Hummer H1 (2002) manual

H1 HUMMER SER VICE MANU AL COMMERCIAL HUMMER ® AM GENERAL CORPORA TION 408 South Byrkit A venue P. O . B o x 7 2 8 Mishaw aka, Indiana 46546-0728 AM General Number 05745159 Copyright © 2002 All Rights Reser ved. Pr inted in U.S.A. T ABLE OF CONTENTS General Information 1 Eng ine 2 Fuel, Emissions and Exhaust 3 Cooling System 4 Tr a n sm i s s i o[...]

________________________________________________________________________________ 1-1 ¨ 05745159 Section 1 General Inf or mation, Lubrication and Maintenance T ABLE OF CONTENTS Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1-2 General Information, Lubrication and Maintenance _________________ ¨ CARBON MONO XIDE WA R N I N G : C a r b o n m o n o x i d e ( e x h a u s t g a s e s ) c a n b e fatal. WA R N I N G : B r a i n d a m a g e o r d e a t h c a n r e s u l t f r o m heavy exposure to carbon monoxide. The f ollowing pre- cautions must be follo wed to ensure pe[...]

________________ General Information, Lubrication and Maintenance 1-3 ¨ 05745159 EMISSION CONTROL INF ORMATION 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). [...]

1-4 General Information, Lubrication and Maintenance _________________ ¨ SAFETY CERTIFICATION LABEL The safety certification label is located on the driver side B- pillar (door latch post) (Figures 1-2, 1-3, and 1-4). The label is required by the National Highway Traffic Safety Administra- tion and includes a tamper-proof feature. If the label is [...]

________________ General Information, Lubrication and Maintenance 1-5 ¨ 05745159 EP A NOISE EMISSION CONTROL INFORMA- TION LABEL The EPA noise emission control information label is located on the passenger side B-pillar (door latch post). The label is re- quired by the EPA and includes a tamper-proof feature. If the label is tampered with, a void [...]

1-6 General Information, Lubrication and Maintenance _________________ ® 1 3 7 Y A 89 3 4 Y E 000001 Digit 1 Manufacturing Country Digit 2 Company/Make Digit 3 Vehicle Type Digit 4 Engine Type Digit 5 Transmission/Drive Digit 6 and 7 Truck Line Series Model, Body Type Digit 12 Sequential, Assigned Serial Number Digit 11 Plant Code Digit 10 Model Y[...]

________________ General Information, Lubrication and Maintenance 1-7 ¨ 05745159 COMPONENT DATA Engine: Manufacturer ................................................................................................................................................................. GM Powertrain Model ..................................................[...]

1-8 General Information, Lubrication and Maintenance _________________ ¨ Thermostat: Starts to Open .......................................................................................................................................................... 190¡ F (88¡ C) Fully Open ..................................................................[...]

________________ General Information, Lubrication and Maintenance 1-9 ¨ 05745159 Service Brake Caliper (Front): Manufacturer ................................................................................................................................................................... Kelsey-Hayes Piston Diameter ...............................[...]

1-10 General Information, Lubrication and Maintenance ________________ ¨ FLUID CAPACITIES Cooling System .................................................................................................................................................................. 26 qt (25 L) Engine: Crankcase (oil pan) only ...................................[...]

_______________ General Information, Lubrication and Maintenance 1-11 ¨ 05745159 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) [...]

1-12 General Information, Lubrication and Maintenance ________________ ¨ ABBREVIATIONS ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Brake System A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternating Current AMPÊ .[...]

_______________ General Information, Lubrication and Maintenance 1-13 ¨ 05745159 BOLT IDENTIFICATION AND T ORQUE LIMITS (DR Y*) * A phosphate and oil bolt is considered dry Bolt Head ID Marks and SAE GRADE BOL T SIZE SAE GRADE NO. 1 OR 2 SAE GRADE NO. 5 SAE GRADE NO. 6 OR 7 SAE GRADE NO. 8 DIA. INCHES MILLI- METERS THREADS PER INCH POUND FEET (NEW[...]

1-14 General Information, Lubrication and Maintenance ________________ ¨ BOLT IDENTIFICATION AND T ORQUE LIMITS (W ET*) *A cadmium plated bolt is considered wet. Bolt Head ID Marks and SAE Grade BOL T SIZE SAE GRADE NO. 1 OR 2 SAE GRADE NO. 5 SAE GRADE NO. 6 OR 7 SAE GRADE NO. 8 DIA. INCHES MILLI- METERS THREADS PER INCH POUND FEET (NEWTON- METERS[...]

_______________ General Information, Lubrication and Maintenance 1-15 ¨ 05745159 U.S./METRIC CON VERSIONS AND EQUIV ALENTS Metric Conv ersions MULTIPLY BY TO GET INCHES 2.54 CENTIMETERS FEET 0.305 METERS MILES 1.609 KILOMETERS SQUARE INCHES 6.451 SQUARE CENTIMETERS CUBIC INCHES 16.39 CUBIC CENTIMETERS FLUID OUNCES 29.573 MILLILITERS PINTS 0.473 LI[...]

1-16 General Information, Lubrication and Maintenance ________________ ¨ PAINT AND T RIM COLOR S 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. REPLACEMENT K E YS Replacement keys ca[...]

_______________ General Information, Lubrication and Maintenance 1-17 ¨ 05745159 T O WING, LIFTING, JUMP STARTING V ehicle Lifting/Jac king P oints 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 case[...]

1-18 General Information, Lubrication and Maintenance ________________ ¨ T o wing 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 th[...]

_______________ General Information, Lubrication and Maintenance 1-19 ¨ 05745159 Con ventional T owing Procedures Front Towing 1. Loop chains around lo wer control arms and secure to tow sling (Figure 1-14). 2. Insert 4Ó x 4Ó x 48Ó length of wood between bumper and sling chains (Figure 1-14). 3. Raise front end and verify that sling is firmly p[...]

1-20 General Information, Lubrication and Maintenance ________________ ¨ 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: ¥ [...]

_______________ General Information, Lubrication and Maintenance 1-21 ¨ 05745159 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.[...]

1-22 General Information, Lubrication and Maintenance ________________ ® Maintenance Inspection Group B: • Inspect fuel injection pump, lines, and fittings for leaks or damage. • Check battery voltage and condition. • Inspect serpentine belt condition. • Inspect exhaust system and shields. • Inspect and rotate tires. • Inspect halfsha[...]

_______________ General Information, Lubrication and Maintenance 1-23 ® 05745159 ❐ Change transmission fi lter . ❐ Check items in Maintenance Groups A, B, and C. ❐ Change geared hub oil. ❐ Change axle oil. ❐ Inspect brake fl uid for moisture contamination. 27,000 Miles (43,400 km) 900 hrs nor mal use or 450 hrs sev ere operation ❐ Ch[...]

1-24 General Information, Lubrication and Maintenance ________________ ¨ RECOMMENDED FUEL/FLUIDS/LUBRICANTS/ CAPACITIES Recommended Fuel Recommended fuel for 6.5L diesel engines is #2 diesel. Do not use any other type fuel. Eng ine Oil Figure 1-17: Oil Viscosity Chart Diesel engine oil capacities are: ¥ 7.0 qts (6.6L) without filter change ¥ 8.0[...]

_______________ General Information, Lubrication and Maintenance 1-25 ¨ 05745159 A/C Refrigerant and Compressor Oil The only refrigerant that can be used is R-134a. No other re- frigerant 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 recommen[...]

1-26 General Information, Lubrication and Maintenance ________________ ¨ Fuel Filter Service Replace the filter element every 6,000 mi (9,600 km), or annu- ally, whichever occurs first (Figure 1-21). See ÒPurging Air From Diesel FilterÓ (Section 3). Figure 1-21: Fuel Filter Location Transmission Fluid Figure 1-22: Transmission Dipstick Location [...]

_______________ General Information, Lubrication and Maintenance 1-27 ¨ 05745159 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 lev[...]

1-28 General Information, Lubrication and Maintenance ________________ ¨ Steering and Suspension Lubrication Points Lubricate steering and suspension components every 3,000 mi. (4 800 km), or semiannually, whichever occurs first. If operat- ing conditions are severe, service at 1,000 mi. (1 600 km) inter- vals. Figure 1-28: Ball Joint/Radius Rod L[...]

_______________ General Information, Lubrication and Maintenance 1-29 ¨ 05745159 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 be- tween ÒHOTÓ and ÒCOLDÓ marks on the cap indicator. If fluid is cool, level should be between ÒADDÓ and ÒCOLDÓ[...]

1-30 General Information, Lubrication and Maintenance ________________ ¨ CDR V alv e Clean the CDR valve with parts solvent and allow to dry. Re- place the valve if oil soaked, or if it wonÕt sustain vacuum/at- mospheric pressure testing, see ÒCDR ValveÓ in Section 3 for pressure testing instructions. Also replace the valve hose if cracked, bri[...]

_______________ General Information, Lubrication and Maintenance 1-31 ¨ 05745159 ESSENTIAL T OOLS NOTE: See page 1-1 of the Service Parts Catalog for information on ordering Kent-Moore tools. Eng ine Fuel, Emissions and Exhaust Tr a n sm i s s i o n / Tr a ns f e r C a s e To o l N o . Description JÐ23523-F Harmonic Balancer Remo v er/Installer S[...]

1-32 General Information, Lubrication and Maintenance ________________ ¨ Wheels, Tires and CTIS Brak es Steering Axles/Suspension and Frame HV A C T ool No. Descr iption JÐ42557 Cam Socket T ool No. Description J Ð 42553 Disc Brake T ool Kit T ool No. Description JÐ24319-B Steering Linkage and T ie-Rod Puller JÐ25033-C Pump Pulley Installer J?[...]

_______________ General Information, Lubrication and Maintenance 1-33 ¨ 05745159 Electrical Electrical Tr oubleshooting MISCELLANEOUS ESSENTIAL T OOLS T ool No. Description TKÐOÐA T ech 1 Diagnostic Scanner T AÐ1151 T ech 1 Adapter , part of TK-O-A T AÐ1152 T ech 1 T est Lead, part of TK-O-A T AÐ1190-A T ech 1 OperatorÕ s Manual, part of TK-[...]

1-34 General Information, Lubrication and Maintenance ________________ ¨ SPECIAL T OOLS Eng ine Fuel, Emissions and Exhaust T ransmission/T ransfer Case Wheels, Tires and CTIS Steering T ool No. Description JÐ29834 V alv e Lifter Remov al T ool JÐ8080 Main Bearing Shell Remover/Installer (In-V ehicle) JÐ6098-10 Camshaft Bearing Remov er/Install[...]

_______________ General Information, Lubrication and Maintenance 1-35 ¨ 05745159 Axles/Suspension and Frame HV A C T ool No. Description JÐ33142 Axle Shaft and Seal Installer JÐ21786 Pinion Rear Bearing Cup Remover JÐ21787 Pinion Front Bearing Cup Remover JÐ8611-01 Rear Pinion Bearing Race Installer JÐ29162 Rear Retaining Seal Installer JÐ86[...]

1-36 General Information, Lubrication and Maintenance ________________ ¨ THIS PAGE INTENTIONALLY BLANK.[...]

________________________________________________________________________________ 2-1 ¨ 05745159 Section 2 Eng ine INTRODUCTION This section contains general information, diesel engine diagno- sis, turbocharger service, and diesel engine repair and overhaul. A table of contents is provided that lists the various repair items and the section page nu[...]

2-2 Engine ______________________________________________________________________ ¨ Oil Pump Oil Pump and Drive Removal . . . . . . . . . . . . . . . . . . . . . . . 2-58 Oil Pump and Pump Drive Service . . . . . . . . . . . . . . . . . . . 2-77 Oil Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Oil Pump Pres[...]

_____________________________________________________________________ Engine 2-3 ¨ 05745159 The turbocharged diesel engine is equipped with a Warner Gear turbocharger. A wastegate, in the turbine housing, con- trols boost. The wastegate is operated by an externally mounted vacuum actuator. The actuator opens the gate to de- crease boost, or closes[...]

2-4 Engine ______________________________________________________________________ ¨ 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, Ul[...]

_____________________________________________________________________ Engine 2-5 ¨ 05745159 ROAD T ESTING 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. W orn, damaged tires or wheels can cause vibration or noise. 2. Check and adj[...]

2-6 Engine ______________________________________________________________________ ¨ 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 pat- tern and pressure, and compression ignition. However, incor- rect injection pump timing, low quality fuel, or in[...]

_____________________________________________________________________ Engine 2-7 ¨ 05745159 Figure 2-6: Checking Current at Each Glow Plug OIL PUMP PRESSURE T EST 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[...]

2-8 Engine ______________________________________________________________________ ¨ Engine Diagnosis PR OBLEM PO TENTIAL CA USE CORRECTION Hard Starting 1. InsufÞcient cranking speed (belo w 100 rpm cold or 180 rpm hot). Caused by: ¥ Lo w batteries ¥ Bad cable connections ¥ Serpentine belt or alternator problem 2. Starter problem ¥ Poor conne[...]

_____________________________________________________________________ Engine 2-9 ¨ 05745159 Hard Starting When Hot 1. Wrong fuel or poor quality fuel. 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. Low compression due to rings, pist[...]

2-10 Engine _____________________________________________________________________ ¨ Engine W ill Not Crank - (Continued) 5. Starter or solenoid problem. 6. Hydrostatic lock. Combustion chambers Þlled with fuel, or coolant due to faulty injec- tors, or blo wn head gasket. (Remov e glow plugs, crank engine and note ßuid coming out of plug holes). [...]

____________________________________________________________________ Engine 2-11 ¨ 05745159 Lo w Power , Poor Accelera- tion 1. V ehicle o verloaded. 2. Lo w grade diesel fuel. 3. Sludge or wax b uildup in fuel Þlter (low fuel supply). 4. Air in fuel supply system. 5. Fuel supply pump failed. 6. Mistimed injection pump. 7. Restriction in air inta[...]

2-12 Engine _____________________________________________________________________ ¨ White Smoke 1. Low quality fuel. 2. Injection pump/engine timing is retarded. 3. Engine coolant entering combustion chamber through blo wn gasket, cracked head, loose/ damaged head bolts. May be accompanied by lo w coolant lev el and overheating. 4. Lo w ambient te[...]

____________________________________________________________________ Engine 2-13 ¨ 05745159 Excessi ve Oil Consumption 1. Prolonged high speed, high load, or ov erload operation. 2. Incorrect oil grade used for high ambient temperature operation. 3. Oil leaks at: ¥ Rocker covers ¥Oil pan ¥ Rear main seal ¥Oil Þlter ¥ T iming chain co ver or [...]

2-14 Engine _____________________________________________________________________ ¨ Overheating (continued) 5. Failed thermostat or radiator cap. 6. Fan clutch inoperati ve. 7. W ater pump inoperative. 8. Blown head gask et. 9. Crack in block, or leaking freeze plug. 10. Coolant temperature gauge or sensor faulty . 5. Check thermostat and cap oper[...]

____________________________________________________________________ Engine 2-15 ¨ 05745159 T URBOCHARGER SER VICE AND DIAGNOSIS Description The turbocharger used on 6.5L diesel engines is a Borg- Warner 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 wast[...]

2-16 Engine _____________________________________________________________________ ¨ T URBOCHARGER OPERATION The wastegate valve controls boost. It is operated by the vac- uum 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 accelerato[...]

____________________________________________________________________ Engine 2-17 ¨ 05745159 T urbocharger Remo v al 1. Remov e front console, rear console, engine cover , and dis- connect related wiring and A/C ducting. 2. Remove turbocharger heat shielding. 3. Loosen clamps attaching turbocharger inlet tubes to exhaust manifolds and turbocharger.[...]

2-18 Engine _____________________________________________________________________ ¨ Turbocharger Diagnosis PR OBLEM PO TENTIAL CA USE CORRECTION Low Power Poor Acceleration (Black smoke not evident at 1/2 to wide open throttle) 1. Lean fuel mixture caused by insufÞcient fuel volume or pressure. 1. Problem is in fuel delivery system. Check fuel su[...]

____________________________________________________________________ Engine 2-19 ¨ 05745159 DIESEL ENG INE IN-V EHICLE SER VICE General Information The repair procedures described in this section cover engine service that can be performed in the vehicle. Engine removal is not required. Left/Right Orientation Left/right orientation throughout this [...]

2-20 Engine _____________________________________________________________________ ¨ 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 N¥m) torque. Tighten insulator stud nuts to 90 l[...]

____________________________________________________________________ Engine 2-21 ¨ 05745159 Installation 1. Clean face of torsional damper with brake cleaner . Smooth surface with Þle, or 280 grit paper , if necessary . 2. Install pulley on damper and install pulley bolts. Tighten bolts until snug. 3. Install serpentine belt on all pulleys except[...]

2-22 Engine _____________________________________________________________________ ¨ FRONT CO V ER OIL SEAL REPLACEMENT 1. Remov e crankshaft pulley and torsional damper . Refer to procedures in this section. 2. Remove oil seal front cover with tool J Ð 22102 or pry tool (Figure 2-19). 3. Clean seal contact surface of torsional damper. Smooth surf[...]

____________________________________________________________________ Engine 2-23 ¨ 05745159 FRONT CO V ER AND TIMING CHAIN Cover Removal 1. Disconnect and remov e batteries and tray . 2. Drain engine coolant. 3. Remove radiator upper and lower hoses. 4. Loosen crankshaft pulley belts. 5. Remove left and right splash shields. 6. Disconnect hood har[...]

2-24 Engine _____________________________________________________________________ ¨ 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 damper with tool J Ð 23523-F (Figure 2-18). 15. Remove[...]

____________________________________________________________________ Engine 2-25 ¨ 05745159 Figure 2-24: Drive Gear, Baffle, and Front Cover Removal Figure 2-25: Drive Gear, Timing Chain, and Sprocket Removal FRONT SEAL BAFFLE INJECTION PUMP DRIVEN GEAR FRONT COVER PUMP GASKET FUEL PUMP INJECTION PUMP DRIVE GEAR INJECTION INJECTION PUMP DRIVE GEAR[...]

2-26 Engine _____________________________________________________________________ ¨ Front Cover Installation 1. Install ne w camshaft thrust plate and spacer if required. 2. Clean front cover and engine block sealing surfaces with carb cleaner and wipe dry. 3. Install drive keys in camshaft and crankshaft. Be sure keys are seated. 4. Assemble and [...]

____________________________________________________________________ Engine 2-27 ¨ 05745159 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 N¥m) torque. 12. Install [...]

2-28 Engine _____________________________________________________________________ ¨ 22. Install fan pulley, fan, and fan clutch. Tighten attaching nuts to 15-20 lb-ft (20-27 N¥m). 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 ra[...]

____________________________________________________________________ Engine 2-29 ¨ 05745159 REAR MAIN OIL SEAL REPLACEMENT 1. Remov e transmission and transfer case assembly . 2. Remove flywheel. Figure 2-32: Rear Main Oil Seal Removal CA UTION: Do not nick or scratch crankshaft seal surface when removing old seal (Figure 2-32). 3. Using small scr[...]

2-30 Engine _____________________________________________________________________ ¨ ROCK ER ARM COV ER SER VICE Right Side Cover Removal 1. Remov e front console and engine cover . 2. 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 b[...]

____________________________________________________________________ Engine 2-31 ¨ 05745159 Right Side Cover Installation 1. Clean cov er mounting surface of cylinder head with brak e or contact cleaner and shop to wels. This product will remov e residue from the surface and ensure proper adhe- sion of ne w sealer . 2. If new rocker arm cover is b[...]

2-32 Engine _____________________________________________________________________ ¨ Left Side Cover Installation 1. Clean cov er mounting rails on cylinder head with brake or contact cleaner and shop to wels. This product will remov e residue from surface and ensure proper adhesion of ne w sealer . 2. If new rocker arm cover is being installed, cl[...]

____________________________________________________________________ Engine 2-33 ¨ 05745159 ROCK ER ARM, SHAFT, AND PUSHROD SER VICE Removal 1. Remov e one or both rocker arm cov ers as needed. Refer to procedures in this section. 2. Remove bolts and retainers that attach rocker arm shafts to cylinder head (Figure 2-36). Note position of bolts for[...]

2-34 Engine _____________________________________________________________________ ¨ Cleaning and Inspection Clean the valve train components in parts cleaning solvent. Carb cleaner or a spray type gasket remover can be used to re- move stubborn deposits. Mark position of the rocker arms on the shafts. Remove the rocker arm retainers with pliers. T[...]

____________________________________________________________________ Engine 2-35 ¨ 05745159 EXHAUST MANIFOLD SERVICE Right Exhaust Manifold Heat Shield Replacement Removal 1. Remov e console and engine access cover . 2. Remove right exhaust manifold rear heat shield screws and locknuts (Figure 2-38). 3. Remove shield attaching screws and remove he[...]

2-36 Engine _____________________________________________________________________ ¨ Right Exhaust Manifold Rear Heat Shield Replacement 1. Remov e console and engine access cover . 2. Detach rear heat shield from transmission fill tube clamp (Figure 2-39). 3. Remove rear heat shield. 4. Install rear heat shield. 5. Attach rear heat shield to trans[...]

____________________________________________________________________ Engine 2-37 ¨ 05745159 CYLINDER HEAD AND GASK ET SER VICE Cylinder Head (Left Side) Removal 1. Remov e 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 s[...]

2-38 Engine _____________________________________________________________________ ¨ Cylinder Head (Left Side) Installation 1. Clean gasket surf ace of cylinder block with scraper if nec- essary . Then remov e protectiv e covering from c ylinder and lifter v alleys. 2. Wipe cylinder block surface clean with solvent and cloth. 3. Position new head g[...]

____________________________________________________________________ Engine 2-39 ¨ 05745159 12. Install fuel injector lines. Tighten line fittings at pump and injector to 19 lb-ft (26 N¥m) torque. 13. Install intake manifold and gaskets. Tighten manifold studs/bolts to 31 lb-ft (42 N¥m) torque. Also install turbocharger, if equipped. 14. Install[...]

2-40 Engine _____________________________________________________________________ ¨ Cylinder Head (Right Side) Installation 1. Clean gasket surf ace of cylinder block with scraper if nec- essary . Scuff sand surface with 180 grit emery or paper to provide better surf ace for gasket seating. Then remo ve protecti ve cov ering from cylinders and lif[...]

____________________________________________________________________ Engine 2-41 ¨ 05745159 V ALV E LIFTER REPLACEMENT The 6.5L diesel engines are equipped with roller-type hydrau- lic 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 hea[...]

2-42 Engine _____________________________________________________________________ ¨ c. 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. 2. Apply cam lube to lifter roller and bearings. 3. Install lifters as follo[...]

____________________________________________________________________ Engine 2-43 ® 05745159 Figure 2-48: Removing/Installing Main Bearing Upper Half with Cotter Pin or Equivalent INTAK E MANIF OLD 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 m[...]

2-44 Engine _____________________________________________________________________ ® EXHAUST MANIFOLDS Removal 1. Remov e consoles and engine cover for access to turbo- charger inlet pipes. F or information regarding inlet pipes, refer to Section 3. 2. Loosen flange clamps that secure left inlet pipe to exhaust manifold and turbocharger. On right s[...]

____________________________________________________________________ Engine 2-45 ® 05745159 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 Loct[...]

2-46 Engine _____________________________________________________________________ ® 23. Disconnect A/C hoses at compressor. Move hoses aside for working clearance. Cap open ends to prevent dirt entry (Figure 2-55). Figure 2-54: Air Horn and Hose Removal/Installation Figure 2-55: Suction/Discharge Hose Assembly Mounting 24. Disconnect bypass hose a[...]

____________________________________________________________________ Engine 2-47 ® 05745159 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 gas[...]

2-48 Engine _____________________________________________________________________ ® Figure 2-60: Engine Mounted on Repair Stand ENG INE INSTALLATION 1. If ne w engine is being installed, transfer mounting brack- ets and insulators, generator , po wer steering pump, A/C compressor , dri ve plate (flywheel), turbochar ger , and nec- essary mounting[...]

____________________________________________________________________ Engine 2-49 ® 05745159 19. Remove protective tape from A/C suction/discharge hose adapter and connect it to compressor. Install new seal washers. Figure 2-61: Suction/Discharge Hose Connection 20. Connect glow relay cable and wires. 21. Position support on back of alternator. The[...]

2-50 Engine _____________________________________________________________________ ® Fan and Pulle y Remo v al 1. Insert spanner J–41240-1 in holes in water pump pulle y (Figure 2-62). 2. Use spanner to hold water pump shaft and wrench J– 41240-5A to loosen nut securing fan clutch to water pump. 3. Remove bolts attaching fan to fan clutch. 4. R[...]

____________________________________________________________________ Engine 2-51 ® 05745159 Po w er Steering Pump and Brack et Remo v al 1. Remov e bolts/nuts attaching pump mounting bracket to block and cylinder head and remo ve pump and bracket as assembly . 2. If pump requires service, remove pump attaching bolts and remove pump from bracket (F[...]

2-52 Engine _____________________________________________________________________ ® Intak e Manif old Remo v al 1. Remov e bolts and studs attaching each manifold half to cylinder head. 2. Tap each manifold half with rawhide mallet to loosen it. 3. Lift and remove manifold halv es and gaskets (Figures 2-70 and 2-71). Discard gaskets. Figure 2-70: [...]

____________________________________________________________________ Engine 2-53 ® 05745159 Fuel Injection Line Remo v al NOTE: Mark or tag fuel injection lines for installation refer- ence. 1. Disconnect lines at injector nozzles (Figure 2-75). 2. Remove clamp and boot from lines at injection pump if equipped. 3. Disconnect and remove injection l[...]

2-54 Engine _____________________________________________________________________ ® Rock er Arm Cov er Remo v al 1. Remov e injection line support bracket from studs (Figure 2-77). 2. Remove cover attaching bolts and studs. 3. Remove rocker arm cover. Tap cover with rubber mallet and twist it to remove. Do not pry on cover. 4. Repeat procedure for[...]

____________________________________________________________________ Engine 2-55 ® 05745159 Cylinder Head Remo v al 1. Remov e cylinder head bolts (Figure 2-81). 2. Remove cylinder head from block. 3. Remove cylinder head gasket. Discard gasket afterward. 4. Repeat procedure for opposite cylinder head. Figure 2-81: Cylinder Head and Gasket Removal[...]

2-56 Engine _____________________________________________________________________ ® W ater Pump/Adapter Plate/Oil Fill T ube Remo v al 1. Remov e oil fill tube from adapter plate (Figure 2-83). 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[...]

____________________________________________________________________ Engine 2-57 ® 05745159 Front Co v er Remo v al 1. Remov e baffle from front co ver (Figure 2-87). 2. Remove bolts attaching front cover to oil pan. 3. Remove bolts attaching front cover to engine block. 4. Remove front cover. Use mallet to loosen cover. Do not pry cover loose. 5[...]

2-58 Engine _____________________________________________________________________ ® Figure 2-90: Oil Filter and Adapter Removal Figure 2-91: Oil Pressure Sending Unit Location Oil Pan Remo v al 1. Drain oil from pan if not pre viously done. 2. Remove pan bolts. 3. Tap pan with rubber mallet to loosen. Then remove pan. 4. Remove pan rear seal (Figu[...]

____________________________________________________________________ Engine 2-59 ® 05745159 Figure 2-94: Oil Pump Drive Removal Camshaft Remo v al 1. Remov e thrust plate and spacer (Figure 2-95). CA UTION: Support camshaft during removal to avoid damag- ing bearings. 2. Remove camshaft from cylinder block. Figure 2-95: Camshaft Removal Piston and[...]

2-60 Engine _____________________________________________________________________ ® Flywheel Remo v al 1. Remov e six capscrews and flywheel from crankshaft (Figure 2-97). 2. Remove flywheel attaching bolts with impact wrench and suitable size socket. 3. Work flywheel off crankshaft flange with rocking motion. Figure 2-97: Flywheel Removal Cranks[...]

____________________________________________________________________ Engine 2-61 ® 05745159 NOTE: Be sure to inspect the piston cooling oil tubes in turbo diesel blocks. Verify that the tubes are clear (Figure 2-101). Figure 2-100: Camshaft Bearing Locations Figure 2-101: Piston Oil Cooling Feed and Spray Orifice Locations Inspection Check all of [...]

2-62 Engine _____________________________________________________________________ ® 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. Figure 2-103: Cylinder Block Valve and Plug Loca[...]

____________________________________________________________________ Engine 2-63 ® 05745159 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 [...]

2-64 Engine _____________________________________________________________________ ® 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 p[...]

____________________________________________________________________ Engine 2-65 ® 05745159 Figure 2-110: Removing Cam Bearings 1 and 5 CA UTION: 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[...]

2-66 Engine _____________________________________________________________________ ® CRANKSHAFT SER VICE 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 sm[...]

____________________________________________________________________ Engine 2-67 ® 05745159 PISTON/CONNECTING ROD OVERHAUL Remove and discard the old piston rings. Use a remover/in- staller 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 rin[...]

2-68 Engine _____________________________________________________________________ ® 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 bush- ing diameter and compare it to diameter of new or known good piston pin. The difference between the tw[...]

____________________________________________________________________ Engine 2-69 ® 05745159 • If a cylinder bore only requires honing to correct a prob- lem, 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 con- necting rod. The rod ID [...]

2-70 Engine _____________________________________________________________________ ® Figure 2-125: Seating Piston Pin Retainer Ring Piston Ring Installation 1. Check end gap of all rings. Insert ring in bore and push it do wn until its about 1-2 inches (2.5-5 cm) below top edge of bore. V erify that ring is level, then check end g ap with feeler ga[...]

____________________________________________________________________ Engine 2-71 ® 05745159 CAMSHAFT, TIMING CHAIN, SPROC K ET, AND DRIVE GEAR SER VICE 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, scuffin[...]

2-72 Engine _____________________________________________________________________ ® Figure 2-131: Oil Filler Tube and Cap CYLINDER HEAD O VERHA UL Disassembly 1. Remov e glow plugs and injectors if not pre viously remov ed. 2. Remove temperature sender from left side head (Figure 2-132). Figure 2-132: Temperature Sender Removal/ Installation 3. Cl[...]

____________________________________________________________________ Engine 2-73 ® 05745159 Figure 2-134: Intake and Exhaust Valve Components Figure 2-135: Pre-combustion Chamber Removal Figure 2-136: Cover Removal/Installation Cleaning and Inspection Clean the cylinder heads and valve components in parts clean- ing solvent. Use carb cleaner and a[...]

2-74 Engine _____________________________________________________________________ ® 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 cha[...]

____________________________________________________________________ Engine 2-75 ® 05745159 Cylinder Head Reassembly 1. Scuf f sand all gasket surfaces with 180 grit paper . 2. Clean the valvetrain parts and cylinder head with solvent and dry with compressed air. 3. Install new freeze plugs in heads if necessary. Apply Permatex #2 or high temp adh[...]

2-76 Engine _____________________________________________________________________ ® LIFTER , PUSHROD, ROC K ER ARM SER VICE 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 [...]

____________________________________________________________________ Engine 2-77 ® 05745159 Figure 2-146: Torsional Damper Inspection Points Figure 2-147: Flywheel Inspection Points OIL PUMP AND PUMP DRIVE SER VICE The oil pump can be disassembled for inspection if desired but not overhauled. The pump is serviced only as a complete as- sembly. Ind[...]

2-78 Engine _____________________________________________________________________ ® OIL FILTER ADAPTER AND BYPASS V ALVE SER VICE 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 surf[...]

____________________________________________________________________ Engine 2-79 ® 05745159 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. Inspe[...]

2-80 Engine _____________________________________________________________________ ® ENG INE ASSEMBLY AND ADJUSTMENT 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.[...]

____________________________________________________________________ Engine 2-81 ® 05745159 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 N•m), outer bolts on main caps 1 and 5 to 48 lb-ft (65 N•m) and ma[...]

2-82 Engine _____________________________________________________________________ ® CRANKSHAFT MAIN CAP TORQUE SEQUENCE 1. T ighten the inner 12 mm bolts to 55 lb-ft (75 N.m). 2. Retighten the inner 12 mm bolts to 55 lb-ft (75 N.m). 3. Tighten the inner 12 mm bolts an additional 90 degrees. 4. Tighten the outer 12 mm bolts (crankshaft bearing caps[...]

____________________________________________________________________ Engine 2-83 ® 05745159 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 [...]

2-84 Engine _____________________________________________________________________ ® 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. (0.17- 0.63 mm). NO[...]

____________________________________________________________________ Engine 2-85 ® 05745159 Figure 2-165: Flywheel Installation CAMSHAFT INSTALLATION 1. Place engine in upright position so cam bearing bores are vertical. 2. Lubricate camshaft bearing journals with engine oil. Then lubricate cam bearings with long nozzle oil can. 3. Lubricate camsh[...]

2-86 Engine _____________________________________________________________________ ® FRONT CO V ER AND BAF FLE INSTALLATION 1. Install new seal in front co ver with installer tool J–22102. 2. Apply sealer to front cover as follows: • Use anaerobic sealer such as Loctite 510 on cover sur- faces that contact block (Figure 2-168). • Use RTV-type[...]

____________________________________________________________________ Engine 2-87 ® 05745159 FUEL INJECTION PUMP INSTALLATION 1. Install injection pump gasket on front co ver studs. 2. Mount injection pump on front cover studs (Figure 2-169). Install retaining nuts finger tighten. 3. Rotate crankshaft if necessary, to place timing mark on injection[...]

2-88 Engine _____________________________________________________________________ ® 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 N•m) (Figure 2-174). 5. Install pulley on water pump shaft flange. Figure 2-174: Oil Fill Tube Installa[...]

____________________________________________________________________ Engine 2-89 ® 05745159 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. CA UTION: Do not apply any ty[...]

2-90 Engine _____________________________________________________________________ ® GLOW PLUG AND INJECTION NOZZLE INSTALLATION 1. Install glo w plugs in each cylinder head (Figure 2-178). T ighten plugs to 8-12 lb-ft (11-16 N•m). Figure 2-178: Glow Plug Installation 2. Install gasket on each injector nozzle (Figure 2-179). 3. Install injector n[...]

____________________________________________________________________ Engine 2-91 ® 05745159 ROCK ER COV ER INSTALLATION 1. Clean mounting flanges on both rocker co vers and cylin- der heads. W ipe flange sealing surfaces of f with isopropyl alcohol to prepare surface for sealer application. 2. Apply RTV-type sealer to cover sealing surfaces. 3. [...]

2-92 Engine _____________________________________________________________________ ® FUEL INJECTOR LINE INSTALLATION 1. Flush injector lines with fresh diesel fuel and compressed air . 2. Attach fuel lines to injectors and pump. Verify line routing and connection (Figures 2-183 and 2-184). 3. Tighten fuel line fittings at injectors and at pump to 1[...]

____________________________________________________________________ Engine 2-93 ® 05745159 T ORSIONAL DAMPER AND CRANKSHAFT PULLEY INSTALLATION 1. Install damper ke y in crankshaft (Figure 2-186). 2. Lubricate crankshaft hub, damper seal contact surface, and damper hub bore with engine oil or chassis grease. 3. Align and install damper on cranksh[...]

2-94 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 proce- dure for reprogramming TDC offset is as follows: 1. V erify[...]

____________________________________________________________________ Engine 2-95 ® 05745159 T OR QUE SPECIFICATIONS Item Lb-Ft. Lb-In. N•m Block drainplugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft thrust [...]

2-96 Engine _____________________________________________________________________ ® ENG INE SPECIF ICATIONS General Data: Displacement 6.5L/395 c.i.d. Type 4 Cycle, Diesel, Liquid-Cooled Bore 4.06 in. (103 mm) Stroke 3.82 in. (97 mm) Compression Ratio 20.2:1 Firing Order 1-8-7-2-6-5-4-3 Oil Pressure 6 psi (69 kPa) at idle (hot); 30 psi (552 kPa) a[...]

____________________________________________________________________ Engine 2-97 ® 05745159 SER VICE PISTON AND CYLINDER BORE SPECIFICATIONS (MM) NOTE: Cylinders #7 and #8 require 0.013 mm (0.005 in.) additional clearance (piston to bore). CRANKSHAFT MAIN JOUR NAL DIAMETER AND BEARING SELECTION (MM) NOTE: U.S. indicates undersize bearing. Bearing [...]

2-98 Engine _____________________________________________________________________ ® BLOCK, CAMSHAFT AND BEAR ING SIZES (MM) NOTE: To convert metric to U.S. sizes, multiply metric (mm) amount by 0.03937. 6.5L Engines Camshaft Journal Diameter O.D (Diameter T olerance 0.55 mm) #1 #2 #3 #4 #5 55.025 54.970 55.025 54.970 55.025 54.970 55.025 54.970 51[...]

____________________________________________________________________ Engine 2-99 ® 05745159 ESSENTIAL T OOLS Procure from Kent-Moore. J–26999-30 J–33139 J–34116 J–22102 J–23523-F J–23951 J–26999 J–39084 J–35555 J–41240-1 J–41240-5A T ool No. Description J–23523-F Harmonic Balancer Remov er/Installer Set J–26999-30 Compres[...]

2-100 Engine ____________________________________________________________________ ® SPECIAL T OOLS Procure from Kent-Moore. T ool No. Description J–29834 V alv e Lifter Remov al T ool J–8080 Main Bearing Shell Remov er/Installer (In-V ehicle) J–6098-10 Camshaft Bearing Remo ver/Installer (use with J–33049) J–8062 V alv e Spring Compresso[...]

________________________________________________________________________________ 3-1 ® 5745159 Section 3 Fuel, Emissions , and Exhaust T ABLE OF CONTENTS Air Cleaner Assembly Air Cleaner Filter Element Service . . . . . . . . . . . . . . . . . . .3-21 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Ai[...]

3-2 Fuel, Emissions, and Exhaust _____________________________________________ ® 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 be- tween the inlet and outlet ports ([...]

____________________________________________ Fuel, Emissions, and Exhaust 3-3 ® 5745159 Fuel Filter -W ater Separator The filter-water separator is located at the driver side of the en- gine compartment firewall (Figure 3-4). It performs five func- tions which are: • Fuel filtering (2-stage) • Water separation • Water detection • Water dra[...]

3-4 Fuel, Emissions, and Exhaust _____________________________________________ ® 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[...]

____________________________________________ Fuel, Emissions, and Exhaust 3-5 ® 5745159 Figure 3-7: Electronic Accelerator Pedal Components Figure 3-8: Electronic Accelerator Pedal (Location) Figure 3-9: Accelerator Pedal Connector Clip Electronic Fuel Injection Pump Operation The electronic fuel injection pump is operated by the power- train cont[...]

3-6 Fuel, Emissions, and Exhaust _____________________________________________ ® PO W ERTRAIN CONTROL MODULE (PCM) The PCM controls operation of all of the engine and transmis- sion outputs. It is on a bracket attached to floor under the cen- ter console. The data link connector is the access point for the scan tool. The connector is under the ins[...]

____________________________________________ Fuel, Emissions, and Exhaust 3-7 ® 5745159 Fuel System Diagnosis—Diesel Engine PR OBLEM PO TENTIAL CA USE CORRECTION Hard Starting 1. Dri ver/o wner not following recommended start procedure. 1. Remind dri ver/o wner of required procedure. Dem- onstrate procedure if necessary . 2. Fuel contaminated, l[...]

3-8 Fuel, Emissions, and Exhaust _____________________________________________ ® No Start Condi- tion (engine cranks but will not run) 1. Excessi ve amount of water or wax b uildup in system. 1. Draw of f sample at drain plug. Drain and flush sys- tem if necessary . 2. Blo wn fuse. 2. Replace fuse. Check for shorts-grounds in affected circuit. 3.[...]

____________________________________________ Fuel, Emissions, and Exhaust 3-9 ® 5745159 Lo w Power , Sluggish Accel- eration 1. Contaminated or lo w-quality fuel. 1. Drain, flush, and refill fuel system. 2. High fuel temperature. 2. Normal condition in high ambient. 3. Restriction in air intak e system. 3. Remove and clean filter , housing, wea[...]

3-10 Fuel, Emissions, and Exhaust ___________________________________________ ® Knock-Ping Under Accelera- tion. 1. Contaminated, incorrect, or lo w quality fuel. 1. Drain, flush, and refill fuel system. 2. Air leak in fuel deli very system. 2. Inspect injector line fittings. Bleed injectors and tighten any loose fittings. Check all fuel supply [...]

___________________________________________ Fuel, Emissions, and Exhaust 3-11 ® 5745159 SCAN T OOL DIAGNOSIS The scan tool is needed for operational testing of electronic components such as the PCM, electronic accelerator pedal po- tentiometer, and engine sensors. The scan tool is connected to the vehicle electrical system through the diagnostic/d[...]

3-12 Fuel, Emissions, and Exhaust ___________________________________________ ® 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 list[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-13 ® 5745159 Low T emperature—High Resistance T est 1. Connect scan tool and start engine. 2. 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. D[...]

3-14 Fuel, Emissions, and Exhaust ___________________________________________ ® Installation 3. Install the O-ring seal above the threads at the bottom of the new solenoid (Figure 3-14). 4. Install the replacement solenoid into the injector pump housing and torque to 19 lb-ft (25 N•m). 5. Connect the electrical connector to the ESO solenoid. 6. [...]

___________________________________________ Fuel, Emissions, and Exhaust 3-15 ® 5745159 Fuel Solenoid Driver Replacement Removal 1. Drain the engine coolant and remov e the upper radiator hose from the thermostat housing. 2. Remove the left intake manifold runner to gain access to the Fuel Solenoid Driver (on the left side of the injection pump). [...]

3-16 Fuel, Emissions, and Exhaust ___________________________________________ ® 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 fau[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-17 ® 5745159 Crankshaft Position Sensor The crankshaft position sensor is a Hall-effect device that mon- itors 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 [...]

3-18 Fuel, Emissions, and Exhaust ___________________________________________ ® Boost Sensor Circuit T est 1. Connect scan tool to diagnostic/data link connector . 2. Start and run engine at idle speed. 3. Record boost sensor voltage. • If voltage is 4.0 volts or more, continue test. • If voltage is less than specified, compare sensor to known[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-19 ® 5745159 AIR CLEANER SER VICE Removal NOTE: To remove dust unloader only, perform steps 1 and 2. 1. Remov e air cleaner (Figure 3-23). 2. Loosen clamp and remove dust unloader from air cleaner assembly. 3. Loosen clamp and disconnect elbow from engine side of air cleane[...]

3-20 Fuel, Emissions, and Exhaust ___________________________________________ ® Figure 3-23: Air Cleaner Assembly and Dust Unloader WEATHERCAP AIR INTAKE DUCT VENT LINE AIR HORN AIR CLEANER ASSEMBLY AIR CLEANER SHIELD TUBE ADAPTER VENT AIR INTAKE SUPPORT AIR CLEANER ASSEMBLY DUST UNLOADER ELBOW SEAL GASKET FITTING AIR INDUCTION HOSE HOOD SEAL[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-21 ® 5745159 Air Cleaner Filter Element Ser vice Removal 1. Remov e ring clamp, cover , and gasket from air cleaner (Figure 3-24). 2. Remove nut and washer assembly and filter element from air cleaner stud. Figure 3-24: Air Cleaner Filter Element Removal/Installation Inspec[...]

3-22 Fuel, Emissions, and Exhaust ___________________________________________ ® Air Induction Hose Replacement Removal 1. Loosen induction hose clamps. 2. Remove hose from air horn and air cleaner (Figure 3-26). Figure 3-26: Air Induction Hose Attachment Installation 1. Install induction hose on air horn and air cleaner . 2. Tighten hose clamps to[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-23 ® 5745159 DRAINAGE BRACK ET REPLACEMENT Removal 1. Remov e air cleaner assembly . 2. Remove three screws and drainage bracket from body (Figure 3-29). Figure 3-29: Drainage Bracket Location Installation 1. Position drainage bracket on body and install bracket scre ws (Fi[...]

3-24 Fuel, Emissions, and Exhaust ___________________________________________ ® MAIN FUEL T ANK Removal 1. Drain tank with recommended equipment. 2. Remove bolts attaching fuel filler housing to body. 3. Remove vapor canister shield and bracket. Then disconnect tank vent lines, and hoses at branch tee in fuel filler housing. 4. Remove clamps attac[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-25 ® 5745159 Fuel Lev el T ransmitter/Pump/V ents/ 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 nec- essary g[...]

3-26 Fuel, Emissions, and Exhaust ___________________________________________ ® 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. P[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-27 ® 5745159 Figure 3-35: Auxiliary Fuel Tank Components TANK FUEL LEVEL GASKET JUMPER AUXILIARY SKID PLATE FRAME ACCESS PLATE O-RING (8) ROLLOVER ACCESS PLATE FUEL ACCESS PLATE TRANSMITTER STRAINER HARNESS FUEL TANK GASKET VALVE RETAINER MOUNTING BRACKETS[...]

3-28 Fuel, Emissions, and Exhaust ___________________________________________ ® FUEL LEV EL T RANSMITTER AND T ANK ACCESS PLATE SER VICE Removal 1. Remov e screws, lockw ashers and fuel lev el 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 [...]

___________________________________________ Fuel, Emissions, and Exhaust 3-29 ® 5745159 Figure 3-37: Fuel Tank Vent Line Locations (Typical) Fuel T ank V ent Line Ser vice Removal 1. Remov e fuel tank. Refer to procedure in this section. 2. Remove clip and fuel tank vent line hose from vent line (Figure 3-37). 3. Remove vent line clamps and disena[...]

3-30 Fuel, Emissions, and Exhaust ___________________________________________ ® FUEL SELECTOR V ALVE The selector valve is used on models equipped with an auxil- iary 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, Emissions, and Exhaust 3-31 ® 5745159 FUEL FILTER SER VICE Fuel Filter Replacement Removal 1. Loosen the hose clamps securing the CTIS compressor (if equipped) to its mounting bracket and slide the compres- sor forward to gain access to the fuel filter . 2. Disconnect fuel inlet and outlet hoses f[...]

3-32 Fuel, Emissions, and Exhaust ___________________________________________ ® Fuel Filter Drain Hose and V alve Replace- ment NOTE: To remove fuel filter drain valve only, perform steps 3 and 4. Removal 1. Disconnect fuel filter drain hose from fuel filter (Figure 3-42). 2. Remove two tie straps and separate drain hose from transmission oil co[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-33 ® 5745159 FUEL LIFT PUMP SER VICE Fuel Lift Pump Replacement Removal 1. Disconnect fuel pump wiring harness (Figure 3-43). 2. Disconnect fuel pump hoses. 3. Loosen clamp and remove pump. 4. Remove adapters and O-rings from fuel pump. Discard O- rings. Figure 3-43: Fuel P[...]

3-34 Fuel, Emissions, and Exhaust ___________________________________________ ® Diesel Injection Pump Fuel Hose or T ube Replacement Removal 1. Remov e supply hose. 2. Remove return hose from injection pump and tube (Figure 3-45). 3. Remove tube-to-injector hose. 4. Remove injector connecting hoses (Figure 3-46). 5. Remove nozzle cap from rear noz[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-35 ® 5745159 GLOW PLUG SERVICE Glow Plug Tip Remo v al (Damaged or Brok en) 1. Remov e fuel injector from necessary cylinder . 2. Using torsional damper bolt (Figure 3-47),rotate crankshaft to bring af fected piston to TDC position. 3. Using pliers, reach through injector n[...]

3-36 Fuel, Emissions, and Exhaust ___________________________________________ ® DIESEL FUEL INJECTION SYSTEM Diesel Injection Line Brack et And Clamp Removal 1. Remov e console and engine covers. 2. Remove air horn. 3. Remove bracket (Figure 3-50). 4. Remove bracket from valve cover studs. 5. Remove line clamps if necessary. Figure 3-50: Injection[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-37 ® 5745159 Fuel Injector Replacement Removal 1. If removing rear injector , remo ve console and engine cov er . Remo ve fuel return hose and cap from injector (Figure 3-52). 2. Disconnect fuel return hoses from necessary injector (Figure 3-53). 3. Remove clamp, and fuel i[...]

3-38 Fuel, Emissions, and Exhaust ___________________________________________ ® Installation 1. Install clamps on injection lines (Figure 3-54). 2. Connect injection lines to pump (Figure 3-55). 3. Connect lines to injectors. Figure 3-55: Fuel Injection Pump Line Connection 4. Tighten injection line nuts to 20 lb-ft (27 N•m). 5. Install injectio[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-39 ® 5745159 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 proce- dure for reprogramming TDC offset is as follows: 1. V e[...]

3-40 Fuel, Emissions, and Exhaust ___________________________________________ ® ENG INE T EMPERATURE SENDER REPLACEMENT 1. Remov e nut, lockwasher , lead, and sender from engine (Figure 3-58). 2. Apply teflon sealant to sender threads, and install sender, lead, lockwasher, and nut on engine (Figure 3-58). Figure 3-58: Engine Temperature Sender GLO[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-41 ® 5745159 FUEL SYSTEM CONTAMINATION Organic Contamination Diesel fuel systems are susceptible to fungi and other micro-or- ganism 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[...]

3-42 Fuel, Emissions, and Exhaust ___________________________________________ ® MUFF LER REPLACEMENT 1. Remov e fasteners attaching muf fl er and gasket to catalytic con verter (Figure 3-60). 2. Remove fasteners attaching muffler to tailpipe. 3. Remove fasteners attaching muffler to frame bracket and insulator. 4. Loosen tailpipe and transfer cas[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-43 ® 5745159 Figure 3-61: Exhaust System HEATSHIELD CATALYTIC CONVERTER GASKET INSULATOR MUFFLER TRANSFER CASE AND EXHAUST PIPE BRACKETS AND U-BOLT FRONT TAILPIPE BRACKET HEATSHIELD CROSSOVER PIPE CUSHIONED LOOP ASSEMBLY TAILPIPE BRACKET CUSHIONED LOOP ASSEMBLY CUSHIONED LO[...]

3-44 Fuel, Emissions, and Exhaust ___________________________________________ ® CROSSO V ER PIPE REPLACEMENT 1. Remov e console and engine cover . 2. Remove passenger side exhaust manifold rear heat shield. 3. Loosen transfer case exhaust pipe bracket U-bolt (Figure 3-62). 4. Disconnect crossover pipe at manifolds and at catalytic converter. 5. Po[...]

___________________________________________ Fuel, Emissions, and Exhaust 3-45 ® 5745159 ESSENTIAL T OOLS Procure from Kent-Moore. T ool No. Description J–29075-AMG Fuel Injector Pressure T est T ool J–29872-A I njection Pump Adjusting T ool (used with ratchet handle) J–29873 Fuel Injector Socket (30mm) J–29698-A I njection Line (flare nut[...]

3-46 Fuel, Emissions, and Exhaust ___________________________________________ ® SPECIAL T OOLS Procure from Kent-Moore. T ool No. Description J–26925 Mag-T ac Engine T achometer J–26925[...]

________________________________________________________________________________ 4-1 ® 05745159 Section 4 Cooling System T ABLE OF CONTENTS Engine Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Diagnosis and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3 Service . . . .[...]

4-2 Cooling System ____________________________________________________________ ® 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 out- side air to help dissipate the heat before[...]

___________________________________________________________ Cooling System 4-3 ® 05745159 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, mounte[...]

4-4 Cooling System ____________________________________________________________ ® RADIATOR AND FAN SHR OUD ASSEMBLY SER VICE Removal 1. Remov e hood (Section 10). 2. Drain cooling system. 3. Remove oil cooler (Section 1). 4. Disconnect upper hose from radiator (Figure 4-4). 5. If equipped with air conditioner, discharge system and remove condenser[...]

___________________________________________________________ Cooling System 4-5 ® 05745159 5. Attach lower mount and radiator to frame bracket with washers, and locknut. Do not tighten (Figure 4-5). 6. 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. [...]

4-6 Cooling System ____________________________________________________________ ® ENG INE COOLING SYSTEM SER VICE Depressurizing/Draining W ARNING: T o av oid injury , do not remov e surge tank filler cap before depressurizing cooling system when engine temperature is abov e 190°F (88°C). 1. If engine is hot, place a thick cloth ov er surge tan[...]

___________________________________________________________ Cooling System 4-7 ® 05745159 SHROUD SHIELD ASSEMBLY REPLACEMENT Removal 1. Remov e radiator and fan shroud. 2. Remove screws and shroud shield assembly from airlift bracket (Figure 4-9). Figure 4-9: Shroud Shield Assembly Replacement Installation 1. Secure shroud shield assembly to airli[...]

4-8 Cooling System ____________________________________________________________ ® 3. Connect surge tank-to-lower radiator hose to surge tank. 4. Connect radiator vent hose to surge tank. 5. Connect overflow hose to surge tank. 6. Fill and purge cooling system. Figure 4-12: Surge Tank Replacement SURGE T ANK-T O-RADIATOR V ENT HOSE REPLACEMENT Remo[...]

___________________________________________________________ Cooling System 4-9 ® 05745159 UPPER RADIATOR HOSE REPLACEMENT Removal 1. Drain cooling system as necessary . 2. Depressurize cooling system. 3. Loosen clamps and remove hose from thermostat housing and radiator (Figure 4-15). Installation 1. Secure upper radiator hose to thermostat housin[...]

4-10 Cooling System __________________________________________________________ ® RADIATOR LOW ER T UBE ASSEMBLY REPLACEMENT Removal 1. Drain cooling system. 2. Remov e drain valv e from lower tube assembly (Figure 4-17). 3. Disconnect radiator lower tube assembly from frame bracket. 4. Loosen clamp and disconnect water pump inlet hose from lower t[...]

_________________________________________________________ Cooling System 4-11 ® 05745159 W ATER PUMP INLET HOSE REPLACEMENT Removal 1. Drain cooling system. 2. Loosen clamps and remove water pump inlet hose from water pump and lower tube assembly (Figure 4-18). Installation 1. Connect water pump inlet hose to lo wer tube assembly and water pump an[...]

4-12 Cooling System __________________________________________________________ ® SURGE T ANK-T O-LO W ER RADIATOR T UBE HOSE REPLACEMENT Removal 1. Drain cooling system. 2. Loosen clamps and remove hose from surge tank and lower tube assembly (Figure 4-20). Installation 1. Install hose on lo wer tube assembly and surge tank and tighten clamps (Fig[...]

_________________________________________________________ Cooling System 4-13 ® 05745159 THERMOSTAT REPLACEMENT 1. Drain engine coolant belo w lev el of water crossov er . 2. Remove bolts attaching thermostat cover to crossover housing. 3. Remove thermostat cover and gasket (Figure 4-22). 4. Remove both thermostats (Figure 4-23). 5. Position new t[...]

4-14 Cooling System __________________________________________________________ ® Installation 1. If ne w pump is being installed, transfer hose adapter fit- tings to ne w pump. Apply Loctite PST to fitting threads beforehand. 2. Apply coat of Permatex no. 2, Ultra Black, or Ultra Copper to each side of water pump gasket. Then position gasket on [...]

_________________________________________________________ Cooling System 4-15 ® 05745159 Figure 4-28: Backing Plate Sealer Application W ATER CR OSSO VER SERVICE Removal 1. Drain engine coolant to belo w lev el of crossover . 2. Disconnect heater, surge tank, and radiator hoses at crossover. 3. Disconnect coolant temperature sensor wires (Figure 4[...]

4-16 Cooling System __________________________________________________________ ® SERPENTINE BELT REPLACEMENT 1. Insert square lug of half-inch dri ve breaker bar in belt ten- sioner . Then mov e tensioner counterclockwise to loosen belt (Figure 4-32). 2. Remove belt from pulleys (Figure 4-33). 3. Position half-inch drive breaker bar in belt tensio[...]

________________________________________________________________________________ 5-1 ® 05745159 Section 5 T ransmission/T ransfer Case T ABLE OF CONTENTS Bulkhead, 76 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 Converter Housing Lower Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13[...]

5-2 Transmission/Transfer Case ______________________________________________ ® Figure 5-1: Transmission Drive and Apply Elements T RANSMISSION GEAR RANGES The 4L80-E gear ranges consist of: Park, Reverse, Neutral, Overdrive D range, manual D range, manual 2 range and Man- ual 1 range. In Park (P) range, none of the clutches and bands are applied.[...]

_____________________________________________ Transmission/Transfer Case 5-3 ® 05745159 T RANSMISSION IDENTIFICATION An I.D. plate is attached to the passenger side of each Hydra- matic Transmission (Figure 5-2). The plate contains the model, Hydra-matic type, model year, calendar year, and Julian calen- dar date. The I.D. plate information is req[...]

5-4 Transmission/Transfer Case ______________________________________________ ® Figure 5-3: Transmission Shift Control Components T RANSMISSION FLUID PRESSURE MANUAL V ALV E P OSITION 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 s[...]

_____________________________________________ Transmission/Transfer Case 5-5 ® 05745159 Figure 5-5: Pressure Switch Actuation Figure 5-6: Hydraulic/Electrical Circuitry for Pressure Switch Assembly (Third Gear Shown) CONTA CT BOD Y FLUID O-RING DIAPHRA GM GROUND CONTA CT ELEMENT SWITCH CONTA CT CONTA CT CONTA CT ELEMENT SWITCH CONTA CT GROUND DIAP[...]

5-6 Transmission/Transfer Case ______________________________________________ ® AUTOMATIC T RANSMISSION INPUT (SHAFT) SPEED SENSOR AND OUTPUT (SHAFT) SPEED SENSOR (V EHICLE SPEED SENSOR) The input and vehicle speed sensors are variable reluctance, magnetic pickup units (Figure 5-7). They consist of a perma- nent magnet surrounded by a wire coil. T[...]

_____________________________________________ Transmission/Transfer Case 5-7 ® 05745159 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 sole- noids are mounted on the valve body and operated by the PCM. [...]

5-8 Transmission/Transfer Case ______________________________________________ ® T OR QUE CON VERTER 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 [...]

_____________________________________________ Transmission/Transfer Case 5-9 ® 05745159 Figure 5-13: Pressure Control Solenoid Boost Schematics ENG INE SENSOR INPUTS The electronic accelerator pedal, coolant temperature sensor, A/C switch, brake switch, and crankshaft position sensor, all affect transmission operation. The electronic accelerator p[...]

5-10 Transmission/Transfer Case _____________________________________________ ® Figure 5-14: Torque Converter Components STATOR HUB TURBINE SHAFT ROLLER CLUTCH STATOR SHAFT (PART OF OIL PUMP COVER) CONVERTER PUMP TURBINE CONVERTER COVER/ IMPELLER CLUTCH PRESSURE PLATE AND DAMPER[...]

____________________________________________ Transmission/Transfer Case 5-11 ® 05745159 T RANSMISSION SER VICEABILITY The Hydra-matic transmission used in Hummer vehicles is ser- viced at two levels. Only external parts are serviced during the warranty period. A transmission internal component failure will require transmission replacement. Service[...]

5-12 Transmission/Transfer Case _____________________________________________ ® Road T est 1. If engine and transmission hav e cooled down, dri v e vehi- cle 10-12 miles to return to normal operating temperature. NOTE: The engine coolant and transmission fluid tempera- tures must be at normal operating levels for a proper road test. The engine and[...]

____________________________________________ Transmission/Transfer Case 5-13 ® 05745159 Functional Test Procedure Step Action V alue(s) Y es No 1 Perform the T ransmission Fluid Checking Proce- dure. Fill the reservoir to the suggested le vel. Is the fluid lev el correct? Go to step 2 2 Check for PCM trouble codes, both current and history . Are [...]

5-14 Transmission/Transfer Case _____________________________________________ ® Figure 5-15: Transmission Elements In Use Chart Clutch Application Chart GEAR 1-2 SHIFT SOLE- NOID A 2-3 SHIFT SOLE- NOID B FOURTH CLUTCH O VER- RUN CLUTCH O VER- DRIVE ROLLER CLUTCH FOR- W ARD CLUTCH DIRECT BAND FRONT BAND INTER- MEDIA TE SPRA G CLUTCH INTER- MEDIA TE[...]

____________________________________________ Transmission/Transfer Case 5-15 ® 05745159 Line Pressure T est 1. Check and adjust fluid le vel if necessary . 2. Raise vehicle on hoist 3. Connect pressure gauge to transmission test port (Figure 5-16). Gauge must have 325-350 psi (2240-2413 kPa) capacity. 4. Start engine and check pressures in Park, [...]

5-16 Transmission/Transfer Case _____________________________________________ ® Fluid Lev el 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 inspec- tion procedur[...]

____________________________________________ Transmission/Transfer Case 5-17 ® 05745159 Transmission Fluid Checking Procedure Step Action V alue(s) Y es No 1 Check the fluid color . Is the fluid color red? Go to step 2 Go to step 11 2 Is the fluid le vel satisfactory? Go to step 21 Go to step 3 3 Check the fluid. Is the fluid foamy? Go to ste[...]

5-18 Transmission/Transfer Case _____________________________________________ ® SCAN T OOL DIAGNOSIS NOTE: The Tech 1 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 vehicle requires use of a VIM (Vehicle Interface Mod ule), part nu[...]

____________________________________________ Transmission/Transfer Case 5-19 ® 05745159 Trouble Code Identification DTC Description DTC T ype Default Action P0218 T ransmission Fluid Overtemperature D 1. The PCM freezes shift adapts. 2. DTC P0218 is stored in PCM history . P0560 Sysem V oltage Malfunction D 1. The PCM inhibits TCC engagement. 2. T[...]

5-20 Transmission/Transfer Case _____________________________________________ ® P0741 T o rque Con verter Clutch System Stuck Of f B 1. The PCM illuminates the MIL. 2. The PCM inhibits TCC engagement. 3. The PCM inhibits fourth gear engagement. 4. The PCM commands increased line pressure. 5. DTC P0741 is stored in PCM history . P0742 T o rque Con [...]

____________________________________________ Transmission/Transfer Case 5-21 ® 05745159 P1860 T o rque Con verter Clutch Pulse W idth Modulation Solenoid Circuit Electri- cal A 1 . The PCM illuminates teh MIL. 2. The PCM inhibits TCC engagement. 3. The PCM inhibits fourth gear engagement. 4. The PCM freezes shift adapts. 5. DTC P1860 is stored in [...]

5-22 Transmission/Transfer Case _____________________________________________ ® Transmission Wiring Diagrams Figure 5-22: Transmission Wiring Diagram 1 of 6 FUSE 2D 20 AMP INTERIOR STS LAMP MIL LAMP FUSE 3A 20 AMP EXTERIOR HOT A T ALL TIMES HOT IN RUN AND ST ART HOT IN RUN AND ST ART FUSE 4B 5 AMP INTERIOR G2 G4 FUSE 1H 5 AMP INTERIOR DLC POWERTRA[...]

____________________________________________ Transmission/Transfer Case 5-23 ® 05745159 Figure 5-23: Transmission Wiring Diagrams 2 of 6 FUSE 2D 20 AMP INTERIOR FUSE 3A 20 AMP EXTERIOR FUSE 4D 15 AMP INTERIOR FUSE 6B 5 AMP INTERIOR 10 OR 291 PK AD BRAKE LAMP TCC/ CRUISE BC 31 40 C1- TO BRAKE LAMP C28-C13 C28-D13 C28-C12 C28-C1 1 C29-B10 C29-B9 TCC[...]

5-24 Transmission/Transfer Case _____________________________________________ ® Figure 5-24: Transmission Wiring Diagrams 3 of 6 FUSE 5C 10AMP INTERIOR FUSE 3A 10 AMP EXTERIOR ON/ OFF SET COAST RESUME ACCEL HOT IN RUN AND ST ART HOT IN RUN AND ST ART A 29 42 37 C1 C29-A1 1 C29-B1 1 C27-D10 C28-D14 C28-C2 C27-D12 C27-D3 C27-D4 C27-D6 C29-B2 C29-B1 [...]

____________________________________________ Transmission/Transfer Case 5-25 ® 05745159 Figure 5-25: Transmission Wiring Diagrams 4 of 6 FUSE 2A 10A EXTERIOR C33-F 351 PK C34 DC SB A M L C32-G C32-F C32-E C32-D C32-C C32-J C32-H C34-E C27-C15 C27-C7 C28-C5 C28-C6 C28-C4 C29-B12 C27-C9 265 LB 264 RD 924 TN 315 YL 237 LG 359 BK 923 BR PRESSURE CONTR[...]

5-26 Transmission/Transfer Case _____________________________________________ ® Figure 5-26: Transmission Wiring Diagrams 5 of 6 FUSE 3A 20A EXTERIOR HOT IN RUN AND ST ART TWISTED P AIR A/T OUTPUT SPEED SENSOR SIGNAL (VSS) BUFFERED VSS SIGNAL POWERTRAIN CONTROL MODULE (PCM) VEHICLE SPEED SENSOR (VSS) AB AB 12 7 C33 676 PP 679 LG VEHICLE SPEED SENS[...]

____________________________________________ Transmission/Transfer Case 5-27 ® 05745159 Figure 5-27: Transmission Wiring Diagrams 6 of 6 Automatic T ransmission Fluid Pressure Manual V alve Position Switch (TFP) T rans Range C Input T rans Range B Input T rans Range A Input C34 P R N D E C Rev Switch Lo Switch D2 Switch D3 Switch D4 Switch C32-S C[...]

5-28 Transmission/Transfer Case _____________________________________________ ® Connector Legend 76 W AY BULKHEAD LOC A TION: LEFT SIDE FIREW ALL PIN CKT COLOR CIRCUIT DESCRIPTION 1 400 LG Ignition Feed + 2 739 PP Left heated windshield po wer + 3 740 YL Right heated windshield po wer + 44 3 D B T railer Brake acti v ation 5 962 BR T railer lights[...]

____________________________________________ Transmission/Transfer Case 5-29 ® 05745159 12 37 RD Ignition relay feed 13 688 RD Rear windo w defrost feed 14 723 YL APP 3 5volt reference 15 724 DG APP 3 signal 16 17 PP + From dimmer module 17 718 DB APP 1 signal 18 353 YL Speedometer signal 19 607 TN ABS module diagnostic line 20 717 WH APP 1 5-volt[...]

5-30 Transmission/Transfer Case _____________________________________________ ® 45 327 YL W ater -in-fuel lamp acti vation 46 80 WH Underhood lamp po wer 47 3 LB Left front turn signal 48 914 PP PCM class 2 communication line to DLC 49 644 YL T achometer signal 50 210 DG Lo w washer fluid le vel lamp acti v ation 51 195 YL Headlight switch feed 5[...]

____________________________________________ Transmission/Transfer Case 5-31 ® 05745159 56 W AY INSTRUMENT PANEL LOC A TION: BEHIND INSTRUMENT P ANEL PIN CKT COLOR DESCRIPTION A1 195 YL Headlight switch feed A2 54 DG Dome lamp switch feed A3 53 DB Dome lamps feed A4 67 BR Rear wiper relay acti vation (not used 99) B1 38 RD Headlamp switch feed B2 [...]

5-32 Transmission/Transfer Case _____________________________________________ ® D2 2 L G Right turn indicator lamp acti v ation D3 961 PP TT4 indicator lamp acti vation E1 42 BR Brak e indicator lamp acti vation E2 603 RD ABS indicator lamp acti v ation E3 793 YL Lo w washer fluid acti v ation E4 943 TN Rear W iper feed (not used 99) F1 12 OR Hig[...]

____________________________________________ Transmission/Transfer Case 5-33 ® 05745159 N7 30 GY Ignition feed to guages N8 941 TN W indshield wiper washer pump acti v ation N9 945 BR Intermittent wiper relay acti vation P6 55 OR Rear cargo lamp acti v ation P7 29 PK Fuel guage signal P8 39 DG Engine temperature guage signal P9 353 YL Speedometer [...]

5-34 Transmission/Transfer Case _____________________________________________ ® 8 W AY STATUS CENTER -LH LOCATION: INSTR UMENT P ANEL PIN CKT COLOR DESCRIPTION A 12 OR Headlamp high beam B 3 LB Left turn lamp C 658 BR Check engine lamp D 327 YL Drain filter lamp E 603 RD ABS lamp F 450 PK Seat belt lamp G 46 WH CTIS pump lamp H 714 DB Check throt[...]

____________________________________________ Transmission/Transfer Case 5-35 ® 05745159 32W AY PCM-BRO WN LOCATION: CENTER CONSOLE, PCM PIN CKT COLOR DESCRIPTION C1 651 PP Crankshaft position sensor ground – C2 439 YL A/C request+ C3 C4 357 TN Intake air temp sensor signal C5 721 LB APP sensor (2) signal C6 466 YL Glow plug enable + C7 264 RD Pr[...]

5-36 Transmission/Transfer Case _____________________________________________ ® D9 156 PK Optical sensor ground – D10 153 LG Cruise control resume/accelerate D11 496 GY Transmission input speed signal (hi) D12 717 WH APP (1) 5 v olt ref. D13 350 GY Boost sensor/crankshaft position sensor 5 volt ref. D14 375 GY Optical sensor 5 volt reference D15[...]

____________________________________________ Transmission/Transfer Case 5-37 ® 05745159 32 W AY PCM-BLUE LOCATION: CENTER CONSOLE, PCM PIN CKT COLOR DESCRIPTION C1 C2 720 TN APP (2) 5 v olt ref. C3 712 LG Fuel inject signal C4 237 LG 1-2 shift solenoid control C5 924 TN T orque con v erter clutch soleniod control C6 315 YL 2-3 shift solenoid contr[...]

5-38 Transmission/Transfer Case _____________________________________________ ® D9 D10 D11 714 RD Check throttle lamp control D12 D13 537 OR Battery D14 154 TN W aste gate solenoid control D15 D16 PIN CKT COLOR DESCRIPTION[...]

____________________________________________ Transmission/Transfer Case 5-39 ® 05745159 24 W AY PCM-BRO WN LOCATION: CENTER CONSOLE, PCM PIN CKT COLOR DESCRIPTION A1 491 BK Closure ground A2 703 OR High resolution sensor signal A3 565 BR Transmission output speed sensor/VSS A4 442 BR Cam sensor signal A5 349 YL Crankshaft position sensor signal A6[...]

5-40 Transmission/Transfer Case _____________________________________________ ® 10 W AY TRANSMISSION-GREY LOCATION: A BEAM, LEFT NEAR LIFT PUMP PIN CKT COLOR CIRCUIT DESCRIPTION A 495 DB T ransmission Input Speed Sensor lo w B 496 GY T ransmission Input Speed Sensor high C 237 LG 1-2 shift solenoid control D 315 YL 2-3 shift solenoid control E 924[...]

____________________________________________ Transmission/Transfer Case 5-41 ® 05745159 10 W AY TRANSMISSION-BLACK LOCATION: A BEAM, LEFT NEAR LIFT PUMP PIN CKT COLOR CIRCUIT DESCRIPTION A 676 PP V ehicle Speed Sensor high B 679 LG V ehicle Speed Sensor lo w C D E 210 DG T ransfer case lock switch light activ ation F 351 PK T ransmission ignition [...]

5-42 Transmission/Transfer Case _____________________________________________ ® 20 W AY TRANSMISSION PASSTHROUGH LOCATION: TR ANSMISSION, LEFT PIN CKT COLOR CIRCUIT DESCRIPTION A 237 LG 1-2 Shift Solenoid acti vation B 315 YL 2-3 Shift Solenoid acti vation C 264 RD Pressure Control Solenoid high D 265 LB Pressure Control Solenoid lo w E 351 PK T r[...]

____________________________________________ Transmission/Transfer Case 5-43 ® 05745159 NOTE: Some corrections indicated in the table below may not be allowed on vehicles covered under the provisions of the war- ranty policy. The proper correction may be transmission replacement. Contact the AMG warranty department for direction in such cases. TRA[...]

5-44 Transmission/Transfer Case _____________________________________________ ® V ehicle Creeps In Neutral 1. Manual v alve mispositioned or stuck. 1. Remove v alv e body and repair as needed. 2. Forw ard clutch fault. 2. Replace transmission. V ehicle Mov es In Park 1. Manual linkage loose, damaged, misadjusted, disconnected. 1. Repair or adjust [...]

____________________________________________ Transmission/Transfer Case 5-45 ® 05745159 6. Overdri ve roller clutch f ailure. 6. Replace transmission. 7. V alv e body fault: • manual valve stuck, damaged • Pressure switch failure 7. Remov e and free-up binding valv es. Replace switch assembly if failed. Replace trans- mission if v alve body bo[...]

5-46 Transmission/Transfer Case _____________________________________________ ® 3. Intermediate clutch air bleed cup plug leaking or missing. 3. Replace transmission. 4. Overrun clutch f ault. 4. Replace transmission. 5. Forw ard clutch fault. 5. Replace transmission. 6. Intermediate clutch fault. 6. Replace transmission. 7. Shift solenoid fault. [...]

____________________________________________ Transmission/Transfer Case 5-47 ® 05745159 No T orque (Dri ve) In Sec- ond 1. W orn or damaged intermediate sprag clutch. 1. Replace transmission. No Overrun Braking In: 1. Rear band or servo f ault. 1. Replace transmission. 2. Main or output shaft damage. 2. Replace transmission. First (1) 3. Lo roller[...]

5-48 Transmission/Transfer Case _____________________________________________ ® Con v erter Clutch Apply T iming Incor - rect 1. Incorrect sensor input signal to PCM caused by inoperati ve sensor . 1. T est operation of all sensors with scan tool. Replace failed sensors as needed. 2. PCM problem. 2. T est with scan tool. Repair wires or module as [...]

____________________________________________ Transmission/Transfer Case 5-49 ® 05745159 DTC P0218 T ransmission 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, [...]

5-50 Transmission/Transfer Case _____________________________________________ ® . DTC P0218 Transmission Fluid Overtemperature Step Action V alue(s) Y es No 1 W as the Powertrain On-Board Diagnostic (OBD) System Check performed? Go to step 2 Go to Power - train OBD Sys- tem Check 2 Install the scan tool. WIth the engine of f, turn the ignition swi[...]

____________________________________________ Transmission/Transfer Case 5-51 ® 05745159 DTC P0560 System V oltage Fault 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[...]

5-52 Transmission/Transfer Case _____________________________________________ ® DTC P0560 System Voltage Fault Step Action V alue Y es No 1 1. Connect scan tool. 2. T urn the ignition switch to “on” position. Important : Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when the “Cl[...]

____________________________________________ Transmission/Transfer Case 5-53 ® 05745159 DTC P0711 T ransmission Fluid T emperature Sensor Circuit Range/P erformance Circuit Description The Automatic Transmission Fluid Temperature (TFT) Sensor is a thermistor (temperature sensitive resistor). The TFT Sen- sor is part of the 4L80-E Automatic Transmi[...]

5-54 Transmission/Transfer Case _____________________________________________ ® Conditions For Setting The DTC • No DTCs P1117 or P1118. • No OSS sensor DTC P0502. • No A/T ISS sensor. DTC P0716 or P0717. • No A/T Component Slipping DTC P1870. • The system voltage is 10.0 - 16.0 volts. • The engine is running greater than 475 rpm for a[...]

____________________________________________ Transmission/Transfer Case 5-55 ® 05745159 DTC P0711 Transmission Fluid Temperature Sensor Circuit Range/Performance Step Action V alue Y es N o 1 W as the Powertrain ON-Board Diagnostic (OBD) System Check performed? — Go to Step 2 Go to Po wertrain OBD System Check 2 Perform the A/T Fluid Checking Pr[...]

5-56 Transmission/Transfer Case _____________________________________________ ® 9 In order to verify your repair , perform the follo wing proce- dure: 1. Select DTC. 2. Select Clear Info. 3. 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[...]

____________________________________________ Transmission/Transfer Case 5-57 ® 05745159 DTC P0712 T ransmission Fluid T emperature (TFT) Sensor Circuit - Lo w Input (High T emperature Indicated) Circuit Description The transmission fluid temperature (TFT) sensor is a ther- mister that controls signal voltage to the PCM. The PCM sup- plies a 5-volt[...]

5-58 Transmission/Transfer Case _____________________________________________ ® Diagnostic Aids • With a transmission fluid overtemperature DTC P1812 also set, check the transmission cooling system. • Check harness routing for a potential short to ground in circuit. Scan tool TFT display should rise steadily to about 100° C (212° F), then st[...]

____________________________________________ Transmission/Transfer Case 5-59 ® 05745159 DTC P0712 Fluid Temperature Circuit Low/High Step Action V alue Y es No 1 Perform transmission fluid checking procedure. W as the fluid checking Procedure performed? — Go to Step 2— 2 1. Install the scan tool. 2. T urn the ignition switch to “on” posi[...]

5-60 Transmission/Transfer Case _____________________________________________ ® DTC P0713 T ransmission Fluid T emperature (TFT) Sensor Circuit - High Input (Lo w T em- perature Indicated) Circuit Description The transmission fluid temperature (TFT) sensor is a ther- mister that controls signal voltage to the PCM which supplies a 5-volt reference [...]

____________________________________________ Transmission/Transfer Case 5-61 ® 05745159 Diagnostic Aids • Check harness for a faulty connection or an open in cir- cuit. • Inspect wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals. Check[...]

5-62 Transmission/Transfer Case _____________________________________________ ® DTC P0713 Fluid Temperature Low Step Action V alue Y e s No 1 Perform the transmission fluid checking procedure. W as the fluid checking Procedure performed? — Go to Step 2 — 2 1. Install the scan tool. 2. W ith the engine “of f, ” turn the ignition switch ?[...]

____________________________________________ Transmission/Transfer Case 5-63 ® 05745159 11 Replace PCM. Is the replacement complete? __ Go to Step 12 __ 12 1. After the repair is complete, use the scan tool to select “DTC, ” then “Clear Info” function. 2. Select “Specific DTC” and enter DTC “P0713. ” 3. Ensure the follo wing condi[...]

5-64 Transmission/Transfer Case _____________________________________________ ® DTC P0716 Input Speed Sensor Circuit - Range/Perf ormance Circuit Description The Transmission input speed sensor consists of a permanent magnet surrounded by a coil of wire. Current is induced in the sensor by the forward clutch housing lugs which pass through the sen[...]

____________________________________________ Transmission/Transfer Case 5-65 ® 05745159 DTC P0716 Input Speed Sensor Range/Performance Step Action V alue Y e s No 1 1. Connect scan tool. 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 “C[...]

5-66 Transmission/Transfer Case _____________________________________________ ® DTC P0717 Input Speed Sensor Circuit - No Signal Circuit Description The transmission input speed sensor consists of a permanent magnet surrounded by a coil of wire. An AC voltage is induced in the sensor by lugs on the rotating forward clutch. Signal voltage and frequ[...]

____________________________________________ Transmission/Transfer Case 5-67 ® 05745159 DTC P0719 Brak e Switch Circuit - Lo w Input, Stuck “ON” Circuit Description The brake switch indicates brake pedal position. The normally- closed brake switch supplies a B+ signal on circuit 810 to the PCM. The signal voltage circuit is opened when the bra[...]

5-68 Transmission/Transfer Case _____________________________________________ ® 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 ma[...]

____________________________________________ Transmission/Transfer Case 5-69 ® 05745159 DTC P0722 Output Speed Sensor Low Input Circuit Description The speed sensor circuit consists of a magnetic induction type sensor, which is the Output Shaft Speed (OSS) Sensor, a Vehi- cle Speed Sensor (VSS) Buffer Module, and wiring. Gear teeth pressed onto th[...]

5-70 Transmission/Transfer Case _____________________________________________ ® Conditions for Clearing the DTC 1. The PCM turns OFF the MIL after three consecuti ve igni- tion cycles without a f ailure reported. 2. 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 c[...]

____________________________________________ Transmission/Transfer Case 5-71 ® 05745159 3 1. T urn the ignition OFF . 2. Disconnect the OSS Sensor connector from the OSS Sensor . 3. Connect a J– 39200 D V OM on AC V oltage scale between terminals A and B at the OSS Sensor . 4. Start the engine, and place the transmission in D3 range. 5. Slo wly [...]

5-72 Transmission/Transfer Case _____________________________________________ ® 11 W ith the connector of f of the VSS Buf fer Module and the ke y to the ON position, measure the voltage between terminal 13 of the VSS Buf fer Harness Connector and a good ground. Is the voltage within the specified v alue? 4.8-5.2 volts DC Go to Step 15 Go to Step[...]

____________________________________________ Transmission/Transfer Case 5-73 ® 05745159 DTC P0723 Output Speed Sensor Intermittent Circuit Description The speed sensor circuit consists of a magnetic induction type sensor, which is the Output Shaft Speed (OSS) Sensor, a Vehi- cle Speed Sensor (VSS) Buffer Module, and wiring. Gear teeth pressed onto[...]

5-74 Transmission/Transfer Case _____________________________________________ ® Conditions for Clearing the DTC 1. The PCM tuns OFF the MIL after three consecuti ve igni- tion cycles without a f ailure reported. 2. 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 cy[...]

____________________________________________ Transmission/Transfer Case 5-75 ® 05745159 3 1. T urn the ignition OFF . 2. Disconnect the OSS Sensor connector from the OSS Sensor . 3. Connect a J– 39200 D V OM (covered in Electrical Section 12) on A C V o ltage scale between terminals A and B at the OSS Sensor . 4. T urn the ignition to the R UN p[...]

5-76 Transmission/Transfer Case _____________________________________________ ® 11 1. W ith the engine OFF , turn the ignition to the R UN position. 2. Using the J– 39200 D V OM, measure the v oltage at the VSS Buf fer Harness connector terminal 13. Is the voltage steady and within the specified v oltage? 4.8-5.2 volts DC Go to Step 13 Go to St[...]

____________________________________________ Transmission/Transfer Case 5-77 ® 05745159 21 In order to verify your repair , perform the fol- lo wing procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the follo wing conditions: • Drive the vehicle in D3. • The PCM must see a Transmission OSS greater than 200 RPM and no[...]

5-78 Transmission/Transfer Case _____________________________________________ ® DTC P0724 Brak e Switch Circuit High Input Circuit Description The brake switch indicates brake pedal position. The normally- closed brake switch supplies a B+ signal on circuit 810 to the PCM. The signal voltage circuit is opened when the brakes are applied. The PCM u[...]

____________________________________________ Transmission/Transfer Case 5-79 ® 05745159 DTC P0724 Brake Switch Circuit High Input Step Action V alue Y e s No 1 1. Install scan tool. 2. T urn ignition switch “on. ” NOTE: Important: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when[...]

5-80 Transmission/Transfer Case _____________________________________________ ® DTC P0730 Incorrect Gear Ratio 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 [...]

____________________________________________ Transmission/Transfer Case 5-81 ® 05745159 DTC P0730 Incorrect Gear Ratio Step Action V alue Y e s No 1 W as the Powertrain On-Board Diagnostic (OBD) Sys- tem Check performed? – Go to Step 2 Go to P ower- train OBD System Check 2 Perform the T ransmission Fluid Checking Procedure. Refer to T ransmissi[...]

5-82 Transmission/Transfer Case _____________________________________________ ® 8 Is the system line pressure lo w only in the specific gear which indicated an incorrect gear ratio? – Go to Step 9 Go to System Diagnosis T able; Low Line Pressure 9 Inspect for fluid pressure loss in the following areas: • 1-2 SS Valve seal • 2-3 SS Valve se[...]

____________________________________________ Transmission/Transfer Case 5-83 ® 05745159 DTC P0741 T or que Con verter Clutch Solenoid Stuck OFF FUSE 2A 10A EXTERIOR C33-F 351 PK C34 DC SB A M L C32-G C32-F C32-E C32-D C32-C C32-J C32-H C34-E C27-C15 C27-C7 C28-C5 C28-C6 C28-C4 C29-B12 C27-C9 265 LB 264 RD 924 TN 315 YL 237 LG 359 BK 923 BR PRESSUR[...]

5-84 Transmission/Transfer Case _____________________________________________ ® Circuit Description The PCM energizes the converter clutch solenoid by creating a ground path on CKT 924. When grounded (energized) by the PCM, enable solenoid stops converter signal oil from exhaust- ing. This causes converter signal oil pressure to increase and shift[...]

____________________________________________ Transmission/Transfer Case 5-85 ® 05745159 DTC P0742 T or que Con verter Clutch Stuck On FUSE 2A 10A EXTERIOR C33-F 351 PK C34 DC SB A M L C32-G C32-F C32-E C32-D C32-C C32-J C32-H C34-E C27-C15 C27-C7 C28-C5 C28-C6 C28-C4 C29-B12 C27-C9 265 LB 264 RD 924 TN 315 YL 237 LG 359 BK 923 BR PRESSURE CONTROL [...]

5-86 Transmission/Transfer Case _____________________________________________ ® Circuit Description The PCM energizes the converter clutch solenoid by creating a ground path on circuit 924. When grounded (energized) by the PCM, the solenoid stops converter signal oil from exhausting. This causes converter signal oil pressure to increase and move t[...]

____________________________________________ Transmission/Transfer Case 5-87 ® 05745159 DTC P0742 Torque Converter Clutch Stuck On Step Action V alue Y e s No 1 1. Connect scan tool. 2. T urn the ignition switch to on. 3. Record the DTC “Freeze Frame” and Failure Records. ” 4. Using the scan tool, verify the “TP Sensor” opera- tion. Are [...]

5-88 Transmission/Transfer Case _____________________________________________ ® DTC P0748 Pressure Control Solenoid (PCS) - Electrical Circuit Description The PCS is a PCM-controlled device used to regulate transmis- sion line pressure. The PCM compares electronic accelerator pedal voltage, engine rpm, and other inputs to determine line pressure a[...]

____________________________________________ Transmission/Transfer Case 5-89 ® 05745159 Diagnostic Aids • Inspect the wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals. Check for weak terminal tension as well. Also check for a chafed wir[...]

5-90 Transmission/Transfer Case _____________________________________________ ® . DTC P0748 Pressure Control Solenoid - Electrical Step Action V alue Y e s No 1 1. Connect scan tool. 2. T urn the ignition switch to on. NOTE: Important: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost whe[...]

____________________________________________ Transmission/Transfer Case 5-91 ® 05745159 DTC P0751 1-2 Shift Solenoid V alv e P erf or mance 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 com[...]

5-92 Transmission/Transfer Case _____________________________________________ ® Stuck Off: (after two occurrences) • Ist 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. Stuck On: (after five occur[...]

____________________________________________ Transmission/Transfer Case 5-93 ® 05745159 DTC P0753 1-2 Shift Solenoid V alve Electrical 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 combinat[...]

5-94 Transmission/Transfer Case _____________________________________________ ® Diagnostic Aids • Inspect the wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals. Check for weak terminal tension as well. Also check for a chafed wire that c[...]

____________________________________________ Transmission/Transfer Case 5-95 ® 05745159 4 1. T urn the ignition “ off ” long enough to po wer do wn PCM. 2. Disconnect the transmission 20-way connector (additional DTCs will set). 3. Install the jumper harness 05743837 on the engine side of the 20-way connector . 4. W ith the engine of f, turn t[...]

5-96 Transmission/Transfer Case _____________________________________________ ® 12 1. Disconnect the internal wiring harness from 1-2 shift solenoid. 2. Using multimeter measure the resistance from solenoid terminals to ground. Are readings greater than v alue indicated? 250K Ω Go to step 13. Go to step 14. 13 Inspect/repair the internal wiring [...]

____________________________________________ Transmission/Transfer Case 5-97 ® 05745159 DTC P0756 2-3 Shift Solenoid V alve P erformance 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 D[...]

5-98 Transmission/Transfer Case _____________________________________________ ® Stuck On: • Commanded Gear equals 1st and ratio equals 3rd for greater than 2 seconds (Actual gear equals 4th). • Commanded Gear equals 2nd and ratio equals 3rd for greater than 2 seconds. • Conditions occur for 4 occurrences. Stuck Off: • Commanded Gear equals[...]

____________________________________________ Transmission/Transfer Case 5-99 ® 05745159 DTC P0756 2-3 Shift Solenoid Valve Performance Step Action V alue Y es No 1 1. Connect scan tool. 2. T urn the ignition switch on. 3. Record “Freeze Frame” and “Failure Records. ” 4. Start engine, apply brake pedal and shift into D1, D2, D3, D4, N, R, a[...]

5-100 Transmission/Transfer Case ___________________________________________ ® DTC P0758, 2-3 Shift Solenoid Electrical 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 to provide four different shift combinations. The solenoid is[...]

___________________________________________ Transmission/Transfer Case 5-101 ® 05745159 Diagnostic Aids • Inspect the wiring for poor electrical connections at the PCM and at the transmission 20-way connector. Look for possible bent, backed out, deformed or damaged ter- minals. Check for weak terminal tension as well. Also check for a chafed wir[...]

5-102 Transmission/Transfer Case ___________________________________________ ® 4 1. T urn ignition “ Off ” . 2. Disconnect transmission 20-way connector (addi- tional DTCs will set). 3. Connect 05743837 Jumper Harness to engine har- ness connector . 4. Stop engine, then turn the ignition switch to the “ Run ” position. 5. Connect test ligh[...]

___________________________________________ Transmission/Transfer Case 5-103 ® 05745159 14 Replace the 2-3 shift solenoid v alve. Is replacement complete? — Go to step 15 — 15 Preform the follo wing procedure in order to verify the repair: 1. Select “ DTC ” on the scan tool. 2. Select “ Clear Info. ” . 3. Select the “ Parameters, 2-3[...]

5-104 Transmission/Transfer Case ___________________________________________ ® DTC P1810 Pressure Switch Assembly (PSA) Fault Circuit Description The PSA consists of five normally open pressure switches. The PCM supplies battery voltage to each range signal. By ground- ing one or more of these circuits through various combinations of the switches,[...]

___________________________________________ Transmission/Transfer Case 5-105 ® 05745159 Condition 3: • No DTCs P0121, P0122, P0123, P0220, P0221, P0222, P0223, P0225, P0226, P0227 or P0228. • No DTCs P0716 or P0717. • No DTCs P0722 or P0723. • No 1-2 shift solenoid DTCs P0751 or P0753. • No 3-4 shift solenoid DTCs P0756 or P0758. • Eng[...]

5-106 Transmission/Transfer Case ___________________________________________ ® DTC P1810 Pressure Switch Circuit Fault Step Action V alue Y e s No 1 Perform follo wing check: • Transmission linkage (from select lever to the manual valve) is properly adjusted. • Fluid check. W ere checks performed? — Go to Step 2 — 2 1. Connect scan tool. 2[...]

___________________________________________ Transmission/Transfer Case 5-107 ® 05745159 9 1. After the repair is complete, use the scan tool to select “DTC, ” then “Clear in fold function. 2. Select “Specific DTC” and enter DTC “P1810. ” 3. Operate the vehicle under the follo wing condi- tions: • Turn the ignition switch “on” [...]

5-108 Transmission/Transfer Case ___________________________________________ ® DTC P1811 Maximum Adapt and Long Shift Circuit Description The Powertrain Control Module (PCM) compares the mea- sured 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[...]

___________________________________________ Transmission/Transfer Case 5-109 ® 05745159 Conditions For Clearing DTC • 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 an[...]

5-110 Transmission/Transfer Case ___________________________________________ ® DTC P1811 Maximum Adapt and Long Shift Step Action V alue Y es No 1 W as the Powertrain ON-Board Diagnostic (OBD) System Check performed? — Go to Step 2 Go to OBD Po wertrain System Check. 2 Hav e you performed the transmission fluid checking procedure? — Go to Ste[...]

___________________________________________ Transmission/Transfer Case 5-111 ® 05745159 10 Did the 2-3 shift time exceed the specified v alue? 1.25 seconds Go to Step 13 Go to Step 11 11 Did the 1-2 shift time exceed the specified v alue? 1.25 seconds Go to Step 14 — 12 Inspect the follo wing 3-4 shift circuit components: • 4th Gear Clutch P[...]

5-112 Transmission/Transfer Case ___________________________________________ ® DTC P1860 T or que Con verter Clutch Pulse Width Modulation Solenoid Electrical Circuit Description The Torque Converter Clutch Pulse Width Modulation Sole- noid Valve (TCC PWM Sol. Valve) controls fluid acting on the converter clutch valve, which then controls TCC appl[...]

___________________________________________ Transmission/Transfer Case 5-113 ® 05745159 Conditions For Clearing DTC 1. The PCM turns OFF the MIL after three consecuti ve igni- tion cycles without a f ailure reported. 2. 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-[...]

5-114 Transmission/Transfer Case ___________________________________________ ® DTC P1860 Torque Converter Clutch Pulse Width Modulation Solenoid Electrical Step Action V alue Y e s No 1 W as the Po wertrain On-Board Diagnostic (OBD) Sys- tem Check performed? — Go to Step 2 Go to Po wer- train OBD System Check 2 1. Install the scan tool (T ech 1)[...]

___________________________________________ Transmission/Transfer Case 5-115 ® 05745159 9 Replace the PCM. Refer to PCM Replacement/Pr o- gramming , Section 6. Is the replacement complete? — Go to Step 17 — 10 1. Disconnect the internal wiring harness at the TCC PWM Sol. V alve. 2. Measure the resistance of the TCC PWM Sol. Va l v e . Is the r[...]

5-116 Transmission/Transfer Case ___________________________________________ ® DTC P1870 T ransmission Component Slipping Circuit Description The PCM monitors the difference in engine speed and trans- mission input speed. In D3 drive range with the converter clutch engaged, engine speed should closely match transmis- sion output speed. In D4 drive[...]

___________________________________________ Transmission/Transfer Case 5-117 ® 05745159 DTC P1870 Transmission Component Slip Step Action V alue Y e s No 1 W as the Po wertrain On-Board Diagnostic (OBD) Sys- tem Check performed? — Go to Step 2 Go to Po wer- train OBD System Check 2 Perform the T ransmission Fluid Checking Procedure. Refer to Lin[...]

5-118 Transmission/Transfer Case ___________________________________________ ® 7 Repeat the procedure in step 5. Drive the v ehicle under the follo wing conditions: • The transmission is in D4. • The TCC is engaged. • The APP angle is 12-70%. Are the results the same as in step 5? 140-500 RPM Go to Step 9 Go to Step 11 8 Refer to 4L80-E Syst[...]

___________________________________________ Transmission/Transfer Case 5-119 ® 05745159 DTC P1871 Undefined Gear Ratio Circuit Description The PCM calculates ratio based on transmission input and out- put speed sensor readings. The PCM compares known trans- mission ratio to calculated ratio, for gear range selected. This DTC detects an unknown ra[...]

5-120 Transmission/Transfer Case ___________________________________________ ® DTC P1871 Undefined Gear Ratio Step Action V alue Y e s No 1 Was the powertrain On-Board Diagnostic (OBD) Sys- tem Check Performed? — Go T o step 2 Go to Po wer- train OBD system Check 2 Perform the transmission fluid checking procedure. Refer to Fluid Le vel and Con[...]

___________________________________________ Transmission/Transfer Case 5-121 ® 05745159 9 In order to verify your repair , perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. Operate the vehicle under the follo wing condi- tions: • K ey ON, the engine is running. • Dri ve the vehicle in 1st, 2nd, 3rd and 4th gear . • The[...]

5-122 Transmission/Transfer Case ___________________________________________ ® DTC P1875 Four -Wheel Dr ive Lo w Switch Fault 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 voltage to the PCM will chang[...]

___________________________________________ Transmission/Transfer Case 5-123 ® 05745159 Action Taken When The DTC Sets • Assume “Low” state when stuck “off' and “High” state when stuck ”on”. • Freeze shift adapts from being updated. • The PCM will illuminate the warning lamp. Conditions For Clearing DTC • The PCM will tu[...]

5-124 Transmission/Transfer Case ___________________________________________ ® DTC P1875 4WD Low Switch Fault Step Action V alue Y es No 1 1. Connect scan tool. 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. 2[...]

___________________________________________ Transmission/Transfer Case 5-125 ® 05745159 Electrical/Garage Shift T est 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 cond[...]

5-126 Transmission/Transfer Case ___________________________________________ ® Torque Converter Evaluation and Diagnosis Replace the torque converter under any of the following condi- tions: • 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 th[...]

___________________________________________ Transmission/Transfer Case 5-127 ® 05745159 TFP Valve Position Switch Resistance Check Step Action V alue(s) Y es No 1 1. Install the J 39775 Jumper harness on the transmission side of the 20 way transmission pass-through connector . 2. Using a D V OM and the J35616 Connector T est Adapter Kit, measure t[...]

5-128 Transmission/Transfer Case ___________________________________________ ® 9 1. Place the gear selector in Lo w (D1). 2. Measure the resistance from terminal N to the transmission case. Is the resistance less than the v alue indicated? 200 Ω Go to step 10 Go to step 14 10 1. Place the gear selector in Lo w (D1). 2. Measure the resistance fro[...]

___________________________________________ Transmission/Transfer Case 5-129 ® 05745159 Automatic Transmission Wiring Harness Check Step Action V alue(s) Y es No 1 1. Install the J 39775 jumper on the transmis- sion 20 way connector . 2. Using a D V OM and a J 35616 T est Adapter Kit, measure the resistance between termi- nals A and E (1-2 Shift S[...]

5-130 Transmission/Transfer Case ___________________________________________ ® 9 Measure the resistance between terminals L and M (T ransmission Fluid T emperature Sensor) Is the resistance within the v alues indicated? 3333-3689 Ω @ 20° C (68°F) 24-31 Ω @ 100°C (212°F) Go to step 10 Go to step 12 10 Measure the resistance from terminals A[...]

___________________________________________ Transmission/Transfer Case 5-131 ® 05745159 T ransmission Cooler Flushing Procedure Equipment Needed • J–35944-A cooler flushing tool with included adapters and J–35944-22 or J–35944-CSE* flushing solution. • Measuring Cup • Funnel • Water Supply (hot water recommended) • Water Hose (at l[...]

5-132 Transmission/Transfer Case ___________________________________________ ® 4. 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 [...]

___________________________________________ Transmission/Transfer Case 5-133 ® 05745159 COOLER LINE AND BYPASS V ALVE SER VICE The transmission and transfer case oil cooler lines are replace- able 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 sepa[...]

5-134 Transmission/Transfer Case ___________________________________________ ® V ENT LINE SER VICE 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[...]

___________________________________________ Transmission/Transfer Case 5-135 ® 05745159 CON VERTER HOUSING UPPER CO VER REPLACEMENT 1. Remov e con verter housing upper co ver from transmission flange (Figure 5-35). 2. Remove gasket from cover. 3. Clean gasket or sealer remains from transmission flange. Figure 5-35: Converter Housing Upper Cover M[...]

5-136 Transmission/Transfer Case ___________________________________________ ® V ALV E BODY SWITCH AND SOLENOID SER VICE 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 • conver[...]

___________________________________________ Transmission/Transfer Case 5-137 ® 05745159 Figure 5-39: Solenoid Identification Valve Body Installation 1. Install replacement solenoid or wiring harness as required. 2. Verify that valve body spacer plate and gasket are in position. Also be sure check-balls were not displaced. There should be eight che[...]

5-138 Transmission/Transfer Case ___________________________________________ ® Figure 5-41: Park Lock Components PARK PAWL STUD BRACKET BOLT (2) DETENT NUT ACTUATOR ROD DETENT SHAFT PIN DETENT SHAFT SEAL RETAINER RETURN SPRING CUP PLUG PAWL SHAFT[...]

___________________________________________ Transmission/Transfer Case 5-139 ® 05745159 T OR QUE CON VERTER/FLEXPLATE/ CON VERTER SEAL REPLACEMENT 1. Remov e transmission as described in this section. 2. Remove torque converter from transmission (Figure 5-42). 3. Remove oil seal from pump. Use standard hook tool to pull seal. Figure 5-42: Torque C[...]

5-140 Transmission/Transfer Case ___________________________________________ ® Figure 5-45: Shift Rod Attachment Figure 5-46: Transmission Shift Rod and Trunnion Figure 5-47: Vehicle Speed Sensor and Switch Harness Connections Figure 5-48: Range Indicator Connection Figure 5-49: Releasing Transmission Case Harness Connectors TRANSFER CASE SHIFT RO[...]

___________________________________________ Transmission/Transfer Case 5-141 ® 05745159 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 [...]

5-142 Transmission/Transfer Case ___________________________________________ ® Figure 5-53: Torque Converter-To-Flexplate Bolt Locations T RANSMISSION INSTALLATION CA UTION: If the transmission was replaced, or repaired to correct a problem that generated metal and clutch disc parti- cles, the transmission cooler and lines must be thoroughly flush[...]

___________________________________________ Transmission/Transfer Case 5-143 ® 05745159 SHIFT CONTROL ASSEMBLY REMO V AL NOTE: Wavy washers eliminate any potential transfer case shift linkage rattle (Figure 5-54). If a rattle is present on a vehi- cle not equipped with a wavy washer, install one as shown. Re- fer to parts manual for wavy washer pa[...]

5-144 Transmission/Transfer Case ___________________________________________ ® SHIFT CONTROL ASSEMBLY SER VICE 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 [...]

___________________________________________ Transmission/Transfer Case 5-145 ® 05745159 PARK/NEUTRAL P OSITION OR BAC KUP LAMP SWITCH REPLACEMENT 1. Remov e driv er side inner kick panel. 2. Open shifter boot cover for access to shift control arms. 3. Disconnect shift rods at shift control arms. 4. Remove bolts attaching shift control housing to t[...]

5-146 Transmission/Transfer Case ___________________________________________ ® SHIFTER BOOT CO VER 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 [...]

___________________________________________ Transmission/Transfer Case 5-147 ® 05745159 Installation 1. W ork shifter boot cover lip into tunnel opening and align edges carefully to match opening. 2. Set shift control assembly into tunnel. Verify that fastener holes are positioned properly and shifter boot cover lip is not exposed. 3. Secure shift[...]

5-148 Transmission/Transfer Case ___________________________________________ ® SHIFT LINKAGE ADJUSTMENT 1. Mov e shift lev er to manual low (1) range. 2. Disconnect transmission shift rod from arm in shift control housing. 3. Verify that transmission shift lever (Figure 5-63) is in manual low (1) range. If not, disconnect lever trunnion and adjust[...]

___________________________________________ Transmission/Transfer Case 5-149 ® 05745159 T RANSFER CASE DESCRIPTION Hummer vehicles are equipped with the New Process Gear, model 242 transfer case. If you have questions about the trans- fer case that are not answered by this section, you can call the T ransfer Case Hotline at 1-800-945-4327 for more[...]

5-150 Transmission/Transfer Case ___________________________________________ ® T RANSFER CASE OIL COOLER The NP 242 used in Hummer vehicles is equipped with an in- ternal 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/out- let tubes. The cooler is int[...]

___________________________________________ Transmission/Transfer Case 5-151 ® 05745159 OPERATING RANGES The three operating ranges are for specific use on or off road. Usage recommendations are: High Lock (HL) High lock range is for use on low traction surfaces. It is an un- differentiated range and should only be employed on unpaved, or low trac[...]

5-152 Transmission/Transfer Case ___________________________________________ ® TRANSFER CASE DIAGNOSIS PR OBLEM PO TENTIAL CA USE CORRECTION T ransfer Case Hard to Shift or W ill Not Shift Into Desired Range 1. V ehicle speed too great to permit shifting. 2. V ehicle dri v en for extended period on pa ved road surface in high lock (HL) range. Inte[...]

___________________________________________ Transmission/Transfer Case 5-153 ® 05745159 T RANSFER CASE SHIFT ROD SER VICE Removal 1. Unfasten snaps and pull v elcro strips apart to open shifter boot cov er . 2. Remove cotter pins and washers securing shift rod to shift arm and range lever (Figure 5-70). 3. Remove shift rod and trunnion as assembly[...]

5-154 Transmission/Transfer Case ___________________________________________ ® 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). 2. Remove switch and/or sensor from transfer case (Figures 5-73 and 5-74). Figure 5-73: Speed[...]

___________________________________________ Transmission/Transfer Case 5-155 ® 05745159 FRONT OUTPUT SHAFT SEAL REPLACEMENT 1. Mark front propeller shaft and transfer case yoke for align- ment reference. 2. Disconnect front propeller shaft at yoke. Retain U-bolts and nuts (Figure 5-76). 3. Remove yoke nut (Figure 5-77). 4. Remove yoke and seal was[...]

5-156 Transmission/Transfer Case ___________________________________________ ® T RANSFER CASE REMO V AL 1. Remov e drain plug and drain oil from transfer case. Rein- stall drain plug afterward. 2. Disconnect propeller shafts from transfer case. 3. Disconnect wiring harness connectors from vehicle speed sensors range switch, and lock switch. 4. Rem[...]

___________________________________________ Transmission/Transfer Case 5-157 ® 05745159 T RANSFER CASE DISASSEMBLY AND OVERHAUL 1. Remov e vehicle speed sensor and both indicator switches. 2. Remove front output shaft yoke (Figure 5-82). Remove yoke nut with suitable size socket and impact wrench. Then remove seal washer and yoke. Figure 5-82: Fro[...]

5-158 Transmission/Transfer Case ___________________________________________ ® Figure 5-86: Rear Retainer Removal 7. Remove speedometer tone wheel and snap rings (Figure 5-87). 8. Remove rear case attaching bolts and remove rear case (Figure 5-88). CA UTION: Loosen the rear case with screwdrivers positioned in the slot at each end of the case. Thi[...]

___________________________________________ Transmission/Transfer Case 5-159 ® 05745159 Figure 5-90: Oil Pump O-ring Location 11. Remove drive sprocket snap ring (Figure 5-91). 12. Remove drive sprocket (Figure 5-92). 13. Remove drive chain. 14. Remove front output shaft and driven sprocket as assembly (Figure 5-93). Figure 5-91: Drive Sprocket Sn[...]

5-160 Transmission/Transfer Case ___________________________________________ ® 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). Figure 5-95: Oil Cooler and[...]

___________________________________________ Transmission/Transfer Case 5-161 ® 05745159 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 (Fig[...]

5-162 Transmission/Transfer Case ___________________________________________ ® 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). Figure 5-101: Differential Snap Ring Location Figure 5-102: Differential Removal Figure 5-103[...]

___________________________________________ Transmission/Transfer Case 5-163 ® 05745159 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). Figure 5-106: Front Retainer Removal 30. Remove s[...]

5-164 Transmission/Transfer 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 apa[...]

___________________________________________ Transmission/Transfer Case 5-165 ® 05745159 Figure 5-114: Mainshaft and Sprocket Gear Removal Figure 5-115: Removing Front Output Shaft Seal T RANSFER CASE CLEANING AND INSPECTION Clean the transfer case components thoroughly with standard parts cleaning solvent. Remove all traces of sealer from the case[...]

5-166 Transmission/Transfer Case ___________________________________________ ® 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. Bearings and Seals The transfer case seals should be replaced during ov[...]

___________________________________________ Transmission/Transfer Case 5-167 ® 05745159 Figure 5-118: Front Output Shaft Front Bearing Installation Figure 5-119: Front Output Shaft Seal Installation Figure 5-120: Front Output Shaft Rear Bearing Removal Figure 5-121: Front Output Shaft Rear Bearing Installation TOOL HANDLE TOOL J–33833 J–8092 F[...]

5-168 Transmission/Transfer Case ___________________________________________ ® INPUT GEAR BEARING REPLACEMENT 1. Remov e old bearing from interior of front case as shown. Use tool handle J–8092 and tool J–29170 (Figure 5-122). 2. Install new bearing using tool handle J–8092 and tool J– 29170 (Figure 5-123). Seat bearing so locating ring is[...]

___________________________________________ Transmission/Transfer Case 5-169 ® 05745159 EXTENSION HOUSING BUSHING AND SEAL REPLACEMENT 1. Remov e old seal with pry tool. 2. Drive out old bushing with tool handle J–8092 and tool J– 33839 (Figure 5-126). 3. Position new bushing on tool J–33839 and tap bushing into place until flush with bushin[...]

5-170 Transmission/Transfer Case ___________________________________________ ® T RANSFER CASE ASSEMBLY 1. Assemble input gear and lo w 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) NOTE: The [...]

___________________________________________ Transmission/Transfer Case 5-171 ® 05745159 Figure 5-133: Shift Sector Installation 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 sp[...]

5-172 Transmission/Transfer Case ___________________________________________ ® Figure 5-137: Front Retainer Installation Figure 5-138: Assembling Low Range Fork and Hub Figure 5-139: Engaging Low Range Fork Pin in Shift Sector 9. Check condition of tone wheel on mainshaft. Replace wheel if teeth are chipped, cracked, or broken. 10. Coat needle bea[...]

___________________________________________ Transmission/Transfer Case 5-173 ® 05745159 Figure 5-141: Differential Pinion and Sprocket Gear Installation Figure 5-142: Assembling Differential Front/Rear Cases Figure 5-143: Mainshaft Bearing Roller Installation Figure 5-144: Installing Differential On Mainshaft 15. Install mode sleeve in mode fork. [...]

5-174 Transmission/Transfer Case ___________________________________________ ® Figure 5-145: Differential Snap Ring Installation Figure 5-146: Intermediate Clutch Shaft Installation Figure 5-147: Intermediate Clutch Shaft Thrust Ring and Snap Ring Installation 18. Install shift rail. Install rail through mode fork, range fork, and into case bore a[...]

___________________________________________ Transmission/Transfer Case 5-175 ® 05745159 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 N • m) (Figure 5-154). 20. Install range lever on sector shaft, then secure lever with wash[...]

5-176 Transmission/Transfer Case ___________________________________________ ® Figure 5-152: Mainshaft, Differential, and Mode Fork Installation Figure 5-153: Shift Rail Installation 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 sproc[...]

___________________________________________ Transmission/Transfer Case 5-177 ® 05745159 30. Position pump assembly in rear case. Be sure pickup screen is seated in case notch as shown (Figure 5-160). Figure 5-155: Front Output Shaft and Sprocket Assembly Figure 5-156: Drive Chain and Sprocket Installation Figure 5-157: Securing Drive Sprocket to M[...]

5-178 Transmission/Transfer Case ___________________________________________ ® Figure 5-158: Oil Pump Seal Installation 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 J – 8092 and installer J33832[...]

___________________________________________ Transmission/Transfer Case 5-179 ® 05745159 Figure 5-162: Rear Case Installation Figure 5-163: Tone Wheel Speedometer Installation Figure 5-164: Installing Mainshaft Bearing In Rear Retainer Figure 5-165: Rear Retainer and Mainshaft Bearing Snap Ring Installation Figure 5-166: Extension Housing Installat[...]

5-180 Transmission/Transfer Case ___________________________________________ ® Figure 5-167: Front Yoke Installation 43. Install drain plug in rear case. Tighten plug to 15-25 lb-ft (20-33 N • m). 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 N • [...]

___________________________________________ Transmission/Transfer Case 5-181 ® 05745159 T RANSFER CASE T OR QUE SPECIFICATIONS T RANSMISSION T OR QUE SPECIF ICATIONS Case bolts (all) . . . . . . . . . . . . . . . . . . . . . . . . . . . Detent plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain/fill plugs . . . . . . . . . . . [...]

5-182 Transmission/Transfer Case ___________________________________________ ® ESSENTIAL T OOLS Procure from Kent-Moore. J–35944-AMG J–35944-500 J–35944-22 J–8614-01 J–33043-2 J–33831 J–33835 J–25025-B J–21867 J–39775 J–8092 J–42497 T ool No. Description J–35944-AMG T ransmission Oil Cooler Flush Kit J–35944-500 Cooler [...]

___________________________________________ Transmission/Transfer Case 5-183 ® 05745159 SPECIAL T OOLS Procure from Kent-Moore. T ool No. Description J–2619-01 Slide Hammer and Adapter J–29369 Bushing/Bearing Remov er Kit J–33839 Rear Output Bushing Remov er (use with J–8092) J–33829 Pilot Bearing Installer (use with J–8092) J–33833 [...]

5-184 Transmission/Transfer Case ___________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

________________________________________________________________________________ 6-1 ® 05745159 Section 6 Wheels and Tires/Central Tire Inflation System (CTIS) T ABLE OF CONTENTS Central Tire Inflation System Air Intake Line and Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-51 Air Leak Troubleshooting . . . . . . . . . . . . . . . . . [...]

6-2 Wheels and Tires/Central Tire Inflation System (CTIS) _________________ ® Figure 6-1: Wheel and Tire Assembly Replacement Installation NOTE: The Wrangler GS-A, 37 X 12.50R16.5 LT touring ra- dial tire has an asymmetrical/directional tread design. The heavier, stiffer tread on the outside shoulder of the tire must face outward when being instal[...]

________________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-3 ® 05745159 c. Remove the brass fitting from the center of the geared hub spindle on the wheel(s) to be worked on. d. Use tire chalk to mark two of the geared hub spindle assembly studs nearest the air valve. W ARNING: In all disassembly operations, ensure tire is totally de[...]

6-4 Wheels and Tires/Central Tire Inflation System (CTIS) _________________ ® 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. W ARNING: Balance weights contain lead. W ash hands after handling. 16. Remove balance weights from rim halves. Discard ba[...]

________________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-5 ® 05745159 8. Inspect outside of tire for sidewall damage. Replace tire if damaged. 9. Inspect tread for puncture damage. If damage is too extensive for patch repair, replace tire. W ARNING: O-ring sealing surfaces must be k ept clean and free from rust and dirt. F ailure t[...]

6-6 Wheels and Tires/Central Tire Inflation System (CTIS) _________________ ® W ARNING: 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[...]

________________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-7 ® 05745159 Figure 6-11: Runflat Compressor Positioning NOTE: Compress runflat by rotating the handle in a clockwise direction. Rotate handle counterclockwise to loosen. 3. Using runflat compressor, compress runflat. 4. Stand tire up and lubricate tire bead and runflat with [...]

6-8 Wheels and Tires/Central Tire Inflation System (CTIS) _________________ ® NOTE: Before installing tire on inner rim half, inspect tire sidewalls for a “paint dot.” Paint dots are often used to indicate the tire’s light spot for balancing purposes. If paint dot is present, position tire on rim halves so that paint dot is aligned with inse[...]

________________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-9 ® 05745159 CA UTION: Tighten locknuts gradually to avoid bending and/ or breaking studs, or damage to wheel components. NOTE: If vehicle is equipped with central tire inflation sys- tem, position shield mounting bracket on outer rim. 15. Line up alignment holes in both whee[...]

6-10 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® Figure 6-17: Leak Check Areas WHEEL HALF STUD REPLACEMENT Removal 1. Remov e wheel from vehicle. 2. Place wheel in tire inflation cage. W ARNING: Ensure the tire is totally deflated before removing wheel loc knuts. F ailure to follo w proper safety precautions may result[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-11 ® 05745159 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). Figure 6-19: Wheel Half Stud Installation 1. Align stud with splines in inner rim and dri[...]

6-12 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® RUNFLAT COMPRESSOR BELT REPLACEMENT Installation 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 comp[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-13 ® 05745159 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[...]

6-14 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® 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. CA UTION: During assembly or disassembly, loose parts which are dropped inside the wheel/tire a[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-15 ® 05745159 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. 3. Install the right and left square nuts in the re[...]

6-16 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® sure using a clip-on air chuck. Do not exceed 50 psi (345 kP a) cold inflation pressure. F ailure to f ollo w 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. [...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-17 ® 05745159 Inspecting Tire T read W ear Tire tread wear is a good indicator of tire balance and suspen- sion condition. Unbalanced tires often cause cupped or scal- loped tread wear patterns (Figure 6-27). Tire wear inspection should be performed for all vibration complaints[...]

6-18 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® WHEEL AND TIRE BALANCING General There are two types of tire and wheel balancing: static and dy- namic. Static balance is the equal distribution of weight around the wheel circumference. Wheels that are statically unbalanced cause a bouncing action called vehicle shake an[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-19 ® 05745159 3. Locate and mark wheel and tire assembly light spot on the tire (Figure 6-31). 4. Record weight and position readings. 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 [...]

6-20 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® T ROUBLESHOOTING 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 late[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-21 ® 05745159 Wheel And Tire Assembly Runout Inspection NOTE: Before measuring the runout of a tire and wheel as- sembly, drive the vehicle long enough to warm up the tires. Then do the following: 1. Install tire and wheel assembly on wheel balancer . 2. Check GG rings to be su[...]

6-22 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® WHEEL ALIGNMENT Check alignment on a rack with the front tires in the straight- ahead position and inflated to manufacturer’s recommended pressure. Preliminary Inspection 1. Check tire condition, tread wear (Figure 6-27), run-out, and inflation. 2. Raise and support ve[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-23 ® 05745159 Figure 6-39: Upper Ball Joint Wear Check 6. Inspect control arm bushings for wear or damage. Replace bushings if necessary. 7. 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 j[...]

6-24 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® Figure 6-41: Suspension Component Identification PITMAN ARM CENTER LINK TIE ROD IDLER ARM TIE ROD HALFSHAFT TIE ROD END GEARED HUB ADJUSTING SLEEVE STABILIZER BAR SPRING SC ALE[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-25 ® 05745159 CHECKING WHEEL ALIGNMENT 1. Mov e vehicle onto alignment rack and position front tires on alignment rack turntables. 2. Place front wheels in straight ahead position on turntables. 3. Install alignment measuring equipment on vehicle wheels. Follow manufacturers in[...]

6-26 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® . 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 se- quence is: a. caster b. camber c. front toe setting d. rear toe setting e. steering st[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-27 ® 05745159 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 Hum[...]

6-28 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® 6. Verify correct camber angle at both front wheels. Be sure side-to-side variation does not exceed 0.5 degree. 7. Leave vehicle on rack for toe settings and steering stop adjustment. Front Wheel Toe Adjustment 1. Position both front wheels on alignment rack turntables. S[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-29 ® 05745159 STEERING STOP ADJUSTMENT NOTE : Alignment equipment currently used in the auto- motive field should be used for steering stop adjustment procedure. This procedure should be followed if align- ment equipment is not available. Removal 1. Loosen jamnut and remove bol[...]

6-30 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® CENTRAL TIRE INFLATION SYSTEM The optional Central Tire Inflation System (CTIS) is unique to the HUMMER. The CTIS allows the driver to increase or de- crease tire pressure based on terrain and climate conditions. The system can also be used to direct air to a tire that ha[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-31 ® 05745159 Figure 6-51: Quick-Disconnect Tab CTIS T ROUBLESHOOTING The following pages contain troubleshooting information for locating and correcting mechanical, pneumatic, and electrical problems that may develop with the CTIS. Electrical Tr oubleshooting Symptoms are list[...]

6-32 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® CTIS AIR LEAK TR OUBLESHOOTING This section contains troubleshooting information for locating and correcting air leaks within the Central Tire Inflation Sys- tem. W ARNING: CTIS air system components are subject to high pressure. Always reliev e air pressure before loosen[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-33 ® 05745159 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 con- nector or tube. Air is leaking around the con- nector[...]

6-34 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® Inspect the deflate v alve and con- nections 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. Air is escaping from the sides of t[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-35 ® 05745159 CTIS Leak Detection Test 1. Start engine and inflate front and rear tires to 40 psi (276 kPa). 2. Turn the tire selector switch to OFF. 3. Turn engine OFF. 4. Remove air vent line located at the air intake horn and listen for air escaping through the vent line. 5[...]

6-36 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® COMPRESSOR SER VICE W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning may result in serious inju[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-37 ® 05745159 CTIS INSTRUMENT CLUSTER W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning may result in [...]

6-38 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® INFLATE/DEF LATE AND TIRE SELECTOR SWITCHES Removal 1. Remov e CTIS instrument cluster panel. 2. Disconnect connector from inflate/deflate switch and tire selector switch (Figures 6-54 and 6-55). 3. Remove inflate/deflate and tire selector switches from CTIS instrument cl[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-39 ® 05745159 COMPRESSOR/LOW PRESSURE INDICATOR LIGHTS Removal 1. Remov e lower closeout panel and swing steering column do wn. 2. Loosen center console and pull back to allow removal of left crash pad. 3. Pull instrument panel back to gain access to the back of the status cent[...]

6-40 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® AIR PRESSURE GAUGE W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning may result in serious injur[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-41 ® 05745159 AIR PRESSURE GAUGE LAMP REPLACEMENT Removal 1. Remov e lower closeout panel and swing steering column do wn. 2. Loosen center console and pull back to allow removal of left crash pad. 3. Pull instrument panel back to gain access to the back of the status centers. [...]

6-42 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® CTIS LOW PRESSURE ALARM REPLACEMENT Removal 1. Remov e the interior fuse box access panel in the left close- out panel under the instrument panel. 2. Remove the low pressure alarm from the face of the interior fuse box (Figure 6-59). Installation 1. Install lo w pressure [...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-43 ® 05745159 CTIS INTERIOR HAR NESS NOTE: Prior to removal, tag all leads for installation. Removal 1. Remov e CTIS instrument cluster panel. 2. Disconnect connector from inflate/deflate and tire selector switches (Figure 6-60). 3. Remove lamp from air pressure gauge. 4. Disco[...]

6-44 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® AIR PRESSURE SWITCH REPLACEMENT W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning may result in [...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-45 ® 05745159 AIR PRESSURE INDICATOR LINES REPLACEMENT W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warni[...]

6-46 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® CTIS COMPRESSOR FUSE REPLACEMENT Removal 1. Raise and secure hood. 2. Remove the left side cowell cover and the fuse box cover. 3. Remove the fuse from the box (Figure 6-63). Installation 1. Install the fuse in the fuse box (Figure 6-63). 2. Install the plastic cover on t[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-47 ® 05745159 DEFLATE V ALVE ASSEMBLY REPLACEMENT W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning ma[...]

6-48 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® DUST EXCLUDER REPLACEMENT W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning may result in seriou[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-49 ® 05745159 FRONT SUPPLY T UBE AND HOSE REPLACEMENT W ARNING: CTIS components are subject to moder- ately high air pressure. Always reliev e air pressure be- fore loosening or remo ving air system components by disconnecting quick-disconnect valv e assemblies. F ail- ure to f[...]

6-50 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® FRONT CTI LINE REPLACEMENT 1. Disconnect line at front hub (Figure 6-69). 2. Loosen clamp on bracket attached to lower control arm, then move air line out of bracket (Figure 6-70). 3. Disconnect front air line at T-fitting secured to front crossmember. 4. Cut tie straps a[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-51 ® 05745159 AIR INTAK E LINE REPLACEMENT Removal 1. Raise and secure hood. 2. Loosen hose clamp and disconnect air intake hose from connector (Figure 6-73). Figure 6-73: Air Intake Hose 3. Loosen clamp and disconnect air cleaner elbow from air horn. 4. Remove nut, washer, cou[...]

6-52 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® QUICK-DISCONNECT V ALVE AND T UBE REPLACEMENT W ARNING: CTIS components are subject to high air pressure. Always reliev e air pressure before loosening or removing air system components by disconnecting quick-disconnect valv e assemblies. F ailure to follo w this warning [...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-53 ® 05745159 REAR T UBE CONNECTION SHIELD REPLACEMENT NOTE: The replacement of the left and right rear tube connec- tion shields is basically the same. This procedure covers the left rear tube connection shield. Removal Remove two bolts, washers, shield, and two washers from s[...]

6-54 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® SPINDLE EXTENSION AND SEAL REPLA CEMENT Removal 1. Remov e rear tube connection shield. 2. Remove four bolts, washers, and steering arm cover from geared hub (Figure 6-79). 3. Remove retaining ring and seal from steering arm cover. 4. Remove spindle extension from spindle[...]

______________ Wheels and Tires/Central Tire Inflation System (CTIS) 6-55 ® 05745159 Installation NOTE: Ensure that any new fittings have pipe sealant pre-ap- plied to threads. If none is present, apply a pipe sealant to fit- ting threads. 1. Secure auxiliary air v alve to existing tee (Figure 6-81). 2. Connect tires to CTIS by pushing in quick-di[...]

6-56 Wheels and Tires/Central Tire Inflation System (CTIS) _______________ ® SPECIAL T OOLS T ool No. Description 05710216 Internal tubeless tire repair kit 05710215 External tubeless tire repair kit 05710215 05710216[...]

________________________________________________________________________________ 7-1 ® 05745159 Section 7 Brak e System T ABLE OF CONTENTS Anti-lock Brake System (ABS) and Automatic Traction Control, TorqTrac 4™ (TT4™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 ABS ECU Replacement . . . . . . . . . . . . . . . . . .[...]

7-2 Brake System ______________________________________________________________ ® BRAK E SYSTEM DIAGNOSIS Road T esting 1. If red warning light is illuminated, note pedal action and brake response. 2. Check brake pedal response with transmission in Neutral and engine running. Pedal should remain firm under steady foot pressure. If pedal falls away[...]

_____________________________________________________________ Brake System 7-3 ® 05745159 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 bra[...]

7-4 Brake System ______________________________________________________________ ® Brak e 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 ma- terials. Under certain conditions, asbestos free lining may generat[...]

_____________________________________________________________ Brake System 7-5 ® 05745159 1. Remov e master cylinder cov er and visually check reser- voirs for lo w fluid le vel 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[...]

7-6 Brake System ______________________________________________________________ ® 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 br[...]

_____________________________________________________________ Brake System 7-7 ® 05745159 HYDRO-BOOST SYSTEM DIAGNOSIS 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 th[...]

7-8 Brake System ______________________________________________________________ ® 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 N•m) of force and start the engine. The pedal will fall and then push back against your foot. A[...]

_____________________________________________________________ Brake System 7-9 ® 05745159 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 c[...]

7-10 Brake System _____________________________________________________________ ® 1. Inspect dust boot for tears or deterioration (Figure 7-6). 2. 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. 3[...]

____________________________________________________________ Brake System 7-11 ® 05745159 Installation 1. Install a washer and coupling to caliper (Figure 7-6). W ARNING: Ensure brak e pads are installed with lin- ings facing rotor . F ailure to do this will cause poor per- formance and damage to equipment and may result in injury . 2. Position br[...]

7-12 Brake System _____________________________________________________________ ® MASTER CYLINDER BLEEDING NOTE: Master cylinder must be filled and kept at least half full during bleeding operation (Figure 7-9). 1. Depress brake pedal slo wly and hold. Loosen front brake line to purge air from the front section of the reserv oir . 2. Tighten front[...]

____________________________________________________________ Brake System 7-13 ® 05745159 HYDRO-BOOST REPLACEMENT Removal 1. Remov e two nuts securing splash shield mount bracket to hydro-boost/master cylinder assembly . 2. Remove nut securing mount bracket to splash shield and remove mount bracket. 3. Remove two nuts securing the master cylinder [...]

7-14 Brake System _____________________________________________________________ ® BRAK E LINE REPLACEMENT Metal brake lines should be inspected for leaks or deterioration every time the vehicle is being serviced. W ARNING: Batteries must be disconnected when the brak e hydraulic system is being serviced and bled. If the ABS motor pump runs when ai[...]

____________________________________________________________ Brake System 7-15 ® 05745159 Figure 7-13: Rear Brake Component Location METAL BRAKE LINES CALIPER FROM ABS/TT4 MODULATOR LINE MOUNTIG CLIP UNION[...]

7-16 Brake System _____________________________________________________________ ® Figure 7-14: Front Brake Component Location C ALIPER MASTER CYLINDER HYDROBOOST METAL BRAKE LINES LINE MOUNTING CLIP METAL LINES TO REAR CALIPERS ABS MODULATOR[...]

____________________________________________________________ Brake System 7-17 ® 05745159 SER VICE BRAK E P EDAL REPLACEMENT Removal 1. Disconnect the stoplight switch (Figure 7-15). 2. Remove pushnut and disconnect stoplight switch rod (if so equipped) from brake pedal assembly. Discard pushnut. (Figure 7-15). 3. Disconnect return spring from bra[...]

7-18 Brake System _____________________________________________________________ ® REAR DUAL SER VICE/PARKING BRAK E PAD REPLACEMENT Removal 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, and clevis pin securing parking brake cable to lever. Discard cotter pin (Figure 7-18). 3. Remove clip secur[...]

____________________________________________________________ Brake System 7-19 ® 05745159 Figure 7-20: Rear Dual Brake Caliper Installation W ARNING: Ensure brak e pads are installed with lin- ings facing rotor . F ailure to do this will cause poor per- formance and damage to equipment and may result in injury . 1. Check brake pad backing plate no[...]

7-20 Brake System _____________________________________________________________ ® REAR DUAL SER VICE/PARKING BRAK E CALIPER REPLACEMENT Removal 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, and clevis pin securing parking brake clevis to lever. Discard cotter pin (Figure 7-21). 3. Remove clip [...]

____________________________________________________________ Brake System 7-21 ® 05745159 Figure 7-23: Rear Dual Service/Parking Brake Caliper Cable Bracket Figure 7-24: Rear Caliper and Bleeder Valve C ALIPER C ABLE CLIP LEVER P ARKING CLEVIS PIN BRAKE CLEVIS P ARKING BRAKE C ABLE C ALIPER C ABLE BRA CKET STOP LEVER BRA CKET C ALIPER PISTON F A C[...]

7-22 Brake System _____________________________________________________________ ® Installation 1. Open bleeder v alve 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). NOTE: Perform step 2 only if caliper guide pins were re- place[...]

____________________________________________________________ Brake System 7-23 ® 05745159 RIGHT PARKING BRAK E CABLE REPLACEMENT Removal 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-26). 3. Remove clip securing cable sleeve[...]

7-24 Brake System _____________________________________________________________ ® LEFT PARKING BRAK E CABLE REPLACEMENT Removal 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-27). 3. Remove clip and cable sleeve from caliper [...]

____________________________________________________________ Brake System 7-25 ® 05745159 PARKING BRAK E ROD REPLACEMENT Removal 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin (Figure 7-28). 3. Remove six clips and spread boot to allow[...]

7-26 Brake System _____________________________________________________________ ® Adjustment 1. Put transmission in P ARK, chock wheels, and release parking brake. 2. Remove six clips and spread boot to allow access to cotter pin (Figure 7-30). 3. Remove cotter pin, washer, and clevis pin securing clevis to bellcrank. Discard cotter pin. 4. Repeat[...]

____________________________________________________________ Brake System 7-27 ® 05745159 Installation 1. Install boot on body . Install upper boot on parking brake hand le ver . 2. Install parking brake hand lever on body and secure with two washers, bolts, washers, and locknuts. 3. Secure parking brake hand lever on body with bolt, nut and lockw[...]

7-28 Brake System _____________________________________________________________ ® Figure 7-34: Front Disc Brake Caliper Assembly CA UTION: 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. Lubricate caliper bore and seal with DO T 3 brake fl uid (Figure[...]

____________________________________________________________ Brake System 7-29 ® 05745159 REAR CALIPER OVERHAUL Rear Caliper Disassembly (Figure 7-37) 1. Mount caliper in vise so parking brake le ver and spring are facing upward. 2. Unseat and remove parking brake lever spring. Use large slip joint pliers. 3. Remove bolt that secures lever retaine[...]

7-30 Brake System _____________________________________________________________ ® 6. 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[...]

____________________________________________________________ Brake System 7-31 ® 05745159 Figure 7-37: Rear Caliper O-RING O-RING BLEEDER SCREW CAP BLEEDER SCREW ACTUATOR SHAFT DUST SEAL LEVER SPRING THRUST SCREW RETAINING RING THRUST SCREW SPRING SHIELD THRUST SCREW SPRING THRUST SCREW ACTUATOR O-RING BEARING THRUST ACTUATOR SHAFT PISTON DUST BOO[...]

7-32 Brake System _____________________________________________________________ ® BRAK E ROTOR Cleaning and Inspection NOTE: Clean all components, examine for wear or damage, and replace if necessary (Figure 7-38). 1. Remov e brake rotor . NOTE: Clean rusted or scaled rotor braking surfaces before at- tempting inspection or measurement. 2. Mount r[...]

____________________________________________________________ Brake System 7-33 ® 05745159 PARKING BRAK E LEV ER ADJUSTMENT Adjustment 1. Adjust linkage. 2. Put transmission in PARK, chock wheels, and release parking brake handle. 3. Turn adjusting knob clockwise as tightly as possible by hand (Figure 7-41). Figure 7-41: Parking Brake Lever Locatio[...]

7-34 Brake System _____________________________________________________________ ® ANTI-LOCK BRAK E SYSTEM (ABS) AND A UTO- MATIC T RACTION CONTR OL, T ORQT RAC 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 sensor[...]

____________________________________________________________ Brake System 7-35 ® 05745159 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) Figure 7-45: Blink Code Sequenc[...]

7-36 Brake System _____________________________________________________________ ® 2-6 Shuttle v alve switch failure. 25 and 27 Brake pedal at rest 3k Ω . Brake pedal 1/2 do wn 2k Ω . Brake pedal full do wn 1k Ω . If wiring and connections OK, replace modulator . 2-7 Continuous po wer to ECU with ignition “ OFF ” . 9 and 27 0 v olts. Less[...]

____________________________________________________________ Brake System 7-37 ® 05745159 3-3 Open circuit between ECU and left front outlet solenoid v alve or wiring. 24 and 27 3.0-5.0 W Check electrical resistance of af fected v alve wir - ing to ground at the ECU connector and at the modulator connector . Repair wiring or replace modulator as n[...]

7-38 Brake System _____________________________________________________________ ® 4-2 Short circuit to ground between ECU and left front inlet sole- noid valv e. 23 and 27 5.0-7.5 W Check electrical resistance of af fected valv e wir- ing to ground at ECU connector and at modulator assembly as necessary . 4-3 Short circuit to ground between ECU an[...]

____________________________________________________________ Brake System 7-39 ® 05745159 4-13 Left r ear wheel speed sensor open circuit. 18 and 35 500-2000 W Check electrical resistance of affected sensor and wiring at ECU connector and at harness plugs. Repair wiring or replace sensor as necessary . 4-14 Left fr ont wheel speed sensor open cir-[...]

7-40 Brake System _____________________________________________________________ ® 5-5 Short circuit to battery between ECU and right rear outlet v alve solenoid or wiring. 5 and 27 0 volts 3.0-5.0 W Check voltages at wiring harness including con- nectors. Check electrical resistance of af fected v alve wiring to ground at ECU connector and at modu[...]

____________________________________________________________ Brake System 7-41 ® 05745159 5-15 Right r ear wheel speed signal is erratic. 16 and 33 Greater than 0.9 volts A C at one tire rev olution per second Check for damaged tone wheel, incorrect sensor adjustment, excessi ve tone wheel runnout (> .041"), excessi ve geared hub input bea[...]

7-42 Brake System _____________________________________________________________ ® 6-6 Short circuit between two solenoid v alve leads of left rear inlet sole- noid v alve. 21 and 4, 5, 6, 7, 22, 23, 24 5.0-7.5 W Check electrical resistance of af fected valv es and wiring at ECU connector and at modulator assem- bly plug. Repair or replace wiring a[...]

____________________________________________________________ Brake System 7-43 ® 05745159 Figure 7-47: ABS/TT4 Main System Diagram. 609 YL RIGHT REAR 994 BR 995 BK C2-23 C2-22 16 33 WHEEL SPEED SENSOR LEFT REAR 992 BR 993 BK C2-32 C2-31 18 35 WHEEL SPEED SENSOR RIGHT FRONT 998 BR 999 BK C2-19 C2-20 17 34 WHEEL SPEED SENSOR 970 TN 971 PP 972 YL 973[...]

7-44 Brake System _____________________________________________________________ ® Figure 7-48: ABS/TT4 Power, Ground and Warning Lamp Circuit. 58 BLK DLC C1-19 C1-34 7 15 606 OR 607 TN 13 14 DIAGNOSTIC ABS ECU IGN FUSE 2B 5 AMP Exterior Fuse Box 9 601 PK TO IGNITION SWITCH 19 8 990 PK 991 LB 990 PK ABS VA LV E RELA Y G2 575 OR FUSE IC 25 AMP Exter[...]

____________________________________________________________ Brake System 7-45 ® 05745159 Figure 7-49: 35 Pin ECU Connector Female Half PIN CKT COLOR DESCRIPTION 1 990 PK ABS v alve relay input 3 961 PP TT4 lamp acti vation 4 977 WH Right rear inlet valv e acti vation 5 976 RD Right rear outlet valv e acti vation 6 973 OR Right front inlet valv e [...]

7-46 Brake System _____________________________________________________________ ® Figure 7-50: 13 Pin Modulator Connector Female Half 25 677 GY Shuttle v alve switch signal 26 603 DG ABS warning lamp acti vation 27 570 BK Ground 30 609 YL Pump motor monitor 31 978 BK Reference ground 32 996 BR Left front wheel speed sensor high 33 994 BR Right rea[...]

____________________________________________________________ Brake System 7-47 ® 05745159 Figure 7-51: 42 Pin Underbody Connector Male Half Figure 7-52: 42 Pin Underbody Connector Female Half PIN CKT COLOR DESCRIPTION 10 996 BR Left front wheel speed sensor lo w signal 11 997 BK Left front wheel speed sensor high signal 19 999 BK Right front wheel[...]

7-48 Brake System _____________________________________________________________ ® ABS MODULATOR REPLACEMENT Remo v al W ARNING: Batteries must be disconnected when the brak e hydraulic system is being serviced and bled. If the ABS motor pump runs when air is in the hydraulic sys- tem, air can get trapped behind the valves in the modu- lator causin[...]

____________________________________________________________ Brake System 7-49 ® 05745159 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 posi[...]

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[...]

____________________________________________________________ Brake System 7-51 ® 05745159 ESSENTIAL T OOLS Procure from Kent-Moore. 8-S07-001 J–42553 9-S07-016 5 10 15 20 25 30 35 4 9 14 19 24 29 34 3 8 13 18 23 28 33 2 7 12 17 22 27 32 1 6 11 16 21 26 31 J 3 55 9 2 P IN O U T B O X J – 35592 00-S07-001 00-S07-002 J-44237 J-42883 T ool No. Des[...]

7-52 Brake System _____________________________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

________________________________________________________________________________ 8-1 ® 05745159 Section 8 Steer ing System T ABLE OF CONTENTS Intermediate Steering Shaft Dust Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13 Remov[...]

8-2 Steering System ___________________________________________________________ ® Po w er Steering Fluid Recommended fluid for the power steering system is Dexron III. Po w er Steering Component Ser vice Most of the power steering pump components are not service- able. The seals and the flow control valve, however, can be serviced. The pump can al[...]

___________________________________________________________ Steering System 8-3 ® 05745159 CENTER LINK REPLACEMENT Removal 1. Raise and support the front of the vehicle. 2. Remove the cotter pin and the slotted nut securing the pitman arm to the center link (Figure 8-3). 3. Remove the cotter pin and the slotted nut securing the idler arm to the ce[...]

8-4 Steering System ___________________________________________________________ ® TIE ROD END REPLACEMENT Removal 1. Raise and support the front of the vehicle. 2. Remove the cotter pin and slotted nut from the geared hub end of the tie rod (Figure 8-4). 3. Using puller J – 24319 – B, remove the tie rod end from the the geared hub. Disassembly[...]

___________________________________________________________ Steering System 8-5 ® 05745159 TIE ROD REPLACEMENT Removal 1. Raise and support the front of the vehicle. 2. Remove the cotter pins and slotted nuts from the center link end and the geared hub end of the tie rod (Figure 8-6). 3. Using puller J – 24319 – B, remove the tie rod from the [...]

8-6 Steering System ___________________________________________________________ ® IDLER ARM REPLACEMENT Removal 1. Raise and support the front of the vehicle. 2. Remove the cotter pin and the slotted nut securing the idler arm to the center link (Figure 8-9). 3. Using puller J – 24319 – B or equivalent, disconnect the idler arm from the center[...]

___________________________________________________________ Steering System 8-7 ® 05745159 STEERING COLUMN REPLACEMENT Removal NOTE: Before removing steering wheel, turn steering column to gain access to intermediate shaft mounting hardware. 1. Remov e steering wheel. 2. Remove close-out panel. 3. Remove locknut, lockwasher, three washers, and thr[...]

8-8 Steering System ___________________________________________________________ ® STEERING COLUMN MULTI-SWITCH REPLACEMENT NOTE: This procedure covers the directional signal, horn, high beam, and hazard light switches. Removal 1. Follo w steps 2, 3, 5 and 6 of Steering Column Replace- ment . 2. Remove two screws and multi-switch from steering colu[...]

___________________________________________________________ Steering System 8-9 ® 05745159 STEERING COLUMN REPAIR Lock and Switch Housing Assembly Disassembly NOTE: The key must stay in the ignition switch at all times. 1. Remov e the lock cylinder and ke y assembly from the lock cylinder housing (Figure 8-14). 2. Remove two screws securing the up[...]

8-10 Steering System __________________________________________________________ ® Steering Column and Shaft Disassembly 1. Remov e two scre ws and the multi-switch assembly from the lock and switch housing (Figure 8-12). 2. Remove two screws and lock and switch housing assembly from steering column (Figure 8-13). 3. Remove six stakes from the tube[...]

_________________________________________________________ Steering System 8-11 ® 05745159 IGNITION SWITCH LOCK CYLINDER REPLACEMENT Removal 1. Disconnect battery ground cable. 2. Remove close-out panel. 3. Remove five screws and lower steering column shroud (Figure 8-16). 4. Disconnect lock cylinder connector from ignition switch connector. 5. Tur[...]

8-12 Steering System __________________________________________________________ ® Figure 8-18: Interlock Cable/Ignition Switch Installation 1. Secure interlock cable to shifter with scre w and nut. T ighten nut to 8 lb-ft (11 N • m) (Figure 8-19). Figure 8-19: Interlock Cable and Shifter 2. Route interlock cable through bracket and install shift[...]

_________________________________________________________ Steering System 8-13 ® 05745159 2. Turn steering wheel left and right several times to bleed off power steering fluid. 3. Remove bolt on intermediate shaft yoke at steering gear and disconnect intermediate shaft from steering gear. 4. Remove nut and lockwasher from steering arm (Figure 8-21[...]

8-14 Steering System __________________________________________________________ ® INTERMEDIATE STEER ING SHAFT DUST BOOT REPLACEMENT Removal 1. Remov e close-out panel. 2. Remove three nuts, six washers, and three screws from dust boot (Figure 8-23). NOTE: Before performing step 3, put scribe marks showing the position of the yoke relative to the [...]

_________________________________________________________ Steering System 8-15 ® 05745159 PO W ER STEERING PUMP AND PULLEY REPLACEMENT Removal 1. Disconnect return lines and high pressure line from back of pump (Figure 8-24). 2. Remove serpentine belt from power steering pump pulley. 3. Using puller J – 25034-C or equivalent, remove pulley from [...]

8-16 Steering System __________________________________________________________ ® PO W ER STEERING HYDRAULIC SYSTEM PRESSURE AND RETUR N 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 re- turn hose and[...]

_________________________________________________________ Steering System 8-17 ® 05745159 PO W ER STEERING COOLER AND COOLER HOSE REPLACEMENT Removal 1. Disconnect two hoses from cooler (Figure 8-28). 2. Remove cooling fan for access into fan shroud. 3. Remove two nuts, four washers, reinforcement plate, two bolts, and cooler. 4. Disconnect hose a[...]

8-18 Steering System __________________________________________________________ ® PO W ER STEERING GEAR SER VICE 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 pe[...]

_________________________________________________________ Steering System 8-19 ® 05745159 PO W ER STEERING SYSTEM DIAGNOSIS CHAR TS 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 al[...]

8-20 Steering System __________________________________________________________ ® Table 2 Power Steering Diagnosis Chart - part 2 Problem Possible Cause Correction “Hiss” Noise 1. Noisy relief v alve in the pump. 1. There is some noise in all power steering systems. One of the most common is a hissing sound most e vident at standstill parking.[...]

_________________________________________________________ Steering System 8-21 ® 05745159 Table 3 Power Steering Diagnosis Chart - part 3 Problem P ossible Cause Corr ection Lo w Oil Pressure Due to Restriction in the Hose 1. Check for kinks in hose. 2. Foreign object stuck in the hose. 1. Remov e the kinks or replace the hose. 2. Remov e the fore[...]

8-22 Steering System __________________________________________________________ ® PURG ING AIR FR OM THE PO W ER STEER ING 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 conne[...]

_________________________________________________________ Steering System 8-23 ® 05745159 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 i[...]

8-24 Steering System __________________________________________________________ ® Gear Housing End Plug Remo v al 1. Rotate end plug retaining ring until one end is under small access hole in housing (Figure 8-32). Figure 8-32: End Plug Retaining Ring Removal 2. Unseat end plug retaining ring with small pin punch and screwdriver (Figure 8-32). Ins[...]

_________________________________________________________ Steering System 8-25 ® 05745159 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). Figure 8-36: Adjuster Plug Thrust Bearing Retainer Removal 4. Remove bearing spacer, thrust bearing and races, and O- ring [...]

8-26 Steering System __________________________________________________________ ® Rack Piston Remo v al and Disassembly 1. Rotate stub shaft counterclockwise until rack piston is e ven with seal groov e in open end of housing. Do not allo w the rack piston to extend out of the housing. It only needs to be about 1/4 inch from the end. 2. Remove rac[...]

_________________________________________________________ Steering System 8-27 ® 05745159 V alv e Body-Stub Shaft-W or mshaft Remo v al and Disassembly 1. Grasp splined end of stub shaft and carefully rotate v alve body/stub shaft assembly out of gear housing. 2. If wormshaft remained engaged in stub shaft cap, disengage and remove wormshaft at th[...]

8-28 Steering System __________________________________________________________ ® Pitman Shaft Bearing and Seal Remov al 1. Remov e seal retaining ring with internal-type snap ring pliers. 2. Remove first backup washer (Figure 8-46). Figure 8-46: Pitman Shaft Bearing and Seal Position 3. Remove seals, second backup washer, and bearing with tool J [...]

_________________________________________________________ Steering System 8-29 ® 05745159 Figure 8-48: Power Steering Gear Components END PLUG END PLUG RACK PISTON RACK PISTON ADJUSTER SIDE COVER GASKET ADJUSTER SCREW PITMAN HOSE WORMSHAFT WORMSHAFT RACES PITMAN SHAFT SINGLE-LIP DOUBLE-LIP SNAP SEAL RINGS O-RINGS VALVE SPOOL VALVE STUB STUB SHAFT [...]

8-30 Steering System __________________________________________________________ ® PO W ER STEERING GEAR ASSEMBLY AND ADJUSTMENT Gear Housing Hose Seat Replacement The hose seats in the gear housing (Figure 8-49), can be re- placed when necessary. Procedure is as follows: 1. Thread appropriate size pan head, hardened sheet metal scre w into seat. 2[...]

_________________________________________________________ Steering System 8-31 ® 05745159 Figure 8-51: Pitman Shaft Seal Installation Rack Piston Assembly 1. Lubricate rack piston bore in gear housing and ne w O-ring and seal ring with po wer steering fl uid. 2. Install new backup O-ring in rack piston seal groove. 3. Install new teflon seal ring[...]

8-32 Steering System __________________________________________________________ ® Figure 8-54: Assembling Remaining Bearing Balls and Ball Guides 7. Remove wormshaft and temporarily install arbor tool J – 21552 as follows: a. Insert arbor tool J – 21552 into rack piston end plug hole. b. Hold arbor tool firmly against wormshaft and turn wormsh[...]

_________________________________________________________ Steering System 8-33 ® 05745159 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 bor[...]

8-34 Steering System __________________________________________________________ ® Figure 8-59: Aligning and Seating Stub Shaft In Valve Body 8. Install O-ring on stub shaft cap (Figure 8-63). 9. 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[...]

_________________________________________________________ Steering System 8-35 ® 05745159 Figure 8-62: Adjuster Plug Assembly Sequence Figure 8-63: Seating Adjuster Plug Retainer Gear Housing Assembly 1. Lubricate wormshaft, stub shaft-v alve body , rack piston, and adjuster plug with po wer steering fl uid. 2. Install wormshaft and stub shaft/va[...]

8-36 Steering System __________________________________________________________ ® Figure 8-64: Positioning End Plug Retaining Ring in Housing PO W ER STEERING GEAR ADJUSTMENTS There are two steering gear adjustments which are: wormshaft bearing preload and pitman shaft overcenter preload. The ad- justments must be performed in the correct sequence[...]

_________________________________________________________ Steering System 8-37 ® 05745159 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 8-67: Placing Second Index Mark On Housing 7. Back off adjuster plug [...]

8-38 Steering System __________________________________________________________ ® Pitman Shaft Over center Preload T orque Adjustment 1. Loosen locknut on pitman shaft adjuster scre w . 2. Turn adjuster screw counterclockwise until fully extended. Then turn screw one full turn clockwise. 3. Rotate stub shaft from stop-to-stop and count number of t[...]

_________________________________________________________ Steering System 8-39 ® 05745159 PO W ER STEERING PUMP REPAIR Disassembly (Figures 8-72 through 8-77) 1. Suction fl uid from reserv oir and disconnect fl uid reservoir hose from pump. 2. Remove power steering pump pulley and bracket. 3. Drain fluid from pump assembly (Figure 8-72). 4. Remo[...]

8-40 Steering System __________________________________________________________ ® 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. Figure 8-75: End Plate Removal CA UTION: If end of driveshaft in steering pump housing is corroded, clean wit[...]

_________________________________________________________ Steering System 8-41 ® 05745159 Cleaning and Inspection (Figure 8-78) NOTE: Clean all components, examine for wear or dam- age, and replace if necessary. 1. Inspect fl ow control v alv e and valv e spring for damage. 2. Inspect studs for damage. 3. Inspect fitting for damage. 4. Inspect ho[...]

8-42 Steering System __________________________________________________________ ® Assembly (Figures 8-72 through 8-83) NOTE: For general assembly instructions refer to Sec- tion 2. 1. Install O-ring seal in bottom groov e of pump body (Figure 8-79). 2. Install driveshaft seal in pump body. 3. Install rotor on thrust plate. 4. Insert splined end of[...]

_________________________________________________________ Steering System 8-43 ® 05745159 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. Figure 8-80: End Plate Installation 15. Install magnet in pump body (Figure 8-81). 16. [...]

8-44 Steering System __________________________________________________________ ® PO W ER STEERING SYSTEM FLUSHING The power steering system can be flushed but only when the fluid does not contain metal particles, foreign material, or de- bris from a gear or pump failure. Flushing is recommended only under the following circumstances: • incorrec[...]

_________________________________________________________ Steering System 8-45 ® 05745159 ESSENTIAL T OOLS Procure from Kent-Moore. T ool Description J–24319-B Steering Linkage and T ie-Rod Puller J–25033-C Pump Pulle y Installer J–33141 Adapter Fittings (used with J–25323) J–25034-C Pump Pulle y Remover J–25323 Po wer Steering System [...]

8-46 Steering System __________________________________________________________ ® SPECIAL T OOLS Procure from Kent-Moore. T ool Description J–6219 Pitman Shaft Seal Installer J–6221 Stub Shaft Bearing and Seal Remover/Installer J–6278 (or J–21551) Pitman Shaft Bearing Remov er/Installer J–7624 Spanner Wrench (Adjuster Plug) J–7754-C In[...]

________________________________________________________________________________ 9-1 ® 05745159 Section 9 Axles , Suspension, and Frame T ABLE OF CONTENTS Airlift Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48, 9-49 Axle Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . .9-25 Pinion Seal Replaceme[...]

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 up- per and lower control arm at each wheel. This suspension sys- tem provides for a smoother ride and allows for more positive[...]

__________________________________________ Axles, Suspension, and Frame 9-3 ® 05745159 RADIUS ROD REPLACEMENT Removal 1. Remov e wheel. 2. Remove cotter pin, slotted nut, and washer securing radius rod to geared hub (Figure 9-4). 3. Using puller J–24319-B or equivalent, separate radius rod from geared hub. 4. Remove locknut, washers, bolt, and r[...]

9-4 Axles, Suspension, and Frame ___________________________________________ ® UPPER BALL JOINT REPLACEMENT Removal 1. Remov e wheel. 2. Raise and support lower control arm. 3. Disconnect the p-clamp securing the vent line and speed sensor lead to the upper control arm. 4. Remove cotter pin and slotted nut from upper ball joint (Figure 9-6). 5. Re[...]

__________________________________________ Axles, Suspension, and Frame 9-5 ® 05745159 LOW ER BALL JOINT REPLACEMENT Removal 1. Remov e wheel. 2. Raise and support lower control arm (Figure 9-8). 3. Remove cotter pin and slotted nut from lower ball joint. Discard cotter pin. 4. Remove four locknuts, bolts, eight washers and lower ball joint from l[...]

9-6 Axles, Suspension, and Frame ___________________________________________ ® Installation 1. Install upper control arm on brackets with two w ashers, eccentrics, bolts, and locknuts. Align reference holes (from remov al step 8) on eccentrics with marks on brack- ets. Do not tighten locknuts (Figure 9-10). 2. Secure upper ball joint to upper cont[...]

__________________________________________ Axles, Suspension, and Frame 9-7 ® 05745159 CONTROL ARM BUSHING REPLACEMENT Removal NOTE: Control arm bushings must be replaced as a set (Figure 9-11). 1. Remov e control arm. 2. Support control arm and press bushing out of control arm. Installation 1. Lubricate outside diameter of bushing with grease. 2.[...]

9-8 Axles, Suspension, and Frame ___________________________________________ ® Installation W ARNING: Low er control arm must be supported dur- ing removal and installation. F ailure 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 lo wer [...]

__________________________________________ Axles, Suspension, and Frame 9-9 ® 05745159 Installation W ARNING: T o avoid injury and damage to equip- ment, support geared hub during removal and installa- tion. 1. Position geared hub between upper and lo wer control arms and secure upper ball joint to geared hub with slotted nut, but do not tighten ([...]

9-10 Axles, Suspension, and Frame _________________________________________ ® Figure 9-16: Tie Rod End Into Geared Hub 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 N•m) (the left side of vehicle uses two p-clamps to secure the speed sensor lead to the ge[...]

________________________________________ Axles, Suspension, and Frame 9-11 ® 05745159 GEARED HUB SIDE CO VER REPLACEMENT NOTE: Geared hub side cover replacement procedures are basically the same for front and rear covers. This procedure covers the front side cover. Removal 1. Remov e wheel. 2. Remove drainplug from geared hub and drain geared hub [...]

9-12 Axles, Suspension, and Frame _________________________________________ ® Figure 9-21: Input Seal Installation Installation 1. Using dri ver handle J – 8092 and input seal installer J-44905, install input seal in dri ve gear retainer . Place the ne w primary seal on the installer with the seamed side of the stainless steel perimeter facing t[...]

________________________________________ Axles, Suspension, and Frame 9-13 ® 05745159 Figure 9-24: Dial Indicator Positioning 5. Remove four bolts, washers, and steering arm cover from geared hub (Figure 9-25). 6. Remove clamp nut lock screw from clamp nut. 7. Using clampnut socket SBAS-07M, remove clamp nut and keyed washer from spindle. NOTE: It[...]

9-14 Axles, Suspension, and Frame _________________________________________ ® Figure 9-27: Input Seal Removal Inspection NOTE: Clean all components, examine for wear or damage, and replace if necessary. Drive and driven gears must be re- placed as matched set (Figure 9-28). 1. Inspect splines and gear teeth on dri ve gear and dri ven gear for dama[...]

________________________________________ Axles, Suspension, and Frame 9-15 ® 05745159 Assembly 1. Place the ne w output seal on the installer J – 44906, with the seamed side of the stainless steel perimeter facing to ward the geared hub and driv e the seal in until the installer bottoms out on the geared hub surface. The seal will be recessed in[...]

9-16 Axles, Suspension, and Frame _________________________________________ ® incorrect, add or subtract shim gaskets and recheck end play. 8. Install driven gear and bearing spacer in geared hub (Figure 9-33). Figure 9-33: Geared Hub Driven Gear Installation 9. Install outer bearing spacer on spindle. 10. Lower geared hub onto spindle and align s[...]

________________________________________ Axles, Suspension, and Frame 9-17 ® 05745159 23. Clean sealing surfaces on geared hub and side cover. Apply anaerobic sealer to side cover and install on geared hub (Figure 9-34). Figure 9-34: Geared Hub Side Cover Removal NOTE: Make sure bolts and holes are free of old Loctite. 24. Apply thread-locking com[...]

9-18 Axles, Suspension, and Frame _________________________________________ ® 6. Remove spindle, bearing spacer, inner bearing, and outer bearing spacer from geared hub. 7. Remove spindle seal from geared hub. Discard spindle seal (Figure 9-38). Figure 9-38: Spindle Seal Removal Cleaning and Inspection 1. Inspect spindle for rough or corroded seal[...]

________________________________________ Axles, Suspension, and Frame 9-19 ® 05745159 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 N•m). 17. Remove fill plug and washer from geared hub (Figure 9-40). Figure 9-40: Geared Hub Fill Plug Loca[...]

9-20 Axles, Suspension, and Frame _________________________________________ ® Figure 9-42: Clampnut Installation 11. Loosen and retighten clampnut to 25 lb-ft (34 N•m). 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 scre[...]

________________________________________ Axles, Suspension, and Frame 9-21 ® 05745159 GEARED HUB SPINDLE STUD REPLACEMENT W ARNING: Always w ear eye protection when replac- ing spindle studs. Severe eye injury may result if metal chips contact eyes. Removal 1. Remov e wheel. 2. Rotate spindle to allow clearance for removal of stud from spindle (Fi[...]

9-22 Axles, Suspension, and Frame _________________________________________ ® Installation 1. Position outer boot and two clamps on shaft near outer joint. 2. Apply packet of grease to outer joint. 3. Position outer boot over outer joint housing and secure clamp with boot banding tool J–22610. 4. Secure smaller clamp on boot and shaft with tool [...]

________________________________________ Axles, Suspension, and Frame 9-23 ® 05745159 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 sha[...]

9-24 Axles, Suspension, and Frame _________________________________________ ® GEARED HUB V ENT LINE REPLACEMENT NOTE: All geared hub vent line replacement procedures are basically the same. This procedure covers the right rear geared hub vent line. Removal NOTE: Speed sensor lead is retained by the vent line clamps and should be removed and reinst[...]

________________________________________ Axles, Suspension, and Frame 9-25 ® 05745159 AXLE ASSEMBLY CO V ER SER VICE Removal 1. Remov e drainplug from axle assembly and drain axle assembly (Figure 9-53). 2. Remove twelve bolts and cover from axle assembly. Figure 9-53: Axle Assembly Cover Service Cleaning and Inspection NOTE: Clean all components,[...]

9-26 Axles, Suspension, and Frame _________________________________________ ® 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. Removal 1. Remov e six bolts, cam-lock washers, and halfshaft from each[...]

________________________________________ Axles, Suspension, and Frame 9-27 ® 05745159 W ARNING: Axle assembly must be supported during removal and installation. F ailure to do this may cause personal injury or damage to equipment. 7. Support axle assembly. 8. Remove four bolts and washers securing axle assembly to side mounting brackets. 9. Lower [...]

9-28 Axles, Suspension, and Frame _________________________________________ ® Figure 9-59: Rear Axle Assembly Installation 4. Raise axle assembly into place and connect vent line. 5. Apply thread-locking compound to axle assembly tapped holes. Install axle assembly on side mounting brackets with four washers and bolts. 6. Secure two output flanges[...]

________________________________________ Axles, Suspension, and Frame 9-29 ® 05745159 Figure 9-62: Axle Mounted In Holding Fixture 7. Position housing so cover faces up. Remove twelve bolts and cover from housing (Figure 9-62). 8. Mark bearing caps and housing for assembly and remove bearing caps (Figure 9-63). Figure 9-63: Housing Spreader Mounti[...]

9-30 Axles, Suspension, and Frame _________________________________________ ® 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 be[...]

________________________________________ Axles, Suspension, and Frame 9-31 ® 05745159 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). Figure 9-71: Output Shaft Be[...]

9-32 Axles, Suspension, and Frame _________________________________________ ® Figure 9-79: Differential Assembly 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 differen[...]

________________________________________ Axles, Suspension, and Frame 9-33 ® 05745159 5. Lubricate outside diameter of front pinion bearing cup with lubricating oil. Using driver handle J–8092 and bearing cup installer J–8611-01, install cup in housing. 6. Install rear pinion bearing on pinion gear (Figure 9-83). Figure 9-83: Pinion Rear Beari[...]

9-34 Axles, Suspension, and Frame _________________________________________ ® 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[...]

________________________________________ Axles, Suspension, and Frame 9-35 ® 05745159 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 g[...]

9-36 Axles, Suspension, and Frame _________________________________________ ® Figure 9-91: Rear Pinion Bearing Location CA UTION: Collapsible spacer controls pinion bearing pre- load. 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 yo[...]

________________________________________ Axles, Suspension, and Frame 9-37 ® 05745159 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 ([...]

9-38 Axles, Suspension, and Frame _________________________________________ ® 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 ba[...]

________________________________________ Axles, Suspension, and Frame 9-39 ® 05745159 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 a[...]

9-40 Axles, Suspension, and Frame _________________________________________ ® FRONT PR OPELLER SHAFT AND U-JOINT SER VICE Front Shaft Removal 1. Remov e U-joint clamp bolts and straps. Then disconnect shaft yoke (Figure 9-104). Figure 9-104: Front Propeller Shaft Attachment at Axle 2. Remove U-bolt nuts and disconnect front shaft from transfer cas[...]

________________________________________ Axles, Suspension, and Frame 9-41 ® 05745159 7. Clean part with solvent. 8. Inspect shaft, slip yokes and U-joints for wear or damage. 9. Replace worn U-joints. Refer to procedure in this section. 10. Install shield on shaft. 11. Start new center bearing on shaft. Figure 9-108: Center Bearing Removal/Instal[...]

9-42 Axles, Suspension, and Frame _________________________________________ ® U-JOINT REPLACEMENT 1. Remov e propeller shaft. 2. Remove grease fitting from cross (Figure 9-111). 3. Remove two bearing cups from cross (rear shaft only). 4. Remove snap rings from bearings in yoke. 5. Position propeller shaft in vise with 1-1/8 socket between vise jaw[...]

________________________________________ Axles, Suspension, and Frame 9-43 ® 05745159 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 packag[...]

9-44 Axles, Suspension, and Frame _________________________________________ ® SHOCK ABSORBER REPLACEMENT NOTE: The procedure for removing and installing all shock absorbers is the same, except rear lower shock pins must be in- stalled with head of pin facing rearward. This procedure covers the left front shock absorber. Removal 1. Remov e two bolt[...]

________________________________________ Axles, Suspension, and Frame 9-45 ® 05745159 FRONT BUMPER AND T OWING BRAC K ETS REPLACEMENT (V EHICLES WITHOUT W INCH) Removal 1. Remov e brushguard, if equipped. 2. Remove four locknuts, washers, bolts, washers, two towing brackets, and front bumper from mounting brackets (Figure 9-115). Installation 1. I[...]

9-46 Axles, Suspension, and Frame _________________________________________ ® FRONT BUMPER MOUNTING BRAC K ET REPLACEMENT Removal NOTE: Mark location of bolts for installation. 1. Support hood in position with jacks. 2. Remove three locknuts, washers, bolts, and washers securing mounting bracket to frame rail (Figure 9-117). 3. Remove two locknuts[...]

________________________________________ Axles, Suspension, and Frame 9-47 ® 05745159 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 tiedo wn bracket with spring washer , bolt, and slotted nut. T ighten [...]

9-48 Axles, Suspension, and Frame _________________________________________ ® LEFT AIRLIFT BRACK ET AND FRONT UPPER CONTROL ARM BRACK ETS REPLACEMENT Removal 1. Remov e left engine splash shield (Section 10). 2. Raise and support front of vehicle. 3. Remove three screws and clamps securing harness to airlift bracket (Figure 9-121). 4. Remove two l[...]

________________________________________ Axles, Suspension, and Frame 9-49 ® 05745159 RIGHT AIRLIFT BRACK ET AND FRONT UPPER CONTROL ARM BRACK ETS REPLACEMENT Removal 1. Remov e battery tray (Section 12). 2. Raise and support front of vehicle. 3. Remove two locknuts, washers, and bolts securing radiator support to airlift bracket (Figure 9-122). W[...]

9-50 Axles, Suspension, and Frame _________________________________________ ® FRONT SUSPENSION BRACE REPLACEMENT (V EHICLES WITHOUT WINCH) Removal W ARNING: T o av oid personal injury or equipment damage, support lo wer control arm during removal and installation. 1. Remov e locknut, washer , bolt, and washer securing brace to frame rail (Figure 9[...]

________________________________________ Axles, Suspension, and Frame 9-51 ® 05745159 SPLASH SHIELD SUPPORT BRACK ET REPLACEMENT Removal 1. Remov e locknut, washer , bolt, and washer securing splash shie ld to b rack et (Figure 9-125). NOTE: Note direction of bolts for installation. 2. Remove two locknuts, washers, bolts, washers, and bracket from[...]

9-52 Axles, Suspension, and Frame _________________________________________ ® REAR BUMPER REPLACEMENT Removal 1. Remov e swing-away spare tire carrier , if equipped (Sec- tion 6). 2. Remove rear license plate bracket (Section 10). 3. Remove trailer hitch, if equipped (Section 13). 4. Remove two locknuts, washers, bolts, and washers securing traile[...]

________________________________________ Axles, Suspension, and Frame 9-53 ® 05745159 SPRING SEAT REPLACEMENT NOTE: Replacement of the four spring seats is basically the same. This procedure covers the right front spring seat. Removal 1. Remov e coil spring. 2. Remove four locknuts, washers, bolts, spring bracket, and front spring seat from frame [...]

9-54 Axles, Suspension, and Frame _________________________________________ ® LEFT ENG INE MOUNT BRAC K ET REPLACEMENT Removal 1. Remov e two bolts securing brake line and oil line clamps to engine mount bracket (Figure 9-129). 2. Remove two locknuts and washers securing engine mount bracket to insulator. CA UTION: To avoid engine oil pan damage, [...]

________________________________________ Axles, Suspension, and Frame 9-55 ® 05745159 RIGHT ENG INE MOUNT BRAC K ET REPLACEMENT Removal 1. Remov e right engine mount and insulator (Section 2). 2. Remove two locknuts, washers, bolts, and washers securing support bracket to engine mount bracket (Figure 9-131). 3. Remove bolt securing vent tube clamp[...]

9-56 Axles, Suspension, and Frame _________________________________________ ® T RANSMISSION MOUNT CROSSMEMBER REPLACEMENT Removal CA UTION: To prevent equipment damage during removal and installation of transmission mount crossmember, transmission must be supported. 1. Place support under transmission and remov e two lock- nuts, washers, bolts, an[...]

________________________________________ Axles, Suspension, and Frame 9-57 ® 05745159 RIGHT INTERMEDIATE BODY MOUNT BRACK ET REPLACEMENT Removal 1. Remov e right intermediate body mount (Section 10). 2. Remove three bolts, washers, and body mount bracket from frame rail (Figure 9-135). Figure 9-135: Right Intermediate Body Mount Bracket Replacemen[...]

9-58 Axles, Suspension, and Frame _________________________________________ ® REAR -REAR TIEDOWN BRACK ET REPLACEMENT Removal Remove two locknuts, washers, bolts, washers, and tie-down bracket from frame rail (Figure 9-137). Installation Install tiedown bracket on frame rail with two washers, bolts, washers, and locknuts. Tighten locknuts to 261 l[...]

________________________________________ Axles, Suspension, and Frame 9-59 ® 05745159 REAR -FRONT TIEDO WN BRACK ET REPLACEMENT Removal 1. Remov e wheel (Section 6). 2. Remove four locknuts, washers, bolts, washers, and tiedown bracket from frame rail (Figure 9-140). 3. Remove two locknuts, washers, bolts, washers, vent tube/ speed sensor lead mou[...]

9-60 Axles, Suspension, and Frame _________________________________________ ® Figure 9-142: Side Mounting Bracket Removal Figure 9-143: Support Bracket Replacement FRONT SUSPENSION FR ONT CROSSMEMBER REPLACEMENT Removal 1. Remov e front lower control arms. 2. Remove lower radiator hose. 3. Remove horn. 4. Remove radiator front mounting bracket. 5.[...]

________________________________________ Axles, Suspension, and Frame 9-61 ® 05745159 Installation 1. Position left and right crossmember mounting brackets on crossmember (Figure 9-145). 2. Install crossmember and mounting brackets on frame rails with four washers, bolts, washers, and locknuts. Do not tighten locknuts. 3. Install left and right mo[...]

9-62 Axles, Suspension, and Frame _________________________________________ ® Figure 9-147: Rear Crossmember Replacement Installation 1. Install left and right rear crossmember mounting brackets on rear crossmember (Figure 9-147). 2. Install rear crossmember and mounting brackets on frame rails. 3. Apply thread-locking compound to hole and secure [...]

________________________________________ Axles, Suspension, and Frame 9-63 ® 05745159 W ARNING: T o av oid personal injury , support cross- member during removal. 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, w[...]

9-64 Axles, Suspension, and Frame _________________________________________ ® FRAME INSPECTION General Information The frame rails are constructed by arc-welding two “C” chan- nels 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 [...]

________________________________________ Axles, Suspension, and Frame 9-65 ® 05745159 VERTICAL (SIDE VIEW) MEASUREMENT 1. Select a hard and le vel surface area 1-1/2 times the size of the vehicle. 2. Raise vehicle at four points until all four wheels are off the surface. W ARNING: When using shim material with jack- stands, the shim material must [...]

9-66 Axles, Suspension, and Frame _________________________________________ ® 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. Stretch string tightly on floor between front [...]

________________________________________ Axles, Suspension, and Frame 9-67 ® 05745159 METHOD 2 1. Position a string across a plumb bob point on each of the frame rail strings (Figure 9-155). 2. Place a square with one leg coincident with a frame rail string (Figure 9-155). 3. Run a line or string along other leg of square to opposite frame rail st[...]

9-68 Axles, Suspension, and Frame _________________________________________ ® 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. • [...]

________________________________________ Axles, Suspension, and Frame 9-69 ® 05745159 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 po[...]

9-70 Axles, Suspension, and Frame _________________________________________ ® WINCH (OPTION) PRIOR TO VIN 186477 Winch T r oubleshooting Winch Inoperative 1. Check for jammed winch cable. 2. Check winch control cable connector for corrosion or loose connection. Clean corroded connector or secure loose connection. 3. Check for loose or damaged winc[...]

________________________________________ Axles, Suspension, and Frame 9-71 ® 05745159 5. Remove two bolts and clamps securing winch cables to winch. 6. Remove three bolts and control box cover from winch. NOTE: It may be necessary to remove plastic coating com- pound from winch in order to perform steps 7 and 8. 7. Remove capscrew, washer, and neg[...]

9-72 Axles, Suspension, and Frame _________________________________________ ® Winch Assembly Repair Disassembly 1. Remov e winch and winch cable. 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). Figur[...]

________________________________________ Axles, Suspension, and Frame 9-73 ® 05745159 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 screw[...]

9-74 Axles, Suspension, and Frame _________________________________________ ® Inspection 1. Inspect drum for damage to splined end flanges and tube (Figure 9-169). Replace winch if damaged. Figure 9-169: Drum Assembly and Gear Housing Assembly 2. Inspect gear end and motor end drum supports for damage. Replace if damaged. 3. Inspect gear housing [...]

________________________________________ Axles, Suspension, and Frame 9-75 ® 05745159 Assembly 1. Position 85 to 87 steel balls in groov e of intermediate ring gear and install intermediate ring gear in gear housing (Figure 9-172). Figure 9-172: Intermediate Ring Gear and Gear Housing 2. Install retaining rings in gear housing. 3. Apply light oil [...]

9-76 Axles, Suspension, and Frame _________________________________________ ® 17. With drum horizontal, install brake into drum. 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 N•m) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage drivesha[...]

________________________________________ Axles, Suspension, and Frame 9-77 ® 05745159 Figure 9-178: Control Leads Figure 9-179: Control Unit and Motor 4. Remove clamp from motor. 5. Place winch on end with motor end up (Figure 9-180). 6. Remove two bolt assemblies and rear cover from motor housing. NOTE: Perform steps 7 through 11 only if replacin[...]

9-78 Axles, Suspension, and Frame _________________________________________ ® 3. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. 4. Coat armature shaft with lubricant and install in brush assembly. 5. Coat head of electric thermal switch with lubricant and connect to two electric thermal switch leads [...]

________________________________________ Axles, Suspension, and Frame 9-79 ® 05745159 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 disas- sembly. Winch T r oubleshooting Winch Ino[...]

9-80 Axles, Suspension, and Frame _________________________________________ ® 4. Remove four nuts, washers, bolts, and winch from front bumper (Figure 9-186). Figure 9-186: Winch and Winch Cables 5. Remove two bolts and clamps securing winch cables to winch. 6. Remove bolt and control box cover from winch. 7. Remove capscrew, washer, and negative [...]

________________________________________ Axles, Suspension, and Frame 9-81 ® 05745159 Winch Assembly Repair Disassembly 1. Remov e winch and winch cable. NOTE: Tag leads for assembly. 2. Remove three nuts and control leads from motor (Figure 9-188). Figure 9-188: Control Leads 3. Loosen clamps and remove control from motor (Figure 9-189). Figure 9[...]

9-82 Axles, Suspension, and Frame _________________________________________ ® 11. Loosen set screw that retains brake. 12. Push brake through open end of drum and remove (Figure 9-191). 13. Remove driveshaft from gear train assembly (Figure 9-192). 14. Turn gear train assembly over with gear end drum support down. Remove ten hex-head screws and ge[...]

________________________________________ Axles, Suspension, and Frame 9-83 ® 05745159 Inspection 1. Inspect drum for damage to splined end flanges and tube (Figure 9-195). Replace winch if damaged. Figure 9-195: Drum Assembly and Gear Housing Assembly 2. Inspect gear end and motor end drum supports for damage. Replace if damaged. 3. Inspect gear [...]

9-84 Axles, Suspension, and Frame _________________________________________ ® Assembly 1. Position 85 to 87 steel balls in groov e of intermediate ring gear and install intermediate ring gear in gear housing (Figure 9-198). Figure 9-198: Intermediate Ring Gear and Gear Housing 2. Install retaining rings in gear housing. 3. Apply light oil to steel[...]

________________________________________ Axles, Suspension, and Frame 9-85 ® 05745159 17. With drum horizontal, install brake into drum (Figure 9-201). 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 N•m) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly as ne[...]

9-86 Axles, Suspension, and Frame _________________________________________ ® Figure 9-204: Control Leads Figure 9-205: Control Unit and Motor 4. Remove clamps from motor. 5. Place winch on end with motor end up (Figure 9-208). 6. Remove two bolt assemblies and rear cover from motor housing. NOTE: Perform steps 7 through 11 only if replacing brush[...]

________________________________________ Axles, Suspension, and Frame 9-87 ® 05745159 3. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. 4. Coat armature shaft with lubricant and install in brush assembly. 5. Coat head of electric thermal switch with lubricant and connect to two electric thermal switc[...]

9-88 Axles, Suspension, and Frame _________________________________________ ® ESSENTIAL TOOLS Procure from Kent-Moore. TOOL DESCRIPTION J–8092 Uni versal Dri ver Handle J–24319-B Steering Linkage and T ie Rod Puller J–8001 Dial Indicator J–29162 Rear Retainer Seal Installer J–44905 Input Seal Installer J–8614-O1 Y o ke Holding T ool (i[...]

________________________________________ Axles, Suspension, and Frame 9-89 ® 05745159 SPECIAL T OOLS Procure from Kent-Moore. J–22610 J–3409-01 PART OF J–3409-01 J–21787 J–8611-01 J–8608 J–21786 J–24385-01 J–39524 J–33142 J–35237 J–29162 TOOL DESCRIPTION J–33142 Axle Shaft and Seal Installer J–21786 Pinion Rear Bearing [...]

9-90 Axles, Suspension, and Frame _________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

_______________________________________________________________________________ 10-1 ® 05745159 Section 10 Body T ABLE OF CONTENTS Airlift to Hood Seal Replacement . . . . . . . . . . . . . . . . . . . . . . .10-51 Armrest Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24 Ashtray Replacement . . . . . . . . . . . . .[...]

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 S[...]

______________________________________________________________________ Body 10-3 ® 05745159 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. Fas- teners should be inspec[...]

10-4 Body _______________________________________________________________________ ® Lockbolt F astener F ailure Lockbolts are used to withstand tension loads and high-shear loads. These fasteners are installed in their holes with an inter- ference fit. No looseness can be permitted. Lockbolts showing evidence of being stretched, broken, loose in t[...]

______________________________________________________________________ Body 10-5 ® 05745159 Table 1: Drill Bit Sizes for Solid Shank Rivets Rivet Diameter Drill Bit Size Drill Bit Diameter 0.0625 in. (1.65 mm) # 51 0.0670 in. (1.70 mm) 0.0938 in. (2.38 mm) # 41 0.0960 in. (2.44 mm) 0.1250 in. (3.18 mm) # 30 0.1295 in. (3.29 mm) 0.1563 in. (3.97 mm[...]

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 ri vets, ri vet holes must be coun- tersunk with a[...]

______________________________________________________________________ Body 10-7 ® 05745159 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 cou[...]

10-8 Body _______________________________________________________________________ ® Aluminum Repair CA UTION: Body repairs should not be made using welding or heat for forming. Heat will only weaken the material and lead to further problems. Material Aluminum material used for repairs should be of the same al- loy and temper as the original if pos[...]

______________________________________________________________________ Body 10-9 ® 05745159 Figure 10-2: Rivet Loads in Shear Figure 10-3: Bolts Replacing Rivets Repair Parts 1. Paint repair parts or patches with epoxy primer before installation. 2. Apply sealing compound to mating surfaces to prevent corrosion. 3. Install part or patch. 4. Paint [...]

10-10 Body ______________________________________________________________________ ® Figure 10-4: Patching Figure 10-5: Patching Cracked Areas Figure 10-6: Proper Rivet Distance Repair by Insertion 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 re[...]

_____________________________________________________________________ Body 10-11 ® 05745159 Figure 10-9: Damaged Body Area Figure 10-10: Sideview of Doubler Fiberglass Repair General Information The HUMMER hood and engine access cover are made of fi- berglass (sheet molding compound). Crack, splits, or holes may be repaired with a glass reinforced[...]

10-12 Body ______________________________________________________________________ ® Repair 1. Repairing cracks or splits. W ARNING: When sanding fiberglass, personal protec- tive equipment (respirator , goggles/shield, glov es, cov er- alls, etc.) must be used. F ailure to do this may result in injury . a. Using sandpaper, remove dirt and paint 3[...]

_____________________________________________________________________ Body 10-13 ® 05745159 CENTER CONSOLE REPLACEMENT Removal 1. Remov e four screw/w ashers from center console. (Figure 10-12). 2. Slide center console back (toward rear seating area) far enough for rear air vents to clear plenum. 3. Lift console from tunnel. Installation 1. Carefu[...]

10-14 Body ______________________________________________________________________ ® Figure 10-14: Glovebox Mounting Installation 1. Assemble console as follo ws: 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 se[...]

_____________________________________________________________________ Body 10-15 ® 05745159 Crashpad Replacement (Right Side) Removal 1. Remov e screw/w ashers, and crashpad from dashboard (Figure 10-16). 2. Disconnect air hose from vent duct. 3. Remove screws, side window vent, and vent duct from crashpad. Installation 1. Secure vent duct and win[...]

10-16 Body ______________________________________________________________________ ® Gauge Replacement NOTE: Gauge replacement is basically the same for all instru- ment panel gauges. Removal 1. Remov e screws and pull gauge panel a way from instru- ment panel (Figure 10-17). 2. Disconnect lamp connector from gauge. NOTE: Tag all leads prior to rem[...]

_____________________________________________________________________ Body 10-17 ® 05745159 Instrument Panel Switch Replacement NOTE: All instrument panel switches are replaced similarly, with the exception of the dimmer control switch. This proce- dure covers the main light switch. CA UTION: Some connectors can be installed incorrectly and cause [...]

10-18 Body ______________________________________________________________________ ® Speedometer/Odometer Replacement Removal 1. Remov e the left A-pillar dash trim (closeout). 2. 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 equipp[...]

_____________________________________________________________________ Body 10-19 ® 05745159 T achometer Replacement NOTE: Mark position of set screws in relationship to tachom- eter 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 r[...]

10-20 Body ______________________________________________________________________ ® ASHTRAY REPLACEMENT Removal 1. Pull front console aw ay from dashpad to gain access to ashtray frame tabs. 2. Pull ashtray receptacle out of frame (Figure 10-25). 3. Straighten frame tabs and remove frame. Installation 1. Insert frame into opening on console and se[...]

_____________________________________________________________________ Body 10-21 ® 05745159 Disassembly 1. Remov e riv ets, retainers, and insulation from engine access cov er (Figure 10-28). 2. Remove seal from access cover. 3. Remove retaining rings, washers, and ring studs from access cover (Figure 10-29). 4. Remove locknuts and shoulder bolts [...]

10-22 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 proce- dure covers the left front seat belt on four-door hard top vehi- cles. Removal 1. Remov e seat. 2. Remove scre[...]

_____________________________________________________________________ Body 10-23 ® 05745159 Installation 1. Secure bracket to B-pillar and body with washers and bolts (Figure 10-31). T ighten bolts to 12 lb-ft (16 N•m). 2. Secure retractor mounting bracket to B-pillar with washers and bolts. Tighten bolts to 24 lb-ft (33 N•m). 3. Route seat be[...]

10-24 Body ______________________________________________________________________ ® Reclining Driver’ s and Front P assenger’s Seat Replacement NOTE: Reclining driver’s and front passenger’s seats are re- placed similarly. This procedure covers the passenger’s seat. Removal Remove bolts, washers, and passenger’s seat from seat base (Fi[...]

_____________________________________________________________________ Body 10-25 ® 05745159 REMO V ABLE LOAD BARRIER AND MOUNTING BRACK ETS REPLACEMENT (STATION W AGON) Removal 1. Remov e driv e screws and carpet assembly from front and back of remov able load barrier (Figure 10-35). 2. Remove necessary interior trim to gain access to mounting bra[...]

10-26 Body ______________________________________________________________________ ® Installation 1. Secure trim mounting brackets to B-bar with four washers and scre ws (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 N•m). 4. Secure strikers to B-pillar wi[...]

_____________________________________________________________________ Body 10-27 ® 05745159 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[...]

10-28 Body ______________________________________________________________________ ® Driver’s Compartment T rim Replacement Removal 1. Remov e overhead speak ers from driv er’ s compartment and passenger’ s compartment (if applicable) (Section 12). 2. Remove visors. 3. Remove seat belt assemblies. 4. Remove covers, screws, and grab handle fro[...]

_____________________________________________________________________ Body 10-29 ® 05745159 Figure 10-43: Rear Compartment Wall Location 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). Installati[...]

10-30 Body ______________________________________________________________________ ® Station W agon Rear Compartment T r im Replacement Removal 1. Remov e rear seats. 2. Remove bolts, washers, upper seat belt bracket, and seat belt assembly from C-pillar (Figure 10-46). Figure 10-46: C- and B-Pillar Trim Component Iden- tification 3. Remove screw/w[...]

_____________________________________________________________________ Body 10-31 ® 05745159 Figure 10-49: Station Wagon Side Wall Component Breakdown B-PILLAR TRIM C-PILLAR CENTER TRIM SEAT BEL T BRACKET HEADLINER SEAT BEL T ASSEMBL Y STA TION W AGON COMP AR TMENT SIDE W ALLS TRIM P ANEL LOWER REAR COMP AR TMENT W ALL UPPER C-PILLAR TRIM LOWER C-P[...]

10-32 Body ______________________________________________________________________ ® Inner Kick P anels Replacement Removal 1. Remov e seats. NOTE: Remove one bolt, washer, and seat buckle for two-pas- senger models. 2. Remove bolts, washers, and seat buckles from front and rear of tunnel (Figure 10-50). Figure 10-50: Seat Belt Buckle Electrical Co[...]

_____________________________________________________________________ Body 10-33 ® 05745159 Installation NOTE: Perform step 1 for two-passenger models only. 1. Secure rear inner kick panel to right rear of tunnel with panel fastener (Figure 10-52). 2. Secure right front inner kick panel to tunnel with panel fasteners. 3. Secure left front inner ki[...]

10-34 Body ______________________________________________________________________ ® T unnel Carpet, P adding, and Hardboard Replacement Removal NOTE: Tunnel carpet, padding, and hardboard replacement is basically the same for all models. This task represents four- passenger model carpet replacement. 1. Remov e inner kick panels. 2. Remove carpet f[...]

_____________________________________________________________________ Body 10-35 ® 05745159 MIRRORS Side Mirror Replacement Removal Remove screws, mirror, and gasket from door hinge (Figure 10-57). Figure 10-57: Side Mirror Assembly Replacement Installation Secure gasket and mirror to door hinge with screws (Figure 10-57). PO W ER MIRRORS Po w er [...]

10-36 Body ______________________________________________________________________ ® Rear view Mirr or Replacement Removal 1. Remov e screw and rearvie w mirror from mirror bracket (Figure 10-59). NOTE: Perform step 2 only if bracket requires replacement. Mark location of bracket prior to removal. 2. Remove bracket from windshield. Cleaning and Ins[...]

_____________________________________________________________________ Body 10-37 ® 05745159 Disassembly 1. Remov e twelve-point bolts, washers, and upper and lo wer hinge plates from door (Figure 10-60). 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 sc[...]

10-38 Body ______________________________________________________________________ ® Figure 10-64: Latch Assembly CA UTION: Firmly support glass during regulator removal to avoid damage. Remove power window regulator (refer to procedure in this section). Cleaning and Inspection NOTE: Clean all components, and examine for wear or dam- age. Replace i[...]

_____________________________________________________________________ Body 10-39 ® 05745159 Figure 10-66: Door Hinges Adjustment 1. Loosen twelve-point scre ws securing upper and lo wer door hinges to pillar (Figure 10-66). 2. Raise door as high as possible. Push hinges toward front of vehicle as far as they will go, and tighten twelve-point screw[...]

10-40 Body ______________________________________________________________________ ® PO W ER WINDO WS Po w er Windo w 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 necessar[...]

_____________________________________________________________________ Body 10-41 ® 05745159 DOOR SEALS REPLACEMENT NOTE: The door seals come in bulk and must be cut to the ap- propriate 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[...]

10-42 Body ______________________________________________________________________ ® Figure 10-71: Door Stop Strap Assembly Figure 10-72: Window Channel Locations Cleaning and Inspection 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 10-7[...]

_____________________________________________________________________ Body 10-43 ® 05745159 Figure 10-73: Glass/Lift Channel Bracket Location Door Glass “W ind Noise” Diagnosis and Repair/Side Windo w 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[...]

10-44 Body ______________________________________________________________________ ® Figure 10-75: Hood Latch Bracket and Latch Plate Replacement Hood Release Cable Assembly Replacement Removal 1. Raise and secure hood. 2. Remove cable handle, two nuts, lockwasher, nut, and cable assembly from cable mounting bracket. 3. Remove cable assembly from c[...]

_____________________________________________________________________ Body 10-45 ® 05745159 6. Remove two nut and lockwasher assemblies, screws, cable clamp bracket, and spacer from bracket assembly. 7. Inspect three nylon bushings in bracket assembly. Remove and discard bushings if damaged. Figure 10-78: Hood Release Latch and Bracket Assembly Mo[...]

10-46 Body ______________________________________________________________________ ® Figure 10-81: Hood Prop Rod Replacement Figure 10-82: Hood Prop Rod and Bracket Replacement Disassembly 1. Remov e hood prop rod from eyebolt (Figure 10-83). 2. Remove locknut, washer, bushing, spring, snapring, bushing, washer, and eyebolt from bracket. Cleaning a[...]

_____________________________________________________________________ Body 10-47 ® 05745159 Hood and Hinge Replacement Removal 1. Raise and secure hood. W ARNING: T o av oid injury , or damage to equipment, support hood during removal and installation. 2. Disconnect two connector plugs from connector receptacles (Figure 10-84). 3. Remove four cott[...]

10-48 Body ______________________________________________________________________ ® 2. Open hood and loosen center hood stop (Figure 10-85). 3. Gently close hood and loosen lower hinge half locknuts (Figure 10-86). Figure 10-86: Lower Hinge Half Locknut Location 4. Gently position hood to obtain proper and even clearance with A-pillar and both fro[...]

_____________________________________________________________________ Body 10-49 ® 05745159 Side Hood Stop Replacement Removal Remove two locknuts, washers, bolts, washers, and side hood stop from body (Figure 10-90). Installation Secure side hood stop to body with two washers, bolts, wash- ers, and locknuts. Tighten bolts to 6 lb-ft (8 N•m) (Fi[...]

10-50 Body ______________________________________________________________________ ® Guide Brack et Assembly Replacement Removal Remove six locknuts, twelve washers, guide bracket assembly, guide plate, and six bolts from hood (Figure 10-93). Installation 1. Loosely attach guide plate and guide bracket assembly to hood with six bolts, twelve washer[...]

_____________________________________________________________________ Body 10-51 ® 05745159 Right Hood Close-Out Seal and Retainer Replacement Removal 1. Remov e two scre ws and upper seal retainer from close-out seal and hood (Figure 10-97). 2. Remove two screws, lower seal retainer, and close-out seal from hood. Figure 10-97: Right Hood Close-Ou[...]

10-52 Body ______________________________________________________________________ ® ENG INE 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 [...]

_____________________________________________________________________ Body 10-53 ® 05745159 HOR N Hor n Replacement Removal 1. Remov e harness connectors and adapters from horn. 2. Remove nut and horn from mounting bracket (Figure 10-101). NOTE: Overtightening horn mounting nut will distort the horn bellows and result in an “off-key” horn tone[...]

10-54 Body ______________________________________________________________________ ® Windshield Assembly Replacement W ARNING: T o av oid injury , or damage to equipment, support windshield during removal and installation. Removal 1. Remov e soft top or loosen roof assembly , as applicable. 2. Remove windshield wiper blade and arm. 3. Remove windsh[...]

_____________________________________________________________________ Body 10-55 ® 05745159 Figure 10-105: Windshield Assembly Seal Replacement Installation 1. Position two seals on windshield assembly (Figure 10-103). 2. Position windshield assembly over A-pillar. 3. Secure windshield assembly to two brackets with six bolts and washers. 4. Connec[...]

10-56 Body ______________________________________________________________________ ® Removal NOTE: Wire harnesses behind console are long enough to al- low for power window master switch removal without remov- ing console for access to electrical connectors. 1. Remov e screws and pull po wer windo w master switch from console (Figure 10-106). 2. Li[...]

_____________________________________________________________________ Body 10-57 ® 05745159 Windshield Wiper Linkage Replacement Removal NOTE: Left and right side windshield wiper linkage replace- ment procedure is the same. This procedure covers the left side. 1. Remov e windshield wiper motor assembly . 2. Remove upper A-pillar trim. 3. Disconne[...]

10-58 Body ______________________________________________________________________ ® WINDSHIELD W ASHER SYSTEM AND COMPONENTS Reser voir and Pump Assembly Replacement Removal 1. Drain reservoir . 2. Remove two screws and retaining bracket securing ABS ECU enclosure. Set aside ECU with enclosure. 3. Disconnect pump connector from reservoir and pump [...]

_____________________________________________________________________ Body 10-59 ® 05745159 Figure 10-112: Windshield Washer Nozzle Replacement Figure 10-113: Windshield Washer Hose Replacement NOZZLE 9-S10-004 ECU ENCLOSURE PUMP ASSEMBLY ECU RETAINING BRACKET CLAMPS[...]

10-60 Body ______________________________________________________________________ ® A-PILLAR FORMER ASSEMBLY REPLACEMENT (SOFT T OP ONLY) Removal 1. Remov e soft top. 2. Remove 12 screws and A-pillar former from A-pillar (Figure 10-114). 3. Clean mounting surface on A-pillar. Cleaning and Inspection NOTE: Clean all components, examine for wear or [...]

_____________________________________________________________________ Body 10-61 ® 05745159 REAR SUPPORT BOW BRACK ET REPLACEMENT Removal 1. Remov e rear support bow assembly . 2. Remove two screws and support bow bracket from body (Figure 10-115). Figure 10-115: Rear Support Bow Bracket Replacement Installation 1. Secure bracket to body with two [...]

10-62 Body ______________________________________________________________________ ® Figure 10-119: Body Mount Cushions Replacement Installation 1. Position lo wer cushion, upper cushion, sleev e, and spacer between body bracket and frame bracket (Figure 10-119). 2. Lower body and ensure lower cushion, sleeve, upper cushion, spacer and body bracket[...]

_____________________________________________________________________ Body 10-63 ® 05745159 FUEL FILLER HOUSING REPLACEMENT Main Fuel T ank Removal 1. Remov e filler cap from filler spout (Figure 10-122). 2. Remove screw securing cap tether (not shown) to fuel filler housing, mark location for reassembly 3. Remove three nuts, washers, capscrews,[...]

10-64 Body ______________________________________________________________________ ® ROADSIDE EMERGENCY EQUIPMENT Tire Jac k and Optional T riangle W ar ning Kit Hold-Down Brac k et Replacement (For T wo-P assenger Model) Removal 1. Remov e two wingnuts, washers, and hold-do wn brackets (Figure 10-124). 2. Remove tire jack and triangle warning kit.[...]

_____________________________________________________________________ Body 10-65 ® 05745159 FOUR -PASSENGER SOFT T O P Interior Trim Replacement Removal 1. Remov e front and rear seats. 2. Remove front and center consoles. 3. Remove speakers from rear wall (Section 12). 4. Remove two panel fasteners from upper center trim of windshield frame (Figu[...]

10-66 Body ______________________________________________________________________ ® Figure 10-128: Rear Wall Compartment Location Installation 1. Secure center trim to rear compartment wall with scre w and washer assembly (Figure 10-128). 2. Secure lower trim and trim to rear compartment wall with two panel fasteners and four screw and washer asse[...]

_____________________________________________________________________ Body 10-67 ® 05745159 Soft T op Mounting Components and Accessories Replacement NOTE: The following removal and installation instructions include replacement of all soft top mounting com- ponents and accessories. Use only the applicable steps for re- placing specific components.[...]

10-68 Body ______________________________________________________________________ ® 4. Remove velcro strips and patches from tonneau area (Figure 10-131). NOTE: Perform steps five and six for both sides of the vehi- cle. The left side is shown. 5. Remove 41 in. (104 cm) tonneau extrusion from side of wheelhouse. 6. Remove 9 in. (23 cm) tonneau ext[...]

_____________________________________________________________________ Body 10-69 ® 05745159 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. Figure 10-136: H-Rail Removal NOTE: While removing the H-rail, note where sealer is place[...]

10-70 Body ______________________________________________________________________ ® Figure 10-137: Rail and Support Structure Locations Figure 10-138: Bow Retainer Bracket Installation 8-S10-001 VELCRO REAR, SIDE, P-CHANNEL H-RAIL B-PILLAR COVER C-PILLAR COVER SUPPORT STRUCTURE FRONT FILLER PIECE FILLER FILLER B-PILLAR COVER LOWER BRACKET INSTALLA[...]

_____________________________________________________________________ Body 10-71 ® 05745159 SOFT T OP SUPPORT ASSEMBLY Removal 1. Remov e soft top. 2. Remove interior grab handles. 3. Remove vinyl wrap and padding from roll cage assembly. 4. Remove inner door seals. 5. Drill rivets on front corner filler plates located at top front of front door o[...]

10-72 Body ______________________________________________________________________ ® T AILGATE T ailgate Chain and Latch Brack ets Replacement Removal Remove four locknuts, eight washers, four bolts, chain bracket, and latch bracket from body (Figure 10-140). Installation Secure chain bracket and latch bracket to body with four bolts, eight washers[...]

_____________________________________________________________________ Body 10-73 ® 05745159 Installation 1. Install two grommets on tailgate (Figure 10-143). 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 horizonta[...]

10-74 Body ______________________________________________________________________ ® Assembly 1. Using three 0.187 in. x 0.626 in. ri vets, fasten hinge to lower set of holes on tailg ate. 2. Fasten hinge to upper set of holes on tailgate with three 0.187 in. x 0.563 in. rivets. Installation 1. Position tailgate on bed and secure with tailgate chai[...]

_____________________________________________________________________ Body 10-75 ® 05745159 Door Handle Replacement Removal 1. Remov e rear door window . 2. Remove four screws and interior door handle from door (Figure 10-148). 3. Remove twelve screws and close-out panel from door. 4. Remove two cotter pins, washers, and latch rods from exterior d[...]

10-76 Body ______________________________________________________________________ ® Figure 10-150: Cargo Door Electric Locks DOOR LOCK MOTOR HARNESS MOTOR LINK ROD AND LOCK CLIPS DOOR HINGE CONTACTS DOOR DOOR HINGE CONTACTS LOCK MOTOR[...]

_____________________________________________________________________ Body 10-77 ® 05745159 Door Stop Replacement Removal 1. Remov e rear door window . 2. Remove four screws and interior door handle from door (Figure 10-149). 3. Remove twelve screws and close-out panel from door. 4. Remove bolt, door stop ball, and retainer from door (Figure 10-15[...]

10-78 Body ______________________________________________________________________ ® INTERIOR AND EXTER IOR LIGHTING REPLACEMENT Ser vice 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. Loosen three scre ws and remove retaining ring from[...]

_____________________________________________________________________ Body 10-79 ® 05745159 Side Mark er Light Lens and Lamp Replacement Removal Remove two screws, cover, lens, and lamp from lamp holder (Figure 10-154). Installation 1. Install lamp. Secure lens, and cov er to lamp holder with two scre ws (Figure 10-154). 2. Ensure side marker ligh[...]

10-80 Body ______________________________________________________________________ ® Figure 10-157: Side Marker Light Assembly Installation 1. Secure gasket, lamp holder , and ground lead on hood with four scre ws, washers, and locknuts (Figure 10-157). 2. Secure lens and cover to lamp holder with two screws. 3. Connect light lead to harness lead. [...]

_____________________________________________________________________ Body 10-81 ® 05745159 Rear T urn Signal Light Replacement Removal NOTE: To remove lamps only, perform steps 1 and 2. 1. Remov e four screws, lens, and gask et from turn signal light (Figure 10-160). Figure 10-160: Rear Turn Signal Light Assembly 2. Remove two lamps from sockets.[...]

10-82 Body ______________________________________________________________________ ® Domelight/Cargo Light Replacement (Models 83, 84, 89, & 91) Removal 1. Remove domelight lens (Figures 10-162 through 10-164). 2. Remove lamp from domelight. 3. Remove screws securing domelight to ground lead and connector. 4. Remove screw and domelight from roo[...]

_____________________________________________________________________ Body 10-83 ® 05745159 Domelight Replacement (Model 90) Removal 1. Using a scre wdriv er , snap the dome light assembly from its base (Figure 10-165) 2. Remove two screws securing domelight base and the support structure. 3. Slowly pull the light base until the connector for the [...]

10-84 Body ______________________________________________________________________ ® Lighted V isor Mirror Replacement Removal 1. Pull mirror assembly from visor (Figure 10-168). 2. Remove lamp. Figure 10-168: Lighted Visor Mirror Replacement Installation 1. Install lamp (Figure 10-168). 2. Install mirror assembly by pressing it into the visor. Und[...]

_____________________________________________________________________ Body 10-85 ® 05745159 Front Driver and P assenger Courtesy Light Replacement Removal 1. Carefully pry courtesy light from mounting bracket (Figures 10-171 and 10-172). 2. Disconnect light from wiring harness. Figure 10-171: Front Driver Side Courtesy Light Replacement Installati[...]

10-86 Body ______________________________________________________________________ ® BACKUP LIGHT SWITCH REPLACEMENT Removal 1. Remov e shift controls housing (Section 5). 2. Pull neutral start switch leads, backup light switch leads, and light lead through boot and remove boot from shift controls housing (Figure 10-174). 3. Remove two screws and l[...]

_____________________________________________________________________ Body 10-87 ® 05745159 SLANT BACK AND COMPONENTS Figure 10-176: Slant Door and Torsion Assembly Slant Door and T orsion Assembly Replace- ment CA UTION: The slant door is heavy. Some assistance will be required for removal and installation. Removal 1. Remov e all the trim on the [...]

10-88 Body ______________________________________________________________________ ® Adjustments 1. Loosen the torsion assembly mounting bolts enough to allo w the slant door to move side to side (Figure 10-176). 2. Loosen the slant door mounting bolts enough to allow for an adjustment of the opening clearance at the top of the door. 3. Position th[...]

_____________________________________________________________________ Body 10-89 ® 05745159 Slant Door Latch Figure 10-178: Slant Door Latch and Handle Break- down Removal 1. Remov e the slant door trim. 2. Disconnect the latch actuator cable from the slant door handle assembly by removing the retaining nut, and bolt (Figure 10-178). 3. Remove the[...]

10-90 Body ______________________________________________________________________ ® Wiper Motor and Components Figure 10-180: Window Wiper Assembly Replacement Removal 1. Remov e the protectiv e nut cov er 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.[...]

_____________________________________________________________________ Body 10-91 ® 05745159 GLASS AND BODY FOR SLANT BAC K Rear Windo w Removal Remove the twenty two window retaining screws, the window retainer bracket and the window (Figure 10-181). Figure 10-181: Slant Door Window Replacement Installation Install the slant door window and the wi[...]

10-92 Body ______________________________________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

_______________________________________________________________________________ 11-1 ® 05745159 Section 11 Heating/V entilation/Air Conditioning (HV A C) T ABLE OF CONTENTS A/C System Refrigerant and Capacity . . . . . . . . . . . . . . . . . . . . 11-5 Air Conditioning/Heater Duct Replacement . . . . . . . . . . . . . . 11-25 Ambient Temperature [...]

11-2 Heating/Ventilation/Air Conditioning (HVAC) _______________________ ® SYSTEM PERF ORMANCE CHECKS Before performing any air conditioning repair, perform the fol- lowing: 1. Check dri vebelt for wear , damage, or loss of tension. Replace dri vebelt as necessary . 1. Check compressor for secure mounting and proper alignment. Tighten loose hardwa[...]

______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-3 ® 05745159 A/C System Leak T esting 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) lig[...]

11-4 Heating/Ventilation/Air Conditioning (HVAC) _______________________ ® 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 V[...]

______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-5 ® 05745159 A/C SYSTEM REFRIGERANT AND CA PACITY 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[...]

11-6 Heating/Ventilation/Air Conditioning (HVAC) _______________________ ® A/C Ser vicing Precautions There are precautions that should be followed when servicing the A/C system. The precautions are necessary to avoid com- ponent damage and personal injury. • Wear eye protection when servicing the system. The re- frigerant is under pressure and [...]

______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-7 ® 05745159 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, com- pressor, or receiver/dryer has been replaced, or there was a large leak. When a system is discharged, it i[...]

11-8 Heating/Ventilation/Air Conditioning (HVAC) _______________________ ® 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[...]

______________________ Heating/Ventilation/Air Conditioning (HVAC) 11-9 ® 05745159 Heater Diagnosis Condition Possible Cause Correction Inadequate or No Heat 1. Heat control knob not set in heat mode, or engine not warmed up. 1. Advise o wner/driv er . 2. Lo w engine coolant lev el. 2. Add coolant as needed and check for leaks. 3. Air in coolant s[...]

11-10 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Air Flow Diagnosis Condition Possible Cause Correction No Air Flow from Outlets 1. Blower motor fuse blo wn. 1. Replace fuse. 2. Blo wer motor harness damage (short, open, loose connection). 2. Check harness continuity with ohmmeter and repair as needed. 3. Blo wer motor fa[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-11 ® 05745159 A/C Pressure Test Diagnosis Condition Possible Cause Correction Lo w Side High High Side High (Discharge Air W arm - Discharge Line W arm to Hot) 1. Condenser fins obstructed or distorted. 1. Clear obstruction with water spray and compressed air . Straighten distor[...]

11-12 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Compressor Diagnosis Condition Possible Cause Corr ection Compressor Noise 1. System overcharge. 1. Recover all R-134a with J–39500-A ser - vice cart and recharge with proper char ge. 2. Dri vebelt problem. 2. Replace belt if worn, frayed, cut or torn. 3. Compressor clutc[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-13 ® 05745159 SPECIFICATIONS System refrigerant — R-134a Compressor oil — PAG (polyalkaline glycol) Refrigerant capacity — 3 lbs.2oz. Compressor type — Harrison HT6 *Low and high side pressures are affected by relative humid- ity. Greater humidity will cause higher pressu[...]

11-14 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® R-134a Pressure-to-Temperature Relationship Chart (with Engine OFF) Psi T emp (°F) R-134a Psi T emp (°F) R-134a Psi T emp (°F) R-134a Psi T emp (°F) R-134a 0 -14.7 25 29.3 70 69.6 200 130.1 1 -12.1 26 30.5 75 72.9 210 133.5 2 -9.6 27 31.7 80 76.1 220 136.7 3 -7.2 28 32.[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-15 ® 05745159 Figure 11-5: Vacuum Door Motors Vacuum Door Motor Arm Positioning OFF MAX A/C A/C Blend F ace Floor Defrost/ Floor Defrost Floor out out out in out in out out Defrost blockof f out out out out out out out in Face out in in half in out out out Defrost out out out out[...]

11-16 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® CLIMATE CONTROL HEAD REPLACEMENT Removal 1. Remov e front console. 2. Remove screw attaching climate control head to support plate side bracket (Figure 11-6). 3. Pull climate control head from behind support plate so that it angles away from longer side bracket. 4. Pull cli[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-17 ® 05745159 PRESSURE HOSE T OR QUE SPECIFICATIONS CA UTION: To avoid potential thread or fitting damage, hand start connections before using wrenches. Air conditioning system fittings are a common source of refrig- erant leaks. When service requires disconnecting and connect- i[...]

11-18 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® AIR CONDITIONING PRESSURE HOSE REPLACEMENT W ARNING: Air conditioning system components are subject to high-pressure R-134a gas. Always disc harge pressure and contain refrigerant using approv ed service equipment. Use extreme care when handling R-134a. Direct contact with [...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-19 ® 05745159 Discharge Hose Replacement Removal 1. Disconnect discharge hose from condenser . Remove and discard O-ring (Figure 11-12). 2. Remove driver side engine splash shield (Section 10). Figure 11-12: Discharge Hose Location 3. Remove tie strap securing discharge hose to o[...]

11-20 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Receiver/Dryer -T o-Ev aporator Core Hose W ARNING: Air conditioning system components are subject to high pressure R-134a gas. Always disc harge pressure and contain refrigerant using approv ed service equipment. Use extreme care when handling R-134a. Direct contact with s[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-21 ® 05745159 RECEIVER/DRYER REPLACEMENT Removal W ARNING: Air conditioning system components are subject to high-pressure R-134a gas. Always disc harge pressure and contain refrigerant using approv ed service equipment. Use extreme care when handling R-134a. Direct contact with [...]

11-22 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® 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 valve’s rearward lower f[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-23 ® 05745159 W ATER CONTR OL V ALVE REPLACEMENT Removal 1. Place a drain container under the vehicle directly belo w the control v alve (Figure 11-19). NOTE: Use extreme caution when working on a hot engine. Let the engine cool down before proceeding. 2. Relieve pressure from co[...]

11-24 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® MAIN A/C - HEAT UNIT CO WL INSULATION REPLACEMENT Removal 1. Remov e air intake weathercap (Section 3). 2. Remove air cleaner assembly shield. 3. Remove vent line from air cleaner assembly. 4. Remove air cleaner assembly and air induction tube. 5. Loosen and remove two clam[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-25 ® 05745159 AIR CONDITIONING/HEATER DUCT REPLACEMENT Passenger Floor Duct Removal 1. Remov e right side crash pad (Section 10). 2. Remove screw securing passenger side closeout panel to upper closeout panel bracket (Figure 11-22). 3. Lower panel down, and pull rearward to remov[...]

11-26 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® DEFROST DUCT AND WINDSHIELD NOZZLES REPLACEMENT Center Defrost Duct Removal 1. Remov e right side crash pad (Section 10). 2. Remove front console (Section 10). 3. Remove engine cover (Section 10). 4. Remove twelve screws, nuts, washers, and closeout panel from A-beam (Figur[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-27 ® 05745159 Passenger Side W indshield Defrost Nozzle Removal 1. Remov e right side crash pad (Section 10). 2. Remove front console (Section 10). 3. Remove diverter assembly. 4. Remove main A/C - heat unit blower housing. 5. Remove four screws, lockwashers and passenger side lo[...]

11-28 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® COMPRESSOR REPLACEMENT W ARNING: Air conditioning system components are subject to high-pressure refrigerant R-134a gas. Always discharge pressure and contain R-134a using appro ved service equipment. Use extreme care when handling R- 134a. Direct contact with skin may caus[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-29 ® 05745159 3. Keep the clutch plate and hub assembly from turning by using the clutch hub holding tool. Remove the shaft nut using nut socket. 4. With center screw forcing tip in place to thrust against the end of the shaft, thread the hub and clutch drive plate assembly remov[...]

11-30 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® COMPRESSOR CLUTCH ROTOR AND/OR BEARING REPLACEMENT Removal 1. Remov e the clutch plate and hub assembly . 2. Using snapring pliers, remo v e retaining ring (Figure 11-30). Figure 11-30: Retaining Ring 3. Install pulley rotor and bearing puller guide on the compressor, and i[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-31 ® 05745159 2. 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). 3. Place bearing s[...]

11-32 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® 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 . 2. Install puller pilot and puller crossbar with puller legs on compressor (Figure 11-39). 3. Ti[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-33 ® 05745159 Figure 11-43: Seal Remover 4. Using O-ring remover, remove and discard seal seat O- ring from the compressor neck (Figure 11-44). 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 b[...]

11-34 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® LOW PRESSURE CUTOF F SWITCH The low pressure cutoff switch is mounted on the receiver/ dryer. The switch is wired in series with the compressor activa- tion circuit. Should pressure drop below the switch’s setting, the switch will open and interrupt current flow to the co[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-35 ® 05745159 BLOW ER MOTOR RESISTOR REPLACEMENT Removal 1. Remov e HV A C harness connector from resistor (Figure 11-50). 2. Remove screws and resistor from cowl. Installation 1. Fasten resistor to co wl with scre ws. 2. Plug HVAC harness connector into resistor. 3. Check blower[...]

11-36 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® HV AC CONTROLS 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[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-37 ® 05745159 UNIT SER VICE W ARNING: When working with refrigerant, always use protective equipment to prev ent injury . Refrigerant handling should be done only by technicians trained and certified in the use of refrigerant and refrigerant service equipment. CA UTION: Use only[...]

11-38 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Heater Core The heater core is composed of copper and brass with numer- ous 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 i[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-39 ® 05745159 MAIN UNIT REPLACEMENT Remo v al 1. Drain Coolant into an approv ed container . 2. Recover refrigerant. 3. Remove raincap and adapter. 4. Remove air intake elbow, air cleaner and splash shield. 5. Remove 4 bolts securing heater core extension tubes. Plug all open hol[...]

11-40 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Installation Lift HVAC unit into the vehicle. 1. Set the lo wer bracket on HV A C 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 HV A C u[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-41 ® 05745159 V ACUUM DOOR MOTOR Replacement 1. Remov e right front crash pad. 2. Locate and remove 2 screws securing vacuum motor cover to main HVAC unit. 3. Locate faulty vacuum motor and remove vacuum line. If multiple motors are to be replaced, tag vacuum lines as they are re[...]

11-42 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® BLEND DOOR MOTOR Replacement 1. Disconnect motor electrical connection. 2. Remove 3 nuts securing motor to bracket (Figure 11-68). 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 [...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-43 ® 05745159 EV APORATOR Replacement 1. Remov e HV A C unit from vehicle (refer to HV A C unit replacement). 2. Remove heater core from main unit (refer to heater core replacement). 3. Remove lower support bracket from HVAC case (Figure 11-72). Figure 11-72: Lower Support Bracke[...]

11-44 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® 8. Remove arm retaining push clip, arm and 2 washers from the floor door and defrost door (Figure 11-78). Figure 11-78: Push Clip Removal 9. Remove defrost motor from the bracket, note position of mounting studs in mounting plate (Figure 11-79). Figure 11-79: Vacuum Door Mo[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-45 ® 05745159 19. Remove screws securing passthrough plate support bracket to the main unit (Figure 1-82). Figure 1-82: Passthrough Plate Support Removal 20. Remove bolt securing passthrough plate to the evaporator manifold connection, remove plate and support bracket. 21. Remove[...]

11-46 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® REAR CONSOLE REPLACEMENT Removal 1. Remov e two scre w/washers securing rear console to side brackets (Figure 1-85). 2. Push console rearward so that the vents are clear from the plenum cutouts. 3. Remove rear console. Installation 1. Position rear console ov er the auxilia[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-47 ® 05745159 AUXILIARY BLOWER SWITCH REPLACEMENT Removal 1. Pull front console aw ay from dashboard. 2. Depress tabs on blower switch and push through faceplate. 3. Remove connector from back of blower switch (Figure 11-88). Installation 1. Secure connector to blo wer switch and[...]

11-48 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® AUXILIARY A/C DRAIN T UBE(S) REPLACEMENT Removal 1. Remov e rear console. 2. Remove clamps from drain tube section being replaced (Figure 11-89). 3. Remove drain tube. Figure 11-89: Auxiliary A/C Drain Tube Replacement Installation 1. Install drain tube section and secure w[...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-49 ® 05745159 AUXILIARY LOW-PRESSURE HOSE REPLACEMENT Removal 1. Discharge air conditioning system. 2. Remove air cleaner assembly and air induction tube (Section 3). 3. Using two wrenches for equalized support, remove auxiliary low-pressure hose from low-pressure hose fitting. R[...]

11-50 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® Figure 11-92: Auxiliary Air Conditioning Components AUXILIARY EXPANSION V ALV E REPLACEMENT Removal 1. Discharge air conditioning system. 2. Remove rear console. 3. Remove prestite tape and bulb clamp. 4. Using two wrenches for equalized support, remove high- pressure hose [...]

_____________________ Heating/Ventilation/Air Conditioning (HVAC) 11-51 ® 05745159 ESSENTIAL T OOLS Procure from Kent-Moore. T ool No. Description J–42551 J–42549 J–42550 J–41459 J–42220 Leak Detector , A/C R134a HV A C Anemometer (not sho wn) HV A C Flow Meter Adapter Kit (not shown) Leak Detection Dye Injector High Intensity Ultra V io[...]

11-52 Heating/Ventilation/Air Conditioning (HVAC) ______________________ ® SPECIAL T OOLS Procure from Kent-Moore. T ool No. Description J – 39500-A A/C Recovery , Recycle, Evacuate and Dischar ge Service Cart (from Robinaire) J – 34021-A Compressor Clutch Pulley , Core and Bearing Replacement T ool Set J – 39500-20A High Side Coupler Adapte[...]

_______________________________________________________________________________ 12-1 ® 05745159 Section 12 Electr ical System T ABLE OF CONTENTS Audio Antenna System Test . . . . . . . . . . . . . . . . . . . . . . . . . . .12-157 CD Changer (Delco) Replacement . . . . . . . . . . . . . . . . . 12-140 Diagnosis-Delco Audio System . . . . . . . . .[...]

12-2 Electrical System _________________________________________________________ ® Power Locks Cargo Door Lock Inoperative . . . . . . . . . . . . . . . . . . . . 12-113 Front Door Harness Replacement . . . . . . . . . . . . . . . . . 12-120 General Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-102 Keyless Entry & Theft [...]

________________________________________________________ Electrical System 12-3 ® 05745159 DIAGNOSTICS The following section of the service manual deals with electri- cal diagnostics. The section consists of three main tools: 1. Diagnostic charts 2. Wiring diagrams 3. Connector legend Diagnostic Charts Diagnostic charts are designed to take you th[...]

12-4 Electrical System _________________________________________________________ ® 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 cur- rent rises above the fuses ’ rating, the metal will me[...]

________________________________________________________ Electrical System 12-5 ® 05745159 Figure 12-3: Grounded Circuit DIAGNOSTIC T OOLS Dig ital Multimeter A digital multimeter (J – 39200) 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 te[...]

12-6 Electrical System _________________________________________________________ ® Figure 12-4: Amperage Test Figure 12-5: Voltage Drop Test Figure 12-6: Ohm Test GROUND BATTERIES BREAKER SWITCH (CLOSED) MULTIMETER LOAD (I.E. LIGHT, MOTOR, SOLENOID, ETC.) GROUND CIRCUIT GROUND BATTERIES BREAKER SWITCH (CLOSED) MULTIMETER GROUND CIRCUIT GROUND BATT[...]

________________________________________________________ Electrical System 12-7 ® 05745159 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 insul[...]

12-8 Electrical System _________________________________________________________ ® 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 ori[...]

________________________________________________________ Electrical System 12-9 ® 05745159 Figure 12-8: Damaged Wire Figure 12-9: Heat Shrink Tubing Figure 12-10: Splice Clip Figure 12-11: Electrical Tape Figure 12-12: Electrical Tape Figure 12-13: Splice Clip Figure 12-14: Heat Shrink Tubing Figure 12-15: Damaged Wire Figure 12-16: Multiple Wire [...]

12-10 Electrical System _______________________________________________________ ® 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 bl[...]

______________________________________________________ Electrical System 12-11 ® 05745159 Figure 12-19: Relay Location (Interior Fuse Box) 9-S12-083 C FE B D A BA A B SIGNAL FLASHER CTIS ALARM MIRROR CUTOUT IGNITION WIPER POWER WINDOW REAR WIPER 4-1-00[...]

12-12 Electrical System _______________________________________________________ ® Upper Mini-Fuse Location *May not be provided. Lower Mini-Fuse Location Figure 12-20: Mini Fuse Identification (Interior Fuse Box) FUSE AMPERA GE CIRCUIT PR O TECTED 1E 5 Spare Fuse 2E – Blank 3E 7.5 Spare Fuse 4E – Blank 5E 15 Spare Fuse 6E – Blank 7E 25 Spare[...]

______________________________________________________ Electrical System 12-13 ® 05745159 Exterior Fuse Box Figure 12-21: Exterior Fuse Box The exterior fuse box is located under the hood on the dri ver ’ s side of the engine compartment. The e xterior fuse box houses mini and maxi fuses, circuit breakers, and relays which supply po wer to many [...]

12-14 Electrical System _______________________________________________________ ® BATTER Y CHARG ING 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 peri- ods at 10, 5, or 2 amps. A 5 amp cha[...]

______________________________________________________ Electrical System 12-15 ® 05745159 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: • J – 38758 Parasitic Draw Test Switch • J – 39200 Digital Multimeter 1. Remov e the negati ve b[...]

12-16 Electrical System _______________________________________________________ ® BATTER Y CABLE REPLACEMENT Battery Negative Cables - Removal 1. Remov e caps from battery negati ve cable (Figure 12-27). 2. Remove battery cable bolts. 3. Disconnect winch negative cable, if equipped (Figure 12-27). Figure 12-27: Battery Negative Cable Connections 4[...]

______________________________________________________ Electrical System 12-17 ® 05745159 Figure 12-29: Battery Positive Cable Connections Battery Positive Cables - Installation 1. Connect starter cable to starter with lockers and nut. T ighten nut to 12-16 lb-ft (16-22 N • m). 2. Secure starter cable to bracket with clamp, capscrew, washer, and[...]

12-18 Electrical System _______________________________________________________ ® BATTER Y REPLACEMENT W ARNING: Battery electrolyte contains sulfuric acid which can cause sev ere burns. If acid contacts eyes or skin, flush aff ected areas liberally with water and ob- tain medical assistance immediately . If acid contacts clothing, flush with wa[...]

______________________________________________________ Electrical System 12-19 ® 05745159 BATTER Y SPLASH SHIELD AND SEAL SER VICE Splash Shield Removal 1. Remov e upper splash shield and seal (Figure 12-32). 2. Remove retainer bolts, and remove seal from battery tray and lower shield (Figure 12-33). 3. Remove lower splash shield bolts and remove [...]

12-20 Electrical System _______________________________________________________ ® Splash Shield Installation 1. Position lo wer shield on bracket and install fasteners (Figure 12-34). 2. Install retainer on upper shield. 3. Install upper shield on tray. 4. Install seals and retainers (Figure 12-33). Figure 12-34: Lower Splash Shield Removal/Instal[...]

______________________________________________________ Electrical System 12-21 ® 05745159 MAJOR PO W ER 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 po[...]

12-22 Electrical System _______________________________________________________ ® ALTERNATOR Removal 1. Disconnect battery negati ve cable. 2. Remove serpentine drivebelt from alternator pulley. 3. Loosen pivot bolt and remove front and rear alternator bolts (Figure 12-36). 4. Pull alternator away from engine. Remove nut and lockwasher and disconn[...]

______________________________________________________ Electrical System 12-23 ® 05745159 ALTERNATOR OVERHAUL Alternator Disassembly 1. Remov e alternator . 2. Mark drive end frame and slip ring end frame for assembly alignment reference. 3. Hold rotor shaft with allen wrench and remove nut, washer, pulley, fan, and thin collar from rotor shaft (F[...]

12-24 Electrical System _______________________________________________________ ® 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. Inspection and Repair [...]

______________________________________________________ Electrical System 12-25 ® 05745159 Figure 12-41: Rectifier Bridge Check Regulator Figure 12-42: Regulator Inspection Points Inspect the regulator for cracks, breaks, broken contacts, or surface defects and replace if damaged (Figure 12-42). Brushes and Brush Holders Figure 12-43: Brush Holder [...]

12-26 Electrical System _______________________________________________________ ® Fan 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). Figure 12-45: Fan Inspection Points Slip Ring End Frame and Bearing Inspect [...]

______________________________________________________ Electrical System 12-27 ® 05745159 Alternator Assembly 1. Install bearing on rotor shaft. Seat bearing against shoul- der (Figure 12-38). 2. Assemble springs and brushes in brush holder and retain with fabricated pin. Pin holds brushes compressed in brush holder and will be removed after assem[...]

12-28 Electrical System _______________________________________________________ ® Alternator Inoperative (No Charge) Step Action V alue(s) Y es No 1 Perform visual inspection on belt, pulleys and battery cables. Is e verything in normal operating condition Go to step 2. Repair and recheck system. 2 Using a battery load tester , place amp pickup on[...]

______________________________________________________ Electrical System 12-29 ® 05745159 Figure 12-52: Alternator Schematic 9-S12-089 AL TERNA TOR FUSE 3B EXTERIOR 20 AMP C4-3 PNK EXTERIOR POWER BUS TO POSITIVE BA TTERY CABLE TO EXTERIOR FUSE BOX TO INTERIOR FUSE BOX FUSIBLE LINK FUSIBLE LINK ORG RED TO LOW COOLANT SENSOR HOT IN RUN AND ST ART BA[...]

12-30 Electrical System _______________________________________________________ ® STARTER Removal 1. Disconnect battery negati ve cable(s) and winch ne gati ve cable, if equipped. 2. Remove converter housing cover. 3. Remove cap and/or adhesive sealant from starter terminal (Figure 12-53). 4. Disconnect starter cable or cables from starter termina[...]

______________________________________________________ Electrical System 12-31 ® 05745159 Figure 12-54: Starter Connections STARTER OVERHAUL Disassembly 1. Remov e starter . 2. Remo ve plug and g asket from pinion housing (Figure 12-55). Figure 12-55: Core Shaft Nut Removal 3. Remove core shaft nut with socket, fabricated socket holding tool, and [...]

12-32 Electrical System _______________________________________________________ ® 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. Figure 12-59: Armature Removal/Installation 16. Remove s[...]

______________________________________________________ Electrical System 12-33 ® 05745159 Figure 12-62: Solenoid Components Inspection 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 dam- aged lead. If one brush length is l[...]

12-34 Electrical System _______________________________________________________ ® Figure 12-64: Solenoid Components Starter Assembly 1. Assemble washer , rubber boot, spring retainer , spring, and spring retainer on core shaft and secure with snap ring (Figure 12-61). 2. Place core shaft assembly in solenoid housing. 3. Install washer, spring, con[...]

______________________________________________________ Electrical System 12-35 ® 05745159 Figure 12-66: Assembling Frame, Armature, and Pinion Housing Figure 12-67: Solenoid Boot Installation Starter Pinion Clearance Adjustment 1. Connect battery and jumper to starter as sho wn (Figure 12-68). Momentarily touch jumper to solenoid frame to shift pi[...]

12-36 Electrical System _______________________________________________________ ® Figure 12-69: Starter Pinion Clearance Measurement and Adjustment Starter T est 1. Connect voltmeter , ammeter , switch and battery to starter as sho wn (Figure 12-70). CA UTION: Do not operate the starter motor for more than 10 seconds at a time. Allow the starter m[...]

______________________________________________________ Electrical System 12-37 ® 05745159 Starter Inoperative Step Action V alue(s) Y es No 1 Inspect battery condition and charge (Refer to battery checking procedure this section). Are bat- teries in good working condition and char ged? Go to step 2 Recharge/Replace batteries as neces- sary 2 Using[...]

12-38 Electrical System _______________________________________________________ ® 10 Repair open or bad connection in CKT32 between neutral saftey switch and start relay . Is condition repaired Repair complete Go to step 1. 11 Remo v e lo wer cover of steering column to access the ignition switch connector . Back probe the white wire (CKT33) with [...]

______________________________________________________ Electrical System 12-39 ® 05745159 Figure 2-71: Starter System Schematic MAXIFUSE #1 40A EXTERIOR ST ARTER RELA Y 37 YEL 58 BLK 32 L T BLU ST ARTER SOLENOID 32 L T BLU NEUTRAL SAFETY SWITCH IGNITION SWITCH 33 WHT C4-1 C2-13 C1-6 MAXIFUSE #8 40A EXTERIOR C1-7 TO BA TTER Y C2-12 9-S12-087.2 4-1-[...]

12-40 Electrical System _______________________________________________________ ® Glow Plugs Inoperative Step Action V alue Y es No 1 Before clearing any DTC ’ s, use the scan tool Cap- ture Info to sav e the Freeze Frame and Failure Records for reference. The PCM ’ s data is deleted once the Clear Info function is used. Did you perform the On[...]

______________________________________________________ Electrical System 12-41 ® 05745159 10 T urn the ignition ON with the engine OFF . V erify that the glo w plug relay control harness is discon- nected. W ith a DMM connected to ground, probe the glo w plug relay control circuit (466 YL) at the glo w plug relay harness connector . Use a scan too[...]

12-42 Electrical System _______________________________________________________ ® 19 Inspect the glo w plug relay control circuit (CKT 466 YL) for a proper connection at the PCM and replace the terminal if necessary . Did you fi nd an improper connection and make the necessary repair? Go to step 30. Go to step 29. 20 Inspect the glo w plug relay [...]

______________________________________________________ Electrical System 12-43 ® 05745159 Figure 2-72: Glow Plug Control Circuit Schematic 30 Use a scan tool to clear the DTC ’ s. Start the engine. Allo w the engine to idle until the engine reaches normal operating temperature. Select the DTC and the speci fi c DTC function. Enter the DTC numbe[...]

12-44 Electrical System _______________________________________________________ ® Fuel Lift Pump Inoperative VIN Z Step Action V alue(s) Y es No 1 Important: Before clearing the DTC ’ s 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 use[...]

______________________________________________________ Electrical System 12-45 ® 05745159 9 Disconnect fuel lift pump relay .Using a DV OM set to measure ohms, measure resistance between C27-D5, and the fuel lift pump relay dark green wire (CKT238). Does resistance exceed speci fi ca- tions? <.2 Ω Repair open or bad connection in CKT 238 bet[...]

12-46 Electrical System _______________________________________________________ ® Figure 2-73: Fuel Lift Pump Schematic FUSE 2D 20A INTERIOR FUEL PUMP RELA Y EXTERIOR FUSE BOX C1-10 G2 POWERTRAIN CONTROL MODULE FUEL PUMP RELA Y CONTROL FUEL LIFT PUMP SIGNAL TO FUEL SELECTOR SWITCH M G2 FUEL LIFT PUMP B A 57 BK 787 GY 787 GY 787 GY C27-D5 57 BK C27[...]

______________________________________________________ Electrical System 12-47 ® 05745159 Fuel Tank Selector System Inoperative (No Tank Switch) Step Action V alue(s) Y es No 1 Important: Before clearing the DTC ’ s use the scan tool Capture Info in order to record the Freeze Frame and the failure records for refer - ence, as the data will be lo[...]

12-48 Electrical System _______________________________________________________ ® 7 Relocate the ground lead of the D V OM set to measure voltage to a kno wn good ground. T urn the ignition OFF for 10 seconds. T urn the ignition ON, and the tank selector switch in the A UX posi- tion, probe the bro wn wire (CKT 789) with the positi ve meter lead. [...]

______________________________________________________ Electrical System 12-49 ® 05745159 Figure 2-74: Fuel Selector Valve Schematic EXTERIOR FUSE BOX G2 G4 FUSE 2D 20A INTERIOR FUSE BOX HOT A T ALL TIMES FUEL SELECTOR SWITCH G4 TO DIMMER MODULE FUEL GAUGE TO GAUGE FUSE I G L S FUEL SELECTOR VA LV E FUEL LEVEL SIGNAL OUT 17 PP 30 GY 29 PK C26-B C2[...]

12-50 Electrical System _______________________________________________________ ® Figure 2-75: Fuel Manager Schematic FUSE 3B 20AMP EXTERIOR FUSE BOX DRAIN FIL TER HOT IN RUN AND ST ART W A TER IN FUEL LIGHT LEFT HAND ST A TUS CENTER C9-D C3-F4 C1-45 BA 327 YL C C9-J W A TER IN FUEL SENSOR FUEL HEA TER 291 PK 57 BK G2 57 BK C A 9-S12-154 FUSE 4B 5[...]

______________________________________________________ Electrical System 12-51 ® 05745159 IGNITION SWITCH REPLACEMENT Removal 1. Remov e steering column covers. 2. Remove multi switch. 3. Remove screw and interlock cable from ignition switch (Figure 2-76). 4. Remove two capscrews and ignition switch from steering column. Installation 1. Apply thre[...]

12-52 Electrical System _______________________________________________________ ® Figure 2-77: Shift Interlock Cable Schematic 59 BK FUSE 4D 15 AMP INTERIOR FUSE BOX INTERLOCK CABLE SOLENOID 83 TN G4 TO TURN SIGNAL SWITCH BRAKE SWITCH TO BA TTER Y 22 RD FUSE 1C 5 AMP INTERIOR FUSE BOX TO IGNITION 9-S12-001 INTERIOR FUSE BO X 10 OR 4-1-00[...]

______________________________________________________ Electrical System 12-53 ® 05745159 CTIS Compressor Inoperative Step Action V alue(s) Y es No 1 Using a D V OM set to measure v oltage, probe the terminals on the CTIS compressor . W ith the CTIS compressor switch set to in fl ate, and the ignition on, is voltage present? 12v Replace the compr[...]

12-54 Electrical System _______________________________________________________ ® CTIS Exhaust Valve Inoperative Step Action V alue(s) Y es No 1 Disconnect exhaust solenoid. Using a D V OM set to measure voltage, probe the light green wire(CKT47) with the positi ve lead, and the black wire(CKT57) with the negati ve lead. Ignition on, mov e the com[...]

______________________________________________________ Electrical System 12-55 ® 05745159 CTIS Front Inflate Valve Inoperative Step Action V alue(s) Y es No 1 Disconnect front in fl ate solenoid. Using a D V OM set to measure voltage connect the positi ve lead to the tan wire(CKT91), and the negati ve lead to the black wire(CKT57). W ith the igni[...]

12-56 Electrical System _______________________________________________________ ® CTIS Rear Inflate Valve Inoperative Step Action V alue(s) Y es No 1 Disconnect front in fl ate solenoid. Using a D V OM set to measure voltage connect the positi ve lead to the grey wire(CKT92), and the ne gativ e lead to the black wire(CKT57). W ith the ignition on[...]

______________________________________________________ Electrical System 12-57 ® 05745159 Figure 2-78: CTIS Schematic REAR SOL DEFLA TE SOL FRONT SOL FRONT LOW PRESSURE REAR LOW PRESSURE 57 BK 92 GY 57 BK 47 LG 57 BK 91 TN A B A B A B G2 640 OR 428 PK 640 OR 428 PK C1-24 C1-58 C1-63 C1-23 C1-57 C3-C4 C3-C2 C3-C3 RF C12-F C12-D C12-E W ARNING LAMP [...]

12-58 Electrical System _______________________________________________________ ® Figure 2-79: Lights Schematic (Sheet 1 of 2) 9-S12-006.1 SIDE MARKER CLEARANCE P ARK/TURN HEAD LIGHTS 13TN 3 LB 12 DR 58 BK 20 RD 2 LG CLEARANCE P ARK/TURN SIDE MARKER 3 LB 2 LG 80 WH 80 WH 58 BK 12 DR 13TN 58 BK 20 RD UNDER HOOD LAMP HOOD HARNESS AB C A B C D G4 C2-[...]

______________________________________________________ Electrical System 12-59 ® 05745159 Figure 2-79: Lights Schematic (Sheet 2 of 2) 9-S12-007.1 20A CB MAXI FUSE 2M EXTERIOR TO BA TTER Y 30A CB MAXI FUSE 3M EXTERIOR TO BA TTER Y 15 WH 14 LB 15 WH 14 LB 20 RD 12 OR 13 TN 3 LB 80 WH 2 LG 21 GY BUSS L1A 5 DG 9 YL FUSE 3F 7.5 A INTERIOR FUSE 4F 7.5 [...]

12-60 Electrical System _______________________________________________________ ® Figure 2-80: Key/Headlight Chime Schematic FUSE 7F 5 AMP INTERIOR FUSE 1G 5 AMP INTERIOR KEY , HEADLIGHT , SEATBEL T CHIME G4 59 BK 640 BR 450 PK 85 GY 159 WH 183 TN 158 BK KEY SWITCH (STEERING COLUMN) G4 59 BK SEA T BEL T SWITCH 85 GY 38 RD 95 YL MASTER LIGHT SWITCH[...]

______________________________________________________ Electrical System 12-61 ® 05745159 HOR N Hor n Replacement Removal 1. Remov e harness connectors and adapters from horn. 2. 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. [...]

12-62 Electrical System _______________________________________________________ ® Horns Inoperative Step Action V alue Y e s No 1 Locate the horn assemblies under the hood. Disconnect the harness from the horn assemblies. W ith a D V OM check the black wires (CKT 58) for resistance to ground. Do both wires meet with speci fi cations ? <.2 Ω [...]

______________________________________________________ Electrical System 12-63 ® 05745159 Figure 2-82: Horn Schematic HORN RELA Y EXTERIOR FUSE BOX HORN HORN FUSE 1D 20 AMP EXTERIOR FUSE BOX 460 BK 1 DB C1-62 7 RD 6 WH G4 G2 58 BK HORN SWITCH 00-S12-007 ADAPTER ADAPTER C39-C TO REMOTE ENTR Y MODULE TO BA TT 7 RD 1F 1E 3F 3E 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 re- placing instrument panel, refer to procedures in this section to remove and/or disconnect the various lamps, switches, an[...]

______________________________________________________ Electrical System 12-65 ® 05745159 Crashpad Replacement (Right Side) Removal 1. Remov e screw/w ashers, and crashpad from dashboard (Figure 2-84). 2. Disconnect air hose from vent duct. 3. Remove screws, side window vent, and vent duct from crashpad. Installation 1. Secure vent duct and windo [...]

12-66 Electrical System _______________________________________________________ ® Instrument Panel Indicator Lamp Replacement NOTE: All instrument panel indicator lamps are replaced basi- cally the same. Removal 1. Remov e instrument panel. 2. Turn lamp socket one-quarter turn counterclockwise, and remove socket from indicator light housing. 3. Pu[...]

______________________________________________________ Electrical System 12-67 ® 05745159 Speedometer/Odometer Replacement Removal 1. Remov e the left A-pillar dash trim (closeout). 2. 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 [...]

12-68 Electrical System _______________________________________________________ ® T achometer Replacement NOTE: Mark position of set screws in relationship to tachom- eter 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 cloc[...]

______________________________________________________ Electrical System 12-69 ® 05745159 LOW COOLANT LAMP INOPERATIV E The coolant level sensor is a solid-state semi-conductor device. The sensor ’ s resistance varies as a function of its temperature. As voltage/current flows through the sensor, sensor tempera- ture increases. In the presence of[...]

12-70 Electrical System _______________________________________________________ ® Figure 2-92: Low Coolant Sensor Schematic LOW COOLANT SENSOR 291 PNK 794 RED 57 BLK FUSE 3B 20 AMP EXTERIOR 794 RED G1 RIGHT ST A TUS CENTER LOW COOLANT LAMP C1-55 C9 J C4 3 1 1 G3 IGNITION AB C C3 N7 G C35 9-S12-092 FUSE 4B 5 AMP INTERIOR FUSE BOX 30 GY IGNITION 4-1[...]

______________________________________________________ Electrical System 12-71 ® 05745159 Oil Pressure Gauge Inoperative Step Action V alue(s) Y es No 1 Is gauge maxed out? Repair open or bad connection in CKT31 or gauge sending. Go to step 2. 2 Using a D V OM set to measure v oltage, check for voltage at the rear of the oil pressure g auge on the[...]

12-72 Electrical System _______________________________________________________ ® Fuel Gauge Inoperative Step Action V alue(s) Y es No 1 Using a D V OM set to measure v oltage, check for voltage at the rear of the fuel g auge on the grey wire(CKT30) connect negati ve meter lead to ground on black wire(CKT59). W ith ignition on, is voltage present?[...]

______________________________________________________ Electrical System 12-73 ® 05745159 Engine Temperature Gauge Inoperative Step Action V alue(s) Y es No 1 Is gauge maxed out with ignition on? Repair short to ground in CKT 39 or faulty sending unit. Go to step 2. 2 Using a D V OM set to measure v oltage, check for voltage at the rear of the oil[...]

12-74 Electrical System _______________________________________________________ ® Figure 2-93: Gauges Schematic FUSE 4B 5 AMP INTERIOR FUSE BOX TO DIMMER SWITCH TO IGNITION VOL T OIL SPEEDO TEMP FUEL G I L I GL S G L SI I GL SI GL S 59 BK 30 GY 17 PP G4 C3-N6 C3-N7 C3-L7 C1-30 C5-C10 G1 OIL PRESSURE SENDER TO IGN SWITCH 31 TN 353 YL C3-P9 C1-I8 39[...]

____________________________________________________ Electrical System 12-74.1 ® 05745159 Dig ital Ratio Ada pter Location The digital ratio adapter is located under the center console on the engine cover, just above the powertrain control module. Removal 1. Remov e the cup holder from the center console. 2. Disconnect the two harness connectors f[...]

12-74.2 Electrical System _____________________________________________________ ® Figure 12-93.2 Digital Ratio Adapter Wiring Diagram TWISTED P AIR VEHICLE SPEED SENSOR (VSS) BA GROUND VEHICLE SPEED SENSOR RETURN 4 679 LG VEHICLE SPEED DIGIT AL RA TIO ADAPTER CRUISE CONTROL REFERENCE SIGNAL 4000 PPM SPEEDO REFERENCE SIGNAL 00-S12-038 +12 VOL T IGN[...]

______________________________________________________ Electrical System 12-75 ® 05745159 HVAC Main Blower Inoperative ALL BUT High Step Action V alue(s) Y es No 1 Ignition on, blo wer switch set to Med2, mode dial set to face. Measure v oltage on the yellow wire(CKT754) at the blo wer relay . Is v oltage present? 8 -10v Replace the blo wer relay [...]

12-76 Electrical System _______________________________________________________ ® 7 Using a D V OM set to measure v oltage, place the positi ve lead on a battery po wer source. Place the ground lead in cavity 6F(CKT440). Using the scan tool, command the compressor clutch on. Does meter display battery voltage? 12v Go to step 8. Go to step 9. 8 Usi[...]

______________________________________________________ Electrical System 12-77 ® 05745159 14 Ignition on, mode dial set to MAX A/C. Discon- nect the high pressure cutout switch on the com- pressor . Using a D V OM set to measure voltage, check for voltage on the tan wire(CKT198). Is voltage present? 12v Go to step 15. Repair open, bad connection, [...]

12-78 Electrical System _______________________________________________________ ® 4 W ith ignition on, using a D V OM set to measure voltage and using J – 35616-92 test adapters probe the GN wire (CKT 399) with the positi ve lead. Place the negati ve lead on a kno wn good ground. Is voltage present? 12v Go to step 5. Repair open or short to grou[...]

______________________________________________________ Electrical System 12-79 ® 05745159 11 Using a D V OM set to measure ohms, check resis- tance between pin B (CKT 58) of the HV A C con- trol head connector and a good ground. Does resistance exceed speci fi cations? <.2 Ω Replace faulty HV A C control head. Locate and repair open or poor [...]

12-80 Electrical System _______________________________________________________ ® Figure 12-94: HVAC Blower Schematic 30A FUSE BUIL T IN HARNESS FUSE TO AL TERNA TOR BA TTER Y TERMINAL FUSE 7C 30A INTERIOR FUSE BOX HOT IN RUN AND ST ART M BLOWER RESISTOR 755 DB 751 OR 752 GY 8 PIN AB C D HV AC CONTROL HEAD 754 YL 364 RD C36-A G4 BLOWER RELA Y BLOW[...]

______________________________________________________ Electrical System 12-81 ® 05745159 Figure 12-95: HVAC Temp Blend Door/Rear Blower FE 8 PIN FUSE 7C 30A INTERIOR HOT IN RUN AND ST ART FUSE 6C 20A INTERIOR HOT IN RUN AND ST ART M REAR HV AC BLOWER HL G4 405 OR 404 YL E4 E3 C6 346 PK C6-C3 399 DG C6-G1 TEMPERA TURE DOOR MOTOR 58 BK GROUND POSIT[...]

12-82 Electrical System _______________________________________________________ ® Figure 12-96: HVAC Compressor Schematic COMPRESSOR RELA Y 86 87 85 30 FUSE 2C 10A INTERIOR HOT IN RUN AND ST ART POWERTRAIN CONTROL MODULE (PCM) A/C REQUEST A/C COMPRESSOR ENABLE DIODE COMPRESSOR CLUTCH G1 HIGH PRESSURE CUTOUT SWITCH LOW PRESSURE SWITCH 438 OR C1-39 [...]

______________________________________________________ Electrical System 12-83 ® 05745159 Windshield Wiper Motor Inoperative All Speeds Step Action V alue(s) Y es No 1 Gain access to the wiper motor connector under the windshield trim. Using a D V OM set to mea- sure resistance, check resistance to ground on the bro wn wire (CKT 59). Is the resist[...]

12-84 Electrical System _______________________________________________________ ® Windshield Wiper Motor Inoperative on High Step Action V alue(s) Y es No 1 Remov e the wiper switch from the instrument panel. T urn the ignition to the “ RU N ” position and the wiper switch to “ HIGH ” . Using a D V OM set to measure voltage, back probe the[...]

______________________________________________________ Electrical System 12-85 ® 05745159 4 Ignition should be in the “ RU N ” position. Using a D V OM set to measure the v oltage, back probe the yello w wire (CKT 65) at the intermittent wiper switch. Is the speci fi ed voltage present? 12v Replace the intermittent wiper switch. Repair the op[...]

12-86 Electrical System _______________________________________________________ ® Figure 12-97: Wiper/Washer Schematic WIPER MOTOR 65 BK 59 BR C3-H8 C3-J6 63 DG 61 RD 28 DB G4 27 OR FUSE 7G 25 AMP INTERIOR FUSE BOX TO IGNITION INTERMITTENT RELA Y WIPER SWITCH C3-J7 C3-H7 27 OR 65 YL 570 BK LOW W ASHER FLUID SWITCH RIGHT HAND ST A TUS CENTER LOW WA[...]

______________________________________________________ Electrical System 12-87 ® 05745159 Rear Window Wiper Inoperative Steps Action V alues Y es No 1 Gain access to the wiper motor connector under the slant door trim.Using a D V OM check resis- tance on the black wire (CKT 59). Is the resis- tance in the speci fi ed range? <.2 Ω Go to step [...]

12-88 Electrical System _______________________________________________________ ® 10 Remo ve the rear wiper switch from the instru- ment panel. Disconnect the wiper switch harness from the switch. T urn the ignition switch to the “ RU N ” position. W ith a D V OM check v oltage on the yello w wire (CKT 65). Is the speci fi ed voltage present?[...]

______________________________________________________ Electrical System 12-89 ® 05745159 Figure 12-98: Rear Wiper Motor Schematic C42 REAR WIPER MOTOR M G4 66 RD FUSE 11 G 25 AMP SWIT CHED 12V INTERMITTENT RELA Y 59 BK C20-L13 62 LB 67 BR C20-C 66 RD G1 59 BK REAR WIPER SWITCH C3-A4 67 BR REAR W ASHER MOTOR M G2 58 BK 59 BK FUSE 13G 25 AMP 65 YL [...]

12-90 Electrical System _______________________________________________________ ® Left Heated Windshield Inoperative Step Action V alue(s) Y es No 1 Gain access to the heated windshield connections. W ith the ignition in the “ RU N ” position, preform a voltage drop test between the yello w wire (CKT 740) and the black wire (CKT 59) going to t[...]

______________________________________________________ Electrical System 12-91 ® 05745159 Right Heated Windshield Inoperative Step Action V alue(s) Y es No 1 Gain access to the heated windshield connections. W ith the ignition in the “ RU N ” position and the heated windshield switch on, preform a voltage drop test between the purple wire (CKT[...]

12-92 Electrical System _______________________________________________________ ® Both Heated Windshields Inoperative Step Action V alue(s) Y es No 1 Gain access to the heated windshield connections. Using a D V OM check the resistance to ground on the black wires at both windshields. Does the resistance meet the speci fi ed value? <.2 Ω Go [...]

______________________________________________________ Electrical System 12-93 ® 05745159 Figure 12-99: Heated Windshield Schematic 59 BK FUSE 2C 30 AMP EXTERIOR FUSE BOX FUSE 2D 30 AMP EXTERIOR FUSE BOX FUSE 1C 5 AMP INTERIOR FUSE BOX HEA TED WINDSHIELD SWITCH TO IGNITION LEFT WINDSHIELD RIGHT WINDSHIELD 17 PP 58 BK 83 TN C6-M7 C1-33 580 BR R-4 L[...]

12-94 Electrical System _______________________________________________________ ® Rear Window Defroster Inoperative Step Action V alue(s) Y es No 1 G ain 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[...]

______________________________________________________ Electrical System 12-95 ® 05745159 Figure 12-100: Rear Window Defroster Schematic J6 N7 FUSE 7C 30 AMP INTERIOR FUSE BOX REAR WINDOW DEFROST SWITCH REAR WINDOW DEFROSTER ( HMC4 & HMSB ) 59 BK C1-13 G4 58 BK G4 9-S12-157 C6 C6 G1 A3 TO HV AC CONTROL P ANEL 399 DG 689 PK TO TEMPERA TURE DOOR[...]

12-96 Electrical System _______________________________________________________ ® Power Windows Inoperative, All Windows Step Action V alue(s) Y es No 1 Remov e relay R4 from the interior fuse box. W ith a D V OM check ca vity G7 for resistance to ground. Does the resistance meet the speci fi ed v alue? <.2 Ω Go to step 2. R epair the open o[...]

______________________________________________________ Electrical System 12-97 ® 05745159 Drivers Window Inoperative Step Action V alue(s) Y es No 1 Do all the other windo ws operate as designed? ––– Go to step 2. Refer to proper chart. 2 Remov e the driv ers power windo w switch and harness from the bezel. W ith a D V OM check the resistanc[...]

12-98 Electrical System _______________________________________________________ ® Power Windows Only Operate Using The Console Switches Step Action V alue(s) Y es No 1 Does the dri vers door windo w operate as designed? ––– Go to step 2. Refer to the proper chart. 2 If the windo w lock out switch is in the “ Lock ” position mov e it to t[...]

______________________________________________________ Electrical System 12-99 ® 05745159 Passenger Front Door Power Window Inoperative Step Action V alue(s) Y es No 1 Do all the other windo ws operate as designed? –– - Go to step 2. Refer to the proper chart. 2 Gain access to the passenger front po wer window switch harness in the door . T ur[...]

12-100 Electrical System ______________________________________________________ ® (Passenger/Drivers) Rear Door Power Window Inoperative NOTE: Refer to the wiring diagram for the circuit numbers. Step Action V alues Y es No 1 Do all the other windo ws operate as designed? –– - Go to step 2. Refer to the proper chart. 2 Gain access to the rear [...]

_____________________________________________________ Electrical System 12-101 ® 05745159 Figure 12-101: Power Window Schematic 226 YL 313 DB C15 227 RD 226 YL B D C G4 9-S12-011 M M LEFT FRONT DOOR WINDOW SWITCH ( ALL MODELS ) LEFT FRONT DOOR WINDOW MOTOR 45 3 12 RIGHT FRONT DOOR WINDOW MOTOR RIGHT FRONT DOOR WINDOW SWITCH ( ALL MODELS ) 45 3 12 [...]

12-102 Electrical System ______________________________________________________ ® PO W ER DOOR LOCK SWITCH REPLACEMENT NOTE: Switch replacement is the same for all doors. Removal 1. Remov e mounting plate, capscrews, and remo ve switch from switch bezel (Figure 12-102). 2. Disconnect door harness from switch. Separate switch from mounting plate. I[...]

_____________________________________________________ Electrical System 12-103 ® 05745159 Figure 12-104: Door Lock Actuator Removal/Installation 5. Remove actuator attaching screws. 6. Remove actuator from door and disconnect actuator rod from clips and actuator. Installation NOTE: Color coding on actuator rod is positioned away from actuator duri[...]

12-104 Electrical System ______________________________________________________ ® Rear Cargo Door Lock Module Replace- ment (HMCS Only). Removal 1. Remov e right rear seat. 2. Remove right rear seat belt ratchet assembly. 3. Remove right rear corner trim assembly (Figure 12-106). Figure 12-106: Removing Right Rear Trim Piece 4. Disconnect rear doo[...]

_____________________________________________________ Electrical System 12-105 ® 05745159 K E YLESS ENTR Y & THEFT DETERRENT SYSTEM OPERATING INSTRUCTIONS K e yless Entr y & 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[...]

12-106 Electrical System ______________________________________________________ ® SYSTEM FEATURES System features can be activated or deactivated as required by the owner. Some system features are active when the vehicle is purchased. Passiv e Theft Deterrent Ar ming This feature will automatically arm the theft deterrent system 30 seconds after y[...]

_____________________________________________________ Electrical System 12-107 ® 05745159 REMOTE ENTR Y SYSTEM Remote Entr y Receiver Replacement Removal 1. Remov e front console enough to gain access to receiv er (Section 10). 2. Disconnect two receiver harness connectors from receiver (Figure 12-109). 3. Remove receiver from two velcro strips. I[...]

12-108 Electrical System ______________________________________________________ ® REMOTE ENTR Y RECEIVER/T RANSMITTER REPLACEMENT Removal 1. Remov e center console. 2. Disconnect wire connection at receiver and remove reciever from engine cover (Figure 12-109). 3. Installation 1. Place hook and loop on back of recei ver and place recie ver on engi[...]

_____________________________________________________ Electrical System 12-109 ® 05745159 5. 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. 6. Press and release the programming sw[...]

12-110 Electrical System ______________________________________________________ ® Power Locks Inoperative w/o Keyless Step Action V alue(s) Y es No 1 Remov e the passenger door lock switch from the bezel. Using a D V OM measure v oltage on pin 3 (CKT 517). Is the speci fi ed voltage present? 12v Go to step 2. R epair the open, or bad connection i[...]

_____________________________________________________ Electrical System 12-111 ® 05745159 Power Door Locks Inoperative, W/ Remote Entry Step Action V alue(s) Y es No 1 Remov e the passenger door lock switch from the bezel. Using a D V OM measure v oltage on pin 3 (CKT 517). Is the speci fi ed voltage present? 12v Go to step 2. R epair the open, o[...]

12-112 Electrical System ______________________________________________________ ® 8 Using a D V OM measure resistance to ground at C30 pin A (CKT 58). Does the resistance meet the speci fi ed value? <.2 Ω Repair the open or bad connection in CKT 517 between the remote entry module and fuse 3H. Repair the open or bad connec- tion in CKT 58 be[...]

_____________________________________________________ Electrical System 12-113 ® 05745159 Cargo Door Lock Inoperative Step Action V alue(s) Y es No 1 D oes power the lock system on v ehicle operate correctly? Go to step 2. Refer to the diagnostic charts that apply . 2 Open the primary cargo door . Using a D V OM measure the voltage across the bras[...]

12-114 Electrical System ______________________________________________________ ® Remote Entry System Inoperative Step Action V alue(s) Y es No 1 Does the panic feature operate when the button is depressed on the transmitter? Go to step 6. Go to step 2. 2 Does the L.E.D. illuminate on the ke yless transmitter when a button is depressed? Go to step[...]

_____________________________________________________ Electrical System 12-115 ® 05745159 Figure 12-110: Power Locks HMCS W/ Remote Entry L/R DOOR LOCK ACTUA T OR R/R DOOR LOCK ACTUA T OR CARGO DOOR LOCK ACTUA T OR 1 17 PK 1 18 BR FUSE 3H 20A INTERIOR G4 1 2 34 5 1 19 TN E C17-A AB L U 3 45 2 1 120 LG 517 OR 121 YL 1 17 PK 1 18 BR L/F DOOR LOCK AC[...]

12-116 Electrical System ______________________________________________________ ® Figure 12-111: Power Locks HMCS W/O Remote Entry B L/R DOOR R/R DOOR CARGO DOOR 1 17 PK 1 18 BR FUSE 3H 20A INTERIOR G4 1 2 34 5 1 19 TN E C17-A AB L U 3 45 2 1 120 LG 517 OR 121 YL 1 17 PK 1 18 BR L/F DOOR LOCK ACTUA T OR D E M U L M L U M U L M U L C22 B A R/F DOOR[...]

_____________________________________________________ Electrical System 12-117 ® 05745159 H Figure 12-112: Power Locks HMC4, XLC2 , HMSB W/ Remote Entry FUSE 3H 20A INTERIOR HOT A T ALL TIMES G4 L U 1 2 34 5 1 19 TN C15-F C14-E C15-A C14-A D 121 YL C14-B C16-F C16-E C17-A C16-A C16-B L U 3 45 2 1 120 LG 517 OR F H 121 YL C31 BA TT INPUT COMMON UNL[...]

12-118 Electrical System ______________________________________________________ ® Figure 12-113: Power Locks HMC4, XLC2 , HMSB W/O Remote Entry L/R DOOR LOCK ACTUA T OR (not used on XLC2) R/R DOOR LOCK ACTUA T OR (not used on XLC2) SLANT BACK DOOR LOCK ACTUA T OR (HMSB only) 1 17 PK 1 18 BR FUSE 3H 20A INTERIOR BA TT G4 1 2 34 5 1 19 TN E C17-A AB[...]

_____________________________________________________ Electrical System 12-119 ® 05745159 Figure 12-114: Remote Entry Module Power/Ground FUSE 1H 5 AMP INTERIOR FUSE 7B 5 AMP INTERIOR G4 A 58 BK 554 GY 840 DG BA TT IGNITION C1-62 TO HORN SWITCH ON STEERING COLUMN TO P ARK LAMP SWITCH TO HORN RELA Y TO P ARK LIGHT 1 DB 14 LB 53 LB FUSE 5 H 15 AMP I[...]

12-120 Electrical System ______________________________________________________ ® PO W ER DOOR LOCK FR ONT DOOR HARNESS REPLACEMENT Removal NOTE: Left and right front power door lock harness replace- ment procedures are similar. 1. Remov e front seat. 2. Remove outer kick panels. 3. Remove power door locks switch from door trim. 4. Remove front do[...]

_____________________________________________________ Electrical System 12-121 ® 05745159 PO W ER DOOR LOCK REAR DOOR AND JUMPER HAR NESS REPLACEMENT Removal NOTE: Left and right rear power door locks harness replace- ment procedures are identical. 1. Remov e front seat. 2. Remove trim from B-beam and B-pillar (Section 10). 3. Remove side trim and[...]

12-122 Electrical System ______________________________________________________ ® Installation 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. Install harness in door bushing. 2. Install support bracket in rear door with two capscre[...]

_____________________________________________________ Electrical System 12-123 ® 05745159 PO W ER WINDO W AND DOOR LOCKS FR ONT DOOR HAR NESS REPLACEMENT Removal 1. Remov e front outer kick panels (Section 10). 2. Remove power window and door lock switches from door. 3. Remove front door trim, vapor barrier, and moisture barrier flap from door (Se[...]

12-124 Electrical System ______________________________________________________ ® Figure 2-119: Power Windows and Door Locks Connections Installation NOTE: Lubricate bushing, grommet, and harness teflon cover with silicone spray. 1. Route harness through harness mounting bracket, mount- ing bracket b ushing, and door bushing (Figure 2-120). 2. Ins[...]

_____________________________________________________ Electrical System 12-125 ® 05745159 Figure 2-121: Power Windows and Door Locks Door Harness POWER DOOR LOCKS POWER WINDOW WINDOW BRACKET DOOR ASSEMBLY RETAINER FRONT DOOR MOUNTING DOOR MOUNTING BRACKET BUSHING BRACKET REINFORCEMENT DOOR HARNESS ACTUATOR REGULATOR BUSHING 4-1-00[...]

12-126 Electrical System ______________________________________________________ ® PO W ER WINDO WS AND DOOR LOCKS REAR DOOR HAR NESS REPLACEMENT Removal 1. Remov e center outer kick panel and lower B-pillar trim (Section 10). 2. Remove power windows switch from door. 3. Remove rear door trim, vapor barrier, and moisture barrier flap from door (Sec[...]

_____________________________________________________ Electrical System 12-127 ® 05745159 Figure 2-123: Rear Door Harness Installation NOTE: Lubricate bushings, grommet, and harness teflon cover with silicone spray. 1. Route harness through harness mounting bracket, mount- ing bracket b ushing, and door bushing (Figure 2-123). 2. Install harness m[...]

12-128 Electrical System ______________________________________________________ ® 7. Connect harness connector to power window regulator (Figure 2-123). 8. Connect harness connector to power door lock actuator. 9. Secure harness to door reinforcement with clamp and self- tapping screw. 10. Secure harness to door assembly with retainer. 11. Secure [...]

_____________________________________________________ Electrical System 12-129 ® 05745159 AUTO-DIMMING REAR VIEW MIRR OR WITH ELECTRONIC COMPASS AND T EMPERATURE (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 lig[...]

12-130 Electrical System ______________________________________________________ ® Figure 2-128: Magnetic Zone Chart 4-1-00[...]

_____________________________________________________ Electrical System 12-131 ® 05745159 AMBIENT T EMPERATURE SENSOR Removal 1. Remov e existing nut, cushioned clamp, and ambient tem- perature sensor jumper harness from the body harness (Figure 12-129). 2. Disconnect the ambient temperature sensor jumper harness from the sensor. 3. Remove self-ta[...]

12-132 Electrical System ______________________________________________________ ® Compass Mirror Display Inoperative Step Action V alue(s) Y es No 1 T urn the ignition to the ON position, and heated windshields OFF . Is compass mirror display operating? No problem found, or inter- mittent. Go to step 2. 2 Gain access to C13, with the ignition ON m[...]

_____________________________________________________ Electrical System 12-133 ® 05745159 Figure 12-130: Compass Mirror Schematic COMP ASS IGNITION FUSE 2C 10 AMP FUSE 3C 7.5 AMP COMP ASS MIRROR GROUND TEMP SENSOR 407 PK 400 LG 140 OR 59 BK 767 BR BF G A D C1-61 C2-8 G4 G2 TO HEA TED WINDSHIELD SWITCH G4 59 BK 400 LG TO IGNITION SWITCH TO IGNITION[...]

12-134 Electrical System ______________________________________________________ ® POW ER SIDE MIRR OR 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 mir[...]

___________________________________________________ Electrical System 12-134.1 ® 05745159 Figure 12-130.2 Power Mirror Assembly Removal POWER MIRROR ASSEMBLY MOUNTING SCREW CONNECTOR GASKET MOUNTING PLATE DOOR JUMPER HARNESS DOOR JUMPER HARNESS CONNECTOR 3-1-01[...]

12-134.2 Electrical System ____________________________________________________ ® Power Side Mirrors Inoperative Step Action V alue(s) Y es No 1 Are both mirrors INOP? Go to step 2. Go to step 4. 2 Remo ve the po wer mirror switch. W ith a D V OM check circuit 517 (PK) for battery voltage. Is the speci fi ed voltage present? > 12.6v Go to step[...]

___________________________________________________ Electrical System 12-134.3 ® 05745159 Figure 12-131: Power Side Mirror Schematic 59 BK 1 23 45678 9 M M LH POWER MIRROR M M RH POWER MIRROR FUSE 3H 20 AMP 517 PK 948 DG/ YL 953 DG 947 DG/ YL 952 DB 942 OR/ BK 944 OR 17 PP TO DIMMER MODULE POWER MIRROR SWITCH LH UP / DOWN RH UP / DOWN RH LEFT / RI[...]

12-134.4 Electrical System ____________________________________________________ ® CRUISE CONTROL SYSTEMS W ARNING: T esting of cruise control should only be preformed in areas were traf fic is light and the road conditions are stable. Figure 12-130.1 : Cruise Control Operation of Cruise Control 1. Mov e the cruise control switch to the “ ON ”[...]

_____________________________________________________ Electrical System 12-135 ® 05745159 Cruise Control Inoperative VIN Z Step Action V alue(s) Y es No 1 Important: Before clearing the DTC’ s, use the scan tool Capture Info in order to record the Freeze Frame and the failure records for refer - ence, as the data will be lost when the Clear Info[...]

12-136 Electrical System ______________________________________________________ ® 9 Using a D V OM set to measure voltage, place the ground lead on the IP ground point. Back probe cavity A11 in C29(CKT151) with the positiv e lead. W ith the ignition on and the cruise control switch on, is voltage present? 12v Check for loose or poor connec- tion a[...]

_____________________________________________________ Electrical System 12-137 ® 05745159 Figure 12-132: Cruise Control Schematic (Sheet 1 of 2) FUSE 5C 10AMP INTERIOR FUSE 3A 10 AMP EXTERIOR ON/ OFF SET COAST RESUME ACCEL HOT IN RUN AND ST ART HOT IN RUN AND ST ART A 29 42 37 C1 C29-A1 1 C29-B1 1 C27-D10 C28-D14 C28-C2 C27-D12 C27-D3 C27-D4 C27-D[...]

12-138 Electrical System ______________________________________________________ ® Figure 2-132: Cruise Control Schematic (Sheet 2 of 2) FUSE 2D 20 AMP INTERIOR FUSE 3A 20 AMP EXTERIOR FUSE 4D 15 AMP INTERIOR FUSE 6B 5 AMP INTERIOR 10 OR 291 PK AD BRAKE LAMP TCC/ CRUISE BC 31 40 C1- TO BRAKE LAMP C28-C13 C28-D13 C28-C12 C28-C1 1 C29-B10 C29-B9 TCC [...]

_____________________________________________________ Electrical System 12-139 ® 05745159 DELCO A UDIO 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 opti[...]

12-140 Electrical System ______________________________________________________ ® RADIO (DELCO) REPLACEMENT Remo v al 1. Insert a radio remov al ke y in the holes in each side of the face of the radio to disengage locking clips from the mounting slee ve (Figure 12-136). 2. Pull radio out of mounting sleeve far enough to expose wire connections and[...]

_____________________________________________________ Electrical System 12-141 ® 05745159 7. Disconnect green wire connection and remove console. 8. 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 enc[...]

12-142 Electrical System ______________________________________________________ ® AUDIO (DELCO MONSOON) ELECTRICAL HAR NESS (MODELS 83, 84 & 91) REPLACEMENT Remo v al 1. Remov e engine cover console. 2. Disconnect harness connector from radio head. 3. Remove Rear Seat Audio (RSA) unit from auxiliary heat and AC cover console. Disconnect RSA co[...]

_____________________________________________________ Electrical System 12-143 ® 05745159 AUDIO (DELCO STANDAR D) ELECTR ICAL HAR NESS (MODEL 89) REPLACEMENT Remo v al 1. Remov e engine cover console. 2. Disconnect radio harness lead from harness connector (Figure 12-142). Figure 12-142: Audio Harness Connections. 3. Remove four screws, clips, cov[...]

12-144 Electrical System ______________________________________________________ ® AUDIO (DELCO STANDAR D) ELECTR ICAL HAR NESS (MODEL 90) REPLACEMENT Remo v al 1. Remov e engine cover console. 2. Disconnect harness lead from radio head (Figure 12-142). 3. Remove four screws, clips, cover, backing plate and right front speaker from trim (Figure 12-[...]

_____________________________________________________ Electrical System 12-145 ® 05745159 1. Identify ignition switch ke y position in which the noise appears, such as: accessory , key on engine not running, and ke y on engine running. 2. Remove fuses one at a time until the complaint condition has been eliminated. 3. Mark the complaint fuse(s) an[...]

12-146 Electrical System ______________________________________________________ ® T EST 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 [...]

_____________________________________________________ Electrical System 12-147 ® 05745159 Figure 12-146: Monsoon Audio Harness Schematic Models 83, 84 & 91. BK RD BK TN B A LF SPEAKER E16 E15 BK RD BK TN B A RF SPEAKER F2 F3 BK RD BK BK TN B RD A B A LEFT CONSOLE SPKR F6 F7 BK RD BK BK TN B RD A B A RIGHT CONSOLE SPKR E13 E14 BK RD BK TN B A L[...]

12-148 Electrical System ______________________________________________________ ® . Figure 12-147: Standard Audio Harness Schematic Models 83, 84, 90 & 91. OFF HEAD P ARK 2 1 P ANEL LIGHT DIMMER 476 GY 59 BK FUSE 1F 5 AMP J6 C1 B4 G3 F3 CB A E D CIRCUIT BREAKER #2 30 AMP FUSE 4G 7.5 AMP FUSE 2H 10 AMP H9 K7 FUSE 2F 5 AMP EXTERNAL FUSE BOX 137 [...]

_____________________________________________________ Electrical System 12-149 ® 05745159 Figure 12-148: Standard Audio Harness Schematic Model 89. BK RD B A LF SPEAKER BK RD B A RF SPEAKER 8 7 6 4 3 RADIO IGNITION BA TT 12V DIMMER ILLUMINA TION GROUND 11 12 13 14 LF LF RF RF C56 00-S12-040 – + – + 4 Ω 4 Ω 813 BK 804 TN 81 1 BK 805 TN 17 P[...]

12-150 Electrical System ______________________________________________________ ® Figure 12-149: CD Changer To Radio Harness, All Models. 13 11 CD CHANGER RADIO 16 10 19 12 SHIELD 9 15 15 18 13 C61 14 14 RIGHT AUDIO SIGNAL LEFT AUDIO SIGNAL AUDIO COMMON DRAIN GROUND D ATA BA TT 00-S12-002 YL WT GY RD BK PP LEFT AUDIO SIGNAL RIGHT AUDIO SIGNAL AUDI[...]

_____________________________________________________ Electrical System 12-151 ® 05745159 SYMPTOM T ABLE SYMPTOM PROCEDURE P A GE NUMBER Display inoperati ve, no sound from any speaker . Chart #1 12-152 No sound from one speaker (Delco std.). Chart #2 12-152 No sound from one speaker (Monsoon). Chart #3 12-153 No sound from any speak er , radio di[...]

12-152 Electrical System ______________________________________________________ ® DISPLAY IS INOPERATIVE, NO SOUND FROM ANY SPEAK ER NO SOUND FROM ONE SPEAK ER (DELCO STANDARD) CHART #1 STEP A CTION V ALUE(S) YES NO 1 Disconnect connector C56. T urn the ignition switch to the “ Run ” position. W ith a D V OM, measure v oltage between terminal [...]

_____________________________________________________ Electrical System 12-153 ® 05745159 NO SOUND FROM ONE SPEAK ER (DELCO MONSOON) CHART #3 STEP A CTION V ALUE(S) YES NO 1 T urn ignition switch to the “ Run ” position . T urn radio “ On ” . Insert cassette or compact disc from Delco Audio system Diagnostic Kit J – 39916-A. Set radio ba[...]

12-154 Electrical System ______________________________________________________ ® NO SOUND FROM ANY SPEAK ER , RADIO DISPLAY OPERATES NORMALLY (DELCO MONSOON) CHART #4 STEP A CTION V ALUE(S) YES NO 1 Disconnect connector C62. T urn ignition switch to the “ Run ” position. T urn radio “ On ” . Insert the cassette or compact disc from Delco [...]

_____________________________________________________ Electrical System 12-155 ® 05745159 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 [...]

12-156 Electrical System ______________________________________________________ ® CASSETTE PLAYER DOES NOT OPERATE PR OPERLY CHART #6 STEP A CTION V ALUE(S) YES NO T ape plays weak, slow or garbled. Go to step 1. T ape inoperativ e. Go to step 3. 1 Inspect and clean moving parts and tape head or use Delco Audio System Diag- nostic Kit J – 39916-[...]

_____________________________________________________ Electrical System 12-157 ® 05745159 ANTENNA SYSTEM T EST CHART #7 STEP A CTION V ALUE(S) YES NO 1 Disconnect negati ve battery cable. Disconnect antenna lead-in cable at the radio recei ver . W ith a D V OM, measure resistance between the coax (outer conductor) con- nector and the negati ve bat[...]

12-158 Electrical System ______________________________________________________ ® REAR SEAT A UDIO (RSA) DOES NOT OPERATE CHAR T #8 STEP A CTION V ALUE(S) YES NO 1 With ignition on, check for voltage at C59 pin A8 (CKT 819 BK). Is voltage present? +12v Go to step 2. Check/repair open circuit between C59 pin A8 and C56 pin 4. 2 With ignition in the[...]

_____________________________________________________ Electrical System 12-159 ® 05745159 CONNECTOR LEGEND NOTE: Connector gender is determined by the terminals. 76 W AY BULKHEAD LOCATION: LEFT SIDE FIREWALL PIN CKT COLOR CIRCUIT DESCRIPTION 1 400 LG Ignition Feed + 2 739 PP Left heated windshield po wer + 3 740 YL Right heated windshield po wer +[...]

12-160 Electrical System ______________________________________________________ ® 11 787 GY Fuel pump + to selector valv e 12 37 RD Ignition relay feed 13 688 RD Rear window defrost feed 14 723 YL APP 3 5v olt reference 15 724 DG APP 3 signal 16 17 PP + FR OM DIMMER MODULE 17 718 DB APP 1 signal 18 353 YL Speedometer signal 19 607 TN ABS module di[...]

_____________________________________________________ Electrical System 12-161 ® 05745159 47 3 LB Left front turn signal 48 914 PP PCM class 2 communication line to DLC 49 644 YL T achometer signal 50 210 DG Low w asher fl uid lev el lamp activ ation 51 195 YL Headlight switch feed 52 603 RD ABS lamp activ ation 53 719 BR APP 1 ground 54 793 YL L[...]

12-162 Electrical System ______________________________________________________ ® 42 W AY UNDERBODY LOCATION: LO W ER LEFT FOOTWELL NEAR ENGINE 9-S12-015 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-S12-016 C2 FEMALE CA V 42 CA V 33 CA V 27 CA V 21 CA V 15 CA V 9 CA V 34 CA V 28 CA V 22 CA V 16 CA V 1[...]

_____________________________________________________ Electrical System 12-163 ® 05745159 14 17 PP Light power from dimmer module 15 16 17 18 19 999 BK Right front wheel speed sensor high signal 20 998 BR Right front wheel speed sensor low signal 21 22 994 BR Right rear wheel speed sensor low signal 23 995 BK Right rear wheel speed sensor high sig[...]

12-164 Electrical System ______________________________________________________ ® 56 W AY INSTRUMENT PANEL LOCATION: BEHIND INSTRUMENT PANEL C3 MALE 9-S12-050 E G F D C B A M P N L K J H 1 2 3 4 5 10 9 8 7 6 PIN A1 PIN H6 C3 FEMALE 9-S12-049 E G F D C B A M P N L K J H 6 7 8 9 10 5 4 3 2 1 CA V H6 CA V A1 PIN CKT COLOR DESCRIPTION A1 195 YL Headli[...]

_____________________________________________________ Electrical System 12-165 ® 05745159 D1 338 DB Glow plug wait lamp acti v ation D2 2 LG Right turn indicator lamp activ ation D3 961 PP TT4 indicator lamp activ ation E1 42 BR Brak e indicator lamp acti vation E2 603 RD ABS indicator lamp acti v ation E3 793 YL Lo w washer fl uid acti v ation E[...]

12-166 Electrical System ______________________________________________________ ® M8 787 GY Fuel selector switch feed from fuel pump relay M9 953 DG Right hand po wer mirror up/do wn signal N6 59 BK Ground N7 30 GY Ignition feed to gauges N8 941 TN W indshield wiper washer pump acti v ation N9 945 BR Intermittent wiper relay activ ation P6 55 OR R[...]

_____________________________________________________ Electrical System 12-167 ® 05745159 12 W AY AMG ENGINE LOCATION: LEFT INTAKE MANIF OLD 9-S12-072 1 23 4 5 7 8 6 9 10 11 12 C4 MALE 9-S12-077 3 2 1 6 8 12 11 10 9 7 5 4 C4 FEMALE PIN CKT COLOR DESCRIPTION 1 34 LB Starter solenoid acti v ation 2 198 TN A/C request from control head 3 291 PK Ignit[...]

12-168 Electrical System ______________________________________________________ ® 40 W AY GM ENGINE LOCATION: LEFT INTAKE MANIF OLD 9-S12-020 9-S12-019 PIN A1 PIN B1 PIN C1 PIN D1 PIN A8 PIN B12 PIN C12 PIN D8 CA V A8 CA V B12 CA V C12 CA V D8 CA V A1 CA V B1 CA V C1 CA V D1 C5 MALE C5 FEMALE PIN CKT COLOR DESCRIPTION A1 39 DG Engine temperature s[...]

_____________________________________________________ Electrical System 12-169 ® 05745159 C4 354 YL Engine coolant temperature signal C5 357 TN Intake air temperature signal C6 C7 C8 C9 C10 31 TN Oil pressure signal to gauge C11 506 LB Glo w plug feedback signal C12 156 PK Optical sensor ground D1 D2 D3 154 TN W astegate solenoid control D4 D5 D6 [...]

12-170 Electrical System ______________________________________________________ ® 56 W AY CONSOLE LOCATION: CENTER CONSOLE C6 MALE 9-S12-050 E G F D C B A M P N L K J H 1 2 3 4 5 10 9 8 7 6 PIN A1 PIN H6 C6 FEMALE 9-S12-049 E G F D C B A M P N L K J H 6 7 8 9 10 5 4 3 2 1 CA V H6 CA V A1 PIN CKT COLOR DESCRIPTION A1 171 RD Feed to RF , RR, LR po w[...]

_____________________________________________________ Electrical System 12-171 ® 05745159 C3 346 PK Ignition feed to rear HV AC blo wer switch C4 D1 45 WH Battery feed to auxiliary po wer outlet D2 D3 E1 319 TN T o right rear power windo w master switch E2 320 LG T o right rear power windo w master switch E3 404 YL Rear HV A C blower lo w fan spee[...]

12-172 Electrical System ______________________________________________________ ® M6 M7 83 TN Ignition feed to heated windshield switch/timer M8 580 BR Heated windshield relay activ ation M9 N6 N7 688 RD Battery feed for rear defrost N8 N9 829 LG Battery feed to radio P6 170 PP Battery feed to po wer windo w lockout switch P7 P8 313 DB T o right f[...]

_____________________________________________________ Electrical System 12-173 ® 05745159 35 W AY ABS ECU LOCATION: WSW RESER VOIR RECESS PIN CKT COLOR DESCRIPTION 1 990 PK ABS valve relay input 2 3 961 PP TT4 lamp activ ation 4 977 WH Right rear inlet v alve acti v ation 5 976 RD Right rear outlet v alve acti v ation 6 973 OR Right front inlet v [...]

12-174 Electrical System ______________________________________________________ ® 24 970 TN Left front outlet valv e acti vation 25 677 GY Shuttle valv e switch signal 26 603 DG ABS warning lamp acti vation 27 570 BK Ground 28 29 30 609 YL Pump motor monitor 31 978 BK Reference ground 32 996 BR Left front wheel speed sensor high 33 994 BR Right re[...]

_____________________________________________________ Electrical System 12-175 ® 05745159 6 W AY ROOF HARNESS LOCATION: CENTER WINDSHIELD PILLAR T RIM PIN CKT COLOR DESCRIPTION A 53 DB Dome lamps feed B 55 OR Car go lamp feed C 54 DG Map light feed D 59 BK Ground E F 9-S12-078 C8 MALE F A C D D F C A 9-S12-078 C8 FEMALE 4-1-00[...]

12-176 Electrical System ______________________________________________________ ® 10 W AY STATUS CENTER -RH LOCATION: INSTRUMENT PANEL PIN CKT COLOR DESCRIPTION A 338 DB W ait lamp B 2 LG Right turn lamp C 961 PP TT4 (atc) lamp D 42 BR Brake lamp E 210 DG T ransfer case lock lamp F 428 PK Low tire air lamp G 794 RD Lo w coolant lamp H 793 YL W ash[...]

_____________________________________________________ Electrical System 12-177 ® 05745159 10 W AY STATUS CENTER -LH LOCATION: INSTRUMENT PANEL 9-S12-017 9-S12-018 F K C10 MALE A E K A F E C10 FEMALE PIN CKT COLOR DESCRIPTION A 12 OR Headlamp high beam lamp B 3 LB Left turn lamp C 658 BR Check engine lamp D 327 YL Drain fi lter lamp E 603 RD ABS l[...]

12-178 Electrical System ______________________________________________________ ® 13 W AY ABS MODULATOR LOCATION: BELOW BR AK E MASTER C YLINDER PIN CKT COLOR DESCRIPTION 1 970 TN Left front outlet valv e activ ation 2 971 PP Left front inlet v alv e activ ation 3 4 977 WH Right rear inlet v alv e activ ation 5 976 RD Right rear outlet valv e acti[...]

_____________________________________________________ Electrical System 12-179 ® 05745159 10 W AY CTIS LOCATION: INSTRUMENT PANEL, RIGHT 9-S12-017 9-S12-018 F K C12 MALE A E K A F E C12 FEMALE PIN CKT COLOR DESCRIPTION A B 17 PP Light po wer from dimmer module C 59 BK Ground D4 7 L G D e fl ate solenoid activ ation E 91 TN Front in fl ate/de fl[...]

12-180 Electrical System ______________________________________________________ ® 8 W AY COMPASS MIRR OR LOCATION: WINDSHIELD CENTER PILLAR T RIM PIN CKT COLOR DESCRIPTION A 59 BK Ground B 400 LG Ignition feed C 841 RD Battery feed D 767 BR T emperature signal from sensor E F G H 53 DB Dome lamp feed 9-S12-029 9-S12-030 CI3 MALE CI3 FEMALE A D E H[...]

_____________________________________________________ Electrical System 12-181 ® 05745159 6 W AY LF DOOR LOCATION: LEFT FR ONT OUTSIDE KIC K PANEL PIN CKT COLOR DESCRIPTION A 56 BK Ground G4 B 120 LG Oscillating power/ground circuit C 117 PK Unlock signal to the driv ers door lock actuators D 118 BR Lock signal to the driv ers door lock actuators [...]

12-182 Electrical System ______________________________________________________ ® 4 W AY LF DOOR LEFT FR ONT OUTSIDE KICK PANEL PIN CKT COLOR DESCRIPTION A 517 OR Fused battery input to the driv ers door lock switch B 56 BK Ground G4 C 56 BK Ground G4 D 171 RD Fused ignition feed to the power windo w circuit 9-S12-033 9-S12-034 C15 MALE C15 FEMALE[...]

_____________________________________________________ Electrical System 12-183 ® 05745159 6 W AY RF DOOR RIGHT FR ONT OUTSIDE KIC K PANEL 9-S12-031 9-S12-032 A F A F C16 MALE C16 FEMALE PIN CKT COLOR DESCRIPTION A 119 TN Oscillating power/ground circuit B 121 YL Unlock signal to the module from the switch C 117 PK Unlock signal to the passenger fr[...]

12-184 Electrical System ______________________________________________________ ® 4 W AY RF DOOR RIGHT FR ONT OUTSIDE KIC K PANEL PIN CKT COLOR DESCRIPTION A 517 OR Fused battery input to the passenger door lock switch B 313 DB Up/do wn signal to the po wer windo w motor C 314 WH Do wn/up signal to the po wer windo w motor D 170 PP Fused ignition [...]

_____________________________________________________ Electrical System 12-185 ® 05745159 8 W AY RR DOOR RIGHT FR ONT OUTSIDE KIC K PANEL PIN CKT COLOR DESCRIPTION A 5 4 DG Map light activ ation B 319 TN Up/do wn signal to the power windo w motor C 320 LG Do wn/up signal to the power windo w motor D 117 PK Unlock signal to the po wer lock actuator[...]

12-186 Electrical System ______________________________________________________ ® 8 W AY LR DOOR LEFT FR ONT OUTSIDE KIC K PANEL PIN CKT COLOR DESCRIPTION A 5 4 DG Map lights acti v ation B 316 TN Up/down signal to the po wer windo w motor C 317 LG Down/up signal to the po wer windo w motor D 117 PK Lock signal to the driv ers side rear door lock [...]

_____________________________________________________ Electrical System 12-187 ® 05745159 6 W AY CARGO DOOR -MODEL 84 RIGHT LO WER B PILLAR PIN CKT COLOR DESCRIPTION A 517 OR Fused battery input to the cargo lock delay module (HMCS only) B 59 BK Ground G4 C 66 RD Fused battery voltage to the rear wiper motor (HMSB only) D Empty E 64 LG Rear wiper [...]

12-188 Electrical System ______________________________________________________ ® 6 W AY RR DOOR JUMPER LOCATION: RIGHT LO W ER B PILLAR 9-S12-032 9-S12-031 A F A F C21 MALE C21 FEMALE PIN CKT COLOR DESCRIPTION A 117 BR Unlock signal to the passenger side rear door lock actuator B 118 PK Lock signal to the passenger side rear door lock actuator C [...]

_____________________________________________________ Electrical System 12-189 ® 05745159 6 W AY LR DOOR JUMPER LOCATION: LEFT LO W ER B PILLAR PIN CKT COLOR DESCRIPTION A 118 BR Lock signal to the driv ers side rear door lock actuator B 117 PK Unlock signal to the driv ers side rear door lock actuator C 316 TN Up/down signal to the po wer windo w[...]

12-190 Electrical System ______________________________________________________ ® 10 W AY P O WER MIRR OR SWITCH LOCATION: INSTRUMENT PANEL, LEFT PIN CKT COLOR DESCRIPTION A 59 BK Ground G4 B 517 PK Fused battery input to the power mirror switch C 948 DG/YL Left po wer mirror vertical control D 952 DB Right po wer mirror vertical control E 947 DG/[...]

_____________________________________________________ Electrical System 12-191 ® 05745159 4 W AY LH P O WER MIRR OR LOCATION: LEFT DOOR 9-S12-039 9-S12-040 B A D C BC D A C24 MALE C24 FEMALE PIN CKT COLOR DESCRIPTION A 942 OR/BK Left po wer mirror common B 947 DG/YL Left po wer mirror horizontal control C 948 DG/YL Left po wer mirror v ertical con[...]

12-192 Electrical System ______________________________________________________ ® 4 W AY RH P O WER MIRR OR LOCATION: RIGHT DOOR 9-S12-039 9-S12-040 B A D C B C D A C25 MALE C25 FEMALE PIN CKT COLOR DESCRIPTION A 944 OR Right po wer mirror common B 952 DB Right power mirror horizontal control C 953 DG Right power mirror v ertical control D 4-1-00[...]

_____________________________________________________ Electrical System 12-193 ® 05745159 6 W AY FUEL T ANK JUMPER LOCATION: C BEAM ABO V E PROP SHAFT 9-S12-031 9-S12-032 A F A F C26 MALE C26 FEMALE PIN CKT COLOR DESCRIPTION A 59 B K Ground B 29 PK Fuel lev el signal to fuel gauge C 675 YL Fuel le vel signal from auxiliary tank D 786 RD Fuel selec[...]

12-194 Electrical System ______________________________________________________ ® 32 W AY PCM-BR OWN LOCATION: CENTER CONSOLE, PCM 9-S12-042 C1 C16 D16 D1 C27 MALE PIN CKT COLOR DESCRIPTION C1 651 PP Crankshaft position sensor ground – C2 439 YL A/C request+ C3 C4 357 TN Intake air temp sensor signal C5 721 LB APP sensor (2) signal C6 466 YL Glo[...]

_____________________________________________________ Electrical System 12-195 ® 05745159 D6 725 GY APP (3) ground D7 506 LB Glow plug feedback signal D8 238 DG Lift pump relay enable + D9 156 PK Optical sensor ground – D10 153 LG Cruise control resume/accelerate D11 496 GY Transmission input speed signal (hi) D12 717 WH APP (1) 5 v olt ref. D13[...]

12-196 Electrical System ______________________________________________________ ® 32 W AY PCM-BLUE LOCATION: CENTER CONSOLE, PCM 9-S12-042 C1 C16 D16 D1 C28 MALE PIN CKT COLOR DESCRIPTION C1 C2 720 TN APP (2) 5 volt ref. C3 712 LG Fuel inject signal C4 237 LG 1-2 shift solenoid control C5 924 TN T orque con verter clutch solenoid control C6 315 YL[...]

_____________________________________________________ Electrical System 12-197 ® 05745159 D6 570 BK Ground G2 D7 570 BK Ground G2 D8 D9 D10 D11 714 RD Check throttle lamp control D12 D13 537 OR Battery D14 154 TN W aste gate solenoid control D15 D16 PIN CKT COLOR DESCRIPTION 4-1-00[...]

12-198 Electrical System ______________________________________________________ ® 24 W AY PCM-BR OWN LOCATION: CENTER CONSOLE, PCM PIN CKT CKT DESCRIPTION A1 491 BK Closure ground A2 703 OR High resolution sensor signal A3 565 BR T ransmission output speed sensor/VSS A4 442 BR Cam sensor signal A5 349 YL Crankshaft position sensor signal A6 223 DB[...]

_____________________________________________________ Electrical System 12-199 ® 05745159 8 W AY REMOTE ENTR Y , GRAY LOCATION: CENTER CONSOLE PIN CKT COLOR DESCRIPTION A 58 B K Module ground G4 B C D 53 L B Dome lamp activ ation E 1 DB Horn Activ ation F 840 DG Fused ignition input to the remote entry module G 554 GY Fused battery input to the re[...]

12-200 Electrical System ______________________________________________________ ® 8 W AY REMOTE ENTR Y , BLAC K LOCATION: CENTER CONSOLE 9-S12-036 A D H E C31 FEMALE PIN CKT COLOR DESCRIPTION A 118 BR Lock signal to the door lock actuators B 122 PP Lock signal from the switch to the module C D 517 OR Fused battery input E 117 PK Unlock signal to t[...]

_____________________________________________________ Electrical System 12-201 ® 05745159 10 W AY T RANSMISSION-GRE Y LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 A EF K A EF K C32 MALE C32 FEMALE PIN CKT COLOR DESCRIPTION A 495 DB Transmission Input Speed Sensor lo w B 496 GY T ransmission Input Speed Sensor high C 237 LG 1-2 shift s[...]

12-202 Electrical System ______________________________________________________ ® 10 W AY T RANSMISSION-BLAC K LOCATION: A BEAM, LEFT NEAR LIFT PUMP 9-S12-023 9-S12-024 A EF K A EF K C33 MALE C33 FEMALE PIN CKT COLOR DESCRIPTION A 676 PP V ehicle Speed Sensor high B 679 LG V ehicle Speed Sensor lo w C D E 210 DG T ransfer case lock switch light ac[...]

_____________________________________________________ Electrical System 12-203 ® 05745159 20 W AY T RANSMISSION P ASS THROUGH LOCATION: TR ANSMISSION, LEFT 9-S12-022 A D E L T Y SK C34 FEMALE PIN CKT COLOR DESCRIPTION A 237 LG 1-2 Shift Solenoid activ ation B 315 YL 2-3 Shift Solenoid acti vation C 264 RD Pressure Control Solenoid high D 265 LB Pr[...]

12-204 Electrical System ______________________________________________________ ® 3 W AY LO W COOLANT SENSOR LOCATION: SUR GE T ANK 2 W A Y HV A C BLOWER LOC A TION: RIGHT A-PILLAR PIN CKT COLOR DESCRIPTION A 291 PK Ignition power B 794 RD Signal output C 57 BK Ground C35 FEMALE C35 MALE A B C 9-S12-090 9-S12-091 A B C 9-S12-105 9-S12-106 C36 MALE[...]

_____________________________________________________ Electrical System 12-205 ® 05745159 4 W AY HV A C BLOWER RESIST OR HARNESS LOC A TION: RIGHT A-PILLAR 3 W AY LOCATION: LEFT A-BEAM NEAR FUEL M ANAGER 9-S12-104 9-S12-103 C 37 MALE C 37 FEMALE A A B B C C D D PIN CKT COLOR DESCRIPTION A 754 YL Blo wer acti vation B 751 OR Medium 1 blower C 755 D[...]

12-206 Electrical System ______________________________________________________ ® 7 W AY TUR N SIGNAL SWITCH HARNESS LOCATION: STEER ING COLUMN 6 W AY TUR N SIGNAL SWITCH HARNESS LOCATION : STEER ING COLUMN PIN CKT COLOR DESCRIPTION A3 L B Left front turn signal, status center signal. B9 Y L Left rear turn signal C1 D B Horn circuit ground D1 3 T [...]

_____________________________________________________ Electrical System 12-207 ® 05745159 8 W AY LIFT GATE JUMPER HAR NESS LOCATION: 4 W AY SLANT DOOR WIPER PLUG TOP OF SLANT DOOR BEHIND TRIM. PIN CKT COLOR DESCRIPTION A 59 BK Ground G4 B 66 RD Rear wiper 12 v common supply C 64 LG Rear wiper 12 v start supply D 62 LB Rear wiper 12 v run supply E [...]

12-208 Electrical System ______________________________________________________ ® 3 W AY FRONT WIPER HARNESS NEAR MOTOR BEHIND A-PILLAR TR IM 2 W AY WIPER MOTOR CONNECTOR NEAR MOTOR BEHIND THE A-PILLAR TRIM PIN CKT COLOR DESCRIPTION A 28 DB Intermittent Po wer Supply B 63 DG Low Speed Po wer Supply C 61 RD High Speed Po wer Supply PIN CKT COLOR DE[...]

_____________________________________________________ Electrical System 12-209 ® 05745159 2 W A Y REAR WINDO W DEFR OSTER HARNESS LOC A TION: C-PILLAR INTERMEDIA TE 4 W A Y REAR WINDO W DEFR OSTER SWITCH CONNECT OR LOC A TION: BA CK OF THE HV A C PIN CKT COLOR DESCRIPTION A 58 BK Ground for the rear windo w defroster G4 B 689 PK Rear window defros[...]

12-210 Electrical System ______________________________________________________ ® 10 W A Y C ARGO DOOR LOCK DELA Y MODULE CONNECTOR LOC A TION: ON MODULE 5 W A Y DRIVERS DOOR LOCK SWITCH CONNECTOR LOC A TION: IN THE DRIVERS DOOR PIN CKT COLOR DESCRIPTION 1 Empty 2 Empty 3 59 BK Ground G4 4 Empty 5 118 BR Lock signal to the cargo door lock delay mo[...]

_____________________________________________________ Electrical System 12-211 ® 05745159 5 W A Y P ASSENGER DOOR LOCK SWITCH CONNECT OR LOC A TION: IN THE P ASSENGERS DOOR PIN CKT COLOR DESCRIPTION 1 122 PP Lock signal from the switch to the module 2 120 LG Oscillating power/ground circuit 3 517 OR Fused battery input to the passenger door lock s[...]

12-212 Electrical System ______________________________________________________ ® 16 W A Y RADIO HARNESS LOC A TION: B A CK OF THE RADIO PIN CKT COLORS DESCRIPTION 1 Empty 2 Empty 3 14 LB Radio illumination 4 137 RD Fused battery input to the radio (Ignition) 5 6 17 P P Dimmer Circuit 7 476 GY Fused radio memory feed (Battery) 8 59 BK Ground G4 9 [...]

_____________________________________________________ Electrical System 12-213 ® 05745159 6 W AY RADIO ACCESSOR Y CONNECTOR LOCATION: BACK OF THE R ADIO 8 W AY RADIO JUMPER CONNECTOR LOCATION: BACK OF THE R ADIO PIN CKT COLOR DESCRIPTION 17 18 830 PK Ampli fi er sense 19 842 OR Rear seat audio enable 20 839 YL Cell phone mute 21 22 843 GY Rear se[...]

12-214 Electrical System ______________________________________________________ ® PIN CKT COLOR DESCRIPTION A1 819 BK Right rear speaker signal (Negati ve) A2 818 PP Right rear speak er signal (Positiv e) A3 821 BK Left rear speaker signal (Negati ve) A4 820 DG Left rear speaker signal (Positiv e) A5 843 GY Rear seat audio control A6 A7 A8 137 RD [...]

_____________________________________________________ Electrical System 12-215 ® 05745159 8 W AY BODY TO CONSOLE CONNECTOR LOCATION: BEHIND THE CENTER CONSOLE PIN CKT COLOR DESCRIPTION A 476 GY Fused radio memory input (Battery) B 137 RD Fused battery input to the radio (Ignition) C 59 BK Ground G4 D 17 PP Dimmer Circuit E 14 LB Radio Illumination[...]

12-216 Electrical System ______________________________________________________ ® CD CHANGER CONNECTOR LOC A TION: BA CK OF THE CD CHANGER PIN CKT COLOR DESCRIPTION 7 –– 8 –– 9 –– BR Shielding for the audio circuits 10 –– WH Right audio signal 11 –– YL Left audio signal 12 –– GY Audio common 13 –– BK Ground G4 14 ––[...]

_____________________________________________________ Electrical System 12-217 ® 05745159 AMPLIFIER CONNECTOR LOCATION: ON THE AMPLIF IER PIN CKT COLOR DESCRIPTION E1 805 GY Right front channel positive input E2 804 WH Left front channel positi ve input E3 813 BK Left front channel negati ve input E4 819 BK Right rear channel negati ve input E5 81[...]

12-218 Electrical System ______________________________________________________ ® F10 826 BK Front subwoofer negati ve signal F11 827 TN Front subwoofer positi ve signal F12 F13 803 BK Right rear speaker negati ve signal F14 802 TN Right rear speaker positi ve signal F15 800 TN Left rear speaker positi ve signal F16 801 BK Left rear speaker negati[...]

_____________________________________________________ Electrical System 12-219 ® 05745159 INTERIOR MINI FUSE BLOCK 1 (LOWER) Buss Cavity CKT . No. Color & Ga. Fuse I1 1A –– ES (5 AMP) -1A- 2A –– 3A –– ET (7.5 AMP) -2A- 4A –– 5A 6A – – – – – -3A- 7A –– EU (10 AMP) -4A- 8A –– 9A –– EW (15 AMP) -5A- 10A –?[...]

12-220 Electrical System ______________________________________________________ ® INTERIOR MINI FUSE BLOCK 2 (UPPER) Buss Cavity CKT . No. Color & Ga. Fuse L1 1E –– ES (5 AMP) -1E- 2E –– 3E –– – -2E- 4E –– 5E 6E – – – – ET (7.5 AMP) -3E- 7E –– – -4E- 8E –– 9E –– EW (15 AMP) -5E- 10E –– 11E –– –[...]

_____________________________________________________ Electrical System 12-221 ® 05745159 B1 5H 517 A 12 OR EX (20 AMP) -3H- 6H 37 D (BUSS B1) 14 RD 7H 70 A 12 YL EZ (30 AMP) -4H- 8H (B USS B1) – 9H 54 B 14 DG EW (15 AMP) -5H- 10H (B USS B1) – 11H 45 A 14 WH EX (20 AMP) -6H- 12H (B USS B1) – 13H 51 A 12 YL – -7H- 14H 37 A (B USS B1) 10 RD [...]

12-222 Electrical System ______________________________________________________ ® INTERIOR FUSE BOX RELAYS IGNITION RELA Y RY -1 Cavity CKT . No Color & Ga. Relay MINI- FUSE / RELA Y BLOCK ➂ B5 687 A 12 GY FB C7 59 H 59 A 18 BK 18 BK B7 37 C 10 RD C6 –– C5 687 B 10 LG WIPER RELA Y RY -2 MINI- FUSE / RELA Y BLOCK ➂ Cavity CKT . No Color[...]

_____________________________________________________ Electrical System 12-223 ® 05745159 Figure 2-150: Interior Fuse Box Fuse/Relay Cavity I.D. 9-S12-080.1 9 8 7 6 5 4 3 2 1 M L K J H G F E D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 MINI-FUSE COLUMNS H G F E D C B A MINI-FUSE ROWS MICRO-RELA Y ROWS MAIN FUSE/ MINI-RELA Y ROWS 1 2 4 3 5 1 5 3 24 REL[...]

12-224 Electrical System ______________________________________________________ ® EXTERIOR MINI FUSE BLOCK Buss Ca vity CKT . No. Color & Ga. Fuse I1 1A –– (FOR DIODE USE ONL Y) -1A- 2A –– 3A 351C 18 PK H (10 AMP) -2A- 4A 16A(BUSS I1) 10 LG 5A 239C 14 PK J (20 AMP) -3A- 6A (BUSS I1) – 1B –– (FOR DIODE USE ONL Y) -1B- 2B –– I2[...]

_____________________________________________________ Electrical System 12-225 ® 05745159 EXTERIOR MAXI FUSE BLOCK Buss Cavity CKT . No. Color & Ga Fuse or Circuit Breaker BUSS BAR 8W 37F 10 YL (40 AMP FUSE) -IM- 8X BUSS – 7W 38A 14 RD (20 AMP CD) -2M- 7X BUSS – 6W 195A 12 YL (30 AMP CB) 6X BUSS – -3M- 5W 688A 12 RD (30 AMP CB) -4M- 5X B[...]

12-226 Electrical System ______________________________________________________ ® EXTERIOR FUSE BOX RELAYS RELA Y R-6 Cavity CKT . No Color & Ga. Relay ABS V A L VE RELA Y 1 991A 18 LB E 2 59G 18 BK 3 575A 12 OR 4 –– 5 990A 12 PK RELA Y R-5 ABS W ARNING RELA Y Cavity CKT . No Color & Ga. Relay 1 990B 16 PK D 2 59B 59C 16 BK 16 BK 3 603[...]

_____________________________________________________ Electrical System 12-227 ® 05745159 Figure 2-151: Exterior Fuse Box Relay Cavity I.D. 9-S12-101 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 123456 A B C D E F 1 4 3 52 13 SP ARE SP ARE SP ARE 51 4 23 R-5 R-3 51 4 23 R-1 51 4 23 R-2 R-4 R-6 2 1 2 1 SP ARE MINI FUSES MAXI FUSES WX Y Z 51 4 23 51 4 23 51 4 23[...]

12-228 Electrical System ______________________________________________________ ® ESSENTIAL T OOLS Procure from Kent-Moore. T ool No. Description TK-O-A T ech 1 Diagnostic Scanner Kit T A-1151 T ech 1 Adapter , part of TK-O-A T A-1152 T ech 1 T est Lead, part of TK-O-A T A-1190-A Operators Manual, T ech 1, part of TK-O-A J – 35616-A Connector T [...]

_______________________________________________________________________________ 13-1 ® 05745159 Section 13 Accessor ies T ABLE OF CONTENTS Air Restriction Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34 Auxiliary Seat Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 Frame Replacemen[...]

13-2 Accessories _______________________________________________________________ ® Figure 13-2: Frame Bracket 4. Remove four nuts, washers, bolts, and winch from front bumper (Figure 13-3). Figure 13-3: Winch and Winch Cables 5. Remove two bolts and clamps securing winch cables to winch. 6. Remove bolt and control box cover from winch. 7. Remove c[...]

______________________________________________________________ Accessories 13-3 ® 05745159 Winch Assembly Repair Disassembly 1. Remov e winch and winch cable. NOTE: Tag leads for assembly. 2. Remove three nuts and control leads from motor (Figure 13-5). Figure 13-5: Control Leads 3. Loosen clamps and remove control from motor (Figure 13-6). Figure[...]

13-4 Accessories _______________________________________________________________ ® 11. Loosen set screw that retains brake. 12. Push brake through open end of drum and remove (Figure 13-8). 13. Remove driveshaft from gear train assembly (Figure 13-9). 14. Turn gear train assembly over with gear end drum support down. Remove ten hex-head screws and[...]

______________________________________________________________ Accessories 13-5 ® 05745159 Inspection 1. Inspect drum for damage to splined end flanges and tube (Figure 13-12). Replace winch if damaged. Figure 13-12: Drum Assembly and Gear Housing Assembly 2. Inspect gear end and motor end drum supports for damage. Replace if damaged. 3. Inspect [...]

13-6 Accessories _______________________________________________________________ ® Assembly 1. Position 85 to 87 steel balls in groov e of intermediate ring gear and install intermediate ring gear in gear housing (Figure 13-15). Figure 13-15: Intermediate Ring Gear and Gear Housing 2. Install retaining rings in gear housing. 3. Apply light oil to [...]

______________________________________________________________ Accessories 13-7 ® 05745159 17. With drum horizontal, install brake into drum (Figure 13-18). 18. Tighten brake retaining set screw to 18-22 ft-lb (24-30 N•m) torque. 19. Install two nylon thrust washers on drum. 20. Install drum assembly on gear train assembly. Rotate drum assembly [...]

13-8 Accessories _______________________________________________________________ ® Figure 13-21: Control Leads Figure 13-22: Control Unit and Motor 4. Remove clamps from motor. 5. Place winch on end with motor end up (Figure 13-25). 6. Remove two bolt assemblies and rear cover from motor housing. NOTE: Perform steps 7 through 11 only if replacing [...]

______________________________________________________________ Accessories 13-9 ® 05745159 3. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. 4. Coat armature shaft with lubricant and install in brush assembly. 5. Coat head of electric thermal switch with lubricant and connect to two electric thermal [...]

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. Removal W ARNING: Stand clear of brushguard after removal of locking pins. Brus[...]

____________________________________________________________ Accessories 13-11 ® 05745159 Figure 13-28: Swing-Away Spare Tire Carrier Breakdown LOCK END CAPS RUBBER WHEEL/TIRE FRAME ASSEMBLY LANYARD END GUIDE HOLD-DOWN STOP ANGLED BUMPER SQUARED SPACER CUSHION SIDE BRACE SIDE BRACKET BLOCK BRACKET RETAINING PLATE GREASE FITTING BRACKET ASSEMBLY PI[...]

13-12 Accessories _____________________________________________________________ ® Installation 1. Install grease fitting in mounting bracket (Figure 13-28). 2. 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 N•m). 3. Secure[...]

____________________________________________________________ Accessories 13-13 ® 05745159 CARGO BED-MOUNTED SPARE TIRE CARR IER REPLACEMENT W ARNING: Always support the tire and wheel assem- bly when removing the lug nuts. The tire and wheel as- sembly weighs approximately 160 lbs (72 kgs) and may cause personal injury if it is not supported prope[...]

13-14 Accessories _____________________________________________________________ ® DRIVELINE PROTECTION Skid Plate Replacement Removal 1. Remov e 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. Remove locknuts, washers, bolts, washers, and skid plate[...]

____________________________________________________________ Accessories 13-15 ® 05745159 Front Shield Replacement Removal 1. Remov e locknuts, washers, bolts, and spacers securing front shield to front crossmember and intermediate shield (Figure 13-33). 2. Remove locknuts, washers, bolts, and front shield from skid plate. Installation 1. Install [...]

13-16 Accessories _____________________________________________________________ ® Intermediate Shield Replacement Removal 1. Remov e six locknuts, washers, bolts, washers, and four rubber washers securing two transmission support brack- ets and intermediate shield to transmission mount cross- member . Remo ve support brackets. Discard locknuts (Fi[...]

____________________________________________________________ Accessories 13-17 ® 05745159 Figure 13-37: Intermediate Shield Installation 1. Install intermediate shield to front crossmember and front shield with two spacers, washers, bolts, w ashers, and lock- nuts. T ighten locknuts to 44 lb-ft (60 N•m) (Figure 13-37). 2. Install right support b[...]

13-18 Accessories _____________________________________________________________ ® . Figure 13-39: Rear Shield ROCK ER PANEL PROTECTION REPLACEMENT Removal NOTE: Removal of rocker panel protection is similar for both sides. This procedure covers one side only. 1. Remov e outer kick panels (Section 10). 2. Pull back carpet from front footwell and re[...]

____________________________________________________________ Accessories 13-19 ® 05745159 T RAILER T O WING Figure 13-42: Trailer Wiring Connector and Dummy Plug Location T railer Jumper Har ness Hummer vehicles come from the factory equipped for easy in- stallation of the trailer jumper harness. The trailer jumper har- ness may be installed as pa[...]

13-20 Accessories _____________________________________________________________ ® 2. The trailer brake circuit will not have power until a fuse (of required amperage) is installed in fuse block position 7H—the far upper right hand corner of the fuse block. Figure 13-44: Trailer Brake Controller Wiring T RAILER HITCH REPLACEMENT Removal 1. Remov [...]

____________________________________________________________ Accessories 13-21 ® 05745159 RUNNING BOARD REPLACEMENT Removal 1. Remov e two clips and pins securing the right and left curved tubes to the recei ver (Figures 13-46 and 13-47). Figure 13-46: Receiver 2. Remove screw, nut, and screw securing the left end cap to the left curved tube (Figu[...]

13-22 Accessories _____________________________________________________________ ® 8. Remove four bolts, lockwashers, J-nuts, and front mounting bracket from body (Figure 13-50). Figure 13-50: Front Mounting Bracket and J-Nut 9. Remove four bolts, lockwashers, and front mounting bracket from rocker panel protection and body (Figure 13-51). Figure 1[...]

____________________________________________________________ Accessories 13-23 ® 05745159 SIDE STEP BARS (T UBULAR) 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. Remo v al 1. Remov e the four bolts securing the tube brackets to the support brackets ([...]

13-24 Accessories _____________________________________________________________ ® 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 pro- cedures are similar. Removal W ARNING: Roo[...]

____________________________________________________________ Accessories 13-25 ® 05745159 Roof Rack Cr ossbar Replacement Removal 1. Remov e roof rack from vehicle.Remove ten floor pieces from roof rack.Roof Rack Crossbar Replacement Removal 1. Remov e roof rack from vehicle. 2. Remove ten floor pieces from roof rack. 3. Remove four locknuts, wash[...]

13-26 Accessories _____________________________________________________________ ® Roof Rack Clamp Replacement Removal 4. Loosen support scre w on clamp securing clip to clamp (Figure 13-58). 5. Loosen locknut securing clip to drip rail. 6. Remove clip from under drip rail. 7. Remove locknut, washer, capscrew, and clamp from roof rack. Installation[...]

____________________________________________________________ Accessories 13-27 ® 05745159 AUXILIARY SEAT Auxiliary Seat Replacement Removal 1. Release and remov e four locking pins from auxiliary seat frame and auxiliary seat (Figure 13-59). 2. Remove auxiliary seat from auxiliary seat frame. Installation 1. Install auxiliary seat on auxiliary sea[...]

13-28 Accessories _____________________________________________________________ ® Auxiliary Seat Frame Replacement Removal 1. Remov e auxiliary seat locking pins. 2. Remove auxiliary seat. 3. Remove four bolts, washers, and auxiliary seat frame from tunnel floor (Figure 13-61). Figure 13-61: Auxiliary Seat Frame Installation 1. Install auxiliary s[...]

____________________________________________________________ Accessories 13-29 ® 05745159 UPHOLSTER Y , LEATHER A UXILIAR Y SEAT Remo v al 1. Remov e the four locking pins securing the auxiliary seat to the seat frame (See Figure 13-63). 2. Remove the auxiliary seat from the seat frame. 3. Seat Base: a. Remove the bolts securing the safety belts t[...]

13-30 Accessories _____________________________________________________________ ® 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[...]

____________________________________________________________ Accessories 13-31 ® 05745159 OFF ROAD LIGHT P AC KAGE KC HiLites High Intensity Discharge Lighting System Remo v al 1. Disconnect battery ground cables. 2. Remove switch from dash, disconnect spare power and ground wires under dash and pull wires through cowl. 3. Remove relay from mount [...]

13-32 Accessories _____________________________________________________________ ® 3. 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 drive[...]

____________________________________________________________ Accessories 13-33 ® 05745159 Diagnostics Table 1: Off Road Light Package Inoperative STEP ACTION VALUE(S) YES NO 1 T urn high beam headlights on. Using a DVOM, check for approximate battery voltage at the white supply wire to the dash switch. Is voltage present? Approxi- mate battery + v[...]

13-34 Accessories _____________________________________________________________ ® AIR RESTRICTION GAUGE Remo v al 1. Disconnect the hose from the air restriction gauge and the hose barb in the air cleaner and remov e the hose (Figure 13-71). 2. Remove two screws securing the gauge and bezel to the mounting bracket and remove the gauge and bezel. 3[...]

____________________________________________________________ Accessories 13-35 ® 05745159 DUAL OIL FILTER Remo v al 1. Remov e oil filters from oil filter adapter . 2. Remove bolt, gasket and two small o-rings securing adapter to engine block and remove adapter. 3. Remove large o-ring, plug and two connectors from adapter. Installation 1. Use pi[...]

13-36 Accessories _____________________________________________________________ ® DELCO COMPACT DISC CHANGER REPLACEMENT Remo v al 1. Remov e four screws retaining the CD changer bezel to the console and remov e bezel (See Figure 13-73). 2. Remove four screws retaining the CD changer mounting brackets to the console. 3. Pull the CD changer out far[...]

____________________________________________________________ Accessories 13-37 ® 05745159 SEAT HEATER NOTE: The following procedures apply to either the left or the right front seat. Remo v al 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 retain[...]

13-38 Accessories _____________________________________________________________ ® Diagnostics Seat Heater Does Not Heat Step Action V alue(S) Y e s No 1 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?[...]

____________________________________________________________ Accessories 13-39 ® 05745159 Figure 13-78: Seat Heater Schematic BLK 7 ORG BLU BLK GRN 2D 2C 2B 2A CONTROL BOX YEL WHT GRY 1C 1B 1A 6 5 4 3 2 1 GRY YEL 2 1 POWER STUD INTERNIAL FUSE BOX FUSE 3G 30 AMP INSTRUMENT P ANEL GROUND POINT 71A WHT RED RED BLK BLU GRN GRY YEL 297B B A CUSHION ELE[...]

13-40 Accessories _____________________________________________________________ ® OFF-ROAD ACCESSOR Y KIT (MODEL 84) Remo v al 1. Remov e four bolts, locknuts, 8 retainer plates and gaskets securing the box to the wheelhouse (See Figure 13-79). 2. Lift the box off the wheelhouse and out of the vehicle. Figure 13-79: Off-Road Accessory Box Mounting[...]

____________________________________________________________ Accessories 13-41 ® 05745159 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 p[...]

13-42 Accessories _____________________________________________________________ ® REMOTE ENTR Y T RANSMITTER BATTER Y REPLACEMENT 1. Remov e the screw in the back of the transmitter (See Figure 13-81). 2. Using a small screw driver or a knife blade, carefully pry the two halves of the transmitter apart exposing the battery. 3. New batteries can be[...]

____________________________________________________________ Accessories 13-43 ® 05745159 STAINLESS STEEL FR ONT BUMPER CO V ER (WITH WINCH) Remo v al 1. Remov e two bolts and the licence plate mount bracket (See Figure 13-83). 2. Remove four bolts, washers and two tow bracket/lifting shackle assemblies. 3. Support the winch and remove the bolts a[...]

13-44 Accessories _____________________________________________________________ ® STAINLESS STEEL UPPER GRILLE COV ER REPLACEMENT Remo v al 1. Remov e the six screws, w ashers and nuts securing the SS grille frame to the original grille frame and remov e the SS grille frame (See Figure 13-85). Figure 13-85: SS Upper Grille Frame R&I 2. Peel th[...]

____________________________________________________________ Accessories 13-45 ® 05745159 SOFT SLANT BACK (MODEL 90) Remo v al 1. Unzip the forward portion of the slant back co ver from the soft top cov er . 2. Release the hook and loop fasteners on the lower sides and the lower rear of the slant back cover. 3. Release the hook and loop fasteners [...]

13-46 Accessories _____________________________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

_____________________________________________________________________ Index 14-1 ® 05745159 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[...]

14-2 Index ______________________________________________________________________ ® 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[...]

_____________________________________________________________________ Index 14-3 ® 05745159 Rear CTI Line Replacement . . . . . . . . . . . 6-50 Rear Tube Connection Shield . . . . . . . . . . 6-53 Spindle Extension and Seal . . . . . . . . . . . . 6-54 Supply Line . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Troubleshooting . . . . . . . [...]

14-4 Index ______________________________________________________________________ ® Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . 2-7 Engine Noise Diagnosis Equipment . . . . . . . . . . . . . . . 2-6 Essential Tools . . . . . . . . . . . . . . . . . . . . . . 2-99 Ident[...]

_____________________________________________________________________ Index 14-5 ® 05745159 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 Inje[...]

14-6 Index ______________________________________________________________________ ® 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 Brack[...]

_____________________________________________________________________ Index 14-7 ® 05745159 I Identification Numbers Engine Identification Number . . . . . . . . . . . 1-5 Transfer Case Identification Number . . . . . . 1-5 Transmission Identification Number . . . . . . 1-4 Vehicle Identification Number Decoding Chart . . . . . . . . . . . . . . .[...]

14-8 Index ______________________________________________________________________ ® 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 Si[...]

_____________________________________________________________________ Index 14-9 ® 05745159 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[...]

14-10 Index _____________________________________________________________________ ® S Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Non-approved accessories . . . . . . . . . . . . . . 1-1 Warnings, cautions, and notes . . . . . . . . . . . 1-1 Scan Tool Diagnosis . . . . . . . . . . . . . . . . . . . . 3-11 Seat Belts Seat [...]

____________________________________________________________________ Index 14-11 ® 05745159 Steering Specifications . . . . . . . . . . . . . . . . . . . 8-44 Steering Gear Adjustment Preload Torques 8-44 Steering Pump Flow Rates and Operating Pressures . . . . . . . . . . . . . . . . . 8-44 Torque Specifications . . . . . . . . . . . . . . . . 8-[...]

14-12 Index _____________________________________________________________________ ® Towing, Lifting, Jump Starting . . . . . . . . . . . . 1-17 Trailer Hitch Replacement . . . . . . . . . . . . . . . 13-20 Trailer Towing Connector . . . . . . . . . . . . . . . 13-19 Transfer Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5-170 Cle[...]

____________________________________________________________________ Index 14-13 ® 05745159 V Vacuum Pump Service . . . . . . . . . . . . . . . . . . . 2-44 Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Replacement . . . . . . . . . . . . . . . . [...]

14-14 Index _____________________________________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]

_______________________________________________________ PCM/Tech 1 Scan Tool 1 ® 05745159 General Information The control module system has a computer, Powertrain Con- trol Module (PCM) to control fuel delivery timing, and some emission control systems. The control module system, monitors a number of engine and vehicle functions and controls the f[...]

2 PCM/Tech 1 Scan Tool ______________________________________________________ ® Diagnostic Information The diagnostic table and functional checks in this manual are designed to locate a faulty circuit or component through logic based on the process of elimination. The charts are prepared with the requirements that the vehicle functioned correctly [...]

_______________________________________________________ PCM/Tech 1 Scan Tool 3 ® 05745159 T ech 1 Scan T ool The diagnostic procedures in this manual assume the use of a Tech 1 scan tool. Since the Tech 1, produced by Expertec, is able to perform functions, such as, bidirectional communica- tion that other scan tools are unable to perform, it has [...]

4 PCM/Tech 1 Scan Tool ______________________________________________________ ® PO W ERTRAIN OBD SYSTEM CHECK Circuit Description The On Board Diagnostic System Check is an organized ap- proach to identifying a problem created by an electronic engine system fault. The OBD system check is the starting point for any driveability diagnosis. The OBD s[...]

_______________________________________________________ PCM/Tech 1 Scan Tool 5 ® 05745159 PCM Programming (TDC Of fset) The PCM will automatically activate the TDC Offset program when the engine coolant is greater than 170°F (77°C). If the PCM is not programmed with a TDC Offset, a P1214 will set. If the PCM and Fuel injection pump are replaced [...]

6 PCM/Tech 1 Scan Tool ______________________________________________________ ® Typical Engine Data Values Idle/Upper Radiator Hose Hot/Closed Throttle/Park or Neutral/ACC. “OFF” T ech 1 P arameter Units Displayed Typical Data V alue Engine Speed RPM ±100 RPM from desired Desired Idle RPM PCM idle command ECT C°/F° 85°C - 105°C (185°F - [...]

_______________________________________________________ PCM/Tech 1 Scan Tool 7 ® 05745159 Resume Switch on/off off TR Switch Park-Neutral, Re verse, Dri ve Ranges Park Crank Ref Missed # 0 (missed) Inj. Pump Cam Reference Missed # 0 (missed) Lift Pump volts 12 - 15 volts Lift Pump System disabled/enabled enabled Engine Load % 4 - 6% Engine T orque[...]

8 PCM/Tech 1 Scan Tool ______________________________________________________ ® No Malfunction Indicator Lamp (MIL) “Check Engine” Step Action V alue(s) Y es N o 1 W as the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2 Go to OBD System Check 2 Attempt to start the engine. Does the engine start? — Go to Step 3 Go to[...]

_______________________________________________________ PCM/Tech 1 Scan Tool 9 ® 05745159 14 Locate and repair short to ground in the status center Ignition Feed circuit. Is the action complete? — Go to Step 20 — 15 Replace the PCM. NO TE: If the PCM is faulty , then PCM must be pro- grammed. Go to PCM Replacement and Programming Procedures. I[...]

10 PCM/Tech 1 Scan Tool _____________________________________________________ ® No Scan Tool Data Step Action V alue(s) Y es N o 1 W as the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2 Go to OBD System Check 2 1. Ignition “OFF” for 30 seconds. 2. Ignition “ON,” Engine “OFF.” Is the MIL “ON”? — Go to St[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 11 ® 05745159 15 1. Ignition “OFF.” 2. Disconnect the PCM Connectors. 3. Ignition “ON.” 4. Check voltage on the DLC connector (pin 2). Is voltage at the specified v alue? 0v Go to Step 28 Go to Step 25 16 Reprogram the EEPR OM and retest. Is serial data present? ?[...]

12 PCM/Tech 1 Scan Tool _____________________________________________________ ® Engine Cranks But Will Not Start Step Action V alue(s) Y es N o 1 NOTE: Before clearing DTC(s) use the Scan Tool “Cap- ture Info” to record Freeze Frame and Failure Record for reference, as data will be lost when “Clear Info” function is used. W as the “On-Bo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 13 ® 05745159 15 1. Turn the ignition “ON,” engine “OFF.” 2. Verify the fuel solenoid is still disconnected. 3. Probe ignition feed circuit (terminal D) at the fuel sole- noid harness connector with a test light connected to ground. Is test light “ON”? — Go to[...]

14 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC (DTC) IDENTIFICATION The MIL (Service Engine Soon) lamp will be “ON” if an emis- sion malfunction exists. If the malfunction clears, the lamp will go “OFF” and the DTC will be stored in the PCM. Any DTCs stored will be cleared if no problem recurs within l5[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 15 ® 05745159 Diagnostic Trouble Code (DTC) Identification DTC Description T ype Illuminate MIL P0112 IA T Sensor Circuit Lo w V oltage B Y es P0113 IA T Sensor Circuit High V oltage B Y es P0117 ECT Sensor Circuit Lo w V oltage B Y es P0118 ECT Sensor Circuit High V oltage[...]

16 PCM/Tech 1 Scan Tool _____________________________________________________ ® P0284 Cylinder Balance System Fault D No P0335 CKP Sensor Circuit Performance A Y es P0370 T iming Reference High Resolution A Y es P0380 Glo w Plug Circuit Performance B Y es P0501 V ehicle Speed Sensor Circuit D No P0567 Cruise Resume Circuit D No P0568 Cruise Set Ci[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 17 ® 05745159 PCM SCHEMATICS FUSE 2D 20A INTERIOR FUEL PUMP RELA Y EXTERIOR FUSE BOX C1-10 G2 POWERTRAIN CONTROL MODULE FUEL PUMP RELA Y CONTROL FUEL LIFT PUMP SIGNAL TO FUEL SELECTOR SWITCH M G2 FUEL LIFT PUMP B A 57 BK 787 GY 787 GY 787 GY C27-D5 57 BK C27-D8 238 DG 537 O[...]

18 PCM/Tech 1 Scan Tool _____________________________________________________ ® FUSE 4D 15 AMP INTERIOR FUSE 6B 5 AMP INTERIOR HOT A T ALL TIMES HOT IN RUN AND ST ART STOP LAMP SWITCH TCC CRUISE BRAKE SWITCH AD BC TO STOP LAMPS C1 31 40 10 OR 291 PK 22 RD 810 PP STOP LAMP SIGNAL TCC/ CRUISE BRAKE SIGNAL FUSE 2C 10 AMP INTERIOR HOT IN RUN AND ST AR[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 19 ® 05745159 FUSE 5C 10AMP INTERIOR FUSE 3A 10 AMP EXTERIOR ON/ OFF SET COAST RESUME ACCEL HOT IN RUN AND ST ART HOT IN RUN AND ST ART A 29 42 37 C1 C29-A1 1 C29-B1 1 C27-D10 C28-D14 C28-C2 C27-D12 C27-D3 C27-D4 C27-D6 C29-B2 C29-B1 C27-C5 C29-A12 C5-D3 C5-A4 AB 154 TN 151[...]

20 PCM/Tech 1 Scan Tool _____________________________________________________ ® FUSE 3B 20AMP EXTERIOR FUSE BOX DRAIN FIL TER HOT IN RUN AND ST ART W A TER IN FUEL LIGHT LEFT HAND ST A TUS CENTER C9-D C3-F4 C1-45 BA 327 YL C C9-J W A TER IN FUEL SENSOR FUEL HEA TER 291 PK 57 BK G2 57 BK C A 9-S12-056 FUSE 4B 5AMP INTERIOR FUSE BOX TO IGNITION SWIT[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 21 ® 05745159 FUSE 3A 20 AMP EXTERIOR HOT IN RUN AND ST ART TO ST ARTER GLOW PLUG CONTROLLER IGN POWER RELA Y POWER BA TTER Y FUSIBLE LINK FUSIBLE LINK FUSIBLE LINK F U S IB L E L IN K F U S IB L E L IN K S F U S IB L E L IN K S G L O W P L U G S L H G L O W P L U G S R H F[...]

22 PCM/Tech 1 Scan Tool _____________________________________________________ ® FUSE 2D 20 AMP INTERIOR STS LAMP MIL LAMP FUSE 3A 20 AMP EXTERIOR HOT A T ALL TIMES HOT IN RUN AND ST ART HOT IN RUN AND ST ART FUSE 4B 5 AMP INTERIOR G2 G4 FUSE 1H 5 AMP INTERIOR DLC POWERTRAIN CONTROL MODULE SERIAL DA T A CLASS II MIL CONTROL STS LAMP CONTROL 914 PP [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 23 ® 05745159 5 VOL T REFERNCE CKP SENSOR SIGNAL SENSOR GROUND CRANK SHAFT POSITION SENSOR (CKP) AB BA B B A A C C C5-B12 C5-B5 C5-B9 BOOST/ BARO PRESSURE SENSOR INT AKE AIR TEMPERA TURE SENSOR (IA T) ENGINE COOLANT TEMP SENSOR (ECT) C5-B10 POWERTRAIN CONTROL MODULE CKP SEN[...]

24 PCM/Tech 1 Scan Tool _____________________________________________________ ® AE BF D C 5 VOL T REFERENCE OPTICAL/ FUEL TEMP SENSOR PUMP CAM SENSOR SIGNAL HIGH RESOLUTION SIGNAL SENSOR GROUND M DA B C C5 C3 B8 C1 C12 C2 375 GY 442 BR 703 OR 156 PK 225 YL C27-D14 C29-A4 C29-A2 C27-D9 C27-C8 FUEL TEMP SIGNAL SENSOR GROUND HIGH RES SIGNAL CAM SENSO[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 25 ® 05745159 DTC P0112 Intak e Air T emperature (IA T) Sensor Circuit Lo w V oltage 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 w[...]

26 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0112 - Intake Air Temperature (IAT) Sensor Circuit Low Voltage Step Action V alue(s) Y es No 1 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” fun[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 27 ® 05745159 DTC P0113 Intak e Air T emperature (IA T) Sensor Circuit High V oltage Circuit Description The intake air temperature sensor is a thermistor that controls signal voltage to the PCM. When the air is cold, the sensor re- sistance is high, therefore the PCM will [...]

28 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0113 - Intake Air Temperature (IAT) Sensor Circuit High Voltage Step Action V alue(s) Y es No 1 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” fu[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 29 ® 05745159 DTC P0117 Eng ine Coolant T emperature (ECT) Sensor Circuit Lo w V oltage 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[...]

30 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0117 - Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage Step Action V alue(s) Y es No 1 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?[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 31 ® 05745159 DTC P0118 Eng ine Coolant T emperature (ECT) Sensor Circuit High V oltage 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[...]

32 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0118 - Engine Coolant Temperature (ECT) Sensor Circuit High Voltage Step Action V alue(s) Y es No 1 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 I[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 33 ® 05745159 DTC P0121 Accelerator P edal P osition (APP) Sensor 1 Circuit P erformance Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator pedal position. There are three sensors located within t[...]

34 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0121 - Accelerator Pedal Position (APP) Sensor 1 Circuit Performance Step Action V alue(s) Y es No 1 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 [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 35 ® 05745159 DTC P0122 Accelerator P edal P osition (APP) Sensor 1 Circuit Lo w V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the AP[...]

36 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0122 - Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage Step Action V alue(s) Y e s No 1 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[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 37 ® 05745159 DTC P0123 Accelerator P edal P osition (APP) Sensor 1 Circuit High V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the AP[...]

38 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0123 - Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage Step Action V alue(s) Y es No 1 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[...]

___________________________________________________ PCM/Tech 1 Scan Tool 38.1 ® 05745159 DTC P0126 Eng ine Coolant T emperature (ECT) Insufficient for Stable Operation Circuit Description While the engine is warming, the PCM monitors the ECT sen- sor to determine how long it takes the engine to reach the cool- ant temperature required for “ Clo[...]

38.2 PCM/Tech 1 Scan Tool ___________________________________________________ ® • A history DTC will clear after forty consecutive warm up cycles, if no failures are reported by this and any other emission related diagnostic. • PCM battery voltage is interrupted. • Using a scan tool. Diagnostic Aids • Using “ Freeze Frame ” and/or “ [...]

___________________________________________________ PCM/Tech 1 Scan Tool 38.3 ® 05745159 T est Description Number(s) below refer to step numbers on the diagnostic table. 2. An ECT f ailure could cause a DTC P0126 to set, so correct any ECT DTC that are set. 6. If it is obvious that the engine is not reaching full operating temperature, for example[...]

38.4 PCM/Tech 1 Scan Tool ___________________________________________________ ® 9 a. Using the Scan tool, clear the DTCs. b. Start the engine and idle at normal operating tem- perature. c. Select “ DTC Specifications ” , then enter the num- ber which was set. d. Operate the vehicle, within the conditions for set- ting this DTC, until the scan [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 39 ® 05745159 DTC P0182 Fuel T emperature Sensor Cir cuit Low V oltage Circuit Description The fuel temperature sensor is a thermistor that controls signal voltage to the PCM. When the fuel is cold, the sensor resis- tance is high, therefore the PCM will see high signal vol[...]

44 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0215 - Engine Shutoff Solenoid Circuit Malfunction Step Action V alue(s) Y es No 1 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 i[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 45 ® 05745159 DTC P0216 Injection Timing Control System Circuit Description Timing of the combustion event is accomplished by delivering a pulse of fuel into the combustion chamber at a desired degree of cylinder travel. This desired degree (defines the current po- sition o[...]

46 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0216 - Injection Timing Control System Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info” Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD System Check. 2 1. Engine at o[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 47 ® 05745159 18 1. Using the Scan Tool, select “DTC”, “Clear Info”. 2. Start engine and idle at normal operating temperature. 3. Select “DTC”, “Specific”, then enter the DTC number which was set. Does the Scan T ool indicate that this diagnostic Ran and P a[...]

48 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0219 Eng ine Ov er speed Condition Circuit Description The PCM has the ability to put the vehicle in an ESO con- trolled idle if an engine overspeed condition has been detected. This is a type D DTC. Conditions for Setting the DTC 5 ESO cycles with an rpm drop. Ac[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 49 ® 05745159 DTC P0219 - Eng ine Ov er speed Condition Step Action V alue(s ) Ye s N o 1 W as the “On-Board Dia gnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD System Check. 2 Replace injection pump. Notice: If injection pump is faulty , the new inje[...]

50 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0220 Accelerator P edal P osition (APP) Sensor 2 Circuit Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module that are scale[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 51 ® 05745159 DTC P0220 - Accelerator Pedal Position (APP) Sensor 2 Circuit Step Action V alue(s) Y es No 1 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 Inf[...]

52 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0221 Accelerator P edal P osition (APP) Sensor 2 Circuit P erformance Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module t[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 53 ® 05745159 DTC P0221 - Accelerator Pedal Position (APP) Sensor 2 Circuit Performance Step Action V alue(s) Y es No 1 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 [...]

54 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0222 Accelerator P edal P osition (APP) Sensor 2 Circuit Lo w V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 55 ® 05745159 DTC P0222 - Accelerator Pedal Position (APP) Sensor 2 Circuit Low Voltage Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. [...]

56 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0223 Accelerator P edal P osition (APP) Sensor 2 Circuit High V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 57 ® 05745159 DTC P0223 - Accelerator Pedal Position (APP) Sensor 2 Circuit High Voltage Step Action V alue(s) Y es No 1 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[...]

58 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0225 Accelerator P edal P osition (APP) Sensor 3 Circuit Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module that are scale[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 59 ® 05745159 DTC P0225 - Accelerator Pedal Position (APP) Sensor 3 Circuit Step Action V alue(s) Y es No 1 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 Inf[...]

60 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0226 Accelerator P edal P osition (APP) Sensor 3 Circuit P erformance Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module t[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 61 ® 05745159 DTC P0226 - Accelerator Pedal Position (APP) Sensor 3 Circuit Performance Step Action V alue(s) Y es No 1 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 [...]

62 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0227 Accelerator P edal P osition (APP) Sensor 3 Circuit Lo w V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 63 ® 05745159 DTC P0227 - Accelerator Pedal Position (APP) Sensor 3 Circuit Low Voltage Step Action V alue(s) Y e s No 1 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[...]

64 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0228 Accelerator P edal P osition (APP) Sensor 3 Circuit High V oltage Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 65 ® 05745159 DTC P0228 - Accelerator Pedal Position (APP) Sensor 3 Circuit High Voltage Step Action V alue(s) Y es No 1 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[...]

66 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0231 Fuel Lift Pump Secondar y Circuit Low V oltage Circuit Description The status of the lift pump is monitored by the PCM. This sig- nal is also used to store a DTC if the fuel pump relay is defec- tive or fuel pump voltage is lost while the engine is running. T[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 67 ® 05745159 DTC P0231 - Fuel Lift Pump Secondary Circuit Low Voltage Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD Sys- te[...]

68 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0236 T urbocharger (TC) Boost System Circuit Description The PCM operates a solenoid to control boost. This solenoid is normally open. By providing a ground path the PCM energizes the solenoid which then allows vacuum to pass to the waste- gate valve. During norma[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 69 ® 05745159 55555555555 DTC P0236 - T urbocharger (TC) Boost System Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD System C[...]

70 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0237 T urbocharger (TC) Boost Sensor Circuit Lo w V oltage Circuit Description The PCM sends a 5 volt reference signal to the boost sensor. As manifold pressure changes, the electrical resistance of the boost sensor also changes. By monitoring the sensor output vo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 71 ® 05745159 DTC P0237 - Turbocharger (TC) Boost Sensor Circuit Low Voltage Step Action V alue(s) Y es No 1 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 “ Clea[...]

72 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0238 T urbocharger (TC) Boost Sensor Circuit High V oltage Circuit Description The PCM sends a 5 volt reference signal to the boost sensor. As manifold pressure changes, the electrical resistance of the boost sensor also changes. By monitoring the sensor output vo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 73 ® 05745159 DTC P0238 - Turbocharger (TC) Boost Sensor Circuit High Voltage Step Action V alue(s) Y es No 1 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 [...]

74 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0251 Injection Pump Cam System 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[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 75 ® 05745159 DTC P0251 - Injection Pump Cam System Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD System Check. 2 Start and [...]

76 PCM/Tech 1 Scan Tool _____________________________________________________ ® 16 1. Using the Scan Tool, select “DTC”, “Clear Info”. 2. Start engine and idle at normal operating temperature. 3. Select “DTC”, “Specific”, then enter the DTC number which was set. 4. Operate vehicle within the conditions for setting this DTC. Does th[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 77 ® 05745159 DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults 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 excee[...]

78 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0263, P0266, P0269, P0272, P0275, P0278, P0281 and P0284 Cylinder Balance System Faults Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info” to record freeze frame and failure records for reference, as data will be[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 79 ® 05745159 DTC P0335 Crankshaft Position (CKP) Sensor Circuit P erformance 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 cranksh[...]

80 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0335 - Crankshaft Position Sensor Circuit Performance Step Action V alue(s) Y es N o 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2. Go to OBD System Check.[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 81 ® 05745159 14 Using the Scan Tool, select “DTC”, “Clear Info”. Start engine and idle at normal operating temperature. Select “DTC”, “Specific”, then enter the DTC number which was set. Operate vehicle within the conditions for setting this DTC. Does the S[...]

82 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0370 Timing Reference High Resolution Circuit Description The optical sensor provides a high resolution signal to the PCM by counting pulses on the sensor disk located in the injec- tion pump. The high resolution is one of the most important in- puts by the PCM fo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 83 ® 05745159 DTC P0370 - Timing Reference High Resolution Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info”. W as the “On-Boar d Diagnostic (OBD) System Chec k” performed? — Go to Step 2. Go to OBD System Check. 2 [...]

84 PCM/Tech 1 Scan Tool _____________________________________________________ ® 9 1. Turn the ignition OFF. 2. Disconnect the PCM. 3. Check the high resolution signal circuit for and open, short ot ground, or short to the sensor ground circuit. 4. If the high resolutin signal circuit is open or shorted to ground, repair as necessary. 5. Was the hi[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 85 ® 05745159 DTC P0380 Glow Plug Cir cuit Perf ormance Circuit Description The glow plug system is used to assist in providing the heat re- quired to begin combustion during engine starting at cold am- bient temperatures. The glow plugs are heated before and during crankin[...]

86 PCM/Tech 1 Scan Tool _____________________________________________________ ® Test Description Number(s) below refer to the number(s) on the diagnostic ta- ble. 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 vo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 87 ® 05745159 10 T urn the ignition ON with the engine OFF . V erify that the glow plug relay control harness is disconnected. W ith a DMM connected to ground, probe the glow plug relay control circuit (466 YL) at the glo w plug relay harness connector . Use a scan tool to [...]

88 PCM/Tech 1 Scan Tool _____________________________________________________ ® 26 Repair the open or poor connections in the glow plug harness. Did you complete the repair? Go to step 30. 27 Repair the short to ground in the glow plug harness. Did you complete the repair? Go to step 30. 28 Replace the glow plug relay . Did you complete the repair[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 89 ® 05745159 DTC P0501 V ehicle Speed Sensor Circuit 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. T[...]

90 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0501 - V ehicle Speed Sensor Circuit Step Action V alue(s) Y es No 1 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. W as [...]

_____________________________________________________ PCM/Tech 1 Scan Tool 91 ® 05745159 DTC P0567 Cruise Resume Circuit 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 PC[...]

92 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0567 - Cruise Resume Circuit Step Action V alue(s) Y es No 1 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. W as the “O[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 93 ® 05745159 DTC P0568 Cruise Set Circuit Circuit Description The cruise Set/Coast switch is an input to the fuel control por- tion of the PCM. These inputs allow the PCM to control and hold a requested speed. Cruise Set/Coast switch sends an igni- tion voltage signal to t[...]

94 PCM/Tech 1 Scan Tool _____________________________________________________ ® 3. This step determines if the PCM or switch is at fault. DTC P0568 - Cruise Set Circuit Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info” to record freeze frame and failure records for reference, as data will be los[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 95 ® 05745159 DTC P0571 Cruise Brake Switch Cir cuit 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+[...]

96 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0571 - Cruise Brake Switch Cir cuit Step Action V alue(s) Y es No 1 Important: Before clearing DTC(s) use the scan tool “Capture Info” W as the “On-Boar d Diagnostic (OBD) System Chec k” performed? — Go to Step 2. Go to OBD System Check. 2 1. Scan tool i[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 97 ® 05745159 16 Replace the faulty PCM. Notice: If the PCM is faulty , the new PCM must be programmed. Go to PCM r eplacement and pr ogr amming pr ocedur es. Is the action complete? — Go to Step 17. — 17 1. Using the Scan T ool, select “DTC”, “Clear Info”. 2. S[...]

98 PCM/Tech 1 Scan Tool _____________________________________________________ ® DTC P0601 - PCM Memor y Check Step Action V alue(s) Y es No 1 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. W as the “On-Bo[...]

_____________________________________________________ PCM/Tech 1 Scan Tool 99 ® 05745159 DTC P0606 - PCM Inter nal Comm unication Interrupted Step Action V alue(s) Y es No 1 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” fun[...]

100 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1125 Accelerator P edal P osition (APP) System Circuit Description The Accelerator Pedal Position (APP) module provides a volt- age signal that changes relative to accelerator position. There are three sensors located within the APP module that are scaled different[...]

____________________________________________________ PCM/Tech 1 Scan Tool 101 ® 05745159 DTC P1125 - Accelerator P edal P osition (APP) System Step Action V alue(s) Y es No 1 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” fu[...]

102 PCM/Tech 1 Scan Tool ___________________________________________________ ® 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. Conditions for Setting the DTC TDC offse[...]

____________________________________________________ PCM/Tech 1 Scan Tool 103 ® 05745159 DTC P1214 - Injection Pump Timing Offset Err or Step Action V alue(s) Y es No 1 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[...]

104 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1216 Fuel Solenoid Response Time T oo Short 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 clo[...]

____________________________________________________ PCM/Tech 1 Scan Tool 105 ® 05745159 DTC P1216 - Fuel Solenoid Response Time T oo Shor t Step Action V alue(s) Y es No 1 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” func[...]

106 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1217 Fuel Solenoid Response Time T oo Long 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 clos[...]

____________________________________________________ PCM/Tech 1 Scan Tool 107 ® 05745159 DTC P1217 - Fuel Solenoid Response Time T oo Long Step Action V alue(s) Y es No 1 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” functi[...]

108 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1218 Injection Pump Calibration Circuit 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 dis- turbed or the PCM has be[...]

____________________________________________________ PCM/Tech 1 Scan Tool 109 ® 05745159 DTC P1218 Injection Pump Calibration Circuit Step Action V alue(s) Y es No 1 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 th[...]

110 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1621 EEPR OM Write Step Action V alue(s) Y es No 1 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 Diag[...]

____________________________________________________ PCM/Tech 1 Scan Tool 111 ® 05745159 DTC P1635 PCM 5 V olt Reference Low Circuit Description The PCM provides a 5 volt supply for use in powering up sen- sors. This test monitors the voltage present at terminals BRD13 (shared by Boost and Crankshaft Position sensors) and BRD14 (Optical/Fuel tempe[...]

112 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1635 - PCM 5 V olt Reference Low Step Action V alue(s) Y es No 1 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 ?[...]

____________________________________________________ PCM/Tech 1 Scan Tool 113 ® 05745159 DTC P1641 Malfunction Indicator Lamp (MIL) Control Cir cuit Circuit Description A dash light is illuminated by the PCM if diagnostics have de- tected certain errors related to the engine performance or en- gine sensor status. Illumination is accomplished by th[...]

114 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1641 - Malfunction Indicator Lamp (MIL) Control Cir cuit Step Action V alue(s) Y es No 1 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” func[...]

____________________________________________________ PCM/Tech 1 Scan Tool 115 ® 05745159 DTC P1643 W ait to Start Lamp Control Circuit Circuit Description A dash light (Wait To Start) is illuminated by the PCM when the glow plugs are commanded ON. When the PCM is com- manding the Wait To Start lamp ON, the voltage potential of the circuit will be [...]

116 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1643 Wait to Start Lamp Control Circuit Step Action V alue(s) Y es No 1 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[...]

____________________________________________________ PCM/Tech 1 Scan Tool 117 ® 05745159 DTC P1654 Check Thr ottle Circuit Circuit Description A dash light is illuminated by the PCM if diagnostics have de- tected certain errors related to the Accelerator Pedal Position (APP) sensor. Illumination is accomplished by the PCM pro- viding a ground path[...]

118 PCM/Tech 1 Scan Tool ___________________________________________________ ® DTC P1654 - Check Thr ottle Circuit Step Action V alue(s) Y es No 1 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 “O[...]

____________________________________________________ PCM/Tech 1 Scan Tool 119 ® 05745159 DTC P1656 W astegate Solenoid Control Circuit 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 wastegat[...]

120 PCM/Tech 1 Scan Tool ___________________________________________________ ® Test Description Number(s) below refer to the step number(s) on the Diagnostic Table. 2. Be sure that both the ON and OFF states are commanded. Repeat the commands as many times as necessary. 3. This check can detect a partially shorted coil which would cause excessive [...]

____________________________________________________ PCM/Tech 1 Scan Tool 121 ® 05745159 . DTC P1656 W astegate Solenoid Control Cir cuit Step Action V alue(s) Y es No 1 Important : Before clearing DTCs use the scan tool Capture Info W as the Powertrain On-Board Diagnostic (OBD) System Check perfom- med? — Go to Step 2. Go to OBD System Check. 2[...]

122 PCM/Tech 1 Scan Tool ___________________________________________________ ® 9 Check for a poor connection at the Boost solenoid and replace temminals as necessary . Did the terminals require replacement? — Go to Step 15. Go to Step 13 10 Repair Boost solenoid control circuit. Is the action complete? — Go to Step 15. — 11 Check for a poor [...]

____________________________________________________ PCM/Tech 1 Scan Tool 123 ® 05745159 CONNECTOR LEGEND 76 W AY BULKHEAD LOCATION: LEFT SIDE FIREWALL PIN CKT COLOR DESCRIPTION 1 400 LG Ignition Feed + 2 739 PP Left heated windshield power + 3 740 YL Right heated windshield power + 4 43 D B T railer Brak e activ ation 5 962 BR Trailer lights 6 33[...]

124 PCM/Tech 1 Scan Tool ___________________________________________________ ® 11 787 GY Fuel pump + to selector valve 12 37 RD Ignition relay feed 13 688 RD Rear windo w defrost feed 14 723 YL APP 3 5volt reference 15 724 DG APP 3 signal 16 17 PP + From dimmer module 17 718 DB APP 1 signal 18 353 YL Speedometer signal 19 607 TN ABS module diagnos[...]

____________________________________________________ PCM/Tech 1 Scan Tool 125 ® 05745159 47 3 LB Left front turn signal 48 914 PP PCM class 2 communication line to DLC 49 644 YL T achometer signal 50 210 DG Low washer fluid le vel lamp acti v ation 51 195 YL Headlight switch feed 52 603 DG ABS lamp activ ation 53 719 BR APP 1 ground 54 793 YL Low[...]

126 PCM/Tech 1 Scan Tool ___________________________________________________ ® 56 W AY INSTRUMENT PANEL LOCATION: BEHIND INSTRUMENT PANEL C3 MALE 9-S12-050 E G F D C B A M P N L K J H 1 2 3 4 5 10 9 8 7 6 PIN A1 PIN H6 C3 FEMALE 9-S12-049 E G F D C B A M P N L K J H 6 7 8 9 10 5 4 3 2 1 CA V H6 CA V A1 PIN CKT COLOR DESCRIPTION A1 195 YL Headlight[...]

____________________________________________________ PCM/Tech 1 Scan Tool 127 ® 05745159 C4 92 GY Rear inflate solenoid activ ation D1 338 DB Glo w plug wait lamp acti vation D2 2 L G Right turn indicator lamp activ ation D3 961 PP TT4 indicator lamp acti vation E1 42 BR Brak e indicator lamp activ ation E2 603 RD ABS indicator lamp activ ation E[...]

128 PCM/Tech 1 Scan Tool ___________________________________________________ ® M7 786 RD Fuel selector valve control M8 787 GY Fuel selector switch feed from fuel pump relay M9 953 DG Right hand power mirror up/do wn signal N6 59 BK Ground N7 30 GY Ignition feed to gauges N8 941 TN W indshield wiper washer pump acti v ation N9 945 BR Intermittent [...]

____________________________________________________ PCM/Tech 1 Scan Tool 129 ® 05745159 40 W AY GM ENGINE LOCATION: LEFT INTAKE MANIF OLD 9-S12-020 9-S12-019 PIN A1 PIN B1 PIN C1 PIN D1 PIN A8 PIN B12 PIN C12 PIN D8 CA V A8 CA V B12 CA V C12 CA V D8 CA V A1 CA V B1 CA V C1 CA V D1 C5 MALE C5 FEMALE PIN CKT COLOR DESCRIPTION A1 39 DG Engine temper[...]

130 PCM/Tech 1 Scan Tool ___________________________________________________ ® C4 354 YL Engine coolant temperature signal C5 357 TN Intake air temperature signal C6 C7 C8 C9 C10 31 TN Oil pressure signal to gauge C11 506 LB Glo w plug feedback signal C12 156 PK Optical sensor ground D1 D2 D3 154 TN W astegate solenoid control D4 D5 D6 D7 D8 PIN C[...]

____________________________________________________ PCM/Tech 1 Scan Tool 131 ® 05745159 10 W AY STATUS CENTER -RH LOCATION: INSTRUMENT PANEL 9-S12-017 9-S12-018 F K C9 MALE A E K A F E C9 FEMALE PIN CKT COLOR DESCRIPTION A 338 DB W ait lamp B 2 LG Right turn lamp C 961 PP TT4 (atc) lamp D 42 BR Brake lamp E 210 DG T ransfer case lock lamp F 428 P[...]

132 PCM/Tech 1 Scan Tool ___________________________________________________ ® 10 W AY STATUS CENTER -LH LOCATION: INSTRUMENT PANEL 9-S12-017 9-S12-018 F K C10 MALE A E K A F E C10 FEMALE PIN CKT COLOR DESCRIPTION A 12 OR Head lamp high beam lamp B 3 LB Left turn lamp C 658 BR Check engine lamp D 327 YL Drain fi lter lamp E 603 RD ABS lamp F 450 [...]

____________________________________________________ PCM/Tech 1 Scan Tool 133 ® 05745159 32 W AY PCM-BR OWN LOCATION: CENTER CONSOLE, PCM 9-S12-042 C1 C16 D16 D1 C27 MALE PIN CKT COLOR DESCRIPTION C1 651 PP Crankshaft position sensor ground – C2 439 YL A/C request+ C3 C4 357 TN Intake air temp sensor signal C5 721 LB APP sensor (2) signal C6 466[...]

134 PCM/Tech 1 Scan Tool ___________________________________________________ ® D6 725 GY APP (3) ground D7 506 LB Glow plug feedback signal D8 238 DG Lift pump relay enable + D9 156 PK Optical sensor ground – D10 153 LG Cruise control resume/accelerate D11 496 GY Transmission input speed signal (hi) D12 717 WH APP (1) 5 v olt ref. D13 350 GY Boo[...]

____________________________________________________ PCM/Tech 1 Scan Tool 135 ® 05745159 32 W AY PCM-BLUE LOCATION: CENTER CONSOLE, PCM 9-S12-042 C1 C16 D16 D1 C28 MALE PIN CKT COLOR DESCRIPTION C1 C2 720 TN APP (2) 5 volt ref. C3 712 LG Fuel inject signal C4 237 LG 1-2 shift solenoid control C5 924 TN T orque con verter clutch solenoid control C6[...]

136 PCM/Tech 1 Scan Tool ___________________________________________________ ® D6 570 BK Ground D7 570 BK Ground D8 D9 D10 D11 714 RD Check throttle lamp control D12 D13 537 OR Battery D14 154 TN W aste gate solenoid control D15 D16 PIN CKT COLOR DESCRIPTION[...]

____________________________________________________ PCM/Tech 1 Scan Tool 137 ® 05745159 24 W AY PCM-BR OWN LOCATION: CENTER CONSOLE, PCM PIN CKT CKT DESCRIPTION A1 491 BK Closure ground A2 703 OR High resolution sensor signal A3 565 BR T ransmission output speed sensor/VSS A4 442 BR Cam sensor signal A5 349 YL Crankshaft position sensor signal A6[...]

138 PCM/Tech 1 Scan Tool ___________________________________________________ ® THIS PAGE INTENTIONALLY BLANK.[...]