer case into gear, and note the following: a. If one or both propeller shafts turn but wheels do not, problem is with differential or axle shafts. b. If propeller shafts turn but transmission or transfer case is noisy, stop engine immediately. Then repair transmission or transfer case as needed. c. If propeller shafts do not rotate and transmission is not noisy, test transmission line pressure as described in this section.
TRANSMISSION DIAGNOSIS
Transmission diagnosis is a three step procedure. The first step involves two preliminary inspection procedures to check external parts. The second step involves road testing to confirm and identify a problem. The third step involves shop testing to locate the problem system or part. Shop testing includes pressure testing, scan tool diagnosis, and visual inspection. 2. 3.
Preliminary Inspection - Vehicle is Driveable

1. If problem involves vibration or noise, check following: tires and wheels for wear or damage drive belt and accessories for wear, or being loose propeller shaft U-joints for wear or damage exhaust pipes, muffler, converter touching body or frame engine/transmission mount wear or damage Check transmission fluid condition as follows: a. Refer to Transmission Fluid Checking Procedure Check transmission fluid level as follows: a. Transmission fluid should be at normal operating temperature for accurate check. Drive vehicle if necessary.
2. 3.
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Road Test
1. If engine and transmission have cooled down, drive vehicle 10-12 miles to return to normal operating temperature.
Road Test Analysis

Shift problems such as harsh, or late shifts, indicate a problem with the wiring, a sensor, low fluid level, or a PCM fault. Complete loss of a gear range when the fluid is cold or hot, indicates failure of a drive element. An important diagnostic tool is the Transmission Elements In Use chart (Figure 5-15). The chart indicates what elements are applied, holding, or overrunning in each gear range. The chart also indicates shift solenoid status in each gear range as well. By comparing elements in use to a problem gear range, the number of parts to be checked can be narrowed considerably. In cases where loss of drive, slow engagement, or engine flare are experienced, a line pressure test is needed. This test checks oil pump and pressure control solenoid output and condition. A torque converter fault will require scan tool testing to determine the problem part. A fault in one of the sensors or solenoids will also require scan tool testing. Incorrect shift points, no 3-4 upshift, converter shudder or slip, and harsh engagement are some of the problems caused by sensor, solenoid, wiring, or a PCM fault. Potential causes for common shift problems are described in the diagnosis guides. Corrective action is also provided. Problem causes are listed in order of probability (most-least).
NOTE: The engine coolant and transmission fluid temperatures must be at normal operating levels for a proper road test. The engine and transmission temperature sensors will inhibit upshifts otherwise. 2. Check torque converter operation as follows: a. Operate vehicle at 50-55 mph (80-88 km/h). b. Lightly apply brakes and check for converter clutch release. Engine rpm will increase slightly when release occurs. c. Release brakes, accelerate again, and check for converter clutch apply. Engine rpm will fall off slightly when apply takes place. d. If shudder occurs during converter clutch apply, or clutch wont release, problem is with one of the converter control valves, solenoid, or fluid level is low. If shudder occurs after clutch apply, problem is with engine, mounts, or other driveline component. e. If more than normal throttle opening is required to accelerate and maintain cruise speed, stator roller clutch may have failed. Check shifting in both D ranges. Verify 1-2 and 2-3 upshifts and 3-4 upshift in overdrive D range. Then manually shift into 2 position at 25 mph. Transmission should immediately shift into second gear but not upshift to third. Stop vehicle and shift into 1 range. Accelerate to 25-30 mph and note operation. Transmission should remain in first gear, provide overrun braking effect at decel, and not upshift. Stop vehicle, shift into reverse and backup. Vehicle should move smoothly in reverse. Check kickdown operation in both D ranges. Transmission should downshift promptly when accelerator pedal is moved to wide open position. Drive vehicle in all gear ranges. The following indicate transmission mechanical or electrical fault: loss of one or more gear ranges engine flare during shifts (indicates clutch slip) rough-harsh shifts noise in one or more gear ranges delayed or harsh engagement in D or R shudder or surge during shifts engine starts in range other than P or N engine stalls after shift to D loss of drive or reverse
3.
4.
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Functional Test Procedure

Step 1 Action Perform the Transmission Fluid Checking Procedure. Fill the reservoir to the suggested level. Is the uid level correct? Check for PCM trouble codes, both current and history. Are PCM trouble codes present? Perform the Road Test Procedure. Was the condition Duplicated? Is a harsh or soft shift condition present? Is the vehicles performance poor? Value(s) Yes Go to step 2 No
Go to the Diagnostic Trouble Code Charts Go to step 4 Go to step 7 Go to Torque converter Clutch Diagnosis Go to step 7 Go to step 8
Go to step 3
3 4 5
Go to step 12 Go to step 5 Go to step 6
6 7
Is the engagement into Drive or Reverse delayed or missing? Perform the Line Pressure Checking Procedure. Is the line pressure correct? Inspect the transmission wire harness connectors and the transmission range switch. Was the problem found and corrected? Is vibration or noise a concern?
Go to step 9 Refer to symptom Diagnosis Tables Refer to symptom Diagnosis Tables Go to step 10
System OK
Refer to Flywheel/Torque Converter Vibration test Locate and repair leak Refer to Symptom Diagnosis Tables Exit Table
10 11
Is the uid leaking? Are other transmission conditions present?
Go to step 11 Go to Step 12
12
Was the condition corrected?
Go to step 1
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Clutch Application Chart

GEAR 1-2 SHIFT SOLENOID A 2-3 SHIFT SOLENOID B FOURTH CLUTCH OVERRUN CLUTCH OVERDRIVE ROLLER CLUTCH FORWARD CLUTCH DIRECT BAND FRONT BAND INTERMEDIATE SPRAG CLUTCH INTERMEDIATE CLUTCH LO ROLLER CLUTCH REAR BAND
ON P-N Rev. R 1st ON ON
OFF
Holding
OFF
Holding
Applied
Applied
OFF
Holding Applied
Holding
O D
2nd
OFF
OFF
Holding Applied
Holding Applied Overrunning Applied Overrunning Overrunning * Applied Overrunning Applied Overrunning Holding
3rd
OFF
ON
Holding Applied
4th
ON
ON
Applied
Overrunning Applied
Applied
Applied
1st
ON
OFF
Applied Applied
2nd
OFF
OFF
Applied
Applied Applied
Holding Applied Overrunning Applied Overrunning * Applied Overrunning Holding
3rd
OFF
ON
Applied
Applied Applied
1st 2 2nd
ON
OFF
Applied
Applied Applied
OFF
OFF
Applied
Applied Applied
Applied Holding Applied Overrunning * Holding Applied
1st
ON
OFF
Applied
Applied Applied
* Holding, but not effective Solenoid operation follows a shift pattern dependent on vehicle speed and throttle position and not gear range. ON = Solenoid energized OFF = Solenoid de-energized Figure 5-15: Transmission Elements In Use Chart
1-1-02
____________________________________________
5-15
Line Pressure Test

1. 2. 3. Check and adjust uid level if necessary. Raise vehicle on hoist Connect pressure gauge to transmission test port (Figure 5-16). Gauge must have 325-350 psi (2240-2413 kPa) capacity. Start engine and check pressures in Park, Neutral and both Drive ranges. Pressure should be a minimum of 35 psi (241 kPa) at idle and increase to a maximum of 171 psi (1179 kPa) at greater throttle openings. Shift transmission into reverse and note pressure. At idle, pressure should be a minimum of 67 psi (462 kPa) and increase to a maximum of 324 psi (2234 kPa) as throttle opening increases. Stop engine, remove gauge, and lower vehicle. If pressures were low in all ranges, pump may need repair or replacement. Problem may be worn, damaged gears, blown out cup plug, cross leakage, or worn bushing. If pressure is high, fault may be with pressure control solenoid, reverse/boost or pressure regulator valves, bad PCM ground or solenoid connection.
PRESSURE GAUGE TRANSMISSION TEST PORT
Amp Feed To Pressure Control Solenoid (From PCM)
Line Pressure - PSI (kPa)
0.0-0.02 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 0.98-1.1
157-177 (1083-1220) 151-176 (1041-1214) 140-172 (965-1186) 137-162 (945-1117) 121-147 (834-1014) 102-131 (703-903) 88-113 (607-779) 63-93 (434-641) 43-73 (296-503) 37-61 (255-421) 35-55 (241-379)
4.
5.
6. 7.
Figure 5-17: Pressure Control Solenoid Test Specifications
RECOMMENDED FLUID
The recommended and preferred fluid for 4L80-E transmissions is Dexron III. In cases where Dexron III is not readily available, Dexron IIE can be used to top off the fluid level. It is not, however, recommended for use as the primary fluid for a fluid change.
Figure 5-16: Pressure Gauge
Pressure Control Solenoid Test

1. 2. 3. 4. 5. 6. 7. Connect scan tool to diagnostic/data link connector. Connect pressure test gauge to transmission. Check fluid level and top off if necessary. Shift into Park and apply parking brakes. Start and operate engine at idle speed. Access override pressure control solenoid test on scan tool. Increase current to pressure control solenoid in amp increments shown in chart (Figure 5-17), and record pressure gauge readings. Allow gauge readings to stabilize for 3-5 seconds after each current change. Stop engine and remove test tools. Compare test pressure readings with charge readings. Pressures should decrease as current to solenoid is increased. Consistently high pressures indicate a fault in the PCM, related wiring, or solenoid. Low pressures indicate an oil pump fault, or hydraulic circuit fault.
Fluid Capacity
Fluid capacity of the 4L80-E used in Hummer vehicles is: Transmission refill capacity (after filter change) is approximately 7.7 qts. (7.3 L). Dry fill capacity (after overhaul) is approximately 13.5 qts (12.8 L) Cooler and line capacity is approximately 1-2 pts (.47.95 L) NOTE: Always fill transmission using the dipstick level as a guide. Residual fluid left in the transmission during service could result in an overfilled condition.
8. 9.
5745159
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5-16
Fluid Level and Condition

Transmission fluid level and condition are important to proper operation. An incorrect fluid level can lead to shift problems, fluid breakdown, and accelerated wear. Check fluid level and condition during the preliminary inspection procedure. This is important, as a low fluid level, or overfill condition can lead to slip and flare, overheating, burned fluid, slow engagement, converter shudder, and no fourth gear upshift. An overfill condition allows the gear train to churn the fluid into foam. this action aerates the fluid causing slip, overheating, oxidation, and overflow from the vent. A low level allows the pump to take in air along with the fluid. Air in the fluid will cause pressures to be low and develop slower than normal shifts.
LIFT HANDLE TO UNLOCK
FRONT OF VEHICLE
Checking Fluid Level

1. 2. 3. 4. 5. 6. Fluid must be at normal operating temperature. Drive vehicle 10-15 miles (15-24 km) if necessary. Position vehicle on level surface. Operate engine at idle speed. Shift transmission into Park. Clean dipstick and top of fill tube with shop towel to avoid dirt entry. Unlock and remove dipstick (Figure 5-19). Correct fluid level is to hot full mark at top of crosshatch (Figure 5-18). Adequate fluid level is anywhere in crosshatch area. Note color and condition of fluid. Refer to fluid condition check. Add fluid only if level is below bottom mark of crosshatch area. Add fluid in 1/4 to 1/2 pint/liter amounts to avoid overfill. However, if overfill condition exists, drain necessary amount of fluid with suction gun and length of small plastic tubing. Or drain excess off at cooler line with engine idling. Install and lock dipstick and shut engine off.
OK CROSSHATCH AREA
FILL TUBE
TRANSMISSION DIPSTICK AND LOCK HANDLE
Figure 5-19: Releasing Transmission Dipstick Lock Handle
7. 8.
9.
ADD FLUID WHEN LEVEL IS BELOW THIS MARK
HOT FULL MARK
Figure 5-18: Transmission Fluid Level Marks
1-1-02
____________________________________________
5-17
Transmission Fluid Checking Procedure

Step 1 2 3 4 Action Check the uid color. Is the uid color red? Is the uid level satisfactory? Check the uid. Is the uid foamy? Check the uid level. The proper uid level should be in the middle fo the X-hatch. Is the level high? Fluid will be low. Add uid to the proper uid level. Is the uid level satisfactory? Check for external leaks. Did you nd any leaks? Correct the leak condition. Did you correct the leak condition? Is the uid level too high? Remove excess uid to the proper level. Refer to Fluid Changing Proceedure. Is the uid level satisfactory? Check for contaminants in the uid. Drain the uid to determine the source of the contamination. Did you drain the uid? Is the uid color an opaque pink? Repair the transmission vent line. Is the repair complete The uid color should be light brown. Transmission uid may turn dark with normal use. This does not always indicate oxidation or contamination. Is the uid color light brown? Drain the uid to determine if the uid is contaminated. A very small amount of material in the bottom pan is a normal condition, but large pieces of metal or other material in the bottom pan require a transmission replacement. Was the uid contaminated? Replace the transmission. Refer to transmission replacement proceedures. Is the replacement complete? Value(s) Yes Go to step 2 Go to step 21 Go to step 8 Go to step 9 No Go to step 11 Go to step 3 Go to step 4 Go to step 5
Go to step 6
6 7 8 9
Go to step 7 Go to step 21 Go to step 9 Go to step 21
Go to step 21
Go to step 10
10
Go to step 15
11 12 13
Go to step 12 Go to step 15 Go to step 14
Go to step13
14
Go to step 15
Go to step 18
15
Go to step 16
5745159
1-1-02
5-18
Transmission Fluid Checking Procedure

Step 16 17 18 19 20 21 Action Clear TRANS ADAPT. Is the proceedure complete? Add new uid. Is the proceedure complete? Change the uid and the lter. Is the procedure complete? Clear TRANS ADAPT. Is the procedure complete? Is the uid level satisfactory? If not, correct as needed. Perform the Functional Test Procedure. Is the functional test completed? Value(s) Yes Go to step 17 Go to step 20 Go to step 10 Go to step 20 Go to step 21 System is OK No
SCAN TOOL DIAGNOSIS

NOTE: The Tech 2 Scan Tool (Figure 5-20) checks function of the solenoids, sensors, and PCM. The scan tool connector is attached to the vehicle data link connector (Figure 5-21).The scan tool provides data on individual circuits, or on all the related electrical components in snap shot mode. The PCM memory and circuits are interrogated by the scan tool. The tool reads diagnostic trouble codes (DTC) and displays fault and performance parameters.
DATA LINK CONNECTOR
01-S05-001
I.P. CLOSEOUT PANEL
Figure 5-21: Data Link Connector
Transmission Warning Lamps

All Hummer vehicles are equipped with a malfunction indicator light (check engine) and a check throttle light. The purpose of the lights is to alert the driver when a transmission/engine, or electronic accelerator pedal circuit fault has occurred. The warning lights are in circuit with the PCM, which controls light operation. The lights are illuminated for a few seconds at startup as part of a bulb check and circuit self test routine. The only other time illumination occurs, is when a system component or circuit fault occurs.
Figure 5-20: TECH 2 Scan Tool
1-1-02
____________________________________________
5-19
Trouble Code Identification

DTC P0218 P0560 Description Transmission Fluid Over temperature System Voltage Malfunction DTC Type C D 1. 2. 1. 2. 3. 4. 5. P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance Transmission Fluid Temperature Sensor Circuit Low Input Transmission Fluid Temperature Sensor Circuit High Input Input Speed Sensor Circuit Intermittent C 1. 2. 3. 1. 2. 3. 1. 2. 3. 1. 2. 3. 4. 1. 2. 3. 4. Default Action The PCM freezes shift adapts. DTC P0218 is stored in PCM history. The PCM inhibits TCC engagement. The PCM freezes shift adapts. The PCM turns off the PC Sol. Valve. The PCM commands an immediate landing into 2nd gear. DTC P0560 is stored in PCM history. The PCM uses a TFT default value of 140 C (284F). The PCM freezes shift adapts. DTC P0711 is stored in the PCM history. The PCM freezes shift adapts. The PCM uses a TFT default value of 140 C (284F). DTC P0712 is stored in PCM history. The PCM freezes shift adapts. The PCM uses a TFT default value of 140 C (284F). DTC P0713 is stored in PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM commands maximum line pressure DTC P0716 is stored in PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM commands maximum line pressure. DTC P0717 is stored in PCM history.
P0712
P0713
P0716
P0717
Input Speed Sensor Circuit Low Input
P0719 P0722
Brake Switch Circuit Low Input Output Speed Sensor Low Input
D B
DTC P0719 is stored in PCM history. 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 1. 2. The PCM illuminates the MIL. The PCM freezes shift adapts The PCM commands maximum line pressure. The PCM calculates the OSS from the ISS. DTC P0722 is stored in the PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts The PCM commands maximum line pressure. The PCM calculates the OSS from the ISS. DTC P0723 is stored in the PCM history. Apply TCC if APP is greater than 0.5% and the vehicle speed is greater than 30 m.p.h. DTC P0724 is stored in PCM history. The PCM commands maximum line pressure. The PCM freezes shift adapts. DTC P0730 is stored in PCM history.
P0723
Output Speed Sensor Intermittent
P0724
Brake Switch Circuit High Input
P0730
Incorrect gear ratio
1. 2. 3.
5745159
1-1-02
5-20

DTC P0741 Description Torque Converter Clutch System Stuck Off DTC Type B 1. 2. 3. 4. 5. 1. 2. 3. 4. 1. 2. 3. P0751 1-2 Shift Solenoid Valve Performance B 1. 2. 3. 4. 1. 2. 3. 4. 1. 2. 3. 4. 5. P0758 2-3 Shift Solenoid Valve Electrical B 1. 2. 3. 4. 5. P1810 Transmission Fluid Pressure Manual Valve Position Switch Assembly Circuit Malfunction B 1. 2. 3. 4. 5. 6. P1811 Maximum Adapt and Long Shift D 1. 2. 3. Default Action The PCM illuminates the MIL. The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement. The PCM commands increased line pressure. DTC P0741 is stored in PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM commands maximum line pressure. DTC P0742 is stored in PCM history The PCM freezes shift adapts. The PCM commands maximum line pressure by disabling the PC Sol. Valve. DTC P0748 is stored in PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM commands maximum line pressure. DTC P0751 is stored in PCM history. The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM commands maximum line pressure. DTC P0753 is stored in PCM history. The PCM illuminates the MIL. The PCM commands an immediate landing into second gear. The PCM freezes shift adapts The PCM commands maximum line pressure. DTC P0756 is stored in PCM history. The PCM illuminates the MIL The PCM commands an immediate landing to second gear. The PCM freezes shift adapts. The PCM commands maximum line pressure. DTC P0758 is stored in the PCM history The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM assumes a D4 shift pattern. The PCM commands maximum line pressure. The PCM commands TCC apply with 4th gear commanded ON. DTC P1810 is stored in the PCM history. The PCM freezes shift adapts. The PCM commands maximum line pressure DTC P1811 is stored in the PCM history.
P0742
Torque Converter Clutch System Stuck On
P0748
Pressure Control Solenoid Circuit Electrical
P0753
1-2 Shift Solenoid Valve Electrical
P0756
2-3 Shift Solenoid Valve Performance
1-1-02
____________________________________________
5-21

DTC P1860 Description Torque Converter Clutch Pulse Width Modulation Solenoid Circuit Electrical DTC Type A 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. 6. 1. 2. 3. Default Action The PCM illuminates the MIL. The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement. The PCM freezes shift adapts. DTC P1860 is stored in PCM history The PCM illuminates the MIL The PCM commands maximum line pressure. The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement The PCM freezes shift adapts DTC P1870 is stored in PCM history The PCM illuminates the MIL. The PCM freezes shift adapts. The PCM assumes a 4wd Lo state if the switch fails when open, or the PCM assumes a 4wd High state if the switch fails when closed, for a transmission shift pattern. DTC P1875 is stored in PCM history.
P1870
Transmission Component Slipping
P1875
Four-Wheel Drive Low Switch Circuit Electrical
4.
5745159
1-1-02
5-22
Transmission Wiring Diagrams
HOT AT ALL TIMES FUSE 2D 20 AMP INTERIOR
HOT IN RUN AND START FUSE 3A 20 AMP EXTERIOR
HOT IN RUN AND START FUSE 4B 5 AMP INTERIOR GRY C10-J STATUS CENTER POWERTRAIN CONTROL MODULE 914 PP 4 G4 554 GRY 9-S12-064 16 2 DLC 30
C1-10 STS LAMP 537 OR 239 PK MIL LAMP
TO C29-B3 714 RD
C10-H C3-G5 658 BR C1-25
C10-C C3-F3
C1-28 C28-C14 MIL CONTROL
C28-C13 C28-D13 BATT BATT
C28-C12 C28-C11 IGN IGN
C28-D11 STS LAMP CONTROL
GROUND GROUND C28-D6 C28-D7 570 BK HOT AT ALL TIMES 59 BK 570 BK FUSE 1H 5 AMP INTERIOR G2
Figure 5-22: Transmission Wiring Diagram 1 of 6
1-1-02
____________________________________________
5-23
BATTERY
FUSE 6B 5 AMP
INTERIOR FUSE BOX

FUSE 2D 20 AMP EXTERIOR FUSE BOX FUSE A31 20 AMP INTERIOR FUSE BOX
STOP LAMP SWITCH B
BRAKE LIGHT SWITCH
G2
22 RD
537C OR
537D OR
570D BK
810 PP
22 RD
570E BK
239B PK
31 C1
40
C29
B10 STOP LAMP SIGNAL
B9 TCC/ CRUISE BRAKE SIGNAL

02-S02-002
D6
D7
D13
C13
C12
C11 C28
PCM POWERTRAIN CONTROL MODULE (PCM)

00-S12-018
Figure 5-23: Transmission Wiring Diagrams 2 of 6
5745159
239D PK
IGNITION C1-10
TO BATTERY
TO BATTERY
1-1-02
5-24

D B 44

722 PP C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1
720 TN
C28-C2
02-S02-004

YL
C69
C1
PCM
153 LG
37
GN
152 DB
42
B11
SET / COAST SIGNAL
RD
151 GY
29
A11
ON / OFF SIGNAL
BR
B 295 BR
FUSE 5C 10 AMP
C29
INTERIOR FUSE BOX
TO IGNITION
02-S12-014
1-1-02
____________________________________________
5-25
AUTOMATIC TRANSMISSON
B A
AUTOMATIC TRANSMISSION
C34
D C
TRANSMISSION FLUID TEMPERATURE SENSOR (TFT)
C32
G 265 LB F 264 RD
L 923 BR
M 359 BK
C34
C27
C33
C15
C7 12V
PCM
C27-C9 PC SOLENOID VALVE HIGH CONTROL C29-B12
PC SOLENOID VALVE LOW CONTROL
PCM
TFT SENSOR SIGNAL
02-S12-016
+5V
LOW REFERENCE
02-S12-015
TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
TORQUE CONVERTER CLUTCH SOLENOID (TCC)
2-3 SHIFT SOLENOID (2-3 SS)
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
TCC PWM SOLENOID CONTROL
2-3 SS VALVE CONTROL FEEDBACK
02-S12-017
5745159
1-1-02
5-26
VEHICLE SPEED SENSOR (VSS)
TO IGNITION EXTERIOR FUSE BOX
SPEEDO / TACH MODULE
FUSE 1D 15 AMP
TWISTED PAIR

C29
GROUND 570 BK
A6
C33
G2
OVER-SPEED WARNING BUZZER (GULF COAST ONLY)
GROUND
570 BK
A7 C3-P9
C28
D6 C1-18
D9
223 DB
570 BR
565 BR
679 LG
239 PK
676 PP
136 TN
12
13
14
353 YL
15
GROUND
VEHICLE OUTPUT SHAFT OVERSPEEDO SPEED REVOLUTION SPEED REFERENCE SIGNAL WARNING SIGNAL SIGNAL
DIGITAL RATIO ADAPTOR

01-S12-020
1-1-02
____________________________________________
5-27
AUTOMATIC TRANSMISSION FLUID PRESURE MANUAL VALVE POSITION SWITCH (TFP)
D2 SWITCH LO SWITCH
D4 SWITCH C C34 J C32 764 PP P
D3 SWITCH B R H 763 DB K 762 OR B6 TRANS RANGE B IINPUT
REV SWITCH A N
C29
B4
B5
TRANS RANGE C IINPUT
TRANS RANGE A IINPUT
01-S12-049
AUTO TRANS INPUT SHAFT SPEED SENSOR A/T ISS
TRANFER CASE VEHICLE SPEED SENSOR VSS
496 GY
495 DB
TWISTED PA I R
TWISTED PA I R
679 LG
676 PP
C33
C32
A 223 DB
DIGITAL RATIO ADAPTER 565 BR C29-A3 VSS OUTPUT SHAFT REVOLUTION SIGNAL TO PCM
C27-D1 A / T ISS LOW
C27-D11 A / T ISS HIGH
C29-A6 VSS 4000 PPM CRUISE CONTROLL REFERENCE SIGNAL
01-S12-050
Figure 5-27: Transmission Wiring Diagrams 6 of 6 5745159 1-1-02
5-28
Connector Legend 76 WAY BULKHEAD LOCATION: LEFT SIDE FIREWALL
C1 MALE
9-S12-048
C1 FEMALE
PIN
1 2 3 4 5 6 7 8 9 10 11 1-1-02
9-S12-047
CKT
400 739 740 43 962 33 37E 37D 786 537 787
COLOR
LG PP YL DB BR WH YL YL RD OR GY
CIRCUIT DESCRIPTION Ignition Feed + Left heated windshield power + Right heated windshield power + Trailer Brake activation Trailer lights neutral safety switch feed start relay feed Ignition switch feed Fuel selector valve control Battery Fuel pump + to selector valve
____________________________________________
5-29
PIN
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 5745159
CKT
37 688 723 724 17 718 353 607 717 961 720 640 92 714 37 338 658 151 31 22 721 580 606 29 39 153 42 198 810 2 152 298 722
COLOR
RD RD YL DG PP DB YL TN WH PP TN OR GY DB RD DB BR GY TN RD LB BR OR PK DG LG BR TN PP LG DB BR PP
CIRCUIT DESCRIPTION Ignition relay feed Rear window defrost feed APP 3 5volt reference APP 3 signal + From dimmer module APP 1 signal Speedometer signal ABS module diagnostic line APP 1 5-volt reference TT4 lamp activation APP 2 5-volt reference IGN+ CTIS warning circuits CTIS rear inate solenoid activation Check throttle lamp activation Battery feed to interiror accessories Wait lamp activation Check engine lamp activation Cruise control ON/OFF signal Oil pressure signal Brake switch signal rest APP 2 sensor signal Not Used for 99 ABS diagnostic line Fuel guage signal Engine temperature signal Cruise resume/accelerate signal Low brake uid lamp activation A/C request TCC brake switch signal Right front turn signal Cruise set/coast signal Backup light switch feed APP 2 ground
1-1-02
5-30
PIN
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
CKT
327 80 3 914 644 210 195 603 719 793 794 41 428 47 46 725 767 1 91 37 12 13 38 16 175 943 5 9 20 21 789 941
COLOR
YL WH LB PP YL DG YL DG BR YL RD TN PK LG WH GY BR DB TN RD OR TN RD LG LB BR DG YL RD GY BR TN
CIRCUIT DESCRIPTION Water-in-fuel lamp activation Underhood lamp power Left front turn signal PCM class 2 communication line to DLC Tachometer signal Low washer uid level lamp activation Headlight switch feed ABS lamp activation APP 1 ground Low coolant lamp activation Low air warning lamp activation Brake uid level sensor feed CTIS buzzer activation Deate solenoid activation CTIS compressor relay activation APP 3 Ground Compass mirror temperature signal Horn relay activation CTIS front inate solenoid activation Batt feed to interior fuse box Headlamp high beam feed Headlamp low beam feed Headlamp switch feed Ignition supply to exterior fuse box fuses 2A, 2B, and 3B Power window relay feed Upper windshield washer pump activation Right rear turn signal Left rear turn signal Front park lamps Rear tail lamp feed Fuel selector valve control Lower windshield washer pump activation
1-1-02
____________________________________________
5-31

6 P N M L K J H 7 8 9 10 5 4 3 2 1 G F E D C B A PIN A1
9-S12-050
C3 MALE
PIN H6
1 G F E D C B A CAV A1
10 9
C3 FEMALE
PIN
A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1
9-S12-049
CKT
195 54 53 67 38 15 640 46 450 47 91 92 338
COLOR
YL DG DB BR RD WH OR WH PK LG TN GY DB Headlight switch feed Dome lamp switch feed Dome lamps feed
DESCRIPTION
Rear wiper relay activation (not used 99) Headlamp switch feed Headlamp feed to dimmer module CTIS switch ignition feed CTIS compressor indicator lamp activation Seat belt lamp activation Deate solenoid activation Front inate solenoid activation Rear inate solenoid activation Glow plug wait lamp activation
5745159
1-1-02
5-32
PIN
D2 D3 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 G5 H6 H7 H8 H9 J6 J7 J8 J9 K6 K7 K8
CKT
2 961 42 603 793 943 12 3 658 327 517 210 794 428 714 14 65 61 17 63 27 948 947 942 19 944
COLOR
LG PP BR RD YL TN OR LB BR YL PK DG RD PK DB LB YL RD PP DG OR DG/YL DB/YL OR/BK YL OR TT4 indicator lamp activation Brake indicator lamp activation ABS indicator lamp activation Low washer uid activation Rear Wiper feed (not used 99)
DESCRIPTION
Right turn indicator lamp activation
High Beam indicator lamp activation Left turn indicator lamp activation Check engine lamp activation Drain Filter lamp activation Power mirror switch battery feed Transfer case lock lamp activation Low coolant lamp activation Low tire air lamp activaion Check throttle lamp activation Headlamp switch feed Ignition feed to intermittent wiper switch High speed windshield wiper signal + from dimmer module Low speed windshield wiper signal Intermittent wiper signal Left hand power mirror up/down signal Left hand power mirror left/right signal Left hand power mirror common +/ Power supply to dimmer module Right hand power mirror common +/
K9 L6 L7 L8 M6 M7 M8 M9 N6
1-1-02
644 476 31 952 789 786 787 953 59
YL GY TN DB BR RD GY DG BK
Tachometer signal Clock battery feed Oil pressure signal to guage Right hand power mirror left/right signal Fuel selector valve control Fuel selector valve control Fuel selector switch feed from fuel pump relay Right hand power mirror up/down signal Ground
____________________________________________
DESCRIPTION
5-33
PIN N7 N8 N9 P6 P7 P8 P9 P10
CKT 30 941 945 55 29 39 353 59
COLOR GY TN BR OR PK DG YL BK Ignition feed to guages
Windshield wiper washer pump activation Intermittent wiper relay activation Rear cargo lamp activation Fuel guage signal Engine temperature guage signal Speedometer signal Ground
5745159
1-1-02
5-34
32WAY PCM-BROWN LOCATION: CENTER CONSOLE, PCM

D1 C1
D16
C16
9-S12-042
C27 MALE
PIN
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 1-1-02 495 784 723 724 787 725 506 238 DB DB YL DG GY GY LB DG Transmission input speed sensor (lo) 4wd low switch signal APP sensor (3) 5 volt ref. APP (3) signal Lift pump feedback signal APP (3) ground Glow plug feedback signal Lift pump relay enable + 713 394 265 RD LG LB Closure signal Boost pressure sensor signal Pressure Control Solenoid (Lo) 354 YL Engine coolant temp signal 357 721 466 264 225 923 TN LB YL RD YL BR Intake air temp sensor signal APP sensor (2) signal Glow plug enable + Pressure Control Solenoid (Hi) Fuel temperature signal Transmission uid temp signal
CKT
651 439
COLOR
PP YL A/C request+
DESCRIPTION
Crankshaft position sensor ground
____________________________________________
DESCRIPTION
5-35
PIN
D9 D10 D11 D12 D13 D14 D15 D16
CKT
156 153 496 717 350 375
COLOR
PK LG GY WH GY GY Optical sensor ground Cruise control resume/accelerate
Transmission input speed signal (hi) APP (1) 5 volt ref. Boost sensor/crankshaft position sensor 5 volt ref. Optical sensor 5 volt reference
5745159
1-1-02
5-36

D1 C1
D16
C16
9-S12-042
C28 MALE
PIN
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 440 570 570 RD BK BK Compressor clutch enable Ground Ground 239 239 537 658 701 PK PK OR BR DB Ignition / axle switch jumper Ignition Battery Malfunction indicator lamp control Engine shutoff solenoid control 720 712 237 924 315 338 914 TN LG LG TN YL DB PP APP (2) 5 volt ref. Fuel inject signal 1-2 shift solenoid control Torque converter clutch soleniod control 2-3 shift solenoid control A/C clutch control ? Class 2 communications (DLC)
CKT
COLOR
DESCRIPTION
1-1-02
____________________________________________
DESCRIPTION
5-37
PIN
D9 D10 D11 D12 D13 D14 D15 D16
CKT
COLOR
714
RD
Check throttle lamp control
537 154
OR TN
Battery Waste gate solenoid control
5745159
1-1-02
5-38

B1 A1
C29 MALE
PIN
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 810 22 152 359 PP RD DB BK
A12
A12
9-S12-028
CKT
491 703 565 442 349 223 709 708 710 711 151 722 719 718 351 764 763 762
COLOR
BK OR BR BR YL DB DB TN OR YL GY PP BR DB PK PP DB OR PTO (1360 rpm) user installed PTO (1070 rpm) user installed Cruise control brake switch TCC brake switch Cruise control set/coast signal Closure ground High resolution sensor signal
DESCRIPTION
Transmission output speed sensor/VSS Cam sensor signal Crankshaft position sensor signal Vehicle speed sensor Injection timing stepper motor (HI) Injection timing stepper motor (LO) Injection timing stepper motor (LO) Injection timing stepper motor (HI) Cruise control on/off signal APP (2) ground APP (1) ground APP (1) signal Front axle switch signal + from jumper
Boost, engine temp, intake air temp, trans temp sensor ground
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10 WAY TRANSMISSION-GREY LOCATION: A BEAM, LEFT NEAR LIFT PUMP
F
9-S12-023
A
9-S12-024
C32 MALE
PIN
A B C D E F G H J K
C32 FEMALE
CIRCUIT DESCRIPTION
CKT
495 496 237 315 924 264 265 763 764 762
COLOR
DB GY LG YL TN RD LG DB PP OR
Transmission Input Speed Sensor low Transmission Input Speed Sensor high 1-2 shift solenoid control 2-3 shift solenoid control Torque Converter Clutch solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission uid pressure manual valve position switch range B Transmission uid pressure manual valve position switch range C Transmission uid pressure manual valve position switch range A
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10 WAY TRANSMISSION-BLACK LOCATION: A BEAM, LEFT NEAR LIFT PUMP
F
9-S12-023
A
9-S12-024
C33 MALE
PIN A B C D E F G H I J 923 359 784 BR BK DB 210 351 DG PK CKT 676 679 COLOR PP LG
C33 FEMALE
CIRCUIT DESCRIPTION
Vehicle Speed Sensor high Vehicle Speed Sensor low
Transfer case lock switch light activation Transmission ignition feed Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transfer case range switch signal
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20 WAY TRANSMISSION PASSTHROUGH LOCATION: TRANSMISSION, LEFT

S K
A
9-S12-022
C34 FEMALE
PIN
A B C D E F G H J K L M N P R S T W X Y 923 359 762 764 763 924 BR BK OR PP DB TN
CKT
237 315 264 265 351
COLOR
LG YL RD LB PK
CIRCUIT DESCRIPTION 1-2 Shift Solenoid activation 2-3 Shift Solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission ignition feed
Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transmission uid pressure manual vavle position switch range A Transmission uid pressure manual valve position switch range C Transmission uid pressure manual valve position switch range B Torque Converter Clutch solenoid activation
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4 WAY CRUISE CONTROL SWITCH CONNECTOR LOCATION: IN THE STEERING COLUMN
A
9-S12-161
9-S12-161
C69 MALE
C69 FEMALE
PIN A B C D
CKT 151 295 153 152
COLOR GY BR LG DB ON/OFF signal to the PCM
DESCRIPTION
Fused battery input to the cruise control switch Resume/Accelerate signal to the PCM Set/Continue signal to the PCM
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NOTE: Some corrections indicated in the table below may not be allowed on vehicles covered under the provisions of the warranty policy. The proper correction may be transmission replacement. Contact the AMG warranty department for direction in such cases.
TRANSMISSION DIAGNOSIS GUIDE

Problem Potential Cause 1. Transmission overlled. 1. Correction Drain Excess Fluid off through ll tube. Use suction gun and small diameter plastic or teon tubing. Drain and change uid and lter. May also be necessary to remove and drain converter. Reseat lter. Remove transmission and reseat pump if necessary. Correct low uid level and check for leaks. Reduce engine/transmission load. Replace transmission if clutch valve or spring condition exists. Replace plugged, damaged cooler.
Fluid Leaking Out of Vent and/or Foaming
2. 3. 4.
Wrong or contaminated uid. Air entering uid due to cross leakage at improperly seated pump cover or lter. Transmission overheat. Caused by: low fluid level blocked oil cooler full load hot climate temperature operation converter clutch valve or spring failure converter stator locked (seized) and will not free wheel at coupling speed Low uid level. Oil cooler problem: Fins blocked with dirt, debris cooler partially plugged cooler (or lines) leaking Converter clutch stuck in applied position. Converter clutch valve, limit valve, or enable valve or spring failure. Oil pump or body seal not seated causing cross leakage. May be accompanied by uid foaming and leakage out vent. Pressure regulator valve stuck in high demand position. Converter stator clutch seized (locked). Engine overheat may also occur. Oil pump problem: loose PCM connection seals failed gears damaged bushing worn, scored pressure regulator valve or spring fault reverse/boost valve fault pressure relief spring collapsed, broken loose pump bolts Pressure control solenoid failed OFF or ON. TCM/PCM fault.
2. 3. 4.
Transmission Overheat
1. 2.
1. 2.
Add uid and check for leaks. Clean dirt/debris with water spray. Replace leaking or plugged cooler. Replace leaking cooler lines or fittings.
3. 4. 5.
3. 4. 5.
Replace converter. Replace transmission. Remove pump and replace seal. Be sure pump body is properly seated. Remove oil pump and free up valve. Replace converter. Repair loose connection. Replace transmission if pump is damaged.
6. 7.
6. 7. 1.
Line Pressure Too High or Too Low
1.
2. 3.
2. 3.
Replace solenoid Replace TCM/PCM.
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TRANSMISSION DIAGNOSIS GUIDE (Contd)

Problem Potential Cause 1. 2. 1. 2. Manual valve mispositioned or stuck. Forward clutch fault. Manual linkage loose, damaged, misadjusted, disconnected. Park pawl, spring, or gear damaged. Low uid level. Shift linkage misadjusted, disconnected, loose. Pressure switch assembly fault. Low uid pressure caused by oil pump fault: worn bushing failed seal broken gears loose bolts Transmission case seal, or gasket failure. Input or turbine shaft damage (splines worn, shaft broken) Roller clutch failure. Torque converter hub damage. 1. 2. 1. 2. 1. Correction Remove valve body and repair as needed. Replace transmission. Repair or adjust linkage as required Inspect and replace pawl, spring, or gear.
Vehicle Creeps In Neutral Vehicle Moves In Park Vehicle Wont Move In Drive Range
1. 2. 3. 4.
Top off uid level. If transmission now operates properly, locate and correct leaks. 2. Correct as required. Replace switch assembly. Remove pump and replace seal. Replace transmission if pump is damaged.
3. 4.
5. 6. 7. 8. 9.
5. 6. 7. 8. 9.
Locate and replace leaking gasket or seal. Replace transmission if either shaft is damaged. Replace transmission. Replace converter. Replace transmission.
Forward clutch problem: piston seal failure clutch plates burned, damaged, missing burned reaction plate worn teeth failed check ball 10. Rear planetary gear set damage: broken pinions sun gear damage 11. Park pawl spring broken. 12. Turbine shaft ball not seating. 13. Mainshaft splines damaged.
10. Replace transmission.
11. Replace spring. 12. Replace transmission. 13. Replace transmission. 1. 2. 3. Top off uid. If vehicle now backs up, check and correct uid leaks. Repair linkage. Overhaul servo.
Vehicle Wont Back Up (No Reverse)
1. 2. 3.
Low uid level. Shift linkage loose, misadjusted, damaged. Reverse servo fault: misassembled piston or seal damage Rear band fault: wrong band apply pin band worn Direct clutch fault: worn, damaged clutch plates check ball leaking or missing
4.
4.
Check and replace apply pin.
5.
5.
Replace transmission.
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Problem 6. 7. Potential Cause Overdrive roller clutch failure. Valve body fault: manual valve stuck, damaged Pressure switch failure Idle speed incorrect (too low). Torque converter clutch stuck in applied position, or clutch is dragging. Forward clutch seized. Fourth clutch seized or dragging. Low uid level. Low uid pressure. Reverse servo seal failure (reverse range only). Low roller clutch failure (not attached or broken). Center support race, splines, or snap ring failure. Forward clutch problem. Overdrive roller clutch problem. Shift solenoid fault (either solenoid). Low roller clutch failure. Center support fault: race broken splines damaged snap ring not seated case damaged Forward clutch fault. Overdrive roller clutch failure. Rear band fault: band worn servo failure incorrect apply pin Shift solenoid fault. Overdrive roller or intermediate sprag clutch damage. Center support problem: snap ring not seated splines or race damaged support bolt missing, damaged 6. 7. Correction Replace transmission. Remove and free-up binding valves. Replace switch assembly if failed. Replace transmission if valve body bores are damaged. Check PCM operation with scan tool on turbo diesel. Check converter clutch valve and solenoid operation. If OK, replace converter. Replace transmission. Replace transmission. Top off uid level and check for leaks. Check line pressure and overhaul pump if low. Overhaul servo. Replace transmission.
Engine Stalls When Transmission Is Shifted Into Gear
1. 2.
1. 2.
3. 4.
3. 4. 1. 2. 3. 1.
Slips In Drive/ Reverse No First Gear In Either D Range
1. 2. 3. 1.
2. 3. 4. 5.
2. 3. 4. 5. 1. 2.
Replace transmission. Replace transmission. Replace transmission. Check with scan tool and replace as needed. Replace transmission. Replace transmission.
No First Gear in 1 Range (Manual Low)
1. 2.
3. 4. 5.
3. 4. 5.
Replace transmission. Replace transmission. Replace transmission.
6.
6. 1. 2.
No Second Gear
1. 2.
Check A and B solenoids with scan tool and repair as needed. Replace transmission. Replace transmission.
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Problem 3. 4. 5. 6. 7. Potential Cause Intermediate clutch air bleed cup plug leaking or missing. Overrun clutch fault. Forward clutch fault. Intermediate clutch fault. Shift solenoid fault. PCM ground wire fault. No feed voltage to shift solenoid B (2-3). Shift solenoid fault. Direct clutch check ball stuck closed (partial apply and drag) Intermediate sprag clutch fault. Center support fault: snap ring not seated bolt missing or broken support worn or damaged Forward or direct clutch pack problem. Shift solenoid A or B problem: loss of supply voltage shorted/open solenoid bad ground leaking O-ring Pressure switch fault. PCM ground fault. Fourth clutch or overrun clutch failure. Forward and clutch or direct clutch failure. Shift solenoid A stuck in off position. Voltage supply wire to solenoid a is loose, shorted, or open. Fault in PCM ground. Filter plugged. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. Correction Replace transmission. Replace transmission. Replace transmission. Replace transmission. Check with scan tool (both solenoids should be off.) Repair bad connection. Locate and repair open in wire harness. Test with scan tool (B should be on and A should be off). Replace failed solenoid. Replace transmission. Replace transmission. Replace transmission.
No Third Gear
1. 2. 3. 4. 5. 6.
7.
7. 1.
Replace transmission. Check and repair solenoid feed wiring. Replace either solenoid if open or shorted. Use scan tool to check (both solenoids should be on).
No Overdrive Fourth Gear
1.
2. 3. 4. 5.
2. 3. 4. 5. 1. 2. 3. 4.
Replace switch. Repair bad ground connection. Replace transmission. Replace transmission. Replace solenoid. Locate and repair wire problem. Locate and repair bad connection. Change fluid and replace filter. Replace transmission if filter is full of clutch material. Dented oil pan can obstruct filter and cause this problem Replace valve, spring, or valve body if valve bore is damaged. Replace solenoid if seized. Repair wire connections to PCM if necessary. Repair wire or replace harness as required.
First and Fourth Gear Only - or Manual Second and Third Only
1. 2. 3. 4.
5.
2-3 shift valve stuck. Shift solenoid B stuck in off position, or not connected to PCM. Feed wire to shift solenoid B open/shorted.
5. 1. 2.
First and Second Gear Only
1. 2.
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Problem Potential Cause 1. Worn or damaged intermediate sprag clutch. 1. Correction Replace transmission.
No Torque (Drive) In Second No Overrun Braking In: First (1) -ORSecond (2)
1. 2. 3. 1. 2. 3. 4.
Rear band or servo fault. Main or output shaft damage. Lo roller or sprag clutch fault. Front band worn, wrong apply pin, or servo problem. Direct clutch housing fault. Overrun clutch fault. Rear gear set problem. Shift solenoid A in off position: open voltage feed wire bad PCM ground solenoid seized 1-2 shift valve fault. PCM, or pulse width solenoid wiring fault (short, open, ground). Fluid contamination. Converter clutch solenoid fault. Fault with converter clutch, enable, or limit valves. PCM fault. Converter clutch failure. Brake switch inoperative. Turbine shaft seal leak. Low uid level. Fluid contaminated or wrong uid.
1. 2. 3. 1. 2. 3. 4. 1.
Replace transmission. Replace transmission. Replace transmission. Replace transmission. Replace transmission. Replace transmission. Replace transmission. Repair solenoid feed or PCM ground wire as needed. Replace solenoid if stuck closed.
Second and Third Gear Only In D Range
1.
2.
2. 1. 2. 3. 4.
Converter Clutch will Not Release or Will Not Apply
1. 2. 3. 4.
Replace valve body if 1-2 valve is scored or spring has collapsed. Locate and repair wiring problem as needed. Drain-change fluid and filter. flush cooler and lines. Replace converter. Test with scan tool and replace if inoperative. Remove oil pump and inspect valves (or pump body) if damaged. Smooth minor burrs, nicks with crocus cloth. Test with scan tool and replace if fault is discovered. Replace converter. Replace switch if open or shorted. Replace transmission. Top off and check for leaks. Drain and change uid and lter. Flush cooler and lines. Replace seals. Replace bushing. Test pressure and replace transmission if necessary. Check solenoid wiring. If OK, replace solenoid.
5. 6. 7. 8.
5. 6. 7. 8. 1. 2.
Converter Clutch Slips or Soft Apply
1. 2.
3. 4. 5. 6.
Turbine shaft seal leak. Oil pump bushing worn. Low uid pressure. Converter clutch (pulse width) solenoid fault.
3. 4. 5. 6.
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Problem Potential Cause 1. 2. 1. Incorrect sensor input signal to PCM caused by inoperative sensor. PCM problem. Pressure control solenoid stuck in off (deenergized) position. Accumulator fault: piston spring broken piston seal damage piston spring missing cover bolts loose gasket damaged Valve body check ball missing or mispositioned. Incorrect PCM calibration. High idle speed. Line pressure too high: pressure control solenoid failed reverse/boost, or pressure regulator valve stuck accumulator spring or seal failure shift sensor failure missing valve body check ball 1. 2. 1. Correction Test operation of all sensors with scan tool. Replace failed sensors as needed. Test with scan tool. Repair wires or module as required. Replace solenoid.
Converter Clutch Apply Timing Incorrect Harsh Shifts (All Drive Ranges)
2.
2.
Overhaul accumulator.
3. 4.
3. 4. 1. 2.
Reposition check balls. Replace transmission if any check balls are missing. Replace PCM. Adjust idle or check PCM with scan tool on turbo diesel. Test pressure control solenoid and sensors with scan tool and replace as needed. Repair accumulator spring, or pressure regulator valves as needed.
Harsh Engagement In Drive and Reverse
1. 2.
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DTC P0218 Transmission Fluid Over temperature
Circuit Description
The flow of transmission fluid starts in the transmission pan. It is then drawn through the filter and transmission case into the oil pump assembly. The oil pump assembly pressurizes the fluid, which becomes the main supply line of fluid. This fluid is directed to various components and hydraulic circuits within the transmission. The pressure regulator valve receives this fluid and directs it to the converter clutch shift valve. The converter clutch shift valve directs hot fluid leaving the torque converter or regulated converter feed fluid, through the cooler line to the transmission oil cooler. The transmission oil cooler is located in front of the radiator. The cooled fluid (center lube) is returned to the transmission through the return cooler line and into center lube port of the transmission. The Automatic Transmission Fluid Temperature (TFT) Sensor, detects the fluid temperature in the transmission pan. If the Powertrain Control Module (PCM) detects a high TFT for a long period of time, then DTC P0218 sets. DTC P0218 is a type C DTC.
Conditions for Clearing the DTC

A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported. The PCM cancels the DTC default actions when the fault no longer exists and the ignition is off long enough in order to power down the PCM.
Diagnostic Aids
Inspect the cooling system fluid level and condition. Verify the customers driving habits, such as trailer towing, etc..... The scan tool Trans. Fluid Temp. (TFT) should rise steadily during warm-up cycles then stabilize. DTC P0218 may set approximately 600 seconds after DTC P0711 has set. Follow the diagnostic table for the DTC P0711. Repairing the condition that set DTC P0711 will likely eliminate DTC P0218. First diagnose and clear any engine DTCs or APP codes that are present. Then inspect for any transmission DTCs that may have reset.

No TFT Sensor DTCs P0712 or P0713 The TFT is greater than 130C (266F) All conditions are met for 410 seconds
Test Description
The numbers below refer to the step numbers on the diagnostic table. 4. This step inspects for air restrictions and loss of transmission fluid flow, causing an extremely high TFT.

The PCM does not illuminate the MIL. The PCM freezes shift adapts from being updated. DTC P0218 is stored in the PCM history.
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.
DTC P0218 Transmission Fluid Over temperature

Step 1 Action Was the Powertrain On-Board Diagnostic (OBD) System Check performed? 1. 2. Install the scan tool. With the engine off, turn the ignition switch to the run position. 3. Record the DTC Failure Records then clear the DTC. 4. Perform the Transmission Fluid Checking Procedure. Was the Transmission Fluid Checking Procedure performed? Inspect the cooling system for the following conditions: Air ow restrictions Air ow blockage Inspect the transmission cooling system for the following conditions: Air ow restrictions Air ow blockage Damaged cooler lines or hoses Low A/T uid cooler ow. Refer to A/T cooler ow test. Was the condition found? Perform the line pressure check procedure. Refer to 4L80-E Line Pressure Check Procedure. Was the condition found? Inspect the torque converter stator for damage. Refer to Torque Converter Clutch Diagnosis. Was the condition found? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditons. Turn the ignition switch to the RUN position. The TFT must be less than 129C (264F) for at least 5 seconds. 4. Select Specic DTC. Enter P0218. 5. Has the test run and passed? Value(s) Yes Go to step 2. No Go to Powertrain OBD System Check. Go to transmission uid checking procedure.
Go to step 3.
Go to step 6.
Go to step 4.
Go to step 6.
Go to step 5.
Go to step 6.
Go to system diagnosis table Transmission Overheating Begin the diagnosis again. Go to step 1.
System OK
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DTC P0560 System Voltage Fault

C10-C C3-F3
C1-28
Circuit Description
Circuit 239 is the voltage feed for the PCM. Circuit 537 is the battery feed for the PCM. This DTC detects a low voltage, a high voltage for a long time, or a high voltage for a short time. This is a type D DTC.
Conditions For Clearing DTC

The DTC can be cleared using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Conditions For Setting DTC

System Voltage Low: Engine speed is greater than 1500 rpm. System voltage is less than 10.5 volts at a maximum transmission temperature of 152 C (305 F). System voltage is less than 6.7 volts at a minimum transmission temperature of -40 C (-40 F). All conditions met for 4 seconds. System Voltage High: System voltage is greater than 19 volts for 4 seconds.
Diagnostic Aids
Charging the battery with a battery charger and jumpstarting an engine may set DTC(s). If DTC(s) set when an accessory is operated, check for faulty connections or excessive current draw. Check for loose/damaged terminals at generator. Check belt wear/tension. If any engine DTCs are present diagnose and clear these DTCs first. Then check to see if the transmission DTCs have set.
Action Taken When DTC Sets

The PCM will cause an immediate shift to second gear. The PCM will turn off Pressure Control Solenoid. The PCM will inhibit converter clutch engagement. The PCM will freeze shift adapts. The PCM will NOT illuminate the Engine/Trans light.
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 3. This test checks charging system voltage. 4. This test checks battery voltage Input at the PCM. 6. This test checks ignition voltage input at the PCM. 1-1-02
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DTC P0560 System Voltage Fault

Step Action 1. 2. Connect scan tool. Turn the ignition switch to on position. Value Yes No
Important: Before clearing DTC(s), use the scan tool to record Failure Records for reference, as data will be lost when the Clear Info function is used.
3. Record the DTC Failure Records. 10.5v NOTE: If any other DTCs are present, Refer to applicable diagnostic charts before continuing. 4. Using multimeter, measure the battery voltage across the battery terminals. Record the measurement for future reference. Is voltage higher than value shown?
Go to step 2. 12-14v Check charging system.
Check Battery.
Start the engine and warm to normal operating temperature. Is generator charging (see voltmeter)? 1. Increase engine speed to 1500 rpm. 2. Observe scan tool system voltage. Is system voltage within specied range? 1. 2. 3. 4. Turn the ignition switch off. Disconnect PCM connector (additional DTCs will set). With engine off, turn the ignition switch on. Using the multimeter and Connector Test Adapter Kit, measure the battery voltage input at PCM connector terminal C28-C13. Is there a voltage variance between the voltage measured at the battery (taken in Step 2) and at terminal C28-C13 that is greater than the value shown? Repair high resistance condition in the power feed circuit 537 OR. Was the circuit repaired? Measure the ignition voltage input at the PCM connector terminal C28-C11. Is there a voltage variance between the voltage measured at the battery and the voltage measured at terminal C28-C11 that is greater than the value shown? Repair high resistance condition in circuit 239 PK. Was the circuit repaired? Test the ignition voltage circuit CKT 537 for a short to ground between the PCM connector C3-C13, C3-D13 and fuse 2D of the interior fuse box. Was a problem found? Replace PCM. Is replacement complete? 1. 2. After the repair is complete, use the scan tool to select DTC P0560. Operate the vehicle under the following conditions: Start the vehicle and warm to normal operating temperature. The PCM must see a system voltage between 8.3 and 18.9 volts. Run the DTC P0560. Has the test run and passed?
Go to step 3. Check charging system
13-15v Go to step 4.
0.5v
Go to step 6.
5 6
0.5v Go to step 7. Go to step 10. Go to step 10. Go to step 11. Go to step 9.
7 8
Go to step 9.
9 10
3. 4. 1-1-02
System OK.
Go to step 1.
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DTC P0711 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE
L 923 BR
M 359 BK
C34
C33
C27-C9
C29-B12
PCM
TFT SENSOR SIGNAL +5V LOW REFERENCE
02-S12-015
Circuit Description
The automatic transmission fluid temperature (TFT) sensor is a thermistor, which changes value based on temperature. The sensor has a negative-temperature coefficient. This means that as the temperature increases, the resistance decreases, and as the temperatures decreases the resistance increases. The PCM supplies a 5volt reference signal to the sensor and measures the voltage drop in the circuit. When the transmission fluid is cold, the sensor resistance is high and the PCM detects high signal voltage. As the fluid temperature warms to a normal operating temperature, the resistance becomes less and the signal voltage decreases. The PCM uses this information to control shift quality and torque converter clutch apply. This is a type C code.
Conditions For Setting The DTC

No ISS sensor DTC P0716 or P0717 No ECT sensor DTC P0117 or P0118. No transmission component slipping DTC P1870. System voltage is 9.0-16.0v. The engine is running for at least 30 seconds. The TFT is -40 to 21 C (-40 to 70F) at start up. The ECT is greater than 80 C (176F). The vehicle speed is greater than 3 mph for 15 minutes. The TCC slip speed is greater than 60 RPM for at least 700 seconds. The TFT has not changed more than 4F in more than 80 seconds. Unrealistic TFT change of more than 68 in 7 seconds.
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Action Taken When The DTC Sets

The PCM will not illuminates the MIL. The PCM commands increased line pressure. The PCM freezes shift adapts. The PCM determines a TFT default using the following matrix:
If the ECT is less than -30C (-22F) then default TFT is set to -28C (-19F). If the ECT is -30 to 110C (-22 to 230F) then default TFT equals ECT plus 10. If the ECT is greater then 110C (230F) default TFT is set to 140C (284F). If ECT and TFT DTCs are both set then default TFT is 140C (284F).
The PCM records the operating conditions when the Conditions for Setting the DTC are met. The PCM stores this information as Failure Records. The PCM stores DTC P0711 in PCM history.
Conditions For Clearing The MIL/DTC

The Tech 2 clears the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a nonemission related diagnostic fault occurring. The PCM cancels the DTC default action when the fault no longer exists and the ignition switch is in the OFF position long enough to power down the PCM.
Diagnostic Aids
When diagnosing for a possible intermittent short or open condition, wiggle the wiring harness while observing test equipment for a change. If any engine DTCs are present diagnose and clear these DTCs first. Then check to see if the transmission DTCs have reset. DTC P0218 may set approximately 600 seconds (10 minutes) after DTC P0711 before proceeding to the diagnostic table for DTC P0218. DTC P0711 defaults to an elevated line pressure condition which may result in partial TCC apply. This may produce an idle surge that could stall the engine.
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 2. This step tests for proper A/T fluid level and condition. 3. This step verifies that the vehicle sets DTC P0711. 5. The 12-volt test lamp is used as a fixed resistance. 6. Perform this step in order to ensure that the PCM monitors circuit 1227. 8. The TFT Sensor is part of the A/T Wiring Harness Assembly 1-1-02
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DTC P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance

Step Action Was the Powertrain ON-Board Diagnostic (OBD) System Check performed? Perform the A/T Fluid Checking Procedure. Did you perform the uid checking procedure? 1. Install the scan tool (TECH 2). 2. With turn the ignition switch to the RUN position. Important: Before clearing the DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the stored data. 3. Record the DTC Freeze Frame and Failure Records. 4. Select Trans. Fluid Temp on the scan tool. 5. Drive the vehicle and observe the scan tool for one of the following conditions: No TFT change An unrealistic change (The TFT change is greater than 36 F (20 C) 14 times in 7 seconds). Did either of the fail conditions occur? Did the scan tool display an unrealistic change condition? 1. 2. 3. Turn the ignition switch OFF. Disconnect the transmission 20-way connector. Install a test lamp between terminal L and terminal M of the engine side of the transmission 20-way connector. Use the Connector Test Adapter Kit. 4. Turn the ignition switch to the RUN position. Does the scan tool TFT display an unrealistic change? 1. Record the scan tool TFT display from step 4. 2. Turn the ignition OFF. 3. Disconnect the transmission 20-way connector. 4. Turn the ignition switch to the RUN position. Is the scan tool Trans. Fluid Temp. the same as in step 4? Replace the PCM. Refer to Section 2. Is the replacement complete? Replace the TFT sensor. Is the replacement complete? In order to verify your repair, perform the following procedure: 1. Select DTC Clear Info. 2. Operate the vehicle under the following conditions: The TFT changes by more than 3 C (5 F) after the engine has been running for 35 seconds. For a period of at least 11 seconds, the TFT does not change more than 36 F (20 C) within 0.2 seconds. 3. Select Specific DTC P0711. Has the test run and passed? Value Yes Go to step 2. Go to step 3. No Go to Powertrain OBD System Check. Go to Transmission Fluid Checking Procedure.
1 2 3
Fault not present at this time. Refer to Diagnostic Aids. Go to step 5.
4 5
Go to step 7.
Go to step 8.
7 8 9
System OK.
Begin the diagnosis again. Go to step 1. 1-1-02
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DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit - Low Input
L 923 BR
M 359 BK
C34
C33
C27-C9
C29-B12
PCM
02-S12-015
Circuit Description
The transmission fluid temperature (TFT) sensor is a thermistor that controls signal voltage to the PCM. The PCM supplies a 5volt reference signal to the sensor and measures the voltage drop in the circuit. When the transmission fluid is cold, the sensor resistance is high and the PCM detects high signal voltage. As the fluid temperature warms to a normal operating temperature, the resistance becomes less and the signal voltage decreases. The PCM uses this information to control shift quality and torque converter clutch apply. DTC P0712 is a type C DTC.
Conditions For Clearing The DTC

A scan tool clears the DTC from PCM history. The PCM clears the DTC from history if the vehicle completes 40 warm-up cycles with out a non emission related diagnostic fault occurring. The PCM cancels the DTC default actions when the fault no longer exists and the ignition switch is OFF long enough in order to power down the PCM.
Diagnostic Aids
DTC P0218 may set approximately 600 seconds after DTC P0712 has set. Follow the diagnostic table for P0712 before proceeding to the table for P0218. DTC P0712 defaults to an elevated line pressure condition which may result in partial TCC apply. This may produce an idle surge that could stall the engine.

Ignition is ON TFT sensor indicating a voltage less than 0.14 volts. All conditions met for 15 seconds.

The PCM does not request MIL illumination. The PCM commands increased line pressure. The PCM freezes shift adapts. TFT is determined by ECT: If the temperature is -22 to 230F, 10 is added to the value and that is estimated as the TFT value. If the temperature is above 230F the TFT value is estimated at 284F. The PCM records the operating conditions and stores the information as a Failure Record and a PCM history code.
Test Description
The numbers below refer to the step numbers on the diagnostic chart. 3.This test checks for a short to ground or a skewed sensor by verifying the fault still exists. 4.This test checks for an internal fault within the transmission by creating an open. 6.This step inspects the TFT sensor signal circuit of the AT wiring harness assembly for being shorted to ground.
1-1-02
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DTC P0712 Fluid Temperature Circuit Low

Step 1 2 Action Perform transmission uid checking procedure. Was the uid checking Procedure performed? Perform the transmission fluid checking procedure. Was the transmission fluid checking procedure preformed? 1. 2. Install the scan tool. Turn the ignition switch to on position. Value Yes Go to step 2. No Check the transmission uid.
Go to step 3.
Important: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. Does the scan tool display a TFT Sensor signal voltage less than shown in the value column? 4 1. Turn the ignition off. 2. Disconnect the transmission 20-way harness connector. 3. Turn the ignition on. Does the scan tool display a TFT Sensor signal voltage greater than shown in the value column? 1. Install J-39775 test harness on transmission side of the 20-way connector. 2. Using a DVOM and Connector Test Adapter Kit, measure resistance between terminals L and M. Does the resistance measure within the specied value? 1. 2. Disconnect the PCM connectors C27. With the harness disconnected from the transmission, check the resistance between terminal L and a good ground. Is the resistance displayed out of limits on the DVOM? Replace the internal wiring harness. Is the replacement complete? Check circuit 923 BR for high resistance or a bad connection. Was a problem found and repaired? Replace the PCM. Is the replacement complete? After the repair is complete, use the scan tool to select DTC, then Clear Info function. 2. Select Specic DTC and enter DTC P0712. 3. Ensure the following conditions are met: TFT sensor indicates a voltage greater than 0.33 volts for 10 seconds. Has the last test failed? 1.
0.2v Refer to Diagnostic Aids.
Go to step 4.
4.92v Go to step 5. 16K at 50 F to 133 at 230 F Go to step 6.
Go to step 6.
Go to step 7.
7 8 9 10
Begin diagnosis again, Go to Step 1 Repair veried, exit DTC table.
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DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit - High Input
L 923 BR
M 359 BK
C34
C33
C27-C9
C29-B12
PCM
02-S12-015
Circuit Description
The TFT sensor is a thermistor which changes value based on temperature. The sensor has a negative-temperature coefficient. This means that as the temperature increases, the resistance decreases, and as the temperature decreases the resistance increases. The PCM supplies a 5-volt reference signal to the sensor and measures the voltage drop in the circuit. When the transmission fluid is cold, the sensor resistance is high and the PCM detects high signal voltage. As the fluid temperature warms to normal operating temperature, the resistance becomes less and signal voltage decreases. DTC P0713 detects a continuous open or short to power in the signal circuit or the sensor. This is a type C code.

The Tech 2 clears the DTC from the PCM history. The DTC will be cleared when the vehicle has achieved 40 warm-up cycles without a failure reported. The PCM will cancel DTC default actions when the fault no longer exists and the ignition is cycled off lone enough to power down the PCM.
Diagnostic Aids
When diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Scan tool displays transmission fluid temperature in degrees. After transmission is operating, the temperature should rise steadily to about 212 F then stabilize. The temperature to resistance value scale may be used to check the TFT sensor at various temperature levels to evaluate the possibility of a skewed (mis-scaled) sensor. A skewed sensor can result in harsh shifts or converter clutch complaints.

TFT sensor indicating a voltage greater than 4.92 volts. Ignition is on. All conditions met for 400 seconds.

The MIL will not illuminate. Transmission default temperature will be 140 C (275 F). NOTE: Scan tool will not display default temperature Shift adapts are frozen Line pressure is increased.
Test Description
3. This step veries a condition in the TFT sensor circuit. 5. This step tests for higher than normal circuit voltage which may also damage the TFT sensor.
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DTC P0713 Fluid Temperature Low

Step Action Did you perform the powertrain diagnostic system check? 1. Install the Tech 2. 2. With the ignition to the RUN position dont start. Important: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame. Does the scan tool display a TFT Sensor signal voltage less than shown in the value column? 1. 2. 3. 4. Turn ignition OFF. Disconnect the transmission harness connector C34. Install the transmission test harness on the transmission. Using a DVOM measure the resistance between terminal L and M of the transmission test harness. Is the resistance less than the specied value? Value Yes Go to step 2. No
1 2
4.92 volts Go to the intermittent conditions chart.
Go to step 3.
100K
Go to step 6.
Go to step 4.
Measure the resistance between terminal L and all other terminals on the transmission test harness. Is there continuity between terminal L and any other terminals? Test circuit 923 BR for a short to voltage between PCM connector C1 and the AT connector C34. Was a condition found and corrected? Test circuits 923 BR and 359 BK for an open between the PCM connector and the transmission connector C34. Was a condition found and corrected? Replace the transmission internal wiring harness. Is the replacement complete? Replace the PCM. Perform the following procedure in order to verify the repair: 1. With the Tech 2 select the DTC. 2. Select Clear Info. 3. Operate the vehicle and verify that the code does not reset. Has the test run and passed?
Go to step 7. Go to step 9. __ Go to step 9. __ Go to step 9. __ __ Go to step 9. __ Go to step 8. __ Go to step 6. Go to step 5.
7 8 9
System is OK.
Go to step 1.
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DTC P0716 Input Speed Sensor Circuit - Range/Performance

AUTO TRANS INPUT SHAFT SPEED SENSOR A/T ISS TRANFER CASE VEHICLE SPEED SENSOR VSS
TWISTED PA I R
496 GY
495 DB
TWISTED PA I R
679 LG
676 PP
C33
C32
A 223 DB
01-S12-050
Circuit Description
The automatic transmission input shaft speed (AT ISS) sensor provides transmission input speed to the powertrain control module (PCM). The AT ISS sensor is a permanent magnet (PM) generator. The sensor mounts into the transmission case and maintains a slight air gap between the sensor and the forward clutch housing. The PM generator produces an AC voltage as the forward clutch housing rotor teeth pass through the sensors magnetic field. The AC voltage level increases as the turbine shaft speed increases. The PCM converts the AC voltage into a digital signal. The PCM determines actual turbine speed using the digital signal. The PCM uses the input speed to calculate torque converter slip speed and gear ratio. This is a type B code.

The PCM illuminates the MIL after 2 consecutive failures. The PCM commands maximum line pressure. Shift adapts are frozen. The operating conditions to set the code are recorded to the freeze frame and failure records.

The PCM will turn the lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared from PCM memory using the Tech 2. The DTC can also be cleared from memory after 40 warm-up cycles without a failure reported. The PCM will cancel the DTC Action Taken items when the fault conditions no longer exist and the ignition is cycled Off' long enough to power down the PCM.
Conditions for Running DTC

System battery voltage normal No DTC P0717. No DTC P0722 or P0723. No shift solenoid DTC P0751 or P0753 Engine speed greater than 475 RPM Throttle position is greater than 15%. Vehicle speed is greater than 20 MPH.
Diagnostic Aids
You may have to drive the vehicle in order to experience the fault. DTC P0716 defaults to an elevated line pressure condition witch may result in partial TCC application. This may produce an idle surge that could stall the engine.

The AT ISS varies by more than 1200 RPM within 4 seconds
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DTC P0716 Input Speed Sensor Range/Performance

Step Action Did you perform the Powertrain Diagnostic System Check? 1. Install the Tech 2. 2. Turn the ignition switch to the RUN position leaving the engine off. 3. Record the DTC Freeze Frame and Failure Records. 4. Clear the DTC. 5. With the transmission in PARK start the engine. 6. Observe the ISS on the Tech 2. 7. Run the engine at 2000 RPM and hold the engine speed steady. Does the Transmission ISS RPM change by more than 1,200 RPM at steady engine speed? 1. Ignition OFF 2. Disconnect wiring harness at the Input Speed Sensor. 3. Install the transmission test jumper harness (J-39775) and use a DVOM to check the resistance on the ISS sensor terminals Does the ISS sensor resistance measure within the specified value? 1. With a DVOM set to measure AC voltage connect to the ISS sensor. 2. Start the engine and leave the transmission in PARK. 3. Accelerate the engine to 2,000 RPM and hold steady. Does the value registered on the DVOM steady? 1. Turn the ignition switch to the OFF position. 2. Set the DVOM to read DC voltage. 3. Turn the ignition switch to the Run position. 4. Measure the voltage at both of the ISS sensor harness connector terminals to a good ground. Does either voltage reading measure greater than the specied value? 1. Test the ISS high signal circuit (496 GY) for a short to power. 2. Test the ISS low signal circuit (495 DB) for a short to power. Was a problem found and repaired? 1. Reconnect the ISS harness connector to the ISS sensor. 2. Turn the ignition to the OFF position. 3. Disconnect the PCM connector C27. 4. Connect a DVOM set to AC voltage to terminals D1 and D11. 5. Remove the fuel pump fuse in the interior fuse box. 6. Turn the ignition to the RUN position crank the engine while observing the DVOM. Does the voltage measure greater than the specified value and remain steady? Value _ Yes Go to step 2. Go to step 3. No Go to Diagnostic System Check. Go to Intermittent conditions in the PCM section.
1 2
1042-2088
Go to step 4.
Go to step 14.
10.0v AC
Go to step 5.
Go to step 14.
10.5v DC
Go to step 6.
Go to step 7.
Go to step 16.
Go to step 7.
Go to step 15.
Go to step 8.
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DTC P0716 Input Speed Sensor Range/Performance

Step Action With a DVOM measure the resistance between terminals D1 and D11 of the PCM connector C27. Does the circuit resistance measure within the specied value? 1. Measure the resistance from the PCM connector C27-D1 to a good ground. 2. Measure the resistance from the PCM connector C27-D11 to a good ground. Does either resistance measure less than the specified value? Test the ISS high signal circuit (496 GY) and the ISS low circuit (495 DB) for a short to ground. Was a condition found and repaired? Does the resistance reading from step 8 measure less than the specied value? Test the ISS high signal circuit (496 GY) and the ISS low signal circuit (495 DB) for a short together. Was the condition found and corrected? Test the ISS high signal circuit (496 GY) and the ISS low signal circuit (495 DB) for high resistance or an open. Was the condition found and corrected? Replace the input speed sensor. Replace PCM. After repair is complete, select scan tool Clear Info function and operate the vehicle under the following conditions: Vehicle drive range and engine running. PCM must see an input speed change of less than 1000 rpm for 1 second. 2. Review the scan tool Specic DTC and enter 0716. Does the test run and pass? 1. Value 1,042-2,088 Yes Go to step 9. No Go to step 11.
50K
Go to step 10.
Go to intermittent conditions in the PCM section.
10 11 12 13
Go to step 16.
1,042-2,088
Go to step 13.
Go to step 16.
14 15 16
Go to step 16. Go to step 16. System OK.
Go to step 1.
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DTC P0717 INPUT SPEED SENSOR CIRCUIT - NO SIGNAL

AUTO TRANS INPUT SHAFT SPEED SENSOR A/T ISS TRANFER CASE VEHICLE SPEED SENSOR VSS
TWISTED PA I R
496 GY
495 DB
TWISTED PA I R
679 LG
676 PP
C33
C32
A 223 DB
01-S12-050
Circuit Description
The automatic transmission input (shaft) speed (A/T ISS) sensor provides transmission input speed to the powertrain control module (PCM). The A/T ISS sensor is a permanent magnet (PM) generator. The sensor mounts into the transmission case and maintains a slight air gap between the sensor and the forward clutch housing. The PM generator produces an AC voltage as the forward clutch housing rotor teeth pass through the sensors magnetic field. The AC voltage level increases as the turbine shaft speed increases. The PCM converts the AC voltage into a digital signal. The PCM determines actual turbine speed using the digital signal. The PCM uses the input speed to calculate torque converter slip speed, and gear ratios. When the PCM detects a low or no input speed during high vehicle and high engine speeds, the DTC P0717 sets. This is a type B code.

The PCM will turn the lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without reported failure. PCM will cancel DTC default actions when the fault no longer exists and ignition is cycled Off long enough to power down the PCM.
Diagnostic Aids
Inspect wiring for poor electrical connections at the PCM and the 20-way connector Look for possible bent, backed out, deformed or damaged terminals. Also, check for chafed wire that could short to bare metal or other wiring. Inspect for broken wire inside the insulation. When diagnosing a possible intermittent short or open condition, move wiring while observing test equipment for a reading change. If any engine DTC(s) or TP Sensor codes are present diagnose and clear these DTC(s) first. Then check for transmission DTC(s) have reset. If any engine DTCs or TPS codes are present diagnose and clear these first. Then check to see if the transmission DTC(s) have reset.

No DTC P0722 or P0723. No switch assembly DTC P1810. Vehicle speed is greater than 20 MPH. Engine running for greater than 7 seconds. Transmission not in Park or Neutral. Input speed is less than 50 RPM for at least 5 second.

The PCM illuminates the malfunction indicator lamp. The PCM will default the transmission to maximum line pressure. The PCM will freeze shift adapts. The PCM will store DTC P0717 in the PCM history. 5745159
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DTC P0717 Input Speed Sensor Circuit Low Input

Step 1 Action Was the Powertrain Diagnostic System checked? Value(s) Yes Go to step 2. No Preform On Board Diagnostic (OBD) System Check. Go to step 3.
Install the Tech 2 Turn the ignition switch to the RUN position without starting the engine. Note: Before clearing the DTC, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Record the DTC Freeze Frame and Failure Records. 4. Clear the DTC. 5. Raise and support the vehicle. 6. Select Transmission ISS. 7. Start the engine and place the transmission selector in D3 range. 8. With the drive wheels rotating, slowly accelerate to 2000 engine RPM and hold. Is the Transmission ISS more than 800 RPM? 1. 2. 3. 4. Turn the ignition switch to the OFF position. Remove the connector from the ISS sensor. Remove the ISS sensor from the transmission. Using a DVOM and a Transmission Test Jumper Harness (J-39775) measure the resistance of the ISS Sensor. Does the sensor resistance measure within the specied value? Test the ISS high signal circuit (496 GY) for an open or short to ground between the PCM connector C27-D11 and cavity A of the ISS sensor connector. Was the condition found and repaired? Test the ISS sensor low input circuit (495 DB) for an open short to ground between the PCM connector C27-D1 and cavity B of the ISS sensor connector. Was the condition found and repaired? Turn the ignition switch to the RUN position without starting the engine. 2. Using a DVOM, set for DC voltage and test lead, measure voltage between cavity A of the ISS sensor connector to a good ground. Does the voltage measure less than the specied value? 1.
1. 2.
__
1042-2088
Go to step 4.
Go to step 11.
Go to step 13.
Go to step 5.
__
Go to step 13.
Go to step 6.
4.0 - 5.1v DC
Go to step 7.
Go to step 8.
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DTC P0717 Input Speed Sensor Circuit Low Input

Step 7 1. Action Turn the ignition switch to the RUN position without starting the engine? 2. Measure the voltage at cavity B of the ISS sensor connector. Does the voltage measure less than the specified? Is the voltage reading in step 6 greater than the specied value? Test the signal circuit (496 GY) and the ground circuit (495 DB) of the ISS sensor for a short to +12v or shorted together between the PCM and the ISS harness connector cavities A and B. Was this condition found and corrected? 1. 2. Re-install the ISS sensor in the transmission. Reconnect the ISS sensor connector to the sensor. 3. Disconnect the PCM connector C27. 4. Using a DVOM, set to AC voltage, probe across terminals D1 and D11 at the PCM connector C27. 5. Remove the fuel pump relay. 6. With the vehicle in PARK, crank the engine. Does the voltage measure above the specified value? Value(s) 0.2v Yes Go to step 10. No Go to step 8.
8 9
5.1v __
Go to step 12. __
10
0.5v
Go to step 12.
__
11 12 13
Replace the ISS sensor. Is replacement complete? Replace the PCM. Is replacement complete? Preform the following procedure in order to verify the repair: 1. Select DTC 2. Select Clear Info. 3. Operate the vehicle under the following conditions: The vehicle in drive range and the engine must be running. The vehicle speed greater than 12 MPH. The PCM must see an input speed greater than 500 RPM for 1 second. 4. Select Specic DTC. 5. Enter DTC P0717. Has the test run and passed?
__ __ __
Go to step 13. Go to step 13. Repair complete.
__ __ Go to Step 1.
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DTC P0719 BRAKE SWITCH CIRCUIT - LOW INPUT

BATTERY
IGNITION
FUSE 6B 5 AMP
INTERIOR FUSE BOX
FUSE 2D 20 AMP EXTERIOR FUSE BOX
FUSE A31 20 AMP INTERIOR FUSE BOX
G2
C1-10
STOP LAMP SWITCH B
BRAKE LIGHT SWITCH
537C OR
537D OR
570D BK
570E BK
239B PK
239D PK
22 RD
31 C1
D6 D7 D13 C13 C12 C11 C28

02-S02-002
C29

00-S12-018
STOP LAMP SIGNAL
22 RD
PCM
Circuit Description
The normally open TCC Brake switch indicates the brake pedal status to the powertrain control module (PCM). Applying the brake pedal interrupts voltage to the PCM. This is a class D code.

A scan tool clears the DTC from PCM memory. The DTC can be cleared from PCM history if the vehicle completes 40 warm-up cycles without a non-emission related diagnostic fault occurring. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

No DTC P0722 or P0723 have set. The PCM detects an open brake switch/circuit (0 volts) for 15 minutes without going off for 2 seconds, and the following events occur seven consecutive times: vehicle speed is less than 8 km/h (5 mph); then vehicle speed is between 8 and 32 km/h (5 and 20 mph) for 4 seconds; then vehicle speed is greater than 32 km/h (20 mph) for 6 seconds.
Diagnostic Aids
Inspect the wiring for poor electrical connections at the PCM and brake switch. Look for damaged terminals, check for weak terminal tension, inspect for broken wire. When diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change. Check customer driving habits and/or unusual driving conditions (i.e. stop and go, expressway or two footed driving). Check brake switch for proper mounting and adjustment.

The PCM will not illuminate the MIL. The PCM records the operating conditions when the conditions for setting the DTC are met. The PCM stores this information as Failure Records. The PCM stores DTC P0719 in PCM history.
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DTC P0719 Brake Switch Circuit - Low Input

Step Action 1. 2. 3. 4. 5. Connect scan tool. Turn the ignition switch on. Record Freeze Frame and Failure Records.' Select Brake Switch on scan tool. Disconnect brake switch connector from brake switch. 6. Install a fused jumper from terminal C to terminal D of brake switch connector. Did brake switch status change from Open to Closed?' Remove and inspect brake fuse for an open. Was the fuse open? Inspect switch wires for a short to ground. Was a problem found and corrected? Replace the brake switch. Inspect switch-to-PCM circuit for open. Is the repair complete? Replace PCM. 1. After repair is complete, use scan tool to select DTC, then Clear Info function. 2. Select Specic DTC and enter DTC P0719. 3. Ensure the following conditions are met: Engine running. Select Brake Switch on scan tool. Depress the brake to ensure the states change with the pedal at rest and depressed. Has the last test failed? Value Yes No
2 3 4 5 6 7
Begin diagnosis again, Go to Step 1. Repair veried, exit DTC table.
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DTC P0722 VEHICLE SPEED SENSOR LOW INPUT

VEHICLE SPEED SENSOR (VSS) TO IGNITION TO SPEEDO
FUSE 1D 15 AMP
TWISTED PAIR
EXTERIOR FUSE BOX

C29
GROUND 570 BK
A6
C33
G2
GROUND
570 BK
A7 C3-P9
C28
D6 C1-18
D9
223 DB
570 BR
565 BR
679 LG
239 PK
676 PP
12
13
353 YL
10
GROUND
VEHICLE OUTPUT SHAFT SPEEDO SPEED REVOLUTION REFERENCE SIGNAL SIGNAL
DIGITAL RATIO ADAPTER

00-S12-038
Circuit Description
The speed sensor circuit consists of a magnetic induction type sensor, which is the Vehicle Speed (VSS), a Digital Ratio Adaptor, and wiring. Gear teeth pressed onto the output shaft carrier assembly induce an alternating voltage into the sensor. This signal transmits to the Digital Ratio Adaptor. The Digital Ratio Adaptor compensates for various final drive ratios. The Digital Ratio Adaptor also converts the AC VSS signal into a 40 pulse per revolution (PPR) DC 5 volt square wave form signal on circuit 565 BR to indicate transmission output speed.This is a type B DTC.

The PCM illuminates the MIL. The PCM Defaults to maximum line pressure. The PCM freezes shift adapts. The PCM defaults to the calculated vehicle speed value using the Input Shaft Speed sensor values. The PCM records and saves the information as Freeze Frame and Failure Records.

1. 2. The PCM turns OFF the MIL after three consecutive ignition cycles without a failure reported. A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the history if the vehicle completes 40 warm-up cycles without a failure reported. The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.

The APP Angle is greater than 12%. The engine torque must be 80-475 lb ft. (108-642 Nm). The engine speed is greater than 475 RPM for 7 seconds. The engine speed is less than 3800 RPM. The A/T ISS Sensor speed is greater than 1500 RPM. The transmission is not in Park or Neutral. The VSS is less than 25 RPM for at least 3.5 seconds.
3.
Diagnostic Aids
Inspect the Speed Sensor wiring for contact with sharp metal edges.
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DTC P0722 Vehicle Speed Sensor Low Input

Step Action Was the Powertrain On-Board Diagnostic (OBD) System Check Performed 1. 2. Install the TECH 2. With the engine OFF, turn the ignition switch to the RUN position. Value Go to step 2. Yes No Go to Powertrain OBD System Check.
Important: Before clearing the DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data.
3. Record the DTC Freeze Frame and Failure Records and DTCs. 4. Raise the drive wheels and support the axle assembly. 5. Start the engine and place the transmission in Drive 1 range. 6. Gradually increase the wheel speed. Does the Transmission VSS increase with the drive wheel speed?
Cannot verify faulty. Exit DTC table and go to Diagnostic Aids. 2.0v AC at 2000 RPM.
Go to step 3.
1. 2. 3.
Turn the ignition OFF. Disconnect the VSS connector from the VSS. Connect a DVOM on AC Voltage scale between terminals A and B at the VSS. 4. Start the engine, and place the transmission in D1 range. 5. Slowly increase the wheel speed. Is the voltage greater than the specied value? 1. 2. Reconnect the VSS connector to the VSS. Disconnect the Digital Ratio Adaptor harness from the DRA. 3. Measure the voltage between terminals 7 and 12 of the DRA Harness Connector. Use a DVOM. 4. Start the engine, and place the transmission in D1. 5. With the wheels turning, slowly accelerate to 2000 RPM. Is the voltage greater than the specied value? Inspect circuits 676 PP and 679 LG for an open. Did you nd a problem? Inspect circuits 676 PP and 679 LG for a short together between the VSS and the DRA. Did you nd a problem? Test the ignition voltage on circuit 239 PK of the DRA for a high resistance or a open. Was the problem found and corrected?
Go to step 4. 2.0v AC at 2000 RPM.
Go to step 14.
Go to step 7. __ Go to step 17. __ Go to step 17. __ Go to step 17.
Go to step 5. Go to step 6. Go to Intermittent Conditions.
5 6
Go to step 8. 1-1-02
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DTC P0722 Vehicle Speed Sensor Low Input (Contd)

Step Action Test the ground circuit 570 BK of the DRA for a high resistance or an open. Was the problem found and corrected? 1. 2. Disconnect the DRA connector. Turn the ignition to the RUN position but dont start it. 3. Test the vehicle speed signal circuit 565 BR for voltage. Does the voltage measure within the specied value? Value __ Go to step 17. 4.8-5.2v DC Go to step 9. Yes No
Go to step 13. 5.2v DC Go to step 12. __
10 11
Does the value in step 9 measure greater then the specied voltage? Test the Vehicle speed signal circuit 565 BR of the DRA for an open or a short to ground between the PCM connector C28-D6 and the DRA. Did you nd and correct the condition? Test the Vehicle speed signal circuit 565 BR of the DRA for a short to voltage between the PCM connector C28-D6 and the DRA. Did you nd and correct the condition? 1. 2. Reconnect the DRA Harness connector to the DRA. With the DVOM set on DC volts and on a good ground, back probe terminal 13 of the DRA. 3. Start the engine, and place the transmission in D1. 4. With the wheels turning, slowly accelerate the engine to 2000 RPM. Is the voltage within the specied values? Replace the VSS. Is the replacement complete? Replace the DRA. Is the replacement complete? Replace the PCM. Is the replacement complete? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: Drive the vehicle under steady acceleration. The PCM must see an output speed of greater than 500 RPM for 1 second. 4. Select Specic DTC. Enter DTC P0722. Has the test run and passed?
Go to step 17. __
Go to step 16.
12
Go to step 17. 1.5-3.5 volts DC
Go to step 16.
13
Go to step 15.
14 15 16 17
System OK
Begin the Diagnosis again. Go to Step 1
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DTC P0723 VEHICLE SPEED SENSOR INTERMITTENT

TO IGNITION
TO SPEEDO
FUSE 1D 15 AMP
TWISTED PAIR
EXTERIOR FUSE BOX

C29
GROUND 570 BK
A6
C33
G2
GROUND
570 BK
A7 C3-P9
C28
D6 C1-18
D9
223 DB
570 BR
565 BR
679 LG
239 PK
676 PP
12
13
353 YL
10
GROUND

00-S12-038
Circuit Description
The speed sensor circuit consists of a magnetic induction type sensor, which is the Vehicle Speed Sensor (VSS), a Digital Ratio Adaptor, and wiring. Gear teeth pressed onto the output shaft carrier assembly induce an alternating voltage into the sensor. This signal transmits to the VSS Buffer Module. The VSS Buffer Module compensates for various final drive ratios. The VSS Buffer Module also converts the alternating current (AC) VSS signal into a 40 pulse per revolution (PPR) 5 volt DC square wave form signal on circuit 565 to indicate transmission output speed. If the PCM detects an unrealistically large change in the VSS reading, then DTC P0723 sets. DTC P0723 is a type B DTC.

The PCM illuminates the MIL The PCM defaults to maximum line pressure. The PCM freezes shift adapts. The PCM defaults to the calculated output speed value using the ISS Sensor values.

1. 2. The PCM tuns OFF the MIL after three consecutive ignition cycles without a failure reported. A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported. The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.

No 4WD Low DTC P1875. No TFP Val. Position Sw. assembly change for greater than 7 seconds. The engine must be running more than 475 RPM for at least 7 second. The VSS RPM decrease is greater than 1000 RPM while in a Drive gear for at least 4 seconds. 3.
Diagnostic Aids
The PCM will default to elevated line pressure which may result in partial TCC apply. This may produce an idle surge that could stall the engine. 1-1-02
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Test Description
2. This step verifies the fault condition. 4. This step verifies the VSS is functioning.
7. This step tests the voltage supply to the Digital Ratio Adaptor. 9. This step tests the integrity of the ground circuit.
DTC P0723 Output Speed Sensor Intermittent

Step Action Was the Powertrain On-Board Diagnostic (OBD) System Check Performed? 1. Install the TECH 2. 2. With the ignition switch to the RUN position. Important: Before clearing the DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Clear the DTC. 4. Raise and support the drive wheels. 5. Start the engine and place the transmission in first gear. 6. Gradually increase the wheel speed. Does the VSS increase with the drive wheel speed? 1. 2. 3. Turn the ignition OFF. Disconnect the VSS connector. Connect a DVOM on AC voltage scale between terminals A and B at the VSS. 4. Start the engine and place the transmission in First gear. 5. With the wheels rotating, slowly accelerate to 2000 engine RPM and hold. Does the voltage measure greater then the specified value? 1. 2. 3. Reconnect the VSS harness to the sensor. Disconnect the harness from the Digital Ratio Adaptor. With the DVOM set to AC measure the voltage between terminals 7 and 12 of the DRA connector. 4. Start the engine and place the transmission in rst gear. 5. With the wheels rotating, slowly accelerate to 2000 engine RPM and hold steady. Does the voltage measure greater then the specified value? Inspect circuits 679 and 676 for an intermittent open. Did you nd a problem? Inspect circuit 676 and 679 for an intermittent short together or a short to ground. Did you nd a problem? Test the ignition circuit (239 PK) of the DRA for an intermittent high resistance or an open. Was the problem found and corrected? Value Go to step 2. Yes No Go to Powertrain OBD System Check.
Go to intermittent conditions.
Go to step 3.
2.0 AC v at 2000RPM
Go to step 4.
Go to step 14.
2.0 AC v at 2000RPM
Go to step 7. __ Go to step 17.
Go to step 5. Go to step 6. Go to intermittent conditions.
5 6
__ Go to step 17. Go to step 17.
Go to step 8.
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DTC P0723 Output Speed Sensor Intermittent (Contd)

Step Action Test the ground circuit 570 BK of the DRA for an intermittent high resistance or an open. Was the condition found and corrected? 1. Disconnect the DRA connector. 2. Turn the ignition to the Run position. 3. Measure the voltage on circuit 565 at the DRA. Is the specied voltage present Does the voltage in step 9 exceed the specied value? Test the VSS circuit 565 for an intermittent short to ground between the PCM connector C28-D6 and the DRA. Was the condition found and repaired? Test the VSS circuit 565 of the DRA for an intermittent short to power between the PCM connector C28-D6 and the DRA. Was the condition found and repaired? 1. 2. Reconnect the DRA connector to the DRA. With a DVOM set to DC voltage backprobe terminal 13 of the DRA 3. Start the engine and place the transmission in first gear. 4. With the wheels rotating, slowly accelerate the engine to 2000 RPM and hold. Is the voltage reading steady within the specied value? Replace the VSS. Is the replacement complete? Replace the Digital Ratio Adaptor. Is the replacement complete? Replace the PCM. Is the replacement complete? Perform the following procedure in order to verify the repair: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: Drive the vehicle under steady acceleration above 10 percent APP. The PCM must see an output speed greater than 500 RPM for 1 second. 4. Select Specic DTC. Enter DTC P0723. Has the test run and passed? Value __ Go to step 17. Go to step 9. Yes No
4.8 - 5.2v DC Go to step 13, 5.2v Go to step 17. Go to step 16. Go to step 12. Go to step 10. Go to step 11.
10 11
12
__ Go to step 17. Go to step 16.
13
1.5-3.5 volts DC
Go to step 15.
14 15 16 17
System OK
Go to step 1.
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DTC P0724 BRAKE SWITCH CIRCUIT HIGH INPUT

FUSE 6B 5 AMP
INTERIOR FUSE BOX
STOP LAMP SWITCH B
BRAKE LIGHT SWITCH
22 RD
31 C1

02-S02-002
C29
STOP LAMP SIGNAL
22 RD
PCM
Circuit Description
The brake switch indicates brake pedal position. The normallyopened brake switch supplies a B+ signal on circuit 22 to the PCM. The signal voltage circuit is closed when the brakes are applied. This DTC detects a closed brake switch during acceleration, then DTC P0724 sets. This is a type C DTC.

The DTC can be cleared using a scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

No DTC P0722, P0723. The PCM detects a closed brake switch or circuit and the following sequence of events occur: 1.The vehicle speed is less then 5 mph. 2.The vehicle speed is 5-20 mph for 3.1 seconds 3 The vehicle speed is greater than 20 mph for 7 seconds. The brake switch is closed for 900 seconds. All conditions are met for eight occurrences.
Diagnostic Aids
Check customer driving habits and/or unusual traffic conditions (i.e. stop and go, expressway). Check brake switch for proper mounting and adjustment. If any engine DTCs or TPS codes are present diagnose and clear these DTCs first. Then check to see if the transmission DTCs have reset.

PCM disregards the brake switch state if the APP sensor is greater than 0.5 percent and the vehicle speed is greater than 25 mph. The PCM will NOT illuminate the warning lamp. Freeze frame and failure records are recorded and DTC P0724 is stored in memory.
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DTC P0724 Brake Switch Circuit High Input

Step Action 1. 2. Install the Tech 2. Turn ignition switch on. Value
Yes
No
NOTE: Important: Before clearing DTC(s), use the scan tool to record Failure Records for reference, as data will be lost when the Clear Info function is used. Record the DTC Failure Records. Select Brake Switch on the scan tool. Disconnect the brake switch connector from he brake switch. Did the brake switch status change from Closed to Open? 3. 4. 5.
Go to step 3.
2 3 4 5
Replace brake switch.

Check switch wires circuit for short to B+. Was a problem found? Replace the PCM. Is the replacement complete? 1. 2. 3. After the repair is complete, use the scan tool to select DTC, then Clear Info function. Select Specic DTC and enter DTC P0724. Ensure the following conditions are met: Select Brake Switch on scan tool, depress brake pedal. Switch state should change as pedal is depressed.
Go to step 4.
System OK.
Go to step 1.
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DTC P0730 INCORRECT GEAR RATIO
Range
Gear
1-2 Sol
2-3 Sol
Fourth Clutch A
Overrun Clutch
O/D Roller Clutch H H H O
FWD Clutch A A A A
Direct Clutch A A
Front Band
Interm. Sprag Clutch * H O O
Interm Clutch A A A
Lo Roller Clutch H O O O
Rear Band
1st 2nd Overdrive 3rd 4th
On Off Off On
Off Off On On
A=Applied H=Holding *=Holding but not effective O=Overrunning
Circuit Description
The Powertrain Control Module (PCM) calculates a ratio based on the Automatic Transmission Input Shaft Speed Sensor (A/T ISS) and Vehicle Speed Sensor (VSS) readings. The PCM compares the known transmission gear ratio to the calculated ratio, for the selected gear range. If the PCM detects an incorrect gear ratio, then DTC P0730 sets. DTC P0730 is a type C DTC.

The PCM does not illuminate the Malfunction Indicator Lamp (MIL). The PCM commands maximum line pressure. The PCM freezes shift adapts. DTC P0730 is stored in PCM memory.

A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported. The PCM cancels the DTC default actions when the fault no longer exits and the ignition is OFF long enough to power down the PCM.

The following conditions are met for 7 seconds: No MAP DTCs P0106, P0107, P0108. No A/T ISS Sensor DTCs P0716 or P0717. No VSS DTCs P0722 or P0723. No TFP Valve Position Switch DTC P1810. The Vehicle Speed is greater than 8 km/h (5 mph). The APP Angle is greater than 25%. The TFT is greater then 20C (68F). System voltage is 9.0-16.0 volts. Ten seconds must have elapsed since the last gear range change. The engine speed is greater than 475 RPM for at least 7 seconds. The engine speed is less than 3750 RPM. The engine torque is 100-642 Nm (80-475 lb ft). The Gear Ratio is one of the following: -Greater than 2.52 or less than 2.42 -Greater than 2.12 or less than 2.04 -Greater than 1.50 or less than 1.45 -Greater than 1.02 or less than 0.98 -Greater than 0.77 or less than 0.73
Diagnostic Aids
Sticking or contaminated shift valves may cause an undefined gear ratio. Refer to the Shift Solenoid Valve State and Gear Ratio table. First diagnose and clear any engine DTCs that are present. Then inspect for any transmission DTCs that may have reset. If a DTC P0717 Input Speed Sensor Circuit Low Input and a DTC P0730 are both present, diagnose DTC P0717 first. DTC P1870 detects an incorrect gear ratio in fourth gear with TCC applied.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 3. This step tests the indicated range signal to the actual selected range. A faulty TFP Valve Position Switch could set DTC P0730. 4. This step tests for proper ratios in each commanded gear state.
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DTC P0730 Incorrect Gear Ratio

Step Action Was the Powertrain On-Board Diagnostic (OBD) System Check performed? Perform the Transmission Fluid Checking Procedure. Refer to Transmission Fluid Checking Procedure. Is the Procedure complete? 1. 2. Install the scan tool. With the engine OFF, turn the ignition switch to the RUN position. Important: Before clearing the DTCs, use the scan tool in order to record the Failure Records for reference. Using the Clear Info function erases the stored Failure Records from the PCM. 3. Clear the DTCs. 4. Start the engine. 5. Apply the parking brake, and select each transmission range: D1, D2, D3, D4, N, R, and P. Does the scan tool TFP Switch A/B/C display match each selected gear range? (Refer to the Range Signal table). 1. 2. Drive the vehicle in Reverse and D4. Hold the vehicle speed above 8 km/h (5 mph) for greater than 2 seconds in the specied gear range. 3. Use the scan tool snapshot mode in order to record the transmission gear ratio for each commanded gear range: Reverse, 1st, 2nd, 3rd and 4th. Are the gear ratios within the parameters for each specied gear range? Value Go to step 3. Yes Go to step 2. No Go to Powertrain OBD System Check. Go to Transmission Fluid Checking Procedure. Refer to DTC P1810 TFP Valve Position Switch CKT Malfunction in this section.
Go to step 4.
Rev2.04-2.12 1st2.52-2.42 2nd1.45-1.50 3rd0.98-1.02 4th0.73-0.77
Refer to Diagnostic Aids.
Go to step 5.
1.
Connect a Pressure Gauge to the transmission line pressure tap. 2. Perform the Line Pressure Checking Procedure. Refer to Line Pressure Check Procedure. Is the line pressure within specications for each selected gear range? 1. Remove the transmission oil pan. 2. Inspect the oil pan and the uid for contamination. Did you nd excessive contamination? Inspect the transmission for the following problems: Sticking shift valves Stuck apply pistons Did you nd the condition? Is the system line pressure low only in the specic gear which indicated an incorrect gear ratio?
Go to step 6.
Go to step 8.
Repair the transmission. Go to step 10.
Go to step 7.
Repair the condition found.
Go to step 9.
Go to the Low Line Pressure table.
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DTC P0730 Incorrect Gear Ratio (Contd)

Step Action Inspect for uid pressure loss in the following areas: 1-2 SS Valve seal 2-3 SS Valve seal Valve body passages Valve body gaskets Band apply pistons and seals Clutch apply pistons and seals Did you nd the condition? 1. 2. 3. Change the AT uid and lter. Inspect for correct transmission uid level. Add new AT uid as necessary. Value Yes Repair the condition found. No Go to step 10.
10
Go to step 11.
NOTE: The clear TAPS function will clear all adapt cells. This may affect transmission performance. The PCM will update the transmission adapt cell values as the vehicle is driven. 4. Using the Tech 2, perform the clear TAPS function. Is the procedure complete?
11
In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: Start the engine Drive the vehicle in Reverse, 1st, 2nd, 3rd and 4th gear The PCM must see a valid gear ratio versus the commanded gear ratio for 7 seconds 4. Select Specic DTC. Enter DTC P0730. Has the test run and passed?
System OK.
Begin the diagnosis again. Go to Step 1.
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DTC P0741 TORQUE CONVERTER CLUTCH SOLENOID STUCK OFF

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
Circuit Description
DTC P0741 detects high torque converter clutch slip speed in commanded 2nd and 3rd gears only. TCC is only commanded on in these gears during Hot Mode, WOT, or if the gear selector indicates D3 or D2. The PCM energizes the converter clutch solenoid by creating a ground path on CKT 924. This blocks the exhaust for the TCC signal fluid and allows filtered 2-3 drive fluid to feed the TCC signal circuit. When the vehicles operating conditions are appropriate for TCC application, the PCM begins the TCC duty cycle to approximately 30 percent. This allows TCC signal fluid pressure to move the converter clutch shift valve into the apply position and direct regulated apply fluid to the torque converter. The PCM then increases, ramps, the duty cycle to approximately 60 percent, where regulated fluid pressure, applies the converter clutch. The vehicle application determines the TCC apply rate. Once the TCC applies, the duty cycle immediately increases to approximately 70 percent to achieve full apply pressure, in the regulated apply fluid circuit. The TCC solenoid valve is de-energized by the PCM opening the ground circuit. This action allows the TCC signal fluid to exhaust through the solenoid and blocks filtered 2-3 drive fluid from entering the TCC signal circuit. This loss of fluid pressure in the TCC signal circuit releases the TCC. 5745159
If the PCM detects high TCC slip when the TCC is commanded ON, then DTC P0741 sets. This is a type B DTC.

No DTC P0722, P0723. No DTCs P0716 or P0717. No DTCs P0742. No DTC P1810 or P1860. The TCC solenoid valve is commanded in 2nd and 3rd gear for greater than 0.6 seconds. The engine must be running greater than 70 percent for 1 second. Engine speed must exceed 475 RPM for at lease 7 seconds. The gear ratio must indicate 2nd or 3rd gear. The APP angle is 15-99 percent. The TFP manual valve position switch must be in D4, D3 or D2 and has not changed state within 4 seconds. The TFT must be 20-150C (68-302 F). The TCC slips speed is greater than 175 RPM for 3 seconds. and all conditions are met for a total of 4 occurrences.
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PCM will inhibit converter clutch apply. PCM will inhibit 4th gear upshift. The PCM will illuminate the warning lamp. The PCM increases line pressure.
Diagnostic Aids
Inspect the wiring for poor electrical at the PCM and the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also, check for chafed wire that could short to bare metal or other wiring Inspect for broken wire inside the insulation. If any engine DTCs or TP Sensor codes are present diagnose and clear these DTCs first. Then check to see if the transmission DTCs have reset.

The PCM will turn the warning light off after three consecutive ignition cycles without a failure reported. The Tech 2 can clear the MIL. The DTC will be cleared from memory after 40 warm up cycles without a fault.
DTC P0741 Torque Converter Clutch Solenoid Stuck OFF

Step 1. Action 1. Install the Tech 2. 2. Record the DTC freeze Frame and Failure records. 3. Clear the DTC. 4. Drive the vehicle with the TCC commanded ON. Is the TCC slip speed greater than 70% of the specified value when the TCC PWM solenoid valve is commanded ON? Inspect the TCC PWM solenoid valve for being mechanically stuck OFF. Was the problem found and corrected? Inspect the torque converter for being mechanically stuck OFF. 2. Inspect the TCC for a damaged exhaust orice. 3. Inspect the torque converter for possible damage. 4. Inspect the converter apply shift valve for being stuck in the off, release position. 5. Inspect for a misaligned or damaged valve body gasket. 6. Inspect for a restricted apply or release passage. Was the problem found and corrected? Perform the following procedure in order to verify the repair: 1. Select the DTC. 2. Select clear info. 3. Drive the vehicle in over drive with steady acceleration and the APP angle over 15%. 4. Select DTC P0741. Has the test run and passed? 1. Value 175 RPM Yes Go to step 2. No Go to diagnostic aids.
2.
Go to step 4.
Go to step 3.
3.
Go to step 4.
4.
System OK.
Go to step 1.
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DTC P0742 TORQUE CONVERTER CLUTCH STUCK ON
TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
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Circuit Description
The PCM energizes the torque converter clutch pulse width modulated solenoid valve by closing the ground circuit. This blocks the exhaust for TCC signal fluid and allows filtered 2-3 drive fluid to feed the TCC signal circuit. When the vehicle operating conditions are appropriate for TCC application, the PCM activates the TCC duty cycle to approximately 30 percent. This allows TCC signal fluid pressure to move the converter clutch shift valve into the apply position and direct regulated apply fluid to the torque converter. This PCM then increases the duty cycle to approximately 60 percent, where regulated apply fluid pressure, applies the converter clutch. The vehicle application determines the TCC apply rate. Once the TCC applies, the duty cycle immediately increases to approximately 70 percent to achieve full apply pressure, in the regulated apply fluid circuit. The TCC PWM solenoid valve is de-energized by the PCM opening the ground circuit. This action allows the TCC signal fluid to exhaust through the solenoid and block filtered 2-3 drive fluid from entering the TCC signal circuit. The loss of fluid pressure in the TCC signal circuit releases the TCC. This DTC detects low torque converter slip when the clutch is commanded OFF. This is a type B DTC.

The PCM will turn off the warning lamp after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The PCM will cancel DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
If the converter clutch is seized with the parking brake applied and any gear range selected, the clutch fluid pressure will apply the clutch and cause an engine stall. If any engine DTCs codes are present diagnose and clear these DTCs first. Then check to see if the transmission DTCs have reset.

The following conditions occur once per TCC cycle two consecutive times: No DTCs. Engine speed is less than 3300 RPM. Engine running greater then 475 RPM for more then 7 seconds. Engine torque between 130 and 475 ft/lbs. Gear range is D4. Commanded gear must be 2nd, 3rd, or 4th. Throttle Position must be greater than 15%. TFT between 68-266 F The TCC slip speed must be -10 to +10 RPM for at least 3 seconds. All conditions met for 3 occurrences.

The PCM illuminates the Malfunction indicator lamp during the second consecutive trip in which the Conditions for setting the DTC are met. The PCM will command maximum line pressure. The PCM will freeze shift adapts. The PCM records the operating conditions when the Conditions for setting the DTC are met. The PCM stores this information as Freeze Frame and Failure Records. The PCM stores the DTC P0742 in PCM history during the Second consecutive trip in which the Conditions for setting are met.
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DTC P0742 Torque Converter Clutch Stuck On Step Action 1. 2. 3. Connect scan tool. Turn the ignition switch to on. Record the DTC Freeze Frame and Failure Records. 4. Using the scan tool, verify the APP sensor operation. Are the APP values within range shown in the value column? Value Yes No
0% at Closed Throttle. 100% at Wide Open Throttle. Go to step 2.
Drive vehicle in D4 drive range under steady acceleration, with an APP angle greater than 15%. Does scan tool display TCC Slip Speed between -10 and +10 RPM, TCC Duty Cycle is 0 percent? The TCC is mechanically stuck ON. Inspect the following items: Clogged exhaust orifice in the TCC solenoid. Converter clutch apply valve stuck in the apply position. Misaligned or damaged valve body gasket. Restricted release passage. Is the problem corrected? 1. After the repair is complete, use the scan tool to select DTC, then Clear Inform function. 2. Operate the vehicle under the following conditions: Drive in D4 with the TCC OFF and the APP angle above 15%. Ensure that the TCC slip speed is 175-1500 RPM for 3 seconds. 3. Select the DTC P0742. Has the test run and passed?
Go to step 3.
Go to step 4.
Repair veried, exist DTC table.
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DTC P0748 PRESSURE CONTROL SOLENOID (PCS) - ELECTRICAL

AUTOMATIC TRANSMISSON
B A
C34
D C
C32
G 265 LB F 264 RD
C27
C15
C7 12V
PCM
PC SOLENOID VALVE HIGH CONTROL PC SOLENOID VALVE LOW CONTROL
02-S12-016
Circuit Description
The PC control solenoid valve is a PCM-controlled device used to regulate transmission line pressure. The PCM compares APP voltage, engine RPM, and other inputs to determine line pressure appropriate for a given load. The PCM will regulate pressure by applying a varying duty cycle to the PC solenoid valve based on the resistance of the solenoid and the amperage need to obtain optimum line pressure. The amperage can vary from 0.1 amps for maximum line pressure to 1.1 amps for minimum line pressure. If the PCM detects a PC duty cycle that exceeds 95 percent or is less than 1.9 percent, then DTC P0748 will set. P0748 is a type C code.

The DTC can be cleared from the PCM history by using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warm-up cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
DTC P0748 defaults to an elevated line pressure condition which may result in partial TCC apply. This may produce an idle surge that could stall the engine.

The system voltage is greater than 10 volts at -40C (40F) TFT or 12.5 volts at 150C(302F) TFT. The engine must be running greater than 475 RPM for at least 7 seconds, and not in fuel cut off mode. The PC duty cycle exceeds 95% or is less than 1.9% All conditions are met for 200 milliseconds (0.2 seconds).
Test Description
2. This test checks the ability of the PCM to command the PC solenoid valve. 3. This test checks the PC solenoid valve and internal wiring harness for incorrect resistance. 6. This step tests the PC solenoid valve and the internal wiring harness for a short to ground. 9. This step tests the entire PC solenoid valve circuit up to the PCM for continuity. 10. This step tests for a short to ground in the PC solenoid valve high control circuit (CKT 264) and the PC solenoid valve low control circuit (CKT 265), of the engine harness.

The PCM will disable the PC solenoid valve, defaulting the transmission to maximum line pressure. The PCM will freeze shift adapts. The PCM will NOT turn on the MIL. The PCM will record and store operating conditions information as a Failure Record.
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DTC P0748 Pressure Control Solenoid - Electrical

Step Action 1. 2. Connect scan tool. Turn the ignition switch to on. Value Yes No
NOTE: Important: Before clearing DTC(s), use the scan tool to record Failure Records for reference, as data will be lost when the Clear Info function is used. 3. 4. 5. Record the DTC Failure Records. Start engine and shift into Park. Using the transmission output control function on the scan tool, apply 0.1 amp through 1.0 amp while observing PC Ref. Current and PC Act. Current. Is the PC Act. Current reading always within the indicated value? 1. 2. 3. Turn ignition off. Disconnect transmission 20-way connector. Install the transmission test harness on the transmission side of the 20-way connector. 4. Using a DVOM and connector test adapter kit, measure the resistance between terminals C and D. Is the resistance within indicated values? 1. Remove transmission oil pan. 2. Disconnect wiring harness at PCS. 3. Measure resistance of PCS. Is resistance within indicated values? 1. Disconnect the automatic transmission wiring harness assembly and the PC solenoid valve. 2. Measure the resistance of the PC solenoid valve. Does the resistance measure within the specied range? Measure the resistance from terminal C of the test harness and the transmission case. Does the resistance measure less than the specified value? Inspect the automatic transmission wiring harness assembly for a short to ground condition. Was a shorted condition found and corrected? Replace the PC solenoid valve. Is the repair complete? Measure the resistance from terminal C and all other terminals, except D, on the transmission test harness. Is the resistance measured on all terminal, except D, less then the specied value. 1. 2. Disconnect the test harness from the transmission. Reconnect the external transmission harness to the transmission. 3. Disconnect the PCM connector C27 and measure the resistance between terminals C7 and C15. Does the resistance measure within the specied range? 0.16 amp
Go to step 2.
3-7 ohms
Go to step 6.
Go to step 3.
3-7 ohms Go to step 5. Go to step 4.
3-7 Go to step 15. 7 Go to step 6. Go to step 15. Go to step 17. Go to step 7. Go to step 8. Go to step 7.
7 8
100 Go to step 15. Go to step 9.
3-7 Go to step 10. Go to step 11. 1-1-02
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DTC P0748 Pressure Control Solenoid - Electrical (Contd)

Step Action 1. Connect a DVOM to terminal C27-C7 and a good ground. 2. Measure the resistance. Does the resistance measure greater than the specified value? Does the resistance in step 9 measure greater than the specied value? 1. Test the PC solenoid valve high control circuit (CKT 264) for an open. 2. Test the PC solenoid valve low control circuit (CKT 265) for an open. Was a problem found and corrected? Test the PC solenoid valve control circuits CKT 264 and CKT 265 for a short together condition. Was a problem found and corrected? Test the PC solenoid valve control circuits CKT 264 and CKT 265 for a short to ground condition. Was a problem found and corrected? Replace the automatic transmission wiring harness assembly. Is the repair complete? Replace the PCM. Is the repair complete? Perform the following procedure in order to verify the repair. 1. Select DTC. 2. Select Clear INFO. 3. Ensure the following conditions are met: The engine is running. The PC duty cycle is 2-95% 4. Select specic DTC 5. Enter DTC P0748. Has the test run and passed? Value Yes No
10
7 Go to step 16. 7 Go to step 12. Go to step 14. Go to step 13.
11 12
13
14
15
16 17
System OK.
Go to step 1.
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DTC P0751 1-2 SHIFT SOLENOID VALVE PERFORMANCE

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
Circuit Description
The 1-2 shift solenoid is used to control fluid acting on the 1-2 and 3-4 shift valves. The solenoid is a normally open valve used with the 2-3 solenoid to allow four different shifting combinations. This DTC detects incorrect Gear Ratios when a Gear is commanded. This is a type B DTC.
TFT is greater than 20 C (69 F). Engine Speed is less than 3650 RPM. Not in Four Wheel Drive Low.
Stuck Off: (after two occurrences)

1st gear is commanded and the ratio is equal to 2nd gear for greater than 1.7 seconds. 4th gear is commanded (with converter clutch locked) and ratio is equal to 3rd gear for greater than 3 seconds.

No DTCs P0106, P0107 or P0108. No DTCs P0722 or P0723. No DTCs P0716 or P0717. No shift solenoid 1-2 DTC P0753. No shift solenoid 2-3 DTC P0758. No Pressure switch assembly DTC P1810. Engine RPM greater then 475 for at least 7 seconds Vehicle speed is greater than 4.2 km/h (2.5 mph). Throttle angle is greater then 12%. Engine Torque between 60 ft/lbs and 450 ft/lbs.
Stuck On: (after five occurrences)

2nd gear is commanded and the ratio is equal to 1st gear for greater than 2.5 seconds.

The PCM will command maximum line pressure. The PCM will freeze shift adapts. The PCM illuminates the MIL.
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Conditions For Clearing The MIL/DTC

The PCM will turn the warning lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The PCM will cancel DTC default actions when the fault no longer exists and ignition is cycled off long enough to power down the PCM.
Test Description
1.This test checks pressure switch function of the PSA. 2.This test checks that the scan tool commanded all shifts, all shift solenoids responded correctly, but all the shifts did not occur. 4L80-E CHART Gear 1-2 Shift Solenoid 2-3 Shift Solenoid
Diagnostic Aids
Verify that the transmission meets the specifications in the 4L80-E shift speed chart. Other internal transmission failures may cause more than one shift to occur.
1 2 3 4
ON OFF OFF ON
OFF OFF ON ON
DTC P0751 1-2 Shift Solenoid Valve Performance

Step Action 1. 2. 3. 4. Connect scan tool. Turn ignition switch on. Record DTC Freeze Frame and Failure Records. Start engine, apply brake pedal and shift to following ranges D1, D2, D3, D4, N, R, and P. Does each selected range match the TFP Switch A/B/C display? 1. Raise vehicle on hoist that allows wheels to rotate. 2. Start engine, shift into D4 range, use scan tool to command 1st, 2nd, 3rd, and 4th gears increasing speed. Did 2-3 or 1-4 only shift pattern occur? Check the shift solenoid/hydraulic circuit for: Shift solenoids for an internal malfunction. Damaged seals on the shift solenoids. Was a problem found and corrected? 1. After the repair is complete, use scan tool to select DTC then Clear Info function. 2. Select Specic DTC and enter DTC P0751. 3. Operate the vehicle under the following conditions Hold the throttle at 20% and accelerate to 55 mph (if the throttle moves more than 3%, stop the vehicle and start over). PCM must see the proper ratio for each commanded gear for greater than one second in D1, D2, D3, and D4. 4. Select Specic DTC. 5. Enter DTC P0571. Has the test run and passed? Value Yes No
Go to step 2.
Go to Pressure Switch Assembly (PSA) Resistance Check.
Go to step 3. Go to Diagnostic Aids.
Go to step 4.
System OK.
Repair veried, exist DTC table.
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5-89
DTC P0753 1-2 SHIFT SOLENOID VALVE ELECTRICAL

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
Circuit Description
The 1-2 shift solenoid valve controls the fluid flow acting on the 1-2 and the 3-4 shift valves. The 1-2 SS valve is a normally open exhaust valve that is used with the 2-3 shift solenoid valve in order to allow four different shifting combinations. The 1-2 SS valve attaches to the control valve body within the transmission. The ignition voltage goes directly to the 1-2 SS valve. The PCM controls the 1-2 SS valve by providing the ground path through circuit 237. If the PCM detects a continuous open or shot to ground in the 1-2 SS valve circuit or the 1-2 SS valve, then DTC P0753 sets. This is a type B DTC.

The PCM will command maximum line pressure. The PCM will freeze shift adapts. The PCM will turn on the warning lamp. The PCM will store a DTC P0753 in the PCM history.

For California emissions, the PCM will turn the warning lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

The engine RPM is greater than 475 for 7 seconds. The above condition is met, and either of the following conditions occur for 4.3 out of 5 seconds. The PCM commands the solenoid on, and the voltage input remains high (B+). The PCM commands the solenoid off and the voltage input remains low.
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Diagnostic Aids
An open ignition feed circuit can cause multiple DTCs. DTC P0753 defaults to an elevated line pressure conditions which may result in partial TCC apply. This may produce an idle surge that could stall the engine. 4L80-E CHART Gear 1-2 Shift Solenoid 2-3 Shift Solenoid
Test Description
3. This test checks the function of the 1-2 shift solenoid and the internal transmission wiring harness. 4. This test checks for power to the 1-2 shift solenoid from the ignition through the fuse. 10. This test measures the resistance of the 1-2 SS valve.
1 2 3 4
ON OFF OFF ON
OFF OFF ON ON
Figure 5-28: Shift Solenoid Valve State Table
DTC P0753 1-2 Shift Solenoid Valve Electrical

Step 1 1. 2. Action Connect the Tech 2. Turn ignition switch to the Run position. Value Yes Go to step 2. No Go to step 3.
NOTE: Important: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record DTC Freeze Frame and Failure Records. Is DTC P0758 or DTC P01860 set? 2 3 1. Inspect applicable fuse. Is the fuse open? Using the transmission output control function on the Tech 2, command the 1-2 SS ON and OFF three times while listening to transmission pan. Does solenoid click when commanded? 1. 2. Turn the ignition OFF for 30 seconds. Disconnect the transmission 20-way connector (additional DTCs will set). 3. Install the transmission test harness on the engine side of the 20-way connector. 4. With the engine off, turn the ignition switch to the Run position. 5. Connect a test lamp from the transmission test harness cavity E to a good ground. Does the test lamp illuminate? Go to step 11. Go to diagnostic aids. Go to step 4. Go to step 4.
Go to step 5.
Go to step 14.
1.
Connect the test lamp between terminal E and A of the transmission test harness. 2. Use the Tech 2 in order to command the 1-2 valve ON and OFF three times. Does the test lamp turn ON and OFF with each command? Is the test lamp always ON?
Go to step 7.
Go to step 6.
Go to step 15.
Go to step 16.
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DTC P0753 1-2 Shift Solenoid Valve Electrical (Contd)

Step 7 1. Action Install the transmission test harness on the transmission; 2. Using a DVOM measure the resistance between terminals A and E of the transmission test harness. Does the resistance measure within the specied range? Measure the resistance to ground on terminals A and E of the transmission test harness. Is the specied value shown? 1. Disconnect the AT wiring harness assembly from the 1-2 SS valve. 2. Measure the resistance of the 1-2 SS valve. Does the resistance measure within the specied range? Disconnect the AT wiring harness assembly from the 1-2 SS valve. 2. Measure the resistance from the components terminals to ground. Is the specied value shown? Test the battery voltage circuit (CKT 351) for a short to ground between the 1-2 SS valve for a short to ground between the AT inline 20-way connector and the 1-2 SS valve. Was a short to ground found and repaired? Test the ignition voltage circuit (CKT 351) for a short to voltage on the transmission wiring harness. Was a short to ground found? 1. Test the 1-2 shift solenoid for a short to ground. 2. Replace the faulty solenoid as necessary. Is the repair complete? Test the battery voltage circuit (CKT 351) for an open. Was an open found and corrected? Test the 1-2 SS valve control circuit (CKT 237) for a short to ground between the PCM connector C28 and the AT inline 20 way connector. Was a short to ground found and repaired? Test the 1-2 SS valve control circuit (CKT 237) for an open or short to power between the PCM connector C28 and the AT inline 20 way connector. Was an open found and repaired? Replace the AT wiring harness assembly from the 1-2 SS valve. Is the replacement complete? Replace the 1-2 SS valve. Is the replacement complete? 1. Value 19-31 Yes Go to step 8. No Go to step 10.
OL
Go to step 12.
19-31
Go to step 18.
10
OL
Go to step 17.
Go to step 18.
11
Go to step 20.
Go to step 12.
12
Go to step 17.
Go to step 13.
13
Go to step 20.
14 15
Go to step 20. Go to step 20
Go to step 19.
16
Go to step 20.
Go to step 19.
17
Go to step 20.
18
Go to step 20.
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DTC P0753 1-2 Shift Solenoid Valve Electrical (Contd)

Step 19 20 Replace the PCM. Is the repair complete? Preform the following procedure in order to verify the repair: 1. With the scan tool select DTC 2. Select Clear Info. 3. Select the parameters 1-2 Sol. and 1-2 Sol. Open/Shorted to GND, and 1-2 Sol. Shorted to Volts. 4. Operate the vehicle under the following conditions: The PCM commands the 1-2 shift solenoid valve On and the 1-2 Sol. Shorted to Voltage is NO. The PCM commands the 1-2 shift solenoid valve Off and the 1-2 Sol. Open/Shorted to GND is No. All conditions are met for 5 seconds. 5. Select Specific DTC. 6. Enter DTC P0753. Has the test run and passed? Action Value Yes Go to step 20. System OK. No Go to step 1.
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DTC P0756 2-3 SHIFT SOLENOID VALVE PERFORMANCE

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
Circuit Description
The 2-3 shift solenoid controls fluid acting on the 2-3 shift valves. The solenoid is normally open and is used with the 1-2 shift solenoid to provide four different shift combinations. This DTC detects a non 1st gear when 1st gear is commanded, or 1st gear when 4th gear is commanded. This is a type A code.
Stuck On:
First gear is commanded and the ratio equals 4th for greater then 2.75 seconds. Second gear is commanded and the gear ratio equals 3rd for greater than 2.75 seconds.
Stuck Off:
Third gear is commanded and the ratio equals 2nd for greater than 3.25 seconds.

No DTC P0722 or P0723. No sensor DTCs P0712 or P0713. No DTC P1810. No shift solenoid electrical DTCs P0753 or P0758. No DTCs P0716 or P0717. Engine running. Not in 4WD Low. Vehicle speed is greater than 6 km/h (4 mph). The APP angle is greater than 12%. Transmission fluid temperature is between 20 and 130C (68 and 266 F). Engine torque is between 80 and 450 ft/lbs. Engine speed is less than 3750 rpm. for at least 7 seconds.

The transmission will immediately land to 2nd gear. The PCM will command maximum line pressure. The PCM will freeze shift adapts. The PCM will illuminate the warning lamp.

The PCM will turn the lamp after three consecutive ignition cycles without a failure reported. The DTC can be cleared by using the scan tool. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off' long enough to power down the PCM. 1-1-02
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Diagnostic Aids
Verify that the transmission meets the specifications in the Shift Solenoid Value State Other internal transmission failures may cause similar shift patterns. The customer may complain of an engine over-rev condition or neutral condition. DTCP0756 defaults to an elevated line pressure condition which may result in partial TCC apply. This may produce an idle surge that could stall the
3.
This test checks for selected gear ratio vs. a ratio not obtainable under normal driving conditions. 4L80-E CHART Gear 1-2 Shift Solenoid 2-3 Shift Solenoid
Test Description
2. This test checks the function of the PSA.
1 2 3 4
ON OFF OFF ON
OFF OFF ON ON
DTC P0756 2-3 Shift Solenoid Valve Performance

Step Action 1. 2. 3. 4. Connect scan tool. Turn the ignition switch on. Record Freeze Frame and Failure Records. Start engine, apply brake pedal and shift into D1, D2, D3, D4, N, R, and P. Does each selected transmission range match TR Switch on the scan tool? Value Yes No
Go to step 2.
Go to Pressure Switch Assembly Resistance Check.
1. 2.
Raise vehicle on lift that allows wheels to turn freely. Start engine and shift into D4 range. Use scan tool to command 1st, 2nd, 3rd, and 4th gears while increasing engine speed. Was 1st gear commanded and not achieved, or 4th gear commanded and other than 4th gear occurred? (Road testing the vehicle may be necessary). 1. Inspect the shift solenoid for an internal malfunction at one or both of the shift solenoids. 2. Inspect the shift solenoid for damaged seals on one or both of the shift solenoids. Was a problem found and corrected? 1. After repair is complete, use scan tool to select DTC, then Clear Info function. 2. Select Specic DTC and enter DTC P0756. 3. Operate the vehicle under the following conditions (only if trafc and road conditions permit): PCM must see the proper gear ratio for each commanded gear for greater than one second in D1, D2, D3, and D4. Hold the throttle at 25% and accelerate to 55 mph. Has the test run and passed?
Go to step 3. Go to Diagnostic Aids.
Go to step 4.
System OK.
Go to step 1
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DTC P0758, 2-3 Shift Solenoid Electrical

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S 924 TN 315 YL
B 237 LG
C34
PCM
C32
02-S12-017
Circuit Description
The 2-3 shift solenoid controls fluid acting on the 2-3 shift valves. The solenoid is a normally open valve. It is used with the 1-2 shift solenoid (SS) to provide four different shift combinations. The solenoid is attached to the control valve body. Ignition voltage is supplied directly to the 2-3 shift solenoid. The PCM controls the solenoid by providing a ground path through circuit 315. This DTC detects a continuous open or short to ground in the 2-3 shift solenoid circuit or 2-3 shift solenoid. This is a type B code.

Immediate shift to second gear. The PCM commands maximum line pressure. Freeze shift adapts from being updated. Inhibit converter clutch engagement. The PCM illuminates MIL.

The PCM turns the warning lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

The engine is running greater then 475 RPM for greater than 7 seconds and system voltage is normal.

The PCM detects either of the following fail conditions for 4.3 of 5 seconds. The PCM commands the solenoid ON and voltage remains high (B+). The PCM commands the solenoid OFF and voltage remains low (zero volts).
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Diagnostic Aids
An open ignition feed circuit can cause multiple DTCs to set. Refer to the Shift Solenoid Valve State table. ETC P0758 defaults to an elevated line pressure conditions which may result in partial TCC apply. This may produce an idle surge that could stall the engine. 4L80-E CHART Gear 1-2 Shift Solenoid 2-3 Shift Solenoid
1 2 3 4
ON OFF OFF ON
OFF OFF ON ON
DTC P0758 2-3 Shift Solenoid B Electrical

Step 1 1. 2. Action Connect the Tech 2. Turn ignition switch to the Run position. Value Yes Go to step 2. No Go to step 3.
NOTE: Important: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record DTC Freeze Frame and Failure Records. Is DTC P0753 or DTC P01860 set? 2 3 1. Inspect applicable fuse. Is the fuse open? Using the transmission output control function on the Tech 2, command the 2-3 SS ON and OFF three times while listening to transmission pan. Does solenoid click when commanded? 1. 2. Turn the ignition OFF for 30 seconds. Disconnect the transmission 20-way connector (additional DTCs will set). 3. Install the transmission test harness on the engine side of the 20-way connector. 4. With the engine off, turn the ignition switch to the Run position. 5. Connect a test lamp from the transmission test harness cavity E to a good ground. Does the test lamp illuminate? Go to step 11. Go to diagnostic aids. Go to step 4. Go to step 4.
Go to step 5.
Go to step 14.
1.
Connect the test lamp between terminal E and B of the transmission test harness. 2. Use the Tech 2 in order to command the 1-2 valve ON and OFF three times. Does the test lamp turn ON and OFF with each command? Is the test lamp always ON?
Go to step 7.
Go to step 6.
Go to step 15.
Go to step 16.
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DTC P0758 2-3 Shift Solenoid B Electrical (Contd)

7 1. Install the transmission test harness on the transmission; 2. Using a DVOM measure the resistance between terminals B and E of the transmission test harness. Does the resistance measure within the specied range? Measure the resistance to ground on terminals B and E of the transmission test harness. Is the specied value shown? 1. Disconnect the AT wiring harness assembly from the 2-3 SS valve. 2. Measure the resistance of the 2-3 SS valve. Does the resistance measure within the specied range? Disconnect the AT wiring harness assembly from the 2-3 SS valve. 2. Measure the resistance from the components terminals to ground. Is the specied value shown? Test the battery voltage circuit (CKT 351) for a short to ground between the 2-3 SS valve for a short to ground between the AT inline 20-way connector and the 2-3 SS valve. Was a short to ground found and repaired? Test the ignition voltage circuit (CKT 351) for a short to voltage on the transmission wiring harness. Was a short to ground found? 1. Test the 1-2 shift solenoid for a short to ground. 2. Replace the faulty solenoid as necessary. Is the repair complete? Test the battery voltage circuit (CKT 351) for an open. Was an open found and corrected? Test the 2-3 SS valve control circuit (CKT 315) for a short to ground between the PCM connector C28 and the AT inline 20 way connector. Was a short to ground found and repaired? Test the 2-3 SS valve control circuit (CKT 315) for an open or short to power between the PCM connector C28 and the AT inline 20 way connector. Was an open found and repaired? Replace the AT wiring harness assembly from the 2-3 SS valve. Is the replacement complete? Replace the 2-3 SS valve. Is the replacement complete? Replace the PCM. Is the repair complete? 1. 19-31 Go to step 8. Go to step 10.
OL
Go to step 12.
19-31
Go to step 18.
10
OL
Go to step 17.
Go to step 18.
11
Go to step 20.
Go to step 12.
12
Go to step 17.
Go to step 13.
13
Go to step 20.
14 15
Go to step 20. Go to step 20
Go to step 19.
16
Go to step 20.
Go to step 19.
17
Go to step 20.
18 19
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DTC P0758 2-3 Shift Solenoid B Electrical (Contd)

20 Preform the following procedure in order to verify the repair: 1. With the scan tool select DTC 2. Select Clear Info. 3. Select the parameters 2-3 Sol. and 2-3 Sol. Open/Shorted to GND, and 2-3 Sol. Shorted to Volts. 4. Operate the vehicle under the following conditions: The PCM commands the 2-3 shift solenoid valve On and the 2-3 Sol. Shorted to Voltage is NO. The PCM commands the 1-2 shift solenoid valve Off and the 2-3 Sol. Open/Shorted to GND is No. All conditions are met for 5 seconds. 5. Select Specific DTC. 6. Enter DTC P0758. Has the test run and passed? System OK. Go to step 1.
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DTC P1810 PRESSURE SWITCH ASSEMBLY (PSA) FAULT

D2 SWITCH LO SWITCH
D3 SWITCH B R H 763 DB K 762 OR B6 TRANS RANGE B IINPUT
REV SWITCH A N
C29
B4
B5
01-S12-049
Circuit Description
The PSA consists of five normally open pressure switches. The PCM supplies battery voltage to each range signal. By grounding one or more of these circuits through various combinations of the switches, the PCM detects what manual valve position has been selected. It then compares actual voltage combinations to a PSA chart in PCM memory. The PSA switch assembly cannot distinguish between Park and Neutral because the monitored valve body pressures are identical in both cases. With the ignition on and engine off, Park/Neutral will be indicated. When the transmission 20-way connector is disconnected, ground potential for the three range signals is removed, and with ignition on, D2 will be indicated. This DTC detects an invalid state of the PSA sensor or the PSA circuit by deciphering the PSA inputs. This is a type B code.
Condition 3: Vehicle speed is greater than 8 km/h (5 mph). APP is greater than 12%.

The PCM will command maximum line pressure. PCM assumes D4 for PRNDL shift pattern. The PCM will freeze shift adapts. The PCM will illuminate the warning lamp.

The PCM will turn the MIL off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.

This DTC will set if any of the following conditions occurs: Condition 1: PCM detects an illegal PSA combination for greater than 25 seconds. Condition 2: Engine speed is less than 50 rpm for 0.5 seconds, between 50 and 525 rpm for 0.3 seconds, and than to greater than 525 rpm and vehicle speed is less then 2.5 MPH. PCM detects gear range as D2 before and after start-up. Condition exists for greater than 7 seconds. 5745159
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5-100
___________________________________________
Diagnostic Aids
Refer to the accompanying chart for the normal range signals and the illegal combinations. This DTC can be falsely set during a fluid fill procedure. After refilling the fluid, power the PCM down. This DTC can be set falsely by low pump pressure or a stuck pressure regulator. This DTC can be set by a slipping forward clutch assembly. It may allow the PCM to see a 2.08:1 ratio (reverse) when the manual valve position is indicated as D4. Range Signal
PSA Switch Logic

A B C
Test Description
2. This test checks the indicated range signal to the manual valve actually selected. 3. This test checks for correct voltage from the PCM to the transmission 20-way connector.
Park Rev Neutral D4 D3 D2 D1 Illegal Illegal
OFF ON OFF OFF OFF OFF ON ON ON
ON ON ON ON OFF OFF OFF OFF ON
OFF OFF OFF ON ON OFF OFF ON ON
ON = 0 volts/ OFF = B+
DTC P1810 Pressure Switch Circuit Fault

Step Action Perform following check: Transmission linkage (from select lever to the manual valve) is properly adjusted. Fluid check. Were checks performed? 1. 2. Connect scan tool. Turn ignition switch to on. Value Yes No
Go to step 2.
NOTE: Important: Before clearing DTC(s), use the scan tool to record Freeze Frame and Failure Records for reference, as data will be lost when the Clear Info function is used. 3. Record the DTC Freeze Frame and Failure Records. 4. Start and run engine at curb idle. 5. Apply service brake and shift into D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool TR Switch display?
Go to step 3.
1.
Inspect the transmission linkage from the gear select lever to the manual valve for proper adjustment. 2. Adjust the linkage as necessary. Did the linkage require adjustment? 1. 2. Turn the ignition OFF. Disconnect the AT inline 20-way connector (additional codes may set). 3. turn the ignition ON with the engine OFF. Does the APP switch A/B/C parameter indicate HI for all range signal states?
1-1-02
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5-101
DTC P1810 Pressure Switch Circuit Fault (Contd)

Step Action Turn ignition OFF. Install the transmission test harness to engine side of transmission 20-way connector. 3. Turn the ignition ON and the engine OFF. 4. Using a DVOM check voltage at harness connector terminals N, R, and P. Is B+ displayed on all three circuits? Ground terminal N and watch the Tech 2 switch parameters A/B/C. When the PSA signal A (CKT 762) is grounded do any other signal circuits indicate LOW? Ground terminal R and watch the Tech 2 switch parameters A/B/C. When the PSA signal B (CKT 763) is grounded do any other signal circuits indicate LOW? Ground terminal P and watch the Tech 2 switch parameters A/B/C. When the PSA signal C (CKT 764) is grounded do any other signal circuits indicate LOW? Test the PSA switch for a short to ground on CKTs 762, 763, 764. Was a condition found? Test the PSA switch for an open on CKTs 762, 763, 764. Was a condition found? Check CKTs 762, 763, 764 for a short together condition. Was a condition found? Test the PSA signals A, B, C circuits of the manual valve for and open or shorted condition internal to the transmission. Was the condition found? Replace the AT wiring harness assembly. Is the repair complete? Replace the PSA valve position switch. Is the repair complete? Replace the PCM. Did you complete the replacement? 1. After the repair is complete, use the scan tool to select DTC, then CLEAR INFO. 2. Then start vehicle, idle for 5 seconds, then drive vehicle in D4 until converter clutch locks for 20 seconds. 3. Select DTC 1810. Does the DTC run and pass? 1. 2. Value Yes No
B+
Go to step 6.
Go to step 7.
Go to step 11. Go to step 16. Go to step 16. Go to step 16. Go to step 15. Go to step 15 Go to step 15. Go to step 12.
10
11 12
13 14 15 16
System OK.
Go to step 1.
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DTC P1811 MAXIMUM ADAPT AND LONG SHIFT

TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
D2 SWITCH LO SWITCH
C33-F
351 PK
TRANSMISSION
C34-E
D3 SWITCH B R H 763 DB K
REV SWITCH A N
TORQUE CONVERTER CLUTCH SOLENOID (TCC) 2-3 SHIFT SOLENOID (2-3 SS) 1-2 SHIFT SOLENOID (1-2 SS)
S 924 TN 315 YL
B 237 LG
C34
C29
762 OR
B4
B5
B6
PCM
C32
TRANS RANGE B IINPUT

TCC PWM SOLENOID CONTROL 2-3 SS VALVE CONTROL FEEDBACK 1-2 SS VALVE CONTROL FEEDBACK
01-S12-049
02-S12-017
Circuit Description
The PCM compares the measured gear ratio to the known actual value. This allows the PCM to determine the actual gear range of the transmission. When an upshift is commanded, the PCM measures the interval during which the gear ratio leaves the current range and changes to reflect the commanded upshift. This interval is expressed on the scan tool as Shift Time. When this interval has exceeded a predetermined limit, the PCM utilizes the shift adapts to attempt to shorten the shift time. If the PCM detects that the maximum allowable shift time has been exceeded, and that the upshift adapts have reached their upper limit, then DTC P1811 sets. This is a type D code.

The DTC can be cleared using the scan tool. The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without reported failure. PCM will cancel DTC default actions when the fault no longer exists and ignition is cycled Off long enough to power down the PCM.
Diagnostic Aids
This code may be caused by a faulty turbocharger or waste gate assembly. Excessive overloading of the vehicle is possible. Verify the vehicle is not towing over the limit or towing in overdrive. It maybe necessary to reset the shift adapts to assure proper shifting. This DTC will result to a default to maximum line pressure. This may produce an idle surge that could stall the engine.

The engine must be running for greater than 5 seconds. One of the following conditions exists, with the adapt cells at the maximum pressure allowed for 5 consecutive occurrences of one shift. - The 1-2 or the 2-3 upshifts are greater than 1.25 seconds. - The 3-4 upshifts are greater than 6.38 seconds.
Test Description
2. This step tests for low fluid level which can cause delayed shifts. 3. This step compares the indicated range signal from the Range Signal Chart to the Automatic Transmission Fluid Pressure switch assembly (PSA) selected gear range. 5. This step tests for low line pressure, which can cause delayed and long shifts.

The PCM will default the transmission to maximum line pressure. The PCM will freeze shift adapts.
1-1-02
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5-103
DTC P1811 Maximum Adapt and Long Shift

Step Action Was the Powertrain Diagnostic System Check? Go to step 2. Value Yes No Go to OBD Powertrain System Check. Go to Transmission Fluid Checking Procedure.
1 2 3
Have you performed the transmission uid checking procedure? Go to step 3. 1. 2. 3. Install the scan tool. Turn the ignition to the RUN position without starting the engine. Record the DTC Freeze Frame Failure Records and DTCs. Use the scan tool snapshot mode in order to record the shift times. Important: If any other engine or transmission DTCs are set, refer to their respective diagnostic tables first. 4. Select TFP sw. A/B/C on the scan tool. 5. Start the engine and apply the brake pedal. 6. Select each gear range: D1, D2, D3, D4, N, R, and P. Does each selected transmission range match the TFP Sw. A/B/C display on the scan tool? Refer to the Range Signal table. 1. Drive the vehicle in D4 in order to obtain a 1-2, a 2-3, and a 3-4 shift time. 2. Using the scan tool, review the shift time information for 12, 2-3, and 3-4 shift times. Were all of the shift times above the specified value? Perform the line pressure test. Refer to Line Pressure Test. Is the line pressure within specications? 1. Remove the transmission oil pan. 2. Inspect the pan and the fluid for contamination. Is there excessive contamination in the transmission oil pan? Inspect the transmission for pressure loss in the following areas: Valve Body Gasket Forward Clutch Seals Turbine Shaft Seals Did you nd and correct a problem? Inspect the 1-2, 2-3, and the 3-4 adapt cells on the scan tool. Were any of the upshift TAP cells greater the specied value? Did the 3-4 shift time exceed the specied value? Did the 2-3 shift time exceed the specied value? Did the 1-2 shift time exceed the specied value? Inspect the following 3-4 shift circuit components: 4th Gear Clutch Plates 4th Gear Clutch Seals Did you nd and correct a problem?
Go to step 4. 1-2, or 2-3 upshifts: 1.25 seconds 3-4 upshifts: 6.38 seconds Go to step 6.
Go to DTC P1810.
Go to step 5.
5 6
Go to step 8. Go to Symptom Diagnosis Table, Low Line Pressure.
Replace the transmission.
Go to step 7.
Go to step 15. 110kPa (16psi) 6.38 seconds 1.25 seconds 1.25 seconds Go to step 15. Go to step 9. Go to step 12. Go to step 13. Go to step 14. Go to Diagnostic Aids. Go to step 10. Go to step 11.
8 9 10 11 12
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DTC P1811 Maximum Adapt and Long Shift (Contd)

Step Action Inspect the following 2-3 shift circuit components: Turbine Shaft Seals Forward Clutch Plates Forward Clutch Seals Direct Clutch Plates Direct Clutch Seals Did you nd and correct a problem? Inspect the following 1-2 shift circuit components: Low Roller Clutch Intermediate Clutch Plates Intermediate Clutch Seals Intermediate Sprag Clutch Over drive Roller Clutch Did you nd and correct a problem? 1. Change the AT uid and lter. 2. Inspect for the correct transmission uid level. 3. Add new AT uid as necessary. 4. Using the Tech 2, perform the Clear TAPS function. Is the above procedure complete? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Turn the ignition key to the RUN position. 4. Review the scan tool DTC info. 5. Select Specic DTC. Enter DTC P1811. Has the test run and passed? Value Yes No
13
Go to step 15.
14
Go to step 15.
15
Go to step 16.
16
System OK.
Go to step 1.
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5-105
DTC P1860 TORQUE CONVERTER CLUTCH PULSE WIDTH MODULATION SOLENOID ELECTRICAL
TO BATTERY
EXTERIOR FUSE BOX
FUSE 2A 10 AMP
C33-F
351 PK
TRANSMISSION
C34-E
S
924 TN 315 YL
B
237 LG
C34
PCM
C32
02-S12-017
Circuit Description
The Torque Converter Clutch Pulse Width Modulation Solenoid Valve (TCC PWM Sol. Valve) controls fluid acting on the converter clutch valve, which then controls TCC apply and release. The TCC PWM Sol. Valve attaches to the control valve body within the transmission. Ignition voltage goes directly to the TCC PWM Sol. Valve. The PCM controls the TCC PWM Sol. Valve by providing a ground path on circuit 924. The current flows through the TCC PWM Sol. Valve coil according to the duty cycle percentage of ON and OFF time. The TCC PWM Sol. Valve provides a smooth engagement of the torque converter clutch by operating on a duty cycle percent of ON time. DTC P1860 is a type A DTC.

The PCM inhibits TCC engagement. The PCM inhibits 4th gear if in hot mode. The PCM illuminates the MIL.

1. 2. The PCM turns OFF the MIL after three consecutive ignition cycles without a failure reported. A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported. The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.
3.

a. b. System voltage is 10-16.5 volts. The engine is running more than 475 RPM for greater than 7 seconds. c. Commanded gear is D1. d. All of the above conditions are met, and one of the following conditions is met for 4.3 out of 5 seconds. The PCM commands the solenoid OFF, and the voltage remains below (zero volts). The PCM commands the solenoid to ON (100%) and the voltage remains high (B+). 5745159
Diagnostic Aids
An open in the ignition feed circuit 351, causes multiple DTCs. A short to voltage on the TCC PWM solenoid ground circuit can set P0741 and P1870. DTC P1860 defaults to an elevated line pressure condition which may result in partial TCC apply. This may produce an idle surge that could stall the engine.
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DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical
Step 1 Action Was the Powertrain On-Board Diagnostic (OBD) System Check performed? 1. 2. Install the scan tool (Tech 2). With the engine OFF, turn the ignition switch to the RUN position. 3. Record the DTC Freeze Frame and Failure Records. 4. If DTCs P0753, P0758, or P1860 are set, inspect the fuse. Is the fuse blown? Value Go to step 2. 2 Yes No Go to Powertrain OBD System Check.
Go to step 4. Go to intermittents.
Inspect circuit 351, the TCC PWM Sol. Valve and the internal wiring harness for a short to ground. Did you nd and correct a problem? 1. 2. 3. Turn the ignition OFF. Disconnect the transmission 20-way connector. Install the transmission test harness on the engine harness connector. 4. Turn the ignition ON leave the engine OFF. 5. Connect a test lamp from the transmission test harness cavity E to ground. Is the test lamp ON?
Go to step 5.
Repair the open or high resistance located in ignition voltage feed circuit 351 to the TCC PWM Sol. Valve. Is the repair complete? 1. Install the test lamp from cavities E to S of the transmission test harness 2. Use the Tech 2 in order to command the TCC PWM Sol. Valve ON and OFF three times. Does the test lamp turn ON when you command the TCC PWM Sol. Valve ON, and does the lamp turn OFF when you command the TCC PWM Sol. Valve OFF?
Go to step 9.
7 8
Inspect circuit 924 for an open or short to ground. Did you nd and repair the problem? 1. 2. Install the transmission test harness on connector C34. Using a DVOM and the transmission test harness. Measure the resistance between terminals E and S. Is the resistance within the specied values?
10-15 Go to step 11. Go to step 17. Go to step 10.
9 10
Replace the PCM. Is the replacement complete? 1. Disconnect the internal wiring harness at the TCC PWM Sol. Valve. 2. Measure the resistance of the TCC PWM Sol. Valve. Is the resistance within the specied values?
10-15 Go to step 12. OL Go to Diagnostic Aids. Go to step 15.
11
Measure the resistance between terminal E and ground and terminal S and ground. Is the resistance innite?
Go to step 13.
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5-107
DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical (Contd)
Step 12 13 Action Inspect the internal wiring harness for an open circuit. Did you nd a problem? 1. Disconnect the internal wiring harness at the TCC PWM Sol. Valve. 2. Measure the resistance between each of the component terminals and ground. Do both readings measure innite? Value Yes Go to step 16. No
OL Go to step 15. Go to step 16. Go to step 17. Go to step 14.
14 15 16
Inspect the internal wiring harness for a short to ground. Did you nd a problem? Replace the TCC PWM Sol. Valve. Is the replacement Complete? Replace the Automatic Transmission Wiring Harness Assembly (A/T Wiring Harness Assy). Is the replacement complete? In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: The TCC PWM Sol. Valve is commanded ON and the volts drop to zero. The TCC PWM Sol. Valve is commanded OFF and the volts increase to B+. All conditions are met for 5 seconds. 4. Select Specic DTC. Enter DTC P1860. Has the test run and passed?
Go to step 17.
17
System OK.
Go to step 1.
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DTC P1870 Transmission Component Slipping

O/D Fourth Overrun Roller Clutch Clutch Clutch A H H H O FWD Clutch A A A A Direct Clutch A A Front Band Interm. Sprag Interm. Clutch Clutch * H O O A A A Lo Roller Clutch H O O O Rear Band
Range
Gear 1st 2nd
1-2 Sol On Off Off On
2-3 Sol Off Off On On
Overdrive 3rd 4th A = Applied H = Holding * = Holding but not effective O = Overrunning
Circuit Description
The PCM monitors the difference in engine speed and VSS. In D3 drive range with the converter clutch engaged, engine speed should closely match transmission output speed. In D4 drive range with the converter clutch engaged, clutch slip speed should be between -20 and +20 rpm. This DTC detects excessive slip when the converter clutch is engaged. This is a type B code.
Condition 2 in the following sequence

The PCM detects a TCC slip speed of 110-500 RPM for 10 seconds. Maximum line pressure is commanded and the shift adapts are frozen. The PCM detects a TCC slip speed of 110-500 RPM for 10 seconds and commands the TCC off for 1.5 seconds. Then the PCM commands the TCC on. The PCM detects a TCC slip speed of 110-500 RPM.
Conditions For Running DTC

The following conditions are met for 10 seconds with 4th gear commanded. No engine speed DTC P0335. No DTCs P0716 or P0717. No DTC P0722 or P0723. No DTCs P0741, P0742 or P1860. No shift solenoid 1-2 DTCs P0751 or P0753. No shift solenoid 2-3 DTCs P0756 or P0758. No DTC P1810. Gear range is D4. APP angle between 12% and 80%. Engine torque between 60 and 280 ft/lbs. Fluid temperature is between 20C and 130C (68 F and 266 F). Engine speed is between 1200 and 3750 rpm. The vehicle speed is 48-176 km/h (30-110 mph). One of the 2 following conditions will set the code:

PCM will command maximum line pressure. PCM will inhibit converter clutch engagement. PCM inhibits 4th gear if in hot mode. PCM will freeze shift adapts and illuminates the MIL.

The PCM will turn the lamp off after three consecutive ignition cycles without a failure reported. The DTC can be cleared using the Tech 2. The DTC will be cleared when the vehicle has achieved 40 warm-up cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
A pressure switch malfunction could set DTC P1870. Inspect for a mechanical failure of the shift solenoids, or converter clutch solenoid. Inspect for internal transmission failures. Inspect for sticky shift valves or contamination that may cause slipping in D4. Defalt to an elevated line pressure condition could result in partial TCC apply. This may produce an idle surge that could stall the engine.
Condition 1 after 3 occurances

The PCM detects a slip of 120-525 RPM for greater then 6.0 seconds.
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DTC P1870 Transmission Component Slip

Step 1 Action Was the Powertrain On-Board Diagnostic (OBD) System Check performed? Perform the Transmission Fluid Checking Procedure. Refer to Line Pressure Check Procedure. Did you perform the procedure? 1. 2. Install the scan tool (Tech 2). With the engine OFF, turn the ignition switch to the RUN position. 3. Record the DTC Freeze Frame and Failure Records. Clear the DTCs. 4. With the engine idling and at normal operating temperature, apply the brake pedal. 5. Select each transmission range: D1, D2, D3, D4, N, R and P. Does each selected transmission range match the scan tool TFP Switch A/B/C display? (Refer to the Range Signal table.) Value Go to step 2. 2 Go to step 3. Yes No Go to Powertrain OBD System Check. Go to Transmission Fluid Checking Procedure.
Go to step 4.
Go to DTC P1810 Pressure Switch Assembly Malfunction.
Drive the vehicle under the following conditions: The transmission is in D4. The TCC is engaged. The APP angle is 12-70%. At any time is the TCC Slip Speed greater then the specied range for 1 second? Drive the vehicle under the following conditions: The transmission is in D3. Command the TCC ON with the scan tool. The APP angle is 12-70%. At any time is the TCC Slip Speed greater then the specied range for 6 second? Repeat the procedure in step 4. Drive the vehicle under the following conditions: The transmission is in D4. The TCC is engaged. The APP angle is 12-70%. Are the results the same as in step 4? Refer to Diagnosis Table, Slipping TCC. Did you nd and correct the problem? 1. Connect a Pressure Gauge to the transmission line pressure tap. 2. Perform the Line Pressure Check. Is the line pressure within specications?
120 RPM Go to Diagnostic Aids.
Go to step 5.
110 RPM
Go to step 7.
Go to step 6.
120 RPM
Go to step 11. Go to the applicable System Diagnosis Table.
7 8
Go to step 9.
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DTC P1870 Transmission Component Slip (Contd)

Step 9 1. 2. Action Remove the transmission oil pan. Inspect for contaminated uid and excessive material in the pan. Is the uid or the pan contaminated? Inspect the 1-2 SS Valve for contamination or damaged seals. 2. Inspect the 2-3 SS Valve for contamination or damaged seals. Did you nd a problem? Value Yes No
Replace the transmission.
Go to step 10.
10
1.
11
Inspect the following components for contamination or sticking: The 2-3 shift valve. The 3-4 shift valve. Did you nd a problem?
Go to step 12. Replace the transmission.
12
In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the following conditions: Drive the vehicle in 4th gear, with the TCC commanded ON. The APP Angle is 12-70%. The PCM must see a slip of -25 to +30 RPM for greater than 1 second. 4. Select Specic DTC. Enter DTC P1870. Has the test run and passed?
System OK.
Go to step 1.
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5-111
DTC P1875 FOUR-WHEEL DRIVE LOW SWITCH FAULT,
IGNITION VOLTAGE 4WD LOW SIGNAL
C27-D2
C33-K 784 DB B
TRANSFER CASE 4WD LOW SWITCH

02-S02-006
Circuit Description
The 4WD low circuit consists of a 4WD indicator, switch, and wiring. When the operator moves the shift lever to 4 Low, the 4WD indicator lamp will illuminate and circuit 784 will change from B+ to zero. The 4WD low switch signal is used to correct transmission output speed signal to PCM. This signal is used to compensate for transfer case gear reduction. The PCM uses the transmission output speed signal to adjust shift points, line pressure, and converter clutch scheduling. This DTC detects a continuous open or short to ground in the 4WD circuit. This is a type C code.
All of the above conditions have been met and either one of the following fail conditions are true. Four wheel drive low is grounded for 7 seconds. Gear ratio between 0.95 and 1.05:1. Four wheel drive low is open for 3 seconds. Gear ratio between 2.66 and 2.76:1 in any two gears.

Assume Low state when stuck off' and High state when stuck on. Freeze shift adapts from being updated. The PCM records Freeze Frame and Failure Records.

No DTCs P0121, P0122 or P0123. No DTC P0502. No 1-2 shift solenoid DTC P0753. No 2-3 shift solenoid DTC P0758. No DTC P1810. No PWM solenoid DTC P1860. Engine speed is greater than 400 rpm for 8 seconds. Gear range is D4. APP angle is between 10% and 100%. TFT is 18-125C (68-248F).

The DTC can be cleared using the scan tool. The DTC will be cleared when the vehicle has achieved 40 warmup cycles without a failure reported. The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power down the PCM.
Diagnostic Aids
Low pump pressure and a slipping transmission may cause this DTC to set. Transfer Case ratio is calculated by dividing the ISS by the VSS.
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DTC P1875 4WD Low Switch Fault

Step 1 1. 2. 3. Action Connect the Tech 2. Turn ignition on. Record and clear DTC Freeze Frame/Failure Records and DTCs and clear the DTCs. 4. While observing scan tool shift transfer case into 4WD Hi and then 4WD Lo. Does scan tool 4WD Lo Switch read NO when in 4WD Hl and YES when in 4WD Lo? Turn ignition off. Disconnect transfer case switch harness connector. Turn the ignition on. Check terminal B on engine side of wiring harness for voltage. Is B+ voltage available at terminal B? 1. Ground switch ground wire to a known good ground. 2. Observe scan tool 4WD Lo Sw data. Does scan tool 4WD Lo indicate YES when the circuit is grounded and NO when it is not grounded? Check terminal at transfer case switch. Was problem found and corrected? Replace transfer case 4WD Lo Switch. Was the 4WD Lo Switch replaced? Check switch harness for open. Was problem found and corrected? 1. Replace the PCM. Was the PCM replaced? 1. After the repair is complete select scan tool Clear Info function and operate the vehicle under the following conditions: Start the engine and drive the vehicle. 4th gear and TCC engagement must occur both in high and low ranges. The PCM must see a valid gear range in both transfer case ranges. Review the scan tool DTC Info. 1. 2. 3. 4. Value Yes No
Problem may be intermittent. Refer to Diagnostic Aids.
Go to step 2.
Go to step 3. Go to step 4. Go to step 8. Go to step 8. Go to step 8. Go to step 8. Go to step 8. Go to step 5. Go to step 7. Go to step 6.
4 5 6 7 8
Repair veried, exit DTC table.
2.
System OK.
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Electrical/Garage Shift Test

Perform this test before a road test in order to make sure that electronic control inputs are connected and operating. If you do not check the inputs before operating the transmission, you could misdiagnose a simple electrical condition as a major transmission condition. A scan tool provides valuable information. Use the scan tool on the transmission for accurate diagnosis. 1. Move the gear selector to Park and set the parking brake. 2. Connect the scan tool to the DLC connector. 3. Start the Engine 4. Verify that the following signals are present on the scan tool: Transmission Input (shaft) Speed Sensor (A/T ISS) Transmission Output(shaft) Speed Sensor (VSS) Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP val.) Vehicle speed Current Gear Reference Transmission Pressure Control Solenoid Amperage (Ref Current) Actual Transmission Pressure Control Solenoid Amperage (ACT CURRENT) Engine Coolant Temperature (ECT) Automatic Transmission Fluid Temperature Signal (TFT) APP angle TCC duty cycle (TCC DC) System Voltage TCC Brake Switch 5. Monitor the TCC BRAKE signal with the scan tool while tapping the brake pedal with your foot. The brake switch signal should be: Open - when the brake pedal is released Closed - when the brake pedal is depressed 6. Monitor the Automatic Transmission Fluid Pressure Manual Valve Position Switch signal by moving the gear selector through all of the ranges. Verify that the FRP Switch state matches the gear range which is indicated on the instrument panel or on the console. Gear selections should be immediate and not harsh. 7. Move the gear selector to Neutral and monitor the APP angle while increasing and decreasing engine RPM with the accelerator pedal. The Throttle angle should increase with the engine RPM.
assembly. The solenoid valve energizes or de-energizes by making or breaking an electrical circuit through a combination of switches and sensors.
Torque Converter Stator

The torque converter stator roller clutch can have two different malfunctions. The stator assembly freewheels in both directions The stator assembly remains locked up at all times
Poor Acceleration at Low Speed

If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds above 50 -55 km/ h (30-35 mph), the car may act normally. For poor acceleration you should first determine that the exhaust system is not blocked, and the transmission is in First gear when starting out. If the engine freely accelerates to high RPM in Neutral, you can assume that the engine and the exhaust system are normal. Check for poor performance in Drive and Reverse to help determine if the stator is freewheeling at all times.
Poor Acceleration at High Speed

If the stator is locked up at all times, performance is normal when accelerating from a standstill. Engine RPM and car speed are limited or restricted at high speeds. Visual examination of the converter may reveal a blue color from overheating. If the converter has been removed, you can check the stator roller clutch by inserting a finger into the splined inner race of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the inner race clockwise, but you should have difficulty in moving the inner race counterclockwise or you may be unable to move the race at all.
Noise
Important: Do not confuse this noise with pump whine noise, which is usually noticeable in Park, Neutral, and all other gear ranges. Pump whine with vary with line pressure. You may notice a torque converter whine when the vehicle is stopped and the transmission is in Drive or Reverse. This noise will increase as you increase the engine RPM. The noise will stop when the vehicle is moving or when you apply the torque converter clutch, because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually coming from the converter: 1. Place your foot on the brake 2. Put the gear selector in Drive. NOTE: You may damage the transmission if you depress the accelerator for more than six seconds. 3. Depress the accelerator to approximately 1200 RPM for no more than six seconds. A torque converter noise will increase under this load. 1-1-02
Torque Converter Clutch Diagnosis

The Torque Converter Clutch (TCC) is applied by fluid pressure, which is controlled by a PWM solenoid valve. This solenoid valve is located inside of the automatic transmission 5745159
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Torque Converter Evaluation and Diagnosis

Replace the torque converter under any of the following conditions: External leaks appear in the hub weld area. The converter hub is scored or damaged. The converter pilot is broken, damaged, or fits poorly into the crankshaft. You discover steel particles after flushing the cooler and cooler lines. The pump is damaged, or you discover steel particles in the converter. The vehicle has TCC shudder and/or no TCC apply. Replace the torque converter only after all hydraulic and electrical diagnoses have been made. The converter clutch material may be glazed The converter has an imbalance which cannot be corrected. Refer to Flywheel/Torque Converter Vibration Test. The converter is contaminated with engine coolant which contains antifreeze. An internal failure occurs in the stator roller clutch. You notice excessive end play. Overheating produces heavy debris in the clutch. You discover steel particles or clutch lining material in the fluid filter or on the magnet, when not internal parts in the unit are worn or damaged. This condition indicates that lining material came from the converter.
If the shudder occurs while the TCC is applying, the problem can be within the transmission or the torque converter. Something is causing one of the following conditions to occur: Something is not allowing the clutch to become fully engaged. Something is not allowing the clutch to release. The clutch is releasing and applying at the same time. One of the following conditions may be causing the problem to occur: Leaking turbine shaft seals A restricted release orifice A distorted clutch or housing surface due to long converter bolts Defective friction material on the TCC plate
If Shudder Occurs After TCC has Applied

If shudder occurs after the TCC has applied, most of the time there is nothing wrong with the transmission! As mentioned above, the TCC is not likely to slip after the TCC has been applied. Engine problems may go unnoticed under light throttle and load, but they may become noticeable after the TCC apply when going up a hill or accelerating. This is due to the mechanical coupling between the engine and the transmission. Once TCC is applied, there is no torque converter assistance. Engine or driveline vibrations could be unnoticeable before TCC engagement.
Do Not Replace the Torque Converter

Do not replace the torque converter if you discover any of the following symptoms: The oil has an oder or the fluid is discolored, even though metal or clutch facing particles are not present. The threads in one or more of the converter bolt holes are damaged. Correct the condition with a new J-nut. Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in the unit and inside the fluid filter.
Flywheel/Torque Converter Vibration Test

1. 2. 3. Start the engine. With the engine at idle speed and the transmission in Park or Neutral, observe the vibration. Turn the key off.
Torque Converter Clutch Shudder

The key to diagnosing Torque Converter Clutch shudder is to note when it happens and under what conditions. TCC shudder which is caused by the transmission should only occur during the apply or the release of the converter clutch. Shudder should never occur after the TCC plate is fully applied.
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TFP Valve Position Switch Resistance Check

Step 1 1. Action Install the J 39775 Jumper harness on the transmission side of the 20 way transmission pass-through connector. 2. Using a DVOM and the J35616 Connector Test Adapter Kit, measure the resistance from terminal N to the transmission case. Is the resistance greater than the value indicated? 1. Disconnect the Automatic Transmission Wiring Harness Assembly form the TFP Val. Position Sw. 2. Measure the resistance from terminal A of the TFP Val. Position Sw. to the switch housing. Is the resistance greater than the value indicated? Measure the resistance from terminal R to the transmission case. Is the resistance greater than the indicated value? 1. Disconnect the Automatic Transmission Wiring Harness Assembly from the TFP Val. Position Sw. 2. Measure the resistance from terminal B of the TFP Val. Position Sw. to the switch housing. Is the resistance greater than the value indicated? Measure the resistance from terminal P to the transmission case. Is the resistance greater than the value indicated? 1. Disconnect the Automatic Transmission Wiring Harness Assembly from the TFP Val. Position Sw. 2. Measure the resistance from terminal C of the TFP Val. Position Sw. to the switch housing. Is the resistance greater than the value indicated? 1. 2. 3. 4. Start the engine, and let the engine idle. Set the parking brake. Place the gear selector in Drive (D4). Measure the resistance from terminal R to the transmission case. Is the resistance less than the indicated value? 1. 2. Place the gear selector in Drive (D4). Measure the resistance from terminal P to the transmission case. Is the resistance less than the value indicated? Value(s) 50 k Yes Go to step 3 No Go to step 2
50 k
go to step 15
go to step 16
50 k
go to step 5
Go to step 4
50 k
Go to step 15
Go to step 16
50 k
Go to step 7
Go to step 6
50 k
Go to step 15
Go to step 16
200
Go to step 8
Go to step 14
200
Go to step 9
Go to step 14
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TFP Valve Position Switch Resistance Check (Contd)

Step 9 1. 2. Action Place the gear selector in Low (D1). Measure the resistance from terminal N to the transmission case. Is the resistance less than the value indicated? 1. 2. Place the gear selector in Low (D1). Measure the resistance from terminal P to the transmission case. Is the resistance less than the value indicated? 1. 2. Place the gear selector in Reverse (R). Measure the resistance from terminal N to the transmission case. Is resistance less than the value indicated? 1. 2. Place the transmission in Reverse (R). Measure the resistance from terminal P to the transmission case. Is the resistance greater than the value indicated? 1. 2. Place the gear selector in Manual Third (D3). Measure resistance from terminal R to the transmission case. Is the resistance greater than the value indicated? 1. Disconnect the Automatic Transmission Wiring Harness from the TFP Val. Position Sw. 2. Inspect the three circuits going to the TFP Val. Position Sw. for an open circuit. Did you nd a problem? Replace the Automatic Transmission Wiring Harness Assembly. Is the replacement complete? 1. 2. Replace the TFP Val. Position Sw. Inspect the Automatic Transmission Wiring Harness Assembly. Is the replacement of the TFP Val. Position Sw. complete? Value(s) 200 Yes Go to step 10 No Go to step 14
10
200
Go to step 11
Go to step 16
11
200
Go to step 12
Go to step 16
12
50 k
Go to step 13
Go to step 16
13
50 k
No problem found. Exit table. Go to step 15
Go to step 16
14
Go to step 16
15
verify repair, go to step 1 verify repair, go to step 1
16
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Automatic Transmission Wiring Harness Check

Step 1 1. Action Install the J 39775 jumper on the transmission 20 way connector. 2. Using a DVOM and a J 35616 Test Adapter Kit, measure the resistance between terminals A and E (1-2 Shift Solenoid) Is the resistance within the values indicated? 1. Disconnect the 1-2 Shift Solenoid Valve from the Automatic Transmission Wiring Harness Assembly 2. Using the DVOM, measure the resistance of the 1-2 SS Valve. Is the resistance within the values indicated? Measure the resistance between terminals B and E (2-3 Shift Solenoid Valve) Is the resistance within the values indicated? Value(s) 19-24 @ 20 C (68F) 24-31 @ 100C (212F) Yes Go to step 3 No Go to step 2
19-24 @ 20 C (68F) 24-31 @ 100C (212F)
go to step 12
Go to step 14
19-24 @ 20 C (68F) 24-31 @ 100C (212F) 19-24 @ 20 C (68F) 24-31 @ 100C (212F)
Go to step 5
Go to step 4
1.
Disconnect the 2-3 SS Valve from the Automatic Transmission Wiring Harness Assembly. 2. Using the DVOM, measure resistance of the 2-3 SS Valve. Is the resistance within the values indicated? Measure the resistance between terminals S and E (Torque Converter Clutch Pulse Width Modulation Solenoid Valve). Is the resistance within the values indicated? 1. Disconnect the Torque Converter Clutch Pulse Width Modulation Solenoid Valve from the Automatic Transmission Wiring Harness Assembly. 2. Using the DVOM, measure the resistance of the TCC PWM Sol. Valve. Is the resistance within the values indicated?
Go to step 12
Go to step 14
10-11 @ 20 C (68F) 13-15 @ 100C (212F) 10-11 @ 20 C (68F) 13-15 @ 100C (212F)
Go to step 7
Go to step 6
Go to step 12
Go to step 14
Measure the resistance between terminals C and D (Pressure Control Solenoid Valve). Is the resistance within the values indicated?
3-5 @ 20 C (68F) 4-7 @ 100C (212F) 3-5 @ 20 C (68F) 4-7 @ 100C (212F)
Go to step 9
Go to step 8
1.
Disconnect the Pressure Control Solenoid Valve from the A/T Wiring Harness Assy. 2. Using the DVOM, measure the resistance of the PC Sol. Valve. Is the resistance within the values indicated?
Go to step 12
Go to step 14
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Automatic Transmission Wiring Harness Check (Contd)

Step 9 Action Measure the resistance between terminals L and M (Transmission Fluid Temperature Sensor) Is the resistance within the values indicated? Value(s) 3333-3689 @ 20 C (68F) 24-31 @ 100C (212F) 250 k Yes Go to step 10 No Go to step 12
10
Measure the resistance from terminals A,B,C,D,E,L,M,N,P,R and S of the A/T Wiring Harness Assy. at the transmission 20 way connector to the transmission case. Is the resistance measured greater than the value indicated? 1. Disconnect the A/T Wiring Harness Assy. from all the components. 2. Measure the resistance from all the components terminals to the transmission case. Is the resistance measured greater than the value indicated? Inspect for high resistance or a shorted condition: Inspect the A/T Wiring Harness Assy. for poor electrical connections at the transmission 20-way connector and at the component connectors. Look for possible bent, backed out, deformed, or damaged terminals. Inspect for weak terminal tension Inspect for chafed wire that could short to bare metal or other wiring. If diagnosing for a possible intermittent condition, move or massage the A/T Wiring Harness Assy. while observing test equipment for a change. Was high resistance or a shorted condition found?
No problem found. Exit table
Go to step 11
11
250 k
Go to Step 12
Go to Step 14
12
Verify the repair and go to Step 1
Go to step 13
13 14
Replace the A/T Wiring Harness Assy. Is the replacement complete? Replace the faulty component. Is the replacement complete?
Verify the repair and go to step 1 Verify the repair and go to step 1
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Transmission Cooler Flushing Procedure

Equipment Needed
J35944-A cooler flushing tool with included adapters and J35944-22 or J35944-CSE* flushing solution. Measuring Cup Funnel Water Supply (hot water recommended) Water Hose (at least 5/8 I.D.) Shop Air Supply (with water/oil filters, regulator and pressure gauge) Air Chuck (with clip if available) Oil Drain Container Five Gallon Pail With Lid Eye Protection Rubber Gloves * Do not substitute with solutions that contain alcohol or glycol. Use of solutions that contain alcohol or glycol may damage J35944-A, oil cooler or transmission components. 4.
5.
the trigger down. The discharge will foam vigorously when the solution is introduced into the water stream. Flush the oil cooler and pipes with water and solution for two minutes. During this flush, attach the air supply to the air valve located on J35944-A for 3-5 seconds at the end of every 15-20 second interval to create a surging action. Release the trigger and turn the water valve on J35944-A to the OFF position.
Back Flush
1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back ushed. Repeat steps 3 and 4 of the INITIAL FLUSH procedure. Release the trigger of J35944-A and allow water only to rinse the oil cooler and pipes for one minute. Turn the water valve on J35944-A to the OFF position and turn OFF the water supply at the faucet. Attach the air supply to the air valve on J35944-A and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose.
2. 3. 4. 5.
Preparation
1. 2. 3. 4. 5. 6. After the repaired or replacement transmission is installed in the vehicle, do not reconnect the oil cooler pipes. Remove the fill cap on J35944-A and fill with 20-21 oz. (0.6L) of flushing solution. Do not overfill. Install the fill cap on J35944-A and pressurize the flusher can using the shop air supply 80-100 psi (550-700 kPa). Connect the J35944-A discharge hose to the oil cooler return pipe. Clip the discharge hose onto the oil drain container. Attach J35944-A to the undercarriage of the vehicle with the hook provided and connect the hose from J35944-A to the other (feed) oil cooler pipe. With the water valve on J35944-A in the OFF position, connect the water hose from the water supply to J35944A. Turn ON the water supply at the water faucet.
Flow Check
1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe to the transmission and the return pipe to the discharge hose. Clip the discharge hose onto the oil drain container. Confirm the transmission is filled with automatic transmission fluid. Start the engine with the transmission in PARK range and run until automatic transmission fluid begins to flow into the oil drain container. Turn off engine, empty oil drain container and fill transmission with automatic transmission fluid. Start the engine with the transmission in PARK range and run for 30 seconds. A minimum of two quarts (1.9 L) must be discharged during this 30 second run time. If uid ow is equal to or greater than 2 qt. in 30 seconds, go to step 4. If uid ow is less than 2 qt. in 30 seconds, perform the following diagnosis: Disconnect the oil cooler feed line at the radiator. Connect the discharge hose to the oil cooler feed line. Clip the discharge hose onto the empty oil drain container. Start the engine with the transmission in PARK range and run for 30 seconds. A minimum of two quarts (1.9 L) must be discharged during this 30 second run time. Do the following according to the flow rate: Insufcient feed ow: Inspect the transmission for leaks or blockage. Sufcient feed ow: Inspect the oil cooler return pipe and the oil cooler for blockages or leaks.
2. 3.
7.
8.
Initial Flush
1. Turn the water valve on J35944-A to the ON position and allow the water to ow through the oil cooler and pipes for 10 seconds to remove any remaining transmission uid. If water does not ow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler ushing and ow check procedure once the blockage is corrected. Turn the water valve on J35944-A to the OFF position and clip the discharge hose onto the five gallon pail with a lid. Turn the water valve on J35944-A to the ON position and depress the trigger to mix cooler flushing solution into the water flow. Use the clip provided on the handle to hold
2.
3.
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Remove the discharge hose, reconnect the cooler feed and return pipes to the transmission and refill the unit to the proper level. Inspect the transmission oil cooler pipe connections at the radiator and transmission for leaks.
Cleanup
1. Disconnect the water supply hose from J35944-A and bleed any remaining air pressure from the can. Remove the ll cap from J35944-A and return any unused ushing solution to its container. Rinse J-35944-A with water. Do not store J35944-A with ushing solution in it. After every third use, clean J35944-A as described in the instructions included with the tool. Dispose of any waste water/solution/transmission fluid in accordance with local regulations.
10. Insert filter pipe in case with twisting motion. Align filter with valve body and work into place (Figure 5-30). 11. Position magnet in oil pan. 12. Install gasket on oil pan and install pan on transmission. Tighten pan bolts to 18 lb-ft (24 Nm) torque. 13. Install rear crossmember and transmission mount. 14. Remove support jack. 15. Refill transmission with Dexron III fluid.
OIL PAN MAGNET TRANSMISSION PAN GASKET
2. 3.
Transmission Fluid And Filter Replacement

1. 2. 3. Support transmission/transfer case assembly with jack positioned under transfer case. Remove bolts attaching rear mount to transmission (Figure 5-28). Remove bolts attaching crossmember to frame brackets and remove crossmember.
SHIFT ROD BRACKET
OIL PAN
ADAPTER
Figure 5-29: Oil Pan Removal/Installation
FRAME BRACKET REAR MOUNT
VALVE BODY INLET PORT SEAL
Figure 5-28: Transmission-to-Crossmember Mounting 4. 5. 6. 7. 8. 9. Loosen transmission oil pan bolts and allow fluid to drain. Move shift rod bracket aside and remove pan gasket, and oil pan (Figure 5-29). Pan gasket is reusable. Remove oil filter from valve body (Figure 5-30). Inspect filter seal (Figure 5-30). Undamaged seal is reusable. Remove magnet from oil pan. Then clean pan and magnet. Install seal in valve body.
FILTER PIPE OIL FILTER
Figure 5-30: Oil Filter Removal/Installation
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COOLER LINE AND BYPASS VALVE SERVICE

The transmission and transfer case oil cooler lines are replaceable parts. The lines consist of metal tubing interconnected by sections of rubber hose (Figure 5-31). Each of the tube or hose sections can be replaced separately. It is not necessary to replace complete assemblies. On 1999 Hummers, the cooler lines are fastened to the transmission with quick connect fittings. The flared end of the line fits tightly into the adapter and is secured to the adapter with a clip. The clip is then secured with a nylon retainer.
NYLON RETAINER CLIP
FILL TUBE REPLACEMENT

1. 2. 3. 4. 5. Remove dipstick from ll tube (Figure 5-33). Remove console and engine cover. Remove bolts attaching fill tube bracket to heat shield and intake manifold (Figure 5-33). Work fill tube out of transmission. Remove fill tube seal from transmission. Discard if damaged.
DIPSTICK ADAPTER
COOLER LINES (TO TRANSFER CASE) TRANSMISSION QUICK CONNECT FITTING
FILL TUBE BYPASS VALVE
TEE FITTINGS
FILL TUBE SEAL
Figure 5-31: Bypass Valve Connections A bypass valve is used in all Hummer vehicles (Figure 5-32). The valve limits pressure buildup in the oil cooler and lines.The bypass valve is attached to the passenger side crossmember-to-frame bracket bolt. The cooler lines are attached to body/chassis components with clamps (Figure 5-31).
METAL TUBE TO TRANSMISSION TO TRANSFER CASE TO COOLER TEE BYPASS VALVE METAL TUBE CHASSIS CLAMP
Figure 5-33: Fill Tube Attachment Install fill tube seal in transmission. Push fill tube into transmission. Secure fill tube to the heat shield and intake manifold. Tighten intake manifoldbolt to 31 lb-ft (42 Nm). 9. Install dipstick in fill tube. 10. Install engine cover and console. 11. Start engine and top off transmission fluid level if required. 6. 7. 8.
Figure 5-32: Transmission/Transfer Case Oil Cooler Line Connection 5745159 1-1-02
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VENT LINE SERVICE

The transmission, transfer case, front and rear hubs, and winch are all connected to a common vent line system (Figure 5-34). The main vent lines are plastic while lines from the hubs to the tee connections consist of rubber hoses. Brass tee fittings are used at each vent line junction. The transmission and transfer case vent lines and fittings are all serviceable parts.
Vent lines or fittings can be replaced individually. It is not necessary to replace all of the lines if only one section is damaged. In cases where plastic vent line is supplied in bulk quantity, the required length can be cut to size with a fine tooth hacksaw blade. Diagonal pliers or similar cutting implements are not recommended. If a plastic line proves difficult to install, a small amount of liquid soap can be used as a lubricant. Do not use any other product to ease line assembly and installation.
TRANSMISSION VENT LINES TEE FITTING
ENGINE MOUNTING BRACKET
TEE FITTING ENGINE MOUNTING BRACKET
VENT LINE FRAME RAIL LINE TO FRONT HUBS AND WINCH
LINE FROM TRANSFER CASE
TEE FITTING LINE FROM REAR HUBS
Figure 5-34: Transmission Vent Line
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CONVERTER HOUSING UPPER COVER REPLACEMENT

1. 2. 3. Remove converter housing upper cover from transmission ange (Figure 5-35). Remove gasket from cover. Clean gasket or sealer remains from transmission flange.
TRANSMISSION FLANGE
CONVERTER HOUSING LOWER COVER REPLACEMENT

1. 2. 3. 4. 5. Remove crossover pipe. Remove converter housing upper cover. Remove lower bolts and remove cover from transmission (Figure 5-36). Remove gasket from housing cover. Clean sealer or gasket remains from transmission flange.
GASKET TRANSMISSION FLANGE
GASKET
TRANSMISSION CONVERTER HOUSING LOWER COVER
CONVERTER HOUSING UPPER COVER
Figure 5-35: Converter Housing Upper Cover Mounting 4. 5. Apply sealer to gasket and install gasket on cover. Install cover on transmission flange. 6. 7. 8. 9. 10.
Figure 5-36: Converter Housing Lower Cover Mounting Apply sealer to gasket and install on cover. Apply sealer to housing cover. Install housing cover on transmission flange. Install converter housing upper cover. Install crossover pipe.
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VALVE BODY SWITCH AND SOLENOID SERVICE

The following electrical components can be replaced once the oil pan and/or valve body are removed from the transmission (Figure 5-37): 1-2 and 2-3 shift solenoids pressure switch pressure control solenoid converter clutch solenoid wiring harness The park lock actuator components are also accessible after valve body removal. Refer to Park Lock Component Service.
CAUTION: The valve body check-balls are not secured and are loose. Keep the valve body level and the spacer plate in position during removal. This will avoid losing or mispositioning the check-balls. The check-balls are not available separately, they are available only as part of a complete valve body assembly.
PRESSURE CONTROL SOLENOID SCREEN WIRING HARNESS VALVE BODY
PRESSURE CONTROL SOLENOID VALVE BODY
HARNESS CASE CONNECTOR PRESSURE SWITCH 1-2 SHIFT SOLENOID
DIPSTICK STOP CABLE CLAMP PRESSURE SWITCH
VALVE BODY BOLT (TYPICAL) SPECIAL BOLT (6) DETENT SPRING LUBE PIPE CLAMP LUBE PIPE RETAINER
2-3 SHIFT SOLENOID
CONVERTER CLUTCH SOLENOID
WIRING HARNESS
LUBE PIPE
Figure 5-37: Valve Body Switch and Solenoid Locations
Figure 5-38: Valve Body Removal/Installation 7. 8. Remove necessary solenoid from valve body. Refer to Figure 5-37 or Figure 5-39 for solenoid locations. Remove wiring harness, if it is to be replaced.
Valve Body Removal

1. 2. 3. 4. Remove oil pan and lter. Refer to Fluid and Filter Replacement procedure in this section. Remove bolts attaching lube pipe clamp and retainer. Then carefully remove lube pipe (Figure 5-38). Disconnect wiring harness from switch and solenoids. Remove special bolts attaching pressure switch to valve body and remove switch. Keep special bolts separate and note position for installation reference (Figure 5-38). Remove bolts attaching dipstick stop and park detent spring to valve body and remove stop and spring. Remove remaining valve body bolts and carefully remove valve body, spacer plate, and gasket.
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2-3 SHIFT SOLENOID B
CAUTION: The valve body bolts must be tightened to specified torque and in the indicated pattern. Overtightening or random tightening will distort the valve body resulting in valve bind, cross leakage, and shift problems. 8. Connect wire harness to solenoids and switch. 9. Install oil filter and oil pan. 10. Refill transmission with Dexron III.
1-2 SHIFT SOLENOID A CONVERTER CLUTCH SOLENOID
PARK LOCK COMPONENT SERVICE

The park lock components can be serviced without removing the transmission. Access to the park lock components requires removal of the oil pan and valve body. Part replacement procedure is as follows.
CLIP PRESSURE CONTROL SOLENOID
CLAMP
Park Lock Component Replacement

1. 2. 3. 4. 5. 6. 7. Remove oil pan and valve body as described in this section. Remove nut that retains detent on shaft (Figure 5-41). Then remove shaft pin. Remove park pawl bracket bolt and bracket. Remove detent and actuator rod (Figure 5-41). Remove park pawl stud, retainer, spring, shaft, and plug (Figure 5-41). Clean parts to be reused with solvent, dry with compressed air, and lubricate with Dexron III. Install pawl shaft in case. Then install pawl on shaft. Install new shaft cup plug in case with 5/16 in. (7.9 mm) diameter rod. Install pawl retainer and return spring (Figure 5-41). Assemble detent and actuator rod. Then install rod over pawl. Install detent shaft and seal. Be sure shaft is properly seated in detent. Install detent nut on shaft. Tighten nut to 18 lb-ft (24 Nm) torque. Install shaft pin. Install actuator rod bracket and bolts. Tighten bolts to 18 lb-ft (24 Nm) torque. Install return spring stud. Install valve body, oil filter and oil pan. Refill transmission with Dexron III. Correct fluid level is at top, or within cross hatch area on dipstick, with fluid hot, engine idling and transmission in park.
Figure 5-39: Solenoid Identification
Valve Body Installation

1. 2. Install replacement solenoid or wiring harness as required. Verify that valve body spacer plate and gasket are in position. Also be sure check-balls were not displaced. There should be eight check-balls. Install valve body guide pins J25025-B in transmission case. Carefully position valve body on guide pins and transmission case. Install 2-3 bolts to hold valve body in place and remove guide pins. Install pressure switch, dipstick stop, harness clamp and detent spring but do not fully tighten bolts at this time. Install lube pipe, retainer, and pipe clamp (Figure 5-38). Tighten valve body bolts to 97 lb-in. (11 Nm) torque. Start at center and work outward in a spiral pattern (Figure 5-40).
3. 4.
5. 6. 7.
8. 9. 10. 11. 12. 13. 14. 15. 16.
Figure 5-40: Valve Body Bolt Tightening Sequence (in Numerical Order) 5745159 1-1-02
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RETAINER
CUP PLUG
SEAL DETENT SHAFT ACTUATOR ROD SHAFT PIN DETENT
STUD RETURN SPRING PARK PAWL
PAWL SHAFT
BRACKET
BOLT (2) DETENT NUT
Figure 5-41: Park Lock Components
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TORQUE CONVERTER/FLEXPLATE/ CONVERTER SEAL REPLACEMENT

1. 2. 3. Remove transmission as described in this section. Remove torque converter from transmission (Figure 5-42). Remove oil seal from pump. Use standard hook tool to pull seal.
TORQUE CONVERTER HUB
TRANSMISSION REMOVAL
1. 2. Remove console and engine cover. Remove bolts attaching transmission fill tube to heat shield and intake manifold (Figure 5-44). Then remove fill tube from transmission case. Cover fill tube bore in case to prevent dirt entry. Disconnect transfer case shift rod at operating lever (Figure 5-45). Disconnect transmission shift rod trunnion from shift control arm (Figure 5-46). Disconnect speed sensor and lock indicator switch wires at rear of transfer case (Figure 5-47). Then disconnect range switch at front of transfer case (Figure 5-48). Remove clamps securing wire harness to transfer case and transmission. Disconnect vent lines at transmission and transfer case. Disconnect transmission harness at case connector by squeezing both lock tabs of harness connector, and pulling it straight out of case connector.
3. 4. 5.
6. 7. 8.
SLOTS
Figure 5-42: Torque Converter Removal/Installation 4. 5. If flexplate is to be replaced, remove attaching bolts and remove driveplate. Position new flexplate on crankshaft flange. Apply 1-2 drops of Loctite 242 to flexplate bolt threads. Then install and tighten bolts to 65 lb-ft (88 Nm) torque.
OIL PUMP
CAUTION: Do not pull, twist, pry, or rotate the harness connector in an attempt to remove it. This action can damage the connector body, pin terminals and solder joints. Release only by squeezing the lock tabs (Figure 5-49). 9. Disconnect harness wires at transmission input speed sensor (Figure 5-50).
BRACKET
SEAL INSTALLER J38694
FILL TUBE BRACKET
CONVERTER SEAL
Figure 5-43: Oil Pump Seal Installation 6. 7. 8. Install converter seal with tool J38694 (Figure 5-43). Install torque converter. Be sure drive lugs on pump gear are engaged in drive slots of converter hub (Figure 5-42). Install transmission as described in this section.
FILL TUBE SEAL
NOTE: Converter will be recessed in housing when installed completely and will turn freely when transmission is installed on engine.
Figure 5-44: Fill Tube Attachment
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WAVY WASHER OPERATING LEVER
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TRANSFER CASE SHIFT ROD
BRACKET
VEHICLE SPEED SENSOR LOCK INDICATOR SWITCH FLAT WASHERS
Figure 5-45: Shift Rod Attachment

SHIFT ROD TRUNNION
Figure 5-47: Vehicle Speed Sensor and Switch Harness Connections

RANGE INDICATOR SWITCH
Figure 5-48: Range Indicator Connection Figure 5-46: Transmission Shift Rod and Trunnion
HARNESS CONNECTOR
LOCK TAB (SQUEEZE)
LOCK TAB (SQUEEZE) CASE CONNECTOR
Figure 5-49: Releasing Transmission Case Harness Connectors 1-1-02
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TRANSMISSION WIRING HARNESS HARNESS CLIPS INPUT SPEED SENSOR FRAME BRACKET
TRANSMISSION ADAPTER
TRANSMISSION MOUNT
Figure 5-50: Speed Sensor Connections 10. Remove transmission harness from retaining clips. 11. Disconnect front propeller shaft and remove rear propeller shaft. 12. Remove exhaust crossover pipe and disconnect exhaust mounting at the transfer case. 13. Remove converter housing covers. 14. Support engine with jack stand and wood block positioned under oil pan. 15. Support transmission with transmission jack. 16. Remove transfer case guide cable. 17. Disconnect cooler lines at transfer case and transmission. 18. Remove nuts attaching transfer case to transmission adapter and remove transfer case with aid of helper. 19. Remove bolts attaching transmission mount to transmission adapter (Figure 5-51). Then remove bolts attaching crossmember to frame brackets and remove crossmember. 20. Secure safety chain around transmission and jack (Figure 5-52). 21. Remove bolts attaching torque converter to driveplate flywheel (Figure 5-53). 22. Remove bolts and studs attaching transmission to engine (Figure 5-52). 23. Move transmission rearward until clear of engine. Then use C-clamp or strap attached to housing to hold converter in place. 24. Move transmission from under vehicle.
CROSSMEMBER
Figure 5-51: Transmission Rear Mounting
STUDS
SAFETY CHAIN
WOOD BLOCK
JACK STAND
TRANSMISSION JACK
Figure 5-52: Transmission Removal/Installation
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TORQUE CONVERTER DRIVEPLATE (FLYWHEEL) CONVERTER BOLT (6)
Figure 5-53: Torque Converter-To-Flexplate Bolt Locations
TRANSMISSION INSTALLATION
CAUTION: If the transmission was replaced, or repaired to correct a problem that generated metal and clutch disc particles, the transmission cooler and lines must be thoroughly flushed and the torque converter replaced. This is necessary to avoid recontaminating and damaging the transmission. 1. 2. 3. Mount transmission on transmission jack and secure transmission with safety chain (Figure 5-52). Tilt transmission converter housing upward slightly to help retain converter during installation. Smooth converter hub with 320-380 grit emery to remove burrs or sharp edges. Clean hub thoroughly afterward. Hub must be smooth to avoid damaging converter seal during installation. Lubricate converter hub and converter seal with transmission fluid. Then install converter. Be sure converter is fully seated in pump before proceeding. Move transmission into position and align transmission converter housing with engine block dowels. Slide transmission forward and into place. Be sure converter pilot is seated in crankshaft and that transmission is aligned on dowels. Install one or two studs or bolts to hold transmission in place. Install and tighten transmission attaching stud and bolts to 35 lb-ft (47 Nm) torque. Apply one or two drops of Loctite 242 to threads of attaching bolts. Then install and tighten bolts to 32 lb-ft (43 Nm) torque. Install converter housing covers. Install transfer case. Tighten attaching nuts to 30 lb-ft (41 Nm) torque.
10. Install rear crossmember and secure transmission mount to adapter. Tighten adapter-to-mount bolts to 65 lb-ft (88 Nm) torque. Tighten crossmember-to-frame bracket bolts to 90 lb-ft (122 Nm) torque. 11. Connect oil cooler lines to transmission and transfer case. Be sure lines are properly secured in clamps and brackets. 12. Connect vent lines to transmission and transfer case. 13. Connect transmission harness to transmission case connector. Be sure harness connector is fully seated and snaps into place. 14. Connect wires to transmission input sensor. 15. Connect wires to transfer case range and lock switches, and to speed sensor. 16. Attach transmission shift rod to arm of control assembly. Then connect transfer case shift rod to range lever on transfer case. 17. Install transfer case guide cable. 18. Check and top off transfer case fluid if necessary. 19. Install starter motor. 20. Install exhaust pipes, muffler, and catalytic converter. 21. Install front and rear propeller shafts. 22. Install transmission fill tube and dipstick. Replace fill tube seal if worn, cut, or distorted. 23. Install engine cover and console. 24. Add four quarts (3.7 liters) of Dexron III to transmission. 25. Drive vehicle long enough to bring transmission fluid to normal operating temperature. 26. Check transmission fluid level. Add fluid in small increments to avoid over filling. Correct hot level is in, or to top of crosshatch area on dipstick with engine idling and transmission in Park.
4.
5.
6. 7.
8. 9.
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SHIFT CONTROL ASSEMBLY REMOVAL

NOTE: Wavy washers eliminate any potential transfer case shift linkage rattle (Figure 5-54). If a rattle is present on a vehicle not equipped with a wavy washer, install one as shown. Refer to parts manual for wavy washer part number. NOTE: Open shifter boot cover (unfasten snaps and pull apart velcro strips) for access to shifter linkage. 1. 2. Remove driver side inner kick panel. Disconnect shift rod trunnions at housing shift arms (Figure 5-54).
8.
Disconnect body harness wires from park/neutral position switch wires.
SHIFT CONTROL ASSEMBLY
SHIFT CONTROL HOUSING PARK/NEUTRAL POSITION SWITCH WIRES SHIFT INDICATOR WIRES BACKUP LIGHT SWITCH WIRES
SHIFTER BOOT COVER (SHOWN OPEN)
SHIFT ARM SHIFT ARM
WAVY WASHERS BOOT PROTECTOR
Figure 5-55: Harness Wire Identification

TRUNNION TRUNNION FLAT WASHERS TRANSFER CASE SHIFT ROD
9. 10. 11. 12.
Disconnect body harness lead from shift indicator wire. Disconnect interlock cable at shifter (Figure 5-56). Remove boot from shift control housing. Remove shift control assembly.
TRANSMISSION SHIFT ROD
Figure 5-54: Shift Rod Connection (Illustration Shown with Shifter Boot Cover Opened) 3. 4. 5. 6. Remove two shift control boot protectors. Remove shift control housing bolts and remove assembly from body (Figure 5-55). Move shift boot away from shift control housing for access to wires (Figure 5-55). Remove wiring tie strap.
SHIFT INTERLOCK CABLE
NOTE: Tag wires for installation reference. 7. Disconnect body harness wires from backup light switch. Figure 5-56: Interlock Cable Attachment 1-1-02
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SHIFT CONTROL ASSEMBLY SERVICE

NOTE: Shifter Boot Cover (procedure in this section) must be removed for access to Shifter Control Boot. The shift control housing and shift arms are not serviceable. The shift arm mechanisms can be lubricated to correct a bind condition when necessary. However, if any of the housing components are worn, or damaged, the housing must be replaced as an assembly.
TRANSMISSION SHIFT INDICATOR
The only control assembly parts that can be replaced separately, include the following (Figure 5-57): shift indicators shift knobs and spring pins housing cover plate and seal switches and retaining nuts wiring tie straps indicator bulb
RELEASE BUTTON SHIFT KNOB
SHIFT KNOB
SPRING PIN
TRANSFER CASE SHIFT INDICATOR
TRANSFER CASE LEVER
SPRING PIN
INDICATOR BULB TRANSMISSION LEVER COVER PLATE
SEAL SHIFT CONTROL HOUSING HOUSING SHIFT ARMS BACKUP LAMP SWITCH
PARK/NEUTRAL POSITION SWITCH
SWITCH NUT TIE STRAP
SWITCH NUT
SWITCH AND LAMP HARNESS
SHIFTER BOOT COVER
Figure 5-57: Shift Control Assembly Serviceable Components (Illustration Shown with Shifter Boot Cover Removed)
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PARK/NEUTRAL POSITION OR BACKUP LAMP SWITCH REPLACEMENT

1. 2. 3. 4. 5. 6. 7. 8. Remove driver side inner kick panel. Open shifter boot cover for access to shift control arms. Disconnect shift rods at shift control arms. Remove bolts attaching shift control housing to tunnel floor. Lift up for access and remove interlock cable. Remove shift control assembly. Remove shifter boot cover and shifter boot (Figure 5-58). Remove position switch screws and remove switch from housing.
SHIFT CONTROL ASSEMBLY
9. Remove tie strap and disconnect switch leads. 10. Disconnect backup or position switch wires at body harness. 11. Install switch on shift control housing and secure with lockwashers and screws. 12. Position wires in shifter boot and install shifter boot on housing assembly. 13. Install shift control assembly. 14. Install housing attaching screws. 15. Connect shift rods to control assembly shift arms. 16. Install inner kick panel.
PARK/NEUTRAL POSITION SWITCH CONTROL HOUSING
TIE STRAP
SHIFTER BOOT
SHIFTER BOOT COVER
Figure 5-58: Shift Housing Switch Replacement
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SHIFTER BOOT COVER REPLACEMENT

A shifter boot cover protects the shifter boot and linkage. The shifter boot cover is made of a silicone coated fiberglass, heat resistant material. This material provides the additional benefits of reduced noise and heat intrusion from under the vehicle into the passenger compartment.
BEZEL
Removal WARNING: Exhaust system components can be extremely hot. To avoid injury, do not touch hot exhaust system components.
1. The exhaust system passes directly under the shift control assembly. Loosen, but do not remove, the two clamps holding the heat shield to the exhaust pipe so that it can be moved out of the way as necessary when performing the following procedure. Unfasten shifter boot cover snaps and pull apart velcro strips to open cover (Figure 5-59).
SHIFTER BOOT COVER LIP CUT FROM COVER LIP TO INTERLOCK CABLE SHIFTER BOOT COVER SNAPS TUNNEL (UNDERNEATH VEHICLE) INTERLOCK CABLE INTERLOCK CABLE SHIFT CONTROL ASSEMBLY
TUNNEL
2.
Figure 5-60: Cutting Shifter Boot Cover
SHIFT RODS
Figure 5-59: Shift Rod Removal 3. 4. 5. Remove shift rods from shift control assembly. Remove bezel from shift control assembly (Figure 5-60). Remove fasteners securing shift control assembly to tunnel and raise shift control assembly until interlock cable contacts tunnel, restricting further upward movement. Cut shifter boot cover from the lip to the interlock cable hole as shown (Figure 5-60). Work shifter boot cover lip out of tunnel opening and remove from under vehicle (Figure 5-61).
Figure 5-61: Shifter Boot Cover Removal
6. 7.
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Installation
1. 2. Work shifter boot cover lip into tunnel opening and align edges carefully to match opening. Set shift control assembly into tunnel. Verify that fastener holes are positioned properly and shifter boot cover lip is not exposed. Secure shift control assembly to tunnel. Install bezel on shift control assembly. Attach shift control rods to shift control assembly. Fasten velcro and snaps to close shifter boot cover opening. Properly position heat shield and tighten mounting clamps securely.
7.
3. 4. 5. 6. 7.
Seat shift control assembly in tunnel opening and secure with assembly attaching bolts. Tighten bolts to 6 lb-ft (8 Nm) torque. 8. Install two shift control housing boot protectors. 9. Connect transmission and transfer case shift rods to shift arms in control housing (Figure 5-54). 10. Install inner kick panel.
TRANSMISSION SHIFT ROD REPLACEMENT

1. 2. 3. Place shift lever in neutral. Remove cotter pin, washer, and trunnion from housing shift arm. Remove cotter pin and washer from shift rod rear trunnion. Disconnect trunnion and remove wave washer and shift rod from shift rod lever (Figure 5-62).
SHIFT CONTROL ASSEMBLY INSTALLATION

1. 2. 3. 4. 5. If cover plate and seal were removed, install new seal and plate. Then install wire harness and shift knobs. Lubricate housing shift mechanism with spray lube. Work interlock cable through boot and connect cable to shift housing (Figure 5-56). Connect harness wires to switches and bulb. Secure switch wires with new tie straps and slide boot up against housing. Be sure wire connectors to body harness are pulled through boot and secured with tie strap. Install shift indicators and bulb if removed.
NOTE: Mark positions of trunnions on shift rods for installation reference. 4. 5. 6. 7. Remove cotter pins securing trunnions to levers and remove rod. Remove bolts attaching shift rod lever and bracket and remove lever and bracket. Install new lever and bracket. Install lever rod and shift rod. Adjust rods and linkage as described in Transmission Shift Linkage Adjustment Procedure.
SHIFT CONTROL HOUSING
6.
TRANSMISSION SHIFT LEVER SHIFT ARM
LEVER ROD
SHIFT ROD FLAT WASHER
WAVY WASHER SHIFT ROD LEVER AND BRACKET BOOT PROTECTOR
Figure 5-62: Shift Linkage Disassembly/Assembly
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SHIFT LINKAGE ADJUSTMENT

1. 2. 3. Move shift lever to manual low (1) range. Disconnect transmission shift rod from arm in shift control housing. Verify that transmission shift lever (Figure 5-63) is in manual low (1) range. If not, disconnect lever trunnion and adjust trunnion in, or out as needed. Then reconnect lever rod to shift lever. Connect shift rod to shift control arm and check indicator alignment at shift lever. If indicator is not quite aligned, turn shift rod trunnion in or out to align. Verify that shift rod and lever trunnions are correctly secured to arm and lever. Replace clevis pins if necessary. Check shift operation. Verify that transmission shifts correctly and that indicator is properly aligned.
SHIFT ROD
REAR MOUNT REAR CROSSMEMBER
4.
5. 6.
TRANSMISSION SHIFT LEVER TRUNNION
Figure 5-64: Rear Mount Replacement
TRANSMISSION INPUT SPEED SENSOR REPLACEMENT

The input speed sensor is the forward sensor in the driver side of the transmission. The rearward sensor is not used in this application. 1. Turn ignition switch to OFF position. 2. Disconnect sensor wires. 3. Remove bolt attaching sensor to case. 4. Remove sensor with pull and twist motion. 5. Remove O-ring seal from sensor (Figure 5-65). 6. Lubricate new O-ring seal with ATF and install it on sensor. 7. Install sensor with push and turn motion. 8. Install and tighten sensor bolt to 97 lb-in. (11 Nm) torque. 9. Connect wires to sensor.
TRUNNION
Figure 5-63: Transmission Shift Linkage
REAR MOUNT REPLACEMENT

1. 2. 3. 4. 5. 6. Support transmission with oor jack and wood blocks. Remove rear mount bolts/nuts and raise transmission slightly. Remove rear mount from crossmember (Figure 5-64). Install mount on crossmember. Tighten attaching nuts to 65 lb-ft (88 Nm) torque. Lower transmission and install mount-to-adapter bolts. Tighten adapter bolts to 28 lb-ft (38 Nm) torque.
BOLT
INPUT SPEED SENSOR
O-RING
Figure 5-65: Speed Sensor Removal/Installation
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TRANSFER CASE DESCRIPTION

Hummer vehicles are equipped with the New Process Gear, model 242 transfer case. If you have questions about the transfer case that are not answered by this section, you can call the Transfer Case Hotline at 1-800-945-4327 for more information. The 242 is a full-time, 4-wheel drive transfer case with three operating ranges plus a neutral position. Operating ranges are High (H), Low (L), and High Lock (HL). Low range (L) position provides a 2.72:1 reduction ratio for greater low speed, off-road torque capability.
LOW RANGE PLANETARY RANGE SLEEVE FRONT RETAINER MODE SLEEVE
The transfer case extension, bearing retainer, rear case, and front case are all aluminum castings. The front and rear output drive sprockets are interconnected by a drive chain (Figure 5-66). A differential in the transfer case, allows the front/rear output shafts to run at differing speeds. This permits full-time, 4-wheel drive operation in high range. The 242 is also equipped with an internal-mount oil cooler.
DIFFERENTIAL DRIVE SPROCKET SPEEDOMETER TONE WHEEL MAINSHAFT
INPUT GEAR ANNULUS GEAR EXTENSION HOUSING REAR RETAINER
FRONT CASE COOLER TUBE DRIVE CHAIN REAR CASE
YOKE FRONT OUTPUT SHAFT DRIVEN SPROCKET
Figure 5-66: Model 242 Transfer Case
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The NP 242 used in Hummer vehicles is equipped with an internal oil cooler (Figure 5-67). The cooler is mounted within the front case and secured by nuts and washers. O-rings are used to seal the cooler inlet/outlet tubes. The cooler is interconnected to the transmission oil cooler circuit. However, transmission and transfer case oil are not intermixed. In operation, oil from the transmission cooler flows through the transfer case cooler. Heat from the transfer case oil is transmitted to the transmission oil which is then conveyed to the transmission cooler.
TRANSFER CASE INTERNAL OIL COOLER SUPPORT BRACKET
TRANSFER CASE IDENTIFICATION

An identification tag is attached to the rear case of each NP 242 transfer case (Figure 5-68). The tag provides the model number, assembly number, serial number, and low range ratio. The serial number also represents the date of build. For example, a serial number of 10-10-99 would represent a build date of October 10, 1999.
O-RING
Figure 5-68: Transfer Case I.D. Tag Information
RECOMMENDED LUBRICANT
Dexron III is the recommended lubricant for the NP 242. Use it for topping off the fluid level and as replacement fluid for fluid changes, or after overhaul. Dexron IIE can also be used for topping off a low fluid level when Dexron III is not readily available. Do not use friction modifiers or similar additives in the NP 242. Use recommended lubricants only.
FRONT CASE
Figure 5-67: Oil Cooler Location
Transfer Case Fluid Level

Correct transfer case fluid level is to the lower edge of the fill plug hole. Recommended fluid is Dexron III. The vehicle must be on a level surface for an accurate fluid level check. If the vehicle is raised on a hoist to check fluid level, a drive-on style hoist is preferred. This type of hoist will keep the vehicle level. The fill plug is just above the drain plug in the rear case. Tightening torque for the plug is 15-25 lb-ft (20-33 Nm).
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OPERATING RANGES
The three operating ranges are for specific use on or off road. Usage recommendations are:
TRANSFER CASE SHIFTING

The transfer case shift lever is adjacent to the transmission shift lever. A straight-line shift pattern is employed (Figure 5-69). The transfer case can be shifted from High (H) to High Lock (HL) and back, at any legal speed without putting the transmission in neutral. The vehicle must be completely stopped and the transmission shifted to neutral before a shift to low range (L). This is necessary because the low range gear must be moved into engagement with the fixed annulus. Once the low range and annulus are engaged, the transfer case is locked into a 2.72:1 reduction ratio. All output to the propeller shafts is undifferentiated and equal. Maximum recommended vehicle speed in low range is 23-31 mph (37-50 kph), with the lower speed preferred.
High Lock (HL)

High lock range is for use on low traction surfaces. It is an undifferentiated range and should only be employed on unpaved, or low traction surfaces; low traction defined as surfaces covered by snow, ice, sand, mud, or dirt. The differential is bypassed (locked out) in this range.
High (H)
High range is the only range recommended for use on hard, or paved road surfaces. This range can be used on, or off-road as desired.
Low (L)
Low range is for low speed, off road operation. The extra pulling power provided is useful when traversing steep grades, or driving in deep mud or sand. The low range gear provides a 2.72:1 reduction ratio when locked in the low range annulus gear.
Neutral
Neutral range is used for towing purposes.
TRANSFER CASE OPERATING RANGES
Figure 5-69: Transfer Case Shift Lever and Bezel
TRANSFER CASE DIAGNOSIS

The diagnosis guides outline probable causes of various transfer case malfunctions. The problem causes are listed in order of potential (most to least probable). The guides do not cover every possible condition or possibility. They do however, provide a means of reducing the number of components requiring further diagnosis and inspection.
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TRANSFER CASE DIAGNOSIS

PROBLEM Transfer Case Hard to Shift or Will Not Shift Into Desired Range 1. POTENTIAL CAUSE Vehicle speed too great to permit shifting. 1. CORRECTION Reduce speed to 15 mph if shifting from H to HL and back. Stop vehicle completely if shifting into low range. Stop vehicle completely. Shift into neutral. Then into high (H) range. Do not operate vehicle on hard road surface in high lock. Adjust rod. Refer to procedure in this section. Remove and inspect housing shift arms. Replace housing if shift arm is damaged or binding. Add uid, or drain and rell transfer case. Remove and overhaul transfer case.
2.
3. 4. 5. 6.
Vehicle driven for extended period on paved road surface in high lock (HL) range. Internal torque load can prevent shifting. Shift rod adjustment is incorrect. Shift control housing fault. Incorrect or low lubricant. Transfer case internal fault. sector damaged or loose range or mode fork failure damaged gear Low lubricant level. Incorrect lubricant Shift rod mispositioned. Internal component wear or damage. Extended operation on paved roads in high lock range. (Causes accelerated bearing, wear, gear wear, and chain stretch.) Not fully engaged in desired gear range. Shift linkage bind or misadjusted. Range or mode fork problem: fork cracked inserts worn, missing shift rail scored shift sector or shaft worn If transfer case jumps out of low range, problem is with low range gear, lockplate, or annulus. Transfer case overlled.
2.
3. 4. 5. 6.
Transfer Case Noisy In All Ranges
1. 2. 3. 4. 5.
1. 2. 3. 4. 5.
Add lubricant and check for leaks. Correct leaks as needed. Drain and rell transfer case. Adjust shift rod as described in the section. Remove and overhaul transfer case. Inform driver that only high range should be used on paved surfaces. Repair transfer case if wear or damage has occurred. Stop vehicle, shift into gear, and resume operation. Adjust shift rod. Correct bind in control housing shift arm. Remove, disassemble transfer case and repair as necessary.
Transfer Case Jumps Out Of Gear
1. 2. 3.
1. 2. 3.
4.
4.
Disassemble transfer case and repair as needed.
Lubricant Leaks From Vent Or Output Shaft Seals
1.
1.
2. 3.
Vent or line restricted, kinked, pinched. Output seal failure (front or rear) caused by wear, incorrect installation, cut seal lip. Vehicle driven for extended periods in high lock on hard, paved road surfaces.
2. 3.
Drain to correct level. Check transfer case cooler if transfer case is overlled and transmission uid level is low. Replace vent or line as needed. Reroute line to eliminate kinks. Replace seal(s). Correct cause of cut seal lip or abnormal wear of seal lip (rough surface on output shaft or yoke). Inform driver that only high range should be used on hard, paved road surfaces.
Rapid Tire Wear
1.
1.
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TRANSFER CASE SHIFT ROD SERVICE

Removal
1. 2. 3. 4. Unfasten snaps and pull velcro strips apart to open shifter boot cover. Remove cotter pins and washers securing shift rod to shift arm and range lever (Figure 5-70). Remove shift rod and trunnion as assembly. Remove trunnion from shift rod if necessary.
Adjustment
1. 2. 3. 4. Apply parking brakes and shift transmission into neutral. Shift transfer case into high lock (HL) position. Disconnect shift rod and trunnion at control housing shift arm (Figure 5-70). Verify that transfer case range lever is in high lock position. This is last detent toward rear (Figure 5-71). Move lever fully into detent if necessary. Adjust shift rod trunnion so it is slip fit in control housing shift arm. Install washer and cotter pin in trunnion. Check shift rod adjustment. Be sure transfer case is firmly engaged in each detent (range) position. Also be sure shift lever aligns with range positions on shift lever bezel.
5. 6.
Installation
1. 2. 3. 4. 5. Install trunnion on shift rod. Connect shift rod and trunnion to shift arm and range lever. Secure shift rod with washers and or cotter pins. Adjust shift rod. Refer to Shift Rod Adjustment procedure. Push velcro strips together and fasten snaps to close shifter boot cover.
SHIFTER BOOT COVER (SHOWN OPEN) ADJUSTING TRUNNION
CONTROL HOUSING SHIFT COTTER PIN WAVY WASHER WAVY WASHER FLAT WASHER
Figure 5-71: Range lever Positions
VENT LINE REPLACEMENT

1. 2. 3. 4. 5. 6.
TRANSFER CASE SHIFT ROD
FLAT WASHER
Loosen clamp and remove vent line from tting on rear of transfer case (Figure 5-72). Remove bolt, clamp, and vent line. If installing a new vent line, transfer clamp to new vent line. Connect vent line to tee fitting. Connect vent line transfer case fitting and tighten clamp. Attach clamp and vent line to transmission. Tighten clamp bolt to 16-20 lb-ft (22-27 Nm).
VENT LINE FITTING TEE FITTING TRANSMISSION
TRANSFER CASE RANGE LEVER
Figure 5-70: Transfer Case Shift Rod Attachment
TRANSFER CASE
Figure 5-72: Transfer Case Vent Line Routing 5745159 1-1-02
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SPEED SENSOR AND/OR SWITCH REPLACEMENT

1. Disconnect harness connector from vehicle speed sensor, lock indicator switch, and/or range indicator switch (Figures 5-73 and 5-74). Remove switch and/or sensor from transfer case (Figures 5-73 and 5-74).
WIRING HARNESS
GUIDE CABLE REPLACEMENT

1. 2. 3. 4. 5. 6. Remove bolts, nuts, and washers attaching cable bracket to mufer bracket (Figure 5-75). Remove bolts, nuts, and washers securing guide cable. Remove guide cable and bracket. Attach guide cable bracket to muffler bracket. Attach guide cable bracket to transfer case with washers and nuts. Install guide cable and brake line support bracket. Tighten bracket bolt to 27-33 lb-ft (37-45 Nm).
MUFFLER BRACKET GUIDE CABLE BRACKET SUPPORT BRACKET
2.
VEHICLE SPEED SENSOR
FRONT PROPELLER SHAFT
LOCK INDICATOR SWITCH
TRANSFER CASE
Figure 5-73: Speed Sensor and Lock Indicator Switch Location

RANGE INDICATOR SWITCH
GUIDE CABLE
Figure 5-75: Guide Cable Attachment
Figure 5-74: Range Indicator Switch Location 3. 4. Install new switch and/or sensor in transfer case. Attach harness connector to switch or sensor.
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FRONT OUTPUT SHAFT SEAL REPLACEMENT

1. 2. 3. 4. 5. 6. 7. Mark front propeller shaft and transfer case yoke for alignment reference. Disconnect front propeller shaft at yoke. Retain U-bolts and nuts (Figure 5-76). Remove yoke nut (Figure 5-77). Remove yoke and seal washer. Use tool J8614-01 to remove yoke if necessary. Remove seal from front case bore with standard hook type seal puller. Coat outer edge of new seal with thin coat of RTV type sealer. Lubricate seal lip with transmission fluid and install seal with tool J38869.
SEAL YOKE WASHER YOKE NUT
CAUTION: The seal can be installed incorrectly. Be sure the seal lip is toward the case interior. 8. Smooth seal contact surface of yoke with 320-400 grit emery coated with transmission fluid. Then clean and install yoke. 9. Install yoke seal washer. 10. Install and tighten yoke nut to 90-130 lb-ft (122-176 Nm) torque. 11. Connect propeller shaft to yoke. Tighten U-bolt nuts to 1318 lb-ft (18-24 Nm) torque. 12. Check and top off transfer case fluid level if necessary.
OIL SEAL
Figure 5-77: Front Output Shaft Yoke and Seal Removal/Installation
TRANSFER CASE FLUID CHANGE

The transfer case fill and drain plugs are both located in the rear case (Figure 5-78). Correct fill level is to the lower edge of the fill plug hole. Recommended fluid is Dexron III. 1. Place vehicle on level surface. Or, if vehicle is raised on hoist for uid change, a drive-on hoist is preferred. Vehicle must be level for accurate rell uid level. 2. Remove drain and fill plugs and drain fluid into approved container. 3. Install and tighten drain plug to 15-25 lb-ft (20-33 Nm) torque. 4. Refill transfer case with Dexron III. Correct level is to lower edge of fill plug hole. 5. Install and tighten fill plug to 15-25 lb-ft (20-33 Nm) torque. 6. Lower vehicle, if on hoist.
FILL PLUG
FRONT PROPELLER SHAFT YOKE
U-BOLT
Figure 5-76: Disconnecting/Connecting Front Propeller Shaft
DRAIN PLUG
Figure 5-78: Transfer Case Drain and Fill Plug Locations 5745159 1-1-02
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TRANSFER CASE REMOVAL

1. 2. 3. 4. 5. 6. 7. 8. Remove drain plug and drain oil from transfer case. Reinstall drain plug afterward. Disconnect propeller shafts from transfer case. Disconnect wiring harness connectors from vehicle speed sensors range switch, and lock switch. Remove wiring harness clamp and move harness away from transfer case. Disconnect vent line from transfer case (Figure 5-72). Disconnect cooler hoses at transfer case (Figure 5-79). Disconnect shift rod at range lever (Figure 5-80). Remove guide cable and bracket (Figure 5-80).
COOLER HOSES TRANSFER CASE
TRANSMISSION ADAPTER TRANSFER CASE
Figure 5-81: Separating Transfer Case From Transmission 11. Slide transfer case rearward and remove it from under vehicle (Figure 5-81).
TRANSFER CASE INSTALLATION

1. 2. 3. 4. 5. 6. 7. 8. 9. Mount transfer case on jack and secure with chain. Apply bead of Loctite 518 to mounting surface of transmission adapter. Align and install transfer case on transmission. Tighten transfer case attaching nuts to 37 lb-ft (50 Nm). Remove jack. Connect shift rod to range lever with washer and cotter pin (Figure 5-80). Install guide cable and bracket. Connect transfer case vent line. Connect cooler hoses to transfer case cooler fittings. Connect front and rear propeller shafts to transfer case. Tighten front shaft U-bolt nuts to 13-18 lb-ft (18-24 Nm) torque. Install vehicle speed sensor. Install range and lock indicator switches. Attach harness clamp to transfer case. Connect wiring harness connectors to speed sensor and switches. Fill transfer case to bottom edge of fill plug hole with Dexron III. Check and adjust shift rod if necessary.
Figure 5-79: Cooler Hose Connections 9. Support transfer case with jack. Secure transfer case to jack with chain. 10. Remove nuts attaching transfer case to transmission adapter (Figure 5-81).
FLAT WASHERS EXHAUST BRACKET
WAVY WASHER GUIDE CABLE AND BRACKET RANGE LEVER SHIFT ROD
10. 11. 12. 13. 14. 15.
Figure 5-80: Shift Rod Attachment
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REAR CASE REAR RETAINER
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TRANSFER CASE DISASSEMBLY AND OVERHAUL

1. 2. Remove vehicle speed sensor and both indicator switches. Remove front output shaft yoke (Figure 5-82). Remove yoke nut with suitable size socket and impact wrench. Then remove seal washer and yoke.
EXTENSION HOUSING
Figure 5-84: Extension Housing Removal

SEAL WASHER
5. 6.
FRONT OUTPUT SHAFT
Remove rear retainer bolts. Then remove mainshaft bearing snap ring (Figure 5-85). Pry rear retainer upward at each lug with screwdriver (Figure 5-86). Remove retainer after breaking sealer bead.
YOKE NUT
YOKE
Figure 5-82: Front Yoke Removal/Installation 3. Remove extension housing bolts. Then tap housing in counterclockwise direction to break sealer bead (Figure 5-83). Use plastic mallet to tap housing. Remove extension housing (Figure 5-84).
EXTENSION HOUSING PLASTIC MALLET REAR RETAINER SNAP RING
4.
Figure 5-85: Mainshaft Snap Ring Bearing Removal
Figure 5-83: Loosening Extension Housing
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REAR CASE REAR RETAINER
LUG OIL PUMP
LUG
SCREWDRIVER
Figure 5-86: Rear Retainer Removal 7. 8. Remove speedometer tone wheel and snap rings (Figure 5-87). Remove rear case attaching bolts and remove rear case (Figure 5-88). Figure 5-88: Rear Case Removal 9. Remove oil pump, pickup tube, hose, and screen (Figure 5-89). 10. Remove O-ring from oil pump inlet port (Figure 5-90).
CAUTION: Loosen the rear case with screwdrivers positioned in the slot at each end of the case. This will avoid damaging the case sealing surfaces.
SNAP RING
REAR CASE
TONE WHEEL SNAP RING
OIL PUMP
MAINSHAFT OIL PICKUP TUBE
HOSE
OIL SCREEN REAR CASE
Figure 5-87: Speedometer Tone Wheel Removal/Installation
Figure 5-89: Oil Pump Assembly Removal
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OIL PUMP
DRIVE CHAIN
DRIVE SPROCKET
INLET PORT O-RING
Figure 5-90: Oil Pump O-ring Location 11. 12. 13. 14. Remove drive sprocket snap ring (Figure 5-91). Remove drive sprocket (Figure 5-92). Remove drive chain. Remove front output shaft and driven sprocket as assembly (Figure 5-93).
Figure 5-92: Drive Sprocket Removal

DRIVEN SPROCKET
FRONT OUTPUT SHAFT
DRIVE SPROCKET
DRIVE SPROCKET SNAP RING
Figure 5-93: Front Shaft and Driven Sprocket Removal Figure 5-91: Drive Sprocket Snap Ring Removal/ Installation 15. Remove range lever nut, washer and lever from sector shaft (Figure 5-94).
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SECTOR SHAFT RANGE LEVER WASHER NUT SHIFT RAIL
MODE FORK ASSEMBLY
Figure 5-94: Range Lever Mounting 16. Remove detent plug, spring, and plunger (Figure 5-95). 17. Remove oil cooler attaching nuts and washers. Then remove cooler, support bracket and O-rings (Figure 5-95). 18. Remove shift rail (Figure 5-96).
OIL COOLER SUPPORT BRACKET O-RING
Figure 5-96: Shift Rail Removal/Installation 19. Remove mainshaft, differential, and mode fork as assembly (Figure 5-97).
FRONT CASE
MAINSHAFT AND DIFFERENTIAL ASSEMBLY
DETENT PLUG
PLUNGER SPRING
MODE FORK ASSEMBLY
Figure 5-95: Oil Cooler and Detent Plug, Spring, Plunger Removal
Figure 5-97: Mainshaft, Differential and Mode Fork Removal
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20. Remove mode fork and sleeve from mainshaft (Figure 5-98). Note position of sleeve for installation reference. Do not disassemble fork assembly. Only the fork pads are serviceable. 21. Remove snap ring that secures intermediate clutch shaft on mainshaft (Figure 5-99).
SNAP RING
INTERMEDIATE CLUTCH SHAFT MAINSHAFT
MODE FORK ASSEMBLY
MODE SLEEVE
Figure 5-99: Intermediate Clutch Shaft Snap Ring Removal/Installation 22. Remove intermediate clutch shaft and tabbed thrust ring from mainshaft (Figure 5-100). Figure 5-98: Mode Fork and Sleeve Removal
THRUST RING
SNAP RING
INTERMEDIATE CLUTCH SHAFT
MAINSHAFT
Figure 5-100: Clutch Shaft Removal 5745159 1-1-02
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23. Remove differential snap ring (Figure 5-101). 24. Remove differential from mainshaft (Figure 5-102). 25. Remove mainshaft needle roller bearings and spacers (Figure 5-103).
NEEDLE ROLLER BEARINGS
BEARING SPACERS
MAINSHAFT
Figure 5-103: Mainshaft Bearing and Spacer Removal

DIFFERENTIAL SNAP RING
Figure 5-101: Differential Snap Ring Location
26. Slide low range fork pin out of shift sector. Then remove low range fork and sleeve as assembly (Figure 5-104). 27. Remove shift sector. 28. Remove shift sector shaft bushing and O-ring (Figure 5-105).
LOW RANGE FORK
PIN
DIFFERENTIAL SHIFT SECTOR SLEEVE
MAINSHAFT
Figure 5-104: Range Fork and Sleeve Removal
Figure 5-102: Differential Removal
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32. Disassemble input gear and low range planetary as follows: a. Remove retaining ring that secures input gear in low range planetary (Figure 5-108). b. Remove lock ring and front thrust washer (Figure 5-109). c. Remove input gear and rear thrust washer from low range planetary (Figure 5-109).
INPUT GEAR SECTOR SHAFT BUSHING
O-RING
Figure 5-105: Sector Shaft Bushing and O-Ring Removal 29. Remove bolts attaching front retainer to front case. Then remove retainer by prying it loose with screwdriver positioned in retainer slot (Figure 5-106).
FRONT RETAINER
SNAP RING
Figure 5-107: Input Gear Snap Ring Removal

INPUT GEAR LOW RANGE PLANETARY
RETAINING RING RETAINER SLOT
Figure 5-108: Input Gear Retaining Ring Removal
Figure 5-106: Front Retainer Removal 30. Remove snap ring that secures input gear in bearing (Figure 5-107). 31. Remove input gear and low range planetary as assembly. Tap input gear with rawhide or plastic mallet to free it from bearing.
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REAR THRUST WASHER
___________________________________________
FRONT THRUST WASHER
CASE BOLTS
LOW RANGE PLANETARY INPUT GEAR LOCK RING
Figure 5-111: Differential Case Bolt Removal

FRONT CASE
Figure 5-109: Input/Low Range Planetary Gear Disassembly Sequence 33. Remove and disassemble differential as follows: a. Scribe or paint mark front and rear cases for assembly reference (Figure 5-110). b. Remove case bolts (Figure 5-111). c. Pry front and rear cases apart with two screwdrivers (Figure 5-112). d. Remove planet gears and thrust washers (Figure 5-113). e. Remove sprocket and mainshaft gears as assembly (Figure 5-114). 34. Remove front output shaft front bearing seal with pry tool (Figure 5-115).
REAR CASE
REAR CASE
Figure 5-112: Separating Differential Cases

SPROCKET GEAR
FRONT CASE
ALIGNMENT SCRIBE OR PAINT MARK
THRUST WASHERS (12) FRONT CASE PLANET GEARS (6)
Figure 5-110: Marking Differential Cases for Assembly Reference
Figure 5-113: Planet Gear Locations In Bottom Case
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MAINSHAFT GEAR
TRANSFER CASE CLEANING AND INSPECTION

Clean the transfer case components thoroughly with standard parts cleaning solvent. Remove all traces of sealer from the case and retainer sealing surfaces. Clean the oil pickup screen with solvent and dry it with compressed air. Also use compressed air to remove solvent residue from all oil feed passages and channels.
SPROCKET GEAR
Geartrain
The differential pinion gears and thrust washers are serviceable components and can be replaced if worn or damaged. The differential cases are also serviceable but must be replaced as a set if either case is damaged. Inspect the mainshaft splines, gear teeth and bearing surfaces carefully for evidence of wear, or damage. Replace the shaft if necessary. Do not attempt to salvage it if damaged. The range and mode forks are serviced as assemblies. Replace either part if damaged. However, the nylon pads in the forks can be replaced if worn, or cracked. Inspect the transfer case snap rings closely. Do not attempt to salvage a distorted snap ring by straightening or reshaping it. Replace any snap ring that is distorted, or worn. Inspect the low range planetary, input gear and thrust washer, retainer, and snap ring. The low range planetary is serviced as an assembly only. Replace it if the case or pinions are damaged. During inspection, also make sure the seal surface of the input gear is in good condition. Minor nicks on this surface can be reduced with crocus cloth. However, replace the gear if the seal surface is severely scored or worn. Check condition of the low range annulus gear (Figure 5-116). Replace the front case and gear as an assembly if the gear is damaged. The annulus gear is not serviced separately. The speedometer tone wheel should be replaced if worn, cracked, or spline teeth are worn. Inspect the differential gears, thrust washers and case halves. Replace the mainshaft gear if the gear teeth or the brass ring on the underside of the gear are damaged. Replace the differential as an assembly if the gears, case halves, or the pins in the lower case half are damaged. Inspect the case halves, extension housing, and both retainers for cracks, porosity, or damaged sealing surfaces. Inspect the shafts, gears, chain and shift components for wear or damage. Inspect all of the transfer case bearings for wear, roughness, pitting, or galling. Replace worn or damaged bearings.
Figure 5-114: Mainshaft and Sprocket Gear Removal

FRONT CASE PRY TOOL
SHAFT SEAL
Figure 5-115: Removing Front Output Shaft Seal
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ANNULUS GEAR FRONT CASE
FRONT OUTPUT SHAFT BEARING AND SEAL REPLACEMENT

1. 2. 3. 4. 5. 6. Remove snap ring securing shaft front bearing in front case (Figure 5-117). Tap old bearing out rear of front case with plastic or raw hide mallet. Install new bearing with tool handle J8092 and installer tool J33833 (Figure 5-118). Lubricate new bearing with Dexron III. Install new shaft seal with seal installer J38869 (Figure 5-119). Then lubricate seal lip with Dexron III. Remove front output shaft rear bearing from rear case as follows: a. Clamp rear case to bench with wood blocks and Cclamps. b. Pull bearing using slide hammer, adapter J2619-01, and puller J26369 (Figure 5-120). c. Install new bearing with tool handle J8092 and installer J33832 (Figure 5-121). The rear bearing bore is chamfered at the top. Install the bearing so it is flush with the chamfer lower edge.
Figure 5-116: Annulus Gear Location In Front Case
Oil Pump
The oil pump is not a serviceable component. Replace the pump as an assembly if the gear teeth are worn, or if the pump has become damaged.
CAUTION: Do not bottom the bearing in the bore. This will block the oil feed hole in the rear case bearing bore.
Bearings and Seals

The transfer case seals should be replaced during overhaul. Use new seals in the oil pump, input gear bearing retainer, front case, and extension housing. Also replace the yoke seal washer and detent plug O-ring.
FRONT CASE
FRONT OUTPUT SHAFT FRONT BEARING
BEARING SNAP RING
Figure 5-117: Front Output Shaft Front Bearing Snap Ring Removal/Installation
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TOOL HANDLE J8092 TOOL J33833
SLIDE HAMMER J2619-01
REAR CASE
TOOL J26369
FRONT OUTPUT SHAFT REAR BEARING
Figure 5-118: Front Output Shaft Front Bearing Installation Figure 5-120: Front Output Shaft Rear Bearing Removal
TOOL J38869 TOOL HANDLE J8092
FRONT OUTPUT SHAFT SEAL
TOOL J33832
BEARING
Figure 5-121: Front Output Shaft Rear Bearing Installation
Figure 5-119: Front Output Shaft Seal Installation
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INPUT GEAR BEARING REPLACEMENT

1. 2. Remove old bearing from interior of front case as shown. Use tool handle J8092 and tool J29170 (Figure 5-122). Install new bearing using tool handle J8092 and tool J 29170 (Figure 5-123). Seat bearing so locating ring is firmly seated against case.
TOOL HANDLE J8092
MAINSHAFT PILOT BEARING REPLACEMENT

1. Remove pilot bearing from input gear with slide hammer J2619-01, and puller tool J29369-1 (Figure 5-124). Support input gear on vise or over precut notch or hole in workbench. Install new pilot bearing in gear with tool handle J8092 and tool J33829 (Figure 5-125). Seat bearing flush with chamfer in bearing bore.
2.
BEARING TOOL J29369-1
TOOL J29170 SLIDE HAMMER J2619-01
INPUT GEAR
Figure 5-122: Input Gear Bearing Removal
Figure 5-124: Removing Mainshaft Pilot Bearing From Input Gear
TOOL HANDLE J8092
TOOL J29170 BEARING LOCATION RING
TOOL HANDLE J8092
NEW BEARING
TOOL J33829
INPUT GEAR
Figure 5-123: Input Gear Bearing Installation
Figure 5-125: Installing Mainshaft Pilot Bearing In Input Gear
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EXTENSION HOUSING BUSHING AND SEAL REPLACEMENT

1. 2. 3. 4. 5. Remove old seal with pry tool. Drive out old bushing with tool handle J8092 and tool J 33839 (Figure 5-126). Position new bushing on tool J33839 and tap bushing into place until flush with bushing bore. Install new seal in housing with J33843 or suitable size installer tool (Figure 5-127). Lubricate seal lip with Dexron III or petroleum jelly.
J33843 OR SUITABLE SIZE SEAL INSTALLER
EXTENSION HOUSING NEW SEAL TOOL HANDLE J8092
TOOL J33839
REMOVAL
Figure 5-127: Extension Housing Seal Installation
REAR THRUST WASHER
TOOL HANDLE J8092
TOOL J33839 LOW RANGE PLANETARY NEW BUSHING
INSTALLATION
Figure 5-128: Rear Thrust Washer Installation
INPUT GEAR
Figure 5-126: Extension Housing Bushing Replacement
LOW RANGE PLANETARY
Figure 5-129: Input Gear Installation 5745159 1-1-02
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TRANSFER CASE ASSEMBLY

1. Assemble input gear and low range planetary: a. Lubricate gear, planetary, and thrust washers with Dexron III. b. Install rear thrust washer in planetary. Be sure washer tabs are aligned in planetary notches as shown (Figure 5-129)
INPUT GEAR LOW RANGE PLANETARY
NOTE: The thrust washers are the same size and are interchangeable. Either washer can be used at the front or rear. c. d. Install input gear in planetary (Figure 5-130). Install front thrust washer. Be sure washer tabs are seated in planetary notches as shown (Figure 5-130). e. Install lock ring (Figure 5-131) and lock ring retainer (Figure 5-132). Lubricate shift sector shaft and install sector in case (Figure 5-133). Install input gear/planetary assembly in front case (Figure 5-134). Use wood hammer handle to tap input gear shaft through bearing. Install input gear snap ring (Figure 5-135). Install front retainer as follows: a. Install new seal in retainer with tool J33831 (Figure 5-136). b. Apply 3/16 in. (5 mm) bead of Loctite 518, Permatex Ultra Black, or Ultra Copper to sealing surface of retainer. c. Align oil feed slot in retainer with feed hole in front case and install retainer (Figure 5-137). d. Install and tighten retainer bolts to 12-18 lb-ft (16-24 Nm).
LOCK RING
2. 3.
Figure 5-131: Lock Ring Installation
4. 5.
LOCK RING RETAINER
Figure 5-132: Input Gear Snap Ring Installation 6.

FRONT THRUST WASHER
7.
Assemble low range fork and hub. Replace pads on fork if worn or damaged (Figure 5-138). Install low range fork and hub. Be sure hub is seated in planetary and that fork pin is seated in shift sector lower slot (Figure 5-139).
Figure 5-130: Front Thrust Washer Installation
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SNAP RING INPUT GEAR BEARING
5-159
FRONT CASE
SHIFT SECTOR
Figure 5-133: Shift Sector Installation
INPUT GEAR SHAFT
Figure 5-135: Input Gear Snap Ring Installation
INPUT GEAR/ PLANETARY ASSEMBLY
TOOL J33831
FRONT RETAINER
INPUT GEAR BEARING
Figure 5-134: Input Gear/Low range Planetary Installation 8. Assemble differential as follows: a. Lubricate differential cases, gears, thrust washers with Dexron III. b. Install mainshaft gear in front case. c. Install sprocket gear. d. Install thrust washer on each front case pinion pin. e. Install long and short pinions in sets as shown. f. Install thrust washer at top of each pinion. g. Align and install rear case on front case. Be sure case alignment paint or scribe marks are matched as shown. h. Install and tighten differential case bolts evenly.
Figure 5-136: Front Retainer Seal Installation
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9.
FRONT RETAINER
10.
11.
12. 13.
INPUT GEAR
14.
Check condition of tone wheel on mainshaft. Replace wheel if teeth are chipped, cracked, or broken. Coat needle bearing surface of mainshaft with petroleum jelly. Then install first spacer, 53 needle bearings, and remaining spacer. Use extra petroleum jelly to hold needle bearings in place (Figure 5-143). Install differential on mainshaft. Verify that needle roller bearings were not displaced before proceeding (Figure 5-144). Install differential snap ring (Figure 5-145). Install intermediate clutch shaft. Be sure shaft is fully seated (Figure 5-146). Install clutch shaft thrust ring and snap ring (Figure 5-147).
Figure 5-137: Front Retainer Installation
MAINSHAFT GEAR
PADS LOW RANGE FORK
HUB
Figure 5-138: Assembling Low Range Fork and Hub

LOW RANGE FORK SHIFT SECTOR
DIFFERENTIAL FRONT CASE
Figure 5-140: Installing Mainshaft Gear In Front Case
LOWER SLOT
Figure 5-139: Engaging Low Range Fork Pin in Shift Sector
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5-161
THRUST WASHERS (6) LONG PINION (3)
SHORT PINION (3)
THRUST WASHERS (6)
NEEDLE ROLLER BEARINGS (HOLD IN PLACE WITH PETROLEUM JELLY)
SPROCKET GEAR
BEARING SPACERS
MAINSHAFT GEAR
Figure 5-143: Mainshaft Bearing Roller Installation
FRONT CASE
Figure 5-141: Differential Pinion and Sprocket Gear Installation

DIFFERENTIAL REAR CASE
MAINSHAFT
Figure 5-144: Installing Differential On Mainshaft 15. Install mode sleeve in mode fork. Replace fork pads if worn or cracked. Do not reuse worn pads (Figure 5-148). 16. Install assembled mode fork and sleeve on mainshaft. Then seat sleeve in differential (Figure 5-149). 17. Install assembled mainshaft, differential, mode fork, and sleeve. Be sure mainshaft is seated in input gear pilot bearing and that mode fork pin is seated in upper slot of shift sector as shown (Figure 5-152).
FRONT CASE CASE ALIGNMENT MARKS
Figure 5-142: Assembling Differential Front/Rear Cases
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DIFFERENTIAL SNAP RING CLUTCH SHAFT THRUST RING
CLUTCH SHAFT SNAP RING INTERMEDIATE CLUTCH SHAFT
Figure 5-145: Differential Snap Ring Installation
Figure 5-147: Intermediate Clutch Shaft Thrust Ring and Snap Ring Installation
INTERMEDIATE CLUTCH SHAFT MAINSHAFT
18. Install shift rail. Install rail through mode fork, range fork, and into case bore and install lock pin (Figure 5-153).
MODE FORK ASSEMBLY
DIFFERENTIAL FORK PADS MODE SLEEVE
Figure 5-146: Intermediate Clutch Shaft Installation
Figure 5-148: Installing Mode Sleeve in Mode Fork
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MANIFOLD
DIFFERENTIAL
MODE FORK ASSEMBLY MAINSHAFT
COOLER SUPPORT BRACKET COOLER SEALING WASHERS MODE SLEEVE
Figure 5-149: Mode Fork and Sleeve Installation 19. Install detent plunger, spring, and plug. Replace O-ring on plug before hand and tighten plug to 12-18 lb-ft (16-24 Nm) (Figure 5-154). 20. Install range lever on sector shaft, then secure lever with washer and nut (Figure 5-154). Tighten nut to 20-25 lb-ft (27-34 Nm). 21. Install shift sector shaft O-ring and nylon bushing. Use thin wall socket to seat O-ring and bushing. 22. Install support bracket onto oil cooler, then install sealing washers, set oil cooler into the transfer case front half and install external hardware. Hand tighten only. (Figure 5-150) 23. Align the upper support tab in the recess of the case and ensure that the lower tab, the one with the extra rivet installed, rests on the recessed casting. The lower tab is designed to have the rivet compressed between the recessed casting area of the front and rear transfer case halves when the halves are bolted together. Make sure that the tabs do not intrude into the machined mating surface area of the transfer case halves. Do not bend the cooler when moving into position, damage to the manifold area could occur from induced stress.While gently holding the cooler with a 3/4" wrench on the manifold, tighten hardware to 15 lb-ft. (Figure 5-151) NOTE: If the cooler is tightened incorrectly, the tension placed on the cooler assembly could cause cracking, leaking and loss of transmission fluid into the transfer case assembly.
TRANSFER CASE FRONT HALF
9-S05-003.1
Figure 5-150: Transfer Case Cooler Support Bracket Installation
CASE HALF RECESS
LOWER SUPPORT TAB
UPPER COOLER SUPPORT TAB TIGHTEN FIRST
HOLD WHEN TIGHTENING HARDWARE
9-S05-002.2
Figure 5-151: Transfer Case Cooler Support Tabs
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MAINSHAFT AND DIFFERENTIAL ASSEMBLY
MODE FORK ASSEMBLY
24. Assemble driven sprocket and front output shaft. Use new snap ring if old one is worn or distorted (Figure 5-155). 25. Install front output shaft and driven sprocket. Then install drive chain (Figure 5-156). 26. Install drive sprocket. Slide sprocket down onto mainshaft. Engage sprocket in chain and work it onto mainshaft splines (Figure 5-156). 27. Secure drive sprocket to mainshaft with new snap ring. Be sure snap ring is fully seated before proceeding (Figure 5-157).
SHIFT SECTOR SHAFT
PLUG
LOCKNUT SECTOR UPPER SLOT WASHER RANGE LEVER DETENT PLUNGER
SPRING
Figure 5-154: Range Cover and Shift Detent Installation

MODE FORK PIN
Figure 5-152: Mainshaft, Differential, and Mode Fork Installation
28. Install new seal in oil pump with tool J33835 (Figure 5-158). 29. Install new O-ring in oil pump inlet port. Then assemble pump, pickup tube, connector hose and pickup screen (Figure 5-159).
MODE FORK
SHIFT RAIL
Figure 5-153: Shift Rail Installation 1-1-02
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5-165
30. Position pump assembly in rear case. Be sure pickup screen is seated in case notch as shown (Figure 5-160).
SNAP RING DRIVEN SPROCKET
DRIVE SPROCKET FRONT OUTPUT SHAFT
DRIVE SPROCKET SNAP RING
Figure 5-157: Securing Drive Sprocket to Mainshaft Figure 5-155: Front Output Shaft and Sprocket Assembly 31. Install magnet in front case pocket (Figure 5-161). 32. Apply 3/16 in. (5 mm) wide bead of Permatex Ultra Black to sealing flange of front case. Be sure sealer encircles each case bolt hole. 33. Align and install rear case on front case (Figure 5-162). Be sure alignment dowel is seated and that oil pump is properly engaged in mainshaft splines. Also be sure front output shaft is seated in rear bearing and shift rail is seated in rear case bore. 34. Install and tighten case bolts in diagonal pattern to 20-25 lb-ft (27-34 Nm).
DRIVE SPROCKET
FRONT OUTPUT SHAFT AND DRIVEN SPROCKET
DRIVE CHAIN
Figure 5-156: Drive Chain and Sprocket Installation
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OIL PUMP REAR CASE
TOOL J33835
OIL PUMP HOUSING PICKUP TUBE OIL PICKUP CASE SCREEN NOTCH
Figure 5-160: Oil Pump Assembly Installation
Figure 5-158: Oil Pump Seal Installation
OIL PUMP FRONT CASE POCKET
CHIP MAGNET OIL PICKUP TUBE CONNECTOR HOSE O-RING OIL PICKUP SCREEN
Figure 5-161: Chip Magnet Installation

INLET PORT
Figure 5-159: Oil Pump and Pickup Component Assembly 35. Install speedometer tone wheel and snap rings (Figure 5-163). 36. Install mainshaft bearing in rear retainer (Figure 5-164). Use tool handle J8092 and installer J33832.
37. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex Ultra Black, or Ultra Copper to flange surface of rear retainer. 38. Align and install rear retainer (Figure 5-165). Install and tighten retainer bolts to 22-25 lb-ft (30-34 Nm). 39. Install mainshaft bearing snap ring (Figure 5-165). 40. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex Ultra Black, or Ultra Copper to extension housing flange. 41. Align and install extension housing on rear retainer (Figure 5-166). Install and tighten housing bolts to 20-25 lb-ft (27-34 Nm). 42. Check seal contact surface of front yoke. Smooth surface with 320-400 grit emery if necessary. Then lubricate seal surface with Dexron III and Install yoke, new seal washer, and new yoke nut. Tighten yoke nut to 130-200 lb-ft (176271 Nm). Use yoke tool J8614-01 to hold yoke while tightening nut (Figure 5-167).
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OIL PUMP REAR CASE
DOWEL
TOOL HANDLE J8092
TOOL J33832
BEARING
Figure 5-164: Installing Mainshaft Bearing In Rear Retainer
MAINSHAFT BEARING
SNAP RING
Figure 5-162: Rear Case Installation
REAR RETAINER
SNAP RING TONE WHEEL SNAP RING MAINSHAFT
Figure 5-165: Rear Retainer and Mainshaft Bearing Snap Ring Installation
REAR RETAINER EXTENSION HOUSING
Figure 5-166: Extension Housing Installation Figure 5-163: Tone Wheel Speedometer Installation 5745159 1-1-02
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YOKE NUT FRONT OUTPUT SHAFT SEAL WASHER FRONT OUTPUT YOKE
Figure 5-167: Front Yoke Installation 43. Install drain plug in rear case. Tighten plug to 15-25 lb-ft (20-33 Nm). 44. Apply Loctite PST to threads of indicator switches and speed sensor. 45. Install indicator switches. Tighten switches to 15-25 lb-ft (20-33 Nm). 46. Install speed sensor. Tighten sensor to 30-35 lb-ft (41-47 Nm). 47. Transfer case can be filled before or after installation in vehicle. Tighten fill plug to 15-25 lb-ft (20-33 Nm) after refill.
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TRANSFER CASE TORQUE SPECIFICATIONS
Case bolts (all) . . . . . . . . . . . . . . . . . . . . . . . . . . . Detent plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain/ll plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust bracket nuts . . . . . . . . . . . . . . . . . . . . . . . Extension housing bolts . . . . . . . . . . . . . . . . . . . . Front retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . Front output shaft yoke nut . . . . . . . . . . . . . . . . . . Indicator switches (both). . . . . . . . . . . . . . . . . . . . Oil cooler tube nuts. . . . . . . . . . . . . . . . . . . . . . . . Range lever nut . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear retainer bolts . . . . . . . . . . . . . . . . . . . . . . . . . Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer case mounting nuts . . . . . . . . . . . . . . . . .
20-25 lb-ft (27-34 Nm) 12-18 lb-ft (16-24 Nm) 15-25 lb-ft (20-33 Nm) 18-22 lb-ft (24-30 Nm) 20-25 lb-ft (27-34 Nm) 12-18 lb-ft (16-24 Nm) 130-200 lb-ft (176-271 Nm) 15-25 lb-ft (20-34 Nm) 150-230 in.-lb (17-26 Nm) 20-25 lb-ft (27-34 Nm) 22-25 lb-ft (30-34 Nm) 30-35 lb-ft (41-47 Nm) 20-26 lb-ft (27-35 Nm)
TRANSMISSION TORQUE SPECIFICATIONS
Adapter-to-case nuts . . . . . . . . . . . . . . . . . . . . . . . Converter bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . Converter housing cover bolts. . . . . . . . . . . . . . . . Manual shaft detent lever nut . . . . . . . . . . . . . . . . Oil pan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pump bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park pawl bracket-to-case bolt . . . . . . . . . . . . . . . Pressure test port plug. . . . . . . . . . . . . . . . . . . . . . Solenoid-to-valve body screw. . . . . . . . . . . . . . . . Transmission-to-engine bolts/studs. . . . . . . . . . . . Valve body screws. . . . . . . . . . . . . . . . . . . . . . . . .
25 lb-ft (34 Nm) 32 lb-ft (44 Nm) 62 lb-in. (7 Nm) 18 lb-ft (24 Nm) 32 lb-ft (44 Nm) 97 lb-in. (11 Nm) 18 lb-ft (24 Nm) 97 lb-in. (11 Nm) 71 lb-in. (8 Nm) 32 lb-ft (44 Nm) 18 lb-ft (24 Nm)
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ESSENTIAL TOOLS
J8614-01
J35944-AMG
J35944-500 J8092
J33043-2 J35944-22
J25025-B J33831 J33835
J42497 J21867 J39775
Tool No. J35944-AMG J35944-500 J35944-22 J8614-01 J8092 J25025-B J39775 J21867 J33831 J33835 J38869 J41623 J42543 J42497 J38694 J8614-5
Description Transmission Oil Cooler Flush Kit Cooler Line Adapters Oil Cooler Flushing Fluid Yoke Holding Tool Universal Driver Handle Dial Indicator and Guide Pin Set Transmission Test Jumper Harness Pressure Gauge and Hose Assembly Input Seal Installer Pump Housing Seal Installer Output Shaft Seal Installer (not shown) Oil Cooler Release Tool (not shown) Selector Shaft Seal Remover/Installer (not shown) Extension Housing Seal Installer (not shown) Installer, Oil Pump to Converter Seal (not shown) Bolt Kit, Yoke Holding Tool (not shown)
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SPECIAL TOOLS
J2619-01
J29369
J33839
J33829
J33833
J33832
J29170
Tool No. J2619-01 J29369 J33839 J33829 J33833 J33832 J29170
Description Slide Hammer and Adapter Bushing/Bearing Remover Kit Rear Output Bushing Remover (use with J8092) Pilot Bearing Installer (use with J8092) Output Shaft Main Bearing Installer (use with J8092) Front Output Shaft Rear Bearing Installer (use with J8092) Input Gear Bearing Remover (use with J8092)
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1-1-02
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6-1
Section 6 Wheels and Tires/Central Tire Ination System (CTIS)

TABLE OF CONTENTS
Central Tire Inflation System Air Intake Line and Assembly. . . . . . . . . . . . . . . . . . . . . . .6-51 Air Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Air Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Air Pressure Gauge Lamp. . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Air Pressure Indicator Lines . . . . . . . . . . . . . . . . . . . . . . . .6-45 Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Auxiliary Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Compressor Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Deflate Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Dust Excluder Replacement . . . . . . . . . . . . . . . . . . . . . . . .6-48 Front CTI Line Replacement . . . . . . . . . . . . . . . . . . . . . . . .6-50 Front Supply Tube and Hose . . . . . . . . . . . . . . . . . . . . . . .6-49 Geared Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Inflate/Deflate and Tire Selector Switches. . . . . . . . . . . . .6-38 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Interior Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Low Pressure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Quick-Disconnect Valve and Tube . . . . . . . . . . . . . . . . . . .6-52 Rear CTI Line Replacement . . . . . . . . . . . . . . . . . . . . . . . .6-50 Rear Tube Connection Shield . . . . . . . . . . . . . . . . . . . . . . 6-53 Spindle Extension and Seal . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Tube Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Indicator Lights Compressor/Low Pressure. . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Runflat Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . 6-12 Steering Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Wheels and Tires Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Checking Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . 6-25 One-Piece Aluminum Wheel and Two-Piece Runflat Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 Tire, Two-Piece Wheel, and Runflat Replacement . . . . . . . 6-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Wheel Alignment Correction . . . . . . . . . . . . . . . . . . . . . . . 6-26 Wheel and Tire Assembly Replacement . . . . . . . . . . . . . . 6-1 Wheel Half Stud Replacement . . . . . . . . . . . . . . . . . . . . . . 6-10 Wheel Runout Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
WHEEL AND TIRE ASSEMBLY REPLACEMENT

WARNING: Always take the wheel to an authorized service center for proper servicing. Use 16.5 inch diameter tires only. Mismatching tire and rim diameters is dangerous. A mismatched tire and rim assembly may explode and can result in serious injury or death. WARNING: Put transmission into the PARK position, apply parking brake, and chock opposite wheel before removing wheel. Avoid removing any wheel when vehicle is on sloping terrain. Personal injury or damage to equipment may result. Remove only the inner group of lug nuts when removing a wheel from the vehicle. Removing the outer nuts which hold the rim together while the assembly is inated could result in serious injury or death. WARNING: Never mix tires of different size or tread design. Never mix bias and radial construction tires. Mixing tire types will adversely affect road handling and can lead to loss of vehicle control, and could result in serious injury or death.
05745159 NOTE: Always depress both CTIS quick-disconnect valve tabs on each axle set to prevent air loss from the other tire. NOTE: Any procedure requiring removal of lug nuts and/or wheel-half nuts on two-piece steel wheels will first require removal of the plastic nut covers. The covers pull straight off of the lug nuts and are removed from the wheel-half nuts by turning counterclockwise.
Removal
NOTE: On vehicles equipped with Central Tire Inflation System (CTIS), mark the wheel mounting studs for installation position, then perform steps 1 and 2. 1. 2. 3. 4. 5. Remove CTIS hose shield. Remove tube and quick-disconnect valve from spindle. Loosen, but do not remove, lug nuts (Figure 6-1). Raise and support corner of vehicle. Remove lug nuts and wheel from geared hub spindle.
3-1-02
6-2
Wheels and Tires/Central Tire Inflation System (CTIS) _________________
TIGHTENING SEQUENCE
HOSE SHIELD LUG NUT
GEARED HUB SPINDLE WHEEL AND TIRE ASSEMBLY
Figure 6-3: Lug Nut Tightening Sequence CAUTION: Do not allow pipe thread sealant into air system. Sealant will damage CTIS components and inhibit the CTIS operation. NOTE: Perform steps 4 and 5 for vehicles equipped with CTIS. 4. 5. Install CTIS quick-connect valve and tube on spindle. Install CTIS hose shield.
Figure 6-1: Wheel and Tire Assembly Replacement
Installation
NOTE: The Wrangler GS-A, 37 X 12.50R16.5 LT touring radial tire has an asymmetrical/directional tread design. The heavier, stiffer tread on the outside shoulder of the tire must face outward when being installed. Before installing on a wheel, inspect sidewall of tire and ensure SIDE FACING OUTWARDS imprint is facing outward (Figure 6-2). NOTE: Install lug nuts with fingers to full engagement. If nuts resist finger tightening examine studs and nuts for damage and replace if damaged. 1. Position wheel on geared hub spindle according to marks on mounting studs and attach with lug nuts (Figure 6-1).
TIRE, TWO-PIECE WHEEL, AND RUNFLAT REPLACEMENT

WARNING: Do not use tire machine. Personal injury or damage to equipment may result.
CAUTION: It is not recommended mixing one-piece wheel runflat assemblies and two-piece take-a-part runflat wheel assemblies on the same vehicle. Runflat profiles are different between the two types of wheel assemblies. CAUTION: Do not mix two piece take-apart wheel components from previous model year vehicles with present production parts. Many features are not the same between the two wheel styles and will not fit together correctly. Present production wheel halves can be identified by a hole between two of the wheel half studs on both halves. These holes must be aligned when assembling the wheel halves.
Removal and Disassembly

1. If the vehicle is equipped with a Central Tire Ination System (CTIS), perform steps a through d: a. Release the quick disconnect fitting located in the center of the geared hub spindle on all four wheels. b. Remove the hose shield and lay aside.
Figure 6-2: Side Facing Outwards Location 2. 3. Remove support and lower corner of vehicle. Two-piece wheel lugnut torque is 110 lb-ft (149 Nm). Use tightening sequence shown (Figure 6-3).
________________
Wheels and Tires/Central Tire Inflation System (CTIS)

8. 9.
6-3
c. d.
Remove the brass fitting from the center of the geared hub spindle on the wheel(s) to be worked on. Use tire chalk to mark two of the geared hub spindle assembly studs nearest the air valve.
WARNING: In all disassembly operations, ensure tire is totally deated before removing wheel half locknuts. Failure to follow proper safety precautions could cause serious injury or death.
2. 3. 4. 5. 6. 7. Remove wheel/tire assembly from vehicle. Inspect vehicle geared hub spindle studs for bending, looseness, or stripped threads. Replace if damaged. Inspect lug nuts for fatigue, stripped threads, or other damage. Replace if damaged. Use tire chalk to mark the valve location on the sidewall of the tire. Remove valve cap and core from air valve and deflate tire. Run a piece of wire through air valve to ensure it is not plugged (Figure 6-3).
Remove wheel half nut covers. When tire is fully deflated, use a circular pattern and loosen twelve wheel half locknuts securing rim halves together. If you hear air escaping, do not proceed. Wait until the sound stops and recheck core housing for obstructions. When you are certain the tire is fully deflated, continue to remove wheel half locknuts. Discard locknuts.
WARNING: Never inate a two-piece wheel assembly with the wheel locknuts removed in an attempt to separate inner and outer rim halves. The assembly will separate under pressure resulting in serious injury or death.
10. Remove outer rim half from inner rim and tire. NOTE: Perform steps 6 and 7 only if damage to core housing, insert, or O-ring is evident. 11. Inspect valve core housing and insert for damage. Replace both if damaged. 12. Remove valve core housing from insert. Remove insert and locknut from outer rim half.
WARNING: Do not use unauthorized tools. Damage to equipment or serious injury may result.
OUTER RIM HALF ALIGNMENT HOLE
WHEEL HALF LOCKNUT
TIRE
VALVE CAP VALVE CORE CORE HOUSING INSERT O-RING LOCKNUT O-RING SEAL
INNER RIM HALF
CLIP-ON BALANCE WEIGHT
00-S06-007
Figure 6-4: Two-Piece Wheel Breakdown
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6-4
13. Remove O-ring from insert. Discard O-ring. 14. Remove O-ring seal from inner rim half. Discard O-ring seal. 15. Remove tire from inner rim half.
WARNING: Balance weights contain lead. Wash hands after handling.

16. Remove balance weights from rim halves. Discard balance weights. 17. Lay tire flat.
RUNFLAT
WARNING: To avoid injury, ensure runat compressor strap is centered around runat.
18. Position runflat compressor on an outer edge of runflat with handle assembly facing up and strap centered around runflat (Figure 6-5).
RUNFLAT COMPRESSOR J39250 COMPRESSOR STRAP
Figure 6-6: Runflat Appearance After Removal
Inspection and Cleaning

CAUTION: Do not reuse a tire which has been run flat without thoroughly inspecting for damage. Failure to follow these instructions may result in damage to equipment. 1. Remove any existing lubricant that has been previously applied to the inside of the tire using a mild detergent soap and water. Dry all wheel and tire parts. Ensure inside of tire is free of any runflat lubricant, dirt, debris, rust, or moisture.
RUNFLAT
CRANK HANDLE
2.
WARNING: Thorough tire inspection is critical. Continued use of worn or damaged tires could result in equipment damage, serious injury or death.
3. 4. 5. Inspect inside of tire for cord or belt separation and inner liner damage. Replace tire if damaged. Inspect tire bead for abrasions. Replace tire if damaged. Check for protruding objects inside tire which may not be visible from outside. If tire is punctured yet repairable, repair with internal (05710215) or external (05710216) tire repair kit. Check tread depth on tire. Tread should not be worn below level of wear bars (Figure 6-7). Markings on the sides of the tires (e.g., the letters TWI or a triangle) show the location of wear bars. Replace tire if tread is worn below wear bars or 3/32 inch (2.38 mm). Inspect runflat for splitting, cracking, wear, or excessive chafing. Damaged runflat performance will be nonexistent or greatly reduced. Replace runflat if damaged (Figure 6-6).
Figure 6-5: Runflat Compressor Operation

NOTE: Compress runflat by rotating the handle assembly in a clockwise direction. Rotate handle assembly counterclockwise to loosen. 19. Using runflat compressor, compress runflat. NOTE: It may be necessary to use a tire spoon and tire lube to remove runflat from tire. When using runflat compressor, it may be necessary to remove handle before removing runflat. 20. Remove runflat from tire and remove runflat compressor from runflat (Figure 6-6). 7. 6.
________________
6-5
8. 9.
Inspect outside of tire for sidewall damage. Replace tire if damaged. Inspect tread for puncture damage. If damage is too extensive for patch repair, replace tire.
CORE HOUSING VALVE INSERT O-RING
CAP
WARNING: O-ring sealing surfaces must be kept clean and free from rust and dirt. Failure to do so could cause the wheel assembly to separate under pressure causing serious injury or death.
10. Using wire brush, clean wheel attaching studs. Clean all dirt and foreign material from rim halves with soap and water and allow to air dry. Ensure O-ring sealing surfaces on rim halves are smooth and clean (Figure 6-8). 11. Inspect rim halves for cracks, bent sealing surfaces, or oversized mounting holes. Replace rim halves if cracked, bent, or if mounting holes are reamed.
WEAR BARS
VALVE CORE
LOCKNUT
WHEEL HALF LOCKNUT OUTER RIM HALF
O-RING
WHEEL HALF STUDS
O-RING SEALING SURFACE
INNER RIM HALF
Figure 6-7: Wear Bar Identification
00-S06-006
Figure 6-8: Two-Piece Rim Breakdown
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6-6
WARNING: Never use wheel assemblies with wheel half studs that are damaged, loose, or have stripped threads. Damaged studs can cause improper assembly which could cause individual fasteners to fail. Any of these situations could cause serious injury or death.
NOTE: When replacing a damaged wheel half stud, also replace two adjacent studs. 12. Inspect inner rim half for cracked, broken, rusted, pitted, bent, loose, or stripped studs. Replace damaged studs along with two adjacent studs. Failure to do so may result in equipment damage, personal injury or death. 13. Inspect valve core for cracks or deterioration. Replace valve core if damaged (Figure 6-8). 14. Inspect core housing for cracks or deterioration. Replace if damaged. 15. Inspect insert and cap for damage. Replace if damaged.
Assembly
WARNING: Never use tubes in the two-piece takeapart wheel assemblies. Use of a tube defeats built-in safety features of the wheel, and could cause the wheel to come apart under pressure, resulting in serious injury or death. Use only replacement parts specied in parts manual. Wheels assembled with components which do not meet specications could cause the assembly to separate under pressure, resulting in serious injury or death. To avoid injury ensure runat compressor strap is centered on runat.
1. Apply one 11-ounce tube of gel lubricant around inside of tire at crown area. Using clean brush, evenly spread gel lubricant 4 to 5 inches wide on tire crown area (Figure 6-10).
Repair
1. 2. If studs are damaged, drive studs out of inner rim half. Discard studs (Figure 6-9). Align splines on studs with splines in inner rim half and drive studs into inner rim half until shoulders seat against inner rim half.
WHEEL HALF STUDS
INNER RIM HALF
TIRE
CROWN AREA OF TIRE
4 TO 5 GEL LUBRICANT INCHES
Figure 6-10: Runflat Gel Lubricant Application

2. Position runflat compressor on an outer edge of runflat with handle assembly facing up and strap centered around runflat (Figure 6-11).
00-S06-008
Figure 6-9: Inner Rim Half Stud Removal
________________

5.
6-7
RUNFLAT RUNFLAT COMPRESSOR
6.
Insert runflat compressor side first as far as possible into tire. Lay tire flat on side. Slowly loosen compressor. Runflat should position itself inside tire. If not, repeat steps 4 through 6 and/or use a tire spoon to assist in installation.
CRANK HANDLE
NOTE: If required, clean and lubricate bearing assembly on runflat compressor after removal. 7. Remove runflat compressor from tire.
STRAP
Figure 6-11: Runflat Compressor Positioning

NOTE: Compress runflat by rotating the handle in a clockwise direction. Rotate handle counterclockwise to loosen. 3. 4. Using runflat compressor, compress runflat. Stand tire up and lubricate tire bead and runflat with tire lube (Figure 6-12).
RUNFLAT SHORTER FLANGE RUNFLAT TIRE
RUNFLAT
LONGER FLANGE
RUNFLAT COMPRESSOR
Figure 6-13: Runflat Positioning

8.
TIRE BEAD
9.
Lubricate O-ring seal with tire lube and install O-ring seal on first ledge of inner rim half. Ensure O-ring seal is not twisted and is uniformly positioned in the groove outside of the studs. Do not overstretch O-ring seal (Figure 6-14). Lubricate tire bead and rim bead seat areas with tire lube.
TIRE
Figure 6-12: Runflat Insertion

NOTE: It may be necessary to remove the handle assembly on runflat compressor before inserting runflat into tire. NOTE: Ensure shorter flange of runflat faces inner rim side of tire (Figure 6-13).
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6-8
NOTE: Before installing tire on inner rim half, inspect tire sidewalls for a paint dot. Paint dots are often used to indicate the tires light spot for balancing purposes. If paint dot is present, position tire on rim halves so that paint dot is aligned with insert hole on outer rim half. NOTE: The Wrangler GS-A, 37 X 12.50R16.5 LTD touring radial tire has a directional tire tread. The heavier, stiffer tread on the outside shoulder of tire must face outward when being installed. Before installing, inspect sidewall of tire and ensure SIDE FACING OUTWARDS imprint is facing outward (Figure 6-11). 10. Center runflat in tire. Carefully lower tire over inner rim half. Check to ensure O-ring seal has not been disturbed (Figure 6-14).
OUTER RIM HALF
CAUTION: Ensure the runflat is properly aligned with the valve stem in the wheel. Improper alignment can result in nonuniform bead pressure and improper runflat operation. 11. Ensure runflat is not binding on flat portion of inner rim half. Runflat should clear inner rim half. 12. Install valve core in core housing. NOTE: Perform the following step only if core housing and insert were removed. 13. Install O-ring into groove on insert. Install insert into valve hole of outer rim half with locknut. Tighten locknut to 40-60 lb-in (5-7 Nm). Apply thread-locking compound to core housing and thread valve bore into insert. Tighten core housing to 25-30 lb-ft (34-41 Nm).
WHEEL HALF LOCKNUT TIRE
RUNFLAT TIRE BEAD VALVE CORE CORE HOUSING INSERT
O-RING STUDS
O-RING SEAL
LOCKNUT INNER RIM HALF
ALIGNMENT HOLE
00-S06-009
Figure 6-14: Two-Piece Wheel with One-Piece Runflat Breakdown
________________

THICKNESS GAUGE STUD
6-9
CAUTION: Tighten locknuts gradually to avoid bending and/ or breaking studs, or damage to wheel components. NOTE: If vehicle is equipped with central tire inflation system, position shield mounting bracket on outer rim. 15. Line up alignment holes in both wheel halves and secure outer rim half on inner rim half with twelve locknuts. NOTE: If tire bead does not seat on the rim flange after inflation, deflate tire completely and remove from rim. Check to ensure that a 16.5 inch diameter tire is being used. Also check for bent or damaged components and replace if necessary. Lubricate tire bead and rim mating surfaces and reinstall tire on rim. NOTE: Never tighten locknuts when tire is in an inflated condition. This will result in less accurate torque. Tighten locknuts to proper torque specifications every 3,000 miles (4800 km). 16. Preliminarily tighten locknuts to 85 lb-ft (115 Nm) in tightening sequence shown (Figure 6-15).
INNER RIM HALF
5 9 3 12 8
7 11 4
Figure 6-16: Checking Wheel Stud Gap

10 2 6
S06-103.1
Figure 6-15: Locknut Tightening Sequence

17. Retighten locknuts to 125 lb-ft (170 Nm) in sequence shown. 18. Check wheel assembly for gaps at each stud. Use a 0.0015 inch (0.038 mm) thickness gauge to detect gaps. If gaps are detected, disassemble and reassemble wheel assembly and recheck for gaps. If gaps are still detected, replace inner rim half (Figure 6-16). 19. Install wheel half locknut covers.
WARNING: Never inate a tire without having checked wheel half locknut torques to ensure the wheel locknuts are tightened to specications. A wheel with improperly tightened locknuts could separate under pressure, resulting in serious injury or death. Always use a tire ination cage for ination purposes. Stand on one side of cage during ination, never directly in front. Keep hands out of the cage during ination. Inate tire to recommended pressure using a clip-on air chuck. Do not exceed 50 psi (345 kPa) cold ination pressure. Failure to follow these instructions may result in serious injury or death.
20. Place wheel in safety cage and inflate tire to recommended tire pressure. 21. Check for leaks around rim edges, insert, and core housing with soapy solution (Figure 6-17).
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CORE HOUSING
_______________
WHEEL HALF STUD REPLACEMENT

RIM EDGE INSERT
Removal
1. 2. Remove wheel from vehicle. Place wheel in tire inflation cage.
WARNING: Ensure the tire is totally deated before removing wheel locknuts. Failure to follow proper safety precautions may result in serious injury or death.
3. Remove valve core from valve bore and deflate tire. Run a wire through valve bore to ensure it is not plugged (Figure 6-18).
VALVE CORE WHEEL LOCKNUT VALVE BORE
Figure 6-17: Leak Check Areas
TIRE
Figure 6-18: Valve Core and Valve Bore

NOTE: When replacing broken rim stud(s), replace studs on both sides of broken stud(s). 4. When tire is fully deflated, loosen wheel locknuts on each side of the broken stud(s). If you hear escaping air, do not proceed. Wait until the sound stops and recheck valve bore. When you are certain tire is fully deflated, proceed to remove wheel locknut. Discard locknut. Drive studs out of inner rim. Discard studs (Figure 6-19).
5.

1. Using wire brush, clean remaining studs. Clean all dirt and foreign material from rim with soap and water and allow to air dry.
WARNING: Never use wheel assemblies with studs that are damaged, loose, or have damaged threads. Damaged studs can cause improper assembly, which could cause individual fasteners to fail. Any of these situations may result in serious injury or death.
______________
6-11
2.
Inspect inner rim for cracked, broken, rusted, pitted, bent, or loose studs, and studs with damaged, mutilated, or deformed threads. Replace defective parts (Figure 6-19). 1
5 9
STUD
7 11 4 10
3 12 8 2 6
S06-103.1
Figure 6-20: Wheel Half LockNut Tightening Sequence

6. Check wheel assembly for gaps at each stud. Use a 0.0015 in. (0.038 mm) thickness gauge to detect gaps. If gaps are detected, disassemble and reassemble wheel assembly and recheck for gaps. If gaps are still detected, replace outer rim half.
Figure 6-19: Wheel Half Stud
Installation
1. Align stud with splines in inner rim and drive stud into inner rim until stud shoulder seats against inner rim (Figure 6-19). Repeat step 1 for all studs being replaced.
2.
CAUTION: Tighten locknuts gradually to avoid bent and broken studs, or damage to wheel components will result. 3. Install locknuts on new studs.
WARNING: Never inate a wheel assembly without having checked wheel locknut torques to ensure the wheel locknuts are tightened to specications. An assembly with improperly tightened locknuts could separate under pressure, resulting in serious injury or death. WARNING: Always use a tire ination cage for ination purposes. Stand on one side of the cage during ination, never directly in front. Keep hands out of cage during ination. Inate assembly to recommended pressure, using a clip-on air chuck. Do not exceed 50 psi (345 kPa) cold ination pressure. Failure to follow these instructions may result in serious injury or death.
7. 8. 9. Place wheel in safety cage and inflate tire to the recommended tire pressure. Check for leaks around rim edges and valve bore with soapy water. Install wheel on vehicle.
NOTE: After replacing broken stud(s), all wheel locknuts must be re-torqued. 4. 5. Tighten locknuts to 85 lb-ft (115 Nm) in sequence shown (Figure 6-20). Tighten locknuts to 125 lb-ft (170 Nm) in sequence shown.
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_______________
RUNFLAT COMPRESSOR BELT REPLACEMENT

Installation
TIRE, ONE-PIECE ALUMINUM WHEEL (OPTION), AND TWO-PIECE RUNFLAT SERVICE

CAUTION: It is not recommended mixing one-piece wheel and runflat assemblies and two-piece take-apart wheel and runflat assemblies on the same vehicle. Runflat profiles differ between the two types of wheel assemblies.
Disassembly
1. Remove the center cap. If the vehicle is equipped with a Central Tire Inflation System (CTIS), perform steps a and b. a. Release the quick disconnect fitting located at the center of the geared hub spindle on all four wheels. b. Remove the 3/4 inch brass fitting from the center of the geared hub spindle on the wheel(s) to be worked on. 2. Remove wheel/tire assembly from vehicle. 3. Inspect geared hub spindle studs for bending, looseness, or stripped threads. Replace if damaged. 4. Inspect lug nuts for fatigue, stripped threads, or other damage. Replace if damaged. 5. Remove valve cap and core from air valve and deflate tire. Run a piece of wire through air valve to ensure it is not plugged.
COMPRESSOR BELT
Figure 6-21: Runflat Compressor Belt Replacement

NOTE: Belt overlap is to be positioned so that you have equal amount of belt on each side of the worm gear shaft assembly. Perform steps 1 and 2 for crank handle runflat compressor. 1. 2. Install belt on compressor with bolt and locknut (Figure 6-21). Loop free end of belt around retaining bracket (Figure 6-22).
WARNING: Balance weights contain lead. Wash hands after handling.

6. Remove balance weights from wheel if present. Discard balance weights. 7. Install wheel/tire assembly on tire machine. 8. Using tire machine break loose both tire beads. 9. Lubricate outside tire bead and use tire machine to remove bead from wheel flange. 10. Pull tire bead up away from wheel to expose runflat assembly. This can be accomplished with pry bars or a bead spreader devise (Figure 6-23).
BELT
RETAINING BRACKET
Figure 6-22:
Runflat Compressor Belt Installation
______________

Inspection and Cleaning
6-13
RETAINING SCREW WASHER LOCKING CLIP SQUARE NUT BEAD SPREADER CROSSBOLT RUNFLAT
Cleaning
1. 2. 3. Remove any existing lubricant that has been applied to the inside of the tire, using tire bufng solution. Clean all wheel, runflat and tire parts using tire buffing solution. Dry all wheel, runflat and tire parts. Ensure inside of tire and all wheel, runflat and tire parts are free of any runflat lubricant, dirt, rust or moisture.
Tire Inspection
1.
SIDE
00-S06-010
Figure 6-23: Runflat Removal

11. Remove the retaining screw,washer and crossbolt locking clip (Figure 6-24). 12. Loosen and remove the crossbolt and square nuts securing the runflat halves together. 13. Repeat steps 11 through 13 for opposing fastener assembly. 14. Reach inside the tire and remove runflat halves from the tire. 15. Lubricate the tire bead and remove the tire from the wheel.
Inspect tire for the following conditions or defects. Replace tire if damaged. a. Inspect inside of tire for cord or belt separation and inner crown area damage. b. Inspect tire bead for damage. c. Check for protruding objects inside tire which may not be visible from outside. If tire is damaged, repair with external (05710215) or internal (05710216) tire repair kit. d. Check tread depth on tire. Tread should not be worn below level of wear bars. Markings on the side of the tires (e.g., the letters TWI or a triangle) show the location of wear bars. Replace tire if tread is worn below bars or 3/32 inch (2.38mm).
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FAC
ING
AR TW
DS
Runat Inspection
1. Inspect runat for the following conditions or defects. Replace runat(s) if damaged. a. Splitting or separation of rubber from composite material. b. Wear or damage of outside rim or centering flange. c. Excessive chafing or particles of the tires steel belt embedded into runflat assemblies. d. Crossbolts for stress fatigue, cracks or thread damage. e. Square nuts for stress fatigue, cracks or other damage. f. Crossbolt locking clip and retaining screw for damage.
Wheel Inspection
1. Inspect wheel for the following conditions or defects. Replace wheel if damaged. a. Cracked or bent. b. Mounting bolt holes for stress fatigue, oversized holes, or other damage. c. Wheel flange for stress fatigue, deformation or other damage. d. Valve and insert for cracks or deterioration. Replace these items if damaged.
6-14
_______________
Assembly
NOTE: If tires are to be replaced allow new tires to reach room temperature (above 60) before mounting. This will make the tire more pliable and easier to work with. CAUTION: During assembly or disassembly, loose parts which are dropped inside the wheel/tire assembly must be re-
moved. Failure to do so could result in damage to wheel/tire assembly. 1. Apply one tube (approximately 11 ounces) of runat gel lubricant to inside crown area of tire. Using clean brush, evenly spread gel lubricant 4 to 5 inches wide on inner crown area.
SIDE
FAC
ING
00-S06-012
Figure 6-24: Runflat Installation
AR TW
DS
SCREW WASHER SQUARE NUT LOCKING CLIP RECESS
CROSS BOLT
______________
6-15
RETAINING SCREW LOCKING CLIP
21 MM
00-S06-013
Figure 6-25: Runflat Assembly

2. Position wheel on tire machine with outside facing up. Lubricate tire beads and mount inside tire bead on wheel. Ensure SIDE FACING OUTWARDS lettering faces up on GSA tires. Install the right and left square nuts in the recesses of one pair of runflat ends. When looking across the runflat to the opposite side, the R square nut should be in the right recess and the L square nut in the left recess (Figure 6-25). Start the cross bolt in one of the square nuts, then in the second nut and tighten until there is full engagement in both nuts. The thread engagement must be equal in both nuts. Using a bead spreader, insert the runflat halves in the tire. Align the gap between the second pair of runflat ends with one of the positioning fences on the wheel. Assemble the second pair of runflat ends as in steps 3 and 4 and adjust the gap between the runflat ends to 53/64" (21 mm). NOTE: The distance between the two runflat end gaps must remain equal to reduce the risk of imbalance. 8. Verify that the positioning fences are centered in the runflat end gaps and the gaps are equal. 9. Torque both cross bolts to 22 lb-ft (30 Nm) and install cross bolt locking clips, screws and washers. 10. Torque the locking clip screws to 30-35 lb-in (4-5 Nm). 11. Lubricate tire bead and mount tire bead on the wheel. NOTE: Before installing a new tire inspect tire sidewalls for a paint dot. Paint dots are often painted on tires to indicate the tires light spot for balancing purposes and may be located on either side of the tire. If paint dot is present, position tire on wheel so that paint dot is aligned with air valve on wheel. If paint dot is not on air valve side of tire, reference paint dot from other side of tire for proper positioning with air valve.
3.
4.
5. 6. 7.
WARNING: Always use a tire ination cage for ination purposes. Stand one side of cage during ination, never directly in front. Keep hands out of the cage during ination. Inate assembly to recommended pres-
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6-16
_______________
sure using a clip-on air chuck. Do not exceed 50 psi (345 kPa) cold ination pressure. Failure to follow these instructions may result in serious injury or death.
12. Before installing valve core, inflate tire to seat beads. Use of tire bead seater may be required. 13. Install valve core, inflate tire to recommended tire pressure and install valve cap. 14. Check for leaks around wheel edges, insert, and air valve with soapy solution. 15. Balance wheel/tire assembly with 15 oz. maximum weight. Refer to tire balance procedure in service manual if necessary. 16. Install wheel/tire assembly on vehicle. a. Roll wheel/tire assembly to the vehicle. b. Place the wheel/tire assembly on the geared hub spindle studs. c. Start the lug nuts by hand. d. Snug the lug nuts. e. Lower the vehicle. f. Torque the lug nuts evenly and sequentially to 110 lbft (149 Nm) (Figure 6-26). If the vehicle is equipped with CTIS perform these additional steps: g. Lubricate the threads on the CTIS fitting with teflon pipe sealant. h. Install the fitting in the geared hub spindle. i. Engage the quick disconnect fittings on all four wheels. 17. Install the center cap.
Figure 6-26: Lug Nut Tightening Sequence
______________
6-17
Inspecting Tire Tread Wear

Tire tread wear is a good indicator of tire balance and suspension condition. Unbalanced tires often cause cupped or scalRIGHT FRONT
loped tread wear patterns (Figure 6-27). Tire wear inspection should be performed for all vibration complaints. Resolve tire wear problems before continuing with diagnosis.
UNDERINFLATION
OVERINFLATION
MULTI-PROBLEM
RIGHT FRONT
TOE-IN WEAR
TOE-OUT WEAR
CAMBER WEAR OR CORNERING
Figure 6-27: Tire Wear Patterns
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6-18
_______________
WHEEL AND TIRE BALANCING

General
There are two types of tire and wheel balancing: static and dynamic. Static balance is the equal distribution of weight around the wheel circumference. Wheels that are statically unbalanced cause a bouncing action called vehicle shake and possible steering nibble or oscillation. This condition will eventually cause uneven tire wear (Figure 6-28).
NOTE: Most electronic off-vehicle balancers are more accurate than on-vehicle spin balancers. They are easy to use and give a dynamic (two-plane) balance. On-vehicle balancing is not recommended. When balancing off-vehicle, the wheel should be mounted to the balancer with a cone through the back side of the center pilot hole or by the wheel (spindle) stud holes. The spindle stud method is recommended for CTIS wheels.
Balancing
1. Remove wheel and tire assembly from the vehicle.
STEERING WHEEL NIBBLE
WARNING: Remove all stones and foreign material from the tire tread before spin balancing. Failure to follow this warning may result in injury.
ADD BALANCE WEIGHTS HERE
NOTE: Deposits of foreign material must be cleaned from the inside of the wheel and the tire tread to obtain a good balance. The tire should be inspected for obvious damage, then balanced according to the equipment manufacturers recommendations. 2. Mount wheel and tire assembly, curb side out, on dynamic balancer and start balance cycle (Figure 6-30).
HEAVY SPOT
DYNAMIC BALANCER
Figure 6-28: Static Imbalance Correction

Dynamic balance is the equal distribution of weight on each side of the centerline, so that when the wheel spins there is no tendency for it to move from side to side. Wheels that are dynamically unbalanced may cause wheel shimmy, vehicle shake or a steering wheel vibration called nibble or oscillation (Figure 6-29).
WHEEL AND TIRE ASSEMBLY STEERING WHEEL NIBBLE
CURB SIDE ADD BALANCE WEIGHTS HERE
Figure 6-30: Dynamic Balancer Mounting
HEAVY SPOT
Figure 6-29: Static Imbalance Correction
______________

WEIGHT CLIP WHEEL AND TIRE ASSEMBLY
6-19
3. 4.
Locate and mark wheel and tire assembly light spot on the tire (Figure 6-31). Record weight and position readings.
LIGHT SPOT
WEIGHT (CLIP-ON TYPE) LIGHT SPOT WHEEL
WHEEL
LIGHT SPOT WEIGHT (TAPE-ON TYPE)
Figure 6-31: Marking Wheel and Tire Assembly Light Spot NOTE: If more than 15 oz. of weight is required to balance the tire, wheel and runflat (if installed) assembly, rotate tire 180 on wheel. Tires on steel two piece wheels can be balanced using either adhesive backed tape-on or clip-on type balance weights. All aluminum wheel and tire assemblies require the use of tape-on weights only. Do not use wheel balancing liquids to balance wheel and tire assembly. Balancing liquids may be incompatible with and cause damage to wheel, tire, runflat, and CTIS components. NOTE: There is very little clearance between geared hubs and the inside diameter of the wheels. When installing tape-on balance weights on the inside diameter of the wheel, position the weights to afford adequate clearance to the geared hubs. 5. Attach balance weights to inner and/or outer edges of wheel (indicated by dynamic balancer), ensuring weight is centered on light spot, or weights are placed evenly to sides of light spot if more than one weight is used. When installing weight clips, use a small hammer or clipclawhammer tool. Tap weights to conform to wheel flange edge contour (Figure 6-32). Start balance cycle and repeat steps 3 through 5 until tire is properly balanced. Remove wheel and tire assembly from dynamic balancer and install on vehicle.
WHEEL AND TIRE ASSEMBLY
Figure 6-32: Balance Weight Placement
6. 7.
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_______________
TROUBLESHOOTING A NON-BALANCING WHEEL AND TIRE ASSEMBLY

NOTE: If a wheel and tire assembly cannot be balanced, or balance cannot be maintained, any of the following conditions may be causing the problem: Runflat movement on the wheel rim. Excessive radial or lateral runout condition of the wheel. Improper seating of tire bead on the wheel flange. NOTE: Perform the following if the runflat is moving on the wheel. If an excessive runout condition is suspected, proceed to Wheel Runout and Wheel and Tire Assembly Runout Inspection.
INBOARD SIDE
OUTBOARD SIDE
CHECK LATERAL RUNOUT HERE CHECK RADIAL RUNOUT HERE
RIM
Suspected Runat Movement Procedure

1. 2. 3. 4. 5. Disassemble wheel and remove runat from tire. Clean inside of tire, wheel, and O-ring seal with soap and water. Allow cleaned parts to dry prior to assembly. Apply runflat gel lubricant at crown area on inside tire area. Install runflat into tire and assemble wheel. Balance wheel and tire assembly. 8.
Figure 6-33: Wheel Runout Inspection Points Assemble and balance wheel and tire assembly (Figure 6-32). Every time a wheel and tire is assembled, it should be balanced.
NOTE: An improperly seated tire will cause runout. Inspect GG rings to be sure bead is properly seated. 9. Be sure that the tire is properly mounted and seated on the wheel. Check the distance between the GG rings on the tire and the wheel flange. The distance between the GG rings and the wheel flange should be the same (concentric) all the way around the tire (Figure 6-34). 10. Verify that GG rings are not recessed below the wheel flange at any point around the wheel. 11. If the GG rings are non-concentric with, or are recessed below the wheel flange, remove the tire from the wheel and reinstall. 12. Balance wheel and tire assembly.
RIM FLANGE GG RINGS
WHEEL RUNOUT INSPECTION

NOTE: It is suggested that the lateral runout check be done first, as excessive lateral runout can affect radial runout. 1. 2. Clean dirt, debris, or rust from wheel. Take measurements from inboard and outboard rim flanges for radial and lateral runout.
CAUTION: Never start the wheel balancer with the dial indicator in place. The checks should be done by slowly rotating the wheel BY HAND ONLY. 3. 4. 5. 6. 7. With wheel or wheel and tire assembly on wheel balancer, place magnetic base roller tip dial indicator in position. Slowly rotate the wheel one revolution and zero the dial indicator. Rotate the assembly one more complete turn and record the indicator reading (Figure 6-33). If measurement for lateral runout exceeds 0.060 inch (1.52 mm), replace the wheel. If measurement for radial runout exceeds 0.060 inch (1.52 mm), replace the wheel.
RIM GG RING
GG RING
TIRE BEAD PROPERLY SEATED
TIRE BEAD NOT SEATED
Figure 6-34: Checking Tire Bead Seating 4-1-00
______________

GEARED HUB
6-21
Wheel And Tire Assembly Runout Inspection

NOTE: Before measuring the runout of a tire and wheel assembly, drive the vehicle long enough to warm up the tires. Then do the following: 1. 2. 3. Install tire and wheel assembly on wheel balancer. Check GG rings to be sure tire bead is properly seated. Position a dial indicator with a magnetic base and a roller tip on the balancer so the different runout checks can be done (Figure 6-35). NEVER start the wheel balancer with the dial indicator in place. The checks should be done by slowly rotating the tire BY HAND ONLY on the tire balancer. Slowly rotate the assembly one complete turn and zero the dial indicator on the low spot. Rotate the assembly one more complete turn and note the amount of total runout.
SPINDLE
4.
5. 6.
DIAL INDICATOR
Figure 6-36: Geared Hub Spindle Runout Inspection
Geared Hub Spindle Runout Inspection

NOTE: In order to measure radial runout, it will be necessary to tape the center tread of the tire (Figure 6-35). Otherwise, the dial indicator stylus will catch in the tread lugs. 7. Measure at points 1 and 2 (Figure 6-35). The maximum allowable lateral and radial runout is 0.120 inch and 0.210 inch, respectively.
DIAL INDICATOR TAPE STRIP 2
Using a dial indicator, position the roller tip on the machined surface outside the bolts on the spindle face. Measure the runout using the following method: 1. Turn the spindle by hand to locate the low spot. 2. Zero the dial indicator. 3. Turn the spindle by hand to check the total lateral runout. 4. 0.005 inch is the acceptable lateral runout.
Measuring Geared Hub Spindle Stud Runout

Position the dial indicator roller to contact the wheel mounting studs. Ensure that the studs are fully pressed in, if not seat or replace the studs as necessary (Figure 6-37). Measure the runout using the following method: 1. Turn the spindle by hand to register on each of the studs. 2. Zero the dial indicator on the lowest stud. 3. Check the total runout on the remaining studs. 4. 0.030 inch is the acceptable radial runout.
GEARED HUB
4 3 1. Tire Lateral Runout Checkpoints 2. Tire Radial Runout Checkpoint 3. Wheel Radial Runout Checkpoints 4. Wheel Lateral Runout Checkpoints 3
Figure 6-35: Wheel and Tire Runout Checkpoints
STUD
Geared Hub Spindle and Stud Runout

When wheel and tire runout occurs on the vehicle but not in off-vehicle inspecting, the geared hub spindle and spindle studs should be checked for radial and lateral runout (Figure 6-36).
SPINDLE
Figure 6-37: Geared Hub Spindle Stud Runout Inspection

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4.
_______________
WHEEL ALIGNMENT
Check alignment on a rack with the front tires in the straightahead position and inflated to manufacturers recommended pressure.
Preliminary Inspection
1. 2. 3. Check tire condition, tread wear (Figure 6-27), run-out, and ination. Raise and support vehicle so wheels are free to rotate. Then secure the steering wheel in straight-ahead position. Check tie rods and upper control arms for distortion, play, or looseness (Figure 6-38). Replace worn, damaged parts before proceeding.
5.
Check upper ball joints: With the vehicle on the ground (being careful not to damage the boot), place the tip of a prybar between the steering knuckle and the ball joint boot (Figure 6-39). With the shank of the prybar contacting the upper control arm as shown, pry upward and note the movement of the ball joint against a ruler. Be careful to measure only the ball joint movement and not the flex of the control arm resulting from prying against it. Any upper ball joint with more than 1/16 (1.6 mm) movement should be replaced. Check geared hubs for spindle end play or side-to-side movement by grasping the edge of the tire and attempting to move the tire up and down.
NOTE: If the vehicle was previously lifted off the ground for other service, center the steering wheel, roll the vehicle forward and back to settle the suspension and relieve the tension on the ball joints before beginning checking procedure.
NOTE: If any spindle movement is apparent, adjust the spindle bearings.
CONTROL ARM BUSHING
UPPER CONTROL ARM
UPPER BALL JOINT
GEARED HUB
CONTROL ARM BUSHING TIE ROD STABILIZER BAR LOWER BALL JOINT
Figure 6-38: Suspension Inspection Components
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6-23
PRYBAR CONTACT POINT
8.
6 5 4 3 2 1
9.
10. 11.
MEASURE MOVEMENT HERE
12.
Figure 6-39: Upper Ball Joint Wear Check

6. 7. Inspect control arm bushings for wear or damage. Replace bushings if necessary. Check lower ball joints: Support lower control arm with a jack or stand to unload lower ball joint. Place bar between lower arm at ball joint and geared hub and measure vertical play obtained by moving pry bar down 13. 14. 15.
(Figure 6-40). Maximum play should not exceed 1/8" (3.5 mm). Replace ball joint if end play exceeds the limit. Check steering center link, idler arm and tie rod ends for wear or damage (Figure 6-41). Replace parts as needed before proceeding. Check idler and steering arms by pulling the center link vertically up and down with a 50 lb. spring scale. Maximum allowable movement is 1/4 inch (7 mm), 1/8 inch (3.5 mm) up or down, when pulled within 2 inch (51 mm) of ball stud. Lower the vehicle. Check tie rod end wear by trying to move the tie rod vertically and horizontally. Replace the tie rod end(s) if any movement is apparent. Inspect the center link for distortion. Center link deformation will cause excessive front wheel toe. If center link deformation is suspected, remove the suspect center link from the vehicle and place it on a level surface next to a new center link. Carefully compare the two parts, checking for distortion and tapered hole wear. Replace the suspect center link if tapered holes are worn or if the center link is distorted. Check the center link and stabilizer bar for cracks or distortion. Replace if necessary. Inspect the stabilizer bar bushings for excessive wear and/ or distortion. Replace if necessary. Check the steering gear for looseness-to-frame, proper
PRYBAR
Figure 6-40: Lower Ball Joint Wear Check
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STABILIZER BAR HALFSHAFT IDLER ARM
_______________
PITMAN ARM
TIE ROD END ADJUSTING SLEEVE
TIE ROD GEARED HUB TIE ROD
CENTER LINK SPRING SCALE
Figure 6-41: Suspension Component Identification
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4. 5.
6-25
CHECKING WHEEL ALIGNMENT

1. 2. 3. Move vehicle onto alignment rack and position front tires on alignment rack turntables. Place front wheels in straight ahead position on turntables. Install alignment measuring equipment on vehicle wheels. Follow manufacturers instructions to avoid incorrect measurements.
Measure and record caster, camber, toe-in, and toe-out. Refer to alignment specifications (Figure 6-42). If alignment angles are within specified limits, move vehicle from rack. However, if angles are incorrect, leave vehicle on alignment rack and proceed to Wheel Alignment Correction.
SERVICE WHEEL ALIGNMENT

SERVICE CHECKING SUSPENSIO N POSITION TIRE PRESSURE (PSI) CASTER (DEGREES) CAMBER (DEGREES) TOE-TOTAL (DEGREES) CASTER (DEGREES) SERVICE SETTING CAMBER (DEGREES) TOE-TOTAL (DEGREES)
FRONT
26
+1.5 to +4.0 (B)
-0.2 to +1.75 (B) -0.2 to +1.75 (B)
0 to +0.25 (C)
+2.5 to +3.5 (A) na
+0 to +0.50 (A) +.25 to +0.75 (A)
0 to +0.19 (C&E) -0.19 to 0 (D&E)
REAR
28 na
-0.25 to 0 (D)
To measure in inches, 0.1 degree = 1/16", 0.19 degrees = 1/8", 0.25 degrees = 5/32 (A) Left and right side to be equal within 0.5 degrees. (B) Left and right side to be equal within 1.0 degrees. (C) Toe-in (Positive sense) left and right sides to be set separately and evenly per wheel. Steering wheel must be held in a center position within + or - 5 degrees (D) Toe-out (negative sense) left and right side to be set separately and evenly per wheel (E) Left and right side toe settings to be equal within 0.10 degree NOTE: Alignment settings should be checked and adjusted on a rack that allows all four wheels/tires to support vehicle weight. Set wheel alignment while the vehicle is in its normally loaded condition. Vehicles which are consistently operated with heavy on-board loads should have alignment adjusted with the vehicle under heavy on-board load. Ride height should be checked and corrected if necessary and the hood should be closed while taking measurements (See Suspension Height Measurement Section 9).
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.

TOE-IN (+) (POSITIVE SENSE)
_______________
TOE-OUT (-) (NEGATIVE SENSE)
FRONT
REAR
NEGATIVE (-) CAMBER
POSITIVE (+) CAMBER
POSITIVE (+) CASTER
Figure 6-42: Wheel Alignment Information
WHEEL ALIGNMENT CORRECTION

Alignment adjustments should be performed one at a time and in sequence to avoid errors. Recommended adjustment sequence is: a. caster b. camber c. front toe setting d. rear toe setting e. steering stops (See Section 8) Leave the vehicle on the alignment rack for each of the adjustment procedures. This way, angle correction can be monitored continuously during actual adjustment. 4. Adjust caster angle by turning the eccentrics on the upper control arm brackets in opposite directions (Figure 6-43). Preferred caster is +2.5 to +3.5 degrees and left-right variation must not exceed 0.5 degree. Turning the front eccentric outward and the rear eccentric inward increases positive caster while turning the front eccentric inward and the rear outward decreases it. Shims are available in 0.060 inch and 0.120 inch (1.5 and 3.0 mm) thicknesses for use behind the control arm mount brackets if the proper angles cannot be achieved with the use of the eccentrics alone. This would be an unusual situation and the vehicle should be inspected thoroughly for bent or worn parts before installing shims. Tighten control arm pivot bolt nuts to 260 lb-ft (359 Nm) torque. Verify correct caster angle at both front wheels. Be sure side-to-side caster variation does not exceed 0.5 degree. Leave vehicle on rack for camber and toe adjustments.
Caster Adjustment
Caster adjustment applies to the front wheels only. It is controlled by turning the pivot bolts and eccentric washers on the upper control arm brackets (Figure 6-43). A positive caster angle is required on all Hummer vehicles. Preferred caster angle is +2.5 to +3.5 degrees. Maximum allowable side-to-side variation is 0.5 degree. 1. Support the vehicle weight with the tires on the turntables. 2. Loosen upper control arm pivot bolt locknuts by holding the bolt head and turning the locknut to allow movement of the bolts (Figure 6-43). 3. Pry the upper control arm brackets open to allow freedom of movement of the control arm bushings. The edges of the control arm bushings are serrated and will be difficult to move if the brackets are not pried open. 5. 6. 7.
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ECCENTRIC FLAT WASHER PIVOT BOLT NUT
6-27
PIVOT BOLT
UPPER CONTROL ARM
UPPER CONTROL ARM BRACKET BUSHING ECCENTRIC REFERENCE HOLE
Figure 6-43: Caster /Camber Adjustment
Camber Adjustment
Camber adjustment applies to the front and rear wheels equally. It is controlled by turning the pivot bolts and eccentric washers on the upper control arm brackets (Figure 6-43). Preferred camber for all Hummer vehicles is zero to +0.5 degree at the front and +0.25 to +0.75 degrees at the rear. Maximum allowable side-to-side variation is 0.5 degree front and rear. 1. Support the vehicle weight with the tires on the turntables and leave the hood closed. 2. Loosen upper control arm pivot bolt nuts by holding the bolt head and turning the nut to allow movement of the bolts (Figure 6-43).
3.
4.
Pry the upper control arm brackets open to allow freedom of movement of the control arm bushings. The edges of the control arm bushings are serrated and will be difficult to move if the brackets are not pried open. Adjust camber angle by rotating the front eccentric of the upper control arm bracket (Figure 6-43). Rotating the front eccentrics inward decreases camber (negative direction) while rotating the front eccentrics outward increases camber (positive direction). Rotating the rear eccentrics of each upper control arm inward or outward in conjunction with the front eccentrics will help maintain the previously set caster angle. Tighten control arm pivot bolts to 260 lb-ft (359 Nm) torque.
5.
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6. 7.
_______________
Verify correct camber angle at both front wheels. Be sure side-to-side variation does not exceed 0.5 degree. Leave vehicle on rack for toe settings and steering stop adjustment.
Rear Wheel Toe Adjustment

1. 2. 3. 4. Position both rear wheels on alignment rack turntables. Loosen clamps on both radius rods (Figure 6-45). Turn the adjusting sleeves until toe measurement is within specifications. Tighten clamp nuts and verify toe adjustment.
UPPER CONTROL ARM
Front Wheel Toe Adjustment

1. Position both front wheels on alignment rack turntables. Set the front wheels in the straight-ahead position and center the steering gear. Loosen adjusting sleeve clamps on both tie rods (Figure 6-44). Turn sleeves until toe measurement is within specifications. Tighten the adjusting sleeve clamp nuts and verify correct toe adjustment.
2. 3. 4.
CAUTION: Be sure that the bolt and nut on the adjusting sleeve clamp nut nearest to the geared hub is facing the halfshaft. The bolt and nut on the adjusting sleeve clamp nearest to the frame must be facing away (180 degrees) from the stabilizer bar. After adjustment, the lengths of both tie rod end assemblies should be the same, plus or minus 1/16 inch (1.6 mm). CAUTION: The sleeve clamps must be positioned between 3/16 and 5/16 from the end of the sleeve and the bolt and nut torqued to 30 lb-ft (41 Nm) (Figure 6-46).
CLAMP CLAMP RADIUS ROD ADJUSTING SLEEVE
SLEEVE CLAMP SLEEVE CLAMP
Figure 6-45: Rear Wheel Toe Adjustment Points
TORQUE TO 30 LB. FT.
TIE ROD ADJUSTING SLEEVE
Figure 6-44: Front Wheel Toe Adjustment Points 5. Verify that steering wheel is centered. Move steering wheel to the straight-ahead position if necessary.
3/16-5/16
Figure 6-46: Sleeve Clamp Position
4-1-00
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6-29
STEERING STOP ADJUSTMENT

NOTE: Alignment equipment currently used in the automotive field should be used for steering stop adjustment procedure. This procedure should be followed if alignment equipment is not available. Removal
1. 2. Loosen jamnut and remove bolt and jamnut from geared hub (Figure 6-47). Remove jamnut from bolt.
RIM LINE C 36 34 LINE B LINE A LEFT FRONT TIRE
TIE ROD CLAMP
JAMNUT GEARED HUB WHEEL STOP
LEFT REAR TIRE
Figure 6-47: Steering Stop Adjustment
Installation
1. 2. 3. Apply thread-locking compound to bolt (Figure 6-48). Thread jamnut on bolt. Secure bolt and jamnut to geared hub. Tighten bolt finger tight. 5. 6. 7. 8.
Figure 6-48:
Checking Alignment
Adjustment NOTE: Prior to adjustment, ensure length of each tie rod is the same. If tie rod lengths are not the same 1/8 in. (3 mm), check toe-in alignment setting.
1. 2. 3. 4. Draw a reference chalk line 30 feet long. Mark this line A (Figure 6-48). Position vehicle so that center of left rear and left front tires are positioned directly on reference line A. Using a protractor, draw a reference line at 34 degrees from line A. Mark this line B. Again, using a protractor, draw a reference line at 36 degrees from line A. Mark this line C.
9. 10. 11. 12. 13.
Roll vehicle forward until center of left front tire is over intersection of lines A, B, and C. Turn steering wheel full left. If centerline of front and rear of left front tire is over area between lines B and C, no adjustment is necessary. If centerline of front and rear of left front tire is not over area between lines B and C, loosen jamnut and turn bolt all the way in. Turn steering wheel until centerline of front and rear of left front tire is over area between lines B and C. Unscrew bolt until head makes contact with wheel stop on lower control arm (Figure 6-47). Secure bolt with jamnut. Check for clearance between tie rod clamp and the rim. Repeat adjustment procedure for opposite side.
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RADIAL TIRE
_______________
CENTRAL TIRE INFLATION SYSTEM

The optional Central Tire Inflation System (CTIS) is unique to the HUMMER. The CTIS allows the driver to increase or decrease tire pressure based on terrain and climate conditions. The system can also be used to direct air to a tire that has a leak. The CTIS controls are located on the instrument panel. An inflate/deflate switch determines if air is added to the tires or released from the tires. When the tires are being inflated, an indicator light on the instrument panel illuminates. If the pressure in any of the tires drops to 8 psi (55 kPa) or below, the low pressure indicator light will illuminate and an alarm will sound. If the tire pressure ever exceeds 55 psi (379 kPa), a relief valve automatically relieves any excess pressure. The tire selector valve position determines whether the pressure in the front, rear or all four tires will be adjusted. The air pressure gauge indicates the current pressure in the tires. Refer to the short, white needle for front tire pressure and the longer, orange needle for the pressure in the rear tires. Temperature rise and fall affects air pressure in a tire. As the vehicle is operated it is typical for the air pressure to rise 3-5 psi (21-34 kPa). As the wheels and tires cool down, the air pressure will drop. This is normal and such a drop in tire pressure does not indicate any leaks in the system. The CTIS consists of an electric air compressor that pumps air through a series of valves, tubes, and hoses to the front and/or rear tires. Compressed air travels through the manifold where three electric valves connected in parallel direct the compressed air to the front, rear or both tires. When deflation is selected, air is routed from the tires through the three electric valves and is exhausted through the deflate valves (Figure 6-49). Each wheel assembly has a manual quick-disconnect valve which can be used to prevent air flow to and from the tire, such as during long-term storage or while changing a tire. If the vehicle will remain dormant for two weeks or more, it is a good practice to disconnect the system at the wheels. These quickdisconnect valves are also used to restrict air flow to the operational tires when the driver wants to direct air flow to a damaged tire. For example, if a tire has a small puncture and has a leak, the quick-disconnect valves on the operational tires can be disconnected, enabling compressed air to be directed exclusively to the leaking tire. This may maintain enough tire pressure in the leaking tire to allow the driver to get the vehicle to an appropriate location for safe tire repair or replacement (Figure 6-50).
1-PIECE RUNFLAT BEADLOCK
HALFSHAFT
WHEEL QUICK DISCONNECT FITTING
AIR SEAL
SPINDLE PASSAGE
FROM COMPRESSOR
Figure 6-49: Central Tire Inflation System (CTIS)
SPINDLE
TUBE SHIELD
Figure 6-50: Quick-Disconnect Valve To disconnect the CTIS from the wheel assemblies, first turn inflate/deflate switch to the OFF position. Release the four quick-disconnect valve assemblies from all four spindles by depressing the quick-disconnect valve tabs attached to the valve spindle nuts (Figure 6-51). When the tabs are depressed, the valve assemblies will spring away from the spindles about 1/2 inch (12.7 mm). To reconnect the quick-disconnect valve assemblies, push the valve assemblies toward the spindles until they click into place.
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CTIS TROUBLESHOOTING
6-31
QUICKDISCONNECT VALVE ASSEMBLY
VALVE SPINDLE NUT
The following pages contain troubleshooting information for locating and correcting mechanical, pneumatic, and electrical problems that may develop with the CTIS.
Electrical Troubleshooting
Symptoms are listed for system malfunctions, and procedures and corrections are diagramed to assist service technicians.
TUBE SHIELD
Figure 6-51: Quick-Disconnect Tab
Figure 6-52: Pneumatic Diagram for Central Tire Inflation System

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_______________
CTIS AIR LEAK TROUBLESHOOTING

This section contains troubleshooting information for locating and correcting air leaks within the Central Tire Inflation System.
WARNING: CTIS air system components are subject to high pressure. Always relieve air pressure before loosening or removing air system component(s) by disconnecting the quick-disconnect valve assemblies at each wheel end. Failure to follow this warning may result in serious personal injury.
10. Check the air pressure in each tire and compare it to the information taken earlier. Note any air pressure loss and concentrate on that tire position. Refer to Troubleshooting Chart 5 Tire and Quick-Disconnect Valve in this Section.. If no air loss is detected, there may be a small leak which will require an overnight evaluation. NOTE: Always complete the entire troubleshooting procedure to ensure that all potential leak points have been corrected.
Verification
After completing the troubleshooting procedure, verify the system by repeating the CTIS Troubleshooting checklist steps.
CTIS Troubleshooting Checklist

1. 2. Fill all tires to at least 40 psi (270 kPa) using the on-board compressor or shop air source. Note the needle positions on the air gauge. If the needles are not even, line them up by inflating the lower pressure tires. Then return the inflate/deflate switch to OFF.
NOTE: The tires are isolated from the rest of the system so that the areas between the compressor selector valve and geared hubs and selector valve can be isolated and checked. 3. 4. 5. Isolate each tire and wheel assembly by disconnecting each quick-disconnect valve. After tires have been isolated, measure and record each tires air pressure. After a minimum of 10 minutes, check to see if the air gauge needles have moved.
WARNING: CTIS air system components are subject to high pressure. Always relieve air pressure before loosening or removing air system components(s) by disconnecting quick-disconnect valve assemblies at each wheel end. Failure to follow this procedure may result in serious personal injury.
NOTE: Leaks can be detected by using soapy water, but commercially available leak detection liquids such as Gaz-Tec work best. Most leaks can be corrected by tightening fittings. Replace the fittings or air lines only when necessary. 6. Determine if the front, rear, or both air systems have leaked. If a leak is detected, concentrate on that area and follow the appropriate troubleshooting chart. Geared Hubs, Seals, and Fittings - Chart 1 Deflate Valve Area - Chart 2 Under Vehicle Air Leak - Chart 3 After checking and repairing leak points, place the selector switch in the BOTH position. Note the gauge needle positions. Reposition or re-inflate to align the needles. Wait at least two minutes and check to see if the needles have moved. If movement is detected, concentrate on detecting the leak point. Follow Refer to Troubleshooting Chart 4 Air Compressor Leak Test in this Section..
7. 8. 9.
NOTE: If tires were hot, air loss may be a result of the tires cooling down. If this is the case, all tires should lose about the same amount of air.
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Troubleshooting Chart 1 Geared Hubs, Seals and Fittings
Inspect the steering arm cover, connector, and tube for damage. Use a soap and water solution or a commercial leak detection product around the connector and steering arm cover.
Damage is found
Replace the connector or tube.
Air is leaking around the connector or tube end.
Loose Component
Tighten the connector, hose clamp or tube fitting.
Leak continues
Remove the connector from the tube and steering arm cover. Inspect connector and tube fitting for damage (frays, stripped threads, cracks, or breaks).
Damage is found
Apply new thread sealant and install connector to steering arm cover and tube fitting or tube.
Air is leaking around steering arm cover.
Remove the vent line and determine if air is escaping. If so, steering arm cover seal is damaged. Replace seal if damaged Damage is found
Steering arm cover seal or extension may need replacement. Remove steering arm cover and inspect the seal for damage (Figure 6-78).
If air is in hub, replace seal.
Replace part if damaged
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_______________
Troubleshooting Chart 2 Deflate Valve Area
Inspect the deate valve and connections for damage (Figure 6-65). Use a soap and water solution to check for leaks.
Air is escaping from the dust excluder or the seams on the Deflate Valve (Figure 6-66).
Replace the deflate valve.
Leaks
Air is escaping from the sides of the check valve.
Replace the check valve.
Tighten all suspect connections. If this fails to seal the air leak, take the connections apart, clean, apply new sealant, and tighten.
Troubleshooting Chart 3 Under Vehicle Air Leak
Follow the CTI lines under the vehicle. Inspect for damage. Use a soap and water or commercial leak detection solution to detect air leaks.
Tighten all suspect connectors. If this fails to stop the air leak, remove the suspect part (elbow, fitting or connector) and inspect the threads for stripping. Clean, apply new pipe sealant, and install into the CTI system.
Troubleshooting Chart 4 Air Compressor Leak Test
Inspect all fittings, tees, valves and hoses connected to the compressor (Figure 6-53). Use soap and water or commercial leak detection product to detect leaks. Air is leaking If air is leaking from a fitting, tee, elbow or tube connection, tighten the part. If leak persists, remove the CTI part, clean, apply new sealant to the threads and install the CTI part.
Check the relief valve to ensure air is not leaking from the relief valve stem area.
Air is leaking
Replace the relief valve.
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6-35
Troubleshooting Chart 5 Tire and Quick-Disconnect Valve
Inspect the quick-disconnect valve, quick-disconnect valve nut, tube, nut and sleeve assembly, insert, and elbow for damage (Figure 6-76).
Quick-disconnect component is frayed, stripped, cracked, or broken.
Replace the component.
Tighten all connections. If air is still leaking, remove the CTI part, clean, apply new sealant to the threads, and install the CTI part.
Inspect the tire for punctures and rim leaks. Use a soap and water solution to check for air leaks around the rim of the tire. Repair or replace the tire as necessary.
CTIS Leak Detection Test

1. 2. 3. 4. 5. Start engine and inate front and rear tires to 40 psi (276 kPa). Turn the tire selector switch to OFF. Turn engine OFF. Remove air vent line located at the air intake horn and listen for air escaping through the vent line. Remove the transmission dipstick from the dipstick tube and listen for air or transmission fluid escaping through the dipstick tube. If air or fluid is detected in steps 4 or 5, inspect the steering arm cover seals using the CTIS leak isolation test.
CTIS Leakdown Testing

NOTE: Suspected air loss in the CTIS after the vehicle has been parked for several days may be attributed to one of the following: improperly seated O-rings, loose air line connection(s), quick-disconnect valve(s) not connected, tire leak(s), faulty valve(s), or a faulty steering arm cover seal. Suspected air leak(s) may be detected using a soap/water solution or equivalent. O-rings that appear to be cut, distorted, or suspected of leaking should be replaced. When traversing off road in extremely muddy terrain, the dust excluder should be inspected for trapped mud. 1. 2. 3. 4. 5. 6. Verify quick-disconnect valves are connected to wheels. Apply parking brake. Start engine and allow to idle. Place tire selector switch to BOTH position and inflate/ deflate switch to INFLATE position. Observe air pressure gauges until air pressure reaches 40 psi (276 kPa). Place inflate/deflate switch to OFF position. Stop engine. Record tire pressure on instrument panel gauges and rightrear tire pressure. Compare recorded pressures to readings taken 30 minutes later, If more than one (1) pound has leaked, check system as described above to detect where the leak is located.
6.
CTIS Leak Isolation Test

1. Start the engine and inate front and rear tires to 40 psi (276 kPa). 2. Turn the tire selector switch to OFF. 3. Turn engine OFF. 4. Close (release) all four wheel quick-disconnect valves. 5. Remove the vent line from one geared hub. 6. Open (engage) the quick-disconnect valve at this wheel to allow air pressure from the tire to enter bored passage inside the geared hub. 7. Listen for escaping air around the steering arm seal through the geared hub vent opening. 8. If air is escaping through the vent line fitting, replace the steering arm seal (Section 16). 9. Inspect the other three geared hubs using steps 5, 6, 7, and 8 above. 10. Replace defective seals as required, then retest system.
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COMPRESSOR SERVICE
WARNING: CTIS components are subject to high air pressure. Always relieve air pressure before loosening or removing air system components by disconnecting quick-disconnect valve assemblies. Failure to follow this warning may result in serious injury.

Clean and inspect compressor, leads, fittings, and mounting hardware. Check for cracks, frayed wire, stripped threads, and improper operation. Replace defective parts.
Installation
CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to all threads before installation. 1. 2. 3. 4. 5. 6. 7. Install compressor on bracket with two clamps. Connect compressor-to-air manifold hose to street tee. Connect air intake hose to fitting and secure with hose clamp. Connect power and ground leads to compressor. Check for correct operation. Check for leaks. Lower and secure hood.
Removal
1. 2. 3. 4. 5. 6. Raise and secure hood. Disconnect power and ground leads from compressor (Figure 6-53). Loosen clamp securing air intake hose to fitting and disconnect hose from fitting. Disconnect compressor-to-air manifold hose from street tee at compressor. Loosen two clamps securing compressor to bracket and remove compressor. Remove street tee from compressor.
AIR INTAKE HOSE
STREET TEE UPPER BRACKET ISOLATOR
COMPRESSOR-TO-AIR MANIFOLD HOSE
9-S06-001
Figure 6-53: CTIS Compressor
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6-37
CTIS INSTRUMENT CLUSTER

NOTE: Prior to removal, tag all leads for installation.
Disassembly
1. 2. Remove inate/deate switch and tire selector switch. Remove air pressure gauge.
Assembly
1. 2. Install air pressure gauge. Install inflate/deflate switch.
Removal
1. Remove screws and CTIS instrument cluster panel from instrument panel (Figure 6-54).
Installation
1. Secure CTIS instrument cluster panel to instrument panel
SWITCH CONNECTOR
SCREW
TIRE SELECTOR SWITCH
INFLATE/ AIR PRESSURE DEFLATE SWITCH GAUGE
Figure 6-54: CTIS Instrument Cluster Appearance (Viewed from Behind)
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INFLATE/DEFLATE AND TIRE SELECTOR SWITCHES

Removal
1. 2. 3. Remove CTIS instrument cluster panel. Disconnect connector from inflate/deflate switch and tire selector switch (Figures 6-54 and 6-55). Remove inflate/deflate and tire selector switches from CTIS instrument cluster and housing.

Clean and inspect inflate/deflate and tire selector switches for damage. Replace defective parts.
Installation
1. 2. 3. 4. Install inate/deate and tire selector switches in housing on CTIS instrument cluster (Figure 6-55). Connect connector to switches. Install CTIS instrument cluster panel. Start engine and ensure switches operate properly.
CTIS CLUSTER PANEL
TIRE SELECTOR SWITCH
INFLATE/DEFLATE SWITCH
Figure 6-55: Inflate/Deflate Switch And Tire Selector Switch
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6-39
COMPRESSOR/LOW PRESSURE INDICATOR LIGHTS

Removal
1. 2. 3. 4. Remove lower closeout panel and swing steering column down. Loosen center console and pull back to allow removal of left crash pad. Pull instrument panel back to gain access to the back of the status centers. Turn lamp one quarter turn, and remove lamps from sockets.
Clean and inspect indicator lamps for damage. Replace defective parts.
Installation
1. 2. 3. 4. 5. Install lamps in sockets and turn one quarter turn (Figure 6-56). Install instrument panel. Install left crash pad and center console. Install steering column and lower closeout panel. Start engine, and operate CTIS system to ensure lamps and switch operate properly.
BACKSIDE OF INSTRUMENT PANEL
BULB HOLDER
STATUS CENTER STATUS CENTER
SPEEDOMETER
9-S06-015
Figure 6-56: Compressor/Low Pressure Indicator Lights
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AIR PRESSURE GAUGE


Clean and inspect air pressure gauge and lamp. Check for cracks and stripped threads. Replace defective parts. CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation.
Removal
1. 2. 3. 4. Remove CTIS instrument cluster panel. Remove lamp from air pressure gauge (Figure 6-57). Disconnect two air pressure indicator lines from air pressure gauge. Remove two nuts, lockwashers, air pressure gauge, and bracket from CTIS instrument cluster (Figure 6-57). Discard lockwashers.
Installation
1. Install air pressure gauge and bracket on CTIS instrument cluster with two nuts and lockwashers. Tighten nuts to 8 lb-in. (0.9 Nm) (Figure 6-57). Connect two air pressure indicator lines to air pressure gauge. Install lamp in air pressure gauge. Install CTIS instrument cluster panel. Start engine and ensure air pressure gauge operates properly.
2. 3. 4. 5.
AIR PRESSURE INDICATOR LINES
PRESSURE GAUGE LAMP
AIR PRESSURE GAUGE BRACKET
AIR PRESSURE GAUGE SCREW
Figure 6-57: Air Pressure Gauge
______________

Installation
1. 2. 3. 4. 5.
6-41
AIR PRESSURE GAUGE LAMP REPLACEMENT

Removal
1. 2. 3. 4. Remove lower closeout panel and swing steering column down. Loosen center console and pull back to allow removal of left crash pad. Pull instrument panel back to gain access to the back of the status centers. Turn lamp one quarter turn, and remove lamps from sockets.
Install lamps in sockets and turn one quarter turn (Figure 6-56). Install instrument panel. Install left crash pad and center console. Install steering column and lower closeout panel. Start engine, and operate CTIS system to ensure lamp and switch operate properly.
AIR PRESSURE GAUGE LAMP
AIR PRESSURE GAUGE
Figure 6-58: Air Pressure Gauge Lamp
05745159
6-42

Installation
1. 2.
_______________
CTIS LOW PRESSURE ALARM REPLACEMENT

Removal
1. 2. Remove the interior fuse box access panel in the left closeout panel under the instrument panel. Remove the low pressure alarm from the face of the interior fuse box (Figure 6-59).
Install low pressure alarm on the interior fuse box. Install the fuse box access panel in the left closeout panel.
INTERIOR FUSE BOX
LOW PRESSURE ALARM
Figure 6-59: Low Pressure Alarm Location
______________

6-43
CTIS INTERIOR HARNESS

NOTE: Prior to removal, tag all leads for installation.
Removal
1. 2. 3. 4. Remove CTIS instrument cluster panel. Disconnect connector from inflate/deflate and tire selector switches (Figure 6-60). Remove lamp from air pressure gauge. Disconnect harness connector from I/P harness connector and remove interior harness.
Clean and inspect CTIS harness and connectors. Check for defects such as frayed wires and cracks. Repair or replace defective parts.
Installation
1. Position interior harness in approximate mounting location and connect harness connector to I/P harness connector (Figure 6-60). Install lamp in air pressure gauge. Connect connector to inflate/deflate and tire selector switches. Install CTIS instrument cluster panel.
2. 3. 4.
CTIS INTERIOR HARNESS
I/P HARNESS CONNECTOR
SWITCH CONNECTORS
TIRE SELECTOR SWITCH SCREW AIR PRESSURE GAUGE INFLATE/ DEFLATE SWITCH
Figure 6-60: CTIS Interior Harness Appearance
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6-44

Removal
1. 2.
_______________
AIR PRESSURE SWITCH REPLACEMENT

NOTE: Front and rear air pressure switches are replaced similarly.
Disconnect harness leads from air pressure switch. Remove air pressure switch from manifold.
CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components.
Installation
1. 2. Apply sealant to threads and screw air pressure switch into manifold. Connect harness leads to air pressure switch.
HARNESS LEADS
FRONT AIR PRESSURE SWITCH
REAR AIR PRESSURE SWITCH
MANIFOLD
9-S06-014
Figure 6-61: Air Pressure Switch Locations
______________
6-45
AIR PRESSURE INDICATOR LINES REPLACEMENT

CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation.
Installation
1. 2. Connect air pressure indicator lines to air pressure gauge (Figure 6-62). Install CTIS instrument cluster panel.
Removal
NOTE: Replacement procedures for the front and rear air pressure indicator lines are basically the same. This procedure covers the front air pressure indicator line. 1. 2. Remove CTIS instrument cluster panel. Disconnect air pressure indicator lines from air pressure gauge (Figure 6-62).
AIR PRESSURE GAUGE
AIR PRESSURE INDICATOR LINES
Figure 6-62: Front Air Pressure Indicator Line

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_______________
CTIS COMPRESSOR FUSE REPLACEMENT

Removal
1. 2. 3. Raise and secure hood. Remove the left side cowell cover and the fuse box cover. Remove the fuse from the box (Figure 6-63).
CTIS COMPRESSOR RELAY REPLACEMENT

Removal
1. 2. 3. Raise and secure hood. Remove left cowl cover and fuse box cover. Remove relay from fuse box (Figure 6-64).
Installation
1. 2. 3. Install the fuse in the fuse box (Figure 6-63). Install the plastic cover on the fuse box and install the left cowl cover. Lower and secure the hood.
Installation
1. 2. 3. Install relay in fuse box (Figure 6-64). Install fuse box cover and left cowl cover. Lower and secure hood.
CTIS 30
CTIS PUMP RELAY RELAY

9-OM5-004
CTIS
FUSE
9-OM5-004
Figure 6-64: CTIS Compressor Relay Mounting
Figure 6-63: CTIS Compressor Fuse Location
______________

6-47
DEFLATE VALVE ASSEMBLY REPLACEMENT

Clean and inspect deflate valve and bracket. Check for cracks and stripped threads. Replace if defective.
Installation
CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation. 1. 2. 3. Secure deate valve to manifold with screws (Figure 6-65). Connect deflate valve electrical connector. Lower and secure hood.
Removal
1. 2. 3. Raise and secure hood. Disconnect deate valve electrical connector (Figure 6-65). Remove screws and deflate valve from manifold.
DEFLATE VALVE
9-S06-003
Figure 6-65: Deflate Valve Assembly Mounting
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Installation
_______________
DUST EXCLUDER REPLACEMENT

CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation. 1. 2. Install dust excluder on manifold (Figure 6-66). Lower and secure hood.
Removal
1. 2. Raise and secure hood. Remove dust excluder from manifold (Figure 6-66).

Clean and inspect dust excluder. Check for cracks and stripped threads. Replace if defective.
MANIFOLD
DUST EXCLUDER
9-S06-004
Figure 6-66: Dust Excluder Location
______________

CTIS SUPPLY LINE REPLACEMENT
1. 2. 3. 4. 5. 6. 7. 8. 9.
6-49
FRONT SUPPLY TUBE AND HOSE REPLACEMENT

WARNING: CTIS components are subject to moderately high air pressure. Always relieve air pressure before loosening or removing air system components by disconnecting quick-disconnect valve assemblies. Failure to follow this warning may result in serious injury.
The HUMMER CTIS uses rubber hoses, nylon tubing, and reinforced (braided) lines. Damaged portions of any air line type should be removed, discarded, and replaced with a new section. Leaks in air lines usually develop where there is constant rubbing or friction against another component, existing air lines, fasteners, frame rail, or air line clamp. Such leaks are usually small and difficult to detect unless adequate air pressure of approximately 20-30 psi (138-207 kPa) is in the line. If a leak is suspected, apply soap suds to the affected area for easier detection and replace damaged section.
Disconnect supply line at pump/valve assembly (Figure 6-67). Disconnect supply hose at T-fitting secured to front frame crossmember (Figure 6-68). Remove tie straps securing hose. Work line out from under vehicle rather than through engine compartment. Tape ends of new hose to prevent dirt entry. Work line up to pump/valve assembly from underneath. Remove tape from hose ends and connect hose to T-fitting and pump/valve assembly. Secure new hose with tie straps. Make sure line is clear of suspension and engine components.
FRONT SUPPLY LINE
9-S06-013
REAR SUPPLY LINE
Figure 6-67: Front and Rear Supply Line Connections

SUPPLY LINE
T-FITTING CROSSMEMBER
Figure 6-68: Supply Hose Connection
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6-50
_______________
FRONT CTI LINE REPLACEMENT

1. 2. 3. 4. 5. 6. 7. Disconnect line at front hub (Figure 6-69). Loosen clamp on bracket attached to lower control arm, then move air line out of bracket (Figure 6-70). Disconnect front air line at T-fitting secured to front crossmember. Cut tie straps and remove front air line. Tape ends of new line to prevent dirt entry. Then route line to front wheel and T-fittings. Secure hose to fittings and in clamp on lower control arm bracket. Install tie straps as needed.
REAR CTI LINE REPLACEMENT

1. 2. 3. 4. 5. 6. 7. Disconnect line at rear wheel and at T-tting (Figure 6-71). Remove line from clamp on lower control arm and from rear hub. If working on right rear line, remove clamp over crossmember to remove line (Figure 6-72). Tape ends of new line to prevent dirt entry. Connect line to T-fitting and rear hub. Secure line in control arm clamp. If working on right rear line, secure line to crossmember with clamp (Figure 6-72).
LEFT REAR UPPER CONTROL ARM
T-FITTING
HUB AIR LINE TO FRONT WHEEL
Figure 6-69: Line Connection to Hub
Figure 6-71: T-Fitting Location

AIR LINE TO RIGHT REAR WHEEL CLAMP
CLAMP AIR LINE
REAR CROSSMEMBER
AIR LINE TO TEE
BRACKET LOWER CONTROL ARM
Figure 6-72: Right Rear Line Routing Over Rear Crossmember
Figure 6-70: Line Bracket and Clamp Location
______________

6-51
AIR INTAKE LINE REPLACEMENT

Removal
1. 2. Raise and secure hood. Loosen hose clamp and disconnect air intake hose from connector (Figure 6-73).
Clean and inspect air intake hose, elbow, coupling assembly and seal. Check for leaks, cracks, and stripped threads. CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation.
AIR HORN
AIR CLAMP INTAKE HOSE CONNECTOR CLAMP
Installation
1. 2. 3. 4. 5. Connect air intake hose to compressor fitting and secure with hose clamp (Figure 6-74). Install seal, coupling, washer, nut, and connector to air horn (Figure 6-73). Connect air cleaner elbow to air horn and secure with clamp. Connect air intake hose to air horn connector and secure with hose clamp. Lower and secure hood.
ELBOW SEAL
TUBE SHIELD REPLACEMENT

1. 2. 3. 4. Remove bolts, washers and tube shield from wheel. Install new CTIS decal on tube shield, if necessary. Install tube shield tab into slot on bracket. Secure tube shield to spindle with bolts and washers.
Figure 6-73: Air Intake Hose

3. 4. 5. Loosen clamp and disconnect air cleaner elbow from air horn. Remove nut, washer, coupling, connector, and seal from air horn. Loosen hose clamp securing air intake hose to compressor fitting (Figure 6-74).
BRACKET TAB
SPINDLE FITTING CLAMP
AIR INTAKE HOSE

9-S06-012
TUBE SHIELD
Figure 6-74: Air Intake Hose to Fitting

6. Remove air intake hose.
Figure 6-75: Tube Shield Assembly
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_______________
QUICK-DISCONNECT VALVE AND TUBE REPLACEMENT

NOTE: The replacement of all four quick-disconnect valves and tube assemblies is identical.
CAUTION: Do not force apart quick-disconnect valve. The quick-disconnect valve is a one-piece component. Damage to quick-disconnect valve will result if forced apart. 4. 5. 6. Remove quick-disconnect valve from spindle. Disconnect tube from elbow, then remove nut and sleeve assembly and insert from tube. Remove elbow.

Clean and inspect tube and quick-disconnect valve. Check for leaks, stripped threads, and cracks. Replace defective parts.
Removal
1. 2. 3. Raise and support vehicle. Remove tube shield. Remove tube and nut from quick-disconnect valve (Figure 6-76).
Installation
CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. NOTE: Apply sealant to threads prior to installation. 1. 2. 3. 4. 5. 6. Install quick-disconnect valve into spindle (Figure 6-76). Install elbow. Install nut on tube and connect tube to quick-disconnect valve. Install nut and sleeve assembly and insert on tube and connect tube to elbow. Install tube shield. Lower vehicle.
ELBOW INSERT SLEEVE NUT
TUBE
NUT
QUICK DISCONNECT VALVE
Figure 6-76: Quick-Disconnect Valve Assembly
______________

GEARED HUB REPLACEMENT (CTIS)
6-53
REAR TUBE CONNECTION SHIELD REPLACEMENT

NOTE: The replacement of the left and right rear tube connection shields is basically the same. This procedure covers the left rear tube connection shield.
Removal
Remove two bolts, washers, shield, and two washers from steering arm cover (Figure 6-77).
NOTE: The geared hub spindle has been bored to allow a direct air passage through the spindle to the quick-disconnect valve assembly. The front of the spindle is bored and tapped to allow installation of a quick-disconnect coupling. The rear of the spindle is bored for the insertion of a spindle extension, which creates an air-tight passageway into the steering arm cover. A bored hole in the steering arm cover allows the installation of a rotary seal and an air line, which routes compressed air to the tires.

Clean and inspect shield and mounting hardware. Check for cracks and stripped threads. Replace defective parts.
STEERING ARM COVER
Removal
1. 2. Remove tube shield. Remove rear tube connection shield.
SHIELD
Figure 6-77: Rear Tube Connection Shield
STEERING ARM COVER
AIR LINE
Installation
Install shield on steering arm cover with two washers, bolts, and two washers. Tighten bolt to 75 lb-ft (102 Nm) (Figure 6-77).
LINE FITTING
7-S06-036.2
Figure 6-78: Line Connection at Steering Arm Cover

3. 4. Remove line fitting from steering arm cover (Figure 6-78). Remove geared hub.
Installation
1. 2. 3. 4. Install geared hub. Apply sealant to line fitting and install in steering arm cover (Figure 6-78). Install rear tube connection shield. Install tube shield.
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6-54
_______________
SPINDLE EXTENSION AND SEAL REPLACEMENT

Removal
1. 2. 3. 4. Remove rear tube connection shield. Remove four bolts, washers, and steering arm cover from geared hub (Figure 6-79). Remove retaining ring and seal from steering arm cover. Remove spindle extension from spindle.
AUXILIARY AIR HOSE REPLACEMENT

Removal
1. Raise and secure hood.
WARNING: The CTIS air system contains air under high pressure. Always relieve air pressure before loosening or removing air system component(s) by disconnecting quick-disconnect valves. Failure to follow this warning may result in personal injury.
2. Isolate tire by depressing metal tab on quick-disconnect valve body. The valve body will pop out approximately 1/4 in. (6 mm) from shuttle. Perform this procedure on remaining three wheels (Figure 6-81).
TAB
GEARED HUB
STEERING ARM COVER SEAL EXTENSION
DISCONNECTED
RETAINING RING
Figure 6-79: Spindle Extension and Seal

Clean and inspect spindle extension and seal. Check for leaks and cracks. Replace defective parts.
SHUTTLE VALVE BODY CONNECTED
Installation
CAUTION: Do not allow sealant or adhesive into air system. Sealant will damage CTIS components. 1. 2. 3. 4. 5. Apply sealant to seal and install seal in steering arm cover (Figure 6-79). Secure seal to steering arm cover with retaining ring. Apply a small amount of adhesive to end of spindle extension and install into spindle. Install steering arm cover on geared hub with four washers and bolts. Tighten bolts to 75 lb-ft (102 Nm). Install rear tube connection shield. 3.
Figure 6-80: CTIS Quick-Disconnect Valve

Remove auxiliary air valve from tee (Figure 6-81).
______________

2.
6-55
Installation
NOTE: Ensure that any new fittings have pipe sealant pre-applied to threads. If none is present, apply a pipe sealant to fitting threads. 1. Secure auxiliary air valve to existing tee (Figure 6-81).
3. 4.
Connect tires to CTIS by pushing in quick-disconnect valve body until valve tee section locks (clicks) into place. Perform this procedure on remaining three wheels (Figure 6-80). Start engine and check CTIS for air leaks around installed fittings. Lower and secure hood.
COMPRESSOR
AUXILIARY AIR VALVE EXISTING TEE
AIR HOSE
9-S06-017
Figure 6-81: CTIS Auxiliary Air Hose
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_______________
SPECIAL TOOLS
05710216
05710215
Tool No. 05710216 05710215
Description Internal tubeless tire repair kit External tubeless tire repair kit
________________________________________________________________________________
7-1
Section 7 Brake System

TABLE OF CONTENTS
Anti-lock Brake System (ABS) and Automatic Traction Control, TorqTrac 4 (TT4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 ABS ECU Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 ABS Modulator Replacement . . . . . . . . . . . . . . . . . . . . . . .7-48 ABS/TT4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .7-34 Fuse and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . .7-50 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 Brake Master Cylinder Bench Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 Brake System Bleeding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 Brake Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 Brake Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 Burnishing Linings and Rotors . . . . . . . . . . . . . . . . . . . . .7-10 Caliper Overhaul, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Disc Brake Caliper Repair, Front . . . . . . . . . . . . . . . . . . . .7-27 Front Service Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . .7-10 Hydro-Boost System Diagnosis. . . . . . . . . . . . . . . . . . . . . . 7-7 Left Parking Brake Cable Replacement . . . . . . . . . . . . . . 7-23 Pad Replacement, Service Brake. . . . . . . . . . . . . . . . . . . . . 7-9 Parking Brake Cable Replacement, L . . . . . . . . . . . . . . . . 7-24 Parking Brake Cable Replacement, R . . . . . . . . . . . . . . . . 7-23 Parking Brake Lever Adjustment. . . . . . . . . . . . . . . . . . . . 7-33 Parking Brake Lever Replacement . . . . . . . . . . . . . . . . . . 7-26 Parking Brake Switch Replacement . . . . . . . . . . . . . . . . . 7-33 Pedal Replacement, Service Brake . . . . . . . . . . . . . . . . . . 7-17 Proportioning Valve Replacement. . . . . . . . . . . . . . . . . . . 7-17 Rotor Replacement, Service Brake . . . . . . . . . . . . . . . . . . 7-17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Hydro-Boost Bleeding the Hydro-boost System. . . . . . . . . . . . . . . . . . . 7-13 Hydro-Boost Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Rear Dual Service/Parking Brake Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Caliper Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Speed Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Tone Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
POWER BRAKE SYSTEM DESCRIPTION

The hydraulic power disc brake system is a four-wheel, inboardmounted design. The dual reservoir master cylinder stores brake fluid and converts mechanical brake pedal force to hydraulic pressure. The proportioning valve provides balanced front-to-rear braking and activates the brake warning lamp in case of a brake hydraulic system malfunction. The dual reservoir master cylinder provides fluid for separate front and rear brake systems (Figure 7-1). The hydro-boost provides power brake assist and is operated by fluid pressure from the power steering pump. The hydro-boost is equipped with an accumulator. The accumulator stores nitrogen gas under pressure in
BRAKE CALIPERS HYDRAULIC BRAKE LINES MASTER CYLINDER
the event that both the normal assist and accumulator assist are not available. The power steering pump provides hydraulic oil pressure to operate the brake systems hydro-boost feature. If the power steering pump fails to supply hydraulic pressure to the hydro-boost, the pressure stored in the accumulator will provide enough hydraulic pressure for approximately four power-assisted stops. Applying the parking brake prevents the rear brake rotors from rotating and can also be used to help stop the vehicle in low speed emergency situations. The disc brakes are mounted on the output flanges of the front and rear axle assemblies.
ABS MODULATOR BRAKE ROTORS
BRAKE CALIPERS
Figure 7-1: Brake System

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7-2
Brake System
______________________________________________________________
BRAKE SYSTEM DIAGNOSIS Road Testing

1. 2. If red warning light is illuminated, note pedal action and brake response. Check brake pedal response with transmission in Neutral and engine running. Pedal should remain firm under steady foot pressure. If pedal falls away, problem is either in hydro-boost, master cylinder, or brakeline. During road test, make normal and firm brake stops in 2540 mph range. Note faulty brake operation such as pull, grab, drag, noise, fade, pedal pulsation, etc. (noise and pedal pulsation during an ABS event is normal). Inspect suspect brake components and refer to problem diagnosis information for causes of various brake conditions.
Pedal Falls Away

A brake pedal that falls away under steady foot pressure is generally the result of a system leak. The leak point could be at a brakeline, fitting, hose, or caliper. Internal leakage in the master cylinder caused by worn or damaged piston cups, may also be the problem cause. If leakage is severe, fluid will be evident at or around the leaking component. However internal leakage in the master cylinder will not be physically evident. Refer to the cylinder test procedure in this section.
3.
Low Pedal
If a low pedal is experienced and the warning light is not on, worn lining and worn rotors are the most likely cause. If the red warning light is on, low fluid in the master cylinder is the most likely cause. A leak at a caliper, brakeline, or brake hose will cause the fluid level in the master cylinder reservoir to become low, triggering the low fluid switch and the red brake warning light.
4.
Component Inspection
Fluid leak points and dragging brake units can usually be located without removing any components. The area around a leak point will be wet with fluid. The components at a dragging brake unit will be quite warm or hot to the touch. During component inspection, pay particular attention to heavily rusted/corroded brake components (e.g. rotors, caliper pistons, lines, etc.). Heavy accumulations of rust may be an indicator of rust and corrosion damage to a brake component. It is wise to remove surface rust in order to accurately determine the depth of rust penetration and damage. Light surface rust is fairly normal and not a major concern (as long as it is removed). However, heavy rust buildup, especially on high mileage vehicles, may actually cover structural damage to such important components as brakelines and rotors.
Spongy Pedal
A spongy pedal is most often caused by air in the system. However, substandard brake lines and hoses will also cause a condition similar to a spongy pedal. The proper course of action is to bleed the system, or replace suspect quality brake lines and hoses.
Hard Pedal or High Pedal Effort

A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or badly worn.
Brake Drag
Brake drag occurs when the lining is in constant contact with the rotor. Drag can occur at one wheel, all wheels, fronts only, or rears only. It is a product of incomplete brakeshoe release. Drag can be minor or severe enough to overheat the linings, and rotors. Brake drag also has a direct effect on fuel economy. If undetected, minor brake drag can be misdiagnosed as an engine or transmission/torque converter problem. Minor drag will usually cause slight surface glazing of the lining. It can also generate hard spots in rotors from the overheatcool down process. In most cases, the rotors, wheels and tires are quite warm to the touch after the vehicle is stopped. Severe drag can char the brake lining all the way through. It can also distort and score rotors to the point of needing replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the lining may generate smoke as it chars from overheating.
Diagnosing Service Brake Problems

Brake Warning Light Operation
The red brake warning light will illuminate when the parking brakes are applied, and when there is a low fluid level in the brake fluid reservoir. If the light comes on, first verify that the parking brakes are fully released. Then check pedal action and fluid level. If a problem is confirmed, inspect the wheel brake hydraulic system.
_____________________________________________________________
Brake System
7-3
Some common causes of brake drag are: seized or sticking caliper piston caliper binding on bushings or pin slides incorrect length caliper mounting bolts (too long) loose caliper mounting bracket misassembled components misadjusted brakelight switch binding brake pedal master cylinder/hydroboost internal fault improperly adjusted parking brake If brake drag occurs at all wheels, the problem may be related to a blocked master cylinder compensator port or faulty hydroboost. An improperly mounted or adjusted brakelight switch can prevent full brake pedal return. The result will be the same as if the cylinder compensator ports are blocked. In this case, the brakes would be partially applied all the time causing drag.
switch direction in favor of the brake unit that is functioning normally. When diagnosing a change in pull condition, remember that pull will return to the original direction if the dragging brake unit is allowed to cool down (and is not seriously damaged).
Rear Brake Grab

Rear grab (or pull) is usually caused by contaminated lining, bent or binding pads or improperly assembled components. This is particularly true when only one rear wheel is involved. However, when both rear wheels are affected, the master cylinder, or an improperly adjusted parking brake could be at fault.
Brakes Do Not Hold After Driving Through Deep Water Puddles

This condition is generally caused by water soaked lining. If the lining is only wet, it can be dried by driving with the brakes lightly applied for a mile or two. However, if the lining is both wet and dirty, disassembly and cleaning will be necessary.
Brake Fade
Brake fade is a product of overheating caused by brake drag. However, brake overheating and subsequent fade can also be caused by riding the brake pedal, making repeating high deceleration stops in a short time span, or constant braking on steep roads. Refer to the Brake Drag information in this section for causes.
Brake Fluid Contamination

There are two basic causes of brake fluid contamination. The first involves allowing dirt, debris, water, or other liquid materials to enter the cylinder reservoirs when the cover is off. The second involves topping off, or filling the cylinder reservoirs with a non-recommended fluid. Brake fluid contaminated with only dirt or debris usually retains a normal appearance. Generally, the foreign material will remain suspended in the fluid and be visible. The fluid and foreign material can be removed from the reservoir with a suction gun but only if the brakes have not been applied. If the brakes are applied after contamination, system flushing will be required. The master cylinder will also have to be flushed or replaced if the contaminants cannot be removed. Foreign material lodged in the reservoir compensator/return ports can cause brake drag by restricting fluid return after brake application. Brake fluid contaminated by a non-recommended fluid, generally appears highly discolored, milky, oily looking, or foamy. In some cases, it may even appear as if the fluid contains sludge. However, be advised that brake fluid will darken over time and occasionally be cloudy in appearance. These are normal conditions and should not be mistaken for contamination. If some type of oil has been added to the system, the fluid will separate into distinct layers. To verify this, drain off a sample with a clean suction gun. Then pour the sample into a glass container and observe fluid action. If the fluid separates into distinct layers, it is definitely contaminated. The only real correction for contamination by non-recommended fluid is to flush the entire hydraulic system and replace all the seals.
Pedal Pulsation
Pedal pulsation whenever the ABS is not active, is caused by components that are loose, or beyond tolerance limits. Disc brake rotors with excessive lateral runout or thickness variation are the primary causes of pulsation. Other causes are loose calipers, and worn, damaged tires.
Brake Pull
A front pull condition could be the result of contaminated lining in one caliper, seized caliper piston, binding caliper, loose caliper, loose or corroded slide pins, improper brakeshoes, or a damaged rotor. A worn, damaged wheel bearing or suspension component are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull. Check the tires to be sure that they are inflated to the appropriate tire pressure. It could be another cause of your vehicle pulling to one side. A common and frequently misdiagnosed pull condition is where direction of pull changes after a few stops. The cause is a combination of brake drag followed by fade at the dragging brake unit. As the dragging brake overheats, efficiency is so reduced that fade occurs. If the opposite brake unit is still functioning normally, its braking effect is magnified. This causes pull to
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Brake Noise
Squeak/Squeal
The factory installed brakelining in Hummer vehicles is made from asbestos free materials. These materials have different operating characteristics than previous lining materials. Under certain conditions, asbestos free lining may generate some squeak, groan or chirp noise. This noise is considered normal and does not indicate a problem. The only time inspection is necessary, is when noise becomes constant or when grinding, scraping noises occur. Constant brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oil. Glazed linings and rotors with hard spots can also contribute to squeak. Dirt and foreign material embedded in the brake lining can also cause squeak/squeal. Loud brake squeak, squeal, scraping, or grinding sounds are a sign of severely worn brake lining. If the lining has worn completely through in spots, metal-to-metal contact occurs. If the condition is allowed to continue, rotors can become so scored that replacement is necessary.
Wheel and Tire Problems

Some conditions attributed to brake components may actually be caused by a wheel or tire problem. A damaged wheel can cause shudder, vibration and pull. A worn or damaged tire can also cause pull. Severely worn tires with little or no tread left can produce a grab-like condition as the tire loses and recovers traction. Flat-spotted tires can cause vibration and wheel tramp and generate shudder during brake operation. A tire with internal damage such as a severe bruise or ply separation can cause pull and vibration.
Diagnosing Parking Brake Problems

Parking Brake Problem Causes
In most cases, the actual cause of an improperly functioning parking brake (too loose/too tight/wont hold), can be traced to a rear brake component. The leading cause of improper parking brake operation, is excessive clearance between the brake pads and the rotor surface. Excessive clearance is a result of lining and/or rotor wear or inoperative adjuster components. Inspect and adjust parking brake lever or linkage as necessary.
Thump/Clunk
Thumping or clunk noises during braking are frequently not caused by brake components. In many cases, such noises are caused by loose or damaged steering, suspension, drive line, or engine components. However, calipers that bind on the slide surfaces can generate a thump or clunk noise. Loose adapter bolts or halfshaft-to-rotor bolts will cause noise.
BRAKE SYSTEM TROUBLESHOOTING

Parking Brake Does Not Hold Vehicle
1. Check parking brake adjustment and ensure linkage and cables operate freely. Adjust parking brake lever and/or cables or replace damaged and worn parts. Inspect rear brake caliper brake pads for serviceability. Minimum brake lining thickness is 1/8 in. (3.2 mm). Replace all rear brake pads if any pad does not meet thickness specifications. Check caliper for binding or dragging. Check for binding caliper guide pins.
Chatter/Shudder
Brake chatter is usually caused by loose or worn components, or glazed/burnt lining. Rotors with hard spots can also contribute to chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
2.
Brake Lining Contamination

Brake lining contamination is a product of leaking calipers, driving through deep water puddles, or lining that has become covered with grease or oil due to leaking axle seals.
3.
Low or Spongy Brake Pedal on First Application or Pedal Goes to Floor

CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage the brake system.
WARNING: Always wear eye protection when bleeding brakes. Failure to do this may cause personal injury if brake uid comes in contact with eyes.
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Brake System
7-5
1.
2.
3.
Remove master cylinder cover and visually check reservoirs for low uid level or contamination. a. If fluid is contaminated, flush system with clean brake fluid. b. If fluid is low, check for worn brake pads, observe for leakage, broken, cracked or kinked lines, worn master cylinder, etc. Replace any worn parts. Add DOT 3 as needed. Check hydro-boost. Depress brake pedal several times, with engine off, to exhaust accumulator pressure. Depress brake pedal and start engine. a. Brake pedal should fall, then push back against operator's foot. b. Perform pressure test (Section 8). c. Replace hydro-boost if not operating properly. Bleed master cylinder then bleed brakes.
4.
Check brake pads for proper installation, contamination, or distortion. Check brake pads for excessive wear. Minimum brake lining thickness is 1/8 in. (3.2 mm). Replace brake pads as axle sets (front or rear) if any pad does not meet specifications
NOTE: To preserve even braking, both calipers must be in equal condition. 5. Check brake calipers for binding as a result of corrosion or dirt. Check brake rotors for free movement. If rotors do not move freely, remove calipers and clean caliper guide pins. 6. Check for frozen piston in brake caliper. If inner pad is not worn to limit, but piston cannot be retracted, rebuild or replace both calipers. 7. Check for pinched or kinked supply and return lines to hydro-boost. Reposition or replace any damaged lines. 8. Check for damaged brake lines. Replace any damaged brake lines. 9. Check for malfunctioning hydro-boost. Depress brake pedal several times, with engine off, to exhaust accumulator pressure. Depress brake pedal and start engine. a. Brake pedal should fall, then push back against operator's foot. b. Perform pressure test (Section 8). c. Replace hydro-boost if not operating properly. 10. Check power steering system. Refer to step 6 in the Diagnostic portion of Hard Steering in Section 8.
Decreased Brake Pedal Travel or Slow Return

1. 2. 3. 4. Check for worn brake pedal return spring. Replace if worn. Check brake pedal bushings for signs of wear or binding. Replace if worn and lubricate as needed. Check for kinked or damaged brake lines which may restrict brake fluid. Replace any damaged lines. Check hydro-boost. Depress brake pedal several times, with engine off, to exhaust accumulator pressure. Depress brake pedal and start engine. a. Brake pedal should fall, then push back against operator's foot. b. Perform pressure test (Section 8). c. Replace hydro-boost if not operating properly. Check brake calipers for binding as a result of corrosion or dirt. Check brake rotors for free movement. If rotors do not move freely, remove calipers and clean caliper guide pins. Check parking brake cable for proper operation and adjustment. Repair as required.
Noisy Brakes
1. Check brake pads for proper installation, contamination, or distortion. Check brake pads for excessive wear. Minimum brake lining thickness is 1/8 in. (3.2 mm). Replace brake pads as sets (front or rear) if any pad does not meet specications. Make sure pads are at and smooth. Check rotor for glazing or scoring. Turn the rotor if glazed or scored. Do not exceed the minimum thickness shown on the inside of the rotor hat section. It is not recommended that rotors be turned when spotted or heat checked. Check halfshaft mounting. a. Apply a thread-locking compound to the halfshaft and rotor-to-output flange capscrews, or use bolts with pre-applied compound, and torque to 57 lb-ft (77 Nm). b. Apply a thread-locking compound to the halfshaft retaining capscrew (in geared hub) and torque to 40 lb-ft (54 Nm). Tighten any loose fasteners.
5.
6.
2.
Excessive Pedal Pressure Required to Stop Vehicle

1. Remove master cylinder cover and visually check reservoir for low uid level or contamination. a. If fluid is contaminated, flush system with clean brake fluid. b. If fluid is low, check for worn brake pads, observe for leakage, broken, cracked or kinked lines, worn master cylinder, etc. Replace any worn parts. Check fluid in power steering pump reservoir. Fill fluid to proper level (Section 1). Check serpentine belt tension. Replace belt (Section 8) if necessary. 3.
2. 3.
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Brake Chatter
On some new vehicles, roughness or a chatter sound from the brakes may be noticed during low speed brake application. The noise is a result of the lining edges of an unburnished brake pad rubbing against the rotor. Burnishing is a part of the vehicle break-in process which fully seats and conditions new brake pads. Although annoying, the brake noise is not detrimental to vehicle safety or performance, and will eventually be eliminated through normal brake use. If chatter or roughness persists on a new vehicle, then chamfering of the brake pad lining edges can be performed. Chamfering of the brake pad is done by slightly grinding or filing the edge of the pad lining on a grinding wheel. To complete the chamfering procedure: 1. Remove the eight service brake pads from the vehicle. Mark each pad for vehicle and caliper location. 2. Chamfer (grind or file) the brake pad lining edges. Ensure both brake pad lining edges are chamfered on each of the eight brake pads (Figure 7-2). Make sure pads are flat and even. 3. Install eight service brake pads at the original vehicle and caliper location. 4. Operate vehicle and check brakes for proper operation.
VIEW DEPICTS BRAKE PAD AFTER BEING CHAMFERED BRAKE PAD LINING EDGE
Erratic Braking Action

1. 2. Check for correct tire pressure.
Check brake pads for binding as a result of corrosion or dirt. Check brake pads for excessive wear. Minimum brake lining thickness is 1/8 in. (3.2 mm). Replace brake pads as sets (front or rear) if any pad does not meet specifications.
3.
Check brake calipers for binding as a result of corrosion or dirt. Check for seized or binding brake caliper pistons. Repair any binding or seized caliper pistons. Check brake rotors for free movement. If rotors do not move freely, remove calipers and clean caliper guide pins (Figure 7-3).
NOTE: Calipers pins must be replaced in pairs. Caliper pins and bushing should be lubricated with an approved brake component lubricant. 4. 5. Check for leaking caliper piston seals. Replace or rebuild any calipers with leaking seals. Check rotor for glazing or scoring. Turn the rotor if glazed or scored. Do not exceed the minimum thickness shown on the inside of the rotor hat section. It is not recommended that rotors be turned when spotted or heat checked. Check for damaged brake lines. Replace any damaged brake lines. Check ABS operation. Check ABS warning lamp. Perform a 20 mph hard deceleration on a slippery surface (sand, gravel, snow, etc). If one or more wheels lock repair the ABS. Refer to ABS diagnostics in this secion. Check toe adjustment. Adjust toe, if necessary. Refer to Section 5.
6. 7.
8.
1/4 18 ADAPTER BRAKE PAD LINING EDGE AREA TO BE REMOVED BY CHAMFERING (GRINDING)
SIDE VIEW OF BRAKE PAD LINING EDGE
S07-043
BRAKE PAD
ROTOR
Figure 7-2: Chamfering Brake Pad
Booster or Pedal Pulsation

1. Check hydro-boost. Depress brake pedal several times, with engine off, to exhaust accumulator pressure. Depress brake pedal and start engine. a. Brake pedal should fall, then push back against operator's foot. b. Perform pressure test (Section 8). c. Replace hydro-boost if not operating properly. Check halfshaft and rotor mounting for missing or loose capscrews. Replace inclined-cam washers, apply a thread locking compound and torque capscrews to 57 lb-ft (77 Nm). Check brake rotor lateral run-out. Refinish any rotor not meeting specifications. Refer to Checking Lateral Runout in this section for more information.
BRAKE LINE/HOSE COUPLING AND COPPER WASHER BRAKE PAD COOLING FINS CALIPER GUIDE PINS BUSHING AND SLEEVE CALIPER
2.
3.
Figure 7-3: Brake Caliper and Brake Pads
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Brake System
7-7
HYDRO-BOOST SYSTEM DIAGNOSIS PROBLEM

Slow Brake Pedal Return or Brakes Apply When Turning Steering Wheel Grabs Suddenly or Booster Chatters Pedal Vibrates Accumulator Leak-Down Reserve System Does Not Hold Charge Excessive Brake Pedal Efforts 1. 2. 3. 4. 5. 1. 2. 3. 1. 2.
POSSIBLE CAUSE
Damaged/broken return spring. Excessive seal friction in booster. Faulty spool action. Restriction in return line from booster to pump reservoir. Damaged input rod end. Faulty spool action caused by contamination. Power steering pump belt slips. Low uid level in power steering pump. Contamination in steering hydro-boost system. Internal leakage in accumulator system 1. 2. 3. 4. 5. 1. 2. 3. 1. 2.
CORRECTION
Replace spring. Replace the hydro-boost. Flush the steering system while pumping the brake pedal. Replace the line. Replace the hydro-booster. Flush steering system while pumping brake pedal. Replace tensioner and/or belt. Fill reservoir and check for external leaks. Flush steering system while pumping brake pedal. Replace hydro-boost.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Loose, glazed, or broken pump belt. No uid in pump reservoir. Leaks in system hoses. Leaks at tube ttings and connections. Leakage at pneumatic accumulator seal. Leakage at piston seal. Leakage at input seal. Leakage at cover-to-housing seal. Leakage at spool plug seal. Leakage at ball plug
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Replace tensioner and/or replace belt. Fill reservoir and check for external leaks. Replace faulty parts. Tighten ttings or replace tube seats or O-rings. Replace O-ring. Overhaul with new seal kit. Overhaul with new seal kit. Overhaul with new seal kit. Overhaul with spool plug seal kit. Replace hydro-boost.
NOTE: The power steering fluid and brake fluid cannot be mixed. If the brake seals contact steering fluid or the steering seals contact brake fluid, seal damage will result.
Noise Diagnosis
The following noises are associated with the hydro-boost and may or may not be cause for concern. Some noises are normal and for the most part temporary in nature. Other noises may be a sign of excessive wear or the presence of air in either the booster or the steering system. 1. A moan or low frequency hum usually accompanied by a vibration in the pedal or steering column may be observed during parking maneuvers or other low-speed maneuvers. This may be caused by a low uid level in the power steering pump or by air in the uid. Holding the pump at relief pressure (steering wheel held all the way in one direction) for more than ve seconds will cause air to enter the system. Check the uid level and ll if needed. The system must then sit for one hour to remove the air. 2. A high-speed fluid noise may be heard when the brake pedal is fully depressed. This condition is normal.
3.
4.
Whenever the accumulator pressure is used, a slight hiss may be noticed. It is the sound of the hydraulic fluid escaping through the accumulator valve, and is completely normal. After the accumulator has been emptied and the engine is started again, another hissing sound may be heard during the first brake application or the first steering maneuver. This is caused by the fluid rushing through the accumulator charging orifice. It is normal and will only be heard once after the accumulator is emptied. If this sound continues however, even though no apparent accumulator pressure assist was made, it could be an indication that the accumulator is not holding pressure and should be checked using the procedure Accumulator Leakdown Test in this section.
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Brake System
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Booster Functional Test

With the engine off, apply the brake pedal several times until the accumulator is completely depleted. Depress the brake pedal using 40 lb-ft (54 Nm) of force and start the engine. The pedal will fall and then push back against your foot.
WARNING: If the reservoir has run very low or dry, bleed the master cylinder before bleeding the remainder of the brake system to keep from introducing additional air into the system. WARNING: Always wear eye protection when bleeding brakes. Failure to do this may cause injury if brake uid comes in contact with eyes. Pressure Bleeding
CAUTION: When using a pressure bleeding tank, (J29532) follow the manufacturer's instructions for its use. Use only DOT 3 brake fluids when bleeding. Do not exceed the recommended working pressure when pressurizing the tank. A tank pressure of 15-20 psi (103-138 kPa) is sufficient to bleed the brake hydraulic system. Release all air pressure from the tank after using it. NOTE: This procedure covers bleeding at one wheel. Repeat bleeding task for remaining wheels. 1. 2. 3. 4. Disconnect batteries. Remove cap from master cylinder. Fill master cylinder if necessary. Install pressure tank bleeder adapter to master cylinder (Figure 7-4). Connect line from pressure tank to adapter.
Accumulator Leakdown Test

1. Start the engine and charge the accumulator by applying the brake pedal or by turning the steering wheel from stop to stop. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two powerassisted applications with the engine off. If the reserve system will not retain a charge for one hour, but functions normally immediately following charging, the accumulator valves are at fault. Replace the hydrobooster.
2.
If the accumulator can be heard charging and discharging but does not hold a charge, replace the hydro-booster. 4. Deplete the accumulator by pressing the brake pedal several times. If the accumulator can has lost its charge, it is possible to rotate or wobble the accumulator can with respect to the housing. Replace the hydro-booster. Handling - The booster should not be carried by the accumulator nor should the booster ever be dropped on the accumulator. The snap ring which holds the accumulator into the housing should be checked for proper positioning before the booster is used. The accumulator contains high pressure gas and with any high pressure gas a certain degree of danger is present if mishandled. Disposal - The accumulator should not be exposed to excessive heat, fire or incineration. Before discarding accumulator following replacement, drill a 1/16 inch diameter hole in the end of accumulator can to relieve the pressure. BE SAFE! Protect your eyes. Wear approved safety glasses.
3.
NOTE: Bleed calipers in the following order: right rear, left rear, right front, left front. 5. Remove protective cap from bleeder screw on caliper assembly (Figure 7-5). 6. Connect short piece of hose to bleeder screw, and place other end of hose in container 3/4 full of brake fluid. 7. Open valve on line from pressure tank to master cylinder allowing pressurized brake fluid to enter system (Figure 7-4). 8. Open bleeder screw 3/4 turn and observe brake fluid in container. Close bleeder screw when brake fluid flows free of air bubbles (Figure 7-5). 9. Disconnect hose from bleeder screw and install protective cap on bleeder screw. 10. Close valve on line from pressure tank to master cylinder (Figure 7-4). 11. Disconnect line from adapter. 12. Remove adapter from master cylinder and fill master cylinder if necessary. 13. Install master cylinder cap. 14. Connect batteries.
SERVICE BRAKE SYSTEM BLEEDING

NOTE: If only the front or rear half of the system has been serviced, it is usually necessary to bleed only that half of the system. However, if a firm brake pedal cannot be obtained after bleeding, it will be necessary to bleed the entire system. The brake hydraulic system can be bled manually or by using a pressure tank and adapters. Each method is outlined in the following procedures.
WARNING: Disconnect the batteries before bleeding the brake system. If the ABS modulator receives power during the bleed procedure, air may become trapped in areas in the modulator that cannot be bled by conventional techniques. The modulator would need to be replaced to obtain a rm brake pedal.
3-1-01
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Brake System
7-9
PRESSURE TANK BLEEDER ADAPTER
BLEEDER SCREW
PROTECTIVE CAP
MASTER CYLINDER
VALVE HOSE
CALIPER ASSEMBLY
Figure 7-5: Manually Bleeding Brake System 5.

PRESSURE TANK
6. 7. 8. 9.
Figure 7-4: Pressure Bleeding Brake System
Manual Bleeding
NOTE: This procedure covers bleeding at one wheel. Repeat bleeding task for remaining wheels. Assistance is required to depress the brake pedal when manually bleeding brakes while mechanic opens and closes bleeder screw. NOTE: Bleed calipers in the following order: right rear, left rear, right front, left front. 1. 2. 3. Disconnect batteries. Remove protective cap from bleeder screw on caliper assembly (Figure 7-5). Connect short piece of hose to bleeder screw, and place other end of hose in container 3/4 full of brake fluid.
When pedal reaches floor, tighten bleeder screw and have assistant slowly release brake pedal. Repeat steps 3 and 4 until fluid flows clear and free of air bubbles. Disconnect hose from bleeder screw and install protective cap on bleeder screw. Connect batteries. Operate vehicle and check brakes for proper operation.
SERVICE BRAKE PAD REPLACEMENT

NOTE: The following procedure applies to the front brake system only.
Removal
1. Using crowfoot, remove two capscrews and washers securing yoke and caliper to adapter.
NOTE: Note positioning of brake pad surfaces for installation. 2. Remove yoke, caliper, and two brake pads.
CAUTION: Check the master cylinder fluid level frequently during the bleeding operation and refill the reservoirs as necessary. Do not allow the master cylinder to run out of fluid at any time, or additional air will be drawn into the system. 4. Have an assistant depress the brake pedal. Open bleeder screw 3/4 turn.

NOTE: Clean all components, examine for wear or damage, and replace if necessary.
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1. 2.
Brake System _____________________________________________________________
3.
Inspect dust boot for tears or deterioration (Figure 7-6). Inspect rotor for heat cracks, spotting, discoloration, pitting, or scoring. Resurface rotors if discolored, pitted, or scored. It is not recommended that rotors be turned when spotted or heat cracks. Inspect brake pads for glazing, oil saturation, or wear. If glazed, oil saturated, or if brake lining thickness is less than 1/8 in. (3.2 mm), replace brake pads. Brake pads should be replaced as an axle set (front or rear).
FRONT SERVICE BRAKE CALIPER REPLACEMENT

NOTE: The following procedure applies to the front brake system only. If removing left front caliper, halfshaft must be removed.
Removal
1. 2. Disconnect brake line from coupling (Figure 7-7). Using crowfoot, remove two capscrews and washers securing yoke and caliper to adapter.
Installation
1. Check brake pad backing plate notches for burrs or excess coating and ensure that the pad will t the adapter slide with enough clearance to afford stick-free movement. Lubricate caliper guide pins, sleeves and adapter slides with Permatex Ultra Disc Brake Caliper Lube prior to installation.
NOTE: Note positioning of brake pad surfaces for installation. 3. 4. Remove yoke, caliper, and two brake pads from adapter. Slide yoke and caliper guide pins out from caliper. Remove coupling and washer from caliper.
2.
Cleaning and Inspection WARNING: Ensure brake pads are installed with linings facing rotor. Failure to do this will cause poor performance, damage to equipment, and may result in injury.
3. Position brake pads on adapter. NOTE: Clean all components, examine for wear or damage, and replace if necessary. 1. 2. 3. 4. 5. 6. 7. Clean mating surfaces of caliper and adapter (Figure 7-7). Inspect caliper and caliper piston for pitting, or damage (Figure 7-6). Inspect caliper guide pins and sleeves for wear. Inspect dust boot and bushings for tears or deterioration. Inspect yoke and caliper guide pins for corrosion. Perform step 6 if corroded. If not, perform step 8 (Figure 7-7). Remove caliper guide pins from yoke. Discard caliper guide pins. Inspect rotor for heat checks, discoloration, pitting, or scoring. Check rotor thickness variation.
NOTE: When installing yoke and caliper, use a suitable tool to compress the piston. 4. Apply a non-hardening thread-locking compound to tapped holes of adapter. Using crowsfoot, secure yoke and caliper to adapter with two washers and capscrews. Tighten capscrews to 30-40 lb-ft (41-54 Nm).
LINING AND ROTOR BURNISHING

After you replace brake pads and/or refinish rotors, it is recommended that the new braking surface be broken in, or burnished. To do this, make 20 stops, one every one to two miles at 30 mph, using medium pedal effort. The amount of time it takes to stop should be approximately five seconds. During this procedure, use care to avoid overheating the brakes.
CALIPER
NOTE: Replace brake pads in sets only. Replace brake pads if brake lining thickness is less than 1/8 in. (3.2 mm) and operation in wet and muddy conditions is expected. 8. Inspect brake pads for glazing, oil saturation, or wear. If glazed, oil saturated, or if brake lining thickness is less than 1/8 in. (3.2 mm), replace both pads and pads from opposite caliper.
PISTON
DUST BOOT
Figure 7-6: Caliper Assembly 4-1-00
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Brake System
7-11
Installation
1. Install a washer and coupling to caliper (Figure 7-6).
MASTER CYLINDER REPLACEMENT

Removal
CAUTION: Cover or plug all open connections immediately after disconnecting to prevent contamination NOTE: Have drainage container ready to catch brake fluid. 1. Disconnect front and rear brake lines from master cylinder (Figure 7-8).
WARNING: Ensure brake pads are installed with linings facing rotor. Failure to do this will cause poor performance and damage to equipment and may result in injury.
2. Position brake pads on adapter (Figure 7-7).
TAPPED HOLE
ADAPTER
CAUTION: Do not apply excessive pressure or force on master cylinder. 2. Remove two locknuts and master cylinder from hydroboost. Discard locknuts (Figure 7-8).
Installation
BRAKE PAD
1.
Bench-bleed master cylinder.

HYDRO-BOOST
BRAKE LINE/HOSE BRAKE PAD COUPLING YOKE
MASTER CYLINDER
COPPER WASHER CALIPER
CALIPER GUIDE PINS
RIGHT MASTER CYLINDER MOUNTING STUD REAR BRAKE LINE FRONT BRAKE LINE
Figure 7-7: Service Brake Components 3. Apply a non-hardening thread-locking compound to threads of caliper guide pins and install pins into yoke (if removed during cleaning and inspection). Tighten caliper guide pins to 30 lb-ft (41 Nm). Lubricate caliper guide pins, sleeves and adapter slides with Permatex Ultra Disc Brake Caliper Lube prior to installation. Position caliper onto yoke.
Figure 7-8: Master Cylinder 2. 3. Install master cylinder to hydro-boost with two locknuts. Tighten locknuts to 22 lb-ft (30 Nm) (Figure 7-8). Install front and rear brake lines to master cylinder. Position front and rear brake lines with a minimum of 1/2" clearance to the hydro-boost accumulator and the right rear modulator output line. Clearance between the front and rear lines is also 1/2" minimum.
4.
5.
NOTE: When installing calipers, use a suitable tool to bottom out piston in caliper if needed. 6. Apply thread-locking compound to tapped holes of adapter. Using crowfoot, secure yoke and caliper to adapter with two washers and capscrews. Tighten two capscrews to 40 lb-ft (54 Nm). Connect brake line to coupling. Bleed brake system.
7. 8.
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Brake System _____________________________________________________________
MASTER CYLINDER BLEEDING

NOTE: Master cylinder must be filled and kept at least half full during bleeding operation (Figure 7-9). 1. 2. 3. 4. 5. Depress brake pedal slowly and hold. Loosen front brake line to purge air from the front section of the reservoir. Tighten front brake line and release brake pedal. Repeat steps 1 and 2 until front reservoir is purged of air. Repeat steps 1 through 3 for rear reservoir with rear brake line. Bleed brake system.
FLANGE CAP RESERVOIR
MASTER CYLINDER
MASTER CYLINDER BENCH BLEEDING

NOTE: Master cylinder must be filled and kept at least half full during bleeding operation. Perform this procedure prior to installing master cylinder on vehicle. 1. 2. 3. Secure master cylinder ange in vise. Remove cover and fill reservoir with DOT 3 brake fluid. Screw threaded end of bleeder hose into brake line port on master cylinder and insert opposite end into reservoir. Repeat step for other bleeder hose (Figure 7-9). Slowly push piston into master cylinder. Do not release piston. Air will be forced into hoses. Repeat as needed until no bubbles noted from lines. Lines must stay in fluid until installed. Refill reservoir with DOT 3 brake fluid and repeat step 4 until no air bubbles remain in brake fluid. Remove bleeder hoses from brake line ports on master cylinder. Install cap on master cylinder and remove from vise. Install master cylinder. Bleed brake system.
BLEEDER HOSES PISTON VISE
4.
Figure 7-9: Bench Bleeding Master Cylinder
5. 6. 7. 8. 9.
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Brake System
7-13
HYDRO-BOOST REPLACEMENT
Removal
1. 2. 3. Remove two nuts securing splash shield mount bracket to hydro-boost/master cylinder assembly. Remove nut securing mount bracket to splash shield and remove mount bracket. Remove two nuts securing the master cylinder to the hydro-boost and pull the master cylinder out and to one side. Disconnect two high pressure lines and one return line from hydro-boost (Figure 7-10). Remove cotter pin, washer, and pushrod from brake pedal bellcrank. Remove spring washer from brake pedal bellcrank and discard cotter pin and spring washer. Remove four nuts, lockwashers, washers, gasket, and hydro-boost from cowl. Discard lockwashers.
BLEEDING THE HYDRO-BOOST SYSTEM

Whenever the booster is removed and installed, the steering system should be bled. 1. Fill the power steering pump reservoir to the proper level and let the uid remain undisturbed for at least two minutes. 2. Start the engine and run momentarily. Add fluid if necessary. 3. Repeat steps 1 and 2 until the fluid level remains constant after running the engine. 4. Turn off the engine. 5. Raise the front of the vehicle so the wheels are off the ground. Support the vehicle with suitable safety stands. 6. Turn the wheels from stop to stop. Add fluid if necessary. 7. Lower the vehicle from the safety stands. 8. Start the engine and depress the brake pedal several times while rotating the steering wheel from stop to stop. 9. Turn the engine off and pump the brake pedal 4 to 5 times. CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage brake system. 10. Check the brake fluid level. Add fluid if necessary. 11. If the fluid is extremely foamy, allow the vehicle to stand a few minutes with the engine on. Then repeat steps 7, 8, and 9. 12. Check for the presence of air in the oil. Air in the oil will give the fluid a milky appearance. Air in the system will also cause the fluid level in the pump to rise when the engine is turned off.
PIN
4. 5.
6.
Installation
1. 2. Install gasket and hydro-boost on cowl with four washers, lockwashers, and nuts. Do not tighten nuts. (Figure 7-10). Install spring washer on brake pedal bellcrank. Connect hydro-boost pushrod to brake pedal bellcrank. Install washer and cotter pin. Tighten nuts to 21 lb-ft (28 Nm). Connect two high pressure lines and one return line to hydro-boost. Install master cylinder and splash shield mount bracket. Bleed hydro-boost system.
3. 4. 5. 6.
GASKET SPRING WASHER
BRAKE PEDAL BELLCRANK
HIGH PRESSURE LINES
RETURN LINE
NUTS
LOCKWASHER WASHER PUSHROD COWL FLATWASHER
HYDRO-BOOST
Figure 7-10: Hydro-boost Replacement Procedure
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Brake System _____________________________________________________________
BRAKE LINE REPLACEMENT

Metal brake lines should be inspected for leaks or deterioration every time the vehicle is being serviced.
Intermediate Brake Line Replacement

NOTE: The procedure is the same for the right and left intermediate brake lines. 1. 2. Disconnect the intermediate brake line from the ABS modulator assembly. Disconnect the intermediate brake line from the rear brake line at the union located forward of the forward-rear crossmember. Remove the capscrews and clamps securing the intermediate brake line to the frame rail and remove the brake line from the vehicle. Reverse the removal procedure for installation and bleed the brake hydraulic system.
WARNING: Batteries must be disconnected when the brake hydraulic system is being serviced and bled. If the ABS motor pump runs when air is in the hydraulic system, air can get trapped behind the valves in the modulator causing a spongy brake pedal.
NOTE: After servicing the brake system, bleed the brakes and refill as necessary.
3.
Front Brake Line Replacement

NOTE: The procedure is the same for the right and left front brake lines. 1. 2. 3. 4. Disconnect the brake line from the caliper. Disconnect the brake line from the the ABS modulator assembly. Remove the capscrew and clamp securing the brake line to the crossmember, and remove the brake line (Figure 7-11). Reverse the removal procedure for installation and bleed the brake hydraulic system.
CROSSMEMBER CLAMP
4.
Rear Brake Line Replacement

Removal
1. 2. Disconnect the rear brake line from the caliper. Disconnect rear brake line from the intermediate brake line at the union located forward of the forward-rear crossmember (Figure 7-12).
REAR LINE INTERMEDIATE LINE UNION
Figure 7-12: Rear Brake Line Replacement

3. Remove the capscrew and clamp securing the rear brake line to the forward-rear crossmember and remove the brake line from the vehicle. Reverse the removal procedure for installation and bleed the brake hydraulic system.
Figure 7-11: Front Brake Line Replacement

4.
____________________________________________________________
Brake System
7-15
METAL BRAKE LINES LINE MOUNTIG CLIP
FROM ABS/TT4 MODULATOR
UNION
CALIPER
Figure 7-13: Rear Brake Component Location
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Brake System _____________________________________________________________
LINE MOUNTING CLIP CALIPER
METAL LINES TO REAR CALIPERS METAL BRAKE LINES ABS MODULATOR
MASTER CYLINDER
HYDROBOOST
Figure 7-14: Front Brake Component Location
____________________________________________________________
Brake System
7-17
SERVICE BRAKE PEDAL REPLACEMENT

Removal
1. 2. Disconnect the stoplight switch (Figure 7-15). Remove pushnut and disconnect stoplight switch rod (if so equipped) from brake pedal assembly. Discard pushnut. (Figure 7-15). Disconnect return spring from brake pedal assembly. Remove cotter pin and washer securing hydro-boost pushrod to brake pedal bellcrank, and disconnect hydroboost pushrod from brake pedal bellcrank. Remove spring washer. Discard cotter pin and spring washer. Remove nut, two washers, pivot pin, and brake pedal assembly from bracket. Remove two bushings from brake pedal assembly. Discard two bushings.
SERVICE BRAKE ROTOR REPLACEMENT

Removal
1. 2. Remove service brake caliper. Remove six capscrews, lockwashers, halfshaft, and rotor from output flange. Discard lockwashers (Figure 7-17).
3. 4.
Installation
1. 2. 3. Apply thread-locking compound to threads of capscrews. Install rotor on output flange. Secure halfshaft and rotor to output flange with twelve inclined cam lockwashers and capscrews with preapplied threadlocker. Tighten capscrews to 57 lb-ft (77 Nm). Install service brake caliper.
5. 6.
4.
Installation
1. 2. Apply silicone grease to inside of two bushings. Install two bushings in brake pedal assembly. Install brake pedal assembly on bracket with pivot pin, two washers, and nut. Using adapter and crowfoot, tighten nut to 60 lb-ft (81 Nm). Install spring washer on brake pedal bellcrank. Connect hydro-boost pushrod to brake pedal bellcrank with washer and cotter pin. Connect return spring to brake pedal assembly. Use the pushnut to install the stoplight switch rod (if so equipped) to brake pedal assembly. Connect the stoplight switch. Operate vehicle and check brakes for proper operation. Check brake lights for proper operation.
RETURN SPRING
3.
4. 5. 6. 7. 8.
HYDROBOOST MASTER CYLINDER REAR BRAKE LINE FRONT BRAKE LINE
PIVOT PIN
Figure 7-16: Hydro-Boost And Master Cylinder Mounting
HYDRO-BOOST PUSHROD STOPLIGHT SWITCH BRACKET BRAKE PEDAL BELLCRANK ROTOR HALFSHAFT
BUSHING STRIKER SPRING WASHER
OUTPUT FLANGE
Figure 7-17: Service Brake Rotor
BRAKE PEDAL ASSEMBLY
Figure 7-15: Service Brake Pedal Components

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Brake System _____________________________________________________________
REAR DUAL SERVICE/PARKING BRAKE PAD REPLACEMENT

Removal
1. 2. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, and clevis pin securing parking brake cable to lever. Discard cotter pin (Figure 7-18). Remove clip securing parking brake cable to caliper cable bracket and disconnect cable from caliper cable bracket. Discard clip.
ROTOR
TAPPED HOLE ADAPTER
ADAPTER SLIDE
BRAKE PAD
3.
BRAKE PAD
CAUTION: Caliper must be supported during removal to prevent damage to brake line. 4. Remove two capscrews and washers securing yoke and caliper to adapter, and pull yoke and caliper away from rotor (Figure 7-19).
CAP SCREW YOKE
NOTE: Note positioning of brake pad surfaces for installation. 5. Remove two brake pads from adapter and rotor.
CALIPER

NOTE: Clean all components, examine for wear or damage, and replace if necessary. 2. 1. Clean mating surfaces of caliper and adapter and lightly lubricate adapter slides with brake component lubricant (Figure 7-19).
CALIPER CABLE BRACKET CLIP
Figure 7-19: Rear Dual Brake Pad and Rotor

Inspect caliper and caliper piston face for pitting or damage (Figure 7-20). Inspect piston dust boot and bushings for tears or deterioration. Inspect caliper cable bracket for looseness, damage, and rotation. Thoroughly clean and inspect rotor for heat checks, discoloration, pitting, or scoring (Figure 7-19).
3. 4. 5.
CAUTION: Ensure that grease and oil are not in contact with rotor and/or brake pad friction surface. Failure to do so will result in damage to equipment and poor performance. NOTE: Replace brake pads in sets only. If operation in wet and muddy conditions is expected, replace brake pads if brake lining thickness is less than 1/8 in. (3.2 mm).
LEVER
6.
COTTER PIN
Inspect brake pads for glazing, oil saturation, or wear. If glazed, oil saturated, or if brake lining thickness is less than 1/8 in. (3.2 mm), replace both pads and pads on opposite caliper.
PARKING BRAKE CABLE CLEVIS PIN PARKING BRAKE CLEVIS WASHER
Figure 7-18: Rear Dual Brake Components
____________________________________________________________
Brake System
7-19
BUSHING CALIPER
CALIPER CABLE BRACKET CALIPER CABLE BRACKET CLIP
CALIPER CABLE BRACKET STOP LEVER CALIPER PISTON FACE DUST BOOT
Figure 7-20: Rear Dual Brake Caliper
Installation WARNING: Ensure brake pads are installed with linings facing rotor. Failure to do this will cause poor performance and damage to equipment and may result in injury.
1. Check brake pad backing plate notches for burrs or excess coating and ensure that the pad will t the adapter slide with enough clearance to afford stick-free movement.
PARKING BRAKE CABLE CLEVIS PIN PARKING BRAKE CLEVIS
Figure 7-21: Rear Dual Brake Caliper Cable CAUTION: Ensure lever is in contact with caliper cable bracket stop. Damage to equipment and poor performance will result if not aligned properly. Ensure that clevis and clevis pin are aligned to the lever. Do not move lever to accommodate a maladjusted clevis. Damage to equipment and poor performance will result. 7. Install parking brake clevis to lever with clevis pin, washer, and cotter pin. Check position of lever and ensure it is in contact with caliper cable bracket stop. Adjust rear dual service/parking brake.
CAUTION: Remove any excess lubricant that may have squeezed out from between mating surfaces. Do not allow any lubricant to come in contact with brake pad friction material or brake rotor surfaces. 2. Lubricate caliper guide pins, sleeves and adapter slides with Permatex Ultra Disc Brake Caliper Lube prior to installation.
8.
NOTE: Always apply thread-locking compound to the tapped holes. 3. 4. Apply thread-locking compound to tapped holes of adapter. Using special tool J42553, rotate caliper piston in a clockwise direction, and at the same time apply force on outer piston face until caliper piston is seated in piston bore (Figure 7-20). Position caliper and yoke on adapter and rotor. Secure yoke to adapter with two washers and capscrews. Using a crowsfoot, tighten capscrews to 40 lb-ft (54 Nm) (Figure 7-19). Install parking brake cable to caliper cable bracket and secure with clip (Figure 7-21).
5.
6.
05745159
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7-20
Brake System _____________________________________________________________
REAR DUAL SERVICE/PARKING BRAKE CALIPER REPLACEMENT

Removal
1. 2. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, and clevis pin securing parking brake clevis to lever. Discard cotter pin (Figure 7-21). Remove clip and parking brake cable from caliper cable bracket. Discard clip. Disconnect brake line from coupling (Figure 7-22). Remove coupling and copper washer from caliper.

NOTE: Clean all components, examine for wear or damage, and replace if necessary. Apply a light coat of brake component lubricant on adapter slides. 1. Clean mating surfaces of caliper and adapter and lubricate adapter slides with brake component lubricant (Figures 7-17 and 7-19). Inspect caliper and caliper piston face for pitting or damage (Figure 7-24). Inspect caliper cable bracket for looseness, damage, and rotation Inspect piston dust boot and bushing for tears or deterioration. Clean cooling fins of rotor (Figure 7-22). Inspect rotor for heat checks, discoloration, pitting, or damage. Inspect yoke and caliper guide pins for corrosion. Perform step 8 if corroded, if not, perform step 9. Remove caliper guide pins from yoke. Discard caliper guide pins. Inspect brake pads for glazing, oil saturation, or wear. If glazed, oil saturated, or if brake lining thickness is less than 1/8 in. (3.2 mm), replace both pads and pads on opposite caliper.
2. 3. 4. 5. 6. 7. 8.
3. 4. 5.
MOUNTING ADAPTER
ROTOR
9.
BRAKE LINE/HOSE COUPLING COPPER WASHER SLIDE SURFACES YOKE
CAUTION: Ensure that grease and oil are not in contact with rotor and/or brake pad friction surfaces. Failure to do so will result in damage to equipment and poor performance.
PLASTIC SLEEVE CALIPER BUSHING
CALIPER GUIDE PIN
Figure 7-22: Rear Dual Brake Components

CAUTION: Caliper must be supported during removal to prevent damage to brake line. 6. 7. Remove two capscrews, washers, yoke, and caliper from adapter. Slide yoke and caliper guide pins out from caliper.
____________________________________________________________
Brake System
7-21
CALIPER CABLE BRACKET CLIP
LEVER
CALIPER CABLE BRACKET STOP
PARKING BRAKE CABLE CLEVIS PIN PARKING BRAKE CLEVIS
LEVER
Figure 7-23: Rear Dual Service/Parking Brake Caliper Cable Bracket
CALIPER CABLE BRACKET CALIPER
BLEEDER VALVE CALIPER PISTON FACE DUST BOOT
Figure 7-24: Rear Caliper and Bleeder Valve
05745159
7-22
Brake System _____________________________________________________________
Installation
1. Open bleeder valve and depress piston into caliper while rotating piston in a clockwise direction, and at the same time apply pressure until piston is seated in piston bore (Figure 7-24).
ADAPTER
NOTE: Perform step 2 only if caliper guide pins were replaced. 2. Apply thread-locking compound to threads of caliper guide pins and install caliper guide pins in yoke. Tighten caliper guide pins to 30 lb-ft (41 Nm) (Figure 7-25). Lubricate caliper guide pins, sleeves and adapter slides with Permatex Ultra Disc Brake Caliper Lube prior to installation. Slide yoke and caliper guide pins into caliper Apply thread-locking compound to tapped holes of adapters. Position caliper and yoke on adapter and rotor. Install caliper and yoke on adapter with two washers and capscrews. Using crowfoot, tighten capscrews to 40 lb-ft (54 Nm). Install copper washer and coupling on caliper and connect brake line to coupling. Install parking brake cable on caliper cable bracket and secure with clip (Figure 7-23).
TAPPED HOLE ROTOR
3.
COUPLING COPPER WASHER BRAKE LINE/HOSE YOKE
4. 5.
6. 7.
SLEEVE BUSHING CALIPER CALIPER GUIDE PIN
CAUTION: Ensure lever is in contact with caliper cable bracket stop. Damage to equipment and poor performance will result if not aligned properly. Ensure that clevis and clevis pin are aligned to lever. Do not move lever to accommodate a misadjusted clevis, or damage to equipment and poor performance will result. 8. Install parking brake clevis on lever and secure with clevis pin, washer, and cotter pin. 9. Check position of lever and ensure it is in contact with caliper cable bracket stop. 10. Bleed brake system. 11. Adjust rear dual service/parking brake.
Figure 7-25: Rear Brake Components
4-1-00
____________________________________________________________
Brake System
7-23
RIGHT PARKING BRAKE CABLE REPLACEMENT

Removal
1. 2. 3. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-26). Remove clip securing cable sleeve to caliper cable bracket and remove parking brake cable assembly from caliper cable bracket. Discard clip. Slide parking brake cable through parking brake cable assembly. Remove clip securing cable sleeve to C-beam. Disconnect parking brake cable from equalizer bar. Discard clip. Remove two capscrews securing two clamps and parking brake cable assembly to frame. Remove capscrew, lockwasher, and clamp from bracket. Discard lockwasher.
Installation
NOTE: Perform step 1 if clamp bracket was removed, if not, proceed to step 2. 1. 2. 3. 4. Rotate bracket inward on support bracket and secure with two capscrews. Install clamp on parking brake cable assembly and install clamp to bracket with lockwasher and capscrew. Install two clamps on parking brake cable assembly and install clamps on frame with two capscrews. Install cable sleeve on C-beam and parking brake cable on equalizer bar and secure with cable clip.
4.
5. 6.
CAUTION: Ensure that the caliper cable bracket is secure with no signs of looseness and the lever is in contact with the caliper cable bracket stop. Damage to equipment and poor performance will result if not aligned properly. 5. 6. 7. Install cable sleeve on caliper cable bracket with brake cable clip. Install brake clevis on lever with clevis pin, washer, and cotter pin. Adjust parking brake lever.
NOTE: Perform step 7 if bracket is damaged. If not replacing bracket, proceed to installation. Note position of cable, bracket, and clamp prior to removal. 7. Remove two capscrews and bracket from support bracket.
PARKING BRAKE CABLE ASSEMBLY
CLIP SUPPORT BRACKET EQUALIZER BAR CALIPER CABLE BRACKET CLIP
PARKING BRAKE CABLE CALIPER CABLE BRACKET STOP LEVER FRAME CABLE SLEEVE
C-BEAM
BRACKET CABLE SLEEVE BRAKE CLEVIS CLEVIS PIN PARKING BRAKE CABLE
Figure 7-26: Right Parking Brake Cable Components
05745159
7-24
Brake System _____________________________________________________________
LEFT PARKING BRAKE CABLE REPLACEMENT

Removal
1. 2. 3. 4. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-27). Remove clip and cable sleeve from caliper cable bracket. Discard clip. Slide parking brake cable through parking brake cable assembly. Remove clip securing cable sleeve to C-beam. Disconnect parking brake cable from equalizer bar. Discard clip. Remove capscrew, washer, nut and lockwasher assembly and washer securing clamp to mounting bracket and parking brake cable assembly. Discard nut and lockwasher assembly. Remove capscrew, lockwasher, clamp, and parking brake cable assembly from bracket. Discard lockwasher.
Installation
NOTE: Perform step 1 if clamp bracket was removed. If not, proceed to step 2. 1. 2. 3. Rotate bracket inward on support bracket and secure with two capscrews (Figure 7-27). Install clamp on parking brake cable assembly and bracket with lockwasher and capscrew. Install clamp on parking brake cable assembly and mounting bracket with washer, capscrew, washer, and nut and lockwasher assembly. Install cable sleeve on C-beam and parking brake cable to equalizer bar and secure with clip.
5.
4.
6.
CAUTION: Ensure that the caliper cable bracket is secure with no signs of looseness and the lever is in contact with the caliper cable bracket stop. Damage to equipment and poor performance will result if not aligned properly. 5. 6. 7. Install cable sleeve on caliper cable bracket with clip. Install brake clevis on lever with clevis pin, washer, and cotter pin. Adjust parking brake lever.
NOTE: Perform step 7 if clamp bracket is damaged. If not replacing bracket, proceed to installation. Note position of cable, bracket, and clamp prior to removal. 7. Remove two capscrews and bracket from support bracket.
CLIP
PARKING BRAKE CABLE EQUALIZER BAR CABLE SLEEVE
SUPPORT BRACKET
CALIPER CABLE BRACKET C-BEAM MOUNTING BRACKET
CLIP CALIPER CABLE BRACKET STOP LEVER CABLE SLEEVE CLEVIS PIN PARKING BRAKE CABLE BRAKE CLEVIS
PARKING BRAKE CABLE ASSEMBLY
BRACKET
Figure 7-27: Left Parking Brake Cable Components
____________________________________________________________
Brake System
7-25
PARKING BRAKE ROD REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-28). Remove six clips and spread boot to allow access to cotter pin (Figure 7-29). Remove cotter pin, washer, clevis pin, and clevis securing brake rod to bellcrank. Discard cotter pin. Disconnect spring from bracket (Figure 7-29). Remove locknut from conical washer, and brake rod from equalizer bar. Discard locknut. Remove clevis, nut and spring from brake rod.
CALIPER CABLE BRACKET
CALIPER CABLE BRACKET STOP
LEVER
CLEVIS PIN BRAKE CLEVIS
Installation
1. 2. Install spring, nut, and clevis on brake rod. Install brake rod on equalizer bar with conical washer and locknut. Tighten locknut far enough to expose 3-5 threads on the end of brake rod. Connect spring to bracket. Spread boot and install clevis to bellcrank with clevis pin, washer and cotter pin. Install six clips on boot.
Figure 7-28: Parking Brake Rod Attachment at Caliper
3. 4. 5.
PARKING BRAKE ADJUSTMENT

NOTE: The integral parking/service brake mechanism has an automatic adjusting feature and does not require periodic manual adjustment. When parking brake components or rear brake pads are replaced, the parking brake linkage must be initially positioned to ensure proper parking brake system operation. The only additional adjustment necessary is accomplished with the parking brake hand lever.
CAUTION: Ensure that the caliper cable bracket is secure with no signs of looseness and the lever is in contact with the caliper cable bracket stop. 6. 7. Install brake clevis on lever with clevis pin, washer, and cotter pin (Figure 7-30). Adjust parking brake.
CLIP SPRING EQUALIZER BAR
BOOT
BELLCRANK CONICAL WASHER CLEVIS FRAME BRACKET BRAKE ROD 1/2 ENGAGEMENT TO EQUALIZE CLEVIS PIN
Figure 7-29: Parking Brake Rod Location
05745159
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Brake System _____________________________________________________________
Adjustment
1. 2. 3. 4. Put transmission in PARK, chock wheels, and release parking brake. Remove six clips and spread boot to allow access to cotter pin (Figure 7-30). Remove cotter pin, washer, and clevis pin securing clevis to bellcrank. Discard cotter pin. Repeatedly apply and adjust parking brake hand lever until bellcrank linear travel is 0.75 in. (19 mm).
BRAKE
NOTE: Perform step 7 on both sides of vehicle. 7. Parking brake rod is properly adjusted if lever is in contact with caliper cable bracket stop (Figure 7-31). 8. Tighten nut against clevis. 9. Install six clips in boot (Figure 7-30) 10. Adjust parking brake lever.
CALIPER CABLE BRACKET
CALIPER CABLE BRACKET STOP BELLCRANK
BRAKE
0.75 in. (19 mm) CLIP LEVER BOOT PARKING BRAKE ROD CLEVIS BELLCRANK CLEVIS PIN
Figure 7-31: Caliper Cable Bracket Stop
PARKING BRAKE HAND LEVER REPLACEMENT

Removal
1. Put transmission in PARK, chock wheels, and release parking brake. Remove parking brake switch. Remove six clips and open lower boot to allow access to clevis pin. Discard clips (Figure 7-32). Remove cotter pin, washer, and clevis pin from clevis and bellcrank. Discard cotter pin. Remove nut and lockwasher assembly, wiring harness clamp, nut and lockwasher assembly, and bolt securing parking brake hand lever to body. Discard nut and lockwasher assemblies (Figure 7-33). Remove three locknuts, washers, and bolts securing parking brake hand lever to body. Discard locknuts. Remove two locknuts, washers, bolts, and washers securing parking brake hand lever to body and remove parking brake lever. Discard locknuts. Remove upper boot from parking brake hand lever. Remove boot from body.
Figure 7-30: Parking Brake Adjustment

CAUTION: Holes in parking brake clevis must align with holes in adjusting bellcrank without force for proper parking brake adjustment. Failure to do this may result in damage to equipment and poor performance. 5. Release parking brake. Loosen nut and adjust clevis so holes in clevis align with holes in bellcrank. Secure clevis to bellcrank with clevis pin, washer, and cotter pin.
2. 3. 4. 5.
CAUTION: Do not overtighten parking brake rod. Overtightening parking brake rod may result in dragging brakes. 6. If necessary, remove excess slack in parking brake cables by turning the parking brake rod clockwise or counterclockwise into the clevis. 6. 7.
CAUTION: Ensure that the caliper cable bracket is secure with no signs of looseness and the lever is in contact with the caliper cable bracket stop. Damage to equipment and poor performance will result if not aligned properly.
8. 9.
____________________________________________________________
Brake System
7-27
Installation
1. 2. 3. Install boot on body. Install upper boot on parking brake hand lever. Install parking brake hand lever on body and secure with two washers, bolts, washers, and locknuts. Secure parking brake hand lever on body with bolt, nut and lockwasher assembly, wiring harness clamp, and nut and lockwasher assembly. Secure parking brake hand lever on body with three bolts, washers, and locknuts. Apply parking brake hand lever and tighten three bolts to 96 lb-in. (11 Nm). Install clevis on bellcrank with clevis pin, washer, and cotter pin (Figure 7-32).
PARKING BRAKE LEVER WIRING HARNESS CLAMP
4. 5. 6.
.
BODY UPPER BOOT
Figure 7-33: Parking Brake Hand Lever Mounting

CLIP
FRONT DISC BRAKE CALIPER REPAIR

Disassembly
LOWER BOOT BELLCRANK
1. 2.
Remove disc brake caliper. Insert wood block between jaw of caliper and piston (Figure 7-34).
CLEVIS
CLEVIS PIN
WARNING: To avoid injury, hold caliper so piston is facing away from your body and keep ngers out of space between piston and wood block. Compressed air used for cleaning should not exceed 30 psi (207 kPa).
3. 4. 5. Remove piston from caliper by applying air pressure to hose inlet of caliper. Remove piston dust boot and seal from caliper bore. Discard dust boot and seal (Figure 7-35). Remove bleeder screw from caliper.
Figure 7-32: Parking Brake Rod Attachment at Hand Lever 7. 8. 9. Install six clips and close lower boot. Install parking brake switch. Adjust parking brake lever.

NOTE: Clean all components, examine for wear or damage, and replace if necessary (Figure 7-35). 1. Inspect caliper bore for scoring, nicks, or corrosion. Minor corrosion can be polished with abrasive crocus cloth or hone. Replace caliper if bore is not repairable. Inspect piston outside diameter for scoring, nicks, corrosion, and worn or damaged chrome plating. Replace piston if there are any surface defects. Inspect bleeder screw for damage or stripped threads. Replace if damaged. Inspect bushing for damage. Replace if damaged.
2.
3. 4.
05745159
7-28
Brake System _____________________________________________________________
Assembly
HOSE INLET
CAUTION: The HUMMER is equipped with DOT 3 fluid. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage brake system. 1. 2. 3. 4. 5. 6. 7. Lubricate caliper bore and seal with DOT 3 brake uid (Figure 7-35). Install seal in groove of caliper bore. Lubricate piston with DOT 3 brake uid install dust boot on piston. Work piston and dust boot into caliper bore. Seat dust boot in caliper. Install bleeder screw in caliper finger tight. Lubricate caliper guide pins, sleeves and adapter slides with Permatex Ultra Disc Brake Caliper Lube (Permatex PN 20356) prior to installation. Install disc brake caliper.
CALIPER
Figure 7-34: Front Disc Brake Caliper
8.
BUSHING BLEEDER SCREW SLEEVE CALIPER
PISTON
SEAL PISTON DUST BOOT CALIPER BORE
Figure 7-35: Front Disc Brake Caliper Assembly
4-1-00
____________________________________________________________
Brake System
7-29
REAR CALIPER OVERHAUL

Rear Caliper Disassembly (Figure 7-37)
1. 2. 3. Mount caliper in vise so parking brake lever and spring are facing upward. Unseat and remove parking brake lever spring. Use large slip joint pliers. Remove bolt that secures lever retainer to thrust screw. Then remove retainer, but do not remove parking brake lever at this time. Remove caliper piston as follows: a. Remove piston retaining screw with hex key and pencil magnet. Use magnet to withdraw screw after loosening it. b. Extend piston by rotating parking brake lever. c. Rotate caliper piston in counter-clockwise direction until it comes off thrust screw. Rotate piston by hand, or use piston retraction tool J-42553 (Figure 7-36).
13. 14. 15. 16.
4.
Remove and discard actuator shaft dust seal. Discard seal. Remove and discard centering pin plug O-ring. Remove and discard centering pin O-ring. Remove O-ring from actuator shaft. Then remove thrust bearing and race from shaft. Discard O-ring but retain bearing and race if in good condition. 17. Disassembly caliper piston as follows: a. Remove retaining ring with internal type ring pliers. b. Remove wave washer. c. Remove thrust washer and bearing. d. Remove cone clutch.
Caliper Cleaning and Inspection

Clean the caliper parts in standard parts cleaning solvent, or denatured alcohol. Dry the parts with compressed air or lint free shop towels. Replace the caliper piston if corroded, rusted, or scored. Do not attempt to salvage any piston where rust or scoring has broken through the piston plating. Also, do not use any type of abrasive material on the piston surface. This practice will damage the plating and cause the piston to stick or seize in the bore. Check condition of the caliper piston bore. Moderate surface discoloration is normal and not a cause for replacement. However, the caliper should be replaced if the bore is corroded, pitted, or scored. The bore can be lightly polished with crocus cloth but must not be honed or sanded. Inspect the thrust screw and actuator shaft parts. Replace the thrust screw, spring shield, and retaining ring if damaged, or distorted. Replace the actuator shaft, bearing plate, and bearing balls if scored, cracked, worn, corroded, or pitted. Also replace the shaft bearing and race as a set if either part is worn, rough, pitted, or scored. Replace the caliper piston cone clutch, bearing and race, or wave washer if worn, scored, or damaged.
DISC BRAKE PISTON RETRACTION TOOL J-42553
CALIPER PISTON
Figure 7-36: Piston Removal

d. Pull piston out of dust boot and remove it from caliper. Remove piston dust boot with pry tool.
5.
CAUTION: Exercise care when removing the boot. Do not allow the pry tool to scratch the caliper piston bore. 6. Remove thrust screw retaining ring. Carefully unseat ring with long, thin, flat blade screwdriver. Apply single wrap of electrical tape around screwdriver blade to avoid scratching bore, or thrust screw spring shield. 7. Grasp thrust screw and slide screw, shield, and spring out of bore as assembly. Rotate brake lever to assist removal. 8. Remove parking brake lever from actuator shaft. 9. Remove actuator shaft bearing balls with pencil magnet. 10. Remove thrust screw centering pin plug and spacer. Then reach inside caliper piston bore and push centering pin out of caliper with finger pressure. 11. Push bearing plate and actuator shaft out of caliper bore using finger pressure. 12. Remove caliper piston seal from groove in piston bore. Use wood pencil to remove seal. Do not use metal tools that will scratch bore. 05745159
Assembly (Figure 7-37)

1. Install new actuator shaft dust seal in caliper. Use one-inch socket to seat seal in housing. The open portion of seal metal retainer faces out. Lubricate seal lip with DOT 3 brake uid afterward. Lubricate actuator shaft, bearings, race, and plate with DOT 3 brake uid. Then install thrust bearing and race on shaft and secure with new O-ring. Install actuator shaft in caliper. Then install plastic bearing plate and the three ball bearings. Install new O-ring on thrust screw centering pin and install pin in caliper. Position pin so blade will align with slot in thrust screw. Lubricate thrust screw with DOT 3 brake uid. Then install spring and retaining ring on thrust screw.
2.
3. 4.
5.
7-30
6.
Brake System _____________________________________________________________
Install thrust screw as follows: a. Align slot in thrust screw with centering pin. b. Insert thrust screw in caliper and seat it on centering pin and on ball bearings. c. Compress thrust screw retaining ring with fingers and install it in caliper bore below piston seal groove. CAUTION: Do not use metal tools to install the retaining ring. Metal tools will score or scratch the caliper bore. d. Push assembly into bore as far as possible. e. Seat retaining ring using unassembled caliper piston. Lightly coat piston with DOT 3 brake uid and insert it in bore. Then push piston sharply downward two or three times to seat retaining ring. Remove piston after ring is seated. Install new O-ring on centering pin plug. Then position spacer on top of centering pin and install plug. Tighten plug securely with hex wrench or socket. Install new caliper piston seal. Start square cut seal into groove at top of bore and work it into place with your fingers. Lubricate seal and bore with fresh DOT 3 brake uid. Assembly caliper piston as follows; a. Install cone clutch in piston. b. Lubricate bearing and race with DOT 3 brake uid and install them on cone clutch. The open side of bearing goes toward race. c. Install wave washer (either side up). d. Install retaining ring with internal-type ring pliers. Flat side of ring goes toward wave washer. Install caliper piston as follows: a. Install new dust boot on caliper piston. b. Lubricate caliper piston with fresh brake fluid. Then insert it through dust boot, into caliper bore, and onto thrust screw. c. Install parking brake lever on actuator shaft and rotate lever to extend thrust screw. d. Rotate piston onto thrust screw by hand, then with suitable size socket. e. Turn parking lever to normal (non-applied) position and complete piston installation as needed. f. Seat piston dust boot in groove at top of caliper bore. Use suitable size boot installer tool or flat punch. Install new O-ring on piston retaining screw and install screw. Tighten screw securely. Install parking brake lever retainer and bolt. Apply 1-2 drops Loctite to bolt threads before installation. Install and seat parking brake lever return spring in cable housing slot.
7.
8.
9.
10.
11. 12. 13.
14. Install bleed screw, if removed Apply anti-seize compound to screw threads beforehand.
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Brake System
7-31
LEVER RETAINER AND BOOT O-RING PLUG THRUST SCREW CENTERING PIN SPACER BLEEDER SCREW CAP BLEEDER SCREW LEVER RETURN SPRING O-RING PARKING BRAKE LEVER ACTUATOR SHAFT DUST SEAL CABLE HOUSING CALIPER ACTUATOR SHAFT THRUST SCREW BEARING PLATE THRUST SCREW SPRING SHIELD THRUST SCREW RETAINING RING ACTUATOR SHAFT BEARINGS RETAINING RING
ACTUATOR SHAFT O-RING
BEARING RACE THRUST BEARING
THRUST SCREW SPRING
WAVE WASHER BEARING RACE THRUST BEARING CONE CLUTCH PISTON SEAL
CALIPER PISTON O-RING PISTON RETAINING SCREW
PISTON DUST BOOT
Figure 7-37: Rear Caliper
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Brake System _____________________________________________________________
BRAKE ROTOR
NOTE: Clean all components, examine for wear or damage, and replace if necessary (Figure 7-38). 1. Remove brake rotor.
tachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter to allow for a better surface finish. Make sure these adaptors are clean and free of nicks. The optional swirl pattern finish will provide the best initial braking effectiveness. For this, use a sanding disc power tool with 120 grit disc for about 10 seconds per side.
Checking Lateral Runout

1. Mount dial indicator with stylus contacting rotor surface 1 in. (25 mm) in from outer edge (Figure 7-39). 2. Turn rotor 360 and note total indicator reading (TIR). If lateral runout exceeds 0.004 in. (0.10 mm) TIR, replace or refinish rotor.
ROTOR
NOTE: Clean rusted or scaled rotor braking surfaces before attempting inspection or measurement. 2. 3. Mount rotor in brake lathe and turn while cleaning surfaces with abrasive crocus cloth. Inspect rotor for heat checks, nicks, broken cooling fins, scoring, discoloration, and pitting. It is not recommended that rotors be turned when spotted or heat checked.
BRAKE ROTOR COOLING FINS
Figure 7-39: Checking Rotor for Lateral Runout Figure 7-38: Brake Rotor and Cooling Fins
NOTE: Clean debris from cooling fins if necessary.
Checking Thickness Variation

1. Measure thickness variation of rotor with micrometer at four equally-spaced points around rotor. Measure 1 in. (25 mm) in from outer edge (Figure 7-40). If thickness variation exceeds 0.005 in. (0.13 mm), replace or refinish rotor.
REFINISHING BRAKE ROTORS

Refinish rotors only under the following circumstances: 1. There is a complaint of brake pulsation. 2. There is excessive scoring. Brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the dimensions shown in the specifications. Original equipment rotors are finished to 0.25-1.27 micrometers (10-50 microinches). Accurate control of rotor tolerances is necessary for the proper performance of disc brakes. Machining should be done only with precision equipment. Service the machining equipment on a regular basis following the manufacturers recommended maintenance procedures. When you refinish rotors, make sure the attaching adapters, tool holders, vibration dampeners, and tool bits are in good condition. Always use sharp cutting tools or bits and use only replacement cutting bits recommended by the equipment manufacturer. Dull or worn tools leave a poor surface finish that will affect initial brake performance. Vibration dampening at-
2.
Refinishing
1. 2. 3. Mount rotor on brake lathe and renish surface. Replace rotor if refinishing causes rotor to fall below minimum thickness of 0.815 in. (20.7 mm). Install brake rotor.
ROTOR
Figure 7-40: Checking Rotor Thickness
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Brake System
SPRING
7-33
PARKING BRAKE LEVER ADJUSTMENT

Adjustment
1. 2. 3. Adjust linkage. Put transmission in PARK, chock wheels, and release parking brake handle. Turn adjusting knob clockwise as tightly as possible by hand (Figure 7-41).
TRANSMISSION SHIFT LEVER TRANSFER CASE SHIFT LEVER
ACTUATING LEVER
ADJUSTING KNOB
Figure 7-42:
Spring and Actuating Lever for Parking Brake
PARKING BRAKE SWITCH REPLACEMENT

Removal
1. 2. Disconnect the two harness leads from the switch leads (Figure 7-43). Remove the switch from the parking brake lever.
Installation
PARKING BRAKE HANDLE
1. 2. 3.
Install the switch on the parking brake lever (Figure 7-43). Connect two switch leads to the harness leads. Ensure parking brake switch operates properly.
SWITCH LEADS HARNESS LEADS
Figure 7-41: Parking Brake Lever Location 4. 5. 6. Apply parking brake handle. If parking brake cannot be applied, turn adjusting knob counterclockwise until parking brake can be applied. Test parking brake. a. Remove chocks. b. Depress service brake pedal and start engine. c. d. Place transfer case shift lever in H (high) and transmission shift lever in D (drive). Slowly let up on service brake pedal. Parking brake should hold vehicle stationary.
SWITCH
CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage brake system. NOTE: After operating in mud or sand, use a low pressure water source to ensure that the parking brake pads, rotor, pad-rotor contact areas, actuating lever, and spring are thoroughly cleaned of mud, sand, or other debris. Lubricate actuating lever as soon as possible (Figure 7-42).
PARKING BRAKE LEVER PARKING BRAKE ROD
Figure 7-43: Parking Brake Switch
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Brake System _____________________________________________________________
ANTI-LOCK BRAKE SYSTEM (ABS) AND AUTOMATIC TRACTION CONTROL, TORQTRAC 4 (TT4) System Description
The ABS/TT4 is a hydraulic add-on system consisting of: Hydraulic modulator and pump assembly Electronic control unit Four wheel speed sensors ABS and TT4 warning lights The add-on ABS/TT4 system is a four channel brake pressure modulation system fitted additional to the standard brake system. TT4 uses ABS and standard brake components to automatically control traction at the wheels when accelerating on low friction surfaces.
System Operation
ABS/TT4 system warning lights located in the status center of the instrument panel illuminate when there is a problem with the system. The lamps also illuminate during the initial key-on for a system self check and bulb test sequence. After key-on the ABS lamp will shine for approximately three seconds then go out and remain out unless there is a fault in the system or the ignition is cycled. The TT4 lamp will shine for three seconds then go out until there is a problem with the system (Figure 7-44). The TT4 lamp will flash during an overheat period due to extended continuous use. Whenever a lamp is lit due to a failure in the system, ABS and TT4 will be shut down partially or wholly, depending on the nature of the fault.
Anti-lock braking operates by continually sensing the speed of each wheel. Wheel speed information is transmitted to an Electronic Control Unit (ECU) which evaluates the information to determine when any wheel is about to lock. If locking commences, the ECU transmits a control signal to the appropriate solenoid valve in the modulator controlling hydraulic pressure to the brake, thus, brake pressure is adjusted to maintain wheel rotation. The TorqTrac 4 system uses many of the same components as the ABS to control wheel spin when accelerating the vehicle on low friction surfaces. Information from the wheel speed sensors is evaluated by the ECU which determines if a wheel is loosing traction and spinning. The ECU actuates the modulator pump to provide hydraulic pressure which is modulated by the solenoid valves and sent to the brake of the spinning wheel. This has the effect of transferring the torque to the non-spinning wheel on the higher friction surface. The system has an overheat protection feature which disables TT4 after 60 seconds of continuous use. This will be indicated by a blinking TT4 lamp. TT4 will automatically return to normal operation after a 60 second cool down period.
ABS/TT4 DIAGNOSTICS Fault Diagnostic Procedure

Faults are stored in the ECU memory in code form. The information can be retrieved by initiating and reading a series of flash and pause sequences (blink codes) on the ABS warning light or with the Wabco Diagnostic Controller. Use of the blink code procedure will determine the location of the fault prior to performing physical wiring and component tests, thus reducing diagnostic time. NOTE: An attempt to initiate the blink code diagnostic may result in a solid on ABS warning lamp without progressing to the start phase of the diagnostic. If the above condition is present, remove the ABS Warning Lamp Relay from the exterior fuse box and perform the blink code diagnostic (See Figure 7-59). After repairs are completed, replace the warning lamp relay in the socket.
ignition ABS on Warning Lamp
3 sec
Blink Code Procedure

To initiate the blink code procedure, connect the blink code switch jumper J44237 to the Diagnostic Link Connector (DLC) of the vehicle. The jumper allows you to short pin 4 to pin 15 of the DLC. 1. Switch on the ignition, the ABS warning light will illuminate and extinguish if there are no active faults. 2. Five seconds after connecting the switch jumper, the ABS warning light will extinguish, indicating the start of the blink code cycle.
T T4
3 sec
T T4 Info Lamp
8-S07-002
Figure 7-44: ABS/TT4 Warning Light Sequence.
4-1-00
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Brake System
7-35
3.
The start phase consists of the ABS warning light flashing in the following sequence (Figure 7-45): Pause = 2.5 seconds (long) Flash = 2.5 seconds (long) Pause = 2.5 seconds (long) Flash = 0.5 seconds (short)
5.
6.
flashes until the next long pause occurs. The number of short flashes obtained is the first part of the code number. The second part of the code number: A pause of 2.5 seconds occurs between the first and second parts, before a series of short flashes occurs. The number of short flashes forms the second part of the code number. The sequence of the start phase, first and second parts will continue until the switch jumper is deactivated.
NOTE: If you are unsure of the code, do not deactivate the switch jumper from the DLC because the code for that fault will be cleared from the memory. 7.
ABS Warning Lamp
2.5 sec 2.5 sec 2.5 sec 0.5 sec
8-S07-003
Figure 7-45: Blink Code Sequence For Start Phase.
8.
It is possible to have more than one fault with the system at a time. However, the first indicated fault must be repaired then cleared by reconnecting the jumper and awaiting the next start phase before the next fault code can be extracted. Repeat the procedure until no further faults are stored in the memory. The memory is cleared when a long pause of 7.5 seconds occurs after the start phase.
Clearing Fault Codes

At the end of a fault code cycle, deactivate the blink code jumper. The fault code will cycle one more time before the lamp remains on solid. Turn off the ignition and the fault code will be cleared from memory. The fault codes, their causes and repair actions are listed in the following table.
ABS Warning Lamp
2.5 sec
0.5 sec
0.5 sec
0.5 sec
2.5 sec
0.5 sec
0.5 sec
0.5 sec
8-S07-004
Figure 7-46: Blink Code Sequence For Code 3.3. 4. The first part of the code number (Figure 7-46:): A pause of 2.5 seconds precedes a series of short flashes. Count the
Fault Code List - Ignition key OFF to test system (except where noted) Test pin locations refer to ABS Pinout Box J35592
Fault Code 2-0 2-1 2-2 Problem Area ECU internal failure. ECU internal failure. Recirculating Pump (RCP) operates continuously. RCP does not operate. Test Pin Locations 12 and 27 30 and 27 Values Ignition ON 0 volts Replace ECU. Replace ECU. Check the RCP wiring, the pump relay and the wiring connections. Repair or replace as required. Check/Repair
2-2
Jumper 9 and 11 27 and 30
Ignition ON approximate battery + voltage.
Check the RCP wiring, the pump relay and fuse and pump connections. Repair or replace as required.
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Brake System _____________________________________________________________
Fault Code 2-4 Problem Area RCP failure (motor locked). Shuttle valve switch failure. Test Pin Locations Jumper 9, 11 and 12 25 and 27 Values Ignition ON RCP motor running. Brake pedal at rest 3k . Brake pedal 1/2 down 2k . Brake pedal full down 1k . 0 volts. Less than 0.2 to chassis ground. Ignition ON approximate battery + voltage. Check/Repair Excessive current failure. If pump does not run with pins linked, check wiring and relays, if OK, replace modulator. If wiring and connections OK, replace modulator.
2-6
2-7
Continuous power to ECU with ignition OFF. No voltage to ABS solenoid valves. Inlet valve supervision time exceded. Reference ground interrupted. Excessive recirculation pump cycle time. RF sensor weak LR sensor weak LF sensor weak RR sensor weak Open circuit between ECU and right front inlet solenoid valve or wiring. Open circuit between ECU and right front outlet solenoid valve or wiring.
9 and 27
Check for proper wiring connections, repair as necessary.
2-8
Jumper 8 and 9 19 and 27 1 and 27 9 and 27 -
Check the valve relay, fuse and wiring. Repair as necessary.
2-9
Check system voltage for normal function. Clear fault. Repair wiring or connection as necessary.
2-10
31
Less than 0.2 to chassis ground. RCP running
2-11
Ignition ON jumper 9, 11 and 12 17 and 34 18 and 35 15 and 32 16 and 33 6 and 27
Check RCP function. Clear fault.
2-12 2-13 2-14 2-15 3-0
Greater than 0.9 volts AC at one tire revolution per second. 5.0-7.5
Check sensor adjustment. Check geared hub bearing play at halfshaft. Adjust or repair as necessary.
Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary.
3-1
7 and 27
3.0-5.0
3-1-02
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Brake System
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Fault Code 3-2 Problem Area Open circuit between ECU and left front inlet solenoid valve or wiring. Open circuit between ECU and left front outlet solenoid valve or wiring. Open circuit between ECU and right rear inlet solenoid valve or wiring. Open circuit between ECU and right rear outlet solenoid valve or wiring. Open circuit between ECU and left rear inlet solenoid valve or wiring. Open circuit between ECU and left rear outlet solenoid valve or wiring. Open circuit between ECU and RCP relay 1. Open circuit between ECU and RCP relay 2. Short circuit to ground between ECU and right front inlet solenoid valve. Test Pin Locations 23 and 27 Values 5.0-7.5 Check/Repair Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. Check electrical resistance of affected valve wiring to ground at the ECU connector and at the modulator connector. Repair wiring or replace modulator as necessary. If no voltage, check RCP relay 1 circuit and relay.
3-3
24 and 27
3.0-5.0
3-4
4 and 27
5.0-7.5
3-5
5 and 27
3.0-5.0
3-6
21 and 27
5.0-7.5
3-7
22 and 27
3.0-5.0
3-8
Jumper 9 and11 30 and 27
Ignition ON approximate battery + voltage. < 0.2
3-9
Pin 12, Circuit 610
Remove relay, check circuit 610 from pin 12 to relay socket.
4-0
6 and 27
5.0-7.5
Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly as necessary.
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Brake System _____________________________________________________________
Fault Code 4-1 Problem Area Short circuit to ground between ECU and right front outlet solenoid valve. Short circuit to ground between ECU and left front inlet solenoid valve. Short circuit to ground between ECU and left front outlet solenoid valve. Short circuit to ground between ECU and right rear inlet solenoid valve. Short circuit to ground between ECU and right rear outlet solenoid valve. Short circuit to ground between ECU and left rear inlet solenoid valve. Short circuit to ground between ECU and left rear outlet solenoid valve. Short circuit to ground between ECU and RCP relay 1. Short circuit to ground between ECU and RCP relay 2. Test Pin Locations 7 and 27 Values 3.0-5.0 Check/Repair Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly as necessary.
4-2
23 and 27
5.0-7.5
4-3
24 and 27
3.0-5.0
4-4
4 and 27
5.0-7.5
4-5
5 and 27
3.0-5.0
4-6
21 and 27
5.0-7.5
4-7
22 and 27
3.0-5.0
4-8
Remove Relay 1 11 or 30 and 27
Open circuit
Check wiring to pump relay and pump connector through pump. Repair wiring or replace modulator as necessary. Check wiring to pump relay and pump connector through pump. Repair wiring or replace modulator as necessary.
4-9
Remove Relay 2 12 and 27
Open circuit
3-1-02
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Brake System
7-39
Fault Code 4-12 Problem Area Right front wheel speed sensor open circuit. Left rear wheel speed sensor open circuit. Left front wheel speed sensor open circuit. Right rear wheel speed sensor open circuit. Short circuit to battery between ECU and right front inlet valve solenoid or wiring. Short circuit to battery between ECU and right front outlet valve solenoid or wiring. Short circuit to battery between ECU and left front inlet valve solenoid or wiring. Short circuit to battery between ECU and left front outlet valve solenoid or wiring. Short circuit to battery between ECU and right rear inlet valve solenoid or wiring. Test Pin Locations 17 and 34 Values 500-2000 Check/Repair Check electrical resistance of affected sensor and wiring at ECU connector and at harness plugs. Repair wiring or replace sensor as necessary. Check electrical resistance of affected sensor and wiring at ECU connector and at harness plugs. Repair wiring or replace sensor as necessary. Check electrical resistance of affected sensor and wiring at ECU connector and at harness plugs. Repair wiring or replace sensor as necessary. Check electrical resistance of affected sensor and wiring at ECU connector and at harness plugs. Repair wiring or replace sensor as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary.
4-13
18 and 35
500-2000
4-14
15 and 32
500-2000
4-15
16 and 33
500-2000
5-0
6 and 27
0 volts 5.0-7.5
5-1
7 and 27
0 volts 3.0-5.0
5-2
23 and 27
0 volts 5.0-7.5
5-3
24 and 27
0 volts 3.0-5.0
5-4
4 and 27
0 volts 5.0-7.5
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Brake System _____________________________________________________________
Fault Code 5-5 Problem Area Short circuit to battery between ECU and right rear outlet valve solenoid or wiring. Short circuit to battery between ECU and left rear inlet valve solenoid or wiring. Short circuit to battery between ECU and left rear outlet valve solenoid or wiring. Short circuit to battery + between ECU and RCP relay 1. Short circuit to battery + between ECU and RCP relay 2. Right front wheel speed signal is erratic. Test Pin Locations 5 and 27 Values 0 volts 3.0-5.0 Check/Repair Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check voltages at wiring harness including connectors. Check electrical resistance of affected valve wiring to ground at ECU connector and at modulator assembly plug. Repair wiring or replace as necessary. Check wiring harness between ECU and relay and pump ground connections. Repair wiring as necessary.
5-6
21 and 27
0 volts 5.0-7.5
5-7
22 and 27
0 volts 3.0-5.0
5-8
11 and 27
0 volts
5-9
12 and 27
0 volts
Check wiring harness between ECU and relay and pump ground connections. Repair wiring as necessary.
5-12
17 and 34
Greater than 0.9 volts AC at one tire revolution per second. Greater than 0.9 volts AC at one tire revolution per second. Greater than 0.9 volts AC at one tire revolution per second.
Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary.
5-13
Left rear wheel speed signal is erratic.
18 and 35
5-14
Left front wheel speed signal is erratic.
15 and 32
3-1-02
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Brake System
7-41
Fault Code 5-15 Problem Area Right rear wheel speed signal is erratic. Test Pin Locations 16 and 33 Values Greater than 0.9 volts AC at one tire revolution per second 6.0-15.0 Check/Repair Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory.
6-0
Short circuit between two solenoid valve leads of right front inlet solenoid valve. Short circuit between two solenoid valve leads of right front outlet solenoid valve. Short circuit between two solenoid valve leads of left front inlet solenoid valve. Short circuit between two solenoid valve leads of right front outlet solenoid valve. Short circuit between two solenoid valve leads of right rear inlet solenoid valve. Short circuit between two solenoid valve leads of right rear outlet solenoid valve.
6 and 4, 5, 7, 21, 22, 23, 24
6-1
7 and 4, 5, 6, 21, 22, 23, 24
6.0-15.0
6-2
23 and 4, 5, 6, 7, 21, 22, 24
6.0-15.0
6-3
24 and 4, 5, 6, 7, 21, 22, 23
6.0-15.0
6-4
4 and 5, 6, 7, 21, 22, 23, 24
6.0-15.0
6-5
5 and 4, 6, 7, 21, 22, 23, 24
6.0-15.0
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Brake System _____________________________________________________________
Fault Code 6-6 Problem Area Short circuit between two solenoid valve leads of left rear inlet solenoid valve. Short circuit between two solenoid valve leads of left rear outlet solenoid valve. Short circuit between solenoid valve and RCP relay 1. Short circuit between solenoid valve and RCP relay 2. Right front wheel speed signal missing. Test Pin Locations 21 and 4, 5, 6, 7, 22, 23, 24 Values 6.0-15.0 Check/Repair Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check electrical resistance of affected valves and wiring at ECU connector and at modulator assembly plug. Repair or replace wiring as necessary and replace modulator if short is internal. Note: Fault code for both affected valves will be stored in memory. Check wiring harness at ECU connector to pump relay. Repair or replace as necessary.
6-7
22 and 4, 5, 6, 7, 21, 23, 24
6.0-15.0
6-8
11 and 4, 5, 6, 7, 21, 22, 23, 24
55.0-65.0
6-9
12 and 4, 5, 6, 7, 21, 22, 23, 24
55.0-65.0
Check wiring harness at ECU connector to pump relay. Repair or replace as necessary.
6-12
17 and 34
Greater than 0.9 volts AC at one tire revolution per second. Greater than 0.9 volts AC at one tire revolution per second. Greater than 0.9 volts AC at one tire revolution per second. Greater than 0.9 volts AC at one tire revolution per second.
Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary. Check for damaged tone wheel, incorrect sensor adjustment, excessive tone wheel runnout (> .041"), excessive geared hub input bearing play and tire size mismatch. Repair or replace as necessary.
6-13
Left rear wheel speed signal missing.
18 and 35
6-14
Left front wheel speed signal missing.
15 and 32
6-15
Right rear wheel speed signal missing.
16 and 33
3-1-02
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Brake System
7-43
LEFT FRONT
RIGHT FRONT
LEFT REAR
RIGHT REAR
WHEEL SPEED SENSOR
WHEEL SPEED SENSOR
WHEEL SPEED SENSOR
WHEEL SPEED SENSOR
999 BK
993 BK
997 BK
998 BR
992 BR
996 BR
C2-11 C7 15
C2-10 32
C2-19 17
C2-20 34
C2-32 18
C2-31 35
C2-23 16
994 BR
C2-22 33
WSS HIGH
WSS HIGH
WSS HIGH
24 C7
23
22
21
31
25
11
MOTOR MONITOR 30
12
WSS HIGH
WSS LOW
WSS LOW
WSS LOW
WSS LOW
995 BK
605 PP
ECU 610 RD
609 YL
PUMP RELAY 1
58 BK G2
C11 1 2 10 11 13 12 5 4 6 9
PUMP RELAY 2
977 WH
973 OR
976 RD
974 DB
978 BK
677 GY
970 TN
971 PP
975 LB
972 YL
602 BR
OUTLET VALVE LF INLET VALVE
OUTLET VALVE RF INLET VALVE
OUTLET VALVE LR INLET VALVE
OUTLET VALVE RR INLET VALVE
REF GROUND
SHUTTLE VALVE SWITCH
TO BATTERY
M
PUMP MOTOR
MAXI FUSE 40A 7M EXTERIOR FUSE BOX
58 BK
MODULATOR
G1
9-S07-001
Figure 7-47: ABS/TT4 Main System Diagram.
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Brake System _____________________________________________________________
DLC 4 34 606 OR 607 TN 15 19
C1
13
14 WARNING RELAY ACTIVATION MONITOR
ABS ECU
WARNING RELAY MONITOR TT4 WARNING LAMP DRIVER 3 VALVE RELAY DRIVER VALVE RELAY MONITOR
DIAGNOSTIC
GROUND
IGN
9 570 BK 301 PK
27 990 PK
19 991 LB
8 990 PK
1 603 RD
26
603 RD 52
21
961 PP
C7
C1 C3
G2
E2
R6 FUSE 2B 5 AMP ABS VALVE RELAY R5 ABS WARNING RELAY
D3
FUSE 1C 25 AMP 575 OR 58 BLK 58 BK 58 BK
EXTERIOR FUSEBOX 1 8 TT4 C54
TO IGNITION
G2
TO BATTERY
G2
G2
ABS C3-N7 30 GY C53-7
See detail in Power/Ground Schematic

SPEEDO/TACH MODULE
C53-12
916 TN
C54-13
See detail in Coolant/Fuel Module Schematic

COOLANT/FUEL MODULE
FUSE 4B 5 AMP
INTERIOR FUSEBOX
TO IGNITION
02-S07-002
Figure 7-48: ABS/TT4 Power, Ground and Warning Lamp Circuit.
3-1-02
____________________________________________________________
Brake System
7-45
C7 FEMALE ONLY
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18
D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35
9-S12-043
Figure 7-49: 35 Pin ECU Connector Female Half
PIN 1 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 21 22 23 24
CKT 990 961 977 976 973 972 991 601 605 610 606 607 997 995 999 993 990 975 974 971 970
COLOR PK PP WH RD OR YL LB PK PP RD OR TN BK BK BK BK PK LB DB PP TN
ABS valve relay input TT4 lamp activation Right rear inlet valve activation Right rear outlet valve activation Right front inlet valve activation Right front outlet valve activation ABS valve relay activation Ignition feed Positive pump relay activation Negative pump relay activation Diagnostic line Diagnostic line Left front wheel speed sensor low
DESCRIPTION
Right rear wheel speed sensor low Right front wheel speed sensor low Left rear wheel speed sensor low ABS valve relay redundant input Left rear inlet valve activation Left rear outlet valve activation Left front inlet valve activation Left front outlet valve activation
05745159
7-46
PIN 25 26 27 30 31 32 33 34 35
Brake System _____________________________________________________________
CKT 677 603 570 609 978 996 994 998 992
COLOR GY DG BK YL BK BR BR BR BR
Shuttle valve switch signal ABS warning lamp activation Ground Pump motor monitor Reference ground
DESCRIPTION
Left front wheel speed sensor high Right rear wheel speed sensor high Right front wheel speed sensor high Left rear wheel speed sensor high
C11 FEMALE ONLY

9-S12-014
Figure 7-50: 13 Pin Modulator Connector Female Half
PIN 1 2 4 5 6 9 10 11 12 13
CKT 970 971 977 976 978 677 972 973 975 974
COLOR TN PP WH RD BK GY YL OR LB DB
Left front outlet valve activation Left front inlet valve activation Right rear inlet valve activation Right rear outlet valve activation Reference ground Shuttle valve switch signal Right front outlet valve activation Right front inlet valve activation Left rear inlet valve activation Left rear outlet valve activation
DESCRIPTION
____________________________________________________________
Brake System
7-47
C2 MALE
PIN 34 PIN 28 PIN 22 PIN 16 PIN 10 PIN 1 PIN 42 PIN 33 PIN 27 PIN 21 PIN 15 PIN 9
9-S12-015
Figure 7-51: 42 Pin Underbody Connector Male Half
C2 FEMALE
CAV 42 CAV 33 CAV 27 CAV 21 CAV 15 CAV 9 CAV 34 CAV 28 CAV 22 CAV 16 CAV 10 CAV 1
9-S12-016
Figure 7-52: 42 Pin Underbody Connector Female Half
PIN 10 11 19 20 22 23 31 32
CKT 996 997 999 998 994 995 992 993
COLOR BR BK BK BR BR BK BR BK
DESCRIPTION
Left front wheel speed sensor low signal Left front wheel speed sensor high signal Right front wheel speed sensor high signal Right front wheel speed sensor low signal Right rear wheel speed sensor low signal Right rear wheel speed sensor high signal Left rear wheel speed sensor low signal Left rear wheel speed sensor high signal
05745159
7-48
Brake System _____________________________________________________________
ABS MODULATOR REPLACEMENT Removal

WARNING: Batteries must be disconnected when the brake hydraulic system is being serviced and bled. If the ABS motor pump runs when air is in the hydraulic system, air can get trapped behind the valves in the modulator causing a spongy brake pedal.
1. 2. 3. Disconnect the batteries. Remove the left front splash shield. Remove the horn bracket and horns (Figure 7-53).
1 AND 13-PIN CONNECTORS
8.
Remove the four bolts, washers and lock washers securing the modulator bracket to the air lift bracket (Figure 7-54).
AIR LIFT BRACKET
9-S07-010
2-PIN PUMP CONNECTOR
Figure 7-54: Modulator and Bracket AssemblyMounting

9. Remove the modulator, mounting bracket and shield from the vehicle. 10. Remove the motor pump wire connector from the modulator bracket and the two bolts securing the modulator to the bracket.
MODULATOR
9-S07-011
Figure 7-53: Brake Line And Wire Connections

4. 5. Remove the thirteen-pin, the two-pin and the one-pin wire connectors from the modulator assembly. Remove the master cylinder brake hoses at the modulator and cap off (note the position of the lines in the modulator for installation). Remove the four wheel brake lines from the modulator and cap off (note the position of the lines in the modulator for installation). Remove the P clamp securing the oil cooler lines to the modulator mounting bracket.
ALIGNMENT PIN
6.
MOUNTING BRACKET
7.
9-S07-012
Figure 7-55: Modulator Mounting
____________________________________________________________
Brake System
7-49
11. Disengage the modulator alignment pin from the mounting bracket and remove the modulator from the mounting bracket. 12. Remove the brake line adapters, noting the position for reinstallation
Installation
1. Install the brake line adapters in the same position as in the original modulator. Torque the 12 mm threaded adapter to 11 lb-ft (15 Nm) and the 10 mm adapter to 9 lb-ft (12 Nm). 2. Place the modulator alignment pin in the hole in the mounting bracket, install the two mount bolts and torque to 5 lb-ft (7 Nm). 3. Connect the motor pump wire connector to the mounting bracket and install the assembly on the left air lift bracket with four bolts, washers and lock washers. Torque the bolts to 28 lb-ft (38Nm). 4. Connect the four wheel brake lines in their respective positions on the modulator and torque to 11 lb-ft (15 Nm). 5. Connect the master cylinder hoses in their respective positions on the modulator and torque to 11 lb-ft (15 Nm). 6. Connect the thirteen-pin, the two-pin and the one-pin wire connectors to the modulator assembly. 7. Install the horn bracket and horns. 8. Install the left front splash shield. 9. Bleed the complete brake system. 10. Connect the batteries.
Figure 7-56: Speed Sensor Removal

3. Remove the speed sensor connector from the retaining clip near the top of the upper A-arm and disconnect the speed sensor lead from the speed sensor harness (Figure 7-57). Remove the capscrews and clips securing the speed sensor lead to the A-arm and geared hub, and remove the sensor from the vehicle.
4.
SENSOR CONNECTOR
CLIP
SPEED SENSOR REPLACEMENT

NOTE: The procedure for speed sensor replacement is basically the same for all four wheel ends.
WARNING: Connect speed sensors to the proper harness connectors. Connecting speed sensors to incorrect harness connectors can cause the ABS/TT4 to malfunction.
Removal
1. 2. Rotate and pull the speed sensor head from the speed sensor mounting bracket and retaining sleeve (Figure 7-56). Remove and discard the speed sensor retaining sleeve.
9-S07-015
Figure 7-57: Speed Sensor Connection
05745159
7-50
Brake System _____________________________________________________________
Installation
NOTE: Left side speed sensor leads route across above the halfshaft cv-joint. Care must be taken to ensure the lead does not come in contact with the cv-joint. 1. Clean all grease, rust and debris from the speed sensor cavity in the speed sensor mounting bracket.
ABS ECU REPLACEMENT

1. 2. Turn ignition switch OFF. Remove the ECU enclosure hold-down bracket and lift the top half of the ECU enclosure up and out of the pocket in the windshield washer fluid reservoir. Pull the ECU and ECU harness out of the lower half of the ECU enclosure, depress the lock tabs on the 35 pin harness connector and swing the connector around until the hook on the end opposite of the lock tab disconnects from the ECU. Reverse the procedure for installation.
3.
SENSOR LEAD
P-CLAMP
4.
P-CLAMP
FUSE AND RELAY REPLACEMENT

The ABS TT4 system has three fuses located in the under-hood fuse/relay center (Figure 7-59): 1. A 5 ampere ignition power fuse. 2. A 25 ampere battery power fuse. 3. A 40 ampere motor pump fuse. The ABS TT4 system has four relays: 1. Valve relay. 2. Warning relay. 3. Pump relay 1. 4. Pump relay 2. The valve relay and the warning relay are located in the underhood fuse/relay center (Figure 7-59). The valve and warning relays are accessible after removal of the under-hood fuse/relay center cover. The two pump relays are located forward of the fuse-relay center and can be accessed after removing the ABS ECU enclosure hold-down bracket.
5 AMP IGNITION VALVE RELAY
WARNING
RELAY
Figure 7-58: Left Side Sensor Lead Routing

2. 3. Install a new speed sensor retainer sleeve in the speed sensor mounting bracket. Lubricate the head of the speed sensor with chassis lube and install in the speed sensor mounting bracket. Push the speed sensor all the way in until it touches the tone wheel on the CV joint. Route the speed sensor lead away from the halfshaft and secure with the clips and capscrews (do not kink the speed sensor lead). Connect the speed sensor connector to the speed sensor harness connector and install into the connector retaining clip.
4.
25 AMP BATTERY
5.
TONE WHEEL REPLACEMENT

NOTE: The tone wheel is pressed onto the outer CV joint of the halfshaft and requires halfshaft replacement when servicing the tone wheel. See section 9.
PUMP RELAY 1 40 AMP MOTOR PUMP PUMP RELAY 2
9-S07-013
Figure 7-59: ABS/TT4 Relay Locations.
____________________________________________________________
Brake System
7-51
ESSENTIAL TOOLS
IN J 3 O 55 U 9 T 2 B O X 3
5 4 10 9 15 14 20 19 25 24 30 29 33 34 35 32 31 28 27 26 23 22 21 18 17 16 13 12 8
2 1 6 11 7
8-S07-001
9-S07-016
J42553
J35592
00-S07-001
J-44237
00-S07-002
J-42883
Tool No. J42553 J35592 J44237 J44238 J42883 J29532 Disc Brake Piston Retraction Tool ABS Pinout Box ABS Blink Code Jumper
Description
Master Cylinder Bleed Adapter (not shown) Wheel Speed Sensor Test Cable Brake Pressure Bleeder (not shown)
05745159
3-1-01
7-52
Brake System _____________________________________________________________
________________________________________________________________________________
8-1
Section 8
Steering System
TABLE OF CONTENTS
Gear Assembly and Adjustment . . . . . . . . . . . . . . . . . . . . 8-30 Gear Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . 8-28 Gear Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . 8-23 Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Power Steering Gear Service . . . . . . . . . . . . . . . . . . . . . . . 8-18 Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Pump and Pulley Replacement . . . . . . . . . . . . . . . . . . . . . 8-15 Purging Air from the System . . . . . . . . . . . . . . . . . . . . . . . 8-22 System Diagnosis Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 Steering Column Ignition Interlock Cable Replacement . . . . . . . . . . . . . . . 8-11 Ignition Switch Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . 8-11 Lock and Switch Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Multi-Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Steering Column Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Steering Column Replacement . . . . . . . . . . . . . . . . . . . . . . 8-7 Steering Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Steering Wheel Hub/ Column Shroud . . . . . . . . . . . . . . . . 8-10 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Tie Rod End Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Tie Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Intermediate Steering Shaft Dust Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 Power Steering Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .8-41 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39 Steering Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44 Steering Gear Adjustment Preload Torques . . . . . . . . . . .8-44 Steering Pump Flow Rates and Operating Pressures . . .8-44 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44 Steering System Center Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-45 Idler Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 Pitman Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Power Steering Cooler and Hose Replacement . . . . . . . . . . . . . . . . . . . . . .8-17 Fluid Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . .8-16 Gear Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-36
STEERING SYSTEM DESCRIPTION

The power steering system consists of the power steering pump, reservoir, steering gear, fluid cooler, and interconnecting lines (Figure 8-1). The purpose of the system is to reduce steering effort at all vehicle speeds and during parking maneuvers. The steering pump used on all models is a constant displacement, rotary pump. The pump supplied by Delphi Saginaw Steering Systems uses a remote reservoir (Figure 8-1). The steering pump on all Hummer vehicles performs two functions. The first function is to provide the necessary fluid pressure for power brake boost to the hydro-boost unit. The second is to provide fluid pressure for steering assist. A recirculating ball-type steering gear is used for all applications. The gear is also supplied by Delphi Saginaw Steering Systems. A steering fluid cooler is used on all Hummer models. The vertical mount cooler is located at the driver side of the fan shroud.
BRAKE HYDRO-BOOST
RESERVOIR POWER STEERING GEAR POWER STEERING COOLER
POWER STEERING PUMP
Figure 8-1: Steering System 05745159
8-2
Steering System
___________________________________________________________
Power Steering Fluid

Recommended fluid for the power steering system is Dexron III.
STEERING ARM
Power Steering Component Service

Most of the power steering pump components are not serviceable. The seals and the flow control valve, however, can be serviced. The pump can also be replaced as an assembly. The steering gear can be removed and overhauled when required. Refer to the overhaul procedure in this section. The fluid coolers and fluid lines are also replaced as assemblies when diagnosis indicates this is necessary.
STEERING GEAR SHAFT
Steering Linkage
The steering linkage consists of a steering (Pitman) arm, center link, idler arm, and left/right tie rods (Figure 8-3). The tie rods connect the center link to steering arms on the left and right side geared hubs. The idler arm stabilizes the center link and is attached to the vehicle frame. The steering arm connects the center link to the steering gear.
SLOTTED NUT CENTER LINK
Steering Linkage Lubricant

Recommended lubricant for linkage lubrication points is NLGI-LB grade lubricating grease. Quality lubricants are available from suppliers such as Mobil, Kendall, and Valvoline. Figure 8-2: Steering (Pitman) Arm Removal
Installation
1. Secure the pitman arm to the steering gear shaft with the lock washer and nut. Tighten the nut to 185 lb-ft (251 Nm). Secure the pitman arm to the center link with the slotted nut. Tighten the slotted nut to 80 lb-ft (108 Nm). Install the cotter pin through the slotted nut. If necessary, tighten the slotted nut to align the holes for cotter pin insertion. DO NOT back off the slotted nut to align the holes. Place the wheels in the straight ahead position and tighten the idler arm to frame bolts to 60 lb-ft (81 Nm). Lubricate the pitman arm and lower the vehicle.
STEERING (PITMAN) ARM REPLACEMENT

NOTE: Ensure front wheels are in straight-ahead position while steering arm is removed and installed.
2. 3.
Removal
1. 2. Raise and support the front of the vehicle. Remove the nut and lock washer from the steering gear shaft (Figure 8-2). Using puller J42548, remove the pitman arm from the steering gear shaft. Remove the cotter pin and slotted nut from the center link end of the pitman arm. Using puller J24319B or equivalent, remove the pitman arm from the center link. Loosen the idler arm to frame mount bolts to allow movement of the idler arm when the pitman arm is tightened to the center link. 4. 5.
3. 4. 5.
4-1-00
___________________________________________________________
Steering System
8-3
CENTER LINK REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Raise and support the front of the vehicle. Remove the cotter pin and the slotted nut securing the pitman arm to the center link (Figure 8-3). Remove the cotter pin and the slotted nut securing the idler arm to the center link. Loosen, but do not remove, the bolts and locknuts securing the idler arm to the frame. Remove the two cotter pins and slotted nuts securing the right and left tie rods to the center link. Using puller J24319B or equivalent, remove the center link from both tie rods, the idler arm and the pitman arm.
Installation
1. 2. Secure the center link to the pitman arm and the idler arm with two slotted nuts and tighten to 80 lb-ft (108 Nm). Install a cotter pin in each slotted nut. If necessary, tighten the slotted nuts to align the holes for cotter pin insertion. DO NOT back off the slotted nuts to align the cotter pin holes. Secure the right and left tie rods to the center link with two slotted nuts and tighten to 70 lb-ft (95 Nm). Install a cotter pin in each slotted nut. If necessary, tighten the slotted nuts to align the holes for cotter pin insertion. DO NOT back off the slotted nuts to align the cotter pin holes. Place the front wheels in the straight ahead position and tighten the idler arm to frame bolts and locknuts to 60 lb-ft (81 Nm). Lower the vehicle.
3. 4.
5.
6.
CENTER LINK STEERING (PITMAN) ARM
IDLER ARM
TIE ROD
TIE ROD
TONE WHEEL
Figure 8-3: Center Link Removal
05745159
4-1-00
8-4
Steering System
___________________________________________________________
TIE ROD END REPLACEMENT

Removal
1. 2. 3. Raise and support the front of the vehicle. Remove the cotter pin and slotted nut from the geared hub end of the tie rod (Figure 8-4). Using puller J24319B, remove the tie rod end from the the geared hub.
3.
Before final tightening of the sleeve clamp hardware, center both tie rod end studs in their sockets (Figure 8-5).
CAUTION: If the stud and socket are not properly aligned, a partial or complete lockout of stud swing could result. Limiting stud swing can increase component wear and a complete lockout can cause component damage. 4. Lubricate tie rod ends.
HALFSHAFT
Disassembly
1. Loosen the locknut on the clamp securing the tie rod end to the adjusting sleeve.
NOTE: Note: Count the number of turns required to remove the tie rod end from the adjusting sleeve. 2. Remove the tie rod end from the adjusting sleeve.
TIE ROD END
Assembly
1. 2. Apply anti-seize compound to the threads in the adjusting sleeve. Thread the tie rod end into the adjusting sleeve, turning the same number of revolutions that were required for removal.
ADJUSTING SLEEVE
GEARED HUB
Installation
1. 2. Secure the tie rod to the geared hub with the washer and slotted nut. Tighten the slotted nut to 70 lb-ft (95 Nm). Install a cotter pin in the slotted nut. If necessary, tighten the slotted nut to align the holes for cotter pin insertion. DO NOT back off the slotted nut to align the cotter pin holes.
CAUTION: Ensure that the outboard clamp faces the halfshaft and the inboard clamp faces away from the stabilizer bar (front only) or damage to equipment may result. Figure 8-4: Tie Rod End Removal
STUD SWING LOCKOUT
CORRECT STUD ORIENTATION
WILL NOT ALLOW ROTATION DURING SUSPENSION TRAVEL

00-S08-002
ALLOWS ROTATION DURING SUSPENSION TRAVEL-NO BIND
Figure 8-5: Tie Rod End Stud and Socket Orientation
4-1-00
___________________________________________________________
Steering System
8-5
TIE ROD REPLACEMENT

Removal
1. 2. 3. Raise and support the front of the vehicle. Remove the cotter pins and slotted nuts from the center link end and the geared hub end of the tie rod (Figure 8-6). Using puller J24319B, remove the tie rod from the center link and the geared hub.
TIE ROD ASSEMBLY HALFSHAFT
Assembly
1. 2. Apply anti-seize compound to the threads in the adjusting sleeve. Thread two tie rod ends into the adjusting sleeve, turning them the same number of revolutions that were required for removal.
Installation
1. 2. 3. Secure the tie rod to the center link with the slotted nut and tighten to 70 lb-ft (95 Nm). Secure the tie rod to the geared hub with the washer and slotted nut. Tighten the slotted nut to 70 lb-ft (95 Nm). Install a cotter pin in each slotted nut. If necessary, tighten the slotted nuts to align the holes for cotter pin insertion. DO NOT back off the slotted nuts to align the cotter pin holes.
GEARED HUB
CAUTION: Ensure that the outboard clamp faces the halfshaft and the inboard clamp faces away from the stabilizer bar (front only) or damage to equipment may result. 4. Before final tightening of the sleeve clamp hardware, center both tie rod end studs in their sockets (Figure 8-5).
CENTER LINK
STABILIZER BAR
CAUTION: If the stud and socket are not properly aligned, a partial or complete lockout of stud swing could result. Limiting stud swing can increase component wear and a complete lockout can cause component damage. 5. 6. Lubricate tie rod ends. Lower vehicle and align toe-in.
Figure 8-6: Tie Rod Removal
Disassembly
1. Loosen two locknuts and clamps securing the tie rod ends to the adjusting sleeve (Figure 8-7).
NOTE: Note: Count the number of turns required to remove each tie rod end from the adjusting sleeve. 2. Remove both tie rod ends from the adjusting sleeve.
CAUTION: The sleeve clamps must be positioned between 3/ 16" and 5/16" from the end of the sleeve and the bolt and nut tightened to 30 lb-ft (41 Nm). 7. Align the sleeve clamps and tighten the bolt and nut assemblies to 30 lb-ft (41 Nm) (Figure 8-8).
ADJUSTING SLEEVE
TIE ROD END
3/16"-5/16"
TIE ROD END
Figure 8-7: Tie Rod Component Parts 05745159
Figure 8-8: Tie Rod Sleeve Clamp Position 4-1-00
8-6
Steering System
___________________________________________________________
IDLER ARM REPLACEMENT

Removal
1. 2. 3. 4. Raise and support the front of the vehicle. Remove the cotter pin and the slotted nut securing the idler arm to the center link (Figure 8-9). Using puller J24319B or equivalent, disconnect the idler arm from the center link. Remove the bolts, washers and locknuts securing the idler arm to the frame and remove the idler arm.
CENTER LINK FRAME
STEERING WHEEL REPLACEMENT

NOTE: Ensure front wheels are in a straight ahead position.
Removal
1. 2. 3. Gain access to nut by removing three screws that hold front cover to rear cover (Figure 8-10). Remove nut securing steering wheel to shaft. Remove steering wheel from shaft with a puller.
Installation
1. 2. 3. 4. Align splines on steering wheel with splines on shaft. Secure steering wheel to shaft with nut. Tighten nut to 35 lb-ft (47 Nm). Secure front cover to rear cover. Operate vehicle and verify steering wheel alignment.
FRONT COVER
STEERING WHEEL
REAR COVER
IDLER ARM
Figure 8-9: Idler Arm Removal
Installation
1. Position the idler arm in the center link and loosely install the bolts, washers and nuts through the frame and idler arm. Secure the idler arm to center link with the slotted nut and tighten to 80 lb-ft (108 Nm). Install the cotter pin through the slotted nut. If necessary, tighten the slotted nut to align the holes for cotter pin insertion. DO NOT back off the slotted nut to align the holes. Place the front wheels in the straight ahead position and tighten the idler arm to frame bolts and locknuts to 60 lb-ft (81 Nm). Lubricate the idler arm and lower the vehicle.
2. 3.
SHAFT
4.
Figure 8-10: Steering Wheel Removal
5.
4-1-00
___________________________________________________________
Steering System
8-7
STEERING COLUMN REPLACEMENT

Removal
NOTE: Before removing steering wheel, turn steering column to gain access to intermediate shaft mounting hardware. 1. 2. 3. Remove steering wheel. Remove close-out panel. Remove locknut, lockwasher, three washers, and thru-bolt from mounting bracket and loosen pivot bolts. Column will drop down as it pivots in bracket (Figure 8-11).
10. Remove two locknuts, washers, pivot bolts, and steering column from mounting bracket.
Installation
1. 2. 3. 4. 5. 6. 7. Hang steering column from mounting bracket with two pivot bolts, washers, and locknuts. Finger tighten locknuts. Install ignition switch and multi-switch on steering column (Figure 8-11). Connect two ignition switch connectors to ignition switch. Connect two multi-switch connectors to multi-switch. Secure shrouds to steering column with five screws. Secure ground wires to steering column with bolt and nut/ lockwasher assembly. Raise steering column to mounting bracket. Insert thrubolt, three washers, lockwasher, and locknut. Finger tighten locknut. Slide intermediate shaft yoke onto splines while carefully aligning scribe marks. Insert bolt and tighten locknut to 60 lb-ft (81 Nm). Tighten thru-bolt locknut to 31 lb-ft (42 Nm). Tighten pivot bolt locknuts to 10 lb-ft (14 Nm). Install steering wheel. Install close-out panel. Operate vehicle to verify steering wheel alignment.
NOTE: Before performing step 4, be certain to put scribe marks that indicate the position of the intermediate shaft yoke relative to the splines. 4. 5. 6. 7. 8. 9. Remove bolt on intermediate shaft yoke and pull yoke from splines (Figure 8-11). Remove five screws and shroud (two halves) from steering column. Disconnect ground wires from steering column. Disconnect two multi-switch connectors from multiswitch. Disconnect two ignition switch connectors from ignition switch. Remove multi-switch and ignition switch from steering column.
8.
9. 10. 11. 12. 13.
THRU-BOLT
MOUNTING BRACKET
31 lb-ft (42 Nm) 10 lb-ft (14 Nm) MULTI-SWITCH SHROUD LOCK CYLINDER CONNECTOR
60 lb-ft (81 N m)
INTERMEDIATE SHAFT PIVOT BOLT IGNITION SWITCH STEERING COLUMN IGNITION SWITCH CONNECTOR SHROUD MULTI-SWITCH CONNECTORS
Figure 8-11: Steering Column Components
05745159
4-1-00
8-8
Steering System
___________________________________________________________
STEERING COLUMN MULTI-SWITCH REPLACEMENT

NOTE: This procedure covers the directional signal, horn, high beam, and hazard light switches.
LOCK AND SWITCH HOUSING ASSEMBLY REPLACEMENT

Removal
1. 2. 3. 4. 5. Disconnect battery ground cable. Follow steps 2, 3, 5 and 6 of Steering Column Replacement. Remove two screws and multi-switch from steering column (Figure 8-12). Remove screw and interlock cable from ignition switch (Figure 8-13). Remove two bolts and lock and switch housing assembly from steering column.
Removal
1. 2. 3. Follow steps 2, 3, 5 and 6 of Steering Column Replacement. Remove two screws and multi-switch from steering column (Figure 8-12). Remove control handle from multi-switch by pulling outward.
Installation
1. 2. 3. Attach control handle to multi-switch (Figure 8-12). Secure multi-switch to steering column with two screws. Perform reverse of Removal Step 2 above.
Installation
1. Apply thread-locking compound to bolt threads and secure lock and switch housing assembly on steering column with two bolts (Figure 8-13). Secure interlock cable to ignition switch with screw. Install multi-switch. Perform reverse of Removal Step 2 above. Connect battery ground cable. Verify that ignition switch operates properly.
STEERING COLUMN
2. 3.
LOCK CYLINDER HOUSING
4. 5. 6.
STEERING COLUMN LOCK AND SWITCH HOUSING ASSEMBLY
MULTI-SWITCH CONTROL HANDLE
INTERLOCK CABLE IGNITION SWITCH
Figure 8-12: Steering Column Multi-Switch Replacement
Figure 8-13: Lock and Switch Housing Assembly Replacement
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Steering System
8-9
STEERING COLUMN REPAIR Lock and Switch Housing Assembly

Disassembly
NOTE: The key must stay in the ignition switch at all times. 1. 2. Remove the lock cylinder and key assembly from the lock cylinder housing (Figure 8-14). Remove two screws securing the upper retainer plate to the lock cylinder housing. Remove the retainer plate, the upper bearing assembly and upper bearing sleeve from the lock cylinder housing. Remove two screws and the multi-switch assembly from the lock cylinder housing (Figure 8-12). Remove two screws securing the ignition switch assembly to the lock cylinder housing. Remove the ignition switch assembly (Figure 8-14). Remove six stakes from the tube and bracket assembly (Figure 8-15). Remove two screws and remove the lock cylinder housing from the tube and bracket assembly.
7.
Remove the retainer ring, shaft, and bearing from the tube and bracket assembly.
Assembly
1. 2. Install the shaft, bearing, and retainer ring into tube and bracket assembly (Figure 8-15). Secure the lock cylinder housing to the tube and bracket assembly with two screws. Tighten screws to 6-7 lb-ft (8.1-9.4 Nm). Stake bearing securely in six (6) places (Figure 8-15). Secure the ignition switch assembly to the lock cylinder housing with two screws. Tighten screws to 35-40 lb-in. (3.9-4.5 Nm) (Figure 8-14). Secure the multi-switch assembly to the lock cylinder housing with two screws. Tighten screws to 35-40 lb-in. (3.9-4.5 Nm) (Figure 8-12). Install the upper bearing assembly and upper bearing sleeve in the lock cylinder housing (Figure 8-14). Install the retainer plate on the lock cylinder housing with two screws. Tighten screws to 35-40 lb-in. (3.9-4.5 Nm). Install the lock cylinder and key assembly in the lock cylinder housing assembly. Verify that ignition switch operates properly.
3. 4.
3. 4.
5.
6. 7. 8. 9.
5. 6.
LOCK CYLINDER HOUSING
UPPER STEERING COLUMN BEARING ASSEMBLY
IGNITION SWITCH ASSEMBLY
STEERING COLUMN LOCK GEAR UPPER BEARING SLEEVE COLUMN LOCK FLAT BEARING COLUMN LOCK GEAR RETAINER IGNITION LOCK CYLINDER AND KEY ASSEMBLY
BEARING RETAINER PLATE
Figure 8-14: Lock and Switch Housing Components 05745159 4-1-00
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Steering System
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Steering Column and Shaft

Disassembly
1. 2. 3. 4. 5. Remove two screws and the multi-switch assembly from the lock and switch housing (Figure 8-12). Remove two screws and lock and switch housing assembly from steering column (Figure 8-13). Remove six stakes from the tube and bracket assembly (Figure 8-15). Remove the shaft, retainer ring, and bearing from tube and bracket assembly. Remove retainer ring and bearing from the shaft.
STAKES STEERING COLUMN TUBE AND BRACKET ASSEMBLY BEARING
STEERING WHEEL HUB COVER AND STEERING COLUMN SHROUD REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. Remove three screws holding front half of steering wheel hub cover to the rear half. Remove steering wheel. Remove rear half of cover. Remove five screws holding lower steering column shroud to upper shroud. Loosen two pivot bolts at rear of steering column mounting bracket. Remove thru-bolt from front of mounting bracket. Steering column will pivot downward. Remove upper shroud.
Installation
1. 2.
RETAINER RING
STEERING COLUMN SHAFT
Figure 8-15: Steering Column and Shaft
3. 4. 5. 6. 7.
Place upper shroud in position over top of steering column. Pivot steering column upward and secure with thru-bolt, three washers, lockwasher, and locknut. Tighten locknuts on pivot bolts. Secure lower shroud to upper shroud with five screws. Place rear half of steering wheel hub cover over shaft. Install steering wheel. Secure front half of shroud to rear half with 3 screws.
Assembly
1. 2. 3. 4. 5. Slide bearing onto shaft and secure it with retaining ring (Figure 8-15). Slide the shaft into the tube and bracket assembly. Install six stakes into the tube and bracket assembly. Secure lock and switch housing assembly to steering column with two screws (Figure 8-13). Connect the multi-switch assembly to the lock and switch housing with two screws (Figure 8-12).
4-1-00
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Steering System
8-11
IGNITION SWITCH LOCK CYLINDER REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Disconnect battery ground cable. Remove close-out panel. Remove five screws and lower steering column shroud (Figure 8-16). Disconnect lock cylinder connector from ignition switch connector. Turn ignition switch to RUN position. Depress lock cylinder detent pin through detent pin hole and remove lock cylinder from steering column.
IGNITION INTERLOCK CABLE REPLACEMENT

Removal
1. Remove ve screws and lower shroud from steering column (Figure 8-17).
31 lb-ft (42 Nm) MOUNTING BRACKET UPPER SHROUD BOLT
Installation
1. 2. 3. 4. 5. 6. 7. Insert lock cylinder into steering column (Figure 8-16). Turn ignition switch to LOCK position. Connect lock cylinder connector to ignition switch connector. Secure lower steering column shroud to steering column with five screws. Install close-out panel. Connect battery ground cable. Verify that ignition switch lock cylinder operates properly.
STEERING COLUMN
10 lb-ft (14 Nm) STEERING COLUMN
LOWER SHROUD
Figure 8-17: Steering Column Shrouds 2. Loosen two locknuts securing steering column to mounting bracket. 3. Remove locknut, lockwasher, three washers, and bolt securing steering column to mounting bracket. 4. Lower steering column and remove upper shroud. 5. Remove screw and interlock cable from ignition switch (Figure 8-18). 6. Disconnect connector from interlock cable. 7. Raise and secure hood. 8. Remove screw securing clamp and interlock cable to bracket. Remove clamp from interlock cable. 9. Remove close-out panel (Section 10). 10. Remove shifter (Section 5). 11. Remove nut and screw securing interlock cable to shifter (Figure 8-19). 12. Remove interlock cable and grommet from vehicle.
LOCK CYLINDER IGNITION SWITCH CONNECTOR
DETENT PIN HOLE LOCK CYLINDER DETENT PIN LOWER STEERING COLUMN SHROUD LOCK CYLINDER CONNECTOR
Figure 8-16: Ignition Switch Lock Cylinder Replacement
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Steering System
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LOCK AND SWITCH HOUSING ASSEMBLY
IGNITION SWITCH CONNECTOR
Test
1. 2. 3. 4.
GROMMET
5.
COWL
6.
INTERLOCK CABLE BRACKET CLAMP
7.
Figure 8-18: Interlock Cable/Ignition Switch
8.
Installation
1. Secure interlock cable to shifter with screw and nut. Tighten nut to 8 lb-ft (11 Nm) (Figure 8-19).
SHIFTER INTERLOCK CABLE
With transmission lever in P, turn ignition key to run. Activate brake switch and move transmission lever to N. Without turning ignition key off, move transmission shift lever to P. Turn ignition key off. To pass test, it should not be possible to move transmission lever out of P unless an extremely high effort is applied. Turn ignition key on. To pass test, it should not be possible to move transmission lever out of P unless an extremely high effort is applied. Activate brake switch. To pass test, transmission lever should be moved from P to N with normal shift effort. Turn ignition key off. To pass test, it should not be possible to remove ignition key while transmission lever is in N. Move transmission lever to P. To pass test, it must be possible to remove ignition key with normal effort applied to ignition key.
STEERING GEAR REPLACEMENT

Removal
NOTE: Ensure front wheels are in the straight-ahead position. Have drainage container ready to catch fluid. 1. Disconnect two power steering lines from steering gear (Figure 8-20).
8 lb-ft (11 Nm)
BRACKET
INTERMEDIATE SHAFT
Figure 8-19: Interlock Cable and Shifter Route interlock cable through bracket and install shifter (Section 5). 3. Secure interlock cable to bracket with clamp and screw (Figure 8-18). 4. Route interlock cable through cowl and secure with grommet. 5. Lower and secure hood. 6. Secure interlock cable to ignition switch with screw. 7. Connect connector to interlock cable. 8. Position upper steering column shroud on steering column (Figure 8-17). 9. Raise steering column and secure steering column on mounting bracket with bolt, three washers, lockwasher, and locknut. Tighten locknut to 31 lb-ft. (42 Nm). 10. Tighten two locknuts securing steering column to mounting bracket. Tighten locknuts to 10 lb-ft (14 Nm). 11. Secure lower steering column shroud to upper shroud with five screws. 12. Install close-out panel (Section 10). 4-1-00 2.
YOKE NOTCH POWER STEERING LINES
YOKE
FRAME
STEERING GEAR SPLINES
STEERING GEAR
Figure 8-20: Steering Gear Mounting
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Steering System
8-13
2. 3. 4. 5. 6.
Turn steering wheel left and right several times to bleed off power steering fluid. Remove bolt on intermediate shaft yoke at steering gear and disconnect intermediate shaft from steering gear. Remove nut and lockwasher from steering arm (Figure 8-21). Using puller J42548, remove steering arm from shaft. Remove three bolts, lockwashers, washers, and steering gear from frame (Figure 8-20).
Removal
1. 2. 3. Remove close-out panel. Remove three nuts, six washers, and three screws from dust boot (Figure 8-22). Remove bolt on intermediate steering shaft yoke at steering gear.
NOTE: Before performing step 4, put scribe marks showing the position of the yoke relative to the splines. 4. Remove bolt on intermediate steering shaft yoke at steering column and remove shaft.
Installation
1. Align steering gear with mounting holes in frame and secure with three washers, lockwashers, and bolts. Tighten bolts to 54-66 lb-ft (73-89 Nm) (Figure 8-20). Align hole in yoke with notch on steering gear splines and slide intermediate shaft on steering gear splines. Insert bolt in yoke and tighten locknut to 60 lb-ft (81 Nm). Connect two power steering lines to steering gear.
STEERING COLUMN
2. 3. 4.
NOTE: Ensure front wheels are in the straight ahead position. 5. 6. 7. 8. Install steering arm on shaft with lockwasher and nut. Tighten nut to 185 lb-ft (251 Nm) (Figure 8-21). Fill power steering reservoir. Purge air from power steering system (Refer to Purging Air From the Power Steering System on page 822 ). Inspect wheel alignment.
DUST BOOT STEERING GEAR INTERMEDIATE STEERING SHAFT
INTERMEDIATE STEERING SHAFT REPLACEMENT

NOTE: Ensure front wheels are in straight-ahead position while removing and installing intermediate steering shaft.
SHAFT STEERING ARM
Figure 8-22: Intermediate Steering Shaft Removal
Installation
1. Align hole in yoke with notch on steering gear splines (Figure 8-20). Insert bolt through yoke and tighten locknut to 60 lb-ft (81 Nm) (Figure 8-22). Align scribe marks and slide yoke onto steering column splines. Insert bolt through yoke and tighten locknut to 60 lb-ft (81 Nm). Apply silicone spray or equivalent to end of steering shaft. Secure dust boot with three screws, six washers and three nuts. Lubricate steering shaft at universal joints. Install close-out panel.
2.
3.
4. 5. Figure 8-21: Steering Arm Removal 05745159
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Steering System
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INTERMEDIATE STEERING SHAFT DUST BOOT REPLACEMENT

Removal
1. 2. Remove close-out panel. Remove three nuts, six washers, and three screws from dust boot (Figure 8-23).
Installation
1. Secure spacer and dust boot to cowl panel with four screws, eight washers, and four locknuts. Tighten locknuts to 60 lb-ft (81 Nm) (Figure 8-23). Insert intermediate steering shaft through dust boot. Align scribe marks and slide yoke onto steering column splines. Tighten locknut on yoke to 60 lb-ft (81 Nm). Apply silicone spray or equivalent to end of steering shaft. Install three screws, six washers, and three nuts on dust boot. Install close-out panel.
STEERING COLUMN
2.
NOTE: Before performing step 3, put scribe marks showing the position of the yoke relative to the splines. 3. 4. Remove bolt on yoke and pull intermediate steering shaft from steering column. Remove four locknuts, eight washers, four screws, spacer, and dust boot from cowl panel and intermediate steering shaft.
3.
4.
DUST BOOT
SPACER COWL PANEL
INTERMEDIATE STEERING SHAFT
Figure 8-23: Intermediate Steering Shaft Dust Boot Replacement
4-1-00
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Steering System
8-15
POWER STEERING PUMP AND PULLEY REPLACEMENT

Removal
1. 2. 3. 4. Disconnect return lines and high pressure line from back of pump (Figure 8-24). Remove serpentine belt from power steering pump pulley. Using puller J25034-C or equivalent, remove pulley from pump. Remove three bolts going through bracket into front of pump (Figure 8-24).
6.
Check condition of O-ring seal and connect high pressure line to back of pump.
CAUTION: In step 7, do not attempt to drive the pulley onto the pump shaft with a hammer. The pulley and pump ring will be damaged. 7. Press pulley onto pump using pulley installer J25033-C or equivalent. Pulley should be flush +/- 0.25 mm (0.010 inch) with the end of the power steering pump shaft. Purge air from power steering system. Start engine and check for leaks.
8. 9.
Installation
1. Apply non-hardening thread sealant to studs on back of pump and secure support bracket with two nuts. Tighten nuts to 45 lb-ft (61 Nm) (Figure 8-24) Maneuver pump into position behind power steering bracket. Secure pump to mounting bracket with three bolts. Secure support bracket to block with bolt. Connect two return lines to power steering pump (Figure 8-24).
2. 3. 4. 5.
POWER STEERING FLUID RESERVOIR
MOUNTING BRACKET
PULLEY
POWER STEERING PUMP
POWER STEERING SUPPORT BRACKET
Figure 8-24: Power Steering Pump Mounting
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Steering System
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POWER STEERING HYDRAULIC SYSTEM PRESSURE AND RETURN HOSE REPLACEMENT

NOTE: Removal and installation procedures are basically the same for all hydraulic system pressure and return hoses. This procedure covers the power steering pump to hydro-boost return hose and the steering gear to hydro-boost pressure hose.
O-RING SEALS
PRESSURE HOSE
STEERING GEAR
Removal
1. 2. 3. 4. Disconnect return hose from power steering pump and hydro-boost (Figures 8-25 and 8-26). Remove locknut, washer, bolt, and two clamps from control valve hose and return hose. (Figure 8-25). Remove locknut, two washers, and bolt securing two clamps and harness clamp to power steering line bracket. Disconnect pressure hose from hydro-boost and steering gear and remove pressure hose. Remove two O-ring seals from pressure hose. Check condition of O-ring seals and replace if necessary (Figures 8-25 and 8-26).
Figure 8-26: Power Steering Hose Replacement at Steering Gear
Installation
1. 2. 3. Connect pressure hose to steering gear and hydro-boost (Figure 8-26). Connect return hose to power steering pump and hydroboost with two clamps (Figures 8-25 and 8-26). Install two clamps on return hose and control valve hose. Secure return hose, control valve hose, and two clamps together with bolt, washer, and locknut (Figure 8-25). Install harness clamp and two clamps on power steering lines bracket with bolt, two washers, and locknut. Purge air from power steering system. Refer to (See Purging Air From the Power Steering System on page 8-22) .
RETURN HOSE
POWER STEERING FLUID RESERVOIR REPLACEMENT

Removal
1. 2. 3. Suction the power steering uid from the reservoir. Loosen the hose clamp and disconnect the power steering pump supply line from the reservoir (Figure 8-27). Remove the two bolts and washers securing the reservoir to the bracket and remove the reservoir.
4. 5.
Installation
1. Installation is the reverse of the removal procedure.
RESERVOIR
PRESSURE HOSE
SUPPLY LINE
O-RING SEALS
HYDRO-BOOST
Figure 8-25: Power Steering Hose Replacement at Brake Hydro-Boost 4-1-00
Figure 8-27: Reservoir Replacement
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Steering System
8-17
POWER STEERING COOLER AND COOLER HOSE REPLACEMENT

Removal
1. 2. 3. 4. 5. Disconnect two hoses from cooler (Figure 8-28). Remove cooling fan for access into fan shroud. Remove two nuts, four washers, reinforcement plate, two bolts, and cooler. Disconnect hose at power steering gear and hose at back of pump. Remove P-clamps holding hoses together and remove hoses.
Installation
1. Secure power steering oil cooler to fan shroud with two bolts, reinforcement plate, four washers, and two nuts (Figure 8-28). Reinstall cooling fan. Connect hoses to cooler and secure with clamps Connect other end of each hose to its respective location at steering gear or pump and secure with clamps. Secure hoses together with P-clamps. Purge air from system.
2. 3. 4. 5. 6.
REINFORCEMENT PLATE
POWER STEERING PUMP
POWER STEERING COOLER
HOSE
POWER STEERING GEAR
Figure 8-28: Power Steering Cooler and Cooler Hoses
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Steering System
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POWER STEERING GEAR SERVICE

The Saginaw recirculating ball, power steering gear (Figure 8-29), is a fully serviceable component. The gear can be adjusted, or overhauled as needed. Overhaul requires that the gear be removed from the vehicle as repair can only be performed on the bench. The steering gear adjustments described in the overhaul section can be performed on the bench or in the vehicle. Refer to the adjustment section for details.
BALL GUIDE GEAR HOUSING
THRUST BEARING
FLUID INLET O-RING SEAL
FLUID OUTLET HOSE FITTING SEAT SEAL TORSION BAR
END PLUG
STUB SHAFT ADJUSTER PLUG VALVE BODY WORMSHAFT STUB SHAFT PIN SHAFT SPOOL VALVE TEFLON SEALS THRUST BEARING
TEFLON RING
RACK PISTON
Figure 8-29: Power Steering Gear Cross Section
4-1-00
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Steering System
8-19
POWER STEERING SYSTEM DIAGNOSIS CHARTS

The diagnosis charts are guidelines to potential system faults. The charts list potential faults in order of probability (most probable to least probable). While the charts outline common faults, they may not cover all possible problem causes. Inspection and diagnosis with analyzer set J25323 should be used to confirm a pump or gear problem.
Table 1 Power Steering Diagnosis Chart - part 1

Problem Poor Return of Steering 1. 2. Possible Cause Tires under-inated. Lower coupling ange rubbing against the steering gear adjuster plug. 3. Steering wheel rubbing against directional signal housing. 4. Binding steering linkage, or ball joints. 5. Steering gear to column misalignment. 6. Tie rod not centralized. 7. Lack of lubricant in the suspension ball joints and steering linkage. 8. Stuck or plugged valve spool. 9. Improper front wheel alignment. 10. Steering gear adjusted too tightly. 11. Kink in return hose. Steering Wheel Surges or Jerks When Turning With Engine Running Especially During Parking Hard Steering Effort in Both Directions 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 8. 9. Low oil level in pump. Loose pump drive belt. Sticky ow control valve. Insufcient pump pressure. Low tire pressure. Lack of lubricant in suspension or ball joints (Worn/contaminated joints). Binding of steering linkage, or ball joints. Steering gear to column misalignment. Pump belt slipping. Low uid level in reservoir. High internal leakage (steering gear or pump). Sticky ow control valve. Steering gear adjusted too tight. 1. 2. 3. 4. 5. 6. 7. Correction Inate to specied pressure. Loosen the pinch bolt and assemble properly. Adjust the steering jacket. Replace the affected parts. Align the column. Adjust tie rod ends as required. Lubricate.
8. Remove, clean, or replace the valve. 9. Check and adjust to specications. 10. Adjust over-center and thrust bearing preload to specications. 11. Replace the hose. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 8. 9. Add power steering uid as required. Adjust bolt. Replace or clean the control valve. Test system with analyzer. Adjust the tire pressure. Lubricate and relubricate at proper intervals or replace joints. Replace all affected parts. Align the steering column. Adjust belt. Fill to proper level. Inspect lines and joints for external leakage. Test system with analyzer.
10. Improper front wheel alignment Foaming Milky Looking Power Steering Fluid, Low Level and Possible Low Pressure 1. Air in the uid and loss of uid due to internal pump leakage causing overow.
Replace pump. Adjust over-center and thrust bearing reload to specications. 10. Check and adjust to specications. 1. Check for leak and correct. Bleed system. Extremely cold temperatures will cause system aeration should the oil level be low. If oil level is correct and pump still foams, remove pump from vehicle and separate reservoir from housing. Check welsh plug and housing for cracks. If plug is loose or housing is cracked, replace housing.
2.
Hose or air leakage in reservoir line.
2.
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Steering System
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Problem Hiss Noise 1. Possible Cause Noisy relief valve in the pump. 1. Correction There is some noise in all power steering systems. One of the most common is a hissing sound most evident at standstill parking. Hiss is a high frequency noise. The noise is present in every valve and results from high velocity uid passing valve orice edges. There is no relationship between this noise and steering performance. Hiss may be expected when the steering wheel is at end of travel or when slowly turning at standstill. Do not replace the pump unless hiss is extremely loud and continuous. A replacement pump will also exhibit slight noise and is not always a cure for hiss. Check the gear mounting bolts. Torque the bolts to specications. Check linkage pivot points for wear. Replace if necessary. Adjust the hose position. Do not bend tubing by hand. Tighten the steering arm bolt. Adjust to specication.
Rattle or Chuckle Noise in Steering Gear
1. 2. 3. 4. 5.
Gear loose on the frame. Steering linkage wear, play, looseness. Pressure hose touching other parts of vehicle. Loose steering arm. Improper over-center adjustment. A slight rattle may occur on turns because of increased clearance off the high pint. This is normal and clearance must not be reduced below specied limits to eliminate this slight rattle. Air in system. Steering gear mounting loose. Steering linkage joints worn. Front wheel bearings incorrectly adjusted or worn. Steering gear improperly adjusted. Damaged or worn steering gear. Keep in mind the road and wind conditions. Front wheels misaligned. Unbalanced steering gear valve. If this is the cause, steering effort will be very light in direction of lead and heavy in opposite direction. Steering shaft binding. Low oil level in the pump. Pump belt slipping. High internal leakage (steering gear or pump).
1. 2. 3. 4. 5.
Excessive Wheel Kickback or Loose Steering
1. 2. 3. 4. 5. 6.
1. 2. 3. 4. 5. 6. 1. 2. 3.
Add oil to the pump reservoir and bleed. Check hose connectors for proper torque. Tighten attaching bolts to specied torque. Replace loose parts. Adjust the bearings or replace with new parts as necessary. Adjust to specications. Disassemble and repair the steering gear. Test the vehicle, going in both directions, on a at road. Adjust to specications. Replace the gear valve body.
Vehicle Leads to One Side or the Other
1. 2. 3.
4. Momentary Increase in Effort when Turning the Wheel Quickly to the Right or Left 1. 2. 3.
4. 1. 2. 3.
Align the column. Add power steering uid as required. Adjust belt pressure. Refer to Power Steering System Pressure Test in this section. Repair as needed.
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Steering System
8-21

Problem Low Oil Pressure Due to Restriction in the Hose 1. 2. Possible Cause Check for kinks in hose. Foreign object stuck in the hose. 1. 2. Correction Remove the kinks or replace the hose. Remove the foreign object or replace the hose. Disassemble the steering gear. Inspect the ring and housing bore. Replace the affected parts. Disassemble steering gear and replace seals. Replace the valve. Replace pump. Replace pump. Replace pump and ush system. Replace pump. Flush the system.
1. Low Oil Pressure Due to Steering Gear. Refer to Power Steering Sys2. tem Test in this Section. 3. Low Oil Pressure Due to Steering Pump. Refer to Power Steering System Test in this Section. 1. 2. 3. 4. 5. 6. 7.
Pressure loss in cylinder due to worn rack 1. piston ring or scored housing bore. Leakage at the valve rings and valve body 2. to the worm seal. Leakage at the valve body or a loose tting 3. spool. Flow control valve stuck or inoperative. Pressure plate not at against the cam ring. Extreme wear of cam ring. Scored pressure plate, thrust plate, or rotor. Vanes sticking in rotor slots. Vanes not installed properly. Air in oil. 1. 2. 3. 4. 5. 6. 7.
8. Low oil level. 9. Pump belt slipping. 10. Damaged hoses or steering gear. Chirp Noise in Steering Pump 1. or Belt Squeal (Particularly Noticeable At Full Wheel Travel and Standstill Parking) Growl Noise in Steering Pump 1. Growl Noise in Steering Pump 1. (Particularly Noticeable Standstill Parking) Groan Noise in Steering Pump Rattle or Knock Noise in Steering Pump 1. 2. 1. 2. 3. Pump belt slipping.
Replace pump. Replace pump. Locate source of leak and correct. Bleed the system. 8. Add power steering uid as required. 9. Adjust belt. 10. Replace as necessary. 1. Replace belt.
Excessive back pressure in hoses or steer- 1. ing gear caused by restriction. Scored pressure plates, thrust plate, or rotor. Extreme wear of cam ring. Low oil level. Air in the oil. Poor pressure hose connection. 1.
Locate restriction and correct. Replace pump and ush system.
1. 2.
Add power steering uid as required. Torque the connector. Bleed the system. Replace pulley or pump. Replace pump. Adjust hose position. Replace pump. Replace pump.
Loose pump pulley. 1. Pump vanes sticking in rotor slots. 2. Pressure hose touching other parts of vehi- 3. cle. Faulty ow control valve. Pump shaft bearing scored. 1. 1.
Swish Noise in Steering Pump 1. Whine Noise in Steering Pump 1.
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PURGING AIR FROM THE POWER STEERING SYSTEM

Air must be bled from the system before pressure testing and anytime the hoses are disconnected or the pump and/or gear is removed for service. Procedure is as follows: 1. All hose connections must be tight. Loose connections might not leak but could allow air into system. 2. Switch ignition off. 3. Turn the steering wheel full left. 4. Top off the reservoir fluid level to "FULL COLD" but do not replace the reservoir filler cap. If fluid was added to the reservoir, allow it to settle for 2-3 minutes before proceeding. 5. Raise and support the vehicle front end. The front tires only have to clear the shop floor. 6. Shift the transmission into Park. 7. With an assistant checking the fluid level and condition, turn steering wheel lock-to-lock at least 40 times. The engine remains off. Trapped air may cause fluid to overflow. Thoroughly clean any spilled fluid to allow for leak check. Keep fluid level at "FULL COLD". 8. While turning wheel, check fluid constantly. There should be no bubbles. If there are any bubbles, recheck the connections and repeat step 7. 9. Start the engine. With engine idling, maintain fluid level. Install reservoir cap. 10. Return wheels to center. Lower front wheels to the ground. 11. Keep engine running for two minutes. 12. Continue turning wheels back and forth until bubbles no longer appear in fluid. 13. Verify the following conditions: smooth power assist noiseless operation proper fluid level no system leaks proper fluid condition 14. If all conditions apply, the procedure is complete.
POWER STEERING SYSTEM PRESSURE TEST

Power steering system performance can be checked with analyzer set J 25323 and hose fitting adapters J 33141. The analyzer checks flow in gallons per minute (gpm) and min/max pressure in psi. Analyzer hose connection is shown in Figure 8-30. Procedure is as follows.
Pressure Test Procedure

NOTE: Fluid must be at operating temperature. Purge air from power steering system. Refer to procedure in this section. 2. Position drain pan under pump and gear to catch spilled fluid. 3. Connect J25323 analyzer hoses to pump and gear (Figure 8-30). Use fitting adapters J33141 to connect hoses to gear and pump as needed. 4. Add power steering fluid to reservoir as required. 5. Shift transmission into Park. 6. Open analyzer valve. 7. Start and run engine at curb idle speed. 8. Note and record flow rate and pressure indicated on analyzer gauge. a. If flow is less than 1.32 gpm (5 liters/min.), pump is faulty. b. If pressure is above 150 psi, (1035 kPa), either a hose is restricted or a problem exists within the gear. c. If flow is greater than 1.32 gpm and pressure is less than 150 psi, continue test. 9. Partially close the analyzer valve, allow pressure to build to 620 psi (4278 kPa), and record flow rate. a. If flow rate decreases by more than 1 gpm (3.7 L/ minute) from the reading in step 8, the pump is at fault. b. If flow rate remains about the same, continue test. 10. Completely close and partially open the analyzer valve three times in succession. Note and record maximum pressures each time. CAUTION: Do not close the analyzer valve for more than 3-4 seconds at a time. Longer periods will result in rapid fluid overheat and pump damage. 11. If pump maximum pressures recorded in step 10 were less than 1150 psi (7929 kPa), the pump is at fault. However, if pressures are at, or above specified limit, continue with test. 12. Increase engine speed to 1500 rpm and record flow rate. a. If flow rate remains within 1 gpm of flow recorded in step 8, continue test. b. If flow rate drops by more than 1 gpm (3.7L/ minute), pump control valve is faulty. 1.
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Steering System
8-23
13. Turn steering wheel lightly against each stop and record maximum pressure. a. If pressure at each stop is about the same as recorded in step 10, and flow drops to 0.5 gpm (1.85 L/min.), continue with test. b. If pressures does not reach maximum recorded in step 10, and flow rate does not fall off, overhaul steering gear to correct internal leakage in valve, or past seal rings. 14. Turn steering wheel to the right, release it., and observe the analyzer gauge. Then turn the wheel to the left, release it, and observe the gauge again. a. If the gauge needle indicates normal pressure then snaps back as the wheel is released. Continue the test. b. If the gauge indicates normal pressure but the needle is slow to return when the wheel is released, the steering gear valve body or spool is sticking. Overhaul will be required to correct the problem. 15. If gear and pump test OK but a problem still exists, check for fluid contamination. Draw off sample with suction gun and empty sample in glass container. Look for burned fluid, foreign material, fluid layering (fluid separates into two layers), foreign material/metal particles in the fluid. Any of these conditions will cause gear and pump problems. Flushing the system with new fluid may correct the problem. 16. If fluid condition is OK but a problem still exists, a problem may exist in the steering linkage, tires/wheels, or suspension part. Further diagnosis will be required.
POWER STEERING GEAR DISASSEMBLY AND OVERHAUL

Cleanliness is extremely important to a successful gear overhaul. Clean the gear exterior before disassembly and make sure the workbench area is clean and dry. Drain as much of the old fluid from the gear as possible beforehand. Dirt and foreign material must not be allowed to enter the gear internal components. Use lint free shop towels for wiping parts and hands clean. Lint from cotton towels will flow through the system and eventually cause the valve body spool, or pump control valve to stick and bind.
Side Cover and Pitman Shaft Removal

1. 2. 3. Remove side cover attaching bolts. Hold adjuster screw with hex wrench and remove adjuster screw nut. Rotate stub shaft as necessary to center pitman shaft teeth in rack piston. Use 12 point socket and ratchet to turn stub shaft. Remove pitman shaft, side cover, and gasket (Figure 8-31).
4.
ADJUSTER LOCKNUT
SIDE COVER
ADJUSTER SCREW
GASKET
FITTING ADAPTERS
PITMAN SHAFT
ANALYZER J-25323
Figure 8-30: Analyzer Pressure Test Connections Figure 8-31: Side Cover and Sector Shaft
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8-24
Steering System
__________________________________________________________
Gear Housing End Plug Removal

1. Rotate end plug retaining ring until one end is under small access hole in housing (Figure 8-32).
RETAINING RING END PLUG O-RING
PUNCH
SCREWDRIVER
GEAR HOUSING
Figure 8-33: End Plug and Seal Removal
Adjuster Plug Removal and Disassembly

1. Remove adjuster plug locknut with punch and hammer (Figure 8-34).
PUNCH RETAINING RING
Figure 8-32: End Plug Retaining Ring Removal 2. Unseat end plug retaining ring with small pin punch and screwdriver (Figure 8-32). Insert punch through access hole in housing as shown. Slowly rotate stub shaft counterclockwise to ease end plug out of housing.
3.
CAUTION: Do not rotate the stub shaft any farther than necessary. The recirculating balls can drop out of the rack piston and fall inside the piston chamber making further disassembly extremely difficult. 4. 5. Remove end plug (Figure 8-33). Remove O-ring seal from housing (Figure 8-33).
ADJUSTER PLUG LOCKNUT
Figure 8-34: Adjuster Plug Locknut Removal 2. Remove adjuster plug from housing with spanner wrench J7624 (Figure 8-35).
4-1-00
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Steering System
STUB SHAFT BEARING O-RING SEAL
8-25
SNAP RING
STUB SHAFT DUST SEAL
SPANNER TOOL J7624
THRUST BEARING SPACER
STUB SHAFT OIL SEAL
ADJUSTER PLUG INNER RACE OUTER RACE
RETAINER
Figure 8-37: Adjuster Plug Components

ADJUSTER PLUG
5. 6.
Remove stub shaft seal retainer. Remove dust seal and oil seal (Figure 8-38). Use tool J6221 to remove seals.
Figure 8-35: Adjuster Plug Removal 3. Remove thrust bearing retainer by prying it up and out at raised point on retainer (Figure 8-36).
TOOL J6221
SPACER
STUB SHAFT BEARING
ADJUSTER PLUG
SCREWDRIVER
RAISED SECTION OF RETAINER
Figure 8-36: Adjuster Plug Thrust Bearing Retainer Removal 4. Remove bearing spacer, thrust bearing and races, and Oring (Figure 8-37). 7.
Figure 8-38: Stub Shaft Bearing Removal Remove stub shaft bearing with tool J6221 (Figure 8-38).
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4-1-00
8-26
Steering System
__________________________________________________________
Rack Piston Removal and Disassembly

1. Rotate stub shaft counterclockwise until rack piston is even with seal groove in open end of housing. Do not allow the rack piston to extend out of the housing. It only needs to be about 1/4 inch from the end. Remove rack piston plug (Figure 8-39). Use a ratchet and socket extension to remove the plug as shown.
EXTENSION PISTON PLUG ARBOR TOOL J21552
2.
WORMSHAFT
RACK PISTON
Figure 8-41: Wormshaft Removal 6. 7. Remove thrust bearing and races from wormshaft. Remove teflon seal rings and backup O-rings from rack piston (Figure 8-42).
BALL GUIDE CLAMP
RATCHET
RACK PISTON
BALL GUIDES
Figure 8-39: Rack Piston Plug Removal 3. Insert arbor tool J21552 into rack piston (Figure 8-40).
RACK PISTON TEFLON RING RACK PISTON BEARING BALLS
ARBOR TOOL J21552
O-RING SEAL
Figure 8-40: Rack Piston Removal 4. Hold arbor tool tightly in rack piston and turn stub shaft counterclockwise to push rack piston out of housing. Then remove rack piston, and arbor tool as assembly (Figure 8-40). Remove wormshaft if it came out of stub shaft (Figure 8-41). 8.
Figure 8-42: Rack Piston Components Remove bolts attaching recirculating ball guide halves to rack piston, remove guides, and remove bearings from rack piston (Figure 8-41). A total of 24 bearings are used; 12 chrome and 12 black.
5.
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Steering System
VALVE SPOOL
8-27
Valve Body-Stub Shaft-Wormshaft Removal and Disassembly

1. 2. 3. 4. 5. Grasp splined end of stub shaft and carefully rotate valve body/stub shaft assembly out of gear housing. If wormshaft remained engaged in stub shaft cap, disengage and remove wormshaft at this time. Remove O-ring from cap end of stub shaft. Lightly tap splined end of stub shaft on wood block to disengage cap from valve body. Grasp stub shaft cap and pull it upward to expose shaft pin (Figure 8-43). Then disengage shaft pin from valve body and separate two components.
O-RING
ROTATE SPOOL TO REMOVE VALVE BODY NOTCH IN STUB SHAFT CAP
Figure 8-44: Valve Spool Removal 7. 8. Remove O-ring from valve spool. Remove seals and O-rings from valve body (Figure 8-45).
O-RINGS
VALVE BODY SPOOL O-RING SHAFT PIN STUB SHAFT
SEAL RINGS VALVE BODY VALVE SPOOL
STUB SHAFT O-RING
Figure 8-45: Stub Shaft/Valve Body Components
Figure 8-43: Stub Shaft Removal 6. Remove spool from valve body with a rotating motion (Figure 8-44).
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Steering System
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Pitman Shaft Bearing and Seal Removal

1. 2. Remove seal retaining ring with internal-type snap ring pliers. Remove first backup washer (Figure 8-46).
RETAINING RING BACKUP WASHER DOUBLE-LIP SEAL BACKUP WASHER SINGLE-LIP SEAL
POWER STEERING GEAR CLEANING AND INSPECTION

Discard all the old O-rings, seals, and seal rings. Do not reuse these parts. Clean the gear housing and components in a standard parts cleaning solution and either wipe them dry with lint-free shop towels or use low pressure compressed air. Examine the wormshaft, pitman shaft, and stub shaft bearings for wear, galling, flat spots, or loss of bearing material (flaking). Also examine the wormshaft and stub shaft thrust bearing races for wear, grooving, discoloration, scoring, or spalling. Replace bearings and races as necessary. Do not reuse parts in marginal condition. Check the gear housing for cracks, damaged threads, scoredworn valve bores, and damaged pressure hose seats. Replace the housing if necessary. The hose seats can be replaced if scored, distorted, or loose. Refer to the procedure in the assembly and adjustment section. Inspect condition of the rack piston, wormshaft, and recirculating bearing balls (Figure 8-48). Replace the bearing balls as a set if any are scored, worn, distorted, have flat spots, or the coating is flaking off. The rack piston should be free from wear and scoring. Also be sure the seal ring groove is in good condition and the edges are not chipped cracked, or peened over. The wormshaft must be smooth and free of scoring or wear to operate properly. Check the ball guide clamp threads in the rack piston. Rough threads can be cleaned up with a tap but damaged threads mean the rack piston will have to be replaced. Check fit of the spool in the valve body. The spool should move freely with a light coating of power steering fluid on it. Replace the valve body and spool as an assembly if either part is worn, scored, or damaged in any fashion. Inspect the stub shaft for wear and damage. Minor nicks and scratches on the shaft surface can be dressed off with crocus cloth or 600 grit emery cloth wetted with oil. However, replace the shaft if scored, or distorted. The adjuster plug threads and bearing bore should be in good condition especially the threads. Replace the plug if the threads are rough, deformed, or chipped. Rough threads will prevent proper preload on the wormshaft thrust bearing. Examine the pitman shaft, side cover, and gasket. Replace the shaft if the sector teeth are damaged, or the bearing and seal contact surfaces are worn, scored, or damaged in any way. Check condition of the side cover bushing. Replace the cover if the bushing is worn as the bushing is not serviceable. Inspect condition of the lash adjuster screw in the pitman shaft. Replace the shaft if the screw is damaged as the screw is not serviced separately.
PITMAN SHAFT BEARING GEAR HOUSING
Figure 8-46: Pitman Shaft Bearing and Seal Position 3. Remove seals, second backup washer, and bearing with tool J6278 (Figure 8-47).
TOOL J6278 OR J21551
PITMAN SHAFT BEARING
7-S08-020
Figure 8-47: Pitman Shaft Bearing Removal 4-1-00
_________________________________________________________
Steering System
8-29
RACK PISTON BACKUP O-RING
ADJUSTER NUT
SIDE COVER
END PLUG O-RING
GASKET
ADJUSTER SCREW PITMAN SHAFT RACK PISTON SEAL RING END PLUG END PLUG RETAINING RING BALL GUIDES BEARING BALLS (24) GUIDE CLAMP WORMSHAFT HOSE SEATS WORMSHAFT THRUST BEARING
RACES
PITMAN SHAFT BEARING SINGLE-LIP SEAL
SEAL RINGS
PISTON PLUG RACK PISTON
BACKUP WASHERS
DOUBLE-LIP SEAL SNAP RING
NUT AND LOCKWASHER O-RINGS LOCKNUT
VALVE BODY SPOOL O-RING VALVE SPOOL STUB SHAFT STUB SHAFT O-RING RETAINER O-RING
OIL SEAL
DUST SEAL ADJUSTER PLUG INNER RACE THRUST BEARING
SNAP RING
STUB SHAFT BEARING
OUTER SPACER RACE
Figure 8-48: Power Steering Gear Components 05745159 4-1-00
8-30
Steering System
__________________________________________________________
POWER STEERING GEAR ASSEMBLY AND ADJUSTMENT Gear Housing Hose Seat Replacement
Pitman Shaft Bearing and Seal Installation

1. 2. Lubricate bearing and seals with power steering uid, or petroleum jelly. Install bearing in gear housing with handle J8092 and installer J6278 or J21551 (Figure 8-50).
The hose seats in the gear housing (Figure 8-49), can be replaced when necessary. Procedure is as follows: 1. Thread appropriate size pan head, hardened sheet metal screw into seat. 2. Pry old seat out of housing using pry tools positioned under screw head. 3. Clean gear housing afterward to remove any chips. 4. Install new seat using spare hose fitting and brass punch.
PRESSURE HOSE SEAT HOUSING
TOOL HANDLE J8092 INSTALLER TOOL J6278 OR J21551
Figure 8-50: Pitman Shaft Bearing Installation 3. 4. 5. Figure 8-49: Pressure Hose Seat 6. 7. Install single lip seal in housing with tool J6219 (Figure 8-51). Be sure seal lip is toward gear housing. Install backup washer on single lip seal (Figure 8-51). Install double lip seal in housing with tool J6219 (Figure 8-51). Be sure seal lip is toward gear housing. Install backup washer on double lip seal. Install seal retaining snap ring.
4-1-00
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Steering System
8-31
4.
Install wormshaft in rack piston. Wormshaft flange should be seated against piston as shown (Figure 8-53).
INSTALLER TOOL J6219
LOAD BEARING BALLS INTO THIS BALL GUIDE PORT WORMSHAFT FLANGE
RACK PISTON GEAR HOUSING
Figure 8-53: Rack Piston Loading Port For Bearing Balls 5. 6. Align worm shaft spiral groove with indicated ball guide circuit port in rack piston (Figure 8-53). Load recirculating bearing balls in rack piston and in ball guides as follows: a. Lubricate bearing balls with power steering fluid. b. Turn wormshaft counterclockwise to load bearing balls in rack piston. c. Load balls in rack piston through indicated ball guide port (Figure 8-53). d. Load balls alternately. Start with chrome ball followed by black ball until rack piston is full (piston will only accommodate around 18 balls). e. Load remaining balls in ball guides. Use petroleum jelly to hold balls and guide halves in place (Figure 8-54). f. Verify that 12 black and 12 chrome balls were installed in correct sequence. g. Assemble and install ball guides (with enclosed balls) on rack piston and secure guides with clamp. Tighten clamp bolts to 43 lb-ft (58 Nm) torque.
Figure 8-51: Pitman Shaft Seal Installation
Rack Piston Assembly

1. 2. 3. Lubricate rack piston bore in gear housing and new O-ring and seal ring with power steering uid. Install new backup O-ring in rack piston seal groove. Install new teflon seal ring in groove over backup O-ring (Figure 8-52).
TEFLON RING
NOTE: BACK-UP O-RING IS INSTALLED UNDER SEAL RING
RACK PISTON
Figure 8-52: Rack Piston Seal Ring Installation
WARNING: The chrome recirculating balls are slightly larger in diameter than the black coated balls. This is required in order to generate and maintain proper wormshaft preload. It is also why the balls must be installed alternately. Incorrect installation, or failure to load all 24 balls will result in loss of preload, bind, and partial loss of steering control. Verify that the balls are correctly loaded before proceeding.
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8-32
Steering System
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BEARING BALLS
BALL GUIDE HALVES
TEFLON COATED SEAL RING (OVER O-RING)
PETROLEUM JELLY
Figure 8-54: Assembling Remaining Bearing Balls and Ball Guides 7. Remove wormshaft and temporarily install arbor tool J21552 as follows: a. Insert arbor tool J21552 into rack piston end plug hole. b. Hold arbor tool firmly against wormshaft and turn wormshaft counterclockwise. This allows wormshaft to back out of piston as arbor tool enters and holds recirculating balls in place. Set rack piston aside temporarily for later installation. Do not allow the arbor tool to slip out of the piston. If this occurs, it will be necessary to disassemble and reload the bearing balls. 4. 5.
Figure 8-55: Valve Body Seal Ring Installation Install new O-ring on valve spool. Install spool in valve body with a turning motion (Figure 8-59). Note that O-ring end of spool faces out.
CAUTION: Do not force the spool into the valve. This could score the spool and valve body resulting in steering problems after installation. Install the spool with a push and turn motion only.
8.
VALVE BODY
Valve Body-Stub Shaft-Wormshaft Assembly

1. 2. 3. Lubricate valve body spool, O-rings, and seal rings with power steering uid. Install new backup O-rings in valve body grooves. Install new teflon coated seal rings in valve body grooves. Note that the seal rings are installed on top of (over) the backup O-rings (Figure 8-55).
SPOOL
Figure 8-56: Valve Body Seal Ring Installation
4-1-00
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Steering System
8-33
6.
Install stub shaft in valve body as follows: a. Insert stub shaft into valve body. b. Leave approximately 1/4 inch (6 mm) space between stub shaft cap and valve body for access to pin (Figure 8-57). c. Align and engage stub shaft pin in valve spool pin bore (Figure 8-57). d. Align notch in stub shaft cap with pin in valve body (Figure 8-58). Then fully seat stub shaft in valve body. Verify that valve body pin is seated in cap notch before proceeding.
NOTCH IN STUB SHAFT CUP
6mm (1/4 ")
VALVE BODY PIN (SEAT IN CAP NOTCH)
PIN BORE IN SPOOL
STUB SHAFT PIN
Figure 8-58: Aligning and Seating Stub Shaft In Valve Body 7. Lubricate wormshaft thrust bearings and races with petroleum jelly to hold them in place. Then install first race followed by the bearing and remaining race (Figure 8-59).
Figure 8-57: Aligning Stub Shaft Pin and Valve Spool Pin Bore
CAUTION: The thrust bearing races both have a concave shape. Be sure the concave side is toward the wormshaft flange as shown. The races will not maintain proper preload on the bearing otherwise.
05745159
4-1-00
8-34
Steering System
__________________________________________________________
Adjuster Plug Assembly

THRUST BEARING
1.
2.
Position new stub shaft bearing on installer tool J6221. Position bearing so ID number is toward installer tool. This will minimize any chance of damaging the bearing during installation. Install stub shaft bearing in adjuster plug with tool J6221 (Figure 8-61). Place adjuster plug on wood block as shown.
CONCAVE (ANGLED) SIDE OF RACES MUST BE TOWARD WORMSHAFT FLANGE
Figure 8-59: Aligning and Seating Stub Shaft In Valve Body 8. 9. Install O-ring on stub shaft cap (Figure 8-63). Align slot in valve body with pin in wormshaft flange and insert wormshaft into valve body (Figure 8-63). Be sure wormshaft flange is fully seated in stub shaft. 10. Set assembly aside for later installation.
TOOL J6221
ADJUSTER PLUG WOOD BLOCK
STUB SHAFT BEARING
ALIGN PIN AND SLOT THRUST BEARING AND RACES VALVE BODY/ O-RING STUB SHAFT ASSEMBLY WORMSHAFT
Figure 8-61: Installing Stub Shaft Bearing and Seals In Adjuster Plug 3. Install stub shaft oil seal and dust seal in adjuster plug with tool J6221. Then install snap ring to secure seals and bearing (Figure 8-62). Assemble and install thrust bearing and races in adjuster plug (Figure 8-62). Be sure races are installed as shown (Figure 8-62). Install spacer and retainer in adjuster plug (Figure 8-62). Seat retainer in adjuster plug with pin punch (Figure 8-63). Install O-ring on adjuster plug (Figure 8-63).
4.
MAKE SURE ANGLE OF THRUST RACES ARE AS SHOWN
Figure 8-60: Wormshaft and Valve Body/Stub Shaft Assembly
5. 6. 7.
4-1-00
_________________________________________________________
Steering System
8-35
Gear Housing Assembly

SNAP RING STUB SHAFT DUST SEAL ADJUSTER PLUG INNER RACE
1. 2.
OUTER RACE RETAINER
3. 4.
STUB SHAFT OIL SEAL
STUB SHAFT BEARING
O-RING SEAL THRUST BEARING
SPACER
Figure 8-62: Adjuster Plug Assembly Sequence
Lubricate wormshaft, stub shaft-valve body, rack piston, and adjuster plug with power steering uid. Install wormshaft and stub shaft/valve body assembly in gear housing. Be sure wormshaft thrust bearings are not displaced during installation. Install adjuster plug in gear housing. Tighten plug only enough to secure it in housing (2-3 threads). Install rack piston as follows: a. Place socket and ratchet on stub shaft. b. Insert rack piston into housing until wormshaft contacts arbor tool previously installed in rack piston (Figure 8-40). Hold arbor tool firmly in place during installation. c. Turn stub shaft clockwise to feed wormshaft into rack piston. Wormshaft will push arbor tool out as it engages piston and recirculating balls.
NOTE: Maintain pressure on the arbor tool at all times during installation. The rack piston will have to be removed and completely reassembled if even one bearing falls out during assembly. 5.
PIN PUNCH
6. 7.
Continue turning stub shaft until wormshaft is fully engaged in rack piston. Install plug in rack piston (Figure 8-39). Tighten plug to 111 lb-ft (150 Nm) torque. Install end plug O-ring in gear housing and install housing end plug (Figure 8-33). Install end plug retaining ring. Position ring ends so neither one is aligned with punch access hole in gear housing (Figure 8-64). Position new gasket on side cover and assemble cover and pitman shaft. Lubricate pitman shaft and sector teeth with power steering fluid. Center rack piston in housing by turning stub shaft as needed. Insert pitman shaft into housing. Be sure that shaft sector teeth are centered in rack piston teeth. Align and seat side cover on gasket and housing. Install and tighten side cover bolts to 44 lb-ft (60 Nm) torque. Install but do not fully tighten adjuster screw lock nut (nut will be tightened during gear adjustment). Adjust steering gear as described in following adjustment procedures.
RETAINER SPACER
8.
9. 10. 11. 12.

O-RING
13. 14. Figure 8-63: Seating Adjuster Plug Retainer 15. 16.
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8-36
Steering System
__________________________________________________________
Wormshaft Bearing Preload Torque Adjustment

RING GAP PUNCH ACCESS HOLE END PLUG RETAINING RING
1.
2. 3.
Mount gear in vise equipped with protective vise jaws. Position gear so adjuster plug is accessible and wormshaft is horizontal. If adjuster plug locknut is installed, loosen nut with punch and hammer and remove it from adjuster plug. Tighten adjuster plug with spanner wrench J7624 (Figure 8-65). Tighten plug until it and wormshaft bearing and races are fully seated (bottomed) in housing.
SPANNER WRENCH J7624
Figure 8-64: Positioning End Plug Retaining Ring in Housing
POWER STEERING GEAR ADJUSTMENTS

There are two steering gear adjustments which are: wormshaft bearing preload and pitman shaft overcenter preload. The adjustments must be performed in the correct sequence which is, bearing preload first and overcenter preload last. The gear adjustments can be performed on the bench, or with the gear mounted in the vehicle. If adjustment is performed with the gear in the vehicle, the pitman arm and intermediate shaft must be disconnected beforehand.
ADJUSTER PLUG
Figure 8-65: Seating Adjuster Plug 4. 5. Tap spanner wrench with mallet to tighten plug to approximately 22 lb-ft (30 Nm) torque. Scribe an index mark on gear housing in line with one of the adjuster plug spanner wrench holes (Figure 8-66). This will be the first index mark.
4-1-00
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Steering System
8-37
FIRST MARK SPANNER WRENCH HOLE IN ADJUSTER PLUG FIRST INDEX MARK (ON HOUSING)
SECOND MARK
SPANNER WRENCH J7624
Figure 8-66: Placing First Index Mark On Housing 6. Measure back counterclockwise 1/2 inch (13 mm) from first index mark and scribe a second index mark on gear housing (Figure 8-67).
Figure 8-68: Backing Off Adjuster Plug To Second Index Mark 8. Install adjuster plug locknut. Hold adjuster plug from turning with spanner wrench while tightening locknut. Tap locknut with hammer to tighten. Then use punch to secure nut (Figure 8-69).
SECOND INDEX MARK (1/2" FROM FIRST MARK)
PUNCH
NOTCH
Figure 8-67: Placing Second Index Mark On Housing 7. Back off adjuster plug to second index mark (Figure 8-71). Be sure hole in adjuster plug is aligned with second mark before proceeding.
ADJUSTER PLUG
LOCK NUT
Figure 8-69: Securing Adjuster Plug Locknut 9. Verify that adjuster plug position remained unchanged during installation. Loosen locknut and reset plug position if necessary.
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8-38
Steering System
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Pitman Shaft Overcenter Preload Torque Adjustment

1. 2. 3. Loosen locknut on pitman shaft adjuster screw. Turn adjuster screw counterclockwise until fully extended. Then turn screw one full turn clockwise. Rotate stub shaft from stop-to-stop and count number of turns. Then turn stub shaft back 1/2 number of turns. This will center rack piston and pitman shaft. Verify that gear is centered. Flat on stub shaft should face upward and be parallel with side cover. In addition, master spline on pitman shaft should be parallel with adjuster screw (Figure 8-70). If gear is not centered, number of turns counted in step 3 may be incorrect, or pitman shaft sector teeth are not centered in rack piston. Make necessary corrections before proceeding.
5.
4.
Measure wormshaft bearing preload as follows: Position suitable size 12 point socket and inch pound torque wrench J7754-C on stub shaft (Figure 8-71). Slowly rotate torque wrench 45 degrees left and right of center. Note torque readings just before and on center in both directions. Correct preload torque is 6 to 15 lb-in (0.7 to 1.7 Nm). If preload torque is within limits, continue with procedure as wormshaft bearing preload is correct. If preload torque is not within limits, wormshaft bearing preload adjustment is incorrect, or wormshaft thrust bearing races were installed backwards. Correct fault before proceeding.
HEX WRENCH IN PRELOAD ADJUSTER SCREW CENTER
SIDE COVER
STUB SHAFT FLAT
PRELOAD ADJUSTER SCREW
Figure 8-71: Checking /Adjusting Pitman Shaft Over-Center Preload 6. Adjust pitman shaft overcenter preload as follows: Leave torque wrench in place on stub shaft. Note wormshaft bearing preload measured in step 5. Then add additional 6-10 lb-in (0.7 to 1.1 Nm) to this figure for required overcenter preload. Adjust overcenter preload by turning pitman shaft adjuster screw clockwise to increase preload, or counterclockwise to decrease preload. Tighten adjuster screw locknut to 36 lb-ft (49 Nm) torque. Use hex wrench to prevent adjuster screw from turning while nut is tightened. Verify that overcenter preload is still correct before installing gear in vehicle.
PITMAN SHAFT MASTER SPLINE
7.
Figure 8-70: Verifying That Gear Is Centered
8.
4-1-00
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Steering System
8-39
POWER STEERING PUMP REPAIR Disassembly

1. 2. 3. 4.
(Figures 8-72 through 8-77)
Suction uid from reservoir and disconnect uid reservoir hose from pump. Remove power steering pump pulley and bracket. Drain fluid from pump assembly (Figure 8-72). Remove two mounting studs from pump assembly.
NOTE: Fitting assembly is spring loaded. Remove carefully to avoid losing parts.
5. 6. Remove fitting assembly and O-ring seal. Discard O-ring seal. Remove flow control valve and valve spring from pump body.
HOUSING
MOUNTING STUD MOUNTING STUD FITTING ASSEMBLY PUMP ASSEMBLY
PUMP BODY VALVE SPRING

7-S08-062.2
O-RING SEAL
FLOW CONTROL VALVE
Figure 8-72: Pump Assembly
CAUTION: Do not overtighten vise as pump body could be distorted.

O-RING SEAL PUMP BODY PUMP SHAFT
7. 8. 9.
Place pump body in vise (Figure 8-73). Tap lightly around edge of housing. Remove housing and O-ring seal from pump body. Discard O-ring seal. 10. Remove three O-ring seals from pump body and discard. (Figure 8-74). 11. Remove magnet from pump body and discard.
HOUSING
Figure 8-73: Reservoir Removal 05745159 4-1-00
8-40
Steering System
__________________________________________________________
RETAINING RING O-RING SEAL PRESSURE PLATE SPRING
END PLATE O-RING SEALS PUMP BODY
Figure 8-75: End Plate Removal
MAGNET PUMP BODY
CAUTION: If end of driveshaft in steering pump housing is corroded, clean with an abrasive crocus cloth before removing shaft. Failure to do so may result in damage to shaft bushing. If bushing is damaged, replace power steering pump assembly.
14. 15. 16. 17. 18. 19. 20. 21. Tap lightly on driveshaft until pressure plate is free Remove pressure plate (Figure 8-76). Remove pump ring and vanes from pump rotor. Remove driveshaft, rotor, and thrust plate assembly from pump body. Remove retaining ring from driveshaft. Remove rotor from driveshaft. Remove thrust plate from driveshaft. Remove dowel pins from pump body.
Figure 8-74: O Ring Seal Removal 12. Remove retaining ring from pump body (Figure 8-75). 13. Remove end plate and pressure plate spring from pump body.
PRESSURE PLATE
PUMP RING RETAINING RING THRUST PLATE PUMP BODY
VANES
ROTOR DRIVESHAFT DOWEL PINS
Figure 8-76: Pressure Plate and Rotor Removal PUMP BODY DRIVESHAFT SEAL 22. Remove two O-ring seals from pump body. Discard Oring seals (Figure 8-77). 23. Remove driveshaft seal from pump body. Discard driveshaft seal.
O-RING SEALS Figure 8-77: Seal Removal 4-1-00
_________________________________________________________
Steering System
8-41
(Figure 8-78)
NOTE: Clean all components, examine for wear or damage, and replace if necessary.
1. Inspect ow control valve and valve spring for damage.
2. 3. 4. 5.
Inspect studs for damage. Inspect fitting for damage. Inspect housing for damage. Inspect remaining components for damage. Replace power steering pump if any component is damaged.
POWER STEERING PUMP
STUD FLOW CONTROL VALVE
HOUSING
FITTING
PRESSURE PLATE
VALVE SPRING
STUD
ROTOR DRIVESHAFT
PUMP BODY
Figure 8-78: Cleaning and Inspection
05745159
4-1-00
8-42
Steering System
__________________________________________________________
Assembly
(Figures 8-72 through 8-83)
NOTE: For general assembly instructions refer to Section 2.

1. 2. 3. 4. 5. 6. 7. Install O-ring seal in bottom groove of pump body (Figure 8-79). Install driveshaft seal in pump body. Install rotor on thrust plate. Insert splined end of driveshaft through thrust plate and rotor. Install retaining ring on driveshaft. Install dowel pins in pump body. Install driveshaft and rotor assembly in pump body.
CAUTION: To avoid damage to equipment, install pump ring with arrow pointing up.
8. 9. Align dowel pins and small holes In pump ring. Install pump ring in pump body.
CAUTION: To avoid damage to equipment, install vanes in rotor with rounded edges facing outward.
10. Install ten vanes in rotor.
CAUTION: To avoid damage to equipment, install pressure plate with spring groove facing upward.
11. Install pressure plate on pump ring ensuring center notches in pressure plate align with dowel pins.
PRESSURE PLATE
VANES ROTOR DRIVESHAFT DOWEL PIN PUMP BODY
PUMP RING RETAINING RING THRUST PLATE DOWEL PIN O-RING SEAL DRIVESHAFT SEAL
Figure 8-79: Pressure Plate and Rotor Installation
4-1-00
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Steering System
8-43
12. Install O-ring seal in center groove in pump body (Figure 8-80). 13. Install pressure plate spring in pump body. 14. Install end plate and retaining ring in pump body.
RETAINING RING END PLATE O-RING SEAL PUMP BODY
17. Install O-ring seal on pump body (Figure 8-82). 18. Install housing on pump body.
O-RING SEAL
PUMP BODY
HOUSING PRESSURE PLATE SPRING
Figure 8-82: O Ring Installation 19. Install two mounting studs on pump assembly. Tighten studs to 35 N.m 26 Ib-ft) (Figure 8-83). 20. Install valve spring and flow control valve in pump body. 21. Install O-ring seal and fitting assembly in pump body. Tighten fitting in pump body to 50 N.m (37 Ib-ft.). 22. Install power steering pump, pulley and bracket.
Figure 8-80: End Plate Installation 15. Install magnet in pump body (Figure 8-81). 16. Install O-ring seal into control valve cavity and two O-ring seals into threaded holes.
O-RING SEAL CONTROL VALVE CAVITY THREADED HOLE O-RING SEAL
PUMP ASSEMBLY FITTING ASSEMBLY HOUSING MOUNTING STUD
PUMP BODY
PUMP BODY
7-S08-062.2
VALVE SPRING
O-RING SEAL
O-RING SEAL THREADED HOLE MAGNET

7-S08-063
FLOW CONTROL VALVE
Figure 8-83: Final Assembly
Figure 8-81: O Ring Installation
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4-1-00
8-44
Steering System
__________________________________________________________
POWER STEERING SYSTEM FLUSHING

The power steering system can be flushed but only when the fluid does not contain metal particles, foreign material, or debris from a gear or pump failure. Flushing is recommended only under the following circumstances: incorrect fluid added to system system filled with incorrect fluid water in the fluid burned, overheated fluid
STEERING SPECIFICATIONS
Recommended fluid is Dextron III.
Steering Gear Adjustment Preload Torques

Wormshaft bearing ..................... 6 to 15 lb-in (0.7 to 1.7 Nm) Pitman shaft overcenter .............. 6 to 10 lb-in (0.7 to 1.1 Nm) NOTE: Overcenter preload is in addition to wormshaft bearing preload. For example, overcenter preload should produce a combined final torque ranging from 12 to 25 inch-pounds.
Flushing Procedure
1. 2. Raise front wheels just enough for them to turn freely. Disconnect fluid return line at pump. Then plug pump return port with rubber cap and hose clamp. 3. Position and secure pump return line in drain pan. 4. Have container of fresh power steering fluid handy. Pump reservoir will need refilling as old fluid is pumped into drain pan. 5. Start and run the engine at curb idle speed. 6. Have helper slowly turn steering wheel back and forth about 3/4 turn in each direction. 7. Continue procedure until only fresh fluid comes out of return line. 8. Stop engine, reconnect pump return line, and add power steering fluid as needed. 9. Purge air from system. Refer to procedure in this section. 10. Stop engine and check fluid level and condition. Repeat flushing procedure if any old fluid is still evident in reservoir fluid.
Torque Specications
Adjuster Plug Locknut................................. 80 lb-ft (109 Nm) Adjuster Screw Locknut ................................ 35 lb-ft (47 Nm) Ball Guide Clamp Bolts................................. 36 lb-ft (49 Nm) Pressure Hose Fittings (at gear)..................... 25 lb-ft (34 Nm) Rack Piston Plug........................................ 111 lb-ft (150 Nm) Side Cover Bolts............................................ 44 lb-ft (60 Nm)
Steering Pump Flow Rates and Operating Pressures

Minimum Flow Rate In Gallons/Liters Per Minute = 1.32 gpm (5.0 liters/min) @ 465 rpm Maximum Flow Rate In Gallons/Liters Per Minute = 3.1 to 3.5 gpm (11.7 to 13.2 liters/min) @ 1500 rpm Minimum Pump Output Pressure 1200 psi (8274 kPa) Maximum Pump Output Pressure: 1,475 - 1,515 psi (10,170 10,446 kPa) NOTE: Pump output pressures are controlled by the pump relief valve setting
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Steering System
8-45
ESSENTIAL TOOLS
J24319-B
J25033-C
J33141
J25034-C J25323 J42548
J8092
Tool J24319-B J25033-C J33141 J25034-C J25323 J42548 J8092
Description Steering Linkage and Tie-Rod Puller Pump Pulley Installer Adapter Fittings (used with J25323) Pump Pulley Remover Power Steering System Analyzer Puller, Pitman Arm Universal Driver Handle
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8-46
Steering System
__________________________________________________________
SPECIAL TOOLS
J4245
J6219
J6221
J6278 or J21551
J7624
J8092 or J7079
J21552
J7754-C
Tool J6219 J6221 J6278 (or J21551) J7624 J7754-C J21552
Description Pitman Shaft Seal Installer Stub Shaft Bearing and Seal Remover/Installer Pitman Shaft Bearing Remover/Installer Spanner Wrench (Adjuster Plug) Inch-Pound Torque Wrench (Over-Center Preload) Rack Piston Arbor
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9-1
Section 9 Axles, Suspension, and Frame

TABLE OF CONTENTS
Airlift Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48, 9-49 Axle Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . .9-25 Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .9-26 Support and Side Mounting Brackets . . . . . . . . . . . . . . . .9-59 Vent Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23 Axle Assembly Cover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-25 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-28 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26 Bumpers Front Bumper and Towing Brackets . . . . . . . . . . . . . . . . .9-45 Rear Bumper Outer Mounting and Tiedown Brackets . . .9-53 Rear Bumper Replacement . . . . . . . . . . . . . . . . . . . . . . . .9-52 Frame Front Suspension Brace Replacement . . . . . . . . . . . . . . .9-50 Front Suspension Front Crossmember . . . . . . . . . . . . . . .9-60 Front Suspension Rear Crossmember . . . . . . . . . . . . . . .9-61 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-64 Left Engine Mount Bracket . . . . . . . . . . . . . . . . . . . . . . . .9-54 Left Intermediate Body Mount Bracket . . . . . . . . . . . . . . .9-57 Lifting Shackle Replacement . . . . . . . . . . . . . . . . . . . . . . .9-47 Radiator Front Mount Bracket . . . . . . . . . . . . . . . . . . . . . .9-46 Rear Suspension Front Crossmember . . . . . . . . . . . . . . .9-62 Rear Suspension Rear Crossmember . . . . . . . . . . . . . . . .9-63 Rear-Front Tiedown Bracket. . . . . . . . . . . . . . . . . . . . . . . .9-59 Rear-Rear Tiedown Bracket . . . . . . . . . . . . . . . . . . . . . . . .9-58 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-67 Right Engine Mount Bracket . . . . . . . . . . . . . . . . . . . . . . .9-55 Right Front Body Mount Bracket . . . . . . . . . . . . . . . . . . . .9-55 Right Intermediate Body Mount Bracket . . . . . . . . . . . . .9-57 Transmission Crossmember Support . . . . . . . . . . . . . . . .9-56 Transmission Mount Crossmember . . . . . . . . . . . . . . . . . 9-56 Transmission Mount Replacement . . . . . . . . . . . . . . . . . . 9-56 Geared Hub Input Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Side Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Spindle Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . 9-19 Spindle Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 Vent Line Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 Halfshaft Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21 Splash Shield Support Bracket Replacement . . . . . . . . . . . . . 9-51 Spring Seat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53 Suspension System Control Arm Bushing Replacement . . . . . . . . . . . . . . . . . . 9-7 Frame Extension Replacement . . . . . . . . . . . . . . . . . . . . . 9-47 Front Bumper and Towing Brackets . . . . . . . . . . . . . . . . . 9-45 Front Bumper Mounting Bracket . . . . . . . . . . . . . . . . . . . . 9-46 Lower Ball Joint Replacement . . . . . . . . . . . . . . . . . . . . . . . 9-5 Lower Control Arm Replacement . . . . . . . . . . . . . . . . . . . . 9-7 Radius Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Rear Upper Control Arm Bracket. . . . . . . . . . . . . . . . . . . . 9-58 Stabilizer Bar Link Replacement . . . . . . . . . . . . . . . . . . . . . 9-2 Stabilizer Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Upper Ball Joint Replacement . . . . . . . . . . . . . . . . . . . . . . 9- 4 Upper Control Arm Replacement . . . . . . . . . . . . . . . . . . . . 9-5 Winch Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72, 9-81 Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-71, 9-80 Electric Thermal Switch/Brush Assembly . . . . . . . 9-76, 9-85 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70, 9-79 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
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9-2
Axles, Suspension, and Frame ___________________________________________
SUSPENSION SYSTEM DESCRIPTION

The HUMMER suspension system consists of a heavy-duty coil spring, a heavy-duty hydraulic shock absorber, and an upper and lower control arm at each wheel. This suspension system provides for a smoother ride and allows for more positive control of the vehicle. Ball joints allow the control arms and geared hubs to change angles for smooth steering during turns. A stabilizer bar is located on the front suspension to aid in stabilizing the vehicle when it is turning. Each end of the stabilizer bar is attached to the lower control arms (Figure 9-1).
FRAME BRACKET PIN BAR LINK
STABILIZER BAR BUSHING
UPPER CONTROL ARM BALL JOINT COIL SPRING SHOCK ABSORBER LOWER CONTROL ARM GEARED HUB
Figure 9-2: Stabilizer Bar Replacement
STABILIZER BAR LINK REPLACEMENT

Removal
1. 2. Remove locknut and two washers securing bar link to stabilizer bar (Figure 9-3). Remove bolt, two washers, and bar link from lower control arm.
Installation
1. Apply thread-locking compound to threads of bolt. Install bar link to lower control arm with two washers and bolt. Tighten bolt to 70 lb-ft (95 Nm) (Figure 9-3). Install bar link on stabilizer bar with two washers and locknut. Tighten locknut to 75 lb-ft (102 Nm).
Figure 9-1: Suspension System

2.
STABILIZER BAR REPLACEMENT

Removal
NOTE: Stabilizer bar must be removed from bar links at each end of lower control arms. 1. 2. 3. Remove two locknuts, three washers, and pin securing bar link to stabilizer bar (Figure 9-2). Remove two locknuts, washers, clamp, and stabilizer bar from frame bracket. Remove bushing from stabilizer bar.
BAR LINK
Installation
1. 2. Install bushing on stabilizer bar (Figure 9-2). Install stabilizer bar on frame bracket with clamp, two washers, and locknuts. Tighten locknuts to 60 lb-ft (81 Nm). Install stabilizer bar on bar link with pin, three washers, and two locknuts. Tighten locknuts to 75 lb-ft (102 Nm).
STABILIZER BAR LOWER CONTROL ARM
3.
Figure 9-3: Stabilizer Bar Link Replacement
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Axles, Suspension, and Frame
9-3
RADIUS ROD REPLACEMENT

Removal
1. 2. 3. 4. Remove wheel. Remove cotter pin, slotted nut, and washer securing radius rod to geared hub (Figure 9-4). Using puller J24319-B or equivalent, separate radius rod from geared hub. Remove locknut, washers, bolt, and radius rod from bracket.
UPPER BALL JOINT WEAR CHECK PROCEDURE

NOTE: If the vehicle was previously lifted off the ground for other service, center the steering wheel, roll the vehicle forward and back to settle the suspension and relieve the tension on the ball joints before beginning checking procedure. 1. With the vehicle on the ground (being careful not to damage the boot), place the tip of a prybar between the steering knuckle and the ball joint boot (Figure 9-5). With the shank of the prybar contacting the upper control arm as shown, pry upward and note the movement of the ball joint against a ruler. Be careful to measure only the ball joint movement and not the flex of the control arm resulting from prying against it. Any upper ball joint with more than 1/16 (1.6 mm) movement should be replaced.
2.
Installation
1. Install radius rod on bracket with washer, bolt, washer, and locknut. Tighten locknut to 260 lb-ft (353 Nm) (Figure 9-4).
3.
CAUTION: Do not loosen slotted nut to install cotter pin. Doing this may result in damage to equipment. NOTE: When slotted nuts are tightened to prescribed torque values, cotter pins must have a minimum of 50% engagement with the nut slots. 2. Install radius rod on geared hub with washer and slotted nut. Tighten slotted nut to 70 lb-ft (95 Nm). Install cotter pin in slotted nut. Install wheel.
3.
STEERING KNUCKLE
PRYBAR
BRACKET RADIUS ROD
7-S09-026.1
Figure 9-5: Upper Ball Joint Wear Check
GEARED HUB
Figure 9-4: Radius Rod Replacement
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9-4
UPPER BALL JOINT REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Remove wheel. Raise and support lower control arm. Disconnect the p-clamp securing the vent line and speed sensor lead to the upper control arm. Remove cotter pin and slotted nut from upper ball joint (Figure 9-6). Remove four locknuts, bolts, eight washers and upper ball joint from upper control arm. Separate upper ball joint from geared hub using ball joint remover J24319-B or equivalent. Remove ball joint.
LOWER BALL JOINT WEAR CHECK

1. 2. Support lower control arm with a jack or stand to unload lower ball joint. Place prybar between lower arm at ball joint and geared hub and measure vertical play obtained by moving pry bar down (Figure 9-7). Maximum play should not exceed 1/8" (3.5 mm). Replace ball joint if end play exceeds the limit.
3.
Installation
1. Position upper ball joint on upper control arm, ensuring upper ball joint is placed above upper control arm (Figure 9-6).
NOTE: Check upper ball joint torque 15 minutes after initial installation. Adjust if necessary. 2. Install upper ball joint on upper control arm with four bolts, locknuts and eight washers. Tighten 3/8 fine thread locknuts to 30 lb-ft (41 Nm).
PRYBAR
NOTE: Do not loosen slotted nut to install cotter pin. 3. Install upper ball joint on geared hub with slotted nut. Using crowfoot and adapter, tighten slotted nut to 65 lb-ft (88 Nm). Install cotter pin in slotted nut. Install the p-clamp securing the vent line and speed sensor lead to the upper control arm. Lubricate upper ball joint. Install wheel.
UPPER BALL JOINT MEASURE MOVEMENT HERE
4. 5. 6.
Figure 9-7: Lower Ball Joint Wear Check
UPPER CONTROL ARM
GEARED HUB
Figure 9-6: Upper Ball Joint Replacement
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9-5
LOWER BALL JOINT REPLACEMENT

Removal
1. 2. 3. 4. 5. Remove wheel. Raise and support lower control arm (Figure 9-8). Remove cotter pin and slotted nut from lower ball joint. Discard cotter pin. Remove four locknuts, bolts, eight washers and lower ball joint from lower control arm. Separate lower ball joint from geared hub using ball joint remover J24319-B or equivalent. Remove lower ball joint.
UPPER CONTROL ARM REPLACEMENT

NOTE: The procedure for removing and installing the front and rear upper control arms is basically the same. This procedure covers the left front upper control arm.
Removal
1. 2. Remove wheel (Section 6). Remove bolt and washer securing vent line/speed sensor lead bracket to geared hub (Figure 9-9). 3. Disconnect vent line from fitting. 4. Remove speed sensor from sensor mount bracket. 5. Remove bolt, p-clamp, vent line and speed sensor lead from upper control arm (Figure 9-10). 6. Remove cotter pin and slotted nut from upper ball joint. 7. Separate upper ball joint from geared hub using ball joint remover. 8. Remove four locknuts, bolts and eight washers securing upper ball joint to upper control arm and remove upper ball joint. 9. Mark position of the eccentric reference holes on the brackets for installation. 10. Remove two locknuts, washers, eccentrics, bolts, and upper control arm from brackets and remove upper control arm.
Installation
1. Install lower ball joint on lower control arm, ensuring lower ball joint is placed below lower control arm and secure with four bolts, locknuts and eight washers. Tighten 7/16 locknuts to 65 lb-ft (80 Nm) (Figure 9-8).
CAUTION: Do not loosen slotted nut to install cotter pin. Doing this may result in damage to equipment. 2. Install ball joint on geared hub with slotted nut. Tighten slotted nut to 73 lb-ft (99 Nm) and install cotter pin in slotted nut. Lubricate lower ball joint. Install wheel (Section 6).
LOWER BALL JOINT
3. 4.
GEARED HUB VENT LINE
VENT LINE BRACKET SPEED SENSOR GEARED HUB
SENSOR LEAD FITTING
LOWER CONTROL ARM
Figure 9-8: Lower Ball Joint Replacement Figure 9-9: Vent Line Connection Replacement
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9-6
Installation
1. Install upper control arm on brackets with two washers, eccentrics, bolts, and locknuts. Align reference holes (from removal step 8) on eccentrics with marks on brackets. Do not tighten locknuts (Figure 9-10). Secure upper ball joint to upper control arm with four washers, bolts, and locknuts. Tighten locknuts to 37 lb-ft (50 Nm).
3.
4. 5. 6. 7. 8. 9.
2.
CAUTION: Do not loosen slotted nut to install cotter pin. Doing this may result in damage to equipment. NOTE: When slotted nuts are tightened to prescribed torque values, cotter pins must have a minimum of 50% engagement with the nut slots.
Install upper ball joint on geared hub with slotted nut. Using crowfoot and adapter, tighten slotted nut to 65 lb-ft (88 Nm). Install cotter pin in slotted nut. Tighten locknuts on brackets to 260 lb-ft (359 Nm). Install p-clamp, vent line and speed sensor lead on upper control arm with bolt. Connect vent line to fitting (Figure 9-9). Install speed sensor in sensor bracket. Secure vent line/speed sensor bracket to geared hub with clamp, washer, and bolt. Tighten bolt to 37 lb-ft (50 Nm). Install wheel (Section 6).
ECCENTRIC PIVOT BOLT
FLAT WASHER
PIVOT BOLT NUT
UPPER BALL JOINT
UPPER CONTROL ARM UPPER CONTROL ARM BRACKET VENT LINE SPEED SENSOR P-CLAMP SPEED SENSOR LEAD VENT LINE
GEARED HUB
ECCENTRIC REFERENCE HOLE
Figure 9-10: Upper Control Arm Assembly Replacement
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9-7
CONTROL ARM BUSHING REPLACEMENT

Removal
NOTE: Control arm bushings must be replaced as a set (Figure 9-11). 1. 2. Remove control arm. Support control arm and press bushing out of control arm.
LOWER CONTROL ARM REPLACEMENT

NOTE: The procedure for removing and installing the front and rear lower control arms is basically the same. This procedure covers the left front lower control arm.
Removal
WARNING: Lower control arm must be supported during removal and installation. Failure to support lower control arm may cause personal injury or damage to equipment.
1. 2. 3. 4. 5. 6. 7. Remove wheel (Section 6). Remove shock absorber. Remove bolt, two washers, and bar link (front only) from lower control arm (Figure 9-12). Remove four locknuts, bolts, and eight washers from lower ball joint and lower control arm (Figure 9-13). Raise and support lower control arm. Remove lower ball joint from arm. Lower the lower control arm and remove coil spring. Remove two locknuts, washers, bolts, and lower control arm from brackets.
Installation
1. 2. 3. 4. 5. Lubricate outside diameter of bushing with grease. Insert bushing in control arm (Figure 9-11). Support control arm and press bushing into control arm until flange on bushing seats on control arm. Install control arm. Adjust caster and camber.
FLANGE CONTROL ARM
BUSHING
NOTE: Removing the lower ball joint from the geared hub will ease installation. 8. 9. Remove cotter pin and slotted nut from lower ball joint. Separate lower ball joint from geared hub using ball joint remover. Remove lower ball joint.
Figure 9-11: Control Arm Bushing Replacement
BAR LINK LOWER CONTROL ARM
Figure 9-12: Bar Link Replacement
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9-8
Installation
WARNING: Lower control arm must be supported during removal and installation. Failure to support lower control arm may cause personal injury or damage to equipment.
NOTE: On lower control arms, bolt heads are toward front of vehicle. 1. Install lower control arm on brackets with two bolts, washers, and locknuts. Do not tighten locknuts (Figure 9-13).
GEARED HUB REPLACEMENT

NOTE: Replacement procedures are basically the same for front and rear geared hubs. This procedure covers the front geared hub.
Removal
1. 2. Remove wheel. Remove drainplug from geared hub and drain geared hub (Figure 9-14).
TIE ROD END BRACKET GEARED HUB
COIL SPRING SPRING POCKET LOWER CONTROL ARM LOWER BALL JOINT GEARED HUB
SLOTTED NUT
DRAINPLUG
Figure 9-14: Geared Hub Drainplug Location

3. 4. 5. 6. 7. 8. 9. Install drainplug in geared hub. Remove bolt, washer, and vent line/speed sensor lead bracket from geared hub (Figure 9-15). Disconnect vent line from geared hub fitting. Remove speed sensor from sensor bracket on geared hub. Remove cotter pin, slotted nut, and washer from tie rod end. (Figure 9-14). Using puller J24319B, disconnect tie rod end from geared hub. Remove access plug, washer, halfshaft retaining bolt, lockwasher, and halfshaft from geared hub (Figure 9-15).
Figure 9-13: Lower Control Arm Replacement

2. 3. 4. Install coil spring on lower control arm ensuring end of coil spring fits in spring pocket of lower control arm. Install lower ball joint on lower control arm, ensuring ball joint is placed below lower control arm. Secure lower ball joint to lower control arm with four bolts, locknuts and eight washers. Tighten locknuts to 65 lb-ft (80 Nm). Install lower ball joint on geared hub with slotted nut. Tighten slotted nut to 73 lb-ft (99 Nm), and install cotter pin in slotted nut. Tighten locknuts on brackets to 260 lb-ft (353 Nm). Apply thread-locking compound to threads of bolt. Install bar link on lower control arm with two washers and bolt. Tighten bolt to 70 lb-ft (95 Nm) (Figure 9-12). Install shock absorber. Install wheel (Section 6).
5.
WARNING: Geared hub must be supported during removal and installation. Failure to support geared hub may cause personal injury or damage to equipment.
10. Remove cotter pin and slotted nut from upper ball joint. Remove ball joint stud from geared hub. 11. Remove cotter pin and slotted nut from lower ball joint. Remove ball joint stud from geared hub. 12. Lower support and remove geared hub.
6. 7.
8. 9.
__________________________________________
9-9
Installation
WARNING: To avoid injury and damage to equipment, support geared hub during removal and installation.
1. Position geared hub between upper and lower control arms and secure upper ball joint to geared hub with slotted nut, but do not tighten (Figure 9-15). Secure lower ball joint to geared hub with slotted nut, but do not tighten. NOTE: Make sure mounting hole and bolt are cleared of old Loctite. 5. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and halfshaft retaining bolt. Tighten halfshaft retaining bolt to 37 lb-ft (50 Nm). Secure washer and access plug to geared hub. Tighten access plug to 8-13 lb-ft (11-18 Nm).
2.
6.
NOTE: If necessary, tighten slotted nut to install cotter pin. When slotted nuts are tightened to prescribed torque values, cotter pins must have a minimum of 50% engagement with the nut slots. 3. 4. Tighten slotted nut securing upper ball joint to geared hub to 65 lb-ft (88 Nm). Install cotter pin. Slide halfshaft into geared hub.
NOTE: If necessary, tighten slotted nut to install cotter pin. 7. Tighten slotted nut securing lower ball joint to geared hub to 73 lb-ft (99 Nm). Install cotter pin. 8. Insert tie rod end into geared hub and secure with washer and slotted nut. Tighten slotted nut to 70 lb-ft (95 Nm). Install cotter pin (Figure 9-14). 9. Connect vent line to geared hub fitting (Figure 9-17). 10. Install speed sensor in sensor bracket and push in until sensor contacts tone wheel on halfshaft.
UPPER BALL JOINT
GEARED HUB SLOTTED NUT GEARED HUB FITTING ACCESS PLUG
VENT LINE BRACKET SPEED SENSOR HALFSHAFT HALFSHAFT RETAINING BOLT
VENT LINE SENSOR BRACKET LOWER BALL JOINT
SLOTTED NUT
Figure 9-15: Geared Hub Replacement

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9-10
_________________________________________
13. Remove fill plug and washer from geared hub (Figure 9-18).
GEARED HUB
TIE ROD END FILL PLUG
SLOTTED NUT
GEARED HUB
Figure 9-16: Tie Rod End Into Geared Hub
VENT LINE GEARED HUB
Figure 9-18: Geared Hub Fill Plug

14. Fill geared hub to proper oil level (Section 1). 15. Install washer and fill plug on geared hub. Tighten fill plug to 8-13 lb-ft (11-18 Nm). 16. Install wheel. 17. Check alignment.
SPEED SENSOR LEAD
GEARED HUB FITTING
Figure 9-17: Vent Line

11. Secure vent line, speed sensor lead and clamp to geared hub with washer and bolt. Tighten bolt to 38 lb-ft (52 Nm) (the left side of vehicle uses two p-clamps to secure the speed sensor lead to the geared hub). 12. Install speed sensor and retaining sleeve into speed sensor bracket and push in until the sensor touches the tone wheel.
________________________________________
9-11
GEARED HUB SIDE COVER REPLACEMENT

NOTE: Geared hub side cover replacement procedures are basically the same for front and rear covers. This procedure covers the front side cover.
GEARED HUB INPUT SEAL REPLACEMENT

Removal
1. 2. 3. Remove wheel. Remove access plug and washer from geared hub (Figure 9-15). Remove halfshaft retaining bolt, lockwasher, and halfshaft from geared hub. Remove v-seal from c-v joint Figure 9.
Removal
1. 2. 3. 4. Remove wheel. Remove drainplug from geared hub and drain geared hub (Figure 9-19). Install drainplug in geared hub. Remove eight bolts, washers, and side cover from geared hub.
CAUTION: Shim gaskets must be reused to maintain proper drive gear bearing adjustment. 4. Remove bolt, washer, and vent line/speed sensor lead bracket from drive gear retainer (Figure 9-20).
VENT LINE BRACKET
GEARED HUB SIDE COVER DRIVE GEAR RETAINER SHIM GASKET GEARED HUB
DRAINPLUG
Figure 9-19: Geared Hub Side Cover Replacement

NOTE: Clean all components, examine for wear or damage, and replace if necessary. 1. 2. Using solvent, clean and dry side cover. Inspect side cover for damage. 5. 6. Figure 9-20: Geared Hub Shim Gasket Location Remove remaining bolts, washers, speed sensor bracket, drive gear retainer, and shim gasket(s) from geared hub. Secure drive gear retainer in vise with inserts and remove input seal. Discard input seal (Figure 9-21).
Installation
1. 2. Apply anaerobic sealant to side cover and allow to set until tacky. Apply thread-locking compound to bolts and install side cover to geared hub with eight washers and bolts. Tighten bolts to 15 lb-ft (20 Nm). Fill geared hub to proper oil level (Section 1). Install wheel.
3. 4.
05745159
4-1-00
9-12

DRIVER HANDLE J8092
_________________________________________
NOTE: Be sure that bolt and bolt hole are cleaned of old Loctite. 6. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and halfshaft retaining bolt. Tighten halfshaft retaining bolt to 37 lb-ft (50 Nm) (Figure 9-22). Secure washer and access plug onto geared hub. Tighten access plug to 8-13 lb-ft. (11-18 Nm). Install wheel.
GEARED HUB HALFSHAFT RETAINING BOLT ACCESS PLUG
00-S09-003
7.
INPUT SEAL INSTALLER J44905 INPUT SEAL DRIVE GEAR RETAINER
8.
Figure 9-21: Input Seal Installation
Installation
1. Using driver handle J8092 and input seal installer J-44905, install input seal in drive gear retainer. Place the new primary seal on the installer with the seamed side of the stainless steel perimeter facing toward the drive gear retainer. Drive the seal in until the installer bottoms against the drive gear retainer. The seal will be recessed in the drive gear retainer approximately 0.310". This dimension is critical and must be achieved using the special tool. (Figure 9-21). Secure shim gasket(s) and drive gear retainer to geared hub with washers and bolts (Figure 9-20). Secure vent line bracket and speed sensor bracket to drive gear retainer with washers and bolts. Tighten all four bolts to 38 lb-ft (52 Nm). Coat lip of input seal with gear oil (Figure 9-21). Stretch the v-seal over the seal area of the halfshaft with the thick side against the c-v joint. Lubricate the thin side of the v-seal with an all purpose grease. This portion of the v-seal will contact the stainless steel portion of the primary seal when the halfshaft is installed.
V-SEAL IN PLACE
ROTOR HALFSHAFT
Figure 9-22: Halfshaft and Geared Hub
GEARED HUB REPAIR

Disassembly
1. 2. Remove geared hub. Position geared hub with spindle supporting geared hub (Figure 9-23).
2. 3.
GEARED HUB
4. 5.
SIDE COVER SPINDLE THICK THIN
Figure 9-23: Geared Hub Disassembly 3. Remove eight bolts, washers, and side cover from geared hub.
CAUTION: If backlash between drive and driven gears is more than 0.018 in. (0.46 mm), both gears must be replaced.
00-S09-002
4.
C-V JOINT
Figure 9-21.1 V-Seal Replacement 4-1-00
Mount dial indicator J8001 on geared hub and index indicator to register from one drive gear tooth. Move drive gear back and forth while holding driven gear stationary to read backlash (Figure 9-24).
________________________________________

STEERING ARM COVER
9-13
GEARED HUB
CLAMPNUT SOCKET CLAMPNUT LOCK SCREW KEYED WASHER
CLAMPNUT DRIVE GEAR DIAL INDICATOR J8001
INNER BEARING BEARING SPACER
Figure 9-24: Dial Indicator Positioning 5. 6. 7. Remove four bolts, washers, and steering arm cover from geared hub (Figure 9-25). Remove clamp nut lock screw from clamp nut. Using clampnut socket SBAS-07M, remove clamp nut and keyed washer from spindle.
GEARED HUB DRIVEN GEAR OUTER BEARING SPACER
NOTE: It may be necessary to lightly tap threaded end of spindle to release it from the inner spindle bearing. 8. 9. 10. 11. Lift geared hub off spindle. Remove inner bearing, bearing spacer, and driven gear from geared hub. Remove outer bearing spacer from spindle. Remove four bolts, washers, drive gear retainer, shim gasket, inboard bearing cup, and drive gear from geared hub (Figure 9-26). Remove retaining washer from inside drive gear or geared hub. Remove spindle seal from geared hub. Discard seal. Remove input seal from drive gear retainer. Discard seal (Figure 9-27).
SPINDLE
Figure 9-25: Geared Hub Breakdown
DRIVE GEAR RETAINER SHIM GASKET INBOARD BEARING CUP DRIVE GEAR RETAINING WASHER
12. 13. 14.
GEARED HUB
SPINDLE SEAL
S06-020
Figure 9-26: Drive Gear Removal 05745159 4-1-00
9-14
_________________________________________
Inspection
DRIVE GEAR RETAINER
NOTE: Clean all components, examine for wear or damage, and replace if necessary. Drive and driven gears must be replaced as matched set (Figure 9-28). 1. 2. Inspect splines and gear teeth on drive gear and driven gear for damage. Inspect spindle for damage and rough or corroded sealing surface. Inspect all bearings and bearing races for damage. Inspect steering arm cover for damage. Inspect geared hub and all threaded holes for damage. Repair any damaged holes using thread repair inserts.
INPUT SEAL
3. 4. 5.
Figure 9-27: Input Seal Removal
DRIVE GEAR
DRIVEN GEAR
BEARING
BEARING RACE
SPINDLE STEERING ARM COVER
GEARED HUB
SEALING SURFACE
Figure 9-28: Geared Hub Component Appearance
4-1-00
________________________________________

3.
9-15
Assembly
1. Place the new output seal on the installer J44906, with the seamed side of the stainless steel perimeter facing toward the geared hub and drive the seal in until the installer bottoms out on the geared hub surface. The seal will be recessed in the geared hub approximately 0.185". This dimension is critical and must be achieved using the special tool. (Figure 9-29).
GEARED HUB SPINDLE SEAL INSTALLER J44906 SPINDLE SEAL
Install retaining washer in shallow end of drive gear (Figure 9-31).
DRIVE GEAR RETAINER SHIM GASKET
INBOARD BEARING CUP DRIVE GEAR RETAINING WASHER GEARED HUB
00-S09-004
DRIVER HANDLE J8092
Figure 9-29: 2.
Spindle Seal Installation 4. 5.
Figure 9-31: Retaining Washer Location Install drive gear and inboard bearing cup in geared hub. Apply thread-locking compound on bolts. Secure shim gasket and drive gear retainer to geared hub with four washers and bolts. Tighten bolts to 25-35 lb-ft (40-48 Nm). Mount dial indicator on geared hub and index indicator to register on end of drive gear (Figure 9-32).
DIAL INDICATOR
Using driver handle J8092 and input seal installer J-44905, install input seal in drive gear retainer. Place the new primary seal on the installer with the seamed side of the stainless steel perimeter facing toward the drive gear retainer. Drive the seal in until the installer bottoms against the drive gear retainer. The seal will be recessed in the drive gear retainer approximately 0.310". This dimension is critical and must be achieved using the special tool. (Figure 9-30).
6.
DRIVER HANDLE J8092
GEARED HUB
INSTALLER J44905
INPUT SEAL DRIVE GEAR RETAINER DRIVE GEAR
Figure 9-32: Dial Indicator Positioning

00-S09-003
7. Figure 9-30: Input Seal Installation 05745159
Move drive gear up and down to read end play. End play should be 0.001-0.006 in. (0.03-0.15 mm). If end play is 4-1-00
9-16
_________________________________________
8.
incorrect, add or subtract shim gaskets and recheck end play. Install driven gear and bearing spacer in geared hub (Figure 9-33).
STEERING ARM COVER CLAMPNUT SOCKET
13. Apply a thin coat of grease to boss (protruding side) of clampnut and install clampnut on spindle. NOTE: If an excessive amount of torque (18-26 lb-in. (2-3 Nm)) is required to tighten clampnut lock screw to remove clampnut wobble, remove screw. Ensure threads of clampnut are clean and free of Loctite. Replace screw with a new one, or remove all previously applied Loctite from threads of old screw and apply fresh Loctite 272 to old screw threads prior to reinstallation. Use a hexagonhead socket with a calibrated torque wrench to tighten and check torque of screw. 14. Tighten clampnut lock screw until all clampnut wobble is removed and clamp nut can still be rotated by hand. 15. Using clampnut socket J42545, tighten clamp nut to 40 lb-ft (54 Nm). Rotate spindle five revolutions both clockwise and counterclockwise to seat bearings. 16. Loosen and retighten clampnut to 25 lb-ft (34 Nm). NOTE: Ensure clampnut does not move while clampnut lock screw is being tightened. 17. Using a hexagon-head socket and pre-set calibrated torque wrench, tighten clampnut lock screw to 90 lb-in. (10 Nm). 18. Mark a temporary line across end of spindle and clampnut. NOTE: Using a feeler gauge, ensure a gap exists between clampnut gap surfaces. If no gap exists, remove and discard clampnut lock screw and clampnut. Acquire new screw and nut and repeat steps 12-18. 19. Using preset torque wrench, apply pressure to clamp nut in a counterclockwise direction until torque wrench clicks, indicating 90 lb-ft (122 Nm) of loosening torque was applied to clampnut. NOTE: Clampnut should not move. To verify no movement occurred, check temporary mark across spindle and clampnut. If clampnut moves, remove and discard clampnut lock screw and clampnut. Repeat steps 12-19 with new screw and nut. 20. Paint or scribe a permanent line across end of spindle and clampnut. NOTE: Immediately install steering arm cover after application of sealer. 21. Clean sealing surfaces on geared hub and steering arm cover. Apply anaerobic sealer to steering arm cover and secure steering arm cover to geared hub. NOTE: Make sure bolts and holes are free of old Loctite. 22. Apply thread-locking compound to bolts. Secure steering arm cover to geared hub with four washers and bolts. Tighten bolts to 65 lb-ft (88 Nm).
CLAMPNUT CLAMPNUT LOCK SCREW GAP KEYED WASHER INNER BEARING BEARING SPACER
GEARED HUB DRIVEN GEAR SPINDLE OUTER SPINDLE BEARING OUTER BEARING SPACER
Figure 9-33: Geared Hub Driven Gear Installation 9. Install outer bearing spacer on spindle. 10. Lower geared hub onto spindle and align splines on driven gear with splines on spindle. Ensure outer spindle bearing seats in bearing cup. 11. Install inner bearing and keyed washer on spindle. NOTE: After clampnut lock screw is installed into clampnut, clampnut must be completely installed on spindle within a ten minute limit. 12. Tighten clampnut lock screw three to five turns into clamp nut. CAUTION: Ensure clampnut is installed on spindle with boss (protruding side) facing inward toward bearing and large chamfer side with engraved part number facing away from bearing.
4-1-00
________________________________________
9-17
23. Clean sealing surfaces on geared hub and side cover. Apply anaerobic sealer to side cover and install on geared hub (Figure 9-34).
GEARED HUB
GEARED HUB
SIDE COVER
Figure 9-34: Geared Hub Side Cover Removal NOTE: Make sure bolts and holes are free of old Loctite. 24. Apply thread-locking compound to bolts. Secure side cover to geared hub with eight washers and bolts. Tighten bolts to 8-13 lb-ft (11-18 Nm). 25. Install geared hub.
STEERING ARM COVER
Figure 9-36: Geared Hub Steering Arm Cover Removal 4. Remove clampnut (Figure 9-37). lock screw from clampnut
GEARED HUB SPINDLE SEAL REPLACEMENT

Removal
1. 2. Remove wheel. Remove drainplug from geared hub and drain geared hub oil. Install drainplug in geared hub. Tighten drainplug to 8-13 lb-ft (11-18 Nm) (Figure 9-35).
GEARED HUB OUTER BEARING SPACER SPINDLE
CLAMPNUT LOCK SCREW
BEARING SPACER CLAMPNUT SOCKET J-42545 CLAMPNUT GEARED HUB DRAINPLUG KEYED WASHER INNER BEARING
Figure 9-37: Clamp Nut Removal 5. Using clampnut socket J42545, remove clampnut and keyed washer from spindle.
Figure 9-35: Geared Hub Drainplug Removal 3. Remove four bolts, washers, and steering arm cover from geared hub (Figure 9-36).
05745159
9-18
6. 7.
_________________________________________
Remove spindle, bearing spacer, inner bearing, and outer bearing spacer from geared hub. Remove spindle seal from geared hub. Discard spindle seal (Figure 9-38).
GEARED HUB SPINDLE SEAL
DRIVER HANDLE J8092
screw with a new one or remove all previously applied Loctite from threads of old screw and apply fresh Loctite 272 to old screw threads prior to reinstallation. Use hex socket and torque wrench to tighten and check screw torque. 8. Tighten clampnut lock screw until all clampnut wobble is removed but clampnut can still be rotated by hand. 9. Using clampnut socket J42545, tighten clampnut to 40 lb-ft (54 Nm) (Figure 9-39). Rotate spindle five revolutions both clockwise and counterclockwise to seat bearings. 10. Loosen and retighten clampnut to 25 lb-ft (34 Nm). NOTE: Ensure clampnut does not move while clampnut lock screw is being tightened.
00-S09-004
INSTALLER J44906
Figure 9-38: Spindle Seal Removal

1. 2. Inspect spindle for rough or corroded sealing surface. Replace if damaged (Figure 9-37). Inspect bearings for damage. Replace if damaged.
Installation
1. Place the new output seal on the installer, with the seamed side of the stainless steel perimeter facing toward the geared hub and drive the seal in until the installer bottoms out on the geared hub surface. The seal will be recessed in the geared hub approximately 0.185". This dimension is critical and must be achieved using the special tool. (Figure 9-38). Coat seal with lubricating oil. Install outer bearing spacer and spindle in geared hub (Figure 9-37). Install bearing spacer, inner bearing, and keyed washer on spindle.
11. Tighten clamp nut lock screw to 90 lb-in. (10 Nm). 12. Mark a temporary line across end of spindle and clamp nut. Then, using a feeler gauge, ensure a gap exists between clampnut gap surfaces. If no gap exists, remove and discard clampnut lock screw and clampnut. Acquire new screw and nut and repeat steps 5-12. 13. Apply 90 lb-ft (122 Nm) of loosening torque to clampnut. Clampnut should not move. To verify no movement occurred, check temporary mark across spindle and clampnut. If clampnut moved, remove and discard clampnut lock screw and clampnut. Repeat steps 5-13 with new screw and nut.
CLAMPNUT LOCK SCREW GEARED HUB KEYED WASHER
2. 3. 4.
NOTE: After clampnut lock screw is installed into clampnut, clampnut must be completely installed on spindle within a ten minute limit.
GAP
5.
Tighten clampnut lock screw three to five turns into clampnut.
CAUTION: Ensure clampnut is installed on spindle with boss (protruding side) facing inward toward bearing and large chamfer side with engraved part number facing away from bearing. 6. 7. Apply a thin coat of grease to boss (protruding side) of clampnut and install clampnut on spindle. If an excessive amount of torque (18-26 lb-in. (2-3 Nm)) is required to tighten clampnut lock screw to remove clampnut wobble, remove clampnut lock screw. Ensure threads of clampnut are clean and free of Loctite. Replace
CLAMPNUT SOCKET SBAS-07M
CLAMP NUT
STEERING ARM COVER
Figure 9-39: Clampnut Installation 14. Paint or scribe a permanent line across end of spindle and clampnut. 15. Clean sealing surfaces on geared hub and steering arm cover. Apply Loctite 518 sealant to steering arm cover and install on geared hub.
4-1-00
________________________________________
9-19
16. Apply thread-locking compound to bolt threads and install steering arm cover on geared hub with four washers and bolts. Tighten bolts to 65 lb-ft (88 Nm). 17. Remove fill plug and washer from geared hub (Figure 9-40).
GEARED HUB
GEARED HUB
FILL PLUG
DRAINPLUG
Figure 9-41: Geared Hub Drainplug Location

7. Tighten clampnut lock screw three to five turns into clampnut.
Figure 9-40: Geared Hub Fill Plug Location

18. Fill geared hub to proper oil level (Section 1). 19. Secure washer and fill plug to geared hub. Tighten fill plug to 8-13 lb-ft (11-18 Nm). 20. Install wheel.
CAUTION: Ensure clampnut is installed on spindle with boss (protruding side) facing inward toward bearing and large chamfer side with engraved part number facing away from bearing. 8. Apply a thin coat of grease to boss (protruding side) of clamp nut and install clamp nut on spindle.
GEARED HUB SPINDLE BEARING ADJUSTMENT

Adjustment
1. 2. Remove wheel. Remove drainplug and drain geared hub oil. Install drainplug into geared hub. Tighten drainplug to 8-13 lb-ft (11-18 Nm) (Figure 9-41). Remove four bolts, washers, and steering arm cover from geared hub. Push steering arm cover away from geared hub (Figure 9-43). Remove clampnut lock screw from clampnut. Using clampnut socket, remove clampnut and keyed washer from spindle. After clampnut lock screw is installed into clampnut, clampnut must be completely installed on spindle within a ten minute limit.
NOTE: If an excessive amount of torque (18-26 lb-in. (2-3 Nm)) is required to tighten clampnut lock screw to remove clampnut wobble, remove screw. Ensure threads of clampnut are clean and free of Loctite. Replace screw with a new one or remove all previously applied Loctite from threads of old screw and apply fresh Loctite 272 to old screw threads prior to reinstallation. Use a hex socket and torque wrench to tighten and check screw torque. 9. Tighten clampnut lock screw until all clampnut wobble is removed and clampnut can still be rotated by hand. 10. Using clampnut socket SBAS-07M, tighten clampnut to 40 lb-ft (54 Nm). Rotate spindle five revolutions both clockwise and counterclockwise to seat bearings (Figure 9-42).
3.
4. 5. 6.
05745159
9-20

CLAMPNUT LOCK SCREW GEARED HUB
_________________________________________
GEARED HUB
CLAMPNUT SOCKET SBAS-07M
CLAMPNUT
GAP
KEYED WASHER STEERING ARM COVER
Figure 9-42: Clampnut Installation

11. Loosen and retighten clampnut to 25 lb-ft (34 Nm). NOTE: Ensure clampnut does not move while clampnut lock screw is being tightened. 12. Using a hexagon-head socket and pre-set calibrated torque wrench, tighten clampnut lock screw to 90 lb-in. (10 Nm). 13. Mark a temporary line across end of spindle and clampnut. NOTE: Using a feeler gauge, ensure a gap exists between clampnut gap surfaces. If no gap exists, remove and discard clampnut lock screw and clampnut. Acquire new screw and nut and repeat steps 6-12. 14. Using pre-set torque wrench, apply pressure to clampnut in counterclockwise direction until torque wrench clicks, indicating 90 lb-ft (122 Nm) of loosening torque was applied to clampnut. NOTE: Clampnut should not move. To verify no movement occurred, check temporary mark across spindle and clampnut. If clampnut moved, remove and discard clampnut lock screw and clampnut. Repeat steps 6-13 with new screw and nut. 15. Paint or scribe a permanent line across end of spindle and clampnut. NOTE: Immediately install steering arm cover after application of sealant. 16. Clean sealing surfaces on geared hub and steering arm cover. Apply anaerobic sealant to steering arm cover and install on geared hub (Figure 9-43).
Figure 9-43: Steering Arm Cover Installation

NOTE: Thoroughly clean old Loctite before applying fresh Loctite. 17. Apply thread-locking compound to bolt threads and secure steering arm cover to geared hub with four washers and bolts. Tighten bolts to 65 lb-ft (88 Nm). 18. Remove fill plug and washer from geared hub (Figure 9-40). 19. Fill geared hub to proper oil level (Section 1). 20. Secure washer and fill plug to geared hub. Tighten fill plug to 8-13 lb-ft (11-18 Nm).
________________________________________
9-21
GEARED HUB SPINDLE STUD REPLACEMENT

WARNING: Always wear eye protection when replacing spindle studs. Severe eye injury may result if metal chips contact eyes.
GEARED HUB HALFSHAFT RETAINING BOLT
Removal
1. 2. 3. Remove wheel. Rotate spindle to allow clearance for removal of stud from spindle (Figure 9-44). Drive stud from spindle. Discard stud.
ROTOR
HALFSHAFT SPINDLE
ACCESS PLUG
Figure 9-45: Halfshaft Retaining Bolt

STUD
5. 6.
Loosen two clamps securing inner boot to inner joint housing and shaft (Figure 9-46). Slide inner boot toward outer joint along shaft.
NOTE: Remove excess grease from bearing assembly. 7. 8. Clamp shaft in soft-jawed vise. Remove retaining ring from inner joint housing by forcing clip up chamfer on inside of housing. Remove housing and six ball bearings from bearing assembly. Move outer race up on shaft to allow for better access to inner race (Figure 9-48). Locate snap ring adjacent to inner race. Remove snap ring from groove and slide up on shaft (Figure 9-48). Tap inner race up on shaft to expose retaining clip. Remove retaining clip and inner race from shaft. Remove outer race, snap ring, and inner boot from shaft. (Figure 9-48). Remove two clamps and outer boot from shaft.
Figure 9-44: Geared Hub Spindle Stud Removal
9. 10. 11. 12. 13. 14. 15.
Installation
1. 2. 3. 4. Install stud in spindle (Figure 9-44). Install three flat washers and hex nut on stud. Tighten hex nut until head on stud seats against spindle. Remove and discard hex nut and three flat washers.
HALFSHAFT BOOT REPLACEMENT

Removal
NOTE: Inner and outer boots are replaced together. The inner CV joint is disassembled to gain access to the halfshaft boots. 1. 2. 3. 4. Remove wheel. Remove access plug and washer from geared hub (Figure 9-45). Remove six bolts, lockwashers, and halfshaft from rotor. Remove halfshaft retaining bolt, lockwasher, and halfshaft from geared hub.

NOTE: Clean all components, examine for wear or damage, and replace halfshaft if necessary. 1. 2. Clean all metallic parts with solvent. Inspect halfshaft assembly for damage or wear, and replace if damaged or worn.
05745159
9-22
_________________________________________
Installation
1. 2. 3. 4. 5. 6. Position outer boot and two clamps on shaft near outer joint. Apply packet of grease to outer joint. Position outer boot over outer joint housing and secure clamp with boot banding tool J22610. Secure smaller clamp on boot and shaft with tool J22610. Clamp shaft in vise with protective jaws. Position two clamps on shaft (Figure 9-49).
INNER JOINT HOUSING BEARING OUTER RACE
7. 8.
Install inner boot on shaft. Push boot past groove on shaft. Install the snap ring and retaining clip into grooves on shaft (Figure 9-48). 9. Align chamfer splines of inner bearing assembly with spline of shaft. Use press or rawhide hammer to install inner race until it snaps in place - flush against spacer ring. 10. Position six ball bearings into bearing assembly and retain with a slight amount of grease (Figure 9-46).
INNER BOOT
OUTER JOINT
RETAINING RING
INNER RACE
Figure 9-46: Halfshaft Boot Replacement
RETAINING CLIP SHAFT SNAPRING
INNER BOOT
INNER RACE OUTER RACE

INNER BOOT RETAINING CLIP SNAP RING GROOVE GROOVE BEARING ASSEMBLY SNAP RING
INNER BOOT
OUTER BOOT
OUTER CV JOINT ASSEMBLY
________________________________________

AXLE VENT LINE REPLACEMENT
9-23
11. Position joint inner housing over bearing assembly. NOTE: Ensure all ball bearings are in the tracks of the inner joint. 12. Secure retainer ring in groove of inner joint housing. 13. Fill inner joint with grease from grease packet. 14. Move inner boot on shaft until boot seats in groove of shaft and inner joint housing. 15. Secure inner boot on shaft and housing with clamps. Tighten clamps with crimping tool J22610. 16. Slide halfshaft splines into geared hub. 17. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and halfshaft retaining bolt. Tighten halfshaft retaining bolt to 37 lb-ft (50 Nm) (Figure 9-45). 18. Install washer and access plug into geared hub. Tighten access plug to 8-13 lb-ft (11-18 Nm). NOTE: Ensure all six bolt holes in the rotor align with holes in output flange. Make sure mounting holes and bolts are cleared of old Loctite. 19. Apply Loctite 272 to six bolts. Secure halfshaft to rotor with twelve lockwashers and bolts. Tighten bolts to 48 lbft (65 Nm). 20. Install wheel.
NOTE: Axle vent line replacement procedures are basically the same. This procedure covers the rear axle vent line.
Removal
1. 2. 3. Disconnect vent line from axle tting and tee tting and remove vent line (Figure 9-50). Remove two line clips and vent line from brake line. Disconnect vent line from two tee fittings and remove vent line.
LINE CLIPS VENT LINE TEE FITTING
BRAKE LINE
VENT LINE AXLE FITTING
Figure 9-50: Axle Vent Line Location
Installation
1. 2. 3. Install vent line and connect to two tee ttings (Figure 9-50). Secure vent line to brake line with two line clips. Connect vent line to axle fitting and tee fitting.
05745159
9-24
_________________________________________
GEARED HUB VENT LINE REPLACEMENT

NOTE: All geared hub vent line replacement procedures are basically the same. This procedure covers the right rear geared hub vent line.
4.
Secure vent line to control arm with clamp and bolt (Figure 9-52).
NOTE: Position clamp at a 45 degree angle toward the wheel before securing with bolt. 5. Secure vent line to bracket with clamp and bolt.
TEE FITTING VENT LINE FRAME
Removal
NOTE: Speed sensor lead is retained by the vent line clamps and should be removed and reinstalled with care when replacing the vent line. 1. 2. 3. 4. 5. 6. Disconnect vent line from geared hub tting (Figure 9-52). Remove bolt, clamp, and vent line from bracket. Remove bolt, clamp, and vent line from control arm. Remove bolt, clamp, and vent line from bracket. Remove bolt, clamp, and vent line from frame (Figure 9-51). Disconnect vent line from tee fitting.
Installation
1. 2. 3. Secure vent line to frame with clamp and bolt (Figure 9-51). Secure vent line to bracket with clamp and bolt (Figure 9-52). Connect vent line to tee fitting and geared hub fitting.
Figure 9-51: Vent Line
45 CLAMP CONTROL ARM VENT LINE
BRACKET
VENT LINE
BRACKET
CONTROL ARM
GEARED HUB FITTING
CLAMP
VENT LINE
Figure 9-52: Geared Hub Vent Line Positioning
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9-25
AXLE ASSEMBLY COVER SERVICE

Removal
1. 2. Remove drainplug from axle assembly and drain axle assembly (Figure 9-53). Remove twelve bolts and cover from axle assembly.
AXLE COVER
AXLE OUTPUT SHAFT SEAL REPLACEMENT

Removal
1. Remove brake caliper and yoke from caliper adapter (disconnect park brake cable from rear calipers) and support caliper to the side being careful not to kink brake line. Disconnect halfshaft at the axle flange and swing off to the side. Remove the brake rotor. Remove the axle output flange retaining nut and the flange. Support the axle assembly, disconnect and move the axle assembly support bracket over to gain access to the output seal. Remove output shaft seal from axle (Figure 9-54).
OUTPUT SHAFT SEAL
2. 3. 4. 5.
6.
AXLE ASSEMBLY
AXLE SHAFT AND SEAL INSTALLER J38869
AXLE ASSEMBLY
DRAINPLUG
Figure 9-53: Axle Assembly Cover Service

NOTE: Clean all components, examine for wear or damage, and replace if necessary. 1. 2. Clean axle assembly cover, bolts, and axle assembly with solvent (Figure 9-53). Inspect axle assembly cover for cracks, wear, or breaks.
Figure 9-54: Axle Output Shaft Seal Replacement
Installation
1. 2. 3. 4. Using seal installer J38869, install output shaft seal in axle assembly (Figure 9-54). Install axle assembly support bracket. Install axle output shaft flange and nut using Loctite 242 (or equivalent) and torque to 166-196 lb ft (224-265 N.m). Install brake rotor and halfshaft. Use bolts with preapplied Loctite or original bolts with Loctite 272 (or equivalent), cam-lock washers and torque 57 lb ft (77 N.m). Install brake caliper and yoke using Loctite 272 (or equivalent) (connect park brake cable on rear calipers) and torque to 40 lb ft (54 N.m).
Installation
1. Apply RTV sealant to cover sealing surface and secure cover to axle assembly with twelve bolts. Tighten bolts to 16 lb-ft (22 Nm). Thread drainplug into axle assembly and tighten to 13-18 lb-ft (18-25 Nm) (Figure 9-53). Fill axle assembly to proper oil level (Section 1).
2. 3.
5.
05745159
9-26
_________________________________________
PINION SEAL REPLACEMENT

NOTE: Removal and installation procedures for pinion seals are basically the same for front and rear axle assemblies. This procedure covers the rear axle assembly pinion seal.
AXLE ASSEMBLY REPLACEMENT

Removal
NOTE: Removal and installation procedures are basically the same for front and rear axle assemblies. This procedure covers both front and rear axle assemblies except where noted. 1. 2. Remove service brake rotors (Section 7). Remove drainplug from axle assembly. Allow oil to drain and install drainplug (Figure 9-56).
Removal
1. 2. 3. 4. 5. 6. Remove six bolts, cam-lock washers, and halfshaft from each output ange rotor. Remove four bolts, two straps, and rear propeller shaft from pinion yoke (Figure 9-55). Using a lb-in torque wrench, measure torque required to rotate pinion and record measurement. Count and record number of exposed threads on end of pinion and mark locknut and pinion for assembly. Remove locknut and pinion yoke from pinion. Remove pinion seal from pinion.
REAR PROPELLER SHAFT PINION SEAL PINION
AXLE ASSEMBLY SUPPORT BRACKET
MOUNTING BRACKET
VENT LINE RUBBER WASHER STRAP PINION YOKE OUTPUT FLANGE AXLE ASSEMBLY BRAKE CALIPER ADAPTER YOKE SEAL INSTALLER J29162 DRAINPLUG
Figure 9-56: Rear Axle Assembly Mounting

3. 4. Remove four bolts, two straps, and rear propeller shaft from pinion yoke (Figure 9-57). Remove rear propeller shaft from transfer case.
Figure 9-55: Pinion Seal Replacement
Installation
1. 2. 3. 4. Using yoke seal installer J29162, install pinion seal on pinion (Figure 9-55). Secure pinion yoke to pinion with locknut. Tighten locknut to original position. Tighten locknut in small increments, until torque required to rotate pinion exceeds original measurement by 2 lb-in (0.2 Nm). Secure rear propeller shaft to pinion yoke with four bolts and two straps. Tighten bolts to 27 lb-ft (37 Nm). Apply Loctite 272 to halfshaft mounting bolts. Secure halfshaft to each output flange and rotor with twelve cam-lock washers and six bolts. Tighten to 57 lb-ft (77 Nm).
NOTE: No washers are required when securing front axle assembly to mounting bracket. 5. 6. Remove two bolts and washers securing axle assembly to mounting bracket (Figure 9-56). Remove two locknuts, four O-ring seals and two output flanges from axle assembly. Discard locknuts and O-ring seals.
5. 6. 7.
________________________________________

AXLE ASSEMBLY
9-27
WARNING: Axle assembly must be supported during removal and installation. Failure to do this may cause personal injury or damage to equipment.
7. 8. 9. 10. 11. 12. 13. 14. Support axle assembly. Remove four bolts and washers securing axle assembly to side mounting brackets. Lower axle assembly slightly and disconnect vent line from axle assembly. Remove axle assembly. Remove four bolts and two brake caliper adapters from axle assembly. Using a lb-in torque wrench, measure torque required to rotate pinion and record measurement. Count and record number of exposed threads on end of pinion and mark locknut and pinion for assembly. Remove locknut and rear pinion yoke from axle assembly (Figure 9-58).
REAR PINION YOKE LOCKNUT
Figure 9-58: Pinion Yoke Removal
TRANSFER CASE
Installation
1. 2. Secure rear pinion yoke to axle assembly with locknut (Figure 9-58). Tighten locknut in small increments, until torque required to rotate pinion yoke exceeds original measurement by 2 lb-in (0.2 Nm). Apply thread-locking compound to axle assembly tapped holes. Secure two brake caliper adapters to axle assembly with four bolts. Tighten bolts to 110-140 lb-ft (149-190 Nm) (Figure 9-59).
3.
PINION YOKE
REAR PROPELLER SHAFT
STRAP
Figure 9-57: Rear Propeller Shaft Removal
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_________________________________________
AXLE ASSEMBLY REPAIR

SIDE MOUNTING BRACKET
Disassembly
MOUNTING BRACKET
1. 2.
Remove axle assembly. Loosen locknut on output shaft assembly (Figure 9-60).
AXLE ASSEMBLY
SEAL WASHER VENT LINE LOCKNUT
LOCKNUT TAPPED HOLES
OUTPUT FLANGE AXLE ASSEMBLY BRAKE CALIPER ADAPTER
OUTPUT SHAFT ASSEMBLY
Figure 9-60: Output Shaft Assembly Removal 3. 4. Using a slide hammer, remove output shaft assembly from axle assembly. Remove locknut, seal washer, output flange and output shaft seal from output shaft. Discard seal washer, output shaft seal, and locknut (Figure 9-61).
OUTPUT SHAFT
Figure 9-59: Rear Axle Assembly Installation 4. 5. Raise axle assembly into place and connect vent line. Apply thread-locking compound to axle assembly tapped holes. Install axle assembly on side mounting brackets with four washers and bolts. Secure two output flanges and two seals to axle assembly with two locknuts. Tighten locknuts to 165-195 lb-ft (224264 Nm).
OUTPUT FLANGE SEAL WASHER
6.
NOTE: No washers required when securing front axle assembly to mounting bracket. Apply thread-locking compound to bolts. Install two washers, bolts, and axle assembly to mounting bracket. 8. Tighten six bolts securing axle assembly to brackets to 125-150 lb-ft (169-203 Nm). 9. Install rear propeller shaft in transfer case (Figure 9-57). 10. Secure rear propeller shaft to pinion yoke with four bolts and two straps. Tighten bolts to 60 lb-ft (81 Nm) (Figure 9-57). 11. Install service brake rotors (Section 7). 12. Fill axle assembly to proper oil level (Section 1). 13. Install vent line to axle assembly. 7.
OUTPUT SHAFT SEAL LOCKNUT
Figure 9-61: Output Shaft Assembly Breakdown 5. 6. Repeat steps 2 through 4 for opposite side. Secure two axle holding fixture adapters to housing with four bolts. Place housing in holding stand (Figure 9-62).
3-1-02
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9-29
DIFFERENTIAL COVER
10. Spread housing 0.010 in. (0.25 mm) and remove dial indicator. 11. Remove differential assembly, two bearing cups, and shims from housing (Figure 9-64). Tag bearing shims and bearing cups for assembly.
DIFFERENTIAL ASSEMBLY BEARING CUP SHIM
AXLE HOLDING FIXTURE J3409-01
BEARING SHIM CUP
AXLE HOUSING SPREADER J3409-01 AXLE HOUSING
Figure 9-62: Axle Mounted In Holding Fixture

7. 8. Position housing so cover faces up. Remove twelve bolts and cover from housing (Figure 9-62). Mark bearing caps and housing for assembly and remove bearing caps (Figure 9-63).
HOUSING
Figure 9-64: Differential Assembly

BEARING CAP AXLE HOUSING SPREADER J24385-01
12. Relieve pressure on axle housing spreader and remove from housing. CAUTION: To avoid damage, do not chisel or wedge ring gear from axle assembly. 13. Remove eight bolts and ring gear from differential assembly (Figure 9-65).
DIFFERENTIAL ASSEMBLY RING GEAR
DIAL INDICATOR J8001
HOUSING
Figure 9-63:
9.
Housing Spreader Mounting
Install axle housing spreader J3409-01 into holes in axle holding fixture adapters and install dial indicator J8001 to read from each end of housing as shown. Then set dial indicator at 0.020 in. (0.5 mm).
Figure 9-65: Ring Gear Removal

14. Rotate housing 90 degrees. Secure cover to housing with two bolts (Figure 9-66).
CAUTION: Over-tightening of axle housing spreader will damage axle housing. 05745159
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_________________________________________
HOUSING
FRONT PINION BEARING
PINION YOKE
PINION NUT
COVER
PINION SEAL
PINION GEAR
COLLAPSIBLE SPACER
Figure 9-66: Axle Housing

15. Remove pinion nut and pinion yoke from pinion gear. 16. Drive pinion gear out of front pinion bearing. 17. Remove cover, pinion gear, and collapsible spacer from housing. Discard collapsible spacer. 18. Remove pinion seal and front pinion bearing from housing. Discard pinion seal. 19. Rotate front of housing upward 90 degrees. Using driver handle J8092 and bearing cup remover J21786, remove pinion rear bearing cup and pinion depth shim from housing (Figure 9-67).
DRIVER HANDLE J8092 BEARING CUP REMOVER J21786 PINION FRONT BEARING CUP
DRIVER HANDLE J8092 BEARING CUP REMOVER J21787
HOUSING
HOUSING
Figure 9-68: Pinion Front Bearing Cup Removal

DIFFERENTIAL SIDE BEARING
PINION DEPTH SHIM
DIFFERENTIAL ASSEMBLY PINION REAR BEARING CUP DIFFERENTIAL SIDE BEARING
Figure 9-67: Pinion Rear Bearing Cup Removal

20. Rotate housing 180 degrees. Using driver handle J8092 and pinion front bearing cup remover J21787, remove front pinion bearing cup from housing (Figure 9-68).
Figure 9-69: Differential Side Bearing Removal
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9-31
PINION GEAR
REAR PINION BEARING
Figure 9-73: Ring Gear
Figure 9-70: Pinion Bearing Removal

21. Remove two differential side bearings from differential assembly (Figure 9-69). 22. Remove rear pinion bearing from pinion gear (Figure 9-70). 23. Remove bearing from output shaft (Figure 9-71). 3.
BEARING
Figure 9-74: Pinion Gear

Inspect splines and sealing surfaces on output flanges, pinion yoke, and output shaft for damage (Figure 9-75) through (Figure 9-77).
OUTPUT SHAFT
Figure 9-71: Output Shaft Bearing Removal
Figure 9-75: Output Flange

NOTE: Clean all components. Examine for wear or damage and replace if necessary. 1. Inspect housing and all threaded holes for damage. Repair any damaged threads with thread repair inserts. Replace axle assembly if housing is damaged (Figure 9-72).
Figure 9-76: Pinion Yoke
Figure 9-77: Output Shaft

4. Inspect all bearings and bearing cups for damage (Figure 9-78).
BEARING CUP
Figure 9-72: Housing

BEARING
NOTE: Ring and pinion gears must be replaced as matched set. 2. Inspect splines and gear teeth on pinion gear and ring gear for damage. Replace both pinion gear and ring gear if either is damaged (Figure 9-73: and Figure 9-74:). 5.
Figure 9-78: Bearing and Bearing Cup

Inspect differential (Figure 9-79). assembly case for damage
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_________________________________________
DIFFERENTIAL ASSEMBLY
Figure 9-79: Differential Assembly
NOTE: If the old pinion is marked -3 and the new pinion is marked +2, the procedure would be as follows: Refer to Old Pinion Marking column at left side of table and locate -3 in this column. Then read to right, across table, until under +2 in New Pinion Marking column. The box where two columns intersect is amount of shim thickness change required. In this case, the number in the intersecting box is -0.005 in. (0.13 mm) which represents the amount to be subtracted from the old shim thickness. If the box number had been a (+) figure, this amount would be added to the old shim thickness. The actual pinion depth measurement must be performed and final shim thickness adjusted as necessary. Pinion shims are available from 0.084-0.111 in. (2.13-2.82 mm) in increments of 0.0005 in. (0.0127 mm). 3. Refer to Old and New Pinion Marking columns on pinion variance table. Note on table where old and new pinion depth variances intersect. This will determine amount to be added or subtracted from original pinion depth shim for desired pinion depth starter shim. Rotate housing so front pinion bearing cup bore faces up (Figure 9-82).
Axle Assembly
NOTE: PINION DEPTH SETTING: Pinion gear depth is the distance from the end face of the pinion to the center line of the output shafts. The dimension is controlled by shims between pinion gear rear bearing cup and differential housing. The pinion gear is etched with two identifying numbers. The first number identifies ring gear and pinion gear as a matched set, and the second number represents pinion depth variance. The second number is preceded by a plus (+) or minus (-) which represents the amount the gear set varies from the standard setting of 2.547 in. (6.46 cm). If using original gear set, use original pinion depth shim as a starter shim and proceed to step 4. 1. Measure thickness of original pinion depth shim and record for reference (Figure 9-80).
4.
DRIVER HANDLE J8092
BEARING CUP INSTALLER J8611-01
PINION FRONT BEARING CUP
Figure 9-80: Pinion Depth Shim

2. Check pinion depth variance number marked on old and new pinion gears and record (Figure 9-81). Refer to Table 4.
PINION GEAR
HOUSING
Figure 9-82: Pinion Front Bearing Cup Installation
PINION DEPTH VARIANCE NUMBER
Figure 9-81: Pinion Depth Variance Number Location
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9-33
Table 4 Pinion Variance Table - Inches (millimeters)

OLD PINION MARKING +4 +3 +2 +1 0 -1 -2 -3 -4 NEW PINION MARKING -4
+0.008 (0.20) +0.007 (+0.18) +0.006 (+0.15) +0.005 (+0.13) +0.004 (+0.10) +0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0
-3
+0.007 (+0.18) +0.006 (+0.15) +0.005 (+0.13) +0.004 (+0.10) +0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03)
-2
+0.006 (+0.15) +0.005 (+0.13) +0.004 (+0.10) +0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05)
-1
+0.005 (+0.13) +0.004 (+0.10) +0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08)
0
+0.004 (+0.10) +0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08) -0.004 (-0.10)
+1
+0.003 (+0.08) +0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08) -0.004 (-0.10) -0.005 (-0.13)
+2
+0.002 (+0.05) +0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08) -0.004 (-0.10) -0.005 (-0.13) -0.006 (-0.15)
+3
+0.001 (+0.03) 0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08) -0.004 (-0.10) -0.005 (-0.13) -0.006 (-0.15) -0.007 (-0.18)
+4
0 0 -0.001 (-0.03) -0.002 (-0.05) -0.003 (-0.08) -0.004 (-0.10) -0.005 (-0.13) -0.006 (-0.15) -0.007 (-0.18) -0.008 (-0.20)
5.
6.
Lubricate outside diameter of front pinion bearing cup with lubricating oil. Using driver handle J8092 and bearing cup installer J8611-01, install cup in housing. Install rear pinion bearing on pinion gear (Figure 9-83).
REAR PINION BEARING PINION GEAR
PILOT WASHER REAR PINION GAUGE BEARING BLOCK
REAR PINION BEARING CUP GAUGE BLOCK FRONT PINION BEARING
PILOT WASHER
Figure 9-83: Pinion Rear Bearing and Pinion Gear Installation

7. Using pinion setting gauge set, install gauge block, rear pinion bearing cup, rear pinion bearing, and pilot washer on stud and secure with gauge block from set J39524 (Figure 9-84). 8.
STUD
Figure 9-84: Pinion Depth Setting Gauge Installation

Position stud assembly in housing and secure with front pinion bearing, pilot washer, and nut. Tighten nut to 10 lbin (1.1 Nm). Rotate the assembly several revolutions to seat the bearing and recheck the torque. Rotate front of housing downward 90 degrees. Assemble arbor and two discs and install in housing (Figure 9-85).
9.
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9-34
_________________________________________
10. Install two bearing caps and four bolts in housing and finger tighten bolts. 11. Install the dial indicator on the arbor post. Push the dial indicator downward until the needle rotates approximately one full turn clockwise. Tighten the dial indicator in this position and recheck.
DIAL INDICATOR J8001 BEARING CAP
ARBOR POST
PINION SETTING KIT J39524
DISC
ARBOR
13. After the zero setting is obtained, rotate the gauge shaft until the dial indicator plunger does not touch the gauge block. 14. Record the dial indicator reading. Example: If the pointer moved counterclockwise and stops between 0 and 11, add 100 inches to measurement for shim thickness. If the pointer moves counterclockwise and stops between 84 and 99, correct shim thickness is indicated. 15. This reading indicates the shim thickness required for a pinion etched with a zero (0) on the pinion head. If the pinion being installed has a plus (+) or minus (-) etching, then an adjustment of the shim thickness is required. Example: If a pinion is etched +3, then 0.003 inches less shim thickness is required. Subtract 0.003 inches from the indicator reading. If a pinion is etched -3, then 0.003 inches more shim thickness is required. Add 0.003 inches to the indicator reading. 16. Remove dial indicator from arbor (Figure 9-85). 17. Remove four bolts, two bearing caps, discs, and arbor from housing. 18. Remove nut, pilot washer, front pinion bearing, and stud assembly from housing (Figure 9-87).
GAUGE BLOCK
REAR PINION PILOT BEARING WASHER
RING PINION BEARING CUP GAUGE BLOCK PILOT WASHER
Figure 9-85: Positioning J39524 Arbor and Discs In Housing

12. Rotate the gauge shaft slowly back and forth until the dial indicator reads the greatest deflection. At the point of greatest deflection, set the dial indicator to zero. Repeat the rocking action of the gauge shaft to verify the gauge setting (Figure 9-86).
DIAL INDICATOR STUD FRONT PINION BEARING
Figure 9-87: Pinion Front Bearing and Depth Tool Removal

19. Remove gauge block, pilot washer, rear pinion bearing, rear pinion bearing cup, and gauge block from stud. 20. Note pinion depth variance marked on pinion gear. If number is preceded by a plus (+) sign, add that amount in thousands to standard setting of 2.547 in. (6.46 cm). If number is preceded by minus (-) sign, subtract that amount in thousands from standard setting of 2.547 in. (6.46 cm). The result of this addition or subtraction is desired pinion depth. Record for reference (Figure 9-88).
INDICATOR PLUNGER
GAUGE BLOCK
Figure 9-86: Gauge Setting
________________________________________
9-35
PINION GEAR
PINION DEPTH VARIANCE NUMBER
23. Rotate housing 180 degrees. Lubricate outside diameter of pinion rear bearing cup with gear oil (Figure 9-90). NOTE: If pinion shim is beveled, be sure beveled side faces bottom of bearing cup bore.
DRIVER HANDLE J8092
Figure 9-88: Pinion Depth Variance Number Location

21. Subtract desired pinion depth (step 14) from total measured pinion depth (step 15). Result of this subtraction is correct pinion depth shim thickness. 22. Lubricate pinion front bearing and pinion seal with gear oil. Using yoke seal installer, install pinion front bearing and pinion seal in housing (Figure 9-89).
REAR PINION BEARING CUP INSTALLER BEARING CUP TOOL J8608
PINION SHIM SEAL INSTALLER J29162 HOUSING
PINION SEAL
PINION FRONT BEARING
HOUSING
Figure 9-90: Pinion Rear Bearing Installation

24. Using driver handle J8092 and bearing cup installer J8608, install correct thickness pinion shim and pinion rear bearing cup in housing. 25. Rotate housing 90 degrees. Lubricate rear pinion bearing with gear oil (Figure 9-91).
Figure 9-89: Pinion Seal Installation

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HOUSING
PINION NUT PINION YOKE
PINION REAR BEARING
COLLAPSIBLE SPACER
PINION GEAR
Figure 9-91: Rear Pinion Bearing Location

CAUTION: Collapsible spacer controls pinion bearing preload. Do not reuse old spacer, or pinion bearing damage may result. 26. Install collapsible spacer on pinion gear and install pinion gear in housing. 27. Install pinion yoke on pinion gear with pinion nut. CAUTION: Do not exceed specified preload torque on pinion bearings. Do not loosen locknut to relieve the preload torque or pinion bearing damage may result. If specified torque is exceeded, remove pinion gear and replace collapsible spacer and locknut and adjust preload again. 28. Tighten pinion nut only enough to remove end play and seat pinion bearings in housing. Rotate pinion yoke while tightening to seat bearings evenly. 29. Measure torque required to rotate pinion gear. Correct pinion bearing preload torque is 17-25 lb-in (2-3 Nm) with new bearings and 10-15 lb-in (1-2 Nm) with used bearings. 30. Continue to tighten pinion nut in small increments until pinion bearing preload torque meets specifications. 31. Install two side bearings on differential assembly (Figure 9-92).
DIFFERENTIAL ASSEMBLY SIDE BEARING SIDE BEARING
NOTE: Side bearing shims are available in thickness from 0.077-0.117 in. (1.96-2.97 mm) in increments of 0.001 in. (0.025 mm). 32. Rotate housing downward 90 degrees. Install side bearing cups and side bearing shims on side bearings. Use 0.080 in. (2 mm) shims as a starting point (Figure 9-93).
BEARING CAP DIFFERENTIAL ASSEMBLY SIDE BEARING SHIM SIDE BEARING BEARING CUP SHIM
BEARING CUP
HOUSING
Figure 9-93: Side Bearing Cup and Shim Installation Figure 9-92: Side Bearing Installation
________________________________________
9-37
33. Install differential assembly, bearing cups, and shims in housing. 34. Install two bearing caps and four bolts in housing. Snug bolts. 35. Mount dial indicator on housing and position indicator to read off ring gear mounting surface of differential assembly (Figure 9-94).
DIAL INDICATOR RING GEAR FLANGE OF CASE
38. Tighten four bolts to 55-70 lb-ft (75-95 Nm). 39. Rotate differential assembly and check runout. Runout should not exceed 0.002 in. (0.05 mm). 40. Remove dial indicator from housing. NOTE: Tag shims and bearing cups for assembly. 41. Remove four bolts, two bearing caps, bearing cups, shims, and differential assembly from housing (Figure 9-96). 42. Install four guide pins in ring gear (Figure 9-95).
BEARING CAP DIFFERENTIAL ASSEMBLY
BEARING CUP
BEARING CUP
Figure 9-94: Dial Indicator Positioning For Case Runout Check

36. Pry between differential assembly and bearing cap on one side of indicator. Pry on opposite side to read end play. 37. Amount read on indicator is shim thickness that should be added to side bearing shims to arrive at zero end play. Add necessary shims and repeat procedure to ensure accuracy.
BEARING SHIM
BEARING SHIM
HOUSING DIFFERENTIAL CASE
Figure 9-96: Differential Assembly Mounting

43. 44. 45. 46. Support ring gear with wood blocks in press. Press differential assembly on ring gear. Remove four guide pins from ring gear. Install ring gear on differential assembly with eight bolts. Tighten bolts to 95-115 lb-ft (129-156 Nm). 47. Install side bearing shims, previously selected to remove differential assembly side play, slide bearing cups, and differential assembly in housing (Figure 9-96). 48. Install two bearing caps in housing with four bolts. Tighten bolts to 55-70 lb-ft (75-95 Nm). 49. Attach dial indicator to housing and position indicator to read off drive side of ring gear tooth at a right angle (Figure 9-97).
GUIDE PIN RING GEAR
Figure 9-95: Ring Gear Guide Pin Installation

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RING GEAR TOOTH DIAL INDICATOR J8001 RING GEAR
HOUSING
PINION YOKE
Figure 9-97: Checking Ring Gear Backlash

NOTE: Backlash must be checked at four equally spaced points on ring gear and must not vary more than 0.002 in. (0.05 mm) between four points checked. 50. Move ring gear back and forth while holding pinion yoke stationary. Note backlash registered on indicator. 51. Ring gear backlash should be 0.005-0.009 in. (0.13-0.23 mm) with 0.008 in. (0.20 mm) desired. If backlash must be adjusted perform steps 52 through 55, if not go to step 56. NOTE: Tag shims and bearing cups for assembly. 52. Remove four bolts, two bearing caps, bearing cups, shims, and differential assembly from housing (Figure 9-96). NOTE: The following example will explain the procedure for adjusting backlash: If side play was removed using 0.090 in. (2.29 mm) shims on each side totaling 0.180 in. (4.57 mm) and backlash, when checked, is found to be 0.011 in. (0.28 mm), add 0.004 in. (0.10 mm) to shim on ring gear side and subtract 0.004 in. (0.10 mm) from shim on opposite side to correct backlash. This will result in 0.094 in. (2.39 mm) shim on ring gear side and 0.086 in. (2.18 mm) shim on other side. Backlash will be approximately 0.007-0.008 in. (0.18 to 0.20 mm). Total Shim Thickness remains 0.180 in. (4.57 mm). 53. To increase backlash, install thinner shim on ring gear side and thicker shim on opposite side. To decrease backlash, install thicker shim on ring gear side and thinner shim on opposite side. Do not change total shim thickness. 54. Install shims, bearing cups, differential assembly, and bearing caps in housing and secure with four bolts. Tighten bolts to 55-70 lb-ft (75-95 Nm). 55. Mount dial indicator and recheck backlash. If necessary, repeat steps 52 through 54. 56. Remove four bolts, bearing caps, bearing cup, shims, and differential assembly from housing. Tag shims and bearing cup for assembly. 57. Install axle housing spreader into holes in axle holding fixture adapters and install dial indicator to read from each end of housing. Indicator must have preload setting of 0.020 in. (0.50 mm) (Figure 9-98).
AXLE HOUSING SPREADER J24385-01
AXLE HOLDING FIXTURE ADAPTER
Figure 9-98: Axle Housing Spreader Mounting

CAUTION: Over-spreading of axle housing will damage housing. 58. Spread housing 0.010 in. (0.25 mm) and remove dial indicator. NOTE: Differential bearings must be preloaded to compensate for heat and loads during operation.
________________________________________
9-39
59. Preload differential side bearings by increasing shim thickness at each side of differential assembly by 0.004 in. (0.10 mm) for a total bearing preload of 0.008 in. (0.20 mm) (Figure 9-96). 60. Lubricate side bearings with gear oil and install differential assembly, bearing cups, shims, and bearing caps in housing and secure with four bolts (Figure 9-96). NOTE: Preloaded differential bearings may change backlash setting. Check and correct backlash if necessary. 61. Remove housing spreader and tighten bolts to 55-70 lb-ft (75-95 Nm). 62. Apply silicone sealant to cover sealing surface and secure cover to housing with twelve bolts. Tighten bolts to 16 lbft (22 Nm) (Figure 9-99).
COVER
66. Using axle shaft and seal installer J33142, install output shaft assemblies into axle assembly (Figure 9-101).
AXLE ASSEMBLY OUTPUT SHAFT ASSEMBLY
AXLE SHAFT AND SEAL INSTALLER J33142
Figure 9-101: Axle Shaft And Seal Installer Usage

67. Using axle shaft and seal installer J33142, install output shaft seals in axle assembly (Figure 9-102).
AXLE ASSEMBLY
OUTPUT SHAFT SEAL
AXLE SHAFT AND SEAL INSTALLER J33142 HOUSING
Figure 9-102: Output Shaft Seal Installation

68. Lubricate sealing surface on output flanges with lubricating oil (Figure 9-103).
OUTPUT SHAFT
Figure 9-99: Housing Cover Installation

63. Remove housing from holding fixture. 64. Remove four bolts and two axle holding fixture adapters from housing. 65. Using press, install output shaft bearings on output shafts (Figure 9-100).
OUTPUT SHAFT
RUBBER WASHER
OUTPUT FLANGE
OUTPUT SHAFT BEARING
Figure 9-103: Output Shaft Seal Installation

69. Install two output flanges, two seals, and two locknuts on output shafts. Finger tighten locknuts. 70. Install axle assembly.
Figure 9-100: Bearing Installation

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FRONT PROPELLER SHAFT AND U-JOINT SERVICE

Front Shaft Removal
1. Remove U-joint clamp bolts and straps. Then disconnect shaft yoke (Figure 9-104).
4.
Remove bolts attaching center bearing to engine mount (Figure 9-106).
FRONT AXLE YOKE ENGINE MOUNT
STRAP
CENTER BEARING
Figure 9-106: Center Bearing Attachment

5.
Move front shaft forward, then rearward over top of transfer case and remove from vehicle.
Figure 9-104: Front Propeller Shaft Attachment at Axle

2. Remove U-bolt nuts and disconnect front shaft from transfer case output yoke (Figure 9-105).
FRONT PROPELLER SHAFT DISASSEMBLY AND OVERHAUL

1. 2. 3. 4. 5. 6. Mark slip yokes for assembly alignment. Mount shaft in vise and remove dust caps (Figure 9-107). Pull slip yokes off propshaft and separate shaft halves. Install standard bearing puller between center bearing and shield. Mount assembly in shop press and press center bearing off shaft. Remove shield from front propeller shaft.
REAR SLIP YOKE AND U-JOINT DUST CAP
FRONT PROP SHAFT TRANSFER CASE SHIFT ROD U-JOINT
TRANSFER CASE OUTPUT YOKE FRONT PROPELLER SHAFT CENTER BEARING DUST CAP FRONT SLIP YOKE AND U-JOINT
U-BOLT
Figure 9-105: Front Propeller Shaft Attachment at Transfer Case

3. Disconnect transfer case shift rod at range lever.
Figure 9-107: Front Propeller Shaft Assembly
________________________________________

REAR PROPELLER SHAFT SERVICE
Removal
1. 2.
9-41
7. 8. 9. 10. 11.
Clean part with solvent. Inspect shaft, slip yokes and U-joints for wear or damage. Replace worn U-joints. Refer to procedure in this section. Install shield on shaft. Start new center bearing on shaft.
STANDARD BEARING PULLER RETAINER
Remove U-bolts, attaching rear shaft to rear axle yoke (Figure 9-109). Slide shaft slip yoke out of transfer case extension housing and remove shaft from vehicle.
TRANSFER CASE EXTENSION HOUSING
CENTER BEARING
U-BOLT FRONT YOKE AND U-JOINT REAR PROPELLER SHAFT REAR U-JOINT REAR AXLE
YOKE
WASHER NUT
SHIELD
SHOULDER
Figure 9-109: Rear Propeller Shaft Attachment

3. Inspect condition of U-joint cross and bearings at each end of shaft (Figure 9-110). Replace either U-joint if worn, loose, seized. Refer to U-joint replacement in this section.
SNAP RING YOKE REAR SHAFT
Figure 9-108: Center Bearing Removal/Installation

12. Install retainer on center bearing. 13. Press center bearing on front propeller shaft until seated against shoulder. Ensure flange on center bearing faces up. 14. Install dust caps on yokes. 15. Coat shaft splines with chassis grease. NOTE: Be sure grease fittings on dust caps are aligned with wide splines in slip yokes. 16. Align and assemble shaft, slip yokes, and dust caps. 17. Lubricate U-joints and slip yokes with chassis grease.
BEARING
CROSS SNAP RING
BEARING
Front Propshaft Installation

1. 2. 3. 4. 5. 6. Position front shaft on engine mount, axle yoke and transfer case yoke. Connect transfer case shift rod to transfer case range lever. Connect front shaft to transfer case yoke with U-bolts and nuts. Tighten nuts to 13-18 lb-ft (18-24 Nm). Connect front shaft to front axle yoke with strap and bolts. Tighten bolts to 13-18 lb-ft (18-24 Nm). Secure center bearing to engine mount with bolts, washers, and locknuts. Tighten bolts to 60 lb-ft (81 Nm). Lubricate propeller shaft U-joints and slip yokes with chassis grease.
CROSS GREASE FITTING
Figure 9-110: U-joint Components (Typical)
Installation
1. 2. 3. Slide propeller shaft slip yoke into extension housing. Connect shaft to axle yoke with U-bolts, lockwashers and nuts. Tighten U-bolt nuts to 13-18 lb-ft (18-24 Nm) Lubricate propeller shaft U-joints.
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U-JOINT REPLACEMENT
1. 2. 3. 4. 5. Remove propeller shaft. Remove grease fitting from cross (Figure 9-111). Remove two bearing cups from cross (rear shaft only). Remove snap rings from bearings in yoke. Position propeller shaft in vise with 1-1/8 socket between vise jaw and bearing being removed. Be sure open end of socket is facing bearing cup (Figure 9-111).
BEARING LARGE SOCKET CROSS SHAFT YOKE SMALL SOCKET
SUSPENSION HEIGHT MEASUREMENT

NOTE: Before checking suspension height, check the following items: a. b. Broken spring coil or shock absorber. Winch plus other aftermarket accessories installed on the front end of the vehicle. c. Worn out control arm bushings. d. Worn out ball joints. e. Damaged frame or suspension components. Check tire pressure, front tires should be at 26 psi and rear tires at 28 psi, curb weight. Ensure that tires and rims are original equipment as supplied by AM General. Position vehicle on level surface. Remove any load from vehicle interior or roof rack. Tools, luggage, recreational equipment, or similar items may produce faulty measurements if left in the vehicle. Jounce vehicle front and rear 2-3 times and allow suspension to settle. Check suspension height by measuring distance between bottom edge of each lower control arm front crossmember bracket and shop floor as indicated by dimension X (Figure 9-112).
1. 2. 3. 4.
5.
BEARING
6.
Figure 9-111: U-Joint Cross and Bearing Installation

6. Place 11/16 socket between opposite bearing and vise jaw. Be sure open end of socket is facing vise jaw. 7. Tighten vise to press bearing cup out of yoke. Then remove bearings from cross. 8. Reverse position of sockets and press remaining bearing out of yoke. 9. Remove cross from yoke. 10. Pack bearing grease into bearings to hold needle rollers in place. CAUTION: Be sure grease fitting on cross faces yoke. Damage to fitting will result if improperly installed. 11. Position cross in yoke. 12. Install first bearing in yoke. Verify bearing cup is aligned with yoke before pressing in with vise. Damage to cross and bearing will result if misaligned. 13. Place yoke in vise with 11/16 socket between vise jaw and bearing cup. Then press bearing cup into yoke far enough to install snap ring. 14. Install remaining bearing in yoke. 15. Place yoke in vise with 11/16 socket between bearing cup and vise jaw. 16. Press bearing cup into yoke far enough to install snap ring. 17. Press remaining two bearings in slip yoke and install snap rings. 18. Install two additional bearing cups on cross (rear shaft only). 19. Install grease fitting in cross. 20. Lube joints and yokes as required.
Figure 9-112: Suspension Height Measurement

a. Suspension height is acceptable if height measured at each side is 16 inches (40.6 cm) or greater and left right measurements do not differ more than 3/4" (19mm). Replace springs only if height measured is less than 16 inches (40.6 cm) at either side, or if right-left variation exceeds 3/4" (19mm).
b.
________________________________________

Installation
9-43
COIL SPRING REPLACEMENT

NOTE: The procedure for removing and installing all four coil springs is basically the same. This procedure covers the left front coil spring. NOTE: Various load capacity springs are used in the Hummer based on powertrain and option packages. Refer to the parts catalog to select the proper replacement spring for the specific application.
NOTE: Index coil spring in spring pocket for a slight gap 1/16 - 1/8 in. (1.59 - 3.18 mm) when spring is in position. 1. Install coil spring over shock absorber and onto lower control arm ensuring end of coil spring ts in spring pocket of lower control arm (Figure 9-113). Ensure coil spring is aligned with spring seat flange, and raise lower control arm. Extend shock absorber into spring seat and install with washer, shock pin, and locknut. Tighten locknut to 300 lbft (407 Nm). Install lower ball joint and geared hub on lower control arm ensuring lower ball joint is placed below lower control arm. Secure lower ball joint to lower control arm with four washers, bolts, washers, and locknuts. Tighten front locknuts to 37 lb-ft (50 Nm) and rear locknuts to 60 lb-ft. (80 Nm). Apply thread-locking compound to threads of bolt. Install bar link on lower control arm with two washers and bolt. Tighten bolt to 70 lb-ft (95 Nm). Install wheel (Section 6).
2. 3.
Removal
1. 2. 3. 4. 5. Remove wheel (Section 6). Remove bolt, two washers, and bar link from lower control arm. Remove four locknuts, washers, bolts, washers, lower ball joint, and geared hub from lower control arm (Figure 9-113). Place jack under lower control arm and raise lower control arm slightly to relieve tension on shock pin. Remove locknut, shock pin, washer, and shock absorber from spring seat and collapse shock absorber.
4.
5.
NOTE: It may be necessary to loosen lower control arm bolts to allow lower control arm to be lowered. 6. Pull geared hub and lower ball joint away from lower control arm and remove coil spring from lower control arm and shock absorber.
SHOCK PIN SPRING SEAT
6.
COIL SPRING GEARED HUB
LOWER BALL JOINT LOWER CONTROL ARM SHOCK ABSORBER
BAR LINK
LOWER CONTROL ARM
SPRING POCKET
Figure 9-113: Coil Spring Replacement

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SHOCK ABSORBER REPLACEMENT

NOTE: The procedure for removing and installing all shock absorbers is the same, except rear lower shock pins must be installed with head of pin facing rearward. This procedure covers the left front shock absorber.
Installation
NOTE: It may be necessary to spread spring seat to allow installation of shock absorber. 1. Position shock absorber in vise, and install bracket on shock absorber with washer, pin, and locknut. Tighten locknut to 300 lb-ft (407 Nm) (Figure 9-114).
Removal
1. 2. 3. Remove two bolts, lockwashers, washers, shock absorber, and bracket from lower control arm (Figure 9-114). Remove locknut, shock pin, washer, and shock absorber from spring seat. Note position of pin for installation. Compress shock absorber and remove shock absorber and bracket.
CAUTION: Do not pry or use sharp tools on shock absorber piston rod. A damaged rod will cause shock failure. 2. 3. Install shock absorber and bracket through lower control arm. Extend shock absorber and secure piston rod end of shock absorber to spring seat with washer, shock pin, and locknut. Tighten locknut to 300 lb-ft (407 Nm). Install bracket on lower control arm with two washers, lockwashers, and bolts. Tighten bolts to 178 lb-ft (241 Nm).
NOTE: Note alignment of shock absorber and bracket for installation reference. 4. Position shock absorber in vise and remove locknut, pin, washer, and bracket from shock absorber.
4.
SPRING SEAT SHOCK PIN
SHOCK ABSORBER
PIN
BRACKET
LOWER CONTROL ARM
Figure 9-114: Shock Absorber Replacement
________________________________________
9-45
FRONT BUMPER AND TOWING BRACKETS REPLACEMENT (VEHICLES WITHOUT WINCH)

Removal
1. 2. Remove brushguard, if equipped. Remove four locknuts, washers, bolts, washers, two towing brackets, and front bumper from mounting brackets (Figure 9-115).
FRONT BUMPER AND TOWING BRACKETS REPLACEMENT (VEHICLES WITH WINCH)

Removal
WARNING: Winch must be supported prior to performing step 1. Failure to observe this warning could result in personal injury.
1. 2. Remove four bolts and washers securing winch to front bumper (Figure 9-116). Remove four locknuts, washers, bolts, washers, and two towing brackets from front bumper and frame extensions. Discard locknuts. Remove five locknuts, washers, six bolts, washers, and front bumper from frame extensions.
Installation
1. Install front bumper and two towing brackets on mounting brackets with four washers, bolts, washers, and locknuts. Tighten bolts to 90 lb-ft (122 Nm) (Figure 9-115). Install brushguard, if removed (Section 10).
FRONT BUMPER
2.
3.
Installation
1. Install front bumper on frame extensions with six washers, bolts, ve washers, and locknuts. Tighten bolts to 90 lb-ft (122 Nm) (Figure 9-116). Install two towing brackets on front bumper and frame extensions with four washers, bolts, washers, and locknuts. Tighten bolts to 90 lb-ft (122 Nm). Install four bolts and washers securing front bumper to winch. Tighten bolts to 60 lb-ft (81 Nm).
2.
3.
TOWING BRACKET MOUNTING BRACKET
FRAME EXTENSION
Figure 9-115: Front Bumper and Towing Bracket Replacement for Vehicles Without Winch
FRONT BUMPER
TOWING BRACKET
Figure 9-116: Front Bumper and Towing Bracket Replacement for Vehicles With Winch
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FRONT BUMPER MOUNTING BRACKET REPLACEMENT

Removal
NOTE: Mark location of bolts for installation. 1. 2. 3. 4. Support hood in position with jacks. Remove three locknuts, washers, bolts, and washers securing mounting bracket to frame rail (Figure 9-117). Remove two locknuts and plate securing mounting bracket to hinge. Remove two locknuts, washers, bolts, washers, towing bracket, and mounting bracket from front bumper.
RADIATOR FRONT MOUNT BRACKET REPLACEMENT

Removal
1. 2. 3. Remove locknut, washer, bolt, washer, and spacer securing radiator to front mount bracket (Figure 9-118). Remove two locknuts, washers, bolts, washers, and front mount bracket from suspension crossmember. Remove mount from front mount bracket.
Installation
1. 2. Install mount in front mount bracket (Figure 9-118). Install front mount bracket on suspension crossmember with two washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm). Install radiator on front mount bracket with spacer, washer, bolt, washer, and locknut. Tighten locknut to 30 lb-ft (41 Nm).
RADIATOR
Installation
1. Install mounting bracket and towing bracket on front bumper with two washers, bolts, washers, and locknuts. Do not tighten locknuts (Figure 9-117). Install mounting bracket on frame rail with three washers, bolts, washers, and locknuts. Do not tighten locknuts. Install mounting bracket on hinge with plate and two locknuts. Tighten hinge locknuts to 28 lb-ft (38 Nm), front bumper locknuts to 90 lb-ft (122 Nm), and frame rail locknuts to 178 lb-ft (241 Nm). Remove jacks supporting hood. 3.
2. 3. 4.
MOUNT
5.
TOWING BRACKET
SPACER FRONT MOUNT BRACKET FRONT BUMPER HINGE SUSPENSION CROSSMEMBER
Figure 9-118: Radiator Front Mount Bracket Replacement

FRAME RAIL MOUNTING BRACKET PLATE
Figure 9-117: Front Bumper Mounting Bracket Replacement
________________________________________

FRAME EXTENSION REPLACEMENT
Removal
1. 2. 3.
9-47
LIFTING SHACKLE REPLACEMENT

Removal
Remove cotter pin, slotted nut, bolt, spring washer, and shackle from tiedown bracket. Discard cotter pin (Figure 9-119).
Installation
1. Install shackle on tiedown bracket with spring washer, bolt, and slotted nut. Tighten slotted nut enough to allow movement of shackle (Figure 9-119). Install cotter pin in slotted nut.
Remove front bumper. Remove hood and hinge (Section 10). Remove two locknuts, washers, bolts, and washers securing front suspension brace to frame extension (Figure 9-120).
NOTE: Note position of winch cable bracket for installation. 4. Remove three locknuts, washers, bolts, and washers securing clamp mounting bracket, frame extension, and bumper mounting bracket to frame.
2.
Installation
1. Install bumper mounting bracket, frame extension, and clamp mounting bracket on frame with three washers, bolts, washers, and locknuts. Do not tighten locknuts (Figure 9-120). Secure front suspension brace to frame extension with two washers, bolts, washers, and locknuts. Tighten all locknuts to 178 lb-ft (241 Nm). Install hinge and hood. Install front bumper.
FRAME CLAMP MOUNTING BRACKET
2. 3. 4. 5.
TIEDOWN BRACKET
SHACKLE
Figure 9-119: Lifting Shackle Replacement
BUMPER MOUNTING BRACKET
FRAME EXTENSION
Figure 9-120: Frame Extension Replacement
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LEFT AIRLIFT BRACKET AND FRONT UPPER CONTROL ARM BRACKETS REPLACEMENT
Removal
1. 2. 3. 4. Remove left engine splash shield (Section 10). Raise and support front of vehicle. Remove three screws and clamps securing harness to airlift bracket (Figure 9-121). Remove two locknuts, washers, and bolts securing radiator support to airlift bracket.
Installation
1. Install airlift bracket, shim(s) and two control arm brackets on frame rail with eight washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-121). Apply thread-locking compound to two bolt holes and secure airlift bracket and control arm brackets to frame rail with two washers and bolts. Tighten bolts to 90 lb-ft (122 Nm). Install upper control arm on control arm brackets with cam washers, bolts, washers, and locknuts. Tighten locknuts to 260 lb-ft (353 Nm). Secure radiator support to airlift bracket with two bolts, washers, and locknuts. Tighten locknuts to 37 lb-ft (50 Nm). Secure harness to airlift bracket with three clamps and screws. Lower front of vehicle. Install left engine splash shield.
2.
3.
WARNING: To avoid personal injury or equipment damage, support lower control arm during removal and installation.
5. Remove two locknuts, washers, bolts, washers, and upper control arm from two control arm brackets.
4.
5. 6. 7.
NOTE: Note direction of bolts for installation. 6. 7. Remove eight locknuts, washers, bolts, washers, two control arm brackets and shim(s) from airlift bracket. Remove two bolts, washers, and airlift bracket from frame rail.
RADIATOR SUPPORT
AIRLIFT BRACKET
HARNESS
FRAME RAIL
UPPER CONTROL ARM SHIM(S) CONTROL ARM BRACKET
Figure 9-121: Left Airlift Bracket and Front Upper Control Arm Bracket Replacement
________________________________________

Installation
1.
9-49
RIGHT AIRLIFT BRACKET AND FRONT UPPER CONTROL ARM BRACKETS REPLACEMENT
Removal
1. 2. 3. Remove battery tray (Section 12). Raise and support front of vehicle. Remove two locknuts, washers, and bolts securing radiator support to airlift bracket (Figure 9-122).
2.
WARNING: To avoid personal injury or equipment damage, support lower control arm during removal and installation
4. Remove two locknuts, washers, bolts, washers, and upper control arm from two control arm brackets.
3.
4. 5.
Install airlift bracket, shim(s), two control arm brackets, and cooler line bracket on frame rail with ten washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-122). Secure upper control arm to two control arm brackets with cam washers, bolts, washers, and locknuts. Tighten locknuts to 260 lb-ft (353 Nm). Install radiator support on airlift bracket with two bolts, washers, and locknuts. Tighten locknuts to 37 lb-ft (50 Nm). Lower front of vehicle. Install battery tray.
NOTE: Note direction of bolts for installation. 5. Remove ten locknuts, washers, bolts, and washers securing control arm brackets, cooler line bracket, and airlift bracket to frame rail. Remove two control arm brackets, shim(s) and airlift bracket from frame rail.
6.
COOLER LINE BRACKET AIRLIFT BRACKET
RADIATOR SUPPORT
FRAME RAIL
CONTROL ARM BRACKET
UPPER CONTROL ARM
SHIM(S)
Figure 9-122: Right Airlift Bracket and Front Upper Control Arm Bracket Replacement
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FRONT SUSPENSION BRACE REPLACEMENT (VEHICLES WITHOUT WINCH)

Removal
1. 2. Remove locknut, washer, bolt, and washer securing brace to frame rail (Figure 9-123). Remove locknut, washer, bolt, washer, and brace from crossmember and lower control arm.
FRONT SUSPENSION BRACE REPLACEMENT (VEHICLES WITH WINCH)

Removal
NOTE: The left and right front suspension braces are replaced basically the same. This procedure covers the left front suspension brace. 1. 2. Remove two locknuts, washers, bolts, and washers securing front suspension brace to frame extension (Figure 9-124). Remove locknut, washer, bolt, washer, and brace from crossmember and lower control arm.
Installation
1. Install brace on crossmember and lower control arm with washer, bolt, washer, and locknut. Do not tighten locknuts (Figure 9-123). Install brace on frame rail with washer, bolt, washer, and locknut. Tighten crossmember locknut to 261 lb-ft (354 Nm) and frame rail locknut to 178 lb-ft (241 Nm).
Installation
1. Install brace on crossmember and lower control arm with washer, bolt, washer, and locknut. Do not tighten locknut (Figure 9-124). Secure brace to frame extension with two washers, bolts, washers, and locknuts. Tighten crossmember locknut to 261 lb-ft (354 Nm) and frame extension locknuts to 178 lb-ft (241 Nm).
2. 3.
2. 3.
FRAME RAIL
LOWER CONTROL ARM
CROSSMEMBER CROSSMEMBER LOWER CONTROL ARM BRACE FRAME EXTENSION
Figure 9-123: Front Suspension Brace Replacement for Vehicles Without Winch
BRACE
Figure 9-124: Front Suspension Brace Replacement for Vehicles With Winch
________________________________________
9-51
SPLASH SHIELD SUPPORT BRACKET REPLACEMENT

Removal
1. Remove locknut, washer, bolt, and washer securing splash shield to bracket (Figure 9-125).
NOTE: Note direction of bolts for installation. 2. Remove two locknuts, washers, bolts, washers, and bracket from frame rail.
Installation
1. Install bracket on frame rail with two washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-125). Install splash shield on bracket with washer, bolt, washer, and locknut. Tighten bolt to 15 lb-ft (20 Nm).
2.
SPLASH SHIELD
BRACKET
FRAME RAIL
Figure 9-125: Splash Shield Support Bracket Replacement
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REAR BUMPER REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. Remove swing-away spare tire carrier, if equipped (Section 6). Remove rear license plate bracket (Section 10). Remove trailer hitch, if equipped (Section 13). Remove two locknuts, washers, bolts, and washers securing trailer harness to rear bumper (Figure 9-126). Disconnect trailer harness from body harness, and pull trailer harness through hole in rear bumper. Remove four locknuts, washers, bolts, and washers securing two tiedown brackets to rear bumper, two mounting brackets, and outer mounting brackets. Remove eight bolts, washers, and rear bumper from two mounting brackets.
Installation
1. Install rear bumper on two mounting brackets and secure with eight washers and bolts. Do not tighten bolts (Figure 9-126). Install two tiedown brackets on rear bumper, two mounting brackets, and outer mounting brackets, with four washers, bolts, washers, and locknuts. Do not tighten locknuts. Tighten bolts installed in step 1 and locknuts installed in steps 2, 3, and 4 to 90 lb-ft (122 Nm). Insert trailer harness through hole in rear bumper and connect trailer harness to body harness. Secure trailer harness to rear bumper with two washers, bolts, washers, and locknuts. Install trailer hitch, if removed. Install rear license plate bracket. Install swing-away spare tire carrier, if removed.
2.
3. 4. 5. 6. 7. 8.
7.
MOUNTING BRACKET
OUTER MOUNTING BRACKET
TIEDOWN BRACKET
BODY HARNESS REAR BUMPER
REAR BUMPER TRAILER HARNESS
Figure 9-126: Rear Bumper Replacement
________________________________________
9-53
SPRING SEAT REPLACEMENT

NOTE: Replacement of the four spring seats is basically the same. This procedure covers the right front spring seat.
REAR BUMPER OUTER MOUNTING BRACKET AND TIEDOWN BRACKET REPLACEMENT

Removal
1. 2. Remove rear body mount (Section 10). Remove two locknuts, washers, bolts, and washers securing tiedown bracket and outer mounting bracket to mounting bracket and rear bumper (Figure 9-128). Remove two bolts and washers securing outer mounting bracket to mounting bracket. Remove four locknuts, washers, bolts, washers, outer mounting bracket, and spacer from frame rail and inner mounting bracket.
Removal
1. 2. Remove coil spring. Remove four locknuts, washers, bolts, spring bracket, and front spring seat from frame rail (Figure 9-127).
3. 4.
Installation
1. Install spring bracket and front spring seat on frame rail with four washers, bolts, washers, and locknuts. Tighten locknuts to 261 lb-ft (354 Nm) (Figure 9-127). Install coil spring.
SPRING BRACKET FRAME RAIL
2.
Installation
NOTE: Ensure spacer on inner side of frame rail is in position before installing spacer and outer mounting bracket. 1. Install spacer and outer mounting bracket on frame rail and inner mounting bracket with four washers, bolts, washers, and locknuts. Do not tighten locknuts (Figure 9-128). Secure outer mounting bracket to mounting bracket with two washers and bolts. Do not tighten bolts. Install tiedown bracket on rear bumper and secure tiedown bracket and outer mounting bracket to mounting bracket and rear bumper with two washers, bolts, washers, and locknuts. Tighten all locknuts and bolts to 90 lb-ft (122 Nm). Install rear body mount (Section 10).
FRAME RAIL
2. 3.
4. 5.
MOUNTING BRACKET FRONT SPRING SEAT
Figure 9-127: Front Spring Seat Replacement
REAR BUMPER TIEDOWN BRACKET SPACER OUTER MOUNTING BRACKET
Figure 9-128: Rear Bumper Mounting Bracket Replacement
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LEFT ENGINE MOUNT BRACKET REPLACEMENT

Removal
1. 2. Remove two bolts securing brake line and oil line clamps to engine mount bracket (Figure 9-129). Remove two locknuts and washers securing engine mount bracket to insulator.
Installation
1. Install engine mount bracket on frame rail with four washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-129). Remove wood block and jack stand from under engine oil pan (Figure 9-130). Secure engine mount bracket to insulator with two washers and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-129). Secure brake line and oil line clamps to engine mount bracket with two bolts.
2. 3.
CAUTION: To avoid engine oil pan damage, wood block must completely cover bottom of oil pan. 3. 4. Support engine under engine oil pan with wood block and jack stand (Figure 9-130). Remove four locknuts, washers, bolts, washers, and engine mount bracket from frame rail (Figure 9-129). 4.
OIL LINE CLAMP
BRAKE LINE CLAMP
ENGINE OIL PAN
INSULATOR
WOOD BLOCK
JACK STAND
Figure 9-130: Supporting Engine
FRAME RAIL
ENGINE MOUNT BRACKET
Figure 9-129: Left Engine Mount Bracket Replacement
________________________________________

RIGHT FRONT BODY MOUNT BRACKET REPLACEMENT
Removal
1. 2.
9-55
RIGHT ENGINE MOUNT BRACKET REPLACEMENT

Removal
1. 2. Remove right engine mount and insulator (Section 2). Remove two locknuts, washers, bolts, and washers securing support bracket to engine mount bracket (Figure 9-131). Remove bolt securing vent tube clamp to engine mount bracket. Remove three locknuts, washers, bolts, washers, support bracket, and engine mount bracket from frame rail.
VENT TUBE CLAMP
Remove right front body mount. Remove three locknuts, washers, bolts, washers, and right front body mount bracket from frame rail (Figure 9-132).
3. 4.
Installation
1. Install right front body mount bracket on frame rail with three washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-132). Install right front body mount (Section 10).
2.
BODY
ENGINE MOUNT BRACKET
SLEEVE
SPACER UPPER CUSHION
SUPPORT BRACKET FRAME RAIL
LOWER CUSHION
FRAME RAIL
Figure 9-131: Right Engine Mount Bracket Replacement
Installation
1. Install support bracket and engine mount bracket on frame rail with three washers, bolts, washers, and locknuts (Figure 9-131). Install support bracket on engine mount bracket with two washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm). Install vent tube clamp on engine mount bracket with bolt. Install right engine mount and insulator (Section 2).
Figure 9-132: Right Front Body Mount Bracket Replacement
2.
3. 4.
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TRANSMISSION MOUNT CROSSMEMBER REPLACEMENT

Removal
CAUTION: To prevent equipment damage during removal and installation of transmission mount crossmember, transmission must be supported. 1. Place support under transmission and remove two locknuts, washers, bolts, and washers securing transmission mount crossmember to two transmission support brackets (Figure 9-133). Remove two locknuts, washers, and transmission mount crossmember from transmission mount.
TRANSMISSION CROSSMEMBER SUPPORT BRACKET REPLACEMENT

Removal
1. 2. Remove transmission mount crossmember. Remove two locknuts and washers securing transmission crossmember support bracket to frame rail (Figure 9-134).
Installation
1. Install transmission crossmember support bracket on two bolts and frame rail with two washers and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-134). Install transmission mount crossmember.
FRAME RAIL
2.
2.
Installation
1. Install transmission mount crossmember on two transmission support brackets with two washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-133). Install crossmember on transmission mount with two washers and locknuts. Tighten locknuts to 28 lb-ft (38 Nm). Remove support.
2.
3.
TRANSMISSION SUPPORT BRACKET
TRANSMISSION MOUNT
TRANSMISSION CROSSMEMBER SUPPORT BRACKET
Figure 9-134: Transmission Crossmember Support Bracket Replacement
TRANSMISSION MOUNT CROSSMEMBER
Figure 9-133: Transmission Mount Crossmember Replacement
________________________________________
9-57
RIGHT INTERMEDIATE BODY MOUNT BRACKET REPLACEMENT

Removal
1. 2. Remove right intermediate body mount (Section 10). Remove three bolts, washers, and body mount bracket from frame rail (Figure 9-135).
LEFT INTERMEDIATE BODY MOUNT BRACKET REPLACEMENT

Removal
1. 2. 3. Remove left intermediate body mount (Section 10). Remove tailpipe hanger (Section 11). Remove three locknuts, washers, and body mount bracket from frame rail (Figure 9-136).
BODY
Installation
1. Install body mount bracket on three bolts and frame rail with three washers and locknuts. Tighten locknuts to 90 lbft (122 Nm) (Figure 9-136). Install tailpipe hanger (Section 11). Install left intermediate body mount (Section 10).
SPACER LOWER CUSHION SLEEVE UPPER CUSHION BODY MOUNT BRACKET FRAME RAIL
2. 3.
BODY
SPACER SLEEVE BODY MOUNT BRACKET FRAME RAIL UPPER CUSHION
Figure 9-135: Right Intermediate Body Mount Bracket Replacement
Installation
1. Apply thread-locking compound to three bolts and install body mount bracket on frame rail with three washers and bolts. Tighten bolts to 90 lb-ft (122 Nm) (Figure 9-135). Install right intermediate body mount (Section 10).
LOWER CUSHION
2.
Figure 9-136: Left Intermediate Body Mount Bracket Replacement
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REAR-REAR TIEDOWN BRACKET REPLACEMENT

BRACKET
Removal
Remove two locknuts, washers, bolts, washers, and tie-down bracket from frame rail (Figure 9-137).
VENT LINE
Installation
Install tiedown bracket on frame rail with two washers, bolts, washers, and locknuts. Tighten locknuts to 261 lb-ft (354 Nm) (Figure 9-137).
FRAME RAIL FITTING
GEARED HUB
Figure 9-138: Rear geared Hub Vent Line Location
Installation
TIEDOWN BRACKET
1.
2.
Figure 9-137: Tiedown Bracket Replacement

3.
REAR UPPER CONTROL ARM BRACKET REPLACEMENT

NOTE: The procedure for removing and installing the four rear upper control arm brackets is basically the same. This procedure covers the right rear upper control arm front bracket.
4.
Install control arm bracket, and vent line mounting bracket on frame rail with four washers, bolts, washers, and locknuts. Tighten locknuts to 172 lb-ft (233 Nm) (Figure 9-139). Attach upper control arm to two upper control arm brackets with cam washers, bolts, washers, and locknuts. Tighten locknuts to 260 lb-ft (353 Nm). Connect vent line to fitting and secure clamp and vent line to bracket with bolt (Figure 9-138). Install wheel.
VENT LINE MOUNTING BRACKET
Removal
1. 2. 3. 4. Remove wheel. Remove bolt, clamp, and vent line from bracket, and disconnect vent line from fitting Remove two locknuts, washers, bolts, washers, and upper control arm from two control arm brackets (Figure 9-139). Remove four locknuts, washers, bolts, washers, vent line mounting bracket, and control arm bracket from frame rail.
CONTROL ARM BRACKET
FRAME RAIL
UPPER CONTROL ARM
Figure 9-139: Rear Upper Control Arm Bracket Replacement
________________________________________

AXLE SUPPORT BRACKET AND SIDE MOUNTING BRACKET REPLACEMENT
Removal
1. 2. 3. 4. 5. 6.
9-59
REAR-FRONT TIEDOWN BRACKET REPLACEMENT

Removal
1. 2. 3. Remove wheel (Section 6). Remove four locknuts, washers, bolts, washers, and tiedown bracket from frame rail (Figure 9-140). Remove two locknuts, washers, bolts, washers, vent tube/ speed sensor lead mounting bracket, and tiedown bracket from rear suspension front crossmember mounting bracket.
VENT TUBE SPEED SENSOR LEAD BRACKET
Remove brake caliper and rotor. Remove locknut, seal washer, and output flange from output shaft. Discard seal washer (Figure 9-141). Remove two bolts and brake adapter from axle. Remove two bolts and washers securing side mounting bracket to axle (Figure 9-142). Remove two locknuts, washers, bolts, washers, support bracket, and side mounting bracket from crossmember. Remove two locknuts, washers, bolts, washers, and side mounting bracket from support bracket (Figure 9-143).
OUTPUT FLANGE BRAKE ADAPTER
TIEDOWN BRACKET
OUTPUT SHAFT
FRAME RAIL
LOCKNUT SEAL WASHER AXLE
Figure 9-141: Brake Adapter and Output Flange Replacement

CROSSMEMBER MOUNTING BRACKET
Installation
1. Install side mounting bracket on support bracket with two washers, bolts, washers, and locknuts (Figure 9-143). Install support bracket and side mounting bracket on crossmember with two washers, bolts, washers, and locknuts (Figure 9-142). Do not tighten bolts. Apply thread-locking compound to tapped holes of axle and install two washers, bolts, and side mounting bracket on axle. Tighten side mounting bracket bolts to 110-139 lb-ft (149-189 Nm) and support bracket bolts to 90 lb-ft (122 Nm). Apply thread-locking compound to tapped holes of axle and install brake adapter on axle with two bolts. Tighten bolts to 110-139 lb-ft (149-189 Nm) (Figure 9-141). Install output flange on output shaft with seal washer and locknut. Tighten locknut to 170 lb-ft (231 Nm). Install brake caliper and rotor.
Figure 9-140: Rear-Front Tiedown Bracket Replacement
2.
Installation
1. Install tiedown bracket and vent tube mounting bracket on rear suspension front crossmember mounting bracket with two washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-140). Install tiedown bracket on frame rail with four washers, bolts, washers, and locknuts. Tighten locknuts to 261 lb-ft (354 Nm). Install wheel. 3.
2.
4.
3.
5. 6.
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SUPPORT BRACKET
_________________________________________
FRONT SUSPENSION FRONT CROSSMEMBER REPLACEMENT

Removal
1. 2. 3. 4. 5. Remove front lower control arms. Remove lower radiator hose. Remove horn. Remove radiator front mounting bracket. Remove two nuts, washers, bolts, and washers securing front crossmember to support bracket (Figure 9-142).
NOTE: Note direction of bolts for installation. 6.

SIDE MOUNTING BRACKET
Remove four locknuts, washers, bolts, and washers securing two splash shield brackets to frame rails (Figure 9-144).
WARNING: To avoid personal injury, support crossmember during removal.

AXLE CROSSMEMBER
7.
Figure 9-142: Side Mounting Bracket Removal
Remove bolt and clamp securing harness to front crossmember (Figure 9-145). 8. Remove four locknuts, washers, bolts, and washers securing crossmember mounting brackets to frame rails. 9. Slide crossmember and mounting brackets down and out from under vehicle. 10. Remove six locknuts, washers, bolts, washers, and left and right mounting brackets from crossmember.
SUPPORT BRACKET
FRAME RAIL
SPLASH SHIELD BRACKET SIDE MOUNTING BRACKET
Figure 9-143: Support Bracket Replacement
Figure 9-144: Splash Shield Mounting
________________________________________
9-61
Installation
1. 2. Position left and right crossmember mounting brackets on crossmember (Figure 9-145). Install crossmember and mounting brackets on frame rails with four washers, bolts, washers, and locknuts. Do not tighten locknuts. Install left and right mounting brackets on crossmember with six washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm). Tighten mounting bracket-to-frame rail locknuts to 261 lbft (354 Nm). Secure harness to crossmember with clamp and bolt. Install four washers, bolts, washers, locknuts, and two splash shield brackets on frame rails. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-144).
FRONT SUSPENSION REAR CROSSMEMBER REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove radiator (Section 4). Remove right front upper control arm. Remove lower radiator tube. Remove right front caliper-to-tee brake line. Remove lower control arms. Remove axle. Remove axle support brackets and side mounting brackets. Remove three bolts, lockwashers, and washers and pull steering gear away from left frame rail (Figure 9-146). Remove three bolts and clamps from two vent line brackets and crossmember (Figure 9-147).
3.
4. 5. 6.
7.
Secure front crossmember to support bracket with two washers, bolts, washers, and nuts (Figure 9-142). 8. Install horn. 9. Install lower radiator hose. 10. Install radiator front mounting bracket. 11. Install front lower control arms.
STEERING GEAR
FRAME RAIL
LEFT FRAME RAIL
Figure 9-146: Steering Gear and Left Frame Rail Location

NOTE: Note direction of bolts for installation.
FRONT CROSSMEMBER
HARNESS
Figure 9-145: Front Crossmember Replacement
10. Remove four locknuts, washers, bolts, washers, and vent line bracket securing rear crossmember to right frame rail. 11. Remove three locknuts, washers, bolts, washers, and vent line bracket securing rear crossmember to left frame rail. 12. Remove bolt and washer securing rear crossmember to left frame rail. 13. Remove six locknuts, washers, bolts, and washers securing rear crossmember to left and right rear crossmember mounting brackets. 14. Slide rear crossmember and mounting brackets down and out from under vehicle. 15. Remove mounting brackets from rear crossmember.
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VENT LINE BRACKET
_________________________________________
9.
LEFT FRAME RAIL CROSSMEMBER MOUNTING BRACKET
10.
11. 12. 13. 14. 15. 16. 17.
Secure vent line to rear crossmember and two vent line brackets with three clamps and bolts. Secure steering gear to left frame rail with three washers, lockwashers, and bolts. Tighten bolts to 60 lb-ft (81 Nm) (Figure 9-146). Install axle support brackets and side mounting brackets. Install axle. Install lower control arms. Install right front caliper-to-tee brake line. Install right front upper control arm. Install lower radiator tube. Install radiator.
REAR SUSPENSION FRONT CROSSMEMBER REPLACEMENT

VENT LINE BRACKET
Removal
1. 2. 3. 4. 5. Remove rear-front tiedown brackets. Remove axle (Section 6). Remove axle support brackets and side mounting brackets. Remove rear lower control arms. Remove three bolts and clamps securing brake line and two vent lines to front crossmember (Figure 9-148) and (Figure 9-149). Remove brake line from tee and tube coupling.
TUBE COUPLING
RIGHT FRAME RAIL
REAR CROSSMEMBER
6.
Figure 9-147: Rear Crossmember Replacement
Installation
1. 2. 3. Install left and right rear crossmember mounting brackets on rear crossmember (Figure 9-147). Install rear crossmember and mounting brackets on frame rails. Apply thread-locking compound to hole and secure crossmember mounting bracket to left frame rail with washer and bolt. Tighten bolt to 65-78 lb-ft (88-106 Nm). Secure crossmember mounting bracket to left frame rail with vent line bracket, three washers, bolts, washers, and locknuts. Do not tighten bolts. Secure crossmember mounting bracket to right frame rail with vent line bracket, four washers, bolts, washers, and locknuts. Do not tighten bolts. Install six washers, bolts, washers, and locknuts securing rear crossmember to left and right mounting brackets. Tighten bolts to 90 lb-ft (122 Nm). Tighten three bolts on mounting bracket and left frame rail to 90 lb-ft (122 Nm). Tighten four bolts on mounting bracket and right frame rail to 90 lb-ft (122 Nm).
4.
BRAKE LINE FRONT CROSSMEMBER
5.
6.
Figure 9-148: Brake Line and Tube Coupling Location

7. Remove two locknuts, washers, bolts, washers, and two radius rods from crossmember mounting brackets (Figure 9-150).
7. 8.
________________________________________

Installation
1.
9-63

8. Loosen six locknuts securing front crossmember to crossmember mounting brackets. 9. Slide front crossmember down and out from under vehicle. 10. Remove six locknuts, washers, bolts, washers, and two crossmember mounting brackets from front crossmember.
BRAKE LINE
2. 3. 4.
5. 6. 7. 8. 9. 10.
Install two crossmember mounting brackets on front crossmember with six washers, bolts, washers, and locknuts. Tighten locknuts to 90 lb-ft (122 Nm) (Figure 9-150). Install front crossmember on frame rails. Install rear-front tiedown brackets. Install radius rods in crossmember mounting brackets with two washers, bolts, washers, and locknuts. Tighten locknuts to 260 lb-ft (353 Nm). Install brake line on tee and tube coupling (Figure 9-148) and (Figure 9-150). Secure brake line and two vent lines to front crossmember with three clamps and bolts. Install axle support brackets and side mounting brackets. Install axle. Install rear lower control arms. Bleed rear brakes.
FRONT CROSSMEMBER
Figure 9-149:
Brake Line and Vent Lines Location
FRONT CROSSMEMBER
RADIUS ROD
Figure 9-150: Front Crossmember Assembly Replacement
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_________________________________________
FRAME INSPECTION General Information

The frame rails are constructed by arc-welding two C channels of preformed steel together to form a box cross section. The frame rails are internally reinforced at bolt hole locations by bushings or full cross-section spacers to prevent channels from collapsing from attaching load. The frame is made by bolting two non-identical frame rails to crossmembers. Crossmembers are held to stringent dimensional tolerances and therefore must be replaced if damaged.
INSPECTION
The visual inspection is the first and most critical step in forming a decision of whether to repair or replace a damaged frame component (Figure 9-151). Factors to consider when making a visual inspection are: 1. Twisted frame rails are not repairable and must be replaced. 2. Transverse tears or breaks extending across or into both upper or lower corners are not repairable by welding. 3. Short longitudinal cracks up to 6 inches (15.2 cm) or split welds can be repaired by heli-arc welding.
TRANSVERSE CRACK FRAME RAILS LONGITUDINAL CRACK MANUFACTURING WELD REINFORCEMENT (NO LESS THAN 6-IN. (15.2 CM) IN LENGTH)
REINFORCEMENT TWISTED RAIL COMPLETE TRANSVERSE CRACK LAP WELD BUCKLE
Figure 9-151: Frame Damage
________________________________________

5. 6.
9-65
VERTICAL (SIDE VIEW) MEASUREMENT

1. 2. Select a hard and level surface area 1-1/2 times the size of the vehicle. Raise vehicle at four points until all four wheels are off the surface.
WARNING: When using shim material with jackstands, the shim material must be placed squarely and rmly under the jackstand. The vehicle could be knocked off the jackstand resulting in personal injury or equipment damage if shim material is placed on top of jackstand.
3. Measure the distance from the floor to the bottom of the frame near each jackstand. Place shim(s) under jackstands as necessary until the floor-to-frame distances are equal at each jackstand.
7.
Measure and record frame rail height at corresponding points on opposite frame rail. Compare measurements from both frame rails. Measurements from comparable points deviating more than 1/8-inch (3 mm) for each 2 feet of linear distance indicates a vertically bent frame. Lower vehicle from jackstands.
HORIZONTAL (BOWING) MEASUREMENT

1. 2. Position vehicle on a smooth level surface. Measure height of frame rails at each end near center of crossmembers. If heights vary by more than 1/8-5/16-inch (3-8 mm), raise frame rail and install jackstands to bring frame to level.
NOTE: Measurements must be taken at identical locations on the left and right frame rails. Failure to do so will result in a faulty indication. 4. Select, measure and record the distance from the floor to the frame rail at several different points on either frame rail.
WARNING: When using shim material with jackstands, the shim material must be placed squarely and rmly under the jackstand. The vehicle could be knocked off the jackstand resulting in personal injury damage if shim material is placed on top of jackstand.
3. Hang a plumb bob at the corner of one frame rail where the frame rail intersects the crossmember. Tape a piece of paper to the floor under plumb bob and mark location where plumb bob stops moving. Repeat procedure for each corner of the frame (Figure 9-154).
REAR SUSPENSION REAR CROSSMEMBER REAR BUMPER OUTER MOUNTING BRACKET
REAR SUSPENSION FRONT CROSSMEMBER LEFT INTERMEDIATE BODY MOUNT BRACKET
LEFT TRANSMISSION CROSSMEMBER SUPPORT BRACKET
LEFT FRONT BODY MOUNT BRACKET FRONT SUSPENSION REAR CROSSMEMBER ENGINE MOUNT BRACKET
RIGHT REAR-REAR TIEDOWN BRACKET RIGHT REAR-FRONT TIEDOWN BRACKET RIGHT INTERMEDIATE BODY MOUNT TRANSMISSION BRACKET CROSSMEMBER RIGHT FRONT BODY MOUNT BRACKET RIGHT FRONT SPRING SEAT
AIR LIFT BRACKETS RIGHT SPLASH SHIELD BRACKET FRONT SUSPENSION FRONT CROSSMEMBER
Figure 9-152: Frame Components
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_________________________________________
NOTE: Strings used for this horizontal bow measurement will remain in place until the next measurement (Frame Skew) is completed. To maintain the integrity of the measurements, the string must be pulled tight and secured. 4. 5. Stretch string tightly on floor between front and rear plumb bob marks under each frame rail (Figure 9-154). Measure front and rear crossmembers to determine center point. Drop a plumb bob from crossmember center points to the floor. Mark location where plumb bob stops moving (Figure 9-154). Stretch a string tightly on floor between front and rear plumb bob marks under crossmembers to determine centerline (Figure 9-154). Select measuring points an equal distance apart along the right and left strings. Measure from these right and left points to the center string. Mark center string. The
distance from the right and left points to the center string should be within 1/4-inch (6 mm) of being equal. If measurements are not equal, one frame rail is bowed.
DIAGONAL (SKEW MEASUREMENT) METHOD 1

1. Measure diagonally from one point on right or left frame rail string to a point on opposite frame rail string (Figure 9-153). Compare to an opposite diagonal measurement. If the two measurements differ by more than 1/4-inch (6 mm), the frame rails are skewed. Repeat this procedure at four other sets of measure points to confirm the skew.
6.
2. 3. 4.
7.
DIAGONAL MEASUREMENTS SHOULD NOT DIFFER BY MORE THAN 1/4-INCH (6 MM) LEFT SIDE STRING
RIGHT SIDE STRING
Figure 9-153: Diagonal Skew Measurement Method I
LEFT FRAME RAIL
PLUMB BOB CENTERLINE STRING MARK LOCATION PAPER
Figure 9-154: Horizontal (Bowing) Measurement
________________________________________

FRAME REPAIRS Cracks
NOTE: All frame welding should be heli-arc type. 1.
9-67
METHOD 2
1. 2. 3. 4. Position a string across a plumb bob point on each of the frame rail strings (Figure 9-155). Place a square with one leg coincident with a frame rail string (Figure 9-155). Run a line or string along other leg of square to opposite frame rail string (Figure 9-155). Measure deviation between string positioned in Step 1 and square leg line or string. Any deviation means the two frame rails are skewed and, consequently, the crossmembers are not at square angles to the frame rails. A deviation of 1/2-inch (12.7 mm) makes a vehicle dog track and it is difficult to align the wheels.
SQUARE
2. 3.
LEFT SIDE RIGHT SIDE STRING STRING LINE OR STRING DEVIATION LIMIT 1/2-INCH (12.5 MM) FROM LEG OF SQUARE
4.
Figure 9-155: Diagonal Skew Measurement Method 2
5.
Cracks not extending across two adjacent faces of the frame rail may be welded. Stop-drill crack with 1/8-inch (3 mm) drill (Figure 9-156) Vee-notch crack (Figure 9-156) Heli-arc weld crack with Mig or Tig welder (using a filler metal in accordance with AWS A5.18) (Figure 9-156) If reinforcement or fishplate is to be added, grind weld to a flat surface (Figure 9-156) A reinforcement or fishplate should be added to a frame rail with a crack in the bottom face Longitudinal welding can be performed on any frame rail face Welded reinforcements or fishplates should not be less than 6-inches (15.2 cm) in length along frame rail. Bolt on reinforcements or fishplates should not be less than 8-inches (20.3 mm) in length. The long bottom edge of fishplate should be heli-arc lap welded to frame component. Puncture holes only in side faces of frame rails may be repaired with combinations of fishplates and/or reinforcements. Welded type should only be used. Puncture holes in bottom face are not repairable and therefore the frame rail should be replaced. Bolted-on repairs should use grade 8 bolts with hardened washers and nuts. Use proper torque when tightening nuts.
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_________________________________________
V-NOTCH CRACK
HELI-ARC WELD CRACK
STOP DRILL WITH 1/8-INCH (3MM) DRILL
GRIND WELD FLAT IF ADDING A REINFORCEMENT
6-S09-007
Figure 9-156: Crack Repair
Bends
1. Do not attempt to repair a bend when: Buckling to a height of 1/4-inch (6 mm) on any one face of the frame rail is involved. The bending also includes more than minor twisting. The frame rail is bent in two directions. The bending involves a collapse of one or more faces of the frame rail at a suspension or body attachment point.
________________________________________
9-69
Straightening
1. When performing straightening repairs with the frame on the vehicle: Use spreader plates or wood blocking to distribute chain force to avoid damage to frame box section. Be sure to loosen sufficient length of frame to allow frame force points to move without causing other damage. Restrain vehicle movement in both directions along line of force application. 2. 3. 4. Vertical bends, except at end sections, require removal of frame rail from vehicle. Application of bulk heating to frame components is not authorized, metal properties will be irreversibly degraded. At the conclusion of a bend repair, carefully inspect welds in the vicinity of repair and area of force application. Any evidence of cracking or chipping of welds must be repaired.
49.150-48.850 INCHES
MEASURE FROM CENTER OF BODY MOUNT BRACKET HOLES
72.304-72.124 INCHES
77.026-76.466 INCHES MEASURE FROM CENTER OF BODY MOUNT BRACKET HOLES 29.30-29.06 INCHES
MEASURE FROM OUTSIDE EDGE OF FRAME RAILS
Figure 9-157: Frame Dimensions
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_________________________________________
WINCH (OPTION) PRIOR TO VIN 186477 Winch Troubleshooting

Winch Inoperative
1. 2. Check for jammed winch cable. Check winch control cable connector for corrosion or loose connection. Clean corroded connector or secure loose connection. Check for loose or damaged winch power cables. Using voltmeter, connect positive meter lead to positive power cable (red) at the winch motor, and negative meter lead to the winch motor ground cables (black). If voltage is not present, repair or replace winch power cables. Disconnect winch control from winch. Using an ohmmeter, check for continuity between the common terminal and the other two terminals on winch control cable connector. Check for continuity one at a time, while holding control in the OUT position and IN position. If continuity is present in both positions, repair winch. If continuity is not present in both positions, replace winch control.
3.
Remove nut, lockwasher, capscrew, and clamp from right frame extension. Discard lockwasher. Pull winch cables through the splash shield to front of vehicle (Figure 9-159).
CLAMP
FRAME BRACKET
3.
4.
Winch Replacement
Removal
WARNING: To avoid personal injury or damage, support winch during removal.
1. 2. Disconnect battery ground cables (Section 12). Remove two battery cable bolts, battery cables, and winch cables from battery (Figure 9-158).
POSITIVE WINCH CABLE NEGATIVE WINCH CABLE BATTERY
POWER CABLES
Figure 9-159: Frame Bracket

4. Remove four nuts, washers, bolts, and winch from front bumper (Figure 9-160).
POSITIVE WINCH CABLE CLAMP WINCH NUT
CONTROL BOX COVER
BATTERY CABLE BOLTS
POSITIVE BATTERY CABLE
NEGATIVE BATTERY CABLE
FRONT BUMPER
Figure 9-158:
Winch Cables On Battery Figure 9-160:
NEGATIVE WINCH CABLE
Winch and Winch Cables
________________________________________

Winch Cable Replacement
9-71
5. 6.
Remove two bolts and clamps securing winch cables to winch. Remove three bolts and control box cover from winch.
WARNING: To avoid injury, wear gloves when handling winch cable.
NOTE: It may be necessary to remove plastic coating compound from winch in order to perform steps 7 and 8. 7. 8. Remove capscrew, washer, and negative winch cable from winch. Remove locknut and positive winch cable from winch. Discard locknut.
Removal
1. 2. 3. Unwind winch cable. Remove set screw and winch cable from drum assembly (Figure 9-161). Remove cotter pin, clevis pin and hook from winch cable. Discard cotter pin.
Installation
NOTE: Positive winch cable must be positioned to align with the opening in the control box cover. 1. 2. 3. 4. 5. 6. 7. 8. 9. Install positive winch cable on winch with locknut (Figure 9-160). Install negative winch cable on winch with washer and capscrew. Coat motor end of winch with coating compound. Install control box cover on winch with three bolts. Secure two winch cables to winch with two clamps and bolts. Install winch on front bumper with four washers, bolts, and nuts. Tighten bolts to 60 lb-ft (81 Nm). Route winch power cables through the splash shield. Install winch cables on frame bracket with clamp, capscrew, lockwasher, and nut (Figure 9-159). Connect battery ground cables (Section 12).
SET SCREW ROPE ANCHOR
WIRE ROPE ASSEMBLY
CLEVIS PIN
COTTER PIN HOOK
Figure 9-161: Winch Cable
Installation
1. 2. Install hook, clevis pin and cotter pin on winch cable. Install winch cable on drum assembly with set screw.
CAUTION: Install winch cable on drum under a load of at least 500 lb (227 kg), or outer wraps will draw into inner wraps and damage cable. NOTE: Spool winch cable according to rotation label on winch or brake will not function. 3. Rewind and lubricate winch cable.
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_________________________________________
Winch Assembly Repair

Disassembly
1. Remove winch and winch cable.
4. 5.
Remove clamps from motor. Mark motor end drum support, gear train assembly, and gear end drum support for assembly (Figure 9-164).
MOTOR (SHOWN WITHOUT CONTROL) SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY
NOTE: Tag leads for assembly. NOTE: It may be necessary to remove plastic coating from winch in order to perform steps 2 through 5. 2. Remove three nuts and control leads from motor (Figure 9-162).
DRUM SUPPORT LEAD CONTROL DRUM NUT DRUM SUPPORT MOTOR END
TIE ROD DRUM SUPPORT MOTOR END
GEAR TRAIN ASSEMBLY
CLAMP MOTOR
Figure 9-164: Drum Support and Gear Train Assembly

6. Remove six bolts, three tie rods, motor end and gear end drum supports from winch. 7. Remove motor, and motor end drum support from drum assembly. 8. Remove motor brake driver and spacer from motor shaft. 9. Remove drum assembly from gear train assembly (Figure 9-164). 10. Remove two nylon thrust washers from drum (Figure 9-165).
BRAKE ASSEMBLY SET SCREW BRAKE RETENTION NOT REMOVABLE
Figure 9-162:
3. Loosen clamp (Figure 9-163). and
Control Leads
remove control from motor
CLAMP
CONTROL
NYLON THRUST WASHER
TOLERANCE RING BEARING NYLON THRUST WASHER
DRUM MOTOR
Figure 9-163:
Control Unit
Figure 9-165: Thrust Washers and Brake
________________________________________
9-73
11. Loosen set screw that retains brake. 12. Push brake through open end of drum and remove (Figure 9-165). 13. Remove driveshaft from gear train assembly (Figure 9-166). 14. Turn gear train assembly over with gear end drum support down. Remove ten hex-head screws and gear housing from gear end drum support. 15. Remove gasket from gear end drum support. Discard gasket (Figure 9-166).
17. Remove clutch lever and O-ring seal from gear housing. Discard O-ring seal. 18. Remove two retaining rings from gear housing (Figure 9-167). NOTE: Intermediate ring gear comes out with 85 to 87 steel balls. Be sure to catch all 85 to 87 steel balls. 19. Remove intermediate ring gear and 85 to 87 steel balls from gear housing. 20. Remove input gear carrier assembly from gear housing (Figure 9-167). 21. Remove intermediate gear carrier and output gear carrier from output ring gear and gear end drum support (Figure 9-168) .
INTERMEDIATE GEAR CARRIER OUTPUT GEAR CARRIER
GEAR TRAIN ASSEMBLY
GASKET
GEAR END DRUM SUPPORT DRIVESHAFT
GEAR HOUSING OUTPUT RING GEAR
Figure 9-166:
Gear Train Assembly

GASKET GEAR END DRUM SUPPORT
16. Remove detent spacer, spring, and detent ball from gear housing (Figure 9-167).
RETAINING RINGS
CLUTCH LEVER
SPRING DETENT BALL DETENT SPACER
CLUTCH RING GEAR
O-RING
Figure 9-168:
Gear Carriers
INPUT CARRIER SUN GEAR GEAR HOUSING
STEEL BALLS
22. Remove output ring gear and gasket from gear end drum support.
Cleaning
CAUTION: To avoid damage to equipment, do not clean brake assembly. Clean and inspect all winch components. Replace defective parts.
Figure 9-167: Gear Housing
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_________________________________________
Inspection
1. Inspect drum for damage to splined end anges and tube (Figure 9-169). Replace winch if damaged.
DRUM SUPPORT MOTOR END DRUM GASKET DRIVE SHAFT OUTPUT GEAR CARRIER ASSEMBLY (THIRD STAGE) INPUT GEAR CARRIER ASSEMBLY (FIRST STAGE) SUN GEAR
THRUST WASHER THRUST WASHER DRUM SUPPORT GEAR END OUTPUT RING GEAR
INTERMEDIATE GEAR CARRIER ASSEMBLY (SECOND STAGE)
GEAR HOUSING
Figure 9-170: Gear Carriers 8. 9. Inspect brake assembly for damage (Figure 9-171). Inspect motor, spline, mating surface, and terminals for damage. Replace motor if damaged (Figure 9-171).
COVER LEADS BALL BEARING DRUM SUPPORT
Figure 9-169: Drum Assembly and Gear Housing Assembly 2. 3. 4. Inspect gear end and motor end drum supports for damage. Replace if damaged. Inspect gear housing for damage. Replace if damaged. Inspect thrust plate for damage or wear. Replace if damaged or worn. Apply grease on thrust plate for assembly. Inspect clutch lever and driveshaft for damage. Replace if damaged. Inspect gear teeth and machined surfaces of intermediate ring gear for damage. Replace if damaged. Inspect gear teeth, splines, and machined surfaces of output ring gear, output gear carrier, intermediate gear carrier, and input gear carrier assembly for damage. Replace any damaged parts (Figure 9-170).
5. 6. 7.
SPACER
SPLINE CONTROL
MOTOR
CLAMP
Figure 9-171: Motor and Control Unit 10. Inspect cover for damage. Replace if damaged. 11. Inspect control for damaged leads, breaks in plastic coating, and damaged mounting base. Replace control if damaged or repair plastic coating.
3-1-01
________________________________________

8. 9. 10. 11.
9-75
Assembly
1. Position 85 to 87 steel balls in groove of intermediate ring gear and install intermediate ring gear in gear housing (Figure 9-172).
DETENT SPACER DETENT BALL RETAINING RING
Install gasket and output ring gear on gear housing. Install intermediate gear carrier on gear housing. Install output gear carrier on intermediate gear carrier. Install gasket on output ring gear (Figure 9-174).
GEAR TRAIN ASSEMBLY GASKET DRIVE SHAFT
CLUTCH LEVER
O- RING SEAL STEEL BALLS
SPRING
GEAR END DRUM SUPPORT
CLUTCH RING GEAR GEAR HOUSING OUTPUT RING GEAR GEAR HOUSING
Figure 9-172: Intermediate Ring Gear and Gear Housing

2. 3. 4. 5. 6. Install retaining rings in gear housing. Apply light oil to steel balls through the clutch lever hole. Apply grease to clutch lever hole and install O-ring seal and clutch lever in gear housing. Install detent ball, spring, and detent spacer in gear housing. Apply aircraft grease to output gear carrier, intermediate gear carrier, and input gear carrier assembly (Figure 9-173).
OUTPUT RING GEAR GASKET INPUT GEAR CARRIER ASSEMBLY
Figure 9-174: Gear Train Assembly

NOTE: Ensure spline on drum support engages in output ring gear. 12. Install gear end drum support on output ring gear and gear housing. 13. Secure gear housing assembly to drum support with ten hex-head screws. Tighten hex-head screws to 100 lb-in. (11 Nm). 14. Turn gear train assembly over with drum support facing up. 15. Install driveshaft in gear train assembly (Figure 9-174). 16. Apply grease to drum bushings, seals, and output spline (Figure 9-175).
BRAKE ASSEMBLY SET SCREW BRAKE RETENSION NOT REMOVABLE
OUTPUT GEAR CARRIER
SUN GEAR THRUST WASHER GEAR HOUSING
INTERMEDIATE GEAR CARRIER
NYLON THRUST WASHER
TOLERANCE RING BEARING NYLON THRUST WASHER
Figure 9-173: Gear Carriers

7. Install input gear carrier assembly in gear housing.
DRUM
NOTE: Be sure ring gear engages in gear housing. 05745159
Figure 9-175:
Thrust Washers and Brakes
9-76
_________________________________________
17. With drum horizontal, install brake into drum. 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 Nm) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline (Figure 9-176).
CLAMP
CONTROL
MOTOR, 12 VDC SHOWN WITHOUT CONTROL
SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY
DRUM SUPPORT MOTOR END
MOTOR
Figure 9-177: Control Unit and Motor

25. Connect three control leads to terminals and secure with nuts (Figure 9-178). 26. Secure control to motor with clamp. 27. Re-coat motor end of winch (including all leads and terminals) with PlastiDip Coating or equivalent waterproofing compound. 28. Install winch assembly and winch cable.
DRUM
Winch Electric Thermal Switch/Brush Assembly Replacement

GEAR TRAIN ASSEMBLY
Removal
Figure 9-176:
Drum Assembly and Gear Train Assembly
NOTE: Tag leads for assembly. NOTE: It may be necessary to remove plastic coating from winch in order to perform steps 2 through 5. 2. 3. Remove three nuts and control leads from motor (Figure 9-178). Loosen clamp and remove control from motor (Figure 9-179).
21. Install brake drive and spacer to motor shaft. 22. Install motor end drum support on drum assembly. 23. Install motor on motor end drum support, ensuring to engage brake drive with brake shaft end. 24. Install three tie rods between drum supports and secure with six bolts. Tighten bolts to 18 lb-ft (24 Nm). NOTE: If motor or control have been pre-coated with sealing compound, remove compound from between motor case and control mounting gear contact area. Failure to do so may cause improper grounding of control.
________________________________________

9.
9-77
DRUM SUPPORT NUT
CONTROL LEADS
Remove nut, lockwasher, washer, and insulator securing brush assembly power stud to motor housing. Discard lockwasher. 10. Remove three nuts, screws, and brush assembly from motor housing. 11. Remove spacer, insulator, and washer from brush assembly power stud.
MOTOR HOUSING ELECTRIC THERMAL SWITCH LEADS ELECTRIC THERMAL SWITCH
CLAMP MOTOR TERMINALS SPACER
Figure 9-178: Control Leads

BOLT ASSEMBLY DRUM SUPPORT BALL BEARING CONTROL REAR COVER
Figure 9-180:
Motor and Gasket
Installation
NOTE: Do not apply coating to any electrical contacts of the armature assembly. Perform steps 1 through 5 only if replacing brush assembly. 1. 2. Install washer, insulator, and spacer on brush assembly power stud (Figure 9-181). Install brush assembly in motor housing with three screws and nuts
ARMATURE ASSEMBLY
SPACER
.
CLAMP MOTOR
SPACER

4. 5. 6. Remove clamp from motor. Place winch on end with motor end up (Figure 9-180). Remove two bolt assemblies and rear cover from motor housing.
BRUSH ASSEMBLY POWER STUD
NOTE: Perform steps 7 through 11 only if replacing brush assembly. 7. 8. Remove electric thermal switch from two electric thermal switch leads. Remove motor housing from drum support and armature assembly from brush assembly (Figure 9-181).
BRUSH ASSEMBLY
MOTOR HOUSING
Figure 9-181:
Brush Assembly and Armature Assembly
05745159
9-78
3. 4. 5.
_________________________________________
6. 7. 8.
Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Coat armature shaft with lubricant and install in brush assembly. Coat head of electric thermal switch with lubricant and connect to two electric thermal switch leads (Figure 9-180). Position spacer over bearing on drum support, and install rear cover on motor housing. Install motor on drum support ensuring to engage motor shaft into brake drum. Secure motor to motor end drum support with two bolt assemblies. Tighten hex-head bolt to 60-70 lb-in. (7-8 Nm) (Figure 9-182).
CONTROL MOTOR
Winch Roller Fairlead (Option) Replacement

The winch roller fairlead provides greater functional versatility. The winch cable can be routed at much sharper angles since the fairlead rollers will keep it from binding on the bumper edges.
Removal
WARNING: To avoid injury or damage, support winch during removal.
1. 2. Remove the cotter pin, hook retainer pin and hook from the winch cable. Remove washers, bolts, and the roller fairlead from the front bumper (Figure 9-183).
FAIRLEAD
HOOK PIN
MOTOR END DRUM SUPPORT
CLAMP WASHER COTTER PIN FRONT BUMPER

NOTE: If motor or control have been pre-coated with sealing compound, remove compound from between motor and control mounting gear contact area. Failure to do so may cause improper grounding or control. 9. Install clamp on motor. 10. Install control on motor. 11. Connect three control leads to terminals and secure with nuts (Figure 9-178). 12. Secure control to motor with clamp. 13. Re-coat motor end of winch (including all leads and terminals) with PlastiDip Coating or equivalent waterproofing compound. 14. Install winch assembly and winch cable. 1. 2.
Figure 9-183: Winch Fairlead
Installation
Install the fairlead on the front bumper with washers and bolts. Tighten bolts to 60 lb-ft (81 Nm) (Figure 9-183). Install the hook, the hook retainer pin and the cotter pin on the winch cable.
________________________________________

Winch Replacement
Removal
9-79
WINCH (OPTION) VIN 186477 AND LATER

NOTE: Individual parts may not be available for some of the following repair procedures. Assemblies must be used in place of individual parts. Check for parts availability before disassembly.

Winch Troubleshooting
Winch Inoperative
1. 2. Check for jammed winch cable. Check winch control cable connector for corrosion or loose connection. Clean corroded connector or secure loose connection. Check for loose or damaged winch power cables. Using voltmeter, connect positive meter lead to positive power cable (red) at the winch motor, and negative meter lead to the winch motor ground cables (black). If voltage is not present, repair or replace winch power cables. Disconnect winch control from winch. Using an ohmmeter, check for continuity between the common terminal and the other two terminals on winch control cable connector. Check for continuity one at a time, while holding control in the OUT position and the IN position. If continuity is present in both positions, repair winch. If continuity is not present in both positions, replace winch control.
BATTERY CABLE BOLTS
3.
4.
Figure 9-184:
3.
Winch Cables On Battery
CLAMP
FRAME BRACKET
POWER CABLES
05745159
9-80
4.
_________________________________________
Remove four nuts, washers, bolts, and winch from front bumper (Figure 9-186).
POSITIVE WINCH CABLE CLAMP WINCH

CONTROL BOX COVER
Removal
1. 2. Unwind winch cable. Remove set screw and winch cable/hook assembly from drum assembly (Figure 9-187).
SET SCREW CABLE ANCHOR
FRONT BUMPER
CABLE/HOOK ASSEMBLY
Figure 9-186:
5. 6. 7. 8.
Remove two bolts and clamps securing winch cables to winch. Remove bolt and control box cover from winch. Remove capscrew, washer, and negative winch cable from winch. Remove bolt and positive winch cable from winch.
Installation
3. Install winch cable/hook assembly on drum assembly with set screw.
Installation
1. 2. 3. 4. 5. 6. 7. 8. 9. Install positive winch cable on winch with bolt (Figure 9-186). Install negative winch cable on winch with washer and capscrew. Coat motor end of winch with coating compound. Install control box cover on winch with bolt. Secure two winch cables to winch with two clamps and bolts. Install winch on front bumper with four washers, bolts, and nuts. Tighten bolts to 60 lb-ft (81 Nm). Route winch power cables through the splash shield. Install winch cables on frame bracket with clamp, capscrew, lockwasher, and nut (Figure 9-185). Connect battery ground cables (Section 12).
________________________________________

4. 5.
9-81

Disassembly
MOTOR (SHOWN WITHOUT CONTROL)
NOTE: Tag leads for assembly. 2. Remove three nuts and control leads from motor (Figure 9-188).
SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY
DRUM SUPPORT CONTROL
DRUM NUT
TIE ROD DRUM SUPPORT GEAR END

00-S13-005
GEAR TRAIN ASSEMBLY
LEAD MOTOR
Figure 9-190: Drum Support and Gear Train Assembly Control Leads
6. from motor Remove six bolts, three tie rods and gear end drum support from winch. 7. Remove motor, and motor end drum support from drum assembly. 8. Remove motor brake driver and spacer from motor shaft. 9. Remove drum assembly from gear train assembly (Figure 9-190). 10. Remove two nylon thrust washers from drum (Figure 9-191).
SET SCREW BRAKE RETENTION NOT REMOVABLE BRAKE ASSEMBLY BRAKE DRIVER
Figure 9-188:
3. Loosen clamps (Figure 9-189). and
remove
control
CLAMP
CONTROL
NYLON THRUST WASHER SPACER NYLON THRUST WASHER

00-S13-006
MOTOR
Figure 9-189:
Control Unit
DRUM

05745159
9-82
_________________________________________
GEAR TRAIN ASSEMBLY
18. Remove two retaining (Figure 9-193).
rings
from
gear
housing
NOTE: Intermediate ring gear comes out with 85 to 87 steel balls. Be sure to catch all 85 to 87 steel balls. 19. Remove intermediate ring gear and 85 to 87 steel balls from gear housing. 20. Remove input and intermediate gear carrier assembly from gear housing (Figure 9-193). 21. Remove and output gear carrier from output ring gear and gear end drum support (Figure 9-194)
.
GASKET GASKET OUTPUT RING GEAR
DRIVESHAFT
GEAR HOUSING
Figure 9-192:
Gear Train Assembly
RETAINING RINGS
Figure 9-194:
Gear Carriers
INTERMEDIATE RING INPUT GEAR CARRIER INTERMEDIATE GEAR CARRIER SUN GEAR
Cleaning
DETENT SPACER SPRING DETENT BALL GEAR HOUSING O-RING
STEEL BALLS
CLUTCH LEVER

17. Remove clutch lever and O-ring seal from gear housing. Discard O-ring seal.
________________________________________

OUTPUT GEAR CARRIER ASSEMBLY (THIRD STAGE)
9-83
Inspection
INPUT GEAR CARRIER ASSEMBLY (FIRST STAGE)
THRUST WASHER DRIVE SHAFT DRUM THRUST WASHER DRUM SUPPORT GEAR END SUN GEAR INTERMEDIATE GEAR CARRIER ASSEMBLY (SECOND STAGE)
OUTPUT RING GEAR
GASKET GEAR HOUSING
Figure 9-196: Gear Carriers 8. 9. Inspect brake assembly for damage (Figure 9-201). Inspect motor, spline, mating surface, and terminals for damage. Replace motor if damaged (Figure 9-197).
CLAMP
Figure 9-195: Drum Assembly and Gear Housing Assembly 2. 3. 4. Inspect gear end and motor end drum supports for damage. Replace if damaged. Inspect gear housing for damage. Replace if damaged. Inspect thrust plate for damage or wear. Replace if damaged or worn. Apply grease on thrust plate for assembly. Inspect clutch lever and driveshaft for damage. Replace if damaged. Inspect gear teeth and machined surfaces of intermediate ring gear for damage. Replace if damaged. Inspect gear teeth, splines, and machined surfaces of output ring gear, output gear carrier, intermediate gear carrier, and input gear carrier assembly for damage. Replace any damaged parts (Figure 9-196).
COVER
5. 6. 7.
DRUM SUPPORT
LEAD
CONTROL
00-S13-007
SPLINE SPACER MOTOR
Figure 9-197: Motor and Control Unit 10. Inspect cover for damage. Replace if damaged. 11. Inspect control for damaged leads and damaged mounting base. Replace control if damaged.
05745159
3-1-01
9-84
_________________________________________
Assembly
INTERMEDIATE RING GEAR RETAINING RING
NOTE: Be sure ring gear engages in gear housing. 8. 9. 10. 11. Install gasket and output ring gear on gear housing. Install intermediate gear carrier on gear housing. Install output gear carrier on intermediate gear carrier. Install gasket on output ring gear (Figure 9-174).
GEAR TRAIN ASSEMBLY GASKET
GEAR HOUSING STEEL BALLS DETENT SPACER SPRING DETENT BALL O- RING SEAL CLUTCH LEVER GEAR HOUSING
DRIVE SHAFT

OUTPUT RING GEAR GASKET INPUT GEAR CARRIER ASSEMBLY SUN GEAR OUTPUT GEAR CARRIER
OUTPUT RING GEAR

NOTE: Ensure spline on drum support engages in output ring gear. 12. Install gear end drum support on output ring gear and gear housing. 13. Secure gear housing assembly to drum support with ten socket-head cap screws. Tighten hex-head screws to 100 lb-in. (11 Nm). 14. Turn gear train assembly over with drum support facing up. 15. Install driveshaft in gear train assembly (Figure 9-200). 16. Apply grease to drum bushings, seals, and output spline.
BRAKE ASSEMBLY SET SCREW BRAKE RETENSION NOT REMOVABLE NYLON THRUST WASHER
GEAR HOUSING
TOLERANCE RING NYLON THRUST WASHER

DRUM
Figure 9-201:
________________________________________
9-85
CLAMP
17. With drum horizontal, install brake into drum (Figure 9-201). 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 Nm) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline (Figure 9-202).
MOTOR, 12 VDC SHOWN WITHOUT CONTROL SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY DRUM SUPPORT MOTOR END
CONTROL
MOTOR
00-S13-006

DRUM
25. Connect three control leads to terminals and secure with nuts (Figure 9-204). 26. Secure control to motor with clamps (Figure 9-203). 27. Install winch assembly and winch cable.
TIE ROD DRUM SUPPORT MOTOR END GEAR TRAIN ASSEMBLY

Removal
NOTE: Tag leads for assembly. 2. 3. Remove three nuts and control leads from motor (Figure 9-204). Loosen clamps and remove control from motor (Figure 9-205).
Figure 9-202:
21. Install brake drive and spacer to motor shaft. 22. Install motor end drum support on drum assembly. 23. Install motor on motor end drum support, ensuring to engage brake drive with brake shaft end. 24. Install three tie rods between drum supports and secure with six bolts. Tighten bolts to 18 lb-ft (24 Nm).
05745159
9-86

DRUM SUPPORT
_________________________________________
9.
CONTROL
NUT MOTOR HOUSING ELECTRIC THERMAL SWITCH LEADS ELECTRIC THERMAL SWITCH
CLAMP
00-S13-005
MOTOR
CONTROL TERMINAL LEAD
SPACER

CLAMP DRUM SUPPORT BOLT ASSEMBLY REAR COVER
Figure 9-206:
Motor and Gasket
Installation
NOTE: Do not apply coating to any electrical contacts of the armature assembly. Perform steps 1 through 5 only if replacing brush assembly. 1.
CONTROL
2.
.
Install washer, insulator, and spacer on brush assembly power stud (Figure 9-207). Install brush assembly in motor housing with three screws and nuts
ARMATURE ASSEMBLY
00-S13-009
SPACER MOTOR
SPACER

4. 5. 6. Remove clamps from motor. Place winch on end with motor end up (Figure 9-208). Remove two bolt assemblies and rear cover from motor housing.
BRUSH ASSEMBLY
MOTOR HOUSING
Figure 9-207:
________________________________________

9-87
3. 4. 5.
6. 7. 8.
Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Coat armature shaft with lubricant and install in brush assembly. Coat head of electric thermal switch with lubricant and connect to two electric thermal switch leads (Figure 9-206). Position spacer in drum support, and install rear cover on motor housing. Install motor on drum support ensuring to engage motor shaft into brake drum. Secure motor to motor end drum support with two bolt assemblies. Tighten hex-head bolt to 60-70 lb-in. (7-8 Nm) (Figure 9-208).
Removal
1. 2. 3. Remove circlips on one vertical and one horizontal roller. Remove one vertical and one horizontal roller. Remove washers, bolts, and the roller fairlead from the front bumper (Figure 9-209).
FAIRLEAD
CLAMP
MOTOR
CONTROL
WASHER
00-S13-008
MOTOR END DRUM SUPPORT
FRONT BUMPER

9. Install clamps on motor. 10. Install control on motor. 11. Connect three control leads to terminals and secure with nuts (Figure 9-204). 12. Secure control to motor with clamps. 13. Install winch assembly and winch cable.
Installation
1. Place the winch cable and hook assembly through the roller fairlead and install the fairlead on the front bumper with washers and bolts. Tighten bolts to 60 lb-ft (81 Nm) (Figure 9-209). Install the horizontal and vertical rollers and circlips.
2.
05745159
9-88
_________________________________________
ESSENTIAL TOOLS
J24319-B J8092
J8001
J29162
J44905
J8614-O1
J42545
TOOL J8092 J24319-B J8001 J29162 J44905 J8614-O1 J42545 J44906 J38869 J35910 J42546 J42547 J42591 Procure from Kent-Moore.
DESCRIPTION Universal Driver Handle Steering Linkage and Tie Rod Puller Dial Indicator Rear Retainer Seal Installer Input Seal Installer Yoke Holding Tool (includes J8614-5 bolt kit) Clampnut Socket Spindle Seal Installer (not shown) Seal Installer (not shown) Axle Boot Crimping Tool (not shown) 1/4 in. Drive Torque Wrench (Preset) (not shown) 3/8 in. Drive Torque Wrench (Preset) (not shown) Steering Cover Seal Installer (not shown)
3-1-01
________________________________________
9-89
SPECIAL TOOLS
J33142
J21786
J21787
J8611-01
J29162
J8608
J39524 J24385-01
J35237
J22610
J3409-01
PART OF J3409-01
TOOL J33142 J21786 J21787 J8611-01 J29162 J8608 J39524 J24385-01 J35237 J3409-01 Part of J3409-01 J22610 Procure from Kent-Moore. Axle Shaft and Seal Installer Pinion Rear Bearing Cup Remover Pinion Front Bearing Cup Remover Rear Pinion Bearing Race Installer Rear Retaining Seal Installer Rear Pinion Bearing Race Installer Pinion Depth Gauge Set Axle Housing Spreader Bearing Installer Stand, with Holding Fixtures Axle Holding Fixture Adapter Keystone Clamp Pliers
DESCRIPTION
05745159
9-90
_________________________________________
_______________________________________________________________________________
10-1
Section 10
Body
TABLE OF CONTENTS
Horn Horn Assembly Replacement . . . . . . . . . . . . . . . . . . . . . 10-53 Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . 10-53 Instrument Panel Dashpad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Gauges and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Indicator Lamp Replacement . . . . . . . . . . . . . . . . . . . . . 10-16 Instrument Panel Replacement . . . . . . . . . . . . . . . . . . . . 10-14 Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Interior Trim B-Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Drivers Compartment Trim Replacement . . . . . . . . . . . 10-28 Floor Carpeting and Padding Replacement . . . . . . . . . . 10-34 Inner Kick Panels Replacement . . . . . . . . . . . . . . . . . . . 10-32 Outer Kick Panel Replacement . . . . . . . . . . . . . . . . . . . . 10-33 Passengers Compartment Trim . . . . . . . . . . . . . . . . . . . 10-26 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Station Wagon Rear Compartment Trim . . . . . . . . . . . . 10-30 Four-Passenger Soft Top . . . . . . . . . . . . . . . . . . . . . . . . . 10-65 License Plate Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 Lift Gate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 Lights Backup Light Switch Replacement . . . . . . . . . . . . . . . . . 10-86 Front Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85 Interior and Exterior Lighting . . . . . . . . . . . . . . . . . . . . . 10-78 Backup Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84 Cargo Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84 Domelight Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-82 Front Turn Signal Light Replacement . . . . . . . . . . . . 10-80 Identification Light Replacement . . . . . . . . . . . . . . . . 10-79 Maplight Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10-83 Optional Trouble Light Replacement . . . . . . . . . . . . . 10-84 Rear Turn Signal Light Replacement . . . . . . . . . . . . . 10-81 Service Headlight Assembly . . . . . . . . . . . . . . . . . . . 10-78 Service Headlight Electrical Connector and Grommet Replacement . . . . . . . . . . . . . . . . . . . . . . 10-85 Side Marker Light Assembly . . . . . . . . . . . . . . . . . . . 10-79 Side Marker Light Lens and Lamp . . . . . . . . . . . . . . . 10-79 Underhood Light Replacement . . . . . . . . . . . . . . . . . 10-84 Rear Seat Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . 10-83 Stoplight Switch Replacement . . . . . . . . . . . . . . . . . . . . 10-86 Load Barrier and Mounting Brackets . . . . . . . . . . . . . . . . . . . 10-25 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Lighted Visor Mirror Replacement . . . . . . . . . . . . . . . . . 10-84 Power Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Rearview Mirror Replacement . . . . . . . . . . . . . . . . . . . . . 10-36 Side Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Airlift to Hood Seal Replacement . . . . . . . . . . . . . . . . . . . . . . .10-51 Armrest Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Ashtray Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20 Body Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Aluminum Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Fiberglass Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11 Lockbolt Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Rivet Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Rivet Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Body Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61 Cargo Tiedown Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .10-72 Center Console Replacement . . . . . . . . . . . . . . . . . . . . . . . . .10-13 Cigarette Lighter Replacement . . . . . . . . . . . . . . . . . . . . . . . .10-19 Dimmer Control Switch Replacement . . . . . . . . . . . . . . . . . . .10-17 Door Glass Wind Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-43 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41 Door Stop Strap Assembly Replacement . . . . . . . . . . . . . . . .10-41 Doors Disassembly, Replacement and Repair . . . . . . . . . . . . .10-36 Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41 Door Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . .10-41 Rear Vertical Door Replacement . . . . . . . . . . . . . . . . . . .10-74 Engine Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20 Hold-Down Striker Replacement . . . . . . . . . . . . . . . . . . .10-20 Inner Flexible Latch Replacement . . . . . . . . . . . . . . . . . .10-20 Engine Access Cover Maintenance . . . . . . . . . . . . . . . . . . . . .10-20 Former Assembly Replacement, A Pillar . . . . . . . . . . . . . . .10-60 Front Console Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .10-13 Front License Plate Bracket Replacement . . . . . . . . . . . . . . .10-62 Front Striker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61 Fuel Filler Housing Replacement . . . . . . . . . . . . . . . . . . . . . .10-63 General Body Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 Glovebox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19 Hood Center Hood Stop Replacement . . . . . . . . . . . . . . . . . . .10-49 Front Hood Screen Replacement . . . . . . . . . . . . . . . . . .10-50 Grille and Screen Replacement . . . . . . . . . . . . . . . . . . . .10-49 Guide Bracket Assembly Replacement . . . . . . . . . . . . .10-50 Hood and Hinge Replacement . . . . . . . . . . . . . . . . . . . . .10-47 Hood Latch And Prop Rod . . . . . . . . . . . . . . . . . . . . . . . .10-43 Hood Prop Rod and Bracket Replacement . . . . . . . . . . .10-45 Hood Release Cable Replacement . . . . . . . . . . . . . . . . .10-44 Hood Retainer Bracket, L . . . . . . . . . . . . . . . . . . . . . . . . .10-50 Hood Retainer Bracket, R . . . . . . . . . . . . . . . . . . . . . . . . .10-50 Latch and Bracket Replacement . . . . . . . . . . . . . . . . . . .10-43 Outer Hood Seal Replacement . . . . . . . . . . . . . . . . . . . . .10-48 Right Close-Out Seal and Retainer . . . . . . . . . . . . . . . . .10-51 Side Hood Stop Replacement . . . . . . . . . . . . . . . . . . . . .10-49 05745159
10-2
Body _______________________________________________________________________
Rear License Plate Bracket Replacement . . . . . . . . . . . . . . . .10-62 Rear Striker Assembly Replacement. . . . . . . . . . . . . . . . . . . .10-61 Rear Support Bow Bracket, Station Wagon . . . . . . . . . . . . . .10-61 Rear Vertical Door Door Frame and Seal Replacement . . . . . . . . . . . . . . . . .10-77 Door Handle Replacement . . . . . . . . . . . . . . . . . . . . . . . .10-75 Door Latch and Latch Rod Replacement . . . . . . . . . . . .10-75 Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74 Door Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .10-77 Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74 Roadside Emergency Equipment . . . . . . . . . . . . . . . . . . . . . .10-64 Seat Belts Seat Belt Assembly Replacement . . . . . . . . . . . . . . . . . .10-22 Seats Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23 Reclining Seat Replacement . . . . . . . . . . . . . . . . . . . . . .10-24 Standard Seat Pedestal Repair . . . . . . . . . . . . . . . . . . . .10-23 Slant Back Glass and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91 Slant Door and Torsion Assembly Replacement . . . . . .10-87 Slant Door Handle, Latch, And Lock Actuator . . . . . . . .10-88 Wiper Motor and Components . . . . . . . . . . . . . . . . . . . . .10-90 Soft Top Mounting Components and Accessories . . . . . . . . . . . .10-67 Soft Top Support/Roll Cage Assembly . . . . . . . . . . . . . .10-71
Speedometer/Odometer Replacement . . . . . . . . . . . . . . . . . . 10-17 Splash Shield (Engine) Replacement . . . . . . . . . . . . . . . . . . . 10-52 Tachometer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Tailgate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Chain Brackets Replacement . . . . . . . . . . . . . . . . . . . . . 10-72 Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 Tailgate and Seals Replacement . . . . . . . . . . . . . . . . . . . 10-72 Tire Jack Jack and Triangle Warning Kit Hold-Down Bracket Replacement . . . . . . . . . . . . . . . . 10-64 Visor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Water Leak Detection and Repair . . . . . . . . . . . . . . . . . . . . . . 10-12 Windshield Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 Glass and Weatherstrip Replacement . . . . . . . . . . . . . . 10-53 Heated Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55 Reservoir and Pump Assembly . . . . . . . . . . . . . . . . . . . . 10-58 Washer Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . 10-58 Washer Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . 10-58 Washer System and Components . . . . . . . . . . . . . . . . . 10-58 Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 Wiper Jumper Harness Replacement . . . . . . . . . . . . . . . 10-58 Wiper Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . 10-57 Wiper Motor Assembly Replacement . . . . . . . . . . . . . . . 10-56 Wiper Pivot Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10-57 Wiper System and Components . . . . . . . . . . . . . . . . . . . 10-56
GENERAL BODY INFORMATION

1. The HUMMER body is constructed from high strength T6 aluminum. Welding should not be performed to make body repairs. Heat generated by welding will reverse the tempering process, causing a reduction in material strength. The hood and engine access covers are made of fiberglass (sheet molding compound). Cracks, splits, or holes may be repaired with a glass-reinforced plastic laminate. Solid 0.1875 in. (4.8 mm) diameter aluminum rivets are the primary method of joining body components. Each rivet is inserted into a hole through two pieces of metal, and a second head is formed by manual or pneumatic impacting, or by squeezing the rivet. When making repairs, use blind rivets of the same size, or oversize, with the appropriate grip length. Blind structural aluminum rivets of 0.1875 in. (4.8 mm) diameter are used in applications where there is access from only one side of the part. Blind rivets are installed using a tool that pulls on the rivet stem causing a bulbed head to form on the back side of the part. Fastening is complete when stem breaks off. High strength is obtained in blind rivets by mechanically locking the remaining stem inside the rivet body. 5. Steel pull-type lockbolt fasteners of 0.1875 in. (4.8 mm) and 0.25 in. (6.4 mm) diameters are used where tension or high-shear loads exist. Lockbolts are two-piece unthreaded fasteners. One part is a high-strength, steelheaded, bolt-like part with serrations on its shank. The mating part is a collar which is swagged over the serrations causing the fastener to be locked in place. To facilitate body repairs, it is acceptable to replace lockbolt fasteners and rivets with 0.25 in. (6.4 mm) series bolts. Do not replace lockbolt fasteners with rivets. Standard threaded fasteners should not be used, as these will quickly wear the aluminum structure. Bolt lengths should be chosen so that the cylinder portion of bolt is bearing on all members being joined. Bolts are designed as AN4-XX or AN4-C-XX, where XX defines grip length. Tighten all bolts to 71 lb in. (8 Nm). Fatigue strength of riveted joints and seams is increased by epoxy adhesive application. Epoxy adhesive requires special material storage and metal preparation along with a low temperature heat cycle for curing. Where possible, extra rivets and thicker metal gauges should be used instead of adhesives when making repairs. Parts may be difficult to separate, even after rivets are removed.
2.
3.
6.
4.
7.
4-1-00
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Body
10-3
BODY INSPECTION AND REPAIR General Information

Damaged areas should be thoroughly cleaned and inspected to determine the cause and extent of damage. Body parts should be inspected for holes, cracks, dents, distortion, or breaks. Fasteners should be inspected for breaks, stretching, looseness, cracked heads, or hole elongation. Seams, flanges, and joints should be inspected for straightness or local deformation as an indication that fasteners may have been stretched or holes elongated. It is possible for this to happen and fasteners will still appear to be tight in their holes. In addition, thoroughly inspect adjacent areas to determine if high loads have been transmitted from the damaged area to other areas. This can result in secondary damage in the form of distorted panels or seams, loosened or sheared fasteners, elongated fastener holes, and/or cracks.
Non-negligible damage must be repaired; or the section must be replaced. Patches can often be applied over damaged body panels, provided the damaged area is first trimmed to remove sharp edges or notches which could cause the start of new cracks. The patch must then be sized to overlap the area to allow for attaching rivets. 3. Damage Repairable by Insertion. In certain cases, patch repairs may not be desirable because of impracticality or because a flush surface is desired. In this case, the damaged area must be cut away and replaced with equivalent material inserted flush with adjacent areas, and backed up with a doubler. 4. Damage requiring replacement of parts. Parts too badly damaged for repair, or cases where replacement is easier than repair, fall into this category. Repair of welded assemblies such as body mounts are also included. Welded assemblies cannot be rewelded without destroying the strength of the part, and must be replaced.
Classication
After the extent of damage has been determined, affected parts should be classified into one of the following categories: Negligible damage Damage repairable by patching Damage repairable by insertion Damage necessitating replacement of parts 1. Negligible damage. Minor dents, nicks, scores, cracks, and holes in a body panel which are within, or are brought within, reasonable limits by a simple procedure without extensive rework are considered negligible damage. These defects should be considered more serious if located in main structural members such as frame rails, A-pillars, or floor crossmembers rather than in body panels such as cowls or rear wheelhouses. Deep wrinkles of undetermined origin in body panels should not be classed as negligible until the source of the wrinkles has been investigated and positively identified. Damage other than small dents, holes, nicks, and scratches will require repair or replacement of the part. Negligible Cracks. Isolated cracks less than 0.50 in. (1.27 cm) long may be classified as negligible cracks provided they are stop drilled at each end to stop propagation. Negligible Holes. Isolated holes no more than 0.50 in. (1.27 cm) in diameter (after they are made round with smooth edges) are classified as negligible holes, provided the distance from the edge of the holes to the nearest line of rivets exceeds the diameter of the hole. Negligible Dents and Distortion. Small dents and distorted areas may be classed as negligible if they can be repaired by hammering or bending without causing the material to crack. Heat will not be used for reforming. 2. Damage repairable by patching. 05745159
Rivet Failure
Signs of rivet failure include tipped heads, looseness, and sometimes chipped or cracked paint. If heads are tipped in the same direction and rivets are loose in consecutive groups, the joint has undergone excessive load. Rivet heads which are tipped in different directions and are not in groups may be improperly installed. With chipped or cracked paint, it may be necessary to remove paint to check the true condition of rivets. Rivets subjected to critical loads, but showing no distortion should be inspected if failure is suspected. The head should be drilled off, and the shank should be carefully punched out. Failure is indicated by notched rivet shanks and misaligned holes. Flush rivets showing head slippage within the dimple or countersink indicate either sheet bearing or rivet shear failure, and must be removed for replacement. If rivet failure cannot be detected by visual inspection, the joint can be checked by drilling and punching out several rivets. If rivet shanks are notched, rivets should be replaced with the next larger size rivets. If rivet holes show elongation due to local failure in tearing of the sheet, the next larger size rivet must be used in replacement. Any deformation of the sheet around the rivet, tear outs, or cracks between rivets usually indicates partially failed or damaged rivets. Complete repair of the joint will require replacement by the next larger size rivets. Use the next 0.031 in. (0.79 mm) larger diameter rivet to obtain a tight joint when original hole has been enlarged. If original size rivet is installed, the rivet will not be able to carry its share of the shear load, and the joint will not meet its strength requirements.
10-4
Body _______________________________________________________________________
Lockbolt Fastener Failure

Lockbolts are used to withstand tension loads and high-shear loads. These fasteners are installed in their holes with an interference fit. No looseness can be permitted. Lockbolts showing evidence of being stretched, broken, loose in their holes, or having heads that do not set flat against the surface must be replaced. Guidelines used for detecting rivet failures also apply to lockbolts.
Blind Rivet Removal

1. 2. 3. 4. 5. 6. 7. 8. File a small, at surface on rivet head. Center punch the flat surface. Support the back side of the rivet, if possible. Using a small drill bit about the size of rivet pin, drill off tapered end of pin which forms the lock. Shear lock, using pin punch to drive out pin. Pry out remainder of locking collar. Using a drill bit slightly smaller than rivet shank, drill almost through rivet head. Pry off rivet head with pin punch. Tap out rivet shank with pin punch.
Lockbolt Removal
1. 2. 3. Working from head side of lockbolt, if accessible, le a small at surface on head, if rounded. Center punch the head. Using a hardened drill bit slightly smaller than lockbolt, drill through the head. In cases where lockbolts are too hard to be drilled with available drills, grind the head down using a cutoff wheel or carbide bit in a die grinder. When using grinder method, cut the head down until it is very thin, but do not grind it off completely, or touch the body part with grinding tool. Use a pin punch to pry off head, or shear it off with a sharp chisel. Ensure part is adequately supported while performing this step. Drive lockbolt out of its hole with a pin punch. Care must be taken so that hole or part is not distorted.
Rivet Hole Drilling

1. Center punch all new rivet locations. Center punch mark must be large enough to prevent drill from slipping out of position, yet it must not dent the surface of the material. To prevent denting, place a bucking bar behind material during punching. Ensure drill bit is the correct size, and points properly ground (Tables 1 and 2). A no. 10 drill bit is used to install standard 1.875 in. (48 mm) blind rivets. Place drill bit in center mark for new rivet locations, or align drill bit with old hole when replacing old rivets with oversize rivets (Table 3). When using a power drill, give the bit a few turns with fingers before starting motor to ensure drill does not jump out of position when motor is started.
4.
2.
5.
3.
NOTE: In cases where the lockbolt head is inaccessible, the locking collar must be removed. Remove collar by grinding, or by splitting axially with a sharp chisel.
Rivet Replacement
NOTE: When removing rivets, care should be taken not to enlarge rivet holes. Enlarged rivet holes require oversize replacement rivets.
NOTE: Hold drill at 90 degree angle to material surface. Avoid excessive pressure, or letting the drill wobble. Do not push the drill through material. 4. 5. 6. Remove all bumps with metal countersink or file. Clean away all drill chips. Ensure that no chips are trapped between metal sheets. Apply corrosion-resistant sealing compound to hole and surrounding area.
Solid Rivet Removal

1. File a at surface on the manufactured head, if accessible. It is always preferable to work on a manufactured head rather than one that is bucked over, since the former will always be more symmetrical around the shank. Indent center of the filed surface with a center punch. Drill through rivet head, using a drill bit slightly smaller than diameter of rivet shank to avoid oversizing rivet hole. Shear weakened rivet head off with a sharp chisel. To prevent panel distortion, support back side of rivet and cut rivet head along direction of rivet line or panel edge. Firmly support the panel from the opposite side and drive out the shank with a pin punch. If rivet is unduly tight due to swelling between sheets, drill the rivet shank out with an undersized drill bit.
2. 3. 4.
5.
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Body
10-5
Table 1: Drill Bit Sizes for Solid Shank Rivets

Rivet Diameter 0.0625 in. (1.65 mm) 0.0938 in. (2.38 mm) 0.1250 in. (3.18 mm) 0.1563 in. (3.97 mm) 0.1875 in. (4.76 mm) 0.2500 in. (6.35 mm) 0.3125 in. (7.94 mm) 0.3750 in. (9.53 mm) # 51 # 41 # 30 # 21 # 10 F W W Drill Bit Size Drill Bit Diameter 0.0670 in. (1.70 mm) 0.0960 in. (2.44 mm) 0.1295 in. (3.29 mm) 0.1590 in. (4.04 mm) 0.1910 in. (4.85 mm) 0.2570 in. (6.53 mm) 0.3230 in. (8.20 mm) 0.3869 in. (9.83 mm)
Table 2: Drill Bit Sizes for Blind Rivets

Rivet Diameter 0.1250 in. (3.18 mm) 0.1563 in. (3.97 mm) 0.1875 in. (4.76 mm) Drill Bit Size #30 #20 #10 Minimum 0.129 in. (3.28 mm) 0.160 in. (4.06 mm) 0.192 in. (4.88 mm) Maximum 0.132 in. (3.35 mm) 0.164 in. (4.17 mm) 0.196 in. (4.98 mm)
Table 3: Oversize Diameter

Rivet Diameter 0.1250 in. (3.18 mm) 0.1563 in. (3.97 mm) 0.1875 in. (4.76 mm) Drill Bit Size #27 #16 #5 Minimum 0.143 in. (3.63 mm) 0.177 in. (4.50 mm) 0.205 in. (5.21 mm) Maximum 0.146 in. (3.71 mm) 0.181 in. (4.60 mm) 0.209 in. (5.31 mm)
05745159
10-6
Body _______________________________________________________________________
Hole Countersinking
NOTE: Some rivet installations in the body require the rivet to be flush with the rivet material surface. In these instances, countersunk or flush-head rivets are used. 1. When using countersunk rivets, rivet holes must be countersunk with a tool having a 100 degree taper, so rivet head will t ush with surface. When using a hand-operated countersinker, the hole must be tried with a rivet so the recess will not be too deep or too shallow. It is best to use a countersinker with a stop on it so depth of the countersink can be controlled. Typical countersinking dimensions for blind rivets are shown in Table 4. The minimum sheet thickness that can be machined for 100 degree countersunk rivets is given in Table 5. Do not remove edge of hole on blind side of joint.
Blind Rivet Driving Practices and Precautions

1. Rivets should be inspected for proper installation. The grip length of each rivet is marked on top of its head to provide positive identication. Use of proper grip length will produce a rivet installation where locking collar is ush with top surface of rivet head. Tolerance limit on ushness is 0.020 in. (0.51 mm). For proper rivet installation, it is imperative that holes be properly prepared, tools be in good working order, and rivets properly installed. When problems occur, the source of trouble could be in any of these areas.
2.
2.
3.
table 4: Countersinking Dimensions for 100 Degree Countersunk Blind Rivets Countersinking Dimensions (100 Degree)
Rivet Diameter 0.1250 in. (3.18 mm) 0.1563 in. (3.97 mm) 0.1875 in. (4.76 mm) Minimum 0.222 in. (5.64 mm) 0.283 in. (7.19 mm) 0.350 in. (8.89 mm) Maximum 0.228 in. (5.79 mm) 0.289 in. (7.34 mm) 0.356 in. (9.0 mm)
Table 5: Minimum Sheet Gauge for 100 Degree Machine Countersunk Rivets
Rivet Size Gauge 0.0938 in. (2.38 mm) 0.040 in. (1.02 mm) 0.1250 in. (3.18 mm) 0.050 in. (1.27 mm) 0.1563 in. (3.97 mm) 0.064 in. (1.63 mm) 0.1875 in. (4.76 mm) 0.072 in. (1.83 mm) 0.2500 in. (6.35 mm) 0.072 in. (1.83 mm)
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Body
10-7
Blind Rivet Installation

NOTE: Ensure the proper rivet grip length is selected for each application (Table 6). Rivets can tolerate only 0.0468 in. (1.19 mm) variation in material thickness for each particular rivet length. For double dimpled sheets, add countersink head height to materials thickness. 1. 2. 3. 4. Insert rivet stem into pulling head of rivet gun or adapter. Hold rivet gun in line with axis of rivet as accurately as possible. Apply a steady, firm pressure against rivet head. Squeeze handles of manual gun. The rivet clamping action will pull sheets together, seat rivet head, and break stem flush with head of rivet.
Table 6: Rivet Grip

Material Thickness Range MINIMUM Not Applicable 0.0625 in. (1.588 mm) 0.1250 in. (3.18 mm) 0.1875 in. (4.76 mm) 0.2500 in. (6.35 mm) 0.3125 in. (7.94 mm) 0.3750 in. (9.53 mm) 0.4375 in. (11.11 mm) 0.5000 in. (12.70 mm) 0.5625 in. (14.29 mm) 0.6250 in. (15.88 mm) 0.6875 in. (17.46 mm) MAXIMUM 0.0625 in. (1.65 mm) 0.1250 in. (3.18 mm) 0.1875 in. (4.76 mm) 0.2500 in. (6.35 mm) 0.3125 in. (7.94 mm) 0.3750 in. (9.53 mm) 0.4375 in. (11.11 mm) 0.5000 in. (12.70 mm) 0.5625 in. (14.29 mm) 0.6250 in. (15.88 mm) 0.6875 in. (17.46 mm) 0.9750 in. (24.77 mm) 1 2 3 4 5 6 7 8 9 10 11 12 Rivet Grip No.
05745159
10-8
Body _______________________________________________________________________
Aluminum Repair
CAUTION: Body repairs should not be made using welding or heat for forming. Heat will only weaken the material and lead to further problems.
4D
D = DIAMETER OF RIVET (PREFERABLY ABOUT 3X THICKNESS OF THICKER SHEET)
Material
Aluminum material used for repairs should be of the same alloy and temper as the original if possible. In general, 6061-T6 aluminum alloy should be used. Material thickness must be the same or thicker. This alloy will work well for flat repairs, but is not well suited to bending because it is quite hard and cracks easily when bent sharply. When bends must be made, use softer 6061-T4 aluminum alloy and increase material thickness by at least 50 percent. As a general rule of thumb, 6061-T4 aluminum alloy should be bent with a minimum bend radius of one to two times material thickness, whereas 6061-T6 aluminum alloy requires at least three times material thickness radius for bends. In all cases, bends should be closely inspected for cracks. A suitable method for avoiding bending cracks is to obtain angles that are extruded from 6061-T6 aluminum alloy or use preformed angles for repairs.
2D
4D
2D
DOUBLE ROW RIVETING PATTERN
3D
6D
Epoxy Adhesive
Where it is necessary to remove parts, note that epoxy adhesive is used in joints. Use care in parts removal to avoid unnecessary distortion. Parts should be separated by peeling action. Before parts are reassembled, it will be necessary to remove any remaining cured epoxy from joints so parts will fit together with good, even contact. Use of epoxy requires special storage and application procedures which do not lend themselves to repair. For this reason, epoxy will not be used for repair. To compensate for the lack of epoxy, additional rivets should be used when making repairs to existing joints.
2D
3D 3D 3D 2D
TRIPLE OR MULTIPLE ROW RIVETING PATTERN

6-S10-025
Figure 10-1:
4.
Riveting Patterns
Rivet Patterns
1. Rivet patterns are denoted by rivet spacing and rivet edge distance. Rivet edge distance is the distance from center of rivet to nearest edge of sheet. Rivet spacing is dened as the distance from center of rivet to center of adjacent rivet (Figure 10-1). Required rivet spacing is determined by strength needed in the joint. A general feel for strength required can be obtained by inspecting rivet patterns in surrounding areas. Body repairs made using single rows of rivets should be performed using rivet spacing not greater than 1.6 in. (4.1 cm) and not less than 0.625 in. (15.9 mm). Use 1 in. (25.4 mm) rivet spacing as a general practice for repairs. Rivet spacing used in original construction may be greater due to additional strength obtained by using epoxy adhesive. Do not use rivet edge distances less than 0.375 in. (9.5 mm). High strength joints or large area patterns may require use of double or multiple rows of rivets to obtain sufficient strength.
2.
Care must be taken to assure rivet hole patterns are transferred accurately in cases where a part with no holes is mated to one which already has rivet holes. Hole patterns may be transferred using one of the following patterns: a. Lay new part in place, and use holes in mating part as a drill template. This requires the new part to be underneath the mating part. Care must be taken not to distort original holes. b. Use the removed part as a drill template by clamping the old and new parts together. This requires that parts rest flat and rivet flange be undistorted.
Joint Design
1. Loads are applied through a joint to fasteners that hold it together. These loads are applied to fasteners in the form of shear loads or tension loads. If load is perpendicular to axis of fasteners, the fasteners are loaded in shear. The fasteners are loaded in tension when load is along axis of fastener, causing a pull on each end of fastener. Rivets are designed to be loaded in shear. Do not create any new joints during repairs which cause rivets to be used in a tension application. Bolts should be used for tension applications or substituted for rivets in very high shear load applications (Figures 10-2 and 10-3).
2.
3.
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Body
10-9
RIVET
RIVETS
Figure 10-2: Rivet Loads in Shear

BOLT BOLT
Figure 10-3: Bolts Replacing Rivets
Repair Parts
1. 2. 3. 4. 5. Paint repair parts or patches with epoxy primer before installation. Apply sealing compound to mating surfaces to prevent corrosion. Install part or patch. Paint repaired area with epoxy primer. Paint repaired area with polyurethane as required.
Table 7: Stop-Drill Sizes for Negligible Cracks

SHEET THICKNESS MINIMUM STOP DRILL BIT SIZE NO. 40 30
0-0.032 in. (0-081 mm) 0.033 in. (0.84 mm) and thicker
Repair of Negligible Damage

1. Negligible cracks are repaired by drilling a small hole at each end of crack to stop crack propagation. This is called stop-drilling. Table 7 gives proper drill sizes for stop-drilling cracks. Negligible holes are repaired by rounding and smoothing edges of holes to alleviate stress risers caused by sharp notches.
Repair by Patching
Most body panel damage that exceeds the limits of negligible damage may be repaired by patching. This procedure involves removal of damaged area and application of a patch to cover the area. The damaged area is prepared by rounding or smoothing of all corners and edges to ensure cracks will not spread into undamaged areas (Figure 10-4). In case of a large crack, it may be desirable to stop-drill the crack rather than cut out a portion of the panel or structural member. Repair is completed by applying a large overlapping patch over the damaged area (Figure 10-5). The overlap must be sufficient to allow the observance of proper rivet edge distance (.25 in. or 6.4 mm). Large areas of damage are best repaired by attaching patch with multiple rows of rivets (Figure 10-6).
2.
CAUTION: Never use heat to reform parts. Part strength is greatly reduced. 3. Small dents and distorted areas may be repaired by bending or hammering as long as the operation does not cause materials to crack or tear. Sharp bends should not be attempted.
05745159
10-10
Body ______________________________________________________________________
Repair by Insertion
DAMAGED AREA PATCH
For damage that is large or more severe in nature than a crack or hole, it is often desirable to remove damaged area, insert a piece of material into removed area and reinforce with a doubler. This is termed repair by insertion. This method of repair is typically stronger and stiffer than an added patch (Figures 10-7 through 10-10).
DOUBLER DAMAGED AREA
Figure 10-4: Patching
MATERIAL
PATCH
Figure 10-7: Reinforcing Damaged Area
CRACK
DOUBLER
PANEL
Figure 10-5: Patching Cracked Areas
MATERIAL
PROPER RIVET EDGE DISTANCE .25 In. (6.4 mm)
Figure 10-8: Doubler
Figure 10-6: Proper Rivet Distance
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Body
10-11
Fiberglass Repair
General Information
DAMAGED AREA
The HUMMER hood and engine access cover are made of fiberglass (sheet molding compound). Crack, splits, or holes may be repaired with a glass reinforced plastic laminate repair kit.
Inspection
NOTE: Hood surface has a thin layer of gel coat that may appear cracked in a spider web-like pattern due to hood flexing. No repair is required. 1. Examine cracks to determine if they are on surface only, or are deep breaks into material thickness. If filler material chips off at bonding flanges, and appears as cracked but not broken through, the area need not be repaired. If total penetration crack greater than 1 in. (25.4 mm) exists in critical areas: hinges, latches, or hood stop areas, repair immediately (Figure 10-11). If total penetration cracks exist in noncritical areas, do not repair until size is greater than 3 in. (76 mm). If severe breaks develop in one area, remove fragmented material and use repair procedure for holes.
HOOD STOP
Figure 10-9: Damaged Body Area
2.
MATERIAL
3.
DOUBLER
DOUBLER
4. 5.
LATCH
Figure 10-10: Sideview of Doubler
HINGE
Figure 10-11: Hood Stop and Hinge
05745159
10-12
Repair
1.
Body ______________________________________________________________________
WATER LEAK DETECTION AND REPAIR

If water has leaked into the vehicle, inspect for leakage points. Spray water, under pressure, against the vehicle in the general area where the leak is believed to be located. Have an assistant inside the vehicle locate and mark the point(s) where any water appears. Water that appears at a certain place inside the vehicle may actually be entering the vehicle from another point. It may be necessary to remove the floor mat, interior trim panels, insulation, dash pad, instrument panel, etc. to gain access and diagnose the leak. Back track the path of water to the point of entry. If it is still not possible to locate the point of entry, try the following: 1. Close all windows and doors. 2. Run a small stream of water over the suspected area(s) of leakage. 3. Using a leak detector-type solution (commercially available), spray a film over the suspect area on the exterior surface. 4. From inside the vehicle, use an air wand and force air onto the suspect leak area and check for pressure bubbles that indicate air is escaping from the vehicle. 5. Repair the leak. If the leak is between body panels or around rivet heads, use Silaprene sealant (P/N 05593929) and wipe the sealant into and/or around the leak area. Be sure to remove any excess sealant while it is still pliable. If the leak is around a door, it may be because the door is not properly aligned. Refer to Door Replacement in this section for instructions on door adjustment. If the door is contacting the weather seal correctly, make sure the weather seal is not damaged and is properly sealed on the door. If the weather seal is not properly sealed, rubber cement can be used to hold it in place. If the weather seal is damaged, replace it. If the leak is around a window held by a weather seal (i.e., door glass), completely dry the area and apply a new window glass seal. If the new seal still does not close out against the glass, the window opening flange may need to be adjusted inward. If the weather seal is damaged, it should be replaced. Check the flange that holds the weather seal for any nicks or burrs that may have caused the damage. Windshield leaks should be repaired by removing the glass and the weather seal that is leaking. Clean off any remaining sealer on the windshield frame and the weather seal, and lay a new bead of sealer evenly around the windshield frame and between the glass and the weather seal. Install the glass and weather seal as an assembly into the frame. Attach the retainers, and allow sealer to harden. 6. Retest the entire vehicle for leaks.
Repairing cracks or splits.
WARNING: When sanding berglass, personal protective equipment (respirator, goggles/shield, gloves, coveralls, etc.) must be used. Failure to do this may result in injury.
a. Using sandpaper, remove dirt and paint 3-4 in. (8-10 cm) around area of crack. b. Rough-sand surface to which mat will be added and underside of surface, if possible. Surface must be dry. c. Bevel edges of crack in a broad V . d. Cut a piece of mat and apply to underside of surface with resin mixture. Extend patch beyond break about 2 in. (5 cm). Press patch firmly into place. Saturate patch with additional layer of resin and then allow 1-3 hours to cure. e. At the same time, cover top exposed surface with resin, allowing 1 to 3 hours to cure. f. For stressed areas, lightly sand first patch and add another patch layer, repeating steps a through c. g. Finish-sand exposed surface. h. Prime and paint. Repairing holes. a. Remove damaged material. b. Using sandpaper, remove dirt and paint in area of hole extending away 3-4 in. (8-10 cm). c. Rough-sand top and underside of surface to which mats will be added. d. Cut two same size pieces of fiberglass mat that will extend about 2 in. (5 cm) past edge of hole. e. Coat both top and underside of surface, and saturate both pieces of mat with the resin mixture. f. When tacky, apply one mat to the inner surface and one to the outer surface. Press the two patches together. g. Allow 1-3 hours to cure. Additional coats of resin may be added if necessary for appearance purposes. Sand lightly between coats. h. Finish-sand exposed surface. i. Prime and paint.
2.
_____________________________________________________________________
Body
10-13
CENTER CONSOLE REPLACEMENT

Removal
1. 2. 3. Remove four screw/washers from center console. (Figure 10-12). Slide center console back (toward rear seating area) far enough for rear air vents to clear plenum. Lift console from tunnel.
FRONT CONSOLE REPLACEMENT

Removal
1. 2. Remove right side crashpad. Remove bolts securing front console to body brackets and screws from top of console (Figure 10-13).
FRONT CONSOLE
Installation
1. Carefully lower center console over auxiliary A/C-heat unit while making sure that rear air vents clear plenum and line up with cutouts. Slide center console forward so that rear air vents fit into plenum cutouts. Secure center console to tunnel bracket with four screw/ washers.
CENTER CONSOLE BRACKET
2. 3.
REAR AIR VENT
Figure 10-13: Front Console Mounting

3. 4. 5. 6. 7. Pull front console away from dashboard. Unplug antenna and electrical connectors from radio. Unplug 56 way console connector from cross body harness. Remove front console assembly. Remove transferable components from console assembly as follows: a. Disconnect electrical leads from cigarette lighters and 12V power supply. b. Remove console harness and mounting clips. c. Remove cigarette lighter, elements, heaters, shells. and bezels. d. Remove ashtray receptacles and frames. e. Remove cup holder. f. Remove CD changer if equipped. g. Remove screws, glovebox, and speednuts (Figure 10-14). h. Remove screws and air vents. i. From inside of console, remove the upper rear support bracket securing the climate control panel and radio to the HVAC plenum. j. Reattach lower support bracket to back of radio.
SCREW/ WASHER
PLENUM CUTOUT
Figure 10-12: Center Console Replacement
NOTE: Faceplate, radio, support plate, and climate control panel will come out as an assembly. k. Remove screws, faceplate, radio, support plate, and climate control panel.
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Body ______________________________________________________________________
FRONT CONSOLE
INSTRUMENT PANEL, GAUGES, AND SWITCHES Instrument Panel (I.P Replacement .)

Removal
NOTE: Tag all leads prior to removal for installation. If replacing instrument panel, refer to procedures in this section to remove and/or disconnect the various lamps, switches, and gauges.
SPEEDNUT GLOVE BOX
Figure 10-14: Glovebox Mounting
Installation
1. Assemble console as follows: a. Insert faceplate, radio, support plate and climate control panel (as one assembly) into front console and secure with screw/washers. b. Remove screw from back of radio and use it to secure the upper support bracket to the lower support bracket. c. Secure upper support bracket to HVAC plenum with screws. d. Insert air vents into console and secure with screws. e. Install glovebox with screws and speednuts. f. Install ashtray frames and receptacles. g. Install cup holder. h. Install CD changer if removed. i. Install cigarette lighter bezels, shells, heaters and elements. j. Secure console harness to console with mounting clips. k. Connect console harness leads to cigarette lighter and 12V power supply. Position console close to dashboard. Connect console harness to body electrical harness. Plug antenna and electrical connectors into radio. Fit console carefully into position. Secure console to body brackets with screws. Install right side crashpad.
1. 2. 3. 4. 5.
Disconnect negative battery cables (Section 12). Remove left side crashpad. Remove close-out panel. Remove wiring harness close-out plate. Remove tachometer and clock assembly from I.P. to access right side I.P. mounting bolt. 6. Remove right side I.P. mounting bolt. 7. Remove two bolts securing I.P. to steering column. 8. Remove two left side I.P. mounting bolts securing I.P. to A-pillar. 9. Disconnect air hose from side window defrost vent. 10. Remove I.P.
Installation
1. Maneuver I.P. into position between steering wheel and rewall. 2. Connect air hose side window defrost vent. 3. Loosely install left side I.P. mounting bolts. 4. Loosely install I.P. to steering column mounting bolts. 5. Install right side I.P. mounting bolts 6. Tighten loosely installed bolts from steps 3 and 4. 7. Install tachometer and clock assembly. 8. Install wiring harness close-out plate. 9. Install close-out panel. 10. Install left side dashpad. 11. Connect negative battery cables (Section 12).
2. 3. 4. 5. 6. 7.
_____________________________________________________________________
Body
10-15
Crashpad Replacement (Right Side)

Removal
1. 2. 3. Remove screw/washers, and crashpad from dashboard (Figure 10-16). Disconnect air hose from vent duct. Remove screws, side window vent, and vent duct from crashpad.
Crashpad Replacement (Left Side)

Removal
1. 2. 3. Remove screw/washers from top of crashpad. Tug gently on crashpad toward steering wheel to free crashpad clips from I. P. clips (Figures 10-15 and 10-16). Lift vent side of crashpad and work console side (duct nozzle) out of front console.
Installation
1. 2. 3. Secure vent duct and window vent to crashpad with screws (Figure 10-16). Connect air hose to vent duct. Secure crashpad to dashboard with screw/washers.
RIGHT SIDE MOUNTING BOLT
Installation
1. 2. Work console side (duct nozzle) of crashpad into front console plenum. Position crashpad on edge of I. P. closest to steering wheel and push crashpad onto I. P. clips (Figures 10-15 and 10-16). Secure crashpad to I. P. with screw/washers.
3.
I. P. CLIPS SIDE WINDOW DEFROST VENT AIR HOSE
LEFT SIDE MOUNTING BOLTS
STEERING COLUMN MOUNTING BOLTS
Figure 10-15: Instrument Panel Replacement

VENT DUCT
AIR HOSE DASHBOARD I. P. CLIPS DUCT NOZZLE/ CONSOLE SIDE
WINDOW VENT
CRASH PAD (LEFT SIDE)
VENT
CRASH PAD (RIGHT SIDE)
Figure 10-16: Crashpad Replacement
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Body ______________________________________________________________________
Gauge Replacement
NOTE: Gauge replacement is basically the same for all instrument panel gauges.
Instrument Panel Indicator Lamp Replacement

NOTE: All instrument panel indicator lamps are replaced basically the same.
Removal
1. 2. Remove screws and pull gauge panel away from instrument panel (Figure 10-17). Disconnect lamp connector from gauge.
Removal
1. 2. 3. Remove instrument panel. Turn lamp socket one-quarter turn counterclockwise, and remove socket from indicator light housing. Pull lamp from socket (Figure 10-18).
NOTE: Tag all leads prior to removal for installation. 3. 4. 5. Remove nut and lockwasher assemblies securing three leads to gauge. Remove hold-down bracket. Remove gauge through front of gauge panel.
LAMP CONNECTOR INSTRUMENT PANEL
Installation
1. 2. 3. 4. Push lamp into socket (Figure 10-18). Insert socket into status center and secure by turning socket clockwise one-quarter turn. Install instrument panel. Start engine and ensure lamp operates properly.
BULB SOCKET
GAUGE PANEL STATUS CENTER
LEAD
HOLD-DOWN BRACKET GAUGE LEADS
Figure 10-17: Gauge Replacement
Installation
1. 2. 3. 4. 5. 6. Insert gauge through front of gauge panel (Figure 10-17). Secure hold-down bracket and lead to gauge with nut and lockwasher assembly. Secure leads to gauge with nut and lockwasher assemblies. Connect lamp connector to back of gauge. Start engine and ensure gauge operates properly. Secure gauge panel to instrument panel with screws.
9-S06-015.1
Figure 10-18: Instrument Panel Indicator Light Replacement
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Body
10-17
Instrument Panel Switch Replacement

NOTE: All instrument panel switches are replaced similarly, with the exception of the dimmer control switch. This procedure covers the main light switch. CAUTION: Some connectors can be installed incorrectly and cause damage to the electrical system. Make note of connector position prior to removal.
WIRING HARNESS
CONNECTOR
Removal
1. 2. 3. Remove closeout panel. Reach up behind IP and push switch from switch housing. Remove connector from switch (Figure 10-19).
HOUSING INSTRUMENT PANEL SWITCH
Installation
1. 2. 3. Install connector on switch (Figure 10-19). Install switch in switch housing. Install closeout panel.
CONNECTOR
Figure 10-20: Instrument Panel Dimmer Control Switch Replacement
Installation
1. 2. 3. Plug connector into wiring harness. Install switch in switch housing (Figure 10-20). Install closeout panel.
SWITCH
HOUSING INSTRUMENT PANEL
Figure 10-19: Instrument Panel Switch Replacement
Instrument Panel Dimmer Control Switch Replacement

Removal
1. 2. 3. Remove closeout panel. Reach up behind instrument panel and push switch from switch housing. Unplug connector from wiring harness (Figure 10-20).
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Body ______________________________________________________________________
Speedometer/Odometer Replacement
Removal
1. 2. Remove the left A-pillar dash trim (closeout). Remove the left footwell closeout panel and disconnect the courtesy light plug, diagnostic link connector and the footwell vent hose from the closeout panel. 3. If equipped with power mirrors, pop the switch from dash and let hang to gain access to the crossbolt nut. 4. Remove the two screws securing the harness hanger to the steering column mount bracket and remove the harness hanger. 5. Loosen the two bolts at the forward steering column pivot point. 6. Remove the steering column crossbolt, nut and washer and tilt the steering column downward. 7. Remove the left and right gauge bezels (with gauges), for access to the rear of the speedometer/odometer, and let the bezels lay loose. 8. Remove two trim screws from the crashpad and pull rearward to release the crashpad. 9. Remove the two plastic protector caps from the rear of the speedometer/odometer mounting studs. 10. Remove the wire connector from the backside of the speedometer.
CROSSBOLT
11. Remove the two speedometer/odometer hold-down bracket nuts and lockwashers and the hold-down bracket. 12. Pull the speedometer/odometer from the dash and remove the two remaining nuts and lockwashers that secure the ground and sending lead connections.
Installation
1. Insert speedometer/odometer into instrument panel and secure with hold-down bracket, electrical connector, and nut and lockwasher assemblies (Figure 10-21). Slide two plastic protector caps onto the speedometer/ odometer mount studs. Install the crashpad using two trim screws. Install the left and right gauge bezels. Tilt the steering column up and install the crossbolt, nut and washer.
2. 3. 4. 5. 6.
Tighten the two bolts at the forward pivot point of the steering column. 7. Screw the harness hanger to the steering column mount bracket. 8. Install the power mirror switch if removed in step 3 above. 9. Install the footwell vent hose, the DLC, the courtesy light plug and the left footwell closeout panel. 10. Install the left A-pillar dash trim (closeout).
PIVOT BOLT
HOLD-DOWN BRACKET SPEEDOMETER/ ODOMETER
POWER MIRROR SWITCH
HARNESS HANGER
POWER MIRROR SWITCH
Figure 10-21: Speedometer/Odometer Replacement
4-1-00
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Body
10-19
Tachometer Replacement
NOTE: Mark position of set screws in relationship to tachometer clock panel before disassembly. Tachometer mounting clamp must be installed in factory position to have proper clearance for reassembly. NOTE: It may be necessary to remove clock for access to tachometer mounting clamp hardware.
CIGARETTE LIGHTER REPLACEMENT

Removal
1. 2. 3. 4. Pull front console away from dashpad enough to gain access to wiring harness connector. Remove wiring harness connector from lighter assembly. Remove element from lighter assembly heater (Figure 10-23). Remove shell from heater, and remove shell, heater, and bezel from console.
Removal
1. 2. 3. 4. Remove screws and tachometer/clock panel from I.P. Unplug tachometer electrical connector from I.P. wiring harness. Loosen set screws and tachometer mounting clamp hardware. Remove clamp from tachometer housing. Remove tachometer from tachometer/clock panel. 1. 2. 3. 4. 5. 6.
Installation
Install bezel and heater in console (Figure 10-23). Install shell on heater. Install wiring harness connector on lighter assembly. Install element in lighter assembly. Engage cigarette lighter to ensure proper operation. Install front console.
Installation
1. 2. Position tachometer in tachometer/clock panel. Slide tachometer mounting clamp onto tachometer housing; close enough to tachometer/clock panel for set screws to make contact. Tighten clamp securely onto tachometer body and tighten setscrews until they contact tachometer/clock panel. Plug tachometer electrical connector into I.P. wiring harness. Secure tachometer/clock panel to I.P. with screws.
TACHOMETER TACHOMETER/CLOCK PANEL
PASSED
WIRING HARNESS CONNECTOR
SHELL
3. 4. 5.
BEZEL HEATER ELEMENT
CONSOLE LIGHTER ASSEMBLY
TACHOMETER MOUNTING CLAMP SET SCREW
Figure 10-23: Cigarette Lighter Breakdown
GLOVEBOX REPLACEMENT
PASSED
Removal
Remove screws and glovebox from front console (Figure 10-24).
CLOCK
Installation
Secure glovebox to front console with screws (Figure 10-24).
CLOCK MOUNTING CLAMP
TACHOMETER MOUNTING CLAMP HARDWARE
6-S10-018.1
FRONT CONSOLE
Figure 10-22: Tachometer Mounting
GLOVEBOX
Figure 10-24: Glovebox

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Body ______________________________________________________________________
ASHTRAY REPLACEMENT
Removal
1. 2. 3. Pull front console away from dashpad to gain access to ashtray frame tabs. Pull ashtray receptacle out of frame (Figure 10-25). Straighten frame tabs and remove frame.
FLEXIBLE LATCH BODY
Installation
1. 2. 3. Insert frame into opening on console and secure it by bending tabs around opening. Push ashtray receptacle into frame (Figure 10-25). Install front console.
HOLD-DOWN STRIKER
CARGO FLOOR
ASHTRAY RECEPTACLE
Figure 10-26: Inner Engine Access Cover Latch Location
Engine Access Cover Replacement

Removal
ASH TRAY FRAME TABS (AFTER BENDING)
1. 2. 3.
FRONT CONSOLE TABS (BEFORE BENDING)

6-S10-122
4.
Remove console. Unlatch flexible latches from keepers on engine access cover hold-down brackets (Figure 10-27). Unlatch engine access cover hold-down latches from engine access cover hold-down strikers. Turn ring studs and remove access cover.
ENGINE ACCESS COVER FLEXIBLE LATCH
RING STUDS
Figure 10-25: Ashtray Mounting
ENGINE ACCESS COVER Inner Engine Access Cover Flexible Latch and Hold-Down Striker Replacement
Removal
1. 2. 3. Remove engine access cover. Remove rivets and hold-down striker from body (Figure 10-26). Remove rivets and flexible latch from cargo floor.
HOLD-DOWN LATCH
HOLD-DOWN STRIKER HOLD-DOWN BRACKET AND KEEPER
Installation
1. 2. 3. Secure exible latch to cargo oor with rivets (Figure 10-26). Secure hold-down striker to body with rivets. Install engine access cover.
Figure 10-27: Engine Access Cover Replacement
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Body
10-21
Disassembly
1. 2. 3. 4. 5. 6. 7. Remove rivets, retainers, and insulation from engine access cover (Figure 10-28). Remove seal from access cover. Remove retaining rings, washers, and ring studs from access cover (Figure 10-29). Remove locknuts and shoulder bolts securing latch guide plates and back plates to access cover and remove latches. Remove rivets, latch guide plates, and back plates from access cover. Remove rivets and keepers from hold-down brackets. Remove rivets, nuts, washers, screws, hold-down brackets, and backing plates from access cover.
ENGINE ACCESS COVER RING STUD RETAINING RINGS
HOLD-DOWN BRACKET
LATCH GUIDE PLATE
KEEPER
Assembly
1. 2. 3. 4. 5. 6. 7. Secure hold-down brackets and backing plates to access cover with rivets, screws, washers, and nuts (Figure 10-29). Secure keepers to hold-down brackets with rivets. Secure latch guide plates and back plates to access cover with rivets. Secure latch guide plates to back plates and access cover with shoulder bolts and locknuts. Install latches. Secure washers and ring studs to access cover with washers and retaining rings. Install seal on access cover (Figure 10-28). Secure insulation to access cover with rivets and retainers.
ENGINE ACCESS COVER RETAINER BACKING PLATE BACK PLATE HOLD-DOWN LATCH
Figure 10-29: Engine Access Cover Fastener Positioning
Installation
1. 2. 3. 4. Position engine access cover and fasten ring studs (Figure 10-29). Secure hold-down latches on hold-down strikers. Latch flexible latches on hold-down bracket keepers. Install console.
SEAL
INSULATION
Figure 10-28: Engine Access Cover, Insulation, and Seal Breakdown
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Body ______________________________________________________________________
SEAT BELT ASSEMBLY REPLACEMENT

NOTE: Replacement of the seat belt assembly is basically the same for all seat locations on all vehicle models. This procedure covers the left front seat belt on four-door hard top vehicles.
WEBBING GUIDE COVER
Removal
1. 2. 3. 4. Remove seat. Remove screw/washer assembly, seat buckle, and washer from body (Figure 10-30). Remove inner kick panel enough to gain access to seat buckle electrical connector. Disconnect seat buckle electrical connector from roof harness connector and pull seat buckle electrical connector through grommet in inner kick panel.
LOWER B-PILLAR TRIM
D-RING B-PILLAR
BRACKET
SEAT BUCKLE
ROOF HARNESS CONNECTOR RETRACTOR COURTESY LIGHT ANCHOR BRACKET
BODY
RETRACTOR MOUNTING BRACKET
Figure 10-31: Seat Belt Assembly Breakdown

6. Remove screw/washer assembly, anchor bracket, and washer from bracket.
SEAT BELT ELECTRICAL CONNECTOR
NOTE: Steps 8 and 9 are applicable to all vehicles except twodoor vehicles with the enlarged cab. 7. Remove courtesy light lamp assembly, rivets, mounting bracket, and washers from lower B-pillar trim (Figure 10-31). 8. Disconnect body harness connector from courtesy light lamp assembly. 9. Remove screw/washer assemblies securing lower B-pillar trim to B-pillar. 10. Remove bolt, washer, and retractor from retractor mounting bracket. Remove seatbelt assembly from lower B-pillar trim. 11. Remove bolts, washers, and retractor mounting bracket from B-pillar. 12. Remove bolts, washers, and bracket from B-pillar and body.
INNER KICK PANEL
Figure 10-30: Seat Belt Electrical Connector Location

5. Remove screw/washer assembly, D-ring, webbing guide cover, and washer from B-pillar (Figure 10-31).
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Body
10-23
Installation
1. 2. 3. Secure bracket to B-pillar and body with washers and bolts (Figure 10-31). Tighten bolts to 12 lb-ft (16 Nm). Secure retractor mounting bracket to B-pillar with washers and bolts. Tighten bolts to 24 lb-ft (33 Nm). Route seat belt assembly through opening in lower Bpillar trim and secure retractor to retractor mounting bracket with washer and bolt. Tighten bolts to 35-40 lb-ft (47-55 Nm). Secure lower B-pillar trim to B-pillar with screw/washer assemblies.
Installation
1. 2. 3. 4. Secure riser to slide set with bolts, lockwashers, and nuts (Figure 10-32). Tighten nuts to 24 lb-ft (33 Nm). Secure cover and height adjuster to slide set with bolts, lockwashers, and nuts. Install bag on height adjuster. Install drivers seat pedestal.
4.
NOTE: Steps 5 and 6 are applicable to all vehicles except twodoor vehicles with the enlarged cab. 5. 6. Connect body harness connector to courtesy light lamp assembly.
Secure courtesy light lamp assembly and mounting bracket to lower B-pillar trim on B-pillar with washers and rivets. 7. Secure anchor bracket to bracket with washer and screw/ washer assembly. Tighten screw/washer assembly to 3540 lb-ft (47-55 Nm). 8. Secure D-ring and webbing guide cover to B-pillar with washer and screw/washer assembly. 9. Route seat buckle electrical connector through grommet in inner kick panel and plug seat buckle electrical connector into roof harness connector (Figure 10-30). 10. Install inner kick panel. 11. Secure seat buckle to body with screw/washer assembly and washer. Tighten screw/washer assembly to 35-40 lb-ft (47-55 Nm). 12. Install seat.
RISER SLIDE SET
DRIVERS AND FRONT PASSENGERS SEATS

COVER
Standard Drivers and Passengers Seat Pedestal Repair

NOTE: Seat pedestal repair is similar for drivers and front passengers seats. This procedure covers the drivers seat pedestal.
HEIGHT ADJUSTER
Removal
1. 2. 3. 4. Remove drivers seat pedestal. Remove bag from height adjuster (Figure 10-32). Remove nuts, lockwashers, and bolts securing height adjuster to slide set and remove height adjuster and cover. Remove nuts, lockwashers, and bolts securing riser to slide set and remove riser.
BAG
Figure 10-32: Seat Pedestal Assembly Breakdown
05745159
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Body ______________________________________________________________________
Reclining Drivers and Front Passengers Seat Replacement

NOTE: Reclining drivers and front passengers seats are replaced similarly. This procedure covers the passengers seat.
Installation
1. 2. 3. Install four spacers and seat pedestal in vehicle. Secure seat pedestal to floor with four washers, lockwashers, and bolts. Tighten bolts to 24 lb-ft (33 Nm). Secure seat to seat pedestal.
Removal
Remove bolts, washers, and passengers seat from seat base (Figure 10-33).
Drivers Seat Armrest Replacement

Removal
1. 2. 3. Remove plastic caps covering exposed screws. Remove short screws and lockwashers attaching armrest to bracket (Figure 10-34). If bracket needs to be replaced, remove long screws attaching bracket to seat support.
BRACKET SEAT SUPPORT LONG SCREW
Installation
Secure passengers seat to seat base with washers and bolts. Tighten bolts to 15 lb-ft (20 Nm) (Figure 10-33).
PASSENGERS SEAT
ARMREST
SHORT SCREW
Figure 10-34: Drivers Seat Armrest Mounting
Installation
SEAT BASE
NOTE: If bracket was removed, perform steps 1 through 3. 1. Secure bracket to seat support with one of the long screws. Do not tighten screw (Figure 10-34). Use large center hole in bracket to locate upper bracket mounting hole in seat support. Secure top section of bracket to seat support with the other long screw. Tighten both long screws to 120 lb-in. (14 Nm). Secure the armrest to the bracket with the short screws and lockwashers. Tighten the short screws to 120 lb-in. (14 Nm). Position the plastic caps over the exposed screw heads.
Figure 10-33: Reclining Front Seat Replacement
2. 3.
Drivers and Front Passengers Seat Pedestal Assembly Replacement

NOTE: Seat pedestal assembly replacement for drivers and front passengers seats is similar. This procedure covers the drivers seat pedestal.
4.
Removal
1. 2. 3. Remove seat from seat pedestal. Remove four bolts, lockwashers, and washers securing seat pedestal to floor. Remove seat pedestal and four spacers from vehicle.
5.
NOTE: The entire armrest can be positioned vertically or horizontally by pushing the armrest up or down. To adjust the angle of the armrest while it is in the horizontal position, use the adjusting knob located under the front end of the armrest. 6. Use the adjusting knob to position the armrest as necessary.
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Body
10-25
REMOVABLE LOAD BARRIER AND MOUNTING BRACKETS REPLACEMENT (STATION WAGON)

Removal
1. 2. 3. 4. 5. Remove drive screws and carpet assembly from front and back of removable load barrier (Figure 10-35). Remove necessary interior trim to gain access to mounting brackets. Remove removable load barrier by lifting barrier up and out of mounting brackets on inner wheel house panels. Remove rivets and mounting bracket from left inner wheel house panel. Remove rivets and mounting bracket from right inner wheel house panel.
INTERIOR TRIM B-Bar Replacement

NOTE: This procedure covers replacement of the B-bar for all vehicles except open top models and 2-door models without an enlarged cab.
Removal
1. 2. 3. Remove seat belt assemblies. Remove trim from B-bar. Remove domelight.
NOTE: It may be necessary to remove any duct tape or tie straps securing electrical wiring harnesses to B-bar. 4. Remove screws, washers, and headliner support from Bbar (Figure 10-36). 5. Remove screws, lockwashers, and mounting brackets from mounting blocks. 6. Remove B-pillar seals and rabbet seals from B-pillar. Inspect and discard seals if damaged. 7. Remove locknuts, washers, and strikers from B-pillar. 8. Remove six locknuts, washers, bolts and mounting blocks from B-pillar. 9. Remove B-bar. 10. Remove screws, washers, and two trim mounting brackets from B-bar.
TRIM MOUNTING BRACKET B-BAR
Inspection
Inspect bumper strips. If damaged, replace.
Installation
1. 2. 3. 4. 5. Secure mounting bracket to left inner wheel house panel with rivets (Figure 10-35). Secure mounting bracket to right inner wheel house panel with rivets. Install removable load barrier in mounting brackets. Install interior trim. Secure carpet assembly to front and back of removable load barrier with drive screws.
RIGHT INNER WHEEL HOUSE PANEL MOUNTING BRACKET REMOVABLE LOAD BARRIER
STRIKER
MOUNTING BRACKET RIVET DRIVE SCREW CARPET ASSEMBLY B-PILLAR SEAL
HEADLINER SUPPORT
BUMPER STRIPS
MOUNTING BLOCK B-PILLAR
Figure 10-35: Removable Load Barrier Location

RABBET SEAL
Figure 10-36: B-Bar Mounting

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Body ______________________________________________________________________
Installation
1. Secure trim mounting brackets to B-bar with four washers and screws (Figure 10-36). 2. Install B-bar. 3. Secure mounting blocks to B-pillar with washers, bolts and locknuts. Tighten locknuts to 24 lb-ft (33 Nm). 4. Secure strikers to B-pillar with washers and locknuts. 5. Install B-pillar seals and rabbet seals on B-pillar. 6. Secure mounting brackets to mounting blocks with lockwashers and screws. 7. Secure headliner support to B-bar with washers and screws. 8. Install domelight. 9. Install trim on B-bar. 10. Install seat belt assemblies.
5. 6. 7.
Remove covers, screws, and grab handle from trim. Remove screw/washer assemblies and upper B- bar trim from roof. Remove screws, washers, and lower B-pillar trim from Bpillar.
NOTE: Perform steps 8 through 10 for station wagon models only. 8. Remove screw/washer assemblies and C-pillar center trim from roof (Figure 10-38). 9. Remove screw/washer assemblies and upper C-pillar trim from roof. 10. Remove screw/washer assemblies and lower C-pillar trim from lower C-pillar.
ROOF UPPER C-PILLAR TRIM C-PILLAR CENTER TRIM
Passengers Compartment Trim Replacement

Removal
1. 2. 3. 4. Remove rear seats. Remove overhead speakers (Section 12). Remove seat belt assemblies. Remove screw/washer assemblies and B-bar center trim from roof (Figure 10-37).
ROOF GRAB HANDLE COVER
~
HEADLINER
C-PILLAR
LOWER C-PILLAR TRIM
REAR COMPARTMENT WALL
~
CENTER B-BAR TRIM
Figure 10-38: Station Wagon Interior Trim Component Identification

UPPER B-BAR TRIM
11. Remove screw/washer assemblies and trim panel from rear compartment wall (Figure 10-39)
B-PILLAR TRIM
Figure 10-37: Driver Side Interior Trim Component Identification
_____________________________________________________________________
Body
10-27
HEADLINER ROOF
WINDOW TRIM
7.
WINDOW TRIM
UPPER WHEELHOUSE TRIM
Secure lower C-pillar trim to lower C-pillar with four screw and washer assemblies (Figure 10-38). 8. Secure upper C-pillar trim to roof with nine screw and washer assemblies. 9. Secure C-pillar center trim to roof with eight screw and washer assemblies. 10. Secure B-pillar trim to B-pillar with washers and screws (Figure 10-40). 11. Secure upper B-bar trim to roof with screw/washer assemblies. 12. Secure B-bar center trim to roof with screw/washer assemblies.
GRAB HANDLE COVER ROOF
TRIM PANEL
PANEL FASTENER
LOWER WHEELHOUSE TRIM
LOWER CENTER LOWER REAR COMPARTMENT TRIM PANEL WALL UPPER B-BAR TRIM
Figure 10-39: Four-Passenger Vehicle Interior Trim Component Identification

12. Remove screw/washer assemblies and window trim from rear compartment wall and roof. 13. Remove panel fasteners and upper wheelhouse trim from wheelhouse. 14. Remove screw/washer assemblies and lower wheelhouse trim from wheelhouse. 15. Remove screw/washer assemblies and lower center trim panel from lower rear compartment wall. 16. Remove domelight. 17. Remove panel fasteners and headliner from roof.
CENTER B-BAR TRIM
B-PILLAR TRIM
Figure 10-40: B-Pillar and Interior Trim Component Identification

13. 14. 15. 16. Secure grab handle to trim with screws and covers. Install seat belt assemblies. Install overhead speakers (Section 12). Install rear seats.
Installation
1. 2. 3. 4. Secure headliner to roof with panel fasteners (Figure 10-39). Secure domelight. Secure lower center trim panel to lower rear compartment wall with screw/washer assemblies. Secure upper and lower wheelhouse trim panels to wheelhouse with screw/washer assemblies and panel fasteners. Secure window trim to rear compartment wall and roof with screw/washer assemblies. Secure trim panel to rear compartment wall with screw/ washer assemblies.
5. 6.
NOTE: Perform steps 7 through 9 for station wagon models only. 05745159
10-28
Body ______________________________________________________________________
Drivers Compartment Trim Replacement

Removal
1. 2. 3. 4. 5. 6. Remove overhead speakers from drivers compartment and passengers compartment (if applicable) (Section 12). Remove visors. Remove seat belt assemblies. Remove covers, screws, and grab handle from trim. (Figure 10-41). Remove screw/washer assemblies and B-bar center trim from roof. Remove screw/washer assemblies and center trim from windshield frame and roof (Figure 10-42).
COVER ROOF
7.
Remove screw/washer assemblies and upper A-pillar trim from roof. 8. Remove screw/washer assembly and lower A-pillar trim from A-pillar. 9. Remove screw/washer assemblies and upper B-bar trim from roof. 10. Remove screws, washers, and B-pillar trim from B-pillar. NOTE: Replacement of the rear drivers compartment trim for 2-door vehicles with and without an enlarged cab is basically the same. Steps 11 through 13 cover 2-door vehicles without an enlarged cab. 11. Remove seats.
B-BAR CENTER TRIM
GRAB HANDLE
Figure 10-41: Drivers Compartment Trim Replacement
UPPER B-BAR TRIM UPPER A-PILLAR TRIM
CENTER TRIM
A-PILLAR
B-PILLAR TRIM
LOWER A-PILLAR TRIM
Figure 10-42: A-Pillar and B-Bar Interior Trim Identification
_____________________________________________________________________
Body
10-29
UPPER REAR COMPARTMENT WALL
4.
Secure trim to upper rear compartment wall with screw/ washer assemblies.
ROOF HEADLINER
LOWER REAR COMPARTMENT WALL
Figure 10-43:
Rear Compartment Wall Location

5. 6.
Figure 10-44: Headliner Positioning

Install seats. Secure B-pillar trim to B-pillar with washers and screws (Figure 10-45). 7. Secure upper B-bar trim to roof with screw/washer assemblies. 8. Secure lower A-pillar trim to A-pillar with screw/washer assembly. 9. Secure upper A-pillar trim to roof with screw/washer assemblies (Figure 10-42). 10. Secure center trim to windshield frame and roof with screw/washer assemblies (Figure 10-45). 11. Secure B-bar center trim to roof with screw/washer assemblies. 12. Secure grab handle to trim with screws and covers.
ROOF CENTER TRIM
13. Remove screw/washer assemblies, B-beam trim, and rear edge trim from B-beam and lower rear compartment wall. 14. Remove domelight. 15. Remove panel fasteners and headliner from roof (Figure 10-44).
Installation
1. 2. Position headliner on roof and install with panel fasteners (Figure 10-44). Install domelight.
NOTE: Perform steps 3 through 5 for 2-door vehicles without an enlarged cab. 3. Secure rear edge trim and B-beam trim to B-beam and rear compartment wall with screw/washer assemblies (Figure 10-43).
B-BAR CENTER TRIM
GRAB HANDLE
COVER UPPER B-BAR TRIM A-PILLAR LOWER A-PILLAR TRIM B-PILLAR TRIM B-PILLAR
Figure 10-45: A-Pillar and B-Bar Interior Trim Components
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Body ______________________________________________________________________
Station Wagon Rear Compartment Trim Replacement

Removal
1. 2. Remove rear seats. Remove bolts, washers, upper seat belt bracket, and seat belt assembly from C-pillar (Figure 10-46).
CENTER TRIM
8.
Remove screw/washer assemblies and two trim panels from lower rear compartment wall (Figure 10-48).
PANEL FASTENERS HEADLINER
UPPER B-PILLAR TRIM
UPPER C-PILLAR TRIM
CENTER TRIM SEAT BELT BRACKET
C-PILLAR
SEAT BELT ASSEMBLY TRIM
Figure 10-46: C- and B-Pillar Trim Component Identification

3. 4. 5. 6. Remove screw/washer assemblies and center trim from Cpillar. Remove screw/washer assemblies from edge of trim on upper B-pillar trim. Remove screw/washer assemblies and upper C-pillar trim from C-pillar. Remove screw/washer assemblies and trim from station wagon compartment side wall (Figure 10-47).
C-PILLAR STATION WAGON COMPARTMENT SIDE WALL TRIM
Figure 10-48: Headliner and Trim Removal

9. Remove panel fasteners and trim panel from rear compartment wall. 10. Remove domelight. 11. Remove panel fasteners and rear headliner from roof.
Installation
1. 2. Secure trim to bottom of rear window. Secure rear headliner to roof with panel fasteners (Figure 10-48). 3. Install domelight. 4. Secure trim panel to compartment wall with two panel fasteners. 5. Secure trim panels to lower rear compartment wall with screw/washer assemblies. 6. Secure lower C-pillar trim to lower side of C-pillar with screw/washer assemblies (Figure 10-49).Secure trim to upper station wagon compartment side wall with screw/ washer assemblies. 7. Secure upper C-pillar trim to C-pillar with screw/washer assemblies. 8. Secure edge of upper trim on B-pillar with screw/washer assemblies. 9. Secure center trim to C-pillar with screw/washer assemblies. 10. Secure seat belt assembly and bracket to C-pillar with washers and bolts. Tighten bolts to 35-40 lb-ft (47-55 Nm). 11. Install rear seat.
LOWER C-PILLAR TRIM
Figure 10-47: C-Pillar Trim Location

7. Remove screw/washer assemblies and lower C-pillar trim from C-pillar.
_____________________________________________________________________
Body
10-31
UPPER C-PILLAR TRIM SEAT BELT BRACKET TRIM PANEL
B-PILLAR TRIM
CENTER TRIM SEAT BELT ASSEMBLY
C-PILLAR
HEADLINER
STATION WAGON COMPARTMENT SIDE WALLS
LOWER C-PILLAR TRIM
Figure 10-49: Station Wagon Side Wall Component Breakdown
05745159
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Body ______________________________________________________________________
Inner Kick Panels Replacement

Removal
1. Remove seats.
PANEL
NOTE: Remove one bolt, washer, and seat buckle for two-passenger models. 2. Remove bolts, washers, and seat buckles from front and rear of tunnel (Figure 10-50).
SEAT BUCKLE B-BEAM TRIM
REAR COMPARTMENT WALL TRIM
PANEL FASTENER
Figure 10-51: Rear Compartment Trim Removal

TWO PASSENGER VEHICLE ONLY
WIRING HARNESS CONNECTOR RIGHT FRONT INNER KICK PANEL SEAT BELT BUCKLE ELECTRICAL CONNECTOR TUNNEL SHIFT CONTROL TRIM PANEL
KICK PANEL
Figure 10-50: Seat Belt Buckle Electrical Connector Location

NOTE: Ensure seat belt buckle electrical connector or wiring harness is pulled out and away from kick panel for ease of installation. 3. Disconnect seat belt buckle electrical connector from wiring harness connector on driver side.
NOTE: Perform steps 4 and 5 for four-passenger models only. 4. 5. Remove panel fasteners, screw/washer assemblies, and rear wall trim from rear compartment wall (Figure 10-51). Remove panel fasteners and rear inner kick panel from tunnel (Figure 10-52).
LEFT FRONT INNER KICK PANEL
REAR INNER KICK PANELS
Figure 10-52: Inner Kick Panel Mounting

6. 7. 8. 9. Remove front and center consoles. Remove screw/washer assemblies, panel fastener, and shift control panel from tunnel (Figure 10-52). Remove panel fasteners and left front inner kick panel from tunnel. Remove panel fasteners and right front inner kick panel.
NOTE: Perform step 10 for two-passenger models only. 10. Remove panel fastener and inner kick panel from rear of tunnel.
_____________________________________________________________________
Body
10-33
Installation
NOTE: Perform step 1 for two-passenger models only. 1. 2. 3. 4. 5. Secure rear inner kick panel to right rear of tunnel with panel fastener (Figure 10-52). Secure right front inner kick panel to tunnel with panel fasteners. Secure left front inner kick panel to tunnel with panel fasteners. Secure shift control trim panel to tunnel with screw/ washer assemblies and panel fastener. Install center and front consoles.
PANEL FASTENER LOWER SEAT BELT CENTER KICK BRACKET PANEL FRONT KICK PANELS
REAR KICK PANELS CENTER KICK PANEL BODY
NOTE: Perform steps 6 and 7 for four-passenger models only. 6. 7. 8. Secure rear inner kick panels with panel fasteners (Figure 10-51). Secure rear wall trim to rear compartment wall with panel fasteners and screw/washer assemblies. Connect driver side seat belt buckle electrical connector (Figure 10-50).
Figure 10-53: Outer Kick Panel Identification
Installation
1. 2. 3. 4. Secure left and right rear outer kick panels to body with panel fasteners (Figure 10-53). Secure rear lower seat belt brackets to body with washers and screws. Secure right center outer kick panel to body with panel fastener. Secure left center outer kick panel to body with panel fasteners. Secure left front outer kick panel to body with panel fasteners. Secure right front outer kick panel to body with panel fasteners. Install door stop straps.
NOTE: Install one seat buckle on two-passenger models. 9. Secure seat buckles to tunnel with washers and bolts. Tighten bolts to 35-40 lb-ft (47-55 Nm). 10. Install seats.
Outer Kick Panel Replacement

Removal
NOTE: Soft top models require removal of speakers from front outer kick panels before performing the following task. 1. 2. 3. 4. 5. 6. 7. Remove door stop straps. Remove panel fasteners and right front outer kick panel from body (Figure 10-53). Remove panel fasteners and left front outer kick panel from body. Remove panel fasteners and left center outer kick panel from body. Remove panel fastener and right center outer kick panel from body. Remove screws, washers, and rear lower seat belt brackets from body. Remove panel fasteners and left and right rear outer kick panels from body. 5. 6. 7.
05745159
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Body ______________________________________________________________________
Tunnel Carpet, Padding, and Hardboard Replacement

Removal
NOTE: Tunnel carpet, padding, and hardboard replacement is basically the same for all models. This task represents fourpassenger model carpet replacement. 1. 2. 3. 4. Remove inner kick panels. Remove carpet from tunnel (Figure 10-54). Remove padding from tunnel. Remove panel fasteners and hardboard from tunnel.
VISOR REPLACEMENT
Removal
NOTE: Visor replacement is the same for each side of the vehicle. This procedure covers the drivers side. NOTE: If your vehicle has the lighted visor mirror, disconnect the visor mirror lead from the roof harness connector before removing the visor (Figure 10-57). Remove screws, lockwashers, washers, and visor from body (Figure 10-57).
Installation
Secure visor mounting brackets to body with four screws, lockwashers, and washers (Figure 10-57).
BODY MOUNTING BRACKETS
Installation
1. 2. 3. 4. Secure hardboard to tunnel with panel fasteners (Figure 10-54). Install padding on tunnel. Install carpet on tunnel. Install inner kick panels.
CARPET
PADDING
VISOR HARDBOARD
Figure 10-55: Visor Mounting

PANEL FASTENER TUNNEL
Figure 10-54:
Carpet and Padding Installation
Figure 10-56: Visor With Lighted Mirror
_____________________________________________________________________
Body
10-35
MIRRORS Side Mirror Replacement

Removal
Remove screws, mirror, and gasket from door hinge (Figure 10-57).
DOOR MIRROR
Installation
Secure gasket and mirror to door hinge with screws (Figure 10-57).
POWER MIRRORS Power Mirror Assembly Replacement

Removal
1. 2. 3. Remove three screws securing power mirror assembly and gasket to mounting plate (Figure 10-58). Disconnect power mirror assembly connector from door jumper harness. Inspect gasket, and replace if damaged.
Installation
NOTE: Ensure door jumper harness is routed through gasket before connecting to power mirror assembly. 1.
GASKET DOOR HINGE
Connect power mirror assembly connector to door jumper harness (Figure 10-58).
NOTE: Wires from power mirror assembly must be coiled in mirror housing to ensure clearance of attachments.
Figure 10-57: Side Mirror Assembly Replacement
DOOR JUMPER HARNESS
POWER MIRROR ASSEMBLY
CONNECTOR DOOR JUMPER HARNESS
CONNECTOR
GASKET
MOUNTING PLATE
Figure 10-58: Power Mirror Assembly
05745159
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Body ______________________________________________________________________
Rearview Mirror Replacement

Removal
1. Remove screw and rearview mirror from mirror bracket (Figure 10-59).
DOOR REPLACEMENT
Door replacement varies in complexity depending on the type and number of components that must be removed from the old door and installed on the new door. Removal and installation of these components are detailed in the previous pages of this section. Any reference to wiring harness removal and installation is covered in Section 12. The following door replacement procedure is written assuming the presence of power equipment. When replacing doors with manual equipment, follow this procedure but skip the power/electrical steps. Refer to manual window regulator removal and installation at the end of this procedure when needed. NOTE: Door replacement is basically the same for all doors.
NOTE: Perform step 2 only if bracket requires replacement. Mark location of bracket prior to removal. 2. Remove bracket from windshield.

Clean epoxy remains from windshield.
Installation
NOTE: Perform step 1 only if bracket was removed. 1. 2. Secure mirror bracket to windshield with quick-drying epoxy. Allow to dry (Figure 10-59). Secure rearview mirror to mirror bracket with screw.
Removal
CAUTION: To avoid damage, support door during removal. 1. 2. 3. 4. Remove sideview mirror (front doors only). Remove door harness from pillar (Section 12). Remove door stop strap assembly. Remove twelve-point bolts and washers securing upper door hinge to pillar (Figure 10-60).
WINDSHIELD
REARVIEW MIRROR
UPPER DOOR HINGE UPPER HINGE PLATE
MIRROR BRACKET
Figure 10-59: Rearview Mirror

PILLAR DOOR
LOWER HINGE PLATE
LOWER DOOR HINGE
Figure 10-60: Door Mounting

5. 6. Close door. Remove twelve-point bolts and washers securing lower door hinge to pillar and remove door.
_____________________________________________________________________
Body
10-37
Disassembly
1. Remove twelve-point bolts, washers, and upper and lower hinge plates from door (Figure 10-60).
WINDOW SWITCH (REAR DOORS) POWER WINDOW SWITCH INSIDE OPERATING ROD DOOR POWER DOOR LOCK SWITCH
MOISTURE BARRIER FLAP
VAPOR BARRIER
INSIDE DOOR HANDLE
Figure 10-62: Vapor Barrier and Moisture Barrier Flap

11. Remove screws, lockwashers, and latch assembly from door (Figure 10-64). 12. Remove all rods from door latch assembly.
DOOR PULL HANDLE ARMREST DOOR
Figure 10-61: Door Trim Breakdown

2. Remove power windows and/or door locks switches from door (refer to procedure in this section). 3. Remove screws and door pull handle or armrest from door trim panel (Figure 10-61). 4. Remove screws securing inside door handle to door trim panel. Pull handle away from trim panel, and disconnect inside operating rod from handle. 5. Remove screw/washer assemblies and door trim panel from door. 6. Remove vapor barrier and moisture barrier flap from door (Figure 10-62). 7. Disconnect inside operating rod from door latch assembly and remove rod (Figure 10-63). 8. Remove lock cylinder clip from lock cylinder. 9. Push lock cylinder through outside of door. Remove clip securing lever and lock operating rod to cylinder and remove cylinder from door (Figure 10-65). 10. Remove nuts and lockwashers securing gasket and outside door handle to door. Disconnect outside operating rod from handle, and remove handle.
DOOR LATCH ASSEMBLY
LOCK CYLINDER
INSIDE OPERATING ROD
LOCK CYLINDER CLIP
Figure 10-63: Inside Operating Rod Location
05745159
10-38
Body ______________________________________________________________________
DOOR OUTSIDE DOOR HANDLE GASKET CLIP
LOCK OPERATING ROD OUTSIDE OPERATING ROD DOOR LATCH ASSEMBLY LOCK CYLINDER
Figure 10-64: Latch Assembly

CAUTION: Firmly support glass during regulator removal to avoid damage. Remove power window regulator (refer to procedure in this section).
Figure 10-65: Lock Cylinder and Outside Door Handle

NOTE: Vapor barrier must be completely sealed at all edges to prevent water entry into the interior of the vehicle. 8. 9. 10. 11. 12. 13. Install moisture barrier flap and vapor barrier on door (Figure 10-62). Secure door trim panel to door with screw/washer assemblies (Figure 10-61). Connect inside operating rod to inside door handle, and install inside door handle on door trim panel with screws. Install door pull handle or armrest on door trim panel with screws. Install power window switch. Secure upper and lower hinge plates to door with washers and twelve-point screws (Figure 10-66).

NOTE: Clean all components, and examine for wear or damage. Replace if necessary.
Assembly
1. 2. Install power windows regulator (refer to procedure in this section). Install all rods on door latch assembly (Figure 10-64).
WARNING: Screws securing latch assembly have metric threads. Substituting non-metric threaded screws can result in door opening during vehicle operation. Do not substitute screws.
3. 4. Secure latch assembly to door with lockwashers and screws. Connect outside operating rod to outside door handle, and secure gasket and outside door handle to door with nuts and lockwashers (Figure 10-65). (Front doors only) Install lock cylinder in door and secure lock operating rod and lever to lock cylinder with clip. (Front doors only) Secure lock cylinder in door with lock cylinder clip (Figure 10-63). Install inside operating rod on door latch assembly.
Installation
CAUTION: To avoid damage, support door during installation. 1. 2. 3. 4. 5. 6. Secure lower door hinge to pillar with washers and twelvepoint screws. Do not tighten screws (Figure 10-66). Secure upper door hinge to pillar with washers and twelve-point screws. Do not tighten screws. Install door stop strap assembly. Install power windows and door locks harness on pillar (Section 12). Install sideview mirror (front doors only). Install sideview mirror (front doors only).
5. 6. 7.
_____________________________________________________________________
Body
10-39
Manual Window Regulator (Optional)

NOTE: At this point it is assumed that door panel has been removed for access to window regulator.
UPPER DOOR HINGE
Removal
1. 2. 3. Remove nuts and lockwashers securing regulator post to window assembly (Figure 10-67). Remove screws and lockwashers securing regulator post to door. Remove screws, lockwashers and regulator from door.
UPPER HINGE PLATE
PILLAR DOOR DOOR LOWER HINGE PLATE LOWER DOOR HINGE WINDOW ASSEMBLY
Figure 10-66: Door Hinges
Adjustment
1. 2. Loosen twelve-point screws securing upper and lower door hinges to pillar (Figure 10-66). Raise door as high as possible. Push hinges toward front of vehicle as far as they will go, and tighten twelve-point screws 6 lb-ft (8 Nm). Loosen twelve-point screws securing upper and lower hinge plates to door. Close door and tighten twelve-point screws.
REGULATOR REGULATOR POST
3. 4.
Figure 10-67: Window Regulator Mounting
Installation
1. 2. 3. Secure regulator to door with lockwashers and screws. Secure regulator post to door with lockwashers and screws. Secure regulator post to window assembly with lockwashers and nuts.
05745159
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Body ______________________________________________________________________
POWER WINDOWS Power Window Regulator Replacement

Removal
NOTE: Operate motor to position glass in opening to provide access to two screws securing glass and its bracket to regulator. If motor is inoperative, other means to remove these screws will be necessary such as drilling access holes in door inner panel. 1. Remove power window and door lock switches from door. Disconnect switches from power window and door lock harness connectors. Remove door trim and vapor barrier .
7. 8.
9.
Remove four screws and lockwashers cable and bracket assembly to door. Discard lockwashers. Remove two screws, lockwashers, and washers securing regulator cable and bracket assembly to window bracket. Discard lockwashers. Remove tie strap and regulator from door. Discard tie strap.
Installation
1. Install regulator in door and secure with tie strap (Figure 10-68). 2. Secure regulator cable and bracket assembly to window bracket with two washers, lockwashers, and screws. 3. Secure regulator cable and bracket assembly to door with four lockwashers and screws. 4. Secure regulator motor to door with screw. 5. Install regulator bracket on door with two lockwashers and screws. 6. Secure regulator bracket to regulator with lockwasher and screw. 7. Connect power window and door lock harness connector to regulator motor. 8. Check operation of regulator. 9. Install door trim and vapor barrier. 10. Install power window and door switches on door. Connect power window and door lock harness connectors to switches.
REGULATOR CABLE AND BRACKET ASSEMBLY
2.
CAUTION: Support window in full up position during regulator removal to avoid damage. NOTE: Prior to removal, mark location of screws for installation. 3. Disconnect power window and door lock harness connector from regulator motor (Figure 10-68) (push locking tab up on bottom of connector). Remove two screws and lockwashers securing regulator bracket to door. Discard lockwashers. Remove screw, lockwasher, and regulator bracket from regulator. Discard lockwashers. Remove screw securing regulator motor to door.
TIE STRAP
4. 5. 6.
WINDOW BRACKET
REGULATOR MOTOR
DOOR
REGULATOR BRACKET POWER WINDOW AND DOOR LOCK HARNESS
Figure 10-68: Power Window Regulator
_____________________________________________________________________
Body
10-41
DOOR SEALS REPLACEMENT

NOTE: The door seals come in bulk and must be cut to the appropriate lengths. For hard top vehicles, cut 12 feet for the doors and 10 feet for the body opening. For soft-top vehicles, cut 6 feet for the doors and 5 feet for the body opening.
Removal
NOTE: Note position of old seals before removal. 1. 2. Remove door strap so that door will swing open far enough to access seals. Remove the old seal from the door frame and the body area. Clean any remaining adhesive residue from the door surface.
BODY SEALS LOCATION BODY SEALS LOCATION
Figure 10-70: Body Seals Location
DOOR STOP STRAP ASSEMBLY REPLACEMENT

Removal
1. 2. 3. Remove bolt, washer, and door stop strap assembly from door (Figure 10-71). Remove two bolts, washers, door stop strap assembly, and courtesy light from A-pillar (front door only). Remove bolt, washer, and door stop strap assembly from B-pillar (rear door only).
Installation
1. 2. Cut the door and body seals to the proper lengths (see note above). Beginning at the bottom of the door, press door seal around the outside of the door frame (Figure 10-69).
DOOR STRAP
Installation
BODY SEAL TERMINATES HERE
1. 2.
3.
Secure door stop strap assembly to door with washer and bolt. Tighten bolt 12 lb-ft (16 Nm) (Figure 10-71). Secure courtesy light and door stop strap assembly to Apillar with two washers and bolts. Tighten bolts to 12 lb-ft (16 Nm) (front door only). Secure door stop strap assembly to B-pillar with two washers and bolts. Tighten bolts to 78 lb-ft (106 Nm) (rear door only).
BODY SEAL TERMINATES HERE ENDS OF DOOR SEAL HERE
DOOR GLASS Door Glass Replacement

NOTE: Door glass replacement is the same for all doors. This procedure covers the right front door.
DOOR SEAL DOOR SEAL CROSS SECTION BODY SEAL CROSS SECTION
Removal
1. 2. Remove window regulator. Remove beltline seal (Figure 10-72).
NOTE: Mark location of screws prior to removal for installation. 3. Remove four screws, lockwashers, front and rear channels, and door window seals from door. Rotate glass/lift channel bracket assembly 90 degrees and remove through window opening (Figure 10-73).
Figure 10-69: Door and Body Seal Replacement

3. 4. Apply body seal in the same location as the seal that was removed. Install door strap. 4.
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Body ______________________________________________________________________
A-PILLAR
DOOR STOP BRACKET
B-PILLAR
DOOR STOP BRACKET STRAP
DOOR
DOOR STOP BRACKET
FRONT DOOR
REAR DOOR
Figure 10-71: Door Stop Strap Assembly

DOOR WINDOW SEAL

NOTE: Clean all components, examine for wear or damage, and replace if necessary. Remove all glass remains from channels and bottom of door (Figures 10-72 and 10-73).
BELTLINE SEAL
Installation
1. 2. Insert glass/lower channel bracket assembly into door through window opening at 90 from installed position. Rotate glass/lower channel bracket assembly so that it is aligned with the appropriate channels (Figure 10-73) Install glass in front and rear channels and channel brackets, and secure channels and channel brackets to door with four lockwashers and screws (Figure 10-72). Install upper and lower window channels. Install window regulator. Operate window several times to ensure glass is properly aligned.
FRONT CHANNEL
3.
4. 5. 6.
REAR CHANNEL
Figure 10-72:
Window Channel Locations
Section 10 Body
_____________________________________________________________________
Body
10-43
HOOD, HOOD LATCH, AND PROP ROD Hood Latch and Bracket Replacement
Removal
GLASS WINDOW
NOTE: If only the rubber latch is to be replaced, the spring pin does not have to be completely out of base. 1. 2. 3. Remove spring pin and rubber latch from base (Figure 10-74). Remove two locknuts, washers, bolts, washers, and base from body. Remove five locknuts, washers, bolts, latch bracket, latch plate, and hood latch stop bracket from hood. Discard locknuts (Figure 10-74).
Disassembly
Remove cotter pin, spring pin, two rollers, and hood latch from rubber latch (Figure 10-74).
Assembly
LIFT CHANNEL BRACKET
Figure 10-73: Glass/Lift Channel Bracket Location
Secure hood latch to rubber latch with two rollers, pin, and cotter pin (Figure 10-74).
SPRING PIN
Door Glass Wind Noise Diagnosis and Repair/Side Window Alignment

Wind noise or whistle generating from the side windows at highway speeds is the result of inadequate sealing of the glass at the upper seal. The glass must be properly aligned in the window opening, adjust door glass as follows:. 1. Loosen, but do not remove, lift channel bracket mounting bolts. 2. Place block of wood (or equivalent symmetrical object) across upper seal of window opening. 3. Roll window up so that glass contacts block of wood and squares itself on window opening. 4. Tighten lift channel bracket mounting bolts. 5. Verify proper window operation.
ROLLER
HOOD LATCH
BASE RUBBER LATCH PIN ROLLER
BODY
Figure 10-74: Hood Latch Replacement
Installation
1. Secure latch plate and hood latch stop bracket to hood with three bolts, washers, and locknuts. Tighten locknuts to 10 lb-ft (14 Nm) (Figure 10-74). Secure latch bracket to latch plate with two bolts, washers, and locknuts. Tighten locknuts to 10 lb-ft (14 Nm). Apply sealing compound before securing base to body with two washers, bolts, washers, and locknuts. Tighten bolts to 6 lb-ft (8 Nm) (Figure 10-74). Secure rubber latch to base with spring pin.
2. 3.
4.
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Body ______________________________________________________________________
LATCH PLATE LATCH BRACKET
CABLE MOUNTING BRACKET
CABLE ASSEMBLY
HOOD WASHER HOOD LATCH STOP BRACKET HANDLE
Figure 10-75: Hood Latch Bracket and Latch Plate Replacement
Figure 10-76: Hood Release Handle Assembly Mounting
Hood Release Cable Assembly Replacement

Removal
1. 2. 3. 4. 5. Raise and secure hood. Remove cable handle, two nuts, lockwasher, nut, and cable assembly from cable mounting bracket. Remove cable assembly from cable clamp bracket (Figure 10-77). Remove cable assembly and grommet from body. Remove lock pin from cable assembly.
LOCK PIN CABLE CLAMP BRACKET CABLE ASSEMBLY
Installation
1. 2. 3. 4. 5. Install lock pin on cable assembly (Figure 10-77). Secure cable assembly to cable clamp bracket. Secure cable assembly to cable mounting bracket with nut, lockwasher, two nuts, and cable handle (Figure 10-76). Install grommet and cable assembly on body and apply sealer around cable and grommet. Lower hood.
APPLY SEALER GROMMET BODY
9-S10-001
Figure 10-77: Hood Release Cable Assembly
Hood Release Latch and Bracket Assembly Replacement

Removal
1. 2. 3. 4. 5. Raise and secure hood. Remove two bolts, lockwashers, and latch assembly from hood (Figure 10-78). Remove pin, spring, and lock arm from latch assembly (Figure 10-79). Remove cable assembly from cable clamp bracket (Figure 10-77). Remove three nuts, lockwashers, bolts, and bracket assembly from body (Figure 10-80).
_____________________________________________________________________
Body
10-45
6. 7.
Remove two nut and lockwasher assemblies, screws, cable clamp bracket, and spacer from bracket assembly. Inspect three nylon bushings in bracket assembly. Remove and discard bushings if damaged.
HOOD
CABLE CLAMP BRACKET SPACER CABLE ASSEMBLY
LATCH ASSEMBLY
PROP ROD
BRACKET ASSEMBLY
NUT AND LOCKWASHER ASSEMBLY
BODY
9-S10-002
Figure 10-78: Hood Release Latch and Bracket Assembly Mounting

1.
LOCK ARM
Figure 10-80: Cable Clamp Bracket Assembly Breakdown
Installation
SPRING
2.
3. 4. 5.
PIN LATCH ASSEMBLY
6. 7.
Insert three nylon bushings into bracket assembly, if removed (Figure 10-80). Secure spacer and cable clamp bracket to bracket assembly with two screws and nut and lockwasher assemblies. Secure bracket assembly to body with three bolts, lockwashers, and nuts. Secure cable assembly to cable clamp bracket (Figure 10-77). Seal grommet with silicone sealer. Secure spring and lock arm to latch assembly with pin (Figure 10-79). Secure latch assembly to hood with two lockwashers and bolts (Figure 10-78). Lower hood.
Hood Prop Rod and Bracket Replacement

Removal
Figure 10-79: Latch Assembly Breakdown
WARNING: To avoid injury or damage to equipment, support hood during hood prop rod and bracket replacement.
1. 2. 3. Raise and support hood. Remove cotter pin, two washers, and hood prop rod from hood (Figure 10-81). Remove four screws, lockwashers, bracket, and hood prop rod from airlift bracket (Figure 10-82).
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Body ______________________________________________________________________
Assembly
HOOD
1.
Secure bushing to bracket with snapring (Figure 10-83).
NOTE: Length of spring with bracket assembled is 2-1/4 in. (5.7 cm). 2. 3. Secure washer, eyebolt, spring, bushing, washer, and locknut to bracket. Install hood prop rod into eyebolt.
HOOD PROP ROD SPRING HOOD PROP ROD BUSHING BUSHING SNAPRING BRACKET
Figure 10-81: Hood Prop Rod Replacement
AIRLIFT BRACKET HOOD PROP ROD
EYEBOLT
Figure 10-83: Hood Prop Rod and Bracket Assembly Breakdown
Installation
1. Secure hood prop rod and bracket to airlift bracket with four lockwashers and screws. Tighten screws to 6 lb-ft (8 Nm) (Figure 10-82). Secure hood prop rod to hood with two washers and cotter pin (Figure 10-81). Lower hood.
2. 3.
BRACKET
Figure 10-82: Hood Prop Rod and Bracket Replacement
Disassembly
1. 2. Remove hood prop rod from eyebolt (Figure 10-83). Remove locknut, washer, bushing, spring, snapring, bushing, washer, and eyebolt from bracket.

NOTE: Clean all components, and examine for wear or damage. Replace if necessary. Inspect two bushings and spring for cracks, wear, or distortion (Figure 10-83).
_____________________________________________________________________
Body
10-47
Hood and Hinge Replacement

Removal
1. Raise and secure hood.
Installation
NOTE: Perform steps 1 and 2 if hinges were removed. 1. Secure two spacers, two lower hinge halves and hinge plates to two brackets with four washers, bolts, washers, and locknuts. Do not tighten bolts (Figure 10-84). Secure hinge plates and two upper hinge halves to hood with four washers and bolts. Tighten bolts to 28 lb-ft (38 Nm). Install hood by mating two upper hinge halves to lower hinge halves and securing with washers, hinge pins, washers, and four cotter pins. Connect two connector plugs to connector receptacles. Secure hood prop rod to hood with two washers and cotter pin (Figure 10-84). Align hood. Check headlight aim and adjust if necessary.
WARNING: To avoid injury, or damage to equipment, support hood during removal and installation.
2. 3. 4. 5. Disconnect two connector plugs from connector receptacles (Figure 10-84). Remove four cotter pins, washers, and two hinge pins securing upper hinge halves to lower hinge halves. Remove cotter pin, two washers, and prop rod from hood (Figure 10-84). Remove hood.
2.
3.
4. 5. 6. 7.
NOTE: Perform steps 6 and 7 if replacing hinges. 6. 7. Remove four bolts, washers, two upper hinge halves, and hinge plates from hood (Figure 10-84). Remove four locknuts, washers, two hinge plates, four bolts, washers, two lower hinge halves, and two spacers from brackets.
Hood Alignment
Alignment should be checked whenever replacing the hood stops, hinges, or latches. Surfaces that adjoin hood seals should be checked for signs of wear from hood movement. 1. Inspect hood prior to adjustment to determine condition of seals, hinges, and stops. Replace or repair any worn parts.
CENTER HOOD STOP
HINGE PLATE UPPER HINGE HALF SPACER
HOOD
COWL PANEL
HINGE PIN
A-PILLAR
LOWER HINGE HALF BRACKET
CONNECTOR PLUG
MIN.3/8 MAX. 1/2
HINGE PLATE
A-PILLAR
HOOD
MIN.3/8 MAX. 1/2
CONNECTOR RECEPTACLE
COWL PANEL
Figure 10-84: Hood and Hinge Assembly Breakdown
MIN.3/8 MAX. 1/2
HOOD COWL PANEL

MIN.3/8 MAX. 1/2
RIGHT SIDE
Inspection and Repair

NOTE: Refer to Fiberglass Repair for inspection and repair of hood.
Figure 10-85: Center Hood Stop Location

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2. 3.
Body ______________________________________________________________________
Open hood and loosen center hood stop (Figure 10-85). Gently close hood and loosen lower hinge half locknuts (Figure 10-86).
LOWER HINGE HALF LOCKNUTS SIDE HOOD STOP
HOOD LATCH
Figure 10-86: Lower Hinge Half Locknut Location

4. Gently position hood to obtain proper and even clearance with A-pillar and both front cowl panels (minimum 3/8 / maximum 1/2) (Figure 10-85). Tighten lower hinge half locknuts to lock adjustment. Open hood gently and position guide bracket assembly to contact center hood stop. Gently close hood to check guide bracket assembly position (Figures 10-85 and 10-87). Tighten and recheck guide bracket assembly position. When properly positioned, tighten to 10 lb-ft (14 Nm) (Figure 10-87). Tighten front lower hinge half locknuts to 28 lb-ft (38 Nm) and recheck hood position (Figure 10-86).
GUIDE BRACKET ASSEMBLY HOOD HOOD CATCH
Figure 10-88: Hood Latch and Stop Location
Outer Hood Seal Replacement

Removal
Remove two bolts, seal retainer, and hood seal from body (Figure 10-89).
5.
Installation
Secure hood seal to body with seal retainer and two bolts (Figure 10-89).
SEAL RETAINER
6.
7.
BODY
Figure 10-87: Guide Bracket Assembly Location

8. Lubricate all hood stops, hinges, and guide brackets. Latch hood (Figure 10-88). 9. Test drive to ensure proper alignment (no squeaks). 10. Check headlight aim and adjust if necessary.
HOOD SEAL
Figure 10-89: Outer Hood Seal Replacement
_____________________________________________________________________
Body
10-49
Side Hood Stop Replacement

Removal
Remove two locknuts, washers, bolts, washers, and side hood stop from body (Figure 10-90).
GRILLE
HOOD
Installation
Secure side hood stop to body with two washers, bolts, washers, and locknuts. Tighten bolts to 6 lb-ft (8 Nm) (Figure 10-90).
SCREEN
Figure 10-91: Grille and Screen Replacement

SIDE HOOD STOP
Center Hood Stop Replacement

Removal
Remove two bolts, washers, center hood stop, and plate from A-beam (Figure 10-92).
Installation
Secure center hood stop and plate to A-beam with two washers and bolts. Tighten bolts to 12 lb-ft (16 Nm) (Figure 10-92).
BODY
CENTER HOOD STOP
Figure 10-90: Side Hood Stop Replacement
Grille and Screen Replacement

Removal
1. 2. Remove six locknuts, washers, bolts, washers, and grille from hood (Figure 10-91). Remove six locknuts, washers, screws, washers, and screen from grille.
A-BEAM
PLATE
Installation
1. Secure screen to grille with six washers, screws, washers, and locknuts. Tighten locknuts to 6 lb-ft (8 Nm) (Figure 10-91). Secure grille to hood with six washers, screws, washers, and locknuts. Tighten locknuts to 7 lb-ft (9 Nm).
Figure 10-92: Center Hood Stop Replacement
2.
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Body ______________________________________________________________________
Guide Bracket Assembly Replacement

Removal
Remove six locknuts, twelve washers, guide bracket assembly, guide plate, and six bolts from hood (Figure 10-93).
Right Hood Retainer Bracket Replacement

Removal
Remove four bolts, lockwashers, washers, right hood retainer bracket, and spacer from hood (Figure 10-95).
Installation
1. Loosely attach guide plate and guide bracket assembly to hood with six bolts, twelve washers, and six locknuts. Tighten locknuts to 10 lb-ft (14 Nm) (Figure 10-93). Lower hood and align guide bracket assembly with center hood stop on A-beam (Figure 10-92). Mark guide bracket assembly position, raise hood, and tighten locknuts to 10 lb-ft (14 Nm) (Figure 10-93).
GUIDE PLATE HOOD GUIDE BRACKET ASSEMBLY
Installation
Secure right hood retainer bracket and spacer to hood with four washers, lockwashers, and bolts (Figure 10-95).
2. 3.
SPACER
RIGHT HOOD RETAINER BRACKET
Figure 10-95: Right Hood Retainer Bracket Replacement
Left Hood Retainer Bracket Replacement

Removal
Figure 10-93: Bracket Assembly Replacement
Remove four bolts, lockwashers, washers, left hood retainer bracket, and four washers from hood (Figure 10-96).
Front Hood Screen Replacement

Removal
1. 2. Remove three locknuts, washers, and carriage bolts securing front hood screen to hood (Figure 10-94). Remove three bolts, harness clamps, washers, and front hood screen from hood.
Installation
Install left hood retainer bracket on hood with eight washers, four lockwashers, and bolts (Figure 10-96).
HOOD
Installation
1. Secure front hood screen to hood with three washers, harness clamps, and bolts. Tighten bolts to 20-30 lb in. (2-3 Nm) (Figure 10-94). Secure front hood screen to hood with three carriage bolts, washers, and locknuts. Tighten locknuts to 21 lb-ft (29 Nm).
2.
Figure 10-96: Left Hood Retainer Bracket
HOOD
HARNESS CLAMP FRONT HOOD SCREEN
Figure 10-94: Front Hood Screen Replacement
_____________________________________________________________________
Body
10-51
Right Hood Close-Out Seal and Retainer Replacement

Removal
1. 2. Remove two screws and upper seal retainer from close-out seal and hood (Figure 10-97). Remove two screws, lower seal retainer, and close-out seal from hood.
UPPER SEAL RETAINER LOWER SEAL RETAINER
Airlift Bracket Seal Replacement

NOTE: Turbo Diesel models have thick foam pads around the inside of the hood grille. These pads help to direct air flow through the radiator and provide better engine cooling. The upper pad is held down by the air lift bracket seal and seal protector. (Figure 10-98).
Removal
Lift protector and seal from airlift bracket (Figure 10-98).
Installation
Slide seal and protector onto airlift bracket (Figure 10-98).
UPPER PAD
SEAL PROTECTOR
AIRLIFT BRACKET SEAL
HOOD CLOSE-OUT SEAL WELLNUT
RETAINING PLATES
SIDE PAD
Figure 10-97: Right Hood Close-Out Seal Location

3. Inspect four wellnuts for damage. Replace if defective or damaged.
SPLASH SHIELD SEAL
Installation
1. 2. Secure close-out seal and lower seal retainer to hood with two screws (Figure 10-97). Secure upper seal retainer to close-out seal and hood with two screws.
Figure 10-98: Foam Pad Mounting
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Body ______________________________________________________________________
ENGINE SPLASH SHIELD REPLACEMENT

NOTE: Turbo Diesel models have thick foam pads around the inside of the hood grille. These pads help to direct air flow through the radiator and provide better engine cooling (Figure 10-98). The side pads are secured to the splash shield seals with retaining plates, screws, and locknuts.
Disassembly
1. 2. Remove seven locknuts, washers, screws, seal, and two retainers from splash shield (Figure 10-99). Remove four rivets and bushing from splash shield.
Assembly
1. 2. Secure bushing to splash shield with four rivets (Figure 10-99). Secure seal and two retainers to splash shield with seven screws, washers, and locknuts.
Removal
WARNING: To avoid injury, or damage to equipment, raise and support hood during removal and installation.
1. 2. 3. 4. 5. 6. 7. 8. Remove hood prop rod and bracket. Disconnect hood harness connector receptacles from connector plugs (Figure 10-99). Remove locknut, washer, bolt, and washer securing splash shield to support bracket. Remove locknut, three washers, and bolt securing splash shield to airlift bracket. Remove bolt, lockwasher, and washer securing splash shield to airlift bracket. Remove screw, two washers, locknut, clamp, and two connector plugs from splash shield. Remove nut and lockwasher assembly and screw securing harness and clamp to splash shield (Figure 10-100). Remove locknut, two washers, bolt and splash shield from bracket (Figure 10-99).
RETAINER SEAL RETAINER AIRLIFT BRACKET SPLASH SHIELD BRACKET SUPPORT BRACKET
Installation
1. 2. 3. 4. 5. Secure splash shield to bracket with, bolt, washers, and locknut (Figure 10-99). Secure harness and clamp to splash shield with screw and nut and lockwasher assembly (Figure 10-100). Secure two connector plugs to splash shield with clamp, screw, two washers, and locknut (Figure 10-99). Secure splash shield to airlift bracket with washer, lockwasher, and bolt. Tighten bolt to 10 lb-ft (14 Nm). Secure splash shield on airlift bracket with washer, capscrew, two washers, and locknut. Tighten capscrew to 10 lb-ft (14 Nm). Secure splash shield to support bracket with washer, bolt, washer, and locknut. Tighten bolt to 6 lb-ft (8 Nm). Attach hood harness connector receptacles to connector plugs. Install hood prop rod and bracket.
6. 7. 8.
CLAMP
SPLASH SHIELD BUSHING CONNECTOR PLUGS HOOD HARNESSES HARNESS
Figure 10-99: Engine (Left) Splash Shield Assembly Replacement
Figure 10-100: Wiring Harness Clamp Location
_____________________________________________________________________
Body
10-53
HORN Horn Replacement

Removal
1. 2. Remove harness connectors and adapters from horn. Remove nut and horn from mounting bracket (Figure 10-101).
WINDSHIELD ASSEMBLY Windshield Glass and Weatherstrip Replacement

Removal
1. 2. 3. 4. 5. 6. Remove windshield wiper arm and blade. Remove six bolts and upper retainer from windshield frame (Figure 10-102). Remove four bolts and center retainer from windshield frame. Remove four bolts and lower retainer. Remove weatherstrip and glass from windshield frame. Clean sealing compound from windshield frame.
NOTE: Overtightening horn mounting nut will distort the horn bellows and result in an off-key horn tone.
Installation
1. 2. Secure horns to mounting bracket with nuts. Plug harness connectors and adapters into horns.
Installation
NUT HORN HORN
1. 2. 3. 4. 5. 6.
NUT
7.
ADAPTERS
Apply a 1/8 in. (3 mm) bead of sealing compound to edge of glass and windshield frame (Figure 10-102). Position weatherstrip on glass. Position glass and weatherstrip to windshield frame with center retainer and four bolts. Secure upper retainer to windshield frame with six bolts. Secure lower retainer to windshield frame with four bolts Apply a thin bead of sealing compound to top edge of outside weatherstrip. Install windshield wiper arm and blade.
WINDSHIELD FRAME
WEATHERSTRIP UPPER RETAINER MOUNTING BRACKET HARNESS CONNECTORS
GLASS
Figure 10-101: Horn and Horn Mounting Bracket Replacement
Horn Mounting Bracket Replacement

Removal
1. 2. Remove two horns. Remove bolts, washers, lockwashers, nuts, and horn mounting bracket from airlift bracket (Figure 10-101).
CENTER RETAINER LOWER RETAINER
Figure 10-102: Windshield Glass Replacement
Installation
1. 2. Secure horn mounting bracket to airlift bracket with bolts, washers, lockwashers, and nuts (Figure 10-101). Install two horns.
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Body ______________________________________________________________________
Windshield Assembly Replacement

WARNING: To avoid injury, or damage to equipment, support windshield during removal and installation.
Removal
1. 2. 3. 4. 5. Remove soft top or loosen roof assembly, as applicable. Remove windshield wiper blade and arm. Remove windshield wiper linkage. Remove windshield wiper arm pivots. Remove two locknuts and bolts securing windshield assembly to A-pillar (Figure 10-103).
WINDSHIELD ASSEMBLY SEALS
WIPER MOTOR
ROOF HARNESS
COMPASS MIRROR CLEARANCE LIGHT
BRACKET A-PILLAR HEATED WINDSHIELD

9-S12-102
Figure 10-104: Wiring Harness Lead Location
Disassembly
NOTE: Perform steps 1 and 2 for open-top models. Perform step 3 for all other models. 1. 2. Remove eleven rivets, former, and seal from windshield assembly (Figure 10-105). Remove eight rivets and two corner caps from windshield assembly, and replace if damaged. Remove thirteen rivets, former, and seal from windshield assembly (Figure 10-105). Clean remains of seal from windshield assembly.
Figure 10-103: Windshield Assembly Mounting

6. Disconnect roof harness, wiper motor, heated windshield, clearance light and compass mirror connections at center pillar and pull harness loose from windshield center pillar (Figure 10-104). 7. Remove six bolts and washers securing windshield assembly to two brackets (Figure 10-103). 8. Remove windshield assembly from A-pillar. 9. Remove two seals from windshield assembly. 10. Clean remains of seals from windshield. 3. 4.
Assembly
NOTE: Perform steps 1 and 2 for open-top models. Perform step 3 for all other models. 1. 2. 3. Secure seal and former to windshield assembly with eleven rivets (Figure 10-105). Secure two corner caps to windshield assembly with eight rivets. Secure seal and former to windshield assembly and secure with thirteen rivets (Figure 10-105).
_____________________________________________________________________
Body
10-55
HEATED WINDSHIELD
FORMER
SEAL
The optional heated windshield is capable of defrosting the windshield glass in less than 10 minutes at 0 F. The system is comprised of a rocker switch with an integrated time delay module (Figure 10-106), two relays, and two fuses , and inglass heating elements.
CONNECTOR TIME DELAY MODULE ROCKER SWITCH
FRONT CONSOLE INDICATOR LIGHT
CLIPS (NOT SHOWN)
POWER WINDOW MASTER SWITCH ASSEMBLY
Figure 10-106: Rocker Switch/Time Delay Module Location
WINDSHIELD ASSEMBLY
DRIVER SIDE WINDSHIELD GLASS CORNER CAP
HEATING ELEMENT JUNCTIONS
PASSENGER SIDE WINDSHIELD GLASS
Figure 10-105: Windshield Assembly Seal Replacement
Installation
1. 2. 3. 4. Position two seals on windshield assembly (Figure 10-103). Position windshield assembly over A-pillar. Secure windshield assembly to two brackets with six bolts and washers. Connect two jumper harness leads to body harness leads and insert grommet into windshield center pillar (Figure 10-104). Secure windshield assembly to A-pillar with two bolts and locknuts (Figure 10-103). Install windshield wiper arm pivots. Install windshield wiper linkage. Install windshield wiper arm and blade. Install soft top.
FRONT CONSOLE
Figure 10-107: Heating Element Junction Location

The rocker switch/time delay module is mounted on the power window master switch on the driver side of the front console (Figure 10-106).
5. 6. 7. 8. 9.
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Removal
Body ______________________________________________________________________
NOTE: Wire harnesses behind console are long enough to allow for power window master switch removal without removing console for access to electrical connectors. 1. 2. 3. Remove screws and pull power window master switch from console (Figure 10-106). Lift connector clip and pull connector from rocker switch/ time delay module. Squeeze clips on rocker switch/time delay module and remove switch/module from bezel.
WINDSHIELD WIPER SYSTEM AND COMPONENTS Windshield Wiper Motor Assembly Replacement
Removal
1. 2. 3. 4. 5. Remove center trim from windshield assembly. Remove roof mounted amplifier cover/speaker housing if equipped. Disconnect windshield wiper motor assembly harness from crossbody harness (Figure 10-108). Remove three bolts, washers, and lockwashers securing windshield wiper motor assembly to windshield assembly. Remove retainer securing windshield wiper linkage to windshield wiper motor cranking pin and remove windshield wiper motor assembly.
Installation
1. 2. 3. Push rocker switch/time delay module into bezel opening and snap into bezel. Attach electrical connector to rocker switch/time delay module. Install power window master switch in console.
Installation
1. Lubricate windshield wiper motor cranking pin and secure windshield wiper linkage to windshield wiper motor cranking pin with retainer (Figure 10-108). Secure windshield wiper motor assembly to windshield assembly with three lockwashers, washers, and bolts. Tighten bolts to 12 lb-ft (16 Nm). Connect windshield wiper motor assembly harness to crossbody harness. Install roof mounted amplifier cover/speaker housing if removed earlier. Secure center trim to windshield assembly.
RETAINER WINDSHIELD WIPER WINDSHIELD WIPER LINKAGE MOTOR CRANKING PIN
2.
3. 4. 5.
WINDSHIELD WIPER MOTOR ASSEMBLY HARNESS WINDSHIELD WIPER MOTOR ASSEMBLY WINDSHIELD ASSEMBLY
9-S10-011
Figure 10-108: Windshield Wiper Motor Assembly Replacement
_____________________________________________________________________
Body
10-57
Windshield Wiper Linkage Replacement

Removal
NOTE: Left and right side windshield wiper linkage replacement procedure is the same. This procedure covers the left side. 1. 2. 3. Remove windshield wiper motor assembly. Remove upper A-pillar trim. Disconnect windshield wiper linkage from windshield wiper pivot cranking lever pin and remove windshield wiper linkage (Figure 10-109).
Windshield Wiper Pivot Replacement

Removal
NOTE: Left and right side windshield wiper pivot replacement procedure is the same. This procedure covers the left side. 1. 2. 3. 4. Remove windshield wiper arm assembly. Remove upper A-pillar trim. Remove windshield wiper linkage from windshield wiper pivot cranking lever pin (Figure 10-110). Remove nut, washer, and rubber washer securing windshield wiper pivot to windshield assembly and remove windshield wiper pivot.
Installation
1. 2. 3. Secure windshield wiper linkage to windshield wiper pivot cranking lever pin (Figure 10-109). Install upper A-pillar trim. Install windshield wiper motor assembly on windshield assembly.
WINDSHIELD WIPER LINKAGE WINDSHIELD ASSEMBLY
Installation
1. 2. 3. 4. Secure windshield wiper pivot to windshield assembly with rubber washer, washer and nut (Figure 10-110). Secure windshield wiper linkage to windshield wiper pivot cranking lever pin. Install upper A-pillar trim. Install windshield wiper arm assembly.
WINDSHIELD WIPER ARM ASSEMBLY
WINDSHIELD ASSEMBLY
WINDSHIELD WIPER LINKAGE
WINDSHIELD WIPER PIVOT CRANKING LEVER PIN
Figure 10-109: Windshield Wiper Linkage Replacement

WINDSHIELD WIPER PIVOT
WINDSHIELD WIPER PIVOT CRANKING LEVER PIN
Figure 10-110: Windshield Wiper Pivot Replacement
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Body ______________________________________________________________________
WINDSHIELD WASHER SYSTEM AND COMPONENTS Reservoir and Pump Assembly Replacement
Removal
1. 2. 3. 4. 5. 6. 7. Drain reservoir. Remove two screws and retaining bracket securing ABS ECU enclosure. Set aside ECU with enclosure. Disconnect pump connector from reservoir and pump assembly (Figure 10-111). Disconnect fluid level connector from fluid level sensor assembly. Remove four bolts, lockwashers, and reservoir assembly from reservoir support assembly. Disconnect windshield washer hose from reservoir and pump assembly. Inspect wellnuts for damage. Replace if damaged.
FLUID LEVEL CONNECTOR PUMP CONNECTOR
Installation
1. 2. Connect windshield washer hose to reservoir and pump assembly. Secure reservoir assembly to reservoir support assembly with four lockwashers and bolts. Tighten bolts to 8 lb-ft (11 Nm) (Figure 10-111). Connect fluid level connector to fluid level sensor assembly. Connect pump connector to pump assembly. Secure ABS ECU enclosure with retaining bracket and two screws. Fill reservoir.
3. 4. 5. 6.
Windshield Washer Nozzle Replacement

Removal
1. 2. Disconnect hose from nozzle (Figure 10-112). Remove screw and nozzle from body.
Installation
1. 2. Secure nozzle to body with screw. Connect hose to nozzle.
Windshield Washer Hose Replacement

Removal
1.
RESERVOIR ASSEMBLY WINDSHIELD WASHER HOSE
2. 3. 4.
Remove two nuts, washers, screws, washers, and clamps securing hose to body (Figure 10-113). Remove two screws and retaining bracket securing ABS ECU enclosure. Set aside ECU with enclosure. Disconnect washer hose from pump and tee. Remove clamps from hose. Disconnect two hoses from tee and nozzles and remove from clamps.
Installation
RESERVOIR SUPPORT ASSEMBLY
1. 2. 3.
Figure 10-111: Windshield Washer Fluid Reservoir and Pump Replacement
4.
Slide two hoses through clamps and connect to tee and nozzles. Slide hose through clamps and connect to tee and pump. Secure hose to body with two clamps, washers, screws, washers, and nuts. Secure ABS ECU enclosure with retaining bracket and two screws.
_____________________________________________________________________
Body
10-59
NOZZLE
Figure 10-112: Windshield Washer Nozzle Replacement
CLAMPS
ECU RETAINING BRACKET
ECU ENCLOSURE
PUMP ASSEMBLY
9-S10-004
Figure 10-113: Windshield Washer Hose Replacement
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Body ______________________________________________________________________
A-PILLAR FORMER ASSEMBLY REPLACEMENT (SOFT TOP ONLY)

Removal
1. 2. 3. Remove soft top. Remove 12 screws and A-pillar former from A-pillar (Figure 10-114). Clean mounting surface on A-pillar.

NOTE: Clean all components, examine for wear or damage, and replace if necessary. Inspect wellnuts. Replace if defective or damaged.
Installation
1. 2. Peel backing paper from A-pillar former and secure former to A-pillar with 12 screws (Figure 10-114). Install soft top.
A-PILLAR FORMER
A-PILLAR
WELLNUT
Figure 10-114: A-Pillar Former Assembly Replacement
_____________________________________________________________________
Body
10-61
REAR SUPPORT BOW BRACKET REPLACEMENT

Removal
1. 2. Remove rear support bow assembly. Remove two screws and support bow bracket from body (Figure 10-115).
REAR SUPPORT BOW BRACKET
REAR STRIKER ASSEMBLY REPLACEMENT

Removal
Remove two screws, washers, backing plate, and rear striker assembly from rear door pillar (Figure 10-117).
Installation
Secure rear striker assembly to rear door pillar with backing plate, two washers, and screws (Figure 10-117). Tighten screws to 12 lb-ft (16 Nm).
REAR DOOR PILLAR REAR STRIKER ASSEMBLY
Figure 10-115: Rear Support Bow Bracket Replacement
BACKING PLATE
Installation
1. 2. Secure bracket to body with two screws (Figure 10-115). Install rear support bow assembly.
Figure 10-117: Rear Striker Assembly Replacement
BODY MOUNT REPLACEMENT

Removal
NOTE: Removal and installation procedures for intermediate and rear body mounts are the same. This procedure covers the left intermediate body mount. 1. Remove locknut, washer, bolt, washer, and two spacers securing sleeve, upper cushion, and lower cushion to body bracket and frame bracket (Figure 10-119). Raise the vehicle at the body reinforcement adjacent to body mount to be removed (Figure 10-118). Raise the body far enough to separate the upper cushion from lower cushion and remove spacer, sleeve, upper cushion, and lower cushion (Figure 10-119).
REAR MOUNT
FRONT STRIKER REPLACEMENT

Removal
Remove locknut, washer, striker guard, and striker from front door pillar (Figure 10-116).
Installation
Secure striker and striker guard to front door pillar with washer and locknut (Figure 10-116). Tighten locknut to 41 lb-ft (56 Nm).
FRONT DOOR PILLAR LOCKNUT
2. 3.
STRIKER GUARD WASHER
FRONT MOUNT STRIKER
INTERMEDIATE MOUNT
Figure 10-118: Left Side Body Mount Locations
Figure 10-116: Front Striker Assembly Replacement

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Body ______________________________________________________________________
BODY BRACKET
SPACER SLEEVE UPPER CUSHION
PROTECTIVE SHIELD
LOWER CUSHION
ATTACHMENT BOLTS
SPACER
FRAME BRACKET LICENSE PLATE SCREWS
Figure 10-119: Body Mount Cushions Replacement
Figure 10-120: Rear License Plate Bracket
Installation
1. 2. Position lower cushion, upper cushion, sleeve, and spacer between body bracket and frame bracket (Figure 10-119). Lower body and ensure lower cushion, sleeve, upper cushion, spacer and body bracket align. Secure with spacer, washer, bolt, washer, and locknut. Tighten locknut to 90 lb-ft (122 Nm).
Front License Plate Bracket Replacement

Removal
1. Remove two capscrews, lockwashers, license plate, and two grommets from bracket. Discard lockwashers (Figure 10-121). Remove two screws, lockwashers, and bracket from bumper. Discard lockwashers.
2.
LICENSE PLATE BRACKETS Rear License Plate Bracket Replacement

Removal
1. 2. 3. 4. 5. Remove four bolts and washers securing the protective light shield to the bumper. Remove two screws, lockwashers, license plate, and two grommets from bracket (Figure 10-120). Remove two bolts and lockwashers securing bracket to bumper. Disconnect two leads from light bracket, and remove bracket. Remove two nut and lockwasher assemblies, screws, and light bracket from bracket. 2. 1.
Installation
Install bracket on bumper with two lockwashers and screws (Figure 10-121). Install license plate on bracket with two grommets, lockwashers, and capscrews.
BUMPER
BRACKET LICENSE PLATE
Installation
1. 2. 3. 4. 5. Secure light bracket to bracket with two screws and nut and lockwasher assemblies (Figure 10-120). Connect two leads to light bracket. Secure bracket to bumper with two lockwashers and bolts. Secure license plate to bracket with two grommets, lockwashers, and screws. Install protective light shield with four bolts and washers.
Figure 10-121: Front License Plate Bracket
_____________________________________________________________________
Body
10-63
FUEL FILLER HOUSING REPLACEMENT Main Fuel Tank

Removal
1. 2. 3. 4. 5. 6. Remove ller cap from ller spout (Figure 10-122). Remove screw securing cap tether (not shown) to fuel filler housing, mark location for reassembly Remove three nuts, washers, capscrews, and washers securing fuel filler housing to filler spout. Remove five screws and washers securing fuel filler housing to right outer wheelhouse panel. Push filler cap through filler housing and remove fuel filler housing. Inspect six speednuts for damage. Replace if defective or missing.
Auxiliary Fuel Tank

Removal
1. 2. 3. 4. 5. Remove ve screws and fuel ller tube splash shield from inside of right rear wheelhouse. Remove filler cap from filler spout (Figure 10-123). Remove screw securing cap tether (not shown) to fuel filler housing, mark location for reassembly Remove three locknuts, washers, bolts, and reinforcement ring securing fuel filler tube to housing. Remove four screws and fuel filler housing from body.
Installation
1. 2. 3. 4. 5. Secure fuel ller housing to body with four screws. Using the fifth screw, install cap tether (not shown) to fuel filler housing at the fifth screw position. Secure fuel filler tube to housing with reinforcement ring, three bolts, washers and locknuts. Screw filler cap into filler spout. Secure fuel filler tube splash shield to brackets in right rear wheelhouse with five screws.
FILLER SPOUT FUEL FILLER HOUSING
Installation
1. Pull ller cap through fuel ller housing and install housing on right outer wheelhouse panel with ve screws.Tighten screws to 18 lb in. (2 Nm) (Figure 10-122) Using the sixth screw, install fuel cap tether (not shown) to fuel filler housing at the sixth screw position. Secure fuel filler housing to filler spout with three washers, capscrews, washers, and nuts. Install filler cap on filler spout.
2. 3. 4.
RIGHT OUTER WHEELHOUSE PANEL
REINFORCEMENT RING
FILLER CAP
FUEL FILLER HOUSING
FILLER SPOUT
FILLER CAP
SPEEDNUT SPEEDNUT RIGHT OUTER WHEELHOUSE PANEL
Figure 10-123: Fuel Filler Housing Auxiliary Fuel Tank
Figure 10-122: Fuel Filler Housing - Main Tank
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ROADSIDE EMERGENCY EQUIPMENT Tire Jack and Optional Triangle Warning Kit Hold-Down Bracket Replacement (For Two-Passenger Model)
Removal
1. 2. 3. Remove two wingnuts, washers, and hold-down brackets (Figure 10-124). Remove tire jack and triangle warning kit. Remove two studs from bracket.
Tire Jack and Optional Triangle Warning Kit Hold-Down Replacement (Four-Passenger Vehicle, Station Wagon, and Open Body)
Removal
1. 2. 3. 4. Remove triangle warning kit and tire jack from under right rear seat. Remove two wing nuts, washers, screws, clamp bracket, and hold-down bracket from seat support (Figure 10-125). Remove nut, washer, screw, washer, and strap bracket from seat support. Remove nut, washer, screw, washer, and strap from strap bracket.
Installation
1. 2. 3. Place tire jack and triangle warning kit in place (Figure 10-124). Install two studs on bracket. Install two hold-down brackets on studs with two washers and wing nuts.
Installation
1. 2. Secure strap to strap bracket with screw, two washers, and nut (Figure 10-125). Secure strap bracket to seat support with screw, two washers, and nut. Secure hold-down bracket and clamp bracket to seat support with two screws, washers, and wing nuts. Position tire jack and triangle warning kit in place, and secure with strap.
SEAT SUPPORT CLAMP BRACKET
HOLD-DOWN BRACKET
3. 4.
STUD
STRAP BRACKET
TIRE JACK BRACKET
TRIANGLE WARNING KIT (OPTIONAL) STRAP HOLD-DOWN BRACKET
Figure 10-124: Emergency Equipment Hold-Down Bracket - Two-Passenger Vehicle
Figure 10-125: Emergency Equipment Hold-Down Bracket Replacement Four-Passenger Vehicle
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FOUR-PASSENGER SOFT TOP Interior Trim Replacement

Removal
1. 2. 3. 4. Remove front and rear seats. Remove front and center consoles. Remove speakers from rear wall (Section 12). Remove two panel fasteners from upper center trim of windshield frame (Figure 10-127). 5. Remove five screw and washer assemblies and upper center and center trim from windshield frame. 6. Remove four screw and washer assemblies and trim from side of rear compartment wall (Figure 10-128). 7. Remove three screws, and upper B-pillar trim piece (Figure 10-126). 8. Remove three screws and lower B-pillar trim from Bpillar (Figure 10-126). 9. Disconnect courtesy light electrical connector, and remove courtesy light lens, two rivets, washers, and courtesy light from trim. 10. Remove four screws, two panel fasteners, lower trim, and trim from rear compartment wall (Figure 10-128).
PANEL FASTENER UPPER CENTER TRIM
11. Remove screw and washer assembly and center trim from rear compartment wall.
UPPER B-PILLAR TRIM
LOWER B-PILLAR TRIM
CENTER TRIM
WINDSHIELD FRAME
Figure 10-127: Upper Trim Replacement
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CENTER TRIM
TRIM
PANEL FASTENER PANEL FASTENER
UPPER CENTER TRIM
WINDSHIELD FRAME
LOWER TRIM
CENTER TRIM
TRIM
Figure 10-128: Rear Wall Compartment Location
Installation
1. 2. 3. 4. Secure center trim to rear compartment wall with screw and washer assembly (Figure 10-128). Secure lower trim and trim to rear compartment wall with two panel fasteners and four screw and washer assemblies. Secure trim to rear compartment wall with four screw and washer assemblies. Connect courtesy light electrical connector, and secure courtesy light to trim with two washers and rivets (Figure 10-126). Secure courtesy light lens to courtesy light bracket.
Figure 10-129: Interior Trim Replacement
5. 6. 7.
Fasten lower B-pillar trim with 3 screws. Position upper B-pillar trim piece, overlapping the lower B-pillar trim piece, attach with 3 screws. 8. Secure center trim to windshield frame with two screw and washer assemblies (Figure 10-129). 9. Secure upper center trim to windshield frame and center trim with two panel fasteners and three screw and washer assemblies. 10. Install speakers on rear wall (Section 12). 11. Install front and center consoles. 12. Install front and rear seats.
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Body
10-67
Soft Top Mounting Components and Accessories Replacement

NOTE: The following removal and installation instructions include replacement of all soft top mounting components and accessories. Use only the applicable steps for replacing specific components.
Removal
1. Remove four-passenger soft top, tonneau cover, or station wagon soft top, if applicable. Refer to the owners manual for proper procedure. Remove tonneau cover wood bow from two retainer brackets (Figure 10-130). Remove four screws and two bow retainer brackets from wheelhouses.
2. 3.
TONNEAU COVER WOOD BOW WHEELHOUSE
BOW RETAINER BRACKET
Figure 10-130: Tonneau Cover Wood Bow Removal

VELCRO STRIP TONNEAU/REAR CURTAIN EXTRUSION TAILGATE CHAIN ATTACHMENT CHANNEL
WHEEL HOUSE
VELCRO PATCH
43 IN. (109 cm) TONNEAU EXTRUSION
VELCRO PATCH 43 IN. (109 CM) VELCRO STRIP 2 IN. (5 CM) FROM EDGE
41 IN. (104 CM) VELCRO STRIP 41 IN. (104 CM) TONNEAU EXTRUSION 9 IN. (23 CM) 9 IN. (23 CM) VELCRO STRIP TONNEAU EXTRUSION
Figure 10-131: Velcro Strip and Patch Removal

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Body ______________________________________________________________________
Remove velcro strips and patches from tonneau area (Figure 10-131).
NOTE: Perform steps five and six for both sides of the vehicle. The left side is shown. 5. 6. 7. 8. 9. Remove 41 in. (104 cm) tonneau extrusion from side of wheelhouse. Remove 9 in. (23 cm) tonneau extrusion from rear of wheelhouse. Remove 43 in. (109 cm) tonneau extrusion from tailgate. Remove five screws, lockwashers, four self-tapping screws, and tonneau/rear curtain extrusion from body. Remove front and rear inner door seals (Figure 10-132).
12. Remove 12 screws securing front attachment rail to the top of the windshield frame, and remove rail. 13. Slide velcro strips in the two side rails rearward to remove, set aside. 14. Remove four screws securing the B-pillar cover to the bottom of the H-rail.
H-RAIL
FILLER PIECE
B-PILLAR COVER
UPPER RETAINING SCREWS
LOWER RETAINING SCREWS INNER DOOR SEAL
8-S10-003
Figure 10-134: B-Pillar Cover Removal

8-S10-002
Figure 10-132: Door Seal Removal

NOTE: This procedure is written for the left side of the vehicle only. Duplicate steps are necessary to service the right hand side. 10. Remove soft top from the vehicle. 11. Remove D-strip seal from windshield frame. Do not remove P-strip seal (Figure 10-133).
P-STRIP SEAL
15. Remove two bolts securing B-pillar cover to the B-pillar. Remove the B-pillar cover. 16. Remove the three screws securing the C-pillar cover to the H-rail. 17. Remove the four bolts securing the lower inner and outer bracket on the C-pillar cover. Remove the cover.
UPPER RETAINING SCREWS
D-STRIP SEAL
C-PILLAR COVER
LOWER RETAINING SCREWS
8-S10-004
Figure 10-133: D-Strip Seal Removal
Figure 10-135: C-Pillar Cover Removal
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18. Remove three screws securing H-Rail to the vehicle safety cage. Leave the L brackets on the safety cage unless the cage is going to be replaced, remove the H-rail.
H-RAIL SCREWS (3)
10. Install front upper corner filler piece with two rivets and sealer (Figure 10-137). 11. Clean excess sealer from mating surfaces. 12. Install new inner door seals. Check door to frame fit and adjust structure if necessary. 13. Install rail and P-seal on top of windshield with (12) screws. 14. Install new rubber D-seal between P-seal and the rail. 15. Install the soft top and secure. NOTE: Clean all surface residue with a tape adhesion promoter before installing extrusions with 2 sided tape.
L-BRACKETS
SUPPORT STRUCTURE H-RAIL
8-S10-004
Figure 10-136: H-Rail Removal

NOTE: While removing the H-rail, note where sealer is placed so during installation, the sealer can be duplicated
Installation
1. Install L brackets to support structure so the bend is to the bottom and the brackets are adjusted upward as far as they could go. Leave the brackets nger tight to ease installation of other components and adjustment later in the procedure. Using a bolt and washer, install the threaded L-brackets onto the H-rail so the bend is upwards. Tighten bolt. Put foam tape on the top mating surface of the C-pillar cover, and place the rear extrusion against the bottom surface of the H-rail. Install three screws (Figure 10-137). Put foam tape on the top edge of the B-pillar cover. Place the cover against the bottom edge of the H-rail and tighten four upper screws (Figure 10-137). Apply sealer to bottom of B- and C-pillar covers. Install the H-rail onto the support structure. Place the Lbrackets installed on the H-rail under the L-brackets on the support structure. Tighten screws when installed. Install lower fasteners in B-pillar cover. Do not tighten (Figure 10-137). Install lower fasteners in C-pillar cover. Do not tighten (Figure 10-137). Adjust H-rail and extrusions so seams are flush, tighten fasteners.
16. Secure tonneau/rear curtain extrusion to body with five lockwashers, capscrews, and four self-tapping screws. Use windshield sealer between the extrusion and the body (Figure 10-131). 17. Install 43 in. (109 cm) tonneau extrusion on tailgate. 18. Secure 9 in. (23 cm) tonneau extrusion to rear of wheelhouse. 19. Secure 41 in. (104 cm) tonneau extrusion to side of wheelhouse, 2 in. (5 cm) from rear corner edge of wheelhouse. 20. Install velcro strips in extrusions. 21. Install one velcro patch on each wheelhouse side and two velcro patches on each tailgate chain attachment channel. 22. Secure two bow retainer brackets to wheelhouses with four screws (Figure 10-138). 23. Leak check the vehicle and add sealer where necessary. 24. Test drive vehicle and check for wind noise. CAUTION: The ideal crown height of the bow is shown. If there is excessive crowning of the bow, cut the end of the wood bow with a saw to reduce the crown. Do not cut more than 0.25 in. (6 mm) at a time, or the bow may become too short. 25. Measure and record the distance across the cargo bed, between each rear support bar brace. Add 0.25 to 0.50 in. (6 to 13 mm) to this dimension and mark and cut the wood bow to this dimension. 26. Position wood bow in two retainer brackets. Lay a straight edge across the wheel houses as shown (Figure 10-138). The ideal bow height is 1.5 in. from the straight edge to the bow crown. 27. Install the four-passenger soft top, tonneau cover, and slant-back soft top or station wagon soft top, if applicable. Refer to the owners manual.
2. 3.
4.
5. 6.
7. 8. 9.
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H-RAIL
FILLER FRONT FILLER PIECE B-PILLAR COVER
FILLER
VELCRO INSTALLATION REAR, SIDE, P-CHANNEL C-PILLAR COVER
B-PILLAR COVER LOWER BRACKET
SUPPORT STRUCTURE
8-S10-001
Figure 10-137: Rail and Support Structure Locations

MEASURE DISTANCE WOOD BOW REAR SUPPORT BAR BRACE WHEEL HOUSE STRAIGHTEDGE
STRAIGHTEDGE
IDEAL BOW HEIGHT
BOW RETAINER BRACKET MEASURE DISTANCE BETWEEN INNER FACE OF REAR SUPPORT BAR BRACES
Figure 10-138: Bow Retainer Bracket Installation
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Body
10-71
SOFT TOP SUPPORT ASSEMBLY

Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove soft top. Remove interior grab handles. Remove vinyl wrap and padding from roll cage assembly. Remove inner door seals. Drill rivets on front corner filler plates located at top front of front door openings. Remove H rails, B- and C-pillar covers. Remove hardware and door striker from B-pillar. Remove fasteners securing the windshield frame to support structure, and rear supports to the body. Using an overhead hoist, remove the support structure as a complete assembly.
Installation
1. 2. 3. Apply sealer to rear support where body contact is made. Lower structure assembly onto vehicle. Install hardware and strikers in B-pillar and front and rear supports. 4. Install H rail, B- and C-pillar covers. Use body sealer where removed. 5. Apply sealer to filler plates and rivet to body using existing holes. 6. Tighten hardware on assembly. 7. Install new inner door seals. 8. Install padding and vinyl wrap on roll cage assembly. 9. Install interior grab handles. 10. Install soft top and leak check.
10. Repair or replace individual pieces as necessary, leaving hardware loose, so the new pieces can be adjusted to the structure once the unit is installed.
B PILLAR B BAR
C PILLAR REAR SUPPORT
C PILLAR CENTER B PILLAR
C PILLAR C PILLAR REAR SUPPORT
Figure 10-139: Support Structure Assembly
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TAILGATE Tailgate Chain and Latch Brackets Replacement

Removal
Remove four locknuts, eight washers, four bolts, chain bracket, and latch bracket from body (Figure 10-140).
CARGO FLOOR
SCREW
Installation
Secure chain bracket and latch bracket to body with four bolts, eight washers, and four locknuts. Tighten bolts to 15 lb-ft (20 Nm) (Figure 10-140).
BODY CHAIN BRACKET
CARGO TIEDOWN
Figure 10-141: Cargo Tiedown Replacement
Tailgate and Seals Replacement

Removal
LATCH BRACKET
1. 2.
Figure 10-140: Tailgate Bracket Installation
Remove six locknuts, washers, and bolts securing tailgate to body (Figure 10-142). Disconnect two chains from tailgate and remove tailgate and shims from body.
Cargo Tiedown Replacement

NOTE: Cargo tiedown replacement is basically the same for all tiedowns.
NOTE: Perform step 3 for two- and four-door models. Perform step 4 and 5 for station wagon and open body models. 3. 4. Remove two vertical seals from tailgate. Discard seals. Remove two vertical and horizontal seals from body and four vertical seals and one horizontal seal from tailgate. Remove two corner seals (station wagon model only). Discard seals (Figure 10-143). Remove two corner seals from tailgate (station wagon model only). Remove two grommets from tailgate. Clean adhesive from tailgate and body.
VERTICAL SEAL BODY CHAIN
Removal
Remove locknut, washer, screw, and cargo tiedown from cargo floor (Figure 10-141).
Installation
Install cargo tiedown on cargo floor with screw, washer, and locknut. Tighten locknut to 65 lb-ft (88 Nm) (Figure 10-141).
5. 6. 7.
SHIM
TAILGATE
Figure 10-142: Tailgate and Seals Replacement
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Installation
1. Install two grommets on tailgate (Figure 10-143).
BRACKET
CHAIN BRACKET
NOTE: Perform steps 2 through 4 for station wagon and open body models. Perform step 5 for two- and four-door models. 2. Remove paper backing and install four vertical seals and one horizontal seal on tailgate. Ensure upper vertical seals overlap lower seals. Remove paper backing from two horizontal and vertical seals and install on body. Remove paper backing from two corner seals and install on tailgate (station wagon model only). Remove paper backing from two vertical seals and install seals on tailgate (Figure 10-142). Secure tailgate to body with six bolts, washers, and locknuts. Shim hinges as needed to align tailgate with body. When aligned, tighten bolts 26 lb-ft (35 Nm). Attach the two tailgate chains bracketed to the body to the tailgate.
HORIZONTAL SEAL BODY HORIZONTAL SEAL VERTICAL SEAL (UPPER)
3. 4. 5. 6.
CHAIN CAP LINK
Figure 10-144: Tailgate Chain Replacement
TAILGATE HINGE REPLACEMENT

NOTE: To facilitate alignment when replacing hinges, place a small strip of masking tape along each side and bottom of hinge before removal.
7.
Removal
Remove tailgate by removing six locknuts, washers, and bolts from the tailgate while still closed. Note number of shims under each hinge and set them aside. Remove tailgate by releasing tailgate chains (Figure 10-145).
VERTICAL SEAL
CHAIN UPPER RETAINER RIVET
TAILGATE VERTICAL SEAL (LOWER) CORNER SEAL
GROMMET
Figure 10-143: Tailgate Mounting Bracketry and Seal Location

SHIM
Tailgate Chain Replacement

Removal
1. 2. 3. Lower tailgate. Open chain cap link and disconnect chain from bracket (Figure 10-144). Unhook chain from chain bracket.
UPPER HINGE
LOWER HINGE
LOWER RETAINER RIVET
Figure 10-145: Tailgate Hinge Replacement
Disassembly
1. Place tailgate on padded work surface and remove hinge retainer rivets. Remove hinge and clean any debris from rivet holes. Clean tailgate and apply a light coat of seam sealant to hinge mounting area.
Installation
1. 2. 3. Hook chain to chain bracket (Figure 10-144). Connect chain to bracket. Raise tailgate.
2.
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Assembly
1. 2. Using three 0.187 in. x 0.626 in. rivets, fasten hinge to lower set of holes on tailgate. Fasten hinge to upper set of holes on tailgate with three 0.187 in. x 0.563 in. rivets.
4.
5.
If alignment is necessary, loosen the seven screws on the interior side of the door hinge. The slots in the hinge will allow up and down adjustment. Tighten the seven screws in the hinge.
Window Replacement
Removal
Remove eleven screws, window retainer bracket, and window from rear vertical door (Figure 10-147).
Installation
1. Position tailgate on bed and secure with tailgate chains. Loosely install bolts, washers, and locknuts into hinges. Insert proper amount of shims under each hinge. Slightly tighten bolts, but not tight enough to restrict movement into alignment with tape marks. Align hinges and tailgate into proper position and torque bolts to 26 lb-ft (35 Nm). Remove any excess sealant from hinges and body. Refinish hinges and fasteners as required.
2. 3.
4.
REAR VERTICAL DOOR REPLACEMENT

Removal
1. 2. 3. Remove seven screws securing hinge to door. Slowly pull door away from the hinge to expose interior lock harness connections. Disconnect interior door lock harness from contacts on hinge, and tape to door to prevent loss.
WINDOW RETAINER BRACKET WINDOW
REAR VERTICAL DOOR
Figure 10-147: Window Replacement
Installation
DOOR FRAME
Secure window to rear vertical door with window retainer bracket and eleven screws (Figure 10-147).
REAR VERTICAL DOOR
Figure 10-146: Rear Vertical Door Replacement
Installation
1. 2. 3. Position door close to hinge to allow the interior door lock harness to be connected to the contacts on the hinge. Secure hinge to door frame with seven screws (Figure 10-146). Verify operation of door locks and door latch .
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Body
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Door Handle Replacement

Removal
1. 2. 3. 4. 5. 6. Remove rear door window. Remove four screws and interior door handle from door (Figure 10-148). Remove twelve screws and close-out panel from door. Remove two cotter pins, washers, and latch rods from exterior door handle. Remove lock motor rod from door handle (Figure 10-150). Remove four spacers and exterior door handle from door.
Door Latch and Latch Rod Replacement

Removal
1. 2. 3. 4. 5. 6. 7. Remove rear door window. Remove four screws and interior door handle from door (Figure 10-149). Remove twelve screws and close-out panel from door. Remove cotter pin, washer, and latch rod from exterior door handle. Remove lock motor rod from door handle (Figure 10-150). Remove three nuts, lockwashers, screws, and lower door latch from door. Remove locknut, washer, screw, and latch rod from lower door latch.
EXTERIOR DOOR HANDLE SPACER
LATCH RODS COTTER PINS INTERIOR DOOR HANDLE
CLOSE-OUT PANEL LATCH ROD
Figure 10-148: Door Handle Replacement
Installation
1. 2. 3. 4. 5. 6. Secure exterior door handle to door with four spacers (Figure 10-148). Install lock motor rod to door handle lock latch with plastic clip (Figure 10-150). Secure latch rods to exterior door handle with two washers and cotter pins. Secure close-out panel to door with twelve screws. Secure interior door handle to door with four screws. Install rear door window.
LOWER DOOR LATCH
Figure 10-149: Door Latch and Latch Rod Replacement
Installation
1. 2. 3. 4. 5. 6. Secure lower door latch to door with three screws, lockwashers, and nuts (Figure 10-149). Secure latch rod to lower door latch with screw, washer, and locknut. Secure latch rod to exterior door handle with washer and cotter pin. Install lock motor rod to door handle lock latch with plastic clip (Figure 10-150). Secure close-out panel to door with twelve screws. Install rear door window. Secure interior door handle to door with four screws.
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DOOR HINGE CONTACTS
DOOR HINGE CONTACTS
MOTOR LINK ROD AND LOCK CLIPS
DOOR LOCK MOTOR HARNESS
DOOR LOCK MOTOR
Figure 10-150: Cargo Door Electric Locks
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Body
10-77
Door Stop Replacement

Removal
1. 2. 3. 4. 5. Remove rear door window. Remove four screws and interior door handle from door (Figure 10-149). Remove twelve screws and close-out panel from door. Remove bolt, door stop ball, and retainer from door (Figure 10-151). Remove bolt, washer, door stop socket, and retainer from right rear wheelhouse.
Door Frame and Seal Replacement

Removal
1. 2. Remove dome lamp fuse. Remove seven screws securing inner portion of door hinge to door frame. 3. When hinge is loose, carefully pull away to access connectors for door lock contacts in the hinge. 4. Disconnect the door lock harness connectors, label them for reassembly. 5. Remove vertical doors from door frame. 6. Remove upper and lower latch guides. 7. Remove inner passenger side closeout panel on inside of door frame. 8. Disconnect dome lamp switch harness from door jamb switch. 9. Remove fourteen screws from door frame (Figure 10-152). 10. Remove door frame completely 11. Remove seal from door frame.
DOOR FRAME SEAL
DOOR STOP SOCKET RETAINING BLOCK
LATCH GUIDE
DOOR STOP BALL RETAINER
Figure 10-151: Door Stop and Latch Guide Replacement
Installation
1. 2. 3. 4. 5. Secure door stop socket to right rear wheelhouse with washer, bolt, and retainer (Figure 10-151). Secure door stop ball to door with bolt and retainer. Secure close-out panel to door with twelve screws (Figure 10-149). Secure interior door handle to close-out panel with four screws. Install rear door window.
Figure 10-152: Door Frame and Seal Replacement
Installation
1. 2. 3. Position seal on door frame (Figure 10-152). Secure door frame to vehicle with fourteen screws. Install a new door jamb switch and connect to dome lamp harness. 4. Install upper and lower latch guides. 5. Install vertical doors on door frame. 6. Connect door lock harness connections to the back of the door hinge contacts. 7. Install interior closeout panel. 8. Close door to adjust new door jamb switch. 9. Install dome lamp fuse. 10. Verify operation of door lamps and cargo switch.
Latch Guide Replacement

Removal
Remove latch guide, two washers, and retaining block from door frame (Figure 10-151).
Installation
Secure latch guide to door frame with two washers and retaining block (Figure 10-151).
Adjustment
Close door and check alignment, then adjust latch guide as necessary. 05745159
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INTERIOR AND EXTERIOR LIGHTING REPLACEMENT Service Headlight Assembly Replacement

Removal
NOTE: To remove headlight only, perform steps 1 and 2. To remove the entire assembly, continue with steps 3 through 6. 1. 2. 3. 4. 5. Loosen three screws and remove retaining ring from headlight mount (Figure 10-153). Disconnect headlight jumper harness from headlight, and remove headlight. Loosen two screws securing headlight mount to headlight housing, and remove mount from housing and spring. Disconnect headlight jumper harness from headlight housing and remove harness. Disconnect three leads from back of housing.
6.
Remove three nuts, lockwashers, washers, and housing from hood.
Installation
NOTE: To install headlight only, perform steps 5 and 6. To install entire assembly, perform all steps. 1. 2. 3. 4. 5. Connect three leads to back of housing (Figure 10-153). Secure headlight housing to hood with three washers, lockwashers, and nuts. Secure headlight mount to housing, with spring and two screws. Connect headlight jumper harness to headlight housing. Connect headlight to jumper harness and secure headlight to headlight mount with retaining ring with retaining ring. Tighten three screws. Connect battery ground cable (Section 12). Check headlight for proper operation.
LEADS
6. 7.
HEADLIGHT HOUSING HEADLIGHT MOUNT RETAINING RING
SPRING HOOD JUMPER HARNESS HEADLIGHT
Figure 10-153: Headlight Assembly Replacement
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Side Marker Light Lens and Lamp Replacement

Removal
Remove two screws, cover, lens, and lamp from lamp holder (Figure 10-154).
LIGHT BRACKET
Installation
1. 2. Install lamp. Secure lens, and cover to lamp holder with two screws (Figure 10-154). Ensure side marker light operates properly.
LAMP HOLDER TABBED SIDE WIRING HARNESS TABBED SIDE IDENTIFICATION LIGHT LENS
Figure 10-155: Identification Light Replacement
Side Marker Light Assembly Replacement

NOTE: Replacement of front and rear light assemblies is basically the same. This procedure covers the front left side marker.
LAMP COVER
Removal
1. 2. 3. 4.
Figure 10-154: Side Marker Light Lens and Lamp Replacement
Identication Light Replacement

NOTE: All identification lights are replaced the same. Bulb is not removable from lens. Light is replaced as an assembly.
Remove four screws, washers, and close-off cover from hood (Figure 10-156). Disconnect harness lead from marker light lead (Figure 10-157). Remove two screws, cover, and lens from marker light. Remove four locknuts, washers, ground lead, gasket, four screws, and marker light from hood.
MARKER LIGHT
Removal
1. 2. Carefully pry tabbed sides of identication light from light bracket (Figure 10-155). Disconnect light from wiring harness.
CLOSE-OFF COVER
Installation
1. 2. Connect identication light to wiring harness (Figure 10-155). Snap light into light bracket.
HOOD
Figure 10-156: Close-Off Cover Location
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GROUND LEAD LIGHT LEAD
HOOD
LIGHT
LENS DOOR
GASKET HARNESS LEAD MARKER LIGHT
Figure 10-157: Side Marker Light Assembly
Installation
1. 2. 3. 4. 5. Secure gasket, lamp holder, and ground lead on hood with four screws, washers, and locknuts (Figure 10-157). Secure lens and cover to lamp holder with two screws. Connect light lead to harness lead. Secure close-off cover to hood with four washers and screws (Figure 10-156). Ensure side marker light operates properly.
HOOD BRACKET
Front Turn Signal Light Replacement

Removal
NOTE: To remove lamp only, perform steps 1 and 2. 1. 2. 3. 4. 5. 6. Remove four screws, lens, and gasket from turn signal light (Figure 10-158). Remove lamp from socket Remove four screws, washers, and close-off cover from hood. Disconnect two connectors from wiring harness. Remove two nut and lockwasher assemblies, washers, bracket, and light from hood (Figure 10-159). Remove two screws, lockwashers, and light from bracket.
WIRING HARNESS CONNECTORS CLOSE-OFF COVER
Figure 10-159: Front Turn Signal Bracket
Installation
NOTE: To install lamp only, perform steps 5 and 6. 1. 2. 3. 4. 5. 6. 7. Secure light to bracket with two lockwashers and screws (Figure 10-159). Secure bracket and light to hood with two washers and nut and lockwasher assemblies. Connect two connectors to wiring harness (Figure 10-158). Secure close-off cover to hood with four screws and washers. Install lamp in socket. Secure gasket and lens to light with four screws. Ensure turn signal works properly.
LAMP
HOOD
LIGHT AND BRACKET LENS GASKET
Figure 10-158: Front Turn Signal Assembly Breakdown
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Rear Turn Signal Light Replacement

Removal
NOTE: To remove lamps only, perform steps 1 and 2. 1. Remove four screws, lens, and gasket from turn signal light (Figure 10-160).
HOUSING GROMMET
SHIELD
LEADS HOUSING WIRING HARNESS
LIGHT
LAMPS
CONNECTORS SOCKETS BEAM
Figure 10-161: Shield and Wiring Location

GASKET LENS
Trouble Light Replacement

NOTE: Parking lights or headlights must be on in order to activate the trouble light or the underhood light.
Figure 10-160: Rear Turn Signal Light Assembly 2. 3. Remove two lamps from sockets. From behind the light, remove three nuts, lockwashers, four leads, and three washers securing light to light housing (Figures 10-160 and 10-161). Remove two nuts, clamps, and screws securing harness to shield (Figure 10-161). Remove two screws, lockwashers, and shield from beam. Disconnect two connectors from wiring harness. Remove light and grommet from housing (Figure 10-160).
Removal
1. 2. Disconnect wiring harness from trouble light. Remove three nut and lockwasher assemblies and trouble light from mounting bracket.
4. 5. 6. 7.
Installation
1. 2. Install trouble light on mounting bracket with three nut and lockwasher assemblies. Connect wiring harness to trouble light.
Installation
NOTE: To install lamps only, perform steps 6 and 7. 1. 2. 3. 4. 5. 6. 7. 8. Install light and grommet in housing (Figure 10-160). Connect two connectors to wiring harness (Figure 10-161). Secure harness to shield with two screws, clamps, and nuts. Secure shield to beam with two lockwashers and screws. Secure light to light housing with three washers, four leads, three lockwashers, and nuts (Figures 10-160 and 10-161). Install two lamps in sockets (Figure 10-160). Secure gasket and lens to light with four screws. Ensure turn signal and backup lights work properly.
05745159
10-82
Body ______________________________________________________________________
Domelight/Cargo Light Replacement (Models 83, 84, 89, & 91)

Removal
1. 2. 3. 4. Remove domelight lens (Figures 10-162 through 10-164). Remove lamp from domelight. Remove screws securing domelight to ground lead and connector. Remove screw and domelight from roof bracket.
FRONT OF VEHICLE
CONNECTORS
Installation
1. 2. 3. Secure domelight, connector, and ground lead to roof bracket with screws (Figures 10-162 through 10-164). Install lamp in domelight. Install domelight lens.
ROOF BRACKET DOMELIGHT LAMP GROUND LEAD LENS FRONT OF VEHICLE
CONNECTOR
Figure 10-163: Rear Domelight (HMCS)
FRONT OF VEHICLE
ROOF BRACKET
GROUND LEAD
DOMELIGHT
LAMP
ROOF BRACKET LENS DOMELIGHT GROUND LEAD
Figure 10-162: Standard Domelight Replacement
LAMP
LENS
Figure 10-164: Cargo Light (HMCS)
4-1-00
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Body
10-83
Domelight Replacement (Model 90)

Removal
1. 2. 3. 4. 5. Using a screwdriver, snap the dome light assembly from its base (Figure 10-165) Remove two screws securing domelight base and the support structure. Slowly pull the light base until the connector for the roof harness is exposed. Disconnect the roof harness from the dome light base. Remove the dome lamp.
LOWER B-PILLAR TRIM
Installation
1. 2. 3. 4. Connect roof harness to dome light base. Install two screws through base and support and attach base to the roof structure. Install light assembly into base. Verify operation.
ROOF STRUCTURE SUPPORT
MOUNTING BRACKET COURTESY LIGHT

S10-212.3
Figure 10-166: Rear Seat Courtesy Light Replacement
Maplight Replacement
NOTE: The maplight will illuminate when the optional remote entry feature is activated.
DOME LIGHT BASE
Removal
Remove maplight assembly from bezel (Figure 10-167).
DOME LIGHT ASSEMBLY
8-S10-005
Installation
Install maplight assembly into bezel.
HEADLINER FRONT OF VEHICLE
Figure 10-165: Domelight Replacement (Model 90)
Rear Seat Courtesy Light Replacement

Removal
1. 2. Carefully pry courtesy light from mounting bracket (Figure 10-166). Disconnect light from electrical connector.
Installation
1. 2. Connect courtesy light to the electrical connector (Figure 10-166). Snap courtesy light into mounting bracket.
BULB
MAPLIGHT ASSEMBLY
BEZEL
BEZEL RETAINING CLIPS
Figure 10-167: Optional Maplight Replacement 05745159 4-1-00
10-84
Body ______________________________________________________________________
Lighted Visor Mirror Replacement

Removal
1. 2. Pull mirror assembly from visor (Figure 10-168). Remove lamp.
VISOR MIRROR LEAD
LIGHT
LAMP
BRACKET
GROUND LEAD HOOD CONNECTORS
LAMP
Figure 10-169: Underhood Light Replacement
VISOR MIRROR ASSEMBLY
Daytime Running Lights (DRL) Module Replacement (Canada Only)

Removal
1. Disconnect the Daytime Running Lights (DRL) connector from the harness assembly (Figure 10-170). Remove two screws, washers, nuts, and DRL module from the kick panel.
MIRROR ASSEMBLY REAR VIEW
Figure 10-168: Lighted Visor Mirror Replacement
2.
Installation
1. 2. Install lamp (Figure 10-168). Install mirror assembly by pressing it into the visor.
Installation
1. 2. Secure DRL module to kick panel with two screws, washers, and nuts (Figure 10-170). Connect the DRL connector to the harness assembly.
A-PILLAR
Underhood Light Replacement

Removal
1. 2. 3. Disconnect two connectors from wiring harness (Figure 10-169). Remove two screws, washers, ground lead, bracket, and light from hood. Remove lamp from light.
HARNESS ASSEMBLY
Installation
1. 2. 3. Install lamp in light (Figure 10-169). Secure light, bracket, and ground lead to hood with two washers and capscrews. Connect two connectors to wiring harness.
DAYTIME RUNNING LIGHTS CONNECTOR DAYTIME RUNNING LIGHTS MODULE
SPEED NUT
LEFT OUTER KICK PANEL
Figure 10-170: Daytime Running LIghts Module
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Body
10-85
Front Driver and Passenger Courtesy Light Replacement

Removal
1. 2. Carefully pry courtesy light from mounting bracket (Figures 10-171 and 10-172). Disconnect light from wiring harness.
INSTRUMENT PANEL
Headlight Electrical Connector and Grommet Replacement

Removal
1. 2. 3. Remove headlight and jumper harness. Remove connector from grommet (Figure 10-173). Remove grommet from headlight housing.
Installation
1. 2. 3. Install grommet in headlight housing (Figure 10-173). Install connector in grommet. Install jumper harness and headlight.
GROMMET WIRING HARNESS MOUNTING BRACKET
COURTESY LIGHT
Figure 10-171: Front Driver Side Courtesy Light Replacement
HEADLIGHT HOUSING
Installation
1. 2. Connect courtesy light to wiring harness (Figures 10-171 and 10-172). Snap light into mounting bracket.
COURTESY LIGHT MOUNTING BRACKET ELECTRICAL CONNECTOR CONNECTOR
Figure 10-173: Headlight Electrical Connector and Grommet Replacement
COURTESY LIGHT
Figure 10-172: Front Passenger Side Courtesy Light Replacement

05745159
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Body ______________________________________________________________________
BACKUP LIGHT SWITCH REPLACEMENT

Removal
1. 2. Remove shift controls housing (Section 5). Pull neutral start switch leads, backup light switch leads, and light lead through boot and remove boot from shift controls housing (Figure 10-174). Remove two screws and lockwashers securing backup light switch to housing. Remove tiedown strap securing backup light switch to neutral start switch, and remove backup light switch.
STOPLIGHT SWITCH REPLACEMENT

Removal
1. 2. Disconnect two harness leads from stoplight switch (Figure 10-175). Remove stoplight switch from bracket.
3. 4.
Installation
1. 2. Install stoplight switch into bracket (Figure 10-175). Connect two harness leads to stoplight switch.
Adjustment
1. 2. 3. Push switch into bracket with brake depressed. Pull up on brake pedal. Switch should ratchet outward to proper position. Check function with engine running.
Installation
1. 2. 3. Secure backup light switch to neutral start switch with tiedown strap (Figure 10-174). Secure backup light switch to shift controls housing with two lockwashers and screws. Position neutral start switch leads, backup light switch leads, and light lead through boot, and install boot on housing. Install shift controls housing (Section 5).
4.
BRAKE PEDAL ARM SWITCH ARM
SUPPORT
SHIFT CONTROLS HOUSING
HARNESS LEADS
STOPLIGHT SWITCH BACKUP LIGHT SWITCH NEUTRAL START SWITCH LEADS TIEDOWN STRAP BACKUP LIGHT SWITCH LEADS BRAKE PEDAL
Figure 10-175: Stoplight Switch Replacement
BOOT
Figure 10-174: Backup Light Switch Replacement
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Body
10-87
SLANT BACK AND COMPONENTS
SLANT DOOR WIRING HARNESS
INTERMEDIATE C-PILLAR
DOOR MOUNTING BOLTS
SLANT BACK TORSION ASSEMBLY
TORSION ASSEMBLY TORSION ASSEMBLY MOUNTING BOLTS
ROOF SHELL
00-S10-003
Figure 10-176: Slant Door and Torsion Assembly
Slant Door and Torsion Assembly Replacement

CAUTION: The slant door is heavy. Some assistance will be required for removal and installation.
Installation
1. Using the torsion assembly mounting hardware, install the torsion assembly (Figure 10-176). Do not fully tighten at this time (See Adjustments). Connect the cargo light switch harness connection. Secure the torsion assembly to the intermediate C-pillar using a nut, lock washer and bolt on both the left and right sides. Using an assistant, carefully install the slant door with the door mounting hardware. Do not fully tighten at this time (See Adjustments). Route and secure the harness to the slant door as illustrated. Connect all electrical components making sure not to damage any terminals in the connectors. Adjust the torsion assembly (See Adjustments).
Removal
1. 2. 3. 4. Remove all the trim on the door (See Section 10). Disconnect the lock solenoid, the rear window defrost, and the wiper motor harness connectors. Carefully remove the harness from the slant door. Using an assistant carefully support the door while removing the door mounting bolts (Figure 10-176). Remove the door. Remove all of the interior trim pieces that cover the torsion assembly. Disconnect the cargo light switch harness connection. Remove both nuts, bolts and washers that secure the torsion assembly to the intermediate C-pillar. Remove six torsion assembly mounting bolts and washers. Carefully remove the torsion assembly.
2. 3.
4.
5. 6. 7.
5. 6. 7. 8. 9.
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Body ______________________________________________________________________
Adjustments
1. 2. Loosen the torsion assembly mounting bolts enough to allow the slant door to move side to side (Figure 10-176). Loosen the slant door mounting bolts enough to allow for an adjustment of the opening clearance at the top of the door. Position the slant door so that it is centered in the door frame.
4. 5. 6. 7.
Make sure that the top of the slant door has adequate clearance to the roof shell when opening and closing. Tighten the torsion assembly mounting bolts to 15 lb-ft (20 N.m). Tighten the slant door mounting bolts to 15 lb-ft (20 N.m). Install previously removed trim.
3.
SLANT DOOR HANDLE, LATCH, AND LOCK ACTUATOR
BOLT DOOR HANDLE GASKET
DOOR HANDLE ASSEMBLY
FLAT WASHER LOCK WASHER RETAINER NUT
LOCK ACTUATOR
LOCK ACTUATOR RETAINING SCREW
00-S10-002 LATCH ACTUATOR CABLE SLANT BACK LATCH LATCH BRACKET MOUNTING BOLT
Figure 10-177: Slant Door Handle and Latch Replacement
Slant Door Handle

Removal
1. 2. 3. 4. 5. Remove the slant door trim (See Section 10). Disconnect the power lock actuator from the slant door handle assembly (Figure 10-177). Remove the latch actuator cable from the slant door handle assembly by removing the retaining nut, and bolt. Remove the four retaining nuts, lock washers and flat washers from the slant door handle assembly. Remove the slant door handle assembly and gasket.
Installation
1. Install the slant door handle assembly and gasket using the previously removed door handle hardware (Figure 10-177). Install the latch actuator cable, retaining bolt, and nut. Connect the power lock actuator to the slant door handle assembly. Replace the slant door trim.
2. 3. 4.
4-1-00
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Body
10-89
Slant Door Latch

RETAINING BOLT DOOR HANDLE ASSEMBLY DOOR HANDLE HARDWARE LATCH ACTUATOR CABLE NUT LATCH MOUNTING BRACKET
BRACKET
Adjustments
1. 2. Loosen the four latch bracket mounting bolts until the latch moves horizontally and vertically (Figure 10-178). Position the latch so the striker is centered in the opening of the latch. The door should latch easily and have minimal movement. Tighten the four latch mounting bracket nuts and bolts to 15 lb-ft (20 N.m). Verify the latch is operating correctly.
3. 4.
DOOR HANDLE GASKET
Slant Door Lock Actuator

ACTUATOR ROD
ACTUATOR
LOCK
LOCK ACTUATOR BRACKET
MOUNTING BOLTS LATCH MOUNTING BOLTS
LOCK ACTUATOR LOCK ACTUATOR MOUNTING BRACKET
LOCK ACTUATOR RETAINING BOLT
00-P12-014
SLANT DOOR LATCH
Figure 10-178: Slant Door Latch and Handle Breakdown
Removal
1. 2. Remove the slant door trim. Disconnect the latch actuator cable from the slant door handle assembly by removing the retaining nut, and bolt (Figure 10-178). Remove the four latch bracket mounting nuts and bolts. Move the lock actuator to the side and remove the latch and bracket assembly. Remove the three bolts and nuts that are securing the latch to the bracket.
LOCK ACTUATOR RETAINING SCREW
Figure 10-179: Slant Door Lock Actuator Replacement
Removal
1. 2. 3. Remove the slant door trim (See Section 10). Remove the lock actuator retaining screw (Figure 10-179). Disconnect the lock actuator rod from the slant door handle assembly.
3. 4. 5.
Installation
1. Install the slant door latch to the bracket using the previously removed door latch hardware (Figure 10-178). Tighten the latch bolts to 12 lb-ft (16 N.m). Align the lock actuator bracket and the latch mounting bracket with the door and install the four retaining bolts. Do not tighten at this time (See Adjustments). Connect the latch actuator cable to the door handle. Adjust the door latch (See Adjustments). Install door trim (See Section 10).
Installation
1. 2. 3. Connect the lock actuator rod to the slant door handle assembly (Figure 10-179). Secure the door lock actuator to the bracket with the lock actuator retaining screw. Install the door trim (See Section 10).
2.
3. 4. 5.
05745159
4-1-00
10-90
Body ______________________________________________________________________
Wiper Motor and Components

WIPER BLADE
WIPER ARM
PLASTIC NUT COVER RETAINER NUT
SHAFT RETAINING HARDWARE
WASHER HOSE
ELECTRICAL CONNECTION
WIPER MOTOR
WIPER MOTOR RETAINING BRACKET WIPER MOTOR MOUNTING SCREW WASHER WIPER MOTOR BRACKET MOUNTING BOLT
00-P12-013
Figure 10-180: Window Wiper Assembly Replacement
Removal
1. Remove the protective nut cover from the base of the wiper arm (Figure 10-180). 2. Remove the wiper arm retainer nut. 3. Disconnect the washer hose from the base of the wiper. 4. Note the position of the wiper arm for installation and remove the wiper arm assembly. 5. Remove the shaft retaining hardware. 6. Remove the interior slant door trim (See Section 10). 7. Disconnect the wiper motor harness connection. 8. Remove the four wiper motor bracket mounting bolts and washers. 9. Pull the wiper motor/bracket assembly out of the door. 10. Remove the wiper motor from the mounting bracket by removing the three wiper motor retaining screws.
Installation
1. 2. Assemble the wiper motor and mounting bracket with the wiper motor mounting hardware (Figure 10-180). Slide the wiper motor and bracket into place and secure with the wiper mounting bracket hardware. Tighten the mounting bolts to 15 lb-ft (20 N.m). Connect the wiper motor electrical connector to the slant door harness. Install the wiper motor shaft retaining hardware. Install the wiper arm assembly in the original position and reconnect the washer hose. Install the wiper arm retainer nut and plastic cover. Verify proper operation of the wiper motor and washer. Install the interior trim for the slant door.
3. 4. 5. 6. 7. 8.
4-1-00
_____________________________________________________________________
Body
10-91
GLASS AND BODY FOR SLANT BACK Rear Window

Removal
Remove the twenty two window retaining screws, the window retainer bracket and the window (Figure 10-181).
SLANT BACK WINDOW
Installation
Install the slant back side window and the window retaining bracket. Secure the window to the bracket with the thirteen window retaining screws (Figure 10-182).
WINDOW RETAINER BRACKET
WINDOW RETAINING SCREW
SLANT BACK DOOR
Figure 10-181: Slant Door Window Replacement
Installation
Install the slant door window and the window retainer bracket. Secure the window to the bracket with the twenty two retaining screws (Figure 10-181).
Slant Back Side Windows

Removal
Remove the thirteen window retaining screws, the window retaining bracket and the slant back side window (Figure 10-182).
SLANT BACK SLANT BACK SIDE WINDOW
SIDE WINDOW RETAINING SCREW WINDOW RETAINING BRACKET
Figure 10-182: Slant Back Side Window Replacement
05745159
4-1-00
10-92
Body ______________________________________________________________________
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11-1
Section 11
Heating/Ventilation/Air Conditioning (HVAC)

TABLE OF CONTENTS
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 Air Intake Assembly Replacement . . . . . . . . . . . . . . . . . 11-45 Cycling Switch Replacement . . . . . . . . . . . . . . . . . . . . . 11-45 Heater Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22 High Pressure Cutoff Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35 Low Pressure Cutoff Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 Main HVAC Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38 Diverter Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38 Heat Unit Cowl Insulation Replacement . . . . . . . . . . . . . 11-24 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38 High Pressure Cutoff Switch . . . . . . . . . . . . . . . . . . . . . . 11-38 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-39 Thermostatic Cycling Switch . . . . . . . . . . . . . . . . . . . . . 11-38 Pressure Hose Torque Specifications . . . . . . . . . . . . . . . . . . 11-17 Rear Console Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46 Receiver Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34 Receiver/Dryer Pressure Switch Replacement . . . . . . . . . . . 11-21 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 System Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Unit Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37 Vacuum Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-41 Water Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22 Water Control Valve Replacement. . . . . . . . . . . . . . . . . . . . . . 11-23
A/C System Refrigerant and Capacity . . . . . . . . . . . . . . . . . . . .11-5 Air Conditioning/Heater Duct Replacement . . . . . . . . . . . . . .11-25 Ambient Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . .11-34 Auxiliary HVAC Unit A/C Drain Tube(s) Replacement . . . . . . . . . . . . . . . . . . .11-48 Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . .11-49 Blower Switch Replacement . . . . . . . . . . . . . . . . . . . . . .11-47 Evaporator/Heater Core Replacement . . . . . . . . . . . . . .11-49 Expansion Valve Replacement . . . . . . . . . . . . . . . . . . . .11-50 Heater Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . .11-47 High-Pressure Hose Replacement . . . . . . . . . . . . . . . . .11-48 Low-Pressure Hose Replacement . . . . . . . . . . . . . . . . . .11-49 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-46 Blend Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-42 Blower Motor Resistor Replacement . . . . . . . . . . . . . . . . . . . .11-35 Climate Control System A/C Pressure Hose Replacement . . . . . . . . . . . . . . . . . .11-18 Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . .11-20 Control Head Replacement . . . . . . . . . . . . . . . . . . . . . . .11-16 Heater Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . .11-22 Heater/A/C Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 System Performance Checks . . . . . . . . . . . . . . . . . . . . . .11-2 Compressor Clutch Core Replacement . . . . . . . . . . . . . . . . . . . . . . . .11-32 Clutch Rotor and/or Bearing Replacement . . . . . . . . . .11-30 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-28 Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .11-32 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-34 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-36 Defrost Duct and Windshield Nozzles Replacement . . . . . . .11-26 Drain Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-24
HVAC SYSTEM DESCRIPTION

The heating, ventilating, and air conditioning system consists of the main unit (heat and A/C, or heat only), auxiliary unit (if equipped), ducting for air, hoses to transport refrigerant, coolant hoses, a water valve, A/C compressor, condenser, receiver dryer, expansion valve, safety switches, and vacuum pump. Function of the system is controlled by the vehicle operator using the control panel on the console
with the main unit, requiring that the main system be in operation to activate the auxiliary unit. The blower in the auxiliary unit is operated using a 3-position switch on the console and provides 2 speeds and an off position.
A/C COMPRESSOR DESCRIPTION

All 2000 vehicles use a common Harrison model HR6 compressor. The compressor is belt driven off the engine accessory drive, and utilizes an electric clutch to engage and disengage the compressor drive. The compressor is lubricated with required GM PAG oil. The compressor is specifically designed to operate with R134a refrigerant.
Auxiliary Unit
A secondary HVAC unit is used on all 4-passenger vehicles as standard equipment. Two-passenger vehicles can be equipped with an auxiliary unit as an option. The auxiliary unit includes a secondary heater core, evaporator, expansion valve, blower motor and controls. Both the heater and A/C work in parallel
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SYSTEM PERFORMANCE CHECKS

Before performing any air conditioning repair, perform the following: 1. Check drivebelt for wear, damage, or loss of tension. Replace drivebelt as necessary. 1. Check compressor for secure mounting and proper alignment. Tighten loose hardware and align as necessary. 2. Visually inspect compressor, hoses and other accessible parts of system for damage or leaks. Look for patches of dirt, dust, and oil build-up. Refrigerant leaks usually involve compressor oil loss. This is especially applicable to clutch end of compressor. 3. Verify operation of climate control system by performing following: a. With the mode (air flow) control knob set to OFF, run engine to operating temperature (180-240F (82116C)). b. Rotate temperature control knob clockwise until it stops at the warmest setting. c. Rotate mode control knob counterclockwise until it stops at the face setting. d. Turn fan control knob to any setting above LO and note direction and temperature of air flow. e. Verify that heated air is coming from instrument panel vents. f. Rotate mode control knob clockwise to the next setting, floor vents, and verify that heated air comes from appropriate vents. g. Continue checking the air flow positions, floor/defrost blend, and defrost. NOTE: Any time the air flow control knob is placed in defrost or a defrost blend position (with an ambient temperature above 40F), the compressor clutch engages to dehumidify the incoming air. h. Rotate the temperature control knob counterclockwise to its coldest extreme. Verify that cold air comes from the defrost vents. If the outside air temperature is 40F or warmer, the refrigeration system will be responsible for cooling the air. If it is cooler than 40F, the compressor will not cycle and the incoming air will simply be the outside air directed into the passenger compartment. Rotate the mode control knob counterclockwise until it stops at the Max A/C panel setting and verify that compressor clutch engages and air becomes colder. Turn the mode dial to the A/C setting. Verify that the air recirculation door closes, and the system brings in outside air. Check that blower motor delivers air at four different speeds. If not, perform electrical troubleshooting. Repair or replace blower motor, switch, relay, or blower motor resistor block. k. Check water control valve operation. Heater Shutoff Valve should open completely when temperature control knob is rotated clockwise.
Heating System Tests

In most cases, a low heat condition means an insufficient quantity of heated engine coolant is flowing through the heater core. Check as follows: 1. Check engine coolant level. If level is low, add coolant and inspect for leaks. If coolant level is correct, continue with tests. 2. Check pressure cap on surge tank for improper sealing with tester J24460-01 or equivalent. If cap is OK, continue with tests. Replace cap if it fails to seal and recheck heater operation. 3. Set heater controls to highest heat setting. 4. Operate engine until coolant is at normal operating temperature (180-220 F or 82-113 C). 5. Check temperature of coolant flowing through heater core inlet and outlet hoses. If both hoses feel hot and are about the same temperature, water control valve is OK and core is not restricted. Continue with test. If both hoses are only warm (or even cool), engine is either not at operating temperature, or a water pump or thermostat problem has occurred. If inlet hose is cool, or only slightly warm, water control valve or vacuum solenoid problem has occurred. Test as described in this section. 6. If heat output is still unsatisfactory but all else checks correctly, problem is with heat door in main unit, or in outlet ducts.
i.
j.
4-1-00
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Electronic leak testing
11-3
A/C System Leak Testing

There are two methods of detecting refrigerant leaks. One method is with the use of an electronic leak detector and the other uses a flourescent tracer dye in the refridgerant which is viewed at the leak site with an ultra violet (black) light.
Recommended electronic leak detector is the D-Tek, pocket portable model (Figure 11-2). It is self powered by NiCad batteries, extremely compact, and will locate leaks as small as 1/4 ounce. The Kent-Moore Tool number is J41995.
Dye leak testing

R134a florescent dye will remain in the lubricant for the life of the vehicle as long as the vehicles AC system has not been flushed. To perform a dye leak test, do the following: 1. Recover the existing R134a refridgerant and record the refridgerant weight. 2. Add R134a florescent dye J41447 using the dye injector J41459. 3. Recharge the AC system following the procedures outlined in chapter 11. 4. Check for leaks using the high intensity black light J-42220. If no leaks can be found, advise the customer of the dye in the system and that it may need to be checked at a later date.
Figure 11-2:
D-Tek Leak Detector
DYE INJECTOR
The D-Tek probe is flexible and can be used to make a 360o check of each hose connector and fitting. The correct method of leak testing fittings is shown in Figure 11-2.1.
00-S11-008
Figure 11-1: Dye Injector Use Figure 11-2.1 Leak Testing Technique at Connections A/C system potential leak points are outlined in Figure 1-3. Be sure to check each fitting and connector carefully with the DTek tool.
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11-4
_______________________
CONNECTOR IDENTIFICATION
COMPRESSOR-OUT CONDENSER - IN CONDENSER - OUT DRYER - IN DRYER - OUT H/P AUX TEE - IN H/P AUX TEE - OUT AUX EVAP - IN AUX EVAP - OUT MAIN EVAP - IN MAIN EVAP - OUT L/P AUX TEE - IN L/P AUX TEE - OUT COMPRESSOR - IN COMPRESSOR - FRONT SEAL SCHRADER VALVES
NOTE: Move detector wand at a slow, consistent rate above and below and around fittings/connnections. Carefully inspect all hose connections to metal ferrules on crimp shells. Also test the small inspection holes on the shells.
Figure 1-3: A/C System Leak Check Points
______________________

Pressure Test Procedure
1.
11-5
A/C SYSTEM REFRIGERANT AND CAPACITY

The required refrigerant for Hummer A/C systems is R-134a. This is a colorless, odorless non-flammable, liquefied gas. A special refrigerant oil is required for use with R-134a which is polyalkaline glycol (PAG). This is the only oil that can be used with R-134a refrigerant. More specifically, General Motors PAG oil must be used with the A/C compressor on the HUMMER. CAUTION: R12 and R-134a refrigerants are not compatible. They must never be intermixed. Unsatisfactory cooling, rapid sludge buildup, and compressor failure will result. System refrigerant capacity is: 3 lbs 2 oz
2.
3. 4. 5. 6.
R-134a Refrigerant Precautions

To avoid product damage and personal injury, the following precautions should be followed when working with R-134a refrigerant. Wear safety goggles when servicing the A/C system as the refrigerant is under pressure. Never mix R-134a and R-12 refrigerants. They are incompatible and will cause severe damage to system components if mixed. Use an approved A/C service cart such as the Kent Moore J39500-A to service the system. Recommended service carts are those capable of evacuation, recovery, recycling, and recharging of systems with R-134a. The only compressor lubricant oil that can used with this system is General Motors PAG oil. Use of substitutes will result in lubricant failure. Lubricate system fittings and o-rings with a 525 viscosity refrigerant oil for leak proof connections. Do not heat containers of R-134a above 125 F (52 C). Never puncture or incinerate containers of R-134a. Avoid breathing R-134a. The gas will irritate the nose, throat, and lungs. In addition, because R-134a is heavier than air, it can displace oxygen in a confined and a poorly ventilated area. Be sure the work area is properly ventilated in case of accidental release into the nearby atmosphere.
7.
8.
Connect gauge hoses on service cart J39500-A to service ports on suction and discharge lines (Figure 11-4). Red hose goes to high side (discharge) port and blue hose to low side (suction) port. Note pressure with engine not running and A/C system inoperative. There should be approximately 50 psi to 70 psi in the system. If pressure is lower or zero, a system leak exists. Add a small charge to the system. Then leak test and repair as necessary before proceeding. Start and run engine at 1200 rpm. Set A/C controls to maximum cooling and set blower to highest speed. Verify that compressor clutch engages. If clutch fails to engage, diagnose and repair before proceeding Record low and high side pressures. Depending on engine speed and shop ambient temperature, low side pressure will range from 18 to 35 psi (124 to 241 kPa) and high side pressure from 176 to 320 psi. Ambient temperatures will affect refrigerant pressures in the system. On cool days, pressures are lower; on hot days pressures are higher. Refer to system pressure comparison chart at end of this section. If low and high side pressures are OK, check air temperature at outlet duct closest to evaporator with thermometer J6742-03. Temperature should range from 33F to 45F depending on ambient temperature. Be sure thermometer tip is inserted into duct to a depth of at least one inch (25 mm). If low and high side pressures are incorrect and air duct outlet temperatures are greater than specified, refer to pressure test diagnosis charts for potential causes.
BLUE SUCTION (LOW SIDE) HOSE
RED DISCHARGE (HIGH SIDE) HOSE
A/C System Pressure Test

System pressure testing involves measuring suction and discharge pressures with manifold gauge set J39183-C, or with the gauges contained in A/C service cart J39500-A. One gauge is for high side (discharge) pressures and one for low side (suction) pressures. The gauges allow pressures to be checked while the system is in operation. On models where access to the service ports is limited, coupler adapters J39500-20A and J39500-24A, will make gauge hose connection easier.
COMPRESSOR
00-S11-002
Figure 11-4: Service Hose Connections at Compressor
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A/C Servicing Precautions

There are precautions that should be followed when servicing the A/C system. The precautions are necessary to avoid component damage and personal injury. Wear eye protection when servicing the system. The refrigerant is under pressure and will cause injury if it contacts the eyes. Never perform system repairs until after the system has been fully discharged. Do not use refrigerant recovery, recycling, charging, and evacuation/discharge servicing equipment that does not meet SAE J2210 standards. Never attempt to replace system components while the engine is running. Avoid having R-134a contact the skin. The refrigerant can cause an injury similar to frostbite. Exercise care when handling R-134a. Do not allow any type of open flame near R-134a. Avoid breathing R-134a fumes. The refrigerant will cause eye, nose, throat, and lung irritation. Never mix R-12 and R-134a in the same system. The two refrigerants are not compatible. Mixing the two will result in failure of the compressor and other system components. Never use PAG oil from an unsealed container. The oil will quickly absorb moisture from the air if not sealed.
Recycling System Refrigerant

The J39500-A service cart (from Kent Moore), will recycle R-134a refrigerant when necessary. The original recovered refrigerant is moved through a combination filtration/dryer unit built into the cart. This unit removes impurities allowing refrigerant reuse. Follow the manufacturers instructions carefully for the recycle process because incorrect use could result in moisture in the refrigerant. The recycle process is accomplished automatically when the service cart is in evacuation mode.
Evacuating the A/C System

CAUTION: Do not evacuate an A/C system that is not completely discharged. Check system pressures with a gauge set if unsure about charge level. The A/C system evacuation process involves applying 26-28 inches Hg to the A/C system for a minimum of 20 minutes. The applied vacuum removes moisture. A vacuum pump built into the service cart generates the necessary vacuum. 1. 2. 3. 4. Connect service cart J39500-A to service ports. Discharge system. Connect vacuum pump to center hose on manifold if gauge set J39183-C is being used. Turn vacuum pump on, and open gauge valves.
Recovering (Discharging) A/C System Refrigerant

1. 2. Shut engine off. Connect hoses from service cart J39500-A to suction and discharge service ports. Red hose goes to discharge side and blue hose to suction side. Use adapter fittings J 39500-20 and 24A if necessary. If manifold gauge set J 39183-C is being used, connect center hose to a recovery tank, or system.
NOTE: High side gauge should drop to zero or below. If not, a blockage in A/C system is indicated. Deduct 1 in. vacuum from maximum attainable reading for each 1000 ft elevation above sea level. 5. 6. Evacuate unit until low pressure gauge reads 26-28 in. Hg. Turn vacuum pump off and allow system to sit undisturbed for 15 min to check for vacuum leaks. If pressure rises, diagnose system leak. Continue evacuation for thirty minutes after correct gauge reading of 26-28 in. Hg vacuum has been achieved. Turn gauge valves to closed position after evacuation is complete. Turn off vacuum pump and disconnect center hose from vacuum pump.
7. 8. 9.
NOTE: If both gauges indicate a zero reading, the system does not contain any refrigerant. Add a small charge, leak test, and make necessary repairs before proceeding. 3. 4. 5. Begin recovery/discharge cycle as described in service cart instructions. Recovery is complete when service cart gauges read slightly below zero. Secure the service cart as described in the manufacturers instructions.
______________________

4.
11-7
Checking/Adding Refrigerant Oil

It is not necessary to check or add oil as routine maintenance. It is necessary to add oil when the evaporator, condenser, compressor, or receiver/dryer has been replaced, or there was a large leak. When a system is discharged, it is also necessary to replace any oil carried out with the refrigerant. CAUTION: All replacement compressors are shipped with 8 oz. (237 ml) of oil in the crankcase. This oil must be drained completely, and replaced in like amount to the failed compressor. Add 2 oz above what is found in the failed compressor. Failure to do so will cause an overcharge of oil in the system and will lower cooling efficiency. An extreme overcharge condition may cause early compressor failure. 1. If a major component was replaced, add clean GM PAG oil as follows. a. Condenser 1 oz. (30 ml). b. Evaporator 3 oz. (84 ml). c. Receiver/Dryer 2 oz. (60 ml). d. Auxiliary Unit - 2 oz. (60 ml). e. Compressor see step 3. f. Any other known quantity of oil. Add oil to the system. Add directly into component. Oil can also be added directly from the service cart after system evacuation. Check oil in compressor: a. Recover/discharge A/C system refrigerant. b. Remove compressor. c. Tip compressor on hose connection end and drain into a clean container. Allow to drain for ten minutes. Measure and discard oil. d. When the new compressor is recieved, drain the oil that was shipped inside. Replace the oil in an equal amout to that which was drained from the old compressor. If less than one ounce (30 ml) is drained from the old compressor, add two ounces (60 ml) to the new compressor. If more than one ounce (30 ml) is drained, replace the same amount in the new one. e. Plug or block ports and turn compressor over slowly several times.
Perform evacuation, recharging, and leak testing of system.
Charging The A/C System

NOTE: If A/C system requires replacement of a major component, refrigerant oil must be added to system to compensate for loss. 1. 2. 3. 4. Evacuate A/C system. Follow manufacturers recommended service procedures for the equipment being used. Connect refrigerant source to center hose if manifold gauge set J39183-C is being used. Open refrigerant R-134a source to allow refrigerant to flow into system. Purge center hose, low-pressure hose, and high-pressure hose as follows: a. b. Slightly loosen center hose at manifold gauge set center port until refrigerant escapes, then tighten hose. Open high-pressure and low-pressure gauge valves to allow refrigerant to flow into high-pressure and lowpressure hoses. Turn high-pressure and low-pressure gauge valves clockwise to OFF position. Purge high-pressure and low-pressure hoses at service ports of compressor.
c. d.
2.
3.
WARNING: Make sure high-pressure gauge valve is in closed position on manifold gauge set during charging. Failure to do so will cause compressor to build pressure in refrigerant container. This could result in injury to personnel or damage to equipment if the container cracks.
5. 6. Start engine and set engine speed at 1500 rpm. Turn A/C system to max cold and blower fan on high speed.
NOTE: Keep refrigerant container upright at all times so refrigerant enters system as a gas. 7. 8. Open low-pressure gauge valve until system is fully charged. Close low-pressure gauge valve.
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SYSTEM DIAGNOSIS
System diagnosis should begin with the system performance checks described in this section. The checks will help verify that a problem actually exists as opposed to an incorrect setting by the vehicle operator. In addition to the performance checks, problem verification will also involve pressure testing, leak testing, individual component testing, air flow and temperature testing, and refrigerant recovery, evacuation, or recharge. The tools and equipment required for this purpose are described in each procedure. The diagnosis charts outline common heater and A/C problems. The potential causes are listed in order of probability (most-to-least probable). However, the charts are guides only and will not outline all of the possible system faults that might occur. System testing is still required for verification. The primary diagnostic method of checking A/C system performance is the pressure test. The test is performed with manifold gauge set J39183-C. The gauges allow suction and discharge pressures to be checked while the system is operating. The pressure test diagnosis charts describe common faults that cause incorrect system pressures.
Water Valve Does Not Operate

Step 1 Action Actuate the water valve lever by hand, does it move freely, and does spring pressure re-open the valve when you release it.? Loosen the clamp securing the water valve to the body. Does the valve move freely now? Using a hand vacuum pump J35555, apply 18Hg to the water valve vacuum motor. Does the valve close and hold vacuum for at least 1 minute. Release the vacuum on the water valve, does the valve return to the open position? Attach J35555 to the vacuum supply line for the water valve. Start and idle the engine. Rotate the temperature control dial to the cold position. Is sufcient vacuum present? With J35555 still attached to water valve vacuum supply line, rotate temperature control dial to the hot position. Does atmosphere vent in? Check for kinks, breaks and blockages in the vacuum harness between the water valve and the HVAC control head. Are any found? With J35555 still attached to water valve vacuum supply line, disconnect HVAC control head 2 hose blk/wht connector. Does atmosphere vent in? Disconnect 2 hose blk/wht connector at HVAC control head. Install J35555 onto blk hose. Start and Idle engine. Is sufcient vacuum present? Locate vacuum connection on rear of vacuum pump. Install J35555 onto connection and start and idle engine. Is sufcient vacuum present? 0Hg 18Hg 18Hg Value(s) Yes go to step 3 No go to step 2
2 3
Problem is corrected go to step 4
Replace the water valve Replace water valve Replace the water valve go to step7
4 5
go to step 5 go to step 6
0 Hg
System is working correctly Repair or replace vacuum harness as necessary Replace the control head
go to step 8
go to step 9
Remove blockage in white vacuum line to water valve go to step 10
18Hg
Replace the control head Locate and repair blockage/breakage in vacuum harness between vacuum pump and HVAC control head
10
18Hg
Replace vacuum pump
______________________

Heater Diagnosis
11-9
Condition Inadequate or No Heat 1. 2. 3. 4. 5. 6. 7. 9.
Possible Cause Heat control knob not set in heat mode, or engine not warmed up. Low engine coolant level. Air in coolant system. Usually occurs after coolant drain and rell. Thermostat faulty. Kinked or collapsed radiator hose or heater hose. Water pump failure. Heater core plugged or leaking. Blower motor fault. 1. 2. 3. 4. 5. 6. 8.
Correction Advise owner/driver. Add coolant as needed and check for leaks. Bleed air from cooling system. Replace thermostat(s) if stuck closed or remains open continuously. Replace hose. Replace pump. Replace core.
10. Check circuit fuse and wiring. Replace motor if foiled. 12. Seal plenum or realign as needed. 14. Replace valve if stuck closed or partially open. Replace solenoid if closed or shorted. 16. Replace main unit. 1. 2. 3. Repair as needed. Repair as needed. Check for low coolant level, coolant leaks, air in system, faulty thermostat or water valve, collapsed hose, plugged heater core, binding air door in main unit. Check circuit fuse and wiring. Replace motor if open or shorted.
11. Outside air leaking into heater core section of plenum. 13. Water control valve or vacuum solenoid fault. 15. Blend air door stuck or misadjusted. Inadequate Defrost 1. 2. 3. Duct restricted or connecting hose is loose. Defroster nozzle misaligned or damaged (bent, cracked, partially closed). Insufcient heat.
4.
Blower motor fault.
4.
NOTE: Improperly adjusted or binding mode door linkage can also cause low, poor or no airflow to any location.
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Heating/Ventilation/Air Conditioning (HVAC) ______________________
Air Flow Diagnosis

Condition No Air Flow from Outlets 1. 2. 3. Possible Cause Blower motor fuse blown. Blower motor harness damage (short, open, loose connection). Blower motor fault. 1. 2. 3. Correction Replace fuse. Check harness continuity with ohmmeter and repair as needed. Run 12V jumper directly to motor. Motor should run at high speed. If motor fails to run, replace it. If motor runs, check resistor. Replace resistor if motor runs when resistor is bypassed or if blower runs at high speed setting but will not run at one or all of the lower settings. Remove passenger side trim to expose both actuator motors and observe linkage operation. Adjust linkage if required. Replace either motor and/or linkage if inoperative. Repair as needed. Repair as needed. Replace motor or resistor if either is inoperative. Adjust as necessary.
4.
Blower motor resistor fault.
4.
Air Flows from Incorrect Outlets
1.
Actuator motor or linkage fault.
1.
Low-Weak Air Flow from Outlets
1. 2. 3. 4.
Restriction in air ducts. Restriction in intake hose into main unit. Blower motor fault. Misadjusted or binding mode door linkage.
1. 2. 3. 4.
A/C System Diagnosis

Condition Water on Passenger Side Floor 1. Possible Cause Evaporator drain hose plugged or installed incorrectly. Coolant leak from heater core. Road splash entering compartment through evaporator/heater core opening, or through intake air inlet area. Water leaking into passenger compartment. Water leaking into passenger compartment. Evaporator drain partially or fully plugged. Mold-Mildew development on evaporator surface, coils, ns. 1. Correction Open hose with utility knife or tirm end off hose. Make sure routing of hose is to outside of passenger compartment. Replace core if leaking. Replace clamps or hoses if leaking at heater core connections. Water test and seal off as needed.
2. 3.
2. 3.
4. Musty Smell 1. 2. 3.
4. 1. 2. 3.
Water test and correct leaks. Water test and correct leaks. Open or tirm off drain hose with utility knife. Correct routing if necessary. Clean evaporator with mild disinfectant soap or replace evaporator as necessary.
_____________________

A/C Pressure Test Diagnosis
11-11
Condition Low Side High High Side High (Discharge Air Warm Discharge Line Warm to Hot) 1.
Possible Cause Condenser ns obstructed or distorted. 1.
Correction Clear obstruction with water spray and compressed air. Straighten distorted ns with tool J36847 or equivalent. Recover excess charge with A/C service cart J39500-A. Evacuate and recharge system. Replace valve. Replace condenser. Evacuate and recharge system. Replace belt or belt tensioner as needed. Discharge system. Replace receiver/dryer and evacuate - recharge system. Locate with D-Tek leak tester. Recharge system and verify proper operation. Add refrigerant and leak test system. Correct leak source and recharge as needed. NOTE: If leak was large, check compressor oil level also and correct as needed.
2. 3. 4. 5. 6.
System overcharged. Air in system. Expansion valve failed. Condenser restricted. Compressor drive belt slipping. Air and moisture in system. Leak at A/C line of 1/2 ounce or less.
2. 3. 4. 5. 6. 1. 2.
Low Side High High Side High (Discharge Air Slightly Cool - Discharge Line Cool) Low Side Low High Side Low
1. 2.
1.
System low on refrigerant.
1.
2. Low Side High High Side Low 1. 2. 3. Low Side Low High Side High 1. 2. 3. 4. Low Side and High Side Normal But Cooling is Inadequate 1.
Expansion valve failed. Internal leak in compressor Expansion valve failure. Drivebelt slip. Expansion valve failed. A/C hose constricted, plugged. Receiver/Dryer restricted or has failed. Condenser problem (blocked, damaged). Air and/or moisture in system.
2. Replace valve, then evacuate and recharge system. 1. 2. 3. 1. 2. 3. 4. 1. Replace compressor and evacuate recharge system. Discharge system. Replace valve and recharge system. Replace belt. Discharge system. Replace valve and recharge. Check hose for kinks. Replace hose if plugged and evacuate - recharge system. Evacuate system. Replace receiver/dryer and recharge system. Evacuate system. Replace condenser and recharge system. Leak test system. Repair leaks if necessary. If leaks are not evident, evacuate and recharge system. Evacuate system, replace receiver/dryer and recharge system.
2.
Receiver/Dryer fault.
2.
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Compressor Diagnosis
Condition Compressor Noise 1. 2. 3. 4. Compressor Does Not Engage 1. 2. 3. 4. 5. 6. Compressor Engages but Cooling is Inadequate 1. 2. 3. 4. 5. 6. Possible Cause System overcharge. Drivebelt problem. Compressor clutch fault. Compressor internal fault. System fuse blown. Clutch wires damaged. Pressure cycling clutch, or A/C cutout switch fault. Compressor clutch failure. Compressor seized. High engine coolant temperature triggering A/C cutout switch. A/C duct restrictions, loose connections. System leaks (high side pressure below 50 psi (345 kPa)). Expansion valve inoperative. Receiver/Dryer fault. Condenser fault. Compressor internal wear. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. Correction Recover all R-134a with J39500-A service cart and recharge with proper charge. Replace belt if worn, frayed, cut or torn. Replace core or pulley bearing as needed. Replace compressor if pressure test indicates worn, inoperative condition. Replace fuse. Check circuit for shorts, ground. Repair wires. Replace switch(s) as needed. Replace clutch core and/or pulley as needed. Replace compressor. Let engine cool down and fix engine cooling system problem first. Repair as needed. Check for leaks with D-Tek tool and repair as needed. Replace valve. Replace Replace condenser. Replace compressor if pressure indicates internal wear or damage.
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11-13
SPECIFICATIONS
System refrigerant R-134a Compressor oil PAG (polyalkaline glycol) Refrigerant capacity 3 lbs.2oz. Compressor type Harrison HT6
A/C System Test Pressures

Ambient Temperature F 70 75 80 85 90 95 100 110 C 21 24 27 29 32 35 38 43 Low Side Pressure Range* Psi 10-32 12-33 17-34 18-35 19-47 21-47 28-51 30-55 kPa 69-221 83-228 117-234 124-241 131-324 145-324 193-352 207-379 High Side Pressure Range* Psi 112-270 120-280 131-310 185-325 210-330 225-350 240-370 255-390 kPa 772-1861 827-1930 903-2137 1276-2172 1448-2275 1551-2413 1655-2551 1758-2689
*Low and high side pressures are affected by relative humidity. Greater humidity will cause higher pressures
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R-134a Pressure-to-Temperature Relationship Chart (with Engine OFF)

Psi 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Temp (F) R-134a -14.7 -12.1 -9.6 -7.2 -4.9 -2.7 -0.6 1.4 3.4 5.3 7.1 8.9 10.6 12.3 13.9 15.4 17.0 18.5 19.9 21.4 22.8 24.1 25.5 26.8 28.0 Psi 25 26 27 28 29 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 Temp (F) R-134a 29.3 30.5 31.7 32.9 34.0 35.1 37.4 39.5 41.6 43.6 45.6 47.4 49.2 51.0 52.8 54.5 56.4 57.8 59.3 60.8 62.4 63.9 65.4 66.8 68.2 Psi 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 Temp (F) R-134a 69.6 72.9 76.1 79.2 82.2 85.0 87.8 90.5 93.1 95.6 98.0 100.4 102.7 104.9 107.1 109.3 111.4 113.3 115.4 117.4 119.3 121.2 123.0 124.8 126.6 Psi 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 Temp (F) R-134a 130.1 133.5 136.7 139.8 142.9 145.9 148.8 151.6 154.3 157.0 159.6 162.2 164.7 167.2 169.6 171.9 174.2 176.5 178.7 180.7 183.1 -
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11-15
FLOOR DOOR MOTOR (RED) DEFROST BLOCKOFF DOOR MOTOR(BLUE)
RECIRCULATE DOOR MOTOR (ORANGE) FACE DOOR MOTOR(YELLOW AND BROWN)
DEFROST DOOR MOTOR (SILVER)
7-S11-031
Figure 11-5: Vacuum Door Motors
Vacuum Door Motor Arm Positioning

OFF Floor Defrost blockoff Face Defrost Recirculate out out out out out MAX out out in out in out out in out out A/C A/C Blend in out half out out out out in out out Face in out out out out Floor Defrost/ Floor out out out out out Defrost out in out in out
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CLIMATE CONTROL HEAD REPLACEMENT

Removal
1. 2. 3. 4. Remove front console. Remove screw attaching climate control head to support plate side bracket (Figure 11-6). Pull climate control head from behind support plate so that it angles away from longer side bracket. Pull climate control head from shorter side bracket.
Installation
1. 2. 3. 4. From behind support plate, angle climate control panel behind shorter of two side brackets. Push climate control head toward longer side bracket until flush, then secure it with a screw. Slide rear bracket onto back lip of climate control head. Install front console.
CONSOLE
CLIMATE CONTROL HEAD SUPPORT PLATE FACE PLATE
AUXILIARY HEAT-A/C SWITCH
Figure 11-6: Climate Control Head Replacement
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11-17
PRESSURE HOSE TORQUE SPECIFICATIONS

CAUTION: To avoid potential thread or fitting damage, hand start connections before using wrenches. Air conditioning system fittings are a common source of refrigerant leaks. When service requires disconnecting and connecting fittings, observe the following: When tightening or loosening hose and tube fittings, use two wrenches for equalized support (Figure 11-7).
INCORRECT
INCORRECT
PROPERLY SEATED
Figure 11-8: Correct Seating O-Rings

FEMALE END MALE END
Figure 11-7: Hose and Tube Fittings

Plug open ends of hoses after disassembly. Do not remove plugs from hose fittings until each component is ready for connection. This will prevent moisture and dirt contamination which can cause compressor wear and system blockage. Make sure that O-rings are properly seated before assembly (Figure 11-8). Carefully interlock male and female ends of hoses (Figure 11-9). Before making any hose and tube connection, apply a few drops of refrigerant oil to the O-rings and threaded portions of the connector. Make connections quickly. Tighten fittings to proper torque specification based on hose size.
CORRECT
INCORRECT
Figure 11-9: Proper Connection of Hose End
Pressure Hose Torque Values

Hose Size Torque (Ft. Lb.) Torque (Newton Meters)
Minimum Maximum Minimum Maximum #6 Liquid Hose #8 Discharge Hose #10 Suction Hose #12 Suction Hose 11 15 21 24 13 20 27 28 15 20 28 33 17 27 36 38
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AIR CONDITIONING PRESSURE HOSE REPLACEMENT

WARNING: Air conditioning system components are subject to high-pressure R-134a gas. Always discharge pressure and contain refrigerant using approved service equipment. Use extreme care when handling R-134a. Direct contact with skin may cause frostbite. Do not smoke in areas where R-134a is stored or used. Failure to follow these warnings may result in serious injury.
CAUTION: Cover all open lines to prevent contamination.
EXPANSION VALVE MANIFOLD BLOCK
SUCTION HOSE
LIQUID LINE
Suction Manifold Hose Assembly

JUNCTION BLOCK SUCTION HOSE O-RING O-RING
00-S11-004
DISCHARGE HOSE
AUXILIARY OUTLETS
Figure 11-11: Suction Manifold Hose Removal
Installation
1. Install the suction hose onto the expansion valve manifold block with a new O-ring. 2. Torque the fitting to 21-27 lb-ft (28-36 Nm). 3. Install auxiliary unit refrigerant line using new O-ring (if equipped). 4. Torque auxiliary unit line to 21-27 lb-ft (28-36 Nm). 5. Install suction hose onto compressor junction block fitting with a new O-ring. 6. Torque the fitting to 21-27 lb-ft (28-36 Nm). 7. Evacuate system for 30 min. 8. Recharge system with 3lbs. 2oz. R134a. 9. Performance test A/C 10. Install air cleaner splash shield.
00-S11-003
Figure 11-10: Suction/Discharge Hose Mounting
Suction Manifold Hose Replacement

Removal
1. 2. 3. 4. 5. 6. Discharge the air conditioning system. Remove air cleaner splash shield Disconnect auxiliary hose connection (if equipped). Disconnect the suction hose from the expansion valve manifold, discard the O-ring (Figure 11-11:). Disconnect the suction hose at the compressor junction block, discard the O-ring (Figure 11-10). Remove the hose assembly from the vehicle.
_____________________

Condenser-to-Receiver/Dryer Hose
11-19
Discharge Hose Replacement

Removal
1. 2. Disconnect discharge hose from condenser. Remove and discard O-ring (Figure 11-12). Remove driver side engine splash shield (Section 10).
CONDENSER O-RING OIL COOLER LINES
WARNING: Air conditioning system components are subject to high pressure R-134a gas. Always discharge pressure and contain refrigerant using approved service equipment. Use extreme care when handling R-134a. Direct contact with skin may cause frostbite. Do not smoke in areas where R-134a is stored or used. Failure to follow these warnings may result in serious injury.
Removal
CAUTION: To avoid potential thread or fitting damage, hand start connections before using wrenches. 1. 2. 3. Discharge air conditioning system. Disconnect hose from condenser and remove O-ring. Discard O-ring (Figure 11-13). Remove hose and O-ring from receiver/dryer. Discard Oring.
CONDENSER
TIE STRAP
TO EVAPORATOR HOSE DISCHARGE HOSE
Figure 11-12: Discharge Hose Location

3. 4. Remove tie strap securing discharge hose to oil cooler lines. Discard tie strap. Remove discharge hose from compressor block and discard O-ring (Figure 11-10).
RECEIVER DRYER
Installation
CAUTION: To avoid potential thread or fitting damage, hand start connections before using wrenches. 1. 2. 3. Position O-ring on discharge hose (Figure 11-10). Secure discharge hose to compressor block. Torque fitting to 15-20 lb-ft (20-27 Nm). Lubricate O-ring, position on discharge hose, and connect hose to condenser. Using two wrenches for equalized support, tighten to 15-20 lb-ft (20-27 Nm). Secure discharge hose to oil cooler lines with tie strap. Install driver side engine splash shield. Evacuate and charge air conditioning system. Check for system leaks. Check A/C operation.
Figure 11-13: Receiver/Dryer Location
Installation
1. Lubricate O-ring with PAG oil, position on hose, and secure hose to condenser. Using two wrenches for equalized support, tighten to 11-13 lb-ft (15-18 Nm). Lubricate O-ring with PAG oil, position on hose, and secure hose to receiver/dryer. Using two wrenches for equalized support, tighten to 11-13 lb-ft (15-18 Nm). Evacuate and charge air conditioning system. Check system for leaks. Check air conditioning system operation.
4. 5. 6. 7. 8.
2.
3. 4. 5.
05745159
11-20
Receiver/Dryer-To-Evaporator Core Hose

CONDENSER REPLACEMENT
Removal
1. Discharge air conditioning system.
Removal
1. 2. 3. 4. Discharge air conditioning system. Disconnect hose from receiver/dryer and remove O-ring. Discard O-ring (Figure 11-13). Disconnect auxiliary hose connection (if equipped). Remove hose and O-ring from expansion valve manifold block. Discard O-ring (Figure 11-11)
NOTE: Cover all open lines to prevent contamination. 2. Disconnect two pressure hoses from condenser and remove O-rings. Discard O-rings.
Installation
1. 2. Lubricate two O-rings with PAG oil and position on hose (Figure 11-11). Secure hose to expansion valve manifold block. Using two wrenches for equalized support, tighten to 11-13 lb-ft (1518 Nm). Torque auxiliary unit line to 11-13 lb-ft (15-18 Nm). Secure hose to receiver/dryer. Using two wrenches for equalized support, tighten to 11-13 lb-ft (15-18 Nm) (Figure 11-13). Leak test system.
CONDENSER
3. 4.
5.
OIL COOLER
Figure 11-14: Condenser Replacement

3. Remove screws, washers, spacers, and condenser from oil cooler (Figure 11-14). Secure condenser to oil cooler with spacers, washers, and screws (Figure 11-14). Lubricate two O-rings with PAG oil and install on pressure lines. Connect two pressure hoses to condenser. Evacuate and charge air conditioning system.
Installation
1. 2. 3. 4.
_____________________

RECEIVER/DRYER PRESSURE SWITCH REPLACEMENT
Removal
1.
11-21
RECEIVER/DRYER REPLACEMENT
Removal
WARNING: Air conditioning system components are subject to high-pressure R-134a gas. Always discharge pressure and contain refrigerant using approved service equipment. Use extreme care when handling R-134a. Direct contact with skin may cause frostbite. Do not smoke in areas where R-134a is stored or used. Failure to follow these warnings may result in serious injury.
NOTE: The receiver/dryer will quickly absorb water from the atmosphere when not sealed. Do not leave system open during service. Receiver/Dryer should be replaced any time major components are replaced. If in doubt, replace unit. 1. 2. Discharge air conditioning system. Disconnect electrical connector from high/low pressure switch (Figure 11-15).
Disconnect pressure switch jumper connector from receiver/dryer pressure switch (Figure 11-16).
NOTE: Unscrew the pressure switch as quickly as possible to avoid excessive loss of refrigerant. 2. Using a wrench, remove the pressure switch from the receiver/dryer.
RECEIVER/DRYER ELECTRICAL CONNECTOR
NOTE: Cover all open lines to prevent contamination. 3. 4. Disconnect two hoses from receiver/dryer and remove Orings. Discard O-rings. Remove two clamps and receiver/dryer from bracket.
O-RINGS CONNECTOR RECEIVER/ DRYER
HOSE
RECEIVER/DRYER PRESSURE SWITCH
Figure 11-16: Receiver/Dryer Pressure Switch Mounting
Installation
HOSE
1.
Thread the new pressure switch on the receiver/dryer tting by hand and use a wrench to nish securing the pressure switch. (Figure 11-16).
NOTE: Install the pressure switch as quickly as possible to avoid excessive loss of refrigerant.
HIGH/LOW PRESSURE SWITCH CLAMPS RECEIVER DRYER BRACKET
2. 3.
Connect the pressure switch jumper electrical connector to the pressure switch. Check the pressure switch fitting for leaks using suitable leak-testing equipment.
Figure 11-15: Receiver/Dryer
Installation
1. Secure receiver/dryer to bracket with two clamps. Position hose attachment ports to front and rear of vehicle (Figure 11-15). Lubricate two O-rings with PAG oil and position on hose fittings. Connect two hoses to receiver/dryer. Connect electrical connector to high/low pressure switch. Test the system for leaks.
2. 3. 4. 5.
05745159
11-22
HEATER HOSE REPLACEMENT

Engine coolant is routed through 5/8 inch diameter heater hose from the engine water crossover to the bottom fitting of the heater shutoff valve. When the valve is open, coolant flows through another length of hose from the valves rearward lower fitting to the heater core inlet port. The heater outlet hose is routed to the valves rearward upper fitting on vehicles without an auxiliary A/C - heat unit. On vehicles equipped with an auxiliary unit, the heater outlet hose is routed to the auxiliary heater core inletthen from the auxiliary heater core outlet to the rearward upper fitting on the heater shutoff valve. The coolant return hose is routed from the forward upper heater shutoff valve fitting to the water pump nipple (Figure 11-17).
WATER CONTROL VALVE

The water control valve determines when coolant will flow through the heater core(s). The design of the valve allows the engine coolant to flow around (bypass) the HVAC system when the temperature dial on the control head is moved to the cold position. The valve is operated by vacuum directed by the control head. When vacuum is applied, the valve bypasses. When atmospheric pressure is vented in, engine coolant flows through the heater core(s) (Figure 11-18).
Removal
1. 2. Drain cooling system (Section 4). Loosen worm gear clamps on either end of hose to be removed.
MOUNTING BRACKET WATER CONTROL VALVE
NOTE: Damage to the heater core can result if too much force is applied to the ports. If the hose is not easily removed by moderate twisting and pulling, cut the hose just beyond the port. Then cut the hose remaining on the port lengthwise and remove it. 3. Remove hose ends from fittings by twisting and pulling.
6-S11-008
Figure 11-18: Water Control Valve

HEATER SHUTOFF VALVE 5/8" DIAMETER HEATER HOSE
5/8" DIAMETER HEATER HOSE
Figure 11-17: Heater Hose Routing Without Auxiliary Unit
Installation
1. 2. 3. With clamps loosely in place, connect hose ends to respective ttings. Tighten clamps. Refill cooling system and check for leaks (Section 4).
_____________________
11-23
WATER CONTROL VALVE REPLACEMENT

Removal
1. Place a drain container under the vehicle directly below the control valve (Figure 11-19).
Installation
CAUTION: Do not overtighten the clamp that secures the control valve to the mounting bracket. Overtightening the clamp can deform the valve housing and cause binding. After tightening, push the plunger in and out of the vacuum diaphragm to ensure the valve is moving freely. 1. 2. 3. 4. 5. 6. 7. Gently secure control valve to mounting bracket with clamp (Figure 11-19). Secure hoses to valve with clamps. Release and remove hose clamp pliers or equivalent tools from valve hoses. Connect the valve vacuum hose (Figure 11-19). Check the coolant level and add coolant if necessary. Tighten coolant pressure cap. Check the valve for proper operation and leaks.
NOTE: Use extreme caution when working on a hot engine. Let the engine cool down before proceeding. 2. 3. 4. 5. 6. 7. Relieve pressure from cooling system by loosening coolant pressure cap. Remove the air intake hoses. Disconnect the vacuum hose from the control valve diaphragm. Clamp control valve hoses with heater hose clamp pliers or equivalent tool. Remove hoses from valve. Remove clamp and valve from mounting bracket.
FROM VACUUM SOLENOID FROM HEATER
CLAMP MOUNTING BRACKET PLUNGER TO HEATER WATER CONTROL VALVE
TO ENGINE
FROM ENGINE
Figure 11-19: Water Control Valve Installation
05745159
11-24
MAIN A/C - HEAT UNIT COWL INSULATION REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove air intake weathercap (Section 3). Remove air cleaner assembly shield. Remove vent line from air cleaner assembly. Remove air cleaner assembly and air induction tube. Loosen and remove two clamps and move surge tank out of the way. Remove drain tube. Remove trim screws, as necessary, from insulation on air intake housing (Figure 11-20). Remove screws and washers, as necessary, from insulation on upper cowl.
Installation
1. Position cowl insulation so that ap side is inserted under surge tank bracket (Figure 11-20). 2. Install three nuts and washers to secure insulation to main A/C - heat unit mounting studs. 3. Install bolts, nuts, and retainers as necessary to secure insulation to front of cowl. 4. Install screws and washers as necessary to secure insulation to upper cowl. 5. Install trim screws as necessary to secure insulation to air intake housing. 6. Install drain tube. 7. Install two surge tank screw clamps to secure surge tank. 8. Install air cleaner assembly and air induction tube (Section 3). 9. Install air cleaner assembly vent line. 10. Install air cleaner assembly shield. 11. Install air intake weathercap.
Remove bolts, nuts, and fasteners, as necessary, from insulation on front of cowl. 10. Remove three nuts and washers from insulation on main A/C - heat unit mounting studs. 11. Remove cowl insulation.
BLOWER MOTOR RESISTOR UPPER COWL FLAP COWL INSULATION
DRAIN TUBE REPLACEMENT

Removal
Remove drain tube from main A/C - heat unit inner cowl area by pulling straight out. If drain tube grommet pulled out with drain tube, it will need to be reinstalled. It may be necessary to loosen drain tube from main A/C - heat unit drain outlet.
SEAL RETAINER OVER INSULATION TRIM SCREWS
AIR INTAKE HOUSING
Installation
Install drain tube and grommet, if removed, to drain tube outlet on main A/C - heat unit (Figure 11-21). Ensure drain tube is attached to main A/C - heat unit drain outlet.
DRAIN TUBE GROMMET
FRONT FASTENERS
Figure 11-20: Cowl Insulation Mounting Figure 11-21: Drain Tube Replacement
_____________________

Driver Floor Duct
11-25
AIR CONDITIONING/HEATER DUCT REPLACEMENT Passenger Floor Duct

Removal
1. 2. 3. 4. 5. 6. Remove right side crash pad (Section 10). Remove screw securing passenger side closeout panel to upper closeout panel bracket (Figure 11-22). Lower panel down, and pull rearward to remove from lower bracket (Figure 11-22). Remove screw securing duct hose to closeout panel (Figure 11-22). Remove screw securing duct hose to the drivers floor duct assembly (Figure 11-22). Remove duct hose
The driver floor vent and floor duct are both integrated as part of the closeout panel assembly. Failure of either component constitutes closeout panel assembly replacement.
Removal
1. 2. Remove screws and closeout panel from instrument panel. Remove duct hose from driver floor duct on back side of closeout panel.
Installation
1. 2. Attach duct hose to driver oor duct on back side of closeout panel. Secure closeout panel to I. P. with screws.
Installation
1. 2. 3. Route new duct hose from drivers oor duct to closeout panel along right side of the main HVAC unit. Secure the duct hose at both ends with a trim screw. Put the bottom of the passenger side closeout panel into the lower bracket., raise the rear to the upper mount bracket and secure with a trim screw. Install crash pad.
DRIVERS FLOOR DUCT CLOSEOUT PANEL DRIVER FLOOR VENT CLOSEOUT PANEL (VIEWED FROM BEHIND)
4.
UPPER BRACKET
DUCT HOSE CONNECTS HERE
DRIVER FLOOR DUCT PASSENGER SIDE CLOSEOUT PANEL
Figure 11-23: Driver floor Duct Appearance

PASSENGER FLOOR VENT
7-S11-074
Figure 11-22: Passenger Floor Duct
05745159
11-26
DEFROST DUCT AND WINDSHIELD NOZZLES REPLACEMENT Center Defrost Duct

Removal
1. 2. 3. 4. 5. Remove right side crash pad (Section 10). Remove front console (Section 10). Remove engine cover (Section 10). Remove twelve screws, nuts, washers, and closeout panel from A-beam (Figure 11-24). Remove eight screws, washers, and drivers and passengers lower windshield retainers from A-beam.
Installation
1. Install center windshield defrost duct into A-beam (Figure 11-24). Align both ends with adjacent duct and insuring a leak-free overlap joint.
NOTE: Apply Silaprene Sealant 05593929 in a continuous bead around the new plusnuts making sure to cover both the edge of the plusnut and the vehicle body. This will provide better sealing. 2. 3. 4. 5. 6. 7. 8. Install new plusnuts into A-beam. Install drivers and passengers lower windshield retainers on A-beam with eight screws and washers. Secure closeout panel to A-beam with twelve screws, plusnuts, and washers. Install engine cover (Section 10). Install front console (Section 10). Check operation of windshield defrosters. Install right side crash pad (Section 10).
NOTE: Plusnuts must be drilled out in order to remove ducts. New plusnuts are installed in the same holes. 6. Remove center defrost duct from A-beam.
PLUSNUT DRIVER LOWER WINDSHIELD RETAINER SIDE WINDOW DEMISTER VENT HOSE
A-BEAM
SIDE WINDOW DEMISTER VENT HOSE
PASSENGER WINDSHIELD DEFROST NOZZLE CLOSEOUT PANEL
CENTER WINDSHIELD DEFROST DUCT DRIVER WINDSHIELD DEFROST NOZZLE
Figure 11-24: Windshield Defrost Ducts and Nozzles
_____________________

Driver Side Windshield Defrost Nozzle
Removal
1. 2. 3. 4. 5. 6.
11-27
Passenger Side Windshield Defrost Nozzle

Removal
1. 2. 3. 4. 5. Remove right side crash pad (Section 10). Remove front console (Section 10). Remove diverter assembly. Remove main A/C - heat unit blower housing. Remove four screws, lockwashers and passenger side lower windshield retainer from A-beam. Remove plusnuts (Figure 11-24). Remove passenger side windshield defrost nozzle and side window demister vent hose from A-beam. Remove side window demister vent hose from defroster nozzle. Slide side window demister vent hose on defrost nozzle (Figure 11-24). Carefully fit defroster nozzle and demister vent hose into A-beam while making sure that it aligns and creates a leak-free overlap joint with the center duct (Figure 11-24). Install four screws, lockwashers and lower windshield retainer on A-beam. Install main A/C - heat unit blower housing. Install diverter assembly. Install front console (Section 10). Install right side crash pad. Check operation of windshield defrosters.
6. 7.
Remove right side crash pad (Section 10). Remove front console (Section 10). Remove four screws, lockwashers and drivers lower wind shield retainer from A-beam. Remove plusnuts (Figure 11-24) Remove center windshield defrost duct. Remove side window demister vent hose and defrost nozzle. Pull toward center of vehicle. Remove defrost nozzle from side window demister hose (Figure 11-24).
Installation
1. 2. 3. 4. 5. 6. 7. 8. Slide side window demister hose on defrost nozzle (Figure 11-24). Install side defrost nozzle and window demister vent hose on A-beam. Slide them toward drivers side. Install center windshield defrost duct. Install four screws, lockwashers and lower windshield retainer on A-beam. Ensure correct overlap joint to adjacent ducts. Install front console (Section 10). Check operation of windshield defrosters. Install right side crash pad (Section 10).
Installation
1. 2.
3. 4. 5. 6. 7. 8.
05745159
11-28
COMPRESSOR REPLACEMENT
WARNING: Air conditioning system components are subject to high-pressure refrigerant R-134a gas. Always discharge pressure and contain R-134a using approved service equipment. Use extreme care when handling R134a. Direct contact with skin may cause frostbite. Do not smoke in areas where R-134a is stored or used. Failure to follow these warnings may result in serious injury.
Installation
NOTE: Sealing washers, by design, do not require lubrication. Lubricating sealing washers during replacement will increase the possibility of contamination, which may result in refrigerant leaks. 1. Drain 8 oz. of oil from the new compressor. Replace the amount that was drained from the previously removed compressor +1 oz. Secure compressor to compressor support bracket with four bolts (Figure 11-25). Insert two sealing washers and secure suction/discharge hose assembly to top of compressor with washer and bolt. Tighten bolt to 28 lb-ft (38 Nm). Connect electrical connector to spade terminals on compressor. Evacuate and charge air conditioning system. Perform air conditioning system service, evacuate, charge, and test for leaks.
2. 3.
Removal
1. 2. Discharge air conditioning system. Disconnect electrical connector (Figure 11-25). from compressor
4. 5. 6.
SEALING WASHERS
SUCTION/DISCHARGE HOSE ASSEMBLY
ELECTRICAL CONNECTOR COMPRESSOR
Compressor Clutch Plate and Hub Replacement

Removal
NOTE: Removal and installation of external compressor parts, and disassembly and assembly of internal parts, must be performed on a clean workbench. The work area, tools, and parts must be kept clean at all times. 1. 2. Remove compressor. Clamp the holding fixture in a vise and attach compressor to holding fixture from set J34021-A with thumb-screws (Figure 11-26).
CLUTCH PLATE AND HUB ASSEMBLY CLUTCH HUB HOLDING TOOL COMPRESSOR SUPPORT BRACKET NUT SOCKET
Figure 11-25: Air Conditioner Compressor and Mounting Hardware

3. 4. 5. 6. Remove serpentine belt from pulley. Remove suction/discharge hose assembly and sealing washers from top of compressor. Discard sealing washers. Remove four bolts and compressor from compressor support bracket. Drain the oil from the compressor and measure the amount.
THUMB-SCREW
HOLDING FIXTURE
COMPRESSOR
Figure 11-26: Compressor
_____________________

3. 4.
11-29
3.
4.
Keep the clutch plate and hub assembly from turning by using the clutch hub holding tool. Remove the shaft nut using nut socket. With center screw forcing tip in place to thrust against the end of the shaft, thread the hub and clutch drive plate assembly remover/installer into the hub. Hold the body of the remover with a wrench, and turn the center screw into the remover body to remove the clutch plate and hub assembly (Figure 11-27).
HUB AND CLUTCH DRIVE PLATE ASSEMBLY REMOVER/INSTALLER
Align the shaft key with the shaft keyway, and place the clutch plate and hub assembly onto the compressor shaft. Remove the forcing tip on clutch plate and hub assembly installer/remover center screw and reverse the body direction on the center screw (Figure 11-29).
DRIVE PLATE INSTALLER
CENTER SCREW DRIVE PLATE INSTALLER BEARING
CLUTCH PLATE AND HUB ASSEMBLY CLUTCH PLATE AND HUB ASSEMBLY HOLDING FIXTURE
AIR GAP 0.02 - 0.03 IN. (0.50 - 0.76 MM)
Figure 11-27: Clutch Plate and Hub Assembly

CAUTION: Do not drive or pound on the clutch hub or shaft. Internal damage to compressor may result. The forcing tip on remover/installer center screw must be flat, or the end of the shaft/axial plate assembly will be damaged. 5. Remove the shaft key and retain for reassembly (Figure 11-28).
CLUTCH PLATE AND HUB ASSEMBLY SHAFT KEYWAY SHAFT KEY
Figure 11-29: Drive Plate Installation

5. Install the clutch plate and hub assembly remover/ installer.
NOTE: The body of the remover/installer should be backed off sufficiently to allow the center screw to be threaded onto the end of the compressor shaft. 6. Hold the center screw with a wrench. Tighten the hex portion of the remover/installer body to press the hub onto the shaft. Tighten the body several turns, remove the installer, and check to see that the shaft key is still in place in the keyway before installing the clutch plate and hub assembly to its final position. The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0.020-0.030 in. (0.50-0.76 mm).
CAUTION: If the center screw is threaded fully onto the end of the compressor shaft, or if the body of the installer is held and the center screw is rotated, the key will wedge and will break the clutch hub.
CLUTCH PULLEY ROTOR
7.
Figure 11-28: Shaft Key
Installation
1. Install the shaft key into the hub key groove. Allow the key to project approximately 1/8 in. (3.2 mm) out of the keyway. The shaft key is curved slightly to provide an interference t in the hub key groove (Figure 11-28). Be sure the frictional surface of the clutch plate and the clutch pulley rotor are clean before installing the clutch plate and hub assembly.
2.
Remove the remover/installer and check for proper positioning of the shaft key (even or slightly above the clutch hub). Install the shaft nut. Hold the clutch plate and hub assembly with clutch hub holding tool, and using nut socket, tighten the nut against the compressor shaft shoulder to 8-16 lb-ft (11-22 Nm) (Figure 11-26). 8. Spin the pulley rotor by hand to see that the rotor is not rubbing the clutch drive plate (Figure 11-28). 9. Add PAG oil to the compressor in an equivelant amount to the oil in the compressor when it was originally removed. 10. Install compressor.
05745159
11-30
COMPRESSOR CLUTCH ROTOR AND/OR BEARING REPLACEMENT

Removal
1. 2. Remove the clutch plate and hub assembly. Using snapring pliers, remove retaining ring (Figure 11-30).
RETAINING RING
5.
To prevent damage to the pulley during bearing removal, the rotor hub must be properly supported. Remove the forcing screw from puller, and with the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks (Figure 11-33).
DRIVER HANDLE
PULLEY ROTOR
BEARING REMOVER
PULLEY ROTOR
Figure 11-33: Bearing Remover

6. Drive the bearing out of the rotor hub with bearing remover and driver handle.
Figure 11-30: Retaining Ring

3. Install pulley rotor and bearing puller guide on the compressor, and install pulley rotor and bearing puller down into the inner circle of slots in the rotor. Turn the puller clockwise in the slots in the rotor (Figures 11-31 and 11-32).
PULLER
CAUTION: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore, or the bearing may be damaged.
Installation
1. Place the pulley rotor on support block to fully support the rotor hub during bearing installation (Figure 11-33).
PULLEY ROTOR AND BEARING PULLER GUIDE
DRIVER HANDLE
Figure 11-31:
Pulley Rotor and Bearing Puller Guide
BEARING INSTALLER PULLEY ROTOR
PULLEY ROTOR AND BEARING PULLER
Figure 11-34: Bearing Installer

CAUTION: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation. The rotor face will bend.
Figure 11-32: Pulley Rotor and Bearing Puller

4. Hold the puller in place and tighten the puller screw against the puller guide to remove the pulley rotor and bearing assembly.
_____________________
11-31
2.
3.
Align the new bearing squarely with the hub bore, and using puller and bearing installer with driver handle, drive the bearing pulley into the hub. The installer will apply force to the outer race of the bearing if used as shown (Figure 11-34). Place bearing staking guide and bearing staking pin in the hub bore. Shift the rotor and bearing assembly on the support block to give full support of the hub under the staking pin location. A heavy-duty rubber band may be used to hold the stake pin in the guide, and the stake pin should be properly positioned in the guide after each impact on the pin (Figure 11-35).
SCREW CROSSBAR BOLT PULLER PILOT
CAUTION: Noisy bearing operation and reduced bearing life may result if outer bearing race is deformed while staking. The stake metal should not contact the outer race of the bearing. Stake three places, 120 degrees apart (Figure 11-36). 6.
ROTOR HOLDING FIXTURE
PULLEY ROTOR AND BEARING INSTALLER
Figure 11-37: Pulley Rotor and Bearing

Position the pulley rotor and bearing installer, and puller pilot directly over the inner race of the bearing. 7. Position puller crossbar on the puller pilot, and assemble two through-bolts and washers through the puller bar slots, and thread them into the holding fixture. The thread of the through-bolts should engage the full thickness of the holding fixture. 8. Tighten the center screw in the puller crossbar to force the pulley rotor and bearing assembly onto the compressor. Should the pulley rotor and bearing installer slip off direct in-line contact with the inner race of the bearing, loosen the center forcing screw and realign the installer and pilot so that the installer will properly clear the compressor. 9. Using snapring pliers, install retaining ring (Figure 11-38). 10. Reinstall clutch plate and hub assembly.
BEARING STAKING GUIDE RUBBER BAND
BEARING STAKING PIN
Figure 11-35: Bearing Staking Guide and Pin

4. Using care to prevent personal injury, strike the staking pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching, the bearing.
PULLEY ROTOR STAKE THREE LOCATIONS 120 DEGREES APART
RETAINING RING
Figure 11-36: Stake Locations

5. With the compressor mounted to the holding fixture, position the rotor and bearing assembly on the front head (Figure 11-37).
Figure 11-38: Retaining Ring
05745159
11-32
COMPRESSOR CLUTCH CORE REPLACEMENT

Removal
1. Perform steps 1 through 4 of Clutch Rotor and/or Bearings replacement procedure. Mark clutch core terminal location on compressor. Install puller pilot and puller crossbar with puller legs on compressor (Figure 11-39). Tighten forcing screw against the puller pilot to remove the clutch core.
PULLER CROSSBAR SCREW
5.
When core is fully seated on the compressor, use a 1/8-in. diameter drift punch and stake the front head at three places, 120 degrees apart, to ensure clutch core remains in positioning (Figure 11-41).
CLUTCH CORE
2. 3.
DRIFT PUNCH
STAKE IN FRONT HEAD (3 LOCATIONS, 120 DEGREES APART)
Figure 11-41: Drift Punch

PULLER PILOT PULLER LEG
NOTE: Stake size should be only one-half the area of the punch tip and approximately 0.010-0.015 in. (0.25-0.38 mm) deep. 6. Install rotor and bearing assembly and clutch plate and hub assembly.
CLUTCH CORE
COMPRESSOR SHAFT SEAL REPLACEMENT

Removal
1. 2. Remove clutch plate and hub assembly. Using snapring pliers, remove the shaft seal retaining ring (Figure 11-42).
Figure 11-39: Clutch Core
Installation
1. 2. Place the clutch core on compressor with the terminal positioned at the marked location (Figure 11-39). Place the clutch core installer over the internal opening of the clutch core housing and align installer with the compressor. Center the puller crossbar in the countersunk center hole of the clutch core installer. Install the through-bolts and washers through the crossbar slots, and thread them into holding fixture. The thread of the through-bolts should engage the full thickness of the holding fixture. (Figure 11-40).
PULLER CROSSBAR SCREW
3.
RETAINING RING
CLUTCH CORE INSTALLER
Figure 11-42: Shaft Seal Retainer Ring

CAUTION: The handle must be hand-tightened securely. Do not use a wrench or pliers. NOTE: Thoroughly clean inside of compressor neck area surrounding the shaft, the exposed portion of the seal, the retainer ring groove and the shaft itself. Any dirt or foreign material getting into compressor may cause damage. 3. Fully engage the knurled tangs of seal remover/installer into recessed portion of seal by turning handle clockwise. Remove seal from the compressor with a rotary-pulling motion. Discard seal (Figure 11-43).
CLUTCH CORE
HOLDING FIXTURE
Figure 11-40: Clutch Core Installer

4. Turn the center forcing screw of the puller crossbar to force the clutch core into the compressor. Be sure clutch core and installer stay aligned during installation.
_____________________
11-33
SEAL REMOVER/ INSTALLER
3.
SEAL COMPRESSOR
Figure 11-43: Seal Remover

4. Using O-ring remover, remove and discard seal seat Oring from the compressor neck (Figure 11-44).
shaft seal retainer ring.) Rotate the installer to seat the Oring and remove the installer. Dip new seal in clean PAG oil and assemble seal onto seal installer by turning handle clockwise. The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that the flared-out side of lip seal is facing and installed towards the compressor. Install seal protector in the seal lip and place over the compressor shaft, and push the seal in place with a rotary motion, or place the seal protector over end of compressor shaft, and slide the new seal onto the shaft with a rotary motion until it stops. Take care not to dislodge the O-ring. Be sure the seal makes good contact with the O-ring. Disengage the installer from the seal and remove the installer and the seal protector (Figure 11-46).
SEAL PROTECTOR SEAL INSTALLER
O-RING
O-RING REMOVER
SHAFT
S11-035
Figure 11-44: O-Ring

5. Recheck shaft and inside of the compressor neck for dirt or foreign material and be sure these areas are clean before installing new parts.
SEAL COMPRESSOR SHAFT
Figure 11-46: Seal Installer

CAUTION: Handling and care of seal protector is important. If seal protector is nicked or the bottom flared, the new seal may be damaged during installation. 4. Using snapring pliers, install new seal retaining ring with its flat side against the seal (Figure 11-47).
Cleaning
Thoroughly clean seal seat O-ring groove in front head.
Installation
CAUTION: Seals should not be reused. Always use a new specification service seal. Be sure that the replacement seal is not scratched or damaged. Make sure that the seal seat and seal are free of lint and dirt. 1. Dip new seal seat O-ring in clean PAG oil and install onto O-ring installer (Figure 11-45).
RETAINING RING O-RING O-RING INSTALLER
Figure 11-45: O-Ring Installer

2. Insert O-ring installer into the compressor neck until installer bottoms. Lower the moveable slide of the O-ring installer to release the O-ring into the seal seat O-ring lower groove. (The compressor neck top groove is for the 5. 6.
Figure 11-47: Seal Retaining Ring

Remove any excess oil from the shaft and inside the compressor neck. Install the clutch plate and hub assembly.
05745159
11-34
LOW PRESSURE CUTOFF SWITCH

The low pressure cutoff switch is mounted on the receiver/ dryer. The switch is wired in series with the compressor activation circuit. Should pressure drop below the switchs setting, the switch will open and interrupt current flow to the compressor clutch. The switch will prevent damage to the system from lack of oil flow due to inadequate charge or very low ambient temperatures. The switch will close when the system pressure rises to safe levels (Figure 11-48).
AMBIENT TEMPERATURE SWITCH HARNESS
CONDENSER
The condenser provides heat exchange for the A/C system. The condenser is located on the front of the radiator and cooler assemblies. Air from forward movement, and the engine cooling fan is forced through the fins of the condenser, removing heat from the highly pressurized refrigerant. Refrigerant enters the condenser as a vapor, and exits as a liquid.
LOW PRESSURE CUTOFF SWITCH
RECEIVER/DRYER
S11-053
Figure 11-48: Receiver/Dryer with Low Pressure Cutoff Switch
RECEIVER/DRYER
The receiver/dryer provides storage for high pressure liquid refrigerant. Desiccant inside of the receiver/dryer assists in removing moisture from the refrigerant. The receiver/dryer also act as a filter, filtering out particles of debris and preventing bubbles of vapor form entering the expansion valve (Figure 11-48).
AMBIENT TEMPERATURE SWITCH

The ambient temperature switch is mounted on the right front of the condenser. The switch, which monitors ambient air temperature, is wired in series with the compressor activation circuit. The switch interrupts current flow to the compressor clutch when outside temperature drop below 45F (10C) (Figure 11-49).
CONDENSER
S11-054
Figure 11-49: Ambient Temperature Switch
_____________________

HIGH PRESSURE CUTOFF SWITCH
11-35
BLOWER MOTOR RESISTOR REPLACEMENT

Removal
1. 2. Remove HVAC harness connector from resistor (Figure 11-50). Remove screws and resistor from cowl.
Installation
1. 2. 3. Fasten resistor to cowl with screws. Plug HVAC harness connector into resistor. Check blower motor operation.
COWL SCREWS RESISTOR
The high pressure cutoff switch is located in the rear of the compressor. The switch is wired in series with the compressor clutch and exposed to high side pressure in the compressor. Should pressure exceed the switch setting, current will be interrupted to the compressor clutch until the pressures drop to safe levels, then the switch will close allowing the clutch to engage (Figure 11-51).
SNAP RING COMPRESSOR (REAR VIEW)
HVAC HARNESS CONNECTOR
HP SWITCH ORING
7-S11-054
Figure 11-51: High Pressure Cutoff Switch
Figure 11-50: Blower Motor Resistor Replacement
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11-36
HVAC CONTROLS
Temperature Dial
The temperature dial controls the temperature of the air exiting the HVAC unit. When the dial is rotated to the cold position, the water valve is shut off and the temperature door isolates the heater core. When the dial is rotated to the HOT position, the water valve opens and the temperature blend door directs air through the heater core. Between COLD and HOT, temperature is regulated by changing the amount of air that passes through the heater core (Figure 11-54).
7-S11-073
HVAC CONTROL HEAD REAR DEFROST (OPTIONAL)

7-S11-073
Figure 11-52: HVAC Control Panel

The HVAC system is operated using a control panel. The panel has controls for: Blower speed Air temperature Mode Air conditioning Rear window defrost (Optional) Status for all of the controls is shown using painted marks on the faceplate of the control panel. Operation is based on driver input, no automatic function is incorporated. Controls for the HVAC system are based on (vacuum) door motors and water valve controls, and (electric) blower motor and temperature door motor controls (Figure 11-52).
7-S11-073
Figure 11-54: Temperature Control Dial
Mode Dial
The mode dial allows the operator to direct air to a selected area. When the driver rotates the dial clockwise and chooses a mode, vacuum is sent to the vacuum motors that must close (Figure 11-55). NOTE: When the main HVAC unit is without vacuum, air will be directed to the defrost and floor vents, and fresh air will be used. The blower motor on the HVAC unit will not function if the mode dial is set at the OFF position. When the dial is positioned on an A/C position, the compressor clutch will be activated.
Blower Speed Dial

The blower speed dial has 4 positions. Low Med 1 Med 2 High The operator selects the fan speed by rotating the dial clockwise (Figure 11-53).
7-S11-073
Figure 11-55: Mode Dial

7-S11-073
Figure 11-53: Blower Speed Dial
_____________________

Diverter Doors
11-37
UNIT SERVICE
WARNING: When working with refrigerant, always use protective equipment to prevent injury. Refrigerant handling should be done only by technicians trained and certied in the use of refrigerant and refrigerant service equipment.
CAUTION: Use only equipment and materials designed to operate with R134a refrigerant. Never substitute parts or materials designed for R12. CAUTION: Never use sealers in or on the HVAC unit that are not designed for ventilation systems. Some sealers release noxious or irritating odors that will be offensive to operators of the vehicle. Neutral cure sealers should be used when sealing any area of the HVAC unit that could potentially expose the operator of the vehicle or the passengers to the released chemicals.
Four diverter doors occupy the outlet area of the main unit. Various positions and combinations of 4 doors provide the system with the following mode selections: Off Maximum A/C - Recirculate A/C A/C Face/Floor blend Face Floor Defrost/Floor blend Defrost All 5 of the mode doors are operated using vacuum door motors mounted externally to the case (Figure 11-57). The motors are as follows: Floor door motor Defrost blockoff motor Face door motor Defrost door motor Recirculate door motor The vacuum motors are capable of 2 positions: fully extended (spring pressure), or fully retracted (vacuum). The face door motor is an exception, having a third position in the middle of travel. A second vacuum inlet is added to the face door motor for this purpose (Figure 11-57). The temperature blend door motor operates the temperature blend door. This door is responsible for regulating outlet air temperature by directing air through the heater core or by blocking air to the core. The temperature blend door motor is electric, and can be positioned at multiple positions.
FLOOR DOOR MOTOR DEFROST BLOCKOFF MOTOR
MAIN HVAC UNIT

The main HVAC unit is comprised of a heater core for heating air, and evaporator for cooling air, mode doors to direct airflow, and an electric blower motor and fan to force air through the case to be heated or cooled, then directed to the selected zones in the vehicle (Figure 11-56).
VACUUM MOTOR COVER
FACE OUTLET
MAIN HVAC UNIT
DEFROST DOOR MOTOR
DRAIN TUBE
FACE DOOR MOTOR
7-P11-001
TEMPERATURE BLEND DOOR

7-S11-031
RECIRCULATE DOOR MOTOR
Figure 11-57: Vacuum Door Motors

7-P11-001.4
Figure 11-56: Main HVAC Unit
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11-38
Heater Core
The heater core is composed of copper and brass with numerous passages allowing heated engine coolant to pass through, transferring heat into the passing air from the blower motor. Coolant flow through the heater core is controlled by the water control valve in the engine compartment (Figure 11-58).
RETAINING BRACKET HEATER CORE
Expansion Valve
The expansion valve controls the flow of refrigerant through the evaporator. Refrigerant must be metered to prevent the liquid refrigerant from flooding the evaporator. The expansion valve is exposed to both low and high pressures, and bases refrigerant flow on the pressure which is exiting the evaporator (Figure 11-60).
EXPANSION VALVE
OUTLET
INLET
7-P11-004
HVAC CASE HALF (FRONT)
7-S11-061
Figure 11-58: Heater Core
Figure 11-60: Expansion Valve
Evaporator
The evaporator is composed of a wide flat aluminum tube bent in a serpentine pattern. Fins extending out from the tube assist in transferring heat from the passing air into the refrigerant which is evaporating inside of the tubes (Figure 11-59).
THERMOSTATIC CYCLING SWITCH
Blower Motor
The blower motor is a permanent magnet electric motor that drives a wheel type fan. The air enters the unit from the outside air intake, or from a door on the interior of the vehicle. The air is then forced through the evaporator and heater core.
BLOWER MOTOR
EVAPORATOR HVAC CASE HALF (REAR)

7-P11-004
BLOWER HOUSING
7-P11-003.1
Figure 11-61: Blower Motor and Housing
Figure 11-59: Evaporator
Rear Defrost Button Thermostatic Cycling Switch

The thermostatic cycling switch is mounted on the side of the main HVAC unit (Figure 11-59). The thermostatic cycling switch is responsible for turning off the compressor clutch when evaporator temperature approaches freezing. Temperature is sensed by a capillary tube inserted in the fins of the evaporator. Should the evaporator reach freezing temperatures, moisture condensing on the fins of the evaporator will freeze and hinder air flow. The thermostatic cycling switch will interrupt current to the compressor clutch until the temperature rises to about 40 F. The vehicle may be equipped with optional rear defrost. The rear defrost is comprised of an electrical grid which is bonded to the rear center glass. When the rear defrost button is pushed, a timed electric current is sent to the grid causing the temperature of the grid and glass to slowly rise, melting frost or evaporating exterior window fogging. The timer in the switch will shut off the current when an adequate amount of time has passed. This option is only available on the XLC2, and HMC4.
_____________________
11-39
MAIN UNIT REPLACEMENT Removal

1. 2. 3. 4. 5. Drain Coolant into an approved container. Recover refrigerant. Remove raincap and adapter. Remove air intake elbow, air cleaner and splash shield. Remove 4 bolts securing heater core extension tubes. Plug all open holes and discard all sealing washers (Figure 11-62).
RELAYS ENGINE HVAC VACUUM CONTROL POWER MIRROR
POWER LOCKS AND WINDOWS RESISTOR
HEATER CORE EXTENSION TUBE
7-S11-062
TEMP BLEND DOOR MOTOR
CYCLING SWITCH BLOWER MOTOR
Figure 11-63: Harness/Connector Identification 15. Pull harnesses clear of HVAC unit and secure. 16. Remove screw(s) securing the floor duct to the top of the HVAC unit. Disconnect the hose going to the passenger floor area and remove hose. 17. Remove bolt securing HVAC manifold block to expansion valve and discard sealing gasket. Cap all openings (Figure 11-64). 18. Remove 2 nuts, washers, and grommets from passthrough mounts (Figure 11-64).
HEATER CORE EXTENSION TUBE

00-S11-005
Figure 11-62: Heater Core Extension Tube Removal 6. Remove any pliable sealer from exterior of the passthrough plate. 7. Remove the center console. 8. Remove the right side crash pad. 9. Remove the fastener from passenger side closeout panel. 10. Lower panel down to gain access to the floor outlet hose, remove the screw securing the hose, and remove the closeout panel. 11. Remove 2 screws securing the passenger side of auxiliary heat/cool unit. Raise the cover up approximately 2" and support with a block of wood. Remove the passenger side door strap bracket and seat belt. 12. Remove the front passenger seat, and the right front inner and outer kick panels. NOTE: Panels are removed to prevent damage that would occur during HVAC unit removal. 13. Note HVAC harness positioning prior to removal/ disconnect. 14. Disconnect the vacuum motor harness, engine HVAC harness, water valve harness, temperature blend door connector, cycling switch connections, power mirror harness, resistor harness, power door lock harness, power window harness and blower motor connections (Figure 11-63).
MANIFOLD BLOCK PASS THROUGH MOUNT HEATER CORE EXTENSION TUBE
Figure 11-64: Passthrough Fastener Removal 19. Remove interior bolt securing left and right side of the HVAC unit to the body. Support the unit prior to removing the second fastener to prevent the unit from falling down and causing possible damage or injury (Figure 11-65). 20. Removal of the unit can be accomplished by lowering and pulling straight rearward.
05745159
11-40
Installation
Lift HVAC unit into the vehicle. 1. Set the lower bracket on HVAC unit on top of the lower body bracket. Ensure that the studs on the pass through plate align with the holes in the body. Harnesses must be positioned to exit to the right side of the HVAC unit. 2. Pivot the unit upwards until it rests against the defrost and floor ducts. Install the right side fastener, and two nuts, washers, and grommets on the passthrough plate. Slowly tighten the front pass through mounts first. This action will pull the unit forward. Ensure that the defrost and heating ducts align properly with the outlets on the HVAC unit before tightening inside mounts.
CAUTION: Be sure to remove all of the devices used to plug the openings in the heater lines and the A/C lines. 6. 7. 8. 9. Install manifold block to expansion valve using a new sealing gasket, torque the fastener to 25 lb ft. Install heater core extension tubes onto passthrough plate using new sealing washers. Torque the fasteners to 32 in lbs. Evacuate A/C system for 45 minutes, with 10 minute hold time for leak check. Refill the cooling system.
NOTE: When refilling, use bleeder screws on engine and radiator to purge as much air as possible from the system. The bleeder screws also allow easier filling of the cooling system. 10. Recharge A/C system to 3lbs 2oz. Add 2oz. oil if the unit is new or evaporator was replaced. 11. Leak check passthrough plate for body leaks using a water hose. If leakage is noted inside vehicle, seal the leaks from the outside using body sealer in small amounts. 12. Leak check the A/C lines using a R134a leak detector. 13. If no leaks are found, install air cleaner housing, elbow, adapter raincap and air cleaner splash shield. 14. Connect vacuum control harness, cycling switch connections, power mirror harness, door lock harness, power window harness, blower motor connections, resistor harness, engine HVAC harness, temperature blend door connector, and water valve harness. 15. Install center console and check operation of A/C and heat. 16. If A/C and heat are functioning properly, install left front and right front passenger side kick panels 17. Install right front seat and crash pad. 18. Install the right side closeout panel.
LEFT SIDE MOUNT
RIGHT SIDE MOUNT
7-S11-058
Figure 11-65: Interior mounting points NOTE: The HVAC unit should have a 1/2 inch spacer between the left side bracket and the body. If the spacer was not present when the unit was removed, it should be installed when the unit is taken out of the vehicle for service. 3. Install left hand interior fastener with the 1/2spacer, it may be necessary to loosen the bracket and slide it left or right to align the hole. Tighten fastener (Figure 11-66).
LEFT SIDE HVAC UNIT MOUNT
1/2 SPACER
7-S11-067
Figure 11-66: Left Side Mount and Spacer 4. 5. Install screw(s) securing drivers floor duct to the main HVAC unit. Install passenger side floor duct and route to the right as previously removed.
_____________________
11-41
VACUUM DOOR MOTOR Replacement

1. 2. 3. Remove right front crash pad. Locate and remove 2 screws securing vacuum motor cover to main HVAC unit. Locate faulty vacuum motor and remove vacuum line. If multiple motors are to be replaced, tag vacuum lines as they are removed. Note position of mounting studs on the motor to be replaced. Mark holes that studs pass through (Figure 11-67).
REFERENCE MARK
4.
7-S11-039
Figure 11-67: Vacuum Door Motor Replacement 5. 6. 7. 8. Note position of motor arm relative to door lever. Mark the side facing away from the HVAC unit. Remove the push clip with side cutting pliers and discard. Remove washer under push clip, do not discard. Remove two mounting nuts and vacuum motor (Figure 11-67).
Installation
Reverse removal procedure
05745159
11-42
BLEND DOOR MOTOR Replacement

1. 2. Disconnect motor electrical connection. Remove 3 nuts securing motor to bracket (Figure 11-68).
ORG
HEATER CORE EXTENSION TUBES
MOUNTING PLATE DOOR SHAFT ADAPTER

7-S11-032
TEMPERATURE BLEND DOOR MOTOR NUT
Figure 11-69: Heater Core Tube Removal 5. 6. Cut sealer around heater core retaining plates (Figure 11-70). Remove 2 retaining plates (Figure 11-70).
7-P11-002
SPACER
HEATER CORE RETAINING PLATES
Figure 11-68: Temperature Blend Door Motor Removal NOTE: Do not loosen set screw on door shaft adapter! 3. Remove motor by pulling it straight off. Do not discard the spacers behind the motor.
SEALER
7-S11-034
Installation
Reverse above removal procedure for installation. 7.
Figure 11-70: Retaining Bracket Removal Pry heater tube mounting plate away from passthrough plate. Pry only in the middle to prevent damaging seal surfaces. Heater tubes extend past the mounting plate and into the passthrough plate (Figure 11-71).
Heater Core Replacement

NOTE: Screws should be noted for length as they are removed to aid in correct reassembly. Some screw lengths are critical to prevent interference with interior parts. NOTE: Most of the screws used are threaded into the plastic housing of the HVAC unit. Care should be used to prevent over-tightening of the hardware and stripping holes out. 1. 2. 3. Remove the unit from vehicle (Refer to unit removal procedure this section) Set the HVAC unit on a bench so the copper heater tubes are visible and upwards. Remove permagum tape from heater tubes at passthrough plate and discard.
7-S11-035
Figure 11-71: Removing Heater Core 8. Pull lightly on heater core to keep heater tubes parallel with the HVAC case. Do not allow the mounting plate end to come away faster than the core. Note positioning of any foam tape on the heater core, and duplicate on new part. 9. Discard the sealing washers on the heater tubes and repair or replace heater core as necessary. Reverse removal for installation. NOTE: Observe screws as they are removed to ensure corrects screws are used in the correct location on assembly.
NOTE: Foam tape and permagum tape should always be replaced with new material where it was removed from during disassembly. The tapes are used to insulate hot and cold parts and prevent condensation from dripping on the passenger floor. 4. Remove 4 bolts securing heater tube mounts to passthrough plate (Figure 11-69).
_____________________
11-43
EVAPORATOR Replacement
1. 2. 3. Remove HVAC unit from vehicle (refer to HVAC unit replacement). Remove heater core from main unit (refer to heater core replacement). Remove lower support bracket from HVAC case (Figure 11-72).
7-S11-043
Figure 11-75: Lower Blower Housing Hardware Removal 6.

7-S11-042
Remove face duct outlet plenum (Figure 11-76).
FACE OUTLET PLENUM
Figure 11-72: Lower Support Bracket Removal 4. Disconnect vacuum harness from vacuum motors. Motors are color coded to vacuum tubing (Figure 11-72).
VACUUM DOOR MOTOR HARNESS
7-S11-059
BRN YEL BLU
RED
Figure 11-76: Face Duct Outlet Plenum 7. Remove floor door travel limiting rivet by drilling head, note the side of the rivet the door is resting on (Figure 11-77).
GRY
BLK
7-S11-051
ORG
WHT
NOTE: Place a reference mark on the case to ensure that the rivet is placed in the same location during reassembly that it was removed from (Figure 11-77).
Figure 11-73: Vacuum Door Motor Harness 5. Remove air intake housing from main unit by removing attaching screws at blower housing (Figure 11-75) and bracket at front of unit (Figure 11-74).
FLOOR OUTLET REFERENCE MARK
DEFROST OUTLET
7-S11-041
7
Figure 11-77: Drilling Door Travel Limiting Rivet

7-S11-052
Figure 11-74: Air Intake Box Front Bracket Removal 05745159
11-44
8.
Remove arm retaining push clip, arm and 2 washers from the floor door and defrost door (Figure 11-78).
SCREW DEFROST DOOR MOTOR PUSH CLIP
7-S11-040
FLOOR DOOR MOTOR
Figure 11-78: Push Clip Removal 9. Remove defrost motor from the bracket, note position of mounting studs in mounting plate (Figure 11-79).
THERMOSTATIC CYCLING SWITCH
S-CLIP
7-S11-048
Figure 11-80: Case Half Hardware Removal 15. Using a putty knife or scraper, carefully spread apart the entire case seam. 16. Separate case halves. Note that the thermostatic cycling switch must stay with the case half containing the evaporator. 17. Remove permagum tape from around liquid and vapor tubes, discard. 18. Remove expansion valve from the passthrough plate, discard gasket (Figure 11-81).
7-S11-046
DEFROST DOOR MOTOR
VACUUM DOOR MOUNTING PLATE
Figure 11-79: Vacuum Door Motor Mounting Plate 10. Remove arm retaining push nuts and washers from remaining vacuum motors. 11. Remove screws securing vacuum motor mounting plate to main HVAC unit, and remove mounting plate. If the floor door travel limiting rivet was not removed, the door arm will prevent removal of the mounting plate by not aligning with the elongated slot (Figure 11-79). 12. Remove screws securing case halves together. Do not attempt to separate case at this time (Figure 11-80). 13. Remove screws securing thermostatic cycling switch to HVAC unit case (Figure 11-80). CAUTION: Do not attempt to pull the switch out of the case, the capillary tube is secured to the evaporator. 14. Using a utility knife, carefully cut through the sealer between the two case halves. Use caution to prevent cutting the case.
EXPANSION VALVE
7-S11-044
Figure 11-81: Expansion Valve Removal
_____________________

Installation
1. 2. 3. 4.
11-45
19. Remove screws securing passthrough plate support bracket to the main unit (Figure 11-82).
5.
7-S11-050
Figure 11-82: Passthrough Plate Support Removal 20. Remove bolt securing passthrough plate to the evaporator manifold connection, remove plate and support bracket. 21. Remove evaporator from unit (Figure 11-83). 22. Carefully remove capillary tube from evaporator, noting positioning in the evaporator fins (Figure 11-83).
6. 7. 8. 9.
Obtain new evaporator. Ensure that any foam tape found on the previously removed unit is duplicated on the replacement. Install extension tubes onto new evaporator using new orings lubricated with refrigerant oil. Install evaporator into the case half the previous evaporator was removed from Position thermostat capillary tube in the same location it was removed from on the original evaporator. I will be necessary to hot glue the tube near the exit hole (Figure 11-83). Install second half of HVAC unit, ensuring that the edges of the case halves engage the S clips around the seam. Install screws securing the two halves together. Install screws securing cycling switch to the side of the HVAC case. Using neutral cure silicone sealer, seal entire parameter of seam. Install the passthrough plate onto the main unit and evaporator. Install bolt securing evaporator extension tubes to the passthrough plate. Use a new sealing washer between the passthrough plate and the evaporator extension tubes.
NOTE: It may be necessary to trim the middle from the gasket as received. The normal span of the gasket will not fit the evaporator extension tube span. 10. Install expansion valve with a new sealing washer and torque to 100 in lbs. 11. Install Vacuum motor bracket onto main unit 12. Install defrost door motor onto mounting plate. 13. Connect all vacuum motors to their perspective door arms using washers and new push clips. 14. Install a new door travel limiting rivet into case, placing the door on the side of the rivet it was originally resting on. 15. Install face duct plenum. 16. Install air intake assembly onto the main case. 17. Install lower support bracket. 18. Install heater core and retaining brackets, using new sealing washers on the heater core tubes. Torque heater manifold to 32 in lbs. 19. Install vacuum harness onto vacuum motors. 20. Install unit into vehicle (refer to HVAC unit removal and installation). 21. Fill the cooling system. 22. Evacuate A/C system for minimum of 45 minutes, with a 10 minute hold time for leak check. Recharge with 3 lbs 2oz , adding same amount of oil that was drained from the original evaporator.
HOT GLUE THERMOSTATIC CYCLING SWITCH

7-S11-060
Figure 11-83: Evaporator Removal 23. Disconnect evaporator extension tubes at the O-ring fittings (Figure 11-84). Discard the O-rings.
EXTENSION TUBES EVAPORATOR
7-S11-045
7-S11-045
Cycling Switch Replacement

Refer to evaporator replacement.
Figure 11-84: Evaporator Extension Tubes Removal
Air Intake Assembly Replacement

Refer to evaporator replacement.
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11-46
REAR CONSOLE REPLACEMENT

AUXILIARY UNIT
O-RING
Removal
1. 2. 3. Remove two screw/washers securing rear console to side brackets (Figure 11-85). Push console rearward so that the vents are clear from the plenum cutouts. Remove rear console.
LARGE A/C HOSE
DRAIN TUBES SMALL A/C HOSE SELF-TAPPING SCREW MOUNTING BRACKET
Installation
1. 2. 3. Position rear console over the auxiliary HVAC unit so that the console vents line up with the plenum cutouts. Push console forward until vents fit into plenum. Secure rear console to side brackets with screw/washers (Figure 11-85).
REAR CONSOLE
Figure 11-86: Auxiliary A/C Components

HEATER CORE PORTS CLAMP
HEATER HOSES
VENTS SIDE BRACKET
SCREW/WASHER
DRAIN TUBES AND TEE
Figure 11-87: Auxiliary Heater Hose Routing

PLENUM PLENUM CUTOUT
00-S11-006
6. 7.
Remove screws securing side brackets to tunnel mounting bracket. Remove auxiliary unit from vehicle.
Figure 11-85: Rear Console Installation
Installation
1. Install auxiliary unit in vehicle and secure side brackets to tunnel mounting bracket with screws (Figure 11-86). 2. Install drain tubes on auxiliary unit (Figure 11-87). 3. Install pressure hoses on auxiliary unit. 4. Wrap low pressure fitting with prestite tape. 5. Secure heater hoses to heater core ports on auxiliary unit with worm gear clamps. Remove hose pinch pliers. 6. Evacuate, charge, and leak test air conditioning system. 7. Check engine coolant level and add coolant as necessary. 8. Start engine and operate auxiliary and front air conditioning system to check for proper operation. 9. Check coolant connections for leakage; repair if necessary. 10. Stop engine, recheck coolant level, and add coolant if necessary. 11. Install rear console (Section 10).
AUXILIARY AIR CONDITIONING/HEATING UNIT REPLACEMENT

Removal
1. 2. 3. 4. 5. Discharge air conditioning system. Remove rear console (Section 10). Remove heater hoses from auxiliary unit heater core ports (Figure 11-87). Remove pressure hoses from auxiliary unit. Remove drain tubes from auxiliary unit (Figure 11-87).
4-1-00
_____________________
11-47
AUXILIARY BLOWER SWITCH REPLACEMENT

Removal
1. 2. 3. Pull front console away from dashboard. Depress tabs on blower switch and push through faceplate. Remove connector from back of blower switch (Figure 11-88).
AUXILIARY HEATER HOSE REPLACEMENT

NOTE: Heater hose replacement is the same for both heater hoses. NOTE: Production heater hose will have full underbody length of foil back insulation sleeve. Make sure replacement hose also has this protection.
Installation
1. 2. 3. Secure connector to blower switch and check operation (Figure 11-88). Install front console. Push blower switch into opening in faceplate.
FRONT CONSOLE FACEPLATE
Removal
1. 2. 3. 4. 5. 6. 7. 8. 1. Drain cooling system (Section 4). Remove air cleaner induction tube (Section 3). Select heater hose to replace, loosen hose clamps, and remove heater hose from hose splice. Remove two P-clamps from underbody securing auxiliary hoses. Remove front and rear consoles. Remove screw clamp securing heater hose to heater core port on auxiliary unit (Figure 11-87). Pull heater hose through tunnel grommet. Remove heater hose.
Installation
Attach one hose end to auxiliary unit heater core port and secure with clamp (Figure 11-87). 2. Route hose through grommet to engine area. 3. Connect hose to hose splice and secure with clamp. 4. Install two P-clamps to underbody securing installed hose to existing hoses. 5. Fill cooling system (Section 4). 6. Install air cleaner induction tube (Section 3). 7. Pressure test cooling system and check for leaks. 8. Install front and rear consoles. 9. Start engine and run until engine warms up. 10. Check heating units for proper operation.
CONNECTOR
BLOWER SWITCH
Figure 11-88: Blower Switch Replacement
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11-48
AUXILIARY A/C DRAIN TUBE(S) REPLACEMENT

Removal
1. 2. 3. Remove rear console. Remove clamps from drain tube section being replaced (Figure 11-89). Remove drain tube.
DRAIN TUBE HEATER TUBE CLAMPS
.
EXPANSION VALVE MANIFOLD
HIGH PRESSURE HOSE CONNECTION (AUX.)

7-S11-063
Figure 11-90: Auxiliary High-Pressure Hose Connection, Front

AUXILIARY UNIT DRAIN TUBE TEE LOW PRESSURE A/C HOSE
EXPANSION VALVE
Figure 11-89: Auxiliary A/C Drain Tube Replacement
O-RING
Installation
1. 2. Install drain tube section and secure with clamps (Figure 11-89). Install rear console.
AUXILIARY HIGH-PRESSURE HOSE REPLACEMENT

NOTE: Production hoses have a full underbody length of foilbacked heat-resistant sleeving. Replacement hoses should have the same level of thermal protection.
MOUNTING BRACKET
HIGH PRESSURE HOSE
Figure 11-91: Auxiliary High-Pressure Hose Connection, Rear
Removal
1. 2. 3. 4. 5. Discharge air conditioning system. Remove air cleaner assembly and air induction tube (Section 3). Remove rear console. Remove front console. Using two wrenches to equalize support, remove auxiliary high-pressure hose from expansion valve manifold. Remove and discard O-ring (Figure 11-90). Using two wrenches for equalized support, remove auxiliary high pressure hose from auxiliary expansion valve. Remove and discard O-ring (Figure 11-91). Remove two P-clamps securing hose to underbody. From under the vehicle pull high-pressure hose through grommet.
Installation
1. 2. Route expansion valve end of hose through grommet to auxiliary unit. Lubricate and position O-ring on high pressure hose and hand thread hose fitting onto expansion valve. Using two wrenches for equalized support, tighten to 11-13 lb-ft (1518 Nm) (Figure 11-91). Route other end of hose to expansion valve manifold (Figure 11-90). Lubricate and position O-ring on hose and secure to high expansion valve manifold. Using two wrenches for equalized support, tighten to 11-13 lb-ft (15-18 Nm). Install two P-clamps to secure hoses to underbody. Install front and rear consoles. Evacuate, charge, and leak test system. Start engine and check A/C operation.
3. 4.
6.
7. 8.
5. 6. 7. 8.
_____________________
11-49
AUXILIARY LOW-PRESSURE HOSE REPLACEMENT

Removal
1. 2. 3. Discharge air conditioning system. Remove air cleaner assembly and air induction tube (Section 3). Using two wrenches for equalized support, remove auxiliary low-pressure hose from low-pressure hose fitting. Remove and discard O-ring (Figure 11-90). Remove two P-clamps securing hoses to underbody. Remove front and rear consoles. Remove prestite tape from low-pressure hose. Using two wrenches for equalized support, remove hose from auxiliary unit. Remove and discard O-ring (Figure 11-91). From under the vehicle, pull low-pressure hose through grommet.
AUXILIARY EVAPORATOR/HEATER CORE REPLACEMENT

Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove auxiliary unit from vehicle. Remove four screws and plenum from housing. With auxiliary unit on bench, remove six plastic locking pins securing unit housing halves together (Figure 11-92). Remove four screws from blower motor support. Remove four screws securing side brackets to upper housing half. Separate housing halves. Remove blower motor assembly from bottom housing. Remove evaporator/heater core assembly from bottom housing. Remove plastic stick pins and mesh filter from evaporator/ heater core assembly.
4. 5. 6.
7.
CAUTION: To avoid potential thread or fitting damage, hand start connections before using wrenches.
NOTE: If expansion valve is to be reused, remove from evaporator/heater core assembly and install on replacement unit.
Installation
1. 2. Route evaporator end of hose through grommet to auxiliary unit. Lubricate and position O-ring on hose and secure to auxiliary unit. Using two wrenches for equalized support, tighten to 21-27 lb-ft (29-37 Nm) (Figure 11-91). Route other end of low-pressure hose to under hood low pressure fittings. Lubricate and position O-ring and secure auxiliary low pressure hose to existing low pressure hose fitting. Using two wrenches for equalized support, tighten to 24-28 lb-ft (33-38 Nm) (Figure 11-90). Install two P-clamps to secure hoses to underbody. Install front and rear consoles. Evacuate, charge, and leak test system. Start engine and check A/C operation.
Installation
1. 2. 3. 4. Install mesh lter on evaporator/heater core assembly with plastic stick pins (Figure 11-92). Install evaporator/heater core assembly in bottom housing. Install blower motor assembly in bottom housing. Install upper housing to lower housing with six plastic locking pins, four blower motor support screws, and four screws securing side brackets to upper housing. Install plenum on housing with four screws. Install auxiliary unit into vehicle. Evacuate, charge, and leak test A/C and heating system.
3. 4.
5. 6. 7.
5. 6. 7. 8.
AUXILIARY BLOWER MOTOR REPLACEMENT

Removal
1. 2. 3. Disconnect auxiliary unit mounting hardware and tilt unit up to gain access to blower motor support screws. Remove support screws and screws securing side brackets to upper housing half. Separate housing halves and remove blower motor assembly from bottom housing.
Installation
1. Installation is the reverse of the removal procedure.
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PLASTIC LOCKING PIN TOP HOUSING BLOWER MOTOR ASSEMBLY EVAPORATOR/HEATER CORE ASSEMBLY CLIP
MESH FILTER PLASTIC PIN BOTTOM HOUSING EXPANSION VALVE
TUNNEL SUPPORT BRACKET PLENUM
Figure 11-92: Auxiliary Air Conditioning Components
AUXILIARY EXPANSION VALVE REPLACEMENT

Removal
1. 2. 3. 4. Discharge air conditioning system. Remove rear console. Remove prestite tape and bulb clamp. Using two wrenches for equalized support, remove highpressure hose from expansion valve. Remove O-ring from hose and discard O-ring (Figure 11-93). Using two wrenches for equalized support, remove expansion valve from auxiliary unit. Remove and discard O-ring (Figure 11-86).
AUXILIARY UNIT
EXPANSION VALVE
LOW PRESSURE A/C HOSE
BULB CLAMP
5.
Installation
1. Install O-ring and expansion valve on auxiliary unit. Using two wrenches for equalized support, tighten to 15-20 lb-ft (20-27 Nm) (Figure 11-86). Position O-ring onto high pressure hose and hand-thread hose fitting onto the expansion valve. Using two wrenches for equalized support, tighten to 11-13 lb-ft (15-17 Nm) (Figure 11-93). Install prestite tape and bulb clamp. Evacuate, charge, and leak test system. Install rear console. Start engine and check operation of auxiliary unit.
MOUNTING BRACKET BULB
HIGH PRESSURE HOSE
Figure 11-93: Expansion Valve Removal/Installation
2.
3. 4. 5. 6.
_____________________
11-51
ESSENTIAL TOOLS
00-S11-010
00-S11-009
J41995
J42220
J41459
Tool No. J42551 J42549 J42550 J41459 J42220
Description Leak Detector, A/C R134a HVAC Anemometer (not shown) HVAC Flow Meter Adapter Kit (not shown) Leak Detection Dye Injector High Intensity Ultra Violet (Black) Light
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SPECIAL TOOLS
J34021-A
J39500-20A
J39500-A
J39500-24A J39183-C
J39037
J6742-03
J23738-A J24182-2A J36847
Tool No. J39500-A J34021-A J39500-20A J39500-24A J39183-C J6742-03 J36847 J24182-2A
Description A/C Recovery, Recycle, Evacuate and Discharge Service Cart (from Robinaire) Compressor Clutch Pulley, Core and Bearing Replacement Tool Set High Side Coupler Adapter (Compact Prole) Low Side Coupler Adapter (Compact Prole) Manifold Gauge Set Thermometer Condenser Fin Straightener Tool Schrader Valve Core Tool
_______________________________________________________________________________
12-1
Section 12 Electrical System

TABLE OF CONTENTS
Audio Antenna System Test . . . . . . . . . . . . . . . . . . . . . . . . . . .12-157 CD Changer (Delco) Replacement . . . . . . . . . . . . . . . . .12-140 Diagnosis-Delco Audio System . . . . . . . . . . . . . . . . . . .12-144 Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-145 Identifying Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . .12-144 Electrical Harness Replacement, Delco Monsoon (Models 83, 84 & 91) . . . . . . . . . . . . . . . . . . . . . . . . . . .12-142 Electrical Harness Replacement, Delco Standard (Model 89) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-143 Electrical Harness Replacement, Delco Standard (Model 90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-144 Electrical Harness Replacement, Delco Standard (Models 83, 84 & 91) . . . . . . . . . . . . . . . . . . . . . . . . . . .12-143 Generator Whine Concerns . . . . . . . . . . . . . . . . . . . . . .12-146 Overhead Console, Speaker and Amplifier Replacement (Delco Monsoon) . . . . . . . . . . . . . . . . .12-140 Radio (Delco) Replacement . . . . . . . . . . . . . . . . . . . . . .12-140 Rear Seat Audio (RSA) Unit Replacement . . . . . . . . . .12-141 Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-151 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-139 Test Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-146 Battery Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14 Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16 Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18 Splash Shield and Seal Service . . . . . . . . . . . . . . . . . . . .12-19 Tray Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18 Brake Shift Interlock System Brake Shift Interlock Cable Inoperative . . . . . . . . . . . . .12-51 Ignition Switch Replacement . . . . . . . . . . . . . . . . . . . . . .12-51 Shift Interlock Cable Schematic . . . . . . . . . . . . . . . . . . .12-52 Charging System Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-22 Alternator Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-23 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-28 Cigarette Lighter Replacement . . . . . . . . . . . . . . . . . . . . . . . .12-68 Cruise Control Cruise Control Inoperative VIN Z . . . . . . . . . . . . . . . . . .12-135 Cruise Control Schematic . . . . . . . . . . . . . . . . . . . . . . .12-137 Cruise Control Systems . . . . . . . . . . . . . . . . . . . . . . . 12-134.4 CTIS CTIS Compressor Inoperative . . . . . . . . . . . . . . . . . . . . .12-53 CTIS Exhaust Valve Inoperative . . . . . . . . . . . . . . . . . . .12-54 CTIS Front Inflate Valve Inoperative . . . . . . . . . . . . . . . .12-55 CTIS Rear Inflate Valve Inoperative . . . . . . . . . . . . . . . .12-56 CTIS Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 Digital Ratio Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-75 Fuel System Fuel Lift Pump Inoperative . . . . . . . . . . . . . . . . . . . . . . . 12-44 Fuel Lift Pump Schematic . . . . . . . . . . . . . . . . . . . . . . . . 12-46 Fuel Manager Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 12-50 Fuel Selector Valve Schematic . . . . . . . . . . . . . . . . . . . . 12-49 Fuel Tank Selector System Inoperative . . . . . . . . . . . . . 12-47 General Information Auxiliary Power Point, Interior Fuse Box . . . . . . . . . . . . 12-10 Auxiliary Power Studs, Exterior Fuse Box . . . . . . . . . . . 12-13 Circuit Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Fuse/Relay Location and Identification . . . . . . . . . . . . . 12-10 Ground Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Glow Plugs Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43 Heated Glass Both Heated Windshields Inoperative . . . . . . . . . . . . . . 12-92 Heated Windshield Schematic . . . . . . . . . . . . . . . . . . . . 12-93 Left Heated Windshield Inoperative . . . . . . . . . . . . . . . . 12-90 Rear Window Defroster Inoperative . . . . . . . . . . . . . . . . 12-94 Rear Window Defroster Schematic . . . . . . . . . . . . . . . . . 12-95 Right Heated Windshield Inoperative . . . . . . . . . . . . . . . 12-91 Horn Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61 Horn Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-63 Horns Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-62 HVAC Systems HVAC Blower Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 12-80 HVAC Compressor Inoperative . . . . . . . . . . . . . . . . . . . . 12-75 HVAC Compressor Schematic . . . . . . . . . . . . . . . . . . . . 12-82 HVAC Main Blower Inoperative ALL BUT High . . . . . . . 12-75 HVAC Temp Blend Door/Rear Blower . . . . . . . . . . . . . . 12-81 HVAC Temperature Door Inoperative . . . . . . . . . . . . . . . 12-77 Instrument Panel Engine Temperature Gauge Inoperative . . . . . . . . . . . . 12-73 Fuel Gauge Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . 12-72 Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-65 Gauges and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64 Gauges Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-74 Low Coolant Lamp Inoperative . . . . . . . . . . . . . . . . . . . . 12-69 Oil Pressure Gauge Inoperative . . . . . . . . . . . . . . . . . . . 12-71 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-64 Lighting Systems Key/Headlight Chime Schematic . . . . . . . . . . . . . . . . . . 12-60 Lights Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-58
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Electrical System _________________________________________________________
Power Locks Cargo Door Lock Inoperative . . . . . . . . . . . . . . . . . . . .12-113 Front Door Harness Replacement . . . . . . . . . . . . . . . . .12-120 General Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .12-102 Keyless Entry & Theft Detterent System Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-105 Keyless Entry Programming . . . . . . . . . . . . . . . . . . . . .12-108 Keyless Entry System Features . . . . . . . . . . . . . . . . . .12-106 Power Locks HMC4, XLC2 , HMSB . . . . . . . . . . . . . . . .12-117 Power Locks HMCS W/ Remote Entry . . . . . . . . . . . . .12-115 Power Locks Inoperative . . . . . . . . . . . . . . . . . . . . . . . .12-110 Rear Door and Jumper Harness . . . . . . . . . . . . . . . . . .12-121 Remote Entry Module Power/Ground . . . . . . . . . . . . . .12-119 Remote Entry System Inoperative . . . . . . . . . . . . . . . .12-114 Slant Door Lock Inoperative . . . . . . . . . . . . . . . . . . . . .12-112 Power Mirrors Ambient Temperature Sensor . . . . . . . . . . . . . . . . . . . .12-131 Auto-Dimming Compass Mirror Calibration and Zone Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-129 Auto-Dimming Rear View Mirror . . . . . . . . . . . . . . . . . .12-129 Compass Mirror Display Inoperative . . . . . . . . . . . . . .12-132 Compass Mirror Schematic . . . . . . . . . . . . . . . . . . . . . .12-133 Power Side Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-134 Power Window and Door Locks Front Door Harness Replacement . . . . . . . . . . . . . . . . .12-123 Power Windows Power Window Schematic . . . . . . . . . . . . . . . . . . . . . . .12-101 Power Windows Inoperative, All Windows . . . . . . . . . . .12-96 Power Windows and Door Locks Rear Door Harness Replacement . . . . . . . . . . . . . . . . .12-126 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-30 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-37 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-31 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-83, 12-84 Wipers Rear Window Wiper Inoperative . . . . . . . . . . . . . . . . . . .12-87 Rear Wiper Motor Schematic . . . . . . . . . . . . . . . . . . . . . .12-89 Windshield Wiper Motor Inoperative All Speeds . . . . . .12-83 Windshield Wipers Intermittent Speeds Inoperative . . .12-84 Wiper/Washer Schematic . . . . . . . . . . . . . . . . . . . . . . . . .12-86
3-1-01
________________________________________________________
Electrical System
12-3
DIAGNOSTICS
The following section of the service manual deals with electrical diagnostics. The section consists of three main tools: 1. Diagnostic charts 2. Wiring diagrams 3. Connector legend
working step by step to more complex tests. This allows problems which may be small in nature to be found quickly, and not overlooked. NEVER skip steps in a diagnostic chart. Each step relies on a previous step for correct diagnosis. Avoid random diagnostics and parts replacement which can lead to long, expensive diagnostic times and may not reveal the problem.
Intermittent Failures
ALL of the charts in this section are for use on current failures. Do not attempt to use these charts to diagnose a problem unless you are sure the problem currently exists. If the problem is intermittent, parts will be unnecessarily replaced, or no problem will be found.
Diagnostic Charts
Diagnostic charts are designed to take you through individual steps to locate a problem. The steps start at a point in the electrical system and progress to find the problem without overlooking items that may be contributing to the problem. In most cases the chart will refer to a wiring diagram, and connector callouts, both of which are provided for reference. The charts are designed to find problems which are current, not intermittent. These charts do not include preliminary visual checks. The preliminary checks must be done prior to using the charts for diagnosis. If the checks are not done, a simple problem such as a blown fuse may be overlooked.
BASIC ELECTRICAL CIRCUITS

WARNING: When removing battery cables, disconnect ground cable rst. Ensure all switches are off before disconnecting battery ground cable
General Wiring Diagrams

Wiring diagrams give a visual representation of the vehicle wiring the diagnostic charts refer to. The wiring diagrams in this section are broken down into systems. The diagrams will include any part of the electrical system which pertains to the system being diagnosed. Refer to the connector legend for connector identification of system connectors. An electrical circuit is a number of electrical devices which are connected in a loop from a positive voltage source (battery positive) to a negative ground source.
Parallel Circuits
The Hummer electrical system is a parallel circuit. In a parallel circuit, the electrical devices form more than one current path to and from the power supply. The supply voltage is the same in each path.
Connector Legend
The connector legend is a reference library of all the vehicle connectors that are called out in the wiring diagrams. Included are drawings of both male and female connector halves called out with pin/cavity arrangement, and a listing of all included circuits.
Circuit Components
A normal circuit path starts at the power supply (battery system or alternator). Next in line is the circuit protection: fusible link, fuse, or circuit breaker. The circuit load, such as lights, motors, or solenoids completes the circuit to the ground system.
Preliminary Checks
The diagnostics in this section are designed to find problems that are not obvious. Before starting any formal diagnostic chart, preliminary checks must be performed. Preliminary checks should include: Visual inspection of all components Inspection of any fuses related to the system Connector inspection Inspection of electrical harnesses Charging system and batteries These types of checks are not included in the diagnostic chart. In fact, most of the charts rely on the fact that you, the technician, has performed these initial inspections.
Circuit protection devices

Fusible Links
A fusible link is a section of wire, usually two gauge sizes smaller than the circuit it protects. If the current rating of a fusible link is compromised, the fusible link will melt open.A special insulation prevents wire fires, and swells when heated to indicate the position of the open in the wire.
Circuit Breakers
Circuit breakers are electrical mechanical devices that will act as a fuse to prevent excess current flow in a circuit. Unlike fuses, the mechanical opening of contacts stops current flow. The contacts will reset in a short period of time. This process will repeat until the current excess is stopped.
Diagnostic Strategy
Whenever a vehicle is being diagnosed for a problem, a strategy should be used. The following charts are strategy based, meaning they all follow the principle of starting simple and 05745159
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12-4
Fuses
The most common protector in the vehicle electrical circuit is a fuse. A fuse is a metallic connector within a circuit that is made of a low melting point metal that acts as a weak link. If current rises above the fuses rating, the metal will melt and separate, leaving an open. The fuse is surrounded by a non flammable plastic covering, and will limit current to a specific amperage. Fuses can be found in range from 1A to 30A, and be mini or maxi types. All fuses used on the HUMMER are blade type.
the size of a secondary controller. The secondary controller is usually a relay.
Circuit Faults
The following are the four electrical fault conditions that cause a malfunction in a circuit: open, short, short to ground, and high resistance connection
Open
An open circuit occurs whenever there is a break in the circuit continuity. The break can be caused by a connector disconnect, a broken wire, or a defective component (Figure 12-1).
Circuit Controllers
Circuit controllers are used to turn the current off and on in a circuit. Controllers can be mechanical or solid state. Solid state controllers combine the use of semi conductors along with electromechanical devices to control current in a circuit. Solid state controllers are typically associated with computers, and engine control systems. Most solid state controllers are specific to a purpose. Mechanical controllers are the most common type, and can be seen as switches or relays. Switches are a primary controller while relays are typically secondary controllers. Primary mechanical controllers are very simple contacts that are either open or closed, and can be changed state. Primary controllers are usually limited in their ability to handle large current flows due to the restriction of size. Secondary mechanical controllers are used in conjunction with the primary controllers to handle larger current draws in a circuit. Primary controllers are used to operate the secondary controllers from a remote location, placing less or no restriction on
Short
A short circuit happens when the current bypasses part of the normal circuit. This bypassing is usually caused by wire pinching or chaffing. Usual symptoms are inappropriate activation or deactivation of a load device (Figure 12-2).
Short To Ground
A grounded circuit is also a short circuit, except the current flows directly to ground with very little restriction. This is usually caused by wire pinching or chaffing against the frame or body (Figure 12-3).
High Resistance Connection

A high resistance connection is an electrical connection that is corroded or loose. High resistance connections cause a decrease in current flow that can affect the proper operation of an electrical load.
S12-161
Figure 12-1: Open Circuit
S12-162
Figure 12-2: 4-1-00
Short Circuit
________________________________________________________
Electrical System
12-5
S12-163
Figure 12-3: Grounded Circuit
DIAGNOSTIC TOOLS Digital Multimeter

A digital multimeter (J39200) is required to safely test for electrical malfunctions on the Hummer. Due to the complexity of the electrical system, a test light should not be used to test electrical circuits. Test lights do not have current limiting capabilities. The use of a test light may actually cause an electronic component to fail. Sharp test light probes may break wire strands, causing circuit failure. Breaks in the insulation allow moisture and contaminants to enter connectors and components, increasing the chances for corrosion. Even a small increase in resistance can give false readings from a sensor to an electronic component. A digital multimeter performs all the tests a test light can perform with a greater degree of accuracy. In addition, a multimeter can be used to test for current in a circuit.
circuit. For example, if you select the 200 volt scale and you are testing for battery voltage, most multimeters will display 12 volts. By selecting the next smallest scale, 20 volts, the display will read 12.8 volts, a more accurate measurement. Position multimeter leads on each side of the load (Figure 12-5).
OHM Test
CAUTION: Before using a multimeter, ensure the circuit is not energized. Even a small voltage applied to an multimeter will damage it. Continuity - Testing for continuity in a circuit requires the use of the lowest ohm scale available. Position the multimeter leads on each side of the circuit or component being tested. A reading of less than one ohm is acceptable continuity (Figure 12-6). Resistance - To test for resistance, first touch the meter leads together to ensure that the meter zeros out, then position the leads of the multimeter on each side of the circuit or component. Adjust the multimeter ohm setting until an acceptable reading is observed. Verify the reading with the specification.
DIAGNOSTIC TESTS
NOTE: Follow all manufacturers recommendations when testing for current. All multi-meters have a maximum current rating. Not all multimeters contain a fuse that protects the multimeter from excess current draw.
Amperage Test
Use caution when testing for current. Always check multimeter owner's manual for maximum current to be tested. Most multimeters are fuse-protected when measuring current. However, some meters are not protected and therefore can be damaged by excessive current. Position multimeter leads after closed switch and before load (Figure 12-4).
Voltage Test
Multimeters have a number of different voltage scales to choose from. Always use the lowest scale possible to test the 05745159 4-1-00
12-6
MULTIMETER
BATTERIES
CIRCUIT BREAKER
LOAD (I.E. LIGHT, MOTOR, SOLENOID, ETC.)
GROUND
SWITCH (CLOSED)
GROUND
Figure 12-4: Amperage Test

MULTIMETER
BATTERIES
CIRCUIT BREAKER
GROUND
SWITCH (CLOSED)
GROUND
Figure 12-5: Voltage Drop Test

MULTIMETER
BATTERIES
CIRCUIT BREAKER
GROUND
SWITCH (OPEN)
LOAD
GROUND
Figure 12-6: Ohm Test
4-1-00
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Electrical System
12-7
CIRCUIT MAINTENANCE AND REPAIR

All electrical connections must be kept clean and tight. Loose or corroded connections may cause a discharged battery, weak starting, dim lights, or possible electrical system damage. Wires must be replaced or repaired if insulation becomes burned, cracked, or deteriorated. When replacing a wire, it is important that the same gauge size wire be used. Refer to wiring diagram for proper wire gauge sizes. Never replace a wire with one of a smaller size or replace a fusible link wire with a wire of a larger size. It should also be noted that fusible link wire utilizes a special insulation covering. When replacing a fusible link wire, the replacement wire should be the type in accordance with SAE J156. Further, fusible link wire should never be shortened or spliced. If a repair is necessary, entire fusible link wire must be replaced with one of the proper gauge size, length and insulation type. Any wire repair must maintain the waterproof integrity of the vehicle. Any splice located below the 30 in. (76 cm.) fording level or in a high splash area must be waterproof and heavy duty adhesive wall shrink tubing should be used as a minimum in these areas. Each harness or wire must be held securely in position to prevent damage to insulation caused by vibrating and chafing. NOTE: Before performing any wire repair, disconnect battery ground cable.
Single Wire Repair (Exposed)

1. Remove damaged area, removing as little wire as possible (Figure 12-8).
NOTE: Care should be exercised in stripping the wire insulation to avoid cutting wire conductor strands. 2. Strip wire ends to the appropriate length required by the splice clip (Figure 12-9).
NOTE: Heat shrink tubing is available in various diameters. Typically the heat shrink tubing will shrink to approximately one-half of its original diameter, therefore the tubing diameter selected for the repair should not be greater than twice the wire insulation diameter to ensure a proper seal. 3. Slide heat shrink tubing over one of the wire ends (Figure 12-10).
NOTE: Splice clips are available for different wire gauge sizes. Therefore, it is important to select the appropriate size for the wire gauge being repaired. 4. 5. 6. 7. Slide both ends of wire into splice clip and crimp splice clip to wire ends (Figure 12-11). Pull wires, by hand, in opposite directions to test the crimp of the splice clip. Center heat shrink tubing over splice clip (Figure 12-12). Using a heat gun or equivalent heat source, apply heat to heat shrink tubing until tubing conforms to splice clip and wire insulation (Figure 12-13). After the splice cools, apply two layers of vinyl adhesive electrical tape to complete the repair (Figure 12-14).
Ground Point legend

G1 - Engine ground-Intake Manifold G2 - Ground Buss Exterior Fuse Box G3 - Body Ground G4 - Instrument Panel Ground Buss Interior G5 - Frame Ground
8.
Single Wire Repair (In a Harness)

1. 2. Remove harness covering in the affected area (Figure 12-15). Repair damaged wire using the exposed single wire repair procedures. (Go to Step 1.) After completing the wire repair, apply two layers of vinyl adhesive electrical tape over the affected area to complete the repair (Figure 12-16).
Wiring Repair
Wiring harness and wires - All wires are of a specific insulation color indicated on the wiring diagrams. Insulation color helps to identify circuits and make correct connections. Insulation colors and their abbreviations are as follows: BK - Black PK - Pink BR - Brown PP - Purple DB - Dark Blue RD - Red DG - Dark Green GY - Gray TN - Tan LB - Light Blue WH - White LG - Light Green YL - Yellow OR - Orange Wire repair is very important for the continued, reliable operation of the vehicle. This repair must be done as described in the following procedure: 3.
Multiple Wire Repair (In a Harness)

NOTE: Since more than one splice is required in this case, stagger the wire splices such that they are no closer than 3 in. (7.6 cm) from each other. Repair affected wires using the single wire repair (in a harness) procedures.
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FUSIBLE LINK MAINTENANCE

The following procedure covers the replacement of fusible links encountered through circuit diagnosis. 1. Disconnect battery ground cable. 2. Carefully remove old fusible link from termination (alternator, power stud, starter). 3. Locate original wiring harness splice between fusible link and wiring harness (Figure 12-7). 4. Cut fusible link splice on harness side. Do not splice into original fusible link; this may be weakened and cause a premature failure and repeat problem. 5. Identify the original fuse link size and length of fuse link cut from vehicle. 6. Matching the wire size, cut a length of fusible link wire to the total length cut from vehicle in Step 4. Be sure to compensate for any harness wire removed with original wire. This will avoid overtight wiring that may become separated with normal operation.
HEAT SHRINK TUBING
NOTE: Fusible link is a wire with special insulation. It is important that replacement material be fusible link wire and it should be labeled as such. The replacement fusible link should be between six and nine inches long. 7. Install a new crimp on connector of the same type and size as the original lug or connector. Seal connection with low temperature heat shrink tubing. 8. Place a piece of heat shrink tubing onto the wire and install a butt connector onto the fusible link. 9. Install the fusible link by connecting it to the wiring harness with the butt connector and heat shrink tubing. 10. Connect terminal end to original location, alternator, power stud, or starter. Reconnect battery ground cable and check circuit(s) affected for proper operation.
TERMINALS BUTT CONNECTOR
WIRING HARNESS
FUSIBLE LINK
BURNT SECTION
CUT HERE TO REPLACE LINK
ORIGINAL SPLICE
S12-022.3
Figure 12-7: Fusible Link
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Electrical System
12-9
HEAT SHRINK TUBING DAMAGED AREA
Figure 12-8:
Damaged Wire
SPLICE CLIP HEAT SHRINK TUBING
Figure 12-13:
Splice Clip
HEAT SHRINK TUBING
STRIPPED WIRE ENDS
Figure 12-9:
Heat Shrink Tubing Figure 12-14:

HEAT SHRINK TUBING
Heat Shrink Tubing
DAMAGED WIRE
SPLICE CLIP
Figure 12-10:
Splice Clip
Figure 12-15:
Damaged Wire
ELECTRICAL TAPE 3.0 INCH MINIMUM
Figure 12-11:
Electrical Tape Figure 12-16:
SPLICE
Multiple Wire Splice
ELECTRICAL TAPE
Figure 12-12: 05745159
Electrical Tape 4-1-00
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Electrical System
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FUSE/RELAY LOCATION AND IDENTIFICATION Interior Fuse Box

The interior fuse box, is located under the instrument panel to the left of the steering column. The fuse box is divided into two mini-fuse junction blocks, relays, and a auxilliary power point.The mini-fuse blocks may be accessed without removing the main fuse box cover (Figure 12-17). To access relays, the main fuse box cover must be removed. Before removing any of the fuse box access covers, refer to the illustrations and charts in this section for the location of specific fuses, relays, and circuit breakers. Doing this will enable you to go directly to the fuse or circuit breaker you want to inspect.
In Line Fuses
Some fuses are placed in-line with the components they are protecting, meaning they are not located in the fuse box but in the actual wire suppling current to the device. The only inline fuse used on the Hummer is in the power feed to the HVAC high blower relay. This fuse is located on the passenger side of the engine compartment inside a black plastic cover.
Auxiliary Power Point

An auxiliary power point is provided to ease installation of aftermarket electrical accessories. The power point is divided into 2 sections: Ignition and Battery. When a power supply is needed, a fuse must be installed into one of the empty slots, and a connection made to the adjacent terminal. The main supply circuits to both sections of the aux. power point are fused to 30 amps. Total amperage draw on either section should not exceed 30 amps.
CTIS BUZZER TERMINAL IGNITION FLASHER
BATTERY
FUSE SLOT
UPPER MINI-FUSE BLOCK
9-OM5-006
H G F E
Figure 12-18: Auxiliary Power Point
INTERIOR FUSE BOX D C B A
LOWER MINI-FUSE BLOCK 1 2 3 4 5 6 7
Figure 12-17: Interior Fuse Box and Mini Fuse Layout Fuses and circuit breakers protect the vehicle's electrical system from damage caused by overloading. An overloaded circuit breaker will switch the circuit on again, causing intermittent operation. A blown fuse will permanently disable the circuit until the fuse is replaced. Whenever a fuse blows or a circuit breaker opens a circuit, all electrical components using that circuit will not operate. Therefore, during diagnosis of any of these electrical components, check the appropriate fuses and circuit breakers for damage (Figure 12-20). 4-1-00
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Electrical System
12-11
C F MIRROR
CUTOUT
B E
A D
POWER WINDOW
REAR WIPER
CTIS ALARM
SIGNAL FLASHER IGNITION WIPER
9-S12-083
Figure 12-19: Relay Location (Interior Fuse Box)
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Upper Mini-Fuse Location FUSE 1E 2E 3E 4E 5E 6E 7E 1F 2F 3F 4F 5F 6F 7F 1G 2G 3G 4G 5G 6G 7G 1H 2H 3H 4H 5H 6H 7H AMPERAGE 5 7.5 15 25 5 5 7.5 7.5 15 5 5 5 5 30 7.5 25 25 5 10 20 30 15 20 25* CIRCUIT PROTECTED Spare Fuse Blank Spare Fuse Blank Spare Fuse Blank Spare Fuse Radio Lights Panel Lights Dimmer Module Front Parking/Running Lights Rear Parking/Running Lights Trailer Lights Underhood and Trouble Lights Light Circuit to Chime CTIS/Key Chime Power Windows Auxilliary Power Point (Ignition) Radio Ignition Blank Rear Wiper/Washer (Slant Back Only) Windshield Wiper/Washer DLC Power Terminal 16 Radio Memory/Clock Power Door Locks/Power Mirror/ Remote entry Battery Auxilliary Power Point (Battery) Dome/Courtesy Lights Auxiliary Power Outlet (console) Trailer Brake Controller FUSE 1A 2A 3A 4A 5A 6A 7A 1B 2B 3B 4B 5B 6B 7B 1C 2C 3C 4C 5C 6C 7C 1D 2D 3D 4D 5D 6D 7D
Lower Mini-Fuse Location AMPERAGE 5 7.5 10 15 20 5 5 5 5 10 7.5 10 10 20 30 15 20 20 15 15 5 CIRCUIT PROTECTED Spare Fuse Spare Fuse Blank Spare Fuse Spare Fuse Blank Spare Fuse Blank Blank Blank Gauges/Indicator Lights/MIL Blank Transmission Brake Switch Remote entry igniton Feed Transmission Shifter Lock/ Heated Windshield A/C Clutch/Rear Defrost/ HVAC Ignition Feed Relay Backup Lights Turn Signals Cruise Control HVAC System HVAC Blower Radio Amplier-Monsoon only PCM Battery/Fuel Lift Pump Cigar Lighters Stoplights Flashers Blank Compass Mirror Battery Feed
*May not be provided. Figure 12-20: Mini Fuse Identification (Interior Fuse Box)
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12-13
Exterior Fuse Box

Fuse/ CB
EXTERIOR FUSE BOX
40A #1
BLANK BLANK 25 10 5 30 30 20 20 BLANK BLANK
Amperage 40A 20A CB 30A CB 30A CB 30A CB 30A 40A 40A 30A 30A
Circuit Protected Starter Circuit Parking Lights Headlights Rear Defrost Power Windows CTIS Compressor ABS/TT4 Hyd. Pump Ignition Switch Batt Feed Auxiliary power stud A Auxiliary power stud B
1 2 3
20A CB #2 30A CB #3 30A CB #4 30A CB #5
ABS WNG. RLY.
ABS VALVE RELAY
20
HORN RELAY
A/C RELAY
5
FUEL PUMP RELAY.
HEATED W/S RELAY
4
FUSE PULLER
30A 40A 40A
#6 #7 #8 30A 30A #9 #10 CTIS PUMP RELAY HEATED W/S RELAY
5 6 7
MAXI-FUSES 1
A B C D
9-OM5-004
8 9 10
Figure 12-23: Maxi-Fuse Identification (Exterior Fuse Box)

MINI-FUSE LAYOUT
Auxiliary Power Studs

The external fuse box provides 2 threaded studs for use as auxiliary power connections. Each stud is fused for up to 30 amps with maxi-fuses located in the external fuse box. Both studs provide battery power.
Figure 12-21: Exterior Fuse Box The exterior fuse box is located under the hood on the drivers side of the engine compartment. The exterior fuse box houses mini and maxi fuses, circuit breakers, and relays which supply power to many of the electrical components in the engine compartment. The exterior fuse box can be accessed by rst removing the left side cowl cover then removing the fuse box cover itself. Fuse and relay locations are labled on the inside of the cover. Spare mini fuses are located in the exterior fuse box for convient replacement. A fuse puller is also provided to ease fuse removal.
FUSE 1A 2A 3A 1B 2B 3B 1C 2C 3C 1D 2D 3D AMPERAGE 10 20 5 20 25 30 20 30 CIRCUIT PROTECTED
PWR STD A PWR STD B
MAXI-FUSES
EXTERNAL FUSE BOX

9-OM5-004
POWER STUD A
POWER STUD B
Blank PCM Ignition Feed Engine Ignition Feed Blank ABS Controller Engine Ignition Feed ABS Valve Relay Heated Windshield Blank Horn Heated Windshield Blank
Figure 12-24: Auxiliary Power Studs
Ground Points
Two main grounding points are provided to ground vehicle systems and add-on items. The main grounding stud is located on the drivers side of the engine compartment next to the exterior fuse box. The second grounding point is located to the left of the instrument panel on the interior of the vehicle. NOTE: Never drill holes in the body to ground electrical items, the corrosion resistance is compromised, and bad grounding could result.
Figure 12-22: Mini-Fuse Identification (Exterior Fuse Box) 05745159 4-1-00
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Electrical System
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BATTERY CHARGING
General Information
A low charge or discharged battery can be recharged as long as the cells are not shorted, sulfated, or damaged. Batteries can be recharged quickly at 20 amp charge levels, or for longer periods at 10, 5, or 2 amps. A 5 amp charge is preferable. The battery charger should be equipped with a polarity sensor to avoid damage through incorrect hookup. Charger capacity should range from 5 to 20 amps for slow and fast charge rates. The time and amp rate of charge required will vary depending on battery condition and temperature. Generally, it takes longer to recharge a cold battery. State of charge will also affect charging time as a partially discharged battery may only require one third the charge time of a fully discharged battery. There are a number of safety precautions that must be observed before charging a battery. The following precautions are necessary to avoid personal injury:
Suggested charge times are outlined in the charge rate chart (Figure 12-25). Note that the chart suggested times and rates are for a battery at 70F (21C). Charge times will be greater if battery temperature is below 55F (13C).
Figure 12-25: Charge Rate Chart
Battery Checking Procedures

Visual Inspection
Check for obvious damage, such as a cracked or broken case or cover or overcharging of the electrical system that could permit loss of electrolyte. If obvious damage is noted, replace the battery.
Battery Charging Precautions

Battery electrolyte contains sulfuric acid which can cause severe burns. Avoid contact with electrolyte by wearing protective gloves and a face shield. Flush skin or eyes with water if contact occurs and seek medical assistance immediately. Always wear eye and facial protection when connecting charging equipment. Never attempt to charge a frozen battery. The case could fracture at the first surge of current. Never charge a battery with a low electrolyte level. Internal arcing and battery explosion could occur. Never exceed a 20 amp charge with a cold battery. Use a lower (5-10 amp) rate until the battery warms up. Never use excessive charge rates. Reduce charge rate if the battery becomes overly warm, or if a steady stream of gas starts to exit the vents. Do not use high charge rates on a completely discharged battery. Use low rates or a trickle charge only. Never allow sparks, or an open flame near a charging battery. The charging process generates hydrogen gas which is highly inflammable. Charge batteries in properly ventilated areas only. Do not allow hydrogen gas to accumulate and concentrate in poorly ventilated areas.
Load Test
Before proper testing, the battery must be in a fully charged state to obtain an accurate test. Load testing requires the use of battery side terminal adapters to ensure good connections. Do not attempt to load test a side post battery by screwing bolts into the terminals as connections. NOTE: When load testing, batteries must be disconnected from each other. 1. Using a battery load tester, measure voltage across the battery terminals. Normal battery voltage should be 12v or higher. Recent cranking or load testing will lower the normal voltage. If no cranking or load testing has been performed, and battery voltage is below 12v, replace the battery. Connect battery load tester to the battery to be tested. If battery has been recently charged, apply a 300 amp load for 15 seconds to remove the surface charge. Skip this step if the battery has not been charged. Wait 15 seconds for the battery to recover. Apply the necessary load test for the battery being tested. The load required should be listed on the battery label, if it is not, use the cold crank amperage divided by 2. (300 cca/2=150 cca)This load should be applied for 30 seconds If the voltage does not drop below the minimum value, the battery is good and should be returned to service. The battery temperature must be estimated by feel and by the temperature the battery has been exposed to for the proceeding few hours. If the battery has been exposed to temperatures below ambient, use the chart below to adjust the minimum test voltage (Figure 12-26).
2.
3.
Charge Rate and Time

Charge rate will depend on battery temperature and degree of discharge. Ideally, charging should not proceed until battery temperature has reached 60F (16C). However, in cases where a cold battery must be charged, start with a 5 amp rate and increase it as battery temperature rises. In the case of a fully discharged battery, a 24 hour trickle charge of 1-2 amps is recommended. A 20 amp charge rate should be used when a battery is only partially discharged. 4-1-00
4.
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Electrical System
12-15
9. Estimated Temperature 70F(21C) 50F(10C) 30F(0C) 15F(-10C) 0F(-18C) 0F(Below -18C) Minimum Voltage 9.6 9.4 9.1 8.8 8.5 8.0 11. 12. 10.
Figure 12-26: Load Test Values vs.Temperature 5. If voltage drops below the minimum value listed, replace the battery.
Parasitic Draw Test

Tools Required: J38758 Parasitic Draw Test Switch J39200 Digital Multimeter 1. Remove the negative battery cable from the rear battery. 2. Install the male end of the parasitic draw test switch over the crossover negative battery cable using the long battery bolt from the battery cable removed in step 1. 3. Open the parasitic draw test switch 4. Connect the negative battery cable to female end of the parsitic draw test switch using a short battery bolt. 5. Close the parsitic draw test switch. 6. Road test the vehicle while activating all accessories, such as the radio and air conditioning. 7. Turn the ignition switch to the off position and remove the key. NOTE: It is important that from this point on, electrical continuity must be maintained in the ground circuit to the battery, either through J38758 in the on position, or through J39200. 8. Some components, such as the PCM or TCM, have timers that draw several amps of current while they cycle down. This can give a false parasitic drain reading. Wait 15 minutes for these components to power down before continuing this test.
13. 14.
Install a jumper wire with a 10 amp fuse between the two terminals on the parasitic draw test switch. Open the switch and wait 10 seconds. If the fuse does not blow, the parasitic load is less than 10 amps and the J39200 can be used. Close the switch on the tester and remove the jumper wire and fuse. Set J39200 to the 10 amp scale and place leads in the correct ports in the meter for amperage testing on the 10 amp scale. Connect the meter leads to the two terminals on the parasitic load test switch and open the switch. Wait 60 seconds then take a reading from the meter. If the current reading is at or below 2 amps, turn the test switch to the on position. Reset the meter to read milliamps. Open the switch and take the reading in milliamps. Find the reserve capacity of the batteries on the vehicle. Since there are 2 batteries, add the reserve capacities together. (100 minutes + 100 minutes = 200 minutes reserve capacity). Divide the number by 4 and the answer, given in milliamps, is the maximum allowable parasitic drain the batteries will support.
NOTE: Always turn the switch knob to the on position before removing each fuse to maintain continuity in the electrical system and to avoid damaging the meter due to accidental overloading, such as opening a door to change a fuse. 15. If current draw is too high, remove system fuses one at a time until the draw returns to a value less than or equal to the maximum allowable for the batteries. Repeat the test for parasitic drain after any repair has been performed. 16. When the cause of excessive current draw has been located and repaired, remove the meter, test switch and terminal adapters and connect the negative battery cable to the battery.
NOTE: If another DVOM is being used other than J39200, ensure that the ammeter will handle 10 amps of current without damage.
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Electrical System
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BATTERY CABLE REPLACEMENT

Battery Negative Cables - Removal
1. 2. 3. Remove caps from battery negative cable (Figure 12-27). Remove battery cable bolts. Disconnect winch negative cable, if equipped (Figure 12-27).
NEGATIVE CABLE TO STARTER
BATTERY
CAP
BOOT CABLE BOLT BATTERY NEGATIVE CABLE CABLE BOLT
CABLE BOLT
WINCH NEGATIVE CABLE BATTERY NEGATIVE CABLE
WITH WINCH ONLY
Figure 12-27: Battery Negative Cable Connections 4. Remove fasteners securing negative cable to cable hanger and starter then remove negative cable (Figure 12-28).
Battery Negative Cables - Installation

1. 2. 3. Connect negative cables to starter, cable hanger, and batteries. Tighten battery cable bolts to 8-12 lb-ft. (11-16 Nm). Install caps on battery cable bolts.
CABLE HANGER
STARTER
Battery Positive Cable - Removal

1. 2. 3. 4. 5. 6. Disconnect battery negative cables. Remove caps from battery positive cable(s) (Figure 12-29). Disconnect starter cable at battery. Disconnect battery positive cable, and winch cable, if equipped, at battery. Remove locknut, washer, capscrew, and clamp securing starter cable to bracket. Disconnect starter cable at starter.
ENGINE HARNESS
Figure 12-28: Negative Cable to Cylinder Block Attachment
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Electrical System
12-17
WITH WINCH ONLY STARTER BATTERY CABLE BOLT
BRACKET
BATTERY POSITIVE CABLE
BATTERY POSITIVE CABLE WINCH POSITIVE CABLE
STARTER CABLE
BATTERY CABLE BOLT
STARTER CABLE CAP BATTERY CABLE BOLT
Figure 12-29: Battery Positive Cable Connections
Battery Positive Cables - Installation

1. 2. 3. 4. 5. 6. Connect starter cable to starter with lockers and nut. Tighten nut to 12-16 lb-ft (16-22 Nm). Secure starter cable to bracket with clamp, capscrew, washer, and locknut. Connect battery positive cable to battery. Connect winch cable to battery positive post (Figure 12-29). Connect battery negative cables. Tighten cable-to-battery bolts to 8-12 lb-ft. (11-16 Nm).
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Electrical System
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BATTERY REPLACEMENT
WARNING: Battery electrolyte contains sulfuric acid which can cause severe burns. If acid contacts eyes or skin, ush affected areas liberally with water and obtain medical assistance immediately. If acid contacts clothing, ush with water and replace affected clothing. Always wear eye protection, and remove all jewelry before working on batteries.
J-HOOK BATTERY HOLDDOWN BRACKET
BATTERY TRAY REPLACEMENT/INSTALLATION

1. 2. 3. 4. 5. 6. Disconnect and remove batteries. Remove splash shield and battery tray shield. Remove battery tray from airlift bracket (Figure 12-31). Install battery tray on airlift bracket. Install battery tray shield and splash shields. Install and connect batteries.
AIRLIFT BRACKET
SPLASH SHIELD
BATTERY
BATTERY TRAY
Figure 12-31:
Battery Tray
BATTERY TRAY
Figure 12-30: Battery Removal/Installation 1. 2. 3. 4. 5. 6. 7. 8. Disconnect battery cables. Remove J-hook, and holddown bracket bolts (Figure 12-30). Remove holddown bracket. Remove one or both batteries as required. Clean battery tray. Install one or both batteries in tray (Figure 12-30). Install holddown bracket and J-hook. Connect battery cables.
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Electrical System
12-19
BATTERY SPLASH SHIELD AND SEAL SERVICE

Splash Shield Removal
1. 2. 3. Remove upper splash shield and seal (Figure 12-32). Remove retainer bolts, and remove seal from battery tray and lower shield (Figure 12-33). Remove lower splash shield bolts and remove lower splash shield.
RETAINER RETAINER SEAL
UPPER SPLASH SHIELD
BATTERY TRAY
Figure 12-32: Upper Splash Shield Attachment

RETAINER
SEAL SEAL RETAINER
BATTERY TRAY LOWER SPLASH SHIELD RETAINER
Figure 12-33: Seal and Retainer Attachment
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Electrical System
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Splash Shield Installation

1. 2. 3. 4. Position lower shield on bracket and install fasteners (Figure 12-34). Install retainer on upper shield. Install upper shield on tray. Install seals and retainers (Figure 12-33).
AIRLIFT BRACKET BATTERY TRAY BRACKET
FRAME RAIL LOWER SPLASH SHIELD
Figure 12-34: Lower Splash Shield Removal/Installation
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Electrical System
12-21
MAJOR POWER DISTRIBUTION

The following charts and illustrations convey how power is distributed from the vehicle batteries to the fuse/relay centers. Power is supplied to the fuse boxes from the batteries through fusible links. Each fuse box has internal power busses that direct the power to the fuses. The busses are indicated on the fuse charts as follows: I = Ignition, B = Battery, A = Accessory, L = Lamps. The fuse charts contain a listing of the cavities in the fuse box, the corresponding circuits, wire colors and gauges (ga.). Power is supplied to an individual fuse by the buss indicated in the left buss column. The circuit number (CKT No.) contains two entries for a fuse: the power supply buss and the outgoing circuit number. The numbers in the cavity column relate to the cavities indicated on the fuse/relay cavity I.D. illustrations. Using this information, you can determine which cavity of a fuse is the power supply cavity and which other fuses are supplied by the same buss.
G4
INTERIOR GROUND BUSS
INTERIOR FUSE BOX G3

EXTERIOR FUSE BOX GROUND BUSS FUSIBLE LINK
FUSIBLE LINKS EXTERIOR POWER BUSS FUSIBLE LINK
G1
ALTERNATOR
ENGINE
FUSIBLE LINK
EXTERIOR FUSE BOX
M
STARTER
FUSIBLE LINK BATTERY BATTERY
GLOWPLUG CONTROLLER
9-S12-088
Figure 12-35: Major Power And Ground Schematic
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Electrical System
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ALTERNATOR
Removal
1. 2. 3. 4. Disconnect battery negative cable. Remove serpentine drivebelt from alternator pulley. Loosen pivot bolt and remove front and rear alternator bolts (Figure 12-36). Pull alternator away from engine. Remove nut and lockwasher and disconnect battery wires from battery alternator terminal (Figure 12-37). Unlock and disconnect field wire (Figure 12-37). Remove pivot bolt and alternator from engine.
BATTERY TERMINAL
5. 6.
Installation
1. 2. 3. 4. Position alternator in bracket and install pivot bolt nger tight. Connect battery wires to alternator. Secure with lockwasher and nut. Tighten nut to 62-80 lb-in (7-9 Nm). Connect field wire to alternator. Move alternator into alignment with lower bracket and install front and rear mounting bolts. Tighten bolts 18 lb-ft (25 Nm). Tighten pivot bolt to 37 lb-ft. (50 Nm). Install serpentine drivebelt on pulley and adjust belt. Connect battery negative cable.
ALTERNATOR
BATTERY WIRES
FIELD WIRES
Figure 12-37: Alternator Connections
5. 6. 7.
PIVOT BOLT
ENGINE
Figure 12-36: Alternator Mounting
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Electrical System
12-23
ALTERNATOR OVERHAUL
Alternator Disassembly
1. 2. 3. Remove alternator. Mark drive end frame and slip ring end frame for assembly alignment reference. Hold rotor shaft with allen wrench and remove nut, washer, pulley, fan, and thin collar from rotor shaft (Figure 12-38). Remove four through-bolts from slip ring end frame and drive end frame. Remove drive end frame and thick collar from rotor shaft. Remove three nuts from stator leads and rectifier bridge. Remove stator from slip ring end frame. 8. Remove standard screws, insulated screws, and washer from components in slip ring end frame. 9. Remove nut and output stud with insulator from slip ring end frame. 10. Remove rectifier bridge, capacitor strap, regulator connector strap, and brush holder from slip ring end frame. 11. Unsolder and separate brush holder and regulator connector. 12. Unsolder and separate connector strap from regulator.
4. 5. 6. 7.
BRUSH HOLDER
BRUSHES REGULATOR STUD
INSULATED SCREWS
INSULATOR REGULATOR CONNECTOR STRAP OUTPUT STUD SLIP RING END FRAME ROTOR SHAFT SLIP RING RECTIFIER BRIDGE
CAPACITOR STRAP
PULLEY
FAN THIN COLLAR STATOR LEAD BEARING ROTOR THICK COLLAR STATOR DRIVE END FRAME
Figure 12-38: Alternator Components
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Electrical System
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Alternator Parts
Cleaning
Use part cleaning solvents on metal parts only. The insulating coatings on wires in the field coil and stator can be damaged by cleaning solvents. Clean encapsulated and exposed wire items by wiping with a clean cloth.
Stator
Check the stator leads for continuity to ground (laminations). Any continuity indicates a grounded stator which should be replaced (Figure 12-40). Examine the stator winding for discoloration due to overheating or short to ground. Normal color is reddish brown to purple. Bare copper, dark spots, or dull black color indicates burned spots. Replace the stator if damaged, shorted or grounded.
STATOR WINDINGS
Inspection and Repair Rotor

Inspect for cracked slip rings, damaged threads, and galling or scoring on bearing journal surfaces on shaft (Figure 12-39). Corrosion or light scoring on the slip rings may be removed with 400 grit emery cloth. Test the slip rings and field coil for opens (high resistance), shorts (very low resistance), and grounds (low resistance) to frame and shaft. Replace the rotor if a fault is detected. Inspect the ball bearing for free play, roughness, leaking seals, and other damage. Replace the bearing if necessary. Seat the new ball bearing against the rotor shoulder.
LAMINATIONS WINDINGS SHAFT SHOULDER STATOR LEADS
Figure 12-40: Stator Inspection Points
BALL BEARING THREADS
Rectifier Bridge
Test the rectifier bridge as follows: 1. The bridge studs are embedded in insulation. To obtain diode readings, the ohmmeter leads must contact the copper strap. 2. Connect the ohmmeter leads to the grounded side and strap as shown and take readings at each strap (Figure 12-41). 3. Repeat step 1 with test leads reversed. 4. All three readings in steps 1 or 2 should read high resistance in one case and low resistance in other case. 5. Connect ohmmeter leads on positive side and strap as shown, and take readings at each strap (Figure 12-41). 6. Repeat process of step 4 with leads reversed. 7. All three readings in steps 4 and 5 should be the same, with resistance high in one set and low in the other set. 8. If any one reading in steps 1, 2, 3, and 4 is not the same as the other two readings, replace rectifier bridge.
SLIP RINGS
Figure 12-39: Rotor Inspection Points
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Electrical System
OHMMETER LEADS
12-25
OHMMETER LEADS GROUNDED SIDE STUDS STRAP
STRAP POSITIVE SIDE
Figure 12-41: Rectifier Bridge Check
Regulator
REGULATOR
NOTE: The pin that retains the brushes temporarily can be made from locally obtained parts. A standard paper clip can be used. Assemble springs and brushes in the brush holder. Compress the springs and brushes in the holder and hold them in position with the temporary pin (pin will be removed after assembly) (Figure 12-43).
Drive End Frame and Bearing

CONTACTS
Figure 12-42: Regulator Inspection Points Inspect the regulator for cracks, breaks, broken contacts, or surface defects and replace if damaged (Figure 12-42).
Inspect the bearing for roughness, looseness in bore, inner race free play, or damaged seals. Replace the end frame and bearing as an assembly if damaged (Figure 12-44).
Brushes and Brush Holders

BRUSH HOLDER TEMPORARY PIN
DRIVE END FRAME
BEARING
BRUSH SPRING
Figure 12-44: Drive End Frame Inspection Inspect the drive end frame for cracks, breaks, or damaged threads. Replace the assembly if casting is cracked or broken. Repair minor through-bolt and adjusting bolt thread damage using a tap. For more serious through-bolt thread damage, replace the end frame.
Figure 12-43: Brush Holder and Brushes Check for broken or disconnected brushes, worn brushes with length less than 0.5 in. (12.7 mm), and broken or distorted springs. Replace brush holder and brushes as an assembly if necessary (Figure 12-43). 05745159
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Fan
Electrical System
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Output Stud Assembly

Inspect the output stud assembly for cracked, or broken insulator, distortion, or damaged threads. Replace the stud assembly if any part is damaged (Figure 12-48).
OUTPUT STUD ASSEMBLY
Inspect the fan for distortion, cracked blades, or broken blades. Minor bending repair is permissible. For broken or missing blade ends, cracks or breaks, replace the fan (Figure 12-45).
FAN BLADE FAN
NUT
STUD
INSULATOR
Figure 12-48: Output Stud Inspection
Pulley
Figure 12-45: Fan Inspection Points
Slip Ring End Frame and Bearing

Inspect the bearing for roughness, looseness in retainer ring, free play, loose inner race, or damaged seals. Replace the bearing if damaged or loose (Figure 12-46).
SLIP RING END FRAME BEARING
Inspect the pulley for distortion, breaks, or sharp edges in the belt grooves. Remove minor burrs and sharp edges with fine tooth file. Replace the pulley if damaged (Figure 12-49).
BELT GROOVES PULLEY
Figure 12-49: Alternator Pulley
Capacitor Strap
Figure 12-46: Slip Ring End Frame Inspect the slip ring end frame for breaks, cracks, evidence of spun ball bearing, or damaged threads. Repair minor thread damage. Replace the end frame if otherwise damaged. Inspect the capacitor strap for breaks, cracks, distorted case, or surface defects. Check capacitor for continuity. Replace if damaged (Figure 12-50).
STRAP CAPACITOR
Collars
Inspect both collars for cracks, bends, or scoring. Replace either part if damaged (Figure 12-47).
THICK COLLAR THIN COLLAR
Figure 12-50: Capacitor Strap Figure 12-47: Fan Spacers 4-1-00
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Electrical System
12-27
Alternator Assembly
1. 2. Install bearing on rotor shaft. Seat bearing against shoulder (Figure 12-38). Assemble springs and brushes in brush holder and retain with fabricated pin. Pin holds brushes compressed in brush holder and will be removed after assembly. Install rectifier bridge in slip ring end frame and install screw, output stud insulator, and nut. Assemble and install brush holder and regulator. Solder connection between brush holder and regulator if either part was replaced. Slide regulator connector strap into regulator contact and solder together. Slip capacitor strap under connector strap and position on rectifier bridge and regulator. Secure capacitor strap with screw and two insulated screws (Figure 12-51).
CAPACITOR STRAP INSULATED SCREWS SCREWS
3. 4.
5. 6.
RECTIFIER BRIDGE
SOLDERED CONNECTION STUD NUT SCREW AND WASHER
Figure 12-51: Rectifier Bridge and Capacitor Strap Location 7. 8. 9. 10. Attach stator leads to rectifier bridge and secure leads with nuts. Install thick collar on rotor shaft (Figure 12-38). Insert rotor shaft through drive end frame and seat bearing against thick collar. Install thin collar, fan, and pulley on rotor shaft and secure with washer and nut. Tighten nut to 40-80 lb-ft (54-109 Nm). Carefully insert rotor through stator and seat ball bearing in slip ring end frame. Be sure drive end frame and stator are aligned and seated. Install through-bolts. Tighten through-bolts evenly to remove any slack. Verify that rotor turns smoothly. Remove brush retaining pin from brush holder. Be sure brushes extend out brush holder and contact slip rings. 4-1-00
11.
12. 13. 14.
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12-28
Electrical System
_______________________________________________________
Alternator Inoperative (No Charge)

Step 1 Action Perform visual inspection on belt, pulleys and battery cables. Is everything in normal operating condition Using a battery load tester, place amp pickup on the alternator fusable link wire. Start and run vehicle at 1500 rpm, load the vehicle batteries with 100 amps for 15 seconds. Does charging system produce equivalent amperage. Perform battery check, refer to battery checking procedure in this section. Are batteries in good condition Using a DVOM set to measure voltage, place the negative lead on a good engine ground. Probe the Batt. terminal on the back of the alternator. Is voltage present? Using a DVOM set to measure resistance, measure resistance between the alternator case and a negative battery connection. Is resistance below specication. Disconnect the positive battery cables, using a DVOM set to measure resistance, measure resistance between the positive battery connection and the Batt. terminal. Is resistance below specication.? Does voltage gauge indicate a low charge condition? Using a DVOM set to measure voltage, and the pink ignition lead disconnected from the alternator, place the negative lead on a good engine ground and the positive lead on the pink ignition lead. Turn the ignition key to on, is voltage present? Check for expanded female terminal in engine harness connector in the alternator ignition feed connector. Is a faulty connection found? 12v 12v >100 amps Value(s) Yes Go to step 2. No Repair and recheck system. go to step 3.
Go to step 7.
Go to step 4.
Replace batteries and recheck charging system. Go to step 5.
Go to step 8.
<.2
Go to step 6.
Locate and repair bad ground connection. Inspect/repair fusible link at alternator Batt terminal. No problem found at this time. Locate and repair open or short to ground in engine ignitionfeedcircuit. Replace the alternator
<.2
Go to step 8.
Replace gauge and check operation. Go to step 9.
Replace female terminal
4-1-00
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Electrical System
12-29
TO POSITIVE BATTERY CABLE
TO EXTERIOR FUSE BOX
ORG
FUSE 3B EXTERIOR 20 AMP
FUSIBLE LINK
TO INTERIOR FUSE BOX
291 PNK
TO LOW COOLANT SENSOR
RED
EXTERIOR POWER BUS

FUSIBLE LINK
C4-3 IGN FEED BATTERY TERMINAL
ALTERNATOR
9-S12-089
Figure 12-52: Alternator Schematic
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12-30
STARTER
Removal
1. 2. 3. 4. 5. 6. 7. 8.
Electrical System
_______________________________________________________
Installation
1. 2. 3. Position shim pack on starter. Position starter in converter housing. Slide starter stud into chassis bracket. Be sure stud nut and washer are behind bracket. 4. Install and tighten starter bolts to 40 lb-ft (54 Nm). 5. Tighten stud nut to 24 lb-ft (33 Nm). 6. Attach starter cable clamp to chassis. 7. Connect solenoid wire to solenoid terminal with clip and screw. Tighten screw to 22 lb-in. (2 Nm). 8. Connect starter cable to starter terminal. Tighten nut to 2531 lb-ft (34-42 Nm). 9. Cover starter terminal and solenoid terminal with silicone sealer. 10. Install converter housing covers. 11. Connect battery negative cable.
STARTER SHIM PACK SOLENOID STARTER STUD CHASSIS BRACKET
Disconnect battery negative cable(s) and winch negative cable, if equipped. Remove converter housing cover. Remove cap and/or adhesive sealant from starter terminal (Figure 12-53). Disconnect starter cable or cables from starter terminals (Figures 12-53 and 12-54). Disconnect solenoid wire from solenoid. Remove starter cable clamp. Loosen locknut and washer securing stud at front of starter to bracket. Have helper support starter and remove starter bolts. Then lower and remove starter and shim (if used).
SOLENOID WIRE
CLIP STARTER BOLT CLAMP
TERMINAL
STARTER CABLE
Figure 12-53: Starter Mounting
4-1-00
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Electrical System
12-31
SOLENOID CONNECTOR FRAME
STARTER CABLES (FROM BATTERY) END PLATE
ARMATURE SHAFT FELT WICK
SPACER TO GLOW PLUG CONTROLLER SOLENOID WIRE THRUST WASHER GASKET SCRIBE MARK SOLENOID CONNECTOR SCRIBE MARK SOLENOID
Figure 12-54: Starter Connections
STARTER OVERHAUL
Disassembly
1. 2. Remove starter. Remove plug and gasket from pinion housing (Figure 12-55). 5. 6. 7. 8. 9. 10.
Figure 12-56: End Plate Removal Remove solenoid screws and remove solenoid. Scribe alignment marks on end plate and frame. Remove end plate bolts and remove end plate and gasket. Remove thrust washer and spacer from armature shaft. Remove felt wick from end plate. Scribe alignment marks on pinion housing and frame (Figure 12-57).
PINION HOUSING
GASKET PLUG
PINION HOUSING
FRAME
LOCKNUT CORE SHAFT SOCKET HOLDING TOOL SOCKET HEX WRENCH SCRIBE MARK GASKET O-RING SCRIBE MARK
Figure 12-57: Frame Removal 11. Remove screws attaching pinion housing to frame. 12. Remove frame, gasket, and O-ring from pinion housing. 13. Remove two plugs and pin from pinion housing and shift lever (Figure 12-58).
Figure 12-55: Core Shaft Nut Removal 3. Remove core shaft nut with socket, fabricated socket holding tool, and hex wrench (Figure 12-55). Holding tool can be fabricated from suitable size square tube. Or, a suitable size thin wall, deep socket can be used. Remove connector nuts and remove solenoid connectors from frame assembly and solenoid (Figure 12-56).
4.
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12-32
PINION HOUSING PIN
Electrical System
_______________________________________________________
SHIFT LEVER
FIELD COIL BRACKET POSITIVE BRUSH LEAD
FRAME
SNAP RING PINION STOP CLUTCH PLUG (2)
NEGATIVE BRUSH LEAD SPRING ARMATURE GASKET ARMATURE PLATE BRUSH HOLDER
Figure 12-60: Brush and Holder Removal/Installation 20. Remove screws and positive brush leads from field coil brackets. Then remove brushes from holders. 21. Remove springs from brush holders. 22. Remove nut and lockwasher assemblies and rubber washers from solenoid housing. Discard rubber washers (Figure 12-61).
SERIES WINDING LEAD COVER ARMATURE PLATE SHIFT LEVER PINION HOUSING GASKET
Figure 12-58: Starter Drive Disassembly 14. Clamp pinion housing in vise and remove screws from end plate and pinion housing (Figure 12-59). 15. Slide armature, end plate, and shift lever out of pinion housing.
ARMATURE
LUG
SOLENOID HOUSING
Figure 12-61: Solenoid Housing Disassembly/Reassembly Figure 12-59: Armature Removal/Installation 16. Remove snap ring and pinion stop from armature shaft, and slide clutch off armature shaft (Figure 12-58). 17. Remove washer and plate from armature shaft (Figure 12-58). 18. Remove gasket from armature plate. 19. Remove nuts, lockwashers, screws, copper washers, and negative brush leads from frame. Remove brushes from brush holders (Figure 12-60). 23. Pull cover away from solenoid housing and remove screw and washer from lug on cover and series winding lead. 24. Remove cover and gasket from solenoid housing. 25. Holding core shaft, remove locknut, washer, and contact from core shaft (Figure 12-62). 26. Remove and separate spring from core shaft and washer. 27. Remove snap ring, spring retainer, spring, spring retainer, rubber boot, and washer from core shaft (Figure 12-62).
4-1-00
______________________________________________________
Electrical System
12-33
Inspection
SOLENOID HOUSING SPRING CONTACT
BOOT
CORE SHAFT
SNAP RING SPRING RETAINER SPRING SPRING RETAINER
Figure 12-62: Solenoid Components
Inspect clutch for broken spring, damaged gear or splines, and non-lockup. Replace clutch if damaged (Figure 12-63). Inspect brushes for cracks, roughness, galling, wear, or damaged lead. If one brush length is less than 0.315 in. (8 mm) or has other damage, replace all brushes as a set. Inspect springs for breaks, distortion, or other damage. Replace any damaged springs. Inspect bearings in head end and pinion housing for cracks, roughness, galling, or damage. Replace bearings if defective (Figure 12-63). Inspect pinion housing for cracks, damaged pinion bearing, and damaged threads. Repair minor thread damage. Replace starter if otherwise damaged. Inspect commutator for damage due to arcing (burned spots and pitting), damaged shaft, splines, or threads. Replace starter if commutator is damaged. Test armature, field coils, and brush holders for shorts, grounds, and open circuits with an armature tester. Replace starter if any one of these parts is defective. Inspect core spring, core shaft, and rubber boot for damage. Replace parts if damaged (Figure 12-64). Inspect contact for burns or damage. Replace contact if burned or damaged. Inspect housing of frame assembly, head end, and solenoid housing for cracks or damage. Replace starter if any part is damaged (Figures 12-64 and 12-65).
BEARING
BRUSH HOLDER
FIELD COIL
FRAME ASSEMBLY
END PLATE
SPRING BRUSH
PINION HOUSING ARMATURE CLUTCH SPLINES GEAR BEARING (IN HOUSING)
COMMUTATOR
Figure 12-63: Starter Components
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12-34
Electrical System
_______________________________________________________
SOLENOID HOUSING CORE SPRING
CONTACT
16. Install O-ring and gasket in pinion housing (Figure 12-66). 17. Coat end plate-to-frame screws with adhesive sealant. CAUTION: As armature is inserted into frame assembly, carefully align brushes on commutator. Brushes chip and break easily. 18. Align scribe marks on frame and pinion housing, and install armature and pinion housing in frame assembly. Install and tighten screws to 50 lb-in. (6 Nm). 19. Saturate felt wick with engine oil and install in end plate (Figure 12-65).
GASKET SCRIBE MARK
SPRING RUBBER BOOT CORE SHAFT
Figure 12-64: Solenoid Components
SCRIBE MARK
SPACER
Starter Assembly
1. Assemble washer, rubber boot, spring retainer, spring, and spring retainer on core shaft and secure with snap ring (Figure 12-61). Place core shaft assembly in solenoid housing. Install washer, spring, contact, washer and locknut on core shaft. Place gasket on cover and secure series winding lead to lug with screw and washer (Figure 12-61). Install cover and gasket on solenoid housing and secure with four rubber washers and nut and lockwasher assemblies. Install negative brushes and positive brushes in brush holders and retain with four springs (Figure 12-60). Connect positive brush leads to field coil brackets with two screws. Connect negative brush leads to frame with copper washers, screws, lockwashers, and nuts. Cover negative lead screw heads with silicone adhesive sealant. Apply chassis grease to armature shaft, shift lever studs, groove of clutch, and inside diameter of end plate (Figure 12-63). Place washer, end plate, and gasket on armature shaft. Place washer, clutch, and pinion stop on armature shaft and retain with snap ring. Position armature and shift lever in position shown for installation (Figure 12-59). Install shift lever on clutch with shift lever studs engaged in clutch groove. Start shift lever into pinion housing as armature is positioned in large bore of pinion housing. Then install screws through armature plate into pinion housing. Tighten screws to 40 lb-in. (5 Nm) (Figure 12-59). Insert pin through pinion housing and shift lever. Then install two plugs in pinion housing (Figure 12-58).
2. 3. 4. 5.
FRAME ASSEMBLY THRUST WASHER(S) FELT WICK END PLATE
Figure 12-65: Starter End Plate Installation 20. Install spacer and thrust washers on armature shaft. 21. Align scribe marks on end plate and frame and install end plate. Tighten end plate screws to 25 lb-in. (3 Nm). 22. Coat threads of end plate screws with adhesive sealant. 23. Install end plate screws. 24. Check end play as described in following procedure. 25. Coat ribbed area of core shaft boot with lithium grease (Figure 12-67). 26. Align end of core shaft in hole in shift lever and install solenoid on frame. Tighten solenoid screws to 50 lb-in. (6 Nm). 27. Install core shaft nut. Tighten nut with socket, fabricated tool, and hex wrench (Figure 12-55)
6. 7. 8. 9. 10.
11. 12.
13. 14.
15.
4-1-00
______________________________________________________
Electrical System
12-35
FRAME PINION HOUSING ARMATURE
BRUSHES
GASKET O-RING COMMUTATOR SCRIBE MARK
SCRIBE MARK
COMMUTATOR
Figure 12-66: Assembling Frame, Armature, and Pinion Housing

BOOT (COAT WITH GREASE) SOLENOID
Starter Pinion Clearance

Adjustment
1. Connect battery and jumper to starter as shown (Figure 12-68). Momentarily touch jumper to solenoid frame to shift pinion into cranking position.
CORE SHAFT
FRAME JUMPER WIRE
Figure 12-67: Solenoid Boot Installation
Figure 12-68: Battery and Jumper Connections for Pinion Clearance Check 2. 3. 4. Check clearance between pinion and snap ring with feeler gauge (Figure 12-69). Disconnect battery. Pinion clearance should be 0.005-0.030 in. (0.127-0.762 mm). If adjustment is necessary, remove end plate and add or remove thrust washer(s) (Figure 12-69).
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12-36
Electrical System
MEASURE CLEARANCE HERE WITH FEELER GAUGE
_______________________________________________________
ARMATURE SHAFT ADD OR SUBTRACT THRUST WASHERS TO ADJUST CLEARANCE END PLATE
PINION HOUSING
Figure 12-69: Starter Pinion Clearance Measurement and Adjustment
Starter Test
1. Connect voltmeter, ammeter, switch and battery to starter as shown (Figure 12-70).
SWITCH
CAUTION: Do not operate the starter motor for more than 10 seconds at a time. Allow the starter motor to cool at least 2 minutes between tests to avoid overheat damage.
WARNING: Starter must be secured to prevent movement from start up torque. Test cables must be of a sufcient gauge size to conduct starter current.
2. Close switch, adjust voltage to 9.5 volts on voltmeter using carbon pile. Check rotating speed of armature with tachometer. Read current draw on ammeter. Maximum current draw should be 65 amps with a minimum armature speed of 5000 rpm. If a low speed, high current condition exists, check armature for shorts or grounds. If a low speed, low current draw exists, inspect starter motor for bad connections or poor brush contact.
VOLTMETER CARBON PILE
3.
STARTER MOTOR
AMMETER
12 VOLT BATTERY
Figure 12-70: Starter Test Connections
4-1-00
______________________________________________________
Electrical System
12-37
Starter Inoperative
Step 1 Action Inspect battery condition and charge (Refer to battery checking procedure this section). Are batteries in good working condition and charged? Using a DVOM set to measure voltage, place the ground lead on a known good ground, and the positive lead on the large blue wire at the starter solenoid (CKT34).Have a helper turn the key to start. Does the meter display adequate voltage? Using a DVOM set to measure resistance, measure resistance between starter body and ground terminal at the batteries. Does resistance meet specications? Locate the start relay attached to the exterior fuse box bracket.Using a DVOM set to measure voltage Back probe the 10 ga. lt.blue wire (CKT34). Rotate the ignition to start. Is voltage present? 12v Value(s) Yes Go to step 2 No Recharge/Replace batteries as necessary Go to step 3
Repair or replace starter and/or solenoid as necessary
<.2
go to step 4
Repair open or bad connection in ground circuit between starter and batteries Go to step 5
12v
Repair open or short to ground in CKT34 between the start relay and the starter solenoid. Go to step 6
Using a DVOM set to measure voltage, place the ground lead on a known good ground, and the positive lead on the 10 ga. yel wire(CKT37) at the start relay.Is voltage present ? Using a DVOM set to measure voltage, place the ground lead on a known good ground, and the positive lead on the small light blue wire at the start relay (CKT32). Rotate the ignition to start. Does the meter display adequate voltage? Using a DVOM set to measure ohms, place the negative lead on a known good ground and probe the black wire at the start relay(CKT59). With the ignition switch off, does resistance read below specied? Disconnect the white wire (CKT33) at the shifter under the vehicle. Using a DVOM set to measure voltage, place the negative lead on a known good ground, and the positive lead on the white wire (CKT33) on the vehicle body harness. Have a helper rotate the key to start. Is adequate voltage displayed? Disconnect the blue wire(CKT32)at the shifter housing. Tag leads for installation. Using a DVOM set to measure ohms, measure resistance across the neutral safety switch. Is resistance below specication?
12v
Repair open or short to ground in CKT37 be-tween start relay and batteries. Go to step 8
12v
Go to step 7
<.2
Replace Start Relay.
Repair open or bad connection in CKT59 between start relay and ground. Go to step 11
12v
Go to step 9
<.2
Go to step 10
Replace neutral safety switch and recheck.
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12-38
Electrical System
_______________________________________________________
Starter Inoperative (Continued)

Step 10 Action Repair open or bad connection in CKT32 between neutral saftey switch and start relay. Is condition repaired Remove lower cover of steering column to access the ignition switch connector. Back probe the white wire (CKT33) with the positive lead of a DVOM set to measure voltage. Place the ground lead on a known good ground. Turn the ignition switch to crank. Is voltage present? Using a DVOM set to measure voltage, place the negative lead on known good ground and backprobe the yellow wires (CKT37) at the ignition switch connectors. Is voltage present? 12v Value(s) Yes Repair complete No Go to step 1.
11
Repair open or short to ground in CKT33 between Ignition switch and the neutral saftey switch. Replace ignition switch.
Go to step 12
12
12v/12v
Repair open or short to ground in CKT37 between maxi fuse and Ignition switch.
4-1-00

______________________________________________________
Electrical System
12-39
MAXIFUSE #1 40A EXTERIOR NEUTRAL SAFETY SWITCH C2-12 33 WHT C2-13
32 LT BLU
37 YEL
C1-6
STARTER RELAY
IGNITION SWITCH
32 LT BLU
58 BLK
C1-7
C4-1 MAXIFUSE #8 40A EXTERIOR STARTER SOLENOID
TO BATTERY
9-S12-087.2
Figure 2-71: Starter System Schematic
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12-40
Electrical System
_______________________________________________________
Glow Plugs Inoperative

Step 1 Action Before clearing any DTCs, use the scan tool Capture Info to save the Freeze Frame and Failure Records for reference. The PCMs data is deleted once the Clear Info function is used. Did you perform the On-Board Diagnostic (OBD) System Check? If DTC P0380 is set after a PCM reash. Connect a scan tool. Turn the ignition ON leaving the engine OFF. Observe the Glow Plug System Type parameter on the scan tool. Does the scan tool display the Glow Plug System Type as California? Value Yes Go to step 2. No
Go to step 3.
Go to (LINKGO TOREPAIR609502) Glow Plug System Type Relearn
Connect a scan tool. Turn the ignition ON leaving the engine OFF. Use the scan tool to command the glow plugs ON and OFF. Observe the Glow Plug System Type parameter on the scan tool. Does the digital multimeter (DMM) display a voltage near the rst specied value with the glow plug commanded ON and near the second specied value with the glow plug commanded OFF? Does the scan tool display a glow plug voltage greater than the specied value? Does the scan tool display a glow plug voltage greater than the specied value? Turn the ignition ON leaving the engine OFF. Touch the battery feed stud on the glow plug controller with an unpowered test lamp connected to ground. Is the test light ON? The DTC is intermittent. If any additional DTCs were stored, refer to those table(s). Were there any additional DTCs stored? Disconnect the glow plug relay control connector. Turn the ignition ON with the engine OFF. With an unpowered test lamp connected to ground, probe the glow plug relay harness ignition feed circuit (CKT 239 PK). Is the test light ON? Turn the ignition ON with the engine OFF. Connect an unpowered test lamp to B+, probe the glow plug relay ground circuit (BK). Is the test light ON?
5.0-5.6 Volts
Go to step 7.
Go to step 4.
0.9-1.5 Volts
4 5 6
5.6 Volts 0.3 Volts
Go to step 10.
Go to step 17.
4-1-00
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Electrical System
12-41
Glow Plugs Inoperative (Contd)

Step 10 Action Turn the ignition ON with the engine OFF. Verify that the glow plug relay control harness is disconnected. With a DMM connected to ground, probe the glow plug relay control circuit (466 YL) at the glow plug relay harness connector. Use a scan tool to command the glow plugs ON and OFF. Does the DMM display a voltage near the rst specied value with the glow plugs commanded ON and near the the second specied voltage with glow plugs commanded OFF? Is the voltage equal to or more than the specied value all the time? Turn the ignition ON leaving the engine OFF. Recconect the glow plug relay control harness. With a DMM connected to ground, backprobe the glow plug relay signal circuit (506 LB) at the PCM harness connector. Use a scan tool to command the glow plugs ON. Observe the DMM while the glow plugs are commanded ON. Is the voltage at the specied value? Turn the ignition OFF. Disconnect the right and left bank glow plug output circuit connectors at the glow plug relay. With an unpowered test lamp connected to B+, probe each circuit. Does each circuit turn ON the test lamp? Turn the ignition OFF. Disconnect each glow plug connector at the glow plug that did not illuminate the test lamp. With an unpowered test lamp connected to B+, probe the terminal on the glow plug. Does each glow plug illuminate the test lamp? Turn the ignition OFF. Disconnect each glow plug connector at the glow plug. With an unpowered test lamp connected to B+, probe each circuit at the glow plug output connectors. Is the test lamp OFF at each of the circuits? Repair an open or a short to ground in the glow plug relay ignition feed circuit (CKT 239 PK). Did you complete the repair? Repair any opens or poor connections in the glow plug relay ground circuit (BK). Did you complete the repair? Inspect the glow plug relay control circuit (466 YL) for an open or short to ground. If the glow plug relay control circuit is open or shorted to ground, repair as necessary. Did you nd and correct the condition? Value 9-12 Volts 0 volts Yes Go to step 12. No Go to step 11.
11 12
1.0 Volt 5.0-5.6 Volts
13
Go to step 26.
Go to step 14.
14
Go to step 26.
Go to step 25.
15
Go to step 20.
Go to step 27.
16
Go to step 30.
17
Go to step 30.
18
Go to step 30.
Go to step 19.
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12-42
Electrical System
_______________________________________________________

Step 19 Action Inspect the glow plug relay control circuit (CKT 466 YL) for a proper connection at the PCM and replace the terminal if necessary. Did you nd an improper connection and make the necessary repair? Inspect the glow plug relay signal circuit (CKT 506 LB) for an open or short to ground. If the glow plug relay signal circuit is open or shorted to ground, repair as necessary. Did you nd and correct the condition? Inspect the glow plug relay signal circuit (CKT 506 LB) for a proper connection at the PCM and replace the terminal if necessary. Did you nd an improper connection and make the necessary repair? Test for a short to voltage in the glow plug relay signal circuit (CKT 506 LB). Did you nd the improper condition? Test for a short to voltage in the glow plug relay control circuit (CKT 466 YL) . Did you nd and correct the condition? Repair the open or poor connection on the battery feed circuit. Did you complete the repair? Replace any glow plug that did not illuminate the test lamp. Did you complete the repair? Repair the open or poor connections in the glow plug harness. Did you complete the repair? Repair the short to ground in the glow plug harness. Did you complete the repair? Replace the glow plug relay. Did you complete the repair? THE NEW PCM MUST BE PROGRAMMED.Replace the PCM. Did you complete the repair? Value Yes Go to step 30. No Go to step 29.
20
Go to step 30.
Go to step 28.
21
Go to step30.
Go to step 22.
22
Go to step 30.
Go to step 28.
23
Go to step 30.
Go to step 29.
24
Go to step 30.
25
Go to step 30.
26
Go to step 30.
27
Go to step 30.
28 29
4-1-00
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Electrical System
12-43

Step 30 Action Use a scan tool to clear the DTCs. Start the engine. Allow the engine to idle until the engine reaches normal operating temperature. Select the DTC and the specic DTC function. Enter the DTC number which was set. Operate the vehicle, with the Conditions for Setting this DTC, until the scan tool indicates the diagnostic Ran. Does the scan tool indicate the diagnostic Passed? Does the scan tool display any addition undiagnosed DTCs? Value Yes Go to step 31. No Go to step 2.
31
System OK.
C9-J
C3-N7 #1 #3 #5 #7

C5-A4
239 PK

30 GY
FUSIBLE LINK
GLOW PLUGS LH
D IGN POWER BATT +
TO IGNITION SWITCH
LEFT BANK OUTPUT
A B
RH STATUS CENTER
C
WAIT
RIGHT BANK OUTPUT
GLOW PLUG RELAY
D
#2 #4 #6 #8
C
C9-A
C3-D1
GLOW PLUGS RH
C5-C11
C5-B4
C1-27
506 LB 466 YL
G1
C28-C7
338 DB
BK
00-S12-011
Figure 2-72: Glow Plug Control Circuit Schematic
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12-44
Electrical System
_______________________________________________________
Fuel Lift Pump Inoperative VIN Z

Step 1 Action Important: Before clearing the DTCs use the scan tool Capture Info in order to record the Freeze Frame and the failure records for reference, as the data will be lost when the clear function is used. Was the On-Board Diagnostic (OBD) System Check performed? 2 Turn the ignition OFF for 10 seconds. Turn the ignition ON. Does the fuel pump operate during the glow plug cycle? Disconnect the fuel lift pump connector. Using a DVOM set to measure voltage, place the ground lead on a known good ground, and the positive lead on the grey wire (CKT787) at the fuel lift pump engine harness connector. Turn the ignition OFF for 10 seconds. Turn the ignition ON. Is voltage present? Place ground lead of DVOM on the black wire (CKT57) at the fuel lift pump engine harness connection.With the positive lead still on the grey wire (CKT787) Turn the ignition OFF for 10 seconds. Turn the ignition ON. Is voltage present? Reconnect the fuel lift pump, Disconnect the fuel lift pump relay. Using a DVOM set to measure voltage, place the ground lead on known good ground, and place the positive lead on the org wire (CKT537). Is voltage present? Place the ground lead of the DVOM set to measure voltage on the black wire (CKT57). With the positive lead still on the org wire (CKT537). Is voltage present? 12v System OK, problem may be intermittent. Go to step 4. Go to step 3. Value(s) Yes Go to step 2. No Go to Powertrain OBD system check.
Go to step 5.
12v
Replace fuel lift pump.
Go to step 5.
12v
Go to step 6.
Repair open or short to ground in CKT537 between fuel pump relay and fuse 2D. Repair open or short to ground in CKT57 between fuel pump relay and engine ground. Go to step 8.
12v
Go to step 7.
Using a DVOM set to measure voltage, place the ground lead on the black wire (CKT57)on the fuel lift pump relay connection. Place the positive lead on the dark green wire (CKT238). Turn the ignition OFF for 10 seconds. Turn the ignition ON. Is voltage present? Reconnect the fuel lift pump relay. Using the scan tool, command the fuel pump relay on. Does the pump run?
12v
Replace the fuel lift pump relay.
12v
Check for open in CKT787 between the fuel lift pump relay and the PCM 32pin xxxx connector pin D5.
Go to step 9.
4-1-00
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Electrical System
12-45
Fuel Lift Pump Inoperative VIN Z (Contd)

Step 9 Action Disconnect fuel lift pump relay.Using a DVOM set to measure ohms, measure resistance between C27-D5, and the fuel lift pump relay dark green wire (CKT238). Does resistance exceed specications? Using a DVOM set to measure ohms, measure continuity to ground between the dark green wire(CKT238) and engine ground. Is continuity present? Replace PCM. Is repair complete? Turn the ignition OFF for 10 seconds. Turn the ignition ON. Does the fuel pump operate during the glow plug cycle? Value(s) <.2 Yes Repair open or bad connection in CKT 238 between PCM and fuel lift pump relay. Repair short to ground in CKT238. Go to step 12. Repair completed. Go to step 1. No Go to step 10.
10
Go to step 11.
11 12
05745159
4-1-00
12-46
Electrical System
_______________________________________________________
FUSE 2D 20A INTERIOR C1-10
537 OR
FUEL PUMP RELAY EXTERIOR FUSE BOX
TO FUEL SELECTOR SWITCH
787 GY G2
787 GY
787 GY
57 BK
C27-D5
FUEL LIFT PUMP SIGNAL
C27-D8
FUEL PUMP RELAY CONTROL
B FUEL LIFT PUMP
A 57 BK 9-S12-051 G2
Figure 2-73: Fuel Lift Pump Schematic 4-1-00
238 DG
______________________________________________________
Electrical System
12-47
Fuel Tank Selector System Inoperative (No Tank Switch)

Step 1 Action Important: Before clearing the DTCs use the scan tool Capture Info in order to record the Freeze Frame and the failure records for reference, as the data will be lost when the clear function is used. Was the On-Board Diagnostic (OBD) System Check performed? 2 Turn the ignition OFF for 10 seconds. Turn the ignition ON. Does the fuel pump operate during the glow plug cycle? Remove fuel tank selector switch from dash, and disconnect switch from harness. Using a DVOM set to measure resistance, probe the black wire of the fuel selector switch connector (CKT 59) with the black lead, and the positive lead on the ground studs at left of dash.Is resistance below specication? Using a DVOM set to measure voltage, place the ground lead on the negative studs to right of the IP panel. Place the positive lead on the grey wire (CKT 787) at the fuel tank selector switch. Turn the ignition OFF for 10 seconds. Turn the ignition ON. Does the meter read voltage? Re-connect fuel tank selector switch. Using a DVOM set to measure voltage, backprobe the red wire (CKT 786) with the negative lead and brown wire (CKT 789) with the positive lead.Turn the ignition OFF for 10 seconds. Turn the ignition ON. With the switch in the AUX position voltage should be present, when the switch is moved to the MAIN position, reverse polarity voltage should be present. If fuel pump shuts off during test, repeat cycle of key. Does meter show opposite voltages when moved between AUX and MAIN Disconnect fuel selector valve electrical connection. Using a DVOM set to measure voltage, probe the brown wire with the positive lead, and the red lead with the negative lead. Turn the ignition OFF for 10 seconds. Turn the ignition ON. With the switch in the AUX position voltage should be present, when the switch is moved to the MAIN position, reverse polarity voltage should be present. Does meter show opposite voltages when moved between AUX and MAIN <.2 Go to step 3. Diagnose Fuel lift pump rst. Repair open or bad connection in CKT 59 between fuel selector switch and IP ground studs. Repair open or short to ground in CKT 787 fuel pump relay and fuel selector switch Replace fuel tank selector switch and recheck system. Value(s) Yes Go to step 2. No Go to Powertrain OBD system check.
Go to step 4
12 v
Go to step 5
12 v+=AUX 12 v-=MAIN
Go to step 5.
12 v+=AUX 12 v-=MAIN
Replace fuel selector valve
Go to step 7.
05745159
4-1-00
12-48
Electrical System
_______________________________________________________
Fuel Tank Selector System Inoperative (No Tank Switch)

Step 7 Action Relocate the ground lead of the DVOM set to measure voltage to a known good ground. Turn the ignition OFF for 10 seconds. Turn the ignition ON, and the tank selector switch in the AUX position, probe the brown wire (CKT 789) with the positive meter lead. Is voltage present? Value(s) 12 v Yes Go to step 8. No Repair open, bad connection or short to ground in CKT 789 between the fuel selector switch and valve. Repair open, bad connection or short to ground in CKT 786.
Turn the ignition OFF for 10 seconds. Turn the ignition ON, and the tank selector switch in the MAIN position, probe the red wire (CKT 786) with the positive meter lead, the ground lead should be on a know good ground. Is voltage present?
12 v
No electrical problems found, problem may be intermittent or mechanical.
4-1-00
______________________________________________________
Electrical System
12-49
M7
36
786 RD
M6
75
37
789 BR
C3
C1
C2
Training 8F
3 1 6 4
TANK TANK CHANGE CHANGE CONTROL CONTROL FUEL SELECTOR SWITCH MAIN TANK AUX TANK FUEL LEVEL FUEL LEVEL FUEL LEVEL SIGNAL OUT SIGNAL SIGNAL 5B 787 GY 59 BK 2B C26-C C3-N6 PCM C3-M8 G4 C1-11 C27-D8 238 DG TO FUEL LIFT PUMP G4 C1-35 FUEL G GAUGE 673 DB 675 YL L 17 PP I S C2-35 30 GY C3-P7 29 PK TO DIMMER MODULE A MAIN TANK FUEL LEVEL SENDING UNIT C1-10 B C26-A G2 AUX TANK FUEL LEVEL SENDING UNIT 9-S12-057 HOT AT ALL TIMES G2 C26-B TO GAUGE FUSE FUEL SELECTOR VALVE
85
87 87A
FUEL LIFT PUMP RELAY

86 59 BK 30 537 OR
EXTERIOR FUSE BOX
Figure 2-74: Fuel Selector Valve Schematic 05745159 4-1-00
59 BK
FUSE 2D 20A INTERIOR FUSE BOX
C38-C
C26
12-50
Electrical System
_______________________________________________________
DRAIN FILTER
C9-D C3-F4 C1-45 327 YL
TO IGNITION SWITCH
291 PK B A WATER IN FUEL SENSOR C FUEL HEATER
C A 57 BK 57 BK G2
9-S12-154
Figure 2-75: Fuel Manager Schematic 4-1-00
______________________________________________________
Electrical System
12-51
IGNITION SWITCH REPLACEMENT

Removal
1. 2. 3. 4. Remove steering column covers. Remove multi switch. Remove screw and interlock cable from ignition switch (Figure 2-76). Remove two capscrews and ignition switch from steering column.
Brake Shift Interlock Cable System Description (Figure 2-76)

The purpose of the brake shift interlock cable is to prevent a driver from engaging a transmission gear before the brakes are applied. When the brake pedal is depressed, voltage from the brake switch de-energizes the interlock solenoid and the cable relaxes. The transmission shift lever can then be pulled out of the park position. If electrical power is lost due to a dead battery or system failure, the solenoid defaults to the open position. With the brake/shift interlock solenoid in the open position the shifter may be moved to any position.
Installation
1. Apply thread-locking compound to capscrew threads and install ignition switch on steering column with two capscrews. Install interlock cable on ignition switch with screw. Install multi switch. Install steering column covers. Ensure ignition switch operates properly.
2. 3. 4. 5.
SOLENOID
Figure 2-76: Brake Shift Interlock Cable
Brake Shift Interlock Cable Inoperative

STEP 1 ACTION Gain access to the brake/shift interlock solenoid. Using a DVOM check for ground on the black wire (CKT 59). Does the resistance meet the specications? With the ignition switch in the run position check the voltage at the tan wire (CKT 83). Is the specied voltage present? VALUES <.2 YES Go to step 2. NO Repair the open or bad connection in CKT 59 between the interlock solenoid and G4. Repair the open or bad connection in CKT 83 between the interlock cable and fuse 1C in the interior fuse box. Go to step 4.
12v
Go to step 3.
With the ignition switch in the run position and the brake switch applied check the voltage at the red wire (CKT 22) on the brake shift interlock solenoid. Is the specied voltage present? Gain access to the brake switch. With a DVOM check the voltage at the orange wire (CKT 10). Is the specied voltage present?
12v
Replace the brake shift interlock cable. Replace the brake switch.
12v
Repair the open or bad connection on CKT 10 between the brake switch and fuse 4D.
05745159
3-1-01
12-52
Electrical System
_______________________________________________________
INTERLOCK CABLE SOLENOID
22 RD
59 BK
G4
BRAKE SWITCH
10 OR
INTERIOR FUSE BOX

FUSE 4D 15 AMP INTERIOR FUSE BOX FUSE 1C 5 AMP INTERIOR FUSE BOX
TO BATTERY
TO IGNITION
9-S12-001
Figure 2-77: Shift Interlock Cable Schematic
4-1-00
83 TN
______________________________________________________
Electrical System
12-53
CTIS Compressor Inoperative

Step 1 Action Using a DVOM set to measure voltage, probe the terminals on the CTIS compressor. With the CTIS compressor switch set to inate, and the ignition on, is voltage present? Move the ground lead to a known good ground and the positive lead still on the compressor, ignition on, compressor switch on inate. Is voltage present? Remove compressor relay from the exterior fuse box. Using a DVOM set to measure voltage, Probe cavity 1(CKT46) of the CTIS compressor relay socket with the positive lead, and cavity 2(CKT59) with the negative lead. Ignition on, CTIS compressor switch to on, is voltage present? Using a DVOM set to measure voltage, check continuity to ground at cavity 2 of the compressor relay socket. Is resistance below specication? Value(s) 12v Yes Replace the compressor No Go to step 2.
12v
Repair open or bad connection in CKT57 between compressor and G2. Go to step 7.
Go to step 3.
12v
Go to step 4.
<.2
Go to step 5.
Repair open or bad connection in CKT59 between compressor relay and G2. Go to step 6.
Remove compressor switch from the dash. Using a DVOM set to measure voltage. Ignition on, compressor switch set to inate. Check for voltage on white wire(CKT46). Is voltage present?
12v
Repair open or bad connection in CKT46 between compressor switch and relay. Replace the compressor switch.
Using a DVOM set to measure voltage, turn the ignition on. Check for voltage at both orange wires(CKT640) at the rear of the compressor switch. Is voltage present?
12v
Repair open, bad connection or short in CKT640 between compressor switch and fuse 1G. Repair open, bad connection, or short in CKT437 between relay and compressor. Repair open, bad connection or short in CKT436 between compressor relay and Maxi fuse#6. 4-1-00
Using a DVOM set to measure continuity measure continuity between cavity 5(CKT437) of the compressor relay socket and the green wire(CKT437) at the compressor. Is resistance below specications? Using a DVOM set to measure voltage, place the positive lead in cavity 3 (CKT436) of the compressor relay. Place the ground lead in cavity 86(CKT59). Is voltage present?
<.2
Go to step 8.
<.2
Replace the compressor relay.
05745159
12-54
Electrical System
_______________________________________________________
CTIS Exhaust Valve Inoperative

Step 1 Action Disconnect exhaust solenoid. Using a DVOM set to measure voltage, probe the light green wire(CKT47) with the positive lead, and the black wire(CKT57) with the negative lead. Ignition on, move the compressor switch to deate. Is voltage present? Check continuity to ground on the black wire(CKT57) at the exhaust solenoid. Is resistance below specication? Value(s) 12v Yes Replace exhaust solenoid. No Go to step 2.
<.2
Go to step 3.
Repair open or bad connection in CKT57 between exhaust solenoid and G2. Repair open, bad connection or short in CKT640 between compressor switch and fuse 1G. Replace compressor switch.
Remove compressor switch. Using a DVOM set to measure voltage, check for voltage at both orange wires (CKT640). With ignition on is voltage present?
12v
Go to step 4.
Using a DVOM set to measure voltage, check for voltage at the light green wire(CKT47) with the ignition on and compressor switch to deate. Is voltage present?
12v
Repair open bad connection or short in CKT 47 between compressor switch and exhaust solenoid.
4-1-00
______________________________________________________
Electrical System
12-55
CTIS Front Inflate Valve Inoperative

Step 1 Action Disconnect front inate solenoid. Using a DVOM set to measure voltage connect the positive lead to the tan wire(CKT91), and the negative lead to the black wire(CKT57). With the ignition on, selector switch set to both, and the compressor switch to inate, is voltage present? Check continuity to ground on the black wire(CKT57) at the front inate solenoid. Is resistance below specication? Value(s) 12v Yes Replace front inate solenoid. No Go to step 2.
<.2
Go to step 3.
Repair open or bad connection in CKT57 between front inate valve and G2. Go to step 4.
Remove selector switch and compressor switch from the I/P. Using a DVOM set to measure voltage, ignition on, and compressor switch set to inate. Check for voltage on both yellow wires(CKT144) at rear of selector switch. Is voltage present. Ignition on, compressor switch on inate, check for voltage on yellow wires(CKT144)at rear of compressor switch. Is voltage present?
12v
Go to step 6.
12v
Repair open, bad connection or short in CKT144 between compressor switch and selector switch. Replace compressor switch.
Go to step 5.
Ignition on, check for voltage at both orange wires(CKT640) at back of compressor switch. Is voltage present?
12v
Repair open, bad connection or short in CKT640 between compressor switch and fuse 1G. Replace the selector switch.
Ignition on, compressor switch set to inate, selector switch set to both. Check for voltage at the tan wire(CKT91) at the back of the selector switch. Is voltage present?
12v
Repair open, bad connection, or short in CKT91 between selector switch and front inate valve.
05745159
4-1-00
12-56
Electrical System
_______________________________________________________
CTIS Rear Inflate Valve Inoperative

Step 1 Action Disconnect front inate solenoid. Using a DVOM set to measure voltage connect the positive lead to the grey wire(CKT92), and the negative lead to the black wire(CKT57). With the ignition on, selector switch set to both, and the compressor switch to inate, is voltage present? Check continuity to ground on the black wire(CKT57) at the rear inate solenoid. Is resistance below specication? Value(s) 12v Yes Replace rear inate solenoid. No Go to step 2.
<.2
Go to step 3.
Repair open or bad connection in CKT57 between rear inate solenoid and G2. Go to step 4.
Remove selector switch and compressor switch from the I/P. Using a DVOM set to measure voltage, ignition on, and compressor switch set to inate. Check for voltage on both yellow wires(CKT144) at rear of selector switch. Is voltage present. Ignition on, compressor switch on inate, check for voltage on yellow wires(CKT144)at rear of compressor switch. Is voltage present?
12v
Go to step 6.
12v
Repair open, bad connection or short in CKT144 between compressor switch and selector switch. Replace compressor switch.
Go to step 5.
Ignition on, check for voltage at both orange wires(CKT640) at back of compressor switch. Is voltage present?
12v
Repair open, bad connection or short in CKT640 between compressor switch and fuse 1G. Replace the selector switch.
Ignition on, compressor switch set to inate, selector switch set to both. Check for voltage at the grey wire(CKT92) at the back of the selector switch. Is voltage present?
12v
Repair open, bad connection, or short in CKT92 between selector switch and front inate valve.
4-1-00
______________________________________________________
Electrical System
12-57
A REAR SOL B
57 BK 92 GY C1-24 C3-C4 C12-F

R
TIRE SELECTOR
F
144 YL C3-B4 C12-G C3-B3 C12-H C3-B4 C12-J
DEFLATE SOL B
47 LG
C1-58
C3-C2
C12-D
A FRONT SOL B
57 BK 91 TN C1-63 C3-C3 C12-E
G2 TO BUZZER (fuse box) C1-23
INFLATE/ DEFLATE
640 OR
FRONT LOW PRESSURE
428 PK
C1-57 C3-G4
WARNING LAMP
144 YL
57 BK
C12-K 59 BK G4
640 OR
REAR LOW PRESSURE
STATUS CENTER IP INTERIOR FUSE BOX CTIS WARNING MINI FUSE 1G 5 AMP C1-59 46 WH
428 PK
57 BK
437 DG
TO BATTERY
G2
CTIS COMPRESSOR
COMPRESSOR RELAY
ENGINE FUSE BOX CTIS COMPRESSOR
MAXI FUSE 6 30 AMP
59 BK
436 YL
9-S12-002
G3
Figure 2-78: CTIS Schematic 05745159 4-1-00
12-58
Electrical System
_______________________________________________________
CLEARANCE PARK/TURN
HEAD LIGHTS
PARK/TURN
CLEARANCE
SIDE MARKER
13TN 12 DR SIDE MARKER 58 BK 3 LB 20 RD 2 LG 58 BK

UNDER HOOD LAMP
IDENTIFICATION
HOOD HARNESS
A B 2 LG C A 13TN B C D
80 WH
G4
80 WH
12 DR
3 LB
58 BK
TO IP INDICATOR LAMPS 20 RD
C2-2
C1-73
C2-3 C2-4 C1-66 C2-5 C2-6 46 C2-7

C2-25 21 GY 9 YL
C1-65
G3
C1-47
C1-41
C1-74 C1-72 5 DG 21 GY C1-71
G1 SIDE MARKER
21 GY
59 BK
5 DG
C2-30 29 140 OR
IDENTIFICATION
SIDE MARKER
59 BK
ID BACKUP STOP/ TAIL/ TURN BACKUP STOP/ TAIL/ TURN
ID
9-S12-006.1
Figure 2-79: Lights Schematic (Sheet 1 of 2) 4-1-00
______________________________________________________
Electrical System
12-59
15 WH 14 LB
FUSE 3F 7.5 A INTERIOR MASTER LIGHT SWITCH FUSE 4F 7.5 A INTERIOR
BUSS L1A
FUSE 6F 5A INTERIOR
C1-67
20A CB MAXI FUSE 2M EXTERIOR TO BATTERY
C1-51
30A CB MAXI FUSE 3M EXTERIOR TO BATTERY
298 BR C2-27 C1-43

BACKUP LIGHT SWITCH FUSE 6F 5A INTERIOR HOT in RUN and START
14 LB 15 WH 20 RD 140 OR
12 OR 13 TN 3 LB 80 WH 2 LG 21 GY 9 YL 5 DG HEADLIGHT FEED RIGHT TURN REAR LEFT TURN REAR RIGHT TURN SIGNAL LEFT TURN SIGNAL LOW BEAM HIGH BEAM
TURN SIGNAL SWITCH
9-S12-007.1
Figure 2-79: Lights Schematic (Sheet 2 of 2) 05745159 4-1-00
12-60
Electrical System
_______________________________________________________
KEY, HEADLIGHT, SEATBELT CHIME
38 RD
MASTER LIGHT SWITCH KEY SWITCH (STEERING COLUMN) 95 YL
SEAT BELT SWITCH 59 BK 85 GY G4
59 BK
640 BR
159 WH
G4 FUSE 1G 5 AMP INTERIOR TO IGN TO DOME LIGHT
158 BK C1 C3 RIGHT SIDE WARNING LIGHT-1P
450 PK
85 GY
183 TN
SEAT BELT
LF
RF
DOOR SWITCHES
LR RR FUSE 7F 5 AMP INTERIOR
14 LB
15 WH
TO TURN SIGNAL SWITCH/ DIMMER
TO PARKING LIGHTS FUSES
HMCS ONLY CARGO DOOR
C1 G7
C1-51
FUSE 5H 15 AMP INTERIOR
20 AMP CB MAXI FUSE 2M ENGINE
30 AMP CB MAXI FUSE 3M ENGINE
TO BATTERY
TO BATTERY
9-S12-003
Figure 2-80: Key/Headlight Chime Schematic 4-1-00
______________________________________________________
Electrical System
12-61
HORN Horn Replacement

Removal
1. 2. Remove harness connectors and adapters from horn. Remove nut and horn from mounting bracket (Figure 2-81).
NOTE: Overtightening horn mounting nut will distort the horn bellows and result in an off-key horn tone.
Installation
1. 2. Secure horns to mounting bracket with nuts. Plug harness connectors and adapters into horns.
NUT HORN
HORN
ADAPTERS
MOUNTING BRACKET
HARNESS CONNECTORS
Figure 2-81: Horn and Horn Mounting Bracket Replacement
Horn Mounting Bracket Replacement

Removal
1. 2. Remove two horns. Remove bolts, washers, lockwashers, nuts, and horn mounting bracket from airlift bracket (Figure 2-81).
Installation
1. 2. Secure horn mounting bracket to airlift bracket with bolts, washers, lockwashers, and nuts (Figure 2-81). Install two horns.
05745159
4-1-00
12-62
Electrical System
_______________________________________________________
Horns Inoperative
Step 1 Action Locate the horn assemblies under the hood. Disconnect the harness from the horn assemblies. With a DVOM check the black wires (CKT 58) for resistance to ground. Do both wires meet with specications? With a DVOM back probe the white wires on the horn assemblies and check for voltage when the horn button is pushed. Is the specied voltage present? Remove the horn relay from the exterior fuse box. With a DVOM check resistance between the relay cavity 1F and the white wire (CKT 6) on the horn assembly. Does the resistance meet the specications? With a DVOM check for voltage in cavities 3E and 1E of the exterior fuse box. Is the specied voltage present? Value <.2 Yes Go to step 2. No Repair the open or bad connection on CKT 58 between the horn assemblies and G2. Go to step 3.
12v
Replace the horn assemblies.
<.2
Go to step 4.
Repair the open or bad connection in CKT 6 between the horn relay and the horn assembly. Repair the open or bad connection in CKT 7 between the horn relay and the exterior fuse box. Go to step 6.
12v
Go to step 5.
With a DVOM check the resistance to ground on cavity 3F, of the exterior fuse box, when the horn switch is pressed. Does the resistance meet the specications? Gain access to connector C39. With a DVOM back probe cavity C on connector 39. Activate the horn switch and watch the resistance on the meter. Does the resistance meet the specications?
<.2
Replace the horn relay.
<.2
Repair the open or bad connection on CKT 1 between the horn switch and the horn relay.
Replace the turn signal assembly.
4-1-00
______________________________________________________
Electrical System
460 BK
12-63
HORN SWITCH TO REMOTE ENTRY MODULE C39-C
G4
C1-62 1 DB 7 RD 3F 3E FUSE 1D 20 AMP EXTERIOR FUSE BOX HORN RELAY EXTERIOR FUSE BOX 1E 7 RD
1F
TO BATT
HORN
ADAPTER
HORN
ADAPTER 6 WH 58 BK
00-S12-007
G2
Figure 2-82: Horn Schematic 05745159 4-1-00
12-64
Electrical System
_______________________________________________________
INSTRUMENT PANEL, GAUGES, AND SWITCHES Instrument Panel (I.P Replacement .)

Removal
NOTE: Tag all leads prior to removal for installation. If replacing instrument panel, refer to procedures in this section to remove and/or disconnect the various lamps, switches, and gauges. 1. 2. 3. 4. 5. Disconnect negative battery cables (Section 12). Remove left side crashpad. Remove close-out panel. Remove wiring harness close-out plate. Remove tachometer and clock assembly from I.P. to access right side I.P. mounting bolt. 6. Remove right side I.P. mounting bolt. 7. Remove two bolts securing I.P. to steering column. 8. Remove two left side I.P. mounting bolts securing I.P. to A-pillar. 9. Disconnect air hose from side window defrost vent. 10. Remove I.P.
SIDE WINDOW DEFROST VENT AIR HOSE I. P. CLIPS
RIGHT SIDE MOUNTING BOLT
LEFT SIDE MOUNTING BOLTS
STEERING COLUMN MOUNTING BOLTS
Figure 2-83: Instrument Panel Replacement
Installation
1. Maneuver I.P. into position between steering wheel and rewall. 2. Connect air hose side window defrost vent. 3. Loosely install left side I.P. mounting bolts. 4. Loosely install I.P. to steering column mounting bolts. 5. Install right side I.P. mounting bolts 6. Tighten loosely installed bolts from steps 3 and 4. 7. Install tachometer and clock assembly. 8. Install wiring harness close-out plate. 9. Install close-out panel. 10. Install left side dashpad. 11. Connect negative battery cables (Section 12).
4-1-00
______________________________________________________
Electrical System
12-65
Crashpad Replacement (Right Side)

Removal
1. 2. 3. Remove screw/washers, and crashpad from dashboard (Figure 2-84). Disconnect air hose from vent duct. Remove screws, side window vent, and vent duct from crashpad.
Gauge Replacement
NOTE: Gauge replacement is basically the same for all instrument panel gauges.
Removal
1. 2. Remove screws and pull gauge panel away from instrument panel (Figure 2-85). Disconnect lamp connector from gauge.
Installation
1. 2. 3. Secure vent duct and window vent to crashpad with screws (Figure 2-84). Connect air hose to vent duct. Secure crashpad to dashboard with screw/washers.
AIR HOSE DASHBOARD I. P. CLIPS DUCT NOZZLE/ CONSOLE SIDE VENT DUCT
NOTE: Tag all leads prior to removal for installation. 3. 4. 5. Remove nut and lockwasher assemblies securing three leads to gauge. Remove hold-down bracket. Remove gauge through front of gauge panel.
LAMP CONNECTOR INSTRUMENT PANEL
GAUGE PANEL
WINDOW VENT LEAD CRASH PAD (LEFT SIDE) VENT CRASH PAD (RIGHT SIDE) GAUGE LEADS
HOLD-DOWN BRACKET
Figure 2-84: Crashpad Replacement
Crashpad Replacement (Left Side)

Removal
1. 2. 3. Remove screw/washers from top of crashpad. Tug gently on crashpad toward steering wheel to free crashpad clips from I. P. clips (Figures 2-83 and 2-84). Lift vent side of crashpad and work console side (duct nozzle) out of front console.
Figure 2-85: Gauge Replacement
Installation
1. 2. 3. 4. 5. 6. Insert gauge through front of gauge panel (Figure 2-85). Secure hold-down bracket and lead to gauge with nut and lockwasher assembly. Secure leads to gauge with nut and lockwasher assemblies. Connect lamp connector to back of gauge. Start engine and ensure gauge operates properly. Secure gauge panel to instrument panel with screws.
Installation
1. 2. 3. Work console side (duct nozzle) of crashpad into front console plenum. Position crashpad on edge of I. P. closest to steering wheel and push crashpad onto I. P. clips (Figures 2-83 and 2-84). Secure crashpad to I. P. with screw/washers.
05745159
4-1-00
12-66
Electrical System
_______________________________________________________
Instrument Panel Indicator Lamp Replacement

NOTE: All instrument panel indicator lamps are replaced basically the same.
Installation
1. 2. 3. Install connector on switch (Figure 2-87). Install switch in switch housing. Install closeout panel.
CONNECTOR
Removal
1. 2. 3. Remove instrument panel. Turn lamp socket one-quarter turn counterclockwise, and remove socket from indicator light housing. Pull lamp from socket (Figure 2-86).
Installation
1. 2. 3. 4. Push lamp into socket (Figure 2-86). Insert socket into status center and secure by turning socket clockwise one-quarter turn. Install instrument panel. Start engine and ensure lamp operates properly.
BULB SOCKET STATUS CENTER SWITCH
HOUSING INSTRUMENT PANEL
Figure 2-87: Instrument Panel Switch Replacement
Instrument Panel Dimmer Control Switch Replacement

Removal
1. 2. 3. Remove closeout panel. Reach up behind instrument panel and push switch from switch housing. Unplug connector from wiring harness (Figure 2-88).
WIRING HARNESS
9-S06-015.1
CONNECTOR
Figure 2-86: Instrument Panel Indicator Light Replacement
Instrument Panel Switch Replacement

NOTE: All instrument panel switches are replaced similarly, with the exception of the dimmer control switch. This procedure covers the main light switch. CAUTION: Some connectors can be installed incorrectly and cause damage to the electrical system. Make note of connector position prior to removal.
HOUSING INSTRUMENT PANEL SWITCH
Figure 2-88: Instrument Panel Dimmer Control Switch Replacement
Removal
1. 2. 3. Remove closeout panel. Reach up behind IP and push switch from switch housing. Remove connector from switch (Figure 2-87).
Installation
1. 2. 3. Plug connector into wiring harness. Install switch in switch housing (Figure 2-88). Install closeout panel.
4-1-00
______________________________________________________
Electrical System
12-67
Speedometer/Odometer Replacement
Removal
1. 2. Remove the left A-pillar dash trim (closeout). Remove the left footwell closeout panel and disconnect the courtesy light plug, diagnostic link connector and the footwell vent hose from the closeout panel. If equipped with power mirrors, pop the switch from dash and let hang to gain access to the crossbolt nut. Remove the two screws securing the harness hanger to the steering column mount bracket and remove the harness hanger. Loosen the two bolts at the forward steering column pivot point. Remove the steering column crossbolt, nut and washer and tilt the steering column downward. Remove two trim screws from the crashpad and pull rearward to release the crashpad. Remove the two speedometer/odometer hold-down bracket nuts and lockwashers and the hold-down bracket.
CROSSBOLT
9.
Pull the speedometer/odometer from the dash Remove the wire connector from the backside of the speedometer.
Installation
1. 2. 3. 4. 5. 6. 7. 8. 9. Insert speedometer/odometer into instrument panel (Figure 2-89). Install the crashpad using two trim screws. Install the left and right gauge bezels. Tilt the steering column up and install the crossbolt, nut and washer. Tighten the two bolts at the forward pivot point of the steering column. Screw the harness hanger to the steering column mount bracket. Install the power mirror switch if removed in step 3 above. Install the footwell vent hose, the DLC, the courtesy light plug and the left footwell closeout panel. Install the left A-pillar dash trim (closeout).
3. 4.
5. 6. 7. 8.
PIVOT BOLT
HOLD-DOWN BRACKET SPEEDOMETER/ ODOMETER
POWER MIRROR SWITCH
HARNESS HANGER
POWER MIRROR SWITCH
Figure 2-89: Speedometer/Odometer Replacement
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Electrical System
_______________________________________________________
Tachometer Replacement
NOTE: Mark position of set screws in relationship to tachometer clock panel before disassembly. Tachometer mounting clamp must be installed in factory position to have proper clearance for reassembly. NOTE: It may be necessary to remove clock for access to tachometer mounting clamp hardware.
CIGARETTE LIGHTER REPLACEMENT

Removal
1. 2. 3. 4. Pull front console away from dashpad enough to gain access to wiring harness connector. Remove wiring harness connector from lighter assembly. Remove element from lighter assembly heater (Figure 2-91). Remove shell from heater, and remove shell, heater, and bezel from console.
Removal
1. 2. 3. 4. Remove screws and tachometer/clock panel from I.P. Unplug tachometer electrical connector from I.P. wiring harness. Loosen set screws and tachometer mounting clamp hardware. Remove clamp from tachometer housing. Remove tachometer from tachometer/clock panel. 1. 2. 3. 4. 5. 6.
Installation
Install bezel and heater in console (Figure 2-91). Install shell on heater. Install wiring harness connector on lighter assembly. Install element in lighter assembly. Engage cigarette lighter to ensure proper operation. Install front console.
Installation
1. 2. Position tachometer in tachometer/clock panel. Slide tachometer mounting clamp onto tachometer housing; close enough to tachometer/clock panel for set screws to make contact. Tighten clamp securely onto tachometer body and tighten setscrews until they contact tachometer/clock panel. Plug tachometer electrical connector into I.P. wiring harness. Secure tachometer/clock panel to I.P. with screws.
TACHOMETER
WIRING HARNESS CONNECTOR
SHELL
3. 4. 5.
BEZEL HEATER ELEMENT
CONSOLE TACHOMETER/CLOCK TACHOMETER PANEL MOUNTING CLAMP SET SCREW

PASSED
LIGHTER ASSEMBLY
Figure 2-91: Cigarette Lighter Breakdown
PASSED
CLOCK
CLOCK MOUNTING CLAMP
TACHOMETER MOUNTING CLAMP HARDWARE
6-S10-018.1
Figure 2-90: Tachometer Mounting
4-1-00
______________________________________________________
Electrical System
12-69
LOW COOLANT LAMP INOPERATIVE

Step 1
Action Disconnect connector C35 from low coolant sensor pigtail. Turn ignition switch to ON. Check terminal A (pink wire) for voltage. Is voltage present? Disconnect connector C35 from low coolant sensor pigtail. Turn ignition switch to ON. Connect a fused jumper from terminal A (pink wire) to terminal B (red wire) of the harness side of connector C35. Does the low coolant lamp light? Check/repair circuit 57 (black wire) from sensor to engine ground. Does the low coolant lamp light?
Value(s) Approximate battery voltage.
Yes Go to step 2.
No Repair circuit 291 from fuse 3B in exterior fuse box. Check/repair signal circuit 794 and lamp in status center.
Go to step 3.
Repair complete.
Repair connection at connector C35 or replace sensor
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Electrical System
_______________________________________________________
LOW COOLANT SENSOR

IGNITION
C35 A
794 RED
291 PNK
IGNITION
57 BLK
FUSE 3B 20 AMP EXTERIOR
C4 3
11 G1
C1-55 30 GY C3 N7 G3
794 RED G
C9 J
LOW COOLANT LAMP

9-S12-092
RIGHT STATUS CENTER
Figure 2-92: Low Coolant Sensor Schematic
4-1-00
______________________________________________________
Electrical System
12-71
Oil Pressure Gauge Inoperative

Step 1 Is gauge maxed out? Action Value(s) Yes Repair open or bad connection in CKT31 or gauge sending. 12v Go to step 4. No Go to step 2.
Using a DVOM set to measure voltage, check for voltage at the rear of the oil pressure gauge on the grey wire(CKT30) connect negative meter lead to ground on black wire(CKT59). With ignition on, is voltage present? Move the negative meter lead to a known good ground. Is voltage present?
Go to step 3.
12v
Repair open or bad connection in CKT59 between oil pressure gauge and G4. Go to step 5. Replace sending unit.
Repair open, bad connection or short in CKT30 between oil pressure gauge and fuse 4B. Replace the oil pressure gauge. Repair short to ground in CKT31.
4 5
Ignition on, remove the tan wire (CKT 31) from the oil pressure gauge. Does the gauge max out? Reconnect signal wire to gauge. Disconnect signal wire(CKT31) at sending unit. With ignition on does gauge max out?
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Electrical System
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Fuel Gauge Inoperative

Step 1 Action Using a DVOM set to measure voltage, check for voltage at the rear of the fuel gauge on the grey wire(CKT30) connect negative meter lead to ground on black wire(CKT59). With ignition on, is voltage present? Move the negative meter lead to a known good ground. IS voltage present? Value(s) 12v Yes Go to step 3. No Go to step 2.
12v
Repair open or bad connection in CKT59 between fuel gauge and G4. Go to step 4. Go to step 5.
Repair open, bad connection or short in CKT30 between fuel gauge and fuse 4B. Replace gauge. Repair open or bad connection in CKT29 between fuel gauge and fuel selector valve? Go to step 7.
3 4
With the ignition on, ground the signal lead does the gauge go to Full? Disconnect fuel selector valve. Using a jumper wire, ground the pink wire(CKT29). With the ignition on does the fuel gauge go to full?
Full Full
Determine fuel level in the main tank. Using a DVOM set to measure resistance, measure resistance to ground on the blue wire(CKT673). Does resistance value correspond with fuel level in tank. Determine fuel level in the auxiliary tank. Using a DVOM set to measure resistance, measure resistance to ground on the yellow wire(CKT675). Does resistance value correspond with fuel level in tank. Gain access to fuel level sending unit connectors. Using a DVOM set to measure resistance, check resistance through the sending unit. Does resistance value correspond with the fuel level in the tank?
Empty=268 Half=124.4 Full=19.3
Go to step 6.
Replace fuel selector valve.
Go to step 7.
Repair open, bad connection or short in CKT 673, 675, or 58.
Replace sending unit.
4-1-00
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Electrical System
12-73
Engine Temperature Gauge Inoperative

Step 1 Action Is gauge maxed out with ignition on? Value(s) Yes Repair short to ground in CKT 39 or faulty sending unit. 12v Go to step 4. No Go to step 2.
Using a DVOM set to measure voltage, check for voltage at the rear of the oil pressure gauge on the grey wire(CKT39) connect negative meter lead to ground on black wire(CKT59). With ignition on, is voltage present? Move the negative meter lead to a known good ground. Is voltage present?
Go to step 3.
12v
Repair open or bad connection in CKT59 between oil pressure gauge and G4. Go to step 5.
Repair open, bad connection or short in CKT30 between oil pressure gauge and fuse 4B. Replace the temperature gauge. Repair open, or bad connection in CKT39 between gauge and sending unit.
With the ignition on, momentarily ground the dark green wire(CKT30) at the rear of the gauge. Does the gauge go to maximum? With the ignition on, momentarily ground the signal wire(CKT39) at the sending unit. Does the gauge go to maximum?
Replace the sending unit.
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4-1-00
12-74
Electrical System
_______________________________________________________
VOLT G I L
OIL G L SPEEDO I S G L S 59 BK 30 GY I
TEMP G L I S
FUEL G L I S
TACHOMETER G L I S
TO CTIS HARNESS 353 YL 39 DG 644 YL C3-K9 C1-49 C5-B9 349 YL TO PCM CRANKSHAFT POSITION SENSOR
9-S12-059.3
C3-N6
17 PP 31 TN 29 PK C3-P8 C3-P9 C1-I8 C1-36 C3-P7 C5-A1 C1-35 ENGINE TEMPERATURE SENSOR C2-35 C26-B 349 YL GAUGE OUTPUT FUEL SELECTOR VALVE 675 YL 679 LG 676 PP 570 BK 239 PK 673 DB C26-C A TO VEHICLE SPEED SENSOR (VSS) G1 MAIN TANK FUEL LEVEL SENDING UNIT B C26-A 58 BK C38-B AUX TANK FUEL LEVEL SENDING UNIT
C3-N7
TO DIMMER SWITCH FUSE 4B 5 AMP INTERIOR FUSE BOX
C3-L7 C1-30
G4
C5-C10
TO IGN SWITCH
OIL PRESSURE SENDER
G1 10 DIGITAL RATIO ADAPTER (DRA) SPEEDO SIGNAL ENGINE SPEED SIGNAL GROUND IGN+ 7 12 8 9
G1
FUSE 3A 20 AMP EXTERIOR FUSE BOX TO IGNITION G2
Figure 2-93: Gauges Schematic 4-1-00

____________________________________________________
Electrical System
12-74.1
Digital Ratio Adapter

Location
The digital ratio adapter is located under the center console on the engine cover, just above the powertrain control module. 3. Pull the digital ratio adapter off of the hook and loop and remove from the center console.
Installation
1. 2. 3. Install the digital ratio adapter in the center console on the hook and loop. Connect the harness connectors to the bottom of the digital ratio adapter. Install the cup holder in the center console.
Removal
1. 2. Remove the cup holder from the center console. Disconnect the two harness connectors from the digital ratio adapter.
ENGINE COVER DIGITAL RATIO ADAPTER
POWERTRAIN CONTROL UNIT
01-S12-017
Figure 12-93.1 Digital Ratio Adapter Removal
Circuit Description
the PCM. Circuit 565 sends a signal of 40 pulses per revolution of the output shaft to the PCM. This signal is used to control shift points, line pressure, TCC and diagnostic codes. Circuit 223 sends a signal of 4000 pulses per mile to the PCM. This signal is used for cruise and DTCs. The DRA sends a separate signal to the speedometer on circuit 353. This signal is a 128,000 pulse per mile signal.
The speed sensor circuit consists of a magnetic induction type sensor, a Digital Ratio Adapter (DRA) and wiring. Geared teeth pressed on the output shaft induce an alternating current in the sensor. This A/C signal is transmitted to the DRA. The DRA compensates for various axle ratios and converts the signal into a digital signals for use by the speedometer, cruise control, and the PCM. The DRA sends two different signal to
Digital Ratio Adapter Out Put Signal to Speedometer

Approximate Reading 30 MPH 60 MPH 30 MPH Input 1066.6 Htz 2133.3 Htz 1066.6 Htz Ascending X X X Descending
NOTE: The above table only applies to 2000 model year vehicles.
05745159
3-1-01
12-74.2
Electrical System
_____________________________________________________
TO IGNITION
TO SPEEDO
FUSE 1D 15 AMP
TWISTED PAIR
EXTERIOR FUSE BOX

C29
GROUND 570 BK
A6
C33
G2
GROUND
570 BK
A7 C3-P9
C28
D6 C1-18
D9
223 DB
570 BR
565 BR
239 PK
679 LG
676 PP
12
13
353 YL
10
GROUND

00-S12-038
Figure 12-93.2 Digital Ratio Adapter Wiring Diagram
3-1-01

______________________________________________________
Electrical System
12-75
HVAC Main Blower Inoperative ALL BUT High

Step 1 Action Ignition on, blower switch set to Med2, mode dial set to face. Measure voltage on the yellow wire(CKT754) at the blower relay. Is voltage present? Ignition on, blower switch set to Med2, mode dial set to face. Measure voltage on the grey wire(CKT752) at the blower resistor. Is voltage present? Ignition on, blower switch set to Med2, mode dial set to face. Measure voltage on the grey wire(CKT752) at pin C of the 8pin connector on the back of the HVAC control head. Is voltage present? Value(s) 8 -10v Yes Replace the blower relay. No Go to step 2.
12v
Replace blower resistor.
Go to step 3.
12v
Repair open, bad connection or short to ground in CKTS 751, 752, and 755 between HVAC control head and resistor block.
Replace control head.
HVAC Compressor Inoperative

Step 1 Action Perform On-board diagnostic system check. Is system functioning properly? Value(s) Yes Go to step 2. No Diagnose problem in on-board diagnostic system rst. Diagnose leak and recharge. Go to step 4. Go to step 5.
2 3 4
Does A/C system have an adequate charge? Is engine in an overheated condition? Connect scan tool to vehicle. Ignition on, nd misc. tests and command compressor clutch on. Does clutch come on? Disconnect the compressor clutch. Connect a test lamp to ground, and probe the brown wire at the clutch connector. Using the scan tool, command the clutch on. Does the test light come on? Remove A/C relay from the exterior fuse box. Using a DVOM set to measure voltage, ignition on, check for voltage at cavities 4E and 6E (CKT400) in the exterior fuse box. Is voltage present? 12v
Go to step 3. Cool down and recheck. Go to step 10.
Replace the compressor clutch. Go to step 7.
Go to step 6.
Repair open, bad connection or short in CKT400 between exterior fuse box and ignition switch.
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Electrical System
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HVAC Compressor Inoperative (Continued)

Step 7 Action Using a DVOM set to measure voltage, place the positive lead on a battery power source. Place the ground lead in cavity 6F(CKT440). Using the scan tool, command the compressor clutch on. Does meter display battery voltage? Using a DVOM set to measure resistance. Check resistance between cavity 4F(CKT348) and the brown wire(CKT348)at the compressor clutch connector. Is resistance below specication? Value(s) 12v Yes Go to step 8. No Go to step 9.
<.2
Replace compressor relay.
Repair open or bad connection in CKT348 between clutch relay and compressor clutch. Replace the PCM.
Ignition on, using a DVOM set to measure voltage, backprobe pin D5 in C28 at the PCM(CKT440) with the negative lead. Place the positive lead on a battery voltage source. Using the scan tool, command the compressor clutch on. Does the meter display battery voltage? Ignition on, locate engine data list, and A/C Request. Turn mode dial on HVAC control head to MAX A/C. Does scan tool display indicate A/C request? Ignition on, mode dial set to MAX A/C. Using a DVOM set to measure voltage, backprobe the tan wire(CKT198) at the temperature cutout switch on the HVAC unit with the positive probe. Place the negative lead on a known good ground. Is voltage present? Ignition on, mode dial set to MAX A/C. Using a DVOM set to measure voltage, backprobe the yellow wire(CKT347) at the temperature cutout switch on the HVAC unit with the positive probe. Place the negative lead on a known good ground. Is voltage present? Using a DVOM set to measure voltage, ignition on, mode dial set to MAX A/C, backprobe for voltage on pin H (CKT347) in the 8 wire connector at the rear of the HVAC control head. Is voltage present?
12v
Repair open, or bad connection in CKT440 between PCM and A/C clutch relay. Replace PCM.
10
Go to step 11.
11
12v
Go to step 14.
Go to step 1.
12
12v
Replace the temperature cutout switch.
Go to step 13.
13
12v
Repair open, bad connection or short in CKT347 between HVAC control head and temperature cutout switch.
Replace control head.
4-1-00
______________________________________________________
Electrical System
12-77
HVAC Compressor Inoperative (Continued)

Step 14 Action Ignition on, mode dial set to MAX A/C. Disconnect the high pressure cutout switch on the compressor. Using a DVOM set to measure voltage, check for voltage on the tan wire(CKT198). Is voltage present? Value(s) 12v Yes Go to step 15. No Repair open, bad connection, or short in CKT198 between temperature cutout switch and high pressure cutout switch. Replace the high pressure cutout switch. Replace ambient temperature switch.
15
Using a DVOM set to measure resistance, check continuity across the two pins on the high pressure cutout switch. Is resistance below specication? Ambient temperature above 45. Disconnect the ambient temperature switch. Using a DVOM set to measure resistance, measure continuity across the ambient temperature switch terminals. Is resistance below specication? Disconnect low pressure cutout switch. Using a DVOM set to measure resistance, measure continuity across the low pressure cutout switch. Is resistance below specication?
<.2
Go to step 16.
16
<.2
Go to step 17.
17
<.2
Repair open, bad connection or short in CKT439 between high pressure cutoff switch and PCM.
Replace the low pressure cutout switch.
HVAC Temperature Door Inoperative

Step 1 Action With the ignition switch in the run position, operate temperature control dial and observe the motor. Does door move? Remove the temperature blend door motor from the side of the HVAC case. With the ignition switch in the run position, operate the temperature control dial and observe the motor. Is the motor turning? Disconnect electrical connector from the temperature blend door motor. Using a DVOM set to measure voltage, and using J35616-92 test adapters, probe the GN wire (CKT 399) with the positive lead and the BK wire (CKT 58) with the negative lead. Turn the ignition switch to the run position. Is voltage present? 12v Value(s) Yes Condition is intermittent. Mechanical problem in the HVAC case. No Go to step 2.
Go to step 4.
Go to step 6.
Go to step 4.
05745159
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12-78
Electrical System
_______________________________________________________
HVAC Temperature Door Inoperative (Continued)

Step 4 Action With ignition on, using a DVOM set to measure voltage and using J35616-92 test adapters probe the GN wire (CKT 399) with the positive lead. Place the negative lead on a known good ground. Is voltage present? With the ignition off, and using a DVOM set to measure ohms, check for resistance between the BK wire (CKT 58) of the temperature blend door, and a good ground. Does resistance exceed specications? Using a DVOM set to read volts, the ignition switch on the run position, and using J35616-92 test adapters, probe the blue wire (CKT 402) with the positive lead, and the BK wire (CKT 58) with the negative lead. Rotate temperature control dial on the HVAC control head from cold to hot and back. Is voltage present at the cold setting and 0v on the hot setting? Disconnect the 8 wire connector at the HVAC control head. Using a DVOM set to measure ohms, check resistance between pin F (CKT 402) of the 8 wire connector and the blue wire (CKT 402) of the temperature blend door connector. Does resistance exceed specications? Check for open or bad connection between the HVAC control head 8 wire connection and the temperature blend door motor connection. Check for loose terminals at the control head. Was a bad connection found? Using a DVOM set to measure voltage, probe pin E (CKT 399) of the 8 wire connector on the HVAC control head with the positive lead, and pin B (CKT 58) of the three wire HVAC control head connector with the negative lead. With ignition on, is voltage present? Using a DVOM set to measure voltage, probe pin E (CKT 399) of the HVAC control head eight wire connector with the positive lead. Attach the negative lead to a known good ground. With the ignition switch in the run position, is voltage present? 12v Value(s) 12v Yes Go to step 5. No Repair open or short to ground between temperature blend door motor and fuse 7C. Go to step 6.
<.2
Locate open or bad connection between temperature blend door motor and G4. Replace the temperature blend door motor.
Cold = 12v Hot = 0v Cold = 12v
Go to step 7.
62K
Go to step 9.
Go to step 8.
Repair or replace harness as necessary.
Go to step 9.
Replace faulty HVAC control head.
Go to step 10.
10
12v
Go to step 11.
Locate short or open between the HVAC control head and fuse 7C.
4-1-00
______________________________________________________
Electrical System
12-79
HVAC Temperature Door Inoperative (Continued)

Step 11 Action Using a DVOM set to measure ohms, check resistance between pin B (CKT 58) of the HVAC control head connector and a good ground. Does resistance exceed specications? Value(s) <.2 Yes Replace faulty HVAC control head. No Locate and repair open or poor connection in the ground circuit between pin B and G4.
05745159
4-1-00
12-80
Electrical System
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TO ALTERNATOR BATTERY TERMINAL 30A FUSE BUILT IN HARNESS FUSE
FUSE 7C 30A INTERIOR FUSE BOX
BLOWER RESISTOR
C37 A D 754 YL
364 RD
C36-A
B G4 C 85 30 371 PP BLOWER RELAY 399 DG BLOWER MOTOR
59 BK
86
87
87A
757 LB
M
C6
C36-B
L8
B1
K7
L6
755 DB
751 OR
8 PIN
752 GY
D
HIGH BLOWER
58 BK G1 C6-G1
E
IGN FEED
LOW BLOWER
MED 2 MED 1 BLOWER BLOWER
HVAC CONTROL HEAD 9-S12-060
Figure 12-94: HVAC Blower Schematic 4-1-00
______________________________________________________
Electrical System
12-81
HOT IN RUN AND START REAR HVAC BLOWER
FUSE 7C 30A INTERIOR
M
H L
TEMPERATURE DOOR MOTOR POSITION SIGNAL GROUND
405 OR E4 G4 C6
IGN INPUT
7 58 BK
10
399 DG
FUSE 6C 20A INTERIOR
59 BK
404 YL E3 C6-C3 9-S12-063
G4
REAR HVAC BLOWER SWITCH RESISTOR MODULE (62K )
C6-G1 346 PK
C6-J1 402 LB F
8 PIN
E IGN INPUT + HVAC CONTROL HEAD
TEMP BLEND MOTOR CONTROL
Figure 12-95: HVAC Temp Blend Door/Rear Blower 05745159 4-1-00
12-82
Electrical System
_______________________________________________________
LOW PRESSURE SWITCH
438 OR
439 YL
DIODE
G1
HIGH PRESSURE CUTOUT SWITCH
C4-5
COMPRESSOR CLUTCH
C27-C2
A/C REQUEST
198 TN
A/C COMPRESSOR ENABLE

C28-D5 440 DB C1-39
348 BR
C4-8
C4-2 TEMP CUTOUT SWITCH HOT IN RUN AND START
HVAC UNIT
86
87
FUSE 2C 10A INTERIOR 85

347 YL 400 LG C1-1
COMPRESSOR RELAY 30
C6-J8 8 PIN H A/C REQUEST
HVAC CONTROL HEAD 9-S12-061
Figure 12-96: HVAC Compressor Schematic 4-1-00
______________________________________________________
Electrical System
12-83
Windshield Wiper Motor Inoperative All Speeds

Step 1 Action Gain access to the wiper motor connector under the windshield trim. Using a DVOM set to measure resistance, check resistance to ground on the brown wire (CKT 59). Is the resistance below the specied value? Turn the ignition switch to the RUN position and the wiper switch to LOW. Using a DVOM set to measure voltage, check for voltage at the dark green wire (CKT 63). Is the specied voltage present? Remove the wiper switch from the instrument panel and turn the ignition to the RUN position. Using a DVOM set to measure voltage, back probe the yellow wire (CKT 65) at the wiper switch. Is the specied voltage present? Value(s) <.2 Yes Go to step 2. No Repair open or bad connection in CKT 59 between the wiper motor and G4. Go to step 3.
12v
Replace the wiper motor.
12v
Replace wiper switch.
Repair the open or bad connection in CKT 65 between the wiper switch and fuse 7G.
Windshield Wiper Motor Inoperative on LOW

Step 1 Action Remove the wiper switch from the instrument panel. Turn the ignition to the RUN position and the wiper switch to LOW. Using a DVOM set to measure voltage, back probe the green wire (CKT 63). Is the specied voltage present? Using a DVOM set to measure voltage, back probe the yellow wire (CKT 65) at the wiper switch. Place the ground lead on a known good ground. With the ignition on, is the specied voltage present? Gain access to the wiper motor connector behind the windshield trim. Using a DVOM set to measure voltage, backprobe the dark green wire (CKT 63). Turn the ignition switch to the RUN position, and set the wiper switch to LOW. Is the specied voltage present? Value(s) 12v Yes Go to step 3. No Go to step 2.
12v
Replace the wiper switch.
Repair open or bad connection in CKT 65 between the wiper switch and fuse 7G. Repair the open or bad connection in CKT 63 between the wiper motor and the wiper switch.
12v
05745159
4-1-00
12-84
Electrical System
_______________________________________________________
Windshield Wiper Motor Inoperative on High

Step 1 Action Remove the wiper switch from the instrument panel. Turn the ignition to the RUN position and the wiper switch to HIGH. Using a DVOM set to measure voltage, back probe the red wire (CKT 61). Is the specied voltage present? With the ignition switch in the RUN position, check the voltage at the yellow wire (CKT 65). Is the specied voltage present? Value(s) 12v Yes Go to step 3. No Go to step 2.
12v
Replace the wiper switch.
Repair the open or bad connection on CKT 65 between the wiper switch and fuse 7G. Repair the open or bad connection on CKT 61 Between the wiper motor and the wiper switch.
Gain access to the wiper motor connector under the windshield trim. Turn the ignition switch to the RUN position and the wiper switch to the HIGH position. Using a DVOM check the voltage at the red wire (CKT 61). Is the specied voltage present?
12v
Windshield Wipers Intermittent Speeds Inoperative

Step 1 Action Do the windshield wipers work normally on the low and high speeds? Value(s) Yes Go to step 2. No Refer to the diagnostic chart for the specic problem on the standard wiper diagnosis. Replace the wiper switch.
Remove the wiper switch from the instrument panel. Disconnect the wiper switch from the harness.Using a DVOM measure resistance between terminals 2 and 3. Is the resistance below the specied value? Turn the ignition switch to the RUN position and the intermittent wiper switch to MEDIUM DELAY . Using a DVOM set to measure voltage, back probe the brown wire (CKT 945) at the intermittent switch. Voltage should pulse from 12 volts to 0 volts every 2-7 seconds depending on position of switch. Is the voltage in the specied range.
<.2
Connect the intermittent wiper switch to the harness. Go to step 3. Go to step 5.
12v pulse 2-7 seconds
Go to step 4.
4-1-00
______________________________________________________
Electrical System
12-85
Windshield Wipers Intermittent Speeds Inoperative (Continued)

Step 4 Action Ignition should be in the RUN position. Using a DVOM set to measure the voltage, back probe the yellow wire (CKT 65) at the intermittent wiper switch. Is the specied voltage present? Value(s) 12v Yes Replace the intermittent wiper switch. No Repair the open or bad connection in CKT 65 between the intermittent wiper switch and fuse 7G. Go to step 6.
Remove the intermittent wiper relay from the fuse box. Turn the ignition switch to the RUN position. Using a DVOM measure voltage drop between cavity B1 (CKT 945) and cavity C3 (CKT 59). The voltage should pulse from 12 volts to 0 volts every 2 to 7 seconds. Is the voltage in the specied ranges? Using a DVOM set to measure resistance, measure resistance to ground at cavity C3 (CKT 59) of the fuse box. Is resistance below specication?
12v pulse 2-7 seconds
Go to step 7.
<.2
Repair the open or bad connection, in CKT 945 between the intermittent wiper switch and the intermittent wiper relay. Go to step 8.
Repair open or bad connection in CKT 59 between the intermittent wiper relay and G4. Repair the open or bad connection in CKT 65 between fuse 7G and the intermittent wiper relay. Go to step 9.
Turn the ignition to the RUN position. Use a DVOM to measure voltage drop between cavity C1 (CKT 65) and cavity C3 (CKT 59). Is the specied voltage present?
12v
With the ignition switch in the RUN position and the wipers on LOW, check the voltage drop between cavity C2 (CKT 28) and cavity C3 (CKT 59). Does the voltage switch from 12 volts to 0 volts as the wiper completes its cycle? Gain access to the wiper motor connection. Back probe the black wire (CKT 65) with the positive lead, and the brown wire(CKT 59) with the negative lead. With the ignition on is the voltage drop in the specied range?
0v 12v 0v
Replace the intermittent wiper relay.
12v
Repair the open or bad connection in CKT 65 between the wiper motor and fuse 7G
05745159
4-1-00
12-86
Electrical System
_______________________________________________________
WIPER/WASHER
65 BK
WIPER MOTOR
M
C44-B C43 C44-A
59 BR G4
C3-H8
28 DB
65 YEL
C3-J6
FUSE 7G 25 AMP INTERIOR FUSE BOX TO IGNITION
WIPER SWITCH
INTERMITTENT RELAY
G4
C3-J7 27 OR 27 OR C3-H7 C3-N9 945 BR LOW WASHER FLUID LIGHT 941 TN C3-N8 C9-J C1-76 C3-N7 INTERMITTENT WIPER / WASHER SWITCH 65 YL
793 YL C1-54 C3-E3 C9-H RIGHT HAND STATUS CENTER
M
59 BK
G1
59 BK
LOW WASHER FLUID SWITCH
30 GY
WASHER MOTOR
G4
G1
TO IGNITION SWITCH
Figure 12-97: Wiper/Washer Schematic 4-1-00
63 DG
9-S12-012
61 RD
570 BK
______________________________________________________
Electrical System
12-87
Rear Window Wiper Inoperative

Steps 1 Action Gain access to the wiper motor connector under the slant door trim.Using a DVOM check resistance on the black wire (CKT 59). Is the resistance in the specied range? Turn the ignition switch to the RUN position and the rear wiper switch on. Using a DVOM back probe the red wire (CKT 66). Is the specied voltage present? Turn the ignition switch to the RUN position. Unplug the wiper motor harness. With a DVOM check the voltage on the light green wire (CKT 64). Is the specied voltage present? Turn the ignition switch OFF. With a DVOM check resistance between the light blue wire (CKT 62) and the red wire (CKT 66) on the wiper motor harness. Is resistance in the specied range? Remove the rear wiper relay (RY-3) from the interior fuse box. With a DVOM check the resistance between cavity F3 in the interior fuse box (** 12153) and the red wire (CKT 66) in the rear wiper motor harness. Is the resistance in the specied range? With a DVOM check resistance between cavity G2 in the interior fuse box and the light blue wire (CKT 62) in the rear wiper motor harness. Is the resistance in the specied range? Remove the rear wiper relay (RY-3). Turn the ignition switch to the RUN position. With a DVOM check voltage at cavity G1 in the interior fuse box. Is the specied voltage present? With a DVOM check cavity G3 in the interior fuse box for a ground. Is a ground present? Turn the ignition switch to the RUN position and the rear wiper switch above the medium selection. Using a DVOM, watch the voltage at cavity F1 in the interior fuse box. Does the voltage pulse from 0v to 12v and back? Values <.2 Yes Go to step 2. No Repair the open or bad connection in CKT 59 between wiper motor and G4. Go to step 3.
12v
12v
Go to step 4.
Repair the open or bad connection in CKT 64 between wiper and fuse 11G. Go to step 5.
<.2
Go to step 7.
<.2
Go to step 6.
Repair the open or bad connection in CKT 66 between rear wiper and relay. Repair the open or bad connection in CKT 62 between rear wiper and relay. Repair the open or bad connection in CKT 64. Repair open or bad ground. Go to step 10.
<.2
Replace the relay (RY-3).
12v
Go to step 8.
8 9
<.2 0v - 12v - 0v
Go to step 9. Replace the relay (RY-3).
05745159
4-1-00
12-88
Electrical System
_______________________________________________________
Rear Window Wiper Inoperative (Continued)

Steps 10 Action Remove the rear wiper switch from the instrument panel. Disconnect the wiper switch harness from the switch. Turn the ignition switch to the RUN position. With a DVOM check voltage on the yellow wire (CKT 65). Is the specied voltage present? With a DVOM check the black wire CKT 59 for ground. Is a ground present? Using a DVOM check the resistance between the brown wire (CKT 67) and cavity F1 in the interior fuse box. Is resistance in specied range? Values 12v Yes Go to step 11. No Repair the open or bad connection on CKT 65.
11
<.2
Go to step 12.
Repair open or bad ground CKT 59. Repair open or bad connection in CKT 67.
12
<.2
Replace rear wiper switch.
4-1-00
______________________________________________________
Electrical System
12-89
REAR WIPER MOTOR
64 LG
C42
A
BATT
C41-C C20-E
62 LB
66 RD
59 BK C41-59 C41-B G4 C20-B
C41-D
MAXI 7W 20 AMP
C20-L13
INTERMITTENT RELAY
C20-C
FUSE 11G 25 AMP
C1-67
C3-B1
SWITCHED 12V
59 BK
66 RD G4 67 BR C3-A4 67 BR 17 PP
59 BK
G1
C1-70 G2
C3-E4
SWITCHED 12V
943 TN
58 BK
REAR WASHER MOTOR
59 BK
REAR WIPER SWITCH

00-S12-015
G1
65 YL
Figure 12-98: Rear Wiper Motor Schematic
05745159
38 RD
HEADLAMP SWITCH FUSE 13G 25 AMP
4-1-00
12-90
Electrical System
_______________________________________________________
Left Heated Windshield Inoperative

Step 1 Action Gain access to the heated windshield connections. With the ignition in the RUN position, preform a voltage drop test between the yellow wire (CKT 740) and the black wire (CKT 59) going to the left hand windshield. Turn the heated windshield ON. Is the specied voltage present? Using a DVOM check the resistance to ground at the black wire (CKT 59) going to the left side windshield. Does the resistance to ground meet the specied range? Value(s) 12v Yes Replace the heated windshield. No Go to step 2.
<.2
Go to step 3.
Repair the open or bad connection in CKT 59 between the windshield and G4. Repair the open or bad connection in CKT 580 between the heated windshield switch and Heated windshield relay (R-4). Repair the open or bad connection in CKT 738 between fuse 2C and R-4. Repair the open or bad connection in CKT 740 between the left side heated windshield and R-4.
Remove the left hand heated windshield relay from the exterior fuse box. Check the voltage drop between cavities 1 (CKT 580) and 2 (CKT 59). With the ignition in the run position, turn the heated windshield switch to ON. Is the specied voltage present?
12v
Go to step 4.
With the ignition still in the run position. Preform a voltage drop test between cavities 2 (CKT 59) and 3 (CKT 738). Is the specied voltage present?
12v
Go to step 5.
With a DVOM check the resistance between cavity 5 (CKT 740) and the yellow wire (CKT 740) going to the left side windshield. Does the resistance meet the specied value?
<.2
Replace relay R-4.
4-1-00
______________________________________________________
Electrical System
12-91
Right Heated Windshield Inoperative

Step 1 Action Gain access to the heated windshield connections. With the ignition in the RUN position and the heated windshield switch on, preform a voltage drop test between the purple wire (CKT 739) and the black wire (CKT 59) going to the right hand windshield. Turn the heated windshield ON. Is the specied voltage present? Using a DVOM check the resistance to ground at the black wire (CKT 59) going to the right side windshield. Does the resistance to ground meet the specied range? Value(s) 12v Yes Replace the heated windshield. No Go to step 2.
<.2
Go to step 3.
Repair the open or bad connection in CKT 59 between the windshield and G4. Repair the open or bad connection in CKT 580 between the heated windshield switch and the heated windshield relay (R-2). Repair the open or bad connection in CKT 738 between fuse 2C and R-2. Repair the open or bad connection in CKT 739 between the left side heated windshield and R-2.
Remove the right hand heated windshield relay from the exterior fuse box. Check the voltage drop between cavities 1 (CKT 580) and 2 (CKT 59). With the ignition in the RUN position, turn the heated windshield switch to ON. Is the specied voltage present?
12v
Go to step 4.
With the ignition still in the RUN position. Preform a voltage drop test between cavities 2 (CKT 59) and 3 (CKT 737). Is the specied voltage present?
12v
Go to step 5.
With a DVOM check the resistance between cavity 5 (CKT 739) and the purple wire (CKT 739) going to the right side windshield. Does the resistance meet the specied value?
<.2
Replace relay R-2.
05745159
4-1-00
12-92
Electrical System
_______________________________________________________
Both Heated Windshields Inoperative

Step 1 Action Gain access to the heated windshield connections. Using a DVOM check the resistance to ground on the black wires at both windshields. Does the resistance meet the specied value? Value(s) <.2 Yes Go to step 2. No Repair the open or bad connection in CKT 59 between the windshields and G4. Go to step 3.
Remove the heated windshield switch from the bezel. Turn the ignition switch to the RUN position and turn the heated windshield switch to the ON position. Using a DVOM check the voltage drop between the brown wire (CKT 580) and the black wire (CKT 58). Is the specied voltage present? Using a DVOM measure the resistance to ground on the black wire (CKT 58) at the heated windshield switch. Does the resistance meet the specication?
12v
Repair the open or bad connection in CKT 580 between the heated windshield switch and the relays. Go to step 4.
<.2
Repair the open or bad connection in CKT 58 between the heated windshield switch and G4. Repair the open or bad connection in CKT 83 between the windshield switch and fuse 1C interior.
With the ignition in the RUN position and the heated windshield switch in the ON position. Use a DVOM to check for voltage at both tan wires (CKT 83) at the heated windshield switch. Is the specied voltage present?
12v
Replace the heated windshield switch.
4-1-00
______________________________________________________
Electrical System
12-93
HEATED WINDSHIELDS
TO DIMMER SWITCH
TO COMPASS/MIRROR RELAY C6-M8
TO HEATED MIRRORS
LEFT WINDSHIELD
RIGHT WINDSHIELD
C6-F3 17 PP
59 BK
G4 C1-3 580 BR C1-2
58 BK
HEATED WINDSHIELD SWITCH
739 PP
740 YL
C1-33
C6-M6
R-4 LEFT WINDSHIELD RELAY
R-2 RIGHT WINDSHIELD RELAY
G4 C6-M7 59 BK 738 RD 59 BK G1 HEATED WINDSHIELD RELAYS
83 TN
FUSE 1C 5 AMP INTERIOR FUSE BOX
G1
FUSE 2C 30 AMP EXTERIOR FUSE BOX
737 OR FUSE 2D 30 AMP EXTERIOR FUSE BOX TO BATTERY
TO IGNITION
TO BATTERY
9-S12-009
Figure 12-99: Heated Windshield Schematic 05745159 4-1-00
12-94
Electrical System
_______________________________________________________
Rear Window Defroster Inoperative

Step 1 Action Gain access to the male side of connector C45 on the C-pillar intermediate. Turn the key to the RUN position and the heated rear window switch to the ON position. With a DVOM check the voltage drop between the pink wire (CKT 689) and the black wire (CKT 58). Is the specified voltage present? Check the black wire (CKT 58) for resistance to ground. Does the resistance meet the specied value? Value(s) 12v Yes Replace the heated rear window. No Go to step 2.
<.2
Go to step 3.
Repair the open or bad connection on the CKT 58 between the heated rear window and G4. Go to step 4.
Remove the HVAC control unit from the center console. Turn the ignition switch to the RUN position and activate the rear window defroster switch. With a DVOM check the voltage drop, on connector C46, between terminals D (CKT 689) and C (CKT 59). Is the specified voltage present? Disconnect connector C46 from the back of the HVAC control unit. With a DVOM check the resistance to ground on terminal C (CKT 59). Does the resistance meet the specications?
12v
Repair the open or bad connection on CKT 689 between the HVAC control and the rear window defroster. Go to step 5.
<.2
Repair the open or bad connection on CKT 59 between the HVAC control and G4. Repair the open or bad connection on CKT 688 between the HVAC control and fuse 4M. Repair the open or bad connection on CKT 399 between the HVAC control and fuse 7C.
With a DVOM check terminal A (CKT 688) for battery voltage. Is the specied voltage present?
12v
Go to step 6.
Turn the ignition switch to the RUN position. With a DVOM check terminal B (CKT 399) for battery voltage. Is the specied voltage present?
12v
Replace the HVAC control unit.
4-1-00
______________________________________________________
Electrical System
12-95
TO IGNITION
REAR WINDOW DEFROSTER ( HMC4 & HMSB )
FUSE 7C 30 AMP INTERIOR FUSE BOX TO TEMPERATURE DOOR CONTROL
C45 TO REAR A/C
399 DG
C6 TO HVAC CONTROL PANEL C46
G1
689 PK
A3
58 BK
G4
D TO BATTERY
FUSE 4M 30 AMP EXTERIOR FUSE BOX
REAR WINDOW DEFROST SWITCH
C J6
C46 N7 C6
688 RD
59 BK
G4
C1-13
688 RD
9-S12-157
Figure 12-100: Rear Window Defroster Schematic
05745159
4-1-00
12-96
Electrical System
_______________________________________________________
Power Windows Inoperative, All Windows

Step 1 Action Remove relay R4 from the interior fuse box. With a DVOM check cavity G7 for resistance to ground. Does the resistance meet the specied value? With a DVOM check the voltage at cavity F7. Is the specied voltage present? Value(s) <.2 Yes Go to step 2. No Repair the open or bad connection in CKT 59 between relay R4 and Ground G4. Repair the open or bad connection in CKT 175 between R4 and fuse 5M in the exterior fuse box. Repair the open or bad connection in CKT 296 between R4 and fuse 2G in the interior fuse box. Repair the open or bad connection in circuit 171 between the drivers window switch and R4.
12v
Go to step 3.
Turn the ignition switch to the Run position. With a DVOM check the voltage at cavity F5. Is the specied voltage present?
12v
Go to step 4.
Remove the drivers door window switch and harness from the bezel. Disconnect the power window switch from the harness. With a DVOM check the resistance between cavity 3 on the drivers power window switch harness and cavity G5 of the interior fuse box. Does the resistance meet the specication?
<.2
Replace relay R4 in the interior fuse box.
4-1-00
______________________________________________________
Electrical System
12-97
Drivers Window Inoperative

Step 1 2 Action Do all the other windows operate as designed? Remove the drivers power window switch and harness from the bezel. With a DVOM check the resistance to ground on cavities 2 (CKT 56) and 4 (CKT 56). Does the resistance on each wire meet the specications? Turn the ignition switch to the Run position and check the voltage on terminal 3 (CKT 170). Is the specied voltage present? Value(s) <.2 Yes Go to step 2. Go to step 3. No Refer to proper chart. Repair the open or bad connection in CKT 56 between the power window switch and G4. Repair the open or bad connection on CKT 170 between the power window switch and relay R4. Replace the drivers door power window switch.
12v
Go to step 4.
Connect the power window switch to the harness. With the ignition in the Run position back probe cavities 1 (CKT 227) and 5 (CKT 226) with a DVOM set to measure voltage. Operate the window switch and observe the voltage polarity. The voltage should switch from +12v to -12v with the operation of the switch. Does the polarity switch? Gain access to the window motor. Disconnect the harness and with a DVOM check the wires for polarity change when the power window switch is operated. Does the polarity change?
+12v to -12v
Go to step 5.
+12v to -12v
Replace the power window motor.
Repair the open or bad connection on circuits 226 and 227 between the power window switch and the power window motor.
05745159
4-1-00
12-98
Electrical System
_______________________________________________________
Power Windows Only Operate Using The Console Switches

Step 1 2 Action Does the drivers door window operate as designed? If the window lock out switch is in the Lock position move it to the Unlock position. Are the power windows operating as designed? Gain access to the power window switches on the console. With a DVOM check for a ground on terminals 2 and 4 of all three power window switches. Do all six wires meet with the specied value for resistance to ground? Turn the ignition switch to the Run position. With a DVOM back probe the purple wire on the power window lock out switch. Make sure the switch is in the Unlock position. Is the specied voltage present? With the ignition still in the Run position check the voltage on the red wire (CKT 171) of the power window lockout switch harness. Is the specied voltage present? Value(s) Yes Go to step 2. No further repair is needed at this time. Go to step 4. No Refer to the proper chart. Go to step 3.
<.2
Repair the open or bad connection between the power window switches and ground G4. Go to step 5.
12v
Refer to the individual window charts.
12v
Replace the power window lock out switch.
Repair the open or bad connection between the power lock out switch and relay R4.
4-1-00
______________________________________________________
Electrical System
12-99
Passenger Front Door Power Window Inoperative

Step 1 2 Action Do all the other windows operate as designed? Gain access to the passenger front power window switch harness in the door. Turn the ignition switch to the run position. With a DVOM check the voltage at terminal 3 (CKT 170). Is the specied voltage present? Value(s) 12v Yes Go to step 2. Go to step 3. No Refer to the proper chart. Repair the open or bad connection in CKT 170 between the power window switch and the power window lock out switch. Repair the open or bad connection on CKT 313 or 314 between the passenger door window switch and the console window switch. Replace the passenger front power window switch.
Disconnect the power window switch from the harness. Using a DVOM check for resistance to ground on terminals 2 (CKT 314) and 4 (CKT 313). Does the resistance meet the specications?
<.2
Go to step 4.
Connect the power window switch to the harness and make sure that the ignition switch is in the run position. With a DVOM back probe terminals 1 (CKT 227) and 5 (CKT 226) at the same time. Check the voltage while operating the switch from Up to Down. Is the specied voltage present and does the polarity change from positive to negative with the action of the switch? Gain access to the power window motor and disconnect the harness. With a DVOM back probe the red wire (CKT 227) and the yellow wire (CKT 226). Operate the power window switch and watch the voltage. Is the specied voltage present and does it change from positive to negative with the action of the switch.
+12v to -12v
Go to step 5.
+12v to -12v.
Replace the passenger front window motor.
Repair the open or bad connection on either CKTS 226 or 227 between the power window motor and switch.
05745159
4-1-00
12-100
Electrical System ______________________________________________________
(Passenger/Drivers) Rear Door Power Window Inoperative

NOTE: Refer to the wiring diagram for the circuit numbers. Step 1 2 Action Do all the other windows operate as designed? Gain access to the rear power window switch harness in the door. Turn the ignition switch to the run position. With a DVOM check the voltage at terminal 3 (CKT 170). Is the specied voltage present? Values 12v Yes Go to step 2. Go to step 3. No Refer to the proper chart. Repair the open or bad connection in CKT 170 between the power window switch and the power window lock out switch. Repair the open or bad connection on the tan wire or the light green wire between the door window switch and the console window switch. Replace the power window switch.
Disconnect the power window switch from the harness. Using a DVOM check for resistance to ground on terminals 2 and 4. Does the resistance meet the specications?
<.2
Go to step 4.
Connect the power window switch to the harness and make sure that the ignition switch is in the run position. With a DVOM back probe terminals 1 and 5 at the same time. Check the voltage while operating the switch from Up to Down. Is the specied voltage present and does the polarity change from positive to negative with the action of the switch? Gain access to the power window motor and disconnect the harness. With a DVOM back probe the red wire and the yellow wire, Operate the power window switch and watch the voltage. Is the specied voltage present and does it change from positive to negative with the action of the switch.
+12v to -12v
Go to step 5.
+12v to -12v.
Replace the window motor.
Repair the open or bad connection in the wires between the power window motor and switch.
4-1-00
_____________________________________________________
Electrical System
12-101
POWER WINDOWS
LEFT FRONT DOOR WINDOW SWITCH ( ALL MODELS ) LEFT FRONT DOOR WINDOW MOTOR TO BATT 5M 30 AMP CIRCUIT EXTERIOR BREAKER FUSE BOX RIGHT FRONT DOOR RIGHT FRONT DOOR WINDOW SWITCH WINDOW MOTOR ( ALL MODELS )
226 YL 227 RD 175 LB
226 YL
C17
227 RD
B D C
C15
C1-69 F7
59 BK
G7
56 BK G4 LEFT REAR DOOR WINDOW SWITCH ( ALL MODELS )
G4
314 WT 313 DB 170 PP
171 RD
296 DG
LEFT REAR DOOR WINDOW MOTOR
G5
F5
POWER WINDOW RELAY R4
RIGHT REAR DOOR WINDOW MOTOR
RIGHT REAR DOOR WINDOW SWITCH ( ALL MODELS )
FUSE 2G 5 AMP 227 RD 226 YL INTERIOR FUSE BOX TO IGNITION 227 RD
226 YL
C21 C E D
C22
C19
317 LG 170 PP 316 TN CONSOLE LEFT REAR WINDOW SWITCH CONSOLE C6 RIGHT FRONT WINDOW SWITCH
K8 K9 A1
G4
C18
319 TN 170 PP 320 LG
H6
E1
E2
P9
P8
P6
CONSOLE RIGHT REAR WINDOW SWITCH
CONSOLE WINDOW LOCK SWITCH
170 PP
58 BK 171 RD
9-S12-011
Figure 12-101: Power Window Schematic 05745159 4-1-00
12-102
POWER DOOR LOCK SWITCH REPLACEMENT

NOTE: Switch replacement is the same for all doors.
POWER DOOR LOCK ACTUATOR REPLACEMENT

Removal
NOTE: Actuator replacement is the same for all doors. 1. 2. 3. Raise window. Remove door trim panel. Remove vapor barrier (Figure 12-103).
Removal
1. 2. Remove mounting plate, capscrews, and remove switch from switch bezel (Figure 12-102). Disconnect door harness from switch.
Separate switch from mounting plate.
Installation
1. 2. 3. Assemble switch and mounting plate. Connect switch to door harness. Install switch and mounting plate on bezel and secure with screws.
VAPOR BARRIER
DOOR HARNESS
SWITCH BEZEL
Figure 12-103: Vapor Barrier Removal/Installation 4. Detach door harness connector from door actuator (Figure 12-104).
SWITCH
Figure 12-102: Power Door Lock Switch Mounting
4-1-00
_____________________________________________________
Electrical System
12-103
CLIP ACTUATOR ROD
Door Lock Actuator Replacement For Rear Cargo Door (HMCS Only)
Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove window from primary rear door. Remove (4) screws and interior door handle. Remove (12) screws securing inner door panel to door. Remove inner door panel. Disconnect link rod from lock actuator by rotating plastic lock clip clockwise. Remove link rod from plastic clip, and plastic clip from actuator. Remove screw securing door lock actuator to bracket. Disconnect door lock harness from actuator. Remove actuator from bracket (Figure 12-105).
CLIP
LOCK LEVER ACTUATOR
HARNESS CONNECTOR
DOOR HARNESS
Figure 12-104: Door Lock Actuator Removal/Installation 5. 6. Remove actuator attaching screws. Remove actuator from door and disconnect actuator rod from clips and actuator.
LINK ROD
Installation
NOTE: Color coding on actuator rod is positioned away from actuator during installation. Actuator rods are color coded as follows: left front, red; right front, green; left rear, yellow; and right rear, blue. 1. 2. 3. Connect clip and actuator rod to lock lever (Figure 12-104). Install opposite clip on actuator and connect rod to actuator. Secure actuator with mounting screws.
ACTUATOR HARNESS
ACTUATOR
Figure 12-105: Cargo Door Lock Actuator
Installation
1. 2. 3. 4. 5. 6. 7. 8. Connect door lock harness to new door lock actuator. Place actuator on bracket so actuator plunger is on the left side of the actuator. Install screw securing door lock actuator to bracket. Install plastic clip into hole in actuator plunger. Install link rod into plastic clip and rotate counter clockwise to lock in place (Figure 12-105). Install inner door pane with (12) screws. Install inner door handle with (4) screws. Verify operation of door handle and door locks.
CAUTION: The actuator threads will strip if overtightened. 4. Connect harness wires to actuator.
NOTE: Vapor barrier must be completely sealed at all edges to prevent water entry into the interior of the vehicle. 5. 6. Install vapor barrier (Figure 12-103). Install door trim panel.
05745159
4-1-00
12-104
Rear Cargo Door Lock Module Replacement (HMCS Only).

Removal
1. 2. 3. Remove right rear seat. Remove right rear seat belt ratchet assembly. Remove right rear corner trim assembly (Figure 12-106).
CARGO BULKHEAD
Rear Cargo Door Lock Harness Jumper Replacement

Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove right rear seat. Remove right rear seat belt ratchet assembly. Remove right rear corner trim assembly (Figure 12-106). Disconnect harness from rear door lock module. Remove slide out bulkhead. Remove closeout panel from passenger side of rear cargo door frame. Disconnect harness from door hinge contacts. Pull the padding and carpet on the cargo area wall upward to expose the harness. Remove remaining trim pieces behind right rear passenger seat. Remove lower passenger side B-pillar trim. Remove passenger side righthand kick panel. Disconnect rear cargo door lock jumper. Remove the harness from the vehicle.
RIGHT REAR CORNER TRIM ASSEMBLY
9. 10. 11. 12. 13.
Figure 12-106: Removing Right Rear Trim Piece 4. 5. Disconnect rear door lock harness jumper assembly from the rear door lock module. Pull the module loose from the velcro attaching it to the body.
Installation
1. Connect rear cargo door lock jumper harness to the connector at the B-Pillar. 2. Route harness along same locations to the rear cargo door lock module. 3. Connect the harness to the door lock module. 4. Route harness to the door hinge contacts and connect it. 5. Install passenger side cargo door frame closeout panel. 6. Reposition the cargo area padding. 7. Install trim pieces behind right rear passenger seat. 8. Install rear passenger righthand side kick panel. 9. Install passenger side lower B-pillar trim. 10. Install removable cargo area bulkhead. 11. Install passenger right rear seat.
Installation
1. 2. 3. 4. 5. 6. 7. Apply new velcro strip to new rear door lock module Affix new module to body and connect rear door lock harness jumper. Verify operation of rear door locks. Install right rear trim piece (Figure 12-106). Apply loctite 242 to seat belt ratchet bolt. Install seat belt ratchet bolt and torque to 35-40 ft-lbs (47-55 Nm). Install right rear seat.
4-1-00
_____________________________________________________
Electrical System
12-105
KEYLESS ENTRY & THEFT DETERRENT SYSTEM OPERATING INSTRUCTIONS Keyless Entry & Theft Deterrent System
The optional keyless entry system allows convenient operation of the vehicle door locks from a distance. Equipped vehicles are supplied with two, three button remote transmitters used to operate the system. Two additional remote transmitters can be added. NOTE: Vehicles not equipped with keyless entry will have a jumper harness installed in place of the receiver module.
Locking the Doors

To lock the vehicle doors, press the lock button on the remote transmitter once. A red L.E.D. on the remote transmitter will illuminate while the button is depressed, indicating that the remote transmitter is functioning. The vehicle parking lights will flash once, and the horn will beep softly to confirm that the command was recieved.The theft deterrent system arms at this time. The theft deterrent system will beep the horn and flash the lights if any door is opened before disarming with the remote transmitter by unlocking the doors.
LOCKING THE DOORS & ARMING THE THEFT DETERRENT SYSTEM
Unlocking the Doors

When approaching the vehicle press the unlock button on the remote transmitter once. This will unlock the drivers door. The vehicle lights will flash 2 times, and the horn will beep twice softly to confirm that the command was received. The interior lights will turn on and remain activated for approximately 30 seconds, and the theft deterrent system will disarm. To unlock the remaining doors, press the unlock button on the remote transmitter a second time.
LOCK BUTTON
UNLOCK BUTTON
PANIC BUTTON
Theft Deterrent System Override

If the battery in the remote transmitter is dead, or the remote transmitter is not operating, the theft deterrent system will need to be overridden once the door is opened. The alarm will start as soon as a door is opened.To override the alarm, place the key in the ignition, and turn it to the on then off position 3 times. The system will remain in override until the doors are locked again with the remote transmitter.
9-OM2-005
Figure 12-107: 3-Button Transmitter
Panic Activation
The panic feature can be used to activate the vehicle audio and visual theft deterrent features to draw attention to yourself during an emergency situation. Simply press and hold the PANIC button for 3 seconds. This will cause the vehicle horn and lights to pulse on and off for approximately 30 seconds. To deactivate the panic feature before the time period expires, press and release the panic button.
LOCK BUTTON PANIC BUTTON
UNLOCK BUTTON GARAGE DOOR OPERATION
9-OM2-004
Figure 12-108: 4-Button Transmitter
05745159
4-1-00
12-106
SYSTEM FEATURES
System features can be activated or deactivated as required by the owner. Some system features are active when the vehicle is purchased.
OPTIONAL GARAGE DOOR ACCESSORY PACKAGE

The Garage Door Accessory Package provides the owner with the ability to operate their existing garage door opener with the same keyless entry remote transmitter used to open and lock your HUMMER. This system includes two 4-button remote transmitters and a garage door receiver that must be installed in your existing garage door system. The package must be purchased from a HUMMER dealership and the remote transmitters programmed to the HUMMER. Installation of the garage door receiver is the responsibility of the Hummer Owner.
Passive Theft Deterrent Arming

This feature will automatically arm the theft deterrent system 30 seconds after you depart the vehicle. The arming will take place even if the lock button isnt pushed on the remote transmitter. Passive locking can also be activated with this feature.
Passive Locking
This feature will lock the doors 30 seconds after the vehicle is departed. The doors will lock automatically even if the lock button is not pushed on the remote transmitter. When this feature is active, the ignition keys should never be left in the vehicle because the system will still lock the doors. This feature requires that the theft deterrent system also be set to passive arming.
Synchronizing the Remote Transmitters

If the keyless entry remote transmitter is operated 50 times or more outside the range of the vehicle, the remote transmitter codes will not match the code that the receiver expects. If the remote transmitter does not activate the lock system, and the batteries are not dead, the remote transmitter may need to be synchronized with the receiver. Stand close to the vehicle and press the lock button twice within one second. If there is no response, try pressing the button twice faster, then slower. If there is still no response, the system must be checked.
Automatic Door Lock*

This feature will lock the doors 3 seconds after the ignition key is turned to the on position. The system will not lock the doors if a door is ajar when the key is turned on.
Battery Replacement
It is suggested that the batteries in your remote transmitters be replaced every 12 months to maintain optimum performance. Should the remote transmitter range begin to decrease or the red L.E.D. on the remote transmitter stop functioning, the battery will need to be replaced.To replace the batteries: 1. Remove the phillips screw from the back of the remote transmitter 2. Carefully pry the top of the remote transmitter away from the bottom part. 3. Remove the old battery making note of battery polarity. 4. Replace the old battery with a new GP27A type. 5. Assemble the remote transmitter. Batteries can be obtained where small camera and watch batteries are sold.
Automatic Door Unlock*

This feature will automatically unlock the drivers door when the ignition key is turned off. The system can be programmed by an authorized HUMMER dealer to unlock all the doors.
Horn Chirp*
This feature chirps the horn when the doors are locked and unlocked.
Disarming the Horn Chirp

The horn chirp feature can be disabled so that only the parking lights will flash during lock and unlock.To disable the horn chirp: 1. Press and release the unlock button on the remote transmitter button once. 2. Open the drivers door and leave it open 3. Turn the ignition on then off 5 times within 5 seconds. Do not start the vehicle. 4. When the key is turned on for the fifth time, the horn will chirp twice to indicate that the feature has been disabled. If it does not, the key cycles were not within the 5 second time frame, and the procedure must be started over. 5. Turn the ignition key off, and test the system with the remote transmitter. 6. To reactivate, repeat the procedure NOTE: * Indicates features which are active when the vehicle is manufactured 4-1-00
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Electrical System
12-107
REMOTE ENTRY SYSTEM Remote Entry Receiver Replacement

Removal
1. 2. 3. Remove front console enough to gain access to receiver (Section 10). Disconnect two receiver harness connectors from receiver (Figure 12-109). Remove receiver from two velcro strips.
Installation
4. 5. 6. 7. 8. Install receiver on two velcro strips. Connect receiver harness connectors to receiver. Program receiver to accept remotes. Check remote entry system for proper operation. Install front console (Section 10).
ENGINE COVER
REMOTE ENTRY MODULE
CONSOLE CONNECTOR
CROSS BODY HARNESS
9-S12-085
PCM
Figure 12-109: Remote Entry Receiver
05745159
4-1-00
12-108
REMOTE ENTRY RECEIVER/TRANSMITTER REPLACEMENT

Removal
1. 2. 3. 1. 2. Remove center console. Disconnect wire connection at receiver and remove reciever from engine cover (Figure 12-109). Installation Place hook and loop on back of receiver and place reciever on engine cover. Connect wire harness and reprogram system. 2.
3. 4.
5. 6.
PROGRAMMING NEW OR REPLACEMENT REMOTE TRANSMITTERS Keyless Entry Remote Transmitter Troubleshooting
1. If the customer's complaint indicates a gradual decrease in range of the remote transmitter, or intermittent operation of the remote transmitter, the battery may need replacement. The red Light Emitting Diode on the keyless entry remote transmitter should illuminate brightly when a remote transmitter button is pressed. The remote transmitter may operate when the battery voltage drops below 4.0V DC, however range and reliability will be sacrificed at this level. When this same battery is measured under load, the voltage will drop close to or below the 3.0 VDC level. Battery replacement is usually recommended when the voltage drops to or below 5.0 VDC with no load. If the battery voltage is at an acceptable level, but the remote transmitter will not activate the system, it may need to be synchronized. To re-synchronize the remote transmitter to the receiver, stand close to the vehicle and press and release the LOCK button 2 times within one second. The vehicle's horn should chirp one time indicating that you have locked the doors and armed the system. If re-synchronizing does not work on your first attempt, try again slower, then again faster.
7.
rent System Override procedure explained in the operating instructions. Gain access to the programming push-button switch located on the keyless entry control module, which is mounted under the center console of the vehicle. Turn the ignition key to the ON position. Within 15 seconds, press and release the programming switch 3 times. The vehicle horn will sound one time indicating that the system is in program mode Press and hold the LOCK button on the remote transmitter until the vehicle horn sounds one long chirp. Repeat step 5 for all remote transmitters that you wish to program (up to four). Turn the ignition key to the OFF position, or wait 15 seconds, and the system will automatically terminate the programming mode. This is indicated by a 3 chirp signal from the vehicle horn.
Remote Transmitter Programming Hints

1. If you wait more than 15 seconds between steps In the programming mode, the system will automatically terminate the programming mode. This is indicated by the 3 chirp signal from the vehicles horn. Simply start over to complete programming of all remote transmitters, 2 Test all programmed remote transmitters to be sure that all buttons are operating, Remember the system will not remotely lock the doors while the ignition key is in the ON position.
2.
CHANGING THE SELECTABLE FEATURES

Some of the features of the keyless entry and theft deterrent system Can be changed or tailored to the needs of the owner.The following is a list of alterable features included in the HUMMER remote entry system 1. Auto Door Lock 2. Auto Drivers Door Unlock 3. Auto passenger doors unlock 4. Active theft deterrent 5. Active door locking
3.
Programming The Keyless Entry Remote Transmitters

You should have access to all keyless entry remote transmitters that will ultimately operate the unit, even if they are currently programmed to do so. Each keyless entry receiver module will learn and store up to four different remote transmitter codes. When a fifth remote transmitters programmed, the first remote transmitter that was originally programmed to the unit will be bumped out of the system memory. 1. To start programming, make sure that the Theft Deterrent System is disarmed, either by using a remote transmitter that is currently programmed, or by using the The Deter4-1-00
Programming the Selectable Features

1. To start programming, make sure that the Theft Deterrent System is disarmed, either by using a remote transmitter that is currently programmed, or by using the Theft Deterrent System Override procedure. Gain access to the programming pushbutton Switch located on the keyless entry control module, which is mounted in the center console of the vehicle. Turn the ignition key to the ON position. Within 15 seconds, press and release the programming Switch 3 times. The vehicle's horn will sound one time indicating that the system is in remote transmitter program mode.
2.
3. 4.
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Electrical System
12-109
5.
6.
7.
8.
Immediately turn the ignition key off (3 chirps indicates exit remote transmitter program mode) and then back on. The vehicle's horn will sound 2 chirps indicating that the system is in feature programming mode. Press and release the programming switch on the keyless entry module 1 time to advance to feature number 1. The vehicle's horn will chirp 1 time If feature 1 is in the ON position, Or 2 times if feature 1 is in the OFF position To change the feature, press and release the LOCK button on the keyless entry remote transmitter, and the appropriate 1 or 2 chirp signal from the horn will identify the new selection for that feature (Refer to the table shown above). To advance to selectable feature number 2, press and release the programming switch on the keyless entry module a second time, and again the vehicle's horn will identify the selection of that feature as on or off. Use the lock button on the keyless entry remote transmitter to
9.
change the feature or proceed to the next step if no change is desired Turn the ignition key off or allow 15 seconds to pass, and the vehicle's horn will sound 3 chirps indicating programming mode has been terminated.
Feature Programming Hints

1. Unless otherwise specied, if you wait more than 15 seconds between steps in the programming mode, the system will automatically terminate the programming mode. This is indicated by the 3 chirp signal from the vehicle's horn. Simply start over to complete programming of all features. Test the system to be sure that all selectable features are functioning according to your customers requests. If you have missed a feature or changed the wrong feature, simply re-enter the feature programming mode to make the appropriate changes.
2.
Feature # 1
Function Auto door lock Factory preset ON
ON or active, one chip indication When active, doors will lock three seconds after the ignition is turned on. Will not operate if a door is ajar. When active, drivers door will unlock three seconds after the ignition is turned off When active, passenger doors will unlock three seconds after the ignition is turned off When active, the theft deterrent system arms when the remote transmitter LOCK button is pushed
OFF or passive, two chip indication No auto lock
Auto drivers door unlock. Factory preset ON Auto passenger doors unlock. Factory preset OFF *Active or passive theft deterrent. Factory preset ACTIVE *This feature must be set to passive prior to setting feature 5 to passive
No drivers auto door unlock
No passenger door auto unlock
When the feature is off, or passive, the theft deterrent system automatically arms 30 seconds after the ignition is turned off and the vehicle is departed. All doors must be closed. When this feature is passive, and feature four is passive, the doors will lock 30 seconds after the ignition is turned off and the vehicle is departed. All doors must be closed
*Active or passive door locking. Factory preset ACTIVE *Passive feature requires feature 4 to be set to passive
When active, doors will lock when LOCK button is pressed, or Auto ignition LOCK feature is active.
05745159
4-1-00
12-110
Power Locks Inoperative w/o Keyless

Step 1 Action Remove the passenger door lock switch from the bezel. Using a DVOM measure voltage on pin 3 (CKT 517). Is the specied voltage present? Value(s) 12v Yes Go to step 2. No Repair the open, or bad connection in CKT 517 between the passenger side door lock switch and fuse 3H. Go to step 3.
Disconnect the passenger door lock switch from the harness. Using a DVOM check the resistance to ground on pins 2 (CKT 120), and 4 (CKT 119). Is the resistance below the specied value? Remove the drivers door lock switch from the bezel, and disconnect it from the harness. On the drivers harness place a jumper wire between pins 1 (CKT 120) and 5 (CKT 119). With a DVOM check for continuity between pins 2 (CKT 120) and 4 (CKT 119) on the passenger door lock harness. Does the resistance meet the specied value? Remove the jumper wire from the drivers door lock switch harness. With a DVOM check the resistance to ground on the drives door lock switch harness pins 2 (CKT 58) and 4 (CKT 58). Does the resistance meet the specied values on both pins? Connect the door lock switches to their harnesses. Using a DVOM back probe pins 1 and 5 of the passenger door lock switch. Move the switch to Lock, then Unlock. Does the voltage alternate between +12v and 12v? Locate connector C31 under the center console. Using a DVOM probe pin F (CKT 121), and pin B (CKT 122). Move the passenger lock switch to Lock then Unlock. Does the voltage alternate between +12v and 12v?
<.2
Go to step 5.
<.2
Go to step 4.
Repair the open, or bad connection in CKT 120, and/ or CKT 119 between the drivers and passenger door switches. Repair the open or bad connection in CKT 58 between the drivers door lock switch and G4. Replace the passenger door lock switch.
<.2
Replace the drivers door lock switch.
+12v and 12v
Go to step 6.
+12v and 12v
Locate the open or bad connection, in CKTS 117 or 118 between C 31 and the door lock actuator.
Locate the open or bad connection in CKTS 121 or 122 between the passenger door lock switch and C31.
4-1-00
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Electrical System
12-111
Power Door Locks Inoperative, W/ Remote Entry

Step 1 Action Remove the passenger door lock switch from the bezel. Using a DVOM measure voltage on pin 3 (CKT 517). Is the specied voltage present? Value(s) 12v Yes Go to step 2. No Repair the open, or bad connection in CKT 517 between the passenger side door lock switch and fuse 3H. Go to step 3.
Disconnect the passenger door lock switch from the harness. Using a DVOM check the resistance to ground on pins 2 (CKT 120), and 4 (CKT 119). Does the resistance meet the specied value? Remove the drivers door lock switch from the bezel and disconnect it from the harness. On the drivers harness place a jumper wire between pins 1 (CKT 120) and 5 (CKT 119). With a DVOM check for continuity between pins 2 (CKT 120) and 4 (CKT 119) on the passenger door lock harness. Does the resistance meet the specied value? Remove the jumper wire from the drivers door lock switch harness. With a DVOM check the resistance to ground on the drives door lock switch harness pins 2 (CKT 58) and 4 (CKT 58). Does the resistance meet the specied value on both pins? Connect the door lock switches to their harnesses. Using a DVOM backprobe pins 1 and 5 of the passenger door lock switch. Move the switch to Lock, then Unlock. Does the voltage alternate between +12v and 12v? Locate connector C31 under the center console. Using a DVOM probe pin F (CKT 121), and pin B (CKT 122). Move the passenger lock switch to Lock then Unlock. Does the voltage alternate between +12v and 12v?
<.2
Go to step 5.
<.2
Go to step 4.
Repair the open, or bad connection in CKT 120, and/or CKT 119 between the drivers and passenger door switches. Repair the open or bad connection in CKT 58 between the drivers door lock switch and G4. Replace the passenger door lock switch.
<.2
Replace the drivers door lock switch.
+12v and 12v
Go to step 6.
+12v and 12v
Go to step 7
Locate the open or bad connection in CKTS 121 or 122 between the passenger door lock switch and C31. Go to step 8.
Using a DVOM Check the voltage drop between connector C31 at pin D (CKT 517) and connector C30 at pin A (CKT 58) with the negative lead. Is the specied voltage present?
12v
Go to step 9.
05745159
4-1-00
12-112
Power Door Locks Inoperative, W/ Remote Entry (Continued)

Step 8 Action Using a DVOM measure resistance to ground at C30 pin A (CKT 58). Does the resistance meet the specied value? Value(s) <.2 Yes Repair the open or bad connection in CKT 517 between the remote entry module and fuse 3H. Go to step 10. No Repair the open or bad connection in CKT 58 between the remote entry receiver and G4. Repair the open or bad connection in CKT 554 between the remote entry module and fuse 1H. Replace remote entry module.
Using a DVOM check the voltage drop on C30 at pins G (CKT 554) and A (CKT 58). Is the specied voltage present?
12v
10
Harness should be connected to the module. Using a DVOM, set to measure voltage, back probe C31 at pins G (CKT 117) and A (CKT 118). Move the lock switch from Lock to Unlock and observe the voltage polarity. Does the voltage switch from +12v to -12v?
+12v and 12v
Repair the open or bad connection in CKT 117 or 118 between the remote entry module and door lock actuator.
Slant Door Lock Inoperative

Step 1 Action Do the other door locks function correctly? Value(s) Yes Go to step 2. No Refer to the diagnostic chart(s) that apply. Repair the open or bad connection in CKT 117 or 118, between C41 and C18. Repair the open or bad connection in CKT 117 or 118, between the actuator and C41.
Gain access to the connector C41. Using a DVOM, set to measure voltage, back probe pins E (CKT 118) and F (CKT 117). Move the drivers lock switch to Lock, then Unlock. Does the voltage alternate between +12v and -12v? Gain access to the slant door actuator motor. Disconnect the harness form the actuator. Using a DVOM, back probe CKTS 117 and 118. Operate the door locks in both Lock and Unlock. Does the voltage pulse +12v then -12v?
+12v and -12v
Go to step 3.
+12v and -12v
Replace the slant door lock actuator.
4-1-00
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Electrical System
12-113
Cargo Door Lock Inoperative

Step 1 Action Does power the lock system on vehicle operate correctly? Open the primary cargo door. Using a DVOM measure the voltage across the brass door contacts on the body. Operate the door locks in both Lock and Unlock. Does the voltage pulse +12v then 12v? Remove inner door panel and disconnect door lock actuator. Using a DVOM set to measure resistance, measure continuity between the door contacts and door lock actuator on CKTS 117 and 121. Does the resistance meet the specication? Gain access to cargo door lock delay module. Disconnect the module connector. Using a DVOM set to measure voltage, probe pins 9 (CKT 517), and 3 (CKT 59). Is the specied voltage present? Check the voltage drop on pin 9 (CKT 517). Is the specied voltage present? +12v then 12v Value(s) Yes Go to step 2. No Refer to the diagnostic charts that apply. Go to step 4.
Go to step 3.
<.2
Replace the door lock actuator.
Locate the open or bad connection in CKT 117 or 121. Go to step 5.
12v
Go to step 6.
12v
Repair the open or bad connection in CKT 59 between the cargo door lock delay module and G4. Go to step 7.
Repair the open or bad connection in CKT 517 between the cargo door lock delay module and fuse 3H. Repair the open or bad connection, in CKT118 between the cargo door lock module and door lock switches. Replace cargo door lock delay module.
Using a DVOM set to measure voltage, probe pin 5 (CKT 118) of the cargo door lock delay module and pin 3. Move a door switch to Unlock. Is the specied voltage present?
12v
Using a DVOM probe pins 6 (CKT 117), and 10 (CKT 121) at the cargo door lock delay module connector. Operate the door lock switch in both Lock and Unlock. Does the voltage alternate between +12v and -12v?
+12v and 12v
Repair open or bad connection in CKT 117 or 118 between the cargo door lock delay module and door contacts.
05745159
4-1-00
12-114
Remote Entry System Inoperative

Step 1 2 3 Action Does the panic feature operate when the button is depressed on the transmitter? Does the L.E.D. illuminate on the keyless transmitter when a button is depressed? Measure the battery voltage of the transmitter battery.Is the specied voltage present? Attempt to re-synchronize the transmitter to the receiver. Is the problem repaired. Reprogram the receiver to the transmitters. Is the problem solved? Gain access to the receiver under the console. Disconnect connector C30 from the receiver. Using a DVOM measure the voltage drop between pins G (CKT 554) and A(CKT 58). Is the specied voltage present? Using a DVOM measure the resistance to ground at C30 pin A(CKT58). Does the resistance meet the specied value? 12v > +5v Value(s) Yes Go to step 6. Go to step 4. Replace the transmitter. No further action required. No further action required. Go to step 8. No Go to step 2. Go to step 3. Replace the transmitter battery Go to step 5. Go to step 6. Go to step 7.
4 5 6
<.2
Repair the open or bad connection in CKT 554 between the receiver and fuse 1H Go to step 9.
Repair the open or bad connection in CKT58 between receiver and G4 Repair the open or bad connection in CTK 517. Replace the remote entry receiver.
Using a DVOM check the voltage drop between C30 pin A (CKT 58) and C31 pin D (CKT 517). Is the specied voltage present? Reconnect C30, and C31 to the remote entry module. Using a DVOM, back probe C31, pins G (CKT 117) and A (CKT 118). Using the remote entry transmitter, attempt to lock and unlock drivers door. Does voltage alternate between +12v and 12v?
12v
+12v and 12v
Refer to the Power Lock INOP diagnostic chart.
4-1-00
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Electrical System
12-115
LEFT FRONT DOOR LOCK SWITCH L U
BATT
RIGHT FRONT DOOR LOCK SWITCH U L
FUSE 3H 20A INTERIOR 2 A C14 B 1 3 5 E 4 F C16 C48 C49 A 4 5 B 3 1 E 2 F
C15-A
120 LG 517 OR
56 BK G4
REMOTE ENTRY MODULE (REM) DRIVER COMMON DOOR UNLOCK UNLOCK H C31 122 PP 121 YL G LOCK ALL DOORS A
COMMON UNLOCK F
DOOR UNLOCK E D
COMMON UNLOCK B
GROUND C30-A 58 BK G4
117 PK
118 BR C C14 D C C16
517 OR C47 C20-A M L U R/F DOOR LOCK ACTUATOR 117 PK 6 D E C18 121 YL 10 117 PK 118 BR 5 LOCK COMMAND LOCK SIGNAL UNLOCK 517 OR 9 BATT
M L U 118 BR 117 PK C19 E D L/F DOOR LOCK ACTUATOR
DOOR CONTACTS B C22 A B A C21 59 BK
117 PK
3 C20-B
M L U L/R DOOR LOCK ACTUATOR
M U L CARGO DOOR LOCK ACTUATOR L
M U G4 R/R DOOR LOCK ACTUATOR
CARGO DOOR LOCK MODULE 9-S12-073
Figure 12-110: Power Locks HMCS W/ Remote Entry 05745159
C17-A
GROUND
119 TN
12-116
LOCK SWITCH L U
BATT
LOCK SWITCH U L
FUSE 3H 20A INTERIOR 2 A C14 C15-A 119 TN 120 LG 517 OR 56 BK G4 B 1 3 5 E 4 F C16 C17-A C48 C49 A 4 5 B 3 1 E 2 F
H H
G G
F F
E E
D D
B B 122 PP 121 YL
A A
C31 (JUMPER) C31
117 PK
118 BR D C C14 117 PK D C C16
517 OR
C47 C20-A M L U R/F DOOR LOCK ACTUATOR 117 PK 6 C19 E D 117 PK D E C18 121 YL 10 117 PK 118 BR DOOR CONTACTS B C22 A B A C21 59 BK 3 C20-B M L L/R DOOR U M U L CARGO DOOR L R/R DOOR M U G4 9-S12-075 CARGO DOOR LOCK MODULE 5 LOCK COMMAND LOCK SIGNAL 517 OR 9 BATT M L U L/F DOOR LOCK ACTUATOR 118 BR
UNLOCK
GROUND
Figure 12-111: Power Locks HMCS W/O Remote Entry
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Electrical System
12-117
HOT AT ALL TIMES FUSE 3H 20A INTERIOR
2 C14-A
1 C14-B G4
3 C15-A U 118 BR L
5 C14-E M B M
4 C15-F 119 TN 120 LG 517 OR 121 YL 121 YL D C31 BATT INPUT DRIVERS DOOR UNLOCK G C31 COMMON UNLOCK PASSENGER DOOR UNLOCK E COMMON UNLOCK COMMON LOCK B H F LOCK ALL DOORS A 117 PK 118 BR L L M D C19 E C41 E F D B 118 BR 117 PK 118 BR A 117 PK
4 C16-A
5 C16-B
3 C17-A
1 C16-E
2 C16-F
REMOTE ENTRY MODULE (REM)
117 PK 122 PP
L/F DOOR LOCK MOTOR
U R/F DOOR LOCK MOTOR E A 117 PK C18 C21
C22
L/R DOOR LOCK MOTOR (not used on XLC2)
M U L SLANT BACK DOOR LOCK MOTOR (HMSB only)
U R/R DOOR LOCK MOTOR (not used on XLC2) 00-S12-017 L
Figure 12-112: Power Locks HMC4, XLC2 , HMSB W/ Remote Entry 05745159
12-118
LEFT FRONT DOOR LOCK SWITCH L U
BATT
RIGHT FRONT DOOR LOCK SWITCH U L
FUSE 3H 20A INTERIOR 2 A C14 B 1 3 5 E 4 F C16 C48 C49 A 4 5 B 3 1 E 2 F
C15-A
119 TN 120 LG 517 OR
56 BK G4
H H
G G
F F
E E
D D
B B 122 PP 121 YL
A A
C31 (JUMPER) C31
117 PK
118 BR D C C14 117 PK D C C16
M L U L L/F DOOR LOCK ACTUATOR 118 BR 117 PK E C19 118 BR 117 PK B C22 A E C41 F B D D E C18
M U R/F DOOR LOCK ACTUATOR
A C21
M L U L/R DOOR LOCK ACTUATOR (not used on XLC2)
M U L SLANT BACK DOOR LOCK ACTUATOR (HMSB only)
M U R/R DOOR LOCK ACTUATOR (not used on XLC2) L
Figure 12-113: Power Locks HMC4, XLC2 , HMSB W/O Remote Entry
C17-A
00-S12-016
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Electrical System
12-119
TO CHIME
TO DOME LAMPS
LF DOOR JUMP SWITCH
RF DOOR JUMP SWITCH 53 LB 54 DG FUSE 5H 15 AMP INTERIOR BATT
BATT
IGNITION
TO HORN SWITCH ON STEERING COLUMN
TO HORN RELAY
TO PARK LIGHT
TO PARK LAMP SWITCH
FUSE 1H 5 AMP INTERIOR 554 GY
FUSE 7B 5 AMP INTERIOR 840 DG
C1-62
14 LB
58 BK
G4
C30
G BATT
F IGN
E HORN ACTIUATION
H PARK LIGHT FLASH
53 LB D DOME LAMPS ACTIUATION
GROUND
REMOTE ENTRY MODULE
1 DB
9-S12-065
Figure 12-114: Remote Entry Module Power/Ground 05745159
12-120
POWER DOOR LOCK FRONT DOOR HARNESS REPLACEMENT

Removal
NOTE: Left and right front power door lock harness replacement procedures are similar. 1. 2. 3. 4. Remove front seat. Remove outer kick panels. Remove power door locks switch from door trim. Remove front door trim.
NOTE: Lubricate bushings, grommet, and door harness teflon cover with silicone spray. 10. Pull harness through A-pillar rubber grommet. 11. Remove and inspect A-pillar rubber grommet. Discard if damaged. 12. Remove two capscrews and support bracket from inner door. 13. Pull harness through door bushing. Inspect door bushing. Replace if damaged. 14. Pull support bracket from harness. Inspect support bracket bushing. Replace if damaged. 15. Disconnect clip from door reinforcement and remove from door harness. 16. Remove tie strap securing door harness to access hole and remove harness. Discard tie strap.
NOTE: Vapor barrier may be positioned under velcro strip, if so, cut around velcro strip to remove vapor barrier. 5. Remove vapor barrier and moisture barrier flap from door (Figure 12-115).
Installation
1. 2. 3. 4. 5.
MOISTURE BARRIER FLAP VAPOR BARRIER
6. 7. 8. 9.
Install harness in support bracket. Install harness through door bushing and support bracket. Install support bracket on inner door with two capscrews. Install rubber grommet in A-pillar. Install harness through grommet until yellow tape touches A-pillar front. Install six-lead and one-lead connectors to door harness leads, matching colors to dash harness. Connect door harness to dash harness. Install P-clamp and door harness on A-pillar with capscrew and nut and lockwasher assembly. Install clamp and door har
ness at yellow tape area with capscrew. Install clip on door harness and connect harness to door lock actuator, window motor and power mirror (if equipped) Lower window. 10. Route lock switch lead up through lower access hole between support bracket and window channel. Secure at top access hole with tie strap (left front door only). Figure 12-115: Vapor Barrier 6. 7. 8. 9. Remove capscrew and clamp securing door harness to door reinforcement. Remove capscrew, nut and lockwasher assembly, and Pclamp securing door harness to A-pillar. Disconnect harness from lock motor, window motor and mirror (if equipped). Disconnect four-lead and six-lead connectors. Remove door harness wires from connectors with extraction tool. Note position of wires for installation of the new harness. NOTE: Vapor barrier must be completely sealed at all edges to prevent water entry into the interior of the vehicle. 11. Route lock switch lead through vapor barrier and moisture barrier flap and install moisture barrier and vapor barrier flap on door. 12. Install front door trim. 13. Install power door locks switch. 14. Install outer kick panels. 15. Install front seat. 16. Verify operation.

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Electrical System
12-121
POWER DOOR LOCK REAR DOOR AND JUMPER HARNESS REPLACEMENT

Removal
NOTE: Left and right rear power door locks harness replacement procedures are identical. 1. 2. 3. 4. Remove front seat. Remove trim from B-beam and B-pillar (Section 10). Remove side trim and outer kick panel (Section 10). Remove rear door trim (Section 10).
9. 10. 11. 12. 13. 14.
NOTE: Vapor barrier may be positioned under velcro strip If so, cut around velcro strip to remove vapor barrier. 5. 6. 7. 8. Remove vapor barrier and moisture barrier flap. Remove capscrew and clamp securing rear door harness to door reinforcement. Disconnect rear door harness from jumper harness. Remove convoluted tubing from rear door harness.
15. 16. 17. 18. 19.
Remove two-lead connector from rear door harness with pin extraction tool. Remove capscrew, washer, nut and lockwasher assembly, and P-clamp from rear door harness and B-pillar. Pull harness through rubber grommet in B-pillar. Remove and inspect grommet. Discard if damaged. Remove two capscrews and support bracket from rear door. Pull harness through door bushing and remove support bracket from harness. Inspect support bracket bushing. Replace if damaged. Inspect bushing in rear door. Replace if damaged. Disconnect door harness connector from actuator lead. Disconnect clip from door reinforcement and remove from rear door harness. Remove rear harness from door. Disconnect jumper harness from dash harness at A-pillar. Remove tie straps and jumper harness (Figure 2-116).
POWER WINDOWS AND LOCKS CROSS BODY HARNESS
A-PILLAR JUMPER HARNESS
Figure 2-116: Door Harness Connection
05745159
4-1-00
12-122
Installation
7. 8. 9. 10. 11. 12. 13. 14. 15.
NOTE: Lubricate bushings, rubber grommet, and door harness teflon cover with silicone spray.Install clip and support bracket on rear door harness (Figure 2-117). 1. 2. 3. 4. 5. 6. Install harness in door bushing. Install support bracket in rear door with two capscrews. Install rubber grommet in B-pillar. Install harness through grommet until yellow tape touches the back of B-pillar. Install P-clamp on harness at yellow tape and B-pillar with capscrew, washer and lockwasher and nut assembly. Install two-lead connector on rear door harness, matching wire colors to jumper harness. Connect harness to jumper harness.
Route rear door harness along bottom of rear door. Secure harness to door reinforcement with clip. Attach door harness connector to actuator. Tighten power window motor mounting screws, if loose. Install convoluted tubing on rear door harness wires and secure with black electrical tape. Install P-clamp on rear door harness at yellow tape area and secure to door reinforcement with one capscrew. Install vapor barrier and moisture barrier flap. Install rear door trim (Section 10). Install side trim and outer kick panel (Section 10). Install trim on B-pillar and B-beam (Section 10). Install front seat (Section 10).
ACTUATOR POWER LEAD B-PILLAR SUPPORT BRACKET BUSHING P-CLAMP DOOR BUSHING CLIP DOOR HARNESS TEFLON COVER SUPPORT BRACKET P-CLAMP DOOR REINFORCEMENT B-PILLAR RUBBER GROMMET REAR DOOR HARNESS TIE WRAP
TWO LEAD CONNECTOR
JUMPER HARNESS PLASTIC TUBING TIE STRAP
Figure 2-117: Door Harness Routing
4-1-00
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Electrical System
12-123
POWER WINDOW AND DOOR LOCKS FRONT DOOR HARNESS REPLACEMENT

Removal
1. 2. 3. Remove front outer kick panels (Section 10). Remove power window and door lock switches from door. Remove front door trim, vapor barrier, and moisture barrier flap from door (Section 10).
NOTE: Tag leads for installation. 4. Disconnect 4-way and 6-way harness connectors from power windows and door locks body harness connectors (Figure 2-118).
NOTE: Perform step 6 for vehicles equipped with power mirrors. 5. 6. Disconnect two harness connectors from power mirrors body harness connectors. Remove screw, nut and lockwasher assembly, and clamp securing harness to A-pillar. Discard nut and lockwasher assembly Remove harness wires from 4-way and 6-way connectors.
10. Disconnect two harness connectors from power mirrors door jumper harness connectors (Figure 2-120). 11. Remove self-tapping screw and clamp securing harness to door reinforcement (Figure 2-120). 12. Remove two self-tapping screws and harness mounting bracket from door assembly. 13. Pull harness through door bushing. 14. Inspect door bushing and replace if damaged. 15. Remove harness mounting bracket and mounting bracket bushing from harness. Inspect bushing and replace if damaged. 16. Disconnect harness connector from power window regulator (push locking tab up on bottom of connector). 17. Disconnect harness connector from power door locks actuator. 18. Remove retainer and harness from door assembly.
7.
NOTE: Lubricate bushings, grommet, and harness teflon cover with silicone spray. 8. 9. Pull harness through A-pillar rubber grommet. Remove and inspect A-pillar rubber grommet. Replace if damaged.
POWER MIRRORS DOOR JUMPER HARNESS CONNECTORS
NOTE: Perform step 11 for vehicles equipped with power mirrors.

HARNESS CONNECTORS
Figure 2-118: Power Mirrors Door Jumper Harness
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POWER MIRRORS BODY HARNESS FRONT DOOR HARNESS POWER WINDOWS AND DOOR LOCKS BODY HARNESS
6-WAY CONNECTOR
TEFLON TUBE
4-WAY CONNECTOR A-PILLAR
GROMMET
Figure 2-119: Power Windows and Door Locks Connections
Installation
NOTE: Lubricate bushing, grommet, and harness teflon cover with silicone spray. 1. 2. 3. Route harness through harness mounting bracket, mounting bracket bushing, and door bushing (Figure 2-120). Install harness mounting bracket on door assembly with two self-tapping screws (Figure 2-121). Route harness through A-pillar rubber grommet (Figure 2-119).
NOTE: When connecting harness wires to 4-way and 6-way connectors, ensure wire colors align with mating connector wires. 4. 5. Connect harness wires to 4-way and 6-way connectors. Connect 4-way and 6-way harness connectors to power windows and door locks body harness connectors.
NOTE: Perform step 6 for vehicles equipped with power mirrors. 6. 7. Connect two harness connectors to power mirrors body harness connectors. Secure harness to A-pillar with clamp, self-tapping screw, and nut and lockwasher assembly.
NOTE: Perform step 8 for vehicles equipped with power mirrors. NOTE: Be careful to match the wire colors, since the harness connectors can be interchanged. 8.
POWER MIRRORS DOOR JUMPER HARNESS CONNECTORS
9. 10. 11. 12. 13. 14. 15. 16. 17.
HARNESS CONNECTORS
Figure 2-120: Power Mirrors Door Jumper Harness
Connect two harness connectors to power mirrors door jumper harness connectors (Figure 2-119). Connect harness connector to power window regulator (Figure 2-121). Connect harness connector to power door lock actuator. Secure harness to door reinforcement with clamp and selftapping screw. Secure harness to door assembly with retainer. Install moisture barrier flap, vapor barrier, and door trim panel on door (Section 10). Install power window and door lock switches on door. Install front outer kick panels (Section 10). Connect battery ground cable (Section 12). Check power windows and door locks for proper operation.
4-1-00
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Electrical System
12-125
POWER DOOR LOCKS ACTUATOR POWER WINDOW REGULATOR MOUNTING BRACKET BUSHING
WINDOW BRACKET
DOOR ASSEMBLY
RETAINER
FRONT DOOR HARNESS MOUNTING BRACKET
DOOR REINFORCEMENT
DOOR BUSHING
Figure 2-121: Power Windows and Door Locks Door Harness
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12-126
POWER WINDOWS AND DOOR LOCKS REAR DOOR HARNESS REPLACEMENT

Removal
1. 2. 3. Remove center outer kick panel and lower B-pillar trim (Section 10). Remove power windows switch from door. Remove rear door trim, vapor barrier, and moisture barrier flap from door (Section 10).
5. 6.
Remove harness wires from 6-way connector. Remove screw, nut and lockwasher assembly, and clamp securing harness to B-pillar. Discard nut and lockwasher assembly.
NOTE: Lubricate bushings, grommet, and harness teflon cover with silicone spray. 7. 8. 9. 10. 11. 12. Pull harness through B-pillar rubber grommet. Remove and inspect B-pillar rubber grommet. Replace if damaged. Remove two self-tapping screws and harness mounting bracket from door assembly (Figure 2-123). Pull harness through door bushing. Inspect door bushing and replace if damaged. Remove harness mounting bracket and mounting bracket bushing from harness. Inspect bushing and replace if damaged. Remove self-tapping screw and clamp securing harness to door reinforcement. Disconnect harness connector from power window regulator (push locking tab up on bottom of connector). Disconnect harness connector from power door lock actuator. Remove retainer securing harness to door assembly. Remove tie strap and harness from door assembly. Discard tie strap.
NOTE: Tag leads for installation. 4. Disconnect 6-way harness connector from power windows and door locks rear door jumper harness connector (Figure 2-122).
GROMMET B-PILLAR
13.
TEFLON TUBE
14. 15.
REAR DOOR HARNESS
16. 17.
6-WAY CONNECTOR REAR DOOR JUMPER HARNESS
Figure 2-122: Rear Door Harness and Rear Door Jumper Harness
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Electrical System
12-127
TIE STRAP
POWER DOOR LOCK ACTUATOR
MOUNTING BRACKET BUSHING
POWER WINDOW REGULATOR DOOR ASSEMBLY
DOOR BUSHING
RETAINER DOOR HARNESS
MOUNTING BRACKET DOOR REINFORCEMENT
CLAMP
Figure 2-123: Rear Door Harness
Installation
NOTE: Lubricate bushings, grommet, and harness teflon cover with silicone spray. 1. 2. 3. Route harness through harness mounting bracket, mounting bracket bushing, and door bushing (Figure 2-123). Install harness mounting bracket on door assembly with two self-tapping screws Route harness through B-pillar rubber grommet (Figure 2-124).
TEFLON TUBE
GROMMET
B PILLAR
REAR DOOR HARNESS
NOTE: When connecting harness wires to 6-way connector, ensure wire colors align with mating connector wires. 4. 5. 6. Connect harness wires to 6-way connector. Connect 6-way harness connector to power windows and door locks rear door jumper harness connector. Secure harness to B-pillar with clamp, screw, and nut and lockwasher assembly.
6-WAY CONNECTOR
REAR DOOR JUMPER HARNESS
Figure 2-124: Rear Door Harness and Rear Door Jumper Harness
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7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Connect harness connector to power window regulator (Figure 2-123). Connect harness connector to power door lock actuator. Secure harness to door reinforcement with clamp and selftapping screw. Secure harness to door assembly with retainer. Secure harness to door assembly with tie strap. Install moisture barrier flap, vapor barrier, and door trim panel on door (Section 10). Install power windows switch on door. Install lower B-pillar trim and center kick panel (Section 10). Connect battery ground cable (Section 12). Check power windows and door locks for proper operation. Remove nut and ground lead from ground stud. Disconnect two window and lock harness connectors from door harness connectors (Figure 2-125). Repeat step 10 for opposite side.
14. Install crash pad (Section 10). 15. Check power windows and door lock for proper operation
A-PILLAR
WINDOW AND LOCK HARNESS CONNECTORS DOOR HARNESS CONNECTORS
20. Remove B-pillar lower trim from both sides of the vehicle. 21. Disconnect lock and window harness connector from rear door harness connector (HMCS, HMC4, HMCO) 22. Repeat step 12 for opposite side (HMCS, HMC4, HMCO). 23. Disconnect vertical door lock jumper from window and door lock harness on the passenger side.(HMCS) 24. Remove tie straps securing harness to vehicle body harness and remove harness. Discard tie straps.
Figure 2-125: Door Harness Connectors
Installation
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Route harness through instrument panel and along A- pillar to both sides of vehicle. Connect harness connector to rear door harness connectors on both sides of vehicle (HMCS, HMC4, HMCO). Connect vertical door lock jumper to window and door lock harness on the passenger side.(HMCS) Connect two front lock and window harness connectors to door harness connectors on both sides of vehicle. Install ground lead on ground stud with nut. Connect two lock and window harness leads to vehicle body harness power leads. Connect two power windows and door locks harness connectors to receiver harness connectors. Secure harness to vehicle body harness with tie straps. Install CTIS gauge panel Install tachometer and clock harness into instrument panel Install two gauge panels on instrument panel with eight screws (Section 12). Install console cover (Section 10). Install front outer kick panels (Section 10).
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Electrical System
12-129
AUTO-DIMMING REAR VIEW MIRROR WITH ELECTRONIC COMPASS AND TEMPERATURE (OPTION)
Description
The Auto-Dimming rear view mirror has the capability to change the opacity of the mirror glass to prevent glare. When a following vehicles head lamps hit the rear light detection sensor, the mirrors opacity will lessen. The now translucent mirror will allow light to pass through it. This effectively lessens the glare on the driver, much like moving the angle on a manual mirror.
Installation
1. 2. Grasp the mirror head with both hands Slide the mirror down onto the window mount and gently rock side to side until mirror base is seated. Do not force the mirror onto the mount. Connect the mirror jumper harness to the rear of the newly installed mirror. Set calibration and zone adjustments. (Refer to AutoDimming compass mirror calibration and zone adjustment).
3. 4.
Removal
1. 2. Disconnect mirror jumper harness from the rear of the mirror assembly (See Figure 2-126). Gently push upward on the mirror head and the compass pod together until the mirror assembly is free of the windshield button.
AUTO-DIMMING COMPASS MIRROR CALIBRATION AND ZONE ADJUSTMENTS

Calibration Adjustment
1. 2. 3. Start the engine. Press and hold the auto-dimming power button until CAL appears in the display and release (Figure 2-127). Drive slowly in a circle away from large metal buildings and power lines until the CAL disappears.
Zone Adjustment
MIRROR JUMPER HARNESS
1. 2.
3.
Press and hold the mode button until ZONE appears in the display (See Figure 2-127). Each depression of the mode button will change the zone number in sequence. Refer to the zone chart below for the zone number of your area of operation (Figure 2-128). When the desired zone is reached, allow the mirror to go to normal mode then turn off the ignition.
AMBIENT LIGHT SENSOR
COMPASS POD AUTO-DIMMING POWER BUTTON AUTO-DIMMING POWER L.E.D COMPASS POD
9-OM2-033.2
MODE BUTTON REAR LIGHT DETECTION SENSOR
9-OM2-035.2
Figure 2-126: Auto-Dimming Mirror Jumper Harness Connection
Figure 2-127: Auto-Dimming Rear View Mirror
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12-130
Figure 2-128: Magnetic Zone Chart
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Electrical System
12-131
AMBIENT TEMPERATURE SENSOR

Removal
1. Remove existing nut, cushioned clamp, and ambient temperature sensor jumper harness from the body harness (Figure 12-129). Disconnect the ambient temperature sensor jumper harness from the sensor. Remove self-tapping screw and ambient temperature sensor from the frame.
Installation
1. 2. 3. 4. Install ambient temperature sensor to the frame with selftapping screw (Figure 12-129). Connect the ambient temperature sensor harness to the sensor. Connect the ambient temperature sensor harness to the body harness. Using cushioned clamp, secure jumper harness to body harness mounting clamp with existing nut and bolt.
2. 3.
BODY HARNESS
AMBIENT TEMPERATURE SENSOR JUMPER HARNESS
EXISTING NUT CUSHIONED CLAMP
SELF-TAPPING SCREW
Figure12-129: Ambient Temperature Sensor
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12-132
Compass Mirror Display Inoperative

Step 1 Action Turn the ignition to the ON position, and heated windshields OFF. Is compass mirror display operating? Gain access to C13, with the ignition ON measure voltage at pin B. Is voltage present? Check for open, or short to ground in CKT 407 between compass cutout relay and compass mirror, and CKT 400 between compass cutout relay and fuse 2C in the interior fuse box. Are any problems found? Check continuity to ground at C13 pin A, is resistance to ground below specied? Check for open or bad connection in CKT 59 between compass mirror and G4. Are any problems found? >.2 Approximate battery voltage Value(s) Yes No problem found, or intermittent. Go to step 4. Repair open or short to ground in CKT 407 and CKT 400. Replace compass mirror Repair open or bad connection in CKT 59. No Go to step 2.
2 3
Go to step 3. Replace mirror cutout relay.
4 5
Go to step 5. No problem found, go to step 1.
Compass Mirror Temperature Display Showing OC, SC or Wrong Temp

Step 1 2 Action Does compass mirror display show OC or SC in place of the temperature? Gain access to C13, measure resistance between pin D and ground. With the vehicle at room temperature (70F), does resistance measured match specications? Measuring resistance to ground at C13 Pin D, does meter display open? Disconnect temperature sensor from underbody harness. Measure resistance between the two pins of the sensor. With the vehicle at room temperature (70F), is resistance in range specied? Higher temperature gives lower resistance readings. Measure resistance to ground at temperature sensor connector pin A. Is resistance below specied? Approx.12 K Value(s) Yes Go to step 3. Replace compass mirror. No Go to step 2. Go to step 3.
3 4
OL Approx.12 K
Repair bad connection at C13. Replace the temperature sensor.
<.2
Go to step 6.
Repair open or bad connection in CKT 58 between temperature sensor and G2. Replace the compass mirror.
Check for open, bad connection, or short to ground in CKT 767 between temperature sensor and compass mirror. Are any problems found?
Repair open, bad connection, or short to ground in CKT 767.
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Electrical System
12-133
COMPASS MIRROR
TEMP SENSOR 6 767 BR D C13 C1-61
COMPASS IGNITION
REVERSE INHIBIT
GROUND
4 407 PK
1 400 LG
IGNITION
3 140 OR
7 768 BK
2 59 BK A
TO HEATED WINDSHIELD SWITCH
580 BR
C2-26 C2-8
COMPASS CUTOUT RELAY
BACK-UP LIGHT SWITCH
GROUND
TEMP SENSOR
298 BR
400 LG
59 BK
G4
C2-27
58 BK G4 G2 FUSE 3C 7.5 AMP

00-S12-003.1
C1-43
INTERIOR FUSE BOX
FUSE 2C 10 AMP
TO IGNITION SWITCH
TO IGNITION SWITCH
Figure 12-130: Compass Mirror Schematic 05745159 4-1-00
12-134
POWER SIDE MIRROR Description

The side mirrors have an option of an internal heater element to aid in defrosting. Heated side mirrors will only be available if the truck is equipped with a heated windshield. The power side mirror system components are: two side mirrors with internal vertical and horizontal control motors (and optional heater elements), the power mirror switch, and the heated windshield switch (optional).
Power Side Mirror Replacement

Removal
1. Remove the three mounting screws securing the power mirror assembly and gasket to mounting plate Figure 12130.2. Disconnect the power mirror assembly connector from the door jumper harness. Inspect the gasket and replace if damaged.
2. 3.
Installation
NOTE: Ensure the door jumper harness is routed through the gasket before connecting the harness to the power mirror assembly. 1. Connect the power mirror assembly connector to the door jumper harness Figure 12-130.2.
NOTE: Wires from the power mirror assembly must be coiled in the mirror housing to ensure clearance to the attachment points. 2. 3. Align the power side mirror and the gasket with the mounting plate on the door. Install the three mounting screws
3-1-02
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Electrical System
12-134.1
POWER MIRROR ASSEMBLY
DOOR JUMPER HARNESS
CONNECTOR CONNECTOR DOOR JUMPER HARNESS
MOUNTING SCREW
GASKET MOUNTING PLATE
Figure 12-130.2 Power Mirror Assembly Removal
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12-134.2
Electrical System ____________________________________________________
Power Side Mirrors Inoperative

Step 1 2 Action Are both mirrors INOP? Remove the power mirror switch. With a DVOM check circuit 517 (PK) for battery voltage. Is the specied voltage present? > 12.6v Value(s) Yes Go to step 2. Go to step 3. No Go to step 4. Repair circuit 517 (PK) between the power mirror switch and fuse 3H in the interior fuse box. Repair circuit 59 (BK) between the power mirror switch and ground G4. Go to step 7 Go to step 6.
With a DVOM check the resistance to ground on circuit 59 (BK). Does the resistance meet the specications? Is only the left side power mirror INOP? Remove the left side power mirror. With a DVOM back probe circuits 942 (OR) with the positive lead, and circuit 59 (BK) with the negative lead. With the DVOM set to check voltage move the power mirror switch to the left side and then up. In both cases the voltage should change from 0v to 12v. Does the voltage change? With a DVOM check resistance on circuit 942 (OR) between the power side mirror and the power mirror control switch. Does the resistance on the circuit meet specications? Remove the left side power mirror. With a DVOM back probe circuits 944 (OR) with the positive lead, and circuit 59 (BK) with the negative lead. With the DVOM set to check voltage move the power mirror switch to the left side and then up. In both cases the voltage should change from 0v to 12v. Does the voltage change? With a DVOM check resistance on circuit 944 (OR) between the power side mirror and the power mirror control switch. Does the resistance on the circuit meet specications?
< 0.2
Replace the power mirror control switch. Go to step 5.
4 5
0v - off 12v - left 0v - off 12v - up
Replace the power side mirror.
< 0.2
Replace the power mirror switch.
Repair circuit 942 (OR) between the power side mirror and the power window switch. Go to step 8.
0v - off 12v - left 0v - off 12v - up
Replace the power side mirror.
< 0.2
Replace the power mirror switch.
Repair circuit 944 (OR) between the power side mirror and the power window switch.
3-1-02
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Electrical System
12-134.3
LH POWER MIRROR
M M
RH POWER MIRROR
M
INTERIOR FUSE BOX
FUSE 3H 20 AMP C24 C B A C25 C B A C3 N6 G4 G1 J8 M9 J9 L8 K6 K8 TO DIMMER MODULE A TO BATTERY 942 OR/ BK 948 DG/ YL 947 DG/ YL 944 OR 953 DG 952 DB 517 PK B C D E F G H J C23
59 BK
17 PP SWITCH ILLUM
BATTERY FEED
RH LEFT / RIGHT
COMMON
RH UP / DOWN
POWER MIRROR SWITCH Figure 12-131: Power Side Mirror Schematic
LH LEFT / RIGHT
LH UP / DOWN
COMMON
GROUND
9-S12-010
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12-134.4
Electrical System ____________________________________________________
CRUISE CONTROL SYSTEMS

WARNING: Testing of cruise control should only be preformed in areas were trafc is light and the road conditions are stable.
In addition, the cruise control is automatically disabled each time you turn the engine off, Or shift into P (Park) N (Neutral) position, or if the Check Throttle Light is illuminated.
Resuming a Set Speed

If the cruise control was turned off by depressing the brake pedal slightly, move the cruise control switch from ON to R/A and hold for approximately one second and release. The vehicle will gradually return to the previously set speed and maintain it. Resuming a set speed will not function if the cruise control was turned off using the cruise control switch, or if the vehicle speed is below cruise control minimum (35 MPH).
9-OM2-031
Figure 12-131.1 : Cruise Control
Operation of Cruise Control

1. 2. 3. Move the cruise control switch to the ON position. Accelerate to the desired speed. Push in the SET button on the end of the turn signal lever and release it at the desired speed. This will set the vehicle speed. NOTE: The vehicle speed will decrease while the SET button is pushed in. The cruise control will not operate under 35 MPH.
Using Cruise Control on Hills

Driving on a hill can affect the performance of the cruise control. This performance can be greatly affected if the vehicle is loaded or towing a trailer. Use of the accelerator pedal will help maintain vehicle speed but brakes will turn cruise off. If vehicle speed is being significantly reduced or increased when using the cruise control on a hill, turn the cruise control off and manually control the vehicle speed.
Inspection
When working on the cruise control system make sure that there are no other problems with the PCM or fueling system. Always road test and verify the problem before attempting any repairs.
Accelerating with the Cruise Control On

Vehicle speed can be momentarily increased after the desired speed has been set. By pressing the accelerator pedal the speed will increase. This action will not interfere with the preset cruising speed. The preset speed will resume after the accelerator pedal is released.
Intermittent problems
All of the charts in this section are for use on current failures. Do not attempt to use these charts to diagnose a problem unless the problem has been verified and currently exists. If the problem is intermittent, parts will be replaced, or no problem will be found.
Resetting the Cruise Control to a Higher Speed

There are two ways to reset the cruise control to a higher speed. 1. Press the accelerator pedal until the desired speed is reached. Push the SET button and release it. Speed should set like normal. 2. Move the cruise control switch from ON to R/A. Hold the switch in place until you reach the desired speed and then hold the control switch in the R/A position for half a second and release. Each time this is done the vehicle speed will increase by 1 MPH.
Turning Off the Cruise Control

There are two ways to turn the cruise control off while driving: 1. Move the cruise control switch to the OFF position. 2. Depress the brake pedal slightly. This turns off the cruise control operation. but does not erase the speed memory. To resume cruise control after touching the brake pedal, follow the instructions under Resuming a set Speed.
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Electrical System
12-135
Cruise Control Inoperative VIN Z

Step 1 Action Important: Before clearing the DTCs, use the scan tool Capture Info in order to record the Freeze Frame and the failure records for reference, as the data will be lost when the Clear Info function is used. Was the Powertrain On-Board Diagnostic (OBD) System check performed? Disconnect cruise control lever from cross body harness under dash. Using a DVOM set to measure resistance, Probe the BRN wire with the negative lead and the RD wire with the positive lead. Turn the cruise on\off switch to on. Does the resistance meet specication? Leave the negative lead in the BRN wire, place the positive lead in the YL wire. With the resume switch in the neutral position, the switch should be open. When the resume switch is moved to the spring loaded position, the switch should close and meet the resistance specication? Leave the negative lead in the BRN wire, place the positive lead in the GRN wire. With the set switch in the neutral position, the meter should display an open, with the switch pushed in the meter should display continuity, does it? Connect scan tool to vehicle, locate cruise control On/Off switch in the engine data list. When the switch is moved on and off, does the engine data list reect the change? Locate resume/accel switch in engine data list. When the switch is moved to the resume/accel position, does the engine data list reect the change? Locate set/coast in engine data list. When the switch is pushed, does the data list reect the change? Locate the brake switches in the engine data list, depress the brake pedal, does the data list reect the change? <.2 Value(s) Yes Go to step 2. No Perform onboard diagnostic system check.
Go to step 3.
Replace cruise control arm.
neutral-open closed<.2
Go to step 4.
neutral-open closed<.2
Go to step 5.
Go to step 6.
Go to step 9.
Go to step 7.
Go to step 10.
Go to step 8.
Go to step 11.
Check for loose or poor connection at PCM if none are found replace the PCM.
Go to step 16.
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12-136
Cruise Control Inoperative VIN Z (Continued)

Step 9 Action Using a DVOM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity A11 in C29(CKT151) with the positive lead. With the ignition on and the cruise control switch on, is voltage present? Value(s) 12v Yes Check for loose or poor connection at PCM if none are found replace the PCM. No Repair open, bad connection or short to ground in CKT151 between the PCM and cruise control arm. Repair open, bad connection or short to ground in CKT153 between the PCM and cruise control arm. Repair open, bad connection or short to ground in CKT152 between the PCM and cruise control arm. Check for open or short to ground/voltage in CKT 22, if none found replace brake switch. Check for open or short to ground/voltage in CKT 810, if none found replace brake switch.
10
Using a DVOM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity D10 in C27(CKT153) with the positive lead. With the ignition on and the cruise control resume/accel button depressed, is voltage present? Using a DVOM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity B11 in C29(CKT152) with the positive lead. With the ignition on and the cruise control set button depressed
12v
11
12v
12
Using a DVOM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity B10 in C29(CKT22) with the positive lead. Depress the brake switch. Is voltage present?
12v
go to step 13.
13
Using a DVOM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity B9 in C29(CKT810) with the positive lead. With the ignition on, is voltage present with the brake NOT applied, and disappear when the brake is depressed?
Brake OFF 12v Brake ON 0v
4-1-00
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Electrical System
12-137
ACCELERATIOR PEDAL POSITION SENSOR
POWERTRAIN CONTROL MODULE (PCM) 44
722 PP
C29-A12
GROUND
C 2 G A
32
721 LB
53
719 BR
GROUND
1 E
17
718 DB
J K
60
725 GY
GROUND
15
724 DG
C27-D4 APP 3 SIGNAL
14
723 YL
C27-D3
20
717 WH
C27-D12
5 VOLT REFERENCE
22 C1 FUSE 3A 10 AMP EXTERIOR C5-A4 A B
720 TN
C28-C2
154 TN
C5-D3
C28-D14 WASTEGATE SOLENOID CONTROL
RESUME ACCEL
YL
153 LG
37
C27-D10 RESUME ACCEL SIGNAL C29-B11 SET COAST SIGNAL
SET COAST FUSE 5C 10AMP INTERIOR
GRN
152 DB
42
B ON/ OFF
RD
151 GY
29 C1
C29-A11 ON / OFF SIGNAL
295 BR
9-S12-055
Figure 12-132: Cruise Control Schematic (Sheet 1 of 2) 05745159 4-1-00
12-138
FUSE 2D 20 AMP INTERIOR
FUSE 4D 15 AMP INTERIOR
FUSE 6B 5 AMP INTERIOR
10 OR
A
BRAKE LAMP TCC/ CRUISE
291 PK
537 OR
239 PK
B 31 C1TO BRAKE LAMP 810 PP C29-B9
C 40
C28-D13
C28-C13 BATTERY POSITIVE
C28-C12
C28-C11 IGNITION VOLTAGE
C29-B10 BRAKE LIGHT SWITCH SIGNAL
22 RD
TCC / CRUISE BRAKE SWITCH
9-S12-069.2
Figure 2-132: Cruise Control Schematic (Sheet 2 of 2) 4-1-00
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Electrical System
12-139
DELCO AUDIO SYSTEM DESCRIPTION

Delco audio systems are available in two configurations: The standard system (Figure 12-133), available on all models, consists of a radio head with cassette player (Hummer logo), either two or four coaxial speakers and an optional 6 disc CD changer. An optional infrared remote control for the radio, cassette player and CD changer is available. The Monsoon system (Figure 12-134), available on models 83 and 84 and 91, uses a radio head and cassette player (Monsoon logo) with a total of six coaxial speakers and two subwoofers. Two coaxial speakers are located in an overhead console and the two subwoofers are housed in a box located under the left rear seat. An amplifier producing 200 watts on eight channels is mounted in the overhead console. The amplifier is activated by output on the left rear channel from the radio. The 6 disc CD changer is standard with the Monsoon system. A 6 disc stacker magazine inserted in the CD changer is controlled by the radio head and optional remote control. The radio and the cassette player can also be controlled by the remote. Rear seat audio, included in the monsoon package, provides second audio access to the radio system with the aid of headphones.
00-OM3-001
Figure 12-133:
Delco Standard Radio Face
00-OM3-005
Figure 12-134: Delco Monsoon Radio Face
PWR SEEK AM FM
TAPE CD VOL P.SET PROG PHONES
00-OM3-002
Figure 12-135: Rear Seat Audio Face
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12-140
RADIO (DELCO) REPLACEMENT

BEZEL
Removal
1. Insert a radio removal key in the holes in each side of the face of the radio to disengage locking clips from the mounting sleeve (Figure 12-136). Pull radio out of mounting sleeve far enough to expose wire connections and disconnect audio harness connector, antenna cable and CD harness connector if equipped.
CD CHANGER
FRONT SUPPORT BRACKET
2.
NOTE: Sleeve may not need to be replaced when radio head is replaced. 3. Straighten locking tabs and pull mounting sleeve out of face plate.
UPPER SUPPORT BRACKET LOCKING MOUNTING SLEEVE TAB
Figure 12-137: CD Changer Removal.
Installation
1. 2. Assure angle adjustments on the sides of the changer are set at 45 before installation. Connect wire harness to the connector on the CD changer and insert changer into the console and the front support bracket. Install four screws in the changer mount brackets and tighten. Install changer bezel with four screws and tighten.
3. 4.
OVERHEAD CONSOLE, SPEAKER AND AMPLIFIER (DELCO MONSOON) REPLACEMENT

RADIO REMOVAL KEYS
Removal
1. 2. 3. Remove upper B-bar cover screws and cover. Remove dome light lens, screws securing ground wires and housing (Figure 12-138). Remove bulb holder and dome light housing.
OVERHEAD CONSOLE
Figure 12-136: Radio Removal.
Installation
1. 2. 3. Install mounting sleeve through face plate and support plate and bend locking tabs to secure. Connect harness connectors and antenna cable to radio. Insert radio into mounting sleeve, align rear mount pin with upper support bracket and push in until locking clips engage. Take care not to damage wiring in radio cavity. Advise end user to reprogram theft lock.
4.
COMPACT DISC CHANGER (DELCO) REPLACEMENT Removal

1. 2. 3. 4. Remove four screws retaining the CD changer bezel to the console and remove bezel (Figure 12-137). Remove four screws retaining the CD changer mounting brackets to the console. Pull the CD changer out far enough to remove the wire harness connector from the changer. If CD changer wire harness is to be replaced, radio must be removed to gain access to harness connection at the radio.
DOME LIGHT HOUSING
SPEAKER COVER
Figure 12-138: Overhead Console Removal. 4. 5. 6. Remove windshield divider bar cover. Remove screws securing overhead console and pull console down to gain access to wiring. Remove blue wire and connector from dome light mount plate.
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Electrical System
12-141
7. 8.
Disconnect green wire connection and remove console. Disconnect 32 pin connector from amplifier and four screws securing amplifier to mounting bracket (Figure 12-139). 9. Remove amplifier. 10. Disconnect 4 pin connector from overhead console speaker enclosure. 11. Remove speakers and wiring from overhead console speaker enclosure.
REAR SEAT AUDIO (RSA) UNIT REPLACEMENT Removal

1. 2. 3. Remove the cup holders from the auxiliary A/C unit cover (Figure 12-140). Reach through the cup holder holes in the cover and release the tension tabs securing the RSA unit to the cover. Pull the RSA unit out enough to expose the harness connector and disconnect the connector.
CUP HOLDER
AUXILIARY UNIT COVER
AMPLIFIER OVERHEAD SPEAKER ENCLOSURE
Figure 12-139: Overhead Speaker & Amplifier Removal.

00-S12-008
PHO
NES
TAPE CD R PW P.SET PROG
VOL
TENSION TAB
S EE
AM FM
RSA UNIT
Installation
1. 2. 3. 4. 5. 6. Install speakers and wiring in overhead console speaker enclosure and connect 4 pin connector to audio harness. Mount amplifier to mounting bracket with four screws and connect 32 pin connector to audio harness. Connect dome light wiring and screw overhead console to roof. Install windshield divider bar cover. Install dome light housing and bulb holder with 3 screws, and dome light lens. Install upper B-bar cover.
Figure 12-140: RSA Unit Replacement.
Installation
1. Connect the harness connector to the RSA unit and insert into the auxiliary unit cover. Push the RSA unit in until the tension tabs lock the unit in place. Press the cup holders in place in the auxiliary unit cover.
2.
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12-142
AUDIO (DELCO MONSOON) ELECTRICAL HARNESS (MODELS 83, 84 & 91) REPLACEMENT Removal
1. 2. 3. Remove engine cover console. Disconnect harness connector from radio head. Remove Rear Seat Audio (RSA) unit from auxiliary heat and AC cover console. Disconnect RSA connector from RSA unit. Remove four screws, clips, cover, and right front speaker from trim (Figure 12-141). Disconnect two leads from right front speaker. Repeat steps 3 and 4 for left front speaker. Remove screws from B-bar cover, windshield divider cover, and overhead console. Disconnect dome light wiring connections and overhead console speaker enclosure connector. Remove four screws, clips, cover, and right rear speaker from trim. Disconnect two leads from right rear speaker. Repeat steps 7 and 8 for left rear speaker. Disconnect lead from subwoofer under left rear seat. Remove trim as necessary to gain access to audio harness. Remove audio harness from vehicle.
Installation
1. 2. Route audio harness to approximate mounting position. Secure audio harness to vehicle with duct tape, where necessary. 3. Connect two leads to right rear speaker. 4. Install right rear speaker and cover on trim with four clips and screws. 5. Repeat steps 3 and 4 for left rear speaker. 6. Connect lead to subwoofer. 7. Connect lead to overhead console speaker enclosure. 8. Connect two leads to right front speaker (Figure 12-141). 9. Install right front speaker and cover on trim and secure with four clips and screws. 10. Repeat steps 7 and 8 for left front speaker. 11. Connect harness lead to radio head. 12. Install engine cover console. 13. Connect RSA connector to RSA unit and install RSA unit in auxiliary heat and AC cover console. 14. Install trim.
TRIM
4. 5. 6. 7.
8. 9. 10. 11. 12. 13.
COVER
SPEAKER
Figure 12-141: Right Front Speaker Models 83, 84 & 91.
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Electrical System
12-143
AUDIO (DELCO STANDARD) ELECTRICAL HARNESS (MODEL 89) REPLACEMENT Removal

1. 2. Remove engine cover console. Disconnect radio harness lead from harness connector (Figure 12-142).
CD AUDIO HARNESS HARNESS
5. 6. 7. 8.
Install right speaker and cover on trim with four clips and screws. Repeat steps 4 and 5 for left speaker. Connect harness lead to audio harness connector (Figure 12-142). Install engine cover console.
AUDIO (DELCO STANDARD) ELECTRICAL HARNESS (MODELS 83, 84 & 91) REPLACEMENT Removal
1. 2. 3. Remove engine cover console. Disconnect harness lead from audio harness connector (Figure 12-142).
00-S12-006
ANTENNA LEAD-IN
Figure 12-142: Audio Harness Connections. 3. Remove four screws, clips, cover, and right speaker from trim (Figure 12-143).
TRIM
Remove four screws, clips, cover, and right front speaker from trim (Figure 12-143). 4. Disconnect two leads from right front speaker. 5. Repeat steps 3 and 4 for left front speaker. 6. Remove four screws, clips, cover, and right rear speaker from trim. 7. Disconnect two leads from right rear speaker. 8. Repeat steps 7 and 8 for left rear speaker. 9. Remove trim as necessary to gain access to audio harness. 10. Remove audio harness from vehicle.
Installation
COVER
1. 2. 3. 4. 5.
SPEAKER
Route audio harness to approximate mounting position. Secure audio harness to vehicle with duct tape, where necessary. Install trim. Connect two leads to right rear speaker.
Figure 12-143: Right Front Speaker Model 89. 4. 5. 6. 7. Disconnect two leads from right speaker. Repeat steps 3 and 4 for left speaker. Remove trim as necessary to gain access to audio harness. Remove audio harness from vehicle.
Install right rear speaker and cover on trim with four clips and screws. 6. Repeat steps 4 and 5 for left rear speaker. 7. Connect two leads to right front speaker (Figure 12-143). 8. Install right front speaker and cover on trim and secure with four clips and screws. 9. Repeat steps 7 and 8 for left front speaker. 10. Connect harness lead to audio harness connector. 11. Install engine cover console.
Installation
1. 2. 3. 4. Route audio harness to approximate mounting position. Secure audio harness to vehicle with duct tape, where necessary. Install trim. Connect two leads to right speaker (Figure 12-143).
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12-144
AUDIO (DELCO STANDARD) ELECTRICAL HARNESS (MODEL 90) REPLACEMENT Removal

1. 2. 3.
.
Installation
1. 2. 3. 4. 5. Route audio harness to approximate mounting position. Secure harness to vehicle with duct tape, where necessary. Install trim. Connect two leads to right rear speaker (Figure 12-145). Install right rear speaker and cover on trim and secure with four clips and screws. 6. Repeat steps 4 and 5 for left rear speaker. 7. Connect two leads to right front speaker (Figure 12-144). 8. Install right front speaker and cover on trim with four clips and screws. 9. Repeat steps 7 and 8 for left front speaker. 10. Connect harness lead to radio head. 11. Install engine cover console.
Remove engine cover console. Disconnect harness lead from radio head (Figure 12-142). Remove four screws, clips, cover, backing plate and right front speaker from trim (Figure 12-144).
BACKING PLATE
SPEAKER
DIAGNOSIS -DELCO AUDIO SYSTEM

1. 2. 3. Verify customer complaint. Follow radio service procedures. If technical service is required, have all the pertinent information ready before placing the call.
COVER
Figure 12-144: Right Front Speaker Model 90. 4. 5. 6. Disconnect two leads from right front speaker. Repeat steps 3 and 4 for left front speaker. Remove four screws, clips, cover, and right rear speaker from trim (Figure 12-145).
TRIM SPEAKER
NOTE: Before performing any diagnostic procedures or using any diagnostic tools, check wiring schematics for component circuitry to determine the location of fuses and circuit breakers in the circuit. Fuses and circuit breakers must be in good working order to perform proper diagnostic procedures. Delco Audio System Diagnostic Kit J39916-A is available from Kent-Moore. The kit contains a diagnostic CD and cassette, a head cleaner cassette and instructions. This kit is designed to isolate the type of malady and the area of its origin by producing tones of various frequencies. By adjusting the fade and balance, a technician can evaluate the sound quality produced in different areas of the system.
Identifying Concerns
Check for technical service bulletins. For reception concerns, determine if the station is obtainable in the customers listening area. To test for audio reception/noise, position the vehicle outside the building with the hood down. Duplicate the customers complaint before trying to diagnose the system. Have the customer demonstrate the condition. Test drive the vehicle with the customer and then test drive another similar model vehicle (with a similar audio system) to do a comparison of the two vehicles to determine if the condition is abnormal. Before diagnosing, identify components, their features and the customers complaint. Determine if any aftermarket equipment is installed on the vehicle. Disconnect the aftermarket equipment and determine if the customers complaint still exists. Perform the following steps to identify a noisy component:
Figure 12-145: Right Rear Speaker Model 90. 7. 8. 9. 10. Disconnect two leads from right rear speaker. Repeat steps 7 and 8 for left rear speaker. Remove trim as necessary to gain access to harness. Remove audio harness from vehicle.
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Electrical System
12-145
1.
2. 3. 4. 5.
6.
7.
Identify ignition switch key position in which the noise appears, such as: accessory, key on engine not running, and key on engine running. Remove fuses one at a time until the complaint condition has been eliminated. Mark the complaint fuse(s) and reinstall all fuses and circuit breakers. Identify all systems and components powered by the complaint fuse(s). Disconnect the components powered by the complaint fuse(s) one at a time until the complaint condition has been eliminated and the noisy component has been identified. Check the ground integrity of the complaint causing component. An interference condition is not necessarily an audible noise. Most noises can be found on weak stations near the low end of the band and are considered to be a normal condition. Malfunctioning and marginal components, relays, and solenoids may induce noise and/or poor reception. Check for a broken (or partially broken) wire inside of the insulation which could cause system malfunction but prove good in a continuity/voltage check with a system disconnected. These circuits may be intermittent or resistive when loaded, and if possible, should be checked by monitoring for a voltage drop with the system operational (under load).
Corrective Action
Use proper tools for diagnostics and repairs. Follow electrical system diagnostic guidelines. Use available noise suppression devices: Filter package P/N 05744279 Utilize the test tape /CD Diagnostic Kit Kent-Moore P/N J39916-A to optimize proper audio diagnostics. If the condition requires the radio to be sent to the service center, describe the symptoms on the warranty form exactly. Do not leave a CD disc or tape in the vehicle. Extreme heat could cause permanent damage. Cassette tapes could be damaged if not stored in the case. The vibration in the vehicle can cause the tape to unwind inside the cartridge. Use available trouble trees. Before removing speaker(s), check all connectors and wiring to the speakers. Examine the connectors for bent or loose pins. Refer to troubleshooting procedures. If a test antenna is used in diagnostics, ground the antenna base to the vehicle body and do not hold the mast. NOTE: Check the antenna coax connectors for corrosion or bad connections/crimps. Route coax separately from the other wires. Shield antenna coax interconnections with aluminum or nickel tape. Check all vehicle grounds, not just antenna and radio grounds. Refer to the antenna diagnostic section. 05745159
Coated screws or bolts can act as poor grounds. Always use a braided ground strap when applying grounds. Keep the ground strap as short as possible, the shorter the ground strap the better. When shielding the dash, wires, hoses (most hoses are conductive unless they have a white stripe), use aluminum foil tape or nickel tape to shield against magnetically induced interference. For optimum performance try varying the following ground techniques: Add a ground at both ends of the tape. Add a ground to just one end of the tape. Do not add ground to the tape. When shielding a harness with tape, attach a ground strap to the end of the tape and then wrap the strap 360 degrees around the tape securing the other end of the strap to a known good chassis ground. Any interference is best corrected by suppression at the source of the interference, if possible. Care should be used when applying suppression. Signal wires (such as sensor outputs, clock, and communication circuits) cannot be suppressed. After adding any suppression, all vehicle systems (even those not related to the audio system) should be checked for proper operation and function. Interference can usually be eliminated by shielding/ grounding or suppressing. Capacitors work best on switch pops and low frequency noise. Filters work best on high frequency whines and static. Whenever possible, make a test harness that includes filters and capacitors. Always check the effectiveness and operation before permanently installing a fix. Recommended capacitor application for an audible pop induced from a switching operation is: Add a capacitor across the contacts of the switch. Add a capacitor from the hot side of the switch to ground. Add a capacitor to each side of the switch to ground. If a complaint condition is only present with the ignition key in the run position and the engine running, perform the following checks: Check the integrity of the engine compartment grounds. Check for malfunctioning relays, solenoids, or other components which may be inducing noise or poor reception. Check the ground integrity of the complaint causing component. For noise and/or poor reception, perform the antenna system test and make the necessary repairs.
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12-146
TEST ANTENNA
The test antenna is simply an antenna that is not mounted on the vehicle. This tool is used as a substitute for the antenna mounted on the vehicle. The technician should connect the test antenna to the antenna input of the radio. Ground the base of the antenna to the vehicles chassis. Do not hold the mast of the antenna. This will decrease the capability of the antenna to receive a station.
GENERATOR WHINE CONCERNS

Check the ground terminal on the battery. Check for coated mounting bolts on the generator bracket. Check for a faulty mounting of the generator to the engine. Make sure grounds at starter and intake manifold are clean and tight. Try the following: If noise is still present, check the charging system. If the charging system is functioning normally, check for technical service bulletins on generator whine. Install a filter P/N 05744279 in the battery feed to the radio. Try installing the filter with the following variations if the noise is not eliminated. a. Install the filter with the single wire side toward the radio and the ground wire attached to a good ground. b. Remove the ground to the filter. c. Reverse the filter so the two wire side is toward the radio with the ground wire attached to a good ground. d. Remove the ground from the filter. If the noise is still present, install another filter P/N 05744279 in the ignition feed to the radio. Install using the same variations as the first filter. If the installation of this filter causes turn on or turn off delays or other noticeable performance concerns, remove it and install a 0.47 mf (microfarad) capacitor in its place. Remove any unneeded filters after repair, before reassembling the vehicle.
1. 2. 3. 4.
5.
6.
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Electrical System
12-147
REAR SEAT AUDIO

A1 C62 819 BK A2 818 PP A3 821 BK A4 843 GY 820 DG A5 A8 137 RD B5 842 OR B6 59 BK B8 C59 14 LB
LF SPEAKER BK 4 A RD B RF SPEAKER BK 4 A RD B LEFT CONSOLE SPKR BK BK A A 4 RD RD B B
833 BK 834 TN
E16 E15
AMPLIFIER
C56 PK 819 BK 818 PP 821 BK 10 RR 9 RR 16 LR 15 LR 14 13 12 11 LF LF RF RF
RADIO
+ + + + +
BATT 12V
F8 E4 E5
835 BK 836 TN
F2 F3
E7 E6 E3 DG
820 DG 813 BK 804 WT 811 BK 805 GY 842 OR 59 BK 14 LB
837 BK TN 838 831 BK TN 832
F6 F7
E2 F1 E1
RIGHT CONSOLE SPKR BK BK A A 4 RD RD B LR SPEAKER BK 4 A RD B RR SPEAKER BK 4 A RD B FRONT SUB WOOFER RD 2 A RD/BK B REAR SUB WOOFER RD 2 A RD/BK B B
E13 E14
+ + + +
E10
8 GROUND 3 ILLUMINATION 6 DIMMER 4 IGNITION 7 BATT 12V 18 19 RSA ENABLE 20 22 RSA CONTROL C57 CELL PHONE MUTE AMPLIFIER SENSE
801 BK 800 TN
F16 F15
E11 E12 829 LG
17 PP 137 RD 476 GY 830 PK 842 OR 839 YL
803 BK 802 TN
F13 F14
+ + +
E8 GROUND E9
BK
827 TN 826 BK
C62
F11 F10
843 GY 59 BK
825 TN 824 BK
F5 F4
PANEL LIGHT DIMMER

C60 H C G B A E D
HEAD
OFF PARK
HEADLIGHT SWITCH
1 59 BK J6 N9 C1 B4 G3 F3 17 PP H9 K7 B1 C1-67 476 GY 137 RD 829 LG 14 LB 14 LB 19 YL G4 38 RD H6
C3
INTERNAL FUSE BOX
FUSE 1D 15 AMP
FUSE 4G 7.5 AMP 297 OR
FUSE 2H 10 AMP
FUSE 1F 5 AMP
FUSE 2F 5 AMP
CIRCUIT BREAKER #2 30 AMP
EXTERNAL FUSE BOX
37 RD
00-S12-001
TO BATTERY
TO IGNITION
37 RD
TO BATTERY
Figure 12-146: Monsoon Audio Harness Schematic Models 83, 84 & 91. 05745159 3-1-01
12-148
.
C57
839 YL 20
RADIO
CELL PHONE MUTE
BK RR SPEAKER 4 A RD B BK LR SPEAKER 4 A RD B BK LF SPEAKER 4 A RD B BK RF SPEAKER 4 A RD B
819 BK 818 TN 821 BK 820 TN 813 BK 804 TN 811 BK 805 TN 59 BK 14 LB 17 PP 137 RD 476 GY 2
10 RR 9 RR 16 LR 15 LR 14 13 12 11 8 3 LF LF RF RF
+ + + +
GROUND ILLUMINATION 6 DIMMER 4 IGNITION 7 BATT 12V
PANEL LIGHT DIMMER

C60 C B A E D
C56
HEAD
OFF PARK
HEADLIGHT SWITCH
C3 59 BK J6 C1 B4 G3 F3 17 PP H9 K7 B1 C1-67 476 GY 137 RD 14 LB 14 LB 19 YL G4 38 RD
1 H6
INTERNAL FUSE BOX
FUSE 2H 10 AMP
FUSE 1F 5 AMP
FUSE 2F 5 AMP
EXTERNAL FUSE BOX
37 RD
00-S12-039
TO BATTERY
TO IGNITION
TO BATTERY
Figure 12-147: Standard Audio Harness Schematic Models 83, 84, 90 & 91. 3-1-01
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Electrical System
C56
12-149
RADIO
LF LF
LF SPEAKER BK 4 RD B BK 4 RD B RF SPEAKER 59 BK 476 GY 17 PP 137 RD 14 LB 8 GROUND 7 BATT 12V 6 DIMMER 4 IGNITION 3 ILLUMINATION A 805 TN 811 BK 12 11 RF RF A 804 TN 13 813 BK 14
+ +
C60 C B A E D
PANEL LIGHT DIMMER
HEADLIGHT SWITCH
OFF PARK
HEAD
C3 59 BK J6 C1 B4 G3 F3 H9 17 PP 476 GY 137 RD 14 LB 14 LB 19 YL G4 38 RD K7 B1 C1-67
1 H6
INTERNAL FUSE BOX
FUSE 2H 10 AMP
FUSE 1F 5 AMP
FUSE 2F 5 AMP
EXTERNAL FUSE BOX
37 RD
00-S12-040
TO BATTERY
TO IGNITION
TO BATTERY
Figure 12-148: Standard Audio Harness Schematic Model 89.
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12-150
CD CHANGER
RADIO
LEFT AUDIO SIGNAL RIGHT AUDIO SIGNAL
11
YL
13
LEFT AUDIO SIGNAL RIGHT AUDIO SIGNAL
10
WT
16
12 AUDIO COMMON 9 DRAIN
GY
19 AUDIO COMMON
SHIELD
15 BATT
RD
15 BATT
13 GROUND
BK
18 GROUND
14 DATA C61
PP
14 DATA C58
00-S12-002
Figure 12-149: CD Changer To Radio Harness, All Models.
3-1-01
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Electrical System
12-151
SYMPTOM TABLE
SYMPTOM Display inoperative, no sound from any speaker. No sound from one speaker (Delco std.). No sound from one speaker (Monsoon). No sound from any speaker, radio display operates normally (Monsoon). Compact disc player does not operate properly. Cassette player does not operate properly. Antenna system test. Rear seat audio does not operate. Radio controls are inoperative. Radio does not turn off. Radio memory (clock and station presets) is inoperative. PROCEDURE Chart #1 Chart #2 Chart #3 Chart #4 Chart #5 Chart #6 Chart #7 Chart #8 Service radio. Service radio. Check the gray wire (CKT 476) for an open or high resistance between C56 terminal 7 and fuse 2H of the interior fuse box. Check the purple wire (CKT 17) for an open or high resistance between C56 terminal 6 and the panel light dimmer. Check for open or poor connection in the black wire (CKT 59) from C62 terminals E8 and E9 to the ground G4. Check for open or poor connection in the light green wire (CTK 829) from C62 terminals E11 and E12 to fuse 1D. If OK, replace amplier. PAGE NUMBER 12-152 12-152 12-153 12-154 12-155 12-156 12-157 12-160
Display dimming does not vary using the I/P dimmer switch (I/P dimming works). Speaker output distorted at high volume (Monsoon).
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12-152
DISPLAY IS INOPERATIVE, NO SOUND FROM ANY SPEAKER CHART #1

STEP 1 ACTION Disconnect connector C56. Turn the ignition switch to the Run position. With a DVOM, measure voltage between terminal 7 and ground G4. With a DVOM, measure the voltage at connector C56 between terminal 7 and terminal 8. VALUE(S) +12v YES Go to step 2. NO Repair the poor connection or open the gray wire (CKT 476) between connector C56 terminal 7 and fuse 2H of the interior fuse box. Repair the poor connection or open in the black wire (CKT 59) between connector C56 terminal 8 and ground G4. Repair open in the red wire (CKT 137) between connector C56 terminal 4 and fuse 4G of the interior fuse box.
+12v
Go to step 3.
With a DVOM measure the voltage at connector C56 between terminal 4 and terminal 8. Check for a poor connection at the radio. If OK, service radio.
+12v
Go to step 4.
NO SOUND FROM ONE SPEAKER (DELCO STANDARD) CHART #2

ACTION 1 Turn the ignition switch to the off position. Disconnect connectors C56, C57 and C58. With a DVOM, measure the resistance at the connector C56 between speaker + and - circuits (see schematics). With a DVOM, measure the resistance at the speaker connection from terminal A to terminal B. With a DVOM measure the resistance at the radio connector of the speaker + and circuits to ground. Check for poor connections at radio or speaker. If OK, service radio. VALUE(S) 4 YES Go to step 3. NO Go to step 2.
Repair open or short circuit in speaker + and - circuits. Go to step 4.
Replace speaker.
Innite resistance.
Repair short to ground in speaker + or - circuit.
3-1-01
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Electrical System
12-153
NO SOUND FROM ONE SPEAKER (DELCO MONSOON) CHART #3

STEP 1 ACTION Turn ignition switch to the Run position. Turn radio On. Insert cassette or compact disc from Delco Audio system Diagnostic Kit J39916-A. Set radio balance and fade controls to the detente (center) position. Set volume at normal listening level. While playing the combination test tone from cassette or compact disc, use a DVOM to backprobe the speaker connector between terminals A and B. Is the voltage greater than 0v AC? Check for a poor connection at the inoperative speaker. If OK, replace the speaker. Is the repair complete? Check the + and - speaker circuits for a short to B+ or ground between the speaker and amplier. Is there a short? Turn the ignition switch to the Off position. Disconnect connector C62. Using a DVOM set to measure resistance, probe the amplier connector between the + and - speaker circuits of the inoperative speaker (see schematics). Is the resistance approximately 2-4 ohms? Using a DVOM, check the resistance at the speaker connection between terminals A and B. Is the resistance 2-4 ohms? Check for poor connection at connector C62. Is connection OK? 2-4 ohms VALUE(S) > 0v AC YES Go to step 2. NO Go to step 3.
System OK.
Repair short to ground or B+.
Go to step 4.
Go to step 6.
Go to step 5.
2-4 ohms
Repair open in speaker + or - circuit between speaker connection and amplier connection. Replace amplier.
Replace the speaker.
Repair connection.
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12-154
NO SOUND FROM ANY SPEAKER, RADIO DISPLAY OPERATES NORMALLY (DELCO MONSOON) CHART #4
STEP 1 ACTION Disconnect connector C62. Turn ignition switch to the Run position. Turn radio On. Insert the cassette or compact disc from Delco Audio System Diagnostic Kit J39916-A. Set radio balance and fade controls to the detente (center) position. Set radio volume at normal listening level. While playing the combination test tone from the cassette or compact disc, use a DVOM to measure AC voltage between connector C62 terminals E6 and E7. Is the voltage greater than 0v AC? Check for a poor connection at the connector C62 terminals E6 and E7. Was a poor connection found? Using a DVOM, check for +12v between the light green wire and the black wire (ckts 829 and 59) at the amplier connection. Turn the ignition switch to the Run position. Turn the radio to the On position. Insert the cassette or compact disc from Delco Audio System Diagnostic Kit J39916-A. Set radio balance and fade controls to the detente (center) position. Set radio volume at normal listening level. While playing the combination test tone from the cassette or compact disc, use a DVOM and backprobe connector C56 between terminals 16 and 15. Is the voltage greater than 0v AC? Check for a bad connection at connector C56 terminals 16 or 15. Is bad connection found? +12v VALUE(S) > 0v AC YES Go to step 2. NO Go to step 4.
Repair connection.
Go to step 3.
Replace amplier.
Repair open or poor connection in ckts 829 and 59. Go to step 5.
> 0v AC
Repair the open or short in ckts 821 or 820 between radio and amplier.
Repair connection.
Replace radio.
3-1-01
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Electrical System
12-155
COMPACT DISC CHANGER DOES NOT OPERATE PROPERLY

NOTE: Steps 1-4 cover the CD changer having no function with the radio operating normally NOTE: Step 5 is used to diagnose a skipping or muted complaint. NOTE: Step 6 is used if the display reads FOCUS or the disc ejected.
CHART #5
STEP 1 ACTION Disconnect connector C61. Turn ignition switch to the Run position. Turn the radio On. Select CD mode on radio display. Using a DVOM, check for voltage on connector C61 between terminals 13 and 15. Is the minimum voltage present? Back probe connector C58 between terminals 18 and 15. Is the minimum voltage present? Using a DVOM, check for voltage on connector C61 terminal 14. Is the minimum voltage present? Back probe connector C58 and check the voltage. Is the minimum voltage present? Check disc for proper insertion, scratches, dirt or nger prints and clean if necessary. Is usual route over a rough road (off road environment)? If so, condition may be normal. Attempt to duplicate on good road surface. Test with known good disc (preferably new disc). Some discs may contain marks not readily visible that may make one track or the entire disc unplayable. Check mounting angle adjustment on both sides of changer. Is angle adjusted to 45 degrees? If checks and adjustments do not cure problem, service changer. FOCUS appears if disc is inserted upside down, dirty, badly scratched or wet. FOCUS appears if moisture condenses on the disc (if a cold disc is inserted into a hot player and vice versa). Allow up to an hour to evaporate condensation. Check with known good disc - verify to customer. Very high internal instrument panel temperatures may cause eject. If checks and adjustments do not cure problem, service changer. 3-1-01 VALUE(S) +12v YES Go to step 3. NO Go to step 2.
+12v
Repair power and/or ground circuits between radio and CD changer. System OK. Check for a poor connection at the CD changer. If OK, service CD changer. Repair the power control circuit between the radio and the CD changer. Service changer.
Check for a poor connection at the radio. If OK, service radio. Go to step 4.
+12v
+12v
Check for a poor connection at the radio. If OK, service radio. Loosen screws and adjust mount angle to 45 degrees.
45 degrees
05745159
12-156
CASSETTE PLAYER DOES NOT OPERATE PROPERLY CHART #6

STEP ACTION Tape plays weak, slow or garbled. Tape inoperative. 1 Inspect and clean moving parts and tape head or use Delco Audio System Diagnostic Kit J 39916-A cleaning cassette. Does tape play OK? Perform motor speed test with diagnostic test tape from Delco Audio System Diagnostic Kit J39916-A. Is motor speed OK? Check player for obstruction through tape door. Is there an obstruction? Remove obstruction. CAUTION: improper removal may damage tape player. Inspect and clean moving parts and tape head or use cleaning cassette. Use diagnostic test tape from J39916-A. Does test tape operate? VALUE(S) YES Go to step 1. Go to step 3. Advise periodic cleaning. Go to step 2. NO
Fault is in tape. System OK.
Service radio.
Go to step 4.
Service radio.
System OK.
Service radio.
3-1-01
_____________________________________________________
Electrical System
12-157
ANTENNA SYSTEM TEST CHART #7

STEP 1 ACTION Disconnect negative battery cable. Disconnect antenna lead-in cable at the radio receiver. With a DVOM, measure resistance between the coax (outer conductor) connector and the negative battery cable. NOTE: To avoid misdiagnosis be sure to zero the meter before taking measurements. Is resistance value greater than.15 ohms? 2 Grasp the antenna mast. While observing the DVOM, wiggle the antenna and the lead-in cable ground strap. Does the meter indicate intermittent continuity? VALUE(S) > .15 ohms YES Check the base of the antenna for a good connection to body ground. Check the coaxial cable interconnects for a poor connection or corrosion. Check the ground connection from the battery negative cable to the body. Repair the antenna ground circuit as necessary. Check the lead-in cable ground strap for a good connection to body ground. Check the coaxial cable interconnects for a poor connection or corrosion. Check the ground connection from the battery negative cable to the body. Repair the antenna ground circuit as necessary. Less than 3.5 ohms Go to step 4. NO Go to step 2.
Go to step 3.
With a DVOM, measure the resistance between the radio coax lead-in connector (center conductor) and the antenna mast. NOTE: To avoid misdiagnosis be sure to zero the meter before taking measurements. Does the measured resistance equal approximately the value listed?
Check the coaxial cable interconnects for a poor connection or corrosion. Repair/replace the antenna coaxial circuit as necessary.
While observing the DVOM, wiggle the antenna. Does the meter indicate intermittent continuity?
Check the coaxial cable interconnects for a poor connection or corrosion. Repair/replace the antenna coaxial circuit as necessary.
See troubleshooting hints for noise and poor reception.
05745159
4-1-00
12-158
REAR SEAT AUDIO (RSA) DOES NOT OPERATE CHART #8

STEP 1 ACTION With ignition on, check for voltage at C59 pin A8 (CKT 819 BK). Is voltage present? With ignition in the RUN position and the radio ON, check for voltage at C59 pin B5 (CKT 842 OR). Is voltage present? Check for continuity between C56 pin 8 (CKT 59 BK) and ground G4. Is there continuity? Check for continuity between C56 pin 8 and C59 pin 6. Is there continuity? With ignition in the RUN position and the RSA on, back probe C59 pin A5 (CKT 843 GY) and check for specied voltage. Is the specified voltage present? With ignition on and RSA on, check for voltage at C57 pin 22 (CKT 843 GY). Is the specified voltage present? Check for an open circuit between C56 pin 15 and C59 pin A4 (CKT 820 DG). Is there continuity? Check for an open circuit between C56 pin 16 and C59 pin A3 (CKT 821 BK). Is there continuity? Check for an open circuit between C56 pin 9 and C59 pin A2 (CKT 818 PP). Is there continuity? Check for an open circuit between C56 pin 10 and C59 pin A1 (CTK 819 BK). Is there continuity? VALUE(S) +12v YES Go to step 2. NO Check/repair open circuit between C59 pin A8 and C56 pin 4. Check/repair open circuit between C59 pin B5 and C57 pin 19. Repair circuit 59 BK between C56 and ground point G4. Repair circuit 59 BK between C56 and C59. Replace RSA unit.
+12v
Go to step 3.
< 0.2 .
Go to step 4.
4 5
< 0.2 . + 5v
+ 5v
Go to step 7.
Check/repair open circuit between C59 pin A5 and C57 pin 22. Check/repair open circuit between C59 pin A4 and C56 pin 15. Check/repair open circuit between C59 pin A3 and C56 pin 16. Check/repair open circuit between C59 pin A2 and C56 pin 9. Check/repair open circuit between C59 pin A1 and C56 pin 10.
< 0.2 .
Go to step 8.
< 0.2 .
Go to step 9.
< 0.2 .
Go to step 10.
10
< 0.2 .
Go to step 1.
4-1-00
_____________________________________________________
Electrical System
12-159
CONNECTOR LEGEND
NOTE: Connector gender is determined by the terminals.
76 WAY BULKHEAD LOCATION: LEFT SIDE FIREWALL
C1 MALE
9-S12-048
C1 FEMALE
PIN 1 2 3 4 5 6 7 8 9 10 05745159 CKT 400 739 740 43 962 33 37E 37D 786 537 COLOR LG PP YL DB BR WH YL YL RD OR Ignition Feed + Left heated windshield power + Right heated windshield power + Trailer Brake activation Trailer lights neutral safety switch feed start relay feed Ignition switch feed Fuel selector valve control Battery
9-S12-047
CIRCUIT DESCRIPTION
4-1-00
12-160
PIN 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
CKT 787 37 688 723 724 17 718 353 607 717 961 720 640 92 714 37 338 658 151 31 22 721 580 606 29 39 153 42 198 810 2 152 298 722 327 80
COLOR GY RD RD YL DG PP DB YL TN WH PP TN OR GY DB RD DB BR GY TN RD LB BR OR PK DG LG BR TN PP LG DB BR PP YL WH Fuel pump + to selector valve Ignition relay feed Rear window defrost feed APP 3 5volt reference APP 3 signal
CIRCUIT DESCRIPTION
+ FROM DIMMER MODULE APP 1 signal Speedometer signal ABS module diagnostic line APP 1 5volt reference TT4 lamp activation APP 2 5volt reference IGN+ CTIS warning circuits CTIS rear inate solenoid activation Check throttle lamp activation Battery feed to interior accessories Wait lamp activation Check engine lamp activation Cruise control ON/OFF signal Oil pressure signal Brake switch signal rest APP 2 sensor signal Not Used for 99 and 2000 ABS diagnostic line Fuel gauge signal Engine temperature signal Cruise resume/accelerate signal Low brake uid lamp activation A/C request TCC brake switch signal Right front turn signal Cruise set/coast signal Backup light switch feed APP 2 ground Water-in-fuel lamp activation Underhood lamp power
4-1-00
_____________________________________________________
Electrical System
12-161
PIN 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
CKT 3 914 644 210 195 603 719 793 794 41 428 47 46 725 767 1 91 37 12 13 38 16 175 943 5 9 20 21 789 941
COLOR LB PP YL DG YL RD BR YL RD TN PK LG WH GY BR DB TN RD OR TN RD LG LB TN DG YL RD GY BR TN Left front turn signal
CIRCUIT DESCRIPTION
PCM class 2 communication line to DLC Tachometer signal Low washer uid level lamp activation Headlight switch feed ABS lamp activation APP 1 ground Low coolant lamp activation Low air warning lamp activation Brake uid level sensor feed CTIS buzzer activation Deate solenoid activation CTIS compressor relay activation APP 3 Ground Compass mirror temperature signal Horn relay activation CTIS front inate solenoid activation Batt feed to interior fuse box Headlamp high beam feed Headlamp low beam feed Headlamp switch feed Ignition supply to exterior fuse box fuses 2A, 2B, and 3B Power window relay feed Upper windshield washer pump activation Right rear turn signal Backup light activation Left rear turn signal Rear tail lamp feed Fuel selector valve control Lower windshield washer pump activation
05745159
4-1-00
12-162
42 WAY UNDERBODY LOCATION: LOWER LEFT FOOTWELL NEAR ENGINE
C2 MALE
9-S12-015
C2 FEMALE
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 CKT 43 20 12 13 3 80 2 767 49 996 997 32 33 COLOR DB RD OR TN LB WH LG BR OR BR BK LB WH Trailer brake activation Front parking lamp feed Headlamp high beam feed Headlamp low beam feed Left front turn signal Underhood lamp power Right front turn signal Compass mirror temperature signal Battery power to trailer connector
9-S12-016
DESCRIPTION
Left front wheel speed sensor low signal Left front wheel speed sensor high signal Neutral safety switch feed to start relay Neutral safety switch ignition feed
4-1-00
_____________________________________________________
Electrical System
12-163
PIN 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
CKT 17
COLOR PP Light power from dimmer module
DESCRIPTION
999 998
BK BR
Right front wheel speed sensor high signal Right front wheel speed sensor low signal
994 995 41 21
BR BK TN GY
Right rear wheel speed sensor low signal Right rear wheel speed sensor high signal Parking brake lamp activation Rear marker lamp feed
298
BR
Backup lamp switch feed
5 9 992 993
DG YL BR BK
Right rear turn signal Left rear turn signal Left rear wheel speed sensor low signal Left rear wheel speed sensor high signal
29 786 789
PK RD BR
Fuel gauge signal Fuel selector valve control Fuel selector valve control
962
BR
Trailer tail lamps
05745159
4-1-00
12-164

6 P N M L K J H 7 8 9 10 5 4 3 2 1 G F E D C B A PIN A1
9-S12-050
C3 MALE
PIN H6
1 G F E D C B A CAV A1
10 9
C3 FEMALE
PIN A1 A2 A3 B1 B2 B3 B4 C1 C2 C3 C4 4-1-00 CKT 195 54 53 38 15 640 46 450 47 91 92 COLOR YL DG DB RD WH OR WH PK LG TN GY Headlight switch feed Dome lamp switch feed Dome lamps feed Headlamp switch feed Headlamp feed to dimmer module CTIS switch ignition feed
9-S12-049
DESCRIPTION
CTIS compressor indicator lamp activation Seat belt lamp activation Deate solenoid activation Front inate solenoid activation Rear inate solenoid activation
_____________________________________________________
Electrical System
12-165
PIN D1 D2 D3 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 G5 H6 H7 H8 H9 J6 J7 J8 J9 K6 K7 K8 K9 L6 L7 L8 M6 M7 05745159
CKT 338 2 961 42 603 793 943 12 3 658 327 517 210 794 428 714 14 65 61 17 63 27 948 947 942 19 944 644 476 31 952 789 786
COLOR DB LG PP BR RD YL TN OR LB BR YL PK DG RD PK DB LB YL RD PP DG OR DG/YL DB/YL OR/BK YL OR YL GY TN DB BR RD Glow plug wait lamp activation
DESCRIPTION
Right turn indicator lamp activation TT4 indicator lamp activation Brake indicator lamp activation ABS indicator lamp activation Low washer uid activation Rear Wiper feed (not used 99) High Beam indicator lamp activation Left turn indicator lamp activation Check engine lamp activation Drain Filter lamp activation Power mirror switch battery feed Transfer case lock lamp activation Low coolant lamp activation Low tire air lamp activation Check throttle lamp activation Headlamp switch feed Ignition feed to intermittent wiper switch High speed windshield wiper signal + from dimmer module Low speed windshield wiper signal Intermittent wiper signal Left hand power mirror up/down signal Left hand power mirror left/right signal Left hand power mirror common +/ Power supply to dimmer module Right hand power mirror common +/ Tachometer signal Clock battery feed Oil pressure signal to gauge Right hand power mirror left/right signal Fuel selector valve control Fuel selector valve control
12-166
PIN M8 M9 N6 N7 N8 N9 P6 P7 P8 P9 P10
CKT 787 953 59 30 941 945 55 29 39 353 59
COLOR GY DG BK GY TN BR OR PK DG YL BK
DESCRIPTION Fuel selector switch feed from fuel pump relay Right hand power mirror up/down signal Ground Ignition feed to gauges Windshield wiper washer pump activation Intermittent wiper relay activation Rear cargo lamp activation Fuel gauge signal Engine temperature gauge signal Speedometer signal Ground

_____________________________________________________
Electrical System
12-167
12 WAY AMG ENGINE LOCATION: LEFT INTAKE MANIFOLD

2 3
3 4
2 1 6 8 12 11
1 6 8 12 11
9-S12-072
4 5 7 9 10
5 7 9 10
9-S12-077
C4 MALE
C4 FEMALE
PIN 1 2 3 4 5 6 7 8 9 10 11 12
CKT 34 198 291
COLOR LB TN PK Starter solenoid activation A/C request from control head
DESCRIPTION
Ignition feed to alternator and low coolant sensor
439
YL
A/C request to PCM
348
BR
A/C compressor clutch activate
794
RD
Low coolant lamp activation
05745159
4-1-00
12-168
40 WAY GM ENGINE LOCATION: LEFT INTAKE MANIFOLD

9-S12-019

9-S12-020
C5 MALE
C5 FEMALE
PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 C1 C2 C3
CKT 39 708 709 239 291 710 711 713 712 491 701 466 651 57
COLOR DG TN RD PK PK OR YL RD LG BK DB YL PP BK
DESCRIPTION Engine temperature signal to gauge Injection timing stepper motor LO Injection timing stepper motor HI Engine ignition feed Engine ignition feed Injection timing stepper motor LO Injection timing stepper motor HI Closure signal to solenoid driver Fuel inject signal to solenoid driver Closure ground to solenoid driver Engine shutoff solenoid enable Glow plug controller enable Crankshaft position sensor ground Ground
442 349 394 359 350 703 225 375
BR YL LG BK GY OR YL GY
CAM signal Crankshaft position signal Boost Pressure Signal Sensor ground Sensor 5 volt reference High resolution signal Fuel temperature signal Optical Sensor 5 volt reference
4-1-00
_____________________________________________________
Electrical System
12-169
PIN C4 C5 C6 C7 C8 C9 C10 C11 C12 D1 D2 D3 D4 D5 D6 D7 D8
CKT 354 357
COLOR YL TN Engine coolant temperature signal Intake air temperature signal
DESCRIPTION
31 506 156
TN LB PK
Oil pressure signal to gauge Glow plug feedback signal Optical sensor ground
154
TN
Wastegate solenoid control
05745159
4-1-00
12-170
56 WAY CONSOLE LOCATION: CENTER CONSOLE

6 P N M L K J H PIN H6 7 8 9 10 5 4 3 2 1 G F E D C B A PIN A1
9-S12-050
C6 MALE
1 G F E D C B A CAV A1 2 3 4 5 10 9
C6 FEMALE
PIN A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 4-1-00 40 476 137 DB GY RD Cigarette lighters battery feed Battery feed to radio Ignition feed to radio 751 OR Medium 1 HVAC blower speed 689 PK Rear window defrost activation CKT 171 COLOR RD
9-S12-049
DESCRIPTION Feed to RF, RR, LR power window switches
_____________________________________________________
Electrical System
12-171
PIN C3 C4 D1 D2 D3 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 G5 H6 H7 H8 H9 J6 J7 J8 J9 K6 K7 K8 K9 L6 L7 L8 05745159
CKT 346
COLOR PK
DESCRIPTION Ignition feed to rear HVAC blower switch
45
WH
Battery feed to auxiliary power outlet
319 320 404 405
TN LG YL 0R
To right rear power window master switch To right rear power window master switch Rear HVAC blower low fan speed activation Rear HVAC blower high fan speed activation
17
PP
Feed from dimmer module
399
DG
Ignition feed to HVAC control head
14 815
LB PK
Park lamp input to radio
58
BK
Ground
59
BK
Ground
347 402
YL LB
A/C request Temperature door motor control line
752 316 317 757
GY TN LG LB
Med 2 HVAC blower speed To left rear power window master switch To left rear power window master switch High HVAC blower speed
755
DB
Low HVAC blower speed 4-1-00
12-172
PIN M6 M7 M8 M9 N6 N7 N8 N9 P6 P7 P8 P9 P10
CKT
COLOR
DESCRIPTION
83 580
TN BR
Ignition feed to heated windshield switch/timer Heated windshield relay activation
688
RD
Battery feed for rear defrost
829 170
LG PP
Battery feed to radio Battery feed to power window lockout switch
313 314
DB WH
To right front power window master switch To right front power window master switch
4-1-00
_____________________________________________________
Electrical System
12-173
35 WAY ABS ECU LOCATION: WSW RESERVOIR RECESS
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18
D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35
9-S12-043
C7 FEMALE ONLY
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 975 974 971 LB DB PP Left rear inlet valve activation Left rear outlet valve activation Left front inlet valve activation 605 610 606 607 997 995 999 993 990 PP RD OR TN BK BK BK BK PK Positive pump relay activation Negative pump relay activation Diagnostic line Diagnostic line Left front wheel speed sensor low Right rear wheel speed sensor low Right front wheel speed sensor low Left rear wheel speed sensor low ABS valve relay redundant input 961 977 976 973 972 991 601 PP WH RD OR YL LB PK TT4 lamp activation Right rear inlet valve activation Right rear outlet valve activation Right front inlet valve activation Right front outlet valve activation ABS valve relay activation Ignition feed CKT 990 COLOR PK ABS valve relay input DESCRIPTION
05745159
4-1-00
12-174
PIN 24 25 26 27 28 29 30 31 32 33 34 35
CKT 970 677 603 570
COLOR TN GY DG BK Left front outlet valve activation Shuttle valve switch signal ABS warning lamp activation Ground
DESCRIPTION
609 978 996 994 998 992
YL BK BR BR BR BR
Pump motor monitor Reference ground Left front wheel speed sensor high Right rear wheel speed sensor high Right front wheel speed sensor high Left rear wheel speed sensor high
4-1-00
_____________________________________________________
Electrical System
12-175
6 WAY ROOF HARNESS LOCATION: CENTER WINDSHIELD PILLAR TRIM
F D
A C
C8 MALE
C8 FEMALE
9-S12-078 9-S12-078
PIN A B C D E F
CKT 53 55 54 59
COLOR DB OR DG BK Dome lamps feed Cargo lamp feed Map light feed Ground
DESCRIPTION
05745159
4-1-00
12-176
10 WAY STATUS CENTER-RH LOCATION: INSTRUMENT PANEL

E F A K
A
9-S12-017
E
9-S12-018
C9 MALE
PIN A B C D E F G H J K CKT 338 2 961 42 210 428 794 793 30 59 COLOR DB LG PP BR DG PK RD YL GY BK Wait lamp Right turn lamp TT4 (atc) lamp Brake lamp Transfer case lock lamp Low tire air lamp Low coolant lamp Washer uid low lamp Ignition feed Ground
C9 FEMALE
DESCRIPTION
4-1-00
_____________________________________________________
Electrical System
12-177
10 WAY STATUS CENTER-LH LOCATION: INSTRUMENT PANEL

E F A K
A
9-S12-017
E
9-S12-018
C10 MALE
PIN A B C D E F G H J K CKT 12 3 658 327 603 450 46 714 30 59 COLOR OR LB BR YL RD PK WH DB GY BK Headlamp high beam lamp Left turn lamp Check engine lamp Drain lter lamp ABS lamp Seat belt lamp CTIS pump lamp Check throttle lamp Ignition feed Ground
C10 FEMALE
DESCRIPTION
05745159
4-1-00
12-178
13 WAY ABS MODULATOR LOCATION: BELOW BRAKE MASTER CYLINDER
CAV 5 CAV 9 CAV 13
CAV 1 CAV 6 CAV 10
C11 FEMALE ONLY

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 677 972 973 975 974 GY YL OR LB DB Shuttle valve switch signal Right front outlet valve activation Right front inlet valve activation Left rear inlet valve activation Left rear outlet valve activation 977 976 978 WH RD BK Right rear inlet valve activation Right rear outlet valve activation Reference ground CKT 970 971 COLOR TN PP Left front outlet valve activation Left front inlet valve activation
9-S12-014
DESCRIPTION
4-1-00
_____________________________________________________
Electrical System
12-179
10 WAY CTIS LOCATION: INSTRUMENT PANEL, RIGHT

E F A K
A
9-S12-017
E
9-S12-018
C12 MALE
PIN A B C D E F G H J K 17 59 47 91 92 46 640 640 PP BK LG TN GY LB OR OR Light power from dimmer module Ground Deate solenoid activation Front inate/deate solenoid activation Rear inate/deate solenoid activation Compressor Relay activation Ignition feed Ignition feed CKT COLOR
C12 FEMALE
DESCRIPTION
05745159
4-1-00
12-180
8 WAY COMPASS MIRROR LOCATION: WINDSHIELD CENTER PILLAR TRIM
A D
9-S12-029
E H
9-S12-030
D A
CI3 MALE
CI3 FEMALE
PIN A B C D E F G H
CKT 59 400 841 767
COLOR BK LG RD BR Ground Ignition feed Battery feed Temperature signal from sensor
DESCRIPTION
53
DB
Dome lamp feed
4-1-00
_____________________________________________________
Electrical System
12-181
6 WAY LF DOOR LOCATION: LEFT FRONT OUTSIDE KICK PANEL
F
9-S12-031
F
9-S12-032
C14 MALE
C14 FEMALE
PIN A B C D E F
CKT 56 120 117 118 119 56
COLOR BK LG PK BR TN BK Ground G4 Oscillating power/ground circuit
DESCRIPTION
Unlock signal to the drivers door lock actuators Lock signal to the drivers door lock actuators Oscillating power/ground circuit Ground G4
05745159
4-1-00
12-182
4 WAY LF DOOR LEFT FRONT OUTSIDE KICK PANEL
D
9-S12-033 9-S12-034
C15 MALE
C15 FEMALE
PIN A B C D
CKT 517 56 56 171
COLOR OR BK BK RD
DESCRIPTION Fused battery input to the drivers door lock switch Ground G4 Ground G4 Fused ignition feed to the power window circuit
4-1-00
_____________________________________________________
Electrical System
12-183
6 WAY RF DOOR RIGHT FRONT OUTSIDE KICK PANEL
F
9-S12-031
F
9-S12-032
C16 MALE
C16 FEMALE
PIN A B C D E F
CKT 119 121 117 118 122 120
COLOR TN YL PK BR PP LG Oscillating power/ground circuit
DESCRIPTION
Unlock signal to the module from the switch Unlock signal to the passenger front door lock actuator Lock signal to the passenger front door lock actuator Lock signal to the module from the switch Oscillating power/ground circuit
05745159
4-1-00
12-184
4 WAY RF DOOR RIGHT FRONT OUTSIDE KICK PANEL
D
9-S12-033
D
9-S12-034
C17 MALE
C17 FEMALE
PIN A B C D
CKT 517 313 314 170
COLOR OR DB WH PP
DESCRIPTION Fused battery input to the passenger door lock switch Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch
4-1-00
_____________________________________________________
Electrical System
12-185
8 WAY RR DOOR RIGHT FRONT OUTSIDE KICK PANEL
A
9-S12-035
H
9-S12-036
C18 MALE
C18 FEMALE
PIN A B C D E F G H
CKT 54 319 320 117 118 53 170 59
COLOR DG TN LG PK BR DB PP BK Map light activation
DESCRIPTION
Up/down signal to the power window motor Down/up signal to the power window motor Unlock signal to the power lock actuator Lock signal to the power lock actuator Dome lamps activation Fused ignition input to the power window switch Ground G4
05745159
4-1-00
12-186
8 WAY LR DOOR LEFT FRONT OUTSIDE KICK PANEL
A
9-S12-035
H
9-S12-036
C19 MALE
C19 FEMALE
PIN A B C D E F G H
CKT 54 316 317 117 118 53 170 59
COLOR DG TN LG PK BR DB PP BK Map lights activation
DESCRIPTION
Up/down signal to the power window motor Down/up signal to the power window motor Lock signal to the drivers side rear door lock actuator Unlock signal to the drivers side rear door lock actuator Dome lamps activation Fused ignition input to the power window switch Ground G4
4-01-00
_____________________________________________________
Electrical System
12-187
6 WAY CARGO DOOR-MODEL 84 RIGHT LOWER B PILLAR
A F D
9-S12-037
F D
A C C
9-S12-038
C20 MALE
PIN A B C D E F 64 62 LG LB CKT 517 59 66 COLOR OR BK RD
C20 FEMALE
DESCRIPTION
Fused battery input to the cargo lock delay module (HMCS only) Ground G4 Fused battery voltage to the rear wiper motor (HMSB only) Empty Rear wiper motor intermittent 12 volt supply (HMSB only) Rear wiper motor intermittent (HMSB only)
05745159
4-1-00
12-188
6 WAY RR DOOR JUMPER LOCATION: RIGHT LOWER B PILLAR
F
9-S12-031
F
9-S12-032
C21 MALE
C21 FEMALE
PIN A B C D E F
CKT 117 118 319 320 170
COLOR BR PK TN LG PP
DESCRIPTION Unlock signal to the passenger side rear door lock actuator Lock signal to the passenger side rear door lock actuator Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch
4-1-00
_____________________________________________________
Electrical System
12-189
6 WAY LR DOOR JUMPER LOCATION: LEFT LOWER B PILLAR
F
9-S12-031
F
9-S12-032
C22 MALE
C22 FEMALE
PIN A B C D E F
CKT 118 117 316 317 170
COLOR BR PK TN LG PP
DESCRIPTION Lock signal to the drivers side rear door lock actuator Unlock signal to the drivers side rear door lock actuator Up/down signal to the power window motor Down/up signal to the power window motor Fused ignition input to the power window switch
05745159
4-1-00
12-190
10 WAY POWER MIRROR SWITCH LOCATION: INSTRUMENT PANEL, LEFT

E F K A
A
9-S12-017
E
9-S12-018
C23 MALE
PIN A B C D E F G H J K CKT 59 517 948 952 947 953 942 944 17 COLOR BK PK DG/YL DB DG/YL DG OR/BK OR PP Ground G4
C23 FEMALE
DESCRIPTION
Fused battery input to the power mirror switch Left power mirror vertical control Right power mirror vertical control Left power mirror horizontal control Right hand power mirror horizontal control Left power mirror common Right power mirror common Power mirror switch illumination
4-1-00
_____________________________________________________
Electrical System
12-191
4 WAY LH POWER MIRROR LOCATION: LEFT DOOR
C D
9-S12-039
B A
B A
9-S12-040
C D
C24 MALE
C24 FEMALE
PIN A B C D
CKT 942 947 948
COLOR OR/BK DG/YL DG/YL Left power mirror common
DESCRIPTION
Left power mirror horizontal control Left power mirror vertical control.
05745159
4-1-00
12-192
4 WAY RH POWER MIRROR LOCATION: RIGHT DOOR
C D
9-S12-039
B A
B A
9-S12-040
C D
C25 MALE
C25 FEMALE
PIN A B C D
CKT 944 952 953
COLOR OR DB DG Right power mirror common
DESCRIPTION
Right power mirror horizontal control Right power mirror vertical control
4-1-00
_____________________________________________________
Electrical System
12-193
6 WAY FUEL TANK JUMPER LOCATION: C BEAM ABOVE PROP SHAFT
F
9-S12-031
F
9-S12-032
C26 MALE
C26 FEMALE
DESCRIPTION
PIN A B C D E F
CKT 59 29 675 786 789
COLOR BK PK YL RD BR Ground Fuel level signal to fuel gauge
Fuel level signal from auxiliary tank Fuel selector valve control +/ Fuel selector valve control /+
05745159
4-1-00
12-194

D1 C1
D16
C16
9-S12-042
C27 MALE
PIN C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 4-1-00 495 784 723 724 787 DB DB YL DG GY Transmission input speed sensor (Low) 4wd low switch signal APP sensor (3) 5 volt ref. APP (3) signal Lift pump feedback signal 713 394 265 RD LG LB Closure signal Boost pressure sensor signal Pressure Control Solenoid (Low) 354 YL Engine coolant temp signal 357 721 466 264 225 923 TN LB YL RD YL BR Intake air temp sensor signal APP sensor (2) signal Glow plug enable + Pressure Control Solenoid (Hi) Fuel temperature signal Transmission uid temp signal CKT 651 439 COLOR PP YL DESCRIPTION Crankshaft position sensor ground A/C request+
_____________________________________________________
Electrical System
12-195
PIN D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16
CKT 725 506 238 156 153 496 717 350 375
COLOR GY LB DG PK LG GY WH GY GY APP (3) ground Glow plug feedback signal Lift pump relay enable + Optical sensor ground Cruise control resume/accelerate
DESCRIPTION
Transmission input speed signal (hi) APP (1) 5 volt ref. Boost sensor/crankshaft position sensor 5 volt ref. Optical sensor 5 volt reference
05745159
4-1-00
12-196

D1 C1
D16
C16
9-S12-042
C28 MALE
PIN C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 4-1-00 440 RD Compressor clutch enable 239 239 537 658 701 PK PK OR BR DB Ignition / axle switch jumper Ignition Battery Malfunction indicator lamp control Engine shutoff solenoid control 720 712 237 924 315 338 914 TN LG LG TN YL DB PP APP (2) 5 volt ref. Fuel inject signal 1-2 shift solenoid control Torque converter clutch solenoid control 2-3 shift solenoid control Wait to start lamp control Class 2 communications (dlc) CKT COLOR DESCRIPTION
_____________________________________________________
Electrical System
12-197
PIN D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16
CKT 570 570
COLOR BK BK Ground G2 Ground G2
DESCRIPTION
714
RD
Check throttle lamp control
537 154
OR TN
Battery Waste gate solenoid control
05745159
4-1-00
12-198

B1 A1
A12
A12
9-S12-028
C29 MALE
PIN A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 810 22 152 359 PP RD DB BK CKT 491 703 565 442 349 223 709 708 710 711 151 722 719 718 351 764 763 762 CKT BK OR BR BR YL DB DB TN OR YL GY PP BR DB PK PP DB OR PTO (1360 rpm) user installed PTO (1070 rpm) user installed Cruise control brake switch TCC brake switch Cruise control set/coast signal Boost, engine temp, intake air temp, trans temp sensor ground Closure ground High resolution sensor signal Transmission output speed sensor/VSS Cam sensor signal Crankshaft position sensor signal Vehicle speed sensor Injection timing stepper motor (HI) Injection timing stepper motor (LO) Injection timing stepper motor (LO) Injection timing stepper motor (HI) Cruise control on/off signal APP (2) ground APP (1) ground APP (1) signal Front axle switch signal + from jumper DESCRIPTION
4-1-00
_____________________________________________________
Electrical System
12-199
8 WAY REMOTE ENTRY, GRAY LOCATION: CENTER CONSOLE
A
9-S12-026
C30 FEMALE
PIN A B C D E F G H
CKT 58
COLOR BK Module ground G4
DESCRIPTION
53 1 840 554 14
LB DB DG GY LB
Dome lamp activation Horn Activation Fused ignition input to the remote entry module Fused battery input to the remote entry module Parking lamps activation
05745159
4-1-00
12-200
8 WAY REMOTE ENTRY, BLACK LOCATION: CENTER CONSOLE
H
9-S12-036
C31 FEMALE
PIN A B C D E F G H
CKT 118 122
COLOR BR PP
DESCRIPTION Lock signal to the door lock actuators Lock signal from the switch to the module
517 117 121 117 121
OR PK YL PK YL
Fused battery input Unlock signal to the door lock actuators Unlock signal from the switch to the module Unlock signal to the drivers door lock actuator Unlock signal from the switch to the module
4-1-00
_____________________________________________________
Electrical System
12-201
10 WAY TRANSMISSION-GREY LOCATION: A BEAM, LEFT NEAR LIFT PUMP
F
9-S12-023
A
9-S12-024
C32 MALE
C32 FEMALE
PIN A B C D E F G H J K
CKT 495 496 237 315 924 264 265 763 764 762
COLOR DB GY LG YL TN RD LG DB PP OR
DESCRIPTION Transmission Input Speed Sensor low Transmission Input Speed Sensor high 1-2 shift solenoid control 2-3 shift solenoid control Torque Converter Clutch solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission uid pressure manual valve position switch range B Transmission uid pressure manual valve position switch range C Transmission uid pressure manual valve position switch range A
05745159
4-1-00
12-202
10 WAY TRANSMISSION-BLACK LOCATION: A BEAM, LEFT NEAR LIFT PUMP
F
9-S12-023
A
9-S12-024
C33 MALE
C33 FEMALE
PIN A B C D E F G H J K
CKT 676 679
COLOR PP LG Vehicle Speed Sensor high Vehicle Speed Sensor low
DESCRIPTION
210 351
DG PK
Transfer case lock switch light activation Transmission ignition feed
923 359 784
BR BK DB
Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transfer case range switch signal
4-1-00
_____________________________________________________
Electrical System
12-203
20 WAY TRANSMISSION PASS THROUGH LOCATION: TRANSMISSION, LEFT

S K
A
9-S12-022
C34 FEMALE
PIN A B C D E F G H J K L M N P R S T W X Y 923 359 762 764 763 924 BR BK OR PP DB TN Transmission Fluid Temperature signal Transmission Fluid Temperature sensor ground Transmission uid pressure manual valve position switch range A Transmission uid pressure manual valve position switch range C Transmission uid pressure manual valve position switch range B Torque Converter Clutch solenoid activation CKT 237 315 264 265 351 COLOR LG YL RD LB PK 1-2 Shift Solenoid activation 2-3 Shift Solenoid activation Pressure Control Solenoid high Pressure Control Solenoid low Transmission ignition feed DESCRIPTION
05745159
4-1-00
12-204
3 WAY LOW COOLANT SENSOR LOCATION: SURGE TANK
A B C
9-S12-090 9-S12-091
A B C
C35 FEMALE
PIN A B C CKT 291 794 57 COLOR PK RD BK Ignition power Signal output Ground
C35 MALE
DESCRIPTION
2 WAY HVAC BLOWER LOCATION: RIGHT A-PILLAR
9-S12-106 9-S12-105
C36 FEMALE
PIN A B CKT 364 58 COLOR RD BK Blower relay power Blower motor ground
C36 MALE
DESCRIPTION
4-1-00
_____________________________________________________
Electrical System
12-205
4 WAY HVAC BLOWER RESISTOR HARNESS LOCATION: RIGHT A-PILLAR

D B C A
9-S12-103
9-S12-104
C 37 FEMALE
PIN A B C D CKT 754 751 755 752 COLOR YL OR DB GY Blower activation Medium 1 blower Low blower Medium 2 blower
C 37 MALE
DESCRIPTION
3 WAY LOCATION: LEFT A-BEAM NEAR FUEL MANAGER
9-S12-152
9-S12-151
C 38 FEMALE
C 38 MALE
PIN A B C
CKT 206 58 59
COLOR WH BK BK Trailer connector ground Ambient temp sensor ground
DESCRIPTION
Main and auxiliary fuel sending units, rear lamps ground
05745159
4-1-00
12-206
7 WAY TURN SIGNAL SWITCH HARNESS LOCATION: STEERING COLUMN

A G D B E
00-S12-014
C 39 FEMALE
PIN A B C D E F G
CKT 3 9 1 13 12 15
COLOR LB YL DB TN OR WH
DESCRIPTION
Left front turn signal, status center signal. Left rear turn signal Horn circuit ground Low beam circuit High beam signal Head lamp feed Empty
6 WAY TURN SIGNAL SWITCH HARNESS LOCATION: STEERING COLUMN
E F
00-S12-013
C 40 FEMALE
PIN A B C D E F CKT 385 22 460 44 2 5 COLOR TN RD BK LB LG DG DESCRIPTION
Hazard signal ground Brake lamp switch signal (receives 12v with brakes applied.) Ground Indicator signal ground Right turn signal, status center signal Right rear turn signal
4-1-00
_____________________________________________________
Electrical System
12-207
8 WAY LIFT GATE JUMPER HARNESS LOCATION:
A
9-S12-035
H
9-S12-036
C 41 MALE
PIN A B C D E F G H CKT 59 66 64 62 118 117 COLOR BK RD LG LB BR PK Ground G4 Rear wiper 12 v common supply Rear wiper 12 v start supply Rear wiper 12 v run supply Unlock/lock signal to power door lock motor Lock/unlock signal to power door lock motor Empty Empty
C41 FEMALE
DESCRIPTION
4 WAY SLANT DOOR WIPER PLUG TOP OF SLANT DOOR BEHIND TRIM. B A A B
C
00-S12-019
D
00-S12-020
C 42 MALE
C 42 FEMALE
PIN A B C D
CKT 59 66 64 62
COLOR BK RD LG LB Ground G4 Rear wiper 12 v Common Supply Rear wiper 12 v Start Supply Rear wiper 12 v Run Supply
DESCRIPTION
05745159
4-1-00
12-208
3 WAY FRONT WIPER HARNESS NEAR MOTOR BEHIND A-PILLAR TRIM

A B
A
9-S12-155
C 43 MALE
C 43 FEMALE
PIN A B C
CKT 28 63 61
COLOR DB DG RD Intermittent Power Supply Low Speed Power Supply High Speed Power Supply
DESCRIPTION
2 WAY WIPER MOTOR CONNECTOR NEAR MOTOR BEHIND THE A-PILLAR TRIM
B A B
9-S12-156
C 44 MALE
C 44 FEMALE
PIN A B
CKT 59 65
COLOR BR BK Ground G4 Intermittent Start Supply
DESCRIPTION
4-1-00
_____________________________________________________
Electrical System
12-209
2 WAY REAR WINDOW DEFROSTER HARNESS LOCATION: C-PILLAR INTERMEDIATE

A B
B
9-S12-106 9-S12-105
C45 MALE
PIN A B CKT 58 689 COLOR BK PK
C45 FEMALE
DESCRIPTION
Ground for the rear window defroster G4 Rear window defroster 12 volt supply
4 WAY REAR WINDOW DEFROSTER SWITCH CONNECTOR LOCATION: BACK OF THE HVAC
A
D
9-S12-158
C46 FEMALE
PIN A B C D CKT 688 399 59 689 COLOR RD DG BK PK DESCRIPTION Fused battery voltage to the rear window defroster switch Fused ignition voltage to the rear window defroster switch Ground G4 Rear window defroster 12 volt supply
05745159
4-1-00
12-210
10 WAY CARGO DOOR LOCK DELAY MODULE CONNECTOR LOCATION: ON MODULE

1
10
00-S12-022
C47 FEMALE
PIN 1 2 3 4 5 6 7 8 9 10 517 121 OR YL 118 117 BR PK 59 BK CKT COLOR Empty Empty Ground G4 Empty Lock signal to the cargo door lock delay module Unlock signal to the cargo door lock delay module Empty Empty Fused battery input to the cargo door lock delay module Lock signal to the cargo door lock actuator DESCRIPTION
5 WAY DRIVERS DOOR LOCK SWITCH CONNECTOR LOCATION: IN THE DRIVERS DOOR
1 5
00-S12-021
C48 FEMALE
PIN 1 2 3 4 5
CKT 120 56 517 56 119
COLOR LG BK OR BK TN Oscillating power/ground circuit Ground G4
DESCRIPTION
Fused battery input to the drivers door lock actuator Ground G4 Oscillating power/ground circuit.
4-1-00
_____________________________________________________
Electrical System
12-211
5 WAY PASSENGER DOOR LOCK SWITCH CONNECTOR LOCATION: IN THE PASSENGERS DOOR
1 5
00-S12-021
C49 FEMALE
PIN 1 2 3 4 5 CKT 122 120 517 119 121 COLOR PP LG OR TN YL DESCRIPTION Lock signal from the switch to the module Oscillating power/ground circuit Fused battery input to the passenger door lock switch Oscillating power/ground circuit Unlock signal from the switch to the module
05745159
3-1-01
12-212
16 WAY RADIO HARNESS LOCATION: BACK OF THE RADIO
15 16 7 8
13 14 5 6
11 12 3 4
9 10 1 2
00-S12-004
C56 FEMALE
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CKT
COLORS Empty Empty
DESCRIPTION
14 137
LB RD
Radio illumination Fused battery input to the radio (Ignition)
17 476 59 818 819 805 811 804 813 820 821
PP GY BK PP BK GY BK WH BK DG BK
Dimmer Circuit Fused radio memory feed (Battery) Ground G4 Right rear speaker signal (Positive) Right rear speaker signal (Negative) Right front speaker signal (Positive) Right front speaker signal (Negative) Left front speaker signal (Positive) Left front speaker signal (Negative) Left rear speaker signal (Positive) Left rear speaker signal (Negative)2
3-1-01
_____________________________________________________
Electrical System
12-213
6 WAY RADIO ACCESSORY CONNECTOR LOCATION: BACK OF THE RADIO
20 17 22 19 21 18
00-S12-102
C57 FEMALE
PIN 17 18 19 20 21 22
CKT
COLOR
DESCRIPTION
830 842 839
PK OR YL
Amplier sense Rear seat audio enable Cell phone mute
843
GY
Rear seat audio control
8 WAY RADIO JUMPER CONNECTOR LOCATION: BACK OF THE RADIO

29 32 35 31 34
30 33 36 01-S12-029
C58 FEMALE
PIN 29 30 31 32 33 34 35 36 CKT BK GY Ground G4 Audio common COLOR YL PP RD WH Left audio signal CD changer to radio data buss +12v Fused battery voltage Right audio signal DESCRIPTION
05745159
3-1-01
12-214
A1 B1
C59 FEMALE
01-S12-028
PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8
CKT 819 818 821 820 843
COLOR BK PP BK DG GY
DESCRIPTION Right rear speaker signal (Negative) Right rear speaker signal (Positive) Left rear speaker signal (Negative) Left rear speaker signal (Positive) Rear seat audio control
137
RD
Fused battery input to the rear seat audio (Ignition)
842 59
OR BK
Rear seat audio enable Ground G4
14
LB
Rear seat audio illumination
3-1-01
_____________________________________________________
Electrical System
12-215
8 WAY BODY TO CONSOLE CONNECTOR LOCATION: BEHIND THE CENTER CONSOLE
9-S12-035
9-S12-036
C60 MALE
C60 FEMALE
PIN A B C D E F G H
CKT 476 137 59 17 14
COLOR GY RD BK PP LB
DESCRIPTION Fused radio memory input (Battery) Fused battery input to the radio (Ignition) Ground G4 Dimmer Circuit Radio Illumination
829 59
LG BK
Fused battery input to the amplier Ground G4
05745159
3-1-01
12-216
CD CHANGER CONNECTOR LOCATION: BACK OF THE CD CHANGER

15 14 13 12 11 10 9 8 7
C61 FEMALE
01-S12-029
PIN 7 8 9 10 11 12 13 14 15
CKT
COLOR
DESCRIPTION
BR WH YL GY BK PP RD
Shielding for the audio circuits Right audio signal Left audio signal Audio common Ground G4 CD changer to radio data buss +12v Fused battery
3-1-01
_____________________________________________________
Electrical System
12-217
AMPLIFIER CONNECTOR LOCATION: ON THE AMPLIFIER
01-S12-027
C62 FEMALE
PIN E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 F1 F2 F3 F4 F5 F6 F7 F8 F9 CKT 805 804 813 819 818 820 821 59 59 842 829 829 831 832 834 833 811 835 836 824 825 837 838 830 COLOR GY WH BK BK PP DG BK BK BK OR LG LG BK TN TN BK BK BK TN BK TN BK TN PK Right front channel positive input Left front channel positive input Left front channel negative input Right rear channel negative input Right rear channel positive input Left rear channel positive input Left rear channel negative input Ground G4 Ground G4 Rear seat audio enable +12v battery input +12v battery input Right console speaker negative signal Right console speaker positive signal Left front speaker positive signal Left front speaker negative signal Right front channel negative input Right front speaker negative signal Right front speaker positive signal Rear subwoofer negative signal Rear subwoofer positive signal Left console negative signal Left console positive signal Amplier sense circuit DESCRIPTION
05745159
3-1-01
12-218
PIN F10 F11 F12 F13 F14 F15 F16
CKT 826 827
COLOR BK TN Front subwoofer negative signal Front subwoofer positive signal
DESCRIPTION
803 802 800 801
BK TN TN BK
Right rear speaker negative signal Right rear speaker positive signal Left rear speaker positive signal Left rear speaker negative signal
3-1-01
_____________________________________________________
Electrical System
12-219
INTERIOR MINI FUSE BLOCK 1 (LOWER)

Buss Cavity 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B 11B 12B 13B 14B 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C 1D 2D 3D 4D 5D 6D 7D 8D 9D 10D 11D 12D 13D 14D CKT. No. (BUSS I1) 30 A (BUSS I1) (BUSS I1) 291 A 16 D (BUSS I1) 840 A 16 C (BUSS I1) 83 C (BUSS A2A) 400 A 400 B 687 C (BUSS A2A) 298 A 687 C (BUSS A2) 8A (BUSS A2) 295 A (BUSS A2) 346 A (BUSS A2) 399 B 687 B (BUSS A2) 829 A (BUSS B2A) 537 A 37 M (BUSS B2A) 40 A 37 M (BUSS B2) 10 A (BUSS B2) 383 A (BUSS B2) (BUSS B2) 841 A 37 b (BUSS B2) Color & Ga. 16 GY 18 PK 12 LG 18 DG 12 LG 16 TN 14 LG 18 LG 14 LG 16 BR 14 LG 14 PP 18 BR 14 PK 12 DG 10LLG 14 LG 14 OR 14 RD 14 DB 14 RD 14 OR 14 YL 18 RD 10 RD Fuse ES (5 AMP) -1AET (7.5 AMP) -2A -3AEU (10 AMP) -4AEW (15 AMP) -5A -6AEU (10 AMP) -7A -1B -2B -3BES (5 AMP) -4B -5BES (5 AMP) -6BES (5 AMP) -7BES (5 AMP) -1CEU (10 AMP) -2CET (7.5 AMP) -3CEU (10 AMP) -4CEU (10 AMP) -5CEX (20 AMP) -6CEZ (30 AMP) -7CEW (15 AMP) 1D EX (20 AMP) -2DEX (20 AMP) -3D EW (15 AMP) -4DEW (15 AMP) -5D -6DES (5 AMP) -7D-
I1
A2A
A2
B2A
B2
05745159
3-1-01
12-220
INTERIOR MINI FUSE BLOCK 2 (UPPER)

Buss Cavity 1E 2E 3E 4E 5E 6E 7E 8E 9E 10E 11E 12E 13E 14E 1F 2F 3F 4F 5F 6F 7F 8F 9F 10F 11F 12F 13F 14F 1G 2G 3G 4G 5G 6G 7G 8G 9G 10G 11G 12G 13G 14G 1H 2H 3H 4H CKT. No. 14 D (BUSS L1) 19 A 14 B (BUSS L1) 20 A 20 B (BUSS L1) 21 A 14 C (BUSS L1) 962 A 14 A (BUSS L1) 80 A 14 B (BUSS L1A) 183 A (BUSS L1A) 640 D (BUSS A1A) 296 A 297 B (BUSS A1A) 71 A 297 B (BUSS A1) 137 A (BUSS A1) (BUSS A1) 64 C (BUSS A1) 65 B 297 A (BUSS A1) 554 A 554 B (BUSS B1A) 476 B 476 A 37 D (BUSS B1A) Color & Ga. 16 LB 14 YL 14 LB 14 RD 18 RD 14 GY 14 LB 14 BR 12 LB 16 WH 14 LB 18 TN 16 OR 16 DG 14 OR 12 WH 14 OR 16 RD 14 LG 14 YL 12 OR 18 GY 18 GY 20 GY 16 GY 14 RD Fuse ES (5 AMP) -1E -2EET (7.5 AMP) -3E -4EEW (15 AMP) -5E -6EEY (25 AMP) -7EES (5 AMP) -1FES (5 AMP) -2FET (7.5 AMP) -3FET (7.5 AMP) -4FEW (15 AMP) -5FES (5 AMP) -6FES (5 AMP) -7FES (5 AMP) -1GES (5 AMP) -2GEZ (30 AMP) -3GET (7.5 AMP) -4G -5GEY (25 AMP) -6GEY (25 AMP) -7GES (5 AMP) 1H EU (10 AMP) -2H-
L1
L1A
A1A
A1
B1A
3-1-01
_____________________________________________________
Electrical System
12-221
INTERIOR MINI FUSE BLOCK 2 (UPPER) (Contd)

Buss Cavity 5H 6H 7H 8H 9H 10H 11H 12H 13H 14H CKT. No. 517 A 37 D (BUSS B1) 70 A (BUSS B1) 54 B (BUSS B1) 45 A (BUSS B1) 51 A 37 A (BUSS B1) Color & Ga. 12 OR 14 RD 12 YL 14 DG 14 WH 12 YL 10 RD Fuse EX (20 AMP) -3HEZ (30 AMP) -4HEW (15 AMP) -5HEX (20 AMP) -6H -7H-
B1
05745159
3-1-01
12-222
INTERIOR FUSE BOX RELAYS

IGNITION RELAY RY-1 Cavity CKT. No Color & Ga. B5 687 A 12 GY MINI- FUSE / C7 59 H 18 BK RELAY BLOCK 59 A 18 BK B7 37 C 10 RD C6 C5 687 B 10 LG WIPER RELAY RY-2 Cavity CKT. No Color & Ga. B1 945 A 16 BR MINI- FUSE / C3 59 A 18 BK RELAY BLOCK 59 B 18 BK B3 27 A 14 OR C2 28 A 14 DB C1 65 C 14 YL REAR WIPER RELAY RY-3 Cavity CKT. No Color & Ga. F1 67 A 20 BR MINI- FUSE / G3 59 B 18 BK RELAY BLOCK 59 C 18 BK F3 66A 14 RD G2 62 A 14 LB G1 64 B 14 LG POWER WINDOW RELAY RY-4 Cavity CKT. No Color & Ga. F5 296 A 16 DG MINI- FUSE / G7 59 C 18 BK RELAY BLOCK 59 D 18 BK F7 175 A 12 LB G6 G5 171 A 12 RD MIRROR CUT-OUT RELAY RY-5 Cavity CKT. No Color & Ga. J7 580 E 18 BR K9 59 D 18 BK MICRO 59 E 18 BK RELAY BLOCK J9 J8 400 C 18 LG 400 B 18 LG K7 407 A 18 PK TURN / HAZARD FLASHER RELAY RY-6 Cavity CKT. No Color & Ga. 1 44 A 14 LB 2 8A 14 PP 3 383 A 14 YL 4 385 A 14 TN 5 59 G 14 BK CTI BUZZER RELAY RY-7 Cavity CKT. No Color & Ga. 1 59 E 18 BK 59 F 18 BK 2 DIODE 20 PK 428 A 3 4 5 DIODE 16 PK 428 B Relay
FB
Relay
FB
Relay
FB
Relay
FB
Relay
FA
Relay
EM
Relay
NOT INSTALLED
3-1-01
_____________________________________________________
Electrical System
12-223
RELAY/MINI-FUSE COLUMNS 9 MICRO-RELAY ROWS M L K J 2 4 3 H G F E MAIN FUSE/ MINI-RELAY ROWS D C B A 2 4 1 5 3 1 5 8 7 6 5 4 3 2 1
H G F E MINI-FUSE ROWS D C B A
2 3
4 5
6 7
8 9 10 11 12 13 14
9-S12-080.1
MINI-FUSE COLUMNS
Figure 2-150: Interior Fuse Box Fuse/Relay Cavity I.D. 05745159 3-1-01
12-224
EXTERIOR MINI FUSE BLOCK

Buss Cavity 1A 2A 3A 4A 5A 6A 1B 2B 3B I2 4B 5B 6B 1C 2C B1 3C 4C 5C 6C 1D 2D B2 3D 4D 5D 6D 1E 2E 3E 4E 5E 6E 1F 2F 3F 4F 5F 6F CKT. No. Color & Ga. Fuse (FOR DIODE USE ONLY) -1AH (10 AMP) -2AJ (20 AMP) -3A(FOR DIODE USE ONLY) -1BG (5 AMP) -2BJ (20 AMP) -3B I (25AMP) -1CK (30 AMP) -2C-3CJ (20 AMP) -1DK (30 AMP) -2D-3DD (HORN RELAY) -1E-2ED (A/C CLUTCH RELAY) -3E-1F-2F -3F-
I1
351C 16A(BUSS I1) 239C (BUSS I1)

18 PK 10 LG 14 PK

601A 16A(BUSS I2) 291C 168(BUSS I2) 575A (BUSS B1) 738A 37M(BUSS B1)
10 LG 14 PK 10 LG 12 OR
10 RD 10 RD

(BUSS B1) 7A 7B (BUSS B2) 737A 37N (BUSS B2)
14 RD 18 RD
10 OR 10 OR

(BUSS B2) 7B
18 RD
7A 400B
14 RD 18 LG
400B 400A 6A
18 LG 14LG 16 WH
1A 348A
18 DB 16 BR
440A
18 DB
3-1-01
_____________________________________________________
Electrical System
12-225
EXTERIOR MAXI FUSE BLOCK

Buss Cavity CKT. No. Color & Ga Fuse or Circuit Breaker
BUSS BAR
8W 8X 7W 7X 6W 6X 5W 5X 4W 4X 3W 3X 2W 2X 1W 1X 2Y 2Z
37F BUSS 38A BUSS 195A BUSS 688A BUSS 175A BUSS 436A BUSS 604A BUSS 37D 37E BUSS
10 YL
14 RD
12 YL
12 RD
12 LB
12 YL
10 PK
12 YL 12 YL

(40 AMP FUSE) -IM(20 AMP CD) -2M(30 AMP CB) -3M(30 AMP CB) -4M(30 AMP CB) -5M(30 AMP FUSE) -6M(40 AMP FUSE) -7M(40 AMP FUSE) -8M(30 AMP FUSE) SPARE STUD A -(9M)(30 AMP FUSE) SPARE STUD B -(10M)(TO MINI FUSE BUSS B1) (TO MINI FUSE BUSS B2)
M8 BUSS
M8 BUSS
1Y 1Z Q1 Q2
M8 BUSS 37M 37N
10RD 10RD
05745159
3-1-01
12-226
EXTERIOR FUSE BOX RELAYS

RELAY R-6 Cavity CKT. No 1 991A 2 59G 3 575A 4 5 990A RELAY R-5 Cavity CKT. No 1 990B 2 59B 59C 3 603A 4 59C 59D 5 RELAY R-4 Cavity CKT. No 1 580A 580B 2 59F 59G 3 738A 4 5 740A RELAY R-3 Cavity CKT. No 1 238A 2 59A 59B 3 787B 4 5 537A RELAY R-2 Cavity CKT. No 1 580A 2 59F 59E 3 737 A 4 5 739A RELAY R-1 Cavity CKT. No 1 46A 2 59A 3 436 A 4 5 437A Color & Ga. 18 LB 18 BK 12 OR 12 PK Color & Ga. 16 PK 16 BK 16 BK 18 RD 16 BK 16 BK Color & Ga. 18 BR 18 BR 18 BK 18 BK 10 RD 10 YL Color & Ga. 18 DG 16 BK 16 BK 16 GY 16 OR Color & Ga. 18 BR 18 BK 16 BK 10 OR 10 PP Color & Ga. 16 WH 16 BK 12 YL 12 DG Relay Relay
ABS VALVE RELAY
Relay
ABS WARNING RELAY
Relay
HEATED WINDSHIELD RELAY
Relay
FUEL LIFT PUMP RELAY
HEATED WINDSHIELD RELAY
Relay
CTIS COMPRESSOR RELAY
3-1-01
_____________________________________________________
Electrical System
12-227
MINI FUSES
1 8 7 6 5 4 3 2 1 W 8 7 6 5 4 3 2 1 X Y A B C D
6 5 4 2 1 R-5 3 5 4 2 1 R-6 3
1 E 1 4 F 5 SPARE SPARE 2 1 2 1 Z 2 SPARE 3 5 4
3 2 SPARE 5 4 2
5 4 2
1 R-3 3
5 4 2
1 R-4 3
1 R-1 3
5 4 2
1 R-2 3
9-S12-101
MAXI FUSES
Figure 2-151: Exterior Fuse Box Relay Cavity I.D.
05745159
3-1-01
12-228
ESSENTIAL TOOLS
TA-1151 TK-O-A TA-1152 TA-1190-A
J-35616A
Tool No. TK-O-A TA-1151 TA-1152 TA-1190-A J35616-A J42645-C J43160 J44237 J24538-B J35592 J42645-99SW 7000041
Description Tech 1 Diagnostic Scanner Kit Tech 1 Adapter, part of TK-O-A Tech 1 Test Lead, part of TK-O-A Operators Manual, Tech 1, part of TK-O-A Connector Test Adapter Set HUMMER Mass Storage Cartridge Kit (not shown) Adapter Cable, Tech 1A (14/16 pin) (not shown) ABS, DLC Jumper Tester, Gauge Pinout Box, ABS Software Package Vehicle Interface Module (VIM) (not shown)
3-1-01
_______________________________________________________________________________
13-1
Section 13 Accessories
TABLE OF CONTENTS
Air Restriction Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-34 Auxiliary Seat Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-27 Frame Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-28 Locking Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . .13-28 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-27 Brushguard Assembly Replacement . . . . . . . . . . . . . . . . . . .13-10 Delco Compact Disc Changer Replacement . . . . . . . . . . . . . .13-36 Dual Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-35 Hourmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-30 Off Road Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-31 Roof Rack Clamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-26 Crossbar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .13-25 End Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-25 Running Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .13-21 Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-37 Spare Tire Carrier Cargo Deck Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 Swing-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 Trailer Hitch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 Trailer Towing Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19 Underbody Protection Front Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . 13-15 Intermediate Shield Replacement . . . . . . . . . . . . . . . . . . 13-16 Rear Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 Skid Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Transfer Case Shield Replacement . . . . . . . . . . . . . . . . . 13-17 Rocker Panel Protection Replacement . . . . . . . . . . . . . . . . . . 13-18 Winch Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Electric Thermal Switch/Brush Assembly . . . . . . . . . . . . 13-7 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
WINCH VIN 186477 AND LATER

NOTE: Individual parts may not be available for some of the following repair procedures. Assemblies must be used in place of individual parts. Check for parts availability before disassembly.
Winch Replacement
Removal
Winch Troubleshooting
Winch Inoperative
1. 2. Check for jammed winch cable. Check winch control cable connector for corrosion or loose connection. Clean corroded connector or secure loose connection. Check for loose or damaged winch power cables. Using voltmeter, connect positive meter lead to positive power cable (red) at the winch motor, and negative meter lead to the winch motor ground cables (black). If voltage is not present, repair or replace winch power cables. Disconnect winch control from winch. Using an ohmmeter, check for continuity between the common terminal and the other two terminals on winch control cable connector. Check for continuity one at a time, while holding control in the OUT position and the IN position. If continuity is present in both positions, repair winch. If continuity is not present in both positions, replace winch control.
BATTERY CABLE BOLTS
3.
4.
Figure 13-1:
3.
Winch Cables On Battery
05745159
13-2
Accessories _______________________________________________________________
CLAMP
Installation
1. 2. Install positive winch cable on winch with bolt (Figure 13-3). Install negative winch cable on winch with washer and capscrew. Coat motor end of winch with coating compound. Install control box cover on winch with bolt. Secure two winch cables to winch with two clamps and bolts. Install winch on front bumper with four washers, bolts, and nuts. Tighten bolts to 60 lb-ft (81 Nm). Route winch power cables through the splash shield. Install winch cables on frame bracket with clamp, capscrew, lockwasher, and nut (Figure 13-2). Connect battery ground cables (Section 12).
FRAME BRACKET
3. 4. 5. 6. 7. 8. 9.

POWER CABLES

4. Remove four nuts, washers, bolts, and winch from front bumper (Figure 13-3).
POSITIVE WINCH CABLE CLAMP WINCH
Removal
1. 2. Unwind winch cable. Remove set screw and winch cable/hook assembly from drum assembly (Figure 13-4).
SET SCREW CABLE ANCHOR
CONTROL BOX COVER
CABLE/HOOK ASSEMBLY
FRONT BUMPER
Installation
3. Install winch cable/hook assembly on drum assembly with set screw.
Figure 13-3:
5. 6. 7. 8.
Remove two bolts and clamps securing winch cables to winch. Remove bolt and control box cover from winch. Remove capscrew, washer, and negative winch cable from winch. Remove bolt and positive winch cable from winch.
______________________________________________________________
Accessories
13-3

Disassembly
SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY MOTOR (SHOWN WITHOUT CONTROL)
NOTE: Tag leads for assembly. 2. Remove three nuts and control leads from motor (Figure 13-5).
DRUM SUPPORT CONTROL DRUM SUPPORT MOTOR END
DRUM NUT
TIE ROD DRUM SUPPORT GEAR END

00-S13-005
GEAR TRAIN ASSEMBLY
LEAD MOTOR
Figure 13-7: Drum Support and Gear Train Assembly

6. Remove six bolts, three tie rods and gear end drum support from winch. 7. Remove motor, and motor end drum support from drum assembly. 8. Remove motor brake driver and spacer from motor shaft. 9. Remove drum assembly from gear train assembly (Figure 13-7). 10. Remove two nylon thrust washers from drum (Figure 13-8).
SET SCREW BRAKE RETENTION NOT REMOVABLE BRAKE ASSEMBLY BRAKE DRIVER
Figure 13-5:
3. Loosen clamps (Figure 13-6). and
Control Leads
remove control from motor
CLAMP CONTROL
NYLON THRUST WASHER SPACER

00-S13-006
MOTOR
NYLON THRUST WASHER DRUM
Figure 13-6:
4. 5.
Control Unit
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13-4
Accessories _______________________________________________________________
17. Remove clutch lever and O-ring seal from gear housing. Discard O-ring seal. 18. Remove two retaining rings from gear housing (Figure 13-10). NOTE: Intermediate ring gear comes out with 85 to 87 steel balls. Be sure to catch all 85 to 87 steel balls. 19. Remove intermediate ring gear and 85 to 87 steel balls from gear housing. 20. Remove input and intermediate gear carrier assembly from gear housing (Figure 13-10). 21. Remove and output gear carrier from output ring gear and gear end drum support (Figure 13-11) .
GEAR TRAIN ASSEMBLY
GASKET GASKET OUTPUT RING GEAR DRIVESHAFT GEAR END DRUM SUPPORT
GEAR HOUSING
Figure 13-9:
Gear Train Assembly
RETAINING RINGS
INTERMEDIATE RING INPUT GEAR CARRIER INTERMEDIATE GEAR CARRIER SUN GEAR
Figure 13-11:
Gear Carriers
Cleaning
DETENT SPACER SPRING DETENT BALL GEAR HOUSING O-RING
STEEL BALLS
CLUTCH LEVER
______________________________________________________________
Accessories
13-5
Inspection
DRUM SUPPORT MOTOR END INPUT GEAR CARRIER ASSEMBLY (FIRST STAGE) OUTPUT GEAR CARRIER ASSEMBLY (THIRD STAGE)
THRUST WASHER DRIVE SHAFT DRUM THRUST WASHER DRUM SUPPORT GEAR END SUN GEAR INTERMEDIATE GEAR CARRIER ASSEMBLY (SECOND STAGE)
OUTPUT RING GEAR
GASKET GEAR HOUSING

8. 9. Inspect brake assembly for damage (Figure 13-18). Inspect motor, spline, mating surface, and terminals for damage. Replace motor if damaged (Figure 13-14).
CLAMP
Figure 13-12: Drum Assembly and Gear Housing Assembly

2. 3. 4. Inspect gear end and motor end drum supports for damage. Replace if damaged. Inspect gear housing for damage. Replace if damaged. Inspect thrust plate for damage or wear. Replace if damaged or worn. Apply grease on thrust plate for assembly. Inspect clutch lever and driveshaft for damage. Replace if damaged. Inspect gear teeth and machined surfaces of intermediate ring gear for damage. Replace if damaged. Inspect gear teeth, splines, and machined surfaces of output ring gear, output gear carrier, intermediate gear carrier, and input gear carrier assembly for damage. Replace any damaged parts (Figure 13-13).
COVER
DRUM SUPPORT LEAD
5. 6. 7.
CONTROL
00-S13-007
SPACER SPLINE MOTOR
Figure 13-14: Motor and Control Unit

10. Inspect cover for damage. Replace if damaged. 11. Inspect control for damaged leads and damaged mounting base. Replace control if damaged.
05745159
13-6
Accessories _______________________________________________________________
Assembly
INTERMEDIATE RING GEAR RETAINING RING
8. 9. 10. 11.
Install gasket and output ring gear on gear housing. Install intermediate gear carrier on gear housing. Install output gear carrier on intermediate gear carrier. Install gasket on output ring gear (Figure 13-17).
GEAR TRAIN ASSEMBLY GASKET
GEAR HOUSING STEEL BALLS DETENT SPACER SPRING DETENT BALL O- RING SEAL CLUTCH LEVER GEAR HOUSING
DRIVE SHAFT

OUTPUT RING GEAR GASKET INPUT GEAR CARRIER ASSEMBLY SUN GEAR OUTPUT GEAR CARRIER
OUTPUT RING GEAR

NOTE: Ensure spline on drum support engages in output ring gear. 12. Install gear end drum support on output ring gear and gear housing. 13. Secure gear housing assembly to drum support with ten socket-head cap screws. Tighten hex-head screws to 100 lb-in. (11 Nm). 14. Turn gear train assembly over with drum support facing up. 15. Install driveshaft in gear train assembly (Figure 13-17). 16. Apply grease to drum bushings, seals, and output spline.
BRAKE ASSEMBLY SET SCREW BRAKE RETENSION NOT REMOVABLE NYLON THRUST WASHER
TOLERANCE RING NYLON THRUST WASHER
GEAR HOUSING

DRUM
Figure 13-18:
NOTE: Be sure ring gear engages in gear housing.
______________________________________________________________
Accessories
13-7
17. With drum horizontal, install brake into drum (Figure 13-18). 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 Nm) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline (Figure 13-19).
CLAMP
CONTROL
MOTOR, 12 VDC SHOWN WITHOUT CONTROL
SPACER (2) BRAKE DRIVER BRAKE ASSEMBLY MOTOR
00-S13-006

25. Connect three control leads to terminals and secure with nuts (Figure 13-21). 26. Secure control to motor with clamps (Figure 13-20). 27. Install winch assembly and winch cable.
DRUM

Removal
1.
GEAR TRAIN ASSEMBLY
Remove winch and winch cable.
NOTE: Tag leads for assembly. 2. Remove three nuts and control leads from motor (Figure 13-21). Loosen clamps and remove control from motor (Figure 13-22).
Figure 13-19:
3.
21. Install brake drive and spacer to motor shaft. 22. Install motor end drum support on drum assembly. 23. Install motor on motor end drum support, ensuring to engage brake drive with brake shaft end. 24. Install three tie rods between drum supports and secure with six bolts. Tighten bolts to 18 lb-ft (24 Nm).
05745159
13-8
Accessories _______________________________________________________________
9.
DRUM SUPPORT
CONTROL
NUT MOTOR HOUSING ELECTRIC THERMAL SWITCH LEADS ELECTRIC THERMAL SWITCH
CLAMP
00-S13-005
MOTOR
CONTROL TERMINAL LEAD
SPACER

BOLT ASSEMBLY CLAMP DRUM SUPPORT REAR COVER
Figure 13-23:
Motor and Gasket
Installation
NOTE: Do not apply coating to any electrical contacts of the armature assembly. Perform steps 1 through 5 only if replacing brush assembly. 1. Install washer, insulator, and spacer on brush assembly power stud (Figure 13-24). Install brush assembly in motor housing with three screws and nuts
ARMATURE ASSEMBLY
CONTROL
2.
.
00-S13-009
SPACER MOTOR
SPACER

4. 5. 6. Remove clamps from motor. Place winch on end with motor end up (Figure 13-25). Remove two bolt assemblies and rear cover from motor housing.
MOTOR HOUSING
BRUSH ASSEMBLY
Figure 13-24:
______________________________________________________________
Accessories
13-9
3. 4. 5.
6. 7. 8.
Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Coat armature shaft with lubricant and install in brush assembly. Coat head of electric thermal switch with lubricant and connect to two electric thermal switch leads (Figure 13-23). Position spacer in drum support, and install rear cover on motor housing. Install motor on drum support ensuring to engage motor shaft into brake drum. Secure motor to motor end drum support with two bolt assemblies. Tighten hex-head bolt to 60-70 lb-in. (7-8 Nm) (Figure 13-25).

Removal
1. 2. 3. Remove circlips on one vertical and one horizontal roller. Remove one vertical and one horizontal roller. Remove washers, bolts, and the roller fairlead from the front bumper (Figure 13-26).
FAIRLEAD MOTOR CONTROL MOTOR END DRUM SUPPORT
00-S13-008
CLAMP WASHER

9. Install clamps on motor. 10. Install control on motor. 11. Connect three control leads to terminals and secure with nuts (Figure 13-21). 12. Secure control to motor with clamps. 13. Install winch assembly and winch cable.
FRONT BUMPER
Installation
1. Place the winch cable and hook assembly through the roller fairlead and install the fairlead on the front bumper with washers and bolts. Tighten bolts to 60 lb-ft (81 Nm) (Figure 13-26). Install the horizontal and vertical rollers and circlips.
2.
05745159
13-10
Accessories
_____________________________________________________________
BRUSHGUARD ASSEMBLY REPLACEMENT

NOTE: Brushguard assemblies may be used on vehicles with or without a winch assembly. The following procedure applies to vehicles without a winch assembly.
SWING-AWAY SPARE TIRE CARRIER REPLACEMENT

Removal
WARNING: Support tire when removing lug nuts. The spare tire and wheel assembly weighs approximately 150 lbs (68 kg) and personal injury may result if the assembly is not properly supported.
1. Remove lug nuts and wheel/tire assembly from frame assembly (Figure 13-28). 2. Remove self-tapping screw and washer securing lanyard to frame and remove lanyard and lock pin. 3. Remove self-tapping screws and guide block from rear bumper. 4. Remove locknuts, washers, bolts, and stop bracket from rear bumper. 5. Remove bolts, washers, and hold-down bracket from stop bracket. 6. Remove bolt, washer, and retaining plate from mounting bracket. 7. Remove frame assembly from mounting bracket. 8. Remove end caps from frame assembly. 9. Remove locknuts, washers, spacer, bolts, washers, and mounting bracket from rear bumper. 10. Remove grease fitting from mounting bracket.
BRUSHGUARD
Removal
WARNING: Stand clear of brushguard after removal of locking pins. Brushguard may swing down, causing personal injury.
1. 2. 3. Remove two locking pins from support brackets and lower brushguard. Remove two locknuts, washers, bolts, washers, and brushguard from support brackets. Remove four locknuts, washers, bolts, washers, and two support brackets from bumper.
Installation
1. Install two support brackets on bumper with four washers, bolts, washers, and locknuts. Tighten locknuts to 68 lb-ft (92 Nm) (Figure 13-27). Position brushguard in brackets and secure with two washers, bolts, washers, and locknuts. Secure brushguard in upward position with two locking pins.
2. 3.
BUMPER
SUPPORT BRACKET LOCKING PIN
Figure 13-27: Brushguard Assembly
____________________________________________________________
Accessories
13-11
END CAPS
LOCK PIN LANYARD WHEEL/TIRE ASSEMBLY RUBBER CUSHION
END CAP
FRAME ASSEMBLY
HOLD-DOWN BRACKET ANGLED SIDE STOP BRACKET GUIDE BLOCK
BUMPER BRACE GREASE FITTING BRACKET ASSEMBLY RETAINING PLATE SPACER
SQUARED SIDE
Figure 13-28: Swing-Away Spare Tire Carrier Breakdown
05745159
13-12
Accessories
_____________________________________________________________
Installation
1. 2. Install grease tting in mounting bracket (Figure 13-28). Attach mounting bracket and spacer to rear bumper with bolts, washers, and locknuts. Raise mounting bracket to highest position possible and tighten nuts to 90 lb-ft (122 Nm). Secure guide block on rear bumper with self-tapping screws. Attach hold-down bracket to stop bracket with washers, and bolts. Do not tighten. Attach stop bracket to rear bumper with bolts, washers, and locknuts. Do not tighten. Lubricate frame assembly. Slide frame assembly into mounting bracket and fasten with bolt, washer and retaining plate. Push three end caps into open ends of frame assembly.
8.
3. 4. 5. 6.
7.
9. 10. 11. 12. 13.
Adjust the stop and hold-down brackets that were previously installed. a. Set frame assembly in locked position so that it rests on bumper guide block. If weight of frame assembly does not rest on guide block, lower mounting bracket until it does. b. Insert locking pin through frame assembly and into stop bracket. c. Mark position of stop bracket. d. Move frame assembly out of the way and tighten stop bracket assembly securely. e. Move frame assembly back to locked position and align hold-down bracket as close to frame assembly as possible. f. Tighten hold-down bracket securely. Secure lanyard assembly to frame assembly with washer and self-tapping screw. Apply cushion tape to frame assembly on surfaces closest to rear of vehicle body. Install lock pin in frame assembly. Secure wheel/tire assembly to frame assembly with lug nuts. Lubricate mounting bracket with multi-purpose grease using the grease fitting.
____________________________________________________________
Accessories
13-13
CARGO BED-MOUNTED SPARE TIRE CARRIER REPLACEMENT

WARNING: Always support the tire and wheel assembly when removing the lug nuts. The tire and wheel assembly weighs approximately 160 lbs (72 kgs) and may cause personal injury if it is not supported properly.
NOTE: Cargo bed-mounted spare tire carrier may be located either directly behind the cab or at the left wheelhouse on two door models. On four door models, spare tire carrier will be located at the left wheelhouse.
FRAME ASSEMBLY
Removal
NOTE: Perform steps 1 and 2 on vehicles with frame assembly stowed in down position. 1. Disconnect lock pins and raise frame assembly to upright position (Figure 13-29).
WHEEL/TIRE ASSEMBLY FRAME ASSEMBLY MOUNTING BRACKET LANYARD AND LOCK PIN ASSEMBLY MOUNTING BRACKET
Figure 13-30:
Frame Assembly Mounting
CARGO FLOOR
Figure 13-31:
LOCK PIN
Mounting Bracket Positioning
Installation
1. 2. Install mounting brackets on cargo oor with washers, lockwashers, and bolts (Figure 13-31). Secure mounting brackets to cargo floor with screws. Tighten screws to 44 lb-ft (60 Nm). Install frame assembly on mounting brackets with bolts and locknuts (Figure 13-30). Install lanyard/lock pin assemblies on mounting brackets and frame assembly with lockwashers and self-tapping screws. With carrier in the upright position, install tire on frame assembly with three lug nuts (Figure 13-29).
Figure 13-29: Cargo Bed-Mounted Spare Tire Carrier Appearance

2. 3. 4. 5. 6. 7. Secure frame assembly in upright position with lock pins. Remove lug nuts securing tire to frame assembly and remove wheel/tire assembly. Remove self-tapping screws, lockwashers, and lanyard/lock pin assemblies from mounting brackets (Figure 13-30). Remove locknuts, bolts and frame assembly from mounting brackets. Remove screws securing mounting brackets to cargo floor (Figure 13-31). Remove bolts, lockwashers, washers, and mounting brackets from cargo floor.
3. 4.
5.
NOTE: Perform steps 6 and 7 to stow frame assembly in down position. 6. 7. Disconnect lock pins and lower frame assembly to down position. Connect lock pins.
05745159
13-14
Accessories
_____________________________________________________________
DRIVELINE PROTECTION Skid Plate Replacement

Removal
1. Remove locknuts, washers, bolts, and washers securing skid plate to front shield (Figure 13-32).
NOTE: Go to step 3 for vehicles equipped with a winch. 2. 3. Remove locknuts, washers, bolts, washers, and skid plate from front bumper. Remove locknuts, washers, bolts, washers, and winch skid plate from winch bumper.
WINCH BUMPER
FRONT BUMPER
FRONT SHIELD WINCH SKID PLATE
FRONT SHIELD SKID PLATE
Figure 13-32: Skid Plate Mounting
Installation
NOTE: Go to step 2 for vehicles equipped with a winch. 1. Install skid plate on front bumper with bolts, washers, and locknuts. Tighten locknuts to 24 lb-ft (33 Nm) (Figure 13-32). Install winch skid plate on winch bumper with bolts, washers, and locknuts (Figure 13-32). Tighten locknuts to 24 lb-ft (33 Nm). Secure skid plate to front shield with bolts, washers, and locknuts. Tighten locknuts to 24 lb-ft (33 Nm).
2.
3.
____________________________________________________________
Accessories
13-15
Front Shield Replacement

Removal
1. Remove locknuts, washers, bolts, and spacers securing front shield to front crossmember and intermediate shield (Figure 13-33). Remove locknuts, washers, bolts, and front shield from skid plate.
Installation
1. 2. 3. Install front shield on skid plate with bolts, washers, and locknuts. Do not tighten locknuts (Figure 13-33). Secure front shield to front crossmember and intermediate shield with spacers, bolts, washers, and locknuts. Tighten locknuts securing front shield to skid plate to 24 lb-ft (33 Nm). Tighten locknuts securing front shield to crossmember and intermediate shield to 44 lb-ft (60 Nm).
2.
SKID PLATE
FRONT CROSSMEMBER
FRONT SHIELD
INTERMEDIATE SHIELD
Figure 13-33: Front Shield Mounting
05745159
13-16
Accessories
_____________________________________________________________
Intermediate Shield Replacement

Removal
1. Remove six locknuts, washers, bolts, washers, and four rubber washers securing two transmission support brackets and intermediate shield to transmission mount crossmember. Remove support brackets. Discard locknuts (Figure 13-34).
INTERMEDIATE SHIELD ENGINE MOUNT BRACKET
FRAME RAIL
TRANSMISSION SUPPORT BRACKET
RUBBER WASHERS
LEFT SUPPORT BRACKET
LEFT MOUNTING BRACKET
Figure 13-35:
FRAME RAIL TRANSMISSION MOUNT CROSSMEMBER
Left Support Bracket
Figure 13-34: Intermediate Shield

2. Remove locknut, washer, capscrew, and washer securing left support bracket to engine mount bracket and frame rail. Discard locknut (Figure 13-35). Remove four locknuts, washers, bolts, washers, and left support bracket from left mounting bracket. Discard locknuts. Remove locknut, washer, capscrew, and washer securing right support bracket to frame rail. Discard locknut (Figure 13-36). Remove four locknuts, washers, bolts, washers, and right support bracket from right mounting bracket. Discard locknuts. Remove two locknuts, washers, bolts, washers, spacers, and intermediate shield from front crossmember and front shield. Discard locknuts (Figure 13-37).
3.
4.
5.
6.
RIGHT SUPPORT BRACKET
RIGHT MOUNTING BRACKET
Figure 13-36: Right Support Bracket
____________________________________________________________
Accessories
13-17
FRONT CROSSMEMBER
FRONT SHIELD
Transfer Case Shield Replacement

Removal
Remove two locknuts, washers, bolts, washers, and transfer case shield from crossmember. Discard locknuts (Figure 13-38).
Installation
Install transfer case shield on crossmember with two washers, bolts, washers, and locknuts (Figure 13-38).
CROSSMEMBER INTERMEDIATE SHIELD
Figure 13-37: Intermediate Shield
TRANSFER CASE SHIELD
Installation
1. Install intermediate shield to front crossmember and front shield with two spacers, washers, bolts, washers, and locknuts. Tighten locknuts to 44 lb-ft (60 Nm) (Figure 13-37). Install right support bracket on right mounting bracket with four washers, bolts, washers, and locknuts. Do not tighten locknuts (Figure 13-36). Secure right support bracket to frame rail with washer, capscrew, washer, and locknut. Tighten locknut to 105 lbft (142 Nm). Install left support bracket on left mounting bracket with four washers, bolts, washers, and locknuts. Do not tighten locknuts (Figure 13-35). Secure left support bracket to engine mount bracket and frame rail with washer, capscrew, washer, and locknut. Tighten locknut to 105 lb-ft (142 Nm). Install two transmission support brackets on transmission mount crossmember with four washers, bolts, washers, and locknuts. Tighten locknuts to 24 lb-ft (33 Nm) (Figure 13-34). Secure intermediate shield to transmission mount crossmember and transmission support brackets with four rubber washers, two washers, bolts, washers and locknuts. Tighten locknuts to 26 lb-in. (3 Nm). Tighten locknuts securing support brackets to mounting brackets to 24 lb-ft (33 Nm).
Figure 13-38: Transfer Case Shield
Rear Shield Replacement

Removal
1. Remove three locknuts, washers, bolts, washers, and spacers securing rear shield to rear-front crossmember. Discard locknuts (Figure 13-39). Remove three locknuts, washers, bolts, washers, and shield from mounting brackets. Discard locknuts. Remove six locknuts, washers, bolts, washers, spacers, and three mounting brackets from rear-rear crossmember. Discard locknuts.
2.
3.
2. 3.
4.
5.
Installation
1. Install three mounting brackets on rear-rear crossmember with six spacers, washers, bolts, washers, and locknuts. Tighten locknuts to 24 lb-ft (33 Nm) (Figure 13-39). Position shield on mounting brackets and secure with three washers, bolts, washers, and locknuts. Do not tighten locknuts. Secure shield to rear-front crossmember with three spacers, washers, bolts, washers, and locknuts. Tighten bolts to 44 lb-ft (60 Nm). Tighten locknuts securing rear shield to mounting brackets to 24 lb-ft (33 Nm)
6.
2.
7.
3.
4.
8.
05745159
13-18
.
Accessories
_____________________________________________________________
REAR-REAR CROSSMEMBER REAR-FRONT CROSSMEMBER
4.
5.
Remove three nuts, washers, bolts, washers, and gaskets securing rocker panel protection to front footwell. Discard gaskets. Remove three nuts, washers, bolts, washers, and gaskets securing spacer (if present) and rocker panel protection to rear footwell (Figure 13-41).
REAR FOOTWELL
ROCKER PANEL PROTECTION AUXILIARY FUEL TANK SKID PLATE MOUNTING BRACKET
REAR SHIELD
Figure 13-39: Rear Shield
ROCKER PANEL PROTECTION REPLACEMENT

Removal
NOTE: Removal of rocker panel protection is similar for both sides. This procedure covers one side only. 1. 2. Remove outer kick panels (Section 10). Pull back carpet from front footwell and rear footwell (4-door models only).
SPACER GASKET
Figure 13-41: Rear Footwell

CAUTION: Rocker panel protection is heavy. Remove with a floor jack. 6. 7. Remove rocker panel protection from body. Inspect three retainer nuts on body. Discard if damaged.
NOTE: Hex-head screws are secured in place with Loctite 242 and may require considerable effort to break loose. 3. Remove nine hex-head screws securing rocker panel protection to body. Support rocker panel protection with floor jack (Figure 13-40).
GASKET FRONT FOOTWELL
Installation
CAUTION: Underbody skid panel is heavy. Raise into place with a floor jack. 1. 2. Raise rocker panel protection to body. Secure rocker panel protection to rear footwell with three gaskets, washers, bolts, washers, and nuts. Do not tighten nuts (Figure 13-41). Secure rocker panel protection to front footwell with three gaskets, washers, bolts, washers, and nuts. Do not tighten nuts (Figure 13-40). Install spacer between rear footwell and rocker panel protection if necessary. Tighten nuts at front and rear footwells to 37 lb-ft (50 Nm) (Figures 13-40 and 13-41).
3.
4.
BODY
NOTE: Apply Loctite 242 to threads of hex-head screws. 5.

ROCKER PANEL PROTECTION
Figure 13-40: Rocker Panel Protection
6. 7.
Remove floor jack and secure rocker panel protection to body with nine hex-head screws. Tighten hex-head screws to 37 lb-ft (50 Nm) (Figure 13-40). Push carpet back in place. Install outer kick panels (Section 10).
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Accessories
13-19
TRAILER TOWING
TRAILER WIRING CONNECTOR FRONT OF VEHICLE
DUMMY PLUG
REAR OF VEHICLE BODY ABOVE REAR BUMPER
Figure 13-42: Trailer Wiring Connector and Dummy Plug Location
Trailer Jumper Harness

Hummer vehicles come from the factory equipped for easy installation of the trailer jumper harness. The trailer jumper harness may be installed as part of the factory trailer towing package or an add-on kit. Body wiring harnesses are designed with a trailer wiring connector at the rear of the vehicle body above the rear bumper (Figure 13-42). Rear bumpers are manufactured with a cut-out for the trailer harness receptacle.
1.
Three shrink-wrapped wire leads can be found under the instrument panel (Figure 13-44), they are: a. Yellowpower b. Redstop light signal c. Dark bluetrailer brake
BODY WIRING HARNESS TRAILER JUMPER HARNESS
Installation
1. 2. Insert the trailer jumper harness through the rear bumper cutout and bolt the receptacle in place (Figure 13-43). Remove the dummy plug and plug the trailer jumper harness connector into the trailer wiring connector.
TRAILER WIRING CONNECTOR
RECEPTACLE
Trailer Brake Controller

Spare wires have been provided in the body harness and routed from the instrument panel/fuse box area to the trailer connector at the rear of the vehicle. Install the trailer brake controller using the manufacturers instructions. The following information about the Hummer electrical system is necessary for installation:
GASKET REAR BUMPER
Figure 13-43: Trailer Jumper Harness Mounting
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Accessories
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The trailer brake circuit will not have power until a fuse (of required amperage) is installed in fuse block position 7Hthe far upper right hand corner of the fuse block.
TRAILER HITCH REPLACEMENT

Removal
1. Remove locknuts, washers, receiver assembly mounting blocks, bolts, and washers from body mount bracket (Figure 13-45). Remove bolts, lockwashers, washers from lower brace weld nuts. Remove brace from bumper and trailer hitch mounting brackets. Remove bolts, washers, and trailer hitch from rear bumper weld nuts.
STEERING COLUMN
2.
3.
Installation
YELLOW/ POWER
1.
2.
3.
DARK BLUE/ TRAILER BRAKE RED/STOP LIGHT
4.
Position trailer hitch receiver on rear bumper and secure with weld nuts, bolts and washers (Figure 13-45). Do not tighten at this time. Secure trailer hitch to body mount bracket with locknuts, washers, receiver assembly mounting blocks, bolts, and washers. Install lower brace to bumper and trailer hitch mounting bracket with bolts, lockwashers, washers and weld nuts. Tighten all locknuts to 90 lb-ft (122 Nm).
Figure 13-44: Trailer Brake Controller Wiring
BODY MOUNT BRACKET RECEIVER ASSEMBLY MOUNTING BLOCK TRAILER HITCH MOUNTING BRACKET LOCKWASHER WASHER BOLT LOWER BRACE
REAR BUMPER
WELD NUT
TRAILER HITCH RECEIVER
SIDE BRACKET
Figure 13-45: Trailer Hitch
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Accessories
13-21
RUNNING BOARD REPLACEMENT

Removal
1. Remove two clips and pins securing the right and left curved tubes to the receiver (Figures 13-46 and 13-47).
CLIP SPRING CLIP PIN REAR MOUNTING AREA SHOWN, FRONT IS SIMILAR MOUNTING BRACKET
STUD
RECEIVER RECEIVER
CLAMP PLATE
Figure 13-46:
2.
Receiver
Figure 13-48:
Receiver and Clamp Plate
Remove screw, nut, and screw securing the left end cap to the left curved tube (Figure 13-47).
LEFT CURVED TUBE LEFT END CAP
NOTE: If vehicle does not have rocker panel protection, perform steps 7 and 8. If vehicle is equipped with rocker panel protection, perform steps 9 and 10. 7. Remove two bolts, lockwashers, and rear mounting bracket from body (Figure 13-49).
BODY RIGHT SIDE SHOWN, LEFT SIDE OPPOSITE
RUNNING BOARD ASSEMBLY RIGHT CURVED TUBE
Figure 13-47: Left End Cap Secured to Left Curved Tube

3. 4. 5. Remove screw, nut, and screw securing the right end cap to the right curved tube. Remove left curved tube from running board. Remove right curved tube from running board.
REAR MOUNTING BRACKET
Figure 13-49:
Rear Mounting Bracket
NOTE: If vehicle has rocker panel protection, remove the extra clamp plate used on the forward mounting area between the mounting bracket and receiver. 6. Remove four nuts, washers, and two clamp plates securing two receivers to studs on mounting brackets (Figure 13-48).
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8.
Accessories
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Remove four bolts, lockwashers, J-nuts, and front mounting bracket from body (Figure 13-50).
LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE
MOUNTING BRACKET CENTER HOLE
BODY
FRONT OF VEHICLE
Figure 13-52: Rear Mounting Bracket

1.
FRONT MOUNTING BRACKET
2.
Figure 13-50: Front Mounting Bracket and J-Nut

3. 9. Remove four bolts, lockwashers, and front mounting bracket from rocker panel protection and body (Figure 13-51).
Install front mounting bracket on body with four J-nuts, lockwashers, and bolts. Tighten bolts to 29-31 lb-ft (39-42 Nm) (Figure 13-50). Install rear mounting bracket on body with two lockwashers and bolts. Tighten bolts to 29-31 lb-ft (39-42 Nm) (Figure 13-49). Install front mounting bracket on rocker panel protection and body with four lockwashers and bolts. Tighten bolts to 29-31 lb-ft (39-42 Nm) (Figure 13-51).
NOTE: If the vehicle does not have rocker panel protection, an extra clamp plate must be used on the forward mounting area between the mounting bracket and receiver.
BODY UNDERBODY SKID PANEL FRONT OF VEHICLE
4.
FRONT MOUNTING BRACKET
Figure 13-51: Front Mounting Bracket

10. Remove two bolts, lockwashers, and rear mounting bracket from rocker panel protection and body (Figure 13-52).
Installation
NOTE: If vehicle does not have rocker panel protection, perform steps 1 and 2. If vehicle is equipped with rocker panel protection, perform steps 3 and 4.
Install rear mounting bracket on rocker panel protection and body with two lockwashers and bolts. Tighten bolts to 29-31 lb-ft (39-42 Nm) (Figure 13-52). 5. Install receiver to studs on two mounting brackets with two clamp plates, four washers, and nuts (Figure 13-48). 6. Remove any extra mounting bracket stud lengths by cutting the stud four thread lengths from the nut. 7. Position right curved tube (with orange plastic bushing) into running board. Ensure right curved tube points toward the side of the running board with the this side toward frame decal (Figure 13-47). 8. Position left curved tube (with black plastic bushing) into running board. 9. Position right end cap on right curved tube with screw, nut, and screw. 10. Position left end cap on the left curved tube with screw, nut, and screw. 11. Position two spring clips on receiver. Ensure the spring clips are positioned 180 degrees from each other (Figure 13-46). Secure the right and left curved tubes to the receiver with two pins and clips.
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Accessories
13-23
SIDE STEP BARS (TUBULAR)
SUPPORT BRACKET
TUBE BRACKET
STEP BAR
9-S13-001
Figure 13-53: Side Step Bar Installation

NOTE: This procedure covers the left side of the vehicle. The procedure for the right side is the same.
Installation
1. 2. 3. 4. 5. Install the front and rear support brackets on the rocker panel protection with bolts, washers and nuts (See Figure 13-53). Put the front and rear floor mats in position and install the rear seat. Install the subwoofer or jack bag if equipped. Slide the tube brackets onto the bar in their respective positions (angled bracket to the rear). Place the bar end caps on the ends of the bar and install the bolts, washers and lockwashers through the tube brackets into the bar. Do not tighten at this time. Hang the bar assembly on the tabs of the support brackets, swing the bar up and secure the tube brackets to the support brackets with bolts, washers, lockwashers and nuts. Tighten the remaining hardware now.
Removal
1. Remove the four bolts securing the tube brackets to the support brackets (See Figure 13-53). 2. Swing the step bar and angle bracket assembly down, disengage the tube brackets from the support brackets and remove the assembly. 3. Remove four bolts securing the step bar to the tube bracket and slide the step bar and end cap out of the tube bracket. 4. Remove the rear seat (and subwoofer or jack bag if equipped). 5. Remove the rear lower trim panel behind the rear seat. 6. Pull the rear floor mat up to expose the support bracket mounting bolts in the rear wheel well area. 7. Remove the two support bracket mounting nuts bolts and washers in the rear wheel well. 8. Remove the two bolts and washers going through the rear support bracket into the rocker panel protection floor area and remove the support bracket. 9. Pull the front floor mat up to expose the support bracket mounting bolts in the front wheel well area. 10. Remove the two support bracket mounting nuts bolts and washers in the front wheel well. 11. Remove the two bolts and washers going through the front support bracket into the rocker panel protection floor area and remove the support bracket. 05745159
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7.
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Accessories
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ROOF RACK Roof Rack Replacement

NOTE: The roof rack is available in three foot, six foot, and nine foot lengths. The following procedure is for a six foot roof rack installed on a station wagon. Three foot and nine foot procedures are similar.
1. 2.
3.
Position roof rack on top of vehicle with rack ends toward front and rear of vehicle (Figure 13-54). Position eight clips (on clamps) under drip rails and over support screws. Tighten locknuts to 20-25 lb-in. (2-3 Nm). Tighten support screws on clamps.
Roof Rack Floor Piece Replacement

Removal
1. 2. Remove four end caps on oor piece. Remove four locknuts, washers, bolts, washers, and floor piece from crossbars and rack ends (Figure 13-55).
END CAP FLOOR PIECE
Removal
WARNING: Roof rack is extremely heavy. Several people may be required to remove and install rack safely. Use care in determining ability to lift the rack. Failure to do so may result in injury.
1. 2. 3. Loosen eight support screws on clamps (Figure 13-54). Loosen eight locknuts securing clips to drip rails. Remove eight clips from under drip rails and remove rack from vehicle.
FRONT OF VEHICLE
CROSSBAR FRONT OF VEHICLE DRIP RAIL
Figure 13-55: Roof Rack Floor Piece

CLAMP CLIP
Installation
NOTE: Floor pieces should be positioned 5 inches (13 cm) from the ends and 3 inches (8 cm) apart. 1. Install oor piece on crossbars and rack ends with four washers, bolts, washers, and locknuts. Tighten locknuts to 25 lb-ft (34 Nm) (Figure 13-55).
Figure 13-54: Roof Rack Clamp
Installation
CAUTION: Clamps are made of aluminum. Overtightening may cause the clamps to crack.
NOTE: Apply a small amount of adhesive to the inside periphery of each end cap before installing it on the floor piece. 2. Install four end caps on floor piece.
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Accessories
13-25
Roof Rack Crossbar Replacement

Removal
1. Remove roof rack from vehicle.Remove ten floor pieces from roof rack.Roof Rack Crossbar Replacement
Roof Rack End Replacement

Removal
Remove four bolts, locknuts, and rack end from sides (Figure 13-57).
Removal
1. 2. 3. Remove roof rack from vehicle. Remove ten floor pieces from roof rack. Remove four locknuts, washers, bolts, washers, and crossbar from sides (Figure 13-56).
FRONT OF VEHICLE
SIDE RACK END
CROSSBAR SIDE
FRONT OF VEHICLE
Figure 13-57: Roof Rack End
Installation
Install rack end on sides with four bolts and locknuts. Tighten locknuts to 15 lb-ft (20 Nm) (Figure 13-57).
Figure 13-56: Roof Rack Crossbar
Installation
1. Install crossbar on sides with four washers, bolts, washers, and locknuts. Tighten locknuts to 25 lb-ft (34 Nm) (Figure 13-56). Install ten floor pieces on roof rack. Install roof rack onto vehicle.
2. 3.
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Roof Rack Clamp Replacement

Removal
4. 5. 6. 7. Loosen support screw on clamp securing clip to clamp (Figure 13-58). Loosen locknut securing clip to drip rail. Remove clip from under drip rail. Remove locknut, washer, capscrew, and clamp from roof rack.
Installation
1. 2. 3. 4. Install clamp on roof rack with capscrew, washer, and locknut. Position clip under drip rail and over support capscrew. Tighten locknut securing clip to drip rail to 20-25 lb-in (23 Nm). Tighten support screw on clamp. Tighten locknut installed in step 1 to 25 lb-ft (34 Nm).
SIDE RACK END
CLAMP
DRIP RAIL CLIP
SUPPORT SCREW
Figure 13-58: Roof Rack Clamp
Section 13 Accessories
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Accessories
13-27
AUXILIARY SEAT Auxiliary Seat Replacement

Removal
1. 2. Release and remove four locking pins from auxiliary seat frame and auxiliary seat (Figure 13-59). Remove auxiliary seat from auxiliary seat frame.
Auxiliary Seat Belt Replacement

Removal
1. Release and tilt forward auxiliary seat.
NOTE: Retain initial seat belt mounting positions during installation. 2. Remove four bolts, washers, and two auxiliary seat belt assemblies from auxiliary seat (Figure 13-60).
Installation
1. 2. Install auxiliary seat on auxiliary seat frame. Install and fasten four locking pins to auxiliary seat frame and auxiliary seat. (Locking pins are properly installed when balls near end of pins are visible.)
AUXILIARY SEAT
AUXILIARY SEAT SEAT BELT ASSEMBLY
Figure 13-60: Auxiliary Seat Belt

SEAT FRAME
Installation
1.
LOCKING PIN
2.
Install two auxiliary seat belt assemblies on auxiliary seat with four washers and bolts (Figure 13-60). Torque to 7278 ft-lb (98-106 Nm). Tilt and fasten auxiliary seat back to normal position.
Figure 13-59: Auxiliary Seat
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Accessories
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Auxiliary Seat Frame Replacement

Removal
1. 2. 3. Remove auxiliary seat locking pins. Remove auxiliary seat. Remove four bolts, washers, and auxiliary seat frame from tunnel floor (Figure 13-61).
Auxiliary Seat Locking Pin Replacement

Removal
NOTE: Left and right side locking pins are replaced the same. This procedure covers the left side only. 1. 2. Remove two screws and locking pin cables from auxiliary seat frame (Figure 13-62). Release and remove two locking pins from auxiliary seat frame and auxiliary seat.
AUXILIARY SEAT
LOCKING PIN CABLE
SEAT FRAME
TUNNEL FLOOR
Figure 13-61: Auxiliary Seat Frame

SEAT FRAME
Installation
1. Install auxiliary seat frame on tunnel oor with four washers and bolts (Figure 13-61). Torque bolts to 27-30 lb-ft (36-40 Nm). Install auxiliary seat. Attach auxiliary seat locking pins to seat frame.
LOCKING PIN
2. 3.
Figure 13-62: Auxiliary Seat Locking Pin
Installation
1. 2. Install and fasten two locking pins on auxiliary seat frame and auxiliary seat (Figure 13-62). Install two locking pin cables on auxiliary seat frame with two screws.
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13-29
UPHOLSTERY, LEATHER AUXILIARY SEAT Removal

1. 2. 3. Remove the four locking pins securing the auxiliary seat to the seat frame (See Figure 13-63). Remove the auxiliary seat from the seat frame. Seat Base: a. Remove the bolts securing the safety belts to the rear of the auxiliary seat cushion frame. 4.
b.
Remove the safety belts from the auxiliary seat cushion frame. c. Release the plastic J retainers from the seat cushion frame and remove the fabric from the seat cushion. Seat Back: a. Release the hook and loop securing the front portion of the fabric to the rear fabric at the bottom of the seat back. b. Pull the fabric upward and remove it from the seat back.
LEATHER UPHOLSTERY
SEAT BACK
HOOK AND LOOP PLASTIC J RETAINER
SEAT CUSHION
SAFETY BELT
LOCKING PIN
SEAT FRAME
Figure 13-63: Auxiliary Seat Cover Installation.
Installation
1. Seat Base: a. Using the original fabric as a template, mark and cut the leather seat cushion upholstery for the safety belt mounting hardware. b. Position the leather on the seat cushion and secure the plastic J retainers to the seat cushion frame. c. Install the safety belts through the leather upholstery into the seat frame and torque the fasteners to 72-78 lb-ft (98-106 Nm). 2. Seat Back: a. Slide the leather upholstery down onto the seat back and secure the hook and loop at the bottom of the seat back. Install the auxiliary seat on the seat frame and secure with the four locking pins.
3.
CAUTION: Locking pins must be fully inserted into the seat frame. The balls near the end of the pins must be visible at the inboard side of the seat frame bracket.
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HOURMETER
By tying into the fuel pump relay hot lead, the hourmeter records engine running time. This is especially useful in fleet applications where vehicles experience extensive idling. The electrical connector is wired into the engine harness, ready for hourmeter installation.
HARNESS CONNECTOR
HOURMETER CONNECTOR
Removal
1. 2. Remove the left side cowl cover (Figure 13-64). Pull tabs on either side of spring clip while simultaneously pulling spring clip away from mounting bracket (Figure 13-64).
00 00
50
LEAD
SPRING CLIP
MOUNTING BRACKET
9-S13-004
Figure 13-65: Electrical Connector Location

6. 1.
HOURMETER
Remove hourmeter assembly from vehicle. Secure mounting bracket to driver side cowl with bolts and washers (Figure 13-64). Push hourmeter into mounting bracket and secure with spring clip. Plug engine harness connector into hourmeter connector (Figure 13-65). Install the cowl cover. Verify that hourmeter records engine running time.
Installation
2.
COWL COVER
9-P13-006
3. 4. 5.
Figure 13-64: Hourmeter Removal

3. 4. 5. Pull hourmeter out of mounting bracket far enough to access mounting bracket bolts. Remove bolts and washers securing mounting bracket to cowl. Follow lead from hourmeter to electrical connectors and unplug connectors (Figure 13-65).
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Accessories
13-31
OFF ROAD LIGHT PACKAGE KC HiLites High Intensity Discharge Lighting System Removal
1. 2. 3. 4. 5. 6. Disconnect battery ground cables. Remove switch from dash, disconnect spare power and ground wires under dash and pull wires through cowl. Remove relay from mount point on hood lock bracket and wire connections on power and ground studs. Loosen battery hold down bracket and slide ballast mounting brackets out. Disconnect the wire connections upstream of each light and remove the ballasts and related wiring. Remove lights from bumper mount brackets. 2. The ballasts mount above the vehicles batteries. Loosen the battery hold-down hardware, and slide two ballast mounting brackets between the batteries and the battery hold-down on the inboard side and two on the outboard side (Figure 13-67). The ballast marked passenger mounts forward of, and close to, the center battery holddown stud with the long wire lead toward the front of the vehicle. This mounting position is important to maintain good hood-to-ballast clearance. Secure the ballasts to the brackets with the screws and washers provided. Tighten the battery hold-down hardware.
KC HILITE
BUMPER MOUNT BRACKET
Figure 13-66: Light Mounting Point
Installation
1. Begin by mounting your HID lights to the front bumper mount brackets on each side of the vehicle. The lights are labeled driver and passenger which will orient the ceramic cover on the bulb downward. Use of the front lower hole in the bumper mount bracket should afford ample clearance to the hood and brush guard (Figure 13-66). Assure the steering stops are adjusted correctly to maintain adequate clearance between the tires and the lights. Suspension deection during off-road driving will affect this clearance.
NOTE: It will be necessary to remove the closeout panel under the left side of the dashboard to make some of the wire connections. Route wiring away from all moving components and excessive heat. Secure harnesses to the vehicle with wire ties.
BALLAST
BALLAST
BATTERY HOLD-DOWN BRACKET
BALLAST MOUNTING BRACKET
Figure 13-67: Ballast Mounting Point
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3.
Accessories
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4.
Route the harness from the ballast along the passenger side of the radiators, under the foam hood seal, to the passenger side light. The driver side light harness routes from the ballast across the top of the radiators, under the foam hood seal, and down the driver side of the radiators to the light. The harness connecting the ballasts and the relay should be routed from the ballasts across the top of the radiators, under the foam hood seal, to the relay mount point at the hood safety lock. From the relay, the power and ground wiring connects to the power distribution studs on the firewall and to the ground stud next to the exterior fuse box. The blue wire routes through the ignition interlock cable grommet in the cowl to the switch. The white (power) and black (ground) wires connect the switch to the orange high beam power wire near the turn signal switch and the instrument panel ground point under the dash. The red wire (Figure 13-70) containing a 30-amp in-line fuse, supplies power to the relay on terminal 30 and connects to the power distribution stud (+) on the firewall. The blue wire connects terminal 86 of the relay to either of the outside terminals on the switch. The red wire connects terminal 87 of the relay to the ballasts. The black wire connects terminal 85 of the relay and the ballasts to the ground distribution stud (-) next to the exterior fuse box. The center (ground) terminal of the switch connects to the instrument panel ground point under the left side of the dash. The white wire connects the remaining outside terminal of the switch to the orange high beam power wire near the turn signal switch (See Figure 13-68).
6.
Mount the switch under the dash on the left side of the steering column using the panel provided. a. Use the closeout panel mount screw nearest the left side of the steering column for the left side of the switch panel and drill the right side switch panel mount hole. Mark (using panel as template), center punch and drill a 5/64 hole for mounting of the panel. b. Mount the switch panel to the dash with the screws provided. Drill a 5/16 hole in the closeout panel forward of the switch for the wires to pass through the closeout panel.
NOTE: It is easier to connect the wiring to the switch terminals before snapping the switch into its hole.
RELAY HOOD SAFETY LATCH
CTIS COMPRESSOR
SWITCH WIRE
9-S13-003
T-TAP
Figure 13-69: Relay Mounting Point, Hood Lock Bracket

SWITCH
LIGHTS BLUE WIRE GROUND POWER WHITE WIRE 3 AMP FUSE WHITE WIRE
T-TAP
RED WIRE
RELAY
86 30 87 85 RED WIRE
INSTRUMENT PANEL GROUND
14 GAUGE ORANGE WIRE COVER

9-S13-029
30 AMP FUSE
BLACK WIRE
POWER DISTRIBUTION STUD ON FIREWALL GROUND STUD AT EXTERIOR FUSE BOX

BLACK WIRE
HIGH BEAM POWER
Figure 13-68: Switch Power Connection

5. Bend the relay tab approximately 90 degrees to the relay and mount the relay to the hood safety lock bracket with the existing screw (Figure 13-69). Mount the relay with the wires facing down to prevent moisture intrusion into the relay.
BALLAST
BALLAST
ORANGE WIRE
TURN SIGNAL SWITCH
7-S12-149.4
KC HID
KC HID
Figure 13-70: Wiring Schematic
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Diagnostics Table 1: Off Road Light Package Inoperative

STEP 1 ACTION Turn high beam headlights on. Using a DVOM, check for approximate battery voltage at the white supply wire to the dash switch. Is voltage present? Turn high beam headlights and HID light switch to the ON position. Check for approximate battery voltage at terminal 86 of relay. Is voltage present? Check for approximate battery voltage at terminal 87 of relay. Is voltage present? VALUE(S) Approximate battery + voltage. Approximate battery + voltage. Approximate battery + voltage. YES Go to step 2. NO Replace/repair circuit breaker/circuit of high beam headlight circuit (CB 3-30A). Replace/repair switch/circuit between switch and relay terminal 86 (blue wire). Repair relay ground circuit (terminal 85), relay power supply circuit with 30 amp in-line fuse (terminal 30). If OK, replace relay. Repair wiring between terminal 87 and ballasts.
Go to step 3.
Go to step 4.
Check red wires at the ballast connectors for voltage. Is voltage present?
Approximate battery + voltage. < .2 W.
Go to step 5.
Using a DVOM, check resistance of the ground circuit (black wire) between the ballast connector and the ground stud at the exterior fuse box. Is the resistance less than.2W?
Go to step 6.
Repair ground circuit/connections.
WARNING: Do not attempt to take voltage readings at the light connectors. Extreme high voltage (approximately 1250 volts) may be present which could cause personal injury or damage to equipment.
Turn HID light switch to the OFF position before disconnecting light connectors. If one light operates and one does not, disconnect light connectors and connect right light to left ballast and left light to right ballast. Does the inoperative light now shine and the other one not?,
Light ON
Replace the ballast connected to the presently inoperative light.
Replace the original inoperative light.
For additional diagnostic information call KC HiLites customer service at 1800-528-0950.
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Accessories
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AIR RESTRICTION GAUGE Removal

1. Disconnect the hose from the air restriction gauge and the hose barb in the air cleaner and remove the hose (Figure 13-71). Remove two screws securing the gauge and bezel to the mounting bracket and remove the gauge and bezel. Remove the hose barb from the air cleaner housing. Using a 1/8 drill bit, drill out two rivets securing the mounting bracket to the A-frame and remove the mounting bracket.
BRACKET A-FRAME GAUGE
Installation
1. 2. Position the mounting bracket on the A-frame and secure with two 1/8 pop rivets. Install the air restriction gauge from the engine side and the bezel from the street side of the bracket and secure with two screws through the bezel into the gauge. Use pipe thread sealant (Loctite 592) and install the brass hose barb in the air cleaner housing. Install the hose from the gauge to the hose barb in the air cleaner housing.
2. 3. 4.
3. 4.
HOSE BARB
Figure 13-71: Air Filter Restriction Gauge Mounting
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DUAL OIL FILTER Removal

1. 2. 3. Remove oil lters from oil lter adapter. Remove bolt, gasket and two small o-rings securing adapter to engine block and remove adapter. Remove large o-ring, plug and two connectors from adapter.
4. 5. 6.
Installation
1. Use pipe thread sealant (Loctite 592) on the threads of the pipe plug and install the pipe plug in the oil lter adapter. Remove any sealant that might have gotten into the oil passage during the pipe plug installation (Figure 13-72). Install two oil filter connectors in the oil filter adapter and tighten to 25 lb ft (34 Nm). Install the large o-ring in the groove on the oil filter adapter.
7.
8.
2. 3.
Install two small o-rings in the grooves in the oil filter bolt. Install the oil filter adapter gasket onto the oil filter bolt with the smooth side facing the bolt head. Lubricate all the o-rings and the oil filter gasket with clean engine oil, insert the oil filter bolt through the oil filter adapter and mount the adapter to the engine block. Position the adapter for easy removal and replacement of the oil filters and tighten the oil filter bolt to 50 lb ft (68 Nm). Lubricate the rubber sealing surface on both oil filters and install the filters on the oil filter adapter. Tighten the oil filters until the sealing surface contacts the adapter then 3/4 turn tighter. Refill the engine with fresh oil if previously drained, or top up the oil level if not previously drained and run the engine until warm while checking for leaks. Your oil capacity should increase by approximately one quart (2.8 ml).
PLUG
ADAPTER
OIL FILTER
O-RING
CONNECTOR
O-RING
GASKET
BOLT
Figure 13-72: Dual Oil Filter Assembly
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DELCO COMPACT DISC CHANGER REPLACEMENT Removal

1. 2. 3. Remove four screws retaining the CD changer bezel to the console and remove bezel (See Figure 13-73). Remove four screws retaining the CD changer mounting brackets to the console. Pull the CD changer out far enough to remove the wire harness connector from the changer and cut the tie strap securing the cable to the console harness (See Figure 13-74). If CD changer wire harness is to be replaced, radio must be removed to gain access to harness connection at the radio (Figure 13-75).
FRONT MOUNT BRACKET BEZEL
Installation
1. Connect wire harness connector to the side of the CD changer and insert the changer into the console and the front support bracket. Secure CD harness to the console harness with a tie strap. Install four screws in the changer mount brackets and tighten. Install changer bezel with four screws and tighten.
2. 3.
Radio Removal
1. Insert both radio removal keys in the holes in the face of the radio to disengage locking clips from the mounting sleeve. Pull radio out of mounting sleeve far enough to expose wire connections and disconnect audio harness connector, antenna cable and CD harness connector if equipped. Straighten locking tabs and pull mounting sleeve out of face plate.
4.
2.
3.
Radio Installation
1. 2. 3.
CD CHANGER
Figure 13-73: CD Changer Installation

4.
CD CHANGER CONSOLE
Install mounting sleeve through face plate and support plate and bend locking tabs to secure. Connect harness connectors and antenna cable to radio. Insert radio into mounting sleeve, align rear mount pin with upper support bracket and push in until locking clips engage. Advise end user to reprogram theftlock.
RADIO
CD CHANGER CABLE
00-S12-009
Figure 13-74: CD Changer Harness Routing
MOUNTING SLEEVE LOCKING TAB
RADIO REMOVAL KEYS
Figure 13-75: Radio Removal
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Accessories
CUSHION FABRIC
13-37
SEAT HEATER
NOTE: The following procedures apply to either the left or the right front seat.
Removal
1. Disconnect two wire connectors at the lower rear of the seat back and clip the wire ties securing the wires to the seat frame. 2. Remove four seat retaining bolts, washers and seat from vehicle. 3. Remove two screws at the front of the seat cushion and remove the cushion. 4. Using a screwdriver, release the fabric retaining clips and pull the fabric back to expose the fabric hold down wire and hog rings. Clip the hog rings and remove the fabric from the seat cushion (Figure 13-76). 5. Peel the heating element off the foam padding. 6. Remove two bolts, washers and the arm rest from the seat back. 7. Remove the arm rest side hinge cover and center cover. 8. Pry the metal fabric retainer channels open on the seat back frame and remove the fabric from the channels. 9. Remove the connector from the seat back wire harness and pull the wires through the hole in the fabric and the seat frame. 10. Roll the fabric up approximately 14 on both sides. 11. Remove the heating element from the foam padding of the seat back (Figure 13-77). 12. Remove the center console cover. 13. Pull the harness through the hole in the trim panel near the seat belt mount point. Disconnect the harness from the switch, pull the control box from its velcro mount on the body and remove the control box and the harness. 14. Remove the switch from the center console cover. 15. Remove the drivers side dash closeout panel. 16. Disconnect the harness from the auxilliary power point and the instrument ground point at the left of the steering column and remove the harness from the dash area.
CUSHION ELEMENT HOG RING
ELECTRICAL CONNECTIONS
Figure 13-76: Seat Cushion Element Removal.
ROLLED FABRIC
BACK ELEMENT
Installation
1. Installation is the reverse of the removal using new hog rings that were clipped in step 4 and inserting the brown wire in position B and the blue wire in position A of the connector in step 9.
Figure 13-77: Back Element Removal.
05745159
13-38
Accessories
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Diagnostics
Seat Heater Does Not Heat

Step 1 Action NOTE: The control box contains a timer that will shut the heater off after one hour of use. The switch must be cycled OFF and ON to restart the heat cycle. Turn ignition to the ON position. Position the seat heater switch to one of the heat positions. Does the switch illuminate? Value(S) Switch light ON Yes Go to step 2. No Check/repair fuse 3G circuit through the auxiliary power point to the switch 2B and 3B (red wire) and ground circuit from IP ground point to the control terminal 2B (black wire). Check circuit between control 2C and switch terminals 7 and 8(black wire). If circuits OK and switch is not illuminated, replace the switch. Go to step 3.
Cycle seat heater switch OFF and ON. Do you hear an audible click coming from the control box? Check switch output power at the control box connection. In high position check for voltage on white and orange wires. In low position check for voltage on white wires. Check resistance at terminals A and D of 4 position cushion connector. Is the resistance within specification?
Audible relay click. Approximate battery + voltage.
Go to step 4.
Go to step 4.
Replace the switch.
3.2 W +-10% (resistance of back and cushion element in series) 1.2 W +- 10% 10K W +- 10% at 77 F
Go to step 6.
Go to step 5.
Isolate the back element and check its resistance. Is the resistance within specification? Check resistance of NTC heat sensor in the cushion element. Is the resistance within specification? Call 1-800-927-6787 for additional troubleshooting assistance.
Replace the cushion element. Replace the control box.
Replace the back element.
Replace cushion element.
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Accessories
13-39
SWITCH
10 WHT 4 4 8 8 BLK
LOW 5B RED YEL
WHT
6 6 1 2B RED
GRY GRN BLU BRN
ORG 3 3 9
HIGH 7 7 BLK A B
A YEL
B GRY
C GRN
D BLU
6 1 2 3 4
BACK ELEMENT
BRN GRN GRY YEL
YEL GRY
CONTROL BOX
GRY WHT YEL 1A 1B 1C 2A 2B 2C 2D GRN BLK BLU ORG
RED RED 1 2 71A WHT
BLK
CUSHION ELEMENT
AUXILIARY POWER POINT
7.5 IGNITION WHT
INSTRUMENT PANEL GROUND POINT
INTERNIAL FUSE BOX
FUSE 3G 30 AMP 297B
POWER STUD
8-S13-001.1
Figure 13-78: Seat Heater Schematic
05745159
13-40
Accessories
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OFF-ROAD ACCESSORY KIT (MODEL 84) Removal

1. 2. Remove four bolts, locknuts, 8 retainer plates and gaskets securing the box to the wheelhouse (See Figure 13-79). Lift the box off the wheelhouse and out of the vehicle.
BEDLINER (MODELS 83, 85 AND 90) Removal

1. Using a sharp knife or gasket scraper cut the edge trim adhesive between the vehicle and the edge trim all around the upper edge of the bedliner. Take care not to damage the edge trim so it can be reused. Remove all the tiedowns in the bed area. Remove the two plastic caps, screws and washers securing the top of the tailgate liner. Pull the tailgate liner off the tailgate. 4. If your vehicle is a soft top model, remove the bolts and nuts securing the C pillar rear support bars to the wheelhouse (See Figure 13-80). Remove the shims from between the support bar brackets. 5. Remove the bedliner. Cut the edge trim off the tailgate. Clean all the remaining adhesive off the bed and tailgate areas and the backside of the edge trim with an adhesive remover.
BOLT
RETAINER PLATE
2. 3.
BOX WHEELHOUSE
6. 7.
LOCKNUT
Installation
8. Place the bedliner into the vehicle. If your vehicle is a soft top model, perform the following steps: Slide the bedliner into the bed from the rear until the front of the bedliner is against the rear support bar brackets. Raise the rear of the bedliner. Make sure that both sides of the liner start sliding under the support bar brackets. Push the liner all the way forward until there is approximately 1/8" clearance between the rear oor edge of the liner and the vehicles D beam assembly (rear oor ange). 9. Align the tiedown holes in the liner with the holes in the vehicle. Install all the tiedowns loosely. Adjust the liner in the bed and torque the tiedowns to 27-30 lb-ft (36-40 Nm) 10. If your vehicle is a soft top model, use the holes in the C pillar rear support bar mount brackets as a template and drill 1/2" holes through the liner. Reinstall the previously removed shims between the liner and the support bar brackets, leaving out one shim on each side to make up for the thickness of the liner. Install the original bolts and nuts through the support bar mount brackets, the shims, the liner and the wheel houses, but do not tighten. Recheck the t of the liner and torque the bolts to 31 lbft (42 Nm). 11. Use rubbing alcohol to clean the body along the top of the liner on the right and left sides. The edge trim will be installed in this area and the vehicle must be clean to insure proper adhesion.
GASKET
Figure 13-79: Off-Road Accessory Box Mounting
Installation
1. Position the tool box on the drivers side rear wheel house ush with the inside edge and centered front to rear making sure that the lid will open without contacting the side window or the upper trim panel. 2. Using the forward inboard and the two outboard holes in the bottom of the tool box as a template, mark the carpet and drill 1/4 holes through the carpet and the wheel house (See Figure 13-79). 3. Mount the tool box by installing three 1/4 bolts, retainer plates and Gaskets from the box side through the wheel house and three gaskets, retainer plates and locknuts on the wheel side. 4. Measure two inches inboard from the rear inboard mount hole in the bottom of the box and mark the box for drilling. 5. Drill a 1/4 hole at the marked position through the box, the carpet and the wheelhouse. 6. Install a 1/4 bolt, retainer plate and Gasket from the box side through the wheel house and a gasket, retainer plate and locknut on the wheel side. Torque all the fasteners to 12 lb ft. 7. Place the kit contents in the tool box and latch the lid before operating the vehicle. CAUTION: Box contents should not exceed 60 pounds.
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Accessories
13-41
NOTE: The edge trim should not be installed over the vertical angle brackets in the front corners of the bed. NOTE: If you are reusing the original edge trim you will need to install a double sided foam tape such as 3M 06382 to the backside of the edge trim pieces. 12. Mark the lengths of edge trim to be used on the right and left sides of the liner. Do not use edge trim under the support tube brackets on soft top models or under the tonneau cover bow bracket on hard top models. Once the proper lengths of edge trim have been marked, cut the edge trim to length. Install the edge trim onto the top edge of the bedliner, but do not remove the adhesive lm backing yet. The edge trim must be installed loosely onto the top edge of the bedliner. A 1/8" gap should be left between the inside edge of the trim and the top of the bedliner to allow for expansion.
13. When all the pieces of edge trim are in their correct location, remove the adhesive lm backing from one piece of trim and press it into place. Repeat until all the pieces of trim are in place. 14. Clean the vehicle tailgate. Center the tailgate cover side to side and push the cover forward until the cover is tight against the top of the tailgate. Using the holes in the upper corners of the cover, mark the tailgate and drill two 5/32" holes in the tailgate for the cover retaining screws. Redrill the holes in the tailgate cover only out to 3/8". Fasten the tailgate cover to the tailgate by installing the screws and washers. Snap a plastic cap over each washer. 15. Clean the tailgate along the bottom edge of the cover with rubbing alcohol to insure proper adhesion of the edge trim. Install the edge trim leaving a 1/8" gap between the inside edge of the trim and the cover for expansion. Remove the adhesive lm backing and press the trim into place.
C PILLAR REAR SUPPORT BAR WHEEL HOUSE ANGLE BRACKET SHIM
EDGE TRIM
TIEDOWN
1/8" GAP LINER
Figure 13-80: Bedliner Installation In Soft top vehicle.
05745159
13-42
Accessories
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REMOTE ENTRY TRANSMITTER BATTERY REPLACEMENT

1. 2.
Remove the screw in the back of the transmitter (See Figure 13-81).
STAINLESS STEEL FRONT BUMPER COVER (WITH BRUSHGAURD AND W/O WINCH)
Removal
1. 2. 3. Remove two bolts and the licence plate mount bracket (See Figure 13-82). Remove four bolts, washers and two tow bracket/lifting shackle assemblies. Pull the SS cover free from the bumper and clean the double sided foam tape from the cover and bumper.
3. 4.
5. 6.
Using a small screw driver or a knife blade, carefully pry the two halves of the transmitter apart exposing the battery. New batteries can be obtained from an electronics supply store. The battery size is 27A 12V. Carefully pry the battery out and install the new battery. Match the polarity markings on the transmitter casing and the battery when installing. Snap the transmitter case halves together and install the screw in the back of the transmitter. Test the operation of the remote entry transmitter.
BUMPER
LICENCE BRACKET TRANSMITTER CASE
BATTERY TOW BRACKET LIFT SHACKLE
SS COVER
Figure 13-82: SS Front Bumper Cover W/O Winch

SCREW
9-S13-017
Installation
1. 2. 3. 4. Clean all grease and dirt from the front bumper and cover and prep the surfaces with alcohol. Apply new double sided foam tape to the back of the cover and press the cover on the bumper. Install two tow bracket/lifting shackle assemblies, four bolts and washers. Torque the bolts to 90 lb-ft (122 Nm). Install the licence plate mounting bracket with two bolts and torque to 8-13 lb-ft (11-18 Nm).
Figure 13-81: Remote Entry Battery Replacement
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Accessories
13-43
STAINLESS STEEL FRONT BUMPER COVER (WITH WINCH)
STAINLESS STEEL REAR BUMPER COVER Removal
Removal
1. 2. 3. 4. Remove two bolts and the licence plate mount bracket (See Figure 13-83). Remove four bolts, washers and two tow bracket/lifting shackle assemblies. Support the winch and remove the bolts and washers securing the bumper to the winch. Pull the cover free from the bumper and clean the double sided foam tape from the bumper and cover.
1. 2. 3. 4.
Remove two bolts and the licence plate mount bracket (See Figure 13-84). Remove four bolts, washers and two tow bracket/lifting shackle assemblies. Remove the bolt covers from the bolt heads. Pull the SS cover free from the bumper and clean the double sided foam tape from the cover and bumper.
SS COVER FRONT BUMPER BUMPER
LICENCE BRACKET
LIFT SHACKLE ASSEMBLY

9-S13-019
STAINLESS COVER LIFTING SHACKLE TOW BRACKET
BOLT COVER
Figure 13-84: SS Rear Bumper Cover
Installation
1. 2. 3. 4. 5. Clean all grease and dirt from the front bumper and cover and prep the surfaces with alcohol. Apply new double sided foam tape to the back of the cover and press the cover on the bumper. Install two tow bracket/lifting shackle assemblies, four bolts and washers. Torque the bolts to 90 lb-ft (122 Nm). Install the licence plate mounting bracket with two bolts and torque to 8-13 lb-ft (11-18 Nm). Install the bolt covers on the bolt heads.
Figure 13-83: SS Front Bumper Cover W/Winch
Installation
1. 2. 3. 4. 5. Clean all grease and dirt from the front bumper and cover and prep the surfaces with alcohol. Apply new double sided foam tape to the back of the cover and press the cover on the bumper. Install two tow bracket/lifting shackle assemblies, four bolts and washers. Torque the bolts to 90 lb-ft (122 Nm). Install the winch mounting bolts and washers and torque to 60 lb-ft (81 Nm). Install the licence plate mounting bracket with two bolts and torque to 8-13 lb-ft (11-18 Nm).
05745159
13-44
Accessories
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STAINLESS STEEL UPPER GRILLE COVER REPLACEMENT Removal

1. Remove the six screws, washers and nuts securing the SS grille frame to the original grille frame and remove the SS grille frame (See Figure 13-85).
4.
5.
6.
Place two 3 inch pieces of double-sided tape on the back side of the eight SS slats, approximately 2 inches from each end of the slat. Starting with the bottom grille slat, peel the backing off the double-sided tape and hook the front edge of the SS slat on the front edge of the original slat and roll the SS slat into place. Press and hold momentarily to ensure a good bond. Continue installing the remaining slats noting that the fourth slat has the tab to cover the grille mesh mounting screw area.
STAINLESS STEEL WHEEL COVER REPLACEMENT Removal

1.
SS GRILLE FRAME
2. 3.
SCREW HOLE
Locate the two lugnut simulators that can be turned by hand and remove the simulators and the plastic inserts. Remove the two nuts and washers securing the wheel cover to the mounting brackets and remove the cover. Remove the bolts, lockwashers and washers securing the mounting brackets and CTIS tube shield (if equipped) from the spindle and remove the brackets and shield.
Figure 13-85: SS Upper Grille Frame R&I

2. Peel the eight SS grille slats off from the original grill slats and remove the double-sided tape with an adhesive remover.
LUG NUT SIMULATOR WHEEL COVER CTIS TUBE SHIELD
PLASTIC INSERT
MOUNTING BRACKET
SPINDLE
SS SLAT ROLL INTO PLACE
Figure 13-87: Wheel Cover Replacement
Installation
1. Install the two wheel cover mounting brackets and CTIS tube shield (if equipped) on the spindle with four bolts, lock washers and washers. Torque the bolts to 37 lb-ft (50 Nm). Place the wheel cover over the studs on the mounting brackets and install the nuts and washers. Torque the nuts to 8-13 lb-ft (11-18 Nm). Install the plastic inserts and the lug nut simulators.
Figure 13-86: SS Upper Grille Slat R&I
Installation
1. 2. 3. Clean all the original and SS grille slats with alcohol. Place the SS grille frame over the original grille frame and loosely install the six SS screws, washers and nuts. Use an alternate tightening sequence and torque the screws to 7 lb-ft (9 Nm). 2.
3.
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Accessories
13-45
SOFT SLANT BACK (MODEL 90) Removal

1. 2. 3. 4. 5. 6. 7. Unzip the forward portion of the slant back cover from the soft top cover. Release the hook and loop fasteners on the lower sides and the lower rear of the slant back cover. Release the hook and loop fasteners on the inside of the cover securing the cover to the support structure. Remove the slant back cover from the slant back support assembly. Release the hook and loop straps securing the formers to the support structure and remove the formers. Loosen the support structure retaining straps and release the strap hooks from the footman loops. Remove the screws securing the hinge brackets to the wheel houses and remove the support structure.
7.
Pull the sides of the cover tight and engage the hook and loop on the sides of the wheelhouses.
SOFT SQUARE BACK (MODEL 90) Removal

1. 2. 3. 4. 5. 6. Unzip the forward portion of the square back cover from the soft top cover. Release the hook and loop fasteners on the lower sides and the lower rear of the square back cover. Release the hook and loop fasteners on the inside of the cover securing the cover to the support structure. Remove the square back cover from the square back support assembly. Loosen the support structure retaining straps and release the strap hooks from the footman loops. Remove the screws securing the hinge brackets to the wheel houses and remove the support structure.
COVER COVER SUPPORT STRUCTURE STRAP STRAP HINGE BRACKET FOOTMAN LOOP FOOTMAN LOOP HINGE BRACKET
SUPPORT STRUCTURE
FORMER
Figure 13-88: Soft Slant Back R & I.
Figure 13-89: Soft Square Back R & I.
Installation
1. Place the support structure on the wheelhouses and install the screws through the hinge brackets into the wheelhouses. Insert the retaining strap hooks in the footman loops and adjust the retaining straps. Place the formers on the forward top corners of the support structure and secure with the hook and loop straps. Engage the hook and loop fasteners on the inside of the cover. Place the cover on the support structure and zip the forward edge to the soft top cover. Pull the rear edge of the cover tight and engage the hook and loop on the tailgate.
Installation
1. Place the support structure on the wheelhouses and install the screws through the hinge brackets into the wheelhouses. Insert the retaining strap hooks in the footman loops and adjust the retaining straps. Place the cover on the support structure and zip the forward edge to the soft top cover. Engage the hook and loop fasteners on the inside of the cover. Pull the rear edge of the cover tight and engage the hook and loop on the tailgate. Pull the sides of the cover tight and engage the hook and loop on the sides of the wheelhouses.
2. 3. 4. 5. 6.
2. 3. 4. 5. 6.
05745159
13-46
Accessories
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Section 14
ndex
Index 14-1
Generator Whine Concerns . . . . . . . . . . 12-146 Overhead Console, Speaker and Amplifier Replacement (Delco Monsoon) . . . . . . 12-140 Radio (Delco) Replacement . . . . . . . . . . 12-140 Rear Seat Audio (RSA) Unit Replacement . . . . . . . . . . . . . . . . . . . . . 12-141 Symptom Table . . . . . . . . . . . . . . . . . . . 12-151 System Description . . . . . . . . . . . . . . . . 12-139 Test Antenna . . . . . . . . . . . . . . . . . . . . . 12-146 Auxiliary Seat . . . . . . . . . . . . . . . . . . . . . . . . 13-27 Belt Replacement . . . . . . . . . . . . . . . . . . . 13-27 Frame Replacement . . . . . . . . . . . . . . . . . 13-28 Locking Pin Replacement . . . . . . . . . . . . 13-28 Replacement . . . . . . . . . . . . . . . . . . . . . . . 13-27 Axle Output Shaft Seal Replacement . . . . . . . . . 9-25 Pinion Seal Replacement . . . . . . . . . . . . . . 9-26 Support and Side Mounting Brackets . . . . 9-59 Vent Line Replacement . . . . . . . . . . . . . . . 9-23 Axle Assembly Cover Service . . . . . . . . . . . . . . . . . . . . . . . 9-25 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 9-26
_____________________________________________________________________
A
A/C Compressor Removal . . . . . . . . . . . . . . . . 2-50 A/C System Refrigerant and Capacity . . . . . . . 11-5 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Air Cleaner Assembly Air Cleaner Filter Element Service . . . . . . 3-21 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . 3-19 Air Conditioning/Heater Duct Replacement . 11-25 Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Air Induction Hose Replacement . . . . . . . . 3-22 Air Intake Vent Line Replacement . . . . . . . . . 3-23 Air Restriction Gauge . . . . . . . . . . . . . . . . . . 13-34 Airlift Brackets . . . . . . . . . . . . . . . . . . . . .9-48, 9-49 Airlift to Hood Seal Replacement . . . . . . . . . 10-51 Anti-lock Brake System (ABS) and Automatic Traction Control, TorqTrac 4 (TT4) ABS ECU Replacement . . . . . . . . . . . . . . . 7-50 ABS Modulator Replacement . . . . . . . . . . 7-48 Installation . . . . . . . . . . . . . . . . . . . . . . 7-49 Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-48 ABS/TT4 Diagnostics . . . . . . . . . . . . . . . . 7-34 Fault Diagnostic Procedure . . . . . . . . . 7-34 Fuse and Relay Replacement . . . . . . . . . . . 7-50 System Description . . . . . . . . . . . . . . . . . . 7-34 System Operation . . . . . . . . . . . . . . . . . . . . 7-34 Armrest Replacement . . . . . . . . . . . . . . . . . . . 10-24 Ashtray Replacement . . . . . . . . . . . . . . . . . . . 10-20 Audio Antenna System Test . . . . . . . . . . . . . . . 12-157 CD Changer (Delco) Replacement . . . . 12-140 Diagnosis-Delco Audio System . . . . . . . 12-144 Corrective Action . . . . . . . . . . . . . . . 12-145 Identifying Concerns . . . . . . . . . . . . 12-144 Electrical Harness Replacement, Delco Monsoon (Models 83, 84 & 91) . . . . . . 12-142 Electrical Harness Replacement, Delco Standard (Model 89) . . . . . . . . . . . . . . . 12-143 Electrical Harness Replacement, Delco Standard (Model 90) . . . . . . . . . . . . . . . 12-144 Electrical Harness Replacement, Delco Standard (Models 83, 84 & 91) . . . . . . 12-143
5745159
B
Basic Symptom Checks . . . . . . . . . . . . . . . . . . 5-14 Cuts Out, Misses . . . . . . . . . . . . . . . . . . . . 5-21 Engine Cranks but Does Not Run . . . . . . . 5-15 Excessive Smoke . . . . . . . . . . . . . . . . . . . . 5-22 Fuel Knock/Combustion Noise . . . . . . . . . 5-20 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Hesitation, Sag, Stumble . . . . . . . . . . . . . . 5-20 Intermittent Condition . . . . . . . . . . . . . . . . 5-17 Lack of Power, Sluggishness, or Sponginess . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Poor Fuel Economy . . . . . . . . . . . . . . . . . . 5-22 Surges/Chugs . . . . . . . . . . . . . . . . . . . . . . . 5-19 Battery Battery Charging . . . . . . . . . . . . . . . . . . . 12-14 Cable Maintenance . . . . . . . . . . . . . . . . . . 12-16 Power Distribution . . . . . . . . . . . . . . . . . . 12-21
3-1-02
14-2
Index
______________________________________________________________________
Replacement . . . . . . . . . . . . . . . . . . . . . . . 12-18 Splash Shield and Seal Service . . . . . . . . 12-19 Tray Replacement . . . . . . . . . . . . . . . . . . 12-18 Blower Motor Resistor Replacement . . . . . . . 11-35 Body Inspection and Repair . . . . . . . . . . . . . . . 10-3 Aluminum Repair . . . . . . . . . . . . . . . . . . . . 10-8 Fiberglass Repair . . . . . . . . . . . . . . . . . . . 10-11 Lockbolt Failure . . . . . . . . . . . . . . . . . . . . . 10-4 Rivet Failure . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Rivet Replacement . . . . . . . . . . . . . . . . . . . 10-4 Body Mount Replacement . . . . . . . . . . . . . . . 10-61 Bolt Identification and Torque Limits (Dry) . . 1-13 Bolt Identification and Torque Limits (Wet) . . 1-14 Boost Pressure Test . . . . . . . . . . . . . . . . . . . . . 2-16 Brake Master Cylinder Bench Bleeding . . . . . . . . . . . . . . . . . . . . . 7-12 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Brake Shift Interlock System . . . . . . . . . . . . . 12-51 Brake Shift Interlock Cable Inoperative . 12-51 Ignition Switch Replacement . . . . . . . . . . 12-51 Shift Interlock Cable Schematic . . . . . . . 12-52 Brake System Bleeding Instructions . . . . . . . . . . . . . . . . . . 7-8 Brake Line Replacement . . . . . . . . . . . . . . 7-14 Brake Rotor . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Refinishing . . . . . . . . . . . . . . . . . . . . . . 7-32 Burnishing Linings and Rotors . . . . . . . . . 7-10 Caliper Overhaul, Rear . . . . . . . . . . . . . . . 7-29 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Disc Brake Caliper Repair, Front . . . . . . . . 7-27 Front Service Brake Caliper . . . . . . . . . . . . 7-10 Hydro-Boost System Accumulator Leakdown Test . . . . . . . . . 7-8 Booster Functional Test . . . . . . . . . . . . . 7-8 Noise Diagnosis . . . . . . . . . . . . . . . . . . . 7-7 Hydro-Boost System Diagnosis . . . . . . . . . . 7-7 Left Parking Brake Cable Replacement . . . 7-23 Pad Replacement, Service Brake . . . . . . . . . 7-9 Parking Brake Lever Adjustment . . . . . . . . . . . . . . . . . 7-33 Lever Replacement . . . . . . . . . . . . . . . 7-26
3-1-02
Switch Replacement . . . . . . . . . . . . . . . 7-33 Parking Brake Cable Replacement, L . . . . 7-24 Parking Brake Cable Replacement, R . . . . 7-23 Pedal Replacement, Service Brake . . . . . . 7-17 Proportioning Valve Replacement . . . . . . . 7-17 Rear Dual Service/Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-25 Caliper Replacement . . . . . . . . . . . . . . 7-20 Pad Replacement . . . . . . . . . . . . . . . . . 7-18 Rod Replacement . . . . . . . . . . . . . . . . . 7-25 Rotor Replacement, Service Brake . . . . . . 7-17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7-4 Brushguard Assembly Replacement . . . . . . . 13-10 Bulkhead, 76 Way . . . . . . . . . . . . . . . . . . . . . . 5-28 Bumpers Front Bumper and Towing Brackets . . . . . 9-45 Rear Bumper Outer Mounting and Tiedown Brackets . . . . . . . . . . . . . . . . . . . 9-53 Rear Bumper Replacement . . . . . . . . . . . . 9-52
C
Camshaft Bearing Replacement . . . . . . . . . . . . . . . . . 2-64 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Timing Chain, Sprocket and Drive Gears . 2-71 Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . 1-2 Cargo Tiedown Replacement . . . . . . . . . . . . . 10-72 Center Console Replacement . . . . . . . . . . . . . 10-13 Central Tire Inflation System Air Intake Line and Assembly . . . . . . . . . . 6-51 Air Leak Troubleshooting . . . . . . . . . . . . . 6-32 Air Pressure Gauge . . . . . . . . . . . . . . . . . . 6-40 Air Pressure Gauge Lamp . . . . . . . . . . . . . 6-41 Air Pressure Indicator Lines . . . . . . . . . . . 6-45 Air Pressure Switch . . . . . . . . . . . . . . . . . . 6-44 Auxiliary Air Hose . . . . . . . . . . . . . . . . . . . 6-54 Compressor Fuse . . . . . . . . . . . . . . . . . . . . 6-46 Compressor Relay . . . . . . . . . . . . . . . . . . . 6-46 Compressor Service . . . . . . . . . . . . . . . . . . 6-36 Deflate Valve Assembly . . . . . . . . . . . . . . 6-47
_____________________________________________________________________
Index
14-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Dust Excluder Replacement . . . . . . . . . . . . 6-48 Front CTI Line Replacement . . . . . . . . . . . 6-50 Front Supply Tube and Hose . . . . . . . . . . . 6-49 Geared Hub Replacement . . . . . . . . . . . . . 6-53 Inflate/Deflate and Tire Selector Switches 6-38 Instrument Cluster . . . . . . . . . . . . . . . . . . . 6-37 Interior Harness . . . . . . . . . . . . . . . . . . . . . 6-43 Low Pressure Alarm . . . . . . . . . . . . . . . . . 6-42 Quick-Disconnect Valve and Tube . . . . . . 6-52 Rear CTI Line Replacement . . . . . . . . . . . 6-50 Rear Tube Connection Shield . . . . . . . . . . 6-53 Spindle Extension and Seal . . . . . . . . . . . . 6-54 Supply Line . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-31 Tube Shield Replacement . . . . . . . . . . . . . 6-51 Charging System Alternator . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 Alternator Overhaul . . . . . . . . . . . . . . . . . 12-23 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-28 Cigarette Lighter Replacement . . . . . .10-19, 12-68 Climate Control System A/C Pressure Hose Replacement . . . . . . . 11-18 Condenser Replacement . . . . . . . . . . . . . . 11-20 Control Head Replacement . . . . . . . . . . . 11-16 Heater Hose Replacement . . . . . . . . . . . . 11-22 Heater/A/C Diagnosis . . . . . . . . . . . . . . . . 11-2 System Performance Checks . . . . . . . . . . . 11-2 Compressor Clutch Core Replacement . . . . . . . . . . . . 11-32 Clutch Rotor and/or Bearing Replacement 11-30 Replacement . . . . . . . . . . . . . . . . . . . . . . . 11-28 Shaft Seal Replacement . . . . . . . . . . . . . . 11-32 Connectors 24 Way PCM-Brown . . . . . . . . . . . . . . . . 5-149 32 Way PCM-Blue . . . . . . . . . . . . . . . . . . 5-147 32 Way PCM-Brown . . . . . . . . . . . . . . . . 5-145 40 Way GM Engine . . . . . . . . . . . . . . . . . 5-143 56 Way Instrument Panel . . . . . . . . . . . . . 5-141 76 Way Bulkhead . . . . . . . . . . . . . . . . . . . 5-138 Converter Housing Lower Cover Replacement . . . . . . . . . . . 5-123 Upper Cover Replacement . . . . . . . . . . . . 5-123
5745159
Crankshaft Bearing Replacement . . . . . . . . . . . . . . . . . 2-42 Connecting Rod Journal Diameter . . . . . . . 2-97 Crankshaft and Main Bearings Removal . . 2-60 End Play Check . . . . . . . . . . . . . . . . . . . . . 2-81 Main Journal Diameter . . . . . . . . . . . . . . . 2-97 Pulley Replacement . . . . . . . . . . . . . . . . . . 2-20 Cruise Control Cruise Control Inoperative VIN Z . . . . . 12-135 Cruise Control Schematic . . . . . . . . . . . 12-137 Cruise Control Systems . . . . . . . . . . . . 12-134.4 CTIS CTIS Compressor Inoperative . . . . . . . . . 12-53 CTIS Exhaust Valve Inoperative . . . . . . . 12-54 CTIS Front Inflate Valve Inoperative . . . 12-55 CTIS Rear Inflate Valve Inoperative . . . . 12-56 CTIS Schematic . . . . . . . . . . . . . . . . . . . . 12-57 Customer Assistance Hummer Service Hotline . . . . . . . . . . . . . . . 1-2 Service Manual Revisions . . . . . . . . . . . . . . 1-2 Cylinder Block Cylinder Bore and Piston Measurement . . 2-62 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Cylinder Head Cylinder Head And Gasket Service . . . . . . 2-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
D
Damper and Flywheel Service . . . . . . . . . . . . . 2-76 Delco Compact Disc Changer Replacement . 13-36 Diagnostic System Check . . . . . . . . . . . . . . . . . 5-5 Diesel Fuel Injection System . . . . . . . . . . . . . . 3-36 Digital Ratio Adapter . . . . . . . . . . . . . . . . . . . 12-75 Dimmer Control Switch Replacement . . . . . . 10-17 Door Glass Wind Noise . . . . . . . . . . . . . . . . . . . . . . 10-43 Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-41 Door Stop Strap Assembly Replacement . . . . 10-41
3-1-02
14-4
Index
______________________________________________________________________
Doors Disassembly, Replacement and Repair . . 10-36 Door Glass . . . . . . . . . . . . . . . . . . . . . . . . 10-41 Door Seals Replacement . . . . . . . . . . . . . 10-41 Rear Vertical Door Replacement . . . . . . . 10-74 Drainage Bracket Replacement . . . . . . . . . . . . 3-23 Dual Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 13-35
E
Engine Assembly and Adjustment . . . . . . . . . . . . . 2-80 Block, Camshaft and Bearing Sizes . . . . . . 2-98 Cleaning Materials . . . . . . . . . . . . . . . . . . . . 2-4 Compression Test . . . . . . . . . . . . . . . . . . . . . 2-4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . 2-7 Engine Noise Diagnosis Equipment . . . . . . . . . . . . . . . 2-6 Essential Tools . . . . . . . . . . . . . . . . . . . . . . 2-99 Identification . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Identification Number . . . . . . . . . . . . . . . . . 1-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Lubricants/Sealants/Coolant Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 2-3 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Mounting Bracket/Insulator . . . . . . . . . . . . 2-19 Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . 2-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Scan Tool Use . . . . . . . . . . . . . . . . . . . . . . . 2-6 Service Piston and Cylinder Bore . . . . . . . 2-97 Special Service Tools . . . . . . . . . . . . . . . . . . 2-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-96 Engine Access Cover . . . . . . . . . . . . . . . . . . . 10-20 Hold-Down Striker Replacement . . . . . . . 10-20 Inner Flexible Latch Replacement . . . . . . 10-20 Engine Access Cover Maintenance . . . . . . . . 10-20 Engine Assembly and Adjustment Crankshaft and Main Bearing Installation . 2-80
3-1-02
Crankshaft Main Bearing Selection . . . . . . 2-80 Engine Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Diagnosis and Troubleshooting . . . . . . . . . . 4-3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine Temperature Sender Replacement . . . . 3-40 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43 Air Intake Assembly Replacement . . . . . 11-45 Cycling Switch Replacement . . . . . . . . . . 11-45 Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Exhaust System Catalytic Converter Replacement . . . . . . . 3-44 Crossover Pipe Replacement . . . . . . . . . . . 3-44 Muffler Replacement . . . . . . . . . . . . . . . . . 3-42 Extension Housing Bushing and Seal . . . . . . 5-157
F
Fan and Clutch Assembly Service . . . . . . . . . . 4-16 Fan-Pulley-Damper Removal . . . . . . . . . . . . . 2-50 Flexplate Replacement . . . . . . . . . . . . . . . . . . 5-127 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Fuel/Fluids/Lubricants . . . . . . . . . . . . . . . . 1-24 Flushing Engine Cooler . . . . . . . . . . . . . . . . . . 2-78 Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . 2-60 Former Assembly Replacement, A Pillar . . 10-60 Frame Front Suspension Brace Replacement . . . . 9-50 Front Suspension Front Crossmember . . . . 9-60 Front Suspension Rear Crossmember . . . . 9-61 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64 Left Engine Mount Bracket . . . . . . . . . . . . 9-54 Left Intermediate Body Mount Bracket . . . 9-57 Lifting Shackle Replacement . . . . . . . . . . . 9-47 Radiator Front Mount Bracket . . . . . . . . . . 9-46 Rear Suspension Front Crossmember . . . . 9-62 Rear Suspension Rear Crossmember . . . . . 9-63 Rear-Front Tiedown Bracket . . . . . . . . . . . 9-59
_____________________________________________________________________
Index
14-5
Rear-Rear Tiedown Bracket . . . . . . . . . . . 9-58 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67 Right Engine Mount Bracket . . . . . . . . . . . 9-55 Right Front Body Mount Bracket . . . . . . . 9-55 Right Intermediate Body Mount Bracket . . 9-57 Transmission Crossmember Support . . . . . 9-56 Transmission Mount Crossmember . . . . . . 9-56 Transmission Mount Replacement . . . . . . 9-56 Front Console Replacement . . . . . . . . . . . . . . 10-13 Front Cover and Baffle Installation . . . . . . . . . 2-86 Front Cover and Oil Filler Tube . . . . . . . . . . . 2-71 Front Cover And Timing Chain . . . . . . . . . . . . 2-23 Front Cover Oil Seal Replacement . . . . . . . . . 2-22 Front Cover Removal . . . . . . . . . . . . . . . . . . . . 2-57 Front License Plate Bracket Replacement . . . 10-62 Front Output Shaft Bearing and Seal Replacement . . . . . . . . 5-154 Seal Replacement . . . . . . . . . . . . . . . . . . . 5-143 Front Striker Replacement . . . . . . . . . . . . . . . 10-61 Fuel Filler Housing Replacement . . . . . . . . . 10-63 Fuel Filter Drain Hose and Valve Replacement . . . . . 3-32 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Fuel Filter Warning Lamp . . . . . . . . . . . . . . . . . 2-4 Fuel Injection Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Fuel Injection Pump Fuel Supply and Return Line Removal . . . 2-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Fuel Injection Pump Boot Replacement . . . . . 3-33 Fuel Injection System Injection Line Bracket and Clamp . . . . . . . 3-36 Fuel Lift Pump Service . . . . . . . . . . . . . . . . . . 3-33 Fuel System Contamination . . . . . . . . . . . . . . . . . . . . . . 3-41 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Electronic Accelerator Pedal . . . . . . . . . . . . 3-4 Electronic Injection Pump . . . . . . . . . . . . . . 3-3 Essential Tools . . . . . . . . . . . . . . . . . . . . . . 3-45 Fuel Filter-Water Separator . . . . . . . . . . . . . 3-3 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 3-4
5745159
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . 3-2 Fuel Lift Pump Inoperative . . . . . . . . . . . 12-44 Fuel Lift Pump Schematic . . . . . . . . . . . . 12-46 Fuel Manager Schematic . . . . . . . . . . . . . 12-50 Fuel Selector Valve . . . . . . . . . . . . . . . . . . 3-30 Fuel Selector Valve Schematic . . . . . . . . 12-49 Fuel Tank Selector System Inoperative . . 12-47 Fuel Tanks, Lines, and Valves . . . . . . . . . . . 3-4 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fuel Tank Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . 3-26 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Fuel Level Transmitter and Tank Access Plate Service . . . . . . . . . . . . . . . . . 3-28 Fuel Tank Vent Line Service . . . . . . . . . . . 3-29 Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . 3-24 Main/Auxiliary Tank Fuel Line . . . . . . . . . 3-29 Vent Filter Replacement . . . . . . . . . . . . . . 3-29
G
Geared Hub Input Seal Replacement . . . . . . . . . . . . . . . 9-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Side Cover Replacement . . . . . . . . . . . . . . 9-11 Spindle Bearing Adjustment . . . . . . . . . . . 9-19 Spindle Seal Replacement . . . . . . . . . . . . . 9-17 Vent Line Replacement . . . . . . . . . . . . . . . 9-24 General Body Information . . . . . . . . . . . . . . . . 10-2 General Information Auxiliary Power Point, Interior Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Auxiliary Power Studs, Exterior Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Circuit Faults . . . . . . . . . . . . . . . . . . . . . . . 12-4 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 12-5 Fuse/Relay Location and Identification . . 12-10 Ground Points . . . . . . . . . . . . . . . . . . . . . 12-13 Preliminary Checks . . . . . . . . . . . . . . . . . . 12-3 Glovebox Replacement . . . . . . . . . . . . . . . . . 10-19
3-1-02
14-6
Index
______________________________________________________________________
Glow Plug Glow Plug and Injection Nozzle . . . . . . . . 2-90 Glow Plug Removal . . . . . . . . . . . . . . . . . . 2-54 Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . 2-6 Operation and Testing . . . . . . . . . . . . . . . . . 2-6 Relay/Controller Replacement . . . . . . . . . . 3-40 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Glow Plugs Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-40 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
H
Halfshaft Boot Replacement . . . . . . . . . . . . . . 9-21 Heated Glass Both Heated Windshields Inoperative . . . 12-92 Heated Windshield Schematic . . . . . . . . . 12-93 Left Heated Windshield Inoperative . . . . 12-90 Rear Window Defroster Inoperative . . . . 12-94 Rear Window Defroster Schematic . . . . . 12-95 Right Heated Windshield Inoperative . . . 12-91 Hood Center Hood Stop Replacement . . . . . . . . 10-49 Front Hood Screen Replacement . . . . . . . 10-50 Grille and Screen Replacement . . . . . . . . 10-49 Guide Bracket Assembly Replacement . . 10-50 Hood and Hinge Replacement . . . . . . . . . 10-47 Hood Latch And Prop Rod . . . . . . . . . . . 10-43 Hood Prop Rod and Bracket Replacement 10-45 Hood Release Cable Replacement . . . . . . 10-44 Hood Retainer Bracket, L . . . . . . . . . . . . 10-50 Hood Retainer Bracket, R . . . . . . . . . . . . 10-50 Latch and Bracket Replacement . . . . . . . 10-43 Outer Hood Seal Replacement . . . . . . . . . 10-48 Right Close-Out Seal and Retainer . . . . . 10-51 Side Hood Stop Replacement . . . . . . . . . 10-49 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61 Horn Assembly Replacement . . . . . . . . . 10-53 Horn Replacement . . . . . . . . . . . . . . . . . . 12-61 Horn Schematic . . . . . . . . . . . . . . . . . . . . 12-63 Horns Inoperative . . . . . . . . . . . . . . . . . . . 12-62
3-1-02
Mounting Bracket Replacement . . . . . . . 10-53 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30 Hummer Service Hotline . . . . . . . . . . . . . . . . . . 1-2 HVAC Ambient Temperature Switch . . . . . . . . . 11-34 Auxiliary HVAC Unit A/C Drain Tube(s) Replacement . . . . 11-48 Blower Motor Replacement . . . . . . . . 11-49 Blower Switch Replacement . . . . . . . 11-47 Evaporator/Heater Core Replacement 11-49 Expansion Valve Replacement . . . . . 11-50 Heater Hose Replacement . . . . . . . . . 11-47 High-Pressure Hose Replacement . . . 11-48 Low-Pressure Hose Replacement . . . 11-49 Replacement . . . . . . . . . . . . . . . . . . . . 11-46 Blend Door Motor . . . . . . . . . . . . . . . . . . 11-42 Compressor Description . . . . . . . . . . . . . . . . . . . . . . 11-1 Condenser . . . . . . . . . . . . . . . . . . . . . . . . 11-34 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36 Defrost Duct and Windshield Nozzles Replacement . . . . . . . . . . . . . . . . . . . . . . 11-26 Drain Tube Replacement . . . . . . . . . . . . . 11-24 Essential Tools . . . . . . . . . . . . . . . . . . . . . 11-51 Heater Hose Replacement . . . . . . . . . . . . 11-22 High Pressure Cutoff Switch . . . . . . . . . . 11-35 Low Pressure Cutoff Switch . . . . . . . . . . 11-34 Main HVAC Unit . . . . . . . . . . . . . . . . . . . 11-37 Blower Motor . . . . . . . . . . . . . . . . . . . 11-38 Diverter Doors . . . . . . . . . . . . . . . . . . 11-37 Evaporator . . . . . . . . . . . . . . . . . . . . . 11-38 Expansion Valve . . . . . . . . . . . . . . . . 11-38 Heat Unit Cowl Insulation Replacement . . . . . . . . . . . . . . . . . . . 11-24 Heater Core . . . . . . . . . . . . . . . . . . . . 11-38 High Pressure Cutoff Switch . . . . . . . 11-38 Replacement . . . . . . . . . . . . . . . . . . . . 11-39 Thermostatic Cycling Switch . . . . . . . 11-38 Rear Console Replacement . . . . . . . . . . . 11-46 Receiver Dryer Replacement . . . . . . . . . . 11-21 Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . 11-34 Receiver/Dryer Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 11-21 Special Tools . . . . . . . . . . . . . . . . . . . . . . 11-52 Specifications . . . . . . . . . . . . . . . . . . . . . . 11-13
_____________________________________________________________________
Index
14-7
System Description . . . . . . . . . . . . . . . . . . 11-1 System Diagnosis . . . . . . . . . . . . . . . . . . . . 11-8 System Performance Checks . . . . . . . . . . . 11-2 Unit Service . . . . . . . . . . . . . . . . . . . . . . . 11-37 Vacuum Door Motor . . . . . . . . . . . . . . . . 11-41 Water Control Valve . . . . . . . . . . . . . . . . 11-22 Water Control Valve Replacement . . . . . 11-23 HVAC Systems HVAC Blower Schematic . . . . . . . . . . . . 12-80 HVAC Compressor Inoperative . . . . . . . . 12-75 HVAC Compressor Schematic . . . . . . . . 12-82 HVAC Main Blower Inoperative ALL BUT High . . . . . . . . . . . . . . . . . . . 12-75 HVAC Temp Blend Door/Rear Blower . . 12-81 HVAC Temperature Door Inoperative . . 12-77 Hydro-Boost Bleeding the Hydro-boost System . . . . . . . 7-13 Hydro-Boost Replacement . . . . . . . . . . . . . 7-13
I
Identification Numbers Engine Identification Number . . . . . . . . . . . 1-5 Transfer Case Identification Number . . . . . . 1-5 Transmission Identification Number . . . . . . 1-4 Vehicle Identification Number Decoding Chart . . . . . . . . . . . . . . . . . . . 1-6 Vehicle Identification Number (VIN) . . . . . 1-5 Indicator Lights Compressor/Low Pressure . . . . . . . . . . . . . 6-39 Information Labels Emission Control Information Label . . . . . . 1-3 EPA Noise Emission Label . . . . . . . . . . . . . 1-5 Safety Certification Label . . . . . . . . . . . . . . 1-4 Input Gear Bearing Replacement . . . . . . . . . . 5-156 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . 12-64 Dashpad Replacement . . . . . . . . . . . . . . . 10-15 Engine Temperature Gauge Inoperative . 12-73 Fuel Gauge Inoperative . . . . . . . . . . . . . . 12-72 Gauge Replacement . . . . . . . . . . . .10-16, 12-65 Gauges and Switches . . . . . . . . . . .10-14, 12-64
5745159
Gauges Schematic . . . . . . . . . . . . . . . . . . 12-74 Indicator Lamp Replacement . . . . . . . . . . 10-16 Instrument Panel Replacement . . . . . . . . 10-14 Low Coolant Lamp Inoperative . . . . . . . . 12-69 Oil Pressure Gauge Inoperative . . . . . . . . 12-71 Replacement . . . . . . . . . . . . . . . . . . . . . . . 12-64 Switch Replacement . . . . . . . . . . . . . . . . . 10-17 Instrument Panel, 56 way . . . . . . . . . . . . . . . . . 5-31 Intake and Exhaust Manifolds . . . . . . . . . . . . . 2-79 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Interior Trim B-Bar Replacement . . . . . . . . . . . . . . . . . 10-25 Drivers Compartment Trim Replacement . . . . . . . . . . . . . . . . . . . . . . 10-28 Floor Carpeting and Padding Replacement . . . . . . . . . . . . . . . . . . . . . . 10-34 Inner Kick Panels Replacement . . . . . . . . 10-32 Outer Kick Panel Replacement . . . . . . . . 10-33 Passengers Compartment Trim . . . . . . . . 10-26 Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-25 Station Wagon Rear Compartment Trim . 10-30 Interior Trim, Four-Passenger Soft Top . . . . . 10-65 Intermediate Steering Shaft Dust Boot Replacement . . . . . . . . . . . . . . . 8-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 In-Vehicle Service, Diesel Engine . . . . . . . . . . 2-19
J
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
K
Keys Replacement Keys . . . . . . . . . . . . . . . . . . . 1-16
3-1-02
14-8
Index
______________________________________________________________________
L
License Plate Brackets . . . . . . . . . . . . . . . . . . 10-62 Lift Gate Assembly . . . . . . . . . . . . . . . . . . . . 10-74 Lifter, Pushrod, Rocker Arm Service . . . . . . . 2-76 Lighting Systems Key/Headlight Chime Schematic . . . . . . . 12-60 Lights Schematic . . . . . . . . . . . . . . . . . . . 12-58 Lights Backup Light Switch Replacement . . . . . 10-86 Front Courtesy Light . . . . . . . . . . . . . . . . 10-85 Interior and Exterior Lighting . . . . . . . . . 10-78 Backup Light Switch . . . . . . . . . . . . . 10-84 Cargo Light . . . . . . . . . . . . . . . . . . . . 10-82 Courtesy Light . . . . . . . . . . . . . . . . . . 10-84 Domelight Replacement . . . . . . . . . . . 10-82 Front Turn Signal Light Replacement 10-80 Identification Light Replacement . . . 10-79 Maplight Replacement . . . . . . . . . . . . 10-83 Optional Trouble Light Replacement 10-84 Rear Turn Signal Light Replacement 10-81 Service Headlight Assembly . . . . . . . 10-78 Service Headlight Electrical Connector and Grommet Replacement . . . . . . . 10-85 Side Marker Light Assembly . . . . . . . 10-79 Side Marker Light Lens and Lamp . . 10-79 Underhood Light Replacement . . . . . 10-84 Rear Seat Courtesy Light . . . . . . . . . . . . . 10-83 Stoplight Switch Replacement . . . . . . . . . 10-86 Load Barrier and Mounting Brackets . . . . . . 10-25 Low Coolant Sensor . . . . . . . . . . . . . . . . . . . . . 4-12 Lubricants/Sealants/Coolant . . . . . . . . . . . . . . . 2-3 Lubrication and Maintenance Items . . . . . . . . . 1-25 Axle and Geared Hub . . . . . . . . . . . . . . . . . 1-27 Body Lubrication Points . . . . . . . . . . . . . . 1-30 Cooling System Fluid Level Check . . . . . . 1-29 Engine Oil and Filter Change . . . . . . . . . . 1-25 Engine Oil Level . . . . . . . . . . . . . . . . . . . . 1-25 Master Cylinder Fluid Level Check . . . . . . 1-29 Power Steering Fluid . . . . . . . . . . . . . . . . . 1-29 Steering and Suspension Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Transfer Case Fluid . . . . . . . . . . . . . . . . . . 1-26
3-1-02
Transmission Fluid . . . . . . . . . . . . . . . . . . . 1-26 Universal and Slip Joint Lubrication . . . . . 1-27
M
Main Fuel Tank Fuel Level Transmitter . . . . . . . . . . . . . . . . 3-25 Tank Cleaning . . . . . . . . . . . . . . . . . . . . . . 3-25 Mainshaft Pilot Bearing Replacement . . . . . . 5-156 Maintenance Inspection Groups . . . . . . . . . . . . . . . . . . . 1-21 Maintenance Schedule . . . . . . . . . . . . . . . . 1-21 Scheduled Maintenance Chart . . . . . . . . . . 1-22 Maintenance Items Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . 1-29 Wheels/Tires/CTIS . . . . . . . . . . . . . . . . . . 1-29 Metric System and Equivalents . . . . . . . . . . . . 1-15 Metric Conversions . . . . . . . . . . . . . . . . . . 1-15 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Lighted Visor Mirror Replacement . . . . . 10-84 Power Mirrors . . . . . . . . . . . . . . . . . . . . . 10-35 Rearview Mirror Replacement . . . . . . . . . 10-36 Side Mirror Replacement . . . . . . . . . . . . . 10-35
O
OBD II Diagnostic Trouble Codes . . . . . . . . . P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage . . . . . . . . . . . P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage . . . . . . . . . . P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage . . . . . . . . . . . P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage . . . . . . . . . . P0121 Accelerator Pedal Position (APP) Sensor 1 Circuit Performance . . . . . . . . . . P0122 Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage . . . . . . . . . P0123 Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage . . . . . . . . . 5-23 5-34 5-36 5-38 5-40 5-42 5-44 5-46
_____________________________________________________________________
Index
14-9
P0126 Engine Coolant Temperature Insufficient For Stable Operation . . . . . . 5-48 P0182 Fuel Temperature Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . 5-50 P0183 Fuel Temperature Sensor Circuit High Voltage . . . . . . . . . . . . . . . . 5-52 P0215 Engine Shutoff Solenoid Control Circuit . . . . . . . . . . . . . . . . . . . . . 5-54 P0216 Injection Timing Control System . . 5-56 P0219 Engine Overspeed Condition . . . . . 5-59 P0220 Accelerator Pedal Position (APP) Sensor 2 Circuit . . . . . . . . . . . . . . 5-60 P0221 Accelerator Pedal Position (APP) Sensor 2 Circuit Performance . . . . 5-62 P0222 Accelerator Pedal Position (APP) Sensor 2 Circuit Low Voltage . . . 5-64 P0223 Accelerator Pedal Position (APP) Sensor 2 Circuit High Voltage . . . 5-66 P0225 Accelerator Pedal Position (APP) Sensor 3 Circuit . . . . . . . . . . . . . . 5-68 P0226 Accelerator Pedal Position (APP) Sensor 3 Circuit Performance . . . . .5-70, 5-71 P0227 Accelerator Pedal Position (APP) Sensor 3 Circuit Low Voltage . . . . . . . . 5-72 P0228 Accelerator Pedal Position (APP) Sensor 3 Circuit High Voltage . . . . . . . . 5-74 P0231 Fuel Lift Pump Secondary Circuit Low Voltage . . . . . . . . . . . . . . . . 5-76 P0236 Turbocharger (TC) Boost System . . 5-79 P0237 Turbocharger (TC) Boost Sensor Circuit Low Voltage . . . . . . . . . . 5-82 P0238 Turbocharger (TC) Boost Sensor Circuit High Voltage . . . . . . . . . 5-84 P0251 Injection Pump Cam System . . . . . 5-87 P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults . . . . . . . 5-90 P0300 Engine Misfire Detected . . . . . . . . . 5-92 P0301-P0308 Specific Cylinder Misfire Detected . . . . . . . . . . . . . . . . . . . 5-94 P0335 Crankshaft Position (CKP) Sensor Circuit Performance . . . . . . . . . . 5-96 P0370 Timing Reference High Resolution 5-99 P0380 Glow Plug Circuit Performance . . 5-102 P0501 Vehicle Speed Sensor Circuit . . . . 5-106
5745159
P0567 Cruise Resume Circuit . . . . . . . . . 5-109 P0568 Cruise Set Circuit . . . . . . . . . . . . . 5-111 P0571 Cruise Brake Switch Circuit . . . . . 5-113 P0601, P0602 and P0606 Internal PCM Errors . . . . . . . . . . . . . . . . . . . . . . 5-116 P1125 Accelerator Pedal Position (APP) System . . . . . . . . . . . . . . . . . . . . 5-117 P1214 Injection Pump Timing Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-119 P1216 Fuel Solenoid Response Time Too Short . . . . . . . . . . . . . . . . . . 5-120 P1217 Fuel Solenoid Response Time Too Long . . . . . . . . . . . . . . . . . . . 5-122 P1218 Injection Pump Calibration Circuit 5-124 P1627 Analog to Digital Performance . . . 5-126 P1635 PCM 5 Volt Reference Low . . . . . 5-127 P1641 Malfunction Indicator Lamp (MIL) Control Circuit . . . . . . . . . . . . . . 5-129 P1643 Wait to Start Lamp Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131 P1654 Check Throttle Circuit . . . . . . . . . 5-133 P1656 Wastegate Solenoid Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135 Off Road Light Package . . . . . . . . . . . . . . . . . 13-31 Oil Filter Adapter Service . . . . . . . . . . . . . . . . . . . . . 2-78 Filter, Adapter, Fittings . . . . . . . . . . . . . . . 2-87 Oil Filter/Adapter/Oil Pressure Sending Unit . 2-57 Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . 2-58 Oil Pump Oil Pump and Drive Removal . . . . . . . . . . 2-58 Oil Pump and Pump Drive Service . . . . . . 2-77 Oil Pump Drive . . . . . . . . . . . . . . . . . . . . . 2-22 Oil Pump Pressure Test . . . . . . . . . . . . . . . . 2-7 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Oil Pump, Oil Pan, Flywheel Installation . . . . 2-84
P
Paint and Trim Colors . . . . . . . . . . . . . . . . . . . 1-16 PCM, 24 Way, Brown . . . . . . . . . . . . . . . . . . . 5-38 PCM, 32 Way, Blue . . . . . . . . . . . . . . . . . . . . . 5-36
3-1-02
14-10
Index _____________________________________________________________________
PCM, 32 Way, Brown . . . . . . . . . . . . . . . . . . . 5-34 Piston/Connecting Rod Installation and Bearing Fit . . . . . . . . . . . . 2-83 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Piston/Connecting Rod Overhaul . . . . . . . . . . 2-67 Piston and Connecting Rod Assembly . . . . 2-69 Piston Ring Installation . . . . . . . . . . . . . . . 2-70 Piston Selection and Fit . . . . . . . . . . . . . . . 2-68 Power Door Locks Front Door Harness Replacement . . . . . 12-120 Power Locks Cargo Door Lock Inoperative . . . . . . . . 12-113 General Replacement . . . . . . . . . . . . . . . 12-102 Keyless Entry & Theft Detterent System Operating Instructions . . . . . . 12-105 Keyless Entry Programming . . . . . . . . . 12-108 Keyless Entry System Features . . . . . . . 12-106 Power Locks HMC4, XLC2 , HMSB . . 12-117 Power Locks HMCS W/ Remote Entry . 12-115 Power Locks Inoperative . . . . . . . . . . . . 12-110 Rear Door and Jumper Harness . . . . . . . 12-121 Remote Entry Module Power/Ground . . 12-119 Remote Entry System Inoperative . . . . . 12-114 Slant Door Lock Inoperative . . . . . . . . . 12-112 Power Mirrors Ambient Temperature Sensor . . . . . . . . 12-131 Auto-Dimming Compass Mirror Calibration and Zone Adjustments . . . 12-129 Auto-Dimming Rear View Mirror . . . . . 12-129 Compass Mirror Display Inoperative . . . 12-132 Compass Mirror Schematic . . . . . . . . . . 12-133 Power Side Mirror . . . . . . . . . . . . . . . . . 12-134 Power Steering Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42 Cleaning and Inspection . . . . . . . . . . . . . . . 8-41 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 8-39 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39 Power Steering Pump and Bracket . . . . . . . . . 2-50 Power Window and Door Locks Front Door Harness Replacement . . . . . 12-123 Power Windows Power Window Schematic . . . . . . . . . . . 12-101
Power Windows Inoperative, All Windows . . . . . . . . . . . . . . . . . . . . . . . . 12-96 Power Windows and Door Locks Rear Door Harness Replacement . . . . . . 12-126 Powertrain Control Module . . . . . . . . . . . . . . . . 3-6 Powertrain Control Module (PCM) . . . . . . . . . . 5-2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Reprogramming . . . . . . . . . . . . . . . . . . . . . . 5-2 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 TDC Offset . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Verifying Vehicle Repair . . . . . . . . . . . . . . . 5-2 Pressure Hose Torque Specifications . . . . . . . 11-17 Propeller Shaft Torque Specifications . . . . . . . . . . . . . . . 5-169 Pushrod, Rocker Arm and Shaft Installation . . 2-90
R
Radiator Lower Hose Replacement . . . . . . . . . . . . . . 4-9 Lower Tube Assembly Replacement . . . . . 4-10 Rear Support Bracket . . . . . . . . . . . . . . . . . . 4-7 Shroud Shield Assembly Replacement . . . . 4-7 Upper Hose Replacement . . . . . . . . . . . . . . 4-9 Radiator and Fan Shroud Assembly . . . . . . . . . 4-4 Rear License Plate Bracket Replacement . . . 10-62 Rear Main Oil Seal Replacement . . . . . . . . . . . 2-29 Rear Main Seal Installation . . . . . . . . . . . . . . . 2-82 Rear Striker Assembly Replacement . . . . . . . 10-61 Rear Support Bow Bracket, Station Wagon . 10-61 Rear Vertical Door Door Frame and Seal Replacement . . . . . 10-77 Door Handle Replacement . . . . . . . . . . . . 10-75 Door Latch and Latch Rod Replacement . 10-75 Door Replacement . . . . . . . . . . . . . . . . . . 10-74 Door Stop Replacement . . . . . . . . . . . . . . 10-77 Window Replacement . . . . . . . . . . . . . . . 10-74 Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Roadside Emergency Equipment . . . . . . . . . . 10-64
3-1-02
____________________________________________________________________
Index
14-11
Rocker Arm Cover Removal . . . . . . . . . . . . . . . . . . . . . 2-54 Cover Service . . . . . . . . . . . . . . . . . . . . . . . 2-30 Shaft and Pushrod Removal . . . . . . . . . . . . 2-54 Shaft and Pushrod Service . . . . . . . . . . . . . 2-33 Rocker Cover Installation . . . . . . . . . . . . . . . . 2-91 Rocker Panel Protection Replacement . . . . . . 13-18 Roof Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24 Clamp Replacement . . . . . . . . . . . . . . . . . 13-26 Crossbar Replacement . . . . . . . . . . . . . . . 13-25 End Replacement . . . . . . . . . . . . . . . . . . . 13-25 Runflat Compressor Belt Replacement . . . . . . . . . . 6-12 Running Board Replacement . . . . . . . . . . . . . 13-21
S
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Non-approved accessories . . . . . . . . . . . . . . 1-1 Warnings, cautions, and notes . . . . . . . . . . . 1-1 Scan Tool Diagnosis . . . . . . . . . . . . . . . . . . . . 3-11 Seat Belts Seat Belt Assembly Replacement . . . . . . 10-22 Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37 Seats Front Seats . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Reclining Seat Replacement . . . . . . . . . . 10-24 Standard Seat Pedestal Repair . . . . . . . . . 10-23 Sensor and Switch Service . . . . . . . . . . . . . . . . 3-40 Sensor, Oil Pressure Switch, and Transmitter . 3-40 Serpentine Belt Removal . . . . . . . . . . . . . . . . . 2-49 Serpentine Belt Replacement . . . . . . . . . . . . . . 4-16 Shift Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-135 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-132 Shift Linkage Adjustment . . . . . . . . . . . . . . . 5-136 Slant Back Glass and Body . . . . . . . . . . . . . . . . . . . . 10-91 Slant Door and Torsion Assembly Replacement . . . . . . . . . . . . . . . . . . . . . 10-87
5745159
Slant Door Handle, Latch, And Lock Actuator . . . . . . . . . . . . . . . . . . . . 10-88 Wiper Motor and Components . . . . . . . . . 10-90 Soft Top Mounting Components and Accessories . 10-67 Soft Top Support/Roll Cage Assembly . . 10-71 Spare Tire Carrier Cargo DeckMounted . . . . . . . . . . . . . . . . 13-13 Swing-Away . . . . . . . . . . . . . . . . . . . . . . 13-10 Specifications Bolt Identification and Torque Limits (Dry) . . . . . . . . . . . . . . . . . . . . . . . 1-13 Bolt Identification and Torque Limits (Wet) . . . . . . . . . . . . . . . . . . . . . . 1-14 Cooling System . . . . . . . . . . . . . . . . . . . . . . 1-7 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Dimensions . . . . . . . . . . . . . . . . . . . 1-7 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . 1-10 Fuel/Air System . . . . . . . . . . . . . . . . . . . . . . 1-7 General A/C Refrigerant and Compressor Oil . 1-25 Air Conditioner . . . . . . . . . . . . . . . . . . . 1-9 Axle/Differential . . . . . . . . . . . . . . . . . . 1-8 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Body Lubrication . . . . . . . . . . . . . . . . . 1-24 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . 1-24 Engine Coolant . . . . . . . . . . . . . . . . . . . 1-24 Engine Oil . . . . . . . . . . . . . . . . . . . . . . 1-24 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Front/Rear Axle and Geared Hub . . . . 1-24 Geared Hub . . . . . . . . . . . . . . . . . . . . . . 1-8 Recommended Fuel . . . . . . . . . . . . . . . 1-24 Service Brake Caliper (Front) . . . . . . . . 1-9 Service/Parking Brake Caliper (Rear) . . 1-9 Service/Parking Brake Rotor (Rear) . . . 1-9 Steering Gear and Pump Fluid . . . . . . . 1-24 Steering Linkage and Suspension . . . . 1-24 Steering System . . . . . . . . . . . . . . . . . . . 1-9 Transfer Case . . . . . . . . . . . . . . . . . . . . . 1-8 Transmission . . . . . . . . . . . . . . . . . . . . . 1-8 Transmission/Transfer Case . . . . . . . . . 1-24 Wheels and Tires . . . . . . . . . . . . . . . . . . 1-9 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Governed Speed . . . . . . . . . . . . . . . . . . . . . . 1-7
3-1-02
14-12
Index _____________________________________________________________________
Lubricating System . . . . . . . . . . . . . . . . . . . 1-7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Vehicle Dimensions . . . . . . . . . . . . . . . . . . 1-11 Vehicle Weights . . . . . . . . . . . . . . . . . . . . . 1-10 Speed Sensor Replacement . . . . . . . . . . . . . . . 7-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Speedometer/Odometer Replacement . . . . . . 10-17 Splash Shield (Engine) Replacement . . . . . . . 10-52 Splash Shield Support Bracket Replacement . . 9-51 Spring Seat Replacement . . . . . . . . . . . . . . . . . 9-53 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 12-37 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31 Steering Specifications . . . . . . . . . . . . . . . . . . . 8-44 Steering Gear Adjustment Preload Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 Steering Pump Flow Rates and Operating Pressures . . . . . . . . . . . . . . . . . 8-44 Torque Specifications . . . . . . . . . . . . . . . . 8-44 Steering Stop Adjustment . . . . . . . . . . . . . . . . 6-29 Steering System Center Link Replacement . . . . . . . . . . . . . . 8-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . 8-45 Idler Arm Replacement . . . . . . . . . . . . . . . . 8-6 Pitman Arm Replacement . . . . . . . . . . . . . . 8-2 Power Steering Cooler and Hose Replacement . . . . . . . 8-17 Fluid Reservoir Replacement . . . . . . . . 8-16 Gear Adjustments . . . . . . . . . . . . . . . . . 8-36 Gear Assembly and Adjustment . . . . . 8-30 Gear Cleaning and Inspection . . . . . . . 8-28 Gear Disassembly and Overhaul . . . . . 8-23 Hydraulic System Pressure . . . . . . . . . 8-16 Power Steering Gear Service . . . . . . . . 8-18 Pressure Test . . . . . . . . . . . . . . . . . . . . 8-22 Pump and Pulley Replacement . . . . . . 8-15 Purging Air from the System . . . . . . . . 8-22 System Diagnosis Charts . . . . . . . . . . . 8-19 System Flushing . . . . . . . . . . . . . . . . . . 8-44 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 8-46 Steering Column Ignition Interlock Cable Replacement . 8-11
3-1-02
Ignition Switch Lock Cylinder . . . . . . . 8-11 Lock and Switch Housing . . . . . . . . . . . 8-8 Multi-Switch Replacement . . . . . . . . . . 8-8 Steering Column Repair . . . . . . . . . . . . . 8-9 Steering Column Replacement . . . . . . . 8-7 Steering Gear Replacement . . . . . . . . . 8-12 Steering Wheel Hub/ Column Shroud . 8-10 Steering Wheel Replacement . . . . . . . . . . . . 8-6 Tie Rod End Replacement . . . . . . . . . . . . . . 8-4 Tie Rod Replacement . . . . . . . . . . . . . . . . . . 8-5 Surge Tank Overflow Hose Replacement . . . . . . . . . . . 4-11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Tank-to-Lower Radiator Tube Hose . . . . . 4-12 Tank-to-Radiator Vent Hose . . . . . . . . . . . . 4-8 Suspension System Control Arm Bushing Replacement . . . . . . . 9-7 Frame Extension Replacement . . . . . . . . . 9-47 Front Bumper and Towing Brackets . . . . . 9-45 Front Bumper Mounting Bracket . . . . . . . . 9-46 Lower Ball Joint Replacement . . . . . . . . . . . 9-5 Lower Control Arm Replacement . . . . . . . . 9-7 Radius Rod Replacement . . . . . . . . . . . . . . . 9-3 Rear Upper Control Arm Bracket . . . . . . . 9-58 Stabilizer Bar Link Replacement . . . . . . . . . 9-2 Stabilizer Bar Replacement . . . . . . . . . . . . . 9-2 Upper Ball Joint Replacement . . . . . . . . . . . 9-4 Upper Control Arm Replacement . . . . . . . . 9-5
T
Tachometer Replacement . . . . . . . . . . . . . . . . 10-19 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Chain Brackets Replacement . . . . . . . . . . 10-72 Chain Replacement . . . . . . . . . . . . . . . . . 10-73 Tailgate and Seals Replacement . . . . . . . 10-72 Tech 2 Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Information . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Thermostat Bypass Hose Replacement . . . . . . . 4-8 Thermostat Replacement . . . . . . . . . . . . . . . . . 4-13
____________________________________________________________________
Index
14-13
Timing Chain/Drive Sprockets/Drive Gear . . . 2-57 Timing Chain-Sprocket-Gear Installation . . . . 2-85 Tire Jack Jack and Triangle Warning Kit Hold-Down Bracket Replacement . . . 10-64 Tone Wheel Replacement . . . . . . . . . . . . . . . . 7-50 Torque Converter/Oil Pump Seal . . . . . . . . . . 5-127 Torsional Damper . . . . . . . . . . . . . . . . . . . . . . 2-21 Torsional Damper/Crankshaft Pulley . . . . . . . 2-93 Towing Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Conventional Towing Procedures . . . . . . . 1-19 Hoisting the Vehicle . . . . . . . . . . . . . . . . . 1-17 Recommendations . . . . . . . . . . . . . . . . . . . 1-18 Recreational . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Vehicle Lifting/Jacking Points . . . . . . . . . . 1-17 When Keys Are Not Available . . . . . . . . . 1-19 Towing, Lifting, Jump Starting . . . . . . . . . . . . 1-17 Trailer Hitch Replacement . . . . . . . . . . . . . . . 13-20 Trailer Towing Connector . . . . . . . . . . . . . . . 13-19 Transfer Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5-158 Cleaning and Inspection . . . . . . . . . . . . . . 5-153 Description . . . . . . . . . . . . . . . . . . . . . . . . 5-137 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5-139 Disassembly and Overhaul . . . . . . . . . . . 5-145 Fluid Change . . . . . . . . . . . . . . . . . . . . . . 5-143 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . 5-138 Guide Cable Replacement . . . . . . . . . . . . 5-142 Identification . . . . . . . . . . . . . . . . . . . . . . 5-138 Identification Number . . . . . . . . . . . . . . . . . 1-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-144 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 5-138 Operating Ranges . . . . . . . . . . . . . . . . . . . 5-139 Recommended Lubricant . . . . . . . . . . . . . 5-138 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144 Shift Rod Service . . . . . . . . . . . . . . . . . . . 5-141 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139 Speed Sensor and Switch Replacement . . 5-142 Torque Specifications . . . . . . . . . . . . . . . 5-169 Vent Line Replacement . . . . . . . . . . . . . . 5-141
Transmission Cooler Line and Bypass Valve Service . . 5-121 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Line Pressure Test . . . . . . . . . . . . . . . . 5-15 Pressure Control Solenoid Test . . . . . . 5-15 Road Test . . . . . . . . . . . . . . . . . . . . . . . 5-12 Electronic Shift Control Components . . . . . 5-3 Engine Sensor Inputs . . . . . . . . . . . . . . . . . . 5-9 Essential Tools . . . . . . . . . . . . . . . . . . . . . 5-170 Fill Tube Replacement . . . . . . . . . . . . . . . 5-121 Fluid And Filter Replacement . . . . . . . . . 5-120 Fluid Temperature Sensor . . . . . . . . . . . . . . 5-6 Gear Ranges . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Gear Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Input and Output Speed Sensors . . . . . . . . . 5-6 Input Speed Sensor Replacement . . . . . . . 5-136 Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-130 Park Lock Component Service . . . . . . . . 5-125 Park/Neutral Position Switch Replacement . . . . . . . . . . . . . . . . . . . . . 5-133 Pressure Control Solenoid . . . . . . . . . . . . . . 5-8 Rear Mount Replacement . . . . . . . . . . . . 5-136 Recommended Fluid . . . . . . . . . . . . . . . . . 5-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127 Scan Tool Diagnosis . . . . . . . . . . . . . . . . . 5-18 Serviceability . . . . . . . . . . . . . . . . . . . . . . . 5-11 Shift Rod Replacement . . . . . . . . . . . . . . 5-135 Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . 5-7 Shifter Boot Cover Replacement . . . . . . . 5-134 Special Tools . . . . . . . . . . . . . . . . . . . . . . 5-171 Torque Converter . . . . . . . . . . . . . . . . . . . . . 5-9 Torque Converter Clutch Solenoid . . . . . . . 5-8 Torque Specifications . . . . . . . . . . . . . . . 5-169 Valve Body Switch and Solenoid Service 5-124 Vent Line Service . . . . . . . . . . . . . . . . . . 5-122 Warning Lamps . . . . . . . . . . . . . . . . . . . . . 5-13 Transmission Identification . . . . . . . . . . . . . . . . 1-4 Transmission Passthrough, 20 way . . . . . . . . . 5-41 Transmission, 10 Way, Black . . . . . . . . . . . . . 5-40 Transmission, 10 Way, Grey . . . . . . . . . . . . . . 5-39
5745159
3-1-02
14-14
Index _____________________________________________________________________
Turbocharger Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Diagnosis . . . . . . . . . . . . . . . . Turbocharger and Center Manifold Removal . Turbocharger and Intake Manifold . . . . . . . . .
2-18 2-17 2-16 2-17 2-16 2-15 2-52 2-93
U
Underbody Protection . . . . . . . . . . . . . . . . . . Front Shield Replacement . . . . . . . . . . . . Intermediate Shield Replacement . . . . . . Rear Shield Replacement . . . . . . . . . . . . . Skid Plate Replacement . . . . . . . . . . . . . . Transfer Case Shield Replacement . . . . . 13-14 13-15 13-16 13-17 13-14 13-17
V
Vacuum Pump Service . . . . . . . . . . . . . . . . . . . 2-44 Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Vehicle Identification Number Decoding Chart . . . . . . . . . . . . . . . . . . . . . . 1-6 Vehicle Identification Number (VIN) . . . . . . . . 1-5 Visor Replacement . . . . . . . . . . . . . . . . . . . . . 10-34
W
Water Crossover Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Water Crossover Service . . . . . . . . . . . . . . . . . 4-15 Water Leak Detection and Repair . . . . . . . . . 10-12
3-1-02
Water Pump Inlet Hose Replacement . . . . . . . . . . . . . . . 4-11 Water Pump and Adapter Plate . . . . . . . .4-13, 4-14 Water Pump and Adapter Plate Installation . . . 2-87 Water Pump and Adapter Plate Removal . . . . 2-56 Weathercap Replacement . . . . . . . . . . . . . . . . . 3-22 Wheels and Tires Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Checking Wheel Alignment . . . . . . . . . . . . 6-25 One-Piece Aluminum Wheel and Two-Piece Runflat Service . . . . . . . . . . . 6-12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 6-56 Tire, Two-Piece Wheel, and Runflat Replacement . . . . . . . . . . . . . . . . 6-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-20 Wheel Alignment . . . . . . . . . . . . . . . . . . . . 6-22 Wheel Alignment Correction . . . . . . . . . . . 6-26 Wheel and Tire Assembly Replacement . . . 6-1 Wheel Half Stud Replacement . . . . . . . . . . 6-10 Wheel Runout Inspection . . . . . . . . . . . . . . 6-20 Winch Assembly Repair . . . . . . . . . . . 9-72, 9-81, 13-3 Cable Replacement . . . . . . . . . 9-71, 9-80, 13-2 Electric Thermal Switch/Brush Assembly . . . . . . . . . . . . . . . 9-76, 9-85, 13-7 Replacement . . . . . . . . . . . . . . . 9-70, 9-79, 13-1 Troubleshooting . . . . . . . . . . . . . . . . .9-70, 13-1 Windshield . . . . . . . . . . . . . . . . . . . . . .12-83, 12-84 Assembly Maintenance . . . . . . . . . . . . . . 10-54 Glass and Weatherstrip Replacement . . . 10-53 Heated Windshield . . . . . . . . . . . . . . . . . . 10-55 Reservoir and Pump Assembly . . . . . . . . 10-58 Washer Hoses Replacement . . . . . . . . . . . 10-58 Washer Nozzle Replacement . . . . . . . . . . 10-58 Washer System and Components . . . . . . . 10-58 Windshield Assembly . . . . . . . . . . . . . . . 10-53 Wiper Jumper Harness Replacement . . . . 10-58 Wiper Linkage Replacement . . . . . . . . . . 10-57 Wiper Motor Assembly Replacement . . . 10-56 Wiper Pivot Replacement . . . . . . . . . . . . 10-57 Wiper System and Components . . . . . . . . 10-56
____________________________________________________________________
Index
14-15
Wipers Rear Window Wiper Inoperative . . . . . . . Rear Wiper Motor Schematic . . . . . . . . . Windshield Wiper Motor Inoperative All Speeds . . . . . . . . . . . . . . . . . . . . . . . Windshield Wipers Intermittent Speeds Inoperative . . . . . . . . . . . . . . . . Wiper/Washer Schematic . . . . . . . . . . . . .
12-87 12-89 12-83 12-84 12-86
5745159
3-1-02
14-16
Index _____________________________________________________________________

2000 Hummer Service Manual

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2000 SERVICE MANUAL

Fuel, Emissions and Exhaust

Wheels and Tires/ Central Tire Ination System

Axles/Suspension and Frame

Heating/Ventilation/ Air Conditioning (HVAC)

Section 1 General Information, Lubrication and Maintenance

General Information, Lubrication and Maintenance

Service Manual Revisions

HUMMER SERVICE HOTLINE

Transfer Case Hotline

ABOUT THIS MANUAL

General Information, Lubrication and Maintenance

EMISSION CONTROL INFORMATION LABEL

Figure 1-1: Emission Control Information Label Information

General Information, Lubrication and Maintenance

SAFETY CERTIFICATION LABEL

Figure 1-3: Safety Certification Label for 10,300 lb GVWR Vehicles

Figure 1-4: Safety Certification Label for 10,800 lb GVWR Vehicles

TRANSMISSION I.D. PLATE

Figure 1-5: Transmission I.D. Plate Location

General Information, Lubrication and Maintenance

EPA NOISE EMISSION CONTROL INFORMATION LABEL

TRANSFER CASE SERIAL NUMBER (ON ID PLATE)

Figure 1-7: Transfer Case I.D. Plate Location

ENGINE SERIAL NUMBER LABEL

Figure 1-8: Engine I.D. Label Location

VEHICLE IDENTIFICATION NUMBER (VIN)

Figure 1-6: EPA Noise Emission Control Information Label Location

TRANSFER CASE IDENTIFICATION

Figure 1-9: VIN Plate Location

General Information, Lubrication and Maintenance

Digit 1 Manufacturing Country

Digit 12 through 17 Sequential, Assigned Serial Number

Vehicle Identication Number Decoding Chart

Class 3, 10,001 lb - 14,000 lb (4,541 kg - 6,356 kg)

General Information, Lubrication and Maintenance

General Information, Lubrication and Maintenance

General Information, Lubrication and Maintenance

Service Brake Caliper (Front):

Service/Parking Brake Caliper (Rear):

Service/Parking Brake Rotor:

Wheels and Tires:

General Information, Lubrication and Maintenance ________________

General Information, Lubrication and Maintenance

General Information, Lubrication and Maintenance ________________

General Information, Lubrication and Maintenance

BOLT IDENTIFICATION AND TORQUE LIMITS (DRY*)

Bolt Head ID Marks and SAE GRADE

General Information, Lubrication and Maintenance ________________

BOLT IDENTIFICATION AND TORQUE LIMITS (WET*)

Bolt Head ID Marks and SAE Grade

General Information, Lubrication and Maintenance

U.S./METRIC CONVERSIONS AND EQUIVALENTS Metric Conversions

U.S. Standard Conversions

General Information, Lubrication and Maintenance ________________

PAINT AND TRIM COLORS

Top Coat Description

R19 W8 B9 Y20 P17 W14 S15 C22 P33 G23

Figure 1-10: Key Code Location

General Information, Lubrication and Maintenance